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

Service guide

APP pumps

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

hpp.danfoss.com

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.

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

23. Place three bolts in mounting ﬂange.

(Remember lubrication as stated in paragraph 1 page 6.) Turn each bolt one round at a time to ensure mounting ﬂange is mounted as straight downwards as possible. Be careful not to squeeze the O-ring.

24. Screw in the rest of the bolts and tighten all screws according to exploded view.

25. Place pump horizontally to get access to

shaft.

26. Lubricate shaft with clean ﬁltered water.

28. Use plastic press bush assembly tool

provided with large diameter pointing towards seal, to press seal against shoulder of stop for shaft seal.

27. Place stop for shaft seal and new shaft seal on shaft. WARNING: Ensure that carbon ring is

pointing outwards. Do not reuse the shaft seal, due to risk of leakage.

29. Press new ceramic ring into shaft seal ﬂange, using plastic tool provided.

WARNING: Ensure that the face with rubber seal is positioned against shoulder in shaft seal ﬂange. Ensure that ceramic ring is pointing outwards.

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

30. Remove old O-ring and ﬁt new one on

shaft seal ﬂange.

32. Tighten the bolts with a torque according

to exploded view.

31. Place shaft seal ﬂange on shaft.

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

4. Disassembling and assembling of the swash plate

WARNING: Make sure that the surface on the swash plate does not get any marks.

1. Place the swash plate upside down.

Remove the 2 bolts holding the swash plate. Remove the mounting ﬂange from the swash plate.

O-rings

Guide pins

2. Check that the O-ring and pin are in good condition (Provided with sealing set).

3. Change the O-ring on the mounting

ﬂange.

5. Mount the assembled part on the

pump. (Remember to lubricate the O-ring).

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 torque of 30 Nm +/-2 Nm. Finally check the surface on the swash plate for any marks or foreign particles.

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

5. Disassembling and assembling of cylinder barrel and valve plate

1. Push a screwdriver into the hole between

cylinder barrel and valve plate. Carefully push downward the screwdriver so that it makes a gap between cylinder barrel and valve plate. Use this gap to put in another screwdriver and loosen the valve plate from the cylinder barrel.

Mount

backup

rings ﬁrst

Mount then

O-rings

2. Remove the O-rings and backup rings. If they have been removed they can not be reused. Mount the new back-up rings on the valve plate ﬁrst and then mount the O-rings.

6. Disassembling and assembling of the ﬂush valve

3. Lubricate the new O-rings/back-up rings

and the liners in the cylinder barrel with clean ﬁltered water. Lower the valve plate upside down on the cylinder barrel. Place the press bush for valve plate (provided in tool set) like on the picture. Screw the bolt into the shaft of the cylinder barrel. Turn the nut slowly clockwise. The valve plate must slide carefully into the cylinder barrel. Stop when the gap between cylinder barrel and valve plate is 1-2 mm.

1. Unscrew the ﬂush valve counter-clockwise

by using a pin wrench.

4. Remove the press bush again by screwing the nut counter-clockwise.

Turn the nut slowly clockwise. The valve plate must slide gently into the cylinder barrel. Stop when the gap between cylinder barrel and valve plate is 1–2 mm.

2. Remove the O-rings (green and black). If necessary, change the valve cone, spring and plug. If the spring is changed it is important that it is located like on the picture. The end of the spring must be against the shoulder of the valve cone.

3. Put a little amount of grease on the thread on the plug. Screw it into the port ﬂange. Tighten with a torque according to exploded viewv.

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

7. Changing pistons

Tools needed are:

• 13 mm combination wrench

• 6 mm allen key

Service kit see parts list 521B0941

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

1. Disconnect the pump from the system, or

close all connection pipes (water supply). Bleed water from the pump.

3. Unscrew the remaining 3 screws using the combination wrench and turn each screw a couple of rounds at the time, to ensure the swash plate is loosened as straight backwards as possible.

Note: There is nothing to hold the swash plate!

Warning: Never unscrew the 2 screws marked with coloured sealer.

2. Loosen all screws on the pump except the 3 screws as shown in the picture above, using the 13 mm combination wrench.

4. Remove the ﬂange/swash plate carefully.

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

5. Place the swash plate upside down to

avoid scratches on the surface.

