Features and benefits..................................................................................................................................................................... 6
System schematic.............................................................................................................................................................................8
Temperature and viscosity......................................................................................................................................................... 12
Selecting a filter.........................................................................................................................................................................13
Line sizing......................................................................................................................................................................................... 14
Radial and axial loading...............................................................................................................................................................15
D Series Model Code
Single pump order code..............................................................................................................................................................16
DE1: D series cast iron gear pump, single section........................................................................................................ 16
A Rotation - viewed from drive shaft........................................................................................................................... 16
C Mounting flange..............................................................................................................................................................17
D Rear cover: Port options, integrated valves, and auxillary flange................................................................. 18
E Flow control valve setting............................................................................................................................................ 19
F Pressure control valve setting.....................................................................................................................................20
H Assembly Screws - depending on rear cover........................................................................................................21
K Special feature.................................................................................................................................................................. 23
Two section (tandem) pump order code.............................................................................................................................. 23
A Rotation - viewed from drive shaft.................................................................................................................................23
C Mounting flange................................................................................................................................................................... 25
R Ports - First section............................................................................................................................................................... 25
S Displacement - Second section........................................................................................................................................26
D Rear cover: Port options, integrated valves and auxillary flange........................................................................26
E Flow control valve.................................................................................................................................................................28
F Pressure control valve..........................................................................................................................................................29
H Assembly screws...................................................................................................................................................................30
K Special features......................................................................................................................................................................33
Three section (triple) pump order code.................................................................................................................................33
A Rotation - viewed from drive shaft.................................................................................................................................34
B1 Displacement - First section........................................................................................................................................... 34
C Mounting flange................................................................................................................................................................... 35
L Ports - First section................................................................................................................................................................35
M Displacement - Second section......................................................................................................................................36
R Ports - Second section.........................................................................................................................................................37
S Displacement - Third section............................................................................................................................................ 37
D Rear cover: Port options, integrated valves and auxiliary......................................................................................38
E Flow control valve.................................................................................................................................................................40
F Pressure control valve..........................................................................................................................................................40
H Assembly screws...................................................................................................................................................................41
K Special feature........................................................................................................................................................................42
Four section (quad) pump order code...................................................................................................................................42
A Rotation - viewed from drive shaft.................................................................................................................................42
B1 Displacement - First section........................................................................................................................................... 43
C Mounting flange................................................................................................................................................................... 44
L Ports - First section................................................................................................................................................................44
M Displacement - Second section......................................................................................................................................45
N Ports - Second section........................................................................................................................................................ 45
P Displacement - Third section............................................................................................................................................46
R Ports - Third Section.............................................................................................................................................................47
S Displacement - Fourth section.........................................................................................................................................47
D Rear cover: Port options, integrated valves and auxiliary flange........................................................................48
E Flow control valve.................................................................................................................................................................50
F Pressure control valve..........................................................................................................................................................51
H Assembly screws...................................................................................................................................................................51
K Special feature........................................................................................................................................................................52
Multiple pump port options...................................................................................................................................................... 56
Rear cover - port options.............................................................................................................................................................58
Load Sense Priority Flow Valve............................................................................................................................................66
Pumps with Load Sense Priority Flow Valves.................................................................................................................67
D Series Dimension Drawings
One Section - Single......................................................................................................................................................................69
Two section - Tandem..................................................................................................................................................................70
Three Section - Triple....................................................................................................................................................................71
Four Section - Quad...................................................................................................................................................................... 72
A Rotation - viewed from drive shaft...................................................................................................................................... 78
B1 Displacement - front section............................................................................................................................................... 78
C Mounting flange.........................................................................................................................................................................79
R Ports - first section......................................................................................................................................................................79
S Displacement - rear section....................................................................................................................................................79
D Rear cover.....................................................................................................................................................................................79
E Flow control valve...................................................................................................................................................................... 80
F Pressure control valve...............................................................................................................................................................80
H Assembly screws........................................................................................................................................................................ 80
J Name plate.................................................................................................................................................................................... 80
K Special features...........................................................................................................................................................................80
The D Series fixed displacement gear pump has been specifically designed for demanding mobile
equipment applications where maximum performance is required at peak power levels and operating
temperatures.
The design integrates cast iron construction with pressure balanced thrust plates to deliver consistent
efficiency across the entire operating range of pressure, speed, and temperature; all in an industryleading package size that maximizes power density.
