OMV series 2

Orbital Motors
Service and Parts
Manual

OMV Orbital motor

Service and parts manual
Table of contens, Special versions
CONTENTS

Special versions............................................................................................................................................... 2
Exploded view OMV series 2 ..................................................................................................................... 3
Spare parts list................................................................................................................................................. 4
Special tools ..................................................................................................................................................... 7
Dismantling...................................................................................................................................................... 8
Dismantling of tacho connection............................................................................................................. 9
Assembling.....................................................................................................................................................10
Assembling of tacho connection ...........................................................................................................11

SPECIAL VERSIONS

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.

COST-FREE REPAIRS

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.

COMMENTS

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.

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

2003 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 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.
Frontpage: F300215.TIF,
Drawing 151-2034.fa

DKMH.PS.150.A1.02 520L0594 Rev. B 08/2003

OMV Orbital motor

Service and parts manual
Exploded view OMV series 2
EXPLODED VIEW OMV
SERIES 2

Tightening torque: t
Item
Item
Item
Item
Item

1
10:
42:
43:
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]

DKMH.PS.150.A1.02 520L0594 Rev. B 08/2003

OMV Orbital motor

Service and parts manual
Spare parts list
Stock per 100 motors**
Number per motor

SPARE PARTS LIST

Item

Spare parts

Code No.
Screw

Dust seal ring

Front cover

Shaft seal

O-ring

Parallel key

Cylindrical shaft
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
Conical seal ring
Bearing housing
Metric:
SAE: standard mounting:
SAE:
SAE C mounting
1/4 BSP.F steel
Drain plug
Metric:
9
SAE: /16 - 18 UNF, incl O-ring
Washer, metric version only 17.5 13.5 1.5 mm [0.69 0.53 0.06 in]
Cardan shaft
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]
Castellated nut
Metric: M 42 3 mm [1.65 0.12 in]
SAE:
11/2 - 18 UNEF
Washer, metric version only
43 78 7 mm [1.69 3.07 0.28 in]
Parallel key
Metric: 16 10 32 mm [0.63 0.39 1.26 in]
9/16 9/16 2 in
SAE:
Tapered shaft
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
Bearing housing
Metric:
OMVW
SAE:
OMVW
Mounting flange
Metric:
OMVS
SAE:
OMVS
O-ring OMVS
140 3 mm [5.51 0.12 in] NBR
Splined shaft
Metric: 54 mm [2.13 in]OMV/OMVW incl. bearings
SAE: 21/8 in OMV/OMVW incl. bearings
standard mounting
SAE C mounting
O-ring
112 3 mm [3.77 0.12 in] NBR

8
9

10
11
14

16
17
18
19

20
21
22
23

24

M8; l = 20 mm [ 0.79 in] standard mounting

M6; l = 20 mm [ 0.79 in] SAE C mounting
60 67 4 mm [2.36 2.64 0.16 in]
standard mounting
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

DKMH.PS.150.A1.02 520L0594 Rev. B 08/2003

681X0288
681X1521
633B3205
151B1684
151B1773
633B3203
633B3204
633B1380
633B0121
682L8015
682L8047
682L9044

6 25
8 25
1 *
1 3
1 3
1 *
1 *
1 *
1 *
1 5
1 5
1 5

151B0102

151B0165
151B0147
633B9021
151B1678
151B1700
151B1771
151-1524
631X2044
684X2120

1
1
1
1
1
1
1
1
1

2
2
*
2
2
2
5
5
5

151B1406
151B1407
151B1408
151B1686
151B1692
681X8208
681X8291
684X1089
682L8020
682L8048

1
1
1
1
1
1
1
1
1
1

3
3
3
3
3
5
5
5
5
5

151B0109

151B0160
151B1680
151B1701
151B1682
151B1701
633B1485
151B0111
151B0169
151B0148
633B1380

1
1
1
1
1
1
1
1
1
2

2
2
2
2
2
*
2
2
2
*

OMV Orbital motor

Service and parts manual
Spare parts list

SPARE PARTS LIST

Item

Spare parts

Stock per 100 motors**

Number per motor
Code No.

25

26
27
28
29
30
31
32
33

34

35
36
37
38
39
40
41
42
43

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

Gearwheel set
OMV/OMVW/OMVS 315
W = 25 mm [0.10 in]
OMV/OMVW/OMVS 400
W = 32 mm [1.56 in]
OMV/OMVW/OMVS 500
W = 40 mm [1.57 in]
OMV/OMVW/OMVS 630
W = 51 mm [2.01 in]
OMV/OMVW/OMVS 800
W = 65 mm [2.56 in]
Guide pin
4, l = 10 mm [0.39 in]
Valve drive
Channel plate
Stop ring for OMVS 630 and 800
Disc valve
Balance plate
a)
Guide pin
5, l = 14 mm [0.55 in] a)
O-ring
70 2 mm, NBR [2.76 0.08 in]
70 2 mm, FPM [2.76 0.08 in]
O-ring
45 2 mm, NBR [1.77 0.08 in]
45 2 mm, FPM [1.77 0.08 in]
Spacer
Spring washer
37 45 0.5 mm [1.46 1.77 0.02 in] a)
Seal plug (plastic)
Metric
SAE
Valve housing
Metric a)
SAE a)
Ball
1/4 in
Spring
Washer
13.9 10.2 1 mm [0.54 0.40 0.04 in]
1/8 BSP.F
Plug
Screw M16
OMV/OMVW/OMVS 315
l = 150 mm [5.91 in]
OMV/OMVW/OMVS 400
l = 150 mm [5.91 in]
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 (aluminium)
OMV/OMVW/OMVS
Name plate (brass)
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

