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Related Manuals for Danfoss H1P 045
Summary of Contents for Danfoss H1P 045
- Page 1 Service Manual H1P 045/053/060/068 Axial Piston Single Pumps www.danfoss.com...
- Page 2 Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Revision history Table of revisions Date Changed June 2020 Changed document number from 'AX00000104' to 'AX152886481964' and added 0405 caution note to start-up procedures November 2018 Major layout update. 0401 April 2018...
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Page 3: Table Of Contents
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Contents Introduction Hydrostatics Servicing Overview..............................5 General Servicing Instructions..............................5 Safety Precautions....................................6 Symbols used in Danfoss literature............................7 Design........................................8 H1 Single Pumps Closed Circuit Pictorial Diagram......................9 H1 system schematic..................................10 Operation Pressure Limiter Valves................................11 Pressure Limiter Sectional View............................ - Page 4 Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Contents System Noise or Vibration................................33 Sluggish System Response................................. 33 Adjustments Standard Procedures..................................35 Charge Pressure Relief Valve Adjustments........................... 36 Pressure Limiter Adjustment..............................37 Engaging the Bypass Function..............................38 Displacement Limiter Adjustment for Single Pumps......................40 Control Neutral Adjustment...............................41...
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Page 5: Hydrostatics Servicing Overview
A worldwide network of Danfoss Global Service Partners is available for major repairs. Danfoss trains and certifies Global Service Partners on a regular basis. You can locate your nearest Global Service Partner using the distributor locator at http://www.danfoss.com. -
Page 6: Safety Precautions
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Introduction Safety Precautions Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury. Take the following general precautions whenever servicing a hydraulic system. Unintended Machine Movement Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. -
Page 7: Symbols Used In Danfoss Literature
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Introduction Symbols used in Danfoss literature WARNING may result in injury Tip, helpful suggestion CAUTION may result in damage to product or Lubricate with hydraulic fluid property Reusable part Apply grease / petroleum jelly... -
Page 8: Design
™ installation. H1 pumps can be used together in combination with other Danfoss pumps and motors in the overall hydraulic system. Danfoss hydrostatic products are designed with many different displacement, pressure and load-life capabilities. Go to the Danfoss website or applicable product catalog to choose the components that are right for your complete closed circuit hydraulic system. -
Page 9: H1 Single Pumps Closed Circuit Pictorial Diagram
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Introduction The Basic Closed Circuit Hydraulic lines connect the main ports 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. -
Page 10: H1 System Schematic
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Introduction H1 system schematic System schematic H1 pump and H1 motor with EDC M3 L1 L2 MA F00B F00A max. min. L3 L4 max. 3 bar [43.5 psi] P003 424 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. -
Page 11: Operation
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Operation Pressure Limiter Valves Pressure limiter valves provide system pressure protection by compensating the pump swash plate position when the set pressure of the valve is reached. A pressure limiter is a non-dissipative (non heat generating) pressure regulating system. -
Page 12: High Pressure Relief Valve (Hprv) And Charge Check Valve
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Operation High Pressure Relief Valve (HPRV) and Charge Check Valve All H1 pumps have a combination high pressure relief and charge check valve. The high pressure relief function is a dissipative (heat generating) pressure control valve for the purpose of limiting excessive system pressures. -
Page 13: Charge Pressure Relief Valve (Cprv)
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Operation Charge Pressure Relief Valve (CPRV) 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. The charge pressure relief valve maintains charge pressure at a designated level above case pressure. -
Page 14: Bypass Function
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Operation Bypass Function The bypass function allows a machine or load to be moved without rotating the pump shaft or prime mover. The single pump HPRV valve also provides a loop bypass function when each of the two HPRV hex plugs are mechanically backed out three full turns. -
Page 15: Electrical Displacement Control (Edc)
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Operation Electrical Displacement Control (EDC) An EDC is a displacement (flow) control. Pump swash plate 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. -
Page 16: Edc Operation