7. It is recommended to place the pistons upside down on an even clean base/ surface.

Warning: Ensure that the piston shoes and piston surfaces are not damaged or scratched during removal.

6. Carefully remove the pistons one by one.

8. Remove the retainer plate.

9. Inspect the piston bushings in the cylinder barrel for scratches or othe damages. Small scratches are accepted if there are no hard particles in the bushings.

If any worn pistons are found, all pistons must be replaced. See page 17.

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

8. Assembling

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

All parts must be absolute clean before mounting

1. Carefully push the retainer plate in place. 2. Ensure that the retainer plate is oriented correctly with its slant surfaces pointing downwards.

3. Insert all the pistons randomly.

4. Tilt the retainer plate for easy insert of the swash plate. Place the pin in the housing.

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

5. Replace the O-ring on mounting ﬂange.

7. Mount the 3 screws as shown below. Turn each screw a couple of rounds at the time, to ensure the swash plate is pulled as straight forward as possible.

Note: Be careful not to squeeze/damage the O-ring.

6. Carefully insert the swash plate into the housing.

8. Insert the remaining screws and cross tighten them according to exploded view.

9. Connect the pump to the rest of the

system. Bleed the pump. Follow the start-up procedures, see instruction 180R9223.

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

9. When should the pistons be replaced?

This section provides guides on how to determine whether the pistons of APP 11-13 and 16-22 are worn and should be replaced.

Note: If the pistons break down, the pump will suﬀer a disastrous breakdown.

1. INo wear or cavitation of the piston shoe. New inspection is required within 4,000 hours.

In case of doubt - the pistons must be replaced. If any worn pistons are found, all pistons must be replaced.

The pictures below are meant as guideline for evaluating the wear of the sliding surface.W

2. Cavitation of the piston shoes. New inspection is required within 2,000 hours.

3.. Cavitation of the piston shoes. All pistons must be replaced within the next 1,000 hours.

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

10. Exploded view APP 11-13

lbf ft]

[22.13 lbf ft ± 2.21

[7.38 lbf ft ± 1.47 lbf ft]

[22.13 lbf ft ± 2.21 lbf ft]

[1.47 lbf ft ± 0.74 lbf ft]

[22.13 lbf ft

± 2.21 lbf ft]

[1.47 lbf

ft ± 0.74 lbf ft]

[22.13 lbf ft

± 2.21 lbf ft]

[1.47 lbf ft

± 0.74 lbf ft]

[7.38 lbf ft ± 1.47 lbf ft]

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

11. Exploded view APP 16-19

[22.13 lbf ft ± 2.21 lbf ft]

[7.38 lbf ft ± 1.47 lbf ft]

± 1.47 lbf ft]

[7.38 lbf ft

[22.13 lbf ft ± 2.21 lbf ft]

[1.47 lbf ft

± 0.74 lbf ft]

[7.38 lbf ft ± 1.47 lbf ft]

[1.47 lbf ft

± 0.74 lbf ft]

[22.13 lbf ft ± 2.21 lbf ft]

[1.47 lbf ft

± 0.74 lbf ft]

[22.13 lbf ft

± 2.21 lbf ft]

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

12. Exploded view APP 22

[22.13 lbf ft ± 2.21 lbf ft]

[7.38 lbf ft ± 1.47 lbf ft]

[1.47 lbf ft

± 0.74 lbf ft]

[22.13 lbf ft ± 2.21 lbf ft]

± 1.47 lbf ft]

[7.38 lbf ft

[1.47 lbf ft

± 0.74 lbf ft]

[22.13 lbf ft ± 2.21 lbf ft]

[1.47 lbf ft

± 0.74 lbf ft]

[22.13 lbf ft

± 2.21 lbf ft]

[7.38 lbf ft ± 1.47 lbf ft]

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

Danfoss A/S High Pressure Pumps DK-6430 Nordborg Denmark

180R9228 | 521B1181 | DKCFN.PI.013.V3.02 | 24

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

Specifications and Main Features

Frequently Asked Questions

User Manual