Heavy-Duty Series 2 Hydrostatic Piston Pumps …

1 Heavy-Duty Series 2 Hydrostatic Piston PumpsParts and ServiceModel 3322 Model 3922 Model 4622 Model 5422 Model 64222 EATONH eavy- duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004 Introduction.. 3ID Tag Information .. 3 Parts DrawingsRequired Tools for Disassembly/Reassembly .. 4 Disassembly Order .. 4 Exploded Views Charge Pump and End Cover Assembly .. 5 Rotating Group and Main Housing .. 6 Parts ListsModels 3322/3922/4622 (54, 64, 75 cc/rev) .. 7 Models 5422/6422 (89, 105 cc/rev) .. 8 Main Housing.. 9 Drive Shaft Subassembly .. 9 End Cover .. 10-11 Controls Manual Control Valve .. 12 Manual Control Valve Wide Band .. 12 Manual Control Valve with N/C Neutral Lockout .. 12 Solenoid Control Kit .. 13 Hydraulic Remote Control Kit.

2 14 Connector Kits .. 14 Electronic Proportional (EP) Displacement Control .. 15-16 Rotating Group/Swashplate Subassembly .. 17-18 Hold-down Kits .. 19 Propel Valve Plate or V-Groove Plate .. 19 Charge Pump Subassembly .. 20 Auxiliary Mounting Kits .. 20-22 Servo Piston and Cover .. 23 Pressure Override Valve.. 24 High Pressure Valve .. 24 Low Pressure Relief Valve .. 25 Kits .. 26 Repair InformationDisassembly .. 27-33 Assembly.. 34-43 Troubleshooting .. 44-53 Valve /Test Port Location .. 45 Gauge Requirements, Gauge Port Size and Location .. 46 Pressure Readings .. 46 Nominal Operating Pressures .. 46 Fault-Logic Tables .. 47-51 Tips .. 52 Hydraulic Fluid Recommendations .. 53-54 Special Tools .. 55-57 Model Code Description .. 58-59 Table ofContents3 EATONH eavy- duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004ID (cc/rev.)

3 0033 = (54)0039 = (64)0046 = (75)0054 = (89)0064 = (105)BIdentifies Type ofProduct22 = VariableDisplacement PumpCIdentifies Specific UnitConfigurationDMonth of ManufactureEYear of ManufactureFSpecific Serial Numberof UnitGDirection of Input ShaftRotation Observed fromShaft End of UnitCW=ClockwiseCCW=CounterclockwiseABCG EDFR efer to specific part listings for your Eatonpump when orderingreplacement are availablefrom eaton . Sample tagshows ordering replace-ment parts, you mustinclude the followinginformation:This Manual provides parts and service information for eaton heavy Series 2 Hydrostatic Piston Pumps , Models 3322, 3922, 4622, 5422 and 6422. Step by stepinstructions for complete disassembly, inspection and reassembly of the pump aregiven. The following recommendations should be followed to insure successful repairs.

4 Most repairs require the removal of the pump from the vehicle. Cleanliness is extremely important. Clean the port areas thoroughly before disconnecting the hydraulic lines. Plug the pump ports and cover open hydraulic lines immediately after they havebeen disconnected. Drain the oil and clean the exterior of the pump before making repairs. Wash all metal parts in clean solvent. Use filtered, moisture-free compressed air to dry the parts. Dot not wipe themdry with paper towels or cloth lint in a hydraulic system will cause damage. Always use new seals when reassembling hydraulic Pumps . Lubricate new rubber seals with a petroleum jelly (Vaseline ) before installation. Torque all bolts over gasketed joints, then repeat the torquing sequence to makeup for gasket all repairs are complete it is essential to verify the accuracy of pump repairson an authorized test Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004 1/4 in.

5 Hex Key 5/16 in. Hex Key 9/16 in. Hex Key 5/8 in. Hex Key 12 mm Hex Key 5/16 in. Socket or End Wrench 1/2 in. Socket or End Wrench 9/16 in. Socket or End Wrench 11/16 in. End Wrench 3/4 in. Socket or End Wrench 1 in. Socket or End Wrench 1-1/4 in. Socket or End Wrench Breaker Bar or Ratchet Wrench Torque Wrench (200 Max. Capacity) Adjustable Pliers Screwdrivers (Small & Large) Internal Retaining Pliers (str..047 Tips) Internal Retainer Pliers (Str. Tips) Dial Indicator with Magnetic Base Depth Micrometer with Extensions Parallel Bars (2) Slide Hammer Split Blade Bearing Puller Hammer (Steel and Plastic) Small Machinist Ruler Small Flashlight Light Petroleum Jelly Suitable Solvents and CleanersSpecial Tools (shown on pages 54-56) End Cover Tool Limit Stop for Bearing ConeInstallation Low Clearance Bearing Puller Seal BulletEnd CoverRotating Assembly & ShaftControlServo Piston Main HousingAuxiliary Mounting AdaptorCharge Pump Cover3452761 Main components must betaken apart in the properorder to prevent damage1 Control (as applicable)2 Auxiliary Mounting adapter (if applicable)

6 3 Charge Pump Cover4 End Cover5 Rotating Group and shaft6 Servo Piston7 Main HousingDisassembly Order for Main ComponentsRequired Tools Disassembly/AssemblyCAUTION5 EATONH eavy- duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004551343423 Charge Pump and Auxiliary Mount (See page 19)44 79786367646059634157656666555556 Obsolete shim adjusted POR76 176 163 Note:this is a typical Series 2configuration. Your model maydiffer slightly from this viewdepending on features Side Ported End CoverModel 5422-6422 Model 3322-4622 DISPLACEMENTM odel 332254,4 cm3 in3/revModel 392263,7 cm3 in3/revModel 462275,4 cm3 in3/revModel 542289,2 cm3 in3/revModel 6422105,5 cm3 in3/revParts DrawingCharge Pump& End CoverAssembly*Note:This is a typical Series 2configuration.

