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Series 40 M25 Axial Piston Pumps and Motors Service Manual

1. 40 10 Exploded View of the M25 0 Style 40 11 Minor Repair and Replacement 5 s rete RE ex 50 1 CL e O 50 1 Minor Repair and Replacement Pumps and 50 2 Shaft Seal Replacement PV PT ttt entree nece 50 2 Trunnion Seal PV 7 PT Control Shaft Side 2 2 1 aee cet ectetuer eo eee na 50 3 Teunntorr Cover PV 7 iier etc tee 50 3 Check and High Pressure Relief Valves 2 22222444 200 dan ttn antt asse ned inn 50 4 Charge Pressure Relief Valves PM T uiii ELE EE ee EIU EE SEO nals 50 4 Easy Ride Valves PV xcs M 50 5 Auxiliary Pump Mounting Pad PV dan ee ER UR desis 50 5 Plug Fitting Torques PV PT PME able scene EYE HAE 50 6 M25 Variable Pump Tandem Pump and Fixed Motor Conversion Information 50 6 Shaft Seal Replacement niter ena ehe
2. Charge Check and Cooler Bypass Valve Charge Pump Trunnion Seal Shaft Seal Charge Check and High Pressure Filter Bypass Valve Relief Valves Filter Bypass Reverse Flow Check Valve U Style Transmission Charge Relief Valve Protect all exposed sealing surfaces and open cavi ties from damage and foreign material It is recommended that all gaskets and O rings 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 50 1 SAUER DANFOSS 5 Axial Piston Pumps Motors and Transmissions Series 40 M25 Minor Repair and Replacement Pumps and Motors 4 Fig 50 2 Remove Seal Carrier Retaining Ring PV PT MF Fig 50 3 Tapping Shaft with Soft Hammer to Remove Seal Carrier from Housing PV MF JE Fig 50 4 Shaft Seal Removed PV PT MF Pj Fig 50 5 Install Seal Carrier with O Ring PV PT MF 50 2 Shaft Seal Replacement PV PT MF Lip type shaft seals are used on the Series 40 M25 variable pump tandem pump and fixed motor These seals can be replaced without major disas sembly of the unit Replacement of the shaft seal generally requires removal of the pump from the machine Remove the retaining ring from the housing NOTE It may be necessary to hold inward pressure a
3. 62 1 Disassembly Procedures for Tandem 62 2 Reconditioning and Replacement of ek tnos 62 2 Assembly Procedures for Tandem PUMP c0ccesceccessscesecoceesecensesuccuesccneeseneneesssserecoeeesuseesensecenescnerseneenevessere 62 3 Major Repair Fixed MOton E EARE TaN 63 1 General 63 1 Disassembly Procedures for Fixed MOtOrF 5 2 tecto a tib dre cec 63 2 Reconditioning and Replacement of Parts 63 3 Assembly Procedures for Fixed dem 63 4 Major Repair U Style TransmissiOn oou itenim ners Ip ire ssa ri Po SR do 65 1 CIIM R 65 1 Disassembly Procedures for U Style Transmission 65 2 Reconditioning and Replacement of PANS isei erasana ieee api aaeeea aa eE aie EO ai EEE 65 4 Assembly Procedures for U Style Transmission 65 5 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Introduction The purpose of this manual is to provide information necessary for the servic
4. ee c a NERO E Rd eee na SERRE 50 7 Minor Repair and Replacement Style 50 7 TLr nnion Seal Cover Control Shaft SIde 1 eine rcnt ente sd ra eo 50 8 riae RS HII 50 8 Check and High Pressure Relief Valves este ead 50 9 Charge Pressure Relef Valve ocior ciii 50 9 Filter Bypass ae edet eie Gn eal 50 10 Heat Exchanger Bypass Vale REED 50 10 Filter Bypass Reverse Flow Check 50 11 Integral Charge PUMP E 50 11 Plugy Fitting Seco ne euS 50 13 M25 U Style Transmission Conversion 50 13 Major Repair Variable Purpose etse ce iir eet ein ae ive eniti t eat 61 1 General e P 61 1 Disassembly Procedures for Variable Displacement Pump seen ener 61 2 Reconditioning and Replacement of PAMS 61 4 Assembly Procedures for Variable Displacement 61 5 Major Tandem Pump iei cde die eene Erbe Ege ideas 62 1 General
5. 40250113 Cross Section View of Series 40 M25 Fixed Displacement Motor 63 1 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Major Repair Fixed Motor Continued Disassembly Procedures for Fixed Motor Prior to performing Major Repairs remove the exter nal components as described in the Minor Repair section Place the motor on a work surface with the end cap up Remove the four 4 screws item B41 that retain the end cap item E01 to the housing item G01 or item G02 Remove the end cap with the valve plate item B52 Do not allow the valve plate to fall from the end cap Remove the gasket item B37 from the housing Carefully remove the valve plate from the end cap It may be necessary to pry the valve plate off with a small screwdriver Remove the alignment sleeves item B40 from the end cap or housing CAUTION Caution must be exercised to prevent damage to the valve plate and end cap surfaces 63 2 7 Series 40 M25 Lay the motor on its side and remove the cylinder block assembly item B22 from the housing Remove the slipper guide item B36 and the piston assemblies item B32 from the cylinder block Using an O ring pick or wire remove the thrust plate item B21 from the housing Remove the retaining ring item 008 and remove the output shaft seal carrier item 007 with the seal item B02 Remove the O ring item 006 from the carrier Pres
6. E Fig 62 7 1 Tg nstall Valve Plate Pins Valve Plate 2 Fig 62 10 Install Fig 62 11 Center Section Assemble Rear Gasket Pump Section to Center Section 62 4 os Fig 62 8 Install Install the valve plate locating pins into the center section Coat the back steel side of the valve plates with petroleum jelly to hold them in position and install the valve plates onto the center section with the bronze face visible The notch on the valve plate must engage the locating pin Be certain the correct valve plate is installed on the center section for each pump section Refer to the appropriate Service Parts Manual for more information Since the tandem pump sections are mounted back to back each section will have a different valve plate installed A clockwise CW rotation unit will have a clockwise CW valve plate installed in the front section and a counterclockwise CCW valve plate installed in the rear section A counterclockwise CCW rotation unit will have a counterclockwise CCW valve plate installed in the front section and a clockwise CW valve plate installed in the rear section Install the four 4 alignment pins in the center sec tion Install a new rear pump housing gasket Assemble the rear pump section onto the center section with valve plate installed Align the drive coupling splines while assembling
7. 40250094 ove Fig 65 12 Components of Motor Shaft Assembly PTO Seal Guide E 40250096 Fig 65 13 Remove Fig 65 14 Remove Pump Shaft and Bearing 65 3 SAUER DANFOSS 5 Axial Piston Pumps Motors and Transmissions Series 40 M25 Major Repair U Style Transmission Continued Fig 65 15 Remove Fig 65 16 Remove Trunnion Covers Swashplate _ 40950100 Fig 65 17 Bearings Installed in Center Section Fig 65 18 Cylinder Block Spring Components 65 4 With a 3 8 hex wrench remove the tapping screws retaining the trunnion seal cover and trunnion cover to the housing Mark the position of the covers for reassembly Thetrunnion seal cover assembly includes an O ring lip seal and trunnion bearing on the control side The trunnion cover assembly includes an O ring and trunnion bearing on the side opposite the control Remove these parts from the housing Tilt and remove the swashplate from the housing Reconditioning and Replacement of Parts After disassembly all parts should be thoroughly cleaned in a suitable solvent Replace all O rings gaskets and seals Inspect all parts for damage nicks or unusual wear patterns Replace all parts having unusual or exces Sive wear or discoloration Cracks are not allowed in any surface of the valve plates or cylinder blocks The running and
8. 0ONNA RBS 00 ao HO7F H07G M10A M20A M10B THRU M10M M20B THRU M20M E01C E02C E01K E02K E01S FOIL FO2L FO1R FO2R 01 5010 N01 N02 N01 N02 N05 N06 Description SPRING HEL COMP 7 BAR 100PSI SPRING HEL COMP 14 BAR 200PSI POPPET CHECK VALVE POPPET CHECK VALVE VALVE RELIEF VALVE RELIEF SHAFT PUMP TAPERED KEY SHAFT PUMP STR KEYED KEY SQUARE SHAFT PUMP SPLINED 13T PLATE VALVE LH PLATE VALVE RH PLATE VALVE RH PLATE VALVE LH SHAFT VARIABLE 9T AUX DRIVE SHAFT VARIABLE 11T AUX DRIVE SWASHPLATE VARIABLE BEARING CARRIER ASSY SWASHPLATE VARIABLE BEARING TAPER ROLLER SHIM TRUNNION SPACER TRUNNION Qty 1 1 rmm i ie d mis ia SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Exploded View of the M25 Fixed Motor The following information is for general parts identi fication ONLY Refer to the applicable Service Parts List when ordering service parts Name Plate SAUER SAUERSUNDS Ames lowa U S A Neuminster Germany Model Code Typ MMF025C A A G A B NNN Model Number Serial Number A 9329 67890 Serial No Fabr Nr MADE IN U S A p CONTENTS Series 40 M25 ___ Model Code Place of Manufacture 40 SAUER DANFOSS Axi
9. 20 O Ring Fitting PV U 9 16 18 O Ring Fitting MF Tee into high press line PT M2 System 600 bar or 10 000 psi Gauge Pressure 7 16 20 O Ring Fitting PV U 9 16 18 O Ring Fitting MF Tee into high press line PT M3 Charge 60 bar or 1000 psi Gauge or Pressure Tee into Charge Supply PV PT E 7 16 20 O Ring Fitting U L1 Case 60 bar or 1000 psi Gauge L2 Pressure 7 8 14 O Ring Fitting PV PT 3 4 16 O Ring Fitting MF Vacuum Gauge Tee into Charge Pump Inlet Line NOTE Tandem pumps have two 2 additional sys tem ports in the rear section Snubbers are recommended to protect pressure gauges Frequent gauge calibration is necessary to insure accuracy M1 Test Port M2 Opposite 4 Left Side View Pressure Supply Fig 30 1 Gauge Connections Variable Pump Left Side View System Pressure Ports A Rear Front Charge Pressure Supply sis B Rear Bottom View _ Front Fig 30 2 Gauge Connections Tandem Pump System Ports Rear View Left Side View Fig 30 3 Gauge Connections Fixed Motor yas Charge Pump Inlet OR Bios To Cooler en Li OK From Cooler D Front View Fig 30 4 Gauge Connections U Style Transmission 30 1 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Start Up Procedure and Maintenanc
10. DANFOSS Axial Piston Pumps Motors and Transmissions CONTENTS Series 40 M25 Functional Description Continued The M25U transmission includes an integral pres sure filter mount on the transmission center section A filter bypass valve and a filter bypass reverse flow check valve are incorporated into the transmission center section CAUTION For the M25 U style transmission the charge pump inlet vacuum should not exceed 8 bar abs 5 in Hg except during cold starts For the M25 pumps refer to the specifications for the specific charge pump being used Since either of the main hydraulic lines can be at high pressure charge check valves are used to direct the charge supply into the low pressure side of the closed loop These check valves located in the tandem pump center section or transmission center section may also incorporate the high pressure relief valve function Any charge flow not being used for the closed circuit is discharged over a direct operating charge relief valve through the tandem pump or transmission housing and back to the system reservoir High Pressure Relief Valves Optional combination check high pressure relief valves may be provided in the variable pump end cap or tandem pump center section for overload protec tion Combination check high pressure relief valves are provided in the style transmission center section These cartridge type relief valves a
11. SAUER CONTENTS 6 DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Major Repair U Style Transmission Continued Pressthe ball bearing onto the pump shaft Install the pump shaft and bearing assembly into the housing Install the PTO seal guide and O ring into the hous ing Install the spiral retaining ring Fig 65 23 Install Fig 65 24 PTO Seal Pump Shaft and Guide Installed Bearing Press the inner bearing spacer and outer bearing onto the motor shaft EM S Fig 65 25 Install the motor shaft assembly into the housing Install the motor shaft bearing retaining pin into the housing P 40250094 i 40250106 Fig 65 26 Install Fig 65 27 Install Motor Shaft Bearing Retaining Assembly Pin Install the pipe plug over the motor shaft bearing retaining pin and torque to 11 to 13 Nm 6 to 10 lbsfeft Coat the thrust plates with petroleum jelly and install into the housing and swashplate The thrust plates are reversible Fig 65 28 Install Fig 65 29 Install Pipe Plug Thrust Plates 65 6 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions 5 Series 40 M25 Major Repair U Style Transmission Continued Assemble each cylinder block kit by installing the piston assemblies into the slipper guide Lubricate the pistons and cylinder block bores Install the assembled guide and pistons into the
