DDC20

Axial Piston Pumps

Service Manual
 DDC20 Axial Piston Pumps
Service Manual
Revisions

History of Revisions Table of Revisions

Date Page Changed Rev.

September 2011 - First printing AA

© 2011 Sauer-Danfoss. All rights reserved.

Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and

other printed material. Sauer -Danfoss reserves the right to alter its products without
prior notice. This also applies to products already ordered, provided that such alterations
can be made without affecting agreed specifications. All trademarks in this material
are properties of their respective owners. Sauer-Danfoss, the Sauer-Danfoss logotype,
the Sauer-Danfoss S-icon, PLUS+1™, What really matters is inside® and Know-How in
Motion™ are trademarks of the Sauer-Danfoss Group.

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 DDC20 Axial Piston Pumps
Service Manual
Contents

Introduction Overview............................................................................................................................................................ 4
Warranty............................................................................................................................................................. 4
General Instructions....................................................................................................................................... 4
Safety Precautions.......................................................................................................................................... 5
Unintended machine movement........................................................................................................ 5
Flammable cleaning solvents................................................................................................................ 5
Fluid under pressure................................................................................................................................. 5
Personal safety............................................................................................................................................ 5
Symbols used in Sauer-Danfoss literature.............................................................................................. 6

Pressure Measurements Gauge Port Locations and Gauge Installation - with Aux Pad........................................................ 7
Gauge Port Locations and Gauge Installation - with Geroter......................................................... 8

Adjustments Pump Adjustment........................................................................................................................................... 9

Standard Procedures...................................................................................................................................... 9
Charge Pressure Relief Valve.....................................................................................................................10
High Pressure Relief Valve - HPRV............................................................................................................11
Loop Flushing Valve......................................................................................................................................12

Troubleshooting Overview..........................................................................................................................................................13
System operating hot..................................................................................................................................13
Transmission operates normally in one direction only...................................................................13
System noise or vibration...........................................................................................................................13
System will not operate in either direction..........................................................................................14
Sluggish system response..........................................................................................................................14

Minor Repair Charge Pump..................................................................................................................................................15

Shaft and Seal.................................................................................................................................................16
High Pressure Relief Valves - HPRV..........................................................................................................18
Charge Pressure Relief Valve.....................................................................................................................19
Loop Flushing Valve......................................................................................................................................20
Bypass Valve....................................................................................................................................................21
Optional Coupling........................................................................................................................................22

Torque chart Fastener Size and Torque Chart................................................................................................................23

Plug Size and Torque Chart - with Gerotor...........................................................................................24
Plug Size and Torque Chart - with Aux Pad..........................................................................................25

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 DDC20 Axial Piston Pumps
Service Manual
Introduction

Overview 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 Sauer-Danfoss Global Service Partners (GSPs) are authorized to

perform major repairs. Sauer-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.

Warranty Performing maintenance, and minor repairs according to the procedures in this manual
will not affect your warranty. Major repairs requiring the removal of the units endcap
voids the warranty unless completed by a Sauer-Danfoss Global Service Partner.

General Instructions w 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 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.

e 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.

l Lubricate moving parts

During assembly, coat all moving parts with clean hydraulic fluid. This assures that these
parts are lubricated during start-up.

d Replace all O-rings and gaskets

Sauer-Danfoss recommends you replace all O-rings, seals, and gaskets during repair.
Lightly lubricate all O-rings with clean petroleum jelly prior to assembly. Grease must be
soluable in hydraulic fluid.

t 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.
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 DDC20 Axial Piston Pumps
Service Manual
Introduction

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

W 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

W 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

W 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 leaks in a pressurized line. Seek medical attention
immediately if you are cut by hydraulic fluid.

Personal safety
W Warning
Protect yourself from injury. Use proper safety equipment, including safety glasses, at all
times.

