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FluHK.66.J1.02

Unloading ValvesPressure Intensifying Valves

Fluid Power

HK.66.J1.02 © Danfoss Fluid Power 10/932

Fluid Power

Unloading valves can provide:• Horsepower Savings• Less Heat Generation• High Speed• High Force• Reduced Component Cost

GeneralUnloading valves are designed specifically for two pump Hi-Locircuits. Just as an automobile transmission shifts gears toprovide either high torque or high speed, the unloading valveallows a Hi-Lo circuit to “shift” from high volume (low pressure) tohigh pressure (low volume). This is particularly useful when highpressure is required for only a small portion of total cycle time.

Introduction

Unloading valves

Type Description Symbol Models

Output from both pumps (P1 & P

2) is combined giving maximum

flow at low pressure.As load pressure increases to setting of the unloading section,

HI-LO Two the high volume pump flow (P1) is “unloaded” directly to tank at 1UL12

Pump Unloader minimum pressure drop. The high pressure pump (P2) 1UL15supplies system with required high pressure-low flow.Built-in relief limits maximum pressure of the high pressurepump (P2) to limit force and protect the system.

Types and Operation

SYS

T

P2 P1

General ApplicationFor use in a two pump system, (high pressure-low flow/lowpressure-high flow) to unload the high volume pump at a pre-selected pressure level.The valve includes:1) the pilot operated pump unloading section;2) isolation check; and3) a direct acting differential piston, high pressure system relief.(The high pressure relief and unloading sections are adjustable.)

Typical Circuit

System

T

P2 P1

Highpressure

lowvolume

Lowpressure

highvolume

3HK.66.J1.02 © Danfoss Fluid Power 10/93

Fluid Power

Cartridges and Parts in Body 1UL12

Unloading valve for HI-LO dual pump

To 150 l/min and 280 bar

T

P

SYS

2 P1

LO HI

How to order

SEALSSV = Viton A

ADJUST. MEANSP = Leak Proof

Screw (Lo)andScrew w/cap (Hi)

BASE PART NO. PORT SIZE12T-8T = 3/4" SAE

(SYS, P1, & T)1/2" SAE (P2)

6-4 = 3/4" NPTF (P2)(SYS, P1, & T)1/2" NPTF (P2)

6W-4W = G 3/4(SYS, P1, & T)G 1/2 (P2)

LOW PRESSURE RANGE15 = 7-105 bar

Std. Setting 35 bar30 = 7-210 bar

Std. Setting 105 bar

HIGH PRESSURE RANGE25 = 35-175 bar

Std. Setting 105 bar40 = 70-280 bar

Std. Setting 175 bar

1UL12 - P 12T-8T - 15 / 40 SV

P2

SYSP1

T

26,99,788,992,0

P2T

SYS

P1

22,4

211,8

42,9

28,5

1D70 ReliefCART. (LO)

1L10 ReliefCartridge (HI)

∅ 10,4

96,569,9

22,4

108,050,8

50,8

Performance curveSpecifications• To 150 l/min and 280 bar.• Reseat pressure is 90% of setting.• Max. Flow P

1 = 115 l/min

P2 = 38 l/min• Max. Pressure P1 = 210 bar

P2 = 280 barWeight: 2,15 kg.

Features• Honed and matched hardened steel

working parts for long life.• Built-in high pressure relief.• Adjustable with min. & max. stops.• 100% performance tested.

Use and operationFor use in a two pump system, (highpressure/low flow, low pressure/highflow) to unload the high volume pumpat a pre-selected pressure level.The valve includes: 1) the pilotoperated unloading section, 2) isolationcheck and 3) a direct acting differentialpiston, high pressure system relief.

The high pressure relief and unloadingsection are adjustable.This valve allows most efficient,economical pump selection, andminimizes horsepower loss and heatgeneration when unloading the highvolume pump. Output from both pumps(P1 & P2) is combined giving maximumflow at low pressure. As load pressureincreases to setting of the unloadingsection, the high volume pump flow(P1) is “unloaded” directly to tank atminimum pressure drop (see curve).The high pressure pump (P2) holdsisolation check closed and suppliessystem with required high pressure-lowflow. System relief limits maximumpressure of the high pressure pump(P2) to limit force and protect thesystem.