12. SAUER 5 Series 40 Pumps Motors and Transmissions Service and Repair Manual SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Contents 0 2 System Circuit Piceno cen ck dat ee 10 1 Functional E 10 2 Technical Data Pumps Motors Style Transmission 10 6 Safety PFECAULOMS is 20 1 Gauge nstallatlon iier Pt m HERE HI OR utr iD eMe 30 1 Start Up Procedure and scu oio tia tne reir aeaaeai ve si Evo Lives 30 2 Component Inspections and Adjustments sa sca 30 3 30 5 Exploded View ofthe M25 aaa a TERR Rep dra eia 40 1 Exploded View of the M25 Variable Tandem nennen nnns 40 5 Exploded View of the M25 Flixed airaa aa a aTi 40 9 Exploded View of the M25 Flixed Motor
13. Retaining Ring 1 40 Fig 61 25 Instal Thrust Plate 250059 Fig 61 24 Install Shaft Seal Cover Fig 61 27 Install Cylinder Block Kit Fig 61 26 Install Piston Assemblies into Cylinder Block 61 6 Using an arbor press press a new Seal into the trunnion seal cover Be careful not to damage the seal For units with tapered roller type swashplate bear ings install the the trunnion shims into the housing next to the swashplate bearing cups and retain with petroleum jelly Locate the shims so that there is no more than 0 20 mm 0 008 in difference in shim thickness from one side of the swashplate to the other Install the trunnion bearing spacers Install the O rings and trunnion covers as described in the Minor Repair section of the Service Manual Install new hex head screws and torque to 15 to 20 Nm 11 to 15 ft Ibsf NOTE When units with tapered roller type swash plate bearings are properly assembled a torque of 0 56 to 2 26 Nm 5 to 20 Ibsfein will be required to rotate the swashplate Using caution to not damage the sealing surface press the ball bearing onto the drive shaft Install the bearing retaining ring onto the shaft Install the drive shaft and bearing into the housing Install the input shaft seal seal cover and O ring as described in the Minor Repair section of the Service Manual Install the retaining ring Coat the thrust plate with pet
14. Components Tapered Roller Bearings Fig 50 9 Torque Trunnion Seal Cover Screws PV PT 50 3 SAUER CONTENTS 6 DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Minor Repair and Replacement Pumps and Motors Cont Check and High Pressure Relief Valves PV PT Remove the check and high pressure relief valves with a 5 16 internal hex wrench Remove the valve cartridge assembly from the pump end cap or center section Inspect the valve and mating seat in the end cap or center section for damage or foreign material It will be necessary to 40250026 Fig 50 10 Remove Fig 50 11 Remove replace the end cap or center section if the seats are Check and Relief Check and Relief damaged Valve Plug PV Valve Plug PT The check poppet or relief valve is retained in the special plug by a circlip The poppet or valve and check valve spring may be removed from the special plug by pulling out at a slight angle When reassem bling install the check valve spring into the special plug with its larger diameter toward the plug and snap the poppet or valve into position in the plug Reinstall the valve cartridges with O rings into the center section Torque the plugs to 41 to 68 Nm 30 to 50 Ibsfeft Fig 50 12 Check and Relief Valve CAUTION Components PV PT The relief valves are factory set and should not be tampered with except for repl
15. Loctite High Performance Sealant 59231 prior to instal lation When reassembling units with tapered roller bearing trunnions install the bearing shims and spacer into the housing in their original order Install the O ring onto the housing and retain with petroleum jelly Lubricate the inside diameter of the new seal with petroleum jelly Wrap the end of the swashplate control shaft with thin plastic to prevent damage to the seal lip during installation Slide the seal cover assembly over the swashplate control shaft and onto the housing Install new hex head screws and torque to 15 to 20 Nm 11 to 15 lbsfeft Reinstall the control linkage onto the swashplate control shaft Trunnion Cover PV PT Plain The O ring under the plain trunnion cover may be replaced after removing the hex screws with a 7 16 or 1 2 hex wrench and the cover On units with tapered roller bearing trunnions the bearing spacer and shims may be removed from the housing after removing the trunnion cover When reassembling units with tapered roller bearing trunnions install the bearing shims and spacer into the housing in their original order Install the O ring onto the housing and retain with petroleum jelly Install the trunnion cover with the stamped identifica tion mark O out Install new hex screws and torque to 15 to 20 Nm 11 to 15 Ibsfeft Fig 50 6 Remove Trunnion Seal Cover PV Fig 50 8 Trunnion Cover
16. Motor Using caution to not damage the sealing surface press the ball bearing item 004 onto the output shaft item 001 Install the bearing retaining ring item 005 onto the shaft Install the output shaft and bearing into the housing item G01 or item G02 Install a new output shaft seal item 02 into the seal carrier item 007 Install a new O ring item 006 onto the seal carrier Install the seal carrier with seal and O ring into the housing PROTECT SEAL LIP FROM DAMAGE Installthe retaining ring item 008 Refer to the Minor Repair section for further information Assemble the piston assemblies item B32 into the slipper retainer item B36 Lubricate the pistons and cylinder block bores Install the assembled retainer and pistons onto the cylinder block by inserting the piston assemblies into the cylinder block bores The pistons and bores are not selectively fitted therefore no specific piston and bore orientation is required Lubricate the pistons and cylinder block bores 40250116 CONTENTS SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Major Repair Fixed Motor Continued The thrust plate item B21 is reversible Coat one 1 side of the thrust plate with grease or petroleum jelly to retain it in the motor housing and install into the Housing and housing Shaft Assembly Lay the motor housing on its side and install the assembled cylinder
17. NOTE The charge pressure supply port and system ports and on the center section are located next to the rear pump section When the sections are properly assembled the inder block spring will hold the center section away from the housing approximately 3 mm 1 8 in Install the four 4 screws and washers that retain the rear housing to the center section and torque evenly to 81 to 95 Nm 60 to 70 Ibfeft CAUTION Be certain all parts are properly aligned Do not force the center section or housing into posi tion SAUER DANFOSS CONTENTS Series 40 M25 Axial Piston Pumps Motors and Transmissions Major Repair Tandem Pump Continued Install a new front pump housing gasket and as semble the front pump section onto the assembled center and rear section Align the drive coupling splines while assembling When the sections are properly assembled the inder block spring will hold the center section away from the housing approximately 3 mm 1 8 in Install the four 4 screws and washers that retain the front housing to the center section and torque evenly to 81 to 95 Nm 60 to 70 Ibfeft Rotate the shaft to assure correct assembly When properly assembled a maximum torque of 9 5 Nm 7 lbsfeft should be required to turn the shaft Assemble the following components as described in the Minor Repair section Auxiliary Mounting Pad Cover Charge Relief Valve C
18. a suitable press pin When installed correctly the bearing cage will protrude from 2 0 to 2 5 mm 0 08 to 0 10 in from the surface of the center section to serve as a pilot for the valve plate CAUTION When installing the needle bearing the printed numbered end of the bearing cage must face the press pin Fig 62 5 Needle Bearing Installed in Center Section Tandem Pump Install the drive coupling into the center section Install the second needle bearing into the center section following the procedure outlined above PUN Fig 62 6 Drive Coupling in place Center Section for Installation of Second Needle Bearing Tandem Pump 402500 Assembly Procedures for Tandem Pump Clean and lightly oil 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 Protect exposed surfaces openings and ports from damage and foreign material Assemble the swashplate swashplate bearings drive shaft and cylinder block of each pump section using the procedures outlined in the Major Repair Vari able Displacement Pump section of this manual 62 3 SAUER DANFOSS 5 Axial Piston Pumps Motors and Transmissions Series 40 M25 Major Repair Tandem Pump Continued
19. block kit into the housing Coatthe back steel side of the valve plate item B52 with petroleum jelly or grease to hold it in position and install the valve plate onto the end cap item E01 with the bronze face visible The notch on the valve plate must engage the locating pin item B39 The motor valve plate is a bi directional valve plate Install the two 2 alignment sleeves item B40 and install a new gasket item B37 onto the housing Install the end cap with valve plate installed onto the housing Torque 54 Nm When the end cap is properly installed the cylinder 40 Ibsfeft block spring will hold the end cap away from the B41 housing approximately 3 mm 1 8 in Install the four 4 screws item B41 that retain the end cap to the housing and torque evenly CAUTION Be certain all parts are properly aligned Do not force the end cap into position on the housing Rotate the shaft to assure correct assembly When End Cap with properly assembled a maximum torque of 9 5 Nm 7 Valve Plat losfeft should be required to turn the shaft aive Assemble the external components as described in the Minor Repair section B52 Lubricate the 2 valve plate surface Gar with hydraulic oil Housing Shaft and Cylinder Block Assembly 40250117 63 5 SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Notes 63 6 SAUER DANF
20. connected directly to the swashplate Movement of the control shaft causes a proportional swashplate movement and change pump flow This control be located on either side of the unit CONTENTS Series 40 M25 A charge relief valve and charge check valves are included in the variable pump end cap and tandem pump center section to control the makeup and cooling oil flow for the system The charge check valves also incorporate the bypass valve function and high pressure relief valve function into their design The Series 40 M25 variable and tandem pumps do not have an integral charge pump They are equipped with an SAE auxiliary pad which may be used to drive a fixed displacement gear pump to provide charge flow and other services The Series 40 M25 fixed displacement motor also incorporates the parallel axial piston slipper design utilizing a fixed swashplate angle The Series 40 M25 U transmission incorporates a variable pump and a fixed motor in a common hous ing This unit includes a 5 98 cc rev 0 365 in rev integral gerotor type charge pump The transmission center section includes the charge pressure relief valve an oil cooler bypass valve a filter bypass valve and reverse flow check valve and the charge check high pressure relief valves HEAT EXCHANGER BY PASS RESERVOIR CYLINDER BLOCK ASSEMBLY VARIABLE DISPLACEMENT HIGH PRESSURE REL
21. cylinder block by inserting the piston assemblies into the cylinder block bores The pistons and bores are not selec tively fitted therefore no specific piston and bore orientation is required Lay the transmission housing on its side and install the cylinder block kits into the housing Place the transmission housing on a work surface with the center section opening up Install the valve plate locating pins into the center section Coat the back steel side of the valve plates with petroleum jelly to hold them in position and install the valve plates onto the center section with their bronze faces visible The notch on each valve plate must engage its locating pin A transmission set up for clockwise CW pump rotation will have a clockwise CW pump valve plate installed A counterclockwise CCW rotation unit will have a counterclockwise CCW pump valve plate installed Be certain the proper valve plate is used for the transmission input rotation Refer to the appropriate Service Parts Manual for more infor mation NOTE Since the pump cylinder block kit is located to the rear of the center section the appear ance of the valve plate will be similiar to that of the valve plate for the rear section of a tandem pump of the same rotation The motor valve plate is a bi directional valve plate Fig 65 31 Install id Cylinder Block Kits Fig 65 30 Install Piston Assemblies into Cy
