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 Rev
March 2020 Added adjustment details for threshold settings and changed document number from
AX00000025
August 2019 Added caution for servo piston removal 0505
August 2018 update adjustment chapter 0504
April 2018 Major layout update, QF080 to QM050 updates 0503
January 2018 update pressure compensator torque values 0502
July 2016 Add G1, G2 controls 0501
December 2015 Add 210 frame size 0500
November 2015 Model code change 0400
July 2015 correct torque values, pages 61, 62 0301
June 2015 add hydraulic controls THHA, THHB 0300
2008-2015 First edition - and next various changes. AA-CB
0607
2 | © Danfoss | March 2020 AX152886484369en-000607
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
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
General description.......................................................................................................................................................................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........................................................................................................................................................................ 33
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
©
Danfoss | March 2020 AX152886484369en-000607 | 3
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Contents
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
Torque chart
Fasteners, plugs with torque chart..........................................................................................................................................67
4 | © Danfoss | March 2020 AX152886484369en-000607
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
parts
Replace all O-rings
and gaskets
During assembly, coat all moving parts with a film of clean hydraulic oil. This
assures that these parts are lubricated during start-up.
Danfoss recommends you replace all O-rings and gaskets during repair. Lightly
lubricate O-rings with clean petroleum jelly prior to assembly.
Secure the unit For repair, place the unit in a stable position with the shaft pointing downward.
Secure the motor while removing and torquing components and fasteners.
Safety precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and others
from injury. Take the following general precautions whenever servicing a hydraulic system.
©
Danfoss | March 2020 AX152886484369en-000607 | 5
W
W
W
W
W
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Introduction
Unintended machine movement
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
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
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
Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.
Hazardous material
Warning
Hydraulic fluid contains hazardous material. Avoid prolonged contact with hydraulic fluid. Always
dispose of used hydraulic fluid according to environmental regulations.
6 | © Danfoss | March 2020 AX152886484369en-000607
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Introduction
Symbols used in Danfoss literature
WARNING may result in injury Tip, helpful suggestion
CAUTION may result in damage to product or
property
Reusable part Apply grease / petroleum jelly
Non-reusable part, use a new part Apply locking compound
Non-removable item Inspect for wear or damage
Option - either part may exist Clean area or part
Superseded - parts are not interchangeable Be careful not to scratch or damage
Measurement required Note correct orientation
Flatness specification Mark orientation for reinstallation
Parallelism specification Torque specification
External hex head Press in - press fit
Internal hex head Pull out with tool – press fit
Torx head Cover splines with installation sleeve
O-ring boss port Pressure measurement/gauge location or
Lubricate with hydraulic fluid
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.
©
Danfoss | March 2020 AX152886484369en-000607 | 7
P005 917
6
7
5
1
2
3
4
10
9
8
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. 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)
8 | © Danfoss | March 2020 AX152886484369en-000607
P005 918
1
2
3
4
7
6
5
9
8
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
H1 general information
Cross-section of H1 motor with electric two-position control
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)
©
Danfoss | March 2020 AX152886484369en-000607 | 9
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
H1 general information
General description
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.
10 | © Danfoss | March 2020 AX152886484369en-000607
P003 423
2
3
6
7
4
10
8
9
16
15
14
13
12
11
17
5
7
18
1
5
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
H1 general information
H1 pictorial diagram
Working loop A (Low pressure) and charge pressure
Working loop B (High pressure)
Servo pressure
Case drain
Suction
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
©
Danfoss | March 2020 AX152886484369en-000607 | 11
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
P003 424
min.max.
L2 NMA
A
B
M5
MB
M4
L1
B
R1
R2
M4
M5
M14 M6 1 2
M3 L1 L2 MA
A
C2 C1
S
F00B F00A
L3 L4
CW
MB
max. 3 bar
[43.5 psi]
n
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
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.
12 | © Danfoss | March 2020 AX152886484369en-000607
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
Physical properties
Physical properties
Features Unit
Displacement
Theoretical flow at
max. displ.
Theoretical torque
at max. displacement
Theor. corner power at rated speed and max.
