DDC20 Axial Piston Variable Displacement Pump Service Manual
Contents
1. Bypass valve plug Item Wrench size Torque M100 17mm 12 Nem 9 lbf ft Optional Coupling Removal Remove the coupling J538 Inspection Inspect the coupling If the coupling is damaged replace it Reassembly Lubricate and install the coupling 24 L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Minor Repair Remove coupling N J538 Coupling P108 580E L1120413 Rev BA March 2014 25 Service Manual DDC20 Axial Piston Pumps Torque charts Fastener Size and Torque Chart P108 590E Item Fastener Wrench size Torque K200 Charge pump cover mounting bolt 6 mm internal hex 20 N m 15 lbf ft Plug Size and Torque Chart with Gerotor J320 CPRV plug L1 Case Drain N120 HPRV plug O ring Plug 3 4 16UNF 2B M3 Charge Pressure Gauge Port O ring Plug 7 16 20UNF 2B M200 bypass valve cartridge MA system pressure gage port O ring plug 9 16 18UNF 2B DDC20 with Gerotor MB system pressure gage port O ring plug 9 16 18UNF 2B L3 Case Drain P108 599E O ring Plug 3 4 16UNF 2B 26 L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Torque charts A Warning Do not over torque the case drain plugs L1 L2 L3 Item Plug Port dimensions Wrench size Torque N120 P120 HPRV 3 4 16 UNF 24mm 78 Nem 57 lbf ft L12. O H150 Gan 2 a P108 530E Loop flushing valve plugs Item Wrench size Torque J220 J230 11 16 inch 35 Nem 26 lbf ft Inspection Inspect the springs H150 Replace the springs if they are warped or bent Inspect the loop flush spool H100 replace it if it is worn or damaged Inspect plugs and spring guides for wear Install new O rings to plugs before assembly Assembly 1 Lubricate and insert the loop flushing spool H100 into endcap Ensure the spool moves freely in its bore 2 Install the spring guides H200 and springs H150 3 Lubricate and install the O rings J220A J230A on the plugs 4 Thread the loop flushing valve plugs J220 J230 into the endcap and torque per table Bypass Valve Removal Remove the bypass valve M100 Remove and discard the O rings M130 and M110 and the backup ring M120 Inspection Inspect the valve If the bypass valve is damaged replace it L1120413 Rev BA March 2014 23 Service Manual DDC20 Axial Piston Pumps Minor Repair Reassembly 1 Lubricate and install new O rings M130 and M110 and backup ring M120 onto cartridge 2 Install the bypass valve Torque per table Bypass valve OLA PONG Wa yp a E nI G M110 P108 557E
3. DDC20 Axial Piston Pumps Torque charts Item Plug Port dimensions Wrench size Torque J220 J230 Loop flushing valve plug 9 16 18 UNF 11 16 inch internal hex 35 Nem 26 Ibfeft M100 M200_ Bypass valve 9 16 18 UNF 17mm 12 Nem 9 Ibfeft J320 CPRV 1 2 20 UNF 17mm 24 Nem 18 lbf ft MA MB System Pressure Gauge Ports 9 16 18 UNF 11 16 inch 35 Nem 26 Ibfeft 28 L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps L1120413 Rev BA March 2014 29 Service Manual DDC20 Axial Piston Pumps 30 L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps L1120413 Rev BA March 2014 31 Products we offer Danfoss Power Solutions is a global manufacturer and supplier of high quality hydraulic and electronic components We specialize in providing state of the art technology and solutions that Bent Axis Motors excel in the harsh operating conditions of the mobile off highway market Building on our extensive e Closed Circuit Axial Piston Pumps and Motors applications expertise we work closely with our customers to ensure exceptional performance for a broad range of off highway vehicles We help OEMs around the world speed up system development reduce costs and bring vehicles to e Displays market faster e Electrohydraulic Power Danfoss Your Strongest Partner in Mobile Hydraulics Steering Go to www powersolution
4. 15 l min 4 US gal min and are referenced to case pressure At higher charge flows the charge pressure will rise over the rated setting 2 The table shows the acceptable pump charge pressure range for some nominal charge relief valve settings refer to model code located on serial number plate 3 If measured pressure is not correct disassemble the valve and look for signs of wear or contamination Refer to Minor Repair section for wrench sizes and torque settings 4 If the valve is worn replace the entire valve assembly 5 Re check the charge pressure setting 6 When the desired charge pressure setting is achieved remove the gauges 10 L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Adjustments Charge pressure relief valve l Charge pressure P108 562E Model code Actual charge pressure 07 7 bar 1 bar This is the actual charge pressure port gauge reading minus the case pressure port gauge reading Factory set at 1800 min rpm with a reservoir temperature of 50 C 120 F High Pressure Relief Valve HPRV The HPRV valves are pre set at the factory No adjustment is possible If you suspect a HPRV valve malfunction replace valve with identical relief setting and test operation of pump Refer to Minor Repair on page 15 for replacement procedures Whenever you replace or open an HPRV check for pro
