Language Code Product Group No.

Version Date
GB EXC 431 13 4 09/02/2004
Applies to
EC340 Volvo, EC390 Volvo

Oil cooling for pump gearbox Campaign EXC400, EXC500

WARNING
Please pay attention to the safety instructions in the Operator's and Service Manuals concerned.

Op nbr 431

14360000 Vacuum pump

Scope: EC340 from and incl. serial no. 1001 - 1431

EC390 from and incl. serial no. 1001 - 1148

Cause: Temperature in the pump gearbox and by the pumps’ axial seals becomes too high,
especially at high ambient temperatures. A rebuild kit has been developed which radically
lowers the oil temperature in the pump gearbox.

Action: Installation of rebuild kit accord. to installation instructions.

Parts required: Kit no. 11707456 (same for EC340 and EC390).
Synthetic transmission oil API GL-5 SAE 75W/90 or Volvo transmission oil 97312 T65
75W/90. Volume: approx. 5 litres.

Ordering: The kit can be ordered from your nearest spare parts department.
(NOTE! Oil not included in kit).

The following parts are included in the kit:

Part no. Designation Quantity

14012431 Pipe fitting 5
14042176 Pipe fitting 4
14014150 Oil hose L =300 mm 1
14347026 Hydraulic hose 1
14 216038 Connection flange 1
959220 Allen bolt 2
14213902 O-ring 1
943475 Hose clamp 8
14347063 Pump kit 1
14347164 Bracket 1
14347163 Bracket 1
946472 Flange bolt 6
13949523 Washer 2
14216037 Connection flange 3
940326 Allen bolt 6
14016494 O-ring 3
14012423 Pipe fitting 7
14245605 Hydraulic hose L = 500 mm 1
14012395 Pipe fitting 11
11033455 Heat exchanger 1
13946752 Flange bolt 2
14215702 Pipe fitting 2
14055215 Hydraulic hose L = 1400 mm 1
14012424 Pipe fitting 1
11707606 Hose connection 2
943368 Hose L = 2100 mm 1
943368 Hose L = 3500 mm 1
943473 Hose clamp 4
944386 Hose L = 300 mm 1
14347123 T-pipe 2
14245626 Hydraulic hose L = 2600 mm 1
14012384 Pipe fitting 3
14056270 Hydraulic hose L = 1800 mm 2
4881440 Cable tie 40
14043547 Pipe fitting 2
14347178 Plug 2
14012455 Nut 2
14012397 Pipe fitting 5
13971095 Flange nut 8
13960143 Washer 8
14347179 Suction filter 1
946440 Flange bolt 2
14347167 Bracket 1
955560 Bolt 3
13976629 Washer 3
14347185 Pipe 1
14347184 Pipe 1
14347138 Bracket 1
13945444 Flange bolt 2
14014146 Oil hose L =170 mm 1
14347199 Pressure limiting valve 1
14012381 Pipe fitting 1
14023409 Plug 1
14241781 Hydraulic hose 1
14347177 Flow distributor 1
13965178 Flange bolt 2
13945407 Flange nut 2
14347017 Bracket 1
959259 Allen bolt 2
13960145 Washer 2
14213557 Pipe fitting 1
14347090 Air nipple 1
14210587 O-ring 1
14347180 Expansion tank 1
13946173 Flange bolt 3
13948217 Flange bolt 3
13948087 Washer 6
943366 Hose L = 800 1
943470 Hose clamp 2

Cost compensation:

Type of compensation Yes No Notes

Material costs x
Labour costs x 8.0 hours
Travel costs x
Other costs x
Daily allowance x

Claim code: The following codes are given on the claim forms:

Type of code Claim form SAS-system

Claim type 0 -
Claim object type - 0
Campaign code EC340: EXC400 EC340: EXC400
EC390: EXC500 EC390: EXC500
in field in field
"Description of the fault" "Campaign"
Mfgc - 05
Warranty code 05 -
Causing Part No. 14265254 14265254
Defect Group 02 02
Function Group 43130 43130
Measure code 14 14

Campaign start: Week 035

Time limit: 2001-08-31

Claims, latest date: 2001-10-31

Installation instructions

WARNING
Risk of burns - stop the diesel engine and allow it to cool down before starting any work.

