Danfoss DDP096 User manual

Service Manual
Digital Displacement® Pump
DDP096
www.danfoss.com

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

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
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DDP servicing overview
This manual includes maintenance information and minor repair procedures of the Digital Displacement®
Pump DDP096. Performing maintenance and minor repair of Digital Displacement®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. Thoroughly clean the pump before beginning maintenance or repair
activities. Since dirt and contamination are the greatest enemies of any type of hydraulic equipment,
follow cleanliness requirements strictly, especially when changing the system filter and when removing
hoses or plumbing.
When removing hoses or plumbing, add port covers – the port covers shipped with the pump are
appropriate. Do not plug ports with rags, especially the inlet port as any pieces left behind can cause
pump to malfunction.
Safety precautions
Always consider safety precautions before beginning a service procedure. Take the following general
precautions whenever servicing a hydraulic 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 machine or disable/disconnect the mechanism while servicing to protect against unintended
movement.
Flammable cleaning solvents
Some cleaning solvents are flammable.
Do not use cleaning solvents in an area where a source of ignition may be present to avoid possible fire.
Fluid under high pressure
Escaping hydraulic fluid under pressure can have sufficient force to penetrate skin causing serious injury
and/or infection.
Additionally, the fluid may cause burns.
Use caution when dealing with hydraulic fluid under pressure.
Always relieve pressure in the system before removing hoses, fittings, gauges, or other components.
Never use hands or any other body parts to check for leaks in a pressurized component; seek medical
attention immediately if you are cut by hydraulic fluid.
Personal safety
Protect yourself from injury whenever servicing a hydraulic system.
Use proper safety equipment, including safety glasses, at all times.
Hazardous material
Hydraulic fluid contains hazardous material.
Avoid prolonged contact with hydraulic fluid. Always dispose of used hydraulic fluid according to state,
and federal environmental regulations.
Service Manual
Digital Displacement® Pump DDP096
Introduction
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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.
Service Manual
Digital Displacement® Pump DDP096
Introduction
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DDP component identification
The DDP096 is a 12-cylinder radial piston hydraulic pump.
The 12 cylinders are arranged into 3 banks (A, B and C) with A being the closest to the mounting flange.
The cylinders are identified by their bank followed by their pumplet number (1, 2, 3 or 4). For instance,
the cylinder from the pumplet 3 positioned in the bank C (the closest to the endcap) is the cylinder C3.
The figure below shows the pump housing with the cylinder labels. These labels are used to identify any
specific components of the pump (e.g., the coil B2). Note that the pumplet numbers are visible on the
pump housing when looking at the pump from the endcap.
B2
A2
C2
B3
C3
A3
C1
A1
B1
A4
C4
B4
Depending on the type of endcap, the pump can either provide flow to one outlet or multiple
independent outlets. Refer to the 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). The wiring harnesses are tied together at
the main anchor.
Most of the wiring harness is covered in black nylon braid for protection. There is a gap of approximately
10 mm between the end of the braid and each connector to ensure that each harness branch is
connected to the correct coil or sensor. Each connector can be identified by the colors of its wires (visible
in the unbraided part), the number of wires, and the length of the branch.
When securing a cable tie, make sure to tension it to form a snug fit but not to crush the wires. The loose
end of the tie should be cut to maximum 1 mm of protrusion.
In certain scenarios, lifting brackets can restrict access to anchoring tie screws and may need to be
temporarily removed during servicing. They should be torqued back to the value specified in Fasteners
and torque.
Service Manual
Digital Displacement® Pump DDP096
Information for servicing DDP096
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Main anchor
The main anchor is installed on the web between pumplets 2 and 3. A cable tie secures the two coil
harnesses and the sensor one to the 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:
•The coil harness “A” has a gray DEUTSCH connector and connects to the valve coils of pumplets 1 and
2
•The coil harness “B” has a black DEUTSCH connector and connects to valve coils of pumplets 3 and 4
On the valve connection end, each branch of the coil harness can be paired with the corresponding coil
according to its length and the wire colors:
•Red for the valves of bank A
•Black for the valves of bank B
•White 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 branch for the speed and temperature sensor (which has 4 wires in total)
•One or several branches for the pressure sensor(s) (which each has 2 wires)
All sensors use a male 4-pin circular connector with straight output and M12x1 thread. In the rest of the
document, it is referred as the M12 connector.
