Danfoss H1P 045 User manual

Service Manual
H1P 045/053/060/068
Axial Piston Single Pumps
www.danfoss.com

Revision history Table of revisions
Date Changed Rev
June 2020 Changed document number from 'AX00000104' to 'AX152886481964' and added
caution note to start-up procedures
0405
November 2018 Major layout update. 0401
April 2018 add EDC with angle sensor 0303
March 2010 Fix Osaka address AC
Nov. 2008 - Sep 2014 Various changes. AB-CB
Jun 2007 First edition AA
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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.......................................................................................................................................... 11
High Pressure Relief Valve (HPRV) and Charge Check Valve..........................................................................................12
HPRV/Charge Check Valve Sectional View......................................................................................................................12
Charge Pressure Relief Valve (CPRV)....................................................................................................................................... 13
Bypass Function..............................................................................................................................................................................14
System Schematic for Single Pump................................................................................................................................... 14
Electrical Displacement Control (EDC)...................................................................................................................................15
EDC Operation...........................................................................................................................................................................16
Manual Override (MOR)............................................................................................................................................................... 17
Manual Displacement Control (MDC) ....................................................................................................................................18
MDC Operation..........................................................................................................................................................................18
MDC Torque................................................................................................................................................................................19
Neutral Start Switch (NSS)..................................................................................................................................................... 19
Case Gauge Port M14..............................................................................................................................................................20
Operating Parameters Input Speed......................................................................................................................................................................................21
System Pressure..............................................................................................................................................................................21
Servo Pressure.................................................................................................................................................................................22
Charge Pressure..............................................................................................................................................................................22
Charge Pump Inlet Pressure.......................................................................................................................................................22
Case Pressure...................................................................................................................................................................................23
External Shaft Seal Pressure.......................................................................................................................................................23
Temperature....................................................................................................................................................................................23
Viscosity.............................................................................................................................................................................................23
Technical Specifications H1 Pumps General Specification..............................................................................................................................................24
H1 Pumps Physical Properties ..................................................................................................................................................24
Fluid Specification......................................................................................................................................................................... 25
Fluid and Filter Maintenance Recommendations
Filtration System.............................................................................................................................................................................27
Pressure Measurements Port Locations and Gauge Installation...................................................................................................................................28
H1P Ports Information.............................................................................................................................................................28
Initial Startup Procedures Unintended Machine Movement.............................................................................................................................................29
Start-Up Procedure........................................................................................................................................................................29
Troubleshooting High Inlet Vacuum.........................................................................................................................................................................31
Unintended Machine Movement....................................................................................................................................... 31
Fluid Under Pressure............................................................................................................................................................... 31
Electrical Troubleshooting..........................................................................................................................................................31
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
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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
Mechanical Neutral Adjustment...............................................................................................................................................43
Pump Setup......................................................................................................................................................................................44
Servo Adjustment.......................................................................................................................................................................... 45
Minor Repair Standard Procedures at Removing Pump.............................................................................................................................46
EDC Control Repair........................................................................................................................................................................47
EDC Control Installation.........................................................................................................................................................48
Control Solenoids Repair.............................................................................................................................................................48
MDC Control Repair.......................................................................................................................................................................49
MDC Control Assembly...........................................................................................................................................................51
Angle sensor on EDC Repair.......................................................................................................................................................52
EDC with Angle Sensor Repair...................................................................................................................................................53
Automotive Control Repair........................................................................................................................................................ 55
AC Control Installation............................................................................................................................................................57
Shaft Seal, Roller Bearing and Shaft Repair...........................................................................................................................58
Charge Pump Repair.....................................................................................................................................................................60
High Pressure Relief Valve Repair.............................................................................................................................................63
Charge Pressure Relief Valve Repair........................................................................................................................................64
Pressure Limiter Repair................................................................................................................................................................ 65
Torque Chart Fasteners and Plugs...................................................................................................................................................................... 66
Fastener Size and Torque Chart................................................................................................................................................68
Plug Size and Torque Chart........................................................................................................................................................68
Service Manual
H1P 045/053/060/068 Axial Piston Single Pumps
Contents
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Hydrostatics Servicing Overview
This manual includes information on installation, maintenance, and minor repair of the . It includes a
description of the unit and its individual components, troubleshooting information, and minor repair
procedures.
Performing minor repairs may require the unit to be removed 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.
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.
For detailed technical information about the , please see the relevant technical information document.
Attention
Major repairs requiring the removal of a unit’s center section, servo sleeves, or front flange voids the
warranty unless a Danfoss Authorized Service Center performs them.
General Servicing Instructions
Follow these general procedures when repairing this product:
Icon Description Instructions
Remove the unit
•If necessary, remove the unit from the vehicle/machine.
