Eaton Heavy Duty 2 Series Manual
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Eaton Heavy Duty 2 Series Manual

Hydrostatic piston pumps
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Heavy-Duty Series 2
Hydrostatic Piston Pumps
Parts and Service
Model 5422
Model 3322
Model 3922
Model 6422
Model 4622

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Summary of Contents for Eaton Heavy Duty 2 Series

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

  • Page 2: Table Of Contents

    Model Code Description ..................58-59 EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 3: Introduction

    0039 = 3.9(64) C Identifies Specific Unit Rotation Observed from 0046 = 4.6(75) Configuration Shaft End of Unit 0054 = 5.4(89) CW=Clockwise D Month of Manufacture 0064 = 6.4(105) CCW=Counterclockwise EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 4: Required Tools For Disassembly/Reassembly

    4 End Cover order to prevent damage 5 Rotating Group and shaft 1 Control (as applicable) 6 Servo Piston 2 Auxiliary Mounting adapter 7 Main Housing (if applicable) EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 5: Parts Drawings

    Note: this is a typical Series 2 configuration. Your model may differ slightly from this view depending on features installed. Obsolete shim adjusted POR Same Side Ported End Cover Model 5422-6422 Model 3322-4622 EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 6: Rotating Group And Main Housing

    Optional External Servo Stop 111 110 ID Tag Optional Optional Magnetic Speed Optional External Speed Sensor Servo Stop Sensor Port Plug EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 7: Parts Lists

    Control Link Sub-assembly 71, 72 See Table 5.0 Manual Control 4994730-xxx Relief Valve, Pressure Override See Table 12.0 (optional) 110700-xxx Relief Valve and/or See Table 13.0,13.1 Check Valve (B Port) EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 8 80, 81,82 101619-102 25,9[.102] Control Valve Orifice 76 4994730-xxx Relief Valve, Pressure Override See Table 12.0 (optional) 78 110700-xxx Relief Valve and/or Check Valve See Table 13.0,13.1 (B Port) EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 9: Models 3322/3922/4622 (54, 64, 75 Cc/Rev)

    * Includes 103227 Pressed Bearing Cone and 103222-188 Retaining Ring ** Includes 103808 Pressed Bearing Cone and 103222-200 Retaining Ring Note: Bearing Cup must be replaced with shaft and new bearing cone. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 10: End Cover

    Remote Filter Ports 110357-000 Code 61 Remote Filter Ports *Note: All end covers include normal SAE-4 gauge ports for “A” & “B” high pressure ports. (Except as noted) EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 11 Integral C-pad 112056-000 Code 62 Integral C-pad/ Gauge Port *Note: All end covers include normal SAE-4 gauge ports for “A” & “B” high pressure ports. (Except as noted) EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 12: Manual Control Valve

    1201 5323 Recommended wire size: 18 - 20 AWG Recommended cable diameter: 2.03 - 2.80 mm Alternate reference source: Power and Signal Group North American Headquarters 1-800-722-5273 www.powerandsignal.com/netstore/start EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 13: Solenoid Control Kit

    Kit No. 990719-000 Swashplate Sensor Kit ITEM PART NO. QTY DESCRIPTION Solenoid Tube Subassembly 107851-000 Swashplate Sensor 16040-208 SF Head Machine Screw 8-32 UN 95897-008 Washer 107762-000 Swashplate Gasket EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 14: Hydraulic Remote Control Kit

    Gasket 95912-200 Cap Screw Hydraulic Remote (parts sold separately) Rating: 2-14 bar[29-203 lbf/in ITEM PART NO. QTY DESCRIPTION 4993691-001 Hydraulic Remote Control Subassembly 110003-000 Gasket 95912-200 Cap Screw EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 15: Electronic Proportional (Ep) Displacement Control

    #10 Lockwasher 114241-024 24 V Solenoid Coil and Wiring Harness 111501-000 Solenoid Tube and O-Rings 110003-000 Control Valve Gasket Parts are included in kit and may be purchased separately. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 16 1204 7948 Recommended wire size: 16 - 18 AWG Recommended cable diameter: 2.03 - 2.80 mm Alternate reference source: Power and Signal Group North American Headquarters 1-800-722-5273 www.powerandsignal.com/netstore/start EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 17: Rotating Group/Swashplate Subassembly

