Danfoss D1 Series User Manual

Service Manual
D1 High Power Open Circuit Pumps
Size 65/130/145/193/260
www.danfoss.com

Danfoss D1 Series Specifications

General

Pump Type	Centrifugal
Series	D1
Power Supply	230 V, 50 Hz
Operating Temperature Range	0°C to 40°C
Housing Material	Cast Iron

Summary

Revision History

Table of Revisions

Lists changes made to the manual over time.

Introduction

Pump Service Overview

Provides an overview of the manual's scope and purpose for D1P pumps.

General Instructions

Basic guidelines for unit handling, cleanliness, and safety precautions.

Safety Precautions

Crucial safety measures to prevent injury and equipment damage during servicing.

Flammable Cleaning Solvents

Precautions for using flammable cleaning solvents safely.

Fluid Under Pressure

Safety warnings regarding hydraulic fluid under pressure.

Personal Safety

General safety advice for personnel working with hydraulic systems.

Symbols Used in Danfoss Literature

Explains symbols used throughout Danfoss technical documentation.

D1 Pumps Design

D1 Pump Cross-Section View

Provides a detailed cross-section diagram of the D1 pump with labeled parts.

Operation

NPNN (Pressure Compensated Control)

Details the NPNN control, focusing on pressure-compensated operation.

NPSN (Pressure Compensated Control + Load Sensing Control)

Explains NPSN control, combining pressure and load sensing for optimized flow.

NPNR (Pressure Compensated Control + Remote Pressure Compensated Control)

Describes NPNR control, integrating PC with remote pressure compensation.

TPSN (Power Control + Pressure Compensated Control + Load Sensing Control)

Covers TPSN control, integrating Power, PC, and LS for optimized power utilization.

NNES (Electric Displacement Control + Load Sensing Control)

Details NNES control, using electric signals for displacement and load sensing.

Solenoid Specification

Technical data and specifications for the solenoid used in D1 pumps.

Standard EDC Valve

Information on the standard Electric Displacement Control valve and its actuation forces.

TPE2/TPE5 (Power Control + Pressure Compensated Control + Electric Displacement Control)

Explains TPE2/TPE5 control, combining Power, PC, and EDC for advanced functionality.

NPE2/NPEO (Pressure Compensated Control + Electric Displacement Control)

Details NPE2/NPEO control, integrating PC with Electric Displacement for precise control.

Operating Parameters

D1P Pressure Overview

Provides key pressure specifications and limits for D1P pumps.

D1P Speed Overview

Details rated, maximum, and minimum speed limits for D1P pumps.

D1P Fluid Overview

Information on fluid properties, velocity, and recommendations for D1P pumps.

Technical Specifications

D1 Pump Specifications

Comprehensive technical data including displacement, torque, and power ratings.

D1P Fluid Specifications

Specific fluid viscosity, temperature, and cleanliness requirements for D1P pumps.

Fluid and Filter Maintenance

Recommendations of Fluid and Filter Maintenance

Guidelines for maintaining hydraulic fluid and filters to ensure pump longevity.

Pressure Measurements

Port Locations and Gauge Installation (65)

Shows port locations and gauge installation details for the 65cc pump size.

Port Locations and Gauge Installation (130/145)

Details port locations and gauge installation for 130/145cc pump sizes.

Port Locations and Gauge Installation (193/260)

Provides port locations and gauge installation for 193/260cc pump sizes.

Initial Start-Up Procedures

General

General guidance and preparation before starting up a new D1 pump installation.

Start-up Procedure

Step-by-step instructions for safely starting up the D1 pump and system.

Troubleshooting

Excessive Noise and/or Vibration

Identifies causes and solutions for noise and vibration issues in D1 pumps.

Low Pump Output Flow

Troubleshooting steps for diagnosing and rectifying low pump output flow.

No or Low System Pressure

Addresses issues related to no or low system pressure and their resolution.

Actuator Response is Sluggish

Solutions for diagnosing and correcting sluggish actuator response in the hydraulic system.

Pressure or Flow Instability

Troubleshooting guide for resolving unstable pressure or flow conditions.

System Operating Hot

Diagnosing and resolving overheating issues in the pump system.

High Inlet Vacuum

Explains causes and consequences of high inlet vacuum and potential damage.

Adjustments

Calculate Power Control Start Point Pressure and Corresponding Flow in Advance

Method to pre-calculate power control start point pressure and corresponding flow.

Electric Displacement Control Adjustment

Procedure for calibrating the Electric Displacement Control on D1 pumps.

Pressure Compensated Control Adjustment

Steps for accurately setting and adjusting the Pressure Compensated Control.

Power Control Adjustment

Guide for adjusting the Power Control settings to optimize pump performance.

Load Sensing Control Adjustment

Procedure for adjusting the Load Sensing Control to match system demand.

TPES/TPE2 (130/145/193/260)

Specific adjustment details for TPES/TPE2 controls across different pump sizes.

TPSN (65)

Adjustment instructions for the TPSN control on the 65cc pump size.

TPSN (130/145)

Adjustment procedures for the TPSN control on 130/145cc pump sizes.

TPSN (193/260)

Adjustment procedures for the TPSN control on 193/260cc pump sizes.

Displacement Limiters Adjustment

Instructions for adjusting the maximum and minimum displacement limiters.

Minor Repairs

D1P Shaft Replacement

Detailed steps for removing and replacing the pump shaft assembly.

Shaft Seal Replacement

Procedure for replacing the lip-type shaft seal without major unit disassembly.

Auxiliary Flange and Charge Pump Replacement

Guide for removing, replacing, or exchanging auxiliary mounting pads and charge pumps.

130/145

Shows assembly diagrams and part references for 130/145cc pump sizes related to minor repairs.

193/260

Displays assembly diagrams and part references for 193/260cc pump sizes related to minor repairs.

Control (193/260)

Steps for removing and installing control units on 193/260cc pump models.

193/260 TPE2 Control

Specific instructions for TPE2 control fittings on 193/260cc pumps.

193/260 TPSN Control

Specific instructions for TPSN control fittings on 193/260cc pumps.

Control (130/145)

Steps for removing and installing control units on 130/145cc pump models.

130/145 TPSN Control

Specific instructions for TPSN control fittings on 130/145cc pumps.

Shuttle Valve or Plug

Procedures for removing and installing shuttle valves or plugs in EDC controls.

Edge Filter (260)

Details on removing and installing the edge filter for the 260cc pump size.

Displacement Limiters

Procedures for removing and installing displacement limiter screws on pumps.

Plug and Fitting Installation

General guidance on installing plugs and fittings with specific torque values.

D1P Plugs and Fasteners

Diagrams and lists of fasteners and their torque specifications for D1P pumps.

D1P Plug Size and Torque Chart

A chart detailing plug sizes and required torque values for D1P pumps.