Danfoss H1F 080 User manual

Service Manual
H1F 080
H1F Bent Axis Fixed Displacement Motor
www.danfoss.com

Revision history Table of revisions
Date Changed Rev
December 2023 Updated title 0102
November 2023 First edition - and next various changes. 0101
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
2 | ©Danfoss | December 2023 AX465363259664en-000102

Introduction H1F About this manual...................................................................................................................................................................5
Warranty.............................................................................................................................................................................................. 5
H1F General instructions............................................................................................................................................................... 5
Safety precautions............................................................................................................................................................................5
H1 general information About the H1F motors....................................................................................................................................................................7
H1F pictorial diagram......................................................................................................................................................................8
H1F system schematic.................................................................................................................................................................... 9
Technical specifications H1F General specifications......................................................................................................................................................... 10
H1F Physical properties............................................................................................................................................................... 10
H1F Operating Parameters.........................................................................................................................................................11
H1F Required inlet pressure table (for cylinder block filling).........................................................................................11
H1F Open circuit requirements.................................................................................................................................................12
Fluid specifications........................................................................................................................................................................13
Determination of nominal motor size....................................................................................................................................13
Operation H1F Shaft rotation direction.......................................................................................................................................................14
H1F Loop flushing shuttle spool...............................................................................................................................................14
H1F loop flushing relief valve....................................................................................................................................................15
Speed sensor................................................................................................................................................................................... 16
H1F speed sensor position....................................................................................................................................................16
H1F Target Ring.........................................................................................................................................................................16
Operating parameters H1F output speed..........................................................................................................................................................................17
H1F system pressure.....................................................................................................................................................................17
Case pressure...................................................................................................................................................................................17
External shaft seal pressure........................................................................................................................................................18
Temperature....................................................................................................................................................................................18
Fluid and filter maintenance Fluid and filter recommendations........................................................................................................................................... 19
Pressure measurements H1F Ports and gage information..............................................................................................................................................20
Initial startup procedures Procedure..........................................................................................................................................................................................21
Troubleshooting Overview........................................................................................................................................................................................... 23
H1F Sluggish operation............................................................................................................................................................... 23
System operating hot...................................................................................................................................................................23
Excessive noise or vibration.......................................................................................................................................................23
Motor operates normally in one direction only..................................................................................................................24
Improper output speed............................................................................................................................................................... 24
H1F Low output Torque.............................................................................................................................................................. 24
Required tools and standard procedures
Minor repair Shaft seal...........................................................................................................................................................................................26
H1F Removal...............................................................................................................................................................................26
H1F Assembly.............................................................................................................................................................................26
Replace speed sensor...................................................................................................................................................................28
H1F Speed Sensor Removal..................................................................................................................................................28
H1F speed sensor reassembly..............................................................................................................................................28
Loop flushing spool.......................................................................................................................................................................29
H1F Loop Flushing Spool Removal.................................................................................................................................... 29
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Contents
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H1F Loop Flushing Reassembly...........................................................................................................................................29
H1F Loop Flushing Charge Relief Removal...........................................................................................................................29
Torque chart H1F Fasteners, plugs with torque chart.................................................................................................................................30
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Contents
4 | ©Danfoss | December 2023 AX465363259664en-000102

