Basic Information H1 Axial Piston Pumps Single And Tandem

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MAKING MODERN LIVING POSSIBLEBasic InformationH1 Axial Piston PumpsSingle and Tandempowersolutions.danfoss.com

Basic InformationH1 Axial Piston Pumps, Single and TandemRevisionsRevision HistoryTable of revisionsDate30 Jul, 2009Nov 2010Nov 2012Apr 2013Aug 2013Oct 2013Page—4-5,14, 32Various13VariousAllChangedFirst edition60/68 added, new back coverFrame 069 added, AC control added, FDC control addedFDC option210/250 addedNew layoutRevAABACACBDAEAFurther available literatureDescriptionOverview, H1 Axial Piston Pumps, Single and TandemBasic Information, H1 Axial Piston Pumps, Single and TandemTechnical InformationH1 Axial Piston Pump, Size 045/053, SingleH1 Axial Piston Pump, Size 045/053, TandemH1 Axial Piston Pump, Size 060/068, SingleH1 Axial Piston Pump, Size 069/078, SingleH1 Axial Piston Pump, Size 089/100, SingleH1 Axial Piston Pump, Size 115/130, SingleH1 Axial Piston Pump, Size 147/165, SingleH1 Axial Piston Pump, Size 210/250, SingleH1 Automotive Control for Single Axial Piston Pumps 045 - 130 ccComplementary ProductsExternal Remote Charge Pressure FilterSpeed and Temperature SensorPressure SensorHydraulic Fluids, Technical InformationHydraulic Fluids and LubricantsExperience with Biodegradable Hydraulic FluidsDesign Guideline for Hydraulic Fluid CleanlinessApplication InformationApplications Manual, Section 1, Selection of Driveline ComponentsApplications Manual, Section 2, Pressure and Speed Limits for Hydraulic UnitsApplications Manual, Section 4, Transmission Circuit RecommendationsPLUS 1 COMPLIANT (Electrical Installation)H1 Electrical Displacement Control (EDC)H1 3-position (FNR) Electric ControlH1 Non-Feedback Proportional Electric (NFPE) ControlService ManualsH1 Axial Piston Pump, Size 045/053, SingleH1 Axial Piston Pump, Size 045/053, TandemH1 Axial Piston Pump, Size 069/078/089/100/115/130/147/165210/250, SingleDanfoss order 0L0928520L0848T000 143EFront cover illustration: F301350211062168 Rev EA Oct 2013

Basic InformationH1 Axial Piston Pumps, Single and TandemContentsDanfoss HydrostaticProduct FamilyGeneral Description. 4General Description H1 Family of Hydrostatic Pumps. 4H1 General InformationA Word about the Organization of this Manual. 5Pressure Limiter Valves . 6High Pressure Relief Valve (HPRV) and Charge Check. 6Bypass Function. 7Charge Pressure Relief Valve (CPRV) . 8Electrical Displacement Control (EDC). 9Automotive Control (AC) . 10Automotive Control Connection Diagram . 11Forward-Neutral-Reverse (FNR) Electric Control. 12Non Feedback Proportional Electric Control (NFPE). 12Fan Drive Control (FDC) Options F1 (12 V) / F2 (24 V). 13Manual Over Ride (MOR). 14Displacement Limiter. 15Life Time. 15Speed and Temperature Sensor. 16OperationOperating ParametersOverview. 19Input Speed. 19System Pressure. 19Servo Pressure. 20Charge Pressure. 20Charge Pump Inlet Pressure. 20Case Pressure. 21External Shaft Seal Pressure. 21Temperature and Viscosity. 21System Design ParametersFiltration System .22Filtration.23Fluid Selection. 27Reservoir. 27Case Drain. 27Charge Pump. 28Bearing Loads & Life . 28Mounting Flange Loads.30Shaft Torque. 31Shaft Availability and Torque Ratings. 31Understanding and Minimizing System Noise. 32Sizing Equations. 3311062168 Rev EA Oct 20133

