Danfoss D1 65, D1 130, D1 145, D1 193, D1 260 Service guide

Service Manual

D1 High Power Open Circuit Pumps

Size 65/130/145/193/260

www.danfoss.com

Service Manual

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

Revision history

Table of revisions

 

 

 

 

 

 

 

Date

Changed

Rev

 

 

 

 

 

July 2019

Added 65cc size

0201

 

 

 

 

 

October 2018

Added Shaft Replacement

0106

 

 

 

 

 

July 2018

Fixed layout

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 2014

First edition

AA

 

 

 

 

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Service Manual

 

 

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

 

Contents

 

 

Introduction

 

 

 

Overview..............................................................................................................................................................................................

5

 

General instructions........................................................................................................................................................................

5

 

Remove the unit..........................................................................................................................................................................

5

 

Keep it clean..................................................................................................................................................................................

5

 

Replace all O-rings and gaskets.............................................................................................................................................

5

 

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

 

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

15

 

NNES (Electric Displacement Control + Load Sensing Control)....................................................................................

17

 

Solenoid Specification............................................................................................................................................................

19

 

Standard EDC Valve.................................................................................................................................................................

20

 

NNES Priority..............................................................................................................................................................................

20

 

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

 

Fluid velocity..............................................................................................................................................................................

24

Technical specifications

 

 

 

D1 pump specifications...............................................................................................................................................................

25

 

D1P fluid specifications................................................................................................................................................................

26

Fluid and filter maintenance

 

 

 

Recommendations of fluid and filter maintenance...........................................................................................................

27

Pressure measurements

 

 

 

Port Locations and Gauge Installation (65)..........................................................................................................................

28

 

Port Locations and Gauge Installation (130/145)...............................................................................................................

29

 

Port Locations and Gauge Instalation (193/260)................................................................................................................

30

Initial start-up procedures

 

 

 

General...............................................................................................................................................................................................

31

 

Start-up Procedure........................................................................................................................................................................

31

Troubleshooting

 

 

 

Excessive Noise and /or Vibration............................................................................................................................................

32

 

Low Pump Output Flow...............................................................................................................................................................

32

 

No or Low System Pressure........................................................................................................................................................

32

 

Actuator Response is Sluggish..................................................................................................................................................

33

 

Pressure or Flow Instability.........................................................................................................................................................

33

 

System Operating Hot..................................................................................................................................................................

34

 

High Inlet Vacuum.........................................................................................................................................................................

34

Adjustments

 

 

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Contents

Calculate Power Control Start Point Pressure and Corresponding Flow in Advance...........................................

35

Electric Displacement Control Adjustment .........................................................................................................................

36

Pressure Compensated Control Adjustment.......................................................................................................................

38

Power Control Adjustment.........................................................................................................................................................

38

Load Sensing Control Adjustment...........................................................................................................................................

38

Displacement Limiters Adjustment.........................................................................................................................................

42

Adjust Displacement Limiters..............................................................................................................................................

42

Minor repairs

 

Shaft replacement.........................................................................................................................................................................

43

Shaft removal.............................................................................................................................................................................

43

Shaft installation.......................................................................................................................................................................

44

Shaft Seal Replacement...............................................................................................................................................................

45

Removal........................................................................................................................................................................................

45

Installation...................................................................................................................................................................................

45

Auxiliary Flange and Charge Pump Replacement.............................................................................................................

46

Auxiliary flange removal........................................................................................................................................................

46

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 installation........................................................................................................................................

52

Edge Filter (260)..............................................................................................................................................................................

52

Edge filter removal...................................................................................................................................................................

52

Edge filter installation.............................................................................................................................................................

52

Displacement Limiters.................................................................................................................................................................

54

Displacement limiter screw removals...............................................................................................................................

54

Displacement limiter screws installation.........................................................................................................................

54

Plug and fitting installation........................................................................................................................................................

56

193 TPE2 control.......................................................................................................................................................................

56

260 TPE2 control.......................................................................................................................................................................

57

130/145 TPSN control.............................................................................................................................................................

58

Plugs and fasteners.......................................................................................................................................................................

59

Fastener and torque chart.....................................................................................................................................................

59

Plug size and torque chart.....................................................................................................................................................

60

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Service Manual

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

Introduction

Pump service overview

This manual includes information on maintenance, troubleshooting, and minor repair of D1P pumps.

Performing minor repairs may require removal from the vehicle/machine. Thoroughly clean the unit before beginning maintenance or repair activities. Since dirt and contamination are the greatest enemies of any type of hydraulic equipment, follow cleanliness requirements strictly. This is especially important when changing the system filter and when removing hoses or plumbing.

