Manitou HYDROSTATIC PUMP H1 069 TO 165 Lift Truck Repair Manual 647424 - PDF DOWNLOAD

647424EN (03/09/2018)

HYDROSTATIC PUMP H1 069 TO 165

REPAIR MANUAL

647424EN

2

DATE OF ISSUE

OBSERVATION

25 / 03 / 2013

- 1st ISSUE

12 / 02 / 2014

- UPDATE

03 / 09 / 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 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Contents Introduction

Disassembly

Inspection

Assembly © Danfoss | May 2018

Overview..............................................................................................................................................................................................5 General instructions........................................................................................................................................................................ 5 Remove the unit.......................................................................................................................................................................... 5 Lubricate moving parts.............................................................................................................................................................5 Replace all O-rings and gaskets............................................................................................................................................. 5 Safety Precautions............................................................................................................................................................................6 Unintended machine movement..........................................................................................................................................6 Flammable cleaning solvents................................................................................................................................................. 6 Fluid under pressure.................................................................................................................................................................. 6 Personal safety............................................................................................................................................................................. 6 Symbols used in Danfoss literature............................................................................................................................................7 Shaft Seal Removal...........................................................................................................................................................................8 Input Shaft Removal........................................................................................................................................................................ 9 EDC Angle Sensor Removal.......................................................................................................................................................... 9 EDC/MDC Control Removal.......................................................................................................................................................... 9 EDC/MDC Control Disassembly................................................................................................................................................ 10 Automotive Control Removal....................................................................................................................................................11 Optional Integrated Filter Removal.........................................................................................................................................12 Auxiliary Pad or End Cover Removal.......................................................................................................................................14 Charge Pump Removal................................................................................................................................................................ 16 Pressure Limiter Valve Removal................................................................................................................................................16 Charge Pressure Relief Valve Removal................................................................................................................................... 17 High Pressure Relief Valve Removal........................................................................................................................................ 18 Endcap Removal.............................................................................................................................................................................18 Cylinder Block Kit Removal.........................................................................................................................................................20 Optinal Displacement Limiter................................................................................................................................................... 21 Servo Cylinder Removal...............................................................................................................................................................22 Servo Piston Removal...................................................................................................................................................................23 Servo Piston Disassembly........................................................................................................................................................... 23 Swashplate and Cradle Bearings Removal............................................................................................................................24 Cylinder Block Kit........................................................................................................................................................................... 25 Disassemble the cylinder block kit.....................................................................................................................................25 Block spring removal...............................................................................................................................................................26 Overview........................................................................................................................................................................................... 28 Pistons and Slippers...................................................................................................................................................................... 28 Ball Guide and Slipper Retainer................................................................................................................................................ 28 Block Spring and Washers...........................................................................................................................................................28 Cylinder Block .................................................................................................................................................................................29 Shaft ...................................................................................................................................................................................................29 Shaft Bearing................................................................................................................................................................................... 29 Swashplate....................................................................................................................................................................................... 30 Cradle Bearings...............................................................................................................................................................................30 Valve Plate........................................................................................................................................................................................ 30 Endcap............................................................................................................................................................................................... 31 Housing ............................................................................................................................................................................................ 31 Pressure Limiter.............................................................................................................................................................................. 32 HPRV Valve....................................................................................................................................................................................... 32 Optional Displacement Limiter.................................................................................................................................................33 Charge Pressure Relief Valve......................................................................................................................................................33 Servo Piston Assembly................................................................................................................................................................. 34 Control............................................................................................................................................................................................... 34 Automotive control................................................................................................................................................................. 34 Optional Integrated Filter........................................................................................................................................................... 35 Overview........................................................................................................................................................................................... 36 520L0874 | AX00000190en-US0302 | 3

Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Contents Cradle Bearings, Swashplate, and Filter Screen Installation ..........................................................................................36 Servo Piston Assembly................................................................................................................................................................. 37 Servo Piston Installation.............................................................................................................................................................. 37 Servo Cylinder Installation..........................................................................................................................................................38 Optinal Displacement Limiter................................................................................................................................................... 39 Install Optional Hold down Clamp.......................................................................................................................................... 39 Hold Down Clamp Dimensions.................................................................................................................................................40 Shaft and Seal Installation...........................................................................................................................................................41 Cylinder Kit Assembly...................................................................................................................................................................42 Cylinder Kit Installation................................................................................................................................................................44 Level Swashplate............................................................................................................................................................................45 Endcap Bushing Installation.......................................................................................................................................................45 Valve Plate and Endcap Installation........................................................................................................................................ 46 Charge Pump Installation........................................................................................................................................................... 48 Auxiliary Pad or End Cover Installation.................................................................................................................................. 49 Charge Pressure Relief Valve Installation.............................................................................................................................. 50 Pressure Limiter Valve Installation...........................................................................................................................................50 HPRV Valve Installation................................................................................................................................................................ 51 Optional Displacement Limiter Installation......................................................................................................................... 52 EDC Control Assembly................................................................................................................................................................. 53 EDC Control Installation.............................................................................................................................................................. 54 EDC Angle Sensor Assembly......................................................................................................................................................55 EDC Control with Angle Sensor Installation.........................................................................................................................56 MDC Control.................................................................................................................................................................................... 58 Automotive Control Installation...............................................................................................................................................61 Optional Integrated Filter Installation....................................................................................................................................62 Startup procedures

Port locations Torque chart

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Overview........................................................................................................................................................................................... 65 Initial Startup Procedures............................................................................................................................................................65 Adjustments.....................................................................................................................................................................................65 Pressure Measurements.............................................................................................................................................................. 65 Port Locations and Gauge Installation................................................................................................................................... 66 Fastener Size and Torques..........................................................................................................................................................68 Plug Size and Torques.................................................................................................................................................................. 68 Fasteners and Plugs...................................................................................................................................................................... 69

520L0874 | AX00000190en-US0302

Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Introduction Overview This manual details major repair procedures for H1 pumps. 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.

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 069/078/089/100/115/130/147/165 H1 Closed Circuit Axial Piston Pumps Service Manual, 520L0848. Minor repairs include service operations you can perform without removing the unit's endcap. Removal of the endcap voids your warranty.

General instructions Follow these general procedures when repairing this product.

Remove the unit If necessary, remove the unit from the vehicle/machine. Chock the wheels on the vehicle or lock the mechanism to inhibit movement. Be aware that hydraulic fluid may be under high pressure and/or hot.

Inspect the outside of the pump and fittings for damage. Cap hoses after removal to prevent contamination.

Keep it clean

Cleanliness is a primary means of assuring satisfactory pump life, on either new or repaired units. Clean the outside of the pump thoroughly before disassembly. Take care to avoid contamination of the system ports. Cleaning parts by using a clean solvent wash and air drying is usually adequate.

As with any precision equipment, keep all parts free of foreign materials and chemicals. Protect all exposed sealing surfaces and open cavities from damage and foreign material. If left unattended, cover the pump with a protective layer of plastic.

Lubricate moving parts

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

Replace all O-rings and gaskets

Danfoss recommends that you replace all O-rings, seals and gaskets. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly.

Secure the unit

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Introduction For repair, place the unit in a stable position with the shaft pointing downward. It will be necessary to secure the pump while removing and torquing end covers, controls, and valves.

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

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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

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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

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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 state, and federal environmental regulations.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps 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.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly Shaft Seal Removal 1. Orient pump with the shaft pointing up.

2. Use a snap ring pliers to remove the top snap ring (J200).

3. Puncture the seal (J250) with a punch or sharp screwdriver.

4. Use a slide-hammer type puller to remove the seal. Discard the seal, it is not reusable.

Remove shaft /seal/bearing J200

J250

J200 J100

J150

J300

P106 057E

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly Input Shaft Removal 1. Use a press or gear puller to press down the shaft.