DKMH.PS.150.A1.02 520L0594 Rev. B 08/2003

151B1100
151B1101
151B1102
151B1103
151B1104
682L2006
151B1389
151B1050
151B1672
151B1049
151B1485
682L9105

1
1
1
1
1
1
1
1
1
1
1
1

5
5
5
5
5
5
5
5
5
5
5
5

633B1379
633B1456

1
1

*
*

633B1429
633B1455
151B1391
684X0086
633X0069
633X0064
151B1705
151B1706
689X1015
013-0662
684X2564
631X2053

1
1
1
1
2
2
1
1
2
2
2
2

*
*
2
10
25
25
2
2
5
5
5
5

681X1883
681X1883
681X1884
681X1884
681X1006

4
4
4
4
4

12
12
12
12
12

151A0407
151A0408
151B0139
151B1031
151B1032
151B1450
151B1704
633B1378
151B1452
684X2012
681X1880
151B1453
682L4922

1
1
1
1
1
1
1
1
1
4
4
1
2

15
15
2
3
2
2
1
10
1
16
16
1
10

OMV Orbital motor

Service and parts manual
Spare parts list
SPARE PARTS LIST
Item

Spare parts

Stock per 100 motors**

Number per motor
Code No.

57
58
59
60
A
B
C
D

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

981X1020
633B3175
682L4008
151A0409
151B0125
151B0129
151B0127
151B1041

NBR: (Buna N, Perbunan), FPM (Viton)

*
**

Contained in spare parts bag A, B, C or D

The number of spare parts to be held in stock for each 100 motors being in service in your district.

DKMH.PS.150.A1.02 520L0594 Rev. B 08/2003

1
1
1
1
1
1
1
1

2
5
2
15
10
10
10
10

OMV Orbital motor

Service and parts manual
Special tools
SPECIAL TOOLS

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

D, E, F and G cannot be bought from Sauer-Danfoss

DKMH.PS.150.A1.02 520L0594 Rev. B 08/2003

OMV Orbital motor

Service and parts manual
Dismantling
DISMANTLING

Item
6 or 18
8*
10, 11
37
42
41
40
39
43
38

Part to remove

Comments

Parallel key
Conical seal ring
Drain plug and washer
Seal plugs (2off )
Plugs (2 off )
Washer (2 off )
Springs (2 off )
Ball (2 off )
Screw (4 off )
Valve housing

On cylindrical or tapered shaft motors

24
28
29
30
35
31

O-ring
Channel plate
Stop ring
Disc valve
Spacer
Balance plate

32
33
34
36
27
26

Guide pin
O-ring
O-ring
Spring washer
Valve drive
Guide pin

25

Gearwheel set

24
14
8
1**)
3 **)
5 **)
2 **)
4 **)
7,19 **)
23

O-ring
Cardan shaft
Conical seal ring
Screw (6 off )
Front cover
O-ring
Dust seal ring
Shaft seal
Shaft incl. bearings

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 af

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!

* OMVS only
**) OMVS except

DKMH.PS.150.A1.02 520L0594 Rev. B 08/2003

OMV Orbital motor

Service and parts manual
Dismantling of tacho connection
DISMANTLING OF TACHO
CONNECTION

Item

Part to remove

54
47
51
49
59

Screw (4 off )
Tacho connection
O-ring
Spacer ring
Retaining ring

58
56
57

Shaft seal
Retaining ring (2 off )
Bearing

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.

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

DKMH.PS.150.A1.02 520L0594 Rev. B 08/2003

OMV Orbital motor

Service and parts manual
Assembling
ASSEMBLING

Item

Part to assemble

Comments

8 **)

Conical seal ring

Fit into recess in bearing housing, placed in the

holding tool.
Use the hydraulic press. (max. 2500 N [550 lbf ])

7, 19 **)
23

Shaft incl. bearings

Always press on the bearing outer ring.

4 **)

Shaft seal

2 **)

Dust seal ring

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

O-ring
Cover
Screw (6 off )

14
24
25

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

Cardan shaft
O-ring
Gearwheel set

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).

**) OMVS except

10

DKMH.PS.150.A1.02 520L0594 Rev. B 08/2003

OMV Orbital motor

Service and parts manual
Assembling
ASSEMBLING

Item
27

Part to assemble

Comments

Valve drive

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

36
33
34
32
31
35

Spring washer (2 off )

O-ring
O-ring
Guide pin
Balance plate
Spacer

38

Valve housing

43

Screw (4 off )

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

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.

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

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
30 - 60 N.m [265.5 - 531 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

*) OMVS only

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].

DKMH.PS.150.A1.02 520L0594 Rev. B 08/2003

11

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Phone: +1 515 239-6000, Fax: +1 515 239 6618
Sauer-Danfoss (Neumnster) GmbH & Co. OHG
Postfach 2460, D-24531 Neumnster
Krokamp 35, D-24539 Neumnster, Germany
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DKMH.PS.150.A1.02 520L0594 Rev. B 08/2003

www.sauer-danfoss.com