H1 New Hydrostatics: of - The Generation

DESIGNED FOR QUALITY AND RELIABILITY INSTALLATION AND PACKAGING BENEFITS OPTIMIZED FOR ELECTRICAL CONTROL EXPANDED
H1- the new generation

of hydrostatics
EXPANDED FUNCTIONALITY GREATER TOTAL EFFICIENCY DESGINED FOR QUALITY AND RELIABILITY INSTALLATION AND PACKAGING
H1 Experience
Training Objectives
• What is H1?
• Features
• Tear down
• Test stand video
• Details
• Final thoughts
• Wrap up
H1 Is...
• The Next Generation Hydrostatic Transmission
Products from Sauer-Danfoss
– Designed for quality and reliability
– Optimized for electrical control
– Better total efficiency
– Expanded functionality
– Installation and packaging benefits
H1 Is…
• Optimized around electronic control solution
– Quality improved because of limited control variation
– PLUS+1 Compatible
– Sensor Compatibility (Speed, Angle, Pressure, Temp)
• Robust Design Focused on Quality

– Significant reduction in number of parts - 250 DPM
• Typical pump (S90): from 190 to 134
– Optimize around high volumes features / options
• Fewer conversions needed
H1 Is…
• Improved Packaging
– Shorter pumps compliment larger Tier engines
– Utilization of “clean” side for easier installations
• Strategic Product Direction
– Many displacement options to cover medium and high
power applications
• Design Synergies
– Common design across family makes installation,
troubleshooting and application of product easier for
EVERYONE
H1 Is…
• Frames not Families:
– Common design across entire displacement range
• Common assembly and product support
• Common porting & troubleshooting
• Synergies found at all design and user levels
– Standardization of parts:
• Control
• Valves (CPRV, HPRV, PL)
• Aux pads
• Charge pumps
• etc
Singular Concept:
• All H1 single pumps (20-250cm3) will be
of the same layout considering the location
of all ports and valves so long
as proper wrench clearance
can be maintained
Singular Concept: Swashplate Pump
• Displacements (20…
250cc)
• 0-18 Degree Swash
Angle
• 9 piston Block
• Reduced Length
• Reduced Power Losses
• Reduced Noise
H1 Pump
Sectional View
H1 Tandem
43 cm³ and 53 cm³
Features
Features
• Lower cost repair
– Iron cylinder block with no cast-on bronze
– “Thick” bi metal valve plate
• leads to fewer block replacements and serviceable VP
• “Spring” slipper hold down (wave washer or
keel- on High power units)
• Mechanical compressed slipper joint stands up to
moments of low inlet pressure
• One piece swashplate
– No bolted or pressed joints
Features
• Splined Charge Pump Drive
– More robust than key or pin drive
• High strength tandem front flange

– No flange – housing joint
– Designed for high loading without
support
Features
• Bearings
– Swashplate bearing is designed for even load
distribution across all rollers
• Reduces hysterisis
• Longer life
• Reduces brinelling sensitivity to being at one position for
long periods, supported also by stiffer swashplate
– Unitized bearing (medium power) removes roller

contact from swashplate
Bearings
• High Power Bearing Design
– Blind installation
– Connection between housing and swash plate
• Medium Power Bearing Design

– Unitized bearing
• Careful: Do NOT drop
• Discard if it comes apart
Features
• Simplified swashplate Servo Piston
assembly
– Robust design with reduced
part count
– Center loaded servo with
reduced hysterisis
Servo Cylinder
Swashplate
Charge Circuit Improvements
• Pressure Balanced charge pump design

– Improved efficiency
• ‘Flatter’ charge relief valve minimizes pressure

rise with flow and reduces power consumption
• Reduced power to drive charge circuit = More

power to work and propel functions
Pressure Balanced Charge Pump
Tandem Configuration
• Tandem is made up of 3 separate
sections that must be used together.
– Rear Housing
– Center Section
• Contains all valving
– Front Housing
H1 Dimension Comparison
90 P 130 H1 147/165 90 P 180

Screen Orientation
Close up of Screen
• Incorrect screen • Correct screen

orientation orientation
Screen Location
Correct Orientation
Incorrect orientation
PL and 5 bolt control screen locations
Orientation
Neutral Setting
Control Neutral Setting
• Null Servo Differential with adjusting screw

• Adjust neutral screw
like other series
• Getting exactly Zero

Servo delta will be
difficult at best
• 1.5 Bar Servo Delta

allowed in neutral
Mechanical Neutral Setting
• Procedure in Service Manual
Teardown Time
• Repair Manual self learning
Mechanical Neutral Setting
• Video
Optimized for electrical control
Electrical Displacement Control
• The same electrical control is used for all H1
pumps
– ?? 5 Bolt / 6 Bolt ??
Electrical Displacement Control
• Fewer parts
• Reduced hydraulic losses
• Improved Linearity
• Same Proportional Solenoid for

EDC and NFPE (and motors)
• Screen in control supply
H1 EDC vs. Traditional EDC
Traditional EDC
(S90) HyTron Control
135 Parts
50 Parts
Control Mechanism
Manual
Tension spring
Auto
EDC link
Cradle
feedback pin
Feedback link
Seal lock nut Center ring
Eccentric
Control spool
adjustment
H1 Control Cut Off (CCO)– tandem
• CCO solenoid connects control pressure to tank for
both controls simultaneously
– Not charge pressure
• Servo pressure to tank

