H1B 060 080 110 160 210 250 bent axis motors service manual
AX152886484369en-000608 Service Manual
H1B 060/080/110/160/210/250 H1 Bent Axis Motors
www.danfoss.com
Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Revision history
Table of revisions
Date
Changed
July 2024
Added metric information
March 2020
Added adjustment details for threshold settings and changed document number from AX00000025
August 2019 Added caution for servo piston removal
August 2018 update adjustment chapter
April 2018
Major layout update, QF080 to QM050 updates
January 2018 update pressure compensator torque values
July 2016
Add G1, G2 controls
December 2015 Add 210 frame size
November 2015 Model code change
July 2015
correct torque values, pages 61, 62
June 2015
add hydraulic controls THHA, THHB
2008-2015
First edition - and next various changes.
Rev 0608 0607
0505 0504 0503 0502 0501 0500 0400 0301 0300 AA-CB
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Contents
Introduction
About this manual............................................................................................................................................................................5 Warranty.............................................................................................................................................................................................. 5 General Instructions........................................................................................................................................................................ 5 Safety precautions............................................................................................................................................................................5 Symbols used in Danfoss literature............................................................................................................................................7
H1 general information
Design of H1 bent axis motor...................................................................................................................................................... 8 About the H1 motors....................................................................................................................................................................10 H1 pictorial diagram..................................................................................................................................................................... 11 H1 system schematic.................................................................................................................................................................... 12
Technical specifications
General specifications.................................................................................................................................................................. 13 Physical properties........................................................................................................................................................................ 13 Operating Parameters.................................................................................................................................................................. 14 H1B speed range diagrams for open and closed circuit..................................................................................................15 Required inlet pressure diagrams (for cylinder block filling)......................................................................................... 16 Open circuit requirements..........................................................................................................................................................17 Fluid specifications........................................................................................................................................................................18 Determination of nominal motor size.................................................................................................................................... 18
Operation
Shaft rotation direction................................................................................................................................................................19 Loop flushing shuttle spool........................................................................................................................................................21 Loop flushing relief valve............................................................................................................................................................ 22 Speed sensor................................................................................................................................................................................... 23 Displacement limiter.....................................................................................................................................................................23
Operating parameters
Output speed...................................................................................................................................................................................24 System pressure............................................................................................................................................................................. 24 Case pressure...................................................................................................................................................................................25 External shaft seal pressure........................................................................................................................................................25 Temperature.................................................................................................................................................................................... 25
Fluid and filter maintenance Fluid and filter recommendations........................................................................................................................................... 26
Pressure measurements
Ports and Gauge Information.................................................................................................................................................... 27
Initial startup procedures Procedure..........................................................................................................................................................................................29
Troubleshooting
Overview........................................................................................................................................................................................... 31 Electrical troubleshooting.......................................................................................................................................................... 31 Sluggish operation........................................................................................................................................................................ 31 System operating hot...................................................................................................................................................................31 Excessive noise or vibration....................................................................................................................................................... 32 Motor operates normally in one direction only..................................................................................................................32 Improper output speed............................................................................................................................................................... 32 Low output torque........................................................................................................................................................................ 32
Required tools and standard procedures
Adjustments
Optional threshold adjustment Electric proportional controls................................................................................. 36 Optional threshold adjustment Hydraulic proportional controls.............................................................................37 Pressure Compensator OverRide (PCOR) adjustment...................................................................................................... 38
Minor repair
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Contents Torque chart
Shaft seal........................................................................................................................................................................................... 41 Electric proportional solenoid replacement........................................................................................................................ 43 Hydraulic proportional actuator replacement.................................................................................................................... 44 Control module replacement.................................................................................................................................................... 45 Electric proportional control module..................................................................................................................................... 47 Hydraulic proportional control module.................................................................................................................................50 Electric two-position control module.....................................................................................................................................52 Hydraulic two-position control module................................................................................................................................ 55 Hydraulic two-position control module with PCOR..........................................................................................................56 Hydraulic two-position control module with PCOR and hydraulic BPD.................................................................... 57 Maximum displacement limiter two-position controls................................................................................................... 59 Servo piston cover proportional control............................................................................................................................60 Replace speed sensor................................................................................................................................................................... 63 Loop flushing spool.......................................................................................................................................................................64 Loop flushing charge relief valve............................................................................................................................................. 65 Minimum Displacement limiter................................................................................................................................................66
Fasteners, plugs with torque chart..........................................................................................................................................67
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Introduction About this manual
This manual includes information for the installation, maintenance, and minor repair procedures for H1 bent axis motors. It includes a description of the unit and its individual components, troubleshooting information, and minor repair procedures.
Performing minor repairs may require removal from the vehicle/machine. Thoroughly clean the unit before beginning maintenance or repair activities. Since dirt and contamination are the greatest enemies of any type of hydraulic equipment, follow cleanliness requirements strictly. This is especially important when changing the system filter and when removing hoses or plumbing.
Only Danfoss global service partners (GSPs) are authorized to perform major repairs.Danfoss trains Global Service Partners and certifies their facilities on a regular basis. You can locate your nearest service partner at www.danfoss.com > Contact us > Danfoss sales and services > Distributor and service partners
Warranty
Performing installation, maintenance, and minor repairs according to the procedures in this manual will not affect your warranty. Major repairs requiring the removal of a unit's rear cover voids the warranty unless done by a Danfoss Global Service Partner.
General Instructions
When repairing H1 variable displacement closed circuit motors follow these general procedures:
Remove the unit
Chock the wheels on the vehicle or lock the mechanism to inhibit movement. Prior to performing repairs, remove the unit from the vehicle/machine. Be aware that hydraulic fluid may be under high pressure and/or hot. Inspect the outside of the motor and fittings for damage. Cap hoses after removal to prevent contamination.
Keep it clean
Cleanliness is a primary means of assuring satisfactory motor life, on either new or repaired units. Clean the outside of the motor thoroughly before disassembly. Take care to avoid contamination of the system ports. Cleaning parts with a clean solvent wash and air drying is usually adequate. Keep all parts free of foreign materials and chemicals. Protect all exposed sealing surfaces and open cavities from damage and foreign material.
Lubricate moving During assembly, coat all moving parts with a film of clean hydraulic oil. This
parts
assures that these parts are lubricated during start-up.
Replace all O-rings Danfoss recommends you replace all O-rings and gaskets during repair. Lightly
and gaskets
lubricate O-rings with clean petroleum jelly prior to assembly.
Secure the unit
For repair, place the unit in a stable position with the shaft pointing downward. Secure the motor while removing and torquing components and fasteners.
Safety precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and others from injury. Take the following general precautions whenever servicing a hydraulic system.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Introduction
Unintended machine movement
W Warning
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable/disconnect the mechanism while servicing.
Flammable cleaning solvents
W Warning
Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area where a source of ignition may be present.
Fluid under pressure
W Warning
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and/or infection. This fluid may also be hot enough to cause burns. Use caution when dealing with hydraulic fluid under pressure. Relieve pressure in the system before removing hoses, fittings, gauges, or components. Never use your hand or any other body part to check for leaks in a pressurized line. Seek medical attention immediately if you are cut by hydraulic fluid.
Personal safety
W Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.
Hazardous material
W Warning
Hydraulic fluid contains hazardous material. Avoid prolonged contact with hydraulic fluid. Always dispose of used hydraulic fluid according to environmental regulations.
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Introduction
Symbols used in Danfoss literature WARNING may result in injury
CAUTION may result in damage to product or property Reusable part
Non-reusable part, use a new part
Tip, helpful suggestion Lubricate with hydraulic fluid Apply grease / petroleum jelly Apply locking compound
Non-removable item
Inspect for wear or damage
Option - either part may exist Superseded - parts are not interchangeable Measurement required
Clean area or part Be careful not to scratch or damage Note correct orientation
Flatness specification
Mark orientation for reinstallation
Parallelism specification
Torque specification
External hex head
Press in - press fit
Internal hex head
Pull out with tool press fit
Torx head
Cover splines with installation sleeve
O-ring boss port
Pressure measurement/gauge location or specification
The symbols above appear in the illustrations and text of this manual. They are intended to communicate helpful information at the point where it is most useful to the reader. In most instances, the appearance of the symbol itself denotes its meaning. The legend above defines each symbol and explains its purpose.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
H1 general information Design of H1 bent axis motor
Cross-section of H1 motor with electric proportional control
1
5
2 3
4
6 7
10
9
8
1. Differential servo piston 2. Valve segment 3. Bearing plate 4. Tapered roller bearing 5. Loop flushing relief valve 6. Ramp spring 7. Loop flushing shuttle spool 8. Electric proportional control 9. Minimum displacement limiter 10. Speed ring (optional)
P005 917
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H1 general information Cross-section of H1 motor with electric two-position control 7
6
1
2
3
5
4
9 8
1. Differential servo piston 2. Valve segment 3. Bearing plate 4. Tapered roller bearing 5. Loop flushing relief valve 6. Loop flushing shuttle spool 7. Electric two-position control 8. Minimum displacement limiter 9. Speed ring (optional)
P005 918
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
H1 general information
About the H1 motors
Series H1 variable displacement motors are bent axis design, incorporating spherical pistons.
These motors are designed primarily to be combined with other products in closed circuit systems to transfer and control hydraulic power. Series H1 motors have a large maximum/minimum displacement ratio of 5:1 and high output speed capabilities.
The expanded function of zero degree capability, coupled with a high performance 32 degree maximum angle, creates opportunities to easily improve the machine performance for:
· Wheel assist on the steering axle of high inertia machines (i.e. combines) and could include Anti Slip
Control
· Off-highway machines requiring Anti Slip Control (i.e. Ag. sprayer) · Multi-motor applications requiring optimized work and transport modes (i.e. wheel loader, Ag
sprayer) utilizing the zero degree position for maximum transport speed
· Improved machine (i.e. single drum roller) gradeability through precise Anti Slip Control
The Anti Slip Control reduces ground damage, increases traction control and improves machine controllability for the operator.
SAE, Cartridge (not available for 210 cm3 and 250 cm3) and DIN flange with radial or axial high pressure port configurations are available including the loop flushing device.
A complete family of controls and regulators are available to fulfill the requirements of a wide range of applications.
Motors normally start at maximum displacement. This provides maximum starting torque for high acceleration.
All controls utilize internally supplied servo pressure. This may be overridden by a pressure compensator which functions when the motor is operating in motor and pump modes. A defeat option is available to disable the pressure compensator override when the motor is running in pump mode during deceleration/braking.
