Bent Axis Variable Motors Repair Instructions Series 51
Contents
1. Install the synchronizing shaft rollers item C50 on the journals of the synchronizing shaft item C60 and retain with grease The recess on each roller MUST be positioned to face the centerline of the synchronizing shaft 4 Position each roller with its outside edge flush with the end of the synchronizing shaft journal A install the second synchronizing shaft support pin item C40 into the motor shaft assembly and retain with grease Install the synchronizing shaft and rollers into the motor shaft The cylinder block end of the shaft is larger than the motor shaft end on all frame sizes C60 C50 The rollers must enter the races in the motor shaft insert and the recess in the end of the synchroniz ing shaft must engage the support pin Tip and rotate the synchro KL O24 nizing shaft in all directions DES to check for binding The synchronizing shaft rollers must move freely in the races in the motor shaft insert WU SAE Flange Version Cartridge Version UV Series 51 MV Repair Instructions BLN 10044 August 30 1993 Page 16 o Major Repair Instructions Assembly SAUER SUNDSTRAND 4 5 Position the motor shaft in the housing as After the six 6 pistons enter their bores tilt th shown in the accompanying illustration Tip the cylinder block so the synchronizing shaft rollers three 3 pistons closest to the minimum angle item C50 enter their races in the2. SAUER SUNDSTRAND Series 51 Variable Motors Repair Instructions SAUER SUNDSTRAND ow B LN 1 0044 Series 51 MV Repair Instructions Original Ersatzteile Page 2 Safety Precautions When Series 51 units are used in vehicular hydro static drive systems the loss of hydrostatic driv eline power in any mode forward reverse or neutral mode of operation may cause a loss of hydrostatic braking capacity A braking system redundant to the hydrostatic transmission must therefore be provided which is adequate to stop and hold the system should the condition de velop Certain service procedures may require the ve hicle machine to be disabled wheels raised off the ground work function disconnected etc while performing them in order to prevent injury to the technician and bystanders Use caution when dealing with hydraulic fluid under pressure Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury This fluid may also be hot enough to burn Serious infection or reactions can develop if proper medical treat ment is not administered immediately Some cleaning solvents are flammable To avoid possible fire do not use cleaning solvents in an area where a source of ignition may be present 6 VY August 30 1993 VY Series 51 MV Repair Instructions cole BLN 10044 August 30 1993 Ersatztelle Page 3 o
3. segment The segment spindle must X pattern while rotating the motor shaft to engage the bearing in the cylinder block ensure proper positioning of the synchro DO NOT ALLOW THE PISTONS OR nizing shaft rollers DO NOT FORCE THE SYNCHRONIZING SHAFT ROLLERS TO END CAP INTO POSITION ON THE FALL OUT OF POSITION HOUSING Install the screws items G32 and G34 When the end cap is in position torque the retaining the end cap assembly to the screws in a double X pattern as indi motor The screws must be installed in cated in the following table their proper locations to ensure adequate Frame size Torque Nm bsfeft thread engagement The internal spring in Eee 66 49 the motor shaft should hold the end cap 78 58 away from the housing a short distance 115 85 135 100 213 157 End cap assembly with valve segment 1 9 Double X Pattern Torquing Sequence 110 Frame Size with Side Port Endcap shown Rotate the motor shaft and check for play between the shaft and cylinder block Any play indicates that the synchro nizing shaft rollers are NOT installed correctly Recheck the end cap screw torque Reinstall the minimum angle servo cover control springs if used 4 way valve spool and sleeve if used and control and multi function block if used Refer to the Series Cartridge Version similar 51 Service Manual for details Series 51 MV Repair Instructions S SAUER G sunpsrrano ceras BLN 10044 August 30 19
