Manitou HYDROSTATIC MOTOR H1 060-080-110-160-250 Lift Truck Repair Manual 647069 - PDF DOWNLOAD

647069EN (30/08/2018)

HYDROSTATIC MOTOR H1 060/080/110/160/250

REPAIR MANUAL

647069EN

2

DATE OF ISSUE

OBSERVATION

01 / 07 / 2009

- 1st ISSUE

14 / 05 / 2014

- UPDATE

30 / 08 / 2018

- UPDATE

MANITOU BF S.A Limited liability company with a Board of Directors.

Head office: 430, Rue de l’Aubinière - 44150 Ancenis - FRANCE Share capital: 39,548,949 euros 857 802 508 RCS Nantes Tel: +33 (0)2 40 09 10 11 www.manitou.com This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other, in part or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document organization that are found in this document, are the intellectual property of MANITOU BF. Any violation of the aforementioned may lead to civil and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU-BF and may not be used without express and formal authorization. All rights are reserved.

Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Contents Introduction

Disassembly

Inspection

Assembly

© Danfoss | April 2018

About this manual............................................................................................................................................................................5 General Instructions........................................................................................................................................................................ 5 Safety precautions............................................................................................................................................................................6 Symbols used in Danfoss literature............................................................................................................................................7 Proportional controls disassembly.............................................................................................................................................8 Two-position controls disassembly........................................................................................................................................... 9 Disassembly of controls with PCOR.........................................................................................................................................10 Electric proportional controls M1CA/M2CA and L1BA/L2BA.........................................................................................11 Electric proportional controls D1MA/D2MA and K1KA/K2KA....................................................................................... 12 Two-position controls T*D* and P*D*.................................................................................................................................... 14 Two-position controls T*G* and P*G*.................................................................................................................................... 15 Two-position control E*AA.........................................................................................................................................................16 Two-position controls HEHE and HFHF..................................................................................................................................17 Two-position control THHA........................................................................................................................................................18 Two-position control THHB........................................................................................................................................................19 Two-position control DHMA...................................................................................................................................................... 20 Two-position control DHMH......................................................................................................................................................21 Two-position control KHKA........................................................................................................................................................22 Two-position control KHKH........................................................................................................................................................23 Two-position controls MHCA and LHBA................................................................................................................................24 Minimum displacement limiter................................................................................................................................................ 25 Maximum displacement limiter—two-position control..................................................................................................25 Speed Sensor................................................................................................................................................................................... 26 Servo piston cover—proportional controls......................................................................................................................... 27 Loop flushing spool and charge relief valve........................................................................................................................ 28 End-cap and servo piston—proportional control..............................................................................................................29 End cap and servo piston—two-position controls............................................................................................................31 Cylinder block and sync Shaft assembly................................................................................................................................32 Shaft assembly................................................................................................................................................................................ 33 Overview........................................................................................................................................................................................... 34 Shaft assembly................................................................................................................................................................................ 34 Pistons and piston rings inspection........................................................................................................................................ 34 Synchronizing shaft.......................................................................................................................................................................35 Cylinder block..................................................................................................................................................................................35 Bearing plate....................................................................................................................................................................................35 Valve segment.................................................................................................................................................................................36 Endcap............................................................................................................................................................................................... 36 Housing ............................................................................................................................................................................................ 37 Control shuttle valve.....................................................................................................................................................................37 Optional Minimum displacement limiter..............................................................................................................................37 Servo piston..................................................................................................................................................................................... 38 Control............................................................................................................................................................................................... 38 Overview........................................................................................................................................................................................... 39 Piston ring.........................................................................................................................................................................................39 Shaft in housing..............................................................................................................................................................................40 Synchronizing shaft.......................................................................................................................................................................41 Pistons and cylinder block.......................................................................................................................................................... 42 Bearing plate....................................................................................................................................................................................43 Servo piston and valve segment—proportional control................................................................................................ 44 Servo piston and valve segment—two position control................................................................................................ 46 End-cap assembly.......................................................................................................................................................................... 47 Loop flushing charge relief valve and spool........................................................................................................................ 48 Shaft seal........................................................................................................................................................................................... 49 Servo cover—proportional control......................................................................................................................................... 50 11020692 | AX00000153en-US0701 | 3

Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Contents Speed sensor................................................................................................................................................................................... 51 Minimum displacement limiter................................................................................................................................................ 52 Maximum displacement limiter—two-position control..................................................................................................53 Electric proportional controls M1CA/M2CA and L1BA/L2BA.........................................................................................54 Electric proportional controls D1M1/D2M2 and K1K1/K2K2......................................................................................... 56 Two-position controls T*D* and P*D*.................................................................................................................................... 58 Two-position controls T*G* and P*G*.................................................................................................................................... 59 Two-position control E*AA.........................................................................................................................................................60 Two-position controls HEHE and HFHF..................................................................................................................................61 Two-position control THHA........................................................................................................................................................62 Two-position control THHB........................................................................................................................................................63 Two-position control DHMA...................................................................................................................................................... 64 Two-position control DHMH......................................................................................................................................................65 Two-position control KHKA........................................................................................................................................................66 Two-position control KHKH........................................................................................................................................................67 Two-position controls MHCA and LHBA................................................................................................................................68 Proportional controls installation............................................................................................................................................ 69 Two-position controls installation........................................................................................................................................... 70 Controls with PCOR installation................................................................................................................................................71 Start-up Procedures

Port locations Torque chart

4 | © Danfoss | April 2018

Overview........................................................................................................................................................................................... 72 Initial startup procedures............................................................................................................................................................72 Adjustments.....................................................................................................................................................................................72 Pressure measurements.............................................................................................................................................................. 72 Ports and Gauge Information.................................................................................................................................................... 73 Fasteners and plugs...................................................................................................................................................................... 75 Fastener size and torque chart..................................................................................................................................................76 Plug size and torque chart..........................................................................................................................................................76

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Introduction About this manual This manual details the major repair procedures for H1 bent axis motors. These include the complete disassembly, inspection, and reassembly of the unit. Where rework of worn or damaged components is possible, specifications appear to ensure these parts meet factory tolerances.

Only Danfoss global service partners (GSPs) are authorized to perform major repairs.Danfoss trains Global Service Partners and certifies their facilities on a regular basis. You can locate your nearest service partner at www.danfoss.com > Contact us > Danfoss sales and services > Distributor and service partners

W

Warning

Use of components that do not comply with rework specifications may result in loss of performance, which may constitute a safety hazard. Do not reuse components that don’t comply to given specifications: replace with genuine Danfoss service parts.

Minor repair procedures, adjustments, and troubleshooting information appear in the H1 Bent Axis Variable Displacement Motors Service Manual, AX00000025. Minor repairs include service operations you can perform without removing the unit’s end-cap. Removal of the end-cap voids your warranty.

Operating parameters and product specifications are given in the H1 Bent Axis Variable Displacement Motors Technical Information,BC00000043.

General Instructions When repairing H1 variable displacement closed circuit motors follow these general procedures: 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.

Lubricate moving parts

During assembly, coat all moving parts with a film of clean hydraulic oil. This assures that these parts are lubricated during start-up.

Replace all O-rings Danfoss recommends you replace all O-rings and gaskets during repair. Lightly and gaskets lubricate O-rings with clean petroleum jelly prior to assembly.

Secure the unit

© Danfoss | April 2018

For repair, place the unit in a stable position with the shaft pointing downward.

Secure the motor while removing and torquing components and fasteners.

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Introduction 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.

6 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Introduction 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.

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Proportional controls disassembly Electric (left) and hydraulic (right) proportional controls disassembly C0110 (4X) 6 mm

C0010 Proportional control F0030

C0110 (4X) 6 mm

37 Nm [27 lbf•ft] C0010 F0030

F0040 F0040

C0130

Electric proportional control

C0130

Hydraulic proportional control

P108841

Proportional end cap can be rotated 180°. This allows for the de-energized position of the motor to be at either maximum or minimum displacement..

1. Remove screws (C0110) using a 6 mm internal hex wrench.

2. Remove control housing (C0010).

3. Remove gasket (C0130) and discard.

4. Remove spring guide (F0030) and spring (F0040).

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Two-position controls disassembly Electric and hydraulic two-position controls with or without PCOR disassembly 6 mm C0120 (2X)

C0110 (2X)

37 Nm [27 lbf•ft]

C0010

C0120 (2X) 10 mm C0110 (2X) 10 mm C0010 2 position control

C0130 C0130

Hydraulic two position control with and without PCOR

Electric two position control with and without PCOR

P108842

1. Remove screws (C0110 and C0120) using a 10 mm internal hex wrench.

2. Remove control housing (C0010).

3. Remove gasket (C0130) and discard.

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Disassembly of controls with PCOR Hydraulic (left) and electric (right) proportional controls with PCOR

C0130 C0130

F0040

F0040

F0030

F0030

C0010 C0010

6 mm 37 Nm [27 lbf•ft] C0120 (2X)

6 mm C0110 (2X)

6 mm

C0120 (2X)

37 Nm [27 lbf•ft]

Hydraulic proportional control with PCOR

C0110 (2X)

37 Nm [27 lbf•ft]

P108843

Electric proportional control with PCOR

1. Remove screws (C0110 and C0120) using a 10 mm internal hex wrench.

2. Remove spring guide (F0030) and spring (F0040).

3. Remove control housing (C0010).

4. Remove gasket (C0130) and discard.

10 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Electric proportional controls M1CA/M2CA and L1BA/L2BA Disassembly of controls M1CA/M2CA and L1BA/L2BA B0040

B0027 26mm

B0029

B0028 B0020

B0050 4 mm (3X)

1/8 in C0060

1/4 in C0050

B0025

B0010

B0035A C0060A

C0050A

E00T2 3 mm

C0025 5 mm

C0100

B0010

C0060A

C0060 1/8 in

M1CA/M2CA and L1BA/L2BA

3 mm E00T3 C0060A C0060 1/8 in

The coil does not need to be removed unless it is being replaced.

