Revision history Table of revisions
Date Changed Rev
December 2015 Add 210 frame size 0500
November 2015 Model code change 0400
July 2015 correct torque values, pages 61, 62 0301
June 2015 add hydraulic controls THHA, THHB 0300
February 2015 add hydraulic controls CB
January 2015 Danfoss Layout CA
March 2013 added 250 frame size BC
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
2 11024924 • Rev 0500 • December 2015
Introduction
Overview..............................................................................................................................................................................................5
Warranty.............................................................................................................................................................................................. 5
General instructions........................................................................................................................................................................ 5
Safety precautions............................................................................................................................................................................6
Symbols used in Danfoss literature............................................................................................................................................7
H1 general information
Design of H1 bent axis motor...................................................................................................................................................... 8
General description.......................................................................................................................................................................10
H1 pictorial diagram..................................................................................................................................................................... 11
H1 system schematic....................................................................................................................................................................12
Technical specifications
General specifications.................................................................................................................................................................. 13
Physical properties........................................................................................................................................................................ 13
Operating parameters..................................................................................................................................................................14
H1B speed range diagrams for open and closed circuit..................................................................................................15
H1B pressure requirements for open and closed circuit................................................................................................. 16
Open circuit requirements..........................................................................................................................................................19
Fluid specifications........................................................................................................................................................................20
Determination of nominal motor sizes..................................................................................................................................20
Operation
Shaft rotation direction................................................................................................................................................................21
Loop flushing shuttle spool........................................................................................................................................................22
Loop flushing relief valve............................................................................................................................................................22
Speed sensor................................................................................................................................................................................... 23
Displacement limiter.....................................................................................................................................................................25
Operating parameters
Output speed...................................................................................................................................................................................26
System pressure............................................................................................................................................................................. 26
Case pressure...................................................................................................................................................................................27
External shaft seal pressure........................................................................................................................................................27
Temperature....................................................................................................................................................................................27
Fluid and filter maintenance
Fluid and filter recommendations........................................................................................................................................... 28
Pressure measurements
Port locations and gauge installation.....................................................................................................................................29
Initial startup procedures
Procedure..........................................................................................................................................................................................31
Troubleshooting
Overview........................................................................................................................................................................................... 33
Electrical troubleshooting.......................................................................................................................................................... 33
Sluggish operation........................................................................................................................................................................ 33
System operating hot...................................................................................................................................................................33
Excessive noise or vibration.......................................................................................................................................................34
Motor operates normally in one direction only..................................................................................................................34
Improper output speed............................................................................................................................................................... 34
Low output torque........................................................................................................................................................................ 35
Required tools and standard procedures
Adjustments
Minimum displacement limiter................................................................................................................................................ 37
Optional threshold adjustment - electric proportional controls..................................................................................38
Optional threshold adjustment - hydraulic proportional controls..............................................................................39
Pressure compensator OVERRIDE (PCOR) adjustment.....................................................................................................40
PCOR adjustment for all except P1/P2..............................................................................................................................40
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Contents
11024924 • Rev 0500 • December 2015 3
Brake pressure defeat option...............................................................................................................................................42
PCOR adjustment for P1/P2 controls.................................................................................................................................42
Minor repair
Shaft seal...........................................................................................................................................................................................43
Electric proportional solenoid replacement........................................................................................................................ 44
Hydraulic proportional actuator replacement....................................................................................................................45
Control module replacement....................................................................................................................................................46
Electric proportional control module.....................................................................................................................................47
Hydraulic proportional control module.................................................................................................................................49
Electric two-position control module.....................................................................................................................................50
Hydraulic two-position control module................................................................................................................................ 52
Hydraulic two-position control module with PCOR..........................................................................................................53
Hydraulic two-position control module with PCOR and hydraulic BPD....................................................................54
Maximum displacement limiter two-position controls................................................................................................... 56
Servo piston cover – proportional control............................................................................................................................56
Replace speed sensor...................................................................................................................................................................58
Loop flushing spool.......................................................................................................................................................................59
Loop flushing charge relief valve.............................................................................................................................................60
Minimum Displacement limiter................................................................................................................................................62
Torque chart
Fasteners and plugs......................................................................................................................................................................63
Fastener size and torque chart..................................................................................................................................................63
Plug size and torque chart..........................................................................................................................................................64
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Contents
4 11024924 • Rev 0500 • December 2015
Overview
This manual includes information for the installation, maintenance, and minor repair of the H1 bent-axis
motor. 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.
A worldwide network of Danfoss Global Service Partners is available for major repair. Danfoss trains and
certifies Global Service Partners on a regular basis. You can locate your nearest Global Service Partner
using the distributor locator at www.powersolutions.danfoss.com. Click on the Sales and Service link.
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
Follow these general procedures when repairing H1 variable displacement closed circuit motors.
Remove the unit
Chock the wheels on the vehicle or lock the mechanism to inhibit movement. Prior to performing repairs,
remove the unit from the vehicle/machine. Be aware that hydraulic fluid may be under high pressure
and/or hot. Inspect the outside of the motor and fittings for damage. Cap hoses after removal to prevent
contamination.
Keep it clean
Cleanliness is a primary means of assuring satisfactory motor life, on either new or repaired units. Clean
the outside of the motor thoroughly before disassembly. Take care to avoid contamination of the system
ports. Cleaning parts with a clean solvent wash and air drying is usually adequate.
Keep all parts free of foreign materials and chemicals. Protect all exposed sealing surfaces and open
cavities from damage and foreign material. If left unattended, cover the motor with a protective layer of
plastic.
Replace all O-rings and gaskets
Danfoss recommends you replace all O-rings and gaskets during repair. Lightly lubricate O-rings with
clean petroleum jelly prior to assembly.
Secure the unit
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Introduction
11024924 • Rev 0500 • December 2015 5
For repair, place the unit in a stable position with the shaft pointing downward. Secure the motor while
removing and torquing components and fasteners.
Safety precautions
Always consider safety precautions before beginning a service procedure. Protect yourself and others
from injury. Take the following general precautions whenever servicing a hydraulic system.
Unintended machine movement
W
Warning
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.
To protect against unintended movement, secure the machine or disable/disconnect the mechanism
while servicing.
Flammable cleaning solvents
W
Warning
Some cleaning solvents are flammable. To avoid possible fire, do not use cleaning solvents in an area
where a source of ignition may be present.
Fluid under pressure
W
Warning
Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious
injury and/or infection. This fluid may also be hot enough to cause burns. Use caution when dealing with
hydraulic fluid under pressure. Relieve pressure in the system before removing hoses, fittings, gauges, or
components. Never use your hand or any other body part to check for leaks in a pressurized line. Seek
medical attention immediately if you are cut by hydraulic fluid.
Personal safety
W
Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times.
Hazardous material
W
Warning
Hydraulic fluid contains hazardous material. Avoid prolonged contact with hydraulic fluid. Always
dispose of used hydraulic fluid according to environmental regulations.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Introduction
6 11024924 • Rev 0500 • December 2015
Symbols used in Danfoss literature
WARNING may result in injury Tip, helpful suggestion
CAUTION may result in damage to product or
property
Lubricate with hydraulic fluid
Reusable part Apply grease / petroleum jelly
Non-reusable part, use a new part Apply locking compound
Non-removable item Inspect for wear or damage
Option - either part may exist Clean area or part
Superseded - parts are not interchangeable Be careful not to scratch or damage
Measurement required Note correct orientation
Flatness specification Mark orientation for reinstallation
Parallelism specification Torque specification
External hex head Press in - press fit
Internal hex head Pull out with tool – press fit
Torx head Cover splines with installation sleeve
O-ring boss port Pressure measurement/gauge location or
specification
The symbols above appear in the illustrations and text of this manual. They are intended to communicate
helpful information at the point where it is most useful to the reader. In most instances, the appearance
of the symbol itself denotes its meaning. The legend above defines each symbol and explains its purpose.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Introduction
11024924 • Rev 0500 • December 2015 7
Design of H1 bent axis motor
Cross-section of H1 motor with electric proportional control
P005 917
6
7
5
1
2
3
4
10
9
8
1. Differential servo piston
2. Valve segment
3. Bearing plate
4. Tapered roller bearing
5. Loop flushing relief valve
6. Ramp spring
7. Loop flushing shuttle spool
8. Electric proportional control
9. Minimum displacement limiter
10. Speed ring (optional)
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
H1 general information
8 11024924 • Rev 0500 • December 2015
Cross-section of H1 motor with electric two-position control
P005 918
1
2
3
4
7
6
5
9
8
1. Differential servo piston
2. Valve segment
3. Bearing plate
4. Tapered roller bearing
5. Loop flushing relief valve
6. Loop flushing shuttle spool
7. Electric two-position control
8. Minimum displacement limiter
9. Speed ring (optional)
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
H1 general information
11024924 • Rev 0500 • December 2015 9
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 cm
3
and 250 cm
3
) and DIN (not available for 250 cm
3
) 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.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
H1 general information
10 11024924 • Rev 0500 • December 2015
H1 pictorial diagram
H1 pump and H1 motor with electric proportional control (EDC)
P003 423E
Reservoir
Heat Exchanger
Bypass Valve
Heat Exchanger
Electric
Displacement
Control
Servo Cylinder
Input
Shaft
Pump
Swashplate
Pressure Limiter Valve
Pressure Limiter
Valve
Charge Check/
High Pressure
Relief Valve
Charge Check/
High Pressure
Relief Valve
To
Motor
Case
Charge
Pressure
Relief
Valve
Loop
Flushing
Valve
Charge Pressure
Filter
Charge
Pump
Output
Shaft
Valve
Segment
Bent Axis Variable
Displacement Motor
Variable
Displacement
Pump
Case
Drain
Working Loop A (Low Pressure)
and Charge Pressure
Servo
Pressure
Working Loop B
(High Pressure)
Suction
H1 Pump and H1 Motor with Electric proportional control
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
H1 general information
11024924 • Rev 0500 • December 2015 11
H1 system schematic
System schematic H1 pump and H1 motor with EDC
P003 424
min.max.
