Hydrostatic Motor H1 060/080/110/160/250

647069EN (30/08/2018)
HYDROSTATIC MOTOR
H1 060/080/110/160/250
REPAIR MANUAL
647069EN
2
DATE OF ISSUE OBSERVATION
01 / 07 / 2009 - 1st ISSUE
14 / 05 / 2014 - UPDATE
30 / 08 / 2018 - UPDATE
MANITOU BF S.A Limited liability company with a Board of Directors.

Head office: 430, Rue de l’Aubinière - 44150 Ancenis - FRANCE
Share capital: 39,548,949 euros
857 802 508 RCS Nantes
Tel: +33 (0)2 40 09 10 11
www.manitou.com
This manual is for information purposes only. Any reproduction, copy, representation, recording, transfer, distribution, or other,
in part or in whole, in any format is prohibited. The plans, designs, views, commentaries and instructions, even the document
organization that are found in this document, are the intellectual property of MANITOU BF. Any violation of the aforementioned
may lead to civil and criminal prosecution. The logos as well as the visual identity of the company are the property of MANITOU-BF
and may not be used without express and formal authorization. All rights are reserved.
Repair Instructions
H1 Bent Axis Variable Displacement Motors, Size 060/080/110/160/210/250
Contents
Introduction
About this manual............................................................................................................................................................................5
General Instructions........................................................................................................................................................................ 5
Safety precautions............................................................................................................................................................................6
Symbols used in Danfoss literature............................................................................................................................................7
Disassembly
Proportional controls disassembly.............................................................................................................................................8
Two-position controls disassembly........................................................................................................................................... 9
Disassembly of controls with PCOR.........................................................................................................................................10
Electric proportional controls M1CA/M2CA and L1BA/L2BA.........................................................................................11
Electric proportional controls D1MA/D2MA and K1KA/K2KA....................................................................................... 12
Two-position controls T*D* and P*D*.................................................................................................................................... 14
Two-position controls T*G* and P*G*.................................................................................................................................... 15
Two-position control E*AA.........................................................................................................................................................16
Two-position controls HEHE and HFHF..................................................................................................................................17
Two-position control THHA........................................................................................................................................................18
Two-position control THHB........................................................................................................................................................19
Two-position control DHMA...................................................................................................................................................... 20
Two-position control DHMH......................................................................................................................................................21
Two-position control KHKA........................................................................................................................................................22
Two-position control KHKH........................................................................................................................................................23
Two-position controls MHCA and LHBA................................................................................................................................24
Minimum displacement limiter................................................................................................................................................ 25
Maximum displacement limiter—two-position control..................................................................................................25
Speed Sensor................................................................................................................................................................................... 26
Servo piston cover—proportional controls......................................................................................................................... 27
Loop flushing spool and charge relief valve........................................................................................................................ 28
End-cap and servo piston—proportional control..............................................................................................................29
End cap and servo piston—two-position controls............................................................................................................31
Cylinder block and sync Shaft assembly................................................................................................................................32
Shaft assembly................................................................................................................................................................................ 33
Inspection
Overview........................................................................................................................................................................................... 34
Shaft assembly................................................................................................................................................................................ 34
Pistons and piston rings inspection........................................................................................................................................ 34
Synchronizing shaft.......................................................................................................................................................................35
Cylinder block..................................................................................................................................................................................35
Bearing plate....................................................................................................................................................................................35
Valve segment.................................................................................................................................................................................36
Endcap............................................................................................................................................................................................... 36
Housing ............................................................................................................................................................................................ 37
Control shuttle valve.....................................................................................................................................................................37
Optional Minimum displacement limiter..............................................................................................................................37
Servo piston..................................................................................................................................................................................... 38
Control............................................................................................................................................................................................... 38
Assembly
Overview........................................................................................................................................................................................... 39
Piston ring.........................................................................................................................................................................................39
Shaft in housing..............................................................................................................................................................................40
Synchronizing shaft.......................................................................................................................................................................41
Pistons and cylinder block.......................................................................................................................................................... 42
Bearing plate....................................................................................................................................................................................43
Servo piston and valve segment—proportional control................................................................................................ 44
Servo piston and valve segment—two position control................................................................................................ 46
End-cap assembly.......................................................................................................................................................................... 47
Loop flushing charge relief valve and spool........................................................................................................................ 48
Shaft seal........................................................................................................................................................................................... 49
Servo cover—proportional control......................................................................................................................................... 50
© Danfoss | April 2018 11020692 | AX00000153en-US0701 | 3

Repair Instructions
Contents
Speed sensor................................................................................................................................................................................... 51
Minimum displacement limiter................................................................................................................................................ 52
Maximum displacement limiter—two-position control..................................................................................................53
Electric proportional controls M1CA/M2CA and L1BA/L2BA.........................................................................................54
Electric proportional controls D1M1/D2M2 and K1K1/K2K2......................................................................................... 56
Two-position controls T*D* and P*D*.................................................................................................................................... 58
Two-position controls T*G* and P*G*.................................................................................................................................... 59
Two-position control E*AA.........................................................................................................................................................60
Two-position controls HEHE and HFHF..................................................................................................................................61
Two-position control THHA........................................................................................................................................................62
Two-position control THHB........................................................................................................................................................63
Two-position control DHMA...................................................................................................................................................... 64
Two-position control DHMH......................................................................................................................................................65
Two-position control KHKA........................................................................................................................................................66
Two-position control KHKH........................................................................................................................................................67
Two-position controls MHCA and LHBA................................................................................................................................68
Proportional controls installation............................................................................................................................................ 69
Two-position controls installation........................................................................................................................................... 70
Controls with PCOR installation................................................................................................................................................71
Start-up Procedures
Overview........................................................................................................................................................................................... 72
Initial startup procedures............................................................................................................................................................72
Adjustments.....................................................................................................................................................................................72
Pressure measurements.............................................................................................................................................................. 72
Port locations
Ports and Gauge Information.................................................................................................................................................... 73
Torque chart
Fasteners and plugs...................................................................................................................................................................... 75
Fastener size and torque chart..................................................................................................................................................76
Plug size and torque chart..........................................................................................................................................................76
4 | © Danfoss | April 2018 11020692 | AX00000153en-US0701

Repair Instructions
Introduction
About this manual

This manual details the major repair procedures for H1 bent axis motors. These include the complete
disassembly, inspection, and reassembly of the unit. Where rework of worn or damaged components is
possible, specifications appear to ensure these parts meet factory tolerances.
Only Danfoss global service partners (GSPs) are authorized to perform major repairs.Danfoss trains Global
Service Partners and certifies their facilities on a regular basis. You can locate your nearest service partner
at www.danfoss.com > Contact us > Danfoss sales and services > Distributor and service partners
W Warning
Use of components that do not comply with rework specifications may result in loss of performance,
which may constitute a safety hazard. Do not reuse components that don’t comply to given
specifications: replace with genuine Danfoss service parts.
Minor repair procedures, adjustments, and troubleshooting information appear in the H1 Bent Axis
Variable Displacement Motors Service Manual, AX00000025. Minor repairs include service operations you
can perform without removing the unit’s end-cap. Removal of the end-cap voids your warranty.
Operating parameters and product specifications are given in the H1 Bent Axis Variable Displacement
Motors Technical Information,BC00000043.
General Instructions
When repairing H1 variable displacement closed circuit motors follow these general procedures:
Remove the unit Chock the wheels on the vehicle or lock the mechanism to inhibit movement.
Prior to performing repairs, remove the unit from the vehicle/machine. Be aware
that hydraulic fluid may be under high pressure and/or hot. Inspect the outside of
the motor and fittings for damage. Cap hoses after removal to prevent
contamination.
Keep it clean Cleanliness is a primary means of assuring satisfactory motor life, on either new or
repaired units. Clean the outside of the motor thoroughly before disassembly.
Take care to avoid contamination of the system ports. Cleaning parts with a clean
solvent wash and air drying is usually adequate. Keep all parts free of foreign
materials and chemicals. Protect all exposed sealing surfaces and open cavities
from damage and foreign material.
Lubricate moving During assembly, coat all moving parts with a film of clean hydraulic oil. This
parts assures that these parts are lubricated during start-up.
Replace all O-rings Danfoss recommends you replace all O-rings and gaskets during repair. Lightly
and gaskets lubricate O-rings with clean petroleum jelly prior to assembly.
Secure the unit For repair, place the unit in a stable position with the shaft pointing downward.
Secure the motor while removing and torquing components and fasteners.

