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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. Remove and discard O-rings (M24A).
11. Using a 3/8 internal hex wrench remove plug (M23).
12. Remove and discard O-ring (M23A).
13. Remove screws (M150 and M151) using a:

•

8mm internal hex wrench for the 80 cc and 110cc motors

•

10 mm internal hex wrench for the 160cc and 250cc motors.

14. Remove the control from the endcap.
15. Remove 4-way valve assembly (F32).

C

Caution

If repair is necessary to the 4-way valve, threshold spring, and ramp spring components, refer to 

Series

51 and Series 51-1 Motors Service Manual

 11008567.

16. Remove and discard O-rings (F324).
17. Remove O-rings (G38), (G36) and (G42) or gasket (N240).
18. Using a 3 mm internal hex, remove orifices (T4, T6, U7).

Inspection

1. Inspect the housing (M1) for signs of corrosion or damage.
2. Replace any damaged parts.

Assembly

1. Using a 3 mm internal hex, install orifices (T4, T6, 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. Using petroleum jelly, lubricate and install a new O-rings (G38, G36 and G42) or install gasket (N240).
5. Install the control assembly to the end cap.
6. Install screws (M150 and M151).
7. Torque screws (M150 and M151) to:

•

78 N•m [58 lbf•ft]. Use an 8mm internal hex wrench for 80 cc and 110cc motors.

•

110 N•m [81 lbf•ft]. Use a 10 mm internal hex for 160cc and 250ccmotors.

8. Install spool (M32).
9. Lubricate O-ring (M23A). Using a 3/8 internal hex wrench, install plug (M23). Torque to 25 Nm [18

lbf•in].

10. Lubricate and install 13 O-rings (M24A). Using an 1/8 internal hex wrench, install 13 plugs M24).

Torque to 6 Nm [4 lbf•in].

11. Lubricate and install O-rings (M84A). Using a 7/16 wrench, install plugs (M84). Torque to 12 Nm [9

lbf•in].

12. Install the PCOR spool assembly (M20).
13. Install spring (M18). Install adjuster (Z*).
14. Lubricate and install O-ring (M16).
15. Install lock nut (M14). Torque to 54 Nm [40 lbf•in].

Service Manual

Series 51 Hydraulic Proportional Controls Service Manual

JA Control

38

11009446 • Rev BA • July 2014

Summary of Contents for 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: ...ate Changed Rev July 2014 Danfoss layout BA November 2010 new last page AC February 2010 Fix Osaka address AB July 2009 First edition AA Service Manual Series 51 Hydraulic Proportional Controls Servic...

Page 3: ...uge Installation 10 Adjustments Threshold Setting 11 Checking Threshold Setting 11 Adjusting Threshold Setting 11 Pressure Compensator OverRide PCOR Setting 12 PCOR Adjustment 12 Checking PCOR Setting...

Page 4: ...ols Operation 28 Functional Description 28 Check Valve 28 Shuttle Valve 28 Connecting Pin 28 Repair 28 Diassembly 28 Inspection 29 Assembly 31 J1 J2 J3 J4 Controls Operation 32 Functional Description...

Page 5: ...r 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...

Page 6: ...nces the appearance of the symbol itself denotes its meaning The legend above defines each symbol and explains its purpose Overview This manual includes information for the installation maintenance an...

Page 7: ...uirements 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 General Desc...

Page 8: ...Valve BPD Spool Shuttle Loop Flush 4 Way Valve Pressure Compensator OverRide PCOR Function The Pressure Compensator OverRide PCOR function allows the motor to match its displacement to the system load...

Page 9: ...celeration 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 hydrau...

Page 10: ...al 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 intern...

Page 11: ...his 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 Threshol...

Page 12: ...e 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 Applying the park brake apply...

Page 13: ...m pressure at this point is the PCOR setting W Warning System pressure may increase rapidly when flow increases Adjusting the PCOR Setting For PCOR valves mounted on a Multiblock use a 1 1 16 inch wre...

Page 14: ...ench size Torque N27 1 8 inch internal hex 7 Nm 4 lbf ft N23 1 inch 40 Nm 30 lbf ft U6 U7 3 mm internal hex 6 Nm 4 lbf ft N29 5 mm internal hex 16 Nm 12 lbf ft N14 1 5 16 inch N A Inspection Clean and...

Page 15: ...not torque until after PCOR adjustment Refer to page 13 for instructions 8 Lubricate and install a new O ring N23A Using a 1 inch hex wrench install plug N23 Torque to 40 N m 30 lbf ft 9 Lubricate and...

Page 16: ...iscard O rings N27A 4 Remove screws N58 5 Remove the multifunction block N1A1 6 Remove and discard O rings G36 G38 and G42 or gasket N240 7 If present remove and discard screens N52 They are no longer...

Page 17: ...ch internal hex wrench Torque to 7 N m 4 lbf ft 2 Using petroleum jelly to retain them install new interface O rings G36 G38 G42 or gasket N240 3 Position the multifunction block on the endcap Install...

Page 18: ...sure It routes this high pressure to the 4 way valve to power the servo piston HA and HB Controls The HA and HB controls have internal porting to feed system A or B pressures respectively to the 4 way...

