Page 1
MAKING
MODERN
LIVING POSSIBLE
Service
Manual
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Motors
Property of American Airlines
powersolutions.danfoss.com
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lbil
Page 2
Service
Manual Series 5t and
Pressure measurements
Gauge information
M3
M4
M5
pressure
Servo
Servo supply
Servo supply
minimum
pressure
pressure
angle
maximum
51-1 Motors
angle
Service Manual
600 bar
fi
9/16-18
O-ring
bar
600
[10,000
9/16-18 O-ring fitting
bar
600
[10,000
9/16-18
O-ring fitting
0,000
psil
fitting
psi]
psi]
Series 51-I
motors
Side
port
Guage
port
pressure
Sysem
Ml
port
M2
B
Gauge information
M1
Property of American Airlines
pressure
System
pressure
System
Guage
port
A
t f008567. Rev
port
BA
A+B
M1+M2
.
June 2014
600 bar
9/16-18
psi]
[10,000
O-ring fitting
Main
port
B
Page 3
Service
Manual
Series
51
and
5l-1 Motors
Service
Manual
Initial
startup
Procedure
procedures
Always
follow
restarting
,&
Tlris
rJisconnectinq
bystanders.
1. Before
2.
3. Fillthe
4. Fill
5.
6. Make
7.
an
warnimg
service
r:rocedure
Take
installing
handling.
Make
certain all
are
clean
reservoir
filter
into
unexpected
the inlet
Check inlet
sure
Fillthe
motor
oil into
the upper
procedure
this
installation
may require
work
function,
necessary
the
the motor
system
before
filling with
with recommended
the reservoir.
vehicle/mach
line leading
properly
line for
inlet
the
line
and/or
case
when
in
which
and so
safety
and/or
components
fluid.
Using
contaminated
ine
movement.
from
the reservoir
tightened fittings
is
free
pump
housing
port.
drain
starting-up
eitherthe
disabiing
of restrictions
pump
the vehicle
forth) v,rhile
grrecautions.
pump,
(reservoir,
hydraulic
with
clean hydraulic
a new
or
performing,
inspect
hoses,
fluid. Filter
fluid may
to
the
and
Series
motor
rnachine
/
the
units for
valves,
damage
pump.
air leaks.
51 or
Series 51-1 installation
has
been removed.
(raising
prevent
to
using
fluid before
injury
damage incurred
fittings,
heat
a 10 micron
components
start
the rarheels
to
the teclrnician
during
exchanger,
(nominal,
which
up. Fill
cf"f
may
by
pouring
when
or
ground,
the
shipping
and
so forth)
no bypass)
result
anil
and
in
filtered
i&
caution
itlever
start
fh-rid.
8.
lnstall
a G60 bar
monitor
9. Disconnect
connections
remains
10.
Use
a common
pressure
1 1.
Enable prime
pressure
warning
"&
Do
not
necessary precautions
initiai
Property of American Airlines
12.
start-up.
lf
necessary,
port.
Once
charge
Charge
and
determine
the
the charge
any
for
in
its neutral
starts
to
mover.
is
established.
start the
bleed excess
pressure
pressure
cause.
prime
mover
[0-1000
external
EDC)
method
prime
should be
psil pressure
pressure
control
from the
position.
to disable
rise.
Start
the
mover
prevent
to
air from
is
established,
See Troubleshootino
unless
the
during
start-up.
input
pump
the
prime
mover
unless
the
machine
the high
increase
as indicated
motor and
gauge
signal
control
prime
and run
pump
movement
pressure
in
the
on
in
the
(linkage
until
mover.
is in
speed
pump
page
pump
are filled
pressure
charge
for
MDC, hydraulic
after
initial
(slowly
Jog
at
the lowest
position
neutral
in
case
lines through
to normal
model
code.
