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General

Follow this procedure when starting-up a new pump or when restarting a pump that has been removed.
Ensure the pump is thoroughly tested on a test stand before installing.

Warning

Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.

To protect against unintended movement, secure the machine or disable/disconnect the mechanism

while servicing.

Start-up procedure

Prior to installing the pump, inspect for damage that may have occurred during shipping.

1. Ensure that the machine hydraulic oil and system components (reservoir, hoses, valves, fittings, and

heat exchanger) are clean and free of any foreign material.

2. Install new system filter element(s) if necessary. Check that inlet line fittings are properly tightened

and free of air leaks.

3. Install the pump. Install a 50 bar [1000 psi] gauge in the charge pressure gauge port M
4. Fill the housing by adding filtered hydraulic fluid to the upper case drain port. If the controls are

installed on top, open the construction plugs in the top of the controls to assist in air bleed.

5. Fill the reservoir with hydraulic fluid of the recommended type and viscosity. Use a 10-micron filler

filter. Ensure construction plug is closed after filling is complete.

6. Disconnect the pump from all control input signals.

Caution

After start-up the fluid level in the reservoir may drop due to system components filling Damage to

hydraulic components may occur if the fluid supply 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 pressure until system is free of air and fluid has been thoroughly filtered.

7. Use a common method to disable the engine to prevent it from starting. Crank the starter for several

seconds. Do not to exceed the engine manufacturer's recommendation. Wait 30 seconds and then

crank the engine a second time as stated above. This operation helps remove air from the system

lines. Refill the reservoir to recommended full oil level.

8. When the gauge begins to register charge pressure, enable and start engine. Let the engine run for a

minimum of 30 seconds at low idle to allow the air to work itself out of the system. Check for leaks at

all line connections and listen for cavitation. Check for proper fluid level in reservoir.

9. When adequate charge pressure is established (as shown in model code), increase engine speed to

normal operating rpm to further purge residual air from the system.

10. Shut the off engine. Connect the pump control signal. Start the engine, checking to be certain the

pump remains in neutral. Run the engine at normal operating speed and carefully check for forward

and reverse control operation.

11. Continue to cycle between forward and reverse for at 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.

12. Check that the reservoir is full. Remove charge pressure gauge and cap port. The pump is now ready

for operation.

Service Manual

H1 45/53/60/68 Tandem Closed Circuit Axial Piston Pumps

Initial startup procedures

28 |

Danfoss | June 2018

520L0928 | AX00000103en-US0303

Содержание H1 Series

Страница 1: ...Service Manual Closed Circuit Axial Piston Pumps H1 45 53 60 68 Tandem www danfoss com...

Страница 2: ...2010 new back page AJ March 2010 add Control Cutoff CCO AI March 2010 Fix Osaka address AH May 2009 add charge pump AG November 2008 correction to running cover bolt torque AF September 2008 correcti...

Страница 3: ...ge inlet pressure 21 Case pressure 21 Temperature and viscosity 21 Temperature 21 Viscosity 21 Technical Specifications H1T general specifications 22 Technical data H1 Tandem 22 Operating parameters H...

Страница 4: ...ctric control module 47 Control solenoids 49 MDC Control 49 MDC illustration tandems 50 MDC Legend tandems 50 Angle sensor on EDC 52 Removal 52 Installation 52 EDC with angle sensor 53 Removal 53 Inst...

Страница 5: ...hese general procedures when repairing this product Remove the unit If necessary remove the unit from the vehicle machine Chock the wheels on the vehicle or lock the mechanism to inhibit movement Be a...

Страница 6: ...aling with hydraulic fluid under pressure Relieve pressure in the system before removing hoses fittings gauges or components Never use your hand or any other body part to check for leaks in a pressuri...

Страница 7: ...ected at one end by a ball 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...

Страница 8: ...shplate feedback pin Piston Slipper Shaft seal Swashplat e Cylinder block Swashplate bearing Swashplate bearing Front shaft bearing Center shaft bearings Rear shaft bearing Pump schematic 045 053 Tand...

Страница 9: ...of the pump to the main ports of the motor Fluid flows in either direction from the pump to the motor and back Either of the hydraulic lines can be under high pressure In pumping mode the position of...

Страница 10: ...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 Flushing...

Страница 11: ...ter valve High Pressure To Servo 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 dis...

