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Mando Elec-Propor. HD
Mando Elec-Propor. HD
6-531
Eaton October 1999
On/Off Switch B
Hydrostatic Pumps. B–
+ – C
Fuse ◊ PWM
Battery or Control D
The EP Control consists of 2 main parts, the Valve Power Supply Driver
Assembly and the Electronic Module. A Module
Proportional
Solenoid 2
Command Input
B
Signal Connector *
Note: Many of the EP Control Assemblies are not C
S1
repairable, i.e. the EP Electronic Control Module has Note: Customer supplies: S2
P
internal circuitry that is environmentally encapsu- ◊ 3A Slo-Blo© (Time Delay) fuse for 12-24Vdc system
lated into its housing. Therefore replacing the
Mechanical
Electronic Module assembly with a new assembly is Proportional Swashplate
necessary if the module is the source of a fault. 2 Solenoid 1 Solenoid Actuated Feedback
Valve Assembly
Complete assembly kits are listed along with
individual components should you choose to
replace individual components. 3
10
1 9
11
2 7
Parts List – EP Control for Series 1 Hydrostatic Pumps
Parts List - Electronic Proportional (EP) Control
Item Part No. QTY Description
8 110306-024 1 Solenoid Coil Subassembly - 24V (includes 2 coils and wiring harness)
9 111390-000 1 EP Control Valve Subassembly - 33-39-46 Displacement - (includes items 7 & 8 – 12V Solenoid Coil & Tube Subassemblies)
9 111390-001 1 EP Control Valve Subassembly - 54-64 Displacement - (includes items 7 & 8 – 12V Solenoid Coil & Tube Subassemblies)
9 111390-002 1 EP Control Valve Subassembly - 76 Displacement -(includes items 7 & 8 – 12V Solenoid Coil & Tube Subassemblies)
9 111390-003 1 EP Control Valve Subassembly - 33-39-46 Displacement - (includes items 7 & 8 – 24V Solenoid Coil & Tube Subassemblies)
9 111390-004 1 EP Control Valve Subassembly - 54-64 Displacement - (includes items 7 & 8 – 24V Solenoid Coil & Tube Subassemblies)
9 111390-005 1 EP Control Valve Subassembly - 76 Displacement - (includes items 7 & 8 – 24V Solenoid Coil & Tube Subassemblies)
10 25083-006 2 O-RIng Plug Socket Head Subassembly*
11 8835-000 1 Control Valve Gasket
*Includes necessary O-Rings.
3
Parts List – EP Control for Series 1 Hydrostatic Pumps
4
Repair Information – EP Control for Series 1 Hydrostatic Pumps
Disassembly
Step 3
Step 1 Using a 1/8" Bit socket or hex key, remove the
Disconnect all power to the input device. Carefully three 10 -18 button head cap screws and
disconnect the command input device to the three- lockwashers.
pin connector on the EP Control Electronics Mod-
ule by releasing the connector latches. Thor-
oughly clean the outside of the control and sur-
rounding pump surface.
Step 4
The solenoid coils can be removed by turning each
solenoid tube knob counterclockwise. Remove the
knob and the associated O-ring. Slide the coil off
of the tube assembly. Repeat for position 2. Each
Step 2 coil is stamped with a position number “1” and “2”
Disconnect the four-pin mating connector between and the voltage “12V” or “24V”. Make a note of
the EP Control Module and the solenoids. Caution each solenoid location. When reassembling the EP
must be used when disconnecting these connec- coils, each coil number must match the location
tors as they also are latched with keepers. number stamped on each coil as shown on page 2.
There are also numbers stamped on the housing
indicating positions #1 and #2.
5
Repair Information – EP Control for Series 1 Hydrostatic Pumps
Step 5 Step 7
Using a 3/4" open end wrench, remove tube Remove and discard the control gasket.
assembly by turning counterclockwise. Repeat on
coil #2.
Step 8
In most cases it will not be necessary to remove
the control orifices that are staked in the control
housing unless the orifice size needs to be
Step 6 changed. The orifice size is stamped on the flat
Using a 1/2" Socket or end wrench, remove the six plate orifices in the pressure and servo-1 ports. If
5/16"- 18 hex head retaining bolts. Note: There are there is an orifice in the servo-2 port it is a
three different bolt lengths. Refer to page 2 for threaded screw-in orifice.
proper placement.