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 DDC20 Axial Piston Pumps
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Introduction

Symbols used in Sauer-  WARNING may result in injury  Tip, helpful suggestion
Danfoss literature
 CAUTION may result in damage to  Lubricate with hydraulic fluid
product or property
 Apply grease / petroleum jelly
 Reusable part
 Apply locking compound
 Non-reusable part, use a new part
 Inspect for wear or damage
 Non-removable item
 Clean area or part
 Option – either part may exist
 Be careful not to scratch or damage
 Superseded – parts are not
interchangeable  Note correct orientation

 Measurement required  Mark orientation for reinstallation

 Flatness specification  Torque specification

 Parallelism specification  Press in – press fit

 External hex head  Pull out with tool – press fit

 Internal hex head  Cover splines with installation

sleeve
 Torx head
 Pressure measurement / gauge
 O-ring boss port location or specification

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 explains its purpose.

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 DDC20 Axial Piston Pumps
Service Manual
Pressure Measurements

Gauge Port Locations The following drawing and table show the gauge port locations and gauge sizes needed
and Gauge Installation - For service information, refer to DDC20 Service Manual L1120413.
with Aux Pad

M3 Charge gauge / E - Charge inlet L1 Case Drain

O-ring Plug 3/4-16UNF-2B System port A
O-ring plug 9/16-18UNF-2B

DDC20 with Aux Pad

System port B

M3 Charge gauge / E - Charge inlet

MA system pressure gauge port L2 Case Drain
O-ring plug 9/16-18UNF-2B O-ring Plug 3/4-16UNF-2B O-ring plug 9/16-18UNF-2B

MB system pressure gauge port L3 Case Drain

O-ring plug 9/16-18UNF-2B O-ring Plug 3/4-16UNF-2B 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]

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 DDC20 Axial Piston Pumps
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Pressure Measurements

Gauge Port Locations The following drawing and table show the gauge port locations and gauge sizes needed
and Gauge Installation - For service information, refer to DDC20 Service Manual L1120413.
with Geroter

L1 Case Drain M3 Charge Pressure Gauge Port

O-ring Plug 3/4-16UNF-2B
O-ring Plug 7/16-20UNF-2B

MA system pressure gage port

O-ring plug 9/16-18UNF-2B

S -Charge
suction port DDC20 with Gerotor

MB system pressure gage port L3 Case Drain P108 598E

O-ring plug 9/16-18UNF-2B O-ring Plug 3/4-16UNF-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]

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Adjustments

Pump Adjustment This section offers instruction on adjustment of pump components. Read through the
entire topic before beginning a service activity. Refer to the Pressure Measurements, section
(previous page) for location of gauge ports and suggested gauge size.

Standard Procedures C 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.

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Adjustments

Charge Pressure Relief The following procedure explains how to check for proper operation of the charge
Valve 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 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 Charge pressure relief valve

pump charge pressure range for
some nominal charge relief valve
settings (refer to model code located J320
J320A
on serial number plate).

3. If measured pressure is not correct, L200

disassemble the valve and look for
signs of wear or contamination. Refer L100
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.

P108 562E
Charge pressure
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-1 (rpm) with a
reservoir temperature of 50° C [120° F].

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Adjustments

High Pressure Relief The HPRV valves are pre-set at the factory. No adjustment is possible.
Valve - HPRV

If you suspect a HPRV valve malfunction, replace valve with identical relief setting and
test operation of pump. Refer to Minor Repair, section for replacement procedures.

Whenever you replace or open an HPRV, check for proper pump operation by cycling
through its full operating range.

HPRV valves

P120A

P120
P100
P110

N110
N100 N120

N120A

P108 568E

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Adjustments

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 Minor Repair, for disassembly procedures.

Loop flushing valve

J230
H150
H200

H100
H200
H150
P108 569E
J220

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Service Manual
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. Always observe the safety
precautions listed in the Introduction section, page 5, and precautions related to your
specific equipment.

