"service manual"
Contents
1. Series 90 90000229 Fig 62 31 Install Slipper Guide Bearing Shim 90000230 Fig 62 32 Install Slipper Guide Bearing CENSO 90000127 Fig 62 33 Install Pistons in Slipper Guide 5 90000181 Fig 62 34 Install Slipper Guide and Pistons 90000231 Fig 62 36 Thrust Plate Installed 90000182 Fig 62 35 Install End Cap Gasket 62 7 SAUER G SUNDSTRAND Axial Piston Pumps and Motors Major Repair Fixed Motor Continued 90000184 Fig 62 37 Install Housing 90000232 Fig 62 38 Housing Installed 90000185 Fig 62 39 Install Shorter End Cap Screws 90000186 Fig 62 40 Torque End Cap Screws 90000225 90000233 Fig 62 41 Bearing Fig 62 42 Install Installed on Shaft Shaft Assembly 62 8 Place the housing over the assembled internal parts with the deep end of the cavity in the housing mated to the long side of the hold down tube The housing will engage the alignment pins in the end cap When the housing is properly installed the hold down tube will hold the housing away from the end cap approxi mately 0 030 in 75 mm 7 Series 90 Install and hand tighten the two 2 short end cap screws to hold the end cap to the housing Place the motor on the work surface with the end cap up andinstallthe remaining end cap screws Tighten the end cap screws evenly to the torque indicated in the accompanying table Frame2. 4 Pd 2 M GI gt NI5R N P d N25R gt m 2 eX a b P M ae SO nd ddp NC gj lt _ d Vt P SY J30 lt d X E Tu Ho J50 ARR d 3 lt doo OR JRO 40 4 SAUER SUNDSTRAND 6 Sal Axial Piston Pumps and Motors Series 90 Exploded View of the Variable Displacement Pump Continued 40 5 SAUER SUNDSTRAND 6 Sal Axial Piston Pumps and Motors Series 90 Exploded View of the Variable Displacement Pump Continued S03 4 i L8T1 L1T1 x LBT2 L9T1 L1TF SPECIAL d 50 eh O gt hd F 776 F 606 OP ey F 806 F 796 v F816 F716 Og Mc 40 6 SAUER SUNDSTRAND 6 e Axial Piston Pumps and Motors Series 90 Exploded View of the Variable Displacement Pump Continued ZA 0 P80 P807 P80 ow P802 Co P70 P70 6 P707 Cu P702 wp 2 e ENDCAP GASKET FACE ENDCAP GASKET FACE ENDCAP GASKET FACE OF ITEM G04X TYPICAL OF ITEM G04X TYPICAL OF ITEM G04X TYPICAL WITH PRESSURE LIMITERS WITH PRESSURE LIMITERS WITHOUT PRESSURE LIMITERS RIGHT HAND ROTATION LEFT HAND ROTATION LEFT RIGHT HAND ROTATION GASKET FACE OF ITEM G068 WITH PRESSURE LIMITERS RIGHT HAND ROTATION NOTES ITEMS G042 amp G046 DO NOT INCLUDE ITEMS G93 G94 G95 G902 G906 G952 amp G956 ITE
3. Cylinder Block Electric 2 Position Control Option 4 Way 2 Position Valve Cradle Swashplate Maximum Angle Control Piston Partial Section A A Cradle Swashplate in full displacement position 90000234 Fig 63 1 Cross Section View of Series 90 Variable Displacement Motor 63 1 SAUER G SUNDSTRAND Hydraulic Power Systems SAUER SUNDSTRAND Hydraulic Power Systems Market Leaders Worldwide SAUER SUNDSTRAND is a world leader in the design and SAUER SUNDSTRAND specializes in integrating a full manufacture of Hydraulic Power Systems Research and range of system components to provide vehicle designers development resources in both North America and Europe with the most advanced total design system enable SAUER SUNDSTRAND to offer a wide range of design solutions utilizing hydraulic power system technology SAUER SUNDSTRAND is Your World Source for Controlled Hydraulic Power Systems Heavy Duty Axial Piston Heavy Duty Bent Axis Cartridge Motors Pumps and Motors Variable Motors Compact Wheel Drives Medium Duty Axial Piston Microcontrollers and Hydrostatic Transmission Pumps and Motors Electrohydraulic Controls Packages Open Circuit Axial Piston Pumps Gear Pumps and Motors Genuine Service Parts Worldwide Service Support Aner P SAUER SUNDSTRAND COMPANY SAUER SUNDSTRAND GMBH amp CO 2800 East 13th Street Postfach 2460 D 24531 N nst
4. Model Code Typ Model Code yp 90M055 NC 0 N 90M055 NG 0 N 8 N 0 C6 W OO 8 N 0 C6 W 00 Model NNN 00 00 24 Code NNN 00 00 24 SENE Mode me dent Nr Number L 94 2029 Number 71 312918 Serial 91 26 67890 Serial N 91 26 67890 Number Serial No Fabr Nr Number Serial No Fabr Nr MADE IN U S A MADE IN GERMANY Place of Manufacture Place of Manufacture Name Plate U S A Production Name Plate German Production 40 13 SAUER SUNDSTRAND 6 Sal Axial Piston Pumps and Motors Series 90 Exploded View of the Fixed Displacement Motor Continued E G90 G041 G048 40 14 SAUER SUNDSTRAND 6 Sal Axial Piston Pumps and Motors Series 90 Exploded View of the Fixed Displacement Motor Continued Item Description Qty Item Description Qty B10 FIXED HOUSING 1 L10 ROLLER BEARING 1 B80 PLUG 2 L20 RETAINING RING 1 C05 CYLINDER BLOCK ASSY 1 L35 SEAL CARRIER 1 C13 SPRING SEAT 1 L40 LIP SEAL 1 C14 SPRING 1 L50 O RING 1 C15 SPRING RETAINER 1 L70 METRIC SCREW 3 1 C16 RETAINING RING C20 SEE W GROUP FOR PISTONS L1C6 SHAFT SPLINED C30 SLIPPER GUIDE L1C7 SHAFT SPLINED C40 SLIPPER GUIDE RETAINER L1K2 SHAFT STRAIGHT KEY C45 SLIPPER GUIDE RETAINER SHIM L8 KEY C50 HOLD DOWN TUBE L1S1 SHAFT SPLINED C80 VALVE PLATE L1T2 SHAFT TAPERED aE lll D50 THRUST PLATE L8 KEY G25 PIN L9 SLOTTED NUT G30 END CAP GASKET
5. SPRING SEAT INNER HYD INCHING SPRING HYD INCHING SPRING WASHERS HYD INCHING SPRING SEAT OUTER HYD INCHING O RING HYD INCHING PLUG THREADED HYD INCHING NUT SEAL LOCK HYD INCHING SCREW ADJUSTING HYD INCHING 3 POS 4 WAY VALVE FNR VALVE ELECTRICAL SCREW 3 POS 4 WAY VALVE W INCH FNR VALVE FNR VALVE ELECTRICAL SCREW INCH VALVE ROTARY VALVE BLOCK PLUG VALVE SPOOL RING RETAINING RETAINER O RING GASKET Qty lt po N N a aa RH HSB 40 11 SAUER SUNDSTRAND 6 Sa Axial Piston Pumps and Motors Series 90 Exploded View of the Fixed Displacement Motor The following information is for general parts identifi cation ONLY Refer to the applicable Service Parts List when ordering service parts H68W H60W L35 H62W Early Production 075 Frame Size H50W H40W amp B B80 ies H50N e 27 G50 j SA H20W P S G50 er F lt H10N d HOON E H20W abd N B80 _ H10W yy G63 H30W ez CODE 61 OPTION S H50W G64 G64 CODE 61 OPTION id B83 lt B80 G63 CODE 61 OPTION oy Ve SH G63 N CODE 61 OPTION B83 B83 SAUER S SUNDSTRAND Ames lowa U S A Neum nster Germany SAUER SUNDSTRAND Ames lowa U S A Neum nster Germany
6. Post Nuts Post Type Type For 130 frame size units with leveler guides remove the four 4 screws holding the leveler guides to the side cover with a5 mm internal hex wrench Remove the leveler guides from the cover Remove swash plate leveler from side cover Remove the side cover O ring 90000197 90000198 Fig 61 18 Remove Fig 61 19 Remove Retaining Screws Leveler Guide Guide Type Type Markthe servo cylinders and housing to identity each servo cylinder with its respective side of the housing Remove the three 3 or four 4 screws retaining each servo cylinder to the housing using a 10 mm or 13 mm hex wrench 90000114 90000115 Fig 61 20 Mark Fig 61 21 Remove Servo Cylinders Servo Cylinder Screws 61 4 SAUER G SUNDSTRAND Axial Piston Pumps and Motors Series 90 Major Repair Variable Pump Continued For earlier production units carefully pry each cylin der from the housing by using a screwdriver in the notches in the cylinder For later production units install an 8 mm or 10 mm screw in the threaded hole in the center of each cylinder and pull the cylinders from the housing The servo piston will remain in the housing NOTE For later production units with displacement limiters remove the limiter screw from each servo cylinder and install an 8 mm or 10 mm screw in its place as a puller screw Remove the cylinder block through the housing end ca
7. SAUER SUNDSTRAN Series 90 Axial Piston Pumps and Motors Repair Manual SAUER G SUNDSTRAND Axial Piston Pumps and Motors General Description Series 90 Variable Displacement Pumps are cradle swashplate design units incorporating parallel axial pistons with slippers These pumps are designed to be combined with other products in closed circuit systems to transfer and control hydraulic power The pump output flow rate is proportional to the pump s input speed and is determined by the swash plate angle which may be infinitely varied between zero and maximum displacement The pump s flow direction is reversed by tilting the swashplate to the opposite side of the zero displace ment position A compact responsive closed loop servo system with a choice of manual hydraulic or electrical input controls the swashplate angle An automotive drive control is also available S Series 90 Series 90 Fixed and Variable Displacement Motors are swashplate design units incorporating parallel axial pistons with slippers These motors are primarily designed to be combined with other products in closed circuit systems to trans fer and control hydraulic power Theoutput speed is proportionaltothe flow rate ofthe hydraulic fluid through the motor and the motor displacement for variable motors Output torque is proportional to the difference in the pressure levels in the high and low sides of the fluid circu
