Related Manuals for Danfoss H1 078
Summary of Contents for Danfoss 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 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 September 2014 Danfoss layout - add MDC 520L0848 | AX00000087en-US0308 © Danfoss | May 2018...
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Page 3: Table Of Contents
Secure the unit..................................... 5 Safety Precautions....................................5 Unintended machine movement............................6 Flammable cleaning solvents..............................6 Fluid under pressure.................................. 6 Personal safety..................................... 6 Symbols used in Danfoss literature............................7 Design........................................7 The System Circuit....................................8 Operation Pressure Limiter Valves................................11 High Pressure Relief Valve (HPRV) and Charge Check...................... 11 Bypass Function....................................12... - Page 4 Filter Bypass Valve and Filter Bypass Switch........................54 Charge Pump....................................55 High Pressure Relief Valves (HPRV)............................58 Charge Pressure Relief Valve..............................59 Pressure Limiter Valve Replacement............................60 Torque Chart Fastener Size and Torques................................62 Plug Size and Torques.................................. 62 Fasteners and Plugs..................................63 520L0848 | AX00000087en-US0308 © Danfoss | May 2018...
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Page 5: Overview
A worldwide network of Danfoss Authorized Service Centers is available for major repairs. Danfoss trains and certifies Authorized Service Centers on a regular basis. You can locate your nearest Authorized Service Center using the distributor locator at www.Danfoss.com. -
Page 6: Unintended Machine Movement
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times. Hazardous Material Warning Hydraulic fluid contains hazardous material. Avoid prolonged contact with hydraulic fluid. Always dispose of used hydraulic fluid according to state, and federal environmental regulations. 520L0848 | AX00000087en-US0308 © Danfoss | May 2018... -
Page 7: Symbols Used In Danfoss Literature
The legend above defines each symbol and explains its purpose. Design Danfoss H1 closed circuit piston pumps convert input torque into hydraulic power. The input shaft transmits rotational force to the cylinder block. Bearings at the front and rear of the pump support the shaft. -
Page 8: The System Circuit
A heat exchanger with bypass valve cools the case drain fluid before it returns to the reservoir. 520L0848 | AX00000087en-US0308 © Danfoss | May 2018... - Page 9 Service Manual H1 Pumps 069/078, 089/100, 115/130, 147/165, 210/250 Introduction System Circuit Diagram 520L0848 | AX00000087en-US0308 | 9 © Danfoss | May 2018...
- Page 10 The schematic 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 motor with electric proportional control (L*) and integrated loop flushing device. 520L0848 | AX00000087en-US0308 10 | © Danfoss | May 2018...
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Page 11: Operation
HPRVs are set at low flow condition. Any application or operating condition which leads to elevated HPRV flow will cause a pressure rise with flow above the valve setting. Consult factory for application. 520L0848 | AX00000087en-US0308 | 11 © Danfoss | May 2018... -
Page 12: Bypass Function
This level is nominally set with the pump running at 1800 520L0848 | AX00000087en-US0308 12 | © Danfoss | May 2018... -
Page 13: Electrical Displacement Control (Edc)
The EDC is a displacement (flow) control. Pump swashplate position is proportional to the input command and therefore vehicle or load speed (excluding influence of efficiency), is dependent only on the prime mover speed or motor displacement. 520L0848 | AX00000087en-US0308 | 13 © Danfoss | May 2018... -
Page 14: Manual Override (Mor)
Refer to control flow table for the relationship of solenoid to direction of flow. Control Solenoid P003 204 EDC Schematic Diagram Showing Manual OverRide F00B F00A Feedback from Swash plate P003 205E 520L0848 | AX00000087en-US0308 14 | © Danfoss | May 2018... -
Page 15: Manual Displacement Control (Mdc)
Deadband on B side – a = 3° ±1° Maximum pump stroke – b = 30° +2/-1° Required customer end stop – c = 36° ±3° Internal end stop – d = 40° 520L0848 | AX00000087en-US0308 | 15 © Danfoss | May 2018... -
Page 16: Mdc Torque
Neutral Start Switch (NSS) The Neutral Start Switch (NSS) contains an electrical switch that provides a signal of whether the control is in neutral. The signal in neutral is Normally Closed (NC). 520L0848 | AX00000087en-US0308 16 | © Danfoss | May 2018... - Page 17 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. MDC schematic diagram P005 701 520L0848 | AX00000087en-US0308 | 17 © Danfoss | May 2018...