1. Place the superstructure so that the pump gearbox is easily accessible from the underside.

2. Stop the diesel engine.

3. Remove the cover 1under the pump gearbox.

 Figure 1
Superstructure

1. Cover

4. Remove the bottom plug 1 and drain the oil from the pump gearbox into a container.

Figure 2
Pump gearbox

1. Bottom plug

5. Fit the bottom plug in the pump gearbox after draining.

6. Fill approx. 2 litres of hydraulic oil through the angle nipple 1.

Press down the emergency stop and run the starter motor for approx. 15-20 sec. to rinse the pump gearbox clean
of any impurities.

Figure 3
Pump gearbox
 1. Angle nipple

7. Once again, remove the bottom plug in the pump gearbox and drain the hydraulic oil into a container.

8. Screw in pipe fitting part no. 14012431 in the bottom plug connection (hidden).
Fit the pipe fitting 3 and the nut 4 with plug.
Fit the pipe fittings 1 and 2 .

Figure 4

1. Pipe fitting part no. 14012397

2. Pipe fitting part no. 14042176
3. Pipe fitting part no. 14043547
4. Nut part no. 14012455
/plug part no. 14347178

9. Fit the bracket 1on the rear right attachment in the engine block with the bolts 2 (3 bolts) and washers (3 washers).
Tips: Clean the threads in the attachment before fitting.

Figure 5
Pump gearbox

1. Bracket part no. 14347167

2. Bolts part no. 955560
/washers part no. 976629

10. On the suction filter 1 fit the pipe fittings 3and the pipe fitting 2 (fit before installing suction filter, see next step).
 Figure 6
Pump gearbox

1. Suction filter part no. 14347179

2. Pipe fitting part no. 14042176
3. Pipe fittings part no. 14012431

11. Fit the suction filter on the bracket with the flange bolts 1.
Arrows on the filter housing indicate flow direction, see arrow.

Figure 7
Suction filter

1. Flange bolts part no. 946440

12. Fit the oil hose 2 and tighten the hose clamps 1 (2 clamps).
NOTE!
Install the oil hose so that no restrictions occur.

Figure 8
 Pump gearbox

1. Hose clamps part no. 943475

2. Oil hose part no. 14014150

13. Fit the pipe fittings 2 pcs. (hidden behind filter), part no. 14012397, 14042176.
Fit the hydraulic hose 2 and the hose clamp 1.

Figure 9
Suction filter

1. Hose clamp part no. 943475

2. Hydraulic hose part no. 14347026

14. Drill 6 holes Ø 11.5 in the left member for attaching the pump kit and heat exchanger according to measurements
in fig. 10.
NOTE!
Measurement 0 is at the plate in front of the counterweight.

Figure 10
Measurement drawing

15. Overview of oil cooling installation for pump gearbox.

NOTE!
See overview figures when these are mentioned in the instructions .

Installation of separate components is described in order.

 Figure 11
Hose routing for oil cooling

1 Hydraulic hose part no. 14241781, between thermostat valve and flow distributor
2 Existing hydraulic hose from fan pump
3 Flow distributor
4 Hydraulic hose part no. 14245626 between flow distributor and pressure limiting valve
5 Oil hose part no. 14014150 between pump gearbox and filter
6 Pressure limiting valve part no. 14347199
7 Hydraulic hose part no. 14056270 between pressure limiting valve and pump kit "pump pressure in"
8 Hydraulic hose part no. 14056270 between leak-oil filter and pump kit "pump pressure out"
9 Hydraulic hose part no. 14245605 between pump kit "gearbox oil out" and heat exchanger "gearbox oil in"
10 Heat exchanger part no. 11033455
11 Pump kit part no. 14347063
12 Hydraulic hose part no. 14055215 between heat exchanger "gearbox oil out" and pump gearbox top- side in
13 Hydraulic hose part no. 14347026 between filter and pump kit "gearbox oil in"
14 Hose part no. 943368 between heat exchanger "coolant out" and intercooler
15 Hose part no. 943368 between heat exchanger "coolant in" and intercooler

Hydraulic diagram for cooling of pump gearbox oil.