4. L80 L70 Remove shaft seal Remove screws item L70 retaining KS L35 bearing housing item L35 to main hous ing item B10 Separate bearing housing ES from main housing co Remove O rings items L85 and L90 L90 L85 shaft Assembly Remove spacer ring item L95 Note orientation L95 Press shaft assembly out of bearing hous ing taking care to not damage the shaft piston sockets and speed sensor ring if installed The inner retaining ring item L80 for the shaft seal carrier may be removed from the bearing housing at this time B10 uga SAUER SUNDSTRAND Major Repair Instructions Disassembly Series 51 MV Repair Instructions BLN 10044 August 30 1993 Page 7 uga 3 mm int hex wrench 060 Int hex wrench 060 3 8 in 080 9 16 in Typical for 060 and 080 Frame Sizes 3 3 mm int hex wrench 060 H F30 F28 060 A F26 F10 F12 For 060 Frame Size remove end cap plug item G80 Re move lock screws item F28 and cone point set screws item F26 F26 Remove feedback fork F24 F28 item F30 thru hole in end cap 060 Remove setting lug item F24 from inside of end cap F24 080 F10 F12 For 080 Frame Size remove end cap plug item G80 Remove lock screw item F28 F26 and cone point set screw item F28 F26 Remove feedback fork setting lug item F24 thru hole in end cap F10 F12 For 110 thru 250 Frame Sizes remove lock screw item F28 a
5. cylinder stop out toward the housing block and the support pin enters its recess in With the synchronizing shaft supported in the the synchronizing shaft motor shaft install the cylinder block and its Lift the cylinder block slightly and guide the synchronizing shaft support pin item C40 onto remaining three 3 pistons into their bores the pistons and synchronizing shaft The cylin After the last piston is in position check the der block must be positioned so the synchroniz position of the rollers closest to the minimum ing shaft rollers will enter their races in the angle stop Maintain an inward force on the block while each piston enters its correspond cylinder block and carefully push it toward the ing bore in the block highest part of the end cap mounting surface A brass rod may be inserted through the cylin and check that all of the synchronizing shaft der block kidneys to guide the pistons into rollers are in position position Start with the six 6 pistons closestto Ifthe cylinder block is properly installed there the lowest part of the end cap mounting sur will be very little rotational free play between face the block and the motor shaft y Lubricate the pistons and cylinder y block bores with hydraulic oil ab Position the motor shaft as shown prior to installing the cylinder block Pistons View in Direction Y Cylinder Block not installed SAE Flange Version shown C
6. with end cap and housing Note orientation of pins a T gt p Note orientation of rollers with synchronizing shaft recess faces the centerline of the shaft and synchronizing shaft with cylinder block and output shaft C05 Note locations of longer and shorter screws Int hex wrench 060 and 080 8mm 110 and 160 10 mm 290 12mm Q20 End Cap Assembly Side Port configuration for 110 160 Geo amp 250 Frame Sizes shown P B50 Pa Nu Optional P 4 mm int O hex wrench Ne A Q RE Ww SAE Flange Version uga Series 51 MV Repair Instructions SAUER SUNDSTRAND a ae Page 5 Major Repair Instructions Disassembly 2A SAE Flange Version Remove screws item L70 retaining flange item L35 to main housing item B10 Remove flange using a suitable puller Remove O ring item L50 and shaft seal item L40 from the flange Press shaft assembly out of main housing taking care to not damage the shaft and speed sensor ring if installed DO NOT DAMAGE PIS TON SOCKETS L50 Refer to Service Manual for seal removal Int hex wrench 060 amp 080 6mm 110 8mm 160 10 mm 250 12mm L35 ooo Series 51 MV Repair Instructions SAUER SUNDSTRAND a Tae Page 6 Major Repair Instructions Disassembly 2B Cartridge Version Refer to Service Manual Int hex wrench 060 amp 080 6 mm for seal removal 110 8mm 160 10 mm gt
7. 93 peaisii Page 19 Major Repair Instructions Exploded View Applies to the indicated frame size s F10 F24 F28 110 160 10 8 7 060 F24 F42 110 E Q10 080 250 F30 Fj2 amp F26 060 060 GQ 060 S F24 060 080 110 250 i F28 080 110 180 250 OR G10 F26 LR W Side Ports 080 110 a 180 250 frame size 060 and 080 only SAUER SUNDSTRAND Hydraulic Power Systems SAUER SUNDSTRAND Hydraulic Power Systems Market Leaders Worldwide SAUER SUNDSTRAND is a world leader in the design and manufacture of Hydraulic Power Systems Research and development resources in both North America and Europe enable SAUER SUNDSTRAND to offer a wide range of design solutions utilizing hydraulic power system technology Heavy Duty Axial Piston Pumps and Motors O ii tg Medium Duty Axial Piston Pumps and Motors Open Circuit Axial Piston Pumps Worldwide Service Support SAUER SUNDSTRAND provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers strategically located in all parts of the world SAUER SUNDSTRAND COMPANY 2800 East 13th Street Ames IA 50010 U S A SAUER S SUNDSTRAND Phone 513 239 6000 FAX 515 239 6618 TWX 9105201150 BLN 10044 July 1993 Heavy Duty Bent Axis Variable Motors Microcontrollers and Electrohydraulic Controls SAUER SUNDSTRAND specializes
