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1. Tools Equipment Required Max Flow Max Flow Adjustment Adjustment e 0 600 psi pressure gauge or Stud 1 Stud 2 J transducer optional ae j in i e 13mm offset closed end nai Hh Locking J wrench Nut 2 i AN e 4mm All h O O gt H ee een T 6 TY wD O N AAA gt a DANU S P fi KS Y El GOL ee CO RNS Aa We Z J X Sy KA Wn FH S7 OT ee 7 Wy i V4 XA SO VLLLLLL LL AX S N A Note 26mm Lis This Service Bulletin is valid CEA m for HPV pumps with either A J H Hydraulic Remote or E O A J O z Electro Hydraulic Remote WO B WW Controls NA eal SS The drawing below illustrates an H1 Control but the information is also valid for HIP E1 E1P and E2 Controls ry Z L e h 1 N N Ve D L e W i j SZ L I _ 7 Ms an j j lt al Solenoid LS l J L E2 Control EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 Maximum Flow Adjustment Procedure for HPV Pumps with H or E Controls Adjustment Procedure A WARNING If performing this procedure on a vehicle care must be taken The pump will be put on stroke during this procedure hence the vehicle must be safely elevated to allow the motor to free wheel
2. 4 D gt ae D Valve III Notes Sa 7 L gt KZ X a r3 w HPV 02 CW Rotation ONLY e Since the oil is being bled over the main relief valves during this procedure monitor the oil temperature in the main loop to avoid over heating e Oil Temperature Limitations for Eaton Components 4 F to 194 F 20 C to 90 C e Changes to any pump setting control supply pressure or system hardware after the POR has been adjusted could alter the performance of the POR It may be necessary to readjust the POR to compensate for any of these changes e Recommended Gauges Qty 1 7500 psi Liquid filled gauge Qty 2 recommended for ease of testing Qty 1 0 200 psi Ap gauge or Ap transducer EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 31 HPV CW Right Hand Rotation Pumps with H1P Control with Pressure Override POR Set Up A Important This is a field adjustment procedure valid for HPV pumps with CW Right Hand rotation and H1P Control Port Identification and auge Port My T Sauga Port Mz Adjustment Locations y 6 D ILZ MAN Fol i Valve Hha Valve Il Valve Ill For a CW Rotation Pump Control Pressure Into Port Y Control Pressure Into Port Z Pump Output Pressure At Port P S Must Adjust Valve Valve Il TA y Valve Ill Mz Valve I Mp 32 EATON D
3. A WARNING The flow adjustment stud is NOT mechanically restricted from being removed completely from the pump Care should be taken when turning the flow adjustment stud OUT as to prevent it from being removed from the pump control c Once the desired maximum flow has been acquired hold Adjustment Stud 1 stationary with the 5mm Allen wrench and tighten Locking Nut 1 with the 17mm wrench EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 Adjusting the Deadband on HPV Pumps with M2P Mechanical Hydraulic with POR Controls Set Up and Procedure Tools Equipment Required e 16mm wrench optional adjustable wrench e Hammer and punch Adjustment Procedure Deadband _ A Note This Service Bulletin is ONLY valid for HPV pumps with M2P Mechanical Hydraulic with POR controls SN _ Deadband Adjustment 2 if a LICONA i Z Vis i Spanner U W YW Nut 4 i E We a N L A GN AAA s A A f T7 U ALLY Tx T o A if 7 AQA OY 1 With the hammer and punch loosen the Spanner Nut on the Deadband Adjustment 2 With the 16mm wrench either turn the Deadband Adjustment IN or OUT to adjust the cam lever deadband to the desired range Hint Turn the Deadband Adjustment IN to reduce the cam lever deadband range or OUT to increase
4. EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 13 HPV CCW Left Hand Rotation Pumps aS important This is a field adjustment with M2P Control with POE ele T r umps wi eft Han Pressure Override PO R rotation and M2P control Procedure Valve III Adjustment 3 Valve Ill Adjustment Final Adjustment 4 A Keep both of the pump work ports P and S closed off or blocked B Turn the control lever CounterClockwise CCW fully and hold it C Slowly turn IN the adjustment screw for Valve III until control pressure APy z is 10 nnn 15 psi higher than the APy z Regulation Begin pressure recorded above value a ann Record the APy z setting psid value e D Tighten the locking nut on Valve Ill and return the control lever to its neutral position E Turn the control lever Clockwise CVV fully and hold it Verify that the pressure is 10 15 psi higher than the Pz y Regulation Begin pressure recorded above value b Record the APz y setting pSid value f Hint f Valve Ill gets too hot it will be difficult to adjust and or get consistent results Allow the pump to cool off if you encounter difficulty adjusting Valve III Final Adjustment A IF the difference between value e and value f is 5 psi or less then NO additional adjustments are required to the POR B IF the
5. Spanner Nut 1 b Use the 18mm wrench on Locking Nut 1 to adjust Regulation Begin Cup 1 Turn it IN to increase the regulation begin pressure or turn it OUT to decrease it c Use the hammer and punch to tighten rotate CW Spanner Nut 1 d Repeat steps 8 and 9 to verify that the regulation begin pressure is correct Follow all steps on pages 7 8 to reset the maximum displacement EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 Regulation Begin Adjustment for HPV Pump with Hydraulic Remote Control Procedure for Left Hand Rotation CCW Pump A Note Prior to performing this procedure verify that the hydraulic neutral on the pump is correctly adjusted Use the instructions on page 3 to check and adjust the hydraulic neutral setting if required Adjustment Procedure 1 Install the 0 600 psi Ap gauge into ports Y and Z HI side into Y and LO side for Left Hand Rotation into 2 CCW Pump 2 Install the 0 6000 psi gauge into gauge port Ms 3 Set the input speed to operational speed 4 While simultaneously monitoring both gauges slowly supply control pressure into port Y Note the pressure on the Ap gauge when you first see pressure at port Ms This is the regulation begin pressure for workport S 5 To Adjust the Regulation Begin Pressure a Use the hammer and punch to loosen rotate CCW Spanner Nut 2 b Use the 18mm wrench on Locking Nut 2 to adjust Regulation Begi
6. Table of Contents Content Page Hydraulic Neutral Adjustment for HPV Pumps Set Up and Procedure 3 Regulation Begin Adjustment or HPV with Electro Hydraulic Remote Control Set Up 4 Procedure for Right Hand Rotation 5 Procedure for Left Hand Rotation 6 Maximum Flow Adjustment Procedure for HPV Pumps with H or E Controls Set Up 7 Procedure 8 HPV Hydraulic Neutral Adjustment Procedure for M1 Cam Control Set Up 9 Procedure 10 HPV CCW Left Hand Rotation Pumps with M2P Control with Pressure Override POR Set Up 11 Procedure 12 HPV CCW Left Hand Rotation Pumps with E1P Control with Pressure Override POR Set Up 15 Procedure 16 HPV CCW Left Hand Rotation Pumps with H1P Control with Pressure Override POR Set Up 19 Procedure 20 HPV CW Right Hand Rotation Pumps with M2P Control with Pressure Override POR Set Up 23 Procedure 24 HPV CW Right Hand Rotation Pumps with E1P Control with Pressure Override POR Set Up 27 Procedure 28 HPV CW Right Hand Rotation Pumps with H1P Control with Pressure Override POR Set Up 31 Procedure 32 Maximum Flow Adjustment Procedure for HPV Pumps with M2P Mechanical Hydraulic with POR Controls Set Up 35 Procedure 36 Adjusting the Deadband on HPV Pumps with M2P Mechanical Hydraulic with POR Controls Set Up and Procedure 37 HPV Maximum Displacement Adjustment for M1 Mechanical Hydraulic Control Set Up and Procedure 38 Regula
7. f is greater than 5 psi then either Valve or Valve II needs to be backed out The side which has the higher value must be backed out until the difference between value e and value f is 5 psi or less C Energize solenoid My to its maximum value and verify that work port pressure P is stable and control pressure does NOT increase decrease for 10 seconds D Energize solenoid Mz to its maximum value and verify that work port pressure S is stable and control pressure does NOT increase decrease for 10 seconds Note If either one or both work port pressures are not stable then repeat the POR adjustment process starting with step 1 above If the control pressure changes during steps C or D above then Valve I and or Valve II is not adjusted correctly Repeat the POR adjustment process starting with step 1 above EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 HPV CW Right Hand Rotation Pumps with H1P Control with Pressure Override POR Set Up A Important This is a field adjustment procedure valid for HPV pumps with CW Right Hand rotation and H1P Control 1 0mm TAA rn WW Weo H I l Y L aed 1 0mm E HN s A F A Mp ji WFIU m wi l 1 X AK wey LU ral Woo uf TG Valve Il CI Valve
