Danfoss H1 P Guide

Service Manual
H1P 069—H1P 250
Axial Piston Single Pumps
www.danfoss.com
Service Manual
H1P 069—H1P 250 Axial Piston Single Pumps
Revision history
2 | © Danfoss | January 2020
Table of revisions
Date
Changed
Rev
January 2020
Corrected the A/B port size for 115/130 frame
0402
December 2018
Major clean-up revision.
0401
July 2008- May 2018
Various changes.
0201-0308
September 2007
First edition.
0101
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Service Manual
H1P 069—H1P 250 Axial Piston Single Pumps
Contents
Introduction
Operation
Operating Parameters
Technical Specifications
Hydrostatics Servicing Overview................................................................................................................................................ 5
General Servicing Instructions.....................................................................................................................................................5
Safety Precautions............................................................................................................................................................................6
Symbols used in Danfoss literature............................................................................................................................................7
General description of H1 family hydrostatic pumps..........................................................................................................7
Design...................................................................................................................................................................................................8
H1 Single Pumps Closed Circuit Pictorial Diagram............................................................................................................10
H1 system schematic.................................................................................................................................................................... 10
Pressure Limiter Valves................................................................................................................................................................ 12
Pressure Limiter Sectional View.......................................................................................................................................... 12
High Pressure Relief Valve (HPRV) and Charge Check Valve.......................................................................................... 12
HPRV/Charge Check Valve Sectional View...................................................................................................................... 13
Charge Pressure Relief Valve (CPRV)....................................................................................................................................... 13
Bypass Function..............................................................................................................................................................................13
System Schematic for Single Pump................................................................................................................................... 14
Electrical Displacement Control (EDC)................................................................................................................................... 14
EDC Operation........................................................................................................................................................................... 15
Manual Override (MOR)............................................................................................................................................................... 16
Manual Displacement Control (MDC) ....................................................................................................................................16
MDC Operation..........................................................................................................................................................................17
MDC Torque................................................................................................................................................................................18
Neutral Start Switch (NSS)..................................................................................................................................................... 18
Case Gauge Port M14.............................................................................................................................................................. 18
Input Speed......................................................................................................................................................................................19
System Pressure..............................................................................................................................................................................19
Servo Pressure.................................................................................................................................................................................20
Charge Pressure..............................................................................................................................................................................20
Charge Pump Inlet Pressure.......................................................................................................................................................20
Case Pressure...................................................................................................................................................................................20
External Shaft Seal Pressure....................................................................................................................................................... 21
Temperature.................................................................................................................................................................................... 21
Viscosity.............................................................................................................................................................................................21
H1 Pumps General Specification.............................................................................................................................................. 22
H1P 069—250 Physical Properties...........................................................................................................................................22
Fluid Specification......................................................................................................................................................................... 23
Fluid and Filter Maintenance Recommendations
Filtration System.............................................................................................................................................................................24
Pressure Measurements
Initial Startup Procedures
Troubleshooting
© Danfoss | January 2020
Port Locations and Gauge Installation................................................................................................................................... 26
H1P Ports Information.............................................................................................................................................................26
Unintended Machine Movement.............................................................................................................................................28
Start-Up Procedure........................................................................................................................................................................28
High Inlet Vacuum......................................................................................................................................................................... 30
Unintended Machine Movement....................................................................................................................................... 30
Fluid Under Pressure............................................................................................................................................................... 30
Electrical Troubleshooting..........................................................................................................................................................30
Integral Filter Bypass.....................................................................................................................................................................30
Neutral Difficult or Impossible to Find................................................................................................................................... 31
Transmission Operates Normally in One Direction Only.................................................................................................31
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Service Manual
H1P 069—H1P 250 Axial Piston Single Pumps
Contents
System Operating Hot..................................................................................................................................................................31
System Will Not Operate in Either Direction........................................................................................................................ 32
System Noise or Vibration...........................................................................................................................................................32
Sluggish System Response......................................................................................................................................................... 32
Adjustments
Minor Repair
Torque Chart
4 | © Danfoss | January 2020
Standard Procedures.................................................................................................................................................................... 34
Charge Pressure Relief Valve Adjustments........................................................................................................................... 34
Pressure Limiter Adjustment..................................................................................................................................................... 35
Engaging the Bypass Function..................................................................................................................................................37
Displacement Limiter Adjustment for Single Pumps........................................................................................................37
Control Neutral Adjustment.......................................................................................................................................................38
Mechanical Neutral Adjustment...............................................................................................................................................40
Unintended Machine Movement....................................................................................................................................... 40
Angle sensor on EDC Repair.......................................................................................................................................................48
EDC with Angle Sensor Repair...................................................................................................................................................49
Fasteners and Plugs...................................................................................................................................................................... 62
Fastener Size and Torque Chart................................................................................................................................................63
Plug Size and Torque Chart........................................................................................................................................................ 64
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Service Manual
H1P 069—H1P 250 Axial Piston Single Pumps
Introduction
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
Remove the unit
Keep it clean
Instructions
•
•
•
•
•
•
•
•
•
•
•
Replace O-ring,
gasket
Secure the unit
© Danfoss | January 2020
•
•
•
•
•
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.
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.
Danfoss recommends that you replace all O-rings, seals and gaskets.
Lightly lubricate all O-rings with clean petroleum jelly prior to assembly.
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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Service Manual
H1P 069—H1P 250 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.
Secure the machine or disable/disconnect the mechanism while servicing to protect against unintended
movement.
Independant 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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H1P 069—H1P 250 Axial Piston Single Pumps
Introduction
Symbols used in Danfoss literature
WARNING may result in injury
Tip, helpful suggestion
CAUTION may result in damage to product or
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.
General description of H1 family hydrostatic pumps
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. The H1 axial piston
variable displacement pumps are of cradle swash-plate design and are intended for closed circuit
applications.
Flow direction is reversed by tilting the swash-plate to the opposite side of the neutral (zero
displacement) position. 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.
• Danfoss hydrostatic products are designed with 14 different displacements (cm³ [in³]):
•
© Danfoss | January 2020
045
053
060
068
069
078
089
100
115
130
147
165
45.0
[2.75]
53.8
[3.28]
60.4
[3.69]
68.0
[4.15]
69.0
[4.22]
78.0
[4.76]
89.2
[5.44]
101.7
[6.21]
115.8
[7.07]
130.8
[7.98]
147.0
[8.97]
165.0 211.5 251.7
[10.07] [12.91] [15.36]
210
250
Danfoss hydrostatic products are designed with many different pressure, load-life and control
capabilities:
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Service Manual
H1P 069—H1P 250 Axial Piston Single Pumps
Introduction
‒
‒
‒
‒
‒
‒
‒
•
•
•
•
Electric Displacement Control (EDC)
Forward-Neutral-Reverse control (FNR)
Non-Feedback Proportional Electric control (NFPE)
Automotive Control (AC)
Fan Drive Control (FDC)
Manual Displacement Control (MDC)
Control-Cut-Off valve (CCO)
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.
Compatible with the Danfoss family of PLUS+1® micro-controllers for easy Plug-and-Perform
installation.
More compact and lightweight
Improved reliability and performance
Go to the Danfoss website or applicable product catalog to choose the components that are right for
your complete closed circuit hydraulic system.
Design
Danfoss H1 closed circuit piston pumps convert input torque into hydraulic power. The input shaft
transmits rotational force to the cylinder block. Bearings at the front and rear of the pump support the
shaft. Splines connect the shaft to the cylinder block. A lip-seal at the front end of the pump prevents
leakage where the shaft exits the pump housing. The spinning cylinder block contains nine reciprocating
pistons. Each piston has a brass slipper connected at one end by a ball joint. The block spring, ball guide,
and slipper retainer hold the slippers to the swashplate. The reciprocating movement of the pistons
occurs as the slippers slide against the inclined swashplate during rotation. Via the valve plate, one half of
the cylinder block is connected to low pressure and the other half to high pressure. As each piston cycles
in and out of its bore, fluid is replenished by charge flow and displaced to the outlet thereby imparting
hydraulic power into the system. A small amount of fluid is allowed to flow from the cylinder block/valve
plate and slipper/swashplate interfaces for lubrication and cooling. Case drain ports return this fluid to
the reservoir.
The angle of the swashplate controls the volume and direction of fluid displaced into the system. The
servo piston controls the angle of the swashplate. The pump control, by varying the pressure at the servo
piston, controls the piston’s position. An electric signal to the control coils transmits the command from
the operator to the pump. Mechanical feedback of the swashplate position to the control through the
feedback pins allows for very precise displacement control and increases overall system stability. Nonfeedback control options do not use the mechanical feedback link.
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H1P 069—H1P 250 Axial Piston Single Pumps
Introduction
Cross section view
Electric displacement control
Servo piston
Auxiliary mounting pad “B”
Valve plate
Swashplate feedback pin
Piston
Slippe r
Shaf t seal
Shaf t
Swashplate
Cylinder block
Charge pump
P106 045E
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.
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Service Manual
H1P 069—H1P 250 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
Displacement Motor
Servo Control
Cylinder
Charge Filter
Motor Swashplate
Charge Check/
High Pressure Relief Valve
Variable
Displacement
Pump
Output
Shaft
Loop
Flushing
Valve
Charge
Pressure
Relief
Valve
Pressure
Limiter
Valve
To Pump
Case
To
Motor
Case
Input
Shaft
Synchronizing
Shaft
Pump Swashplate
Charge Check/High Pressure Relief Valve
P104 464E
H1 system schematic
System schematic H1 pump and H1 motor with EDC
M14
M6
1
2
R2
R1
C2
C1
M3 L1
F00B
L2
L2 MA
MA N
A A
F00A
n
M5
CW
max.
min.