L2 NMA
A
B
M5
MB
M4
L1
B
R1
R2
M4
M5
M14 M6 1 2
M3 L1 L2 MA
A
C2 C1
S
F00B F00A
L3 L4
CW
MB
max. 3 bar
[43.5 psi]
n
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.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
H1 general information
12 11024924 • Rev 0500 • December 2015
General specifications
General specifications
Design
Piston motor with variable displacement bent axis design
Direction of rotation
Bi-directional
Pipe connections
Main pressure ports: ISO split flange boss
Remaining ports: SAE straight thread O-ring boss
Recommended installation
Discretionary, the housing must always be filled with hydraulic fluid
Physical properties
Physical properties
Features Unit
Size
060 080 110 160 210 250
Displacement
maximum
cm
3
[in
3
]
60
[3.66]
80
[4.88]
110
[6.71]
160
[9.76]
210
[12.81]
250
[15.25]
minimum
12
[0.73]
16
[0.98]
22
[1.34]
32
[1.95]
42
[2.56]
50
[3.05]
Theoretical flow
at max. displ.
at rated speed
l/min
[US gal/min]
216
[57]
256
[68]
319
[84]
416
[110]
504
[133]
550
[145]
at max. speed
270
[71]
328
[87]
407
[108]
528
[139]
630
[166]
700
[185]
Theoretical torque
at max. displacement
N•m/bar
[lbf•in/1000 psi]
0.96
[583]
1.27
[777]
1.75
[1069]
2.55
[1555]
3.34
[2038]
3.98
[2426]
Theor. corner power at rated
speed and max. working pressure
(∆p = 450 bar [6527 psi])
kW
[hp]
266
[357]
321
[430]
396
[531]
513
[689]
609
[817]
684
[917]
Mass moment of inertia of
rotating components
kg•m
2
[slug•ft
2
]
0.0038
[0.0028]
0.0062
[0.0046]
0.0108
[0.0080]
0.0211
[0.0156]
0.0306
[0.0226]
0.0402
[0.0296]
Case volume
l
[US gal]
0.9
[0.24]
1.0
[0.26]
1.4
[0.37]
2.7
[0.71]
2.8
[0.74]
4.1
[1.08]
Weight dry (Electric proportional control)
Configuration Unit Size 060 Size 080 Size 110 Size 160 Size 210 Size 250
SAE
kg [lb]
29.8 [65.7] 34.8 [76.7] 48.8 [107.6] 61.9 [136.5] 81.0 [178.6] 87.0 [196.2]
DIN
28.3 [62.4] 34.4 [75.8] 45.0 [99.2] 59.3 [130.7] 75.0 [165.3] –
Cartridge
26.9 [59.3] 33.0 [72.6] 41.8 [92.2] 54.7 [120.6] – –
Mounting flange
Size 060 080 110 160 210 250
SAE ISO 3019/1
127-4 (SAE C) 4-bolt 152-4 (SAE-D) 4-bolt 165-4 (SAE E)
DIN ISO 3019/2, B4
125 HL 4-bolt 140 HL 4-bolt 160 HL 4-bolt 180 HL 4-bolt 200 HL 4-bolt
–
Cartridge
Pilot Ø160 mm
2-bolt (200 dist.)
M16
Pilot Ø190 mm
2-bolt (224 dist.)
M20
Pilot Ø200 mm
2-bolt (250 dist.)
M20
– –
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Technical specifications
11024924 • Rev 0500 • December 2015 13
Customer ports
Size 060 080 110 160 210 250
Axial and radial
1)
DN19 typ I DN25 typ I DN25 typ I DN32 typ I DN32 typ I DN32 typ I
Case drain ports
2)
0.875-14UN-2B
[
7
∕
8
-14UN-2B]
1.0625-12UN-2B
[1
1
∕
16
-12UN-2B]
1.313-12UN-2B
[1
5
∕
16
-12UN-2B]
Axial gauge ports
2)
0.875-14UN-2B
[
7
∕
8
-14UN-2B]
1.0625-12UN-2B [1
1
∕
16
-12UN-2B]
Gauge ports
2)
0.5625-18UNF-2B [
9
∕
16
-18UNF-2B]
1)
Split flange boss per ISO 6162, 40 MPa series.
2)
SAE O-ring boss
Operating parameters
Output speed
Features Unit
Size
060 080 110 160
210
250
Rated output
speed
max.displ. 32°
min
-1
(rpm)
3600 3200 2900 2600
2350
2200
min. displ. 6°
5900 5300 4800 4250
3850
3650
zero displ. 0°
6600 5950 5350 4750
4300
4050
Maximum output
speed
max. displ. 32°
4500 4100 3700 3300
3000
2800
min. displ. 6°
7250 6600 5950 5250
4800
4500
zero displ. 0°
7950 7200 6500 5750
5250
4900
System and case pressure, Ambient temperature
Parameter
Unit
All sizes
System pressure
Maximum working
bar [psi]
450 [6527]
Maximum
480 [6962]
Minimum above case pressure
(open and closed circuit)
See graphs in H1B pressure requirements for
open and closed circuit on page 16.
Case pressure
Rated
3 [44]
Maximum
5 [73]
Minimum
0.3 [4]
Ambient
temperature
*
Maximum
°C [°F]
70 [158]
Minimum
-40 [-40]
*
Air temperature close to the unit
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Technical specifications
14 11024924 • Rev 0500 • December 2015
H1B speed range diagrams for open and closed circuit
Displacement (%)
H1B060 Speed diagram
0 20 40 60 80 100
P003 557E
0
1000
2000
3000
4000
5000
6000
7000
8000
Speed (rpm)
Intermittent operation
H1B080 Speed diagram
0
1000
2000
3000
4000
5000
6000
7000
8000
0 20 40 60 80 100
P003 509E
Displacement (%)
Speed (rpm)
Intermittent operation
Displacement (%)
H1B110 Speed diagram
0
1000
2000
3000
4000
5000
6000
7000
0 20 40 60 80 100
P003 511E
Speed (rpm)
Intermittent operation
For operation within this speed range
contact Sauer Danfoss Representative
Displacement (%)
H1B160 Speed diagram
0
1000
2000
3000
4000
5000
6000
7000
0 20 40 60 80 100
P301 307E
Speed (rpm)
Intermittent operation
Displacement (%)
H1B210 Speed diagram
0
1000
2000
3000
4000
5000
6000
7000
0 20 40 60 80 100
P006 001E
Speed (rpm)
Intermittent operation
For operation within this speed range
contact Sauer-Danfoss Representative
For operation within this speed range
contact Sauer Danfoss Representative
Displacement (%)
H1B250 Speed diagram
0
1000
2000
3000
4000
5000
6000
7000
0 20 40 60 80 100
P301 457E
Speed (rpm)
Intermittent operation
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.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Technical specifications
11024924 • Rev 0500 • December 2015 15
H1B pressure requirements for open and closed circuit
Required inlet pressure (for cylinder block filling)
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.
30bar
20bar
15bar
10bar
5bar
2bar
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
0 10 20 30 40 50 60 70 80 90 100
Speed [rpm]
Displacement [%]
H1B060
Required Inlet Pressure (for cylinderblock filling) Required Inlet Pressure (for cylinderblock filling)
Required Inlet Pressure (for cylinderblock filling) Required Inlet Pressure (for cylinderblock filling)
Required Inlet Pressure (for cylinderblock filling) Required Inlet Pressure (for cylinderblock filling)
30bar
20bar
15bar
10bar
5bar
2bar
0
1000
2000
3000
4000
5000
6000
7000
8000
0 10 20 30 40 50 60 70 80 90 100
Speed [rpm]
Displacement [%]
H1B080
30bar
20bar
15bar
10bar
5bar
2bar
0
1000
2000
3000
4000
5000
6000
7000
0 10 20 30 40 50 60 70 80 90 100
Speed [rpm]
Displacement [%]
H1B110
30bar
20bar
15bar
10bar
5bar
2bar
0
1000
2000
3000
4000
5000
6000
7000
0 10 20 30 40 50 60 70 80 90 100
Speed [rpm]
Displacement [%]
H1B160
30bar
20bar
15bar
10bar
5bar
2bar
0
1000
2000
3000
4000
5000
6000
0 10 20 30 40 50 60 70 80 90 100
Speed [rpm]
Displacement [%]
H1B250
P006 002E
Max. speed
Rated speed
Max. speed
Rated speed
Max. speed
Rated speed
Max. speed
Rated speed
Max. speed
Rated speed
30bar
20bar
15bar
10bar
5bar
2bar
0
1000
2000
3000
4000
5000
6000
0 10 20 30 40 50 60 70 80 90 100
Speed [rpm]
Displacement [%]
H1B210
Max. speed
Rated speed
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.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Technical specifications
16 11024924 • Rev 0500 • December 2015
Required outlet pressure (minimum for short time usage)
The required outlet pressure (above case pressure) makes sure, that there is no pulling between piston and shaft.
The required pressure is 0 bar at 0 rpm and increases with rpm.
H1B060 Required outlet pressure (min. for short time usage)
0 20 40 60 80 100
Displacement [%]
9000
8000
7000
6000
5000
4000
3000
2000
1000
0
Speed [rpm]
4 bar
3 bar
2 bar
Max. speed
Rated speed
H1B080 Required outlet pressure (min. for short time usage)
0 20 40 60
80 100
Displacement [%]
8000
7000
6000
5000
4000
3000
2000
1000
0
Speed [rpm]
4 bar
3 bar
2 bar
Max. speed
Rated speed
H1B110 Required outlet pressure (min. for short time usage)
H1B210 Required outlet pressure (min. for short time usage)
0 20 40 60 80 100
Displacement [%]
7000
6000
5000
4000
3000
2000
1000
0
Speed [rpm]
4 bar
3 bar
2 bar
Max. speed
Rated speed
H1B160 Required outlet pressure (min. for short time usage)
4 bar
3 bar
2 bar
Max. speed
Rated speed
0
20
40 60
80 100
P006 003E
Displacement [%]
7000
6000
5000
4000
3000
2000
1000
0
6000
5000
4000
3000
2000
1000
0
Speed [rpm]
4 bar
3 bar
2 bar
Max. speed
Rated speed
0
20
40 60
80 100
Displacement [%]
Speed [rpm]
H1B250 Required outlet pressure (min. for short time usage)
4 bar
3 bar
2 bar
Max. speed
Rated speed
6000
5000
4000
3000
2000
1000
0
0
20
40 60
80 100
Displacement [%]
Speed [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.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Technical specifications
11024924 • Rev 0500 • December 2015 17
Required low pressure (minimum for extended usage)
These minimum pressures are required for a high duty cycle, defined as 200 hours at 350 bar. Similarly, a duty cycle of 200 hours at 250
bar requires 50% of these pressures. This low pressure (above case pressure) is required to prevent cavitation, which comes from the
pressure change in the cylinder block. There is very high flow velocity in the porting grooves of the valve segment, which causes
cavitation.
