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Hydraulic two-position control module with PCOR and hydraulic BPD

Disassembly

1. Using a 1/8 inch internal hex wrench, remove three plugs (C0060). Remove and discard O-rings

(C0060A).

2. Using a 1/4 inch internal hex wrench, remove four plugs (C0050). Remove and discard O-rings

(C0050A).

3. Using a 1/4 inch internal hex, remove plug (C0140). Remove spool (C0020).
4. Use a 5mm internal hex wrench to remove the shuttle valve (C0025).
5. Using a 22 mm hex wrench, remove adapter (B0300). Remove and discard O-ring (QB0300).
6. Using a 17 mm hex wrench, remove pressure compensator adjusting plug (C0090). Remove and

discard O-ring (M223).

7. Remove spring (C0080). Remove spool (C0070).
8. If necessary, use a 3 mm internal hex wrench to remove orifices (E00T2) and (E00T3).

Inspection
Clean and inspect the machined surfaces on the control and the endcap. If any nicks or scratches are
found, replace the control/endcap assembly.

Assembly

Two-position control assembly (THHB)

C0050

C0060

C0050

P108923

C0025

1/4 inch

C0060

1/8 in

1/8 in

THHB

C0050

C0070

C0080

C0090

M223

B0300

B0310

B0330

B0320

QB300

C0050

C0140

C0020

E00T2

E00T3

1. If previously removed, install orifices (E00T3 and E00T2) using a 3mm internal hex wrench. Torque to

6 N•m [4 lbf•ft].

2. Lubricate and install spools and (C0070) and spring (C0080).
3. Lubricate and install O-ring (M223).
4. Install pressure compensator adjusting plug (C0090). Torque to 25 N•m [18 lbf•ft].
5. Lubricate and install O-ring (QB0300).
6. Install adapter (B0300). Torque to 67 N•m [49 lbf•ft].
7. Lubricate and install spool (C0020).
8. Using a 1/4 inch internal hex wrench, install plug (C0140). Torque to 14 N•m [10 lbf•ft].

Service Manual

H1 Bent Axis Motors, Size 060/080/110/160/210/250 cm3

Minor repair

56 |

©

Danfoss | August 2018

AX00000025en-US0504

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Содержание H1B 060

Страница 1: ...Service Manual H1B 060 080 110 160 210 250 H1 Bent Axis Motors www danfoss com...

Страница 2: ...or torque values 0502 July 2016 Add G1 G2 controls 0501 December 2015 Add 210 frame size 0500 November 2015 Model code change 0400 July 2015 correct torque values pages 61 62 0301 June 2015 add hydrau...

Страница 3: ...nt limiter 22 Operating parameters Output speed 23 System pressure 23 Case pressure 24 External shaft seal pressure 24 Temperature 24 Fluid and filter maintenance Fluid and filter recommendations 25 P...

Страница 4: ...ydraulic two position control module with PCOR 55 Hydraulic two position control module with PCOR and hydraulic BPD 56 Maximum displacement limiter two position controls 58 Servo piston cover proporti...

Страница 5: ...le or lock the mechanism to inhibit movement Prior to performing repairs remove the unit from the vehicle machine Be aware that hydraulic fluid may be under high pressure and or hot Inspect the outsid...

Страница 6: ...This fluid 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 u...

Страница 7: ...orientation for reinstallation Parallelism specification Torque specification External hex head Press in press fit Internal hex head Pull out with tool press fit Torx head Cover splines with installat...

Страница 8: ...2 Valve segment 3 Bearing plate 4 Tapered roller bearing 5 Loop flushing relief valve 6 Ramp spring 7 Loop flushing shuttle spool 8 Electric proportional control 9 Minimum displacement limiter 10 Spee...

Страница 9: ...egment 3 Bearing plate 4 Tapered roller bearing 5 Loop flushing relief valve 6 Loop flushing shuttle spool 7 Electric two position control 8 Minimum displacement limiter 9 Speed ring optional Service...

Страница 10: ...cm3 and DIN not available for 250 cm3 flange with radial or axial high pressure port configurations are available including the loop flushing device A complete family of controls and regulators are av...

Страница 11: ...Displacement Control EDC 4 Charge Pump 5 Charge Check High Pressure Relief Valve 6 Loop Flushing Valve 7 Pressure Limiter Valve 8 Charge Pressure Relief Valve 9 Servo Cylinder 10 Charge Pressure Filt...

Страница 12: ...ic above shows the function of a hydrostatic transmission using an H1 axial variable displacement pump with electric proportional displacement control EDC and an H1 bent axis variable displacement mot...