8. D3 1 Variable Orifice Adjustment Se This procedure is intended for for HPV with CA Control field adjustments only Regulation Begin Setting Set Up and Procedure Tools Equipment Required f 03 1 Orifice e Engine RPM Tachometer Adjustment e 13mm wrench e 4mm Allen key Adjusting D3 1 Important Variable Orifice ZN Eaton recommends that the vehicle be lifted off the ground throughout this procedure This test must be performed with the oil at operating temperature DANGER The HPVCA pump will be put on stroke during this procedure as a result the vehicle s propel motor s will be turning while measurements adjustments are taking place 1 While monitoring the Engine RPM slowly increase the Engine RPM until the vehicle s propel motor s start to rotate 2 Record the Engine RPM at which the propel motor s started their rotation This RPM Value is the pump s regulation begin RPM and must match the value specified for the vehicle Contact Eaton Engineering for this value 3 To adjust the D3 1 variable orifice setting a Loosen the lock nut while holding the adjustment stud in place b Turn the adjustment in to decrease the Regulation Begin RPM Setting c Turn the adjustment out to increase the Regulation Begin RPM Setting d Tighten the lock nut while holding the adjustment stud in place EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 A Important Power Limiter Valve Adjustment a DSE E for HPV
9. Hydraulic 2 Neutral Adjustment sts laa oo wy M2P Control Adjustment Procedure 1 2 3 Install the 0 600 psi pressure gauges into gauge ports Mp and Ms to measure work port pressures P and S Set the input speed to high idle With the pump in neutral measure the pressure difference between work ports P and S Note Pump in neutral means no control pressure or current supplied to the controls For M2P controls the lever must be in neutral position a If the maximum pressure difference is 29 psi 2 bar or less then adjustment to the hydraulic neutral is NOT required Remove all gauges from the pump b If the maximum pressure difference is greater than 29 psi 2 bar then go to step 4 Loosen the Spanner Nut with the hammer and punch Using a 16mm wrench and the digital calipers adjust the Hydraulic Neutral Adjustment to 14 75mm as illustrated in the sketch above Repeat steps 2 and 3 Continue to make small adjustments to the Hydraulic Neutral Adjustment until the pressure difference between work ports P and S is less than 29 psi Secure the Hydraulic Neutral Adjustment by tightening the Spanner Nut once all settings are final Remove all gauges from the pump EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 Regulation Begin Adjustment for HPV With Electro Hydraulic Remote Control Set Up Tools Equipment Required Span
10. System pressure will be unstable This is an expected pump reaction C While monitoring work port pressure S SLOWLY turn the adjustment screw for Valve Il IN until the pressure just stabilizes Important You must slowly turn the adjustment screw in ONLY until the pressure stabilizes and then stop If you continue to turn the adjustment screw in system pressure will continue to increase and an unnecessary amount of oil will be forced over the main relief valve thus the operation of the POR will become less efficient D Tighten the locking nut on Valve II and de energize solenoid My E Repeat steps A through D for solenoid Mz while monitoring work port pressure P and adjusting Valve EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 17 HPV CCW Left Hand Rotation Pumps a inportant This is a field adjustment with FIP Control with procedure valid for HPV pumps with CCW Left Hand Pressure Override PO R rotation and E1P Control Procedure Valve III Adjustment 3 Valve Ill Adjustment A Keep both of the pump work ports P and S closed off or blocked B Energize solenoid My to its maximum value and hold it C Slowly turn IN the adjustment screw for Valve III until control pressure APy z is 10 15 psi higher than the APy z Regulation Begin pressure recorded above value a Record the APy z setting pSId v
11. Z 1 ig W B Valve Il Oar aT P Ne 3 A loo 66 OQ WY EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 HPV CCW Left Hand Rotation Pumps a laworsant This is a field adjustment with FIP Control with procedure valid for HPV ith CCW Left Hand Pressure Override POR ah Catal Procedure Pressure Override POR Adjustment Valve and Valve II Adjustments f 2 POR Setup A Measure and record the regulation begin pressures below APy z Regulation Begin psi value a APz y Regulation Begin psi value b B Turn OUT the adjustment screw for Valve III all the way it is mechanically restricted from being removed completely C Turn OUT the adjustment screw for Valve and Valve II by 3 4 full turns WARNING Care should be taken NOT to remove the adjustment screw in Valve and Valve II completely Do NOT turn OUT the adjustment screw more than 19mm as illustrated left D Connect the 0 7500 psi liquid filled gauges to work port gauge ports Mp and Ms E Connect the 0 200 psi Ap gauge transducer to control gauge ports Y and Z Valve and Valve Il Adjustments A Close OFF or block both of the pump work ports P and S B Energize solenoid My to its maximum value and hold it Note
12. and S is 29 psi 2 bar or less If not confirm gauges or transducers are calibrated and functioning correctly You may need to repeat the entire procedure to insure the hydraulic neutral is set correctly Secure the Hydraulic Neutral Adjustment by tightening the spanner nut Remove all gauges from the pump EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 HPV CCW Left Hand Rotation Pumps with M2P Control with Pressure Override POR Set Up A Important This is a field adjustment procedure valid for HPV pumps with CCW Left Hand rotation and M2P control p TN f GAD UW F B Ne ey D gt P ad alt CT X i A 5 7 af f J DX L K ME Im a wil wC fe ar L T E L foes EA 7M5 D LJ A x xZ Valve Valve I H Valve I Ly uc HPV 02 CCW l Rotation ONLY f LL yy T E A IH 1 Yi yZ Notes e Since the oil is being bled over the main relief valves during this procedure monitor the oil temperature in the main loop to avoid over heating e Oil Temperature Limitations for Eaton Components 4 F to 194 F 20 C to 90 C e Changes to any pump setting control supply pressure or system hardware after the POR has been adjusted could alter the performance of the POR It may be necessary to readjust the POR to compensate for any of these changes e Recommend
13. control pressure changes during steps C or D above then Valve I and or Valve II is not adjusted correctly Repeat the POR adjustment process starting with step 1 above EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 HPV CCW Left Hand Rotation Pumps with H1P Control with Pressure Override POR Set Up A Important This is a field adjustment procedure valid for HPV pumps with CCW Left Hand rotation and H1P Control IEN i O F B MT P EY wl 1 E I i Ka l w wt 1 weap xE l NAN SUC Y 19mm K MEM ili LFN 4 J 1 0mm am MX wa U L A JEN sC z Valve II Valve D l we HPV 02 CCW lt d Valve III p Rotation ONLY Notes e Since the oil is being bled over the main relief valves during this procedure monitor the oil temperature in the main loop to avoid over heating e Oil Temperature Limitations for Eaton Components 4 F to 194 F 20 C to 90 C e Changes to any pump setting control supply pressure or system hardware after the POR has been adjusted could alter the performance of the POR It may be necessary to readjust the POR to compensate for any of these changes e Recommended Gauges Qty 1 7500 psi Liquid filled gauge Qty 2 recommended for ease of testing Qty 1 0 200 psi Ap gauge or Ap transducer EATON Duraforce HPV Ser
14. it 3 Once the desired deadband range is acquired use the hammer and punch to tighten the Spanner Nut EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 37 38 HPV Maximum Displacement Adjustment for M1 Mechanical Hydraulic Control Set Up and Procedure Tools Equipment Required Direction X z gt Direction Y LL ja i ER oF e 13mm open or close ie end wrench L 4mm Allen wrench V rp 74 a NE N p S f Direction Y a a o lt G Neutral SEN A afp Q Y Position O D i k Direction X Hh a P Max Displacement V Flow Stop for Direction Y Max Displacement Flow Stop for Direction X Flow Orientation Turn Lever Pressure In Direction From Port For CW Right Hand Rotation X P Y S For CCW Left Hand Rotation X S Y P Adjustment Procedure amp Loosen the flow stop lock nut with 13mm wrench 2 Turn the cam lever in the appropriate direction 3 Turn the adjustment stud IN to decrease the flow or OUT to increase the flow using the 4mm Allen wrench When desired flow is acquired hold the adjustment stud stationary with the 4mm Allen wrench and tighten the lock nut with the 13mm wrench the proper torque for the lock nut is 14 N m 10 ft lb EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 Regulation Begin Adjustment for HPV Pump with Hydraulic Remote C