Coil O-rings and Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of new coil and plug.

1. If replacing the coil, remove the plastic cap (B0040).

2. Remove the coil nut (B0027) using a 26 mm 12-point socket.

3. Remove the coil and discard the O-rings (B0025, B0028, B0029).

4. Remove three screws (B0050) using a 4 mm internal hex wrench.

5. Remove solenoid (B0010).

6. Remove and discard O-ring (B0035A).

7. Remove control spool (C0100).

8. Using a 1/8 inch internal hex wrench, remove plugs (C0060).

9. Remove orifices (E00T2 and E00T3) using a 3 mm internal hex wrench.

10. Tag the orifices for reassembly.

11. Using a 1/4 inch internal hex wrench, remove plugs (C0050).

12. Remove and discard O-ring (C0050A).

13. Remove shuttle valve assembly (C0025) using a 5 mm internal hex wrench. © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Electric proportional controls D1MA/D2MA and K1KA/K2KA Disassembly of controls D1MA and D2MA B0040

B0029 B0027

D*M* control

B0028

B0020 B0025

B0050 4 mm

B0010

B0027 B0028

C0060

B0035

1/8 in

B0025

C0050 1/4 in

C0010

C0060 1/8 in

E00T3

B0020 B0032 17 mm

B0034

C0060 C0070

E00T3 C0060

C0060

C0080 C0090

1/8 in

M223

C0050

C0020 C0030

1/4 in

The coil does not need to be removed unless it is being replaced.

Coil O-rings and Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of new coil and plug.

12 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Disassembly of controls K1KA and K2KA B0040

B0029 B0027

K*K* control

B0028 B0020 B0025

B0050 4 mm

B0010 B0035A C0100

C0060 E00T2 C0050 1/4 in

1/8 in

C0060

C0050

C0060 1/8 in

C0060 1/4 in

C0030 C0020

C0060 C0070 C0080 C0060 1/8 in

M223

E00T3 C0060

C0090 B0025

B0034A

B0028 B0027

B0032 17 mm B0020

1. Remove the coil nut (B0027) using a 26 mm 12-point socket.

2. Remove the coils and discard the O-rings.

3. Remove solenoid (B0032) using a 3/4 inch open end wrench.

4. Remove and discard O-ring (B0034A).

5. Remove three screws (B0050) using a 4 mm internal hex wrench.

6. Remove solenoid (B0010).

7. Remove and discard O-ring (B0035A).

8. Remove control spool (C0100).

9. Using a 1/8 inch internal hex wrench, remove plugs (C0060).

10. Remove orifices (E00T2 and E00T3) using a 3 mm internal hex wrench.

11. Tag the orifices for reassembly.

12. Using a 1/4 inch internal hex wrench, remove plugs (C0050).

13. Using a magnet, remove spring (C0030) and spool (C0020).

14. Using a 1 inch wrench, remove adjuster (C0090).

15. Remove and discard O-ring (M223).

16. Remove spring (C0080) and spool (C0070) using a magnet.

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Two-position controls T*D* and P*D* Disassembly of two-position control T*D* and P*D* B0026 B0028 B0022 B0024 B0032 17 mm B0034

B0026

1/4 in C0050

B0024

B0028 B0022

C0050A B0032 17 mm

C0060 1/8 in C0060A

B0034 C0060 1/8 in C0060A

C0060 1/8 in

C0060 1/8 in C0070

C0060A E00T3 3 mm

C0020 E00T2 3 mm

C0080 M223 C0090 17 mm

C0030

T*D* and P*D*

C0050A C0050 1/4 in

Coil O-rings and Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of new coil and plug.

1. Use a 26 mm 12-point socket to remove the coil nuts (B0026).

2. Remove coils (B0022) and O-rings (B0024) and (B0028).

3. Using a 17 mm hex wrench on the flats, remove solenoid assemblies (B0032).

4. Remove and discard O-rings (B0034).

5. Using a 1/8 inch internal hex wrench, remove four plugs (C0060).

6. Remove and discard O-rings (C0060A).

7. Using a 1/4 inch internal hex wrench, remove plugs (C0050).

8. Using a 17 mm hex wrench, remove pressure compensator adjusting plug (C0090).

9. Remove and discard O-ring (M223).

10. Remove springs (C0030) and (C0080).

11. Remove spools (C0020) and (C0070).

12. Remove orifices (E00T2 and E00T3) using a 3 mm internal hex wrench.

13. Tag the orifices for reassembly.

14 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Two-position controls T*G* and P*G* Disassembly of two-position control T*G* and P*G* B0028 B0022

B0026

B0024

T*G* and P*G*

C0050 B0032

C0050

B0034

C0030 C0010

C0020 C0060

C0060

C0070 C0080

E00T3

M223 C0090

E00T2 B0034 B0032 B0024 B0022

B0028 B0026

Coil O-rings and Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of new coil and plug.

1. Remove the coil nut (B0026) using a 26 mm 12-point socket.

2. Remove coil (B0022) and O-rings (B0024 and B0028).

3. Remove solenoid (B0032) using a 17 mm hex wrench on the flats.

4. Remove and discard O-ring (B0034).

5. Using a 1/8 inch internal hex wrench, remove plugs (C0060).

6. Remove and discard O-rings (C0060A).

7. Using a 1/4 inch internal hex wrench, remove plugs (C0050).

8. Remove spring (C0030).

9. Remove spool (C0020).

10. Remove orifices (E00T2 and E00T3) using a 3 mm internal hex wrench.

11. Tag the orifices for reassembly.

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Two-position control E*AA Disassembly of two-position control E*AA B0026 B0028 B0024 B0032

17 mm

B0020 C0020 B0034 C0060 C0060 1/8 in

1/8 in

C0060 C0025

E*AA

C0050

1/4 in

Coil O-rings and Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of new coil and plug.

1. Remove the coil nut (B0026) using a 26 mm 12-point socket.

2. Remove coil (B0022) and O-rings (B0024 and B0028).

3. Using a 17 mm hex wrench on the flats, remove solenoid (B0032).

4. Remove and discard O-ring (B0034A).

5. Remove spool (C0020).

6. Using a 1/8 inch internal hex wrench, remove plugs (C0060).

7. Using a 1/4 inch internal hex wrench, remove plugs (C0050).

8. Remove shuttle valve assembly (C0025) using a magnet.

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Two-position controls HEHE and HFHF Disassembly of two-position controls HEHE and HFHF C0140

HEHE

C0160 C0160A

3/8 inch

C0080

C0050 1/4 in

C0150 1/4 inch

C0060 C0060

C0050 C0025

C0050

C0060 C0140

C0060 1/8 in

C0160 C0160A

3/8 inch

C0050 C0080 C0150

C0060 C0060

C0060

1/8 in

HFHF

C0050

C0060 1/8 in

C0050

1/4 in

C0025 P108 576E

Coil O-rings and Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of new coil and plug.

1. Using a 1/8 inch internal hex wrench, remove plug (C0160) and four plugs (C0060).

2. Using a 1/4 inch internal hex wrench, remove plugs (C0050).

3. Remove shuttle valve assembly (C0025) using a 5 mm internal hex wrench.

4. Using a 3/8 inch internal hex wrench, remove plug (C0140).

5. Remove spring (C0080).

6. Remove spool (C0150).

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Two-position control THHA Disassembly of two-position control THHA 1/4 inch C0050

B0300

C0050 C0025

B0310 QB300 B0330 B0320

C0060 1/8 in

E00T3

THHA

C0050

C0070 C0060 1/8 in

C0080

E00T2

M223 C0090

P108913

Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of a new plug.

1. Using a 1/8 inch internal hex wrench, remove plugs (C0060).

2. Remove and discard O-rings (C0060A).

3. Using a 1/4 inch internal hex wrench, remove plugs (C0050).

4. Remove and discard O-ring (C0050A).

5. Remove shuttle valve assembly (C0025) using a 5 mm internal hex wrench.

6. Using a 22 mm hex wrench, remove adapter (B0300).

7. Remove and discard O-ring (QB0300).

8. Remove pressure compensator adjusting plug (C0090) using a 17 mm hex wrench.

9. Remove and discard O-ring (M223).

10. Remove spring (C0080) and spool (C0070) using a magnet.

11. Remove orifices (E00T2 and E00T3) using a 3 mm internal hex wrench.

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Two-position control THHB Disassembly of two-position control THHB 1/4 inch C0050

B0300

C0050 C0025

B0310 QB300 B0330 B0320

THHB

C0050

C0070 C0060 1/8 in

E00T3

C0080

C0060 1/8 in

E00T2

M223 C0090

C0020 C0140

C0050 P108923

Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of a new plug.

1. Using a 1/8 inch internal hex wrench, remove plugs (C0060).

2. Remove and discard O-rings (C0060A).

3. Using a 1/4 inch internal hex wrench, remove plugs (C0050).

4. Remove and discard O-ring (C0050A).

5. Remove shuttle valve assembly (C0025) using a 5 mm internal hex wrench.

6. Using a 22 mm hex wrench, remove adapter (B0300).

7. Remove and discard O-ring (QB0300).

8. Remove pressure compensator adjusting plug (C0090) using a 17 mm hex wrench.

9. Remove and discard O-ring (M223).

10. Remove spring (C0080) and spool (C0070) using a magnet.

11. Remove orifices (E00T2 and E00T3) using a 3 mm internal hex wrench.

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Two-position control DHMA Disassembly of two-position control DHMA

C0090 C0090A C0080 C0070 C0060A E00T2 C0060 1/8 in 8 N•m C0060 [6 lbf•ft]

6 N•m [4 lbf•ft] 3 mm

C0060

C0060A C0010 C0060A

C0060

1/8 in 8 N•m C0060 [6 lbf•ft]

C0060A

C0060A

C0050A

3 mm E00T3 6 N•m [4 lbf•ft]

C0110 C0120 B0061

C0060

C0060A

C0060A

C0025

C0060

C0100

C0060A C0060

0010 0020

C0050

C0050A C0050 40 N•m [30 lbf•ft]

B0190 B0060

B0010

0020 0010

DHMA

B0180 P108834

B0050

The hydraulic actuator does not need to be removed unless it is being replaced. Hydraulic actuator Orings are not included in the overhaul seal kit. They are included with the purchase of a new hydraulic actuator.

Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of a new plug.

1. Remove three screws (B0050) using a 4 mm internal hex wrench.

2. Remove hydraulic actuator (B0010).

3. Remove and discard O-ring (B0190).

4. Remove control spool (C0100).

5. Using a 1/8 inch internal hex wrench, remove plugs (C0060).

6. Remove orifices (E00T2 and E00T3) using a 3 mm internal hex wrench.

7. Tag the orifices for reassembly.

8. Using a 1/4 inch internal hex wrench, remove plugs (C0050).

9. Remove shuttle valve assembly (C0025) using a magnet.

10. Using a 1 inch wrench, remove adjuster (C0090).

11. Remove and discard O-ring (C090A).

12. Remove spring (C0080) and spool (C0070) using a magnet.

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Two-position control DHMH Disassembly of two-position control DHMH C0090 C0090A C0080

C0070 E00T2

1/8 in 8 N•m [6 lbf•ft] C0060

6 N•m [4 lbf•ft] 3 mm

C0140 C0060A

C0050 40 N•m [30 lbf•ft] C0050A

C0060 C0010

C0060A

1/8 in 8 N•m [6 lbf•ft]

C0050 C0050A C0060

C0060

C0060A

C0060A

40 N•m C0050A C0050 [30 lbf•ft]

1/8 in C0060 C0060A 8 N•m [6 lbf•ft] C0060 C0060A

C0060A

C0120 C0110

0010 0020

C0060A C0060 1/8 in 8 N•m [6 lbf•ft]

C0100

6 N•m [4 lbf•ft] 3 mm C0060A C0060 1/8 in 8 N•m [6 lbf•ft]

E00T3

C0060

C0020

C0140 C0050A C0050 40 N•m [30 lbf•ft]

B0190

B0061 B0060

B0010 0020

0010

B0180

DHMH

B0050

P108832

The hydraulic actuator does not need to be removed unless it is being replaced. Hydraulic actuator Orings are not included in the overhaul seal kit. They are included with the purchase of a new hydraulic actuator.

Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of a new plug.

1. Remove three screws (B0050) using a 4 mm internal hex wrench.

2. Remove hydraulic actuator (B0010).

3. Remove and discard O-ring (B0190).

4. Remove control spool (C0100).

5. Using a 1/8 inch internal hex wrench, remove plugs (C0060).

6. Remove orifices (E00T2 and E00T3) using a 3 mm internal hex wrench.

7. Tag the orifices for reassembly.

8. Using a 1/4 inch internal hex wrench, remove plugs (C0050).

9. Remove shuttle valve assembly (C0025) using a magnet.

10. Using a 1 inch wrench, remove adjuster (C0090).

11. Remove and discard O-ring (C090A).

12. Remove spring (C0080) and spool (C0070) using a magnet.

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Two-position control KHKA Disassembly of two-position control KHKA B0050 B0180 B0060

KHKA

B0010 B0061 B0190 C0120

E00T3 C0110 C0060 C0050

C0100

C0050 C0060

C0025

C0060

C0060 C0060

C0070 C0080

E00T2 C0060

M223

C0090 P109035

The hydraulic actuator does not need to be removed unless it is being replaced. Hydraulic actuator Orings are not included in the overhaul seal kit. They are included with the purchase of a new hydraulic actuator.

Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of a new plug.

1. Remove three screws (B0050) using a 4 mm internal hex wrench.

2. Remove hydraulic actuator (B0010).

3. Remove and discard O-ring (B0190).

4. Remove control spool (C0100).

5. Using a 1/8 inch internal hex wrench, remove plugs (C0060).

6. Remove orifices (E00T2 and E00T3) using a 3 mm internal hex wrench.

7. Tag the orifices for reassembly.

8. Using a 1/4 inch internal hex wrench, remove plugs (C0050).

9. Remove shuttle valve assembly (C0025) using a magnet.

10. Using a 1 inch wrench, remove adjuster (C0090).

11. Remove and discard O-ring (M223).

12. Remove spring (C0080) and spool (C0070) using a magnet.

22 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Two-position control KHKH Disassembly of two-position control KHKH B0050 B0180 B0060

KHKH

B0010 B0061 B0190 C0120

E00T3

C1400

C0060

C0110

C0100

C0050 C0060

C0020 C0060

C0060 C0070 E00T2 C0060

C0080

C1400

M223

C0090 P109036

The hydraulic actuator does not need to be removed unless it is being replaced. Hydraulic actuator Orings are not included in the overhaul seal kit. They are included with the purchase of a new hydraulic actuator.

Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of a new plug.

1. Remove three screws (B0050) using a 4 mm internal hex wrench.

2. Remove hydraulic actuator (B0010).

3. Remove and discard O-ring (B0190).

4. Remove control spool (C0100).

5. Using a 1/8 inch internal hex wrench, remove plugs (C0060).

6. Remove orifices (E00T2 and E00T3) using a 3 mm internal hex wrench.

7. Tag the orifices for reassembly.

8. Using a 1/4 inch internal hex wrench, remove plugs (C0050).

9. Using a 1/4 inch internal hex wrench, remove two plugs (C1400).

10. Using a magnet, remove shuttle valve assembly (C0020).

11. Using a 1 inch wrench, remove adjuster (C0090).

12. Remove and discard O-ring (M223).

13. Remove spring (C0080) and spool (C0070) using a magnet.

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Two-position controls MHCA and LHBA Disassembly of two-position controlMHCA and LHBA

B0050

MHCA & LHBA B0180 B0010 0010 0020 B0061 B0060 0020

B0190

C0060 C0050 40 N•m [30 lbf•ft]

C0100

C0060A

C0050A

0010

C0110 E00T2 6 N•m [4 lbf•ft] 3 mm

C0025

C0010 C0060 C0060A

3 mm E00T3 6 N•m [4 lbf•ft] C0060A

C0060 1/8 in 8 N•m [6 lbf•ft]

P108835

The hydraulic actuator does not need to be removed unless it is being replaced. Hydraulic actuator Orings are not included in the overhaul seal kit. They are included with the purchase of a new hydraulic actuator.

Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of a new plug.

1. Remove three screws (B0050) using a 4 mm internal hex wrench.

2. Remove hydraulic actuator (B0010).

3. Remove and discard O-ring (B0190).

4. Remove control spool (C0100).

5. Using a 1/8 inch internal hex wrench, remove plugs (C0060).

6. Remove orifices (E00T2 and E00T3) using a 3 mm internal hex wrench.

7. Tag the orifices for reassembly.

8. Using a 1/4 inch internal hex wrench, remove plugs (C0050).

9. Remove shuttle valve assembly (C0025) using a magnet.

10. Using a 1 inch wrench, remove adjuster (C0090).

11. Remove and discard O-ring (C090A).

12. Remove spring (C0080) and spool (C0070) using a magnet.

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Minimum displacement limiter

N0010

6 mm

N0020

19 mm

N0120

1. Remove and discard cap (N0120).

2. While holding position of adjustment screw (N0010) with a 6 mm internal hex wrench, remove locknut (N0020) using a 19 mm hex wrench and discard lock-nut.

3. Mark the position of adjustment screw (N0010) for re-installation.

4. Remove adjustment screw.

Maximum displacement limiter—two-position control It is not necessary to remove the maximum displacement limiter unless it is being replaced.

1. Remove screw (P0100) using internal hex wrench.

See the table for wrench size below: Wrench size (internal hex)

© Danfoss | April 2018

Size

060/080/110

160/210/250

Wrench size

6 mm

8 mm

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly P0100 P0200

P107 866E

2. Remove spacer (P0200).

Speed Sensor

J0020

J0020 J0010

J0010

O J0010A J0010A

J0010

J0010

J0010A

J0010A O J0020

J0020

P107833

1. Remove screw (J0020) using a 5 mm internal hex wrench.

2. Remove speed sensor or plug (J0010).

3. Remove and discard O-ring (J0010A).

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Servo piston cover—proportional controls

P0050

P0030 P0010 P0020 10 mm (4X)

P107867

1. Remove four screws (P0020) using a 10 mm internal hex wrench.

2. Remove servo piston cover (P0010).

3. Remove and discard O-ring (P0030).

4. Remove screw (P0050) carefully not to damage inside of end-cap.

See the table for wrench size below: Wrench size (internal hex)

© Danfoss | April 2018

Size

060/080

110

160/210/250

Wrench size

8 mm

10 mm

12 mm

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Loop flushing spool and charge relief valve 24 mm K0030 K0020

K0030A

K0010 K0020

K0030 24 mm K0030A F0010 L0050

L00** 24 mm

Loop flushing charge relief valve is available as complete assembly only. If you suspect valve malfunction, replace with new valve.

1. Remove two plugs (K0030) using a 24 mm hex wrench.

2. Remove and discard O-rings (K0030A).

3. Remove springs (K0020).

4. Remove spool (K0010) from end-cap.

5. Remove loop flushing relief valve (L00**) using a 24 mm wrench.

6. Remove and discard O-ring (L0050).

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly End-cap and servo piston—proportional control Remove end-cap and servo piston F0060

F0070 5 mm

Rear view of valve segment proportional controls

F0020

F0050

G0070

F0120 See table F0090 4 mm

P0040 QM050

P0043 P0044

Proportional end-cap can be rotated 180 degrees. Mark position of end-cap on housing for later reassembly. Do not press spindle out of valve segment.