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Page 18: Operating Parameters
Servo pressure is the pressure in the Servosystem needed to position and hold the pump on stroke. It depends on system pressure and speed. At minimum servo pressure the pump will run at reduced stroke depending on speed and pressure. 520L0848 | AX00000087en-US0308 18 | © Danfoss | May 2018... -
Page 19: Charge Pressure
0.4 bar [5.8 psi] above the case pressure. The case pressure limits must also be followed to ensure the shaft seal is not damaged. 520L0848 | AX00000087en-US0308 | 19 © Danfoss | May 2018... -
Page 20: Temperature And Viscosity
The minimum temperature relates to the physical properties of component materials. Size heat exchangers to keep the fluid within these limits. Danfoss recommends testing to verify that these temperature limits are not exceeded. Viscosity For maximum efficiency and bearing life, ensure the fluid viscosity remains in the recommended range. -
Page 21: Technical Specifications
Main pressure ports: SAE straight thread O-ring boss Remaining ports: SAE straight thread O-ring boss Recommended installation position Pump installation recommended with control position on the top or side. Consult Danfoss for non conformance to these guidelines. The housing must always be filled with hydraulic fluid. -
Page 22: Operating Parameters
= 75 (b ≥2) 35-45 Recommended inlet screen mesh size 100 - 125 Ratings and data are based on operation with premium petroleum-based hydraulic fluids containing oxidation, rust, and foam inhibitors. 520L0848 | AX00000087en-US0308 22 | © Danfoss | May 2018... -
Page 23: Fluid And Filter Maintenance
Change filters with the fluid or when the filter indicator shows it’s necessary. Replace all fluid lost during filter change. For detailed filtration information, see Danfoss publication 520L0463 Fluids and Filtration. For information on biodegradable fluids see Danfoss publication 520L0465 Biodegradable Hydraulic Fluids. -
Page 24: Pressure Measurements
System Ports A and B 450 bar, 600 [10,000] 210/250 20 min. full thread Split flangeboss per ISO 6162 depth; Recommended screw in depth 1.5 x thread dia. Charge Pump Inlet 520L0848 | AX00000087en-US0308 24 | © Danfoss | May 2018... - Page 25 Service Manual H1 Pumps 069/078, 089/100, 115/130, 147/165, 210/250 Pressure Measurements Port locations System Port B System Port A G302 D065 P106033 520L0848 | AX00000087en-US0308 | 25 © Danfoss | May 2018...
