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
11009442 • Rev CA • January 2015 3
Service Manual
Contents
N2 Controls
E1, E2, F1, F2 Controls
G1, G2, G7
U1, U2
PC, PD
Series 51 Two Position Controls Service Manual
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
Operation..........................................................................................................................................................................................29
Functional Description........................................................................................................................................................... 29
Repair..................................................................................................................................................................................................29
Disassembly................................................................................................................................................................................29
Inspection....................................................................................................................................................................................30
Assembly......................................................................................................................................................................................30
Operation..........................................................................................................................................................................................32
Functional Description........................................................................................................................................................... 32
Repair..................................................................................................................................................................................................32
Disassembly................................................................................................................................................................................32
Assembly......................................................................................................................................................................................33
Operation..........................................................................................................................................................................................35
Functional Description........................................................................................................................................................... 35
Repair..................................................................................................................................................................................................35
Disassembly................................................................................................................................................................................36
Inspection....................................................................................................................................................................................37
Assembly......................................................................................................................................................................................37
Operation..........................................................................................................................................................................................39
Functional Description........................................................................................................................................................... 39
Repair .................................................................................................................................................................................................39
Disassembly................................................................................................................................................................................39
Inspection....................................................................................................................................................................................41
Assembly......................................................................................................................................................................................41
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
4 11009442 • Rev CA • January 2015
W
W
W
W
W
Service Manual
Introduction
Safety Precautions
Series 51 Two Position Controls Service Manual
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
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
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
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
Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.
Hazardous Material
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.
11009442 • Rev CA • January 2015 5
Service Manual
Series 51 Two Position Controls Service Manual
Introduction
Symbols used in Danfoss literature
WARNING may result in injury Tip, helpful suggestion
CAUTION may result in damage to product or
property
Reusable part Apply grease / petroleum jelly
Non-reusable part, use a new part Apply locking compound
Non-removable item Inspect for wear or damage
Option - either part may exist Clean area or part
Superseded - parts are not interchangeable Be careful not to scratch or damage
Measurement required Note correct orientation
Flatness specification Mark orientation for reinstallation
Parallelism specification Torque specification
External hex head Press in - press fit
Internal hex head Pull out with tool – press fit
Torx head Cover splines with installation sleeve
Lubricate with hydraulic fluid
O-ring boss port 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.
6 11009442 • Rev CA • January 2015
Service Manual
Introduction
Overview
General instructions
Series 51 Two Position Controls Service Manual
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.
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.
11009442 • Rev CA • January 2015 7
Tamper resistant
cap
Servo piston
Minimum
displacement
limiter
Valve segment
Spacer
Miximum
displacement
limiter
4-way
valve
P101 195E
Service Manual
Operation
Two-position Controls
Series 51 Two Position Controls Service Manual
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
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
8 11009442 • Rev CA • January 2015
and system pressure remains nearly constant at the PCOR setting.
N20
N16
N27
N23
N27
N18
N14
N29
N23
P101 906
N20
N20A
M22
M24
M10
M12
NT42
M16
M16A
M18
M18A
N26
N14
C2/C4
P107 960E
N240
G36
M1
(TM, TN)
(may be on
either side of spool)
M1
Service Manual
Operation
Series 51 Two Position Controls Service Manual
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
Example of T* PCOR option
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.
11009442 • Rev CA • January 2015 9
M4
M3
M1
L1
L2
M5
M2
M8M7
X1
B
XB XA
A
Max.
displ.
P101 907
PCOR
Multifunction Block
Control
BPD
Loop flushing
Shuttle
Shuttle valve
Brake defeat spool
P106 431E
PCOR spool
PCOR adjuster
Service Manual
Operation
Series 51 Two Position Controls Service Manual
EP, EQ electrohydraulic proportional control with pressure compensator and hydraulic brake pressure defeat.
BPD option
10 11009442 • Rev CA • January 2015
Lock nut
Threshold
adjusting
screw
P107 856E
4-way
valve
Threshold spring
For T* controls
PCOR
adjusting
screw
Service Manual
Operation
Series 51 Two Position Controls Service Manual
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
Multifunction Block
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
11009442 • Rev CA • January 2015 11
n
T6
T2
T7
T1
T3
U6
max.
disp.
A
L2 M4 M3 N
M1
L1
M2
M5
B
P106 391E
T5
T4
U7
M7
M8
X X
E* F*
Loop flush
Shuttle
spool
4-way valve
Control
PCOR
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
12 11009442 • Rev CA • January 2015
M2
Y
side port
M4
M1
Main ports A+B
M5
M7
L2
M3
L1
M1
M5
W
W
M3
Y
P101 204E
System pressure A+B
Guage port M1+M2
Axial port
Main
port B
Main
port A
M5
M3
M4
Y
W
Y
Axial port
P101 204E
M5
Service Manual Series 51 Two Position Controls Service Manual
Pressure measurements
Port Locations and Gauge Installation
Series 51 motors
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)
11009442 • Rev CA • January 2015 13
A
Shaft center
DIN connector 43650-AM2
A-A
Solenoid wiring
Charge pressure relief valve
P106 392E
M5
XB
XA
M7
M8
Z
Z
P106 393E
Service Manual
Pressure measurements
Series 51 Two Position Controls Service Manual
G1, G2 controls
Legend
Abbreviation Definition
M5 Gauge port: servo pressure max. angle (9/16-18UNF)
E1/E2, F1/F2. H1/H2, and K1/K2 controls
14 11009442 • Rev CA • January 2015
X1
XB
XA
X4
Z
XB
Solenoid for
electric 2 position control
XA
X4
Z
P106 395E
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
Legend
Abbreviation Definition
M7, M8 Gauge port control pressure (9/16-18UNF)
X (A, B, and 1) Control pressure port (9/16-18UNF)
11009442 • Rev CA • January 2015 15
Spring seat
P101 911
Locknut
10 mm
9 Nm [6.6 lbf•ft]
3 mm
Service Manual
Adjustments
Threshold Setting
Series 51 Two Position Controls Service Manual
Adjusting Threshold Setting
Threshold on two-position controls is 3 bar [44 psi], except on T* controls.