15. j n A i A HPV 02 CCW Ey x FY 4 Valve It Vavel gt Rotation ONLY M Mz t Valve ne Pax T T Notes e Since the oil is being bled over the main relief valves during this procedure monitor the oil temperature in the main loop to avoid over heating e Oil Temperature Limitations for Eaton Components 4 F to 194 F 20 C to 90 C e Changes to any pump setting control supply pressure or system hardware after the POR has been adjusted could alter the performance of the POR It may be necessary to readjust the POR to compensate for any of these changes e Recommended Gauges Qty 1 7500 psi Liquid filled gauge Qty 2 recommended for ease of testing Oty 1 0 200 psi Ap gauge or Ap transducer EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 15 HPV CCW Left Hand Rotation Pumps with E1P Control with Pressure Override POR Set Up Port Identification and Adjustment Locations A Important This is a field adjustment procedure valid for HPV pumps with CCW Left Hand rotation and E1P Control Valve For a CCW Rotation Pump Energize Solenoid My Gauge Port Y T Gauge Port Z iF r h L i CN a Q Q j Valve Il lA A f CU IN H WO Y O Valve Ill Energize Solenoid Mz Control Pressure At Port Y Z Pump Output Pressure at Port S P Must Adjust Valve II Valve Valve III mE
16. screw for Valve IN until the pressure just stabilizes Important You must slowly turn the adjustment screw in ONLY until the pressure stabilizes and then stop If you continue to turn the adjustment screw in system pressure will continue to increase and an unnecessary amount of oil will be forced over the main relief valve thus the operation of the POR will become less efficient D Tighten the locking nut on Valve and remove the control pressure from port Y E Repeat steps A through D for control port Z while monitoring work port pressure S and adjusting Valve II EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 33 34 HPV CW Right Hand Rotation Pumps meals This is a field adjustment with H1P Control with procedure valid for HPV pumps with CW Right Hand Pressure Override PO R rotation and H1P Control Procedure Valve IIl Adjustment 3 Final Adjustment 4 Valve Ill Adjustment A Keep both of the pump work ports P and S closed off or blocked B Supply full control pressure into port Y and hold it C Slowly turn IN the adjustment screw for Valve III until control pressure APy z is 10 unu 15 psi higher than the APy z Regulation Begin pressure recorded above value a hat Record the APy z setting psid value e D Tighten the locking nut on Valve Ill and remove the contro
17. then Valve I and or Valve II is not adjusted correctly Repeat the POR adjustment process starting with step 1 above EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 HPV CW Right Hand Rotation Pumps with E1P Control with Pressure Override POR Set Up A Important This is a field adjustment procedure valid for HPV pumps with CW Right Hand rotation and E1P Control O 1 AN A X 2 ir y a T gt A ps l ea el 1 pe l J LO y eo wu L 1 J Hay Z a HU g dy E 7 KA oo fh p Y l X HPV 02 CW oe ae vana TH Va i 7 Rotation ONLY My Mz F O Valve III van a i T Notes e Since the oil is being bled over the main relief valves during this procedure monitor the oil temperature in the main loop to avoid over heating e Oil Temperature Limitations for Eaton Components 4 F to 194 F 20 C to 90 C e Changes to any pump setting control supply pressure or system hardware after the POR has been adjusted could alter the performance of the POR It may be necessary to readjust the POR to compensate for any of these changes e Recommended Gauges Qty 1 7500 psi Liquid filled gauge Qty 2 recommended for ease of testing Oty 1 0 200 psi Ap gauge or Ap transducer EATON Duraforce HPV Service Ma
18. with M2P Mechanical Hydraulic with POR control with POR Controls Procedure Adjustment Procedure Set the pump input speed to operational speed 1 2 Turn the cam lever CCW as illustrated above fully Measure the rotational speed of the motor the wheel the gearbox etc and calculate if the pump is supplying enough flow If using a short circuit line measure the flow from the flowmeter To adjust the maximum flow a Use a 17mm wrench to loosen Locking Nut 2 b Use a 5mm Allen wrench to turn Adjustment Stud 2 Turn it IN to decrease the maximum flow or OUT to increase it A WARNING The flow adjustment stud is NOT mechanically restricted from being removed completely from the pump Care should be taken when turning the flow adjustment stud OUT as to prevent it from being removed from the pump control c Once the desired maximum flow has been acquired hold Adjustment Stud 2 stationary with the 5mm Allen wrench and tighten Locking Nut 2 with the 17mm wrench Turn the cam lever CW as illustrated on the previous page fully Measure the rotational speed of the motor the wheel the gearbox etc and calculate if the pump is supplying enough flow If using a short circuit line measure the flow from the flowmeter To adjust the maximum flow a Use a 17mm wrench to loosen Locking Nut 1 b Use a 5mm Allen wrench to turn Adjustment Stud 1 Turn it IN to decrease the maximum flow or OUT to increase it
19. If this is NOT possible then the pump work ports P and S must be short circuited to each other Install a properly sized flow meter in the short circuit line between P and S to avoid movement of the motor Optional Install the 0 600 psi gauge into gauge port Y Set the input speed to high idle For E2 Controls make sure that Ms Solenoid is energized a 1 82A 12VDC b 1 10A 24VDC Supply full control pressure to port Y or full current to solenoid My Optional Confirm that the pressure at port Y is adequate to put the pump at full displacement Measure the rotational speed of the motor the wheel the gearbox etc and calculate if the pump is supplying enough flow If using a short circuit line measure the flow from the flow meter To Adjust the Maximum Flow a Use the 13mm wrench to loosen Locking Nut 2 b Use the 4mm Allen wrench to turn Max Flow Adjustment Stud 2 Turn it IN to decrease the maximum flow or turn it OUT to increase it Z WARNING The flow adjustment stud is NOT mechanically restricted from being removed completely from the pump Care should be taken when turning the flow adjustment stud OUT DO NOT turn the adjustment stud OUT more than 26mm as illustrated on previous page c Once the desired maximum flow has been acquired hold the flow adjustment stud stationary with the 4mm Allen wrench and tighten the locking nut with the 13mm wrench the proper torque for the lock
20. PV Service Manual E PUPI TS020 E July 2012 HPV CW Right Hand Rotation Pumps A limponani This is a field adjustment with M2P Control with procedure valid for HPV ith CW Right Hand Pressure Override POR rotation ahd M2P control Procedure Pressure Override POR Adjustment Valve and Valve II Adjustments 1 2 POR Setup A Measure and record the regulation begin pressures below APy z Regulation Begin psi value a APz y Regulation Begin psi value b B Turn OUT the adjustment screw for Valve III all the way it is mechanically restricted from being removed completely C Turn OUT the adjustment screw for Valve and Valve II by 3 4 full turns A WARNING Care should be taken NOT to remove the adjustment screw in Valve and Valve II completely Do NOT turn OUT the adjustment screw more than 19mm as illustrated left D Connect the 0 7500 psi liquid filled gauges to work port gauge ports Mp and Ms E Connect the 0 200 psi Ap gauge transducer to control gauge ports Y and Z Valve and Valve Il Adjustments A Close OFF or block both of the pump work ports P and S B Turn the control lever CounterClockwise CCW fully and hold it Note System pressure will be unstable This is an expected pump reaction C While monitoring work port pressure P SLOWLY turn the adjustment screw for Valve IN
21. Pump with CA Control field adjustments only Set Up and Procedure Power Limiter Tools Equipment Required e 0 600psi Differential Pressure Gauge e 11mm wrench e 10mm Wrench e 3mm Allen Key Adjusting the Power Important Limiter Valve A Vehicle s drive system must be kept in Neutral throughout this procedure In order to insure this condition it is recommended to disconnect both My and Mz solenoid connections This test must be performed with the oil at operating temperature 1 Install the 0 600psi Differential Gauge as follows a Connect the HI side to the ML port b Connect the LO side to the Msp port 2 While monitoring the pressure on the Differential Gauge a Increase the Engine RPM from the low idle all the way to max RPM b The pressure value on the Differential Gauge during max RPM is the Power Limiter Valve setting Contact Eaton Engineering for this value 3 To adjust the Power Limiter Valve setting a Loosen the lock nut while holding the adjustment stud in place b Crack open the upper part of the power limiter valve body while holding the adjustment stud in place DANGER Do not move this portion of the valve body more than 1 8 of a turn Excessive movement can result in disassembly of the valve c While holding the Valve body in place turn the adjustment in to increase the Power Limiter Valve setting or out to decrease it d Tighten the upper part of the Power Limiter valve while
