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Danfoss H1P Series, Service Manual

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Danfoss H1P Series Service Manual Download Page 48

W

Warning

Calibration of sensor output in vehicle software is mandatory after sensor replacement because output
signal can vary from one sensor to the other.

EDC with Angle Sensor Repair

D250

D150

Feedback link

Dowel pins (D300) must remain in the housing.

1. Clean pump externally with clean solvent to remove debris.
2. Using a 5 mm internal hex wrench, remove the six cap screws (D250)
3. Remove the control module and gasket (D150) and discard the gasket.
4. Install a new gasket (D150).
5. Ensure assembly fixture is positioned over the linkage spring in EDC center.
6. Position the control on the pump housing and ensure that feedback pin on swashplate is positioned

properly in control arm.

Service Manual

H1P 069—H1P 250 Axial Piston Single Pumps

Minor Repair

 

48 | 

©

 Danfoss | September 2020

AX152886482551en-000504

Summary of Contents for H1P Series

Page 1: ...Service Manual H1P 069 H1P 250 Axial Piston Single Pumps www danfoss com...

Page 2: ...removed pressure limiter screens 0504 January 2020 Corrected the A B port size for 115 130 frame 0402 December 2018 Major clean up revision 0401 July 2008 May 2018 Various changes 0201 0308 September...

Page 3: ...Port M14 18 Operating Parameters Input Speed 19 System Pressure 19 Servo Pressure 20 Charge Pressure 20 Charge Pump Inlet Pressure 20 Case Pressure 20 External Shaft Seal Pressure 21 Temperature 21 Vi...

Page 4: ...pass Function 37 Displacement Limiter Adjustment for Single Pumps 37 Control Neutral Adjustment 38 Mechanical Neutral Adjustment 40 Unintended Machine Movement 40 Minor Repair Angle sensor on EDC Repa...

Page 5: ...neral procedures when repairing this product Icon Description Instructions Remove the unit If necessary remove the unit from the vehicle machine Chock the wheels on the vehicle or lock the mechanism t...

Page 6: ...onents and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and installing system lines Fluid Under Pressure Escaping hydraulic fluid under pressure can hav...

Page 7: ...l and explains its purpose General description of H1 family hydrostatic pumps The H1 family of closed circuit variable displacement axial piston pumps is designed for use with all existing Danfoss hyd...

Page 8: ...all joint The block spring ball guide and slipper retainer hold the slippers to the swashplate The reciprocating movement of the pistons occurs as the slippers slide against the inclined swashplate du...

Page 9: ...on 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 fluid fr...

Page 10: ...nt Motor System Pressure Servo Pressure Charge Low Loop Pressure Suction Case Drain System Return Charge Filter Charge Pump Reservoir Heat Exchanger Bypass Valve Displacement Control Heat Exchanger Ch...

Page 11: ...ement pump with electric proportional displacement control EDC and an H1 bent axis variable displacement motor with electric proportional control L and integrated loop flushing device Service Manual H...

Page 12: ...direction necessary to regulate the system pressure including into stroke overrunning or over center winch payout The pressure limiter is optional on H1 pumps except H1T 045 053 tandem pumps Pressure...

Page 13: ...ure at a designated level above case pressure This level is nominally set with the pump running at 1800 min 1 rpm and with a fluid viscosity of 32 mm s 150 SUS In forward or reverse charge pressure wi...

Page 14: ...nes which line is high pressure as well as the direction of fluid flow Electrical Displacement Control EDC An EDC is a displacement flow control Pump swash plate position is proportional to the input...

Page 15: ...perating loop change with load the control assembly and servo swashplate system work constantly to maintain the commanded position of the swashplate The EDC incorporates a positive neutral deadband as...

Page 16: ...ground The vehicle or device must always be in a safe condition when using the MOR function Refer to control flow table for the relationship of solenoid to direction of flow Manual Displacement Contro...

Page 17: ...s is required to take the backlash out of the mechanical connections between the Bowden cable and the control C Caution High case pressure may cause excessive wear and the NSS to indicate that the con...

Page 18: ...rovides a signal of whether the control is in neutral The signal in neutral is Normally Closed NC Neutral Start Switch schematic P005 702 M14 M5 M4 M3 Neutral Start Switch data Max continuous current...

Page 19: ...m pressure 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...

Page 20: ...e angle and may be higher than the minimum charge pressure shown in the Operating parameters tables Maximum charge pressure is the highest charge pressure allowed by the charge relief adjustment and w...

Page 21: ...perature is based on material properties and should never be exceeded Cold oil will generally not affect the durability of the transmission components but it may affect the ability of oil to flow and...