Materials• Body – High-strength aluminium alloy.• Internal parts – Hardened steel.• Cartridges – Steel.• Seals – Viton A standard.

∆p vs flow

0151760

5,5

8,3

14

l/min

11

2,8

1UL1

2 un

load

P to

T1

114

bar

HK.66.J1.02 © Danfoss Fluid Power 10/934

Fluid Power

Cartridges and Parts in Body 1UL15

Unloading valve for HI-LO dual pump

To 305 l/min and 280 bar

How to order

Specif ications• To 305 l/min and 280 bar.• Max. Flow P1 = 227 l/min P2 = 132 l/min• Max. Pressure P1 = 210 bar

P2 = 280 bar• Weight: 7,71 kg.

Features• Honed and matched hardened steel

working parts for long life.• Built-in high pressure relief.• Adjustable with min. & max. stops.• 100% performance tested.

Use and operationFor use in a two pump system, (highpressure/low flow, low pressure/highflow) to unload the high volume pumpat a pre-selected pressure level.The valve includes:1) the pilot operated unloading section,2) isolation check and 3) a direct actingdifferential piston, high pressuresystem relief.

The high pressure relief and unloadingsection are adjustable.This valve allows most efficient,economical pump selection, andminimizes horsepower loss and heatgeneration when unloading the highvolume pump. Output from both pumps(P1 & P2) is combined giving maximumflow at low pressure. As load pressureincreases to setting of the unloadingsection, the high volume pump flow(P1) is “unloaded” directly to tank atminimum pressure drop (see curve).The high pressure pump (P2) holdsisolation check closed and suppliessystem with required high pressure-lowflow. System relief limits maximumpressure of the high pressure pump(P2) to limit force and protect thesystem.

T

P

SYS

2 P1

LO HI

Performance curve

∆p vs flow

1UL1

5 unlo

ad P

to T

1

0227760

5,5

8,3

14

l/min

11

2,8

151

bar

303

Materials• Body — High-strength aluminium alloy.• Internal parts – Hardened steel.• Cartridges – Steel.• Seals – Viton A standard.

PORT SIZE16T-12T = 1" SAE

(SYS, P1, & T)3/4" SAE (P2)

8-6 = 1" NPTF(SYS, P1, & T)3/4" NPTF (P2)

8W-6W = G1(SYS, P1, & T)G 3/4 (P2)

1UL15 - P 16T-12T - 15 / 25 SV

SEALSSV = Viton A

BASE PART NO. ADJUST. MEANSP = Leak Proof

Screw (Lo)andScrew w/cap (Hi)

LOW PRESSURE RANGE15 = 7-105 bar

Std. Setting 35 bar30 = 7-210 bar

Std. Setting 105 bar

HIGH PRESSURE RANGE25 = 35-175 bar

Std. Setting 105 bar40 = 70-280 bar

Std. Setting 175 bar

SYS

38,1

P2

1D70 Reliefcartridge (LO)

≈ 186

76,2

87,4

152,4

P2

P1

T

SYS

≈ 279

130,1

36,6

1L10 Reliefcartridge (HI)

177,8

11,240,4 77,0

∅ 13,5

P1

P2

T

5HK.66.J1.02 © Danfoss Fluid Power 10/93

Fluid Power

Hydraulic Intensifiers provide:• Continuous Holding Power• Very High Pressure Clamping• Light Weight Compact Design• Potential for Intensification of Dissimilar Fluids

GeneralA hydraulic intensifier converts low input pressure from a smalllow pressure pump or sub-circuit to high pressure up to 690 bareliminating the need for a high pressure pump, or hi-low typecircuit. It is best suited for use with low horsepower, variablevolume pumps.

Type Description Symbol Models

The pressure intensifier design allows free-flow of oil through theinlet and pressure check section until high pressure is required,

Hydraulic then reciprocates to intensify pressure to 690 bar. 1T11Intensifier It holds high pressure continuously and automatically makes up

for any leakage in the system. The automatic reciprocation featureresults in no loss of pressure while holding, cutting or clamping.

Types and Operation

General ApplicationThis one-of-a-kind fully hydraulic pressure intensifier wasdesigned specifically for high pressure, low volume applications,such as – holding – clamping – cutting – crimping – molding – orfor hydraulic power tools.

