Manitou Sauer Danfoss Hydrostatic Pump H1 069-078 089-100 115-130 147-165 Repair Manual 647424EN

647424EN (12/02/2014)

HYDROSTATIC PUMP H1 069/078, 089/100, 115/130, 147/165 Repair manual

MANITOU BF B.P 10249 - 44158 ANCENIS Cedex Tél. 33 (0) 2 40 09 10 11 Fax commercial France : 02 40 09 10 96 // Export : 33 2 40 09 10 97 www.manitou.com

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647424EN

DATE OF ISSUE

OBSERVATION

25 / 03 / 2013

- 1st Date of Issue

12 / 02 / 2014

- UPDATE

THE TEXTS AND PICTURES IN THIS DOCUMENT CANNOT BE REPRODUCED EITHER TOTALLY OR PARTLY.

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

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Revisions History of Revisions

Table of Revisions Date

Page

Changed

Rev.

November 2012 June 2011 January 2011 August 2010 July 2010 March 2010 October 2009 September 2009 July 2009 April 2009 December 2008 April 2008 April 2008 Jul 2007

all various 13 and 39 38 last last various 16, 24, 38 11, 43 various various various all -

add 069 frame size add protection bracket to automotive control correcting sort string for alignment pins G450 Update valve plate drawing New back page Fix Osaka Address various edits and corrections new valve plate Added automotive control Added 089/100 remove special tool numbers Added special tools part numbers Added 115/130 First edition

AO AN AM AL AK AJ AI AH AG AF AE AC AB AA

© 2012 Sauer-Danfoss. All rights reserved.

Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material. Sauer -Danfoss reserves the right to alter its products without prior notice. This also applies to products already ordered, provided that such alterations can be made without affecting agreed specifications. All trademarks in this material are properties of their respective owners. Sauer-Danfoss, the Sauer-Danfoss logotype, the Sauer-Danfoss S-icon, PLUS+1™, What really matters is inside® and Know-How in Motion™ are trademarks of the Sauer-Danfoss Group.

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520L0874 • Rev AO • November 2012

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

Disassembly

Inspection

Overview............................................................................................................................................................ 5 General instructions....................................................................................................................................... 5 Safety Precautions.......................................................................................................................................... 6 Unintended machine movement........................................................................................................ 6 Flammable cleaning solvents................................................................................................................ 6 Fluid under pressure................................................................................................................................. 6 Personal safety............................................................................................................................................ 6 Symbols used in Sauer-Danfoss Literature............................................................................................ 7

Shaft Seal Removal......................................................................................................................................... 8 Input Shaft Removal....................................................................................................................................... 8 EDC Control Removal..................................................................................................................................... 9 EDC Control Disassembly...........................................................................................................................10 Automotive Control Removal...................................................................................................................11 Optional Integrated Filter Removal........................................................................................................12 Auxiliary Pad or End Cover Removal......................................................................................................13 Charge Pump Removal................................................................................................................................14 Pressure Limiter Valve Removal...............................................................................................................14 Charge Pressure Relief Valve Removal...................................................................................................15 High Pressure Relief Valve Removal........................................................................................................15 Endcap Removal............................................................................................................................................16 Cylinder Block Kit Removal........................................................................................................................17 Optinal Displacement Limiter...................................................................................................................17 Servo Cylinder Removal..............................................................................................................................18 Servo Piston Removal..................................................................................................................................18 Servo Piston Disassembly..........................................................................................................................19 Swashplate and Cradle Bearings Removal...........................................................................................19 Cylinder Block Kit...........................................................................................................................................20

Overview..........................................................................................................................................................21 Pistons and Slippers.....................................................................................................................................21 Ball Guide and Slipper Retainer...............................................................................................................21 Block Spring and Washers..........................................................................................................................21 Cylinder Block . ..............................................................................................................................................22 Shaft ..................................................................................................................................................................22 Shaft Bearing...................................................................................................................................................22 Swashplate.......................................................................................................................................................23 Cradle Bearings..............................................................................................................................................23 Valve Plate........................................................................................................................................................24 Endcap..............................................................................................................................................................24 Housing ...........................................................................................................................................................25 Pressure Limiter.............................................................................................................................................25 HPRV Valve.......................................................................................................................................................26 Optional Displacement Limiter................................................................................................................26 Charge Pressure Relief Valve.....................................................................................................................26 Servo Piston Assembly................................................................................................................................27 Control...............................................................................................................................................................27 Optional Integrated Filter...........................................................................................................................28

