E PUPI TM019 E HPR Conversion Manual
E PUPI TM019 E HPR Conversion Manual
E PUPI TM019 E HPR Conversion Manual
Content Page #
Tools Required 2
Introduction 3
Model Code 4
Exchanging Pressure Compensator Springs
Set Up and Procedure 6
Externally Disabling the Load Sense
Set Up and Procedure 7
Exchanging Control types LP, E1L and H1L
Set Up and Procedure
Exchanging the Horsepower Spring with TL2 or ETP Controls 9
Set Up and Procedure
Activating the Z1 and Z2 Ports on HPR Pumps with TL2 or ETP Controls
Set Up and Procedure 11
Exchanging Solenoids on E1L Controls 13
Set Up and Procedure
Installing a PTO Kit Directly (without Auxiliary Pump)
Set Up and Procedure 14
Torque Chart 17
Maximum Displacement Adjustment Single HPR Pumps
Set Up and Procedure 18
Minimum Displacement Adjustment Single HPR Pumps
Set Up and Procedure 19
Operational Parameters 20
Part Numbers Listing 22
Tools Required
Exchanging Pressure Exchanging Control Types Activating the Z1 and Installing a PTO Kit
Compensator Springs LP, E1L & H1L Z2 Ports with TL2 or onto HPR Pump Directly
ETP Controls (W/O Auxiliary Pump)
5mm Allen wrench 6mm Allen wrench
2mm Allen wrench Metric Wrench (various sizes
New pressure compensator Torque wrench capable of depending on the unit size)
spring setting 23 N-m (17 ft-lb) 6mm Allen wrench
Allen wrench (various sizes
Torque wrench capable of Torque wrench capable of
depending on the unit size)
setting 14 N-m (10 ft-lb) 23 N-m (17 ft-lb).
Exchanging the
Horsepower Spring - with Grease or petroleum jelly
TL2 or ETP Controls (optional)
Externally Disabling the Exchanging Solenoids on
Load Sense 6mm Allen wrench E1L Controls PTO Kit
This manual will provide you with information and procedures Cleanliness
for general conversions of Eaton DuraForce HPR Self-
Cleanliness is extremely important when repairing a
Regulating Pump for Open Loop Operations. Procedures
hydrostatic pump or motor. Before disconnecting the lines,
outlined in this manual will allow you to be more flexible
clean foreign material from exterior of unit. Work in a clean
with your inventory and better service your customers.
area. Clean all metal parts in clean solvent. Blow parts dry
To ensure accuracy of conversion and prevent part loss
with air. Dont wipe parts with cloth or paper towel, because
or damage, certain components or subassemblies are
lint or other matter could cause damage. Check all mating
disassembled, inspected, and reassembled when removed
surfaces. Replace any parts that have scratches or burrs that
from the pump.
could cause leakage. Dont use coarse grit paper, files or
grinders on parts.
Training
You have been provided information on the conversion of Environmental Concerns
DuraForce products. Proper application of the information Protection of the natural fundamentals of life is one of our
requires specific training and may require use of specialized predominant tasks. We are continuously improving the
tooling and equipment. All requests for training must be protection of the environment as far as applications are
coordinated through your Eaton Account Manager. He can concerned. We encourage you to contribute your share to
also provide you price and availability of any specialized comply with this demand. In connection with work to be
tooling. If you choose to proceed with the conversion of the performed, the environmental regulations of the machine
DuraForce products absent the necessary training and/or manufacturer must be respected.
these specialized tools, you do so at your risk.
In general:
Eaton will accept no claim for warranty resulting from
deficiencies in the conversion. Please refer to the G
reases and oils which cannot be used any more have to
Eaton literature web site for warranty information at be collected. They are normally a threat to water reserves
www.eaton.com/hydraulics/warranty. and must be kept away from the environment.
Adhere to national and local regulations for waste disposal.
Labeling Converted Units
All units that have been converted must retain the original Seals
Eaton label and have a second Eaton label placed on the unit. A good conversion policy is to replace all old seals with new
This second label at a minimum must state seals whenever units are disassembled. This avoids potential
Converted Eaton Model Code # (Final Eaton model code of damage during seal removal. Lubricate seals with petroleum
the converted unit) jelly. Use only clean and recommended oil when assembling
unit. Information on recommended filters and fluids can be
Conversion done by (Name of your company) found in the Operational Parameters section.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
55 75 105 135 165 210 280 55 75 105 135 165 210 280
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38
55 75 105 135 165 210 280 55 75 105 135 165 210 280
Pressure Compensator
Spring Pressure Spring Free Spring Wire
Part Number Range, bar Length, mm Diameter, mm
Install the new Pressure Compensator Spring into the Tighten each S.H.C.S. with the 5mm Allen wrench and
5 9
pump control. See table above for available springs. torque each one to 14 N-m (10 ft-lb).
6 Reinstall the Spring Hat from step #3. Restamp the pump control with the new Control Part
10
Number to reflect the correct spring.
Refer to Eaton for a listing of control part numbers.
LEP Control
A LP control type
S.H.C.S. (3 Places)
Load Sense/Pressure
Compensator Control
O-Ring
(3 Places)
5 Use a 21mm wrench to loosen the lock nut as 6 Once the lock nut is loose, remove the spring and the
shown here. two spring hats as shown here.
9 Install the spring hats, spring and the lock nut back
into the spring housing.
10
Hand tight the lock nut to keep it in position.
11 Torque the lock nut to 45 ft-lb (61 Nm).
Install the spool back into the spring housing as shown 13 Install the spring housing back on the control block.
