Eaton EP Control User manual

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
P
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