Danfoss CDS Directional Control Valve User guide

CDS Directional

ControlValve

Assembly andTest

Manual

	CDS Directional ControlValve Assembly andTesting Manual
	Using this manual
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AND COMPLEMENTARY	type above each item.Complementary information such as notes,captions,and drawing
INFORMATION	annotations are also set in blue type.
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© 2005 Sauer-Danfoss.All rights reserved.Printed in U.S.A.

Sauer-Danfoss accepts no responsibility for possible errors in catalogs,brochures and other printed material. Sauer-Danfoss reserves the right to alter its products without prior notice.This also applies to products already ordered provided that such alterations aren’t in conflict with agreed specifications.All trademarks in this material are properties of their respective owners.Sauer-Danfoss and the Sauer-Danfoss logotype are

trademarks of the Sauer-Danfoss Group.Detroit Diesel®,Cummins®,and Caterpillar® trademarks are properties of their respective owners.

Front cover illustrations:F101 489,F301 112,P104 394

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	CDS Directional ControlValve Assembly andTesting Manual
	Contents
INTRODUCTION	Overview...........................................................................................................................................................	4
	General instructions......................................................................................................................................	4
	Safety precautions.........................................................................................................................................	5
	Unintended machine movement.......................................................................................................	5
	Flammable cleaning solvents...............................................................................................................	5
	Fluid under pressure................................................................................................................................	5
	Personal safety...........................................................................................................................................	5
	Symbols used in Sauer-Danfoss literature.............................................................................................	6
	Required tools.................................................................................................................................................	6
ASSEMBLY	Assembly instructions..................................................................................................................................	7
	Centering types...............................................................................................................................................	9
	Spring centered assembly (A)..............................................................................................................	9
	Three position detent assembly (B) .................................................................................................	10
	Spring/detent detent assembies (C,D&E) ......................................................................................	11
	Spring center/float detent assembly (J).........................................................................................	13
	Hydraulic kickout (F)..............................................................................................................................	14
	Spring center assembly (G,H,I)..........................................................................................................	14
	Auxiliary valves..............................................................................................................................................	15
	Load check......................................................................................................................................................	16
	Handle assembly..........................................................................................................................................	17
	Joystick assembly.........................................................................................................................................	18
	Alternate joystick assembly......................................................................................................................	19
	Cable assembly.............................................................................................................................................	20
	Oil and test conditions...............................................................................................................................	22
TESTING	Adjusting pressure settings......................................................................................................................	22
	Main relief valve ......................................................................................................................................	22
	Work port relief valve............................................................................................................................	22
	Adjusting main/port relief valves......................................................................................................	22
	Leakage testing.............................................................................................................................................	23
	Work port leakage..................................................................................................................................	23
	Load check leakage................................................................................................................................	23
	Function testing............................................................................................................................................	24
	Spring Center Function .......................................................................................................................	24
	Detent Functions....................................................................................................................................	24
	Float Functions........................................................................................................................................	25
	Pneumatic Function..............................................................................................................................	25
	Hydraulic Function.................................................................................................................................	25
	Solenoid Function .................................................................................................................................	26
	ThreeWay Spools....................................................................................................................................	26
	Backpressure test.........................................................................................................................................	26
TROUBLESHOOTING	The valve leaks...............................................................................................................................................	28
	It still leaks.......................................................................................................................................................	28
	Sticky spool ....................................................................................................................................................	29
	Relief doesn’t work.......................................................................................................................................	29
	Cable binds.....................................................................................................................................................	29
APPENDIX A	Appendix ATesting certification form..................................................................................................	30

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	CDS Directional ControlValve Assembly andTesting Manual
	Introduction
OVERVIEW	This manual provides information and procedures for the assembly of a new CDS valve
	group using the following guidelines:

The specification sheet (CDS build tool and CDS order form) is compiled by the distributor and assigned a number provided by Sauer-Danfoss.The order form is then sent to Sauer Danfoss (preferably electronically [FAX]) and reviewed and approved by the Sauer-DanfossTechnical SupportTeam (TST) or customer service (CDS) assigned personnel.The specification sheet will then be logged into a master file.Once it is determind that the distributor wants S-D to start providing this assembly,a SauerDanfoss part number will be assigned.

After final testing,the test certification,(Appendix A),is to be completed by the assembly/testing personnel.A copy of the certification must be sent to theTST at SauerDanfoss,Easley,SC.

