OMP, OMP C, OMPW, and OMPW N Series 7 and 8. Repair Instructions

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1 , C, W, and W N Series and 8

2 Orbital Motors, C, and W/N Series and 8 Table of Contents Revision View Safety Precautions Date Page Changed Revision 29 Jun, 200 all Changed from Danfoss to Sauer Danfoss lay out AA Apr 200 Japan location AB Sep 200 New back cover AC 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 WWarning Unintended movement of the machine or mechanism may cause injury to the technican or bystanders. To protect against uintended movement, secure the machine or disable / disconnect the mechanism while servicing. Flammable cleaning solvents WWarning 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 WWarning 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 WWarning Protect yourself from injury. Use proper safety equipment, including safety glasses, at all times. Contents Revision view... 2 Safety precautions... 2 Contents... 2 Special versions... 3 Cost-free repairs... 3 Exploded view, metric version series 8 with integrated spigot flange... 4 Exploded view for / C metric version, series with separate spigot flange... Exploded view for W, metric version series... Spare part list... Tightening torque... Tools and dismantling...2 Cleaning...3 Assembly 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 can be made without affecting agreed specifications. All trademarks in this material are properties of their respective owners. Sauer-Danfoss, the Sauer-Danfoss logotype, the Sauer-Danfoss S-icon, PLUS+, What really matters is inside and Know-How in Motion are trademarks of the Sauer-Danfoss Group. Frontpage: F30 23, F30228 Drawing Rev AC Sep 200

3 Orbital Motors, C, and W/N Series and 8 Special Versions and Cost-free Repairs Special Versions Cost-free Repairs The list of spare parts cannot be used when ordering parts for special versions. In this respect, please contact the sales organisation for Sauer-Danfoss. We would point out that cost-free repairs as mentioned in Sauer-Danfoss General Conditions of Sale, are carried out only at Sauer-Danfoss Nordborg or at service shops authorised by Sauer-Danfoss. Series Housing Gearwheel set Output shaft with spool valve Cardan shaft Series 8 Housing Gearwheel set Output shaft with spool valve Cardan shaft 028 Rev AC Sep 200 3

4 Orbital Motors, C, and W/N Series and 8 Metric Version, Series 8 with Integrated Spigot Exploded View, Metric Version Series 8 with Integrated Spigot Rev AC Sep 200

5 Orbital Motors, C, and W/N Series and 8 / C Metric Version, Series with Separate Spigot Exploded View and C, Metric Version Series with Separate Spigot 028 Rev AC Sep 200

6 Orbital Motors, C, and W/N Series and 8 W and W N Metric Version, Series Exploded View for W, Metric Version Series 028 Rev AC Sep 200

7 Orbital Motors, C, and W/N Series and 8 Spare Part List Item Spare Part Dimensions Code no. Screw Dust seal ring ø2 mm, ø, spl. shaft (HPS) ø28. mm tapered shaft ø2 mm shaft ø32 mm shaft Spigot flange ø2 mm, ø, spl. shaft (HPS) ø2 mm, ø, spl. shaft ø2 mm shaft ø2 mm shaft ø2 mm 3 mm tapered shaft ø32 mm shaft, (HPS) ø32 mm shaft Shaft seal ø2 mm, ø, spl. shaft (HPS) ø2 mm, ø, spl. 28. mm tapered shaft ø2 mm, ø, spl. shaft 28. mm tapered shaft ø32 mm shaft, (HPS) ø32 mm shaft O-ring ø2 mm, ø, spl. 28. mm tapered shaft ø2 mm ø32 mm shaft Bearing race ø2 mm, ø, spl. shaft ø2 mm, ø, spl. shaft 28. mm tapered shaft ø32 mm shaft Axial needle bearing ø2 mm, ø, spl. shaft ø2 mm, ø, spl. shaft 28. mm tapered shaft ø32 mm shaft M: L = M: L = M: L = mm mm mm mm mm, HSN mm, NBR mm, FPM mm mm mm, NBR mm, NBR mm, NBR mm mm mm mm 8X989 8X9 8X024 33B B000 33B B03 33B338 33B B033 33B323 33B9 33B333 33B X mm X X398 Series 8* Number per motor Series with separate spigot flange C A4 C W W N NBR: (Buna N, Perbunan) FPM: Viton (ISO 29) HPS: High pressure shaft seal *Series 8 wih integrated spigot flange 028 Rev AC Sep 200