The pressure compensator option features a low pressure rise to ensure optimal power utilization throughout the entire displacement range of the motor.
Speed sensor options are available to cover all frame sizes and flange styles.
They are capable of sensing the following, all in one package:
· Speed · Direction (only group "J", option "S") · Temperature (only group "J", option "S")
The electric controls are specifically designed for the Danfoss family of PLUS+1® microcontrollers for easy "Plug and Perform" installation.
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H1 general information H1 pictorial diagram
14
15 2
3 12
11 17
9
7
5
13
6 18
4
10
8
5 7
Working loop A (Low pressure) and charge pressure Working loop B (High pressure) Servo pressure Case drain Suction
16 1
P003 423
1. Bent Axis Variable Displacement Motor 2. Axial Piston Variable Displacement Pump 3. Electric Displacement Control (EDC) 4. Charge Pump 5. Charge Check / High Pressure Relief Valve 6. Loop Flushing Valve 7. Pressure Limiter Valve 8. Charge Pressure Relief Valve 9. Servo Cylinder
10. Charge Pressure Filter 11. Heat Exchanger 12. Heat Exchanger Bypass Valve 13. Valve Segment 14. Pump Swashplate 15. Input Shaft 16. Output Shaft 17. Reservoir 18. to Motor Case
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
H1 general information
H1 system schematic
System schematic H1 pump and H1 motor with EDC
M14
M6 1 2
R1
R2
C2
C1
F00B F00A
M3 L1 L2 MA
L2
AA
MA N
n
M5 CW
M4
max.
min.
L1
BB
S L3 L4
MB
M4 M5
MB
max. 3 bar [43.5 psi]
P003 424
The schematic above shows the function of a hydrostatic transmission using an H1 axial variable displacement pump with electric proportional displacement control (EDC) and an H1 bent axis variable displacement motor with electric proportional control (L*) and integrated loop flushing device.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Technical specifications General specifications
General specifications Design Direction of rotation Pipe connections
Recommended installation
Piston motor with variable displacement bent axis design
Bi-directional
Main pressure ports: ISO split flange boss Remaining ports: SAE straight thread O-ring boss Discretionary, the housing must always be filled with hydraulic fluid
Physical properties
Physical properties
Features
Unit
Displacement
maximum minimum
cm3 [in3]
Theoretical flow at max. displ.
at rated speed at max. speed
l/min [US gal/min]
Theoretical torque at max. displacement
N·m/bar [lb·in/1000 psi]
Theor. corner power at rated speed and max. working pressure (p = 450 bar [6527 psi])
kW [hp]
Mass moment of inertia of rotating components
kg·m2 [slug·ft2]
Case volume
l [US gal]
060 60 [3.66] 12 [0.73] 216 [57] 270 [71] 0.96 [583]
080 80 [4.88] 16 [0.98] 256 [68] 328 [87] 1.27 [777]
Size
110
160
210
250
110 [6.71] 160 [9.76] 210 [12.81] 250 [15.25]
22 [1.34] 32 [1.95] 42 [2.56] 50 [3.05]
319 [84] 416 [110] 504 [133] 550 [145]
407 [108] 528 [139] 630 [166] 700 [185]
1.75 [1069] 2.55 [1555] 3.34 [2038] 3.98 [2426]
266 [357] 321 [430] 396 [531] 513 [689] 609 [817] 684 [917]
0.0038 [0.0028]
0.9 [0.24]
0.0062 [0.0046]
1.0 [0.26]
0.0108 [0.0080]
1.4 [0.37]
0.0211 [0.0156]
2.7 [0.71]
0.0306 [0.0226]
2.8 [0.74]
0.0402 [0.0296]
4.1 [1.08]
Weight dry (Electric proportional control)
Configuration
060
080
SAE
29.8 kg [65.7 lb]
34.8 kg [76.7 lb]
DIN Cartridge
28.3 kg [62.4 lb] 26.9 kg [59.3 lb]
34.4 kg [75.8 lb] 33.0 kg [72.6 lb]
Size
110
160
48.8 kg [107.6 lb] 61.9 kg [136.5 lb]
45.0 kg [99.2 lb]
59.3 kg [130.7 lb]
41.8 kg [92.2 lb]
54.7 kg [120.6 lb]
210 81.0 kg [179 lb] 75.0 kg [165 lb]
250 87.0 kg [196.2 lb] 79.6 kg [175.5 lb]
Mounting flange Configuration
SAE ISO 3019/1 DIN ISO 3019/2, B4 Cartridge
060
080
127-4 (SAE C) 4-bolt
125 HL 4-bolt
140 HL 4-bolt
Pilot Ø160 mm 2-bolt (200 dist.)
M16
Pilot Ø190 mm 2-bolt (224 dist.)
M20
Size
110
160
152-4 (SAE-D) 4-bolt
160 HL 4-bolt
180 HL 4-bolt
Pilot Ø200 mm 2-bolt (250 dist.) M20
210
250
165-4 (SAE E)
200 HL 4-bolt
200 HL 4-bolt
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Technical specifications
Customer ports
Size
060
080
Axial and radial1)
Case drain ports2)
Axial gauge ports2)3)
DN19 typ 1
DN25 typ 1
0.875 [78]14UN-2B 0.875 [78]14UN-2B
Radial gauge port2)3)
1) Split flange Boss per ISO6162, 40 MPa series 2) SAE O-ring boss 3) Countersink may be deeper that specified in the standard.
110
160
DN25 typ 1
DN32 typ 1
1.0625 [1116]12UN-2B 1.0625 [1116]12UN-2B
210
250
DN32 typ 1
DN32 typ 1
1.313 [1516]12UN-2B]
0.5625 [916]18UNF-2B
Operating Parameters
Output Speed Output Speed Rated
Maximum
Displacement
Maximum 32° Minimum 6° Zero 0° Maximum 32° Minimum 6° Zero 0°
Unit
min-1 (rpm)
060 3600 5900 6600 4500 7250 7950
080 3200 5300 5950 4100 6600 7200
Size
110
160
2900 4800 5350 3700 5950 6500
2600 4250 4750 3300 5250 5750
210 2350 3850 4300 3000 4800 5250
250 2200 3650 4050 2800 4500 4900
System and Case Pressure, Ambient Temperature
Parameter
All sizes
System pressure
Maximum working
450 bar [6527 psi]
Maximum
480 bar [6962 psi]
Minimum1)
2)
Case pressure
Rated
3 bar [44 psi]
Maximum
5 bar [73 psi]
Minimum
0.3 bar [4 psi]
Ambient temperature3)
Maximum
70 °C [158 °F]
Minimum
-40 °C [-40 °F]
1) Minimum above case pressure (open and closed circuit) 2) See the graphs Required inlet pressure diagrams (for cylinder block filling) on page 16. 3) Air temperature close to the unit.
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Technical specifications
H1B speed range diagrams for open and closed circuit
Speed (rpm) versus Displacement (%), Intermittent operation (grey area)
8000
8000
H1B 060
7000
7000
H1B 080
6000 5000 4000 3000
6000 5000 4000 3000
2000
2000
1000
1000
0
0
0%
20%
40%
60%
80%
100% 0%
20%
40%
60%
80%
100%
P003 557
P003 509
7000
7000
H1B 110
H1B 160
6000
6000
5000
5000
4000
4000
3000
3000
2000
2000
1000
1000
0
0
0%
20%
40%
60%
80%
100% 0%
20%
40%
60%
80%
100%
P003 511
P301 307
6000
6000
H1B 210
H1B 250
5000
5000
4000
4000
3000
3000
2000
2000
1000
1000
0
0
0%
20%
40%
60%
80%
100% 0%
20%
40%
60%
80%
100%
P006 001
P301 457
W Warning
Zero degree capability results in a high risk of overspeed and drops in efficiency if the motor operates between 020% displacement.
For open circuit applications it is not allowed to operate in the intermitent area. For closed circuit applications operating in the intermittent area, please contact your local Danfoss Power Solutions representative.
Contact your Danfoss representative for any operation above Rated speed. In these cases, a special option is available for 160cc, 210cc and 250cc, for applications with speeds between rated speed and maximum speed for delta pressures over 310 bar.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Technical specifications
Required inlet pressure diagrams (for cylinder block filling)
Speed (rpm) and Pressure (bar) versus Displacement (%)
9000
8000
8000
H1B 060
7000
H1B 080
7000 6000 5000 4000 3000 2000 1000
30bar
20bar 15bar 10bar
5bar 2bar
6000 5000 4000 3000 2000 1000
30bar
20bar 15bar 10bar
5bar 2bar
0
0%
20%
40%
60%
80%
100%
P006 010
0 0%
20%
40%
60%
80%
100%
P006 011
Speed (rpm) and Pressure (bar) versus Displacement (%)
7000
7000
6000
H1B 110
6000
H1B 160
5000
5000
4000 3000 2000 1000
0 0%
20%
40%
60%
30bar
20bar 15bar 10bar
5bar 2bar
4000 3000 2000 1000
80%
100%
P006 012
0 0%
20%
40%
60%
30bar
20bar 15bar 10bar 5bar 2bar
80%
100%
P006 013
Speed (rpm) and Pressure (bar) versus Displacement (%)
6000
6000
H1B 210
H1B 250
5000
5000
4000
4000
3000 2000 1000
0 0%
20%
40%
60%
30bar
20bar 15bar 10bar
5bar 2bar
3000 2000 1000
80%
100%
P006 014
0 0%
20%
40%
60%
30bar
20bar 15bar 10bar 5bar 2bar
80%
100%
P006 015
Bold dashed line: Maximum speed Bold solid line: Rated speed This pressure ensures that the cylinder block will be properly filled and that there is no pulling between piston and shaft. The required pressure is 0 bar at 0 rpm and increases with rpm.
For open circuit applications it is not allowed to operate above rated speed. For closed circuit applications operating between rated and max. speed, please contact your local Danfoss Power Solutions representative.
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Technical specifications
Open circuit requirements
H1 Bent Axis Motors may be used in Open Circuit (OC) applications.
Since loop flushing is typically not used in OC-applications it is essential to provide sufficient cooling capacity. This can be done by motor case cross flushing.
The flow rate needs to be adjusted to the cooling demand.
The highest case drain outlet port must always be used for the return flow to the cooler or tank.
