Danfoss H1T 045 User Manual Download

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Service Manual

H1T 045/053, 060/068

Axial Piston Tandem Pumps

www.danfoss.com

Summary of Contents for H1T 045

Page 1: ...Service Manual H1T 045 053 060 068 Axial Piston Tandem Pumps www danfoss com...

Page 2: ...about PL screens 0405 November 2018 Major layout update 0401 June 2018 Angle sensor topics added 0303 August 2017 Minor update 0302 May 2017 Added frames H1T 060 068 0301 Oct 2007 March 2015 Various...

Page 3: ...9 MDC Torque 20 Neutral Start Switch NSS 20 Case Gauge Port M14 20 Control Cut Off CCO and Brake Release Valves 20 Operating Parameters Input Speed 23 Independent Braking System 23 System Pressure 23...

Page 4: ...l Adjustment 52 Pump setup 52 Servo Adjustment for Tandem Pumps 53 Minor repair Standard Procedures at Removing Pump 56 EDC Control Repair 56 EDC Control Installation 57 Control Solenoids Repair 58 MD...

Page 5: ...ral 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 to...

Page 6: ...ss when removing and installing system lines Fluid Under Pressure Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection This...

Page 7: ...l hex head Press in press fit Internal hex head Pull out with tool press fit Torx head Cover splines with installation sleeve O ring boss port Pressure measurement gauge location or specification The...

Page 8: ...ase Drain and Heat Exchanger The pump and motor require case drain lines to remove hot fluid from the system The pump and motor drain from the topmost port to ensure the cases remain full of fluid The...

Page 9: ...t of fluid is allowed to flow from the cylinder block valve plate and slipper swashplate interfaces for lubrication and cooling Case drain ports return this fluid to the reservoir An external charge p...

Page 10: ...Cutoff Valve System Pressure Servo Pressure Low Loop Pressure Suction Case Drain System Return Charge Pressure Cylinder block assembl y Motor swashplat e Output shaft Motor servo piston P106147 Loop F...

Page 11: ...MA MD D B MB MC C M5 M4 H1 Tandem E M3 ccw flow out B flow out D C1 C2 M14 C1 C2 M14 1 2 Supply Ground CONTROL SOLENOID C1 Ground Supply 1 2 Supply Ground Ground Supply CONTROL SOLENOID C2 1 2 Supply...

Page 12: ...ment tandem pumps with electric displacement control EDC System schematic tandem pumps C1 C1 C2 C2 M14 M14 CW F00B F00A F00B F00A A B MA E C D MD MB M3 L3 MC M4 M5 M4 M5 PTO X7 P003 207E Service Manua...

Page 13: ...he high and low loops When the pressure limiter setting is reached the valve ports oil to the low pressure side of the servo piston The change in servo differential pressure rapidly reduces pump displ...

Page 14: ...e HPRV valve is always factory set above the setting of the pressure limiter The system pressure shown in the order code for pumps with only HPRV is the HPRV setting The system pressure shown in the o...

Page 15: ...f working loop 2 Charge check and HPRV 1 High pressure side of working loop 2 Charge check and HPRV Service Manual H1T 045 053 060 068 Axial Piston Tandem Pumps Operation Danfoss September 2020 AX1528...

Page 16: ...165 Single 210 250 30 l min 7 9 US gal min 15 l min 3 9 US gal min 22 7 l min 6 0 US gal min 40 0 l min 10 6 US gal min Charge pressure relief valve Electrical Displacement Control EDC An EDC is a dis...

Page 17: ...rating 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 a...

Page 18: ...ound 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 Control...

Page 19: ...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 contr...

Page 20: ...n 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 out of the control Cont...

Page 21: ...case 045 053 Tandem P106 148E M4 M5 M5 M4 M3 L3 MB MC MA MD C D B A E X7 C1 C2 C1 C2 CW CW Flow out C Flow out A 060 068 Tandem M5 M4 A MA MD D B MB MC C M5 M4 H1 Tandem E M3 ccw flow out B flow out D...