working pressure (∆p = 450 bar [6527 psi])
Mass moment of inertia of rotating
components
Case volume
maximum
minimum
at rated speed
at max. speed
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
060 080 110 160 210 250
cm3 [in3]
l/min
[US gal/min]
N•m/bar
[lb•in/1000 psi]
kW [hp] 266 [357] 321 [430] 396 [531] 513 [689] 609 [817] 684 [917]
2
kg•m
[slug•ft2]
l [US gal] 0.9 [0.24] 1.0 [0.26] 1.4 [0.37] 2.7 [0.71] 2.8 [0.74] 4.1 [1.08]
60 [3.66] 80 [4.88] 110 [6.71] 160 [9.76] 210 [12.81] 250 [15.25]
12 [0.73] 16 [0.98] 22 [1.34] 32 [1.95] 42 [2.56] 50 [3.05]
216 [57] 256 [68] 319 [84] 416 [110] 504 [133] 550 [145]
270 [71] 328 [87] 407 [108] 528 [139] 630 [166] 700 [185]
0.96 [583] 1.27 [777] 1.75 [1069] 2.55 [1555] 3.34 [2038] 3.98 [2426]
0.0038
[0.0028]
0.0062
[0.0046]
0.0108
[0.0080]
Size
0.0211
[0.0156]
0.0306
[0.0226]
0.0402
[0.0296]
Weight dry (Electric proportional control)
Configuration Size
060 080 110 160 210 250
SAE
DIN
Cartridge
29.8 kg [65.7 lb] 34.8 kg [76.7 lb] 48.8 kg [107.6 lb] 61.9 kg [136.5 lb] 81.0 kg [179 lb] 87.0 kg [196.2 lb]
28.3 kg [62.4 lb] 34.4 kg [75.8 lb] 45.0 kg [99.2 lb] 59.3 kg [130.7 lb] 75.0 kg [165 lb] 79.6 kg [175.5 lb]
26.9 kg [59.3 lb] 33.0 kg [72.6 lb] 41.8 kg [92.2 lb] 54.7 kg [120.6 lb] – –
Mounting flange
Configuration Size
060 080 110 160 210 250
SAE ISO 3019/1
DIN ISO 3019/2, B4
Cartridge
©
Danfoss | March 2020 AX152886484369en-000607 | 13
2-bolt (200 dist.)
127-4 (SAE C) 4-bolt 152-4 (SAE-D) 4-bolt 165-4 (SAE E)
125 HL 4-bolt 140 HL 4-bolt 160 HL 4-bolt 180 HL 4-bolt 200 HL 4-bolt
Pilot Ø160 mm
M16
Pilot Ø190 mm
2-bolt (224 dist.)
M20
Pilot Ø200 mm
2-bolt (250 dist.) M20 – –
200 HL 4-bolt
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Technical specifications
Customer ports
Size 060 080 110 160 210 250
Axial and radial
Case drain ports
Axial gauge
2)3)
ports
Radial gauge
2)3)
port
1)
Split flange Boss per ISO6162, 40 MPa series
2)
SAE O-ring boss
3)
Countersink may be deeper that specified in the standard.
1)
2)
Operating Parameters
DN19 typ 1 DN25 typ 1 DN25 typ 1 DN32 typ 1 DN32 typ 1 DN32 typ 1
0.875 [7∕8]–14UN-2B 1.0625 [11∕16]–12UN-2B 1.313 [15∕16]–12UN-2B]
0.875 [7∕8]–14UN-2B
0.5625 [9∕16]–18UNF-2B
Output Speed
Output Speed Displacement Unit
Maximum 32°
Rated
Maximum
Minimum 6° 5900 5300 4800 4250 3850 3650
Zero 0° 6600 5950 5350 4750 4300 4050
Maximum 32° 4500 4100 3700 3300 3000 2800
Minimum 6° 7250 6600 5950 5250 4800 4500
Zero 0° 7950 7200 6500 5750 5250 4900
min
(rpm)
1.0625 [11∕16]–12UN-2B
Size
060 080 110 160 210 250
3600 3200 2900 2600 2350 2200
-1
System and Case Pressure, Ambient Temperature
Parameter All sizes
System pressure Maximum working 450 bar [6527 psi]
Maximum 480 bar [6962 psi]
Minimum
Case pressure Rated 3 bar [44 psi]
Maximum 5 bar [73 psi]
Minimum 0.3 bar [4 psi]
Ambient temperature
3)
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.
1) 2)
14 | © Danfoss | March 2020 AX152886484369en-000607
P003 557
0
1000
2000
3000
4000
5000
6000
7000
8000
0% 20% 40% 60% 80% 100%
H1B 060
0
1000
2000
3000
4000
5000
6000
7000
8000
P003 509
0% 20% 40% 60% 80% 100%
H1B 080
0
1000
2000
3000
4000
5000
6000
7000
P003 511
0% 20% 40% 60% 80% 100%
H1B 110
0% 20% 40% 60% 80% 100%
P301 307
0
1000
2000
3000
4000
5000
6000
7000
H1B 160
0
1000
2000
3000
4000
5000
6000
P006 001
0% 20% 40% 60% 80% 100%
H1B 210
0
1000
2000
3000
4000
5000
6000
0% 20% 40% 60% 80% 100%
P301 457
H1B 250
W
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Technical specifications
H1B speed range diagrams for open and closed circuit
Speed (rpm) versus Displacement (%), Intermittent operation (grey area)
Warning
Zero degree capability results in a high risk of overspeed and drops in efficiency if the motor operates between 0–20% 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.
