Danfoss MP1 User Manual Download

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Service Manual

Variable Displacement Pumps

MP1

www.danfoss.com

Summary of Contents for MP1

Page 1: ...Service Manual Variable Displacement Pumps MP1 www danfoss com...

Page 2: ...t strings on MDC and additional options to MDC illustration 0107 January 2018 update control current table 0106 November 2017 Add NFPE 0105 October 2017 Remove HDC 0104 July 2017 update ports and plug...

Page 3: ...d Data 15 Control Response 16 MP1 EDC response time 16 Manual Over Ride MOR 16 Swash Plate Angle Sensor for EDC Controls 18 Swash Plate Angle Sensor Parameters EDC 18 Swash Plate Angle Sensor Connecto...

Page 4: ...Sluggish System Response 45 Adjustments Pump adjustment 46 Standard Procedures 46 Charge Pressure Relief Valve 46 Displacement Limiter 47 Control Neutral Adjustment 48 Mechanical Hydraulic Neutral Ad...

Page 5: ...on 60 MP1 CPRV assembly 60 MP1 loop flushing removal 28 32 61 MP1 loop flushing spool inspection 62 Reassembly 62 Shaft Removal 62 Inspection 63 Shaft Reassembly 63 Fastener size and torque chart Fast...

Page 6: ...nstructions Remove the unit If necessary 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 h...

Page 7: ...ressure 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 Use caution when dealing with hydraulic fl...

Page 8: ...boss port Pressure measurement gauge location or specification The symbols above appear in the illustrations and text of this manual They are intended to communicate helpful information at the point w...

Page 9: ...0 0020 0 0015 0 0030 0 0022 Mass kg lb 29 6 65 3 38 83 8 Oil volume liter US gal 1 5 0 40 2 0 0 53 Mounting flange ISO 3019 1 flange 101 2 SAE B Input shaft outer diameter splines and tapered shafts...

Page 10: ...ications Features Units 28 32 38 45 Viscosity Intermittent1 mm2 sec SUS 5 42 Minimum 7 49 Recommended range 12 80 66 370 Maximum cold start 2 1600 7500 Temperature range3 Minimum cold start C F 40 40...

Page 11: ...ny application or operating condition which leads to elevated HPRV flow will cause a pressure rise with flow above a valve setting Consult factory for application review Excessive operation of the HPR...

Page 12: ...pressure The charge pressure relief valve setting is specified within the model code of the pump pumps with charge pump have the CPRV set at 1800 rpm while MP1 pumps without charge pump have the CPRV...

Page 13: ...ge and the size of the plug Working Loop Low Pressure Working Loop High Pressure Shuttle Spool Orifice Plug P400342 Loop flushing performance 25 20 35 40 45 30 15 10 5 0 0 4 8 10 12 14 Charge pressure...

Page 14: ...located in the supply line immediately before the control porting spool EDC control P003 191 EDC schematic Feedback from Swash plate P T F00B M14 C1 C2 F00A P003 478E EDC operation EDC s are current...

Page 15: ...harge pressure the spring loaded servo piston will automatically return the pump to the neutral position Control Signal Requirements EDC Pump displacement vs control current 0 b a b a 100 100 Displace...

Page 16: ...sponse time Stroking direction 0 8 mm 0 03 in orifice 1 0 mm 0 04 in orifice 1 3 mm 0 05 in orifice No orifice 28 32 38 45 28 32 38 45 28 32 38 45 28 32 38 45 Neutral to full flow 1 3 s 2 1 s 0 9 s 1...

Page 17: ...MOR and schematic P003 204 Feedback from Swash plate P T F00B M14 C2 C1 F00A P003 205E Service Manual MP1 Operation Danfoss April 2019 AX00000244en 000201 17...

Page 18: ...or is available for all EDC controls for 12 V and 24 V Swash plate angle vs output of supply voltage 18 13 8 100 90 80 70 60 50 40 30 20 10 0 Swashplate angle Sensor output of supply voltage 3 0 2 7 1...

Page 19: ...4 1 11105824 Wedge lock WM 4S 1 not available Socket contact 0462 201 2031 3 Interface with ECU EDC Interface with ECU diagram ECU Supply Signal GND GND OUT VCC 100 nF 20 k 100 nF Manual displacement...

Page 20: ...the actuation system and the control block Its shaft is sealed by means of a special O ring which is applied for low friction The special O ring is protected from dust water and aggressive liquids or...

Page 21: ...3 bar Customers must install some support to limit the setting range of their Bowden cable to avoid an overload of the MDC Customers can apply their own handle design but they must care about a robust...

Page 22: ...d response Typical response times at the following conditions p 250 bar 3626 psi Charge pressure 20 bar 290 psi Viscosity and temperature 30 mm s 141 SUS and 50 C 122 F Speed 1800 min 1 rpm MP1 MDC re...