A sensor harness exists for each DDP096 service configuration:
•1-service pump [P]: one pressure sensor is used in port M (single-outlet pump)
•2-service pump [P1 / (P2 + P4)] or [(P1 + P2) / P4]: two pressure sensors are used in ports M1 and M4
(multi-outlet pump)
•3-service pump [P1 / P2 / P4]: three pressure sensors are used in ports M1, M2 and M4 (multi-outlet
pump)
More wiring harness options are available on request; please contact your Danfoss representative.
Service Manual
Digital Displacement® Pump DDP096
Information for servicing DDP096
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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.
Absolute cleanliness is required, and the pump must be installed in clean conditions. Any contamination
of the pump or hydraulic fluid can have a significant detrimental impact on the service life of the pump.
1. Make certain all system components (reservoir, hoses, valves, fittings, heat exchanger, etc.) are clean
prior to filling with fluid.
Do not use any cleaning materials that may deposit lint or other debris in the hydraulic system. Do
not use PTFE tapes to seal fittings.
2. Make certain that the case of the pump is fully filled with hydraulic fluid before being brought into
operation.
Use hydraulic fluid free of air and water. Excess bubbles or moisture can cause damage to the pump’s
internal components.
3. Remove air from the pump - refer to the Air removal section of the Technical Information manual for
more information.
Fluid and filter recommendations
To ensure optimum life of the Digital 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 reservoir daily for proper fluid level, the presence of water, and rancid fluid odor. Water in the
fluid may be noted by a cloudy or milky appearance or free water in the bottom of the reservoir. Rancid
odor indicates the fluid has been exposed to excessive heat. Change the fluid immediately if these
conditions occur. Correct the problem immediately.
Change the fluid and filter per the vehicle/machine manufacturer’s recommendations or at the below
intervals. Change the fluid more frequently if it becomes contaminated with foreign matter (dirt, water,
grease, etc.) or if the fluid is subjected to temperature levels greater that the recommended maximum.
Dispose of used hydraulic fluid properly. Never reuse hydraulic fluid.
Change filters whenever the fluid is changed or when the filter indicator shows that it is necessary to
change the filter. Replace all fluid lost during filter change.
Fluid and filter change interval
Reservoir type Maximum change interval
Sealed 2000 hours
Breather 500 hours
Service Manual
Digital Displacement® Pump DDP096
Mechanical installation and maintenance
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Mechanical tools
This list shows the required tools to disassemble/assemble the pump.
•Snap-ring pliers (suitable for 58 mm internal circlips)
•Cable tie cutters
•Cable tie tensioner and cutter (optional)
•3 mm hex key
•19 mm hex wrench with deep socket
•22 mm hex wrench (deep socket recommended)
•Phoenix Contact torque screwdriver – TSD 04 SAC (Phoenix Contact part number: 1208429)
•Phoenix Contact tool – SACC BIT M12-D20 (Phoenix Contact part number: 1208445)
•Appropriate torque wrenches (see Fasteners 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 of the pump that are not categorically
mechanical or electrical.
•Thread sealant Loctite 243 or similar thread locking compound
•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).
Service Manual
Digital Displacement® Pump DDP096
Required tools
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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.
3. Using snap-ring pliers, remove the circlip (E102) retaining the shaft seal.
4. Remove the shaft seal (E103) following the process described below:
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 running
surface on the shaft.
b) Attach a slide hammer or appropriate puller to the screw head and pull to remove the seal.
c) Discard the seal.
W
Warning
Do not damage the housing bore, shaft or bearing when removing the shaft seal.
Shaft seal and circlip (retaining ring)
E103
E102
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Digital Displacement® Pump DDP096
Minor repair
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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.
3. Clean the shaft and the housing if necessary taking care not to damage the running surfaces.
4. Cover the shaft splines with a protective sleeve or packaging tape to prevent damage to the seal
during installation.
5. Inspect the new seal (E103).
The inner diameter is supplied pre-greased; do not wipe this grease away and maintain cleanliness
during the entire process.
6. Lubricate the outer 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 to press on the dust lip on the inside or scratch the shaft surface to avoid binding and
damaging the seal.