L1
M4
B B
S L3
L4
max. 3 bar
[43.5 psi]
10 | © Danfoss | January 2020
MB
M4
M5
MB
P003 424
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H1P 069—H1P 250 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.
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Service Manual
H1P 069—H1P 250 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.
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
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.
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H1P 069—H1P 250 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. 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
Relief mode
Charging mode
P003 268
P003 269
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
Bypass Function
The HPRV valve also provides a loop bypass function when each of the two HPRV hex plugs are
mechanically backed out 3 full turns. Engaging the bypass function hydraulically connects both A & B
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Service Manual
H1P 069—H1P 250 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.
C
Caution
The HPRV valves are not tow valves. Damage to the pump and motor can occur when operating without
charge flow. Limit vehicle/machine movement to no more than 20% of maximum speed and no longer
that three minutes. Reseat the HPRV valves after vehicle/machine movement.
System Schematic for Single Pump
The schematic below shows the function of an H1P axial piston variable displacement pump with electric
displacement control (EDC).
M14
M6 1
2
R2
R1
C2
C1
M3 L2
MA
A
F00B F00A
M4
CW
B
M5
S
L4
MB
P003 418E
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.
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.
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Operation
Electrical Displacement Control
EDC schematic, feedback from swash plate
M14
C1
C2
F00B
F00A
Feedback from
Swash plate
T
P
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.
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 springloaded servo piston will automatically return the pump to the neutral position.
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Service Manual
H1P 069—H1P 250 Axial Piston Single Pumps
Operation
Manual Override (MOR)
All controls are available with a manual override functionality, either as a standard or as an option for
temporary actuation of the control to aid in diagnostics.
Control with manual override
P003 204
MOR schematic (EDC control shown)
M14
C1
C2
F00B
F00A
T
P
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.
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.
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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. 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
Displacement
100 %
"A"
-d -b
-c
-a
"0"
100 %
d
Lever rotation
a
bc
"B"
P301 752
Deadband on B side: a = 3° ±1°
Maximum pump stroke: b = 30° +2/-1°
Required customer end stop: c = 36° ±3°
Internal end stop: d = 40°
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.
•
•
•
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.
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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]
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
M14
M5
M4
M3
P005 702
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
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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Operating Parameters
Input Speed
Minimum
speed
is the lowest input speed recommended during engine idle condition. Operating below
minimum speed limits the pump’s ability to maintain adequate flow for lubrication and
power transmission.
Rated speed
is the highest input speed recommended at full power condition. Operating at or
below this speed should yield satisfactory product life.
Operating conditions between rated and maximum speed should be restricted to less
than full power and to limited periods of time.
Maximum
speed
is the highest operating speed permitted. Exceeding maximum speed reduces product
life and can cause loss of hydrostatic power and braking capacity. For most drive
systems, maximum unit speed occurs during downhill braking or negative power
conditions.
W
Warning
Never exceed the maximum speed limit under any operating conditions.
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
turbo-charged and Tier 4 engines.
For more information please see Pressure and Speed Limits, BLN-9884, when determining speed limits for
a particular application.
System Pressure
Hydraulic unit life depends on the speed and normal operating — or weighted average — pressure that
can only be determined from a duty cycle analysis.
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.
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 drive line
generates the maximum calculated pull or torque in the application.
Maximum
working
pressure
is the highest recommended application pressure and 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.
Application pressures above maximum working pressure will only be considered
with duty cycle analysis and factory approval.
Pressure spikes are normal and must be considered when reviewing maximum
working pressure.
© Danfoss | January 2020
Maximum
pressure
is the highest intermittent pressure allowed under any circumstances. Applications
with applied pressures between rated and maximum require factory approval with
complete application, duty cycle, and life expectancy analysis.
Minimum low
loop pressure
must be maintained under all operating conditions to avoid cavitation.
All pressure limits are differential pressures referenced to low loop (charge) pressure.
Subtract low loop pressure from gauge readings to compute the differential.
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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.
Minimum servo pressure at corner power holds the pump on full stroke at max speed and max
pressure.
Maximum servo pressure is the highest pressure typically given by the charge pressure setting.
Charge Pressure
An internal charge relief valve regulates charge pressure. Charge pressure supplies the control with
pressure to operate the swashplate and to maintain a minimum pressure in the low side of the
transmission loop.
The charge pressure setting listed in the order code is the set pressure of the charge relief valve with the
pump in neutral, operating at 1800 min-1 (rpm), and with a fluid viscosity of 32 mm2/s [150 SUS].
Pumps configured with no charge pump (external charge supply) are set with a charge flow of 30 l/min
[7.93 US gal/min] and a fluid viscosity of 32 mm2/s [150 SUS].
The charge pressure setting is referenced to case pressure. Charge pressure is the differential pressure
above case pressure.
Minimum
charge
pressure
is the lowest pressure allowed to maintain a safe working condition in the low side of
the loop. Minimum control pressure requirements are a function of speed, pressure,
and swashplate angle, and may be higher than the minimum charge pressure shown
in the Operating parameters tables.
Maximum
charge
pressure
is the highest charge pressure allowed by the charge relief adjustment, and which
provides normal component life. Elevated charge pressure can be used as a
secondary means to reduce the swashplate response time.
Charge Pump Inlet Pressure
At normal operating temperature charge inlet pressure must not fall below rated charge inlet pressure
(vacuum).
Minimum charge inlet
pressure
is only allowed at cold start conditions. In some applications it is
recommended to warm up the fluid (e.g. in the tank) before starting the
engine and then run the engine at limited speed.
Maximum charge inlet
pressure
may be applied continuously.
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.
The auxiliary pad cavity of axial pumps configured without integral charge pumps is referenced to case
pressure. Units with integral charge pumps have auxiliary mounting pad cavities referenced to charge
inlet (vacuum).
Possible component damage or leakage.
Operation with case pressure in excess of stated limits may damage seals, gaskets, and/or housings,
causing external leakage. Performance may also be affected since charge and system pressure are
additive to case pressure.
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Operating Parameters
External Shaft Seal Pressure
In certain applications the input shaft seal may be exposed to external pressure. In order to prevent
damage to the shaft seal the maximum differential pressure from external sources must not exceed 0.4
bar (5.8 psi) over pump case pressure.
The case pressure limits of the pump must also be followed to ensure the shaft seal is not damaged.
C
Caution
Regardless of the differential pressure across the shaft seal, the shaft seal has been known to pump oil
from the external source (e. g. gear box) into the pump case.
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 quoted 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 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.
The minimum viscosity should be encountered only during brief occasions of maximum ambient
temperature and severe duty cycle operation.
The maximum viscosity should be encountered only at cold start.
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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
Remaining ports: SAE straight thread O-ring boss
Recommended installation position
Pump installation position is discretionary, however the recommended control position is on the top or
at the side with the top position preferred. If the pump is installed with the control at the bottom,
flushing flow must be provided through port M14 located on the EDC, FNR and NFPE control.
Vertical input shaft installation is acceptable. If input shaft is at the top, 1 bar case pressure must be
maintained during operation. The housing must always be filled with hydraulic fluid. Recommended
mounting for a multiple pump stack is to arrange the highest power flow towards the input source.
Consult Danfoss for nonconformance to these guidelines.
Auxiliary cavity pressure
Auxiliary cavity pressure will be inlet pressure with internal charge pump or case pressure with external
charge supply. For reference see Operating Parameters. Please verify mating pump shaft seal capability.
H1P 069—250 Physical Properties
Frame size
069/078, 089/100
115/130, 147/165
210/250
Oil volume
2.0 l [0.5 US gal]
3.0 l [ 0.8 US gal]
7.2 l [ 1.9 US gal]
Mounting flange
SAE flange, size C (SAE J
744) mounting pad
SAE flange, size D (SAE J
744) mounting pad
SAE flange, size E (ISO
3019-1 flange 177-4)
mounting pad
Auxiliary mounting
SAE A, SAE B, SAE B-B, SAE SAE A, SAE B, SAE B-B, SAE SAE A, SAE B, SAE B-B, SAE
C
C, SAE D
C, SAE D, SAE E
Splined Shafts
•
•
•
Suction port
1.625 [1 5/8] –12UN-2B
Main port configuration
Ø25.4 - 450 bar split
flange boss per ISO 6162
M12x1.75
Case drain ports L1, L3, L2, L4
(SAE O-ring boss).
0.875 [7/8] -12UNF-2B
1.0625 [1 1/16] -12UNF-2B Port ISO 11926-1; 1
1.0625 [1 1/16] -12UNF-2B 1.3175 [1 5/16]-12UNF-2B 5/16-12 (SAE O-ring boss)
only L2 and L4
Other ports
SAE O-ring boss
Customer interface threads
Metric fastener
14-teeth 12/24
21-teeth 16/32
23-teeth 16/32
•
•
13-teeth 8/16
27-teeth 16/32
•
•
•
13-teeth 8/16
17-teeth 8/16
27-teeth 16/32
Ø38 - 350 bar split flange
boss per ISO 6162
M12x1.75
Ø31.5 - 450 bar split
flange boss ISO 6162
M12x1.75
Ø38 - 450 bar split flange
boss ISO 6162
M16x2
For more info see Port Locations and Gauge Installation on page 26
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Technical Specifications
Fluid Specification
Viscosity
Intermittent1)
5 mm2/s [42 SUS]
Minimum
7 mm2/s [49 SUS]
Recommended range
12 – 80 mm2/s [66 – 370 SUS]
Maximum
1600 mm2/s [7500 SUS]
1) Intermittent = Short term t < 1 min per incident and not exceeding 2 % of duty cycle based load-life.