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Operation EDC Operation H1 EDC’s are current driven controls requiring a Pulse Width Modulated (PWM) signal. Pulse width modulation allows more precise control of current to the solenoids. The PWM signal causes the solenoid pin to push against the porting spool, which pressurizes one end of the servo piston, while draining the other. -
Page 17: Manual Override (Mor)
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Operation Manual Override (MOR) All controls are available with a manual override functionality, either as a standard or as an option for temporary actuation of the control to aid in diagnostics. Control with manual override... -
Page 18: Manual Displacement Control (Mdc)
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Operation Manual Displacement Control (MDC) A Manual proportional Displacement Control (MDC) consists of a handle on top of a rotary input shaft. The shaft provides an eccentric connection to a feedback link. This link is connected on its one end with a porting spool. -
Page 19: Mdc Torque
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Operation • Customers must install some support to limit the setting range of their Bowden cable to avoid an overload of the MDC. • Customers can apply their own handle design but they must care about a robust clamping connection between their handle and the control shaft and avoid overload of the shaft. -
Page 20: Case Gauge Port M14
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Operation 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. 20 | ©... -
Page 21: Operating Parameters
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Operating Parameters Input Speed Minimum is the lowest input speed recommended during engine idle condition. Operating below speed minimum speed limits the pump’s ability to maintain adequate flow for lubrication and power transmission. -
Page 22: Servo Pressure
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Operating Parameters Maximum is the highest intermittent pressure allowed under any circumstances. Applications pressure with applied pressures between rated and maximum require factory approval with complete application, duty cycle, and life expectancy analysis. -
Page 23: Case Pressure
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 24: Technical Specifications
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Technical Specifications H1 Pumps General Specification Axial piston closed circuit variable displacement pumps of cradle swash-plate design with clockwise or counterclockwise direction of rotation. Pipe connections • Main pressure ports: ISO split flange boss •... -
Page 25: Fluid Specification
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Technical Specifications Fluid Specification Viscosity 5 mm /s [42 SUS] Intermittent 7 mm /s [49 SUS] Minimum 12 – 80 mm /s [66 – 370 SUS] Recommended range 1600 mm /s [7500 SUS] Maximum Intermittent = Short term t <... -
Page 26: Fluid And Filter Maintenance Recommendations
Replace all fluid lost during filter change. Hydraulic fluid contains hazardous material. Avoid contact with hydraulic fluid. Always dispose of used hydraulic fluid according to state and federal environmental regulations. For further information see Danfoss publication Technical Information, Hydraulic Fluids and Lubricants, BC0000093. 26 | ©... -
Page 27: Filtration System
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Fluid and Filter Maintenance Recommendations Filtration System To prevent premature wear, ensure only clean fluid enters the hydrostatic transmission circuit. A filter capable of controlling the fluid cleanliness to ISO 4406 class 22/18/13 (SAE J1165) or better, under normal operating conditions, is recommended. -
Page 28: Pressure Measurements
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Pressure Measurements Port Locations and Gauge Installation When testing system pressures, calibrate pressure gauges frequently to ensure accuracy. Use snubbers to protect gauges. The drawing and following table show the port locations and gauge sizes needed. -
Page 29: Initial Startup Procedures
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Initial Startup Procedures Unintended Machine Movement Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. Secure the machine or disable/disconnect the mechanism while servicing to protect against unintended movement. - Page 30 Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Initial Startup Procedures 15. Shut off the engine. 16. Connect pump control signal. 17. Start engine, checking to be certain pump remains in neutral. Run engine at normal operating speed and carefully check for forward and reverse control operation.
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Page 31: Troubleshooting
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Troubleshooting This section provides troubleshooting steps to follow if you are having problems with your machine until you solve the problem. Some of the troubleshooting items are system specific. Always observe the safety precautions listed in the Introduction section and precautions related to your specific equipment. -
Page 32: Neutral Difficult Or Impossible To Find
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 33: System Will Not Operate In Either Direction
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 34 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.
