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Danfoss D1 Series - User Manual

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

Table of Contents

Questions and Answers

  • W
    wadeleslieAug 4, 2025
    Why is my Danfoss Water Pump so noisy and vibrating?
    • M
      medinalisaAug 4, 2025
      Excessive noise and vibration in your Danfoss Water Pump can stem from several issues. It could be due to insufficient hydraulic fluid causing cavitation; in this case, fill the reservoir to the proper level. Air in the system might also be the culprit, leading to noisy, erratic control; purge the air, tighten the fittings, and check the inlet for leaks. Other potential causes include improper inlet conditions (correct the pump inlet pressure/vacuum conditions), a loose or incorrect shaft coupling (repair or replace the coupling, ensuring the correct one is used), misaligned shafts (correct the shaft misalignment), or hydraulic fluid viscosity being above acceptable limits (allow the system to warm up or use fluid with the appropriate viscosity grade).
  • R
    Randy BurkeNov 19, 2025
    What to do if my Danfoss Water Pump has low output flow?
    • J
      joneschristineNov 19, 2025
      If your Danfoss Water Pump has low output flow, several factors could be responsible. Insufficient hydraulic fluid can limit output; ensure the reservoir is filled to the proper level. High fluid viscosity or low temperature may prevent proper pump operation; allow the system to warm up or use fluid with the correct viscosity. An external relief valve set too low can also cause this issue; adjust it following the manufacturer's recommendations, ensuring it's above the PC setting. Other potential causes include an incorrect LS signal (inspect the system), an incorrect input signal (adjust the hydraulic or electric signal), high inlet vacuum (correct inlet pressure), low input speeds (adjust input speed), or an incorrect rotational configuration (use a pump with the appropriate configuration...

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

D1 P Pressure Overview

Provides key pressure specifications and limits for D1P pumps.

D1 P Speed Overview

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

D1 P 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.

D1 P 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

D1 P 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.

D1 P Plugs and Fasteners

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

D1 P Plug Size and Torque Chart

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

Danfoss D1 Series Specifications

General IconGeneral
Pump TypeCentrifugal
SeriesD1
Power Supply230 V, 50 Hz
Operating Temperature Range0°C to 40°C
Housing MaterialCast Iron

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