©
Danfoss | March 2020 AX152886484369en-000607 | 15
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
0% 20% 40%
60%
80% 100%
P006 010
30bar
20bar
15bar
10bar
5bar
2bar
H1B 060
1000
2000
3000
4000
5000
6000
7000
8000
0
0% 20% 40%
60%
80% 100%
P006 011
30bar
20bar
15bar
10bar
5bar
2bar
H1B 080
1000
2000
3000
4000
5000
6
7000
000
0% 20% 40%
60%
80% 100%
P006 012
30bar
20bar
15bar
10bar
5bar
2bar
0
H1B 110
1000
2000
3000
4000
5000
6
7000
000
0% 20% 40%
60%
80% 100%
P006 013
30bar
20bar
15bar
10bar
5bar
2bar
0
H1B 160
0% 20% 40%
60%
80% 100%
P006 014
30bar
20bar
15bar
10bar
5bar
2bar
0
1000
2000
3000
4000
5000
6000
H1B 210
0% 20% 40%
60%
80% 100%
P006 015
30bar
20bar
15bar
10bar
5bar
2bar
0
1000
2000
3000
4000
5000
6000
H1B 250
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 (%)
Speed (rpm) and Pressure (bar) versus Displacement (%)
Speed (rpm) and Pressure (bar) versus Displacement (%)
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.
16 | © Danfoss | March 2020 AX152886484369en-000607
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
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
Power Solutions 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 will ensure 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.
©
Danfoss | March 2020 AX152886484369en-000607 | 17
Vg • n
1000 •
v
Qe =
Vg • p •
mh
20 •
Me =
Qe • p •
t
600
=
Me • n
9550
Pe=
n =
Qe • 1000 •
v
V
g
Vg • n
231 •
v
Qe =
Vg • p •
mh
2 •
Me =
Vg • n • p •
t
396 000
Pe=
n =
Qe • 231 •
v
V
g
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Technical specifications
Fluid specifications
Fluid specifications
Features Unit
Minimum intermittent
Viscosity
Temperature range
Cleanliness and Filtration
1)
At the hottest point, normally case drain port.
2)
Minimum: cold start, short term t<3 min, p<50 bar, n<1000 rpm.
Recommended range
Maximum intermittent
Minimum
1)2)
Rated
Maximum intermittent
Required cleanliness per ISO 4406
Efficiency (charge pressure filtration)
Efficiency (suction / return line filtration)
Recommended inlet screen mesh size
All sizes
7 [49]
mm2/s
[SUS]
°C
[°F]
-
β-ratio
µm 100 – 125
12-80 [66-366]
1600 [7416]
-40 [-40]
104 [220]
115 [240]
22/18/13
β
= 75 (β10 ≥ 10)
15-20
β
= 75 (β10 ≥ 2)
35-45
Determination of nominal motor size
Based on SI units Based on US units
Where:
Q
Input flow (l/min)
e
M
Output torque (N•m)
e
P
Output power (kW)
e
n Speed (min-1)
V
Motor displacement per rev. (cm3/rev)
g
p
High pressure (bar)
high
p
Low pressure (bar)
low
∆p High pressure minus Low pressure (bar)
η
Motor volumetric efficiency
v
η
Mechanical-hydraulic efficiency
mh
η
Motor total efficiency (ηv • ηmh)
t
Where:
Q
Input flow [US gal/min]
e
M
Output torque [lb•in]
e
P
Output power [hp]
e
n Speed [rpm]
V
Motor displacement per rev. [in3/rev]
g
p
High pressure [psi]
high
p
Low pressure [psi]
low
∆p High pressure minus Low pressure [psi]
η
Motor volumetric efficiency
v
η
Mechanical-hydraulic efficiency
mh
η
Motor total efficiency (ηv • ηmh)
t
18 | © Danfoss | March 2020 AX152886484369en-000607
CCW CW
P006030
B
A
CCW CW
P006031
B
A
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
Flow into port A Clockwise
Flow into port B Counterclockwise
Controls M1, M2, K1, K2, KH, MH
Flow into port A Counterclockwise
Flow into port B Clockwise
©
Danfoss | March 2020 AX152886484369en-000607 | 19
CCW CW
P006032
B
A
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 Counterclockwise
Flow into port B Clockwise
20 | © Danfoss | March 2020 AX152886484369en-000607
P006033
A
LFRV
B
P003 437
A
B
L2
W
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.
Legend:
A System loop A
B System loop B
LFRV to Loop flushing relief valve
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.
©
Danfoss | March 2020 AX152886484369en-000607 | 21
P003 491
P003 487
A
B
L2
40 bar
30 bar
20 bar
10 bar
10 15 20 30 40
50
5
10 20 30 40 50 60
P006 034
0
X
Y
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 sizes
Loop flushing relief valve schematic
X Loop flushing flow (l/min)
Y Low system pressure minus case pressure (bar)
22 | © Danfoss | March 2020 AX152886484369en-000607
P003450
P003489
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, 11046759.
Sensor position
Sensor position in SAE, DIN and Cartridge housing.
SAE and DIN housing
Cartridge housing
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 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.
Displacement limiter
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.
©
Danfoss | March 2020 AX152886484369en-000607 | 23
W
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 15–34 rpm, ± 5 %, depending on system pressure, in
applications that require low speed stability. Motor output speed becomes more stable as speed
increases.
