DH/DS Orbital Motors Assembly and Test Procedures
Contents
1. 0 625 120 65 4 75 15 88 0 625 Bp 0 76 0 03 X 45 7 93 0 312 P107 977E i Q 82 55 3 25 a 1 4 inch ps roll pin Y 6 35 0 25 THRU 4X q 23 0 06 53 19 53 19 t2094 moog 0 76 0 03 X 45 Bevel 4X 44 45 13 49 0 531 X2 La 4445 pst 1 75 0 76 0 03 X 45 Bevel 2X 15 88 Radius 1 58 0 062 0 625 Dimensions mm in 11065435 Rev AD October 2011 SAUER DH and DS Motors DANFOSS Assembly and Test Procedures Module Components Genuine Part Module Components The housing module and gear wheel set module ship in separate packages Each module is packaged in a VCI plastic bag Housing module Gear wheel set module Housing module sealed in plastic Gear wheel set module sealed in plastic Housing Module Quantity Package Components Spool Shaft Temporary bolts 2 do not use for assembly Package Components TITO IRE eem 1 8 11065435 Rev AD October 2011 SAUER DH and DS Motors DANFOSS Assembly and Test Procedures AS se m b ly Genuine Parts Motor Assembly Position motor with shaft pointing down Use A2 flange tool or C flange tool depending on your housing configuration 1 Remove and discard the two temporary bolts that fasten the end Cover 2 Remove end cover and distributor plate from the housing 3 Grease an O ring and pos2. all motors of a given flange type Follow these general procedures when assembling DH and DS Motors Keep it clean As with any precision equipment keep all parts free of foreign materials and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material If left unattended cover the motor with a protective layer of plastic Lubricate O rings Lightly lubricate all O rings with clean petroleum jelly prior to assembly 11065435 Rev AD October 2011 SAUER DANFOSS Safety Precautions DH and DS Motors Assembly and Test Procedures S Introduction Genuine Parts 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 A 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 A 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 A 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 bur
3. hirci Procedures Assembly Drawings DH Exploded View 11065435 Rev AD October 2011 na a PP OI Ae J um s A if n i i i j s il A i or j yy oh I if i E im TI fi m ULP T S S d 1 cr F i F 17 SAUER DH and DS Motors DANFOSS Assembly and Test Procedures Assembly Drawings DS Exploded View 18 11065435 Rev AD October 2011 DH and DS Motor EE Pavel bly nee Procedures Notes 11065435 Rev AD October 2011 19 SAUER DANFOSS Products we offer e Bent Axis Motors e Closed Circuit Axial Piston Pumps and Motors e Displays e Electrohydraulic Power Steering e Electrohydraulics e Hydraulic Power Steering e Integrated Systems e Joysticks and Control Handles e Microcontrollers and Software e Open Circuit Axial Piston Pumps e Orbital Motors e PLUS 1 GUIDE e Proportional Valves e Sensors e Steering e Transit Mixer Drives Members of the Sauer Danfoss Group Comatrol www comatrol com Schwarzm ller Inverter www schwarzmueller inverter com Turolla www turollaocg com Hydro Gear www hydro gear com Sauer Danfoss Daikin www sauer danfoss daikin com 11065435 Rev AD October 2011 Sauer Danfoss is a global manufacturer and supplier of high quality hydraulic and electronic components We specialize in providing state of the art technology and solutions that excel in the harsh operating conditions of the mob
4. SAUER DANFOSS Assembly and Test Procedures SAUER DH and DS Motors DANFOSS Assembly and Test Procedures S Revisions Genuine Parts History of Revisions Table of Revisions Date Page changea Rev October 2011 edits to General Instructions October 2010 new back page March 2010 Fix Osaka address 2011 Sauer Danfoss All rights reserved Sauer Danfoss accepts no responsibility for possible errors in catalogs brochures and other printed material Sauer Danfoss reserves the right to alter its products without prior notice This also applies to products already ordered provided that such alterations aren t in conflict with agreed specifications All trademarks in this material are properties of their respective owners Sauer Danfoss and the Sauer Danfoss logotype are trademarks of the Sauer Danfoss Group 2 11065435 Rev AD October 2011 SAUER DANFOSS Introduction Tools Assembly Testing Motor Identification Assembly Drawings DH and DS Motors Assembly and Test Procedures Contents aUi mem E U General Instructions csetssscsessssscscsssssscscssssssssssssssscssesessssssesesess Safety PC CAUTIONS oed area qa item rrt per Pene ven Unintended Machine Movement eerte Flammable Cleaning Solvents esses Fluid Under PEGSSUTG sccsccnssecowessvssnsdassaevesctosctsssusaeiesssvedaiaawsiacieedaiusasiens Per