8. Ibsfeft flange item L35 Install new seal 250 174 Nm 128 Ibsfeft item L40 in flange ney y Sla L40 F j Refer to Service Manual for seal installation Install and torque screws item L70 Lubricate seal lip with grease am CD CD gt CD CD T L35 mS L50 shaft Assembly Housing supported in press Side View Series 51 MV Repair Instructions SAUER SUNDSTRAND a Tae Page 14 Major Repair Instructions Assembly 3A Cartridge Version uga The inner retaining ring item L80 for the shaft seal carrier may be installed in the bearing housing at this time Press shaft assembly into bearing housing item L35 DO NOT DAMAGE THE PISTON SOCK ETS OR SHAFT SEAL SURFACE Install spacer ring item L95 The end of the spacer with the larger inside diameter is installed next to the inner shaft bearing Cup Install O rings items L85 and L90 and install main housing item B10 Install and torque screws item L70 VAT SIE Torque 060 amp 080 32 Nm 24 lbsfeft 110 63 Nm 46 Ibsfeft 160 110 Nm 81 Ibsfeft Refer to Service Manual for seal installation Series 51 MV Repair Instructions SAUER SUNDSTRAND a ae Page 15 Major Repair Instructions Assembly 4 uga Install the first synchronizing shaft support pin item C40 into the Cylinder recess in the cylinder block and Block em retain with grease
9. Major Repair Instructions General CAUTION DISCLAIMER OF LIABILITY These repair instructions are provided for technicians who have been trained by Sauer Sundstrand in the SAUER SUNDSTRAND repair of Sauer Sundstrand Series 51 motors Sauer Sundstrand recommends that any repairs be performed by Sauer Sundstrand trained technicians Sauer Sundstrand expressly disclaims any liability for workman ship related failures resulting from repairs performed by any person using these instructions The procedures on the following pages are for the complete During the assembly of the Series 51 variable motor all disassembly and reassembly Major Repair of the Series surfaces which have relative motion between parts should 51 Variable Displacement Motors be coated with a film of clean hydraulic oil This will assure that these surfaces will be lubricated during start up Cleanliness is a primary means of assuring satisfactory hydraulic motor life on either new or repaired units Clean Itis recommended that all O rings and gaskets be replaced ing parts by using a clean solvent wash and air drying is Lightly lubricate all O rings with clean petroleum jelly prior usually adequate As with any precision equipment all to assembly All gasket sealing surfaces must be cleaned parts must be kept free of foreign materials and chemicals prior to installing new gaskets Protect all exposed sealing surfaces and open cavities from damage
10. and foreign material Refer to the Series 51 Bent Axis Variable Displacement Motors Service Manual for further information Multi function Block Pressure Compensator Minimum E Override Displacement Limiter Control Hydraulic Valve Segment T ou Proportional Shaft E Bearing Plat Tapered Roller Bearings A gt AN Ro 2 LAT RSR J RSR ER Sa i S EA 4 Way Valve DIR E S and Sleeve UWS ESINIYSOS Sauls Wy EE Vy IN OS D A 2 Control A EN raz Ge Springs xA prng EMY v S Synchronizing Oe 2100 Shaft and Rollers End Cap AN Housing Servo Piston AFS NU Cylinder S ee Charge Pressure Relief Valve Minimum Angle servo Cover Copyright 1993 Sauer Sundstrand Company All rights reserved Contents subject to change Printed in U S A 0893H Series 51 MV Repair Instructions SAUER SUNDSTRAND US Page 4 Major Repair Instructions Disassembly 1 Remove the control and multi function block if installed 4 way valve spool and sleeve if installed control springs if installed and minimum angle servo cover from the motor Refer to the Series 51 Service Manual for details Remove the screws items G32 and G34 retaining the end cap assembly to the motor housing Remove the end cap assembly gasket item G60 and alignment pins item B50 C10 Remove the internal motor parts as shown Note orientation of segment
