Hydraulic Boom 1093 - Model TR-14 New

♦♦ OPERATION AND MAINTENANCE MANUAL
CUSTOMER: Vale
PROJECT: 1093
HYDRAULIC BOOM - MODEL TR-14
AND ELECTRO-HYDRAULIC
CONTROLS
REVISION: 00
Date: April 2014
Prepared by:
TRAMAC CORPORATION TRAMAC EQUIPEMENT LTD

12 Orben Drive, Suite /3 3421 Industriel Boulevard
Landing, New Jersey, USA Laval, Québec, Canada
Tél: 973-770-4457 Tél: 450-663-8122
Fax: 973-770-0812 Fax: 450-663-6797
email: salesus@tramac.com email: sales@tramac.com
Rev: New Page 1 of 54

HYDRAULIC BOOM - MODEL TR-14 AND
ELECTRO-HYDRAULIC CONTROLS
TABLE OF CONTENTS
1 INTRODUCTION ....................................................................................................... 5
1.1 TR-14 HYDRAULIC BOOM DESCRIPTION.......................................................... 5
1.2 HYDRAULIC POWER PACK DESCRIPTION........................................................ 6
1.3 ELECTRICAL CONTROLS ................................................................................... 6
2 DATA SHEET & SPECIFICATIONS............................................................................ 7
2.1 Boom Specifications .............................................................................................. 7
2.2 Hydraulic Power Unit ............................................................................................. 9
3 INSTALLATION ...................................................................................................... 10
3.1 BOOM INSTALLATION ..................................................................................... 10
3.2 HYDRAULIC POWER UNIT INSTALLATION .................................................... 11
3.3 HYDRAULIC HOSE CONNECTIONS ................................................................. 11
3.4 ELECTRICAL INSTALLATION .......................................................................... 12
4 Hydraulic Schematic .................................................................................................. 13
5 INITIAL START-UP ................................................................................................. 15
5.1 Before start-up: .................................................................................................... 15
5.2 Start-up procedure:............................................................................................... 15
6 BOOM ADJUSTMENTS ........................................................................................... 18
6.1 PRESSURE ADJUSTMENTS: ............................................................................. 18
6.1.1 Load Sensing Pump No 1 Pressure Setting ........................................................ 18
6.1.2 Main Pump No 1 Pressure Setting.................................................................... 18
6.1.3 Load Sensing Pump No 2 Pressure Setting ........................................................ 19
6.1.4 Main Pump No 1 Pressure Setting.................................................................... 19
6.2 Slewing Ring / Pinion Backlash Adjustment ........................................................... 21
6.3 GEAR REDUCER LUBRICATION ...................................................................... 22
7 TROUBLESHOOTING:............................................................................................. 23
8 RECOMMENDED MAINTENANCE INSPECTION PROGRAM: ................................ 25
8.1 Daily Inspection ................................................................................................... 25
8.2 Weekly General Inspection ................................................................................... 25
8.3 Monthly General Inspection .................................................................................. 25
8.4 Every Year .......................................................................................................... 25
9 Safety ....................................................................................................................... 26
9.1 General information ............................................................................................. 26
9.2 Personnel Safety .................................................................................................. 26
9.2.1 Machine Operator .......................................................................................... 26
9.2.2 Maintenance Personnel ................................................................................... 26
10 Lubrication............................................................................................................. 27
10.1 Recommended Grease ....................................................................................... 27
10.2 Grease Points ................................................................................................... 27
11 PART LIST ............................................................................................................ 28
11.1 BOOM SWING DETAIL .................................................................................. 28
11.2 BOOM ARM DETAIL ...................................................................................... 30
11.3 DIPPER STICK DETAIL .................................................................................. 32
11.4 HYDRAULIC PIPE AND HOSE DIAGRAM ..................................................... 34
11.5 BOOM CYLINDER PART DIAGRAM .............................................................. 42
11.6 DIPPERSTICK CYLINDER PART DIAGRAM .................................................. 42
11.7 HAMMER CYLINDER PART DIAGRAM ........................................................ 43
11.8 HYDRAULIC POWER UNIT PART DIAGRAM ................................................ 43
11.9 Control Panel CP-01 Part Diagram ..................................................................... 45
11.10 OPERATOR CONSOLE PARTS .................................................................... 46
11.11 HPU LOCAL CONTROL PANEL JB-01 ......................................................... 47
11.12 COMPONENT REMOVAL INSTRUCTION ................................................... 48
11.13 ROTATION GEARBOX REPLACEMENT ..................................................... 48
11.14 MAIN BEARING REPLACEMENT ............................................................... 49
11.14.1 General Instruction ................................................................................... 49
11.14.2 Removal of the Stick ................................................................................ 49
11.14.3 Removal of the Boom Arm ....................................................................... 51
11.14.4 Removal of the Pivoting Base ................................................................... 51
11.14.5 Installation of the Slewing Ring ................................................................. 53
12 DRAWING LIST .................................................................................................... 53

Figure 2-1 Boom Installation Side View ................................................. 7

Figure 2-2 Boom Reach Diagram ..................................................... 8
Figure 3-1 HPU Hydraulic Connections to Boom .......................................... 12
Figure 4-1 Hydraulic Schematic ..................................................... 13
Figure 4-2 Electrical Block Diagram .................................................. 14
Figure 5-1HPU Control Panel ....................................................... 15
Figure 5-2 Hydraulic Power Unit Control Panel ........................................... 16
Figure 5-3 Manual Hydraulic Control Valves............................................. 17
Figure 5-4 Operator Console ....................................................... 17
Figure 6-1 Pressure Gauge Locations .................................................. 20
Figure 6-2 Pump Pressure Adjustment Screws ............................................ 20
Figure 6-3 Gearbox oil reservoir/level indicator ........................................... 22
Figure 10-1Grease Point Location .................................................... 27
Figure 11-1 Boom Swing Part Diagram ................................................ 28
Figure 11-2 Boom Arm Part Diagram ................................................. 30
Figure 11-3 Dipper Stick Part Diagram................................................. 32
Figure 11-4 Piping and Hose Diagram ................................................. 34
Figure 11-5 Piping and Hose Detail A ................................................. 35
Figure 11-6 Piping and Hose Detail B ................................................. 35
Figure 11-7 Piping and Hose Detail C ................................................. 36
Figure 11-8 Piping and Hose Detail D ................................................. 36
Figure 11-9 Piping and Hose Detail E ................................................. 37
Figure 11-10 Piping and Hose Detail F ................................................. 37
Figure 11-11 Piping and Hose Detail G ................................................ 38
Figure 11-12 Piping and Hose Detail H ................................................ 38
Figure 11-13 Piping and Hose Detail I ................................................. 39
Figure 11-14 Piping and Hose Detail J ................................................. 39
Figure 11-15 Boom Cylinder Part .................................................... 42
Figure 11-16 Dipperstick Part Diagram ................................................ 42
Figure 11-17 Hammer Part Diagram .................................................. 43
Figure 11-18 HPU Part Diagram ..................................................... 43
Figure 11-19 Control Panel CP-01 .................................................... 45
Figure 11-20 Operator Console Panel.................................................. 46
Figure 11-21 HPU Local Control Panel JB-01 ............................................ 47
Figure 11-22 Stick Cylinder Pin Removal ............................................... 50
Figure 11-23 Stick Removal ........................................................ 50
Figure 11-24 Boom Arm Removal .................................................... 51
Figure 11-25 Removal of the pivoting base .............................................. 52
Figure 11-26 Slewing Ring Removal .................................................. 52

1 ♦ INTRODUCTION
The purpose of this manual is to assist in the operation and maintenance of the TR14 Hydraulic
Boom for Vale.
We have included all information presently available to the best of our knowledge and
experience, but reserve the right to make amendments in the future, as required.
The rock breaker system is constructed of materials suitable for heavy duty service in a hard
rock open pit mining operations.
The rock breaker system includes the following main assemblies:
• Breaker boom assembly TR-14
• Hydraulic breaker tool
• Electric powered hydraulic power pack
• Electric local control station
1.1 TR-14 HYDRAULIC BOOM DESCRIPTION

Each TR14 boom has the following main components:
• Fixed base
• Swivel base
• Primary arm
• Secondary arm
• Stick
• 2 levers
• Hydraulic System and Cylinders
• Electrical components
The impact rock breaker boom is of heavy duty construction, articulated with a jib knuckled
mounted on a turntable. It is constructed of high strength steel with reinforced areas for rugged
operation.
All pivot pins are of high quality steel with retaining head. All pivots are fitted with replaceable
bushing with high wear resistance.

Hydraulic cylinder have self aligning spherical bearing on the barrel and rod ends to ensure that
cylinders are not subjected to any side loading during operation.
The impact rock breaker boom is also equipped with an automatic pivot pin greasing system with
a large grease reservoir.
1.2 HYDRAULIC POWER PACK DESCRIPTION

The impact rock breaker boom is powered by a hydraulic pump system composed of two electric
motors each coupled to a high efficiency pump.
The hydraulic electric motor pumps are not supplied with any starter panel and/or cable. The
customer has to supply his own starter with its panel. However Tramac provides the control to
activate the starter which includes the starting and stopping push button and interlock as several
shutting down alarms.
A pressure relief valve is provided to safeguard overloading of the hydraulic pump and the
electric motor.
A sealed oil reservoir with vent breather is provided. The reservoir is equipped with strainer, oil
level indicator, oil level sensing device and temperature sensor.
A high pressure oil filter and oil cooler are provided on the return line. The cooler motor has a
fan directly mounted on the output shaft. It is activated by the high temperature switch when the
oil reaches 140oF.
One oil heater is installed on the power unit tank and is controlled by a temperature switch. The
heater is automatically activated when the oil temperature reaches 60oF or less.
A diagnostic alarm system consisting of indicators for low oil and high temperature is provided.
1.3 ELECTRICAL CONTROLS

The control panel integrates all interlocks for the starting and stopping of the hydraulic pumps. A
standard relay logic design is used to insure easy and quick field trouble shooting.
On its front panel, indicator lights come on if any alarm occurs. In addition, an on/off selector
switch and an emergency stop are integrated on the front panel.
Final location of the panel remains to the customer’s choice. It must be connected to power
source and to the MCC or pump starter panel.
The operator can choose the location to operate the boom from the operator’s cabin or with a
wireless control station.
The local operator’s console is hardwired to the control panel through the use of two 16 pins
connector. Two joysticks, a start, stop and an emergency stop buttons are installed on the
console. The console is pre-wired and pre-tested, no electrical connection is required.

2 DATA SHEET & SPECIFICATIONS
2.1 Boom Specifications

Boom model: TR-14
Figure 2-1 Boom Installation Side View

Figure 2-2 Boom Reach Diagram
Type of swing: Slewing Ring with two (2) planetary reducer /

hydraulic motor assemblies
Type of control: Electro-proportional hydraulic valve
Controls: From operator cabins (24 volt electric joysticks)
Breaker Model: V1200 (supplied by other)
Reach:
- Max. Horizontal with breaker 14.4 m (47 ft 4 in)
- Max. Horizontal without breaker 7.0 m (23 ft 0 in)
- Max. Vertical without breaker 10.5 m (34 ft 5 in)
- Max. Vertical without breaker 7.4 m (24 ft 3 in)
Hydraulic Cylinders:
- Main boom (QTY:2): 8" bore, 5" rod dia.
- Dipperstick: 10" bore, 6" rod dia.
- Tool Tilt: 7" bore, 4-1/2" rod dia.
Maximum Operating Pressure: 2800 psi
Type of lubrication: Automatic lube system for the arm and breaker.
Gear Reducer Oil: Shell Omala 220, Grade ISO 220
Approx. weight of boom sub-assembly: 24102 kg (without hammer)
2.2 Hydraulic Power Unit

- Reservoir capacity: 300 gallons (us)
- Electric motor No 1: 75 HP, 440 VAC/3ph/60 Hz
- Electric motor No 2: 75 HP, 440 VAC/3ph/60 Hz
- Motor Cooler: 2 HP 440 VAC/3ph/60 Hz
- Pump type: Piston
- Flow pump: 40 gpm @ 1775 rpm
- Oil heater : 2 KW, 440 VAC/3ph/60 Hz
Weight : 2100 kg

3 INSTALLATION
For transportation purposes, the boom has been disassembled into main sections: fixed and
pivoting base, main boom section and dipper stick (including fixing cap, links #1 and #2).
Proceed first by anchoring the fixed base, then assemble the dipper stick on the boom, and
finish with all the hydraulic and greasing connections.
Refer to drawing 1093MW-A-004 for pedestal foot print and loading situation.
3.1 BOOM INSTALLATION

1) Make sure the anchoring surface is flat and clean. Verify that anchors are in accordance
with the installation dimensions;
2) If applicable, slide the neoprene pad (between base and concrete) in place. Be sure that
all anchors match the holes in the pad;
3) Install the fixed base over the pad, make sure that the fixed base points towards the
direction where the front of the boom should be ("front" of the base must match the
"front" of concrete base);
*** It is essential to respect the orientation of the base because of the location of
mechanical stoppers and boom rotation limit switches;
4) Install the neoprene washers and then steel washers in place;
5) Screw the nuts over the anchors and tighten;

*** Nuts must be equally tight. There's no specific torque because of the large
variety of bolt conditions. Just tighten until neoprene pad starts to protrude
towards the exterior. When the machine will be in working condition, the
tightening must be checked by working with the boom and observing if the pad
remains with the same clamping force in all conditions. If the pad seems to
become loose it must be retightened. Do not over tight to avoid damage to the
pad. * * *
6) Lock each nut by screwing another nut on top of the first one;
7) Link and connect the rest of the boom;
8) Install the breaker and tool according to breaker's manufacturer specifications;
9) Connect the boom electrically and hydraulically. Hoses should be routed in the center of
the pedestal base. Make sure that hoses and cables are not rubbing on steel parts
when the machine is turning. The correct length of hoses is important to prevent that
type of situation. Double check after a few hours of operation;
10) If not already installed prior to shipment, install the breaker auto-lube unit on the side of
the pivoting base. A plate has been welded to support the lubrication system and
hoses have been furnished to complete the installation.
Note 1: Refer to drawing 1093-H-001 and diagram on the following pages to connect
hydraulically the pedestal base.
Note 2: Some hydraulic and greasing hoses were disconnected to disassemble the
boom. Identification plates were attached to these hoses and/or to the ports to facilitate
connections.
3.2 HYDRAULIC POWER UNIT INSTALLATION

1) The power unit must be located at the proper location. It is preferable to anchor the
power unit;
2) Follow the hydraulic schematics drawings 1093MV-H-001 in the drawing package and
the hydraulic connections shown on Figure 3-1 HPU Hydraulic Connections to Boom
to connect each circuit of the unit. Typically, there are two (2) main hydraulic lines to
connect, two (2) drain lines and one Load Sensing line;
3) The unit must be electrically connected and properly tested before applying power.
Standard testing procedures must be used, wire to wire tests, rotation of motor,
verification of each alarm, tightening of all hoses, etc.
4) It will also be important to verify the proper functioning of this unit at the beginning of the
operation. Also, oil level and temperature must be monitored.
3.3 HYDRAULIC HOSE CONNECTIONS

1) Connect the port tagged "MP" on the boom to the port tagged "MP" on the on the power
unit.
2) Connect port tagged “R” on the boom to the port tagged “R” on the power unit
3) Connect port tagged “LS” on the boom to the port tagged “LS” on the power unit
4) Connect port tagged “DRAIN 1” on the boom to the port tagged “DRAIN 1” on the power
unit
5) Connect port tagged “DRAIN 2” on the boom to the port tagged “DRAIN 2” on the power
unit
6) Re-connect all hoses between sections of the boom

Figure 3-1 HPU Hydraulic Connections to Boom
3.4 ELECTRICAL INSTALLATION

1) All electrical connections must be done by a professional electrician and must be in
accordance with the control schematic.
2) Wiring of the motors and heater is standard and can be connected like any high power
devices. Connections to these devices are under the responsibility of the customer.
3) This 24 VDC junction box is located on the pivoting base of the hydraulic rock breaker.
It’s pre-wired and tested, however it still need to be wired to the main control panel.
Cable between the junction box and the control panel is to be supplied and installed
by the customer.

