Eaton® DuraForce™

HPV Conversion Procedures

 Table of Contents

Content Page #

Introduction 3
Model Code 4
Tools Required 6
Exchanging Response Orifices in HPV Pump Controls
Set Up and Procedure 7
Exchanging Cold-Start Relief Valves
Set Up and Procedure 8
Exchanging Charge Relief Valves
Set Up and Procedure 9
Exchanging Combineation Relief/Make-Up Valves
Set Up and Procedure 10
Exchanging POR Spool
Set Up and Disassembly Procedure 11
Disassembly Procedure (continued) 12
Assembly Procedure 13
Installing a Filter Elimination Block
Set Up and Procedure 14
Exchanging Controls
Set Up 15
Procedure 16
Converting to Manual Control
Set Up 17
Procedure to Convert to a Standard HPV Manual Control 18
Installing Power Take-Off (PTO) Kits onto HPV Pumps with Eaton Charge Pumps Attached
Set Up 21
Procedure "A" 22
Procedure "B" 23
Installing a PTO Kit onto HPV Pumps Directly (without Auxiliary Pump)
Set Up 28
Procedure 29
Changing Rotation on Eaton Charge Pumps
Set Up and Procedure 32
Procedure (continued) 33
Assembling Tandem Eaton Charge Pumps
Set Up and Procedure 35
Procedure (continued) 36
Exchanging Regulation Begin Springs
Set Up and Procedure to Install Filter Elimination Book 40
Procedure to Exchange the Valve III for POR function 41
Exchanging Solenoids on HPV Pumps Controls
Set Up and Procedure 42
HPV Maximum Displacement Adjustment for M1 (Mechanical-Hydraulic Control
Set Up and Procedure 43
Maximum Flow Adjustment Procedure with "H" or "E" Controls
Set Up 44
Adjustment Procedure 45
Operational Parameters 46

2 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Introduction
This manual will provide you with information and
procedures for general conversions of Eaton® DuraForce™
HPV Variable Pump for Closed Loop Operations. Procedures
outlined in this manual will allow you to be more flexible
with your inventory and better service your customers.
To ensure accuracy of conversion and prevent part loss
or damage, certain components or subassemblies are
disassembled, inspected, and reassembled when removed
from the pump.
Training
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 the 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.
Labeling Converted Units
All units that have been converted must retain the original
Eaton label and have a second Eaton label placed on the unit.
This second label at a minimum must state
Converted Eaton Model Code # (Final Eaton model code of
the converted unit)
Conversion done by (Name of your company)
Conversion Parts
All requests for specific conversion part information should
be addressed to your Eaton account representative.
Additional information can be found through your Eaton
customer connect portal. All requests or inquiries must be
accompanied by the complete model and serial number of
the base unit you want to convert.
EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012
Cleanliness
Cleanliness is extremely important when repairing a
hydrostatic pump or motor. Before disconnecting the lines,
clean foreign material from exterior of unit. Work in a clean
area. Clean all metal parts in clean solvent. Blow parts dry
with air. Don’t wipe parts with cloth or paper towel, because
lint or other matter could cause damage. Check all mating
surfaces. Replace any parts that have scratches or burrs that
could cause leakage. Don’t use coarse grit paper, files or
grinders on parts.
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:
•G
 reases 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.
• Adhere to national and local regulations for waste disposal.
Seals
A good conversion policy is to replace all old seals with new
seals whenever units are disassembled. This avoids potential
damage during seal removal. Lubricate seals with petroleum
jelly. Use only clean and recommended oil when assembling
unit. Information on recommended filters and fluids can be
found in the Operational Parameters section.
Torque
All torque specifications are for lubricated threads. Bolts for
gasketed surfaces should be checked for proper torque.
3
 Model Code
HPV – Variable Pump for Closed Loop Operation

HPV 055 R 0 S1 M E 1 E E L 1 1 0 0G
BA A E 000 000 00 A A A

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

55 75 105 135 165 210 280 55 75 105 135 165 210 280

1 2 3 Product H CA: speed related hydraulic t t t t

HPV – Closed Loop Variable l l l l l l l mechanical (*c)(*d)(*r)(*z)
Displacement Pump K – E1T: electro-proportional / t
torque cut-off (*c)(*y)
4 5 6 Displacement
055 –
13  ontrol Pressure Range
C
055 cc/r l Hydraulic and Electric Controls
075 – 075 cc/r l 0 – not applicable (M1;CA) • • • • • • •
105 – 105 cc/r l 1 – 4-10 bar l l l l l l l
135 – 135 cc/r l 2 – 4-16 bar (not for E5) • • • • • • •
165 – 165 cc/r l 14  ontrol Solenoids
C
210 – 210 cc/r l 0 – not applicable (M1; H1; H1P) l l l l l l l
280 – 280 cc/r l A – AMP / 12V l l l l l l l
7 Rotation B – AMP / 24 V l l l l l l l
R – CW l l l l l l l C – DIN / 12 V • • • • • • •
L – CCW l l l l l l l D – DIN / 24 V • • • • • • •
8 Mounting Flange E – Deutsch / 12V (E1; E1P; E2; • • • • • • •
0 – SAE J744 standard (size 135: CA)(*z)
l l l l l l
(*d)) F – Deutsch / 24V (E1; E1P; E2; • • • • • • •
1 – SAE J744 standard / additional CA)(*z)
• • •
threads (sizes 105; 135: (*u)) 15Response Orifices
2 – SAE J744 standard / additional • l 0 – without response orifices l l l l l l l
holes (sizes 135; 165: (*u) / C – 0,8 mm (standard for M1, H1, • • • • • • •
size 135: (*d)) H1P controls)
9 10 Input Driveshaft E – 1,0 mm (standard for E1, E1P, l l l l l l l
S1 – splined ANSI B92.1 12/24- 14 E2 controls)
l l •
teeth (SAE J744 C) (size 105: G – 1,2 mm • • • • • • •
(*w)) J – 1,5 mm • • • • • • •
S2 – splined ANSI B92.1 12/24- 17 l • 16 System Relief Valves
teeth (SAE J744 C-C)
A – 150 bar • • • • • • •
S3 – splined ANSI B92.1 8/16- 13 l
teeth (SAE J744 D&E) B – 200 bar • • • • • • •
S4 – splined ANSI B92.1 8/16- 15 l l C – 250 bar l l l l l l l
teeth (SAE J744 F) (sizes 210, D – 285 bar • •
280: (*t)) – 300 bar
E • • • • •
T1 – splined ANSI B92.1 16/32- 21 l l
teeth (*t) F – 305 bar • •
T2 – splined ANSI B92.1 16/32- 23 l G – 350 bar l l l l l l l
teeth (*t) H – 360 bar • •
T3 – splined ANSI B92.1 16/32- 27 l l l J – 380 bar • • • • • • •
teeth (*t) K – 400 bar • •
T4 – splined ANSI B92.1 16/32- 33 l – 420 bar
L l l l l l l l
teeth (*t)
17 Charge Relief Valves
11 Porting
– ISO 6149 metric 0 – purge orifice • • • • • • •
M l l l l l l l
– DIN 3852 1 – 19 bar l l l
D • • • •
2 – 20 bar l l l l
12 Pump Control
3 – 22,5 bar l l l
A – M1: mechanical hydraulic • • • • • • • – 23 bar
4 l l l l
B – H1: hydraulic proportional l l l l l l l – 24 bar
5 l l l
C – H1P: hydraulic proportional / l l l l l l l – 29 bar
6 l l l l
pressure cut-off
7 – 17.5 bar (CA control only, t t t t
D – E1: electro-proportional (*y) l l l l l l l CA default)
E – E1P: electro-proportional / l l l l l l l
pressure cut-off (*y) 18 Filter Configuration
– E2: electro-proportional / 0 – No Filter–straight flange port • • •
F • • • • • • •
shutt-off (*z) (*d)
1 – Filter flange with filter cartridge l l l l l l l
G E5: electric three position (*y) • • • • • • •
2 – 90° charge port flange without l l l l l l l
• Available Option l Preferred Option filter
t Separate Specification Required
4 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012
 Model Code
HPV – Variable Pump for Closed Loop Operation

