Eaton® DuraForce™

HMF Conversion Procedures

 Table of Contents

Content Page #

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

Tools Required
Blocking the Case Exchanging Purge Exchanging Shuttle Exchanging Cross-Over
Flushing Feature Valves Valve Assemblies Relief Valves
• 12mm Allen wrench • 13mm wrench • 12mm Allen wrench • 24mm wrench
• 13mm Wrench (for Closed • 17mm wrench • Heat gun / torch • 36mm wrench
Loop Purge Valve)
• Torque wrench capable of • Eaton shuttle assembly tool • Torque wrench capable of
• 17mm Wrench (for Open Loop setting 15 N-m (11 ft-lb) setting 100 N-m (74 ft-lb)
Purge Valve) • Green Loctite 648

• Torque wrench capable of • Torque wrench capable of 100

setting 122 N-m (90 ft-lb) ft-lb (136 N-m)

• Needle-nose pliers
• Blocked Purge Valve
• Rubber Mallet (optional)
• Disabled Shuttle Spool

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

Introduction

This manual will provide you with information and procedures Cleanliness
for general conversions of Eaton® DuraForce™ HMF Fixed
Cleanliness is extremely important when repairing a
Displacement Open and Closed Loop Hydraulic Motors.
hydrostatic pump or motor. Before disconnecting the lines,
Procedures outlined in this manual will allow you to be
clean foreign material from exterior of unit. Work in a clean
more flexible with your inventory and better service your
area. Clean all metal parts in clean solvent. Blow parts dry
customers. To ensure accuracy of conversion and prevent
with air. Don’t wipe parts with cloth or paper towel, because
part loss or damage, certain components or subassemblies
lint or other matter could cause damage. Check all mating
are disassembled, inspected, and reassembled when
surfaces. Replace any parts that have scratches or burrs that
removed from the motor.
could cause leakage. Don’t use coarse grit paper, files or
grinders on parts.
Training
You have been provided information on the conversion of Environmental Concerns
DuraForce products. Proper application of the information Protection of the natural fundamentals of life is one of our
requires specific training and may require use of specialized predominant tasks. We are continuously improving the
tooling and equipment. All requests for training must be protection of the environment as far as applications are
coordinated through your Eaton Account Manager. He can concerned. We encourage you to contribute your share to
also provide you price and availability of any specialized comply with this demand. In connection with work to be
tooling. If you choose to proceed with the conversion of the performed, the environmental regulations of the machine
DuraForce products absent the necessary training and/or manufacturer must be respected.
these specialized tools, you do so at your risk.
In general:
Eaton will accept no claim for warranty resulting from
deficiencies in the conversion. Please refer to the •G
 reases and oils which cannot be used any more have to
Eaton literature web site for warranty information at be collected. They are normally a threat to water reserves
www.eaton.com/hydraulics/warranty. and must be kept away from the environment.
• Adhere to national and local regulations for waste disposal.
Labeling Converted Units
All units that have been converted must retain the original Seals
Eaton label and have a second Eaton label placed on the unit. A good conversion policy is to replace all old seals with new
This second label at a minimum must state seals whenever units are disassembled. This avoids potential
Converted Eaton Model Code # (Final Eaton model code of damage during seal removal. Lubricate seals with petroleum
the converted unit) jelly. Use only clean and recommended oil when assembling
unit. Information on recommended filters and fluids can be
Conversion done by (Name of your company) found in the Operational Parameters section.

Conversion Parts Torque

All requests for specific conversion part information should All torque specifications are for lubricated threads. Bolts for
be addressed to your Eaton account representative. gasketed surfaces should be checked for proper torque.
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.

