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Danfoss DDP096, Service Manual

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Danfoss DDP096 Service Manual Download Page 3

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.................................................................................................................................................. 6

Main anchor.................................................................................................................................................................................. 7

Coil harness................................................................................................................................................................................... 7

Sensor harness............................................................................................................................................................................. 7

Mechanical installation and maintenance

Start-up procedure.......................................................................................................................................................................... 8

Fluid and filter recommendations..............................................................................................................................................8

Required tools

Mechanical tools...............................................................................................................................................................................9

Electrical tools....................................................................................................................................................................................9

Additional tools.................................................................................................................................................................................9

Minor repair

Shaft seal........................................................................................................................................................................................... 10

DDP shaft seal removal...........................................................................................................................................................10

DDP shaft seal installation.....................................................................................................................................................11

Coil.......................................................................................................................................................................................................12

DDP coil removal...................................................................................................................................................................... 12

DDP coil inspection and disposal....................................................................................................................................... 13

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 and temperature sensor inspection........................................................................................................... 15

DDP speed and temperature sensor installation..........................................................................................................15

Coil harness A.................................................................................................................................................................................. 16

DDP coil harness "A" removal...............................................................................................................................................16

DDP coil harness "A" installation.........................................................................................................................................17

Coil harness B.................................................................................................................................................................................. 18

DDP coil harness "B" removal...............................................................................................................................................18

DDP coil harness "B" installation......................................................................................................................................... 19

Sensor harness (single-outlet pump)......................................................................................................................................20

DDP sensor harness (single-outlet pump) removal..................................................................................................... 20

DDP sensor harness (single-outlet pump) installation............................................................................................... 20

Sensor harness (multi-outlet pump)....................................................................................................................................... 21

DDP sensor harness (multi-outlet pump) removal.......................................................................................................21

DDP sensor harness (multi-outlet pump) installation.................................................................................................22

Torque chart

Fasteners and torque....................................................................................................................................................................23

Service Manual

Digital Displacement® Pump DDP096

Contents

 

©

 Danfoss | April 2022

AX398964822217en-000101 | 3

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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