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OMV Series 2 Orbital Motors Repair Instructions

OMV Orbital Motor Repair Instruction Table of contens, Special versions


Contents
Table of contens, Special versions ................................................................................................................................2 Exploded view OMV series 2 ..........................................................................................................................................2 Spare parts list .....................................................................................................................................................................3 Special tools .........................................................................................................................................................................7 Dismantling ..........................................................................................................................................................................8 Dismantling of tacho connection.................................................................................................................................9 Assembling ........................................................................................................................................................................ 10 Assembling/assembling of tacho connection ...................................................................................................... 11

Special Versions Cost-free Repairs

The list of spare parts cannot be used when ordering parts for special OMV 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. a) After week 27.97 the tightening pin has a new location. When repairing motors manufacturing before week 27.97 it will therefore be necessary to replace end cover, balance plate, tightening pin and spring washer. b) After week 22.07 the thickness of the front cover is increased with 5 mm therefore the screws is changet from 681X0288 (l = 20 mm) to 681X0287 (l = 25 mm). When repairing motors manufacturing before week 22.07 where it is necessary to change the front cover it is also necessary to change the screws in the front cover.

Comments

Series Marking

The series number is altering when parts in the motor are changed. The OMV series marking follows its date marking: XXX-2

OMV Series 2

2007 Sauer-Danfoss. All rights reserved. Printed in Europe 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 arent in conict 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. Frontpage: F300215.TIF,
Drawing 151-2034.fa

520L0594 Rev CB Dec 2008

OMV Orbital Motor Repair Instruction Exploded View OMV Series 2


Exploded View OMV Series 2

Tightening torque: t Item 1 Item 10: Item 42: Item 43: Item 54: 30 - 40 N.m [ 270 - 354 lbf.in] 30 - 60 N.m [270 - 530 lbf.in] 10 - 15 N.m [90 - 130 lbf.in] 190 - 210 N.m [1680 - 1860 lbf.in] 4 - 6 N.m [35 - 53 lbf.in]

520L0594 Rev CB Dec 2008

OMV Orbital Motor Repair Instruction Spare Parts List


Spare Parts List
Number per motor Code No 681X0288 6 681X0287 6 681X1521 8 633B3205 1 11029816 1 151B1773 1 633B3203 1 633B3204 1 633B1380 1 633B0121 1 682L8015 1 682L8047 1 682L9044 1 151B0102 151B0165 151B0147 633B9021 151B1678 151B1700 151B1771 151-1524 631X2044 684X2120 151B1406 151B1407 151B1408 151B1686 151B1692 681X8208 681X8291 684X1089 682L8020 682L8048 151B0109 151B0160 151B1680 151B1701 151B1682 151B1702 633B1485 151B0111 151B0169 151B0148 633B1380 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2

Item 1 2 3 4 5 6

Spare parts Screw Dust seal ring Front cover Shaft seal O-ring Parallel key M8; l = 20 mm [ 0.79 in] standard mounting b) M8; l = 25 mm [1.0 in] b) M6; l = 20 mm [ 0.79 in] SAE C mounting 60 67 4 mm [2.36 2.64 0.16 in] standard mounting b) SAE C mounting 80 60 7 mm [3.15 2.36 0.27 in] NBR 80 60 7 mm [3.15 2.36 0.27 in] FPM 112 3 mm [4.41 0.12 in] standard mounting 96 2 mm [3.78 0.08 in] SAE C mounting Metric 14 9 70 mm SAE: 1/2 1/2 21/4 in, standard mounting SAE: 1/2 1/2 2 1/2 in, SAE C mounting Metric: 50 mm OMV/OMVW incl. bearings and parallel key SAE: 21/4 in OMV/OMVW incl. bearings and parallel key Standard mounting SAE C mounting Metric: SAE: standard mounting: SAE: SAE C mounting Metric: 1/4 BSP.F steel SAE: 9/16 - 18 UNF, incl O-ring 17.5 13.5 1.5 mm [0.69 0.53 0.06 in] OMV/OMVW/OMVS 315 l = 115 mm [4.53 in] OMV/OMVW/OMVS 400 l = 122 mm [4.80 in] OMV/OMVW/OMVS 500 l = 130 mm [5.12 in] OMV/OMVW/OMVS 630 l = 141 mm [5.55 in] OMV/OMVW/OMVS 800 l = 155 mm [6.10 in] Metric: M 42 3 mm [1.65 0.12 in] SAE: 11/2 - 18 UNEF 43 78 7 mm [1.69 3.07 0.28 in] Metric: 16 10 32 mm [0.63 0.39 1.26 in] SAE: 9/16 9/16 2 in Metric: 60 mm OMV/OMVW incl. bearings and item 16, 17, 18 SAE: 2 1/4 in OMV/OMVW incl. bearings and item 16, 18 Metric: OMVW SAE: OMVW Metric: OMVS SAE: OMVS 140 3 mm [5.51 0.12 in] NBR Metric: 54 mm [2.13 in]OMV/OMVW incl. bearings SAE: 21/8 in OMV/OMVW incl. bearings standard mounting SAE C mounting 112 3 mm [3.77 0.12 in] NBR

