Eaton Heavy Duty 2 Series Manual Download

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EATON

Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004

Low

Neutral

Inspect Charge

Relief Valve

(At Pump)

Inspect Charge

Relief Valve

(At Motor)

Repair

Replace

Repair

Replace

Repair

Replace

Repair

Replace

Repair

Replace

Repair

Replace

Low in

Forward

Reverse

Low in

Neutral,Forward

Reverse

Check

Charge

Pressure

Inspect

Pump Control

Valve

Inspect System

By−Pass Valve

(if Used)

Inspect

Inlet

Filter

Replace

Transmission

(Pump & Motor)

Inspect
Charge

Pump

Inspect Charge

Relief Valve

(At Pump)

Defective

Clogged

Defective

System Response
Sluggish

Troubleshooting

Fault-Logic Tables

Summary of Contents for Heavy Duty 2 Series

Page 1: ...Heavy Duty Series 2 Hydrostatic Piston Pumps Parts and Service Model 3322 Model 3922 Model 4622 Model 5422 Model 6422...

Page 2: ...12 Solenoid Control Kit 13 Hydraulic Remote Control Kit 14 Connector Kits 14 Electronic Proportional EP Displacement Control 15 16 Rotating Group Swashplate Subassembly 17 18 Hold down Kits 19 PropelV...

Page 3: ...instructions for complete disassembly inspection and reassembly of the pump are given The following recommendations should be followed to insure successful repairs Most repairs require the removal of...

Page 4: ...h 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 Cleaner...

Page 5: ...l may differ slightly from this view depending on features installed Same Side Ported End Cover Model 5422 6422 Model 3322 4622 DISPLACEMENT Model 3322 54 4 cm3 rev 3 32 in3 rev Model 3922 63 7 cm3 re...

Page 6: ...85 86 86 61 87 32 Optional Magnetic Speed Sensor ID Tag 31 6 32 87 Optional Speed Sensor Port Plug 28 27 66 28 27 26 Optional External Servo Stop 109 108 110 111 Optional External Servo Stop 34 35 33...

Page 7: ...202 3 Dowel 57 110457 000 4 Static Face Seal 59 8761 017 2 O Ring between end cover and housing 60 108562 000 2 Back up Ring between end cover and housing 61 25083 01 1 O Ring Plug 62 107887 1 O Ring...

Page 8: ...hipping Strap not shown 70 111402 000 1 Control Link Sub assembly 71 72 See Table 5 0 Manual Control 12 76 4994730 xxx 1 2 Relief Valve Pressure Override See Table 12 0 optional 23 78 110700 xxx 1 1 R...

Page 9: ...pline Front of Tandem 113720 000 113719 000 103227 000 103222 188 27 Tooth 24 48 Pitch Spline 114681 000 114680 000 103227 000 103222 188 1 500 Taper With 3 8 Square Key 4992795 001 4992794 001 103227...

Page 10: ...Charge pressure Gauge Port 110356 000 Code 62 No Remote Filter Ports 110434 000 Code 62 M12 X 1 75 Yes 7 8 14 UNF Charge pressure Gauge Port 5422 110358 000 Code 61 Yes Remote Filter Ports 110541 000...

Page 11: ...4994224 001 Code 62 Yes Integral C pad No Charge Pump 114693 000 Code 62 Yes Integral C pad No Charge Pump Gauge Ports 4622 4997058 001 Code 61 No Remote Filter Ports 112596 000 Code 62 Yes 113721 00...

Page 12: ...anual Control Valve with N C Neutral Lockout Kit Kit No 990705 000 ITEM PART NO QTY DESCRIPTION 110039 000 1 Manual Control Valve with 6 N C Neutral Lockout 7 108992 000 1 Control Gasket 8 95912 088 1...

Page 13: ...assembly 93 8761 010 1 O Ring 94 109196 000 1 Hollow Dowel Can be purchased separately Kit No 990863 000 Solenoid 12Vdc Control W Swashplate Feedback Sensor DIN 43650 ITEM PART NO QTY DESCRIPTION 6 11...

Page 14: ...O QTY DESCRIPTION 6 4993691 001 1 Hydraulic Remote Control Subassembly 7 110003 000 1 Gasket 8 95912 200 5 Cap Screw Item 6 Table 5 6 Hydraulic Remote Control Kits Kit No 990763 000 Swashplate Sensor...

Page 15: ...ics 12V Kit No 9900043 000 Code EC ITEM PART NO QTY DESCRIPTION 4 95912 200 5 5 16 18 Hex Head Cap Screw 2 75 6 4993054 012 1 Valve Subassembly includes Solenoid Coil and Tube Subassemblies 114241 012...

Page 16: ...2 03 2 80 mm Alternate reference source Power and Signal Group North American Headquarters 1 800 722 5273 www powerandsignal com netstore start Solenoid Coil Mating Connector Kit not required when us...

