Danfoss APP S 2.0-3.5 and Service guide

Danfoss
Brand
Danfoss
Model
APP S 2.0-3.5 and
Type
Service guide
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
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
2
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
NOTE: If the pump is disassembled within the warranty period, the pump is no longer covered
by the warranty.
Introduction
Table of Contents 1. Disassembling the pump ..............................................................................................................................................3
2. Assembling the pump....................................................................................................................................................7
3. Disassembling and assembling of the swash plate ........................................................................................13
4. Disassembling and assembling of cylinder barrel and valve plate ...........................................................14
5. Disassembling and assembling of the ushing valve ......................................................................................15
6. How to replace the shaft seal .................................................................................................................................... 15
7. Changing pistons ......................................................................................................................................................... 16
7.1 Disassembling ................................................................................................................................................................. 16
7.2 Assembling .......................................................................................................................................................................18
8. Spare parts list APP S 2.0-3.5 ...................................................................................................................................20
8.1 Explode view APP S 2.0-3.5 ........................................................................................................................................21
9. Spare parts list APP S 674 2.0-3.5 ...........................................................................................................................22
9.1 Explode view APP 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 it must
be possible to place the pump vertically with
the shaft pointing downwards. This can be
done with a distance block with a minimum
height of 50 mm.
Tools needed:
• 6 mm allen key
• 8 mm allen key
• Torque wrench
• 2 screwdrivers
• 1 press bush tool (part of seal kit)
• Distance block
Our CLP RO pumps have changed the name as listed below:
CLP674 050-058 RO: will now be called APP S 674 3.0-3.5
CLP 674 085-152 RO: will now be called APP S 674 5.1-9.0
CLP674 365-640 RO: will now be called APP S 674
This is ONLY a name change.
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
3
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
1. Disassembling the
pump
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.
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
4
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
7. Through the inlet port lever the shaft seal
with a screw driver between shaft seal and
spring. Use one hand 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 ange.
9. Carefully remove the spring by lifting it
with a screwdriver and one hand to pull
the spring up.
12. Remove end ange.
11. Place pump on a distance block. Make
sure there is enough free space for the
shaft beneath the housing. Remove all bolts.
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
5
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
14. Remove 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.
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
6
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
18. Remove the guide pin.
19. Pull the cylinder barrel straight upwards in
a continuous lift to ensure no damage of
house bearing. This can only be done if the
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.
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 ange.
22. Remove the guide pin.
Note: The following operation is only
necessary if O-ring on port ange has to
be changed.
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
7
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
24. Remove bolts and port ange.
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).
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 be absolute clean before mounting.
2. Place the housing with pump label
pointing downwards and insert guide pin
for positioning the port ange on housing.
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
8
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
3. Mount new O-ring on port ange and
lubricate with water.
4. Position port ange by aligning pin hole
over guide pin.
6.
Lubricate the threads with PTFE lubrication
.
Insert screws on the port ange. Tighten
screws to a torque of 30 ± 3 Nm.
5.
Carefully press the port ange 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 ange.
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
9
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
9. Ensure port plate is tted tightly against
the bottom.
Important: If valve plate is disassembled
from cylinder barrel, please see page 15
before continuing.
8. Position port plate by 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, Nordborg.
13. Lubricate and position the retainer guide.12. Place the spring in cylinder barrel.
Distance
block
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
10
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
14. Lubricate retainer guide and position the
retainer ball. 15. Position the retainer plate.
17. Lubricate and position the pistons in the
retainer plate and cylinder barrel.
19. Change and lubricate O-ring in the end
ange. Position end ange 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 ange, see page 13 for
assembling of swash plate. Remember to
place the guide pin in the housing.
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
11
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
20.
Lubricate and place two bolts in end 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 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
positioned against shoulder in shaft seal
ange.
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
12
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
26. Mount new shaft seal with the carbon seal
face pointing upwards. Press seal down and
at the same time turn the seal clockwise
until spring stops at distance ring.25. Lubricate shaft with clean ltered water.
27. Right position of the spring can be
inspected through the ushing 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, the shaft has sharp edges.