2. Remove the lower snap ring (J200).

3. Pull the shaft (J100) out of pump.It may be necessary to tap lightly on the shaft to dislodge it from the internal pump components.

4. Remove snap ring (J300).

5. Press bearing (J150) from shaft.

EDC Angle Sensor Removal It is not necessary to remove the sensor unless it is being replaced.

1. Clean the pump to remove debris.

2. Remove protection cover screws (D767) using a 4 mm internal hex wrench.

3. Remove the protection cover from the control. (If the protection cover is damaged, replace it with a new one upon reassembly.)

4. Remove sensor screws (D770) using a 4 mm internal hex wrench.

5. Remove and discard the sensor.

EDC angle sensor D767

D770

Item

Wrench size

Torque

D767

4 mm

1.85 N•m [1.36 lbf•ft]

D770

4 mm

1.85 N•m [1.36 lbf•ft]

EDC/MDC Control Removal 1. Remove control screws (D250) using a 5 mm internal hex wrench. Remove the control from the pump Some older pumps may have a five bolt control. This control uses a different gasket and has no control screeen (D084).

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly 2. Remove and discard the gasket (D150).

3. Using a 13 mm deep well socket wrench, remove feedback pin (D200) from top of swashplate.

4. Leave dowel pins (D300) in housing.

5. If necessary, use a 3 mm internal hex to remove orifices (F00A, F00B) for cleaning. Note location of each for reassembly.

Orifices A and B may be different size.

6. If necessary, remove screen (D084). Use a hook to remove steel ring and screen. Note orientation for installing new screen. Replace screen if removed.

Remove control (EDC shown)

D250 5 mm

D150

D084 F00A

3 mm F00B

D200 13 mm deep well socket D300 (2X) Dowel pin P106 048E

EDC/MDC Control Disassembly It is not necessary to remove solenoids (D025) unless you are replacing them.

1. Use a 4 mm internal hex wrench to remove cap screws (D050).

2. Remove solenoids (D025). Remove and discard O-rings (D025A).

Do not disassemble internal parts of control. Internal parts are not available separately. Control is sold as a complete unit only.

If you suspect a coil malfunction, remove the coil. Remove the plastic nut with a 26 mm 12 point socket. Install a new coil. Torque nut to 5 N•m [3.7 lbf•ft].

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly Disassemble the control D050 (3X) 4 mm

D025A D025 D025A D050 (3X) 4 mm

P106 061E

Automotive Control Removal 1. Drain pump completely before removing control. Disconnect and remove wiring (D640).

2. Fabricate a special tool to remove two plastic plugs (D610). See drawing below for tool dimensions.

Push down on plug and turn 45 degrees counterclockwise. Discard plugs.

Wax seals will be destroyed when the plugs are removed. Do not damage the housing in the plug sealing area.

3. Use a 5 mm internal hex to remove two screws (D674). Remove shield (D672).

4. Use a 5 mm internal hex to remove six screws (D250). Remove control from pump.

5. Remove and discard gasket (D150).

Alignment pins are pressed into control. Do not remove them.

6. If necessary, use a 3 mm internal hex to remove orifices (F00A, F00B) from housing. Tag each orifice for reinstallation. Each orifice may be a different size.

7. If it is necessary to remove the screens, drill out screen retention ring (D098) and remove and discard screen (D084). Note screen orientation for reassembly.

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Warning

Do not allow metal fragments to fall into control housing. This may cause erratic pump operation.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly Special Tool Special tool

Plug

Drill out retention ring

Screen

Retention Ring

45 deg.

Ø 9.22 mm Ø 14 mm Ø 1.7 mm (x3)

P108021

Remove control Security wax seal (2X) D610 (2X) D610A (2X) D250 5 mm (6X)

D672

D674

D084

D150

D098

F00A

3 mm F00B

P106 708E

Optional Integrated Filter Removal 1. Use a 24 mm wrench to remove plug (T015). Remove and discard filter (T150).

2. Remove and discard O-ring (T045) and O-ring (T035).

3. Use an 8 mm internal hex to remove screws (T250).

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly 4. Remove filter adapter (T010). Discard gasket (T350).

Remove filter and adapter

24 mm T015 T045

T350 T035

T010

T250 (3X) 8 mm

T150 P106 136E

5. Use an 8 mm internal hex wrench to remove plugs (T025). Remove O-rings (T025A); discard.

6. Remove spring (T030), and spool (T020).

7. If necessary, use a 3 mm internal hex wrench to remove cap screws (T300) and switch (T200).

It is not necessary to remove switch (T200) unless you are replacing it.

T025 8 mm

T025A

T030

T020

3 mm T300

T200

T025 8 mm

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P106 138E

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly Auxiliary Pad or End Cover Removal 1. Position pump so end cover (K100) or auxiliary pad is on top.

2. Remove end cover/auxiliary pad screws (K400) using a 10 mm internal hex wrench.

Alignment pins (G450) are in end cover. They may dislodge during disassembly.

3. Remove and discard gasket (K150).

4. Remove thrust washer (K500). Note thrust washer orientation.

5. Remove pressure balance plate (S200) and seal (S300). Note plate orientation. Discard seal (S300).

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly 6. Remove coupling (K200).

Remove end cover and charge pump 147/165 shown K400 10 mm

K100

G450

G450 K150

K500

S300

S200

K200

S150

S100

S250

S300

P106 047E

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly 069/078/089/100 Auxiliary pads

B flange

A flange

115/130/147/165 Auxiliary pads

B flange

A flange

C flange

Charge Pump Removal 1. Remove charge pump outer ring (S150), and gearset (S100).

2. Remove valve plate (S250) with seal (S300). Discard seal (S300).

If charge pump requires replacement, replace as a kit. Kit includes (S300), (S250), (S100), (S150), and (S200).

Pressure Limiter Valve Removal 1. Using a 22 mm wrench, remove pressure limiter cartridges or plugs (L300, L400).

Pressure limiters (L300, L400) are available as complete units only. O-ring (L022) is available separately.

2. Remove and discard O-ring (L022).

Right and left pressure settings may be different. Tag each valve for re-assembly.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly Remove pressure limiter L400 22 mm

L300 22 mm

L022 L022

E101 336E

Charge Pressure Relief Valve Removal 1. Using a 22 mm wrench, remove the charge pressure relief valve (V010).

2. Discard O-ring (V024).

Charge pressure relief valve (V010) is available as complete unit only. Seal (V024) is available separately.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly Remove charge pressure relief valve

V024

V010 22 mm

P106 159E

High Pressure Relief Valve Removal Using a 30 mm (115/130/147/165) or 22 mm (069/078/089/100) wrench, remove the HPRV valves (L100, L200). Discard O-rings (L060) and seals (L068).

HPRV valves may not have the same pressure setting. Tag each valve for re-assembly.

Remove high pressure relief valves

L060 L068

L200 L100

42

Pressure code marked on end P106 039E

Endcap Removal See table below for endcap screw wrench sizes 1. Remove two endcap screws (G400).

2. Remove four endcap screws (G350).

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly 3. Carefully remove the endcap (G100). and valveplate (C025). Valveplate may be stuck to endcap.

Alignment pin (C020) may remain in endcap.

C

Caution

Note valveplate orientation for proper reassembly.

4. Place the endcap and valve plate in a clean area, protecting them from contamination.

5. Remove and discard gasket (G150).

6. If necessary, use a suitable puller to remove bushing (G550) by pressing out. Do not remove bushing unless worn or damaged.

7. Remove locating pins (B010).

8. If necessary, remove lubrication orifice (G980) using a small screwdriver. Remove bushing to access orifice.

If necessary, use a hook to remove retaining rings (B060) and screens (B040). 069/078 cm³ pumps have two screens, 089/100/115/130/147/165 cm³ pumps have three. Screens are not reusable.