4 Hydraulic Schematic
The boom hydraulic and electrical schematic is shown on the next Figures
Figure 4-1 Hydraulic Schematic

Figure 4-2 Electrical Block Diagram

5 INITIAL START-UP
5.1 Before start-up:

1. Check that all metal bracing and straps put in place to secure equipment during
transportation have been removed;
2. Verify that all anchor bolts are in place and adequately tightened (675 N.m);
3. Check all possible interference with surrounding structure (before starting any machine);
4. Verify that no hydraulic hose has been pinched or improperly routed;
5. Check that all hydraulic hose has been properly tightened;
6. Check hydraulic oil of the gear reducers at the expansion tank and adjust level, if
required;
7. Verify that all ball valves are open to allow free hydraulic fluid flow.
5.2 Start-up procedure:

1. From the local control panel (CP-01), verify that all indicator lights are in normal state.
2. From the HPU control panel (JB-01) press the Power Unit Jog Start button and verify that
the motor/pump is running in proper rotation. Press the Oil Cooler Jog Start button and
verify that the fan motor is running in proper rotation.
POWER UNIT OIL COOLER

JOG START JOG START
R G
Figure 5-1HPU Control Panel
3. From the local control panel (CP-01) start the hydraulic power unit, make sure that it is
running smoothly and that there are no leaks (always be ready to stop the motor in case
of problem);
POWER
LOW OIL RETURN HIGH OIL LOW OIL LOW GREASE ON
LEVEL FILTER AL TEMPERATUR TEMPERATUR LEVEL
E E B
R R R R R
OFF ON
LOW OIL FILTER ALARM OIL COOLER OIL HEATER LUBRIFICATION

PRESSURE RESET RUNNING RUNNING UNCOMPLETE
R N G G R
POWER UNIT STOP START

RUNNING POWER UNIT POWER UNIT
G R G
EMERGENCY
STOP
Figure 5-2 Hydraulic Power Unit Control Panel
4. At the base of the boom, activate manually carefully each function of the boom to ensure
that air trapped in the hydraulic system is evacuated. Verify that the boom operates
smoothly and there is no mechanical interference.
5. During the operation of the hammer, ensure that the hammer bit is in contact with solid
rock.
6. Verify that the oil level in the reservoir remains within the operating range as the system
is being filled out.

PRESSURE
(MP)
RETURN (R)
HAMMER TILT BOOM
ROTATION STICK
Figure 5-3 Manual Hydraulic Control Valves
7. From the operator console test all functions of the boom and make sure that they match
the markings on the controls;
Figure 5-4 Operator Console
8. Make sure that all limit switches on all equipment are working properly;
9. Re-verify position of mechanical stoppers to prevent any accident or damage.

6 BOOM ADJUSTMENTS
6.1 PRESSURE ADJUSTMENTS:

All necessary adjustments have been made at the factory. Under normal conditions, no further
adjustments are needed. The factory settings are shown below. They shall not be increased
without CDB approval. In case adjustment is needed, proceed as follow.
Install 5000 psi manometers at the port GPP and at port X of each pump as shown in Figure 6-1
Pressure Gauge Location. The gauges at the pump shall also be equipped with a drain valves
connected to the reservoir.
Each pump shall be adjusted individually.
6.1.1 Load Sensing Pump No 1 Pressure Setting

1. To prevent the pump No 2 to run, remove the relay R101. Unlock the compensator
adjustments and load sensing on the two pumps.
2. Starts the pump and verify the only pump No 1 is running. When the pump is in operation
without any functions activated, fully open the drain valve installed on the X port of the
pump No 1 making sure the manometers indicate no pressure.
3. Adjust the load sensing on the pump No 1 to read 400 psi on the monometer installed on
X port of the pump. See Figure 6-2 Pump Pressure Adjustment Screws for location of the
setting screws.
4. Lock the load sensing adjustments.
5. Turn off the drain valves at port X of pumps to allow pressure rise in the next step.
6.1.2 Main Pump No 1 Pressure Setting

1. When pump is in operation activate one function of the boom to extend a cylinder like the
tilt to its maximum position in order to get a maximum hydraulic charge. Maintain this
function activated during this whole step.
2. Check the pressure on GPP and raise the pump pressure adjustment to approximately
3600 psi if possible. If pressure stabilizes before 3600 psi, turn the adjusting screw 2
turns after pressure has stabilized.
3. Increase the relief valve pressure of the main boom body valve to 3200 psi. If pressure
stabilizes before 3200 psi, turn the adjusting screw 2 turns after pressure has stabilized.
Repeat steps 6 and 7 until it is possible to reaches 3000 psi on the boom body valve.
4. While reading the pressure on GPP manometer, reduce the pump pressure adjustment

to 2800 psi.
5. Stop the pump and re-install the relay 101 for the next step.
6.1.3 Load Sensing Pump No 2 Pressure Setting

1. To prevent the pump No 1 to run, remove the relay R100. Unlock the compensator
adjustments and load sensing on the two pumps.
2. Starts the pump and verify the only pump No 2 is running. When the pump is in operation
without any functions activated, fully open the drain valve installed on the X port of the
pump No 2 making sure the manometers indicate no pressure.
3. Adjust the load sensing on the pump No 1 to read 400 psi on the monometer installed on
X port of the pump. See Figure 6-2 Pump Pressure Adjustment Screws for location of the
setting screws.
4. Lock the load sensing adjustments.
5. Turn off the drain valves at port X of pumps to allow pressure rise in the next step.
6.1.4 Main Pump No 1 Pressure Setting

1. When pump is in operation activate one function of the boom to extend a cylinder like the
tilt to its maximum position in order to get a maximum hydraulic charge. Maintain this
function activated during this whole step.
2. While reading the pressure on GPP manometer, reduce the pump pressure adjustment
to 2800 psi.
3. Stop the pump and re-install the relay 100 for the next step.

Figure 6-1 Pressure Gauge Locations
Figure 6-2 Pump Pressure Adjustment Screws

6.2 Slewing Ring / Pinion Backlash Adjustment

The backlash of the slewing ring shall be at least 0.43 mm and less than 0.71 mm. The backlash
is measured using a feeler gauge in the zone of maximum radial gear runout. See Figure below:
If the backlash is outside of these limits, it shall be adjusted by following the procedure below:
Unscrew the bolts securing the gear reducer mounting plate to the swivel base
Adjust the backlash using the two gear reducer position adjustment bolts
Ensure the backlash is between 0.43mm and 0.71 mm through the travel of the gear
Torque the bolts securing the gear reducer mounting plate to the swivel base (164 N.m)
Inspect the backlash again to ensure it is within limit
Bolts securing
the mounting
plate
Adjustment bolts
Backlash

6.3 GEAR REDUCER LUBRICATION

The first lube oil change must be made between 50 and 100 hours of service. Subsequent oil
changes must be made after 2.500 hours of service time or at least once every 12 month.
The oil level should be checked at least once a month. If the gearbox oil level decreases by
more than 10%, the unit should be carefully inspected for leakage. Different types of oil should
not be mixed even if they have the same trademark. It is especially important to avoid mixing
mineral oil with synthetic oil.
The recommended oil for the gear reducer is Shell Omala 220, Grade ISO 220. The total
quantity needed is 6.6 litres.
Oil Level Indicator
Figure 6-3 Gearbox oil reservoir/level indicator
The oil level shall be between the min and the max mark.
ATTENTION:
When checking the oil levels in gear units equipped with a hydraulic motor or both, if the levels
have risen, this means that oil is penetrating from the motor rotary seal.

7 TROUBLESHOOTING:
1. Problem: Excessive backlash in boom rotation
Cause: incorrect pinion adjustment
Solution: Adjust backlash with tolerances has shown in section 6.2
2. Problem: Slow or no movement of all functions
Cause: Inadequate pressure / flow supplied by the hydraulic power unit
Solution: Troubleshoot hydraulic power unit
or
Cause: No electrical command sent to electro-proportional valve
Solution: Try to operate function manually. If it functions correctly, troubleshoot electrical system
3. Problem: Slow or no movement of one function only
Cause: Inadequate pressure / flow supplied at that section
Solution: Try to operate function manually. If functions ok, troubleshoot electrical system
or
Cause: electro-proportional valve faulty
Solution: replace proportional valve and/or electric coil
or
Cause: counterbalance valve bloc faulty
Solution: replace counterbalance bloc assembly and/or valve cartridge
4. Problem: Swivel base reaches the mechanical stop when rotated to maximum
position
Cause: Electrical switches misadjusted
Solution: readjust switches

5. Problem: One function stalls or does not move
Cause: Pressure setting too low
Solution: readjust pressure settings
6. Problem: Cylinder is leaking
Cause: worn or damaged seals
Solution: replace cylinder

8 RECOMMENDED MAINTENANCE INSPECTION PROGRAM:
8.1 Daily Inspection

Verify all lubrication points for proper lubrication.
Check hoses and fittings for proper condition.
8.2 Weekly General Inspection

Verify all points per inspection program, paragraphs 8.1;
Verify that all mechanical equipment are in good working order;
Inspect all bolted connections and tighten as required;
Inspect all lubrication points for proper lubrication;
Verify and inspect any points of excessive vibration or noise during machine operation including
hydraulic power unit;
Inspect hydraulic hoses, piping and connections for leaks and excessive wear. Replace and
tighten as required;
Inspect all hydraulic cylinder pivot points, mountings and rod seals for wear or damage;
8.3 Monthly General Inspection

Verify all points per inspection program, paragraphs 8.1 & 8.2;
Verify oil level in gear reucer and add as required;
8.4 Every Year
Replace oil level in gear reducer
Perform detailed component inspection (visual) for cracks or damage. Report any crack and repair
as required.

9 Safety
9.1 General information

Because the machinery is under operator control at all time, the operator, maintenance people and other
personnel working in the area must be fully aware of machinery safety hazards.
9.2 Personnel Safety
9.2.1 Machine Operator

Before operating machinery, machine operator must pay strict attention to the following:
• that the machine is in good operating condition;
• that all personnel is completely removed from machinery working areas, to avoid injuries from flying
material and debris or accidental injuries from boom movements;
• at no time should the equipment be used as a manlift.
9.2.2 Maintenance Personnel

Before working on machinery:
• Shut off and lock main electrical disconnect switch;
• When working on, or making repairs, ensure that the machinery is securely blocked, locked and is in a
dormant state to insure against movement.

10 Lubrication
To maintain efficient operation and help reduce reparation costs or machine downtime, it is important that the
equipment’s lubrication points be well lubricated on a regular basis.
It is essential that maintenance people get familiar with the equipment’s greasing feature.
Note: We highly recommend the use of anti-seize compound on the pins when replacing or putting them back
in their place.
The boom is equipped an automatic greasing system along with piping and hoses for all articulated joints.
In addition, the hammer has also its own lubricating pump.
10.1 Recommended Grease
All bearings including the slewing ring are to be greased Mobil Temp SHC 600, Grade 32-680.
10.2 Grease Points
Figure 10-1Grease Point Location

11 PART LIST
11.1 BOOM SWING DETAIL
Figure 11-1 Boom Swing Part Diagram

Item QTY Description P/N
1 1 Fixed Base 1106-WPM-M-001
2 1 Pivoting Base 1106-WPM-M-005
3 1 Slewing Ring TR-16 1043-211-906-07
4 2 Planetary Gear Reducer 1043-211-906-04
5 2 Hydraulic Motor 1043-211-906-05
6 2 Pinion Gear 1043-211-921-01
7 2 Pinion gear End Plate (included in item 6)
8 1 Pin T1 1043-T-01
9 2 Pin T3 1043-T-03
10 1 Swing Protection Valve Assembly 1071-212-722-25
13 2 Limit Switch 446-08-606-15
14 1 Hammer Grease Pump (Supplied by other) 86383759 + DP2/3
15 1 Boom Grease Pump 1106-G-001-49
16 18 Neoprene Washer 1043-210-110-02
17 18 Steel Washer 1043-210-110-08
18 1 Neoprene Pad 1043-210-110-11
19 54 Washer 1043-211-927-01
20 2 Rotating Motor Bracket 1106-WPM-M-006
21 2 Oil Expansion Tank / oil level sight glass 1093-TE-M-107-00

11.2 BOOM ARM DETAIL
Figure 11-2 Boom Arm Part Diagram

1 1 Boom Main Arm 1106-WPM-M-007
2 2 Boom Cylinder 8 in Bore, 5 in Rod 1093-G-001-01
3 1 Dipper Stick Cylinder 10 in B0re, 5 in Rod 1043-211-916-02
4 2 Bushing No 1 (T1) 1043-B-1
5 2 Pin T3 1043-T-03
6 1 Pin T9 1043-T09
7 2 Pin T6 1043-T06
8 2 Boom Cylinder Valve Assembly 1071-212-722-24
9 2 Dipper Stick Cylinder Valve Assembly 1071-212-722-25

11.3 DIPPER STICK DETAIL
Figure 11-3 Dipper Stick Part Diagram

1 1 Dipper Stick Arm 1106-WPM-M-009
2 1 Breaker Cylinder 7 in Bore, 4-1/2 in Rod 1043-211-916-03
3 1 Outer Link 1106-WPM-M-012
4 1 Inner Link 1106-WPM-M-011
5 1 Breaker Attachment 1106-WPM-M-010
6 1 Pin T5 1043-T-05
7 2 Bushing No 2 (Pin T6) 1043-B-02
8 2 Pin T4 1043-T-04
9 2 Bushing No 5 (Pin T7) 1043-B-05
10 2 Bushing No 6 (Pin T8) 1043-B-06
11 2 Pin T8 1043-T08
12 2 Pin T7 1043-T07
13 2 Bushing No 3 (Pin T7) 1043-B-03
14 2 Bushing No 4 (Pin T8) 1043-B-04
15 2 Breaker Cylinder Valve Assembly 1071-212-722-25

11.4 HYDRAULIC PIPE AND HOSE DIAGRAM

Pipes are identified by a number while hoses are identified by letters.
Figure 11-4 Piping and Hose Diagram

Figure 11-5 Piping and Hose Detail A
Figure 11-6 Piping and Hose Detail B

Figure 11-7 Piping and Hose Detail C
Figure 11-8 Piping and Hose Detail D

Figure 11-9 Piping and Hose Detail E
Figure 11-10 Piping and Hose Detail F

Figure 11-11 Piping and Hose Detail G
Figure 11-12 Piping and Hose Detail H

Figure 11-13 Piping and Hose Detail I
Figure 11-14 Piping and Hose Detail J

The following table provides the pipe number:

24 1 Pipe 1112-P-002-01-L
25 1 Pipe 1112-P-002-01-R
26 1 Pipe 1112-P-002-02-L
27 1 Pipe 1112-P-002-02-R
28 2 Pipe 1112-P-002-03
29 1 Pipe 1112-P-002-04
30 1 Pipe 1112-P-002-05
31 1 Pipe 1112-P-003-01-L
32 1 Pipe 1112-P-003-01-R
33 2 Pipe 1112-P-003-02
The following table provides the hose part number

Length
in
A-A 41 1 Hydraulic Hose 1093-MV-P-001-A
B-B 41 1 Hydraulic Hose 1093-MV-P-001-B
C-C 32 1 Hydraulic Hose 1093-MV-P-001-C
D-D 32 1 Hydraulic Hose 1093-MV-P-001-D
E-E 88 1 Hydraulic Hose 1093-MV-P-001-E
F-F 82 1 Hydraulic Hose 1093-MV-P-001-F
G-G 88 1 Hydraulic Hose 1093-MV-P-001-G
H-H 82 1 Hydraulic Hose 1093-MV-P-001-H
I-I 64 1 Hydraulic Hose 1093-MV-P-001-I
J-J 64 1 Hydraulic Hose 1093-MV-P-001-J
K-K 51 1 Hydraulic Hose 1093-MV-P-001-K
L-L 51 1 Hydraulic Hose 1093-MV-P-001-L
M-M 51 1 Hydraulic Hose 1093-MV-P-001-M
N-N 94 1 Hydraulic Hose 1093-MV-P-001-N
O-O 94 1 Hydraulic Hose 1093-MV-P-001-O
P-P 30 1 Hydraulic Hose 1093-MV-P-001-P
Q-Q 30 1 Hydraulic Hose 1093-MV-P-001-Q
R-R 93 1 Hydraulic Hose 1093-MV-P-001-R
S-S 81 1 Hydraulic Hose 1093-MV-P-001-S
T-T 81 1 Hydraulic Hose 1093-MV-P-001-T
U-U 81 1 Hydraulic Hose 1093-MV-P-001-U
V-V 89 1 Hydraulic Hose 1093-MV-P-001-V
W-W 89 1 Hydraulic Hose 1093-MV-P-001-W
X-X 89 1 Hydraulic Hose 1093-MV-P-001-X
Y-Y 81 1 Hydraulic Hose 1093-MV-P-001-Y
Z-Z 27 1 Hydraulic Hose 1093-MV-P-001-Z
AB-AB 25-3/4 1 Hydraulic Hose 1093-MV-P-001-AB
AC-AC 46-1/2 1 Hydraulic Hose 1093-MV-P-001-AC
AD-AD 41 1 Hydraulic Hose 1093-MV-P-001-AD
AE-AE 35-1/2 1 Hydraulic Hose 1093-MV-P-001-AE
AF-AF 39 1 Hydraulic Hose 1093-MV-P-001-AF
AG-AG 20 1 Hydraulic Hose 1093-MV-P-001-AG

Length
in
AH-AH 20 1 Hydraulic Hose 1093-MV-P-001-AH
AJ-AJ 151 1 Hydraulic Hose 1093-MV-P-001-AJ
AK-AK 154 1 Hydraulic Hose 1093-MV-P-001-AK
AL-AL 96 1 Hydraulic Hose 1093-MV-P-001-AL
AM-AM 108 1 Hydraulic Hose 1093-MV-P-001-AM
AN-AN 55 1 Hydraulic Hose 1093-MV-P-001-AN
AO-AO 33 1 Hydraulic Hose 1093-MV-P-001-AO
AP-AP 55 1 Hydraulic Hose 1093-MV-P-001-AP
AQ-AQ 52 1 Hydraulic Hose 1093-MV-P-001-AQ
AR-AR 16-1/2 1 Hydraulic Hose 1093-MV-P-001-AR

