Steering Unit: Service Manual

Service Manual

Steering Unit
OSPU

powersolutions.danfoss.com
Service Manual
Steering Unit OSPU

Revision history Table of revisions
Date Changed Rev
April 2017 Updated LS copy valve 0102
September 2014 First edition AA
2 | © Danfoss | April 2017 L1412234 | AX00000142en-US0102

Service Manual
Steering Unit OSPU
Contents
Safety
Safety precautions............................................................................................................................................................................4
Symbols
Symbols used in Danfoss Literature.......................................................................................................................................... 5
Exploded view and seal kit
OSPU exploded view.......................................................................................................................................................................6
OSPU parts list................................................................................................................................................................................... 6
Seal kit for OSPU............................................................................................................................................................................... 7
Tools
Tools for OSPU................................................................................................................................................................................... 8
Dismantling
Dismantling OSPU......................................................................................................................................................................... 10
Assembling
Assembling OSPU.......................................................................................................................................................................... 17
Tightening torques for connections
Tightening torques........................................................................................................................................................................27
© Danfoss | April 2017 L1412234 | AX00000142en-US0102 | 3

Service Manual
Steering Unit OSPU
Safety
Safety precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and others
from injury. Take the following general precautions whenever servicing a hydraulic system.
W Warning
Unintended vehicle or machine movement hazard.

Unintended movement of the machine or mechanism may cause injury to the technican or bystanders.
To prevent uintended movement, secure the machine or disable/disconnect the mechanism while
servicing.
W Warning
Flammable cleaning solvents

Some cleaning solvents are flammable. To eliminate the risk of fire, do not use cleaning solvents in an
area where a source of ignition may be present.
W Warning
Fluid under pressure

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.
W Warning
Personal safety
Protect yourself from injury. Use proper safety equipment, including safety glasses at all times.
W Warning
Product safety
Steering units are safety components and therefore it is extremely important that the greatest care is
taken when servicing these products. There is not much wear on a steering unit and therefore they
normally outlast the application they are built into. Therefore the only recommended service work on
steering units is:
• Changing shaft seals and O-rings
• Disassemble, clean and assemble if contaminated
• Make hydraulic testing including valve setting.

Service Manual
Steering Unit OSPU
Symbols
Symbols used in Danfoss Literature

•
= Non removable part, use a new part
•
= External hex head
•
= Internal hex head
•
= Lubricate with hydraulic fluid
•
= Inspect for wear or damage
•
= Note correct orientation
•
= Mark orientation for reinstallation
•
= Torque specification
•
= Press in - press fit
•
= Pull out with tool - press fit
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.

Service Manual
Steering Unit OSPU
OSPU exploded view
40
25
26
27
28
41 40
43 25
30 26
31 27
32 28
41
35 33
50 1
34
51
44
45
52
46 5
53
37 7
3 10
4
13 11
2
18
16
12
18
17
18
19
20
21
22 24 P301 762
OSPU parts list
OSPU parts list

Parts list Num. per unit Item Tigtening
torque
Dust seal ring 1 1 -
Housing & spool/sleeve set 1 2 -
Ball Ø8.5 mm 1 3 -
Threaded bushing (Screw below surface of housing) 1 4 -
Shaft seal 1 5 -
Bearing assembly 1 7 -
Ring 1 10 -
Cross pin 1 11 -
Set of springs 1 12 -
Cardan shaft 1 13 -
Distributor plate 1 16 -
Gearwheel set 1 17 -
O-ring ø79.4 x ø2.0 mm 3 18 -
End cover 1 19 -
Washer 7 20 -

Service Manual
Steering Unit OSPU
OSPU parts list (continued)