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
13
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
1. Unscrew centre bolt from swash plate. 2.
Remove 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
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
14
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
1. Carefully lift valve plate assembly free
with the aid of a screwdriver.
2. Replace O-rings and backup rings on
valve plate.
4. Lubricate the new O-rings/back-up rings
and the liners in the cylinder barrel with
clean ltred 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
Backup ring
O-ring
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
15
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
1. Remove shaft seal cover.
2. Carefully push the ushing valve up
through the outlet connection, using a
small screwdriver.
4. Flushing valve parts.3. Remove complete ushing valve set.
5. Press a new spring 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 ushing valve upside down. If spring
is not properly assembled, it will fall of.
6. Lubricate valve with clean ltered water
and push by hand the valve into the hole.
5. Disassembling and
assembling of the
ushing valve
6. How to replace the
shaft seal
Disassembling, please see Assembling, please see
Page 3 items 2 to 4 Page 11 item 22 to 24
Page 3 items 5 to 6 Page 12 items 25 to 29
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
16
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
7. Changing pistons 7.1 Disassembling
To understand the pump design better, please
see the exploded view in item 9.
1. Disconnect 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 ange. 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 pistons one by
one with the other hand.
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
17
180R9281 / 521B1275 / DKCFN.PI.013.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.
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
18
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
7.2 Assembling
2. Place 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.
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
19
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
7. Replace the O-ring and mount the ange.
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.
Instruction Disassembling and assembling APP S 2.0-3.5 / APP S 674 2.0-3.5
20
180R9281 / 521B1275 / DKCFN.PI.013.C4.02 / 10.2015
8. Spare parts list APP S 2.0-3.5
180B4265 - Seal set
180B4197 - Shaft seal
180B4231 - Cylinder barrel
180B4232 - Valve plate set
180B4233 - Retainer set
180B4234 - Piston set
APP S 2.0 - Swash plate on
request
APP S 2.5 - Swash plate on
request
180B4235 - Swash plate
APP S 3.0
180B4236 - Swash plate
APP S 3.5
180B4237 - Flushing valve set
Pos. Qty. Designation Material
1 1 Housing Super Duplex / PEEK
2 2 Pin AISI 316
x
5 9 Screw M8x20 AISI 316
x
9 1 O-ring NBR
x
11 1 End ange Super Duplex
31 1 Swash plate Super Duplex
x
1)
x
1)
x
1)
x
1)
32 1 Tight tting bolt Super Duplex
x
1)
x
1)
x
1)
x
1)
34 1 Pin PEEK
x
61 1 Cylinder barrel Super Duplex/PEEK
x
1)
62 1 Spring Hastelloy C4
x
63 1 Spring guide PEEK
x
64 1 Retainer ball Super Duplex
x
1)
65 1 Retainer plate Super Duplex
x
1)
66 7 Piston Super Duplex/PEEK
x
1)
67 1 Key AISI 316
x
91 1 Port plate Super Duplex/PEEK
x
92 1 Valve plate Super Duplex
x
1)
93 7 Back-up ring PTFE
x
94 7 O-ring NBR
x
121 1 Port ange 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
127 3 Screw M6x16 AISI 316
x
128 8 Screw M8x55 AISI 316
x
130 3 O-ring NBR
x
131 2 Connection cover AISI 316
132 2 O-ring NBR
x
133 8 Screw M8x25 AISI 316
x
134 3 Bleed screw M6 Super Duplex
x
2)
144 2 Tailstock screw M12 AISI 316
x
145 2 Check nut M12 AISI 316
x
152 1 Valve cone PEEK
x
153 1 Spring Hastelloy C276
x
154 1 Valve guide Super Duplex
x
2)
155 1 O-ring NBR
x
1 Press bush tools
x
1 Instruction
x x x x x x x x x x x
¹
)
Including PMI report
²
)
Including material certicate - no traceability
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Danfoss APP S 2.0-3.5 and Service guide

Danfoss
Brand
Danfoss
Model
APP S 2.0-3.5 and
Type
Service guide
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