1. Remove set screw (F0070) using a 5 mm internal hex wrench.

2. Use a magnet to remove pin (F0060) and discard pin.

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly 3. Remove servo piston head (P0040) using expanding pliers.

Servo piston cover and bushing

Servo piston head

Expanding pliers

4. Remove piston seal (P0044) and O-ring (P0043) from piston head; discard seal and O-ring.

5. Remove eight screws (F0120) from end cap assembly.

See the table for wrench size below: Wrench size (internal hex) Size

060/080

110

160

210/250

Wrench

8 mm

10 mm

12 mm

14 mm

6. Remove end cap assembly.

7. Remove and discard gasket (G0070).

8. Remove hold down screw (F0090) using a 4 mm internal hex wrench.

9. Remove valve segment (QM050).

10. Remove setting lug (F0050) from servo piston (F0020) .

11. Remove servo piston (F0020) from end-cap.

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly End cap and servo piston—two-position controls Remove end-cap and servo piston P0043

Rear view of valve segment - two position control

P0044 F0020

G0070 QM050 F0120 See table

F0090

4 mm

1. Remove eight screws (F0120) from end cap assembly.

See the table for wrench size below: Wrench size (internal hex) Size

060/080

110

160

210/250

Wrench

8 mm

10 mm

12 mm

14 mm

2. Remove end cap assembly.

3. Remove and discard gasket (G0070).

4. Remove hold down screw (F0090) using a 4 mm internal hex wrench.

5. Remove valve segment (QM050).

6. Remove servo piston (F0020) carefully not to damage inside of end-cap.

7. Remove and discard seal ring (P0044) and O-ring (P0043).

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Cylinder block and sync Shaft assembly Remove cylinder block

G0040

M0010

G0040

M0020

M0030 Bronze surface

1. Remove cylinder block assembly (M0020).

2. Remove bearing plate (M0030) from cylinder block and note orientation for reassembly.

3. Set cylinder block and components on a clean dry surface.

C

Caution

Take care that the sealing surfaces of the cylinder block do not become contaminated or scratched.

This may lead to poor performance or motor failure.

4. Remove synchronizing shaft assembly (M0010) and set on clean dry surface.

5. Remove alignment pins (G0040).

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Disassembly Shaft assembly

G0030 G0020

G0010

G0050A G0050

3/16 inch internal hex

G0055A H00** H0230

G0055 1/8 inch

Cartridge model has shaft lock screw (G0055) on top of housing.

Shaft, bearings, pistons and speed ring are not serviceable. Replace as a unit if damaged.

1. Remove retaining ring (G0030).

2. Use seal puller to remove seal (G0020) and discard.

3. Remove shaft locking screw (G0050).

Wrench size is shown in illustration.

Take care not to damage machined surfaces of housing or shaft assembly.

4. Remove and discard O-ring (G0050A).

5. Press shaft assembly (H00**) out of housing by pressing on front face of shaft.

C

Caution

For motors with cartridge flange, be sure to remove speed sensor before pressing shaft out of housing.

Take care not to damage pistons when pressing shaft out of housing.

6. If replacing piston rings (H0230), use a small pair of expanding pliers to remove them.

Refer to Pistons and piston rings inspection on page 34 inspection.

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Inspection Overview After disassembly, wash all parts (including the end-cap and housing) thoroughly with clean solvent and blow out oil passages in the housing and endcap with compressed air. Allow to air dry. Conduct inspection in a clean area and keep all parts free from contamination. Clean and dry parts again after any rework or resurfacing.

Shaft assembly Check to see that the shaft and its splines are straight and free of damage or heavy wear. Inspect the shaft journal where it meets the shaft seal. Replace the shaft assembly if grooved at the sealing land surface.

Clean the sealing area with a nonabrasive material if necessary.

Check that the spacer ring between the bearings is still fixed by bearing preload and that there is no play between the bearings. Clean bearings with a solvent and lubricate with hydraulic fluid. Inspect for wear or pitting. If you find excessive wear, replace the shaft assembly.

Check that there is not excessive axial endplay of the pistons in the piston shoe.

Inspect shaft assembly

Shaft bearings

E101 329E

Pistons and piston rings inspection Inspect sides of piston heads and piston rings for scuffing or marking.

If scuffing or marking are present, replace shaft assembly and cylinder block assembly.

• • •

If contact (polished) area on ring surface is more than 3/4 of the area, replace piston rings.

If scuffing or marks are visible, replace piston rings and inspect cylinder block bores for scratches or damage.

Inspect piston heads

Inspect piston rings wear area Marks or scuffing indicate unacceptable wear P107 758E

Look for marks or scuffing

34 | © Danfoss | April 2018

Marks or scuffing indicate unacceptable wear

P106 554E

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Inspection Synchronizing shaft Inspect synchronizing shaft, pins, and rollers. Replace parts as a complete unit if damaged or worn or if shaft is twisted. If twisted, closely inspect cylinder block and pistons for damage.

Inspect synchronizing shaft

P107 834

Cylinder block Examine the running face of the cylinder block for scratches, grooves and other damage. Ensure that no scratches or grooves exist; these can drastically reduce output flow, increase internal leakage, and reduce life of motor. Check piston bores for scratches, grooves, or other damage. Replace cylinder block assembly if damaged.

Inspect needle bearing for scratches, pitting, and wear. Ensure that bearing moves smoothly. If damaged, replace cylinder block assembly. Bearing is not available separately.

Inspect cylinder block

Needle bearing

P106 627E

Bearing plate Deep or outstanding grooves in the sealing lands of the bearing plate decrease motor efficiency.

Appearance should be flat and smooth on both the running face and the bottom surface. Perform a magnetic particle inspection to detect cracks.

Inspect bearing plate

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Inspection

• • • •

Inspect the bearing plate for scratches and grooves.

Check the plate for evidence of any cavitation along the running face of the bearing plate. If pitting from cavitation exists, replace the bearing plate.

Check for excessive wear on the brass running face. If you observe any discoloration or burn marks, replace the bearing plate.

Inspect the mating surfaces of the valve segment and cylinder block for any possible contamination; even a few thousandths of a millimeter can affect motor operation.

Run your fingernail or a pencil tip across the diameter of the sealing land surface to check for grooves.

Lap or replace if detectable grooves or nicks are present. Replace bearing plate if cracked.

Valve segment Carefully inspect each machined surface of the valve segment and spindle for wear, scratching, grooves, and other types of damage. All surfaces should be smooth. Inspect the bearing plate running surface for flatness and brass transfer. Excessive brass transfer indicates bearing plate needs replacement. Replace valve segment assembly if necessary.

Inspect valve segment

E101 338E

Endcap Inspect all machined surfaces of the endcap for scratches, smearing or pits. Carefully check the valve segment cradle bearing surface for wear. Check bore of loop flushing relief valve and loop flushing spool.

If damaged, replace endcap.

Inspect endcap

E101 342E

36 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Inspection Housing Inspect the housing to ensure that it is clean and free of foreign material. Inspect the endcap mating surface.

Inspect housing

E101 344E

Control shuttle valve Inspect the shuttle valve for damage or contamination. Check that shuttle ball moves freely in the housing Control shuttle Shuttle ball

P106 693E

Optional Minimum displacement limiter Inspect the displacement limiter screw threads. Check end of screw for damage.Ensure that the screw is not bent. Replace the seal nut.

Inspect displacement limiter

E101 345E

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Inspection Servo piston Inspect servo piston for wear, scratches, grooves or damage. Replace if necessary.

Inspect servo piston Proportional

Two-position

P101 337E

Control Inspect control housing, spools, and solenoids for wear or damage. Replace components as necessary.

Lubricate all moving parts during reassembly.

Inspect control - components

P106 253E

38 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Overview This section describes assembly procedures for the H1 motor. If special tools are needed for assembly, they appear in this section. After assembly, adjust motor according to the settings listed on the model code stamped on the serial number plate. Perform adjustments with motor on an appropriate test stand.

Refer to H1 Bent Axis Variable Displacement Motors Service Manual, AX00000025, for further instructions and adjustments for the H1 motor.

Piston ring Install and lubricate new rings, if piston rings (H0230) are being replaced.

Installation of piston rings Piston rings are not symmetrical.

Note proper orientation.

H0230 Mark indicates top of piston ring

Piston rings are not symmetric, note proper orientation. Mark indicates top of piston ring.

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Shaft in housing Shaft in housing assembly

P

(H00**)

G0050A

G0050 3/16 inch internal hex 8 N•m [6 lbf•ft]

G0010

G0055A

G0055 1/8 inch

Cartridge model has shaft lock screw (G0055) on top of housing.

Cartridge model has shaft lock screw (G0055) on top of housing.

1. Lubricate bearings and press shaft assembly (H00**) into housing.

2. Lubricate and install new O-ring (G0050A) on shaft locking screw (G0050).

3. Install shaft locking screw (G0050) and torque to 8 N•m [6 lbf•ft].

40 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Synchronizing shaft M0012 Install this pin into the cylinder block

M0011 M0013

M0012

1. Position the motor with shaft pointing down.

2. Using petroleum jelly to retain them, install synchronizing shaft rollers (M0013) on the journals of the synchronizing shaft (M0011).

The rollers are symmetrical. You may install them in either direction on the synchronizing shaft.

3. Position each roller with its outside edge flush to the end of the synchronizing shaft journal.

4. Install one synchronizing shaft support pin (M0012) into the spring guide of the motor shaft.

5. Install the synchronizing shaft and rollers into the motor shaft.

You may install either end of the synchronizing shaft into the cylinder block.

6. After installation, tip and rotate the synchronizing shaft in all directions to check for binding.

Ensure synchronizing shaft rollers move freely in the races of the motor shaft.

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Pistons and cylinder block 1. Position the shaft as shown in the illustration.