Remove endcap and components 147/165 shown G350 (4X)

G400 (2X)

G100 G980 C020

G550 C025

B060

G150 B010

B010

B040 (3X) P106 058E

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly Endcap screw wrench sizes - internal hex Item

069/078

089/100/115/130

147/165

G400

6mm

8mm

10mm

G350

12mm

14mm

17mm

Cylinder Block Kit Removal 1. Remove cylinder block assembly (C010).

2. Set cylinder block assembly on a clean dry surface.

C

Caution

Do not scratch the running surfaces of the cylinder block or slippers. Scratches in these surfaces can lead to poor performance or pump failure.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly Remove cylinder block kit C010

P106 056E

Optinal Displacement Limiter If so equipped, remove and discard locking nut (E500). Mark position and remove displacement limiter screw (E400).

Remove displacement limiter screw

P107 992E

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly Displacement Limiter wrench sizes Displacement

Locknut wrench size

Adjusting screw wrench size

069/078/089/100

13 mm

4 mm internal hex

115/130/147/165

22 mm

6 mm internal hex

Servo Cylinder Removal 1. Remove four locking screws (E350) with a 10 mm wrench. Remove locking plates (E300).

2. Using a 3/4 inch deep socket, unthread the servo cylinders (E150) from each side of the pump. The servo piston will be loose after the servo cylinders are removed. Discard O-rings (E250).

C

Caution

Do not allow loose servo piston to damage internal machined surfaces of pump.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly Remove the servo cylinders

E250

E150 E300

E350 11 mm

E101 330E

Servo Piston Removal Tilt the swashplate up to disengage the servo arm from the piston. Remove the servo piston assembly (E100).

Remove the servo piston

E100

E101 430E

Servo Piston Disassembly 1. Remove and discard the seals (E025). © Danfoss | May 2018

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly 2. Remove the slider block (E015).

The servo (E100) is available as an assembly only. The seals (E025) and slider block (E015) are available as repair items.

Remove O-rings, seals, and slider block

E100 E025 (2X) E015

E025 P101 337E

Swashplate and Cradle Bearings Removal 1. Remove the swashplate (D070). Note the cradle bearing orientation and position for reassembly. If reusing the bearings, reinstall them in the same location and orientation.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly 2. Remove cradle bearings (D075).

Remove swashplate and cradle bearings

D070

D075

D075

P106 059E

Cylinder Block Kit Disassemble the cylinder block kit 1. Pull to remove the slipper retainer (C20) with the pistons (C10) from the cylinder kit.

The pistons are not selectively fitted, however units with high hourly usage may develop wear patterns. Number the pistons and bores for reassembly if they are to be reused.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly 2. Remove the ball guide (C15) and spring washer (C25). Discard the spring washer.

Disassemble the cylinder block kit

C10

C20

C15

C25

C05

C35

C30

C40

C45 P106 060E

Block spring removal Most repairs do not require block spring removal. Perform this procedure only if you suspect problems with the block spring.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Disassembly Using a press, apply pressure on the block spring washer (C40) to compress the block spring (C30).

Compress the spring enough to safely remove the spiral retaining ring (C45). While maintaining pressure, unwind the spiral retaining ring. Carefully release the pressure and remove the outer block spring washer, block spring, and inner block spring washer (C35) from the cylinder block.

W

Warning

Risk of personal injury: Compressing the block spring requires 350 to 400 N [80 to 90 lbf]. Use a press sufficient to maintain this force with reasonable effort. Ensure the spring is secure before attempting to remove the spiral retaining ring. Release the pressure slowly after the retaining ring is removed.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Inspection Overview After disassembly, wash all parts (including the end-cap and housing) thoroughly with clean solvent and allow them to air dry. Blow out the oil passages in the housing and endcap with compressed air. Conduct your inspection in a clean area and keep all parts free from contamination. Clean and dry the parts again after any rework or resurfacing.

Pistons and Slippers Inspect the pistons for damage and discoloration. Discolored pistons may indicate excessive heat; do not reuse.

Inspect pistons Inspect the running surface of the slippers. Replace any piston assemblies with scored or excessively rounded slipper edges. Replace any piston assemblies with worn slippers. Replace any piston assemblies with excessive end-play.

Slipperfoot thickness and piston/slipper endplay are documented in ReWork specifications maual 520L1033.

Inspect Pistons Slipper

P104 109E

Ball Guide and Slipper Retainer Ensure the ball guide is free of nicks and scratches, and not scored. Examine for discoloration that may indicate excessive heat or lack of lubrication. The slipper retainer should be flat, and slippers should fit in the retainer with minimal side play. Discard and replace any damaged parts. Discard and replace spring washer Inspect guide and retainer Slipper retainer

Ball guide Spring washer E101 362E

Block Spring and Washers If the cylinder kit was fully disassembled, a visual inspection of the cylinder block, spring, and washers should indicate minimal wear. Replace the cylinder block kit if cracks are visible, or other damage is present.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Inspection Inspect block spring and washers Washer

Cylinder block spring Washer Retaining ring P101 472

Cylinder Block Examine the running face of the cylinder block. The surface should be smooth and free of nicks and burrs.

Remove any burrs. Ensure that no scratches or grooves exist; these may drastically reduce output flow and life of pump.

Minimum height, maximum bore diameter, total block height and running face flatness specifications are documented in ReWork specifications manual 520L1033.

Inspect cylinder block Cylinder block

check for burrs P101 067E

Shaft Check to see that the shaft and its splines are straight and free of damage or heavy wear. Inspect the step where the block splines contact the block spring washer. Inspect the shaft surface where it meets the shaft seal. Replace the shaft if a groove exists at the sealing land. Clean the sealing area with a nonabrasive material if necessary. Lubricate the shaft with hydraulic fluid before reassembly.

Inspect shaft

E101 329E

Shaft Bearing Clean the bearing with a solvent and lubricate it with hydraulic fluid. Inspect for wear, or pitting. Rotate the bearing in your hand. Replace it if it does not rotate smoothly. © Danfoss | May 2018

520L0874 | AX00000190en-US0302 | 29

Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Inspection Inspect shaft bearing

E101 343E Swashplate Carefully inspect each machined surface of the swashplate for wear. Ensure that all machined surfaces are smooth. Inspect the swashplate's slipper running surface for flatness and brass transfer. If you see excessive brass transfer on the running surface, you should replace the pistons and swashplate. Check the journals for scratches. Replace the swashplate if any damage is found.

Inspect swashplate

E101 338E

Cradle Bearings Inspect the cradle bearings for damage or excessive wear. Slide the bearings by hand and feel for roughness. Replace the cradle bearings if they are scratched, warped, or worn.

Replace the cradle bearings as a pair.

Inspect cradle bearings

E101 339E

Valve Plate Inspect the valve plate for scratches and grooves. Check for pitting along the running face of the valve plate. If pitting from cavitation exists, replace the valve plate. Check for excess wear on the brass running face. If any discoloration or burn marks are observed, replace the valve plate.

Run a fingernail or pencil tip across the diameter of the sealing land surface (see illustration). You should feel no deep or outstanding grooves. Grooves or scratches will decrease pump flow. Lap or replace the 30 | © Danfoss | May 2018

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Inspection valve plate if grooves or nicks are present. Inspect the mating surfaces of the endcap and valve plate for any possible contamination. Contamination of even a few thousandths of an inch will affect the pumps performance.

Ensure that the valve plate is flat and smooth on both the running face and the bottom surface. Perform a magnetic particle inspection to detect cracks. Replace the valve plate if any cracks exist.