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Page 35: Adjustments
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Adjustments This section offers instruction on inspection and adjustment of pump components. Read through the entire topic before beginning a service activity. Refer to Pressure Measurements on page 28 for location of gauge ports and suggested gauge size. -
Page 36: Charge Pressure Relief Valve Adjustments
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Adjustments Charge Pressure Relief Valve Adjustments Operate the system with the pump in neutral (zero displacement), when measuring charge pressure. This procedure explains how to check and adjust the charge pressure relief valve. -
Page 37: Pressure Limiter Adjustment
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Adjustments Pressure Limiter Adjustment Lock motor output shaft to adjust the pressure limiter setting. Lock the vehicle’s brakes or rigidly fix the work function so it cannot rotate. Pressure limiter adjustment System pressure gauge port MB... -
Page 38: Engaging The Bypass Function
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Adjustments 5. Activate the control input until pressure in the high side of the system loop stops rising. This pressure is the PL setting. 6. Return the pump to neutral and adjust the PL setting using an internal hex wrench. - Page 39 Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Adjustments HPRV Wrench Size and Torque Value Frame size Wrench size Torque 045—100 22 mm 70 N•m [52 lbf•ft] If machine is towable with HPRVs opened three turns and if wheels are locked (not towable) with HPRV valves closed, bypass function is working correctly.
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Page 40: Displacement Limiter Adjustment For Single Pumps
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Adjustments Displacement Limiter Adjustment for Single Pumps If your pump has displacement limiters, you will find them on either servo cover. You can limit forward and reverse displacement independently. Displacement limiters are not pre-set by the factory. We install them as far as possible without contacting the servo piston. -
Page 41: Control Neutral Adjustment
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Adjustments Control Neutral Adjustment All functions of the Electric Displacement Control (EDC), are preset at the factory. If necessary, adjust the pump to neutral with the pump running on a test stand or on the vehicle/machine with the prime mover operating. - Page 42 Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Adjustments 6. Rotate the neutral adjusting screw clockwise until the pressure increases on the gauge. Note the angular position of the wrench. 7. Rotate the neutral adjusting screw counterclockwise until the pressure increases by an equal amount on the other gauge.
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Page 43: Mechanical Neutral Adjustment
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Adjustments Mechanical Neutral Adjustment Mechanical neutral is set with the pump running at 1800 min (rpm). To set neutral, you must stroke the pump in each direction. The procedure is the same for each side of each pump for both the front and rear sections. -
Page 44: Pump Setup
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Adjustments Pump Setup The figure below shows the locations of system and gauge ports you use when adjusting the servo neutral postion. System Pressure Gauge Ports Servo pressure Servo pressure Solenoid C1... -
Page 45: Servo Adjustment
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Adjustments Servo Adjustment Servo Adjustment E350 E300 Servo can Servo can locking bolt locking plate P106 490E E300 Servo cylinder clamp E350 Servo cylinder clamp bolt 1. Run prime mover at 1800 min (rpm). -
Page 46: Minor Repair
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair Standard Procedures at Removing Pump Before working on the pump, thoroughly clean the outside. If the pump has an auxiliary pump attached, remove both pumps as a single unit. 1. With the prime mover off, thoroughly clean all dirt and grime from the outside of the pump. -
Page 47: Edc Control Repair
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair EDC Control Repair Control module and solenoid removal/installation D050 (3X) 4 mm 5 N•m [4 lbf•ft] D250 D025A 5 mm 13.5 N•m [10 lbf•ft] D025 D025A D050 (3X) 4 mm D084 5 N•m... -
Page 48: Edc Control Installation
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair EDC Control Installation Inspect the machined surfaces on the control and top of the pump. If you find any nicks or scratches, replace the component. Ensure you install dowel pins (D300) in housing before installing control. -
Page 49: Mdc Control Repair
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair MDC Control Repair MDC with CCO D250 D065 D692 D065 D250 D693 D750 D735 D084 D098 F00T MDC with neutral start switch D250 D065 D150 D200 D300 (2X) F00A F00B... - Page 50 Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair D80 – Solenoid D81 – O-ring D098 – Retaining ring D750 – Neutral start switch D751 – O-ring Wrench size and torque Item Description Wrench size Torque D065 O-ring plug 3/16 internal hex 12 N•m [9 lbf•ft]...
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Page 51: Mdc Control Assembly
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair MDC Control Assembly Ensure you install dowel pins (D300) in housing before installing control. The pump will lose control, causing a potentially hazardous situation. If a feedback pin comes off during operation, ensure the feedback pin is properly torqued before continuing with reassembly. -
Page 52: Angle Sensor On Edc Repair
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair Angle sensor on EDC Repair D767 D770 1. Clean the exterior of the pump to remove debris. 2. Remove protection cover screws (D767) using a 4 mm internal hex wrench. -
Page 53: Edc With Angle Sensor Repair
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair 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. - Page 54 Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair 7. Pull assembly fixture out before installing control screws. Solenoid shaft Control spool Adjusting screw (cam) Feedback pin Maximum adjustment less than 120° Remove plug (D065) and verify the swashplate feedback pin is properly positioned between control feedback arms.