Page 22: ...ating Parameters Please verify mating pump shaft seal capability H1P 069 250 Physical Properties Frame size 069 078 089 100 115 130 147 165 210 250 Oil volume 2 0 l 0 5 US gal 3 0 l 0 8 US gal 7 2 l 1...

Page 23: ...xceeding 2 of duty cycle based load life Temperature Minimum 1 40 C 40 F Rated 104 C 220 F Recommended range2 60 85 C 140 185 F Maximum Intermittent 115 C 240 F 1 Cold start Short term t 3 min p 50 ba...

Page 24: ...luids and Lubricants BC0000093 Filtration System To prevent premature wear ensure only clean fluid enters the hydrostatic transmission circuit A filter capable of controlling the fluid cleanliness to...

Page 25: ...of particles greater than a given diameter x in microns upstream of the filter to the number of these particles downstream of the filter Filtration cleanliness level and x ratio recommended minimum C...

Page 26: ...protect gauges The drawing and following table show the port locations and gauge sizes needed Port locations M6 MB MA M3 M5 L3 L1 L2 System Port B M4 S System Port A L4 G302 L2 D065 P106033 H1P Ports...

Page 27: ...165 210 250 L1 L3 Wrench 7 8 14 UNF 2B 3 8 internal hex 1 1 16 12 UNF 2B 9 16 internal hex 1 1 16 12 UNF 2B 9 16 internal hex 1 1 16 12 UNF 2B 9 16 internal hex L2 L4 Wrench 1 1 16 12 UNF 2B 9 16 inte...

Page 28: ...ype and viscosity fill inlet line from reservoir to pump Use a 10 micron filler filter 6 Disconnect the pump from all control input signals Do not disconnect a FDC control from control input signals D...

Page 29: ...l operating speed and carefully check for forward and reverse control operation 18 Continue to cycle between forward and reverse for at least five minutes to bleed all air and flush system contaminant...

Page 30: ...oid prolonged contact with hydraulic fluid Always dispose of used hydraulic fluid according to state and federal environmental regulations Electrical Troubleshooting Electrical troubleshooting Item De...

Page 31: ...ectly Servo pressure low or decaying Damaged servo seals may prevent servo piston from stroking the pump Check for torn missing servo seals Replace and retest Only a Danfoss Authorized Service Center...

Page 32: ...place the charge pump System pressure Low system pressure does not provide enough power to move load Measure system pressure Continue to next step High pressure relief or pressure limiter valves Defec...

Page 33: ...om system Contaminated control orifices Control orifices are plugged Clean control orifices Contaminated control screens EDC supply screen is plugged Replace control screens Only a Danfoss Authorized...

Page 34: ...and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and installing system lines Charge Pressure Relief Valve Adjustments Operate the system with the pump i...

Page 35: ...orts when the desired charge pressure setting is achieved Pressure Limiter Adjustment W Warning Pumps with only HPRV valves no longer contain pressure limiter screens and retainers To convert such pum...

Page 36: ...te at normal speed 4 Use a 14 mm wrench for H1P 69 100 or a 17 mm wrench for H1P 115 250 to loosen the locking nut L024 5 Activate the control input until pressure in the high side of the system loop...

Page 37: ...able for torque values HPRV Wrench Size and Torque Value Frame size Wrench size Torque 045 100 22 mm 70 N m 52 lbf ft 115 250 30 mm 110 N m 81 lbf ft If machine is towable with HPRVs opened three turn...

Page 38: ...djusting screw while torquing the locknut to the value in the table below Displacement Limiter Adjustment Data Frame 069 078 089 100 115 130 147 165 210 250 Locknut wrench size torque 13 mm 24 N m 18...

Page 39: ...the neutral adjusting screw D015 stationary while loosening the locknut D060 with a 13 mm wrench 5 Observe pressure gauges and if necessary turn adjusting screw D015 to reduce pressure differential A...

Page 40: ...u must provide a 100 Hz PWM signal to the control solenoids If you perform this adjustment with the pump installed in a vehicle or machine safely elevate the wheels or disconnect the mechanism to allo...

Page 41: ...tach a 600 bar 10 000 psi gauge to each system pressure port MA and MB 3 Remove servo cylinder locking screws E350 and plates E300 from both sides of the pump 4 Disconnect the control solenoids from t...

Page 42: ...on the M5 side in until the system pressure differential starts to decrease Continue turning the servo cylinder in until the system delta pressure results in no machine movement System delta pressure...

Page 43: ...ation 6 Look at the hydraulic fluid for signs of system contamination oil discoloration foam in the oil sludge or metal particles 7 Before replacing the pump replace all filters and drain the hydrauli...