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.

For detailed technical information, refer to the Technical Information manual.

General instructions

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 high pressure and/or hot. Inspect the outside 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. Clean the outside of the pump thoroughly before disassembly. Take care to avoid contamination of the system ports. Cleaning parts by using a clean solvent wash and air drying is usually adequate.

As with any precision equipment, you must keep all parts free of foreign material and chemicals. Protect all exposed sealing surfaces and open cavities from damage and foreign material. If left unattended, cover the pump with a protective layer of plastic.

Replace all O-rings and gaskets

Danfoss recommends that you replace all O-rings, seals and gaskets. Lightly lubricate all O-rings with clean petroleum jelly prior to assembly.

Secure the unit

If removed from machine, place the unit in a stable position with the shaft pointing downward. It will be necessary to secure the pump while removing and torquing fasteners and components.

Safety precautions

Unintended Machine Movement

Unintended movement of the machine or mechanism may cause injury to the technician or bystanders. Secure the machine or disable/disconnect the mechanism while servicing to protect against unintended movement.

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Service Manual

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Introduction

Flammable Cleaning Solvents

Some cleaning solvents are flammable.

Do not use cleaning solvents in an area where a source of ignition may be present to avoid possible fire.

Fluid Under Pressure

Escaping hydraulic fluid under pressure can have sufficient force to penetrate your skin causing serious injury and/or infection. This fluid may also be hot enough to cause burns.

Relieve pressure 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 fluid under pressure. Seek medical attention immediately if you are cut by hydraulic fluid.

Personal Safety

Protect yourself from injury whenever servicing a hydraulic system.

Use proper safety equipment, including safety glasses, at all times.

Symbols used in Danfoss literature

WARNING may result in injury

CAUTION may result in damage to product or property

Reusable part

Non-reusable part, use a new part

Non-removable item

Option - either part may exist

Superseded - parts are not interchangeable

Measurement required

Flatness specification

Parallelism specification

External hex head

Internal hex head

Torx head

O-ring boss port

Tip, helpful suggestion

Lubricate with hydraulic fluid

Apply grease / petroleum jelly

Apply locking compound

Inspect for wear or damage

Clean area or part

Be careful not to scratch or damage Note correct orientation

Mark orientation for reinstallation

Torque specification

Press in - press fit

Pull out with tool – press fit

Cover splines with installation sleeve

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 where it is most useful to the reader. In most instances, the appearance of the symbol itself denotes its meaning. 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

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Introduction

bearings at the front and rear of the pump and is splined into the cylinder block . A lip-seal at the front end of the pump prevents leakage where the shaft exits the pump housing. The spinning cylinder block contains nine reciprocating pistons. Each piston has a brass slipper connected at one end by a ball joint. The slippers are held to the swashplate by the retainer. The block spring holds the cylinder block to the valve plate. The reciprocating movement of the pistons occurs as the slippers slide against the inclined swashplate during rotation. Via the valve plate, one half of the cylinder block is connected to pump inlet and the other half to pump outlet. As each piston cycles in 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 plate and slipper / swashplate interfaces for lubrication and cooling. Case drain ports are provided to return this fluid to the reservoir.

The volume of fluid displaced into the system circuit is controlled by the angle of the swashplate. The swashplate is forced into an inclined position (into stroke) by the bias piston and spring. The servo piston opposes the action of the bias piston and spring forcing the swashplate out of stroke.

The pump control, by varying the pressure at the servo piston, controls the displacement of fluid in the system circuit.

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Danfoss D1 65, D1 130, D1 145, D1 193, D1 260 Service guide

Service Manual

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

Introduction

D1 pump cross-section view

D1 pump

6

 

5

 

4

3

7

 

8 2

1

16

15

 

 

 

 

9

 

 

10

14

 

11

 

13

12

 

 

1.Shaft seal

2.Roller bearing

3.Housing

4.Minimum displacement limiter

5.Bias piston

6.Control

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 different depending on the pump size.

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Service Manual

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

Operation

NPNN (Pressure Compensated Control)

D1P 130/145/193/260+NPNN

Pressure Compensated Control (P) Principle

The P control design maintains a constant pressure in the hydraulic circuit as flow varies. The P control modulates pump flow accordingly to maintain system pressure at the P setting as the P adjusting screw and spring defines.

Pressure Compensated Control (P) Operation

When system pressure, acting on the non-spring end of the P spool, overcomes the force of the 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 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.

