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Danfoss D1 130 Service Manual Download Page 53

2. Install the plug G255 and torque to the required specification.

D900

D900

D920

D901

D902

D910

G255

G254

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

Service Manual

D1 High Power Open Circuit Pumps Size 65/130/145/193/260

Minor repairs

 

©

 Danfoss | July 2019

L1527453 | AX00000292en-CN0201 | 53

Summary of Contents for D1 130

Page 1: ...Service Manual D1 High Power Open Circuit Pumps Size 65 130 145 193 260 www danfoss com...

Page 2: ...ayout 0105 June 2018 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 AB January...

Page 3: ...Displacement Control 21 TPE2 TPE5 Priority 21 NPE2 NPE0 Pressure Compensated Control Electric Displacement Control 22 Operating parameters Pressure 23 Speed 23 Fluid 23 Viscosity 24 Temperature 24 Fl...

Page 4: ...Auxiliary flange installation 46 130 145 47 193 260 48 Control 193 260 49 Removal 49 Installation 49 Control 130 145 51 Shuttle Valve or Plug 52 Shuttle valve or plug removal 52 Shuttle valve or plug...

Page 5: ...of the pump and fittings for damage Cap hoses after removal to prevent contamination Keep it clean Cleanliness is a primary means of assuring satisfactory pump life on either new or repaired units Cle...

Page 6: ...le part use a new part Apply locking compound Non removable item Inspect for wear or damage Option either part may exist Clean area or part Superseded parts are not interchangeable Be careful not to s...

Page 7: ...and out of its bore fluid is drawn from the inlet and displaced to the outlet thereby imparting power into the system circuit A small amount of fluid is allowed to leak from the cylinder block valve...

Page 8: ...rol 7 Valve plate 8 Endcap 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 diffe...

Page 9: ...P spring the spool shifts porting system pressure to the servo piston and the swashplate angle decreases When system pressure drops below the P setting the P spring shifts the spool in the opposite di...

Page 10: ...y msec 130cc 150 270 145cc 150 270 193cc1 280 500 260cc 154 327 1 Tested at 1800rpm Values may vary depending on application conditions For more information please contact Danfoss Power Solutions Serv...

Page 11: ...ystem pressure and load pressure The S spring sets the threshold of operation S setting Because the swashplate is biased to maximum angle the pump attempts to deliver full flow to the hydraulic system...

Page 12: ...d Sensing LS Response Recovery Times 80 C 1500rpm LS Setting at 25 bar Frame Size Response msec Recovery msec 130cc 260 360 145cc 260 360 193cc1 233 264 260cc 309 327 1 Tested with a LS setting of 20b...

Page 13: ...The external valve changes pressure in the pilot line causing the PC control to operate at a lower pressure When the pilot line is vented to reservoir the pump maintains pressure at the load sense se...

Page 14: ...l control the maximum outlet pressure of the pump 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 pu...

Page 15: ...acement 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 PB workin...

Page 16: ...reases without the drive powers being exceeded PB Vg C The hydraulic output power characteristic T is influenced by the efficiency of the pump T characteristic Q max 0 0 Flow Pressure Pressure Compens...

Page 17: ...E spool s linear spring The control reaches equilibrium when the position of the swashplate spring feedback force exactly balances the input command solenoid force from the operator As working pressu...

Page 18: ...263 bar 390 msec 193cc 160 bar 186 msec 260cc 200 bar 390 msec MOR Each Electric Displacement Control EDC is equipped with a Manual Over Ride MOR function for temporary actuation of the control to ai...

Page 19: ...nal required for optimum control performance Mating connector for Solenoid Description Ordering Number Quantity Mating Connector DEUTSCH DT06 2S 1 Wedge Lock DEUTSCH W2S 1 Socket contact 16 and 18 AWG...

Page 20: ...ve DEUTSCH DT04 2P 74 5 4 5 3 A 2 1 45 37 1 36 7 4 13 M18x1 5 A Actuation Forces Breakaway Force First actuation 45 N 10 12 lbf max Repeat of Actuation 25 N 5 62 lbf max NNES Priority Both the Electri...

Page 21: ...ge 15 Pressure Compensated Control P Principle and Operation Please refer to NPNN Pressure Compensated Control on page 9 Electric Displacement Control E2 E5 Principle and Operation Please refer to NNE...

Page 22: ...nsing Control on page 17 Shuttle Valve Pilot Supply Please refer to Electric Displacement Control E Operating Instruction section at NNES Electric Displacement Control Load Sensing Control on page 17...

