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Eaton® DuraForce™ HMF Conversion Procedures

2 EATON Duraforce HMF Conversion Procedures Manual E-MOPI-TM004-E July 2012

Content Page #

Table of Contents

• 12mm Allen wrench

• 13mm Wrench (for Closed Loop Purge Valve)

• 17mm Wrench (for Open Loop Purge Valve)

• Torque wrench capable of setting 122 N-m (90 ft-lb)

• Needle-nose pliers

• Blocked Purge Valve

• Rubber Mallet (optional)

• Disabled Shuttle Spool

Tools Required 2

Introduction 3

Model Code 4

Block Case Flushing Feature

Set Up 5

Procedure to Disable the Shuttle Valve Assembly 6

Procedure to Disable the Purge Valve 8

Exchange Purge Valves

Set Up 9

Procedure to Exchange a Close Loop Purge Valve with an Open Loop Purge Valve 9

Procedure to Exchange an Open Loop Purge Valve with a Close Loop Purge Valve 9

Exchange Shuttle Valve Assemblies

Set Up 10

Disassembly Procedure 11

Assembly Procedure 12

Exchange Cross-over Relief Valve

Set Up 13

Procedure to Exchange Single-Setting Relief Valves with Dual-Setting 13

Procedure to Exchange Dual-Setting Relief Valves with Single-Setting 13

Operational Parameters 14

Part Numbers Listing 16

Blocking the Case Flushing Feature

Exchanging Purge Valves

Exchanging Shuttle Valve Assemblies

Exchanging Cross-Over Relief Valves

• 13mm wrench

• 17mm wrench


• 12mm Allen wrench

• Heat gun / torch

• Eaton shuttle assembly tool

• Green Loctite 648

• Torque wrench capable of 100 ft-lb (136 N-m)

• 24mm wrench

• 36mm wrench


Tools Required

3EATON Duraforce HMF Conversion Procedures Manual E-MOPI-TM004-E July 2012

This manual will provide you with information and procedures for general conversions of Eaton® DuraForce™ HMF Fixed Displacement Open and Closed Loop Hydraulic Motors. Procedures outlined in this manual will allow you to be more flexible with your inventory and better service your customers. To ensure accuracy of conversion and prevent part loss or damage, certain components or subassemblies are disassembled, inspected, and reassembled when removed from the motor.

Training

You have been provided information on the conversion of DuraForce products. Proper application of the information requires specific training and may require use of specialized tooling and equipment. All requests for training must be coordinated through your Eaton Account Manager. He can also provide you price and availability of any specialized tooling. If you choose to proceed with the conversion of the DuraForce products absent the necessary training and/or these specialized tools, you do so at your risk.

Eaton will accept no claim for warranty resulting from deficiencies in the conversion. Please refer to the Eaton literature web site for warranty information at www.eaton.com/hydraulics/warranty.

Labeling Converted Units

All units that have been converted must retain the original Eaton label and have a second Eaton label placed on the unit. This second label at a minimum must state

Converted Eaton Model Code # (Final Eaton model code of the converted unit)

Conversion done by (Name of your company)

Conversion Parts

All requests for specific conversion part information should be addressed to your Eaton account representative. Additional information can be found through your Eaton customer connect portal. All requests or inquiries must be accompanied by the complete model and serial number of the base unit you want to convert.

Cleanliness

Cleanliness is extremely important when repairing a hydrostatic pump or motor. Before disconnecting the lines, clean foreign material from exterior of unit. Work in a clean area. Clean all metal parts in clean solvent. Blow parts dry with air. Don’t wipe parts with cloth or paper towel, because lint or other matter could cause damage. Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage. Don’t use coarse grit paper, files or grinders on parts.

Environmental Concerns

Protection of the natural fundamentals of life is one of our predominant tasks. We are continuously improving the protection of the environment as far as applications are concerned. We encourage you to contribute your share to comply with this demand. In connection with work to be performed, the environmental regulations of the machine manufacturer must be respected.

In general:

• Greases and oils which cannot be used any more have to be collected. They are normally a threat to water reserves and must be kept away from the environment.

• Adhere to national and local regulations for waste disposal.

Seals

A good conversion policy is to replace all old seals with new seals whenever units are disassembled. This avoids potential damage during seal removal. Lubricate seals with petroleum jelly. Use only clean and recommended oil when assembling unit. Information on recommended filters and fluids can be found in the Operational Parameters section.

