Revision history Table of revisions
Date Changed Rev
November 2015 Minor text change at pages 7 and 18. 0501
September 2014 MDC, CCO, and Swash Angle Sensor options added 0500
October 2013 Layout changes EA
May 2014 Converted to DITA CMS system DB
Aug 2013 Converted to Danfoss layout DA
August 2013 Frame size 069 added, AC control option added, FDC control option added CA
Nov 2010 Size 060/068 added BA
Jul 2009 First edition AA
Basic Information H1 Axial Piston Pumps, Single and Tandem
2 11062168 • Rev 0501 • November 2015
Danfoss hydrostatic product family
General description H1 family of hydrostatic pumps..........................................................................................................4
A word about the organization of this manual..................................................................................................................... 4
H1 pumps literature reference.................................................................................................................................................... 5
H1 pumps technical specifications overview
Operation
Pressure limiter valves.................................................................................................................................................................... 7
High Pressure Relief Valve (HPRV) and charge check..........................................................................................................7
Bypass function.................................................................................................................................................................................8
Charge Pressure Relief Valve (CPRV) .........................................................................................................................................9
Electrical Displacement Control (EDC)...................................................................................................................................10
Manual Displacement Control (MDC).....................................................................................................................................11
Automotive Control (AC) ............................................................................................................................................................12
Automotive Control connection diagram ........................................................................................................................... 13
Forward-Neutral-Reverse (FNR) electric control.................................................................................................................14
Non Feedback Proportional Electric control (NFPE)..........................................................................................................14
Fan Drive Control (FDC) options F1 (12 V) / F2 (24 V)....................................................................................................... 15
Manual Over Ride (MOR).............................................................................................................................................................16
Swash plate angle sensor for NFPE and AC2 controls......................................................................................................17
Control-Cut-Off valve (CCO valve)........................................................................................................................................... 18
Displacement limiter.....................................................................................................................................................................18
Life time.............................................................................................................................................................................................19
Speed and temperature sensor................................................................................................................................................ 20
Operating parameters
Input speed...................................................................................................................................................................................... 22
System pressure............................................................................................................................................................................. 22
Servo pressure.................................................................................................................................................................................23
Charge pressure..............................................................................................................................................................................23
Charge pump inlet pressure...................................................................................................................................................... 23
Case pressure...................................................................................................................................................................................23
External shaft seal pressure........................................................................................................................................................24
Temperature and viscosity......................................................................................................................................................... 24
System design parameters
Filtration system ............................................................................................................................................................................25
Filtration............................................................................................................................................................................................26
Fluid selection.................................................................................................................................................................................30
Reservoir............................................................................................................................................................................................30
Case drain......................................................................................................................................................................................... 31
Charge pump...................................................................................................................................................................................31
Bearing loads & life .......................................................................................................................................................................31
Mounting flange loads.................................................................................................................................................................33
Shaft torque..................................................................................................................................................................................... 34
Shaft availability and torque ratings.......................................................................................................................................34
Understanding and minimizing system noise.....................................................................................................................35
Determination of nominal pump sizes.................................................................................................................................. 36
Basic Information
H1 Axial Piston Pumps, Single and Tandem
Contents
11062168 • Rev 0501 • November 2015 3
General description H1 family of hydrostatic pumps
The H1 axial piston variable displacement pumps are of cradle swashplate design and are intended for
closed circuit applications.
The flow rate is proportional to the pump input speed and displacement.
The latter is infinitely adjustable between zero and maximum displacement.
Flow direction is reversed by tilting the swashplate to the opposite side of the neutral (zero
displacement) position.
•
14 different displacements:
45.0 cm³ [2.75 in³] 53.8 cm³ [3.28 in³]
60.4 cm³ [3.69 in³] 68.0 cm³ [4.15 in³]
69.0 cm³ [4.22 in³] 78.0 cm³ [4.76 in³]
89.2 cm³ [5.44 in³] 101.7 cm³ [6.21 in³]
115.8 cm³ [7.07 in³] 130.8 cm³ [7.98 in³]
147.0 cm³ [8.97 in³] 165.0 cm³ [10.07 in³]
211.5 cm³ [12.91 in³] 251.7 cm³ [15.36 in³]
•
Electric displacement control (EDC)
•
Forward-Neutral-Reverse (FNR)
•
Non Feedback Proportional Electric (NFPE)
•
Fan Frive Control (FDC)
•
Manual displacement control (MDC)
•
Control-Cutt-Off (CCO)-valve
•
Improved reliability and performance
•
More compact and lightweight
The H1 family of closed circuit variable displacement axial piston pumps is designed for use with all
existing Danfoss hydraulic motors for the control and transfer of hydraulic power. H1 pumps are compact
and high power density where all units utilize an integral electro-hydraulic servo piston assembly that
controls the rate (speed) and direction of the hydraulic flow. H1 pumps are specifically compatible with
the Danfoss family of PLUS+1
®
microcontrollers for easy Plug-and-Perform installation.
H1 pumps can be used together in combination with other Danfoss pumps and motors in the overall
hydraulic system. Danfoss hydrostatic products are designed with many different displacement, pressure
and load-life capabilities.
Go to the Danfoss website or applicable product catalog to choose the components that are right for
your complete closed circuit hydraulic system.
A word about the organization of this manual
General information covering all displacements of the H1 range is given in the beginning of this manual.
This includes definitions of operating parameters and system design considerations. Sections later in this
book detail the specific operating limitations for each frame and give a full breakdown of available
displacements, features and options.
The table below shows the available range of H1 pumps as of this printing, with their respective speed,
pressure, theoretical flow ratings, and mounting flange.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
Danfoss hydrostatic product family
4 11062168 • Rev 0501 • November 2015
H1 pumps literature reference
H1 Pumps available literature overview
Description
Type
Order number
Overview H1 Axial Piston Pumps, Single and Tandem Technical Information L1012919
H1 Axial Piston Pumps, Single and Tandem Basic Information 11062168
H1 Axial Piston Tandem Pumps, Size 045/053 Technical Information 11063345
H1 Axial Piston Single Pumps, Size 045/053 Technical Information 11063344
H1 Axial Piston Single Pumps, Size 060/068 Technical Information 11071685
H1 Axial Piston Single Pumps, Size 069/078 Technical Information 11062169
H1 Axial Piston Single Pumps, Size 089/100 Technical Information 11069970
H1 Axial Piston Single Pumps, Size 115/130 Technical Information 11063346
H1 Axial Piston Single Pumps, Size 147/165 Technical Information 11063347
H1 Axial Piston Single Pumps, Size 210/250 Technical Information L1208737
H1 Axial Piston Single Pumps, Size 045/053 Service Manual
520L0958
H1 Axial Piston Tandem Pumps, Size 045/053 Service Manual
520L0928
H1 Axial Piston Single Pumps, Size 069–165 Service Manual
520L0848
Further available literature
Title
Type
Order number
Electrical Displacement Control (EDC) Electrical Installation 11022744
3-position Electric Control (FNR) Electrical Installation 11025001
Non-Feedback Proportional Electric Control (NFPE) Electrical Installation 11025002
Automotive Control (AC) for H1 Axial Piston Single Pumps Electrical Installation L1223856
Automotive on PLUS+1 for MC024 Technical Information L1120636
Speed and Temperature Sensor Technical Information 11046759
Pressure Sensor Technical Information L1007019
External Remote Charge Pressure Filter Technical Information 11064579
Hydraulic Fluids and Lubricants Technical Information 520L0463
Design Guideline for Hydraulic Fluid Cleanliness Technical Information 520L0467
Experience with Biodegradable Hydraulic Fluids Technical Information 520L0465
Basic Information H1 Axial Piston Pumps, Single and Tandem
Danfoss hydrostatic product family
11062168 • Rev 0501 • November 2015 5
Pump Displacement Speed Pressure Weight dry
(W/O PTO
and Filter)
Control
options
Mounting
flange
Rated Max Max working
pressure
1)
Max pressure
cm³ [in³] min
-1
(rpm) bar [psi] bar [psi] kg [lb] SAE
Size 045/053 Single Pumps Technical Information, Danfoss order number: 11063344
H1P045
45.0 [2.75] 3400 3500 420 [6090] 450 [6525] 41 [90] EDC, FNR,
NFPE, MDC,
AC
2)
, FDC
B
2-bolt flange
H1P053
53.8 [3.28] 380 [5510] 400 [5800]
Size 045/053 Tandem Pumps Technical Information, Danfoss order number: 11063345
H1P045
45.0 [2.75] 3400 3500 420 [6090] 450 [6525] 65 [143] EDC, FNR,
NFPE, MDC
B
2-bolt flange
H1P053
53.8 [3.28] 380 [5510] 400 [5800]
Size 060/068 Single Pumps Technical Information, Danfoss order number: 11071685
H1P060
60.4 [3.69] 3500 4000 420 [6090] 450 [6525] 50 [110] EDC, FNR
NFPE, MDC,
AC
2)
, FDC
C
4-bolt flange
H1P068
68.0 [4.15] 380 [5510] 400 [5800]
Size 068/078 Single Pumps Technical Information, Danfoss order number: 11062169
H1P069
69.2 [4.22] 3500 4000 450 [6525] 480 [6960] 56 [123] EDC, FNR,
NFPE, MDC,
AC
2)
, FDC
C
4-bolt flange
H1P078
78.1 [4.77]
Size 089/100 Single Pumps Technical Information, Danfoss order number: 11069970
H1P089
89.2 [5.44] 3300 3800 450 [6525] 480 [6960] 62 [137] EDC, FNR,
NFPE, MDC,
AC
2)
, FDC
C
4-bolt flange
H1P100
101.7 [6.21]
Size 115/130 Single Pumps Technical Information, Danfoss order number: 11063346
H1P115
115.2 [7.03] 3200 3400 450 [6525] 480 [6960] 83 [187] EDC, FNR,
NFPE, MDC,
AC
2)
, FDC
D
4-bolt flange
H1P130
130.0 [7.93]
Size 147/165 Single Pumps Technical Information, Danfoss order number: 11063347
H1P147
147.2 [8.98] 3000 3100 450 [6525] 480 [6960] 96 [211] EDC, MDC,
FDC
D
4-bolt flange
H1P165
165.1 [10.08]
Size 210/250 Single Pumps Technical Information, Danfoss order number: L1208737
H1P210
211.5 [12.91] 2600 2800 450 [6525] 480 [6960] 163 [360] EDC, MDC,
FDC
E
4-bolt flange
H1P250
251.7 [15.36]
1)
Applied pressures above maximum working pressure requires Danfoss application approval.