Basic InformationH1 Axial Piston Pumps, Single and TandemDanfoss Hydrostatic ProductFamilyGeneral DescriptionThe H1 axial piston variable displacement pumps are of cradle swashplate design and are intendedfor closed circuit applications.The flow rate is proportional to the pump input speed and displacement.The latter is infinitely adjustable between zero and maximum displacement.Flow direction is reversed by tilting the swashplate to the opposite side of the neutral (zerodisplacement) position.yy 14 different displacements:yyyyyyyyyyyy45.0 cm360.4 cm369.0 cm389.2 cm3115.8 cm³147.0 cm³211.5 cm³[2.75 in3][3.69 in3][4.22 in3][5.44 in3][7.07 in³][8.97 in³][12.91 in³]53.8 cm368.0 cm378.0 cm3101.7 cm3130.8 cm³165.0 cm³251.7 cm³[3.28 in3][4.15 in3][4.76 in3][6.21 in3][7.98 in³][10.07 in³][15.36 in³]Electric displacement control (EDC)Forward-Neutral-Reverse (FNR)Non Feedback Proportional Electric (NFPE)Fan Frive Control (FDC)Improved reliability and performanceMore compact and lightweightGeneral DescriptionH1 Family ofHydrostatic PumpsThe H1 family of closed circuit variable displacement axial piston pumps is designed for use with allexisting Danfoss hydraulic motors for the control and transfer of hydraulic power. H1 pumps arecompact and high power density where all units utilize an integral electro-hydraulic servo pistonassembly that controls the rate (speed) and direction of the hydraulic flow. H1 pumps are specificallycompatible with theDanfoss family of PLUS 1 microcontrollers for easy Plug-and-Perform installation.H1 pumps can be used together in combination with other Danfoss pumps and motors in the overallhydraulic system. Danfoss hydrostatic products are designed with many different displacement,pressure and load-life capabilities.Go to the Danfoss website or applicable product catalog to choose the components that are right foryour complete closed circuit hydraulic system.411062168 Rev EA Oct 2013

Basic InformationH1 Axial Piston Pumps, Single and TandemH1 General InformationA Word about theOrganization of this ManualGeneral information covering all displacements of the H1 range is given in the beginning of thismanual. This includes definitions of operating parameters and system design considerations. Sectionslater in this book detail the specific operating limitations for each frame and give a full breakdown ofavailable displacements, features and options.The table below shows the available range of H1 pumps as of this printing, with their respectivespeed, pressure, theoretical flow ratings, and mounting flange.Technical ³]min-1 (rpm)Size 045/053 Single PumpsH1P04545.0[2.75]3400 3500H1P05353.8 [3.28]Size 045/053 Tandem PumpsH1P04545.0[2.75]3400 3500H1P05353.8 [3.28]Size 060/068 Single PumpsH1P06060.4 [3.69]3500 4000H1P06868.0[4.15]Size 069/078 Single PumpsH1P06969.2[4.22]3500 4000H1P07878.1[4.77]Size 089/100 Single PumpsH1P08989.2 [5.44]3300 3800H1P100101.7 [6.21]Size 115/130 Single PumpsH1P115115.2 [7.03]3200 3400H1P130130.0 [7.93]Size 147/165 Single PumpsH1P147147.2 [8.98]3000 3100H1P165165.1 [10.08]Size 210/250 Single PumpsH1P210211.5 [12.91]2600 2800H1P250 251.7 [15.36]PressureWeight dry(W/O PTOControl OptionsMax working Max pressureand Filter)pressure*bar[psi]bar[psi]kg [lb]Technical Information, Danfoss Order Number 11063344L1223856420 [6090] 450 [6525]EDC, FNR, NFPE,AC41 [90]AC, FDC380[5510]400 [5800]Technical Information, Danfoss Order Number 11063345420 [6090] 450 [6525]65 [143]EDC, FNR, NFPE380[5510]400 [5800]Technical Information, Danfoss Order Number11071685L1223856420 [6090] 450 [6525]EDC,FNR50 [110]ACNFPE, AC, FDC380[5510]400 [5800]Technical Information, Danfoss Order Number 11062169L1223856450[6525]480[6960]56 [123]EDC, FNR, NFPE,AC, FDCTechnical Information, Danfoss Order Number 11069970450[6525]480[6960]62 [137][6525]480[6960]83 [187]450[6525]480[6960]96 [211]ACEDC, FDCB2-bolt flangeB2-bolt flangeC4-bolt flangeC4-bolt flangeC4-bolt flangeL1223856EDC, FNR, NFPE,AC, FDCTechnical Information, Danfoss Order Number 11063347SAEL1223856EDC, FNR, NFPE,AC, FDCTechnical Information, Danfoss Order Number 11063346450ACMountingFlangeACD4-bolt flange-D4-bolt flange-E4-bolt flange-Technical Information, Danfoss Order Number L1208737450[6525]480[6960]163 [360]* Applied pressures above maximum working pressure requires Danfoss application approval.11062168 Rev EA Oct 2013EDCT301 060E5