29.
cornpletely
gauge
lines for
start-up. This
prime
rotate)
possible
{swash
pump
is actuated
the high
operating
lf charge
port
ensures
speed
plaie
pressure
speed.
pressure
with
clean hyclraulic
of
the
HDC,
that the
mover
until charge
at
0" anqle). Take
in
stroke durinq
pump
or electrical
pump
until charge
gauge
sysrem
is low,
shut
to
down
1.,-
Low
1 1008567
C*uti*n
charge
.
Rev
pressure
.
BA
June
may affect
2014
the operators
ability
to controlthe
machine.
27
Page 4
''*ft"nre#&d
.d!/-Yry*
service
Initial
Manual
startup
procedures
series
51 and
13,
shut down the
14.
Connect the
15. Reconnectthemachinefunction
16.
Start the
17. che.kfol
charge
18.
Continue
19.
Shut
20, Remove
21.
Plug
the
22.
Check reservoir
23,
Add
filtered
The
motor
prime
forward
pressure
to cycle
prime
down
gauges.
gauge ports.
fluid
transmission
/
5l-l
Motors
prlme
mover.
external control
mover, checking
reverse
and
may
decrease
slowly
between
mover.
level.
to the reservoir,
is now
service
ready
Manual
input slgnal.
if disconnected
to ensure
machine
slightly
during forward
forward
if
needed.
for
operation.
pump
the
operation,
and reverse
earlier.
remains In
with
prime
the
or reverse
for at
least five
neutral.
mover
operation.
minutes.
at nomal
operating
speed,
Property of American Airlines
.
t 1008567
Rev
BA
.
June 2014
Page 5
Service
Manual
Troubleshooting
Series
51
and 51-1 Motors
Service
Manual
Sluggish
Check
1
2.
3.
4.
5.
1
8.
System
system
Controlorifices
Threshold
controls)
Control spoolor
Pressure
Control
Charge
System
setting
com
input
pressure
pressure
Internalleakage
operating
(proportional
piston
pensator
signal
hot
setting
Cause
Blocked
or
response.
will cause PCOR
restricted orifice will
Orifices
controlto
Inappropriately high
motor at the wrong
A sticky
4-way
sluggish response.
Inappropriately
will
shift motorto
pressure
improper
An
may
cause sluggish response.
lnappropriately
flushing
pressure
Inappropriately
cause sluggish
Excessive
and affect
spool or control
low
or erratic input
low
relief valve
to motor
low system
response.
leakage will
performance.
maximum displacement
control.
installed
cause sluggish
the
to
wrong locations
be sluggish.
threshold setting will
tlme.
piston
pressure
compensati ng setti
signalto
pressure
may cause
setting
improper
pressure
cause lower charge
shift the
will
cause
at lower
the control
at loop
supply
setting
pressure
ng
may
Corrective
Remove,
appropriate
action,,
inspect
orifi
Checkthreshold
Clean and inspect
piston.
Replace if
pressure
Check
necessary.
Check input
necessary.
Measure
Adjust
Measure
signal
change
loop flushing relief
system
limiter or system
Install loop
flow. lf
repair.
flushing defeat
case flow is
your
Contact
and clean
ces are installed.
setting. AdJust
the
necessary.
compensator
pressure
pressure.
relief valve
all orifices.
4-way valve
or electric
in forward
valve
Adjust
if
option
excessive,
Danfoss
service
Ensure
the
if necessary.
spool and
setting. Adjust
current
if necessary.
control
if
and correct if
and
reverse.
pump pressure
necessary.
and monitor
motor may require
provider.
case
major
Check
'l
Oillevel
2.
Heat exchanger
3.
Loop flushing
4.
System
5.
Air in
6.
Internalleakage
Excessive
Check
I
Oillevelin reservoir
2.
