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52

1.

Inspect External Pump Control
Linkage for:

Manual Operated Controls

A.

Misadjusted or disconnected

B.

Binding, bend or broken

Hydraulic Remote Controls

A.

Improper pilot pressure

B.

Defective proportional valve

(see proportional valve manual)

Electrical Operated Controls

A.

Disconnected electric signal
connection

2.

Inspect Pump Control Valve for:

Manual Operated Controls

A.

Plugged control orfice

B.

Damaged mounting gasket

C.

Misadjusted, damaged or broken
neutral return spring

D.

Broken control connector pin

E.

Broken or missing control linkage
pin(s)

F.

Worn, struck or bent control
spool

Hydraulic Remote Controls

A.

Plugged control orfice

B.

Damaged mounting gasket

C.

Misadjusted, damaged or broken
neutral return spring

D.

Broken control connector pin

E.

Broken or missing control linkage
pin(s)

F.

Worn, struck or bent control
spool

G.

Worn, or stuck hydraulic control
pistons

Electrical Operated Controls

A.

Plugged control orfice

B.

Damaged mounting gasket

C.

Worn, stuck or bent control spool

D.

Stuck solenoid valve(s)

E.

Defective solenoid coil(s)

F.

Misadjusted Potentiometer

G. Defective Potentiometer
H. Misadjusted speed sensor (on

motor when used)

I.

Defective speed sensor

J. Defective electronics module

3.

Inspect Servo Piston for:

A. Improper servo piston adjustment

4.

Inspect System Relief Valves for:

A. Improper pressure relief setting

(consult owners/operator manual
for system relief valve settings)

B. Valve poppet held off seat
C. Broken valve springs (2)
D. Broken valve stem

5.

Inspect Shuttle Valve for:

A. Bent or broken return centering

spring

B. Worn or stuck shuttle spool
C. Bent or broken shuttle spool

6.

Inspect Charge Check Valves for:

A. Valve held off seat
B. Broken valve spring

7.

Check Oil Level in Reservoir:

A. Consult owner/operators manual for

the proper type fluid and level

8.

Inspect Heat Exchanger for:

A. Obstructed air flow (air cooled)
B. Obstructed water flow (water

cooled)

C. Improper plumbing (inlet to outlet)
D. Obstructed or insufficient fluid flow
E. Cooling fan failure (if used)

9. Inspect Heat Exchanger By-Pass Valve for:

A. Improper pressure setting
B. Stuck or broken valve

Troubleshooting 

– Series 2 Variable Displacement Pump

Summary of Contents for 2 Series

Page 1: ...No 6 636 August 1997 Eaton Heavy Duty Hydrostatic Pumps Parts Repair Information Series 2 Hydrostatic Pumps...

Page 2: ...l Valve with N C Neutral Lockout Potentiometer Kit 18 Manual Control Valve with N C Neutral Lockout Kit 19 Manual Control Valve with Potentiometer Kit 20 Solenoid Control Valve Speed Sensor Mating Con...

Page 3: ...ble Displacement Pumps Models 33 39 46 54 and 64 Step by step instructions for complete disassembly inspection and reassembly of the pump are given The following recommendations should be followed to...

Page 4: ...ton Model No Serial No Rotation Eaton Corporation Hydraulics Division Spencer Iowa 51301 A B C G E D F 0000 00 000 00 00 000000 ID Tag A Displacement cu in rev 0033 3 3 0039 3 9 0046 4 6 0054 5 4 0064...

Page 5: ...i 3 v e r 2 3 3 9 8 3 9 5 4 4 4 5 4 4 6 Model Number Displacement 5 13 43 42 3 15 95 4 76 4 79 78 63 67 64 60 59 Detail of Charge Pump Adaptor Pads are on Pages 15 16 63 NOTE This is a typical Series...

Page 6: ...cause critical calibrations have been made at the factory the Servo Assembly should not be disassembled 44 54 53 54 53 45 46 45 46 14 56 56 NOTE This is a typical Series 2 configuration your model may...

Page 7: ...18 67 31 66 40 1 30 117 48 49 119 116 7 Control Valve Gasket Control Valve Refer to pages 17 23 for Valve Options 62 66 29 85 85 86 86 61 87 32 Optional Magnetic Speed Sensor ID Tag Refer to Page 4 fo...