2)
See Technical Information, Automotive control for single axial piston pumps, Danfoss Order number: L1223856 for more details.
Basic Information H1 Axial Piston Pumps, Single and Tandem
H1 pumps technical specifications overview
6 11062168 • Rev 0501 • November 2015
Pressure limiter valves
Pressure limiter valves provide system pressure protection by compensating the pump swashplate
position when the set pressure of the valve is reached. A pressure limiter is a non-dissipative (non heat
generating) pressure regulating system.
Each side of the transmission loop has a dedicated pressure limiter valve that is set independently. A
pump configured with pressure limiter must have pressure limiters on both sides of the system pressure
loop. The pump order code allows for different pressure settings to be used at each system port.
The pressure limiter setting is the differential pressure between the high and low loops. When the
pressure limiter setting is reached, the valve ports oil to the low-pressure side of the servo piston. The
change in servo differential pressure rapidly reduces pump displacement. Fluid flow from the valve
continues until the resulting drop in pump displacement causes system pressure to fall below the
pressure limiter setting.
An active pressure limiter destrokes a pump to near neutral when the load is in a stalled condition. The
pump swashplate moves in either direction necessary to regulate the system pressure, including into
stroke (overrunning) or over-center (winch payout).
The pressure limiter is optional for H1 single pumps and not available for tandem pumps.
High Pressure Relief Valve (HPRV) and charge check
All H1 pumps are equipped with a combination high pressure relief and charge check valve. The high-
pressure relief function is a dissipative (with heat generation) pressure control valve for the purpose of
limiting excessive system pressures. The charge check function acts to replenish the low-pressure side of
the working loop with charge oil. Each side of the transmission loop has a dedicated HPRV valve that is
non-adjustable with a factory set pressure. When system pressure exceeds the factory setting of the
valve, oil is passed from the high pressure system loop, into the charge gallery, and into the low pressure
system loop via the charge check.
The pump order code allows for different pressure settings to be used at each system port. When a HPRV
valve is used in conjunction with a pressure limiter, the HPRV valve is always factory set above the setting
of the pressure limiter. The system pressure order code for pumps with only HPRV is a reflection of the
HPRV setting.
The system pressure order code for pumps configured with pressure limiter and HPRV is a reflection of
the pressure limiter setting.
HPRV´s are factory set at a low flow condition. Any application or operating condition which leads to
elevated HPRV flow will cause a pressure rise with flow above a valve setting. Consult factory for
application review. Excessive operation of the HPRV will generate heat in the closed loop and may cause
damage to the internal components of the pump.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
Operation
11062168 • Rev 0501 • November 2015 7
Bypass function
The single pump HPRV valve also provides a loop bypass function when each of the two HPRV hex plugs
are mechanically backed out 3 full turns. Engaging the bypass function mechanically connects both A & B
sides of the working loop to the common charge gallery. The bypass function allows a machine or load to
be moved without rotating the pump shaft or prime move.
Bypass function not available for tandem pumps.
C
Caution
Excessive speeds and extended load/vehicle movement must be avoided. The load or vehicle should be
moved not more than 20 % of maximum speed and for a duration not exceeding 3 minutes. Damage to
drive motor(s) is possible. When the bypass function is no longer needed care should be taken to reseat
the HPRV hex plugs to the normal operating position.
System schematic, single pump
A
B
MA
S
M3
C2
C1
M4
M5
MBL4
L2
M6 1 2
R2
R1
M14
F00B F00A
CW
P003 418E
System schematic, tandem pump
C1
C1
C2C2
M14
M14
CW
F00B
F00A
F00B F00A
A
B
MA
E
C D
MD
MB
M3
L3
MC
M4
M5
M4
M5
PTO
X7
P003 207E
Basic Information
H1 Axial Piston Pumps, Single and Tandem
Operation
8 11062168 • Rev 0501 • November 2015
Charge Pressure Relief Valve (CPRV)
The charge pressure relief valve maintains charge pressure at a designated level above case pressure. The
charge pressure relief valve is a direct acting poppet valve which opens and discharges fluid to the pump
case when pressure exceeds a designated level. This level is nominally set with the pump running at 1800
rpm. For external charge flow the CPRV is set according to below table. In forward or reverse, charge
pressure will be slightly lower than when in neutral position. The charge pressure relief valve setting is
specified on the model code of the pump. Typical charge pressure increase from 1.2 - 1.5 bar per 10 l/min
[17.4 - 21.8 psi per 2.64 US gal/min].
Charge pressure relief valve flow setting for external charge supply
Single 045/053
15 l/min 3.9 [US gal/min]
Tandem 045/053
30 l/min 7.9 [US gal/min]
Single 060/068/069/078/089/100/115/130/147/165
22.7 l/min 6.0 [US gal/min]
Single 210/250
40.0 l/min 106 [US gal/min]
System schematic, single pump
A
B
MA
S
M3
C2
C1
M4
M5
MBL4
L2
M6 1 2
R2
R1
M14
F00B F00A
CW
P003 418E
System schematic, tandem pump
C1
C1
C2C2
M14
M14
CW
F00B
F00A
F00B F00A
A
B
MA
E
C D
MD
MB
M3
L3
MC
M4
M5
M4
M5
PTO
X7
P003 207E
Basic Information
H1 Axial Piston Pumps, Single and Tandem
Operation
11062168 • Rev 0501 • November 2015 9
Electrical Displacement Control (EDC)
EDC principle
An EDC is a displacement (flow) control. Pump swashplate position is proportional to the input command
and therefore vehicle or load speed (excluding influence of efficiency), is dependent only on the prime
mover speed or motor displacement.
The Electrical Displacement Control (EDC) consists of a pair of proportional solenoids on each side of a
three-position, four-way porting spool. The proportional solenoid applies a force input to the spool,
which ports hydraulic pressure to either side of a double acting servo piston. Differential pressure across
the servo piston rotates the swashplate, changing the pump‘s displacement from full displacement in
one direction to full displacement in the opposite direction. Under some circumstances, such as
contamination, the control spool could stick and cause the pump to stay at some displacement.
A serviceable 125 µm screen is located in the supply line immediately before the control porting spool.
