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