8 Orbital Motors, C, and W/N Series and 8 Spare Part List Item Spare Part Dimensions Code no. Bearing race 9 ø28. mm tapered shaft 32 mm shaft Castellated nut mm tapered shaft Washer for 28. mm tapered shaft Parallel key for ø2 mm shaft for ø2 mm shaft 2 for ø shaft for ø32 mm shaft for ø28. mm tapered shaft 3 Housing + output shaft Cardan shaft mm mm Series 8* Number per motor Series with separate spigot flange C A X009 C M20. 8X mm 84X230 A8 32 mm, DIN88 A8 3 mm ¼ ¼ ¼ in, B.S.4 A0 8 4 mm, DIN88 B 4 mm, DIN88 L = 3.8 mm L = 9.2 mm L = 4.9 mm L = 92.3 mm L =.8 mm L = 94.0 mm L = 94.0 mm L =.8 mm L = 98.0 mm L = 80. mm L = 00. mm L = 83.3 mm L = 00. mm L = 8. mm L = 08. mm L = 9.2 mm L = 3. mm L = 9.4 mm L = 20.0 mm L = 02.9 mm L = 28. mm L =.4 mm L = 39. mm L = 22. mm 82L803 82L900 82L803 82L809 82L O-ring.9.8 mm, NBR 33B Distributor plate -3 NBR: (Buna N, Perbunan) FPM: Viton (ISO 29) HPS: High pressure shaft seal *Series 8 wih integrated spigot flange W W N Rev AC Sep 200

9 Orbital Motors, C, and W/N Series and 8 Spare Part List Item Spare Part Dimensions Code no Gear wheel set End cover Side port without drain Side port motor End port motor Washer Side port motor End port motor Screw Side port motor W = 4. mm W =.2 mm W =. mm W =. mm W = 0.4 mm W = 3.0 mm W =.3 mm W = 20.8 mm W = 2.0 mm W = 32. mm W = 40.9 mm W = 2.0 mm mm mm M8.2 l = 30 mm l = 30 mm l = 3 mm l = 3 mm l = 40 mm l = 40 mm l = 4 mm l = 0 mm l = mm l = 0 mm l = 0 mm l = 80 mm X0 84X0 8X0238 8X0238 8X09 8X09 8X080 8X080 8X08 8X082 8X083 8X084 8X08 8X088 Series 8* Number per motor Series with separate spigot flange C A4 C W W N End port motor M8.2 l = 40 mm l = 4 mm l = 4 mm l = 0 mm l = mm l = 0 mm l = mm l = mm l = 8 mm 8X080 8X08 8X08 8X082 8X083 8X084 8X08 8X08 8X089 NBR: (Buna N, Perbunan) FPM: Viton (ISO 29) HPS: High pressure shaft seal *Series 8 wih integrated spigot flange 028 Rev AC Sep 200 9

10 Orbital Motors, C, and W/N Series and 8 Spare Part List Item Spare Part Dimensions Code no. 22 Name plate Side port motor-aluminium Side port motor-brass End port motor-aluminium A04 A042 A04 Series 8* Number per motor Series with separate spigot flange C A4 C 24 Washer. 3.. mm 84X220 2 Drain plug Check valve incl. item 2 Only for motors with builtin check valves O-ring.0. mm, NBR 33B Plug Side port motor-plastic plug End port motor-steel plug End port motor-plastic plug Spare parts bag for motors with HPS and ø2 mm, ø, spl. shaft (Series 8) 33X004 3X90 33X W W N pcs. Dust seal pcs. shaft seal (series 8) 3 pcs. O-ring 3 pcs. O-ring pcs. Washer pcs. Washer Spare parts bag for motors with standard shaft seal and ø2 mm, ø, spl.shaft 28. mm tapered shaft pcs. Dust seal pcs. Shaft seal (series ) pcs. O-ring pcs. O-ring 3 pcs. O-ring pcs. Washer pcs. Washer Spare parts bag for motors ø32 and 3 mm tapered shaft (Series /) mm NBR mm HSN.9.8 mm NBR mm NBR mm. 3.. mm mm NBR mm NBR mm NBR mm NBR.9.8 mm NBR mm. 3.. mm 33B030 33B03 33B3 33B30 84X0 84X B338 33B9 33B333 33B3 84X0 84X220-9 ** pcs. Dust seal pcs. Shaft seal pcs. O-ring 3 pcs. O-ring pcs. Washer pcs. Washer NBR: (Buna N, Perbunan) FPM: Viton (ISO 29) HPS: High pressure shaft seal *Series 8 wih integrated spigot flange **Excl.dust seal ring 33B mm NBR mm NBR mm NBR.9.8 mm NBR mm. 3.. mm 33B398 33B323 33B28 33B3 84X0 84X Rev AC Sep 200