The motor case, the control system and the working lines connected to Port A and B must be kept full of oil at all times, whether in a dynamic or static condition.
The plumbing must not allow the oil to drain down and be replaced with air in the control or rotating group.
The minimum pressure in the inlet port and the outlet port, measured at gage ports MA and MB, must be equal or higher as shown in the graphs Required inlet pressure diagrams (for cylinder block filling) on page 16.
Counter balance valves may be used to maintain the minimum pressure requirements. Also the Danfoss Meter-in / Meter-out PVG technology may be used.
Check valves and sufficient charge pressure supply are also possible.
At no time shall the motor be allowed to operate above the rated speed limits. If flow limiter valves are used, they must be selected accordingly. Select Motor controls which use the high loop system pressure to shift the servo piston. This ensures proper function under all conditions.
Valve blocks, such as counter balance valves attached to the inlet and/or outlet ports, must not interfere with any part of the motor. A review of the outline drawings or appropriate 3D models must be completed.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Technical specifications
Fluid specifications
Fluid specifications
Features
Minimum intermittent
Viscosity
Recommended range
Maximum intermittent
Minimum
Temperature range1)2) Rated
Maximum intermittent
Required cleanliness per ISO 4406
Efficiency (charge pressure filtration) Cleanliness and Filtration
Efficiency (suction / return line filtration)
Recommended inlet screen mesh size 1) At the hottest point, normally case drain port. 2) Minimum: cold start, short term t<3 min, p<50 bar, n<1000 rpm.
Unit mm2/s [SUS]
°C [°F] -ratio µm
All sizes 7 [49] 12-80 [66-366] 1600 [7416] -40 [-40] 104 [220] 115 [240] 22/18/13 15-20 = 75 (10 10) 35-45 = 75 (10 2) 100 125
Determination of nominal motor size
Based on SI units
Qe
=
Vg · n 1000 ·
v
Me =
Vg · p · 20 ·
mh
Based on US units
Qe =
Vg · n 231 · v
Me =
Vg · p · 2 ·
mh
Pe =
Me · n 9550
=
Qe · p · 600
t
Pe =
Vg · n · p · 396 000
t
n
=
Qe · 1000 · Vg
v
Where:
Qe Input flow (l/min)
Me Output torque (N·m)
Pe Output power (kW)
n
Speed (min-1)
Vg phigh plow p
Motor displacement per rev. (cm3/rev) High pressure (bar) Low pressure (bar) High pressure minus Low pressure (bar)
v Motor volumetric efficiency mh Mechanical-hydraulic efficiency
t Motor total efficiency (v · mh)
n =
Qe · 231 · Vg
v
Where:
Qe Input flow [US gal/min]
Me Output torque [lb·in] Pe Output power [hp]
n Speed [rpm]
Vg phigh plow p
Motor displacement per rev. [in3/rev] High pressure [psi] Low pressure [psi] High pressure minus Low pressure [psi]
v Motor volumetric efficiency mh Mechanical-hydraulic efficiency
t Motor total efficiency (v · mh)
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Operation Shaft rotation direction
Shaft rotation direction is determined with a view from the shaft end. Rotation direction of the motor will be dependent on the control option used as illustrated below.
In the second number or letter of the control code, 1 means 12 VDC, 2 means 24 VDC, and H means hydraulic.
Controls L1, L2, D1, D2, LH, DH
CCW
B
CW
A
Flow into port A Flow into port B Controls M1, M2, K1, K2, KH, MH
P006030
Clockwise Counterclockwise
Flow into port A Flow into port B
CCW
A
CW
B
P006031
Counterclockwise Clockwise
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Operation
Controls E1, E2, F1, F2, P1, P2, T1, T2, TA, TH, HE, HF
Flow into port A Flow into port B
CCW
A
CW
B
P006032
Counterclockwise Clockwise
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Operation
Loop flushing shuttle spool
An integral loop flushing shuttle spool is used to separate system A and system B pressures.
System delta pressure will cause the shuttle spool to shift, allowing the low side system pressure to flow to the loop flushing relief valve.
A
B
L2
A
Legend: A B LFRV
LFRV
P006033
System loop A System loop B to Loop flushing relief valve
B
P003 437
W Warning
Unintended vehicle or machine movement hazard. Excessive motor loop flushing flow may result in the inability to build required system pressure in some conditions. Maintain correct charge pressure under all conditions of operation to maintain pump control performance in hydrostatic systems.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Operation
Loop flushing relief valve
The loop flushing relief valve is incorporated into all H1 motors and uses the loop flushing option in installations that require fluid to be removed from the low pressure side of the system circuit due to cooling requirements.
The loop flushing relief valve is also used to facilitate the removal of contaminants from the loop.
The loop flushing valve is equipped with an orificed charge pressure relief valve designed with a cracking pressure of 16 bar [232 psi].
Valves are available with several orifice sizes to meet the flushing flow requirements of all system operating conditions.
Loop flushing relief valve (cross section)
Loop flushing relief valve schematic
L2
A
P003 491
Loop flushing relief valve sizes
40 bar
5 10 15 20
30 bar
20 bar
Y
10 bar
B
P003 487
30 40 50
0
10
20
30
40
50
60
X
P006 034
X Loop flushing flow (l/min) Y Low system pressure minus case pressure (bar)
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Operation Speed sensor
The speed sensor is designed for rugged outdoor, mobile or heavy industrial speed sensing applications. The detection of the speed is contactless and does not need any calibration or adjustments.
For more information, see Speed and Temperature Sensor, Technical Information, BC152886482203.
Sensor position Sensor position in SAE, DIN and Cartridge housing.
SAE and DIN housing
Cartridge housing
Displacement limiter
P003450
P003489
Target Ring
Speed (target) rings vary according to the diameter of the cylinder block or shaft on which they are installed. The number of teeth is shown in the table below.
The number of speed (target) ring teeth
H1B and H1F size 060
080
110
160
210
250
Teeth
71
78
86
95
104
108
Excessive axial shaft loading during installation of motors with speed sensors and cartridge housings must be avoided. High axial shaft loads during installation of motors can lead to a movement of the shaft and damage the speed sensor.
All Series H1 motors incorporate mechanical displacement limiters.
The minimum displacement of the motor is preset at the factory with a set screw in the motor housing. A tamper-proof cap is provided.
For 0° motors, the minimum displacement screw can be substituted with a plug that uses less space.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Operating parameters Output speed
Start and low speed stability. The motor produces maximum starting torque at maximum displacement. Stable operation can be achieved at 1534 rpm, ± 5 %, depending on system pressure, in applications that require low speed stability. Motor output speed becomes more stable as speed increases.
Rated speed is the highest output speed recommended at full power condition. Operating at, or below this speed will yield satisfactory product life.
Maximum speed is the highest operating speed permitted. Exceeding maximum speed reduces the product life and can cause loss of hydrostatic power and dynamic braking capacity. Never exceed the maximum speed limit under any operating conditions.
Operation between rated and maximum speed is reserved for intermittent operation (see H1B speed range diagrams for open and closed circuit on page 15) not to exceed 10 minutes durations, 2% of duty cycle based load-life, and 310 bar system delta pressure. Speed above rated are anticipated to occur during downhill braking (negative power). Contact factory for any operation above Rated speed when negative power is not involved.
During hydraulic braking and downhill conditions, the prime mover must be capable of providing sufficient braking torque in order to avoid pump over speed. This is especially important to consider for turbocharged and Tier 4 engines.
W Warning
Unintended vehicle or machine movement hazard. Exceeding maximum speed may cause a loss of hydrostatic drive line power and braking capacity. You must provide a braking system, redundant to the hydrostatic transmission, sufficient to stop and hold the vehicle or machine in the event of hydrostatic drive power loss. The braking system must also be sufficient to hold the machine in place when full power is applied.
System pressure
System pressure is the differential pressure between high pressure system ports. It is the dominant operating variable affecting hydraulic unit life. High system pressure, which results from high load, reduces expected life. Hydraulic unit life depends on the speed and normal operating, or weighted average, pressure that can only be determined from a duty cycle analysis.
Application pressure is the high pressure relief or pressure limiter setting normally defined within the order code of the pump. This is the applied system pressure at which the driveline generates the maximum calculated pull or torque in the application.
Maximum working pressure is the highest recommended application pressure. Maximum working pressure is not intended to be a continuous pressure. Propel systems with application pressures at, or below, this pressure should yield satisfactory unit life given proper component sizing.
Maximum pressure is the highest allowable application pressure under any circumstance. For applications which are above the maximum working pressure, please contact Danfoss
Minimum pressure must be maintained under all operating conditions to avoid cavitation.
All pressure limits are differential pressures referenced to low loop (charge) pressure. Subtract the low loop gauge pressure from the high loop gauge pressure readings to compute the differential.
Summing pressure is the sum of both the low and high loop pressures. Summing pressure above 30 bar [435 psi] guarantees reliable use within the rated speed.
Servo pressure is the pressure in the servo system and is supplied from the high side of the loop to keep the motor at the required displacement.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Operating parameters 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.
C Caution
Possible component damage or leakage. Operation with case pressure in excess of stated limits may damage seals, gaskets, speed sensors and/or housings, causing external leakage. Performance may also be affected since charge and system pressures are referenced to case pressure.
External shaft seal pressure
In certain applications, the output shaft seal may be exposed to external pressures. The shaft seal is designed to withstand an external pressure up to 0.25 bar [3.6 psi] above the case pressure. The case pressure limits must also be followed to ensure the shaft seal is not damaged.
Temperature
The high temperature limits apply at the hottest point in the transmission, which is normally the motor case drain. The system should generally be run at or below the published rated temperature.
The maximum intermittent temperature is based on material properties and should never be exceeded.
Cold oil will generally not affect the durability of the transmission components, but it may affect the ability of oil to flow and transmit power. Therefore, temperatures should remain 16 °C [30 °F] above the pour point of the hydraulic fluid.
The minimum temperature relates to the physical properties of component materials.
Size heat exchangers too keep the fluid within these limits. Danfoss recommends testing to verify that these temperature limits are not exceeded.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Fluid and filter maintenance
Fluid and filter recommendations
To ensure optimum life, perform regular maintenance of the fluid and filter. Contaminated fluid is the main cause of unit failure. Take care to maintain fluid cleanliness when servicing.
Check the reservoir daily for proper fluid level, the presence of water, and rancid fluid odor. Fluid contaminated by water may appear cloudy or milky or free water may settle in the bottom of the reservoir. Rancid odor indicates the fluid has been exposed to excessive heat. Change the fluid immediately if these conditions occur. Correct the problem immediately.