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Page 26: Initial Startup Procedures
Normal charge pressure fluctuation may occur during forward and reverse operation. 13. Check that the reservoir is full. Remove charge pressure gauge. The pump is now ready for operation. 520L0848 | AX00000087en-US0308 26 | © Danfoss | May 2018... -
Page 27: Troubleshooting
Fill reservoir to proper level. of system. Heat exchanger. Heat exchanger is not sufficiently cooling the system. Check air flow and input air temperature for heat exchanger. Clean, repair or replace heat exchanger. 520L0848 | AX00000087en-US0308 | 27 © Danfoss | May 2018... -
Page 28: Integral Filter Bypass
Control orifices are blocked. Clean control orifices. Pump control screens Control screens are blocked. Replace control screens. Only a Danfoss Authorized Service Center may remove the unit’s endcap without voiding the warranty. Bypass function open If bypass function is open, the system loop will be Close bypass valves. -
Page 29: System Noise Or Vibration
Control orifices are plugged. Clean control orifices. orifices Contaminated control EDC supply screen is plugged. Replace control screens. Only a Danfoss Authorized Service screens Center may remove the unit’s endcap without voiding the warranty. Pump inlet vacuum Inlet vacuum is too high resulting in reduced system Measure charge inlet vacuum. -
Page 30: Transmission Operates Normally In One Direction Only
Check for torn/missing servo seals. Replace and retest. Only decaying stroking the pump. a Danfoss Authorized Service Center may remove the servo piston without voiding the warranty. Bypass function open Open bypass will cause one or both directions to be Close bypass function. -
Page 31: Adjustments
Listed pressures assume a pump speed of 1800 min¯¹ (rpm). At higher pump speeds (with higher charge flows) the charge pressure will rise over the rated setting. Depending on the pressure rating, the charge pressure relief valve may have one or two springs. 520L0848 | AX00000087en-US0308 | 31 © Danfoss | May 2018... -
Page 32: Pressure Limiter Adjustment
16 mm L024 Locking nut L028 Plug (special) L028 68 [50] 14 mm L012 30 [22] 19 mm L012 Cartridge L012 Cartridge L012 70 [52] 22 mm 22 mm P106351 520L0848 | AX00000087en-US0308 32 | © Danfoss | May 2018... - Page 33 6. Repeat steps four and five until you reach the desired PL setting. After adjustment, torque the locknut (L024) to 20 N•m [15 lbf•ft]. Do not over torque. 7. Shut down the prime mover. Remove gauges and replace plugs. Pressure Limiter Settings Pressure limiter setting HPRV setting 520L0848 | AX00000087en-US0308 | 33 © Danfoss | May 2018...
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Page 34: Engaging The Bypass Function
L150 P106 649E HPRV Wrench Size and Torque Values Displacement Wrench size and torque 069/078/089/100 22 mm - 70 N•m [52 lbf-ft] 115/130/147/165/210/250 30 mm - 110 N•m [81 lbf-ft] 520L0848 | AX00000087en-US0308 34 | © Danfoss | May 2018... -
Page 35: Displacement Limiter Adjustment
22 mm - 80 N•m [59 lbf-ft] 6 mm 12.4 cm /turn [0.757 in /turn] 22 mm - 80 N•m [59 lbf-ft] 6 mm 13.9 cm /turn [0.848 in /turn] 520L0848 | AX00000087en-US0308 | 35 © Danfoss | May 2018... -
Page 36: Control Neutral Adjustment
Then rotate the neutral adjusting screw counterclockwise until the pressure increases by an equal amount on the other gauge. Again note the angular position of the wrench. 520L0848 | AX00000087en-US0308 36 | © Danfoss | May 2018... -
Page 37: Mechanical Neutral Adjustment
Pressure differential between M4 and M5 (optional) • Pressure differential between A and B (optional) Refer to Pressure measurement and the illustration on the next page for gauge port locations and information. 520L0848 | AX00000087en-US0308 | 37 © Danfoss | May 2018... - Page 38 Solenoid C1 port M4 port M5 System Port B Gauge port MB Gauge port MA Solenoid C2 System Port A system pressure system pressure Servo pressure port M4 P106 489E 520L0848 | AX00000087en-US0308 38 | © Danfoss | May 2018...
- Page 39 7. Remove all gauges and replace gauge port plugs. You can find wrench sizes and plug torques in the Plug Size and Torque Chart. Servo Adjustment E350 E300 Servo can Servo can locking bolt locking plate P106 490E 520L0848 | AX00000087en-US0308 | 39 © Danfoss | May 2018...
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Page 40: Minor Repair
Inspect the machined 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 housing before installing control. 520L0848 | AX00000087en-US0308 40 | © Danfoss | May 2018... - Page 41 5 mm 13.5 N•m [9.8 lbf•ft] D025 D025A D050 (3X) 4 mm D084 5 N•m D098 [4 lbf•ft] D150 F100 (2X) 3 mm 2.5 N•m [1.8 lbf•ft] D300 (2X) P106 650E 520L0848 | AX00000087en-US0308 | 41 © Danfoss | May 2018...