Rated speed is the highest output speed recommended at full power condition. Operating at, or below
this speed will yield satisfactory product life.
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.
System pressure
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 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.
24 | © Danfoss | March 2020 AX152886484369en-000607
C
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.
Caution
Possible component damage or leakage.
Operation with case pressure in excess of stated limits may damage seals, gaskets, and/or housings,
causing external leakage. Performance may also be affected since charge and system 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.
©
Danfoss | March 2020 AX152886484369en-000607 | 25
C
W
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 Max oil change interval
Sealed 2000 hours
Breather 500 hours
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
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.
26 | © Danfoss | March 2020 AX152886484369en-000607
L2
MB
MA
L1
M5
System Port A
P108829
(System Port B
on reverse side)
(M4 on reverse side)
Radial Ported Endcap
Axial Ported Endcap
System
Port B
System
Port A
M5
L2
MA
(M4 on
reverse side)
(MB on
reverse side)
X1
XB
(Port XA
on reverse side)
X1
XB
(Port XA
on reverse side)
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)
System split flange boss ports, A/B: Code 62 per ISO 6162, Type 1
Port Size 060 Size 080, 110 Size 160, 210, 250
A, B
3/4 in; Thread: M10 x 1.5
min. 18 mm [0.71 in]
Radial/Axial end-cap ports
Port Size 060 Size 080, 110, 160, 210, 250 System pressure obtained
MA, MB (Radial)
MA, MB (Axial)
7/8-14 UNF
Wrench (int. hex): 3/8 in
7/8-14 UNF
Wrench (int. hex): 3/8 in
1 in; Thread: M12 x 1.75
min. 23 mm [0.91 in]
1 1/16-12UN
Wrench (int. hex): 9/16 in
9/16-18 UNF
Wrench (int. hex): 1/4 in
1 1/4 in; Thread: M12 x 1.75
min. 23 mm [0.91 in]
600 bar [8702 psi]
600 bar [8702 psi]
©
Danfoss | March 2020 AX152886484369en-000607 | 27
P108924
X1
XB
(Port XA
on reverse side)
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Pressure measurements
Ports and gauge Information
Port Size 060/080 Size 110/160 Size 210/250 Pressure obtained
L1, L2
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.
7/8-14 UNF
Wrench: 3/8 in
Port locations (hydraulic 2-position controls with PCOR; control specific ports only)
1 1/16-12UN
Wrench: 9/16 in
1 5/16-12UN
Wrench: 5/8 in
10 bar [145 psi]
Case drain
600 bar [8700 psi]
100 bar [1450 psi]
1)
2)
28 | © Danfoss | March 2020 AX152886484369en-000607
W
C
W
C
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Initial startup procedures
Procedure
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.
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.
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.
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.
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.
©
Danfoss | March 2020 AX152886484369en-000607 | 29
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.
30 | © Danfoss | March 2020 AX152886484369en-000607
W
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
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.
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 Cause Corrective action
1.
Motor operates at one
displacement only.
2. Erratic motor function Electrical connection to motor is intermittent.
Control coil failure
Measure resistance at coil pins. Resistance at 20°C
[70°F] should be:
Proportional controls: 14.20 Ω (24V) or 3.66 Ω (12V)
•
Two-position controls: 8.4 Ω (24V) or 34.5 Ω (12V)
•
Replace coil if necessary.
Disconnect connector, check wires and terminals,
reconnect wires. Check terminals for corrosion and
correct position.
Sluggish operation
Check Cause Corrective action
1. Control orifices Blocked or restricted orifice may cause sluggish
response. Orifices installed in the wrong locations
may cause PCOR control to be sluggish.
2. Threshold setting (proportional
controls)
3. Control spool A sticky control may cause sluggish response or no
4. Pressure compensator setting Low pressure compensator setting may shift motor
5. Control input signal An improper or erratic input signal to the control
6. Internal leakage Excessive leakage will cause lower charge pressure
Inappropriately high or low threshold setting may
shift the motor at the wrong time.
response.
to maximum displacement at lower pressure.
may cause sluggish response.
and affect performance.
Remove, inspect and clean all orifices. Ensure the
appropriate orifices are installed and in the correct
location.
Check threshold setting. Adjust if necessary.
Clean and inspect the control spool. Replace if
necessary.
Check pressure compensator setting. Adjust if
necessary.
Check input signal and correct if necessary.
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 Cause Corrective action
1. Oil level Insufficient hydraulic fluid may cause overheating. Fill reservoir to proper level.
2. Heat exchanger Blocked heat exchanger or low air flow may cause
system overheating.
3. Loop flushing flow Restricted orifice in loop flushing cartridge reduces
flow.
4. Loop flushing shuttle Loop flushing shuttle may be sticking in one
direction.
Check temperature upstream and downstream of heat
exchanger. Clean, repair, or replace heat exchanger if
necessary.
Measure case drain flow. Clean or replace orifice
cartridge.
Ensure shuttle moves freely in its bore.
