Danfoss Series 51-1 Controls B1, Series 51-1 Controls B2, Series 51-1 Controls B7, Series 51-1 Controls E1, Series 51-1 Controls E2 Service guide
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MAKING MODERN LIVING POSSIBLE
Service Manual
Series 51-1 Controls B1, B2, B7,
E1, E2, E7, F1, F2, N1, T1, T2, T7,
TA, TH, P7, P8
powersolutions.danfoss.com
Service Manual Series 51-1 Controls B1, B2, B7, E1, E2, E7, F1, F2, N1, T1, T2, T7, TA, TH, P7, P8
Revision history Table of revisions
Date Changed Rev
February 2015 Danfoss layout BA
January 2008 First edition AA
2 11009443 • Rev BA • February 2015
Service Manual
Series 51-1 Controls B1, B2, B7, E1, E2, E7, F1, F2, N1, T1, T2, T7, TA, TH, P7, P8
Contents
Introduction
Safety precautions............................................................................................................................................................................4
Unintended machine movement..........................................................................................................................................4
Flammable cleaning solvents.................................................................................................................................................4
Fluid under pressure..................................................................................................................................................................4
Personal safety............................................................................................................................................................................. 4
Hazardous material.................................................................................................................................................................... 4
Symbols used in Danfoss literature............................................................................................................................................5
General instructions........................................................................................................................................................................ 5
Keep it clean..................................................................................................................................................................................5
Inspect for system contamination........................................................................................................................................ 6
Replace the O-rings and gaskets........................................................................................................................................... 6
Lubricate all moving parts....................................................................................................................................................... 6
Torque procedure.......................................................................................................................................................................6
Overview..............................................................................................................................................................................................6
Required tools, gauge port and orifice locations
Required tools....................................................................................................................................................................................8
Port locations and gauge installation....................................................................................................................................... 8
Orifice locations................................................................................................................................................................................ 9
N1 two-position control
Functional Description.................................................................................................................................................................10
Adjustments.....................................................................................................................................................................................10
Minor repair......................................................................................................................................................................................10
E1, E2, E7, F1, F2 two-position controls
Functional description................................................................................................................................................................. 13
Adjustments.....................................................................................................................................................................................14
Minor repair......................................................................................................................................................................................14
B1, B2, B7 two-position controls
Functional description................................................................................................................................................................. 17
Adjustments.....................................................................................................................................................................................17
Minor repair......................................................................................................................................................................................17
T1, T2, T7, TA, TH Pressure Compensator (PC) controls
Functional Description.................................................................................................................................................................20
Overview......................................................................................................................................................................................20
Option TA.................................................................................................................................................................................... 20
Option TH.................................................................................................................................................................................... 20
Option T1T2/T7 .........................................................................................................................................................................21
Brake pressure defeat..............................................................................................................................................................21
Schematics.................................................................................................................................................................................. 23
Adjustment.......................................................................................................................................................................................24
PC start pressure....................................................................................................................................................................... 24
Minor repair......................................................................................................................................................................................26
Control housing........................................................................................................................................................................ 26
TA option components...........................................................................................................................................................27
TH option components.......................................................................................................................................................... 28
T1, T2, T7 option components............................................................................................................................................. 29
Servo/PC supply option CA (with hydraulic signal)..................................................................................................... 30
Servo/PC supply option C2 (without external signal)................................................................................................. 31
Servo/PC supply options D1/D2/D7.................................................................................................................................. 32
Servo/PC supply options L5/R5........................................................................................................................................... 34
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Service Manual
Introduction
Safety precautions
Series 51-1 Controls B1, B2, B7, E1, E2, E7, F1, F2, N1, T1, T2, T7, TA, TH, P7, P8
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 acm³ording to state, and federal environmental regulations.
4 11009443 • Rev BA • February 2015
Service Manual
Series 51-1 Controls B1, B2, B7, E1, E2, E7, F1, F2, N1, T1, T2, T7, TA, TH, P7, P8
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
General instructions
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.
