Danfoss APP 11-13, APP 16-22 Service guide

Service guide

APP pumps

APP 11-13 and APP 16-22 Disassembling and assembling

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Service guide | Disassembling and Assembling, APP 11-13 and APP 16-22

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 ..................................................................................11

5. Disassembling and assembling of cylinder barrel and valve plate .....................................................12

6. Disassembling and assembling of the ﬂush valve ....................................................................................12

7. Changing pistons ..................................................................................................................................................13

8. Assembling ..............................................................................................................................................................15

9. When should the pistons be replaced? .........................................................................................................17

10. Exploded view APP 11-13 ..................................................................................................................................18

11. Exploded view APP 16-19 ..................................................................................................................................19

12. Exploded view APP 22 .........................................................................................................................................20

This document covers the instructions for disassembling and assembling the axial piston pumps APP 11-13 and APP 16-22.

1. Introduction

Tools provided with toolset 180B4222:

• 10 mm combination wrench

• 13 mm combination wrench

• 6 mm allen key

• Adjustable pin wrench

• Stop for retainer plate

• Press bush for valve plate

• Extractor

• M8x20 mm allen screw

• Press bush (Plastic)

• M8 mm eye bolt

• M8 mm nut

• M8 x 70 mm screw

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 100 mm.

For a better understanding of the pump, please see the exploded view on page 18, 19 and 20.

WARNING: Do not reuse disassembled O-rings or shaft seal as they might be damaged. Always use new O-rings.

Important: It is essential that the pump is serviced in conditions of absolute cleanliness.

Service guide | Disassembling and Assembling, APP 11-13 and APP 16-22

2. Disassembling the pump

1. Disconnect the pump from the rest of the system.

2. Using a 10 mm combination wrench, unscrew the four bolts from shaft seal ﬂange. If shaft seal ﬂange is stuck, screw in two bolts in holes in the ﬂange to remove it.

3. Remove ceramic ring from ﬂange by carefully pushing it from the back of the sealing ring.

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 ﬁltered water.

7. Turn pump into vertical position with shaft

pointing downwards. Ensure minimum 100 mm (3,94 inch) free space for the shaft.

6. Carefully remove the shaft seal assembly using the shaft seal extractor supplied in the toolset. The extractor must ﬁt underneath the shaft seal. Press the arms of the extractor together when turning the bolt.

8. Using a 13 mm combination wrench, remove all the bolts on the mounting ﬂange except the three shown in the next picture.

WARNING:

Do not loosen the two screws keeping swash plate in place.

Service guide | Disassembling and Assembling, APP 11-13 and APP 16-22

9. Unscrew the remaining three bolts. Turn

each bolt one round at the time to make sure that the ﬂange is removed as straight forward as possible.

10. Screw the eye bolt in the M8 hole in the middle of the ﬂange. Pull it straight upwards.

11. Swash plate must be placed so that its

surface is not scratched. For further disassembling of swash plate, see page 11.

13. Remove the retainer plate and the retainer

ball. Note: As the retainer ball is not attached

to the retainer plate, it might fall out.

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.

14. Remove the retainer guide, the 4 springs and the spring guide.

Service guide | Disassembling and Assembling, APP 11-13 and APP 16-22

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.

16. Place cylinder barrel upside down. For further disassembling of cylinder barrel and valve plate see page 12.

17. Remove the port plate by hand.

19. Place the pump horizontally.

20. Remove the remaining screws in port

ﬂange by using a 13 mm combination wrench. Carefully separate house and port ﬂange. Ensure that pin for the positioning house is not lost.

18. Remove, by hand, the two pins. Note: The following operation is only

necessary if O-ring on port ﬂange is to be changed.

21. For further disassembling of ﬂush valve, see page 12.

Service guide | Disassembling and Assembling, APP 11-13 and APP 16-22

3. Assembling the pump WARNING:

Do not use silicone when assembling the pump. Do not reuse disassembled O-rings; they might be damaged. Always use new O-rings.

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.

Important: It is essential that the pump is serviced in conditions of absolute cleanliness. All parts must be absolute clean before mounting.

1. Lubrication:

• To prevent seizing-up, lubricate all threads with PTFE lubrication type.

• O-rings inside pump may be lubricated only with clean ﬁltered water.

• O-rings for port ﬂange, mounting ﬂange and ﬂushing valve must be lubricated.

• It is important to lubricate ALL parts to be assembled with clean ﬁltered water (Especially all PEEK parts).

3. Insert guide pin for positioning housing

on port ﬂange. Ensure that two screw holes can be reached from below.

2. Place port ﬂange with O-ring pointing upwards.

4. Mount the O-ring. Remember lubrication of the O-ring with clean ﬁltered water.

5. Position housing by aligning pin hole over guide pin.

6. Gently press downwards. Be careful not to squeeze the O-ring. If O-ring is damaged the pump will leak.

Service guide | Disassembling and Assembling, APP 11-13 and APP 16-22

7. Screw in at least two screws from below.

8. Place housing horizontally. Screw in the rest of the screws on port ﬂange. Tighten screws according to exploded view.

9. Place pump vertically. Place 10.5 mm pins

in port ﬂange.

10. Position port plate by using the two pins.

Do not use force for this operation.

13. Make sure there is enough free space for

the shaft beneath the housing. Minimum 100 mm (3,94 inch). Carefully lower cylinder barrel into housing.

11. Ensure port plate is ﬁtted tightly against the bottom.

IMPORTANT:

Lubricate port plate with clean ﬁltered fresh water.

If valve plate is disassembled from cylinder barrel please see page 12 before continuing.

12. Screw eye bolt in cylinder barrel.

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.

Service guide | Disassembling and Assembling, APP 11-13 and APP 16-22

15. Place the 7 springs and 3 pins in cylinder

barrel. The pin holes are assymetric.

17. Place retainer plate in cylinder barrel.

Note:(Remember to lubricate the

retainer plate and cylinder bushings with clean ﬁltered water).

16. Place the spring guide and the retainer guide on the cylinder shaft.

18. Ensure that retainer plate is oriented correctly, i.e. with its slant surfaces pointing downwards.

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 ﬂange, see page 11 for assembly of swash plate.

20. Place the guide pin in the housing.

21. Lubricate piston shoes and swash plate with clean ﬁltered water.

22. Mount assembled swash plate, using the guide pin.

Danfoss APP 11-13, APP 16-22 Service guide

Specifications and Main Features

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