Danfoss H1P 280 Service Manual
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Danfoss H1P 280 Service Manual

Axial piston single pumps
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Service Manual
H1P 069—H1P 280
Axial Piston Single Pumps
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Summary of Contents for Danfoss H1P 280

  • Page 1 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps www.danfoss.com...
  • Page 2 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Revision history Table of revisions Date Changed December 2021 Added HDC control 0701 January 2021 Added 280 frame size content 0601 September 2020 Changed document number from 'AX00000087' to 'AX152886482551' and...

  • Page 3: Table Of Contents

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Contents Introduction Hydrostatics Servicing Overview..............................5 General Servicing Instructions..............................5 Safety Precautions....................................6 General description of H1 family hydrostatic pumps......................7 Design........................................7 H1 Single Pumps Closed Circuit Pictorial Diagram......................9 H1 system schematic..................................9 Operation Pressure Limiter Valves................................
  • Page 4 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Contents Neutral Difficult or Impossible to Find........................... 32 Transmission Operates Normally in One Direction Only....................32 System Operating Hot..................................32 System Will Not Operate in Either Direction........................33 System Noise or Vibration................................33 Sluggish System Response................................. 33 Adjustments Standard Procedures..................................

  • 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 069—H1P 280 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: General Description Of H1 Family Hydrostatic Pumps

    The flow rate is proportional to the pump input speed and displacement. The latter is infinitely adjustable between zero and maximum displacement. H1 pumps can be used together in combination with other Danfoss pumps and motors in the overall hydraulic system.
  • Page 8 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Introduction feedback pins allows for very precise displacement control and increases overall system stability. Non- feedback control options do not use the mechanical feedback link. Cross section view Servo piston Electric displacement control Auxiliary mounting pad “B”...

  • Page 9: H1 Single Pumps Closed Circuit Pictorial Diagram

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Introduction H1 Single Pumps Closed Circuit Pictorial Diagram Heat Exchanger Bypass Valve System Pressure Reservoir Displacement Control Servo Pressure Charge/Low Loop Pressure Heat Exchanger Suction/Case Drain/ System Return Charge Pump Bent Axis Variable...
  • Page 10 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Introduction 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 069—H1P 280 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: Hprv/Charge Check Valve Sectional View

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Operation The system pressure shown in the order code for pumps with pressure limiter and HPRV is a reflection of the pressure limiter setting: 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.

  • Page 13: System Schematic For Single Pump

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Operation sides of the working loop to the common charge gallery. The bypass function allows you to move a machine or load without rotating the pump shaft or prime mover. Caution The HPRV valves are not tow valves.

  • Page 14: Edc Operation

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Operation Electrical Displacement Control EDC schematic, feedback from swash plate F00B F00A Feedback from Swash plate P003 478E P003 191 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.

  • Page 15: Hydraulic Displacement Control (Hdc)

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Operation Hydraulic Displacement Control (HDC) HDC principle An HDC is a Hydraulic Displacement Control. Pump swashplate position is proportional to the input command and therefore vehicle speed or load speed (excluding influence of efficiency), is dependent only on the prime mover speed or motor displacement.
  • Page 16 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Operation The HDC incorporates a positive neutral dead band as a result of the control spool porting, preloads from the servo piston assembly, and the linear control spring. Once the neutral threshold point is reached, the swashplate is positioned directly proportional to the control pressure.

  • Page 17: Manual Override (Mor)

    Service Manual H1P 069—H1P 280 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.

  • Page 18: Mdc Operation

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Operation Under some circumstances, such as contamination, the control spool could stick and cause the pump to stay at some displacement. For the MDC with CCO option the brake port (X7) provides charge pressure when the coil is energized to activate static function such as a brake release.

  • Page 19: Mdc Torque

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Operation MDC Torque Description Value Torque required to move handle to maximum displacement 1.4 N•m [12.39 lbf•in ] Torque required to hold handle at given displacement 0.6 N•m [5.31 lbf•in] Maximum allowable input torque 20 N•m [177 lbf•in]...

  • Page 20: Operating Parameters

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Operating Parameters Input Speed is the lowest input speed recommended during engine idle condition. Operating below Minimum minimum speed limits the pump’s ability to maintain adequate flow for lubrication and speed power transmission.

  • Page 21: Servo Pressure

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Operating Parameters Servo Pressure Servo pressure is the pressure in the servo system 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.