8. S N np x k 2 oa an ua amo S Series 90 Exploded View of the Variable Displacement Motor 055 and 075 Continued Item H10W H20W H30W H40W H50W H60W H62W H64W H66W H68W L10 L20 L35 L40 L50 L70 L80 L90 M1 P35 P100 P200 P300 P400 P600 P601 P700 S07 T30 T40 T50 T60 T100 Y40 Y50 Y60 Y100 Description SHUTTLE VALVE SPOOL SPRING GUIDE SPRING O RING SPECIAL PLUG CHARGE RELIEF VALVE PLUG O RING SPRING CHARGE RELIEF POPPET LOCK NUT SHAFT SPLINED SHAFT TAPERED KEY SLOTTED NUT RETAINING RING ROLLER BEARING SEAL CARRIER LIP SEAL O RING SCREW FRONT COVER GASKET O RING CONTROL VALVE SCREW VARIABLE MOTOR HOUSING FRONT COVER SCREW PLUG PLUG PRESS COMPENSATOR VALVE SPECIAL PLUG CYLINDER BLOCK KIT W PISTONS FILTER SCREEN O RING BACK UP RING O RING ORIFICE PLUG O RING BACK UP RING O RING ORIFICE PLUG Qty pO N N N ee x sak 4 pha aA LK N 40 19 SAUER G SUNDSTRAND Axial Piston Pumps and Motors Major Repair Variable Pump General The procedures on the following pages are for the complete disassembly and reassembly Major Re pair of the Series 90 Variable Displacement Pump Cleanliness is a primary means of assuring satisfac tory hydraulic pump life on either new or repaired units Cleaning parts by using a clean solvent
9. the pump must be disassembled and the problem corrected Assemble and adjust the following components as described in the Minor Repair section of the Series 90 Service Manual Charge Pump Auxiliary Mounting Pad Where Applicable Shaft Seal Control Filter Option Charge Relief Valve Multi Function Valves Displacement Limiter s Rotate the pump shaft with a torque wrench to assure correct assembly When properly assembled the torque required to turn the shaft after break away should be within the ranges shown in the accompany ing table Torque to Turn Shaft Variable Pump at 0 ft losf Nm Frame Size Minimum Maximum 7 5 10 2 90000192 Fig 61 104 Shaft Fig 64 105 Install Bearing Installed Shaft Assembly 90000103 9 12 2 10 13 6 13 17 6 15 5 21 WARNING Always test the pump prior to putting it into service to verify correct pressure limiter and control function Improper function of these systems can result in uncontrollable move ment of the vehicle machine 61 20 SAUER G SUNDSTRAND Axial Piston Pumps and Motors Major Repair Fixed Motor General The procedures on the following pages are for the complete disassembly and reassembly Major Re pair of the Series 90 Fixed Displacement Motor Cleanliness is a primary means of assuring satisfac tory hydraulic motor life on either new or repaired units Cleaning parts by using a clean solvent wash and ai
10. 62 6 SAUER G SUNDSTRAND Axial Piston Pumps and Motors Major Repair Fixed Motor Continued Place the slipper guide retainer shim on the hold down tube The tab with the V notch must be positioned in the tube cutout which is located 45 counter clockwise from the longest side of the tube assembly Assemble the bronze slipper guide bearing on top of the slipper guide retainer shim positioning the tab with the V notch in the same position as noted above NOTE Certain frame sizes utilize a one piece slip per guide retainer shim and bearing The one piece shim and bearing is installed with the tab with the V notch positioned as noted above and with its bronze side facing up toward the slipper guide Assemblethe piston assemblies intothe slipper guide Lubricate the pistons and cylinder block bores Install the assembled slipper guide and pistons into the cylinder block by inserting the pistons into the cylinder block bores The pistons and bores are not selec tively fitted therefore no specific piston and bore orientation is required Place anew gasket on the end cap The beaded side of the gasket must be positioned away from the end cap Lubricate the slipper running surfaces then place the thrust plate onthe slipperfaces The side ofthethrust plate with the chamfered edge must be positioned away from the slipper faces The slots in the thrust plate must be positioned over the tabs on the hold down tube
11. Code 01 00 24 Model Number 94 4002 Serial Number T L 91 26 67890 Serial No Fabr Nr MADE IN U S A Lo L Place of Manufacture Name Plate U S A Production 40 17 SAUER SUNDSTRAND 6 Sal Axial Piston Pumps and Motors Series 90 Exploded View of the Variable Displacement Motor 055 and 075 Continued 40 18 SAUER G SUNDSTRAND Axial Piston Pumps and Motors Item B20 B30 B50 B51 B74 B76 B80 B83 B83 C05 2 3 4 5 C20 C30 C40 C50 C65 C70 C80 D10 D20 D30 D50 E15 E25 E35 F15 F25 F35 F45 F49 F65 G20 G30 G41 G50 G61 G62 G63 G64 G70 G80 G82 G84 G86 G90 G95 G96 H10N H50N H60N Description PIN CRADLE BEARING PIN PIN PLUG PLUG PLUG PLUG SPEED SENSOR CYLINDER BLOCK ASSEMBLY SPRING RETAINER RING SEAT PISTON ASSEMBLY SLIPPER GUIDE SLIPPER GUIDE BEARING SPACER WASHER SCREW VALVE PLATE HOLD DOWN ARM O RING HOLD DOWN PIN SWASHPLATE CAP SET SCREW NUT SEAL LOCK SPECIAL PLUG O RING SPRING SERVO PISTON ASSEMBLY PISTON SEAL RING SPRING JOURNAL BEARING END CAP GASKET END CAP PLUG PORT SHIPPING COVER GASKET PORT SHIPPING COVER SPLIT FLANGE CLAMP SHIPPING COVER SCREW PLUG SPRING PIN BALL CRUSH RING ORIFICE SCREW SCREW SCREW LOOP FLUSHING SPOOL DEFEAT PLUG PLUG Qty ala AMA PMH HBB jJ RANMA ONMAH BBB Ap N gt N
12. Continued 90000150 80000152 Fig 61 82 Torque Cylinder Screws Fig 61 83 Install Cage Locator Link Pump Housing EH Fig 61 84 Install Locator Link Pin Fig 61 85 Install Locator Link Screw 042 Pumps A 20 4 90000196 Fig 61 87 Install Leveler on Side Cover 90000153 Fig 61 86 Check for Servo Arm to Slider Block Clearance 61 16 Install the three 3 or four 4 screws in each servo cylinder Torque to 10 ft lbsf 13 5 Nm for 030 thru 055 pumps 18 ft lbsf 24 Nm for 075 pumps and 24 ft lbsf 32 Nm for 100 and 130 pumps NOTE For units equipped with an automotive con trol the servo cylinder screws on the center ing assist spring side of the housing will be installed later Align the slot in the swashplate bearing cage with the headed spring pin in the swashplate and the pin hole in the housing Hook the cage locator link over the spring pin between the washer and the swashplate Rotate the link into the slot in the bearing cage NOTE A washer is not installed on the spring pin in 030 frame size pumps Align the hole in the locator link with the hole in the housing and install the link anchor pin thru the link and into the housing A flat head screw is used as the link pin in 042 frame size pumps Install a new screw with locking com pound through the locator link and into the housing Tighten the screw into the housing until the head of the
13. M90M SCREW C20 PISTON S40 NEUTRAL START SWITCH KIT C80 PUMP VALVE PLATE M14 FEEDBACK LINK S30 OVERHAUL SEAL KIT C70 SCREW M810 ADAPTER PLATE CONTROL 130 CC 1 E40 NUT M820 O RING 130 CC 1 E50 O RING M830 O RING 130 CC 1 E60 SCREW M840 O RING 130 CC 2 F11 O RING M850 PLUG 130 CC 1 F12 PISTON RING M860 SCREW 130 CC 6 F40 O RING M870 PLUG 130 CC 1 F50 O RING G088 GASKET G306 END CAP GASKET AXIAL PORTS G308 END CAP GASKET TWIN PORTS J40A O RING NOOM FILTRATION MANIFOLD KIT INT N10M MANIFOLD N15M O RING N20M NUT J50A O RING N25M TUBE J90A O RING N30M PLUG J90B O RING N40L FILTER J90C O RING N A N40P FILTER K50 O RING L40 LIP SEAL NOOR FILTRATION MANIFOLD KIT RMT L50 O RING N10R MANIFOLD N15R O RING M77M MANIFOLD GASKET M80 CONTROL GASKET N um Ay B lt Q Qk xk Qk Q Ny N20R NUT M95E O RING N25R TUBE M96E O RING N30R PLASTIC PLUG M97E O RING NOOR PLUG N15 O RING P6 O RING N10S REDUCER FITTING SUCTION FLT 1 P13 O RING N30S PLUG 1 P2A MULTI FUNCTION VALVE ASSY 1 P2B MULTI FUNCTION VALVE ASSY 1 P6 O RING 2 40 10 SAUER G SUNDSTRAND Axial Piston Pumps and Motors S mda Series 90 Exploded View of the Variable Displacement Pump Continued Item W001 W002 W003 W004 W005 W006 W007 W008 W009 W010 W011 W012 W013 W014 W015 W10A W121 W122 W
14. Motors Series 90 Major Repair Variable Pump Continued The threaded holes in the swashplate for the hold down screws must be cleaned of old locking com pound prior to reassembly A 6 mm 030 thru 100 pumps or 8 mm 130 pumps thread tap may be used for this purpose Inspect the swashplate guide for wear The guide may be removed by removing the special locking Screw with a 5 mm 030 042 6 mm 055 075 100 or 8 mm 130 internal hex wrench x Servo arm alignmentis critical to proper pump opera SEN 90000128 Fig 61 49 Clean Threaded Holes in tion For this reason removal of the servo arm from Swashplate the swashplate is not recommended If the servo arm must be removed from the swash plate remove the locking screw with a 13 mm 030 042 055 075 or 17 mm 100 130 hex wrench Keystone design servo arms must be parallel within 0 010 in 0 25 mm total to the wide surface ofthe slot in the swashplate when installed Press fit design servo arms must be carefully aligned with the slot and threaded holes in the swashplate while installing and must be pressed completely into the swashplate slot NOTE Keystone design servo arms and swashplates are no longer available for serv icing 055 075 and 100 frame size pumps A swashplate servo arm kit is available to service these units Refer to the appropriate Service Parts Manual for more information Torque the servo arm to swashplate locking scr
15. SAUER 6 SUNDSTRAND 55 50010 USA Spes D Krokamp 35 D 24539 Neum nster Germany Phone 515 239 6000 FAX 515 239 6618 Phone 04321 871 0 Fax 04321 871 122 BLN 9949 Rev B July 1992