Page 23: ...abs without charge pump inlet pressure Operating at or below this speed should yield satisfactory product life Maximum speed The highest recommended operating speed at full power conditions Operating...

Page 24: ...overview Minimum Temperature Relates to the physical properties of the component materials Cold oil will not affect the durability of the pump components However it may affect the ability of the pump...

Page 25: ...rnal rotating components kg m2 slug ft2 0 0151 0 0111 0 0299 0 0221 0 0306 0 0226 0 0299 0 0221 0 0306 0 0226 0 0576 0 0426 0 2080 0 1537 Mass kg lb 47 104 68 150 74 163 68 150 74 163 106 234 141 311...

Page 26: ...ISO 4406 Temperature Range 40 90 C 40 194 F 20 18 15 Temperature Range 90 115 C 194 239 F 19 17 14 1 Intermittent Short term t 3min per incident 2 Cold start Short term t 3min p 30 bar 435 psi n 1000...

Page 27: ...tely Change the fluid and filter per the vehicle machine manufacturer s recommendations or at these intervals Change the fluid more frequently if it becomes contaminated with foreign matter dirt water...

Page 28: ...n M18x1 5 8mm 0 60 bar 0 870 23 psi MB Outlet pressure gauge port M12x1 5 6mm 0 600 bar 0 8702 26 psi M4 Servo piston chamber pressure gauge port M12x1 5 6mm 0 600 bar 0 8702 26 psi M5 Suction pressur...

Page 29: ...size Wrench size Range of gauge L1 L2 L3 Case drain M26x1 5 12 mm 0 60 bar 0 870 23 psi MB Outlet M12x1 5 6 mm 0 600 bar 0 8702 26 psi M4 Servo piston chamber M12x1 5 6 mm 0 600 bar 0 8702 26 psi 130...

Page 30: ...chamber M12x1 5 6 mm 0 600 bar 0 870 23 psi 193 260 Port location Control type TPE2 MB E External Control Port L1 S Inlet Port B Outlet Port M4 L3 L2 193 260 Port location Control type TPSN MB L1 X Lo...

Page 31: ...be certain it is free of restrictions and air leaks 5 To ensure the pump stays filled with oil install the case drain line in the upper most case drain port 6 Install a gauge at port MB to monitor sys...

Page 32: ...operating temperatures Check external system relief valve setting External relief valve set below PC setting causes low output flow Adjust external relief valve following manufacturer s recommendation...

Page 33: ...its Hydraulic fluid viscosity above acceptable limits or low fluid temperature will not allow the pump to fill or control to operate properly Allow system to warm up before operation or sue fluid with...

Page 34: ...r proper operation Check pump inlet pressure vacuum High inlet vacuum adds heat to system Correct inlet pressure vacuum conditions High Inlet Vacuum Item Description Action Check fluid temperature Low...

Page 35: ...desired power setting is 90kW the pump input speed is 1500 rpm and the pump s theoretical displacement is 193cc then solve for start point Pressure 90 P 1500 193 10 3 600 912 Start point Pressure is...

Page 36: ...s 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 s...

Page 37: ...ntrol adjusting screw torque the lock nut to 9 5 N m 84 lbf in 6 Test another current value Input 500 mA to electric displacement control check if the displacement is within the range specified in the...

Page 38: ...placement Control input 700mA to obtain maximum displacement By doing this the functions will not interfere with each other if maximum displacement is commanded by the EDC at all times the MTC functio...

Page 39: ...ntrol lock nut While watching the pressure gauges turn the LS control adjusting screw counterclockwise until the desired pressure differential between port MB and port X is achieved LS setting Clockwi...

Page 40: ...screw Pressure compensated control lock nut Load sensing adjustment screw Load sensing lock nut M12x1 5 0 600 bar 6 mm 22 5 27 5 N m 4 mm 13 mm 21 6 24 6 N m 4 mm 13 mm 21 6 24 6 N m 4 mm 13 mm 21 6...

Page 41: ...193 260 P400255 Measurement Point Outlet Pressure Port MB M12x1 5 0 600 bar 6 mm 22 5 27 5 N m Power Control Adjusting Screw 4 mm Power Control Lock Nut 13 mm 21 6 24 6 N m Pressure Compensated Contr...

Page 42: ...ent 4 Loosen the maximum or minimum displacement limiter lock nut with an external hex wrench and turn the adjusting screw with an internal hex wrench until the desired flow is achieved Option Descrip...

Page 43: ...grees mounting flange side up remove the snap ring F210 using snap ring pliers 4 Remove the shaft seal seal group F220 remove and discard the O ring F230 Shaft seal F222 and carrier F221 are set as on...

