Eaton EP Control Manual de usuario

Electronic Proportional (EP) Control for

Medium Duty 72400 Piston Pumps

Parts & Service 08-10-0003

EN-0901

2EATON EP Control for Medium Duty 72400 Piston Pumps Parts & Service 08-10-0003-EN-0901 September 2001

EP Control for

Medium Duty

72400 Piston

Pumps

Table of Contents

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Parts and Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Interconnect Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Troubleshooting Reference Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3EATON EP Control for Medium Duty 72400 Piston Pumps Parts & Service 08-10-0003-EN-0901 September 2001

In order to assure the most

reliable installation and

operation of any electronic

control, proper component

selection and installation

procedures must be followed

with respect to interconnec-

tion wiring harnesses, input

command signal devices,

fusing, and input power

switching.

Appropriate industry practices

must be followed to prevent

damage of and shorting of all

electrical and electronic

components caused by

environmental hazards and

application specific hazards.

Typical hazards that damage

the wiring harnesses or other

components are abrasion,

moving objects, and heat from

the engine or exhaust system.

Moisture can damage poorly

sealed connectors and/or

components, causing short

circuits and other problems

like corrosion.

A switch must be installed

in line with (+ battery) power

to the electronic module, so

that power may quickly be

disconnected in case of

emergency (component failure

or inadvertent commands).

A fuse rated at the maximum

module operating current (3

Amp) must be installed in the

+ battery line to the electronic

module.

All the electrical connections

to the EP Control electronic

module must be disconnected

prior to performing any

electrical welding on the

vehicle or machine. The elec-

tronic module and/or the

hydraulic pump are not to be

used as a connection point for

electrical welding equipment.

During initial start-up and/or

checkout of the machine after

service, the machine must be

placed on jack stands to pre-

vent inadvertent movement.

The reliable operation and

suitability of this product is

dependent upon how it is

applied and the other

components used in the

system. The system integrator

must review all aspects of the

application

and all of the components

used to assure proper

operation and reliability.

This manual provides the

necessary information to

troubleshoot and repair the

EP Control for Eaton®Medium

Duty 72400 piston pumps.

The EP Control consists of two

main parts, the valve assembly

and the electronic module.

Note: Many EP Control

components are not repairable,

i.e., the EP Control electronic

module has internal circuitry that

is environmentally encapsulated

into its housing. Replacing the

electronic module with a new

one is necessary if the module

is the source of a fault.

Complete kits are listed along

with individual components

should you choose to replace

individual components.

CAUTION

Information contained in this parts and service manual is

accurate as of the publication date and is subject to change

without notice. Performance values are typical values.

Customers are responsible for selecting products for their

applications using normal engineering methods.

4EATON EP Control for Medium Duty 72400 Piston Pumps Parts & Service 08-10-0003-EN-0901 September 2001

Parts List

ITEM PART NO. QTY. DESCRIPTION

1111520-016 1 Electronic Module - 1-6 V Input - 12/24 V

1111520-020 1 Electronic Module - ±4-20 mA Input - 12/24 V

2101673-175 4 10-24 Button Head Cap Screw (1/8" hex key) - 1.75"

316045-203 4 #10 Lockwasher

416147-326 6 10-24 Hex Head Cap Screw (5/32” hex key) - 2.75"

5111501-000 2 Solenoid Tube Subassembly*

6114241-012 1 Solenoid Coil Subassembly - 12 V (includes two coils and wiring harness)

6114241-024 1 Solenoid Coil Subassembly - 24 V (includes two coils and wiring harness)

74993057-012 1 Valve Assembly - (includes items 5 & 6 - 12 V Solenoid Coil & Tube Subassemblies)

74993057-024 1 Valve Assembly - (includes items 5 & 6 - 24 V Solenoid Coil & Tube Subassemblies)

872400-752 2 Electronic Module Bracket

916147-312 4 10-24 Hex Head Cap Screw (5/32" hex key) - 1.25" (can use existing from pump)

10 72400-631 1 Control Valve Gasket

*Includes necessary O-Rings.

