Danfoss Bent Axis Motors Service guide

MAKING MODERN LIVING POSSIBLE

Service Manual

Bent Axis Motors

Series 51 Two Position Controls

powersolutions.danfoss.com

Service Manual	Series 51 Two Position Controls Service Manual

Revision history	Table of revisions
	Date	Changed	Rev
	January 2015	Danfoss layout	CA
	March 2009	Added TA, TH, TN, PC, PD	BA
	February 2008	First edition	AA

2	11009442 • Rev CA • January 2015

Service Manual	Series 51 Two Position Controls Service Manual
Contents
Introduction
	Safety Precautions............................................................................................................................................................................	5
	Unintended Machine Movement..........................................................................................................................................	5
	Flammable Cleaning Solvents................................................................................................................................................	5
	Fluid Under Pressure..................................................................................................................................................................	5
	Personal Safety.............................................................................................................................................................................	5
	Hazardous Material.....................................................................................................................................................................	5
	Symbols used in Danfoss literature............................................................................................................................................	6
	Overview..............................................................................................................................................................................................	7
	General instructions........................................................................................................................................................................	7
	Keep it Clean.................................................................................................................................................................................	7
	Inspect for System Contamination.......................................................................................................................................	7
	Replace the O-rings and Gaskets...........................................................................................................................................	7
	Lubricate all Moving Parts........................................................................................................................................................	7
	Torque Procedure.......................................................................................................................................................................	7
Operation
	Two-position Controls....................................................................................................................................................................	8
	Control Options.................................................................................................................................................................................	8
	Pressure Compensator Override (PCOR) Option.............................................................................................................	8
	Brake Pressure Defeat (BPD)....................................................................................................................................................	9
	Threshold Spring.......................................................................................................................................................................	11
	Multifunction Block..................................................................................................................................................................	11
Pressure measurements
	Port Locations and Gauge Installation...................................................................................................................................	13
Adjustments
	Threshold Setting...........................................................................................................................................................................	16
	Adjusting Threshold Setting.................................................................................................................................................	16
	PCOR Setting....................................................................................................................................................................................	16
	PCOR Adjustment.....................................................................................................................................................................	16
	Checking PCOR Setting on a Test Stand..........................................................................................................................	17
	Adjusting the PCOR Setting..................................................................................................................................................	17
Pressure Compensator Override (PCOR)
	Repair..................................................................................................................................................................................................	18
	Disassembly................................................................................................................................................................................	18
	Inspection....................................................................................................................................................................................	18
	Assembly......................................................................................................................................................................................	18
Multifunction Block
	Repair..................................................................................................................................................................................................	20
	Disassembly................................................................................................................................................................................	20
	Inspection....................................................................................................................................................................................	21
	Assembly......................................................................................................................................................................................	21
T1, T2, T3, T4, TA, TH, TM, TN
	Operation..........................................................................................................................................................................................	22
	TA Control....................................................................................................................................................................................	22
	TH Control...................................................................................................................................................................................	22
	T1, T2, T3, T4 Control...............................................................................................................................................................	22
	TM, TN Controls.........................................................................................................................................................................	22
	N Module Option Codes..............................................................................................................................................................	22
	Overview......................................................................................................................................................................................	22
	C0/C3 3.........................................................................................................................................................................................	22
	C2/C4.............................................................................................................................................................................................	23
	C7/C8.............................................................................................................................................................................................	23
	L5/L6..............................................................................................................................................................................................	23
	R5/R6.............................................................................................................................................................................................	23
	E7, E8, F7, F8................................................................................................................................................................................	23
	Schematic Diagrams.....................................................................................................................................................................	23

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Service Manual	Series 51 Two Position Controls Service Manual

Contents
Repair..................................................................................................................................................................................................	25
Removing Solenoid(s).............................................................................................................................................................	25
T1/T2/T3/T4 controls..........................................................................................................................................................	25
Disassembly................................................................................................................................................................................	25
T1/T2/T3/T4/TA/TH/TM/TN controls............................................................................................................................	25
Inspection....................................................................................................................................................................................	27
Assembly......................................................................................................................................................................................	27
Solenoid Assembly...................................................................................................................................................................	28
T1/T2/T3/T4 controls..........................................................................................................................................................	28
N2 Controls
Operation..........................................................................................................................................................................................	29
Functional Description...........................................................................................................................................................	29
Repair..................................................................................................................................................................................................	29
Disassembly................................................................................................................................................................................	29
Inspection....................................................................................................................................................................................	30
Assembly......................................................................................................................................................................................	30
E1, E2, F1, F2 Controls
Operation..........................................................................................................................................................................................	32
Functional Description...........................................................................................................................................................	32
Repair..................................................................................................................................................................................................	32
Disassembly................................................................................................................................................................................	32
Assembly......................................................................................................................................................................................	33
G1, G2, G7
Operation..........................................................................................................................................................................................	35
Functional Description...........................................................................................................................................................	35
Repair..................................................................................................................................................................................................	35
Disassembly................................................................................................................................................................................	36
Inspection....................................................................................................................................................................................	37
Assembly......................................................................................................................................................................................	37
U1, U2
Operation..........................................................................................................................................................................................	39
Functional Description...........................................................................................................................................................	39
Repair .................................................................................................................................................................................................	39
Disassembly................................................................................................................................................................................	39
Inspection....................................................................................................................................................................................	41
Assembly......................................................................................................................................................................................	41
PC, PD
Operation..........................................................................................................................................................................................	42
Functional Description...........................................................................................................................................................	42
PC Control..............................................................................................................................................................................	42
PD Control..............................................................................................................................................................................	42
Adjustment.................................................................................................................................................................................	42
PC, PD PCOR Adjuster Stop-pin......................................................................................................................................	42
Repair..................................................................................................................................................................................................	43
Schematic Diagrams................................................................................................................................................................	43