22. S To adjust the regulation begin pressure a Remove End Plug 2 with the 24mm wrench b Add shims to Shim Set 2 to INCREASE the regulation begin setting or remove shims to DECREASE the regulation begin setting Note You may need to add or remove shims to or from Shim Set 1 if you cannot acquire the desired regulation begin pressure by changing shims from Shim Set 2 c Reinstall End Plug 2 and torque it to 150 N m 111 ft lb Repeat steps 4 and 5 until the desired regulation begin pressure is acquired Install the 0 600 psi Ap gauge into ports Z and Y HI side into Z and LO side into Y Install the 0 6000 psi gauge into port Mp Set the input speed to operational speed While simultaneously monitoring both gauges slowly turn the cam lever CW as illustrated on page 42 Record the pressure on the Ap gauge when you first see pressure at port Mp This is the regulation begin pressure for workport P To adjust the regulation begin pressure a Remove End Plug 1 with the 24mm wrench b Add shims to Shim Set 2 to INCREASE the regulation begin setting or remove shims to DECREASE the regulation begin setting Note You may need to add or remove shims to or from Shim Set 1 if you cannot acquire the desired regulation begin pressure by changing shims from Shim Set 2 c Reinstall End Plug 1 and torque it to 150 N m 111 ft lb 12 Repeat steps 10 and 11 until the desired regulation begin pressure i
23. S020 E July 2012 21 22 HPV CCW Left Hand Rotation Pumps ay inportan This is a field adjustment with H l P Control with procedure valid for HPV pumps with CCW Left Hand Pressure Override PO R rotation and H1P Control Procedure Valve III Adjustment 3 Valve Ill Adjustment A Keep both of the pump work ports P and S closed off or blocked B Supply full control pressure into port Y and hold it C Slowly turn IN the adjustment screw for Valve III until control pressure APy z is 10 15 psi higher than the APy z Regulation Begin pressure recorded above value a Record the APy z setting Pidi value e D Tighten the locking nut on Valve Ill and remove the control pressure from port Y E Supply full control pressure into port Z and hold it Verify that the pressure is 10 15 psi higher than the APz y Regulation Begin pressure recorded above value b Record the APz y setting psid value f Hint f Valve Ill gets too hot it will be difficult to adjust and or get consistent results Allow the pump to cool off if you encounter difficulty adjusting Valve III Final Adjustment 4 Final Adjustment ann A IF the difference between value e and value f is 5 psi or less then NO additional adjustments are required to the POR B IF the difference between value e and value f is great
24. TS020 E July 2012 29 30 HPV CW Right Hand Rotation Pumps ea pale This is a field adjustment with E l P Control with procedure valid for HPV pumps with CW Right Hand Pressure Override PO R rotation and E1P Control Procedure Valve IlI Adjustment 3 Final Adjustment 4 Valve Ill Adjustment A Keep both of the pump work ports P and S closed off or blocked B Energize solenoid My to its maximum value and hold it C Slowly turn IN the adjustment screw for Valve III until control pressure APy z is 10 nnn 15 psi higher than the APy z Regulation Begin pressure recorded above value a Hah Record the APy z setting pSid value e D Tighten the locking nut on Valve Ill and de energize solenoid My E Energize solenoid Mz to its maximum value and hold it Verify that the pressure is 10 15 psi higher than the APz y Regulation Begin pressure recorded above value b Record the APz y setting pSid value f Hint f Valve III gets too hot it will be difficult to adjust and or get consistent results Allow the pump to cool off if you encounter difficulty adjusting Valve III Final Adjustment A IF the difference between value e and value f is 5 psi or less then NO additional adjustments are required to the POR B IF the difference between value e and value
25. Valve I 2 ot E HPV 02 CW _ Rotation ONLY L t 2 F A i i I Yy 2 Notes e Since the oil is being bled over the main relief valves during this procedure monitor the oil temperature in the main loop to avoid over heating e Oil Temperature Limitations for Eaton Components 4 F to 194 F 20 C to 90 C e Changes to any pump setting control supply pressure or system hardware after the POR has been adjusted could alter the performance of the POR It may be necessary to readjust the POR to compensate for any of these changes e Recommended Gauges Qty 1 7500 psi Liquid filled gauge Qty 2 recommended for ease of testing Oty 1 0 200 psi Ap gauge or Ap transducer EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 23 24 HPV CW Right Hand Rotation Pumps with M2P Control with Pressure Override POR Set Up Port Identification and T auge Port Y Adjustment Locations i Waa UU A A C Oe Valve A Valve Ill For a CW Rotation Pump Turn Lever Clockwise Pa A Important This is a field adjustment procedure valid for HPV pumps with CW Right Hand rotation and M2P control Valve Il Turn Lever Counter Clockwise Control Pressure At Port Z Y Pump Output Pressure at Port S P Must Adjust Valve II Valve Valve IlI EATON Duraforce H
26. al setting if required Adjustment Procedure for Right Hand CW Rotation Pumps 1 w 10 11 Install the 0 600 psi Ap gauge into port Y and Z HI side into Y and LO side into Z Install the 0 6000 psi gauge into port Mp Set the input speed to operational speed While simultaneously monitoring both gauges slowly turn the cam lever CCW as illustrated on page 42 Record the pressure on the Ap gauge when you first see pressure at port Mp This is the regulation begin pressure for workport P To adjust the regulation begin pressure a Remove End Plug 2 with the 24mm wrench b Add shims to Shim Set 2 to INCREASE the regulation begin setting or remove shims to DECREASE the regulation begin setting Note You may need to add or remove shims to or from Shim Set 1 if you cannot acquire the desired regulation begin pressure by changing shims from Shim Set 2 c Reinstall End Plug 2 and torque it to 150 N m 111 ft lb Repeat steps 4 and 5 until the desired regulation begin pressure is acquired Install the 0 600 psi Ap gauge into ports Z and Y HI side into Z and LO side into Y Install the 0 6000 psi gauge into port Ms Set the input speed to operational speed While simultaneously monitoring both gauges slowly turn the cam lever CW as illustrated on page 42 Record the pressure on the Ap gauge when you first see pressure at port Ms This is the regulation begin pressure f
27. alue e D Tighten the locking nut on Valve IIl and de energize solenoid My E Energize solenoid Mz to its maximum value and hold it Verify that the pressure is 10 15 psi higher than the APz y Regulation Begin pressure recorded above value b Record the APz y setting psid value f Hint f Valve III gets too hot it will be difficult to adjust and or get consistent results Allow the pump to cool off if you encounter difficulty adjusting Valve III Final Adjustment 4 Final Adjustment ann A IF the difference between value e and value f is 5 psi or less then NO additional adjustments are required to the POR B IF the difference between value e and value f is greater than 5 psi then either Valve or Valve II needs to be backed out The side which has the higher value must be backed out until the difference between value e and value f is 5 psi or less C Energize solenoid My to its maximum value and verify that work port pressure S is stable and control pressure does NOT increase decrease for 10 seconds D Energize solenoid Mz to its maximum value and verify that work port pressure P is stable and control pressure does NOT increase decrease for 10 seconds Note If either one or both work port pressures are not stable then repeat the POR adjustment process starting with step 1 above If the
28. difference between value e and value f is greater than 5 psi then either Valve or Valve II needs to be backed out The side which has the higher value must be backed out until the difference between value e and value f is 5 psi or less C Turn the control lever CounterClockwise CCVV fully and verify that work port pressure S is stable and control pressure does NOT increase decrease for 10 seconds D Turn the control lever Clockwise CV fully and verify that work port pressure P is stable and control pressure does NOT increase decrease for 10 seconds Note If either one or both work port pressures are not stable then repeat the POR adjustment process starting with step 1 above If the control pressure changes during steps C or D above then Valve and or Valve II is not adjusted correctly Repeat the POR adjustment process starting with step 1 above EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 HPV CCW Left Hand Rotation Pumps with E1P Control with Pressure Override POR Set Up A Important This is a field adjustment procedure valid for HPV pumps with CCW Left Hand rotation and E1P Control X se iA l yw 1 f amp g elr ik CIF 1 Le Ka tT ME IW wid S J L T uw i i XALI Ms O A
