Danfoss APP(W) 5.1, APP(W) 10.2 Service guide

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

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

Introduction

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

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

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.

Tools needed:

• Toolset (code no. 180B4162)

• Seal set (code no. 180B4161)

• Screwdriver

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

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

1. Disassembling the pump

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

3. Carefully remove the mounting ﬂange from the housing.

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, provided with the tool set. The extractor must ﬁt underneath the shaft seal.

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

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

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

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

Mount backup ring ﬁrst

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

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

Then mount O-ring

11. Mount the new O-rings.

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

13. Remove the port plate by hand.

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

2. Assembling the pump

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

Guide pin

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.

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

2. Carefully slide the cylinder barrel into the

housing.

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

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

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

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.

7. Mount the new shaft seal following the

instructions in chapter 5 see page 8-11.

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

8. Position the guide pin in the housing.

Guide pin

9. Position and carefully press, by hand, the

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

3. Disassembling swash plate

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

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.

11. Mount the seal retainer ring Tighten the

ring with a torque of 60 ± 5 Nm.

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

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

3. Remove the swash plate and the spacer.

4. Assembling swash plate

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

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

4. The mounting ﬂange is now ready to be

mounted on the housing.

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

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.

3. Carefully remove the ﬂange from the

casing.

4. Wet the shaft and shaft seal with clean

ﬁltered water.

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

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.

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.

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.

Guide pin

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.

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.

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

16. Wet the parts with clean ﬁltered water.

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

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).

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.

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

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

20. Remount the retaining ring and tighten by hand.

Seal retaining ring

Ceramic ring

21. Tighten the retaining ring to a torque of

60 ± 5 Nm using the tool provided.

Rubber seal

Carbon ring

O-ring

Stop bush

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

Danfoss A/S

High Pressure Pumps Nordborgvej 81 DK-6430 Nordborg Denmark

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

Danfoss APP(W) 5.1, APP(W) 10.2 Service guide

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