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Series 51

Bent Axis Variable Motors Repair Instructions

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q When Series 51 units are used in vehicular hydrostatic drive systems, the loss of hydrostatic driveline 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 develop. q Certain service procedures may require the vehicle/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.

Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 2

August 30, 1993

Safety Precautions
q 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 treatment is not administered immediately. q 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.

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 3

August 30, 1993

Major Repair Instructions General

CAUTION DISCLAIMER OF LIABILITY These repair instructions are provided for technicians who have been trained by Sauer-Sundstrand in the 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 workmanship related failures resulting from repairs performed by any person using these instructions. The procedures on the following pages are for the complete disassembly and reassembly (Major Repair) of the Series 51 Variable Displacement Motors. Cleanliness is a primary means of assuring satisfactory 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. During the assembly of the Series 51 variable motor, all surfaces which have relative motion between 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. Refer to the Series 51 Bent Axis Variable Displacement Motors Service Manual for further information.

Multi-function Block Control (Hydraulic Proportional)

Pressure Compensator Override

Minimum Displacement Limiter Valve Segment Bearing Plate Tapered Roller Bearings Motor Output Shaft

4-Way Valve and Sleeve

Control Springs Synchronizing Shaft and Rollers

Piston

End Cap Servo Piston Cylinder

Housing 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

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 4

August 30, 1993

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). Remove the internal motor parts as shown.
Note orientation of segment with end cap and housing. C20 Note orientation of pins. Note orientation of rollers with synchronizing shaft (recess faces the centerline of the shaft), and synchronizing shaft with cylinder block and output shaft. C05 G32 Note locations of longer and shorter screws Int. hex wrench 060 and 080: 8 mm 110 and 160: 10 mm 250: 12 mm

B05

C10

G34

Q20 B50 G60 B50 U4 (Optional) 4 mm int. hex wrench

End Cap Assembly (Side Port configuration for 110, 160, & 250 Frame Sizes shown)

SAE Flange Version

Cartridge Version

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 5

August 30, 1993

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 PISTON SOCKETS!
Shaft Assembly B10

L50

Refer to Service Manual for seal removal.

L40

L35

L70

Int. hex wrench 060 & 080: 6 mm 110 : 8 mm 160: 10 mm 250: 12 mm

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 6

August 30, 1993

Major Repair Instructions Disassembly 2B Cartridge Version

Int. hex wrench 060 & 080: 6 mm 110 : 8 mm 160: 10 mm L70

Refer to Service Manual for seal removal.

L80

Remove shaft seal. Remove screws (item L70) retaining bearing housing (item L35) to main housing (item B10) Separate bearing housing from main housing. Remove O-rings (items L85 and L90).
L35

L90 L85

Shaft Assembly

Remove spacer ring (item L95). Note orientation. Press shaft assembly out of bearing housing, 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 L95

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 7

August 30, 1993

Major Repair Instructions Disassembly 3

3 mm int. hex wrench (060) F28 F26 F10 F30 (060) F12 3 mm int. hex wrench (060) Int. hex wrench: 060: 3/8 in 080: 9/16 in G80 G80A F26 F24 (060) F28 F24 (080) F12 G10

For 060 Frame Size, remove end cap plug (item G80). Remove lock screws (item F28) and cone point set screws (item F26). Remove feedback fork (item F30) thru hole in end cap. Remove setting lug (item F24) from inside of end cap.
F10

For 080 Frame Size, remove end cap plug (item G80). Remove lock screw (item F28) and cone point set screw (item F26). Remove feedback fork / setting lug (item F24) thru hole in end cap.
F10

F26 F28

End Cap (Typical for 060 and 080 Frame Sizes) Axial port style shown 5 mm int. hex wrench (080)

F12

For 110 thru 250 Frame Sizes, remove lock screw (item F28) and cone point set screw (item F26). Remove feedback fork / setting lug (item F24) from inside of end cap.

5 mm int. hex wrench (110, 160, 250) [4 mm mm int. hex wrench used for very early production motors.] G10

F26 F28 F24 (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 replacement is required. Inspect servo piston bore in end cap for damage or wear.

End Cap (Typical for 110, 160, and 250 Frame Sizes) Side port style shown

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 8

August 30, 1993

Major Repair Instructions Reconditioning and Replacement 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. 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 individually serviceable. Inspect shaft bearings (items L10 and L20) for wear and 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 L0XX) 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 shaft by an interference press fit. IF A PISTON (OR PISTONS) MUST BE REPLACED, A COMPLETE SHAFT ASSEMBLY (item L0XX) INCLUDING PISTONS AND NEW BEARINGS MUST BE INSTALLED. The replacement output shaft assembly (item L0XX) includes pistons and bearings.

W10

L84
L140

L150

L1XX

L120 L130 L110

L0XX

L20 L30

L10 L60

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 9

August 30, 1993

Major Repair Instructions Reconditioning and Replacement 2 Piston Rings

L230

A small pair of retaining ring pliers may facilitate the removal of the piston rings (Item L230) from the pistons. 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 located on this side of piston ring.