11.5 BOOM CYLINDER PART DIAGRAM
Item Qty Description P/N

1 1 Rod Assembly RD-1093-001-01
2 1 Tube Assembly TB-1093-001-01
3 1 Head Assembly (Gland) GL-1093-001-01
4 1 Piston Assembly PST-1093-001-01
5 1 Stop Tube BU-103-001-01
6 2 Spherical Bearing SBB64-2RS/Z
7 1 Seal Kit SK-1093-001-01
Figure 11-15 Boom Cylinder Part
11.6 DIPPERSTICK CYLINDER PART DIAGRAM

1 1 Rod Assembly RD-1093-211-916-02
2 1 Tube Assembly TU-1093-211-916-02
3 1 Head Assembly (Gland) GL-1093-211-916-02
4 1 Piston Assembly PST-1093-211-916-02
5 1 Stop Tube BU-1093-211-916-02
6 2 Spherical Bearing SB-1093-211-916-02
7 1 Seal Kit SK-1093-211-916-02
Figure 11-16 Dipperstick Part Diagram

11.7 HAMMER CYLINDER PART DIAGRAM

1 1 Rod Assembly RD-1043-211-916-03
2 1 Tube Assembly TU-1043-211-916-03
3 1 Head Assembly (Gland) GL-1043-211-916-03
4 1 Piston Assembly PST-1043-211-916-03
5 1 Stop Tube BU-1043-211-916-03
6 2 Spherical Bearing SB-1043-211-916-03
7 1 Seal Kit SK-1043-211-916-03
Figure 11-17 Hammer Part Diagram
11.8 HYDRAULIC POWER UNIT PART DIAGRAM
Figure 11-18 HPU Part Diagram


1 2 Electric Motor 75 HP 440/3/60 1093-H-001-01
3 2 Pump Adaptor 1093-H-001-03
4 2 Motor Pump Coupling 1093-H-001-04
5 2 Hydraulic Pump E1008, 40 GPM 1087-622-05
6 2 Temperature Switch TW 2000
7 2 Suction Strainer 2-1/2 in NPT 1043-211-922-10
8 1 Return Filter 1043-211-922-11
9 2 Ball Valve 2-1/2 in 1093-H-001-09
10 1 Level Indicator 343-30-532-08
12 1 Oil Cooler with 2 HP Motor 440/3/60 1093-H-001-12
14 1 Low Level Switch 1083-318-06
15 1 Breather Cap 343-30-532-07
16 1 Inspection Door 446-08-913-19
17 1 Ball Valve ¾ in 446-08-913-18
18 1 Oil Heater 1093-H-001-18
24 1 Pump Combining Block 1071-212-722-28
29 1 Pressure Switch SS1 SPA-2-4M-c-HC
30 1 Dual Pressure Switch SW 2000

11.9 Control Panel CP-01 Part Diagram
Figure 11-19 Control Panel CP-01

3 7 Red Pilot Light 1068-211-340-08
4 1 Blue Pilot Light 1068-211-340-04
5 1 Black Push Button 1068-211-340-07
6 3 Green Pilot Light 800F-3NG
7 1 2 Position Selector Switch 1068-211-340-05
8 1 Red Push Button 1068-211-340-10
9 1 Green Push Button 1068-211-342-10
10 1 Twist to Release Red Mushroom Button 1068-211-343-04
11 1 Power Supply 230 VAC to 24 VDC, 120 watts 1043-211-940-18
12 1 Micrologix 1500 (1764-28BXB+1764-LSP) 1112-E-020-12
13 1 Compact I/O Module 1769-1Q6 1112-E-020-13
14 1 Compact I/O Module 1769-OW8 1112-E-020-14
15 1 Microcontroller MC050-10 1112-E-020-15
23 1 Relay 4DPT 700-HC14Z24 + Base 1043-211-940-21-1 & 2
24 11 Relay 2DPT 24 VDC 1068-211-340-18 & 19
32 1 Heavy Duty Connector 10 Pins 1083-390-30
35 1 End Cap 1769-ECR 1083-E-020-35

11.10 OPERATOR CONSOLE PARTS
Figure 11-20 Operator Console Panel

4 1 Green Push Button 1068-211-342-10
5 1 Red Push Button 1068-211-340-10
6 1 Twist to Release Red Mushroom 1068-211-343-04
7 2 Joystick JS6000 1043-211-930-03
8 1 Heavy duty Connector 6 pins 1083-390-31

11.11 HPU LOCAL CONTROL PANEL JB-01
Figure 11-21 HPU Local Control Panel JB-01

3 2 Grey Push Button 1112-E-022-03

11.12 COMPONENT REMOVAL INSTRUCTION
11.13 ROTATION GEARBOX REPLACEMENT
1. The boom shall be in park position.
2. Electrical power shall be isolated per standard procedure.
3. Remove the hydraulic motor.
Motor mounting bolt
Slack adjusting bolts
Gearbox mounting plate assembly

mounting bolt
4. Install two lifting eyes at location where the hydraulic motor was installed.
Lifting eyes
5. Un-tighten slack adjusting bolts. Remove gearbox mounting plate assembly bolts and lift the unit using
the overhead crane.

6. To remove the pinion gear, remove bolts No 35 and slide out the gear.
7. To re-install the gear, proceed in reverse order. For adjusting the gear, follows instruction detailed in the
TR12 OMM, Section 6.2.
11.14 MAIN BEARING REPLACEMENT
11.14.1 General Instruction

In addition to regular hand tools, an overhead crane to lift and move heavy boom parts and a telescopic boom
to allow personnel to disconnect hoses and remove pins.
To replace the slewing bearing, the boom shall be dismantled in 4 main sub-assemblies:
• The stick
• The arm boom
• The pivoting base
11.14.2 Removal of the Stick

1. The boom shall be positioned so that the stick is in horizontal position such that the end of the stick rest
on the plinth.
2. The hydraulic power unit shall be isolated.
3. With the overhead crane, support the rod end on the stick cylinder with a slink and remove the cylinder
pin. Lower the cylinder and remove the slink.

Overhead Crane
Figure 11-22 Stick Cylinder Pin Removal

4. Disconnect all hydraulic and greasing hoses between the stick and the secondary arm.
5. Install a slink from the overhead crane to the lifting lug of the stick. Install a manual chain block between
the overhead and the end of the stick (with slinks). Adjust the chain block in order to balance the stick.
Lift the stick until load is removed from the pin.
Overhead Crane
Boom Arm
Manual Chain
Block
Hydraulic Hose Links Stick Pin
Stick
Figure 11-23 Stick Removal

6. Remove the stick pivot pin using a puller.
7. Remove and deposit the stick away from the boom.

11.14.3 Removal of the Boom Arm

1. Disconnect all hydraulic and greasing hoses between the boom arm and the pivoting base.
2. Install a slink from the overhead crane to the lifting lug of the boom arm. Install a manual chain block
between the overhead crane and the second lifting lug of the boom arm (with slinks). Adjust the chain
block and the crane in order to balance the boom arm. Lift the arm until load is removed from the pins.
Overhead Crane
Manual Chain Block
Hydraulic Boom Arm

Hose Links
Arm Pin
Manual Chain
Block
Tilting Cylinder Pin (2)
Figure 11-24 Boom Arm Removal

3. Install manual chain block between the boom cylinder rod end and the lifting lug of the pivoting base
(with slings). Adjust the chain block until pressure on the boom cylinder pin is removed. Remove the pin
and repeat for the second cylinder. Leave the cylinders with the boom arm.
4. Remove the boom arm pivot pin using a puller.
5. Remove and deposit the arm away from the boom.
11.14.4 Removal of the Pivoting Base

1. Remove the two gearboxes as per section 11.13.
2. Disconnect all hydraulic and greasing hoses
3. Disconnect the electrical cabling at the junction box
4. Install 4 slinks to raise the pivoting base

Overhead Crane
Mounting bolts (40)
Figure 11-25 Removal of the pivoting base

5. Remove all bolts between the pivoting base and the slewing ring
6. Remove and deposit the pivoting base away from the boom
Overhead Crane
Figure 11-26 Slewing Ring Removal

7. Install two lifting eyes on the slewing ring
8. Remove all bolts between the fixed base and the slewing ring (54)
9. Lift and discard the slewing ring
11.14.5 Installation of the Slewing Ring

To re-install the new slewing ring, proceed in reverse order. New mounting bolts of the slewing ring shall be
used and shall be torqued at 1615 ft-lb (2200 Nm)
Note: We highly recommend the use of anti-seize compound on the pins when replacing or putting them back
in their place.
12 DRAWING LIST
Item Description DWG No

1 Assembly Drawing 1093MV-A-001 and 1093MV-A-003
2 Boom General Arrangement 1093MV-G-001
3 HPU General Arrangement 1093MV-G-002
4 Pedestal Foot Print 1093MV-A-004
5 Hydraulic Schematic 1093MV-H-001
6 Hydraulic Piping 1093MV-P-001
7 Greasing Points 1093MV-P-005
8 Greasing Connection 1093MV-P-006
9 Electrical Schematic 1093MV-E-001 to 1093MV-E-009
10 Electrical Control Panel Layouts 1093MV-E-020 to 1093MV-E-023

APPENDIX: VENDOR MANUALS
1- Brevini Gearbox ED2090
2- Hydraulic Motor DS200
3- Automatic Breaker Greaser M1008-PO
4- Automatic Articulation Pin Greaser Greco G3
5- Electric motor Data Sheets
6- Hydraulic Pump ERR100BLS2520NNN3K5NLAIN
7- Main Valve Manifold EX72_GB_00
8- Temperature and pressure switch Barksdale TW 2000 and SW 2000
9- Pressure Switch SSI SPA-2-4M-C-HC
10- Controller Danfoss MC-050-10
11- Joystick Danfoss JS6000-XY-CAN-HS-N1N-J331-A200N-NRNNNNN
12- Oil Level Switch MP Filtri RLG1 T3 S1A A500