Page 44: ...ution Do not hit the shaft using a protective sleeve is recommended Be careful with contaminants during the process 3 Coat with assembly grease to hold the O ring F230 in bearing hole C Caution Be car...

Page 45: ...Polish the sealing area on the shaft if necessary 2 Lubricate new O ring F230 with petroleum jelly and fit in the housing groove 3 Lubricate the lip of the new shaft seal with clean hydraulic fluid Pl...

Page 46: ...ump discard it if it is damaged D1P auxiliary flange installation 1 Push in the new charge pump far enough to clear the retaining ring groove if impeller was replaced 2 Use the appropriate snap ring p...

Page 47: ...150 H150 H150 H130 H130 H120 H120 H130 H130 H125 H120 H120 H100 H100 H100 H100 H110 H110 H110 H110 H200 H200 H200 H200 NN D5 C5 B1 A1 Service Manual D1 High Power Open Circuit Pumps Size 65 130 145 19...

Page 48: ...00 H100 H120 H120 H120 H120 H200 H110 H110 H100 H100 H120 H120 H108 H105 H107 H130 H130 H130 H130 H140 H140 H140 H140 H140 H150 H150 H150 H150 H130 H150 E3 option is only for 260 Service Manual D1 Hig...

Page 49: ...et in the bias piston hole then install the control housing assembly onto the endcap using the mounting bolts Control seal type and mounting bolts Control Seal type Mounting bolts TC DC feedback link...

Page 50: ...2 5 27 5 N m 6mm D180 22 5 27 5 N m P400293 193 260 TPSN Control P400294 6mm D175 22 5 27 5 N m D145 Service Manual D1 High Power Open Circuit Pumps Size 65 130 145 193 260 Minor repairs 50 Danfoss Ju...

Page 51: ...130 145 130 145 TPSN Control D150 D140 D175 P400259 6mm 22 5 27 5 N m Service Manual D1 High Power Open Circuit Pumps Size 65 130 145 193 260 Minor repairs Danfoss July 2019 L1527453 AX00000292en CN0...

Page 52: ...E port in the endcap 2 Install shuttle valve seat D920 according to the direction showing in the picture 3 Install E port plug assembly D900 4 If the shuttle valve is not used replace it with the plug...

Page 53: ...255 G254 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 Service Manual D1 High Power Open Circui...

Page 54: ...minimum top of the pump are the same 1 Clockwise turn the adjusting screw F110 with the appropriate internal hex wrench until you feel it start against the swashplate 2 Install the lock nut F120 while...

Page 55: ...F110 F120 F110 F120 P400265 Service Manual D1 High Power Open Circuit Pumps Size 65 130 145 193 260 Minor repairs Danfoss July 2019 L1527453 AX00000292en CN0201 55...

Page 56: ...port L1 M33 x 2 17 mm hex 68 4 83 6 Nm G225 Outlet pressure test port MB M12 x 1 5 6 mm hex 22 5 27 5 Nm G230 Bias orifice 3 mm hex 3 6 4 4 Nm G240 Bias orifice plug M8 x 1 4 mm hex 9 9 12 1 Nm G235...

Page 57: ...12 x 1 5 6 mm hex 22 5 27 5 Nm G250 Servo orifice plug M12 x 1 5 6 mm hex 22 5 27 5 Nm G253 Bias orifice plug 5 16 24 UNF 2A 1 8 in 9 9 12 1 Nm G254 Edge filter 6 mm hex 9 9 12 1 Nm G255 Edge filter p...

Page 58: ...MB M12 x 1 5 6 mm hex 22 5 27 5 Nm G235 Servo pressure test port M4 M12 x 1 5 6 mm hex 22 5 27 5 Nm G250 Servo orifice plug M14 x 1 5 6 mm hex 30 6 37 4 Nm F140 Drain port L3 M26 x 1 5 12 mm hex 68 4...

Page 59: ...N m 221 27 lbf in D175 Control assembly screws 6 mm internal hex 25 N m 221 27 lbf in 6 mm internal hex 25 N m 221 27 lbf in 6 mm internal hex 25 N m 221 27 lbf in 6 mm internal hex 25 N m 221 27 lbf...

Page 60: ...7 3 lbf in 13 mm external hex 21 6 24 6 N m 191 18 217 7 3 lbf in D880 S locknut 13 mm external hex 21 6 24 6 N m 191 18 217 7 3 lbf in 13 mm external hex 21 6 24 6 N m 191 18 217 7 3 lbf in 13mm ext...

Page 61: ...rdborg 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 Ji...

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