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.
Hazardous material
W Warning
Hydraulic fluid contains hazardous material. Avoid prolonged contact with hydraulic fluid. Always
dispose of used hydraulic fluid according to environmental regulations.

Repair Instructions
Introduction
Symbols used in Danfoss literature
WARNING may result in injury Tip, helpful suggestion
CAUTION may result in damage to product or Lubricate with hydraulic fluid

property
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
Disassembly
Proportional controls disassembly

Electric (left) and hydraulic (right) proportional controls disassembly
C0110 (4X)
6 mm
37 Nm
C0110 (4X) [27 lbf•ft]
C0010 6 mm
Proportional C0010
control
F0030
F0030
F0040
F0040
C0130 C0130
Electric proportional control Hydraulic proportional control P108841
Proportional end cap can be rotated 180°. This allows for the de-energized position of the motor to be at
either maximum or minimum displacement..
1. Remove screws (C0110) using a 6 mm internal hex wrench.
2. Remove control housing (C0010).
3. Remove gasket (C0130) and discard.
4. Remove spring guide (F0030) and spring (F0040).

Repair Instructions
Disassembly
Two-position controls disassembly

Electric and hydraulic two-position controls with or without PCOR disassembly
6 mm
C0120 (2X)
C0120 (2X) C0110 (2X) 37 Nm 10 mm
[27 lbf•ft] C0110 (2X)
10 mm
C0010
C0010
2 position
control
C0130
C0130
Hydraulic two position control with and without PCOR Electric two position control with and without PCOR
P108842
1. Remove screws (C0110 and C0120) using a 10 mm internal hex wrench.


Repair Instructions
Disassembly
Disassembly of controls with PCOR

Hydraulic (left) and electric (right) proportional controls with PCOR
C0130
C0130
F0040
F0040
F0030
F0030
C0010
C0010
6 mm
37 Nm
[27 lbf•ft] C0120 (2X) 6 mm
6 mm
C0120 (2X) 37 Nm
C0110 (2X) 37 Nm
[27 lbf•ft] P108843
[27 lbf•ft] C0110 (2X)
Hydraulic proportional control with PCOR Electric proportional control with PCOR
1. Remove screws (C0110 and C0120) using a 10 mm internal hex wrench.

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

Repair Instructions
Disassembly
Electric proportional controls M1CA/M2CA and L1BA/L2BA

Disassembly of controls M1CA/M2CA and L1BA/L2BA
B0040
B0027
26mm
B0029
B0028
B0020
B0050
4 mm B0025
(3X)
B0035A B0010
1/8 in
1/4 in C0060
C0050 C0060A
C0050A E00T2
3 mm C0100
C0025
5 mm
B0010
C0060A
C0060 3 mm
1/8 in E00T3
C0060A
C0060
M1CA/M2CA and L1BA/L2BA 1/8 in
The coil does not need to be removed unless it is being replaced.

Coil O-rings and Plug O-rings are not included in the overhaul seal kit. They are included with the
purchase of new coil and plug.
1. If replacing the coil, remove the plastic cap (B0040).

2. Remove the coil nut (B0027) using a 26 mm 12-point socket.
3. Remove the coil and discard the O-rings (B0025, B0028, B0029).
4. Remove three screws (B0050) using a 4 mm internal hex wrench.
5. Remove solenoid (B0010).
6. Remove and discard O-ring (B0035A).
7. Remove control spool (C0100).
8. Using a 1/8 inch internal hex wrench, remove plugs (C0060).
9. Remove orifices (E00T2 and E00T3) using a 3 mm internal hex wrench.
10. Tag the orifices for reassembly.
12. Remove and discard O-ring (C0050A).
13. Remove shuttle valve assembly (C0025) using a 5 mm internal hex wrench.

Repair Instructions
Disassembly
Electric proportional controls D1MA/D2MA and K1KA/K2KA

Disassembly of controls D1MA and D2MA
B0029 B0040
B0027
D*M* control
B0028
B0020
B0025
B0050
4 mm
B0010
B0027
B0028
C0060
1/8 in B0035
B0025
C0050 C0010
1/4 in C0060
1/8 in
B0020 E00T3
B0032
17 mm B0034
C0060
C0070
E00T3
C0080
C0060
C0060 C0090
1/8 in
M223
C0020 C0050
C0030 1/4 in
The coil does not need to be removed unless it is being replaced.


Repair Instructions
Disassembly
Disassembly of controls K1KA and K2KA

B0040
B0029
K*K* control B0027

B0028
B0020
B0050 B0025
4 mm
B0010
B0035A
C0100
C0060
1/8 in C0060
E00T2 C0060
C0050 C0050 C0060 1/8 in
1/4 in 1/4 in
C0030
C0020
C0060
C0070
C0080
C0060 E00T3 M223
1/8 in C0060
C0090
B0034A B0025
B0028
B0032
B0027
17 mm
B0020

2. Remove the coils and discard the O-rings.
3. Remove solenoid (B0032) using a 3/4 inch open end wrench.
6. Remove solenoid (B0010).
13. Using a magnet, remove spring (C0030) and spool (C0020).
14. Using a 1 inch wrench, remove adjuster (C0090).
15. Remove and discard O-ring (M223).
16. Remove spring (C0080) and spool (C0070) using a magnet.

Repair Instructions
Disassembly
Two-position controls T*D* and P*D*

Disassembly of two-position control T*D* and P*D*
B0026
B0028
B0022
B0024
B0032
17 mm
B0026 B0034 1/4 in

B0028 B0024 C0050
B0022 C0050A
B0032
17 mm C0060
1/8 in
B0034 C0060A
C0060 C0060
1/8 in 1/8 in
C0060A C0060A C0070
C0060 C0080
1/8 in M223
E00T3 C0090
3 mm C0020
17 mm
E00T2
3 mm C0030
T*D* and P*D* C0050A

C0050
1/4 in
1. Use a 26 mm 12-point socket to remove the coil nuts (B0026).
2. Remove coils (B0022) and O-rings (B0024) and (B0028).
3. Using a 17 mm hex wrench on the flats, remove solenoid assemblies (B0032).
4. Remove and discard O-rings (B0034).
5. Using a 1/8 inch internal hex wrench, remove four plugs (C0060).
6. Remove and discard O-rings (C0060A).
8. Using a 17 mm hex wrench, remove pressure compensator adjusting plug (C0090).
10. Remove springs (C0030) and (C0080).
11. Remove spools (C0020) and (C0070).

Repair Instructions
Disassembly
Two-position controls T*G* and P*G*

Disassembly of two-position control T*G* and P*G*
B0028
B0022
B0026
T*G* and P*G*
B0024 C0050
B0032
C0050
B0034
C0030
C0020 C0010
C0060
C0060
C0070
E00T3 C0080 M223
C0090
E00T2
B0034
B0032
B0024
B0022
B0028
B0026
2. Remove coil (B0022) and O-rings (B0024 and B0028).
3. Remove solenoid (B0032) using a 17 mm hex wrench on the flats.
4. Remove and discard O-ring (B0034).
8. Remove spring (C0030).
9. Remove spool (C0020).

Repair Instructions
Disassembly
Two-position control E*AA

Disassembly of two-position control E*AA
B0026
B0028
B0024
B0032 17 mm
B0020
C0020
B0034
C0060 1/8 in
C0060
1/8 in
C0060
C0025
E*AA C0050 1/4 in
2. Remove coil (B0022) and O-rings (B0024 and B0028).
3. Using a 17 mm hex wrench on the flats, remove solenoid (B0032).
8. Remove shuttle valve assembly (C0025) using a magnet.

Repair Instructions
Disassembly
Two-position controls HEHE and HFHF

Disassembly of two-position controls HEHE and HFHF
C0140 C0160
3/8 inch
C0160A
HEHE C0050
C0080 1/4 in
C0150
C0050 C0060
1/4 inch
C0060
C0025
C0050
C0060
C0160 C0060
C0140 C0160A 1/8 in
3/8 inch
C0050
C0080
C0150
C0060
C0060 C0060 1/8 in
C0050 HFHF
C0060
1/8 in
C0050 1/4 in
C0025
P108 576E
1. Using a 1/8 inch internal hex wrench, remove plug (C0160) and four plugs (C0060).
4. Using a 3/8 inch internal hex wrench, remove plug (C0140).
5. Remove spring (C0080).

