Danfoss 72400 Electronic Proportional Control Installation Guide

Danfoss 72400 Electronic Proportional Control

Specifications

• Model: EP Control Kits
• Input Voltage: 1-6 V, 12 V, 24 V
• Control Module: Electronic Module
• Required Tools: Various screws, hex key, bit socket

Product Usage Instructions

Installation

1. Disassembly:
   • Step 1: Clean the pump thoroughly. If conversion will be performed without removing the pump from the machine, lower the case fluid level below EP Control mounting surface.
   • Step 2: Remove the manual displacement control using a 5/32 hex key or bit socket by unscrewing the cap screws and discarding them.
   • Step 3: Carefully lift the manual displacement control away from the pump to disengage the feedback link from the servo piston land.
   • Step 4: Remove the control valve gasket from the pump housing and discard it. Use a 5/32 hex key or bit socket to remove the top hex head cap screws on each side of the servo piston cap for mounting L brackets of the electronic module.
2. Reassembly:
   • Step 6: Clean the control mounting surface. Install a new control valve gasket by aligning it with bolt and porting holes. Locate the EP Control valve assembly, electronic module, bolts, washers, and control valve gasket.
3. Neutral Adjustment:
   • Caution : Ensure all hoses and fittings are connected before attempting to check neutral adjustment.
   • Disengage the input drive to the vehicle or elevate wheels.
   • Install a charge pressure gauge (0-1000 psi or 0-1500 psi recommended).
   • Start the prime mover.
   • Loosen the locknut holding the neutral adjustment screw until it is just snug enough to rotate. Use a 9/16 end wrench to hold the locking nut while rotating the neutral adjustment screw.
   • Note the number stamped on the cap of the low-pressure relief valve for high setting reference.

Frequently Asked Questions (FAQ)

• Q: What are the typical performance values of this product?
  A: Performance values are typical and subject to change without notice. Customers should select products for their applications using normal engineering methods.

Danfoss® Electronic Proportional (EP) Control for Medium Duty 72400 Piston Pumps
Installation Guide

• Information contained in this installation booklet is accurate as of the publication date and is subject to change without notice. Performance values are typical val-ues. Customers are responsible for selecting products for their applications using normal engineering methods.

Introduction

The following information describes the installation of the Electronic Proportional
(EP) Control for Danfoss ® Medium Duty 72400 piston pumps. Review this information to become familiar with the procedures required before beginning any installation.

• CAUTION and operation of any electronic control, proper component selection and installation procedures must be followed with respect to interconnection wiring harnesses, input command signal devices, fusing, and input power switching.
• Appropriate industry practices must be followed to prevent damage of and shorting of all electrical and electronic components caused by environmental hazards and application specific hazards. Typical hazards that damage the wiring harnesses or other components are abrasion, moving objects, and heat from the engine or exhaust system. Moisture can damage poorly sealed connectors and/or components, causing short circuits and other problems like corrosion.
• A switch must be installed in line with (+ battery) power to the electronic module, so that power may quickly be disconnected in case of emergency (component failure or inadvertent commands). A fuse rated at the maximum module operating current (3 Amp) must be installed in the + battery line to the electronic module.
• All the electrical connections to the EP Control electronic module must be disconnected prior to performing any electrical welding on the vehicle or machine. The electronic module  and/or the hydraulic pump are not to be used as a connection point for electrical welding equipment.
• During initial start-up and/or checkout of the machine after service, the machine must be placed on jack stands to prevent inadvertent movement.
• The reliable operation and suitability of this product is dependent upon how it is applied and the other components used in the system. The system integrator must review all aspects of the application and all of the components used to assure proper operation and reliability.

Identification of Components

Required tools f or Installation:

• 1/8″ Bit Socket or Hex Key
•  5/32″ Bit Socket or Hex Key
• 9/16″ Open End Wrench
•  3/4″ Open End Wrench
• Flat Blade Screwdriver
• 1 2 VDC Power Supply or Battery
• Voltage Ohm Meter (VOM)
• Charge Pressure Gauge

EP Control Kits

Installation

Disassembly

• Step 1
  Clean the pump thoroughly. If conversion will be performed without removing pump from machine, case fluid level will need to be lowered below EP Control mounting surface.

• Step 2
  Remove the manual displacement control. Using a 5/32″ hex key or bit socket, remove the cap screws and discard.

• Step 3
  Carefully lift the manual displacement control away from the pump to disengage the feedback link from the servo piston land.

• Step 4
  Remove the control valve gasket from the pump housing and discard.
  With a 5/32″ hex key or bit socket, remove the two top hex head cap screws on each side of the servo piston cap so the “L” brackets for the electronic module can be mounted.

• Step 6
  Locate the EP Control valve assembly, electronic module, bolts, washers and control valve gasket. Clean the control mounting surface and install a new control valve gasket by aligning with bolt and porting holes.

• Step 7
  Carefully install the EP Control valve assembly on the pump housing, making sure the feedback link is installed in the appropriate servo piston land. Note: There is a narrow land on the servo piston for the EP Control feedback link and a wide land for the swashplate link.

• Step 8
  Use a 5/32″ hex key or bit socket to install the six 10-24 hex head cap screws. Torque to 60-68 lbf·in.

Step 9

• Neutral Adjustment

• Caution : All hoses and fittings must be connected, and the pump ready for operation before attempting to check neutral adjustment. Electrical wiring harnesses for the solenoid coils and command input should be left disconnected while adjust-ing neutral.