Inspect vehicle for leaks daily.
Change the fluid and filter per the vehicle/machine manufacturer's recommendations or at these intervals. We recommend first fluid change occur at 500 hours of operation. Change the fluid more frequently if it becomes contaminated with foreign matter (dirt, water, grease, etc) or if the fluid is subjected to temperature levels greater than the recommended maximum.
Fluid and filter change interval Reservoir type Sealed Breather
Max oil change interval 2000 hours 500 hours
C Caution
High temperatures and pressures accelerate fluid aging. This may require more frequent fluid changes.
Change filters when changing fluid or when the filter indicator directs. Replace all fluid lost during filter change
W Warning
Hydraulic fluid contains hazardous material. Avoid contact with hydraulic fluid. Always dispose of used hydraulic fluid according to state, and federal environmental regulations. Never reuse hydraulic fluid.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Pressure measurements
Ports and Gauge Information The following drawing with accompanying table show the port locations and gauge sizes needed for installation. Ports locations (proportional control)
M5 (M4 on
reverse side)
MA (MB on
reverse side)
System Port A
System Port B
XB
(Port XA
on reverse side) L2
X1
Axial Ported Endcap
M5 (M4 on reverse side)
L1
MA MB
System Port A (System Port B on reverse side)
XB (Port XA on reverse side)
L2 Radial Ported Endcap
X1
P108829
System split flange boss ports, A/B: Code 62 per ISO 6162, Type 1
Port
Size 060
Size 080, 110
A, B
3/4 in; Thread: M10 x 1.5
1 in; Thread: M12 x 1.75
min. 18 mm [0.71 in]
min. 23 mm [0.91 in]
Size 160, 210, 250
1 1/4 in; Thread: M12 x 1.75 min. 23 mm [0.91 in]
Radial/Axial end-cap ports - Inch Version
Port
Size 060
MA, MB (Radial)
7/8-14 UNF Wrench (int. hex): 3/8 in
MA, MB (Axial)
9/16-18 UNF Wrench (int. hex): 1/4 in
Size 080, 110, 160, 210, 250
1 1/16-12UN Wrench (int. hex): 9/16 in
9/16-18 UNF Wrench (int. hex): 1/4 in
System pressure obtained 600 bar [8702 psi] 600 bar [8702 psi]
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Pressure measurements
Radial/Axial end-cap ports - Metric Version
Port
Size 060
MA, MB (Radial)
M22 x 1.5 Wrench (int. hex): 10mm
MA, MB (Axial)
M14 x 1.5 Wrench (int. hex): 6mm
Size 080, 110, 160, 210, 250
M27 x 2 Wrench (int. hex): 12mm
M14 x 1.5 Wrench (int. hex): 6mm
System pressure obtained 600 bar [8702 psi] 600 bar [8702 psi]
Ports and gauge Information - Inch version
Port
Size 060
Size 080,110,160
Size 210,250
L1, L2
7/8-14 UNF Wrench: 3/8 in
1 1/16-12UN Wrench: 9/16 in
1 5/16-12UN Wrench: 5/8 in
M4, M5
9/16-18 UNF; Wrench (int. hex): 1/4 in
X1, XA, XB
9/16-18 UNF; Wrench (int. hex): 1/4 in
1) Servo pressure rod end.
2) X1 Control pressure supply, hydraulic actuator. XA/XB BPD, PCOR inactive at A/B.
Pressure obtained
10 bar [145 psi] Case drain 600 bar [8700 psi] 1) 100 bar [1450 psi] 2)
Ports and gauge Information - Metric version
Port
Size 060/080
Size 110/160
Size 210/250
Pressure obtained
L1, L2
M22 x 1.5
M27 x 2
M33 x 2
Wrench (int. hex): 10mm Wrench (int. hex): 12mm Wrench (int. hex): 14mm
M4, M5
M14 x 1.5 Wrench (int. hex): 6mm
X1, XA, XB
M14 x 1.5 Wrench (int. hex): 6mm
1) Servo pressure rod end.
2) X1 Control pressure supply, hydraulic actuator. XA/XB BPD, PCOR inactive at A/B.
10 bar [145 psi] Case drain 600 bar [8700 psi] 1)
100 bar [1450 psi] 2)
Port locations (hydraulic 2-position controls with PCOR; control specific ports only)
X1
XB (Port XA
on reverse side)
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Initial startup procedures
Procedure
W Warning
This service procedure may require disabling the vehicle / machine (raising the wheels off the ground, disconnecting work function) while performing, to prevent injury to the technician and bystanders. Take the necessary safety precautions.
Always follow this procedure when starting-up a new H1 installation or when the motor has been removed.
1. Before installing the motor, inspect the units for possible damage incurred during shipping and handling.
2. Make certain all system components (reservoir, hoses, valves, fittings, heat exchanger, and so forth) are clean before filling with fluid.
3. Fill the reservoir with recommended hydraulic fluid. Pass this fluid through a 10 micron (nominal, no bypass) filter before it enters the reservoir.
4. Fill the inlet line leading from the reservoir to the pump. 5. Check inlet line for properly tightened fittings. Make sure the inlet line is free of restrictions and air
leaks. 6. Fill the motor and pump housings with clean hydraulic fluid before start up. Fill by pouring filtered oil
into the upper case drain port.
C Caution
Never start the prime mover unless the motor and pump housings are filled completely with clean hydraulic fluid.
7. For closed loop systems, install a 0-60 bar [0-1000 psi] pressure gauge in the charge pressure gauge port of the pump to monitor the charge pressure during start-up.
For open circuit systems, use gauges in system ports.
8. Disconnect any external control input signal from the pump control until after initial start-up. This ensures that the pump remains in its neutral position.
9. Jog (slowly rotate) prime mover until charge pressure starts to rise. 10. Start the prime mover and run at the lowest possible speed until charge pressure builds.
W Warning
Do not start the prime mover unless the pump is in neutral position (swash plate at 0° angle). Take necessary precautions to prevent machine movement in case pump is actuated (in stroke) during initial start-up.
© Danfoss | July 2024
If necessary, bleed excess air from the high pressure lines through the high pressure system gauge ports. 11. Once charge pressure is established, increase to normal operating speed. Charge pressure should be as indicated in the pump model code. If charge pressure is low, shut down and determine cause.
C Caution
Low charge pressure may affect ability to control the machine. 12. Shut down the prime mover. 13. Connect the external control input signal. 14. Reconnect the machine function if disconnected earlier. 15. Start the prime mover, checking to ensure the pump remains in neutral.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Initial startup procedures
16. Check for forward and reverse machine operation, with the prime mover at normal operating speed. Charge pressure may decrease slightly during forward or reverse operation.
17. Continue to cycle slowly between forward and reverse for at least five minutes. 18. Shut down prime mover. 19. Remove gauges. Replace plugs at the gauge ports. 20. Check reservoir level. Add filtered fluid if needed. The motor/transmission is now ready for operation.
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Troubleshooting Overview
This section provides general steps to follow if you observe undesirable system conditions. Follow the steps until you solve the problem. Some of the items are system specific. Always observe the safety precautions in the Introduction section.
W Warning
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable/disconnect the mechanism while servicing.
Electrical troubleshooting Check 1. Motor operates at one
displacement only.
2. Erratic motor function
Cause Control coil failure
Electrical connection to motor is intermittent.
Corrective action
Measure resistance at coil pins. Resistance at 20°C [70°F] should be:
· Proportional controls: 14.20 (24V) or 3.66 (12V) · Two-position controls: 8.4 (24V) or 34.5 (12V)
Replace coil if necessary.
Disconnect connector, check wires and terminals, reconnect wires. Check terminals for corrosion and correct position.
Sluggish operation Check 1. Control orifices
2. Threshold setting (proportional controls)
3. Control spool
4. Pressure compensator setting
5. Control input signal
6. Internal leakage
Cause
Corrective action
Blocked or restricted orifice may cause sluggish response. Orifices installed in the wrong locations may cause PCOR control to be sluggish.
Remove, inspect and clean all orifices. Ensure the appropriate orifices are installed and in the correct location.
Inappropriately high or low threshold setting may Check threshold setting. Adjust if necessary. shift the motor at the wrong time.
A sticky control may cause sluggish response or no Clean and inspect the control spool. Replace if
response.
necessary.
Low pressure compensator setting may shift motor Check pressure compensator setting. Adjust if
to maximum displacement at lower pressure.
necessary.
An improper or erratic input signal to the control Check input signal and correct if necessary. may cause sluggish response.
Excessive leakage will cause lower charge pressure and affect performance.
Install loop flushing defeat option and measure case flow. If case flow is excessive, motor may require major repair. Contact your Danfoss authorized service center.
System operating hot Check 1. Oil level 2. Heat exchanger
3. Loop flushing flow 4. Loop flushing shuttle
© Danfoss | July 2024
Cause
Corrective action
Insufficient hydraulic fluid may cause overheating. Fill reservoir to proper level.
Blocked heat exchanger or low air flow may cause system overheating.
Check temperature upstream and downstream of heat exchanger. Clean, repair, or replace heat exchanger if necessary.
Restricted orifice in loop flushing cartridge reduces Measure case drain flow. Clean or replace orifice
flow.
cartridge.
Loop flushing shuttle may be sticking in one direction.
Ensure shuttle moves freely in its bore.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Troubleshooting
Check 5. Air in system 6. Internal leakage
Cause Entrained air generates heat under pressure
Excessive internal leakage may overheat the system.
Corrective action
Look for foam or bubbles in reservoir. Check for leaks on inlet side of charge pump.
Install loop flushing defeat option and monitor case flow. If case flow is excessive, motor may require major repair. Contact your Danfoss authorized service center.
Excessive noise or vibration Check 1. Oil level in reservoir 2. Air in system
3. Shaft coupling
4. Shaft alignment
Cause Insufficient hydraulic fluid may cause cavitation. Air bubbles may lead to cavitation.
Loose shaft coupling may create excess noise.
Misaligned shafts may create excessive noise and vibration and can damage motor.
Corrective action
Fill reservoir to proper level. Look for foam or bubbles in reservoir. Check for leaks on inlet side of charge pump. Replace loose shaft coupling. Replace or repair motor if shaft splines show excessive wear. Correct shaft misalignment.