520L0874 • Rev AO • November 2012

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

Overview..........................................................................................................................................................29 Cradle Bearings, Swashplate, and Filter Screen Installation ..........................................................29 Servo Piston Assembly................................................................................................................................30 Servo Piston Installation.............................................................................................................................30 Servo Cylinder Installation.........................................................................................................................31 Optinal Displacement Limiter...................................................................................................................32 Install Optional Hold down Clamp..........................................................................................................32 Hold Down Clamp.........................................................................................................................................33 Dimensions......................................................................................................................................................33 Shaft and Seal Installation..........................................................................................................................34 Cylinder Kit Assembly..................................................................................................................................35 Cylinder Kit Installation...............................................................................................................................36 Level Swashplate...........................................................................................................................................36 Endcap Bushing Installation......................................................................................................................37 Valve Plate and Endcap Installation........................................................................................................38 Charge Pump Installation...........................................................................................................................39 Auxiliary Pad or End Cover Installation.................................................................................................39 Charge Pressure Relief Valve Installation..............................................................................................40 Pressure Limiter Valve Installation...........................................................................................................40 HPRV Valve Installation................................................................................................................................41 Optional Displacement Limiter Installation.........................................................................................41 Control Assembly..........................................................................................................................................42 Control Installation.......................................................................................................................................43 Automotive Control Installation..............................................................................................................44 Optional Integrated Filter Installation...................................................................................................45

Startup Procedures

Overview..........................................................................................................................................................46 Initial Startup Procedures...........................................................................................................................46 Adjustments....................................................................................................................................................46 Pressure Measurements..............................................................................................................................46

Port Locations

Port Locations and Gauge Installation..................................................................................................47

Torque Chart

Fastener Size and Torques..........................................................................................................................48 Plug Size and Torques..................................................................................................................................48 Fasteners and Plugs......................................................................................................................................49

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520L0874 • Rev AO • November 2012

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions 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 Sauer-Danfoss Global Service Partners (GSPs) are authorized to perform major repairs. Sauer-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 Sauer-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 H1 variable displacement closed circuit pumps. w Remove the unit Prior to performing major repairs, 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 and plug ports after removal to prevent contamination. e 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 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. l Lubricate moving parts During assembly, coat all moving parts with clean hydraulic fluid. This assures that these parts are lubricated during start-up. d Replace all O-rings and gaskets Sauer-Danfoss recommends you replace all O-rings, seals, and gaskets during repair.

Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. Grease must be soluable in hydraulic fluid. t Secure the unit For major repair, place the unit in a stable position with the shaft pointing downward. It is necessary to secure the pump while removing and torquing the endcap bolts.

520L0874 • Rev AO • November 2012

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

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520L0874 • Rev AO • November 2012

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Introduction Symbols used in SauerDanfoss Literature

 WARNING may result in injury

 Clean area or part

 Non-reusable part, use a new part

 Be careful not to scratch or damage

 External hex head

 Note correct orientation

 Internal hex head

 Torque specification

 Lubricate with hydraulic fluid

 Pull out with tool – press fit

 Apply grease / petroleum jelly

 Cover splines with installation cylinder

 Inspect for wear or damage

 Mark orientation for reinstallation

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.

520L0874 • Rev AO • November 2012

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

Input Shaft Removal

Remove shaft /seal/bearing J200

J250

J200 J100

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.

J150

4. Remove snap ring (J300).

5. Press bearing (J150) from shaft.

J300

P106 057E

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520L0874 • Rev AO • November 2012

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Disassembly EDC Control Removal

1. Remove control screws (D250) using a 5 mm internal hex wrench. Remove the control from the pump

Remove control

D250 5 mm

Some older pumps may have a five bolt control. This control uses a different gasket and has no control screeen (D084).