Basic InformationH1 Axial Piston Pumps, Single and TandemOperationPressure Limiter ValvesPressure limiter valves provide system pressure protection by compensating the pump swashplateposition when the set pressure of the valve is reached. A pressure limiter is a non-dissipative (nonheat generating) pressure regulating system.Each side of the transmission loop has a dedicated pressure limiter valve that is set independently. Apump configured with pressure limiter must have pressure limiters on both sides of the systempressure loop. The pump order code allows for different pressure settings to be used at each systemport.The pressure limiter setting is the differential pressure between the high and low loops. When thepressure limiter setting is reached, the valve ports oil to the low-pressure side of the servo piston. Thechange in servo differential pressure rapidly reduces pump displacement. Fluid flow from the valvecontinues until the resulting drop in pump displacement causes system pressure to fall below thepressure limiter setting.An active pressure limiter destrokes a pump to near neutral when the load is in a stalled condition.The pump swashplate moves in either direction necessary to regulate the system pressure, includinginto stroke (overrunning) or over-center (winch payout).The pressure limiter is optional for H1 single pumps and not available for tandem pumps.High Pressure ReliefValve (HPRV)and Charge CheckAll H1 pumps are equipped with a combination high pressure relief and charge check valve. Thehigh-pressure relief function is a dissipative (with heat generation) pressure control valve for thepurpose of limiting excessive system pressures. The charge check function acts to replenish thelow-pressure side of the working loop with charge oil. Each side of the transmission loop has adedicated HPRV valve that is non-adjustable with a factory set pressure. When system pressureexceeds the factory setting of the valve, oil is passed from the high pressure system loop, into thecharge gallery, and into the low pressure system loop via the charge check.The pump order code allows for different pressure settings to be used at each system port. When aHPRV valve is used in conjunction with a pressure limiter, the HPRV valve is always factory set abovethe setting of the pressure limiter. The system pressure order code for pumps with only HPRV is areflection of the HPRV setting.The system pressure order code for pumps configured with pressure limiter and HPRV is a reflectionof the pressure limiter setting.HPRV s are factory set at a low flow condition. Any application or operating condition which leads toelevated HPRV flow will cause a pressure rise with flow above a valve setting. Consult factory forapplication review. Excessive operation of the HPRV will generate heat in the closed loop and maycause damage to the internal components of the pump.611062168 Rev EA Oct 2013

Basic InformationH1 Axial Piston Pumps, Single and TandemOperationThe single pump HPRV valve also provides a loop bypass function when each of the two HPRV hexplugs are mechanically backed out 3 full turns. Engaging the bypass function mechanically connectsboth A & B sides of the working loop to the common charge gallery. The bypass function allows amachine or load to be moved without rotating the pump shaft or prime move.Bypass function not available for tandem pumps.C CautionExcessive speeds and extended load/vehicle movement must be avoided. The load or vehicle shouldbe moved not more than 20 % of maximum speed and for a duration not exceeding 3 minutes.Damage to drive motor(s) is possible. When the bypass function is no longer needed care should betaken to reseat the HPRV hex plugs to the normal operating position.System schematic, single pumpM14M6 12R1R2Bypass FunctionC2C1M3 L2MAAF00B F00AHigh pressure relief valve,charge check valveand bypass functionPressure limitervalveM4CWBM5SMBL4P003 418ESystem schematic, tandem pumpM14C1M14C1C2MBX7M3C2MCL3F00BF00BF00AM5High pressure relief valve,charge check valveM4CWPTOM5M4MA A11062168 Rev EA Oct 2013F00ABE C D MDP003 207E7