8. Press by hand into housing until it bottoms out.
Seal may need to be pressed or tapped into place. If a tool is used, a ring with inner diameter of 49
mm ± 0.1 mm, outer diameter of 56.9 mm ± 0.1mm and rounded edges is recommended.
9. Using snap-ring pliers, install the circlip (E102) that retains the shaft seal.
10. Remove the installation sleeve on the shaft end.
Service Manual
Digital Displacement® Pump DDP096
Minor repair
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DDP coil
There are 12 coils in a Digital Displacement®Pump DDP096 pump. Each valve is controlled by a coil which
is mounted over the coil core. If multiple coils need to be replaced, repeat the procedure below.
DDP coil removal
1. Clean and dry the area around the coil and the coil connector to remove any contamination and
fluids.
2. Disconnect the desired coil connector (K600) from the coil harness (J001 or J002) by pushing on the
retaining clip at the top of the connector.
C
Caution
Do not bend the coil wires excessively in any direction. It may be necessary to loosen an anchoring tie
by removing an M5x12 screw (J008) using a 3 mm internal key. Make sure to torque the screw back
within the value range specified in Fasteners 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 introduce
contamination and may cause loss or damage of the axial O-ring. Please contact your Danfoss
representative for advice.
4. Before removing the coil, note the direction in which the MCON connector is pointing.
5. Remove the coil and discard the screw.
Coils and coil screws
Pumplet 1
K700
K600
Pumplet 4
Each pumplet has the same arrangement of coils: coil connectors from banks A and C point
anticlockwise around the pump (looking from the front shaft) while the coil connectors from bank B
point towards the rear of the pump. More information on the coil identification can be found in
Component identification.
Service Manual
Digital Displacement® Pump DDP096
Minor repair
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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.
There is no integrated circuit or electronics in the coil.
DDP coil installation
1. Install 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 hole to the coil core and
torque within the value range specified in the Fasteners and torque.
4. Connect the loose cable of the coil harness (J001 or J002) to the MCON connector of the coil replaced.
A click should be heard if properly inserted.
Service Manual
Digital Displacement® Pump DDP096
Minor repair
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DDP 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.
DDP pressure sensor removal
1. Clean the exterior of the pump to remove debris.
2. Disconnect the M12 connector of the pressure sensor (J004) from the sensor harness (J003).
3. Using a 22 mm hex wrench (deep socket recommended), remove the pressure sensor.
4. Discard the sensor.
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. Install the pressure sensor in the adequate port using a 22 mm hex wrench (deep socket
recommended) and torque within the value range specified in Fasteners and torque.
3. Spread fresh liquid thread locking compound (1 to 3 drops) on the male M12 thread of the pressure
sensor.
4. Connect the loose sensor harness branch (J003) to the pressure sensor and using the Phoenix Contact
torque screwdriver and tool, torque with the preset torque setting specified in Fasteners and torque.
Service Manual
Digital Displacement® Pump DDP096
Minor repair
14 | ©Danfoss | April 2022 AX398964822217en-000101

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.
2. Disconnect the M12 connector of the speed and temperature sensor (J010) from the sensor harness
(J003).
3. Using a 19 mm hex wrench with deep socket, remove the speed and temperature sensor from the
port W.
Speed and temperature sensor
Pumplet 2
Pumplet 3
J010
DDP speed and temperature sensor inspection
1. Check if there are particles stuck to the tip of the sensor, especially if it gave erroneous readings.
2. If particles are found, determine the cause (e.g., filter clogged, contamination downstream, etc.).
3. Clean the sensor then re-install if the particle issue is resolved.
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 sensor to any metal as the tip is magnetic and can pick up debris.
1. Check if the sealing form ring is correctly in place on the speed and temperature sensor (J010) and
lubricate with clean hydraulic fluid.
2. Install the speed and temperature sensor in port W and, using a 19 mm hex wrench with deep socket,
torque within the value range specified in Fasteners and torque.
3. Spread fresh liquid thread locking compound (1 to 3 drops) on the male M12 thread of the speed and
temperature sensor.
4. Connect the loose sensor harness branch (J003) to the speed and temperature sensor and, using the
Phoenix Contact torque screwdriver and tool, torque with the preset torque setting specified in
Fasteners and torque.