Features and benefits
•
High strength cast iron construction allows consistently efficient performance and long life in
continuous operation at 276 bar [4000 psi] and peak conditions of 303 bar [4400 psi].
•
Custom engineered bearings, pressure-balanced load plates, and viton seals optimize internal
lubircation allowing for long life with intermittent fluid temperatures up to 115 °C [239 °F] and fluid
viscosities as low as 8 mm2/sec (cSt) [36 SUS].
•
Compact three-piece design maximizes power density and creates one of the shortest multisection
pumps (with up to four pumping sections) in the global marketplace.
•
Bearings located in the front flange increase radial/axial load carrying capability and eliminate the
need for most bolt-on outrigger bearings.
Quick chart overview
The D Series pump blends the traditional Group 2 (SAE-A) and Group 3 (SAE-B) frame sizes in a single
package with displacements from 7 to 45 cm3 (0.43 to 2.75 in3).
These displacements, in addition to a wide variety of shafts, flanges, ports, and integrated valve options
can be used in virtually any combination to offer greater design flexibility and meet specific application
requirements.
6. Optional: flow control with load sensing priority flow or factory preset fixed priority flow divider valve
7. SAE-A/SAE-B 2-bolts mounting flange
8. Optional: Side or rear port options
Cast iron housings, bearings
The three piece structural members of the pump are made of high-strength cast ductile iron. Cast iron
provides contamination resistance, thermal stability and the strength needed for consistently high levels
of performance and durability needed in demanding off highway applications.
Heavy-duty low friction PTFE-lined sleeve bushings are optimized to provide long life in low viscosity,
high pressure conditions. The bearings are located in the front mounting flange, rear cover, and bearing
plate (for multiple section pumps) and allow the D pump to be 20% shorter than a typical bearing block
Microcontroller
(PLUS+1TM)
Filter
T3
T2
T1
Temperature
sensors
D Series
gear pump
D Series
gear motor
RESERVOIR
DIESEL ENGINE
P107 929E
case drain
CANBUS J1939
Technical Information
D Series and XD Series Gear Pumps
General Information
design pump. In addition, the proximity of the front bearing to the mounting flange increases the radial
load capacity of the pump, eliminating the need for most bolt-on outrigger requirements.
Pressure balance, sealing
The pump incorporates two steel-backed bronze thrust plates seated in depressions in the mounting
flange, rear cover, and bearing plate (for multiple section pumps). Underneath the front plate (known as
the deflecting plate) is the load seal.
The E-shaped load seal distributes system pressure underneath the plate and enables the plate to deflect
and maintain a tight sealing surface against the side face of the gears.
The tight sealing action allows the pump to maintain very high levels of volumetric efficiency, even when
operating in extreme temperature, pressure and speed conditions.
One-piece gear design
All D Series pump gear shafts are of one-piece design. This enables the shaft to provide uniform high
strength and accurate gear profile relative to the journals for smooth mesh operation. The integral gear
shafts are made of heat treated AISI 8620 steel, manufactured to precise tolerances and surface finishes,
for maximal life and minimal leakage. This integral design eliminates the potential problems of fatigue
stress and gear face mismatch often associated with two-piece gear shaft designs.
System schematic
Multiple pump configuration
D Series pumps can be coupled together to produce tandem, triple and even quadruple section units.
The interconnecting chambers accommodate fluid flow between sections and allow the number of inlet
connections to be minimized. Systems that require operation with different fluids and/or reservoirs can
be accommodated with sealed auxiliary covers between sections.
Gear Pump/Gear Motor Fan Drive System with Electronic Control
Use these formulas to determine the nominal pump size for a specific application.
Pressure
Definitions of the D Series operating parameters appear below. Consult Danfoss technical support for
applications running outside of these parameters.
Peak pressure
Peak pressure is the highest intermittent pressure allowed. The relief valve overshoot (reaction time)
determines peak pressure. It is assumed to occur for less than 100 ms. The illustration to the right shows
peak pressure in relation to rated pressure and reaction time (100 ms maximum).
Rated pressure
Rated pressure is the average, regularly occurring operating outlet pressure that should yield satisfactory
product life. The maximum machine load demand determines rated pressure. For all systems, the load
should move below this pressure.