Shaft alignment - top view Position the motor shaft as shown prior to installing the cylinder block

P104 103

(Cylinder block not installed)

2. Tip the 3 pistons closest to the minimum angle stop out, toward the housing.

3. Tip the 6 remaining pistons forward (toward the lowest part of the end-cap mounting surface).

4. Tip the synchronizing shaft forward (toward the lowest part of the end-cap mounting surface).

5. Using petroleum jelly to retain it, install one synchronizing shaft support pin into the recess in the cylinder block.

6. Position the cylinder block so one of the synchronizing shaft roller raceways is aligned between the two bottom pistons.

7. Install the cylinder block and its support pin on the lower six pistons and synchronizing shaft.

The synchronizing shaft rollers enter their races in the cylinder block, while the last two of the six pistons enter their corresponding bores in the cylinder block.

8. Insert a brass rod through the cylinder block kidneys to guide the pistons into position.

9. Start with the six pistons closest to the lowest part of the end cap mounting surface.

The support pin enters its recess in the synchronizing shaft.

10. Lift the cylinder block slightly and guide the remaining 3 pistons into their bores.

11. Check the position of the rollers after the last piston is in position by trying to turn the cylinder block.

It should not have any free travel. If a roller is not in position, remove the block and repeat steps 5.-12.

12. Maintain an inward force on the cylinder block.

13. Carefully push it toward the highest part of the end cap mounting surface.

14. Tilt the housing back so the cylinder block remains in place.

15. Hold the cylinder block and turn the shaft in both directions.

If you feel any play, one or more of the rollers are not in place. Ensure synchronizing shaft rollers move freely in the races in the motor shaft. If installed correctly there is no free play between cylinder block and shaft.

16. Lubricate the pistons and cylinder block bores liberally with hydraulic fluid.

Hold cylinder block parallel to end-cap surface of housing until end-cap is installed.

42 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Bearing plate

M0030

1. Install the bearing plate (M0030) with its steel side facing the cylinder block.

2. Lubricate the bronze side of the plate with hydraulic oil.

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Servo piston and valve segment—proportional control Install servo piston and valve segment F0090

4 mm 8 Nm [6 lbf•ft] Rear view of proportional valve segment

QM050

P0050 P0040

F0050

P0043 P0044 F0020 F0060 F0070

5 mm 34 N•m [25 lbf•ft]

1. Lubricate and install servo piston (F0020).

C

Caution

Do not allow loose servo to damage machined surfaces of end-cap.

2. Lubricate and install setting lug (F0050).

3. Install new pin (F0060) and ensure pin is in groove of setting lug.

4. Install set screw (F0070) using a 5 mm internal hex wrench, torque to 34 N•m [25 lbf•ft].

5. Lubricate and install valve segment (QM050) and ensure valve segment spindle properly sets on setting lug ball.

6. Install hold down screw (F0090) using a 4 mm internal hex wrench, torque screw to 6 N•m [4.5 lbf•ft].

7. Lubricate and install O-ring (P0043) and seal ring (P0044) onto servo piston head (P0040).

O-ring (P0043) and seal ring (P0044) O-ring (P0043)

Seal ring (P0044)

Piston head

8. Press onto servo piston.

Take care not to damage seals.

9. Install screw (P0050).

See the table for wrench size below:

44 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Wrench size (internal hex) Size

060/080

110

160/210/250

Wrench size

8 mm

10 mm

12 mm

C

Caution

Do not torque until valve segment is installed.

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Servo piston and valve segment—two position control Install servo piston and valve segment P0043 Rear view of valve segment - two position control

P0044

F0020

F0090

4 mm

6 N•m [4.5 lbf•ft]

QM050

1. Lubricate and install O-ring (P0043) and seal ring (P0044) onto servo piston.

2. Lubricate and install servo piston (F0020).

C

Caution

Do not allow loose servo to damage machined surfaces of end-cap.

3. Install valve segment (QM050).

Ensure valve segment spindle ball end slides into servo piston hole.

4. Install hold down screw (F0090) using a 4 mm internal hex wrench and torque screw to 6 N•m [4.5 lbf•ft].

46 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly End-cap assembly F0120 see table for wrench size and torque

G0070

G0040

G0040

1. If previously removed, install locator pins (G0040) in housing.

2. Install new gasket (G0070).

3. Install the end cap assembly in position marked during disassembly.

Ensure valve segment spindle engages the bearing in the cylinder block 4. Install screws (F0120) and tighten the screws by hand using sequence below: End-cap torque sequence

5

8

2

4

3

1 7

6

P106 691E

5. When end cap is properly seated, torque screws (F0120) using the sequence.

Please see tables for wrench size and torque: © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Wrench size (internal hex) Size

060/080

110

160

210/250

Wrench

8 mm

10 mm

12 mm

14 mm

060

080

110

160

210/250

66 N•m [49 lbf•ft]

78 N•m [58 lbf•ft]

115 N•m [85 lbf•ft]

213 N•m [157 lbf•ft]

318 N•m [235 lbf•ft]

Torque for F0120

6. Rotate the motor shaft and check for play between the shaft and cylinder block.

Any play indicates that the synchronizing shaft rollers are not installed correctly.

Loop flushing charge relief valve and spool 24 mm 67 N•m [49 lbf•ft] K0030 K0020 K0030A

K0010 K0020 K0030A K0030

24 mm 67 N•m [49 lbf•ft]

L0050 L00** 24 mm 67 N•m [49 lbf•ft]

1. Lubricate and install spool (K0010) and springs (K0020) into end-cap.

2. Lubricate and install new O-rings (K0030A) on each plug (K0030).

3. Torque both plugs to 67 N•m [49 lbf•ft] using a 24 mm hex wrench.

4. Lubricate and install new O-ring (L0050) onto loop flushing charge relief valve cartridge (L00**).

5. Install loop flushing charge relief valve using a 24 mm hex wrench with torque to 67 N•m [49 lb•ft].

48 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Shaft seal

G0020 G0030

1. Lubricate inside diameter of new seal.

2. Cover the shaft splines with shaft cover or packing tape to avoid damaging the seal during installation.

3. Using seal installation tool, press seal into housing bore.

Damage to the seal may result if the seal rubs on the shaft assembly when the motor is in operation.

Do not press the seal in too far if you are not using the seal installation tool.

4. Use a snap ring pliers to install retaining ring (G0030) into housing bore.

5. Use seal installation tool to press seal and retaining ring into housing until retaining ring snaps into its groove.

Seal installation tool dimensions: 110/160/210/250 (left) and 060/080 (right) 100 mm [3.94 in]

180 mm [7.09 in]

150 mm 100 mm [5.90 in] [3.94 in]

69 mm 58 mm [2.6 in] [2.3 in]

82 mm [3.15 in]

56 mm 48 mm [2.2 in] [1.9 in]

70 mm [2.76 in]

45°

45° + 0.10

5.15 mm - 0.0 [0.20 in + -0.004 0.0 ]

© Danfoss | April 2018

5 mm [0.2 in]

P107 738E

+ 0.10 5.4 mm - 0.0 + 0.004 [0.21 in - 0.0 ]

5 mm [0.2 in]

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Servo cover—proportional control Installation of servo bushing cover

(previously installed) P0050 see table

P0030 P0010 P0020 10 mm (4X) 115 N•m [85 lbf•ft]

1. Torque servo piston bushing screw (P0050).

See the table for wrench size below: Wrench size (internal hex) Size

060/080

110

160/210/250

Wrench size

8 mm

10 mm

12 mm

Torque for P0050 060/080

110

160/210/250

66 N•m [49 lbf•ft]

115 N•m [85 lbf•ft]

213 N•m [157 lbf•ft]

2. Lubricate and install new O-ring (P0030).

3. Install cover (P0010).

4. Install four screws (P0020) using a 10 mm internal hex wrench with torque to 115 N•m [85 lbf•ft].

50 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Speed sensor

J0020

J0020 J0010

J0010

O J0010A J0010A

J0010

J0010

J0010A

J0010A O J0020

J0020

P107833

1. Lubricate and install new O-ring (J0010A) on speed sensor or plug (J0010).

2. Install speed sensor or plug into housing.

3. Torque screw (J0020) using a 5 mm internal hex wrench to 8 N•m [6 lbf•ft].

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Minimum displacement limiter

N0010

6 mm

N0020

19 mm

N0120

Refer to H1 Bent Axis Motors Service Manual, AX00000025 for adjustment procedures.

1. If previously removed, replace displacement limiter screw (N0010) and lock-nut (N0020) to original position.

2. Hold displacement limiter in place using a 6 mm internal hex and install a new lock-nut (N0020) using a 19 mm wrench.

3. When motor is properly adjusted, torque lock-nut to 45 N•m [33 lbf•ft].

4. Install new cap (N0120).

52 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Maximum displacement limiter—two-position control P0100 P0200

P107 866E

It is not necessary to remove the maximum displacement limiter unless it is being replaced.

1. Install spacer (P0200).

2. Install screw (P0100).

See the table for wrench size and torque below: Wrench size (internal hex) and torque

© Danfoss | April 2018

Size

060/080/110

160/210/250

Wrench size

6 mm

8 mm

Torque

37 N•m [28 lbf•ft]

66 N•m [48 lbf•ft]

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Electric proportional controls M1CA/M2CA and L1BA/L2BA B0027 26 mm 12-point 3.5 N•m [2.6 lbf•ft]

B0040 B0029

B0028 B0020

M1CA/M2CA and L1BA/L2BA

B0050 (3x) 4 mm 6 N•m [4 lbf•ft]

C0060 1/8 in 8 N•m [6 lbf•ft] C0050 1/4 in C0050A 40 N•m C0025 [30 lbf•ft] 5 mm 14 N•m [10 lbf•ft]

B0025

B0010

B0035A

C0060A

E00T2 3 mm 6 N•m [4 lbf•ft]

C0100 B0010

C0060A

C0060 1/8 in 8 N•m [6 lbf•ft]

E00T3 3 mm 6 N•m [4 lbf•ft] C0060A C0060 1/8 in 8 N•m [6 lbf•ft]

Coil O-rings and Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of new coil and plug.