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Page 55: Automotive Control Repair
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair Automotive Control Repair Drain pump completely before removing control. Possible erratic pump operation. Do not allow metal fragments to fall into control housing. Do not fail to install screen. Security wax seal (2X) 13.3 Nm... - Page 56 Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair Caution Do not damage the housing in the plug sealing area. 5. Use a 5 mm internal hex to remove two screws (D674) and remove shield (D672). 6. Use a 5 mm internal hex to remove six screws (D250) and remove control from pump.
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Page 57: Ac Control Installation
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair AC Control Installation Inspect control, pump housing and plastic PC board housing, and its sealing areas. Caution Do not damage the plastic housing in the plug sealing area when installing the screws. -
Page 58: Shaft Seal, Roller Bearing And Shaft Repair
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair Shaft Seal, Roller Bearing and Shaft Repair The shaft assembly is serviceable without disassembling the pump. Orient the pump on the work surface so the shaft is pointing to the side. - Page 59 Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair 15. Press the seal until it is flush within +0.12mm [0.005 in] or -0.72 mm [0.0028 in] of the inside lip of the carrier: see illustration. Positioning seal in seal carrier Press flush to this surface +0.12 mm [ 0.005 in] / -0.72 mm [ 0.028 in]...
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Page 60: Charge Pump Repair
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair Charge Pump Repair If an auxiliary pump is attached, remove auxiliary pump and coupling before servicing charge pump. Position pump with front shaft pointing downward. Attach securely to a proper work stand. - Page 61 Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair 2. Remove and discard gasket (K150). 3. Remove thrust washer (K500). Note thrust washer orientation. 4. Use a small hook to remove pressure balance plate (S200) and seal (S300); discard seal.
- Page 62 Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair Auxilliary pads K350 (see table) K300 K250 K400 8 mm SAE B SAE A E101 533E Cover Screw K350 Aux. Cover Pad Cover Pad A Cover Pad B Wrench size and torque 17 mm 48 N•m [35 lbf•ft]...
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Page 63: High Pressure Relief Valve Repair
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair High Pressure Relief Valve Repair L060 L068 L150 P106 039E see table 1. Using a hex wrench wrench shown in the table below, remove the HPRVs (L150). 2. Inspect the sealing surfaces in the pump for nicks or scratches, check the valves for damage. -
Page 64: Charge Pressure Relief Valve Repair
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair Charge Pressure Relief Valve Repair Caution Replace the charge pressure relief valve (V010) as a complete unit. Do not attempt to repair the internal components of the valve. V024 V010... -
Page 65: Pressure Limiter Repair
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Minor Repair Pressure Limiter Repair Caution Replace the pressure limiter valve (V010) as a complete unit. Do not attempt to repair the internal components of the valve. L300 L400 L022 E101336 1. Using a 22 mm wrench, remove the pressure limiter valve (L100), and discard O-ring. -
Page 66: Torque Chart
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Torque Chart Fasteners and Plugs L200 High pressure relief valve V020 Charge pressure adjusting screw V022 Charge pressure locking nut Charge pressure cartridge K400 Rear cover / auxiliary pad L100 mounting bolt... - Page 67 Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Torque Chart B020 O-ring plug, 1-1/16 - 12 G251 O-ring plug, 9/16 - 18 D250 Electric control mounting bolt G300 O-ring plug, 9/16 - 18 M14 O-ring plug, 7/16 - 20 D015 Neutral adjusting screw...
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Page 68: Fastener Size And Torque Chart
Service Manual H1P 045/053/060/068 Axial Piston Single Pumps Torque Chart Fastener Size and Torque Chart H1P 045/053 and 060/068 Item Fastener Wrench size Torque D015 Neutral adjust screw 4 mm internal hex D050 Coil mounting bolt 4 mm internal hex 8 N•m [9 lbf•ft]... - Page 69 Phone: +86 21 2080 6201 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 subsequent changes being necessary in specifications already agreed.