16. SAUER G SUNDSTRAND Axial Piston Pumps and Motors S 7 Series 90 Major Repair Variable Pump Continued 90000199 Fig 61 30 Remove Feedback Link 90000125 Fig 61 31 Remove Hold Down Screws 90000200 Fig 61 32 Remove Fig 61 33 Remove 90000126 Pistons and Guide from Swashplate Earlier Production Pistons and Guide from Swashplate Later Production 90000127 90000129 Fig 61 34 Remove Fig 61 35 Remove Pistons from Slipper Journal Bearing from Guide End Cap BE 90000132 Fig 61 36 Install Journal Bearing in End Cap 90000133 Fig 61 37 Journal Bearing Installed in End Cap 61 6 Remove the feedback link from the head of the special screw on the swashplate assembly Using a 10 mm or 13 mm hex wrench remove the four 4 screws holding the slipper guide hold down mecha nism to the swashplate Disassemble the hold down mechanism and remove the slipper guide and pistons from the swashplate NOTE Later production pumps use a fixed clear ance hold down mechanism Earlier produc tion 055 thru 100 frame size pumps use a spring loaded hold down mechanism Removethe piston assemblies from the slipper guide Reconditioning and Replacement of Parts After disassembly all parts should be thoroughly cleaned in a suitable solvent Replace all O rings gaskets and the shaft seal Inspect all parts for damage nicks or unusual wear patterns Replace
17. Split line in bearing MUST be located within noted arcs but NOT in line with drain groove in bearing bore Drain Groove Fig 62 20 Orientation of Split Line in Journal Bearing Earlier Production Split line in bearing MUST be located within noted arc opposite the drain groove in bearing bore Drain Groove Fig 62 21 Orientation of Split Line in Journal Bearing Later Production 62 4 6 Remove the valve plate and alignment pins from the end cap CONTENTS Series 90 Remove the piston assemblies from the slipper guide Reconditioning and Replacement of Parts After disassembly all parts should be thoroughly cleaned in a suitable solvent Replace the shaft seal and all gaskets Inspect all parts for damage nicks or unusual wear patterns Replace all parts having unusual or exces sive wear or discoloration If the end cap journal bearing needs replacement as evidenced by large amounts of the metal back of the bearing being visible through the plastic bearing material remove the bearing with a suitable puller Do not damage the valve plate surface of the end cap Lightly lubricate the steel backing of a new journal bearing Press the journal bearing into the end cap using a suitable press pin The split line in the bearing must be located as shown in the accompanying illustrations but NOT in line with the drain groove in the end cap bearing bore Pec SAUER G S
18. Variable Displacement Pump seen 61 2 Reconditioning and Replacement of Parts nennen nennen 61 6 Assembly Procedures for Variable Displacement Pump sese 61 12 Major Repair Fixed Motor itr Ree Ebr EH uu eda ERE SU ERR Eee ee XR E ne desea 62 1 e c 8 62 1 Disassembly Procedures for Fixed Displacement Motor 62 2 Reconditioning and Replacement of Parts U nennen 62 4 Assembly Procedures for Fixed Displacement Motor 62 6 Major Repair Vatrtable MOILOTF uu uu esee Deere chr nee venue LE untere sane be ead ada 63 1 General wp 63 1 SAUER G SUNDSTRAND Axial Piston Pumps and Motors Introduction This manual provides Major Repair procedures for the Series 90 variable displacement pumps and fixed and variable displacement motors Minor Repairs are those repairs which can be performed without removing the end cap or side cover These repairs can be performed by any customer without affecting the unit warranty These repairs are described in the Series 90 Service Manual Bulletin BLN 9947 Major Repairs are those repairs which require the removal of the end cap or side cover These repairs are to be performed only by Sauer Sundstrand Au thorized Service Centers a
19. pumps and motors which are not normally included in the typical mechanic s set of tools These include An internal puller for removing the shaft journal bear ing from the end cap Example Snap On Tools Puller Set CG45 Sizing arbors for the end cap shaft journal bearing Sauer Sundstrand part number 9510667 XXXX CAUTION CONTENTS Series 90 The pump or motor shaft must NOT be used to size the bearing Inadequate clearance between the shaft and bearing will result in inadequate lubrication and shortened bearing life Dimensions for the sizing arbors are shown in the accompanying figure and table The arbors are made of AISI 4140 steel A 4 to 8 RMS microfinish and a hardness of 50 to 57 Rc is required on Diameter A Diameter A Dimension B Minimum Frame 0 0001 in or Size 0 00254 mm 25 300 mm 28 010 mm 1 1818 in 1 3785 in 1 5000 in 44 984 mm A tool to aid in holding and installing the assembled cylinder block and swashplate into the variable pump housing may be made from a positive lock quick release pin and a large flat washer 1 inch inside diameter with clearance flats ground on the outside diameter The 1 inch diameter pin is defined by military specification MS 17985 C 16 60 and is available from a number of sources These include QRP Incorporated Reach Road amp North Drive PO Box T3572 Williamsport PA 17701 0572 Telephone 717 322 8060 Carr Lane Manufa
20. wash and air drying is usually adequate As with any precision equipment all parts must be kept free of foreign materials and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material Valve Plate Piston Charge Pump Control Piston S Series 90 During the assembly of the Series 90 variable pump all surfaces which have relative motion between two parts should be coated with a film of clean hydraulic oil This will assure that these surfaces will be lubricated during start up It is recommended that all O rings and gaskets be replaced Lightly lubricate all O rings with clean petroleum jelly prior to assembly All gasket sealing surfaces must be cleaned prior to installing new gaskets Manual Displacement Control Q Roller Bearing Input Shaft A NIN s Cylinder Block Cradle Swashplate 90000189 Fig 61 1 Cross Section View of Series 90 Variable Displacement Pump 61 1 SAUER G SUNDSTRAND Axial Piston Pumps and Motors 7 Series 90 Major Repair Variable Pump Continued T 90000102 9000010
21. 000208 Fig 61 62 Position Fig 61 63 Position Slipper Guide Spacers Bearing 90000209 90000210 Fig 61 64 Position Fig 61 65 Position Flat Washers Leaf Springs and Spring Aligners 90000211 90000212 Fig 61 66 Install Fig 61 67 Spring Screws Loaded Hold Down Assembled 61 13 SAUER SUNDSTRAND x Axial Piston Pumps and Motors Series 90 Major Repair Variable Pump Continued Torque the hold down screws to 10 ft Ibsf 13 5 Nm for 030 thru 100 frame size pumps or 24 ft Ibsf 32 5 Nm for 130 pumps The slipper guide and piston slippers must be able to slide freely on the swash plate Lubricate the pistons and cylinder block bores Install the assembled swashplate and pistons into the cylin der block by inserting the pistons into the cylinder block bores The pistons and bores are not selec 90000138 Fig 61 68 Torque Fig 61 69 Install tively fitted therefore no specific piston and bore Hold Down Screws Pistons into Cylinder orientation is required Block Check that the swashplate bearing race locating pins are secure in the housing Install the swashplate bearing races into the housing positioning the races on the locating pins Retain the races in position with petroleum jelly The locating pins are offset in the housing to assure proper assem bly 90000140 E 90000124 Fig 61 70 Bearing Fig 61 71 Install Race Locator Pins in Swashplate Bearing Housin
22. 21 26A W30A W302 W304 W41A W402 W414 W501 W502 W503 W504 W505 W506 W521 W522 W523 W524 W525 W526 W527 W528 W529 W541 W542 W543 W544 W545 W546 W547 W548 W550 W551 Description VALVE BLOCK FBA PLUG PLUG O RING O RING STARTING THROTTLE FBA NUT SEAL LOCK PLUG EXPANDER PLUG ASSY NUT O RING POPPET SPRING SEAT ORIFICE THERMOVALVE FBA PLATE FBA SCREW MAIN ORIFICE FBA PRESSURE RELIEF VALVE FBA O RING NUT SEAL LOCK THROTTLE OR PRESS VALVE FBA O RING NUT SEAL LOCK SCREW LESS INCHING PLATE LESS INCHING O RING LESS INCHING PLUG LESS INCHING SPOOL LESS INCHING PLUG LESS INCHING SCREW MECH INCHING PLATE MECH INCHING O RING MECH INCHING PLUG MECH INCHING SPOOL MECH INCHING WASHER FLAT MECH INCHING O RING MECH INCHING O RING MECH INCHING PLUG MECH INCHING CYLINDER ASSY HYD INCHING SCREW HYD INCHING PISTON CYLINDER HYD INCHING PISTON HYD INCHING SEAL PISTON HYD INCHING SEAL RETAINER HYD INCHING PLUG HYD INCHING BLEED SCREW HYD INCHING PIN HYD INCHING O RING HYD INCHING Qty a QS Sk wak Sk Coes Ces Ce Ce ak k ek l Sk k N ln o pw amp Xx c Item W552 W553 W554 W555 W556 W557 W558 W559 W560 W561 W562 W563 W70A W701 W702 Description PLUG HYD INCHING O RING HYD INCHING O RING HYD INCHING SPOOL HYD INCHING
