Danfoss 51 Series Service Manual
Hydraulic proportional controls
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Also See for 51 Series:
- Service manual (64 pages) ,
- Repair instructions (36 pages) ,
- Service kit instructions (2 pages)
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Summary of Contents for Danfoss 51 Series
- Page 1 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...
- Page 2 Service Manual Series 51 Hydraulic Proportional Controls Service Manual Revision history Table of revisions Date Changed July 2014 Danfoss layout November 2010 new last page February 2010 Fix Osaka address July 2009 First edition 11009446 • Rev BA • July 2014...
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Page 3: Table Of Contents
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.................................. - Page 4 Service Manual Series 51 Hydraulic Proportional Controls Service Manual Contents Inspection....................................22 Assembly......................................22 H1, H2, K1, K2 Controls Operation......................................23 Functional Description................................23 Solenoid Valve................................... 23 Repair........................................23 Removing Solenoid Valve..............................24 Disassembly....................................24 Inspection....................................24 Assembly......................................24 Installing Solenoid..................................24 HP Controls Operation......................................25 Functional Description................................25 HP Control....................................25 Shuttle Valve....................................25 Connecting Pin..................................
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Page 5: Safety Precautions
Service Manual Series 51 Hydraulic Proportional Controls Service Manual Introduction Safety Precautions 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. -
Page 6: Symbols Used In Danfoss Literature
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. -
Page 7: General Instructions
Service Manual Series 51 Hydraulic Proportional Controls Service Manual Introduction General Instructions 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. -
Page 8: Multiblock
Service Manual Series 51 Hydraulic Proportional Controls Service Manual Introduction Threshold and Ramp Springs Threshold adjustment screw locknut P106 438E 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. -
Page 9: Brake Pressure Defeat (Bpd) Option
Service Manual Series 51 Hydraulic Proportional Controls Service Manual Introduction Optional Orifices: T4, T5, T6, U6, U7 P106 415E 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. -
Page 10: Pressure Measurements
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... -
Page 11: Adjustments
Service Manual Series 51 Hydraulic Proportional Controls Service Manual Adjustments Threshold Setting 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. -
Page 12: Pressure Compensator Override (Pcor) Setting
Service Manual Series 51 Hydraulic Proportional Controls Service Manual Adjustments Locknut and Threshold Locknut 10 mm 9 Nm [6.6 lbf•ft] Adjusting screw Spring seat P101 911 Pressure Compensator OverRide (PCOR) Setting PCOR Adjustment In order to measure and adjust the start pressure setting for the PCOR function: 1. -
Page 13: Checking Pcor Setting On A Test Stand
Service Manual Series 51 Hydraulic Proportional Controls Service Manual Adjustments 5. Stroke the pump very slowly to gradually increase the system pressure. An alternate method to slowly increase the system pressure is to use the pump’s pressure limiter (PL) valve. Lower the PL setting below the PCOR setting. Stroke the pump to about one-fourth displacement. -
Page 14: Pcor
Service Manual Series 51 Hydraulic Proportional Controls Service Manual PCOR Optional PCOR Housing Disassembly 1. Remove plugs (N27). Remove and discard O-rings (N27A). 2. Using a 1 inch wrench, remove plug (N23). Remove and discard O-ring (N23A). 3. Remove locknut (N14). 4. - Page 15 Service Manual Series 51 Hydraulic Proportional Controls Service Manual PCOR 4. Lubricate and install spool and spring guide assembly (N20). 5. Install spring (N18) to cavity. 6. Lubricate and install new O-ring (N16J). Install adjustment plug (Z00). 7. Using a 1-1/16 inch hex wrench, install locknut (N14). Do not torque until after PCOR adjustment. Refer to page 13 for instructions.