    103817-000 Shoe Retainer Plate 103818-000 Shoe Piston Subassembly 104199-000 Shoe Piston Subassembly 108341-000 Fixed Clr Thrust Plate 107854-000 Fixed Clr Thrust Plate 109254-000 Swashplate Subassembly 109366-000 Swashplate Subassembly EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 18 104211-000 Shoe Retainer Plate 110222-000 Shoe Piston Subassembly 106609-000 Shoe Piston Subassembly 108341-000 Fixed Clr Thrust Plate 107854-000 Fixed Clr Thrust Plate 109254-000 Swashplate Subassembly 109366-000 Swashplate Subassembly EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 19: Hold-Down Kits

    106988-000 107808-000 104857-000 107143-000 V-Groove Plate (Counterclockwise) 106456-000 106457-000 104964-000 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) EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 20: Charge Pump Subassembly

    990679-000 28cc/1.70 CID – 95912-200 103223-000 108026-000 8761-157 109302-004 101311-000 109312-000 – – – 990673-000 28cc/1.70 CID – 95912-200 – 108027-000 8761-157 109302-002 101311-000 109312-000 107882-004 107881-004 – EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 21 EATON EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E April 2004...
  • Page 22 EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 23: Servo Piston And Cover

    Thread Seal, with externally adjustable stop in one direction 16254-28 Washer 111830-000 Set Screw 1/2-20 96097-050 Nut 1/2-20 111864-000 Cover .50-20 Tap for Servo Piston 114220-000 Cover .50-20 Tap for Adjustable Stop EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 24: Pressure Override Valve

    110700-150. This setting represents a psi(lbf/in ) of 1500 lbf/in . Ranges for the high pressure relief valves are available from 1500 to 6000 lbf/in in increments of 500 lbf/in 110700-XXX 110700-099 EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 25: Low Pressure Relief Valve

    * Number of shims required to achieve PSI setting: 300-320 psi = 5 shims; 320-340 psi = 6 shims; 340-348 psi = 7 shims; 435 psi = 12 shims 990713-000 EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 26: Kits

    O-Ring Pad 8761-017 O-Ring (charge cover) 108562-000 Back-up Ring 15-2 103223-000 Sealing Washer 8761-016 Speed Sensor O-Ring 15-4 8761-156 Charge Cover O-Ring 107762-000 Swashplate Gasket 8761-010 Swashplate O-Ring EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 27: Disassembly

    Release the latches and disconnect the connectors between the electronics module and the command CAUTION: Handle electronic input device. equipment with care. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 28 14. Using a pair of needle 11. Using a 9/16" hex key nose pliers remove or allen wrench, the valve poppet. remove the two high pressure relief valves or check valve sub- assemblies. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 29 Eccentric ring position in the end cover is used to determine charge pump input rotation. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 30 The bear- with the internal ing cup is a slip fit pressure override into the end cover. option have the additional O-rings and backup rings shown. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 31 Note: See the special tool section for dimensions required to make a low clearance bearing puller. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 32 42. Remove the piston bearing race. It may subassemblies and piston retainer. Place be a slip- or press-fit in the housing. them on a clean, protective surface for inspection and cleaning. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 33 52. Unscrew the cover from the servo piston adjustment screw. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 34: Assembly

    16 ft. then the washer. The lbs. [21,7 Nm] to 17 ft. beveled side of the lbs. [23 Nm]. washer must face the seal. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 35 Spacer Piston Shoe swashplate on the Swashplate rotating group. Thrust Plate 11a. Measure the height of the retaining strap spacer (dimension A) using a micro meter of dial vernier calipers. EATON Heavy-Duty Series 2 Hydrostatic Pumps Repair E-PUPI-TI004-E April 2004...
  • Page 36 Lubricate and install the slide block on the swashplate. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 37 27.Check the drive shaft end play. slot to adjust the zero position. 27a. Install the end cover without either the valve or bearing plates, aligning it with the alignment tool dowels. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 38 Freely lubricate the bearing plate and install it on the cylinder barrel subassembly, aligning it with the dowel pins. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 39 Small Recess large recess cast into the charge pump cover subassembly. The large recess side of the charge pump cover must face Large Recess toward the charge pump inlet. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 40 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]. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 41 50. Install the high pressure valves or check valve assem- blies. Torque to 120–130 ft. lbs. [162,7–176,2 Nm]. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 42 Electronic Proportional (EP) control 61. Connect the electronic valve, follow steps 59 through 65. module and the solenoid coils. The connectors must be latched securely. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 43 The Series 2 Variable tool. Drive the seal in Displacement Pump is just far enough to now ready for test and install the spacer installation. washer and retaining ring. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 44: Troubleshooting

    Troubleshooting This section provides the information necessary to troubleshoot a typical hydrostatic system using an Eaton Series 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 insure contin- uous and satisfactory transmission life.