  • Disengage the input drive to vehicle or elevate wheels.
  • Install charge pressure gauge. A 0-1000 psi or 0-1500 psi pressure gauge is recommended.
  • Start the prime mover.
  • Loosen the locknut holding the neutral adjustment screw until it is just snug enough that the threaded screw can be rotated. Use a 9/16″ end wrench to hold the locking nut while rotating the neutral adjustment screw.
  • Note the number stamped on the cap of the low pressure relief valve. -022 is 220 psig (15 bar), -030 is 305 psig (21 bar), etc. This will be the high setting. Settings can vary from 155 psig (11 bar) to 325 psig (22.4 bar).
  • Slowly rotate the neutral adjustment screw clockwise until charge pressure drops to its low setting. Mark the neutral adjustment screw location.
  • Note: The charge pressure low setting is usually 40-60 psig lower than the high setting.
  • Rotate the neutral adjustment screw counterclockwise. The charge pressure will rise. Continue turning counterclockwise until the pressure drops again to its low setting. Mark the neutral adjustment screw location.
  • Rotate the neutral adjustment screw to the position between the two marks.
  • Carefully hold adjustment screw while torquing locknut. Torque locknut to 10±1 lbf·ft. Neutral adjustment is completed.

• Step 10
  Install the two “L ” brackets on each end of the servo piston cap with the flat end facing up to hold the electronic module. Replace the 10-24 cap screws on the pump and torque with 5/32″ hex key or bit socket to 60-68 lbf·in.

• Step 11
  Connect the four-pin connector between the EP Control electronic module and the solenoid coils. The connectors must be latched securely.

• Step 12

  • Carefully position the EP Control electronic module. Tuck all cables under the module. Caution: Av oid pinching cables at mounting points.
  • Install the four lockwashers and four 10-24 button head cap screws. Place two of the screws through the “L” brackets. Using a 1/8” hex key or bit socket, torque the four screws to 60-68 lbf·in.

• Step 14
  If applicable, disconnect power to the input device. Connect the command input device to the three-pin connector on the EP Control electronic module.

• Step 15
  Disconnect electrical power to the vehicle or system. Connect the electrical power source to the two-pin connector on the EP Control electronic module. Install a 3 Amp SLO-BLO® fuse per the Interface Diagram on page 15.

• Step 16
  The pump is now ready to return to operation.

Interconnect Schematic

Command Input Signal Connector

EP Control Electronic Module Mating Connector Kit 990762-000 contains plug used to seal mating end connector.
Power Supply Connector

Fuse Rating
3 Amp SLO-BLO® (Time Delay) fuse for 12-24 Vdc system – customer supplied

Pump Displacement vs. Input Signal

A

(MAX)

| B

(MIN)

| C| D

(MIN)

| E

(MAX)

|
---|---|---|---|---|---
Command Input Signal| | | |
1-6 Vdc| 1.5 Vdc    3.3 Vdc| 3.5 Vdc| 3.7 Vdc    5.5 Vdc
±4-20 mA| -20 mA     -4.5 mA| 0 mA| +4.5 mA  +20 mA
±100 mA| -100 mA  -7.5 mA| 0 mA| +7.5 mA  +100 mA
Shaft Rotation| | |
CCW| Solenoid #2| Neither| Solenoid #1
| Flow OUT port “B”| No flow| Flow OUT port “A”
CW| Solenoid #2| Neither| Solenoid #1
| Flow OUT port “A”| No Flow| Flow OUT port “B”

Note: The +20 mA command input signal configuration operates the pump in one direction. The customer has to change the polarity on the -20 mA signal to operate the pump in the opposite direction.

Troubleshooting

Troubleshooting Reference Settings

Solenoid 4-Pin Connector

Note: Only 12 volt coils are used with EP Control electronics module

Joystick Position
DC VOLTAGE MEASURED ACROSS DESIGNATED PINS AT THE CUSTOMER THREE-PIN CONNECTOR

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• PLUS+1® displays
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• PLUS+1® sensors
• PLUS+1® software
• PLUS+1® software services, support and training
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• Steering components and systems
• Telematics

Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and electric components. We specialize in providing state-of-the-art technology and solutions that excel in the harsh operating conditions of the mobile off-highway market as well as the marine sector. Building on our extensive applications expertise, we work closely with you to ensure exceptional performance for a broad range of applications. We help you and other customers around the world speed up system development, reduce costs and bring vehicles and vessels to market faster. Danfoss Power Solutions – your strongest partner in mobile hydraulics and mobile electrification. Go to www.danfoss.com for further product information. We offer you expert worldwide support for ensuring the best possible solutions for outstanding performance. And with an extensive network of Global Service Partners, we also provide you with comprehensive global service for all of our components.

• Local address:
• Hydro-Gear
• www.hydro-gear.com
• Daikin-Sauer-Danfoss
• www.daikin-sauer-danfoss.com
• Danfoss
• Power Solutions (US) Company
• 2800 East 13th Street
• Ames, IA 50010, USA
• Phone: +1 515 239 6000
• Danfoss
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• D-24539 Neumünster, Germany Phone: +49 4321 871 0
• Danfoss
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• DK-6430 Nordborg, Denmark Phone: +45 7488 2222
• Danfoss
• Power Solutions Trading
• (Shanghai) Co., Ltd.
• Building #22, No. 1000 Jin Hai Rd Jin Qiao, Pudong New District Shanghai, China 201206 Phone: +86 21 2080 6201

Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products already on order provided that such alterations can be made without subsequent changes being necessary in specifications already agreed.

References

• Daikin Sauer Danfoss - Home
• Leading Drivetrain Manufacturer - Hydro-Gear

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