Danfoss APP Series, APP 5.1, APP 10.2, APPW 5.1, APPW 10.2 Service Manual

Service guide

APP pumps

APP(W) 5.1-10.2 Disassembling and assembling

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Service guide | Disassembling and Assembling, APP(W) 5.1-10.2

Table of Contents

NOTE: If the pump is disassembled within the warranty period, the pump is no longer covered by the warranty.

Introduction

This document covers the instructions for disassembling and assembling the axial piston pump APP(W) 5.1-10.2

Tools needed:

• Toolset (code no. 180B4162)

• Seal set (code no. 180B4161)

• Screwdriver

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

To understand the pump design better, please see exploded view on last page.

WARNING: Do not reuse disassembled O-ring or shaft seal as they might be damaged.

Contents

Introduction ................................................................................................................................................................................2

1. Disassembling the pump ..............................................................................................................................................3

2. Assembling the pump ...................................................................................................................................................5

3. Disassembling swash plate ..........................................................................................................................................6

4. Assembling swash plate ................................................................................................................................................7

5. Change of shaft seal .......................................................................................................................................................8

6. Exploded view for APP (W) 5.1-10.2 ......................................................................................................................12

Service guide | Disassembling and Assembling, APP(W) 5.1-10.2

1. Disassembling the pump

2. Unscrew the 8 screws in the mounting ﬂange.

5. Carefully remove the shaft seal assembly using the shaft-seal extractor supplied, provided with the tool set. The extractor must ﬁt underneath the shaft seal.

7. Remove the pistons, retainer plate, stop bush and retainer ball from the cylinder barrel.

1. Unscrew the seal-retaining ring counterclockwise and remove it.

4. Wet the shaft and shaft seal with clean (ﬁltered) water.

3. Carefully remove the mounting ﬂange from the housing.

6. Remove the whole cylinder barrel and carefully place it on a suitable clean surface.

Service guide | Disassembling and Assembling, APP(W) 5.1-10.2

8. Carefully remove the valve plate assembly using a screwdriver.

11. Mount the new O-rings.

13. Remove the port plate by hand.

10. Mount the new back-up rings on the new valve plate.

9. Remove the O-rings and back-up rings from the valve plate.

12. Carefully press, by hand, the cylinder barrel onto the valve plate.

Mount backup ring ﬁrst

Then mount O-ring

Service guide | Disassembling and Assembling, APP(W) 5.1-10.2

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

WARNING: Do not reuse disassembled O-ring or shaft seal as they might be damaged.

2. Assembling the pump

5. Position all the pistons, one in each piston

bore, in the cylinder barrel. It may be necessary to tilt the retaining ring to allow the pistons to ﬁt into the piston bores.

4. Carefully position all the pistons into the retainer plate.

3. Fit the retainer guide onto the shoulder of the shaft.

7. Mount the new shaft seal following the

instructions in chapter 5 see page 8-11.

6. Position the new white stop bush on top of the retainer guide.

2. Carefully slide the cylinder barrel into the

housing.

1. When mounting the port plate position the port plate over the guide pin. IMPORTANT: Make sure that the guide pin is located in the locating hole in the port plate.

Guide pin

Service guide | Disassembling and Assembling, APP(W) 5.1-10.2

11. Mount the seal retainer ring Tighten the

ring with a torque of 60 ± 5 Nm.

Turn each screw 2 rounds at a time to

ensure the ﬂange is mounted as straight as possible Tighten the screws to a torque of 30 ±3 Nm. To prevent seizing-up, lubricate the threads on the 8 screws with grease, screw them into the pump and tighten by hand. Use Molykote® D paste from Dow Corning or Klüber UH1 84-201 from Klüber lubrication.

10. Screw the 8 screws into the ﬂange and the housing.

8. Position the guide pin in the housing.

9. Position and carefully press, by hand, the

combined ﬂange and swash plate into the housing. IMPORTANT: Ensure not to cut the O-ring.