7 8 9 10 11

Cylindrical shaft Conical seal ring Bearing housing Drain plug Washer, metric version only

14

Cardan shaft

16 17 18 19 20 21 22 23 24

Castellated nut Washer, metric version only Parallel key Tapered shaft Bearing housing Mounting flange O-ring OMVS Splined shaft O-ring

520L0594 Rev CB Dec 2008

OMV Orbital Motor Repair Instruction Spare Parts List


Spare Parts List
Number per motor Code No 151B1100 1 151B1101 1 151B1102 1 151B1103 1 151B1104 1 682L2006 1 151B1389 1 151B1050 1 151B1672 1 151B1049 1 151B1485 1 682L9105 1 633B1379 1 633B1456 1 633B1429 1 633B1455 1 151B1391 1 684X0086 1 633X0069 2 633X0064 2 151B1705 1 151B1706 1 689X1015 2 013-0662 2 684X2564 2 631X2053 2 681X1883 4 681X1883 4 681X1884 4 681X1884 4 681X1006 4 1 151B0139 1 151B1031 1 151B1032 1 151B1450 1 151B1704 1 633B1378 1 151B1452 1 684X2012 4 681X1880 4 151B1453 1 682L4922 2

Item

Spare parts OMV/OMVW/OMVS 315 OMV/OMVW/OMVS 400 OMV/OMVW/OMVS 500 OMV/OMVW/OMVS 630 OMV/OMVW/OMVS 800 W = 25 mm [0.10 in] W = 32 mm [1.56 in] W = 40 mm [1.57 in] W = 51 mm [2.01 in] W = 65 mm [2.56 in] 4, l = 10 mm [0.39 in]

25

Gearwheel set

26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42

Guide pin Valve drive Channel plate Stop ring for OMVS 630 and 800 Disc valve Balance plate Guide pin O-ring O-ring Spacer Spring washer Seal plug (plastic) Valve housing Ball Spring Washer Plug

a) 5, l = 14 mm [0.55 in] a) 70 2 mm, NBR [2.76 0.08 in] 70 2 mm, FPM [2.76 0.08 in] 45 2 mm, NBR [1.77 0.08 in] 45 2 mm, FPM [1.77 0.08 in] 37 45 0.5 mm [1.46 1.77 0.02 in] a) Metric SAE Metric a) SAE a) 1/4 in

43

44 46 47 48 49 50 51 52 53 54 55 56

13.9 10.2 1 mm [0.54 0.40 0.04 in] 1/8 BSP.F OMV/OMVW/OMVS 315 l = 150 mm [5.91 in] OMV/OMVW/OMVS 400 l = 150 mm [5.91 in] Screw M16 OMV/OMVW/OMVS 500 l = 160 mm [6.30 in] OMV/OMVW/OMVS 630 l = 160 mm [6.30 in] OMV/OMVW/OMVS 800 l = 180 mm [7.09 in] Name plate OMV/OMVW/OMVS Valve housing with tacho connection and valve drive, metric version only Tacho connection Valve drive incl. guide pin Spacer ring Tacho valve housing O-ring 40 2 mm [1.57 0.08 in] NBR Tacho bearing housing Washer 8.5 5.6 1 mm [0.33 0.22 0.04 in] Screw M5 l = 15 mm [0.59 in] Tacho drive shaft Retaining ring 6.0 0.7 [0.24 0.03 in] DIN 6799