Repair Instructions
Disassembly
Two-position control THHA

Disassembly of two-position control THHA
1/4 inch
C0050 B0300
C0050
B0310
QB300
B0330 C0050 THHA
C0025 B0320
C0060 C0070
1/8 in E00T3
C0060
1/8 in C0080
M223
E00T2 C0090
P108913
Plug O-rings are not included in the overhaul seal kit. They are included with the purchase of a new plug.
6. Using a 22 mm hex wrench, remove adapter (B0300).
7. Remove and discard O-ring (QB0300).
8. Remove pressure compensator adjusting plug (C0090) using a 17 mm hex wrench.

Repair Instructions
Disassembly
Two-position control THHB

Disassembly of two-position control THHB
1/4 inch
C0050 B0300
C0050
B0310
QB300
B0330 THHB
C0025 B0320 C0050
C0070
C0060
E00T3 C0080
1/8 in C0060 M223
1/8 in C0090
E00T2 C0020
C0140
C0050
P108923
6. Using a 22 mm hex wrench, remove adapter (B0300).
7. Remove and discard O-ring (QB0300).
8. Remove pressure compensator adjusting plug (C0090) using a 17 mm hex wrench.

Repair Instructions
Disassembly
Two-position control DHMA

Disassembly of two-position control DHMA
C0090
C0090A
C0080
C0070
C0060A
6 N•m [4 lbf•ft]
E00T2 C0060
3 mm
C0060
C0060A
1/8 in
C0010
8 N•m C0060
C0060
[6 lbf•ft] C0060A C0060A
1/8 in
C0060 8 N•m
C0060A
C0060A C0060 [6 lbf•ft]
C0050A C0050
3 mm E00T3
C0110 6 N•m [4 lbf•ft]
C0120 C0060A
C0025
B0061 C0060
C0100 C0060A C0050A
0010 C0060
0020 C0050 40 N•m
[30 lbf•ft]
B0190
B0060
B0010
0020 DHMA
0010
B0180
P108834
B0050
The hydraulic actuator does not need to be removed unless it is being replaced. Hydraulic actuator O-
rings are not included in the overhaul seal kit. They are included with the purchase of a new hydraulic
actuator.
2. Remove hydraulic actuator (B0010).

Repair Instructions
Disassembly
Two-position control DHMH

Disassembly of two-position control DHMH
C0090
C0090A
C0080
C0070
E00T2
3 mm
1/8 in
8 N•m
C0140 1/8 in
[6 lbf•ft] C0060 C0060
C0060A 8 N•m
C0010 C0060A [6 lbf•ft]
C0050
40 N•m C0050
[30 lbf•ft] C0050A C0050A C0060
C0060A
C0060 C0060A 40 N•m
1/8 in C0060 C0060A C0050A C0050 [30 lbf•ft]
8 N•m C0060A 6 N•m [4 lbf•ft]
[6 lbf•ft] E00T3
C0060 3 mm
C0060 C0060A
C0060A C0060
C0120 1/8 in
C0060A
8 N•m
C0060 C0020 [6 lbf•ft]
C0110
C0100 1/8 in
C0140
8 N•m
[6 lbf•ft] C0050A
0010
0020 C0050
B0190 40 N•m
B0061 [30 lbf•ft]
B0010 B0060
0020
0010
B0180 DHMH
B0050
P108832
actuator.

Repair Instructions
Disassembly
Two-position control KHKA

Disassembly of two-position control KHKA
B0050
B0180
B0060
KHKA B0010
B0061
B0190
C0120
E00T3
C0100
C0110
C0060
C0050
C0050
C0060
C0025 C0060
C0060
C0070
C0060 E00T2 C0080
C0060
C0090
M223
P109035
actuator.

Repair Instructions
Disassembly
Two-position control KHKH

Disassembly of two-position control KHKH
B0050
B0180
B0060
KHKH B0010
B0061
B0190
C0120
E00T3 C0100
C0110
C0060
C0050
C1400
C0060
C0020 C0060
C0060 C0070
E00T2 C0080
C0060
C0090
M223
C1400
P109036
actuator.
9. Using a 1/4 inch internal hex wrench, remove two plugs (C1400).
10. Using a magnet, remove shuttle valve assembly (C0020).

Repair Instructions
Disassembly
Two-position controls MHCA and LHBA

Disassembly of two-position controlMHCA and LHBA
B0050
MHCA & LHBA

B0180
B0010
0010
0020
B0061
B0060
0020
B0190
0010
C0060
C0100
C0060A C0110
C0050 C0050A
40 N•m E00T2
C0025 6 N•m [4 lbf•ft]
[30 lbf•ft] 3 mm
C0010
C0060
C0060A 3 mm
E00T3 6 N•m [4 lbf•ft]
C0060A
C0060
1/8 in
8 N•m
[6 lbf•ft]
P108835
actuator.

Repair Instructions
Disassembly
Minimum displacement limiter
N0010 6 mm
N0020 19 mm
N0120
1. Remove and discard cap (N0120).

2. While holding position of adjustment screw (N0010) with a 6 mm internal hex wrench, remove lock-
nut (N0020) using a 19 mm hex wrench and discard lock-nut.
3. Mark the position of adjustment screw (N0010) for re-installation.
4. Remove adjustment screw.
Maximum displacement limiter—two-position control
It is not necessary to remove the maximum displacement limiter unless it is being replaced.
1. Remove screw (P0100) using internal hex wrench.
See the table for wrench size below:
Wrench size (internal hex)

Size 060/080/110 160/210/250
Wrench size 6 mm 8 mm

Repair Instructions
Disassembly
P0100
P0200
P107 866E
2. Remove spacer (P0200).
Speed Sensor
J0020 J0020
J0010
J0010 O
J0010A
J0010A
J0010 J0010 J0010A

J0010A
O
J0020
J0020 P107833
1. Remove screw (J0020) using a 5 mm internal hex wrench.

2. Remove speed sensor or plug (J0010).
3. Remove and discard O-ring (J0010A).

Repair Instructions
Disassembly
Servo piston cover—proportional controls
P0050
P0030
P0010
P0020
10 mm
(4X) P107867
1. Remove four screws (P0020) using a 10 mm internal hex wrench.

2. Remove servo piston cover (P0010).
3. Remove and discard O-ring (P0030).
4. Remove screw (P0050) carefully not to damage inside of end-cap.

Size 060/080 110 160/210/250
Wrench size 8 mm 10 mm 12 mm

Repair Instructions
Disassembly
Loop flushing spool and charge relief valve
24 mm
K0030
K0020
K0030A
K0010
K0020
K0030
24 mm
K0030A
F0010
L0050
L00**
24 mm
Loop flushing charge relief valve is available as complete assembly only. If you suspect valve malfunction,
replace with new valve.
1. Remove two plugs (K0030) using a 24 mm hex wrench.
2. Remove and discard O-rings (K0030A).
3. Remove springs (K0020).
4. Remove spool (K0010) from end-cap.
5. Remove loop flushing relief valve (L00**) using a 24 mm wrench.
6. Remove and discard O-ring (L0050).

Repair Instructions
Disassembly
End-cap and servo piston—proportional control

Remove end-cap and servo piston
F0060 F0070
Rear view of valve segment 5 mm
proportional controls F0020
G0070 F0050
F0120
See table
F0090
P0040 P0043
4 mm P0044
QM050
Proportional end-cap can be rotated 180 degrees. Mark position of end-cap on housing for later
reassembly. Do not press spindle out of valve segment.
1. Remove set screw (F0070) using a 5 mm internal hex wrench.
2. Use a magnet to remove pin (F0060) and discard pin.

Repair Instructions
Disassembly
3. Remove servo piston head (P0040) using expanding pliers.

Servo piston cover and bushing
Servo
piston
head
Expanding
pliers
4. Remove piston seal (P0044) and O-ring (P0043) from piston head; discard seal and O-ring.
5. Remove eight screws (F0120) from end cap assembly.