23. 3 Fig 61 2 Pump Fig 61 3 Remove Positioned on End Shaft and Bearing Cap 90000104 Fig 61 4 Remove Bearing from Shaft Fig 61 5 Pump Positioned on Flange 90000193 Fig 61 6 Remove Small End Cap Screws 90000105 Fig 61 7 Remove Large End Cap Screws 61 2 Disassembly Procedures for Variable Displacement Pump Prior to performing Major Repairs on the Series 90 Variable Displacement Pump remove the external components as described in the Minor Repair sec tion of the Series 90 Service Manual These include the following Auxiliary Mounting Pad Where Applicable Charge Pump Control Filter Options Charge Relief Valve Multi Function Valves Shaft Seal After removal of these components place the pump on a work surface with the shaft up Remove the shaft and bearing assembly from the housing The bearing outside diameter is a slip fit in the housing bore NOTE If the shaft and bearing stick in the housing lightly tap the end of the shaft with a soft mallet to free the bearing Remove the retaining ring and press the shaft out of the bearing Place the pump on the work surface with the end cap up NOTE If the pump was equipped with an auxiliary mounting pad temporarily reinstall two 2 of the large screws which fasten the end cap to the housing These screws will hold the end cap against internal spring pres sure while the small screws ar
24. DC CONTROL KIT 3 POS F N R 12V MODD CONTROL KIT 3 POS F N R 24V M1DC CONTROL 3 POS F N R 12V M1DD CONTROL 3 POS F N R 24V M80 CONTROL GASKET M87D WASHER SEAL 042 M90D SCREW MOEA EDC KIT W MS CONNECTOR MOEP EDC KIT W PACKARD CONNECTOR M1EA EDC W MS CONNECTOR M1EP EDC W PACKARD CONNECTOR M9EA PCP TYPE 3 OIL FILLED MS M9EA PCP TYPE 3 OIL FILLED PACKARD lt s x Q k 2 D M K000 ADJ CHARGE RELIEF KIT K10 PLUG ASSY K50 O RING ae lll P O K70 SPRING M80 CONTROL GASKET K80 POPPET M87E WASHER SEAL 042 K90 NUT M90E SCREW M91E PLASTIC CAP MS L10 ROLLER BEARING 1 M95E O RING L20 RETAINING RING 1 M96E O RING L35 SEAL CARRIER 1 M97E O RING L40 LIP SEAL 1 M98E SCREW L50 O RING 1 M14 FEEDBACK LINK L70 SCREW 3 MOHA HDC KIT MOHC HDC KIT M1HA HDC M1HC HDC M80 CONTROL GASKET M90H SCREW M14 FEEDBACK LINK L1C3 SHAFT PV SPLINED L1C6 SHAFT PV SPLINED L1C7 SHAFT PV SPLINED L1C8 SHAFT PV SPLINED L1F1 SHAFT PV SPLINED L1K1 SHAFT PV STRAIGHT KEY L1K2 SHAFT PV STRAIGHT KEY L1K3 SHAFT PV STRAIGHT KEY L1S1 SHAFT PV SPLINED L1T1 SHAFT PV TAPERED L1T2 SHAFT PV TAPERED L1T3 SHAFT PV TAPERED L8 KEY L9 SLOTTED NUT MOMA MDC W O NEUTRAL START SWITCH M7M CONTROL HANDLE M71M WASHER M72M NUT M80 CONTROL GASKET M90M SCREW M14 FEEDBACK LI
25. G50 PLUG S07 CYLINDER BLOCK KIT W PISTONS 1 G70 PLUG C20 PISTON 9 G90 SCREW G95 SCREW G96 SCREW S30 OVERHAUL REPAIR KIT G30 END CAP GASKET HOW ORING NS Bap Hw A Sk a pa G047 END CAP AXIAL PORTS 1 K50 O RING G048 END CAP TWIN PORTS 1 L40 LIP SEAL G20 JOURNAL BEARING 1 L50 O RING G61 PORT SHIPPING COVER GASKET 2 G62 PORT SHIPPING COVER 2 G63 SPLIT CLAMP 4 G64 SCREW SHIPPING COVER 4 H10N LOOP FLUSHING SPOOL DEFEAT 1 H50N PLUG 2 H10W SHUTTLE VALVE SPOOL 1 H20W SPECIAL WASHER 2 H30W SPRING 2 HOW ORING 2 H50W SPECIAL PLUG 2 K000 PLUG 1 K10 PLUG ASSY 1 K50 O RING 1 K610 SHIM A R K70 SPRING 1 K80 POPPET 1 40 15 SAUER SUNDSTRAND 6 Sal Axial Piston Pumps and Motors Series 90 Exploded View of the Variable Displacement Motor 055 and 075 The following information is for general parts identifi cation ONLY Refer to the applicable Service Parts List when ordering service parts Y100 Y102 T D L35 Early Production Y50 075 Frame Size Yeo E15 5 4 T 50 L40 B83 H68W H60W H62W H64W wm 8 m HeoN G50 DF dads H50W 1 H40W eam H30W H20W Vol M H10N G70 FK R E aq T Dun I H20W H40W H50W G63 G64 CODE 61 OPTION G64 CODE 61 OPTION SAUER SUNDSTRAND Ames lowa U S A Neum nster Germany Model Code Typ 90S055 NB 2 0 8 N 4 S1 W 01 L Model
26. MS G041 amp G048 DO NOT INCLUDE ITEMS G93 G94 G95 G951 amp G958 P70 E GASKET FACE OF ITEM G068 WITH PRESSURE LIMITERS LEFT HAND ROTATION 40 7 SAUER SUNDSTRAND x Axial Piston Pumps and Motors Series 90 Exploded View of the Variable Displacement Pump Continued Item Description Qty Item Description Qty B10 VARIABLE HOUSING 1 F736 SPRING GUIDE INNER 1 B20 PIN 2 F746 SPRING 1 B30 BEARING 1 F776 SPRING GUIDE OUTER 1 B50 PIN 2 F786 RETAINING RING 1 B70 PLUG 2 F796 NUT 1 B80 PLUG 1 F806 NUT LOCK 1 B90 CONTROL FILTER SCREEN 3 F816 NUT SEAL LOCK 1 C05 CYLINDER BLOCK ASSY 1 F826 WASHER FLAT 4 C13 SPRING SEAT il C14 CYLINDER BLOCK SPRING 1 G048 END CAP TWIN PORTS C15 SPRING RETAINER 1 G046 END CAP AXIAL PORTS C16 RETAINING RING 1 G20 JOURNAL BEARING C20 PISTON 9 G40 BUSHING C30 SLIPPER GUIDE 1 G61 PORT SHIPPING COVER GASKET C40 SLIPPER GUIDE BEARING 1 G62 PORT SHIPPING COVER C50 SPACER 4 G63 SPLIT CLAMP C65 WASHER 4 G64 SCREW SHIPPING COVER C70 SCREW 4 G068 VALVE HOUSING ASSY C80 VALVE PLATE G078 SCREW k k k U U sk sk Pap P D50 SWASHPLATE ASSY 1 G088 GASKET D80 CAGE LOCATOR LINK 1 G93 SPACER D85 PIN 1 G94 LIFTING BRACKET D95 SPRING 1 G95 WASHER E10 SIDE COVER 1 G306 END CAP GASKET E20 LEVELER 1 G308 END CAP GASKET E22 SPRING SEAT 2 G506 PLUG E24 SHIM 2 G508 PLUG E30 GUIDE POST 2 G526 PLUG E40 NU
27. NK I4 l l l l la l l l l la cla l2 a a MOAC ADAPTER PLATE FBA CONTROL M77A ADAPTER PLATE FBA M78A SCREW M90A SCREW M92A SCREW M98A SCREW MOMB MDC W NEUTRAL START SWITCH M7M CONTROL HANDLE M71M WASHER M72M NUT M80 CONTROL GASKET M90M SCREW 540 NEUTRAL START SWITCH M14 FEEDBACK LINK uu MOCA CONTROL COVER PLATE KIT M1C COVER PLATE M80 CONTROL GASKET M87C WASHER SEAL 042 MOMC MDC W SOL VALVE M7M CONTROL HANDLE 1 ll 40 9 SAUER SUNDSTRAND x Axial Piston Pumps and Motors Series 90 Exploded View of the Variable Displacement Pump Continued M80 CONTROL GASKET Item Description Qty Item Description Qty M71M WASHER 1 P13 O RING 2 M72M NUT 1 P30 PLASTIC PLUG 2 M74M SOLENOID VALVE 1 P70 CHECK VALVE 2 M75M CONTROL MANIFOLD 1 P702 PLUG 1 M77M MANIFOLD GASKET 1 P80 SPECIAL PLUG 2 M78M SCREW 2 P802 SPECIAL PLUG 3 1 M90M SCREW 6 S10 SERVO PISTON KIT 1 M14 FEEDBACK LINK 1 F11 O RING 2 F12 PISTON RING 2 MDC W SOL VALVE NSS M7M CONTROL HANDLE M71M WASHER M72M NUT M75M CONTROL MANIFOLD M76M SOLENOID VALVE M77M MANIFOLD GASKET M78M SCREW T001 9 CONTROL ORIFICE KIT T201 ORIFICED CHECK VALVE T301 SPRING T401 SPRING RETAINER T560 5 CONTROL ORIFICE FBA T660 5 CONTROL ORIFICE FBA m N M80 CONTROL GASKET S07 CYL BLOCK KIT W PISTONS
28. R SUNDSTRAND 6 E em Axial Piston Pumps and Motors Series 90 Major Repair Variable Pump Continued Fig 61 42 055 Pump Side Port End Cap Fig 61 43 055 Pump Twin Port End Cap Fig 61 44 075 Pump Side Port End Cap Fig 61 45 075 Pump Twin Port End Cap Rotation Block Fig 61 46 100 Pump Side Port End Cap Fig 61 47 100 Pump Twin Port End Cap 61 8 SAUER SUNDSTRAND 6 2 Axial Piston Pumps and Motors Series 90 Major Repair Variable Pump Continued Fig 61 48 130 Pump Twin Port End Cap Servo Relief Valves O Ring Plugs for Pressure Limiter Pump Pipe Plugs Automotive Control O Ring Plugs Rotation in Holes in Hole in Holes Open Holes no so emen 28 Nowe WARNING Uncontrollable movement of the vehicle ma chine and its attachments can result from in stalling the pressure limiter logic plugs in the incorrect ports for the pump rotation Correct pressure limiter function MUST be verified This can be accomplished by testing the pump before it is installed or by defining and per forming a test in the vehicle machine before it is released from repair Torque the servo relief valves or relief valve passage plugs to 9 ft lbsf 12 Nm Torque the rotation pipe plugs to 4 ft lbsf 5 4 Nm Whenreinstalling the rotation block and gasket torque the screws to 12 ft lbsf 16 Nm 61 9 SAUER SUNDSTRAND x Axial Piston Pumps and
29. Size 030 Position the motor on its end cap Using caution to prevent damage to the sealing surface press the roller bearing onto the drive shaft For units with a 3 piece bearing press the inner race onto the shaft then install the outer race cage assem bly and the special washer Install the bearing retain ing ring onto the shaft Install the shaft and bearing assembly through front of housing aligning the shaft spline with the cylinder block spline Continue to lower the shaft into the unit and carefully align the end of the shaft with the end cap journal bearing Then lower the shaft and bearing assembly into position Rotate the shaft by hand The rotating assembly should turn freely If it does not rotate freely the motor must be disassembled and the problem cor rected Pec SAUER SUNDSTRAND x Axial Piston Pumps and Motors Series 90 Major Repair Fixed Motor Continued Install the shaft seal as described in the Minor Repair section of the Series 90 Service Manual Rotate the motor shaft with atorque wrenchto assure correct assembly When properly assembled the torque required to turn the shaft after break away shouldbe withinthe ranges shown inthe accompany ing table Torque to Turn Shaft Fixed Motor at 17 Ibsf ft Nm Frame Size Minimum Maximum 5 6 8 10 13 6 5 5 7 5 11 14 9 8 5 11 5 14 19 10 5 14 2 17 23 Assemble the following components as
