Danfoss APP 21 Bedienungsanleitung

Service guide

APP pumps

APP 21 - 46 and APP W HC 15 - 30

Disassembling and assembling

hpp.danfoss.com

Service guide |Disassembling and Assembling, APP 21 - 46 and APP W HC 15 -30

2 | 180R9406 | AX274339308034en-000302

This document covers the instructions for disassembling and assembling the axial piston pumps

APP 21-46 and APP W HC 15-30

Tools provided 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 ø45

• M8 allen screw (20 mm and 140 mm)

• Press bush ø45 (Plastic)

• M8 mm eye bolt

• M8 mm nut

• M8 x 70 mm screw

1. Introduction

Table of Contents Contents

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

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

3. Assembling the pump .......................................................................................................................................... 6

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

5. Disassembling andassembling of cylinder barrel and valve plate......................................................11

6. Disassembling and assembling of the ush valve....................................................................................11

7. Changing pistons..................................................................................................................................................12

8. When should the pistons be replaced...........................................................................................................17

9. Exploded view APP 21-26 , APP 30/1500 and APP W HC 15-24 ..........................................................18

10. Exploded view APP 30/1200, APP 38/1500, APP 46/1780 and APP W HC 30..................................19

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 the exploded view on page 18 and 19.

WARNING:

Do not reuse disassembled O-rings or shaft

seal as they might be damaged. Always use

new O-rings.

Service guide | Disassembling and Assembling, APP 21 - 46 and APP W HC 15 - 30

2. Disassembling the

pump

2. Using a 10 mm combination wrench,

unscrew the four bolts from shaft seal

ange.

If shaft seal ange is stuck, screw in two

bolts in holes in the ange to remove it.

1. Disconnect the pump and motor from the

system. Remove non-return valve and

connector from the pump.

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.

3. Remove ceramic ring from ange by

gently pushing it from the back of the

sealing ring.

6. Carefully remove the shaft seal assembly

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.

Service guide |Disassembling and Assembling, APP 21 - 46 and APP W HC 15 -30

4 | 180R9406 | AX274339308034en-000302

9. Unscrew the remaining three bolts. Turn

each bolt one round at the time to make

sure that the ange 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.

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

middle of the ange. Pull it straight

upwards.

8. Using a 13 mm combination wrench,

remove all the bolts on the mounting

ange except the three shown in the next

picture.

WARNING:

Do not loosen the two screws keeping

swash plate in place.

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.

13. Remove the retainer plate and the retainer

ball.

Warning: So not loosen the three screws

in the retainer plate.

Service guide | Disassembling and Assembling, APP 21 - 46 and APP W HC 15 - 30

14. Remove the retainer guide, the 4 springs

and the spring guide.

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.

16. Place cylinder barrel upside down.

For further disassembling of cylinder

barrel and valve plate see page 11.

18. Remove, by hand, the two pins.

Note: The following operation is only

necessary if O-ring on port ange is to

be changed.

19. Place the pump horizontally.

20. Remove the remaining screws in port

ange by using a 13 mm combination

wrench. Carefully separate house and port

ange. Ensure that pin for the positioning

house is not lost.

21. For further disassembling of ush valve,

see page 11.

Service guide |Disassembling and Assembling, APP 21 - 46 and APP W HC 15 -30

6 | 180R9406 | AX274339308034en-000302

3. Assembling the pump

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.

3. Mount O-ring.

4. Insert pin for positioning housing

on port ange.

Ensure that two screw holes can be

reached from below.

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.

1. Lubrication:

• To prevent seizing-up, lubricate all

threads with PTFE lubrication type.

• O-rings inside pump may be lubricated

only with clean ltered water.

• O-rings for port ange, mounting ange

and ushing valve must be lubricated.

• It is important to lubricate ALL parts to

be assembled with clean ltered water

(Especially all PEEK parts). 2. Place port ange with O-ring pointing

upwards.

WARNING:

Do not use silicone when assembling the

pump. Do not reuse disassembled O-rings;

they might be damaged. Always use new

O-rings.

Important:

It is essential that the pump is serviced in

conditions of absolute cleanliness. All parts

must be absolute clean before mounting.

Service guide | Disassembling and Assembling, APP 21 - 46 and APP W HC 15 - 30

9. Place pump vertically. Place 10.5 mm pins

in port ange.

10. Position port plate by using the two pins.

Do not use force for this operation.

8. Place housing horizontally. Screw in the

rest of the screws on port ange. Tighten

screws to a torque according to exploded

view.

12. Screw eye bolt in cylinder barrel.

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.

14. Unscrew M8 eye bolt.

15. Place the four springs and spring guide in

cylinder barrel. Springs must be

positioned in the holes.

11. Ensure port plate is tted 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.

Service guide |Disassembling and Assembling, APP 21 - 46 and APP W HC 15 -30

8 | 180R9406 | AX274339308034en-000302

17. 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.

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 10 for assembly

of swash plate.

20. Lubricate piston shoes and swash plate

with clean ltered water. Remember to

place the pins in housing.

21. Place the pins in the housing.

16. Retainer guide, retainer ball and

retainer plate must be mounted as

indicated in below picture.

22. Place the mounting ange.

Remember to place the guide pin in the

housing.

. Place three bolts in mounting ange.

Turn each bolt one round at a time to

ensure mounting ange is mounted as

straight downwards as possible. Be careful

not to squeeze O-ring.

23. Screw in the rest of the bolts and cross

tighten all screws to a torque according to

exploded view.

24. Place pump horizontally to get access to

shaft.

Service guide | Disassembling and Assembling, APP 21 - 46 and APP W HC 15 - 30

25. Lubricate shaft with clean ltered water.

26. Place stop for 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.

27. Use plastic assembly tool provided with

large diameter pointing downwards, to

press seal home against shoulder of stop

for shaft seal.

30. Place shaft seal ange on shaft. Tighten

the bolts with a torque according to

exploded view.

29. Remove old O-ring and t new one on

shaft seal ange.

Service guide |Disassembling and Assembling, APP 21 - 46 and APP W HC 15 -30

10 | 180R9406 | AX274339308034en-000302

1. Place the swash plate upside down.

Remove the 2 bolts holding the swash

plate. Remove the mounting ange from

the swash plate.

3. Change the O-ring on the mounting

ange.

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

condition (provided with seal set).

4. Mount the swash plate on the 2 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 torqueaccording to exploded

view. Finally check the surface on the

swash plate for any marks or foreign

particles.

5. Mount the assembled part on the pump.

4. Disassembling and

assembling of the

swash plate

WARNING:

Make sure that the surface on the swash

plate does not get any marks.

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