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M7-31 Danfoss PVG 32 FLG 140 K3

Index

Index ........................................................................................................................................................ 1 
Proportional valve Danfoss PVG 32 ..................................................................................................... 2 
1. General about proportional valves ................................................................................................... 2 
2. PVG 32 general .................................................................................................................................. 2 
2.1 Properties ....................................................................................................................................... 2 
2.2 Cross section view and part descripton Standart PVG .................................................................. 4 
2.2.1Cross section view .................................................................................................................... 5 
3. End element PVG 32 new ................................................................................................................. 6 
3.1 Components ................................................................................................................................... 6 
3.2 Function (Constant flow) ................................................................................................................. 6 
3.3 Others ............................................................................................................................................. 7 
4. Working element ................................................................................................................................ 8 
4.1 Components ................................................................................................................................... 8 
4.2 Function .......................................................................................................................................... 8 
5. Main spool ........................................................................................................................................ 10 
5.1 Flow compensation ....................................................................................................................... 10 
5.2 Pressure compensation ................................................................................................................ 10 
5.3 Spool Codes ................................................................................................................................. 11 
5.4 Palfinger spools ............................................................................................................................ 11 
5.5 FLG Hydraulic diagram ................................................................................................................. 13 
5.6 Valve description inlet element PVSK .......................................................................................... 14 
6.3 PVSK Inlet element. Operating conditions ................................................................................... 15 
6. Modules ............................................................................................................................................. 16 
6.1 Types ............................................................................................................................................ 16 
6.2 Control .......................................................................................................................................... 17 
6.3 Plug and wiring ............................................................................................................................. 19 
7. Danfoss PVEH Module / S4............................................................................................................ 20 
7.1 Passive fault monitoring................................................................................................................ 21 
7.2 Active fault monitoring .................................................................................................................. 22 

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M7-31 Danfoss PVG 32 FLG 140 K3

Proportional valve Danfoss PVG 32

1. General about proportional valves

The Danfoss PVG 32 is a fully proportional valve. Proportional valves are permanent acting valves
where the hydraulic output quantity signal proportional to the electrical Input signal is.

The detection of the spool position is done by an inductive position encoder.

Proportional valves are relatively little dirt sensitive and therefore robust in business.
The FLG control valve is different to the standard version because of:

 Using an inlet element with emergency function Y0.

 Special designed inlet element for the connection of an extern manual pump.

 Customer designed configuration of the working elements and spools.

2. PVG 32 general

2.1 Properties

 Pressure
o Max. pressure at P-connection 40 MPa
o Max. pressure at A/B connection 35 MPa
o Max. pressure at T- connection, static / dynamic 2,5 MPa / 4 MPa

 Oil flow

o P- connection 140 l/min

o A/B- connection with pressure compensator 100 l/min
o A/B- connection without pressure compensator 125 l/min

 Spool travel
o In both directions ± 7 mm

 Oil temperature (input)

o recommended oil temperature 30  60°C
o min. temperature –30 °C
o max. temperature + 90°C

 Oil viscosity
o recommended viscosity 12 to 75 mm²/s

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M7-31 Danfoss PVG 32 FLG 140 K3

 Filtration
o Max. contamination 19/16

 max. 10 elements on a valve block

 low weight

 Shock valves + Anti cavitations valves to protect exit ports

 Primary valves to set output pressure individually.(Only in the working section mast lifting /
lowering)

 Selective LS- controlled extraction, separate for LSA und LSB- connector (as use able in
combination with an extern overload system.

 The valve can prepared for constant flow and variable flow systems
(Crayler only uses constant flow systems).

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M7-31 Danfoss PVG 32 FLG 140 K3
2.2 Cross section view and part description Standard PVG

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M7-31 Danfoss PVG 32 FLG 140 K3

2.2.1Cross section view

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M7-31 Danfoss PVG 32 FLG 140 K3

3. End element PVG 32 new

3.1 Components

 integrated main relief valve (system pressure up to 40 MPa)

 Pressure gage connection (M)
 Modification to Load sensing possible
 Connections P and T
 LS connection for signal to variable pump

1 Pressure relief valve

2 LS-signal
3 LS-connection
4 Tank channel
5 Pressure channel
6 Pressure adjustment
spool
7 Anchor screw
8 Plug open centre
Orifice Closed Centre
9 Pressure gauge
10 Pressure reducing valve
Pilot oil (by Crayler in the
inlet element placed)

3.2 Function (Constant flow)

a) Pump Off No pressure in the system. The inlet compensator closes the connection
between P and T.

b) Pump On The back pressure acts on the compensator (0, 1 MPa) and opens it. The
full oil flow goes straight to the tank.

c) Activation If a function is activated, a Load sensing signal acts on the compensator and
closes it. Due to this, the necessary working pressure builds up. The
required oil flow flows to the acted function, the remaining flow goes to the
tank (constant flow system).

d) Max. Pressure At maximum working pressure, the integrated main relief valve opens and
the LS signal is blown to tank. Due to this, the compensator cannot hold the
pump pressure anymore and opens to tank as well.

