Service Information
Document Title: Function Group: Information Type: Date:
Hydraulic pump, 913 Service Information 05/03/2024
description
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EC200D Volvo
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Hydraulic pump, description
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Model Production site Serial number start Serial number stop
EC200D Volvo Changwon 280011 310000
Model code
DPA 117 T - 0N8D - 2N1A
Port connection
Code Descriptions
DPA DPA Series
117 Pump size (63cc/rev), (90cc/rev), (117cc/rev), (140,cc/rev)
T T (Tandem type), P (Parallel type)
0 0 (Standard), 1 (Installed only gear case), 2 (Installed PTO pump)
N N (Standard), C (with PCU)
8 Pilot pump: 1 (15cc/rev), 3 (10cc/rev), 5 (15cc/rev), 6 (15cc/rev), 7 (10cc/rev), 8 (10cc/rev),
D EPPR valve: N (None), D (direct power control), I (Inverse proportional)
2 Power control: 1 (Constant power control), 2 (Variable power control)
N Flower control: N (Negative, P (Positive), E (Electrical)
1A Regulator design
Figure 1
Structure, main pump
Figure 2
Hydraulic diagram
Port connection
No. Port name Port size Remarks
A1, A2 Delivery port SAE 6000 psi 1″
B1 Suction port SAE 2500 psi 2 1/2″
Dr1 Drain port PF 3/4–23
Dr2 Drain port PF 1/4–15
Dr3 Drain port PF 1/2–19
Pi1, i2 Pilot port PF 1/4–15
a1, a2 Gauge port PF 3/8–18
a1s, a2s Gauge port PF 1/4–15
Pg Servo assist port PF 1/4–15
Psft Power shift port PF 1/4–15
A3 Gear pump delivery port PF 1/2–19
B3 Gear pump suction port PF 3/4–20.5
a3 Gauge port PF 1/4–15
Figure 3
Main pump, sectional view
04 Gear pump 13 Cylinder spring 22 Actuator stopper (min) 41 Socket screws
6 6 3
11 Shaft (F) 21 Swash plate (F) 31 Main case 41 Wrench screws
1 1 1 4
11 Shaft (R) 21 Swash plate (R) 31 Front cover 41 Plug
2 2 4 5
11 Spline coupling 21 Metal bearing (L) 31 Rear cover 41 Plug
3 3 5 7
12 Taper roller bearing 21 Metal bearing (R) 31 Valve plate (F) 42 Oil seal
1 4 2 1
12 Needle bearing 21 Shoe plate 31 Valve plate (R) 45 Backup ring
2 5 3 1
13 Cylinder block 22 Con rod 31 Seal cover 45 Backup ring
1 1 7 2
13 Piston 22 Actuator socket 31 Adjust spacer 45 Hex nut
2 2 9 3
13 Shoe 22 Piston - L 32 Valve plate pin 45 Eye bolt
3 3 3 4
13 Retainer 22 Piston - S 32 Spring pin 47 Name plate
4 4 4 1
13 Spherical bush 22 Actuator stopper (max) 41 Socket screws 47 Rivet screws
5 5 2 2
Sectional view tightening torque
No. Size Tightening torque: Nm (lbf ft)
412 M10 62.0 (11.1)
413 M8 31.5 (23.3)
414 M5 7.5 (5.6)
415 PF 1/2 98.0 (72.5)
417 NPTF 1/16 13.7 (10.1)
Pump, principle of operation
The components of swash plate piston pump can be divided into three sub-groups.
The rotary group consists of shaft (F) (111), shaft (R) (112), cylinder block (131), piston and shoe (132, 133), retainer
(134), spherical bush (135) and cylinder spring (136). The drive shaft is supported by bearings (121, 122). The shoe is
swaged over the spherical end of the piston for forming a spherical ball joint. It has a pocket to relieve thrust force
generated by loading pressures and to make a hydraulic balance so that it slides lightly over the shoe plate (215).
The sub group consisting of the pistons (223) and shoes (133) are pressed against the shoe plate (215) by the
cylinder springs (136) (acting through the retainer (134) and the spherical bush (135). The force developed by these
cylinder springs (136) also press the cylinder block (131) against the valve plate (312, 313).
The swash plate group consists of swash plate (211, 212), shoe plate (215), piston-L (223), piston-S (224), con-rod
(221), actuator stopper (max) (225), actuator stopper (min) (226), front cover (314), metal bearing (213, 214).
The swash plate (211, 212) has a cylindrical part supported by the hydrostatic bearing of the swash plate support
and a plane part formal on the opposite side of the sliding surface of the shoe plate (215).
The lienr movement of the piston-L (223) and piston-S (224) produced by the regulator pressure applied to either
and is translated through the feedback lever into an angular movement of the swash plate which varies the tilting
or swash angle of the pump. The actuator stopper (225, 226) and hex nut (453) available to adjust the maximum
and minimum tilting angle condition.
The main case group consists of main case (311), valve plate (312, 313) and valve plate pin (323).
The valve plate (312, 313) with its two “kidney” shaped ports is installed onto the valve plate located by the valve
plate pin (323). These two ports supply oil to the cylinder block and discharge oil from the cylinder block. The oil
passage switched by the valve plate is connected to the externally piped suction and outlet pressure ports through
the main case (311).