• Optional brake port controlled by solenoid
– Energized: port pressurized
– De-energized: port tanked
Override Solenoid
H1 Control Cut Off
Control Control
Assembly Assembly
Control
Override
X9 X
Valve
Brake Port
Charge
Supply
H1 Control override (COR)– single pumps
• Destrokes pump with de-energized
solenoid
– Overrides the operator input to the
control
– Does not effect loop charge pressure…
only control
Two position
solenoid for COR
Driving the Control
• 0-1800 mA
• Current Controlled
• PWM Signal
• NOT Direct battery power
Options
Aux Pad Options
• No pad, A, B, C, D pad are • Largest pad in each frame

bolt-on adaptors will be integrated into
depending on frame size endcap
Example: 147/165 Aux Pads
• Largest pad (SAE ‘D’) is • All other pads are modular

integrated into the endcap and “convertible”,
making it endcap specific including no-pad
H1 Integral Filtration Option
• Single pumps with integral
filters and filter bypass sensor
– Full flow, charge pressure filtration
– Bypass
– Filter pre-bypass sensor
– Sensor switch closes prior to filter
bypass
– The integral filter is endcap specific
H1 integral filters
Bypass
Pressure
Start 5,3 bar
End 6,4 bar

Filter Bypass Sensor
Pressure
Start 4 bar
End 6 bar
H1 Pressure limiter (PL)
• Pressure limiter
– H1 single pumps can be equipped with an optional,
integrated pressure limiter
– Separate PL and HPRV
PL & high pressure relief valve (HPRV)
• Adjustable pressure Limiter setting
• Fixed High Pressure Relief Valve setting

– Cartridge style
– Charge check
– Bypass Function
• HPRV‘s need to be set 30-50 bar above PL

setting
PL/HPRV Settings
HPRV‘s will be set 30-50 bar above PL setting by:
Series
Product Type
Frame Size
Rotation
A B
Revision
Description
H1 P 165 R _ _
General Product
D
Control
F
Orifices, Stroke time
E
Displacement Limitation
Control
G
End cap Type
Nomenclature
H
Mounting Flange
J
Input Shaft
Customer
Interfaces
K
Auxiliary Pad
A2 C3 N _ D3 G G2 H2 _
M
Protection Type Side A & B
High Pressure Setting Side A
L 42 L
N
Protection Type Side A & B
System
High Pressure Setting Side B

Protection
42 _ L
S
Charge Pump
M
T
Filtration
V
Charge Relief Pressure Setting

System
Charging
Special Hardware Features

X
Paint & Tag

Special
Features
Hardware
Settings
30 _ NN _NNN_ NNN
Features
Customer
Valves
H1 Schematic
Animation
Charge
Bypass
HPRV
PL
H1 Pump
end cap sectional view
• HPRV + CPRV PL Pressure Limiter
PL
Charge
Bypass
HPRV
H1 HPRV
Charge Check Function
Back to H1
Scematic
Back to H1
Endcap
Sectional
View
H1 HPRV
Bypass Function
Back to H1 Back to H1
• For moving the vehicle short distance Scematic Endcap
Sectional
View
!NOT For TOWING!
Forward Backward
H1 HPRV
Relief Function
Back to H1
Scematic
Back to H1
Endcap
Sectional
View
H1
Pressure Limiter function
• Pressure Limiter
Back to H1
Scematic
Back to H1
Endcap
Sectional
View
Rotation Change
Tandem Rotation Change
Tandem Rotation Change
Single Rotation Change
Single Rotation Change
Final Thoughts
Parts Manual Usage Note
• You Can
Order:
– Endcap w/
Bushing
– Bushing
• You cannot
order:
– Endcap w/out
bushing
H1 is...?
• S90 and S40 direct replacement?
• Revolution in S-D hydraulic pump design?
• The future of S-D?
• The end of S-D?
• Hydraulically controled?
• Focused on 250 DPM?
• Very conversion friendly?
How do I...?
• Change Rotation on Tandem/Single H1?
• Drive the EDC?
• Set PL with respect to the HPRV?
• Set Control Neutral?
• Set Mechanical Neutral?
• Change Filtration options?
• Change Aux Pad options?


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DESIGNED FOR QUALITY AND RELIABILITY INSTALLATION AND PACKAGING BENEFITS OPTIMIZED FOR ELECTRICAL CONTROL EXPANDED

H1- the new generation

• Robust Design Focused on Quality

• High strength tandem front flange

– Unitized bearing (medium power) removes roller

• Medium Power Bearing Design

• Pressure Balanced charge pump design

• ‘Flatter’ charge relief valve minimizes pressure

• Reduced power to drive charge circuit = More

90 P 130 H1 147/165 90 P 180

• Incorrect screen • Correct screen

• Null Servo Differential with adjusting screw

• Getting exactly Zero

• 1.5 Bar Servo Delta

• Reduced hydraulic losses

• Same Proportional Solenoid for

Seal lock nut Center ring

• Servo pressure to tank

• No pad, A, B, C, D pad are • Largest pad in each frame

• Largest pad (SAE ‘D’) is • All other pads are modular

• Fixed High Pressure Relief Valve setting

• HPRV‘s need to be set 30-50 bar above PL

High Pressure Setting Side B

Charge Relief Pressure Setting

Special Hardware Features

Paint & Tag

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