1. Using a 10 mm wrench loosen the locknut on the adjustment screw.
2. Turn adjusting screw out till it stops. Then turn in five turns.
3. While holding the position of the adjustment screw:
tighten the locknut
•
using a 10 mm wrench torque the locknut to 9 N•m [6.6 lbf•ft].
•
For T* controls the threshold screw adjusts the the PCOR setting.
Locknut and threshold
PCOR Setting
PCOR Adjustment
To measure and adjust the start pressure setting for the PCOR function:
1. Install a 600 bar [10000 psi] gauge at port M, M2 or M5 to read high system pressure.
16 11009442 • Rev CA • January 2015
Service Manual
Adjustments
Series 51 Two Position Controls Service Manual
2. Install a 600 bar [10000 psi] gauge at port M3 to read minimum servo pressure.
3. Safely prevent the motor shaft from moving by:
applying the park brake, apply an extreme load, or
•
positioning the machine against an immovable object, or
•
use other means to hold the machine.
•
4. Start the prime mover. Operate at medium speed.
5. Stroke the pump very slowly to gradually increase the system pressure.
An alternate method to slowly increase the system pressure is to use the pump’s pressure limiter (PL)
valve. Lower the PL setting below the PCOR setting. Stroke the pump to about one-fourth
displacement. Raise the PL setting slowly to increase system pressure until pressure at the M3 port
drops down. System pressure at this point is the PCOR setting. Adjust the PL back to its proper setting
after checking the PCOR setting.
6. Increase system pressure until pressure at port M3 drops down, system pressure at this point is the
PCOR setting.
Checking PCOR Setting on a Test Stand
Increase system pressure until the system flow begins to increase (+8 l/min [2 US gal/min]). System
pressure at this point is the PCOR setting.
System pressure may increase rapidly when flow increases.
Adjusting the PCOR Setting
For PCOR valves mounted on a multiblock, use a 1-1/16 inch wrench to loosen the lock nut on the
adjusting screw. Using a large screw driver or a 13 mm wrench turn the adjusting screw clockwise to
increase pressure setting or counter clockwise to decrease pressure setting. One turn of the adjusting
screw changes the setting approximately 69 bar [1000 psi].
For controls using the threshold adjusting screw for PCOR adjustment, use a 10 mm wrench to loosen the
locknut. Using a 3 mm wrench turn the adjusting screw clockwise to increase pressure or counter
clockwise to decrease pressure setting. One turn of the adjusting screw changes the setting
approximately 55 bar [800 psi].
11009442 • Rev CA • January 2015 17
N82
N29
N20
N14
N18
Z00
N87
U6
U7
N24P
P106 384E
N23
N27
N27
N16J
Service Manual
Series 51 Two Position Controls Service Manual
Pressure Compensator Override (PCOR)
Repair
Disassembly
1. Remove plugs (N27). Remove and discard O-rings (N27A).
2. Using a 1 inch hex wrench, remove plug (N23). Remove and discard O-ring (N23A).
3. Remove locknut (N14).
4. Remove adjustment plug (Z00). Remove and discard O-ring (N16J).
5. Remove spring (N18).
6. Remove spool and spring guide assembly (N20).
7. Remove screws (N29).
8. Remove and discard O-rings (N24P, N82).
9. If present, remove orifices (U6, U7).
PCOR
Tool size and torque
Item Wrench size Torque
N27 1/8 inch internal hex 7 N•m [4 lbf•ft]
N23 1 inch 40 N•m [30 lbf•ft]
U6, U7 3 mm internal hex 6 N•m [4 lbf•ft]
N29 5 mm internal hex 16 N•m [12 lbf•ft]
N14 1-5/16 inch N/A
Inspection
Clean and inspect components for damage or foreign material. Replace damaged parts.
Assembly
1. If previously removed, use a 3mm internal hex wrench to install orifices (U6, U7). Torque to 6 N•m [4
lbf•ft].
2. Using petroleum jelly to retain them, install new interface O-rings (N24P, N82).
3. Position PCOR on multiblock. Install screws (N29). Torque using a 5 mm internal hex wrench to 16
18 11009442 • Rev CA • January 2015
N•m [12 lbf•ft].
Service Manual Series 51 Two Position Controls Service Manual
Pressure Compensator Override (PCOR)
4. Lubricate and install spool and spring guide assembly (N20).
5. Install spring (N18) to cavity.
6. Lubricate and install new O-ring (N16J). Install adjustment plug (Z00).
7. Using a 1-1/16 inch hex wrench, install locknut (N14). Do not torque until after PCOR adjustment.
Refer to page 17 for instructions.
8. Lubricate and install a new O-ring (N23A). Using a 1 inch hex wrench, install plug (N23). Torque to 40
N•m [30 lbf•ft].
9. Lubricate and install new O-rings (N27A). Using a 1/8 inch internal hex wrench, install and torque
plugs (N27) to 7 N•m [4 lbf•ft].
11009442 • Rev CA • January 2015 19
G42
G42
G38
G38
G38
G36
N52
N30
N1A1
N58
P101210
N27
N27
N27
N27
N26
N26
N240
Service Manual Series 51 Two Position Controls Service Manual
Multifunction Block
Repair
Disassembly
1. Using a ¼ inch internal hex wrench, remove plugs (N26). Remove and discard O-rings (N26A).
2. Remove the double resolver spool (N30).
3. Using a 1/8 inch internal hex wrench, remove plugs (N27). Remove and discard O-rings (N27A).
4. Remove screws (N58).
5. Remove the multifunction block (N1A1).
6. Remove and discard the O-rings (G36, G38, G42) or gasket (N240).
7. If present, remove and discard screens (N52).
E*, F* control
20 11009442 • Rev CA • January 2015
Tool size and torque
Item Wrench size Torque
N27 1/8 inch internal hex 7 N•m [4 lbf•ft]
N26 1/4 inch internal hex 37 N•m [28 lbf•ft]
N58
(80, 110)
8 mm internal hex 78 N•m [58 lbf•ft]
Service Manual Series 51 Two Position Controls Service Manual
Multifunction Block
Tool size and torque (continued)
Item Wrench size Torque
N58
(160, 250)
Inspection
Clean and inspect components for damage or foreign material. Replace damaged parts.