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M7-31 Danfoss PVG 32 FLG 140 K3

3.3 Others

 The pilot oil pressure is limited by a pressure reducing valve and is set to approx.
1, 5 MPa (15bar). The pressure reduction valve is additional equipped with a safety
function to limit the pilot pressure to 3, 0 MPa (30bar). The valve is placed in the end
element of the control valve.

TIPP: There is no connection to measure the pilot pressure. If required, a hand lever cap
can be modified with a pressure gage connection.

 The valve bank has 3 anchor screws, tightened with 25 Nm.

 The modification kit from constant flow to LS contains a small orifice (pos.8) instead
of the plug.

 Crayler use only a open centre system for the working hydraulic.

 In the inlet element is placed the emergency cut of function and the HPCO (high
pressure carry over) function (not in use by Crayler).
In the end element is placed the pressure compensator, the pilot operated main relief
valve and as well the orifice.

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M7-31 Danfoss PVG 32 FLG 140 K3

4. Working element

4.1 Components

1 Primary valve
2 Pilot oil
3 Spool
4 Shuttle valve
5 Anchor screw
6 Pressure compensator
7 LSA and LSB connection
8 Oil flow adjustment screws
9 Shock- and suction valve

4.2 Function

a) Compensator The pressure compensator is necessary to get a steady and constant oil
flow through the element. The compensator avoids the influence and
interference of other functions (movements) during operation.

b) Shuttle valve A chain of shuttle valves (two per element) is necessary to transmit the
highest load signal to the pressure compensator in the inlet element.

c) Primary valve Primary valves (only in combination with a pressure compensator) are
available to set the output pressure to an individual level. These valves are
not used at the Crayler application

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M7-31 Danfoss PVG 32 FLG 140 K3
d) Shock valve Shock valves are available to protect the output lines from load shocks.
These valves are always combined with an anti cavitations valve. The
setting of the shock valves must be different to the setting of the primary
valve.

Schock 32 50 63 80 100 125 140 150 160 175 190 210 230 240 250 280 300 320 345
Max. 40 50 64 80 100 112 120 130 145 160 180 200 210 220 250 270 290 315
Primär
Min. 30
Primär

e) Setting screws Two setting screws allow setting the maximum spool travel on each element.
With this setting, the maximum working speed can be reduced (not
recommended with RRC system, would reduce the module life time).

f) LSA, LSB The LSA and LSB connection allow to switch off a function by taking the
internal LS signal to tank (used for instance for overload protection
systems).

Danfoss offers various possibilities for the working element configuration.

These differ according to the requirement on controllability and adjustment possibilities.

The following versions are available

 Element with working connections A and B, no primary valves or shock valves.

 Element with working connections A and B, two shock valves mounted.

 Element with working connections A and B, two primary valves mounted.

 Element with working connections A and B, two primary valves and two shock
valves mounted.

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M7-31 Danfoss PVG 32 FLG 140 K3

5. Main spool
Danfoss offers a wide range of main spools for the PVG 32 proportional valve.
Generally they can be divided into pressure and flow compensated spools.

5.1 Flow compensation

The pump pressure is controlled from the highest working pressure of the valve bank.

On constant flow systems, this is done by the pressure compensator in the inlet element, on variable
pumps this is done by the pump regulator.

The pump pressure is therefore always the sum of the load signal and the spring pressure of the
compensator. At variable systems, the sum of the load pressure and the stand by pressure.

Finally flow compensated spools have a very steady and good to control oil flow.

5.2 Pressure compensation

On functions with a very high inertia moment or functions with load holding valves, flow
compensated spools do not work properly due to the counter pressure on the tank side of the spool.
Such functions require pressure compensated spools (or partly pressure compensated spools).

Pressure compensated spools also have disadvantages

 the oil flow is depending on the load

 the dead band of the hand lever is depending on the load

 the pump pressure can be much higher than the load pressure

This means, that pressure compensated spools, should only be used in case of problems with
bouncing loads due to load holding valves.

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M7-31 Danfoss PVG 32 FLG 140 K3
5.3 Spool Codes

To identify different spools without any doubt in all situations, Danfoss uses a code on each spool.