  • Page 45: Valve /Test Port Location

    System Pressure Test Port For Port B Charge Pressure Relief Valve Check Valve or Optional Port B High Pressure Relief Valve Optional Speed Sensor (Not Shown) Charge Pump EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 46: Gauge Requirements, Gauge Port Size And Location

    The original valve pressure will increase approximately 3 PSI [,21 bar ] per 1 GPM [3,8 l/min] additional flow over the valve. The charge pressures given above are typical. Higher charge pressures may be set at the factory for your particular application. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 47: Fault-Logic Tables

    Neutral Difficult or Impossible Inspect External Inspect Inspect Pump Control Pump Control Servo Piston Replace Pump Linkage (if Used) Valve Adjustment Defective Defective Misadjusted Repair Repair Re−Adjust Replace Replace EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 48 Linkage (if Used) Valves Valve Defective Defective Defective Repair Repair Repair Replace Replace Replace Inspect Inspect Replace Shuttle Charge Pump Valve Check Valves Defective Defective Repair Repair Replace Replace EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 49 Inspect Inspect Motor Inspect Transmission IPOR Valve By−Pass Valve System Relief (Pump & Motor) (if Used) (if Used) Valves Defective Defective Defective Repair Repair Repair Replace Replace Replace EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 50 Relief Valve Relief Valve Relief Valve Inlet Pump (At Motor) Filter (At Pump) (At Pump) Clogged Defective Defective Defective Defective Repair Repair Repair Repair Replace Replace Replace Replace Replace EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 51 Replace Replace Inspect Inspect Inspect Transmission IPOR Valve System Relief Pump Control (Pump & Motor) (if Used) Valves Valve Defective Defective Defective Repair Repair Repair Replace Replace Replace EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 52: Tips

    D. Stuck solenoid valve(s) E. Defective solenoid coil(s) Mis-adjusted Potentiometer G. Defective Potentiometer H. Mis-adjusted speed sensor (on motor when used) Defective speed sensor J. Defective electronics module EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 53: Hydraulic Fluid Recommendations

    Cleanliness Cleanliness of the fluid is extremely important. Eaton recommends that the fluid used in its hydrostatic components be maintained at ISO Cleanliness Code 18/13 per SAE J1165. The code allows a maximum of 2500 particles per milliliter greater than 5 µm and a maximum of 80 particles per milliliter greater than 15 µm.
  • Page 54 However, only the vegetable oil content is biodegradable. Systems being converted from mineral oil to vegetable oil should be repeatedly flushed with vegetable oil to ensure 100% biodegradability. EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 55: Special Tools

    Series 2 Pump .38 R End Cover Tool Models 33-46 1.00 .25R Hold Down Arm +.015 Unit Assembly Guide .063 R -.000 .063 2 PLACES 2 PLACES FH00-1754 EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 56 2.36/2.38 1.55/1.57 4.26/4.24 2.99/3.01 1.49/1.51 .130/.140 Models 3322/3922/4622 (All dimensions are given 2.55/2/57 1.64/1.66 4.46/4.43 3.18/2.21 1.59/1.61 .180/.190 Models 5422/6422 in inches.) (All dimensions are given in inches.) EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 57 DRIVER 1.750 4994026-001 4994028-001 *45,2 0,13 [1.778 0.005] Driver 2.490 Units using seal 110192-000 **49,1 0,13 [1.933 0.005] SEAL ID BULLET DRIVER 1.875 4994027-001 4994028-002 5.250 7 .00 EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...

  • Page 58: Model Code Description

    [5500-6500 lbf/in 25,4 [1.00] - code 61 per SAE J518 same side location 25,4 [1.00] - Code 62 with M12 X 1.75 Threaded Holes same side location EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 59 1,65 [.065] Diameter 1,85 [.073] Diameter 2,06 [.081] Diameter 2,39 [.094] Diameter 2,59 [.102] Diameter Control Special Features No Control Special Features Destroke Valve Charge Pump Displacement None EATON Heavy-Duty Series 2 Hydrostatic Pumps Parts and Repair E-PUPI-TS004-E October 2004...
  • Page 60 Telephone: 952 937-9800 Australia Tel: (49) 7221 682-0 Fax: 952 974-7722 Tel: (61) 3 9319 8222 Fax: (49) 7221 682-788 www.hydraulics.eaton.com Fax: (61) 3 9318 5714 © 2004 Eaton Corporation All Rights Reserved Printed in USA Document No. E-PUPI-TS004-E October 2004...

This manual is also suitable for:

Heavy duty 2 3922Heavy duty 2 4622Heavy duty 2 5422Heavy duty 2 6422Heavy duty 2 3322Heavy duty 2 3323-100 ... Show all

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