Danfoss APP 21-43 User manual

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Instruction

APP pump instruction

APP 21-43

MAKING MODERN LIVING POSSIBLE

Instruction

Disassembling and assembling

APP 21-43

Instruction Disassembling and assembling APP 21-43

2180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 06.2013

This document covers the instructions for

disassembling and assembling the axial piston

pumps APP 21-43.

Tools provides with toolset 180B4172:

10 mm combination wrench

13 mm combination wrench

6 mm allen key

Adjustable pin wrench

Stop for retainer plate

Press bush for valve plate

Shaft seal extractor ø 45

M8 allen screw (20 mm and 140 mm)

Press bush ø 45 (Plastic)

M8 mm eye bolt

M8 mm nut

M8 x 70 mm screw

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 downwards.

This can be done between two pallets or

between two boards on a pallet provided that

the distance is minimum 50 mm.

For a better understanding of the pump, please

see exploded view on page 12 and 13.

WARNING:

Do not reuse disassembled O-rings or shaft

seal as they might be damaged. Always use

new O-rings.

Note: It is essential that the pump is serviced

in conditions of absolute cleanliness.

2. Disassembling

1. Introduction

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

2. Disassembling ..........................................................................2

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

4. Assembling the pump...................................................................6

5. Disassembling and assembling of the swash plate ......................................10

6. Disassembling and assembling of of cylinder barrel-/ valve ..............................11

7. Disassembling and assembling of the ﬂush plate........................................11

8. Exploded view APP 21-26, APP 30/1500.................................................12

9. Exploded view APP 30/1200, APP 38/1500, APP 43/1700.................................13

Table of Contents

Instruction Disassembling and assembling APP 21-43

180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013

3. Disassembling

the pump

1. Disconnect the pump and motor from the

system. Remove non-return valve and

connector from the pump.

2. Using a 10 mm combination wrench, unscrew

the four bolts from shaft seal ﬂange.

If shaft seal ﬂange is stuck, place two bolts in

screw holes in shaft seal ﬂange to remove it.

4. Mount the M8 allen screw from the tool set in

the top of the shaft.

3. Remove ceramic ring from ﬂange by gently

pushing it from the back of the sealing ring.

5. Wet the shaft and shaft seal with clean ﬁltered

water.

7. Turn pump into vertical position with shaft

pointing downwards.

6. Carefully remove the shaft seal assembly

using the shaft seal extractor supplied in the

toolset. The extractor must ﬁt underneath

the shaft seal. Press the arms of the extractor

together when turning the bolt.

Instruction Disassembling and assembling APP 21-43

4180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013

8. Using a 13 mm combination wrench, remove

all the bolts on the mounting ﬂange except

the three shown in picture 9.

WARNING:

Do not loosen the two screws keeping

swash plate in place.

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

middle of the ﬂange. Pull it straight upwards.

12. Remove by hand the pistons one by one.

Be careful not to scratch the pistons. Tilt the

retainer plate to horizontal position for easy

removal of pistons, if required.

WARNING:

Do not use any tools.

9. Unscrew the remaining three bolts. Turn each

bolt one round at the time to make sure that

the ﬂange is removed as straight forward as

possible.

11. Swash plate must be placed so that its surface

is not scratched. For further disassembling of

swash plate, see page 10.

13. Remove the retainer plate and the retainer

ball.

Note: As the retainer ball is not attached to

the retainer plate, it might fall out.

Instruction Disassembling and assembling APP 21-43

180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013

14. Remove the retainer guide, the 4 springs and

the spring guide.

16. Place cylinder barrel upside down.

For further disassembling of cylinder barrel

and valve plate see page 11.

18. Remove, by hand, the two guide pins.

Note: The following operation is only

necessary if O-ring on port ange is to be

changed.

20. Remove the remaining screws in port ﬂange

by using a 13 mm combination wrench.

21. Carefully separate house and port ﬂange.

Ensure that guide pin for the positioning

house is not lost.

For further disassembling of ﬂush valve, see

page 11.

15. Mount a 8 mm eye bolt in the cylinder barrel.

Pull straight upwards. A continuous lift will

elevate the cylinder barrel out of housing.

This can only be done if shaft seal is removed.

WARNING:

If the cylinder barrel is dropped or lowered

too fast into housing, the main bearing/

shaft bearing might be damaged. It is not

replaceable.

17. Remove the port plate by hand.

19. Place the pump horizontally.

Instruction Disassembling and assembling APP 21-43

6180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013

4. Assembling the pump

1. Lubrication

• To prevent seizing-up, lubricate threads on

screws.