  • Page 22: External Shaft Seal 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 23: Technical Specifications

    Service Manual H1P 069—H1P 280 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 24: Fluid Specification

    Service Manual H1P 069—H1P 280 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 25: Fluid And Filter Maintenance Recommendations

    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. 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 26 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Fluid and Filter Maintenance Recommendations Because each system is unique, only a thorough testing and evaluation program can fully validate the filtration system. Please see Design Guidelines for Hydraulic Fluid Cleanliness Technical Information, BC152886482150 for more information.

  • Page 27: Pressure Measurements

    Service Manual H1P 069—H1P 280 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 28 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Pressure Measurements Port Information System ports A/B Port size Frame size 069/078 089/100 115/130 147/165 210/250/280 24.5 mm 24.5 mm 31.5 mm 31.5 mm 38 mm M12 x 1.75 M12 x 1.75 M12 x 1.75...

  • Page 29: Initial Startup Procedures

    Service Manual H1P 069—H1P 280 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 069—H1P 280 Axial Piston Single Pumps Initial Startup Procedures 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.

  • Page 31: Troubleshooting

    Service Manual H1P 069—H1P 280 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

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Troubleshooting System Will Not Operate in Either Direction Item Description Action Oil level in reservoir. Insufficient hydraulic fluid to supply system loop. Fill reservoir to proper level. Pump control orifices Control orifices are blocked.
  • Page 34 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Troubleshooting Item Description Action Low prime mover speed Low engine speed reduces system performance. Adjust engine speed. Charge pressure Incorrect pressure affects system performance. Measure and adjust charge pressure relief or replace charge pump.

  • Page 35: Adjustments

    Service Manual H1P 069—H1P 280 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 on page 27 for location of gauge ports and suggested gauge size.

  • Page 36: Pressure Limiter Adjustment

    Pumps with only HPRV valves no longer contain pressure limiter screens and retainers. To convert such pumps to those with pressure limiter valves, please contact your Danfoss service partner. H1P Base Models with pressure setting option B include PL screens and retainers.
  • Page 37 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Adjustments Clockwise and counter clockwise rotation Clockwise rotation Counterclockwise rotation Pressure limiter valves Pressure limiter valves Controls Controls Controls Controls Port A Port B Port B Port A Port B Port B...

  • Page 38: Engaging The Bypass Function

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Adjustments 9. After adjustment, torque the lock nut (L024) to 20 N·m [15 lbf·ft]. Caution Do not over torque. 10. Shut down the prime mover. 11. Remove gauges and replace plugs.

  • Page 39: Control Neutral Adjustment

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Adjustments Displacement Limiter Adjustment Limiting Screw (see table) Locknut (see table) P104 469E 1. Loosen the locknut. 2. Rotate the adjusting screw to achieve the desired maximum displacement. 3. Set the adjusting screw against the servo piston by feel before counting turns.
  • Page 40 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Adjustments Control neutral adjustment Neutral adjusting screw 4 mm Servo pressure gauge port M4 0 - 50 bar [0 - 1000 psi] Locknut 3/16 in 13 mm 19 N•m [14 lbf•ft] 10 N•m...

  • Page 41: Mechanical Neutral Adjustment

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Adjustments 7. Rotate the neutral adjusting screw counterclockwise until the pressure increases by an equal amount on the other gauge. Note the angular position of the wrench. 8. Rotate the neutral adjusting screw clockwise half the distance between the wrench positions noted above.
  • Page 42 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Adjustments System Pressure Gauge Ports Servo pressure Servo pressure Solenoid C1 port M4 port M5 System Port B Gauge port MB Gauge port MA System Port A Solenoid C2 system pressure...
  • Page 43 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Adjustments Servo Adjustment Servo Adjustment E350 E300 Servo can Servo can locking bolt locking plate P106 490E Servo cylinder clamp E300 Servo cylinder clamp bolt E350 1. Run prime mover at 1800 min (rpm).

  • Page 44: Minor Repair

    Service Manual H1P 069—H1P 280 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.
  • Page 45 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair 1. Using 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 orifices (F100) using a 3 mm internal hex wrench.

  • Page 46: Control Solenoids Repair

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair 5. Install solenoid with three cap screws (D050) using a 4 mm internal hex wrench and torque screws to 5 N•m [4 lbf•ft]. 6. Install coil using a 12 point 27 mm socket and torque coil nut to 5 N•m [3.7 lbf•ft].

  • Page 47: Mdc Control Repair

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair MDC Control Repair 1. Using a 5 mm internal hex wrench, remove the siz cap screws (D250). 2. Remove the control module and gasket (D150) and discard the gasket.
  • Page 48 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair MDC illustration - single pumps 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)
  • Page 49 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair MDC Legend - single pumps Wrench size and torque Item Description Wrench size Torque D065 O-ring plug 3/16 internal hex 12 N•m [9 lbf•ft] D084 Screen D098 Ring D200...