Страница 12: ...ated level above case pressure The charge pressure relief valve is a direct acting poppet valve that opens and discharges fluid to the pump case when pressure exceeds a designated level This level is...

Страница 13: ...the input command solenoid force from the operator As hydraulic pressures in the operating loop change with load the control assembly and servo swashplate system work constantly to maintain the comma...

Страница 14: ...attempting to use the MOR feature An O ring seals 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 r...

Страница 15: ...and swash plate rotation The MDC changes the pump displacement between no flow and full flow into opposite directions Under some circumstances such as contamination the control spool could stick and...

Страница 16: ...indicate that the control is not in neutral High case pressure may cause excessive wear Customers can apply their own handle design but they must care about a robust clamping connection between their...

Страница 17: ...th pumps The valve is normally open for fail safe operation The solenoid must be energized for the pump to operate When the machine control circuits energize the CCO solenoid it connects charge supply...

Страница 18: ...round Supply CONTROL SOLENOID C2 1 2 Supply Ground CONTROL SOLENOID C2 Ground Supply 1 2 Supply Ground Ground Supply CONTROL SOLENOID C1 X7 1 2 Supply Ground Ground Supply CCO SOLENOID 1 2 Supply Grou...

Страница 19: ...ontact Danfoss Connector 1 2 P003 480 Connector ordering data Description Quantity Ordering data Mating connector 1 DEUTSCH DT06 2S Wedge lock 1 DEUTSCH W2S Socket contact 16 and 18 AWG 2 DEUTSCH 0462...

Страница 20: ...ressure that you can only determine from a duty cycle analysis Applied pressure is the chosen application pressure in the order code for the pump This is the pressure at which the drive line generates...

Страница 21: ...his condition may also affect performance since charge and system pressure are referenced to case pressure Temperature and viscosity Temperature High temperature limits apply at the hottest point in t...

Страница 22: ...heoretical 0 8 N m bar 488 lbf in 1000 psi 0 9 N m bar 549 lbf in 1000 psi 0 96 N m bar 590 lbf in 1000 psi 1 08 N m bar 610 lbf in 1000 psi Mass moment of inertia of rotating components 0 0078 kg m2...

Страница 23: ...aximum 34 bar 435 psi Control pressure Minimum at corner power for EDC MDC FNR 21 5 bar 312 psi 18 5 bar 268 psi Maximum 40 bar 580 psi Case pressure Rated 3 bar 44 psi Maximum 5 bar 73 psi Lip seal e...

Страница 24: ...ion 15 20 75 10 10 x suction and return line 35 45 75 10 2 inlet screen mesh size 100 125 m Service Manual H1 45 53 60 68 Tandem Closed Circuit Axial Piston Pumps Technical Specifications 24 Danfoss J...

Страница 25: ...s 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 recommended...

Страница 26: ...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 AM3 9 1...

Страница 27: ...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 A B...

Страница 28: ...entrapment in oil under high pressure may damage hydraulic components Check carefully for inlet line leaks Do not run at maximum pressure until system is free of air and fluid has been thoroughly fil...

Страница 29: ...t secure the machine or disable disconnect the mechanism while servicing C Caution Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system c...

Страница 30: ...ttings If the system relief valves are worn contaminated or valve settings are too low the relief valves will be overworked Verify settings of high pressure relief valves and replace valves as necessa...

Страница 31: ...old oil If oil is cold it may be too viscous for proper function and pump cavitates Allow the oil to warm up to its normal operating temperature with engine at idle speed Pump inlet vacuum High inlet...

Страница 32: ...il sludge or metal particles 6 If there are signs of contamination in the hydraulic fluid replace all filters and drain the hydraulic system Flush the lines and refill the reservoir with the correct f...

Страница 33: ...ch 24 Nm 17 lb ft 0 50 bar 0 1000 psi L2 045 053 Case drain port 9 16 inch 48 5 Nm 35 8 lb ft 0 10 bar 0 100 psi L2 060 068 Case drain port 5 8 inch 148 Nm 109 lb ft 0 10 bar 0 100 psi Listed pressure...

Страница 34: ...essure factory set at 1800 min 1 rpm with a reservoir temperature of 50 C 120 F Charge check HPRV adjustment The charge check HPRV combines the charge check and high pressure relief functions Whenever...