EDC control
P003 191
EDC schematic
Feedback from
Swash plate
PTF00B
M14
C1 C2
F00A
P003 478E
EDC operation
H1 EDC’s are current driven controls requiring a Pulse Width Modulated (PWM) signal. Pulse width
modulation allows more precise control of current to the solenoids. The PWM signal causes the solenoid
pin to push against the porting spool, which pressurizes one end of the servo piston, while draining the
other. Pressure differential across the servo piston moves the swashplate.
A swashplate feedback link, opposing control links, and a linear spring provide swashplate position force
feedback to the solenoid. The control system reaches equilibrium when the position of the swashplate
spring feedback force exactly balances the input command solenoid force from the operator. As
hydraulic pressures in the operating loop change with load, the control assembly and servo/swashplate
system work constantly to maintain the commanded position of the swashplate.
The EDC incorporates a positive neutral deadband as a result of the control spool porting, preloads from
the servo piston assembly, and the linear control spring. Once the neutral threshold current is reached,
the swashplate is positioned directly proportional to the control current. To minimize the effect of the
control neutral deadband, we recommend the transmission controller or operator input device
incorporate a jump up current to offset a portion of the neutral deadband.
The neutral position of the control spool does provide a positive preload pressure to each end of the
servo piston assembly.
When the control input signal is either lost or removed, or if there is a loss of charge pressure, the spring-
loaded servo piston will automatically return the pump to the neutral position.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
Operation
10 11062168 • Rev 0501 • November 2015
Manual Displacement Control (MDC)
MDC principle
An MDC is a Manual proportional Displacement Control (MDC).
The MDC consists of a handle on top of a rotary input shaft. The shaft provides an eccentric connection to
a feedback link. This link is connected on its one end with a porting spool. On its other end the link is
connected the pumps swashplate. This design provides a travel feedback without spring. When turning
the shaft the spool moves thus providing hydraulic pressure to either side of a double acting servo piston
of the pump.
Differential pressure across the servo piston rotates the swash plate, changing the pump`s displacement.
Simultaneously the swashplate movement is fed back to the control spool providing proportionality
between shaft rotation on the control and swashplate rotation. The MDC changes the pump
displacement between no flow and full flow into opposite directions.
The MDC is sealed by means of a static O-ring between the actuation system and the control block. Its
shaft is sealed by means of a special O-ring which is applied for low friction. The special O-ring is
protected from dust, water and aggressive liquids or gases by means of a special lip seal.
MDC control
P301 749
MDC schematic diagram
P005 701
M14
M5
M4
M3
MDC operation
In difference to other controls the MDC spool provides a mechanical deadband. This is required to
overcome the tolerances in the mechanical actuation.
The MDC contains an internal end stop to prevent turning the handle into any inappropriate position.
The internal end stop is not applicable for any limitation of the Bowden cable stroke, except the applied
torque to the shaft will never exceed 20 Nm. Customers must install some support to limit the setting
range of their Bowden cable.
The MDC provides a permanent restoring moment in direction to its neutral position. This is required to
take the backlash out of the mechanical connections between the Bowden cable and the control. The
restoring moment is appropriate turning the shaft back to neutral when the connection to the Bowden
cable is lost. It is not appropriate to force a Bowden cable or a joystick back to neutral!
Neutral Start Switch
MDC controls are available with neutral start schwitch (NSS). The Neutral Start Switch contains an
electrical switch that provides a signal of whether the control is in neutral. The signal in neutral is
normally closed (NC).
Basic Information
H1 Axial Piston Pumps, Single and Tandem
Operation
11062168 • Rev 0501 • November 2015 11
MDC NSS schematic diagram
P005 702
M14
M5
M4
M3
Automotive Control (AC)
The AC-1 and AC-2 propel transmission system consists of an H1 variable pump, embedded electronic
controller, and service tool configurable PLUS+1® software that allows the customer to completely
optimize vehicle performance. The embedded electronic controller provides an electric input signal
activating one of two solenoids that port charge pressure to either side of the pump servo cylinder. The
AC has no mechanical feedback mechanism but AC-2 is available with an electronic feedback signal for
the swash plate position.
The pump displacement is proportional to the solenoid signal current, but it also depends upon pump
input speed and system pressure. This characteristic also provides a power limiting function by reducing
the pump swash plate angle as system pressure increases. A typical response characteristic is shown in
the accompanying graph.
Under some circumstances, such as contamination, the control spool could stick and cause the pump to
stay at some displacement.
A serviceable 125 µm screen is located in the supply line immediately before the control porting spool.
Automotive Control (AC)
P003 544
CAN PPC
PSC
PPU
CC2
CC1
WARRANTY VOID IF REMOVED
CC3
Automotive Control (AC) schematic
P301 236
C2C1
F00A T PF00B
Basic Information H1 Axial Piston Pumps, Single and Tandem
Operation
12 11062168 • Rev 0501 • November 2015
Automotive Control connection diagram
Batt.
12/24V
DC
+ -
S 1
1
F1
2
Terminals
Batt. (+)
Terminals
Batt. (-)
1
2
3
4
5
6
DEUTSCH connector
DTM/6 pin
Sensor A (+)
Analog Input A
Sensor A (-)
Sensor B (-)
PPC
Analog Input B
Sensor B (+)
1
2
3
DEUTSCH connector
DTM/3 pin
CAN High
CAN Low
CAN Shield
CAN
1
2
3
4
5
6
DEUTSCH connector
DTM/6 pin
PWM C1 (+)
PWM C2 (+)
Digital Output A1 (+)
Digital Output A2 (-)
PSC
PWM C2 (-)
PWM C1 (-)
1
2
3
DEUTSCH connector
DTM/3 pin
Sensor (+)
Pump RPM Input (Frequency)
Sensor (-)
PPU
Terminals
Sensor (-)
Terminals
Sensor (+)
CC1p01
CC1p02
CC1p03
CC1p04
Motor RPM/Direction
CC1p05
1
2
3
4
5
6
7
8
9
10
11
12
DEUTSCH connector
DTM/12 pin
Inch Input (Analog-Red)
Mode Switch B Input (Digital-Nom)
Motor PROP/PCOR Output (PWM)
Motor Direction Input (Analog)
Sensor (+)
Sensor (-)
Inch Input (Analog-Nom)
Motor BPD Output (Digital)
Digital Output B2 (-)
Digital Output B1 (+)
Mode Switch A Input (Digital)
Mode Switch B Input (Digital-Red)
CC2
1
2
3
4
5
6
7
8
9
10
11
12
DEUTSCH connector
DTM/12 pin
Battery (-)
Battery (+)
Sensor (+)
Sensor (-)
Motor RPM Input (Frequency)
Forward Input (Digital)
Reverse Input (Digital)
Sensor (+)
Sensor (-)
Drive Pedal Input (Analog-Nom)
Drive Pedal Input (Analog-Red)
Neutral Input (Digital)
CC1
CC2p04
CC1p06
CC1p07
CC1p12
e.g.
Hand Brake
Seat-Switch
FNR
Switch
CC1p08
CC1p09
Rv
Rv
Drive/Creep/Joystick/
Rocker Pedal
CC1p10
CAN Bus
CANp01
CANp02
CANp03
PSCp01
PSCp06
PSCp03
PSCp04
PSCp02
PSCp05
C1
C2
Electronic Displacement
Control Pump
Pump RPM
PPUp02
PPUp03
PPUp01
Mode Switch B
CC2p02
2-P
BPD
PROP
CC2p03
CC2p03
CC2p08
CC2p05
CC2p06
Electronic Displacement
Control Motor
Rv
Rv
Inch Pedal
CC2p07
Alternative Brake
Pressure Inch Sensor
Reverse
Motion
Parking
Brake
CC2p11
CC2p10
CC2p09
CC1p03
CC1p04
CC1p08
CC1p09
PPUp01
PPUp03
CC2p05
CC2p06
CC2p01
CC2p12
CNT
B
A
CC1p11
Mode Switch A
FNR in
Reverse
Brake
Light
Fault
LED
Vehicle-Speed-Dependent
Output-Signal
Reverse
LED
Brake
Light
FNR in
Reverse
Fault
LED
Forward
LED
Brake
Light
3
Nominal
Redundant
3
Reverse
Motion
FNR in
Reverse
1
2
DEUTSCH connector
DT/2 pin
CC3
CC3p01
CC3p02
3
2
1
Contact capability min. 10A
Melting fuse 16A
Functional options
P003 536E
Basic Information H1 Axial Piston Pumps, Single and Tandem
Operation
11062168 • Rev 0501 • November 2015 13
Forward-Neutral-Reverse (FNR) electric control
The 3-Position (F-N-R) control uses an electric input signal to switch the pump to a full stroke position.