Valve plate thickness, flatness, and parallelism are documented in ReWork Specifications Maual 520L1033.

Inspect valve plate timing pin (not shown). Replace if worn or damaged.

Inspect valve plate

Clockwise valveplate

Counterclockwise valveplate

P108 061E

Endcap Inspect the endcap. Inspect all machined surfaces for scratches or pits. Carefully check the bearing surface for wear. Inspect the valve seats carefully for wear or cracks. Replace the endcap if any damage is found.

Endcap flatness specifications are documented in ReWork Specifications Maual 520L1033.

Inspect endcap

P108 399E

Housing Inspect the housing to ensure that it is clean and free of foreign material. Inspect the swashplate bearing surfaces, and endcap and control mating surfaces.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Inspection Inspect housing

P108 400E

Pressure Limiter Pressure limiter valves are available as complete units only. If you suspect valve malfunction, replace the valve(s) and test pump operation. Replace the O-rings if you are reusing the existing valve.

Inspect pressure limiter valve

E101 435E

HPRV Valve HPRV valves are available as complete units only. If you suspect valve malfunction, replace the valve(s) and test pump operation. Replace the O-rings before reassembly.

Inspect HPRV valve

42

Pressure code marked on end P106 662E

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Inspection Pressures marked on HPRV valve Code

Pressure bar [psi]

15

150[2175]

20

200 [2900]

23

230 [3336]

25

250 [3626]

28

208 [4061]

30

300 [4351]

33

330 [4786]

35

350 [5076]

38

380 [5511]

40

400 [5801]

42

420 [6092]

43

430[6237]

44

440[6382]

45

450 [6527]

48

480 [6962]

Optional Displacement Limiter Inspect the displacement limiter screw threads. Ensure that the screw is not bent. Replace the sealnut upon reassembly.

Inspect displacement limiter Displacement limiter screw

Sealnut E101 345E

Charge Pressure Relief Valve The charge pressure relief valve is available as a complete unit only. If you suspect valve malfunction, replace the valve and test pump operation. Replace the O-rings if you are reusing the existing valve.

Inspect charge pressure relief valve

P106 040E

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Inspection Servo Piston Assembly Inspect the slider block (E015) for wear or damage. Replace it if necessary. Inspect the springs for warping or cracking. Inspect the servo piston for wear, cracks, or damage. Replace the entire assembly if the servo piston or springs are damaged.

Do not disassemble the servo piston assembly. Seals and O-rings are available as a replacement kit.

Inspect servo assembly

E100 E025 (2X) E015

E025 P101 337E

Control Inspect the sealing surfaces of the control. If you find nicks or scratches that may allow fluid leakage, replace the control. Inspect the feedback spring and linkage. The control is only available as a complete unit. If you suspect control operation problems, replace the control with a new unit and test pump operation. If necessary, you may remove the control, and clean the control orifices. Use a 3 mm internal hex. wrench Torque to 2.5 N•m [1.8 lbf•ft]. If screen is plugged, remove retaining ring and screen and replace with new screen.

If you suspect a coil malfunction, remove the coil by removing the plastic nut with a 26 mm 12 point socket. Install a new coil. Torque the nut to 5 N•m [3.7 lbf•ft].

Inspect control

O-ring

Solenoid

screen retaining ring orifices P106 253E

Automotive control Inspect all machined surfaces on the control housing. Inspect the solenoid and its sealing areas. If any damage is found, replace all damaged components.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Inspection Optional Integrated Filter Check all machined surfaces for nicks and scratches. Check the bypass valve poppet, spring, and seat.

Check the bypass indicator switch operation. Replace damaged parts as necessary. Replace all seals and gaskets before reassembly.

Inspect filter adapter and bypass valve

P106 140E

Clean and inspect all filter adapter parts. Check the gasket surfaces for nicks and scratches. Check the bypass valve poppet, spring, and seat. Check the bypass indicator switch operation. Replace damaged parts as necessary. Replace all seals and gaskets before reassembly.

P106 142E

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly Overview This section describes assembly procedures for the H1 pump. If special tools are needed for assembly or adjustment, they appear in this section. After assembly, adjust the pump according to the settings listed on the model code stamped on the serial number plate. Connect pump to an appropriate test stand.

Refer to H1 Closed Circuit Axial Piston Pumps Service Manual 520L0848 for further instructions and adjustments for the H1 pump.

Cradle Bearings, Swashplate, and Filter Screen Installation 1. Position the housing as shown in the illustration.

2. Coat the cradle bearings (D075) with hydraulic fluid and install them into the pump housing. Fit the retaining pins into the holes in housing.

If the cradle bearings are reused, reinstall them in their original orientation and position.

3. Swing the bearings fully to each side to check for smooth operation.

4. Install the swashplate. Ensure the retaining pins fit securely in the swashplate. Check that the swashplate moves correctly on the cradle bearings.

5. Position the swashplate in its neutral (flat) position.

6. If previously removed, press new filter screens (B040) into the housing. Install the screens and in the same orientation as when they were removed. Press in the retaining ring (B060).

Install cradle bearings, swashplate, and screens

D070

D075

D075

B060 B040 (3X)

Correct screen orientation

Incorrect screen orientation E101 346E

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly Servo Piston Assembly 1. Lubricate and install new piston seals and O-rings (E025). Stretch the O-rings onto the servo piston, then install the piston seals on top of the O-rings. Allow the seals to relax after installation and use a servo cylinder to resize them before further assembly.

2. Lubricate and install the slider block (E015).

Assemble servo Seal O-ring E025 E015

E025

E100

P101 337E

Servo Piston Installation Tilt the swashplate up and install the servo piston assembly (E100). Ensure the swashplate pin fits in the servo slider block (E015).

Do not allow the loose servo to damage the internal machined surfaces of pump.

Do not damage the seals when installing the servo cylinders.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly Install servo piston

E100

E101 331E

Servo Cylinder Installation 1. Lubricate new O-rings (E250) and install them on each servo cylinder.

2. While holding the servo piston in place, thread the servo cylinders into the housing. Thread the cylinders an equal distance in each side of the pump until each cylinder contacts the servo assembly.

Do not compress the servo piston springs.

Install servo cylinders

E250

10 mm 14 N•m [10 lbf•ft] E350 Servo piston E150

E300

E101 330E

3. Position the locking plates (E300) to engage the tab into the notch on the servo cylinder (E150). Using a 10 mm hex wrench, install screws (E350). Torque to 14 N•m [10 lbf•ft].

After pump assembly is complete, mount the pump on a test stand. Perform mechanical neutral adjustment and control neutral adjustment. Refer to H1 Closed Circuit Axial Piston Pumps 069/078/089/100/115/130/147/165 Service Manual 520L0848 for adjustment procedures.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly Optinal Displacement Limiter If so equipped, install the displacement limiter screw (E400) a few turns. Install and tighten the locking nut (E500). Adjust the displacement limiter after the pump has been set for mechanical neutral.

Refer to H1 Pumps Service Manual 520L0848 for instructions on setting mechanical neutral and adjusting the displacement limiter.

Install displacement limiter screw

P107 993E

Displacement Limiter Adjustment Data Displacement

Locknut wrench size and torque

Adjusting screw wrench size

Approximate displacement change per revolution of adjusting screw

069/078

13 mm - 30 N•m [28 lbf-ft]

4 mm

7.4 cm3 [0.45 in3]

115

22 mm - 70 N•m [52 lbf-ft]

6 mm

10.8 cm3 [0.66 in3]

130

22 mm - 70 N•m [52 lbf-ft]

6 mm

12.2 cm3 [0.45 in3]

147

22 mm - 70 N•m [52 lbf-ft]

6 mm

12.4 cm3 [0.74 in3]

165

22 mm - 70 N•m [52 lbf-ft]

6 mm

13.9 cm3 [0.85 in3]

Install Optional Hold down Clamp Install a hold down clamp to hold the swashplate in position. Position the clamp so no gap occurs between the clamp and the machined endcap surface of the housing.

