Danfoss Series 51 - HZ, Series 51 - HA, Series 51 - HB, Series 51 - HE, Series 51 - HS Service guide
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MAKING MODERN LIVING POSSIBLE
Service Manual
Series 51 - HZ, HA, HB, HE, HS, H1,
H2, K1, K2, HP, HC, J1, J2, J3, J4, JA
Hydraulic Proportional Controls
powersolutions.danfoss.com
Service Manual Series 51 Hydraulic Proportional Controls Service Manual
Revision history Table of revisions
Date Changed Rev
July 2014 Danfoss layout BA
November 2010 new last page AC
February 2010 Fix Osaka address AB
July 2009 First edition AA
2 11009446 • Rev BA • July 2014
Service Manual
Contents
Introduction
Pressure measurements
Adjustments
PCOR
Multifunction block
HZ, HA, HB, HE Controls
HS Control
Series 51 Hydraulic Proportional Controls Service Manual
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..............................................................................................................................................................................................6
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
General Description.........................................................................................................................................................................7
Overview........................................................................................................................................................................................ 7
Threshold and Ramp Springs..................................................................................................................................................7
Multiblock......................................................................................................................................................................................8
Pressure Compensator OverRide (PCOR) Function........................................................................................................ 8
Brake Pressure Defeat (BPD) Option.................................................................................................................................... 9
Port locations and Gauge Installation.................................................................................................................................... 10
Threshold Setting...........................................................................................................................................................................11
Checking Threshold Setting................................................................................................................................................. 11
Adjusting Threshold Setting.................................................................................................................................................11
Pressure Compensator OverRide (PCOR) Setting...............................................................................................................12
PCOR Adjustment.....................................................................................................................................................................12
Checking PCOR Setting on a Test Stand.......................................................................................................................... 13
Adjusting the PCOR Setting..................................................................................................................................................13
Optional PCOR Housing...............................................................................................................................................................14
Disassembly................................................................................................................................................................................14
Inspection....................................................................................................................................................................................14
Assembly......................................................................................................................................................................................14
Optional Multifunction block ................................................................................................................................................... 16
Disassembly................................................................................................................................................................................16
Inspection....................................................................................................................................................................................17
Assembly......................................................................................................................................................................................17
Operation..........................................................................................................................................................................................18
Functional Description........................................................................................................................................................... 18
HZ Control...................................................................................................................................................................................18
HA and HB Controls................................................................................................................................................................. 18
HE Control................................................................................................................................................................................... 18
Repair..................................................................................................................................................................................................19
Disassembly................................................................................................................................................................................19
Inspection....................................................................................................................................................................................20
Assembly......................................................................................................................................................................................20
Operation..........................................................................................................................................................................................21
Functional Description........................................................................................................................................................... 21
Repair..................................................................................................................................................................................................21
Disassembly................................................................................................................................................................................21
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Service Manual
Contents
H1, H2, K1, K2 Controls
HP Controls
HC Controls
J1, J2, J3, J4 Controls
JA Control
Series 51 Hydraulic Proportional Controls Service Manual
Inspection....................................................................................................................................................................................22
Assembly......................................................................................................................................................................................22
Operation..........................................................................................................................................................................................23
Functional Description........................................................................................................................................................... 23
Solenoid Valve........................................................................................................................................................................... 23
Repair..................................................................................................................................................................................................23
Removing Solenoid Valve......................................................................................................................................................24
Disassembly................................................................................................................................................................................24
Inspection....................................................................................................................................................................................24
Assembly......................................................................................................................................................................................24
Installing Solenoid....................................................................................................................................................................24
Operation..........................................................................................................................................................................................25
Functional Description........................................................................................................................................................... 25
HP Control...................................................................................................................................................................................25
Shuttle Valve...............................................................................................................................................................................25
Connecting Pin..........................................................................................................................................................................25
Repair..................................................................................................................................................................................................26
Disassembly................................................................................................................................................................................26
Inspection....................................................................................................................................................................................27
Assembly......................................................................................................................................................................................27
Operation..........................................................................................................................................................................................28
Functional Description........................................................................................................................................................... 28
Check Valve.................................................................................................................................................................................28
Shuttle Valve...............................................................................................................................................................................28
Connecting Pin..........................................................................................................................................................................28
Repair..................................................................................................................................................................................................28
Diassembly..................................................................................................................................................................................28
Inspection....................................................................................................................................................................................29
Assembly......................................................................................................................................................................................31
Operation..........................................................................................................................................................................................32
Functional Description........................................................................................................................................................... 32
Solenoid Valve........................................................................................................................................................................... 32
Repair..................................................................................................................................................................................................33
Removing the Solenoid Valve..............................................................................................................................................33
Disassembly................................................................................................................................................................................34
Inspection....................................................................................................................................................................................34
Assembly......................................................................................................................................................................................35
Installing the Solenoid Valve................................................................................................................................................35
Operation..........................................................................................................................................................................................36
Functional Description........................................................................................................................................................... 36
Signal Pressure...........................................................................................................................................................................36
Repair..................................................................................................................................................................................................36
Disassembly................................................................................................................................................................................36
Inspection....................................................................................................................................................................................38
Assembly......................................................................................................................................................................................38
4 11009446 • Rev BA • July 2014
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Service Manual
Introduction
Safety Precautions
Series 51 Hydraulic Proportional 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.
