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Danfoss H1 078, Service Manual

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Danfoss H1 078 Service Manual Download Page 53

4. Install the remaining snap-ring.

Shaft Assembly

J100

P106038

J150

J300

J250

J200

J200

Protective

cover

Seal 

installation 

tool

J150

J220

Seal Installation Tool

P106492

55 mm

[2.17 in]

120 mm

[4.72 in]

078/089/100

78 mm

[3.07 in]

82 mm

[3.23 in]

115/130 
147/165

7 mm

[0.28 in]

51 mm

[2. in]

68.5 mm

[2.70 in]

50°

80°

44.7 mm

[1.76 in]

89.4 mm

[3.52 in]

7 mm

[0.276 in]

78 mm

[3.07 in]

75.6 mm

[2.97 in]

210/250

4.4 mm

[0.17 in]

80°

57.5 mm

[2.26 in]

89.4 mm

[3.52 in]

External Filter Replacement

Removal

1. With the prime mover off, hold the filter (T150) in place, and remove the plug (T015) using a 24 mm

wrench.

2. Remove the filter.
3. Remove and discard the seal (T045) and O-ring (T035).

Service Manual

H1 Pumps 069/078, 089/100, 115/130, 147/165, 210/250

Minor Repair

 

©

 Danfoss | May 2018

520L0848 | AX00000087en-US0308 | 53

Summary of Contents for H1 078

Page 1: ...Service Manual Axial Piston Pumps H1 069 078 089 100 115 130 147 165 210 250 www danfoss com...

Page 2: ...ry 2017 minor edit shaft repair illustration 0306 January 2017 minor edit 0305 September 2016 minor edits 0304 July 2016 minor edits 0303 January 2016 minor edits 0302 July 2015 add 210 250 0300 Septe...

Page 3: ...tem pressure 18 Servo pressure 18 Charge pressure 19 Charge pump inlet pressure 19 Case pressure 19 External shaft seal pressure 19 Temperature and viscosity 20 Technical Specifications Overview 21 Ge...

Page 4: ...ntrol 40 Control Solenoids 42 MDC Control 42 Angle sensor on EDC 45 Removal 45 Installation 46 EDC with angle sensor 46 Removal 46 Installation 47 Automotive Control 48 Bearing and Shaft Replacement 5...

Page 5: ...ehicle or lock the mechanism to inhibit movement Be aware that hydraulic fluid may be under high pressure and or hot Inspect the outside of the pump and fittings for damage Cap hoses after removal to...

Page 6: ...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 ha...

Page 7: ...front end of the pump prevents leakage where the shaft exits the pump housing The spinning cylinder block contains nine reciprocating pistons Each piston has a brass slipper connected at one end by a...

Page 8: ...position of the pump swashplate determines which line is high pressure as well as the direction of fluid flow Case Drain and Heat Exchanger The pump and motor require case drain lines to remove hot fl...

Page 9: ...e To Motor Case Charge Pressure Relief Valve Loop Flushing Valve Charge Pressure Filter Charge Pump Output Shaft Valve Segment Bent Axis Variable Displacement Motor Variable Displacement Pump Case Dra...

Page 10: ...nction of a hydrostatic transmission using an H1 axial variable displacement pump with electric proportional displacement control EDC and an H1 bent axis variable displacement motor with electric prop...

Page 11: ...147 165 210 250 Single Pumps High Pressure Relief Valve HPRV and Charge Check All H1 pumps have a combination high pressure relief and charge check valve The high pressure relief function is a dissip...

Page 12: ...on allows you to move a machine or load without rotating the pump shaft or prime mover C Caution The HPRV valves are not tow valves Damage to the pump and motor can occur when operating without charge...

Page 13: ...spring provide swashplate position force feedback to the solenoid The control system reaches equilibrium when the position of the swashplate spring feedback force exactly balances the input command s...

Page 14: ...the MOR plunger Initial actuation of the function requires additional force to overcome the O ring resistance A threshold force of 45 N is typically required at first actuation Additional actuations t...

