Danfoss APP 21-43 User manual

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Instruction
APP pump instruction
APP 21-43
MAKING MODERN LIVING POSSIBLE
Instruction
Disassembling and assembling
APP 21-43

Instruction Disassembling and assembling APP 21-43
2180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 06.2013
This document covers the instructions for
disassembling and assembling the axial piston
pumps APP 21-43.
Tools provides with toolset 180B4172:
10 mm combination wrench
13 mm combination wrench
6 mm allen key
Adjustable pin wrench
Stop for retainer plate
Press bush for valve plate
Shaft seal extractor ø 45
M8 allen screw (20 mm and 140 mm)
Press bush ø 45 (Plastic)
M8 mm eye bolt
M8 mm nut
M8 x 70 mm screw
Important: It is essential that the pump is
serviced in conditions of absolute cleanliness.
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.
For a better understanding of the pump, please
see exploded view on page 12 and 13.
WARNING:
Do not reuse disassembled O-rings or shaft
seal as they might be damaged. Always use
new O-rings.
Note: It is essential that the pump is serviced
in conditions of absolute cleanliness.
2. Disassembling
1. Introduction
1. Introduction ............................................................................2
2. Disassembling ..........................................................................2
3. Disassembling the pump ................................................................3
4. Assembling the pump...................................................................6
5. Disassembling and assembling of the swash plate ......................................10
6. Disassembling and assembling of of cylinder barrel-/ valve ..............................11
7. Disassembling and assembling of the flush plate........................................11
8. Exploded view APP 21-26, APP 30/1500.................................................12
9. Exploded view APP 30/1200, APP 38/1500, APP 43/1700.................................13
Table of Contents

Instruction Disassembling and assembling APP 21-43
3
180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013
3. Disassembling
the pump
1. Disconnect the pump and motor from the
system. Remove non-return valve and
connector from the pump.
2. Using a 10 mm combination wrench, unscrew
the four bolts from shaft seal flange.
If shaft seal flange is stuck, place two bolts in
screw holes in shaft seal flange to remove it.
4. Mount the M8 allen screw from the tool set in
the top of the shaft.
3. Remove ceramic ring from flange by gently
pushing it from the back of the sealing ring.
5. Wet the shaft and shaft seal with clean filtered
water.
7. Turn pump into vertical position with shaft
pointing downwards.
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.

Instruction Disassembling and assembling APP 21-43
4180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013
8. Using a 13 mm combination wrench, remove
all the bolts on the mounting flange except
the three shown in picture 9.
WARNING:
Do not loosen the two screws keeping
swash plate in place.
10. Screw the eye bolt in the M8 hole in the
middle of the flange. Pull it straight upwards.
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.
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.
11. Swash plate must be placed so that its surface
is not scratched. For further disassembling of
swash plate, see page 10.
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.

Instruction Disassembling and assembling APP 21-43
5
180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013
14. Remove the retainer guide, the 4 springs and
the spring guide.
16. Place cylinder barrel upside down.
For further disassembling of cylinder barrel
and valve plate see page 11.
18. Remove, by hand, the two guide pins.
Note: The following operation is only
necessary if O-ring on port ange is to be
changed.
20. Remove the remaining screws in port flange
by using a 13 mm combination wrench.
21. Carefully separate house and port flange.
Ensure that guide pin for the positioning
house is not lost.
For further disassembling of flush valve, see
page 11.
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.
17. Remove the port plate by hand.
19. Place the pump horizontally.

Instruction Disassembling and assembling APP 21-43
6180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013
4. Assembling the pump
1. Lubrication
• To prevent seizing-up, lubricate threads on
screws.
• O-rings inside pump may be lubricated only
with clean filtered water.
• O-rings for port flange, mounting flange
and black O-ring on flushing valve may be
lubricated with a small amount of grease.
• 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.
5. Position housing aligning pin hole over
guide pin.
6. Gently press downwards. Be careful not to
squeeze O-ring. If O-ring is damaged, the
pump will leak.
7. Screw in at least two screws.
4. Mount O-ring.
2. Place port flange with O-ring pointing upwards.
IMPORTANT:
It is essential that the pump is serviced in
conditions of absolute cleanliness. All parts
must be absolute clean before mounting.
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.
WARNING:
Do not use silicone when assembling the
pump. Do not reuse dismantled O-rings;
they might be damaged. Always use new
O-rings.

Instruction Disassembling and assembling APP 21-43
7
180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013
8. Place housing horizontally. Screw in the rest of
the screws on port flange. Tighten screws to a
torque of 30 ± 2 Nm.
10. Position port plate by using the two guide pins.
Do not use force for this operation. 12. Screw eye bolt in cylinder barrel.
14. Unscrew M5 eye bolt.
15. Place the four springs and spring guide in
cylinder barrel. Springs must be positioned in
the holes.
13. Make sure there is enough free space for
the shaft beneath the housing. Gently lower
cylinder barrel into housing.
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.
9. Place pump vertically. Place 10.5 mm guide pins
in port flange.
11. Ensure port plate is fitted tightly against the
bottom.
IMPORTANT:
Lubricate port plate with clean ltered fresh
water.
If valve plate is disassembled from cylinder
barrel please see page 11 before continuing.

