Danfoss H1 45 Setup guide

MAKING MODERN LIVING POSSIBLE
Repair Instructions
Closed Circuit Axial Piston Pumps
H1 45/53/60/68
powersolutions.danfoss.com

Revision history Table of revisions
Date Changed Rev
September 2014 add MDC control CB
March 2014 Danfoss Layout CA
March 2013 Control topic titles - to be more generic BC
June 2011 add protection shield for automotive control BB
October 2010 add 060-068 BA
August 2010 new back page AH
March 2010 add automotive control AG
February 2010 Fix Osaka address AF
April 2008 many minor edits AC
July 2007 First edition AA
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
2520L0957 • Rev CB • September 2014

Introduction Overview..............................................................................................................................................................................................5
General Instructions........................................................................................................................................................................ 5
Remove the unit..........................................................................................................................................................................5
Keep it clean..................................................................................................................................................................................5
Lubricate moving parts.............................................................................................................................................................5
Replace all O-rings and gaskets............................................................................................................................................. 5
Secure the unit.............................................................................................................................................................................6
Safety Precautions............................................................................................................................................................................6
Unintended machine movement..........................................................................................................................................6
Flammable cleaning solvents.................................................................................................................................................6
Fluid under pressure..................................................................................................................................................................6
Personal safety.............................................................................................................................................................................6
Symbols used in Danfoss literature............................................................................................................................................7
Disassembly Shaft Seal Removal...........................................................................................................................................................................8
Input Shaft...........................................................................................................................................................................................8
Control Removal............................................................................................................................................................................... 9
Control Disassembly.....................................................................................................................................................................10
Remove the Automotive Control.............................................................................................................................................10
Auxiliary Pad or End Cover Removal.......................................................................................................................................11
Charge Pump Removal................................................................................................................................................................ 12
Pressure Limiter Removal............................................................................................................................................................13
Charge Pressure Relief Valve Removal...................................................................................................................................13
High Pressure Relief Valve Removal........................................................................................................................................14
Endcap Removal.............................................................................................................................................................................14
Cylinder Block Kit Removal.........................................................................................................................................................15
Servo Sleeve Removal.................................................................................................................................................................. 16
Servo Piston Removal...................................................................................................................................................................17
Swashplate and Swashplate Bearing Removal................................................................................................................... 17
Servo Piston Disassembly........................................................................................................................................................... 18
Cylinder Kit....................................................................................................................................................................................... 19
Disassemble the cylinder block kit.....................................................................................................................................19
Block spring removal...............................................................................................................................................................19
Inspection Overview........................................................................................................................................................................................... 21
Pistons and Slippers......................................................................................................................................................................21
Ball Guide, Slipper Retainer, and Hold-Down Pins.............................................................................................................21
Block Spring, and Washers..........................................................................................................................................................21
Cylinder Block .................................................................................................................................................................................22
Shaft ...................................................................................................................................................................................................22
Shaft Bearing................................................................................................................................................................................... 22
Swashplate....................................................................................................................................................................................... 23
Valve Plate........................................................................................................................................................................................ 23
Endcap............................................................................................................................................................................................... 24
Housing ............................................................................................................................................................................................ 24
Pressure Limiter..............................................................................................................................................................................25
HPRV Valve....................................................................................................................................................................................... 25
Cradle Bearings...............................................................................................................................................................................26
Optional Displacement Limiter.................................................................................................................................................26
Charge Pressure Relief Valve......................................................................................................................................................27
Servo Piston Assembly.................................................................................................................................................................27
Control............................................................................................................................................................................................... 28
Assembly Overview........................................................................................................................................................................................... 29
Shaft and Seal Installation...........................................................................................................................................................29
Cradle Bearings and Swashplate Installation.......................................................................................................................30
Servo Piston Assembly.................................................................................................................................................................32
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Contents
520L0957 • Rev CB • September 2014 3