Page 15: ...pump displacement between no flow and full flow into opposite directions Under some circumstances such as contamination the control spool could stick and cause the pump to stay at some displacement A...

Page 16: ...Customers can apply their own handle design but they must care about a robust clamping connection between their handle and the control shaft and avoid overload of the shaft Customers can connect two...

Page 17: ...DC Electrical protection class IP67 IP69K with mating connector Case Gauge Port M14 The drain port should be used when the control is mounted on the unit s bottom side to flush residual contamination...

Page 18: ...ssure is the differential pressure between high pressure system ports It is the dominant operating variable affecting hydraulic unit life High system pressure which results from high load reduces expe...

Page 19: ...e the swashplate response time Charge pump inlet pressure At normal operating temperature charge inlet pressure must not fall below rated charge inlet pressure vacuum Minimum charge pump inlet pressur...

Page 20: ...0 F above the pour point of the hydraulic fluid The minimum temperature relates to the physical properties of component materials Size heat exchangers to keep the fluid within these limits Danfoss rec...

Page 21: ...flange SAE flange size C SAE J 744 mounting pad SAE flange size D SAE J 744 mounting pad SAE flange size E ISO 3019 1 flange 177 4 mounting pad Auxiliary mounting SAE A SAE B SAE B B SAE C SAE A SAE...

Page 22: ...t 0 2 24 Maximum bar psi 4 0 58 Case pressure Rated bar psi 3 0 40 Maximum 5 0 75 Fluid Specifications Feature Unit Value Viscosity Minimum mm2 sec SUS 7 49 Recommended Range 12 80 66 370 Maximum 1600...

Page 23: ...anges may be required Change the fluid more frequently if it becomes contaminated with foreign matter dirt water grease etc or if the fluid is subjected to temperature levels greater than the recommen...

Page 24: ...er 50 1000 115 130 147 165 210 250 M4 M5 7 16 20 UNF 2B 3 16 internal hex Servo pressure 50 1000 115 130 147 165 210 250 M6 9 16 18 UNF 2B 1 4 internal hex Charge pressure pre integrated filter 50 100...

Page 25: ...M6 MB MA M3 M5 L3 L1 L2 System Port B M4 S System Port A L4 G302 L2 D065 P106033 Service Manual H1 Pumps 069 078 089 100 115 130 147 165 210 250 Pressure Measurements Danfoss May 2018 520L0848 AX00000...

Page 26: ...ly runs out Ensure reservoir remains full of fluid during start up Air entrapment in oil under high pressure may damage hydraulic components Check carefully for inlet line leaks Do not run at maximum...

Page 27: ...ardous material Avoid contact with hydraulic fluid Always dispose of used hydraulic fluid according to state and federal environmental regulations Electrical Troubleshooting Item Description Action Co...

Page 28: ...er If No go to next step Neutral Neutral set improperly Shunt servo gauge ports M4 and M5 together with external hose and see if pump comes back to neutral If Yes Control neutral improperly set If neu...

Page 29: ...causes noise cavitation Check that inlet line is not restricted and is of proper size Check filter and bypass switch Shaft couplings A loose shaft coupling will cause excessive noise Replace loose sh...

Page 30: ...blem changes direction replace the valve that does not operate correctly Exchange high pressure relief valves Exchanging the high pressure relief valves will show if the problem is related to the valv...

Page 31: ...the charge pressure relief valve 1 Install a 50 bar 1000 psi pressure gauge in charge pressure gauge port M3 Install a 10 bar 100 psi gauge at case drain port L1 L2 L3 or L4 Operate the system with th...

Page 32: ...Install a 50 bar 1000 psi pressure gauge in the charge pressure gauge port M3 Ensure charge pressure is properly set before checking pressure limiter If you change pressure limiter settings you must...

