Eaton 33 User manual

Electronic Proportional (EP) Control for

Heavy Duty Series 2 Piston Pumps

Parts & Service 08-10-0002

EN-0901

Model 33

Model 39

Model 46

Model 54

Model 64

2EATON EP Control for Heavy Duty Series 2 Piston Pumps Parts & Service 08-10-0002-EN-0901 September 2001

EP Control for

Heavy Duty Series

2 Piston Pumps

Table of Contents

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

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

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

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

Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Interconnect Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting Reference Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3EATON EP Control for Heavy Duty Series 2 Piston Pumps Parts & Service 08-10-0002-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.

The purpose of this manual is to

provide the necessary informa-

tion to troubleshoot and repair

the EP Control for Eaton®Heavy

Duty Series 2 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 publication 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 Heavy Duty Series 2 Piston Pumps Parts & Service 08-10-0002-EN-0901 September 2001

EP Control Kits

MODEL CODE INPUT VALVE ELECTRONIC

KIT NO. REFERENCE KIT DESCRIPTION SIGNAL ASSEMBLY MODULE VOLTAGE

9900040-000 EE EP Ctrl Kit HD Series 2 33/64: 1-6 V input 1-6 V 4993054-012 111520-016 12/24

9900042-000 EG EP Ctrl Kit HD Series 2 33/64: ±4-20 mA input ±4-20 mA 4993054-012 111520-020 12/24 V

9900043-000 EC EP Ctrl Kit HD Series 2 33/64: 12 V coils w/o electronics — 4993054-012 — 12 V

9900044-000 ED EP Ctrl Kit HD Series 2 33/64: 24 V coils w/o electronics — 4993054-024 — 24 V

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

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

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

Parts

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 3 10-24 Button Head Cap Screw (1/8 hex key) - 1.75"

316045-203 3 #10 Lockwasher

495912-200 5 5/16"-18 Hex Head Cap Screw - 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)

74993054-012 1 Valve Assembly - (includes items 5 & 6 - 12 V Solenoid Coil & Tube Subassemblies)

74993054-024 1 Valve Assembly - (includes items 5 & 6 - 24 V Solenoid Coil & Tube Subassemblies)

8110003-000 1 Control Valve Gasket

*Includes necessary O-Rings.

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 Heavy Duty Series 2 Piston Pumps Parts & Service 08-10-0002-EN-0901 September 2001

Required Tools for

Disassembly, Repair and Test

•1/8" Bit Socket or Hex Key

•1/4" Bit Socket or Hex Key

•1/2" Open-End Wrench or 1/2" Socket

•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

Parts

6EATON EP Control for Heavy Duty Series 2 Piston Pumps Parts & Service 08-10-0002-EN-0901 September 2001

Disassembly Step 1

Disconnect all power to the

input device. Carefully

disconnect the three-pin

connector between the EP

Control electronics module and

the command input device by

releasing the connector latches.

Thoroughly clean the outside of

the EP Control and surrounding

pump surface.

Step 3

Disconnect the four-pin

connector between the EP

Control electronic module and

the solenoid coils. Caution must

be used when disconnecting

these connectors as they are

latched with keepers.

Step 2

Using a 1/8" bit socket or hex

key, remove the three 10-24

button head cap screws and

lockwashers.

Repair & Service

7EATON EP Control for Heavy Duty Series 2 Piston Pumps Parts & Service 08-10-0002-EN-0901 September 2001

Step 5

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.

Step 6

Using a 3/4" open-end wrench,

remove solenoid tube subassembly

by turning counterclockwise.

Repeat on the second tube.

If just replacing the coil and tube

subassemblies, skip to Reassembly,

Step 16.

Step 4

Using a Phillips screwdriver, remove

the set screw and lockwasher

which hold the

Metri-Pack®connector to the

EP Control valve assembly.

Repair & Service

8EATON EP Control for Heavy Duty Series 2 Piston Pumps Parts & Service 08-10-0002-EN-0901 September 2001

Step 7

Using a 1/4" hex key (or 1/2"

socket/end wrench), remove the

five 5/16"-18 hex head cap screws.

Step 8

Carefully lift the valve assembly

straight up away from the pump.

Take care not to damage the feed-

back link or swashplate link.

Step 9

Caution must be used so that

the swashplate link remains

seated on the swashplate pin.

Repair & Service

9EATON EP Control for Heavy Duty Series 2 Piston Pumps Parts & Service 08-10-0002-EN-0901 September 2001

Reassembly

Step 11

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.

Step 12

Clean the EP Control mounting

surface. Install a new control valve

gasket by aligning with screw and

porting holes.

Step 10

Remove and discard the control

valve gasket.

Repair & Service

10 EATON EP Control for Heavy Duty Series 2 Piston Pumps Parts & Service 08-10-0002-EN-0901 September 2001

Step 15

Using a 1/4" hex key (or 1/2"

socket/end wrench), tighten the five

5/16"-18 hex head cap screws.

Torque to 22±2 lbf·ft.

Step 13

Carefully align the EP Control valve

assembly to the pump housing.

Align the hole in the EP Control

feedback link with the swashplate

link.

Step 14

Carefully lower the valve assembly

straight down onto the pump,

guiding the EP Control feedback link

onto the swashplate link. The EP

Control feedback link must engage

the swashplate link.

Feedback Link

Swashplate Link

Repair & Service

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