EP Control Kits

MODEL CODE INPUT VALVE ELECTRONIC

KIT NO. REFERENCE KIT DESCRIPTION SIGNAL ASSEMBLY MODULE VOLTAGE

9900015-000 EE EP Ctrl Kit MD 72400: 1-6 V input, w/o brackets 1-6 V 4993057-012 111520-016 12/24 V

9900016-000 EC EP Ctrl Kit MD 72400: 12 V coils w/o electronics — 4993057-012 — 12 V

9900017-000 ED EP Ctrl Kit MD 72400: 24 V coils w/o electronics — 4993057-024 — 24 V

9900019-000 EG EP Ctrl Kit MD 72400: ±4-20 mA input, w/o brackets ±4-20 mA 4993057-012 111520-020 12/24 V

9900021-000 EG EP Ctrl Kit MD 72400: ±4-20 mA input ±4-20 mA 4993057-012 111520-020 12/24 V

9900022-000 EE EP Ctrl Kit MD 72400: 1-6 V input 1-6 V 4993057-012 111520-016 12/24 V

990830-000 EP Ctrl Electronic Module 1-6 V 1-6 V — 111520-016 —

990832-000 EP Ctrl Electronic Module ±4-20 mA ±4-20 mA — 111520-020 —

72400-942 Brackets and Screws

Note: All kits using Eaton EP Control Electronic Modules use 12 V coils.

Parts

Electronic Module Mating Connector Kit

KIT NO. PART (QTY.) DELPHI PACKARD P/N

990762-000 Command Input Signal Connector (1) 1211 0293

Terminal (3) 1204 8074

Cable Seal (3) 1204 8086

Cavity Plug (1) 1205 9168

Secondary Lock (1) 1205 2845

Power Supply Connector (1) 1205 2641

Terminal (2) 1204 8074

Cable Seal (2) 1204 8086

Secondary Lock (1) 1205 2634

Recommended wire size: 16 - 18 AWG

Recommended cable diameter: 2.03 - 2.80 mm

Alternate reference source: Pioneer Standard Electronics 1-800-257-6613

www.pios.com

Solenoid Coil Mating Connector Kit

(not needed when using an Eaton Electronic Module)

KIT NO. PART (QTY.) DELPHI PACKARD P/N

9900023-000 Connector (1) 1218 6568

Terminal (4) 1204 8074

Cable Seal (4) 1204 8086

Secondary Lock (1) 1204 7948

Recommended wire size: 16 - 18 AWG

Recommended cable diameter: 2.03 - 2.80 mm

Alternate reference source: Pioneer Standard Electronics 1-800-257-6613

www.pios.com

Solenoid Connector Update Kit

KIT NO. PART (QTY.) DELPHI PACKARD P/N

9900045-000 Tool (1) 1209 4429

4-Pin Housing Connector (Female) (1) 1218 6568

4-Pin Housing Connector (Male) (1) 1218 6271

EP Control Connector Kits

5EATON EP Control for Medium Duty 72400 Piston Pumps Parts & Service 08-10-0003-EN-0901 September 2001

Parts

•1/8" Bit Socket or Hex Key

•5/32" Bit Socket or Hex Key

•9/16" Open-End Wrench

•3/4" Open-End Wrench

•Flat Blade Screwdriver

•12 VDC Power Supply or Battery

•Voltage Ohm Meter (VOM)

•Charge Pressure Gauge

Required Tools for Disassembly, Repair and Test

6EATON EP Control for Medium Duty 72400 Piston Pumps Parts & Service 08-10-0003-EN-0901 September 2001

Disassembly

Step 2

Using a 5/32" hex wrench (or bit

socket), remove the two cap

screws on each side of the pump

holding the “L” brackets to the

pump.

Step 3

Using a 1/8" hex key (or bit socket),

remove the four 10-24 button head

cap screws and lockwashers on top

of the electronic control.

Disconnect the four-pin connector

between the EP Control module

and the solenoids. Caution must be

used when disconnecting these

connectors as they are latched with

keepers.

