Sauer Danfoss DH Series Reference guide

Local address:
Sauer-Danfoss GmbH & Co. OHG
Postfach 2460, D-24531 Neumünster
Krokamp 35, D-24539 Neumünster, Germany
Phone: [phone]
Fax: [phone]
Sauer-Danfoss ApS
DK-6430 Nordborg, Denmark
Phone: [phone]
Fax: [phone]
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 mobile o-highway market.
Building on our extensive applications expertise, we work closely
with our customers to ensure exceptional performance for a broad
range of o-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 o-highway vehicles are at work, so is Sauer-Danfoss.
We oer 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.
Products we oer:
•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+1™ GUIDE
•Proportional Valves
•Sensors
•Steering
•Transit Mixer Drives
Members of the Sauer-Danfoss Group:
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmueller-inverter.com
Turolla
www.turollaocg.com
Hydro-Gear
www.hydro-gear.com
Sauer-Danfoss-Daikin
www.sauer-danfoss-daikin.com
Sauer-Danfoss (US) Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: [phone]
Fax: [phone]
Sauer-Danfoss-Daikin LTD.
Shin-Osaka TERASAKI 3rd Bldg. 6F
1-5-28 Nishimiyahara, Yodogawa-ku
Osaka 532-0004, Japan
Phone: [phone]
Fax: [phone]
www.sauer-danfoss.com
DH and DS Motors
Assembly and Test
Procedures

211065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test Procedures
© 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 conict with agreed specications. 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 new back page AC
March 2010 last Fix Osaka address AB
April 2009 - First edition AA
History of Revisions

3
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
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 Identication ....................................................................................................................................16
DH Exploded View .......................................................................................................................................17
DS Exploded View ........................................................................................................................................18

411065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test Procedures
Introduction
Overview
Follow these general procedures when assembling DH and DS Motors.
eKeep 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.
dLubricate O-rings
Lightly 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 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 all motors of a given ange type.

5
11065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test Procedures
Introduction
Safety Precautions 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
W 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
W Warning
Some cleaning solvents are ammable. To avoid possible re, do not use cleaning
solvents in an area where a source of ignition may be present.
Fluid Under Pressure
W Warning
Escaping hydraulic uid under pressure can have sufcient force to penetrate your skin
causing serious injury and/or infection. This uid may also be hot enough to cause burns.
Use caution when dealing with hydraulic uid under pressure. Relieve pressure in the
system before removing hoses, ttings, 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 uid.
Personal Safety
W Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.
Hazardous Material
W Warning
Hydraulic uid contains hazardous material. Avoid prolonged contact with
hydraulic uid. Always dispose of used hydraulic uid according to state, and federal
environmental regulations.

611065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test 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

7
11065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test Procedures
Tools
Tools (continued)
Ø 12.7 [0.5] ± 0.254 [0.01]
1.58 [0.062] X 45°
15.88 [0.625]
0.76 [0.03] X 45°
15.88 [0.625]
7.93
[0.312]
- 0.127 [0.005]
+0
15.88
[0.625]
152.4
[6]
80.99
[3.188]
65.05
[2.562]
53.19
[2.094]
53.19
[2.094]
74.63
[2.938]
90.49
[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] 53.19
[2.094]
Section A - A
AA
0.76 [0.03] X 45° Bevel (4X)
Holding tool for motors with C flange

811065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test Procedures
Module Components
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
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 Washers (DS) 7
Bolts plus Belonging Washers (DH) 6
Cardan Shaft 1

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11065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test Procedures
Assembly
Motor Assembly Position motor with shaft pointing down. Use A2 ange tool or C ange tool depending
on your housing conguration.
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.

10 11065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test Procedures
Assembly
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.
Motor Assembly
(continued)
Ensure Proper Rotation

11
11065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test Procedures
Assembly
Motor Assembly
(continued)
Install Distributor Plate
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
cardan shaft.
For smaller displacements,retain the
cardan shaft using the fork tool.

12 11065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test Procedures
Assembly
Motor Assembly
(continued)
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).
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•in].

13
11065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test Procedures
Testing
Testing Assembled Motor Hydraulic Fluid Specifications
General Testing Conditions
Fluid type Mineral hydraulic oil class HM, ISO 6743/4
Viscosity range 35 ± 3 cSt
Oil cleanliness 18/13 – contamination degree, ISO 4406
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.
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 at this limit. If so the motor is good.
If the motor begins to turn below the specified pressure, the motor check is OK.
Starting Pressure

14 11065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test Procedures
Testing
Maximum starting pressure (bar)
Motor type 7 bar 10 bar
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

15
11065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test Procedures
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.

16 11065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test Procedures
Motor Identication
Motor Identification Fit a nameplate onto the end cover and stamp or etch the following data in the marked
elds:
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 cm³
4 Code number 151-3702
5 Series number 1

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

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

19
11065435 • Rev AD • October 2011
DH and DS Motors
Assembly and Test Procedures
Notes

11065435 •Rev AD • October 2011
Local address:
Sauer-Danfoss GmbH & Co. OHG
Postfach 2460, D-24531 Neumünster
Krokamp 35, D-24539 Neumünster, Germany
Phone: [phone]
Fax: [phone]
Sauer-Danfoss ApS
DK-6430 Nordborg, Denmark
Phone: [phone]
Fax: [phone]
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 mobile o-highway market.
Building on our extensive applications expertise, we work closely
with our customers to ensure exceptional performance for a broad
range of o-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 o-highway vehicles are at work, so is Sauer-Danfoss.
We oer 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.
Products we oer:
•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+1™ GUIDE
•Proportional Valves
•Sensors
•Steering
•Transit Mixer Drives
Members of the Sauer-Danfoss Group:
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmueller-inverter.com
Turolla
www.turollaocg.com
Hydro-Gear
www.hydro-gear.com
Sauer-Danfoss-Daikin
www.sauer-danfoss-daikin.com
Sauer-Danfoss (US) Company
2800 East 13th Street
Ames, IA 50010, USA
Phone: [phone]
Fax: [phone]
Sauer-Danfoss-Daikin LTD.
Shin-Osaka TERASAKI 3rd Bldg. 6F
1-5-28 Nishimiyahara, Yodogawa-ku
Osaka 532-0004, Japan
Phone: [phone]
Fax: [phone]
www.sauer-danfoss.com