Service Information

Document Title: Function Group: Information Type: Date:

Pump, assembly 913 Service Information 28/08/2018
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ECR88 Volvo

Pump, assembly
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Model Production site Serial number start Serial number stop
ECR88 Volvo

Op nbr 00000

Precautions
Perform the following preparation before starting reassembly.

Check each part for scratches incurred during use or disassembly. If there are scratches, remove the scratches using
a fine oilstone or sandpaper as necessary, and wash using clean cleaning oil, dried by compressed air.
Replace seal parts with new parts (including oil seal and gasket).
Polish the sliding parts of piston assembly (10), cylinder (11), port plate (12) and cam (8) with #2000 paper on the
table.

Figure 1
Polishing sliding part
Apply grease thinly to seal parts before installing them.
When installing sliding parts, coat them with clean hydraulic oil before assembly.

Assembly of piston pump body

1. Assembly of bushing
Install O-ring (18) into the O-ring groove (A) of cover (59).
 Figure 2
Assembly, O-ring

2. Assembly of port plate

Coat bushing (61) with grease (to prevent it falling), then install it in the bore in port plate (12). Next align port plate
(12) with the positioning pin of cover (59).

Figure 3
Assembly, port plate

3. Assembly of piston assembly

Install return plate (9), with spring (57), retainer SPH (17) and piston assembly (10) installed, into cylinder (11).
NOTE!
Use the markings placed on the side of the return plate (9) and cylinder (11) before disassembly to ensure that
piston assembly (10) is installed in the same bores as before disassembly.
 Figure 4
Assembly, piston assembly

4. Assembly of cradle cover

Install cradle (7), (16) to housing (4), then tighten the countersunk screw (6) to tightening torque 5.9 N·m (4.4 lbf·ft).

Figure 5
Assembly, cradle cover
NOTE!
To keep cradle (7), (16) parallel, first temporarily tighten countersunk screw (6), then coat the cradle (7), (16) with
hydraulic oil, install cam (8) and rotate it several times to settle the cradle. Then remove cam (8) before tightening
countersunk screw (6) to the specified torque.
 Tools: Allen wrench 3, 5 mm
Torque wrench

5. Assembly of shaft
Apply hydraulic oil on port plate (12) (moving surface with cylinder (11)) and install cylinder (11). Coat the shoe
moving surface of piston assembly (10) with hydraulic oil, then install the shoe moving surface to cam (8).
Install shaft (1) so that cylinder (11) and the spline mesh.

NOTE!
Pay attention to the installation direction of the shaft.
 Figure 6
Assembly, shaft

6. Assembly of rod PW and rod RE

In order to position power piston assembly (42) upward (for easy assembly), install a spring (jig a) at the bottom of
power piston assembly (42) and install the cap (jig b). In this state, in between power piston assembly (42) and cam
(8) is linked by rod PW (33).
In order to position power piston RE (58) upward (for easy assembly) the same as when installing rod PW (33),
install spring (60) at the bottom of power piston RE (58), then install the cap (jig c). In this state, in between piston
RE (58) and cam (8) is linked by rod RE (56).
NOTE!
Coat grease on the rounded part of rod PW (33) and rod RE (56) (to prevent dropping).

NOTE!
Pay attention to the installation direction of rod PW (33) and rod RE (56). For both of them, the end with the larger
 diameter makes contact with the cam.

Figure 7
Assembly, rod PW and rod RE

7. Assembly of housing
Gradually lower the housing side assembly to the cover side assembly, then perform temporary tightening using
the screw (74).
NOTE!
When performing this operation, if the cam (8) and cradle (7), (16) are difficult to install, tap the housing side lightly
for easier installation.

NOTE!
Take care to avoid getting your fingers caught between housing (4) and cover (59).

Tools: Allen wrench 12 mm

 Figure 8
Assembly, housing

8. Assembly of taper roller inner bearing

Using a driver jig (a), install the tapered roller bearing (5) by striking the jig with a hammer.
Ensure that the jig fits properly onto the inner race. Do not strike the rollers or cage.
 Figure 9
Assembly, taper roller inner bearing

9. Assembly of taper roller bearing outer race

Install the tapered roller bearing (5) outer race.
 Figure 10
Assembly, taper roller inner bearing

10. Assembly of oil seal

Clean and remove all grease from the part where oil seal (2) of seal retainer (52) is installed. Next remove grease
from the outside periphery of oil seal (2), apply liquid packing (Threebond kk “1211” white color or equivalent
product) and use the installation jig (a) to install seal retainer (52).
NOTE!
Take care to install oil seal (2) in the correct direction.