30. T 2 G546 PLUG E50 O RING 1 G906 SCREW E60 SCREW 6 G956 SCREW E61 WASHER FLAT 6 G958 SCREW E70 PLUG 1 80 SPRING 2 H05B H CHARGE PUMP 1 F11 O RING 2 H05L SPACER NO CHARGE PUMP 1 F12 PISTON RING 2 H30 PORT PLATE 2 F20 SLIDER BLOCK 1 H40 PIN 1 H50 CHARGE PUMP SHAFT 1 F003 SERVO SLEEVE KIT NO LIMITER 2 H60 KEY 1 F004 SERVO SLEEVE KIT ADJUSTABLE 2 H70 RETAINING PLATE 1 F40 O RING 2 H80 SCREW 6 F50 O RING 2 H90 PLASTIC PLUG 1 F60 SCREW 6 H90L PLUG 1 F344 SCREW 2 F354 NUT 2 J00A AUX MTG A FLANGE J00B AUX MTG B FLANGE 00 AUX FLANGE J00D AUX MTG D FLANGE JOOT AUX MTG A FLANGE 11T JOOV AUX MTG B B FLANGE JOON AUX MTG FLANGE NONE J10A V COUPLING J15 CHARGE PUMP COVER ASSY J15N CHARGE PUMP COVER ASSY F106 SERVO PISTON FBA F136 NEUTRAL SPRING CANNISTER FBA F146 SCREW F306 SERVO SLEEVE FBA F606 SCREW F706 O RING F716 NEUTRAL SPRING COVER FBA F726 SCREW _ _ Q 40 8 SAUER SUNDSTRAND 6 Sal Axial Piston Pumps and Motors Series 90 Exploded View of the Variable Displacement Pump Continued Item Description Qty Item Description Qty J30 BUSHING M90C SCREW 6 J40A V O RING M14 FEEDBACK LINK 1 J50A V O RING J60A T FLANGE ADAPTOR J60B V FLANGE ADAPTOR J60C FLANGE ADAPTOR J60D FLANGE ADAPTOR J70A V WASHER J80A V SCREW J80N SCREW J90A V O RING J92A V COVER PLATE J95A V SCREW MO
31. UNDSTRAND Axial Piston Pumps and Motors Major Repair Fixed Motor Continued When installed correctly the bearing will be flush to 0 020 in 0 50 mm below the valve plate surface of the end cap If a new journal bearing was installed the bearing mustbe sized with the appropriate arbor to assure the minimum bore diameter is met Carefully press the sizing arbor into the bearing to size it CAUTION The arbors are precision finished to size the journal bearings without damaging them Dam aged arbors must be replaced Do not attempt to use the drive shaft in place of an arbor Bearing damage and shortened life will result from inadequate lubrication clearance Compress the cylinder block spring and remove the spiral retaining ring retainer spring and spring seat Reassemble in the reverse order mn Series 90 E 90000173 Fig 62 23 Sizing Journal Bearing 90000133 Fig 62 22 Journal Bearing Installed in End Cap Fig 62 24 Cylinder Block Spring Components 62 5 SAUER SUNDSTRAND x Axial Piston Pumps and Motors Series 90 Major Repair Fixed Motor Continued Assembly Procedures for Fixed Displacement Motor Clean and lightly oil parts prior to assembly of the motor Be sure to torque all threaded parts to recom mended torque levels CAUTION Most parts have critical high tolerance sur faces Caution must be exercised to prevent damage to these surfa
32. ake a second measurement at a point Establish 180 from the first point of measurement at the opposite edge of swashplate surface These mea surements must not vary by more than 001 in 025 mm Angle Rotate the side cover which will also rotate the leveler and swashplate until the zero angle position is established as determined by the depth measure ment After the zero angle position has been established tighten the two 2 screws to hold the side cover Installthe remaining four 4 screws with flat washers NOTE The threads of the two 2 side cover screws installed in thru holes the housing must be coated with a sealing compound to prevent leaks New screws have sealant pre applied First torque the four 4 side cover screws installed in blind holes to 10 ft lbsf 13 5 Nm for 030 and 042 pumps 24 ft lbsf 32 5 Nm for 055 thru 100 pumps and 47 ft lbsf 64 Nm for 130 pumps Then torque the two 2 side cover screws installed in thru holes to 7 7 ft lbsf 10 4 Nm for 030 and 042 pumps 18 5 ft lbsf 25 Nm for 055 thru 100 pumps and 37 ft lbsf 50 Nm for 130 pumps 90000160 90000109 Fig 61 96 Torque Fig 61 97 Install Side Cover Screws Alignment Pins and Valve Plate Install the end cap alignment pins into the housing Lubricate the running surface of the cylinder block and Install the valve plate on the alignment pins NOTE Note the direction of the arr
33. all parts having unusual or exces sive wear or discoloration Ifthe end cap journal bearing needs replacement as evidenced by large amounts of the metal back of the bearing being visible through the plastic bearing material remove the bearing with a suitable puller Do not damage the valve plate surface of the end cap Lightly lubricate the steel backing of a new journal bearing Press the journal bearing into the end cap using a suitable press pin When installed correctly the bearing will be flush to 0 020 in 0 50 mm below the valve plate surface of the end cap NOTE For 042 frame size pumps the bearing is located 0 827 to 0 846 in 21 00 to 21 50 mm from the front surface of the charge pump recess in the end cap Pec SAUER G SUNDSTRAND Axial Piston Pumps and Motors Series 90 Major Repair Variable Pump Continued Ifa new journal bearing is installed the bearing must be sized with the appropriate arbor to assure the minimum bore diameter is met Carefully press the sizing arbor into the bearing to size it CAUTION The arbors are precision finished to size the journal bearings without damaging them Dam aged arbors must be replaced Do not attempt erre to use the drive shaft in place of an arbor Fig 61 38 Sizing Fig 61 39 Servo Inadequate clearance between the shaft and Journal Bearing Relief Valves and bearing will result in inadequate lubrication Rotation Plugs in and
34. ces during assembly Protectexposed surfaces openings and ports from damage and foreign material Place the end cap on the work surface with the valve plate surface up Install the alignment pins in the end cap NOTE The size of the alignment pins has changed on certain frame size motors Refer to the appropriate Service Parts Manual for more information 90000166 I 90000174 Fig 62 25 Install Fig 62 26 Install Installthe valve plate on the end cap with the locating Alignment Pins Valve Plate notches positioned over the alignment pins NOTE This is a bi directional valve plate with no directional arrow cut outs It can be as sembled with either side adjacent to the end cap Lubricate the end cap journal bearing and the cylinder block and valve plate running surfaces Position the cylinder block assembly on the valve plate ex UM Place the hold down tube over the cylinder block with Fig 62 27 Position Fig 62 28 Install the fluted end adjacent to the end cap Cylinder Block Hold Down Tube NOTE If a new housing is to be installed a new tube must also be used Position the straight fingers on the hold down tube overthe valve plate locating tabs and inthe clearance holes in the end cap The long side of the tube must be positioned on the same side as the end cap gauge ports 90000177 90000178 Fig 62 29 Hold Fig 62 30 Position Down Tube Fingers of Long Side of Hold Down Tube
35. cturing Co 4200 Carr Lane Court PO Box 13149 St Louis MO 63119 Telephone 314 647 6200 Lockwell Products Division of The Hartwell Corporation 900 T South Richfield Road Placentia 92670 Telephone 714 579 4425 SAUER SUNDSTRAND 6 Axial Piston Pumps and Motors Series 90 Exploded View of the Variable Displacement Pump The following information is for general parts identifi cation ONLY Refer to the applicable Service Parts List when ordering service parts K018 L35 B70 K10 THRU Early Production E e r K042 075 Frame Size B83 G532 on n G3 9 18S lt G542 8 kon L40 Ww S MA U C i K018 L THRU K042 G501 G508 G511 T G515 G63 CODE 61 OPTION E G64 CODE 61 OPTION BOTH SIDES i G501 P g c nom 61 OPTION 9508 Di G508 SAUER SUNDSTRAND SAUER SUNDSTRAND Ames lowa U S A Neum nster Germany Ames lowa U S A Neum nster Germany Model Code Typ 2 Model Code Typ 90L055 EA 1 N 90L055 EA 1 N 6 S 3 C 03 E Peri 6 S 3 C6 C 03 Wes HNN 35 35 24 9 HNN 35 35 24 Mogel ident Nr Modei Number 94 2029 Dgan 687459 Serial A 88 26 67890 Serial N 88 26 67890 Number Serial T Fabr Nr Number Serial MADE N Nr Ld Place of Manufacture Place of Ma
36. described in the Minor Repair section Charge Pressure Relief Valve Loop Flushing Valve 62 9 SAUER G SUNDSTRAND Axial Piston Pumps and Motors Major Repair Variable Motor General The procedures for the complete disassembly and reassembly Major Repair of the Series 90 Variable Displacement Motor will appear in a future revision of this publication Cleanliness is a primary means of assuring satisfac tory hydraulic motor life on either new or repaired units Cleaning parts by using a clean solvent wash and air drying is usually adequate As with any precision equipment all parts must be kept free of foreign materials and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material Piston E KI I bel eS cid O Valve Plate S Series 90 During the assembly of the Series 90 variable motor all surfaces which have relative motion between two parts should be coated with a film of clean hydraulic oil This will assure that these surfaces will be lubri cated during start up It is recommended that all O rings and gaskets be replaced Lightly lubricate all O rings with clean pe troleum jelly prior to assembly All gasket sealing surfaces must be cleaned prior to installing new gaskets Minimum Angle Control Piston Cradle Swashplate LI UH 7 ib HH uq LLL vom