HPV 055 R 0 S1 M E 1 E E L 1 1 0 0G
BA A E 000 000 00 A A A

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

55 75 105 135 165 210 280 55 75 105 135 165 210 280

19 Swash Angle Sensor BF – Internal gear pump tandem • • • • • •

0 – Without swash angle sensor l l l l l l l 22,5+22,5 cc
S – With swash angle sensor (*m) • • • • • BG – external gear pump 31 cc (*r) • • •
BH – external gear pump 38 cc • • • • •
20 21  uxiliary Pad and Shaft
A
Definition BJ – external gear pump 44 cc (*r) • •
0G – to add gear pump see • • • • • • • BK – HPV/R 55 mounting • • • • • • •
positions 22,23 preparation (*s)
AA – SAE J744 A Pad without shaft • • • • • • • BL – HPV/R 75 mounting • • • • • •
coupling (default) preparation (*s)
AB – SAE J744 A / ANSI B92.1 • • • • BM – HPV/R 105 mounting • • • • •
16/32 - 9 teeth (A) preparation (*s)
AC – SAE J744 A / ANSI B92.1 • • BN – HPV/R 135 mounting • • •
16/32 - 11 teeth preparation (*s)
AD – - SAE J744 A / ANSI B92.1 • BP – HPV/R 165 mounting • •
16/32 - 13 teeth preparation (*s)
AE – SAE J744 B without shaft • • • • • • • BQ – HPV/R 210 mounting • •
coupling preparation (*s)
AF – SAE J744 B / ANSI B92.1 • • • • • • • BR – HPV/R 280 mounting •
16/32 - 13 teeth (B) preparation (*s)
AG – SAE J744 B / ANSI B92.1 • • • • • 24  uxiliary Drive on Gear Pump
A
16/32 - 15 teeth (B-B) 0 – Without internal gear pump • • • • l • •
AH – SAE J744 C without shaft • • • • • • • A – SAE J744 A / ANSI B92.1 l l l l l l
coupling 16/32 - 9 teeth (A) (default)
AJ – SAE J744 C / ANSI B92.1 • • • • • • • B – SAE J744 B without shaft • • • •
12/24 - 14 teeth (C) coupling
AK – SAE J744 C / ANSI B92.1 • • • • C – SAE J744 B / ANSI B92.1 • • • •
16/32 - 21 teeth 16/32 - 13 teeth (B)
AL – SAE J744 C / ANSI B92.1 • • • D – SAE J744 B / ANSI B92.1 • • • •
16/32 - 23 teeth 16/32 - 15 teeth (B-B)
AM – SAE J744 D without shaft • • • E – SAE J744 C without shaft • • • •
coupling coupling
AN – SAE J744 D / ANSI B92.1 • F – SAE J744 C / ANSI B92.1 • • • •
8/16 - 13 teeth (D) 12/24 - 14 teeth (C)
AP – SAE J744 D / ANSI B92.1 • 25
12/24 - 17 teeth Gear Pump Supply
0 – without gear pump l l l l l l l
AQ – SAE J744 D / ANSI B92.1 • • •
16/32 - 27 teeth E – external supply port l l l l l l l
AR – SAE J744 E without shaft • 26 27 28  D
 isplacement Setting – P Port
coupling 000 – Catalog Pump Rating l l l l l l l
AS – SAE J744 E / ANSI B92.1 • • 29 30 31 
 isplacement Setting – S Port
D
16/32 - 27 teeth 000 – Catalog Pump Rating l l l l l l l
AT – SAE J744 E / ANSI B92.1 •
32 33
Special Requirements
16/32 - 33 teeth
00 – without special requirements l l l l l l l
22 23  harge Pump (Internal Gear)
C (default)
or Tandem Adapter
– without 34
Surface Coating
00 l l l l l l l
– Internal gear pump 16 cc 0 – anti rust conservation oil l l l l l l l
BA l l l l
(default)
BB – Internal gear pump 22,5 cc l l l l
A – primer blue l l l l l l l
BC – Internal gear pump tandem • • • •
16+16 cc 35 Unit Identification
– Internal gear pump tandem A – Eaton l l l l l l l
BD • • • •
16+22,5 cc 36
Type Code Release
BE – Internal gear pump tandem • • • • A – Revision Level l l l l l l l
22,5+16 cc

(*c) Always set option C in position 24 (*m) ISO metric porting only (see position 11) (*t) Recommended if HPV/R unit is attached (*w) Not for tandem units (see position 22,23)
(*d) DIN porting only (see position 11) (*r) CW rotation only (see position 7) to PTO (see position 22,23) (*y) Solenoids with square cross section
(*e) Availability depends on controller type (*s) Second HPV/R unit has to be specified (*u) Required for PTO flange size C (see (*z) Solenoids with circular cross section
(see position 12) separately position 22,23)

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 5

 Tools Required
Exchanging Response
Orifices in Controls
• 4mm Allen wrench
• 3mm Allen wrench
• Two M8 teflon-coated set
screws (Eaton Part Number
0009033195), if required
• Two M6 orifices (Eaton Part
Numbers presented in table
below)
• Torque wrench capable of
setting between 5.9 N-m (4.4
ft-lb) and 15 N-m (11 ft-lb)
Exchanging Cold-Start
Relief Valves
• 14mm wrench
• Torque wrench capable of
setting 30 Nm (22ft-lb)
Exchanging Charge Relief
Valves
• 14mm wrench
(HPV55,75,105)
• 24mm wrench
(HPV135, 165, 210, 280)
• Torque wrench capable
of setting between 30N-m
(22ft-lb) and 40 N-m (30 ft-lb)
Exchanging Combination
Relief/Make-Up Valves
• 12mm Allen wrench (HPV55)
• 24mm wrench
(HPV75, HPV105)
• 30mm wrench
(HPV135, HPV165, HPV210,
HPV280 )
• Torque wrench capable of
setting 140 N-m (103 ft-lb)
[HPV55, 75, and 105 ONLY]
• Torque wrench capable of
setting 250 N-m (184 ft-lb)
[HPV135, 165, 210 and 280
ONLY]
Exchanging POR Spool
• 18mm socket wrench
• Small Magnet
• Torque wrench capable of
100 ft-lb (136 N-m).
6 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012
Installing a Filter
Elimination Block
• 6mm Allen wrench
• Torque wrench capable of
setting 25 N-m (18 ft-lb)
Exchanging Controls
• 6mm Allen wrench
• Torque wrench capable of
setting 25 N-m (18 ft-lb)...
[For "Type-A" controls ONLY]
• Torque wrench capable of
setting 34 N-m (25 ft-lb)...
[For "Type-B" controls ONLY]
Converting to Manual
Control
• Measurement Tool (refer to
Tool List in LINDOS)
• 6mm Allen wrench
• Torque wrench capable of
setting 34 N-m (25 ft-lb)
• Blue Loctite No. 243 (for
correct part number please
refer to Eaton Spare Parts
Catalog)
• Two M8 S.H.C.S. G10.9 (for
correct part number please
refer to Eaton Spare Parts
Catalog)
• Acetylene torch
• Digital depth calipers
• Finger for Manual control (for
correct part number please
refer to Eaton Spare Parts
Catalog)
• 0.1mm finger shims (for correct
part number please refer to
Eaton Spare Parts Catalog)
0 .5mm finger shims (for correct
part number please refer to
Eaton Spare Parts Catalog)
• Snap ring (for correct part
number please refer to Eaton
Spare Parts Catalog)
• Snap ring wrench (to squeeze
a snap ring open)
• Manual control (with all
o-rings, metal split pins, and
mounting S.H.C.S. already
included)
Installing Power Take-Off
(PTO) Kits onto Pumps
with Eaton Charge Pumps
Attached
Procedure "A"
• Metric wrenches
• Torque wrench
(setting as specified)
• Clean grease for o-rings
Procedure "B"
• Metric wrenches
• Metric Allen wrenches
• PTO Kit for HPV (please refer
to Eaton Price and Policy
Guide for part numbers)
• Snap ring wrench (to open or
expand a snap ring)
• Torque wrench capable of
setting between
13 N-m (10 ft-lb) and 85 N-m
(63 ft-lb)
• Clean grease for o-rings
Installing a PTO Kit onto
HPV Pumps Directly (W/O
Auxiliary Pump)
• Metric Wrench (various sizes
depending on the unit size)
• Allen wrench (various sizes
depending on the unit size)
• Grease or petroleum jelly
(optional)
• PTO Kit
Changing Rotation on
Eaton Charge Pumps
• Metric Wrenches and Allen
Keys.
• Torque wrench capable of
60 N-m (44 ft-lb)
• New intake plate (only if
using internal or combination
internal / external feed charge
pump).
• O-rings (refer to LINDOS).
• Plugs (refer to LINDOS).
• Green Loctite No. 270.
• Petroleum Jelly (clean grease)
for o-rings.
Assembling Tandem Eaton
Charge Pumps
• 5 mm Allen Wrench.
• 10 mm socket wrench.
• Snap Ring Pliers
(to widen a snap ring).
• Torque wrench capable of
110 N-m (81 ft-lb).
• Petroleum Jelly or
clean grease.
Exchanging Regulation
Begin Springs
• Spanner Wrench.
• New Regulation Begin Spring.
• Regulation Begin Cup O-Ring
(it may be required).
• Pliers.
• Torque Wrench capable of
11 ft-lb (15 N-m), if applicable.
• 13mm Wrench, if applicable.
Exchanging Rectangular
Solenoids on HPV Pump
Controls
• 3mm Allen wrench
• Torque wrench capable of
setting 2.7 N-m (2.0 ft-lb)
HPV Maximum
Displacement Adjustment
for M1 (Mechanical-
Hydraulic Control)
• 13mm open or close
end wrench
• 4mm Allen wrench
Maximum Flow
Adjustment Procedure
with "H" or "E" Controls
• 0-600 psi pressure gauge or
transducer (optional)
• 13mm offset closed-end
wrench
• 4mm Allen wrench
Exchanging Response Orifices in Controls
Set Up and Procedure