22. cylinder block spring and remove the spiral retaining ring outer washer spring and inner washer Reassemble in the reverse order SAUER DANFOSS Axial Piston Pumps Motors and Transmissions CONTENTS Series 40 M25 Major Repair Variable Pump Continued Assembly Procedures for Variable Displacement Pump Clean and lightly oil parts prior to assembling 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 Protect exposed surfaces openings and ports from damage and foreign material Begin the assembly of the pump by installing the swashplate in the housing Make sure the swash plate control shaft is located on the correct side of the housing note the marks made during disassembly For units with journal type swashplate bearings in stall the bearings into the housing and onto the swashplate trunnions For units with tapered roller type swashplate bear ings install the bearing cones onto the swashplate trunnions and install the bearing cups into the hous ing If the housing swashplate or swashplate bearings were not replaced on units with tapered roller type swashplate bearings the original shims will be rein stalled between the bearing cups and the bearing spacers If any of these parts were replaced the following
23. sealing surfaces of the valve plates and cylinder blocks must be flat and free of nicks and burrs Replace valve plates or cylinder blocks that show evidence of metal transfer wear or erosion on the running surface If scratches which can be felt with a fingernail or pencil lead are found on the bronze surface of the valve plates or the running surface of the cylinder blocks polish or replace the parts Inspect the needle bearings in the center section If replacement is necessary remove the shaft needle bearings using a suitable puller Do not damage the Press new needle bearings into the center section using a suitable press pin When installed correctly the bearing cage will protrude from 2 3 to 2 8 mm 0 09to 0 11 in from the surface of the center section to serve as pilots for the valve plates CAUTION When installing the needle bearing the printed numbered end of the bearing cage must face the press pin Replace all piston assemblies if brass slippers are Scored or excessively rounded at the edges Compress the cylinder block spring and remove the spiral retaining ring outer washer spring and inner washer Reassemble in the reverse order 5 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Major Repair U Style Transmission Continued Assembly Procedures for U Style Transmis sion Clean and lightly oil parts prior to assembly of th
24. the machined surface of the end cap as indicated Inspect the needle bearing item B38 in the end cap item E01 If replacement is necessary remove the shaft needle bearing using a suitable puller Do not damage the valve plate surface of the end cap Press a new needle bearing into the end cap using a suitable press pin When installed correctly the bear ing cage will protrude from the machined surface of the end cap as indicated to serve as a pilot for the valve plate NOTE Wheninstalling the needle bearing the printed numbered end of the bearing cage should face the press pin Replace all piston assemblies if brass slippers are scored or excessively rounded at the edges Compress the cylinder block spring item B26 and remove the spiral retaining ring item B28 outer washer item B25 spring and inner washer Reas semble in the reverse order 3 05 to 3 55 mm B38 12 to 14 in B39 E01 2 0 to 2 5mm 08 to 10 in INSTALLED HEIGHT OF ITEMS B38 amp B39 B28 B25 lt D B26 Cylinder Block 40250115 63 3 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Major Repair Fixed Motor Continued Lubricate seal lip with grease Seal Carrier Assembly Shaft and Bearing Assembly G01 or 602 B32 B36 with hydraulic oil Cylinder Block 63 4 7 Series 40 M25 Assembly Procedures for Fixed
25. 0 51 mm 0 02 in below the surface of the seal counterbore in the front of the cover CAUTION When installing the needle bearing the printed numbered end of the bearing cage must face the press pin Install the gerotor drive pin in the groove in the drive shaft and retain with petroleum jelly Prior to assembly lubricate the gerotor assembly with clean hydraulic oil Install the gerotor assembly into the charge pump cover Install the O ring and retain with petroleum jelly NOTE The charge pump rotation is determined by the position of the charge pump cover on the transmission center section Installthe charge pump assembly over the drive shaft and onto the transmission center section orienting it forthe proper input shaft rotation direction Be certain the gerotor engages the drive pin in the shaft The flat on the charge pump cover should be located away from the heat exchanger ports for clockwise CW input rotation and next to the heat exchanger ports for counterclockwise CCW input rotation Torque the charge pump cover screws to 37 to 50 Nm 27 to 37 Ibsf ft Install a new shaft seal as outlined in the Shaft Seal Replacement section SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Minor Repair and Replacement U Style Transmission Continued Plug Fitting Torques If any plugs or fittings are removed from the unit during servicing th
26. 25 Variable Pump The following information is for general parts identi fication ONLY Refer to the applicable Service Parts List when ordering service parts 805 c 01 05 Mos Bg com M02 gt a 5 M208 9 gt THRU S06 RU E p S13A 512 S13D Name Plate SAUER 57 SAUERSUNDS Ames lowa U S A Neuminster Germany Model Code Typ MPV025C SRA 7 NN BAAA BDD Model Code DLAFF NNN Model Number ER er Serial Number A 9129 67890 Serial No Fabr Nr MADE IN U S A LLL Place of Manufacture 40 1 SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Exploded View of the M25 Variable Pump Continued N10 Noo 9 40 2 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions CONTENTS Series 40 M25 Exploded View of the M25 Variable Pump Continued Item B01 B02 B21 B22 B32 B36 B26 B25 B28 B37 B38 B39 B40 B42 B44 B45 B49 B50 B51 B52 B53 E04 E05 E06 E07 E08 H01 05 H06 H08 J01 M01 M02 M03 M04 M05 N07 N08 N09 N10 S14 15 S16 Description HOUSING VARIABLE SEAL LIP PLATE THRUST CYLINDER BLOCK KIT PISTON ASSY RETAINER SLIPPER SPRING WASHER RING RETAINING GASKET END CAP BEARING NEEDLE PIN ST HDLS PIN PLUG PLASTIC PLUG PLASTIC PLUG ST
27. AINING TRUNNION KIT SEAL SIDE TRUNNION KIT PLAIN TRUNNION KIT PLAIN TRUNNION KIT SEAL SIDE PLATE VALVE PUMP LH PLATE VALVE PUMP RH SHAFT MOTOR SPLINED 18T U SHAFT MOTOR SPLINED 17T U VALVE CHECK RELIEF Qty a a N A c A a ae 40 13 SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Notes 40 14 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Minor Repair and Replacement Trunnion Seal Auxiliary _ Shaft Seal Easy Ride Valves Charge Check and High Pressure Relief Valves with Bypass Variable Displacement Pump Charge Relief Valve Shaft Seal Fixed Displacement Motor Fig 50 1 Minor Repairs General Minor Repairs may be performed following the pro cedures in this section without voiding the unit war Cleanliness is a primary means of assuring satisfac tory transmission 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 Auxiliary Pad CONTENTS Series 40 M25 Trunnion Seals pu o o Q Q High Pressure Relief Charge Relief valve Valves with Bypass Variable Displacement Tandem Pump Shaft Seal
28. Axial Piston Pumps Motors and Transmissions Series 40 M25 Exploded View of the M25 Variable Tandem Pump Continued Mp Nog 570 07 51 6 lt ae lt 2 EL WS B39 D V 25 S PUN On E Wels c 4 2 M FO2L 928 B25 aA 826 40 7 Axial Piston Pumps Motors and Transmissions SAUER DANFOSS CONTENTS Series 40 M25 Exploded View of the M25 Variable Tandem Pump Continued Item Description 01 HOUSING VARIABLE FRONT B02 SEAL LIP B03 HOUSING VARIABLE REAR B21 PLATE THRUST B22 CYLINDER BLOCK KIT B32 PISTON ASSY B36 RETAINER SLIPPER B26 SPRING B25 WASHER B28 RING RETAINING B37 GASKET END CAP B38 BEARING NEEDLE B39 PIN ST HDLS B40 PIN B42 PLUG PLASTIC B44 PLUG PLASTIC B45 PLUG ST THD B49 SCREW DRIVE B50 SCREW HEX HD B51 SEAL LIP B52 WASHER B53 LIFTING BRACKET E03 BEARING BALL E04 BEARING BALL E05 RING RETG E06 O RING E07 CARRIER SEAL E08 RING INTERNAL RETAINING E11 RING EXTERNAL RETAINING G09 COUPLING H01 PLUG ASSY CHG RELIEF H05 O RING H06 SHIM CHG RELIEF H08 POPPET CHG RELIEF 401 M01 PLUG SPECIAL M02 O RING M03 O RING M04 SPRING CONICAL COMP M05 RING INTERNAL RETAINING N07 O RING N08 COVER TRUNNION PLAIN N09 COVER TRUNNION N10 SCREW S14 O RING 515 PLATE COVER S16 SCREW HEX HD 40 8 Qty
29. CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Exploded View of the M25 Variable Tandem Pump The following information is for general parts identi fication ONLY Refer to the applicable Service Parts List when ordering service parts 10 di 22709 M02 gt a 7 e P Ps Se M20B 808 p M03 A M02 509 o M01 Kio CO T pd oa 90 E M21A 2 bom ilc 22 E gt E OS 9 20 THRU 7L 09 lo 2 lt lt 21 Le d 07 507 Age M03 W nI E 7 PU amp S na ah M gt SN lt 04 Pa a ro N08 7 2 M02 S16 B45 03 4 H06 HO7F N10 H07G M11B x d c THRU m P E de L Name Plate SAUER SAUERSUNDS Ames lowa U S A Neuminster Germany Model Code Typ MPTO25C SRAG NN 7 BAAA BDD DLAFF Model Code BCAA BDD DRAFF Model Number a Serial Number 8926 67890 Serial No Fabr Nr MADE IN U S A LLL Place of Manufacture 40 5 SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Exploded View of the M25 Variable Tandem Pump Continued E06 N EX 55 B02 05 N 9 27710 40 6 SAUER CONTENTS DANFOSS M
30. Case Outlet Fittings 57 Nm Housing Plugs PV amp PT 42 558 7 8 14 O Ring Case Outlet Fittings 68 Nm Housing Plugs MF 50 Ibsfeft 3 4 16 O Ring Charge Pressure Inlet 95 Nm System Ports 70 Ibsf ft 7 8 14 O Ring M25 Variable Pump Tandem Pump and Fixed Motor Conversion Information Changing high pressure relief valves and charge pressure relief settings are considered to be Minor Repairs The auxiliary mounting flange drive spline on variable pumps may be changed by changing the coupling It is possible to change the variable pump tandem pump or fixed motor shaft without major disassembly of the unit Remove the shaft seal Then with the unit positioned with the mounting flange UP remove the shaft and bearing assembly Install the replacement shaft and bearing assembly into the housing Re place the shaft seal carrier The rear tandem pump section shaft with auxiliary mounting flange drive spline may be changed similar manner CAUTION Do not remove both the front and rear pump section shafts from tandem pumps at the same time The coupling between the pump sections will move out of position requiring disassem bly of the unit Changing the direction of pump rotation or changing the location of the control trunnions in the housing s requires major disassembly of the unit SAUER DANFOSS Axial Piston Pumps Motors and Transmissions 5 Ser
31. Continuous ALL UNITS Maximum Cold Start Temperature at Hottest Point in Transmission normally at case drain Maximum ALL UNITS Continuous Fluid Viscosity Limits 2 SUS Optimum 13 70 Min Continuous 9 0 55 Min Intermittent 6 4 47 ALL UNITS Max Continuous 110 500 Max Cold Start 1600 7500 Suggesied Filtration Dedicated Reservoir Beta 10 1 5 to 2 0 ALL UNITS Common Reservoir Beta 10 10 to 20 Charge Inlet Vacuum at Sea Level Normal bar abs Refer to Refer to in Hg specifications specifications Cold Start bar abs for specific Charge for specific Charge in Hg Pump being used Pump being used DNA Does Not Apply 10 6 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Safety Precautions CONTENTS Series 40 M25 When Series 40 units used in vehicular hydrostatic drive systems the loss of hydro static drive line power in any mode accelera tion deceleration or neutral mode of op eration may cause aloss of hydrostatic brak ing capacity A braking system redundant to the hydrostatic transmission must there fore be provided which is adequate to stop and hold the system should the condition develop Certain service procedures may require the vehicle machine to be disabled wheels raised off the ground work function discon nected etc while performing them in order to prevent injury to the technician and by st
32. ER SUNDSTRAND COMPANY SAUER SUNDSTRAND GMBH amp CO 2800 East 13th Street Postfach 2460 D 24531 Neum nster Ames 50010 U S A Krokamp 35 D 24539 Neum nster Germany Phone 515 239 6000 FAX 515 239 6618 Phone 04321 871 0 Fax 04321 871 465