37. e Housing 62 2 Disassembly Procedures for Fixed Displacement Motor 7 Series 90 Prior to performing Major Repairs on the Series 90 Fixed Displacement Motor remove the external com ponents as described in the Minor Repair section of the Series 90 Service Manual These include the following Charge Relief Valve Loop Flushing Valve Shaft Seal After removal of the components defined in Minor Repair place motor on the end cap Remove the shaft and bearing assembly from the housing The bearing outside diameter is a slip fit in the housing bore Remove the retaining ring and press the shaft out of the bearing Place the motor on the work surface with the end cap up Using a 19 mm and a 13 mm hex wrench for 055 motors a 19 mm and a 17 mm hex wrench for 075 motors or a 24 mm and a 17 mm hex wrench for 100 and 130 motors loosen the screws which retain the end cap to the housing Remove the five 5 longer Screws Place the motor on its end cap Remove the two 2 shorter screws holding the end cap to housing Lift the housing off of the end cap NOTE The dowel pins and gasket should remain with the end cap The thrust plate should remain in the housing The piston assem blies should remain with the other internal parts on the end cap but may stick to the thrust plate Pec Axial Piston Pumps and Motors Series 90 SAUER G SUNDSTRAND Major Repair Fixed Motor Continued Place
38. e removed Using a5 mm or 6 internal hex wrench or a 10 mm hex wrench remove the two 2 or three 3 small screws which fasten the end cap to the pump hous ing Using an 8 mm internal hex wrench for 042 pumps a 19 mm hex wrench for 055 pumps a 24 mm hex wrench for 075 and 100 pumps or a 14 mm internal hex wrench for 130 pumps remove the large screws which fasten the end cap to pump housing SAUER SUNDSTRAND 6 e Axial Piston Pumps and Motors Series 90 Major Repair Variable Pump Continued Remove end cap from housing The alignment pins andvalve plate will normally remain with the housing Remove the end cap gasket Remove the swash plate leveler spring shims ifinstalled from the spring pockets in the end cap Remove three 3 springs from pump the two 2 long swashplate leveler T Bar springs and the short swashplate hold down spring 2 NOTE Certain units are equipped with dual swash Fig 61 8 Ramus Fig 61 9 Eamus plate leveler springs an inner spring nested End Cap Swashplate Springs inside each of the standard springs Remove the alignment pins and valve plate noting direction of arrows on valve plate Mark the orientation of the side cover to the housing 90000109 90000110 Fig 61 10 Remove Fig 61 11 Mark Valve Plate Side Cover and Housing Straighten the locking tabs used on earlier produc tion units and remove the six 6 side cover screws
39. ew to 24 ft Ibsf 32 Nm for 030 042 055 and 075 pumps 31 ft lbsf 42 Nm for 100 pumps or 47 ft lbsf 64 Nm for 130 pumps Assemble the swashplate guide to the swashplate with the special locking screw Torque the screw to 10 ft lbsf 13 5 Nm for 030 and 042 pumps 24 ft lbsf 32 Nm for 055 075 and 100 pumps or 40 ft lbsf 54 Nm for 130 pumps NOTE Later production 100 pumps use the same size swashplate guide as 075 pumps When installing the guide onto the 100 swashplate be certain the straight sides of the guide are perpendicular to the slipper surface of the swashplate while tightening the screw Stn 90000202 Fig 61 50 Torque Swashplate Guide Screw 61 10 SAUER SUNDSTRAND Axial Piston Pumps and Motors Pec Series 90 Major Repair Variable Pump Continued If the the headed roll pin and flat washer for the bearing cage locator link must be installed on the swashplate the distance between the washer and the side of the swashplate must be as indicated below Distance H Frame Size 0 003 0 010 in 40 01 0 25 mm Frame Size 042 100 2 50 washer not used Distance t 0 010 in 40 25 mm 140 3 60 21 5 33 240 9 45 170 4 32 220 5 59 Inspect the servo piston and seal rings for wear If worn remove the seal rings and expander O rings from the piston Install new expander O rings into the seal grooves in the servo piston Carefully instal
40. ews which fasten the end cap to the housing These screws will hold the end cap against internal spring pressure while the small screws are installed Tighten the large end cap screws evenly to the torque indicated in the accompanying table Ibsfsft 43 58 Install the two 2 or three 3 smaller screws holding the end capto the housing Torque the 6 mm screws to 10 ft lbsf 13 5 Nm and the 8 mm screws to 28 ft losf 38 Nm NOTE A lifting bracket is installed on one 1 of the smaller end cap screws Cap Installed Fig 61 102 Install Large End Cap Screws Fig 61 103 Install Small End Cap SAUER SUNDSTRAND x Axial Piston Pumps and Motors Series 90 Major Repair Variable Pump Continued Position the pump on its end cap Using caution to prevent damage to the sealing surface press the roller bearing onto the drive shaft For units with a 3 piece bearing press the inner race ontotheshaft then installthe outer race cage assem bly and the special washer Install the bearing retain ing ring onto the shaft Installthe shaftand bearing assembly through front of housing aligning the shaft spline with the cylinder block spline Continue to lower the shaft into the unit and carefully align the end of the shaft with the end cap journal bearing Thenlowerthe shaft and bearing assembly into position Rotate the shaft by hand The rotating assembly shouldturnfreely If itdoes not rotate freely
41. g Races Assemble and lubricate the bearing cage and install it on the bearing races Install the bronze slider block on the swashplate servo arm Install the feedback link on the head of the special screw on the swashplate assembly WARNING 90000213 90000143 Fig 61 72 Bearing Fig 61 73 Install e MT Cage Installed Slider Block To avoid the possibility of the pump sticking in stroke the feedback link must NOT be installed in pumps equipped with non feedback con trols such as the cover plate 3 position sole noid and automotive control Position the servo piston in the housing NOTE For units equipped with an automotive con trol the machined end of the servo piston with the threaded hole must be located on the side of the housing where the centering 90000144 90000142 assist spring sleeve will be installed Fig 61 74 Install Fig 61 75 Position ii Feed Back Link Servo Piston 61 14 SAUER G SUNDSTRAND Axial Piston Pumps and Motors mn Series 90 Major Repair Variable Pump Continued Carefully lower the cylinder block and swashplate assembly into the housing through the end cap open ing NOTE A tool to aid in holding and installing the assembled cylinder block and swashplate may be made from a positive lock quick release pin and a large flat washer 1 inch inside diameter with clearance flats ground on the outside diameter Insert the pin thru the cy
42. it The motor s direction of rotation depends on the direction of fluid flow through the motor Variable Displacement Motors are available with 2 position electric solenoid or hydraluic displacement control and utilize internally supplied servo pres sure Variable motors normally start at maximum displacement Activation of the motor control results in the motor shifting to minimum displacement TheSeries 90 Advanced Technology Today The Most Technically Advanced Hydraulic Units in the Industry 8 Sizes of Variable Displacement Pumps 6 Sizes of Fixed Displacement Motors Complete Family of Control Systems Proven Reliability and Performance Optimum Product Configurations Compact Lightweight Copyright 1987 1991 1992 Sauer Sundstrand Company All rights reserved Contents subject to change Printed in U S A 0792 H SAUER SUNDSTRAND x isi Axial Piston Pumps and Motors Series 90 Contents uy e 0 2 Safely drei u u u u qasapas 20 1 Too D 20 2 Exploded View of the Variable Displacement Pump l 40 1 Exploded View of the Fixed Displacement Motor 40 13 Exploded View of the Variable Displacement Motor n 40 17 Major Repair Variable Pump us 61 1 elc 61 1 Disassembly Procedures for
43. l the piston seal rings in the piston grooves over the expander O rings Do not stretch the seal rings any more than necessary when install ing Lubricate the seal rings and carefully slide the servo piston into the servo cylinders Allow the assembly to set for at least 5 minutes to allow the seal rings to return to their original unstretched size Then re move the servo cylinders Compress the cylinder block spring and remove the spiral retaining ring retainer spring and spring seat Reassemble in the reverse order i Fig 61 52 Roll Pin 90000203 Fig 61 51 Roll Pin and Washer Installed and Washer Dimension 90000204 90000141 Fig 61 53 Install Fig 61 54 Install Servo Piston Seal Servo Piston Seal Expander Ring Ring oe Fig 61 55 Cylinder Block Spring Components 61 11 SAUER SUNDSTRAND x Axial Piston Pumps and Motors Series 90 Major Repair Variable Pump Continued Assembly Procedures for Variable Displacement Pump Clean and lightly oil all parts prior to assembly of the pump Be sure to torque all threaded parts to recom mended torque levels CAUTION Most parts have critical high tolerance sur faces Caution must be exercised to prevent damage to these surfaces during assembly Protectexposed surfaces openings and ports from damage and foreign material Assemblethe piston assemblies intothe slipper guide Lubricate the slippe