List of M6 Orifices
Available from Eaton
Part Orifice
Number Diameter

0009037005* 0.6mm*
0009037052 0.7mm
0009037047 0.8mm
0009037059 0.9mm
0009037045 1.0mm
0009037050 1.2mm
0009037515 1.3mm
0009037074 1.4mm
0009037046 1.5mm
0009037073 1.6mm
0009037511 1.8mm
0009037099 1.9mm
0009037510 2.1mm
*Not Recommended

Note Procedure to Exchange Response Orifices

The Reponse Orifices are used to control the rate of
displacement change on the HPV pump. They restrict the 
1 Using the illustration above, locate the HPV control
oil flowing into and out of the actuator piston chambers. type and the location of the Response Orifices.
Decreasing the diameter of the orifice results in greater
restriction, thus the pump will be slower when changing Remove the two outer M8 set screws with the 4mm
2
displacement. Likewise, increasing the diameter of the Allen wrench. Discard them once removed. If the
orifice results in less restriction, thus the pump will change outer plugs are P/N 009524046, remove them with
displacement more rapidly. T25 Torque type wrench and keep them for reuse.

Eaton does NOT recommend using Response Orifices Remove the two existing Response Orifices with the
3
smaller than 0.7mm. There are no restrictions on the 3mm Allen wrench and replace them with the two
maximum size of the Response Orifices, but be warned new Response Orifices. Torque each one to 5.9 N-m
that increasing the orifice size too much will lead to abrupt (4.4 ft-lb).
displacement changes in the HPV.
Either install two new teflon-coated M8 set screws
4
(P/N 0009033195) and torque each one to 10 N-m (7.4
ft-lb) or reinstall o-ring plugs (P/N 0009524046) and
torque each one to 15 N-m (11 ft-lb).

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 7

 Exchanging Cold-Start Relief Valves
Set Up and Procedure

Procedure to Exchange Cold-Start Relief Valves

Based on the rotation of the pump, refer to the
1
illustration above to verify the position of the
Cold-Start Relief Valve.


2 Remove the existing Cold-Start Relief Valve from the
pump with the 14mm wrench.


3 Inspect the O-Ring on the new Cold-Start Relief Valve
to insure it is in good condition (i.e. undamaged).

Install the new Cold-Start Relief Valve and tighten it

4
with the 14mm wrench. Torque it to 30 N-m (22 ft-lb).

8 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Exchanging Charge Relief Valves Important
This procedure must
Set Up and Procedure be performed in a clean
environment using clean
Parts, Tools and Lubricants.

Procedure to Exchange Charge Relief Valves

Remove the existing Charge Relief Valve with the
1
appropriate wrench.


2 Inspect the O-Ring on the new Charge Relief Valve to
insure it is in good condition (i.e. undamaged).


3 Install the new Charge Relief Valve and tighten it.
Torque it to 30 N-m (22 ft-lb) for HPV55, HPV75,
HPV105. For HPV135, HPV165, HPV210 and HPV280
torque it to 40 N-m (30 ft-lb).

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 9

 Exchanging Combination Relief /
Make-Up Valves
Set Up and Procedure

Procedure to Exchange Combination

Relief/Make-Up Valves

1 Remove the two existing Relief/Make-Up Valves with
the appropriate wrench.


2 After removal, inspect O-Ring #1 to verify it is in good
condition (i.e. undamaged). Please note that O-Ring
#1 is NOT part of the Relief/Make-Up Valve. It is an
o-ring fitted into the pump housing as illustrated
above.

Prior to installing the two new Relief/Make-Up Valves,

3
inspect O-Ring #2 on each of them to confirm they
are in good condition (i.e. undamaged).


4 Install the two new Relief/Make-Up Valves and tighten
them with the appropriate wrench.


5 Torque each Relief/Make-Up Valve to:
- 140 N-m (103 ft-lb) for HPV55, HPV75, and HPV105
pumps.
- 250 N-m (184 ft-lb) for HPV135, HPV165, HPV210
and HPV280 pumps.

10 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Exchanging POR Spool
Set Up and Disassembly Procedure

Important
This document is valid for
HPV pumps with H1P and
E1P controls. This document
uses an E1P control type to
demonstrate all necessary
steps for the procedure but
it is also valid for H1P control
type.
The POR spool on the H1P
and E1P controls change
with the rotation of the unit
as seen to the right; in order
to have a functioning POR,
the POR spool must match
the pump’s rotation.

Disassembly Procedure

This is an E1P control. The POR function on this control In order to remove the POR spool from the control
depends on the POR spool which is shown in the next image. body, you must first remove one of the POR cartridge
assemblies located on either side of the POR spool.

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 11

 Exchanging POR Spool
Disassembly Procedure (continued)

1 Use an 18mm socket wrench to loosen the POR 3 Use a small clean magnet to pull out the remaining
cartridge assembly as shown. piece of the POR cartridge from the housing.

A better look at all the parts that are included in the

POR cartridge assembly.

2 Remove the POR cartridge assembly as shown.

4 Using a small clean magnet remove the POR spool

from the housing as shown.