System operating hot

Item Description Action
Oil level in reservoir. Insufficient hydraulic fluid will not meet cooling demands Fill reservoir to proper level.
of system.
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. Low charge pressure will overwork system. Measure charge pressure. Inspect and/or replace charge
relief valve. Inspect charge pump. Repair or replace
charge pump.
Charge pump inlet vacuum. High inlet vacuum will overwork system. A dirty filter Check charge inlet vacuum. If high, inspect inlet filter and
will increase the inlet vacuum. Inadequate line size will replace as necessary. Check for adequate line size, length
restrict flow. or other restrictions
System relief pressure If the system relief valves are worn, contaminated, Verify settings of high pressure relief valves and replace
settings. or valve settings are too low, the relief valves will be valves as necessary.
overworked.
System pressure. Frequent or long term operation over system relief Measure system pressure. If pressure is too high, reduce
setting will create heat in system 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 Exchange the high pressure relief valves. If the problem
other functions normally. 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 Low oil level leads to cavitation. Fill reservoir.
Aeration of the oil/pump Air in system decreases efficiency of units and controls. Find location where air is entering into the system and fix.
inlet vacuum Air in system is indicated by excessive noise in pump, Check that inlet line is not restricted and is proper size.
foaming in oil, and hot oil.
Cold oil If oil is cold, it may be too viscous for proper function and Allow the oil to warm up to its normal operating
cause cavitation 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 Unusual noise may indicate sticking valves. Possible Clean/replace valves and test pump. May be a normal
valves contamination. condition.

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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.
depressurized.
Low charge pressure with Low charge pressure insufficient to recharge system loop Measure charge pressure with the pump in neutral. If
pump in neutral pressure is low, go to Pump charge relief valve
Low charge pressure with Low charge pressure resulting from elevated loop Isolate pump from motor by blocking system ports.
pump in stroke leakage. 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, Replace pump charge relief valve as necessary
or set too low will depressurize the system.
Charge pump inlet filter. A clogged filter will under supply system loop. Inspect filter and replace if necessary.
Charge pump. A malfunctioning charge pump will provide insufficient Repair or replace the charge pump.
charge flow.

System pressure Low system pressure does not provide enough power to Measure system pressure. Continue to next step.
move load
High pressure relief valves Defective high pressure relief valves cause system Replace high pressure relief valves.
pressure to be low
Control Linkage Linkage operating 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 Incorrect system pressures will affect system reaction Replace high pressure relief valves
time. High pressure relief valve with orifice may affect
system reaction time.
Low prime mover speed Low engine speed will reduce system performance 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 Measure charge inlet vacuum. Inspect line for proper
pressure. sizing. Replace filter. Confirm proper bypass operation.
Bypass valve Slightly activated bypass valve will cause cross port Verify that the bypass valve is closed and that the valve is
leakage. seating properly. Clean, repair, or replace it as necessary.

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Minor Repair

Charge Pump Disassembly Charge pump

1. Position the pump with the shaft end
pointing down. K200

2. Mark the orientation of the charge

pump cover on the endcap for
proper reassembly.
K150
3. Remove cap screws (K200). Remove
the charge pump cover (K150).

4. Remove and discard O-ring (K100). K100

5. Remove gerotor (K010). Push out the

drive pin (K050). K010

Inspection K050
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). P108 524E

4. Install the cover in its original

position. Charge pump cover bolts
Item Wrench size Torque
5. Install screws (K200). Torque screws
K200 6 mm internal hex 20 N•m [15 lbf•ft]
per table.

Charge pump cover orientation

Clockwise rotation Counterclockwise rotation

Flat
side Flat
side

P108 587E

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Minor Repair

Shaft and Seal Shaft seal removal Seal, Shaft, Bearing

1. Orient pump with the shaft pointing
up.

C Caution 2. Using a retaining ring pliers, remove F125

Do not damage the retaining ring (F125) .
housing bore, shaft or
bearing when removing 3. Remove the shaft seal (F120) and F120
the shaft and shaft seal. discard. C

Carefully drive a small sheet-metal screw F115

into the shaft seal to facilitate removal.
Be careful not to damage the bearing F110
below the seal. Attach a slide hammer or
appropriate puller to the screw head and
pull to remove the seal. F105

Shaft removal
1. Using a retaining ring pliers, remove
retaining ring (F115).
F100
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.
C

C 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.

P108 526E

Shaft inspection
Ensure the shaft and its splines are straight and free of damage or heavy 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.

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Minor Repair

Shaft and Seal Bearing inspection

(continued) 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 Install shaft /seal/bearing

1. Position the pump with the shaft end
pointing up.

If previously removed; press bearing onto F125

shaft by applying force to the inner race.

2. Lubricate and install bearing (F105) F120

with hydraulic fluid.