Motor operates normally in one direction only
Check 1. Charge pressure
Cause
If charge pressure is low in one direction, the loop flushing shuttle spool may be sticking to one side.
Corrective action
Measure charge pressure in forward and reverse. If pressure drops significantly lower in one direction, inspect and repair loop flushing shuttle spool.
Improper output speed Check 1. Oil level in reservoir
8. Internal leakage
Cause
Insufficient hydraulic fluid may reduce system efficiency.
Excess internal leakage may cause lower charge pressure and affect motor performance including output speed.
Corrective action
Fill reservoir to proper level.
Install loop flushing defeat option and measure case flow. If case flow is excessive, motor may require major repair. Contact your Danfoss authorized service center.
Low output torque Check 1. Pressure compensator setting 2. Control orifices 3. Pressure compensator spool 4. Control spool 5. Two position solenoid 6. Control input signal
Cause
Corrective action
High pressure compensator setting may cause
Check and adjust pressure compensator setting.
improper motor displacement for torque required.
Blocked or restricted orifice may cause motor to shift improperly.
Remove, inspect and clean all orifices.
Sticking pressure compensator spool may cause Remove and inspect pressure compensating spool. control to hold motor at minimum displacement. Repair or replace control if necessary.
Sticking control spool may cause motor to shift improperly.
Remove and inspect control spool. Repair or replace control if necessary.
Two position control not shifting motor to maximum displacement.
Inspect solenoid valve for bent stem or damaged coil. Repair or replace if necessary.
Improper control input signal may cause motor to Correct control input signal. stay at minimum displacement.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Troubleshooting
Check 7. Threshold setting
(proportional control) 8. Internal leakage
Cause
Corrective action
Improper threshold setting may cause improper motor displacement for torque required.
Check and adjust threshold setting.
Excess internal leakage may cause charge pressure to decay, reducing output torque.
Install loop flushing defeat option and monitor case flow. If case flow is excessive, motor may require major repair. Contact your Danfoss authorized service center.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Required tools and standard procedures
Required tools
The service procedures described in this manual can be performed using common mechanic's hand tools. Special tools, if required, are shown. When testing system pressures, calibrate pressure gauges frequently to ensure accuracy. Use snubbers to protect gauges.
Standard procedures
C Caution
Contamination can damage internal components and void the manufacturer's warranty. Take precautions to ensure system cleanliness when removing and reinstalling system lines
1. With the prime mover off, thoroughly clean all dirt and grime from the outside of the motor. Ensure the surrounding areas are clean and free of contaminants such as dirt and grime.
2. If removing the motor, tag each hydraulic line connected to the motor. If you disconnect hydraulic lines, plug each open port to keep dirt and contamination out of the motor.
3. Inspect the system for contamination. Look at the hydraulic fluid for signs of system contamination, such as oil discoloration, foam in the oil, sludge, or small metal particles.
4. Remove the motor as a single unit.
C Caution
Be careful not to damage solenoids and electrical connections when using straps or chains to remove motor from machine.
5. Perform motor function test. 6. Before re-installing the motor on the machine, drain the system, flush all lines, replace all filters, and
fill with new hydraulic fluid.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Adjustments Adjusting the minimum displacement limiter
Minimum displacement limiter
N1000 6 mm
19 mm 45 N·m [32 lb·ft]
N2000
N0120
1. Remove cap (N0120).
Removing the cap destroys the caps locking mechanism. Replace with a new cap. 2. Using a 6 mm internal hex wrench, hold adjusting screw (N1000) in place. 3. Using a 19 mm hex wrench, loosen seal locknut (N2000). 4. Turn adjusting screw clockwise to increase minimum displacement or counterclockwise to decrease
minimum displacement.
Minimum displacement is inversely related to maximum shaft speed. To increase maximum speed, decrease minimum displacement. Adjusting displacement limits also affects output torque. Refer to the table below for displacement change per turn.
Displacement change per turn
Size
Displacement change
060
2.1 cm3 [0.13 in3]
080
2.6 cm3 [0.16 in3]
110
3.2 cm3 [0.20 in3]
160
4.1cm3 [0.25 in3]
210
5.1 cm3 [0.31 in3]
250
5.5 cm3 [0.34 in3]
5. When properly adjusted, hold adjusting screw in place and torque seal lock-nut to 45 N·m [32 lbf·ft].
6. With motor on machine or test stand, verify correct motor function. Refer to Ports and Gauge Information on page 27 for location of gauge ports and suggested gauge sizes.
7. Install new cap (N0120).
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Adjustments Optional threshold adjustment Electric proportional controls
Adjusting threshold on test stand
1. Connect flow meter to A or B system port. Refer to Ports and Gauge Information on page 27 for port locations.
2. Connect solenoid to PWM signal generator at 150 Hz.
Threshold is the electric signal when the motor starts to change from maximum to minimum displacement.
3. Run prime mover at operating speed.
Threshold adjustment
adjusting screw
3 mm
B0040
4. Adjust PWM signal to current calculated from the H1B 060/080/110/160/210/250 Technical Information (BC152886483576) document in the corresponding control section. Note the flow reading.
5. If adjustment is necessary, remove cap (B0040). Using a 3mm internal hex wrench, turn adjusting screw clockwise or counterclockwise until flow starts to change from maximum. One full turn of the adjusting screw changes the threshold by approximately 48 mA for 12V controls and 24mA for 24V controls. CW turn decreases the setting and CCW turn increases the setting. Test your adjustment by lowering the current, then increasing the current until the displacement starts to change. Readjust the setting if necessary.
6. When threshold is adjusted correctly, stop prime mover, install cap (B0040), and install motor on vehicle. Run vehicle and test for proper motor operation.
Adjusting threshold on a machine or test stand without flow meter
1. Install 600 bar [10,000 psi] gauges to ports M5 and M4. Connect solenoid to PWM signal. 2. Raise wheels off ground, or disconnect the work function.
W Warning
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable/disconnect the mechanism while servicing.
3. Run prime mover at operating speed. Stroke the pump to get some rotation of motor shaft. 4. Increase signal current until M4 pressure becomes 1/2 of the M5 pressure. Check the signal current at
this point. 5. If adjustment is necessary, remove cap (B0040). Turn the adjusting screw until the signal current
matches the model code setting. 6. When threshold is adjusted correctly, stop prime mover, install cap. Run vehicle and test for proper
motor operation. 7. Remove from test stand.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Adjustments Optional threshold adjustment Hydraulic proportional controls
Adjusting threshold on test stand
1. Connect flow meter to A or B system port. Refer to Ports and Gauge Information on page 27 for port locations.
2. Connect a variable pressure supply to X1 port (0-50 bar).
Threshold is the pressure at which the motor starts to change from maximum to minimum displacement.
3. Run prime mover at operating speed.
Threshold adjustment
adjusting screw
3 mm
B0040
© Danfoss | July 2024
4. Adjust control pressure to pressure listed in model code. Note flow reading. 5. If adjustment is necessary, remove nut (B0180). Using a 6mm internal hex wrench, turn adjusting
screw clockwise or counterclockwise until flow starts to change from maximum. One full turn of the adjusting screw changes the threshold by approximately 2.3 bar. CW turn increases the setting and CCW turn decreases the setting. Test your adjustment by lowering the control pressure, then increasing the control pressure until the displacement starts to change. Readjust the setting if necessary. 6. When threshold is adjusted correctly, stop prime mover, install nut (B0180), and install motor on vehicle. Run vehicle and test for proper motor operation.
Adjusting threshold on a machine or test stand without flow meter
1. Install 600 bar [10,000 psi] gauges to ports M5 and M4. Connect a variable pressure supply to X1 port (0-50 bar).
2. Raise wheels off ground, or disconnect the work function.
W Warning
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable/disconnect the mechanism while servicing.
3. Run prime mover at operating speed. Stroke the pump to get some rotation of motor shaft. 4. Increase X1 pressure until M4 pressure becomes 1/2 of the M5 pressure. Check the X1 pressure at this
point. 5. If adjustment is necessary, remove nut (B0180). Turn the adjusting screw until the X1 pressure
matches the model code setting. 6. When threshold is adjusted correctly, stop prime mover, install nut (B0180). Run vehicle and test for
proper motor operation. 7. Remove from test stand.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Adjustments
Pressure Compensator OverRide (PCOR) adjustment PCOR adjustment for all controls except P1/P2 controls is described below. PCOR adjustment for P1/P2 controls is electrically adjusted using a proportional solenoid.
Nominal settings 240 bar [3500 psi] at 800 mA (12 V), 400 mA (24 V) or per model code.
No adjustment is available for the Brake Pressure Defeat (BPD) option. Coil is either energized or deenergized, if coil is used.
W Warning
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. To protect against unintended movement, secure the machine or disable/disconnect the mechanism while servicing.
Setup
1. Install motor in machine. 2. Install 600 bar pressure gauge at system port MA or MB (whichever side is regulated by the PCOR).
Optionally, the gauge can be installed in the system gauge port M5. 3. Install sensor to read engine speed. 4. Install sensor to read wheel speed. 5. Install data acquisition device which is able to record data over time using the sensors installed in
steps 2 4 above. 6. Deactivate any inching systems connected to the brakes if applicable. 7. Prepare site for testing (two options are available).
a) Lift machine so wheels are no longer engaging the ground, or b) Use a straight, flat surface to drive machine during testing.
Testing
1. Start machine engine. 2. Set engine to high idle (rated speed) and maintain for the duration of the testing. 3. Turn the machine wheels at a constant speed (motor will be at minimum displacement).
a) Allow wheels to turn at constant speed if using setup 7a. b) Drive machine at constant speed if using setup 7b. 4. Begin data acquisition (system pressure, engine speed, and wheel speed). 5. Slowly apply the service brake to continuously increase the load on the system until the wheel speed (setup 7a) or driving speed (setup 7b) decreases by approximately 1/3. 6. Stop machine and turn off engine. 7. Stop data acquisition.
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Adjustments
Analysis
1. Using appropriate software for the data acquisition device, plot the system pressure, wheel speed and engine speed versus time.
2. As the system pressure increases (from applying the brakes), the engine speed and wheel speed will start decreasing.
3. When the system pressure stops rising and remains constant, that pressure will be the PCOR setting. The engine speed should remain constant during this period while the wheel speed continues to decrease. See Graph below.