©
Danfoss | March 2020 AX152886484369en-000607 | 31
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Troubleshooting
Check Cause Corrective action
5. Air in system Entrained air generates heat under pressure Look for foam or bubbles in reservoir. Check for leaks
on inlet side of charge pump.
6. Internal leakage Excessive internal leakage may overheat the
system.
Excessive noise or vibration
Check Cause Corrective action
1. Oil level in reservoir Insufficient hydraulic fluid may cause cavitation. Fill reservoir to proper level.
2. Air in system Air bubbles may lead to cavitation. Look for foam or bubbles in reservoir. Check for leaks
3. Shaft coupling Loose shaft coupling may create excess noise. Replace loose shaft coupling. Replace or repair motor
4. Shaft alignment Misaligned shafts may create excessive noise and
vibration and can damage motor.
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.
on inlet side of charge pump.
if shaft splines show excessive wear.
Correct shaft misalignment.
Motor operates normally in one direction only
Check Cause Corrective action
1. Charge pressure If charge pressure is low in one direction, the loop
flushing shuttle spool may be sticking to one side.
2. Pressure compensator control If pressure compensator operates in one direction
only, the motor may stay at minimum
displacement in the opposite direction.
Measure charge pressure in forward and reverse. If
pressure drops significantly lower in one direction,
inspect and repair loop flushing shuttle spool.
Check brake pressure defeat spool. It may be sticking
or receiving an improper signal. Repair spool or
correct input signal.
Improper output speed
Check Cause Corrective action
1. Oil level in reservoir Insufficient hydraulic fluid may reduce system
efficiency.
2. Threshold setting Improper threshold setting may cause motor to
have wrong displacement for given signal.
3. Pressure compensator setting Improper pressure compensator setting may shift
motor displacement at wrong pressure.
4. PC spool Pressure compensator spool sticking may shift
motor to improper displacement.
5. Control orifices Blocked or restricted orifice may cause motor to
shift improperly.
6. Control spool Sticky proportional control spool may cause motor
to shift improperly.
7. Control input signal Improper input signal may cause motor to shift
improperly.
8. Internal leakage Excess internal leakage may cause lower charge
pressure and affect motor performance including
output speed.
Fill reservoir to proper level.
Check threshold setting. Refer to Control Service
Manual for adjustment procedure.
Check pressure compensator setting. Adjust if
necessary. Refer to Control Service Manual for
adjustment procedure.
Check pressure compensator spool. Repair or replace
if needed. Refer to Control Service Manual for
adjustment procedure.
Remove, inspect and clean all orifices.
Check control spool for proper operation. Repair if
necessary. Refer to control adjustment procedure.
Correct control input signal.
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.
32 | © Danfoss | March 2020 AX152886484369en-000607
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Troubleshooting
Low output torque
Check Cause Corrective action
1. Pressure compensator setting High pressure compensator setting may cause
improper motor displacement for torque required.
2. Control orifices Blocked or restricted orifice may cause motor to
shift improperly.
3. Pressure compensator spool Sticking pressure compensator spool may cause
control to hold motor at minimum displacement.
4. Control spool Sticking control spool may cause motor to shift
improperly.
5. Two position solenoid Two position control not shifting motor to
maximum displacement.
6. Control input signal Improper control input signal may cause motor to
stay at minimum displacement.
7. Threshold setting
(proportional control)
8. Internal leakage Excess internal leakage may cause charge pressure
Improper threshold setting may cause improper
motor displacement for torque required.
to decay, reducing output torque.
Check and adjust pressure compensator setting.
Remove, inspect and clean all orifices.
Remove and inspect pressure compensating spool.
Repair or replace control if necessary.
Remove and inspect control spool. Repair or replace
control if necessary.
Inspect solenoid valve for bent stem or damaged coil.
Repair or replace if necessary.
Correct control input signal.
Check and adjust threshold setting.
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.
©
Danfoss | March 2020 AX152886484369en-000607 | 33
C
C
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
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.
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.
34 | © Danfoss | March 2020 AX152886484369en-000607
N0020
N0120
N0010
19 mm
6 mm
45 N•m
[32 lb•ft]
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Adjustments
Adjusting the minimum displacement limiter
Minimum displacement limiter
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 (N0010) in place.
3. Using a 19 mm hex wrench, loosen seal locknut (N0020).
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 060 080 110 160 210 250
Displacement
change
3
2.1 cm
[0.13 in3]
2.6 cm
[0.16 in3]
3
3
3.2 cm
[0.20 in3]
3
4.1cm
[0.25 in3]
5.1 cm
[0.31 in3]
3
5.5 cm
[0.34 in3]
3
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).
©
Danfoss | March 2020 AX152886484369en-000607 | 35
B0040
adjusting
screw
3 mm
W
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
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 60 mA for 12V controls
and 30mA 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.
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.
36 | © Danfoss | March 2020 AX152886484369en-000607
Locking nut
(B0180)
adjusting
screw
6 mm
19 mm
45 N•m
[32 lbf•ft]
W
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
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.
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.
©
Danfoss | March 2020 AX152886484369en-000607 | 37
W
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Adjustments
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.
