Electronic Proportional (EP) Control for Medium …

1 Electronic Proportional (EP) Control for Medium Duty 72400 Piston Pumps2 EATON EP Control for Medium Duty 72400 Piston Pumps Service & Repair E-PUPI-TS003-E September 2002EP Control forMedium Duty72400 PistonPumpsTable of ContentsIntroduction .. 3 Parts and Kits .. 4 Tools Required .. 5 Disassembly .. 6 Reassembly .. 8 Neutral Adjustment .. 10 Interconnect Schematic .. 13 Troubleshooting .. 14 Troubleshooting Reference Settings .. 173 EATON EP Control for Medium Duty 72400 Piston Pumps Service & Repair E-PUPI-TS003-E September 2002In order to assure the mostreliable installation andoperation of any electroniccontrol, proper componentselection and installationprocedures must be followedwith respect to interconnec-tion wiring harnesses, inputcommand signal devices,fusing, and input industry practicesmust be followed to preventdamage of and shorting of allelectrical and electroniccomponents caused byenvironmental hazards andapplication specific hazards that damagethe wiring harnesses or othercomponents are abrasion,moving objects, and heat fromthe engine or exhaust can damage poorlysealed connectors and/orcomponents, causing shortcircuits and other problemslike switch must be installed in line with (+ battery)

2 Powerto the Electronic module, sothat power may quickly bedisconnected in case ofemergency (component failureor inadvertent commands).A fuse rated at the maximummodule operating current (3 Amp) must be installed in the+ battery line to the the electrical connectionsto the EP Control electronicmodule must be disconnectedprior to performing anyelectrical welding on thevehicle or machine. The elec-tronic module and/or thehydraulic pump are not to beused as a connection point forelectrical welding initial start-up and/orcheckout of the machine afterservice, the machine must beplaced on jack stands to pre-vent inadvertent reliable operation andsuitability of this product isdependent upon how it isapplied and the othercomponents used in thesystem. The system integratormust review all aspects of theapplication and all of the componentsused to assure properoperation and manual provides thenecessary information totroubleshoot and repair the EP Control for Eaton MediumDuty 72400 piston EP Control consists of twomain parts, the valve assemblyand the Electronic : Many EP Controlcomponents are not repairable, , the EP Control electronicmodule has internal circuitry thatis environmentally encapsulatedinto its housing.

3 Replacing theelectronic module with a newone is necessary if the moduleis the source of a kits are listed alongwith individual componentsshould you choose to replaceindividual contained in this parts and service manual isaccurate as of the publication date and is subject to changewithout notice. Performance values are typical are responsible for selecting products for theirapplications using normal engineering EP Control for Medium Duty 72400 Piston Pumps Service & Repair E-PUPI-TS003-E September 2002 Parts List ITEMPART Module - 1-6 V Input - 12/24 V1111520-0201 Electronic Module - 4-20 mA Input - 12/24 V2101673-175410-24 Button Head Cap Screw (1/8" hex key) - "316045-2034#10 Lockwasher416147-326610-24 Hex Head Cap Screw (5/32 hex key) - "5111501-0002 Solenoid Tube Subassembly* 6114241-0121 Solenoid Coil Subassembly - 12 V (includes two coils and wiring harness)6114241-0241 Solenoid Coil Subassembly - 24 V (includes two coils and wiring harness)74993057-0121 Valve Assembly - (includes items 5 & 6 - 12 V Solenoid Coil & Tube Subassemblies)

4 74993057-0241 Valve Assembly - (includes items 5 & 6 - 24 V Solenoid Coil & Tube Subassemblies)872400-7522 Electronic Module Bracket916147-312 410-24 Hex Head Cap Screw (5/32" hex key) - " (can use existing from pump)1072400-6311 Control Valve Gasket*Includes necessary O-Rings. EP Control KitsMODEL CODEINPUTVALVEELECTRONICKIT NO. REFERENCEKIT DESCRIPTION SIGNAL ASSEMBLY MODULE VOLTAGE 9900015-000 EEEP Ctrl Kit MD 72400: 1-6 V input, w/o brackets 1-6 V 4993057-012 111520-016 12/24 V 9900016-000 ECEP Ctrl Kit MD 72400: 12 V coils w/o electronics 4993057-012 12 V 9900017-000 EDEP Ctrl Kit MD 72400: 24 V coils w/o electronics 4993057-024 24 V 9900019-000 EGEP Ctrl Kit MD 72400: 4-20 mA input, w/o brackets 4-20 mA 4993057-012 111520-020 12/24 V 9900021-000 EGEP Ctrl Kit MD 72400: 4-20 mA input 4-20 mA 4993057-012 111520-020 12/24 V 9900022-000 EEEP 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 ScrewsNote.