Adjustment
1. If adjustment is required, use a 3mm internal hex to hold the PCOR adjusting screw in place and use a 10mm wrench to loosen the PCOR lock nut. One full turn of the adjusting screw changes the PCOR setting by approximately 90 Bar. a) Turn adjusting screw clockwise to increase the PCOR setting. b) Turn adjusting screw counterclockwise to decrease the PCOR setting.
Locknut 10 mm
Adjusting screw
3 mm
2. Use a 3mm internal hex to hold the PCOR adjusting screw in place and use a 10mm wrench to tighten the lock nut to 8 N-m [6 lbf-ft].
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Adjustments
3. Repeat Testing, Analysis, and Adjustment steps as necessary to reach the desired PCOR setting.
Engine Speed
H1B PCOR Adjustment
PCOR Setting
Wheel Speed
Begin Application of Service Brake
System Pressure Minimum Displacement
Displacement Range
TIME
Max Displacement
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Minor repair Shaft seal
Removal 1. 1. Using snap ring pliers, remove retaining ring (G0030). 2. 2. Use a slide-hammer style puller to remove seal (G0020). Be careful not to damage the shaft or seal
bore when removing. Discard seal.
Inspection Inspect retaining ring for wear or damage. Replace if necessary. Inspect shaft for wear or groove at seal area.
Assembly 1. Lubricate inside diameter of new seal. Cover the shaft splines with shaft cover or packing tape to
avoid damaging the seal during installation. 2. Using seal installation tool, press seal into housing bore. 3. Using a snap ring pliers, install retaining ring (G0030). 4. Use seal installation tool to press seal and retaining ring into housing until retaining ring snaps into
its groove.
If not using seal installation tool: Do not press seal beyond snap-ring groove. Stop pressing just when you have room to install the retaining ring into the bore. Pressing the seal and snap-ring together ensures proper installation depth. Using the seal installation tool prevents pressing the seal too deeply.
Shaft seal
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G0020 G0030
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair
110/160/210/250 - Seal installation tool dimensions, 060/080 - Seal installation tool dimensions
100 mm [3.94 in]
180 mm [7.09 in]
150 mm 100 mm [5.90 in] [3.94 in]
69 mm 58 mm [2.6 in] [2.3 in]
5.15
mm
+ -
0.10 0.0
[0.20
in
+ 0.004 - 0.0
]
82 mm [3.15 in]
45°
5 mm [0.2 in]
56 mm 48 mm [2.2 in] [1.9 in] P107 738E
5.4
mm
+ 0.10 - 0.0
[0.21
in
+ 0.004 - 0.0
]
70 mm [2.76 in]
45° 5 mm [0.2 in]
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair Electric proportional solenoid replacement
Removal
1. Disconnect electrical connection and remove three cap screws (B0050) using a 4 mm internal hex wrench.
2. Remove the solenoid (B0010) and O-ring (B0035A). Discard the O-ring. 3. Remove valve spool (C0100).
Inspection Clean and inspect valve spool and all machined surfaces for damage or wear. Replace parts if necessary.
Assembly
1. Lubricate and install valve spool (C0100). 2. Using petroleum jelly, lubricate and install new O-ring (B0035A). 3. Install cap screws (B0050) using a 4 mm internal hex wrench. Torque screws to 6 N·m [4 lbf·ft]. 4. Reconnect electrical connections and test the motor for proper operation.
Replacing solenoid
B0010
B0050
4 mm 6 N·m [ 4 lbf·ft]
B0035A
C0100
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc Minor repair Hydraulic proportional actuator replacement
Removal 1. Remove three cap screws (B0050) using a 4 mm internal hex wrench. 2. Remove the actuator (B0010). Inspection
Clean and inspect all machined surfaces for damage or wear. Replace parts if necessary. Assembly Replacing actuator
B0050
B0010
P108828
1. Install cap screws (B0050) using a 4 mm internal hex wrench and torque screws to 6 N·m [4 lbf·ft]. 2. Test the motor for proper operation.
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Minor repair
Control module replacement
Removal 1. Remove four cap screws (C0110 and/or C0120). Refer to table for wrench sizes. 2. Remove control (C0010) from motor. Remove and discard gasket (C0130). 3. Proportional control only - using a magnet, remove spring seat (F0030) and spring (F0040).
Inspection Clean and inspect the machined surfaces on the control and the endcap. If you find any nicks or scratches, replace control or endcap. Inspect valve spool, washer, and spring. Replace if necessary.
Assembly Control module removal/installation
C0010 Proportional control
F0030
F0040
C0130
C0110 (4X) 6 mm
37 Nm [27 lbf·ft]
C0120 (2X) 10 mm
115 Nm [85 lbf·ft]
C0010 2 position control
C0130
C0110 (2X) 10 mm
115 Nm [85 lbf·ft]
C0010 Proportional control
F0030
F0040 C0130
C0110 (4X) 6 mm
37 Nm [27 lbf·ft]
Electric proportional control
Two position control
Hydraulic proportional control
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair
1. Lubricate and install spring (F0040) and spring seat (F0030) into servo. 2. Install a new gasket (C0130). 3. Position control on motor. 4. Install four cap screws (C0110 and/or C0120).
C0110 and C0120 Wrench Size
Screw
Control
Torque
C0110 C0110, C0120
Electric / Hydraulic proportional Two-position
37 N·m [27 lbf·ft]
115 N·m [85 lbf·ft]
Internal Hex Wrench 6 mm
10 mm
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Minor repair
Electric proportional control module
Coil O-rings are not included in the overhaul seal kit. They may be purchased as a separate kit.
Disassembly 1. Remove the plastic cap (B0040) and O-ring (B0029). Discard the O-ring. 2. Remove the solenoid nut (B0027) using a 26mm 12-point socket. Remove and discard the O-ring
(B0028). 3. Remove the coil (B0020A). Remove and discard the O-ring (B0025). 4. Use a 4 mm internal hex wrench to remove screws (B0050). Remove solenoid (B0010). 5. Remove and discard O-ring (B0035A). 6. Remove spool (C0100). 7. Using a 1/4 in internal hex wrench remove plug (C0050) and discard O-ring (C0050A). 8. Use a 5 mm internal hex to remove shuttle valve (C0025). 9. Using a 1/8 in internal hex wrench, remove 3 plugs (C0060) and discard O-rings (C0060A). 10. Using a 3 mm internal hex, remove 2 orifices (E00T3 and E00T2).
Inspection Inspect the machined surfaces on the control and the endcap. If you find any nicks or scratches, replace the control or endcap assembly. Check that shuttle ball moves freely in housing (C0025).
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair Assembly
Proportional control block assembly
B0027 26 mm
3.5 N·m [2.6 lbf·ft]
B0020A
B0040
B0029 B0027 B0028
B0020
B0050
4mm 6 N·m [4 lbf·ft]
B0025
1/4 in C0050 40 N·m C0050A [30 lbf·ft]
C0025 5 mm
8 N·m [6 lbf·ft]
8 N·m [6 lbf·ft]
1/8 in C0060
C0060A
B0035A
6 N·m [4 lbf·ft] 3 mm E00T2
B0010 C0100
C0060 C0060A
1/8 in 8 N·m [6 lbf·ft]
B0010
3 mm
6 N·m [4 lbf·ft] E00T3
C0060A C0060
1/8 in 8 N·m [6 lbf·ft]
1. Install orifices (E00T3 and E00T2) with torque to 6 N·m [4 lbf·ft]. 2. Lubricate and install new O-rings (C0060A). 3. Install and torque plugs (C0060) to 8 N·m [6 lbf·ft] using a 1/8 inch internal hex wrench. 4. Lubricate and install spool (C0025) into control block using a 5 mm internal hex wrench, torque to 14
N·m [11 lbf·ft] 5. Install new O-ring (C0050A). 6. Install and torque plug (C0050), check torque tables 7. Lubricate and install spool (C0100). 8. Lubricate and install new O-ring (B035A). 9. Install solenoid (B0010) using a 4 mm internal hex wrench. 10. Install screws (B0050) with torque to 6 N·m [4 lbf·ft]. 11. Lubricate and install new O-ring (B0025) onto solenoid. 12. Install coil (B0020A).
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Minor repair
13. Lubricate and install new O-ring (B0028) onto solenoid. 14. Install coil nut (B0027) and torque to 3.5 N·m [2.6 lbf·ft] using a 26 mm 12-point socket.
Do not over torque. 15. Install new O-ring (B0029) and plastic cap (B0040) to solenoid.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair Hydraulic proportional control module
Disassembly
1. Use a 4 mm internal hex wrench to remove screws (B0050). Remove actuator (B0010). 2. Remove and discard O-ring (B0035A). 3. Using an internal hex wrench remove plug (C0050) and discard O-ring (C0050A). 4. Use a 5 mm internal hex to remove shuttle valve (C0025). 5. Using a 1/8 in internal hex wrench, remove 3 plugs (C0060) and discard O-rings (C0060A). 6. Using a 3 mm internal hex, remove 2 orifices (E00T3 and E00T2).
Inspection
Inspect the machined surfaces on the control and the endcap. If you find any nicks or scratches, replace the control or endcap assembly. Check that shuttle ball moves freely in housing (C0025).
Assembly
C0090
C0090A C0080 C0070
1/8 in
E00T2
6 N·m [4 lbf·ft] 3 mm
8 N·m [6 lbf·ft] C0060
C0060A
C0140 C0010
C0050 C0050A
C0060 C0060A
C0060 8 N·m
C0060A
[6 lbf·ft]
C0060A C0060
C0060 C0060A
C0050A C0050
C0060 C0060A
0010 0020
B0061 B0010
C0120 C0110
C0060A C0060
C0060A
C0100
C0060
1/8 in 8 N·m [6 lbf·ft]
B0190
B0060
E00T3
6 N·m [4 lbf·ft] 3 mm
C0060A C0060 1/8 in
8 N·m
C0020
[6 lbf·ft]
C0140
C0050A C0050 40 N·m [30 lbf·ft]
0020 0010
B0180
DHMH
B0050
P108832
1. Install orifices (E00T3 and E00T2) with torque to 6 N·m [4 lbf·ft]. 2. Lubricate and install new O-rings (C0060A). 3. Install and torque plugs (C0060) to 8 N·m [6 lbf·ft] using a 1/8 inch internal hex wrench. 4. Lubricate and install spool (C0025) into control block using a 5 mm internal hex wrench, torque to 14
N·m [11 lbf·ft] 5. Install new O-ring (C0050A).