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.

D150

D084 F00A

3 mm F00B

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

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.

520L0874 • Rev AO • November 2012

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

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].

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.

Disassemble the control D050 (3X) 4 mm

D025A D025 D025A D050 (3X) 4 mm

P106 061E

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520L0874 • Rev AO • November 2012

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Disassembly 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). W Remove control from pump.

5. Remove and discard gasket (D150).

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

Drill Out Retention Ring

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.

Screen

Retention Ring P108 022E

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

Security wax seal (2X)

Remove control

D610 (2X) D610A (2X)

Special Tool

Special tool

D250 5 mm (6X)

Plug

D672

D674

45 deg.

D084

D150

D098

Ø 9.22 mm Ø 14 mm Ø 1.7 mm (x3)

F00A

3 mm F00B

P108 021E

P106 708E

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

4. Remove filter adapter (T010). Discard gasket (T350).

Remove filter and adapter

24 mm T015 T045

T250 (3X) 8 mm

T350 T035

T010

T150 P106 136E

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

T025 8 mm

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

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.

3 mm T300

T200

T025 8 mm

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520L0874 • Rev AO • November 2012

T025A

T030

P106 138E

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Disassembly Auxiliary Pad or End Cover Removal

1. Position pump so end cover (K100) or auxiliary pad is on top.

Remove end cover and charge pump 147/165 shown

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

K400 10 mm

Alignment pins (G450) are in end cover.

They may dislodge during disassembly.

K100

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).

G450 G450

K150

K500

S300

6. Remove coupling (K200).

S200

069/078/089/100 Auxiliary pads K200

S150

S100

B flange

S250

A flange

S300

115/130/147/165 Auxiliary pads

B flange

A flange

C flange P106 047E

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

Remove pressure limiter L400 22 mm

L300 22 mm

L022 L022

E101 336E

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520L0874 • Rev AO • November 2012

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Disassembly Charge Pressure Relief Valve Removal

1. Using a 22 mm wrench, remove the charge pressure relief valve (V010).

Remove charge pressure relief valve

2. Discard O-ring (V024).

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

V024

V010 22 mm

High Pressure Relief Valve Removal

1. 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).

P106 159E

Remove high pressure relief valves

L060

HPRV valves may not have the same pressure setting. Tag each valve for reassembly.

L068

L200 L100

42

Pressure code marked on end P106 039E

520L0874 • Rev AO • November 2012

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069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Disassembly Endcap Removal

See table below for endcap screw wrench sizes

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

1. Remove two endcap screws (G400).

G400 (2X)

2. Remove four endcap screws (G350).

C Caution Note valveplate orientation for proper reassembly.

3. Carefully remove the endcap (G100). and valveplate (C025). C Valveplate may be stuck to endcap. Alignment pin (C020) may remain in endcap.

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

5. Remove and discard gasket (G150).

G100 G980 C020

G550 C025

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.

B060

G150 B010

Endcap screw wrench sizes - internal hex

16

069/078 6mm 12mm

089/100/115/130 8mm 14mm

520L0874 • Rev AO • November 2012

B040 (3X) P106 058E

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.

Item G400 G350

B010

147/165 10mm 17mm

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Disassembly Cylinder Block Kit Removal

1. Remove cylinder block assembly (C010).

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.

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

Optinal Displacement Limiter

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

Remove cylinder block kit C010

P106 056E

Remove displacement limiter screw

P107 992E

Displacement Limiter wrench sizes Displacement 069/078/089/100

Locknut wrench size Adjusting screw wrench size 13 mm 4 mm internal hex

115/130/147/165

22 mm

520L0874 • Rev AO • November 2012

6 mm internal hex

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069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Disassembly Servo Cylinder Removal

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

2. Remove four locking screws (E350) with a 10 mm wrench. Remove locking plates (E300).

3. 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.

CDiscard O-rings (E250).

Remove the servo cylinders

E250

E150 E300

E350 11 mm

Servo Piston Removal

E101 330E

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

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520L0874 • Rev AO • November 2012

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

1. Remove and discard the seals (E025).

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.