11009446 • Rev BA • July 2014 5
Service Manual
Series 51 Hydraulic Proportional 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
Lubricate with hydraulic fluid
Overview
Torx head Cover splines with installation sleeve
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.
This manual includes information for the installation, maintenance, and minor repair of Series 51
hydraulic proportional controls. It includes a description of the unit and its individual components, and
minor repair procedures.
Performing minor repairs may require removal of the unit from the vehicle/machine. Thoroughly clean
the unit before beginning maintenance, or repair activities. Since dirt and contamination are the greatest
enemies of any type of hydraulic equipment, follow cleanliness requirements strictly. This is especially
important when changing the system filter and when removing hoses or plumbing.
A worldwide network of Danfoss Global Service Partners is available for major repairs. Danfoss Global
Service Partners are trained by the factory and certified on a regular basis. You can locate your nearest
Global Service Partner using the distributor locator at www.powersolutions.danfoss.com. Click on the
Sales and Service link.
6 11009446 • Rev BA • July 2014
Service Manual
Introduction
General Instructions
Series 51 Hydraulic Proportional Controls Service Manual
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.
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.
General Description
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.
Overview
Hydraulic proportional controls infinitely vary the motor displacement between maximum and minimum
by feeding a variable hydraulic signal pressure to the end of the 4-way valve directly, or to a piston that
moves the 4-way valve As signal-pressure shifts the 4-way valve, it ports pressure to the ends of the servo
piston, changing motor displacement. A threshold spring and a ramp spring act on the opposite end of
the 4-way valve.
Threshold and Ramp Springs
The threshold adjustment screw varies the threshold spring force required to move the 4-way valve and
start the change in displacement. The ramp spring(s)—2 used in 160cc and 250cc motors, and one used
in the 80 cc and 110cc motors—increase the force on the 4-way valve as the servo piston moves toward
minimum displacement. This provides a motor displacement proportional to the input signal pressure.
The control operating threshold (the signal pressure when the motor starts to shift) is adjustable. Adjust it
using the adjusting screw in the end cap.
Changing ramp spring force requires replacing the springs. There are several spring rates available.
Optional orifices may be installed at several locations to regulate shift speed. Refer to the Model Code for
your motor for details.
11009446 • Rev BA • July 2014 7
Spring seat
Threshold spring
Threshold adjustment screw
locknut
J50
Spring seat
S10*
S20
S10*
S10
J30
Ramp spring(s)
P106 438E
n
T6
T2
T1
T7 T8
T3
T4
U6
U7
T5
max.
disp.
A
L2 M4 M3 N
M1
L1
M2
M7
X1
M5
XA XB
B
P106 417E
Control
Multiblock
PCOR Valve
BPD Spool
Shuttle
Loop Flush
4-Way Valve
Service Manual
Introduction
Series 51 Hydraulic Proportional Controls Service Manual
Threshold and Ramp Springs
Multiblock
Some hydraulic proportional controls are used in conjunction with the multiblock. The multiblock is a
manifold with a shuttle-valve that routes high loop (system pressure) from port A or port B to the 4-way
valve to serve as servo supply and to the PCOR function. The shuttle valve also routes the low pressure
side of the loop to the PCOR function.