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Minor repair
6. Install and torque plug (C0050), check torque tables. 7. Install actuator (B0010) using a 4 mm internal hex wrench. 8. Install screws (B0050) with torque to 6 N·m [4 lbf·ft].
If replacing the hydraulic actuator, set the threshold pressure to the proper setting. Refer to Adjusting threshold on test stand on page 37
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair
Electric two-position control module
Coil O-rings are not included in the overhaul seal kit. They are included with the purchase of a new coil.
Disassembly 1. Use a 26 mm 12-point socket to remove coil nuts (B0026) and O-ring (B0028). 2. Remove coils (B0022) and O-rings (B0024). Discard O-rings. 3. Using a 17 mm open-end wrench on the flats provided, remove solenoid assemblies (B0032). 4. Remove and discard O-rings (B0034). 5. Using a 1/8 inch internal hex wrench, remove four plugs (C0060). Remove and discard O-rings
(C0060A). 6. Using an internal hex wrench, remove two plugs (C0050). Remove and discard O-rings (C0050A). 7. Using a 17 mm hex wrench, remove pressure compensator adjusting plug (C0090). Remove and
discard O-ring (M223). 8. Remove springs (C0030) and (C0080). Remove spools (C0020) and (C0070). 9. If necessary, use a 3 mm internal hex wrench to remove orifices (E00T2) and (E00T3).
Inspection Clean and inspect the machined surfaces on the control and the endcap. If any nicks or scratches are found, replace the control/endcap assembly.
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Minor repair Assembly
Two-position control assembly
B0026 3.5 N·m [2.6 lbf·ft]
B0028 B0022
B0024
17 mm B0032 25 N·m [19 lbf·ft]
T*D* and P*D*
B0026 3.5 N·m [2.6 lbf·ft] B0028
B0024
B0034
1/4 in 40 N·m [30 lbf·ft]
C0050
B0022
C0050A
17 mm B0032 25 N·m [19 lbf·ft]
C0060 1/8 in 8 N·m [6 lbf·ft]
B0034 C0060A
C0060A
B0026 B0028 B0022
B0024
C0060
1/8 in
8 N·m [6 lbf·ft] C0060
1/8 in
C0060A
8 N·m [6 lbf·ft] E00T3 3 mm
6 N·m
[4 lbf·ft]
C0050
C0060 1/8 in 8 N·m [6 lbf·ft]
C0070
C0080 M223
C0020
C0090
E00T2 3 mm
6 N·m
C0030
17 mm 25 N·m [18 lbf·ft]
[4 lbf·ft]
C0050A C0050
1/4 in
40 N·m [30 lbf·ft]
C0050
B0032 B0034
T*G* and P*G*
C0030 C0020
C0060
C0010
E00T3
E00T2
C0060
C0070 C0080 M223
C0090
B0034 B0032 B0024 B0022
B0028 B0026
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair
1. If previously removed, install orifices (E00T3 and E00T2) using a 3 mm internal hex wrench. Torque to 6 N·m [4 lbf·ft].
2. Lubricate and install spools (C0020) and (C0070) and springs (C0080) and (C0030). 3. Lubricate and install O-ring (M223). Install pressure compensator adjusting plug (C0090). Torque to
25 N·m [18 lbf·ft]. 4. Lubricate and install two O-rings (C0050A). Using an internal hex wrench, install plugs (C0050). 5. Lubricate and install four O-rings (C0060A). Using a 1/8 inch internal hex wrench, install plugs
(C0060). Torque to 8 N·m [6 lbf·ft]. 6. Lubricate and install O-rings (B0034). 7. Install solenoids (B0032) using a 17 mm open-end wrench on the flats provided. Torque to 25 N·m [19
lbf·ft] . 8. Lubricate and install new O-rings (B0024) on solenoids. 9. Install coils (B0022). 10. Lubricate and install new O-rings (B0028). 11. Install coil nuts (B0026) using a 26 mm 12-point socket. Torque to 3.5 N·m [2.6 lbf·ft].
Do not over torque.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair Hydraulic two-position control module
Disassembly
1. Using a 1/8 inch internal hex wrench, remove plug (C0160). Remove and discard O-ring (C0160A). 2. Using a 1/8 inch internal hex wrench, remove three plugs (C0060). Remove and discard O-rings
(C0060A). 3. Using an internal hex wrench, remove two plugs (C0050). Remove and discard O-rings (C0050A). 4. Use a 5mm internal hex wrench to remove the shuttle valve (C0025). 5. Using a 3/8 internal hex wrench, remove plug (C0140). Remove and discard O-ring (C0140A). 6. Remove spring (C0080). Remove spool (C0150). 7. If necessary, use a 3 mm internal hex wrench to remove orifices (E00T2) and (E00T3).
Inspection
Clean and inspect the machined surfaces on the control and the endcap. If any nicks or scratches are found, replace the control/endcap assembly.
Assembly Hydraulic two-position control assembly (HEHE, HFHF)
C0140
HEHE
C0080 C0150 C0050 C0025
3/8 inch
C0160 C0160A
C0050
C0060 C0060
C0140 3/8 inch
C0080 C0150 C0060
C0160 C0160A
C0050
C0060
C0060 C0060
1/8 in
C0050
C0060 1/8 in
C0060 1/8 in
C0050
HFHF
C0025
C0050
P108 576E
1. Lubricate and install spool (C0150) and spring (C0080). 2. Using a 3/8 inch internal hex wrench, install plug (C0140). Torque to 25 N·m [18 lbf·ft]. 3. Lubricate and install spool (C0025). 4. Using an internal hex wrench, install two plugs (C0050). 5. Using a 1/8 inch internal hex wrench, install four plugs (C0060). Torque to 8 N·m [6 lbf·ft]. 6. Using a 1/8 inch internal hex wrench, install plug (C0160). Torque to 25 N·m [18 lbf·ft].
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair Hydraulic two-position control module with PCOR
Disassembly
1. Using a 1/8 inch internal hex wrench, remove two plugs (C0060). Remove and discard O-rings (C0060A).
2. Using an internal hex wrench, remove three plugs (C0050). Remove and discard Orings (C0050A). 3. Use a 5mm internal hex wrench to remove the shuttle valve (C0025). 4. Using a 22 mm hex wrench, remove adapter (B0300). Remove and discard O-ring (QB0300). 5. Using a 17 mm hex wrench, remove pressure compensator adjusting plug (C0090). Remove and
discard O-ring (M223). 6. Remove spring (C0080). Remove spool (C0070). 7. If necessary, use a 3 mm internal hex wrench to remove orifices (E00T2) and (E00T3).
Inspection
Clean and inspect the machined surfaces on the control and the endcap. If any nicks or scratches are found, replace the control/endcap assembly.
Assembly Two-position control assembly (THHA)
C0050 C0050
C0025
B0300
B0310 QB300 B0330 B0320
C0050
THHA
C0060 1/8 in
E00T3 E00T2
C0060 1/8 in
C0070
C0080 M223 C0090
P108913
1. If previously removed, install orifices (E00T3 and E00T2) using a 3 mm internal hex wrench with torque to 6 N·m [4 lbf·ft].
2. Lubricate and install spool and (C0070) and spring (C0080). 3. Lubricate and install O-ring (M223). 4. Install pressure compensator adjusting plug (C0090) with torque to 25 N·m [15 lbf·ft]. 5. Lubricate and install O-ring (QB0300). 6. Install adapter (B0300) with torque to 67 N·m [49 lbf·ft]. 7. Lubricate and install spool (C0025). 8. Install three plugs (C0050) using an internal hex wrench, check torque tables. 9. Install two plugs (C0060) using a 1/8 inch internal hex wrench, with torque to 8 N·m [6 lbf·ft].
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair Hydraulic two-position control module with PCOR and hydraulic BPD
Disassembly
1. Using a 1/8 inch internal hex wrench, remove three plugs (C0060). Remove and discard O-rings (C0060A).
2. Using an internal hex wrench, remove four plugs (C0050). Remove and discard O-rings (C0050A). 3. Using a 1/4 inch internal hex, remove plug (C0140). Remove spool (C0020). 4. Use a 5mm internal hex wrench to remove the shuttle valve (C0025). 5. Using a 22 mm hex wrench, remove adapter (B0300). Remove and discard O-ring (QB0300). 6. Using a 17 mm hex wrench, remove pressure compensator adjusting plug (C0090). Remove and
discard O-ring (M223). 7. Remove spring (C0080). Remove spool (C0070). 8. If necessary, use a 3 mm internal hex wrench to remove orifices (E00T2) and (E00T3).
Inspection
Clean and inspect the machined surfaces on the control and the endcap. If any nicks or scratches are found, replace the control/endcap assembly.
Assembly Two-position control assembly (THHB)
C0050 C0050
C0025
B0300
B0310 QB300 B0330 B0320
C0050
THHB
© Danfoss | July 2024
C0060 1/8 in
E00T3 E00T2
C0070
C0060 1/8 in
C0020
C0080 M223 C0090
C0140 C0050
P108923
1. If previously removed, install orifices (E00T3 and E00T2) using a 3mm internal hex wrench. Torque to 6 N·m [4 lbf·ft].
2. Lubricate and install spools and (C0070) and spring (C0080). 3. Lubricate and install O-ring (M223). 4. Install pressure compensator adjusting plug (C0090). Torque to 25 N·m [18 lbf·ft]. 5. Lubricate and install O-ring (QB0300). 6. Install adapter (B0300). Torque to 67 N·m [49 lbf·ft]. 7. Lubricate and install spool (C0020). 8. Using a 1/4 inch internal hex wrench, install plug (C0140). Torque to 14 N·m [10 lbf·ft].
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair
9. Lubricate and install shuttle (C0025). 10. Using an internal hex wrench, install four plugs (C0050), check torque tables. 11. Using a 1/8 inch internal hex wrench, install three plugs (C0060). Torque to 8 N·m [6 lbf·ft].
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc Minor repair Maximum displacement limiter two-position controls
It is not necessary to remove the maximum displacement limiter unless it is being replaced. Disassembly Models with maximum displacement limiter: Remove screw (P0100) using a 6 mm internal hex, and spacer (P0200). Assembly Maximum displacement limiter assembly
P0100 6 mm P0200
P107 866E
1. Install spacer (P0200) and screw (P0100) using a 6 mm internal hex. 2. Torque screw to 37 N·m [28 lbf·ft].
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair Servo piston cover proportional control
Removal
P0041
P0043 P0044
P0040
O-ring (P0043)
Seal ring (P0044)
Piston
P0050 see table
P0030
P0010 10 mm 115 N·m [85 lbf·ft] P0020
1. Remove four screws (P0020) using a 10 mm internal hex wrench. 2. Remove servo piston cover (P0010). 3. Remove and discard O-ring (P0030). 4. Remove screw (P0050).