P characteristic

Q max

<![if ! IE]>

<![endif]>Flow

0

0

Pressure

It is recommended that a relief valve be installed in the pump outlet for additional system protection.

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Service Manual

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Operation

Response/Recovery

Pressure Compensated (PC) Control Response/Recovery Times* @80°C, 350 bar, 1500rpm

Frame Size

Response (msec)

Recovery (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.

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

Operation

NPSN (Pressure Compensated Control + Load Sensing Control)

D1P 130/145/193/260+NPSN

Pressure Compensated Control (P) Principle and Operation

Please refer to NPNN (Pressure Compensated Control) on page 9

Load Sensing Control (S) Principle

The S control design matches pump flow with system demand. The S control senses the flow demand of the system as a pressure drop across the external control valve (1).

As (1) opens and closes, the pressure difference (delta) across the valve changes. When opening, the delta decreases. When closing, the delta increases. The S control then increases or decreases pump flow to the system until the pressure delta becomes equal to the S setting as defined by the S adjusting screw and spring.

Load Sensing Control (S) Operation

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 spring end. This arrangement allows the S spool to act on the delta between system 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. When the flow being delivered exceeds demand, the pressure delta across the (1) is great enough to overcome spring force and shift the S spool porting system pressure to the servo piston. The pump de-strokes reducing flow until the delta across the (1) becomes equal to the S setting.

When flow being delivered is less than demand, the delta across the (1) drops below the S setting and the S spring shifts the spool connecting the servo piston to pump case. The pump strokes increasing flow until the delta across the (1) becomes equal to the S setting.

When the external control valve (1) is placed in neutral, it connects the LS signal line to drain. With no LS pressure acting on the non-spring end of the LS spool, the pump adjusts stroke to whatever position necessary to maintain system pressure at the LS setting. The pump is now in low pressure standby mode.

(1) is not in the scope of supply.

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Operation

S characteristic

Q max

<![if ! IE]>

<![endif]>Flow

0

0

Pressure

 

<![if ! IE]>

<![endif]>P setting

For additional system protection, install a relief valve in the pump outlet line.

NPSN Priority

The Pressure Compensated Control (P) has priority over the Load Sensing Control (S).

Response/Recovery

Load 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 20bar

 

 

Values may vary depending on application conditions. For more information, please contact Danfoss Power Solutions

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Service Manual

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

Operation

NPNR (Pressure Compensated Control + Remote Pressure Compensated Control)

D1P 130/145/193/260+NPNR

Pressure Compensated Control (P) Principle and Operation

Please refer to NPNN (Pressure Compensated Control) on page 9.

Remote Pressure Compensated Control (R) Principle

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 20bar.

Remote Pressure Compensated Control (R) Operation

The remote PC control uses a pilot line connected to an external hydraulic valve. 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 setting. When pilot flow is blocked, the pump maintains pressure at the PC setting. An on-off solenoid valve can be used in the pilot line to create a low-pressure standby mode. A proportional solenoid valve, coupled with a microprocessor control, can produce an infinite range of operating pressures between the low pressure standby setting and the PC setting.

R characteristic

Q max

<![if ! IE]>

<![endif]>Flow

 

<![if ! IE]>

<![endif]>setting

 

<![if ! IE]>

<![endif]>setting

 

 

<![if ! IE]>

<![endif]>RP

 

<![if ! IE]>

<![endif]>PC

 

 

 

 

 

0 0

Pressure

 

 

 

 

For additional system protection, install a relief valve in the pump outlet line.

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Service Manual

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

Operation

NPNR Priority

When the pump’s X-port is vented to tank, or limited to some pressure setting via a remote valve, the remote pressure compensator function will 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 pump’s maximum pressure.

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Service Manual

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

Operation

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

D1P 130/145+TPSN

X

(1)

B

MB

Vg max Vg min

L3

S

M4 L1 L2

P400251

D1P 193/260+TPSN

*Control oil filter is optional

 

(1)

 

 

 

 

 

 

 

X

 

B

 

 

 

MB

 

 

 

 

 

 

Vg max

Vg min

 

 

 

CW

 

 

L3

S

M4

L1

L2

 

 

 

 

P400080

Power Control (T) Principle

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.

PB = working pressure

PB • Vg = C

Vg = displacement

C = constant

The precise control with a hyperbolic control characteristic, provides an optimum utilization of available power.

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Service Manual

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Operation

Power Control (T) Operation

The working pressure acts on a rack-pivot via a roller jack which produces a rotating torque, an externally adjustable spring force counteracts this which determines the power setting.