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Service Manual	Series 51 Two Position Controls Service Manual

Introduction

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.

Unintended Machine Movement

W Warning

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

W Warning

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

W Warning

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

W Warning

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

Hazardous Material

W Warning

Hydraulic fluid contains hazardous material. Avoid prolonged contact with hydraulic fluid. Always dispose of used hydraulic fluid according to state and federal environmental regulations.

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Service Manual	Series 51 Two Position Controls Service Manual

Introduction

Symbols used in Danfoss literature

WARNING may result in injury

CAUTION may result in damage to product or property

Reusable part

Non-reusable part, use a new part

Non-removable item

Option - either part may exist

Superseded - parts are not interchangeable Measurement required

Flatness specification

Parallelism specification

External hex head

Internal hex head

Torx head

O-ring boss port

Tip, helpful suggestion

Lubricate with hydraulic fluid

Apply grease / petroleum jelly

Apply locking compound

Inspect for wear or damage

Clean area or part

Be careful not to scratch or damage Note correct orientation

Mark orientation for reinstallation Torque specification

Press in - press fit

Pull out with tool – press fit

Cover splines with installation sleeve

Pressure measurement/gauge 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.

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Service Manual	Series 51 Two Position Controls Service Manual

Introduction

Overview

This manual includes information for the installation, maintenance, and minor repair of Series 51 twoposition controls. It includes a description of each control, instructions for adjustment, and minor repair procedures.

General instructions

Keep it Clean

You can complete many repairs or adjustments without removing the unit from the machine, provided the unit is accessible and you can thoroughly clean it before beginning any procedures.

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

As with any precision equipment, keep all parts free of foreign materials and chemicals. Protect all exposed sealing surfaces and open cavities from damage and foreign material. Cap all hoses after removal, and plug all open ports. Cover any unattended parts with a protective layer of plastic.

Inspect for System Contamination

Inspect the motor for signs of system contamination. If you find contamination, fully disassemble, clean and inspect all components of the motor.

Replace the O-rings and Gaskets

Replace all O-rings and gaskets. Discard them only after you make certain that you have the correct replacement parts. Lightly lubricate all O-rings with clean petroleum jelly before assembly.

Lubricate all Moving Parts

During reassembly, coat all moving parts with a film of clean hydraulic oil. This helps lubricate the surfaces during start-up.

For fluid quality requirements, refer to 520L0463 Hydraulic Fluids and Lubricants, Technical Information.

Torque Procedure

During reassembly, cross torque all retaining screws to the given value. Do not overtorque.

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Service Manual	Series 51 Two Position Controls Service Manual

Operation

Two-position Controls

Two-position controls shift the motor to either maximum or minimum displacement. Control input may be hydraulic or electric. To change displacement, the control routes pilot pressure to one end of the servo piston while draining the other.

A 4-way valve integral to the motor’s endcap routes the flow of oil in all two-position controls except N2, G1, G2 and PC. The 4-way valve consists of a spool and a logic sleeve. The control shifts the spool and ports pressure to one end of the servo and drains the other. Ports in the logic sleeve regulate the flow from the valve to the servo piston ends. The sleeve logic may be standard or reversed. The standard logic sleeve defaults the motor displacement to maximum and shifts to minimum displacement when the control operates. The reverse logic sleeve defaults the motor displacement to minimum and shifts to maximum displacement when the control operates.

With N2 controls, external valving pressurized and drains the servo piston ends. With G1, G2 controls, a two-position 4-way solenoid cartridge valve replaces the 4-way valve. The PC control feeds servo supply pressure directly to the minimum displacement end of the servo piston.

Optional orifices in the control and motor end cap modulate shift speed.

Series 51 servo mechanism

4-way valve

Servo piston

Tamper resistant
cap
Minimum
displacement
limiter
Valve segment
	Spacer
Miximum
displacement
limiter	P101 195E

Control Options

Pressure Compensator Override (PCOR) Option

The PCOR function allows the motor to match its displacement to the system load. The PCOR overrides the control command allowing the motor to increase displacement when system pressure reaches a set level due to load. This permits the motor to regulate system pressure by modulating the displacement of the rotating group. As displacement increases, so does available torque while output speed decreases and system pressure remains nearly constant at the PCOR setting.