H1F About this manual
This manual includes information for the installation, maintenance, and minor repair procedures for H1
bent axis fixed motors. It includes a description of the unit and its individual components,
troubleshooting information, and minor repair procedures.
Performing minor repairs may require removal from the vehicle/machine. Thoroughly clean the unit
before beginning maintenance or repair activities. Since dirt and contamination are the greatest enemies
of any type of hydraulic equipment, follow cleanliness requirements strictly. This is especially important
when changing the system filter and when removing hoses or plumbing.
Only Danfoss global service partners (GSPs) are authorized to perform major repairs.Danfoss trains Global
Service Partners and certifies their facilities on a regular basis. You can locate your nearest service partner
at www.danfoss.com > Contact us > Danfoss sales and services > Distributor and service partners
Warranty
Performing installation, maintenance, and minor repairs according to the procedures in this manual will
not affect your warranty. Major repairs requiring the removal of a unit’s rear cover voids the warranty
unless done by a Danfoss Global Service Partner.
H1F General instructions
When repairing H1 fixed displacement closed circuit motors follow these general procedures:
Remove the
unit
Chock the wheels on the vehicle 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 outside of the
motor and fittings for damage. Cap hoses after removal to prevent contamination.
Keep it clean Cleanliness is a primary means of assuring satisfactory motor life, on either new or
repaired units. Clean the outside of the motor thoroughly before disassembly. Take
care to avoid contamination of the system ports. Cleaning parts with a clean solvent
wash and air drying is usually adequate. Keep all parts free of foreign materials and
chemicals. Protect all exposed sealing surfaces and open cavities from damage and
foreign material.
Lubricate
moving parts
During assembly, coat all moving parts with a film of clean hydraulic oil. This assures
that these parts are lubricated during start-up.
Replace all O-
rings and
gaskets
Danfoss recommends you replace all O-rings and gaskets during repair. Lightly
lubricate O-rings with clean petroleum jelly prior to assembly.
Secure the unit For repair, place the unit in a stable position with the shaft pointing downward.
Secure the motor while removing and torquing components and fasteners.
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
W
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.
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Introduction
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Flammable cleaning solvents
W
Warning
Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area
where a source of ignition may be present.
Fluid under pressure
W
Warning
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious
injury and/or infection. 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 use your hand or any other body part to check for leaks in a pressurized line. Seek
medical attention immediately if you are cut by hydraulic fluid.
Personal safety
W
Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.
Hazardous material
W
Warning
Hydraulic fluid contains hazardous material. Avoid prolonged contact with hydraulic fluid. Always
dispose of used hydraulic fluid according to environmental regulations.
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Introduction
6 | ©Danfoss | December 2023 AX465363259664en-000102

