Manitou Sauer Danfoss Hydrostatic Pump H1 045 053 060 068 Repair Manual 647039EN – PDF DOWNLOAD

Description

Manitou Sauer Danfoss Hydrostatic Pump H1 045 053 060 068 Repair Manual 647039EN – PDF DOWNLOAD

DESCRIPTION:

Manitou Sauer Danfoss Hydrostatic Pump H1 045 053 060 068 Repair Manual 647039EN – PDF DOWNLOAD

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.

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TABLE OF CONTENTS:

Manitou Sauer Danfoss Hydrostatic Pump H1 045 053 060 068 Repair Manual 647039EN – PDF DOWNLOAD

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………………………………………………………………………………………………………………………………………8
Control Removal……………………………………………………………………………………………………………………………. 9
Control Disassembly……………………………………………………………………………………………………………………10
Automotive Control Removal…………………………………………………………………………………………………….11
Auxiliary Pad or End Cover Removal…………………………………………………………………………………………12
Charge Pump Removal………………………………………………………………………………………………………………..12
Pressure Limiter Removal……………………………………………………………………………………………………………13
Charge Pressure Relief Valve Removal………………………………………………………………………………………13
High Pressure Relief Valve Removal…………………………………………………………………………………………..13
Endcap Removal…………………………………………………………………………………………………………………………..14
Cylinder Block Kit Removal…………………………………………………………………………………………………………14
Servo Sleeve Removal………………………………………………………………………………………………………………….15
Servo Piston Removal………………………………………………………………………………………………………………….16
Swashplate and Swashplate Bearing Removal………………………………………………………………………..17
Servo Piston Disassembly…………………………………………………………………………………………………………..18
Cylinder Kit……………………………………………………………………………………………………………………………………19
Disassemble the cylinder block kit……………………………………………………………………………………….19
Block spring removal………………………………………………………………………………………………………………19
Overview……………………………………………………………………………………………………………………………………….20
Pistons and Slippers…………………………………………………………………………………………………………………….20
Ball Guide, Slipper Retainer, and Hold-Down Pins…………………………………………………………………..20
Block Spring, and Washers………………………………………………………………………………………………………….20
Cylinder Block ………………………………………………………………………………………………………………………………21
Shaft ………………………………………………………………………………………………………………………………………………21
Shaft Bearing…………………………………………………………………………………………………………………………………21
Swashplate…………………………………………………………………………………………………………………………………….22
Valve Plate……………………………………………………………………………………………………………………………………..22
Endcap…………………………………………………………………………………………………………………………………………..23
Housing …………………………………………………………………………………………………………………………………………23
Pressure Limiter……………………………………………………………………………………………………………………………24
HPRV Valve…………………………………………………………………………………………………………………………………….24
Cradle Bearings…………………………………………………………………………………………………………………………….24
Optional Displacement Limiter………………………………………………………………………………………………….25
Charge Pressure Relief Valve………………………………………………………………………………………………………25
Servo Piston Assembly………………………………………………………………………………………………………………..25
Control……………………………………………………………………………………………………………………………………………26
Overview……………………………………………………………………………………………………………………………………….27
Shaft and Seal Installation…………………………………………………………………………………………………………..27
Cradle Bearings and Swashplate Installation…………………………………………………………………………..28
Servo Piston Reassembly…………………………………………………………………………………………………………….29
Servo Piston Installation……………………………………………………………………………………………………………..30
Servo Cylinder Installation………………………………………………………………………………………………………….30
Cylinder Kit Reassembly………………………………………………………………………………………………………………31
Cylinder Kit Installation……………………………………………………………………………………………………………….32
Timing Pin and Endcap Bushing Installation…………………………………………………………………………..32
Endcap Bushing Installation tools……………………………………………………………………………………………..33
Endcap Bushing Orientation………………………………………………………………………………………………………33
Valve Plate and Endcap Installation…………………………………………………………………………………………..34
Charge Pump Installation……………………………………………………………………………………………………………35
Auxiliary Pad or End Cover Installation…………………………………………………………………………………….36
Charge Pressure Relief Valve Installation………………………………………………………………………………….37
Pressure Limiter Installation……………………………………………………………………………………………………….37
HPRV Valve Installation………………………………………………………………………………………………………………..38
Optional Displacement Limiter Installation……………………………………………………………………………..38
Control Assembly…………………………………………………………………………………………………………………………39
Control Installation………………………………………………………………………………………………………………………40
Automotive Control Installation………………………………………………………………………………………………..41
Overview……………………………………………………………………………………………………………………………………….42
Initial Startup Procedures……………………………………………………………………………………………………………42
Adjustments………………………………………………………………………………………………………………………………….42
Pressure Measurements………………………………………………………………………………………………………………42
Port Locations and Gauge Installation……………………………………………………………………………………..43
Fastener Size and Torque Chart………………………………………………………………………………………………….44
Plug Size and Torque Chart…………………………………………………………………………………………………………44
Fasteners and Plugs……………………………………………………………………………………………………………………..45

PLEASE NOTE:

• This is the same manual used by the dealers to diagnose and troubleshoot your vehicle
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