5. for possible errors in catalogues brochures and other printed material Danfoss reserves the right to alter its products without notice This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed All trademarks in this material are property of the respective companies Danfoss and the Danfoss logotype are trademarks of Danfoss A S All rights reserved L1120413 Rev BA March 2014 www danfoss com Danfoss A S 2014
6. neutral If bypass valve is open the system loop will be depressurized Low charge pressure insufficient to recharge system loop Close bypass valve Measure charge pressure with the pump in neutral If pressure is low go to Pump charge relief valve Low charge pressure with pump in stroke Low charge pressure resulting from elevated loop leakage Isolate pump from motor by blocking system ports With pump in partial stroke and engaged for only a few seconds check pump charge pressure Low charge pressure indicates a malfunctioning pump Continue to next step Good charge pressure indicates a malfunctioning motor or other system component Check motor charge relief operation if present Pump charge relief valve A pump charge relief valve that is leaky or contaminated or set too low will depressurize the system Replace pump charge relief valve as necessary Charge pump inlet filter Charge pump A clogged filter will under supply system loop A malfunctioning charge pump will provide insufficient charge flow Inspect filter and replace if necessary Repair or replace the charge pump System pressure Low system pressure does not provide enough power to move load Measure system pressure Continue to next step High pressure relief valves Defective high pressure relief valves cause system pressure to be low Replace high pressure relief valves Control Linkage Linkage op
7. should fit together smoothly Using retaining ring pliers install the seal retaining ring F125 L1120413 Rev BA March 2014 19 Service Manual DDC20 Axial Piston Pumps Minor Repair Install shaft seal bearing C F125 e op P108 553E 20 L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Minor Repair High Pressure Relief Valves HPRV Removal 1 Mark the location of each valve for proper reassembly 2 Remove the HPRV valve plugs N120 P120 3 Remove and discard O rings N120A P120A 4 Use a magnet to remove the valves N110 P110 and springs N100 P100 High pressure relief valves Pon P110 N100 E CHE C P108 565E HPRVplug Item Wrench size Torque N120 P120 24mm 78 Nem 57 lbf ft Inspection Inspect the springs H150 Replace the springs if they are warped or bent Inspect the loop flush spool H100 replace it if it is worn or damaged Inspect plugs and spring guides for wear Assembly 1 Lubricate and install new O rings N120 P120 onto each plug 2 Verify that the springs N100 P100 are properly retained on the valves N110 P110 3 Install the valves in their original location as noted during disassembly Ensure each valve assembly moves freely in its bore 4 Tor
8. 413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Pressure Measurements Gauge Port Locations and Gauge Installation with Geroter The following drawing and table show the gauge port locations and gauge sizes needed For service information refer to DDC20 Service Manual L1120413 L1 Case Drain M3 Charge Pressure Gauge Port O ring Plug 3 4 16UNF 2B O ring Plug 7 16 20UNF 2B Q O MA system pressure gage port O ring plug 9 16 18UNF 2B S Charge suction port DDC20 with Gerotor L3 Case Drain P108 598E O ring Plug 3 4 16UNF 2B MB system pressure gage port O ring plug 9 16 18UNF 2B Port Information Port Identifier Port Size Wrench Size Pressure Obtained Gauge Size bar psi L1 L2 L3 3 4 16 UNF 5 16 inch internal hex Case Drain 10 100 MA MB 9 16 18 UNF 11 16 hex wrench System Pressure 500 5000 S 7 8 14 UNF N A plastic shipping plug Charge Inlet 2 30 Vacuum M3 7 16 20 UNF 3 16 inch internal hex Charge Pressure 50 1000 L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Adjustments Pump Adjustment Standard Procedures Charge Pressure Relief Valve This section offers instruction on adjustment of pump components Read through the entire topic before beginning a service activity R