Assembly
1. Lubricate and install new O-rings (N27A). Install plugs (N27) using a 1/8 inch internal hex wrench.
Torque to 7 N•m [4 lbf•ft].
2. Using petroleum jelly to retain them, install new interface O-rings (G36, G38, G42) or gasket (N240).
3. Position the multifunction block on the endcap. Install screws (N58). Torque screws as shown in the
table.
4. Lubricate and install the double-resolver spool (N30). Spool is symmetrical, either end first.
5. Lubricate and install new O-rings (N26A). Using a 1/4 inch internal hex wrench, install plugs (N26).
Torque to 37 N•m [28 lbf•ft].
10 mm internal hex 110 N•m [81 lbf•ft]
11009442 • Rev CA • January 2015 21
Service Manual
T1, T2, T3, T4, TA, TH, TM, TN
Operation
Series 51 Two Position Controls Service Manual
TA Control
The TA control does not have two-position operation, it is Pressure Compensating Over-Ride (PCOR)
operation only. It uses a sensing piston (M12) to shift the 4-way valve when system pressure reaches the
PCOR setting. The 4-way valve then ports high system pressure to the servo piston, shifting the motor
toward maximum displacement. The 4-way sleeve is reverse logic: the motor is biased to minimum
displacement. The sensing piston has different area lands that allow high system pressure between the
lands to push the 4-way valve against the threshold spring. The PCOR function threshold setting is
adjustable from 110 to 370 bar [1595 to 5365 psi].
TH Control
The TH control is a hydraulic two-position override with the PCOR function as described above. This
control holds the motor at maximum displacement when an external signal of 10 to 35 bar [145 to 507
psi] is applied to the X1 port.
The non-signal pressure at the X1 port must be equal to the motor’s case pressure or else the PCOR
setting will be altered.
N Module Option Codes
T1, T2, T3, T4 Control
The Tl, T2, T3, T4 controls are electric, two-position override with the PCOR function discussed earlier.
These controls hold the motor displacement at maximum when an external electric signal is applied. The
solenoid is available in four configurations: 12V (T1) or 24V (T2) with DIN 4360 connectors and 12V (T3) or
24V (T4) with Jet jr. Timer connector with Zener commutating diode.
TM, TN Controls
The TM and TN controls are electric two-position with a proportional PCOR solenoid. Full current to the
solenoid holds the motor at maximum displacement. Lesser current varies the PCOR setting, no current
equals full PCOR setting. This coil is available in two configurations; 12V (TM) or 24V (TN) with jet Jr. Timer
connector with Zener commutating diode. These controls also have an electric Brake Pressure Defeat
(BPD) spool. An electric solenoid shifts the BPD spool when energized. This coil is available in two
configurations; 12V (E7- F7) or 24V (E8 - F8) with Jet jr. Timer connector with Zener commutating diode.
Logic for this option is:
• E7 or E8 at XB port energized = system pressure A to PCOR only,
• F7 or F8 at XA port energized = system pressure B to PCOR only.
See TA option for the PCOR operation in T* controls.
Overview
Module N of the motor’s order code indicates circuit options affecting features such as BPD and PCOR.
These are explained below. The pressure required to shift the motor varies with system pressure and by
frame size.
C0/C3 3
The C0 or C3 order code requires an external hydraulic signal into port XA or XB while draining the
opposite port. Signal pressure into port XA shifts the spool so only system pressure A is fed to the 4-way
valve for servo supply and to the sensing piston. Signal pressure into port XB shifts the spool so only
system pressure B is fed to the 4-way valve for servo supply and to the sensing piston. The C0 code is for
internal servo supply and the C3 code is for external servo supply with a plug at U5.
22 11009442 • Rev CA • January 2015
n
max.
disp.
T2
T3
T7 T8
T1
B
XB
M2
M5(X3)
L1
M1
NM3M4L2
A
XA
P106 358E
V
X4
X4
X4 X4
T1/2/3/4 - R5/R6
T1/2/3/4 - L5/L6
T1/2/3/4 - C2/C4
T1/2/3/4 - C0/C3
Service Manual
T1, T2, T3, T4, TA, TH, TM, TN
Series 51 Two Position Controls Service Manual
C2/C4
The C2 or C4 order ode uses no BPD option: PCOR function operates when either system pressure is high.
The BPD spool resolves high pressure and routes it to the 4-way valve for servo supply and to the sensing
piston. The C2 code is for internal servo supply and the C4 code is for external servo supply with a plug at
U5.
C7/C8
The C7 or C8 order code uses no BPD option. An external signal pressure, applied to port X4, manages the
PCOR function. The N26 plug in the control housing blocks the passage connecting internal system
pressure to the sensing piston. The sensing piston operates only from the external pressure at the X4
port. The C7code is for internal servo supply and the C8 code is for external servo supply with a plug at
U5.
L5/L6
The L5 order code defeats the PCOR function on system pressure A. The BPD spool is pinned in one
position, allowing PCOR function only when system port B is high.
R5/R6
The R5 order code defeats the PCOR function on system pressure B. The BPD spool is pinned in one
position, allowing PCOR function only when system port A is high.
Schematic Diagrams
T1/ T2/ T3/ T4 schematic
E7, E8, F7, F8
These options include an electrically operated BPD spool . An electric solenoid shifts the BPD spool when
energized. This coil is available in two configurations; 12V (E7/F7) or 24 V (E8/F8) with Jet jr. Timer
connector with Zener commutating diode.
11009442 • Rev CA • January 2015 23
V
X4
X4 X4
max.
disp.