Service Manual
Digital Displacement® Pump DDP096
Minor repair
©Danfoss | April 2022 AX398964822217en-000101 | 15

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” is tied up to the main anchor (located between pumplets 2 and 3) and has 2 preassembled
anchoring ties.
DDP coil harness "A" removal
1. On the pump-to-controller harness end, disconnect the gray DEUTSCH connector of the coil harness
“A” (J001).
2. Disconnect all MCON connectors (A1, B1, C1, A2, B2, C2) from the valve coils (K600) of pumplets 1 and
2.
3. Using a 3 mm hex key, remove the M5x12 screws (J008) of the two anchoring ties (one is located
between pumplets 4 and 1 while the other one is between pumplets 1 and 2).
4. If the unit is a multi-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 cutter to cut the cable tie
located approximately 50 mm from the main anchor. This cable tie wraps around the coil harness “A”
bundle, the M2 pressure sensor branch and the M1 pressure sensor branch (if present).
Both cable tie positions can be seen in the figure Multi-outlet pump (sensors and harness AE).
6. Using cable tie cutters, cut the cable tie of the main anchor.
7. Safely remove the loose coil harness “A” from the pump harness and discard the screws.
W
Warning
Do not damage any wire of the pump harness when cutting cable ties.
Coil harness “A” (other harnesses are not shown for ease of visualization)
J008 Pumplet 1
J008
Pumplet 2
J007
J001
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Digital Displacement® Pump DDP096
Minor repair
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Multi-outlet pump (sensors and harness AE)
J003
J002
J001
J004 (M1)
J004 (M2)
J004 (M4)
J010
J007
Pumplet 3
J007
J007
J007
Pumplet 2
J007
DDP coil harness "A" installation
1. Lay out the coil harness “A” (J001) by putting all the tails together.
2. Identify the two sets of three MCON connectors that split from the coil harness. Note that each set of
connectors should be composed of different wire colors (red, black, and white).
a) Connect the set of MCON connectors which is the furthest away from the gray DEUTSCH
connector to the valve coils of pumplet 1 (A1, B1, C1).
b) Connect the set of MCON connectors which is the closest from the gray DEUTSCH connector to the
valve coils of pumplet 2 (A2, B2, C2).
The MCON connector will click when properly inserted.
For both sets, pay attention to the wire color code for the coil connections: red for coils A1 and A2;
black for coils B1 and B2; white for coils C1 and C2.
3. Using a 3 mm hex key, insert the new nylon patched M5x12 screws (J008) on 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 pump with an M1 pressure sensor, fasten a cable tie (J007) under the M2
port to secure the coil harness “A” bundle against the M1 pressure sensor branch.
5. If the unit is a multi-outlet pump with an M2 pressure sensor, fasten a cable tie (J007) approximately
50 mm from the main anchor which wraps around the coil harness “A” bundle, the M2 pressure
sensor branch and the M1 pressure sensor branch (if present).
The cable tie positions can be seen in Removal under figure Multi-outlet pump (sensors and harness
AE).
6. Secure the coil harness “A” with a cable tie at the main anchor together with the coil harness “B”
(J002) and the sensor harness (J003). Note that the three DEUTSCH connectors should be at the same
distance (approximately 220 mm) from the main anchor of the pump.
7. On the pump-to-controller harness end, connect the gray DEUTSCH connector of the coil harness “A.”
Service Manual
Digital Displacement® Pump DDP096
Minor repair
©Danfoss | April 2022 AX398964822217en-000101 | 17

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” is tied up to the main anchor (located between pumplets 2 and 3) and has 1 preassembled
anchoring tie.
DDP coil harness "B" removal
1. On the pump-to-controller harness end, disconnect the black DEUTSCH connector of the coil harness
“B” (J002).
2. Disconnect all MCON connectors (A3, B3, C3, A4, B4, C4) from the valve coils (K600) of pumplets 3 and
4.
3. Using a 3 mm hex key, remove the M5x12 screw (J008) of the anchoring tie (located between
pumplets 3 and 4).
4. If the unit is a multi-outlet 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 next to the anchoring tie of coil harness “B” (between pumplets 3
and 4).
b) Cut the cable tie located above pumplet 3 (next to the indication “3” on the housing).
