Danfoss 180F4161 User manual

Service guide
Vane pump upgrade kit 180F4161
iSave 21 ERD
Disassembling and assembling
hpp.danfoss.com

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161
2180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017
Table of Contents
1. General Introduction
Contents
1. General Introduction........................................................................2
1.1 Parts included in the vane pump upgrade kit 180F4161 .....................................2
2. Disassembling the iSave ................................................................3
2. Disassembling the vane pump ..........................................................4
3. Assembling the vane pump - with parts from the vane pump upgrade kit ................6
4. Assembling the iSave....................................................................9
5. Exploded view vane pump .............................................................10
6. Exploded view iSave ...................................................................11
1.1 Parts included in the vane pump
upgrade kit 180F4161
This document covers the instructions for
installing the vane pump upgrade kit 180F4161.
Important: It is essential that the iSave and
vane pump are serviced in conditions of abso-
lute cleanliness.
For a better understanding of the vane pump and
iSave, please see the exploded views in the sec-
tions 5 and 6.
The weight of the iSave is 65 kg / 143 lb
and it must be lifted with suitable lifting
equipment.
To prevent cold welding, lubricate threads of
screws with grease; screw them into the compo-
nent and tighten them by the hand. Use PTFE
lubrication type.
Tools needed for upgrading vane pump::
- 10 mm socket
- Torque wrench
- Adjustable spanner
- Loctite 270
- 6 mm allen key socket (160 mm long)
Qty. Description
1Stator ring
8Vanes
1Side plate out
1 Side plate in
4 Peek pin Ø6.9
2Pin Ø6x10
2Pin Ø4x9
3O-ring 112x2.5
1O-ring 44x3
1 O-ring 80x2
2 Steel location pin for stator ring
10 Screws for M8x16
10 Screws for M8x25
8Screws for M8x65

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161
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180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017
1. Place the iSave on a clean table.
3. Remove the vane pump.
2. Unscrew the bolts in the flange.
2. Disassembling the
iSave

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161
4180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017
1. Gently adjust the spanner wrench around
the coupling and use it as back stop.
3. Remove all bolts in the HP out connection
flange.
2. Unscrew the bolt in the middle of the
coupling and remove the coupling.
4. Remove the flange.
5. Remove side plate and pin
2. Disassembling the
vane pump
6. Side plate removed.

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161
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180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017
7. Gently remove the rotor.
Note: Loose parts inside the rotor.
8. Remove vanes.
9. Gently remove side plate and pin. 10. Remove the int. flange

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161
6180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017
3. Assembling the vane
pump - with parts from
the vane pump
upgrade kit
1. Place the new O-ring and guide pin in
the int. flange. 2. Place the new side plate on the int.
flange.
3. Side plate mounted correct. 4. Place new stator ring on the int. flange.
5. Turn the vane pump around, so the int.
flange faces up. Fasten screws with a
torque according to exploded view.
6. Place the 4 new pins in the rotor.

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161
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180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017
7. Gently place the rotor in the bearing. 8. Position the 8 new vanes in the rotor.
The pins may be moved by using a
screwdriver.
9. Check that all vanes are positioned
correctly.
10. One vane is NOT positioned correctly.
11. Replace the new O-ring on the flange and
wet the flange properly with clean filtered
water.
12. Position the new side plate over the guide
pin.

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161
8180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017
13 Make sure that the new guide pin is located
in the locating hole in the side plate. See
#12.
14. Place the pump housing with the pin
orientated upwards. Fit the flange
including side plate into both the bearing
in the flange and in the stator.
15. Make sure that the guide pin is located in
the location hole.
16. Change the new O-ring in the HP out
connection flange.
18. Fit the coupling into the pump.
Glue the threat on the bolt with “Loctite
270” and tighten the bolt with a torque
according to exploded view.
17. Bolt the flange onto the vane pump.
Tighten the bolt witha torque according
to exploded view.
Ten new
screws

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161
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180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017
19. Change the two new O-rings in the
flange.
4. Assembling the
iSave
1. Fit the steel coupling onto the shaft of the
pressure exchanger.
Correct
positions
2. Fit the polymer coupling insert on the
steel coupling. Note correct position of
the hole in the insert.
3. Orient both the steel coupling and the
2 guide holes on the vane pump to fit into
the pressure exchanger.
4. Mount the bolts into the flange and tighten
them a torque according to exploded
view,
20. Install the 2 new labels on top of each
product label to cover the old code no. as
illustrated above.
Spare parts must be ordered according to
the new code no. 180F7018

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161
10 180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017
5. Exploded view
vane pump
Dimensions without tolerances acc. To ISO 2768-1 designation C.

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161
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180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017
6. Exploded view iSave
Dimensions without tolerances acc. To ISO 2768-1 designation C.

Danfoss A/S
High Pressure Pump
Nordborgvej 81
DK-6430 Nordborg
Denmark
© Danfoss | DCS (im) | 2017.10 180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 06 | 12