Temperature
Minimum 1)
-40°C [-40°F]
Rated
104°C [220°F]
Recommended range2)
60 – 85°C [140 – 185°F]
Maximum Intermittent
115°C [240°F]
1) Cold start = Short term t > 3 min, p ≤ 50 bar [725 psi], n ≤ 1000 min-1 (rpm).
2) At the hottest point, normally case drain port.
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Fluid and Filter Maintenance 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 and
correct the problem immediately if these conditions occur.
• Inspect vehicle for leaks daily. Change the fluid and filter per the vehicle/machine manufacturer's
recommendations or at intervals shown in the table. We recommend first fluid change at 500 hours.
Fluid and filter change interval
•
•
•
•
Reservoir type
Max oil change interval
Sealed
2000 hours
Breather
500 hours
High temperatures and pressures will result in accelerated fluid aging. More frequent fluid changes
may be required.
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.
Dispose of used hydraulic fluid properly. Never reuse hydraulic fluid.
Change filters with the fluid or when the filter indicator shows it's necessary.
Replace all fluid lost during filter change.
Hydraulic fluid contains hazardous material.
Avoid contact with hydraulic fluid. Always dispose of used hydraulic fluid according to state and federal
environmental regulations.
For further information see Danfoss publication Technical Information, Hydraulic Fluids and Lubricants,
BC0000093.
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.
These cleanliness levels can not be applied for hydraulic fluid residing in the component housing/case or
any other cavity after transport.
The filter may be located on the pump (integral) or in another location (remote). The integral filter has a
filter bypass sensor to signal the machine operator when the filter requires changing. Filtration strategies
include suction or pressure filtration.
The selection of a filter depends on a number of factors including the contaminant ingression rate, the
generation of contaminants in the system, the required fluid cleanliness, and the desired maintenance
interval. Filters are selected to meet the above requirements using rating parameters of efficiency and
capacity.
Filter efficiency can be measured with a Beta ratio (βX). For simple suction filtered closed circuit
transmissions and open circuit transmissions with return line filtration, a filter with a β-ratio within the
range of β35-45 = 75 (β10 ≥ 2) or better has been found to be satisfactory.
For some open circuit systems, and closed circuits with cylinders being supplied from the same reservoir,
a considerably higher filter efficiency is recommended. This also applies to systems with gears or clutches
using a common reservoir.
For these systems, a charge pressure or return filtration system with a filter β-ratio in the range of β15-20 =
75 (β10 ≥ 10) or better is typically required.
Because each system is unique, only a thorough testing and evaluation program can fully validate the
filtration system.
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Fluid and Filter Maintenance Recommendations
Please see Design Guidelines for Hydraulic Fluid Cleanliness Technical Information, BC00000095 for more
information.
Filter βx-ratio is a measure of filter efficiency defined by ISO 4572. It is defined as the ratio of the number
of particles greater than a given diameter (“x” in microns) upstream of the filter to the number of these
particles downstream of the filter.
Filtration, cleanliness level and βx-ratio (recommended minimum)
© Danfoss | January 2020
Cleanliness per ISO 4406
22/18/13
Efficiency βx (charge pressure filtration)
β15-20 = 75 (β10 ≥ 10)
Efficiency βx (suction and return line filtration)
β35-45 = 75 (β10 ≥ 2)
Recommended inlet screen mesh size
100 – 125 µm
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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.
Port locations
M5
L3
M4
L1
M3
System
Port B
S
System Port A
L2
L4
L2
G302
MB
M6
MA
D065
P106033
H1P Ports Information
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Pressure Measurements
Port Information
System ports A/B
Port size
Frame size
069/078
A/B
089/100
24.5 mm
M12 x 1.75
24.5 mm
M12 x 1.75
115/130
147/165
31.5 mm
M12 x 1.75
210/250
31.5 mm
M12 x 1.75
38 mm
M16 x 2
System Ports A and B 450 bar, Split flange boss per ISO 6162; 20 min. full thread depth
Recommended screw in depth 1.5 x thread dia.
Gauge size
600 bar [10 000 psi]
System pressure gauge (MA/MB) ports
Ports/wrench
Frame size
115/130
System pressure: MA/MB
Wrench
147/165
9/16-18 UNF
1/4 internal hex
Gauge size
210/250
9/16-18 UNF
1/4 internal hex
9/16-18 UNF
1/4 internal hex
600 bar [10 000 psi]
Case drain ports
Ports/wrench
size
Frame size
069/078
089/100
115/130
147/165
L1/ L3
Wrench
7/8-14 UNF 2B
3/8 internal hex
1 1/16-12 UNF 2B
9/16 internal hex
1 1/16-12 UNF 2B
9/16 internal hex
1 1/16-12 UNF 2B —
9/16 internal hex
L2/L4
Wrench
1 1/16-12 UNF 2B
9/16 internal hex
1 1/16-12 UNF 2B
9/16 internal hex
1 5/16-12 UNF 2B
5/8 internal hex
1 5/16-12 UNF 2B
5/8 internal hex
Gauge size
210/250
1 5/8-12 UNF
5/8 internal hex
10 bar [100 psi]
Charge/servo pressure gauge ports (M3/M4/M5/M6)
Ports - pressure obtained
Charge pressure (after filter) M3
9/16-18 UNF
1/4 internal hex wrench size
Servo pressure M4/M5
7/16-20 UNF 2B
3/16 internal hex wrench size
Charge pressure (pre integrated filter) M6
9/16-18 UNF 2B
1/4 internal hex wrench size
Gauge size (All)
© Danfoss | January 2020
Size: 115/130/147/165/210/250
50 bar [1000 psi]
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H1P 069—H1P 250 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.
Start-Up Procedure
Prior to installing the pump, inspect for damage that may have occurred during shipping.
Follow this procedure when starting-up a new pump installation or when restarting an installation in
which the pump has been removed and re-installed on a machine. Ensure pump has been thoroughly
tested on a test stand before installing on a machine.
1. Ensure that the machine hydraulic oil and system components (reservoir, hoses, valves, fittings, and
heat exchanger) are clean and free of any foreign material.
2. Install new system filter element(s) if necessary. Check that inlet line fittings are properly tightened
and there are no air leaks.
3. Install the pump and a 50 bar [1000 psi] gauge in the charge pressure gauge port M.
4. Fill the housing by adding filtered oil in the upper case drain port.
If the control is intalled on top, open the construction plug in the top of the control to assist in air
bleed.
5. Fill the reservoir with hydraulic fluid of the recommended type and viscosity; fill inlet line from
reservoir to pump.
Use a 10-micron filler filter.
6. Disconnect the pump from all control input signals.
7. Close construction plug removed in the step 4.
C
Caution
After start-up the fluid level in the reservoir may drop due to system components filling. Damage to
hydraulic components may occur if the fluid supply runs out. Ensure reservoir remains full of fluid
during start-up. Air entrapment in oil under high pressure may damage hydraulic components. Check
carefully for inlet line leaks. Do not run at maximum pressure until system is free of air and fluid has
been thoroughly filtered.
8. Use a common method to disable the engine to prevent it from starting.
9. Crank the starter for several seconds.
C
Caution
Do not to exceed the engine manufacturer’s recommendation. Wait 30 seconds and then crank the
engine a second time as stated above.
This operation helps to remove air from the system lines.
10. Refill the reservoir to recommended fluid level.
11. When the gauge begins to register charge pressure, enable and start engine.
Let the engine run for a minimum of 30 seconds at low idle to allow the air to work itself out of the
system.
12. Check for leaks at all line connections and listen for cavitation.
13. Check for proper fluid level in the reservoir.
14. Increase engine speed to normal operating rpm to further purge residual air from the system, when
adequate charge pressure is established (as shown in model code).
15. Shut off the engine.
16. Connect pump control signal.
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Initial Startup Procedures
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.
18. Continue to cycle between forward and reverse for at least five minutes to bleed all air and flush
system contaminants out of the system loop.
Normal charge pressure fluctuation may occur during forward and reverse operation.
19. Check that the reservoir is full and remove charge pressure gauge.
The pump is now ready for an operation.
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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.
High Inlet Vacuum
High inlet vacuum causes cavitation which can damage internal pump components.
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.
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.
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.
Electrical Troubleshooting
Electrical troubleshooting
Item
Description
Action
Control operates pump in
one direction only.
Control coil failure
•
No pump function
No power to controller
Restore power to controller.
Erratic pump function
Electrical connection to pump is bad.
Disconnect connection, check wires, reconnect wires.
•
Filter bypass indicator switch Filter switch may be bad.
•
•
Measure resistance at coil pins. Resistance should be
14.20 Ω (24V) or 3.66 Ω (12V) at 20°C [70°F].
Replace coil.
Check/replace filter switch.
Add gauge to filter bypass port to verify proper fluid flow
and verify switch operation by measuring resistance.
‒ Open resistance ≥ 510 Ω
‒ Closed resistance ≤ 122 Ω
Use a manual override to check proper pump operation and verify electrical problem, if available.
Integral Filter Bypass
Item
Description
Action
Filter bypass activated
Filter is plugged causing fluid to bypass filter.
Replace filter. Check that bypass switch indicates proper
operation after filter is replaced.