'·, ., '· '· '· '· '· ' ·
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TITLE:
GENERAL ARRANGEMENT
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JUL. 2013 FOR APPROVAL MAB
NO. DATE REVISIONS 8Y
i i
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VALE
.///
PROJECT:
2 BOOMS TR-14 + 2x75HP + V12OO
./
REFERENCES: SEAL:
TITLE:
GENERAL ARRANGEMENT
./
_.,,,,,,. SECTION A-A
DATE: SCALE: DRAWING NO:
JUL. 2013 1 - 40
DRAWN BY: CHECKED: APPROI/ED: 1093MV-A-001-02
MAB MD SR
2/2
11
10
9
8
7
6
5
HYDRAUUC
BOOM TR-14 4
3
2
STEEL SUPPORT
(SUPPLY BY OTHERS)
. 0
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1.
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-3 COVERAGE
\
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-5
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L
-6 L
,¾, 1 APRIL 20141 FINAL DRAWING MCT
\\ -7 & OCT. 2013 1 FOR CONSTRUCTION MCT
11. JUL. 2013 FOR APPROVAL MAB
NO. DATE REVISIONS BY
-8
-9 REACH DIAGRAM
1 - 50
-10
CUSTOMER,
-11
VALE
PROJECT,
2 BOOMS TR-14 + 2x75HP + V12O0
0 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 METER
REFERENCES, SEAL,
TITLE,
REACH DIAGRAM
i � i
DATE: SCALE: DRAWING NO,
JUL. 2013 1 - 50 '1'
DRAWN BY: CHECKED: APPROVED: 1093MV-A-003-02 1
1
�
�
1
1
MAB MD SR LJ
>------2261 mm------1 >-------2000mm-----1
FRONT
F1
911700mm
F1 VERTICAL FORCE 47 KIPS (209 KN)
20· F2 HORIZONTAL FORCE 33 KIPS (147 KN)
1YP.
M1 OVERTURNING MOMENT 701,000 LBS-FT (949,855 N-m)
(18) 070mm HOLES
EQUALLY SPACED ON 02000mm B.C.
M2 HORIZONTAL MOMENT 95.000 LBS-FT (128,190 N-m)
(15) 070mm HOLES NOTE: - THESE FORCES ARE STATlC ONLY. A FACTOR MUST BE AOD FOR DYNAMIC
EQUALLY SPACED ON 01700mm B.C. -i CONSIDERATION (50% MINIMUM)
RFAR RFAR - TENSION ON ANCHOR BOLT: 39 KIPS (173 KN) / EACH
- DESIGNED ACCORDING TO SAFETY FACTOR FOR PEDESTAL = 2
VIEW "A-A" VIEW "B-B" - DESIGNED ACCORDING TO SAFETY FACTOR FOR ANCHORS BOLTS = 4
TR-14 BASE TR-11 EMBEQQEQ PLATE (BASED ON YIELD POINT OF ANCHOR AT 55KSI)
LOADING SITUATIONS
FOR TR-14 BOOM WITH v12OO BREAKER
PIVOTING BASE
1652mm
(18) BOLTS 2 1/2"-NC (GRADE 5 MIN.)
ON 02000mm B.C. FIXED BASE
(SUPPLY BY OTHERS)
F1
NEOPRENE PADS (3/4" or 20mm)
1000mm
F1 VERTICAL FORCE 30 KIPS (135 KN)
"B" F2 HORIZONTAL FORCE 35 KIPS (155 KN) ,0,,
,0,,
M1 OVERTURNING MOMENT 430,000 LBS-FT (583,000 N-m)
& APRIL 2014 FINAL DRAWING MCT
M2 HORIZONTAL MOMENT 70,000 LBS-FT (95,000 N-m) OCT. 2013 VIEW A-A UPDATED MAB
Li', OCT. 2013 FOR CONSTRUCTION MAB
EMBEDDED PLATE
1Zl2138mm x 91914mm x 50mm
SUPPLY BY OTHERS
1 H---- o1700mm -----.jjl
0
oo.é,.
0 0 NOTE: - THESE FORCES ARE STATIC ONLY. A FACTOR MUST BE ADD FOR DYNAMIC JUNE 2013 FOR APPROVAL MAB
0 .Ô.
CONSIDERATION (50% MINIMUM)
6; 0
0 0
oo-6_
0
0
o
,6.
'.:6.:oo
- TENSION ON ANCHOR BOLT: 20 KIPS (90 KN) / EACH
- DESIGNED ACCORDING TO SAFETY FACTOR FOR PEDESTAL = 2
- DESIGNED ACCORDING TO SAFE1Y FACTOR FOR ANCHORS BOLTS = 4
(BASED ON YIELD POINT OF ANCHOR AT 55KSI)
Â
LOADING SITUATIONS
BY OTHERS
FOR TR-11 BOOM WITH BRV-32 BREAKER
VALE
I CUSTOMER:
PIPE 12" STD LONG RADIUS
TO HPU FOR HYDRAULIC HOSES
(BY OTHERS)
PROJECT:
2 BOOMS TR-14 + 2x75HP + V1200
PEDESTAL FOOT PR/NT AND LOADING SITUATIONS REFERENCES: SEAL:
TITLE:
PEDESTAL FOOT PRINT AND LOADING SITUATIONS
DATE:
JUL. 2013
SCALE:
1=25
DRAWING NO:
i
î i
1::).. 1
1 DRAWN BY: 1 CHECKED: 1 APPRDVED: 11093MV-A-004-03 11 � 1
MAB M.D. S.R.
ITEMIOTY DESCRIPTION REMARKS
BOOM CYLINDER, 8" BORE, 5 ROD, 54" STROKE 1093-G-001-01
DIPPERSTICK CYLI NDER, 1O" BORE, 6" ROD, 77" STROKE 1093-G-001-02
BREAKER CYLINDER, 7" BORE, 4 1/2" ROD, 33 1/2" STROKE 1043-211-916-03
PLANETARY REDUCER, TORQUE HUB 1043-211-906-04
HYDRAULIC MOTOR 1043-211-906-05
BREAKER MODEL V1200
BEARING ROTEK 1043-211-906-07
_§_ I 1 IPIN T-1 (o7" X 66 3/8" LG 1043-T-01
.9. I 2 IPIN T-2 (o4" X 21 7/8" LG 1043-T-02
� IPIN T-3 (o4" X 14 5/8" LG 1043-T-03
11 1 1 IPIN T-4 (03 1/2" X 11 3/4" LG 1043-T-04
PIN T-5 (o4" X 25" LG 1043-T-05
05 1/2" X 50 1/8" LG 1043-T-06
REAR FRONT
MUS o3 1/2" X 29 1/8" LG 1043-T-07
l/�6ig��I�;< 41 o4" X 31 7/8" LG 1043-T-08
PIN T-9 {o4" X 11 1/2" LG 1043-T-09
BUSHING #1 (08 1/2 " _ X_o_7•-•-X- 8-"LG 1043-B-01
BUSHING #2 (o7 1/4" X o5 1/2" X 6"LG
"'
1043-B-02
BUSHING #3 (o4 1/2" X o3 1/2" X 3"LG 1043-B-03
FIXED BASE BOOM
BUSHING #4 (o5" X o4" X 5"LG 1043-B-04
BUSHING #5 (04 1/2�2" X 5"LG 1043-B-05
L/BZ BUSHING #6 (05 1/2" X o4" X 6"LG 1043-8-06
ISPACER #1 (04 1/2" X 03 1/2" X 2 3/4" LG 1043-E-01
@g@@ BOLT SOCKET HEAD 3/8"-16NC X 3" LG PL, GR. 8
MECANICAL STOPPER BOLT SOCKET HEAD 3/8"-16NC X 5 1/2" LG PL, GR. 8
26 1 8
IBOLT 1/2"-13NC X 2" LG + LW PL, GR. 5
27 1 20
IBOLT 5/8"-11NC X 1 3/4" LG + LW PL, GR. 5
28 1 4
ISOUARE HEAD BOLT 5/8-11 NC x 4" LG, FULLY THREADED PL, GR. 5
,.
SECTION "A-A 29 1 8
INUT 5/8"-11NC PL, GR. 5
30 1 7
IBOLT 3/4"-10NC X 1 1/4" LG PL, GR. 5
RQTATING MQIOB BRACKET 31 1 4
IBOLT 3/4"-10NC X 1 1/2" LG PL, GR. 5
32 1 24
IBOLT 3/4"-10NC X 1 1/2" LG PL, GR. 8
33 1 4
IBOLT 3/4"-10NC X 2" LG PL, GR. 5
34 1 2
ISOUARE HEAD BOLT 3/4"-10NC X 3 1/2" LG, FULLY THREADED PL, GR. 5
35 1 8
36 I 10
INUT 3/4"-10NC PL, GR. 8
]_7 1 11
IFLAT WASHER 3/4" WIDE, PLATED
38 1 8
IFLAT WASHER 3/4" PLATED
F I XED BASE 39 1 36
ILOCK WASHER 3/ 4• PL, GR. 5
40 1 2
IBOLT 1"-8NC X 3 3/4" LG + LW PL, GR. 5
41 1 94
IBOLT 1 1/4"-7NC X 5" LG + FW (A-325 PL, GR. 8
ROTATION DETAIL 42 1 54
IWASHER o 1 3/8" INT. x O 2 1/2" EXT. x 1 3/8" 1043-211-927-01
5738MM 43 1 1
IBOOM GREASE PUMP 1093-G-001-42
(18'-10") SCALE: 1 :12 44 I 2
IPINION GEAR 1043-211-921-01
45 1 1
IHAMMER GREASE PUMP 86383759 + DP2/3
MUST 46 I 2
IBOOM CYLINDER MANIFOLD 1071-212-722-24
±Z 1 2
!STICK & BREAKER MANIFOLD 1071-212-722-25
48 1 8
8
ILOCK WASHER 5/16" PLATED
QUANTITIES IN BOM ARE FOR ONE ASSEMBLY ONLY.
2936MM
(9'-7")
DIPPERSTICK
OIL EXPANSION TANK @3 L.
L.
,&. APRIL 2014 F I NAL DRAWING MCT
1632MM & OCT. 2013 GENERAL REVISION MAB
(5'-4") & SEPT 2013 FOR CONSTRUCTION MAB
5499MM
(18'-1/2") JUNE 2013 FOR APPROVAL MAB
l ••"'tlJJ\ILld\U'0) ."
&,.
REVISIONS
C
NO. DATE BY
�eern,
SEE ROTATION DETAIL BY OTHERS
f------------------------------------- 12141MM
' -------------------------------------+---------
(39 -10") CUSTOMER:
PROJECT:
VALE
2 BOOMSTR-14 + 2x75HP + V1200
REFERENCES: SEAL:
TITLE:
GENERAL ASSEMBLY GENERAL ASSEMBLY
1/2" - 1'-0"
OTY: 2
1---------------------1,
1 DATE, SCALE, 1 DRAWING NO: li
BOOM ASSEMBLY WEIGHT: 24 102 KG JUNE 2013 1 1/2" - 1'-0"
BREAKER V-1200 WEIGHT: 1 601 KG
1093MV-G-001-03 1
'
MAB M.D. SR
DRAWN BY: 1 CHECKED: 1 APPROVED:
DRAIN FOR
OIL RETENTION PAN
2505mm (98 5/8")
799mm (31 7/16")
813mm (32")
LIFTING EYE 050mm (2") 752mm (29 5/8")
737mm (29") CAPACITY: 2625 KG
f---------72" --------j 12
16 LJ
1 1
1 1 FOR ITEM NUMBER, REFERE□ TO DRAWING. 1093MV-H-001-00
1 1
1 1 1 756mm (29 3/4")
1 1 1
1
2373mm (91 1/16") 1 1 1 I
1 868mm (34 3/16")
Il
--W
�':::cl-::::'/' 1
tJll!I
1
Il
,g 1
L ___ � j
Il 1
�=ccct==�J
j 2316mm (91 3/16")
1656mm (65 3/16")
,6.
,6.
,6.
� APRIL 2014 FINAL DRAWING MCT
Il
___ JI.._ & OCT. 2013 FOR CONSTRUCTION MAB
.&. JUNE 2013 FOR APPROVAL MAB
4) HOLES FOR ANCHOR BOLT 05/8"
>---------- - 2734mm (107 5/8") ------------<
>--------2038mm (80 1/4")-------, >--------- 2505mm (98 5/8") ---------j
(CENTER TO CENTER FOR ANCHOR BOLT) (CENTER TO CENTER FOR ANCHOR BOLT)
>---------2297mm (90 7/16") ---------<
DRAIN FOR
OIL RETENTION PAN
CUSTOMER:
PROJECT:
2 BOOMS TR-14
REFERENCES: SEAL:
POWER UNIT ARRANGEMENT TITLE:
POWER UNIT ARRANGEMENT
3/4" - 1'-0"
WEIGHT: 2100 KG DATE CALE , DRAWING NO
1
TANK CAPACITY: 300 GALLONS (1135 LITERS) 1 .� ' 1
JUNE 2013 3/4 - 1 -0" 1 �
;!,_
DRAWN BY: 1 CHECKED: 1 APPROVED: 1093MV-G-002-02
MAB MD SR
ITEMIQTY. DESCRIPTION PART NUMBER
2 ELECTRICAL MOTOR 75 H.P. 1750 R.P.M. 1093-H-001-01
440,"3,"60 TEFC FRAME 364,"5T C FLANGE
SERVICE FACTOR 1.25
2 - ITEM REMOVED
MP 3 2 PUMP ADAPTOR 1112-H-001-03
1-1/2" 4 2 MOTOR/PUMP COUPLING 1112-H-001-04
LS
(BY OIHERS) 5 2 HYD. PUMP,MODEL E100B,40GPM@1475RPM 1087-622-05
3/8" 6 2 TEMPERATURE SWITCH, TWO INDEPENDANT ; 1093-H-001-06
(11'1' OIHERS) WITH BULBWELL ; 1093-H-001-06B
7 2 SUCTION STRAINER 2 1/2"-NPT ; 1043-211-922-10
CONNECTION POINT CONNECTION POINT
8 1 RETURN FILTER WITH PRESSURE GAGE 1093-H-001-08
1-1/2" SAE CODE 61 SPLIT FLANGE 3/8" SAE 37' (JIC) FLARE (MALE)
9
PORTS 2" CODE 61 1093-H-001-0BE
2 BALL VALVE 2-112"-NPT 1093-H-001-09
10 1 LEVEL INDICATOR 343-30-532-08
-----------------------------7
11 - ITEM REMOVED -
12 1 OIL COOLER WITH MOTOR 440/3/60 #1093-H-001-12
2HP AND 1500RPM
uNn / 1/2" 2"
13
14
-
1
ITEM REMOVED
LOW LEVEL SWITCH 1083-318-06
powER
/ 3/8"
f.lP GPP LS \(BY OIHERS) \ (BY OIHERS) (BY OIHERS) 15 1 BREATHER CAP 343-30-532-07
D
16 2 INSPECTION DOOR ol18" 446-08-913-19
GPPI ' - - - - - - �1� - - - - - - ' - - - - - - - - - - - - - - - - - - - - - - - - - - - 7 1 1 17 1 BALL VALVE 3/4" -NPT 446-08-913-18
'f'
✓,,-
1 1 18 1 OIL HEATHER 1093-H-001-18
19 1 MONOBLOC VALVE POST CONPENSATOR 1071-212-722-23
DRAIN 1 'DRAIN 2 R1 20 2 BOOM CYLINDER MANIFOLD 1071-212-722-24
18) 1 1 21 1 STICK CYLINDER MANIFOLD 1071-212-722-25
1�,,_1 1 1 22 1 BREAKER CYLINDER MANIFOLD ; 1071-212-722-25
1
ST.fil)S_J
' 1 1
23 1 SWING PROTECTION MANIFOLD ; 1071-212-722-27
J
0
1 1
CONNECTION POINT 24 1 PUMP COMBINING BLOCK ; 1071-212-722-28
CONNECTION POINT I I CONNECTION POINT
25 2 CHECK VALVE 1112-H-001-25
1
' 25 1/2" SAE 37' (JIC) 3/8" SAE 37' (JIC) 1 1/2" SAE CODE 61
FLARE (MALE) 1 FLARE (MALE) 1 SPLIT FLANGE 26 2 CAVITY PLUG
1
1 1 27 2 SHUTTLE VALVE
'
L_
1 1 28 1 BREAKER GREASE PUMP
j
MP1 P1
L_______
1 1
l.S1 IL.S2 P2 MP2 1 1
____________ ___________
1
1
1
1 1/4" ..
-7 -7
1
1
1
1
-�
1
� � �---------------�
� �
�- �\f��--=-�-
12
lM2
�M4 75HP 1750 RPM �__.c---- IM4
L '
75HP 1750 RPM � ,-.- - - -
-
100 CC MAX 40GPM 1 100 CC MAX 40GPM
LS MAX STOP AJUSTABLE L2 LS MAX STOP AJUSTABLE L2
PLEASE SEE NOTE #1
ADJUST RELIEF VALVE TO 2850 PSI
C ,
s
"' PLEASE SEE NOTE #1 l
ÎL1
I ADJUST RELIEF VALVE TO 2850 PSI
-
'
"'
------<>---
I L1
------7 NOTE 1 :PRESSURE RELIEF VALVE OR SIMILAR SYSTEM CONTROL
AT THE PUMP OUTLET IS INCLUDED
ADJUST STANDBY PRES. TO 400 PSI ADJUST STANBY PRES. TO 400 PSI
/ NOTE 2:ALL SECTION PORT (A AND B) ON HYDRAULIC VALVE
l 1/2" /\ ) ARE 1" FLANGE PORT CODE 62
î L_1_:-. 11/2" NOTE 3:DESIGN OPERATING PRESSURE AT 3000 PSI /\
DESIGN RETURN PRESSURE AT 500 PSI L_1_:-.
&
,,ç:y?
1
2 1/2" 2 1/2"
1
NOTE 4:ALL HOSES MUST BE SAE1OOR12, EN 856 TYPE R12
14
1
1 18 NOTE 5:INTERCONNECTING HOSES BY OTHERS
1
8 22 PSI
20'C(HEATHER) l@I
�� 85'C(ALARM)
1
1@1
1
::---... 1s·c(ALARM) 1[!1'2...'.!_�
�-i BO'C{COOLER) l�.ia;,j
1 !!'�� l':,.
l':,.
& APRIL 2014 FINAL DRAWING P.L.
[IJ g g Li NOV 2013 PRESSURE VALUE MODIFIED P.L.
� &
300 GALLONS (1135 LITERS) &
NOV 2013 FOR CONSTRUCTION P.L.
� & OCT 2013 FOR APPROVAL P.L.
16
17
VALE
CUSTOMER:
PROJECT:
BOOM TR-14 & HPP-150 WITH BREAKER V1200
REFERENCES: SEAL:
HYDRAULIC SCHEMATIC TITLE:
HYDRAULIC SCHEMATIC
n
DATE:
OCT 2013
SCALE:
1/2" - 1 ·-0·
DRAWING NO: i
'1'
! i
DRAWN BY: CHECKED: APPROVED: 1093MV-H-001-03 1 � 1
1/2
1 � 1
PL MD SR 1- 1
STICK TILT
'¾{:::::] '¾{:::::] HYQRAULtc
(1) CYLINDER
BO R E: 10"
ROD: 6"
(1) CYLINDER
BO R E: 7"
ROD: 4 1/2"
1093MV-E-001 1093MV-E-001
BREAKER
ST ROKE: 77" ST R OKE: 33 1/2" V1200
32/45 GPM @ 2250 PSI
36 ADJUST TO
� 1300PSI
ADJUST TO ADJUST TO
2300PSI 1300PSI
ADJUST TO
1400PSI
36
1"
-
W:i:
0
00 -
W:i
0
00
"-u "-u PIPE 1-1/4"
CL(/)
1 CL(/)
1
0 0 SCH.160
- 00 - 00 '>------,
w :i W:i: 1"
"-u "- u 1-1/4"
CL(/)
1 CL(/)
1
· '
'..,.
L__________..,1"''---�
·
-�
.
0
L________/1••>---- -�-
1
w1 :i
- &l - &l
9'cu
a_(/)
';._
i i
PIPE 1" -
0
00
SCH.80 w :r: w :i w w :r:
9ccu a_ u a_ 9cc u
1 a_ (/) ·CL 1(/) CL a_ (/)
1 3/8"
PIPE 1" PS1
CH.BO
1" 1" 1" 1" 1" 1" 3/4" 3/4" 1-1/2"
19 BREAKER GREASE PUMP
B. {J_
,--
ADJUST RELIEF VALVE
TO 3200PSI
M�--------+--tf-----+-----+--+--t----+----+-+-+----+----+-++----+-----+-++----t----+-+--------�
----------7 CLOSE CENTER
NOTE 1:P RESSU RE RELIEF VALVE O R SIMILAR SYSTEM CONT R OL
,. AT THE PUMP OUTLET IS INCLUDED
., NOTE 2:ALL SECTION PO RT (A AND B) ON HYD RAULIC VALVE
'
--,
1
*
1
1
r--irr=r
'1
*
1
1
'
-,
1
*
1
1
-,
'1
*
1
A R E 1" FLANGE PO R T CODE 62
NOTE 3:DESIGN OPERATING PRESSU RE AT 3000 PSI /\
&
DESIGN R ETU RN P RESSU RE AT 500 PSI L__1___',
---i
L-T-J L-T-J L-T-J L-T-J
-
*
1 1 1 1
---j
NOTE 4:ALL HOSES MUST BE SAE1OO R12, EN 856 TYPE R 12
-Î-j
li
CONNECTION POINT
1 1 1 1 NOTE 5:INTE R CONNECTING HOSES BY OTHE RS
3/8" SAE 37" (JIC) FLA RE (MALE)
IPP
3/8"
(BY OlHERS)
(
LS
_ ___ L -- Jl!_____
t-----+-t--�---t-------+->--,__----,j-------o--;>--t----,;-------.--,-t---------o-+�,________..-_
-- Jl!_____ ___Jl!_____ ___Jl!_____ ---- I""
I
Ll (_____ 7
--..__l,'------ --'-------+
l':,,
1 T ---
CONNEC TION POINT I �-----+--�--------�-------A-----�-------<i------�--------�---------�------� 1-1/2" ( l':,,
1-1/2" SAE CODE 61 SPLIT FLANGE p ADJUST TO ADJUST TO ADJUST TO 1
: 2200PSI 1500PSI 2200PSI 1 ,& APRI L 2014 FINAL DRAW ING P.L.
I
MP
•
1 1 1 & NOV 2013 P R ESSU RE VALUE MODIFIED P.L.
(BY OlHERS) "
1-1/2" ('
&, NOV 2013 FOR CONSTR UCTION P.L.
1
1
1
1
1
� OCT 2013 FO R APP R OVAL P.L.
1
1 �------------------------------------------------------------------------------------------------------------------JIL-----� NO. DATE R EV ISIONS BY
1
1 1 R1
1 1
1 i CONNECTION POI NT 1 CONNECTION POINT
CONNECTION POINT
2 E JIC) LAR (MA 3/8 (MAL 2" SAE CODE 61 SPLI T FLANGE
/
r
:� '
L---�--� �_: _ : � �:
_________________________________________________________ �:-=-�:::_ E� -----
t
1 1
1 1 (BY 01HERS)2"
D R AI N 1 D R AI N 2
1
--------i;�,,----------------_
VALE
CUSTOME R:
_J
(BY OlHERS)
1/2" PROJECT:
HYDRAULIC SCHEMATIC
(BY OlHERS) BOOM TR-14 & HPP-15O WITH BREAKER V12OO
REFERENCES: SEAL:
TITLE:
HYDRAULIC SCHEMATIC
DATE: SCAL.E: ORAWING NO:
OCT 2013 3/4" - l -0"
11093MV-H-001-03
'
DRAWN BY: CHECKED: APPROVED:
� 1
� 1
� 2/2
ITIM NOJQlY. UNE NO.
1093MV-P-001-01
CONNECTION LENGTH UNE NO,
2 1093MV-P-001-02
A-A 41 IN 1093MV-P-001-A 3 1093MV-P-001-03
4 1093MV-P-001-04
B-B 41 IN 1093MV-P-001-B 5 11 l1093MV-P-001-05
3 11093MV-P-001-06
C-C 32 IN 1093MV-P-001-C 1 11093MV-P-001-07
3 l1093MV-P-001-08
D-D 32 IN 1093MV-P-001-D
1093MV-P-OO1-09
E-E 88 IN 1093MV-P-001-E 10 2 l1093MV-P-001-10
11 2 11093MV-P-001-11
F-F 82 IN 1093MV-P-001-F 12 26 l1093MV-P-001-12
13 8 l1093MV-P-001-13
G-G 88 IN 1093MV-P-001-G
14 8 l1093MV-P-001-14
H-H 82 IN 1093MV-P-001-H 15 3 l1093MV-P-001-15
16 1093MV-P-001-16
J-J 64 IN 1093MV-P-001-J 17 1093MV-P-001-17
K-K 64 IN 1093MV-P-001-K
18 1093MV-P-001-18
19 3 l1093MV-P-001-19
L-L 51 IN 1093MV-P-001-L 20 2 11093MV-P-001-20
21 2 11093MV-P-001-21
M-M 51 IN 1093MV-P-001-M
22 2 11093MV-P-001-22
N-N 94 IN 1093MV-P-001-N 23 2 l1093MV-P-001-23
24 2 l1093MV-P-001-24
0-0 94 IN 1093MV-P-001-0 25 4 l1093MV-P-001-25
P-P 30 IN 1093MV-P-001-P QUANTITIES fN THE LIST ARE FOR QNLY ONE ASSEMBL,Y
Q-Q 30 IN 1093MV-P-001-Q
R-R 93 IN 1093MV-P-001-R
s-s 81 IN 1093MV-P-001-S
T-T 81 IN 1093MV-P-001-T
u-u 81 IN 1093MV-P-001-U
13
V-V 89 IN 1093MV-P-001-V
w-w 89 IN 1093MV-P-001-W
X-X 89 IN 1093MV-P-001-X
Y-Y 81 IN 1093MV-P-001-Y
z-z 27 IN 1093MV-P-001-Z
AB-AB 25 3/4 IN 1093MV-P-001-AB
AC-AC 46.5 IN 1093MV-P-001-AC 1/8" - 1"
AD-AD 41 IN 1093MV-P-001-AD
AE-AE 35 1/2 IN 1093MV-P-001-AE
AF-AF 39 IN 1093MV-P-001-AF
6
6
AG-AG 20 IN 1093MV-P-001-AG
6
AH-AH 20 IN 1093MV-P-001-AH
L'.Î':. 1 APRIL 20141 FINAL DRAWING MCT
AJ-AJ 151 IN &:,. 1 NOV. 2013 1 POUR CONSTRUCTION MCT
1093MV-P-001-AJ
AK-AK 154 IN 1093MV-P-001-AK
AL-AL 96 IN 1093MV-P-001-AL
AM-AM 108 IN 1093MV-P-001-AM
AN-AN 55 IN 1093MV-P-001-AN
AO-AO 33 IN 1093MV-P-001-AO
CUSTOMER:
VALE
AP-AP 55 IN 1093MV-P-001-AP
AQ-AQ 52 IN 1093MV-P-001-AQ PROJECT:
2 BOOMS TR-14 + 2X75HP + V1200
AR-AR 16 1/2 IN 1093MV-P-001-AR REFERENCES: SEAL:
HYDRAULIC PIPING ASSEMBLY
q
TITLE:
Il o
3/8" - 1'-0"
TR-14
DATE: 1 SCALE: 1 DRAWING NO:
�
1093MV-P-001-01
NOV. 2013 3/8" - 1'-0"
DRAWN BY
"'
a,
CHECKm APPROVED
MCT MAB
1 /2
2X
24
'9
DETAIL "A"
DETAIL '"B"
1" = 1'-0"
3/4 " = 1'-0"
DETAIL ·c·
3/4" - 1'-0"
DET AIL
3/16" =
"Q"
1"
Z 116
VIEW •H-H"
1/4" - 1"
(IN BACK OF THE BOOM)
VJEW "G-G
,.
1/4" - 1"
(IN FRONT OF THE BOOM) SEE�
SEE�
SEE i1EilllL..I
RETURN VALVE ADAPTER
z l 13
DETAIL •E"
3/16" - 1"
Q
6
6
6
6
13)
I _.,.\.---f' 1 I 1& APRIL 2014 FINAL DRAWING MCT
&. NOV. 2013 POUR CONSTRUCTION MCT
NO. DAlE REVISIONS BY
"G"
SWING BLOC
VALVE
DETAIL E CUSTOMER,
1/8" - 1"
VALE
PROJECT,
2 BOOMS TR-14 + 2X75HP + V12OO
REFERENCES, SEAL,
HYDRAULIC PIPING ASSEMBLY TITLE,
3/8" - 1 '-0"
TR-14 0
0
DAlE: SCALE: DRAWING NO, 1
NOV. 2013 3/8" = 1 '-0"
1093MV-P-001-01
1
::,
0
MCT MAB
2/2
.
ITEM QU. DESCRIPTION REMARQUES
1 1 PUMP & RESERVOIR ASSEMBLY 1106-G-001-49
2 1 MASTER DIVIDER VALVE 1093-P-005-02
3 1 SECONDARY DIVIDER VALVE H1 1093-P-005-03
4 1 SECONDARY DIVIDER VALVE #2 1093-P-005-04
5 2 PERFORMER INDICATOR, RESET-TYPE 2000 PSI 1093-P-005-05
6 1 LOW LEVEL ALARM 1093-P-005-06
7 1 ELECTRICAL POWER 1093-P-005-07
B 1 CYCLE SWITCH 1093-P-005-08
QUANTITIES ARE FOR ONE ASSEMBLY ONLY.
0
A--\-® 20T @- -------A
A--\-® 20T @- -------A
A- I@ 20T@ -A
@ 10S@- ------- E
@ 40S@ -e
K- @ 20T @
@ 10T@ -c
K--- - @ 20T @
-
•@ 10T@--------o (2Ys
K- @ 20T @
a--- - @ 40T @
@ 15S @t -M
8
0 0
@ 40S @
20S @
20S @
0 !:,,
!:,,
!:,,
!:,,
!:,,
GRACQ G3
& 1 APRIL 20141 FINAL DRAWING MCT
0.25 CUBIC INCH/SHOT NO. OATE REVISIONS BY
5 MIN/7 CYCLE
, �_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_-_ }
