Loop Flushing

Valve

Technical
Information
 Loop Flushing Valve
Technical Information
General information

Application The loop flushing valve, applied in a hydrostatic transmission circuit, maintains high
quality of the working fluid in the transmission power loop. While many transmissions
can operate satisfactorily without a loop flushing valve, the addition of loop flushing
improves fluid quality and generally extends transmission life.

Consider the loop flushing valve when any of these exist:

• Sustained operation at low pressure and high speed
• Operation where continuous pressure exceeds 1000 hours per year
• Cylinders in the hydrostatic circuit
• Flow restricting valves in the power loop
• Frequent operation of high pressure relief valves
• Long power loop lines
• Extraordinary life requirements

Sauer-Danfoss recommends monitoring fluid quality under field operating conditions

for extended periods of time to determine loop flushing requirements. For a complete
discussion of loop flushing and fluid quality, refer to Sauer-Danfoss bulletins BLN-9886
Transmission Circuit Recommendations and 520L0463 Hydraulic Fluids and Lubricants,
Technical Information.

Description The high pressure ports (1 and 2) of the Schematic diagram

Orifice
valve are externally connected to the (optional)
work or system auxiliary ports of the System press.
gauge port 5
main hydrostatic transmission circuit. The X Drain port
valve drain port (4) must be externally 4

connected to the case drain return line

of the transmission — preferably at the
motor so that fluid flushes through the
motor case and returns to the reservoir.
System press.
X
gauge port 6
The shuttle valve exposes the low X
pressure side of the circuit to the System port
Charge press. System port
1
charge relief valve. When properly set gauge port 3 2

(see Adjustment Procedure, page 5) the P104 162E

charge relief valve flushes a desired

quantity of working fluid from the transmission power loop. The charge pump replaces
this fluid.

You may specify a drain orifice to limit maximum flushing flow in circuits where the low
side pressure is high or varies over a large range.

2 520L0641 • Rev DC • August 2010

 Loop Flushing Valve
Technical Information
General information

Specifications System pressure

Maximum high side 480 bar [6961 psi]
Maximum low side 70 bar [1015 psi]

Charge relief setting Nominal charge relief settings are

Minimum 15 bar [218 psi] ±1.4 bar [±20 psi] and are set at a flow
Maximum 28 bar [406 psi] of 3.8 ±0.9 l/min [1 ±0.25 US gal/min] at
49º C [120º F]

Model code 8800485--

Charge pressure
15 to 28 bar, 1 bar increments
Example:
20 = 20 bar [290 psi]

Orifice
00 = None
09 = Ø 2.40 mm [0.0945 in.]
12 = Ø 3.19 mm [0.1255 in.]

Performance Valve without orifice

(psi) (bar)
Low system pressure (above drain)

600
40
Maximum setting
500 35

30
400
25
300 20
Adjustment range
15
200
10
100
5
Minimum setting
0
0 1 2 3 4 5 6 (US gal/min)
(l/min) 0 2 4 6 8 10 12 14 16 18 20 22
P104 185E
Flow
Valve with 2.40 mm [0.0945 in.] orifice
(psi) (bar)
Low system pressure (above drain)

1000 70

60

750
Maximum setting 50

Minimum setting 40
500
30

20
250
10
Adjustment range
0
0 1 2 3 4 5 6 (US gal/min)
(l/min) 0 2 4 6 8 10 12 14 16 18 20 22 P104 186E
Flow

520L0641 • Rev DC • August 2010 3

 Loop Flushing Valve
Technical Information
General information

Mounting Installation drawing

95.0 21.3
[3.74] [0.84]
Adjustable charge
87.6 14.0
relief valve
[3.45] [0.55]
1-1/16 in hex (locknut)
9/16 in-18 SAE str. thd.
1/2 in hex (adjustment) 78.2
[3.08] O-ring boss
36.8
[1.45] drain port 4
36 max
[1.417] 15.9
[0.625]
9/16 in-18 SAE str. thd. 8.6 typical
O-ring boss [0.34]
system pressure
gauge port 5
15.2
60.5 73.7 [0.60]
80.8
[2.38] [2.90]
[3.18]

Ø 10.7
[0.42]
Mounting holes 31.8
9/16 in-18 SAE str. thd.
[1.25]
O-ring boss
system pressure
9/16 in-18 SAE str. thd. gauge port 6
O-ring boss
charge pressure 9/16 in-18 SAE str. thd.
gauge port 3 O-ring boss
system port 2

9/16 in-18 SAE str. thd. 60.7 13.0

O-ring boss [0.51] Third-angle
[2.39]
projection
system port 1 P104 163E mm [in]

Mount the loop flushing valve on any convenient flat surface that provides adequate
support around the two mounting holes. Ensure the surfaces under the mounting bolts
form a flat plane.

