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Summary of Contents for Danfoss DDC20
- Page 1 Service Manual Axial Piston Pumps DDC20 powersolutions.danfoss.com...
- Page 2 Service Manual DDC20 Axial Piston Pumps Revision history Table of revisions Date Changed August 2017 change charge pump housing 0302 March 2015 add implement pump option March 2014 Danfoss layout September 2011 First printing L1120413 | AX00000135en-US0302 © Danfoss | August 2017...
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Page 3: Table Of Contents
Service Manual DDC20 Axial Piston Pumps Contents Introduction Overview......................................4 Warranty......................................4 General Instructions..................................4 Remove the unit..................................4 Keep it clean....................................4 Lubricate moving parts................................4 Replace all O-rings and gaskets............................. 4 Secure the unit..................................... 5 Safety Precautions....................................5 Unintended machine movement............................5 Flammable cleaning solvents..............................5 Fluid under pressure.................................. -
Page 4: Overview
A worldwide Global Service Partner Network is available for major repairs. Major repairs require the removal of the unit’s endcap, which voids the warranty unless done by a Global Service Partner. Danfoss Global Service Partners are trained by the factory and certified on a regular basis. You can locate your nearest Global Service Partner using the distributor locator at www.powersolutions.danfoss.com... -
Page 5: Secure The Unit
Service Manual DDC20 Axial Piston Pumps Introduction Secure the unit 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. -
Page 6: Symbols Used In Danfoss Literature
Service Manual DDC20 Axial Piston Pumps Introduction Symbols used in Danfoss literature WARNING may result in injury Tip, helpful suggestion CAUTION may result in damage to product or Lubricate with hydraulic fluid property Reusable part Apply grease / petroleum jelly... -
Page 7: Pressure Measurements
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. L1 Case Drain M3 Charge gauge / E - Charge inlet... -
Page 8: Gauge Port Locations And Gauge Installation - With Geroter
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. L1 Case Drain M3 Charge Pressure Gauge Port O-ring Plug 3/4-16UNF-2B... -
Page 9: Gauge Port Locations And Gauge Installation - With Implement Pump
Service Manual DDC20 Axial Piston Pumps Pressure Measurements Gauge Port Locations and Gauge Installation - with Implement Pump The following drawing and table show the gauge port locations and gauge sizes needed. A System Port M3 Charge Gauge/ M3 Charge Pressure Gauge Port... -
Page 10: Adjustments
Service Manual DDC20 Axial Piston Pumps Adjustments Pump Adjustment This section offers instruction on adjustment of pump components. Read through the entire topic before beginning a service activity. Refer to Pressure Measurements on page 7 for location of gauge ports and suggested gauge size. -
Page 11: High Pressure Relief Valve - Hprv
Service Manual DDC20 Axial Piston Pumps Adjustments 6. When the desired charge pressure setting is achieved, remove the gauges. Charge pressure relief valve J320 QJ040 L200 L100 P109626 Charge pressure Model code Actual charge pressure 7 bar ± 1 bar 18 bar ±... -
Page 12: Loop Flushing Valve
Service Manual DDC20 Axial Piston Pumps Adjustments HPRV valves QJ020 J150 P100 P110 N110 N100 J140 QJ020 P109625 Loop Flushing Valve 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... -
Page 13: Troubleshooting
Service Manual DDC20 Axial Piston Pumps Troubleshooting Overview 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. -
Page 14: System Will Not Operate In Either Direction
Service Manual DDC20 Axial Piston Pumps Troubleshooting System will not operate in either direction Item Description Action Oil level in reservoir Low oil level leads to cavitation. Fill reservoir. Open bypass valve If bypass valve is open, the system loop will be Close bypass valve. -
Page 15: Minor Repair
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). - Page 16 Service Manual DDC20 Axial Piston Pumps Minor Repair Item Wrench size Torque K200 6 mm internal hex 20 N•m [15 lbf•ft] Charge pump cover orientation Clockwise rotation Counterclockwise rotation Flat Flat side side P109624 L1120413 | AX00000135en-US0302 16 | ©...