Under some circumstances, such as contamination, the control spool could stick and cause the pump to
stay at some displacement. A serviceable 125 µm screen is located in the supply line immediately before
the control porting spool.
FNR control
P003 193
3-Position electric control, hydraulic schematic
P003 189
C2C1
F00A
M14
T PF00B
Non Feedback Proportional Electric control (NFPE)
The Non Feedback Proportional Electric (NFPE) control is an electrical automotive control in which an
electrical input signal activates one of two proportional solenoids that port charge pressure to either side
of the pump servo cylinder. The NFPE control has no mechanical feedback mechanism. The pump
displacement is proportional to the solenoid signal current, but it also depends upon pump input speed
and system pressure. This characteristic also provides a power limiting function by reducing the pump
swashplate angle as system pressure increases. Under some circumstances, such as contamination, the
control spool could stick and cause the pump to stay at some displacement. A serviceable 125 µm screen
is located in the supply line immediately before the control porting spool.
NFPE control
P003 192
NFPE schematic
P003 188
C2C1
F00A
M14
T PF00B
Basic Information H1 Axial Piston Pumps, Single and Tandem
Operation
14 11062168 • Rev 0501 • November 2015
Fan Drive Control (FDC) options F1 (12 V) / F2 (24 V)
The Fan Drive Control (FDC) is a non-feedback control in which an electrical input signal activates the
proportional solenoid that ports charge pressure to either side of the pump servo cylinder. The single
proportional solenoid is used to control pump displacement in the forward or reverse direction. The
control spool is spring biased to produce maximum forward pump displacement in the absence of an
electrrical input signal. Based on the spring bias spool default forward flow for a CW rotation pump is out
of Port B while default forward flow for a CCW rotation pump is out of Port A.
FDC control
P301 441
FDC schematic
PT
F00B
M14
C1 C2
F00A
P301 442
The pump displacement is proportional to the solenoid
signal current, but it also depends upon pump input
speed and system pressure.
This characteristic also provides a power limiting function
by reducing the pump swashplate angle as system
pressure increases. The pump should be configured with
0.8 mm control orifices to provide slowest respponse and
maximize system stability.
Additionally pressure limiter (PL) valves are used to limit
maximum fan trim speed in both forward and reverse
directions.
Under some circumstances, such as contamination, the
control spool could stick and cause the pump to stay at
some displacement.
Pump displacement vs. control current
100%
100%
Displacement
0
Signal Current (mA(DC
Avg
))
Max Current
H1 FDC control
N
a
b
a = Forward Threshold
b = Reverse Threshold
N = Neutral Override Current
P301 443
∆p = 0 bar
∆p = 0 bar
∆p = 300 bar
Reverse
Forward
Basic Information H1 Axial Piston Pumps, Single and Tandem
Operation
11062168 • Rev 0501 • November 2015 15
Manual Over Ride (MOR)
All controls are available with a Manual Over Ride (MOR) either standard or as an option for temporary
actuation of the control to aid in diagnostics.
Forward-Neutral-Reverse (FNR) and Non Feedback Proportional Electric (NFPE) controls are always
supplied with MOR functionality.
Unintended MOR operation will cause the pump to go into stroke. The vehicle or device must always be
in a safe condition (i.e. vehicle lifted off the ground) when using the MOR function. The MOR plunger has
a 4 mm diameter and must be manually depressed to be engaged. Depressing the plunger mechanically
moves the control spool which allows the pump to go on stroke. The MOR should be engaged
anticipating a full stroke response from the pump.
W
Warning
An o-ring seal is used to seal the MOR plunger where initial actuation of the function will require a force
of 45 N to engage the plunger. Additional actuations typically require less force to engage the MOR
plunger. Proportional control of the pump using the MOR should not be expected.
Refer to the control flow table in the size specific technical information for the relationship of solenoid to
direction of flow.
P003 204
MOR-Schematic diagram (EDC shown)
Feedback from
Swash plate
PTF00B
M14
C2
C1
F00A
P003 205E
Basic Information H1 Axial Piston Pumps, Single and Tandem
Operation
16 11062168 • Rev 0501 • November 2015
Swash plate angle sensor for NFPE and AC2 controls
The angle sensor detects the swash plate angle position and direction of rotation from the zero position.
The swash angle sensor works on the AMR sensing technology. Under the saturated magnetic field, the
resistance of the element varies with the magnetic field direction. The output signal give a linear output
voltage for the various magnet positions in the sensing range. The swashplate angle sensor is available
for all NFPE and AC2 controls.
P301 750
-25° -20° -15° -10° -5° 0° 5° 10° 15° 20° 25°
5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
Swashplate angle
Output voltage (V)
P005 704E
Signal 1 (nominal)
Signal 2 (redundant)
Swashplate angle vs. output voltage (calibrated at 50 °C)
Basic Information H1 Axial Piston Pumps, Single and Tandem
Operation
11062168 • Rev 0501 • November 2015 17
Control-Cut-Off valve (CCO valve)
The H1 pump offers an optional control cut off valve integrated into the control. This valve will block
charge pressure to the control, allowing the servo springs to de-stroke both pumps regardless of the
pump´s primary control input. There is also a hydraulic logic port, X7, which can be used to control other
machine functions, such as spring applied pressure release brakes. The pressure at X7 is controlled by the
control cut off solenoid. The X7 port would remain plugged if not needed.
In the normal (de-energized) state of the solenoid charge flow is prevented from reaching the controls. At
the same time the control passages and the X7 logic port are connected and drained to the pump case.
The pump will remain in neutral, or return to neutral, independent of the control input signal. Return to
neutral time will be dependent on oil viscosity, pump speed, swashplate angle, and system pressure.
When the solenoid is energized, charge flow and pressure is allowed to reach the pump control. The X7
logic port will also be connected to charge pressure and flow.
The solenoid control is intended to be independent of the primary pump control making the control cut
off an override control feature. It is however recommended that the control logic of the CCO valve be
maintained such that the primary pump control signal is also disabled whenever the CCO valve is de-
energized. Other control logic conditions may also be considered.
MDC and EDC controls are available with a CCO valve.
The response time of the unit depends on the control type and the used control orifices.
The CCO-valve is available with 12 V or 24 V solenoid.
CCO-schematic (MDC shown)
P005 703
M14
M5
M4
M3
X7
Displacement limiter
All H1 pumps are designed with optional mechanical displacement (stroke) limiters factory set to max.
displacement.
The maximum displacement of the pump can be set independently for forward and reverse using the
two adjustment screws to mechanically limit the travel of the servo piston down to 50 % displacement.
Adjustment procedures are found in the H1 Service Manual. Adjustments under operating conditions
may cause leakage. The adjustment screw can be completely removed from the threaded bore if backed
out to far.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
Operation
18 11062168 • Rev 0501 • November 2015
Displacement limiter
P003 266
Life time
The life of the product depends on several factors, such as speed, pressure, swash plate angle, to name a
few. For detailed product life calculation, please contact your Danfoss representative.
Basic Information H1 Axial Piston Pumps, Single and Tandem
Operation
11062168 • Rev 0501 • November 2015 19
Speed and temperature sensor
Description
Function of the speed sensor is to detect the shaft speed and the direction of rotation. Typically the
sensor will be mounted to the housing of a Danfoss pump or motor and senses the speed from a target
ring that is rotating inside the pump or motor. Because of the digital output signals for speed and
direction and a non speed dependent output voltage level, the sensor is ideal for high and low speed
measurements.
For diagnostics and other purposes, the sensor also has the capability to detect the case oil temperature.
The speed sensor is designed for rugged outdoor, mobile or heavy industrial speed sensing applications.
The detection of the speed is contactless. It is custom-designed for Danfoss. It is a plug and perform
device that does not need any calibration or adjustments.
Theory of operation
The speed sensor is externally powered and, in response to the speed of the target ring, outputs a digital
pulse signal. A magnet inside the sensor provides the magnetic field that changes with the position of
the target teeth. The target ring is attached to the cylinder block or the shaft. Hall sensors change from
high/low state as the target teeth pass by the sensor´s face. The digital (on-off-on-off) pulse train is fed to
a controller, which interprets its rate of change as a speed. The speed sensor uses two Hall sensors with
specific distance and orientation resulting in a pulse train output shift of 90° between the two sensors. A
logic circuit decodes the two signals to provide an additional direction indication (high or low depending
on direction). Due to the design of the sensor, the duty cycle (ratio between on and off time at constant
speed) of both speed signals at any working condition is close to 50 % and can be used for better
resolution at low speeds.
