Danfoss APP S 674 2.0-3.5 User manual

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Instruction
Disassembling and assembling
APP S 674 2.0-3.5 pumps
MAKING MODERN LIVING POSSIBLE

Instruction Disassembling and assembling APP S 674 2.0-3.5
2180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
1. Introduction ............................................................................3
2. Disassembling the pump ................................................................3
3. Assembling the pump...................................................................8
4. Disassembling and assembling of the swash plate ......................................14
5. Disassembling and assembling of cylinder barrel and valve plate........................15
6. Disassembling and assembling of the ushing valve ....................................16
7. How to replace the shaft seal ...........................................................17
8. Changing pistons ......................................................................17
8.1 Disassembling .........................................................................17
8.2 Assembling ............................................................................19
9. Exploded view APP S 674 2.0-3.5 pumps ................................................21
10. When should the pistons be replaced...................................................22
This document covers the instructions for
disassembling and assembling the axial piston
pumps APP S 674 2.0-3.5.
Table of Contents
Our CLP RO pumps have changed the name as listed below:
CLP674 050-058 RO: will now be called APP S 674 3.0-3.5
CLP 674 085-152 RO: will now be called APP S 674 5.1-9.0
CLP674 365-640 RO: will now be called APP S 674
This is ONLY a name change.

Instruction Disassembling and assembling APP S 674 2.0-3.5
3
180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
Important: It is essential that the pump is
serviced in conditions of absolute cleanliness.
For a better understanding of the pump, please
see the exploded view in item 9.
Note:
When disassembling and assembling it must
be possible to place the pump vertically with
the shaft pointing downwards. This can be
done with a distance block with a minimum
height of 50 mm.
1. Introduction Tools needed:
• 6 mm allen key
• 8 mm allen key
• Torque wrench
• 2 screwdrivers
• 1 press bush tool (part of seal kit)
• Distance block
2. Disassembling the
pump
1. Disconnect the pump from the rest of the
system.
2. Using a 6 mm allen key, unscrew the 3 bolts
from shaft seal cover.
3. Remove shaft seal bushing. 4. Remove O-ring with a small screwdriver.

Instruction Disassembling and assembling APP S 674 2.0-3.5
4180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
5. Remove ceramic ring from cover by
carefully pushing it from the back of the
sealing ring with a screwdriver.
6. Clean and then wet the shaft with clean
water.
7. Through the inlet port lever the shaft seal
with a screw driver between shaft seal and
spring. Use one hand to pull the shaft seal
up.
WARNING:
Be careful not to scratch the shaft.
8. Carefully remove the shaft seal and
distance ring.
9. Carefully remove the spring by lifting it
with a screwdriver and one hand to pull the
spring up.
10. Using a 8 mm allen key, unscrew all bolts on
the end ange.

Instruction Disassembling and assembling APP S 674 2.0-3.5
5
180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
13. Swash plate must be placed so that its
surface is not scratched. For further
disassembling of swash plate, see page 14.
11. Place pump on a distance block. Make sure
there is enough free space for the shaft
beneath the housing. Remove all bolts.
Distance
block
12. Remove end ange.
14. Remove the 2 pistons. Be careful not to
scratch the pistons.
WARNING:
Do not use any tools.
15. Remove the retainer plate with the
remaining pistons.
16. Remove the retainer ball.

Instruction Disassembling and assembling APP S 674 2.0-3.5
6180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
17. Remove the retainer guide and the spring.
18. Remove the guide pin. 19. Pull the cylinder barrel straight upwards in
a continuous lift to ensure no damage of
house bearing. This can only be done if the
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.
20. Place cylinder barrel upside down. For
further disassembling of cylinder barrel
and valve plate see page 15.
21. Remove the port plate in the housing by
hand.

Instruction Disassembling and assembling APP S 674 2.0-3.5
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180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
22. Remove the guide pin.
Note: The following operation is only
necessary if O-ring on port ange has to
be changed.
23. Turn the pump upside down. Unscrew the
8 bolts in port ange.
24. Remove bolts and port ange.