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Service Manual	Series 51 Two Position Controls Service Manual

Operation

The PCOR setting pressure is adjustable from 130 to 370 bar [1890 to 5370 psi]. Optional orifices at locations T4, T5, T6, U6, or U7 regulate the speed of the PCOR operation.

PCOR option

		N18
	N20	N14
		N16
N27
		N29
N23
N23	N27	P101 906
Example of T* PCOR option
(TM, TN)		G36
(may be on		N240
either side of spool) M1
		M12

M10

M18 M18A

N20

N26	C2/C4

	M24
N20A	N14	NT42
		M16A
	M16
M1	M22
		P107 960E

Brake Pressure Defeat (BPD)

The PCOR function can be equipped with a brake pressure defeat option that defeats PCOR operation during dynamic braking. A spool in the multifunction block directs acceleration system pressure to the PCOR valve. During deceleration, braking pressure is blocked from the PCOR. This limits engine overspeeding while the vehicle is slowing down. The BPD spool requires an external signal to communicate motor rotation. This signal can be pressure to either port XA or XB, or it can be an electric signal to a solenoid.

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Service Manual	Series 51 Two Position Controls Service Manual

Operation

EP, EQ electrohydraulic proportional control with pressure compensator and hydraulic brake pressure defeat.

XB	XA	A
BPD	Shuttle
	PCOR
Multifunction Block		B

M4	M3
	M1
Loop flushing	L1
Max.
displ.
	L2
	M5
	M2
M7	M8
	P101 907
X1	Control

BPD option

Brake defeat spool

Shuttle valve

PCOR adjuster

PCOR spool

P106 431E

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Service Manual	Series 51 Two Position Controls Service Manual

Operation

Threshold Spring

A threshold spring acts on the opposite end of the 4-way valve. Adjusting the threshold screw changes the pressure required to move the 4-way valve and start the change in displacement.

Optional orifices may be installed at several locations to regulate shift speed. Refer to the model code for your motor for details.

Threshold and ramp springs

Lock nut

Threshold adjusting screw

Threshold spring

Multifunction Block

For T* controls PCOR adjusting screw

4-way valve

P107 856E

Some controls are used in conjunction with a multifunction block. The purpose of the multifunction block is to route high loop (system) pressure from port A or B to the 4-way valve for servo supply pressure, and to direct low loop pressure from port A or B to the control for pilot pressure. The spool that

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Service Manual	Series 51 Two Position Controls Service Manual

Operation

resolves high pressure for servo supply and low pressure for control pilot also feeds these pressures to an optional Pressure Compensating Over-Ride (PCOR) valve.

Multifunction block schematic

Loop flush

Shuttle
spool
		T4
	PCOR	T6
U7	U6
T5

L2	M4	M3	N
A			M1
			n
	max.
	disp.
T2	T3
	T1		L1
T7
			M5
B			M2

	E* F*		4-way valve
		X	Control
	X		P106 391E
	M8	M7

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Service Manual	Series 51 Two Position Controls Service Manual

Pressure measurements

Port Locations and Gauge Installation

Series 51 motors

M3		Y
M3	Main ports A+B
L1
		Y
		side port
	M1
	M5	M5

L2	M1
	M7

Axial port

System pressure A+B

Guage port M1+M2

Y

Axial port

M5

W

M2 M4

W

	P101 204E
Y
	Main
M3	port B

W

	M4
	M5
Main
port A	P101 204E

Legend

Abbreviation	Definition
L1	Case drain; (1-5/16-12UNF)
L2	Alternate case drain: (1-5/16-12UNF)
M1	Gauge port: system pressure A (9/16-18UNF)
M2	Gauge port: system pressure B (9/16-18UNF)
M3	Gauge port: servo pressure min. angle (9/16-18UNF)
M4, M5	Gauge port: servo pressure max. angle (9/16-18UNF)
M7	Control pressure port (9/16-18UNF)

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Service Manual	Series 51 Two Position Controls Service Manual

Pressure measurements

G1, G2 controls

M5

Shaft center

A-A

Solenoid wiring

DIN connector 43650-AM2

A

Charge pressure relief valve

P106 392E

Legend

Abbreviation Definition

M5	Gauge port: servo pressure max. angle (9/16-18UNF)

E1/E2, F1/F2. H1/H2, and K1/K2 controls

	Z
	XA
	M8
	M7
	XB
Z	P106 393E

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Service Manual	Series 51 Two Position Controls Service Manual

Pressure measurements

Gauge ports with U1/U2 controls and T1, T2, T3, T4, TA, and TH controls

		Z
		XA
		XA
		<![if ! IE]> <![endif]>X1
	X4	<![if ! IE]> <![endif]>X4
		XB
		XB
	Z	P106 395E
Legend
Abbreviation	Definition
M7, M8	Gauge port control pressure (9/16-18UNF)
X (A, B, and 1)	Control pressure port (9/16-18UNF)

Solenoid for

electric 2 position control

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