33. For Technical Information on Series 40 pumps and motors refer to SAUER SUNDSTRAND publications BLN 9989 and BLN 9990 For Fluid Quality Requirements refer to publication BLN 9987 or 697581 SAUER SUNDSTRAND provides a complete repair service for its products Contact any SAUER SUND STRAND Authorized Service Center for details SAUER SUNDSTRAND Authorized Service Center locations are listed in publication BLN 2 40527 or 698266 40250118 Fig 0 2 Series 40 M25 Fixed Displacement Motor 40250002 Fig 0 3 Series 40 M25 U Style Transmission SAUER DANFOSS Axial Piston Pumps Motors and Transmissions System Circuit Description The Series 40 M25 pumps motors and U style transmission can be applied in drive systems to transfer and control power These units provide an infinitely variable speed range between zero and maximum in both forward and reverse modes of operation Series 40 M25 pumps motors and transmissions incorporate a compact state of the art design using the parallel axial piston slipper design in conjunction witha tiltable swashplate to vary the pump s displace ment Reversing the direction of tilt of the variable pump swashplate reverses the flow of oil from the pump and thus reverses the direction of the motor output rotation A direct displacement control system is used on the Series 40 M25 pumps and M25 U transmission pump The swashplate control shaft is
34. IEF PUMP W CHECK amp BY PASS VALVES CHARGE RELIEF FIXED DISPLACEMENT CYLINDER BLOCK S m m WY ASSEMBLY Sy BENZ Nf HIS gezeigt H 77 OUTPUT 22 m SUCTION FLOW CHARGE PRESSURE HIGH PRESSURE O FLOW 40250112 Fig 10 1 Typical Series 40 M25 Variable Pump Fixed Motor Transmission Schematic SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Functional Description INPUT FLOW BI DIRECTIONAL HEAT EXCHANGER W BYPASS RESERVOIR Fig 10 2 Basic Closed Circuit 01050003 CHARGE PUMP e INPUT CHARGE CHECK amp INLET FILTER RELIEF VALVES RESERVOIR 01050004 Fig 10 3 Charge System Typical for Variable Pump and Tandem Pump 10 2 CONTENTS Series 40 M25 Basic Closed Circuit The main ports of the pump are connected by hydrau lic lines or passages in the M25U transmission center section to the main ports of the motor Fluid flows in either direction from the pump to the motor then back to the pump in this closed circuit Either of the hydraulic lines can be under high pressure The direction and speed of fluid flow and the motor output shaft rotation depends on the position of the pump swashplate The system pressure is determined by the machine load Case Drain and Heat Exchanger The variable pump tandem pump and transmission require ca
35. OSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Troubleshooting Fault Logic Diagrams Check Control Replace Linkage Transmission Pump and Motor Defective Defective TRANSMISSION OPERATES IN ONE DIRECTION ONLY Check Oil Level OK Inspect Heat OK heck Chargeigx gt Check System in Reservoir Exchanger Pressure Pressure Low No Load and Defective Under Load Fill to Proper Repair or Level Replace Inspect Charge Inspect Charge Inspect Inlet ge Relief Valve 4 PPS Reduce Defective Defective OK Clogged Transmission Load Replace Replace Replace Transmission TRANSMISSION OPERATING HOT Pump and Motor Check Oil Level Inspect Heat y Check Charge ic gt Check System High in Reservoir Exchanger Pressure Pressure Load Low Defective Onde Laad Reduce OK Transmission Fill to Proper Repair or Load Level Replace Inspect Check Relief Valves or Charge Check Valves Inspect Charge Inspect Charge Pre ord Rere 14 esc Detective Defective Defective Replace Replace Replace Replace Transmission LOSS OF POWER OR TRANSMISSION WILL NOT OPERATE IN EITHER DIRECTION Pump Motor 30 5 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Notes 30 6 5 Series 40 M25 SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Exploded View of the M
36. OSS Axial Piston Pumps Motors and Transmissions Major Repair U Style Transmission General The procedures on the following pages are for the complete disassembly and reassembly Major Re pair of the Series 40 M25 U Style Transmission Cleanliness is a primary means of assuring satisfac tory transmission 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 7 Series 40 M25 During the assembly of the Series 40 M25U trans mission all surfaces which have relative motion between two parts should be coated with a film of clean hydraulic oil This will assure that these sur faces will be lubricated during start up It is recommended that all gaskets and O rings 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 40250085 Fig 65 1 Cross Section View of Series 40 M25 U Style Transmission 65 1 5 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Major Repair Style Transmission Continued Disassembly Procedures for U Style T
37. Pumps Motors and Transmissions CONTENTS Series 40 M25 Exploded View of the M25 U Style Transmission Continued 0008 0004 0005 0006 0007 0008 0009 0010 0012 0013 0014 0015 0016 0017 0019 0020 0021 0022 0024 0027 0028 0029 0030 0031 0032 0033 0034 0035 0037 0038 0039 0040 0041 0042 0043 0044 0045 0046 0047 0048 0049 0050 0051 Description HOUSING CHARGE PUMP SCREW HOUSING TRANSMISSION GASKET HOUSING CENTER SECTION HOUSING CHARGE PUMP PLUG ST THD PLUG SCREW HEX HD PLUG PLASTIC SCREW HEX HD SCREW HEX HD PLUG SPECIAL SCREW PLUG ST THD PLUG PIPE PIN BEARING BALL COLLAR SHAFT PUMP U SEAL GUIDE RING RETG O RING BEARING BALL PLATE THRUST SWASHPLATE VARIABLE CYLINDER BLOCK KIT PISTON ASSEMBLY RETAINER SLIPPER SPRING WASHER RING RETAINING PIN O RING GEROTOR PIN ST HDLS BEARING NEEDLE SEAL LIP SEAL PACKAGING NIPPLE PIN ST HDLS BEARING NEEDLE PLUG PLASTIC SHIM CAP PLASTIC O RING SPRING VALVE RELIEF Qty bh ADDN B AN PAP CN a PAP ANY NMP DH PN NM WD A BR a A Item 0061 0062 0064 0066 0068 0069 0082 0084 0085 0086 0087 0089 0003L 0065L 0003R 0065R 0036L 0036R 0023 0023 0070 Description SEAL LIP SPRING SCREW O RING SPRING SPRING PLATE VALVE MOTOR PLUG SEAL SPRING CONICAL COMP PLUG ST THD RING RET
38. THD SCREW DRIVE SCREW HEX HD SEAL LIP WASHER LIFTING BRACKET BEARING BALL RING RETG O RING CARRIER SEAL RING INTERNAL RETAINING PLUG ASSY CHG RELIEF O RING SHIM CHG RELIEF POPPET CHG RELIEF END CAP PLUG SPECIAL O RING O RING SPRING CONICAL COMP RING INTERNAL RETAINING O RING COVER TRUNNION PLAIN COVER TRUNNION SCREW O RING PLATE PAD COVER SCREW HEX HD Qty BDA DW NY a a gt A N gt A WHA ANNNNNDN A Item HO7F H07G M10A M20A M10B THRU M10M M20B THRU M20M E01C E02C EO1K E02K E01S FOIL FO1R 512 13 139 T01 T02 T04 05 N01 N02 N01 N02 N05 N06 Description SPRING HEL COMP 7 BAR 100PSI SPRING HEL COMP 14 BAR 200PSI POPPET CHECK VALVE POPPET CHECK VALVE VALVE RELIEF VALVE RELIEF SHAFT PUMP TAPERED KEY SHAFT PUMP STR KEYED KEY SQUARE SHAFT PUMP SPLINED 13T PLATE VALVE LH PLATE VALVE RH PIN COUPLING 9T AUX DRIVE COUPLING 11T AUX DRIVE PISTON SLEEVE ASSY SPRING HEL COMP O RING PLUG SPECIAL SWASHPLATE VARIABLE BEARING CARRIER ASSY SWASHPLATE VARIABLE BEARING TAPER ROLLER SHIM TRUNNION SPACER TRUNNION Qty 1 1 A ee ds 40 3 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Notes 40 4 CONTENTS Series 40 M25 SAUER
39. a force of approximately 10 2 2 Ibsf to compress it to a length of 45 7 mm 1 28 inches Inspect the poppet and mating seat in the end cap for damage or foreign material Reinstall the poppet spring and plug with O ring into the center section Torque the plug to 41 to 95 Nm 30 to 70 Ibsfeft SAUER DANFOSS Axial Piston Pumps Motors and Transmissions CONTENTS Series 40 M25 Minor Repair and Replacement U Style Transmission Continued Filter Bypass Reverse Flow Check Valve Remove the reverse flow check valve plug with a 7 8 hex wrench Remove the spring and poppet from the center sec tion Do not interchange parts with another valve The spring used in the reverse flow check valve is identi fied with a blue dye mark and requires a force of approximately 1 3 0 3 Ibsf to compress it to a length of 45 7 mm 1 28 inches Inspect the poppet and mating seat in the end cap for damage or foreign material Reinstall the poppet spring and plug with O ring into the center section Torque the plug to 41 to 95 Nm 30 to 70 Ibsfeft Integral Charge Pump Remove the two 2 screws retaining the charge pump cover using a 9 16 hex wrench Remove the charge pump assembly Remove the gerotor drive pin from the groove in the shaft Remove the gerotor assembly from the charge pump cover Remove the retaining ring if used and the shaft seal from the cover Inspect all parts that
40. acing the en tire valve Charge Pressure Relief Valve PV PT Remove the charge relief valve hex plug with a 1 wrench Remove the spring and poppet from the end cap or center section Do not alter the shims which may be installed be Fig 50 13 Remove Fig 50 14 Remove tween the spring and valve plug or interchange parts Charge Relief Valve Charge Relief Valve with another valve Inspect the poppet and mating Plug PV Plug PT seat in the end cap for damage or foreign material Reinstall the poppet spring and plug with shims and O ring into the center section Torque the plug to 54 to 135 Nm 40 to 100 Ibsf ft Fig 50 15 Charge Relief Valve Components PV PT 50 4 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions 7 Series 40 M25 Minor Repair and Replacement Pumps and Motors Cont Easy Ride Valves PV Remove the Easy Ride valve by removing the hex plug using a 11 16 hex wrench Remove the spring and sleeve assembly with the poppet piston Re move the poppet piston from the sleeve assembly Inspect the seat area in the end cap and the seat end of the poppet piston for damage or foreign material The poppet piston must slide freely in the sleeve assembly Inspect the spring for damage Reinstall the poppet piston into the sleeve assembly Install the sleeve assembly spring and plug with O ring Torque the plug to 20 to 47 Nm 15 to 35 Ibsfeft A
41. al Piston Pumps Motors and Transmissions CONTENTS Series 40 M25 Exploded View of the M25 Fixed Motor Continued Item B02 B21 B22 B37 B38 B39 B40 B41 B45 B47 B52 B53 40 10 Description SEAL LIP PLATE THRUST CYLINDER BLOCK KIT M25 GASKET END CAP MF BEARING NEEDLE PIN SLEEVE SCREW HEX HEAD PLUG PLUG PLATE VALVE MOTOR BRACKET LIFTING Qty 004 005 006 007 008 001 E01 G01 G02 Description BEARING BALL RING RETAINING O RING CARRIER SEAL RING RETAINING SHAFT MF END CAP MF HOUSING MF HOUSING MF 20CC Qty a ae a SAUER DANFOSS CONTENTS Axial Piston Pumps Motors and Transmissions Series 40 M25 Exploded View of the M25 U Style Transmission The following information is for genera fication ONLY Refer to the applicable List when ordering service parts parts identi Service Parts Model Number Serial Number Plate SAUER 57 SAUERSUNDS Ames lowa U S A Neuminster Germany Model Code Typ M90 25001 8926 67890 Serial No Fabr Nr MADE IN U S A L Model No Ident Nr Model Code Place of Manufacture 40 11 SAUER CONTENTS 5 Axial Piston Pumps Motors and Transmissions Series 40 M25 Exploded View of the M25 U Style Transmission Continued 40 12 SAUER DANFOSS Axial Piston
42. anders 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 Some cleaning solvents are flammable To avoid possible fire do not use cleaning sol vents in an area where a source of ignition may be present 20 1 SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Notes 20 2 SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Gauge Installation Gauge Ports Various pressure and vacuum gauge readings can be a great asset in troubleshooting problems with the Series 40 M25 transmission or support system It will be necessary to connect a high pressure gauge to the system pressure gauge ports variable pump fixed motor and U style transmission or tee into the system high pressure lines tandem pump to check the setting of the system pressure relief valves Measuring the charge pump inlet vacuum will help locate restrictions in the inlet lines filter etc Case pressure readings can help locate restrictions in the return lines return oil cooler and return filter Gauge Information M1 System 600 bar or 10 000 psi Gauge Pressure 7 16