NOTE!
The numbers 1 to 7except 3 indicate new components, and others are standard components.
Figure 12
Diagram

1 Pressure limiting valve

2 Flow distributor
3 Pump gearbox
4 Filter
5 Heat exchanger
6 Pump kit "gearbox oil"
7 Pump kit "hydraulic oil"
1:g Fan pump
1:d Servo pump
19:e Thermostat valve for cooling fan
8:g Non-return valve, refilling
4:e Hydraulic motor for cooling fan
18:b Leak-oil filter
18:d Hydraulic oil cooler

16. Cut up the oil hose 1and apply contact adhesive in the hose and on the contact surface on the bracket 2 and fit the
hose (this is to prevent chafing of the fuel hoses for an eventual engine heater).

Figure 13
Bracket

1. Oil hose part no. 14014146

2. Bracket part no. 14347163

17. Fit the brackets 1 and 3 with attaching bolts 2 (4 pcs.) in the member (flange bolt heads on outside).
 Figure 14
Fitting brackets inside member

1 Bracket part no. 14347164 3 Bracket part no. 14347163

2 Bolted flanges: Flange bolt part no. 946472, washers (8 pcs.) part
no. 960143 and flange nuts part no. 971095

18. Fit the flange bolts 1 and washers.

Figure 15
Member

1. Flange bolts part no. 946472, washers part no. 949523

19. Fit the connection flanges 2 (3 pcs.) with the bolts3(6 bolts) and pipe fittings 1 (3 pcs.).
NOTE!
Fit O-rings (3 pcs.) part no. 14016494 in the connection flanges.

Fit the connection flange 5 with the bolts 4 (2 bolts) and the pipe fitting 6 .

NOTE!
Fit the O-ring part no. 14213902 in the connection flange.
 Figure 16
Pump kit with connections

1 Pipe fittings part no. 14012423 4 Allen bolts part no. 959220
2 Connection flanges part no. 14216037 5 Connection flange part no. 14216038
3 Allen bolts part no. 940326 6 Pipe fitting part no. 14012431

20. Fit the pump kit 4in the bracket with bracket 1, flange bolts 2 (2 bolts) and flange nuts 3 (4 nuts, of which 2 hidden
to the right on pump kit).
Connection A , pump pressure out.
Connection C, gearbox oil out.
Connection B, pump pressure in.
Connection D, gearbox oil in.

Figure 17
Pump kit installation

1. Bracket part no. 14347138

2. Flange bolts part no. 945444
3. Flange nuts part no. 971095
4. Pump kit part no. 14347063

21. Fit the pipe fittings 1 (2 pcs.) and hose connections 2(2 pcs.) on the heat exchanger 5 .
Fit the pipe fittings 3 (2 pcs.) and pipe fittings4 (2 pcs.).
 Figure 18
Heat exchanger with connections

1 Pipe fittings part no. 14012395 4 Pipe fittings part no. 14012395
2 Hose connections part no. 11707606 5 Heat exchanger part no. 11033455
3 Pipe fittings part no. 14215702

22. Fit the heat exchanger in the bracket with the flange bolts 1.
Connection A, coolant in .
Connection B, gearbox oil out.
Connection C, coolant out.
Connection D, gearbox oil in.

Figure 19
Installation of heat exchanger

1. Flange bolts part no. 946752

23. Remove the existing air bleeder plug and angle nipple and fit the pipe fittings 1, 2and 3 .
Fit the pipe fitting 4and hydraulic hose 5.
 Figure 20
Pump gearbox

1 Pipe fitting part no. 14012431 4 Pipe fitting part no. 14213557
2 Pipe fitting part no. 14043547, plug part no. 5 Hydraulic hose part no. 14055215, pipe
14347178, nut part no. 1401455 fitting part no. 14012395
3 Pipe fitting part no. 14012397 A Oil filling

24. Connect the vacuum pump, see instructions "connection/disconnection of vacuum pump" in section 9 of the Service
Manual.