Before,during and after the assembly/disassembly of new CDS groups,absolute cleanliness and care must be observed with regard to internal and external parts of the units concerned.Use non-volatile,petroleum based solutions for cleaning valves and/or modules.Replace all parts considered likely to cause malfunction during subsequent testing and report nonconforming product to Sauer-Danfoss (TST).Replace all loose O-rings (without exceptions) with new O-rings.Lubricate all moving parts with hydraulic oil before assembly.Lubricate all O-rings with petroleum jelly.Lubricate all detent and spring centered accessories with LUBRIPLATE 730-1 or equvaliant.

Refer to this manual and the CDS Specification sheet for module designations,item numbers,spare parts numbers,tightening torques,etc.,whether assembling new groups or making repairs.

Refer to Directional ControlValvesTechnical Information Manual 520L0564 for more detailed information including order codes and specifications.

GENERAL INSTRUCTIONS Follow these general procedures when assembling CDS stack valves.

eKeep it clean

Cleanliness is a primary means of assuring satisfactory valve life,on either new or repaired units.Clean the outside of the valve thoroughly before assembly.Take care to avoid contamination of the system ports.Cleaning parts by using a clean solvent wash and air drying is usually adequate.

As with any precision equipment,all parts must be kept free of foreign materials and chemicals.Protect all exposed sealing surfaces and open cavities from damage and foreign material.If left unattended,cover the valve with a protective layer of plastic.

lLubricate moving parts

During assembly,coat all moving parts with a film of clean hydraulic oil.This assures that these parts will be lubricated during start-up.

dLubricate all O-rings and gaskets

Lightly lubricate all O-rings with clean petroleum jelly prior to assembly.If the stack valve is being repaired,it is recommended that all O-rings be replaced..

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CDS Directional ControlValve Assembly andTesting Manual

Introduction

SAFETY PRECAUTIONS Always consider safety precautions before beginning a service procedure.Protect yourself and others from injury.Take thefollowinggeneralprecautionswheneverservicinga hydraulicsystem.

Unintended machine movement

WWarning

Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.To protect against unintended movement,secure the machine or disable / disconnect the mechanism while servicing.

Flammable cleaning solvents

WWarning

Some cleaning solvents are flammable.To avoid possible fire,do not use cleaning solvents in an area where a source of ignition may be present.

Fluid under pressure

WWarning

Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and/or infection.This fluid may also be hot enough to cause burns. Use caution when dealing with hydraulic fluid under pressure.Relieve pressure in the system before removing hoses,fittings,gauges,or components.Never use your hand

or any other body part to check for leaks in a pressurized line.Seek medical attention immediately if you are cut by hydraulic fluid.

Personal safety

WWarning

Protect yourself from injury.Use proper safety equipment,including safety glasses,at all times.

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CDS Directional ControlValve Assembly andTesting Manual

Introduction

SYMBOLS USED IN	WARNING may result in injury	Tip,helpful suggestion
SAUER-DANFOSS	CAUTION may result in damage to	Lubricate with hydraulic fluid
LITERATURE
	product or property	Apply grease/petroleum jelly
	Reusable part
		Apply locking compound
	Non-reusable part,use a new part
		Inspect for wear or damage
	Non-removable item
		Clean area or part
	Option – either part may exist
		Be careful not to scratch or damage
	Superseded – parts are not
		Note correct orientation
	interchangeable
	Measurement required	Mark orientation for reinstallation
	Flatness specification	Torque specification
	Parallelism specification	Press in – press fit
	External hex head	Pull out with tool – press fit
	Internal hex head	Cover splines with installation
	Torx head	sleeve
		Pressure measurement/gauge
	O-ring boss port
		location or specification
	The symbols above appear in the illustrations and text of this manual.They are intended
	to communicate helpful information at the point where it is most useful to the reader.
	In most instances,the appearance of the symbol itself denotes its meaning.The legend
	above defines each symbol and explains its purpose.
REQUIRED TOOLS	The following tools are required to build a CDS control valve :
	Hand tools:
	Hex head wrench:3/32,1/8,5/32,1/4
	Sockets:3/8 deep well,11 mm,13 mm,17 mm,1 inch,22 mm,32 mm
	Phillips and flat head screw driver
	Torque wrench:3/8 drive 0-68 N•m [0-50 lbf•ft].

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	CDS Directional ControlValve Assembly andTesting Manual
	Assembly
ASSEMBLY
	The valve is to be assembled in accordance with the CDS stack valve order form.
INSTRUCTIONS
	Following assembly steps include installation of optional relief valves and optional
	control components.

The assembly sequence for CDS stack valve groups is as follows :

1.Ensure that all parts required,according to the completed CDS stack valve order form are present.Unpack and inspect all parts for damage and cleanliness.Ensure that all parts are free of nicks,burrs,contamination etc.