9. L2 L3 Case drain 3 4 16 UNF 5 16 inch internal hex 29 Nem 21 lbf ft J220 J230 Loop flushing valve plug 9 16 18 UNF 11 16 inch internal hex 35 Nem 26 lbf ft M100 M200 Bypass valve 9 16 18 UNF 17mm 12 Nem 9 lbf ft J320 CPRV 1 2 20 UNF 17mm 24 Nem 18 lbf ft MA MB System Pressure Gauge Ports 9 16 18 UNF 11 16 inch 35 Nem 26 Ibfeft M3 Charge Pressure Gauge Port 7 16 20 UNF 3 16 inch internal hex 19 Nem 14 lbf ft Plug Size and Torque Chart with Aux Pad M3 Charge gauge E Charge inlet O ring plug 9 16 18UNF 2B N120 HPRV plug L1 Case Drain O ring Plug 3 4 16UNF 2B J320 CPRV plug Loop flushing valve plug J220 DDC20 with Aux Pad M100 bypass valve cartridge M3 Charge gauge E Charge inlet MA system pressure gage port L2 Case Drain O ring plug 9 16 18UNF 2B O ring plug 9 16 18UNF 2B O ring Plug 3 4 16UNF 2B P120 HPRV plug Q Loop flushing valve plug L3 Case Drain J230 O ring Plug 3 4 16UNF 2B DDC20 with Aux Pad P108 600E SE MB system pressure gage port O ring plug 9 16 18UNF 2B A Warning Do not over torque the case drain plugs L1 L2 L3 Item Plug Port dimensions Wrench size Torque N120 P120 HPRV 3 4 16 UNF 24mm 78 Nem 57 lbf ft M3 E Charge gauge Charge inlet 9 16 18 UNF 1 4 inch internal hex 35 Nem 26 Ibfeft L1 L2 L3 Case drain 3 4 16 UNF 5 16 inch internal hex 29 Nem 21 Ibfeft L1120413 Rev BA March 2014 27 Service Manual
10. M E 10 Standard Proc dures sscsvsesssesrsisayaceonssessersasesacesusnssenoitagacebuess otnsiagascubusssucensiayacecensssensasiaqasacovanasseasvaya esuonsatassusasaeenninsancovaaassioes 10 Charge Pressure Relief Valve cssscsssssccssssscsssecssstesssusecssnssessusecssusecssnsesesnseessnseeesusecssnscessasecesusecssuseeesaseessnsesesnseessnseessaseeeenseesse 10 High Pressure Relief Valve HBM 11 LOOP Flushing ELE 12 Eelere EE 13 Sekten operating hotas Seeerei 13 Transmission operates normally in ONE direction on 13 Systemi Deler or VIDCAUION 0 TT ST c anioien Ca c C 0701 13 System will not operate in either directon EEN 13 leie Eu een E 14 Charge PUM E 15 Disassembly teste 15 ISO EE 15 Assembly 18 Shaft and Seal 17 Shaft seal removal Ek Sh ft removal egene rer 19 ll TN 19 Bari IMSPOCUION BE 19 Assembly E 19 High Pressure Relief Valves HPN 21 PREMIO EE 21 ISDGGIOT eegene dee E ESEE A ENNEA EE 21 Assembly riennoista e giang 1x5 30btp6g11as8ses0x6ldabtuissoa Bi ta6 21 Charge Pressure Relief Valve aaa Removal wd Inspection 22 le EE 22 Loop Fl shing Va V Ges ctewszczrsseidsssctsssdaveuess consscacassusesvccchatesdaayasaceccguasscea ivssbaasa SALT S iTi NEES 22 PREM OW E 22 INSPECTION eegen retten dee dE Ee EEGEN ER Ee Yi 601556 S4 ba6 16k bai tia iti 1 i a E Ea ia iae T PEE rE IRET 23 e 23 L1120413 Rev BA March 2014 3 Service Manual DDC20 Ax
11. MAKING MODERN LIVING POSSIBLE Service Manual DDC20 Axial Piston Pumps powersolutions danfoss com Service Manual DDC20 Axial Piston Pumps Revision History Table of Revisions Date Changed Rev March 2014 Danfoss layout BA September 2011 First printing AA 2 L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Contents Introduction Pressure Measurements Adjustments Troubleshooting Minor Repair OVENI EW ee Ee 5 Warranty General Instructions Remove the unit Keep it clean Lubricate moving parts Replace all O rings and Gaskets sscsssseccsseccssssecsssssesseessssseesssesessuscessueeessuseessnsecssueeessuseessnseessuseessuecesseeeecaseessneeesaseessaeeesse 5 Secure the UM it esssscsccsasscssccinssesshonssbocetnssessantsssascntuniessanceanencetuassasantiabecedbantesceataescdvanssasentiabcubintutscbatsabest vansedustbidnededvadetindoianertdve 6 SPRY PRECAUTION S read EES 6 Unintended machine movement EEN 6 Flammable cleaning SOIVENtS e ccsssccssessccseccssssessssssesssccessuseccsseesssuecessuecessseecsssseccsnscessuseccsueeessuscessuseessueesssuseessaseessuseessuses 6 Eluid uder TTT Personal safety ds Symbols used in Danfoss literature Gauge Port Locations and Gauge Installation with AUX Baden 8 Gauge Port Locations and Gauge Installation With Geroter ENEE 9 PAU THAD AG SHI
12. O ring K100 5 Remove gerotor K010 Push out the drive pin K050 Inspection Inspect all machined surfaces for wear or damage If any nicks scratches or wear are found replace the cover and or gerotor Assembly 1 Install drive pin K050 into the shaft 2 Lubricate and install the gerotor 3 Lubricate and install O ring into cover K105 4 Install the cover in its original position 5 Install screws K200 Torque screws per table L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Minor Repair Charge pump e K200 K150 CD _ K100 FF a geg ECH B TS 2 Ge N 6 2 2 2 P108 524E Item Wrench size Torque K200 6 mm internal hex 20 Nem 15 lbf ft 16 L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Minor Repair Charge pump cover orientation Clockwise rotation Flat J side LA Shaft and Seal Shaft seal removal 1 Orient pump with the shaft pointing up Counterclockwise rotation Flat side P108 587E 2 Usi