30bar
25bar
20bar
15bar
10bar
0
1000
2000
3000
4000
5000
6000
0 20 40 60 80 100
Speed [rpm]
30bar
25bar
20bar
15bar
10bar
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
0 20 40 60 80 100
Speed [rpm]
H1B060 Required Low Pressure (minimum for extended usage) H1B080 Required Low Pressure (minimum for extended usage)
H1B110 Required Low Pressure (minimum for extended usage) H1B160 Required Low Pressure (minimum for extended usage)
H1B250 Required Low Pressure (minimum for extended usage)
30bar
25bar
20bar
15bar
10bar
0
1000
2000
3000
4000
5000
6000
7000
8000
0 20 40 60 80 100
Speed [rpm]
Displacement [%]Displacement [%]
30bar
25bar
20bar
15bar
10bar
0
1000
2000
3000
4000
5000
6000
7000
0 20 40 60 80 100
Speed [rpm]
30bar
25bar
20bar
15bar
10bar
0
1000
2000
3000
4000
5000
6000
7000
0 20 40 60 80 100
Speed [rpm]
Max speed
Rated speed
Max speed
Rated speed
Max speed
Rated speed
Max speed
Rated speed
Max speed
Rated speed
30bar
25bar
20bar
15bar
10bar
0
1000
2000
3000
4000
5000
6000
0 20 40 60 80 100
Speed [rpm]
H1B210 Required Low Pressure (minimum for extended usage)
Max speed
Rated speed
P006 004E
Displacement [%]Displacement [%]
Displacement [%]Displacement [%]
For open circuit applications it is not allowed to operate above rated speed. For closed circuit applications operating between rated
and max speed, and for specific duty cycle interpretation or analysis, please contact your local Danfoss Power Solutions representative.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Technical specifications
18 11024924 • Rev 0500 • December 2015
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 H1B pressure requirements for open and closed circuit 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.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Technical specifications
11024924 • Rev 0500 • December 2015 19
Fluid specifications
Fluid specifications
Features Unit
All sizes
Viscosity
Minimum intermittent
mm
2
/s
[SUS]
7 [49]
Recommended range
12-80 [66-366]
Maximum intermittent
1600 [7416]
Temperature range
1)2)
Minimum
°C
[°F]
-40 [-40]
Rated
104 [220]
Maximum intermittent
115 [240]
Cleanliness and Filtration
Required cleanliness per ISO 4406
-
22/18/13
Efficiency (charge pressure filtration)
β-ratio
β
15-20
= 75 (β
10
≥ 10)
Efficiency (suction / return line filtration)
β
35-45
= 75 (β
10
≥ 2)
Recommended inlet screen mesh size
µm 100 – 125
1)
At the hottest point, normally case drain port.
2)
Minimum: cold start, short term t<3 min, p<50 bar, n<1000 rpm.
Determination of nominal motor sizes
V
g
• n
1000 •
v
Q
e
=
l/min
Based on SI units Based on US units
Input flow:
Output torque:
Output power:
Speed:
N•m
kW
min
-1
[lb•in]
[hp]
min
-1
(rpm)
[US gal/min]
V
g
• n
231 •
v
Q
e
=
V
g
• p •
mh
20 •
M
e
=
Q
e
• p •
t
600
=
M
e
• n
9550
P
e
=
n =
Q
e
• 1000 •
v
V
g
V
g
• p •
mh
2 •
M
e
=
V
g
• n • p •
t
396 000
P
e
=
n =
Q
e
• 231 •
v
V
g
Where: SI units [US units]
V
g
p
high
p
low
∆p
n
η
v
η
mh
η
t
=
=
=
=
=
=
=
=
Motor displacement per rev.
High pressure
Low pressure
p
high
– p
low
Speed
Motor volumetric efficiency
Mechanicall-hydraulic efficiency
Motor total efficiency (η
v
• η
mh
)
cm
3
/rev [in
3
/rev]
bar [psi]
bar [psi]
bar [psi]
min
-1
(rpm)
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Technical specifications
20 11024924 • Rev 0500 • December 2015
Shaft rotation direction
Shaft rotation direction is determined with a view to the shaft end. Rotation direction of the motor will be
dependent on the control option used as illustrated below and summarized in the table.
Control option L*, D*, LH, DH
Control option M*, K*, MH
Control option E*, F*, P*, T*, TA, TH, HE, HF
P003 488
CCW CW
CCW CW
CCW CW
Port “B”
Port “A”
Port “A”
Port “B”
Port “A”
Port “B”
Direction of rotation (view from the shaft end)
Control options Flow into port Direction of rotation
L*, D*, LH, and DH
*
A CW
B CCW
M*, K*, MH, E*, F*, P*, T*, TA, TH, HE, and HF
A CCW
B CW
*
1 = 12 V
DC
OR 2 = 24 V
DC
.
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Operation
11024924 • Rev 0500 • December 2015 21
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.
P003 490E
System
loop A
to Loop flushing
relief valve
System
loop B
P003 437
A
B
L2
W
Warning
Unintended vehicle or machine movement hazard.
Excessive motor loop flushing flow may result in the inability to build required system pressure in some
conditions. Maintain correct charge pressure under all conditions of operation to maintain pump control
performance in hydrostatic systems.
Loop flushing relief valve
The loop flushing relief valve is incorporated into all H1 motors. Use the loop flushing option in
installations that require fluid to be removed from the low pressure side of the system circuit due to
cooling requirements.
The loop flushing relief valve is also used to facilitate the removal of contaminants from the loop.
The loop flushing valve is equipped with an orificed charge pressure relief valve designed with a cracking
pressure of 16 bar [232 psi].
Valves are available with several orifice sizes to meet the flushing flow requirements of all system
operating conditions.
P003 491
P003 487
A
B
L2
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Operation
22 11024924 • Rev 0500 • December 2015
40 [580]
30 [435]
20 [290]
10 [145]
10 15 20 30 40 5005
10
[2.6]
20
[5.3]
30
[7.9]
40
[10.6]
50
[13.2]
60
[15.9]
70
[18.5]
P003 492E
0
Loop Flushing Relief Valve Size
Loop Flushing Flow l/min [US gal/min]
Low System Pressure minus Case Pressure
bar [psi]
Speed sensor
Two optional speed sensors are available. 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.
Order number
149055 11102032
Supply voltage 4.5 – 8 V
DC
7 – 32 V
Speed signals two, 90° phase shift one
Direction signal one –
Temperature signal one –
Temperature ratings
Parameter Min Max Note
Operating Temperature-Range -40°C 104°C 115°C Intermittent = Short term
t < 1min per incident and not
exceeding 2 % of duty cycle based
load-life
Protection characteristics
Parameter Note
Protection code IP-Class IP67 and IP69k according IEC 60529 &
DIN 40050
• IP67 w/o connector installed
• IP69k with connector installed
EMC-Emission EN 61000-6-3
EMC- Immunity (EMI) 100 V/m incl. 1 kHz AM 80 %, ISO
11452-5 and ISO 11452-2
ESD:
Air discharge
Contact discharge
EN 61000-4-2:
15 kV
8 kV
Vibration 30 G (294 m/s²)
Shock 50 G (490 m/s²)
Case pressure 5 bar maximum
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Operation
11024924 • Rev 0500 • December 2015 23
Technical data
Min. Max. Note
Supply voltage range 4.5 V
DC
8 V
DC
Supply protection - 30 V
DC
30 V over voltage protection.
Shuts off above 9 V.
Max. required supply current - 25 mA
Max. output current - 50 mA
Operation mode NPN& PNP Push-Pull amplifier
Output signal
range
Low & clockwise 5% 12%
High &
counterclockwise
88% 95%
Temperature signal
-40°C = 2.203V 104°C = 0.734V
V
o
=1.795V – [0.0102 ∙ T]
Detectable frequency range 1 Hz 10 000 Hz
Speed and temperature sensor Order number 149055
Connector terminals
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
Color of connector Black
Technical data
Min. Max. Note
Supply voltage range 7 V
DC
32 V
DC
Supply protection - 36 V
DC
36 V over voltage protection and -36
V permanent reverse polarity
protection
Max. required supply current - 30 mA
Max. output current - 50 mA
Operation mode NPN open collector With internal 2k7 pull-up resistor to
supply
Output signal
range
Low 2% 10%
High 55% 85% Max. output voltage 24V
Detectable frequency range 1 Hz 10.000 Hz
Speed and temperature sensor Order number 11102032
Connector terminals
Sensor pinout
1 NC
2 NC
3 Speed signal 1
4 Supply
5 Ground
6 NC
4
3 2 1
5 6
P301 549
Color of connector White (natural plastic color)
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Operation
24 11024924 • Rev 0500 • December 2015
Mating connectors
Material Number Name Note
11033865 Assembly Bag, DEUTSCH, DTM06 6-
SOCKET Black
(20-24 AWG) / 0.2 – 0.5 mm²
11033863 Assembly Bag, DEUTSCH, DTM06 6-
SOCKET Grey
For more information, see Speed and Temperature Sensor, Technical Information 11046759.
Sensor position
SAE and DIN housing
P003450
Cartridge housing
P003489
Target ring
Target ring size H1B 060 H1B 080 H1B 110 H1B 160 H1B 210 H1B 250
Number of teeth 71 78 86 95 104 108
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.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Operation
11024924 • Rev 0500 • December 2015 25
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 5 minute durations. Speed above
rated are anticipated to occur during downhill braking (negative power). Contact factory for any
operation above Rated speed when negative power is not involved.
During hydraulic braking and downhill conditions, the prime mover must be capable of providing
sufficient braking torque in order to avoid pump over speed. This is especially important to consider for
turbocharged and Tier 4 engines.
W
Warning
Unintended vehicle or machine movement hazard.
Exceeding maximum speed may cause a loss of hydrostatic drive line power and braking capacity. You
must provide a braking system, redundant to the hydrostatic transmission, sufficient to stop and hold the
vehicle or machine in the event of hydrostatic drive power loss. The braking system must also be
sufficient to hold the machine in place when full power is applied.
System pressure
System pressure is the differential pressure between high pressure system ports. It is the dominant
operating variable affecting hydraulic unit life. High system pressure, which results from high load,
reduces expected life. Hydraulic unit life depends on the speed and normal operating, or weighted
average, pressure that can only be determined from a duty cycle analysis.
Application pressure is the high pressure relief or pressure limiter setting normally defined within the
order code of the pump. This is the applied system pressure at which the driveline generates the
maximum calculated pull or torque in the application.
Maximum working pressure is the highest recommended application pressure. Maximum working
pressure is not intended to be a continuous pressure. Propel systems with application pressures at, or
below, this pressure should yield satisfactory unit life given proper component sizing.