•Chock the wheels on the vehicle or lock the mechanism to inhibit movement.
•Be aware that hydraulic fluid may be under high pressure and/or hot.
•Inspect the outside of the pump and fittings for damage.
•Cap hoses after removal to prevent contamination.
Keep it clean
•Cleanliness is a primary means of assuring satisfactory pump life, on either
new or repaired units.
•Clean the outside of the pump thoroughly before disassembly.
•Take care to avoid contamination of the system ports.
•Cleaning parts by using a clean solvent wash and air drying is usually
adequate.
•As with any precision equipment, keep all parts free of foreign materials and
chemicals.
•Protect all exposed sealing surfaces and open cavities from damage and
foreign material.
•If left unattended, cover the pump with a protective layer of plastic.
Replace O-ring,
gasket •Danfoss recommends that you replace all O-rings, seals and gaskets.
•Lightly lubricate all 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.
•It will be necessary to secure the pump while removing and torquing end
covers, controls, and valves.
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Introduction
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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.
Secure the machine or disable/disconnect the mechanism while servicing to protect against unintended
movement.
Independent Braking System
Unintended vehicle or machine movement hazard. Exceeding maximum speed may cause a loss of
hydrostatic drive line power and braking capacity.
Machine manufacturer is responsible to 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.
High Inlet Vacuum
High inlet vacuum causes cavitation which can damage internal pump components.
Manufacturer’s Warranty
Contamination can damage internal components and void the manufacturer’s warranty.
Take precautions to ensure system cleanliness when removing and installing system lines.
Fluid Under Pressure
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.
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. Use caution when dealing with
hydraulic fluid under pressure. Seek medical attention immediately if you are cut by hydraulic fluid.
Flammable Cleaning Solvents
Some cleaning solvents are flammable.
Do not use cleaning solvents in an area where a source of ignition may be present to avoid possible fire.
Personal Safety
Protect yourself from injury whenever servicing a hydraulic system.
Use proper safety equipment, including safety glasses, at all times.
Hazardous Material
Hydraulic fluid contains hazardous material.
Avoid prolonged contact with hydraulic fluid. Always dispose of used hydraulic fluid according to state,
and federal environmental regulations.
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Introduction
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Symbols used in Danfoss literature
WARNING may result in injury Tip, helpful suggestion
CAUTION may result in damage to product or
property Lubricate with hydraulic fluid
Reusable part Apply grease / petroleum jelly
Non-reusable part, use a new part Apply locking compound
Non-removable item Inspect for wear or damage
Option - either part may exist Clean area or part
Superseded - parts are not interchangeable Be careful not to scratch or damage
Measurement required Note correct orientation
Flatness specification Mark orientation for reinstallation
Parallelism specification Torque specification
External hex head Press in - press fit
Internal hex head Pull out with tool – press fit
Torx head Cover splines with installation sleeve
O-ring boss port Pressure measurement/gauge location or
specification
The symbols above appear in the illustrations and text of this manual. They are intended to communicate
helpful information at the point where it is most useful to the reader. In most instances, the appearance
of the symbol itself denotes its meaning. The legend above defines each symbol and explains its purpose.
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Introduction
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Design
The H1 axial piston variable displacement pumps are of cradle swashplate design and are intended for
closed circuit applications.
The flow rate is proportional to the pump input speed and displacement.
The latter is infinitely adjustable between zero and maximum displacement.
Flow direction is reversed by tilting the swashplate to the opposite side of the neutral (zero
displacement) position.
The H1 family of closed circuit variable displacement axial piston pumps is designed for use with all
existing Danfoss hydraulic motors for the control and transfer of hydraulic power. H1 pumps are compact
and high power density where all units utilize an integral electro-hydraulic servo piston assembly that
controls the rate (speed) and direction of the hydraulic flow. H1 pumps are specifically compatible with
the Danfoss family of PLUS+1™microcontrollers for easy Plug-and-Perform™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.
Cross section view
Slipper
Piston
Cylinder block
Swashplat e
Shaft
Shaft seal
Electric displacement control Servo piston
Valve plate
Swashplate feedback pin
Swashplate bearing
P106 337E
Front bearing
Rear bearing
Charge Pump
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Introduction
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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.
In pumping mode the position of the pump swashplate determines which line is high pressure as well as
the direction of fluid flow.
Case Drain and Heat Exchanger
The pump and motor require case drain lines to remove hot fluid from the system. The pump and motor
drain from the topmost port to ensure the cases remain full of fluid.
The motor case drain can connect to the lower drain port on the pump housing or it can tee into the case
drain line upstream of the heat exchanger. A heat exchanger with bypass valve cools the case drain fluid
before it returns to the reservoir.