3. Install retaining ring (F110) using F115

retaining ring pliers.
F110
4. Install shaft (F100) with bearing
(F105) into housing. Ensure the shaft
splines engage the block splines and F105
the shaft end slides smoothly into
the rear bearing. It may be necessary
to tap lightly on the shaft to seat the
bearing.

5. Using retaining ring pliers, install the

retaining ring (F115). F100

6. Cover shaft splines with an

installation sleeve or packaging tape
to protect seal during installation.
Lubricate new shaft seal (F120), press
C Caution into housing until it bottoms out.
Do not damage the Press evenly to avoid binding and
housing bore, shaft or rear damaging the seal. C
bearing when installing
the shaft and shaft seal. 7. Using retaining ring pliers, install the
All components should fit seal retaining ring (F125) .
together smoothly.

P108 553E

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 DDC20 Axial Piston Pumps
Service Manual
Minor Repair

High Pressure Relief Removal

Valves - HPRV 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

P120A

P120
P100
P110

N110
N100
N120

N120A

P108 565E

HPRV plug
Item Wrench size Torque
N120/P120 24 mm 78 N•m [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).

2. Install the valves in their original location as noted during disassembly. Ensure each
valve assembly moves freely in its bore.

3. Torque plugs per table.

4. Operate vehicle/machine through full range of controls to ensure proper operation.

Check for leaks.

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Minor Repair

Charge Pressure Relief Removal Charge pressure relief valve

Valve 1. Remove the charge pressure relief
valve plug (J320). Remove and J320
discard O-ring (J320A). J320A

3. Use a magnet to remove the spring L200

(L200).
L100

4. 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.

P108 559E

Reassembly
1. Insert the charge relief valve poppet
(L100) and spring (L200) into the
endcap.
Charge pressure relief valve plug
3. Lubricate and install a new O-ring Item Wrench size Torque
(J320A). J320 17 mm 24 N•m [18 lbf•ft]

4. Install the charge relief valve plug

(J320). Torque per table.

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Minor Repair

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).

Disassemble loop flushing valve

J230

J230A

H150
H200

H100 J220
H200
H150 J220A

P108 530E

Loop flushing valve plugs

Item Wrench size Torque
J220/J230 11/16 inch 35 N•m [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.

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Minor Repair

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.

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

M200
M100 M120
M120

M130
M130
M110
M110 P108 557E

Bypass valve plug

Item Wrench size Torque
M100 17 mm 12 N•m [9 lbf•ft]

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 DDC20 Axial Piston Pumps
Service Manual
Minor Repair

Optional Coupling Removal Remove coupling

Remove the coupling (J538).

Inspection
Inspect the coupling. If the coupling is
damaged, replace it.
J538
Coupling
Reassembly
Lubricate and install the coupling.

P108 580E

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Service Manual
Torque charts

Fastener Size and Torque

Chart

K200

P108 590E

Item Fastener Wrench size Torque

K200 Charge pump cover mounting bolt 6 mm internal hex 20 N•m [15 lbf•ft]

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 DDC20 Axial Piston Pumps
Service Manual
Torque charts

Plug Size and Torque J320 CPRV plug

Chart - with Gerotor L1 Case Drain M3 Charge Pressure Gauge Port
O-ring Plug 3/4-16UNF-2B
N120 HPRV plug O-ring Plug 7/16-20UNF-2B

W Warning
Do not
over torque
M200 bypass valve cartridge
the case drain
plugs
MA system pressure gage port
(L1, L2., L3 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

Item Plug Port dimensions Wrench size Torque

N120/P120 HPRV 3/4-16 UNF 24 mm 78 N•m [57 lbf•ft]
L1/L2/L3 Case drain 3/4-16 UNF 5/16 inch internal 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 N•m [18 lbf•ft]
MA/MB System Pressure Gauge Ports 9/16-18 UNF 11/16 inch 35 N•m [26 lbf•ft]
M3 Charge Pressure Gauge Port 7/16-20 UNF 3/16 inch internal hex 19 N•m [14 lbf•ft]