25. Remove the partition between the engine compartment and hydraulic compartment.

26. Fit the flow distributor 2 on the bracket 1.

Fit the bracket 1 on the connecting valve on P3’s block half.
Disconnect the existing pipe 4(with hose from fan pump) from the existing pipe fitting 3, and fit the pipe on the
flow distributor.

Figure 21
Flow distributor

1 Bracket part no. 14347017, washer part no. 13960145, bolt part 3 Existing pipe fitting
no. 959259
2 Flow distributor part no. 14347177, flange bolt part no. 4 Existing pipe
13965178, flange nut part no. 13945407

27. NOTE!
Fit the pipe fittings 3 (3 pcs.), pipe fittings 2 on the flow distributor before it is installed on the block.

Fit the hydraulic hose 1, overview figure hose 4 and hydraulic hose 4 , overview figure hose 1.

Figure 22
Flow distributor
 1. Hydraulic hose part no. 14245626
2. Pipe fittings part no. 14012395
3. Pipe fittings part no. 14012423
4. Hydraulic hose part no. 14241781

28. Fit the pipe fittings 2 and 3 on the pressure limiting valve.
Fit the pipe fitting 1 and pipe plug 4.

Figure 23
Pressure limiting valve

1. Pipe fitting part no. 14012395

2. Pipe fitting part no. 14012423
3. Pipe fitting part no. 14012381
4. Pipe plug part no. 14023409

29. Fit the pipe fittings 4 (3 pcs. ) and two existing hoses.
Fit the pressure limiting valve 3 .
Important ! Change the set pressure from 25 to 50bar by turning in the adjusting screw 2turns.
Fit the hydraulic hose 1, overview figure hose 8 .
Fit the hydraulic hose 2, overview figure hose 7 .
Fit the hydraulic hose 5, overview figure hose 4 .

Figure 24
Leak-oil filter

1 Hydraulic hose part no. 14056270 4 Pipe fittings part no. 14012384
2 Hydraulic hose part no. 14056270 5 Hydraulic hose part no. 14245626
3 Pressure limiting valve part no. 14347199

30. Fit the pipe fittings 1 (3 pcs.).

 Fit the hydraulic hose 2, overview figure hose 8 .
Fit the hydraulic hose 3, overview figure hose 9.
Fit the hydraulic hose 4, overview figure hose 7 .
Fit the hydraulic hose 5, overview figure hose13 .

Figure 25
Hose installation

1 Pipe fittings part no. 14012395 4 Hydraulic hose

2 Hydraulic hose 5 Hydraulic hose, hose clamp part no. 943475
3 Hydraulic hose part no. 14245605

31. Fit the hose 1 (3500 mm), hose 3 (2100 mm) and 2 hose clamps (hoses should be connected on the intercooler
later on in instructions).
Fit the hydraulic hose 2 , overview figure hose 12.
Fit the hydraulic hose 4, overview figure hose 9 .

Figure 26
Heat exchanger

1. Hose part no. 943368, hose clamp part no. 943473

2. Hydraulic hose
3. Hose part no. 943368, hose clamp part no. 943473
4. Hydraulic hose

32. Disconnect the vacuum pump.

33. Clamp the hose from the suction filter with the cable tie 1 together with the existing hose.
NOTE!
Clamp the hose so that no folds occur on the hose.

Minimum measurement with diesel engine off, see dimension lines in fig. 27, between the filter and cover shall be
22 mm.
 Figure 27
Suction hoses

1. Cable tie

34. Overview of installation of pump kit and heat exchanger.

Figure 28
Left member, inside

35. Clamp the hoses at suitable places with cable ties 1 and the hoses from the flow distributor and leak-oil filter.
Hoses for the intercooler should be routed under the exhaust pipe at an adequate distance, against the intercooler.