13. acuum Low charge pressure will overwork system High inlet vacuum will overwork system A dirty filter will increase the inlet vacuum Inadequate line size will restrict flow Measure charge pressure Inspect and or replace charge relief valve Inspect charge pump Repair or replace charge pump Check charge inlet vacuum If high inspect inlet filter and replace as necessary Check for adequate line size length or other restrictions System relief pressure settings If the system relief valves are worn contaminated or valve settings are too low the relief valves will be overworked Verify settings of high pressure relief valves and replace valves as necessary System pressure Frequent or long term operation over system relief setting will create heat in system Measure system pressure If pressure is too high reduce loads Transmission operates normally in one direction only Item Description Action Control linkage Control linkage operating improperly Repair replace control linkage High pressure relief valve Malfunctioning HPRV can affect one direction while the other functions normally Exchange the high pressure relief valves If the problem changes direction replace the valve that does not operate correctly Settings may be different for forward reverse System noise or vibration Item Description Action Oil level in reservoir L
14. affect your warranty Major repairs requiring the removal of the units endcap voids the warranty unless completed by a Danfoss Global Service Partner Remove the unit A Prior to performing major repairs remove the unit from the vehicle machine Chock the wheels on the vehicle or lock the mechanism to inhibit movement Be aware that hydraulic fluid may be under high pressure and or hot Inspect the outside of the pump and fittings for damage Cap hoses and plug ports after removal to prevent contamination Keep it clean Cleanliness is a primary means of assuring satisfactory pump life on either new or repaired units Clean the outside of the pump thoroughly before disassembly Take care to avoid contamination of the system ports Cleaning parts using a clean solvent wash and air drying is usually adequate As with any precision equipment keep all parts free of foreign materials and chemicals Protect all exposed sealing surfaces and open cavities from damage and foreign material If left unattended cover the pump with a protective layer of plastic Lubricate moving parts A During assembly coat all moving parts with clean hydraulic fluid This assures that these parts are lubricated during start up Replace all O rings and gaskets M Danfoss recommends you replace all O rings seals and gaskets during repair Lightly lubricate all O rings with clean petroleum jelly pr
15. avy wear Inspect the shaft surface where it meets the shaft seal Replace the shaft if a groove exists at the sealing land surface that may let dirt into or hydraulic fluid out of the unit Clean the sealing area with a nonabrasive material if necessary Lubricate the shaft with a light coat of hydraulic fluid before assembly Bearing inspection Clean bearing with a solvent and lubricate with hydraulic fluid Inspect for wear or pitting The bearing should rotate smoothly Replace the bearing if you feel any roughness Assembly 1 Position the pump with the shaft end pointing up If previously removed press bearing onto shaft by applying force to the inner race 2 Lubricate and install bearing F105 with hydraulic fluid Install retaining ring F110 using retaining ring pliers 4 Install shaft F100 with bearing F105 into housing Ensure the shaft splines engage the block splines and the shaft end slides smoothly into the rear bearing It may be necessary to tap lightly on the shaft to seat the bearing Using retaining ring pliers install the retaining ring F115 Cover shaft splines with an installation sleeve or packaging tape to protect seal during installation Lubricate new shaft seal F120 press into housing until it bottoms out Press evenly to avoid binding and damaging the seal Caution Do not damage the housing bore shaft or rear bearing when installing the shaft and shaft seal All components