Страница 13: ...pressure p 450 bar 6527 psi kW hp 266 357 321 430 396 531 513 689 609 817 684 917 Mass moment of inertia of rotating components kg m2 slug ft2 0 0038 0 0028 0 0062 0 0046 0 0108 0 0080 0 0211 0 0156...

Страница 14: ...5900 5300 4800 4250 3850 3650 Zero 0 6600 5950 5350 4750 4300 4050 Maximum Maximum 32 4500 4100 3700 3300 3000 2800 Minimum 6 7250 6600 5950 5250 4800 4500 Zero 0 7950 7200 6500 5750 5250 4900 System...

Страница 15: ...2000 3000 4000 5000 6000 P006 001 0 20 40 60 80 100 H1B 210 0 1000 2000 3000 4000 5000 6000 0 20 40 60 80 100 P301 457 H1B 250 W Warning Zero degree capability results in a high risk of overspeed and...

Страница 16: ...ar versus Displacement 0 20 40 60 80 100 P006 014 30bar 20bar 15bar 10bar 5bar 2bar 0 1000 2000 3000 4000 5000 6000 H1B 210 0 20 40 60 80 100 P006 015 30bar 20bar 15bar 10bar 5bar 2bar 0 1000 2000 300...

Страница 17: ...be equal or higher as shown in the graphs Required inlet pressure diagrams for cylinder block filling on page 16 Counter balance valves may be used to maintain the minimum pressure requirements Also t...

Страница 18: ...Vg n 1000 v Qe Vg p mh 20 Me Qe p t 600 Me n 9550 Pe n Qe 1000 v Vg Vg n 231 v Qe Vg p mh 2 Me Vg n p t 396 000 P e n Qe 231 v Vg Where Qe Input flow l min Me Output torque N m Pe Output power kW n Sp...

Страница 19: ...Clockwise Flow into port B CounterClockwise Controls M1 M2 K1 K2 KH MH Direction of rotation CCW CW P006031 B A Flow into port A CounterClockwise Flow into port B Clockwise Controls E1 E2 F1 F2 P1 P2...

Страница 20: ...loop A B System loop B LFRV to Loop flushing relief valve P003 437 A B L2 W Warning Unintended vehicle or machine movement hazard Excessive motor loop flushing flow may result in the inability to buil...

Страница 21: ...rge pressure relief valve designed with a cracking pressure of 16 bar 232 psi Valves are available with several orifice sizes to meet the flushing flow requirements of all system operating conditions...

Страница 22: ...alled The number of teeth is shown in the table below The number of speed target ring teeth H1B size 060 080 110 160 210 250 Teeth 71 78 86 95 104 108 Excessive axial shaft loading during installation...

Страница 23: ...must also be sufficient to hold the machine in place when full power is applied System pressure System pressure is the differential pressure between high pressure system ports It is the dominant opera...

Страница 24: ...owed to ensure the shaft seal is not damaged Temperature The high temperature limits apply at the hottest point in the transmission which is normally the motor case drain The system should generally b...

Страница 25: ...rst fluid change occur at 500 hours of operation Change the fluid more frequently if it becomes contaminated with foreign matter dirt water grease etc or if the fluid is subjected to temperature level...

Страница 26: ...it flange boss ports A B Code 62 per ISO 6162 Type 1 Port Size 060 Size 080 110 Size 160 210 250 A B 3 4 in Thread M10 x 1 5 min 18 mm 0 71 in 1 in Thread M12 x 1 75 min 23 mm 0 91 in 1 1 4 in Thread...

Страница 27: ...600 bar 8700 psi 1 X1 XA XB 9 16 18 UNF Wrench int hex 1 4 in 100 bar 1450 psi 2 1 Servo pressure rod end 2 X1 Control pressure supply hydraulic actuator XA XB BPD PCOR inactive at A B Port locations...

Страница 28: ...bar 0 1000 psi pressure gauge in the charge pressure gauge port of the pump to monitor the charge pressure during start up For open circuit systems use gauges in system ports 8 Disconnect any external...

Страница 29: ...o cycle slowly between forward and reverse for at least five minutes 18 Shut down prime mover 19 Remove gauges Replace plugs at the gauge ports 20 Check reservoir level Add filtered fluid if needed Th...

Страница 30: ...threshold setting may shift the motor at the wrong time Check threshold setting Adjust if necessary 3 Control spool A sticky control may cause sluggish response or no response Clean and inspect the co...

Страница 31: ...ol It may be sticking or receiving an improper signal Repair spool or correct input signal Improper output speed Check Cause Corrective action 1 Oil level in reservoir Insufficient hydraulic fluid may...