29. e I and or Valve II is not adjusted correctly Repeat the POR adjustment process starting with step 1 above EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 A Note This Service Bulletin is ONLY valid for HPV pumps with the M2P Mechanical Hydraulic with POR control Maximum Flow Adjustment Procedure for HPV Pumps with M2P Mechanical Hydraulic with POR Controls Set Up Tools Equipment Required Adjustment Stud 2 Adjustment Stud 1 a nimArench Locking Nut 2 Locking Nut 1 e 5mm Allen wrench lO CW U N aN ce AA _ i i J m We Tv OW V C A A WARNING T TH If performing this procedure on L amp LJ E a vehicle care must be taken N AA The pump will be put on stroke Oo during this procedure hence 7 H the vehicle must be safely l A elevated to allow the function p Z a i to free wheel If this is NOT e l possible then the pump work ports P and S must be short A circuited to each other Install a properly sized flowmeter in the short circuit line between P and S to avoid movement of the function EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 35 36 Maximum Flow Adjustment A Note This Service Bulletin is ONLY Procedure for H PV Pumps valid for HPV pumps with the M2P Mechanical Hydraulic
30. e conversion of the DuraForce products absent the necessary training and or these specialized tools you do so at your risk Eaton will accept no claim for warranty resulting from deficiencies in the conversion Please refer to the Eaton literature web site for warranty information at www eaton com hydraulics warranty EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 49 50 EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 51 E T N Powering Business Worldwide Eaton Eaton Hydraulics Group USA Hydraulics Group Europe 14615 Lone Oak Road Route de la Longeraie 7 Eden Prairie MN 55344 1110 Morges USA Switzerland Tel 952 937 9800 Tel 41 0 21 811 4600 Fax 952 294 7722 Fax 41 0 21 811 4601 www eaton com hydraulics 2012 Eaton Corporation All Rights Reserved Printed in USA Document No E PUPI TS020 E July 2012 Eaton Hydraulics Group Asia Pacific Eaton Building No 7 Lane 280 Linhong Road Changning District Shanghai 200335 China Tel 86 21 5200 0099 Fax 86 21 2230 7240
31. ed Gauges Qty 1 7500 psi Liquid filled gauge Qty 2 recommended for ease of testing Oty 1 0 200 psi Ap gauge or Ap transducer EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 11 HPV CCW Left Hand Rotation Pumps with M2P Control with Pressure Override POR Set Up Port Identification and Adjustment Locations one Port Y A Important This is a field adjustment procedure valid for HPV pumps with CCW Left Hand rotation and M2P control Oo SS Valve vA For a CCW Rotation Pump Turn Lever Clockwise oo Turn Lever Counter Clockwise Control Pressure At Port Z Y Pump Output Pressure at Port P S Must Adjust Valve Valve II Valve I Lf E 12 EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 HPV CCW Left Hand Rotation Pumps bona This is a field adjustment with M2P Control with procedure valid for HPV ith CCW LeftHand Pressure Override POR Date A Cota Procedure Pressure Override POR Adjustment Valve and Valve II Adjustments 1 2 POR Setup A Measure and record the regulation begin pressures below APy z Regulation Begin psi value a APz y Regulation Begin psi value b B Turn OUT the adjustment screw for Valve III all the way it is mechanical
32. eing removed completely C Turn OUT the adjustment screw for Valve and Valve II by 3 4 full turns A WARNING Care should be taken NOT to remove the adjustment screw in Valve and Valve II completely Do NOT turn OUT the adjustment screw more than 19mm as illustrated left D Connect the 0 7500 psi liquid filled gauges to work port gauge ports Mp and Ms E Connect the 0 200 psi Ap gauge transducer to control gauge ports My and Mz Valve and Valve II Adjustments A Close OFF or block both of the pump work ports P and S B Supply full control pressure into port Y and hold it Note System pressure will be unstable This is an expected pump reaction C While monitoring work port pressure S7 SLOWLY turn the adjustment screw for Valve Il IN until the pressure just stabilizes Important You must slowly turn the adjustment screw in ONLY until the pressure stabilizes and then stop If you continue to turn the adjustment screw in system pressure will continue to increase and an unnecessary amount of oil will be forced over the main relief valve thus the operation of the POR will become less efficient D Tighten the locking nut on Valve II and remove the control pressure from port Y E Repeat steps A through D for control port Z while monitoring work port pressure P and adjusting Valve EATON Duraforce HPV Service Manual E PUPI T
33. ent Required e Two 2 high pressure gauges or transducers 6000 psi e 16mm wrench optional adjustable wrench e Special pointing device provided by Eaton e Digital calipers optional depth micrometers e Hammer and punch A WARNING If performing this procedure on a vehicle care must be taken The pump will be put on stroke during this procedure hence the vehicle must be safely elevated to allow the motor to free wheel If this is NOT possible then clear all personnel from the machine to avoid injury when the machine moves Hydraulic Neutral Adjustment i Y Parallel 14 75mm ics Neutral aa _ Alignment Position T Marks Note The maximum displacement on this control must be set prior to using this Service Bulletin Please follow all steps on page 38 before continuing with this Service Bulletin Note The following steps are ONLY to be carried out by those individuals trained on this particular procedure EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 HPV Hydraulic Neutral Adjustment Procedure for M1 Cam Control Procedure Adjustment Procedure 10 11 12 13 Install the two high pressure gauges to measure work port pressure P and S Orient the alignment marks so that they are parallel with the centerline of the hydraulic neutral adjustment as illustrated above Set the input speed to high idle Measure the pressure difference between
34. er than 5 psi then either Valve or Valve II needs to be backed out The side which has the higher value must be backed out until the difference between value e and value f is 5 psi or less C Supply full control pressure into port Y and verify that work port pressure S is stable and control pressure does NOT increase decrease for 10 seconds D Supply full control pressure into port Z and verify that work port pressure P is stable and control pressure does NOT increase decrease for 10 seconds Note If either one or both work port pressures are not stable then repeat the POR adjustment process starting with step 1 above If the control pressure changes during steps C or D above then Valve and or Valve II is not adjusted correctly Repeat the POR adjustment process starting with step 1 above EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 HPV CW Right Hand Rotation Pumps with M2P Control with Pressure Override POR Set Up A Important This is a field adjustment procedure valid for HPV pumps with CW Right Hand rotation and M2P control a FN z 9 7 AJ Oe A Ws fear x AW z i ax 2 iN lt DES ji LE L WJ Wi D ey J 7 IT d Mp WD VY 4 Ye 7 WX d eee NEN Ty WW W age K Valve IL m
35. holding the adjustment stud in place e Tighten the lock nut while holding the adjustment stud in place EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 47 48 Switching Valve Adjustment for A Important This procedure is intended for HPV Pump with CA Control field adjustments only Set Up and Procedure Tools Equipment Required e 0 600psi Pressure Gauge e Engine RPM Tachometer e 13mm wrench e 4mm Allen key Switching Valve Adjustment Adjusting the Important Switching Valve Z Eaton recommends that the vehicle be lifted off the ground throughout this procedure This test must be performed with the oil at operating temperature DANGER The HPVCA pump will be put on stroke during this procedure as a result the vehicle s propel motor s will be turning while measurements adjustments are taking place 1 Install the 0 600psi Gauge on test port Y of the pump control 2 With the vehicle lifted off the ground Energize solenoid Mz 3 While monitoring the Engine RPM and the pressure in port Y a Slowly increase the Engine RPM from low idle b The pressure in port Y will increase as the Engine RPM increases then will suddenly drop back to charge pressure c Record the Engine RPM when the pressure in port Y suddenly drops back to charge pressure 4 This Engine RPM value must be equal to the mid point between Engine low idle RPM and Pump s Regulation Begin E