The Danfoss code normally starts with 157B7 . . . plus three figures more, all other codes like
157B9..., 157X.... are special spools.

The three final figures mean:

Figure 6: 0 .......... closed neutral position

1 .......... open neutral position
4 .......... one side open to tank (A -> T)
5 .......... one side open to tank (B -> T)

Figure 7: 0 .......... without primary valves, flow compensated

1 .......... without primary valves, pressure compensated
2 .......... with primary valves, flow compensated
3 .......... with primary valves, pressure compensated
4 .......... without primary valves, pressure compensated only on A
5 .......... without primary valves, pressure compensated only on B
6 .......... with primary valves, pressure compensated only on A
7 .......... with primary valves, pressure compensated only on B

Figure 8: 0 ............. 10 l/min

1 ............. 25 l/min
2 ............. 40 l/min
3 ............. 65 l/min
4 ........... 100 l/min
5 ............... 5 l/min
8 ............. 20 l/min
9 ............. 15 l/min

5.4 Palfinger spools

The following list shows the most common spools on Palfinger cranes and coMPares the
Palfinger number with the Danfoss number (selection).

Danfoss number Palfinger number Danfoss number Palfinger number

157B7000 .................. EV-2673 157B7020 ..................... EV-1891

157B7001 .................. EV-1407 157B7021 ..................... EV-1411
157B7002 .................. EV-1408 157B7022 ..................... EV-1412
157B7003 .................. EV-1409 157B7023 ..................... EV-1413
157B7004 .................. EV-2514 157B7024 ..................... EV-1615
157B7010 .................. EV-2248 157B7025 ..................... EV-1890
157B7011 .................. EV-1410 157B7030 ..................... EV-3559
157B7012 .................. EV-3798 157B7031 ..................... EV-2144
157B7013 .................. EV-2090 157B7032 ..................... EV-2288
157B7015 .................. EV-3594 157B7033 ..................... EV-2065

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M7-31 Danfoss PVG 32 FLG 140 K3
Danfoss number Palfinger number Danfoss number Palfinger number

157B7035 .................. EV-3832 157B7020 ..................... EV-1891

157B7041 .................. EV-2120
157B7042 .................. EV-2066 157B7402 ..................... EV-2499
157B7043 .................. EV-1904 157B7403 ..................... EV-1954
157B7052 .................. EV-2500 157B7404 ..................... EV-3951
157B7053 .................. EV-2068 157B7421 ..................... EV-3549
157B7061 .................. EV-1414 157B7422 ..................... EV-2164
157B7062 .................. EV-1415 157B7423 ..................... EV-1955
157B7063 .................. EV-1416 157B7424 ..................... EV-3964
157B7064 .................. EV-2067 157B7452 ..................... EV-2774
157B7071 .................. EV-2112 157B7453 ..................... EV-2410
157B7072 .................. EV-2069 157B7472 ..................... EV-2165
157B7073 .................. EV-2345 157B7473 ..................... EV-2179
157B7074 .................. EV-2582
157B7501 ..................... EV-3161
157B7100 .................. EV-2993 157B7502 ..................... EV-2516
157B7101 .................. EV-2501 157B7503 ..................... EV-2674
157B7102 .................. EV-2063 157B7521 ..................... EV-2912
157B7103 .................. EV-2064 157B7522 ..................... EV-3632
157B7104 .................. EV-1903 157B7524 ..................... EV-1878
157B7105 .................. EV-2619 157B7542 ..................... EV-2268
157B7110 .................. EV-3799 157B7543 ..................... EV-2653
157B7111 .................. EV-2989 157B7562 ..................... EV-1718
157B7112 .................. EV-2277 157B7563 ..................... EV-1719
157B7113 .................. EV-2230
157B7120 .................. EV-3061 157B9002 ..................... EV-2507
157B7121 .................. EV-2074 157B9004 ..................... EV-2505
157B7122 .................. EV-1417 157B9020 ..................... EV-3158
157B7123 .................. EV-1418 157B9021 ..................... EV-3159
157B7124 .................. EV-1798 157B9022 ..................... EV-2503
157B7125 .................. EV-3550 157B9024 ..................... EV-2502
157B7131 .................. EV-3496 157B9064 ..................... EV-3156
157B7133 .................. EV-2186 157B9074 ..................... EV-3157
157B7161 .................. EV-2075 157B9104 ..................... EV-2506
157B7162 .................. EV-2062 157B9120 ..................... EV-3160
157B7163 .................. EV-3821 157B9124 ..................... EV-2504
157B7164 .................. EV-2061 157B9753 ..................... EV-2515
157B7171 .................. EV-3401
157B7173 .................. EV-2992 157X0528 ..................... EV-3907
157B7174 .................. EV-2005 157X0529 ..................... EV-3908
157X0530 ..................... EV-3909
157X0531 ..................... EV-3910
157X0532 ..................... EV-3911

General

The modification of a control valve configuration requires a very high knowledge and technical
understanding of the machine and the valve bank.