System pressure is the differential between the inlet and outlet ports. It is a dominant operating variable
affecting hydraulic unit life. High system pressure reduces expected pump life. System pressure must
remain at, or below, rated pressure during normal operation to achieve expected life.
Inlet vacuum
Inlet vacuum must be controlled in order to realize expected performance and pump life. System design
must meet inlet vacuum requirements during all modes of operation. Expect lower inlet vacuums during
cold start situations. Low vacuum condition should improve quickly as fluid warms.
Pressure rise rate
The maximum pressure rise rate is the rate of increase in system pressure as measured at the outlet port
of the pump. High pressure rise rates are commonly seen on work function applications during motor
start-up, completion of cylinder stroke, and during rapid shifting of control valves. The maximum
pressure rise rate of the D pump is 11,720 bar/sec [170,000 psi/sec]. During rapid rise rate situations, the
system pressure must not exceed the rated pressure of the pump.
Temperature and viscosity
Temperature
High temperature limits apply at the inlet port of the pump. The pump should run at or below the
maximum continuous temperature.
Minimum (cold start) temperature relates to the physical properties of component materials.
Cold oil, generally, doesn’t affect the durability of pump components. It may affect the ability of oil to
flow and transmit power. For this reason, keep the temperature at 16°C [29 °F] above the pour point of
the hydraulic fluid.
Continuous temperature is the temperature at or below the temperature which normal pump life can
be expected.
Maximum temperature is the highest temperature that is tolerable by the machine for a transient/
limited time (duty cycle 1% or less). At maximum temperature, oil viscosity must not go lower than
minimum recommended viscosity.
Viscosity
Continuous viscosity: Recommended viscosity range for maximum efficiency and pump life.
Minimum viscosity occurs only during brief occasions of maximum fluid temperature and severe duty
cycle operation. It’s the minimum acceptable viscosity to guarantee the pump life. (Duty
cycle 1% or less)
Maximum viscosity occurs only during cold start at very low temperatures. It is the upper limit of
viscosity that allows the pump to start. During this condition, limit speeds until the system warms up.
Temperature and viscosity requirements must be concurrently satisfied.
Speed
Maximum speed is the limit recommended for operation at rated pressure. It is the highest speed at
which normal life can be expected.
The lower limit of operating speed is the minimum speed.
Ratings and data for gear pumps are based on operation with premium hydraulic fluids containing
oxidation, rust, and foam inhibitors. These fluids must possess good thermal and hydrolytic stability to
prevent wear, erosion, and corrosion of internal components.
Use only clean fluid in the pump and hydraulic circuit.
Caution
Never mix hydraulic fluids.
Filtration
Filters
Use a filter that conforms to Class 22/18/13 of ISO 4406 (or better). It may be on the pump outlet
(pressure filtration), inlet (suction filtration), or reservoir return (return-line filtration).
Selecting a filter
When selecting a filter, please consider:
•
contaminant ingression rate (determined by factors such as the number of actuators used in the
system)
•
generation of contaminants in the system
•
required fluid cleanliness
•
desired maintenance interval
•
filtration requirements of other system components
Measure filter efficiency with a Beta ratio (βX). For:
•
suction filtration, with controlled reservoir ingression, use a β
•
return or pressure filtration, use a pressure filtration with an efficiency of β10 = 75
βx ratio is a measure of filter efficiency defined by ISO 4572. It is the ratio of the number of particles
greater than a given diameter ( “X“ in microns) upstream of the filter to the number of these particles
downstream of the filter.
Fluid cleanliness level and βx ratio
Fluid cleanliness level (per ISO 4406)
βx ratio (suction filtration)
βx ratio (pressure or return filtration)
Recommended inlet screen size
The filtration requirements for each system are unique. Evaluate filtration system capacity by monitoring
and testing prototypes.
Reservoir
The reservoir provides clean fluid, dissipates heat, removes entrained air, and allows fluid volume
changes associated with fluid expansion and cylinder differential volumes. A correctly sized reservoir
accommodates maximum volume changes during all system operating modes. It promotes deaeration of
the fluid as it passes through, and accommodates a fluid dwell-time between 60 and 180 seconds,
allowing entrained air to escape.
Minimum reservoir capacity depends on the volume required to cool and hold the oil from all retracted
cylinders, allowing for expansion due to temperature changes. A fluid volume of 1 to 3 times the pump
output flow (per minute) is satisfactory. The minimum reservoir capacity is 125% of the fluid volume.