• O-rings inside pump may be lubricated only

with clean ﬁltered water.

• O-rings for port ﬂange, mounting ﬂange

and black O-ring on ﬂushing valve may be

lubricated with a small amount of grease.

• It is important to lubricate ALL parts to

be assembled with clean ﬁltered water

(Especially all PEEK parts).

3. Insert guide pin for positioning housing on

port ﬂange.

Ensure that two screw holes can be reached

from below.

5. Position housing aligning pin hole over

guide pin.

6. Gently press downwards. Be careful not to

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

pump will leak.

7. Screw in at least two screws.

4. Mount O-ring.

2. Place port ﬂange with O-ring pointing upwards.

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 50 mm.

WARNING:

Do not use silicone when assembling the

pump. Do not reuse dismantled O-rings;

they might be damaged. Always use new

O-rings.

Instruction Disassembling and assembling APP 21-43

180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013

8. Place housing horizontally. Screw in the rest of

the screws on port ﬂange. Tighten screws to a

torque of 30 ± 2 Nm.

10. Position port plate by using the two guide pins.

Do not use force for this operation. 12. Screw eye bolt in cylinder barrel.

14. Unscrew M5 eye bolt.

15. Place the four springs and spring guide in

cylinder barrel. Springs must be positioned in

the holes.

13. Make sure there is enough free space for

the shaft beneath the housing. Gently lower

cylinder barrel into housing.

WARNING:

If cylinder barrel is dropped or lowered too

fast into housing, main bearing and shaft

bearing might be damaged. Replacement can

only be done at Danfoss, Nordborg.

9. Place pump vertically. Place 10.5 mm guide pins

in port ﬂange.

11. Ensure port plate is ﬁtted tightly against the

bottom.

IMPORTANT:

Lubricate port plate with clean ltered fresh

water.

If valve plate is disassembled from cylinder

barrel please see page 11 before continuing.

Instruction Disassembling and assembling APP 21-43

8180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013

16. Retainer guide, retainer ball and retainer plate

must be mounted in the order indicated in

picture below.

18. Place retainer plate in cylinder barrel.

Note: If pistons are replaced, place new

pistons in clean ltered water for a couple of

minutes. Exercise piston shoes to make them

“run” smoother.

20. Lubricate piston shoes and swash plate with

clean ﬁltered water.

22. Place three bolts in mounting ﬂange.

Turn each bolt one round at a time to ensure

mounting ﬂange is mounted as straight

downwards as possible. Be careful not to

squeeze O-ring.

21. Remember to place the guide pin in the

housing.

23. Screw in the rest of the bolts and cross tighten

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

Note: Screws for lifting eye are shorter than the

rest.

17. Ensure that retainer plate is oriented correctly,

ie with its slant surfaces pointing downwards.

19. Place pistons in retainingplate and cylinder

barrel. When pistons are placed, tilt retaining

plate for easier placement of swash plate.

If swash plate has been disassembled from

mounting ﬂange, see page 10 for assembly of

swash plate.

Instruction Disassembling and assembling APP 21-43

180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013

24. Place pump horizontally to get access to shaft.

Shaft seal

25. Lubricate shaft with clean ﬁltered water.

26. Place stop for shaft seal and shaft seal on shaft.

WARNING:

Ensure that carbon ring is pointing outwards.

28. Press new ceramic ring into retainer ring by

using plastic tool provided.

WARNING:

Ensure that the face with rubber seal is

positioned against shoulder in shaft seal

ange.

30. Place shaft seal ﬂange on shaft. Tighten the

bolts with a torque of 10Nm +/-2 Nm.

27. Use plastic assembly tool provided with

large diameter pointing downwards, to press

seal home against shoulder of stop for shaft seal.

29. Remove old O-ring and ﬁt new one on shaft

seal ﬂange.

Instruction Disassembling and assembling APP 21-43

10 180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013

5. Disassembling and

assembling of the

swash plate

WARNING:

Make sure that the surface on the swash plate

does not get any marks.

1. Place the swash plate upside down. Remove

the 2 bolts holding the swash plate. Remove

the mounting ﬂange from the swash plate.

3. Change the O-ring on the mounting ﬂange.

5. Mount the assembled part on the pump.

4. Mount the swash plate on the 2 guide pins.

Carefully by hand tilt the unit to horizontal

position and mount the 2 bolts which hold

the swash plate. Tighten the bolts with a

torque of 30 Nm +/-2 Nm. Finally check the

surface on the swash plate for any marks or

foreign particles.

2. Check that the O-ring and pin are in good

condition. (Provided with sealing set).

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