Maximum pressure is the highest allowable application pressure under any circumstance. For
applications which are above the maximum working pressure, please contact Danfoss
Minimum pressure must be maintained under all operating conditions to avoid cavitation.
All pressure limits are differential pressures referenced to low loop (charge) pressure. Subtract the low
loop gauge pressure from the high loop gauge pressure readings to compute the differential.
Summing pressure is the sum of both the low and high loop pressures. Summing pressure above 30 bar
[435 psi] guarantees reliable use within the rated speed.
Servo pressure is the pressure in the servo system and is supplied from the high side of the loop to keep
the motor at the required displacement.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Operating parameters
26 11024924 • Rev 0500 • December 2015
Case pressure
Under normal operating conditions, the rated case pressure must not be exceeded. During cold start,
case pressure must be kept below maximum intermittent case pressure. Size drain plumbing accordingly.
C
Caution
Possible component damage or leakage.
Operation with case pressure in excess of stated limits may damage seals, gaskets, and/or housings,
causing external leakage. Performance may also be affected since charge and system pressures are
referenced to case pressure.
External shaft seal pressure
In certain applications, the output shaft seal may be exposed to external pressures. The shaft seal is
designed to withstand an external pressure up to 0.25 bar [3.6 psi] above the case pressure. The case
pressure limits must also be followed to ensure the shaft seal is not damaged.
Temperature
The high temperature limits apply at the hottest point in the transmission, which is normally the motor
case drain. The system should generally be run at or below the published rated temperature.
The maximum intermittent temperature is based on material properties and should never be
exceeded.
Cold oil will generally not affect the durability of the transmission components, but it may affect the
ability of oil to flow and transmit power. Therefore, temperatures should remain 16 °C [30 °F] above the
pour point of the hydraulic fluid.
The minimum temperature relates to the physical properties of component materials.
Size heat exchangers too keep the fluid within these limits. Danfoss recommends testing to verify that
these temperature limits are not exceeded.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Operating parameters
11024924 • Rev 0500 • December 2015 27
Fluid and filter recommendations
To ensure optimum life, perform regular maintenance of the fluid and filter. Contaminated fluid is the
main cause of unit failure. Take care to maintain fluid cleanliness when servicing.
Check the reservoir daily for proper fluid level, the presence of water, and rancid fluid odor. Fluid
contaminated by water may appear cloudy or milky or free water may settle in the bottom of the
reservoir. Rancid odor indicates the fluid has been exposed to excessive heat. Change the fluid
immediately if these conditions occur. Correct the problem immediately.
Inspect vehicle for leaks daily.
Change the fluid and filter per the vehicle/machine manufacturer’s recommendations or at these
intervals. We recommend first fluid change occur at 500 hours of operation. Change the fluid more
frequently if it becomes contaminated with foreign matter (dirt, water, grease, etc) or if the fluid is
subjected to temperature levels greater than the recommended maximum.
Fluid and filter change interval
Reservoir type Max oil change interval
Sealed 2000 hours
Breather 500 hours
C
Caution
High temperatures and pressures accelerate fluid aging. This may require more frequent fluid changes.
Change filters when changing fluid or when the filter indicator directs. Replace all fluid lost during filter
change
W
Warning
Hydraulic fluid contains hazardous material. Avoid contact with hydraulic fluid. Always dispose of used
hydraulic fluid according to state, and federal environmental regulations. Never reuse hydraulic fluid.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Fluid and filter maintenance
28 11024924 • Rev 0500 • December 2015
Port locations and gauge installation
The following table and drawing show the port locations and gauge sizes needed.
Port Information
Port identifier 060 080 110/160 210/250 Pressure
obtained
Gauge size,
bar [psi]
Port size Wrench
size
int. hex
Port size Wrench
size
int. hex
Port size Wrench
size
int. hex
Port size Wrench
size
int. hex
L1, L2 7/8-14 UNF 3/8 7/8-14 UNF 3/8 in. 1 1/16-12UN 9/16 in. 1 5/16-12UN 5/8 in. Case drain 10 [100]
MA, MB
(Radial endcap)
7/8-14 UNF 3/8 1 1/16-12UN 9/16 in. 1 1/16-12UN 9/16 in. 1 1/16-12UN 9/16 in. System
pressure
600 [10,000]
MA, MB
(Axial endcap)
9/16-18 UNF 1/4 9/16-18 UNF 1/4 in. 9/16-18 UNF 1/4 in. 9/16-18 UNF 1/4 in. System
pressure
600 [10,000]
M4 9/16-18 UNF 1/4 9/16-18 UNF 1/4 in. 9/16-18 UNF 1/4 in. 9/16-18 UNF 1/4 in. Servo pressure
rod end
600 [10,000]
M5 9/16-18 UNF 1/4 9/16-18 UNF 1/4 in. 9/16-18 UNF 1/4 in. 9/16-18 UNF 1/4 in. Servo pressure
piston end
600 [10,000]
X1
9/16-18 UNF 1/4 9/16-18 UNF 1/4 in. 9/16-18 UNF 1/4 in. 9/16-18 UNF 1/4 in. Control
pressure
supply,
hydraulic
actuator
100 [1500]
XA
9/16-18 UNF 1/4 9/16-18 UNF 1/4 in. 9/16-18 UNF 1/4 in. 9/16-18 UNF 1/4 in. BPD, PCOR
inactive at A
100 [1500]
XB
9/16-18 UNF 1/4 9/16-18 UNF 1/4 in. 9/16-18 UNF 1/4 in. 9/16-18 UNF 1/4 in. BPD, PCOR
inactive at B
100 [1500]
System Ports
Port identifier 060 080, 110 160/210/250
Split flange boss, thread M10 x 1.5 Split flange boss, thread M12 x 1.75 Split flange boss, thread M12 x 1.75
A 3/4 inch code 62 per ISO 6162 Type 1,
min. thread 18mm [0.71 in]
1 inch code 62 per ISO 6162 Type 1,
min. thread 23mm [0.91 in]
1 1/4 inch code 62 per ISO 6162 Type 1,
min. thread 23mm [0.91 in]
B 3/4 inch code 62 per ISO 6162 Type 1,
min. thread 18mm [0.71 in]
1 inch code 62 per ISO 6162 Type 1,
min. thread 23mm [0.91 in]
1 1/4 inch code 62 per ISO 6162 Type 1,
min. thread 23mm [0.91 in]
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Pressure measurements
11024924 • Rev 0500 • December 2015 29
Port locations proportional control
L2
MB
MA
L1
M5
System Port A
P108829
(System Port B
on reverse side)
(M4 on reverse side)
Radial Ported Endcap
Axial Ported Endcap
System
Port B
System
Port A
M5
L2
MA
(M4 on
reverse side)
(MB on
reverse side)
X1
XB
(Port XA
on reverse side)
X1
XB
(Port XA
on reverse side)
Port locations hydraulic 2-position controls with PCOR (control specific ports only )
P108924
X1
XB
(Port XA
on reverse side)
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Pressure measurements
30 11024924 • Rev 0500 • December 2015
Procedure
W
Warning
This service procedure may require disabling the vehicle / machine (raising the wheels off the ground,
disconnecting work function) while performing, to prevent injury to the technician and bystanders. Take
the necessary safety precautions.
Always follow this procedure when starting-up a new H1 installation or when the motor has been
removed.
1. Before installing the motor, inspect the units for possible damage incurred during shipping and
handling.
2. Make certain all system components (reservoir, hoses, valves, fittings, heat exchanger, and so forth)
are clean before filling with fluid.
3. Fill the reservoir with recommended hydraulic fluid. Pass this fluid through a 10 micron (nominal, no
bypass) filter before it enters the reservoir.
4. Fill the inlet line leading from the reservoir to the pump.
5. Check inlet line for properly tightened fittings. Make sure the inlet line is free of restrictions and air
leaks.
6. Fill the motor and pump housings with clean hydraulic fluid before start up. Fill by pouring filtered oil
into the upper case drain port.
C
Caution
Never start the prime mover unless the motor and pump housings are filled completely with clean
hydraulic fluid.
7. For closed loop systems, install a 0-60 bar [0-1000 psi] pressure gauge in the charge pressure gauge
port of the pump to monitor the charge pressure during start-up.
For open circuit systems, use gauges in system ports.
8. Disconnect any external control input signal from the pump control until after initial start-up. This
ensures that the pump remains in its neutral position.
9. Jog (slowly rotate) prime mover until charge pressure starts to rise.
10. Start the prime mover and run at the lowest possible speed until charge pressure builds.
W
Warning
Do not start the prime mover unless the pump is in neutral position (swash plate at 0° angle). Take
necessary precautions to prevent machine movement in case pump is actuated (in stroke) during
initial start-up.
If necessary, bleed excess air from the high pressure lines through the high pressure system gauge
ports.
11. Once charge pressure is established, increase to normal operating speed. Charge pressure should be
as indicated in the pump model code. If charge pressure is low, shut down and determine cause.
C
Caution
Low charge pressure may affect ability to control the machine.
12. Shut down the prime mover.
13. Connect the external control input signal.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Initial startup procedures
11024924 • Rev 0500 • December 2015 31
14. Reconnect the machine function if disconnected earlier.
15. Start the prime mover, checking to ensure the pump remains in neutral.
16. Check for forward and reverse machine operation, with the prime mover at normal operating speed.
Charge pressure may decrease slightly during forward or reverse operation.
17. Continue to cycle slowly between forward and reverse for at least five minutes.
18. Shut down prime mover.
19. Remove gauges. Replace plugs at the gauge ports.
20. Check reservoir level. Add filtered fluid if needed.
The motor/transmission is now ready for operation.
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Initial startup procedures
32 11024924 • Rev 0500 • December 2015
Overview
This section provides general steps to follow if you observe undesirable system conditions. Follow the
steps until you solve the problem. Some of the items are system specific. Always observe the safety
precautions in the Introduction section.
W
Warning
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.
To protect against unintended movement, secure the machine or disable/disconnect the mechanism
while servicing.
Electrical troubleshooting
Item Description Action
Motor operates at one
displacement only.
Control coil failure Measure resistance at coil pins.
Proportional controls: Resistance should be 14.20 Ohms (24V) or
3.66 Ohms (12V) at 20°C [70°F].
Two-position controls: Resistance should be 8.4 Ohms (24V) or
34.5 Ohms (12V) at 20°C [70°F].
Replace coil if necessary.
Erratic motor function Electrical connection to motor is intermittent. Disconnect connector, check wires and terminals, reconnect wires.
Check terminals for corrosion and correct position.