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.
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.
38 | © Danfoss | March 2020 AX152886484369en-000607
Locknut
Adjusting screw
10 mm
3 mm
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
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.
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].
©
Danfoss | March 2020 AX152886484369en-000607 | 39
H1B PCOR Adjustment
System Pressure
Engine Speed
Wheel Speed
Displacement Range
Minimum Displacement
Max Displacement
TIME
Begin Application of
Service Brake
PCOR Setting
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.
40 | © Danfoss | March 2020 AX152886484369en-000607
G0030
G0020
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
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
©
Danfoss | March 2020 AX152886484369en-000607 | 41
P107 738E
180 mm
[7.09 in]
82 mm
[3.15 in]
5 mm
[0.2 in]
45°
5.15 mm
100 mm
[3.94 in]
69 mm
[2.6 in]
58 mm
[2.3 in]
+ 0.10
- 0.0
[0.20 in
+ 0.004
- 0.0
]
150 mm
[5.90 in]
70 mm
[2.76 in]
5 mm
[0.2 in]
45°
5.4 mm
100 mm
[3.94 in]
56 mm
[2.2 in]
48 mm
[1.9 in]
+ 0.10
- 0.0
[0.21 in
+ 0.004
- 0.0
]
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
42 | © Danfoss | March 2020 AX152886484369en-000607
B0010
4 mm
6 N•m [ 4 lbf•ft]
B0050
B0035A
C0100
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
©
Danfoss | March 2020 AX152886484369en-000607 | 43
P108828
B0050
B0010
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
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.
44 | © Danfoss | March 2020 AX152886484369en-000607
C0010
Proportional
control
C0110 (4X)
F0030
F0040
C0130
6 mm
C0110 (2X)
C0010
2 position
control
C0120 (2X)
10 mm
C0130
Electric proportional control
Two position control
10 mm
115 Nm [85 lbf•ft]
37 Nm
[27 lbf•ft]
115 Nm
[85 lbf•ft]
Hydraulic proportional control
C0110 (4X)
6 mm
37 Nm
[27 lbf•ft]
C0010
Proportional
control
F0030
F0040
C0130
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
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
©
Danfoss | March 2020 AX152886484369en-000607 | 45
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 Internal Hex
C0110
C0110, C0120
Electric / Hydraulic proportional 37 N•m
Two-position 115 N•m
Wrench
6 mm
[27 lbf•ft]
10 mm
[85 lbf•ft]
46 | © Danfoss | March 2020 AX152886484369en-000607
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
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).
©
Danfoss | March 2020 AX152886484369en-000607 | 47
B0050
B0010
B0035A
B0010
E00T3
C0060A
C0060
C0060
E00T2
C0025
C0050A
C0060A
C0050
26 mm
1/4 in
1/8 in
1/8 in
C0100
B0027
5 mm
3 mm
3 mm
1/8 in
C0060
C0060A
B0025
B0040
B0029
B0027
B0028
B0020
B0020A
4mm
6 N•m
[4 lbf•ft]
8 N•m
[6 lbf•ft]
40 N•m
[30 lbf•ft]
8 N•m
[6 lbf•ft]
8 N•m
[6 lbf•ft]
3.5 N•m
[2.6 lbf•ft]
8 N•m
[6 lbf•ft]
6 N•m [4 lbf•ft]
6 N•m [4 lbf•ft]
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair
Assembly
Proportional control block assembly
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) to 40 N•m [30 lbf•ft] using a 1/4 inch internal hex wrench.
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).
48 | © Danfoss | March 2020 AX152886484369en-000607
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
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.
©
Danfoss | March 2020 AX152886484369en-000607 | 49
P108832
B0050
B0010
C0010
E00T3
C0060A
C0050A
B0060
C0050
1/8 in
C0140
3 mm
1/8 in
C0060
C0060A
40 N•m
[30 lbf•ft]
8 N•m
[6 lbf•ft]
8 N•m
[6 lbf•ft]
6 N•m [4 lbf•ft]
0010
0020
B0180
B0061
0010
0020
E00T2
1/8 in
C0060
8 N•m
[6 lbf•ft]
C0060A
C0070
C0080
C0090A
C0090
C0060A
1/8 in
C0060
8 N•m
[6 lbf•ft]
C0050
40 N•m
[30 lbf•ft]
C0050A
C0050
40 N•m
[30 lbf•ft]
B0190
C0100
C0120
C0110
C0140
C0020
C0060A
1/8 in
C0060
8 N•m
[6 lbf•ft]
C0050A
C0060
C0060A
C0060A
C0060
3 mm
6 N•m [4 lbf•ft]
C0060AC0060
C0060
C0050A
C0050
C0060
C0060A
DHMH
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 a 1/4 in 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
50 | © Danfoss | March 2020 AX152886484369en-000607
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).
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair
6. Install and torque plug (C0050) to 40 N•m [30 lbf•ft] using a 1/4 inch internal hex wrench.
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
©
Danfoss | March 2020 AX152886484369en-000607 | 51
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 a 1/4 inch 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.