43. are to be reused If either of the gerotor assembly parts needs to be replaced they must both be replaced Always replace the O rings 40250044 Fig 50 37 Remove Filter Bypass Reverse Flow Check Valve Plug U Dou 2 48 40250016 Fig 50 38 Filter Bypass Reverse Flow Check Valve U Fig 50 40 Remove Charge Pump Assembly U Fig 50 39 Remove Charge Pump Cover Screws U Fig 50 41 Charge Pump Components U 50 11 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions 7 Series 40 M25 Minor Repair and Replacement U Style Transmission Continued Fig 50 42 Bearing Fig 50 43 Install Installed in Charge Pump Cover U Gerotor Drive Pin U Fig 50 44 Install Fig 50 45 Install Gerotor Assembly in Charge Pump Pump Cover U Assembly U Charge Pump Charge Pump Cover A 0250051 Fig 50 46 Orienting Fig 50 47 Orienting Charge Pump Cover Charge Pump Cover CW U CCW U ror Fig 50 48 Torquing Fig 50 49 Installing Charge Pump Cover Shaft Seal Screws U 50 12 Inspectthe shaft bearing in the charge pump cover for wear or damage If replacement is necessary re move the needle bearing from the cover using a suitable puller Press a new needle bearing into the cover using a suitable press pin When installed correctly the bearing cage will be flush to
44. ass Reverse Flow Check Valve Charge Pump 65 8 SAUER DANFOSS CONTENTS 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 SAUER SUNDSTRAND is Your World Source for technology Controlled Hydraulic Power Systems Heavy Duty Axial Piston Pumps and Motors Heavy Duty Bent Axis Cartridge Motors Variable Motors Compact Wheel Drives gt Medium Duty Axial Piston Pumps and Motors Microcontrollers and Hydrostatic Transmission Electrohydraulic Controls Packages Open Circuit Axial Piston Pumps Gear Pumps and Motors Genuine Service Parts Worldwide Service Support SAUER SUNDSTRAND provides comprehensive worldwide service for its products through an extensive network of Authorized Service Centers ii strategically located all parts of the world LY ur 1 Genuine Parts Original Ersatzteile SAUER S DANFOSS BLN 10056 Rev July 2012 S SAU
45. atterns Replace all parts having unusual or exces sive wear or discoloration Cracks are not allowed in any surface of the valve plate or cylinder block The running and sealing surfaces of the valve plate and cylinder block must be flat and free of nicks and burrs Replace valve plates or cylinder blocks that show evidence of metal trans fer wear or erosion on the running surface If scratches which can be felt with a fingernail or pencil lead are found on the bronze surface of the valve plate or the running surface of the cylinder block polish or replace the parts Inspect the needle bearing in the end cap If replace ment is necessary remove the shaft needle bearing using a suitable puller Do not damage the valve plate surface of the end cap Press a new needle bearing into the end cap using a suitable press pin When installed correctly the bear ing cage will protrude from 2 0 to 2 5 mm 0 08 to 0 10 in from the surface of the end cap to serve as a pilot for the valve plate CAUTION When installing the needle bearing the printed numbered end of the bearing cage must face the press pin Replace any bearing cups or cones that show spalling or wear Tapered roller bearing cups and cones should be kept together and not mixed If replace ment is necessary always replace both the cup and the cone Replace all piston assemblies if brass slippers are scored or excessively rounded at the edges Compress the
46. e Fluids Hydraulic fluids used with Sauer Sundstrand prod ucts should be carefully selected with assistance from a reputable supplier following the guidelines presented in SAUER SUNDSTRAND Bulletin BLN 9887 or Publication SDF Id No 697581 Start Up Procedure The following start up procedure should always be followed when starting up a new installation or when restarting an installation in which either the pump or motor had been removed from the system WARNING The following procedure may require the ve hicle machine to be disabled wheels raised off the ground work function disconnected etc while performing the procedure in order to prevent injury to the technician and bystand ers Prior to installing the pump or transmission inspect the unit for damage incurred during shipping and handling Make certain all system components res ervoir hoses valves fittings heat exchanger etc are clean prior to filling with fluid Fill the reservoir with recommended hydraulic fluid which should be passed through a 10 micron nomi nal no bypass filter prior to entering the reservoir The inlet line leading from the reservoir to the charge pump must be filled prior to start up Check inlet line for properly tightened fittings and make sure it is free of restrictions and air leaks Be certain to fill the pump motor and or trans mission housing with clean hydraulic fluid prior to start up Fill the housing by
47. e motor Be sure to torque all threaded parts to recommended 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 Install the swashplate into the housing Make sure the swashplate control shaft is located on the desired side of the housing note the marks made during disassembly Install the trunnion cover with O ring and trunnion bearing into the housing and over the swashplate trunnion NOTE The trunnion bearings are pressed into the cover assemblies so the split in each bearing will be located closest to the center section Using an arbor press press a new seal into the trunnion seal cover The outer face of the seal should be pressed flush with the outer surface of the seal cover Be careful not to damage the seal Install the trunnion seal cover with O ring seal and trunnion bearing into the housing and over the swash plate trunnion as described in the Minor Repair section of the Service Manual Wrap the end of the swashplate control shaft with thin plastic to prevent damage to the seal lip during installation Install the hex head tapping screws and torque to 8 to 12 Nm 6 to 9 Ibsfeft 40250 E Fig 65 21 Install ig 65 22 Torque Trunnion Seal Cover Trunnion Cover Screws 102 65 5
48. e and repair of the SAUER SUNDSTRAND Series 40 M25 Pumps Motors and U Style Transmissions This manual includes unit and component descrip tion troubleshooting adjustments and minor and major repair procedures Minor Repairs are those repairs which can be per formed without removing the housing s from the end cap or center section These repairs can be per formed by any customer without affecting the unit warranty Major Repairs are those repairs which require the removal of the housing s from the end cap or center section These repairs are to be performed only by SAUER SUNDSTRAND Authorized Service Centers and or original equipment manufacturers who have been adequately trained by SAUER SUNDSTRAND to perform these repairs Performing major repairs on Series 40 products may affect the unit warranty sta tus thus the factory should be consulted prior to undertaking such repairs 40250001 Fig 0 1 Series 40 M25 Variable Displacement Pump and Tandem Pump CONTENTS Series 40 M25 Many repairs or adjustments can be completed with out removing the unit from the vehicle or machine provided the unit is accessible and can be thoroughly cleaned before beginning any procedures Dirt or contamination is the greatest enemy of any type of hydraulic equipment The greatest possible cleanliness is necessary when starting up the sys tem changing filters or performing any other service procedure
49. e inside diameter of the new seal with petroleum jelly Install the O ring onto the seal carrier and lubricate with petroleum jelly Slide the seal carrier assembly over the shaft and into the housing bore Hold inward pressure against the shaft to compress the cylinder block spring while pressing the seal carrier into position Install the retaining ring SAUER DANFOSS 5 Axial Piston Pumps Motors and Transmissions Series 40 M25 Minor Repair and Replacement Pumps and Motors Cont Trunnion Seal PV PT Control Shaft Side Remove the control linkage from the swashplate control shaft With a 7 16 or 1 2 wrench remove the hex screws retaining the trunnion seal cover to the unit housing Remove the trunnion seal cover with lip seal and the O ring On units with tapered roller bearing trunnions the bearing spacer and shims may be removed from the housing after removing the trunnion seal cover Place the seal cover in an arbor press and press out the old seal Once removed the seal is not reusable Inspect the seal cover for damage Inspect the sealing area on the shaft for rust wear or contamina tion Polish the sealing area on the shaft if necessary Usingthe arbor press press the new seal into the seal cover from the inside until it bottoms in its bore Be careful not to damage the seal or the cover NOTE The outside diameter of the new seal may be coated with a sealant such as
50. ee of foreign materials and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material 7 Series 40 M25 During the assembly of the Series 40 M25 tandem pump all surfaces which have relative motion be tween 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 With Tapered Roller Trunnion Bearings With Journal Trunnion Bearings 40250076 Fig 62 1 Cross Section View of Series 40 M25 Variable Displacement Tandem Pump 62 1 SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Major Repair Tandem Pump Continued Fig 62 2 Separate Fig 62 3 Separate Front Housing from Rear Housing from Center Section Center Section 40250078 Fig 62 4 Shaft Needle Bearings and Drive Coupling Removed Tandem Pump 62 2 Disassembly Procedures for Tandem Pump Prior to performing Major Repairs on the Series 40 M25 Tandem Pump remove the external compo nents as described in the Minor Repair section These include the following Auxiliary Mounting Pad Cover Charge Re
51. ey should be torqued as indicated in the following tables J e arge Pump Inle 95 to 230 Nm 1 1 16 12 O Ring 70 to 170 Ibseft Oil Cooler Ports 41 to 95 Nm 3 4 16 O Ring 30 to 70 Ibsfeft Pressure Gauge Ports 14 7 16 20 O Ring 8 to 10 Ibsfeft oop Passage Plugs AT to 95 Nm 3 4 16 O Ring 30 to 70 Ibsf ft oop Passage Flug to Nm 9 16 16 O Ring 15 to 20 Ibsfeft M25 U Style Transmission Conversion Information Changing high pressure relief valves and charge pressure relief settings are considered to be Minor Repairs Changing the direction of rotation or changing the location of the control trunnion in the housing requires major disassembly of the unit 50 13 SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Notes 50 14 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Major Repair Variable Pump General The following procedures are for the complete disas sembly and reassembly Major Repair of the Series 40 M25 Variable 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 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
52. gainst the shaft to compress the cylinder block spring while removing the retaining ring After removing the retaining ring the seal carrier will move out approximately 6 mm 1 4 in due to the cylinder block spring force on the shaft Lightly tap the end of the shaft with a soft mallet until the seal carrier can be removed from the housing NOTE After the seal carrier is removed the shaft and bearing assembly are free in the hous ing Do not remove shaft unless unit is positioned with the mounting flange UP If the unit is positioned horizontally when the shaft is removed the cylinder block could move out of place making shaft installation difficult Remove the O ring from the seal carrier Place the seal carrier in an arbor press and press out the old seal An appropriately sized pipe spacer or Socket wrench can be used as a press tool Once removed the seal is not reusable Inspect the seal carrier the new seal and the O ring for damage Inspect the sealing area on the shaft for rust wear or contamination Polish the sealing area on the shaft if necessary Usingthe arbor press press the new seal into the seal carrier Be careful not to damage seal NOTE Theoutside diameter of the new seal may be coated with a sealant such as Loctite High Performance Sealant 59231 prior to instal lation Wrap the spline or key end of shaft with thin plastic to prevent damage to the seal lip during installation Lubricate th
53. harge Check High Pressure Relief Valves Fig 62 12 Front Pump Section Assembled to Center Section Fig 62 13 Torq Housing Screws 40250084 ue 62 5 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Notes 62 6 CONTENTS Series 40 M25 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Major Repair Fixed Motor General The following procedures are for the complete disas sembly and reassembly Major Repair of the Series 40 M25 Fixed Motor 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 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 7 Series 40 M25 During the assembly of the Series 40 M25 fixed motor all surfaces which have relative motion be tween 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 Sy
