Sauer Danfoss DH 100 Assembly And Test Procedures Download Page 3

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11065435 • Rev AD • October 2011

DH and DS Motors
Assembly and Test Procedures

Contents

Introduction

Tools

Motor Identification

Assembly

Testing

Assembly Drawings

Overview ........................................................................................................................................................... 4
General Instructions ...................................................................................................................................... 4
Safety Precautions.......................................................................................................................................... 5

Tools .................................................................................................................................................................... 6

Module Components .................................................................................................................................... 8
Motor Assembly .............................................................................................................................................. 9

Testing Assembled Motor .........................................................................................................................13
Hydraulic Schematic ....................................................................................................................................15

Motor Identification ....................................................................................................................................16

DH Exploded View .......................................................................................................................................17
DS Exploded View ........................................................................................................................................18

Summary of Contents for DH 100

Page 1: ...DH and DS Motors Assembly and Test Procedures ...

Page 2: ...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 Revisions Table of Revisions Date Page Changed Rev October 2011 4 edits to General Instructions AD October 2010 last...

Page 3: ...mbly Drawings Overview 4 General Instructions 4 Safety Precautions 5 Unintended Machine Movement 5 Flammable Cleaning Solvents 5 Fluid Under Pressure 5 Personal Safety 5 Hazardous Material 5 Tools 6 Module Components 8 Motor Assembly 9 Testing Assembled Motor 13 Hydraulic Schematic 15 Motor Identification 16 DH Exploded View 17 DS Exploded View 18 ...

Page 4: ...lubricate all O rings with clean petroleum jelly prior to assembly General Instructions 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 ho...

Page 5: ...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...

Page 6: ... Procedures Tools 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 Holding tool for motors with C flange Fork tool ...

Page 7: ... 3 562 120 65 4 75 4X radius 2 7 0 5 181 7 125 149 23 5 875 4X Ø 11 32 inch THRU 3 8 UNC Tap 2X Ø 7 93 0 312 0 762 0 03 X 60 Lead P107 977E Dimensions mm in Holding tool for motors with A2 flange horseshoe P107 978E Ø 82 55 3 25 120 65 4 75 15 88 0 625 181 7 125 90 45 Radius 1 58 0 062 6 35 0 25 THRU 4X 1 53 x 0 06 0 1 4 inch roll pin 0 76 0 03 X 45 Bevel 2X 44 45 1 75 13 49 0 531 X2 53 19 2 094 5...

Page 8: ...et module Housing module sealed in plastic Gear wheel set module sealed in plastic Housing Module Package Components Quantity Motor Housing 1 Spool Shaft 1 End Cover 1 Drain Plug and Washer 1 Shaft Seal 1 Dust Seal Ring 1 Bearing Set 1 Distributor Plate 1 Temporary bolts do not use for assembly 2 Gear Wheel Set Module Package Components Quantity O rings 3 Gear Wheel Set 1 Bolts plus Belonging Wash...

Page 9: ...th 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 position it in the O ring groove Ensure spool shaft timing is correct ...

Page 10: ...lation 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 Motor Assembly continued Ensure Proper Rotation ...

Page 11: ...est 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 ge...

Page 12: ...tall washers and end cover bolts DH 6 DS 7 Install End Cover 8 Grease an O ring and place it in the O ring groove on the top of the gear set 11 Tighten the bolts using a 13 mm socket Torque to 30 35 N m 22 25 lbf ft 12 If drain plug was removed during assembly or test Torque to 32 44 N m 24 33 lbf in Install Shipping Plugs 13 Tighten the shipping plugs after testing Torque to 2 5 5 0 N m 22 44 lbf...

Page 13: ...nd the system ports facing up the motor must turn to the right clockwise when supplying pressure to the right connection port Rotation With the motor disengaged and no outside load on the output shaft slowly raise the oil supply pressure until the motor starts Then lower 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...

Page 14: ...DH 25 x DH 32 x DH 36 x DH 40 x DH 50 x DH 60 x DH 80 x DH 100 x DH 125 x DH 160 x DH 200 x DH 250 x DH 275 x DH 315 x DH 400 x DH 630 x Testing continued Test Data on DH Motors Maximum starting pressure bar Motor type 7 bar 10 bar DH 50 x DH 80 x DH 100 x DH 125 x DH 160 x DH 200 x DH 250 x DH 275 x DH 315 x DH 390 x Test Data on DS Motors ...

Page 15: ...Schematic Hydraulic Schematic 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 ...

Page 16: ...it 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 1 2 3 4 5 Item Description Example 1 Place and date of manufacture 43A105 2 Type of motor DS or DH 3 Displacement 80 cm 4 Code number 151 3702 5 Series number 1 ...

Page 17: ...17 11065435 Rev AD October 2011 DH and DS Motors Assembly and Test Procedures Assembly Drawings DH Exploded View ...

Page 18: ...18 11065435 Rev AD October 2011 DH and DS Motors Assembly and Test Procedures Assembly Drawings DS Exploded View ...

Page 19: ...19 11065435 Rev AD October 2011 DH and DS Motors Assembly and Test Procedures Notes ...

Page 20: ...pert 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 Products we offer Bent Axis Motors Closed Circuit Axial Piston Pumps and Motors Displays Electrohydraulic ...

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