Danfoss 180F4161 User manual

Service guide

Vane pump upgrade kit 180F4161

iSave 21 ERD

Disassembling and assembling

hpp.danfoss.com

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161

2180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017

Table of Contents

1. General Introduction

Contents

1. General Introduction........................................................................2

1.1 Parts included in the vane pump upgrade kit 180F4161 .....................................2

2. Disassembling the iSave ................................................................3

2. Disassembling the vane pump ..........................................................4

3. Assembling the vane pump - with parts from the vane pump upgrade kit ................6

4. Assembling the iSave....................................................................9

5. Exploded view vane pump .............................................................10

6. Exploded view iSave ...................................................................11

1.1 Parts included in the vane pump

upgrade kit 180F4161

This document covers the instructions for

installing the vane pump upgrade kit 180F4161.

Important: It is essential that the iSave and

vane pump are serviced in conditions of abso-

lute cleanliness.

For a better understanding of the vane pump and

iSave, please see the exploded views in the sec-

tions 5 and 6.

The weight of the iSave is 65 kg / 143 lb

and it must be lifted with suitable lifting

equipment.

To prevent cold welding, lubricate threads of

screws with grease; screw them into the compo-

nent and tighten them by the hand. Use PTFE

lubrication type.

Tools needed for upgrading vane pump::

- 10 mm socket

- Torque wrench

- Adjustable spanner

- Loctite 270

- 6 mm allen key socket (160 mm long)

Qty. Description

1Stator ring

8Vanes

1Side plate out

1 Side plate in

4 Peek pin Ø6.9

2Pin Ø6x10

2Pin Ø4x9

3O-ring 112x2.5

1O-ring 44x3

1 O-ring 80x2

2 Steel location pin for stator ring

10 Screws for M8x16

10 Screws for M8x25

8Screws for M8x65

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161

180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017

1. Place the iSave on a clean table.

3. Remove the vane pump.

2. Unscrew the bolts in the ﬂange.

2. Disassembling the

iSave

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161

4180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017

1. Gently adjust the spanner wrench around

the coupling and use it as back stop.

3. Remove all bolts in the HP out connection

ﬂange.

2. Unscrew the bolt in the middle of the

coupling and remove the coupling.

4. Remove the ﬂange.

5. Remove side plate and pin

2. Disassembling the

vane pump

6. Side plate removed.

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161

180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017

7. Gently remove the rotor.

Note: Loose parts inside the rotor.

8. Remove vanes.

9. Gently remove side plate and pin. 10. Remove the int. ﬂange

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161

6180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017

3. Assembling the vane

pump - with parts from

the vane pump

upgrade kit

1. Place the new O-ring and guide pin in

the int. ﬂange. 2. Place the new side plate on the int.

ﬂange.

3. Side plate mounted correct. 4. Place new stator ring on the int. ﬂange.

5. Turn the vane pump around, so the int.

ﬂange faces up. Fasten screws with a

torque according to exploded view.

6. Place the 4 new pins in the rotor.

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161

180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017

7. Gently place the rotor in the bearing. 8. Position the 8 new vanes in the rotor.

The pins may be moved by using a

screwdriver.

9. Check that all vanes are positioned

correctly.

10. One vane is NOT positioned correctly.

11. Replace the new O-ring on the ﬂange and

wet the ﬂange properly with clean ﬁltered

water.

12. Position the new side plate over the guide

pin.

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161

8180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017

13 Make sure that the new guide pin is located

in the locating hole in the side plate. See

#12.

14. Place the pump housing with the pin

orientated upwards. Fit the ﬂange

including side plate into both the bearing

in the ﬂange and in the stator.

15. Make sure that the guide pin is located in

the location hole.

16. Change the new O-ring in the HP out

connection ﬂange.

18. Fit the coupling into the pump.

Glue the threat on the bolt with “Loctite

270” and tighten the bolt with a torque

according to exploded view.

17. Bolt the ﬂange onto the vane pump.

Tighten the bolt witha torque according

to exploded view.

Ten new

screws

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161

180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017

19. Change the two new O-rings in the

ﬂange.

4. Assembling the

iSave

1. Fit the steel coupling onto the shaft of the

pressure exchanger.

Correct

positions

2. Fit the polymer coupling insert on the

steel coupling. Note correct position of

the hole in the insert.

3. Orient both the steel coupling and the

2 guide holes on the vane pump to ﬁt into

the pressure exchanger.

4. Mount the bolts into the ﬂange and tighten

them a torque according to exploded

view,

20. Install the 2 new labels on top of each

product label to cover the old code no. as

illustrated above.

Spare parts must be ordered according to

the new code no. 180F7018

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161

10 180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017

5. Exploded view

vane pump

Dimensions without tolerances acc. To ISO 2768-1 designation C.

This manual suits for next models

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