XA
A
L2
M4
M3
N
M1
L1
M2
XB
B
M5(X3)
P106 360E
n
T2
T3
T7 T8
T1
TA - R5/R6
TA - L5/L6
TA - C2/C4
TA - C0/C3
V
X4
X4 X4
max.
disp.
XA
A
L2
M4
M3
N
M1
L1
M2
XB
B
M5(X3)
P106 359E
n
T2
T3
T7 T8
T1
X1
X1
X1
X1
TH - R5/R6
TH - L5/L6
TH - C2/C4
TH - C0/C3
Service Manual Series 51 Two Position Controls Service Manual
T1, T2, T3, T4, TA, TH, TM, TN
TA schematic
TH schematic
24 11009442 • Rev CA • January 2015
X4
X4
max.
disp.
A
L2
M4
M3
N
M1
L1
M2
B
M5(X3)
P107 827E
n
T2
T3
T7 T8
T1
TM-E 7 (12V)
TN-E 8 (24V)
TM-F 7 (12V)
TN-F 8 (24V)
Service Manual
T1, T2, T3, T4, TA, TH, TM, TN
TM/TN schematic
Series 51 Two Position Controls Service Manual
Repair
Removing Solenoid(s)
T1/T2/T3/T4 controls
Solenoid(s) (M1) available as complete assembly only. Do not remove the solenoid(s) unless you intend to
replace them.
If replacing the solenoid(s) (M1), remove plastic nut, remove coil, and use a thin 3/4 inch wrench to
remove solenoid.
Disassembly
T1/T2/T3/T4/TA/TH/TM/TN controls
1. Using a 1/4 inch internal hex wrench, remove plugs (NT40). Remove and discard O-rings (NT40A).
2. Using a 1/4 inch internal hex wrench, remove plug (M16). Remove and discard O-ring (M16A).
TA controls have a steel plug and TH controls have a plastic plug at (M1).
3. If present, remove pin (N14). Remove shuttle spool (NT42).
4. Using a 1/8 inch internal hex, remove plug (M18). Discard O-ring (M18A).
5. Remove plug (N20). Remove and discard O-ring (N20A).
6. Using a 3 mm internal hex, remove plug (N26), if present.
7. Remove screws (M22) and spacers (M24), if present.
8. Remove the control housing (M10). Discard O-rings (G38, G42, G36) or gasket (G240).
9. Remove the 4-way valve assembly (F32). Discard O-rings (F324).
Read Series 51 and 51-1 Bent Axis Motors Service Manual 11008567 for minor repair instructions for
the 4-way valve, threshold spring, and ramp spring components, if repair is necessary.
10. Remove spring (J10*) and spring seats (J30, J20).
11009442 • Rev CA • January 2015 25
N20
N20A
M22
M24
M10
M12
NT42
M16
M16A
M18
M18A
N26
N14
L5/L6, R5/R6
C0/C3
C2/C4
P101 245E
G420
F32
F324
G36
J30
J10*
J20
M1
(TM, TN)
(may be on
either side of spool)
M1
E*/F*
(used with TM, TN only)
(used with TA, TH only)
NT41
Service Manual Series 51 Two Position Controls Service Manual
T1, T2, T3, T4, TA, TH, TM, TN
11. Remove piston (M12).
Module disassembly
Legend
Item Wrench size Torque
M22
(80, 110)
M22
(160, 1250)
Item Wrench size Torque
M16, N20, NT40 1/4 internal hex 37 N•m [28 lbf•ft]
N26 3 mm internal hex
26 11009442 • Rev CA • January 2015
8 mm internal hex 78 N•m [58 lbf•ft]
10 mm internal hex 110 N•m [81 lbf•ft]
1.
7 N•m [2.7 lbf•ft]
P106 361E
XBXA
3/4 in.
3/4 in.
Service Manual Series 51 Two Position Controls Service Manual
T1, T2, T3, T4, TA, TH, TM, TN
Item Wrench size Torque
M18 1/8 internal hex 6 N•m [4.5 lbf•ft]
Inspection
1. Clean and inspect the housing and spools for wear, damage or foreign material.
2. Check internal passages for contamination and clean them if necessary.
Position motor with shaft horizontally and control surface up to allow easier assembly of all
components.
Assembly
1. Install spring seat (J30), spring (J10*), and seat (J20).
2. Lubricate and install O-rings (F324).
3. Install the 4-way valve assembly (F32).
4. Using petroleum jelly, lubricate and install O-rings (G38, G42, G36), or install gasket (G420).
5. Install spool (M12).
6. Position control housing (M10) on motor.
7. Install spacers (M24), if used, and screws (M22). Torque screws per table on page 2
8. If present, install plug (N26) using a 3 mm internal hex. Torque to 9 N•m [7 lbf•ft].
9. Lubricate and Install new O-ring (M18A). Install plug (M18). Using a 1/8 internal hex, torque to 6 N•m
[4.5 lbf•ft].
10. Lubricate and Install new O-ring (N20A). Install plug (N20). Using a 1/4 internal hex, torque to 37 N•m
[28 lbf•ft].
11. Lubricate and install shuttle spool (NT42).
12. Install pin (N14), if used. Refer to drawing and table below for spool position.
13. Install spring (NT41) if used (E7/E8/F7/F8 spool only).
14. Lubricate and Install new O-rings (NT40A, M16A). Install plugs (NT40, M16). Using a 1/4 inch internal
hex, torque plugs to 37 N•m [28 lbf•ft].
TH control uses a plastic plug for (M1). TA control uses a steel plug for (M1).
