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 |
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Revision history |
Table of revisions |
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Date |
Changed |
Rev |
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January 2015 |
Danfoss layout |
CA |
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March 2009 |
Added TA, TH, TN, PC, PD |
BA |
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February 2008 |
First edition |
AA |
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2 |
11009442 • Rev CA • January 2015 |
Service Manual |
Series 51 Two Position Controls Service Manual |
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Contents |
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Introduction |
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Safety Precautions............................................................................................................................................................................ |
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Unintended Machine Movement.......................................................................................................................................... |
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Flammable Cleaning Solvents................................................................................................................................................ |
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Fluid Under Pressure.................................................................................................................................................................. |
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Personal Safety............................................................................................................................................................................. |
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Hazardous Material..................................................................................................................................................................... |
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Symbols used in Danfoss literature............................................................................................................................................ |
6 |
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Overview.............................................................................................................................................................................................. |
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General instructions........................................................................................................................................................................ |
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Keep it Clean................................................................................................................................................................................. |
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Inspect for System Contamination....................................................................................................................................... |
7 |
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Replace the O-rings and Gaskets........................................................................................................................................... |
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Lubricate all Moving Parts........................................................................................................................................................ |
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Torque Procedure....................................................................................................................................................................... |
7 |
Operation |
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Two-position Controls.................................................................................................................................................................... |
8 |
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Control Options................................................................................................................................................................................. |
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Pressure Compensator Override (PCOR) Option............................................................................................................. |
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Brake Pressure Defeat (BPD).................................................................................................................................................... |
9 |
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Threshold Spring....................................................................................................................................................................... |
11 |
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Multifunction Block.................................................................................................................................................................. |
11 |
Pressure measurements |
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Port Locations and Gauge Installation................................................................................................................................... |
13 |
Adjustments |
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Threshold Setting........................................................................................................................................................................... |
16 |
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Adjusting Threshold Setting................................................................................................................................................. |
16 |
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PCOR Setting.................................................................................................................................................................................... |
16 |
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PCOR Adjustment..................................................................................................................................................................... |
16 |
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Checking PCOR Setting on a Test Stand.......................................................................................................................... |
17 |
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Adjusting the PCOR Setting.................................................................................................................................................. |
17 |
Pressure Compensator Override (PCOR) |
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Repair.................................................................................................................................................................................................. |
18 |
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Disassembly................................................................................................................................................................................ |
18 |
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Inspection.................................................................................................................................................................................... |
18 |
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Assembly...................................................................................................................................................................................... |
18 |
Multifunction Block |
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Repair.................................................................................................................................................................................................. |
20 |
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Disassembly................................................................................................................................................................................ |
20 |
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Inspection.................................................................................................................................................................................... |
21 |
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Assembly...................................................................................................................................................................................... |
21 |
T1, T2, T3, T4, TA, TH, TM, TN |
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Operation.......................................................................................................................................................................................... |
22 |
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TA Control.................................................................................................................................................................................... |
22 |
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TH Control................................................................................................................................................................................... |
22 |
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T1, T2, T3, T4 Control............................................................................................................................................................... |
22 |
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TM, TN Controls......................................................................................................................................................................... |
22 |
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N Module Option Codes.............................................................................................................................................................. |
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Overview...................................................................................................................................................................................... |
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C0/C3 3......................................................................................................................................................................................... |
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C2/C4............................................................................................................................................................................................. |
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C7/C8............................................................................................................................................................................................. |
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L5/L6.............................................................................................................................................................................................. |
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R5/R6............................................................................................................................................................................................. |
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E7, E8, F7, F8................................................................................................................................................................................ |
23 |
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Schematic Diagrams..................................................................................................................................................................... |
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11009442 • Rev CA • January 2015 |
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Service Manual |
Series 51 Two Position Controls Service Manual |
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Contents |
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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 |
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Operation.......................................................................................................................................................................................... |
29 |
Functional Description........................................................................................................................................................... |
29 |
Repair.................................................................................................................................................................................................. |
29 |
Disassembly................................................................................................................................................................................ |
29 |
Inspection.................................................................................................................................................................................... |
30 |
Assembly...................................................................................................................................................................................... |
30 |
E1, E2, F1, F2 Controls |
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Operation.......................................................................................................................................................................................... |
32 |
Functional Description........................................................................................................................................................... |
32 |
Repair.................................................................................................................................................................................................. |
32 |
Disassembly................................................................................................................................................................................ |
32 |
Assembly...................................................................................................................................................................................... |
33 |
G1, G2, G7 |
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Operation.......................................................................................................................................................................................... |
35 |
Functional Description........................................................................................................................................................... |
35 |
Repair.................................................................................................................................................................................................. |
35 |
Disassembly................................................................................................................................................................................ |
36 |
Inspection.................................................................................................................................................................................... |
37 |
Assembly...................................................................................................................................................................................... |
37 |
U1, U2 |
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Operation.......................................................................................................................................................................................... |
39 |
Functional Description........................................................................................................................................................... |
39 |
Repair ................................................................................................................................................................................................. |
39 |
Disassembly................................................................................................................................................................................ |
39 |
Inspection.................................................................................................................................................................................... |
41 |
Assembly...................................................................................................................................................................................... |
41 |
PC, PD |
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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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11009442 • Rev CA • January 2015 |
Service Manual |
Series 51 Two Position Controls Service Manual |
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Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury. Take the following general precautions whenever servicing a hydraulic system.