Filter bypass indicator switch Filter bypass indicator switch is indicating wrong bypass
situation.
30 | © Danfoss | January 2020
Check/replace filter switch.
• Open resistance ≥ 510 Ω
• Closed resistance ≤ 122 Ω
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Troubleshooting
Neutral Difficult or Impossible to Find
Item
Description
Action
Input to pump control
Input to control module is operating improperly
Disconnect input and check to see if pump comes back to
neutral.
• If Yes – input fault, replace or repair external controller
• If No – go to next step
Neutral
Neutral set improperl
Shunt servo gauge ports (M4 and M5) together with
external hose and see if pump comes back to neutral.
• If Yes – Control neutral improperly set (see Control
Neutral Adjustment on page 38).
• If neutral is still impossible to set, balance the swashplate
(see Mechanical Neutral Adjustment on page 40).
• If you still cannot set neutral, replace the control.
Transmission Operates Normally in One Direction Only
Item
Description
Action
Input to pump control.
Input to control module is operating improperly.
Check control input and repair or replace as necessary.
Control orifices
Control orifice(s) are blocked.
Clean control orifices.
Control screens
Control screen(s) are blocked.
Replace control screens. Only a Danfoss Authorized Service
Center may remove the unit’s endcap without voiding the
warranty.
Exchange system pressure
limiters
Exchanging the pressure limiter valves will show if the
problem is related to the valve function.
If the problem changes direction, replace the valve that
does not operate correctly.
Exchange high pressure
relief valves
Exchanging the high pressure relief valves will show if the
problem is related to the valve function.
If the problem changes direction, replace the valve that
does not operate correctly.
Servo pressure low or
decaying
Damaged servo seals may prevent servo piston from
stroking the pump.
Check for torn/missing servo seals. Replace and retest. Only
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
inoperative.
Close bypass function.
Item
Description
Action
Oil level in reservoir
Insufficient hydraulic fluid will not meet cooling demands
of system.
Fill reservoir to proper level.
Heat exchanger
Heat exchanger is not sufficiently cooling the system.
•
Charge pressure
Low charge pressure will overwork system.
Charge pump inlet vacuum
High inlet vacuum will overwork system.
A dirty filter will increase the inlet vacuum. Inadequate line
size will restrict flow.
System Operating Hot
•
•
•
•
•
•
Check air flow and input air temperature for heat
exchanger
Clean, repair or replace heat exchanger
Measure charge pressure.
Inspect and adjust or replace charge relief valve.
Inspect charge pump; repair or replace charge pump.
Check charge inlet vacuum. If high, inspect inlet filter
and replace as necessary
Check for adequate line size, length or other restrictions
System relief pressure
settings
If the system relief valves are worn, contaminated, or valve
settings are too low, the relief valves will be overworked.
Verify settings of pressure limiters and high pressure relief
valves and adjust or replace valves as necessary.
System pressure
Frequent or long term operation over system relief setting
will create heat in system.
Measure system pressure. If pressure is too high, reduce
loads.
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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.
Clean control orifices.
Pump control screens
Control screens are blocked.
Replace control screens. Only a Danfoss Authorized Service
Center may remove the unit’s endcap without voiding the
warranty.
Bypass function open
If bypass function is open, the system loop will be
depressurized.
Close bypass valves. Replace high pressure relief valve if
defective.
Low charge pressure with
pump in neutral
Low charge pressure insufficient to recharge system loop.
Measure charge pressure with the pump in neutral. If
pressure is low, go to Pump charge relief valve.
Low charge pressure with
pump in stroke
Low charge pressure resulting from elevated loop leakage.
Insufficient control pressure to hold pump in stroke.
Deadhead the pump to isolate it from the motor.With
pump in partial stroke and engaged for only a few seconds,
check pump charge pressure. Low charge pressure
indicates a malfunctioning pump. Continue to next step.
Good charge pressure indicates a malfunctioning motor or
other system component. Check motor charge relief
operation (if present).
Pump charge relief valve
A pump charge relief valve that is leaky, contaminated, or
set too low will depressurize the system.
Adjust or replace pump charge relief valve as necessary.
Charge pump inlet filter
A clogged filter will under supply system loop.
Inspect filter and replace if necessary.
Charge pump
A malfunctioning charge pump will provide insufficient
charge flow.
Repair or replace the charge pump.
System pressure
Low system pressure does not provide enough power to
move load.
Measure system pressure. Continue to next step.
High pressure relief or
pressure limiter valves
Defective high pressure relief or pressure limiter valves
cause system pressure to be low.
Repair or replace high pressure relief or pressure limiter
valves.
Input to control
Input operating improperly
Repair/replace control.
Item
Description
Action
Reservoir oil level
Low oil level leads to cavitation.
Fill reservoir.
Aeration of the oil/pump
inlet vacuum
Air in system decreases efficiency of units and controls.
Excessive noise, foaming oil, and hot oil all indicate air in
system.
Find location where air is entering into the system and
repair. Check that inlet line is not restricted and is proper
size.
Cold oil
If oil is cold, it may be too viscous for proper function and
pump cavitates.
Allow the oil to warm up to its normal operating
temperature with engine at idle speed.
Pump inlet vacuum
High inlet vacuum causes noise/cavitation.
Check that inlet line is not restricted and is of proper size.
Check filter and bypass switch.
Shaft couplings
A loose shaft coupling will cause excessive noise.
Replace loose shaft coupling..
Shaft alignment
Misaligned shafts create noise.
Align shafts.
Charge/system relief valves
Unusual noise may indicate sticking valves and possible
contamination.
Clean/replace valves and test pump.
System Noise or Vibration
Sluggish System Response
Item
Description
Action
Oil level in reservoir
Low oil level causes sluggish response.
Fill reservoir.
High pressure relief valves/
pressure limiter settings
Incorrect pressure settings affects system reaction time.
Adjust or replace high pressure relief valves.
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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.
Air in system
Air in system produces sluggish system response.
Fill tank to proper level. Cycle system slowly for several
minutes to remove air from system.
Contaminated control
orifices
Control orifices are plugged.
Clean control orifices.
Contaminated control
screens
EDC supply screen is plugged.
Replace control screens. Only a Danfoss Authorized Service
Center may remove the unit’s endcap without voiding the
warranty.
Pump inlet vacuum
Inlet vacuum is too high resulting in reduced system
pressure.
Measure charge inlet vacuum. Inspect line for proper sizing.
Replace filter. Confirm proper bypass operation.
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Service Manual
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Adjustments
This section offers instruction on inspection and adjustment of pump components. Read through the
entire topic before beginning a service activity.
Refer to Pressure Measurements for location of gauge ports and suggested gauge size.
Standard Procedures
1. Ensure the surrounding area is clean and free of contaminants like dirt and grime.
2. With the prime mover off, thoroughly clean the outside of the pump.
3. Tag each hydraulic line, if removing the pump.
4. When you disconnect hydraulic lines, cap them and plug each open port to prevent contamination.
5. Inspect the system for contamination.
6. Check the hydraulic fluid for signs of contamination: oil discoloration, foam in the oil, sludge, or metal
particles.
7. If there are signs of contamination in the hydraulic fluid, replace all filters and drain the hydraulic
system.
8. Flush the lines and refill the reservoir with the correct filtered hydraulic fluid.
9. Before re-installing the pump, test for leaks.
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.
Charge Pressure Relief Valve Adjustments
Operate the system with the pump in neutral (zero displacement), when measuring charge pressure.
This procedure explains how to check and adjust the charge pressure relief valve.
Charge Pressure Adjustment
Optional construction port M14
Case drain port L4
0 - 10 bar [0 - 100 psi]
3/16 in
0 - 10 bar [0 - 100 psi]
3/8 in (069/078) /
9/16 in (089/100/147/165)
5/8 in (210/250)
70 N•m [52 lbf•ft]
12 N•m [9 lbf•ft]
Locknut
13 mm
12 N•m
[9 lbf•ft]
Case drain port L2
0 - 10 bar [0 - 100 psi]
9/16 (069/078) / 5/8 in (147/165/210/250)
70 N•m [52 lbf•ft] (078)
150 N•m [110 lbf•ft] (147/165/210/250)
Adjustment
screw
5 mm
Charge pressure gauge port M3
0 - 50 bar [0 - 1000 psi]
1/4 in
24 N•m [18 lbf•ft]
P104466
1. Install a 50 bar [1000 psi] pressure gauge in charge pressure gauge port M3.
2. Install a 10 bar [100 psi] gauge at case drain port L2 or L4.
The table below shows the acceptable actual pump charge pressure range for some nominal CPRV
settings (refer to model code located on serial number plate).
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Adjustments
Charge Pressure Range according to model code
Code
20
24
26
30
Actual charge
pressure, bar [psi]
20 ± 1.5
[290 ± 21.8]
24 ± 1.5
[348 ± 21.8]
26 ± 1.5
[377 ± 21.8]
30 ± 1.5
[435 ± 21.8]
The factory set pressures at 1800 min-1 (rpm) pump speed and a reservoir temperature of 50°C
[120°F], and are referenced to case pressure. At higher pump speeds with higher charge flows the
charge pressure will rise over the rated setting. Depending on the pressure rating, the charge
pressure relief valve may have one or two springs.
3. Loosen the locknut and turn the adjusting screw clockwise to increase the setting, and
counterclockwise to decrease it.