Page 33: ...ench size is in the diagram on the previous page Turn the adjusting screw clockwise to increase the PL setting counterclockwise to decrease it The adjustment is very sensitive Change per turn is appro...

Page 34: ...o open the HPRVs L150 rotate three revolutions counterclockwise Do not rotate more than 3 revolutions leakage will result 2 To close the HPRVs rotate them clockwise until seated See table above for to...

Page 35: ...r establishing the desired maximum displacement setting hold the adjusting screw while torquing the locknut to the value in the table below 4 Test operation of the vehicle machine to verify proper max...

Page 36: ...4 and M5 Disconnect the external control input electrical connections from the control Start the prime mover and operate at normal speed 2 Use a 4mm internal hex wrench to hold the neutral adjusting s...

Page 37: ...with a small movement of the eccentric screw on EDC controls however non feedback controls NFPE FNR FDC lack this mechanism To stroke a pump with non feedback control you must provide a 100 Hz PWM si...

Page 38: ...C1 and C2 to the signal source Ensure the source supplies no current to the solenoids until required in the following procedure The figure below shows the locations of sysem and gage ports you use wh...

Page 39: ...he M5 side in until the system pressure differential starts to decrease Maintain servo pressure differential between 1 2 bar 14 29 psi during this step Continue turning the servo cylinder in until the...

Page 40: ...contamination 3 Look at the hydraulic fluid for signs of system contamination oil discoloration foam in the oil sludge or metal particles Reassembly 1 Before replacing the pump replace all filters and...

Page 41: ...ix cap screws D250 5 Using a 5 mm internal hex wrench torque the cap screws D250 to 13 3 N m 9 8 lbf ft Remove plug on top of control to ensure the swashplate feedback pin is properly positioned in th...

Page 42: ...lectrical connections and test the pump for proper operation MDC Control Removal Refer to exploded diagram below 1 Using a 5 mm internal hex wrench remove the six cap screws D250 2 Remove the control...

Page 43: ...ith neutral start switch MDC with neutral start switch and CCO F00T F00B F00P D692 D693 D750 D065 D250 D81 D80 D750 D065 D250 D81 D80 D250 D065 D750 D751 D751 D084 D098 Service Manual H1 Pumps 069 078...

Page 44: ...d surfaces on the control and top of the pump If you find any nicks or scratches replace the component Reassembly Ensure you install dowel pins D300 in the housing before installing the control 1 Inst...

Page 45: ...mm internal hex wrench torque the cap screws D250 to 13 3 Nm 9 8 lbf ft Angle sensor on EDC Removal 1 Clean the exterior of the pump to remove debris 2 Remove protection cover screws D767 using a 4 mm...

Page 46: ...cover with screws D767 Torque screws to 1 85 N m 1 36 lbf ft W Warning Calibration of sensor output in vehicle software is mandidtory after sensor replacement because output signal can vary from one s...

Page 47: ...itioning the control on the pump housing ensure assembly fixture is positioned over the linkage spring in EDC center as shown on the right 3 Position control on pump housing Ensure that feedback pin o...

Page 48: ...rews to 13 5 N m 10 lbf ft following torque sequence shown 1 2 3 6 5 4 Torque sequence 6 screw control D065 W Warning Calibration of sensor output in vehicle software is mandidtory after sensor replac...

Page 49: ...se a 3 mm internal hex to remove orifices F00A F00B from housing Tag each orifice for reinstallation Each orifice may be a different size 7 If it is necessary to remove the screens drill out screen re...

Page 50: ...on ring is installed W Warning Failure to install screen will result in erratic pump operation Proper Screen Orientation P106 618E D084 D084 Incorrect screen orientation Correct screen orientation D09...

Page 51: ...ool to install new plastic plugs with O rings D610 Press plugs in and turn 45 degrees clockwise If control will continue to be under warranty install new sealing wax of a different color original wax...

Page 52: ...fter you remove the shaft take care not to move or jar the pump Reassembly can be difficult if the internal components move while the shaft is out 5 Remove snap ring J300 Press bearing J150 from shaft...