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Page 16: Multifunction Block
Service Manual Series 51 Hydraulic Proportional Controls Service Manual Multifunction block Optional Multifunction block Disassembly 1. Using a ¼ inch internal hex wrench, remove plugs (N26). Remove and discard O-rings (N26A). 2. Remove the spool (N30). 3. Using a 1/8 inch internal hex wrench, remove plugs (N27). Remove and discard O-rings (N27A). 4. -
Page 17: Inspection
Service Manual Series 51 Hydraulic Proportional Controls Service Manual Multifunction block Legend Item Wrench size Torque 1/8 inch internal hex 7 Nm [4 lbf•ft] 1/4 inch internal hex 37 Nm [28 lbf•ft] 8 mm internal hex 78 Nm [58 lbf•ft] 80cc, 110cc 10 mm internal hex 110 Nm [81 lbf•ft]... -
Page 18: Hz, Ha, Hb, He Controls
Service Manual Series 51 Hydraulic Proportional Controls Service Manual HZ, HA, HB, HE Controls Operation Functional Description The HZ, HA, HB, and HE controls consist of a ported housing mounted directly to the end cap. Variable signal pressure fed to port X1 is routed to the end of the 4-way valve. A threshold spring and ramp spring(s) act on the opposite end of the 4-way valve. -
Page 19: Repair
Service Manual Series 51 Hydraulic Proportional Controls Service Manual HZ, HA, HB, HE Controls Repair Disassembly 1. Remove screws (M22) using a: • 8 mm internal hex wrench for 80 cc and 110cc motors • 10 mm internal hex wrench for 160 cc and 250 cc motors. 2. -
Page 20: Inspection
Service Manual Series 51 Hydraulic Proportional Controls Service Manual HZ, HA, HB, HE Controls Legend Item Wrench size Torque 1/8 internal hex 6 Nm [4 lbf•ft] 5 mm internal hex 12 Nm [6 lbf•ft] 1/4 internal hex 31 Nm [27 lbf•ft] M22 (80, 110) 8 mm internal hex 78 Nm [58 lbf•ft]... -
Page 21: Hs Control
Service Manual Series 51 Hydraulic Proportional Controls Service Manual HS Control Operation Functional Description The HS control consists of a ported housing mounted on a multiblock. External variable signal pressure fed to port X1 is routed to 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. -
Page 22: Inspection
Service Manual Series 51 Hydraulic Proportional Controls Service Manual HS Control Disassembly M17A E101 489E 4. Remove plug (M17) using a 1/4 internal hex wrench. 5. Remove and discard O-ring (M17A). Inspection 1. Inspect the housings for damage or foreign material. 2. -
Page 23: H1, H2, K1, K2 Controls
Service Manual Series 51 Hydraulic Proportional Controls Service Manual H1, H2, K1, K2 Controls Operation Functional Description The H1, H2, K1, and K2 controls consist of a ported housing mounted on the multiblock. It contains a solenoid valve and internal porting to direct the external variable signal pressure through the solenoid valve to the end of the 4-way valve. -
Page 24: Removing Solenoid Valve
Service Manual Series 51 Hydraulic Proportional Controls Service Manual H1, H2, K1, K2 Controls Removing Solenoid Valve 1. Using a 3/4 wrench, remove the coil nut from the solenoid cartridge valve (M1). 2. Remove the coil from the solenoid cartridge valve (M1). Using a 7/8 wrench, remove the solenoid cartridge valve (M1) from the control housing. -
Page 25: Hp Controls
Service Manual Series 51 Hydraulic Proportional Controls Service Manual HP Controls Operation Functional Description The HP and HC two-line hydraulic proportional controls vary the motor displacement between maximum and minimum by feeding hydraulic signal pressure to both ends of a piston. A pin connects the piston to the 4-way valve. -
Page 26: Repair
Service Manual Series 51 Hydraulic Proportional Controls Service Manual HP Controls Repair Disassembly 1. Using a 4 mm internal hex wrench remove screws (M36). 2. Remove the housing cover (M10). Remove gasket (M12). 3. Remove spring (M16). 4. Remove housing (M1HP) with the shuttle valve assembly. 5. -
Page 27: Inspection
Service Manual Series 51 Hydraulic Proportional Controls Service Manual HP Controls Legend Item Wrench size Torque 4 mm internal hex 6.4 Nm [4.7 lbf•ft] Inspection 1. Clean and inspect all parts. 2. Discard any parts that are worn or damaged. Assembly 1. -
Page 28: Hc Controls
Service Manual Series 51 Hydraulic Proportional Controls Service Manual HC Controls Operation Functional Description The HC control consists of a ported housing, mounted directly on the end cap. It contains a check valve, a shuttle valve, a piston, a connecting pin, and a bias spring. The HC control does not have pressure compensating override (PCOR) function. -
Page 29: Inspection
Service Manual Series 51 Hydraulic Proportional Controls Service Manual HC Controls 4. Remove and discard O-ring (M48A). 5. Remove check ball seat (M46) using a 5 mm internal hex. 6. Remove check ball (M47) using a pencil magnet. 7. Using a 1/4-inch internal hex, remove plugs (M34). 8. - Page 30 Service Manual Series 51 Hydraulic Proportional Controls Service Manual HC Controls HC Control Disassembly F324 N240 M1HC M34A M50A M48A P101 882 Legend Item Wrench size Torque 1/4 internal hex 37 Nm [27 lbf•ft] 10 mm 18 N•m [13.3 lbf•ft] 1/4 internal hex 37 Nm [27 lbf•ft] 4 mm internal hex...