Parts list Num. per unit Item Tigtening
torque
Pin bolt screw 1 21 30±6 N•m
Screw 6 22 30±6 N•m
Model/Code label 1 24 -
Adjusting screw for shock valve 2 25 -
Spring with thrust pad for shock valve 2 26 -
Ball ø3/16 in for shock valve 2 27 -
Seat for shock valve 2 28 6+0/-1 N•m
Adjusting screw for relief valve 1 30 -
Spring for relief valve 1 31 -
Piston for relief valve 1 32 -
Ball Ø3/16 in for suction valve 2 33 -
Bushing with pin for suction valve 2 34 -
LS copy valve 1 35 -
Check valve 1 37 25±5 N•m
O-ring ø9.0 x ø1.5 mm 2 40 -
O-ring ø6.0 x ø1.5 mm 2 41 -
O-ring ø12.42 x ø1.78 mm 1 43 -
O-ring ø15.3 x ø2.2 mm 1 44 -
O-ring ø12.5 x ø1.8 mm 1 45 -
O-ring ø9.5 x ø1.0 mm 1 46 -
Torque compensator valve plug 1 50 -
Torque compensator valve spring 1 51 -
Torque compensator valve spool 1 52 -
Torque compensator valve ball, Ø13.0 mm 1 53 -
Seal kit for OSPU
Seal kit, Danfoss code 11140740 is valid for all codes of OSPU's.
Spare part kit for OSPU, code no. 11140740

Parts list Number per spare part kit Item
Dust seal ring 1 1
Shaft seal 1 5
O-ring 3 18
Washer 7 20
O-ring 2 40
O-ring 2 41
O-ring 1 43
O-ring 1 44
O-ring 1 45
O-ring 1 46

Service Manual
Steering Unit OSPU
Tools
Tools for OSPU
Tools
Holding tool for the entire steering unit. 120±2
Material: Appropriate metal or hard plastic. 90±1
5±1
This tool is not available from Danfoss. 1x45°
20±1
ø46±0.5 2xø15±0.1
-0
0.5/
5+
ø1
4
ø6
7x
100±2
7x51.4°
150±2 P301 644
Assembly tool for dust seal.

Material: Free cutting steel.
This tool is not available from Danfoss.
100±5
min 35
0.5x45°
ø26±0.1
min ø40 P301 643

Service Manual
Steering Unit OSPU
Tools
Tools (continued)
Assembly tool for shaft seal, O-ring/Roto Glyd type:
Code number: 11092408.
Torque wrench 0 - 70 N•m.

13 mm socket spanner.
2.75 - 5 and 8 mm Allan key.
12 mm screwdriver.
2 mm screwdriver.
13 mm ring spanner.
Plastic hammer.
Tweezers.
These tools are not available from Danfoss.

Service Manual
Steering Unit OSPU
Dismantling
Dismantling OSPU
Dismantling OSPU
Place the unit in the holding tool on gear set end.
Screw out the adjusting screws for shock valves (25). O-
ring (40) is fitted on adjusting screw (25).
Remove the springs with trust pads for shock valves (26).
Remove the balls for shock valves (27).
Screw out the seats for shock valves (28). O-ring (41) is
fitted on seat (28).

Service Manual
Steering Unit OSPU
Dismantling
Dismantling OSPU (continued)

Screw out the adjusting screw for relief valve (30). O-ring
(43) is fitted on adjusting screw (30).
Remove the spring for relief valve (31).
Remove the piston for relief valve (32).

Service Manual
Steering Unit OSPU
Dismantling

Screw out the plug for the torque compensator valve
(50). Spring (51), spool (52) and O-rings (44, 45 and 46) is
fitted to the plug (50).
Remove the spool (52) and spring (51) from the plug (50).
Remove the ball (53) from housing.
Replace the unit in the holding tool on steering column

end.

Service Manual
Steering Unit OSPU
Dismantling

Remove the screws (21 and 22) with washers (20).
Remove the end cover (19), sideways.
Lift the gearwheel set (17) off the unit. Remove the two
O-rings (18).
Remove the cardan shaft (13).

Service Manual
Steering Unit OSPU
Dismantling

Remove the distributor plate (16).
Remove the threaded bushing (4) from housing.
Remove the O-ring (18) from housing.
Shake out the check valve ball (3), suction valve pins (34),
balls (33) and LS copy valve (35).

Service Manual
Steering Unit OSPU
Dismantling

Place the housing with the ports facing down on the
work bench. Ensure that the cross pin (11) in the spool
and sleeve set (2) is in the horizontal position. The pin
(11) can be observed through the open end of the spool.
Press the spool (2) inwards (from the housing mounting
face end) and the sleeve (2), ring (7) and bearing
assembly (6) will be pushed out of the housing together.
Take bearing races and needle bearing (7) from the spool
and sleeve set (2). The outer bearing (7) race can
sometimes “stick” in the housing, therefore check that it
has come out.
Press out the cross pin (11).
Remove the ring (10).