12 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Exchanging POR Spool
Assembly Procedure
A better look at the POR cartridge cavity after the POR
6 Install the POR cartridge back into the control housing
cartridge and POR spool have been removed.
5 Insert the new POR spool into position as shown here.
Important
The POR spool must slide into its position without any
efforts; in case of any resistance, stop and inspect
parts for any type of damage.
EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012
as shown here and torque it to 96 ft-lb (130 N-m).
7 For pump controls with the POR feature remove the
original “L” or “R” stamping from the pump control
if they do not agree with the pump’s new rotation
(Location shown as “stamping1”here). Re-stamp the
control around the same location with the correct
rotation:
• Clockwise (CW): R
• Counterclockwise (CCW): L
Important
• Inspect the unit name tag and correct the rotation
indicator if necessary to reflect the new rotation.
• At the end of this procedure, the unit must be tested
for functionality and settings.
13
 Installing a Filter Elimination Block Important
This procedure must
Set Up and Procedure be performed in a clean
environment using clean
Parts, Tools and Lubricants.

Procedure to Install a Filter Elimination Block

Remove All S.H.C.S from the Filter Mounting Flange Install the Filter Elimination Block onto the pump (For
1 4
with the 6mm Allen wrench. the 90˚ FEB on HPV55…135, the port can be oriented
towards the front or rear of the pump). Use the new

2 Remove the Filter Element, Filter Mounting Flange, S.H.C.S. that came with the Filter Elimination Block to
and the two existing S.H.C.S. from the pump and fasten it to the pump.
keep together as an assembly. Make sure that
the o-ring beneath the Filter Mounting Flange is 
5 Tighten all new S.H.C.S. with the 6mm Allen wrench
also removed and kept with the other parts as an and torque each one to 25 N-m (18 ft-lb).
assembly.


3 Prior to installing the Filter Elimination Block, inspect
the O-Ring to insure it is in good condition (i.e.
undamaged) and is properly placed in the o-ring
groove.

14 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Exchanging Controls
Set Up

Important
Not all HPV controls are directly or indirectly interchangeable with each other. Those
HPV controls which contain the integrated pressure override (POR) feature, can ONLY
be interchanged with pumps controls which also contain the POR feature. You CANNOT
interchange HPV pump controls without the POR feature, with the controls that have the
POR feature.
Z

The pump controls (Henceforth called Type-A Controls) illustrated directly below are
completely interchangeable with each other and no special considerations must be made:
Z

H1 CONTROL E1 CONTROL E2 CONTROL

Y

H1 CONTROL E1 CONTROL E2 CONTROL

The pump controls (Henceforth called Type-B Controls) illustrated directly below are
completely interchangeable with each other and no special considerations must be made:

E1P CONTROL H1P CONTROL M2FP CONTROL

Note Important
The standard HPV Manual control is indirectly interchange- This Conversion Bulletin
E1P CONTROL
able with those HPV controls H1P the POR feature M2FP CONTROL
CONTROL
without can be used if exchanging
("Type-A" Controls). However, special instructions are required "Type-A" controls with
to do this conversion. Please refer to the section titled each other or if exchanging
Converting to Manual Control found within this bulletin on "Type-B" controls with each
how to make this conversion. The standard HPV Manual other.
control is completely non-interchangeable with those HPV
controls with the POR feature ("Type-B" Controls).

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 15

 Exchanging Controls
Procedure
1 Remove the four Socket Head Cap Screws (S.H.C.S.)
with the 6mm Allen wrench, then set them aside.
2 Pull the existing control straight off of the pump.
Note
There will be two metal split pins used to hold the control
in place after the four S.H.C.S. are remove. There will be a
slight resistance to remove the existing control - This is due
to the split pins. You can over come this resistance by pulling
the control straight off of the pump.
3 There will be one large o-ring and several small o-rings
on the bottom of the existing control. Some or all of
the o-rings may stick to the pump when the existing
control is removed. Make sure to remove all o-rings
from the pump and keep them all with the existing
control.
4 Set aside the existing control, the o-rings, and the four
S.H.C.S. as an assembly - Do not reuse any of these
parts for this conversion.
5 Once the existing control is removed, the Finger will
protrude from the pump as illustrated below.
16 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012
6 The Alignment Stud must mate with the female linkage
inside of the new control. Take this opportunity to
locate the female linkage inside of the new control.
7 Prior to installing the new control, check it to insure that
the following things are present:
a Two metal split pins pressed into two passages on
the bottom of the control
bO
 ne large o-ring in good condition (i.e. undamaged)
and properly placed in the o-ring groove
cS
 everal small o-rings in good condition (i.e.
undamaged) and properly placed in the o-ring
grooves .
Note
You can use a little petroleum jelly to help hold all o-rings in place.
8 Install the new control onto the pump making sure that:
a The Alignment Stud on the Finger is properly
positioned into the female linkage inside the new
control.
b The metal split pins are aligned with the
corresponding passages in the pump.
9 Fasten the new control with four new S.H.C.S. Tighten
the S.H.C.S. with the 6mm Allen wrench and torque
each one to:
• 25 N-m (18 ft-lb)…..[For "Type-A" controls ONLY]
• 34 N-m (25 ft-lb)…..[For "Type-B" controls ONLY]
10 Test the pump for functionality using Eaton Test
Procedures and adjust the control if necessary to
achieve desired settings.
Converting to Manual Control
Set Up
Z
Y
H1 CONTROL E1 CONTROL
The pump controls
(Henceforth called Type-A
Controls) illustrated directly
above are completely
interchangeable with
each other and no special
considerations must be
made. Please refer to the
section titled Exchanging
Controls found within this
document for detailed
instructions on how to
exchange "Type-A" controls
with other "Type-A" controls.
EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012
Important
This Conversion Bulletin is
ONLY valid if exchanging
"Type-A" controls with the
standard HPV Manual
Control.
E2 CONTROL
The standard HPV Manual
Control is interchangeable
with the HPV controls
("Type-A" Controls)
illustrated above, but
special instructions
are required to do this
conversion. The standard
HPV Manual Control is
NOT interchangeable with
those HPV controls with the
integrated pressure override
(POR) feature.
17
 Converting to Manual Control Important
This Conversion Bulletin is
Procedure to Convert to a Standard HPV Manual Control ONLY valid if exchanging
"Type-A" controls with the
standard HPV Manual
Control.

1 Note
From the existing control, remove the four S.H.C.S.
with the 6mm Allen wrench, then set them aside. Please note the dimension "25.4mm" illustrated below. This
dimension can be acquired via the digital depth calipers by
using the measurement tool demonstrated during training. This
2 Pull the existing control straight off of the pump. dimension signifies that the Finger is shimmed for a "Type-A"
Control. The Finger itself is specially configured and sized for the
"Type-A" Controls only. A new Finger and shimming is required
for the Manual Control, as explained below.
Note
There will be two metal split pins used to hold the control
in place after the four S.H.C.S. are remove. There will be a
slight resistance to remove the existing control - This is due
to the split pins. You can over come this resistance by pulling
the control straight off of the pump.

3 There will be one large o-ring and several small o-rings

on the bottom of the existing control. Some or all of
the o-rings may stick to the pump when the existing
control is removed. Make sure to remove all o-rings
from the pump and keep them all with the existing
control.

4 Set aside the existing control, the o-rings, and the four
S.H.C.S. as an assembly - Do not reuse any of these
parts for this conversion.

5 Once the existing control is removed, the Finger will

protrude from the pump as illustrated below.

18 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Converting to Manual Control Important
This Conversion Bulletin is
Procedure to Convert to a Standard HPV Manual Control ONLY valid if exchanging
"Type-A" controls with the
standard HPV Manual
Control.

6 The existing Finger must be removed from the pump. 8 Shim the new Finger as follows (Use the illustration
To do this, use the following steps (Use the illustration below as a reference):
above as a reference): aM
 easure the length of measurement tool as
a With the Acetylene torch, slowly heat the two Dimension “A”:
S.H.C.S. Do not heat them too hot - You only need
to heat them enough to break the Loctite loose.
b With the 6mm Allen wrench, remove the two
S.H.C.S. Once removed, discard them.
cP
 ull the Finger from the pump. Be careful, the
Finger may still be hot.