54. ides of the pump motor closed circuit allowing the motor to turn Both valves must be opened for bypass operation and must be fully closed for normal operation The system prime mover should be shut down when opening or closing the bypass valves NOTE Opening the bypass valves more than 4 turns may result in external leakage WARNING Opening the bypass valves will result in a loss of hydrostatic braking capacity Take precau tions to prevent unexpected machine move ment when opening the valves Series 40 M25 CHARGE CHECK VALVES FROM CHARGE PUMP Fig 10 9 Variable Pump Circuit with Easy Ride Valves 40250008 SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Technical Data Pumps Motors and U Style Transmission Product Type M25 M25 M25 M25 U Style Variable Pump Tandem Pump Fixed Motor Transmission Displacement cc rev 25 25 each section 25 25 Pump amp Motor in rev 1 5 1 5 each section 1 5 1 5 Pump amp Motor Maximum Allowable Pun Full Angle variable units 5000 ALL UNITS oe Flange ys rm per SAE J744 Input Shaft Std Spline Number of Teeth and Pitch 13T 16 32 15T 16 32 DNA Input 20T 24 48 PTO 22T 24 48 Output Shaft Std Spline Number of Teeth and Pitch 13T 16 32 18T 16 32 Weight 24 9 11 25 4 4 55 25 56 Pressure Maximum ALL UNITS Continuous Case Pressure
55. ies 40 M25 Minor Repair and Replacement U Style Transmission Shaft Seal Replacement If the shaft seal is accessible with the charge pump installed on the transmission proceed as follows Remove the seal retaining ring used on later produc tion units from the charge pump cover Carefully remove the seal from the bore in the charge pump cover The face of the seal may be punctured with sharp instrument such as a screwdriver to aid in prying the seal out or a slide hammer type puller may be used to remove the seal Care must be taken so as not to damage the charge pump cover or shaft Once removed the seal is not reusable Inspectthe charge pump cover the new seal and the shaft for damage Inspect the sealing area on the shaft for rust wear or contamination Polish the sealing area on the shaft if necessary Lubricate the inside diameter of the new seal with petroleum jelly Wrap the spline end of the shaft with thin plastic to prevent damage to the seal lip during installation NOTE The outside diameter of the new seal may be coated with a sealant such as Loctite High Performance Sealant 59231 prior to instal lation Press the new seal into the charge pump cover being certain the seal is perpendicular to the shaft Be careful not to damage seal On earlier production units the outer face of the seal should be located from 1 42 to 2 44 mm 0 056 to 0 096 in below the outer surface of the charge pu
56. its side and remove the motor cylinder block kit from the housing Remove the pump cylinder block kit from the pump shaft Remove the slipper guide and the piston assemblies from the cylinder block kits NOTE The pump and motor cylinder block kits are identical In order to avoid mixing wear pat terns do not mix parts between the pump 40250058 Fig 65 7 Cylinder and motor kits Cylinder Blocks Block Kit from Housing Components 1025009 Fig 65 6 Remove 65 2 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Major Repair 0 Style Transmission Continued Using an O ring pick or wire remove the thrust plates from the swashplate and housing Using a 3 16 internal hex wrench remove the pipe plug over the motor shaft bearing retaining pin Using a 4 40 4 40 threads per inch or 8 32 8 32 threads per inch machine screw remove the motor shaft bearing retaining pin from the housing Remove the motor shaft assembly Press the motor shaft out of the bearings and spacer Remove the spiral retaining ring and remove the PTO seal guide with O ring from the housing Slide the pump shaft and bearing assembly from the housing Press the shaft out of the bearing Thrust Plates Bearing Retaining Pin CONTENTS Fig 65 8 Remove Series 40 M25 Pipe Plug Fig 65 10 Remove Fig 65 11 Rem Motor Shaft Assembly Fig 65 9 Remove i
57. lief Valve Charge Check High Pressure Relief Valves After removal of these components mark the location of the pump housings and center section and re move the four 4 screws using a 5 8 hex wrench and washers which retain each pump housing to the center section Remove the housings from the center section and valve plates Do not allow the valve plates to fall from the center section Remove the gaskets and align ment pins from the center section Once the pump sections are removed from the center section they may be disassembled using the proce dures outlined in the Major Repair Variable Pump section of this manual The center section serves as the end cap for both pump sections NOTE A drive shaft seal cover assembly is used only on the front pump section The rear pump section shaft bearing is held in the housing with a retaining ring only Reconditioning and Replacement of Parts The following procedures apply to the tandem pump center section Inspectthe needle bearings and drive coupling in the center section If replacement is necessary remove the shaft needle bearings using a suitable puller Do not damage the valve plate surface of the end cap Remove the drive coupling located between the bearings 5 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Major Repair Tandem Pump Continued Press a new needle bearing into the center section using
58. linder Block d int m 4 Fig 65 32 Install Fig 65 33 Instal Valve Plate Pins Pump and Motor Valve Plates Cw CCW Fig 65 35 Motor Valve Plate 65 7 5 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Major Repair U Style Transmission Continued Install the two 2 alignment pins and install a new center section gasket onto the housing Fig 65 36 Install Alignment Pins and Center Section Gasket Install the center section with valve plates onto the transmission housing CAUTION Be certain all parts are properly aligned Do not force the center section into position on the housing When the center section is properly installed the cylinder block springs will hold the end center section away from the housing approximately 3 mm 1 8 in Section Installed Center Section Screws Install the six 6 screws that retain the center section to the housing and torque evenly to 45 to 55 Nm 33 to 41 Ibsfeft Rotate the pump and motor shafts to assure correct assembly When properly assembled a maximum torque of 4 7 Nm 3 5 Ibsf ft should be required to turn either shaft Assemble the following components as described in the Minor Repair section of this manual Charge Check High Pressure Relief Valves Charge Relief Valve Heat Exchanger Bypass Valve Filter Bypass Valve Filter Byp
59. ll the four 4 screws and washers that retain the housing to the end cap and torque evenly to 81 to 95 Nm 60 to 70 Ibfeft CAUTION Be certain all parts are properly aligned Do not force the end cap into position on the housing Rotate the shaft to assure correct assembly When properly assembled a maximum torque of 9 5 Nm 7 lbsfeft should be required to turn the shaft Assemble the following components as described in the Minor Repair section Auxiliary Mounting Pad Coupling and Cover Easy Ride Valves Charge Relief Valve Charge Check High Pressure Relief Valves 095 z S 40 Fig 61 29 Install Valve Plate 740 Fig 61 28 Install Valve Plate Pin CCW Fig 61 30 Pump Valve Plates Fig 61 31 Install Fig 61 32 End End Cap Gasket and Installed End Cap 61 7 SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Notes 61 8 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Major Repair Tandem Pump General The following procedures are for the complete disas sembly and reassembly Major Repair of the Series 40 M25 Tandem 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 wash and air drying is usually adequate As with any precision equipment all parts must be kept fr
60. material lt lt T3 With Journal Trunnion Bearings 7 Series 40 M25 During the assembly of the Series 40 M25 variable pump all surfaces which have relative motion be tween 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 With Tapered Roller Trunnion Bearings 40250053 Fig 61 1 Cross Section View of Series 40 M25 Variable Displacement Pump 61 1 SAUER DANFOSS CONTENTS Axial Piston Pumps Motors and Transmissions Series 40 M25 Major Repair Variable Pump Continued Fig 61 2 Remove Fig 61 3 Remove Housing Screws End Cap 402500 Fig 61 4 Remove Fig 61 5 Remove Valve Plate Cylinder Block 40250059 ve 40250058 Fig 61 6 Cylinder Fig 61 7 Remo Block Kit Thrust Plate Disassembled 6 40250061 40250060 a Fig 61 8 Remove Fig 61 9 Remove Shaft Seal Cover Shaft and Bearing 61 2 Disassembly Procedures for Variable Displace ment Pump Prior to performing Major Repairs on the Series 40 M25 Variable Pump remove the external compo nents as de
61. mp cover On later produc tion units the seal must be pressed in far enough to allow the retaining ring to be installed Installthe seal retaining ring used on later production units into the charge pump cover If the shaft seal is not accessible with the charge pump cover installed on the transmission proceed as follows Remove the charge pump cover from the transmis sion as outlined in the Charge Pump section Carefully remove the seal from the bore in the charge pump cover Once removed the seal is not reusable Inspectthe charge pump cover the new seal and the shaft for damage Inspect the sealing area on the shaft for rust wear or contamination Polish the sealing area on the shaft if necessary Install the new seal into the charge pump cover as previously described Lubricate the inside diameter of the new seal with petroleum jelly Reinstall the charge pump cover as outlined in the Charge Pump section being careful not to damage the seal on the shaft splines Fig 50 21 Installing Shaft Seal with Charge Pump Installed U FUE Fig 50 22 Shaft Seal Installed 0 Fig 50 23 Installing Charge Pump Cover gt with Shaft Seal U 50 7 CONTENTS SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Minor Repair and Replacement U Style Transmission Continued Trunnion Seal Cover Control Shaft Side Remove the contr
62. n Series 40 M25 products regular maintenance of the fluid and filter must be performed Check the reservoir daily for proper fluid level the presence of water noted by a cloudy to milky appear ance or free water in bottom of reservoir and rancid fluid odor indicating excessive heat The fluid and filter must be changed per the vehicle machine manufacturer s recommendations In the absence of such recommendations the following intervals may be used System with a sealed type reservoir 2000 hrs System with a breathing type reservoir 500 hrs It may be necessary to change the fluid more fre quently than the above intervals if the fluid becomes contaminated with foreign matter dirt water grease etc or if the fluid has been subjected to temperature levels greater than the maximum recommended Never reuse fluid The filter should be changed whenever the fluid is changed or whenever the filter indicator shows that it is necessary to change the filter SAUER DANFOSS CONTENTS Axial Piston Pumps Motors and Transmissions Series 40 M25 Component Inspections and Adjustments Direct Displacement Control Inspect the connection of the control linkage to the swashplate control shaft to insure that the linkage is properly attached Neutral position of the swashplate is determined by the vehicle machine control linkage Check High Pressure Relief Valves When a problem occurs in one direction i
63. nterchange the charge check or check relief valves to see if the problem changes to the other direction If so one valve is malfunctioning or the check relief valve car tridge does not have the proper setting CAUTION The relief valves are factory set and should not be tampered with except for replacing the en tire cartridge Disassembly may change the setting and cause erratic unit operation or premature failure The pressure setting of the valve in bar is indicated three 3 digit code stamped on the cartridge For the M25 PV and PT the cartridge must be removed from the special plug in order to read the code Whenreinstalling torque the plugs to 41 to 68 Nm 30 to 50 Ibsfeft for the M25 PV and or 41 to 95 Nm 30 to 70 Ibsfeft for the M25 style transmission Bypass Valves Variable Pump Tandem Pump The bypass function is accomplished by manually opening the charge check high pressure relief valves If the system is operating hot check that the valves are fully seated by turning the special plugs four 4 on tandem pumps clockwise with a 5 16 internal hex wrench Torque the plugs to 41 to 68 Nm 30 to 50 Ibsfeft Pump Charge Relief Valve If charge pressure is low the charge relief valve should be inspected Inspect for foreign material holding the poppet open and for scoring or wear on the poppet and seat in the end cap or center section Adjustment of the charge pressure is acc