Instruction Disassembling and assembling APP 21-43
8180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013
16. Retainer guide, retainer ball and retainer plate
must be mounted in the order indicated in
picture below.
18. Place retainer plate in cylinder barrel.
Note: If pistons are replaced, place new
pistons in clean ltered water for a couple of
minutes. Exercise piston shoes to make them
“run” smoother.
20. Lubricate piston shoes and swash plate with
clean filtered water.
22. Place three bolts in mounting flange.
Turn each bolt one round at a time to ensure
mounting flange is mounted as straight
downwards as possible. Be careful not to
squeeze O-ring.
21. Remember to place the guide pin in the
housing.
23. Screw in the rest of the bolts and cross tighten
all screws to a torque of 30 +/- 2 Nm.
Note: Screws for lifting eye are shorter than the
rest.
17. Ensure that retainer plate is oriented correctly,
ie with its slant surfaces pointing downwards.
19. Place pistons in retainingplate and cylinder
barrel. When pistons are placed, tilt retaining
plate for easier placement of swash plate.
If swash plate has been disassembled from
mounting flange, see page 10 for assembly of
swash plate.

Instruction Disassembling and assembling APP 21-43
9
180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013
24. Place pump horizontally to get access to shaft.
Shaft seal
25. Lubricate shaft with clean filtered water.
26. Place stop for shaft seal and shaft seal on shaft.
WARNING:
Ensure that carbon ring is pointing outwards.
28. Press new ceramic ring into retainer ring by
using plastic tool provided.
WARNING:
Ensure that the face with rubber seal is
positioned against shoulder in shaft seal
ange.
30. Place shaft seal flange on shaft. Tighten the
bolts with a torque of 10Nm +/-2 Nm.
27. Use plastic assembly tool provided with
large diameter pointing downwards, to press
seal home against shoulder of stop for shaft seal.
29. Remove old O-ring and fit new one on shaft
seal flange.

Instruction Disassembling and assembling APP 21-43
10 180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013
5. 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.
3. Change the O-ring on the mounting flange.
5. Mount the assembled part on the pump.
4. Mount the swash plate on the 2 guide 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.
2. Check that the O-ring and pin are in good
condition. (Provided with sealing set).

Instruction Disassembling and assembling APP 21-43
11
180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013
Mount
back-up rings
first
Mount then
O-rings
6. Disassembling and
assembling of cylinder
barrel-/ valve plate
7. Disassembling and
assembling of the
ush valve
1. Push a screwdriwer into the hole between
cylinder barrel and valve plate. Gently 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.
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
cylinder barrel.
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.
1. Unscrew the flush valve counter-clockwise by
using a pin wrench.
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 of 30 Nm +/- 3 Nm.
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.
4. Remove the press bush again by screwing the
nut counter-clockwise.
Mount the cylinder barrel into the pump.

Instruction Disassembling and assembling APP 21-43
12 180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013
8. Exploded view
APP 21-26 and APP 30/1,500
[22.13 lbf ft ± 2.21 lbf ft]
[22.13 lbf ft ± 2.21 lbf ft]
[22.13 lbf ft ± 2.21 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]
[7.38 lbf ft ± 1.47 lbf ft]
[7.38 lbf ft ± 1.47 lbf ft]
[1.47 lbf ft ± 0.74 lbf ft]
[7.38 lbf ft ± 1.47 lbf ft]
[7.38 lbf ft ± 1.47 lbf ft]
[22.13 lbf ft ± 2.21 lbf ft]

Instruction Disassembling and assembling APP 21-43
13
180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013
9. Exploded view
APP 30/1,200, APP 38/1,500, APP 43/1,700
[22.13 lbf ft ± 2.21 lbf ft]
[22.13 lbf ft ± 2.21 lbf ft]
[22.13 lbf ft ± 2.21 lbf ft]
[22.13 lbf ft ± 2.21 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]
[7.38 lbf ft ± 1.47 lbf ft]
[7.38 lbf ft ± 1.47 lbf ft]
[7.38 lbf ft ± 1.47 lbf ft]
[7.38 lbf ft ± 1.47 lbf ft]
[22.13 lbf ft ± 2.21 lbf ft]

Instruction Disassembling and assembling APP 21-43
14 180R9121 / 521B1018 / DKCFN.PI.013.A4.02 / 10.2013
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice.
This also applies to products already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
Danfoss A/S
High Pressure Pumps
DK-6430 Nordborg
Denmark