Spool and pin location
Option Spool (NT42) location Pin (N14)
C2/C4 loose in bore No
C0/C3 Center of the bore Yes
L5/L6 3/4 inch from XA end Yes
R5/R6 3/4 inch from XB end Yes
11009442 • Rev CA • January 2015 27
P107 828E
M1
(T1/2/3/4)
Coil
Plastic nut
Solenoid
O-ring
O-ring
M1A
O-ring
thin 3/4 inch
wrench
(TM, TN)
(solenoid may be on
either side of spool)
M1
Service Manual Series 51 Two Position Controls Service Manual
T1, T2, T3, T4, TA, TH, TM, TN
Solenoid Assembly
T1/T2/T3/T4 controls
1. Lubricate and install O-ring (M1A). Install solenoid stem.
2. Using a thin 3/4 inch wrench on the flats provided, torque to 47 N•m [35 lbf•ft].
3. Install coil with O-rings.
4. Install plastic nut. Tighten by hand.
Solenoid assembly
28 11009442 • Rev CA • January 2015
L1
L2
A
B
(M4)Y1 Y2(M3)
M1
M2
max.
disp.
P101 205E
Service Manual
N2 Controls
Operation
Series 51 Two Position Controls Service Manual
Functional Description
The N2 control consists of a cover plate mounted on the motor’s endcap, a seal plug in place of the fourway valve, and passage plugs at locations T1, T2, and T3.
The servo piston is powered externally. You may use orifices in the signal lines to control shift speeds.
The N2 control has no servo supply and no PCOR options.
Schematic diagram
Control logic
Displacement Signal
Y1 (M4) Y2 (M3)
Maximum High Drained
Minimum Drained High
Repair
Disassembly
1. Remove screws (M14).
2. Remove cover plate (M1).
3. Remove and discard O-rings (G36, G38, G42) or gasket (N240).
4. Remove plug (M10). An M8 threaded hole is provided in the plug for a puller screw.
5. Remove and discard O-ring (M12).
6. If necessary, remove plug (M18) using a 13mm hex wrench. Remove and discard seal washer (M16).
7. Using a 3 mm internal hex wrench, remove plugs (G30). Remove and discard O-rings (G30A).
8. Using a 3 mm internal hex wrench, remove orifices (T2, T3) if present. Tag orifices for reassembly.
9. Using a 1/4 inch internal hex wrench, remove plug (G12). Remove and discard O-ring (G12A).
10. Using a 3 mm internal hex wrench, remove orifice (T1) if present. Tag orifice for reassembly.
11009442 • Rev CA • January 2015 29
Service Manual Series 51 Two Position Controls Service Manual
N2 Controls
Inspection
Clean and inspect components for damage or foreign material. Replace damaged parts as necessary.
Assembly
1. Lubricate and install new O-ring (M12) to plug (M10).
2. Install the plug (M10) to the four-way valve cavity in the end cap.
3. Using petroleum jelly to retain them, install new interface O-rings (G36, G38, G42) on the end cap, or
install gasket (G420).
4. Install cover plate (M1).
5. Install screws (M14). Torque as shown in the table.
6. If previously removed, install a new seal washer (M16) on plug (M18). Using a 13mm hex wrench,
torque to 18 N•m [13.3 lbf•ft].
7. Using a 3 mm internal hex wrench, install orifices (T1, T2, T3) if used. Torque to 6 N•m [4 lbf•ft].
8. Lubricate and install new O-rings (G30A) onto plugs (G30). Using a 3 mm internal hex wrench, install
plugs. Torque to 9 N•m [7 lbf•ft].
30 11009442 • Rev CA • January 2015
M18
M16
M10
P101 217E
M14
G420
G30A
G30
G12A
G12
T3
T1
G30
G30A
T2
Service Manual Series 51 Two Position Controls Service Manual
N2 Controls
9. Lubricate and install new O-ring (G12A) onto plug (G12). Using a 1/4 inch internal hex wrench, install
plug. Torque to 37 N•m [28 lbf•ft]..
N2 Control
Wrench size and torque
Item Frame Wrench size Torque
M14 80, 110 8 mm internal hex 78 N•m [58 lbf•ft]
M14 160, 250 10 mm internal hex 110 N•m [81 lbf•ft]
11009442 • Rev CA • January 2015 31
M7
M8
X X
)( )(
T4
T6
A1
B1
U5
T2
T1
T7
T8
T3
M1
L2
A
X3
(M5)
M2
L1
B
M4 M3
XXX
X
)()(
)(
)(
X
max.
disp
F1 / F2E1 / E2
P101 207E
Multifunction block
T4
T6
U6
U7
T5
XA
XB
U6
U7
T5
PCOR option
without brake
pressure defeat
PCOR option
with brake
pressure defeat
Service Manual
E1, E2, F1, F2 Controls
Operation
Series 51 Two Position Controls Service Manual
Functional Description
The E* and F* two-position controls consist of a ported housing containing a cartridge style, 3-way, twoposition, solenoid valve. The control housing mounts to the multifunction block containing the doubleresolver spool.
The resolver spool takes high pressure (system A or system B) and routes it to the four-way valve as servo
supply, and sends low-loop pressure to the solenoid valve to operate the four-way valve. The solenoid
valve, when energized, sends pilot pressure (low loop pressure) to the end of the four-way valve, to shift
the motor’s displacement.
E* controls use the standard logic sleeve. F* controls use the reverse logic sleeve. Optional orifices T1, T2,
T3, T7, and T8 control shift speeds. This table shows control logic, input voltage, and connector options
for each control type. E* and F* controls have the option of PCOR.
Control logic, voltage, and connector type
Type Sol. on Sol. off Volts Connector
E 1 min. max. 12 DIN 46350
2 min. max. 24 DIN 46350
5 min. max. 12 Packard
F 1 max. min. 12 DIN 46350
2 max. min. 24 DIN 46350
Schematic diagram
Repair
Disassembly
Solenoid valve (M1) is available as a complete assembly only.
1. Using a 7/8 inch wrench, remove the cartridge (M1) from the control housing.
32 11009442 • Rev CA • January 2015
M14
M20
M19A
M19
M22A
M22
M16
M1
P106 382E
Nut
Coil
Cartridge
Service Manual
E1, E2, F1, F2 Controls
Series 51 Two Position Controls Service Manual
2. Using a ¼ inch internal hex wrench, remove plugs (M22, M19). Remove and discard O-rings (M22A,
M19A).