Torque

All torque specifications are for lubricated threads. Bolts for gasketed surfaces should be checked for proper torque.

Introduction


• Available Option l Preferred Option t Separate Specification Required

Model CodeHMF Fixed Displacement Motors (Open & Closed Loop Operation)

The following 21 digit coding system has been developed to identify preferred feature options for a HMF Closed or Open Loop Hydraulic Motor. Use this code to specify a motor with the desired features. All 21-digits of the code must be present to release a new product number for ordering. Please contact your local customer service representative for leadtime questions.

1 2 3 ProductHMF – Fixed Displacement

Motorsl l l l l l l

4 5 6 Displacement028 – 28 cc l035 – 35 cc l050 – 50 cc l055 – 55 cc l075 – 75 cc l105 – 105 cc l135 – 135 cc l

7 Mounting FlangeB – SAE B, 2-Bolt l lC – SAE C, 2-Bolt l l l lD – SAE D, 2-Bolt l

8 Output ShaftC – splined ANSI B92.1 16/32

- 15 teeth (SAE J744 B-B)l l

D – splined ANSI B92.1 12/24 - 14 teeth (SAE J744 C)

l l l •

J – splined ANSI B92.1 8/16 - 13 teeth (SAE J744 D&E)

l

K – splined ANSI B92.1 16/32 - 21 teeth

l l l •

L – splined ANSI B92.1 16/32 - 23 teeth

l

M – splined ANSI B92.1 16/32 - 27 teeth

l

9 PortingM – ISO 6149 metric l l lD – DIN 3852 l l l l l l l

10 Port OrientationR – radial ports l l l l l l l

L – axial ports l l l

11 Attachments to Service Ports0 – without l l l l l l l

12 13 Crossover Relief Valves Integrated00 – - without l l l l l l

AA – single-stage 210 bar (*p) (*q) l l l l l l l

AC – single-stage 250 bar (*p) (*q) l l l l l l l

AE – single-stage 420 bar (*p) (*q) l l l l l l l

AG – single-stage 350 bar (*p) (*q) l l l l l l l

AP – two-stage 200/380 bar (*d) (*p) (*q)

l l l l l l l

AQ – single-stage 300 bar (*p) (*q) l l l l l l l

14 Purge Relief Valve0 – without purge devices l l l l l l lA – 10 bar standard purge flow l l l l l lB – 14 bar standard purge flow l l l l l lC – 10 bar reduced purge flow • • • • • •D – 14 bar reduced purge flow • • • • • •E – 10 bar increased purge flow • • • • • •F – flow controlled 6 l/min (*o) l l l l l lG – blank plug instead of relief

valve (*v)• • • • • •

15 Purge Shuttle Valve0 – Without purge devices l l l l l l l1 – Standard shuttle valve l l l l l l2 – Damped shuttle valve • • • • • •3 – Shuttle valve blocked • • • • • •16 Speed Sensor in Motor Housing0 – Without l l l l l l lA – 7 impulses l lB – 9 impulses l

17 18 Special Requirements00 – Without (default) l l l l l l l

19 Surface Coating0 – Anti-rust conservation oil

(default)l l l l l l l

A – Primer blue l l l l l l l

20 Unit IdentificationA – DuraForce l l l l l l l

21 Type Code ReleaseA – Revision Level l l l l l l l

28 35 50 55 75 105 135 28 35 50 55 75 105 135

HMF 105 C D M R 0 00 A 1 0 00 A A A

1 17 182 3 4 5 6 9 14 19118 10 15 2016 217 12 13

(*d) DIN porting only (see position 9)(*m) ISO metric porting only (see position 9)(*o) Open loop operation only(*p) Radial service ports only (see position 10)(*q) Without purging devices only (see position 14 and 15)(*v) With blocked purge shuttle valve only (position 15)


Blocking the Case Flushing FeatureSet Up

Important

This procedure must be performed in a clean environment using clean Parts, Tools and Lubricants


Blocking the Case Flushing FeatureProcedure to Disable the Shuttle Valve Assembly

Remove the M22 Plug with the 12mm Allen wrench.

Important

This procedure applies to HMF Motors with “Standard” or “Optimized” Shuttle Valve Assemblies. For unit with “Dampened” Shuttle Valve Assembly please move to “Procedure to Disable the Purge Valve” section near the end of this document.