Air in
Cause
Insufficient
Blocked
sufficiently
pressure
charge
Inappropriately
setting
lmproper
cooling
pressure
system
Property of American Airlines
noise
or vibration
system
lf
system
heat
Entrained
causes
Excessive
Cause,
Insufficient
Air
hydraulic
heat
exchanger
cool
will reduce
orifice
purposes.
relief valve
generated.
will be
generates
air
cavitation
internal
hydraulic
bubbles may
fluid will
or low
the system.
high
loop
flushing relief
prevent
or
size
settings
leakage will
lead to cavitation.
will
fluid
not
heat
will
loop flushing
give proper
aretoo fow,
under
overheat the
cause
cause overheating.
air flow will
not
valve
flow.
flow
excess
pressure
system. Install
cavitation. Fill reservoir
O
for
and
Corrective
Fill reservoir
Check
temperature
exchanger.
necessary.
Monitor
case
relief valve
Adjust
system relief valve
Look
for
foam or
on inlet
side of
loop
flow.
lf case
repair.
Contact
Corrective
Lookforfoam
inlet
on
side
action
proper
to
Clean, repair,
drain
setting
flushing
flow
level,
upstream
flow.
or replace
bubbles in
pump.
charge
defeat option
is
excessive, motor
your
Danfoss
action
proper
to
of charge
level.
or
bubbles in reservolr.
pump.
replace
or
lf low
settings.
reservoir.
and
adjust
with
service
downstream
heat
exchanger if
loop
flushing
orificed
type relief.
Check for
and
monitor case
may require
provider.
Checkfor
of heat
leak
major
leak
| 1
008567
.
Rev BA
.
June 201 4
Page 6
Service Manual
Troubleshooting
Series 51
and 51-1
Motors Service
Manual
Check
3.
Shaft coupling
4.
Shaft alignment
Motor
operates normally
Check
1
Charge
2,
Motor control
3.
Pressure
lmproper
output speed
Check
1
Oillevelin reservoir
2.
Threshold
3.
P ressu re
4.
Controlspoolor
5.
Controlorifices
6.
Control
7.
Control input
8.
lnternal
pressure
compensator
setting
compensator
piston
piston
signal
leakage
Cause
Loose
Misaligned
damage motor.
in one direction
Cause
lf charge
flushing
lf controlshifts motorto
one
to operate.
control lf
setting
pressure
only, the motor
in
the otherdirection
Cause
Insufficient hydraulic
efficiency.
lmproper
have wrong
lmproper
motor displacement
Pressure compensator
holds
Blocked
shaft coupling
shafts create
only
pressure
is
shuttle spool
direction,
compensator operates in
threshold setting will
pressure
motor
or restricted
low
motor may not have
will stay at minimum
displacement
compensator
wrong
at
creates excess noise.
excessive noise
in
one direction,
may be
sticking to one
minimum
fluid
will
for
reduce
given
displacement in
enough torque
one direction
displacement
cause
signal.
setting
at wrong
orifice
pressure.
piston
or spoolsticking
displacement.
causes motor
and
the loop
system
motor
shifts
to shift
Corrective
Replace
if
shaft
Correct shaft
Corrective
Measure
pressure
side.
loop flushing shuttle spool.
Measure
check
control operation.
input
signal if
Check
or receiving
correct input
Corrbctive
Fill reservoir
to
Check
th reshold setting. Refer
manual
pressure
Check
necessary.
pressure
Check
or replace
Remove,
action
loose
shaft coupling. Replace
splines are worn excessively.
misalignment.
action
pressure
charge
drops in one direction,
in forward
maximum and minimum
Repair control
defeat spool. lt
signal.
brake
necessary.
pressure
improper
an
signal.
action
proper
to
level.
to
for adjustment
if needed.
inspect,
procedure.
compensator setting.
compensator
and
piston
clean allorifices.
or
and reverse.
inspect
and
servo
or correct
may be sticking
Repair
spool or
control
Adjust
orspool.
repair
motor
repair
pressures
service
if
Repair
lf
to
improperly.
control
input
piston
causes motorto
signal causes
shift
motor to shift
Check
control
necessary.