The approximate adjustment per turn
Number of springs
Change per turn
1 Spring
consult factory
2 Springs
3.9 bar [56.6 psi]
4. Torque locknut to 12 N•m [9 lbf•ft], while holding the adjusting screw.
5. Remove the gauges and plug the ports, when the desired charge pressure setting is achieved.
Pressure Limiter Adjustment
Lock motor output shaft to adjust the pressure limiter setting. Lock the vehicle’s brakes or rigidly fix the
work function so it cannot rotate.
Pressure limiter adjustment
Pressure limiter
adjusting screw
8 mm
Pressure limiter
locking nut
14 mm
12 N•m [9 lbf.ft]
Charge pressure gauge port M3
0 - 50 bar [0 - 1000 psi]
1/4 in
43 N•m [32 lbf•ft]
HPRV valve
System pressure gauge port MB
0 - 600 bar [0 - 10,000 psi]
1/4 in
43 N•m [32 lbf•ft]
System pressure gauge port MA
(on bottom)
0 - 600 bar [0 - 10,000 psi]
1/4 in
43 N•m [32 lbf•ft]
Endcaps are different for clockwise and counter clockwise rotation.
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Adjustments
Clockwise and counter clockwise rotation
Clockwise rotation
Pressure limiter valves
Controls
Port A
Counterclockwise rotation
Pressure limiter valves
Controls
Port B
Controls
Port B
Controls
Port A
Port B
System
pressure
Port B
System
pressure
*
*
Port A
System
pressure
* Clockwise rotation as seen from
shaft end of pump
Port A
System
pressure
* Counterclockwise rotation as seen
from shaft end of pump
If you change pressure limiter settings, you must also change the HPRV valve to maintain proper PL
function. Refer to table below for corresponding settings.
Pressure limiter setting (bar)
PL setting
150
180
200
230
250
280
300
330
350
380
400
410
420
430
440
450
460
470
480
HPRV
setting
200
230
250
280
300
330
350
380
400
420
450
480
510
1. Install 600 bar [10 000 psi] pressure gauges in the high pressure gauge ports (MA and MB).
2. Install a 50 bar [1000 psi] pressure gauge in the charge pressure gauge port (M3).
Ensure charge pressure is properly set before checking pressure limiter.
3. Start the prime mover and operate at normal speed.
4. Use a 17 mm wrench to loosen the locking nut (L024).
5. Activate the control input until pressure in the high side of the system loop stops rising. This pressure
is the PL setting.
6. Return the pump to neutral and adjust the PL setting using an internal hex wrench.
Wrench size is in the diagram on the previous page.
7. Turn the adjusting screw clockwise to increase the PL setting, counter clockwise to decrease it.
The adjustment is very sensitive. Change per turn is 90 bar [1305 psi].
The model code on the serial plate gives the factory setting of the PL (Pressure Limiter). The PL setting
is referenced to charge pressure. Subtract charge pressure from system pressure gauge readings to
compute the effective PL setting.
The model code on the serial plate gives the factory setting of the PL (Pressure Limiter). The PL setting is
referenced to charge pressure. Subtract charge pressure from system pressure gauge readings to
compute the effective PL setting.
8. Repeat steps 4. and 5. until you reach the desired PL setting.
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Adjustments
9. After adjustment, torque the locknut (L024) to 12 N•m [9 lbf•ft].
C
Caution
Do not over torque.
10. Shut down the prime mover.
11. Remove gauges and replace plugs.
Engaging the Bypass Function
It is possible to damage the drive motor(s) by operating in bypass mode without charge pressure.
Move the vehicle/machine at a speed not more than 20% of maximum for a duration not exceeding 3
minutes.
Use this procedure to bypass the pump to allow moving the vehicle/machine short distances when you
cannot start the prime mover.
Engaging the Bypass Function
L150
P106 649E
1. To open the HPRVs (L150), rotate three revolutions counterclockwise using a hex wrench.
C
Caution
Do not rotate more than 3 revolutions, leakage will result.
2. Rotate them clockwise until seated to close the HPRVs.
See the following table for torque values:
HPRV Wrench Size and Torque Value
Frame size
Wrench size
Torque
045—100
22 mm
70 N•m [52 lbf•ft]
115—250
30 mm
110 N•m [81 lbf•ft]
If machine is towable with HPRVs opened three turns and if wheels are locked (not towable) with HPRV
valves closed, bypass function is working correctly.
Displacement Limiter Adjustment for Single Pumps
If your pump has displacement limiters, you will find them on either servo cover. You can limit forward
and reverse displacement independently.
Displacement limiters are not pre-set by the factory. We install them as far as possible without contacting
the servo piston. Limiting displacement requires clockwise adjustment of the limiting screw.
C
Caution
Before adjusting the displacement limiter, mark the position of the servo cylinder. Be sure the servo
cylinder does not turn when setting the displacement limiter locknut.
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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.
Refer to the table for change per turn. Clockwise rotation decreases displacement, counterclockwise
rotation increases it. Adjustment is possible from zero to maximum.
Approximate displacement change cm3 [in3] per revolution
069
078
089
100
115
147
165
210
250
6.0 [0.37]
7.4 [0.45]
9.3 [0.57]
10.7 [0.65]
10.8 [0.66]
12.2 [0.75]
12.4 [0.76]
13.9 [0.85]
17.4 [1.06]
4. After establishing the desired maximum displacement setting, hold the adjusting screw while
torquing the locknut to the value in the table below.
Displacement Limiter Adjustment Data
Frame
069/078
089/100
115/130, 147/165, 210/250
Locknut wrench size, torque
13 mm, 24 N•m [18
lb•ft]
17 mm, 48 N•m [35
lb•ft]
22 mm, 80 N•m [59 lb•ft]
Adjusting screw wrench size
4 mm
5 mm
6 mm
5. Test operation of the vehicle/machine to verify proper maximum speed of vehicle/work function.
Control Neutral Adjustment
All functions of the Electric Displacement Control (EDC), are preset at the factory. If necessary, adjust the
pump to neutral with the pump running on a test stand or on the vehicle/machine with the prime mover
operating. If adjustment fails to give satisfactory results, you may need to replace the control or coils. See
Minor repair for details.
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Adjustments
Control neutral adjustment
Neutral adjusting screw
4 mm
Servo pressure gauge port M4
0 - 50 bar [0 - 1000 psi]
3/16 in
19 N•m [14 lbf•ft]
Locknut
13 mm
10 N•m
[7 lbf•ft]
Servo pressure gauge port M5
0 - 50 bar [0 - 1000 psi]
3/16 in
19 N•m [14 lbf•ft]
Servo pressure gauge port M5
0 - 50 bar [0 - 1000 psi]
3/16 in
19 N•m [14 lbf•ft]
Servo pressure gauge port M4
0 - 50 bar [0 - 1000 psi]
3/16 in
19 N•m [14 lbf•ft]
P106 145E
1. Install a 50 bar [1000 psi] gauge in each of the two servo gauge ports (M4 and M5).
2. Disconnect the external control input (electrical connections) from the control.
3. Start the prime mover and operate at normal speed.
4. Use a 4 mm internal hex wrench to hold the neutral adjusting screw (D015) stationary while
loosening the locknut (D060) with a 13 mm wrench.
5. Observe pressure gauges and if necessary, turn adjusting screw (D015) to reduce pressure differential.
Adjustment of the EDC is very sensitive. Be sure to hold the hex wrench steady while loosening the
locknut. Total adjustment is less than 120 degrees.
Neutral Adjustment (EDC) (bottom view)
Solenoid shaft
Control spool
Feedback pin
Adjusting
screw
(cam)
Maximum
adjustment
less than 120°
P106 046E
Illustration shows how cam on adjusting pin rotates to adjust for neutral position after pump is reinstalled.
6. Rotate the neutral adjusting screw clockwise until the pressure increases on the gauge.
Note the angular position of the wrench.
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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.
The gauges should read the same pressure, indicating that the control is in its neutral position.
9. Hold the neutral adjusting screw stationary and tighten the locknut (D060). Torque to 12 N•m [9
lbf•ft].
C
Caution
Do not over torque.
10. When the neutral position is set, stop the prime mover and remove the gauges.
11. Install the gauge port plugs.
12. Reconnect the external control input.
A small pressure differential of 1.5 bar [22 psi] or less is acceptable. Zero differential is usually not
possible.
Mechanical Neutral Adjustment
Mechanical neutral is set with the pump running at 1800 min-1(rpm). To set neutral, you must stroke the
pump in each direction. The procedure is the same for each side of each pump for both the front and rear
sections.
You can do this with a small movement of the eccentric screw on EDC controls, however non-feedback
controls (NFPE/FNR) lack this mechanism. To stroke a pump with non-feedback control, you must provide
a 100 Hz PWM signal to the control solenoids. If you perform this adjustment with the pump installed in a
vehicle or machine, safely elevate the wheels or disconnect the mechanism to allow safe operation
during adjustment.
This procedure details setting neutral for the entire pump, one side at a time. Alternate M4/M5 and
MA/MB to zero out forward and reverse directions of the front unit, then move the gauges to M4/M5 of
the rear unit and MC/MD (system gauge ports for the rear unit). Refer to the drawing on the next page to
identify all ports. The front and rear sections are basically mirror images of each other. The control
solenoids C1 and C2 are marked on each control.
While performing this adjustment, you monitor the following pressures:
Servo pressure at M4 and M5
•
•
•
•
System pressure at MA and MB
Pressure differential between M4 and M5 (optional)
Pressure differential between A and B (optional)
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.
Pump Setup
The figure below shows the locations of system and gauge ports you use when adjusting the servo
neutral postion.