Page 23: ...20 A Max voltage 36 VDC Electrical protection class IP67 IP69K with mating connector Case gauge port M14 The drain port should be used when the control is mounted on the unit s bottom side to flush re...

Page 24: ...e FNR electic control FNR principle The 3 position FNR control uses an electric input signal to switch the pump to a full stroke position Under some circumstances such as contamination the control spo...

Page 25: ...control FNR P003 193 FNR hydraulic schematic P003 189 C2 C1 F00A M14 T P F00B Pump displacement vs electrical signal P003 190E 100 0 100 Voltage VDC Displacement Service Manual MP1 Operation Danfoss A...

Page 26: ...0 529 DIN 40 050 part 9 IP 67 IP 69K part 9 with mating connector Bi directional diode cut off voltage 28 VDC 53 VDC PWM signal required for optimum control performance Pump output flow direction vs c...

Page 27: ...38 45 Neutral to full flow 2 1 s 2 6 s 1 1 s 1 6 s 0 8 s 1 1 s 0 7 s 0 7 s Full flow to neutral 1 1 s 1 8 s 0 9 s 1 0 s 0 6 s 0 7 s 0 3 s 0 3 s Non Feedback Proportional Electric Control NFPE The Non...

Page 28: ...ommended 100 Hz IP Rating IEC 60 529 IP 67 DIN 40 050 part 9 IP 69K with mating connector Connector color Black PWM signal required for optimum control performance Pump output flow direction vs contro...

Page 29: ...p servo piston to achieve pump displacement pumps with NFPH control have a special servo cylinder capable of providing proportional control with a hydraulic input Swashplate position is proportional t...

Page 30: ...ntrols are available with optional control passage orifices to assist in matching the rate of swashplate response to the application requirements e g in the event of electrical failure The time requir...

Page 31: ...mm 0 04 orifice 1 3 mm 0 05 orifice 28 32 38 45 28 45 38 45 28 45 38 45 Neutral to full flow 1 5 s 2 2 s 0 9 s 1 4 s 0 6 s 0 8 s Full flow to neutral 0 9 s 1 1 s 0 6 s 0 7 s 0 4 s 0 5 s Service Manual...

Page 32: ...put signal Return to neutral time will be dependent on oil viscosity pump speed swashplate angle and system pressure When the solenoid is energized charge flow and pressure is allowed to reach the pum...

Page 33: ...9 5 V 19 V Nominal coil resistance at 20 C 10 7 41 7 Supply current Maximum 850 mA 430 mA Minimum 580 mA 300 mA PWM frequency Range 50 200 Hz 50 200 Hz Preferred 100 Hz 100 Hz Electrical protection c...

Page 34: ...y set to max displacement The maximum displacement of the pump can be set independently for forward and reverse using the two adjustment screws to mechanically limit the travel of the servo piston Adj...

Page 35: ...ss System Pressure System pressure is the differential pressure between system ports A and B It is the dominant operating variable affecting hydraulic unit life High system pressure which results from...

Page 36: ...t be exceeded During cold start case pressure must be kept below maximum intermittent case pressure Size drain plumbing accordingly C Caution Possible component damage or leakage Operation with case p...

Page 37: ...e recommended range The minimum viscosity should be encountered only during brief occasions of maximum ambient temperature and severe duty cycle operation The maximum viscosity should be encountered o...

Page 38: ...found to be satisfactory For some open circuit systems and closed circuits with cylinders being supplied from the same reservoir a higher filter efficiency is recommended This also applies to systems...

Page 39: ...6 12 9 16 internal hex metric M27x2 12 mm MA MB 28 32 System Gauge 600 bar 10 000 psi inch 9 16 18 11 16 inch metric M14x1 5 19 mm MA MB 38 45 System Gauge 600 bar 10 000 psi inch 16 7 8 inch metric M...

Page 40: ...ort locations L2 M14 M5 M3 F AM3 E M4 AM3 L1 B A S A M MB L2 M14 M5 F AM3 E M4 AM3 L1 B B A M3 A MA MB S 28 32 38 45 Service Manual MP1 Pressures measurements 40 Danfoss April 2019 AX00000244en 000201...

Page 41: ...control is installed on top open the construction plug in the top of the control to assist in air bleed 5 Fill the reservoir with hydraulic fluid of the recommended type and viscosity Use a 10 micron...

Page 42: ...12 Continue to cycle between forward and reverse for at least five minutes to bleed all air and flush system contaminants out of loop Normal charge pressure fluctuation may occur during forward and r...

Page 43: ...nism while servicing C Caution Contamination can damage internal components and void the manufacturer s warranty Take precautions to ensure system cleanliness when removing and reinstalling system lin...

Page 44: ...anges direction replace the valve that does not operate correctly Remember to return HPRVs to their original position afterward Settings may be different for forward reverse Servo pressure Servo press...

Page 45: ...d test pump May be a normal condition Neutral Difficult or Impossible to Find Item Description Action Input to pump control Input to control module is operating improperly Disconnect input and check t...