Page 22: ...ontinuous 16 VDC 32 VDC IP Rating IEC 60 529 IP 67 DIN 40 050 part 9 IP 69K with mating connector Pin connector any order For additional information please contact Danfoss 1 2 Service Manual H1T 045 0...

Page 23: ...ng capacity Machine manufacturer is responsible to provide a braking system redundant to the hydrostatic transmission sufficient to stop and hold the vehicle or machine in the event of hydrostatic dri...

Page 24: ...life expectancy analysis Minimum low loop pressure must be maintained under all operating conditions to avoid cavitation All pressure limits are differential pressures referenced to low loop charge pr...

Page 25: ...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 whi...

Page 26: ...rature 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 tr...

Page 27: ...avity pressure Auxiliary cavity pressure will be inlet pressure with internal charge pump or case pressure with external charge supply For reference see Operating Parameters Please verify mating pump...

Page 28: ...3500 min 1 rpm Maximum 3500 min 1 rpm 4000 min 1 rpm 1 Full performance pressure and displacement possible at minimum charge and control pressure supply System pressure Description Size 045 Size 053...

Page 29: ...eeding 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 bar...

Page 30: ...erval Sealed 2000 hours Breather 500 hours High temperatures and pressures will result in accelerated fluid aging More frequent fluid changes may be required Change the fluid more frequently if it bec...

Page 31: ...6 18 UNF 1 4 internal hex System pressure 600 bar 10 000 psi M3 9 16 18 UNF 2B 1 4 internal hex Charge pressure 50 bar 1000 psi M4 M5 7 16 20 UNF 2B 3 16 internal hex Servo pressure 50 bar 1000 psi AM...

Page 32: ...3 AM3 9 16 18 UNF 2B 1 4 internal hex Charge pressure 50 bar 1000 psi M4 M5 7 16 20 UNF 2B 3 16 internal hex Servo pressure 50 bar 1000 psi M14 7 16 20 3 16 internal hex Case gauge port 10 bar 100 psi...

Page 33: ...e in case of sufficient servo pressures During start up provide a signal to keep the pump in neutral 7 Close construction plug removed in the step 4 C Caution After start up the fluid level in the res...

Page 34: ...least five minutes to bleed all air and flush system contaminants out of the system loop Normal charge pressure fluctuation may occur during forward and reverse operation 19 Check that the reservoir...

Page 35: ...ystem must also be sufficient to hold the machine in place when full power is applied Manufacturer s Warranty Contamination can damage internal components and void the manufacturer s warranty Take pre...

Page 36: ...r filter is replaced Filter bypass indicator switch Filter bypass indicator switch is indicating wrong bypass situation Check replace filter switch Open resistance 510 Closed resistance 122 Neutral Di...

Page 37: ...overworked Verify settings of pressure limiters and high pressure relief valves and adjust or replace valves as necessary System pressure Frequent or long term operation over system relief setting wil...

Page 38: ...aft coupling will cause excessive noise Replace loose shaft coupling Shaft alignment Misaligned shafts create noise Align shafts Charge system relief valves Unusual noise may indicate sticking valves...

Page 39: ...if removing the pump 4 When you disconnect hydraulic lines cap them and plug each open port to prevent contamination 5 Inspect the system for contamination 6 Check the hydraulic fluid for signs of co...

Page 40: ...This procedure explains how to check and adjust the charge pressure relief valve Charge pressure adjustment L2 P109550 M3 045 053 060 068 1 2 M3 L2 1 2 Lock nut wrench size 19 mm torque 40 N m 29 5 lb...

Page 41: ...1 5 bar 319 21 8 psi 24 1 5 bar 348 21 8 psi 26 1 5 bar 377 21 8 psi 28 1 5 bar 406 21 8 psi 30 1 5 bar 435 21 8 psi 32 1 5 bar 464 21 8 psi 34 1 5 bar 493 21 8 psi 36 1 5 bar 522 21 8 psi Listed pre...

