isave.danfoss.com
Service instruction
Disassembling and assembling
iSave 21
MAKING MODERN LIVING POSSIBLE
Tel:+44(0)1706869777
E‐mail:sales@desal.co.uk
Web:www.desal.co.uk
Service instruction Disassembling and assembling iSave 21
2
180R9219 / 521B1171 / DKCFN.PI.0 03.K3.02 / 11.2013
1. General introduction....................................................................2
2. Disassembling the iSave.................................................................3
3. Disassembling the pressure exchanger ..................................................4
4. Assembling the pressure exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
5. Disassambling the vane pump..........................................................12
6. Assembling the vane pump ............................................................13
7. Assembling the iSave ..................................................................17
8. Exploded view vane pump ...................................................... 18
9. Exploded view pressure exchanger............................................... 19
10. Exploded view iSave ...................................................................20
Table of Contents
This document covers the instructions for
disassembling and assembling the iSave 21.
Important: It is essential that the iSave is
serviced in conditions of absolute cleanliness.
For a better understanding of the iSave, please
see the exploded view in item 8, 9 and 10.
The weight of the iSave is 65 kg / 143 lb
and it must be lifted with suitable lifting
equipment.
The weight of the pressure exchanger alone is
28 kg / 62 lb.
It is essential that the iSave is serviced in
conditions of absolute cleanliness
To prevent cold welding, lubricate threads of
screws with grease screw them into the component and tighten them by the hand. Use PTFE
lubrication type.
Tools needed for disassembling the iSave:
- 6 mm and 8 mm allen key
- 2 screwdrivers
- 2 M8 bolts
- Plastic tube
- Plastic tool for shaft seal assembly
- Loctite 270
Torque wrench with special socket
Code no. 180Z0610
1. General Introduction
Service instruction Disassembling and assembling iSave 21
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180R9219 / 521B1171 / DKCFN.PI.0 03.K3.02 / 11.2013
2. Disassembling
the iSave
1. Place the iSave on a clean table.
3. Remove the vane pump.
2. Unscrew the bolts in the ange.
Service instruction Disassembling and assembling iSave 21
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180R9219 / 521B1171 / DKCFN.PI.0 03.K3.02 / 11.2013
3. Disassembling the
pressure exchanger
1. Unscrew the bolts in the ange.
3. Gently push out the ange.
2. Screw in the two M8 bolts.
4. Wet the shaft and shaft seal with clean
ltered water. Gently lever the shaft
assembly free using 2 screwdrivers.
5. Unscrew the bolts in the ange. 6. Gently remove the ange.
Note: Loose parts on the inside of the ange.
Service instruction Disassembling and assembling iSave 21
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180R9219 / 521B1171 / DKCFN.PI.0 03.K3.02 / 11.2013
7. Gently remove the cylinder barrel.
9. Gently remove the housing.
Note: Loose parts on the inside of the ange.
8. Unscrew the bolts in the ange.
10. Remove port plate and pin.
Pin
11. Unscrew high-pressure bearing using a
special socket.
Service instruction Disassembling and assembling iSave 21
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180R9219 / 521B1171 / DKCFN.PI.0 03.K3.02 / 11.2013
13. Remove the high-pressure bearing. 14. Gently lift the valve plate assembly free
with the aid of the screwdrivers.
15. Gently remove both valve plates. 16. Replace the O-rings and the back-up rings
on the valve plate.
4. Assembling the
pressure exchanger
2. Lubricate all the bores in the cylinder barrel
with grease and clean ltered water.
1. Mount the new back-up rings on the valve
plate rst and then the new O-rings.
Service instruction Disassembling and assembling iSave 21
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180R9219 / 521B1171 / DKCFN.PI.0 03.K3.02 / 11.2013
18. Adjust the distance between the cylinder
drum and the secon d valve plate.
The distance must be about 4-6 mm.
This is not critical.
3. Gently press, by hand, the rst valve plate
onto the cylinder barrel.
Note: don’t scratch the valve plate when
placing it on the plastic tube.
4. Gently press, by hand, the second valve
plate onto the cylinder barrel by placing it
on the plastic tube.
Note: don’t scratch the valve plate when
placing it on the plastic tube.
The distance must be about 4-6 mm.
This is not critical.
5. Adjust the distance between the cylinder barrel
and the second valve plate (short shaft end).
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