16. efer to Pressure Measurements on page 8 for location of gauge ports and suggested gauge size Q Caution Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lines 1 With the prime mover off thoroughly clean the outside of the pump 2 If removing the pump from the machine tag each hydraulic line connected to the pump If hydraulic lines are disconnected plug each open port to ensure that dirt and contamination do not get into the pump 3 Ensure the surrounding areas of the machine are clean and free of contaminants such as dirt and grime 4 Look at the hydraulic fluid for signs of system contamination oil discoloration foam in the oil sludge or small metal particles 5 If there are signs of contamination in the hydraulic fluid drain the hydraulic system replace all filters flush the lines and fill the system with the proper hydraulic fluid The following procedure explains how to check for proper operation of the charge pressure relief valve Charge pressure is the measured pressure minus case drain pressure 1 Install a 50 bar 1000 psi pressure gauge at the charge pressure gauge port Install a 10 bar 100 psi gauge at one of the case pressure ports Operate the system with the pump in neutral zero displacement when measuring charge pressure Pressure listed in model code assumes a charge flow of
17. erating improperly Repair replace control linkage Sluggish system response Item Description Action Oil level in reservoir Low oil level causes sluggish response Fill reservoir High pressure relief valves Low prime mover speed Incorrect system pressures will affect system reaction time High pressure relief valve with orifice may affect system reaction time Low engine speed will reduce system performance Replace high pressure relief valves Adjust engine speed Air in system Air in system will produce sluggish system response Fill tank to proper level Cycle system slowly for several minutes to remove air from system Pump inlet vacuum Inlet vacuum is too high resulting in reduced system pressure Measure charge inlet vacuum Inspect line for proper sizing Replace filter Confirm proper bypass operation Bypass valve Slightly activated bypass valve will cause cross port leakage Verify that the bypass valve is closed and that the valve is seating properly Clean repair or replace it as necessary 14 L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Minor Repair Charge Pump Disassembly 1 Position the pump with the shaft end pointing down 2 Mark the orientation of the charge pump cover on the endcap for proper reassembly 3 Remove cap screws K200 Remove the charge pump cover K150 4 Remove and discard
18. ial Piston Pumps Contents ue ER Inspection Reassembly 24 Optional ege IIe Un D 24 ue Inspection Reassembly Torque charts Fastener Size and Torque Chart Plug Size and Torque Chart with Gerotor Plug Size and Torque Chart with Aux Pad 4 L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Introduction Overview Warranty General Instructions This manual includes information on maintenance troubleshooting and minor repair of DDC20 pumps Performing minor repairs may require removal from the vehicle machine Thoroughly clean the unit before beginning maintenance or repair activities Since dirt and contamination are the greatest enemies of any type of hydraulic equipment follow cleanliness requirements strictly This is especially important when changing the system filter and when removing hoses or plumbing A worldwide network of Danfoss Global Service Partners GSPs are authorized to perform major repairs Danfoss trains Global Service Partners and certifies their facilities on a regular basis You can locate your nearest Authorized Service Center using the distributor locator at www sauer danfoss com For more detailed informaion about DDC20 pumps including operating parameters and technical specifications refer to DDC20 Technical Information Manual L1104976 Performing maintenance and minor repairs according to the procedures in this manual will not
19. ior to assembly Grease must be soluable in hydraulic fluid L1120413 Rev BA March 2014 5 Service Manual DDC20 Axial Piston Pumps Introduction Secure the unit SS For major repair place the unit in a stable position with the shaft pointing downward It is necessary to secure the pump while removing and torquing components and fasteners Safety Precautions Always consider safety precautions before beginning a service procedure Protect yourself and others from injury Take the following general precautions whenever servicing a hydraulic system Unintended machine movement A Warning Unintended movement of the machine or mechanism may cause injury to the technician or bystanders To protect against unintended movement secure the machine or disable disconnect the mechanism while servicing Flammable cleaning solvents A Warning Some cleaning solvents are flammable To avoid possible fire do not use cleaning solvents in an area where a source of ignition may be present Fluid under pressure A Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and or infection This fluid may also be hot enough to cause burns Use caution when dealing with hydraulic fluid under pressure Relieve pressure in the system before removing hoses fittings gauges or components Never use your hand or any other body part to check for leak