Page 42: ...ns to ensure proper pump operation The charge check HPRVs are preset at the factory no adjustment is possible Checking for proper charge check HPRV operation If you suspect charge check HPRV malfuncti...

Page 43: ...rigidly fix the work function so it cannot rotate Ensure charge pressure is properly set before checking pressure limiter Pressure limiter adjustment P109551 060 068 M3 L2 1 2 3 3 4x 4x 2x 2x AM3 MB M...

Page 44: ...port M3 Ensure charge pressure is properly set before checking pressure limiter 3 Start the prime mover and operate at normal speed 4 Use a 17 mm wrench to loosen the locking nut L024 5 Activate the...

Page 45: ...024 to 12 N m 9 lbf ft C Caution Do not over torque 10 Shut down the prime mover 11 Remove gauges and replace plugs Service Manual H1T 045 053 060 068 Axial Piston Tandem Pumps Adjustments Danfoss Sep...

Page 46: ...ns to ensure proper pump operation The charge check HPRVs are preset at the factory no adjustment is possible Checking for proper charge check HPRV operation If you suspect charge check HPRV malfuncti...

Page 47: ...tate three revolutions counterclockwise using a hex wrench C Caution Do not rotate more than 3 revolutions leakage will result 2 Rotate them clockwise until seated to close the HPRVs See the following...

Page 48: ...of the adjustment screw while not limiting the maximum displacement of the pump A small amount of clockwise screw adjustment is required before the 100 displacement condition is reached C Caution Bef...

Page 49: ...splacement setting hold adjusting screw in place and tighten the locknut Refer to the table for change per turn Clockwise rotation decreases displacement counterclockwise rotation increases it Adjustm...

Page 50: ...nnect the external control input electrical connections from the control 3 Start the prime mover and operate at normal speed 4 Use a 4 mm internal hex wrench to hold the neutral adjusting screw D015 s...

Page 51: ...d read the same pressure indicating that the control is in its neutral position 9 Hold the neutral adjusting screw stationary and tighten the locknut D060 Torque to 10 N m 9 lbf ft 12 N m 9 lbf ft C C...

Page 52: ...f each other The control solenoids C1 and C2 are marked on each control While performing this adjustment you monitor the following pressures Servo pressure at M4 and M5 System pressure at MA and MB or...

Page 53: ...Cutoff CCO 1 MB MC X7 AM3 MC MB AM3 Legend Ports per ISO 11926 1 A B C D System port 1 5 16 12 MA MB MC MD System gauge port 9 16 18 M3 AM3 Charge port 9 16 18 M4 M5 Servo gauge port 7 16 20 X7 Brake...

Page 54: ...d M5 is less than 2 5 bar 36 psi 4 Using a 3 4 in deep socket unthread both servo cylinders 2 3 turns This step ensures the servo cylinders have no contact with the servo piston 5 Stroke the pump by t...

Page 55: ...e opposite direction by turning the eccentric screw in the opposite direction or by supplying current to solenoid C2 to complete setting neutral Reverse gauge locations M4 for M5 MB for MA etc from th...

Page 56: ...ion 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 hydraulic...

Page 57: ...lling control 1 Install a new gasket D150 2 If you removed screen D084 install a new one with the mesh facing outward Remove plug on top of control to ensure the swashplate feedback pin is properly po...

Page 58: ...If you find any nicks or scratches replace the component 4 Lubricate new O ring D025A using petroleum jelly and install 5 Install solenoid with three cap screws D050 using a 4 mm internal hex wrench...

Page 59: ...g a 5 mm internal hex wrench remove the six cap screws D250 2 Remove the control module and gasket D150 and discard the gasket 3 If necessary remove servo orifices F00A F00B supply orifice F00P and ta...

Page 60: ...orientation D084 D084 Incorrect screen orientation Correct screen orientation D098 Remove plug on top of control to ensure the swashplate feedback pin is properly positioned in the center of the cont...