Therefore it is not allowed to change spools (or also other parts of the valve) without a clear order
from the producer of the machine.

This is especially also valid for the interchanging of the A and B port connections.

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M7-31 Danfoss PVG 32 FLG 140 K3
5.5 FLG Hydraulic diagram

3
9
2

7 9

10
5
11

Legend:

Number Parts Designation

1 Power supply pump / emergency manual pump. Separated by an shuttle valve
2 Inlet element spool PVSK
3 Module PVEO (on / off) with by-pass opportunity with the yellow seal. Moves pos.2
4 Pilot pressure reduction valve (1,5 MPa and safety valve 3,o MPa is in one cartridge)
5 Main relieve valve
6 Pressure gauge
7 Proportional module working function
8 Inlet element pressure maintenance valve
9 Port relieve valve
10 Primary valve
11 Pretension valve

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M7-31 Danfoss PVG 32 FLG 140 K3
5.6 Valve description inlet element PVSK

PVG 32 with integrated emergency cut off function and HPCO high pressure carry over function.
This emergency function regulates the oil flow for the working function. The module is under voltage
as soon as an proportional function on the transmitter is moved.

This is the safety loop in the case that an working element module get stuck in activated position.

In the end element are placed the pressure compensator, pilot operated main relive valve as well the
orifice for Open Centre / Closed Centre modification.

Parts

1 PVEO (on/ off Module)

2 Emergency operating seal (yellow seal)
3 PVSK Inlet element
4 Pretension valve
5 End element Constant pump OC
End element variable displacement pump CC
6 Emergency operating
7 Main spool
8 Pilot oil reduction valve
9 Anchor screw (spare part number depends of the number of element)

the inlet spool is placed in the new inlet element (PVSK). (Current less neutral position and working
position, 12 Volt power)

An emergency operating mode (protected by the yellow cap seal)

Purpose: to use the working hydraulic, without electrical power, in case of problems with the module
or the radio remote control.

This by – pass screw must be used also in case of manual operating mode.
(In case of an error on RRC or cable mode.)

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M7-31 Danfoss PVG 32 FLG 140 K3

6.3 PVSK Inlet element. Operating conditions

6.3-1 Emergency mode (no movement on the transmitter)

The PVEO module is current less; the spool is in neutral position.

The oil supply to the working elements is locked. The oil flow goes to the tank.
The oil flow goes via the internal tank canal to the tank connection in the end element.
(LS variant looked complete)

6.3-2 Working mode (movement on the transmitter)

The PVEO Module (Y0) gets current, the spool moves in direction of the hand levers.
The oil flow goes via the working elements to the pressure compensator into the end element to
the tank connection.

6.3-3 Emergency mode (manual mode)

Due do turn in (clockwise) the yellow cup on the front side of the PVSK inlet element, a M 6mm
hexagon head screw will by pass the spool inside and moves the spool in the working position.

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M7-31 Danfoss PVG 32 FLG 140 K3

6. Modules

6.1 Types

Generally a wide selection of control modules is available for the Danfoss PVG32 control valve (all
versions).

At Crayler forklifts, on the PVEH type is used

 PVEH proportional module „high“without direction indication and“AMP” plug.

The PVEH signifies a “high” controllability, suitable for Crayler forklift.

The PVEM module (as well as all other proportionally controlled modules) has an integrated inductive
way transducer to monitor the spool position and send a signal to the integrated hybrid electronic.

The position of the spool is controlled internally according to the inlet signal.

Integrated electronics
Closed loop control of the main spool

Pilot-oil

Electronic

Valves

Feed back transducer

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M7-31 Danfoss PVG 32 FLG 140 K3
6.2 Control

All Danfoss modules are voltage controlled.

The input voltage (UDC) can be either 12V or 24V (the same modules).

The spool is in neutral position, if the signal voltage is 50% of the reference voltage UDC.
Maximum speed occurs at a signal of 25% or 75% of the reference voltage.

This means, the signal wire of a 12V system contains a neutral signal of 6V, which lowers down to
3V to get full speed in one direction and increases up to 9V to get full speed in the other direction.

The hybrid electronic controls the four internal magnetic valves of the module, which finally feed the
pilot pressure to the spool.

