Danfoss D–Series Cast Iron Gear Motors User guide
Technical Information
D–Series Cast Iron Gear Motors
Including Fan Drive
www.danfoss.com
Technical Information
D–Series Cast Iron Gear Motors, Including Fan Drive
Revision history Table of revisions
Date Changed Rev
March 2021 Updated product code information for anti-cavitation / shock valve function; updated radial
and axial loading information
May 2020 Updated table in Dimension drawings section: Standard motor 0103
December 2019 Dimensions for standard motor change. 0102
October 2019 First edition 0101
0105
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Technical Information
D–Series Cast Iron Gear Motors, Including Fan Drive
Contents
General information
Overview..............................................................................................................................................................................................5
Features and Benefits................................................................................................................................................................ 5
Fan drive motors......................................................................................................................................................................... 5
Features................................................................................................................................................................................................6
Benefits.................................................................................................................................................................................................6
System schematics...........................................................................................................................................................................7
Product features................................................................................................................................................................................8
Technical specifications................................................................................................................................................................. 9
Fluid specifications.......................................................................................................................................................................... 9
Sizing equations.............................................................................................................................................................................10
Operating Parameters
Overview........................................................................................................................................................................................... 11
Pressure............................................................................................................................................................................................. 11
Peak pressure.............................................................................................................................................................................11
Rated pressure...........................................................................................................................................................................11
System pressure........................................................................................................................................................................11
Back pressure............................................................................................................................................................................. 11
Case drain pressure..................................................................................................................................................................11
Temperature and viscosity......................................................................................................................................................... 12
Temperature...............................................................................................................................................................................12
Viscosity........................................................................................................................................................................................12
Speed............................................................................................................................................................................................ 12
Hydraulic fluid.................................................................................................................................................................................12
Filtration............................................................................................................................................................................................ 13
Filters.............................................................................................................................................................................................13
Selecting a filter.........................................................................................................................................................................13
Reservoir............................................................................................................................................................................................13
Line sizing......................................................................................................................................................................................... 14
Motor life...........................................................................................................................................................................................14
Motor shaft connection............................................................................................................................................................... 14
Radial and axial loading...............................................................................................................................................................15
Product code
Model code.......................................................................................................................................................................................16
Fan drive motor code example.................................................................................................................................................16
A - Sense of rotation................................................................................................................................................................ 16
B1 - Displacement.....................................................................................................................................................................16
B2 - Input shaft...........................................................................................................................................................................16
C - Mounting flange.................................................................................................................................................................17
D1 - Cover....................................................................................................................................................................................17
D2 - Rear cover port option...................................................................................................................................................18
D - Rear cover availability.......................................................................................................................................................18
E - Relief valve availability......................................................................................................................................................19
F - Anti-cavitation/shock valve function.......................................................................................................................... 20
G - Integrated reversing modulating function...............................................................................................................20
J - Name plate............................................................................................................................................................................ 21
K - Name plate............................................................................................................................................................................21
Dimension drawings
Mounting flanges...........................................................................................................................................................................23
Shaft options....................................................................................................................................................................................24
Port options......................................................................................................................................................................................27
Selecting port options..................................................................................................................................................................28
Integrated reversing motor with proportional relief and shock/anti-cavitation valves...................................... 29
Features and benefits..............................................................................................................................................................29
Technical data............................................................................................................................................................................29
Integrated reversing function..............................................................................................................................................30
Options
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Technical Information
D–Series Cast Iron Gear Motors, Including Fan Drive
Contents
Standard relief valve..................................................................................................................................................................... 31
Anti-cavitation check valve........................................................................................................................................................ 32
Proportional relief valve with anti-cavitation valve...........................................................................................................33
Valve settings.............................................................................................................................................................................34
Performance graphs................................................................................................................................................................ 35
Valve settings.............................................................................................................................................................................36
Performance graphs................................................................................................................................................................ 36
Hall effect speed sensor...............................................................................................................................................................37
Dimension drawings
Fan drive motor.............................................................................................................................................................................. 39
Standard motor.............................................................................................................................................................................. 39
Standard motor with split flange ports..................................................................................................................................40
Integrated reversing motor with proportional relief and shock/anti-cavitation valves...................................... 42
Performance data
Motor performance graphs........................................................................................................................................................44
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300
250
200
150
100
50
0
0 5 10 15 20 25 30 35 40 45 50
Displacement
cm3/rev
P
ressure
psi
P107 949E
400
350
SGM3Y Aluminum
Gear Motor
SGM2Y Aluminum
Gear Motor
D SERIES Cast Iron Gear Motor
SERIES 40 Piston Motor
Bar
in3/rev
5000
4000
3000
2000
1000
0
0.5
0
1.0
1.5
2.0 2.5
3.0
Technical Information
D–Series Cast Iron Gear Motors, Including Fan Drive
General information
Overview
The Danfoss D Series fixed displacement gear motor has been specifically designed for demanding
mobile equipment applications where maximum performance is required at peak power levels and
operating temperatures.
