Danfoss APP 11-13 User manual

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Instruction

Disassembling and assembling

APP 11-13 and APP 16-22

MAKING MODERN LIVING POSSIBLE

Instruction Disassembling and assembling APP 11-13 and APP 16-22

2180R9228 / 521B1181 / DKCFN.PI.013.A2.02 / 10.2013

This document covers the instructions for

disassembling and assembling the axial piston

pumps APP 11-13 and APP 16-22.

Tools provided with toolset 180B4222:

• 10 mm combination wrench

• 13 mm combination wrench

• 6 mm allen key

• Adjustable pin wrench

• Press bush for valve plate

• Extractor

• M8x20 mm allen screw

• Press bush (plastic)

• M8 eye bolt

• M8 mm nut

• M8x70 mm screw

1. Disassembling ..........................................................................3

2. Disassembling the pump ................................................................3

3. Assembling the pump...................................................................7

4. Disassembling and assembling of the swash plate ......................................12

5. Disassembling and assembling of cylinder barrel/valve plate ...........................13

6. Disassembling and assembling of the ush valve .......................................14

7. APP 11-13, Exploded view ..............................................................15

8. APP 16-19, Exploded view ..............................................................16

9. APP 22, Exploded view .................................................................17

Table of Contents

Instruction Disassembling and assembling APP 11-13 and APP 16-22

180R9228 / 521B1181 / DKCFN.PI.013.A2.02 / 10.2013

1. Disassembling Important: It is essential that the pump is

serviced in conditions of absolute cleanliness.

Place the pump on a pallet or other stable

surface above the ground. Ensure that the pump

cannot roll. It must be possible to place the

pump vertically with the shaft pointing down-

wards. This can be done between two pallets or

between two boards on a pallet provided that

the distance to the ground is minimum 100 mm.

(3,94 inches). See example page 4 item 7.

For a better understanding of the pump, please

see exploded views on page 15 to 17.

WARNING:

Do not reuse disassembled O-rings or shaft

seal as they might be damaged. Always use

new O-rings.

2. Disassembling the

pump

1. Disconnect the pump from the rest of the

system.

2. Using the 10 mm combination wrench,

unscrew the four bolts from shaft seal

ange. If shaft seal ange is stuck, place

two bolts in threaded holes in shaft seal

ange to remove it.

3. Remove ceramic ring from ange by

carefully pushing it from the back of the

sealing ring.

Instruction Disassembling and assembling APP 11-13 and APP 16-22

4180R9228 / 521B1181 / DKCFN.PI.013.A2.02 / 10.2013

4. Mount the M8 allen screw from the tool set

in the top of the shaft.

5. Wet the shaft and shaft seal with clean

(ltered) water.

6. Carefully remove the shaft seal using the

shaft seal extractor supplied in the toolset.

The extractor must t underneath the shaft

seal. Press the arms of the extractor

together when turning the bolt.

7. Turn pump into vertical position with shaft

pointing downwards. Ensure minimum

100 mm (3,94 inch) free space for the shaft.

Instruction Disassembling and assembling APP 11-13 and APP 16-22

180R9228 / 521B1181 / DKCFN.PI.013.A2.02 / 10.2013

8. Using the 13 mm combination wrench,

remove all the bolts on the mounting

ange except the three shown in the

picture in item 9.

WARNING: Do not loosen the two screws

keeping the swash plate in place.

9. Unscrew the remaining three bolts. Turn

each bolt one round at the time to make

sure that the ange is removed as straight

upward as possible.

10. Screw the eye bolt in the M8 hole in the

middle of the ange. Pull it straight

upwards.

11. Swash plate must be placed so that its

surface is not scratched. For further dis-

assembling of swash plate, see page 12.

12. Remove the pistons one by one. Be careful

not to scratch pistons. Tilt the retainer plate

to horizontal for easy removal of pistons, if

required.

WARNING: DO NOT USE ANY TOOLS.

13. Remove the retainer plate.

Note: As the retainer guide is not

attached to the retainer plate, it might fall

out.

Instruction Disassembling and assembling APP 11-13 and APP 16-22

6180R9228 / 521B1181 / DKCFN.PI.013.A2.02 / 10.2013

14. Remove the retainer guide, the spring

guide, the 7 springs and the 3 pins.

15. Mount the M8 eye bolt in the cylinder

barrel. Pull straight upwards. A continuous

lift will elevate cylinder barrel out of

housing. This can only be done if shaft seal

is removed.

WARNING: If the cylinder barrel is

dropped into housing, the shaft bearing

in the port ange might be damaged.

Replacement of the shaft bearing in the

port ange can then only be done at

Danfoss DK-Nordborg.