Size 060/080 110 160 210/250
Wrench 8 mm 10 mm 12 mm 14 mm
6. Remove end cap assembly.
7. Remove and discard gasket (G0070).
8. Remove hold down screw (F0090) using a 4 mm internal hex wrench.
9. Remove valve segment (QM050).
10. Remove setting lug (F0050) from servo piston (F0020) .
11. Remove servo piston (F0020) from end-cap.

Repair Instructions
Disassembly
End cap and servo piston—two-position controls

Remove end-cap and servo piston
P0043
Rear view of valve segment
P0044
- two position control
F0020
G0070
QM050
F0120
See table
F0090 4 mm
1. Remove eight screws (F0120) from end cap assembly.


Size 060/080 110 160 210/250
2. Remove end cap assembly.
3. Remove and discard gasket (G0070).
4. Remove hold down screw (F0090) using a 4 mm internal hex wrench.
5. Remove valve segment (QM050).
6. Remove servo piston (F0020) carefully not to damage inside of end-cap.
7. Remove and discard seal ring (P0044) and O-ring (P0043).

Repair Instructions
Disassembly
Cylinder block and sync Shaft assembly

Remove cylinder block
G0040
M0010 G0040
M0020
M0030
Bronze
surface
1. Remove cylinder block assembly (M0020).

2. Remove bearing plate (M0030) from cylinder block and note orientation for reassembly.
3. Set cylinder block and components on a clean dry surface.
C Caution
Take care that the sealing surfaces of the cylinder block do not become contaminated or scratched.
This may lead to poor performance or motor failure.
4. Remove synchronizing shaft assembly (M0010) and set on clean dry surface.
5. Remove alignment pins (G0040).

Repair Instructions
Disassembly
Shaft assembly
G0030
G0020
G0010
G0050A
G0050
3/16 inch internal hex
G0055A Cartridge model has

G0055 shaft lock screw (G0055)
H00** 1/8 inch on top of housing.
H0230
Shaft, bearings, pistons and speed ring are not serviceable. Replace as a unit if damaged.
1. Remove retaining ring (G0030).
2. Use seal puller to remove seal (G0020) and discard.
3. Remove shaft locking screw (G0050).
Wrench size is shown in illustration.
Take care not to damage machined surfaces of housing or shaft assembly.
4. Remove and discard O-ring (G0050A).
5. Press shaft assembly (H00**) out of housing by pressing on front face of shaft.
C Caution
For motors with cartridge flange, be sure to remove speed sensor before pressing shaft out of
housing.
Take care not to damage pistons when pressing shaft out of housing.
6. If replacing piston rings (H0230), use a small pair of expanding pliers to remove them.
Refer to Pistons and piston rings inspection on page 34 inspection.

Repair Instructions
Inspection
Overview
After disassembly, wash all parts (including the end-cap and housing) thoroughly with clean solvent and
blow out oil passages in the housing and endcap with compressed air. Allow to air dry. Conduct
inspection in a clean area and keep all parts free from contamination. Clean and dry parts again after any
rework or resurfacing.
Shaft assembly
Check to see that the shaft and its splines are straight and free of damage or heavy wear. Inspect the shaft
journal where it meets the shaft seal. Replace the shaft assembly if grooved at the sealing land surface.
Clean the sealing area with a nonabrasive material if necessary.
Check that the spacer ring between the bearings is still fixed by bearing preload and that there is no play
between the bearings. Clean bearings with a solvent and lubricate with hydraulic fluid. Inspect for wear
or pitting. If you find excessive wear, replace the shaft assembly.
Check that there is not excessive axial endplay of the pistons in the piston shoe.
Inspect shaft assembly
Shaft bearings
E101 329E
Pistons and piston rings inspection

Inspect sides of piston heads and piston rings for scuffing or marking.
• If scuffing or marking are present, replace shaft assembly and cylinder block assembly.
• If contact (polished) area on ring surface is more than 3/4 of the area, replace piston rings.
• If scuffing or marks are visible, replace piston rings and inspect cylinder block bores for scratches or
damage.
Inspect piston heads Inspect piston rings

wear area
Marks or scuffing indicate

unacceptable wear
Marks or scuffing indicate
P107 758E unacceptable wear
Look for
P106 554E
marks or scuffing

Repair Instructions
Inspection
Synchronizing shaft
Inspect synchronizing shaft, pins, and rollers. Replace parts as a complete unit if damaged or worn or if
shaft is twisted. If twisted, closely inspect cylinder block and pistons for damage.
Inspect synchronizing shaft
P107 834
Cylinder block
Examine the running face of the cylinder block for scratches, grooves and other damage. Ensure that no
scratches or grooves exist; these can drastically reduce output flow, increase internal leakage, and reduce
life of motor. Check piston bores for scratches, grooves, or other damage. Replace cylinder block
assembly if damaged.
Inspect needle bearing for scratches, pitting, and wear. Ensure that bearing moves smoothly. If damaged,
replace cylinder block assembly. Bearing is not available separately.
Inspect cylinder block
Needle
bearing
P106 627E
Bearing plate
Deep or outstanding grooves in the sealing lands of the bearing plate decrease motor efficiency.
Appearance should be flat and smooth on both the running face and the bottom surface. Perform a
magnetic particle inspection to detect cracks.
Inspect bearing plate

Repair Instructions
Inspection
• Inspect the bearing plate for scratches and grooves.

• Check the plate for evidence of any cavitation along the running face of the bearing plate. If pitting
from cavitation exists, replace the bearing plate.
• Check for excessive wear on the brass running face. If you observe any discoloration or burn marks,
replace the bearing plate.
• Inspect the mating surfaces of the valve segment and cylinder block for any possible contamination;
even a few thousandths of a millimeter can affect motor operation.
Run your fingernail or a pencil tip across the diameter of the sealing land surface to check for grooves.
Lap or replace if detectable grooves or nicks are present. Replace bearing plate if cracked.
Valve segment
Carefully inspect each machined surface of the valve segment and spindle for wear, scratching, grooves,
and other types of damage. All surfaces should be smooth. Inspect the bearing plate running surface for
flatness and brass transfer. Excessive brass transfer indicates bearing plate needs replacement. Replace
valve segment assembly if necessary.
Inspect valve segment
E101 338E
Endcap
Inspect all machined surfaces of the endcap for scratches, smearing or pits. Carefully check the valve
segment cradle bearing surface for wear. Check bore of loop flushing relief valve and loop flushing spool.
If damaged, replace endcap.
Inspect endcap
E101 342E

Repair Instructions
Inspection
Housing
Inspect the housing to ensure that it is clean and free of foreign material. Inspect the endcap mating
surface.
Inspect housing
E101 344E
Control shuttle valve

Inspect the shuttle valve for damage or contamination. Check that shuttle ball moves freely in the
housing
Control shuttle
Shuttle ball
P106 693E
Optional Minimum displacement limiter

Inspect the displacement limiter screw threads. Check end of screw for damage.Ensure that the screw is
not bent. Replace the seal nut.
Inspect displacement limiter
E101 345E

Repair Instructions
Inspection
Servo piston
Inspect servo piston for wear, scratches, grooves or damage. Replace if necessary.
Inspect servo piston
Proportional
Two-position
P101 337E
Control
Inspect control housing, spools, and solenoids for wear or damage. Replace components as necessary.
Lubricate all moving parts during reassembly.
Inspect control - components
P106 253E

Repair Instructions
Assembly
Overview
This section describes assembly procedures for the H1 motor. If special tools are needed for assembly,
they appear in this section. After assembly, adjust motor according to the settings listed on the model
code stamped on the serial number plate. Perform adjustments with motor on an appropriate test stand.
Refer to H1 Bent Axis Variable Displacement Motors Service Manual, AX00000025, for further instructions
and adjustments for the H1 motor.
Piston ring
Install and lubricate new rings, if piston rings (H0230) are being replaced.
Installation of piston rings
Piston rings are not symmetrical.

Note proper orientation.
H0230
Mark indicates
top of piston ring
Piston rings are not symmetric, note proper orientation. Mark indicates top of piston ring.

Repair Instructions
Assembly
Shaft in housing
Shaft in housing assembly
P
(H00**)
G0050A
G0050
3/16 inch internal hex
G0010
G0055A Cartridge model has

G0055 shaft lock screw (G0055)
1/8 inch on top of housing.
Cartridge model has shaft lock screw (G0055) on top of housing.

