Danfoss D1 Series Service Manual

High power open circuit pumps

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Service Manual

D1 High Power Open Circuit Pumps

Size 65/130/145/160/193/260

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Summary of Contents for Danfoss D1 Series

Page 1 Service Manual D1 High Power Open Circuit Pumps Size 65/130/145/160/193/260 www.danfoss.com...
Page 2 Major Update 0104 October 2017 Added Size 130 0103 June 2016 Added Size 260 0102 April 2016 Converted to Danfoss layout - DITA CMS 0101 July 2015 Added 145 cc information January 2014 First edition © Danfoss | October 2024 AX189986484780en-000501...
Page 3 Secure the unit..................................... 5 Safety precautions....................................5 Unintended machine movement............................5 Flammable cleaning solvents..............................6 Fluid Under Pressure..................................6 Personal safety..................................... 6 Symbols used in Danfoss literature............................6 Design........................................6 Cross-section view................................... 8 Operation NPNN (pressure compensated control)............................9 NPSN (pressure compensated control + load sensing control)..................11 NPNR (pressure compensated control + remote pressure compensated control)..........13...
Page 4 Displacement limiter screws installation......................... 60 Plug and fitting installation................................62 193 TPE2 control..................................62 260 TPE2 control..................................63 130/145 TPSN control................................64 Plugs and fasteners..................................65 Fastener and torque chart..............................65 Plug size and torque chart..............................66 © Danfoss | October 2024 AX189986484780en-000501...
Page 5 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.danfoss.com.
Page 6 The legend above defines each symbol and explains its purpose. D1 pumps design Danfoss D1 high power open circuit piston pumps convert input torque into hydraulic power. Rotational force is transmitted through the input shaft to the cylinder block. The input shaft is supported by roller ©...
Page 7 The pump control, by varying the pressure at the servo piston, controls the displacement of fluid in the system circuit. © Danfoss | October 2024 AX189986484780en-000501 | 7...
Page 8 9. Charge pump 10. Servo piston 11. Cylinder block 12. Maximum displacement limiter 13. Piston 14. Swashplate 15. Swashplate Bearing 16. Input shaft Some internal parts may be different depending on the pump size. © Danfoss | October 2024 AX189986484780en-000501...
Page 9 P setting, the P spring shifts the spool in the opposite direction connecting the servo piston to pump case and the swashplate angle increases. The swashplate is maintained at whatever angle is required to keep system pressure at the P setting. © Danfoss | October 2024 AX189986484780en-000501 | 9...
Page 10 PC control response and recovery Frame Size Response (msec) Recovery (msec) 65cc 130cc 145cc 160cc 193cc 260cc Tested at 1800rpm Values may vary depending on application conditions. For more information, please contact Danfoss Power Solutions. © 10 | Danfoss | October 2024 AX189986484780en-000501...
Page 11 Through internal porting, system pressure [upstream of (1)] is applied to the non-spring end of the S spool, and through hydraulic line connected at port X, load pressure [downstream of (1)] is applied to the © Danfoss | October 2024 AX189986484780en-000501 | 11...
Page 12 Response (msec) Recovery (msec) 65cc 130cc 145cc 160cc 193cc 260cc Tested with a LS setting of 20bar Values may vary depending on application conditions. For more information, please contact Danfoss Power Solutions © 12 | Danfoss | October 2024 AX189986484780en-000501...
Page 13 The remote PC control is a two-stage control that allows multiple PC settings. Remote PC controls are commonly used in applications requiring low and high pressure PC operation. For this control, Danfoss recommends a load sense setting of 25 bar. Remote pressure compensated control (R) operation The remote PC control uses a pilot line connected to an external hydraulic valve.
Page 14 If the pump’s outlet pressure reaches the pressure setting of the pressure compensator (PC) function, the PC function will take priority and limit the pump’s maximum pressure. © 14 | Danfoss | October 2024 AX189986484780en-000501...