Note
There will be two metal split pins used to hold the Finger
in place after the two S.H.C.S. are remove. There will b Install the measurement tool on the finger.
be a slight resistance to remove the Finger - This is due cU
 sing the digital depth calipers, measure from the
to the split pins. You can over come this resistance by top of the measurement tool to the pump housing
pulling the Finger straight off of the pump. as Dimension “B” (see illustration below):
dC
 alculate Shim thickness:
dL
 eave the two metal split pins in the pump for
reuse. (Or reinstall them if they come out of the
pump with the Finger) Total Shim and Snap
+0.1mm
Ring Thickness = A - B + 19.4 - 0.0mm

The new Finger for the Manual Control must be Important

7
installed: The amount of shim calculated in the previous step
a Install the new Finger into the pump by pressing includes the snap ring thickness; when measuring actual
it onto the two metal split pins. Refer to the shims for selection, the snap ring must be included also.
illustration above to insure the new Finger is
oriented correctly.
bF
 ollowing the manufacturer’s recommendations, e Install the required Shims onto the new Finger.
apply Blue Loctite No. 243 into the threaded holes f Install the new Snap Ring.
on the swash plate.
c Install the two new M8 S.H.C.S. into the pump and
Measurement
tighten them with the 6mm Allen wrench. Torque
Tool
each one to 34 N-m (25 ft-lb).

"B"

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 19

 Converting to Manual Control Important
This Conversion Bulletin is
Procedure to Convert to a Standard HPV Manual Control ONLY valid if exchanging
"Type-A" controls with the
standard HPV Manual
Control.

9 Repeat the measurement steps with the shims and
snap ring installed to confirm your selection.
Important
The Alignment Stud must mate with the female linkage
inside of the Manual Control. Take this opportunity to
locate the female linkage inside of the new control.
11 Install the new control onto the pump making sure that:
a The Alignment Stud on the Finger is properly
positioned into the female linkage inside the new
control.
b The metal split pins are aligned with the
corresponding passages in the pump.

10 Prior to installing the Manual Control, verify that the Note

following things are present:
As illustrated below, removing the metal plug or plastic shipping
a Two metal split pins pressed into two passages plug from this port will make it easier to install the Alignment
on the bottom of the control Stud into the female linkage. You can use this port as a window
bO
 ne large o-ring in good condition (i.e. during the installation of the Manual Control.
undamaged) and properly placed in the o-ring
groove
cS
 everal small o-rings in good condition (i.e.
undamaged) and properly placed in the o-ring
grooves

Note
You can use a little petroleum jelly to help hold the Leave This Manual
o-rings in place. Port Open Control

12 Fasten the Manual Control with four new S.H.C.S.

Tighten the S.H.C.S. with the 6mm Allen wrench and
torque each one to 25 N-m (18 ft-lb).

13 Test the pump for functionality using Eaton Test

Procedures and adjust the control if necessary to
achieve desired settings.

20 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Installing Power Take-Off (PTO) Kits Important
This procedure must
onto HPV Pumps with Eaton be performed in a clean
environment using clean
Charge Pump Attached Parts, Tools and Lubricants.

Set Up

Important
The instructions contained in the following document is valid
for all size HPV pumps. Appearances and dimensions of the
illustrations in this document will vary according to the size
HPV pump the user is working with.
There are two (2) procedures included in this section:
Procedure "A": How to install an SAE "A" PTO Kit on an HPV
pump while using the Eaton charge pump.
Procedure "B": How to install an SAE "B" or larger PTO Kit on
an HPV pump while using the Eaton charge pump.

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 21

 Installing Power Take-Off (PTO) Kits
onto HPV Pumps with Eaton Charge
Pump Attached
Procedure "A"

The illustration below highlights some key items that
1 will be referenced throughout Procedure "A".
Note
All HPV pumps supplied from Eaton with an Eaton
charge pump is already equipped with an SAE "A"
PTO Kit. As explained below, there is no additional
hardware required to have an SAE "A" PTO. Steps
#2-#5 explain how to install an additional pump.
Inspect the O-Ring to ensure that it is in good condition
4 (i.e. undamaged) - Replace if damaged. Make sure that
the O-Ring is properly positioned in the o-ring groove.
You can use a little grease to help hold it in position.
5 As illustrated below, install the pump with an SAE "A"
pilot and SAE "A" spline drive shaft into the back of the
HPV charge pump. You may have to rotate the new
pump drive shaft to allow its splines to align with the
splines in the charge pump coupling.

Fasten the new pump to the HPV charge pump with

threaded bolts (not supplied by Eaton) and torque
accordingly.

Remove and discard the two (2) Hex Head Bolts from
2
the Charge Pump Cover Plate.

3 Remove and discard the Cover Plate from the back of

the charge pump.

22 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Installing Power Take-Off (PTO) Kits
onto HPV Pumps with Eaton Charge
Pump Attached
Procedure "B"

The illustration below highlights some key items that

1 will be referenced throughout Procedure "B".

Remove and discard the two(2) Charge Pump Remove the two(2) Hex Head Bolts from the Charge
2 3
Mounting Bolts. Remove the Charge Pump and Charge Pump Cover Plate.
Pump O-Ring from the back of the HPV. Keep the
Charge Pump O-Ring for reuse.
4 Remove the Cover Plate.

5 Remove O-Ring #1 and inspect it for damage. Replace

it if damaged, otherwise keep it for reuse.

6 Remove O-Ring #2 and inspect it for damage. Replace

it if damaged, otherwise keep it for reuse. Remove the
seven (7) Fastening Bolts and Washers and keep them
for reuse.

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 23

 Installing Power Take-Off (PTO) Kits
onto HPV Pumps with Eaton Charge
Pump Attached
Procedure "B" (continued)

Position the Charge Pump as illustrated below. Pull the Flip the drive shaft over so that it is oriented as shown
7 9 below. Using a snap ring wrench, remove the Outer
Intake Plate out of the Charge Pump (it should just slide
off of the drive shaft). When doing this, please note the Snap Ring from the drive shaft and keep it for reuse.
Inner Needle Bearing will slide off still inserted in the
Intake Plate.
Remove O-Ring #3 from the Charge Pump and inspect
it for damage. Replace it if damaged; otherwise keep
both the Intake Plate and O-Ring #3 for reuse.

Slide the Inner Gear off of the drive shaft as illustrated

10 below. Once the Inner Gear is removed, the Shaft Key
will slide out of the drive shaft. Keep both the Inner
Gear and Shaft Key for reuse.

Pull the drive shaft straight out of the Charge Pump as

8 illustrated below. Please note that the Inner Gear and
two Snap Rings will be removed along with the drive
shaft.

Using a snap ring wrench, remove the Inner Snap Ring

11 from the drive shaft and keep it for reuse.
The drive shaft is no longer needed for this conversion -
Set it aside.

24 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Installing Power Take-Off (PTO) Kits
onto HPV Pumps with Eaton Charge
Pump Attached
Procedure "B" (continued)

Use the illustration below for the following steps:
12
a Acquire the new charge pump drive shaft. You will
notice that it has two spline ends. The spline ends
are different from each other. One end is identical to
the drive shaft from step #11. As shown below, the
end that is identical to the drive shaft in step #11 is
pointing downward.
b Reinstall the Outer Snap Ring from step #9.
c Reinstall the Shaft Key from step #10.
dR
 einstall the Inner Gear from step #10 making sure
to capture the Shaft Key.
Use the illustration below for the following steps:
14
a Position the Charge Pump as shown.
bF
 lip the new drive shaft 180° from its orientation in
step #13.
c Apply a thin layer of grease to the designated
surface of the drive shaft.
d Install the drive shaft into the Charge Pump. Please
note that the drive shaft must be installed into the
Outer Needle Bearing.

As illustrated below, reinstall the Inner Snap Ring from

13 step #11.