1. Lubricate bearings and press shaft assembly (H00**) into housing.
2. Lubricate and install new O-ring (G0050A) on shaft locking screw (G0050).
3. Install shaft locking screw (G0050) and torque to 8 N•m [6 lbf•ft].

Repair Instructions
Assembly
Synchronizing shaft
M0012
Install this pin into the
cylinder block M0011
M0013
M0012
1. Position the motor with shaft pointing down.

2. Using petroleum jelly to retain them, install synchronizing shaft rollers (M0013) on the journals of the
synchronizing shaft (M0011).
The rollers are symmetrical. You may install them in either direction on the synchronizing shaft.
3. Position each roller with its outside edge flush to the end of the synchronizing shaft journal.
4. Install one synchronizing shaft support pin (M0012) into the spring guide of the motor shaft.
5. Install the synchronizing shaft and rollers into the motor shaft.
You may install either end of the synchronizing shaft into the cylinder block.
6. After installation, tip and rotate the synchronizing shaft in all directions to check for binding.
Ensure synchronizing shaft rollers move freely in the races of the motor shaft.

Repair Instructions
Assembly
Pistons and cylinder block

1. Position the shaft as shown in the illustration.
Shaft alignment - top view
Position the motor shaft
as shown prior to installing
the cylinder block
P104 103
(Cylinder block not installed)
2. Tip the 3 pistons closest to the minimum angle stop out, toward the housing.
3. Tip the 6 remaining pistons forward (toward the lowest part of the end-cap mounting surface).
4. Tip the synchronizing shaft forward (toward the lowest part of the end-cap mounting surface).
5. Using petroleum jelly to retain it, install one synchronizing shaft support pin into the recess in the
cylinder block.
6. Position the cylinder block so one of the synchronizing shaft roller raceways is aligned between the
two bottom pistons.
7. Install the cylinder block and its support pin on the lower six pistons and synchronizing shaft.
The synchronizing shaft rollers enter their races in the cylinder block, while the last two of the six
pistons enter their corresponding bores in the cylinder block.
8. Insert a brass rod through the cylinder block kidneys to guide the pistons into position.
9. Start with the six pistons closest to the lowest part of the end cap mounting surface.
The support pin enters its recess in the synchronizing shaft.
10. Lift the cylinder block slightly and guide the remaining 3 pistons into their bores.
11. Check the position of the rollers after the last piston is in position by trying to turn the cylinder block.
It should not have any free travel. If a roller is not in position, remove the block and repeat steps 5.-12.
12. Maintain an inward force on the cylinder block.
13. Carefully push it toward the highest part of the end cap mounting surface.
14. Tilt the housing back so the cylinder block remains in place.
15. Hold the cylinder block and turn the shaft in both directions.
If you feel any play, one or more of the rollers are not in place. Ensure synchronizing shaft rollers
move freely in the races in the motor shaft. If installed correctly there is no free play between cylinder
block and shaft.
16. Lubricate the pistons and cylinder block bores liberally with hydraulic fluid.
Hold cylinder block parallel to end-cap surface of housing until end-cap is installed.

Repair Instructions
Assembly
Bearing plate
M0030
1. Install the bearing plate (M0030) with its steel side facing the cylinder block.
2. Lubricate the bronze side of the plate with hydraulic oil.

Repair Instructions
Assembly
Servo piston and valve segment—proportional control

Install servo piston and valve segment
F0090 4 mm
8 Nm [6 lbf•ft]
Rear view of
proportional
valve segment
QM050
P0050
P0040
F0050
P0043
P0044
F0020
F0060
F0070 5 mm
34 N•m
[25 lbf•ft]
1. Lubricate and install servo piston (F0020).
C Caution
Do not allow loose servo to damage machined surfaces of end-cap.
2. Lubricate and install setting lug (F0050).
3. Install new pin (F0060) and ensure pin is in groove of setting lug.
4. Install set screw (F0070) using a 5 mm internal hex wrench, torque to 34 N•m [25 lbf•ft].
5. Lubricate and install valve segment (QM050) and ensure valve segment spindle properly sets on
setting lug ball.
6. Install hold down screw (F0090) using a 4 mm internal hex wrench, torque screw to 6 N•m [4.5 lbf•ft].
7. Lubricate and install O-ring (P0043) and seal ring (P0044) onto servo piston head (P0040).
O-ring (P0043) and seal ring (P0044)
O-ring Seal ring
(P0043) (P0044)
Piston head
8. Press onto servo piston.
Take care not to damage seals.
9. Install screw (P0050).

Repair Instructions
Assembly

Size 060/080 110 160/210/250
C Caution
Do not torque until valve segment is installed.

Repair Instructions
Assembly
Servo piston and valve segment—two position control

Install servo piston and valve segment
P0043
Rear view of valve segment P0044
- two position control
F0020
4 mm F0090
6 N•m QM050
[4.5 lbf•ft]
1. Lubricate and install O-ring (P0043) and seal ring (P0044) onto servo piston.
2. Lubricate and install servo piston (F0020).
C Caution
Do not allow loose servo to damage machined surfaces of end-cap.
3. Install valve segment (QM050).
Ensure valve segment spindle ball end slides into servo piston hole.
4. Install hold down screw (F0090) using a 4 mm internal hex wrench and torque screw to 6 N•m [4.5
lbf•ft].

Repair Instructions
Assembly
End-cap assembly
F0120
see table for
wrench size and torque
G0070
G0040
G0040
1. If previously removed, install locator pins (G0040) in housing.

2. Install new gasket (G0070).
3. Install the end cap assembly in position marked during disassembly.
Ensure valve segment spindle engages the bearing in the cylinder block
4. Install screws (F0120) and tighten the screws by hand using sequence below:
End-cap torque sequence
5 8
2 4
3 1
7 6
P106 691E
5. When end cap is properly seated, torque screws (F0120) using the sequence.
Please see tables for wrench size and torque:

Repair Instructions
Assembly

Size 060/080 110 160 210/250
Torque for F0120

060 080 110 160 210/250
66 N•m [49 lbf•ft] 78 N•m [58 lbf•ft] 115 N•m [85 lbf•ft] 213 N•m [157 lbf•ft] 318 N•m [235 lbf•ft]
6. Rotate the motor shaft and check for play between the shaft and cylinder block.
Any play indicates that the synchronizing shaft rollers are not installed correctly.
Loop flushing charge relief valve and spool
24 mm
67 N•m [49 lbf•ft]
K0030
K0020
K0030A
K0010
K0020
K0030A
K0030
24 mm
67 N•m [49 lbf•ft]
L0050
L00**
24 mm
67 N•m [49 lbf•ft]
1. Lubricate and install spool (K0010) and springs (K0020) into end-cap.
2. Lubricate and install new O-rings (K0030A) on each plug (K0030).
3. Torque both plugs to 67 N•m [49 lbf•ft] using a 24 mm hex wrench.
4. Lubricate and install new O-ring (L0050) onto loop flushing charge relief valve cartridge (L00**).
5. Install loop flushing charge relief valve using a 24 mm hex wrench with torque to 67 N•m [49 lb•ft].

Repair Instructions
Assembly
Shaft seal
G0020
G0030
1. Lubricate inside diameter of new seal.

2. Cover the shaft splines with shaft cover or packing tape to avoid damaging the seal during
installation.
3. Using seal installation tool, press seal into housing bore.
Damage to the seal may result if the seal rubs on the shaft assembly when the motor is in operation.
Do not press the seal in too far if you are not using the seal installation tool.
4. Use a snap ring pliers to install retaining ring (G0030) into housing bore.
5. Use seal installation tool to press seal and retaining ring into housing until retaining ring snaps into
its groove.
Seal installation tool dimensions: 110/160/210/250 (left) and 060/080 (right)
180 mm 150 mm
100 mm [7.09 in]
100 mm [5.90 in]
[3.94 in] [3.94 in]
69 mm 58 mm 56 mm 48 mm 70 mm
82 mm
[2.6 in] [2.3 in] [2.2 in] [1.9 in] [2.76 in]
[3.15 in]
45°
45°
+ 0.10 5 mm
+ 0.10 5 mm 5.4 mm - 0.0 [0.2 in]
5.15 mm - 0.0 + 0.004
[0.2 in] P107 738E [0.21 in - 0.0 ]
[0.20 in + -0.004
0.0 ]

Repair Instructions
Assembly
Servo cover—proportional control

Installation of servo bushing cover
(previously installed)
P0050
see table
P0030
P0010
P0020
10 mm (4X)
115 N•m [85 lbf•ft]
1. Torque servo piston bushing screw (P0050).