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Adjustments
System Pressure Gauge Ports
Servo pressure
port M4
Servo pressure
port M5
Solenoid C1
System
Port B
System Port A
Gauge port MA
system pressure
Gauge port MB
system pressure
Solenoid C2
Servo pressure
port M4
P106 489E
For more information see H1P Ports Information on page 26.
1. Attach a 50 bar [1000 psi] gauge to each servo pressure port M4 and M5.
2. Attach a 600 bar [10 000 psi] gauge to each system pressure port (MA and MB).
3. Remove servo cylinder locking screws (E350) and plates (E300) from both sides of the pump.
4. Disconnect the control solenoids from the vehicle wiring harness.
5. If using a PWM signal to set mechanical neutral, connect the control solenoids C1 and C2 to the signal
source.
Ensure the source supplies no current to the solenoids until required in the following procedure.
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Adjustments
Servo Adjustment
Servo Adjustment
E350
Servo can
locking bolt
E300
Servo can
locking plate
P106 490E
E300
Servo cylinder clamp
E350
Servo cylinder clamp bolt
1. Run prime mover at 1800 min-1 (rpm).
2. If using a PWM signal, ensure the signal is off.
3. Check the servo pressure gauges, ensure the differential between M4 and M5 is less than 2.5 bar [36
psi].
4. Using a 3/4 in deep socket, unthread both servo cylinders 2-3 turns.
This step ensures the servo cylinders have no contact with the servo piston.
5. Stroke the pump by turning the control eccentric screw (or supplying current to solenoid C1) until the
servo pressure at port M4 is 1 to 2 bar [14– 29 psi] greater than at port M5 and the system pressure
gauges indicate displacement.
Pressure should be greater at port MA for clockwise rotation, or MB for counterclockwise rotation.
This also indicates the servo piston is in contact with the servo cylinder on side M5.
6. Maintain servo pressure differential between 1-2 bar [14-29 psi] during this step. Slowly thread the
servo cylinder on the M5 side in until the system pressure differential starts to decrease. Continue
turning the servo cylinder in until the system delta pressure results in no machine movement.
System delta pressure (ports MA to MB or MC to MD) between 3-4 bar typically does not cause
machine movement. If service of a pump is not performed on the machine, validation of machine
movement must be checked upon machine start up.
7. Repeat steps 1. to 5. but stroke the pump in the opposite direction by turning the eccentric screw in
the opposite direction, or by supplying current to solenoid C2 to complete setting neutral.
Reverse gauge locations (M4 for M5, MB for MA etc.) from those stated above since the pump is now
stroking the other direction.
8. Set neutral for the rear pump by repeating steps 1. to 6. on the rear pump. Remember that the rear
pump is a mirror image of the front pump and therefore the locations of the servo gauge ports
(M4/M5) and the control solenoids (C1/C2) are opposite.
9. Remove all gauges and replace gauge port plugs.
You can find wrench sizes and plug torques in the Plug Size and Torque Chart on page 64.
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Minor Repair
Standard Procedures at Removing Pump
Before working on the pump, thoroughly clean the outside. If the pump has an auxiliary pump attached,
remove both pumps as a single unit.
1. With the prime mover off, thoroughly clean all dirt and grime from the outside of the pump.
2. Tag, disconnect, and cap each hydraulic line connected to the pump.
3. As hydraulic lines are disconnected, plug each open port, to ensure that dirt and contamination do
not get into the pump.
Be careful, do not damage solenoids and electrical connections when using straps or chains to
support the pump.
4. Ensure the work surface and surrounding area are clean and free of contaminants such as dirt and
grime.
5. Inspect the system for contamination.
6. Look at the hydraulic fluid for signs of system contamination, oil discoloration, foam in the oil, sludge,
or metal particles.
7. Before replacing the pump, replace all filters and drain the hydraulic system.
8. Flush the system lines and fill the reservoir with the correct, filtered hydraulic fluid.
9. Fill the pump with clean, filtered hydraulic fluid.
10. Attach the pump to the prime mover and torque mounting screws according to the manufacturers
recommendation.
11. Replace all hydraulic lines.
12. Ensure the charge inlet line is filled with fluid.
EDC Control Repair
Control module and solenoid removal/installation
D050 (3X)
4 mm
5 N•m [4 lbf•ft]
D025A
D1
D250
5 mm
13.5 N•m
[10 lbf•ft]
D025
D025A
D084
5 N•m
[4 lbf•ft]
D150
F100 (2X)
3 mm
2.5 N•m
[1.8 lbf•ft]
D050 (3X)
4 mm
D300 (2X)
P106 052E
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H1P 069—H1P 250 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.
Tag and number the orifices for reinstallation.
4. If screen (D084) is clogged, use a hook to remove retaining ring (D098) and screen.
5. Remove and discard screen (D084).
EDC Control Installation
Inspect the machined surfaces on the control and top of the pump. If you find any nicks or scratches,
replace the component.
Ensure you install dowel pins (D300) in housing before installing control.
1. Install a new gasket (D150).
2. If you removed screen (D084), install a new one with the mesh facing outward.
Remove plug on top of control to ensure the swashplate feedback pin is properly positioned in the
center of the control module when installing control.
Proper screen orientation
D084
D084
Incorrect screen
orientation
Correct screen
orientation
P106 618E
3. If previously removed, install orifices using a 3 mm internal hex wrench and torque to 2.5 N•m [1.8
lbf•ft].
4. Install the control module and six cap screws (D250).
5. Using a 5 mm internal hex wrench, torque the cap screws (D250) to 13.3 N•m [9.8 lbf•ft].
Torque sequence
1
2
6
5
4
3
Control Solenoids Repair
1. Disconnect electrical connection and remove the three cap screws (D050) using a 4 mm internal hex
wrench.
2. Remove the solenoid (D025) and O-ring (D025A). Discard the O-ring.
3. If necessary, remove the coil using a 12 point 26 mm socket.
Inspect the machined surfaces on the control and top of the pump. If you find any nicks or scratches,
replace the component.
4. Lubricate new O-ring (D025A) using petroleum jelly and install.
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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].
7. Reconnect electrical connections and test the pump for proper operation.
Control Solenoids Repair
1. Disconnect electrical connection and remove the three cap screws (D050) using a 4 mm internal hex
wrench.
2. Remove the solenoid (D025) and O-ring (D025A). Discard the O-ring.
3. If necessary, remove the coil using a 12 point 26 mm socket.
Inspect the machined surfaces on the control and top of the pump. If you find any nicks or scratches,
replace the component.
4. Lubricate new O-ring (D025A) using petroleum jelly and install.
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].
7. Reconnect electrical connections and test the pump for proper operation.
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Minor Repair
MDC Control Repair
MDC with CCO
D250
D065
D692
D065
D693
D250
D750
D735
D81
D084
D098
D80
F00T
MDC with neutral start switch
D250
D065
D150
D200
D300 (2X)
F00A
F00B
F00P
D751
D750
P108784
MDC with neutral start switch and CCO
D250
D065
D751
D750
D81
D80
MDC Repair Legend:
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Minor Repair
D80 – Solenoid
D81 – O-ring
D098 – Retaining ring
D750 – Neutral start switch
D751 – O-ring
Wrench size and torque
Item
Description
Wrench size
Torque
D065
O-ring plug
3/16 internal hex
12 N•m [9 lbf•ft]
D200
Feedback pin
13 mm deep well socket
22.5-27.5 N•m [16.6-20.3 lbf•ft]
D250
Cap screw
5 mm internal hex
13.3 N•m [9.8 lbf•ft]
D735
Plug
3/4 inch
30 N•m [22 lbf•ft]
F00A, F00B
Servo orifice
F00P
Supply orifice
3 mm internal hex
2.5 N•m [1.8 lbf•ft]
F00T
Tank orifice
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 servo orifices (F00A, F00B), supply orifice (F00P), and tank orifices (F00T) using a
3 mm internal hex wrench.
Tag and number the orifices for reinstallation.
4. If screen (D084) is clogged, use a hook to remove retaining ring (D098) and screen.
5. Remove and discard screen (D084).
6. Before removing the control, note the position of the control lever for reassembly.
The functionality of the MDC control and the neutral position of the pump can be lost.
Do not disassemble the MDC control.
MDC Repair Legend, Wrench size and Torque
D084
Screen
D80
Solenoid
D81
O-ring
D098
Retaining ring
D750
Neutral start switch
D751
O-ring
Wrench size and torque
© Danfoss | January 2020
Item
Description
Wrench size
Torque
D065
O-ring plug
3/16 internal hex
12 N•m [9 lbf•ft]
D200
Feedback pin
13 mm deep well socket
22.5-27.5 N•m [16.6-20.3 lbf•ft]
D250
Cap screw
5 mm internal hex
13.3 N•m [9.8 lbf•ft]
D735
Plug
3/4 inch
30 N•m [22 lbf•ft]
F00A, F00B
Servo orifice
F00P
Supply orifice
3 mm internal hex
2.5 N•m [1.8 lbf•ft]
F00T
Tank orifice
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Minor Repair
MDC Control Assembly
Ensure you install dowel pins (D300) in housing before installing control.
The pump will lose control, causing a potentially hazardous situation.
If a feedback pin comes off during operation, ensure the feedback pin is properly torqued before
continuing with reassembly.
1. Install a new gasket (D150).
2. If previously removed, install orifices using a 3 mm internal hex wrench and torque to 2.5 N•m [1.8
lbf•ft].