Multifunction Schematic
Pressure Compensator OverRide (PCOR) Function
The Pressure Compensator OverRide (PCOR) function allows the motor to match its displacement to the
8 11009446 • Rev BA • July 2014
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, available torque
increases. Output speed decreases and system pressure remains nearly constant at the PCOR setting.
The PCOR setting is adjustable from 110 to 370 bar [1595 to 5365 psi]. Optional orifices at locations T4, T5,
T6, U6, and U7 regulate the PCOR operation speed.
T4
T6
T5
U7
U6
P106 415E
Shuttle valve
Brake defeat spool
PCOR spool
P106 431E
PCOR adjuster
Service Manual
Introduction
Series 51 Hydraulic Proportional Controls Service Manual
Optional Orifices: T4, T5, T6, U6, U7
Brake Pressure Defeat (BPD) Option
The PCOR function can be equipped with an optional brake pressure defeat (BPD) option that defeats the
PCOR operation during dynamic braking. A shuttle spool ahead of the PCOR valve directs only
acceleration system pressure to the PCOR. During deceleration the dynamic braking pressure is blocked
from the PCOR limiting rapid deceleration, uncontrolled pressures or engine over-speeding while the
vehicle/machine is slowing down. An external hydraulic signal pressure fed to ports XA or XB are required
to operate the BPD spool. PCOR operation on one system pressure side is also an option.
BPD Option
11009446 • Rev BA • July 2014 9
M2
M1
Threshold
adjustment
M3
M5
M1
M5
M3
A
L2
L1
M7
P106 434E
M4
M4
X1
M7
X1
Radial ported motor
M3
M5
B
A
M4
System port A
M1+M2
System port B
Axial ported motor
Service Manual Series 51 Hydraulic Proportional Controls Service Manual
Pressure measurements
Port locations and Gauge Installation
The following table and drawings show the port locations and gauge sizes needed. When testing system
pressures, calibrate pressure gauges frequently to ensure accuracy. Use snubbers to protect gauges.
Port Information
Port identifier Port size Wrench size Reading Gauge size, bar [psi]
L1, L2 1 1/16-12 UNF 9/16 internal hex Case drain 10 bar [100 psi]
M1, M2 9/16-18 UNF 1/4 internal hex System pressure 600 bar [10,000 psi]
M3, M4, M5 9/16-18 UNF 1/4 internal hex Servo pressure 50 bar [1000 psi]
X1, M7 9/16-18 UNF 1/4 internal hex Control pressure 50 bar [1000 psi]
Port Locations
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Service Manual
Adjustments
Threshold Setting
Series 51 Hydraulic Proportional Controls Service Manual
Checking Threshold Setting
1. Install a 50 bar [600 psi] gauge at port M3 to read minimum servo pressure.
2. Install a 50 bar [600 psi] gauge at port M4 to read maximum servo pressure.
3. Install meter to read signal current.
4. Increase the signal current to the proper setting.
The pressure at port M3 should rise to about 100 psi [6.89 bar] higher than the pressure at port M4.
This causes the servo piston to move toward minimum position. Signal current at this point is the
threshold setting.
On a test stand, increase signal current until the flow from the motor begins to decrease. The signal
current at this point is the threshold setting.
Adjusting Threshold Setting
1. Using a 10 mm wrench, loosen the locknut on the adjustment screw.
2. Using a 3 mm internal hex wrench turn the adjusting screw:
Clockwise (cw) to increase the setting
•
Counterclockwise (ccw) to decrease the setting.
•
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].
•
11009446 • Rev BA • July 2014 11
Adjusting screw
Spring seat
P101 911
Locknut
10 mm
9 Nm [6.6 lbf•ft]
Service Manual
Adjustments
Series 51 Hydraulic Proportional Controls Service Manual
Locknut and Threshold
Pressure Compensator OverRide (PCOR) Setting
PCOR Adjustment
In order to measure and adjust the start pressure setting for the PCOR function:
1. Install a 600 bar [10000 psi] gauge at port M1 or M2 or M5 to read high system pressure.
2. Install a 600 bar [10000 psi] gauge at port M3 to read minimum servo pressure.
3. Lock the motor shaft from moving by:
4. Start the prime mover. Operate at medium RPM.
Applying the park brake, apply an extreme load, or
•
Position the machine against an immovable object, or
•
Other means to hold the machine.
•
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