The D Series motor is available in displacements of 17.6cm³ to 48,3cm³ [1.08 in3 to 2.95 in3]. This motor
delivers consistent efficiency across the entire operating range of pressure, speed, and temperature; all in
an industry-leading package size that maximizes power density.
Features and Benefits
•
High strength cast iron construction allows consistently efficient performance in continuous
operation at 276 bar (4000 psi) and 110°C (230°F).
•
Custom engineered shaft bearings and dual pressure-balanced thrust plates optimize internal
bearing lubrication, allowing for high starting torque and long life with fluid viscosities as low as 8
mm²/sec (cSt) [52 SUS].
•
Compact three-piece design with bearings located in the front flange and rear cover minimizes the
overall package length and increases radial load carrying capability, eliminating the need for
outrigger bearings on most applications.
•
Variety of integrated valve options make the D Series motor ideally suited for high performance fan
drive applications.
Fan drive motors
D Series cast iron motors complement the Danfoss portfolio of fan drive products. Including aluminum
and cast iron pumps and motors, piston pumps and motors, valves and microcontrollers, you can apply
the Danfoss range in various combinations to create high-performance fan drive systems. D series motors
with integrated reversing and proportional relief valves are PLUS+1® Compliant for easy plug-andperform™ installations and offer precise control of fan speed to optimize engine cooling performance.
Quick reference chart: Fan drive motors
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One piece steel gears
with 12 tooth profile
Flexible configuration
of shaft, flange
and ports
Heavy duty, low friction
hydrodynamic journal bearings
High strength
ductile iron
body and covers
P107 920E
Pressure balanced
bronze-on-steel
thrust plates
High performance
integrated
PLUS+1
High temperature
Viton ® seals
Dust protector
Radial
case drain
compliant
TM
valves
Technical Information
D–Series Cast Iron Gear Motors, Including Fan Drive
General information
Features
Quality components and construction
Benefits
•
Pressure-balanced thrust plates for improved efficiency at extreme pressures and temperatures
•
High-temperature Viton® seals for today’s hotter running machines
•
Three-piece ductile iron construction for increased durability, increased power density, with reduced
adverse efficiency effects at high temperatures
•
High quality steel backed bronze bearings for maximum pressure handling capacity, located in the
front flange, allowing extended radial loading capacity without an external roller bearing
•
Output shaft external dust protector to protect the oil seal from contamination damage
•
Available side or rear ports, SAE A or B flange, with a variety of shafts for versatility
•
Integrated, normally-closed electrohydraulic proportional relief valve option for today’s highperforming fan systems
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PLUS+1
TM
Microcontroller
Filter
T3
T2
T1
Temperature
sensors
D Series
gear pump
D Series
gear motor
RESERVOIR
DIESEL ENGINE
P107 929E
Case drain
CAN bus
T3
T2
T1
Temperature
sensors
RESERVOIR
D Series
gear motor
Microcontroller
(PLUS+1TM)
Filter
DIESEL ENGINE
Series 45
variable pump
P107 931E
Case drain
CAN bus
Technical Information
D–Series Cast Iron Gear Motors, Including Fan Drive
General information
System schematics
Gear pump/gear motor system with electronic control
Piston pump/gear motor system with electronic control
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Technical Information
D–Series Cast Iron Gear Motors, Including Fan Drive
General information
Gear pump/gear motor system with integrated reversing valve
Product features
Features Descriptions
Construction
Displacements
Continuous
Pressure
Peak Pressure