Basic InformationH1 Axial Piston Pumps, Single and TandemOperationCharge Pressure Relief Valve(CPRV)The charge pressure relief valve maintains charge pressure at a designated level above case pressure.The charge pressure relief valve is a direct acting poppet valve which opens and discharges fluid tothe pump case when pressure exceeds a designated level. This level is nominally set with the pumprunning at 1800 rpm. For external charge flow the CPRV is set according to below table. In forward orreverse, charge pressure will be slightly lower than when in neutral position. The charge pressurerelief valve setting is specified on the model code of the pump.Typical charge pressure increase from 1.2 - 1.5 bar per 10 l/min [17.4 - 21.8 psiper 2.64 US gal/min].Charge pressure relief valve setting for external charge supplyFlowSingle 045/053Tandem 045/053Single 060/068/069/078/089/100/115/130/147/165Single 210/25015 l/min30 l/min22.7 l/min40.0 l/min3.9 [US gal/min]7.9 [US gal/min]6.0 [US gal/min]10.6 [US gal/min]T000 157ESystem schematic, single pumpM14M6 12R2R1C2C1M3 L2MAAF00B F00ACharge pressurerelief valveM4CWBM5SL4MBP003 418ESystem schematic, tandem pumpM14C1M14Charge pressurerelief valveC2MBX7M3C1C2MCL3F00BF00BF00AM5CWPTOMA A11062168 Rev EA Oct 2013M4M5M48F00ABE C D MDP003 207E

Basic InformationH1 Axial Piston Pumps, Single and TandemOperationElectrical DisplacementControl (EDC)EDC PrincipleAn EDC is a displacement (flow) control. Pump swashplate position is proportional to the input commandand therefore vehicle or load speed (excluding influence of efficiency), is dependent only on the primemover speed or motor displacement.The Electrical Displacement Control (EDC) consists of a pair of proportional solenoids on each side of athree-position, four-way porting spool. The proportional solenoid applies a force input to the spool, whichports hydraulic pressure to either side of a double acting servo piston. Differential pressure across theservo piston rotates the swashplate, changing the pump‘s displacement from full displacement in onedirection to full displacement in the opposite direction. Under some circumstances, such as contamination,the control spool could stick and cause the pump to stay at some displacement.EDC-Schematic diagramM14C1C2F00BF00AFeedback fromSwash plateTPP003 478EP003 191A serviceable 125 µm screen is located in the supply line immediately before the control porting spool.EDC OperationH1 EDC’s are current driven controls requiring a Pulse Width Modulated (PWM) signal. Pulse widthmodulation allows more precise control of current to the solenoids. The PWM signal causes the solenoidpin to push against the porting spool, which pressurizes one end of the servo piston, while draining theother. Pressure differential across the servo piston moves the swashplate.A swashplate feedback link, opposing control links, and a linear spring provide swashplate position forcefeedback to the solenoid. The control system reaches equilibrium when the position of the swashplatespring feedback force exactly balances the input command solenoid force from the operator. As hydraulicpressures in the operating loop change with load, the control assembly and servo/swashplate system workconstantly to maintain the commanded position of the swashplate.The EDC incorporates a positive neutral deadband as a result of the control spool porting, preloads fromthe servo piston assembly, and the linear control spring. Once the neutral threshold current is reached, theswashplate is positioned directly proportional to the control current. To minimize the effect of the controlneutral deadband, we recommend the transmission controller or operator input device incorporate a jumpup current to offset a portion of the neutral deadband.The neutral position of the control spool does provide a positive preload pressure to each end of the servopiston assembly.When the control input signal is either lost or removed, or if there is a loss of charge pressure, the springloaded servo piston will automatically return the pump to the neutral position.11062168 Rev EA Oct 20139