6
Repair Information – EP Control for Series 1 Hydrostatic Pumps
Reassembly
Step 3
Step 1
Locate the new solenoid coil subassembly. Each
Clean the control mounting surface. Install a new
solenoid tube assembly comes with new O-rings.
control gasket by aligning with bolt and porting
Refer to the drawing on page 2 for detail. The tube
holes.
assemblies are interchangeable. Be sure to install
new O-rings.
Step 2
Step 3
Carefully install the EP control housing assembly
Using a 3/4" open end wrench, replace the tube
on the pump housing, using a sideways motion to
assembly by turning clockwise. Torque the sole-
insert the feedback link into the swashplate link
noid tubes to 20±2 lbf·ft. Repeat on tube assembly
and aligning the control. Replace and hand tighten
#2.
the six 5/16"-18 hex head retaining bolts. Note:
There are three different bolt lengths. Refer to page
Replace the coils. The solenoid coil position
2 for proper placement.
number should match the position number
stamped on each coil assembly and the stamping
on the control housing (refer to page 2).
7
Repair Information – EP Control for Series 1 Hydrostatic Pumps
Charge Pressure Gauge
0 - 600 PSI [ 0 - 37 bar ]
300
200 400
100 500
0
PSI 600
Step 5 Step C
Attach the retaining knob, and hand tighten. Start the prime mover.
Charge Pressure Gauge Low
Charge Pressure Gauge High 0 - 600 PSI [ 0 - 37 bar ]
0 - 600 PSI [ 0 - 37 bar ]
300
300 200 400
200 400
100 500
100 500
PSI
0
PSI 600
0 600
High Low
Step D
Make note of the charge pressure gage reading. Is
the gage reading at the high or low setting?
Pressure readings will vary depending on the
Step 6 installed relief valve setting (Model Code Position
Using a 1/2" socket or end wench, Tighten the six 27), ranging from 21 bar [304.5 lbf/in2] to 30 bar
5/16"- 18 hex head retaining bolts. Note: There are [435 lbf/in2].
three different bolt lengths. Refer to page 2 for
proper placement. Torque the bolts to 16 lbf·ft. Note: The charge pressure relief valve used in
motors are usually set 40-60 psi lower than the
Step 7 charge relief valves used in pumps.
Neutral Adjustment
Step E
Step A a. Adjust the locknut so it is just snug
Disengage the input drive to vehicle or elevate enough that the threaded adjustment screw
wheels. can be rotated. Using a 9/16" end wench to
hold the locking nut, slowly rotate the
Step B neutral adjustment screw clockwise or
Install charge pressure gage. counterclockwise until charge pressure
drops to the low setting.
8
Repair Information – EP Control for Series 1 Hydrostatic Pumps
Alignment slot to be
towards control spool ± 90˚
Solenoid Solenoid
Spool
9
Repair Information – EP Control for Series 1 Hydrostatic Pumps
Step 10
Power should still be disconnected to the input
device. Connect the command input device to the
three-pin connector on the EP Control Electronics.
Step 11
Connect the electrical power source to the two-pin
connector on the EP Control Electronics. Install a
fuse per the interface diagram on the next page.
Recheck your work and then reconnect the power
to the vehicle or system.
Step 12
The pump is now ready to return to operation.
Interconnect Schematic
Customer Power Supply Solenoid
Furnished Connector ** Connector ***
A
A+
On/Off Switch B
B–
+ – C
Fuse ◊ PWM
Battery or Control D
Power Supply Driver
Proportional
A Module Solenoid 2
Command Input
B
Signal Connector *
C
S1 P
Note: Customer supplies: S2
◊ 3A Slo-Blo© (Time Delay) fuse for 12-24Vdc system
Mechanical
Proportional Swashplate
Solenoid 1 Solenoid Actuated Feedback
Valve Assembly
10
Troubleshooting – EP Control for Series 1 Hydrostatic Pumps
Command Signal Check Command input signal. Disconnect the customer mating three pin
Missing connector from the electronic control module three pin connector.
Inspect the two connectors for corrosion, loose contacts, loose wires and
broken wires.
Defective Solenoid Check Solenoid Coil. Disconnect customer 2 pin and 3 pin connectors
Coil from the electronic control module. Inspect the connectors for corrosion,
loose contacts, loose wires and broken wires. Remove the electronic
control module. Follow steps on page 5. Disconnect the two mating four
pin connectors. Measure the coil resistance across the designated pins at
the solenoid four pin connector. Refer to the solenoid 4-pin connector
chart on page 15 for typical readings.