Both cable tie positions can be seen in the figure Multi-outlet pump (sensors and harness AE) below.
5. Using cable tie cutters, cut the cable tie of the main anchor.
6. Safely remove the loose coil harness “B” from the pump harness and discard the screw.
W
Warning
Do not damage any wire of the pump harness when cutting cable ties.
Coil harness “B” (other harnesses are not shown for ease of visualization)
J002
Pumplet 4
J008
Pumplet 3
J007
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Digital Displacement® Pump DDP096
Minor repair
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Multi-outlet pump (sensors and harness AE)
J003
J002
J001
J004 (M1)
J004 (M2)
J004 (M4)
J010
J007
Pumplet 3
J007
J007
J007
Pumplet 2
J007
DDP coil harness "B" installation
1. Lay out the coil harness “B” (J002) by putting all the tails together.
2. Identify the two sets of three MCON connectors that split from the coil harness. Note that each set of
connectors should be composed of different wire colors (red, black, and white).
a) Connect the set of MCON connectors which is the furthest away from the black DEUTSCH
connector to the valve coils of pumplet 4 (A4, B4, C4).
b) Connect the set of MCON connectors which is the closest from the black DEUTSCH connector to
the valve coils of pumplet 3 (A3, B3, C3).
The MCON connector will click when properly inserted.
For both sets, pay attention to the wire color code for the coil connections: red for coils A3 and A4;
black for coils B3 and B4; white for coils C3 and C4.
3. Using a 3 mm hex key, insert the new nylon 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 pressure sensor, there are two cable ties to fasten.
a) Fasten a cable tie (J007) above pumplet 3 (next to the indication “3” on the housing) to secure the
coil harness “B” against the M4 pressure sensor branch.
b) Fasten another cable tie next to the anchoring tie of coil harness “B” (located between pumplets 3
and 4) to secure the coil harness “B” against the M4 pressure sensor branch.
Both cable tie positions can be seen in the figure Multi-outlet pump (sensors and harness AE) in
Removal.
5. Secure the coil harness “B” with a cable tie at the main anchor together with the coil harness “A”
(J001) and the sensor harness (J003). Note that the three DEUTSCH connectors should be at the same
distance (approximately 220 mm) from the main anchor of the pump.
6. On the pump-to-controller harness end, connect the black DEUTSCH connector of the coil harness
“B.”
Service Manual
Digital Displacement® Pump DDP096
Minor repair
©Danfoss | April 2022 AX398964822217en-000101 | 19

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. On the pump-to-controller harness end, disconnect the green DEUTSCH connector of the sensor
harness (J003).
2. Disconnect the M12 connector of the pressure sensor (J004) placed in port M from the sensor harness
branch.
3. Disconnect the M12 connector of the speed and temperature sensor (J010) placed in port W from the
sensor harness branch.
4. Using cable tie cutters, cut the cable tie (J007) of the main anchor.
5. Safely remove the loose sensor harness from the pump harness.
W
Warning
Do not damage any wire of the pump harness when cutting the cable tie.
Sensor harness – Single-outlet pump (coil harnesses are not shown for ease of visualization)
J003
Pumplet 1
J004
J010
Pumplet 2
J007
DDP sensor harness (single-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 speed and temperature sensor harness branch (the one with 4
wires) to the sensor (J010) in port W and using the Phoenix Contact torque screwdriver and tool,
torque with the preset torque setting specified in Fasteners and torque.
4. Connect the M12 connector of the pressure sensor harness branch (the one with 2 wires) to the
sensor (J004) in port M and using the Phoenix Contact torque screwdriver and tool, torque with the
preset torque setting specified in Fasteners and torque.
5. Secure the sensor harness with a cable tie (J007) at the main anchor together with the coil harness “A”
(J001) and coil harness “B” (J002). Note that the three DEUTSCH connectors should be at the same
distance (approximately 220 mm) from the main anchor of the pump.
6. On the pump-to-controller harness end, connect the green DEUTSCH connector of the sensor
harness.
Service Manual
Digital Displacement® Pump DDP096
Minor repair
20 | ©Danfoss | April 2022 AX398964822217en-000101