12 Volt 100% of UDC

9 Volt 75%
Working range

-7mm 12 Volt 50% Dead band 7%

25% Working range

3 Volt

0 Volt 0%

The spool moves because of the pilot pressure acting on it.

 If the element gets no power at all, the spool is free and only centred by the spring force.

 If power is given to the module, the spool is centred hydraulically.

 Finally the working signal from the control unit starts the movement, controlled by the
internal electronic of each module.

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M7-31 Danfoss PVG 32 FLG 140 K3
No signal and no power to the module
The tank ports are open, so the spool is not centerred hydraulically but held in position with the
spring force.

U =0V
DC
US = 0 V PVEH
B A

Neutral signal
All valves are locked.
There is no pilot oil acting on the spool but also the tank lines are not free so the spool is centerred
hydraulically.

U = On US = Constant (0,5 x UDC )

DC

B A

Working signal
The logic of the electronic controls the four magnetic valves and allows the pilot oil to move the
spool. As soon as the required position is reached (known by the internal feed back transducer), all
valves close and the spool is locked in working position.

UDC= On US = Actuation
(0,5 -> 0,75 x U )
DC

B A

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6.3 Plug and wiring

Due to the voltage control of the system it is quite easy to measure the working signals on various
places. Two different controlling types are known:

Single module control

Only the function which is active gets electric power

Advantage: Error on other modules does no influence the system

As shown in the diagram, the signals from the RRC system are wired through the Crayler junction
box before they are given to the Danfoss control valve.
If a function does not work properly, the wiring, the relays as well as the module has to be checked.

Example lifting mast:

120 Junction number

A120 permanent signal, as soon as the respective joystick is acted

V120 Joystick control signal

31 Permanent negative signal

K37 Relay contact of lifting mast in vertical position

K2 Relay contact side shift in middle position

K3 Relay contact high limitation

S2 Sealed by pass button on terminal box

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M7-31 Danfoss PVG 32 FLG 140 K3
7. Danfoss PVEH Module / S4
The new Danfoss module for Palfinger cranes is called PVEH module series 4.

Due to the integrated electronic no adjustments or software is necessary.

The integrated way feed back transducer measures the spool position travel in relation to the
operating signal.

4 solenoid valves are controlling direction, speed and position of the operating spools.

Features:

 Operating voltage between 11 and 32 Volts (no separate 12 and 24 V module necessary)

 4 internal solenoid valves

 Protection IP 69 K

 Internal fault monitoring system with luminous diode

 Inductive way transducer

 Low power consumption

 No adjustment necessary

Function of the fault monitoring (luminous diode)

Constant red = internal error

Red flashing = external error

constant = OK (working)

There is a PVEH module Series 4 with feed back signal (DI), Palfinger part number EC 5416 and a
PVEH series 4 without DI function, Palfinger part number EV 5417.

PVEH Modul without DI-Feedback

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M7-31 Danfoss PVG 32 FLG 140 K3
.

7.1 Passive fault monitoring

If an internal or external error occurs, a warning signal is created, which switches off the internal
solenoid valves. The spool moves into neutral position.

7.1-1 Monitoring of signal range

The module permanently controls the signal power supply. The allowed range is between 15% and
85% of the feed voltage.
If the signal is out of range, the module switches off and shows internal

7.1-2 Spool position monitoring

If the spool monitoring feeler has a broken wire or a short cut, the module switches off and shows
internal error.

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M7-31 Danfoss PVG 32 FLG 140 K3
7.1-3 Monitoring of the closed circuit

The actual position of the spool must be similar with the acted signal during the joystick.
(Inputsignal).
If the actual position is bigger than the stipulated position, the module recognises an error and Stop
the movement.
There again, if the actual position is closer to the neutral position than stipulated, any error appears.

If an fault occurs, following acts into the module.

7.2 Active fault monitoring

The system acts with a delay of 500 – 750 ms.

The magnetic valves loose power and the spool moves into neutral position.
A restart of the system is necessary.

7.2-1 To high power supply:

The system switches off, if the power supply exceeds 36 Volt.

7.2-2 To low power supply:

The system switches off, if the power supply is less than 8.5 V.

7.2-3 Internal tact signal:

The Magnet valves are locked as long as the internal tact frequency is disturbed.
And as result, the spool stays in the neutral position.

7.2-4 Plug connection:

Three cables from this four pole AMP Plug are connected.

Contact 1 Proportional signal. Depends of the movement on the joystick the signal intensity on
the plug is changing. (3Volt until 9 Volt)

Contact 2 Plus 12 Volt

Contact 3 Minus 12 Volt

Point of view of a module plug

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