44. linder blockand swashplate and lock in place with the flat washer under the swash plate Hold the cylinder block and swashplate assembly approximately 1 2 12 mm above the cradle bear ings Properly position the feedback link in the control opening Position the servo piston on the slider block taking care not to wedge the block The parts should slide freely Lower the cylinder block and swashplate assembly until the swashplate is properly located on the cradle bearings NOTE If an assembly tool was used to install the cylinder block and swashplate release and remove the pin The flat washer should fall through the shaft opening of the housing Hold the servo piston in position and install the servo cylinders NOTE Be sure to assemble the correct servo cylin der on each side of the housing For units equipped with an automotive control a spe cial servo cylinder is installed on the center ing assist spring side of the housing yp Fig 61 77 Install Cylinder Block and Swashplate pen 90000214 Fig 61 76 Install Cylinder Block and Swashplate 90000151 9 0148 000 Fig 61 78 Position Fig 61 79 Position Servo Piston and Slider Block Feedback Link 90000216 90000149 Fig 61 80 Lower Swashplate onto Bearings Fig 61 81 Install Servo Cylinders 61 15 SAUER G SUNDSTRAND Axial Piston Pumps and Motors 6 7 Series 90 Major Repair Variable Pump
45. n causing seri capacity A braking system redundant to ous injury This fluid may also be hot the hydrostatic transmission must there enough to burn Serious infection or reac fore be provided which is adequate to stop tions can develop if proper medical treat and or hold the system should the condi ment is not administered immediately tion develop Some cleaning solvents are flammable To Certain service procedures may require the avoid possible fire do not use cleaning vehicle machine to be disabled wheels solvents in an area where a source of igni raised off the ground work function discon tion may be present nected etc while performing them in order AlwaystestSeries 90 units priorto reinstall to prevent injury to the technician and by ing in order to verify correct function of standers controls and other systems 20 1 SAUER G SUNDSTRAND Axial Piston Pumps and Motors Tool Information 90000129 90000170 Fig 20 1 Removing Fig 20 2 Removing Journal Bearing PV Journal Bearing MF MV p 0 10 2 54 F A DIA 5 1 0 02 0 51 R l 90000134 90000188 Fig 20 3 Sizing Fig 20 4 Journal Journal Bearing in Bearing Sizing Arbor End Cap PV Dimensions 90000215 Rc Fig 20 5 Install Fig 20 6 Install Flat Assembly Tool PV Washer on Assembly Tool 20 2 Certain tools are helpful disassembling and as sembling Series 90
46. nd or original equipment manufacturers who have been adequately trained by Sauer Sundstrand to perform these repairs Per forming major repairs on the Series 90 products may affectthe unit warranty status thus the factory should be consulted prior to undertaking such repairs S mda Series 90 These repair procedures when used in conjunction with the Series 90 Service manual Bulletin BLN 9947 provide complete service and repair informa tion for the Series 90 products For Technical Information on Series 90 pumps and motors refer to BLN 10029 and BLN 10030 For Fluid Quality Requirements referto bulletin BLN 9887 or Publication SDF Id No 697581 Sauer Sundstrand provides a complete repair serv ice for its products Contact any Sauer Sundstrand Authorized Service Center for details Sauer Sund strand Authorized Service Center locations are listed in BLN 2 40527 or Publication SAW Id No 698266 90000015 Series 90 Variable Displacement Pump 90000016 Series 90 Fixed Displacement Motor SAUER SUNDSTRAND IJ Axial Piston Pumps and Motors Series 90 Safety Precautions When Series 90 units are used in vehicular Use caution when dealing with hydraulic hydrostatic drive systems the loss of hydro fluid under pressure Escaping hydraulic static drive line power in any mode of opera fluid under pressure can have sufficient tion may cause aloss of hydrostatic braking force to penetrate your ski
47. nufacture Name Plate U S A Production Name Plate German Production 40 1 SAUER SUNDSTRAND 6 re Axial Piston Pumps and Motors Series 90 Exploded View of the Variable Displacement Pump Continued BOS MOMB MOME PX OR xe MOMC A 90D E lt MOMS M74M M78M M77M 75 540 uo _M72M xc ccc NE P E C AN mim MIHG aT TTT M7MA M1HG 201 M1HH M1MC j THRU MIHK MIHL amp T001 T209 MIMD MIHM MIHN SS THRU N T222 MIME zn 55 9 m Jua Wu saan I amp i T T301 E 050 THRU T401 RON 7309 THRU Te EE T322 1409 2 OR T350 T422 T450 ca m MOHA MOHC 96 E MOHF MOHG g M0HH M0HJ MOHK MOHL M850 MOHM MOHN REF LA M830 M M84 gt 8 NI M820 MD REF 2 Z EARLY PRODUCTION 130 PUMPS ONLY 40 2 SAUER SUNDSTRAND 6 e Axial Piston Pumps and Motors Series 90 Exploded View of the Variable Displacement Pump Continued wa W74A W755 lt gt W756 gt WwP52 aN W753 W757 W756 W701 W755 2 W70A W754 W750 40 3 SAUER SUNDSTRAND 6 re Axial Piston Pumps and Motors Series 90 Exploded View of the Variable Displacement Pump Continued N15M 3 Don 2
48. oduction pumps do not have remov able hardened swashplate leveler spring seats Install the inner spring spacer washers if used Install a new side cover O ring Hold the swashplate leveler toward the end cap end ka venae Ed of the housing so the leveler will clear the side of the Fig 61 90 Leveler Fig 61 91 Install swashplate during side cover installation Install the Spring Seats Side Cover on side cover and swashplate leveler Installed Housing Install two 2 side cover screws with flat washers finger tight into the blind holes in the housing to hold the cover while checking the zero angle position of the swashplate m 90000156 Fig 61 92 Leveler Fig 61 93 Install Positioned on Two 2 Side Cover Swashplate Screws SAUER SUNDSTRAND x Axial Piston Pumps and Motors Series 90 Major Repair Variable Pump Continued If allthe parts which affect the zero angle setting are being reused rotate the side cover to align the marks on the cover and housing that were made at disas sembly Apply a force of 5 to 10 Ibsf 22 to 44 N to the swashplate levelerto ensure both arms are in contact with the swashplate Make sure the swashplate is properly located on its bearings Use a depth mi crometer to measure the distance from the end cap Fig 61 94 Fig 61 95 Rotate face of the housing to the outer edge of the swash Swashplate Position Side Cover to plate surface T
49. ow cut outs in the valve plate The arrows must point in the direction of pump rotation For example a right hand clockwise rotation pump must have the arrows pointing in the clockwise direction when viewed from the shaft end The photo on this page shows a valve plate installed for clockwise CW rotation 61 18 SAUER G SUNDSTRAND Axial Piston Pumps and Motors Major Repair Variable Pump Continued Install the two 2 long springs with inner springs if used on the swashplate leveler spring seats Install the short spring on the servo arm link Place new end cap gasket on the housing located by the alignment pins Take care not to bend or damage the end cap gasket during installation Lubricate the end cap journal bearing Install the hardened shims in the end cap pockets for the swashplate leveler springs Retain the shims with Pec 4 002 petroleum jelly Fig 61 98 Install Springs and End Cap Gasket Lower end cap onto housing while positioning the three 3 springs in their pockets in the end cap When properly installed the end cap will engage the alignment pins but the springs will hold the end cap 1 8 to 1 4 in 3 to 8 mm away from the housing Install the four 4 large end cap screws Fig 61 99 Install Leveler Spring Fig 61 100 Ins Fig 61 101 End NOTE If the pump will be equipped with an auxiliary End Cap mounting pad temporarily install two 2 of the large scr
50. p opening The swashplate and piston assembly will remain in the housing Remove the swashplate bearing cage link pin from the housing through the control opening NOTE Aflathead screw is usedasthe link pin in 042 frame size pumps It may be removed with a 3 mm internal hex wrench Remove the bearing cage locater link from the swash plate through the control opening Remove the swashplate and pistons through the housing side cover opening Disengage the servo arm from the slider block located in the servo piston as the assembly is removed Remove the servo piston and slider block from hous ing NOTE Units equipped with an automotive control have a threaded hole in one end of the servo piston for the centering assist spring assem bly For these units note the orientation of the servo piston in the housing Remove the swashplate cradle bearing cage Remove the bearing races The bearing races are a loose fit on two 2 locating pins in the housing 90000116 90000117 Fig 61 22 Remove Fig 61 23 Remove Servo Cylinders Cylinder Block ee 90000119 Fig 61 24 Remove Fig 61 25 Remove 90000118 Bearing Cage Link Bearing Cage Pin Locator Link 1 1 90000120 90000121 Fig 61 26 Remove Fig 61 27 Remove Servo Piston and Slider Block Swashplate and Pistons 90000123 90000124 Fig 61 28 Remove Fig 61 29 Remove Swashplate Bearing Swashplate Bearing Cage Races 61 5