About the H1F motors
Series H1 fixed displacement motors are bent axis design, incorporating spherical pistons.
These motors are designed to be combined with other products in closed or open circuit systems to
transfer hydraulic power.
High performing 32 degree maximum angle, creates opportunities to easily improve the machine
performance for:
•Multi-motor applications requiring optimized work and transport modes (i.e. wheel loader, mobile
crane, drill rigs, winches, harvestors).
SAE, Cartridge and DIN flange with radial or axial high pressure port configurations are available. Loop
flushing is also available with these options.
Speed sensor options are available to cover all frame sizes and flange styles.
They are capable of sensing the following, all in one package:
•Speed
•Direction (Group "J": option "S" and option "B")
•Temperature (Group "J": options "S" and option "B")
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
H1 general information
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H1F pictorial diagram
Working loop A (Low pressure) and charge pressure
Working loop B (High pressure)
Servo pressure
Case drain
Suction
1. Bent Axis Fixed Displacement Motor
2. Axial Piston Variable Displacement Pump
3. Electric 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 Filter
11. Heat Exchanger
12. Heat Exchanger Bypass Valve
13. Pump Swashplate
14. Input Shaft
15. Output Shaft
16. Reservoir
17. to Motor Case
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
H1 general information
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H1F system schematic
System schematic H1 pump and H1F motor
L2 N
A
B
L1
B
R1
R2
M4
M5
M14 M6 1 2
M3 L1 L2 MA
A
C2 C1
S
F00B F00A
L3 L4
CW
MB
max. 3 bar
[43.5 psi]
n
L3
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 fixed displacement motor with integrated loop flushing device.
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
H1 general information
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H1F General specifications
General specifications
Design Piston motor with fixed displacement bent axis design
Direction of rotation Bi-directional
Pipe connections Main pressure ports: ISO split flange boss
Remaining ports: SAE straight thread O-ring boss
Recommended installation Discretionary, the housing must always be filled with hydraulic fluid
H1F Physical properties
Physical properties
Features Unit Size
080
Displacement (max) cm3[in3]80.8 [4.93]
Theoretical flow at max. displ. at rated speed l/min
[US gal/min]
320 [84.5]
at max. speed 400 [105.7]
Theoretical torque
at max. displacement
N•m/bar
[lb•in/1000 psi]
1.27 [777]
Theor. corner power at rated speed and max. working
pressure (∆p = 450 bar [6527 psi]) kW [hp] 330 [442.5]
Mass moment of inertia of rotating components kg•m2
[slug•ft2]
0.006320
[0.00466]
Case volume l [US Gal] 0.8 [.21]
Weight dry
Configuration Size
080
SAE 22.1 kg [48.7 lb]
DIN 22.9 kg [50.5 lb]
Cartridge 23.3 kg [51.4 lb]
Mounting flange
Configuration Size
080
SAE ISO 3019/1 127-4 (SAE C) 4-bolt
DIN ISO 3019/2, B4 140 HL 4-bolt
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Technical specifications
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Customer ports
Configuration Size
080
Axial and radial1) DN25 typ 1
L1, L22) M22x1,5
Bleed port3) M14x1,5
1) Split flange Boss per ISO6162, 40 MPa series
2) Metric O-ring boss
3) Countersink may be deeper that specified in the standard.
H1F Operating Parameters
Output Speed
Output Speed Displacement Unit Size
080
Rated Maximum 32° min-1
(rpm)
4500
Maximum Maximum 32° 5000
System and Case Pressure, Ambient Temperature
Parameter All sizes
System pressure Maximum working delta 450 bar [6527 psi]
Maximum working abs 480 bar [6962 psi]
Max delta 480 bar [6962 psi]
Max abs 510 bar [7397 psi]
Min low loop 7.5 bar [109 psi]
Case pressure Rated 3 bar [44 psi]
Maximum 5 bar [73 psi]
Minimum 0.3 bar [4 psi]
Ambient temperature1) Maximum 70 °C [158 °F]
Minimum -40 °C [-40 °F]
1) Air temperature close to the unit.
H1F Required inlet pressure table (for cylinder block filling)
80cc
Speed (RPM) Pressure (Bar)
900 2
1400 5
2100 10
2800 15
3200 20
4000 30
This pressure ensures that the cylinder block will be properly filled and that there is no pulling between
piston and shaft.
The required pressure is 0 bar at 0 rpm and increases with rpm.
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Technical specifications
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For open circuit applications it is not allowed to operate above rated speed. For closed circuit
applications operating between rated and max. speed, please contact your local Danfoss Power Solutions
representative.
H1F Open circuit requirements
H1 bent axis motors may be used in Open Circuit (OC) applications.
Since loop flushing is typically not used in OC-applications it is essential to provide sufficient cooling
capacity. This can be done by motor case cross flushing. The flow rate needs to be adjusted to the cooling
demand.
The highest case drain outlet port must always be used for the return flow to the cooler or tank.
The motor case and the working lines connected to Port A and B must be kept full of oil at all times,
whether in a dynamic or static condition.
The plumbing must not allow the oil to drain down and be replaced with air in the rotating group.
The minimum pressure in the inlet port and the outlet port, must be equal or higher as shown in the
tables.H1F Required inlet pressure table (for cylinder block filling) on page 11 .
Counter balance valves may be used to maintain the minimum pressure requirements. Danfoss meter-in /
meter-out PVG technology may be used. Check valves and sufficient charge pressure supply are also
possible.
At no time shall the motor be allowed to operate above the rated speed limits. If flow limiter valves are
used, they must be selected accordingly. This ensures proper function under all conditions.
Valve blocks, such as counter balance valves attached to the inlet and/or outlet ports, must not interfere
with any part of the motor. A review of the outline drawings or appropriate 3D models must be
completed.
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Technical specifications
12 | ©Danfoss | December 2023 AX465363259664en-000102

Fluid specifications
Fluid specifications
Features Unit All sizes
Viscosity
Minimum intermittent
mm2/s
[SUS]
7 [49]
Recommended range 12-80 [66-366]
Maximum intermittent 1600 [7416]
Temperature range1)2)
Minimum
°C
[°F]
-40 [-40]
Rated 104 [220]
Maximum intermittent 115 [240]
Cleanliness and Filtration
Required cleanliness per ISO 4406 -22/18/13
Efficiency (charge pressure filtration) β-ratio β15-20 = 75 (β10 ≥ 10)
Efficiency (suction / return line filtration) β35-45 = 75 (β10 ≥ 2)
Recommended inlet screen mesh size µm 100 – 125
1) At the hottest point, normally case drain port.
2) Minimum: cold start, short term t<3 min, p<50 bar, n<1000 rpm.
Determination of nominal motor size
Based on SI units Based on US units
Vg• n
1000 • v
Qe=
Vg• p • mh
20 •
Me=
Qe• p • t
600
=
Me• n
9550
P
e=
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:
QeInput flow (l/min)
MeOutput torque (N•m)
PeOutput power (kW)
nSpeed (min-1)
VgMotor displacement per rev. (cm3/rev)
phigh High pressure (bar)
plow Low pressure (bar)
∆p High pressure minus Low pressure (bar)
ηvMotor volumetric efficiency
ηmh Mechanical-hydraulic efficiency
ηtMotor total efficiency (ηv• ηmh)
Where:
QeInput flow [US gal/min]
MeOutput torque [lb•in]
PeOutput power [hp]
nSpeed [rpm]
VgMotor displacement per rev. [in3/rev]
phigh High pressure [psi]
plow Low pressure [psi]
∆p High pressure minus Low pressure [psi]
ηvMotor volumetric efficiency
ηmh Mechanical-hydraulic efficiency
ηtMotor total efficiency (ηv• ηmh)
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Technical specifications
©Danfoss | December 2023 AX465363259664en-000102 | 13