5. an shaft For smaller displacements retain the cardan shaft using the fork tool 11065435 Rev AD October 2011 11 SAUER DH and DS Motors DANFOSS Assembly and Test Procedures 6 Assembly Genuine Parts Motor Assembly Install End Cover continued 8 Grease an O ring and place it in the O ring groove on the top of the gear set 9 Place the end cover over the gear set Note orientation of end cover for DH models 10 Install washers and end cover bolts DH 6 DS 7 11 Tighten the bolts using a 13 mm socket Torque to 30 35 Nem 22 25 Ibfeft 12 If drain plug was removed during assembly or test Torque to 32 44 Nem 24 33 Ibfein Install Shipping Plugs 13 Tighten the shipping plugs after testing Torque to 2 5 5 0 Nem 22 44 Ibf in 12 11065435 Rev AD October 2011 SAUER DANFOSS Testing Assembled Motor DH and DS Motors Assembly and Test Procedures S Testin g Genuine Parts Hydraulic Fluid Specifications General Testing Conditions Fluid type Mineral hydraulic oil class HM ISO 6743 4 Oil cleanliness 18 13 contamination degree ISO 4406 Rotation With the shaft pointing toward you and the system ports facing up the motor must turn to the right clockwise when supplying pressure to the right connection port Starting Pressure With the motor disengaged and no outside load on the output shaft slowly raise the oil supply pressure until the motor starts Then lo
6. ile off highway market Building on our extensive applications expertise we work closely with our customers to ensure exceptional performance for a broad range of off highway vehicles We help OEMs around the world speed up system development reduce costs and bring vehicles to market faster Sauer Danfoss Your Strongest Partner in Mobile Hydraulics Go to www sauer danfoss com for further product information Wherever off highway vehicles are at work so is Sauer Danfoss We offer expert worldwide support for our customers ensuring the best possible solutions for outstanding performance And with an extensive network of Global Service Partners we also provide comprehensive global service for all of our components Please contact the Sauer Danfoss representative nearest you Local address Sauer Danfoss US Company 2800 East 13th Street Ames IA 50010 USA Phone 1515 239 6000 Fax 1515 239 6618 Sauer Danfoss GmbH amp Co OHG Postfach 2460 D 24531 Neum nster Krokamp 35 D 24539 Neum nster Germany Phone 449 43218710 Fax 49 4321 871 122 Sauer Danfoss ApS DK 6430 Nordborg Denmark Phone 45 7488 4444 Fax H45 7488 4400 Sauer Danfoss Daikin LTD Shin Osaka TERASAKI 3rd Bldg 6F 1 5 28 Nishimiyahara Yodogawa ku Osaka 532 0004 Japan Phone 81 6 6395 6066 Fax 81 6 6395 8585 wwwW Sauer danfoss com
7. ition it in the O ring groove Ensure spool shaft timing is correct 11065435 Rev AD October 2011 9 SAUER DH and DS Motors DANFOSS Assembly and Test Procedures S Assembly Genuine Parts Motor Assembly Ensure Proper Rotation continued You must install the internal gear wheel correctly in relation to the commutation of the spool valve to get proper rotation 4 Install the spool shaft with a lower valve about 5 degrees clockwise from the center of the housing as shown When mounting the gear set step 7 ensure the smallest gap is facing directly away from the system ports of the housing Gap 10 11065435 Rev AD October 2011 SAUER DH and DS Motors DANFOSS Assembly and Test Procedures Assembly Genuine Parts Motor Assembly Install Distributor Plate continued 5 Mount the distributor plate on the housing and place the cardan shaft into the spool shaft On smaller displacements be sure to place the end of the cardan shaft with the longest splines into the spool shaft Install Gear Set 6 Grease an O ring and place it in the O ring groove on the bottom side of the gear set For larger displacement gear sets the bottom side has recessed splines in the gear wheel 7 Place the gear set onto the cardan shaft so that the smallest gap between the gear wheel and the gear rim face opposite the system ports and the internal splines of the gear wheel line up to those on the card