3. Install the control module and six cap screws (D250).
4. Using a 5 mm internal hex wrench, torque the cap screws (D250) to 13.3 N•m [9.8 lbf•ft].
Torque sequence
1
2
6
5
4
3
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.
3. Remove the protection cover from the control.
4. Discard the protection cover if it is damaged.
5. Remove sensor screws (D770) using a 4 mm internal hex wrench.
6. Remove and discard the sensor.
7. Position a new sensor on control housing.
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Minor Repair
8. Using a 4 mm internal hex wrench, fasten sensor to control housing with screws (D770). Torque
screws to 1.85 N•m [1.36 lbf•ft].
9. Position protection cover on control housing over sensor.
10. Using a 4 mm internal hex wrench, fasten protection cover with screws (D767). Torque screws to 1.85
N•m [1.36 lbf•ft].
W
Warning
Calibration of sensor output in vehicle software is mandatory after sensor replacement because output
signal can vary from one sensor to the other.
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. Remove the control module and gasket (D150) and discard the gasket.
4. Install a new gasket (D150).
5. Ensure assembly fixture is positioned over the linkage spring in EDC center.
6. Position the control on the pump housing and ensure that feedback pin on swashplate is positioned
properly in control arm.
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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.
8. Install the control module and six cap screws (D250).
9. Using a 5 mm internal hex wrench, fasten control to pump with screws (D250).
10. Torque screws to 13.3 N•m [9.8 lbf•ft] following torque sequence shown.
Torque sequence
(6 screw control)
5
4
2
1
6
3
D065
For proper neutral adjustment procedure, refer to Control Neutral Adjustment on page 38 topic.
W
Warning
Calibration of sensor output in vehicle software is mandatory after sensor replacement because output
signal can vary from one sensor to the other.
Automotive Control Repair
Drain pump completely before removing control.
Possible erratic pump operation.
Do not allow metal fragments to fall into control housing. Do not fail to install screen.
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Minor Repair
Security
wax seal (2X)
13.3 Nm
[9.8 lbf•ft]
D610 (2X)
D250
5 mm
(6X)
D672
D674
D084
D640
D098
2.5 Nm
[1.8 lbf•ft]
F00A
D150
3 mm F00B
P107 990E
1. Disconnect and remove wiring (D640).
2. Fabricate a special tool to remove two plastic plugs (D610).
See drawing below for tool dimensions.
Special
tool
Plug
45 deg.
Ø 9.22 mm
Ø 14 mm
Ø 1.7 mm (x3)
P108 021E
3. Push down on plug and turn 45 degrees counterclockwise.
4. Discard plugs.
Wax seals will be destroyed when the plugs are removed.
C
Caution
Do not damage the housing in the plug sealing area.
5. Use a 5 mm internal hex to remove two screws (D674) and remove shield (D672).
6. Use a 5 mm internal hex to remove six screws (D250) and remove control from pump.
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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.
Tag and number the orifices for reinstallation.
9. If it is necessary to remove the screens, drill out screen retention ring (D098).
Drill Out Retention Ring
Screen
Retention
Ring
P108 022E
Note screen orientation for reassembly.
10. Remove and discard screen (D084).
AC Control Installation
Inspect control, pump housing and plastic PC board housing, and its sealing areas.
C
Caution
Do not damage the plastic housing in the plug sealing area when installing the screws.
Inspect the machined surfaces on the control and top of the pump. If you find any nicks or scratches,
replace the component.
If pump has been rebuilt or a new control is being installed, control software must be recalibrated. Refer
to H1 Automotive Control User Manual for recalibration instructions.
1. If you removed screen (D084), install a new one with the mesh facing outward.
2. Install a new retaining ring (D098).
Be sure screen will not move axially in bore after retention ring is installed.
Proper screen orientation
D098
D084
D084
Correct screen
orientation
Incorrect screen
orientation
3. If previously removed, install orifices using a 3 mm internal hex wrench and torque to 2.5 N•m [1.8
lbf•ft].
4. Install a new gasket (D150).
5. Install the control module and six cap screws (D250).
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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
1
2
6
5
4
3
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.
If control will continue to be under warranty, install new sealing wax of a different color (original wax
is blue). Pumps without sealing wax installed will not be warrantied.
9. Install protection bracket (D672).
10. Install screws (D674). Torque to 5 N•m [3.7 lbf•ft].
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.
1. Remove the retaining ring (J200) using retaining ring pliers. Press the bearing off the shaft.
2. Pull the shaft (J100) with bearing (J150) out of the pump.
If necessary, tap lightly on the shaft to dislodge it from the cylinder block.
C
Caution
Do not damage the housing bore, shaft or bearing when removing the shaft and bearing.
3. For 069/078, 115/130, 147/165 — Puncture the seal (J250) and use a slide-hammer type puller to
remove the seal. Discard the seal.
4. For 89/100, 210/250 — Use a small pry device against the raised edge of the seal carrier to remove
the seal/carrier assembly. Discard the assembly.
5. Use a press or gear puller to press down on the shaft.
6. Using a snap-ring pliers, remove the inner snap-ring (J200).
7. Pull the shaft (J100) with bearing (J150) out of the pump.
If necessary, tap lightly on the shaft to dislodge it from the cylinder block.
C
Caution
Do not damage the housing bore, shaft or bearing when removing the shaft and bearing.
8. After you remove the shaft, take care not to move or jar the pump. Reassembly can be difficult if the
internal components move while the shaft is out.
9. Remove snap-ring (J300).
10. Press bearing (J150) from shaft.
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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.
3. Rotate the bearing, if it does not rotate smoothly, replace it.
4. Press bearing (J150) on shaft. Install snap-ring (J300).
5. Install the shaft/bearing assembly into the pump.
6. Rotate the shaft to align it with the block and charge pump splines.
7. Press down on the shaft and replace the inner snap ring (J200).
8. Cover end of the shaft with an installation sleeve to protect the seal during installation.
9. Lubricate the seal. Tap on the seal replacing tool or an appropriate deep-socket to press in the seal.
10. Remove the protective cover.
Seal Installation Tool
7 mm
[0.276 in]
55 mm
[2.17 in]
50°
44.7 mm
[1.76 in]
68.5 mm
[2.70 in]
51 mm
[2. in]
78 mm
[3.07 in]
120 mm
[4.72 in]
078/089/100
7 mm
[0.28 in]
89.4 mm
[3.52 in]
57.5 mm
[2.26 in]
78 mm
[3.07 in]
80°
82 mm
[3.23 in]
115/130
147/165
4.4 mm
[0.17 in]
89.4 mm
[3.52 in]
80°
75.6 mm
[2.97 in]
210/250
P106492
11. Install the remaining snap ring (J200).
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H1P 069—H1P 250 Axial Piston Single Pumps
Minor Repair
External Filter Repair
T035
T045
T150
T015
24mm
P106 035E
1. With the prime mover off, hold the filter (T150) in place, and remove the plug (T015) using a 24 mm
wrench.
2. Remove the filter.
3. Remove and discard the seal (T045) and O-ring (T035).
4. Inspect the plug and sealing surfaces in the filter bracket.
5. Replace any damaged components.
6. Install new seal (T045) and O-ring (T035) on plug.
7. Apply hydraulic fluid to the O-ring and seal for lubrication.
8. Insert the plug into the bracket.
9. Use a 24 mm wrench to hold the plug in place and install the replacement filter.
Hand tighten filter till it contacts O-ring, then tighten 1/2 turn further.
10. Start the prime mover.
Cycle the pump through normal machine operation and check for leaks.
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Minor Repair
Filter Bypass Valve and Switch Repair
T025
6 mm
16-20 N•m
[12 - 15 lbf•ft]
T350
T040
T030
T010
T020
T200
T300
3 mm
1.5 N•m
[1 lbf•ft]
T025
6 mm
16-20 N•m
[12 - 15 lbf•ft]
T250
T040
6mm
32 N•m
[24 lbf•ft]
P106 138E
1. Remove three screws (T250) using a 6mm internal hex wrench.
2. Remove the filter adapter (T010) and gasket (T350). Discard the gasket.
3. Remove plugs (T025) using an 8 mm internal hex wrench.
4. Remove and discard O-rings (T040).
5. Remove spring (T030), and poppet (T020).
6. If necessary, remove cap screws (T300) and bypass switch (T200) using a 3 mm internal hex wrench.
It is not necessary to remove bypass switch (T200) unless it is being replaced.
7. Inspect poppet (T020) for bending or damage, and replace if necessary.
8. Inspect spring (T030) for cracks or warpage, and replace if necessary.
9. Inspect sealing surface of filter adapter (T010) for scratches or damage; resurface or replace scratched
or damaged part.
10. Lubricate and replace O-ring (T040) on plug (T025).
11. Install poppet (T020), spring (T030), and plug (T025). Torque to 18 N•m [13 lbf•ft].
12. If replacing bypass switch, install and torque 3 mm cap screws (T300) to 1.4 N•m [1 lbf•ft].
13. Install adapter assembly (T010) using new gasket (T350) to pump.
14. Install cap screws (T250) using a 6 mm internal hex wrench. Torque to 32 N•m [24 lbf•ft].
Charge Pump Repair (Removable Auxiliary Pad)
If an auxiliary pump is attached, remove auxiliary pump and coupling before servicing charge pump.
Position pump with front shaft pointing downward. Attach securely to a proper work stand.