3. Using a 4 mm internal hex wrench, remove screws (M14).
4. Remove the control housing from the multifunction block.
5. Remove and discard O-rings (M16, M20).
E*, F* control
Tool sizes and torques
Item Wrench size Torque
M14 4 mm internal hex 6 N•m [4 lbf•ft]
M22, M19 1/4 inch internal hex 37 N•m [28 lbf•ft]
M1 nut 3/4 wrench 6 N•m [4 lbf•ft]
M1 cartridge 7/8 wrench 78 N•m [58 lbf•ft]
Assembly
1. Using petroleum jelly to retain them, install new interface O-rings (M16, M20).
2. Position the control housing on the multifunction block. Install screws (M14). Using a 4 mm internal
hex wrench, torque to 6 N•m [4 lbf•ft].
3. Lubricate and install new O-rings (M19A, M22A). Install plugs (M19, M22). Using a 1/4 inch internal
hex wrench, torque to 37 N•m [28 lbf•ft].
4. Lubricate the O-rings and install a new solenoid cartridge (M1). Using a 7/8 inch hex wrench, torque
to 30 N•m [22 lbf•ft]. Do not overtorque.
5. Install the coil to the cartridge stem.
11009442 • Rev CA • January 2015 33
M14
M20
M19A
M19
M22A
M22
M16
M1
P106 382E
Nut
Coil
Cartridge
Service Manual Series 51 Two Position Controls Service Manual
E1, E2, F1, F2 Controls
6. Install the coil nut. Using a 3/4 inch hex wrench, torque to 6 N•m [4 lbf•ft]. Do not overtorque.
E*, F* control
Tool sizes and torques
Item Wrench size Torque
M14 4 mm internal hex 6 N•m [4 lbf•ft]
M22, M19 1/4 inch internal hex 37 N•m [28 lbf•ft]
M1 nut 3/4 wrench 6 N•m [4 lbf•ft]
M1 cartridge 7/8 wrench 78 N•m [58 lbf•ft]
34 11009442 • Rev CA • January 2015
T1
)()(
)(
T2
T3
M1
L2
A
M2
L1
B
M4 M3
XXX
X
X
X
max.
disp..
M5
P101 213
Service Manual
G1, G2, G7
Operation
Series 51 Two Position Controls Service Manual
Functional Description
The G* two-position controls consist of a ported housing that contains a four-way, 2-position, solenoid
operated cartridge valve. A seal plug is installed in the four-way valve cavity in the motor’s endcap. The
control contains a loop-flushing shuttle valve and relief valve. The loop-flushing and four-way valve
components normally found in the motor’s endcap are not used with G* controls. A special endcap is
used with the G* controls.
The loop-flushing shuttle valve resolves which port, system A or system B, is at a lower pressure. It then
routes low-loop pressure to the loop-flushing relief valve and to the solenoid operated cartridge valve.
The loop-flushing relief valve allows fluid to pass out of the working loop into the motor’s case for
cooling and contamination removal.
When energized, the solenoid valve routes low loop pressure to the minimum displacement end of the
servo piston while draining the maximum displacement end to motor case, shifting the motor to
minimum displacement. When de-energized, the valve routes low loop pressure to the maximum
displacement end of the servo, while draining the minimum displacement end. Orifices at locations T1,
T2, and T3 control shift speed.
Repair
G* controls solenoid details
Type Sol. on Sol.off Volts Connector
G 1 min. max. 12 DIN 46350
2 min. max. 24 DIN 46350
7 min. max. 12 Jet Junior Timer
Schematic diagram
Solenoid (M1) is available as a complete assembly only. Do not remove the valve unless you plan to
replace it.
11009442 • Rev CA • January 2015 35
G36
G38
G38
G42
G42
F32
F324
M1
M15
M15A
M10
G20
G20A
K14
K16
K16
K14
K18
T3
T2
M150
M151
M152
G20
G20A
T1
M14
M14A
K80
K70
K10
K50
K90
P101 212
G420
Service Manual
G1, G2, G7
Series 51 Two Position Controls Service Manual
G* control
Tool sizes and torques
Item Wrench size Torque
M15 1/8 inch internal hex 9 N•m [7 lbf•ft]
M14 1/4 inch internal hex 37 N•m [28 lbf•ft]
G20 1-1/16 inch hex 37 N•m [28 lbf•ft]
T1, T2, T3 3 mm internal hex 6 N•m [4 lbf•ft]
K90 1-1/16 inch hex 52 N•m [38 lbf•ft]
M1 coil nut 3/4 hex wrench 6 N•m [4 lbf•ft]
M1 cartridge 7/8 hex wrench 78 N•m [58 lbf•ft]
36 11009442 • Rev CA • January 2015
M150/151
(80, 110)
M150/151
(160, 250)
Disassembly
1. Using a 1-1/16 inch wrench, remove the loop-flushing relief valve locknut (K90).
2. Using a 13 mm wrench, remove the adjustment plug (K10). Remove and discard the O-ring (K50) from
the plug.
3. Remove spring (K70), and poppet (K80).
8 mm internal hex 78 N•m [58 lbf•ft]
10 mm internal hex 110 N•m [81 lbf•ft]
Service Manual
G1, G2, G7
Series 51 Two Position Controls Service Manual
4. Remove two plugs (G20). Remove and discard O-rings (G20A).
5. Remove loop-flushing springs (K14), seats (K16), and spool (K18).
6. Using a 3/4 inch wrench, remove coil nut and coil from solenoid valve (M1).
7. Using a 7/8 inch wrench, remove solenoid valve (M1).
8. Using a 1/8 inch internal hex wrench, remove plug (M15). Remove and discard O-ring (M15A).
9. Remove screws (M150, M151) and washers (M152). Remove control (M10).
10. Remove and discard O-rings (G38, G42, G36) or gasket (G420).
11. Remove plug (F32). There is a 6 mm threaded hole in the seal plug for a puller screw. Remove and
discard O-rings (F324).