1. Lubricate and install shuttle valve spool assembly (C0025) using a 5 mm internal hex wrench with torque to 14 N•m [10 lbf•ft].

2. Lubricate and install O-rings (C0050A) onto plugs (C0050).

3. Using a 1/4 inch internal hex wrench, install plugs (C0050) with torque to 40 N•m [30 lbf•ft].

4. Install orifices (E00T3 and E00T2) using a 3 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

5. Lubricate and install four O-rings (C0060A) onto plugs (C0060).

6. Using a 1/8 inch internal hex wrench, install plugs (C0060) with torque to 8 N•m [6 lbf•ft].

7. Install control spool (C0100).

8. Lubricate and install a new O-ring (B0035A).

9. Install solenoid (B0010).

10. Install three screws (B0050) using a 4 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

11. If previously removed, install the solenoid coil.

54 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly 12. Replace O-rings (B0025, B0028, B0029).

13. Install the coil nuts (B0027) using a 26 mm 12-point socket with torque to 3.5 N•m [2.6 lbf•ft].

Do not over torque.

14. Install the plastic cap (B0040).

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Electric proportional controls D1M1/D2M2 and K1K1/K2K2 Assembly of control D1M1/D2M2 B0029 3.5 N•m [2.6 lbf•ft]

D1M1/D2M2

B0040

B0027 B0028

4 mm 6 N•m [4 lbf•ft]

B0050 (3x)

3.5 N•m [2.6 lbf•ft]

B0027

B0010 C0060

B0028

B0025

1/8 in 8 N•m [6 lbf•ft] C0050

1/4 in 40 N•m [30 lbf•ft]

B0035 C0010

B0032 25 N•m [19 lbf•ft]

1/8 in 8 N•m [6 lbf•ft]

B0034

C0060

C0060 E00T3 C0060

1/8 in 8 N•m [6 lbf•ft] C0020 C0030

56 | © Danfoss | April 2018

C0060

E00T3

B0020 17 mm

B0020

B0025

C0050

C0070 C0080

C0090

25 N•m [18 lbf•ft]

M223

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Assembly of control K1K1/K2K2 B0040

B0029

K1K1/K2K2

3.5 N•m [2.6 lbf•ft]

B0027 B0028 B0020

4 mm

B0050

B0025

6 N•m [4 lbf•ft] B0010 1/4 in

C0060

C0050

40 N•m [30 lbf•ft]

1/8 in

B0035A

8 N•m [6 lbf•ft]

C0100

1/8 in

C0060

E00T2

8 N•m [6 lbf•ft] C0050

C0030 C0020 C0070 C0080 C0060 1/8 in 8 N•m [6 lbf•ft]

M223

E00T3

C0090

C0060

B0025

B0034A 17 mm

25 N•m [18 lbf•ft] B0028

B0032

B0027 3.5 N•m [2.6 lbf•ft]

25 N•m [19 lbf•ft] B0020

Coil O-rings and Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of new coil and plug.

1. Lubricate and install spring (C0080) and spool (C0070).

2. Lubricate and install new O-ring (M223) on adjuster (C0090).

3. Install pressure compensator adjusting plug (C0090) using a 1 inch wrench with torque to 25 N•m [18 lbf•ft].

4. Lubricate and install spools (C0020) and springs (C0030).

5. Lubricate O-rings on plugs (C0050).

6. Using a 1/4 inch internal hex wrench, install plugs (C0050) with torque to 40 N•m [30 lbf•ft].

7. Install orifices (E00T3 and E00T2) using a 3 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

8. Lubricate O-rings on plugs (C0060).

9. Using a 1/8 inch internal hex wrench, install plugs (C0060) with torque to 8 N•m [6 lbf•ft].

10. Install control spool (C0100).

11. Lubricate and install a new O-ring (B0035A).

12. Install solenoid (B0010).

13. Install three screws (B0050) using a 4 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

14. Lubricate and install a new O-ring (B0034A).

15. Install solenoid (B0032) using a 3/4 inch open end wrench with torque to 25 N•m [19 lbf•ft].

16. Install coils with new O-rings (B0024, B0028).

17. Install the coil nuts (B0027) using a 26 mm 12-point socket with torque to 3.5 N•m [2.6 lbf•ft].

Do not over torque. © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Two-position controls T*D* and P*D* Assembly of two-position control T*D* and P*D* B0028 B0022

B0026 3.5 N•m [2.6 lbf•ft]

B0024 B0032

17 mm 25 N•m [19 lbf•ft] B0034

B0026 3.5 N•m [2.6 lbf•ft] B0028

T*D* and P*D* 1/4 in 40 N•m [30 lbf•ft]

B0024

C0050 B0022 C0050A B0032 17 mm 25 N•m [19 lbf•ft]

C0060

1/8 in 8 N•m [6 lbf•ft]

B0034 C0060A C0060 1/8 in 8 N•m [6 lbf•ft] C0060A C0060 1/8 in 8 N•m [6 lbf•ft] E00T3

3 mm 6 N•m [4 lbf•ft]

C0060A C0060

1/8 in 8 N•m [6 lbf•ft] C0070 C0080

C0020 E00T2 3 mm C0030 6 N•m C0050A [4 lbf•ft] C0050 1/4 in 40 N•m [30 lbf•ft]

M223 C0090 17 mm 25 N•m [18 lbf•ft]

1. Lubricate and install new O-rings (B0034) onto solenoids (B0032).

2. Using a 17 mm hex wrench on the flats, install solenoids (B0032) with torque to 25 N•m [19 lbf•ft] .

3. Lubricate O-rings on plugs (C0060).

4. Install the coil nuts (B0026) using a 26 mm 12-point socket with torque to 3.5 N•m [2.6 lbf•ft].

Do not over torque.

5. Lubricate and install four O-rings (C0060A) onto plugs (C0060).

6. Using a 1/8 inch internal hex wrench, install plugs (C0060) with torque to 8 N•m [6 lbf•ft].

7. Lubricate and install spools (C0020 and C0070) and springs (C0080 and C0030).

8. Lubricate and install O-ring (M223) onto adjusting plug (C0090).

9. Install pressure compensator adjusting plug with torque to 25 N•m [18 lbf•ft].

Refer to H1 Bent Axis Motors Service Manual, AX00000025 for adjustment procedures.

10. Lubricate and install O-rings (C0050A) onto plugs (C0050).

11. Using a 1/4 inch internal hex wrench, install plugs (C0050) with torque to 40 N•m [30 lbf•ft].

12. Install orifices (E00T3 and E00T2) using a 3 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Two-position controls T*G* and P*G* Assembly of two-position control T*G* and P*G* B0028 B0022

B0026

B0024

T*G* and P*G*

C0050 B0032

C0050

B0034

C0030 C0010

C0020 C0060

C0060

C0070 C0080

E00T3

M223 C0090

E00T2 B0034 B0032 B0024 B0022

B0028 B0026

1. Lubricate and install new O-rings (B0034) onto solenoids (B0032).

2. Using a 17 mm hex wrench on the flats, install solenoids (B0032) with torque to 25 N•m [19 lbf•ft] .

3. Lubricate O-rings on plugs (C0060).

4. Install the coil nuts (B0026) using a 26 mm 12-point socket with torque to 3.5 N•m [2.6 lbf•ft].

Do not over torque.

5. Using a 1/8 inch internal hex wrench, install plugs (C0060) with torque to 8 N•m [6 lbf•ft].

6. Lubricate and install spools (C0020) and springs (C0030).

7. Using a 1/4 inch internal hex wrench, install plugs (C0050) with torque to 40 N•m [30 lbf•ft].

8. Install orifices (E00T3 and E00T2) using a 3 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Two-position control E*AA Assembly of two-position control E*AA 3.5 N•m [2.6 lbf•ft]

B0026 B0028

B0024 B0032

17 mm 25 N•m [19 lbf•ft]

E*AA

B0020 C0020 B0034 C0060 C0060 1/8 in 8 N•m [6 lbf•ft]

1/8 in 8 N•m [6 lbf•ft]

C0060 C0025 C0050

1/4 in 40 N•m [30 lbf•ft]

1. Lubricate and install shuttle valve spool assembly (C0025) using a 5 mm internal hex wrench with torque to 14 N•m [10 lbf•ft].

2. Lubricate O-rings on plugs (C0050).

3. Using a 1/4 inch internal hex wrench, install plugs (C0050) with torque to 40 N•m [30 lbf•ft].

4. Lubricate O-rings on plugs (C0060).

5. Using a 1/8 inch internal hex wrench, install plugs (C0060) with torque to 8 N•m [6 lbf•ft].

6. Lubricate and install spool (C0020).

7. Lubricate and install new O-rings (B0034) onto solenoids (B0032).

8. Using a 17 mm hex wrench on the flats, install solenoids (B0032) with torque to 25 N•m [19 lbf•ft] .

9. Install coils with new O-rings (B0024, B0028).

10. Install the coil nuts (B0026) using a 26 mm 12-point socket with torque to 3.5 N•m [2.6 lbf•ft].

Do not over torque.

60 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Two-position controls HEHE and HFHF Assembly of two-position control HEHE and HFHF C0140

HEHE

C0160 C0160A

3/8 inch 25 N•m [18 lbf•ft]

C0080 C0150

1/4 in 40 N•m [30 lbf•ft]

C0050 1/4 in 40 N•m [30 lbf•ft]

C0060 C0060

C0050 C0025

C0050

C0060

C0140

C0060 1/8 in 8 N•m [6 lbf•ft]

C0160 C0160A

3/8 inch 25 N•m [18 lbf•ft]

C0050

C0080 C0150

C0060 C0060

C0060

1/8 in 8 N•m [6 lbf•ft]

C0050

C0060 1/8 in 8 N•m [6 lbf•ft]

C0050 C0025

HFHF 1/4 in 40 N•m [30 lbf•ft]

P108 573E

Coil O-rings and Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of new coil and plug.