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

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

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

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

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

1 2 3 Product 14 Purge Relief Valve

HMF – Fixed Displacement l l l l l l l 0 – without purge devices l l l l l l l
Motors – 10 bar standard purge flow
A l l l l l l
4 5 6 Displacement B – 14 bar standard purge flow l l l l l l
028 – 28 cc l – 10 bar reduced purge flow
C • • • • • •
035 – 35 cc l – 14 bar reduced purge flow
D • • • • • •
050 – 50 cc l – 10 bar increased purge flow
E • • • • • •
055 – 55 cc l – flow controlled 6 l/min (*o)
F l l l l l l
075 – 75 cc l – blank plug instead of relief
G • • • • • •
105 – 105 cc l valve (*v)
135 – 135 cc l 15 Purge Shuttle Valve
7Mounting Flange 0 – Without purge devices l l l l l l l
B – SAE B, 2-Bolt l l 1 – Standard shuttle valve l l l l l l
C – SAE C, 2-Bolt l l l l 2 – Damped shuttle valve • • • • • •
D – SAE D, 2-Bolt l 3 – Shuttle valve blocked • • • • • •
8Output Shaft 16  peed Sensor in Motor Housing
S
C – splined ANSI B92.1 16/32 l l 0 – Without l l l l l l l
- 15 teeth (SAE J744 B-B) A – 7 impulses l l
D – splined ANSI B92.1 12/24 l l l • B – 9 impulses l
- 14 teeth (SAE J744 C)
17 18
Special Requirements
J – splined ANSI B92.1 8/16 - l
00 – Without (default) l l l l l l l
13 teeth (SAE J744 D&E)
K – splined ANSI B92.1 16/32 l l l 19
Surface Coating
•
- 21 teeth 0 – Anti-rust conservation oil l l l l l l l
L – splined ANSI B92.1 16/32 l (default)
- 23 teeth A – Primer blue l l l l l l l
M – splined ANSI B92.1 16/32 l 20
Unit Identification
- 27 teeth A – DuraForce l l l l l l l
9Porting 21
Type Code Release
M – ISO 6149 metric l l l A – Revision Level l l l l l l l
D – DIN 3852 l l l l l l l
10 Port Orientation
R – radial ports l l l l l l l
L – axial ports l l l
11  ttachments to Service Ports
A
0 – without l l l l l l l
12 13  rossover Relief Valves Integrated
C
00 – - 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
– two-stage 200/380 bar (*d) (*d) DIN porting only (see position 9)
AP l l l l l l l
(*p) (*q) (*m) ISO metric porting only (see position 9)
AQ – single-stage 300 bar (*p) (*q) l l l l l l l (*o) Open loop operation only
(*p) Radial service ports only (see position 10)
• Available Option l Preferred Option (*q) Without purging devices only (see position 14 and 15)
t Separate Specification Required (*v) With blocked purge shuttle valve only (position 15)

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

Blocking the Case Flushing Feature Important
This procedure must
Set Up be performed in a clean
environment using clean
Parts, Tools and Lubricants

EATON Duraforce HMF Conversion Procedures Manual E-MOPI-TM004-E July 2012 5

 Blocking the Case Flushing Feature Important
This procedure applies
Procedure to Disable the Shuttle Valve Assembly 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 M22 Plug with the 12mm Allen wrench. 3 Remove the Washer and Shuttle Spool simultaneously
with the needle-nose pliers being careful not damage
the spool or use a pencil magnet.

2 Remove the spring with the needle-nose pliers 4 Remove the Washer from the Shuttle Spool.
or pencil magnet.

5 Replace the Original Shuttle Spool with the Disabled

Shuttle Spool

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

Blocking the Case Flushing Feature Important
This procedure applies
Procedure to Disable the Shuttle Valve Assembly (continued) 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.

6 Reinstall the Washer onto the Disabled Shuttle Spool. 8 Reinstall the spring.

7 Reinstall the Washer/Disabled Shuttle Spool 9 Reinstall the M22 Plug. Torque the M22 Plug to
subassembly back into the Shuttle Body. 122 N-m (90 ft-lb).

EATON Duraforce HMF Conversion Procedures Manual E-MOPI-TM004-E July 2012 7

 Blocking the Case Flushing Feature Important
This procedure applies to
Procedure to Disable the Purge Valve HMF Motors with Standard,
Optimized or Dampened
Shuttle Valve Assemblies.

1 Remove the purge valve. 3 Install the blocked purge valve back into the motor and
torque it to 15 N-m (11 ft-lb)

Blocked Purge Valve

2 Replace the existing purge valve with the blocked

purge valve

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

Exchanging Purge Valves
Set Up and Procedure

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

1 Remove the Closed Loop Purge Valve 
1 Remove the Open Loop Purge Valve
with the 13mm wrench. with the 17mm wrench.

Install the Open Loop Purge Valve and tighten it with Install the Closed Loop Purge Valve and tighten it with
2 2
the 17mm wrench. Torque it to 15 N-m (11 ft-lb). the 13mm wrench. Torque it to 15 N-m (11 ft-lb).

EATON Duraforce HMF Conversion Procedures Manual E-MOPI-TM004-E July 2012 9

 Exchanging Shuttle Valve Assemblies Important
Although these locations
Set Up 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.