12. Using a 1/4 inch internal hex wrench, remove plug (M14). Remove and discard O-ring (M14A).
13. Using a 3 mm internal hex wrench, remove orifice (T1).
Inspection
Clean and inspect components for damage or foreign material. Replace damaged parts as necessary.
Assembly
1. Using a 3 mm internal hex wrench, install orifice (T1). Torque to 6 N•m [4 lbf•ft].
2. Lubricate and install new O-rings (F324). Install plug (F32).
3. Using petroleum jelly to retain them, install new O-rings (G36, 38, 42) or install gasket (G420).
4. Position control on endcap.
5. Install washers (M152) on to the retaining screws (M150 and M151). Install the screws and torque as
shown in the table.
6. Lubricate and install new O-ring (M14A). Using a 1/4 inch internal hex wrench, install plug (M14).
Torque to 37 N•m [28 lbf•ft].
7. Lubricate and install new O-ring (M15A). Using a 1/8 inch internal hex wrench, install plug (M15).
Torque to 9 N•m [7 lbf•ft].
8. Lubricate and install loop-flushing spool (K18), spring seats (K16), and springs (K14).
9. Lubricate and install new O-rings (G20A). Using an 11/16 inch hex wrench, install plugs (G20). Torque
to 37 N•m [28 lbf•ft].
10. Install poppet (K80) and spring (K70).
11. Lubricate and install a new O-ring (K50) on adjustment plug (K10). Install the plug.
12. Using a 1-1/16 inch hex wrench, install locknut (K90). Do not torque the locknut until after
adjustment.
13. Lubricate O-rings on valve (M1). Using a 7/8 inch hex wrench, install the cartridge and torque to 30
N•m [22 lbf•ft]. Do not overtorque.
14. Install the coil onto the cartridge stem. Install the coil nut using a 3/4 inch hex wrench, torque to 6
N•m [4 lbf•ft]. Do not overtorque.
After assembly, adjust the loop-flushing relief valve. Refer to 11008567 Series 51 and 51-1 Basic Service
Manual for adjustment procedure.
11009442 • Rev CA • January 2015 37
G36
G38
G38
G42
G42
F32
F324
M1
M15
M15A
M10
G20
G20A
K14
K16
K16
K14
K18
T3
T2
M150
M151
M152
G20
G20A
T1
M14
M14A
K80
K70
K10
K50
K90
P101 212
G420
Service Manual Series 51 Two Position Controls Service Manual
G1, G2, G7
G* control
Tool sizes and torques
Item Wrench size Torque
M15 1/8 inch internal hex 9 N•m [7 lbf•ft]
M14 1/4 inch internal hex 37 N•m [28 lbf•ft]
G20 1-1/16 inch hex 37 N•m [28 lbf•ft]
T1, T2, T3 3 mm internal hex 6 N•m [4 lbf•ft]
K90 1-1/16 inch hex 52 N•m [38 lbf•ft]
M1 coil nut 3/4 hex wrench 6 N•m [4 lbf•ft]
38 11009442 • Rev CA • January 2015
M1 cartridge 7/8 hex wrench 78 N•m [58 lbf•ft]
M150/151
(80, 110)
M150/151
(160, 250)
8 mm internal hex 78 N•m [58 lbf•ft]
10 mm internal hex 110 N•m [81 lbf•ft]
U5
T3
T2
T7
T8
T1
M1
L2
A
X3(M5)
M2
L1
B
M4 M3
XXX
X
X
X
)()(
)(
)(
X
max.
disp.
P101 214E
Service Manual
U1, U2
Operation
Series 51 Two Position Controls Service Manual
Functional Description
The U* two-position controls consist of a ported housing containing a shuttle spool and a solenoid. The
shuttle spool resolves which port, system A or system B, is at higher pressure, routing that high pressure
to the four-way valve to power the servo piston. The solenoid actuates the four-way valve causing the
motor to shift displacement. The sensing piston functions only as a push-rod in this control.
The motor defaults to minimum displacement, shifting to maximum when the solenoid operates.
Optional orifices at locations T1, T2, T3, T7, and T8 control shift speeds.
This table shows control logic, input voltage, and connector options for each control type.
Control logic, input voltage and connector options
Type SOL on SOL off Volts Connector
U 1 max. min. 12v DIN 46350
2 max. min. 24 v DIN 46250
Schematic diagram
Repair
The PCOR option is not available with U1/U2 controls.
Disassembly
1. Using a 1/4 inch internal hex wrench, remove plugs (M16, N20, NT40). Remove and discard O-rings
(M16A, 20A, NT40A).
2. Remove shuttle spool (NT42).
3. Using a 3mm internal hex wrench, remove plug (N26).
4. Using a 1/8 inch internal hex wrench, remove plug (M18). Remove and discard O-ring (M18A).
5. Remove coil nut and coil from solenoid (M1).
6. Using a thin 3/4 inch hex wrench, remove cartridge (M1) from control. Keep the pushrod in the
cartridge.
7. Remove screws (M22) and washers (M24).
8. Remove control housing (M10). Remove and discard O-rings (G36, G38, G42) or gasket (G420).
11009442 • Rev CA • January 2015 39
C
N20
N20A
M22
M24
M10
M12
NT42
M16
M16A
M18
M18A
N26
C2/C4
P107 832E
G420
F32
F324
G36
J30
J10*
J20
M1
Service Manual Series 51 Two Position Controls Service Manual
U1, U2
9. Remove piston (M12).
10. Remove the 4-way valve assembly (F32). Discard O-rings (F324).
Caution
Read Series 51 and 51-1 Bent Axis Motors Service Manual 11008567 for minor repair instructions for the
4-way valve, threshold spring, and ramp spring components, if repair is necessary.
11. Remove spring (J10*) and spring seats (J30, J20).
Solenoid (M1) is available as a complete assembly only.