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 25

 Installing Power Take-Off (PTO) Kits
onto HPV Pumps with Eaton Charge
Pump Attached
Procedure "B" (continued)

Use the illustration below for the steps below: Use the illustration below for the following steps:
15 16
aR
 einstall O-Ring #3 from step #7. Make sure that aR
 einstall the seven (7) Fastening Bolts and Washers
it is properly positioned in the o-ring groove. Use a from Step #6 to fasten the Intake Plate to the Charge
small amount of grease to help hold it in position. Pump. Torque each Fastening Bolt to 13 N-m (10 ft-lb).
b Apply a thin layer of grease to the designated bR
 einstall O-Ring #2 from step #6 into the Charge
surface of the drive shaft. Pump. Make sure that the o-ring is properly
positioned in the o-ring groove. Use a small amount
c Align the seven (7) threaded holes in the Intake
of grease to help hold the o-ring in position.
Plate with the holes in the charge pump housing.
Then install the Intake Plate into the charge pump.
The seven (7) holes in the Intake Plate and charge pump
housing are NOT evenly spaced. The Intake Plate can
only be mounted with all seven Fastening Bolts when
oriented in one particular position - The correct position.

As illustrated below, reinstall the O-Ring into the HPV

17 o-ring groove. Use a small amount of grease to help
hold the o-ring in position.

18 Reinstall the Charge Pump back into the HPV. You may
have to rotate the charge pump drive shaft to allow the
mating splines to align. Once aligned, the Charge Pump
should easily slide into the HPV.

26 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Installing Power Take-Off (PTO) Kits
onto HPV Pumps with Eaton Charge
Pump Attached
Procedure "B" (continued)

As illustrated below, reinstall O-Ring #1 into the charge
19
pump o-ring groove. Use a small amount of grease to
help hold the o-ring in position.
20 Install the PTO Coupling onto the charge pump drive
shaft.
As illustrated below, install the PTO O-Ring into the PTO
23 Adapter Flange o-ring groove. Use a small amount of
grease to help hold the o-ring in position.
At this point, there are two options to finish:
• As illustrated below, install the new pump onto
the PTO Adapter Flange. The new pump must
have a mount and spline drive shaft to match the
PTO flange and coupling just installed. Mount the
pump with bolts (not supplied by Eaton) and torque
accordingly.
OR
• Y
 ou can install a cardboard or platic cover (not supplied
by Eaton) over the opening in the PTO flange.

As illustrated to the right, install the PTO Adapter

21
Flange onto the Charge Pump. The PTO Adapter
Flange will have two mounting holes (unthreaded and
countersunk) and two attachment holes (threaded)
[Refer to the illustration on the top right of this page
for hole identification]. Align the PTO Adapter Flange
so that the two mounting holes align with the two
mounting holes in the Charge Pump.

22 Fasten the PTO Adapter Flange to the Charge Pump

and HPV by using two long S.H.C.S. Torque each
S.H.C.S. to 85 N-m (63 ft-lb).

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 27

 Installing a PTO Kit onto HPV Pumps Important
This procedure must
Directly (Without Auxiliary Pump) be performed in a clean
environment using clean
Set Up Parts, Tools and Lubricants

Important
This procedure is valid for
all sizes of HPV pumps
(without auxiliary pumps)
and various sizes of PTO
kits. The steps in this
document are performed
using an HPV135 with E1P
control type and an SAE C
PTO kit.

28 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Installing a PTO Kit onto HPV Pumps
Directly (Without Auxiliary Pump)
Procedure

1 Remove the two bolts that secure the PTO cover on 3 Remove the o-ring and inspect it to make sure that it is
the back of the HPV pump. not damaged.

4 Install the o-ring back on the pump using petroleum jelly.

2 Remove the PTO cover as shown here.

5 Position the PTO plate as shown here.

Important
PTO plates used with HPV pumps differ in look and
size. Since the bolt pattern on the HPV pump's rear
head is asymmetric, there is only one way to align the
PTO plate and the HPV pump's rear head.

6 Identify the bolts on the HPV pump’s rear head that

match with the bolt holes on the PTO plate.

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 29

 Installing a PTO Kit Directly
(Without Auxiliary Pump)
Procedure

7 In order to install the PTO plate, the identified bolts 8 Install the PTO plate on the HPV pump’s rear head as
must be removed. shown here.

Important Important
Do not remove all the bolts from the rear head; Pay attention to the o-ring on the rear head to prevent
this will result in separating the rear head from the damages.
housing which will require further disassembly of the
pump to correct. Align bolt holes on the PTO plate with the holes on the
9
rear head.

Important
The location and number of removed bolts may vary
depending on the HPV pump’s size and the PTO kit 10 Install the new bolts on the PTO plate as shown below.
selected.
Note
These new bolts are longer than the original bolts
removed from the rear head. For the correct bolt
length and part number refer to Lindos.

11 Torque the bolts. (See torque chart at the end of this

document).

30 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Installing a PTO Kit Directly
(Without Auxiliary Pump)
Procedure

12 Install the new o-ring on the back of the PTO Plate 14 Tighten the bolts on the PTO cover.
using petroleum jelly.

13 Install the new PTO Cover as shown here.

Torque (ft-lb)
Dimensions 4.6 4.8 5.8/22H/45H 6.8 8.8 10.9 12.9
Standard Thread M4 0.7 1.0 1.3 1.5 2.0 2.8 3.4
M5 1.5 2.0 2.5 3.0 4.1 5.9 7.0
M6 2.7 3.5 4.4 5.2 7.0 9.6 11.8
M8 6 8 10 13 17 24 29
M10 13 17 21 25 34 47 57
M12 22 30 37 44 59 81 100
M14 35 46 58 69 92 133 159
M16 54 7 4 90 108 144 203 243
M20 107 140 177 213 284 398 479
M24 184 243 302 365 487 686 811
M30 376 498 620 738 996 1364 1659
M36 649 863 1084 1298 1733 2434 2876
Fine Pitch Thread M8 X 1 7 9 12 14 18 26 31
M10 X 1 15 19 24 29 38 53 70
M10 X 1.25 13 18 22 27 36 50 60
M12 X 1.25 24 32 41 49 65 92 111
M12 X 1.5 23 30 38 46 61 85 103
M14 X 1.5 38 52 64 77 103 144 173
M16 X 1.5 58 77 96 116 155 218 258
M18 X 1.5 85 111 140 170 225 313 376
M20 X 1.5 118 155 195 236 313 443 531
M22 X 1.5 159 210 262 313 420 590 708
M24 X 2 199 266 332 398 531 738 885
M27 X 2 291 387 483 579 774 1106 1328
M30 X 2 398 535 667 800 1069 1512 1844
M36 X 3 686 922 1151 1379 1844 2581 3024

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 31

 Changing Rotation on Important
This procedure must
Charge Pumps be performed in a clean
environment using clean
Set Up and Procedure Parts, Tools and Lubricants

Important
To change rotation on an
Eaton charge pump, the plug
and cold start relief valve
must be exchanged with
each other.
Some clockwise (right-hand)
charge pumps may not have
the plug on the opposite
side of the cold start relief
valve; in this case, you must
replace the charge pump
with a left handed version.

1 Remove the existing plug from the charge pump and

discard it.

Note
There may be a plug with an o-ring on it. If the charge
pump you are working on has this type of plug, then
you can reuse it.

Remove the existing cold start relief valve from the

2
charge pump. Inspect the o-ring on the cold start
relief valve to ensure that it is in good condition (i.e.
undamaged). Replace it if damaged.

3 Reinstall the cold start relief valve into the charge pump
where the plug from step #1 was. Torque the cold start
relief valve to 30 N-m (22 ft-lb).

4 Apply Blue Loctite No. 243 to the threads of a new

Plug. Install the Plug into the charge pump where the
cold start relief was. Torque the Plug to 60 N-m (44
ft-lb).