H1 Single Pumps Closed Circuit Pictorial Diagram
P104 464E
Charge
Pressure
Relief
Valve
Loop
Flushing
Valve
To Pump
Case
To
Motor
Case
Servo Control
Cylinder
Variable
Displacement
Pump
Input
Shaft
Pump Swashplate
Pressure
Limiter
Valve
Charge Check/High Pressure Relief Valve
Synchronizing
Shaft
Output
Shaft
Motor Swashplate
Bent Axis Variable
Displacement Motor
System Pressure
Servo Pressure
Charge/Low Loop Pressure
Suction/Case Drain/
System Return
Charge Filter
Charge Pump
Reservoir
Heat Exchanger
Bypass Valve
Displacement Control
Heat Exchanger
Charge Check/
High Pressure Relief Valve
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Introduction
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H1 system schematic
System schematic H1 pump and H1 motor with EDC
P003 424
min.max.
L2 NMA
A
B
M5 MB M4
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
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.
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Introduction
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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.
Each side of the transmission loop has a dedicated pressure limiter valve that is set independently. A
pump configured with pressure limiter must have pressure limiters on both sides of the system pressure
loop. The pump order code allows for different pressure settings to be used at each system port.
The pressure limiter setting is the maximum differential pressure between the high and low loops. When
the pressure limiter setting is reached, the valve ports oil to the low-pressure side of the servo piston. The
change in servo differential pressure rapidly reduces pump displacement. Fluid flow from the valve
continues until the resulting drop in pump displacement causes system pressure to fall below the
pressure limiter setting.
An active pressure limiter destrokes a pump to near neutral when the load is in a stalled condition. The
pump swash-plate moves in either direction necessary to regulate the system pressure, including into
stroke (overrunning) or over-center (winch payout).
The pressure limiter is optional on H1 pumps (except H1T 045/053 tandem pumps).
Pressure Limiter Sectional View
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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. The charge check function replenishes the low pressure side of the working loop with
charge oil.
Each side of the transmission loop has a dedicated HPRV valve that is non-adjustable with a factory set
pressure. When system pressure exceeds the factory setting of the valve, oil is passed from the high
pressure system loop, into the charge gallery, and into the low pressure system loop via the charge
check.
The pump may have different pressure settings to be used at each system port. When an HPRV valve is
used in conjunction with a pressure limiter, the HPRV valve is always factory set above the setting of the
pressure limiter. The system pressure shown in the order code for pumps with only HPRV is the HPRV
setting.
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. Consult factory for application review.
Excessive operation of the HPRV will generate heat in the closed loop and may cause damage to the
internal components of the pump.
HPRV/Charge Check Valve Sectional View
HPRV and Charge Check Valve with Bypass Function (except 045/053)
Relief mode
P003 268
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Operation
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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.
This level is nominally set with the pump running at 1800 min-1(rpm), and with a fluid viscosity of 32
mm²/s [150 SUS]. In forward or reverse, charge pressure will be slightly lower than in neutral position. The
model code of the pump specifies the charge pressure relief valve setting. Typical charge pressure
increase from 1.2-1.5 bar per 10 l/min [17.4-21.8 psi per 2.64 US gal/min]. For external charge flow the
CPRV is set according to the table below:
CPRV flow setting for external charge supply
Tandem 045/053 Single 045/053 Single 060—165 Single 210/250
30 l/min [7.9 US gal/min] 15 l/min [3.9 US gal/min] 22.7 l/min [6.0 US gal/min] 40.0 l/min [10.6 US gal/min]
Charge pressure relief valve
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Operation
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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.
Engaging the bypass function mechanically connects both A & B sides of the working loop to the
common charge gallery.
Possible damage to hydromotor(s).
Excessive speeds and extended load/vehicle movement must be avoided. The load or vehicle should be
moved not more than 20% of maximum speed and for a duration not exceeding 3 minutes. When the
bypass function is no longer needed, care should be taken to re-seat the HPRV hex plugs to the normal
operating position.
Bypass function not available for tandem pumps.
System Schematic for Single Pump
The schematic below shows the function of an H1P axial piston variable displacement pump with electric
displacement control (EDC).
A
B
MA
S
M3
C2
C1
M4
M5
MBL4
L2
M6 1 2
R2
R1
M14
F00B F00A
CW
P003 418E
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Operation
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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.
The Electrical Displacement Control (EDC) consists of a pair of proportional solenoids on each side of a
three-position, four-way porting spool. The proportional solenoid applies a force input to the spool,
which ports hydraulic pressure to either side of a double acting servo piston. Differential pressure across
the servo piston rotates the swash plate, changing the pump‘s displacement from full displacement in
one direction to full displacement in the opposite direction.
A serviceable 125 μm screen is located in the supply line immediately before the control porting spool.
Under some circumstances, such as contamination, the control spool could stick and cause the pump to
stay at some displacement.