Page 15 The power control regulates the displacement of the pump depending on the working pressure so that a given drive power is not exceeded at constant drive speed, this function can prevent engine stall or protect electric generator. • V Working pressure © Danfoss | October 2024 AX189986484780en-000501 | 15...
Page 16 The hydraulic output power (characteristic T) is influenced by the efficiency of the pump. T characteristic Q max Pressure TPSN priority The pressure compensated control (P) has priority over the power control (T). Power control has priority over load sensing control (S). © 16 | Danfoss | October 2024 AX189986484780en-000501...
Page 17 The hydraulic displacement control uses a hydraulic pilot operated valve to vary the pump’s displacement from maximum displacement to minimum displacement. The swashplate angle (pump displacement) is inversely proportional to the hydraulic pilot pressure signal to the HDC control valve (control pilot pressure). © Danfoss | October 2024 AX189986484780en-000501 | 17...
Page 18 The pump will maintain the resulting displacement regardless of changes in working pressure from the load until the HDC pilot pressure signal is changed. © 18 | Danfoss | October 2024 AX189986484780en-000501...
Page 19 The PWM signal causes the solenoid pin to push against the E spool, which depressurizes the end of servo piston, the swashplate angle increases under the force of the bias piston. © Danfoss | October 2024 AX189986484780en-000501 | 19...
Page 20 If E port is not connected, remove the shuttle valve Typical operating curve Hysteresis EDC Hysteresis Input hysteresis <4.5% Output hysteresis @50% displacement <4.0% Values may vary depending on application conditions. For more information, please contact Danfoss Power Solutions © 20 | Danfoss | October 2024 AX189986484780en-000501...
Page 21 193cc (160 bar) 186 msec 260cc (200 bar) 390 msec Values may vary depending on application conditions. For more information, please contact Danfoss Power Solutions Manual override (MOR) Each electric displacement control (EDC) is equipped with a manual override (MOR) function for temporary actuation of the control to aid in diagnostics, even if insufficient or no current is supplied to the solenoid actuator.
Page 22 Danfoss mating connector kit K29657 The mating connector is not included in the delivery contents, this can be delivered by Danfoss on request. Plug polarity is not necessary (Ex. either pin 1 or pin 2 can be used as positive).
Page 23 Both the Electric Displacement Control (EDC) and the Load Sensing Control (LS) are used to control the pump’s displacement. The pump will output the smallest displacement when both control functions are given control instruct. © Danfoss | October 2024 AX189986484780en-000501 | 23...
Page 24 NNES (electric displacement control + load sensing control) TPE2/TPE5 priority The Pressure Compensated Control (P) has priority over the Power Control (T), and the Power Control (T) has priority over Electric Displacement Control (EDC). © 24 | Danfoss | October 2024 AX189986484780en-000501...
Page 25 (Max Power Setting) to 600 mA (Minimum Power Setting). The power setting will decrease as the input current increases. The power setting code in MMC is the max input power of the pump at 1500rpm and 200mA PWM signal, and the setting variation range can be seen below: © Danfoss | October 2024 AX189986484780en-000501 | 25...
Page 26 Min setting:90kw Max setting:110kw 193cc Min setting:110kw 82kw Max setting:150kw 260cc 103kw Min setting:145kw Max setting:205kw If no PWM signal is sent to the control, ETC setting will exceed the specified value. © 26 | Danfoss | October 2024 AX189986484780en-000501...
Page 27 19. displacement control + load sensing control) To determine if an external control pilot supply is needed, please consult your Danfoss Power Solutions representative. D1P pumps configured with an NPE2 control will come with a shuttle valve installed at the E port. D1P pumps with an NPE0 control will not include the shuttle valve.
Page 28 Working outside of the pump's operating parameters may result in shortened life expectancy of the pump. Always work within the operating conditions of the pump application. With accurate duty cycle information, your Danfoss Power Solutions representative can assist you in calculating expected pump life. D1P fluid overview Ratings and performance data for D1 pumps are based on operating with premium hydraulic fluids containing oxidation, rust, and foam inhibitors.