Service Manual
Steering Unit OSPU
Dismantling

Carefully press the spool out of the sleeve.
Press the neutral position springs (12) out of the slot of

the spool.
Remove dust seal (1) and shaft seal (Roto Glyd) (5)
carefully with a screw driver or similar tool.
The steering unit OSPU is now completely dismantled.
Cleaning
Clean all parts carefully in Shellsol K or similar cleaner
fluid.
Inspection and replacement

Replace all seals and washers. Check all parts carefully
and make any replacements as is necessary.

Service Manual
Steering Unit OSPU
Assembling
Assembling OSPU
Assembling
Place the two flat neutral position springs in the slot.
Place the curved springs between the flat ones and press
them into place.
Configuration of spring set (12). There can be different

numbers of curved springs depending on configuration
of spring set. There can be 2, 4 or 6 curved springs.
150-386.10
OSPU
Spool and sleeve can be positioned relatively to each
other in 2 positions. Both positions possible are valid due
to symmetry of the OSPU spool/sleeve sets.
Guide the spool into the sleeve (2). Make sure the
centering springs (12) are placed into the slot.
Line up the spring set (12).

Service Manual
Steering Unit OSPU
Assembling
Assembling (continued)
Guide the ring (10) down over the sleeve.
The ring should be able to move free of the springs.
Fit the cross pin (11) into the spool/sleeve.
Fit bearing races and needle bearing (7) as shown on the

drawing below.
1
C Caution
Assembly pattern for standard bearing 2
1. Outer bearing race
2. Needle bearing
3
3. Inner bearing race
4. Spool
5. Sleeve 4
*The inside chamfer on the inner bearing race must face 5

the chest of the inner spool.
150-383.10

Service Manual
Steering Unit OSPU
Assembling
Place the steering unit housing with the port face down
on the work bench. Guide the outer part of the assembly
tool into the bore for the spool/sleeve set (2).
Grease the shaft seal (Roto Glyd, 5) with hydraulic oil and
place them on the tool. Ensure that the Roto Glyd seal is
placed on the insertion tool as per the photograph.
Hold the outer part of the assembly tool in the bottom of

the steering unit housing and guide the inner part of the
tool right to the bottom.
Press and turn the shaft seal (5) into position in the
housing.

Service Manual
Steering Unit OSPU
Assembling
Draw the inner and outer parts of the assembly tool out
of the steering unit bore, leaving the guide from the
inner part in the bore.
With a light turning movement, guide the spool and

sleeve into the bore.
Fit the spool set holding the cross pin (11) horizontal.
The spool set will push out the assembly tool guide. The
shaft seal (5) are now installed.
Place the steering unit housing on the holding tool on

the steering column end. Put the check valve ball (3) into
the hole indicated by the circle.

Service Manual
Steering Unit OSPU
Assembling
Screw the threaded bushing (4) lightly into the check
valve bore. The top of the bush must lie just below the
surface of the housing.
Place a ball (33) in the two bolt holes indicated by the

circles.
Place the pins (34) in the same two bolt holes.
Place the LS copy valve (35) into the hole indicated by the
circle. The conical end must point downwards.

Service Manual
Steering Unit OSPU
Assembling
Insert the o-ring (18) in the grove on the housing.
Place the distributor plate (16) so that the channel holes

match the holes in the housing.
Guide the cardan shaft (13) down into the bore so that
the slot is parallel with the connection flange ports and
lines up with the cross pin (11).
Place the 2 O-rings (18) in the two groves in the gear rim.
Fit the gearwheel and rim (17) on the cardan shaft (13).
Place the gear wheel side with all the deeper splines
facing downwards. Only this side will fit on the cardan
shaft due to all gear sets used in OSPU has timing
securing: splines of gear wheel and cardan shaft can only
be assembled with correct timing.