Speed (target) rings
Speed (target) rings vary according to the diameter of the cylinder block or shaft on which they are
installed. The number of teeth are shown in the table below:
Pump size Number of teeth Pump size Number of teeth
H1P045/053 79 H1P089/100 86
H1P069/078 86 H1P115/130 102
H1P060/068 92 H1P147/165 108
Speed sensor technical data
Parameter
Min. Nom. Max.
Supply 4.75 V
DC
5 V
DC
5.25 V
DC
Supply protection – – 30 V
DC
Max. required supply current – – 25 mA
Output mode NPN & PNP
Connector and terminals
1)
DEUTSCH DTM04–6P (Series 6-Pin)
Sensor pinout
1 Speed signal 2
2 Direction signal
3 Speed signal 1
4 Supply
5 Ground
6 Temperature
4
3 2 1
5 6
Protection code IP-class IP 67 and IP 69k according to IEC 60529 & DIN 40050
1)
For more details please see Speed and Temperature Sensor, Technical Information 11046759.
Basic Information H1 Axial Piston Pumps, Single and Tandem
Operation
20 11062168 • Rev 0501 • November 2015
Description Quantity Ordering number
Mating connector 1 Deutsch® DT06-6S
Wedge lock 1 Deutsch® WM65
Socket contact (16 and 18 AWG) 6 Deutsch® 0462-201-2031
Danfoss mating connector kit 1 11033865
Temperature sensor
Temperature measurement range Minimum
-40 °C [-40 °F]
Maximum
+125 °C [257 °F]
Tolerance
± 5 °C [± 51 °F]
Temp. measurement response time in oil
T
90
= 360 s
Output signal at
*
Minimum
-40 °C [-40 °F], 2.203 V
Maximum
+125 °C [257 °F], 0.520 V
*
see the formula below for temperature range.
The formula used to calculate the case oil temperature:
T
=
0.0102
(1.795 – V
O
)
T – Temperature (°C)
V
O
– Measured output voltage (V)
Temperature vs. time
0
0
10
20
30
40
50
60
70
80
90
-100 100 200 300 400 500 600 700 800 900 1000
P003531E
Real temperature
Temperature
Signal
T
90
definition
T
90
Time (S)
Temperature (°C)
90 % of ∆ Temp
∆ Temp
Basic Information
H1 Axial Piston Pumps, Single and Tandem
Operation
11062168 • Rev 0501 • November 2015 21
Input speed
Minimum speed is the lowest input speed recommended during engine idle condition. Operating below
minimum speed limits the pump’s ability to maintain adequate flow for lubrication and power
transmission.
Rated speed is the highest input speed recommended at full power condition. Operating at or below
this speed should yield satisfactory product life.
Maximum speed is the highest operating speed permitted. Exceeding maximum speed reduces product
life and can cause loss of hydrostatic power and braking capacity. Never exceed the maximum speed
limit under any operating conditions.
Operating conditions between Rated and Maximum speed should be restricted to less than full power
and to limited periods of time. For most drive systems, maximum unit speed occurs during downhill
braking or negative power conditions.
For more information consult Pressure and speed limits, BLN-9884, when determining speed limits for a
particular application.
During hydraulic braking and downhill conditions, the prime mover must be capable of providing
sufficient braking torque in order to avoid pump over speed. This is especially important to consider for
turbocharged and Tier 4 engines.
W
Warning
Unintended vehicle or machine movement hazard
Exceeding maximum speed may cause a loss of hydrostatic drive line power and braking capacity. You
must provide a braking system, redundant to the hydrostatic transmission, sufficient to stop and hold the
vehicle or machine in the event of hydrostatic drive power loss. The braking system must also be
sufficient to hold the machine in place when full power is applied.
System pressure
System pressure is the differential pressure between high pressure system ports. It is the dominant
operating variable affecting hydraulic unit life. High system pressure, which results from high load,
reduces expected life. Hydraulic unit life depends on the speed and normal operating, or weighted
average, pressure that can only be determined from a duty cycle analysis.
Application pressure is the high pressure relief or pressure limiter setting normally defined within the
order code of the pump. This is the applied system pressure at which the driveline generates the
maximum calculated pull or torque in the application.
Maximum working pressure is the highest recommended application pressure. Maximum working
pressure is not intended to be a continuous pressure. Propel systems with application pressures at, or
below, this pressure should yield satisfactory unit life given proper component sizing.
Maximum pressure is the highest allowable application pressure under any circumstance. Application
pressures above Maximum Working Pressure will only be considered with duty cycle analysis and factory
approval.
Pressure spikes are normal and must be considered when reviewing Maximum Working pressure.
Minimum low loop pressure must be maintained under all operating conditions to avoid cavitation.
All pressure limits are differential pressures referenced to low loop (charge) pressure. Subtract low loop
pressure from gauge readings to compute the differential.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
Operating parameters
22 11062168 • Rev 0501 • November 2015
Servo pressure
Servo pressure is the pressure in the Servosystem needed to position and hold the pump on stroke. It
depends on system pressure and speed. At minimum servo pressure the pump will run at reduced stroke
depending on speed and pressure.
Minimum servo pressure at corner power holds the pump on full stroke at max speed and max
pressure.
Maximum servo pressure is the highest pressure typically given by the charge pressure setting.
Charge pressure
An internal charge relief valve regulates charge pressure. Charge pressure supplies the control with
pressure to operate the swashplate and to maintain a minimum pressure in the low side of the
transmission loop.
The charge pressure setting listed in the order code is the set pressure of the charge relief valve with the
pump in neutral, operating at 1800 min
-1
[rpm], and with a fluid viscosity of 32 mm²/s [150 SUS].
Pumps configured with no charge pump (external charge supply) are set with a charge flow of 30 l/min
[7.93 US gal/min] and a fluid viscosity of 32 mm²/s [150 SUS].
The charge pressure setting is referenced to case pressure. Charge pressure is the differential pressure
above case pressure.
Minimum charge pressure is the lowest pressure allowed to maintain a safe working condition in the
low side of the loop. Minimum control pressure requirements are a function of speed, pressure, and
swashplate angle, and may be higher than the minimum charge pressure shown in the Operating
parameters tables.
Maximum charge pressure is the highest charge pressure allowed by the charge relief adjustment, and
which provides normal component life. Elevated charge pressure can be used as a secondary means to
reduce the swashplate response time.
Charge pump inlet pressure
At normal operating temperature charge inlet pressure must not fall below rated charge inlet pressure
(vacuum). Minimum charge pump inlet pressure is only allowed at cold start conditions. In some
applications it is recommended to warm up the fluid (e.g. in the tank) before starting the engine and then
run the engine at limited speed. Maximum charge pump inlet pressure may be applied continuously.
Case pressure
Under normal operating conditions, the rated case pressure must not be exceeded. During cold start case
pressure must be kept below maximum intermittent case pressure. Size drain plumbing accordingly.
Auxiliary Pad Mounted Pumps. The auxiliary pad cavity of H1 pumps configured without integral charge
pumps is referenced to case pressure. Units with integral charge pumps have auxiliary mounting pad
cavities referenced to charge inlet (vacuum).
C
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 pressure are
additive to case pressure.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
Operating parameters
11062168 • Rev 0501 • November 2015 23
External shaft seal pressure
In certain applications, the input shaft seal may be exposed to external pressures. The shaft seal is
designed to withstand an external pressure up to 0.4 bar [5.8 psi] above the case pressure. The case
pressure limits must also be followed to ensure the shaft seal is not damaged.
Temperature and viscosity
Temperature
The high temperature limits apply at the hottest point in the transmission, which is normally the motor
case drain. The system should generally be run at or below the quoted rated temperature.
The maximum intermittent temperature is based on material properties and should never be
exceeded.
Cold oil will generally not affect the durability of the transmission components, but it may affect the
ability of oil to flow and transmit power; therefore temperatures should remain 16 °C [30 °F] above the
pour point of the hydraulic fluid.
The minimum temperature relates to the physical properties of component materials.
Size heat exchangers to keep the fluid within these limits. Danfoss recommends testing to verify that
these temperature limits are not exceeded.
Viscosity
For maximum efficiency and bearing life, ensure the fluid viscosity remains in the recommended range.
The minimum viscosity should be encountered only during brief occasions of maximum ambient
temperature and severe duty cycle operation.