Page 29 SAE J183, M2C33F or G automatic transmission fluids (ATF), Dexron II (ATF) meeting Allison C-3 or Caterpillar T0‑2 requirements, and certain specialty agricultural tractor fluids. For more information on hydraulic fluid selection, see Danfoss Power Solutions publications BC152886484524 Hydraulic Fluids and Lubricants, Technical Information, and 520L0465 Experience with Biodegradable Hydraulic Fluids, Technical Information.
Page 30 2 [29] Counterclockwise (CCW) & Clockwise (CW) directions as viewed from the shaft end of the pump. Caution Applied pressures above maximum working pressure requires Danfoss application approval. Maximum (peak) pressure is the highest intermittent (t<1s) outlet pressure allowed. ©...
Page 31 Intermittent = Short term t < 3min per incident. Cold start = Short term t < 3min, p ≤ 30 bar [435 psi], n ≤ 1000 min (rpm) , please contact Danfoss Power Solutions especially when the temperature is below -25 °C [-13 °F].
Page 32 Replace all fluid lost during filter change. Warning Hydraulic fluid contains hazardous material. Avoid contact with hydraulic fluid. Always dispose of used hydraulic fluid according to state, and federal environmental regulations. Never reuse hydraulic fluid. © 32 | Danfoss | October 2024 AX189986484780en-000501...
Page 33 0-600 bar [0-8702.26 psi] gauge port Suction pressure gauge port M12x1.5 0-600 bar [0-8702.26 psi] D1P 65 port locations with TPSN control Load sensing signal port X Outlet port B Inlet port S © Danfoss | October 2024 AX189986484780en-000501 | 33...
Page 34 Servo piston chamber M12x1.5 6 mm 0-600 bar [0-8702.26 psi] 130/145/160 Port locations, Control type: TPSN S : Inlet port X : Load sensing signal port B : Outlet port P400254 © 34 | Danfoss | October 2024 AX189986484780en-000501...
Page 35 E : External Control Port S : Inlet Port B : Outlet Port 193/260 Port location, Control type: TPSN X : Load Sensing Signal Port S : Inlet Port B : Outlet Port P400092 © Danfoss | October 2024 AX189986484780en-000501 | 35...
Page 36 10. Shut down the prime mover and remove the pressure gauge. Replace plug at port MB. 11. Check the fluid level in the reservoir; add clean filtered fluid if necessary. The pump is now ready for operation. © 36 | Danfoss | October 2024 AX189986484780en-000501...
Page 37 Check external relief valve. External relief valve setting below PC Adjust external relief valve according setting. to manufacturer’s recommendations. External relief valve must be set above PC setting to operate properly. © Danfoss | October 2024 AX189986484780en-000501 | 37...
Page 38 Relief valve setting must be above PC setting to operate properly. Check external relief valve. Chattering external relief valve may Adjust or replace relief valve. cause unstable feedback to pump control. © 38 | Danfoss | October 2024 AX189986484780en-000501...
Page 39 Hydraulic fluid viscosity above High fluid viscosity causes high inlet Select fluid with appropriate viscosity acceptable limits. vacuum. for expected operating temperature. Caution High inlet vacuum causes cavitation which can damage internal pump components. © Danfoss | October 2024 AX189986484780en-000501 | 39...
Page 40 Flow vs Pressure curve during torque limiting 3. Calculate corresponding flow by using the following formula: P • Q Power [kW] = 600 • η 245 • Q 90 = 600 • (.912) Q=201 l/min © 40 | Danfoss | October 2024 AX189986484780en-000501...
Page 41 To protect against unintended movement, secure the machine or disable / disconnect the mechanism while servicing. Caution Contamination can damage internal components and void the manufacturer’s warranty. Take precautions to ensure system cleanliness when removing and reinstalling system lines. © Danfoss | October 2024 AX189986484780en-000501 | 41...
Page 42 Back out the screw to the reference length mentioned in the previous step and adjust carefully to ensure proper function. Danfoss recommends a prime mover speed of 1500rpm for testing (unless specified otherwise). The testing setup must be plumbed in a way so the EDC function works properly. Please refer to Electric Displacement Control (E) Operating Instruction.