1

Remove the spring with the needle-nose pliers or pencil magnet.

2

Remove the Washer and Shuttle Spool simultaneously with the needle-nose pliers being careful not damage the spool or use a pencil magnet.

3

Remove the Washer from the Shuttle Spool.4

Replace the Original Shuttle Spool with the Disabled Shuttle Spool

5


Blocking the Case Flushing Feature Procedure to Disable the Shuttle Valve Assembly (continued)

Important

This procedure applies to HMF Motors with “Standard” or “Optimized” Shuttle Valve Assemblies. For unit with “Dampened” Shuttle Valve Assembly please move to “Procedure to Disable the Purge Valve” section near the end of this document.

Reinstall the Washer onto the Disabled Shuttle Spool.6

Reinstall the Washer/Disabled Shuttle Spool subassembly back into the Shuttle Body.

7

Reinstall the spring.8

Reinstall the M22 Plug. Torque the M22 Plug to 122 N-m (90 ft-lb).

9


Blocking the Case Flushing FeatureProcedure to Disable the Purge Valve

Remove the purge valve.

Important

This procedure applies to HMF Motors with Standard, Optimized or Dampened Shuttle Valve Assemblies.

1

Replace the existing purge valve with the blocked purge valve

2

Install the blocked purge valve back into the motor and torque it to 15 N-m (11 ft-lb)

3

Blocked Purge Valve


Exchanging Purge Valves Set Up and Procedure

Procedure to Exchange a Closed Loop Purge Valve with an Open Loop Purge Valve

Remove the Closed Loop Purge Valve with the 13mm wrench.

Install the Open Loop Purge Valve and tighten it with the 17mm wrench. Torque it to 15 N-m (11 ft-lb).

Procedure to Exchange an Open Loop Purge Valve with a Closed Loop Purge Valve

Remove the Open Loop Purge Valve with the 17mm wrench.

Install the Closed Loop Purge Valve and tighten it with the 13mm wrench. Torque it to 15 N-m (11 ft-lb).

1

2

1

2


Exchanging Shuttle Valve AssembliesSet Up

Important

Although these locations may differ from one unit type to the other, the internal parts are the same.

This procedure must be performed in a clean environment using clean Parts, Tools and Lubricants.

Important

The following image illustrates the different types of shuttle valve assemblies used on Eaton Hydraulics H** motors:

HMF75 HMR75 HMV75


Exchanging Shuttle Valve AssembliesDisassembly Procedure

Remove the plug from the shuttle valve assembly as shown here.

Note

An HMV motor is used to show the necessary steps throughout this document. The same process can be used for HMF motors.

1 In order to break loose the Loctite used to keep the shuttle body in place, heat the area directly above the shuttle assembly as shown here.

3

Remove the first set of shuttle spool, spring and shim combination.

2

Use the special Eaton tool to remove the shuttle body.4

Remove the remaining shuttle spool, spring and shim combination.

5

Important

There are three types of shuttle valve assemblies used on DuraForce units and there are two different types of tools used to remove the shuttle bodies.

A better look at the shuttle valve assembly is shown below.

New Tool 600.880.0001


Exchanging Shuttle Valve AssembliesAssembly Procedure

Apply Green Loctite 648 on the threads inside the rear head where the shuttle body will be installed.

Assemble the first set of shuttle spool/shim/spring into the shuttle body as shown during the training.

Insert the whole set into the shuttle cavity on the rear head and torque it using the special Eaton tool (refer to the torque chart at the bottom of this page)

Note

An HMV motor is used to show the necessary steps throughout this document. The same process can be used for HMF motors.

1 Install the plug and torque it (refer to the torque chart at the bottom of this page).

5

2

3

Insert the second set of shuttle spool/shim/spring into the shuttle body.

4

Item Description Torque Value ft-lb (N-m)

Standard shuttle body 100+7 (136+9)Dampened shuttle body 44+7 (60+9)Optimized shuttle body 44+7 (60+9)Shuttle cavity plug 90+7 (122+9)

Torque Chart


Exchanging Cross-Over Relief ValvesSet Up and Procedure

Procedure to Exchange Single-Setting Relief Valves with Dual-Setting

Note

If performing this procedure on a machine, make sure that there is enough clearance to remove the Single-Setting Relief Valves and to install the Dual-Setting Relief Valves as illustrated above.