Servo Piston Installation..............................................................................................................................................................32
Servo Cylinder Installation..........................................................................................................................................................33
Cylinder Kit Assembly...................................................................................................................................................................34
Cylinder Kit Installation................................................................................................................................................................35
Timing Pin and Endcap Bushing Installation....................................................................................................................... 35
Endcap Bushing Installation tools............................................................................................................................................36
Endcap Bushing Orientation......................................................................................................................................................36
Valve Plate and Endcap Installation........................................................................................................................................37
Charge Pump Installation........................................................................................................................................................... 38
Auxiliary Pad or End Cover Installation..................................................................................................................................39
Charge Pressure Relief Valve Installation.............................................................................................................................. 40
Pressure Limiter Installation.......................................................................................................................................................41
HPRV Valve Installation................................................................................................................................................................41
Optional Displacement Limiter Installation......................................................................................................................... 42
Control Assembly...........................................................................................................................................................................43
Control Installation........................................................................................................................................................................44
MDC Control.................................................................................................................................................................................... 44
Reassembly.................................................................................................................................................................................47
Automotive Control Installation...............................................................................................................................................48
Startup procedures Overview........................................................................................................................................................................................... 50
Initial Startup Procedures............................................................................................................................................................50
Adjustments.....................................................................................................................................................................................50
Pressure Measurements.............................................................................................................................................................. 50
Port locations Port Locations and Gauge Installation...................................................................................................................................51
Torque chart Fastener Size and Torque Chart................................................................................................................................................52
Plug Size and Torque Chart........................................................................................................................................................52
Fasteners and Plugs...................................................................................................................................................................... 53
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Contents
4520L0957 • Rev CB • September 2014

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 H1 078/147/165
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.
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.
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.
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 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.
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Introduction
520L0957 • Rev CB • September 2014 5

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.
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.
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Introduction
6520L0957 • Rev CB • September 2014

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.
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Introduction
520L0957 • Rev CB • September 2014 7

Shaft Seal Removal
1. Orient pump with the shaft pointing up.
2. Remove the spiral ring (J300) from the front housing to release the shaft seal carrier (J275).
3. Pry on the lip of the seal carrier to remove it from the pump.
4. Remove and discard the O-ring (J260) and seal (J250) from the seal carrier.
Remove shaft /seal/bearing
J150
J100
J200
J250
J260
J275
J300
E101 403E
Input Shaft
1. Pull the shaft with bearing out of the pump. If necessary, tap lightly on the shaft to dislodge it from
the internal pump components.
W
Warning
Do not damage the housing bore, shaft or bearing when removing the shaft and shaft seal.
2. Remove the snap ring (J200) using snap ring pliers.
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Disassembly
8520L0957 • Rev CB • September 2014

3. Use an adequate press to remove the bearing from the shaft.
Control Removal
1. Remove control screws (D250) using a 5 mm internal hex wrench. Remove the control from the pump
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. If necessary, remove the screen (D084).
C
Caution
Screen (D084) may be loose and fall out of control. Take caution not to lose it.
5. If necessary, remove orifices (F100) using a 3 mm internal hex wrench.
Dowel pins (D300) are a press fit and will remain in housing.
Remove control
E101 404E
D250 (6X)
5 mm
D150
D200
13 mm
D300 (2X)
D084
F100
3 mm
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Disassembly
520L0957 • Rev CB • September 2014 9

Control Disassembly
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].
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.
Disassemble the control
E101 405E
D025
D025A
D025A
D050 (3X)
4 mm
D050 (3X)
4 mm
Remove the Automotive Control
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. Remove and
discard gasket (D150).
Alignment pins are pressed into control. Do not remove them.
5. 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.
6. If it is necessary to remove the screens (D084), drill out screen retention ring (D098) and remove and
discard screen. Note screen orientation for proper reassembly.
W
Warning
Do not allow metal fragments to fall into control housing. This may cause erratic pump operation.
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Disassembly
10 520L0957 • Rev CB • September 2014

Special
tool Plug
P108021
Ø 1.7 mm (x3)
Ø 9.22 mm
45 deg.
Ø 14 mm
Screen
Retention
Ring
Drill out retention ring
Remove control
D250
5 mm
(6X)
D150
F00A
3 mm F00B
P106 708E
D610 (2X)
D610A (2X)
Security
wax seal (2X)
D084
D098
D674
D672
Auxiliary Pad or End Cover Removal
Remove auxiliary pump, if present.
1. Position pump so end cover (K100) or auxiliary pad is on top.
2. Remove end cover/auxiliary pad screws (K400) using an 8 mm internal hex wrench.
Alignment pins (G450) are in end cover. They may dislodge during disassembly.
3. Remove and discard gasket (K150).
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Disassembly
520L0957 • Rev CB • September 2014 11

4. Remove thrust washer (K500). Note thrust washer orientation.
5. Remove pressure balance plate (S200) and seal (S300). Note plate orientation. Discard seal (S300).
6. Remove coupling (K200).
Remove end cover and charge pump
E101 406E
K500
S100
S300
S200
K200
K150
K400
10 mm
K100
S300
S250
G450
G450
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), and (S200).
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Disassembly
12 520L0957 • Rev CB • September 2014

