Eaton EP Control User manual

Eaton®Electronic Proportional (EP) Control

for Medium Duty 72400 Piston Pumps

Installation 04-10-0003

EN-0901

EATON CORPORATION Fluid Power

EP Control for Medium Duty 72400 Piston Pumps

Installation 04-10-0003-EN-0901 September 2001

Table of Contents

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

Identification of Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Required Tools for Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

EP Control Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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

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

Neutral Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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

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

Troubleshooting Reference Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Information contained in this installation booklet is accurate as of the publication

date and is subject to change without notice. Performance values are typical val-

ues. Customers are responsible for selecting products for their applications

using normal engineering methods.

EATON CORPORATION Fluid Power

EP Control for Medium Duty 72400 Piston Pumps

Installation 04-10-0003-EN-0901 September 2001

Introduction

The following information describes the installation of the Electronic Proportional

(EP) Control for Eaton®Medium Duty 72400 piston pumps. Review this information

to become familiar with the procedures required before beginning any installation.

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 interconnection 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 electronic 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 prevent 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.

CAUTION

EATON CORPORATION Fluid Power

EP Control for Medium Duty 72400 Piston Pumps

Installation 04-10-0003-EN-0901 September 2001

Identification of Components

Electronic

Module

2 ea. Electronic

Module Bracket

Solenoid Coil

Subassembly

Valve Assembly

Solenoid Coil

Subassembly

Control Valve

Gasket

Solenoid Tube

Subassembly

Solenoid Tibe

Subassembly

4 ea. 1.75" -

10-24 Button Head

Cap Screws

4 ea. #10

Lockwashers

6 ea. 2.75" - 5/32" 10-24

Hex Head Cap Screws

Torque to 60-68 lbf-in.

2 ea. 1.25" - 5/32" 10-24

Hex Head Cap Screws

Torque to 60-68 lbf-in.

2 ea. 1.25" - 5/32" 10-24

Hex Head Cap Screws

Torque to 60-68 lbf-in.

Required tools

for Installation:

•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

EATON CORPORATION Fluid Power

EP Control for Medium Duty 72400 Piston Pumps

Installation 04-10-0003-EN-0901 September 2001

MODEL INPUT VALVE ELECTRONIC

KIT NO. CODE REF. KIT DESCRIPTION SIGNAL ASSEMBLY MODULE VOLTAGE

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

1-6 V input,

w/o brackets

9900016-000 EC EP Ctrl Kit MD 72400: — 4993057-012 — 12 V

12 V coils w/o

electronics

9900017-000 ED EP Ctrl Kit MD 72400: — 4993057-024 — 24 V

24 V coils

w/o electronics

9900018-000 EL EP Ctrl Kit MD 72400: ±100 mA 4993057-012 111520-100 12/24 V

±100 mA input,

w/o brackets

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

±4-20 mA input,

w/o brackets

9900020-000 EL EP Ctrl Kit MD 72400: ±100mA 4993057-012 111520-100 12/24 V

±100 mA input

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

±4-20 mA input

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

1-6 V input

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

Module 1-6 V

990831-000 EP Crtl Electronic ±100 mA — 111520-100 —

Module ±100 mA

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

Module ±4-20 mA

72400-942 Brackets and Screws

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

EP Control Kits

EATON CORPORATION Fluid Power

EP Control for Medium Duty 72400 Piston Pumps

Installation 04-10-0003-EN-0901 September 2001

Disassembly

Step 1

Clean the pump thoroughly. If conversion will be performed without removing

pump from machine, case fluid level will need to be lowered below EP Control

mounting surface.

Step 2

Remove the manual displacement control. Using a 5/32" hex key or bit socket,

remove the cap screws and discard.

Step 3

Carefully lift the manual displacement control away from the pump to disengage the

feedback link from the servo piston land.

Installation

EATON CORPORATION Fluid Power

EP Control for Medium Duty 72400 Piston Pumps

Installation 04-10-0003-EN-0901 September 2001

Step 4

Remove the control valve gasket from the pump housing and discard.

With a 5/32" hex key or bit socket, remove the two top hex head cap screws on

each side of the servo piston cap so the “L” brackets for the electronic module can

be mounted.

Remove

top hex

head cap

screws

on each

side.

EATON CORPORATION Fluid Power

EP Control for Medium Duty 72400 Piston Pumps

Installation 04-10-0003-EN-0901 September 2001

Reassembly

Step 6

Locate the EP Control valve assembly, electronic module, bolts, washers and

control valve gasket. Clean the control mounting surface and install a new control

valve gasket by aligning with bolt and porting holes.

Step 7

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 link.

Step 8

Use a 5/32" hex key or bit socket to install the six 10-24 hex head cap screws.

Torque to 60-68 lbf·in.

EATON CORPORATION Fluid Power

EP Control for Medium Duty 72400 Piston Pumps

Installation 04-10-0003-EN-0901 September 2001

Step 9

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 adjust-

ing 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.

E. Note the number stamped on the cap of the low pressure relief valve. -022 is

220 psig (15 bar), -030 is 305 psig (21 bar), etc. This will be the high setting.

Settings can vary from 155 psig (11 bar) to 325 psig (22.4 bar).

EATON CORPORATION Fluid Power

EP Control for Medium Duty 72400 Piston Pumps

Installation 04-10-0003-EN-0901 September 2001

F. Slowly rotate the neutral adjustment screw clockwise until charge pressure drops

to its low setting. Mark the neutral adjustment screw location.

Note: The charge pressure low setting is usually 40-60 psig lower than the high

setting.

G. Rotate the neutral adjustment screw counterclockwise. The charge pressure will

rise. Continue turning counterclockwise until the pressure drops again to its low

setting. Mark the neutral adjustment screw location.

H. Rotate the neutral adjustment screw to the position between the two marks.

I. Carefully hold adjustment screw while torquing locknut. Torque locknut to 10±1

lbf·ft. Neutral adjustment is completed.

Alignment slot to be

towards control spool ±90˚

Spool

Solenoid Solenoid

300

200 400

100 500

0600

PSI

300

200 400

100 500

0600

PSI

High

Setting Range

Low

Setting Range

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