-
ELECTRICAL POWER
MAX 2000 PSI
VALE
CUSTOMER:
2 BOOMS TR-14
PROJECT:
REFERENCES: SEAL:
LUBRIFICATION SHEMATIC TrrLE:
LUBRIFICATION SHEMATIC
APRIL 2014 1/2" - 1 '-0"
DRAWN BY, 1 CHECKEO, 1 APPROVED: 1 1093MV-P-005-00
MCT PL SR
ITEM NO QTY. UNE NO. CONNECTION LENGTH UNE NO.
1 7 1093MV-P-005-01 A1-A1 28" 1093M'I-P-005-A1
A2-A2 28" 1093M'I-P-005-A2
2 45 1093MV-P-005-02 B1-B1 42" 10931.1'1-P-005-81
C1-C1 30 112" 1093MV-P-005-C1
3 1 1093MV-P-005-03 D1-D1 60" 1093MV-P-005-01
E1-E1 - ITEM CANCELLEO
4 6 1093MV-P-005-04 E2-E2 - ITEM CANCELLEO
F1-F1 95 1093MV-P-005-F1
5 2 1093MV-P-DD5-05 F2-F2 95" 1093MV-P-005-F2
6 2 1093MV-P-005-06 G1-G1 23" 1093MV-P-005-G1
H1-H1 23" 1093MV-P-005-H1
7 8 1093MV-P-DD5-07 H2-H2 22" 1093MV-P-005-H2
H3-H3 ?1" 1093MV-P-005-H3
8 1 1093MV-P-005-08 H4-H4 61" 1093MV-P-005-H4
H5-H5 18" 1093MV-P-005-H5
QUANTITIES IN THE LIST ARE FOR ONLY ONE ASSEMBLY H6-H6
H7-H7
57"
20"
1093MV-P-005-H6
1093MV-P-005-H7
HB-HB 52" 1093MV-P-005-HB
H9-H9 20" 1093MV-P-005-H9
J1-J1 41" 1093M'I-P-005-J1
J2-J2 44" 1093M'I-P-005-J2
J3-J3 46 1 /2" 10931.1'1 P 005 J3
J4-J4 48 1/2" 1093M'I-P-005-J4
K1-K1 25" 1093MV-P-005-K1
K2-K2 66" 1093MV-P-005-K2
K3-K3 50" 1093MV-P-005-K3
K4-K4 34" 1093MV-P-005-K4
MI-M1 56" 10931.1'1-P-005-MI
M2-M2 60" 1093M'I-P-005-M2
N1-N1 52" 10931.1'1-P-005-NI
N2-N2 52" 1093M'I-P-005-N2
N3-N3 53" 1093M'I-P-005-N3
N4-N4 51" 1093M'I-P-005-N4
N5-N5 41 10931.1'1-P-005-NS
� N6-N6
P1-P1
46"
42"
1093MV-P-005-N6
1093M'I-P-005-P1
P2-P2 43" 1093MV-P-005-P2
P3-P3 44" 1093MV-P-005-P3
P4-P4 149" 1093M'I-P-005-P4
P5-P5 82" 1093M'I-P-005-P5
P6-P6 43" 1093M'I-P-005-P6
P7-P7 40" 1093M'I-P-005-P7
PB-PB 37" 10931.1'1-P-005-PB
P9-P9 38" 1093MV-P-005-P9
P10-P10 39" 1093MV-P-005-P10
P11-P11 1?0" 1093MV-P-005-P11
P12-P12 121" 1093MV-P-005-P12
1· - 1'-o· P13-P13 70" 1093M'I-P-005-P13
01-01 17 1/2" 10931.1'1-P-005-QI
R1-R1 - ITEM CANCELLEO
R2-R2 - ITEM CANCELLEO
S1-S1 148" 1093MV-P-005-S1
S? -S? 1SO" 1 nn,.., -P--OOS -S?
QUANTITIES IN THE LIST ARE FOR ONLY ONE ASSEMBLY
1" - 1'-0"
6
6
6
6
LJ'; 1 APRIL 20141 FINAL DRAWING MCT
&,, 1 NOV. 2013 1 FOR CONSTRUCTION MCT
GREASE PIPING ASSEMBL Y CUSTOMER:
3/8" - 1 '-0"
QTY, 2
VALE
PROJECT:
2 BOOMS TR-14 + 2X75HP + V1200
REFERENCES: SEAL:
TITLE:
GREASE PIPING ASSEMBLY
Il!
SECTION •A-A•
1/8" - 1'-Q" DATE: SCALE:
<D
1093MV-P-006-01
NOV. 2013 3/8" - 1 ·-0·
MCT MAB
1/3.
SEE DETAIL "E" SEE i,ETAJL'.'.E'.
C1
©
L VIEW
3/4" = 1'-0"
c-c
BRACKET FOR 1 HOSE
DETAIL
1" =
"a"
1'-0"
�
BRACKET FOR 1 HOSE
SECONDARY DIVIDER VALVE
DETAIL "C: SECTION "D-D"
3/4" = 1'-0"
1/8" = 1"
NOTE: LINKS AND BREAKER ATTACHEMENT
ARE NOT SHOWN FOR CLARITY
,.
DETAIL "E
1" = 1'-0"
�c
t:,.
t:,.
1" = 1'-0"
t:,.
HOSE CONNECTE□
t:,.
TO BREAKER
(GOMES WITH "G" Lr,, 1 APRIL 20141 FINAL ORAWING MCT
THE BREAKER)
.&, 1 NOV. 2013 1 FOR CONSTRUCTION MCT
1/2" = l'-o·
Id =1 c4 C71 r----, '== '= bl �
"G" CUSTOMER:
GREASE PIPING ASSEMBL Y VALE
3/8" - 1'-0"
PROJECT:
2 BOOMS TR-14 + 2X75HP + V12OO
REFERENCES: SEAL:
TITLE:
=
11093MV-P-006-01
NOV. 2013 3/8" 1'-0"
1 DRAWN BY I CHEC�rn. 1 APPROVED
MCT MAB
2/3:-
BOOM GREASE
PUMP
1
/
� 13! 6
3/8" = 1"
"K" "K"
"J"
SECTION "!-/" SECTION "J-J"
3/4" = 1·-0·
VIEW "G-G" 3/4" = 1'-o·
1· - 1'-0"
..EBQt::/I
,6,
,6,
,6,
,6,
& APRIL 20141 FINAL DRAWING MCT
& NOV. 2013 1 FOR CONSTRUCTION MCT
1/2" - 1"
SECTION "H-H"
3/4" = 1'-0"
..BfM
CUSTOMER:
SECTION "K-K" VALE
3/4" = 1'-o·
PROJECT:
2 BOOMS TR-14 + 2X75HP + V1200
REFERENCES: SEAL:
TITLE:
GREASE PIPING ASSEMBL Y 1------....------....--------------11 <D
3/4" = 1'-0" DATE: SCAL.E: DRAWING NO: 8
1093MV-P-006-01 �
NOV 2013 3/4" = 1 '-0" d_
DRAWN 0BY CHECKED APPROVED
MCT MAB
3/3.
MOUNT INSIOE OF CRUS ER CONTROL ROOM
DESCRIPTION
H
r--------------------------------------------------- ------------7
1
1
ITEM QU.
1 ? UMIT SWITCH
UMIT SWITCH LEVER
REMARQUES
·�
3 2 JOYSTlCK WITH �BUS COMMUNICATION 043 21 930 03
� 1 OPERATOB'S CONSOLE 2 2 ""-M-•n•-1!<�
1
a
MULTI-POINT LEVEL SWITCH 1043 211 922 ·18
1 4
R ? Hl" n TEMPERATURE SWITCH
(0 1 r--------------------, " 1
Q PROPORTIONNAI. VALVE COil HYDROCONTROL
1 1 l'Il
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l"3E'1 _c-_lV\t-nA
1
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7
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1
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COMPONENT LAYOUT IS
FO R EXAMPLE ONLY
1
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ü
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:
1
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18 COND. f18 (30M) 1
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0 1 1 1
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1 1 1 1 ------------- ]!..._00,�!�---------- FOR
1
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1
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1
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e
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1
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1
1
I
I
1
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1
1
:
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1
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1,
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1
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' 1
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n 1 440 VAC /V[J 3 �H
PH7èeo HZ 1 1 1 SWING RIGHT I
1
1 1 ZS-02
1 C 01 '-----' 1
if"'
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I
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20 COND. J16
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'L H I 1
=
1
-------- OIL OOLER '-----' ZS-0 8
440 VAC/ 2HP/ 3PH; 60HZ 1 1 LP-o,;c-01 r---7 1
1
1
--
�--------__D
-0 180 R.P.M. 1 1 P I PIIC, 3 CONO. #16 1
ooM GREASEI
** NOTE **
I PUMP 1
I P1 1 - CABLE BY VENDOR
1
1 I 24 VOC 1
1 (5) I ,_, - 1 1 LP-01 - - - - CABLE BY OTH ER
1 L__ J I
1 r---_,/'"" �l PIIC, if ë8�6'. i�J 1 � i�G�
1
: LOW OIL.LS� � 1 �.-�{:ON 1 C-01 H 1
D. 116 I Ô_JI LS L-02
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: 1
1 (ALARM) 1 -01 C-01 L ---
r 1
1
6 1
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�
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I
�i� APR 2014 FINAL DRAWING
L J
1 HIGH TEMPE RATURE SW ITT/,� lSH-01 C-01 sv-02/c-01 r===,
',@s .oPIIC 4 {OND. 116 PIIC 2 CONO. ·,1e n...lV'� SWING RIGHT NOV 2 013 GENERAL REVIEW
IA
MAJ
I lSH-
1 1 L�/V"J SV-02 OCT 2013 AOD PS-01 ML
MAJ
1 1 SP1:85"C 1 SV-03/C-;01 r===,
PIIC, 2 CONO. •16 0-X--0 ��IN OCT 2013 FOR CONSTRUCTION ML
1 1 ALARM I 1
1
1 i SPbf°CI L J
SV-04/C-;01 r---
r----------,
I - 1 ---, JULY 2013 FOR APPROVAL ML
1 1 NEMA lYPE 4 1 PI/C, 2 CONO. •16 0-X--0
181
1 L<:..��J � 1 �-C� OUT '"'· 1
1 1 L---J REVI SIONS
i@s r�.
1 r---,
1 1
1 LOW TEM PE RATURE �� lSL-01 C-01 PIIC, fë8�6. 1�J r,:,v:::::;... BOOM UP
IMlE
1
BY
4/CONO. #18
L�/V"J SV-05
I
J 1
c
1 JUNCTlON BOX 1 SV-08 C-01 r===
1 1 1 16 COND.:...fl!I____
1-------
Is PIIC, 2 CON[ l16 n...lV'�I �� DOWN
1 1 a I 6
1 1 wii; 1 L�J
I P I
0
1 sP2:2crc1 SV-07/C-;01 r---,
c1
1 l'== ==IIIF=' 1 P11C 2 CONO. •16 o-X-o i ;\0-.! �
: o
L��J L___J
I L __:-____�___ J sv oetc-01
P11C 2 CONO. 116
'IIIF
.¾,_ PRESSURE �� 1 :*-J ;\0-.!oSllT
: PS PS-01/C-01
SV-096.C-01 r---,
1r0---7
I 1 PIIC, 4 COND. f18
1 PIIC, 2 CON . 116 0-X--0
1 �MiER
I
CUSTOMER:
1 L----..( -· ••
1
'7'
1
1
L�Jfe
---
1
L _____________________________________ J
TRAMAC VALE P OJ CT:
r rPDSH-01/C-01
�
1 RETURN FILTER
R E
G-f"°O I PIIC, 4 cbNO. f16 2 BOOM TR-14 & HPP-150 WITH BREAKER V1200
1 CLOGG ED SWITCH I
I PDSH-01 ��!tPg_ R EFERENCES: SE:AL:
O j
1
T :
L-------------------------------------------------------------------� ITLE WIRING ARRANGMENT
i------'�-'-"-��-'-=�------------1n
- - 1 1
o--- ----
- = -- � - - - _ _ _ ______
D�WING N O: lsl
JULY 2013 N1S I J. 1
DA1E:
WIRING ARRANGEMENT
·-""
ML JT
CIECKEI> -
DT
1093MV-E-001 !,!
L_g_J
*** NOTE ***
TERMINAL REFERENCE:
L1
SUPPLY
°231:Nl>C, 60HZ, 15.'.
N
□ CONTROL PANEL TERMINALS
PC-01
◊ OPERATOR'S CONSOLE
OP-01
Ill JUNCTION BOX TERMINALS POWER UNIT
JB-02
JUNCTION BOX TERMINALS HYDRAIJUC ARM
2 [;iiil JB-01
3
[I
4 r---------------------------------------------------------....J 8 1-------4 ��
PL-01
�iHT liiiil
�
5
GND
CABLE BY: COLOR CODE:
---
POWER SUPPLY
23
---
1:N1foJ4Vdc CDB 231:N/>C 1111/F\ BROWN
+f -�
OTHERS 231:N/>C (NEl/lRAL' BWE
�-IIJJf-----------1□
_COM 241/0C POWER RED
6 I
OVDC POWER BLACK
WIRES :
241/0C INPUT SIG. GRAY
!
EM ERGENCY � � WIRES 16 AWG
-02 EXCEPT BETW
� CONlROll..1.Ef; 241/DC OUTPUT SIG WHITE
1 �1 02 2 EMRGENCY STOP o!c TERMINAL 18 AWG
7 i :EL..l____a 1 -d ( R1) CONlROL REI.AY l:JNLESS N CAN NETWORK YELLOW
1--c1-tio
-� - - -c1Z{i1o- 9 1 9, 36
400V 1'C 3PH L1:
L2:
L3:
FIJ-04 17��t�LSP
8
1---------------1 IVDC+ VDC
GROUND
EM BEDDED INPUT M ODULE
R1
EM RGENCY STOP
CONTROL CONTACT 9 INO DC COMO
9' �1
POW,B�ii **
ë��o- �ëi?�o- **
STOP 10 IN1
NOTE
• CABLE BY VENDOR
\'>--
ii=-----------0 c�'!;"/1
srART PO� �i� 11 IN2
B • CABLE BY OTHER
o
RES� ----
RESET FILTER �� -
P 12 ' IN3 .6. 1
----
APR 2014 FINAL DRAWING MAJ
JOG POWE �tii 13
JOG sr�
••= 1 _
----E>
-----w-
r-r-JN0.4
IN4 DC COM1
NOV 2013 CHANGED FILTER CLOGGED LOGIC GC
NOV 2013 GENERAL REVIEW MAJ
JOG sr� -----w----- OCT 2013 FllR CONSTRUCTION ML
<ra'�
••-1 -,- r-r-JN0.5
JOG OIL 14 ----E> IN5 AUG 2013 FllR APPROVAL ML
NO. 1 111.lE REVISIONS BY
0.6
L.OW OIL LEVEL 15 �-----
LSL-01 11 IN6
î 1 L"' rw------
;5Qi<f'a � r-r-JN0.7
RETURN FILTER 16 1 IN7
CLOGGED
PDSH-01
L---.J
24V/01 ,M
17
CUSTOM ER:
TO DWG TO DWG TO DWG
TRAMAC VALE
1093MV-E-003 1093MV-E-OD3 1093MV-E-OD3 PROJECT:
2 BOOM TR-14 &: HPP-150 WITH BREAKER V1200
REFERENCES: SEAL:
TTTLE:
·n
CONTROL /0 SCHEMATIC
1
- 1093MV-E-002
,�'
CONTROL 1/0 SCHEMATIC 111.lE: SCAI.E: DRAWING NO: I! 1
'1'
1� 1
AUG 2013 NlS
DIWINll'O CHEa<EO: 1� 1
ML MAJ DT L.:..J
FROM DWG FROM DWG FROM DWG *** ***
1093MV-E-002 1093MV-E-002 1093MV-E-002
NOTE
241//0�0M t+24V/01 ,M lERMINAL REFERENCE:
19 1 1 Î lil --------------------- 24 VDC
□ CONTROL PANEL lERMINALS
PC-01
OPERATOR'S CONSOLE
LOW OIL TEMP. 20
◊ OP-01
1 IINB JUNCTION BOX lERMINALS POWER UNIT
lSL-01 l.àl � ------1
li! JB-02
HIGH HIGH OIL TEMP. 21 IIN9 JUNCTION BOX lERMINALS HYDRAULIC ARM
lSHH-01 1 1 1 1
JB-01
�------1 [;iiil
..
LOW LOW OIL TEMP. 22 1 1 IIN10
lSLL-01
�I� ------1 [I
HIGH OIL TEMP. 23 1 1 1 1 IIN11
lSH-01 �------1
�
LOW PRESSURE 24 IN12
PS-01 2
LG.PS+
�--
25 �--- IN13
230VN:. IL.IVE\ BROWN
12on.A.
230VN:. (NEUlRAI I BWE
26 IN14
24VDC POWER RED
OVDC POWER BLN:.K
27 IN15 DC COM2 WIRES :
24VDC INPUT SIG. GRAY
� WIRES ARE 18 AWG
rf
EXCEPT B CONTROLLEJ; 24VDC OUTPUT SIG. WHITE
lERMINAL
� 18 AWG
�NLESS
I NO CAN NEIWORK YELLOW
EMBEDDED OUTPUT MODULE
400V N:. 3PH L1:
FU-05 L2:
�+24V/03 TO HYDRAUUC CONTROLLER
28 VDC 0 OlJTO 1 1 1 1
� L3:
� �lfo/:l��-E-005
29 VDC 1 OlJT1 11 1 1
�
( R )1-------
l ��Wi
LOW OIL LEVEL AIARM
UGHT
1
HIGH HIGH OIL lEMPERATURE AIARM
30 VDC 2 OlJT2 11 1 ( R ) UGHT
� ��Wl
:
LOW LOW OIL lEMPERATURE AIARM
31 OlJT3 1 ( R )
1------------ly--.( UGHT
��W1
CLOGGED AIARM
32 OlJT411 1
._____________. R ) ♦ ��
PL-05
HYDRAULIC PUMP RUNNING CONFIRMATION
33 OlJT5 1 1 1 G ��Wi UGHT
OIL COOLER RUNNING CONFIRMATION
** NOTE **
34 OlJT6 1 : ,, ' W1-----<1 ��Wf UGHT • CABLE BY VENOOR
� --- • CABLE BY OTHER
'
OIL HE:AlER RUNNING CONFIRMATION
1-------------1 G
35 OIJT7 11 1 �,________....,1 ��W! UGHT
1 1
1
EMRGENCY STOP
36
R1
VDC 3 OlJTB 11 -<ri;, POWER UNIT MOTOR
't 1
APR 2014 FINAL DRAWING MAJ
CONTROL CONTACT 1 1-1 ----------- , � ,. .101J A2 t '&JNTROL RELAY NOV 2013 GENERAL REVIEW
OCT 2013 AOD PS-01 ML
MA.)
11 OIL COOLER
37 OlJT9 11 1 1 A1� 102J A2 t �roL RELAY OCT 2013 FOR CONSTRUCTION ML
AUG 2013 FOR APPROVAL ML
38 VDC 4 OlJT10I 1 NO. 1 REVISIONS Ill'
î
1 1 A1lR103J A2 t Sl\-Jk��ELAY
132
MIE
J
39 OlJT11 D Al� A2 Ws�l"W��,.:u:
VDC COM2
CUSTOMER:
)!4V/01 ,M TRAMAC VALE
PROJECT:
2 BOOM TR-14 & HPP-150 WITH BREAKER V1200
REFERENCES: SEAL:
TO DWG TO DWG
1093MV-E-004 1093MV-E-004 Tl1lE:
CONTROL 1/0 SCHEMATIC
CONTROL 1/0 SCHEMA TIC ..,..,
AUG 2013 N1S
SColl.E, DRAWING NO: I! 1
,�'
'1'
ML
DRAWN BY':
MAJ
CHECl<Elh
DT
-.o\/Ell: 1093MV-E-003 1� 1 ,g'
0
FROM DWG
1093MV-E-003
FROM DWG
1093MV-E-003
*** NOTE ***
24 VDC
±24V/01 :OM lERMINAL REFERENCE:
STOP PB-11
ALLEN-IIRADLEY
COMPACT 1/0 MODULE
1769-IQ16
□ CONTROL PANEL lERMINALS
PC-01
STOP POWER UNIT 48 OPERATOR'S CONSOLE
PB-11 INO
OP-01
START
__j__f_B-12 JUNCTION BOX lERMINALS POWER UNIT
START POWER UNIT
PB-12 47 IN1 lil JB-02
JUNCTION BOX lERMINALS HYDRAUUC ARM
A [;iiil
LOW GREASE LEVEL
LSL-02 48 -----��----- r---,
IN2 JB-01
[I
GREASE CYCLE SWITCH
ZS-03 49 -----��----- L ___ Jr----,
L_ ___ ....J
&
IN3
liiiil
t2:,.
50 ------D--� 1-------0-:-----
FROM ELECTRICAI. ROOl,t 400V MCC
IN4
�
POWER UNIT MOTOR f1 RUNNING t2:,.
51 ------D--� 1-------0-:----- IN5
�--
FROM ELECTRICAI. ROOl,t 400V MCC
POWER UNIT MOTOR f2 RUNNING t2:,.
52 ------D--� 1-------0-:-----
FROM ELECTRICAI. ROOM 400V MCC
IN6 23fN,C ILJVE'\ BROWN
OIL COOLER RUNNING 23fN,C {NEUTRAI' BLUE
t2:,.
53 ------D--� 1-------0-:-----
FROM ELECTRICAI. ROOM 400V MCC
IN7 DC COMOl 1-------------------------ill 24VDC POWER
OVDC POWER
RED
BLACK
OIL HEAlER RUNNING WIRES :
24VDC INPUT SIG. BLUE
INB �E��J1!o�ll5 24VDC OUTPUT SIG. WHITE
a: lERMINAL 18 AWG
�NLESS N CAN NEIWORK YELLOW
400V AC 3PH L1:
IN9
L2:
L3:
IN10
IN11
IN12
IN13
IN14
IN15 DC COM1
** NOTE **
ALLEN �RADLEY
F\J-06 COMP� -; ODULE = CABLE BY VENDOR
2A ed!-'bJA
,+24V/05 LOW OIL PRESSURE ALARM --- = CABLE BY OTHER
54 VDC1 OUTO ��Wir UGHT t2:,.
LOW GREASE LEVEL ALARM D,.
55 OUT1 ��J UGHT A APR 2014 1 FINAL DRAWING MAJ
NOV 2013 1 GENERAL REVIEW MAJ
LUBRIFICATION CYCLE AIARM
56 OUT2 STATIJS UGHT OCT 2013 1 AOD 4 MOTOR MONITORING CONTACT .te PL-OIi ML
PL-11
& OCT 2013 1 FOR CONSTRUCTION I ML
AUG 2013 1 FOR APPROVAL ML
57 OUT3
DIOE REVISIONS "'
58 VDC2 OUT4
59 OUTS
60 OUT6
CUSTOMER:
61
62
i4V/01 OUT7 OM TRAMAC VALE
PROJECT:
2 BOOM TR-14 & HPP-150 WITH BREAKER V1200
REFERENCES: SEAL:
TO DWG TO DWG
1093MV-E-005 1093MV-E-005 Tlll.E:
CONTROL 1 0 SCHEMATIC
_,
CONTROL !/0 SCHEMATIC ""lE:
AUG 2013
so,œ
NTS
DRAWING NO: �I
1 1
..........
ML
CHElllCED,
MAJ
APPROVED,
DT
1093MV-E-004 �'il
FROM DWG
1093MV-E-004
FROM DWG
1093MV-E-004
*** NOTE ***
24V/01 ,M TERMINAI. R EFERENCE:
70 24 VDC
CONTROL PANEL TERMINAI.S
□ PC-01
OPERATOR'S CONSOLE
OP-01
SAUER DANFOSS
JUNCTION BOX TERMINAI.S POWE R UNIT
CONTROLLER
MCOS0-01 0-01
Ill JB-02
JUNCTION BOX TERMINAI.S HYDRAUUC ARM
71 C1 -P1 C1 -P26
JB-01
FU-07
[;iiil
2A
72 C1 -P2 C1 -P27 [I
73 C1 -P3 C1 -P28 liiiil
74 CANBl/l!'Ji!WORK {... l C1 -P4 C1 -P29
llWG 1093-MV-E-008
�
75 . C1 -P5 C1 -P30
�--
76 C1 -P6 C1 -P31
DWG 1093-MV-E-003
e:J.&i.ri�G�
2'9NAC t= BROWN
C1 -P7 C1 -P32 2'9NAC (NEUTRAl.l BWE
24VDC POWE R RED
C1 -P8 C1 -P33 OVDC POWE R BLACK
WI RES :
C1 -P9 C1 -P34 E 1
�E�i AR / &,�L.I.EI, 24VDC OUlPUT SIG. WHITE
&: TE RMIN 8 AWG
2 V/014 lJNL.ESS N� CAN NEIWORK
��--- �O..:_O
- = �� C1 -P1 0 C1 -P35
YELLOW
e 400V 1'C 3PH L1:
n
,-----, IN1 0.1
78 C1 -P11 C1 -P36
L2:
ZS-02
Gc:::Jtl �-- LJ:
OUT1_1
L----...J
79 C1 -P1 2 C1 -P37 �
SV-01
� 1 �lïW�Al.�
OUT1-1
C1 -P1 3 C1 -P38 � Wii�lrMlfCA
SV-02
80
OUT1_1 M
81 C1 -P1 4 C1-P39 � �c!rllrlàl�
SV-03
0UT1_1 �c'rô��i_�M
82 C1 -P1 5 C1 -P40 �
SV-04
83 C1 -P1 6 C1 -P41 &
OUT1_1 �At.flM
84 C1 -P1 7 C1 -P42 � IBo'a°W'
SV-05
OUT1_1 111,JaD&W�<v,®t
C1 -P1 8 C1 -P43 �
SV-06
85
OUT1_1 ARM
86 C1 -P1 9 C1 -P44 � 1ll_,-11>�� ** NOTE **
SV-07
0UT1_1 = CABLE BY VENDO R
87 C1 -P20 C1 -P45 � 1ll_�M_�M - - - = CABLE BY OTHER
SV-08
OUT1_1 �A'tiARM
CANBUJN�mwoRK {-- I C1 -P21 C1 -P46 �
88
llWG 1093-MV-E-006 SV-09
�1 APR 2014 FINAi. DRAWING
89 C1 -P22 C1 -P47
MAJ
NOV 2013 PINOUT ADJUSTMENT
90 C1 -P23 C1 -P48 NOV 2013 GENERAL REIIIEW MAJ
OCT 2013 FOR CONSTRUCTION ML
91 C1 -P24 C1-P49 AUG 2013 FOR APPR OVAI. ML
NO. 1 111.lE R EI/ISIONS av
92 C1 -P25 C1 -P50
93
FU-08
94
CUSTOME R:
'l-4V/01 TRAMAC VALE
95 PROJECT:
,M
2 BOOM TR-1 4 &: HPP-1 50 WITH BREAKER V1200
REFERENCES: SEA!.:
TO DWG TO DWG
1093MV-E-006 1093MV-E-006 TITLE:
HYDRAUUC CONTROLLER SCHEMATIC
111.lE: DRAWING NO:
,_ 1
I! 1
-·
HYORAULIC CONTROLLER SCHEMA TIC AUG 2013 NT5
SOM.E:
1093MV-E-005 1�L.:.J
,g 1
1 1 1
DIWNBY: CHECIŒD;
ML DT
1
IIAJ
FROM DWG FROM DWG
*** NOTE ***
1093MV-E-005 1093MV-E-005
TERMINAL REFERENCE:
100
4V/01
24 voc
COM
PC-01
OP-01
JUNCTION BOX TERMINALS POWER UNIT
lil JB-02
JUNCTION BOX TERMINALS HYDRAUUC ARM
[;iiil JB-01
[I
FIJ-09
1A
,+24V/08 +24V/08 COM COM liiiil
101 --).>--- -<? ,------------------- --).>--- -f7 �
��
�
�--
-�PON
230VAC Il�
f------ -
BROWN
102 1 Cd c �±------------f\-----7.)....-----0 CO+ ►
230VAC (NEl/TRAL' BLUE
103
104
105 r q e vv CO-
1 1
1 1
c2-j/s
�'---- ----
�-------------+-+-----7,.-;:
C2-'4/6
-0 CO- �CAN'J E
RK
1 - -E---005 WIRES :
24VOC
OVDC POWER
POWER
BIACK
RED
106
1 1
Il
�-----).)....-----0 COS m WIRES
EXCEPT BEIW
�
16 AWG
24VOC INPUT SIG. GRAY
CONTRO>LLEF 24VOC OUTPUT SIG. WHITE
C2-flND ► &: TERMINAL
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AUG 2013 FOR APPROVAL ML
NO. 1 D,\TE REVISIONS Ill'
CUSTOMER:
112
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PROJECT:
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AUG2013 FOR APPRr:N/>J.. ML
NO. Dt.TE REVISIONS BY
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"""""""' CIEl(ED,
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Brevini Gearbox
ED2090
Hydraulic Motor
151 2336 DS200