16. Place cylinder barrel horizontal to ensure it

can not roll. For further disassembling of

cylinder barrel and valve plate see page 13.

17. Remove the port plate. 18. Remove the two guide pins.

19. Place the pump horizontally.

Instruction Disassembling and assembling APP 11-13 and APP 16-22

180R9228 / 521B1181 / DKCFN.PI.013.A2.02 / 10.2013

3. Assembling the pump

20. Remove the remaining screws in port

ange using the 13 mm combination

wrench.

21. Carefully separate house and port ange.

Ensure that the guide pin for the position-

ing of the house is not lost. For further

disassembling of ush valve, see page 14.

Important:

It is essential that the pump is serviced in

conditions of absolute cleanliness. All parts

must be absolute clean before mounting.

Note: Place the pump on a pallet or other

stable surface above the ground. Ensure that

the pump cannot roll. It must be possible to

place the pump vertically with the shaft

pointing downwards. This can be done

between two pallets or between two boards on

a pallet provided that the distance is minimum

100 mm (3,94 inch) – see photo page 4 para-

grap h 7.

WARNING:

Do not use silicone when assembling the

pump.

Do not reuse disassembled O-rings as they

might be damaged. Always use new O-rings.

Do not reuse the shaft seal, due to risk of

leakage.

1. Lubrication

• To prevent seizing-up, lubricate threads on

screws.

• O-rings inside pump must be lubricated

only with clean ltered water.

• O-rings for port ange, end ange and

black O-ring on ushing valve must be

lubricated.

• It is important to lubricate ALL parts before

and during assembling with clean ltered

water. (Especially all PEEK parts)

2. Place port ange as illustrated.

3. Insert guide pin for positioning housing on

port ange. Ensure that two screw holes

can be reached from below.

Instruction Disassembling and assembling APP 11-13 and APP 16-22

8180R9228 / 521B1181 / DKCFN.PI.013.A2.02 / 10.2013

4. Mount the O-ring. Remember lubrication of

the O-ring with clean ltered water.

5. Position housing by aligning pin hole over

guide pin.

6. Gently press downwards. Be careful not to

squeeze the O-ring. If O-ring is damaged

the pump will leak.

7. Screw in at least two screws from below. 8. Place housing horizontally. Cross screw the

rest of the screws in on port ange. Tighten

screws to a torque of 30 ± 2 Nm.

9. Place pump vertically. Place 10.5 mm guide

pins in port ange.

11. Ensure the port plate is tted tightly

against the bottom.

Important:

Lubricate port plate with clean ltered water.

If valve plate is disassembled from cylinder barrel

please see page 13 before continuing.

10. Position port plate using the two guide

pins. Do not use force for this operation.

12. Screw in M8 eye bolt in the cylinder barrel.

Instruction Disassembling and assembling APP 11-13 and APP 16-22

180R9228 / 521B1181 / DKCFN.PI.013.A2.02 / 10.2013

14. Unscrew M8 eye bolt.

13. Make sure there is enough free space for

shaft beneath the housing. Minimum 100

mm (3,94 inch). Carefully lower cylinder

barrel into housing.

WARNING:

If cylinder barrel is dropped or lowered

too fast into housing, the shaft bearing

might be damaged.

Replacement of the shaft bearing can then

only be done at Danfoss DK- Nordborg.

15. Place the 7 springs and 3 pins in cylinder

barrel. The pin holes are assymetric.

16. Place the spring guide and the retainer

guide on the cylinder shaft.

17. Place retainer plate in cylinder barrel.

(Remember to lubricate the retainer plate

and cylinder bushings with clean ltered

water).

18. Ensure that retainer plate is oriented

correctly, with its slant surfaces pointing

downwards.

Instruction Disassembling and assembling APP 11-13 and APP 16-22

10 180R9228 / 521B1181 / DKCFN.PI.013.A2.02 / 10.2013

19. Place pistons in retainer plate and cylinder

barrel. When pistons are placed, tilt retainer

plate for easier placement of swash plate.

If swash plate has been disassembled from

mounting ange, see page 12 for assembly of

swash plate.

20. Place the guide pin in the housing.

21. Lubricate piston shoes and swash plate

with clean ltered water.

22. Mount assembled swash plate, using the

guide pin.

23. Place three bolts in mounting ange.

(Remember lubrication as stated in

paragraph 1 page 7.)

Turn each bolt one round at a time to

ensure mounting ange is mounted as

straight downwards as possible.

Be careful not to squeeze the O-ring.

24. Screw in the rest of the bolts and tighten all

screws to a torque of 30 +/- 2 Nm.

25. Place pump horizontally to get access to

shaft.

26. Lubricate shaft with clean ltered water.

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