Remove swashplate and cradle bearings

D070

2. Remove cradle bearings (D075).

D075

D075

P106 059E

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069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Disassembly Cylinder Block Kit

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

Disassemble the cylinder block 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.

C10

2. Remove the ball guide (C15) and spring washer (C25). Discard the spring washer.

C20

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

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.

3. 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

C15

C25

C05

C35

C30

C40

C45 P106 060E

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520L0874 • Rev AO • November 2012

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

Inspect pistons Slipper

P104 109E

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

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.

Inspect block spring and washers Washer

Cylinder block spring Washer Retaining ring

P101 472

520L0874 • Rev AO • November 2012

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

Inspect shaft bearing Shaft Bearing

22

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.

520L0874 • Rev AO • November 2012

E101 343E

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

Inspect cradle bearings

Replace the cradle bearings as a pair.

E101 339E

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

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520L0874 • Rev AO • November 2012

Inspect endcap

P108 399E

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

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

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25

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

Pressures marked on HPRV valve Code 15 20 23 25 28 30 33 35 38 40 42 43 44 45 48

Optional Displacement Limiter

Pressure bar [psi] 150[2175] 200 [2900] 230 [3336] 250 [3626] 208 [4061] 300 [4351] 330 [4786] 350 [5076] 380 [5511] 400 [5801] 420 [6092] 430[6237] 440[6382] 450 [6527] 480 [6962]

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

42

Pressure code marked on end P106 662E

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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520L0874 • Rev AO • November 2012

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

Do not disassemble the servo piston assembly.

Seals and O-rings are available as a replacement kit.

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.

Inspect servo assembly

E100 E025 (2X) E015

E025 P101 337E

Control

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 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.

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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27

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions 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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520L0874 • Rev AO • November 2012

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

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

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

Install servo piston

Do not damage the seals when installing the servo cylinders.

E100

E101 331E

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520L0874 • Rev AO • November 2012

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Assembly 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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31

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

1. 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 069/078 13 mm - 30 N•m [28 lbf-ft]

Adjusting screw wrench size 4 mm

Approximate displacement change per revolution of adjusting screw 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.

Install hold down clamp Hold down clamp No gap between clamp and housing

E101 402E

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069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Assembly 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 11.7 mm

5 mm

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

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

520L0874 • Rev AO • November 2012

P107 879E

33

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Assembly Shaft and Seal Installation Holdown clamp holds swashplate in place when housing is rotated.

Swashplate will fall out of place without holdown clamp.

C Caution Do not scratch the housing or shaft during shaft 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).

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

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

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 J300 J150

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

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520L0874 • Rev AO • November 2012

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

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

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

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.

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

Assemble cylinder kit

C10

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 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.

C20

C15

C25

C05

C40

C30

C35

C45 E101 350E

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069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Assembly Cylinder Kit Installation

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

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

E101 351E

Prevent shaft from rotating

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.

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069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Assembly Endcap Bushing Installation

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

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.

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37

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Assembly Valve Plate and Endcap Installation

Install endcap components 147/165 shown

1. Remove the holdown clamp.

G350

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.

Torque sequence

6

5 2

4

3

1

P106 193E

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

G400

G100 G980 C020 G550 C025

G150 B010

B010

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

7. Wrench sizes and torques are listed in the table below.

Use torque sequence shown.

Valveplate orientation

Clockwise valveplate

E101 358E

Counterclockwise valveplate

Notch used for EDC or FNR controls

Endcap screw wrench sizes and torques Item G400

G350

069/078 6mm 32 Nm [24 lbf•ft] 12mm 170 Nm [125 lbf•ft]

089/100/115/130 8mm 64 Nm [47 lbf•ft] 14mm 300 Nm [220 lbf•ft]

147/165 10mm 110 Nm [81 lbf•ft] 17mm 400 Nm [295 lbf•ft]

CW

CCW

Notch used for NFPE or AC controls

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P108 060E

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Assembly Charge Pump Installation

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

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

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).