U* control
40 11009442 • Rev CA • January 2015
Item Wrench size Torque
M22
(80, 110)
Tool size and torque
8 mm internal hex 78 N•m [58 lbf•ft]
Service Manual
U1, U2
Series 51 Two Position Controls Service Manual
Tool size and torque (continued)
Item Wrench size Torque
M22
(160, 1250)
M16, N20, NT40 1/4 inch internal hex 37 N•m [28 lbf•ft]
N26 3 mm internal hex
M18 1/8 inch internal hex 78 N•m [58 lbf•ft]
M1 cartridge 3/4 inch hex 47 N•m [35 lbf•ft]
Inspection
Clean and inspect components for damage or foreign material. Replace damaged parts as necessary.
Assembly
Refer to the illustration on the previous page.
1. Position motor with control surface up for easier assembly.
2. Install spring seat (J30), spring (J10*), and seat (J20).
3. Lubricate and install O-rings (F324) to four-way valve.
4. Lubricate and install the 4-way valve assembly (F32).
5. Lubricate and install piston (M12).
6. Using petroleum jelly to retain them, lubricate and install O-rings (G38, G42, G36), or install gasket
(G420).
7. Position control on endcap.
8. Install washers (M24) and screws (M22). Torque as shown in the table on the previous page.
9. Using a 3 mm internal hex wrench, install the plug (N26) to the control housing. Torque to 6 N•m [4
lbf•ft].
10. Lubricate the shuttle spool (NT42) and install into the cavity in the control housing.
11. Lubricate and install new O-rings (M16A, N20A, NT40A). Install plugs (M16, N20, NT40) using a 1/4
inch internal hex wrench. Torque to 37 N•m [28 lbf•ft].
12. Lubricate and install new O-ring (M18A). Install plug (M18) using a 1/8 inch internal hex wrench.
Torque to 9 N•m [7 lbf•ft].
13. Install new cartridge (M1) with pushrod. Using a thin 3/4 inch hex wrench, torque to 47 N•m [35 lbf•ft].
14. Install coil (M1) to the cartridge stem. Hand-tighten the coil nut.
10 mm internal hex 110 N•m [81 lbf•ft]
1.
7 N•m [2.7 lbf•ft]
11009442 • Rev CA • January 2015 41
Service Manual
PC, PD
Operation
Series 51 Two Position Controls Service Manual
Functional Description
PC Control
The PC control consists of a multifunction block with PCOR valve attached. The multifunction block
contains the servo supply spool. It resolves high loop pressure for servo supply, and routes the high loop
pressure to the PCOR valve. At the same time it connects the low loop pressure to the PCOR.
The PC control uses a ported plug in place of the 4-way valve that connects the servo supply pressure to
the minimum displacement end of the servo piston. It drains the maximum displacement end to case
through orifice T7.
System pressure operates the PCOR valve. When system pressure reaches the PC threshold pressure, the
PCOR spool shifts, routing system pressure to the maximum displacement end of the servo piston,
saturating the T7 orifice, while draining the minimum displacement end to low loop. Optional orifices at
locations T1, T2, T3, T5, T7, U6 and U7 control shift speed. Brake pressure defeat option is not available
with the PC control.
PD Control
The PD control consists of a multifunction block with PCOR valve attached. The multifunction block
contains the servo supply spool that resolves high loop pressure, routing it to the 4-way valve for servo
supply, and to the PCOR valve.
The motor defaults to minimum displacement, shifting to maximum when directed by an external
hydraulic signal applied to port X1. This signal acts on the 4-way valve. When the signal pressure
overcomes the threshold spring force, the valve shifts.
External pressure in the range of 5 to 12 bar [72.5 to 174 psi] is required at port X1 to shift the motor to
maximum displacement. The threshold setting is adjustable within this range.
Pressure from an external source, applied to port X4 operates the PCOR valve. When this external
pressure reaches the PCOR setting, the PCOR spool shifts. This routes high system pressure to the
maximum displacement end of the servo piston while the minimum displacement end drains through
the 4-way valve out of X1.
Port X4 requires external pressure in the range of 130 to 370 bar [1890 to 5370 psi] to operate the PCOR
valve and shift the motor to maximum displacement. The PCOR threshold pressure setting is adjustable
within this range. Optional orificesT1, T2, T3, T7, T8, and U7 control shift speed. The PD control does not
have brake pressure defeat option.
Adjustment
PC, PD PCOR Adjuster Stop-pin
A stop-pin is installed in the PCOR adjuster to prevent over-travel of the PCOR valve spool. If the spool is
allowed to over-travel, due to high system pressure, it will close off flow to the servo piston. This would
keep the PCOR from shifting the motor toward maximum displacement and regulating the system
pressure.
The stop-pin must protrude from the spring seat (dimension X, shown) 24 mm [0.94 inch] for PCOR
settings of 110 to 260 bar [1600 to 3750 psi] or 19 mm [0.74 inch] for PCOR settings of 270 to 370 bar
[3900 to 5370 psi].
42 11009442 • Rev CA • January 2015
n
T6
T2
T7
T1
T3
U6
max.
disp.
A
L2 M4 M3 N
M1
L1
M2
M5
P106 376E
T5
T4
U7
Service Manual Series 51 Two Position Controls Service Manual
PC, PD
Stop pin dimension
Repair
Refer to Pressure Compensator Override (PCOR) on page 18, and Multifunction Block on page 20, earlier in
this book for repair instructions.
Schematic Diagrams
PC schematic
11009442 • Rev CA • January 2015 43
T2
T1
T7
T3
U7
M1
L2
A
M2
B
M4 M3
XXX
X
X
X3(M5)
X
X4
)(
Max.
disp.
X1
P101 236E
Service Manual Series 51 Two Position Controls Service Manual
PC, PD
PD schematic
P101 236E
44 11009442 • Rev CA • January 2015
Service Manual Series 51 Two Position Controls Service Manual
11009442 • Rev CA • January 2015 45
Service Manual Series 51 Two Position Controls Service Manual
46 11009442 • Rev CA • January 2015
Service Manual Series 51 Two Position Controls Service Manual
11009442 • Rev CA • January 2015 47
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