H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Contents
Introduction
About this manual............................................................................................................................................................................5
General Instructions........................................................................................................................................................................ 5
Symbols used in Danfoss literature............................................................................................................................................7
H1 general information
Design of H1 bent axis motor...................................................................................................................................................... 8
General description.......................................................................................................................................................................10
H1 system schematic....................................................................................................................................................................12
Technical specifications
General specifications.................................................................................................................................................................. 13
H1B speed range diagrams for open and closed circuit..................................................................................................15
Open circuit requirements..........................................................................................................................................................17
Determination of nominal motor size....................................................................................................................................18
System pressure............................................................................................................................................................................. 24
Case pressure...................................................................................................................................................................................25
External shaft seal pressure........................................................................................................................................................25
Fluid and filter recommendations........................................................................................................................................... 26
Pressure measurements
Ports and Gauge Information....................................................................................................................................................27
System operating hot...................................................................................................................................................................31
Excessive noise or vibration....................................................................................................................................................... 32
Motor operates normally in one direction only..................................................................................................................32
Electric proportional solenoid replacement........................................................................................................................ 43
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
Fasteners, plugs with torque chart..........................................................................................................................................67
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 unitChock 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 cleanCleanliness 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 unitFor 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.
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.
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Introduction
Symbols used in Danfoss literature
WARNING may result in injuryTip, helpful suggestion
CAUTION may result in damage to product or
property
Reusable partApply grease / petroleum jelly
Non-reusable part, use a new partApply locking compound
Non-removable itemInspect for wear or damage
Option - either part may existClean area or part
Superseded - parts are not interchangeableBe careful not to scratch or damage
Measurement requiredNote correct orientation
Flatness specificationMark orientation for reinstallation
Parallelism specificationTorque specification
External hex headPress in - press fit
Internal hex headPull out with tool – press fit
Torx headCover splines with installation sleeve
O-ring boss portPressure 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.
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.
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.
Minimum 6°590053004800425038503650
Zero 0°660059505350475043004050
Maximum 32°450041003700330030002800
Minimum 6°725066005950525048004500
Zero 0°795072006500575052504900
min
(rpm)
1.0625 [11∕16]–12UN-2B
Size
060080110160210250
360032002900260023502200
-1
System and Case Pressure, Ambient Temperature
ParameterAll sizes
System pressureMaximum working450 bar [6527 psi]
Maximum480 bar [6962 psi]
Minimum
Case pressureRated3 bar [44 psi]
Maximum5 bar [73 psi]
Minimum0.3 bar [4 psi]
Ambient temperature
3)
Maximum70 °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.
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.
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.
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.
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.
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:
ASystem loop A
BSystem loop B
LFRVto 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.
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
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 size060080110160210250
Teeth71788695104108
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.
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.
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
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 typeMax oil change interval
Sealed2000 hours
Breather500 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.
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.
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
CheckCauseCorrective action
1.
Motor operates at one
displacement only.
2.Erratic motor functionElectrical 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
CheckCauseCorrective action
1.Control orificesBlocked 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 spoolA sticky control may cause sluggish response or no
4.Pressure compensator settingLow pressure compensator setting may shift motor
5.Control input signalAn improper or erratic input signal to the control
6.Internal leakageExcessive 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
CheckCauseCorrective action
1.Oil levelInsufficient hydraulic fluid may cause overheating.Fill reservoir to proper level.
2.Heat exchangerBlocked heat exchanger or low air flow may cause
system overheating.
3.Loop flushing flowRestricted orifice in loop flushing cartridge reduces
flow.
4.Loop flushing shuttleLoop 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.
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Troubleshooting
CheckCauseCorrective action
5.Air in systemEntrained air generates heat under pressureLook for foam or bubbles in reservoir. Check for leaks
on inlet side of charge pump.
6.Internal leakageExcessive internal leakage may overheat the
system.
Excessive noise or vibration
CheckCauseCorrective action
1.Oil level in reservoirInsufficient hydraulic fluid may cause cavitation.Fill reservoir to proper level.
2.Air in systemAir bubbles may lead to cavitation.Look for foam or bubbles in reservoir. Check for leaks
3.Shaft couplingLoose shaft coupling may create excess noise.Replace loose shaft coupling. Replace or repair motor
4.Shaft alignmentMisaligned 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
CheckCauseCorrective action
1.Charge pressureIf charge pressure is low in one direction, the loop
flushing shuttle spool may be sticking to one side.
2.Pressure compensator controlIf 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
CheckCauseCorrective action
1.Oil level in reservoirInsufficient hydraulic fluid may reduce system
efficiency.
2.Threshold settingImproper threshold setting may cause motor to
have wrong displacement for given signal.
3.Pressure compensator settingImproper pressure compensator setting may shift
motor displacement at wrong pressure.
4.PC spoolPressure compensator spool sticking may shift
motor to improper displacement.
5.Control orificesBlocked or restricted orifice may cause motor to
shift improperly.
6.Control spoolSticky proportional control spool may cause motor
to shift improperly.
7.Control input signalImproper input signal may cause motor to shift
improperly.
8.Internal leakageExcess 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.
H1 Bent Axis Motors, Size 060/080/110/160/210/250 cc
Troubleshooting
Low output torque
CheckCauseCorrective action
1.Pressure compensator settingHigh pressure compensator setting may cause
improper motor displacement for torque required.
2.Control orificesBlocked or restricted orifice may cause motor to
shift improperly.
3.Pressure compensator spoolSticking pressure compensator spool may cause
control to hold motor at minimum displacement.
4.Control spoolSticking control spool may cause motor to shift
improperly.
5.Two position solenoidTwo position control not shifting motor to
maximum displacement.
6.Control input signalImproper control input signal may cause motor to
stay at minimum displacement.
7.Threshold setting
(proportional control)
8.Internal leakageExcess 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.
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
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
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
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.
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.
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.
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).
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).
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.
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Ames, IA 50010, USA
Phone: +1 515 239 6000
Danfoss
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