51. r drying is usually adequate As with any precision equipment all parts must be kept free of foreign materials and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material S Series 90 During the assembly of the Series 90 fixed motor all surfaces which have relative motion between two parts should be coated with a film of clean hydraulic oil This will assure that these surfaces will be lubri cated during start up It is recommended that all O rings and gaskets be replaced Lightly lubricate all O rings with clean pe troleum jelly prior to assembly All gasket sealing surfaces must be cleaned prior to installing new gaskets Valve Plate Piston Roller Bearing I J s I Output Shaft E _ Loop Flushing Valve edis oom MER J b _ E Cylinder Block Fixed Swashplate 90000190 Fig 62 1 Cross Section View of Series 90 Fixed Displacement Motor 62 1 SAUER G SUNDSTRAND Axial Piston Pumps and Motors Major Repair Fixed Motor Continued 90000187 Fig 62 2 Motor Positioned on End 90000164 Fig 62 3 Remove Shaft and Bearing 20000225 Fig 62 4 Remove Bearing from Shaft i 90000165 Fig 62 5 Remove Longer End Cap Screws E 50000188 Fig 62 6 Remove Shorter End Cap Screws 90000184 Fig 62 7 Remov
52. r running surfaces Center the pistons and guide on the swashplate NOTE Later production pumps use a fixed clear ance hold down mechanism Earlier produc tion 055 075 and 100 frame size pumps use a spring loaded hold down mechanism Ser 90000127 90000135 vice parts for the spring loaded hold down Fig 61 56 Install Fig 61 57 Position mechanism are no longer available If hold Piston Assemblies Pistons and Guide down parts require replacement on these into Slipper Guide on Swashplate earlier production units the fixed clearance hold down mechanism must be installed Refer to the appropriate Service Parts Man ual for more information Assemble one half of the fixed clearance hold down mechanism as follows Position two 2 spacers over the threaded holes in the swashplate as shown Position the slipper guide bearing on top of the spacers and slipper guide CAUTION The split between the slipper guide bearing i 90000205 0000206 plates must be located in line with the swash Fig 61 58 Position Fig 61 59 Position plate arm The bearing surface of the bearing Spacers Guide Bearing plates must be located next to the guide 61 12 SAUER G SUNDSTRAND Axial Piston Pumps and Motors Series 90 Major Repair Variable Pump Continued Install two 2 new screws with locking compound and flat washers through the slipper guide bearing and spacers Finger tighten the screw
53. s into the swashplate NOTE Inspect the flat washers for raised edges or burrs The smooth side of the flat washers must be installed next to the slipper guide bearing CAUTION Always use new screws with proper locking compound Assemble the other half of the fixed clearance hold down mechanism in a similar manner Assemble one half of the spring loaded hold down mechanism as follows Lubricate the slipper guide bearing and position it on top of the slipper guide CAUTION The split between the slipper guide bearing plates must be located in line with the swash plate arm The bearing surface of the bearing plates must be located next to the slipper guide Position two 2 spacers in the holes of the guide bearing and over the threaded holes in the swash plate as shown Position two 2 flat washers on top of the spacers Position two 2 leaf springs on top of the washers Position two 2 spring aligners on top of the leaf springs Install two 2 new screws with locking compound through the spring aligners leaf springs flat washers and spacers Finger tighten the screws into the swashplate CAUTION Always use new screws with proper locking compound Assemble the other half of the spring loaded hold down mechanism in a similar manner 90000136 90000137 Fig 61 60 Install Screws and Flat Washers Fig 61 61 Fixed Clearance Hold Down Assembled 90000207 90
54. screw is positioned at a height distance H of 0 178 to 0 188 in 4 53 to 4 79 mm from the ma chined surface of the pump housing CAUTION Always use a new screw with proper locking compound Do NOT torque this screw against the locator link The link MUST rotate freely Push the swashplate assembly toward the control side of the housing until the swashplate guide con tacts the bearing race Check for clearance between the servo arm and the slider block If no clearance is present recheck the assembly of the bearing cage and races Position the swashplate leveler T Bar on the side cover Note the orientation of the leveler and the cover Pec SAUER SUNDSTRAND x Axial Piston Pumps and Motors Series 90 Major Repair Variable Pump Continued For units with leveler guide posts install the two 2 guide posts and sealing nuts Torque to 6 7 lbsfeft 9 0 Nm for 030 and 042 pumps 17 lbsfeft 23 Nm for 055 thru 100 pumps or 32 Ibsfeft 54 Nm for 130 pumps For 130 frame size units with leveler guides install the guides onto the side cover Install the four 4 locking screws holding the guides to the side cover Torque to 6 7 lbsfeft 9 0 Nm 90000154 90000219 NOTE If the screw holes in the side cover are thru Fig 61 88 Install Fig 61 89 Install coated with sealing compound Nuts Post Type Screws Guide Type Install the leveler spring seats NOTE Earlier pr
55. shortened bearing life End Cap Typical NOTE The charge pump shaft bushing in the end cap may be replaced in a similar manner to the drive shaft journal bearing Certain frame size pumps with twin port end caps may have the servo relief valves and rotation plugs located in a removable rotation block Remove the rotation blockscrews with a5 mm internal hex wrench and remove the block and gasket For pumps with pressure limiter function except units with automotive control remove the servo relief valves from the end cap or rotation block with a screw driver For pumps with pressure limiter defeat and or auto motive control remove the servo relief passage plug s from the end cap or rotation block with a 3 16 in i internal hex wrench Fig 61 40 030 Pump Twin Port End Cap Note the position of the rotation pipe plugs and remove them from the end cap or rotation block with a 1 8 in internal hex wrench Install the servo relief valves or relief valve passage plugs into the end cap or rotation block as shown in the accompanying illustrations and chart NOTE Pumps with pressure limiter function except those units with automotive control MUST have servo relief valves installed in the end cap or rotation block to limit servo pressures Install the rotation pipe plugs into the end cap or rotation block as shown in the accompanying illustra tions and chart Fig 61 41 042 Pump Twin Port End Cap 61 7 SAUE
56. the housing on the end cap face with soft material between end of housing and work table so the thrust plate will not be damaged when it is freed from housing Entering thru the shaft end of the housing using a brass rod carefully apply a force to the I D of the thrust plate and disengage from the housing 90000167 90000168 Fig 62 8 Remove Fig 62 9 Thrust Thrust Plate from Plate Removed Housing Remove the end cap gasket from the end cap Remove the hold down tube with the slipper guide and piston assemblies from the end cap and cylinder block 90000182 90000169 Fig 62 10 Remove Fig 62 11 Remove End Cap Gasket Tube with Slipper Guide and Pistons Remove the slipper guide and piston assemblies from the hold down tube Remove the slipper guide bearing 90000226 90000227 Fig 62 12 Remove Fig 62 13 Remove Slipper Guide and Slipper Guide Pistons Bearing Remove the slipper guide bearing shim if used y Remove the cylinder block from the end cap 90000179 90000228 Fig 62 14 Remove Fig 62 15 Remove Slipper Guide Cylinder Block Bearing Shim 62 3 SAUER G SUNDSTRAND Axial Piston Pumps and Motors Major Repair Fixed Motor Continued 90000174 90000127 Fig 62 16 Remove Fig 62 17 Remove Pistons from Slipper Guide Valve Plate 90000170 90000171 Fig 62 18 Remove Fig 62 19 Install Journal Bearing Journal Bearing in from End Cap End Cap
57. with flat washers on later production units using a 10 mm hex wrench for 042 pumps a 13 mm hex wrench for 055 thru 100 pumps or a 17 mm hex wrench for 130 pumps Remove side cover and swashplate leveler T Bar assembly from housing 2236 90000111 90000112 NOTE Certain units equipped with dual swashplate Fig 61 12 Remove Fig 61 13 Remove leveler springs have spacer washers on the Side Cover Screws Side Cover leveler spring seats They may be removed at this time 61 3 SAUER SUNDSTRAND x Axial Piston Pumps and Motors Series 90 Major Repair Variable Pump Continued Remove spring seats from swashplate leveler NOTE Earlier production pumps do not have remov able hardened spring seats 90000194 90000195 Fig 61 14 Remove Fig 61 15 Remove Leveler Spring Seats Leveler Spring Seats Post Type Guide Type For units with leveler guide posts remove the two 2 guide posts and sealing nuts holding the leveler to the side cover Use a 17 mm open end wrench and a 10 mm hex wrench on 030 and 042 frame size pumps Use a 3 4 in open end wrench and a 13 mm hex wrench on 055 075 and 100 frame size pumps Use a 24 mm open end wrench and a 17 mm hex wrench on 130 frame size pumps Remove swashplate leveler from side cover Remove the side cover O 90000196 ring Fig 61 17 Remove a us Z 3 9000011 Fig 61 16 Remove Leveler Post Seal Leveler
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