H1F Shaft rotation direction
Shaft rotation direction is determined with a view from the shaft end.
CCW CW
Flow into port A Clockwise
Flow into port B Counterclockwise
H1F Loop flushing shuttle spool
An integral loop flushing shuttle spool is used to separate system A and system B pressures.
System delta pressure will cause the shuttle spool to shift, allowing the low side system pressure to flow
to the loop flushing relief valve.
Legend:
ASystem loop A
BSystem 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 build required system pressure in some
conditions. Maintain correct charge pressure under all conditions of operation to maintain pump control
performance in hydrostatic systems.
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Operation
14 | ©Danfoss | December 2023 AX465363259664en-000102

H1F loop flushing relief valve
The loop flushing relief valve is incorporated into all H1 motors used in closed circuit applications to
remove fluid from the low pressure side of the system circuit to meet cooling requirements.
The loop flushing relief valve is also used to facilitate the removal of contaminants from the loop.
The loop flushing valve is equipped with an orificed charge 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.
A loop flushing defeat option is available.
Loop flushing relief valve (cross section)
P003 491
Loop flushing relief valve schematic
P003 487
A
B
L2
Loop flushing relief valve sizes
40 bar
30 bar
20 bar
10 bar
10 15 20 30 40
50
5
10 20 30 40 50 60
P006 034
0 X
Y
XLoop flushing flow (l/min)
YLow system pressure minus case pressure (bar)
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Operation
©Danfoss | December 2023 AX465363259664en-000102 | 15

Speed sensor
The speed sensor is designed for rugged outdoor, mobile or heavy industrial speed sensing applications.
The detection of the speed is contactless and does not need any calibration or adjustments.
For more information, see Speed and Temperature Sensor, Technical Information, BC152886482203.
H1F speed sensor position
Sensor position in cartridge housing
Cartridge housing
H1F Target Ring
Speed (target) rings vary according to the diameter of the cylinder block or shaft on which they are
installed. The number of teeth is shown in the table below.
The number of speed (target) ring teeth
H1F size 080
Teeth 78
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Operation
16 | ©Danfoss | December 2023 AX465363259664en-000102

H1F output speed
Start and low speed stability. The motor produces maximum starting torque at maximum
displacement. Stable operation can be achieved at 15–34 rpm, ± 5 %, depending on system pressure, in
applications that require low speed stability. Motor output speed becomes more stable as speed
increases.
Rated speed is the highest output speed recommended at full power condition. Operating at, or below
this speed will yield satisfactory product life. Do not exceed rated speed in open circuit applications.
Maximum speed is the highest operating speed permitted. Exceeding maximum speed reduces the
product life and can cause loss of hydrostatic power and dynamic braking capacity. Never exceed the
maximum speed limit under any operating conditions.
Operation between rated and maximum speed is reserved for intermittent operation (seeH1F Operating
Parameters on page 11 ) not to exceed 10 minutes durations, 2% of duty cycle based load-life, and 310
bar system delta pressure. Speed above rated are anticipated to occur during downhill braking (negative
power). Contact factory for any operation above Rated speed when negative power is not involved.
During hydraulic braking and downhill conditions, the prime mover must be capable of providing
sufficient braking torque in order to avoid pump over speed. This is especially important to consider for
turbocharged and Tier 4 engines.
W
Warning
Unintended vehicle or machine movement hazard.
Exceeding maximum speed may cause a loss of hydrostatic drive line power and braking capacity. You
must provide a braking system, redundant to the hydrostatic transmission, sufficient to stop and hold the
vehicle or machine in the event of hydrostatic drive power loss. The braking system must also be
sufficient to hold the machine in place when full power is applied.
H1F system pressure
System pressure is the differential pressure between high pressure system ports. It is the dominant
operating variable affecting hydraulic unit life. High system pressure, which results from high load,
reduces expected life. Hydraulic unit life depends on the speed and normal operating, or weighted
average, pressure that can only be determined from a duty cycle analysis.
Application pressure is the high pressure relief or pressure limiter setting normally defined within the
order code of the pump. This is the applied system pressure at which the driveline generates the
maximum calculated pull or torque in the application.
Maximum working pressure is the highest recommended application pressure. Maximum working
pressure is not intended to be a continuous pressure. Propel systems with application pressures at, or
below, this pressure should yield satisfactory unit life given proper component sizing.
Maximum pressure is the highest allowable application pressure under any circumstance. For
applications which are above the maximum working pressure, please contact Danfoss
Minimum pressure must be maintained under all operating conditions to avoid cavitation.
All pressure limits are differential pressures referenced to low loop (charge) pressure. Subtract the low
loop gauge pressure from the high loop gauge pressure readings to compute the differential.
Summing pressure is the sum of both the low and high loop pressures. Summing pressure above 30 bar
[435 psi] guarantees reliable use within the rated speed.
Case pressure
Under normal operating conditions, the rated case pressure must not be exceeded. During cold start,
case pressure must be kept below maximum intermittent case pressure. Size drain plumbing accordingly.
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Operating parameters
©Danfoss | December 2023 AX465363259664en-000102 | 17