Page 43 72.5 ± 5 80 ± 5 96.5 ± 5 145 ± 5 500mA ± 8 mA 48.75 ± 5 97.5 ± 5 108.8 ± 5 120 ± 5 144.8 ± 5cc 217.5 ± 5 © Danfoss | October 2024 AX189986484780en-000501 | 43...
Page 44 LS control adjusting screw, torque the control lock nut to 21.6~24.6 N•m [191-218 lbf•in]. 4. Adjust Power control and pressure compensated control (if used). © 44 | Danfoss | October 2024 AX189986484780en-000501...
Page 45 5. After Step 4, slowly operate a hydraulic function that will demand approximately half flow from the pump, but keep outlet pressure below the power control pressure starting point (if Power control is used). Danfoss recommends loading the outlet pressure to 50bar. Warning Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and/or infection.
Page 46 4 mm Pressure compensated Load sensing adjustment screw control lock nut Load sensing 4 mm 13 mm lock nut 21.6 - 24.6 N·m 13 mm 21.6 - 24.6 N·m © 46 | Danfoss | October 2024 AX189986484780en-000501...
Page 47 Power Control Lock Nut 13 mm Load Sensing Lock Nut 21.6 - 24.6 N·m 13 mm 21.6 - 24.6 N·m P400255 Please refer to for information about the other control options. Operation © Danfoss | October 2024 AX189986484780en-000501 | 47...
Page 48 5 mm 5 mm 8 mm 8 mm 17 mm 17 mm 24 mm 24 mm Nuts 43~48 N·m 43~48 N·m 180~206 N·m 180~206 N·m [380.58~424.84 lbf·in] [380.58~424.84 lbf·in] [1593.13~1823.25 lbf·in] [1593.13~1823.25 lbf·in] © 48 | Danfoss | October 2024 AX189986484780en-000501...
Page 49 Shaft seal (F222) and carrier (F221) are set as one group. remove and discard group. 5. Danfoss recommends screwing in the max displacement limiter enough so to prevent internal component movement during the shaft removal. Remove shaft and front bearing assembly (E000T) after shaft seal group has been removed.
Page 50 (F210) in housing. 5. If the pump has an impeller, reinstall it after the shaft installation is complete. F210 F221 F220 F222 F230 E000T P400617 © 50 | Danfoss | October 2024 AX189986484780en-000501...
Page 51 Install seal with the cupped side toward the shaft bearing. Do not damage the seal during installation. 5. Using the appropriate snap ring pliers, install the seal retaining ring. 6. Remove the installation sleeve. F230 F220 F210 P400096 © Danfoss | October 2024 AX189986484780en-000501 | 51...
Page 52 5. Install the drive coupling (H200) if present. 6. Install the cover (H150) with seal (H130), lubricate the seal with petroleum jelly. 7. Install the screws (H140) and torque to required torques. © 52 | Danfoss | October 2024 AX189986484780en-000501...
Page 53 All torques tolerance ±10% H200 H110 H110 H200 H100 H120 H100 H110 H120 H130 H200 H100 H150 H125 H120 H110 H130 H140 H100 H200 H120 H140 H110 H130 H100 H150 H140 H120 H130 H150 H140 © Danfoss | October 2024 AX189986484780en-000501 | 53...
Page 54 A1/A3 H100 H200 H105 H120 H110 H107 H130 H200 H130 H100 H150 H150 H110 H120 H140 H130 H140 H100 H150 H120 H130 H140 H150 H140 * E3 option is only for 260. © 54 | Danfoss | October 2024 AX189986484780en-000501...
Page 55 3 long bolts (D170) & 2 short bolts (D180) NPNR (130-260) Gasket (D145) 5 short bolts (D175) Torque requirements Bolt Torque D175 22.5-27.5 N·m [199-243 lbf·in] D170 22.5-27.5 N·m [199-243 lbf·in] D180 22.5-27.5 N·m [199-243 lbf·in] © Danfoss | October 2024 AX189986484780en-000501 | 55...