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Page 42: Control Solenoids
5. Before removing the control, note the position of the control lever for reassembly. Caution Do not disassemble the control, otherwise the functionality of the control and the neutral position of the pump can be lost! 520L0848 | AX00000087en-US0308 42 | © Danfoss | May 2018... - Page 43 D098 F00T MDC with neutral start switch D250 D065 D150 D200 D300 (2X) F00A F00B D751 F00P D750 P108784 MDC with neutral start switch and CCO D250 D065 D751 D750 520L0848 | AX00000087en-US0308 | 43 © Danfoss | May 2018...
- Page 44 Insure feedback pin is properly torqued before continuing with reassembly. 3. If you removed screen (D084), install a new one. Install it with the mesh facing outward (see drawing). Install retaining ring (D098). MDC - Proper screen orientation 520L0848 | AX00000087en-US0308 44 | © Danfoss | May 2018...
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Page 45: Angle Sensor On Edc
3. Remove the protection cover from the control. 4. If protection cover is damaged, discard. 5. Remove sensor screws (D770) using a 4 mm internal hex wrench. 6. Remove and discard the sensor. Position sensor D767 D770 520L0848 | AX00000087en-US0308 | 45 © Danfoss | May 2018... -
Page 46: Installation
1. Clean pump externally with clean solvent to remove debris. 2. Remove control screws (D250) using a 5 mm internal hex wrench. 3. Remove the control from the pump. Dowel pins (D300) must remain in housing. 520L0848 | AX00000087en-US0308 46 | © Danfoss | May 2018... -
Page 47: Installation
2. Before positioning 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 on swashplate is positioned properly in control arm. 520L0848 | AX00000087en-US0308 | 47 © Danfoss | May 2018... -
Page 48: Automotive Control
For proper neutral adjustment procedure, refer to Automotive Control Removal 1. Drain pump completely before removing control. Disconnect and remove wiring (D640). 520L0848 | AX00000087en-US0308 48 | © Danfoss | May 2018... - Page 49 Security wax seal (2X) 13.3 Nm [9.8 lbf•ft] D610 (2X) D250 5 mm D672 (6X) D674 D084 D640 D098 2.5 Nm [1.8 lbf•ft] F00A D150 3 mm F00B P107 990E 520L0848 | AX00000087en-US0308 | 49 © Danfoss | May 2018...
- Page 50 3. Install new gasket (D150) to bottom of control. If pump has been rebuilt or a new control is being installed, control software must be recalibrated. Refer to H1-Automotive Control User Manual 70012797 for recalibration instructions. 520L0848 | AX00000087en-US0308 50 | © Danfoss | May 2018...
- Page 51 If control will continue to be under warranty, install new sealing wax of a different color (original wax is blue). Pumps without sealing wax installed will not be warrantied. 7. Install protection bracket (D672). Install screws (D674). Torque to 5 N•m [3.7 lbf•ft]. 520L0848 | AX00000087en-US0308 | 51 © Danfoss | May 2018...
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Page 52: Bearing And Shaft Replacement
Tap on the seal replacing tool or an appropriate deep-socket to press in the seal. Remove the protective cover. Refer to Seal Installation Tool illustration below for installation sleeve and seal installation tool part numbers and dimensions. 520L0848 | AX00000087en-US0308 52 | © Danfoss | May 2018... -
Page 53: External Filter Replacement
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). 520L0848 | AX00000087en-US0308 | 53 © Danfoss | May 2018... -
Page 54: Filter Bypass Valve And Filter Bypass Switch
6. If necessary, use a 3 mm internal hex wrench to remove cap screws (T300) and bypass switch (T200). It is not necessary to remove switch (T200) unless it is being replaced. 520L0848 | AX00000087en-US0308 54 | © Danfoss | May 2018... -
Page 55: Charge Pump
4. Remove pressure-balance plate (S200) with seal (S300). Note orientation of plate and seal. Discard seal. 5. Remove charge pump coupling (K200). 6. Remove charge pump gearset (S100) and outer ring (S150). 520L0848 | AX00000087en-US0308 | 55 © Danfoss | May 2018... - Page 56 4. Remove pressure-balance plate (S200) with seal (S300). Note orientation of valve plate and seal. Discard seal (S300). 5. Remove charge pump coupling K200). 6. Remove charge pump gearset (S100) and outer ring (S150). 520L0848 | AX00000087en-US0308 56 | © Danfoss | May 2018...