Page 8: ...page 14 15 4 Cap Screw 5 16 18 Soc HD 2 see Charge Pump Parts List on page 14 15 15 A 1 Charge Pump Drive Shaft see Charge Pump Kit Assembly Parts List on page 14 15 15 A 1 Key see Charge Pump Kit Ass...

Page 9: ...housing see page 27 60 A 2 Back up Ring located between end cover and housing see page 27 61 C 25083 01 1 O Ring Plug 62 C 107887 1 O Ring Plug Soc HD 63 A 25706 006 2 O Ring Plug 64 A 25090 010 1 O...

Page 10: ...le Displacement Pump 87 C 1 O Ring see gasket kit 990710 000 page 27 95 A 1 Charge Pump Adaptor Kits see page 14 15 116 C 1 Drive Shaft Seal see Shaft Seal Kit page 26 117 C 1 Ring Retaining see Shaft...

Page 11: ...107575 107575 108707 108707 Servo Piston Sub Assembly Part Number Part Number Part Number Part Number Part Number Item Qty Description 54 4 cm3 rev 63 7 cm3 rev 75 4 cm3 rev 89 2 cm3 rev 105 5 cm3 re...

Page 12: ...th 24 48 Pitch Spline Output includes 103227 Pressed Bearing Cone and 103222 188 Retaining Ring 108646 1 Drive Shaft S A 21 Tooth 16 32 Input Pitch Spline 27 Tooth 24 48 Pitch Spline Output includes 1...

Page 13: ...03242 103815 103815 12 4 1 Cylinder Barrel Spring 103240 103240 103813 103813 12 5 1 Spacer Shaft Spring 107758 107758 108337 108337 12 6 1 Barrel and Sleeve 109427 109418 109430 109433 12 7 4 Cap Scr...

Page 14: ...olt Mount No Shaft Seal 9 Tooth 16 32 Pitch Spline Available For All Models B pad High Torque Charge Pump Dual 2 Bolt Mount No Shaft Seal 13 Tooth 16 32 Pitch Spline Available For All Models BB pad Hi...

Page 15: ...1 6 7 8 A N 9 5 1 1 6 7 8 5 7 1 2 1 9 5 9 A N 0 0 0 7 2 0 8 0 1 7 5 1 1 6 7 8 2 0 0 4 0 3 9 0 1 0 0 0 1 1 3 1 0 1 0 0 0 2 1 3 9 0 1 3 0 0 2 8 8 7 0 1 3 0 0 1 8 8 7 0 1 A N 0 0 0 4 8 6 0 9 9 e u q r o...

Page 16: ...rev 62 N Remote Filter Ports 110628 1 75 4 cm3 rev 61 Y 110301 1 75 4 cm3 rev 62 M12X1 75 N 110201 1 75 4 cm3 rev 62 M12X1 75 Y 109470 1 75 4 cm3 rev 62 N 109147 1 75 4 cm3 rev 62 Y 110358 1 89 2 cm3...

Page 17: ...9280 000 1 Control Link S A 96081 031 1 Nut 5 16 18 96100 031 1 Washer 103048 000 1 Control Lever 95729 000 1 Control Lever Item 6 C Control Valves 990704 000 Manual Control Valve Kit Item Part No Qty...

Page 18: ...lly Closed Parts included in Kit P N 990719 000 see Below 990719 000 Potentiometer Kit Part No Qty Description 107851 000 1 Potentiometer 16040 208 2 Screw SF Head Mach 8 32 UN 95897 008 2 Washer 1077...

Page 19: ...5912 150 4 Cap Screw SOC HD 5 16 18 GR 8 109280 000 1 Control Link S A 96081 031 1 Nut 5 16 18 96100 031 1 Washer 103048 000 1 Control Lever 95729 000 1 Control Lever N C Normally Closed Connector 1 C...

Page 20: ...sher 103048 000 1 Control Lever 95729 000 1 Control Lever 107851 000 1 Potentiometer 16040 208 2 Screw 8 32 UN 95897 008 2 Washer 107762 000 1 Potentimeter Gasket 109195 000 1 Feedback Shaft S A 8761...

Page 21: ...n o C 5 2 1 2 1 9 5 9 2 8 R G 8 1 6 1 5 D H c o S w e r c S p a C 5 7 1 2 1 9 5 9 5 8 R G 8 1 6 1 5 D H c o S w e r c S p a C 0 0 0 1 5 8 7 0 1 1 r e t e m o i t n e t o P 8 0 2 0 4 0 6 1 2 N U 2 3 8...