MAKING MODERN LIVING POSSIBLE
Technical Information
Orbital Motors
DH and DS
powersolutions.danfoss.com
Technical Information Orbital Motors, DH and DS
F 301 245
A Wide Range of Orbital Danfoss Power Solutions is a world leader within production of low speed hydraulic motors with high
Motors torque. We can offer more than 3000 different hydraulic motors, categorised in types, variants and
sizes (incl. different shaft versions).
The motors vary in size (rated displacement) from 8 cm3 [0.50 in3] to 800 cm3 [48.9 in3] per revolution.
Speeds range up to approx. 2500 min-1 (rpm) for the smallest type and up to approx
600 min-1 (rpm) for the largest type.
Maximum operating torques vary from 13 Nm [115 lbf·in] to 2700 Nm [24,000 lbf·in] (peak) and
maximum outputs are from 2.0 kW [2.7 hp] to 70 kW [95 hp].
Characteristic features:
yy Smooth running over the entire speed range
yy Constant operating torque over a wide speed range
yy High starting torque
yy High return pressure without the use of drain line (High pressure shaft seal)
yy High efficiency
yy Long life under extreme operating conditions
yy Robust and compact design
yy High radial and axial bearing capacity
yy For applications in both open and closed loop hydraulic systems
yy Suitable for a wide variety of hydraulics fluids
Frontpage: P300 048, P300 047, P300 047b, F300 020, 151-1914
2 520L0439 • Rev BA • Jan 2014