5 All kits using Eaton EP Control Electronic Modules use 12 V Module Mating Connector KitKIT (QTY.)DELPHI PACKARD P/N990762-000 Command Input SignalConnector (1) 1211 0293 Terminal (3)1204 8074 Cable Seal (3)1204 8086 Cavity Plug (1)1205 9168 Secondary Lock (1) 1205 2845 Power SupplyConnector (1) 1205 2641 Terminal (2) 1204 8074 Cable Seal (2) 1204 8086 Secondary Lock (1) 1205 2634 Recommended wire size: 16 - 18 AWGR ecommended cable diameter: - mmAlternate reference source: Pioneer Standard Electronics Coil Mating Connector Kit (not needed when using an Eaton Electronic Module)KIT (QTY.)DELPHI PACKARD P/N9900023-000 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: - mmAlternate reference source: Pioneer Standard Electronics Connector Update KitKIT (QTY.)

6 DELPHI PACKARD P/N9900045-000 Tool (1) 1209 44294-Pin Housing Connector (Female) (1) 1218 65684-Pin Housing Connector (Male) (1) 1218 6271EP Control Connector Kits5 EATON EP Control for Medium Duty 72400 Piston Pumps Service & Repair E-PUPI-TS003-E September 2002 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 GaugeRequired Tools for Disassembly, Repair and Test6 EATON EP Control for Medium Duty 72400 Piston Pumps Service & Repair E-PUPI-TS003-E September 2002 DisassemblyStep 2 Using a 5/32" hex wrench (or bitsocket), remove the two capscrews on each side of the pumpholding the L brackets to 3 Using a 1/8" hex key (or bit socket),remove the four 10-24 button headcap screws and lockwashers on topof the Electronic the four-pin connectorbetween the EP Control moduleand the solenoids.

7 Caution must beused when disconnecting theseconnectors as they are latched 1 Disconnect all power to the inputdevice. Carefully disconnect thecommand input device from thethree-pin connector on the EPControl electronics module byreleasing the connector clean the outside of theEP Control and surrounding PumpRepair & Service7 EATON EP Control for Medium Duty 72400 Piston Pumps Service & Repair E-PUPI-TS003-E September 2002 Step 5 Using a 3/4" open-end wrench,remove each tube subassembly byturning counterclockwise. If only replacing the coil and tubesubassemblies, skip to Reassembly,Step 6 Using a 5/32" hex key (or bitsocket), remove the six 10-24 hexhead cap screws. Carefully lift the EP Control valveassembly upward and slide theassembly away from the pump todisengage the feedback link fromthe servo piston.

8 Note which slotthe feedback link is assembled 4 The two solenoid coils can beremoved by turning each solenoidtube knob the knob and associatedO-ring. Slide the coil off the tubesubassembly. Repeat for other coil. Note:Each coil is stamped with aposition number 1 and 2 andthe voltage 12V or 24V . Thereare also numbers stamped on thevalve assembly indicating positions#1 and #2. When reassembling thecoils, the numbers stamped on thecoil and valve assembly mustmatch. Refer to page & Service8 EATON EP Control for Medium Duty 72400 Piston Pumps Service & Repair E-PUPI-TS003-E September 2002 Step 7 Remove and discard the controlvalve 8In most cases it will not benecessary to remove the controlorifices that are staked in the pumphousing. Only remove if the orificesize needs to be changed.

9 Theorifice size is stamped on the flatplate orifices in the pressure,servo-1, and servo-2 9 Clean the EP Control mountingsurface. Install a new Control valvegasket by aligning with screw andporting & Service9 EATON EP Control for Medium Duty 72400 Piston Pumps Service & Repair E-PUPI-TS003-E September 2002 Step 10 Carefully install the EP Control valveassembly on the pump housing,making sure the feedback link isinstalled in the appropriate servopiston :There is a narrow land on theservo piston for the EP Controlfeedback link and a wide land forthe swashplate follower. Replace and hand tighten the six10-24 hex head cap screws. Step 11 Locate the new solenoid tubesubassembly. Each solenoid tubesubassembly comes with new O-rings installed on the tubes. The tube subassemblies areinterchangeable.

10 Step 12 Using a 3/4" open-end wrench,replace each tube subassembly byturning clockwise. Torque thesolenoid tubes to lbf for other tube the coils. Note:Theposition number stamped on thecoil and the valve assembly & Service10 EATON EP Control for Medium Duty 72400 Piston Pumps Service & Repair E-PUPI-TS003-E September 2002 Step 13 Attach the retaining knob, andtorque to 12 1 lbf 14 Using a 5/32" hex key or bit socket,tighten the six 10-24 hex head capscrews. Torque to 60-68 lbf 15 Neutral AdjustmentCaution:All hoses and fittingsmust be connected, and the pumpready for operation beforeattempting to check neutraladjustment. Electrical wiringharnesses for the solenoid coils and command input should be leftdisconnected while Disengage the input drive tovehicle or elevate charge pressure gauge.