Defective Electronic Check electronic control module. Disconnect customer 2 pin and 3 pin
Control Driver connectors from the electronic control module. Inspect the connectors
Module for corrosion, loose contacts, loose wires and broken wires. Remove the
electronic control module. Refer to instructions on page 5. Caution: The
engine or motor driving the pump should not be running. Connect
command input device and power to the module. Measure the current to
the coil at the four pin connector. Activate the input device end to end
and at neutral. Monitor the currrent on one coil, and then on the other.
Refer to Command Input Device chart on page 15 for typical readings.
11
Troubleshooting – EP Control for Series 1 Hydrostatic Pumps
Flow only in one Command Signal Check Command input signal. Disconnect the customer mating three pin
direction Missing connector from the electronic control module three pin conector. Inspect
the two connectors for corrosion, loose contacts, loose wires and broken
wires.
Defective Solenoid Check Solenoid Coil. Disconnect customer 2 pin and 3 pin connectors
Coil from the electronic control module. Inspect the connectors for corrosion,
loose contacts, loose wires and broken wires. Remove the control
module. Disconnect the two mating four pin connectors. Measure the
coil resistance across the designated pins at the solenoid four pin
connector. Refer to the solenoid 4-pin connector chart on page 15 for
typical readings.
Defective Solenoid Check Solenoid Tube Assembly. Disconnect customer 2 pin and 3 pin
Tube Assembly connectors from the electronic control module. Inspect the connectors
for corrosion, loose contacts, loose wires and broken wires. Remove the
two solenoid tube assemblies. Visually inspect the actuator pin in the
tube assembly. The pin should be free to move.
12
Repair Information – EP Control for Series 1 Hydrostatic Pumps
Flow in Neutral Command Signal Check Command input signal. Disconnect the customer mating three pin
Missing connector from the electronic control module three pin connector.
Inspect the two connectors for corrosion, loose contacts, loose wires and
broken wires.
Neutral out of Check Neutral Adjustment. Disconnect customer 2 pin and 3 pin
adjustment connectors from the electronic control module. Inspect the connectors
for corrosion, loose contacts, loose wires and broken wires. Remove the
electronic control module. Disconnect the two mating four pin
connectors. Follow instructions for setting neutral on page 8 step 7.
Flow Limited, cannot Command Signal Check Command input signal. Disconnect the customer mating three pin
achieve full pump Missing connector from the electronic control module three pin connector.
stroke Inspect the two connectors for corrosion, loose contacts, loose wires and
broken wires.
13
Repair Information – EP Control for Series 1 Hydrostatic Pumps
Defective Electronic Check electronic control module. Disconnect customer 2 pin and 3 pin
Control Driver connectors from the electronic control module. Inspect the connectors
Module for corrosion, loose contacts, loose wires and broken wires. Remove the
electronic control module. Refer to instructions on page 5. Caution:
The engine or motor driving the pump should not be running. Connect
command input devices and power to the module. Measure the current
to the coil at the four pin connector. Activate the input device end to end
and at neutral. Monitor the currrent on one coil, and then on the other.
Refer to Command Input Device chart on page 15 for typical readings.
Manual Override Check manual override. Disconnect customer 2 pin and 3 pin connectors
does not function from the electronic control module. Inspect the connectors for corrosion
loose contacts, loose wires and broken wires. Remove the solenoid
actuated valve assembly. Refer to instructions on page 6. Use a small
Philips screwdriver to push on the manual override of the solenoid
tubes’ s actuator pin should move the spool.
Does not return to Command Signal Check Command input signal. Disconnect the customer mating three pin
Neutral Missing connector from the electronic control module three pin conector. Inspect
the two connectors for corrosion, loose contacts, loose wires and broken
wires.
14
Troubleshooting – EP Control for Series 1 Hydrostatic Pumps
Neutral out of Check Neutral Adjustment. Disconnect customer 2 pin and 3 pin
adjustment connectors from the electronic control module. Inspect the connectors
for corrosion, loose contacts, loose wires and broken wires. Remove the
electronic control module. Disconnect the two mating four pin
connectors. Follow instructions for setting neutral on page 8 step 7.
Troubleshooting
Reference Settings
DC voltage measured
across designated pins
Joystick at the customer three
Position pin connector
A to B
Full – Forward 5 Vdc
Neutral 0A 0A
Max command
Minimum 1.5 A
in the opposite 0A
Maximum 2 A
direction
15
Eaton Corporation Eaton Ltd. Eaton B.V. Sumitomo Eaton Hydraulic Co.
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THE DUTCH COUNCIL
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Reg. No. 24
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