Page 46: ...of contamination oil discoloration foam in the oil sludge or metal particles 6 If there are signs of contamination in the hydraulic fluid replace all filters and drain the hydraulic system Flush the...

Page 47: ...C Caution Before adjusting the displacement limiter mark the position of the servo cylinder Be sure the servo cylinder does not turn when setting the displacement limiter locknut 1 Loosen the lockingn...

Page 48: ...e disconnect the mechanism while servicing 1 Install a 50 bar 1000 psi gauge in each of the two servo gauge ports M4 and M5 Disconnect the external control input electrical hydraulic connections from...

Page 49: ...cating that the control is in its neutral position 6 Hold the neutral adjusting screw stationary and tighten the lock nut Torque to 10 Nm 7 lbf ft Do not over torque the nut 7 When the neutral positio...

Page 50: ...posite direction by turning the adjusting screw in the opposite direction or by supplying current hydraulic pressure to solenoid C2 Reverse gauge locations M4 for M5 MB for MA from those stated above...

Page 51: ...ation must be greater than the pressure at port B A for clockwise rotation This step ensures the servo is in contact with the servo cylinder on side M4 5 Slowly turn in the servo cylinder on the M4 si...

Page 52: ...ork surface and surrounding area are clean and free of contaminants such as dirt and grime 5 Inspect the system for contamination 6 Look at the hydraulic fluid for signs of system contamination oil di...

Page 53: ...on the control and top of the pump If you find any nicks or scratches replace the component MP1 EDC control assembly Ensure you install dowel pins D300 in the housing before installing the control 1 I...

Page 54: ...be replaced Use a 12 point 26 mm socket Torque the coil nut to 5 N m 3 7 lbf ft 3 Inspect the machined surface on the control If you find any nicks or scratches replace the component 4 Lubricate new...

Page 55: ...module and gasket D150 and discard the gasket 3 Optional If necessary remove servo orifices F00A F00B supply orifice F00P and tank orifices F00T using a 3 mm internal hex wrench It is recommended to...

Page 56: ...2 N m 9 lbf ft D200 feedback pin 5 mm internal hex 13 3 Nm 9 8 lbf ft D250 cap screw 5 mm internal hex 13 3 Nm 9 8 lbf ft QD70 solenoid QD81 O ring QD75 neutral start switch assembly QD751 O ring QD73...

Page 57: ...internal hex wrench and torque to 2 5 N m 1 8 lbf ft 3 Install the control module and six cap screws D250 4 Using a 5 mm internal hex wrench torque the cap screws D250 to 13 3 N m 9 8 lbf ft Torque se...

Page 58: ...hes or pitting Scratches on these components will cause a loss of charge pressure If any component shows signs of wear scratching or pitting replace it MP1 charge pump assembly 1 Lubricate and install...

Page 59: ...or scratches Check the high pressure relief valves for damage Replace any damaged components HPRV Valve Reassembly 1 Lubricate and install new O rings M022 and backup rings M023 2 Install the HPRV va...

Page 60: ...spect washer spring and seat Replace charge pressure relief valve if damage is found Inspect the sealing surfaces of the pump for nicks or scratches MP1 CPRV assembly 1 Install seat V400 spring V300 a...

Page 61: ...5 Using a 3 mm internal hex remove orifice L200 MP1 loop flushing torque information Loop flushing removal L150 L100 L200 G115 P109066 9Q50A Identification and torque Item Wrench size Torque Plug L15...

Page 62: ...30 lbf ft Shaft Removal The shaft assembly is serviceable without disassembling the pump 1 Position the pump with the shaft pointing up 2 Remove the first spring clip J300 3 Carefully remove and disc...

Page 63: ...assembly 1 Press the bearing J150 onto the shaft J100 and replace the retaining ring J200 2 Install the shaft bearing assembly into the pump 3 Install first spring clip J300 4 Cover the shaft with a p...

Page 64: ...70 G075 G010 G030 G040 G035 K300 D250 G045 G015 E085 E090 N100 M100 V100 H130 H130 H130 G060 G010 G020 G015 G025 G070 G075 G010 G035 G030 G040 G065 38 45 28 32 Service Manual MP1 Fastener size and tor...

Page 65: ...1 4 inch internal hex 40 N m 29 5 Ft lbs for 9 16 35 3 N m 26 Ft lbs for M14 G020 G025 Servo gauge 28 32 6 mm or 3 16 inch internal hex 25 N m 18 4 Ft lbs for 7 16 25 N m 18 4 Ft lbs for M12 G020 G02...

Page 66: ...Service Manual MP1 66 Danfoss April 2019 AX00000244en 000201...

Page 67: ...Service Manual MP1 Danfoss April 2019 AX00000244en 000201 67...

Page 68: ...5 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 Jin Hai Rd Jin Qiao Pudo...

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