Install the suction line above the bottom of the reservoir to take advantage of gravity separation and
prevent large foreign particles from entering the line. Cover the line with a 100-125 micron screen. The
pump should be below the lowest expected fluid level. Put the return-line below the lowest expected
fluid level to allow discharge into the reservoir for maximum dwell and efficient deaeration. A baffle (or
baffles) between the return and suction lines promotes deaeration and reduces fluid surges.
Line sizing
Choose line sizes that accommodate maximum fluid velocity to reduce system noise, pressure drops, and
overheating in order to maximize system life and performance. Line velocities shown in the following
table provide a general rule of thumb. Final selection of line sizing and fittings must comply with all
pressure ratings.
Pump life
Pump shaft connection
Inlet
Outlet6-9 [20-30]
m/sec [ft/sec]
2.4-4.3 [8-14]
Most systems use hydraulic oil containing 10% dissolved air by volume. Over-areation, or entrained air is
the result of flow line restrictions, where the dissolved air comes out of solution, or when air is allowed to
leak into the hydraulic circuit. These include inadequate pipe sizes, sharp bends, or elbow fittings,
causing reduction of flow-line cross-sectional area. This problem will not occur if these circuit
recommendations are followed, rated speed requirements are maintained, and reservoir size and
location are adequate.
Pump life is a function of speed, system pressure, and other system parameters (such as fluid quality and
cleanliness).
All Danfoss gear pumps use hydrodynamic journal bearings with an oil film between the gear/shaft and
bearing surfaces. If the oil film is sufficiently sustained through proper system maintenance and
operating within recommended limits, long life can be expected.
ß10 life expectancy number is generally associated with rolling element bearings. It does not exist for
hydrodynamic bearings.
When submitting an application for review, provide machine duty cycle data including percentage of
time at various loads and speeds. We strongly recommend a prototype testing program to verify
operating parameters and their impact on life expectancy before finalizing any system design.
Shaft options for gear pumps include tapered, splined, or parallel shafts.
Plug-in drives, with a splined shaft, can impose severe radial loads when the mating spline is rigidly
supported. Increasing spline clearance does not alleviate this condition.
higher radial loads at lower pressures
contact your S-D representative
25.4 mm
[1 inch]
Recommended loading position
CW Rotation
CCW Rotation
Technical Information
D Series and XD Series Gear Pumps
Operating Parameters
Lubricate all shaft couplings. Failure to do so will result in premature shaft failure.
Use plug-in drives if the concentricity between the mating spline and pilot diameter is within 0.1 mm
[0.004 in]. Lubricate the drive by flooding it with oil. A 3-piece coupling minimizes radial or thrust shaft
loads.
Caution
To avoid spline shaft damages it is recommended to use carburized and hardened steel couplings with
80-82 HRA surface hardness.
Radial and axial loading
Allowable radial shaft loads are a function of the load position, load orientation, and operating pressure.
All external shaft loads have an effect on bearing life, and may affect pump performance.
In applications where external shaft loads cannot be avoided, minimize the impact on the pump by
optimizing the orientation and magnitude of the load. Use tapered input shafts for applications with
radial shaft loads. The table below shows the preferred orientation for radial loads assuming maximum
pressure. For assistance concerning shaft loading, contact your Danfoss representative.
Maximum radial and axial loads
RatingsUnits 7101113141719212325293236384145
Maximum
Integrated Priority Flow Divider,
cartridge style relief
for settings up to: 221barand
34.3 l/min
[3200 psi and 9 US gal/min]
Integrated Steering Cover,
Priority Relief Valve
(Cartridge Style) for settings up
to: 221 bar and 34.3 l/min
[3200 psi and 9 US gal/min]
Integrated Load Sense Divider
(Dynamic), Priority Relief Valve
A variety of integrated load sense priority flow divider covers are available from Danfoss. Please contact
your technical representative to determine which hardware best suits specific application needs.