Page 22: ...0 0 1 1 0 0 2 2 1 9 5 9 0 0 0 0 8 2 9 0 1 0 2 4 4 2 2 0 1 1 5 7 1 3 7 6 1 0 1 3 0 2 5 4 0 6 1 0 0 0 8 9 6 0 9 9 c d V 2 1 l o r t n o C P E A m 0 2 4 2 1 0 7 0 3 0 1 1 0 0 0 3 0 0 0 1 1 0 0 2 2 1 9 5...

Page 23: ...l o S l o r t n o C P E c d V 2 1 d e t a u t c A 2 1 0 7 0 3 0 1 1 0 0 0 3 0 0 0 1 1 0 0 2 2 1 9 5 9 0 0 0 0 8 2 9 0 1 1 6 5 0 1 1 2 1 0 6 0 3 0 1 1 A N Includes Solenoid Tube S A and Coil Above par...

Page 24: ...hi Packard P N 1212 4075 Recomended wire size 16 18 AWG Recomended cable diameter 2 0 2 40 mm Alternate reference source Pioneer Standard Electronics 1 800 257 6613 Includes Cable Seal 990768 000 MUX...

Page 25: ...010 1 Bearing Shim 41 A 103798 015 1 Bearing Shim 41 A 103798 020 1 Bearing Shim 41 A 103798 030 1 Bearing Shim Item Part No Qty Description 48 C 9900713 000 1 LPRV Plug S A Includes Below 48 1 10907...

Page 26: ...16254 8 1 Thread Seal 49 C 8785 012 2 O Ring 57 A 110457 000 4 Static Face Seal 59 A 8761 017 2 O Ring 60 A 108562 000 2 Back up Ring 87 C 8761 016 1 O Ring speed sensor 91 107762 000 1 Gasket potent...

Page 27: ...ng the disassembly of the pump see Figure 2 To remove the control valve assembly use 1 4 in bit socket or hex key and remove the control valve assembly s five retaining cap screws With the retaining c...

Page 28: ...ng flange from the pump end cover see Figure 17 Turn the auxiliary pump adapter over and using an O Ring pick or similar tool remove the seal ing ring see Figure 18 Figure 9 Next using a 9 16 hex key...

Page 29: ...ermine charge pump input rotation Before removing you may want to note its position for reas sembly see Figure 25 Next remove the charge pump valve plate The position of this valve plate is also used...

Page 30: ...TE If a small screwdriver or similar tool is used to pry the bearing plate from the cylinder barrel extreme caution must be used not to scratch or damage the cylinder barrel s or bearing plates lapped...

Page 31: ...k of this manual see Figure 43 Reposition the swashplate and rotating group back on the sup port base Next using a 1 4 in allen wrench or bit socket re move the screws spacers and strap from only one...

Page 32: ...t Pump Next using a 3 4 in end wrench remove the servo adjustment screw lock nut and special bev eled washer from the adjustable side servo piston cover see Fig ure 55 With the lock nut and washer re...

Page 33: ...tall the remaining servo pis ton cover and remaining four servo cover retaining cap screws Torque cap screws to 16 ft lbs 21 7 Nm to 17 ft lbs 23 Nm see Figure 69 Complete Reassembly Before reassembly...

Page 34: ...reassemble the rotating group see Figure 73 The second step is to measure the combined thickness of both the piston slippers and retainer as shown here The difference between step one and step two is...

Page 35: ...e to assemble the swashplate rotating group and shaft assembly into the pump housing see Figure 82 VERY CAREFULLY pick up the entire assembly and install it into the pump housing Install by aligning t...

Page 36: ...all the rear bearing shims and cup into the pump end cover To check the shaft end play the pump end cover must be installed without either the valve or bearing plates This will help to remove the cyli...

Page 37: ...ly alignment tool and dowels on the pump hous ing The next step is to install the charge pump assembly into the pump end cover before in stalling the end cover on the pump housing see Figure 103 The p...

Page 38: ...the other side see Figure 112 Repair Information Series 2 Variable Displacement Pump Install the dowel pin in the end cover Lightly coat the end cover side of the valve plate with pe troleum Jelly Vas...

Page 39: ...tically into the pump housing In doing it vertically there will be less chance of the parts falling out of posi tion see Figure 121 Torque plug to 100 ft lbs 135 6 NM to 105 ft lbs 142 3 Nm see Figure...