Specifications and Materials• Output Flow to 164 ml/min• Driving Flow 1,5 l/min• Maximum Output Pressure – 690 bar• Maximum Cycle Rate — 5 CPS• Lower Body (High Pressure End) – Steel• Upper Body (Cylinder End) — Aluminium• Internal Parts – Steel

Typical Circuit

Tank (T)

Inlet Pressure (P)

High pressureclamping cylinder

P.O.check

HighPressure

(HP)

Pressure intensifying

Introduction

HK.66.J1.02 © Danfoss Fluid Power 10/936

Fluid Power

Specifications• Output to 164 cc/min and 690 bar.• Max. inlet pressure 112 bar based upon

6.5:1 ratio.• Min. inlet pressure 17 bar.• Max. backpressure in tank line —

13,8 bar.• Max. inlet flow 1,5 l/min.• Max. cycle rate — 5 cps.• Pressure drop with 7,5 l/min through

pumping checks — 9,1 bar (180 SSUoil).

• Min. recommended oil viscosity —59 SSU.

• Pressure intensification ratio — 6.5:1.• Weight: 2,36 kg.

Features• Eliminates typical problems of single

stroke styles and air/oil systems.Output to 690 bar 6.5:1 ratio.

• Continuous Holding Power. Fullyhydraulic design with built-in automaticreciprocation provides continuousintensified pressure output to 690 barMakes up for system leakage automati-cally.

• Total Circuit Convenience. Integrateddesign includes suction and highpressure checks — does not requireseparate sequence valving in circuit.Separate inlet ports permit intensifica-tion of separate fluids.

• Compact, Light Weight. Only 222 mm× 67 mm dia. Can be mounted any-where — conveniently located close toactuator, eliminates long runs of highpressure lines.

• Reliable High Quality. Rugged designwith only two main moving parts useshigh strength aluminium and steel withworking parts hardened, ground,matched and honed for trouble-free,reliable long-life.

• Patented Design.

Use and operationThis one-of-a-kind fully hydraulicpressure intensifier was designedspecifically for high pressure, low volumeapplications, such as – holding –clamping – cutting – crimping – molding –or for hydraulic power tools.

It converts low input pressure from asmall low pressure pump or sub-circuit tohigh pressure up to 690 bar and caneliminate the need for a high pressurepump, or hi-low type circuit. Is bestsuited for use with low horsepower,variable volume pumps.Note: A 690 bar pilot operated check isavailable.The pressure intensifier design allowsfree-flow of oil through the inlet andpressure check section until highpressure is required, then reciprocates tointensify pressure to 690 bar. It holdshigh pressure continuously and automati-cally makes up for any leakage in thesystem.The automatic reciprocation featureresults in no loss of pressure whileholding, cutting or clamping.

Materials• Body and housing — High-strength

aluminium and steel.• Internal parts — Steel.

How to order 1T11 - 4T - 6 S

PRESSURE INTENSIFICATIONRATIO6 = 6.5:1

SEALSS = Buna-N

SV = Viton A

PORT SIZE4T = 1/4" SAE2W = G 1/4

BASE PART NO.

Pressure (P)

High pressureclamping cylinder

P.O.check

Highpressure

(HP)

Directionalcontrol valve

Inlet (I)

Tank (T)

Typical circuit

Parts in Body 1T11

≈ 222

50,869,6

∅ 6,6 9,7

66,6

50,8

15,8

9,7

1/4" SAE Ports

G 1/4 Ports

59,4

61,2

84,1

47,5

80,8

HPT

PI

Hydraulic pressure intensifier

Output to 164 cc/min and 690 bar

7HK.66.J1.02 © Danfoss Fluid Power 10/93

Fluid Power

Hydraulic Intensifiers provide:• Continuous Holding Power• Very High Pressure Clamping• Light Weight Compact Design• Used Extensively on Utility Vehicles

GeneralA hydraulic intensifier converts low input pressure from a smalllow pressure pump or sub-circuit to high pressure up to 690 bareliminating the need for a high pressure pump, or hi-low typecircuit. It is best suited for use with low horsepower, variablevolume pumps.

