INSTRUCTION

Internal pump elements

APP5.1-10.2
180R9093

180R9093
This document covers the instructions for changing internal pump elements on the axial piston pumps APP5.1‑10.2.

Note: It is essential that the pump is serviced in conditions of absolute cleanliness.

Tools needed:
4. Wet the shaft and shaft seal with clean (filtered) soap-water.
• Shaft seal tool (code no. 180B4162)
• Service set shaft seal (code no. 180B4161) 5. Carefully remove the shaft seal assembly using the shaft-seal
• Screwdriver extractor supplied, provided with the tool set. The extractor
must fit underneath the shaft seal.

To understand the pump design better, please see exploded view on last
page.

1. Unscrew the seal-retaining ring counterclockwise and remove

it.

2. Unscrew the 8 screws in the mounting flange.

6. Remove the whole cylinder barrel and carefully place it on a

suitable clean surface.

3. Carefully remove the mounting flange from the housing.

521B0740 DKCFN.PI.013.ED5.02 07-2008

 7. Remove the pistons, retaining plate, distance ring and retaining 12. Carefully press, by hand, the cylinder barrel onto the valve plate.
ball from the cylinder barrel.

13. Position the port plate over the guide pin.

IMPORTANT: Make sure that the guide pin is located in the
locating hole in the port plate.

Guide pin

8. Carefully remove the valve plate assembly using a screwdriver.

9. Remove the O-rings and back-up rings from the valve plate. 14. Carefully slide the cylinder barrel into the housing.
10. Mount the new back-up rings on the new valve plate.

11. Mount the new O-rings.

Mount backup ring first

Then mount O-ring

2 DKCFN.PI.013.ED4.02 521B0740
 15. Fit the retaining ball onto the shoulder of the shaft. 19. Mount the new shaft seal following the instructions in ”Shaft
Seal - APP 5.1 - 10.2” (521B0738).

16. Carefully position all the pistons into the retaining ring.

17. Position all the pistons, one in each piston bore, in the cylinder
barrel. It may be necessary to tilt the retaining ring to allow the
pistons to fit into the piston bores.
20. Unscrew the screw.

21. Turn the mounting flange upside down.

18. Position the new white spacer on top of the retaining ball.

22. Remove the swash plate and the spacer.

521B0740 DKCFN.PI.013.ED4.02 3
 27. Position the guide pin in the housing.

23. Replace the O-rings.

Guide pin

28. Position and carefully press, by hand, the combined flange and
swash plate into the housing.
24. Mount the spacer on the swash plate. IMPORTANT: Ensure not to cut the O-ring.

29. Screw the 8 screws into the flange and the housing.
Turn each screw 2 rounds at a time to ensure the flange is
mounted as straight as possible
25. Position the swash plate on the mounting flange using the Tighten the screws to a torque of 30 ±3 Nm.
guide pins and fix it with the screw. To prevent seizing-up, lubricate the threads on the 8 screws
with grease, screw them into the pump and tighten by hand.
Use Molykote® D paste from Dow Corning or Klüber UH1 84-201
from Klüber lubrication.

30. Mount the seal retainer ring

Tighten the ring with a torque of 30 ±3 Nm.

26. The mounting flange is now ready to be mounted on the

housing.

4 DKCFN.PI.013.ED4.02 521B0740
 Parts list for APP 5.1-10.2

180B4161 - Sealset (APP5,1-10,2)

180B4160 - Cylinder barrel (APP5,1-10,2)

180B4158 - Valve plate set (APP5,1-8,2)

180B4159 - Valve plate set (APP10,2)

180B4156 - Retainer set (APP5,1-8,2)

180B4157 - Retainer set (APP10,2)

180B4154 - Piston set (APP5,1-8,2)

180B4155 - Piston set (APP10,2)

180B4129 - Swashplate set (APP5,1)

180B4130 - Swashplate set (APP6,5)

180B4131 - Swashplate set (APP7,2)

180B4132 - Swashplate set (APP8,2)

180B4133 - Swashplate set (APP10,2)

Pos. Qnt. Designation Material

1 1 Housing Duplex

2 1 Pin (ø6*10) AISI316 X

3 2 Bleed screw Duplex X

4 2 O-ring (ø4,5*1,5) NBR X

31 1 Swash plate 5,1 Super duplex X

31 1 Swash plate 6,5 Super duplex X

31 1 Swash plate 7,2 Super duplex X

31 1 Swash plate 8,2 Super duplex X

31 1 Swash plate 10,2 Super duplex X

34 2 Pin (ø6*10) AISI316 X X X X X X

36 1 O-ring (ø117*2,5) NBR X X X X X X X X

61 1 Cylinder barrel Super duplex X

64 1 Retainer guide Super duplex X X

65 1 Retainer plate 5,1-8,2 Super duplex X

65 1 Retainer plate 10,2 Super duplex X

66 9 Piston 5,1-8,2 Super duplex X

66 9 Piston 10,0 Super duplex X

67 1 Key 10*8*45 AISI302 X

91 1 Portplate 5,1-8,2 Super duplex/PEEK X

91 1 Portplate 10,2 Super duplex/PEEK X

92 1 Valve plate Super duplex X X

93 9 Backup ring PEEK X X X

94 9 O-ring (ø18,3*2,4) NBR X X X

181 1 Port flange Super duplex

182 1 O-ring (ø135*3) NBR X

183 1 Guide pin Super duplex

184 1 Pin (ø6*10) AISI316 X

185 1 Pin (ø6*10) PEEK X

186 8 Screw M8*20 AISI316 X

187 2 Port connection/plug

211 1 Flange AISI316

212 1 O-ring (ø135*3) NBR X X X X X X X X

213 1 Plate PEHD 1000

PEHD 1000 X X X X X

214 1 O-ring (ø58*2) NBR X

215 1 Shaft seal Hasteloy/NBR X

216 1 Stop bush PEEK X

217 1 Bush Super duplex

218 8 Screw M8*20 AISI316

AISI316 X X X X X X X X

219 1 Screw AISI316

AISI316 X X X X X X
Instruction X X X X X X X X X X X X X

521B0740 DKCFN.PI.013.ED4.02 5
 Exploded view

6 DKCFN.PI.013.ED4.02 521B0740