Page 40: ...rd see Figure 131 Using a seal driver or similar drive the seal into the pump housing Drive the seal in just far enough to install the spacer washer and retaining ring see Figure 132 Figure 129 Next i...

Page 41: ...ostatic pump Using this section will help you to diagnose any minor problems that may occur Maintaining cleanliness while you work will prevent contamination of the hydrostatic system and insure con t...

Page 42: ...Optional Port B High Pressure Relief Valve Check Valve or Optional Port A High Pressure Relief Valve Manual Control Valve System Pressure Test Port For Port A System Pressure Test Port For Port B Char...

Page 43: ...0 100 500 0 600 PSI Inlet Vacuum Gauge 30 to 30 inHg Mercury 1 to 2 bar Compound Gauge Compound 0 5 10 15 20 25 30 10 20 30 Vac Press Charge Pressure Gauge 0 600 PSI 0 37 bar Optional System Gage Port...

Page 44: ...ow or charge pressure and system or high pressure These pressures will vary per each individual application and operating conditions Nominal Operating Pressures At Normal Operating Temperature Inlet V...

Page 45: ...diagrams This will give expedient aid in correcting minor problems eliminating unnecessary machine down time Following the fault logic diagrams are diagram action comments to further help explain the...

Page 46: ...eplace Replace Pump Repair or Replace Inspect Charge Check Valves 6 Repair or Replace Inspect System Relief Valves 4 Repair or Replace Repair or Replace Inspect Shuttle Valve 5 Ok OK Defective Defecti...

Page 47: ...ward or Reverse Inspect Inlet Filter 11 Inspect Motor By Pass Valve if Used 10 Check Oil Level in Reservoir 7 Inspect Charge Pump 15 Ok Below Level Clean Inspect Heat Exchanger 8 Clogged Ok Defective...

Page 48: ...eplace Repair or Replace Repair or Replace Low in Forward or Reverse Low in Neutral Forward or Reverse Check Charge Pressure Inspect Pump Control Valve 2 Inspect System By Pass Valve if Used 10 Inspec...

Page 49: ...f Used 1 Inspect Inlet Filter 11 Inspect Pump Control Valve 2 Check Oil Level in Reservoir 7 Inspect Charge Pump 15 Ok Below Level Defective Ok Ok Defective Inspect Motor By Pass Valve if Used 10 Ok D...

Page 50: ...r bent control spool D Stuck solenoid valve s E Defective solenoid coil s F Misadjusted Potentiometer G Defective Potentiometer H Misadjusted speed sensor on motor when used I Defective speed sensor J...

Page 51: ...ifferent cleanliness requirements are used in the same system the cleanest standard should be applied OEM s and distributors who use Eaton hydrostatic components in their products should provide for t...

Page 52: ...60 F max fluid temp reservoir Biodegradable Oil Vegetable Guidelines Additional Notes Viscosity and ISO cleanliness requirements must be maintained as outlined on page 14 Based on limited product test...

Page 53: ...R 2 560 005 R 38 R 2 PLACES 2 231 3 731 3 641 005 1 731 005 211 005 1 875 1 247 005 1 013 005 785 005 060 X 45 250 6 000 3 462 001 519 1 00 50 1 50 4 25 312 2 PLACES 002 THRU 1 500 FH00 1754 Series 2...

Page 54: ...embly with the bearing already pressed into place In the event a bearing is replaced in the field it must be pressed into place to the following dimensions in order prevent damage to the pump l e d o...

Page 55: ...ries 2 Variable Displacement Pump The following 31 digit coding system has been developed to identify all of the configuration options for the Series 2 hydrostatic pump Use this model code to specify...

Page 56: ...27 9 cm3 r 1 70 in3 r Pump Disp 54 105 cm3 rev 5 34 7 cm3 r 2 12 in3 r Pump Disp 89 105 cm3 rev Position 25 Auxiliary Mounting 0 None High Speed Charge Pump Models 54 to 75 cm3 rev 1 None High Torque...

Page 57: ...othes Fife Scotland KY7 4NW Telephone 01 592 771 771 Fax 01 592 773 184 Eaton GmbH Hydraulics Products Am Schimmersfeld 7 40880 Ratingen Germany Telephone 02102 406 830 Fax 02102 406 800 ISO 9001 CERT...

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