Size 060/080 110 160/210/250
Torque for P0050

060/080 110 160/210/250
66 N•m [49 lbf•ft] 115 N•m [85 lbf•ft] 213 N•m [157 lbf•ft]
2. Lubricate and install new O-ring (P0030).
3. Install cover (P0010).
4. Install four screws (P0020) using a 10 mm internal hex wrench with torque to 115 N•m [85 lbf•ft].

Repair Instructions
Assembly
Speed sensor
J0020 J0020
J0010
J0010 O
J0010A
J0010A
J0010 J0010 J0010A

J0010A
O
J0020
J0020 P107833
1. Lubricate and install new O-ring (J0010A) on speed sensor or plug (J0010).
2. Install speed sensor or plug into housing.
3. Torque screw (J0020) using a 5 mm internal hex wrench to 8 N•m [6 lbf•ft].

Repair Instructions
Assembly
Minimum displacement limiter
N0010 6 mm
N0020 19 mm
N0120
Refer to H1 Bent Axis Motors Service Manual, AX00000025 for adjustment procedures.
1. If previously removed, replace displacement limiter screw (N0010) and lock-nut (N0020) to original
position.
2. Hold displacement limiter in place using a 6 mm internal hex and install a new lock-nut (N0020) using
a 19 mm wrench.
3. When motor is properly adjusted, torque lock-nut to 45 N•m [33 lbf•ft].
4. Install new cap (N0120).

Repair Instructions
Assembly
Maximum displacement limiter—two-position control

P0100
P0200
P107 866E
It is not necessary to remove the maximum displacement limiter unless it is being replaced.
1. Install spacer (P0200).
2. Install screw (P0100).
See the table for wrench size and torque below:
Wrench size (internal hex) and torque

Size 060/080/110 160/210/250
Wrench size 6 mm 8 mm
Torque 37 N•m [28 lbf•ft] 66 N•m [48 lbf•ft]

Repair Instructions
Assembly
Electric proportional controls M1CA/M2CA and L1BA/L2BA
B0027
26 mm 12-point B0040
3.5 N•m [2.6 lbf•ft]
B0029
B0028
B0020
M1CA/M2CA and L1BA/L2BA
B0050 (3x)
4 mm B0025
C0060
B0010
1/8 in B0035A
C0050 C0060A E00T2
1/4 in 3 mm
C0050A
40 N•m 6 N•m
C0025 C0100
[30 lbf•ft] [4 lbf•ft]
5 mm
14 N•m [10 lbf•ft]
B0010
E00T3
3 mm
C0060A
C0060 6 N•m
1/8 in [4 lbf•ft]
8 N•m [6 lbf•ft] C0060A
C0060
1/8 in
1. Lubricate and install shuttle valve spool assembly (C0025) using a 5 mm internal hex wrench with
torque to 14 N•m [10 lbf•ft].
2. Lubricate and install O-rings (C0050A) onto plugs (C0050).
3. Using a 1/4 inch internal hex wrench, install plugs (C0050) with torque to 40 N•m [30 lbf•ft].
4. Install orifices (E00T3 and E00T2) using a 3 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].
5. Lubricate and install four O-rings (C0060A) onto plugs (C0060).
7. Install control spool (C0100).
8. Lubricate and install a new O-ring (B0035A).
9. Install solenoid (B0010).
10. Install three screws (B0050) using a 4 mm internal hex wrench with torque to 6 N•m [4 lbf•ft].
11. If previously removed, install the solenoid coil.

Repair Instructions
Assembly
12. Replace O-rings (B0025, B0028, B0029).

13. Install the coil nuts (B0027) using a 26 mm 12-point socket with torque to 3.5 N•m [2.6 lbf•ft].
Do not over torque.
14. Install the plastic cap (B0040).

Repair Instructions
Assembly
Electric proportional controls D1M1/D2M2 and K1K1/K2K2

Assembly of control D1M1/D2M2
B0029 B0040
3.5 N•m B0027
D1M1/D2M2 [2.6 lbf•ft]
B0028
4 mm B0050
(3x) B0020
6 N•m [4 lbf•ft] B0025
B0027 3.5 N•m

B0010
[2.6 lbf•ft]
C0060 1/8 in
B0028
B0035
B0025 C0050 1/4 in
40 N•m C0010
[30 lbf•ft] C0060 1/8 in
B0020 E00T3
17 mm B0032
B0034
C0060
25 N•m C0070
[19 lbf•ft]
E00T3 C0080
C0060 C0090 25 N•m
C0060 1/8 in [18 lbf•ft]
8 N•m [6 lbf•ft] M223
C0020 C0050
C0030

Repair Instructions
Assembly
Assembly of control K1K1/K2K2

B0040
B0029
K1K1/K2K2 3.5 N•m B0027

[2.6 lbf•ft]
B0028
B0020
4 mm B0050 B0025
6 N•m
[4 lbf•ft]
B0010
1/4 in C0050 C0060 1/8 in B0035A

40 N•m 8 N•m [6 lbf•ft]
[30 lbf•ft] C0100 1/8 in
C0060
C0050
C0030
C0020
C0070
C0080
C0060 M223
1/8 in E00T3
8 N•m [6 lbf•ft] C0090 25 N•m
C0060
[18 lbf•ft]
B0034A B0025
B0032 B0028
17 mm
25 N•m B0027
[19 lbf•ft] 3.5 N•m
[2.6 lbf•ft]
B0020
1. Lubricate and install spring (C0080) and spool (C0070).
2. Lubricate and install new O-ring (M223) on adjuster (C0090).
3. Install pressure compensator adjusting plug (C0090) using a 1 inch wrench with torque to 25 N•m [18
lbf•ft].
4. Lubricate and install spools (C0020) and springs (C0030).
5. Lubricate O-rings on plugs (C0050).
12. Install solenoid (B0010).
15. Install solenoid (B0032) using a 3/4 inch open end wrench with torque to 25 N•m [19 lbf•ft].
16. Install coils with new O-rings (B0024, B0028).
Do not over torque.

Repair Instructions
Assembly
Two-position controls T*D* and P*D*

Assembly of two-position control T*D* and P*D*
B0028
B0022
B0026
3.5 N•m
[2.6 lbf•ft] B0024
17 mm
B0032 25 N•m [19 lbf•ft] T*D* and P*D*
B0034 1/4 in
B0026 40 N•m [30 lbf•ft]
3.5 N•m B0024
[2.6 lbf•ft] B0028 C0050
B0022
C0050A
17 mm B0032
25 N•m [19 lbf•ft] C0060 1/8 in 8 N•m [6 lbf•ft]
B0034
C0060A C0060A
C0060
C0060 1/8 in 8 N•m [6 lbf•ft]
1/8 in
8 N•m [6 lbf•ft] C0060A C0070
C0060
1/8 in C0080 M223
8 N•m [6 lbf•ft] E00T3 C0090
C0020
3 mm E00T2 17 mm
6 N•m 3 mm C0030 25 N•m
[4 lbf•ft] 6 N•m [18 lbf•ft]
[4 lbf•ft] C0050A
C0050
1/4 in
40 N•m [30 lbf•ft]
1. Lubricate and install new O-rings (B0034) onto solenoids (B0032).

2. Using a 17 mm hex wrench on the flats, install solenoids (B0032) with torque to 25 N•m [19 lbf•ft] .
Do not over torque.
5. Lubricate and install four O-rings (C0060A) onto plugs (C0060).
7. Lubricate and install spools (C0020 and C0070) and springs (C0080 and C0030).
8. Lubricate and install O-ring (M223) onto adjusting plug (C0090).
9. Install pressure compensator adjusting plug with torque to 25 N•m [18 lbf•ft].
Refer to H1 Bent Axis Motors Service Manual, AX00000025 for adjustment procedures.
10. Lubricate and install O-rings (C0050A) onto plugs (C0050).