While it is possible to assemble the pump without the use of a swashplate hold down clamp, this practice is not recommended. Applied pressure is required to seat the swashplate in the bearings.

Also, if the swashplate is loose when the pump is rotated, the swashplate or housing may be damaged.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly Install hold down clamp Hold down clamp No gap between clamp and housing

E101 402E

Hold Down Clamp Dimensions 147/165 hold down clamp dimensions Sharp corner

15.3 mm

10 mm

40 mm

65 mm

128.5 mm

8 mm

15° 9.8 mm 48 mm

8 mm

25 mm

16 mm

30 mm

Offset is required to clear speed ring

P107 877E

069/078 hold down clamp dimensions Sharp corner

17.2 mm

40 mm

10 mm 60 mm

100 mm

8 mm 5 mm

11.7 mm 48 mm 23 mm P107 878E Offset is required to clear speed ring

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly 115/130 hold down clamp dimensions Sharp corner

17.2 mm

10 mm

65 mm

40 mm

119.65 mm

9 mm 5.5 mm

10.7 mm 48 mm

23 mm Offset is required to clear speed ring

P107 879E

Shaft and Seal Installation 1. With the swashplate hold down clamp in place, orient the pump with the front flange as shown 2. Lubricate bearing (J150) with clean hydraulic fluid. Press the bearing onto the shaft. Using a snap ring pliers, install bearing snap ring (J300).

Holdown clamp holds swashplate in place when housing is rotated. Swashplate will fall out of place without holdown clamp.

3. Install the shaft into the housing. It may be necessary to tap the shaft to seat the bearing.Using a snap ring pliers, install lower seal snap ring (J200).

C

Caution

Do not scratch the housing or shaft during shaft installation.

4. To protect the shaft seal during installation, cover end of shaft with a protective cover.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly 5. Lubricate the seal (J250) with hydraulic fluid. Using a seal installation tool or appropriate deep socket, press the seal into the housing until it bottoms out against the lower snap-ring. Press evenly to avoid binding and damaging the seal. Install the upper snap ring (J200).

Install shaft /seal/bearing

J150

J300

Protective cover J100

J250 Seal installation tool

J200 P106 038E

J200

Seal installation tool 7 mm [0.276 in] 55 mm [2.17 in]

50°

44.7 mm [1.76 in]

68.5 mm [2.70 in]

51 mm [2. in]

78 mm [3.07 in]

120 mm [4.72 in]

078

7 mm [0.28 in]

89.4 mm [3.52 in]

80°

82 mm [3.23 in]

115/089/100 130/147/165 P106 492E

Cylinder Kit Assembly 1. Coat all parts with clean hydraulic fluid prior to reassembly.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly 2. Install the inner block spring washer (C40), block spring (C30), and outer washer (C35) into the cylinder block. Using a press, compress the block spring enough to expose the retaining ring groove.

Wind the spiral retaining ring (C45) into the groove in the cylinder block.

W

Warning

Risk of personal injury: Compressing the block spring requires about 350 to 400 N [80 to 90 lbf]. Use a press sufficient to maintain this force with reasonable effort. Ensure the spring is secure before attempting to install the spiral retaining ring. Release the pressure slowly after the retaining ring is installed.

3. Turn the block over and install new spring washer (C25) and ball guide (C15). Do not reuse spring washer.

Position sharp edge of spring washer (C25) against ball guide (C15) to avoid excessive cylinder block wear.

4. Insert the pistons (C10) into the slipper retainer (C20). Install the piston/retainer assembly into the cylinder block. Ensure the concave surface of the retainer seats on the ball guide. If you're reusing the

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly pistons, install them to the original block bores. Lubricate the pistons, slippers, retainer, and ball guide before assembly. Set the cylinder block kit aside on a clean surface until needed.

Assemble cylinder kit

C10

C20

C15

C25

C05

C40

C30

C35

C45 E101 350E

Cylinder Kit Installation 1. Position the pump in horizontal position (as shown). Slide the cylinder block kit onto the shaft.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly 2. While holding the shaft in place, slightly rotate the cylinder block kit to help start the shaft splines over the ball guide and align it with the block splines.

Install cylinder block kit

Slightly rotate cylinder block

Prevent shaft from rotating

E101 351E

Level Swashplate 1. Position the pump with the shaft pointing down.

2. Ensure the swashplate is seated correctly on the bearings.

3. Use depth micrometers to measure distance X and Y as shown.

4. Turn the servo cylinders in or out until the swashplate is level ± 0.025 mm [0.001in].

Measuring block

X

Y Swashplate

P107 876E

After the pump is completely assembled, set swashplate neutral on a test stand. Refer to H1 Pumps 069/078/089/100/115/130/147/165 Service Manual 520L0848 for proper setting neutral instructions.

Endcap Bushing Installation 1. If previously removed, install orifice (G980) and bushing (G550) into endcap.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly 2. Lubricate the new bushing and use a suitable press to install it. Align the lubrication hole in the bushing with the lubrication orifice in the endcap.

Install bushing

(078 ) 3mm ±0.05mm [0.12 in ±0.002in] (115/130/147/165 ) 4 mm ±0.05mm [0.18in ±0.002in] Installation depth

Bushing installation tool

P106 503E

Ensure that the bushing is properly installed. Improper installation resulting in improper depth or misalignment will result in premature bushing and charge pump failure.

Valve Plate and Endcap Installation 1. Remove the holdown clamp.

2. Clean the valve plate (C025) and endcap surface. Install the valve plate alignment pin (C020).

3. Install the end cap alignment pins B010.

4. Apply a liberal amount of assembly grease to the backside of the valve plate surface to hold it in place and position it on the endcap.

For proper pump operation, it is extremely important to ensure that there is no contamination between the endcap and valve plate.

5. Install a new gasket (G150). Do not reuse the old one. Install an installation cylinder on the rear shaft splines to protect the bushing during assembly.

Do not bend or warp the gasket in an attempt to straighten it. This may damage the embossing under the rubber coating.

6. Install endcap with cap screws (G350) and (G400).

7. Wrench sizes and torques are listed in the table below. Use torque sequence shown.

Torque sequence

6

5

4

2

1

3 P106 193E

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly Endcap screw wrench sizes and torques Item

069/078

089/100/115/130

147/165

G400

6mm 32 Nm [24 lbf•ft]

8mm 64 Nm [47 lbf•ft]

10mm 110 Nm [81 lbf•ft]

G350

12mm 170 Nm [125 lbf•ft]

14mm 300 Nm [220 lbf•ft]

17mm 400 Nm [295 lbf•ft]

Install endcap components 147/165 shown G350

G400

G100 G980 C020 G550 C025

G150 B010

B010

E101 358E

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly Valveplate orientation

Clockwise valveplate

Counterclockwisealveplate v

Notch used for EDC or FNR controls

CCW

CW

Notch used for NFPE or AC controls

P108 060E

Charge Pump Installation Charge pump components are available as a complete kit only. Kit includes (S300), (S250), (S100), (S150), and (S200).

1. Install new seals (S300) to the valve plate and pressure-balance plate. Lubricate the valve plate (S250) and install in the same orientation as when it was removed.

2. Lubricate and install outer ring (S150) and charge pump gearset (S100).

3. Lubricate and install coupling (K200).

4. Lubricate and install the pressure-balance plate (S200) in same orientation as when it was removed.

5. Lubricate and install thrust washer (K500) in the same orientation as when it was removed.

The bump on the thrust washer fits in the hole in the end cover.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly Remove end cover and charge pump 147/165 shown K400 10 mm 92 N•m [68 lbf•ft] K100

G450

G450 K150

K500

S300

S200

K200

S150

S100

S250

S300

P106 116E

Auxiliary Pad or End Cover Installation 1. Install alignment pins (G450). Install gasket (K150).