36. ing nut is 10 ft lb 14 N m EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 Optional Install the 0 600 psi gauge into gauge port Z Set the input speed to high idle For E2 Controls Make sure that Ms Solenoid is energized a 1 82A 12VDC b 1 10A 24VDC Supply full control pressure to port Z or full current to solenoid Mz Optional Confirm that the pressure at port Z is adequate to put the pump at full displacement Measure the rotational speed of the motor the wheel the gearbox etc and calculate if the pump is supplying enough flow If using the short circuit line measure the flow from the flow meter To Adjust the Maximum Flow a Use the 13mm wrench to loosen Locking Nut 1 b Use the 4mm Allen wrench to turn Max Flow Adjustment Stud 1 Turn it IN to decrease the maximum flow or turn it OUT to increase it Z WARNING The flow adjustment stud is NOT mechanically restricted from being removed completely from the pump Care should be taken when turning the flow adjustment stud OUT DO NOT turn the adjustment stud OUT more than 26mm as illustrated on previous page Once the desired maximum flow has been acquired hold the flow adjustment stud stationary with the 4mm Allen wrench and tighten the locking nut with the 13mm wrench the proper torque for the locking nut is 10 ft lb 14 N m HPV Hydraulic Neutral Adjustment Procedure for M1 Cam Control Set Up Tools Equipm
37. l setting if required Adjustment Procedure 1 for Right Hand Rotation CW Pump 2 w 10 11 Install the 0 600 psi Ap gauge into ports Y and Z HI side into Y and LO side into Z Install the 0 6000 psi gauge into gauge port Mp Set the input speed to Operational Speed While simultaneously monitoring both gauges slowly supply control pressure into port Y Note the pressure on the Ap gauge when you first see pressure at port Mp This is the regulation begin pressure for workport P To Adjust the Regulation Begin Pressure a Use the hammer and punch to loosen rotate CCW Spanner Nut 2 b Use the 13mm wrench on Locking Nut 2 to adjust Regulation Begin Cup 2 Turn it IN to increase the regulation begin pressure or turn it OUT to decrease it c Use the hammer and punch to tighten rotate CW Spanner Nut 2 d Repeat steps 3 and 4 to verify that the regulation begin pressure is correct Install the 0 600 psi Ap gauge into ports Z and Y HI side into Z and LO side into Y Install the 0 6000 psi gauge into gauge port Ms Set the input speed to operational speed While simultaneously monitoring both gauges slowly supply control pressure into port Z Note the pressure on the Ap gauge when you first see pressure at port Ms This is the regulation begin pressure for workport S To Adjust the Regulation Begin Pressure a Use the hammer and punch to loosen rotate CCW
38. l pressure from port Y E Supply full control pressure into port Z and hold it Verify that the pressure is 10 15 psi higher than the APz y Regulation Begin pressure recorded above value b Record the APz y setting pSid value f Hint f Valve III gets too hot it will be difficult to adjust and or get consistent results Allow the pump to cool off if you encounter difficulty adjusting Valve III Final Adjustment A IF the difference between value e and value f is 5 psi or less then NO additional adjustments are required to the POR an B IF the difference between value e and value f is greater than 5 psi then either Valve or Valve II needs to be backed out The side which has the higher value must be backed out until the difference between value e and value f is 5 psi or less C Supply full control pressure into port Y and verify that work port pressure P is stable and control pressure does NOT increase decrease for 10 seconds D Supply full control pressure into port Z and verify that work port pressure S is stable and control pressure does NOT increase decrease for 10 seconds Note If either one or both work port pressures are not stable then repeat the POR adjustment process starting with step 1 above If the control pressure changes during steps C or D above then Valv
39. ly restricted from being removed completely C Turn OUT the adjustment screw for Valve and Valve II by 3 4 full turns A WARNING Care should be taken NOT to remove the adjustment screw in Valve and Valve II completely Do NOT turn OUT the adjustment screw more than 19mm as illustrated left D Connect the 0 7500 psi liquid filled gauges to work port gauge ports Mp and Ms E Connect the 0 200 psi Ap gauge transducer to control gauge ports Y and Z Valve and Valve Il Adjustments A Close OFF or block both of the pump work ports P and S B Turn the control lever CounterClockwise CCV fully and hold it Note System pressure will be unstable This is an expected pump reaction C While monitoring work port pressure S SLOWLY turn the adjustment screw for Valve Il IN until the pressure just stabilizes Important You must slowly turn the adjustment screw in ONLY until the pressure stabilizes and then stop If you continue to turn the adjustment screw in system pressure will continue to increase and an unnecessary amount of oil will be forced over the main relief valve thus the operation of the POR will become less efficient D Tighten the locking nut on Valve II and return the control lever to its neutral position E Repeat steps A through D but turn the control lever Clockwise CVV fully and monitor work port pressure P and adjust Valve
40. n Cup 2 Turn it IN to increase the regulation begin pressure or turn it OUT to decrease it c Use the hammer and punch to tighten rotate CW Spanner Nut 2 d Repeat steps 3 and 4 to verify that the regulation begin pressure is correct 6 Install the 0 600 psi Ap gauge into ports Z and Y HI side into Z and LO side into Y 7 Install the 0 6000 psi gauge into gauge port Mp 8 Set the input speed to operational speed 9 While simultaneously monitoring both gauges slowly supply control pressure into port Z Note the pressure on the Ap gauge when you first see pressure at port Mp This is the regulation begin pressure for workport P 10 To Adjust the Regulation Begin Pressure a Use the hammer and punch to loosen rotate CCW Spanner Nut 1 b Use the 18mm wrench on Locking Nut 1 to adjust Regulation Begin Cup 1 Turn it IN to increase the regulation begin pressure or turn it OUT to decrease it c Use the hammer and punch to tighten rotate CW Spanner Nut 1 d Repeat steps 8 and 9 to verify that the regulation begin pressure is correct 11 Follow all steps on pages 7 8 to reset the maximum displacement EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 41 A Note Regulation Begin Adjustment for This Service Bulletin is ONLY HPV Pumps with M2P Mechanical valid for HPV pumps with M2P Mechanical Hydraulic Hydraulic with POR Controls with POR controls Set U
41. ner Nut 1 Regulation Begin Cup 2 Locking Mechanism for e Multi meter capable of Pee Begin Cup Spanner Nut 2 reading 0 to 1000 mA Locking e 0 6000 psi pressure gauge Nut HNA we X EQ or transducer T H e 13mm offset closed end wrench e Hammer and punch Regulation S Begin Cup 1 A Important AFTER adjusting the regulation begin you must reset the pump maximum displacement setting Follow f gt the instructions on pages 7 8 to reset the pump maximum displacement 5 ci E _ to py CLL a My Mz e Z WARNING If performing this procedure on a vehicle care must be taken The pump will be put on stroke during this procedure hence the vehicle must be safely elevated to allow the motor to free wheel If this is NOT possible then the pump workports P and S must be short circuited to each other to avoid movement of the motor E2 Control EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 Regulation Begin Adjustment for HPV With Electro Hydraulic Remote Control Procedure for Right Hand Rotation A Note Prior to performing this procedure verify that the hydraulic neutral on the pump is correctly adjusted Adjustment Procedure for Right Hand Rotation CW Pump 1 Connect the multi meter to measure current at solenoid My 2 Install the 0 6000 psi gauge into gauge po
42. ngine RPM 20RPM see page 46 5 To adjust the Switching Valve Setting a Loosen the lock nut while holding the adjustment stud in place b Turn the adjustment in to increase the Switching Valve value c Turn the adjustment out to decrease the Switching Valve value d Tighten the lock nut while holding the adjustment stud in place EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 Additional Information Environmental Concerns Protection of the natural fundamentals of life is one of our predominant tasks We are continuously improving the protection of the environment as far as applications are concerned We encourage you to contribute your share to comply with this demand In connection with work to be performed the environmental regulations of the machine manufacturer must be respected In general e Greases and oils which cannot be used any more have to be collected They are normally a threat to water reserves and must be kept away from the environment e Adhere to national and local regulations for waste disposal Important You have been provided information on the conversion of DuraForce products Proper application of the information requires specific training and may require use of specialized tooling and equipment All requests for training must be coordinated through your Eaton Account Manager He can also provide you price and availability of any specialized tooling If you choose to proceed with th