1. Lubricate and install spool (C0150) and spring (C0080).

2. Using a 3/8 inch internal hex wrench, install plug (C0140) with torque to 25 N•m [18 lbf•ft] 3. Lubricate and install shuttle valve spool assembly (C0025) using a 5 mm internal hex wrench with torque to 14 N•m [10 lbf•ft].

4. Using a 1/4 inch internal hex wrench, install plugs (C0050) with torque to 40 N•m [30 lbf•ft].

5. Using a 1/8 inch internal hex wrench, install plugs (C0060) with torque to 8 N•m [6 lbf•ft].

6. Using a 1/8 inch internal hex wrench, install plug (C0160) with torque to 25 N•m [18 lbf•ft].

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Two-position control THHA Assembly of two-position control THHA 1/4 inch C0050

B0300

C0050 C0025

B0310 QB300 B0330 B0320

C0060 1/8 in

E00T3

THHA

C0050

C0070 C0060 1/8 in

C0080

E00T2

M223 C0090

P108913

Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of a new plug.

1. Install orifices (E00T3 and E00T2) using a 3 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

2. Lubricate and install spring (C0080) and spool (C0070).

3. Lubricate and install new O-ring (M223) on adjuster (C0090).

4. Install pressure compensator adjusting plug (C0090) using a 1 inch wrench with torque to 25 N•m [18 lbf•ft].

5. Lubricate and install O-ring (QB0300).

6. Install adapter (B0300) with torque to 67 N•m [49 lbf•ft].

7. Lubricate and install shuttle valve spool assembly (C0025) using a 5 mm internal hex wrench with torque to 14 N•m [10 lbf•ft].

8. Using a 1/4 inch internal hex wrench, install plugs (C0050) with torque to 40 N•m [30 lbf•ft].

9. Using a 1/8 inch internal hex wrench, install plugs (C0060) with torque to 8 N•m [6 lbf•ft].

10. Using a 1/8 inch internal hex wrench, install plug (C0160) with torque to 25 N•m [18 lbf•ft].

62 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Two-position control THHB Assembly of two-position control THHB 1/4 inch C0050

B0300

C0050 C0025

B0310 QB300 B0330 B0320

THHB

C0050

C0070 C0060 1/8 in

E00T3

C0080

C0060 1/8 in

E00T2

M223 C0090

C0020 C0140

C0050 P108923

Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of a new plug.

1. Install orifices (E00T3 and E00T2) using a 3 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

2. Lubricate and install spring (C0080) and spool (C0070).

3. Lubricate and install new O-ring (M223) on adjuster (C0090).

4. Install pressure compensator adjusting plug (C0090) using a 1 inch wrench with torque to 25 N•m [18 lbf•ft].

5. Lubricate and install O-ring (QB0300).

6. Install adapter (B0300) with torque to 67 N•m [49 lbf•ft].

7. Lubricate and install spool (C0020).

8. Using a 1/4 inch internal hex wrench, install plugs (C0140) with torque to 14 N•m [10 lbf•ft].

9. Using a 1/4 inch internal hex wrench, install plugs (C0050) with torque to 40 N•m [30 lbf•ft].

10. Using a 1/8 inch internal hex wrench, install plugs (C0060) with torque to 8 N•m [6 lbf•ft].

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Two-position control DHMA Assembly of control DHMA

C0090 C0090A C0080 C0070 C0060A E00T2 C0060 1/8 in 8 N•m C0060 [6 lbf•ft]

6 N•m [4 lbf•ft] 3 mm

C0060

C0060A C0010 C0060A

C0060

1/8 in 8 N•m C0060 [6 lbf•ft]

C0060A

C0060A

C0050A

3 mm E00T3 6 N•m [4 lbf•ft]

C0110 C0120 B0061

C0060

C0060A

C0060A

C0025

C0060

C0100

C0060A C0060

0010 0020

C0050

C0050A C0050 40 N•m [30 lbf•ft]

B0190 B0060

B0010

0020 0010

DHMA

B0180 B0050

P108834

The hydraulic actuator does not need to be removed unless it is being replaced. Hydraulic actuator Orings are not included in the overhaul seal kit. They are included with the purchase of a new hydraulic actuator.

Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of a new plug.

1. Lubricate and install spring (C0080) and spool (C0070).

2. Lubricate and install new O-ring (M223) on adjuster (C0090).

3. Install pressure compensator adjusting plug (C0090) using a 1 inch wrench with torque to 25 N•m [18 lbf•ft].

4. Lubricate and install shuttle valve spool assembly (C0025) using a 5 mm internal hex wrench with torque to 14 N•m [10 lbf•ft].

5. Lubricate O-rings on plugs (C0050).

6. Using a 1/4 inch internal hex wrench, install plugs (C0050) with torque to 40 N•m [30 lbf•ft].

7. Install orifices (E00T3 and E00T2) using a 3 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

8. Lubricate O-rings on plugs (C0060).

9. Using a 1/8 inch internal hex wrench, install plugs (C0060) with torque to 8 N•m [6 lbf•ft].

10. Install control spool (C0100).

11. Lubricate and install a new O-ring (B0190).

12. Install hydraulic actuator (B0010).

13. Install three screws (B0050) using a 4 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

64 | © Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Two-position control DHMH Assembly of control DHMH C0090 C0090A C0080

C0070 E00T2

1/8 in 8 N•m [6 lbf•ft] C0060

6 N•m [4 lbf•ft] 3 mm

C0140 C0060A

C0050 40 N•m [30 lbf•ft] C0050A

C0060 C0010

C0060A

1/8 in 8 N•m [6 lbf•ft]

C0050 C0050A C0060

C0060

C0060A

C0060A

40 N•m C0050A C0050 [30 lbf•ft]

1/8 in C0060 C0060A 8 N•m [6 lbf•ft] C0060 C0060A

C0060A

C0120 C0110

0010 0020

C0060A C0100

6 N•m [4 lbf•ft] 3 mm C0060A C0060 1/8 in 8 N•m [6 lbf•ft]

E00T3

C0060

C0060 1/8 in 8 N•m [6 lbf•ft]

C0020

C0140 C0050A C0050 40 N•m [30 lbf•ft]

B0190

B0061 B0060

B0010 0020

0010

B0180

DHMH

B0050

P108832

The hydraulic actuator does not need to be removed unless it is being replaced. Hydraulic actuator Orings are not included in the overhaul seal kit. They are included with the purchase of a new hydraulic actuator.

Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of a new plug.

1. Lubricate and install spring (C0080) and spool (C0070).

2. Lubricate and install new O-ring (M223) on adjuster (C0090).

3. Install pressure compensator adjusting plug (C0090) using a 1 inch wrench with torque to 25 N•m [18 lbf•ft].

4. Lubricate and install spool (C0020).

5. Lubricate O-rings on plugs (C0050).

6. Using a 1/4 inch internal hex wrench, install plugs (C0050) with torque to 40 N•m [30 lbf•ft].

7. Install orifices (E00T3 and E00T2) using a 3 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

8. Lubricate O-rings on plugs (C0060).

9. Using a 1/8 inch internal hex wrench, install plugs (C0060) with torque to 8 N•m [6 lbf•ft].

10. Install control spool (C0100).

11. Lubricate and install a new O-ring (B0190).

12. Install hydraulic actuator (B0010).

13. Install three screws (B0050) using a 4 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Two-position control KHKA Assembly of control KHKA B0050 B0180 B0060

KHKA

B0010 B0061 B0190 C0120

E00T3 C0110 C0060 C0050

C0100

C0050 C0060

C0025

C0060

C0060 C0060

C0070 C0080

E00T2 C0060

M223

C0090 P109035

The hydraulic actuator does not need to be removed unless it is being replaced. Hydraulic actuator Orings are not included in the overhaul seal kit. They are included with the purchase of a new hydraulic actuator.

Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of a new plug.

1. Lubricate and install spring (C0080) and spool (C0070).

2. Lubricate and install new O-ring (M223) on adjuster (C0090).

3. Install pressure compensator adjusting plug (C0090) using a 1 inch wrench with torque to 25 N•m [18 lbf•ft].

4. Lubricate and install shuttle valve spool assembly (C0025) using a 5 mm internal hex wrench with torque to 14 N•m [10 lbf•ft].

5. Lubricate O-rings on plugs (C0050).

6. Using a 1/4 inch internal hex wrench, install plugs (C0050) with torque to 40 N•m [30 lbf•ft].

7. Install orifices (E00T3 and E00T2) using a 3 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

8. Lubricate O-rings on plugs (C0060).

9. Using a 1/8 inch internal hex wrench, install plugs (C0060) with torque to 8 N•m [6 lbf•ft].

10. Install control spool (C0100).

11. Lubricate and install a new O-ring (B0190).

12. Install hydraulic actuator (B0010).

13. Install three screws (B0050) using a 4 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Two-position control KHKH Assembly of control KHKH B0050 B0180 B0060

KHKH

B0010 B0061 B0190 C0120

E00T3

C1400

C0060

C0110

C0100

C0050 C0060

C0020 C0060

C0060 C0070 E00T2 C0060

C0080

C1400

M223

C0090 P109036

The hydraulic actuator does not need to be removed unless it is being replaced. Hydraulic actuator Orings are not included in the overhaul seal kit. They are included with the purchase of a new hydraulic actuator.

Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of a new plug.