The maximum viscosity should be encountered only at cold start.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
Operating parameters
24 11062168 • Rev 0501 • November 2015
Filtration system
To prevent premature wear, ensure only clean fluid enters the hydrostatic transmission circuit. A filter
capable of controlling the fluid cleanliness to ISO 4406 class 22/18/13 (SAE J1165) or better, under normal
operating conditions, is recommended.
These cleanliness levels can not be applied for hydraulic fluid residing in the component housing/case or
any other cavity after transport.
The filter may be located on the pump (integral) or in another location (remote). The integral filter has a
filter bypass sensor to signal the machine operator when the filter requires changing. Filtration strategies
include suction or pressure filtration.
The selection of a filter depends on a number of factors including the contaminant ingression rate, the
generation of contaminants in the system, the required fluid cleanliness, and the desired maintenance
interval. Filters are selected to meet the above requirements using rating parameters of efficiency and
capacity.
Filter efficiency can be measured with a Beta ratio
1)
(β
X
). For simple suction filtered closed circuit
transmissions and open circuit transmissions with return line filtration, a filter with a β-ratio within the
range of β
35-45
= 75 (β
10
≥ 2) or better has been found to be satisfactory.
For some open circuit systems, and closed circuits with cylinders being supplied from the same reservoir,
a considerably higher filter efficiency is recommended. This also applies to systems with gears or clutches
using a common reservoir.
For these systems, a charge pressure or return filtration system with a filter β-ratio in the range of β
15-20
=
75 (β
10
≥ 10) or better is typically required.
Because each system is unique, only a thorough testing and evaluation program can fully validate the
filtration system.
Please see Design Guidelines for Hydraulic Fluid Cleanliness Technical Information, 520L0467 for more
information.
Filtration, cleanliness level and β
x
-ratio (recommended minimum)
Cleanliness per ISO 4406
22/18/13
Efficiency β
x
(charge pressure filtration)
β
15-20
= 75 (β
10
≥ 10)
Efficiency β
x
(suction and return line filtration)
β
35-45
= 75 (β
10
≥ 2)
Recommended inlet screen mesh size
100 – 125 µm
1)
Filter β
x
-ratio is a measure of filter efficiency defined by ISO 4572. It is defined as the ratio of the number of particles greater than a
given diameter (“
x
” in microns) upstream of the filter to the number of these particles downstream of the filter.
Basic Information H1 Axial Piston Pumps, Single and Tandem
System design parameters
11062168 • Rev 0501 • November 2015 25
Filtration
The suction filter is placed in the circuit between the
reservoir and the inlet to the charge pump as shown in
the accompanying illustration.
W
Warning
Clogged filters can cause cavitation, which damages
the charge pump.
We recommend a filter bypass with a filter bypass sensor
to prevent damage due to blocked suction filters.
Suction filtration
P003 471E
Reservoir
Strainer
Filter
Charge
pump
Charge
relief
valve
to pump case
to low pressure
side of loop
and servo control
Charge pressure filtration (full charge pump flow)
Two types of pressure filtration exist for most H1 pumps. The two types are: remote pressure filtration
(filter remotely mounted on vehicle) and integral pressure filtration (filter mounted to the endcap). Verify
option availability in the size specific technical information.
In either case the filtration circuit is the same with the filter element situated in the circuit downstream
the charge pump and upstream of the charge relief valve such that full charge flow is continuously
filtered, as shown in the accompanying illustrations.
Charge pressure filtration can mitigate high inlet vacuum in cold start-ups and provides fluid filtration
immediately prior to entrance to the loop and the control system. Pressure filtration provides a higher
level of filtering efficiency than suction filtration.
Filters used in charge pressure filtration circuits must be rated to at least 35 bar [508 psi] pressure. A 100 –
125 µm screen located in the reservoir or in the charge inlet line is recommended when using charge
pressure filtration.
A filter bypass valve is necessary to prevent filter damage and to avoid contaminants from being forced
through the filter media by high pressure differentials across the filter.
In the event of high pressure drop associated with a blocked filter or cold start-up conditions, fluid will
bypass the filter. Working with an open bypass should be avoided.
Remote charge pressure filtration
Ports at the endcap are available to allow for the charge filter to be located conveniently for easy service
and replacement.
Care should be taken to minimize the hydraulic pressure drops associated with long connecting lines,
small diameter hoses, or restrictive port adaptors at the filter head or endcap. Ensure the normal
operating pressure drop across the remote filtration in and out ports is sufficiently below the crack
pressure setting of the recommended filter bypass valve.
C
Caution
Remote filter heads without bypass and poor plumbing design can encounter excessive pressure drops
that can lead to charge pump damage in addition to contaminants being forced through the filter media
and into the transmission loop.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
System design parameters
26 11062168 • Rev 0501 • November 2015
Integral charge pressure filtration
The H1 integral pressure filter head is designed with a filter bypass valve and noncontacting bypass
sensor. The pressure differential acting on the filter element also acts on a spring biased bypass spool.
This spool is designed with a magnetic area. When a certain spool position is reached, the magnet closes
a switch in the bypass sensor which allows R2 to be in parallel with R1. This occurs without any
mechanical contact between the spool and the bypass sensor.
The position of the bypass spool is indicated by the change in the measured sensor resistance. The
change in resistance occurs when R2 is switched in and out of the circuit.
When the filter is not being bypassed, the nominal measured resistance is 510 Ω. When the switch is
closed, the nominal measured resistance is 122 Ω.
The bypass spool is designed so the bypass sensor switch will be closed before oil bypasses the filter
element. This gives the machine operator an indication that the filter is very close to bypassing and a
filter replacement is required.
For cold start conditions, it is typical that the filter may bypass for a short amount of time while the oil is
warming up. At normal operating oil temperatures, a system that does not yet need a filter replacement
will operate in the non-bypass mode. The addition of an oil temperature sensor and additional control
logic, is recommended to properly determine if a filter replacement is required.
Technical data, pressures
Filter bypass sensor switch closure
∆p 3.7 - 5.1 bar [54 - 74 psi]
Bypass valve
∆p 5.6 ± 0.9 bar [80 ± 13 psi]
Technical data, electric
Max. voltage
48 V
Max. power
0.6 W
Switch open
510 Ω
Switch closed
122 Ω
Resistor tolerance
1 %
Temperature range
-20 ÷ +100 °C [-4 ÷ +212 °F]
IP Rating (IEC 60 529) + DIN 40 050
IP 69K part 9 with mating connector
Integral filter head with filter bypass sensors
Bypass spool
Filter
bypass sensor
Filter
element
P003 359E
Basic Information
H1 Axial Piston Pumps, Single and Tandem
System design parameters
11062168 • Rev 0501 • November 2015 27
Min β
7.5
(c) according to ISO 16889 (clean filter element only)
Nominal flow at 30 mm²/s and Δp 0.5 bar [7.3 psi]
Short 60 l/min
Min β
7.5
(c) = 75 (β
5
(c) ≥ 10)Medium 80 l/min
Long 105 l/min
Schematic
P003 195
21
M6
out
in
R1
R2
Bypass sensor
open
Bypass valve
closed
Connector
P003 198E
Connector
Deutsch DTM04-2P
M6
9
/
16
-18
before filter (upstream)
Pin location
P003 186
1 2
Connector Pinout
Pin Assignment Or Pin Assignment
1 Voltage
Alternative
pinout
1 Ground
2 Ground 2 Voltage
H1 Filter bypass sensor mating connector parts list
Description Quantity Order number
Mating connector 1 Deutsch DTM06-2S
Secondary wedge lock 1 Deutsch WM-2S
Socket terminal 2 Deutsch 0462-201-20141
Danfoss mating connector kit 1 11031205
The H1 pumps with an integrated filter option are shipped with a filter length as indicated:
H1 pump size Filter element length Replacement filter order
number
H1P069/078, H1P089/100 Medium 11004918
H1P115/130, H1P147/165 Long 11004919
Below diagram shows the differential pressure between filter “in” and “out” with a filter element
completely blocked, so that all flow runs across the filter bypass valve.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
System design parameters
28 11062168 • Rev 0501 • November 2015
Filter bypass characteristic (completely blocked element)
0
20
[5.28]
40
[10.57]
60
[15.85]
80
[21.13]
100
[26.42]
120
[31.70]
0
22
[319]
20
[290]
18
[261]
16
[232]
14
[203]
12
[174]
10
[145]
8
[116]
6
[87]
4
[58]
2
[29]
Flow l/min [US gal/min]
Differential pressure over filter bypass bar [psi]
(blocked filter element)
P003 185E
Filter bypass
sensor activated
8 mm
2
/s [52 SUS]
74 mm
2
/s [342 SUS]
1600 mm
2
/s [7406 SUS]
Bypass sensor clearance
The bypass sensor is activated by the magnetic bypass
valve. No steel parts are allowed within a radius of 150
mm [5.91 in]. Moving steel devices or parts are not
allowed within a radius of 250 mm [9.84 in].