2. Install the end cover or auxiliary pad. Install cap screws (K400) using a 10 mm internal hex wrench.

Torque to 92 Nm [68 lbf•ft]. Follow the torque sequence shown below.

If a second pump is used, re-install it on auxiliary pad.

Ensure proper torque on aux pad screws (K400). If necessary, replace screws.

If the pump is equipped with an aux pad, install a running cover and O-ring prior to testing. © Danfoss | May 2018

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly Torque sequence

5

7

1 3

4 2

8

6 P106 196E

Charge Pressure Relief Valve Installation 1. Install a new O-ring (V024).

2. Using a 22 mm wrench, install the charge pressure relief valve (V010).

3. Torque to 52 N•m [38 lbf•ft].

Refer to Danfoss publication H1 069/078/089/100/115/130/147/165 Service Manual 520L0848 for instructions on adjusting charge pressure relief.

Install charge pressure relief valve

V024

V010 22 mm 52 N•m [38 lbf•ft]

P106 115E

Pressure Limiter Valve Installation 1. Lubricate and install O-rings (L022).

2. Install pressure limiter valves (L300, L400). See table below for torques and wrench sizes.

Refer to Danfoss publication H1 069/078/089/100/115/130/147/165 Service Manual 520L0848 for instructions on adjusting pressure limiter.

50 | © Danfoss | May 2018

Model

069/078/089/100

115/130/147/165

Torque N•m [lbf•ft]

30 [22]

70 [52]

Wrench size

14 mm

22 mm

520L0874 | AX00000190en-US0302

Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly Install pressure limiter L400 22 mm

L300 22 mm

L022 L022

E101 361E

HPRV Valve Installation 1. Install new O-rings (L060, L068) on the cartridges (L100, L200).

2. Install and torque the HPRV valves per the table below.

© Danfoss | May 2018

Model

069/078/089/100

115/130/147/165

Torque N•m [lbf•ft]

70 [52]

110 [81]

Wrench size

22 mm

30 mm

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly Install HPRV valve

L060 L068

L200 L100 P106 114E

Optional Displacement Limiter Installation 1. Thread the adjusting screw (E400) into the servo cylinder.

2. Thread locking nut (E500) onto the displacement limiter adjusting screw. Torque the locknut per the table below.

Refer to Danfoss publication H1 069/078/089/100/115/130/147/165 Service Manual 520L0848 for instructions on adjusting displacement limiter.

When torquing the locking nut, be sure the servo cylinder does not turn.

Install the displacement limiter

E400 see table E500 see table

52 | © Danfoss | May 2018

E101 357E

Displacement

Locknut wrench size and torque

Adjusting screw wrench size

Approximate displacement change per revolution of adjusting screw

069/078

13 mm - 24 N•m [18 lbf-ft]

4 mm

7.4 cm3/turn [0.452 in3/turn]

089

17 mm - 48 N•m [35 lbf-ft]

5 mm

9.3 cm3/turn [0.57 in3/turn]

100

17 mm - 48 N•m [35 lbf-ft]

5 mm

10.7 cm3/turn [0.65 in3/turn]

520L0874 | AX00000190en-US0302

Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly Displacement

Locknut wrench size and torque

Adjusting screw wrench size

Approximate displacement change per revolution of adjusting screw

115

22 mm - 80 N•m [59 lbf-ft]

6 mm

10.8 cm3/turn [0.66 in3/turn]

130

22 mm - 80 N•m [59 lbf-ft]

6 mm

12.2 cm3/turn [0.745 in3/turn]

147

22 mm - 80 N•m [59 lbf-ft]

6 mm

12.4 cm3/turn [0.757 in3/turn]

165

22 mm - 80 N•m [59 lbf-ft]

6 mm

13.9 cm3/turn [0.848 in3/turn]

EDC Control Assembly Assemble control D050 (3X) 4 mm 8 N•m [6 lbf•ft] D025B 26 mm 5 N•m [3.7 lbf•ft] D025A D025

D025A D025

D050 (3X) 4 mm 8 N•m [6 lbf•ft] E101 352E

If you suspect a coil malfunction, remove the coil (D025B) by removing the plastic nut with a 26 mm 12 point socket. Install a new coil. Torque nut to 5 N•m [3.7 lbf•ft].

1. Install new O-rings (D025A) on the solenoids (D025), and attach the solenoids with M6 cap screws (D050) using 4 mm internal hex wrench. Torque to 8 N•m [6 lbf•ft].

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly 2. Press a new retaining ring (D094) and screen (D084) into the control assembly. Install the retaining ring and screen as shown.

Proper screen orientation

D098 D084

D084

Incorrect screen orientation

Correct screen orientation

P106 618E

EDC Control Installation Install the control D250 5 mm 13.3 N•m [9.8 lbf•ft]

D150 D200 13 mm Deep well socket 3 mm 2.5 N•m F00A [1.8 lbf•ft] F00B

22.5-27.5 N•m [16.6-20.3 lbf•ft] D300

E101 353E

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly 1. Use a 13 mm deep well socket to install the feedback pin (D200) in the swashplate. Torque to 25 N•m [18.5 lbf•ft]. Do not overtorque.

W

Warning

If feedback pin comes off during operation, pump will loose controllability causing a potentially hazardous situation. Ensure feedback pin is properly torqued before further assembly.

2. If removed, install control orifices (F00A, F00B) in their original positions using a 3mm internal hex wrench. Torque to 5 N•m [2 lbf•ft].

3. Install dowel pins (D300) in the housing.

4. Install a new gasket (D150).

5. Position the control on the pump housing.

6. Remove the plug on top of the control to visually ensure that the feedback pin is engaged in the control arms.

7. Using a 5 mm internal hex wrench, fasten the control to the pump with cap screws (D250). Torque the screws to 13.3 N•m [9.8 lbf•ft]. Follow the torque sequence shown below.

8. Adjust the swashplate to neutral, the control to neutral, and if necessary, the displacement limiter, after assembly is complete. Refer to H1 Closed Circuit Axial Piston Pump Service Manual 520L0848 for adjustment procedures.

Torque sequence 2

1 6

5

4

3

P106 195E

EDC Angle Sensor Assembly 1. Position the sensor on the control housing.

2. Using a 4 mm internal hex wrench, fasten sensor to control housing with screws (D770). Torque screws to 1.85 N•m [1.36 lbf•ft].

3. Postion protection cover on control housing over sensor.

4. Using a 4 mm internal hex wrench, fasten protection cover with screws (D767). Torque screws to 1.85 N•m [1.36 lbf•ft].

W

Warning

Calibration of sensor output in vehicle software is manditory after sensor replacement because output signal can vary from one sensor to the next.

© Danfoss | May 2018

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly EDC Angle sensor D767

D770

Item

Wrench size

Torque

D767

4 mm

1.85 N•m [1.36 lbf•ft]

D770

4 mm

1.85 N•m [1.36 lbf•ft]

EDC Control with Angle Sensor Installation 1. Install new control gasket (D150).

2. Before positioning the control on the pump housing ensure assembly fixture is positioned over the linkage spring in EDC center as shown on the right.

3. Position control on pump housing. Ensure that feedback pin on swashplate is positioned properly in control arm.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly 4. Pull assembly fixture out before installing control screws.

Solenoid shaft Control spool

Adjusting screw (cam)

Feedback pin Maximum adjustment less than 120°

Remove plug (D065) and verify the swashplate feedback pin is properly positioned between control feedback arms.