Page 19: ...ls only 5 Remove and discard O rings M16A 6 If present remove orifice M12 using a 5mm internal hex wrench HZ controls only 7 If present remove shuttle valve M10 HZ controls only If necessary tap the h...

Page 20: ...wrench HZ controls only Torque to 8 N m 6 lbf ft C Caution Overtorquing orifice M12 may crush shuttle valve M10 3 Lubricate and Install new O rings to all plugs 4 Using a 1 4 inch internal hex wrench...

Page 21: ...ing and ramp spring s act on the opposite end of the 4 way valve HS Schematic 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 BP...

Page 22: ...m jelly to retain it install a new O ring M12 2 Install the HS valve housing on to the multifunction block 3 Using a 4 mm internal hex install screws M10 Torque to 6 4 Nm 4 7 lbf ft 4 Lubricate and in...

Page 23: ...d valve are the same for H1 H2 K1 and K2 controls The control housings are different between the H1 H2 and the K1 K2 controls The logic for the control is If H1 or H2 are energized operation is propor...

Page 24: ...e M1 coil nut 3 4 inch 6 Nm 4 lbf ft M1 solenoid valve 7 8 inch 12 Nm 6 lbf ft M22 M18 M24 1 4 internal hex 31 Nm 27 lbf ft M14 4 mm internal hex 6 4 Nm 4 7 lbf ft Assembly 1 Using petroleum jelly to...

Page 25: ...50 cc motors one in 80 cc and 110 cc motors increases the force on the 4 way valve as the servo piston moves toward minimum displacement This provides a motor displacement proportional to the input si...

Page 26: ...the pilot piston M14 Remove and discard O ring M24 6 Remove pin M18 from the multifunction block 7 Use screw M36 as a threaded puller to remove plug M28 Remove O ring M30 8 Remove shuttle spool M26 9...

Page 27: ...toward the inside of the block 6 Install pin M18 in the multiblock 7 Position the control valve housing on the multifunction block 8 Install the pilot piston M14 into the control valve housing over pi...

Page 28: ...r signal pressure to the top of the servo piston It ports lower signal pressure to the bottom of the servo piston Connecting Pin The connecting pin links the piston to the 4 way valve The bias spring...

Page 29: ...2 Remove cover M12 Remove gasket M14 13 Remove spring seat M20 Remove spring M22 14 Remove the pilot piston M24 15 Remove spring seat M25 Remove pin M26 16 Remove spring J10 17 Remove screws M10 and w...

Page 30: ...P101 882 G36 M1HC M28 N240 Legend Item Wrench size Torque M48 1 4 internal hex 37 Nm 27 lbf ft M40 10 mm 18 N m 13 3 lbf ft M34 1 4 internal hex 37 Nm 27 lbf ft M28 4 mm internal hex 6 4 Nm 4 7 lbf ft...

Page 31: ...all cover M12 11 Using a 4 mm internal hex wrench install screws M28 Torque to 6 4 Nm 4 7 lbf ft 12 Install adjustment screw M18 Install locknut M16 13 Hold adjustment screw in place and torque locknu...

Page 32: ...rt X1 Solenoid Valve The solenoid valve item M1 is a 2 position 3 way valve that passes the external signal pressure to the end of the 4 way valve or blocks the external signal and drains the end of t...

Page 33: ...M23 M23A M24 U7 N84 M21 M18 M16 M14 M20 N34 N33 N33 N34 M22 M24 M24A M22A M24 M24 U6 M151 M150 M1 Z G38 G42 G38 G42 G36 N32 M22 M22A M15 M1 Note Orifices T4 and T6 and PCOR adjuster Z are not included...

Page 34: ...internal hex wrench remove plugs M22 N34 11 Remove and discard O rings M22A N34A 12 Remove spool N32 13 Using a 3 8 internal hex remove plug M23 Discard O rings M23A 14 Remove screws M150 and M151 usi...

Page 35: ...ing M23A Using a 3 8 internal hex wrench install plug M23 Torque to 95 Nm 70 lbf in 11 Lubricate and install 15 O rings M24A Using an 1 8 internal hex wrench install 15 plugs M24 Torque to 6 Nm 4 lbf...

Page 36: ...D spool resolves which signal pressure is higher and routes this signal pressure to the end of the 4 way valve The signal pressure shifts the 4 way valve and it ports servo supply pressure to the ends...

Page 37: ...hex 78 Nm 58 lbf ft M150 M151 160 1250 10 mm internal hex 110 Nm 81 lbf ft M14 1 1 16 54 Nm 40 lbf ft Item Wrench size Torque T4 T6 U7 3 mm internal hex 3 7 Nm 2 7 lbf ft M23 3 8 internal hex 25 Nm 18...

Page 38: ...internal hex install orifices T4 T6 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 Using petroleum jelly lubricate and install a new O ri...

Page 39: ...C Caution Readjust the PCOR to its proper setting Service Manual Series 51 Hydraulic Proportional Controls Service Manual JA Control 11009446 Rev BA July 2014 39...

Page 40: ...rg Denmark Phone 45 7488 2222 Danfoss Power Solutions US Company 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 Danfoss Power Solutions Shanghai Co Ltd Building 22 No 1000 Jin Hai Rd Jin...

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