Basic InformationH1 Axial Piston Pumps, Single and TandemOperationAutomotive Control (AC)C1C2F00BF00ATPP301 236A serviceable 125 µm screen is located in thesupply line immediately before the controlporting spool.1011062168 Rev EA Oct 2013WARRANTY VOID IF REMOVEDAutomotive Control (AC) schematicCC2Under some circumstances, such ascontamination, the control spool could stick andcause the pump to stay at some displacement.CC3CAN PPC PSC PPUThe pump displacement is proportional to thesolenoid signal current, but it also depends uponpump input speed and system pressure. Thischaracteristic also provides a power limitingfunction by reducing the pump swash plateangle as system pressure increases. A typicalresponse characteristic is shown in theaccompanying graph.CC1The AC-1 and AC-2 propel transmission systemconsists of an H1 variable pump, embeddedelectronic controller, and service toolconfigurable PLUS 1 software that allows thecustomer to completely optimize vehicleperformance. The embedded electroniccontroller provides an electric input signalactivating one of two solenoids that port chargepressure to either side of the pump servocylinder. The AC has no mechanical feedbackmechanism but AC-2 is available with anelectronic feedback signal for the swash plateposition.P003 544

Basic InformationH1 Axial Piston Pumps, Single and TandemOperationAutomotive ControlConnection DiagramCC1DEUTSCH connectorDTM/12 pinBattery (-)Battery ( )Sensor ( )Sensor (-)Motor RPM Input (Frequency)Forward Input (Digital)Reverse Input (Digital)Sensor ( )Sensor (-)Drive Pedal Input (Analog-Nom)Drive Pedal Input (Analog-Red)Neutral Input (Digital)CANCC1p02Motor .Hand e/Creep/Joystick/Rocker PedalCC1p10CC1p11TerminalsSensor ( )RvCC1p09TerminalsSensor (-)123CANp01CAN BusCANp02CANp03TerminalsBatt. ( NR Output-SignalCC3DEUTSCH connectorDTM/6 pinPWM C1 ( )PWM C2 ( )Digital Output A1 ( )Digital Output A2 (-)PWM C2 (-)PWM C1 (-)CC1p03CC1p04DEUTSCH connectorDTM/6 pinSensor A ( )Analog Input ASensor A (-)Sensor B (-)Analog Input BSensor B ( )PSCCC1p01CC1p03DEUTSCH connectorDTM/3 pinCAN HighCAN LowCAN ShieldPPC123456789101112DEUTSCH connectorDT/2 ronic DisplacementControl PumpPPUp03PPUSensor ( )Pump RPM Input (Frequency)Sensor inalsBatt. (-)Pump RPMPPUp02DEUTSCH connectorDTM/3 pinElectronic DisplacementControl MotorCC2p08DEUTSCH connectorDTM/12 pinBPDCC2p04Inch Input (Analog-Red)Mode Switch B Input (Digital-Nom)Motor PROP/PCOR Output (PWM)Motor Direction Input (Analog)Sensor ( )Sensor (-)Inch Input (Analog-Nom)Motor BPD Output (Digital)Digital Output B2 (-)Digital Output B1 ( )Mode Switch A Input (Digital)Mode Switch B Input (Digital-Red)123456789101112CC2p01Contact capability min. 10A2Melting fuse 16A3Functional optionsMode Switch ch PedalCC2p07 Batt. 12/24V DCRvAlternative BrakePressure Inch ngBrakeFNR inReverseBrakeLightFNR 68 Rev EA Oct 2013Mode Switch AP003 536E11

Basic InformationH1 Axial Piston Pumps, Single and TandemOperationForward-Neutral-Reverse(FNR) Electric ControlThe 3-Position (F-N-R) control uses an electricinput signal to switch the pump to a full strokeposition.Under some circumstances, such ascontamination, the control spool could stick andcause the pump to stay at some displacement.3-Position electric control, hydraulic schematicM14C1C2F00BF00ATPP003 189A serviceable 125 µm screen is located in thesupply line immediately before the controlporting spool.Non Feedback ProportionalElectric Control (NFPE)P003 193The Non Feedback Proportional Electric (NFPE) control is an electrical automotive control in which anelectrical input signal activates one of two proportional solenoids that port charge pressure to eitherside of the pump servo cylinder. The NFPE control has no mechanical feedback mechanism.The pump displacement is proportional to the solenoid signal current, but it also depends uponpump input speed and system pressure. Thischaracteristic also provides a power limitingfunction by reducing the pump swashplateangle as system pressure increases.Under some circumstances, such ascontamination, the control spool could stickand cause the pump to stay at somedisplacement.NFPE SchematicM14C1C2F00BF00ATPP003 188A serviceable 125 µm screen is located in thesupply line immediately before the controlporting spool.1211062168 Rev EA Oct 2013P003 192