Type Description Symbol Models

Types and Operation

1.5 GPM

Intensifier

0,75 l/min

T*P

Dump valve

Unloading

Relief

HP B A

Tool Retract Actuate

4RH11Handle

Tank

1TR11Toolmatemanifold

*Plug T forclosed centersystems

The pressure intensifier design allowsfree-flow of oil through the inlet andpressure check section until highpressure is required, then reciprocates tointensify pressure to 690 bar.It holds high pressure continuously andautomatically makes up for any leakagein the system. The automatic reciproca-tion feature results in no loss of pressurewhile holding, cutting or clamping.

HydraulicIntensifier

1TR114RH11

General ApplicationFor use with any conventional hydraulic system. Designed tooperate cutters, crimpers, or any high pressure hydraulic toolsrequiring up to 690 bar. Used extensively on utility vehicles.

Specifications and Materials• Output Flow to 164 ml/min• Driving Flow 1,5 l/min• Maximum Output Pressure – 690 bar• Maximum Cycle Rate — 5 CPS• Lower Body (High Pressure End) – Steel• Upper Body (Cylinder End) — Aluminium• Internal Parts – Steel

Pressure intensifying

Introduction

HK.66.J1.02 © Danfoss Fluid Power 10/938

Fluid Power

9,5

7,9

2,0

Actuate Retract

127,0

22,2

22,2

50,8

44,5

3,110,7

10,4

206,4

120,7

88,9 206,4

96,8 130,2

5/16-18 UNC – 285/8 deep 120,725,4

Hydraulic pressure intensifier

Output to 164 cm3/min and 690 bar

9HK.66.J1.02 © Danfoss Fluid Power 10/93

Fluid Power

Specifications• Output to 164 cc/min and 690 bar.• Max. inlet pressure 112 bar based upon

6.5:1 ratio.• Min. inlet pressure 17 bar.• Max. backpressure in tank line —

13.8 bar.• Max. inlet flow 1,5 l/min.• Max. cycle rate — 5 cps.• Pressure drop with 7,5 l/min through

pumping checks — 9,1 bar(180 SSU oil).

• Min. recommended oil viscosity —59 SSU.

• Pressure intensification ratio — 6.5:1.• Weight: 5,90 kg.

Features• Compact — only 114,30 × 88,90 ×

206,38 — provides more work room andusable pay load on aerial elbowbuckets.

• Light Weight — only 5,90 kg — unitcan be easily transported on typicalutility truck or mounted right on bucketin convenient location.

• “Hold” and “Reversing” Capability —pressure intensification can be stoppedand held or reversed at any point in thecycle.

• Reciprocating Intensifier — providesclean, smooth ultra high pressure.Gives positive maximum pressurecrimps on cable connectors.

• Adjustable Maximum PressureControl (set at factory) — providesvariable maximum crimping pressure —allows use of tools with differentmaximum pressure requirements.

• Remote Control Unit and Tool Handle— allows complete control of system atthe tool.

• Built In Relief — prevents tool damage— factory set up to 690 bar.

• Free Flow — through unit for rapidclosing of tool — saves time with rapidadvance — allows more operations perhour.

• Unit Will Operate On Open Or ClosedCenter Hydraulic Systems

Use and operationThis one-of-a-kind fully hydraulicpressure intensifier was designedspecifically for high pressure, low volumeapplications, such as – holding –clamping – cutting – crimping – molding –or for hydraulic power tools.It converts low input pressure from asmall low pressure pump or sub-circuit tohigh pressure up to 690 bar and caneliminate the need for a high pressurepump, or hi-low type circuit. Is best suitedfor use with low horsepower, variablevolume pumps.

Note: A 690 bar pilot operated check isavailable.The pressure intensifier design allowsfree-flow of oil through the inlet andpressure check section until highpressure is required, then reciprocates tointensify pressure to 690 bar. It holdshigh pressure continuously and automati-cally makes up for any leakage in thesystem. The automatic reciprocationfeature results in no loss of pressurewhile holding, cutting or clamping.

The Unloading Relief is an adjustablepressure relief valve which will dump thehigh pressure side of the circuit to tankwhen the high pressure reaches reliefsetting. When the unloading relief begins

opening, the high pressure then works ona larger area on the piston, thus requiringless pressure to hold the relief open thanto start opening it. As a result, pressurein the “HP” line (to the tool) reaches reliefsetting and then drops off to approxi-mately 70 bar. (When this occurs, theintensifier section continues to recipro-cate without increasing pressure in thetool.) This unloading feature can be feltby the operator through the control leveron the handle, indicating that themaximum pressure has been reached.