Page 44: ...nter of the control module when installing control Proper screen orientation P106 618E D084 D084 Incorrect screen orientation Correct screen orientation 3 If previously removed install orifices using...

Page 45: ...t the machined surfaces on the control and top of the pump If you find any nicks or scratches replace the component 4 Lubricate new O ring D025A using petroleum jelly and install 5 Install solenoid wi...

Page 46: ...ever for reassembly The functionality of the MDC control and the neutral position of the pump can be lost Do not disassemble the MDC control MDC Repair Legend Wrench size and Torque D084 Screen D80 So...

Page 47: ...rench 3 Remove the protection cover from the control 4 Discard the protection cover if it is damaged 5 Remove sensor screws D770 using a 4 mm internal hex wrench 6 Remove and discard the sensor 7 Posi...

Page 48: ...remove debris 2 Using a 5 mm internal hex wrench remove the six cap screws D250 3 Remove the control module and gasket D150 and discard the gasket 4 Install a new gasket D150 5 Ensure assembly fixtur...

Page 49: ...wing torque sequence shown 1 2 3 6 5 4 Torque sequence 6 screw control D065 For proper neutral adjustment procedure refer to Control Neutral Adjustment on page 38 topic W Warning Calibration of sensor...

Page 50: ...1 7 mm x3 9 22 mm 45 deg 14 mm 3 Push down on plug and turn 45 degrees counterclockwise 4 Discard plugs Wax seals will be destroyed when the plugs are removed C Caution Do not damage the housing in th...

Page 51: ...control and top of the pump If you find any nicks or scratches replace the component If pump has been rebuilt or a new control is being installed control software must be recalibrated Refer to H1 Auto...

Page 52: ...aft to dislodge it from the cylinder block C Caution Do not damage the housing bore shaft or bearing when removing the shaft and bearing 3 For 069 078 115 130 147 165 Puncture the seal J250 and use a...

Page 53: ...inner snap ring J200 8 Cover end of the shaft with an installation sleeve to protect the seal during installation 9 Lubricate the seal Tap on the seal replacing tool or an appropriate deep socket to p...

Page 54: ...nents 6 Install new seal T045 and O ring T035 on plug 7 Apply hydraulic fluid to the O ring and seal for lubrication 8 Insert the plug into the bracket 9 Use a 24 mm wrench to hold the plug in place a...

Page 55: ...spect spring T030 for cracks or warpage and replace if necessary 9 Inspect sealing surface of filter adapter T010 for scratches or damage resurface or replace scratched or damaged part 10 Lubricate an...

Page 56: ...p coupling K200 6 Remove pressure balance plate S200 with seal S300 Discard seal S300 Note orientation of valve plate and seal 7 Remove charge pump coupling K200 8 Remove charge pump gear set S100 and...

Page 57: ...e valve plate S250 with seal S300 Discard seal S300 Note the orientation of valve plate and seal 8 Inspect carefully the valve and pressure balance plates for wear scratches or pits Scratches on these...

Page 58: ...7 8 Cover K550 Torque Sequence 1 2 3 5 4 6 P106 659E 11 Ensure proper torque on aux pad screws K400 and if necessary replace screws If charge pump replacement is necessary replace complete charge pum...

Page 59: ...urfaces of the pump for nicks or scratches 4 Lubricate and install the new seal V024 5 Install the charge pressure relief valve and torque to 52 N m 38 lbf ft 6 Operate vehicle machine through full ra...

Page 60: ...g O ring is available separately 4 Lubricate O ring with petroleum jelly 5 Replace pressure limiter valve and torque to 70 N m 52 lbf ft 6 Operate pump at full range of controls to ensure proper machi...

Page 61: ...ng bolt V020 Charge pressure adjusting screw V022 Charge pressure locking nut V010 Charge pressure cartridge L150 High pressure relief valve L150 High pressure relief valve Service Manual H1P 069 H1P...

Page 62: ...ue D015 Neutral adjust screw 4 mm internal hex NA D050 Coil mounting bolt 4 mm internal hex 8 N m 6 lbf ft D060 Neutral adjust locking nut 13 mm 10 N m 7 lbf ft D200 Swash plate feedback pin not shown...

Page 63: ...h size Torque B015 7 16 20 3 16 mm internal hex 12 N m 9 lbf ft B035 069 078 1 1 16 12 9 16 internal hex 70 N m 52 lbf ft B035 147 165 1 5 16 12 5 8 internal hex 150 N m 110 lbf ft D065 7 16 20 3 16 i...

Page 64: ...foss Power Solutions US Company 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 Danfoss Power Solutions Trading Shanghai Co Ltd Building 22 No 1000 Jin Hai Rd Jin Qiao Pudong New District...

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