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Page 31: Assembly
Service Manual Series 51 Hydraulic Proportional Controls Service Manual HC Controls Legend (continued) Item Wrench size Torque 4 mm internal hex M10 (060, 080, 110) 8 mm internal hex 78 Nm [58 lbf•ft] M10 (160, 250) 10 mm internal hex 110 Nm [81 lbf•ft] Assembly 1. -
Page 32: J1, J2, J3, J4 Controls
Service Manual Series 51 Hydraulic Proportional Controls Service Manual J1, J2, J3, J4 Controls Operation Functional Description J1, J2, J3, and J4 controls are one-line hydraulic proportional with a solenoid valve that overrides the hydraulic signal to hold the motor at maximum displacement. The control housing contains a solenoid valve, a pressure compensating override (PCOR) valve, optional brake pressure defeat (BPD) valve, and passages to route oil to the 4-way valve and to the servo piston ends. -
Page 33: Repair
Service Manual Series 51 Hydraulic Proportional Controls Service Manual J1, J2, J3, J4 Controls Repair Removing the Solenoid Valve It is not necessary to remove the valve unless it is being replaced. Individual parts are not available. Replace entire valve. Solenoid for J1, J2 If replacing the valve, use a 7/8 wrench to remove the valve from the housing. -
Page 34: Disassembly
Service Manual Series 51 Hydraulic Proportional Controls Service Manual J1, J2, J3, J4 Controls Legend (continued) Item Wrench size Torque M150, M151 10 mm internal hex 110 Nm [81 lbf•ft] (160, 1250) Item Wrench size Torque 1 1/16 54 Nm [40 lbf•ft] T4, T5, U6, U7 3 mm internal hex 3.7 Nm [2.7 lbf•ft]... -
Page 35: Assembly
Service Manual Series 51 Hydraulic Proportional Controls Service Manual J1, J2, J3, J4 Controls Assembly 1. Using a 3mm internal hex, install orifices (T4, T5, U6, U7). Torque to 3.7 Nm [2.7 lbf•ft]. 2. Lubricate and install O-rings (F324). 3. Install the 4-way valve assembly (F32). 4. -
Page 36: Ja Control
Service Manual Series 51 Hydraulic Proportional Controls Service Manual JA Control Operation Functional Description JA control is a stand-alone, dual signal hydraulic proportional control. The control housing contains a pressure compensating override (PCOR) valve, a brake pressure defeat (BPD) valve, and passages to route oil to the 4-way valve and to the servo piston ends. - Page 37 Service Manual Series 51 Hydraulic Proportional Controls Service Manual JA Control Control Disassembly N240 M84A M23A M24A E101 480E Legend Item Wrench size Torque M150, M151 8 mm internal hex 78 Nm [58 lbf•ft] (80, 110) M150, M151 10 mm internal hex 110 Nm [81 lbf•ft] (160, 1250) 1 1/16...
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Page 38: Inspection
Service Manual Series 51 Hydraulic Proportional Controls Service Manual JA Control 6. Using a 7/16 wrench remove pin/plugs (M84). 7. Remove and discard O-rings (M84A). 8. Remove spool (M32). 9. Using a 1/8 internal hex wrench remove 13 plugs (M24). 10. - Page 39 Service Manual Series 51 Hydraulic Proportional Controls Service Manual JA Control Caution Readjust the PCOR to its proper setting 11009446 • Rev BA • July 2014...
- Page 40 Phone: +86 21 3418 5200 Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without changes being necessary in specifications already agreed..
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