W Warning
Unintended 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.
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.
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.
W Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.
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.
11009442 • Rev CA • January 2015 |
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Service Manual |
Series 51 Two Position Controls Service Manual |
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Introduction
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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11009442 • Rev CA • January 2015 |
Service Manual |
Series 51 Two Position Controls Service Manual |
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Introduction
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.
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 the motor for signs of system contamination. If you find contamination, fully disassemble, clean and inspect all components of the motor.
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.
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.
During reassembly, cross torque all retaining screws to the given value. Do not overtorque.
11009442 • Rev CA • January 2015 |
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Service Manual |
Series 51 Two Position Controls Service Manual |
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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 |
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cap |
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Minimum |
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displacement |
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limiter |
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Valve segment |
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Spacer |
Miximum |
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displacement |
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limiter |
P101 195E |
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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11009442 • Rev CA • January 2015 |
Service Manual |
Series 51 Two Position Controls Service Manual |
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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
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N18 |
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N20 |
N14 |
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N16 |
N27 |
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N29 |
N23 |
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N23 |
N27 |
P101 906 |
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Example of T* PCOR option |
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(TM, TN) |
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G36 |
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(may be on |
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N240 |
either side of spool) M1 |
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M12 |
M10
M18 M18A
N20
N26 |
C2/C4 |
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M24 |
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N20A |
N14 |
NT42 |
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M16A |
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M16 |
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M1 |
M22 |
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P107 960E |
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 |
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Service Manual |
Series 51 Two Position Controls Service Manual |
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Operation
EP, EQ electrohydraulic proportional control with pressure compensator and hydraulic brake pressure defeat.
XB |
XA |
A |
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BPD |
Shuttle |
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PCOR |
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Multifunction Block |
B |
M4 |
M3 |
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M1 |
Loop flushing |
L1 |
Max. |
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displ. |
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L2 |
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M5 |
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M2 |
M7 |
M8 |
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P101 907 |
X1 |
Control |
BPD option
Brake defeat spool
Shuttle valve
PCOR adjuster
PCOR spool
P106 431E
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11009442 • Rev CA • January 2015 |
Service Manual |
Series 51 Two Position Controls Service Manual |
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Operation
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
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
11009442 • Rev CA • January 2015 |
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Service Manual |
Series 51 Two Position Controls Service Manual |
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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 |
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spool |
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T4 |
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PCOR |
T6 |
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U7 |
U6 |
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T5 |
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L2 |
M4 |
M3 |
N |
A |
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M1 |
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n |
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max. |
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disp. |
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T2 |
T3 |
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T1 |
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L1 |
T7 |
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M5 |
B |
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M2 |
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E* F* |
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4-way valve |
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X |
Control |
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X |
P106 391E |
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M8 |
M7 |
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11009442 • Rev CA • January 2015 |
Service Manual |
Series 51 Two Position Controls Service Manual |
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Series 51 motors
M3 |
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Y |
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M3 |
Main ports A+B |
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L1 |
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Y |
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side port |
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M1 |
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M5 |
M5 |
L2 |
M1 |
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M7 |
Axial port
System pressure A+B
Guage port M1+M2
Y
Axial port
M5
W
M2 M4
W
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P101 204E |
Y |
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Main |
M3 |
port B |
W
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M4 |
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M5 |
Main |
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port A |
P101 204E |
Legend
Abbreviation |
Definition |
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L1 |
Case drain; (1-5/16-12UNF) |
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L2 |
Alternate case drain: (1-5/16-12UNF) |
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M1 |
Gauge port: system pressure A (9/16-18UNF) |
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M2 |
Gauge port: system pressure B (9/16-18UNF) |
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M3 |
Gauge port: servo pressure min. angle (9/16-18UNF) |
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M4, M5 |
Gauge port: servo pressure max. angle (9/16-18UNF) |
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M7 |
Control pressure port (9/16-18UNF) |
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11009442 • Rev CA • January 2015 |
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Service Manual |
Series 51 Two Position Controls Service Manual |
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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
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Z |
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XA |
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M8 |
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M7 |
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XB |
Z |
P106 393E |
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11009442 • Rev CA • January 2015 |
Service Manual |
Series 51 Two Position Controls Service Manual |
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Pressure measurements
Gauge ports with U1/U2 controls and T1, T2, T3, T4, TA, and TH controls
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Z |
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XA |
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XA |
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<![if ! IE]> <![endif]>X1 |
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X4 |
<![if ! IE]> <![endif]>X4 |
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XB |
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XB |
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Z |
P106 395E |
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Legend |
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Abbreviation |
Definition |
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M7, M8 |
Gauge port control pressure (9/16-18UNF) |
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X (A, B, and 1) |
Control pressure port (9/16-18UNF) |
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Solenoid for
electric 2 position control
11009442 • Rev CA • January 2015 |
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