Danfoss Bent Axis Motors Service guide
MAKING MODERN LIVING POSSIBLE
Service Manual
Bent Axis Motors
Series 51 Two Position Controls
powersolutions.danfoss.com
Service Manual Series 51 Two Position Controls Service Manual
Revision history Table of revisions
Date Changed Rev
January 2015 Danfoss layout CA
March 2009 Added TA, TH, TN, PC, PD BA
February 2008 First edition AA
2 11009442 • Rev CA • January 2015
Service Manual
Series 51 Two Position Controls Service Manual
Contents
Introduction
Safety Precautions............................................................................................................................................................................5
Unintended Machine Movement..........................................................................................................................................5
Flammable Cleaning Solvents................................................................................................................................................5
Fluid Under Pressure..................................................................................................................................................................5
Personal Safety.............................................................................................................................................................................5
Hazardous Material.....................................................................................................................................................................5
Symbols used in Danfoss literature............................................................................................................................................6
Overview..............................................................................................................................................................................................7
General instructions........................................................................................................................................................................ 7
Keep it Clean.................................................................................................................................................................................7
Inspect for System Contamination....................................................................................................................................... 7
Replace the O-rings and Gaskets...........................................................................................................................................7
Lubricate all Moving Parts........................................................................................................................................................7
Torque Procedure....................................................................................................................................................................... 7
Operation
Two-position Controls.................................................................................................................................................................... 8
Control Options.................................................................................................................................................................................8
Pressure Compensator Override (PCOR) Option............................................................................................................. 8
Brake Pressure Defeat (BPD)....................................................................................................................................................9
Threshold Spring.......................................................................................................................................................................11
Multifunction Block..................................................................................................................................................................11
Pressure measurements
Port Locations and Gauge Installation...................................................................................................................................13
Adjustments
Threshold Setting...........................................................................................................................................................................16
Adjusting Threshold Setting.................................................................................................................................................16
PCOR Setting....................................................................................................................................................................................16
PCOR Adjustment.....................................................................................................................................................................16
Checking PCOR Setting on a Test Stand.......................................................................................................................... 17
Adjusting the PCOR Setting..................................................................................................................................................17
Pressure Compensator Override (PCOR)
Repair..................................................................................................................................................................................................18
Disassembly................................................................................................................................................................................18
Inspection....................................................................................................................................................................................18
Assembly......................................................................................................................................................................................18
Multifunction Block
Repair..................................................................................................................................................................................................20
Disassembly................................................................................................................................................................................20
Inspection....................................................................................................................................................................................21
Assembly......................................................................................................................................................................................21
T1, T2, T3, T4, TA, TH, TM, TN
Operation..........................................................................................................................................................................................22
TA Control....................................................................................................................................................................................22
TH Control................................................................................................................................................................................... 22
T1, T2, T3, T4 Control............................................................................................................................................................... 22
TM, TN Controls.........................................................................................................................................................................22
N Module Option Codes..............................................................................................................................................................22
Overview......................................................................................................................................................................................22
C0/C3 3......................................................................................................................................................................................... 22
C2/C4.............................................................................................................................................................................................23
C7/C8.............................................................................................................................................................................................23
L5/L6..............................................................................................................................................................................................23
R5/R6............................................................................................................................................................................................. 23
E7, E8, F7, F8................................................................................................................................................................................23
Schematic Diagrams..................................................................................................................................................................... 23
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
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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
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