Sluggish operation
Check Cause Corrective action
1. Control orifices Blocked or restricted orifice may cause sluggish
response. Orifices installed in the wrong locations
may cause PCOR control to be sluggish.
Remove, inspect and clean all orifices. Ensure the
appropriate orifices are installed and in the correct
location.
2. Threshold setting (proportional
controls)
Inappropriately high or low threshold setting may
shift the motor at the wrong time.
Check threshold setting. Adjust if necessary.
3. Control spool A sticky control may cause sluggish response or no
response.
Clean and inspect the control spool. Replace if
necessary.
4. Pressure compensator setting Low pressure compensator setting may shift motor
to maximum displacement at lower pressure.
Check pressure compensator setting. Adjust if
necessary.
5. Control input signal An improper or erratic input signal to the control
may cause sluggish response.
Check input signal and correct if necessary.
6. Internal leakage Excessive leakage will cause lower charge pressure
and affect performance.
Install loop flushing defeat option and measure case
flow. If case flow is excessive, motor may require major
repair. Contact your Danfoss authorized service
center.
System operating hot
Check Cause Corrective action
1. Oil level Insufficient hydraulic fluid may cause overheating. Fill reservoir to proper level.
2. Heat exchanger Blocked heat exchanger or low air flow may cause
system overheating.
Check temperature upstream and downstream of heat
exchanger. Clean, repair, or replace heat exchanger if
necessary.
3. Loop flushing flow Restricted orifice in loop flushing cartridge reduces
flow.
Measure case drain flow. Clean or replace orifice
cartridge.
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Troubleshooting
11024924 • Rev 0500 • December 2015 33
Check Cause Corrective action
4. Loop flushing shuttle Loop flushing shuttle may be sticking in one
direction.
Ensure shuttle moves freely in its bore.
5. Air in system Entrained air generates heat under pressure Look for foam or bubbles in reservoir. Check for leaks
on inlet side of charge pump.
6. Internal leakage Excessive internal leakage may overheat the
system.
Install loop flushing defeat option and monitor case
flow. If case flow is excessive, motor may require major
repair. Contact your Danfoss authorized service
center.
Excessive noise or vibration
Check Cause Corrective action
1. Oil level in reservoir Insufficient hydraulic fluid may cause cavitation. Fill reservoir to proper level.
2. Air in system Air bubbles may lead to cavitation. Look for foam or bubbles in reservoir. Check for leaks
on inlet side of charge pump.
3. Shaft coupling Loose shaft coupling may create excess noise. Replace loose shaft coupling. Replace or repair motor
if shaft splines show excessive wear.
4. Shaft alignment Misaligned shafts may create excessive noise and
vibration and can damage motor.
Correct shaft misalignment.
Motor operates normally in one direction only
Check Cause Corrective action
1. Charge pressure If charge pressure is low in one direction, the loop
flushing shuttle spool may be sticking to one side.
Measure charge pressure in forward and reverse. If
pressure drops significantly lower in one direction,
inspect and repair loop flushing shuttle spool.
2. Pressure compensator control If pressure compensator operates in one direction
only, the motor may stay at minimum
displacement in the opposite direction.
Check brake pressure defeat spool. It may be sticking
or receiving an improper signal. Repair spool or
correct input signal.
Improper output speed
Check Cause Corrective action
1. Oil level in reservoir Insufficient hydraulic fluid may reduce system
efficiency.
Fill reservoir to proper level.
2. Threshold setting Improper threshold setting may cause motor to
have wrong displacement for given signal.
Check threshold setting. Refer to Control Service
Manual for adjustment procedure.
3. Pressure compensator setting Improper pressure compensator setting may shift
motor displacement at wrong pressure.
Check pressure compensator setting. Adjust if
necessary. Refer to Control Service Manual for
adjustment procedure.
4. PC spool Pressure compensator spool sticking may shift
motor to improper displacement.
Check pressure compensator spool. Repair or replace
if needed. Refer to Control Service Manual for
adjustment procedure.
5. Control orifices Blocked or restricted orifice may cause motor to
shift improperly.
Remove, inspect and clean all orifices.
6. Control spool Sticky proportional control spool may cause motor
to shift improperly.
Check control spool for proper operation. Repair if
necessary. Refer to control adjustment procedure.
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Troubleshooting
34 11024924 • Rev 0500 • December 2015
Check Cause Corrective action
7. Control input signal Improper input signal may cause motor to shift
improperly.
Correct control input signal.
8. Internal leakage Excess internal leakage may cause lower charge
pressure and affect motor performance including
output speed.
Install loop flushing defeat option and measure case
flow. If case flow is excessive, motor may require major
repair. Contact your Danfoss authorized service
center.
Low output torque
Check Cause Corrective action
1. Pressure compensator setting High pressure compensator setting may cause
improper motor displacement for torque required.
Check and adjust pressure compensator setting.
2. Control orifices Blocked or restricted orifice may cause motor to
shift improperly.
Remove, inspect and clean all orifices.
3. Pressure compensator spool Sticking pressure compensator spool may cause
control to hold motor at minimum displacement.
Remove and inspect pressure compensating spool.
Repair or replace control if necessary.
4. Control spool Sticking control spool may cause motor to shift
improperly.
Remove and inspect control spool. Repair or replace
control if necessary.
5. Two position solenoid Two position control not shifting motor to
maximum displacement.
Inspect solenoid valve for bent stem or damaged coil.
Repair or replace if necessary.
6. Control input signal Improper control input signal may cause motor to
stay at minimum displacement.
Correct control input signal.
7. Threshold setting
(proportional control)
Improper threshold setting may cause improper
motor displacement for torque required.
Check and adjust threshold setting.
8. Internal leakage Excess internal leakage may cause charge pressure
to decay, reducing output torque.
Install loop flushing defeat option and monitor case
flow. If case flow is excessive, motor may require major
repair. Contact your Danfoss authorized service
center.
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Troubleshooting
11024924 • Rev 0500 • December 2015 35
Required tools
The service procedures described in this manual can be performed using common mechanic’s hand
tools. Special tools, if required, are shown. When testing system pressures, calibrate pressure gauges
frequently to ensure accuracy. Use snubbers to protect gauges.
Standard procedures
C
Caution
Contamination can damage internal components and void the manufacturer’s warranty. Take
precautions to ensure system cleanliness when removing and reinstalling system lines
1. With the prime mover off, thoroughly clean all dirt and grime from the outside of the motor. Ensure
the surrounding areas are clean and free of contaminants such as dirt and grime.
2. If removing the motor, tag each hydraulic line connected to the motor. If you disconnect hydraulic
lines, plug each open port to keep dirt and contamination out of the motor.
3. Inspect the system for contamination. Look at the hydraulic fluid for signs of system contamination,
such as oil discoloration, foam in the oil, sludge, or small metal particles.
4. Remove the motor as a single unit.
C
Caution
Be careful not to damage solenoids and electrical connections when using straps or chains to remove
motor from machine.
5. Perform motor function test.
6. Before re-installing the motor on the machine, drain the system, flush all lines, replace all filters, and
fill with new hydraulic fluid.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Required tools and standard procedures
36 11024924 • Rev 0500 • December 2015
Minimum displacement limiter
Adjusting the minimum displacement limiter
1. Remove cap (N0120).
Removing the cap destroys the caps locking mechanism. Replace with a new cap.
2. Using a 6 mm internal hex wrench, hold adjusting screw (N0010) in place.
3. Using a 19 mm hex wrench, loosen seal locknut (N0020).
4. Turn adjusting screw clockwise to increase minimum displacement or counterclockwise to decrease
minimum displacement. Minimum displacement is inversely related to maximum shaft speed. To
increase maximum speed, decrease minimum displacement. Adjusting displacement limits also
affects output torque. Refer to table for displacement change per turn.
5. When properly adjusted, hold adjusting screw in place and torque seal locknut to 45 N•m [32 lbf•ft].
6. With motor on machine or test stand, verify correct motor function. Refer to Port locations and gauge
installation on page 29 for location of gauge ports and suggested gauge sizes.
7. Install new cap (N0120).
Minimum displacement limiter
N0020
N0120
N0010
19 mm
6 mm
P106 547E
45 N•m
[32 lb•ft]
Displacement change per turn
Model Displacement change
250 5.5 cm
3
[0.34 in
3
]
210 5.1 cm
3
[0.31 in
3
]
160 4.1cm
3
[0.25 in
3
]
110 3.2 cm
3
[0.20 in
3
]
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Adjustments
11024924 • Rev 0500 • December 2015 37
Displacement change per turn (continued)
Model Displacement change
080 2.6 cm
3
[0.16 in
3
]
060 2.1 cm
3
[0.13 in
3
]
Optional threshold adjustment - electric proportional controls
Adjusting threshold on test stand
1. Connect flow meter to A or B system port. Refer to Port locations and gauge installation on page 29 for
port locations.
2. Connect solenoid to PWM signal generator at 100 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
E101 548E
B0040
adjusting
screw
3 mm
4. Adjust PWM signal to current listed in model code. Note flow reading.
5. 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. Test your adjustment
by lowering the current, then increasing the current until the displacement starts to change. Readjust
the setting if necessary.
6. When threshold is adjusted correctly, stop prime mover, install cap (B0040), and install motor on
vehicle. Run vehicle and test for proper motor operation.
Adjusting threshold on a machine or test stand without flow meter
1. Install 600 bar [10,000 psi] gauges to ports M5 and M4. Connect solenoid to PWM signal.
2. Raise wheels off ground, or disconnect the work function.
W
Warning
Unintended movement of the machine or mechanism may cause injury to the technician or
bystanders. To protect against unintended movement, secure the machine or disable/disconnect the
mechanism while servicing.
3. Run prime mover at operating speed. Stroke the pump to get some rotation of motor shaft.
4. Increase signal current until M4 pressure becomes 1/2 of the M5 pressure. Check the signal current at
this point.
5. If adjustment is necessary, remove cap (B0040). Turn the adjusting screw until the signal current
matches the model code setting.
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H1B 060/080/110/160/210/250 Bent Axis Motors
Adjustments
38 11024924 • Rev 0500 • December 2015
6. When threshold is adjusted correctly, stop prime mover, install cap. Run vehicle and test for proper
motor operation.
7. Remove from test stand.
Optional threshold adjustment - hydraulic proportional controls
Adjusting threshold on test stand
1. Connect flow meter to A or B system port. Refer to Port locations and gauge installation on page 29 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
P108830
Locking nut
(B0180)
adjusting
screw
6 mm
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. Test your adjustment
by lowering the pressure, then increasing the pressure until the displacement starts to change.
Readjust the setting if necessary.