92 N•m [68 lbf•ft] K100 G450 G450

K150

K500

3. Lubricate and install coupling (K200).

4. Lubricate and install the pressurebalance 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.

S300

S200

K200

S150

Auxiliary Pad or End Cover Installation

1. Install alignment pins (G450). Install gasket (K150).

S100

S250

Ensure proper torque on aux pad screws (K400).

If necessary, replace screws.

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.

S300

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

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

Torque sequence 5

7

1 3

4 2 P106 116E

8

6 P106 196E

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069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Assembly Charge Pressure Relief Valve Installation

1. Install a new O-ring (V024).

Install charge pressure relief valve

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

3. Torque to 52 N•m [38 lbf•ft].

V024

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

V010 22 mm 52 N•m [38 lbf•ft]

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

Install pressure limiter

L400 22 mm

Torque N•m [lbf•ft] Wrench size

40

069/078 30 [22] 14 mm

089/100/115 130/147/165 70 [52] 22 mm

520L0874 • Rev AO • November 2012

L300 22 mm

L022 L022

E101 361E

Model

P106 115E

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Assembly HPRV Valve Installation

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

Install HPRV valve

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

L060 Model

069/078

Torque N•m [lbf•ft] Wrench size

70 [52] 22 mm

089/100/115 130/147/165 110 [81] 30 mm

L068

L200 L100 P106 114E

Optional Displacement Limiter Installation

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

1. Thread the adjusting screw (E400) into the servo cylinder.

Install the displacement limiter

2. Thread locking nut (E500) onto the displacement limiter adjusting screw.

Torque the locknut per the table below.

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

E400 see table E500 see table

E101 357E

Displacement Locknut wrench size and torque 069/078 13 mm - 24 N•m [18 lbf-ft]

Adjusting screw wrench size 4 mm

Approximate displacement change per revolution of adjusting screw 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]

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]

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41

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

Assemble control D050 (3X) 4 mm 8 N•m [6 lbf•ft]

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].

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

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].

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 D094 D084

Correct screen orientation

D084

Incorrect screen orientation

P106 618E

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520L0874 • Rev AO • November 2012

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

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.

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 2. If removed, install control orifices (F00A, F00B) in their original positions using a 3mm internal hex wrench. Torque to 2.5 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.

Torque sequence 2

1 6

5

4

3

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.

P106 195E

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069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Assembly 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 2. If previously removed, use a 3 mm internal hex to install orifices (F00A, F00B) in original orientation. Torque to 2.5 N•m [1.8 lbf•ft].

W Warning Failure to install screen will result in erratic pump operation.

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 on page 40.

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 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.

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].

Install control 13.3 Nm [9.8 lbf•ft]

Special plug installation tool Special tool

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

D250 5 mm (6X)

D672

Plug

D674 D084

D640

D098

45 deg.

Ø 9.22 mm

2.5 Nm [1.8 lbf•ft] F00A

D150

3 mm F00B

Ø 14 mm Ø 1.7 mm (x3) P108 021E

Replacing solenoids Follow the solenoid replacement procedure on page 42.

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520L0874 • Rev AO • November 2012

P107 990E

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Assembly 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 1.2-1.8 N•m, [0.8-1.3 lbf•ft].

2. Lubricate and install new O-rings (T025A) on plugs (T025).

Assemble filter adapter T025 8 mm T025A T030

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

T020

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

T200

5. Install a new gasket (T350).

T300

T025 8 mm

T025A P106 142E

T015 T350 T045

T250 (3X) 8 mm

T035

T010

T150 P106 140E

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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45

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Startup procedures Overview

Install pump on test stand. Adjust per Sauer-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 • Port locations • Gauge installation • Leakage test per Sauer-Danfoss test HPP 112

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520L0874 • Rev AO • November 2012

069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions 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 L1, L3 (069/078/089/100) L2, L4 (069/078/089/100) L1, L3 (115/130/147/165) L2, L4 (115/130/147/165) MA, MB M3 M4, M5 M6

Port size 7/8-14 UNF 2B 1 1/16-12 UNF 2B 1 1/16-12 UNF 2B 1 5/16-12 UNF 2B 9/16-18 UNF 9/16-18 UNF 2B 7/16-20 UNF 2B 9/16-18 UNF 2B