The Handle incorporates a holdingfeature. This enables the operator to stopthe tool at any position by just releasingthe lever. By releasing the lever (withoutdepressing it in the opposite direction)port “A” will be blocked and flow will stop.With no flow through the orifice in thedirection control valve spool, pressurewill equalize on the two ends of thespool, permitting the spring to shift it anddivert system flow to tank. Likewise, thedump valve will open the path from the“HP” port to “Low Tank”. Pressure will betrapped in the tool by the check valveand retract valve. When the lever isdepressed in the “retract” direction, theretract valve is opened allowing thereturn spring in the tool to retract theplunger, forcing the oil therein throughthe “Low Tank” port.

Materials• Body and housing — High-strength

aluminium and steel.• Internal parts — Steel.• Handle — High-strength steel.• Internal Parts — Steel.• Seals — Buna-N.

Power Unit

How to order

1TR11 - T - 6 S

BASE PART NO. SEALSS = Buna-N

SV = Viton A

PORT SIZEHP manifold port Handle port HP 3/8" NPTFA manifold port Handle port A 1/8" NPTFB manifold port Handle port B 1/8" NPTFP manifold port System pressure source 3/8" SAE or NPTFT manifold port* Normal system tank line 1/2" SAE or NPTFLow Tank manifold port Special separate tank line 1/4" NPTF

PRESSURE INTENSIFICATION RATIO6 = 6.5:1

Control Handle

4RH11 - S

SEALSS = Buna-N

SV = Viton A

BASE PART NO.

Hydraulic pressure intensifier

HK.66.J1.02 © Danfoss Fluid Power 10/9310

Fluid Power

Notes

11HK.66.J1.02 © Danfoss Fluid Power 10/93

Fluid Power

Fluid Control Products

Product and catalogue survey CatalogueProducts

Ordering No.

Spreader Valves HK.66.B -.02

600 Series Valves HK.66.C -.02

400 Series Valves HK.66.D -.02

Relief Valves HK.66.F -.02

Sequence Valves HK.66.G-.02

Pressure Reducing Valves HK.66.H -.02

Motion Control Valves HK.66.I -.02

Unloading Valves and Pressure Intensifying Valves HK.66.J -.02

Needles and Restrictor Valves HK.66.K -.02

Flow Regulator Valves and Flow Divider Valves HK.66.L -.02

Pilot operated Check Valves HK.66.M-.02

Directional Control/Logic Valves HK.66.N -.02

Solenoid Directional Control Valves HK.66.O-.02

HK.66.J1.02 © Danfoss Fluid Power 10/93

World Class Leadership in TechnologyDanfoss Fluid Power, a division of Danfoss, Inc., offers one of the world’slargest selections of quality fluid power components. An exceptional overalloffering of Danfoss, Dukes, Fluid Controls and Webster components allowsyou to choose the right products to meet your application. All of our units aremanufactured and tested to exacting engineering and quality control stan-dards to provide reliable long lasting performance.

Danfoss ProductsDanfoss products are known throughout the world for their quality, reliabilityand flexibility. From hydraulic motors, pumps, actuators and hydrostaticsteering components, to proportional hydraulics and electronics, Danfosscomponents redefine the leading edge.

Dukes ProductsThe Dukes name is recognized as the premier U.S. manufacturer of mobiledirectional control valves for applications to 115 l/min. Your specific needscan be addressed with mono-block or stack valves, or if required, a customdesigned valve.

Fluid Controls ProductsBeginning with the development of a compact, pilot-operated hydraulic reliefvalve over 40 years ago, Fluid Controls has remained a pioneer in hydraulicproduct miniaturization. Along with the wide variety of cartridge valves cur-rently available, Fluid Controls also features parts-in-body valves, andhydraulic integrated circuits to meet all of your requirements.

Webster ProductsSince 1945, Webster has been at the forefront in the development ofhydraulic gear pumps and cost effective multi-circuit components. Offering awide range of gear pumps and motors, Webster products can be found in amultitude of applications. The AC and DC power unit lines offer dependable,self-contained sources of hydraulic power. Flow dividers and rotary shearvalves further enhance the Webster line and expand the choices availablefrom Danfoss Fluid Power.

Danfoss A/S (SW-C) DTP 10.93 AO