20. ng a retaining ring pliers remove retaining ring F125 3 Remove the shaft seal F120 and discard Caution Do not damage the housing bore shaft or bearing when removing the shaft and shaft seal Carefully drive a small sheet metal screw into the shaft seal to facilitate removal Be careful not to damage the bearing below the seal Attach a slide hammer or appropriate puller to the screw head and pull to remove the seal L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Minor Repair Seal Shaft Bearing C F125 P108 526E 18 L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Minor Repair Shaft removal 1 Using a retaining ring pliers remove retaining ring F115 2 Pull the shaft F100 with bearing F105 out of the pump If necessary tap lightly on the shaft to dislodge it from the internal pump components Caution Moving the pump with the shaft removed may dislodge the rotating group making reassembly impossible without removing the endcap 3 If replacing the bearing F105 remove retaining ring F110 using a retaining ring pliers 4 Press on the inner race to remove the bearing F105 from the shaft Shaft inspection Ensure the shaft and its splines are straight and free of damage or he
21. ow oil level leads to cavitation Fill reservoir Aeration of the oil pump inlet vacuum Air in system decreases efficiency of units and controls Air in system is indicated by excessive noise in pump foaming in oil and hot oil Find location where air is entering into the system and fix Check that inlet line is not restricted and is proper size Cold oil If oil is cold it may be too viscous for proper function and cause cavitation Allow the oil to warm up to its normal operating temperature with engine at idle speed Pump inlet vacuum High inlet vacuum causes noise cavitation Check that inlet line is not restricted and is proper size Check filter and bypass valves if present Shaft couplings A loose shaft coupling will cause excessive noise Replace loose shaft coupling Shaft alignment Misaligned shafts creates noise Align shafts Charge High pressure relief valves Unusual noise may indicate sticking valves Possible contamination Clean replace valves and test pump May be a normal condition System will not operate in either direction Item Description Action Oil level in reservoir Low oil level leads to cavitation Fill reservoir L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Troubleshooting Item Description Action Open bypass valve Low charge pressure with pump in
22. per pump operation by cycling through its full operating range L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Adjustments Loop Flushing Valve HPRV valves P108 568E The loop flushing valve is not adjustable If you suspect a loop flushing malfunction disassemble the valve and check for worn damaged or scored components Replace parts if necessary Refer to Minor Repair on page 15 for disassembly procedures Loop flushing valve L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Troubleshooting Overview System operating hot This section provides general steps to follow if you observe undesirable system conditions Follow these steps until you solve the problem Some of the items are system specific For areas this manual covers we reference the section Always observe the safety precautions listed in ntroduction on page 5 and precautions related to your specific equipment Item Description Action Oil level in reservoir Insufficient hydraulic fluid will not meet cooling demands of system Fill reservoir to proper level Heat exchanger Heat exchanger not sufficiently cooling the system Check air flow and input air temperature for heat exchanger Clean repair or replace heat exchanger Charge pressure Charge pump inlet v