THE SPHERICAL SURFACE OF THE PISTON RING MUST CONFORM TO THE SPHERICAL SHAPE OF THE PISTON!

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 10

August 30, 1993

Major Repair Instructions Reconditioning and Replacement 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. Frame size Distance "A" mm [in] 060 27.5 to 27.7 [1.08 to 1.09] 080 32.6 to 32.8 [1.28 to 1.29] 110 34.5 to 34.7 [1.36 to 1.37] 160 39.4 to 39.6 [1.55 to 1.56] 250 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 requires 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: Frame size Distance "A" mm [in] Diameter "B" mm [in] 060 3.0 to 3.5 [0.12 to 0.14] 25.97 [1.022] 080 11.5 to 12.0 [0.45 to 0.47] 27.97 [1.101] 110 13.5 to 14.0 [0.53 to 0.55] 31.96 [1.258] 160 14.5 to 15.0 [0.57 to 0.59] 34.96 [1.376] 250 18.5 to 19.0 [0.73 to 0.75] 41.96 [1.652]

C10

B05

"A"

C02

C01

"B"

"A"

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 11

August 30, 1993

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 F30 Torque: (060) 5 Nm [44 lbsfin] F26 Torque: (060) 8.5 Nm [75 lbsfin] (060) F10 Torque: F12 (060) 54 Nm [40 lbsfft] (080) 95 Nm [70 lbsfin] Multi-function Groove Block / Control G80 F26 F24 (060) F28 For 060 Frame Size, install 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). G80A G10

End Cap (Axial port style shown) Typical for 060 and 080 Frame Sizes

For 080 Frame Size, install feedback fork / setting lug (item F24) into the servo piston thru the hole in the end cap. The 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. Install and torque the end cap plug (item G80).

F24 (080) F10 F12 Groove

Multi-function Block / Control

F26 Lubricate with Hydraulic Oil

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 12

August 30, 1993

Major Repair Instructions Assembly 2

Lubricate with Hydraulic Oil

F10
For 110 thru 250 Frame Sizes, install feedback fork / setting lug (item F24) into the servo piston from inside of the end cap. The 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.

F12 Groove

Multi-function Block / Control

F26

G10

F24 (110, 160, 250)

End Cap (Side port style shown) Typical for 110, 160, and 250 Frame Sizes

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).

Torque the cone point set screw (item F26) to 5 Nm [44 lbsfin]. After torquing the cone point set screw, install and torque the lock screw (item F28).

Torque: (080, 110, 160, 250) (M8) 19 Nm [14 lbsfft] (M10) 36 Nm [26.5 lbsfft]

Torque: (060) 8.5 Nm [75 lbsfin] F28

F26 Torque: 5 Nm [44 lbsfin] 060 Frame Size

F26 Torque: 5 Nm [44 lbsfin] 080, 110, 160, 250 Frame Sizes F28

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 13

August 30, 1993

Major Repair Instructions Assembly 3A SAE Flange Version

Support the main housing (item B10) so the bearing bore is vertical. Press shaft assembly into main housing. Install new O-ring (item L50) on flange (item L35). Install new seal (item L40) in flange. Install flange assembly. PROTECT SEAL LIP FROM DAMAGE! Install and torque screws (item L70).

L70

Torque: 060 & 080: 32 Nm (24 lbsfft) 110: 63 Nm (46 lbsfft) 160: 110 Nm (81 lbsfft) 250: 174 Nm (128 lbsfft) Refer to Service Manual for seal installation. Lubricate seal lip with grease.

L40

L35 L50

Shaft Assembly

B10

B10

19

Housing supported in press. (Side View)

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 14

August 30, 1993

Major Repair Instructions Assembly 3A Cartridge Version

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 SOCKETS 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).

B10

L85

L90 L95

Shaft Assembly

L35

Torque: 060 & 080: 32 Nm (24 lbsfft) 110: 63 Nm (46 lbsfft) 160: 110 Nm (81 lbsfft) L70 L80

Refer to Service Manual for seal installation.

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 15

August 30, 1993

Major Repair Instructions Assembly 4

Cylinder Block

Install the first synchronizing shaft support pin (item C40) into the recess in the cylinder block, and retain with grease. 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. Position each roller with its outside edge flush with the end of the synchronizing shaft journal. 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. The rollers must enter the races in the motor shaft insert, and the recess in the end of the synchronizing shaft must engage the support pin. Tip and rotate the synchronizing shaft in all directions to check for binding. The synchronizing shaft rollers must move freely in the races in the motor shaft insert.
SAE Flange Version Cartridge Version