P003 356E
mm
[in]
38
[1.50]
150 min
[5.91]
250 min
[9.84]
37
[1.46]
Remote charge pressure filtration, full flow
Reservoir
Charge
pump
Charge
relief
valve
to pump case
to low pressure
side of loop
and servo
control
Strainer
P003 472E
Filter with bypass
Bypass
Filter bypass
sensor
Integral charge pressure filtration, full flow
Reservoir
Charge
pump
Charge
relief
valve
to pump case
to low pressure
side of loop
and servo
control
Strainer
P003 473E
Filter with bypass
Bypass
Filter bypass
sensor
Basic Information H1 Axial Piston Pumps, Single and Tandem
System design parameters
11062168 • Rev 0501 • November 2015 29
Independent braking system
W
Warning
Unintended vehicle or machine movement hazard
The loss of hydrostatic drive line power, in any mode of operation (forward, neutral, or reverse) may cause
the system to lose hydrostatic 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.
Fluid selection
Ratings and performance data are based on operating with hydraulic fluids containing oxidation, rust
and foam inhibitors. These fluids must possess good thermal and hydrolytic stability to prevent wear,
erosion, and corrosion of pump components.
C
Caution
Never mix hydraulic fluids of different types.
Fire resistant fluids are also suitable at modified operating conditions.
Please see Hydraulic Fluids and Lubricants Technical Information, 520L0463, for more information.
Refer to Experience with Biodegradable Hydraulic Fluids Technical Information, 520L0465, for information
relating to biodegradable fluids. Contact Danfoss for fluids not mentioned below.
The following hydraulic fluids are suitable:
•
Hydraulic Oil ISO 11 158 - HM
(Seal compatibility and vane pump wear resistance per DIN 51 524-2 must be met)
•
Hydraulic Oil ISO 11 158 - HV
(Seal compatibility and vane pump wear resistance per DIN 51 524-3 must be met)
•
Hydraulic Oil DIN 51 524-2 - HLP
•
Hydraulic Oil DIN 51 524-3 - HVLP
•
Automatic Transmission Fluid ATF A Suffix A (GM)
•
Automatic Transmission Fluid Dexron II (GM), which meets Allison C-3 and Caterpillar TO-2 test
•
Automatic Transmission Fluid M2C33F and G (Ford)
•
Engine oils API Classification SL, SJ (for gasoline engines) and CI-4, CH-4, CG-4, CF-4 and CF
(for diesel engines)
•
Super Tractor Oil Universal (STOU) special agricultural tractor fluid
Reservoir
The hydrostatic system reservoir should accommodate maximum volume changes during all system
operating modes and promote de-aeration of the fluid as it passes through the tank. A suggested
minimum total reservoir volume is 5⁄8 of the maximum charge pump flow per minute with a minimum
fluid volume equal to ½ of the maximum charge pump flow per minute. This allows 30 seconds fluid
dwell for removing entrained air at the maximum return flow. This is usually adequate to allow for a
closed reservoir (no breather) in most applications.
Locate the reservoir outlet (charge pump inlet) above the bottom of the reservoir to take advantage of
gravity separation and prevent large foreign particles from entering the charge inlet line. A 100-125 µm
screen over the outlet port is recommended. Position the reservoir inlet (fluid return) to discharge below
the normal fluid level, toward the interior of the tank. A baffle (or baffles) will further promote de-aeration
and reduce surging of the fluid.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
System design parameters
30 11062168 • Rev 0501 • November 2015
Case drain
All single H1 pumps are equipped with multiple drain ports whereas some H1 pumps are equipped with
two case drain port sizes. Port selection and case drain routing must enable the pump housing to
maintain a volume of oil not less than half full and normal operating case pressure limits of the unit are
maintained. Case drain routing and design must consider unit case pressure ratings.
A case drain line must be connected to one of the case outlets to return internal leakage to the system
reservoir.
Charge pump
Charge flow is required on all H1 pumps applied in closed circuit installations. The charge pump provides
flow to make up internal leakage, maintain a positive pressure in the main circuit, provide flow for
cooling and filtration, replace any leakage losses from external valving or auxiliary systems, and to
provide flow and pressure for the control system.
Many factors influence the charge flow requirements and the resulting charge pump size selection. These
factors include system pressure, pump speed, pump swashplate angle, type of fluid, temperature, size of
heat exchanger, length and size of hydraulic lines, control response characteristics, auxiliary flow
requirements, hydrostatic motor type, etc. When initially sizing and selecting hydrostatic units for an
application, it is frequently not possible to have all the information necessary to accurately evaluate all
aspects of charge pump size selection.
Unusual application conditions may require a more detailed review of charge pump sizing. Charge
pressure must be maintained at a specified level under all operating conditions to prevent damage to the
transmission. Danfoss recommends testing under actual operating conditions to verify this.
Charge pump sizing/selection
In most applications a general guideline is that the charge pump displacement should be at least 10 % of
the total displacement of all components in the system. Unusual application conditions may require a
more detailed review of charge flow requirements. Please refer to Selection of Drive Line Components,
BLN-9885 for a detailed procedure.
System features and conditions which may invalidate the 10 % guideline include (but are not limited to):
•
Continuous operation at low input speeds (< 1500 min
-1
(rpm))
•
High shock loading and/or long loop lines
•
High flushing flow requirements
•
Multiple Low Speed High Torque motors
•
High input shaft speeds
Bearing loads & life
Bearing life is a function of speed, system pressure, charge pressure, and swashplate angle, plus any
external side or thrust loads. The influence of swashplate angle includes displacement as well as
direction. External loads are found in applications where the pump is driven with a side/thrust load (belt
or gear) as well as in installations with misalignment and improper concentricity between the pump and
drive coupling. All external side loads will act to reduce the normal bearing life of a pump. Other life
factors include oil type and viscosity.
In vehicle propel drives with no external shaft loads and where the system pressure and swashplate
angle are changing direction and magnitude regularly, the normal L
20
bearing life (80 % survival) will
exceed the hydraulic load-life of the unit.
In non propel drives such as vibratory drives, conveyor drives or fan drives, the operating speed and
pressure are often nearly constant and the swashplate angle is predominantly at maximum. These drives
have a distinctive duty cycle compared to a propulsion drive. In these types of applications a bearing life
review is recommended.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
System design parameters
11062168 • Rev 0501 • November 2015 31
Applications with external shaft loads H1 pumps are designed with bearings that can accept some
external radial and thrust loads. When external loads are present, the allowable radial shaft loads are a
function of the load position relative to the mounting flange, the load orientation relative to the internal
loads, and the operating pressures of the hydraulic unit. In applications where external shaft loads cannot
be avoided, the impact on bearing life can be minimized by proper orientation of the load. Optimum
pump orientation is a consideration of the net loading on the shaft from the external load, the pump
rotating group and the charge pump load.
•
In applications where the pump is operated such that nearly equal amounts of forward vs. reverse
swashplate operation is experienced; bearing life can be optimized by orientating the external side
load at 0° or 180° such that the external side load acts 90° to the rotating group load (for details see
drawing below).
•
In applications where the pump is operated such that the swashplate is predominantly (> 75 %) on
one side of neutral (e.g. vibratory, conveyor, typical propel); bearing life can be optimized by
orientating the external side load generally opposite of the internal rotating group load. The direction
of internal loading is a function of rotation and system port, which has flow out. Tables are available
in the Controls section of each H1 size specific technical information that illustrates the flow out port
as a function of pump rotation and energized EDC solenoid.
•
H1 pumps are designed with bearings that can accept some thrust load such that incidental thrust
loads are of no consequence. When thrust loads are anticipated the allowable load will depend on
many factors and it is recommended that an application review be conducted.
Contact Danfoss for a bearing life review if external side loads are present.
Radial load position
P003 318E
L
270° R
e
R
e
M
e
180° R
e
90° R
e
0° R
e
M
e
= Shaft moment
L = Flange distance
R
e
= External force to the shaft
Allowable shaft loads and moments are shown for each size specific technical information.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
System design parameters
32 11062168 • Rev 0501 • November 2015
Mounting flange loads
Adding tandem mounted auxiliary pumps and/or subjecting pumps to high shock loads may result in
excessive loading of the mounting flange.