2. Turn the mounting ﬂange upside down.1. Unscrew the screw in the mounting ﬂange.

3. Disassembling swash plate

Guide pin

Service guide | Disassembling and Assembling, APP(W) 5.1-10.2

2. Mount the spacer on the swash plate.1. Replace the O-rings.

3. Remove the swash plate and the spacer.

3. Position the swash plate on the mounting ﬂange using the guide pins and ﬁx it with the screw.

4. The mounting ﬂange is now ready to be

mounted on the housing.

4. Assembling swash plate

Service guide | Disassembling and Assembling, APP(W) 5.1-10.2

5. Change of shaft seal

1. Unscrew the seal retaining ring

counterclockwise and remove it.Tools provided according to 180B4162

3. Carefully remove the ﬂange from the

casing.

4. Wet the shaft and shaft seal with clean

ﬁltered water.

2. Unscrew the 8 screws in the mounting ﬂange.

5. Carefully remove the shaft seal assembly using the shaft-seal extractor supplied. The extractor must ﬁt underneath the shaft seal.

Service guide | Disassembling and Assembling, APP(W) 5.1-10.2

7. Scrap the old stop bush (if black) and place the new white stop bush on top of the retaining guide.

10. Slide the new shaft seal over the torpedo with the carbon seal face pointing upwards (see also drawing on last page). IMPORTANT: Be careful not to damage

the carbon seal face on the shaft seal.

6. Ensure that no dirt has entered into the

pump. IMPORTANT: If loose particles are

observed, the pump must be dismantled and thoroughly cleaned with clean ﬁltered water.

8. Fit the hollow bush (torpedo) onto the

shaft.

9. Thoroughly wet the torpedo, shaft and

replacement shaft seal with plenty of clean ﬁltered water. Do not use silicone grease.

11. Use the plastic assembly tool provided,

large diameter pointing downwards, to press the seal home against the shoulder of the spacer.

Service guide | Disassembling and Assembling, APP(W) 5.1-10.2

12. Remove the old O-ring and ﬁt the

new O-ring on the adapter.

14. Screw the 8 screws into the ﬂange and the casing. To prevent cold welding,

lubricate the threads on the 8 screws with grease, screw them into the pump

and tighten by hand. Use Molykote® D paste from Dow Corning or Klüber UH1 84-201 from Klüber lubrication.

13. Place the guide pin in the casing. Position the combined ﬂange and swash plate onto the guide pin and press it gently, by hand, into the casing. Ensure not to squeeze the O-ring.

15. Remove the ceramic ring from the seal retaining ring.

16. Wet the parts with clean ﬁltered water.

Guide pin

Service guide | Disassembling and Assembling, APP(W) 5.1-10.2

19. To prevent cold welding, lubricate the thread and O-ring on the retaining ring with grease, screw it into the pump and tighten it by hand. Use Molykote® D paste from Dow Corning or Klüber UH1 84-201 from Klüber lubrication.

20. Remount the retaining ring and tighten by hand.

18. Remove the old O-ring and ﬁt the new one

on the retaining ring (see also drawing on last page).

21. Tighten the retaining ring to a torque of

60 ± 5 Nm using the tool provided.

17. Push the new ceramic ring into the retaining ring, using the plastic tool provided. Make sure the face with the rubber seal is positioned against the shoulder in the retaining ring (see drawing on last page).

Seal retaining ring

Stop bush

Ceramic ring

Rubber seal

Carbon ring

O-ring

180R9238 | DKCFN.PI.078.F3.02 | 521B1196 | 12

Danfoss A/S

High Pressure Pumps Nordborgvej 81 DK-6430 Nordborg Denmark

6. Exploded view for APP (W) 5.1-10.2

Danfoss APP Series, APP 5.1, APP 10.2, APPW 5.1, APPW 10.2 Service Manual

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