Instruction Disassembling and assembling APP S 674 2.0-3.5
8180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
3. Assembling the pump
WARNING:
Do not use silicone when assembling the
pump. Do not reuse disassembled O-rings;
they might be damaged. Always use new
O-rings.
1. Lubrication:
• To prevent seizing-up, lubricate all threads
with PTFE lubrication type.
• O-rings inside pump may be lubricated
only with clean ltered water.
• O-rings for port ange, mounting ange
and ushing valve must be lubricated.
• It is important to lubricate ALL parts to be
assembled with clean ltered water
(Especially all PEEK parts).
2. Place the housing with pump label
pointing downwards and insert guide pin
for positioning the port ange on housing.
4. Position port ange by aligning pin hole
over guide pin.
3. Mount new O-ring on port ange and
lubricate with water.
Important:
It is essential that the pump is serviced in
conditions of absolute cleanliness. All parts
must be absolute clean before mounting.

Instruction Disassembling and assembling APP S 674 2.0-3.5
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180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
6. Lubricate the threads with PTFE lubrication.
Insert screws on the port ange. Tighten
screws to a torque of 30 ± 3 Nm.
8. Position port plate by using the guide pin.
Do not use force for this operation.
9. Ensure port plate is tted tightly against
the bottom.
Important: If valve plate is disassembled
from cylinder barrel, please see page 15
before continuing.
5. Carefully press the port ange downwards.
Do not squeeze the O-ring. If the O-ring is
damaged, the pump will leak.
7. Place a 10.5 mm guide pin in the port ange.

Instruction Disassembling and assembling APP S 674 2.0-3.5
10 180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
13. Lubricate and position the retainer guide.12. Place the spring in cylinder barrel.
14. Lubricate retainer guide and position the
retainer ball.
15. Position the retainer plate.
10. Place the pump on a distance block. Make
sure, there is enough free space for the
shaft beneath the housing. Lubricate inside.
Distance
block
11. Carefully lower cylinder barrel into the
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.

Instruction Disassembling and assembling APP S 674 2.0-3.5
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180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
16. Ensure the retainer plate is oriented
correctly.
21. Screw in the rest of the bolts and tighten all
screws to a torque of 30 +/- 3 Nm.
17. Lubricate and position the pistons in the
retainer plate and cylinder barrel.
18. Lubricate the piston shoes. Tilt retainer
plate for easier placement of swash plate. If
the swash plate has been disassembled
from end ange, see page 14 for assem-
bling of swash plate. Remember to place
the guide pin in the housing.
19. Change and lubricate O-ring in the end
ange. Position end ange aligning pin
hole over the guide pin.
20. Lubricate and place two bolts in end ange.
Turn each bolt one round at a time to
ensure mounting ange is mounted as
straight downwards as possible. Be careful
not to squeeze the O-ring.

Instruction Disassembling and assembling APP S 674 2.0-3.5
12 180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
25. Lubricate shaft with clean ltered water. 26. Mount new shaft seal with the carbon seal
face pointing upwards. Press seal down and
at the same time turn the seal clockwise
until spring stops at distance ring.
24. Position the shaft seal distance ring.23. Remove old O-ring and place the new one
on shaft seal cover.
22. Lubricate and press new ceramic ring into
the shaft seal cover by using the press bush
tool.
WARNING:
Ensure that the face with rubber seal is
positioned against shoulder in shaft seal
ange.

Instruction Disassembling and assembling APP S 674 2.0-3.5
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180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
28. Position the shaft seal cover on shaft. Be
careful not to damage the ceramic ring.
WARNING!
Be careful, the shaft has sharp edges.
29. Hold the cover down with one hand and
tighten the bolts with a torque of 12 Nm
±1 Nm.
27. Right position of the spring can be
inspected through the ushing valve hole.
Shaft seal mounted.

