Service guide

Vane pump upgrade kit 180F4161iSave 21 ERDDisassembling and assembling

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Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161

2 180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017

Table of Contents

1. General Introduction

Contents

1. General Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21.1 Parts included in the vane pump upgrade kit 180F4161 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22. Disassembling the iSave . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32. Disassembling the vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43. Assembling the vane pump - with parts from the vane pump upgrade kit . . . . . . . . . . . . . . . . 64. Assembling the iSave. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95. Exploded view vane pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106. 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

1 Stator ring

8 Vanes

1 Side plate out

1 Side plate in

4 Peek pin Ø6.9

2 Pin Ø6x10

2 Pin Ø4x9

3 O-ring 112x2.5

1 O-ring 44x3

1 O-ring 80x2

2 Steel location pin for stator ring

10 Screws for M8x16

10 Screws for M8x25

8 Screws for M8x65

Service guide | Disassembling and assembling iSave 21 vane pump with upgrade kit 180F4161

3180R9402 | 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

4 180R9402 | 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

5180R9402 | 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

6 180R9402 | 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

7180R9402 | 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

8 180R9402 | 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

9180R9402 | 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.

Correctpositions

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

11180R9402 | 521B1455 | DKCFN.PI.003.T1.02 | 10.2017

6. Exploded view iSave

Dimensions without tolerances acc. To ISO 2768-1 designation C.

Danfoss A/SHigh Pressure PumpNordborgvej 81DK-6430 NordborgDenmark

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