23. que plugs per table 5 Operate vehicle machine through full range of controls to ensure proper operation Check for leaks Charge Pressure Relief Valve Removal 1 Remove the charge pressure relief valve plug J320 Remove and discard O ring J320A L1120413 Rev BA March 2014 21 Service Manual DDC20 Axial Piston Pumps Minor Repair 2 Use a magnet to remove the spring L200 3 Use a magnet to remove the charge relief poppet L100 Inspection Inspect charge relief valve plug spring and poppet for wear or damage Replace parts if they are damaged Reassembly 1 Insert the charge relief valve poppet L100 and spring L200 into the endcap 2 Lubricate and install a new O ring J320A 3 Install the charge relief valve plug J320 Torque per table Charge pressure relief valve Charge pressure relief valve plug Item Wrench size Torque J320 17mm 24 Nem 18 lbf ft Loop Flushing Valve Removal 1 Remove the loop flushing valve plugs J220 J230 Remove and discard O rings J220A J320A 2 Use a magnet to remove the springs H150 and spring guides H200 3 Use a magnet to remove the loop flushing spool H100 22 L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Minor Repair Disassemble loop flushing valve
24. s danfoss com for further product information e Electrohydraulics e Hydraulic Power Steering Wherever off highway vehicles are at work so is Danfoss e Integrated Systems We offer expert worldwide support for our customers ensuring the best possible solutions for outstanding performance And with an extensive network of Global Service Partners we also provide e Joysticks and Control Handles e Microcontrollers and Please contact the Danfoss Power Solution representative nearest you Software Open Circuit Axial Piston Pumps e Orbital Motors e PLUS 1 GUIDE e Proportional Valves Sensors Steering e Transit Mixer Drives Comatrol www comatrol com Local address Schwarzmiiller Inverter www schwarzmueller inverter com Turolla www turollaocg com Valmova www valmova com Hydro Gear www hydro gear com Daikin Sauer Danfoss www daikin sauer danfoss com Danfoss Danfoss Power Solutions US Company Power Solutions GmbH amp Co OHG 2800 East 13th Street Krokamp 35 Ames IA 50010 USA D 24539 Neum nster Germany Phone 1 515 239 6000 Phone 49 4321 871 0 comprehensive global service for all of our components Power Solutions ApS Nordborgvej 81 DK 6430 Nordborg Denmark Phone 45 7488 2222 Danfoss Power Solutions Shanghai Co Ltd Building 22 No 1000 Jin Hai Rd Jin Qiao Pudong New District Shanghai China 201206 Phone 86 21 3418 5200 Danfoss can accept no responsibility
25. s in a pressurized line Seek medical attention immediately if you are cut by hydraulic fluid Personal safety A Warning Protect yourself from injury Use proper safety equipment including safety glasses at all times Symbols used in Danfoss literature WARNING may result in injury CAUTION may result in damage to product or property Reusable part II Non reusable part use a new part Non removable item Option either part may exist 6 L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Introduction Q J O Gi 5 co Gi A is t e Ss The symbols shown above appear in the illustrations and text of this manual They are intended to communicate helpful information at the point where it is most useful to the reader In most instances the appearance of the symbol itself denotes its meaning The legend above defines each symbol and Superseded parts are not interchangeable Measurement required Flatness specification Parallelism specification External hex head Internal hex head Torx head O ring boss port Tip helpful suggestion Lubricate with hydraulic fluid Apply grease petroleum jelly Appl
26. y locking compound Inspect for wear or damage Clean area or part Be careful not to scratch or damage Note correct orientation Mark orientation for reinstallation Torque specification Press in press fit Pull out with tool press fit Cover splines with installation sleeve Pressure measurement gauge location or specification explains its purpose L1120413 Rev BA March 2014 Service Manual DDC20 Axial Piston Pumps Pressure Measurements Gauge Port Locations and Gauge Installation with Aux Pad The following drawing and table show the gauge port locations and gauge sizes needed For service information refer to DDC20 Service Manual L1120413 M3 Charge gauge E Chargeinlet D Case Drain O ring plug 9 16 18UNF 28 O ring Plug 3 4 16UNF 28 System port A DDC20 with Aux Pad System port B M3 Charge gauge E Charge inlet O ring plug 9 16 18UNF 2B L2 Case Drain O ring Plug 3 4 16UNF 2B MA system pressure gauge port O ring plug 9 16 18UNF 2B Q MB system pressure gauge port L3 Case Drain O ring plug 9 16 18UNF 2B O ring Plug 3 4 16UNF 28 P108 561E Port Information Port Identifier Port Size Wrench Size Pressure Obtained Gauge Size bar psi L1 L2 L3 3 4 16 UNF 5 16 inch internal hex Case Drain 10 100 MA MB 9 16 18 UNF 11 16 hex wrench System Pressure 500 5000 M3 E 9 16 18 UNF 1 4 inch internal hex Charge Pressure 50 1000 L1120
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