Instruction Disassembling and assembling APP S 674 2.0-3.5
14 180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
4. Disassembling and
assembling of the
swash plate
1. Unscrew centre bolt from swash plate. 2. Remove swash plate, guide pin and O-ring.
3. Place guide pin and carefully align swash
plate over guide pins.
4. Lubricate centre bolt thread with a PTFE
lubricant type.
5. Position the centre bolt and tighten to
12 Nm ±1 Nm.
6. Finally check the surface on the swash plate
for any marks or foreign particles and place
new O-ring.
O-ring

Instruction Disassembling and assembling APP S 674 2.0-3.5
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180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
1. Carefully lift valve plate assembly free with
the aid of a screwdriver.
5. Disassembling and
assembling of cylinder
barrel and valve plate
3. Mount the new back-up rings on the valve
plate. Then mount the O-rings.
Backup-ring
O-ring
4. Lubricate the new O-rings/back-up rings
and the liners in the cylinder barrel with
clean ltred water.
2. Replace O-rings and back-up rings on valve
plate.
O-ring Backup-
ring
5. Carefully press, by hand, valve plate onto
cylinder barrel. The cylinder barrel is now
ready for mounting.

Instruction Disassembling and assembling APP S 674 2.0-3.5
16 180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
6. Disassembling and
assembling of the
ushing valve
1. Remove shaft seal cover.
3. Remove complete ushing valve set. 4. Flushing valve parts
2. Carefully push the ushing valve up
through the outlet connection, using a
small screwdriver.
5. Press a new spring onto shoulders of the
poppet guide and the poppet. The spring
must be fastened on both collars. Then
mount new O-ring on the poppet guide.
Turn ushing valve upside down. If spring is
not properly assembled, it will fall of.
6. Lubricate valve with clean ltered water
and push by hand the valve into the hole.

Instruction Disassembling and assembling APP S 674 2.0-3.5
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180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
8. Changing pistons
To understand the pump design better, please
see the exploded view in item 9.
1. Disconnect the pump from the rest of the
system or close inlet valve.
2. Loosen all screws on the pump except the
two screws as shown in the picture below.
Note: There is still water inside the pump.
3. Unscrew the remaining screws.
8.1 Disassembling
4. Remove the ange. Remove pin or ensure it
stays in place. Ensure not to scratch the
swash plate surface.
7. How to replace the
shaft seal Disassembling, please see Assembling, please see
Page 3 items 2 to 4 Page 12 item 22 to 26
Page 4 items 5 to 6 Page 13 items 27 to 29
5. While holding the retainer plate with one
hand, carefully remove the pistons one by
one with the other hand.

Instruction Disassembling and assembling APP S 674 2.0-3.5
18 180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
9. Inspect the piston liners.8. Remove guide and spring.
10. Replace any worn parts.
7. Remove retainer plate and ball.WARNING:
Ensure that the piston shoes and the
piston surfaces are not damaged during
removal. It is recommended to place the
pistons upside down on an even and
clean base/surface.
6.

Instruction Disassembling and assembling APP S 674 2.0-3.5
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180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
8.2 Assembling
1. Ensure the liner and the end of cylinder
barrel are wetted.
2. Place the spring.
3. Place the guide. 4. Place the ball on the retainer plate.
WARNING!
Ensure right assembling and placement
of the retainer plate. See item 16, page 11.
5. Place the retainer plate and hold it with one
hand. Insert the pistons one by one with
the other hand.
6. Wet the pistons.

Instruction Disassembling and assembling APP S 674 2.0-3.5
20 180R9281 / 521B1275 / DKCFN.PI.013.C3.02 / 05.2013
7. Replace the O-ring and mount the ange.
Ensure the guide pin is mounted.
8. Mount two screws as shown below and
tighten them.
9. Mount the remaining bolts and cross
tighten them to a torque of 30 Nm ± 3 Nm.
10. Connect the pump to the rest of the
system.
11. Bleed the pump before starting it.