Figure 29
Hose routing

1. Cable ties

36. Connect a suitable connection fitting 1 with a hose to the existing connection fitting on the radiator and drain
approx. 25-30 litres of coolant in a container or similar.
 Figure 30
Radiator

1. Connection fitting

37. Remove the cable ties for electrical cabling, loosen rubber clamps 3.
Loosen the hose clamps 1 respective 4, and remove the pipe 2 .

Figure 31
Diesel engine

1. Hose clamp
2. Pipe
3. Rubber clamps
4. Hose clamp

38. Disconnect the brackets 3 from the engine.

Loosen the hose clamps 1 respective 4 , and remove the pipe 2 .

Figure 32
Diesel engine
 1. Hose clamp
2. Pipe
3. Brackets
4. Hose clamp

39. Fit the pipe 2with existing brackets and existing hose clamp 1.

Figure 33
Diesel engine

1. Hose clamp
2. Pipe part no. 14347185

40. Fit the T-pipe 4 and the hose 3,overview figure hose 14.
Cut the hose 2 to 150 mm (300 mm cut in half) and fit the hose with hose clamps 1 (2 pcs.).

Figure 34
Diesel engine

1. Hose clamps part no. 943475

2. Hose part no. 944386
3. Hose + hose clamp part no. 943473
4. T-pipe part no. 14347123

41. Fit the pipe 1 with existing rubber clamps and hose clamp 2.
 Figure 35
Diesel engine

1. Pipe 14347184
2. Hose clamp

42. Fit the T-pipe 1and the hose 2, overview figure hose 15.
Fit the hose 3 (half hose length from step 39) and fit the hose with hose clamps 4 (2 pcs.).

Figure 36
Diesel engine

1. T-pipe part no. 14347123

2. Hose + hose clamp part no. 943473
3. Hose part no. 944386
4. Hose clamps part no. 943475

43. Clamp the hose in the brackets and along the pipe with cable ties 1 according to the figure.

Figure 37
Diesel engine
 1. Cable ties

44. Clamp the hoses from the intercooler at an adequate distance from the exhaust pipe.

45. Remove the cap 1 and refill the drained coolant.

Figure 38
Expansion tank

1. Cap

46. Fit the existing air venting plug from the pump gearbox on the expansion tank 2and fit the tank in the grating with
the flange bolts 1 (one washer on both sides of the grating).
NOTE!
If level sheet metal grating (yellow paint) is installed, use flange bolts part no. 13946173, and with galvanized
slotted grating use flange bolts part no. 13948217.

Fit the air nipple 4 in the pump gearbox and fit the hose 3.

Figure 39
Space above pump gearbox

1. Flange bolts part no. 13946173 or part no. 13948217, washers part no. 13948087
2. Expansion tank part no. 14 347 180
3. Hose part no. 943366, hose clamps part no. 943470
4. Air nipple part no. 14 347 090, O-ring part no. 14210587

47. Fill gearbox oil through the plug on the pipe fitting A, see fig. 20 and check the oil level by pulling up the air
nipple and measuring the oil level with the existing oil dipstick.
Oil volume: approx. 5 litres, synthetic API GL5SAE 75/90 or Volvo transmission oil 97312 T65 75W/90.
Change interval for oil and oil filter part no. 11707521 is 1000 hours .
NOTE!
Changing the leak-oil filter is recommended when changing axial seals in hydraulic pumps.
 48. Start the diesel engine.
Check for leaks and repair if needed.

49. Check the coolant level and top up, if needed.

50. Check the oil level in the pump gearbox by removing the air nipple 4 and check with the existing oil dipstick and
adjust level, if needed.
NOTE!
Oil level in the pump gearbox is checked every50thoperating hour with the existing oil dipstick.

Keep the oil dipstick in a suitable location in the machine, for example, in the toolbox, between checks.

51. Refit the plate under the pump gearbox.

NOTE!
Check that there is sufficient distance between the filter and the cover, see min. measurement in fig. 27. The filter may not
touch the cover, even when the engine is under max. load with maximal elongation of the engine rubber cushions.