11 Orbital Motors, C, and W/N Series and 8 Spare Part List Tightening Torque Item Code number Torque N m Torque [lbf in] 8X989-8 [4-0] 8X024-8 [4-0] 8X9-0 [4-88] 0 8X [800-9] [20-3] [33-390] 28 3X [80-200] 028 Rev AC Sep 200

12 Orbital Motors, C, and W/N Series and 8 Special Tools Special Tools SJ F3003 F30094 F Fork. For use when fitting cardan shaft. Code No.: SJ Main holding tool (horse hole): Code No.: SJ SJ P30029 Holding tool for motor with square mounting flange: Code No.: SJ Holding tool for W N. Code No.: SJ Mandrel: Code No.: SJ -044 Mandrel: Code No.: SJ or SJ F9000- Dismantling Item Part to remove Comments 0 Castellated nut Washer 2 Parallel key 28 Seal plugs Put the motor in a holding tool, with the output shaft downward. For end port version use 0 mm hexagon socket spanner. 2, 24 Drain plug, washer (if present) Use a mm spanner socket. 2, 20 Screws, washers Use a 3 mm spanner socket. 9 End cover Remove end cover sideways. 8, Gear wheel set O-rings (2 off) 4 Cardan shaft, Distributor plate O-ring Keep fingers under the gearwheel set to prevent the parts from falling out Rev AC Sep 200

13 Orbital Motors, C, and W/N Series and 8 Dismantling / Cleaning Dismantling (continued) Item Part to remove Comments 3 Output shaft Motors with integrated spigot flange: Place the motor housing on the work bench and press the shaft out of the motor housing. Shaft and bearings should normally not be removed from W N. However, if necessary for inspection and cleaning, remove the shaft from the housing by gently tapping the axle journal with a plastic hammer. The front bearing can thus remain in the housing. After this, turn the motor. Screws ( off) Use Torx-spanner type T30, 9 mm screwdriver or 4 mm hexagon socket spanner. 2 Washer Only W N 4 Spigot flange, O-ring, bearing race Motors with integrated spigot flange: Remove bearing and bearing race from the motor housing. 8 Needle bearing 3 Shaft seal Dust seal Motors with separate spigot flange: Use a 2 mm screwdriver Motors with integrated spigot flange: With mandrel and plastic hammer, carefully knock out the shaft seal. Motors with separate spigot flange: Knock out the shaft seal / dust seal with a plastic hammer. Use mandrel SJ or SJ F Bearing race Only /W N with ø32 mm/28. mm tapered shaft. Use a 2 mm screwdriver. 2 Check valves (2 off) Only with check valves. Pull the check valve out with, for example, a ground (shortened) 3. mm screw tap. Cleaning Cleaning Clean all parts carefully with low aromatic kerosine. Inspection and replacement Check all parts carefully and replace if necessary. Lubrication Before assembly, lubricate all parts with hydraulic oil and grease rubber parts with vaseline. 028 Rev AC Sep 200 3