HMF75 HMR75 HMV75

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

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

Exchanging Shuttle Valve Assemblies Note
An HMV motor is used to
Disassembly Procedure show the necessary steps
throughout this document.
The same process can be
used for HMF motors.

1 Remove the plug from the shuttle valve assembly as 3 In order to break loose the Loctite used to keep the
shown here. shuttle body in place, heat the area directly above the
shuttle assembly as shown here.

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

2 Remove the first set of shuttle spool, spring and shim

combination.

5 Remove the remaining shuttle spool, spring and shim

combination.

Important New Tool 600.880.0001

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.

EATON Duraforce HMF Conversion Procedures Manual E-MOPI-TM004-E July 2012 11

 Exchanging Shuttle Valve Assemblies Note
An HMV motor is used to
Assembly Procedure show the necessary steps
throughout this document.
The same process can be
used for HMF motors.

1 Apply Green Loctite 648 on the threads inside the 5 Install the plug and torque it (refer to the torque chart at
rear head where the shuttle body will be installed. the bottom of this page).

2 Assemble the first set of shuttle spool/shim/spring

into the shuttle body as shown during the training.
3 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)

4 Insert the second set of shuttle spool/shim/spring into

the shuttle body.

Torque Chart
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)

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

Exchanging Cross-Over Relief Valves
Set Up and Procedure

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


1 Remove the Dual-Setting Relief Valves with the 36mm

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

2 Make sure that the O-Ring was removed with each

2 Make sure that the O-Ring was removed with each relief valve.
relief valve.
Inspect the Single-Setting Relief Valves to insure that
3
Inspect the Dual-Setting Relief Valves to insure that the O-Ring is in place and is not damaged.
3
the O-Ring is in place and is not damaged.
Install the Single-Setting Relief Valves and tighten
4
Install the Dual-Setting Relief Valves and tighten them them with the 24mm wrench. Torque each relief valve
4
with the 36mm wrench. Torque each relief valve to 80 to 100 N-m (74 ft-lb).
N-m (59 ft-lb).

EATON Duraforce HMF Conversion Procedures Manual E-MOPI-TM004-E July 2012 13

 Operational Parameters Eaton high pressure units are designed for excellent
reliability and long service life. The actual service life of a
Lifetime Recommendations 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 Adverse Factors Affecting Service Life
Speed Lower continuous maximum speed Speed Between continuous maximum speed and intermittent
Operating Pressure Less than 300 bar Δp on average maximum speed
Maximum Pressure Only at reduced displacement Operating Pressure More than 300 bar Δp on average
Viscosity 15 ... 30 cSt Viscosity Less than 10 cSt
Power Continuous power or lower Power Continuous operation close to maximum power
Purity of Fluid 18/16/13 in accordance with ISO 4406 or better Purity of Fluid Lower than 18/ 16/ 13 in accordance with ISO 4406

Operational parameters.
Filtration
In order to guarantee cleanliness level of the Eaton Hydraulic Fluid level can extend the
long-term proper function lubricant must comply Recommendation 03-401- service life of the hydraulic
and high efficiency of with the following 2010. Maintaining the system significantly.
the hydraulic pumps the criteria according to recommended cleanliness

For reliable proper function and long service life Filling and operation of hydraulic systems
18/16/13 in accordance with ISO 4406 or better 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
Commissioning has to be filtered. We recommend the implementation
The minimum cleanliness level requirement for the of suitable filters to ensure that the required cleanliness
hydraulic oil is based on the most sensitive component. level of the oil is achieved and maintained during
For commissioning we recommend a filtration in order to operation.
achieve the required cleanliness level.
International standard
Code number according to ISO 4406
18/16/13

Filtration
For Reliable Proper Function and Long Service Life 18/16/13 in accordance with ISO 4406 or better
Minimum Requirements 20/18/15 in accordance with ISO 4406
Commissioning 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

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

Operational Parameters In order to ensure the functional performance and high
efficiency of the hydraulic motors the viscosity and
Pressure Fluids 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.

Permitted Pressure Fluids • Mineral oil HLP to DIN Eaton offers an oil testing
51 524-2 service in accordance with
VDMA 24 570 and the test
• Biodegradable fluids in apparatus required for in-house
accordance with ISO 15 testing. Prices available on
380 on request request.