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Minor Repair
Charge Pump Repair (removable auxiliary pad)
S200
S300
S300
S250
S100
K400
10 mm
92 Nm [68 ft•lb]
S150
P106 036E
K200
K500
G450
K150
K100
K400
10 mm
92 Nm [68 ft•lb]
K100
1. Using a 10 mm internal hex wrench, remove cap screws (K400).
2. Remove charge pump cover or auxiliary pad (K100) and gasket (K150), and discard the gasket.
Alignment pins (G450) may remain in cover or endcap.
3. Remove auxilliary pump and O-ring (K250), and discard O-ring.
4. Remove charge pump cover screws (K450) and charge pump cover (K550).
5. Remove thrust washer (K500).
Note the orientation of thrust washer. Coated side is towards charge pump coupling (K200).
6. Remove pressure-balance plate (S200) with seal (S300). Discard seal (S300).
Note orientation of valve plate and seal.
7. Remove charge pump coupling K200).
8. Remove charge pump gear set (S100) and outer ring (S150).
9. Inspect carefully the valve and pressure balance plates for wear, scratches or pits.
Scratches on these components will cause a loss of charge pressure.
If any component shows signs of wear, scratching, or pitting, replace it.
Charge Pump Repair (Integrated Auxiliary Pad)
If an auxiliary pump is attached, remove auxiliary pump and coupling before servicing charge pump.
Position pump with front shaft pointing downward. Attach securely to a proper work stand.
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H1P 069—H1P 250 Axial Piston Single Pumps
Minor Repair
Charge Pump Repair (integrated auxiliary pad)
S200
S300
S300
K450
6 mm
10 Nm [7 ft•lb]
S250
S100
K550
S150
P106 353E
K200
K500
K250
1. Remove auxilliary pump and O-ring (K250), and discard O-ring.
2. Remove charge pump cover screws (K450) and charge pump cover (K550).
3. Remove thrust washer (K500).
Note the orientation of thrust washer. Coated side is towards charge pump coupling (K200).
4. Remove pressure-balance plate (S200) with seal (S300). Discard seal (S300).
Note orientation of valve plate and seal.
5. Remove charge pump coupling K200).
6. Remove charge pump gear set (S100) and outer ring (S150).
7. Remove valve plate (S250) with seal (S300). Discard seal (S300).
Note the orientation of valve plate and seal.
8. Inspect carefully the valve and pressure balance plates for wear, scratches or pits.
Scratches on these components will cause a loss of charge pressure.
If any component shows signs of wear, scratching, or pitting, replace it.
Charge Pump Reassembly
1. Install new seals (S300) in the valve (S250) and pressure balance (S200) plates.
2. Install valve plate (S250) in the same orientation as removed.
3. Lubricate and install charge pump gearset (S100) and outer ring (S150).
4. Install charge pump coupling (K200).
5. Install pressure-balance plate (S200) in the same orientation as removed.
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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.
9. Using a 10 mm internal hex wrench, torque the cap screws (K400) to 92 N•m [68 ft•lb],
10. OR using a 6 mm internal hex wrench, torque the cap screws (K450) to 10 N•m [7 lbf•ft].
Torque in sequence below.
Cover (K100) Torque Sequence
Cover (K550) Torque Sequence
5
5
2
1
7
1
3
4
4
2
6
3
P106 659E
6
8
P106 196E
11. Ensure proper torque on aux. pad screws (K400), and if necessary, replace screws.
If charge pump replacement is necessary, replace complete charge pump kit.
High Pressure Relief Valve Repair
L060
L068
L150
P106 039E
see table
1. Using a hex wrench wrench shown in the table below, remove the HPRVs (L150).
2. Inspect the sealing surfaces in the pump for nicks or scratches, check the valves for damage.
3. Replace any damaged components.
4. Remove and discard the O-rings (L060) and backup rings (L068).
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Minor Repair
5. Lubricate and install new backup rings (L068) and O-rings (L060).
6. Install HPRVs, and torque to the value in the table.
Frame size
Wrench size
Torque
069/078/089/100
22 mm
70 N•m [52 lbf•ft]
115/130/147/165/210/250
30 mm
110 N•m [81 lbf•ft]
7. Operate the vehicle/machine through full range of controls to ensure proper operation.
8. Check for leaks.
Charge Pressure Relief Valve Repair
C
Caution
Replace the charge pressure relief valve (V010) as a complete unit. Do not attempt to repair the internal
components of the valve.
V024
V010
22 mm
52 N•m
[38 lbf•ft]
P106 040E
1. Using a 22 mm wrench, remove the charge pressure relief valve (V010).
2. Discard a seal (V024).
3. Inspect the sealing surfaces of the pump for nicks or scratches.
4. Lubricate and install the new seal (V024).
5. Install the charge pressure relief valve, and torque to 52 N•m [38 lbf•ft].
6. Operate vehicle/machine through full range of controls to ensure proper operation.
See Charge Pressure Relief Valve Adjustment for adjustment instructions.
Pressure Limiter Repair
C
Caution
Replace the pressure limiter valve (V010) as a complete unit. Do not attempt to repair the internal
components of the valve.
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Minor Repair
L300
L400
O
L022
E101336
1. Using a 22 mm wrench, remove the pressure limiter valve (L100), and discard O-ring.
2. Inspect the sealing surfaces of the pump for nicks or scratches.
3. Install new O-ring.
O-ring is available separately.
4. Lubricate O-ring with petroleum jelly.
5. Replace pressure limiter valve and torque to the value in the table below.
Frame size
Wrench size
Torque
069/078/089/100/115/130/147/165
22 mm
70 N•m [52 lbf•ft]
210/250
24 mm
70 N•m [52 lbf•ft]
6. Operate pump at full range of controls to ensure proper machine operation.
See Pressure Limiter Adjustment on page 35 for adjustment instructions.
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Torque Chart
Fasteners and Plugs
L150
High pressure
relief valve
V020
Charge pressure
adjusting screw
V022
Charge pressure
locking nut
V010
Charge pressure
cartridge
K400
Rear cover / auxiliary pad
mounting bolt
L150
High pressure
relief valve
T015
Filter mounting bolt
P106 066E
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Torque Chart
B015 O-ring plug, 7/16 - 20
D015 Neutral adjusting screw
D060 Neutral adjust locking nut
L010 Pressure limiter adjusting screw
L024 Pressure limiter locking nut
L028 Pressure limiter plug (special)
D050 Coil mounting bolt
L012 Pressure limiter cartridge
G302 O-ring plug, 5/16 - 24 UNF
B020 O-ring plug
1-1/16 - 12
G300 O-ring plug, 9/16 - 18
E350
Servo can locking bolt
B035 O-ring plug, see table
D250
Electric control
mounting bolt
G250 O-ring plug, 9/16 - 18
G302 O-ring plug
5/16 - 24 UNF
D065 O-ring plug, 7/16 - 20
P106 497E
Fastener Size and Torque Chart
H1P 069—250
Item
Fastener
Wrench size
Torque
D015
Neutral adjust screw
4 mm internal hex
NA
D050
Coil mounting bolt
4 mm internal hex
8 N•m [6 lbf•ft]
D060
Neutral adjust locking nut
13 mm
10 N•m [7 lbf•ft]
D200
Swash plate feedback pin (not shown)
13 mm deep well socket
25 N•m [18 lbf•ft]
D250
Electric control mounting bolt
5 mm internal hex
13.3 N•m [9.8 lbf•ft]
E350
Servo can locking bolt
10 mm
14.5 N•m [11 lbf•ft]
T015
Filter mounting bolt
24 mm
21 N•m [15 lbf•ft]
T025
Filter adapter gage plug
6 mm internal hex
18 N•m [13 lbf•ft]
V010
Charge pressure cartridge
22 mm
52 N•m [38 lbf•ft]
V020
Charge pressure adjusting screw
4 mm internal hex
NA
V022
Charge pressure locking nut
13 mm
19 mm (210/250)
12 N•m [9 lbf•ft]
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Torque Chart
Plug Size and Torque Chart
Item B020
Frame size
069/078
147/165
210/250
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]
70 N•m [52 lbf•ft]
150 N•m [110 lbf•ft]
Items for pump frame size H1P 069—250
64 | © Danfoss | January 2020
Item
O-ring plug
Wrench size
Torque
B015
7/16–20
3/16 mm internal hex
12 N•m [9 lbf•ft]
B035 (069/078) 1 1/16–12
9/16 internal hex
70 N•m [52 lbf•ft]
B035 (147/165) 1 5/16–12
5/8 internal hex
150 N•m [110 lbf•ft]
D065
7/16–20
3/16 internal hex
12 N•m [9 lbf•ft]
G250
9/16–18
1/4 internal hex
40 N•m [29.5 lbf•ft]
G300
9/16–18
3/16 internal hex
40 N•m [29.5 lbf•ft]
G302
5/16–24 UNF
1/8 internal hex
5 N•m [4 lbf•ft]
AX00000087en-000402
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Daikin-Sauer-Danfoss
www.daikin-sauer-danfoss.com
Danfoss
Power Solutions (US) Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: +1 515 239 6000
Danfoss
Power Solutions GmbH & Co. OHG
Krokamp 35
D-24539 Neumünster, Germany
Phone: +49 4321 871 0
Danfoss
Power Solutions ApS
Nordborgvej 81
DK-6430 Nordborg, Denmark
Phone: +45 7488 2222
Danfoss
Power Solutions Trading
(Shanghai) Co., Ltd.
Building #22, No. 1000 Jin Hai Rd
Jin Qiao, Pudong New District
Shanghai, China 201206
Phone: +86 21 2080 6201
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already on order provided that such alterations can be made without subsequent changes being necessary in specifications already agreed.
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© Danfoss | January 2020
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