52 | © Danfoss | March 2020 AX152886484369en-000607
1/8 in
8 N•m [6 lbf•ft]
17 mm
25 N•m [19 lbf•ft]
C0060
C0060A
C0060A
C0060
E00T3
E00T2
C0020
C0030
1/4 in
40 N•m [30 lbf•ft]
C0050
C0050A
1/8 in 8 N•m [6 lbf•ft]
C0060
C0060A
3 mm
6 N•m
[4 lbf•ft]
1/8 in 8 N•m [6 lbf•ft]
C0060
C0070
C0080
C0050
C0050A
17 mm
C0090
M223
1/8 in
8 N•m [6 lbf•ft]
3 mm
6 N•m
[4 lbf•ft]
1/4 in
40 N•m [30 lbf•ft]
25 N•m
[18 lbf•ft]
B0028
B0022
B0024
B0032
B0028
B0022
B0024
B0032
B0034
17 mm
25 N•m [19 lbf•ft]
B0034
B0026
3.5 N•m
[2.6 lbf•ft]
B0026
3.5 N•m
[2.6 lbf•ft]
T*D* and P*D*
C0060
E00T2
E00T3
C0010
C0060
C0050
C0030
C0020
C0050
B0024
B0026
B0028
B0034
T*G* and P*G*
B0022
B0032
B0028
B0022
B0024
B0032
B0034
B0026
C0070
C0080
C0090
M223
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair
Assembly
Two-position control assembly
©
Danfoss | March 2020 AX152886484369en-000607 | 53
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 a 1/4 inch internal hex wrench, install plugs (C0050).
Torque to 25 N•m [19 lbf•ft].
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.
54 | © Danfoss | March 2020 AX152886484369en-000607
C0050
C0050
C0060
C0060
C0050
C0060
C0060
C0160
C0160A
C0140
C0050
C0060
C0060
C0050
C0050
C0060
C0060
C0160
C0160A
C0140
P108 576E
C0080
C0150
C0025
C0025
C0150
C0080
1/4 inch
1/4 in
1/8 in
1/8 in
3/8 inch
1/4 in
1/8 in
3/8 inch
HEHE
HFHF
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 a 1/4 inch 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)
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 a 1/4 inch internal hex wrench, install two plugs (C0050). Torque to 40 N•m [30 lbf•ft].
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].
©
Danfoss | March 2020 AX152886484369en-000607 | 55
C0050
C0060
C0050
C0060
C0070
P108913
C0025
1/4 inch
1/8 in
1/8 in
THHA
C0050
C0080
C0090
M223
B0300
B0310
B0330
B0320
QB300
E00T2
E00T3
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 a 1/4 inch 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)
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 a 1/4 inch internal hex wrench, with torque to 40 N•m [30 lbf•ft].
9. Install two plugs (C0060) using a 1/8 inch internal hex wrench, with torque to 8 N•m [6 lbf•ft].
56 | © Danfoss | March 2020 AX152886484369en-000607
C0050
C0060
C0050
P108923
C0025
1/4 inch
C0060
1/8 in
1/8 in
THHB
C0050
C0070
C0080
C0090
M223
B0300
B0310
B0330
B0320
QB300
C0050
C0140
C0020
E00T2
E00T3
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 a 1/4 inch 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)
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).
©
Danfoss | March 2020 AX152886484369en-000607 | 57
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].
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair
9. Lubricate and install shuttle (C0025).
10. Using a 1/4 inch internal hex wrench, install four plugs (C0050). Torque to 40 N•m [30 lbf•ft].
11. Using a 1/8 inch internal hex wrench, install three plugs (C0060). Torque to 8 N•m [6 lbf•ft].
58 | © Danfoss | March 2020 AX152886484369en-000607
6 mm
P107 866E
P0200
P0100
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
1. Install spacer (P0200) and screw (P0100) using a 6 mm internal hex.
2. Torque screw to 37 N•m [28 lbf•ft].
©
Danfoss | March 2020 AX152886484369en-000607 | 59
P0043
P0050
P0030
P0010
P0020
10 mm
115 N•m [85 lbf•ft]
see table
P0040
P0044
P0041
Seal ring
(P0044)
O-ring
(P0043)
Piston
C
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair
Servo piston cover – proportional control
Removal
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).
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.
60 | © Danfoss | March 2020 AX152886484369en-000607
Servo
piston
head
Expanding
pliers
Seal ring
(P0044)
O-ring
(P0043)
Piston head
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair
5. Using expanding pliers, remove piston head (P0040).
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).
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 060/080 110 160/210/250
Wrench size 8 mm 10 mm 12 mm
©
Danfoss | March 2020 AX152886484369en-000607 | 61
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair
Torque for P0050
Size 060/080 110 160/210/250
Torque
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.
66 N•m [49 lbf•ft] 115 N•m [85 lbf•ft] 213 N•m [157 lbf•ft]
62 | © Danfoss | March 2020 AX152886484369en-000607
J0020
J0010A
J0010
5 mm
8 N•m [6 lbf•ft]
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
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].