• Other pressure fluids on

request

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

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

In order to be able to select the working temperature leakage fluid temperature

the right hydraulic fluid range (see tables). is always higher than the
it is necessary to know The temperature should circuit temperature. Please
the working temperature not exceed 90°C (194°F) contact Eaton if the stated
in the hydraulic circuit. in any part of the system. conditions cannot be met
The hydraulic fluid should Due to pressure and in special circumstances.
be selected such that its speed influences the
optimum viscosity is within

Viscosity Working Temperature Viscosity Class

Recommendations Temperature [mm²/s] = [cSt] at 40°C (104°F)
Approx. 30 to 40°C (86 to 104°F) 22
Approx. 40 to 60°C (104 to 140°F) 32
Approx. 60 to 80°C (140 to 176°F) 46 or 68
Further information regarding installation can be found in the operating instructions.

EATON Duraforce HMF Conversion Procedures Manual E-MOPI-TM004-E July 2012 15

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

Blocking Purge Valves p. 8

Part # Description Qty

6003435526 Plug 1
0009630107 O-ring 1

Purge Valves - Open Loop p. 9

Part # Description Qty

0009630107 O-ring 1
6003451030 Valve Sleeve 1
6003450352 Valve Piston 1
0009210910 Compression Spring 1
9289003013 Shim, 0.5mm as req'd
9289003010 Shim, 0.1mm as req'd
6003435528 Screw Plug 1

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

Part # Description Qty Part # Description Qty

0009630107 O-ring 1 0009630107 O-ring 1
6003451008 Valve Sleeve 1 6003451008 Valve Sleeve 1
9516003252 Ball 1 9516003252 Ball 1
0009211007 Spring 1 0009211007 Spring 1
9289003006 Shim, 0.5mm as req'd 9289003006 Shim, 0.5mm as req'd
9289003003 Shim, 0.1mm as req'd 9289003003 Shim, 0.1mm as req'd
6003435512 Screw Plug 1 6003435512 Screw Plug 1
6003454000 Orifice 1

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

Part # Description Qty Part # Description Qty

0009630107 O-ring 1 0009630107 O-ring 1
6003451008 Valve Sleeve 1 6003451008 Valve Sleeve 1
9516003252 Ball 1 9516003252 Ball 1
0009211009 Spring 1 0009211009 Spring 1
9289003006 Shim, 0.5mm as req'd 9289003006 Shim, 0.5mm as req'd
9289003003 Shim, 0.1mm as req'd 9289003003 Shim, 0.1mm as req'd
6003435512 Screw Plug 1 6003435512 Screw Plug 1
6003454000 Orifice 1

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

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

Shuttle Valves p. 10

Part # Description Qty

Standard
6003405642 Standard Shuttle 1
Dampened
6003405620 Dampened Shuttle 1
Optimized
6003405651 Optimized Shuttle 1

Cross-Over Relief Valves - Single Setting p. 13 Cross-Over Relief Valves - Dual Setting p. 13

Part # Description Qty Part # Description Qty

250 bar 90/280 bar
6013405915 Relief Valve, 250 bar 2 6013405927 Relief Valve, 90/280 bar 2
270 bar 110/230 bar
6013405905 Relief Valve, 270 bar 2 6013405931 Relief Valve, 110/230 bar 2
350 bar 110/310 bar
6013405919 Relief Valve, 350 bar 2 6013405929 Relief Valve, 110/310 bar 2
180/280 bar
6013405969 Relief Valve, 180/280 bar 2

EATON Duraforce HMF Conversion Procedures Manual E-MOPI-TM004-E July 2012 17

 Notes

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

Notes

EATON Duraforce HMF Conversion Procedures Manual E-MOPI-TM004-E July 2012 19

Eaton Eaton Eaton
Hydraulics Group USA Hydraulics Group Europe Hydraulics Group Asia Pacific
14615 Lone Oak Road Route de la Longeraie 7 Eaton Building
Eden Prairie, MN 55344 1110 Morges No.7 Lane 280 Linhong Road
USA Switzerland Changning District, Shanghai
Tel: 952-937-9800 Tel: +41 (0) 21 811 4600 200335 China
Fax: 952-294-7722 Fax: +41 (0) 21 811 4601 Tel: (+86 21) 5200 0099
www.eaton.com/hydraulics Fax: (+86 21) 2230 7240

© 2012 Eaton Corporation

All Rights Reserved
Printed in USA
Document No. E-MOPI-TM004-E
July 2012