Service Manual
Steering Unit OSPU
Assembling
Place the end cover (19) in position. Ensure that the bar
codes and writing are parallel with port face.
Fit the pin bolt screw (21) with washer (20) and place it in
the hole shown.
Fit the six screws (22) with new washers (20) and insert
them. Cross-tighten all the screws (22 and 23) with a
torque of 30 ±-6 N•m [265.5 ± 53 lbf•in].
Replace the unit in the holding tool on gear set end.

The OSPU can now be function tested manually: it must
be possible to rotate input shaft with torque < 3.5 N•m
[31 lbf•in].
Assemble the torque compensator valve: new O-rings
(46) in spool (52), (44 and 45) on plug (50), spring (51) and
spool (52) to be pressed into plug (50).

Service Manual
Steering Unit OSPU
Assembling
Install the ball (53) in the housing.
Screw in the entire torque compensator plug w. parts

(50) with an 8 mm Allan key into the cavity indicated by
the arrow.
Torque 30 +10/-0 N•m [265 +88/-0 lbf•in].
Install the piston (32) to housing.
Install the spring (31) on top of the piston (32).

Service Manual
Steering Unit OSPU
Assembling
Place o-ring (43) on adjusting screw (30). Screw in the
adjustment screw (30) with an 5 mm Allan key.
Make the pressure setting on a test panel according to
valve setting specification.
Place o-ring (41) on the shock valve seats (28). Screw in

the seats (28) with a 2.75 mm Allan key into the cavities
indicated by the circles. Torque 6 ±1 N•m [53 ±9

lbf•in].
Place one ball (27) in each of the shock valve cavities.
Place springs with trust pads (26) over the two balls.

Service Manual
Steering Unit OSPU
Assembling
Place o-rings (40) on adjusting screws (25).
Screw in the two adjusting screws (25) using a 5 mm
Allan key.
Make the pressure setting on a test panel according to
valve setting specification.
Place the dust seal ring (1) in the housing.
Fit the dust seal ring in the housing using special tool for
dust seal assembly (see page 7) and a plastic hammer.
Screw in the plastic plugs into the connection ports to

keep the ports clean during storage and transportation.

Service Manual
Steering Unit OSPU
Tightening torques for connections
Tightening torques
Connections Recommended tightening torque N•m [lbf•in]
With cutting edge With copper washer With alum. washer O-ring
G 1⁄4 35 [309] 35 [309] 35 [309] -
G 3⁄8 70 [619] 45 [398] 50 [442] -
G 1⁄2 100 [885] 55 [486] 80 [708] -
G 3⁄4 180 [1593] 90 [796] 130 [1150] -
7⁄16-20 UNF - - - 20 [177]
3⁄4-16 UNF - - - 60 [531]
7⁄8-14 UNF - - - 90 [796]
1 1⁄16-12 UN - - - 120 [1062]
M12 • 1.5 30 [265] 20 [177] 30 [265] 25 [221]
M18 • 1.5 80 [708] 55 [486] 70 [619] 50 [442]
M22 • 1.5 100 [885] 65 [575] 80 [708] 60 [531]
9/16 - 18 UNF, ORFS - - - 25 [221]
11/16 - 16 UN, ORFS - - - 27 [239]
Danfoss Steering Components can withstand the tightening torques stated. However it is recommended
to use torque levels stated by supplier of fittings.

Products we offer: Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and
electronic components. We specialize in providing state-of-the-art technology and solutions
• Bent Axis Motors
that excel in the harsh operating conditions of the mobile off-highway market. Building on
• Closed Circuit Axial Piston our extensive applications expertise, we work closely with our customers to ensure
Pumps and Motors exceptional performance for a broad range of off-highway vehicles.
• Displays
We help OEMs around the world speed up system development, reduce costs and bring
• Electrohydraulic Power vehicles to market faster.
Steering
• Electrohydraulics Danfoss – Your Strongest Partner in Mobile Hydraulics.
• Hydraulic Power Steering Go to www.powersolutions.danfoss.com for further product information.