  • Page 50: Angle Sensor On Edc Repair

    Service Manual H1P 069—H1P 280 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 51: Edc With Angle Sensor Repair

    Service Manual H1P 069—H1P 280 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 52: Automotive Control Repair

    Service Manual H1P 069—H1P 280 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.
  • Page 53 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair 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 1.
  • Page 54 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair 7. Remove and discard gasket (D150). Alignment pins are pressed into control. Do not remove them. 8. If necessary, remove orifices (F00A, F00B) using a 3 mm internal hex.
  • Page 55 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair 6. Using a 5 mm internal hex wrench, torque the cap screws (D250) to 13.3 N•m [9.8 lbf•ft]. Torque sequence 7. Connect wiring (D640). 8. Install new plastic plugs with O-rings (D610) using the special tool, press plugs in and turn 45 degrees clockwise.

  • Page 56: Shaft, Seal And Bearing Repair

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair Shaft, Seal and Bearing Repair The input shaft, seal and front bearing are serviceable without disassembling the entire pump. Orient the pump on the work surface so the shaft is pointing up.
  • Page 57 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair Shaft, Bearing Installation J150 J300 J150 Protective cover J100 J250 J200 J200 Seal installation tool J220 P106038 1. Inspect the shaft journals for wear, scratching, and pits. 2. Check the splines for fretting; replace if damaged.

  • Page 58: External Filter Repair

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair 11. Remove the protective cover. Seal Installation Tool 89.4 mm 89.4 mm 57.5 mm 44.7 mm [3.52 in] [3.52 in] [2.26 in] [1.76 in] 7 mm 68.5 mm [0.276 in] [2.70 in]...

  • Page 59: Filter Bypass Valve And Switch Repair

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair Filter Bypass Valve and Switch Repair T025 6 mm 16-20 N•m [12 - 15 lbf•ft] T350 T040 T030 T010 T020 T300 3 mm T250 1.5 N•m [1 lbf•ft] 32 N•m T040 [24 lbf•ft]...

  • Page 60: Charge Pump Repair (Integrated Auxiliary Pad)

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair Charge Pump Repair (removable auxiliary pad) S200 S300 S300 S250 S100 K400 10 mm S150 92 Nm [68 ft•lb] P106 036E K200 K500 K150 G450 K400 K100 K100 10 mm 92 Nm [68 ft•lb]...
  • Page 61 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair Charge Pump Repair (integrated auxiliary pad) S200 S300 S300 K450 6 mm S250 10 Nm [7 ft•lb] S100 K550 S150 P106 353E K200 K500 K250 1. Remove auxilliary pump and O-ring (K250), and discard O-ring.

  • Page 62: High Pressure Relief Valve Repair

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair 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). 8. Install the auxiliary pad or charge pump cover and cap screws.

  • Page 63: Charge Pressure Relief Valve Repair

    Pumps with only HPRV valves no longer contain pressure limiter screens and retainers. To convert such pumps to those with pressure limiter valves, please contact your Danfoss service partner. H1P Base Models with pressure setting option B include PL screens and retainers.
  • Page 64 Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Minor Repair L300 L400 L022 E101336 1. Using a 22 mm or 24 mm wrench, remove the pressure limiter valve (L100), and discard the O-ring. 2. Inspect the sealing surfaces of the pump for nicks or scratches.

  • Page 65: Torque Chart

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Torque Chart Fasteners and Plugs L150 High pressure relief valve V020 Charge pressure adjusting screw V022 Charge pressure locking nut K400 Rear cover / auxiliary pad mounting bolt V010 Charge pressure...

  • Page 66: Fastener Size And Torque Chart

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Torque Chart B015 O-ring plug, 7/16 - 20 D015 Neutral adjusting screw L010 Pressure limiter adjusting screw D060 Neutral adjust locking nut L024 Pressure limiter locking nut L028 Pressure limiter plug (special)

  • Page 67: Plug Size And Torque Chart

    Service Manual H1P 069—H1P 280 Axial Piston Single Pumps Torque Chart Plug Size and Torque Chart Item B020 Frame size 069/078 147/165 210/250/280 O-ring plug 7/8–14 1-1/16–12 1-5/16–12 Wrench size 3/8 internal hex 9/16 internal hex 5/8 internal hex Torque 70 N•m [52 lbf•ft]...
  • Page 68 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.

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