- Page 57 5. Install pressure-balance plate (S200) in the same orientation as removed. 6. Install the thrust washer (K500). Coated side goes towards charge pump coupling (K200). 7. Install a new cover gasket (K150). If removed,install guide pins (K450). 520L0848 | AX00000087en-US0308 | 57 © Danfoss | May 2018...
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Page 58: High Pressure Relief Valves (Hprv)
Inspect the sealing surfaces in the pump for nicks or scratches. Check the valves for damage. Replace any damaged components. Reassembly 1. Lubricate and install new backup rings (L068) and O-rings (L060). 2. Install HPRVs. Torque to the value in the table below. 520L0848 | AX00000087en-US0308 58 | © Danfoss | May 2018... -
Page 59: Charge Pressure Relief Valve
Inspect the sealing surfaces of the pump for nicks or scratches. Reassembly 1. Lubricate and install new seal (V024). 2. Install the charge pressure relief valve. Torque to 52 N•m [38 lbf•ft]. 520L0848 | AX00000087en-US0308 | 59 © Danfoss | May 2018... -
Page 60: Pressure Limiter Valve Replacement
2. Replace pressure limiter valve. Torque to the value in the table below. 3. Operate pump at full range of controls to ensure proper machine operation. Pressure limiter is available as complete unit only. O-ring is available separately. 520L0848 | AX00000087en-US0308 60 | © Danfoss | May 2018... - Page 61 L300 L400 L022 E101336 Wrench Size and Torque 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] 520L0848 | AX00000087en-US0308 | 61 © Danfoss | May 2018...
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Page 62: Torque Chart
3/16 mm internal hex 12 N•m [9 lbf•ft] B020 (069/078) 7/8 - 14 3/8 internal hex 70 N•m [52 lbf•ft] B020 (147/165) 1-1/16 - 12 9/16 internal hex 70 N•m [52 lbf•ft] 520L0848 | AX00000087en-US0308 62 | © Danfoss | May 2018... -
Page 63: Fasteners And Plugs
V022 Charge pressure locking nut K400 Rear cover / auxiliary pad mounting bolt V010 Charge pressure cartridge L150 High pressure relief valve T015 Filter mounting bolt P106 066E 520L0848 | AX00000087en-US0308 | 63 © Danfoss | May 2018... - Page 64 Servo can locking bolt D250 G250 O-ring plug, 9/16 - 18 Electric control mounting bolt G302 O-ring plug 5/16 - 24 UNF D065 O-ring plug, 7/16 - 20 P106 497E 520L0848 | AX00000087en-US0308 64 | © Danfoss | May 2018...
- Page 65 Service Manual H1 Pumps 069/078, 089/100, 115/130, 147/165, 210/250 520L0848 | AX00000087en-US0308 | 65 © Danfoss | May 2018...
- Page 66 Service Manual H1 Pumps 069/078, 089/100, 115/130, 147/165, 210/250 520L0848 | AX00000087en-US0308 66 | © Danfoss | May 2018...
- Page 67 Service Manual H1 Pumps 069/078, 089/100, 115/130, 147/165, 210/250 520L0848 | AX00000087en-US0308 | 67 © Danfoss | May 2018...
- Page 68 Phone: +86 21 3418 5200 Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without changes being necessary in specifications already agreed.