C
Caution
Possible component damage or leakage.
Operation with case pressure in excess of stated limits may damage seals, gaskets, speed sensors and/or
housings, causing external leakage. Performance may also be affected since charge and system pressures
are referenced to case pressure.
External shaft seal pressure
In certain applications, the output shaft seal may be exposed to external pressures. The shaft seal is
designed to withstand an external pressure up to 0.25 bar [3.6 psi] above the case pressure. The case
pressure limits must also be followed 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 be run at or below the published rated temperature.
The maximum intermittent temperature is based on material properties and should never be
exceeded.
Cold oil will generally not affect the durability of the transmission components, but it may affect the
ability of oil to flow and transmit power. Therefore, temperatures should remain 16 °C [30 °F] above the
pour point of the hydraulic fluid.
The minimum temperature relates to the physical properties of component materials.
Size heat exchangers too keep the fluid within these limits. Danfoss recommends testing to verify that
these temperature limits are not exceeded.
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Operating parameters
18 | ©Danfoss | December 2023 AX465363259664en-000102

Fluid and filter recommendations
To ensure optimum life, perform regular maintenance of the fluid and filter. Contaminated fluid is the
main cause of unit failure. Take care to maintain fluid cleanliness when servicing.
Check the reservoir daily for proper fluid level, the presence of water, and rancid fluid odor. Fluid
contaminated by water may appear cloudy or milky or free water may settle in the bottom of the
reservoir. Rancid odor indicates the fluid has been exposed to excessive heat. Change the fluid
immediately if these conditions occur. Correct the problem immediately.
Inspect vehicle for leaks daily.
Change the fluid and filter per the vehicle/machine manufacturer’s recommendations or at these
intervals. We recommend first 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 levels greater than the recommended maximum.
Fluid and filter change interval
Reservoir type Max oil change interval
Sealed 2000 hours
Breather 500 hours
C
Caution
High temperatures and pressures accelerate fluid aging. This may require more frequent fluid changes.
Change filters when changing fluid or when the filter indicator directs. Replace all fluid lost during filter
change
W
Warning
Hydraulic fluid contains hazardous material. Avoid contact with hydraulic fluid. Always dispose of used
hydraulic fluid according to state, and federal environmental regulations. Never reuse hydraulic fluid.
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Fluid and filter maintenance
©Danfoss | December 2023 AX465363259664en-000102 | 19

H1F Ports and gage information
The following drawing with accompanying table show the port locations and gauge sizes needed for
installation.
Ports locations (proportional control)
Axial Ported Endcap
Radial Ported Endcap
System split flange boss ports, A/B: Code 62 per ISO 6162, Type 1
Port Size 080
A, B 1 in; Thread: M12 x 1.75
min. 24 mm [0.94 in]
Ports and gauge Information
Port Size 080 Pressure obtained
L1, L2 M22 x 1.5
Wrench (int. hex): 17 mm
10 bar [145 psi]
Case drain
L3 M14 x 1.5
Wrench (int. hex): 12 mm
Service Manual
H1F Bent Axis Fixed Displacement Motors, Size 080
Pressure measurements
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