Auxilliary pads
SAE B SAE A
K400
8 mm
E101 533E
Pressure Limiter Removal
1. Using a 14 mm wrench, remove pressure limiter cartridges (L300) and (L400).
Pressure limiter (L300 / L400) is available as complete unit only. Seal (L022) is available separately.
2. Remove and discard O-ring (L022).
Right and left pressure settings are different. Tag each valve for later re-assembly
Remove pressure limiter
E101 415E
14 mm
L300 / L400
L022
Charge Pressure Relief Valve Removal
Using a 22 mm wrench, remove the charge pressure relief valve (V10). Discard O-ring (V024).
Charge pressure relief valve (V10) is available as complete unit only. Seal (V024) is available
separately.
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Disassembly
520L0957 • Rev CB • September 2014 13

Remove charge pressure relief valve
E101 407E
V10
V024
22 mm
High Pressure Relief Valve Removal
Using a 22 mm 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
E101 416E
L100 / L200
22 mm
L068
L060
42 Pressure code
marked on end
Endcap Removal
1. Remove two endcap screws (G400) using a 10 mm internal hex wrench.
2. Remove four endcap screws (G350) using a 10 mm internal hex wrench.
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, remove bushing (G550) using a suitable puller.
7. Remove locating pins (B010).
If necessary, use a hook to remove screens (B040) and discard.
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Disassembly
14 520L0957 • Rev CB • September 2014

Remove endcap and components
C025
G100
G550
G150
B010
G350 (4X)
G400 (2X)
E101 408E
B010
10 mm
10 mm
C020
B040 (2x)
Cylinder Block Kit Removal
1. Remove cylinder block assembly (C010).
2. Set cylinder block and components 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.
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Disassembly
520L0957 • Rev CB • September 2014 15

Remove cylinder block kit
E101 409E
C010
Servo Sleeve Removal
1. If equipped with displacement limiter, remove and discard locking nut (E550) and remove
displacement limiter screw (E450).
2. Remove the locking screws (E350) with a 10 mm hex wrench. Remove the locking plates (E300).
3. Using a 3/4 inch deep socket, unthread the servo sleeves (E600) from each side of the pump. Servo
piston will be loose after servo cylinders are removed. Discard O-rings (E250).
C
Caution
Do not allow loose servo piston to damage internal machined surfaces of pump.
Remove optional displacement limiter
4 mm
13 mm
E101 398E
E450
E550
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Disassembly
16 520L0957 • Rev CB • September 2014

Remove servo cylinders
E250
E600
E300
E101 410E
E350 10 mm
Servo Piston Removal
Tilt swashplate up to disengage servo arm from piston. Remove the servo piston assembly (E100).
Remove servo piston
P108 489E
E100
Swashplate and Swashplate Bearing Removal
1. Lift the swashplate (D070) out by grasping the swashplate pin. Swashplate bearings will remain on
the swashplate.
2. Remove bearings. Note bearing orientation.
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Disassembly
520L0957 • Rev CB • September 2014 17

Remove swashplate and swashplate bearings
E101 412E
D075 (045/053)
D075 (045/053)
D070
D070 (060/068)
D070 (060/068)
045/053
old style swashplate bearing
If pump with old style bearing is being repaired;
discard old style bearing, and replace with new
style bearing.
Servo Piston Disassembly
1. Remove and discard seals (E025).
2. Remove slider block (E015).
Servo (E100) is available as an assembly only. Seals (E025) and slider block (E015) are available as
repair items.
Remove O-rings, seals, and slider block
P107 959E
E025
E025
E015
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Disassembly
18 520L0957 • Rev CB • September 2014

Cylinder 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.
2. Remove the ball guide (C15).
3. Remove the three pins (C25).
Block spring removal
Most repairs do not require block spring removal. Perform this procedure only if you suspect problems
with the block spring.
Turn the block over. Using a press, apply pressure on the block spring washer (C35) 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 (C40) from 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 remove the spiral retaining ring. Release the pressure slowly after the retaining ring is
removed.
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Disassembly
520L0957 • Rev CB • September 2014 19

Disassemble cylinder block kit
E101 395E
C45
C35
C30
C40
C05
C25
C15
C20
C10
C50
Repair Instructions H1 45/53/60/68 Closed Circuit Axial Piston Pumps
Disassembly
20 520L0957 • Rev CB • September 2014