Remove the Single-Setting Relief Valves with the 24mm wrench.

Make sure that the O-Ring was removed with each relief valve.

Inspect the Dual-Setting Relief Valves to insure that the O-Ring is in place and is not damaged.

Install the Dual-Setting Relief Valves and tighten them with the 36mm wrench. Torque each relief valve to 80 N-m (59 ft-lb).

Procedure to Exchange Dual-Setting Relief Valves with Single-Setting

Note

If performing this procedure on a machine, make sure that there is enough clearance to remove the Dual-Setting Relief Valves as illustrated above.

Remove the Dual-Setting Relief Valves with the 36mm wrench.

Make sure that the O-Ring was removed with each relief valve.

Inspect the Single-Setting Relief Valves to insure that the O-Ring is in place and is not damaged.

Install the Single-Setting Relief Valves and tighten them with the 24mm wrench. Torque each relief valve to 100 N-m (74 ft-lb).

1

2

3

4

1

2

3

4


Operational ParametersLifetime Recommendations

Eaton high pressure units are designed for excellent reliability and long service life. The actual service life of a hydraulic unit is determined by numerous factors. It can be extended significantly through proper maintenance of the hydraulic system and by using high-quality hydraulic fluid.

Beneficial Conditions For Long Service Life

Speed Lower continuous maximum speedOperating Pressure Less than 300 bar Δp on averageMaximum Pressure Only at reduced displacementViscosity 15 ... 30 cStPower Continuous power or lowerPurity of Fluid 18/16/13 in accordance with ISO 4406 or better

Adverse Factors Affecting Service Life

Speed Between continuous maximum speed and intermittent maximum speed

Operating Pressure More than 300 bar Δp on average

Viscosity Less than 10 cSt

Power Continuous operation close to maximum power

Purity of Fluid Lower than 18/ 16/ 13 in accordance with ISO 4406

Filtration

For Reliable Proper Function and Long Service Life 18/16/13 in accordance with ISO 4406 or betterMinimum Requirements 20/18/15 in accordance with ISO 4406Commissioning The minimum purity requirement for the hydraulic oil is based on the most sensitive

system component. For commissioning we recommend a filtration in order to achieve the required purity.

Filing in Operation of Hydraulic Systems The required purity of the hydraulic oil must be ensured during filling or topping up. When drums, canisters or large-capacity tanks are used the oil generally has to be filtered. We recommend the implementation of suitable measures (e.g. filters) to ensure that the required minimum purity of the oil is also achieved during operation

International Standard Code number according to ISO 4406 purity class according to SAE AS 4059 18/16/13 corresponds to 8A/7B/7C 20/18/15 9A/8B/8C

Operational parameters. Filtration

In order to guarantee long-term proper function and high efficiency of the hydraulic pumps the

cleanliness level of the lubricant must comply with the following criteria according to

Eaton Hydraulic Fluid Recommendation 03-401-2010. Maintaining the recommended cleanliness

level can extend the service life of the hydraulic system significantly.

For reliable proper function and long service life

18/16/13 in accordance with ISO 4406 or better

Commissioning

The minimum cleanliness level requirement for the hydraulic oil is based on the most sensitive component. For commissioning we recommend a filtration in order to achieve the required cleanliness level.

Filling and operation of hydraulic systems

The required cleanliness level of the hydraulic oil must be ensured during filling or topping up. When drums, canisters, or large-capacity tanks are used the oil generally has to be filtered. We recommend the implementation of suitable filters to ensure that the required cleanliness level of the oil is achieved and maintained during operation.

International standard Code number according to ISO 440618/16/13


Operational ParametersPressure Fluids

In order to ensure the functional performance and high efficiency of the hydraulic motors the viscosity and purity of the operating fluid should meet the different operational requirements. Eaton recommends using only hydraulic fluids which are confirmed by the manufacturer as suitable for use in high pressure hydraulic installations or approved by the original equipment manufacturer.

• Mineral oil HLP to DIN 51 524-2

• Biodegradable fluids in accordance with ISO 15 380 on request

• Other pressure fluids on request

Eaton offers an oil testing service in accordance with VDMA 24 570 and the test apparatus required for in-house testing. Prices available on request.