A. Taper roller bearing side

B. Cylinder output shaft side

Figure 11
Assembly, oil seal

11. Assembly of seal retainer

Install the same number of shims (3) that were installed before disassembly, install the seal protector (a) to shaft (1),
 and install oil seal (2) and seal retainer (52) to housing (4). Remove the seal protector and install screw (53) with
tightening torque 32.4 N·m (24.0 lbf·ft).
NOTE!
Thinly coat the lip surface of oil seal (2) with grease.

NOTE!
The thickness of shims (3) may require adjustment due to replacement of parts, etc.

Tools: Allen wrench 6 mm

Torque wrench

Figure 12
Assembly, seal retainer

12. Assembly of screw

Using screw hole M 12 for the pump intake (a) , install plate (b) and secure it to the work platform. Tighten screw
(74) to tightening torque 176.6 N·m (130.7 lbf·ft).

Tools: Allen wrench 12 mm

Torque wrench
 Figure 13
Assembly, holded screw

13. Tightening cap

Remove the assembly jig (cap, spring), then install spring (45), stopper (48), set screw (51), and cap (49) with nut
(51), tightening to tightening torque 343 N·m (253.8 lbf·ft).
NOTE!
When you remove the assembly jig (a, b), make sure that power piston assembly (42) does not move to cap (49)
side. (Rod PW (33) will come off.)

NOTE!
If Rod PW (33) does come loose, start again from step 6.

Tools: Spanner wrench 41 mm

Torque wrench
 Figure 14
Tightening, cap

14. Tightening cap RE

Remove the assembly jig, install cap RE (65), applying tightening torque of 215.8 N·m (159.7 lbf·ft).

Tools: Spanner wrench 36 mm

Torque wrench

Figure 15
Tightening, cap RE

15. Assembly check

After the body is assembled, protect the spline of shaft (1) with a cloth, etc., and use a pipe wrench to turn shaft (1)
to check that it turns smoothly without resistance.

Figure 16
Checking, assembly

The above completes assembly of the main body.

Assembly of control unit (servo case assembly)

16. Install sleeve (34) to servo case (36) from cap SP (25) side.
NOTE!
Install sleeve (34) with the elongated hole toward the back.
 Figure 17
Assembly, sleeve

17. Install link (71) with pin (72) installed from the side joining with cover (4), insert pin (72) into the elongated hole of
sleeve (34), and align the link support hole of the servo cover with the link support hole (a). Install plug (69) from
the side so that it passes through the link support hole. Install snap ring (68) using snap ring pliers, then install O-
rings (27), (73).
 Figure 18
Assembly, link

18. Install piston U (39) to servo case (36) and tighten cap SR (44) to tightening torque 39 N·m (28.9 lbf·ft).
NOTE!
Check that the link moves smoothly.

NOTE!
Make sure that you install rod (37), piston B (38) and piston U (39) in the correct direction.

Tools: Spanner wrench 27 mm

Torque wrench
 Figure 19
Assembly, piston

The above completes assembly of the control unit.

Components assembly

19. Assembly of control unit

Install pin (35) through the hole in cover (59) into the groove in power piston assembly (42).
NOTE!
If the groove of power piston assembly (42) is out of phase, use a scriber, etc. to follow the circumference and to
align the phase of cover (59) pin hole, power piston assembly (42) and groove.
 Figure 20
Assembly, control unit

20. Align the cutout of link (71) with the phase of the power piston assembly (42), and install it to the main body so
that the pin enters between the cutout grooves. Tighten screw (70) to tightening torque 64.7 N·m (47.9 lbf·ft).
NOTE!
Check link join

With servo case (36) lightly placed on top of cover (59), parallel pin (19) permits clearance of about 3 mm between
servo case (36) and cover (59). Through this clearance, use a thin tool, etc. to push link (71) to check that it does not
move. If it is deficient, link (71) moves.

Tools: Allen wrench 8 mm

Torque wrench
 Figure 21
Checking, link join

21. Assembly of gear pump (NP***)

Install O-ring (21) and collar (a) to cover (59), then install coupling (66) to shaft (1), and check the phase of gear
pump (67) when you install it. Tighten screw (75) with polished washer (76) installed, to tightening torque of 32.4
N·m (24.0 lbf·ft).
If there is no gear pump (NP**), tighten the blind cover together with the screws to tightening torque 32.4 N·m
(24.0 lbf·ft).

Tools: Allen wrench 6 mm

Torque wrench
 Figure 22
Assembly, gear pump

22. Assembly check

When all installation is completed, protect the spline of shaft (1) with a cloth, etc., and use a pipe wrench to turn
shaft (1) to check that it turns smoothly without resistance and also check at the gear pump port that the gear of
the gear pump (67) is turning.

Figure 23
Assembly check

This completes overall assembly.