5. Using a 5 mm internal hex wrench, fasten control to pump with screws (D250). Torque screws to 13.5 N•m [10 lbf•ft] following torque sequence shown.

Torque sequence (6 screw control) 5

4

2

1

6

3

D065

W

Warning

Calibration of sensor output in vehicle software is mandidtory after sensor replacement because output signal can vary from one sensor to the next.

For proper neutral adjustment procedure, refer to Control Neutral Adjustment in H1P 69-250 Service Manual 520L0848

© Danfoss | May 2018

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly D250

D150

Feedback link

Item

Wrench size

Torque

D250

5 mm

13.5 N•m [10 lbf•ft]

MDC Control

Removal Refer to exploded diagram, below.

1. Using a 5 mm internal hex wrench, remove the six cap screws (D250).

2. Remove the control module and gasket (D150). Discard the gasket.

3. If necessary, remove servo orifices (F00A, F00B), supply orifice (F00P), and tank orifices (F00T) using a 3 mm internal hex wrench. Tag and number them for reistallation.

4. If screen (D084) is clogged, use a hook to remove the retaining ring (D098) and the screen. Discard the screen and replace with a new screen.

5. Before removing the control, note the position of the control lever for reassembly.

C

Caution

Do not disassemble the control, otherwise the functionality of the control and the neutral position of the pump can be lost!

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly MDC illustration - single pumps

MDC with CCO D250

D065 D692

D065

D693

D250

D750 D735 D81

D084 D098

D80

F00T

MDC with neutral start switch D065

D150

D200 D300 (2X) F00A F00B F00P

D250

D751 D750

P108784

MDC with neutral start switch and CCO D250

D065

D751 D750 D81 D80

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly MDC Legend - single pumps Wrench size and torque Item

Description

Wrench size

Torque

D065

O-ring plug

3/16 internal hex

12 N•m [9 lbf•ft]

D084

screen

-

-

D098

ring

-

-

D200

feedback pin

13 mm deep well socket

22.5-27.5 Nm [16.6-20.3 lbf•ft]

D250

cap screw

5 mm internal hex

13.3 Nm [9.8 lbf•ft]

D80

solenoid

-

-

D81

Oring

-

-

D750

neutral start switch

-

-

D751

Oring

-

-

D735

plug

3/4 inch

30 Nm [22 lbf•ft]

F00A

servo orifice

3 mm internal hex

2.5 Nm [1.8 lbf•ft]

F00B

servo orifice

3 mm internal hex

2.5 Nm [1.8 lbf•ft]

F00P

supply orifice

3 mm internal hex

2.5 Nm [1.8 lbf•ft]

F00T

tank orifice

3 mm internal hex

2.5 Nm [1.8 lbf•ft]

Inspection Inspect the machined surfaces on the control and top of the pump. If you find any nicks or scratches, replace the component.

Reassembly Ensure you install dowel pins (D300) in the housing before installing the control.

1. Install a new gasket (D150).

2. Install dowel pins (D300) in the housing.

W

Warning

If the feedback pin comes off during operation, the pump will lose controllability causing a potentially hazardous situation. Insure feedback pin is properly torqued before continuing with reassembly.

3. If you removed screen (D084), install a new one. Install it with the mesh facing outward (see drawing).

Install retaining ring (D098).

MDC - Proper screen orientation D098 D084

Correct screen orientation

60 | © Danfoss | May 2018

D084

Incorrect screen orientation

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly 4. If previously removed, install orifices using a 3 mm internal hex wrench. Torque to 2.5 Nm [1.8 lbf ft].

Remove the plug on top of the control to ensure the swashplate feedback pin is properly positioned in the center of the control module when installing control.

5. Install the control module and six cap screws (D250).

Torque sequence 2

1 6

5

4

3

6. Using a 5 mm internal hex wrench, torque the cap screws (D250) to 13.3 Nm [9.8 lbf ft].

Automotive Control Installation 1. If previously removed, install new screen (D084) in original orientation. Press in new retention ring (D098). Be sure screen will not move axially in bore after retention ring is installed.

W

Warning

Failure to install screen will result in erratic pump operation.

2. If previously removed, use a 3 mm internal hex to install orifices (F00A, F00B) in original orientation.

Torque to 5 N•m [1.8 lbf•ft].

3. Install new gasket (D150) to bottom of control.

4. Install control on pump. Use a 5 mm internal hex to install six screws (D250). Torque to 13.3 N•m [9.8 lbf•ft]. Follow torque sequence shown EDC Control Installation on page 54 Do not damage the plastic housing when installing the screws.

5. Connect wiring (D640).

6. Use the specially fabricated tool to install new plastic plugs with O-rings (D610). Press in and turn 45 degrees clockwise.

If the control will continue to be under warranty, install new sealing wax. Pumps without sealing wax installed will not be warrantied.

7. Install the protection bracket (D672). Install screws (D674). Torque to 5 N•m [3.7 lbf•ft].

If pump has been rebuilt or a new control is being installed, control software must be recalibrated.

Refer to H1-Automotive Control User Manual 70012797 for recalibration instructions.

© Danfoss | May 2018

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly Install control 13.3 Nm [9.8 lbf•ft]

Security wax seal (2X) D610 (2X)

D250 5 mm (6X)

D672

D674 D084

D640

D098

2.5 Nm [1.8 lbf•ft] F00A

D150

3 mm F00B P107 990E

Special plug installation tool Special tool

Plug

45 deg.

Ø 9.22 mm Ø 14 mm Ø 1.7 mm (x3) P108 021E

Replacing solenoids Follow the solenoid replacement procedure on EDC Control Assembly on page 53.

Optional Integrated Filter Installation 1. If replacing switch (T200), use a 4 mm internal hex wrench to install cap screws (T300) and switch (T200). Torque to 2-8 N•m, [0.8-3 lbf•ft].

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly 2. Lubricate and install new O-rings (T025A) on plugs (T025).

3. Install spring (T030), and spool (T020).

4. Use an 8 mm internal hex wrench to install plugs (T025) and torque to 16-20 N•m, [12-15 lbf•ft].

5. Install a new gasket (T350).

Assemble filter adapter T025 8 mm T025A T030

T020

T200

T300

T025 8 mm

T025A P106 143E

T015 T350 T045

T250 (3X) 8 mm

T035

T010

T150 P106 141E

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Assembly 6. Use an 8 mm internal hex to install screws (T250). Torque to 29-35 N•m, [21-26 lbf•ft].

7. Lubricate and install a new seal (T045) and O-ring (T035).

8. Lubricate the filter seal and install a new filter (T150). Use a 24 mm wrench to hold plug (T015) in place and install the replacement filter. Hand tighten the filter till it contacts the O-ring, then tighten it 1/2 turn further.

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Startup procedures Overview Install pump on test stand. Adjust per Danfoss testing specifications TS-392. Refer to H1 069/078/089/100/115/130/147/165 Closed Circuit Axial Piston Pumps Service Manual 520L0848 for startup procedures, adjustments, and pressure measurements for H1 pump.

Initial Startup Procedures Startup procedures include: • Ensure that the system components are clean

• • • • • •

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

Adjustments Adjustment procedures include: • Mechanical neutral

• • • •

Charge pressure relief adjustment Pressure limiter adjustment Displacement limiter adjustment Electronic displacement control (EDC) adjustment

Pressure Measurements Pressure measurement procedures include: • Required tools

• • •

© Danfoss | May 2018

Port locations Gauge installation Leakage test per Danfoss test HPP 112

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Port locations Port Locations and Gauge Installation The following table and drawing show the port locations and gauge sizes needed. When testing system pressures, calibrate pressure gauges frequently to ensure accuracy. Use snubbers to protect gauges.

