Danfoss APP S Series Disassembling And Assembling Download

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Instruction

Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5

180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015

9.1 Explode view

APP S 674 2.0-3.5

Summary of Contents for APP S Series

Page 1: ...ro solutions com Instruction APP S APP S 674 pumps APP S 2 0 3 5 APP S 674 2 0 3 5 pumps Disassembling and assembling ...

Page 2: ...S 674 2 0 3 5 23 10 When should the pistons be replaced 24 This document covers the instructions for disassembling and assembling the axial piston pumps APP S 2 0 3 5 APP S 674 2 0 3 5 pumps Important It is essential that the pump is serviced in conditions of absolute cleanliness For a better understanding of the pump please see the exploded view in section 7 Note When disassembling and assembling...

Page 3: ...p 2 Using a 6 mm allen key unscrew the 3 bolts from shaft seal cover 1 Disconnect the pump from the rest of the system 3 Remove shaft seal bushing 4 Remove O ring with a small screwdriver 5 Remove ceramic ring from cover by carefully pushing it from the back of the sealing ring with a screwdriver 6 Clean and then wet the shaft with clean water ...

Page 4: ...nd to pull the shaft seal up WARNING Be careful not to scratch the shaft 8 Carefully remove the shaft seal and distance ring 10 Using a 8 mm allen key unscrew all bolts on the end flange 9 Carefully remove the spring by lifting it with a screwdriver and one hand to pull the spring up 12 Remove end flange 11 Place pump on a distance block Make sure there is enough free space for the shaft beneath t...

Page 5: ...ove 2 pistons Be careful not to scratch the pistons WARNING Do not use any tools 13 Swash plate must be placed so that its surface is not scratched For further disassembling of swash plate see page 14 15 Remove the retainer plate with the remaining pistons 16 Remove the retainer ball 17 Remove the retainer guide and the spring ...

Page 6: ...haft seal is removed WARNING If the cylinder barrel is dropped or lowered too fast into housing the main bearing shaft bearing might be damaged 21 Remove the port plate in the housing by hand 20 Place cylinder barrel upside down For further disassembling of cylinder barrel and valve plate see page 14 23 Turn the pump upside down Unscrew the 8 bolts in port flange 22 Remove the guide pin Note The f...

Page 7: ...flushing valve must be lubricated It is important to lubricate ALL parts to be assembled with clean filtered water Especially all PEEK parts WARNING Do not use silicone when assembling the pump Do not reuse disassembled O rings they might be damaged Always use new O rings 2 Assembling the pump Important It is essential that the pump is serviced in conditions of absolute cleanliness All parts must ...

Page 8: ... lubricate with water 4 Position port flange by aligning pin hole over guide pin 6 Lubricate the threads with PTFE lubrication Insert screws on the port flange Tighten screws to a torque of 30 3 Nm 5 Carefully press the port flange downwards Do not squeeze the O ring If the O ring is damaged the pump will leak 7 Place a 10 5 mm guide pin in the port flange ...

Page 9: ... using the guide pin Do not use force for this operation 10 Place the pump on a distance block Make sure there is enough free space for the shaft beneath the housing Lubricate inside 11 Carefully lower cylinder barrel into the 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 Nordbo...

Page 10: ...e pistons in the retainer plate and cylinder barrel 19 Change and lubricate O ring in the end flange Position end flange aligning pin hole over the guide pin 16 Ensure the retainer plate is oriented correctly 18 Lubricate the piston shoes Tilt retainer plate for easier placement of swash plate If the swash plate has been disassembled from end flange see page 13 for assembling of swash plate Rememb...

Page 11: ...straight downwards as possible Be careful not to squeeze the O ring 21 Screw in the rest of the bolts and tighten all screws to a torque of 30 3 Nm 24 Position the shaft seal distance ring 23 Remove old O ring and place the new one on shaft seal cover 22 Lubricate and press new ceramic ring into the shaft seal cover by using the press bush tool WARNING Ensure that the face with rubber seal is posi...

Page 12: ...me turn the seal clockwise until spring stops at distance ring 25 Lubricate shaft with clean filtered water 27 Right position of the spring can be inspected through the flushing valve hole Shaft seal mounted 29 Hold the cover down with one hand and tighten the bolts with a torque of 12 Nm 1 Nm 28 Position the shaft seal cover on shaft Be careful not to damage the ceramic ring WARNING Be careful th...

Page 13: ... swash plate guide pin and O ring 4 Lubricate centre bolt thread with a PTFE lubricant type 3 Place guide pin and carefully align swash plate over guide pins 6 Finally check the surface on the swash plate for any marks or foreign particles and place new O ring 5 Position the centre bolt and tighten to 12 Nm 1 Nm 3 Disassembling and assembling of the swash plate O ring ...