Page 53: ...2 70 in 50 80 44 7 mm 1 76 in 89 4 mm 3 52 in 7 mm 0 276 in 78 mm 3 07 in 75 6 mm 2 97 in 210 250 4 4 mm 0 17 in 80 57 5 mm 2 26 in 89 4 mm 3 52 in External Filter Replacement Removal 1 With the prim...

Page 54: ...on and check for leaks External Filter Replacement T015 24mm P106 035E T150 T035 T045 Filter Bypass Valve and Filter Bypass Switch Removal 1 Remove three screws T250 using a 6mm internal hex wrench 2...

Page 55: ...0 T300 T020 T030 T040 16 20 N m 12 15 lbf ft T025 6 mm T040 16 20 N m 12 15 lbf ft T010 T250 T350 6mm 32 N m 24 lbf ft Charge Pump If the pump has an auxiliary pump attached remove the auxiliary pump...

Page 56: ...p and O ring K250 Discard O ring 2 Remove charge pump cover screws K450 and charge pump cover K550 3 Remove thrust washer K500 Note its orientation Coated side is towards charge pump coupling K200 4 R...

Page 57: ...signs of wear scratching or pitting replace it Reassemby 1 Install new seals S300 in the valve S250 and pressure balance S200 plates 2 Install valve plate S250 in the same orientation as removed 3 Lub...

Page 58: ...4 5 6 7 8 Cover K550 Torque Sequence 1 2 3 5 4 6 P106 659E High Pressure Relief Valves HPRV Removal Using a hex wrench wrench shown in the table below remove the HPRVs L150 Remove and discard the O r...

Page 59: ...ete unit Do not attempt to repair the internal components of the valve Torque to 52 N m 38 lbf ft See Charge Pressure Relief Valve djustment page 31 for adjustment instructions Removal Using a 22 mm w...

Page 60: ...g a 22 mm wrench remove the pressure limiter valve L100 Discard O ring Inspection Inspect the sealing surfaces of the pump for nicks or scratches Reassemby 1 Install new O ring Lubricate O ring with p...

Page 61: ...rque Values Displacement Wrench size and torque 069 078 089 100 115 130 147 165 22 mm 70 N m 52 lbf ft 210 250 24 mm 70 N m 52 lbf ft Service Manual H1 Pumps 069 078 089 100 115 130 147 165 210 250 Mi...

Page 62: ...ternal hex 25 N m 18 5 lbf ft L010 Pressure limiter adjust screw 8 mm NA L012 Pressure limiter cartridge 17 mm 40 N m 22 lbf ft L024 Pressure limiter locking nut 14 mm 20 N m 15 lbf ft L150 High press...

Page 63: ...4 internal hex 40 N m 29 5 lbf ft G300 9 16 18 3 16 internal hex 40 N m 29 5 lbf ft G302 5 16 24 UNF 1 8 internal hex 5 N m 4 lbf ft Fasteners and Plugs P106 066E T015 Filter mounting bolt K400 Rear c...

Page 64: ...Neutral adjusting screw D060 Neutral adjust locking nut D050 Coil mounting bolt B015 O ring plug 7 16 20 G302 O ring plug 5 16 24 UNF G300 O ring plug 9 16 18 B035 O ring plug see table G250 O ring pl...

Page 65: ...Service Manual H1 Pumps 069 078 089 100 115 130 147 165 210 250 Danfoss May 2018 520L0848 AX00000087en US0308 65...

Page 66: ...Service Manual H1 Pumps 069 078 089 100 115 130 147 165 210 250 66 Danfoss May 2018 520L0848 AX00000087en US0308...

Page 67: ...Service Manual H1 Pumps 069 078 089 100 115 130 147 165 210 250 Danfoss May 2018 520L0848 AX00000087en US0308 67...

Page 68: ...olutions ApS Nordborgvej 81 DK 6430 Nordborg 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 Trading...

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