1. Lubricate and install spring (C0080) and spool (C0070).

2. Lubricate and install new O-ring (M223) on adjuster (C0090).

3. Install pressure compensator adjusting plug (C0090) using a 1 inch wrench with torque to 25 N•m [18 lbf•ft].

4. Lubricate and install spool (C0020).

5. Lubricate O-rings on plugs (C0050).

6. Using a 1/4 inch internal hex wrench, install plugs (C0050) with torque to 40 N•m [30 lbf•ft].

7. Install orifices (E00T3 and E00T2) using a 3 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

8. Lubricate O-rings on plugs (C0060).

9. Using a 1/8 inch internal hex wrench, install plugs (C0060) with torque to 8 N•m [6 lbf•ft].

10. Install control spool (C0100).

11. Lubricate and install a new O-ring (B0190).

12. Install hydraulic actuator (B0010).

13. Install three screws (B0050) using a 4 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Two-position controls MHCA and LHBA Assembly of controls MHCA and LHBA

B0050

MHCA & LHBA B0180 B0010 0010 0020 B0061 B0060 0020

B0190

C0060 C0050 40 N•m [30 lbf•ft]

C0100

C0060A

C0050A

0010

C0110 E00T2 6 N•m [4 lbf•ft] 3 mm

C0025

C0010 C0060 C0060A

3 mm E00T3 6 N•m [4 lbf•ft] C0060A

C0060 1/8 in 8 N•m [6 lbf•ft]

P108835

1. Lubricate and install spool (C0020).

2. Lubricate O-rings on plugs (C0050).

3. Using a 1/4 inch internal hex wrench, install plugs (C0050) with torque to 40 N•m [30 lbf•ft].

4. Install orifices (E00T3 and E00T2) using a 3 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

5. Lubricate O-rings on plugs (C0060).

6. Using a 1/8 inch internal hex wrench, install plugs (C0060) with torque to 8 N•m [6 lbf•ft].

7. Install control spool (C0100).

8. Lubricate and install a new O-ring (B0190).

9. Install hydraulic actuator (B0010).

10. Install three screws (B0050) using a 4 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Proportional controls installation C0110 (4X) 6 mm

C0010 Proportional control F0030

C0110 (4X) 6 mm

37 Nm [27 lbf•ft] C0010 F0030

F0040 F0040

C0130

Electric proportional control

C0130

Hydraulic proportional control

P108841

1. Install new gasket (C0130).

2. Install spring (F0040) and spring guide (F0030).

3. Install control housing (C0010).

4. Install torque screws (C0110) using a 6 mm internal hex wrench with torque to 37 N•m [28 lbf•ft].

© Danfoss | April 2018

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Two-position controls installation Hydraulic and electric two-position controls with or without PCOR 6 mm C0120 (2X)

C0110 (2X)

37 Nm [27 lbf•ft]

C0010

C0120 (2X) 10 mm C0110 (2X) 10 mm C0010 2 position control

C0130 C0130

Hydraulic two position control with and without PCOR

Electric two position control with and without PCOR

1. Install new gasket (C0130).

2. Install control housing (C0010).

3. Install torque screws (C0110 and C0120) using a 10 mm internal hex wrench with torque to 115 N•m [85 lbf•ft].

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Assembly Controls with PCOR installation Hydraulic and electric two-position controls with PCOR

C0130 C0130

F0040

F0040

F0030

F0030

C0010 C0010

6 mm 37 Nm [27 lbf•ft] C0120 (2X)

6 mm C0110 (2X)

37 Nm [27 lbf•ft]

Hydraulic proportional control with PCOR

6 mm

C0120 (2X) C0110 (2X)

37 Nm [27 lbf•ft]

P108843

Electric proportional control with PCOR

1. Install new gasket (C0130).

2. Install control housing (C0010).

3. Install torque screws (C0110 and C0120) using a 10 mm internal hex wrench with torque to 115 N•m [85 lbf•ft].

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Start-up Procedures Overview Install motor on a test stand and adjust per Danfoss testing specifications TS-396.

Refer to H1 Bent Axis Variable Displacement Motors Service Manual, AX00000025, for start-up procedures, adjustments, and pressure measurements for H1 motors. motor.

Initial startup procedures Startup procedures include: • Ensure system components are clean

• • • • • •

Install new filters Fill system with fluid Disable engine Disconnect control Crank engine and check for adequate charge pressure Check for proper control function

Adjustments Adjustment procedures include: Displacement limiter adjustment

• • •

Electronic displacement control (EDC) threshold adjustment PCOR adjustment

Pressure measurements Pressure measurement procedures include: Required tools

• • • •

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Port locations Gauge installation Leakage test per Danfoss test HPP 112

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Port locations Ports and Gauge Information The following drawing with accompanying table show the port locations and gauge sizes needed for installation.

Ports locations (proportional control)

M5 (M4 on reverse side) MA (MB on reverse side) System Port A XB (Port XA on reverse side)

L2

System Port B

X1 Axial Ported Endcap M5 (M4 on reverse side) L1 System Port A (System Port B on reverse side)

MA MB

XB (Port XA on reverse side)

L2 Radial Ported Endcap

X1 P108829

System split flange boss ports, A/B: Code 62 per ISO 6162, Type 1 Port

Size 060

Size 080, 110

Size 160, 210, 250

A, B

3/4 in; Thread: M10 x 1.5 min. 18 mm [0.71 in]

1 in; Thread: M12 x 1.75 min. 23 mm [0.91 in]

1 1/4 in; Thread: M12 x 1.75 min. 23 mm [0.91 in]

Radial/Axial end-cap ports

© Danfoss | April 2018

Port

Size 060

Size 080, 110, 160, 210, 250

System pressure obtained

MA, MB (Radial)

7/8-14 UNF Wrench (int. hex): 3/8 in

1 1/16-12UN Wrench (int. hex): 9/16 in

600 bar [8702 psi]

MA, MB (Axial)

7/8-14 UNF Wrench (int. hex): 3/8 in

9/16-18 UNF Wrench (int. hex): 1/4 in

600 bar [8702 psi]

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Port locations Ports and gauge Information Port

Size 060/080

Size 110/160

Size 210/250

Pressure obtained

L1, L2

7/8-14 UNF Wrench: 3/8 in

1 1/16-12UN Wrench: 9/16 in

1 5/16-12UN Wrench: 5/8 in

10 bar [145 psi] Case drain

M4, M5

9/16-18 UNF; Wrench (int. hex): 1/4 in

600 bar [8700 psi] 1)

X1, XA, XB

9/16-18 UNF; Wrench (int. hex): 1/4 in

100 bar [1450 psi] 2)

1) Servo pressure rod end.

2) X1 – Control pressure supply, hydraulic actuator. XA/XB – BPD, PCOR inactive at A/B.

Port locations (hydraulic 2-position controls with PCOR; control specific ports only) X1

XB (Port XA on reverse side)

P108924

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Torque chart Fasteners and plugs Port/fastener and plug locations and sizes Proportional controls with radial ported endcap M4 F0100

P0020

L00**

L1 G0060 MB F0150

MA F0150

System Port B

M5 F0100

J0020

System Port A K0030 XB B0060

XA B0060 X1 B0060

C0060 B0050

G0050

C0110 and C0120

L2 G0060

N0010

N0020

P108831

Two position controls with radial ported endcap

XA B0060

M4 F0100

X1 B0060 M5 F0100

System Port A

MB F0150

L1 G0060

K0030 L00**

MA F0150

System Port B

L2 G0060

© Danfoss | April 2018

XB B0060

P108925

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Repair Instructions H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250 Torque chart Fastener size and torque chart Item

Fastener

Wrench size

Torque

P0020

Servo piston cover screws

10 mm internal hex wrench

115 N•m [85 lbf•ft]

F0120 (210, 250)

End-cap screws

14 mm internal hex wrench

318 N•m [235 lbf•ft]

F0120 (160)

End-cap screws

12 mm internal hex wrench

213 N•m [157 lbf•ft]

F0120 (110)

End-cap screws

10 mm internal hex wrench

115 N•m [85 lbf•ft]

F0120 (080)

End-cap screws

8 mm internal hex wrench

78 N•m [58 lbf•ft]

F0120 (060)

End-cap screws

8 mm internal hex wrench

66 N•m [49 lbf•ft]

C0110 (proportional)

Control assembly screws

6 mm internal hex wrench

37 N•m [28 lbf•ft]

C0110, C0120 (two-position)

Control assembly screws

10 mm internal hex wrench

115 N•m [85 lbf•ft]

B0050

Solenoid screws

4 mm internal hex wrench

6 N•m [4 lbf•ft]

J0020

Speed sensor screw

5 mm internal hex wrench

8 N•m [6 lbf•ft]

N0010

Displacement limiter screw

6 mm internal hex wrench

N/A

L00**

Loop flushing charge relief

24 mm hex

67 N•m [49 lbf•ft]

N0020

Displacement limiter lock-nut

19 mm hex

45 N•m [33 lbf•ft]

Item

O-ring plug

Wrench size

Torque

F0100

9/16 – 18UNF

1/4 internal hex wrench

40 N•m [30 lbf•ft]

G0050 (SAE and DIN flange)

7/16 – 20UNF

3/16 internal hex wrench

8 N•m [6 lbf•ft]

G0055 (Cartridge model only, not shown).

5/16 – 24UNF

1/8 internal hex wrench

8 N•m [6 lbf•ft]

G0060 (110/160)

1-1/16 – 12UN

9/16 internal hex wrench

G0060 (060/080)

7/8 – 14UN

3/8 internal hex wrench

G0060 (210/250)

1-5/16 - 12UN

5/8 internal hex wrench

C0060

5/16 – 24UNF

1/8 internal hex wrench

8 N•m [6 lbf•ft]

F0150 (Radial end-cap, size: 080/110/160/210/250)

1-1/16 – 12UN

9/16 internal hex wrench

115 N•m [85 lbf•ft]

F0150 (060)

7/8 – 14UN

3/8 internal hex wrench

95 N•m [70 lbf•lb]

F0160 (Axial end-cap) C0050 and B0060

9/16 – 18UNF

1/4 internal hex wrench

40 N•m [30 lbf•ft]

L00** and K0030

M18 – 1.5

24 mm hex wrench

67 N•m [49 lbf•ft]

Plug size and torque chart

76 | © Danfoss | April 2018

70 N•m [52 lbf•lb]

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