Speed
Mounting
Shaft (types)
Fluid viscosity
Filtration
requirement
Inlet options
Fluids
Operating
temperature
Integrated valve
options
Heavy duty ductile iron 3-piece construction
17.6 to 48.3 cm³ [1.08 to 2.95 in3/rev]
276 bar [4000 psi] to 40.9 cm³ [2.50 in3]
303 bar [4400 psi] to 40.9 cm³ [2.50 in3]
600 to 3400 min-1 (rpm) - up to 40.9 cm³ [2.50 in3]
SAE A two bolt, SAE B two bolt
SAE straight keyed, 1:8 tapered keyed, splined
8 mm²/sec (cSt) [52 SUS] minimum, 1600 mm²/sec (cSt) [7500 SUS] maximum
22/18/13 ISO 4406 at motor inlet
SAE O-ring boss, SAE split flange
Petroleum/mineral based
-40°C [-40°F] minimum for cold start
110°C [230°F] normal operating conditions 115°C [239°F] peak intermittent
Proportional relief valve, normally closed, 12 Vdc and 24 Vdc
Two position directional control valve, 12 Vdc and 24 Vdc
Relief valve
Anti-cavitation check valve
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Technical Information
D–Series Cast Iron Gear Motors, Including Fan Drive
General information
Technical specifications
Technical data for D Motors
Ratings Units 17 19 21 23 25 29 32 36 38 41 45
Displacement cm3/rev 17.6 19.9 22.4 23.2 26.2 30.6 34.4 38.6 40.9 42.9 48.3
in3/rev 1.08 1.22 1.37 1.42 1.6 1.87 2.1 2.36 2.5 2.62 2.95
Rated pressure bar 276 276 276 276 276 276 276 276 276 241 210
psi 4000 4000 4000 4000 4000 4000 4000 4000 4000 3495 3045
Peak pressure bar 303 303 303 303 303 303 303 303 303 265 231
psi 4400 4400 4400 4400 4400 4400 4400 4400 4400 3843 3350
Speed at rated pressure maximum 3400 3400 3400 3400 3400 3400 3400 3400 3400 3000 3000
minimum
Start speed at 1000 PSI rpm 400 400 400 400 400 400 400 400 400 400 400
Standard Weight kg 8.53 8.66 8.80 8.94 9.07 9.38 9.53 9.84 9.93 10.16 10.43
lb 18.8 19.1 19.4 19.7 20.0 20.7 21.0 21.7 21.9 22.4 23.0
Mass moment of inertia of
internal rotating components
Theoretical torque at rated
pressure
Theoretical power at rated
speed
Case drain pressure bar 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0 5.0
*
minimum speed at maximum pressure
x10-6 kg•m² 127 138 146 156 172 191 206 228 239 255 276
x10-6slug•ft² 94 102 107 115 127 141 152 168 176 188 204
N•m 65.7 73.4 79.2 87.0 98.2 112.1 122.9 139.6 146.9 138.4 132.4
lbf•ft 48.5 54.2 58.4 64.2 72.4 82.7 90.7 102.9 108.3 102.1 97.6
kW 23.4 26.1 28.2 31.0 35.0 39.9 43.8 49.7 46.1 43.5 41.6
hp 31.2 34.9 37.6 41.3 46.6 53.2 58.4 66.3 61.1 58.0 55.5
psi 72.5 72.5 72.5 72.5 72.5 72.5 72.5 72.5 72.5 72.5 72.5
*
1000 600 600 600 600 600 600 600 600 600 600
Fluid specifications
Parameter Unit Minimum Continuous Maximum
Viscosity
Temperature °C [°F] -40 [-40] 110 [230] 115 [239]
Cleanliness n/a ISO 4406 Class 22/18/13 or better
Filtration efficiency charge filtration β
mm²/sec (cSt)
[SUS]
8
[52]
10 - 100
[59 - 456]
=75(β10≥10)
15-20
1600
[7500]
Ratings are based on operation with premium petroleum-based hydraulic fluids containing oxidation,
rust, and foam inhibitors.
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Based on SI units
Input flow Q = (l/min)
Output torque M = (N•m)
Output power P = (kW)
Motor speed n = (min
-1
(rpm))
Based on US units
Input f low Q = (US gal/min)
Output torque M = (lbf•in)
Output power P = (hp)
Motor speed n = (min
-1
(rpm))
SI units [US units]
Vg= Displacement per revolution cm3/rev [in3/rev]
pO= Outlet pressure bar [psi]
pi= Inlet pressure bar [psi]
∆p = pO– pi(system pressure) bar [psi]
n = Speed min-1(rpm)
ηv= Volumetric eff ciency
ηm= Mechanical eff ciency
ηt= Overall eff ciency (ηv• ηm)
Variables
Vg• n
1000 • η
v
Q • 1000 • η
v
V
g
Vg• n
231 • η
v
Vg• ∆p • η
m
20 • π
Q • ∆p • η
t
600
Vg• ∆p • η
m
2 • π
Q • ∆p • η
t
1714
Q • 231• η
v
V
g
Technical Information
D–Series Cast Iron Gear Motors, Including Fan Drive
General information
Sizing equations
Use these formulas to determine the nominal motor size for a specific application.