Basic InformationH1 Axial Piston Pumps, Single and TandemOperationThe Fan Drive Control (FDC) is a non-feedback control in which an electrical input signal activates theproportional solenoid that ports charge pressure to either side of the pump servo cylinder. The singleproportional solenoid is used to control pump displacement in the forward or reverse direction. Thecontrol spool is spring biased to produce maximum forward pump displacement in the absence of anelectrrical input signal. Based on the spring bias spool default forward flow for a CW rotation pump isout of Port B while default forward flow for a CCW rotation pump is out of Port A.The pump displacement is proportional to thesolenoid signal current, but it also depends uponpump input speed and system pressure. Thischaracterisistic also provides a power limitingfunction by reducing the pump swashplate angleas system pressure increases. The pump should beconfigured with 0.8 mm control orifices to provideslowest respponse and maximize system stability.Additionally pressure limiter (PL) valves are used tolimit maximum fan trim speed in both forward andreverse directions.Under some circumstances, such as contamination,the control spool could stick and cause the pumpto stay at some displacement.P301 441FDC-Schematic diagramM14C1C2TF00BF00APP301 442Pump displacement vs. control currentForward100%H1 FDC control p030ar0b prbaDisplacementFan Drive Control (FDC)OptionsF1 (12 V) / F2 (24 V)aNbMax Current p 0rba100%0Reversea Forward Thresholdb Reverse ThresholdN Neutral Override CurrentSignal Current (mA(DCAvg))P301 44311062168 Rev EA Oct 201313

Basic InformationH1 Axial Piston Pumps, Single and TandemOperationManual Over Ride (MOR)All controls are available with a Manual Over Ride (MOR) either standard or as an option fortemporary actuation of the control to aid in diagnostics.Forward-Neutral-Reverse (FNR) and Non Feedback Proportional Electric (NFPE) controls are alwayssupplied with MOR functionality.Unintended MOR operation will cause the pump to go into stroke. The vehicle or device must alwaysbe in a safe condition (i.e. vehicle lifted off the ground) when using the MOR function. The MORplunger has a 4 mm diameter and must be manually depressed to be engaged. Depressing theplunger mechanically moves the control spool which allows the pump to go on stroke. The MORshould be engaged anticipating a full stroke response from the pump. WarningAn o-ring seal is used to seal the MOR plunger where initial actuation of the function will require aforce of 45 N to engage the plunger. Additional actuations typically require less force to engage theMOR plunger. Proportional control of the pump using the MOR should not be expected.Refer to the control flow table in the size specific technical information for the relationship ofsolenoid to direction of flow.P003 204MOR-Schematic diagram (EDC shown)M14C1C2F00BF00AFeedback fromSwash plate1411062168 Rev EA Oct 2013TPP003 205E

Basic InformationH1 Axial Piston Pumps, Single and TandemOperationDisplacement LimiterAll H1 pumps are designed with optional mechanical displacement (stroke) limitersfactory set to max. displacement.The maximum displacement of the pump can be set independently for forward and reverse using thetwo adjustment screws to mechanically limit the travel of the servo piston down to 50 %displacement. Adjustment procedures are found in the H1 Service Manual. Adjustments underoper

Applications Manual, Section 1, Selection of Driveline Components BLN-9885 Applications Manual, Section 2, Pressure and Speed Limits for Hydraulic Units BLN-9884 . Service Manuals H1 Axial Piston Pump, Size 045/053, Single 520L0958 H1 Axial Piston Pump, Size 045/053, Tandem 520L0928 . Danfoss

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