Page 61: ...using 8 Using a 4 mm internal hex wrench fasten sensor to control housing with screws D770 Torque screws to 1 85 N m 1 36 lbf ft 9 Position protection cover on control housing over sensor 10 Using a 4...

Page 62: ...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...

Page 63: ...x wrench fasten control to pump with screws D250 10 Torque screws to 13 3 N m 9 8 lbf ft following torque sequence shown 1 2 3 6 5 4 Torque sequence 6 screw control D065 For proper neutral adjustment...

Page 64: ...O ring J260 5 Press the seal J250 out of the carrier and discard 6 Pull the shaft J100 with bearing J150 out of the pump If necessary tap lightly on the shaft to dislodge it from the cylinder block C...

Page 65: ...the seal carrier Press the seal until it is flush within 0 12 mm 0 005 in or 0 72 mm 0 003 in of the inside lip of the carrier Positioning seal in seal carrier P106 498E Seal Press flush to this surf...

Page 66: ...2 S300 K205 K101 K400 x4 K250 K301 K351 K975 K351 K975 A flange B flange S200 Wrench size and torque Item K350 K351 A flange K351 B flange K400 Wrench size 10 mm internal hex 8 mm internal hex 18 mm 1...

Page 67: ...Replacing the journal bearings P107 999E Geroter cover Journal bearing 1 72 mm 0 3 0 07 inch 0 011 Charge Pump Installation 1 Lubricate and install new seal K150 2 Install housing K300 Install screws...

Page 68: ...03 assemblies from the center section using a magnet 3 Inspect the valves and mating seats in the valve seat plugs K007 for damage or foreign material 4 Lubricate and install new O rings K008 K010 and...

Page 69: ...nd the ports controlled by those valves HPRV port relationship HPRV valve Controls port B HPRV valve Controls port A HPRV valve Controls port D HPRV valve Controls port C Service Manual H1T 045 053 06...

Page 70: ...and replacement of the O rings These valves are factory set and are not field adjustable Refer to the pump model code for the factory setting when ordering replacements QL301 P109251 L101 L060 L068 L2...

Page 71: ...scratches Check the valves for damage Replace any damaged components 5 Lubricate and install new backup rings L068 and O rings L060 6 Install HPRV and pressure limiter valves in their original locatio...

Page 72: ...ze 1 inch torque to 52 N m 38 lbf ft 1 Using a 27 mm V10 1 or a 1 in V10 2 wrench remove the charge pressure relief valve 2 Discard the O rings V10A 3 Inspect the sealing surfaces of the pump and char...

Page 73: ...t Do not attempt to repair the internal components of the valve Control cutoff valve 045 053 E101 401E G10 G20 G30 G10A 9 N m 7 lbf ft 46 N m 34 lbf ft 1 1 16 in 24 mm Service Manual H1T 045 053 060 0...

Page 74: ...the sealing surfaces of the pump and control valve for nicks or scratches 7 Replace components as necessary 8 Lubricate and install new O rings G10A onto the valve 9 Install the control valve G10 Tor...

Page 75: ...250 D065 D050 V10 E350 K007 G350 K350 G250 B015 G250 D060 D015 B020 P109564 G350 K350 A Pad B Pad Service Manual H1T 045 053 060 068 Axial Piston Tandem Pumps Torque Chart Danfoss September 2020 AX152...

Page 76: ...ntrol cut off valve 1 1 16 in hex 45 N m 33 lbf ft G10B Control cut off valve coil nut 24 mm hex 10 N m 7 5 lbf ft K007 Charge check HPRV 8 mm internal hex 80 N m 60 lbf ft K350 A pad cover mounting s...

Page 77: ...ize Torque B015 7 16 20 3 16 internal hex 20 N m 15 lbf ft B020 45 53 1 1 16 12 9 16 internal hex 48 N m 35 lbf ft B020 60 68 1 3 8 12 5 8 internal hex 148 N m 109 lbf ft D065 7 16 20 3 16 internal he...

Page 78: ...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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