Danfoss DDC20 Service Manual Download | Manualshive

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Optional coupling

DDC20/24 optional coupling removal

Remove the coupling (J538).

DDC20/24 coupling inspection

Inspect the coupling. If the coupling is damaged, replace it.

DDC20/24 coupling assembly

Lubricate and install the coupling (J538).

DDC20/24 Remove coupling

P108 580E

J538

Coupling

Service Manual

DDC20/24 Axial Piston Pumps

Minor repair

©

Danfoss | August 2019

L1120413 | AX00000135en-000401 | 25

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Summary of Contents for DDC20

Page 1: ...Service Manual Axial Piston Pumps DDC20 24 www danfoss com...

Page 2: ...019 Added DDC24 0401 August 2017 change charge pump housing 0302 March 2015 add implement pump option CA March 2014 Danfoss layout BA September 2011 First printing AA Service Manual DDC20 24 Axial Pis...

Page 3: ...ve 10 Loop flushing valve 11 Troubleshooting Troubleshooting overview 12 System operating hot 12 Transmission operating normally in one direction only 12 System noise or vibration 12 System will not o...

Page 4: ...ner General instructions Remove the unit 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 t...

Page 5: ...ng 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 W Warning Escaping hydraulic fluid...

Page 6: ...system pressure gauge port O ring plug 9 16 18UNF 2B L1 Case Drain O ring Plug 3 4 16UNF 2B L2 Case Drain O ring Plug 3 4 16UNF 2B M3 Charge gauge E Charge inlet Port Information Port Identifier Port...

Page 7: ...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...

Page 8: ...O ring plug 3 4 16UNF 2B D Implement Discharge O ring plug 9 16 18UNF 2B M3 Charge Gauge O ring plug 9 16 18UNF E Implement Return E Implement Return Port Information Port Identifier Port Size Wrench...

Page 9: ...filters flush the lines and fill the system with the proper hydraulic fluid DDC20 24 charge pressure relief valve adjustment The following procedure explains how to check for proper operation of the...

Page 10: ...1800 min 1 rpm with a reservoir temperature of 50 C 120 F DDC20 24 high pressure relief valve HPRV adjustment The HPRV valves are set at the factory No adjustment is possible If you suspect a HPRV va...

Page 11: ...f the loop flush valve is malfunctioning disassemble the valve and check for worn damaged or scored components Replace parts if necessary Refer to Removal for replacement procedures Loop flushing valv...

Page 12: ...ge 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 valv...

Page 13: ...ad 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 L...

Page 14: ...pump cover K150 4 Remove and discard O ring K100 5 Remove gerotor K010 Push out the drive pin K050 DDC20 24 machined surface inspection Inspect all machined surfaces for wear or damage If any nicks s...

Page 15: ...23 K200 K100 K010 K050 K150 Charge pump cover mounting bolts Item Wrench size Torque K200 6 mm internal hex 20 N m 15 lbf ft Service Manual DDC20 24 Axial Piston Pumps Minor repair Danfoss August 2019...

Page 16: ...100 K110 4 Remove gerotor K010 Remove locating pins K250 from housing Remove implement pump K210 K200 K250 K100 K110 K010 K150 Implement pump cover bolts Item Description Wrench size Torque K200 Cap s...

Page 17: ...and shaft seal DDC20 24 shaft seal removal 1 Orient pump with the shaft pointing up 2 Using a retaining ring pliers remove retaining ring F125 3 Remove the shaft seal F120 and discard C Caution Do no...

Page 18: ...Remove Seal Shaft Bearing F125 F115 F120 F110 F105 F100 Service Manual DDC20 24 Axial Piston Pumps Minor repair 18 Danfoss August 2019 L1120413 AX00000135en 000401...

Page 19: ...rea with a nonabrasive material if necessary 5 Lubricate the shaft with a light coat of hydraulic fluid before assembly DDC20 24 shaft bearing inspection 1 Clean bearing with a solvent and lubricate w...

Page 20: ...t Press evenly to avoid binding and damaging the seal C Caution Do not damage the housing bore shaft or rear bearing when installing the shaft and shaft seal All components should fit together smoothl...

Page 21: ...the plug and internal parts of cartridge If parts are worn or damaged replace the entire cartridge DDC20 24 high pressure relief valve HPRV assembly 1 Lubricate and install new O rings QJ020 onto eac...

Page 22: ...0 for wear or damage 2 Inspect spring L200 Replace any damaged components DDC20 24 charge pressure relief valve CPRV assembly 1 Lubricate and insert the charge relief valve poppet L100 and spring L200...

Page 23: ...for wear 4 Install new O rings to plugs before assembly DDC20 24 loop flushing valve assembly 1 Lubricate and insert the loop flushing spool H100 into endcap Ensure the spool moves freely in its bore...

Page 24: ...nd back up ring before assembly DDC20 24 bypass valve assembly 1 Lubricate and install new O rings M130 and M110 and backup ring M120 onto cartridge 2 Install the bypass valve M100 M200 Torque valve p...

Page 25: ...inspection Inspect the coupling If the coupling is damaged replace it DDC20 24 coupling assembly Lubricate and install the coupling J538 DDC20 24 Remove coupling P108 580E J538 Coupling Service Manua...

Page 26: ...cover mounting bolts 8 mm internal hex 39 N m 29 lbf ft DDC20 24 implement pump fasteners and torque chart P108803 K200 K210 Item Fastener Wrench size Torque K200 Charge pump cover mounting bolt 8 mm...

Page 27: ...nal hex 29 N m 21 lbf ft J220 J230 Loop flushing valve plug 9 16 18 UNF 11 16 inch internal hex 35 N m 26 lbf ft M100 M200 Bypass valve 9 16 18 UNF 17 mm 12 N m 9 lbf ft J320 CPRV 1 2 20 UNF 17 mm 24...

Page 28: ...8 UNF 1 4 inch internal hex 35 N m 26 lbf ft L1 L2 L3 Case drain 3 4 16 UNF 5 16 inch internal hex 30 N m 22 lbf ft J220 J230 Loop flushing valve plug 9 16 18 UNF 11 16 inch internal hex 35 N m 26 lbf...

Page 29: ...return 9 16 18 UNF 1 4 inch internal hex 35 N m 26 lbf ft L1 L2 L3 Case drain 3 4 16 UNF 5 16 inch internal hex 29 N m 21 lbf ft M200 Bypass valve 9 16 18 UNF 17 mm 12 N m 9 lbf ft J320 CPRV 1 2 20 UN...

Page 30: ...dborg Denmark Phone 45 7488 2222 Danfoss Power Solutions US Company 2800 East 13th Street Ames IA 50010 USA Phone 1 515 239 6000 Danfoss Power Solutions Trading Shanghai Co Ltd Building 22 No 1000 Jin...

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