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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:

Danfoss 

Power Solutions GmbH & Co. OHG

Krokamp 35

D-24539 Neumünster, Germany

Phone: +49 4321 871 0

Danfoss 

Power Solutions ApS

Nordborgvej 81

DK-6430 Nordborg, Denmark

Phone: +45 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, 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.

All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.

©

 Danfoss | April 2022

AX398964822217en-000101

Products we offer:

Cartridge valves

DCV directional control

valves

Electric converters

Electric machines

Electric motors

Gear motors

Gear pumps

Hydraulic integrated

circuits (HICs)

Hydrostatic motors

Hydrostatic pumps

Orbital motors

PLUS+1

®

 controllers

PLUS+1

®

 displays

PLUS+1

®

 joysticks and

pedals

PLUS+1

®

 operator

interfaces

PLUS+1

®

 sensors

PLUS+1

®

 software

PLUS+1

®

 software services,

support and training

Position controls and

sensors

PVG proportional valves

Steering components and

systems

Telematics

Hydro-Gear

www.hydro-gear.com
Daikin-Sauer-Danfoss

www.daikin-sauer-danfoss.com 

Summary of Contents for DDP096

Page 1: ...Service Manual Digital Displacement Pump DDP096 www danfoss com...

Page 2: ...Revision history Table of revisions Date Changed Rev April 2022 First edition 0101 Service Manual Digital Displacement Pump DDP096 2 Danfoss April 2022 AX398964822217en 000101...

Page 3: ...DDP coil installation 13 Pressure sensor 14 DDP pressure sensor removal 14 DDP pressure sensor installation 14 Speed and temperature sensor 15 DDP speed and temperature sensor removal 15 DDP speed an...

Page 4: ...system in addition to other vehicle or machine precautions Unintended machine movement Unintended movement of the machine or mechanism may cause injury to the technician or bystanders Secure the machi...

Page 5: ...the product during transportation Do not hit the shaft Avoid any damage to wires connectors sensors and coils when transporting the pump Service Manual Digital Displacement Pump DDP096 Introduction Da...

Page 6: ...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...

Page 7: ...for the valves of bank C Customer specific harness may not follow the same color codes please contact your Danfoss representative Sensor harness A sensor wiring harness is typically composed of One br...

Page 8: ...tal Displacement Pump DDP096 perform regular maintenance of the fluid and filter Contaminated fluid is the main cause of unit failure Take care to maintain fluid cleanliness when servicing Check the r...

Page 9: ...ers and torque Electrical tools This list contains tools needed for testing electrical components of the pump Multimeter Additional tools This list contains tools or other objects for the maintenance...

Page 10: ...ow a Carefully drive a small sheet metal self tapping screw into the shaft seal to facilitate removal Be careful not to damage the bearing below the seal and be careful to not mark the shaft seal runn...

Page 11: ...uter diameter of the new shaft seal and the shaft surface with clean hydraulic fluid 7 Insert the seal evenly and concentrically to the shaft such that the flat face is facing outwards Take care not t...

Page 12: ...s and torque 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...

Page 13: ...ll the coil K600 with the connector pointing in the same orientation as before 2 Use a new nylon patched M5x12 screw K700 3 Using a 3 mm hex key fasten the coil with the M5x12 screw in the central hol...

Page 14: ...ensor Pressure sensor Pumplet 2 Pumplet 3 J004 DDP pressure sensor installation 1 Check if the O ring is correctly in place on the pressure sensor J004 and lubricate with clean hydraulic fluid 2 Insta...

Page 15: ...lved DDP speed and temperature sensor installation W Warning Do not remove the protective cap off the speed and temperature sensor until ready for installation Take care not to expose the tip of the s...

Page 16: ...lti outlet pump with an M1 pressure sensor use a cable tie cutter to cut the cable tie J007 positioned under the M2 port 5 If the unit is a multi outlet pump with an M2 pressure sensor use a cable tie...

Page 17: ...n the two anchoring ties one is located between group 1 and 2 the other one between group 1 and 4 and torque within the value range specified in Fasteners and torque 4 If the unit is a multi outlet pu...

Page 18: ...let pump with an M4 pressure sensor two additional cables ties connecting the M4 pressure sensor branch to the coil harness B should be removed using cable tie cutters a Cut the cable tie J007 located...

Page 19: ...patched M5x12 screws J008 on the anchoring tie located between pumplet 3 and 4 and torque within the value range specified in Fasteners and torque 4 If the unit is a multi outlet pump with an M4 press...

Page 20: ...e outlet pump installation 1 Lay out the sensor harness J003 2 Spread fresh liquid thread locking compound 1 to 3 drops on the male M12 thread of all the sensors 3 Connect the M12 connector of the spe...

Page 21: ...the main anchor The cable tie wraps around the coil harness A bundle the M2 pressure sensor branch and the M1 pressure sensor branch if present 6 If the multi outlet pump has an M4 pressure sensor us...

Page 22: ...M1 M2 and or M4 Use the Phoenix Contact torque screwdriver and tool and torque with the preset torque setting specified in Fasteners and torque 5 If the multi outlet pump has an M1 pressure sensor fa...

Page 23: ...oenix Contact tools part number 1208445 part number 1208429 0 36 0 27 0 44 0 32 J008 Anchoring tie screw for wiring harness M5x12 10 9 with nylon patch 3 mm internal hex 1 8 1 33 2 2 1 62 K700 Coil sc...

Page 24: ...anfoss 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 Pudong New Distri...

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