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Peak pressure
Rated pressure
Reaction time (100 ms max)
Time
Pressure
P107 861E
Technical Information
D–Series Cast Iron Gear Motors, Including Fan Drive
Operating Parameters
Overview
Definitions of the D Series operating parameters appear here. Consult your Danfoss representative for
applications running outside of these parameters.
Pressure
Peak pressure
Peak pressure is the highest intermittent pressure allowed.
The relief valve overshoot (reaction time) determines peak pressure. It is assumed to occur for less than
100 ms. The accompanying illustration shows peak pressure in relation to rated pressure and reaction
time (100 ms maximum).
Rated pressure
Rated pressure is the average, regularly occurring operating inlet pressure that should yield satisfactory
product life. The maximum machine load at the motor shaft determines rated pressure.
System pressure
System pressure is the differential between the inlet and outlet ports.
It is a dominant operating variable affecting hydraulic unit life. High system pressure, resulting from high
load at the motor shaft, reduces expected life. System pressure must remain at, or below, rated pressure
during normal operation to achieve expected life.
Back pressure
The hydraulic load downstream of the motor determines the back pressure. The D Series motor can work
with back pressure up to 100% of the maximum rated inlet pressure.
Case drain pressure
Case drain pressure is the pressure in the case drain line. Route case drain plumbing directly to the
reservoir to keep the case drain pressure as low as possible. Maximum continuous case drain pressure
allowed is 5 bar [72.5 psi].
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Rated
69
[1000]
Pressure - bar [psi]
0
400
P107 960E
Speed - min¯¹ (rpm)
Operating
envelope
Rated
600
Technical Information
D–Series Cast Iron Gear Motors, Including Fan Drive
Operating Parameters
Temperature and viscosity
Temperature and viscosity requirements must be concurrently satisfied.
Temperature
High temperature limits apply at the inlet port of the motor. Ensure the motor runs at or below the
maximum continuous temperature.
Cold oil, generally, does not affect the durability of motor components. It may affect the ability of oil to
flow and transmit power. For this reason, keep the temperature at 16°C [61 °F] above the pour point of
the hydraulic fluid.
Minimum (cold start) temperature relates to the physical properties of component materials.
Continuous temperature is the temperature at or below which you may expect normal motor life.
Maximum temperature is the highest temperature that is tolerable by the machine for a transient/
limited time. (Duty cycle 1% or less)
Viscosity
Minimum viscosity occurs only during brief occasions of maximum fluid temperature and severe duty
cycle operation. It’s the minimum acceptable viscosity to guarantee the motor life. (Duty cycle 1% or less)
Maximum viscosity occurs only during cold start at very low temperatures. It is the upper limit of
viscosity that allows the motor to start.
Continuous viscosity is the viscosity range at which you may expect normal motor.
Hydraulic fluid
Speed
Maximum speed is the limit for a particular gear motor when operating at rated pressure. It is the
highest speed at which you may expect normal life.
The lower limit of operating speed is the minimum speed.
Minimum speed increases as operating system pressure increases. When operating under higher
pressures, a higher minimum speed must be maintained, as shown.
Ratings and data for gear motors are based on operation with premium hydraulic fluids containing
oxidation, rust, and foam inhibitors. These fluids must possess good thermal and hydrolytic stability to
prevent wear, and corrosion of internal components. Use petroleum/mineral-based fluids. Ensure only
clean fluid enters the hydraulic system.
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C
Technical Information
D–Series Cast Iron Gear Motors, Including Fan Drive
Operating Parameters
Caution
Never mix hydraulic fluids.
Filtration
Filters
Use a filter that conforms to Class 22/18/13 of ISO 4406 (or better). It may be on the motor outlet
(discharge filtration) or inlet (pressure filtration).
Selecting a filter
When selecting a filter, please consider:
•
Contaminant ingression rate (determined by factors such as the number of actuators used in the
system)
•
Generation of contaminants in the system
•
Required fluid cleanliness
•
Desired maintenance interval
•
Filtration requirements of other system components
Reservoir
Measure filter efficiency with a Beta ratio (βX). βx ratio is a measure of filter efficiency defined by ISO 4572.
It is the ratio of the number of particles greater than a given diameter (in microns) upstream of the filter
to the number of these particles downstream of the filter.
•
For discharge filtration with controlled reservoir ingression, use a β
•
For pressure filtration, use a filtration with an efficiency of β10 = 75
The filtration requirements for each system are unique. Evaluate filtration system capacity by monitoring
and testing prototypes.