NNNNoflow control setting, standard for units without integrated flow control valves
04X3.8 l/min [1 US gal/min]
08X7.6 l/min [2 US gal/min]
11X11.4 l/min [3 US gal/min]
15X15.1 l/min [4 US gal/min]
19X18.9 l/min [5 US gal/min]
23X22.7 l/min [6 US gal/min]
27X26.5 l/min [7 US gal/min]
30X30.3 l/min [8 US gal/min]
34X34.3 l/min [9 US gal/min]
000Nopressure control settings, standard for units without integrated pressure control valves
03434 bar [500 psi]
04141 bar [600 psi]
04848 bar [700 psi]
05555 bar [800 psi]
06262 bar [900 psi]
06969 bar [1000 psi]
07676 bar [1100 psi]
08383 bar [1200 psi]
09090 bar [1300 psi]
09797 bar [1400 psi]
103103 bar [1500 psi]
110110 bar [1600 psi]
117117 bar [1700 psi]
124124 bar [1800 psi]
131131 bar [1900 psi]
138138 bar [2000 psi]
145145 bar [2100 psi]
152152 bar [2200 psi]
159159 bar [2300 psi]
165165 bar [2400 psi]
172172 bar [2500 psi]
179179 bar [2600 psi]
186186 bar [2700 psi]
193193 bar [2800 psi]
200200 bar [2900 psi]
207207 bar [3000 psi]
214214 bar [3100 psi]
221221 bar [3200 psi]
For integrated priority flow divider (PFD) cover
with cartridge style relief valve
(Cover optionsF09A, F09B, F13A, F13B, F21A, F21B,
F25A, F25B)
For integrated steering cover with cartridge style
relief valve (Cover options D23A, D23B, D24A,
D24B)
For integrated load sense (LS) cover with cartridge
relief valve (Cover options L01A, L01B, L08A, L08B)
H Assembly Screws - depending on rear cover
AB1B2CDEFHJK
D E1● ●
(Choose Table 1 or Table 2)
Table 1. Single pumps without auxiliary cover or integrated valves
CodeDescription
AA
AC
AM
AP
AR
AS
AL
AT
BB
BC
BM
BP
BR
BS
BT
BW
PP
SAE A 2-bolt
SAE A 2-bolt, use with integral PFD/Steering Cover
SAE A 2-bolt, with T seal
SAE A 2-bolt, with T seal, use with integral PFD/Steering cover
SAE A 2-bolt, use with 15 T spline input drive
SAE A 2-bolt, use with integral PFD/Steering cover and 15 T input spline
SAE A 2-bolt, two shaft seals with weep hole
SAE A 2-bolt, two shaft seals with weep hole, use with integral PFD/Steering cover
SAE B 2-bolt
SAE B 2-bolt, use with integral PFD/Steering cover
SAE B 2-bolt, with T seal
SAE B 2-bolt, with T seal, use with integral PFD/Steering cover
SAE B 2-bolt, use with 15 T spline input drive
SAE B 2-bolt, use with integral PFD/Steering cover and 15 T input spline
SAE B 2-bolt, two shaft seals with weep hole, use with integral PFD/Steering Cover
SAE B 2-bolt, two shaft seals with weep hole
Perkins 6 bolt flange with (2) seals (use with WT input shaft and clockwise rotation)
R Ports - First section
AB1B2CRSDEFHJK
D E 2● ● ●
CodeDescription
1011 1/16-12 side inlet, 7/8-14 side outlet
1031 5/16-12 side inlet, 7/8-14 side outlet
1041 5/16-12 side inlet, 1 1/16-12 side outlet
113No inlet, 7/8-14 side outlet
1251 5/8-12 side inlet, 1 1/16-12 side outlet
126No inlet, 1 1/16-12 side outlet
341Noinlet, 3/4 side split flange outlet (SAE Code 61)
342
11/4 side split flange inlet, 3/4 side split flange outlet(SAE Code
401No inlet, 1/2-14 side outlet
4023/4-14 side inlet, 1/2-14 side outlet
4031-11 side inlet, 1/2-14 side outlet
4041 1/4-11 side inlet, 1/2-14 side outlet
405No inlet, 3/4-14 side outlet
4071-11 side inlet, 3/4-14 side outlet
4081 1/4-11 side inlet, 3/4-14 side outlet
7041 1/4 side tube inlet, 7/8-14 side ORB outlet
70811/4 side tube inlet, 1 1/16-12 side ORB outlet
71611/2 side tube inlet, 1 1/16-12 side ORB outlet
7171 1/2 side tube inlet, 7/8-14 side ORB outlet