Keep it clean
You can complete many repairs or adjustments without removing the unit from the machine, if 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.
11009443 • Rev BA • February 2015 5
Service Manual
Introduction
Series 51-1 Controls B1, B2, B7, E1, E2, E7, F1, F2, N1, T1, T2, T7, TA, TH, P7, P8
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
Overview
During reassembly, cross torque all retaining screws to the given value. Do not overtorque.
Series 51-1 motor controls operate by routing the flow of oil to the servo piston in the motor’s endcap.
The servo piston has a differential area of 2:1.
The larger area acts to reduce displacement.
•
The smaller area works to increase displacement.
•
Due to the simplified design of the Series 51-1, only two-position and pressure compensator controls are
available.
An external hydraulic or electric signal operates two-position controls. Pressure comes from the low side
of the system loop and the control routes it to either the rod or piston end of the servo piston to set the
motor’s displacement.
Pressure compensator (PC) controls automatically set the displacement of the motor based on system
pressure. PC controls allow the motor to increase available torque based on system demand by
increasing the motor’s displacement.
The motor defaults to minimum displacement until system pressure reaches the PC set pressure. The PC
set pressure is adjustable in a range from 110 to 370 bar [1595 to 5365 psi]. Pressure is taken from the
high side of the system loop to operate the servo piston.
PC controls:
6 11009443 • Rev BA • February 2015
Value
segment
Servo piston
Service Manual Series 51-1 Controls B1, B2, B7, E1, E2, E7, F1, F2, N1, T1, T2, T7, TA, TH, P7, P8
Introduction
can have a maximum displacement lock that holds the displacement at maximum when a hydraulic
•
or electric signal is applied.
can be equipped with a brake pressure defeat option that holds the motor at minimum
•
displacement during dynamic braking. A hydraulic or electric signal operates the brake pressure
defeat feature.
Differential area servo piston
11009443 • Rev BA • February 2015 7
N1 Control
P101 242E
MON*
M5 Gauge port
Servo supply pressure
0.5625 [9/16] 18UNF-2B
M3 Gauge port
Servo pressure min-angle
0.5625 [9/16] 18UNF-2B
M4 Gauge port
Servo pressure max-angle
0.5625 [9/16] 18UNF-2B
T* Controls
P101 244Ea
M3 Gauge port
Servo pressure min-angle
0.5625 [9/16] 18UNF-2B
M4 Gauge port
Servo pressure max-angle
0.5625 [9/16] 18UNF-2B
Pressure Compensator
adjusting screw
MOE*
MOF*
MOB*
M5 Gauge port
Servo supply pressure
0.5625 [9/16] 18UNF-2B
M3 Gauge port
Servo pressure min-angle
0.5625 [9/16] 18UNF-2B
M4 Gauge port
Servo pressure max-angle
0.5625 [9/16] 18UNF-2B
M5 Gauge port
Servo supply pressure
0.5625 [9/16] 18UNF-2B
M3 Gauge port
Servo pressure min-angle
0.5625 [9/16] 18UNF-2B
Service Manual Series 51-1 Controls B1, B2, B7, E1, E2, E7, F1, F2, N1, T1, T2, T7, TA, TH, P7, P8
Required tools, gauge port and orifice locations
Required tools
You can perform the service procedures in this manual using common mechanic’s hand tools. Special
tools, if required, are shown. Calibrate pressure gauges frequently to ensure accuracy. Use snubbers to
protect pressure gauges. For controls N*, E*, F*, and B* use a 600 psi [45 bar] gauge for M3, M4, and M5
gauge (pressure) ports. For T* controls use a 10,000 psi [600 bar] gauge for M3 and M4 gauge (pressure)
ports..