520L0594 Rev CB Dec 2008

OMV Orbital Motor Repair Instruction Spare Parts List


Spare Parts List
Number per motor Code No 981X1020 1 633B3175 1 682L4008 1 151A0409 1 151B0125 1 151B0129 1 151B0127 1 151B1041

Item 57 58 59 60 A B C D

Spare parts Bearing 8 22 7 mm [0.31 0.87 0.27 in] Shaft seal 8 22 6.5 mm [0.31 0.87 0.25 in] Retaining ring 22 1 DIN 472 Name plate (aluminium) for OMV/OMVW/OMVS with tacho connection Set of seals NBR OMV, OMVW, OMVS item 8, 22, 24, 33 and 34 Set of seals NBR OMV, OMVW, item 2, 4, 5, 8, 24, 33 and 34 Set of seals FPM OMV, OMVW, OMVS item 4, 33 and 34 Set of seals NBR OMVS item 8 and 22

NBR: (Buna N, Perbunan), FPM (Viton) * Contained in spare parts bag A, B, C or D

520L0594 Rev CB Dec 2008

OMV Orbital Motor Repair Instruction Special Tools


Special Tools A B C

G
A: B: C: D: E: F: G: Main holding tool. Code number: SJ 151-9000-1 Holding tool for OMV and OMVW. Code number: SJ 151B9000-2 Holding tool for OMVS. Code number: SJ 151-8000-1 Mandrel for output shaft removal Mandrel and backstop for fitting shaft seal Two guide bolts Mandrel to remove balance plate

520L0594 Rev CB Dec 2008

OMV Orbital Motor Repair Instruction Dismantling


Dismantling
Item 6 or 18 8* 10, 11 37 42 41 40 39 43 38 24 28 29 30 35 31 Part to remove Parallel key Conical seal ring Drain plug and washer Seal plugs (2 off ) Plugs (2 off ) Washer (2 off ) Springs (2 off ) Ball (2 off ) Screw (4 off ) Valve housing O-ring Channel plate Stop ring Disc valve Spacer Balance plate 32 33 34 36 27 26 25 24 14 8 1**) 3 **) 5 **) 2 **) 4 **) 7, 19 **) 23 Guide pin O-ring O-ring Spring washer Valve drive Guide pin Gearwheel set O-ring Cardan shaft Conical seal ring Screw (6 off ) Front cover O-ring Dust seal ring Shaft seal Comments On cylindrical or tapered shaft motors

Place the motor in holding tool Use I 5 mm Allan head spanner Tilt motor, springs and balls come out Use 22 mm socket spanner Lift off carefully as a unit, holding your fingers under the channel plate (Item no. 28)

Only on OMVS 630 and 800

Fill in oil into the spacer hole and use the 18.4 mm [0.72 in] mandrel as a piston to press up the balance plate.

Series 2 only Hold fingers under the gearwheel set to prevent the parts from dropping out

Not on OMVS, is already removed Unscrew with 13 mm socket spanner

Item no. 2 and 4 to be knocked out by means of the special mandrel (E on page 8) Press out the shaft/bearing assembly using a hydraulic press (pressing force max. 2500 N) using the special mandrel (D on page 8) Shaft/bearing assembly should not be dismantled!