Port information Port identifier

Port size

Wrench size

Reading

Gauge size, bar [psi]

L1, L3 (069/078/089/100)

7/8-14 UNF 2B

3/8 internal hex

Case drain

10 [100]

L2, L4 (069/078/089/100)

1 1/16-12 UNF 2B

9/16 internal hex

Case drain

10 [100]

L1, L3 (115/130/147/165)

1 1/16-12 UNF 2B

9/16 internal hex

Case drain

10 [100]

L2, L4 (115/130/147/165)

1 5/16-12 UNF 2B

5/8 internal hex

Case drain

10 [100]

MA, MB

9/16-18 UNF

1/4 internal hex

System pressure

600 [10,000]

M3

9/16-18 UNF 2B

1/4 internal hex

Charge pressure- after filter

50 [1000]

M4, M5

7/16-20 UNF 2B

3/16 internal hex

Servo pressure

50 [1000]

M6

9/16-18 UNF 2B

1/4 internal hex

Charge pressure - pre integrated filter

50 [1000]

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Port locations Port locations

Case drain Port L3

Gage port M4 servo pressure 7/16-20 UNF 2B

Port L1 Case drain

Gauge port M5 Servo pressure 7/16-20 UNF-2B Gauge port M3 Charge pressure after filter 9/16-18 UNF-2B

System Port B

Charge pump inlet S 1 5/8-12 UNF 2B

System Port A

Case drain Port L4 use highest port as outlet

G300 5/16-24 UNF-2B air bleed

D065 O-ring plug 7/16-20 UNF-2B use for air bleed when filling pump

© Danfoss | May 2018

Charge pressure Gauge port M6 pre integrated filter 9/16-18 UNF-2B

Case drain port L2 1 5/16-12 UNF-2B

Gauge port MB System pressure 9/16-18 UNF-2B

Gauge port MA System pressure 9/16-18 UNF-2B P106 033E

520L0874 | AX00000190en-US0302 | 67

Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Torque chart Fastener Size and Torques Item

Fastener

Wrench size

Torque

D015

Neutral adjust screw

4 mm internal hex

NA

D050

Coil mounting bolt

4 mm internal hex

8 N•m [6 lbf•ft]

D060

Neutral adjust locking nut

13 mm

10 N•m [7 lbf•ft]

D200

Swash plate feedback pin (not shown)

13 mm deep well socket

25 N•m [18 lbf•ft]

D250

Electric control mounting bolt

5 mm internal hex

13.3 N•m [9.8 lbf•ft]

E350

Servo can locking bolt

10 mm

14 N•m [10 lbf•ft]

G350 (069/078)

Endcap screw (4)

12 mm internal hex

170N•m [125 lbf•ft]

G400 (069/078)

Endcap screw (2)

6 mm internal hex

32N•m [24 lbf•ft]

G350 (089/100/115/130)

Endcap screw (4)

14 mm internal hex

300 N•m [220 lbf•ft]

G400 (089/100/115/130)

Endcap screw (2)

8 mm internal hex

64 N•m [47 lbf•ft]

G350 (147/165)

Endcap screw (4)

17 mm internal hex

400N•m [295 lbf•ft]

G400 (147/165)

Endcap screw (2)

10 mm internal hex

110N•m [81 lbf•ft]

K400

Rear cover/Aux pad mounting bolt

10 mm internal hex

92 N•m [68 lbf•ft]

K450

Charge Pump Cover Screw

5 mm internal hex

25 N•m [18 lbf•ft]

L010 (069/078)

Pressure limiter adjust screw

8 mm

NA

L012 (069/078)

Pressure limiter cartridge

14 mm

30 N•m [22 lbf•ft]

L010 (089/100/115/130/147/165)

Pressure limiter adjust screw

5 mm internal hex

NA

L012 (089/100/115/130/147/165)

Pressure limiter cartridge

22 mm

70 N•m [52 lbf•ft]

L024 (069/078)

Pressure limiter locking nut

14 mm

20 N•m [15 lbf•ft]

L150 (069/078)

High pressure relief valve

22 mm

70 N•m [52 lbf•ft]

L024 (089/100/115/130/147/165)

Pressure limiter locking nut

17 mm

20 N•m [15 lbf•ft]

L028 (089/100/115/130/147/165)

Pressure limiter plug (special)

30 mm

110 N•m [81 lbf•ft]

L150 (089/100/115/130/147/165)

High pressure relief valve

19 mm

68 N•m [50 lbf•ft]

T015

Filter mounting bolt

17 mm

21 N•m [16 lbf•ft]

T025

Filter adapter gage plug

6 mm internal hex

18 N•m [13 lbf•ft]

V010

Charge pressure cartridge

22 mm

52 N•m [38 lbf•ft]

V020

Charge pressure adjusting screw

4 mm internal hex

NA

V022

Charge pressure locking nut

13 mm

12 N•m [9 lbf•ft]

Plug Size and Torques Item

O-ring plug

Wrench size

Torque

B015

7/16 - 20

3/16 mm internal hex

12 N•m [9 lbf•ft]

B020 (069/078/ 089/100/115/130)

7/8 - 14

3/8 internal hex

50N•m [37 lbf•ft]

B020 (147/165)

1-1/16 - 12

9/16 internal hex

70 N•m [52 lbf•ft]

B035 (069/078/ 089/100/115/130)

1 1/16 - 12

9/16 internal hex

70 N•m [52 lbf•ft]

B035 (147/165)

1 5/16 - 12

5/8 internal hex

70 N•m [52 lbf•ft]

D065

7/16 - 20

3/16 internal hex

12 N•m [9 lbf•ft]

G250

9/16 - 18

1/4 internal hex

40 N•m [30 lbf•ft]

G300

9/16 - 18

3/16 internal hex

40 N•m [30 lbf•ft]

G302

5/16 - 24 UNF

1/8 internal hex

5 N•m [4 lbf•ft]

68 | © Danfoss | May 2018

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Torque chart Fasteners and Plugs 078 Pressure limiter

115/130/147/165 Pressure limiter L010 Adjusting screw

L028 Adjusting screw

L024 Locking nut

L024 Locking nut

L028 Plug (special) L012 Cartridge

D015 Neutral adjusting screw D060 Neutral adjust locking nut

L012 Cartridge

B015 O-ring plug, 7/16 - 20 Pressure limiter G400 Endcap screw

D050 Coil mounting bolt

G302 O-ring plug, 5/16 - 24 UNF

B020 O-ring plug 1-1/16 - 12

G350 Endcap screw

G300 O-ring plug, 9/16 - 18

B030 O-ring plug, 1-5/16 - 12

E350 Servo can locking bolt

D250 Electric control mounting bolt

G250 O-ring plug, 9/16 - 18

G302 O-ring plug 5/16 - 24 UNF

D065 O-ring plug, 7/16 - 20

© Danfoss | May 2018

P106 066E

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Repair Instructions H1 - 069/078, 089/100, 115/130, 147/165 Axial Piston Pumps Torque chart D015 Neutral adjusting screw D060 Neutral adjust locking nut

B015 O-ring plug, 7/16 - 20 L010 Pressure limiter adjusting screw L024 Pressure limiter locking nut L028 Pressure limiter plug (special)

D050 Coil mounting bolt

L012 Pressure limiter cartridge G302 O-ring plug, 5/16 - 24 UNF

B020 O-ring plug 1-1/16 - 12

G300 O-ring plug, 9/16 - 18

B035 O-ring plug, see table

E350 Servo can locking bolt

D250 Electric control mounting bolt

G250 O-ring plug, 9/16 - 18

G302 O-ring plug 5/16 - 24 UNF

D065 O-ring plug, 7/16 - 20

70 | © Danfoss | May 2018

P106 497E

520L0874 | AX00000190en-US0302