Fluid cleanliness level and βX ratio
Fluid cleanliness level (per ISO 4406)
βX ratio (discharge filtration)
βX ratio (pressure or return filtration)
Recommended inlet screen size
The reservoir provides clean fluid, dissipates heat, removes entrained air, and allows fluid volume
changes associated with fluid expansion and cylinder differential volumes. A correctly sized reservoir
accommodates maximum volume changes during all system operating modes. It promotes de-aeration
of the fluid as it passes through, and accommodates a fluid dwell-time between 60 and 180 seconds,
allowing entrained air to escape.
Minimum reservoir capacity depends on the volume required to cool and hold the oil from all retracted
cylinders, allowing for expansion due to temperature changes. A fluid volume of 1 to 3 times the pump
output flow (per minute) is satisfactory. The minimum reservoir capacity is 125% of the fluid volume.
Install the suction line above the bottom of the reservoir to take advantage of gravity separation and
prevent large foreign particles from entering the line. Cover the line with a 100-125 micron screen. The
pump should be below the lowest expected fluid level.
Put the return-line below the lowest expected fluid level to allow discharge into the reservoir for
maximum dwell and efficient deaeration. A baffle (or baffles) between the return and suction lines
promotes deaeration and reduces fluid surges.
Class 22/18/13 or better
β
= 75 and β10 = 2
35-45
β10 = 75
100 – 125 μm [0.004 – 0.005 in]
35-45
= 75 filter
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Technical Information
D–Series Cast Iron Gear Motors, Including Fan Drive
Operating Parameters
Line sizing
Choose pipe sizes that accommodate minimum fluid viscosity to reduce system noise, pressure drops
and overheating in order to maximize system life and performance. Line velocity should not exceed 6.0
m/s [20.0 ft/s]. Route case drain line direct to tank.
Most systems use hydraulic oil containing 10% dissolved air by volume. Over-aeration, or entrained air is
the result of flow line restrictions, where the dissolved air comes out of solution, or when air is allowed to
leak into the hydraulic circuit. These include inadequate pipe sizes, sharp bends, or elbow fittings,
causing reduction of flow-line cross-sectional area. This problem will not occur if these circuit
recommendations are followed, rated speed requirements are maintained, and reservoir size and
location are adequate.
Motor life
Motor life is a function of speed, system pressure, and other system parameters (such as fluid quality and
cleanliness).
All Danfoss gear motors use hydrodynamic journal bearings that rely on an oil film between the gear
shaft and bearing surfaces at all times. You can expect long life when this film is sustained through
proper system maintenance and operating within recommended limits.
A B10 bearing life expectancy number is generally associated with rolling element bearings. It does not
exist for hydrodynamic bearings.
High pressure impacts motor life. When submitting an application for review, provide machine duty cycle
data that includes percentages of time at various loads and speeds. We strongly recommend a prototype
testing program to verify operating parameters and their impact on life expectancy before finalizing any
system design.
Motor shaft connection
Shaft options for gear motors include tapered, splined, and parallel shafts.
Plug-in drives, with a splined shaft, can impose severe radial loads when the mating spline is rigidly
supported. Increasing spline clearance does not alleviate this condition.
Use plug-in drives only if the concentricity between the mating spline and pilot diameter is within 0.1
mm [0.004 in]. Lubricate the drive by flooding with oil. A three-piece coupling minimizes radial or thrust
shaft loads.
Motor shaft connection
To avoid spline shaft damage, use carburized and hardened steel couplings with 80-82 HRA surface
hardness.
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Technical Information
D–Series Cast Iron Gear Motors, Including Fan Drive
Operating Parameters
Radial and axial loading
External shaft loads may have an effect on bearing life, and may affect motor performance depending on
several factors such as load position and orientation, operating pressure, oil viscosity and motor speed.
D-motors are capable of carrying most plastic fans up to 11.75 kg (26 lbm) at rated pressure and speed.
For any other application where radial and/or axial shaft loads are present, pleas fill in the Motor shaft
load data form and contact your Danfoss representative for technical assistance.
Shaft loading
Motor shaft load data form
Item Value Based on SI or US units
Motor displacement □ cm3/rev □ in3/rev
Rated system pressure □bar □PSI
Peak pressure
Motor shaft rotation □left □right
Motor minimum speed min-1 (RPM)
Motor maximum speed
Radial load □N □lbf
Angular orientation from 12:00 (α) 12:00 - 11:59
Axial load □N □lbf
Distance from flange (L1) □mm □in
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