Wrench size 3/8 internal hex 9/16 internal hex 9/16 internal hex 5/8 internal hex 1/4 internal hex 1/4 internal hex 3/16 internal hex 1/4 internal hex

Reading Case drain Case drain Case drain Case drain System pressure Charge pressure- after filter Servo pressure Charge pressure - pre integrated filter

Gauge size, bar [psi] 10 [100] 10 [100] 10 [100] 10 [100] 600 [10,000] 50 [1000] 50 [1000] 50 [1000]

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

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

520L0874 • Rev AO • November 2012

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

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069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions 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 D250 E350 G350 (069/078) G400 (069/078) G350 (089/100/115/130) G400 (089/100/115/130) G350 (147/165) G400 (147/165) K400 K450 L010 (069/078) L012 (069/078) L010 (089/100/115/130/147/165) L012 (089/100/115/130/147/165) L024 (069/078) L150 (069/078) L024 (089/100/115/130/147/165) L028 (089/100/115/130/147/165) L150 (089/100/115/130/147/165) T015 T025 V010 V020 V022

Swash plate feedback pin (not shown) Electric control mounting bolt Servo can locking bolt Endcap screw (4) Endcap screw (2) Endcap screw (4) Endcap screw (2) Endcap screw (4) Endcap screw (2) Rear cover/Aux pad mounting bolt Charge Pump Cover Screw Pressure limiter adjust screw Pressure limiter cartridge Pressure limiter adjust screw Pressure limiter cartridge Pressure limiter locking nut High pressure relief valve Pressure limiter locking nut Pressure limiter plug (special) High pressure relief valve Filter mounting bolt Filter adapter gage plug Charge pressure cartridge Charge pressure adjusting screw Charge pressure locking nut

13 mm deep well socket 5 mm internal hex 10 mm 12 mm internal hex 6 mm internal hex 14 mm internal hex 8 mm internal hex 17 mm internal hex 10 mm internal hex 10 mm internal hex 5 mm internal hex 8 mm 14 mm 5 mm internal hex 22 mm 14 mm 22 mm 17 mm 30 mm 19 mm 17 mm 6 mm internal hex 22 mm 4 mm internal hex 13 mm

25 N•m [18 lbf•ft] 13.3 N•m [9.8 lbf•ft] 14 N•m [10 lbf•ft] 170N•m [125 lbf•ft] 32N•m [24 lbf•ft] 300 N•m [220 lbf•ft] 64 N•m [47 lbf•ft] 400N•m [295 lbf•ft] 110N•m [81 lbf•ft] 92 N•m [68 lbf•ft] 25 N•m [18 lbf•ft] NA 30 N•m [22 lbf•ft] NA 70 N•m [52 lbf•ft] 20 N•m [15 lbf•ft] 70 N•m [52 lbf•ft] 20 N•m [15 lbf•ft] 110 N•m [81 lbf•ft] 68 N•m [50 lbf•ft] 21 N•m [16 lbf•ft] 18 N•m [13 lbf•ft] 52 N•m [38 lbf•ft] NA 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) B020 (147/165) B035 (069/078/ 089/100/115/130)

7/8 - 14 1-1/16 - 12 1 1/16 - 12

3/8 internal hex 9/16 internal hex 9/16 internal hex

50N•m [37 lbf•ft] 70 N•m [52 lbf•ft] 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 G302

9/16 - 18 5/16 - 24 UNF

3/16 internal hex 1/8 internal hex

40 N•m [30 lbf•ft] 5 N•m [4 lbf•ft]

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520L0874 • Rev AO • November 2012

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

520L0874 • Rev AO • November 2012

P106 066E

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069/078, 089/100, 115/130, 147/165 H1 Axial Piston Pumps Repair Instructions Torque chart Fasteners and Plugs (continued) B015 O-ring plug, 7/16 - 20

D015 Neutral adjusting screw D060 Neutral adjust locking nut

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

E350 Servo can locking bolt

B035 O-ring plug, see table

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

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520L0874 • Rev AO • November 2012

P106 497E