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Summary of Contents for Danfoss DDP096
- Page 1 Service Manual Digital Displacement® Pump DDP096 www.danfoss.com...
- Page 2 Service Manual Digital Displacement® Pump DDP096 Revision history Table of revisions Date Changed April 2022 First edition 0101 © Danfoss | April 2022 AX398964822217en-000101...
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Page 3: Table Of Contents
Service Manual Digital Displacement® Pump DDP096 Contents Introduction Servicing overview...................................4 Safety precautions....................................4 Unintended machine movement............................4 Flammable cleaning solvents..............................4 Fluid under high pressure................................4 Personal safety..................................... 4 Hazardous material..................................4 Pump handling.................................... 5 Information for servicing DDP096 Component identification................................6 Wiring harness....................................6 General harness information.............................. -
Page 4: Servicing Overview
Pumps DDP096 according to the procedures detailed in this manual will not affect your warranty. Any other repair operation voids the warranty. For more information about the DDP096 service parts, please refer to the DDP096 Parts Manual. Performing minor repairs requires the DDP096 pump to be disconnected from the DPC12 controller and removed from the vehicle/machine. -
Page 5: Pump Handling
Service Manual Digital Displacement® Pump DDP096 Introduction Pump handling There is potential to damage the product during transportation. Do not hit the shaft. Avoid any damage to wires, connectors, sensors, and coils when transporting the pump. © Danfoss | April 2022... -
Page 6: Information For Servicing Ddp096
DDP096 Technical Information manual, BC306384089197, for more information. Wiring harness General harness information The wiring harness of DDP096 pumps requires the three following sub-harnesses: • Two coil harnesses (“A” and “B”) • One sensor harness These wiring harnesses can be individually replaced if needed and are supplied with cable ties (securing one harness branch to the pump housing or to another branch). -
Page 7: Main Anchor
Coil harness There are two coil harnesses (“A” and “B”) for the DDP096. Each valve coil needs to be connected to a coil harness for full pump function and control. On the pump-to-controller harness end, they can be quickly differentiated by the color and key insert of the DEUTSCH connector: •... -
Page 8: Mechanical Installation And Maintenance
Digital Displacement® Pump DDP096 Mechanical installation and maintenance Start-up procedure Follow the DDP096 commissioning procedure of the Technical Information manual when restarting an installation in which the pump has been removed. The DPC12 controller should already be mounted properly in the system. -
Page 9: Required Tools
Pump stand For most of the minor repairs, it is recommended to mount and secure the DDP096 to a 4-bolt SAE C stand in a horizontal position or in a vertical position with the input shaft pointing downwards (with a minimum ground clearance of 80 mm). -
Page 10: Minor Repair
DDP shaft seal The Digital Displacement ® Pump DDP096 uses a lip-type shaft seal. DDP shaft seal removal 1. Orient the pump with the input shaft pointing upward. 2. Clean the surfaces of the seal and around the seal to prevent any contamination. -
Page 11: Ddp Shaft Seal Installation
Service Manual Digital Displacement® Pump DDP096 Minor repair DDP shaft seal installation 1. Orient the pump with the input shaft pointing upward. 2. Inspect the pump housing seal bore and the sealing area on the shaft for rust, wear, and contamination. -
Page 12: Coil
3. Using a 3 mm hex key, remove the central M5x12 screw (K700) retaining the coil from the coil core. Check that the coil core has not come loose. If so, do not remove the coil core as this will introduce contamination and may cause loss or damage of the axial O-ring. Please contact your Danfoss representative for advice. -
Page 13: Ddp Coil Inspection And Disposal
Service Manual Digital Displacement® Pump DDP096 Minor repair DDP coil inspection and disposal 1. Check the resistance of the coil with a multimeter. At 20°C, the resistance should be around 0.67 – 0.76 Ohms. 2. If there is evidence of short circuit, then dispose the coil according to local regulations or send back to Danfoss. -
Page 14: Pressure Sensor
A DDP096 can have multiple pressure sensors depending on the number of services. The minor repair instruction is given for a single-outlet DDP096 (port M), but the procedure is the same for a multi-outlet pump (port M1, M2 or M4). If multiple pressure sensors need to be replaced, repeat the procedures. -
Page 15: Speed And Temperature Sensor
Digital Displacement® Pump DDP096 Minor repair DDP speed and temperature sensor All DDP096 pumps feature a speed and temperature sensor. This sensor is installed in the port W between pumplets 2 and 3. DDP speed and temperature sensor removal 1. Clean the exterior of the pump to remove debris. -
Page 16: Coil Harness A
Service Manual Digital Displacement® Pump DDP096 Minor repair DDP coil harness "A" The coil harness “A” has a gray DEUTSCH connector on one end, and coil connectors to pumplets 1 and 2 on the other end. There are three wire colors (red, black, and white) for each coil connector. The coil harness “A”... -
Page 17: Ddp Coil Harness "A" Installation
Service Manual Digital Displacement® Pump DDP096 Minor repair Multi-outlet pump (sensors and harness AE) J003 J002 J004 (M1) J001 J004 (M2) J007 Pumplet 2 J004 (M4) J007 J007 J010 J007 J007 Pumplet 3 DDP coil harness "A" installation 1. Lay out the coil harness “A” (J001) by putting all the tails together. -
Page 18: Coil Harness B
Service Manual Digital Displacement® Pump DDP096 Minor repair DDP coil harness "B" The coil harness “B” has a black DEUTSCH connector on one end, and coil connectors to pumplets 3 and 4 on the other end. There are three wire colors (red, black, and white) for each coil connector. The coil harness “B”... -
Page 19: Ddp Coil Harness "B" Installation
Service Manual Digital Displacement® Pump DDP096 Minor repair Multi-outlet pump (sensors and harness AE) J003 J002 J004 (M1) J001 J004 (M2) J007 Pumplet 2 J004 (M4) J007 J007 J010 J007 J007 Pumplet 3 DDP coil harness "B" installation 1. Lay out the coil harness “B” (J002) by putting all the tails together. -
Page 20: Sensor Harness (Single-Outlet Pump)
Minor repair DDP sensor harness (single-outlet pump) The single-outlet DDP096 pump has one pressure sensor in port M. The sensor harness is tied up to the main anchor (located between pumplets 2 and 3). DDP sensor harness (single-outlet pump) removal 1. -
Page 21: Sensor Harness (Multi-Outlet Pump)
Minor repair DDP sensor harness (multi-outlet pump) The multi-outlet DDP096 pump can have up to three pressure sensors in ports M1, M2 and M4. The sensor harness is tied up to the main anchor (located between pumplets 2 and 3) DDP sensor harness (multi-outlet pump) removal 1. -
Page 22: Ddp Sensor Harness (Multi-Outlet Pump) Installation
Service Manual Digital Displacement® Pump DDP096 Minor repair Multi-outlet pump (sensors and harness AE) J003 J002 J004 (M1) J001 J004 (M2) J007 Pumplet 2 J004 (M4) J007 J007 J010 J007 J007 Pumplet 3 DDP sensor harness (multi-outlet pump) installation 1. Lay out the sensor harness (J003) by putting all the tails together. -
Page 23: Torque Chart
Service Manual Digital Displacement® Pump DDP096 Torque chart DDP096 fasteners and torque Item Description Fastener Tool Min Torque N•m Max Torque N•m [ft•lbf] [ft•lbf] J004 M14 pressure sensor 22 mm external hex 40 [29.50] 44 [32.45] J010 M14 speed and 19 mm external hex 31.5 [23.23]... - Page 24 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.