AP2D18, AP2D25, AP2D28, AP2D36 Series

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Ningbo Hengnuo Hydraulic Drive Co.,Ltd

3 year

Product details

AP2D Series Gear Pump Technical Overview (AP2D18/25/28/36)

(Focus: Engineering Specifications, Failure Analysis, Maintenance Protocols, and Cross-Compatibility)

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1. Core Specifications & Performance Envelope

A. Key Parameters

【表格】

Model Displacement (cc/rev) Max. Pressure (bar) Theoretical Flow (L/min @ 2,200 RPM) Max. Speed (RPM) Port Thread

AP2D18 17.8 280 39.2 3,000 G1/2" (BSPP)

AP2D25 25.0 280 55.0 3,000 G3/4" (BSPP)

AP2D28 28.2 280 62.0 3,000 G3/4" (BSPP)

AP2D36 35.5 280 78.1 3,000 G1" (BSPP)

• Flow Efficiency:

• Volumetric Efficiency: 92–94% (clean ISO VG46 oil, 20°C)

• Mechanical Efficiency: 88–90% (at rated pressure)

• Viscosity Range:

• Optimal: 22–46 cSt (ISO VG32–VG46)

• Critical Limit: 10–500 cSt (avoid sustained operation <15 cSt or >400 cSt)

B. Design Highlights

• Gear Geometry:

• Helical Gears(15° helix angle): Reduces noise by 12 dB vs. spur gears.

• Pressure Balance Grooves: Minimizes axial thrust (extends shaft bearing life by 30%).

• Sealing System:

• Double Lip PTFE Rotary Seals: Withstands 280 bar intermittent pressure spikes.

• Case Drain Port: Mandatory for external leakage detection (required flow: 0.5–1 L/min).

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2. Failure Mode Analysis (FMEA)

A. Top 3 Failure Root Causes

【表格】

Failure Mode Probability (%) Impact on System Detection Method

Gear Tooth Wear 45 20–30% flow loss; increased noise (≥85 dB) Ultrasonic wear testing (ASTM E1065)

Shaft Seal Leakage 30 Oil loss (1–2 L/day); risk of hydraulic lock Dye penetrant inspection (ISO 3452)

Case Cracking 15 Catastrophic failure; safety hazard Magnetic particle testing (ASTM E709)

B. Case Study: Gear Tooth Wear

• Scenario: AP2D28 pump fails after 1,800 hours in aHitachi ZX200-3excavator.

• Root Cause:

• Silica Contamination: 25 mg/L in oil (ISO 4406:22/20/17; target: ≤18/16/13).

• Abrasive Mechanism: Silica particles (20–50 μm) act as cutting tools on gear teeth.

• Mitigation:

• Upgrade filtration toDonaldson P165678(β10≥750, 99.9% efficiency at 10 μm).

• Reduce oil change interval from 1,000 to 750 hours in silica-rich environments.

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3. Maintenance & Troubleshooting

A. Preventive Maintenance Schedule

【表格】

Interval (Hours) Task Acceptable Limits

50 Check case drain flow; inspect shaft seals ≤1 L/min; no visible leaks

250 Measure gear end play (with dial indicator) 0.05–0.12 mm

500 Perform oil analysis (particle count, water content, TAN) ISO 18/16/13; ≤0.1% water; TAN <0.5

1,000 Disassemble pump; replace seals, bearings, and gears (if worn >0.05 mm) N/A

B. Emergency Repair Protocol

1. Isolate Pump:

• Close suction/discharge valves; depressurize system (wait ≥10 minutes).

2. Seal Replacement:

• UseParker O-Ring Kit 2230-016(Viton material for high-temp applications).

• Torque mounting bolts to45–50 Nm(use torque-angle gauge).

3. Post-Repair Test:

• Run pump at 1,000 RPM; monitor case drain flow (should stabilize at ≤0.8 L/min).

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4. Cross-Compatibility Guide

A. Direct OEM Replacements

【表格】

Target Machine OEM Pump Part No. AP2D Equivalent Performance Match

Komatsu PC130-7 KMP12V-03000 AP2D25 ±3% flow; same mounting footprint

Kobelco SK140SR-3 KYB-PVM-02BG-10 AP2D28 ±2% pressure; same shaft keyway

Volvo EC140E 14524549 AP2D36 ±5% torque; requires adapter plate

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Ningbo Hengnuo Hydraulic Drive Co.,Ltd

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