6. When threshold is adjusted correctly, stop prime mover, install nut (B0180), and install motor on
vehicle. Run vehicle and test for proper motor operation.
Adjusting threshold on a machine or test stand without flow meter
1. Install 600 bar [10,000 psi] gauges to ports M5 and M4. Connect a variable pressure supply to X1 port
(0-50 bar).
2. Raise wheels off ground, or disconnect the work function.
W
Warning
Unintended movement of the machine or mechanism may cause injury to the technician or
bystanders. To protect against unintended movement, secure the machine or disable/disconnect the
mechanism while servicing.
3. Run prime mover at operating speed. Stroke the pump to get some rotation of motor shaft.
4. Increase X1 pressure until M4 pressure becomes 1/2 of the M5 pressure. Check the X1 pressure at this
point.
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Adjustments
11024924 • Rev 0500 • December 2015 39
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
W
Warning
Unintended movement of the machine or mechanism may cause injury to the technician or bystanders.
To protect against unintended movement, secure the machine or disable/disconnect the mechanism
while servicing.
PCOR adjustment for all except P1/P2
Setup
1. Install motor in machine.
2. Install 600 bar pressure gauge at system port MA or MB (whichever side is regulated by the PCOR).
Optionally, the gauge can be installed in the system gauge port M5.
3. Install sensor to read engine speed.
4. Install sensor to read wheel speed.
5. Install data acquisition device which is able to record data over time using the sensors installed in
steps 2 – 4 above.
6. Deactivate any inching systems connected to the brakes if applicable.
7. Prepare site for testing (two options are available).
a) Lift machine so wheels are no longer engaging the ground, or
b) Use a straight, flat surface to drive machine during testing.
Testing
1. Start machine engine.
2. Set engine to high idle (rated speed) and maintain for the duration of the testing.
3. Turn the machine wheels at a constant speed (motor will be at minimum displacement).
a) Allow wheels to turn at constant speed if using setup 7a.
b) Drive machine at constant speed if using setup 7b.
4. Begin data acquisition (system pressure, engine speed, and wheel speed).
5. Slowly apply the service brake to continuously increase the load on the system until the wheel speed
(setup 7a) or driving speed (setup 7b) decreases by approximately 1/3.
6. Stop machine and turn off engine.
7. Stop data acquisition.
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H1B 060/080/110/160/210/250 Bent Axis Motors
Adjustments
40 11024924 • Rev 0500 • December 2015
Analysis
1. Using appropriate software for the data acquisition device, plot the system pressure, wheel speed
and engine speed versus time.
2. As the system pressure increases (from applying the brakes), the engine speed and wheel speed will
start decreasing.
3. When the system pressure stops rising and remains constant, that pressure will be the PCOR setting.
The engine speed should remain constant during this period while the wheel speed continues to
decrease. See Graph below.
Adjustment
1. If adjustment is required, use a 3mm internal hex to hold the PCOR adjusting screw in place and use a
10mm wrench to loosen the PCOR lock nut. One full turn of the adjusting screw changes the PCOR
setting by approximately 90 Bar.
a) Turn adjusting screw clockwise to increase the PCOR setting.
b) Turn adjusting screw counterclockwise to decrease the PCOR setting.
P106 723E
Locknut
Adjusting screw
10 mm
3 mm
2. Use a 3mm internal hex to hold the PCOR adjusting screw in place and use a 10mm wrench to tighten
the lock nut to 8 N-m [6 lbf-ft].
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Adjustments
11024924 • Rev 0500 • December 2015 41
3. Repeat Testing, Analysis, and Adjustment steps as necessary to reach the desired PCOR setting.
H1B PCOR Adjustment
System Pressure
Engine Speed
Wheel Speed
Displacement Range
Minimum Displacement
Max Displacement
TIME
Begin Application of
Service Brake
PCOR Setting
Brake pressure defeat option
No adjustment is available for the brake pressure defeat option. Coil is either energized or de-energized,
if coil is used.
PCOR adjustment for P1/P2 controls
PCOR setting 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.
Service Manual
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Adjustments
42 11024924 • Rev 0500 • December 2015
Shaft seal
Removal
1. 1. Using snap ring pliers, remove retaining ring (G0030).
2. 2. Use a slide-hammer style puller to remove seal (G0020). Be careful not to damage the shaft or seal
bore when removing. Discard seal.
Inspection
Inspect retaining ring for wear or damage. Replace if necessary. Inspect shaft for wear or groove at seal
area.
Assembly
1. Lubricate inside diameter of new seal. Cover the shaft splines with shaft cover or packing tape to
avoid damaging the seal during installation.
2. Using seal installation tool, press seal into housing bore.
3. Using a snap ring pliers, install retaining ring (G0030).
4. Use seal installation tool to press seal and retaining ring into housing until retaining ring snaps into
its groove.
If not using seal installation tool: Do not press seal beyond snap-ring groove. Stop pressing just when
you have room to install the retaining ring into the bore. Pressing the seal and snap-ring together
ensures proper installation depth. Using the seal installation tool prevents pressing the seal too
deeply.
Shaft seal
P106 548E
G0030
G0020
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H1B 060/080/110/160/210/250 Bent Axis Motors
Minor repair
11024924 • Rev 0500 • December 2015 43
110/160/210/250 - Seal installation tool dimensions, 060/080 - Seal installation tool dimensions
P107 738E
180 mm
[7.09 in]
82 mm
[3.15 in]
5 mm
[0.2 in]
45°
5.15 mm
100 mm
[3.94 in]
69 mm
[2.6 in]
58 mm
[2.3 in]
+ 0.10
- 0.0
[0.20 in
+ 0.004
- 0.0
]
150 mm
[5.90 in]
70 mm
[2.76 in]
5 mm
[0.2 in]
45°
5.4 mm
100 mm
[3.94 in]
56 mm
[2.2 in]
48 mm
[1.9 in]
+ 0.10
- 0.0
[0.21 in
+ 0.004
- 0.0
]
Electric proportional solenoid replacement
Removal
1. Disconnect electrical connection and remove three cap screws (B0050) using a 4 mm internal hex
wrench.
2. Remove the solenoid (B0010) and O-ring (B0035A). Discard the O-ring.
3. Remove valve spool (C0100).
Inspection
Clean and inspect valve spool and all machined surfaces for damage or wear. Replace parts if necessary.
Assembly
1. Lubricate and install valve spool (C0100).
2. Using petroleum jelly, lubricate and install new O-ring (B0035A).
3. Install cap screws (B0050) using a 4 mm internal hex wrench. Torque screws to 6 N•m [4 lbf•ft].
Service Manual
H1B 060/080/110/160/210/250 Bent Axis Motors
Minor repair
44 11024924 • Rev 0500 • December 2015
4. Reconnect electrical connections and test the motor for proper operation.
Replacing solenoid
B0010
P106 724E
4 mm
6 N•m [ 4 lbf•ft]
B0050
B0035A
C0100
Hydraulic proportional actuator replacement
Removal
1. Remove three cap screws (B0050) using a 4 mm internal hex wrench.
2. Remove the actuator (B0010).
Inspection
Clean and inspect all machined surfaces for damage or wear. Replace parts if necessary.
Assembly
1. Install cap screws (B0050) using a 4 mm internal hex wrench. Torque screws to 6 N•m [4 lbf•ft].
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Minor repair
11024924 • Rev 0500 • December 2015 45
2. Test the motor for proper operation.
Replacing actuator
P108828
B0050
B0010
Control module replacement
Removal
1. Remove four cap screws (C0110 and/or C0120). Refer to table for wrench sizes.
2. Remove control (C0010) from motor. Remove and discard gasket (C0130).
3. Proportional control only - using a magnet, remove spring seat (F0030) and spring (F0040).
Inspection
Clean and inspect the machined surfaces on the control and the endcap. If you find any nicks or
scratches, replace control or endcap. Inspect valve spool, washer, and spring. Replace if necessary.
Assembly
1. Lubricate and install spring (F0040) and spring seat (F0030) into servo.
2. Install a new gasket (C0130). Position control on motor.
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Minor repair
46 11024924 • Rev 0500 • December 2015
3. Install four cap screws (C0110 and/or C0120). Torque (C0110) to 37 N•m [27 lbf•ft] for proportional
control. Torque (C0110) and (C0120) to 115 Nm [85 lbf•ft] for 2 position control.
Control module removal/installation
C0010
Proportional
control
C0110 (4X)
P106 520E
F0030
F0040
C0130
6 mm
C0110 (2X)
C0010
2 position
control
C0120 (2X)
10 mm
C0130
Electric proportional control
Two position control
10 mm
115 Nm [85 lbf•ft]
37 Nm
[27 lbf•ft]
115 Nm
[85 lbf•ft]
Hydraulic proportional control
C0110 (4X)
6 mm
37 Nm
[27 lbf•ft]
C0010
Proportional
control
F0030
F0040
C0130
C0110 and C0120 Wrench Size
Control Screw Internal
Hex
Wrench
Electric and Hydraulic proportional C0110 6 mm
Two-position C0110
C0120
10 mm
10 mm
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).
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Minor repair
11024924 • Rev 0500 • December 2015 47
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).
Assembly
1. Install orifices (E00T3 and E00T2). Torque to 6 N•m [4 lbf•ft].
2. Lubricate and install new O-rings (C0060A). Using a 1/8 inch internal hex wrench, install and torque
plugs (C0060) to 8 N•m [6 lbf•ft].
3. Lubricate and install spool (C0025) into control block. Using a 5 mm internal hex wrench, torque to 14
N•m [11 lbf•ft]
4. Install new O-ring (C0050A). Using a 1/4 inch internal hex wrench, install and torque plug (C0050) to
40 N•m [30 lbf•ft].
5. Lubricate and install spool (C0100).
6. Lubricate and install new O-ring (B035A).
7. Install solenoid (B0010). Using a 4 mm internal hex wrench. Install screws (B0050). Torque to 6 N•m [4
lbf•ft].
8. Lubricate and install new O-ring (B0025) onto solenoid. Install coil (B0020A). Lubricate and install new
O-ring (B0028) onto solenoid.
9. Install coil nut (B0027) and torque to 3.5 N•m [2.6 lbf•ft] using a 26mm 12-point socket. Do not
overtorque.