Страница 32: ...control if necessary 5 Two position solenoid Two position control not shifting motor to maximum displacement Inspect solenoid valve for bent stem or damaged coil Repair or replace if necessary 6 Contr...

Страница 33: ...and grime 2 If removing the motor tag each hydraulic line connected to the motor If you disconnect hydraulic lines plug each open port to keep dirt and contamination out of the motor 3 Inspect the sy...

Страница 34: ...ed decrease minimum displacement Adjusting displacement limits also affects output torque Refer to the table below for displacement change per turn Displacement change per turn Size 060 080 110 160 21...

Страница 35: ...0040 and install motor on vehicle Run vehicle and test for proper motor operation Adjusting threshold on a machine or test stand without flow meter 1 Install 600 bar 10 000 psi gauges to ports M5 and...

Страница 36: ...nstall nut B0180 and install motor on vehicle Run vehicle and test for proper motor operation Adjusting threshold on a machine or test stand without flow meter 1 Install 600 bar 10 000 psi gauges to p...

Страница 37: ...d 5 Install data acquisition device which is able to record data over time using the sensors installed in steps 2 4 above 6 Deactivate any inching systems connected to the brakes if applicable 7 Prepa...

Страница 38: ...elow Adjustment 1 If adjustment is required use a 3mm internal hex to hold the PCOR adjusting screw in place and use a 10mm wrench to loosen the PCOR lock nut One full turn of the adjusting screw chan...

Страница 39: ...H1B PCOR Adjustment System Pressure Engine Speed Wheel Speed Displacement Range Minimum Displacement Max Displacement TIME Begin Application of Service Brake PCOR Setting Service Manual H1 Bent Axis M...

Страница 40: ...ing seal installation tool press seal into housing bore 3 Using a snap ring pliers install retaining ring G0030 4 Use seal installation tool to press seal and retaining ring into housing until retaini...

Страница 41: ...mm 0 2 in 45 5 15 mm 100 mm 3 94 in 69 mm 2 6 in 58 mm 2 3 in 0 10 0 0 0 20 in 0 004 0 0 150 mm 5 90 in 70 mm 2 76 in 5 mm 0 2 in 45 5 4 mm 100 mm 3 94 in 56 mm 2 2 in 48 mm 1 9 in 0 10 0 0 0 21 in 0...

Страница 42: ...r damage or wear Replace parts if necessary Assembly 1 Lubricate and install valve spool C0100 2 Using petroleum jelly lubricate and install new O ring B0035A 3 Install cap screws B0050 using a 4 mm i...

Страница 43: ...all machined surfaces for damage or wear Replace parts if necessary Assembly Replacing actuator P108828 B0050 B0010 1 Install cap screws B0050 using a 4 mm internal hex wrench and torque screws to 6 N...

Страница 44: ...eplace control or endcap Inspect valve spool washer and spring Replace if necessary Assembly Control module removal installation C0010 Proportional control C0110 4X F0030 F0040 C0130 6 mm C0110 2X C00...

Страница 45: ...four cap screws C0110 and or C0120 C0110 and C0120 Wrench Size Screw Control Torque Internal Hex Wrench C0110 Electric Hydraulic proportional 37 N m 27 lbf ft 6 mm C0110 C0120 Two position 115 N m 85...

Страница 46: ...and discard O ring B0035A 6 Remove spool C0100 7 Using a 1 4 in internal hex wrench remove plug C0050 and discard O ring C0050A 8 Use a 5 mm internal hex to remove shuttle valve C0025 9 Using a 1 8 i...

Страница 47: ...ll and torque plugs C0060 to 8 N m 6 lbf ft using a 1 8 inch internal hex wrench 4 Lubricate and install spool C0025 into control block using a 5 mm internal hex wrench torque to 14 N m 11 lbf ft 5 In...

Страница 48: ...B0027 and torque to 3 5 N m 2 6 lbf ft using a 26 mm 12 point socket Do not over torque 15 Install new O ring B0029 and plastic cap B0040 to solenoid Service Manual H1 Bent Axis Motors Size 060 080 1...

Страница 49: ...n C0140 3 mm 1 8 in C0060 C0060A 40 N m 30 lbf ft 8 N m 6 lbf ft 8 N m 6 lbf ft 6 N m 4 lbf ft 0010 0020 B0180 B0061 0010 0020 E00T2 1 8 in C0060 8 N m 6 lbf ft C0060A C0070 C0080 C0090A C0090 C0060A...

Страница 50: ...rnal hex wrench 8 Install screws B0050 with torque to 6 N m 4 lbf ft If replacing the hydraulic actuator set the threshold pressure to the proper setting Refer to Adjusting threshold on test stand on...

