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Series 51
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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.
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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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Minimum Displacement Limiter Valve Segment Bearing Plate Tapered Roller Bearings Motor Output Shaft
Piston
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B05
C10
G34
End Cap Assembly (Side Port configuration for 110, 160, & 250 Frame Sizes shown)
Cartridge Version
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L50
L40
L35
L70
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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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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
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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W10
L84
L140
L150
L1XX
L0XX
L20 L30
L10 L60
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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.
THE SPHERICAL SURFACE OF THE PISTON RING MUST CONFORM TO THE SPHERICAL SHAPE OF THE PISTON!
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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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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).
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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
F26
G10
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]
F26 Torque: 5 Nm [44 lbsfin] 080, 110, 160, 250 Frame Sizes F28
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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
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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
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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
C60
C50
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"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
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G34
End Cap (Typical Side Port configuration shown) U4 (Optional) Torque: 13.5 Nm [10 lbsfft]
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.
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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)
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)
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F28 (080, 110, 180, 250) G10 (W/Side Ports) G34 G32
OR
F26 (080, 110, 180, 250) G60 B50
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
B10
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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. SAUER-SUNDSTRAND specializes 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.
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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