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Page 17: Implement Pump
Service Manual DDC20 Axial Piston Pumps Minor Repair Implement Pump Removal 1. Position the pump with the shaft end pointing down. 2. Remove cap screws (K200/K210). Remove the implement pump housing (K150). 3. Remove and discard O-ring (K100/K110). 4. Remove gerotor (K010). Remove locating pins (K250) from housing. -
Page 18: Shaft And Seal
Service Manual DDC20 Axial Piston Pumps Minor Repair Inspection Inspect all machined surfaces for wear or damage. If any nicks, scratches or wear and found replace the housing and/or gerotor. Assembly 1. Install locating pins (K250) into the endcap. 2. Lubricate and install gerotor (K010). - Page 19 Service Manual DDC20 Axial Piston Pumps Minor Repair Seal, Shaft, Bearing F125 F120 F115 F110 F105 F100 P108 526E L1120413 | AX00000135en-US0302 | 19 © Danfoss | August 2017...
- Page 20 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.
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Page 21: High Pressure Relief Valves - Hprv
Service Manual DDC20 Axial Piston Pumps Minor Repair 7. Using retaining ring pliers, install the seal retaining ring (F125) . Install shaft /seal/bearing F125 F120 F115 F110 F105 F100 P108 553E High Pressure Relief Valves - HPRV Removal 1. Mark the location of each valve for proper reassembly. -
Page 22: Charge Pressure Relief Valve
Service Manual DDC20 Axial Piston Pumps Minor Repair 4. Use a magnet to remove the valves (N110/P110) and springs (N100/P100). High pressure relief valves QJ020 J150 P100 P110 N110 N100 J140 QJ020 P109625 HPRV plug Item Wrench size Torque J140/J150 24 mm 78 N•m [57 lbf•ft]... -
Page 23: Loop Flushing Valve
Service Manual DDC20 Axial Piston Pumps Minor Repair 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. -
Page 24: Bypass Valve
Service Manual DDC20 Axial Piston Pumps Minor Repair 3. Use a magnet to remove the loop flushing spool (H100). Disassemble loop flushing valve J230 J230A H150 H200 J220 H100 H200 H150 J220A P108 530E Loop flushing valve plugs Item Wrench size... - Page 25 Service Manual DDC20 Axial Piston Pumps Minor Repair 2. Install the bypass valve. Torque per table. Bypass valve M200 M100 M120 M120 M130 M130 M110 P108 557E M110 L1120413 | AX00000135en-US0302 | 25 © Danfoss | August 2017...
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Page 26: Optional Coupling
Service Manual DDC20 Axial Piston Pumps Minor Repair Bypass valve plug Item Wrench size Torque M100 17 mm 12 N•m [9 lbf•ft] Optional Coupling Removal Remove the coupling (J538). Inspection Inspect the coupling. If the coupling is damaged, replace it. -
Page 27: Torque Charts
Service Manual DDC20 Axial Piston Pumps Torque charts Fastener Size and Torque Chart - with Charge Pump K200 P109627 Item Fastener Wrench size Torque K200 Charge pump cover mounting bolt 6 mm internal hex 20 N•m [15 lbf•ft] Fastener Size and Torque Chart - with Implement Pump... -
Page 28: Plug Size And Torque Chart - With Gerotor
Service Manual DDC20 Axial Piston Pumps Torque charts Plug Size and Torque Chart - with Gerotor J320 J140 M200 J220 DDC20 with Gerotor P109628 Warning Do not over torque the case drain plugs (L1, L2., L3 Item Plug Port dimensions... -
Page 29: Plug Size And Torque Chart - With Aux Pad
Service Manual DDC20 Axial Piston Pumps Torque charts Plug Size and Torque Chart - with Aux Pad J320 J140 J220 M100 DDC20 with Aux Pad M3 / E J150 J230 DDC20 with Aux Pad P108600 Warning Do not over torque the case drain plugs (L1, L2, L3). -
Page 30: Plug Size And Torque Chart - With Implement Pump
Service Manual DDC20 Axial Piston Pumps Torque charts Plug Size and Torque Chart - with Implement Pump M3 / E M3 / E J140 J320 M200 DDC20 with Implement Pump J150 P108804 Warning Do not over torque the case drain plugs (L1, L2, L3). - Page 31 Service Manual DDC20 Axial Piston Pumps L1120413 | AX00000135en-US0302 | 31 © Danfoss | August 2017...
- Page 32 Phone: +86 21 3418 5200 Danfoss can accept no responsibility 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 changes being necessary in specifications already agreed.