Page 56 Service Manual D1 High Power Open Circuit Pumps Minor repairs 193/260 TPE2 Control D145 22.5-27.5 N ·m D170 D180 22.5-27.5 N ·m P400293 193/260 TPSN Control D145 D175 22.5-27.5 N.m P400294 © 56 | Danfoss | October 2024 AX189986484780en-000501...
Page 57 Service Manual D1 High Power Open Circuit Pumps Minor repairs Control (130/145/160) 130/145 TPSN Control D150 D140 22.5-27.5 N·m D175 P400259 © Danfoss | October 2024 AX189986484780en-000501 | 57...
Page 58 4. If the shuttle valve is not used, replace it with the plug (D900). The shuttle valve must also be installed in NNES and TPE2/TPE5 controls if the application requires this feature. To determine if a shuttle valve is needed, please consult with your Danfoss representative.
Page 59 D901 D902 G254 G255 Wrench size and torque Item Wrench size Torque G254 6mm hex 9.9-12.1 Nm G255 6mm hex 30.6-37.4 Nm D900 6mm hex 30.6-37.4 Nm D901 22mm hex 30.6-37.4 Nm © Danfoss | October 2024 AX189986484780en-000501 | 59...
Page 60 Frame size, cm Wrench size, mm Torque, N∙m [lbf∙in] 5 (screws), 17 (nuts) 43~48 [380.58~424.84] 130/145/160 5 (screws) 17 (nuts) 43~48 [380.58~424.84] 8 (screws), 24 (nuts) 180~206 [1593.13~1823.25] 8 (screws), 24 (nuts) 180~206 [1593.13~1823.25] © 60 | Danfoss | October 2024 AX189986484780en-000501...
Page 61 Service Manual D1 High Power Open Circuit Pumps Minor repairs F120 F110 F110 F120 P400265 © Danfoss | October 2024 AX189986484780en-000501 | 61...
Page 62 Drain port L3 (M33 x 2) 17 mm hex 68.4-83.6 Nm F150 Drain port L2 (M33 x 2) 17 mm hex 68.4-83.6 Nm G250 Servo orifice plug (M12 x 1.5) 6 mm hex 22.5-27.5 Nm © 62 | Danfoss | October 2024 AX189986484780en-000501...
Page 63 Drain port L3 (M33 x 2) 17 mm hex 68.4-83.6 Nm F150 Drain port L2 (M33 x 2) 17 mm hex 68.4-83.6 Nm F160 Drain port L1 (M33 x 2) 17 mm hex 68.4-83.6 Nm © Danfoss | October 2024 AX189986484780en-000501 | 63...
Page 64 Drain port L3 (M26 x 1.5) 12 mm hex 68.4-83.6 Nm F150 Drain port L2 (M26 x 1.5) 12 mm hex 68.4-83.6 Nm F160 Drain port L1 (M26 x 1.5) 12 mm hex 68.4-83.6 Nm © 64 | Danfoss | October 2024 AX189986484780en-000501...
Page 65 T adjusting screw 4 mm internal 4 mm internal 4 mm internal D870 S adjusting screw 4 mm internal 4 mm internal 4 mm internal D110 E2 adjusting 3 mm internal screw © Danfoss | October 2024 AX189986484780en-000501 | 65...
Page 66 [1991.42 F150 lbf·in] G225 M12X1.5 6 mm 25 N·m M12X1.5 6 mm 25 N·m M12X1.5 6 mm 25 N·m internal hex [221.27 lbf·in] internal hex [221.27 lbf·in] internal hex [221.27 lbf·in] G235 © 66 | Danfoss | October 2024 AX189986484780en-000501...
Page 67 Phone: +86 21 2080 6201 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 subsequent changes being necessary in specifications already agreed.

This manual is also suitable for:

D1p 065D1p 130 D1p 145D1p 160D1p 193 D1p 260