Failure to provide a flat mounting surface could create valve housing distortion when
the mounting bolts are torqued. Housing distortion may bind internal components and
reduce the drive and/or braking capacity of the system.

WWarning
The loss of hydrostatic drive line power in any mode of operation may cause a loss
of hydrostatic braking capacity. A braking system, redundant to the hydrostatic
transmission, must be provided which is adequate to stop and hold the system should
such a condition develop.

4 520L0641 • Rev DC • August 2010

 Loop Flushing Valve
Technical Information
Service information

Adjustment For initial setting of the valve package: Adjustment diagram

procedure Relief valve adjustment
1. Plumb an in-line flow meter into the h1/2 in
drain line.
Locknut
h1-1/16 in
If a flow meter is not available, use a t42 to 55 N•m
clean container with a known volume [31 to 41 lbf•ft]
and a stop watch to measure flow rate.

2. Set the brakes or otherwise restrict

machine motion.

3. Stroke the transmission pump

to build at least 34 bar [500 psi]
differential system pressure.
Drain
9/16 in - 18 str. thd.
4. Adjust the relief valve in the flushing P104 165E
O-ring boss port
valve package to obtain the desired
drain flow. Typically 7.5 to 11.4 l/
min [2 to 3 US gal/min] is sufficient.
Rotating the adjusting screw counter-clockwise increases flow and decreases the
effective pressure setting by approximately 5 bar [73 psi] per turn.

5. Torque the locknut 42 to 55 N•m [31 to 41 lbf•ft].

6. Verify that pump charge pressure is above recommended minimum.

7. Remove the flow meter from the circuit.

Service information Component installation torque

Description Wrench size Torque
Gauge port plugs 9
/16 in hex 27 to 47 N•m [20 to 35 lbf•ft]
Charge relief lock nut 1 ¹/16 in hex 42 to 55 N•m [31 to 41 lbf•ft]
Orifice plug /16 in internal hex
3 22 to 27 N•m [16 to 20 lbf•ft]
Shuttle spool plugs /16 in
11 36 to 44 N•m [27 to 33 lbf•ft]
Hose/tube fittings — 27 to 47 N•m [20 to 35 lbf•ft]

520L0641 • Rev DC • August 2010 5

 Loop Flushing Valve
Technical Information
Service information

Service information Exploded view

(continued)
t42 to 55 N•m
[31 to 41 lbf•ft]
h1-1/16 in

t27 to 47 N•m
[20 to 35 lbf•ft]
h9/16 in
3

d 3A i11 Enlarged bold type item

numbers are recomended
parts to be stocked for servicing

t36 to 44 N•m
[27 to 33 lbf•ft]
h11/16 in
16

d16A t27 to 47 N•m

[20 to 35 lbf•ft]
1 h9/16 in
2A d
15
2

12 I3/16 in
t22 to 47 N•m
[20 to 35 lbf•ft]

13

15
4A d
d
4
t27 to 47 N•m 16A
[20 to 35 lbf•ft] 2A d 3A
h9/16 in
2 d
3
16

t27 to 47 N•m
[20 to 35 lbf•ft] 2A d
h9/16 in
2 E101 098E

6 520L0641 • Rev DC • August 2010

 Loop Flushing Valve
Technical Information
Service information

Service information Replacement parts

(continued) Item Part Number Description Quantity
1 8800538 Housing assembly 1
2 9005100-5600 Plug 3
2A 9004201-3700 O-ring 3
3 9005100-5600 Plug 2
3A 9004201-3700 O-ring 2
4 9005100-5600 Plug 1
4A 9004201-3700 O-ring 1
9 8510012 Charge relief valve kit 1
11 9004201-6200 O-ring 1
12 8800242-0009 Orifice plug – Ø 2.40 mm [0.0945 in] 1 (opt.)
12 8800242-0011 Orifice plug – Ø 3.19 mm [0.1255 in] 1 (opt.)
13 8800550 Shuttle spool 1
15 513596 Spring guide assembly 2
16 518016 Special plug 2
16A 9004201-3700 O-ring 2

520L0641 • Rev DC • August 2010 7

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