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Minor repair
48 11024924 • Rev 0500 • December 2015
10. Install new O-ring (B0029) and plastic cap (B0040) to solenoid.
Proportional control block assembly
B0050
B0010
B0035A
B0010
E00T3
C0060A
C0060
C0060
E00T2
C0025
C0050A
C0060A
C0050
P106 521E
26 mm
1/4 in
1/8 in
1/8 in
C0100
B0027
5 mm
3 mm
3 mm
1/8 in
C0060
C0060A
B0025
B0040
B0029
B0027
B0028
B0020
B0020A
4mm
6 N•m
[4 lbf•ft]
8 N•m
[6 lbf•ft]
40 N•m
[30 lbf•ft]
8 N•m
[6 lbf•ft]
8 N•m
[6 lbf•ft]
3.5 N•m
[2.6 lbf•ft]
8 N•m
[6 lbf•ft]
6 N•m [4 lbf•ft]
6 N•m [4 lbf•ft]
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).
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Minor repair
11024924 • Rev 0500 • December 2015 49
Assembly
1. Install orifices (E00T3 and E00T2). Torque to 6 N•m [4 lbf•ft].
2. Lubricate and install new O-rings (C0060A). Using a 1/8 inch internal hex wrench, install and torque
plugs (C0060) to 8 N•m [6 lbf•ft].
3. Lubricate and install spool (C0025) into control block. Using a 5 mm internal hex wrench, torque to 14
N•m [11 lbf•ft]
4. Install new O-ring (C0050A). Using a 1/4 inch internal hex wrench, install and torque plug (C0050) to
40 N•m [30 lbf•ft].
5. Install actuator (B0010). Using a 4 mm internal hex wrench. Install screws (B0050). Torque to 6 N•m [4
lbf•ft].
P108832
B0050
B0010
C0010
E00T3
C0060A
C0050A
B0060
C0050
1/8 in
C0140
3 mm
1/8 in
C0060
C0060A
40 N•m
[30 lbf•ft]
8 N•m
[6 lbf•ft]
8 N•m
[6 lbf•ft]
6 N•m [4 lbf•ft]
0010
0020
B0180
B0061
0010
0020
E00T2
1/8 in
C0060
8 N•m
[6 lbf•ft]
C0060A
C0070
C0080
C0090A
C0090
C0060A
1/8 in
C0060
8 N•m
[6 lbf•ft]
C0050
40 N•m
[30 lbf•ft]
C0050A
C0050
40 N•m
[30 lbf•ft]
B0190
C0100
C0120
C0110
C0140
C0020
C0060A
1/8 in
C0060
8 N•m
[6 lbf•ft]
C0050A
C0060
C0060A
C0060A
C0060
3 mm
6 N•m [4 lbf•ft]
C0060AC0060
C0060
C0050A
C0050
C0060
C0060A
DHMH
6. If replacing the hydraulic actuator, set the threshold pressure to the proper setting. Refer to Adjusting
threshold on test stand on page 39
Electric two-position control module
Coil O-rings are not included in the overhaul seal kit. They are included with the purchase of a new coil.
Disassembly
1. Use a 26 mm 12-point socket to remove coil nuts (B0026) and O-ring (B0028).
2. Remove coils (B0022) and O-rings (B0024). Discard O-rings.
3. Using a 17 mm open-end wrench on the flats provided, remove solenoid assemblies (B0032).
4. Remove and discard O-rings (B0034).
5. Using a 1/8 inch internal hex wrench, remove four plugs (C0060). Remove and discard O-rings
(C0060A).
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Minor repair
50 11024924 • Rev 0500 • December 2015
6. Using a 1/4 inch internal hex wrench, remove two plugs (C0050). Remove and discard O-rings
(C0050A).
7. Using a 17 mm hex wrench, remove pressure compensator adjusting plug (C0090). Remove and
discard O-ring (M223).
8. Remove springs (C0030) and (C0080). Remove spools (C0020) and (C0070).
9. If necessary, use a 3 mm internal hex wrench to remove orifices (E00T2) and (E00T3).
Inspection
Clean and inspect the machined surfaces on the control and the endcap. If any nicks or scratches are
found, replace the control/endcap assembly.
Assembly
1. If previously removed, install orifices (E00T3 and E00T2) using a 3mm internal hex wrench. Torque to
6 N•m [4 lbf•ft].
2. Lubricate and install spools (C0020) and (C0070) and springs (C0080) and (C0030).
3. Lubricate and install O-ring (M223). Install pressure compensator adjusting plug (C0090). Torque to
40 N•m [30 lbf•ft].
4. Lubricate and install two O-rings (C0050A). Using a 1/4 inch internal hex wrench, install plugs (C0050).
Torque to 25 N•m [19 lbf•ft].
5. Lubricate and install four O-rings (C0060A). Using a 1/8 inch internal hex wrench, install plugs
(C0060). Torque to 8 N•m [6 lbf•ft].
6. Lubricate and install O-rings (B0034).
7. Using a 17 mm open-end wrench on the flats provided, install solenoids (B0032). Torque to 25 N•m
[19 lbf•ft] .
8. Lubricate and install new O-rings (B0024) on solenoids.
9. Install coils (B0022). Lubricate and install new O-rings (B0028).
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Minor repair
11024924 • Rev 0500 • December 2015 51
10. Using a 26 mm 12-point socket, install coil nuts (B0026). Torque to 3.5 N•m [2.6 lbf•ft]. Do not
overtorque.
2 position control assembly
P106 722E
1/8 in
8 N•m [6 lbf•ft]
17 mm
25 N•m [19 lbf•ft]
C0060
C0060A
C0060A
C0060
E00T3
E00T2
C0020
C0030
1/4 in
40 N•m [30 lbf•ft]
C0050
C0050A
1/8 in 8 N•m [6 lbf•ft]
C0060
C0060A
3 mm
6 N•m
[4 lbf•ft]
1/8 in 8 N•m [6 lbf•ft]
C0060
C0070
C0080
C0050
C0050A
17 mm
C0090
M223
1/8 in
8 N•m [6 lbf•ft]
3 mm
6 N•m
[4 lbf•ft]
1/4 in
40 N•m [30 lbf•ft]
25 N•m
[18 lbf•ft]
B0028
B0022
B0024
B0032
B0028
B0022
B0024
B0032
B0034
17 mm
25 N•m [19 lbf•ft]
B0034
B0026
3.5 N•m
[2.6 lbf•ft]
B0026
3.5 N•m
[2.6 lbf•ft]
Hydraulic two-position control module
Disassembly
1. Using a 1/8 inch internal hex wrench, remove plug (C0160). Remove and discard O-ring (C0160A).
2. Using a 1/8 inch internal hex wrench, remove three plugs (C0060). Remove and discard O-rings
(C0060A).
3. Using a 1/4 inch internal hex wrench, remove two plugs (C0050). Remove and discard O-rings
(C0050A).
4. Use a 5mm internal hex wrench to remove the shuttle valve (C0025).
5. Using a 3/8 internal hex wrench, remove plug (C0140). Remove and discard O-ring (C0140A).
6. Remove spring (C0080). Remove spool (C0150).
7. If necessary, use a 3 mm internal hex wrench to remove orifices (E00T2) and (E00T3).
Inspection
Clean and inspect the machined surfaces on the control and the endcap. If any nicks or scratches are
found, replace the control/endcap assembly.
Assembly
1. Lubricate and install spool (C0150) and spring (C0080).
Service Manual
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Minor repair
52 11024924 • Rev 0500 • December 2015
2. Using a 3/8 inch internal hex wrench, install plug (C0140). Torque to 25 N•m [18 lbf•ft].
3. Lubricate and install spool (C0025).
4. Using a 1/4 inch internal hex wrench, install two plugs (C0050). Torque to 40 N•m [30 lbf•ft].
5. Using a 1/8 inch internal hex wrench, install four plugs (C0060). Torque to 8 N•m [6 lbf•ft].
6. Using a 1/8 inch internal hex wrench, install plug (C0160). Torque to 25 N•m [18 lbf•ft].
C0050
C0050
C0060
C0060
C0050
C0060
C0060
C0160
C0160A
C0140
C0050
C0060
C0060
C0050
C0050
C0060
C0060
C0160
C0160A
C0140
P108 576E
C0080
C0150
C0025
C0025
C0150
C0080
1/4 inch
1/4 in
1/8 in
1/8 in
3/8 inch
1/4 in
1/8 in
3/8 inch
HEHE
HFHF
Hydraulic two-position control module with PCOR
Disassembly
1. Using a 1/8 inch internal hex wrench, remove two plugs (C0060). Remove and discard O-rings
(C0060A).
2. Using a 1/4 inch internal hex wrench, remove three plugs (C0050). Remove and discard Orings
(C0050A).
3. Use a 5mm internal hex wrench to remove the shuttle valve (C0025).
4. Using a 22 mm hex wrench, remove adapter (B0300). Remove and discard O-ring (QB0300).
5. Using a 17 mm hex wrench, remove pressure compensator adjusting plug (C0090). Remove and
discard O-ring (M223).
6. Remove spring (C0080). Remove spool (C0070).
7. If necessary, use a 3 mm internal hex wrench to remove orifices (E00T2) and (E00T3).
Inspection
Clean and inspect the machined surfaces on the control and the endcap. If any nicks or scratches are
found, replace the control/endcap assembly.
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Minor repair
11024924 • Rev 0500 • December 2015 53
Assembly
1. If previously removed, install orifices (E00T3 and E00T2) using a 3mm internal hex wrench. Torque to
6 N•m [4 lbf•ft].
2. Lubricate and install spool and (C0070) and spring (C0080).
3. Lubricate and install O-ring (M223). Install pressure compensator adjusting plug (C0090). Torque to
40 N•m [30 lbf•ft].
4. Lubricate and install O-ring (QB0300). Install adapter (B0300). Torque to 67 N•m [49 lbf•ft].
5. Lubricate and install spool (C0025).
6. Using a 1/4 inch internal hex wrench, install three plugs (C0050). Torque to 40 N•m [30 lbf•ft].
7. Using a 1/8 inch internal hex wrench, install two plugs (C0060). Torque to 8 N•m [6 lbf•ft].
Assemble two position control - THHA
C0050
C0060
C0050
C0060
C0070
P108913
C0025
1/4 inch
1/8 in
1/8 in
THHA
C0050
C0080
C0090
M223
B0300
B0310
B0330
B0320
QB300
E00T2
E00T3
Hydraulic two-position control module with PCOR and hydraulic BPD
Disassembly
1. Using a 1/8 inch internal hex wrench, remove three plugs (C0060). Remove and discard O-rings
(C0060A).
2. Using a 1/4 inch internal hex wrench, remove four plugs (C0050). Remove and discard O-rings
(C0050A).