Shaft incl. bearings

* OMVS only **) OMVS except

520L0594 Rev CB Dec 2008

OMV Orbital Motor Repair Instruction Dismantling of Tacho Connection


Dismantling of Tacho Connection
Item 54 47 51 49 59 Part to remove Screw (4 off ) Tacho connection O-ring Spacer ring Retaining ring Comments Remove from tacho valve housing

Loosen tacho shaft package (by tapping lightly at the end of the shaft) and extract the package from tacho housing

58 56 57

Shaft seal Retaining ring (2 off ) Bearing

After dismantling, clean all parts in low aromatic kerosene. Examine the parts and exchange them if necessary. Immidiately before assembly, lubricate each part with hydraulic oil and grease rubber parts with vaseline

520L0594 Rev CB Dec 2008

OMV Orbital Motor Repair Instruction Assembling


Assembling
Item 8 **) 7, 19 **) 23 Part to remove Conical seal ring Shaft incl. bearings Comments Fit into recess in bearing housing, placed in the holding tool Use the hydraulic press (max 2500 N [550 lbf ]) Always press on the bearing outer ring. Shaft/ bearing assembly should not be dismantled. 4 **) Shaft seal Knock into position in the front cover, using the assembly mandrel. Grease lip with vaseline. Use assembly mandrel, plastic hammer and support (to prevent the shaft seal from being knocked out). Grease lip with vaseline Grease with vaseline Use a 13 mm socket spanner. Tighten to 30 - 40 N.m [265.5 - 354 lbf.in] Turn the motor upside down. Fill up splines area in the shaft with oil. Mount 2 off guide bolts Grease lip with vaseline Hold fingers under the gearwheel set to prevent parts falling out. Hole 6 mm [0.24 in] to be aligned with hole in the bearing housing. Mark the wheel of the gearwheel set at the point where the tip of a spline tooth is opposite the bottom of a tooth in the external rotor teeth (see drawing)

2 **)

Dust seal ring

5 **) 3 **) 1 **)

O-ring Cover Screw (6 off )

14 24 25

Cardan shaft O-ring Gearwheel set

**) OMVS except

10

520L0594 Rev CB Dec 2008

OMV Orbital Motor Repair Instruction Assembling/assembling of tacho connection


Assembling
Item 27 Part to remove Valve drive Comments Mark the bottom of a spline tooth on the valve drive. Line up mark on rotor and valve drive Applies to motors with tacho connection: Pin on valve drive must point upwards 24 26 28 30 O-ring Guide pin Channel plate Disc valve Grease with vaseline

36 33 34 32 31 35 38

Spring washer (2 off ) O-ring O-ring Guide pin Balance plate Spacer Valve housing

Align mark on valve drive with a hole in the outer rim. (A on drawing). Turn disc valve counter clockwise until splines in the two parts engage Place into valve housing Greased with vaseline Greased with vaseline

43 39 40 41 42 6 or 18 10, 11 8 *) 37 *) OMVS only

Screw (4 off ) Ball (2 off ) Spring (2 off ) Washer (2 off ) Plug (2 off ) Parallel key Drain plug and washer Conical seal ring Seal plug (2 off )

Grease with vaseline to prevent the spacer from dropping out Mount unit on the rest of the motor. Ports should face in the same direction as the drain port Lubricate threads and cross tighten screws to 190 - 210 N.m [1680 - 1860 lbf.in]

Tighten to 10 - 15 N.m [90 - 130 lbf.in] Fill motor with oil before plugging. Tighten to 30 - 60 N.m [265.5 - 531 lbf.in] Grease with vaseline to keep in place

Assembling of Tacho Connection

The tacho connection must be reassembled in reverse order in relation to the procedure described under disassembling the tacho connection. 4 screws (pos. 53) to be tightened to 4 - 6 N.m [35.5 - 53 lbf.in].

520L0594 Rev CB Dec 2008

11

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Local address:

Sauer-Danfoss (US) Company 2800 East 13th Street Ames, IA 50010, USA Phone: +1 515 239-6000 Fax: +1 515 239 6618 Sauer-Danfoss GmbH & Co. OHG Postfach 2460, D-24531 Neumnster Krokamp 35, D-24539 Neumnster, Germany Phone: +49 4321 871-0 Fax: +49 4321 871 122

Sauer-Danfoss ApS DK-6430 Nordborg, Denmark Phone: +45 7488 4444 Fax: +45 7488 4400 Sauer-Danfoss-Daikin LTD Sannomiya Grand Bldg. 8F 2-2-21 Isogami-dori, Chuo-ku Kobe, Hyogo 651-0086, Japan Phone: +81 78 231 5001 Fax: +81 78 231 5004

520L0594 Rev CB Dec 2008

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