8. ns 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 A Warning Protect yourself from injury Use proper safety equipment including safety glasses at all times Hazardous Material A Warning Hydraulic fluid contains hazardous material Avoid prolonged contact with hydraulic fluid Always dispose of used hydraulic fluid according to state and federal environmental regulations 11065435 Rev AD October 2011 5 SAUER DH and DS Motors DANFOSS Assembly and Test Procedures S Too S Genuine Parts Tools Proper assembly of DH DS motors requires these tools You may use the dimensions and information in the drawings on the next page to fabricate them Holding tool for motors with A2 flange horseshoe D o O E la MS i Me v i e Fork tool 6 11065435 Rev AD October 2011 DH and DS Motor hee bly PA Procedures Tools Genuine Parts Tools continued Holding tool for motors with A2 flange horseshoe 181 7 125 149 23 5 875 4X radius 2 7 0 5 4X 11 32 inch THRU 3 8 UNC Tap 12 7 0 5 0 254 0 01 1 58 0 062 X 45 0 0 762 0 03 X 60 Lead 15 88
9. sonal S die OY seisuse HUR tO err Mone Hazardous Material eese ente ttntnntntntnt tenuis Module CompoHnetits siaccsscsccsstasucdevoseasiavssesessiucsosaewsistaueorsvienswansvossusesedads Motor Assemb IY d O aini Testing Assembled Motor csssssssssssssscscsscsssssscssesscsessssssescsesssessssess Hydraulic SchematiC ss sseessssssessssesssesssesssesssesssessseosseosseosseosseosseosseosses Motor Identification esesssesseseseseseseesesesesesesseseseseseseseseesesesesesesseseseseseseess DH Exploded VieW ssssissisrsisssissssssusssesuisesosseisssissisaissnssesssesrucsaessuisvisuseasisss DS Exploded VIGW dicens oreet ir DE Ero Nu EHE U DICERE RERO HIVE 11065435 Rev AD October 2011 S Genuine Parts SAUER DANFOSS Overview General Instructions DH and DS Motors Assembly and Test Procedures S Introduction dinane Fait This manual includes information on assembly and testing of DH and DS Motors To provide timely motor delivery when a customer places an order you need to have all the necessary modules and equipment on hand DH and DS motor assembly is based on a modular building concept Each motor consists of two modules the housing module and the gear wheel set module When assembled these two modules constitute a complete motor The variation in motor size displacement is determined by the gear wheel set module One housing module is common for
10. wer the differential pressure to the limit shown in the table below 7 or 10 bar 102 or 145 psi Check that the motor is still turning at this limit If so the motor is good If the motor begins to turn below the specified pressure the motor check is OK 11065435 Rev AD October 2011 13 SAUER DH and DS Motors DANFOSS Assembly and Test Procedures S Testi n g Genuine Parts Testing continued Test Data on DH Motors Maximum starting pressure bar 14 11065435 Rev AD October 2011 SAUER DANFOSS Hydraulic Schematic DH and DS Motors Assembly and Test Procedures S Schematic Genuine Parts The following schematic shows the proper connection of the motor to the hydraulic power unit for testing purposes Note the position of the two pressure gauges Position them as close as possible to the ports of the motor for the most accurate reading DH ZDS Hydraulic lest Setup 11065435 Rev AD October 2011 15 SAUER DH and DS Motors DANFOSS Assembly and Test Procedures S Motor Identification Genuine Parts Motor Identification Fit a nameplate onto the end cover and stamp or etch the following data in the marked fields Order nameplates separately They are not included in the motor modules SAUER DANFOSS S 0420 Lem Description rampie Place and date of manufacture 43A105 Type of motor DS or DH 16 11065435 Rev AD October 2011 DH and DS Motor EE A bly
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