• Integrated Systems Wherever off-highway vehicles are at work, so is Danfoss. We offer expert worldwide support
• Joysticks and Control for our customers, ensuring the best possible solutions for outstanding performance. And
Handles with an extensive network of Global Service Partners, we also provide comprehensive global
service for all of our components.
• Microcontrollers and
Software Please contact the Danfoss Power Solution representative nearest you.
• Open Circuit Axial Piston
Pumps
• Orbital Motors
• PLUS+1® GUIDE
• Proportional Valves
• Sensors
• Steering
• Transit Mixer Drives
Comatrol
www.comatrol.com Local address:
Turolla
www.turollaocg.com
Hydro-Gear
www.hydro-gear.com
Daikin-Sauer-Danfoss
www.daikin-sauer-danfoss.com
Danfoss
Power Solutions Trading
Danfoss Danfoss Danfoss (Shanghai) Co., Ltd.
Power Solutions (US) Company Power Solutions GmbH & Co. OHG Power Solutions ApS Building #22, No. 1000 Jin Hai Rd
2800 East 13th Street Krokamp 35 Nordborgvej 81 Jin Qiao, Pudong New District
Ames, IA 50010, USA D-24539 Neumünster, Germany DK-6430 Nordborg, Denmark Shanghai, China 201206
Phone: +1 515 239 6000 Phone: +49 4321 871 0 Phone: +45 7488 2222 Phone: +86 21 3418 5200
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products
already on order provided that such alterations can be made without changes being necessary in specifications already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
© Danfoss | April 2017 L1412234 | AX00000142en-US0102

Steering Unit: Service Manual

Uploaded by

Copyright:

Available Formats

Steering Unit: Service Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Steering Unit: Service Manual

Uploaded by

Copyright:

Available Formats

Service Manual

Revision history Table of revisions

Date Changed Rev

April 2017 Updated LS copy valve 0102

September 2014 First edition AA

2 | © Danfoss | April 2017 L1412234 | AX00000142en-US0102

© Danfoss | April 2017 L1412234 | AX00000142en-US0102 | 3

Unintended vehicle or machine movement hazard.

Flammable cleaning solvents

Fluid under pressure

4 | © Danfoss | April 2017 L1412234 | AX00000142en-US0102

Symbols used in Danfoss Literature

© Danfoss | April 2017 L1412234 | AX00000142en-US0102 | 5

Exploded view and seal kit

OSPU exploded view

OSPU parts list

OSPU parts list

6 | © Danfoss | April 2017 L1412234 | AX00000142en-US0102

Exploded view and seal kit

OSPU parts list (continued)

Seal kit for OSPU

Spare part kit for OSPU, code no. 11140740

© Danfoss | April 2017 L1412234 | AX00000142en-US0102 | 7

Tools for OSPU

Material: Appropriate metal or hard plastic. 90±1

150±2 P301 644

Assembly tool for dust seal.

min ø40 P301 643

8 | © Danfoss | April 2017 L1412234 | AX00000142en-US0102

Torque wrench 0 - 70 N•m.

© Danfoss | April 2017 L1412234 | AX00000142en-US0102 | 9

Remove the balls for shock valves (27).

10 | © Danfoss | April 2017 L1412234 | AX00000142en-US0102

Dismantling OSPU (continued)

Remove the spring for relief valve (31).

Remove the piston for relief valve (32).

© Danfoss | April 2017 L1412234 | AX00000142en-US0102 | 11

Dismantling OSPU (continued)

Remove the ball (53) from housing.

Replace the unit in the holding tool on steering column

12 | © Danfoss | April 2017 L1412234 | AX00000142en-US0102

Dismantling OSPU (continued)

Remove the end cover (19), sideways.

Remove the cardan shaft (13).

© Danfoss | April 2017 L1412234 | AX00000142en-US0102 | 13

Dismantling OSPU (continued)

Remove the threaded bushing (4) from housing.

Remove the O-ring (18) from housing.

14 | © Danfoss | April 2017 L1412234 | AX00000142en-US0102

Dismantling OSPU (continued)

Press out the cross pin (11).

Remove the ring (10).

© Danfoss | April 2017 L1412234 | AX00000142en-US0102 | 15

Dismantling OSPU (continued)

Press the neutral position springs (12) out of the slot of

The steering unit OSPU is now completely dismantled.

Inspection and replacement

16 | © Danfoss | April 2017 L1412234 | AX00000142en-US0102

Configuration of spring set (12). There can be different