11. artridge Version Similar Series 51 MV Repair Instructions SAUER SUNDSTRAND a ae Page 17 Major Repair Instructions Assembly 6 Install the bearing plate locating pins item Install the end cap alignment pins item C20 into the cylinder block The longer B50 and gasket item G60 Carefully end of each shouldered pin is installed into locate the cylinder block in the approxi the block Install the bearing plate item mate center of the housing opening DO C10 on the cylinder block with its steel NOT ALLOW THE PISTONS OR SYN side facing toward the block Lubricate the CHRONIZING SHAFT ROLLERS TO bronze side of the plate with hydraulic oil FALL OUT OF POSITION End Cap Typical Side Port configuration shown N U4 Optional B05 Torque 13 5 Nm 10 Ibsfeft Install the valve segment item B05 into the end cap so the segment spindle en gages the setting lug in the servo piston and retain with heavy grease The hole in the end of the segment should be installed opposite the minimum displacement ad justment screw Locate the valve segment p A and servo piston in the approximate center of their travel SAE Flange Version shown Un Cartridge Version similar uga Series 51 MV G Repair Instructions SAUER SUND STRAND BLN 10044 August 30 1993 Page 18 Major Repair Instructions Assembly 7 Install the end cap assembly and valve Tighten the screws by hand in a double
12. ed on this side of piston ring THE SPHERICAL SURFACE OF THE PISTON RING MUST PA CONFORM TO THE SPHERICAL SHAPE OF THE PISTON O Series 51 MV Repair Instructions BLN 10044 August 30 1993 Page 10 Major Repair Instructions Reconditioning and or Block bed 3 Bearing Plate Valve Segment and Cylinder Block Inspect the running bronze surface of the bearing plate item C10 for damage and excessive wear The sealing surfaces must be free from scratches and nicks The locating pin holes must not be worn Replace the bearing plate if damaged or worn Inspect the valve segment item B05 for damage or wear on the sealing surfaces Inspect the spindle for wear Check that the spindle is located correctly in the valve segment by measuring Distance A If this dimension is not within the range shown in the accompanying chart it indicates that the spindle has moved in the valve segment and the assembly must be replaced Distance A mm Ti 27 5 to 27 7 1 08 to 1 09 32 6 to 32 8 1 28 to 1 29 34 5 to 34 7 1 36 to 1 37 39 4 to 39 6 1 55 to 1 56 44 2 to 44 4 1 74 to 1 75 Inspect the cylinder block assembly for wear or damage The piston bores must be smooth The bearing plate surface must be free from scratches or nicks and the holes for the bearing plate locating pins must not be worn The races for the synchronizing shaft rollers must not be worn Inspect the cylinder block bearing item C02 If it requ
13. he offset of the fork must be located away from the multi function block control end of the end cap Install the cone point set screw item F26 so that its point enters the groove in the feedback fork setting lug Do not tighten the set screw at this time For all Frame Sizes the feedback fork 060 or feedback fork setting lug 080 thru 250 MUST be positioned perpendicular to the setting piston for proper control spring operation A 26 9 mm 1 06 in diameter rod with the end machined perpendicular to its axis may be inserted through the valve sleeve bore in the end cap to align the fork while tightening the cone point set screw item F26 2 Lubricate with Hydraulic Oil lab BLN 10044 August 30 1993 Page 12 Multi function Block Control Torque the cone point set screw item F26 to 5 Nm 44 lbsfein After torquing the cone point set screw install and torque the lock screw item F28 Torque 080 110 160 250 8 19 Nm 14 lbsfeft F26 F26 Torque 5 Nm Torque 5 Nm 44 lbsfein 44 lbsfein 060 Frame Size Series 51 MV Repair Instructions SAUER SUNDSTRAND Aoa Page 13 Major Repair Instructions Assembly 3A SAE Flange Version Support the main housing item B10 so the bearing bore is vertical uga Press shaft assembly into main Torque housing 060 amp 080 32 Nm 24 Ibsfeft a 110 63 Nm 46 lbsfeft Install new O ring item L50 on L70 160 110 Nm 81
14. in integrating a full range of system components to provide vehicle designers with the most advanced total design system SAUER SUNDSTRAND is Your World Source for Controlled Hydraulic Power Systems Cartridge Motors Compact Wheel Drives Hydrostatic Transmission Packages Gear Pumps and Motors SAUER SUNDSTRAND GMBH amp CO Krokamp 35 Postfach 2460 D 24531 Neum nster Germany Telephone 04321 871 0 Telefax 04321 871 465 Telex 299776
15. ires replacement remove the bearing using a suitable puller DO NOT DAMAGE THE BEARING PLATE SURFACE OF THE CYLINDER BLOCK Press the new bearing into the cylinder block using a Suitable press pin Press the bearing into the cylinder block until it is located the proper distance below the bearing plate surface as indicated by Distance A in the following table Distance A mm in Diameter B mm in 3 0 to 3 5 0 12 to 0 14 25 97 1 022 11 5 to 12 0 0 45 to 0 47 27 97 1 101 SAUER SUNDSTRAND 13 5 to 14 0 0 53 to 0 55 31 96 1 258 14 5 to 15 0 0 57 to 0 59 34 96 1 376 18 5 to 19 0 0 73 to 0 75 41 96 1 652 Series 51 MV Repair Instructions saver SUNDSTRAND aa ie Page 11 Major Repair Instructions Assembly 1 For all Frame Sizes carefully install a new glide ring item F10 on the servo piston item F12 Lubricate the glide ring and install the servo piston into the end cap item G10 The end of the servo piston with the glide ring is located opposite the multi function block control mounting surface of the end cap Lubricate with Hydraulic Oil okip Oo F30 Torque 060 5 Nm 44 lbsfein 0 060 Torque 060 8 5 Nm 75 Ibsfein F12 Torque 060 54 Nm 40 Ibsfeft anse OX 080 95 Nm 70 lbsfein Block Control G80 F24 j F26 IN SF G80A 060 F28 D uga XSI A iY CO Groove For 060 Frame Size i