14 Orbital Motors, C, and W/N Series and 8 Assembly Assembly Item Part to install Comments Place the motor housing in the holding tool with the flange upwards. 2 Check valves (2 off) Only with check valves Grease the check valves (fitted with new O-rings) and fit them in their bores with light blows using plastic hammer. 9 Bearing race Only /W N with ø32 mm / 28. mm tapered shaft. Shaft seal Motors with integrated spigot flange: Lubricate the shaft seal on the outside with hydraulic oil. Fit the shaft seal correctly onto mandrel SJ -044 and carefully press the shaft seal into position in the motor housing. Motors with separate spigot flange: Knock the seal into position in the spigot flange. Check that the seal lies against the cover recess. Use mandrel SJ or SJ F Dust seal ring Place the dust seal ring in the spigot flange and knock it into position with a plastic hammer and appropriate mandrel. SJ or SJ F9000-, Bearing race O-ring Motors with integrated spigot flange: Fit bearing and bearing race onto the shaft and mount together with the shaft. Motors with separate spigot flange: Grease the O-ring with vaseline and fit the bearing race and O-ring into the spigot flange. 8 Needle bearing 4 Spigot flange Turn so that the holes line up. 2 Washer Only W N Screws ( off) Tightening torque Torx screws M: -8 Nm [4-0 lbf in] Slotted screws M: -8 N m [4-0 lbf in] Hexagon socket screws M: -0 N m [4-0 lbf in] Hexagon socket screws M: 2- N m [4-0 lbf in] After this, turn the motor. 3 Output shaft Grease the journals with hydraulic oil. The rear shaft end must be marked before fitted. The mark must be positioned vertically above a commutation slot leading up to the front annular channel. For W N, guide the shaft into the motor housing back with the rear needle bearing fitted on the shaft. Bring the shaft in line with the back of the motor by gently tapping the shaft with a plastic hammer. Check that the shaft rotates easily O-ring Grease the O-ring and put it in the O-ring groove of the housing. Distributor plate Turn the distributor plate so that the holes line up Rev AC Sep 200

15 Orbital Motors, C, and W/N Series and 8 Assembly Assembly Item Part to install Comments 4 Cardan shaft Guide the cardan shaft down into the motor housing. Only 2, 32 and 40 Place the assembly tool under the upper splines of the cardan shaft. In case of different splines lengths turn the cardan shaft to ensure the long splines end is fitted in the output shaft. Transfer marking from output shaft to cardan shaft. 8, Gearwheel set Place the O-rings (greased) in the O-ring grooves of the gearwheel. In gearwheels with non through splines place the gearwheel with the recess in the spline hole facing down towards the housing. Place the gearwheel set on the cardan shaft so that the top of a tooth in the external teeth of the gearwheel is vertically above the mark on the cardan shaft. Turn the gearwheel set counter clockwise until the cardan shaft and the gearwheel start to mesh ( ). Turn the gearwheel rim so that the holes made for the screws line up. 9 End cover Turn the end cover so that the holes line up. 20, 2 Washer, screws Use a 3 mm spanner socket Tightening torque: 30-3 N m [2-30 lbf in]. 24, 2 Washer, drain plug Use a mm spanner socket. Tightening torque: 30-0 N m [20-3 lbf in]. 28 Seal plugs Threaded plug (if present) End port version: Screw plastic plugs into end ports. Screw in the side port plugs using 0 mm hexagon socket spanner. Tightening torque: 0-0 N m [44-20 lbf in]. Side port version: Screw in plastic plugs. 2 Parallel key To be secured with tape or plastic ring Washer 0 Castellated nut 028 Rev AC Sep 200

16 Products we offer: Bent Axis Motors Closed Circuit Axial Piston Pumps and Motors Displays Electrohydraulic Power Steering Electrohydraulics Hydraulic Power Steering Integrated Systems Joysticks and Control Handles Microcontrollers and Software Open Circuit Axial Piston Pumps Orbital Motors PLUS+ GUIDE Proportional Valves Sensors Steering Transit Mixer Drives Sauer-Danfoss is a global manufacturer and supplier of highquality hydraulic and electronic components. We specialize in providing state-of-the-art technology and solutions that excel in the harsh operating conditions of the mobile 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 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: Members of the Sauer-Danfoss Group: Comatrol Schwarzmüller-Inverter Turolla Sauer-Danfoss (US) Company 2800 East 3th Street Ames, IA 000, USA Phone: Fax: Sauer-Danfoss ApS DK-430 Nordborg, Denmark Phone: Fax: Hydro-Gear Sauer-Danfoss-Daikin Rev AC Sep 200 Sauer-Danfoss GmbH & Co. OHG Postfach 240, D-243 Neumünster Krokamp 3, D-2439 Neumünster, Germany Phone: Fax: Sauer-Danfoss-Daikin LTD. Shin-Osaka TERASAKI 3rd Bldg. F --28 Nishimiyahara, Yodogawa-ku Osaka , Japan Phone: Fax:

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