24 L1120413 • Rev AA • September 2011

 DDC20 Axial Piston Pumps
Service Manual
Torque charts

Plug Size and Torque

M3 Charge gauge / E -Charge inlet
Chart - with Aux Pad O-ring plug 9/16-18UNF-2B L1 Case Drain
O-ring Plug 3/4-16UNF-2B
N120 HPRV plug J320 CPRV plug

W Warning
Do not
over torque M100 bypass valve cartridge
Loop flushing valve plug

the case drain J220 DDC20 with Aux Pad

plugs M3 Charge gauge / E -Charge inlet
MA system pressure gage port L2 Case Drain O-ring plug 9/16-18UNF-2B
(L1, L2, L3). O-ring plug 9/16-18UNF-2B O-ring Plug 3/4-16UNF-2B P120 HPRV plug

Loop flushing valve plug

MB system pressure gage port L3 Case Drain J230
O-ring plug 9/16-18UNF-2B O-ring Plug 3/4-16UNF-2B DDC20 with Aux Pad P108 600E

Item Plug Port dimensions Wrench size Torque

N120/P120 HPRV 3/4-16 UNF 24 mm 78 N•m [57 lbf•ft]
M3/E Charge gauge/Charge inlet 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]
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 N•m [18 lbf•ft]
MA/MB System Pressure Gauge Ports 9/16-18 UNF 11/16 inch 35 N•m [26 lbf•ft]

L1120413 • Rev AA • September 2011 25

 DDC20 Axial Piston Pumps
Service Manual
Notes

26 L1120413 • Rev AA • September 2011

DDC20 Axial Piston Pumps
Service Manual
Notes

L1120413 • Rev AA • September 2011 27

Products we offer: Sauer-Danfoss is a global manufacturer and supplier of high-
quality hydraulic and electronic components. We specialize in
• Bent Axis Motors providing state-of-the-art technology and solutions that excel in
the harsh operating conditions of the mobile off-highway market.
• Closed Circuit Axial Piston Pumps
Building on our extensive applications expertise, we work closely
and Motors
with our customers to ensure exceptional performance for a broad
• Displays range of off-highway vehicles.
• Electrohydraulic Power Steering
We help OEMs around the world speed up system development,
• Electrohydraulics reduce costs and bring vehicles to market faster.
Sauer-Danfoss – Your Strongest Partner in Mobile Hydraulics.
• Hydraulic Power Steering
• Integrated Systems
• Joysticks and Control Handles
Go to www.sauer-danfoss.com for further product information.
• Microcontrollers and Software
• Open Circuit Axial Piston Pumps
• Orbital Motors Wherever off-highway vehicles are at work, so is Sauer-Danfoss.
• PLUS+1™ GUIDE
We offer expert worldwide support for our customers, ensuring
• Proportional Valves the best possible solutions for outstanding performance. And with
an extensive network of Global Service Partners, we also provide
• Sensors
comprehensive global service for all of our components.
• Steering
• Transit Mixer Drives
Please contact the Sauer-Danfoss representative nearest you.

Local address:

Members of the Sauer-Danfoss Group:

Comatrol
www.comatrol.com

Schwarzmüller-Inverter
www.schwarzmueller-inverter.com
Sauer-Danfoss (US) Company Sauer-Danfoss ApS
2800 East 13th Street DK-6430 Nordborg, Denmark
Ames, IA 50010, USA Phone: +45 7488 4444
Turolla
Phone: +1 515 239 6000 Fax: +45 7488 4400
www.turollaocg.com Fax: +1 515 239 6618

Hydro-Gear Sauer-Danfoss GmbH & Co. OHG Sauer-Danfoss-Daikin LTD.

www.hydro-gear.com Postfach 2460, D-24531 Neumünster Shin-Osaka TERASAKI 3rd Bldg. 6F
Krokamp 35, D-24539 Neumünster, Germany 1-5-28 Nishimiyahara, Yodogawa-ku
Phone: +49 4321 871 0 Osaka 532-0004, Japan
Sauer-Danfoss-Daikin Fax: +49 4321 871 122 Phone: +81 6 6395 6066
Fax: +81 6 6395 8585
www.sauer-danfoss-daikin.com

L1120413 • Rev AA • September 2011 www.sauer-danfoss.com