Eaton EP Control User manual

Eaton®Electronic Proportional (EP) Control
for Medium Duty 72400 Piston Pumps
Installation 04-10-0003
EN-0901

2
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.

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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

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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

5
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

6
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

7
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.

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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.

9
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).

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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