Pressure Fluid Temperature Range [°C] -20 to +90

Working viscosity range [mm²/s] = [cSt] 10 to 80Optimum working viscosity [mm²/s] = [cSt] 15 to 30Max. viscosity (short time start up) [mm²/s] = [cSt] 1000

Permitted Pressure Fluids

Recommended Viscosity Ranges

Viscosity Recommendations

In order to be able to select the right hydraulic fluid it is necessary to know the working temperature in the hydraulic circuit. The hydraulic fluid should be selected such that its optimum viscosity is within

the working temperature range (see tables).

The temperature should not exceed 90°C (194°F) in any part of the system. Due to pressure and speed influences the

leakage fluid temperature is always higher than the circuit temperature. Please contact Eaton if the stated conditions cannot be met in special circumstances.

Working Temperature Viscosity Class

Temperature [mm²/s] = [cSt] at 40°C (104°F)

Approx. 30 to 40°C (86 to 104°F) 22Approx. 40 to 60°C (104 to 140°F) 32Approx. 60 to 80°C (140 to 176°F) 46 or 68

Further information regarding installation can be found in the operating instructions.


Eaton Part NumbersHMF Fixed Displacement Motors (Open & Closed Loop Operation)

Part # Description Qty

6003435526 Plug 10009630107 O-ring 1

Blocking Purge Valves p. 8


0009630107 O-ring 16003451030 Valve Sleeve 16003450352 Valve Piston 10009210910 Compression Spring 19289003013 Shim, 0.5mm as req'd9289003010 Shim, 0.1mm as req'd6003435528 Screw Plug 1

Purge Valves - Open Loop p. 9


0009630107 O-ring 16003451008 Valve Sleeve 19516003252 Ball 10009211007 Spring 19289003006 Shim, 0.5mm as req'd9289003003 Shim, 0.1mm as req'd6003435512 Screw Plug 1

Purge Valves - Closed Loop, 10 bar Standard p. 9


0009630107 O-ring 16003451008 Valve Sleeve 19516003252 Ball 10009211007 Spring 19289003006 Shim, 0.5mm as req'd9289003003 Shim, 0.1mm as req'd6003435512 Screw Plug 16003454000 Orifice 1

Purge Valves - Closed Loop, 10 bar Reduced p. 9


0009630107 O-ring 16003451008 Valve Sleeve 19516003252 Ball 10009211009 Spring 19289003006 Shim, 0.5mm as req'd9289003003 Shim, 0.1mm as req'd6003435512 Screw Plug 1

Purge Valves - Closed Loop, 14 bar Standard p. 9


0009630107 O-ring 16003451008 Valve Sleeve 19516003252 Ball 10009211009 Spring 19289003006 Shim, 0.5mm as req'd9289003003 Shim, 0.1mm as req'd6003435512 Screw Plug 16003454000 Orifice 1

Purge Valves - Closed Loop, 14 bar Reduced p. 9



Standard6003405642 Standard Shuttle 1Dampened6003405620 Dampened Shuttle 1Optimized6003405651 Optimized Shuttle 1

Shuttle Valves p. 10


90/280 bar6013405927 Relief Valve, 90/280 bar 2110/230 bar6013405931 Relief Valve, 110/230 bar 2110/310 bar6013405929 Relief Valve, 110/310 bar 2180/280 bar6013405969 Relief Valve, 180/280 bar 2

Cross-Over Relief Valves - Dual Setting p. 13


250 bar6013405915 Relief Valve, 250 bar 2270 bar6013405905 Relief Valve, 270 bar 2350 bar6013405919 Relief Valve, 350 bar 2

Cross-Over Relief Valves - Single Setting p. 13

Eaton Part NumbersHMF Fixed Displacement Motors (Open & Closed Loop Operation)


Notes

EatonHydraulics Group USA14615 Lone Oak RoadEden Prairie, MN 55344USATel: 952-937-9800Fax: 952-294-7722www.eaton.com/hydraulics

EatonHydraulics Group EuropeRoute de la Longeraie 71110 MorgesSwitzerlandTel: +41 (0) 21 811 4600Fax: +41 (0) 21 811 4601

Eaton Hydraulics Group Asia PacificEaton BuildingNo.7 Lane 280 Linhong Road Changning District, Shanghai200335 ChinaTel: (+86 21) 5200 0099Fax: (+86 21) 2230 7240

© 2012 Eaton CorporationAll Rights Reserved Printed in USADocument No. E-MOPI-TM004-EJuly 2012

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