12 here. Please note the spool orientation
Use the existing bolts to secure the spring housing and
14 Torque them to 17ft-lb (23 N-m).
Important
At the end of this procedure, this unit must be functionally
tested to insure the proper horsepower setting.
ETP Controls For a better view, some of the images in this document
show the pump control only. It is not necessary to remove
Set-up and Procedure the control from the pump in order to complete this
procedure.
This procedure must be performed in a clean environment
using clean Parts, Tools and Lubricants.
External Connection
Operating State Z1 Port Z2 Port Internal Plug between Z1 and Z2
1 Remove the two bolt holding the horsepower 3 Inspect the o-ring on the horsepower adjustment
adjustment assembly as shown here. assembly, replace it if necessary.
4 Install the M4X6 plug (P/N 9133339061) in the 5 Install the horsepower adjustment assembly as
threaded passage and torque it to 1.70 N-m shown here.
(15 in-lb) shown here.
A better view of the control block with the Install the two bolts and torque them to 23 N-m
plug installed. 6 (17 ft-lb).
Remove the existing Solenoid O-Ring and keep it with Tighten the S.H.C.S. with the 3mm Allen wrench and
2 5 torque each one to 2.7 N-m (2.0 ft-lb).
the existing solenoid as an assembly.
3 Make sure that the new Solenoid O-Ring is in good
condition (i.e. undamaged) and is properly placed in
the o-ring groove on the new solenoid.
6
Identify the bolts on the HPR pumps rear head that Important The location and number of removed bolts
match with the bolt holes on the PTO plate. may vary depending on the HPR pumps size and the PTO kit
selected.
Install the PTO plate on the HPR pumps rear head as Install the new o-ring on the back of the PTO Plate
8 12
shown here. using petroleum jelly.
9 Align bolt holes on the PTO plate with the holes on 14 Tighten the bolts on the PTO cover.
the rear head.
Torque Chart
M8 6 8 10 13 17 24 29
M10 13 17 21 25 34 47 57
M12 22 30 37 44 59 81 100
Important
Important
Adjustment Procedure to Set the Warning! The minimum displacement adjustment stud is
NOT restricted from being removed completely from the
Pump at Minimum Displacement pump. Care must be taken to insure you do not remove the
adjustment stud completely from the pump.
With the prime mover OFF, disconnect the load sense
1 line from the pump control block. eS
lowly turn the adjustment stud IN until it just
touches the stroking piston inside of the pump.
2 Securely plug the end of the load sense line.
f Then turn the adjustment stud OUT 1/4 turn.
3 Leave the load sense port on the pump control block
gH
old the adjustment stud stationary with the
vented to atmosphere.
6mm Allen wrench and tighten the seal nut with
4
Start the prime mover and adjust it to high idle. the 19mm wrench (The proper torque for the seal
nut is 60 N-m [44 ft-lb]).
5 To Adjust the Pump Minimum Displacement: h Turn the prime mover OFF.
aU
se the figure above to determine where the iU
nplug the end of the load sense line and
"Minimum Displacement Adjustment" is for the reconnect it to the load sense port on the
rotation of your pump.
pump control block.
bH
old the adjustment stud stationary with
the 6mm Allen wrench. Note: T
o decrease the minimum displacement,
turn the adjustment stud OUT
c Loosen the seal nut with the 19mm wrench.
d Slowly turn the adjustment stud OUT until you T
o increase the minimum displacement,
feel it lose contact with the stroking piston turn the adjustment stud IN
inside of the pump.
Beneficial Conditions for Long Service Life Operational Parameters. HPR Suction Speed
Speed Lower continuous maximum speed
1,25
Operating Pressure Less tan 300 bar p on average
Max. Pressure Only at reduced displacement 1,2 1,3
Viscosity 15...30 cSt ba
r
1,2
Power Continuous power or lower 1,15 ba
r
Purity of Fluid 18/16/13 in accordance with ISO 4406 1,1
Operational Parameters.
Filtration
In order to guarantee cleanliness level of the Hydraulic Fluid cleanliness level can
long-term proper function lubricant must comply Recommendation extend the service life
and high efficiency of the with the following criteria 03-401-2010. Maintaining of the hydraulic system
hydraulic pumps the according to Eaton the recommended significantly.
For reliable proper function and long service life Filling and operation of hydraulic systems
18/16/13 in accordance with ISO 4406 or better The required cleanliness level of the hydraulic oil must
be ensured during filling or topping up. When drums,
Commissioning canisters, or large-capacity tanks are used the oil generally
The minimum cleanliness level requirement for the has to be filtered. We recommend the implementation of
hydraulic oil is based on the most sensitive component. suitable filters to ensure that the required cleanliness level
For commissioning we recommend a filtration in order to of the oil is achieved and maintained during operation.
achieve the required cleanliness level.
International standard
Code Number According to ISO 4406
18/16/13
Viscosity Recommendations
Working Temperature[C] Viscosity[mm/s] = [cSt]at 40 C
Approx. 30 to 40 22
Approx. 40 to 60 32
Approx. 60 to 80 46 or 68
Controls - E1L, ISO Port, 12V DIN p. 8 Controls - H1L, ISO Port p. 8
Controls - E1L, ISO Port, 24V DIN p. 8 Controls - LP, ISO Port, 125-230 bar Press. Comp. p. 8
Controls - E1L, ISO Port, 12V AMP p. 8 Controls - LP, ISO Port, 231-350 bar Press. Comp. p. 8
Controls - E1L, ISO Port, 24V AMP p. 8 Controls - LP, ISO Port, 351-420 bar Press. Comp. p. 8