Correct
control input signal.
piston
for
proper
operation.
Repair if
Sticliy
improperly.
lmproper
improperly.
Excess internal
pressure
output
and
affects system
speed.
leakage causes
lower
charge
performance
including
Install
loopflushing defeat
flow-
lf case
repair.
Contact
flow is excessive,
your
Danfoss
option and monitor
motor may require
Service Provider.
case
major
Property of American Airlines
Low
outputtorque
Check
I
System
2.
Charge
3.
Pressu
pressure
pressure
re compensator
Cause
Low
torque.
Low
improper
setting High
improper
t 1 008557
.
Rev BA
pressure
system
loop flushing relief valve
supply
pressure
at motor
pressure
compensator
to motor
motor displacement
.
June 2014
reduces output
setting may
control.
setting causes
for
torque
cause
required.
Corrective,action'
level.
charge
pressure
valve
pressure
pressure
Measure system
limiter
or relief
proper
the
Measure
Adjust loop flushing
check
and adjust
the
at
setting
is low, increase
in forward
relief valve
compensator
motor. lf the
pressure
setting to
reverse.
and
setting if necessary.
setting.
Page 7
.-#jr".l4(
li o s
;iexP
Service
Manual
Troubleshooting
Check
A
T.
Control
orifices
5.
Pressure
compensator
spool
6-
Controlspoolor
7.
8.
9.
10.
position
Two
Control input
Threshold
Internal
leakage
solenoid
signal
setting
piston
Series 51
piston
or
and 51-1 Motors
Cause
Blocked
or restricted orifice
improperly.
pressure
Sticking
causes
controlto hold
displacement.
Sticking 4-way
motor to
position
Two
maximum
lmproper
at minimum
lmproper
displacement
Excess internal
decay, reducing
spool or control
shift
improperly.
control not shifting
displacement.
control input
displacement.
threshold
for
leakage
output
Service
compensator
motor
Manual
causes motor
piston
minimum
at
piston
motor
signal causes
setting causes improper
torque required.
causes
charge
torque.
to
or spool
causes
to
motor to
pressure
shift
stay
motor
to
Corrective action
Remove, inspect
Remove
and inspect
Repair
or replace if necessary.
Remove
and inspect 4-way
Repair or
lnspect
Repair or replace
Correct
Check and adjust
Install loop
flow.
repair. Contact
replace if necessary.
solenoid valve
control input
flushing
case
lf
flow is
and
clean allorifices.
control spool
for bent
if necessary.
signal.
threshold
defeat
excessive, motor
your
Danfoss
and sensing
spool and control
stem or
bad coil.
setting.
option and monitor
may require
Service
Provider.
piston.
piston.
case
major
Property of American Airlines
.
1
1
008567
Rev BA
.
June 201 4
31
Page 8
Service Manual
Adjustments
Overview
Series
51 and
...,fu Warninq
51-1
Motors
Service
Manual
This
disconnectinq
technician
Adjust
refer
Charge
Set the
procedure
service
anc.l
components
to Pressure
pressure
charge
may require
the worl<
bystanders.
function,
of
the Series
measuremenfs
relief valve
pressure
relief valve
arrd so forth)
T..ike
tlre necessary
51 and
page
on
disabiing
to
motorchargereliefvalveisset2to4bar
(measured
temperature
Measuring
1.
Install a
pressure).
2.
Install
3.
