Danfoss PAH 2-6.3 User manual

danfoss.high-pressurepumps.com
Instruction
Disassembling and assembling
PAH 2-6.3, PAHT 2-6.3 and
PAHT G 2-6.3
MAKING MODERN LIVING POSSIBLE

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
2180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013
Table of Contents 1. Disassembling ..........................................................................3
2. Inspection .............................................................................7
2.1 Port plate and valve plate ...............................................................7
2.2 Pistons..................................................................................7
2.3 Cylinder barrel ..........................................................................8
2.4 Housing ................................................................................8
2.5 Swash plate .............................................................................9
3. Assembling ............................................................................10
4. Spare parts list for PAH 2 / PAHT 2 ......................................................18
5. Exploded view PAH 2 / PAHT 2..........................................................19
6. Spare parts list for PAHT G 2 ............................................................20
7. Exploded view PAHT G 2 ...............................................................21
8. Spare parts list for PAH 4-6.3 / PAHT 3.2-6.3 .............................................22
9. Exploded view PAH 4-6.3 / PAHT 3.2-6.3 ................................................23
10. Spare parts list for PAHT G 3.2-6.3 ......................................................24
11. Exploded view PAHT G 3.2-6.3..........................................................25
12. Tool sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Note:
If the pump is dismantled during the warranty
period, the pump is no longer under warranty.
This document covers the instructions for
disassembling and assembling the axial piston
pumps PAH / PAHT / PAHT G 2-6.3.
Tools provided with tool set 180Z0235:
• Shaft bush, torpedo
• Press bush Ø18 (Plastic)

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
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180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013
3. Dismantle the front cover using a vice. 4. Remove the shaft seal using two screw-
drivers.
5. Remove the two small O-rings from the
ange. Remove the seal from the front
cover using a screwdriver.
6. Unscrew the four screws for the housing.
2. Remove the parallel key and unscrew the
front cover.
1. Tools required for dismantling.1. Disassembling

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
4180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013 4
7. Remove the housing. 8. Remove the cylinder barrel.
9. Remove the pistons and the retaining plate
from the cylinder barrel.
NB: Items 10.1.a. and 10.1.b. concern
PAH 2, PAHT 2 and PAHT G 2 only
10.1.a. Remove the spring. 10.1.b. Remove the stop.

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
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180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013
NB: Items 10.2.a. through 10.2.c. concern
PAH 4-6.3, PAHT 3.2-6.3 and
PAHT G 3.2-6.3 only
10.2.a. Remove the retaining guide. 10.2.b. Remove the spring guide.
10.2.c. Remove the spring.
NB: The following items concern PAH 2-6.3,
PAHT 2-6.3 and PAHT G 2-6.3 only
11. Loosen the valve plate using two screw-
drivers. Place one of the screwdrivers in the
slot of the valve plate.
12. Remove the valve plate.

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
6180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013 6
13. Remove the ve O-rings and the ve
back-up O-rings.
14. Remove the port plate from the ange.
15. Wash all parts and replace all seals
(inclusive shaft seal).
17. If the pump has failed, the reason for the
failure must be found and xed before the
repaired pump is re-installed.
16. Inspect all parts carefully (see “Inspection”)
and replace any worn parts.
Port plate
Stop
Spring
Valve plate
with sealing
Pistons
Retaining plate
Cylinder barrel
Front cover
Flange
Housing with
swash plate
and bearing

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
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180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013
2. Inspection 2.1 Port plate and valve plate
1. Neither port plate nor valve plate must
show any sign of wear.
2. Hold a ruler against the surface of the
plates and check the tightness against a
light source.
3. Check that both O-rings and back-up rings
are not broken and do not show severe
wear.
2.2 Pistons
1. The play in the ball and socket joint must
not exceed 0.1 mm.
2. The thickness of the piston shoes must be
at least 2.85 mm.
3. Hold a ruler against the surfaces of the
piston shoes to check that the surfaces are
even and smooth and without any scratches.
4. PAHT only:
It is acceptable that the (black) treated
surfaces of the pistons are partly worn o.

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
8180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013 8
2.3 Cylinder barrel
1. Check the outer bearing surface for large
wear grooves (not critical).
3. Ensure that the pistons can move freely in
the bushings.
2. Check that the bushings are free from
seizure and large scratches.
2.4 Housing
1. Check that the swash plate surface is
smooth and without any big scratches
(depth more than 0.1 mm).
2. Check the bearing (the black part) for large
wear grooves (not critical).
1
2

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
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180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013
2.5 Swash plate
Mounted swash plate: 1. Unscrew center bolt from the swash plate.
2. Remove swash plate and guide pin. Guide pin

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
10 180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013
3. Assembling
2. Parts and tools required for assembly.
Check that all parts are OK.
Replace all seals.
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).
Important:
It is essential that the pump is serviced in
conditions of absolute cleanliness. All parts
must be absolute clean before mounting.
3. Mount the O-ring on the ange. 4. Mount the port plate in its right position
using the pin as guide.
Guide
pin

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
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180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013
5. Mount the valve plate with seals on the
cylinder barrel.
6. Press the valve plate into the cylinder barrel
using a piece of plastic.
7. Check that the gap between the cylinder
barrel and the valve plate is 1.5-2.5 mm.
8. Mount the cylinder barrel in the ange.

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
12 180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013 12
9.1 NB: Items 9.1.a through 9.1.c concern
PAH 2, PAHT 2 and PAHT G 2 only
9.1.a Mount the stop. 9.1.b Mount the spring in the centre hole.
9.1.c Mount the retaining plate.

