Sauer Danfoss 20 Series Service Manual
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Sauer Danfoss 20 Series Service Manual

Axial piston pumps
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Series 20
Axial Piston Pumps
Service Manual and
Repair Instructions

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  • Page 1 Series 20 Axial Piston Pumps Service Manual and Repair Instructions...

  • Page 2: Introduction And Description

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Introduction, Description INTRODUCTION The purpose of this manual is to provide you with the information necessary for the normal maintenance and servicing of the Sauer-Danfoss hydrostatic series 20 units. This includes a description of the units and their components as well as troubleshooting, pressure setting and repair procedures.

  • Page 3: Table Of Contents

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Contents CONTENTS Introduction and description ........................... 2 Model Code ..................................4 Recommended tools and installation ........................5 List of tools necessary for minor repairs and maintenance of units of all sizes ........5 Additional tools list for complete stripping of units ..................

  • Page 4: Model Code

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Model Code TYPE DESIGNATION AND ORDER CODE S P V 2 Producer mark Series of product c i f Pump variable according to construction Association (at present = A1) type 20 Units with working mark Displacement cm...

  • Page 5: Recommended Tools And Installation

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Recommended Tools and Installation LIST OF TOOLS 1 Circlip pliers ∅ 2 to 2.5 mm NECESSARY FOR MINOR 1 Screw driver 3 mm REPAIRS AND 1 Screw driver 6 mm MAINTENANCE OF UNITS 1 Screw driver 9 mm OF ALL SIZES...

  • Page 6: Trouble Shooting, Gauge Installation And Information

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Recommended Tools and Installation TROUBLE SHOOTING, GAUGE INSTALLATION AND INFORMATION P000 341 Gauge Information 60 bar [870 psi] - Gauge Charge Pressure 7/16 - 20 UNF O-ring Fitting 600 [8700 psi] bar - Gauge System Pressure 7/16 - 20 UNF O-ring Fitting Vacuum gauge...

  • Page 7: Start-Up Procedure

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Start-up procedure PRECONDITIONS FOR Cleanliness: Ensure that the pipes, pipe connections and hoses as well as all other TROUBLE-FREE components are completely clean. OPERATION Ventilation and venting of the oil reservoir via an air filter. Operating fluid: HLP fluid according to DIN 51524, ATF type A SUFFIX A, HD-SAE motor oils, see Fluid Manufacturers,Technical Information.

  • Page 8: First-Time Operation

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Start-up procedure PRECONDITIONS FOR The charge pressure measured at the charge pressure gauge connection port of the TROUBLE-FREE pump with the adjusting lever in the neutral position should be approx. 15 bar [217.6 psi] OPERATION (continued) at a pump input speed n = 1500 min (rpm).
  • Page 9 Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Start-up procedure Control handle Gauge port - servo cylinder pressure (both side) Gauge port "M": Charge pressure Port "S": Suction port (charge pump) Port "A"+"B": High pressure Case drain ports P000 337E DKMH.PS.315.B1.02 520L0535...

  • Page 10: Plumbing Installation (Variable Displac. Pump - Fixed Displac. Motor)

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Start-up procedure PLUMBING INSTALLA- TION (VARIABLE DISPLACEMENT PUMP - FIXED DISPLACEMENT MOTOR) P000 341 SYSTEM CIRCUIT DESCRIPTION HEAT EXCHANGER BYPASS VALVE RESERVOIR VACUUM GAUGE CONTROL HANDLE HEAT EXCHANGER SERVO CONTROL CYLINDER REVERSIBLE VARIABLE DISPLACEMENT PUMP FIXED...

  • Page 11: System Maintenance

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions System Maintenance INLET FILTER (BETWEEN The filter element must be exchanged as soon as the pressure drops below 0.75 bar FLUID RESERVOIR AND [10.9 psi] absolute (-0.25 bar [-3.6 psi]) when the transmission is at normal operating CHARGE PUMP) temperature.The filter must also be exchanged each time the pressure fluid is changed.

  • Page 12: Trouble Shooting

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Trouble Shooting TRANSMISSION Inspect high pressure Insert charge relief valve Check control OPERATES IN ONE check valves (see Series 20 Axial Piston linkage DIRECTION ONLY Motors, Service Manual (see page 14) and Repair Instruction) Defective Defective...

  • Page 13: Neutral Difficult Or Impossible To Find

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Trouble Shooting NEUTRAL DIFFICULT OR IMPOSSIBLE TO FIND Check control Inspect control valve Replace linkage (see page 15) pump Defective Defective Repair Replace control valve or replace (see page 23) SYSTEM WILL NOT OPERATE IN EITHER DIRECTION Check fluid Inspect motor...

  • Page 14: Inspection Instructions

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Trouble Shooting INSPECTION Checking the charge pressure INSTRUCTIONS 1. Clean the charge pressure gauge connection on the pump. 2. Pressure gauge (see recommended measuring instruments) to be connected. 3. Set operating speed at 1500 min 4.

  • Page 15: Checking The Servo Valve (Control Valve)

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Trouble Shooting INSPECTION Checking the servo valve (control valve) 89, 90 INSTRUCTIONS F000 083 F000 082 1. Disconnect the external control 2. Remove the cap screws (see page 22). linkage from the control handle and check for neutral operating with control handle.

  • Page 16: Disassembly And Assembly

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly SECTIONAL VIEW Axial piston variable displacement pump Swash plate Control handle Servo valve (control valve) Charge pump Input shaft Charge check valve Shaft seal Cylinder block assembly Servo cylinder P005 121E DKMH.PS.315.B1.02 520L0535...

