Danfoss ISave 21 Original operating manual

isave.danfoss.com

Service instruction

Disassembling and assembling

iSave 21

MAKING MODERN LIVING POSSIBLE

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Service instruction Disassembling and assembling iSave 21

180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013

1. General introduction....................................................................2

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

3. Disassembling the pressure exchanger ..................................................4

4. Assembling the pressure exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

5. Disassambling the vane pump..........................................................12

6. Assembling the vane pump ............................................................13

7. Assembling the iSave ..................................................................17

8. Exploded view vane pump ...................................................... 18

9. Exploded view pressure exchanger............................................... 19

10. Exploded view iSave ...................................................................20

Table of Contents

This document covers the instructions for

disassembling and assembling the iSave 21.

Important: It is essential that the iSave is

serviced in conditions of absolute cleanliness.

For a better understanding of the iSave, please

see the exploded view in item 8, 9 and 10.

The weight of the iSave is 65 kg / 143 lb

and it must be lifted with suitable lifting

equipment.

The weight of the pressure exchanger alone is

28 kg / 62 lb.

It is essential that the iSave is serviced in

conditions of absolute cleanliness

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 disassembling the iSave:

- 6 mm and 8 mm allen key

- 2 screwdrivers

- 2 M8 bolts

- Plastic tube

- Plastic tool for shaft seal assembly

- Loctite 270

Torque wrench with special socket

Code no. 180Z0610

1. General Introduction

Service instruction Disassembling and assembling iSave 21

180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013

2. Disassembling

the iSave

1. Place the iSave on a clean table.

3. Remove the vane pump.

2. Unscrew the bolts in the ange.

Service instruction Disassembling and assembling iSave 21

180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013

3. Disassembling the

pressure exchanger

1. Unscrew the bolts in the ange.

3. Gently push out the ange.

2. Screw in the two M8 bolts.

4. Wet the shaft and shaft seal with clean

ltered water. Gently lever the shaft

assembly free using 2 screwdrivers.

5. Unscrew the bolts in the ange. 6. Gently remove the ange.

Note: Loose parts on the inside of the ange.

Service instruction Disassembling and assembling iSave 21

180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013

7. Gently remove the cylinder barrel.

9. Gently remove the housing.

Note: Loose parts on the inside of the ange.

8. Unscrew the bolts in the ange.

10. Remove port plate and pin.

11. Unscrew high-pressure bearing using a

special socket.

Service instruction Disassembling and assembling iSave 21

180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013

13. Remove the high-pressure bearing. 14. Gently lift the valve plate assembly free

with the aid of the screwdrivers.

15. Gently remove both valve plates. 16. Replace the O-rings and the back-up rings

on the valve plate.

4. Assembling the

pressure exchanger

2. Lubricate all the bores in the cylinder barrel

with grease and clean ltered water.

1. Mount the new back-up rings on the valve

plate rst and then the new O-rings.

Service instruction Disassembling and assembling iSave 21

180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013

18. Adjust the distance between the cylinder

drum and the second valve plate.

The distance must be about 4-6 mm.

This is not critical.

3. Gently press, by hand, the rst valve plate

onto the cylinder barrel.

Note: don’t scratch the valve plate when

placing it on the plastic tube.

4. Gently press, by hand, the second valve

plate onto the cylinder barrel by placing it

on the plastic tube.

Note: don’t scratch the valve plate when

placing it on the plastic tube.

The distance must be about 4-6 mm.

This is not critical.

5. Adjust the distance between the cylinder barrel

and the second valve plate (short shaft end).

Service instruction Disassembling and assembling iSave 21

180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013

7. Tighten the high-pressure bearing using

special socket and torque wrench with

70Nm±7

6. Mount the high-pressure bearing

8. Remove old O-ring with a new one 9. Position the housing over the guide pin

10. Mount all bolts in the ange and tighten

them all with 30Nm±3

Service instruction Disassembling and assembling iSave 21

180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013

11. Fit the guide pin in the ange.

13. Position the port plate over the guide pin.

Note: Make sure that the guide pin is located

in the locating hole in the port plate.

There are two dierent port plates in the iSave. One of them can be mounted on both anges in

the pressure exchanger. Make sure that they are assembled on the right ange.

12. Location hole in port plate.

14. Gently guide the cylinder barrel into the

bearing in the ange.

16. Wrong! large center hole.15. Check the next port plate is correct.

Correct small

center hole

Wrong! large

center hole

Service instruction Disassembling and assembling iSave 21

180R9219 / 521B1171 / DKCFN.PI.003.K3.02 / 11.2013

21. Mount all bolts in the ange and tighten

them to a torque of 30 Nm ± 3 Nm.

20. Position the port ange over the guide pin.

22. Wet the shaft seal with clean ltered water.

Do not use silicone grease.

Fit the shaft seal with the carbon surface upward.

17. Position the port plate over the guide pin.

19. Change the O-ring in the ange and

position the guide pin.

O-ring Guide pin

18 Check that the port plate ts the center

bearing and the guide pin.

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