Electrical Displacement Control
P003 191
EDC schematic, feedback from swash plate
Feedback from
Swash plate
PTF00B
M14
C1 C2
F00A
P003 478E
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Operation
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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. Pressure differential across the servo piston moves the
swashplate.
A swashplate feedback link, opposing control links, and a linear spring provide swashplate position force
feedback to the solenoid. The control system reaches equilibrium when the position of the swashplate
spring feedback force exactly balances the input command solenoid force from the operator. As
hydraulic pressures in the operating loop change with load, the control assembly and servo/swashplate
system work constantly to maintain the commanded position of the swashplate.
The EDC incorporates a positive neutral deadband as a result of the control spool porting, preloads from
the servo piston assembly, and the linear control spring. Once the neutral threshold current is reached,
the swashplate is positioned directly proportional to the control current. To minimize the effect of the
control neutral deadband, we recommend the transmission controller or operator input device
incorporate a jump up current to offset a portion of the neutral deadband.
The neutral position of the control spool does provide a positive preload pressure to each end of the
servo piston assembly.
When the control input signal is either lost or removed, or if there is a loss of charge pressure, the spring-
loaded servo piston will automatically return the pump to the neutral position.
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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
P003 204
MOR schematic (EDC control shown)
PTF00B
M14
C2
C1
F00A
Feedback from swash plate.
The MOR plunger has a 4 mm diameter and must be manually depressed to be engaged. Depressing the
plunger mechanically moves the control spool which allows the pump to go on stroke. The MOR should
be engaged anticipating a full stroke response from the pump.
An o-ring seal is used to seal the MOR plunger where initial actuation of the function will require a force
of 45 N to engage the plunger. Additional actuation typically require less force to engage the MOR
plunger.
Proportional control of the pump using the MOR should not be expected.
W
Warning
Unintended MOR operation will cause the pump to go into stroke; example: vehicle lifted off the ground.
The vehicle or device must always be in a safe condition when using the MOR function.
Refer to control flow table for the relationship of solenoid to direction of flow.
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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. On its other end the link is connected the pumps swashplate.
This design provides a travel feedback without spring. When turning the shaft the spool moves thus
providing hydraulic pressure to either side of a double acting servo piston of the pump.
Differential pressure across the servo piston rotates the swash plate, changing the pump’s displacement.
Simultaneously the swashplate movement is fed back to the control spool providing proportionality
between shaft rotation on the control and swash-plate rotation. The MDC changes the pump
displacement between no flow and full flow into opposite directions.
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. The X7 port must not be used for any continuous oil
consumption.
The MDC is sealed by means of a static O-ring between the actuation system and the control block. Its
shaft is sealed by means of a special O-ring which is applied for low friction. The special O-ring is
protected from dust, water and aggressive liquids or gases by means of a special lip seal.
Manual Displacement Control Pump displacement vs. control lever rotation
"0" Lever rotation
"A"
Displacement
100 %
a
-a
100 %
"B"
-b
-d
bc
d
-c
P301 752
Deadband on Bside: a = 3° ±1°
Maximum pump stroke: b = 30° +2/-1°
Required customer end stop: c = 36° ±3°
Internal end stop: d = 40°
MDC Operation
The MDC provides a mechanical dead-band required to overcome the tolerances in the mechanical
actuation. The MDC contains an internal end stop to prevent turning the handle into any inappropriate
position.
The MDC provides a permanent restoring moment appropriate for turning the MDC input shaft back to
neutral position only. This is required to take the backlash out of the mechanical connections between
the Bowden cable and the control.
C
Caution
High case pressure may cause excessive wear and the NSS to indicate that the control is not in neutral
position. In addition, if the case pressure exceeds 5 bar there is a risk of an insufficient restoring moment.
The MDC is designed for a maximum case pressure of 5 bar and a rated case pressure of 3 bar.
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•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.
•Customers can connect two MDC’s on a tandem unit in such a way that the actuation force will be
transferred from the pilot control to the second control. The kinematic of the linkages must ensure
that either control shaft is protected from torque overload.
C
Caution
Using the internal spring force on the input shaft is not an appropriate way to return the customer
connection linkage to neutral, or to force a Bowden cable or a joystick back to neutral position. It is not
applicable for any limitation of the Bowden cable stroke, except the applied torque to the shaft will never
exceed 20 N•m.
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]
C
Caution
Volumetric efficiencies of the system will have impacts on the start and end input commands.
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).
Neutral Start Switch schematic
P005 702
M14
M5 M4 M3
Neutral Start Switch data
Max. continuous current with switching 8.4 A
Max. continuous current without switching 20 A
Max. voltage 36 VDC
Electrical protection class IP67 / IP69K with mating connector
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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.
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