  • Page 17: Exploded View

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly EXPLODED VIEW P005 113 Description of parts: 1 Hexagonal screw 28 Piston assembly 65 Hexagonal screw 2 Washer 29 Thrust plate 66 Washer 3 Charge pump assembly 30 Screw 67 Trunnion 4 Gasket charge pump...

  • Page 18: Minor Repairs

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MINOR REPAIRS The areas of repair indicated may be serviced, following the procedures in this manual, without invalidating the warranty. Preparation for assembly When using a lifting device, the hooks at the end of the slings, are to be fastened in the rings fitted at the front and rear of the motor body.

  • Page 19: Changing The Shaft Seal Disassembly

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MINOR REPAIRS Changing the shaft seal (disassembly) Clamp seal puller on seal-stationary F000 086 F000 087 It is recommended that all shaft seal The seal-stationary is removed next. It parts be replaced.

  • Page 20: Changing The Shaft Seal Assembly

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MINOR REPAIRS Changing the shaft seal (assembly) (continued) 71 Bronze ring Slide the bronze sealing ring over the shaft and onto the shaft pilot diameter with the O-ring facing the unit. Work the ring into place using hand force only.

  • Page 21: Changing The Charge Pump And The Charge Check Valves

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MINOR REPAIRS Changing the charge pump and the charge check valves 1, 2 Socket wrench (continued) F000 092 To remove the charge pump, loosen the four (4) cap screws that form a rectangu- lar pattern.
  • Page 22 Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MINOR REPAIRS To inspect or replace the charge relief The removal of the charge check valves (continued) valve, use a “1“ wrench to remove the requires the use of a draglink socket. hex plug and the spring and valve cone.

  • Page 23: Changing The Servo Valve (Control Valve)

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MINOR REPAIRS Changing the servo valve (control valve) (continued) 89, 90 F000 046 F000 083 Thoroughly clean external surfaces with steam or clean solvent and blow dry. Remove the nine (9) cap screws (using 7/16 wrench) and swing control away from housing.

  • Page 24: Major Repairs

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MAJOR REPAIRS Changing the valve- and bearing plate (disassembly) 1. Disassembly the charge pump (see 10 7, 8, 9 Socket insert pages 21, 22). 2. The end-cap screws may not be loosened until the shaft seal has been removed (see page 19).

  • Page 25: Changing The Valve And Bearing Plate Assembly

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MAJOR REPAIRS counterclockwise clockwise (continued) F000 099 The pump valve plate has two tapered slots running in opposite directions. F000 100 The valve plate illustrated on the left is for left handed (counter clockwise) Remove the bearing plate and the operation, and the valve plate illustrated...
  • Page 26 Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MAJOR REPAIRS The valve plate must be positioned with (continued) the slot in the valve plate on the dowel pin of the end cap housing. Torque spanner 7, 8, 9 with extension piece F000 103...

  • Page 27: Changing The Cylinder Block Kit Disassembly

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MAJOR REPAIRS Changing the cylinder block kit (disassembly) (continued) Cone bearing F000 104 After removal of the bearing, slip the spacer out of the bore of the cylinder Cone bearing F000 066 block.

  • Page 28: Changing The Cylinder Block Kit Assembly

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MAJOR REPAIRS Changing the cylinder block kit (assembly) (continued) F000 107 F000 106 The cylinder block assembly should be Before reassembling the cylinder block installed next. It is necessary to check assembly, the thrust plate must be alignment of the ball guide and cylinder withdrawn from the swash plate, and be...

  • Page 29: Changing The Swash Plate And Servo Piston Disassembly

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MAJOR REPAIRS Changing the swash plate and servo piston (disassembly) (continued) In order to be able to replace the swash plate and the servo pistons, the opera- tions previously described on the pages 19, 21, 22, 23 and 25 must be carried out.
  • Page 30 Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MAJOR REPAIRS (continued) Cone bearing F000 114 Take care that the plastic shims are kept together with the respective trunnions. F000 113 Mark the trunnion to facilitate correct re-assembly later, and loosen the three screws on each trunnion.Than remove the trunnion.

  • Page 31: Changing The Swash Plate And Servo Piston Assembly

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MAJOR REPAIRS Changing the swash plate and servo piston (assembly) Swash plate (continued) Once several parts have been replaced as connecting link necessary lay the swash plate complete with servo piston, in the pump housing and bring the swash plate connecting link into the correct position.
  • Page 32 Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MAJOR REPAIRS If adjustment required follow these steps. (continued) a. Back out both servo housings until the spring load is released on the swash plate (check by rocking swash plate).

  • Page 33: Changing The Pump Shaft

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MAJOR REPAIRS 50 Cone bearing Torque 54, 55, 102 (continued) spanner F000 069 Take care that the shaft seal is only fitted after the end cap has been screwed down.
  • Page 34 Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Disassembly and Assembly MAJOR REPAIRS Next loosen the front cover screws and remove the front cover together with the gasket. (continued) The shaft with bearing can then be removed. Should the bearings be damaged, the bearing cup in the front cover must also be replaced.

  • Page 35: Installation Torque Values

    Series 20 – Axial Piston Pumps Service Manual and Repair Instructions Installation Torque Values Installation torque values Nm [lbf•in], series 20 Frame size End cap 36.6 [324] - 50.2 [444] 36.6 [324] - 50.2 [444] 36.6 [324] - 50.2 [444] 61.0 [540] - 73.2 [648] Charge pump 13.6 [120] - 14.9 [132]...
  • Page 36 OUR PRODUCTS Sauer-Danfoss Hydraulic Power Systems – Market Leaders Worldwide Hydrostatic transmissions Sauer-Danfoss is a comprehensive supplier providing complete Hydraulic power steering systems to the global mobile market. Electro-hydraulic power steering Sauer-Danfoss serves markets such as agriculture, construction, road building, material handling, municipal, forestry, turf care, and many Electric power steering others.

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