Страница 51: ...0060 Remove and discard O rings C0060A 6 Using a 1 4 inch internal hex wrench remove two plugs C0050 Remove and discard O rings C0050A 7 Using a 17 mm hex wrench remove pressure compensator adjusting...

Страница 52: ...N m 6 lbf ft 3 mm 6 N m 4 lbf ft 1 4 in 40 N m 30 lbf ft 25 N m 18 lbf ft B0028 B0022 B0024 B0032 B0028 B0022 B0024 B0032 B0034 17 mm 25 N m 19 lbf ft B0034 B0026 3 5 N m 2 6 lbf ft B0026 3 5 N m 2 6...

Страница 53: ...bf ft 5 Lubricate and install four O rings C0060A Using a 1 8 inch internal hex wrench install plugs C0060 Torque to 8 N m 6 lbf ft 6 Lubricate and install O rings B0034 7 Install solenoids B0032 usin...

Страница 54: ...hes are found replace the control endcap assembly Assembly Hydraulic two position control assembly HEHE HFHF C0050 C0050 C0060 C0060 C0050 C0060 C0060 C0160 C0160A C0140 C0050 C0060 C0060 C0050 C0050...

Страница 55: ...e the control endcap assembly Assembly Two position control assembly THHA C0050 C0060 C0050 C0060 C0070 P108913 C0025 1 4 inch 1 8 in 1 8 in THHA C0050 C0080 C0090 M223 B0300 B0310 B0330 B0320 QB300 E...

Страница 56: ...t the machined surfaces on the control and the endcap If any nicks or scratches are found replace the control endcap assembly Assembly Two position control assembly THHB C0050 C0060 C0050 P108923 C002...

Страница 57: ...rench install four plugs C0050 Torque to 40 N m 30 lbf ft 11 Using a 1 8 inch internal hex wrench install three plugs C0060 Torque to 8 N m 6 lbf ft Service Manual H1 Bent Axis Motors Size 060 080 110...

Страница 58: ...placement limiter Remove screw P0100 using a 6 mm internal hex and spacer P0200 Assembly Maximum displacement limiter assembly 6 mm P107 866E P0200 P0100 1 Install spacer P0200 and screw P0100 using a...

Страница 59: ...044 P0041 Seal ring P0044 O ring P0043 Piston 1 Remove four screws P0020 using a 10 mm internal hex wrench 2 Remove servo piston cover P0010 3 Remove and discard O ring P0030 4 Remove screw P0050 Serv...

Страница 60: ...estion Assembly 1 Lubricate and install new O ring P0043 and seal ring P0044 on piston P0041 Seal ring P0044 O ring P0043 Piston head Allow seals time to relax before installing piston 2 Install pisto...

Страница 61: ...57 lbf ft 3 Lubricate and install new O ring P0030 and install servo piston cover P0010 4 Using a 8 mm or 10 mm internal hex install screws P0020 Torque to 115 N m 85 lbf ft Service Manual H1 Bent Axi...

Страница 62: ...y Speed sensor assembly J0020 J0010A J0010 5 mm 8 N m 6 lbf ft 1 Lubricate and install new O ring J0010A 2 Install speed sensor J0010 3 Install screw J0020 using a 5 mm internal hex wrench with torque...

Страница 63: ...y are cracked or bent Reassembly Loop flushing reassembly K0010 K0030 K0030A K0020 K0030 K0030A K0020 67 N m 49 lbf ft 67 N m 49 lbf ft 24 mm 24 mm 1 Lubricate and install spool K0010 2 Lubricate and...

Страница 64: ...you suspect malfunction replace valve Assembly 1 Install new O ring L0050 2 Using a 24 mm hex wrench install valve L00 Torque to 67 N m 49 lbf ft Loop flushing charge relief valve replacement L0050 L0...

Страница 65: ...nt limiter screw N0010 Inspection Inspect set screw for wear or damage Replace set screw if necessary Assembly 1 Using a 6 mm internal hex wrench install adjustment screw N0010 to original position 2...

Страница 66: ...hex 6 N m 4 lbf ft C0110 Control proportional assembly screws 6 mm internal hex 37 N m 28 lbf ft C0110 C0120 Control two position assembly screws 10 mm internal hex 115 N m 85 lbf ft J0020 Speed sens...

Страница 67: ...0UNF Cartridge only not shown 3 16 internal hex 8 N m 5 lbf ft G0060 060 080 7 8 14UN 3 8 internal hex 70 N m 52 lbf lb G0060 110 160 1 1 16 12UN 9 16 internal hex 70 N m 52 lbf lb G0060 210 250 1 5 1...

Страница 68: ...r Solutions 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 Tradi...

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