64. ol linkage from the swashplate control shaft With a 3 8 wrench remove the hex tapping screws retaining the trunnion seal cover and bearing carrier to the unit housing Remove the trunnion seal cover and bearing carrier with lip seal and the O ring Place the seal cover and bearing carrier in an arbor press and press out the old seal Once removed the U seal is not reusable Inspect the seal cover and bearing carrier for dam age Inspect the sealing area on the shaft for rust wear or contamination Polish the sealing area on the shaft if necessary Using the arbor press press the new seal into the seal cover and bearing carrier until the outside face of the seal is flush with the outer surface of the cover Be careful not to damage the seal NOTE The outside diameter of the new seal may be coated with a sealant such as Loctite High Performance Sealant 59231 prior to instal lation Fig 50 25 Trunnion Cover Components Journal Bearings 0 Install the O ring onto the bearing carrier and retain with petroleum jelly Lubricate the inside diameter of the new seal with petroleum jelly Wrap the end of the swashplate control shaft with thin plastic to prevent damage to the seal lip during installation Slide the seal cover and bearing carrier assembly over the swashplate control shaft and onto the hous ing Install the hex head tapping screws and torque to 8 to 12 Nm 6 to 9 Ibsfeft Reinstall the con
65. omplished by changing the shim thickness behind the spring The variable pump and tandem pump charge pres sure relief valve is usually factory set at 13 8 bar A 200 psi above case pressure under test conditions The U style transmission charge pressure relief valve is usually factory set at 11 7 bar 170 psi above case pressure under test conditions Exact charge pressure may vary in various applications Fig 30 5 Check High Pressure Relief Valves PV PT 40250010 Fig 30 6 Check High Pressure Relief Valves U Fig 30 7 Charge Relief Valve PV PT 40250012 30 3 SAUER DANFOSS CONTENTS Axial Piston Pumps Motors and Transmissions Series 40 M25 Component Inspections and Adjustments Continued Fig 30 9 Easy Ride Valves PV ee ee i 0250014 Fig 30 10 Heat Exchanger Bypass Valv U af mc 40250016 Fig 30 12 Filter Bypass Reverse Flow Check Valve U 30 4 Easy Ride Valves Variable Pump When a problem occurs in one direction interchange the Easy Ride valves to see if the problem changes to the other direction If so one valve is malfunction ing Inspect for foreign material holding the poppet piston off its seat and for roughness or wear on the poppet surface and its seat in the end cap The poppet piston must slide freely in the sleeve assembly Heat Exchanger Bypass Valve U Style Transmis
66. pouring filtered oil into the upper case drain port Install a 0 to 60 bar or 0 to 1000 psi pressure gauge in the charge pressure gauge port to monitor the charge pressure during start up With the pump swashplate in its neutral 0 angle position jog or slowly rotate prime mover until charge pressure starts to rise Start the prime mover and run at the lowest possible RPM until charge pressure has been established Excess air may be bled from the high pressure lines through the high pressure gauge ports or by carefully loosening the high pressure lines 30 2 5 Series 40 M25 WARNING Do not start prime mover unless pump is in neutral position 0 swashplate angle Take precautions to prevent machine movement in case pump is actuated during initial start up Once charge pressure has been established in crease speed to normal operating RPM Charge pressure should be a minimum of 7 bar 100 psi above case pressure If charge pressure is incorrect shut down and determine cause for improper pres sure With motor output shaft disconnected or drive wheels raised off of the ground run system at full input and output speeds in both directions Operate system for at least fifteen 15 minutes Shut down prime mover remove gauges and plug ports Check reservoir level and add fluid if neces sary The transmission is now ready for operation Maintenance To insure optimum service life o
67. pposite side of the loop through the charge check This limits the pressure rise rate in the loop and reduces the acceleration rate of the vehicle Loop pressure is orificed into the space between the poppet piston and the sleeve assembly through ports inthe poppet piston and the clearance between it and the sleeve The sleeve moves compressing the spring until the spring force equals the hydraulic force SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Functional Description Continued Once the sleeve assembly stops moving the pres sure between the poppet piston and sleeve moves the poppet piston toward its seat sealing off the passage If the loop pressure is above the functional range of the valve approximately 103 bar 1500 psi the sleeve assembly will contact the plug and the poppet piston will be rapidly forced onto its seat A typical Easy Ride valve cycle requires 0 5 to 1 0 seconds depending on system oil viscosity and loop pressure Bypass Valve Variable Pump and Tandem Pump In some applications it is desirable to bypass fluid around the variable displacement pump allowing for example a vehicle to be moved short distances at low speeds without running the prime mover This is accomplished by manually operated bypass valves incorporated into the charge check high pressure relief valves in the variable pump or tandem pump When open unscrewed 4 turns maximum these valves connect both s
68. procedure must be performed to determine the proper shim thickness 1 Install the bearing spacers into the housing with no shims 2 Install the trunnion covers onto the housing In stall the hex head screws and tighten 3 Installa magnetic base dial indicator onto the seal cover and read the swashplate end play while moving the swashplate back and forth by hand Add shims to provide 0 05 to 0 1 mm 0 002 to 0 004 in preload on the swashplate bearings For example if the indicator reads 1 02 mm 0 040 in end play when moving the swashplate back and forth shims of 1 07 to 1 12 mm 0 042 to 0 044 in total thickness should be installed between the bearing cups and the spacers Refer tothe appropriate Service Parts Manual for avail able shim thicknesses and part numbers 4 Remove the trunnion covers from the housing Remove the bearing spacers 40250065 250068 Fig 61 18 Install Trunnion Bearings Tapered Roller Fig 61 17 Install Trunnion Bearings Journal Fig 61 19 Check Swashplate End Play j Tapered Roller 61 5 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions CONTENTS Series 40 M25 Major Repair Variable Pump Continued Fig 61 20 Trunnion Fig 61 21 Torque Cover Components Trunnion Cover Tapered Roller Screws 250062 61 a 402500 Fig 61 23 Install Shaft and Bearing into Housing Fig 61 22 Instal Shaft Bearing
69. ransmis sion Prior to performing Major Repairs on the Series 40 M25U transmission remove the external compo nents as described in the Minor Repair section of this manual These include the following Charge Check High Pressure Relief Valves Charge Relief Valve Heat Exchanger Bypass Valve Filter Bypass Valve Filter Bypass Reverse Flow Check Valve Charge Pump Remove the six 6 screws using a 5 8 hex wrench 3 8 internal hex wrench which retain the center section to the housing Note the positions of the longer and shorter screws The cylinder block springs will separate the center section from the housing Remove the center section from the housing TET CAUTION Fig 65 2 Remove ig 65 2 Remove Center Section Center Section and The pump and motor cylinder blocks may stick Screws Valve Plates to the valve plates and center section Exer cise caution to prevent damage to the sealing surfaces Remove the gasket and two 2 alignment pins from the housing Carefully remove the valve plates from the center section It may be necessary to pry the valve plates off with a small screwdriver Remove the valve plate pins from the center section 8 Fig 65 4 Remove Fig 65 5 Remove gt CAUTION Valve Plates from Valve Plate Pins Center Section Uf Caution must be exercised to prevent damage to the valve plate and center section surfaces Lay the transmission on
70. re factory set and are not field adjustable Changing the maxi mum system pressure can be accomplished by installing different cartridges with the desired setting Direct Displacement Control The direct displacement control DDC may be lo cated on either side of the unit and provides a simple method of control Movement of the swashplate control shaft produces a proportional swashplate movement and change in pump flow and motor shaft speed and or direction The vehicle machine control system must be designed to return the swashplate to its neutral position 1 D MEI ORR FILTER l 7 9 2Z lt gt 74 HEAT EXCHANGER RESERVOIR 1 INLET STRAINER 40250003 Fig 10 4 Charge System U Style Transmission Fig 10 5 Tandem Pump with Direct Displacement Control SAUER DANFOSS Axial Piston Pumps Motors and Transmissions Functional Description Continued 40250005 Fig 10 6 Variable Pump with Auxiliary Mounting Pad Fig 10 7 U Style Transmission with B Charge Pump From Closed Loop System Pressure To Charge Checks Charge Pressure Poppet Piston Sleeve Assembly Spring 40250007 Fig 10 8 Cross Section View of Easy Ride Valve 10 4 5 Series 40 M25 Auxiliary Mounting Pads An SAE auxiliary mounting pad is standard on Series 40 M25 variable and tandem pump
71. ries 40 M25 Minor Repair and Replacement Style Transmission Continued Fig 50 33 Remove Heat Exchanger Bypass Valve Plug U 90250014 alve 50043 Fig 50 35 Remove Filter Bypass Valve Plug U 1 90250015 Fig 50 36 Filter Bypass Valve 0 50 10 Heat Exchanger Bypass Valve Remove the heat exchanger bypass valve plug with a 7 8 hex wrench Remove the spring and poppet from the center sec tion Do not interchange parts with another valve Earlier production transmissions use a spring in the heat exchanger bypass valve which is identified by a yellow dye mark and requires a force of approxi mately 22 5 5 Ibsf to compress it to a length of 45 7 mm 1 28 inches Later production transmissions use a spring in the heat exchanger bypass valve which is identified by a red dye mark and requires a force of approximately 10N 2 2 Ibsf to compress it to a length of 1 28 inches 45 7 mm Inspectthe poppet and mating seat in the end cap for damage or foreign material Reinstall the poppet spring and plug with O ring into the center section Torque the plug to 41 to 95 Nm 30 to 70 Ibsfeft Filter Bypass Valve Remove the filter bypass valve hex plug with a 7 8 wrench Remove the spring and poppet from the center sec tion Do not interchange parts with another valve The spring used in the filter bypass valve is identified by ared dye mark and requires
72. roleum jelly and install onto the swashplate The thrust plate is reversible Assemble the piston assemblies into the slipper guide Lubricate the pistons and cylinder block bores Install the assembled guide and pistons into the cylinder block by inserting the piston assemblies into the cylinder block bores The pistons and bores are not selectively fitted therefore no specific piston and bore orientation is required Lay the pump housing on its side and install the cylinder block kit into the housing SAUER DANFOSS Axial Piston Pumps Motors and Transmissions 5 Series 40 M25 Major Repair Variable Pump Continued Install the valve plate locating pin into the end cap Coat the back steel side of the valve plate with petroleum jelly to hold it in position and install the valve plate onto the end cap with the bronze face visible The notch on the valve plate must engage the locating pin Be certain the correct valve plate is installed on the end cap for the pump rotation and configuration Refer to the appropriate Service Parts Manual for more information Install the two 2 alignment pins and install a new gasket onto the housing Install the end cap with valve plate installed onto the housing aligning the marks made at disassembly When the end cap is properly installed the cylinder block spring will hold the end cap away from the housing approximately 3 mm 1 8 in Insta