43. nically restricted from being removed completely C Turn OUT the adjustment screw for Valve and Valve II by 3 4 full turns A WARNING Care should be taken NOT to remove the adjustment screw in Valve and Valve II completely Do NOT turn OUT the adjustment screw more than 19mm as illustrated left D Connect the 0 7500 psi liquid filled gauges to work port gauge ports Mp and Ms E Connect the 0 200 psi Ap gauge transducer to control gauge ports Y and Z Valve and Valve II Adjustments A Close OFF or block both of the pump work ports P and S B Energize solenoid My to its maximum value and hold it Note System pressure will be unstable This is an expected pump reaction C While monitoring work port pressure P SLOWLY turn the adjustment screw for Valve IN until the pressure just stabilizes Important You must slowly turn the adjustment screw in ONLY until the pressure stabilizes and then stop If you continue to turn the adjustment screw in system pressure will continue to increase and an unnecessary amount of oil will be forced over the main relief valve thus the operation of the POR will become less efficient D Tighten the locking nut on Valve and de energize solenoid My E Repeat steps A through D for solenoid Mz while monitoring work port pressure S and adjusting Valve II EATON Duraforce HPV Service Manual E PUPI
44. nual E PUPI TS020 E July 2012 27 28 HPV CW Right Hand Rotation Pumps with E1P Control with Pressure Override POR Set Up Port Identification and Adjustment Locations Valve For a CW Rotation Pump Energize Solenoid My Gauge Port Y a x A Important 7 Gauge Port Z l H Vahve Il Valve Ill Energize Solenoid Mz Control Pressure At Port Y Z Pump Output Pressure at Port P S Must Adjust Valve Valve II Y Valve Ill Z t a p3 Valve f Mp WA oO OO KI Q O ANS E EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 This is a field adjustment procedure valid for HPV pumps with CW Right Hand rotation and E1P Control HPV CW Right Hand Rotation Pumps A limportant This is a field adjustment with FIP Control with procedure valid for HPV ith CW RightHand Pressure Override POR rotation and EIP Control Procedure Pressure Override POR Adjustment Valve and Valve II Adjustments f 2 POR Setup A Measure and record the regulation begin pressures below APy z Regulation Begin psi value a APz y Regulation Begin psi value b B Turn OUT the adjustment screw for Valve III all the way it is mecha
45. ontrol Set Up Tools Equipment Required Spanner Nut 1 Regulation Begin Cup 2 Locking Mechanism for e 0 600 psi Ap gauge optional Regulation Begin Cup Spanner Nut 2 two 2 0 600 psi pressure gauges or transducers Locking e 0 6000 psi pressure gauge Nut 1 hz or transducer e 13mm offset iN closed end wrench e Hammer and punch Regulation Begin Cup 1 A Important AFTER adjusting the o regulation begin you must N reset the pump maximum WW displacement setting Follow ps mee the instructions on pages 7 8 to reset the pump maximum displacement W to A WARNING If performing this procedure on a vehicle care must be taken The pump will be put on stroke during this procedure hence the vehicle must be safely elevated to allow the function to free wheel If this is NOT possible then the pump workports P and S must be short circuited to each other to avoid movement of the function EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 40 Regulation Begin Adjustment for HPV Pump with Hydraulic Remote Control Procedure for Right Hand CW Rotation A Note Prior to performing this procedure verify that the hydraulic neutral on the pump is correctly adjusted Use the instructions on page 3 to check and adjust the hydraulic neutra
46. or workport S To adjust the regulation begin pressure a Remove End Plug 1 with the 24mm wrench b Add shims to Shim Set 2 to INCREASE the regulation begin setting or remove shims to DECREASE the regulation begin setting Note You may need to add or remove shims to or from Shim Set 1 if you cannot acquire the desired regulation begin pressure by changing shims from Shim Set 2 c Reinstall End Plug 1 and torque it to 150 N m 111 ft lb 12 Repeat steps 10 and 11 until the desired regulation begin pressure is acquired EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 43 44 Regulation Begin Adjustment for HPV Pump with M2P Mechanical Hydraulic with POR Controls Procedure for Left Hand CCW Rotation A Note Prior to performing this procedure verify that the hydraulic neutral on the pump is correctly adjusted Use the instructions on page 3 to check and adjust the hydraulic neutral setting if required Adjustment Procedure for Left Hand CCW Rotation Pumps 10 11 Install the 0 600 psi Ap gauge into ports Y and Z HI side into Y and LO side into Z Install the 0 6000 psi gauge into port Ms Set the input speed to operational speed While simultaneously monitoring both gauges slowly turn the cam lever CCW as illustrated on page 42 Record the pressure on the Ap gauge when you first see pressure at port Ms This is the regulation begin pressure for workport
47. p Shim Set 17 Tools Equipment Required e 0 600 psi Ap gauge optional two 2 0 600 psi pressure gauges or transducers e 0 6000 psi pressure gauge 4 or transducer f e 24mm wrench T e torque wrench capable of setting 150 N m 111 ft lb e regulation begin shims refer to the Eaton spare parts catalog for part numbers Note for shim set 2 0 1mm shim change 0 38 change in lever movement End Plug 1 End Plug F Y J VY iccw i j O j ZO i 7 fo E CCW I Of S h mna A WARNING If performing this procedure on a vehicle care must be taken The pump will be put on stroke during this procedure hence the vehicle must be safely elevated to allow the function to free wheel If this is not possible then the pump workports P and S must be short circuited to each other to avoid movement of the function EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 Regulation Begin Adjustment for HPV Pumps with M2P Mechanical Hydraulic with POR Controls Procedure for Right Hand CW Rotation A Note Prior to performing this procedure verify that the hydraulic neutral on the pump is correctly adjusted Use the instructions on page 3 to check and adjust the hydraulic neutr
48. rt Mp 3 Set the pump input speed to high idle 4 For E2 controls make sure that Ms Solenoid is energized a 1 82A 12VDC b 1 10A 24VDC 5 While simultaneously monitoring the gauge and multi meter slowly energize solenoid My Note the current on the multi meter when you first see pressure increase at port Mp This is the regulation begin setting for workport P 6 To Adjust the Regulation Begin Setting a Use the hammer and punch to loosen Spanner Nut 2 b Use the 18mm wrench on Locking Nut 2 to adjust Regulation Begin Cup 2 Turn it IN to increase the regulation begin setting or turn it OUT to decrease it c Use the hammer and punch to tighten Spanner Nut 2 d Repeat steps 3 through 5 to verify that the regulation begin setting is Control Range A 2 8bar B 4 10bar C 4 16bar Regulation Begin for 12 VDC 350 mA 450 mA 450 mA Regulation Begin for 24 VDC 175 mA 225 mA 225 mA 7 Repeat steps 1 through 6 for solenoid Mz and gauge port Ms to adjust the regulation begin setting for workport S Note Adjustments should be made to Regulation Begin Cup 1 EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 Regulation Begin Adjustment for HPV With Electro Hydraulic Remote Control Procedure for Left Hand Rotation A Note Prior to performing this procedure verify that the hydraulic neutral on the pump is correctly adjusted Adjustment Procedure for Lef
49. s acquired EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 Cold Start Valve Adjustment for ae This procedure is intended for HPV Pump with CA Control field adjustments only Set Up and Procedure Tools Equipment Required e 0 600psi Pressure Gauge e 10mm wrench X2 Cold Start Valve Adjustment Adjusting the Important Cold Start Valve ZS Vehicle s drive system must be kept in Neutral throughout this procedure In order to insure this condition it is recommended to disconnect both My and Mz solenoid connections This test must be performed with the oil at operating temperature 1 Install the 0 GOOpsi Gauge on test port Mt of the pump s filter block 2 While monitoring the pressure on the Mt port a Increase the Engine RPM from the low idle all the way to max RPM b The pressure value at port Mt during max RPM is the Cold Start Valve setting Contact Eaton Engineering for the correct value for your pump DANGER In order to prevent damages to the filter element this value must be kept lower than 580psi 3 To adjust the Cold Start Valve setting a Loosen the lock nut while holding the adjustment stud in place b Turn the adjustment in to increase the Cold Start Valve setting c Turn the adjustment out to decrease the Cold Start Valve setting d Tighten the lock nut while holding the adjustment stud in place EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 45 46