Страница 35: ...mm 3 HPRV Valve 22 mm 70 Nm 52 lb ft M3 AM3 Charge pressure gauge port inch 43 Nm 32 lb ft 0 50 bar 0 1000 psi L2 Case drain port 5 8 inch 148 Nm 109 lb ft 0 10 bar 0 100 psi MA MB MC MD System press...

Страница 36: ...ure limiter adjusting valve 20 Nm 15 lb ft B 2 Pressure limiter adjusting valve 20 Nm 15 lb ft A 3 Pressure limiter adjusting valve 20 Nm 15 lb ft C 4 Pressure limiter adjusting valve 20 Nm 15 lb ft D...

Страница 37: ...ding settings 2 Start the prime mover and operate at normal speed 3 Use a 14 mm wrench to loosen the locking nut L024 4 Activate the control input until pressure in the high side of the system loop st...

Страница 38: ...ing 400 450 410 420 430 480 440 450 460 510 470 480 Engaging the Bypass Function 060 068 only Use this procedure to bypass the pump to allow moving the vehicle machine short distances when you cannot...

Страница 39: ...imum displacement of the pump A small amount of clockwise screw adjustment is required before the 100 displacement condition is reached 1 Mark servo cylinder location in case it rotates during displac...

Страница 40: ...l hex 6 0 cc turn 60 13 mm 23 N m 17 lbf ft 4 mm internal hex 5 9 cc turn 68 13 mm 23 N m 17 lbf ft 4 mm internal hex 6 6 cc turn Control Neutral Adjustment All functions of the Electric Displacement...

Страница 41: ...1000 psi 3 16 in Servo pressure gauge port M4 0 50 bar 0 1000 psi 3 16 in Servo pressure gauge port M5 0 50 bar 0 1000 psi 3 16 in 19 N m 14 lbf ft 19 N m 14 lbf ft 19 N m 14 lbf ft 4 Rotate the neut...

Страница 42: ...echanism to allow safe operation during adjustment This procedure details setting neutral for the entire pump one side at a time The procedure is the same for each side of each pump so you will need t...

Страница 43: ...ates E300 from both sides of the pump 4 Disconnect the control solenoids from the vehicle wiring harness 5 If using a PWM signal to set mechanical neutral connect the control solenoids C1 and C2 to th...

Страница 44: ...uge port locations 45 53 MD MA M4 M5 P109257 D A C B M4 M5 E300 E350 Control Cutoff CCO 1 MB MC X7 AM3 MC MB AM3 Service Manual H1 45 53 60 68 Tandem Closed Circuit Axial Piston Pumps Adjustments 44 D...

Страница 45: ...heck the servo pressure gauges Ensure the differential between M4 and M5 is less than 2 5 bar 36 psi 3 Using a 3 4 in deep socket unthread both servo cylinders 2 3 turns This step ensures the servo cy...

Страница 46: ...ut stroke the pump in the opposite direction by turning the eccentric screw in the opposite direction or by supplying current to solenoid C2 Reverse gauge locations M4 for M5 MB for MA etc from those...

Страница 47: ...ts such as dirt and grime 2 Inspect the system for contamination 3 Look at the hydraulic fluid for signs of system contamination oil discoloration foam in the oil sludge or metal particles Replacement...

Страница 48: ...viously removed install orifices F100 using a 3 mm internal hex wrench Torque to 2 5 N m 1 8 lbf ft 4 Install the control module and six cap screws D250 5 Using a 5 mm internal hex wrench torque the c...

Страница 49: ...l 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 module a...

Страница 50: ...eep well socket 22 5 27 5 Nm 16 6 20 3 lbf ft D250 cap screw 5 mm internal hex 13 3 Nm 9 8 lbf ft D750 neutral start switch D751 Oring D735 plug 3 4 inch 30 Nm 22 lbf ft F00A servo orifice 3 mm intern...

Страница 51: ...one Install it with the mesh facing outward see drawing Install retaining ring D098 MDC Proper screen orientation D084 D084 Incorrect screen orientation Correct screen orientation D098 4 If previously...

Страница 52: ...ft Installation 1 Position sensor on control housing 2 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 3 Postion protection co...

Страница 53: ...m Wrench size Torque D250 5 mm 13 5 N m 10 lbf ft Installation 1 Install new control gasket D150 2 Before positioning the control on the pump housing ensure assembly fixture is positioned over the lin...