Repair Instructions
Assembly
Two-position controls T*G* and P*G*

Assembly of two-position control T*G* and P*G*
B0028
B0022
B0026
T*G* and P*G*
B0024 C0050
B0032
C0050
B0034
C0030
C0020 C0010
C0060
C0060
C0070
E00T3 C0080 M223
C0090
E00T2
B0034
B0032
B0024
B0022
B0028
B0026

Do not over torque.
6. Lubricate and install spools (C0020) and springs (C0030).

Repair Instructions
Assembly
Two-position control E*AA

Assembly of two-position control E*AA
3.5 N•m
B0026
[2.6 lbf•ft]
B0028
B0024 17 mm
B0032 25 N•m [19 lbf•ft] E*AA
B0020
C0020
B0034
C0060 1/8 in
C0060 8 N•m [6 lbf•ft]
1/8 in
8 N•m [6 lbf•ft] C0060
C0025 1/4 in
40 N•m
C0050 [30 lbf•ft]
6. Lubricate and install spool (C0020).
9. Install coils with new O-rings (B0024, B0028).
Do not over torque.

Repair Instructions
Assembly
Two-position controls HEHE and HFHF

Assembly of two-position control HEHE and HFHF
C0140 C0160
3/8 inch
C0160A
HEHE 25 N•m [18 lbf•ft] C0050
C0080 1/4 in
40 N•m [30 lbf•ft]
C0150
1/4 in C0050 C0060
40 N•m C0060
C0025
[30 lbf•ft]
C0050
C0060
C0060
C0160 1/8 in
C0140 8 N•m [6 lbf•ft]
3/8 inch C0160A
25 N•m [18 lbf•ft] C0050
C0080
C0150
C0060
C0060 C0060 1/8 in
C0050
HFHF
C0060
1/8 in
C0050 1/4 in
C0025 40 N•m [30 lbf•ft] P108 573E
1. Lubricate and install spool (C0150) and spring (C0080).
2. Using a 3/8 inch internal hex wrench, install plug (C0140) with torque to 25 N•m [18 lbf•ft]
6. Using a 1/8 inch internal hex wrench, install plug (C0160) with torque to 25 N•m [18 lbf•ft].

Repair Instructions
Assembly
Two-position control THHA

Assembly of two-position control THHA
1/4 inch
C0050 B0300
C0050
B0310
QB300
B0330 C0050 THHA
C0025 B0320
C0060 C0070
1/8 in E00T3
C0060
1/8 in C0080
M223
E00T2 C0090
P108913
lbf•ft].
5. Lubricate and install O-ring (QB0300).
6. Install adapter (B0300) with torque to 67 N•m [49 lbf•ft].
10. Using a 1/8 inch internal hex wrench, install plug (C0160) with torque to 25 N•m [18 lbf•ft].

Repair Instructions
Assembly
Two-position control THHB

Assembly of two-position control THHB
1/4 inch
C0050 B0300
C0050
B0310
QB300
B0330 THHB
C0025 B0320 C0050
C0070
C0060
E00T3 C0080
1/8 in C0060 M223
1/8 in C0090
E00T2 C0020
C0140
C0050
P108923
lbf•ft].
5. Lubricate and install O-ring (QB0300).
6. Install adapter (B0300) with torque to 67 N•m [49 lbf•ft].

Repair Instructions
Assembly
Two-position control DHMA

Assembly of control DHMA
C0090
C0090A
C0080
C0070
C0060A
E00T2 C0060
3 mm
C0060
C0060A
1/8 in
C0010
8 N•m C0060
C0060
[6 lbf•ft] C0060A C0060A
1/8 in
C0060 8 N•m
C0060A
C0060A C0060 [6 lbf•ft]
C0050A C0050
3 mm E00T3
C0110 6 N•m [4 lbf•ft]
C0120 C0060A
C0025
B0061 C0060
C0100 C0060A C0050A
0010 C0060
0020 C0050 40 N•m
[30 lbf•ft]
B0190
B0060
B0010
0020 DHMA
0010
B0180
P108834
B0050
actuator.
lbf•ft].
11. Lubricate and install a new O-ring (B0190).
12. Install hydraulic actuator (B0010).

Repair Instructions
Assembly
Two-position control DHMH

Assembly of control DHMH
C0090
C0090A
C0080
C0070
E00T2
3 mm
1/8 in
8 N•m
C0140 1/8 in
[6 lbf•ft] C0060 C0060
C0060A 8 N•m
C0010 C0060A [6 lbf•ft]
C0050
40 N•m C0050
[30 lbf•ft] C0050A C0050A C0060
C0060A
C0060 C0060A 40 N•m
1/8 in C0060 C0060A C0050A C0050 [30 lbf•ft]
8 N•m C0060A 6 N•m [4 lbf•ft]
[6 lbf•ft] E00T3
C0060 3 mm
C0060 C0060A
C0060A C0060
C0120 1/8 in
C0060A
8 N•m
C0060 C0020 [6 lbf•ft]
C0110
C0100 1/8 in
C0140
8 N•m
[6 lbf•ft] C0050A
0010
0020 C0050
B0190 40 N•m
B0061 [30 lbf•ft]
B0010 B0060
0020
0010
B0180 DHMH
B0050
P108832
actuator.
lbf•ft].

Repair Instructions
Assembly
Two-position control KHKA

Assembly of control KHKA
B0050
B0180
B0060
KHKA B0010
B0061
B0190
C0120
E00T3
C0100
C0110
C0060
C0050
C0050
C0060
C0025 C0060
C0060
C0070
C0060 E00T2 C0080
C0060
C0090
M223
P109035
actuator.
lbf•ft].

Repair Instructions
Assembly
Two-position control KHKH

Assembly of control KHKH
B0050
B0180
B0060
KHKH B0010
B0061
B0190
C0120
E00T3 C0100
C0110
C0060
C0050
C1400
C0060
C0020 C0060
C0060 C0070
E00T2 C0080
C0060
C0090
M223
C1400
P109036
actuator.
lbf•ft].

Repair Instructions
Assembly
Two-position controls MHCA and LHBA

Assembly of controls MHCA and LHBA
B0050
MHCA & LHBA

B0180
B0010
0010
0020
B0061
B0060
0020
B0190
0010
C0060
C0100
C0060A C0110
C0050 C0050A
40 N•m E00T2
C0025 6 N•m [4 lbf•ft]
[30 lbf•ft] 3 mm
C0010
C0060
C0060A 3 mm
C0060A
C0060
1/8 in
8 N•m
[6 lbf•ft]
P108835


Repair Instructions
Assembly
Proportional controls installation
C0110 (4X)
6 mm
37 Nm
C0110 (4X) [27 lbf•ft]
C0010 6 mm
Proportional C0010
control
F0030
F0030
F0040
F0040
C0130 C0130
Electric proportional control Hydraulic proportional control P108841
1. Install new gasket (C0130).

2. Install spring (F0040) and spring guide (F0030).
3. Install control housing (C0010).
4. Install torque screws (C0110) using a 6 mm internal hex wrench with torque to 37 N•m [28 lbf•ft].

Repair Instructions
Assembly
Two-position controls installation

Hydraulic and electric two-position controls with or without PCOR
6 mm
C0120 (2X)
C0120 (2X) C0110 (2X) 37 Nm 10 mm
[27 lbf•ft] C0110 (2X)
10 mm
C0010
C0010
2 position
control
C0130
C0130
Hydraulic two position control with and without PCOR Electric two position control with and without PCOR

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

Repair Instructions
Assembly
Controls with PCOR installation
Hydraulic and electric two-position controls with PCOR
C0130
C0130
F0040
F0040
F0030
F0030
C0010
C0010
6 mm
37 Nm
[27 lbf•ft] C0120 (2X) 6 mm
6 mm
C0120 (2X) 37 Nm
C0110 (2X) 37 Nm
[27 lbf•ft] P108843
[27 lbf•ft] C0110 (2X)
Hydraulic proportional control with PCOR Electric proportional control with PCOR

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

Repair Instructions
Start-up Procedures
Overview
Install motor on a test stand and adjust per Danfoss testing specifications TS-396.
Refer to H1 Bent Axis Variable Displacement Motors Service Manual, AX00000025, for start-up procedures,
adjustments, and pressure measurements for H1 motors. motor.
Initial startup procedures