50. t Hand Rotation CCW Pump Connect the multi meter to measure current at solenoid Mz Install the 0 6000 psi gauge into gauge port Mp Set the pump input speed to high idle For E2 controls make sure that Ms Solenoid is energized a 1 82A 12VDC b 1 10A 24VDC 5 While simultaneously monitoring the gauge and multi meter slowly energize solenoid Mz Note the current on the multi meter when you first see pressure increase at port Mp This is the regulation begin setting for workport P 6 To Adjust the Regulation Begin Setting a Use the hammer and punch to loosen Spanner Nut 1 b Use the 13mm wrench on Locking Nut 1 to adjust Regulation Begin Cup 1 Turn it IN to increase the regulation begin setting or turn it OUT to decrease it c Use the hammer and punch to tighten Spanner Nut 1 d Repeat steps 3 through 5 to verify that the regulation begin setting is A WNA Control Range A 2 8bar B 4 10bar C 4 16bar Regulation Begin for 12 VDC 350 mA 450 mA 450 mA Regulation Begin for 24 VDC 175 mA 225 mA 225 mA 7 Repeat steps 1 through 6 for solenoid My and gauge port Ms to adjust the regulation begin setting for workport S Note Adjustments should be made to Regulation Begin Cup 2 EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 Maximum Flow Adjustment Procedure for HPV Pumps with H or E Controls Set Up
51. tion Begin Adjustment for HPV Pump with Hydraulic Remote Control Set Up 39 Procedure for Right Hand CW Rotation 40 Procedure for Left Hand CCW Rotation 41 Regulation Begin Adjustment for HPV Pumps with M2P Mechanical Hydraulic with POR Controls Set Up 42 Procedure for Right Hand CW Rotation 43 Procedure for Left Hand CCVV Rotation 44 Cold Start Valve Adjustment for HPV Pump with CA Control Set Up and Procedure 45 D3 1 Variable Orifice Adjustment for HPV with CA Control Regulation Begin Setting Set Up and Procedure 46 Power Limiter Valve Adjustment for HPV Pump with CA Control Set Up and Procedure 47 Switching Valve Adjustment for HPV Pump with CA Control Set Up and Procedure 48 IMPORTANT INFO will be moving this to the front with generic tool list 42 EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 Hydraulic Neutral Adjustment Note for HPV Pumps Set Up and Procedure Tools Equipment Required e Two 2 0 600 psi pressure gauges or transducers e 16mm wrench optional adjustable wrench e Digital calipers optional depth micrometers e Hammer and punch This Service Bulletin is valid for HPV pumps controls except the M1 control For HPV pumps with M1 Control refer to pages 9 10 for the hydraulic neutral adjustment instructions Hydraulic Neutral Adjustment 14 75 Ms y Solenoid fi S m ie J E2 Control
52. turn the control lever to its neutral position E Turn the control lever Clockwise CVV fully and hold it Verify that the pressure is 10 15 psi higher than the APz y Regulation Begin pressure recorded above value b Record the APz y setting psid value f Hint If Valve III gets too hot it will be difficult to adjust and or get consistent results Allow the pump to cool off if you encounter difficulty adjusting Valve III Final Adjustment A IF the difference between value e and value f is 5 psi or less then NO additional adjustments are required to the POR B IF the difference between value e and value f is greater than 5 psi then either Valve or Valve II needs to be backed out The side which has the higher value must be backed out until the difference between value e and value f is 5 psi or less C Turn the control lever CounterClockwise CCVV fully and verify that work port pressure P is stable and control pressure does NOT increase decrease for 10 seconds D Turn the control lever Clockwise CVV fully and verify that work port pressure S is stable and control pressure does NOT increase decrease for 10 seconds Note If either one or both work port pressures are not stable then repeat the POR adjustment process starting with step 1 above If the control pressure changes during steps C or D above
53. until the pressure just stabilizes Important You must slowly turn the adjustment screw in ONLY until the pressure stabilizes and then stop If you continue to turn the adjustment screw in system pressure will continue to increase and an unnecessary amount of oil will be forced over the main relief valve thus the operation of the POR will become less efficient D Tighten the locking nut on Valve and return the control lever to its neutral position E Repeat steps A through D but turn the control lever Clockwise CVV fully and monitor work port pressure S and adjust Valve II EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 25 26 HPV CW Right Hand Rotation Pumps gt porian This is a field adjustment with M2P Control with procedure valid for HPV pumps with CW Right Hand Pressure Override PO R rotation and M2P control Procedure Valve III Adjustment 3 Final Adjustment 4 Valve Ill Adjustment A Keep both of the pump work ports P and S closed off or blocked B Turn the control lever CounterClockwise CCW fully and hold it C Slowly turn IN the adjustment screw for Valve III until control pressure APy z is 10 it att 15 psi higher than the APy z Regulation Begin pressure recorded above value a Hat Record the APy z setting PSid value e D Tighten the locking nut on Valve Ill and re
54. uraforce HPV Service Manual E PUPI TS020 E July 2012 Valve Il HPV CW Right Hand Rotation Pumps A portant This is a field adjustment with H1P Control with procedure valid for HPV ith CW Right Hand Pressure Override POR rotation and HIP Control Procedure Pressure Override POR Adjustment Valve and Valve II Adjustments f 2 POR Setup A Measure and record the regulation begin pressures below APy z Regulation Begin psi value a APz y Regulation Begin psi value b B Turn OUT the adjustment screw for Valve III all the way it is mechanically restricted from being removed completely C Turn OUT the adjustment screw for Valve and Valve II by 3 4 full turns A WARNING Care should be taken NOT to remove the adjustment screw in Valve and Valve II completely Do NOT turn OUT the adjustment screw more than 19mm as illustrated left D Connect the 0 7500 psi liquid filled gauges to work port gauge ports Mp and Ms E Connect the 0 200 psi Ap gauge transducer to control gauge ports My and Mz Valve and Valve II Adjustments A Close OFF or block both of the pump work ports P and S B Supply full control pressure into port Y and hold it Note System pressure will be unstable This is an expected pump reaction C While monitoring work port pressure P SLOWLY turn the adjustment
55. vice Manual E PUPI TS020 E July 2012 19 20 HPV CCW Left Hand Rotation Pumps with H1P Control with Pressure Override POR Set Up Port Identification and Gauge Port My T A Important This is a field adjustment procedure valid for HPV pumps with CCW Left Hand rotation and H1P Control Gauge Port Mz Yy Adjustment Locations N AN IRO e l L JZ SZI H E Valve II ag H A H vave lo lo Of WS S Ss pe Ns Aj i Ea 7 J Valve Ill For a CCW Rotation Pump Control Pressure Into Port Y Control Pressure Into Port Z Pump Output Pressure At Port S P Must Adjust Valve II Valve My T Valve lll Mz Valve E Vane Il Mp EATON Duraforce HPV Service Manual E PUPI TS020 E July 2012 HPV CCW Left Hand Rotation Pumps Alpena This is a field adjustment with H1P Control with procedure valid for HPV ith CCW Left Hand Pressure Override POR rotation and HIP Control Procedure Pressure Override POR Adjustment Valve and Valve II Adjustments f 2 POR Setup A Measure and record the regulation begin pressures below APy z Regulation Begin psi value a APz y Regulation Begin psi value b B Turn OUT the adjustment screw for Valve III all the way it is mechanically restricted from b
56. work ports P and S e f the maximum pressure difference is 29 psi 2 bar or less then adjustment to the hydraulic neutral is NOT required Remove all gauges from the pump e f the maximum pressure difference is greater than 29 psi 2 bar then go to step 5 Loosen the spanner nut on the Hydraulic Neutral Adjustment with the hammer and punch Using a 16mm wrench and the digital calipers adjust the hydraulic neutral adjustment to 14 75mm as illustrated in the sketch above Install the special pointing device onto the cam lever With the pump aligned in neutral as described in step 2 make a small mark on the pump control either with a pen or a magic marker where the pointer of the pointing device is pointing Move the control lever in one direction until the pressure difference between the work ports P and S is 580 psi 40 bar Make a small mark where the pointer is Move the control lever in the opposite direction until the pressure difference is 580 psi 40 bar Make a small mark where the pointer is The initial mark made in step 8 should be directly in the middle of the other two marks made in steps 9 and 10 If not make a very small adjustment to the hydraulic neutral adjustment Erase all previous marks and repeat steps 8 through 11 until the initial mark is directly in the middle of the other two marks Repeat steps 1 through 4 and verify that the maximum pressure difference between work ports P

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