C40

C50 C60 Q20 C40

C60

C50

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 16

August 30, 1993

Major Repair Instructions Assembly 5

Position the motor shaft in the housing as shown in the accompanying illustration. Tip the three (3) pistons closest to the minimum angle stop out, toward the housing. With the synchronizing shaft supported in the motor shaft, install the cylinder block and its synchronizing shaft support pin (item C40) onto the pistons and synchronizing shaft. The cylinder block must be positioned so the synchronizing shaft rollers will enter their races in the block, while each piston enters its corresponding bore in the block. A brass rod may be inserted through the cylinder block kidneys to guide the pistons into position. Start with the six (6) pistons closest to the lowest part of the end cap mounting surface. After the six (6) pistons enter their bores, tilt the cylinder block so the synchronizing shaft rollers (item C50) enter their races in the cylinder block, and the support pin enters its recess in the synchronizing shaft. Lift the cylinder block slightly and guide the remaining three (3) pistons into their bores. After the last piston is in position, check the position of the rollers closest to the minimum angle stop. Maintain an inward force on the cylinder block and carefully push it toward the highest part of the end cap mounting surface, and check that all of the synchronizing shaft rollers are in position. If the cylinder block is properly installed, there will be very little rotational free-play between the block and the motor shaft.

"Y"
Position the motor shaft as shown prior to installing the cylinder block.

Lubricate the pistons and cylinder block bores with hydraulic oil.

Cylinder Block

Pistons C40 C50 C60 C50

View in Direction "Y" (Cylinder Block not installed)

SAE Flange Version shown Cartridge Version Similar

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 17

August 30, 1993

Major Repair Instructions Assembly 6

Install the bearing plate locating pins (item C20) into the cylinder block. The longer end of each shouldered pin is installed into the block. Install the bearing plate (item C10) on the cylinder block, with its steel side facing toward the block. Lubricate the bronze side of the plate with hydraulic oil. Install the end cap alignment pins (item B50) and gasket (item G60). Carefully locate the cylinder block in the approximate center of the housing opening. DO NOT ALLOW THE PISTONS OR SYNCHRONIZING SHAFT ROLLERS TO FALL OUT OF POSITION!
G32

G34

End Cap (Typical Side Port configuration shown) U4 (Optional) Torque: 13.5 Nm [10 lbsfft]

B50 C10 C20 B50 G60

B05

Install the valve segment (item B05) into the end cap so the segment spindle engages 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 adjustment screw. Locate the valve segment and servo piston in the approximate center of their travel.

SAE Flange Version shown Cartridge Version similar

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Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

BLN-10044 Page 18

August 30, 1993

Major Repair Instructions Assembly 7

Install the end cap assembly and valve segment. The segment spindle must engage the bearing in the cylinder block. DO NOT ALLOW THE PISTONS OR SYNCHRONIZING SHAFT ROLLERS TO FALL OUT OF POSITION! Install the screws (items G32 and G34) retaining the end cap assembly to the motor. The screws must be installed in their proper locations to ensure adequate thread engagement. The internal spring (in the motor shaft) should hold the end cap away from the housing a short distance. Tighten the screws by hand in a "doubleX" pattern while rotating the motor shaft to ensure proper positioning of the synchronizing shaft rollers. DO NOT FORCE THE END CAP INTO POSITION ON THE HOUSING! When the end cap is in position, torque the screws in a "double-X" pattern as indicated in the following table: Frame size Torque Nm [lbsfft] 060 66 [49] 080 78 [58] 110 115 [85] 160 135 [100] 250 213 [157] 7 / 15
G32

End cap assembly with valve segment

3 / 11

2 / 10

5 / 13

G34

6 / 14

1/9 4 / 12 8 / 16 "Double-X" Pattern Torquing Sequence (110 Frame Size with Side Port Endcap shown)

SAE Flange Version shown Cartridge Version similar

Rotate the motor shaft and check for "play" between the shaft and cylinder block. Any play indicates that the synchronizing 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 multifunction block (if used). Refer to the Series 51 Service Manual for details.

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F24 F10 (110, 160, F30 F12 250) (060) (060) F28 (060) F26 (060) F24 (060)

Series 51 MV Repair Instructions

Genuine Parts Original Ersatzteile

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August 30, 1993

Major Repair Instructions Exploded View

(....) = Applies to the indicated frame size(s).
Q10 L35 L50 L40 L70 L0XX F10 F24 (080) F12 (080, 110, 180, 250)

F28 (080, 110, 180, 250) G10 (W/Side Ports) G34 G32

OR
F26 (080, 110, 180, 250) G60 B50

F26 (060) F28 (060) B10

Q030

U4XX

B50

W10

L60 (frame size 060 and 080 only) L30 Q20 C02 C20 C05
L110 L150

L10

L20

L70
L130 L120 L140

C10 B05

L1XX L0XX

L84

L230

L35
L0XX Q30

L95 L85 L90

B10

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BLN-10044 July 1993

SAUER-SUNDSTRAND COMPANY 2800 East 13th Street Ames IA 50010 U.S.A. Phone: (515) 239-6000 FAX: (515) 239-6618 TWX: 9105201150

SAUER-SUNDSTRAND GMBH & CO. Krokamp 35 Postfach 2460 D-24531 Neumnster Germany Telephone: (04321) 871-0 Telefax: (04321) 871 465 Telex: 299776