Note
For those plugs with the o-ring, do not apply Loctite
and torque it to 35 N-m (26ft-lb).

32 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Changing Rotation on
Charge Pumps
Procedure

Important
If you have an internal feed or a combination internal /
external feed charge pump follow steps #5 through #19.
If you are working with an external feed charge pump, the
procedure is complete.
With the internal feed or combination internal/external
feed charge pump, there is an intake plate that must be
exchanged to accommodate the rotation change. Use these
illustrations for the following charge pump disassembly/
assembly instructions.

5 Remove the two(2) hex head bolts from the cover plate
and keep them for reuse.

6 Remove the cover plate and O-Ring #1 and keep them

for reuse.

7 Remove O-Ring #2 and keep it for reuse.

Remove the seven(7) fastening bolts and washers. Keep

8 them for reuse.

Pull the intake plate out of the charge pump (it should
9
just slide out). When doing this, please note that the
needle bearing will slide off of the shaft along with the
intake plate.

10 Do not press the needle bearing out of the intake plate.

It is installed with Green Loctite No. 270 on its outer
race. The needle bearing will be destroyed if removed
from the Intake Plate, so just leave it in place.

11 Make sure that O-Ring #3 is properly positioned in the

charge pump o-ring groove. Use a small amount of
petroleum jelly to help hold O-Ring #3 in place.

12 Refer to LINDOS for the new intake plate part number to

match the new pump rotation. You must also use a new
needle bearing.

Apply a thin, uniform layer of Green Loctite No. 270 to

13
the outer race of the new needle bearing.

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 33

 Changing Rotation on
Charge Pumps
Procedure

14 The orientation of the needle bearing is important. On

one face of the needle bearing, there will be some
stamping (bearing manufacturer's name, etc.) and the
other side will be blank. The side of the needle bearing
with the stamping must be facing away from the charge
pump when installed into the intake plate (as illustrated
above). Install the new needle bearing into the new
intake plate and wipe away any excess Loctite.

15 Align the seven(7) threaded holes in the new intake plate

with the holes in the charge pump housing. Then install
the new intake plate into the charge pump.

Note
The seven(7) threaded holes in the charge pump housing and
intake plate are not evenly spaced. The intake plate can only
be mounted with all seven fastening bolts when oriented in
one particular position - The correct position.

16 Reuse the seven(7) fastening bolts and washers

to fasten the intake plate to the charge pump then
torque the fastening bolts to 13 N-m (9.5 ft-lb).

17 Reinstall O-Ring #1 into the charge pump o-ring

groove. Use a small amount of petroleum jelly to
help hold O-Ring #1 in place.

18 Reinstall the cover plate and fasten it to the charge

pump with the two(2) hex head bolts.

19 Reinstall O-Ring #2 into the charge pump and make

sure that it is properly positioned in the o-ring
groove. Use a small amount of petroleum jelly to
help hold O-Ring #2 in place.

At this point the Rotation Change is complete.

34 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Assembling Tandem Charge Pumps Important
This procedure must
Set Up and Procedure be performed in a clean
environment using clean
Parts, Tools and Lubricants

Note
The front charge pump does
not need modified. The
following instructions are for
modifying the rear charge
pump.

1 Remove the cover plate and the o-ring behind it as 3 Remove the seven (7) bolts shown here.
shown here.

2 Remove the mounting o-ring from the opposite side.

4 Also, remove the seven (7) washers as shown here.

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 35

 Assembling Tandem Charge Pumps
Procedure

5 Gently, tap on the shaft’s end to push out the shaft 8 Remove the gear as shown here.
and port plate cover from the charge pump housing.

6 Separate the port plate cover from the shaft. 9 Remove the key and the second snap ring from
the shaft.

7 Remove the first snap ring using snap ring pliers as 10 Replace the existing shaft with the one required for
demonstrated during the training. tandem assembly as shown here.

36 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Assembling Tandem Charge Pumps
Procedure

11 Install one of the snap rings then install the key 15 Inspect the o-ring around the outer gear and make sure
on the shaft. that it is positioned properly.

16 Align the bolt holes on the port plate cover with the
holes on the charge pump housing.

Note
This bolt pattern is not symmetric; there is only one
way to align them.

12 Install the gear on the shaft.

13 Install the second snap ring.

14 Insert the new shaft / gear assembly into the charge 17 Install the port plate cover as shown here.
pump housing as shown here.

Important
Make sure the side with a chamfer on the gear (as
shown) is facing the charge pump housing.

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 37

 Assembling Tandem Charge Pumps
Procedure

18 Install all seven (7) washers. 22 Install the o-ring on the charge pump mounting face as
shown here.

19 Install all seven (7) bolts and torque them

to 13 N-m (9.5 ft-lb).

23 Inspect the o-ring on the back of the front charge pump

to insure it is positioned correctly.
20 Install the snap ring on the short shaft designed for
tandem assembly. The snap ring is positioned on the
slot that is cut into the shaft spline.

24 Align the shaft on the rear charge pump with the spline
on the front charge pump and insert it.

21 Insert the short shaft designed for tandem assembly Important

into the front face of the charge pump as shown here.
Pay attention to the o-rings during this step to prevent
damages.

38 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Assembling Eaton Charge Pumps
Procedure

25 Insert the mounting bolts into the tandem charge 30 Torque the two mounting bolts to 110 N-m (81 ft-lb).
pump assembly as shown.

31 Inspect the o-ring on the back of rear charge pump to

insure it is positioned properly.

32 Install the PTO cover on the back of the rear charge

pump.

26 Inspect the o-ring on the back of the HPV pump to

insure there are no damages.

27 Make sure that the coupling is positioned correctly.

28 Align the splines on the charge pump shaft with the At this point, the assembly of tandem Eaton charge pumps
coupling is complete.

29 Install the tandem charge pump assembly on the HPV

pump.

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 39

 Exchanging Regulation Begin Springs Important
This procedure must
Set Up and Procedure be performed in a clean
environment using clean
Parts, Tools and Lubricants

Important
Although the drawing to the
right represents an H1control
type, this procedure can be
used for all control types
on HPV pumps, except for
Manual Controls.

Procedure to Exchange Regulation Begin Springs

Important
After this procedure has been completed, both Regulation 
5 Place the spring and spring hat inside the regulation
Begin and Maximum Displacement adjustments must be begin cup then install the sub-assembly in the pump
reset. control. Turn the regulation begin cup IN until the
spanner nut touches the pump control housing.

1 Use the spanner wrench to loosen the spanner nut. It
is important not to move the spanner nut more than a 6
Tighten the spanner nut.
quarter of a turn.

7 As mentioned above, reset the regulation begin and
Important maximum displacement adjustments.
Do not to move the spanner nut more than a quarter of a Repeat steps #1 through #7 for the regulation begin
turn since it will be used as your initial positioning guide 8
spring on the opposite side of the pump control, as
during assembly. required.

2 Rotate and remove the Regulation begin sub- Important
assembly. This sub-assembly includes the spring
hat, spanner nut, regulation begin cup, maximum If you are working on a control with POR function and
displacement adjustment and locking nut. converting from 2-8 bar springs to 4-10, 4-16 bar or vice
versa, you must also change valve III as follows:
Note
2-8 bar:
The spring hat and the spring may or may not come out with Valve P/N 600 340 5512
the regulation begin cup. You may have to remove the spring
using pliers. 4-10 bar:
Valve P/N 600 340 5510
The o-ring on the regulation begin cup may be damaged
during removal. 4-16 bar:
Valve P/N 600 340 5510
3 Replace the regulation begin spring with a new one.

Inspect the spring hat for damages then install it on

4
the spring.