Page 14: ...d backup rings on valve plate 4 Lubricate the new O rings back up rings and the liners in the cylinder barrel with clean filtred water 3 Mount the new back up rings on the valve plate Then mount the O rings 5 Carefully press by hand valve plate onto cylinder barrel The cylinder barrel is now ready for mounting 4 Disassembling and assembling of cylinder barrel and valve plate O ring Backup ring Bac...

Page 15: ...g onto shoulders of the poppet guide and the poppet The spring must be fastened on both collars Then mount new O ring on the poppet guide Turn flushing valve upside down If spring is not properly assembled it will fall of 6 Lubricate valve with clean filtered water and push by hand the valve into the hole 5 Disassembling and assembling of the flushing valve 6 How to replace the shaft seal Disassem...

Page 16: ...isconnect the pump from the rest of the system or close inlet valve 2 Loosen all screws on the pump except the two screws as shown in the picture below Note There is still water inside the pump 4 Remove the flange Remove pin or ensure it stays in place Ensure not to scratch the swash plate surface 3 Unscrew the remaining screws 5 While holding the retainer plate with one hand carefully remove the ...

Page 17: ...3 C4 02 10 2015 6 WARNING Ensure that the piston shoes and the piston surfaces are not damaged during removal It is recommended to place the pistons upside down on an even and clean base surface 7 Remove retainer plate and ball 9 Inspect the piston liners 8 Remove guide and spring 10 Replace any worn parts ...

Page 18: ...ace the spring 1 Ensure the liner and the end of cylinder barrel are wetted 4 Place the ball on the retainer plate WARNING Ensure right assembling and placement of the retainer plate See item 16 page 10 3 Place the guide 6 Wet the pistons 5 Place the retainer plate and hold it with one hand Insert the pistons one by one with the other hand ...

Page 19: ... 013 C4 02 10 2015 7 Replace the O ring and mount the flange Ensure the guide pin is mounted 8 Mount two screws as shown below and tighten them 10 Connect the pump to the rest of the system 11 Bleed the pump before starting it 9 Mount the remaining bolts and cross tighten them to a torque of 30 Nm 3 Nm ...

Page 20: ...x1 62 1 Spring Hastelloy C4 x 63 1 Spring guide PEEK x 64 1 Retainer ball Super Duplex x1 65 1 Retainer plate Super Duplex x1 66 7 Piston Super Duplex PEEK x1 67 1 Key AISI 316 x 91 1 Port plate Super Duplex PEEK x 92 1 Valve plate Super Duplex x1 93 7 Back up ring PTFE x 94 7 O ring NBR x 121 1 Port flange Super Duplex PEEK 122 1 O ring NBR x 123 1 O ring NBR x 124 1 Shaft seal NBR x 125 1 Cover ...

Page 21: ...Instruction Disassembling and assembling APP S 2 0 3 5 APP S 674 2 0 3 5 21 180R9281 521B1275 DKCFN PI 013 C4 02 10 2015 8 1 Explode view APP S 2 0 3 5 ...

Page 22: ... PEEK x 64 1 Retainer ball Super Duplex x1 65 1 Retainer plate Super Duplex x1 66 7 Piston Super Duplex PEEK x1 67 1 Key AISI 316 x 91 1 Port plate Super Duplex PEEK x 92 1 Valve plate Super Duplex x1 93 7 Back up ring PTFE x 94 7 O ring NBR x 121 1 Port flange Super Duplex PEEK 122 1 O ring NBR x 123 1 O ring NBR x 124 1 Shaft seal NBR x 125 1 Cover for shaft seal Super Duplex 126 1 Pin PEEK x 12...

Page 23: ...Instruction Disassembling and assembling APP S 2 0 3 5 APP S 674 2 0 3 5 23 180R9281 521B1275 DKCFN PI 013 C4 02 10 2015 9 1 Explode view APP S 674 2 0 3 5 ...

Page 24: ... next 500 1 000 hours Picture 3 Cavitation of the piston shoes All pistons must be replaced within the next 100 200 hours This section provides guidance on how to determine whether the parts of the pump are worn and should be replaced In case of doubt the pistons must be replaced The pictures below are meant as a guideline for evaluating the wear of the sliding surface Note If the pistons break do...

Page 25: ...Instruction Disassembling and assembling APP S 2 0 3 5 APP S 674 2 0 3 5 25 180R9281 521B1275 DKCFN PI 013 C4 02 10 2015 ...

Page 26: ... Danfoss DCS im 2015 10 180R9281 521B1275 DKCFN PI 013 C4 02 Danfoss A S High Pressure Pumps DK 6430 Nordborg Denmark ...

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