Страница 54: ...ibration of sensor output in vehicle software is mandidtory after sensor replacement because output signal can vary from one sensor to the next For proper neutral adjustment procedure refer to Control...

Страница 55: ...the bearing off the shaft Shaft assembly 45 53 shown P106 150E J150 J100 J200 J250 J260 J275 J300 J150 Protective sleeve Inspection Inspect the shaft journals for wear scratching and pits Check the sp...

Страница 56: ...d seal ring K250 3 Using a 10 mm internal hex remove screws K400 Remove cover K101 4 Remove and discard seal S300 5 Remove geroter cover S200 Note the position of the alignment pin S500 in the housing...

Страница 57: ...K975 A flange B flange S200 Legend Item Wrench size Torque K351 A flange 8 mm internal hex 64 N m 47 lbf ft K351 B flange 18 mm 76 N m 56 lbf ft K400 10 mm internal hex 92 N m 68 lbf ft K350 10 mm in...

Страница 58: ...he aux pad K101 9 Using a 10 mm internal hex install screws K400 Torque screws per listing in table 10 Lubricate and install seal K250 Install running cover K301 11 Install screws K351 and brackets K9...

Страница 59: ...rate vehicle machine through full range of controls to ensure proper operation Check for leaks Charge check HPRV 80 N m 59 lbf ft K010 K009 K008 K007 H003 H002 R150 4X R200 4X 8 mm Rear pump location...

Страница 60: ...acements Removal 1 Mark the location of each valve prior to removal 2 Using a 22mm wrench remove the HPRVs 3 Remove and discard the Orings L060 and backup rings L068 Inspection Clean oil off the seali...

Страница 61: ...lug assembly 14 mm 30 N m 22 lbf ft QL300 301 400 401 Pressure limiter valve assembly 17 mm 30 N m 22 lbf ft L100 L101 L200 L201 High Pressure Relief Valve 22 mm 70Nm 51 6 lbf ft Charge pressure relie...

Страница 62: ...mponents as necessary Reassembly 1 Lubricate and install new O rings V10A 2 Install the charge pressure relief valve V10 Torque to 52 Nm 38 lbf ft 3 Operate vehicle machine through full range of contr...

Страница 63: ...il G20 3 Use a 1 1 16 in hex wrench to remove the control cutoff valve G10 Remove and discard the O rings and backup rings G10A Inspection Inspect the sealing surfaces of the pump and control valve fo...

Страница 64: ...nsure proper operation 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 H1 45 53 60 68 Tandem Closed Circuit Axial Piston Pumps Mi...

Страница 65: ...Control cutoff valve 060 068 G10A G10 G20 G30 G10A G10 G20 G30 Service Manual H1 45 53 60 68 Tandem Closed Circuit Axial Piston Pumps Minor repair Danfoss June 2018 520L0928 AX00000103en US0303 65...

Страница 66: ...mm internal hex NA L300 L400 L101 L201 Pressure limiter cartridge 14 mm hex 30 N m 22 lbf ft L024 Pressure limiter locking nut 14 mm hex 20 N m 15 lbf ft L100 L200 L101 L201 High pressure relief valve...

Страница 67: ...ons 045 053 D250 D065 D050 V10 E350 K007 G350 K350 G250 B015 G250 D060 D015 B020 P109564 G350 K350 A Pad B Pad Service Manual H1 45 53 60 68 Tandem Closed Circuit Axial Piston Pumps Torque chart Danfo...

Страница 68: ...068 P109558 B015 B015 B020 G250 D065 G250 D065 G250 B015 G250 G250 B015 B020 B020 B020 G250 V10 Service Manual H1 45 53 60 68 Tandem Closed Circuit Axial Piston Pumps Torque chart 68 Danfoss June 201...

Страница 69: ...Service Manual H1 45 53 60 68 Tandem Closed Circuit Axial Piston Pumps Danfoss June 2018 520L0928 AX00000103en US0303 69...

Страница 70: ...Service Manual H1 45 53 60 68 Tandem Closed Circuit Axial Piston Pumps 70 Danfoss June 2018 520L0928 AX00000103en US0303...

Страница 71: ...Service Manual H1 45 53 60 68 Tandem Closed Circuit Axial Piston Pumps Danfoss June 2018 520L0928 AX00000103en US0303 71...

Страница 72: ...lutions 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 S...

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