Startup procedures include:
• Ensure system components are clean
• Install new filters
• Fill system with fluid
• Disable engine
• Disconnect control
• Crank engine and check for adequate charge pressure
• Check for proper control function
Adjustments
Adjustment procedures include:
• Displacement limiter adjustment
• Electronic displacement control (EDC) threshold adjustment
• PCOR adjustment
Pressure measurements
Pressure measurement procedures include:
• Required tools
• Port locations
• Gauge installation
• Leakage test per Danfoss test HPP 112

Repair Instructions
Port locations
Ports and Gauge Information

The following drawing with accompanying table show the port locations and gauge sizes needed for
installation.
Ports locations (proportional control)
M5
(M4 on
reverse side)
MA
(MB on
reverse side)
System System
Port A Port B
XB
(Port XA
on reverse side)
L2
X1
Axial Ported Endcap
M5
(M4 on reverse side)
L1
System Port A
(System Port B
on reverse side)
MA
MB
XB
(Port XA
on reverse side)
L2 X1
Radial Ported Endcap P108829
System split flange boss ports, A/B: Code 62 per ISO 6162, Type 1
Port Size 060 Size 080, 110 Size 160, 210, 250
A, B 3/4 in; Thread: M10 x 1.5 1 in; Thread: M12 x 1.75 1 1/4 in; Thread: M12 x 1.75
min. 18 mm [0.71 in] min. 23 mm [0.91 in] min. 23 mm [0.91 in]
Radial/Axial end-cap ports

Port Size 060 Size 080, 110, 160, 210, 250 System pressure obtained
MA, MB (Radial) 7/8-14 UNF 1 1/16-12UN
600 bar [8702 psi]
Wrench (int. hex): 3/8 in Wrench (int. hex): 9/16 in
MA, MB (Axial) 7/8-14 UNF 9/16-18 UNF
600 bar [8702 psi]
Wrench (int. hex): 3/8 in Wrench (int. hex): 1/4 in

Repair Instructions
Port locations
Ports and gauge Information

Port Size 060/080 Size 110/160 Size 210/250 Pressure obtained
L1, L2 7/8-14 UNF 1 1/16-12UN 1 5/16-12UN 10 bar [145 psi]
Wrench: 3/8 in Wrench: 9/16 in Wrench: 5/8 in Case drain
M4, M5 9/16-18 UNF; Wrench (int. hex): 1/4 in 600 bar [8700 psi] 1)
X1, XA, XB 9/16-18 UNF; Wrench (int. hex): 1/4 in 100 bar [1450 psi] 2)
1) Servo pressure rod end.
2) X1 – Control pressure supply, hydraulic actuator. XA/XB – BPD, PCOR inactive at A/B.
Port locations (hydraulic 2-position controls with PCOR; control specific ports only)
XB
X1
(Port XA
on reverse side)
P108924

Repair Instructions
Torque chart
Fasteners and plugs

Port/fastener and plug locations and sizes
Proportional controls with radial ported endcap P0020

M4 L00** J0020 M5
F0100 L1 F0100
G0060
MB
System MA F0150 System
Port B F0150 Port A
K0030
XA XB
B0060 B0060
X1
B0060 C0060
B0050 G0050 C0110 and C0120 L2
G0060 N0020
N0010
P108831
Two position controls with radial ported endcap

XA M4
F0100 XB
B0060 X1 B0060
B0060
L1 K0030
M5
F0100 G0060
L00**
System MA System
MB F0150
Port A F0150 Port B
L2
G0060 P108925

Repair Instructions
Torque chart
Fastener size and torque chart
Item Fastener Wrench size Torque
P0020 Servo piston cover screws 10 mm internal hex wrench 115 N•m [85 lbf•ft]
F0120 (210, 250) End-cap screws 14 mm internal hex wrench 318 N•m [235 lbf•ft]
F0120 (160) End-cap screws 12 mm internal hex wrench 213 N•m [157 lbf•ft]
C0110 (proportional) Control assembly screws 6 mm internal hex wrench 37 N•m [28 lbf•ft]
C0110, C0120 (two-position) Control assembly screws 10 mm internal hex wrench 115 N•m [85 lbf•ft]
B0050 Solenoid screws 4 mm internal hex wrench 6 N•m [4 lbf•ft]
J0020 Speed sensor screw 5 mm internal hex wrench 8 N•m [6 lbf•ft]
N0010 Displacement limiter screw 6 mm internal hex wrench N/A
L00** Loop flushing charge relief 24 mm hex 67 N•m [49 lbf•ft]
N0020 Displacement limiter lock-nut 19 mm hex 45 N•m [33 lbf•ft]
Plug size and torque chart
Item O-ring plug Wrench size Torque

F0100 9/16 – 18UNF 1/4 internal hex wrench 40 N•m [30 lbf•ft]
G0050 (SAE and DIN flange) 7/16 – 20UNF 3/16 internal hex wrench 8 N•m [6 lbf•ft]
G0055 (Cartridge model only, not 5/16 – 24UNF 1/8 internal hex wrench 8 N•m [6 lbf•ft]
shown).
G0060 (110/160) 1-1/16 – 12UN 9/16 internal hex wrench
G0060 (060/080) 7/8 – 14UN 3/8 internal hex wrench 70 N•m [52 lbf•lb]
G0060 (210/250) 1-5/16 - 12UN 5/8 internal hex wrench
C0060 5/16 – 24UNF 1/8 internal hex wrench 8 N•m [6 lbf•ft]
F0150 (Radial end-cap, size: 1-1/16 – 12UN 9/16 internal hex wrench 115 N•m [85 lbf•ft]
080/110/160/210/250)
F0150 (060) 7/8 – 14UN 3/8 internal hex wrench 95 N•m [70 lbf•lb]
F0160 (Axial end-cap)

9/16 – 18UNF 1/4 internal hex wrench 40 N•m [30 lbf•ft]
C0050 and B0060
L00** and K0030 M18 – 1.5 24 mm hex wrench 67 N•m [49 lbf•ft]

Hydrostatic Motor H1 060/080/110/160/250

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Hydrostatic Motor H1 060/080/110/160/250

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647069EN (30/08/2018)

DATE OF ISSUE OBSERVATION

01 / 07 / 2009 - 1st ISSUE

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

© Danfoss | April 2018 11020692 | AX00000153en-US0701 | 3

4 | © Danfoss | April 2018 11020692 | AX00000153en-US0701

About this manual

© Danfoss | April 2018 11020692 | AX00000153en-US0701 | 5

Unintended machine movement

Flammable cleaning solvents

Fluid under pressure

6 | © Danfoss | April 2018 11020692 | AX00000153en-US0701

Symbols used in Danfoss literature

WARNING may result in injury Tip, helpful suggestion

CAUTION may result in damage to product or 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

© Danfoss | April 2018 11020692 | AX00000153en-US0701 | 7

Proportional controls disassembly

Electric proportional control Hydraulic proportional control P108841

8 | © Danfoss | April 2018 11020692 | AX00000153en-US0701

Two-position controls disassembly

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

© Danfoss | April 2018 11020692 | AX00000153en-US0701 | 9

Disassembly of controls with PCOR

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

10 | © Danfoss | April 2018 11020692 | AX00000153en-US0701

Electric proportional controls M1CA/M2CA and L1BA/L2BA

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

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

© Danfoss | April 2018 11020692 | AX00000153en-US0701 | 11

Electric proportional controls D1MA/D2MA and K1KA/K2KA

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

12 | © Danfoss | April 2018 11020692 | AX00000153en-US0701

Disassembly of controls K1KA and K2KA

K*K* control B0027

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

© Danfoss | April 2018 11020692 | AX00000153en-US0701 | 13

Two-position controls T*D* and P*D*

B0026 B0034 1/4 in

T*D* and P*D* C0050A

14 | © Danfoss | April 2018 11020692 | AX00000153en-US0701

Two-position controls T*G* and P*G*

© Danfoss | April 2018 11020692 | AX00000153en-US0701 | 15

Two-position control E*AA

16 | © Danfoss | April 2018 11020692 | AX00000153en-US0701

Two-position controls HEHE and HFHF

© Danfoss | April 2018 11020692 | AX00000153en-US0701 | 17

Two-position control THHA

18 | © Danfoss | April 2018 11020692 | AX00000153en-US0701

Two-position control THHB

© Danfoss | April 2018 11020692 | AX00000153en-US0701 | 19

Two-position control DHMA

KK control B0027

Two-position controls TD and PD

TD and PD C0050A

Two-position controls TG and PG