Port locations and gauge installation
Two-position controls
8 11009443 • Rev BA • February 2015
T3
U5
U5
E100 293E
B* control codes E* and F* control codes
N* control codes
T* control codes
T3
T2
U5
T3
T2
U5
T3
T3
T2
T3
T2
U5
U5
U5
T3
Service Manual Series 51-1 Controls B1, B2, B7, E1, E2, E7, F1, F2, N1, T1, T2, T7, TA, TH, P7, P8
Required tools, gauge port and orifice locations
Orifice locations
11009443 • Rev BA • February 2015 9
X1(M3)
M5
B
M4
L1
N
L2
A
P001 779E
n
min.
disp.
T2
T3
U5
Service Manual Series 51-1 Controls B1, B2, B7, E1, E2, E7, F1, F2, N1, T1, T2, T7, TA, TH, P7, P8
N1 two-position control
Functional Description
The N1 control consists of a ported housing that is mounted on the endcap over the piston end of the
servo piston.
The housing contains two external ports, designated M3 and M5. These ports serve as the control inputs.
There are three interface ports1 that connect to the rod and piston ends of the servo, and to the servo
supply port in the endcap. The servo supply connects to the output of the loop flushing spool so it
dispenses low loop pressure to the control regardless of motor direction.
The control routes servo supply pressure through orifices U5 and T2 to the rod end of the servo piston.
This holds the motor at maximum displacement until pressure from an external source is applied at port
M3. This signal pressure then routes through orifice T3 to the piston end of the servo, shifting the motor
to minimum displacement. Typically 20 to 25 bar [290 to 360 psi] is necessary to shift the motor.
You may also install a plug in place of orifice U5, blocking the connection to servo supply. You can then
apply pressure from an external source at port M5 to shift the motor to maximum displacement.
Orifices T2 and T3 set the control response by limiting the flow to either end of the servo piston.
Schematic diagram
N1 control schematic diagram
Adjustments
This control requires no adjustments.
Minor repair
Disassembly
1. Thoroughly clean all external surfaces before disassembly. Mark components as necessary to ensure
you reassemble the unit correctly.
2. Remove the 4 screws (M16). Use an 8mm internal hex wrench.
1
Interface ports are those between the control and the endcap.
10 11009443 • Rev BA • February 2015
3. Remove the control housing (M1N*) from the endcap.
M14
M14
M16
M12
M1N*
G42
G420
P101176
Service Manual
N1 two-position control
Series 51-1 Controls B1, B2, B7, E1, E2, E7, F1, F2, N1, T1, T2, T7, TA, TH, P7, P8
4. After ensuring you have the correct replacement parts, remove and discard the interface O-rings
(G42), or remove the control gasket (G420) from the endcap.
5. Using a 1/4-inch internal hex wrench remove plugs (M14) from the housing.
Fasteners are metric. Porting plugs are SAE.
6. Using a 1/8-inch internal hex wrench remove plug (M12) from the housing.
7. After ensuring you have the correct replacement parts, remove and discard O-rings (M12A and M14A)
from the plugs (M12 and M14).
8. If necessary, remove T2, T3, and U5 control orifices. Use a 3mm internal hex wrench. Tag the orifices
for reassembly.
N1 control exploded
Inspection
Clean and inspect all parts for damage. Check orifices and passages in control housing for foreign
material.
Assembly
1. If removed, install control orifices T2, T3, and U5 to their proper location. Using a 3mm internal hex
wrench, torque the orifices to 6 N•m [4 lbf•ft].
2. Lubricate and install new O-rings on the housing plugs (M12). Using a 1/8-inch internal hex wrench,
torque them to 9 N•m [7 lbf•ft]
3. Lubricate and install new O-rings on the housing plugs (M14). Using a 1/4-inch internal hex wrench,
torque them to 37 N•m [28 lbf•ft].
4. Using clean petroleum jelly to retain them, install new interface O-rings (G42) or a new control gasket
(G420) on the endcap.
11009443 • Rev BA • February 2015 11
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