40 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Exchanging Regulation Begin Springs
Procedure to Exchange the Valve III for POR function

1 As shown here use a 13mm wrench to loosen the
valve III body.
Note
Valve III is made of two different bodies. All together
there are 3 places where a wrench can be applied:
The main body, the second part of the body and the
locking nut. Separating the two body pieces can result
in damage or loss of internal parts. Please insure that
the wrench is applied to the main body as shown here.
5 The Pump control is stamped to reflect the correct
regulation begin spring range, shown as “Stamping2”
here. This stamping must change to reflect the correct
spring range:
Control Pressure Range: 2-8 bar: A
4-10 bar: B
4-16 bar: C
Control Pressure Range and 2-8 bar: D
limited spool stroke, by 4-10 bar: E
mechanical end stop: 4-16 bar: F

Important
At the end of this procedure, the unit must be tested
for functionality and settings.

2 Remove the valve III in one piece as shown here.

Inspect the o-ring on the replacement valve for

3
damage and replace as required. Install valve III into
the cavity.

4 Torque the valve III body to 11 ft-lb (15 N-m).

Note
The POR must be reset on the pump control after
valve III is exchanged.

EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012 41

 Exchanging Rectangular
Solenoids on Controls
Set Up and Procedure

Procedure to Exchange Rectangular Solenoids:;


1 Remove the four S.H.C.S. from the Proportional
Solenoid with the 3mm Allen wrench. Keep the four
S.H.C.S. with the existing solenoid as an assembly.


2 Remove the existing Solenoid O-Ring and keep it with
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.


4 Install the new Proportional Solenoid onto the pump
control and fasten it with the four new S.H.C.S. that
came with the new solenoid.


5 Tighten the S.H.C.S. with the 3mm Allen wrench and
torque each one to 2.7 N-m (2.0 ft-lb).

42 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Maximum Displacement Adjustment for M1
(Mechanical-Hydraulic) Control
Set Up and Procedure

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:
1 Loosen the flow-stop lock nut with 13mm wrench.

2 Turn the cam lever in the appropriate direction.

Turn the adjustment stud IN to decrease the flow

3
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 Conversion Procedures Manual E-PUPI-TM020-E July 2012 43

 Maximum Flow Adjustment Procedure
with “H” or “E” Controls
Set Up

Note
This Service Bulletin is valid
for HPV pumps with either
"H" (Hydraulic Remote) or "E"
(Electro-Hydraulic Remote)
Controls
The drawing below illustrates
an "H1" Control, but the
information is also valid for
“H1P”, “E1”. “E1P, and “E2”
Controls.

Ms
Solenoid

E2 Control

44 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Maximum Flow Adjustment Procedure
with “H” or “E” Controls
Adjustment Procedure
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
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.
1 (Optional) Install the 0-600 psi gauge into gauge port "Y".
2 Set the input speed to high idle.
3 For E2 Controls, make sure that Ms Solenoid is
energized.
Supply full control pressure to port "Y" or full current
4 10
to solenoid "My". (Optional) Confirmthat the pressure
at port "Y" is adequate to put the pump at full
displacement.
Measure the rotational speed of the motor, the
5 11
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.
6 To Adjust the Maximum Flow:
a. Use the 13mm wrench to loosen "Locking Nut #2".
b. U
 se 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..
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. O
 nce 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]).
EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012
7 (Optional) Install the 0-600 psi gauge into gauge port "Z".
8 Set the input speed to high idle.
9 For E2 Controls, Make sure that Ms Solenoid is
energized.
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.
12 To Adjust the Maximum Flow:
a. Use the 13mm wrench to loosen "Locking Nut #1".
b. U
 se 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.
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.
13 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]).
45
 Operational Parameters Eaton high pressure units are designed for excellent
reliability and long service life. The actual service life of a
Life Time Recommendations hydraulic unit is determined by numerous factors. It can be
extended significantly through proper maintenance of the
hydraulic system and by using high-quality hydraulic fluid.

Beneficial Conditions For Long Service Life
Speed Lower continuous maximum speed
Operating Pressure Less than 300 bar on average
Max. Pressure Only at reduced displacement
Viscosity 15 ... 30 cSt
Power Continuous power or lower
Purity of Fluid 18/16/13 in ac. with ISO 4406 or better
Adverse Factors Affecting Service Life
Speed Between continuous maximum speed and
intermittent maximum speed
Operating Pressure More than 300 bar on average
Viscosity Less than 10 cSt
Power Continuous operation close to max. power
Purity of Fluid Lower than 18/16/13 in acc. with ISO 4406

Operational parameters.
Filtration
In order to guarantee
long-term proper function
and high efficiency of
the hydraulic pumps the
cleanliness level of the Eaton Hydraulic Fluid level can extend the
lubricant must comply Recommendation 03-401- service life of the hydraulic
with the following 2010. Maintaining the system significantly.
criteria according to recommended cleanliness

For reliable proper function and long service life
18/16/13 in accordance with ISO 4406 or better
Commissioning has to be filtered. We recommend the implementation
The minimum cleanliness level requirement for the
hydraulic oil is based on the most sensitive component.
For commissioning we recommend a filtration in order to
achieve the required cleanliness level.
Filling and operation of hydraulic systems
The required cleanliness level of the hydraulic oil must
be ensured during filling or topping up. When drums,
canisters, or large-capacity tanks are used the oil generally
of suitable filters to ensure that the required cleanliness
level of the oil is achieved and maintained during
operation.
International standard
Code number according to ISO 4406
18/16/13

Available filter sizes

Filter size 55 75 105 135 165 210 280
No. 2 x          
No. 3 x x x x x x x

46 EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012

Operational Parameters
Pressure Fluids
Permitted pressure fluids
•M
 ineral oil HLP to DIN
524-2
•B
 iodegradable fluids in
accordance with ISO 15
380 on request
•O
 ther pressure fluids on
request
Recommend viscosity ranges
Pressure fluid temperature range
Working viscosity range
Optimum working viscosity
Max. viscosity (short time start up)
In order to be able to
select the right hydraulic
fluid it is necessary
to know the working
temperature in the
hydraulic circuit. The
hydraulic fluid should
be selected such that is
Viscosity recommendations
Working temperature [°C]
Approx. 30 to 40
Approx. 40 to 60
Approx. 60 to 80
Further information regarding installation can be found in the operating instructions.
Eaton offers an oil testing
service in accordance with
VDMA 24 570 and the
test apparatus required for
in-house testing. Prices
available on request.
[°C]
[mm²/s] = [cSt]
[mm²/s] = [cSt]
[mm²/s] = [cSt]
optimum viscosity is within
the working temperature
range (see tables).
The temperature should
not exceed 90 °C in any
part of the system. Due
to pressure and speed
influences the leakage
Viscosity class [mm²/s] = [cSt] at 40 °C
22
32
46 or 68
EATON Duraforce HPV Conversion Procedures Manual E-PUPI-TM020-E July 2012
In order to ensure the functional performance and high
efficiency of the hydraulic pumps the viscosity and
purity of the operating fluid should meet the different
operational requirements. Eaton recommends using only
hydraulic fluids which are confirmed by the manufacturer
as suitable for use in high pressure hydraulic installations
or approved by the original equipment manufacturer.
-20 to +90
10 to 80
15 to 30
1000
fluid temperature is always
higher than the circuit
temperature. Please
contact Eaton if the stated
conditions cannot be met
in special circumstances.
47
Eaton
Hydraulics Group USA
14615 Lone Oak Road
Eden Prairie, MN 55344
USA
Tel: 952-937-9800
Fax: 952-294-7722
www.eaton.com/hydraulics
© 2012 Eaton Corporation
All Rights Reserved
Printed in USA
Document No. E-PUPI-TM020-E
July 2012
Eaton Eaton
Hydraulics Group Europe Hydraulics Group Asia Pacific
Route de la Longeraie 7 Eaton Building
1110 Morges No.7 Lane 280 Linhong Road
Switzerland Changning District, Shanghai
Tel: +41 (0) 21 811 4600 200335 China
Fax: +41 (0) 21 811 4601 Tel: (+86 21) 5200 0099
Fax: (+86 21) 2230 7240