Applications which experience extreme resonant vibrations or shock may require additional pump
support. The overhung load moment for multiple pump mounting may be estimated using the formula
below.
Overhung load example
P005 275
L1
L2
L3
F2 F1
F3
Estimating overhung load moments, max. and rated acceleration factors for some typical applications:
M
R
= g • G
R
(W1L1 + W2L2 + ... + WnLn)
M
S
= g • G
S
(W1L1 + W2L2 + ... + WnLn)
Where:
M
R
– Rated load moment, N•m [lbf•in]
M
S
– Shock load moment, N•m [lbf•in]
W – Mass/Weight of pump, kg [lb]
L – Distance from mounting flange to pump center of gravity, m [in] (refer to Installation drawings.)
g – Gravity 9.81 m/s²
G
R
– Calculation factor for rated (vibratory) acceleration (G’s). This factor depends on the application.
G
S
– Calculation factor for max. shock acceleration (G’s). This factor depends on the application.
Allowable overhung load moment values are given for each size specific technical information. Exceeding
these values requires additional pump support.
Typical G loads for various applications
Application Calculation factor
Rated (vibratory) acceleration G
R
Maximum (shock) acceleration G
S
Skid Steer Loader 8 15-20
Trencher (rubber tires) 3 8
Asphalt Paver 2 6
Windrower 2 5
Aerial Lift 1.5 4
Turf Care Vehicle 1.5 4
Vibratory Roller 6 10
Use these in the absence of specific data for a rough estimation.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
System design parameters
11062168 • Rev 0501 • November 2015 33
Shaft torque
The rated torque is a measure of tooth wear and is the torque level at which a normal spline life of 2 x
109 shaft revolutions can be expected. The rated torque presumes a regularly maintained minimum level
of lubrication via a moly-disulfide grease in order to reduce the coefficient of friction and to restrict the
presence of oxygen at the spline interface. It is also assumed that the mating spline has a minimum
hardness of Rc 55 and full spline depth. The rated torque is proportional to the minimum active spline
length.
Maximum torque ratings are based on torsional fatigue strength considering 100.000 full load reversing
cycles. However, a spline running in oil-flooded environment provides superior oxygen restriction in
addition to contaminant flushing. The rated torque of a flooded spline can increase to that of the
maximum published rating. A flooded spline would be indicative of a pump driven by a pump drive or
plugged into an auxiliary pad of a pump.
Maintaining a spline engagement at least equal to the Pitch Diameter will also maximize spline life. Spline
engagements of less than ¾ Pitch Diameter are subject to high contact stress and spline fretting.
Shaft torque for tapered shafts
The rated torque is based on the contact pressure between the shaft and hub surfaces with poor surface
contact areas. With an increased quality of the contact areas, the contact pressure between the shaft and
hub is increased and allows higher torque to be transmitted.
When a key is used for orientation of the hub on the shaft in conjunction with poor quality contact
surfaces, the transmitted torque will drop significantly. This is due to the key carrying the torque, which
limits the shaft torque carrying capability.
Maximum torque rating is based on an ideal contact area of 100 % and the retaining nut properly
torqued. This allows for the highest contact pressure between the shaft and the hub.
Shaft availability and torque ratings
Alignment between the mating spline’s Pitch Diameters is another critical feature in determining the
operating life of a splined drive connection. Plug-in, or rigid spline drive installations can impose severe
radial loads on the shafts.
The radial load is a function of the transmitted torque and shaft eccentricity. Increased spline clearance
will not totally alleviate this condition; BUT, increased spline clearance will prevent mechanical
interference due to misalignment or radial eccentricity between the pitch diameters of the mating
splines. Spline life can be maximized if an intermediate coupling is introduced between the bearing
supported splined shafts.
Multiple pump installations must consider the loads from the entire pump stack and all torques are
additive. Charge pumps loads must also be included.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
System design parameters
34 11062168 • Rev 0501 • November 2015
Through torque diagram
2. stage 1. stage
3. stage
P003 333E
M
e1
for the second pump
M
e3
for the next pump
M
e1
for the first pump
M
e
input torque
Attention
Torque required by auxiliary pumps is additive. Ensure requirements do not exceed shaft torque ratings.
Rated and maximum torque ratings for each available shaft is shown in the H1 size specific technical
information.
Understanding and minimizing system noise
Noise is transmitted in fluid power systems in two ways: as fluid borne noise, and structure borne noise.
Fluid-borne noise (pressure ripple or pulsation) is created as pumping elements discharge oil into the
pump outlet. It is affected by the compressibility of the oil, and the pump’s ability to transition pumping
elements from high to low pressure. Pulsations travel through the hydraulic lines at the speed of sound
(about 1400 m/s [4600 ft/sec] in oil) until there is a change (such as an elbow) in the line. Thus, amplitude
varies with overall line length and position.
Structure born noise is transmitted wherever the pump casing connects to the rest of the system. The
way system components respond to excitation depends on their size, form, material, and mounting.
System lines and pump mounting can amplify pump noise.
Follow these suggestions to help minimize noise in your application:
•
Use flexible hoses.
•
Limit system line length.
•
If possible, optimize system line position to minimize noise.
•
If you must use steel plumbing, clamp the lines.
•
If you add additional support, use rubber mounts.
•
Test for resonants in the operating range; if possible avoid them.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
System design parameters
11062168 • Rev 0501 • November 2015 35
Determination of nominal pump sizes
The following equations are helpful when sizing hydraulic pumps. Generally, the sizing process is
initiated by an evaluation of the machine system to determine the required motor speed and torque to
perform the necessary work function.
Variables:
Vg = Pump displacement per rev.
∆p = p
HP
– p
NP
p
HP
= High pressure
p
NP
= Low pressure
n = Input speed
η
v
= Pump volumetric efficiency
η
mh
= Pump mechanical-hydraulic (torque) efficiency
η
t
= Pump overall efficiency (η
v
• η
m
)
SI units [US units]
cm
3
/rev [in
3
/rev]
bar [psi]
bar [psi]
bar [psi]
min
-1
(rpm)
First, the motor is sized to transmit the maximum required torque. The pump is then selected as a flow
source to achieve the maximum motor speed. Refer to Selection of Drive Line Components, BLN-9885, for
a more complete description of hydrostatic drive line sizing.
Basic Information
H1 Axial Piston Pumps, Single and Tandem
System design parameters
36 11062168 • Rev 0501 • November 2015
Basic Information H1 Axial Piston Pumps, Single and Tandem
11062168 • Rev 0501 • November 2015 37
Basic Information H1 Axial Piston Pumps, Single and Tandem
38 11062168 • Rev 0501 • November 2015
Basic Information H1 Axial Piston Pumps, Single and Tandem
11062168 • Rev 0501 • November 2015 39
Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and
electronic 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. Building on
our extensive applications expertise, we work closely with our customers to ensure
exceptional performance for a broad range of off-highway vehicles.
We help OEMs around the world speed up system development, reduce costs and bring
vehicles to market faster.
Danfoss – Your Strongest Partner in Mobile Hydraulics.
Go to www.powersolutions.danfoss.com for further product information.
Wherever off-highway vehicles are at work, so is Danfoss. We offer expert worldwide support
for our customers, ensuring the best possible solutions for outstanding performance. And
with an extensive network of Global Service Partners, we also provide comprehensive global
service for all of our components.
Please contact the Danfoss Power Solution representative nearest you.
Local address:
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 3418 5200
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 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.
11062168 • Rev 0501 • November 2015 www.danfoss.com
©
Danfoss A/S, 2014
Products we offer:
•
Bent Axis Motors
•
Closed Circuit Axial Piston
Pumps and Motors
•
Displays
•
Electrohydraulic Power
Steering
•
Electrohydraulics
•
Hydraulic Power Steering
•
Integrated Systems
•
Joysticks and Control
Handles
•
Microcontrollers and
Software
•
Open Circuit Axial Piston
Pumps
•
Orbital Motors
•
PLUS+1
®
GUIDE
•
Proportional Valves
•
Sensors
•
Steering
•
Transit Mixer Drives
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmueller-
inverter.com
Turolla
www.turollaocg.com
Hydro-Gear
www.hydro-gear.com
Daikin-Sauer-Danfoss
www.daikin-sauer-danfoss.com