If the moment generated by working pressure exceeds the moment generated by spring force, the control valve is actuated by the rack-pivot, and pump reduces displacement. The lever length at the rackpivot is shortened and the working pressure can increase at the same rate as the displacement decreases 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

<![if ! IE]>

<![endif]>Flow

00

Pressure

 

 

 

Pressure Compensated Control (P) Principle and Operation

Please refer to NPNN (Pressure Compensated Control) on page 9

Load Sensing Control (S) Principle and Operation

Please refer to NPSN (Pressure Compensated Control + Load Sensing Control) on page 11

TPSN Priority

The Pressure Compensated Control (P) has priority over the Power Control (T), Power Control has priority over Load Sensing Control (S).

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Service Manual

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

Operation

NNES (Electric Displacement Control + Load Sensing Control)

D1P 130/145/193/260 NNES

E B

MB

Vgmax

Vgmin

W Warning

L3

S

M4 L1 L2

 

(1) Adjustment is not permissible

Electric Displacement Control (E) Principle

The electric displacement control uses an electric proportional solenoid valve to vary the pump’s displacement from minimum displacement to maximum displacement or from maximum displacement to minimum displacement. The swashplate angle (pump displacement) is proportional to the electrical input signal (control current).

Electric Displacement Control (E) Operation

This control is current driven, requiring a Pulse Width Modulated (PWM) signal. Pulse width modulation allows more precise control of current to the solenoid. 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

A swashplate feedback link provides swashplate position force to the solenoid through the 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 pressure changes with load, the control and servo/swashplate system work constantly to maintain the commanded position of the swashplate.

Electric Displacement Control (E) Operating Instruction

To make sure the electric displacement control works properly, a minimum control pressure of 30 bar [435 psi] is required. The required control pressure is taken either from the working pressure, or from the externally applied control pressure at the E port.

If you can’t make sure that the working pressure is above 30 bar all the time, then a minimum of 30bar [435 psi] pressure supply at the E port is mandatory in order to control the displacement of the pump at all times. This pressure supply can be provided from different sources, such as an additional small gear or piston pump and a relief valve, or an accumulator.

If E port is not connected, remove the shuttle valve

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Operation

Typical operating curve

Hysteresis

EDC Hysteresis1

Input hysteresis

<4.5%

 

 

Output hysteresis @50% displacement

<4.0%

 

 

1 Values may vary depending on application conditions. For more information, please contact Danfoss Power Solutions

Response/Recovery

Response/Recovery Times @ 1500rpm (50°C)1

Response 0%-100%

130cc (263 bar)

260 msec

 

 

 

 

145cc (263 bar)

260 msec

 

 

 

 

193cc (160 bar)

272 msec

 

 

 

 

260cc (200 bar)

370 msec

 

 

 

Response 100%-0%

130cc (263 bar)

390 msec

 

 

 

 

145cc (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 aid in diagnostics, even if insufficient or no current is supplied to the solenoid actuator. Initial activation of the MOR function will require a higher force to overcome the sticking effect between the pin and O-ring seal. Repeated activation of this functionality should provide better controllability.

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Operation

W Warning

Do not actuate the MOR unless the machine is in a “SAFE” mode. Unintended MOR operation will cause the pump to go into stroke, use only for diagnosis purposes.

Solenoid Specification

Technical data - Solenoid

Voltage

24V (±20%)

 

 

Start current at Vg min.

200 mA

 

 

End Current at Vg max.

600 mA

 

 

Maximum current

770 mA

 

 

Coil Resistance @ 20 °C [70 °F]

22.7 Ω

 

 

PWM Range

70~200 Hz

 

 

PWM Frequency (preferred)*

100 Hz

IP Rating (IEC 60 529) + DIN 40 050, part 9

IP 67

 

 

IP Rating (IEC 60 529) + DIN 40 050, part 9 with

IP 69K

mating connector

 

 

 

* PWM signal 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)

DEUTSCH 0462-201-16141

2

 

 

 

Danfoss mating connector kit

K29657

1

 

 

 

The mating connector is not included in the delivery contents, this can be delivered by Danfoss on request.

Compatible PLUS+1® controllers(see below):

 

MC012

L1301095

 

 

 

 

MC024

L1315302

 

 

 

 

MC038

11051653

 

 

 

 

MC050

L1301752

 

 

 

 

MC088

11006645

 

 

 

 

For further information: please visit: http://www.danfoss.com/Products/MobileElectronics/index.htm

 

 

© Danfoss | July 2019

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