Page 17: ...00 1 Barrel and Sleeve 6 990723 000 1 Hold down Kit 7 104211 000 1 Shoe Retainer Plate 8 104199 000 9 Shoe Piston Subassembly 9 107854 000 1 Fixed Clr Thrust Plate 10 109366 000 1 Swashplate Subassemb...

Page 18: ...0 1 Barrel and Sleeve 6 990723 000 1 Hold down Kit 7 104211 000 1 Shoe Retainer Plate 8 106609 000 9 Shoe Piston Subassembly 9 107854 000 1 Fixed Clr Thrust Plate 10 109366 000 1 Swashplate Subassembl...

Page 19: ...000 104006 000 V Groove Plate Clockwise 111823 001 4993532 001 4993881 001 114557 000 Quiet Plate Counterclockwise 113169 000 113632 000 113148 000 112375 000 Quiet Plate Clockwise Magnified Magnified...

Page 20: ...ADAPTER COVER SEALING COVER COVER RETAINING ECCENTRIC GEROTOR VALVE O RING BOLTS WASHERS SUBASSY O RING SHAFT KEY RING RING SUBASSY PLATE KIT NO DISPLACEMENT 96 20 19 18 24 21 22 23 15 16 17 990665 0...

Page 21: ...7 000 8761 157 109304 001 101305 000 109312 000 107882 002 107881 002 108362 000 9900074 000 17cc 1 06 CID 8761 042 108076 000 8761 159 95912 175 108027 000 8761 157 109304 001 101305 000 109312 000 9...

Page 22: ...5 CID 104511 150 8761 159 108081 000 8761 159 108027 000 8761 157 109306 002 101311 000 109312 000 990791 000 21cc 1 25 CID 104511 150 111084 000 8761 159 108027 000 8761 157 109306 002 101311 000 109...

Page 23: ...ard Servo Piston Cover Model 3322 3922 4622 ITEM PART NO DESCRIPTION 29 108145 000 Cover No Tap 30 109331 000 Cover 50 20 Neutral Adjustment 34 35 33 30 Optional External Servo Stop 109 29 108 110 111...

Page 24: ...310 3 4500 4994730 500 344 7 5000 4994730 550 379 2 5500 4994730 575 396 4 5750 4994730 600 413 7 6000 4994730 650 448 1 6500 Do not set to this pressure level without Eaton Engineering approval 11073...

Page 25: ...Pressure Relief Valve Item 1 PRESSURE PART NO SETTING bar lbf in2 103072 030 20 7 300 103072 032 22 1 320 103072 033 22 5 326 3 103072 034 23 4 340 103072 035 24 1 350 103072 037 25 5 369 8 103072 038...

Page 26: ...ft Seal Kits Item 116 Models 3322 3922 4622 Seal Kit No 990709 000 PART NO QTY DESCRIPTION 108395 000 1 Drive Shaft Seal 101680 250 1 Retaining Ring 107836 000 1 Spacer Models 5422 6422 Seal Kit No 99...

Page 27: ...Use only clean recommended hydraulic fluid on finished surfaces before reassembly Thoroughly clean the exterior of the pump before disassembly Make sure all open ports are sealed 1 Remove the control...

Page 28: ...e size and location Orifice sizes are stamped on the face of each orifice Orifices are staked to retain them in their pockets 8 Remove the control valve gasket and discard 7 Lift the valve assem bly s...

Page 29: ...ews for the charge pump cover 18 Using a large pair of adjustable pliers remove the charge pump cover Gently rock the cover back and forth as you pull upward 19 Remove the sealing O ring for the charg...

Page 30: ...emove the end cover retaining cap screws Use caution as the end cover has an internal preload If the end cover doesn t rise when the cap screws are loosened you may have to tap the end cover to break...

Page 31: ...bear ing puller under the rear bearing Note See the special tool section for dimensions required to make a low clearance bearing puller 34 Install the puller on the bearing puller DO NOT REMOVETHE BEA...

Page 32: ...wash plate and rotating group back on the support base Using a 1 4 in allen wrench or bit socket remove the screws spacers and strap from one side of the swashplate Loosen but do not remove the other...

Page 33: ...le side servo piston cover 51 Using a 1 2 in end wrench or socket remove the retaining cap screws and remove the servo piston cover from the pump housing 52 Unscrew the cover from the servo piston adj...

Page 34: ...stall new seals on both servo piston covers 4 Place the servo piston cover on the servo piston adjustment screw Screw about half way down the screw Install a new threaded seal and beveled washer Place...

Page 35: ...height of the retaining strap spacer dimension A using a micrometer of dial vernier calipers 11b Lubricate and reassemble the rotating group 11c Measure the com bined thickness of the piston shoes an...