Step 1

Disconnect all power to the input

device. Carefully disconnect the

command input device from the

three-pin connector on the EP

Control electronics module by

releasing the connector latches.

Thoroughly clean the outside of the

EP Control and surrounding pump

surface.

To Pump

Repair & Service

7EATON EP Control for Medium Duty 72400 Piston Pumps Parts & Service 08-10-0003-EN-0901 September 2001

Step 5

Using a 3/4" open-end wrench,

remove each tube subassembly by

turning counterclockwise.

If only replacing the coil and tube

subassemblies, skip to Reassembly,

Step 12.

Step 6

Using a 5/32" hex key (or bit

socket), remove the six 10-24 hex

head cap screws.

Carefully lift the EP Control valve

assembly upward and slide the

assembly away from the pump to

disengage the feedback link from

the servo piston. Note which slot

the feedback link is assembled into.

Step 4

The two solenoid coils can be

removed by turning each solenoid

tube knob counterclockwise.

Remove the knob and associated

O-ring. Slide the coil off the tube

subassembly. Repeat for other coil.

Note: Each coil is stamped with a

position number “1” and “2” and

the voltage “12V” or “24V”. There

are also numbers stamped on the

valve assembly indicating positions

#1 and #2. When reassembling the

coils, the numbers stamped on the

coil and valve assembly must

match. Refer to page 3.

Repair & Service

8EATON EP Control for Medium Duty 72400 Piston Pumps Parts & Service 08-10-0003-EN-0901 September 2001

Step 7

Remove and discard the control

valve gasket.

Step 8

In most cases it will not be

necessary to remove the control

orifices that are staked in the pump

housing. Only remove if the orifice

size needs to be changed. The

orifice size is stamped on the flat

plate orifices in the pressure,

servo-1, and servo-2 ports.

S2 S1

Reassembly Step 9

Clean the EP Control mounting

surface. Install a new control valve

gasket by aligning with screw and

porting holes.

Repair & Service

9EATON EP Control for Medium Duty 72400 Piston Pumps Parts & Service 08-10-0003-EN-0901 September 2001

Step 10

Carefully install the EP Control valve

assembly on the pump housing,

making sure the feedback link is

installed in the appropriate servo

piston land.

Note: There is a narrow land on the

servo piston for the EP Control

feedback link and a wide land for

the swashplate follower.

Replace and hand tighten the six

10-24 hex head cap screws.

Step 11

Locate the new solenoid tube

subassembly. Each solenoid tube

subassembly comes with new

O-rings installed on the tubes.

The tube subassemblies are

interchangeable.

Step 12

Using a 3/4" open-end wrench,

replace each tube subassembly by

turning clockwise. Torque the

solenoid tubes to 32.5 ±2.5 lbf·ft.

Repeat for other tube subassembly.

Replace the coils. Note: The

position number stamped on the

coil and the valve assembly must

match.

Repair & Service

10 EATON EP Control for Medium Duty 72400 Piston Pumps Parts & Service 08-10-0003-EN-0901 September 2001

Step 13

Attach the retaining knob, and

torque to 12±1 lbf·ft.

Step 14

Using a 5/32" hex key or bit socket,

tighten the six 10-24 hex head cap

screws. Torque to 60-68 lbf·ft.

Step 15

Neutral Adjustment

Caution: All hoses and fittings

must be connected, and the pump

ready for operation before

attempting to check neutral

adjustment. Electrical wiring

harnesses for the solenoid coils

and command input should be left

disconnected while adjusting

neutral.

A. Disengage the input drive to

vehicle or elevate wheels.

B. Install charge pressure gauge. A

0-1000 psi or 0-1500 psi pressure

gauge is recommended.

C. Start the prime mover.

D. Loosen the locknut holding the

neutral adjustment screw until it

is just snug enough that the

threaded screw can be rotated.

Use a 9/16" end wrench to hold

the locking nut while rotating the

neutral adjustment screw.

Repair & Service

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