2.	Install a nut and lock washer on one	Install inlet section first
	end of each tie rod.Guide tie rods
	through holes in each section (inlet
	section first).
3.	Place all lubricated O-rings in their
	respective grooves in the different
	modules before installing them.

4Install shims between each section, one per tie rod.

Install shims between each section

Install shims between each section including Inlet and Outlet sections.

6.Install the basic valve section module(s) indicated on the order form against the inlet section. Ensure that the machined surface of the next section faces the O-rings of the previous section.

This will ensure that the O-rings do not fall out during assembly

The first spool listed in model number is closest to the inlet section.

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CDS Directional ControlValve Assembly andTesting Manual

Assembly

7.	Install the outlet section against the	Install outlet section
	last basic valve section.
8.	Install lockwashers and nuts on end
of tie rods.
Install the lock washers and nuts hand
tight so the sections can’t separate and
allow the O-rings to fall out of place.
9.	Lay the stack down on its mounting
	feet.Adjust washers and nuts so	Torque tie rods
	tie rods stick out equal distance on
	either side of valve.

10.Tighten tie rod nuts incrementaly in staggered order.

Tie rod nut torque:

•CDS 60 is 16-18 N•m [13-15 lbf•ft] ,

•CDS 100 is 25-27 N•m 18-20 [lbf•ft] using a 1/2 inch socket.

11.Check each spool to ensure free movement of all sections.Any binding or sticking in spools is unacceptable.If binding/sticky spools are present,disassemble the stack and inspect for cause.Replace parts as required.

Spool movement will have a slight drag from the O-rings.Be careful not to shift the spool end past the O-rings.Shifting spool end past the O-rings may damage the O-rings.

12.The spools are pre-installed into the spool bores of each valve section at the factory. Each spool is matched to its housing.Do not interchange spools.Inter-changing a spool from one section to another,may cause spool to bind and/or create high internal spool leakage.

Install plug/relief valve in inlet section

13.Install the specified option (plug or relief valve) to the inlet section. Torque to 27-39 N•m [20-25 lbf•ft]

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		CDS Directional ControlValve Assembly andTesting Manual
		Assembly
CENTERING TYPES		Assemble the spring/detent assemblies to the valve as specified in the order form.The
		stem(s) for each assembly must have Liquid LockThreadsTM or equivalent applied.For
		CDS 60 tighten the stem(s) to a torque of 2.7-4.0 N•m [2-3 lbf•ft] using a 11mm socket.
		For CDS 100 tighten the stem(s) to a torque of 4.0-5.4 N•m [3-4 lbf•ft] using a 13mm
		socket.
For loose sections,
complete assembly with
section clamped in a		Spring centered assembly (A)
protective jawed vice		1. Install the stem and spring assembly	Spring/detent assemblies
before adding to stack..		on the spool using Liquid Lock
		ThreadsTM or equivalent. For CDS
		60 tighten the stem(s) to a torque
		of 2.7-4.0 N•m [2-3 lbf•ft] using a

11mm socket.For CDS 100 tighten the stem(s) to a torque of 4.0-5.4 N•m [3-4 lbf•ft] using a 13mm socket.

2. Lubricate the spring assembly with	Lubricate spring assembly
Lubriplate 730-1TM or equivalent.

3. Install the end cap over the spring	Install endcap over spring assembly
package.Apply Liquid LockThreadsTM
or equivalent and install the two
(2) screws and washers using the
appropriate screw driver.
Screw torque:
• CDS 60 and CDS 100 2.7-4.0 N•m [2-3
lbf•ft].

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CDS Directional ControlValve Assembly andTesting Manual

Assembly

CENTERING TYPES	Three position detent assembly (B)	Install detent assembly
(continued)	1. Install stem on spool using using
	Liquid LockThreadsTM or equivalent.
	For CDS 60 tighten the stem(s) to
	a torque of 2.7-4.0 N•m [2-3 lbf•ft]
	using a 11mm socket.For CDS 100
	tighten the stem(s) to a torque of
	4.0-5.4 N•m [3-4 lbf•ft] using a 13mm
	socket.
	2. Fasten cap to spool with two screws
	and washers.Using a 5/32 hex driver,
	torque screws to 5.5-8.2 N•m [4-6
	lbf•ft].

Install spring in detent assembly

3Lubricate the steel balls and spring with LUBRIPLATE 730-1TM or equivalent.

4.Install one ball and the spring into the holes of the end cap.

5.Install second ball on other end of spring.

Install cover in detent assembly

6Compress the balls against the spring evenly and slip the sleeve over the end.

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