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Danfoss iSave 21, Service Manual

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Danfoss iSave 21 Service Manual Download Page 5

Service guide 

Disassembling and assembling iSave 21

5

180R9219  |  521B1171  |  DKCFN.PI.003.K4.02  |  03.2016

7. 

If bearing in flange need to be changed  

 

gently press the bearing out from the  

 

back side with a tube or a drift.

 

Place the new bearing in the hole in the  

 flange.

8. 

Lubricate the new bearing with clean  

 

filtered water. With use of a hand press  

 

gently press the new bearing in place  

 

until it is in line with the flange surface.

 

 

 

Do not use a hammer!

9. 

Gently remove the cylinder barrel. 

10.  Unscrew the bolts in the flange. 

11.  Gently remove the housing.

Note: Loose parts on the inside of the flange.

12.  Remove port plate and pin.

Pin

Summary of Contents for iSave 21

Page 1: ...Service guide Energy Recovery Device iSave 21 Disassembling and assembling hpp danfoss com ...

Page 2: ... kg 143 lb and it must be lifted with suitable lifting equipment The weight of the pressure exchanger alone is 28 kg 62 lb 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 iSave 21 tool kit 180F4126 2 screwdrivers Loctite 270 1 General Introduction Contents ...

Page 3: ...Save 21 3 180R9219 521B1171 DKCFN PI 003 K4 02 03 2016 1 Place the iSave on a clean table 3 Remove the vane pump 2 Unscrew the bolts in the flange 2 Disassembling the iSave 3 Use internal coupling tool to remove coupling part from exchanger shaft ...

Page 4: ...ure exchanger 1 Unscrew the bolts in the flange 3 Gently push out the flange 2 Screw in the two M8 bolts 4 Wet the shaft and shaft seal with clean filtered water Gently lever the shaft assembly free using 2 screwdrivers 5 Unscrew the bolts in the flange 6 Gently remove the flange Note Loose parts on the inside of the flange ...

Page 5: ...ift Place the new bearing in the hole in the flange 8 Lubricate the new bearing with clean filtered water With use of a hand press gently press the new bearing in place until it is in line with the flange surface Do not use a hammer 9 Gently remove the cylinder barrel 10 Unscrew the bolts in the flange 11 Gently remove the housing Note Loose parts on the inside of the flange 12 Remove port plate a...

Page 6: ...3 K5 02 03 2016 13 Unscrew high pressure bearing using a special socket 14 Remove the high pressure bearing 15 Gently lift the valve plate assembly free with the aid of the screwdrivers 17 Replace the O rings and the back up rings on the valve plate 16 Gently remove both valve plates ...

Page 7: ...tered water 1 Mount the new back up rings on the valve plate first and then the new O rings IMPORTANT It is essential that the iSave is serviced in conditions of absolute cleanliness All Parts must be absolute clean before mounting WARNING Do not use silicone when assembling the iSave Do not reuse dismantled O rings they might be damaged Always use new O rings Lubrication To prevent seizing up lub...

Page 8: ...5 Mount the high pressure bearing 6 Tighten the high pressure bearing using special socket and torque wrench with 90Nm 9 7 Replace old O ring with a new one 8 Position the housing over the guide pin 10 9 Mount all bolts in the flange and tighten them all with 30Nm 3 10 Fit the guide pin in the flange ...

Page 9: ...n the pressure exchanger Make sure that they are assembled on the right flange 12 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 13 Gently guide the cylinder barrel into the bearing in the flange 14 Check the port plate is correct small center hole 15 Wrong large center hole New design Old design New design Old design ...

Page 10: ...ate fits the center bearing and the guide pin 20 Mount all bolts in the flange and tighten them to a torque of 30 Nm 3 Nm 19 Position the port flange over the guide pin 21 Wet the shaft seal with clean filtered water Do not use silicone grease Fit the shaft seal with the carbon surface upward 18 Change the O ring in the flange and position the guide pin O ring Guide pin ...

Page 11: ...e careful not to damage the carbon seal face on the shaft seal 24 Shaft seal in right position 25 Remove the old ceramic ring from the flange Position the new O ring on the seal flange 26 Push the new ceramic ring into the flange using plastic tool provided small diameter Make sure the face with the rubber seal is positioned against the shoulder in the flange Before assembly wet the parts with cle...

Page 12: ...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 5 Disassembling the vane pump 6 Side plate removed ...

Page 13: ...ice guide Disassembling and assembling iSave 21 13 180R9219 521B1171 DKCFN PI 003 K4 02 03 2016 7 Gently remove the rotor Note Loose parts inside the rotor 8 Remove vanes 9 Gently remove side plate and pin ...

Page 14: ...hole in the side plate 6 Assembling the vane pump 4 Place the 4 pins in the rotor 3 Position the side plate over the guide pin Note Make sure that the guide pin is located in the locating hole in the port plate See 2 5 Gently place the rotor in the bearing 6 Position the 8 vanes in the rotor The pins may be moved by using a screwdriver ...

Page 15: ... One vane is NOT positioned correctly 9 Replace the O ring on the flange and wet the flange properly with clean filtered water 10 Position the side plate over the guide pin 11 Make sure that the guide pin is located in the locating hole in the side plate See 10 12 Fit the flange into both the bearing in the flange and the location pin in the stator ...

Page 16: ... guide pin is located in the location hole 14 Change the O ring in the HP out connection flange 16 Fit the coupling into the pump Glue the threat on the bolt with Loctite 270 and tighten the bolt with 10 Nm 1 Nm 17 Change the two O rings in the flange 15 Bolt the flange onto the vane pump Tighten the bolt with 30 Nm 3 Nm ...

Page 17: ...upling 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 with 30 Nm 3 Nm ...

Page 18: ...Danfoss A S High Pressure Pump Nordborgvej 81 DK 6430 Nordborg Denmark Danfoss DCS im 2016 03 180R9219 521B1171 DKCFN PI 003 K5 02 18 ...

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