When the pump’s shaft (F) (111) is driven by a prime mover (Electric motor, Engine etc.), the cylinder block being
spline coupled to the shaft will also rotate. If the swash plate has been tilted, the pistons arranged in the cylinder
block due to the shoe being retained on the swash plate surface will both rotate with the cylinder block and
reciprocate once per revolution. Paying attention to one such piston then it will move away from the valve plate for
half a rotation (suction stroke) and move towards the valve plate for the second half of rotation (oil delivery stroke).
The larger the tilt angle, the longer the piston stroke and the higher the pump’s displacement. As the swash plate
tilting angle approaches so the piston makes no stroke and thereby delivers no oil.
Installation
No. Items Instructions
1 Installation position. Install the pump with drive shaft horizontal in general.
2 External load to shaft end. Apply neither radial nor thrust load externally to the pump shaft end. If
your vehicle is operated by belt or gear, consult us in advance.
3 Removal of rust preventing Since the shaft end splined section has been coated with rust preventing
paint. paint, remove it with cleaning liquid before using the pump. Apply
lubricant, such as molybdenum disulfide, before installing this section
on the coupling. When cleaning liquid is used, be careful not to get
cleaning liquid on oil seal.
4 Coupling and centering of Couple the pump drive shaft with the prime mover shaft with a flexible
pump. coupling in general. For centering between the coupling and drive shaft,
keep the alignment within ±0.03mm.
5 Tightening of pump mounting For the tightening torques of the pump mounting bolts, refer to the
bolts. values of their respective sizes shown in "Tightening Torques".
Piping
No. Items Instructions
1 Rotating and delivery direction. Refer to the indications shown in the installation drawing.
2 Flushing of pipes. Carry out acid pickling and flushing of the suction pipe, the delivery
pipes and tank. Especially, thoroughly clean the suction pipe.
3 Installation of suction and When installing pipings, prevent the suction and delivery ports of the
delivery port. pump from being forcedly stressed.
4 Drain port. 1) Raise the drain pipe of the pump higher than the pump and route it
to the tank, as shown in the following figures.
Figure 4
2) For a tandem type double-pump, install the drain pipe on the front
pump first as far as possible. It is desirable to provide a filter in the drain
line.
3) Height from the oil level to the center of the shaft must be within 1m.
4) The oil in the pump case must be refilled when the pump has not
been operated for one month or longer.
5 Drain pressure. Please ensure, as stated previously, that the maximum steady state drain
line pressure (constant mean pressure) at the pump casing does not
exceed 0.1MPa. (Maximum peak pressure 0.4MPa). A suitable drain line
hose and drain line filter when required must be selected to ensure this.
Filtration and Contamination Control
The most important means to prevent premature damage to the pump and associated equipment and to extend its working
life, is to ensure that hydraulic fluid contamination control of the system is working effectively. This begins by ensuring that
at the time of installation that all piping, tanks etc. are rigorously cleaned in a sanitary way. Flushing should be provided
using an off line filtration system and after flushing, the filter elements should be replaced. A full flow return line filter of 10
micron nominal should be utilized and in addition a 150 micron mesh suction strainer is recommended.
No. Items Instructions
1 Filtration In the circuit, do not forget to provide a filter of 10 micron in the
actuator return pipe. The following figure shows examples. In addition,
provide a filter of 80 to 150 mesh at the suction side.
Figure 5
2 Contamination The relationship between contamination level and pump life is very
difficult to predict as it depends on the type and nature of the
contaminant present in the system. Sand or Silica in particular, due to its
abrasive nature, does significantly reduce the expected life of a pump.
Based on the precondition that there is no significant presence of Silica
type substances then a minimum Cleanliness level of 18/15 to ISO 4406
is recommended.
Cautions for operation
No. Items Instructions
1 Storage for a long period. It is undesirable to leave the pump out of use for a long period of a year
or more. In such a situation. it is recommended that the pump is run for
a short period on a more frequent basis even if it is just unloaded. With
regard to a pump held in storage then rotating the shaft on a frequent
basis is sufficient. If the pump is left out for more than the suggested
time it will require a service inspection.
2 Change of rotating direction. The rotating direction is as indicated by the arrow plate. If it must be
changed during its service life, contact us.
Pump Case Filling and Air Venting
No. Items Instructions
1 Pump Case filling Be sure to fill the pump casing with oil through the drain port - filling
only the suction line with oil is totally insufficient. The pump contains
bearings and high-speed sliding parts including pistons with shoes and
spherical bushes that need to be continuously lubricated. Part seizure or
total premature failure will occur very quickly if this procedure is not
rigidly followed.
2 Air Venting. When air is left in the circuit or pump, it may cause a malfunction or
damage. Completely vent the air in the pump.
Pump Case Filling and Air Venting
1) Check to see that the piping and full hydraulic circuit is completed.
2) Check to ensure that direction of rotation is correct and the suction and delivery lines are connected correctly.
3) Run the pump unloaded for a period to ensure that all residual air within the system is released.
4) After starting, continue the idling for a while to vent air completely from the circuit.
5) Check for external leakage, abnormal noise and vibrations.
6) When the pump is attached to a gear box, check that the box is full of oil to its proper level.