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
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180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013
9.2.c Mount the retainer guide on the spring
guide.
9.2.d Mount the retaining plate on the retainer
guide.
9.2 NB: Items 9.2.a through 9.2.d concern
PAH 4-6.3, PAHT 3.2-6.3 and
PAHT G 3.2-6.3 only
9.2.a Mount the spring in the centre hole. 9.2.b Mount the spring guide.
9.3 NB: The following items concern PAH
2-6.3, PAHT 2-6.3 and PAHT G 2-6.3 only
10. Insert the pistons. 11. All pistons inserted.

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
14 180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013 14
15. Mount the pump housing using the pin as
guide.
16. Press the housing down by hand and insert
the screws.
Alignment
hole
Guide pin
12. Place pin and place swash plate ttet on
guide pin and center hole.
13. Place the screw in the center hole. 14. Tighten to a torque of 10 ±1 Nm.

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
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180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013
17. Tighten the screws to a torque of 13 Nm. 18. Mount the two O-rings in the ange and
the O -ring on the front cover.
19. Wet the shaft seal with water and mount it
in the front cover. Ensure that it is pressed
to the bottom.
20. Mount the washer with the edge pointing
upwards.
21. Mount the spring. 22. Fit the hollow bush onto the shaft.

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
16 180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013
25. Press the shaft seal in position. 26. Remove the bush.
27. Mount the front cover and align it to the
screw holes.
28. Tighten the screws to a torque of 7 Nm.
23. Wet the shaft seal and slide it over the
bush.
24. Use the shaft seal tool when pressing the
shaft seal downwards.

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
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180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
18 180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013
4. Spare parts list for
PAH 2 / PAHT 2
180B4100 - Seal set (PAH 2-6.3 / PAHT 2-6.3) 180B4104 - Cylinder barrel set (PAHT 2-6.3) 180B4112 - Cylinder barrel set (PAH2-6.3) 180B4101 - Valve plate set (PAH 2-6.3 / PAHT 2-6.3) 180B4102 - Piston set (PAHT 2) 180B4110 - Piston set (PAH 2-6.3) 180B4301 - Swash plate set (PAH 2 / PAHT 2)
Pos. Qnt. Designation Material
1 1 Housing AISI 304 / PEEK
2 1 Pin Ø5 x 10 AISI 316 x
5 4 Screw M6 x 16 AISI 316 x
31 1 Swash plate AISI 431 x
32 1 Screw M6 x 8 AISI 304 x
33 1Washer AISI 304 x
34 1 Pin Ø4 x 8 AISI 316 x
61 1Cylinder barrel AISI 431 / PEEK x x
62 1Spring AISI 304 x x
63 1Spring guide PEEK
64 1Retainer ball PEEK
65 1Retainer plate 1.4301 x x
66 5 Piston AISI 431/ PEEK x x
67 1 Key 5 x 5 x 20 AISI 316Ti x
69 1Stop PEEK x x
91 1 Port plate AISI 304 / PEEK x
92 1 Valve plate AISI 431 x
93 5 Back up ring PTFE x
94 5 O-ring Ø8,73 x Ø1,78 NBR x
121 1Port ange AISI 304 / PEEK
122 1 O-ring Ø70 x Ø2,72 NBR x
123 1 O-ring Ø75,92 x Ø1,78 NBR x
124 1Shaft seal AISI 304 / NBR x
125 1End cover AISI 304
126 1 Pin Ø4 x 8 AISI 316
127 2 Screw M5 x 20 AISI 304 x
136 2 O-ring Ø7 x Ø1,5 NBR x
1Service instruction xxxxxxx

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
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180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013
5. Exploded view
PAH 2 / PAHT 2

Instruction Disassembling and assembling PAH 2-6.3, PAHT 2-6.3 and PAHT G 2-6.3
20 180R9094 / 521B0985 / DKCFN.PI.011.N4.02 / 09.2013
180B4307 - Seal set (PAHT G 2-6.3) 180B4311 - Cylinder barrel set (PAHT G 2-6.3) 180B4308 - Valve plate set (PAHT G 2-6.3) 180B4309 - Piston set (PAHT G 2) 180B4310 - Piston set (PAHT G 3.2-6.3) 180B4317 - Swash plate set (PAHT G 2)
Pos. Qnt. Designation Material
1 1 Housing AISI 304 / PEEK
2 1 Pin Ø5 x 10 AISI 316 x
5 4 Screw M6 x 16 AISI 316 x
31 1 Swash plate AISI 431 x
32 1 Screw M6 x 8 AISI 304 x
33 1Washer AISI 304 x
34 1 Pin Ø4 x 8 AISI 316 x
61 1Cylinder barrel AISI 431 / PEEK x
62 1Spring AISI 304 x x
63 1Spring guide PEEK x
64 1Retainer ball PEEK x
65 1Retainer plate 1.4301 x x
66 5 Piston AISI 431/ PEEK x x
67 1 Key 5 x 5 x 20 AISI 316Ti x
69 1Stop PEEK x
91 1 Port plate AISI 304 / PEEK x
92 1 Valve plate AISI 431 x
93 5 Back up ring PTFE x
94 5 O-ring Ø8,73 x Ø1,78 NBR x
121 1Port ange AISI 304 / PEEK
122 1 O-ring Ø70 x Ø2,72 NBR x
123 1 O-ring Ø75,92 x Ø1,78 NBR x
124 1Shaft seal AISI 304 / NBR x
125 1End cover AISI 304
126 1 Pin Ø4 x 8 AISI 316
127 2 Screw M5 x 20 AISI 304 x
136 2 O-ring Ø7 x Ø1,5 NBR x
1Service instruction x x x x x x
6. Spare parts list for
PAHT G 2