A Wide Range of Orbital The programme is characterised by technical features appealing to a large number of applications
Motors and a part of the programme is characterised by motors that can be adapted to a given application.
(continued) Adaptions comprise the following variants among others:
yy Motors with corrosion resistant parts

yy Wheel motors with recessed mounting flange
yy OMP and OMR- motors with needle bearing
yy OMR motor in low leakage version
yy OMR motors in a super low leakage version
yy Short motors without bearings
yy Ultra short motors
yy Motors with integrated positive holding brake
yy Motors with integrated negative holding brake
yy Motors with integrated flushing valve
yy Motors with speed sensor
yy Motors with tacho connection
yy All motors are available with black finish paint
The Danfoss Orbital Motors are used in the following application areas:
yy Construction equipment
yy Agricultural equipment
yy Material handling & Lifting equipment
yy Forestry equipment
yy Lawn and turf equipment
yy Special purpose
yy Machine tools and stationary equipment
yy Marine equipment
Survey of Literature with Detailed data on all Danfoss Orbital Motors can be found in our motor catalogue, which is divided
Technical Data on Danfoss into individual subcatalogues:
Hydraulic Motors y General information on Danfoss Orbital Motors: function, use, selection of orbital motor, hydraulic
systems, etc.
y Technical data on small motors: OML and OMM
y Technical data on medium sized motors: OMP, OMR, OMH
y Technical data on medium sized motors: DH and DS
y Technical data on medium sized motors: OMEW
y Technical data on medium sized motors: VMP
y Technical data on medium sized motors: VMR
y Technical data on large motors: OMS, OMT and OMV
y Technical data on large motors: TMT
y Technical data on large motors: TMV
A general survey brochure on Danfoss Orbital Motors gives a quick motor reference based on power,
torque, speed and capabilities.
T301 123
520L0439 • Rev BA • Jan 2014 3

Contents A Wide Range of Orbital Motors...................................................................................................................................... 2

Survey of Literature with Technical Data on Danfoss Hydraulic Motors............................................................... 3
DH and DS Orbital Motor Data Survey......................................................................................................................... 5
Speed, Torque and Output..................................................................................................................................................... 5
DH.................................................................................................................................................................................................... 6
Versions.......................................................................................................................................................................................... 6
Code Numbers............................................................................................................................................................................ 7
Technical Data............................................................................................................................................................................. 8
Technical Data for DH with 1 in Cylindrical and 1 in-6b Splined Shaft............................................................ 8
Max. Permissible Shaft Seal Pressure.................................................................................................................................. 9
Pressure Drop in Motor............................................................................................................................................................ 9
Oil Flow in Drain Line.............................................................................................................................................................. 10
Direction of Shaft Rotation.................................................................................................................................................. 10
Permissible Shaft Loads for DH........................................................................................................................................... 11
Function Diagrams.................................................................................................................................................................. 12
Shaft Version.............................................................................................................................................................................. 17
Port Thread Versions............................................................................................................................................................... 18
Dimensions................................................................................................................................................................................. 19
Dimensions – US Version................................................................................................................................................ 19
DS...................................................................................................................................................................................................22
Versions........................................................................................................................................................................................22
Code Numbers..........................................................................................................................................................................23
Technical Data........................................................................................................................................................................... 24
Technical data for DS with 1 in cylindrical and 1 in-6b splined shaft............................................................. 24
Max. Permissible Shaft Seal Pressure................................................................................................................................25
Pressure Drop in Motor..........................................................................................................................................................25
Max. permissible shaft seal pressure..........................................................................................................................25
Oil Flow in Drain Line.............................................................................................................................................................. 26
Direction of Shaft Rotation.................................................................................................................................................. 26
Permissible Shaft Loads for DS........................................................................................................................................... 27
Function Diagrams.................................................................................................................................................................. 28
Shaft Version.............................................................................................................................................................................. 33
Port Thread Versions...............................................................................................................................................................34
Dimensions................................................................................................................................................................................. 35
Dimensions – US Version................................................................................................................................................ 35
Hydraulic Systems.................................................................................................................................................................38
Installation of the Danfoss Orbital Motors.....................................................................................................................38
Starting Up and Running in the Hydraulic System......................................................................................................38
Operation....................................................................................................................................................................................38
Maintenance..............................................................................................................................................................................38
Weight of Motors................................................................................................................................................................... 39
Speed, Torque and Output The bar diagrams, see page 5, are useful for a quick selection of relevant motor size for the applica-
tion. The final motor size can be determined by using the function diagram for each motor size.
yy DH can be found on pages 12-16

yy DS can be found on pages 28-32
The function diagrams are based on actual tests on a representative number of motors from our
production. The diagrams apply to a return pressure between 5 and 10 bar
[75 and 150 psi] when using mineral based hydraulic oil with a viscosity of 35 mm2/s
[165 SUS] and a temperature of 50°C [120°F]. For further explanation concerning how to read and use
the function diagrams, please consult the paragraph "Selection of motor size" in the technical
information "General" 520L0232.
4 520L0439 • Rev BA • Jan 2014

DH and DS Orbital Motor

Data Survey
Speed, Torque and Output Max. Speed

min-1
(rpm)
2000
1800
1600
1400
1200
1000
800
600
400
200
36 50 80 100 125 160 200 250 315 400 50 80 100 125 160 200 250 315 375
DH DS
Max. Torque
lbf•in Nm
5000
550
4500 500
4000 450
3500 400
3000 350
300
2500
250
2000
200
1500
150
1000
100
500 50
36 50 80 100 125 160 200 250 315 400 50 80 100 125 160 200 250 315 375
DH DS
hp kW
Max. Torque
16 12
14
10
12
8
10
8 6
6
4
4
2
2
36 50 80 100 125 160 200 250 315 400 50 80 100 125 160 200 250 315 375
DH DS
Intermittent Continuous 151-1871.11

values values
520L0439 • Rev BA • Jan 2014 5

Technical Information Orbital Motors, DH
DH
Versions
Main type designation

High pressure shaft seal
Flange port version
Standard shaft seal

European version
Drain connection
Side port version
Mounting flange
End port version
Check valve
US version
Port size
Specials
Shaft
7/8 - 14 UNF    No No DH
2 hole oval flange Cyl. 1 in 7/8 - 14 UNF    Yes No DH
(A2-flange) 1/2 - 14 NPTF    No No DH
1 in - 6B spl. 7/8 - 14 UNF    No No DH
Square flange 7/8 - 14 UNF    No No DH
Cyl. 1 in
(C-flange) 1/2 - 14 NPTF    No No DH
Function diagram - see page : →
Features available (options):

Reverse rotation
Drain port
Painted
6 520L0439 • Rev BA • Jan 2014

Code Numbers
DISPLACEMENT [cm3]
Technical data – Page
Dimensions – Page
CODE NUMBERS
36 50 80 100 125 160 200 250 315 400

151- 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 8 19
151- - 3401 3402 3403 - - - 3407 3408 3409 8 20
151- 2080 2081 2082 2083 - 2085 2086 2087 2088 2089 8 19
151- 2010 2011 2012 2013 - 2015 2016 2017 2018 2019 8 19
151- 2040 2041 2042 2043 2044 2045 2046 2047 2048 2048 8 21
151- 2120 2121 2122 2123 2124 2125 2126 2127 2128 2129 8 21
→ 12 12 13 13 14 14 15 15 16 16
Ordering
Add the four character prefix “151-” to the four digit numbers from the chart for complete code
number.
Example:
151-2000 for an DH 36 with A2-flange, cyl. 1 in shaft, port size 7/8 - 14 UNF and without drain
connection.
Orders will not be accepted without the four character prefix.
520L0439 • Rev BA • Jan 2014 7

Technical Data
Technical Data for DH with 1 in Cylindrical and 1 in-6b Splined Shaft

Type DH DH DH DH DH DH DH DH DH DH
Motor size 36 50 80 100 125 160 200 250 315 400
Geometric cm3 36.0 48.6 77.8 97.3 125.0 155.7 194.6 242.3 306.1 389.2
displacement [in3] [2.20] [2.97] [4.76] [5.95] [7.65] [9.53] [11.91] [14.83] [18.73] [23.82]
min-1 cont. 1050 930 780 620 485 390 310 250 200 155
Max. speed [rpm] int.2) 1270 1090 975 780 605 485 390 315 245 195
59 79 125 158 203 235 267 305 355 410
cont.
Nm [520] [700] [1110] [1400] [1800] [2080] [2360] [2700] [3140] [3630]
Max. torque1) [lbf·in] 76 106 163 214 270 320 360 415 470 485
int. 2) [670] [940] [1440] [1890] [2390] [2830] [3190] [3670] [4160] [4290]
5.8 6.8 8.8 8.8 8.8 8.1 7.4 6.6 6.0 5.5
cont.
kW [7.9] [9.3] [12.0] [12.0] [12.0] [10.9] [9.0] [8.9] [8.0] [7.4]
Max. output [hp] 7.0 8.2 11.4 11.8 11.0 11.1 9.8 8.8 7.8 6.4
int. 2) [9.5] [11.2] [15.5] [16.0] [15.0] [14.1] [13.1] [11.8] [10.5] [8.6]
124 124 124 124 124 117 103 97 90 83
cont.
bar [1800] [1800] [1800] [1800] [1800] [1700] [1500] [1400] [1300] [1200]
Max. pressure drop [psi] 166 166 166 166 166 159 141 131 121 97
int.2) [2400] [2400] [2400] [2400] [2400] [2300] [2050] [1900] [1750] [1400]
38 45 60 60 60 60 60 60 60 60
l/min cont. [10.0] [11.9] [15.9] [15.9] [15.9] [15.9] [15.9] [15.9] [15.9] [15.9]
Max. oil flow [US gal/
min] 45 55 75 75 75 75 75 75 7 75
int.2) [11.9] [14.5] [19.8] [19.8] [19.8] [19.8] [19.8] [19.8] [19.8] [19.8]
Max. starting pressure bar 10 10 10 10 10 10 7 7 7 7
with unloaded shaft [psi] [145] [145] [145] [145] [145] [145] [100] [100] [100] [100
at max. press. drop 53 72 115 144 185 217 240 279 330 385
cont. [470] [635] [1020] [1275] [1640] [1920] [2125] [2470] [2920] [3405]
Min. starting Nm [lbf·in]
torque at max. press. drop 66 96 154 192 247 295 327 379 444 451
int. 2) [585] [850] [1360] [1700] [2185] [2610] [2895] [3355] [3930] [3990]
Nm [lbf·in]
Max return pressure

Type Max. inlet pressure with drain line
bar 138 138
cont.
[psi] [2000] [2000]
DH 36 - 400
bar 172 172
int.1)
[psi] [2500] [2500]
1)
6B splined shaft is recommended for operating torque of 280 Nm [2500 lbf·in] or more.
2)
Intermittent operation: the permissible values may occur for max. 10% of every minute.
8 520L0439 • Rev BA • Jan 2014

Technical Data
Max. Permissible Shaft Seal DH with HPS and DH with HPS and drain connection:
Pressure without drain connection: The shaft seal pressure equals the
The shaft seal pressure equals the pressure in the drain line.
average of input pressure
and return pressure.
Pseal = Pin + Preturn

2
151-1743.10
151-1855.10
Max. permissible shaft seal pressure
Pressure Drop in Motor
The curve applies to an unloaded motor shaft and an oil viscosity of 35 mm2/s [165 SUS]
A: DH 80 - 400
B: DH 36-50
520L0439 • Rev BA • Jan 2014 9

Technical Data
Oil Flow in Drain Line The table shows the max. oil flow in the Pressure drop Viscosity Oil flow in drain
drain line at a return pressure less than line
bar mm2/s l/min
5-10 bar [75-150 psi]. [psi] [SUS] [US gal/min]
20 2.5
100 [100] [0.66]
[1450] 35 1.8
[165] [0.78]
20 3.5
140 [165] [0.93]
[2030] 35 2.8
[165] [0.74]
Direction of Shaft Rotation
10 520L0439 • Rev BA • Jan 2014

Technical Data
Permissible Shaft Loads for The permissible radial shaft load (PR) depends on
DH yy speed (n)
yy distance (l) from the point of load to the mounting flange
yy mounting flange version
yy shaft version
Mounting flange Square flange 2-hole oval flange (US version)

1 in cylindrical shaft
Shaft version 1 in-6B splined shaft
Permissible 650 × 228000 N*
shaft load (PR) l in mm n 87 + l .
Permissible 1460 × 898
shaft load (PR) l in inch n 3.425 + l lbf*.
* n > 200 min-1 (rpm); l < 55 mm [2.2 in]
n < 200 min-1 (rpm); => PRmax = 6500 N [1460 lbf], when using above formulas n has to be 200 min-1 (rpm).
The curve shows the relation between PR and n

yy when l = 27 mm [1.06 in] for motors with oval and square mounting flange
520L0439 • Rev BA • Jan 2014 11

Technical Data
Function Diagrams
Explanation of function diagram use, basis and conditions can be found on page 4.
yy A: Continuous range
yy B: Intermittent range (max. 10% operation every minute)
Max. permissible continuous/intermittent pressure drop for the actual shaft version can be found on
page 8.
Intermittent pressure drop and oil flow must not occur simultaneously.
12 520L0439 • Rev BA • Jan 2014