Page 36: ...n the rear bearing so it can be used as a handle 20 Carefully lift the entire subassembly and install it into the pump housing Align the two notches in the swashplate with the two clocking links and t...

Page 37: ...down springs and washers on the swashplate hold down arms 25 Install two hold down arm assembly alignment tools and dowels Note The alignment tool is a special tool Dimensions required to make this to...

Page 38: ...ring shims as necessary 29 Lubricate and install the pump housing sealing and back up rings Note On units with the pressure override option special tapered sealing and back up rings are used Correct i...

Page 39: ...ar on the charge pump coupling by aligning with the drive key Next install the charge pump coupling subassembly and gerotor s outer ring into the pump end cover 36 Lightly coat the charge pump sealing...

Page 40: ...ing cap screws For models 3322 3922 and 4622 torque cap screws to 35 40 ft lbs 54 47 4 Nm On models 5422 and 6422 torque the cap screws to 60 65 ft lbs 81 3 88 1 Nm 41 If you are using the special hol...

Page 41: ...p housing as there will be less chance of the parts falling out of position 49 Torque plug to 100 105 ft lbs 135 6 142 3 Nm 46 Remove the input shaft retaining ring Use a pair of internal retaining ri...

Page 42: ...l EP control valve follow steps 59 through 65 59 For units with an optional EP control valve carefully align the valve assembly to the pump housing Align the hole in the control feedback link with the...

Page 43: ...spacers may be used 66 Install the seal into the pump housing protecting the shaft seal with a seal bullet or similar tool Install the seal with the lip of the seal facing inward SeeTools on page 56 6...

Page 44: ...s 2 hydrostatic 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 insu...

Page 45: ...heck Valve or 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 F...

Page 46: ...rge pressure reading of 340 PSI 23 4 bar Minus Case pressure reading of 20 PSI 1 5 bar Equals Differential Pressure of 360 D PSI 23 4 bar Typical hydrostatic circuits usually include inlet pressure ca...

Page 47: ...chine down time Following the fault logic diagrams are diagram action comments to further help explain the action steps shown in the diagrams Where applicable the action comment number of the statemen...

Page 48: ...Replace 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 Defect...

Page 49: ...n Forward or Reverse Low in Neutral Forward 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...

Page 50: ...Replace 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 Inspe...

Page 51: ...ow in Forward or Reverse Low in Neutral Forward or Reverse Inspect External Pump Control Linkage if Used 1 Inspect Inlet Filter 11 Inspect Pump Control Valve 2 Check Oil Level in Reservoir 7 Inspect C...

Page 52: ...gged control orifice B Damaged mounting gasket C Worn stuck or bent control spool D Stuck solenoid valve s E Defective solenoid coil s F Mis adjusted Potentiometer G Defective Potentiometer H Mis adju...

Page 53: ...per SAE J1165 The code allows a maximum of 2500 particles per milliliter greater than 5 m and a maximum of 80 particles per milliliter greater than 15 m When components with different cleanliness req...

Page 54: ...39 cSt 2158 cSt 18 13 60 SUS 80 180 SUS 10 000 SUS Hydraulic Fluid Recommendations Viscosity Cleanliness Guidelines Additional Notes Viscosity and ISO cleanliness requirements must be maintained as o...

Page 55: ...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 Pump End Cover T...

Page 56: ...n in inches Material Stentor Heat Treatment 45 55 Rc All dimensions are given in inches A B 5 00 6 00 Dia 2 50 C D 302 322 1 101 99 F A 052 072 021 041 B C D E 510 490 240 260 125 094 R 375 O Dowel Pi...

Page 57: ...housing bore as seal is pressed in to minimize chance of damaging seal 5 Using the driver and a mallet push the seal until the tool bottoms on the pilot of flange 6 Remove the tool and insert the reta...

Page 58: ...7 bar 3000 lbf in2 with 2 bar 29 lbf in2 N 241 bar 3500 lbf in2 with 2 bar 29 lbf in2 P 276 bar 4000 lbf in2 with 2 bar 29 lbf in2 R 310 bar 4500lbf in2 with 2 bar 29 lbf in2 S 345 bar 5000 lbf in2 wi...

Page 59: ...43650 20 Control Orifice Supply P 21 Control Orifice Servo S1 22 Control Orifice Servo S2 0 None A 0 53 021 Diameter B 0 71 028 Diameter C 0 91 036 Diameter D 1 12 044 Diameter E 1 22 048 Diameter F 1...

Page 60: ...aton 14615 Lone Oak Road Eden Prairie MN 55344 USA Telephone 952 937 9800 Fax 952 974 7722 www hydraulics eaton com Eaton 20 Rosamond Road Footscray Victoria 3011 Australia Tel 61 3 9319 8222 Fax 61 3...

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