7 Your model may differ slightly from this viewdepending on features Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 20041226 4744545354534546145656211867316640130117 4811682818077062662985858686618732 Optional Magnetic Speed SensorID Tag3163287 OptionalSpeedSensorPort Plug2827 66282726 Optional External Servo Stop 109108110111 Optional External Servo Stop 343533108162111110 Parts DrawingRotating Group& Main HousingAssembly*Note:This is a typical Series 2configuration. Your model may differ slightly from this viewdepending on features Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004 REFERENCEITEMP/NQTY. DESCRIPTIONPAGES1 See Table Housing 92 See Table Shaft Sub-assembly93 See Table , Cover 10-114103090-3258 Hex Bolt HD 3/8-16 Gr.

8 85 See Table Cover Gasket256,7,8,9 See Table 1 Control Valve12-1612 See Table Kit Sub-assembly17-1813 See Table Valve/V-Groove/Quiet Plate19141032411 Bearing Plate (Models 33/39)141041981 Bearing Plate (Model 46)15,16,17,18,19,20,21,22,23,24 Charge Pump SubassemblySee Table , *2 Ring Seal26 See Table , 1 Servo Piston Sub-assembly23278761-144*2O-Ring28108300 *2 Ring Seal29 See Table Piston Cover 2330 See Table Piston Cover233195862-0888 Hex Bolt HD 5/16-18 Gr 5328761-139*2O-Ring3316254-81 Thread seal3496097-0501 Nut, Hex .50-203516254-281 Washer40103232-0001 Bearing Cup41 See Table End Cover Bearing Shim Kit2642/43 108295-0001 Bearing Cup/Bearing Cone Subassembly441075752 Swash Bearing Sub-assembly451083312 Race Pin461088232 Clocking Link471081521 Slide Block48 See Table **1 Low Pressure Relief Valve Plug25498785-012*1O-Ring531082142 Hold Down Spring5416048-4802 Hold Down Washer551075822 Hollow Dowel5698202 3 Dowel57110457-000*4 Static Face Seal598761-017*2O-Ring (between end cover and housing)60108562-000*2 Back-up Ring (between end cover and housing)6125083-011O-Ring Plug621078871O-Ring Plug Soc HD6325706-0062O-Ring Plug6425090-0101O-Ring Plug6525090-0043O-Ring Plug6625083-00412O-Ring Plug (not all positions shown)

9 6725083-0023O-Ring Plug (used with Pressure Override option)68965591 Shipping Strap (not shown)70111402-0001 Control Link Sub-assembly71, 72 See Table Control12764994730-xxx(1)2 Relief Valve, Pressure Override See Table (optional) 2378110700-xxx(1)1 Relief Valve and/or See Table , Valve (B Port) 23*available in gasket kit 990710-000**available in kit (1)See Table for correct part number identification and pressure only with remote or pressure side DESCRIPTIONPAGES79110700-XXXXXX(1)1 Relief Valve and/or Check Valve (A Port)See Table , ,81,82 See Table Valve Orifice88395653-0122 Soc Pipe Plug .125-27 NPTF (inside charge pump inlet port)8495653-0062 Soc Pipe Plug .062-27 NPTF (inside charge pump inlet port)85**1 Magnetic Speed Sensor (optional)1083071 Plug (optional)8616160-1251 Retaining Ring (optional)878761-016*1O-Ring95, 96, 97, 105 See Charge Pump Sub-assembly 20-22116**1 Drive Shaft Seal117**1 Ring, Retaining118**1 Spacer11995653-0121 Soc Pipe Plug.

10 125-27 NPTF (optional) 1634994730-XXX1 Pressure Override Relief Valve (optional)See Table NutParts ListModels 3322/3922/46228 EATONH eavy- duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004 REFERENCEITEM P/NQTY. DESCRIPTIONPAGES1 See Table Housing 92 See Table Shaft Subassembly93 See Table , Cover 10-114103091-3258 Hex Bolt HD 7/16-16 Gr85 See Table Cover Gasket 266,7,8,9 See Tables Valve1412 See Table Kit Subassembly1613 See Table Valve/V-Groove/Quiet Plate18141038521 Bearing Plate (Model 54)141038141 Bearing Plate (Model 64)15,16,17,18,19,20,21,22,23,24 Charge Pump SubassemblySee Table *2 Ring Seal26 See Table Piston Sub-assembly22278761-157*2O-Ring28108915 *2 Ring Seal29, 30 See Table Piston Cover 223195912-0888 Screw, Cap Soc HD 5/16-18 Gr 8328761-145*2O-Ring3316254-81 Thread seal3496097-0501 Nut, Hex.