73. s This pad is used for mounting an auxiliary hydraulic pump orseparate charge pump Either a 9 tooth or 11 tooth drive spline is available The M25U transmission includes a 22 tooth 24 48 pitch splined PTO drive on the rear end of the pump drive shaft Charge Pumps The M25 variable pump and tandem pump do not include integral charge pumps and require that a separate fixed displacement charge pump be pro vided as part of the system A fixed displacement gerotor type charge pump is provided as a part of the M25U transmission Easy Ride Valves Variable Pump The M25 variable pump is available with optional Easy Ride valves to reduce the rate of change in acceleration jerkiness in vehicle propel applica tions These valves limit the rate of pressure rise in the closed loop by permitting flow from the high to the low pressure side through the charge circuit when system pressure increases suddenly Each Easy Ride valve consists of a poppet piston sleeve assembly spring and plug which are in stalled in the pump end cap The poppet piston and its seat form a valve to close off the passage between one side of the closed loop and the charge pressure passage The spring pre loads the sleeve assembly and holds the poppet piston closed against its seat in the end cap when loop pressure is low A sudden increase in loop pressure will force the poppet piston off its seat allowing some high pres sure fluid to flow to the o
74. s the old seal out of the carrier Refer to the Minor Repair section for further information Slide the output shaft and bearing assembly out of the housing Remove the retaining ring item 005 and press the output shaft item 001 out of the bearing item 004 Refer to Minor Repair section for seal removal information ON B02 Ax NN Reconditioning and Replacement section for information on items B38 and B39 and items B25 B26 and B28 40250114 SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Major Repair Fixed Motor Continued Reconditioning and Replacement of Parts Inspect all parts for damage nicks or unusual wear patterns Replace all parts having unusual or exces Sive wear or discoloration Cracks are not allowed in any surface of the valve plate item B52 or cylinder block The running and sealing surfaces of the valve plate and cylinder block mustbe flat and free of nicks and burrs Replace valve plates or cylinder blocks that show evidence of metal transfer wear or erosion on the running surface If scratches which can be felt with a fingernail or pencil lead are found on the bronze surface of the valve plate or the running surface of the cylinder block polish or replace the parts Remove the valve plate locating spring pin item B39 if necessary Press a new valve plate pin into the end cap until it protrudes from
75. scribed in the Minor Repair section These include the following Auxiliary Mounting Pad Cover and Coupling Easy Ride Valves Where Applicable Charge Relief Valve Charge Check High Pressure Relief Valves After removal of these components mark the orien tation of the pump housing and end cap and remove the four 4 screws using a 5 8 hex wrench and washers which retain the housing to the end cap Remove the housing from the end cap and valve plate Do not allow the valve plate to fall from the end cap Remove the gasket and alignment pins from the end cap Carefully remove the valve plate from the end cap It may be necessary to pry the valve plate off with a small screwdriver CAUTION Caution must be exercised to prevent damage to the valve plate and end cap surfaces Remove the valve plate pin from the end cap Lay the pump housing on its side and remove the cylinder block from the housing Remove the slipper guide and the piston assemblies from the cylinder block Using an O ring pick or wire remove the thrust plate from the swashplate Remove the retaining ring and remove the shaft seal cover per the instructions in the Minor Repair sec tion Remove the drive shaft and bearing assembly from the housing SAUER DANFOSS Axial Piston Pumps Motors and Transmissions CONTENTS Series 40 M25 Major Repair Variable Pump Continued Remove the retaining ring and press the shaf
76. se drain connections to remove hot fluid from the system The variable pump case should be drained from the upper drain port insure the case remains full of fluid The tandem pump case should be drained from the upper drain port of the rear pump section The pump case drain is connected to the lower drain port on the motor housing The upper motor housing drain port is then connected to the reservoir A heat exchanger with a bypass valve may be required to cool the case drain fluid before it returns to the reservoir The M25U transmission case is usually drained through the output and PTO shaft bearings Ports for connecting a heat exchanger into the charge circuit are located in the transmission center section A heat exchanger bypass valve is incorporated into the transmission center section CAUTION Continuous case pressure should not exceed 1 7 bar 25 psi Charge System and Filter The charge pump is used to supply cool fluid to the system and keeps the closed loop charged to prevent cavitation The charge pump draws its fluid from the system reservoir CAUTION Sufficient charge flow MUST be provided to the charge inlet port of the M25 variable pump or tandem pump to ensure that charge pressure is maintained whenever the pump is operating A filter is required to insure that only clean fluid enters the closed loop Either suction or pressure filtration may be used with the M25 variable and tandem pump SAUER
77. sion If the M25U transmission is operating hot the heat exchanger bypass valve in the transmission center section should be inspected Inspect for foreign material holding the poppet open and for scoring or wear on the poppet and seat in the housing Earlier production transmissions use a heat exchanger bypass valve with a nominal setting of 7 4 107 psi The spring for this valve has a yellow dye mark and requires a force of approximately 22 N 5 5 Ibsf to compress it to a length of 45 7 mm 1 28 inches Later production transmissions use a heat exchanger bypass valve with a nominal setting of 4 8 bar A 70 psi The spring used in this valve has a red dye mark and requires a force of approximately 10 N 2 2 Ibsf to compress it to a length of 45 7 mm 1 28 inches Filter Bypass and Reverse Flow Check Valves U Style Transmission Inspect the filter bypass and reverse flow check valves for foreign material holding the poppet open and for scoring or wear on the poppet and seat in the housing The filter bypass valve has a nominal setting of 4 8 bar A 70 psi The spring used in this valve has a red dye mark and requires a force of approximately 10 N 2 2 Ibsf to compress it to a length of 45 7 mm 1 28 inches The spring used in the reverse flow check valve has ablue dye mark and requires a force of approximately 1 3 N 0 3 Ibsf to compress it to a length of 45 7 mm 1 28 inches SAUER CONTENTS DANF
78. t design charge check and high pressure relief valves must also be installed Refer to the appropriate Service Parts Manual for more information Reinstall the valve cartridges into the center section Installthe check valve springs with their larger diame ter toward the plugs Reinstall the plugs with O rings into the center section Torque the plugs to 41 to 95 Nm 30 to 70 Ibsfeft CAUTION The relief valves are factory set and should not be tampered with except for replacing the en tire valve Charge Pressure Relief Valve Remove the charge relief valve hex plug with a 7 8 wrench Remove the spring and poppet from the center sec tion Do not alter the shims which may be installed be tween the spring and plug or interchange parts with another valve Inspect the poppet and mating seat in the end cap for damage or foreign material Reinstallthe poppet spring and plug with shims and O ring into the center section Torque the plug to 41 to 95 Nm 30 to 70 Ibsfeft Fig 50 28 Remove Fig 50 29 Remove Check and Relief Valve Plug A U Check and Relief Valve Plug B U 0250010 Fig 50 30 Check High Pressure Relief Valves U 90280041 Fig 50 31 Remove Charge Relief Valve Plug U 5 Fig 50 32 Charge Relief Valve Components U 90250012 50 9 SAUER DANFOSS CONTENTS Axial Piston Pumps Motors and Transmissions Se
79. t out of the bearing Mark the positions of the trunnion seal cover and trunnion cover on the housing With a 7 16 or 1 2 hex wrench remove the hex screws retaining the trunnion seal cover and trunnion cover to the housing Remove the trunnion seal cover assembly and trun nion cover from the housing Remove the O rings On units with journal bearings remove the swash plate bearing assemblies from the housing and swash plate The assemblies are a slip fit in the housing On units with tapered roller bearings remove the bearing spacers and shims from the housing Do not alter the shim thickness Remove the bearing cups from the housing and the bearing cones from the swashplate The cups and cones are a slip fit in the housing and on the swashplate Tilt and lift the swashplate from the housing Fig 61 10 Remove Fig 61 11 Remove Bearing from Shaft Covers Fig 61 12 Swashplate Bearing Components 40250065 Fig 61 13 Remove Swashplate 61 3 SAUER DANFOSS 5 Axial Piston Pumps Motors and Transmissions Series 40 M25 Major Repair Variable Pump Continued Cap Fig 61 15 Cylinder Block Spring Components 61 4 Reconditioning and Replacement of Parts After disassembly all parts should be thoroughly cleaned in a suitable solvent Replace all O rings gaskets and seals Inspect all parts for damage nicks or unusual wear p
80. trol linkage onto the swashplate control shaft Trunnion Cover Plain The O ring under the plain trunnion cover may be replaced after removing the hex tapping screws with a 3 8 hex wrench and the cover and bearing carrier Install the O ring onto the bearing carrier and retain with petroleum jelly Install the trunnion cover and bearing carrier Install the hex head tapping screws and torque to 8 to 12 Nm 6 to 9 Ibsf ft Fig 50 27 Torque Trunnion Seal Cover Screws U 50 8 SAUER DANFOSS Axial Piston Pumps Motors and Transmissions CONTENTS Series 40 M25 Minor Repair and Replacement U Style Transmission Continued Check and High Pressure Relief Valves Remove the check and high pressure relief valve plugs with a 7 8 hex wrench Remove the springs and valve cartridges from the center section Inspect the valves and mating seats in the center section for damage or foreign material It will be necessary to replace the center section if the seats are damaged Several designs of the charge check and high pres sure relief valve have been used in the M25U trans mission Do not attempt to mix different vintage parts The valve cartridge spring plug and transmission center section were changed at date code 87 39 and are not individually interchangable with earlier design parts NOTE If the center section must be replaced on a unit with a date code prior to 87 39 the lates
81. uxiliary Pump Mounting Pad PV PT Remove the two 2 hex screws retaining the flange cover or auxiliary pump using a 9 16 wrench and remove the cover or pump and the sealing ring On variable pumps the drive coupling may be re moved at this time If a locating pin is present it may be removed from the coupling at this time Pumps with steel pad covers use a single square cut sealing ring If an auxiliary pump is installed an O ring seal must be installed on the pump pilot On variable pumps reinstall the drive coupling with its locating pin if used Reinstall the sealing ring and flange cover with the identifying mark OUT or auxiliary pump Torque the screws to 27 to 34 Nm 20 to 25 Ibsfeft Fig 50 17 Easy Ride Valves Removed PV Fig 50 16 Remove Easy Ride Valves PV PV Fig 50 19 Auxiliary Pad Cover and Drive Coupling Removed PV 40250030 Fig 50 20 Pad Cover Removed PT 50 5 SAUER CONTENTS DANFOSS Axial Piston Pumps Motors and Transmissions Series 40 M25 Minor Repair and Replacement Pumps and Motors Cont 50 6 Plug Fitting Torques PV PT MF If any plugs or fittings are removed from the unit during servicing they should be torqued as indicated in the following table Pressure Gauge Ports amp 12 Nm 7 16 20 O 5 9 Ibsfeft Pressure Gauge Ports MF 20 Nm 9 16 18 O Ring 15 lbsfeft

Series 40 M25 Axial Piston Pumps and Motors Service Manual

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