©
Danfoss | March 2020 AX152886484369en-000607 | 63
K0010
K0030
K0030A
K0020
K0030
K0030A
K0020
67 N•m
[49 lbf•ft]
67 N•m [49 lbf•ft]
24 mm
24 mm
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Minor repair
Loop flushing spool
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
Loop flushing reassembly
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].
64 | © Danfoss | March 2020 AX152886484369en-000607
L0050
L00**
67 N•m [49 lbf•ft]
24 mm
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
©
Danfoss | March 2020 AX152886484369en-000607 | 65
N0020
N0120
N0010
19 mm
6 mm
45 N•m
[32 lb•ft]
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 | March 2020 AX152886484369en-000607
K0030
B0050
G0060
L1
J0020
C0060
C0110 and C0120
P0020
L2
G0060
M5
F0100
System
Por t A
L00**
N0010
N0020
MB
F0150
MA
F0150
XB
System
Por t B
M4
F0100
XA
X1
G0050
B0060
B0060
B0060
X1
XB
XA
K0030
G0060
L1
L2
G0060
M4
F0100
System
Por t B
L00**
MA
F0150
MB
F0150
System
Por t A
B0060
B0060
M5
F0100
B0060
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)
Two-position controls port, plug and fasteners (with radial ported endcap)
Fastener size and torque chart
Item Fastener Wrench size Torque
B0050
C0110
C0110, C0120
J0020
N0010
N0020
P0020
Plug size and torque chart
Item O-ring plug Wrench size Torque
B0060
C0050
C0060
©
Danfoss | March 2020 AX152886484369en-000607 | 67
Solenoid screws
Control (proportional) assembly screws
Control (two-position) assembly screws
Speed sensor screw
Displacement limiter screw
Displacement limiter lock-nut
Servo piston cover screws
9/16 - 18UNF 1/4 internal hex 40 N•m [30 lbf•ft]
9/16-18 UNF (not shown) 1/4 internal hex 40 N•m [30 lbf•ft]
5/16 - 24UNF 3/8 internal hex 8 N•m [5 lbf•ft]
4 mm internal hex 6 N•m [4 lbf•ft]
6 mm internal hex 37 N•m [28 lbf•ft]
10 mm internal hex 115 N•m [85 lbf•ft]
5 mm internal hex 8 N•m [6 lbf•ft]
6 mm internal hex N/A
19 mm 45 N•m [32 lbf•ft]
10 mm internal hex 115 N•m [85 lbf•ft]
Service Manual
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Torque chart
Plug size and torque chart (continued)
Item O-ring plug Wrench size Torque
F0100
F0150 (060)
F0150 (080, 110,
160, 210, 250)
G0050
G0055
G0060 (060, 080)
G0060 (110, 160)
G0060 (210, 250)
K0030
L00**
F0160
9/16 - 18UNF 1/4 internal hex 40 N•m [30 lbf•ft]
1-1/16 - 12 UN (Radial endcap) 9/16 internal hex
5/16 - 24UNF (SAE and DIN flange) 1/8 internal hex 8 N•m [5 lbf•ft]
7/16 - 20UNF (Cartridge only/not shown) 3/16 internal hex 8 N•m [5 lbf•ft]
7/8 - 14UN 3/8 internal hex 70 N•m [52 lbf•lb]
1-1/16 - 12UN 9/16 internal hex 70 N•m [52 lbf•lb]
1-5/16 - 12UN 5/8 internal hex 70 N•m [52 lbf•lb]
M18 - 1.5 24 mm hex 67 N•m [49 lbf•ft]
M18 - 1.5 24 mm hex 67 N•m [49 lbf•ft]
9/16-18 UNF (Axial endcap, not shown) 1/4 internal hex 40 N•m [30 lbf•ft]
95 N•m [70 lbf•ft]
115 N•m [85 lbf•ft]
68 | © Danfoss | March 2020 AX152886484369en-000607
Danfoss
Power Solutions GmbH & Co. OHG
Krokamp 35
D-24539 Neumünster, Germany
Phone: +49 4321 871 0
Danfoss
Power Solutions ApS
Nordborgvej 81
DK-6430 Nordborg, Denmark
Phone: +45 7488 2222
Danfoss
Power Solutions (US) Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: +1 515 239 6000
Danfoss
Power Solutions Trading
(Shanghai) Co., Ltd.
Building #22, No. 1000 Jin Hai Rd
Jin Qiao, Pudong New District
Shanghai, China 201206
Phone: +86 21 2080 6201
Products we offer:
Hydro-Gear
www.hydro-gear.com
Daikin-Sauer-Danfoss
www.daikin-sauer-danfoss.com
DCV directional control
•
valves
Electric converters
•
Electric machines
•
Electric motors
•
Gear motors
•
Gear pumps
•
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.
Local address:
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products
already on order provided that such alterations can be made without subsequent changes being necessary in specifications already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
©
Danfoss | March 2020 AX152886484369en-000607
Loading...