16. nd cone point set screw item F26 Remove feedback fork setting lug item F24 from inside of end cap F26 F28 110 160 250 For all Frame Sizes remove servo piston item F12 from end cap item G10 Inspect glide ring item F10 for damage or wear Remove glide ring from servo piston if re placement is required Inspect servo piston bore in end cap for damage or wear Axial port style shown 5 mm int hex wrench 080 5 mm int hex wrench 110 160 250 4 mm mm int hex wrench used for very early production motors Typical for 110 160 and 250 Frame Sizes side port style shown Series 51 MV Repair Instructions SAUER SUNDSTRAND August 30 1993 age 1 Shaft Assembly The optional magnetic speed sensor ring item W10 is pressed onto a machined surface of the output shaft flange DO NOT DAMAGE THE MAGNETIC SPEED SENSOR RING Check the seal area of the shaft item L110 and the output splines for damage Or wear W10 L84 Major Repair Instructions Reconditioning and rep acemeng Inspect the synchronizing shaft insert item L140 and the spring seat item L120 for wear The internal spring item L130 must not be damaged These parts are retained by three 3 hardened steel pins item L150 pressed into blind holes in the synchronizing shaft insert and are not W individually serviceable L1XX gt Inspect shaft bearings items L10 and L20 for wear a
17. nd roughness Check that the bearing retaining nut item L60 is firmly staked to the output shaft and that no noticeable looseness is present in the bearings IF THE BEARING ADJUSTMENT FOR USED BEARINGS IS INCORRECT OR IF USED BEARINGS MUST BE REPLACED A COMPLETE SHAFT ASSEMBLY item L20 LOXX INCLUDING PISTONS AND NEW BEARINGS MUST BE INSTALLED Check the piston assemblies Item L84 for damage or wear It is normal for the piston balls to be tight in their sockets The piston sockets are retained in the output LOXX L30 shaft by an interference press fit L10 IF A PISTON OR PISTONS MUST BE REPLACED A COMPLETE SHAFT AS L60 SEMBLY item LOXX INCLUDING PIS TONS AND NEW BEARINGS MUST BE INSTALLED The replacement output shaft assembly item LOXX includes pistons and bear Ings Series 51 MV Repair Instructions SAUER SUNDSTRAND e August 30 1993 age Major Repair Instructions Reconditioning and Replaceme 2 Piston Rings A small pair of retaining ring pliers may facilitate the re gt Te eae moval of the piston rings Item L230 from the pistons ose Install new piston rings onto the pistons WHEN INSTALLING NEW SPHERICAL PISTON RINGS MAKE SURE THE SPHERICAL SURFACE CONFORMS TO THE SHAPE OF THE PISTON A radial identification mark is provided on the outer side of the piston rings The ends of each piston ring must NOT overlap each other Radial identification mark locat
18. nstall setting lug item F24 into the servo piston from inside of end cap Install the cone point set screw item F26 so that its point enters the groove in the setting lug and torque Install and torque the lock screw item F28 Install the feedback fork Item F30 into the servo piston thru the hole in the end cap The contact pads on the fork must face toward the multi function block control end of the end cap Install the cone point set screw so that its point enters the groove in the feedback fork Do not tighten the set screw at this time Install and torque the end cap plug item G80 End Cap Axial port style shown Typical for 060 and 080 Frame Sizes For 080 Frame Size install feed back fork setting lug item F24 into the servo piston thru the hole in the end cap The offset of the F24 fork must be located away from 080 the multi function block control F10 end of the end cap Install the cone point set screw item F26 so that its point enters the groove in the feedback fork setting lug Do not tighten the set screw at this time Install and torque the end cap plug item G80 Multi function Block Control Lubricate with Hydraulic Oil ib SAUER SUNDSTRAND Series 51 MV Repair Instructions Major Repair Instructions Assembly F10 For 110 thru 250 Frame Sizes install feedback fork setting lug item F24 into the servo piston from inside of the end cap T
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