Operate
(forward
Series
51 charge
with the
a 0 to 60
pump
of 50"
Cl'122'F].
pressure
charge
0 to 60
bar
[0
bar
to
[0
the system with
or reverse).
pressure
in
its neutral
Charge
to t 000
t 000
the
relief valve
psil pressure
psil
prime
Adjustment
plug
,^A
\_-/
\@-
vehicle
the
wlrile
safety
Series
51-l motors
gauge
23,
for
the modelorder
[29to58psil
or zero-angle
pressure
gauge
mover
is referenced
gauge
port
in
at normal
t
"7
I
l16
lock
i-*"1
l-t'l
l.'-'l
machine
1
performing,
precautions
port
locations
code specifications.In
(raising
in order
perfollowing
and sizes):
wheels
the
prevent
to
procedures
most
off the
injury
to the
(where
applications,
belowthesettingofthepumpchargereliefvalve
position).
in
Ll or
This setting
{additive)
port
Ml
L2 to
measure
operating
to case
(use
or M2
speed and
case
assumes
pressure.
which
ever is
pressure.
pump
the
reservoir
a
at low loop
at half
nut
ground,
necessary,
the
stroke
0't 208E
Older
Series 5'l and
pressure
relief valve
Series
(not
51-1 motors
shown).
may
be equipped
with an
externalscrew
adjustable
charge
Property of American Airlines
Adjusting
warning
"dh
Itrcorrect
inadequate
conditions to maintain
1. Loosen
2,
32
I 1
Turn
008567
charge
the
.
pressure
charge
pressure
loop flushinq
lock
the
Rev
nut using
adjustment
.
BA
June
setiings
flows.
pump
plug
201 4
may
resuit
You must
performance
a 11/16
hex wrench.
with
a large
in
the inability
maintain
ihe
screwdriverar
to
correct
l3mm
build required
pressure
charge
hex
wrench.
system
uncler
pressure
all
operation
and
or
/
Page 9
Service
Manual
Adjustments
Series
51 and
51-I
Motors
Service
ffi@
Manual
Clockwise
setting. The
psil per
3. After adjusting
rotation
charge
turn.
the
4. Removethegauges.
5. Reinstallthe
Motors
Charge
Series
port
with loop
relief
valve
51-l charge
plugs.
flushing
pressure
Adjustment
of
the
pressure
plug,
page
on
plug
plug
increases
setting
torque
defeated,
44)
do not require
relief valve
ttl,u
ffi
52 Nm
the
will
be
the locknut
or equipped
inch
[38lbf'ftl
setting,
reduced
to 52
N.m
with
adjustment.
and
counterclockwise
increased
or
lbf.ft].
[38
an
orificed
rate
at a
Do not
charge
rotation
of approximately
decreases
overtorque
pressure
relief
valve
the
3.4 bar
(see
[50
Minimum
displacement
limiter
.fu Warnlng
Adjustment
Consult'with
minimum
appropriate
The
factory
lffi
I
o avoid
irut
{Y20)
Property of American Airlines
Detect
maintaining
increase
result in
Adjustin
1.
Remove
resistant
2. Discard
displacement
Caurion
unexpected
after
changes
in
displacement
an
increase
g
minimum
the
of
the minimum
the
Original
test
apparatus.
sets
minimum
everv
in
motor
the motor
in shaft
the tamper
cap
destroys
(Qt
cap
dispiacement
Equipment
setting.
displacement.
changes
adiustment.
in
displacement
at minimum
will result
speed.
displacement
resistant
the locking
zO1
after comparing
Manufacturer
After
adjustment,
operating
by
displacement
in
a decrease
(e120)
cap
device.
limiter
can
or
rrerifv
A
tamper-resistant
ccnditioris
providing
it with
a constant
and monitoring
in shaft
from
the adjusting
a new
result
in
your
Danfoss
minimunr
cap
prevent
and to
speed,
one to make
undesirable
representative
displacement
covers
the
external
flow
of fluid
the motor
while
a
decrease
(ylO).
screw
sure
or
unsafe
settinq
adjustment
lealcage,
to
the motor,
output
in
Removing
new
the
speed
contjitions.
before
chapging
bv
using
screw.
torque
while
shaft
speed.
displacement
the
tamper
one fits.
the
an
the lock
An
will
1 1008567
.