C Caution
For the safe removal of end cap and servo piston, please refer to the H1B Bent Axis Variable Motor Repair Instructions available to Authorized Service Centers.
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Minor repair
5. Using expanding pliers, remove piston head (P0040).
Servo piston head
Expanding pliers
6. Remove and discard seal ring (P0044) and O-ring (P0043).
Inspection
Clean and inspect bushings and machined surfaces for wear or damage. If wear or damage are found, replace component in question.
Assembly
1. Lubricate and install new O-ring (P0043) and seal ring (P0044) on piston (P0041).
O-ring (P0043)
Seal ring (P0044)
© Danfoss | July 2024
Piston head
Allow seals time to relax before installing piston. 2. Install piston and install screw (P0050).
See the table for wrench size below:
Wrench size (internal hex)
Size
060/080
Wrench size
8 mm
110 10 mm
160/210/250 12 mm
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Minor repair
Torque for P0050
Size Torque
060/080 66 N·m [49 lbf·ft]
110 115 N·m [85 lbf·ft]
160/210/250 213 N·m [157 lbf·ft]
3. Lubricate and install new O-ring (P0030) and install servo piston cover (P0010). 4. Using a 8 mm or 10 mm internal hex install screws (P0020). Torque to 115 N·m [85 lbf·ft].
Refer to the H1B Bent Axis Variable Motor Repair Instructions (available to Authorized Service Centers) if further motor disassembly is needed.
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair Replace speed sensor
Removal 1. Using a 5 mm internal hex wrench, remove screw (J0020). 2. Remove speed sensor (J0010). 3. Discard O-ring (J0010A).
Assembly Speed sensor assembly
J0020 5 mm 8 N·m [6 lbf·ft]
J0010
J0010A
1. Lubricate and install new O-ring (J0010A). 2. Install speed sensor (J0010). 3. Install screw (J0020) using a 5 mm internal hex wrench with torque to 8 N·m [6 lbf·ft].
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair Loop flushing spool
Loop flushing reassembly
Removal 1. Remove plugs (K0030) using a 24 mm hex wrench. 2. Remove and discard O-rings (K0030A). 3. Use a magnet to remove springs (K0020) and spool (K0010).
Inspection Clean and inspect spool (K0010). If spool is damaged or worn replace it. Replace springs if they are cracked or bent.
Reassembly
K0030
24 mm 67 N·m [49 lbf·ft]
K0030A
K0020
K0010
K0030
24 mm
67 N·m [49 lbf·ft]
K0020 K0030A
1. Lubricate and install spool (K0010). 2. Lubricate and install springs (K0020). 3. Lubricate and install new O-rings (K0030A). 4. Install plugs (K0030) using a 24 mm hex wrench with torque to 67 N·m [49 lbf·ft].
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair Loop flushing charge relief valve
Removal 1. Using a 24 mm hex wrench remove valve (L00**) 2. Remove and discard O-ring (L0050).
Do not disassemble valve. If you suspect malfunction, replace valve.
Assembly 1. Install new O-ring (L0050). 2. Using a 24 mm hex wrench, install valve (L00**). Torque to 67 N·m [49 lbf·ft].
Loop flushing charge relief valve replacement
L0050
L00**
24 mm 67 N·m [49 lbf·ft]
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair
Minimum Displacement limiter
Removal 1. Remove cap (N0120).
Removing the cap destroys the caps locking mechanism. Replace with a new cap. 2. While holding the position of the adjustment screw, remove the seal locknut (N0020) using a 19mm
hex wrench. Discard the locknut. After removing the locknut, mark the position of the limiter screw for reassembly. 3. Using a 6 mm internal hex, remove displacement limiter screw (N0010).
Inspection Inspect set screw for wear or damage. Replace set screw if necessary.
Assembly 1. Using a 6 mm internal hex wrench, install adjustment screw (N0010) to original position. 2. Using a 6 mm internal hex wrench, to hold the position of the adjustment screw, install a new seal
locknut (N0020) using a 19mm hex wrench. Torque to 45 N·m [32 lbf·ft]. 3. Install new cap (N0120).
Displacement limiter assembly
66 | © Danfoss | July 2024
19 mm 45 N·m [32 lb·ft]
N0020
N0010 6 mm N0120
AX152886484369en-000608
Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Torque chart
Fasteners, plugs with torque chart
Proportional controls port, plug and fasteners (with radial ported endcap)
M4 F0100
L00**
P0020
System Port B
MA F0150
L1 J0020 G0060
MB F0150
XA B0060
X1 B0060
B0050
G0050
C0060
C0110 and C0120 G0060 L2 N0010
Two-position controls port, plug and fasteners (with radial ported endcap)
XA B0060
M4 F0100
System Port A
MB F0150
L1 M5 G0060 F0100
MA F0150
X1 B0060
M5 F0100
System Port A
K0030 B0060 XB
N0020
XB B0060
K0030 L00** System Port B
© Danfoss | July 2024
G0060 L2
Fastener size and torque chart
Item
Fastener
B0050
Solenoid screws
C0110
Control (proportional) assembly screws
C0110, C0120
Control (two-position) assembly screws
J0020
Speed sensor screw
N1000
Displacement limiter screw
N2000
Displacement limiter lock-nut
P0020
Servo piston cover screws
Wrench size 4 mm internal hex 6 mm internal hex 10 mm internal hex 5 mm internal hex 6 mm internal hex 19 mm 10 mm internal hex
Torque 6 N·m [4 lbf·ft] 37 N·m [28 lbf·ft] 115 N·m [85 lbf·ft] 8 N·m [6 lbf·ft] N/A 45 N·m [32 lbf·ft] 115 N·m [85 lbf·ft]
Plug size and torque chart - Inch version
Item
O-ring plug
B0060
9/16 - 18UNF
C0050
9/16-18 UNF (not shown)
C0060
5/16 - 24UNF
Wrench size 1/4 internal hex 1/4 internal hex 3/8 internal hex
Torque 40 N·m [30 lbf·ft] 40 N·m [30 lbf·ft] 8 N·m [5 lbf·ft]
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Service Manual H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Torque chart
Plug size and torque chart - Inch version (continued)
Item
O-ring plug
F0100
9/16 - 18UNF
F0150 (060)
F0150 (080, 110, 160, 210, 250)
1-1/16 - 12 UN (Radial endcap)
G0050
5/16 - 24UNF (SAE and DIN flange)
G0055
7/16 - 20UNF (Cartridge only/not shown)
G0060 (060, 080) 7/8 - 14UN
G0060 (110, 160) 1-1/16 - 12UN
G0060 (210, 250) 1-5/16 - 12UN
K0030
M18 - 1.5
L00**
M18 - 1.5
F0160, C0050 and 9/16-18 UNF B0060
Wrench size 1/4 internal hex
9/16 internal hex
1/8 internal hex 3/16 internal hex 3/8 internal hex 9/16 internal hex 5/8 internal hex 24 mm hex 24 mm hex 1/4 internal hex
Torque 40 N·m [30 lbf·ft] 95 N·m [70 lbf·ft] 115 N·m [85 lbf·ft]
8 N·m [5 lbf·ft] 8 N·m [5 lbf·ft] 70 N·m [52 lbf·lb] 70 N·m [52 lbf·lb] 70 N·m [52 lbf·lb] 67 N·m [49 lbf·ft] 67 N·m [49 lbf·ft] 40 N·m [30 lbf·ft]
Plug size and torque chart - Metric version
Item
O-ring plug
B0060
9/16 - 18UNF
C0050
9/16-18 UNF (not shown)
C0060
5/16 - 24UNF
F0100
M14x1.5
F0150 (060)
M22x1.5
F0150 (080, 110, 160, 210, 250)
M27x2 (Radial endcap)
G0050
5/16 - 24UNF (SAE and DIN flange)
G0055
7/16 - 20UNF (Cartridge only/not shown)
G0060 (060, 080) M22x1.5
G0060 (110, 160) M27x2
G0060 (210, 250) M33x2
K0030
M18 x1.5
L00**
M18 x1.5
F0160, C0050 and M14x1.5 B0060
Wrench size 1/4 internal hex 1/4 internal hex 3/8 internal hex 6mm internal hex 10mm internal hex
12mm internal hex
1/8 internal hex 3/16 internal hex 10mm internal hex 12mm internal hex 14mm internal hex 24 mm hex 24 mm hex 6mm internal hex
Torque 40 N·m [30 lbf·ft] 40 N·m [30 lbf·ft] 8 N·m [5 lbf·ft] 47 N·m [35 lbf·ft] 105 N·m [77 lbf·ft] 180 N·m [132 lbf·ft]
8 N·m [5 lbf·ft] 8 N·m [5 lbf·ft] 70 N·m [52 lbf·lb] 70 N·m [52 lbf·lb] 70 N·m [52 lbf·lb] 67 N·m [49 lbf·ft] 67 N·m [49 lbf·ft] 47 N·m [35 lbf·ft]
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Products we offer:
· Cartridge valves
· DCV directional control
valves
· Electric converters
· Electric machines
· Electric motors
· Gear motors
· Gear pumps
· Hydraulic integrated
circuits (HICs)
· Hydrostatic motors
· Hydrostatic pumps
· Orbital motors
· PLUS+1® controllers
· PLUS+1® displays
· PLUS+1® joysticks and
pedals
· PLUS+1® operator
interfaces
· PLUS+1® sensors
· PLUS+1® software
· PLUS+1® software services,
support and training
· Position controls and
sensors
· PVG proportional valves
· Steering components and
systems
· Telematics
Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and electric components. We specialize in providing state-of-the-art technology and solutions that excel in the harsh operating conditions of the mobile off-highway market as well as the marine sector. Building on our extensive applications expertise, we work closely with you to ensure exceptional performance for a broad range of applications. We help you and other customers around the world speed up system development, reduce costs and bring vehicles and vessels to market faster. Danfoss Power Solutions your strongest partner in mobile hydraulics and mobile electrification. Go to www.danfoss.com for further product information. We offer you expert worldwide support for ensuring the best possible solutions for outstanding performance. And with an extensive network of Global Service Partners, we also provide you with comprehensive global service for all of our components.
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