3. Using a 1/4 inch internal hex, remove plug (C0140). Remove spool (C0020).
4. Use a 5mm internal hex wrench to remove the shuttle valve (C0025).
5. Using a 22 mm hex wrench, remove adapter (B0300). Remove and discard O-ring (QB0300).
6. Using a 17 mm hex wrench, remove pressure compensator adjusting plug (C0090). Remove and
discard O-ring (M223).
7. Remove spring (C0080). Remove spool (C0070).
8. If necessary, use a 3 mm internal hex wrench to remove orifices (E00T2) and (E00T3).
Inspection
Clean and inspect the machined surfaces on the control and the endcap. If any nicks or scratches are
found, replace the control/endcap assembly.
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Minor repair
54 11024924 • Rev 0500 • December 2015
Assembly
1. If previously removed, install orifices (E00T3 and E00T2) using a 3mm internal hex wrench. Torque to
6 N•m [4 lbf•ft].
2. Lubricate and install spools and (C0070) and spring (C0080).
3. Lubricate and install O-ring (M223). Install pressure compensator adjusting plug (C0090). Torque to
40 N•m [30 lbf•ft].
4. Lubricate and install O-ring (QB0300). Install adapter (B0300). Torque to 67 N•m [49 lbf•ft].
5. Lubricate and install spool (C0020).
6. Using a 1/4 inch internal hex wrench, install plug (C0140). Torque to 14 N•m [10 lbf•ft].
7. Lubricate and install shuttle (C0025).
8. Using a 1/4 inch internal hex wrench, install four plugs (C0050). Torque to 40 N•m [30 lbf•ft].
9. Using a 1/8 inch internal hex wrench, install three plugs (C0060). Torque to 8 N•m [6 lbf•ft].
Assemble two position control - THHB
C0050
C0060
C0050
P108923
C0025
1/4 inch
C0060
1/8 in
1/8 in
THHB
C0050
C0070
C0080
C0090
M223
B0300
B0310
B0330
B0320
QB300
C0050
C0140
C0020
E00T2
E00T3
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Minor repair
11024924 • Rev 0500 • December 2015 55
Maximum displacement limiter two-position controls
It is not necessary to remove the maximum displacement limiter unless it is being replaced.
Disassembly
Models with maximum displacement limiter: Remove screw (P0100) using a 6 mm internal hex, and
spacer (P0200).
Assembly
Install spacer (P0200) and screw (P0100).
Using a 6 mm internal hex, torque screw to 37 N•m [28 lbf•ft].
Maximum displacement limiter parts
6 mm
P107 866E
P0200
P0100
Servo piston cover – proportional control
Removal
1. Using a 10 mm internal hex wrench, remove four screws (P0020).
2. Remove servo piston cover (P0010).
3. Remove and discard O-ring (P0030).
4. Remove screw (P0050). See table for wrench size.
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56 11024924 • Rev 0500 • December 2015
5. Using expanding pliers, remove piston head (P0040). Remove and discard seal ring (P0044) and O-
ring (P0043).
Servo piston cover and bushing
P106 726E
Servo
piston
head
Expanding
pliers
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Minor repair
11024924 • Rev 0500 • December 2015 57
P0043
P0050
P0030
P0010
P0020
P106 524E
10 mm
115 N•m [85 lbf•ft]
see table
P0040
P0044
P0041
Seal ring
(P0044)
O-ring
(P0043)
Piston
P0050 wrench size and torque
Model Wrench size Torque
060/080 8 mm 66 N•m [49 lbf•ft]
110 10 mm 115 N•m [85 lbf•ft]
160/210/250 12 mm 213 Nm [157 lbf•ft]
Inspection
Clean and inspect bushings and machined surfaces for wear or damage. If wear or damage are found,
replace component in question.
Assembly
1. Lubricate and install new O-ring (P0043) and seal ring (P0044) on piston (P0041).
Allow seals time to relax before installing piston.
2. Install piston and install screw (P0050). Torque screw (P0050) per table.
3. Lubricate and install new O-ring (P0030) and install servo piston cover (P0010).
4. Using a 8 mm or 10 mm internal hex install screws (P0020). Torque to 115 N•m [85 lbf•ft].
Replace speed sensor
Removal
1. Using a 5 mm internal hex wrench, remove screw (J0020).
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58 11024924 • Rev 0500 • December 2015
2. Remove speed sensor (J0010).
3. Discard O-ring (J0010A).
Assembly
1. Lubricate and install new O-ring (J0010A).
2. Install speed sensor (J0010).
3. Using a 5 mm internal hex wrench, install screw (J0020). Torque to 8 N•m [6 lbf•ft].
Speed sensor
J0020
J0010A
J0010
5 mm
8 N•m [6 lbf•ft]
P107 859E
Loop flushing spool
Removal
1. Remove plugs (K0030) using a 24 mm hex wrench.
2. Remove and discard O-rings (K0030A).
3. Use a magnet to remove springs (K0020) and spool (K0010).
Inspection
Clean and inspect spool (K0010). If spool is damaged or worn replace it. Replace springs if they are
cracked or bent.
Reassembly
1. Lubricate and install spool (K0010).
2. Lubricate and install springs (K0020).
3. Lubricate and install new O-rings (K0030A).
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11024924 • Rev 0500 • December 2015 59
4. Using a 24 mm hex wrench, install plugs (K0030). Torque to 67 N•m [49 lbf•ft]
Loop flushing assembly
K0010
K0030
K0030A
K0020
K0030
K0030A
K0020
P106537
67 N•m
[49 lbf•ft]
67 N•m [49 lbf•ft]
24 mm
24 mm
Loop flushing charge relief valve
Removal
1. Using a 24 mm hex wrench remove valve (L00**)
2. Remove and discard O-ring (L0050).
Do not disassemble valve. If you suspect malfunction, replace valve.
Assembly
1. Install new O-ring (L0050).
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60 11024924 • Rev 0500 • December 2015
2. Using a 24 mm hex wrench, install valve (L00**). Torque to 67 N•m [49 lbf•ft].
Loop flushing charge relief valve replacement
P106538
L0050
L00**
67 N•m [49 lbf•ft]
24 mm
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Minor repair
11024924 • Rev 0500 • December 2015 61
Minimum Displacement limiter
Removal
1. Remove cap (N0120).
Removing the cap destroys the caps locking mechanism. Replace with a new cap.
2. While holding the position of the adjustment screw, remove the seal locknut (N0020) using a 19mm
hex wrench. Discard the locknut. After removing the locknut, mark the position of the limiter screw
for reassembly.
3. Using a 6 mm internal hex, remove displacement limiter screw (N0010).
Inspection
Inspect set screw for wear or damage. Replace set screw if necessary.
Assembly
1. Using a 6 mm internal hex wrench, install adjustment screw (N0010) to original position.
2. Using a 6 mm internal hex wrench, to hold the position of the adjustment screw, install a new seal
locknut (N0020) using a 19mm hex wrench. Torque to 45 N•m [32 lbf•ft].
3. Install new cap (N0120).
Displacement limiter assembly
N0020
N0120
N0010
19 mm
6 mm
P106 547E
45 N•m
[32 lb•ft]
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Minor repair
62 11024924 • Rev 0500 • December 2015
Fasteners and plugs
Port, plug and fastener locations
K0030
B0050
G0060
L1
J0020
C0060
C0110 and C0120
P0020
L2
G0060
M5
F0100
System
Port A
L00**
N0010
N0020
P108831
Proportional controls with radial ported endcap
MB
F0150
MA
F0150
XB
System
Port B
M4
F0100
XA
X1
G0050
B0060
B0060
B0060
P108925
X1
XB
XA
K0030
G0060
L1
L2
G0060
M4
F0100
System
Port B
L00**
MA
F0150
MB
F0150
System
Port A
B0060
B0060
M5
F0100
B0060
Two position controls with radial ported endcap
Fastener size and torque chart
Item Fastener Wrench size Torque
B0050 Solenoid screws 4 mm internal hex 6 N•m [4 lbf•ft]
C0110 (proportional) Control assembly screws 6 mm internal hex 37 N•m [28 lbf•ft]
C0110 & C0120
(two-position)
Control assembly screws 10 mm internal hex 115 N•m [85 lbf•ft]
J0020 Speed sensor screw 5 mm internal hex 8 N•m [6 lbf•ft]
N0010 Displacement limiter screw 6 mm internal hex N/A
N0020 Displacement limiter locknut 19 mm 45 N•m [32 lbf•ft]
P0020 Servo piston cover screws 10 mm internal hex 115 N•m [85 lbf•ft]
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Torque chart
11024924 • Rev 0500 • December 2015 63
Plug size and torque chart
Item O-ring plug Wrench size Torque
B0060 9/16 - 18UNF 1/4 internal hex 40 N•m [30 lbf•ft]
C0050 (not shown) 9/16-18 UNF 1/4 internal hex 40 N•m [30 lbf•ft]
C0060 5/16 - 24UNF 3/8 internal hex 8 N•m [5 lbf•ft]
F0100
9/16 - 18UNF 1/4 internal hex 40 N•m [30 lbf•ft]
F0150 (060)
Radial endcap
1-1/16 - 12 UN 9/16 internal hex 95 N•m [70 lbf•ft]
F0150 (080, 110,
160, 250)
Radial endcap
1-1/16 - 12 UN 9/16 internal hex 115 N•m [85 lbf•ft]
G0050 5/16 - 24UNF (SAE and DIN flange) 1/8 internal hex 8 N•m [5 lbf•ft]
G0055
(cartridge model
only) (not shown)
7/16 - 20UNF (Cartridge) 3/16 internal hex 8 N•m [5 lbf•ft]
G0060 (060, 080) 7/8 - 14UN 3/8 internal hex 70 N•m [52 lbf•lb]
G0060 (110, 160) 1-1/16 - 12UN 9/16 internal hex 70 N•m [52 lbf•lb]
G0060 (250) 1-5/16 - 12UN 5/8 internal hex 70 N•m [52 lbf•lb]
K0030 M18 - 1.5 24 mm hex 67 N•m [49 lbf•ft]
L00** M18 - 1.5 24 mm hex 67 N•m [49 lbf•ft]
F0160
Axial endcap
(not shown)
9/16-18 UNF 1/4 internal hex 40 N•m [30 lbf•ft]
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
Torque chart
64 11024924 • Rev 0500 • December 2015
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
11024924 • Rev 0500 • December 2015 65
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
66 11024924 • Rev 0500 • December 2015
Service Manual H1B 060/080/110/160/210/250 Bent Axis Motors
11024924 • Rev 0500 • December 2015 67
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.
11024924 • Rev 0500 • December 2015 www.danfoss.com
©
Danfoss A/S, 2015
Products we offer:
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•
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•
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•
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•
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•
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•
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Software
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