Rev BA. June
2014
33
Page 10
Service Manual
Series
51-1
Controls
81
,B.2,B7,El,EZ,El,FI,
F2,
N1, T1,T2,T7,TA,TH,p7,pg
T1
,T2,T7,T
Schematic
Schematic
(R5
A,
TH Pressure
diagrams
-
diagrams-TH
shown)
Tl
/72/f7
Compensator
(PC)
controls
T1t2t7
C2
Adjustment
warning
$
perform
Do not
as
described. lf
ppropriate
a
PC
The
5366
.
Property of American Airlines
pressure
start
pressure
psil.
To measure
applythe
prccedure
tlris
trecessary,
test
stand.
compensator
the
vehicle's
unless
remove
the motor
pressure
start
pressure
start
brakes to lock
the machine
frorn
setting is
setting:
the
motor shaft
can be
safely
application
the
adjustable in
from
turning
operaied
perform
and
range
a
wfiile
from
loading
this
1 10
procedure
to 370
the motor
in
bar
[15g5
shaft
an
to
or
.
add
an elrtreme
To
check
or
t. lnstall
2,
a 600
displacement)
Due
to the
Install
a
displacement)of
|
1009443
.
Rev
600 bar
reset
bar
controf's
.
BA
load
to the workfunction
pressure
the
psi]
[10,000
of
the servo
configuration
psi] gauge
[10,000
the servo
February
201
compensator
gauge
at
piston.
the
at
piston.
5
of the
port
M4
pressure
port
M3
machine.
setting
to monitor
at M4
to monitor
on a vehicre:
pressure
will
equal
pressure
the
at
the rod
system
at
the
end
pressure.
piston
(maximum
(minimum
end
Page 11
Service
Manual
Series
51-1 Controls
81, B,2,B7,EI,EZ,ET,Fl,
F2,
Nl, T7,T2,T7,TA,TH,
pZ, pg
T1,T2,T7,T
A,TH
Pressure
Compensator
3. Start
the
4'
5. Watch
PC setting
Stroke
a)
lower
b) stroke
c) adjust
PC
This
is the
you
lf
don't
depends
pump
setting
the
on the
(PC)
prime
mover
very
pump's
the
pump
the
the
multifunction
pressure.
gauge
PC
setting.
get
the
controls
and
operate at normal
slowly
to
multifunction
to approximately
port
at
M3.
pressure
correct
application.
gradually
(Series
valve
When
M4
increase
(series
valve
1/4
90)
pressure
setting,
speed.
system
90)
or
displacement
or HPRV
in
M3 begins
repeat
step 4
pressure
HPRV
(Ht
to
)
to decrease,
using
to
PC
the
setting
(H1)
below
the
slowly increase
note
a different
pC
setting
system
pressure
the
option.
pressure,
pressure
The
result
at
or:
to
port
the
M4.
To
check
or
reset
1. Monitor
2.
Increase
PC
To
adjust
1.
Use a 1Omm
2.
Property of American Airlines
Using
setting,
The
3.
Using
system
the
setting.
pressure
the
a 3mm
counter-clockwise
pressure
1Omm
a
pressure
the
flow.
pressure
system
compensator
hex
wrench
internal
compensator
hex
hexwrench,
wrench
compensator
until flow
to
loosen
to decrease
setting
to hold
setting
begins
to increase.
setting:
the
seal
locknut.
turn
the
PC adjusting
the
setting.
changes
the adjustment
at
a rate
on
a
test
stand:
System
screw
of
approximiiety-o
in
place
screw
gauge
clockwise
torque
pressure
to increase
r-ar
taoO
the
seal locknut
at
this
the
ptif per
point
is
\
pressure
turn
to 52 N.m
the
t38lbf.ftl.
4.
Recheck
1
1009443
the
.
Rev BA
pressure
.
February
compensator
201
5
setting
and readjust
the as necessary.
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