Technical Data
Function Diagrams
page 8.
520L0439 • Rev BA • Jan 2014 13

Technical Data
Function Diagrams
page 8.
14 520L0439 • Rev BA • Jan 2014

Technical Data
Function Diagrams
page 8.
520L0439 • Rev BA • Jan 2014 15

Technical Data
Function Diagrams
page 8.
16 520L0439 • Rev BA • Jan 2014

Technical Data
Shaft Version
US version
A: Cylindrical shaft
1 in
C: Woodruff key
1
/4 × 1 in
SAE J502
US version
B: Splined shaft
1 in - SAE 6B
* Deviates from B.S. 2059
(SAE 6B)
520L0439 • Rev BA • Jan 2014 17

Port Thread Versions
A: UNF main ports B: NPTF main ports

E: 7
/8 - 14 UNF F: /2 - 14 NPTF
1
O-ring boss port
C: UNF drain port

G: 7
/16 - 20 UNF
O-ring boss port
18 520L0439 • Rev BA • Jan 2014

Dimensions
Dimensions – US Version Side port version with 2 hole oval mounting flange (A2-flange).
Port thread version.
L mm L1mm
Type [in] [in]
119.7 5.9
DH 36 [4.71] [0.23]
120.3 6.5
DH 50 [4.74] [0.26]
124.2 10.4
DH 80 [4.89] [0.41]
126.8 13.0
DH 100 [4.99] [0.51]
130.5 16.7
DH 125 [5.14] [0.66]
134.6 20.8
DH 160 [5.30] [0.82]
139.8 26.0
DH 200 [5.50] [1.02]
146.3 32.5
DH 250 [5.76] [1.28]
154.7 40.9
DH 315 [6.09] [1.61]
165.8 52.0
DH 400 [6.53] [2.05]
D: 7⁄8 - 14 UNF,
16.7 mm [0.66 in] deep
O-ring boss port or
1/2 - 14 NPTF
520L0439 • Rev BA • Jan 2014 19

Dimensions
With drain connection.
L mm L1mm
Type [in] [in]
119.7 5.9
DH 36 [4.71] [0.23]
120.3 6.5
DH 50 [4.74] [0.26]
124.2 10.4
DH 80 [4.89] [0.41]
126.8 13.0
DH 100 [4.99] [0.51]
130.5 16.7
DH 125 [5.14] [0.66]
134.6 20.8
DH 160 [5.30] [0.82]
139.8 26.0
DH 200 [5.50] [1.02]
146.3 32.5
DH 250 [5.76] [1.28]
154.7 40.9
DH 315 [6.09] [1.61]
165.8 52.0
DH 400 [6.53] [2.05]
C: 7⁄16 - 20 UNF,
12 mm [0.47 in] deep
D: 7⁄8 - 14 UNF,
16.7 mm [0.66 in] deep
O-ring boss port or
1/2 - 14 NPTF
20 520L0439 • Rev BA • Jan 2014

Dimensions
Dimensions – US Version Side port version with square mounting flange (C-flange).
L mm L1mm
Type [in] [in]
119.7 5.9
DH 36 [4.71] [0.23]
120.3 6.5
DH 50 [4.74] [0.26]
124.2 10.4
DH 80 [4.89] [0.41]
126.8 13.0
DH 100 [4.99] [0.51]
130.5 16.7
DH 125 [5.14] [0.66]
134.6 20.8
DH 160 [5.30] [0.82]
139.8 26.0
DH 200 [5.50] [1.02]
146.3 32.5
DH 250 [5.76] [1.28]
154.7 40.9
DH 315 [6.09] [1.61]
165.8 52.0
DH 400 [6.53] [2.05]
D: 7⁄8 - 14 UNF;
16.7 mm [0.66 in] deep
or 1⁄2 - 14 NPTF
E: 3⁄8 - 16 UNC;
(4-off)
520L0439 • Rev BA • Jan 2014 21

Technical Information Orbital Motors, DS
DS
Versions
Main type designation

High pressure shaft seal
Flange port version
Standard shaft seal

European version
Drain connection
Side port version
Mounting flange
End port version
Check valve
US version
Port size
Specials
Shaft
7/8 - 14 UNF    No No DS
2 hole oval flange Cyl. 1 in 7/8 - 14 UNF    Yes No DS
(A2-flange) 1/2 - 14 NPTF    No No DS
1 in - 6B spl. 7/8 - 14 UNF    No No DS
Square flange 7/8 - 14 UNF    No No DS
Cyl. 1 in
(C-flange) 1/2 - 14 NPTF    No No DS
Function diagram - see page : →
Features available (options) :

Reverse rotation
Drain port
Painted
22 520L0439 • Rev BA • Jan 2014

Code Numbers
DISPLACEMENT [cm3]
Technical data – Page
Dimensions – Page
CODE NUMBERS
50 80 100 125 160 200 250 315 375

151- 2301 2302 2303 2304 2305 2306 2307 2308 - 24 35
151- - 3702 3703 3704 - 3706 3707 3708 - 24 36
151- - 2382 2383 - 2385 2386 2387 - 2389 24 35
151- - 2312 2313 2314 - 2316 - 2318 2319 24 35
151- 2341 2342 2343 2344 2345 2346 2347 2348 2349 24 37
151- 2421 - 2423 - 2425 2426 2427 - 2429 24 37
→ 28 28 29 29 30 30 31 31 32
Ordering
Add the four character prefix “151-” to the four digit numbers from the chart for complete code
number.
Example:
151-2305 for an DS 160 with A2-flange, cyl. 1 in shaft, port size 7/8 - 14 UNF and without drain
connection.
Orders will not be accepted without the four character prefix.
520L0439 • Rev BA • Jan 2014 23

Technical Data
Technical data for DS with 1 in cylindrical and 1 in-6b splined shaft

Type DS DS DS DS DS DS DS DS DS
Motor size 50 80 100 125 160 200 250 315 375
Geometric cm3 51.6 80.3 99.8 124.1 155.4 198.2 248.1 310.1 390.7
displacement [in3] [3.16] [4.91] [6.11] [7.60] [9.51] [12.13] [15.18] [18.98] [23.91]
min-1 cont. 770 755 605 480 380 305 245 190 155
Max. speed [rpm] int. 2) 955 945 760 600 475 380 305 240 195
93 159 193 247 314 350 370 415 455
cont.
Nm [820] [1405 [1710] [2190] [2780] [3100] [3270] [3670] [4030]
Max. torque1) [lbf·in] 116 206 237 304 378 429 469 485 515
int. 2) [1025] [1820] [2100] [2690] [3350] [3800] [4150] [4290] [4560]
6.6 10.7 10.7 10.7 10.7 9.6 8.0 6.9 5.8
cont.
kW [8.9] [14.3] [14.3] [14.3] [14.3] [12.9] [10.7] [9.3] [7.8]
Max. output [hp] 7.8 13.0 13.0 13.0 12.6 11.8 9.9 8.0 6.9
int.2) [10.5] [17.4] [17.4] [17.4] [16.9] [15.8] [13.3] [10.7] [9.3]
138 138 138 138 138 124 107 97 83
cont.
bar [2000] [2000] [2000] [2000] [2000] [1800] [1550] [1400] [1200]
Max. pressure drop [psi] 172 172 172 172 172 155 138 114 97
int.2) [2500] [2500] [2500] [2500] [2500] [2250] [2000] [1650] [1400]
40 60 60 60 60 60 60 60 60
l/min cont. [10.6] [15.9] [15.9] [15.9] [15.9] [15.9] [15.9] [15.9] [15.9]
Max. oil flow [US gal/
min] 50 75 75 75 75 75 75 75 75
int.2) [13.2] [19.8] [19.8] [19.8] [19.8] [19.8] [19.8] [19.8] [19.8]
Max. starting pressure bar 10 10 10 10 10 10 7 7 7
with unloaded shaft [psi] [145] [145] [145] [145] [145] [145] [100] [100] [100]
at max. press. drop 76 118 164 204 256 294 318 358 387
cont. [670] [1045] [1455] [1810] [2265] [2600] [2815] [3170] [3425]
Min. starting Nm [lbf·in]
torque
at max. press. drop int.2) 95 148 205 255 320 367 408 423 453
Nm [lbf·in] [840] [1305] [1820] [2260] [2830] [3250] [3615] [3745] [4010]
Max return pressure

Type Max. inlet pressure with drain line
bar 138 138
cont.
[psi] [2000] [2000]
DS 50 - 375
bar 172 172
int.1)
[psi] [2500] [2500]
1) 6B splined shaft is recommended for operating torque of 280 Nm [2500 lbf·in] or more.
2) Intermittent operation: the permissible values may occur for max. 10% of every minute.
24 520L0439 • Rev BA • Jan 2014

Technical Data
Max. Permissible Shaft Seal DS with HPS and without drain connection: DS with HPS and drain connection:
Pressure The shaft seal pressure equals the average of The shaft seal pressure equals the pressure in the
input pressureand return pressure. drain line.
Pseal = Pin + Preturn

2
151-1743.10
151-1855.10
Max. permissible shaft seal pressure
Pressure Drop in Motor
The curve applies to an unloaded motor shaft and an oil viscosity of 35 mm2/s [165 SUS]
520L0439 • Rev BA • Jan 2014 25

Technical Data
Oil Flow in Drain Line The table shows the max. oil flow in the drain line Pressure drop Viscosity Oil flow in drain
at a return pressure less than 5-10 bar [75-150 line
bar mm2/s l/min
psi]. [psi] [SUS] [US gal/min]
20 2.5
100 [100] [0.66]
[1450] 35 1.8
[165] [0.78]
20 3.5
140 [165] [0.93]
[2030] 35 2.8
[165] [0.74]
Direction of Shaft Rotation
26 520L0439 • Rev BA • Jan 2014

Technical Data
Permissible Shaft Loads for The permissible radial shaft load (PR) depends on
DS yy speed (n)
yy distance (l) from the point of load to the mounting flange
yy mounting flange version
yy shaft version
Mounting flange Square flange 2-hole oval flange (US version)

1 in cylindrical shaft
Shaft version 1 in-6B splined shaft
Permissible 650 × 228000 N*
shaft load (PR) l in mm n 87 + l .
Permissible 1460 × 898
shaft load (PR) l in inch n 3.425 + l lbf*.
* n > 200 min-1 (rpm); l < 55 mm [2.2 in]
n < 200 min-1 (rpm); => PRmax = 6500 N [1460 lbf], when using above formulas n has to be 200 min-1 (rpm).
The curve shows the relation between PR and n

yy when l = 27 mm [1.06 in] for motors with oval and square mounting flange
520L0439 • Rev BA • Jan 2014 27

Technical Data
Function Diagrams
page 24.
28 520L0439 • Rev BA • Jan 2014

Technical Data
Function Diagrams
page 24.
520L0439 • Rev BA • Jan 2014 29

Technical Data
Function Diagrams
page 24.
30 520L0439 • Rev BA • Jan 2014

Technical Data
Function Diagrams
page 24.
520L0439 • Rev BA • Jan 2014 31

Technical Data
Function Diagrams
page 24.
32 520L0439 • Rev BA • Jan 2014

Technical Data
Shaft Version
US version
A: Cylindrical shaft
1 in
C: Woodruff key
1/4 × 1 in
SAE J502
US version
B: Splined shaft
1 in - SAE 6B
* Deviates from B.S. 2059
(SAE 6B)
520L0439 • Rev BA • Jan 2014 33

Technical Data
Port Thread Versions
A: UNF main ports B: NPTF main ports

E: 7
/8 - 14 UNF F: /2 - 14 NPTF
1
O-ring boss port
C: UNF drain port

G: 7
/16 - 20 UNF
O-ring boss port
34 520L0439 • Rev BA • Jan 2014

Dimensions
L mm L1mm
Type [in] [in]
125.6 9.0
DS 50 [4.94] [0.35]
130.6 14.0
DS 80 [5.14] [0.55]
130.6 14.0
DS 100 [5.14] [0.55]
134.0 17.4
DS 125 [5.28] [0.69]
138.4 21.8
DS 160 [5.45] [0.86]
144.4 27.8
DS 200 [5.69] [1.09]
151.4 34.8
DS 250 [5.96] [1.37]
160.1 43.5
DS 315 [6.30] [1.71]
171.4 54.8
DS 375 [6.75] [2.16]
D: 7⁄8 - 14 UNF,
16.7 mm [0.66 in] deep
O-ring boss port or
1/2 - 14 NPTF
520L0439 • Rev BA • Jan 2014 35

Dimensions
With drain connection.
L mm L1mm
Type [in] [in]
125.6 9.0
DS 50 [4.94] [0.35]
130.6 14.0
DS 80 [5.14] [0.55]
130.6 14.0
DS 100 [5.14] [0.55]
134.0 17.4
DS 125 [5.28] [0.69]
138.4 21.8
DS 160 [5.45] [0.86]
144.4 27.8
DS 200 [5.69] [1.09]
151.4 34.8
DS 250 [5.96] [1.37]
160.1 43.5
DS 315 [6.30] [1.71]
171.4 54.8
DS 375 [6.75] [2.16]
C: 7⁄16 - 20 UNF,
D: 7⁄8 - 14 UNF,
16.7 mm [0.66 in] deep
O-ring boss port or
1/2 - 14 NPTF
36 520L0439 • Rev BA • Jan 2014

Dimensions
Dimensions – US Version Side port version with square mounting flange (C-flange).
L mm L1mm
Type [in] [in]
125.6 9.0
DS 50 [4.94] [0.35]
130.6 14.0
DS 80 [5.14] [0.55]
130.6 14.0
DS 100 [5.14] [0.55]
134.0 17.4
DS 125 [5.28] [0.69]
138.4 21.8
DS 160 [5.45] [0.86]
144.4 27.8
DS 200 [5.69] [1.09]
151.4 34.8
DS 250 [5.96] [1.37]
160.1 43.5
DS 315 [6.30] [1.71]
171.4 54.8
DS 375 [6.75] [2.16]
D: 7⁄8 - 14 UNF;
16.7 mm [0.66 in] deep
or 1⁄2 - 14 NPTF
E: 3⁄8 - 16 UNC;
(4-off)
520L0439 • Rev BA • Jan 2014 37

Hydraulic Systems
Installation of the Danfoss About the design

Orbital Motors yy To ensure efficient operation all hydraulic components must be installed according to their
individual instructions.
yy The pump line must include a gage connection.
yy To ensure designed contact and minimize the stress all mounting flanges must be flat.
yy Hydraulic lines must be fitted correctly to prevent air entrapment.
About the assembly

yy Follow the mounting instructions printed on the inside of the cardboard box.
yy To prevent contamination, do not remove the plastic plugs from the connection ports until the
fittings are ready to be assembled.
yy Check that there is full face contact between the motor mounting flange and the mating part.
yy Do not force the motor into place when tightening the mounting screws.
yy Avoid unsuitable sealing material on fittings such as pack twine, Teflon and others.
yy Use only bonded seals, O-rings, steel washers and the like.
yy When tightening the fittings never use a torque higher than the max. tightening torque stated in
the instructions.
yy Make sure that the cleanliness of the oil used is better than 20/16 (ISO 4406). Always use a filter for
oil refilling.
Starting Up and Running in yy Through a small-meshed filter fill up the tank with oil to the upper oil level mark .
the Hydraulic System yy Start the drive engine, and if possible, let it work at its lowest speed. If the motor is provided with
bleed screws, keep these open until the emerging oil is non-foaming.
yy Check that all components are correctly connected (pump following the right direction of rotation
etc.).
yy In load-sensing systems, also make sure that the signal lines are free of entraped air.
yy Indications of air in the hydraulic system:
–– foam in the tank
–– jerky movements of motor and cylinder
–– noise
yy If required, refill with oil.
yy Connect the system to a separate tank that includes a filter (fineness max. 10 µm) with twice the
capacity of the max. oil flow. Let the entire system run without load (no pressure) for about 30
minutes.
yy Do not load the system until it is all bled and clean.
yy Check the tightness of the system and make sure that its performance is satisfactory.
yy Change the oil filter, and if required, refill with oil.
Operation yy Do not expose the motor to pressures, pressure drops and speeds above the max. values stated in
the catalogue.
yy Filter the oil to ensure that the contamination level 20/16 (ISO 4406) or better.
Maintenance yy When working with hydraulic systems, the main criteria of operating safety and endurance is
careful maintenance
yy Always renew and replace oil, oil filters and air filters according to the instructions given by the
respective manufacturers
yy Regularly check the condition of the oil
yy Frequently check system tightness and oil level
38 520L0439 • Rev BA • Jan 2014

Weight of Motors
Code no Weight Code no Weight Code no Weight

kg [lb] kg [lb] kg [lb]
151-2000 5.1 11.2 151-2085 5.7 12.6 151-2344 5.9 13.0
151-2001 5.1 11.2 151-2086 5.9 13.0 151-2345 6.1 13.4
151-2002 5.2 11.5 151-2087 6.1 13.4 151-2346 6.4 14.1
151-2003 5.4 11.9 151-2088 6.4 14.1 151-2347 6.9 15.2
151-2004 5.5 12.1 151-2089 6.9 15.2 151-2348 7.4 16.3
151-2005 5.7 12.6 151-2120 4.8 10.6 151-2349 7.9 17.4
151-2006 5.9 13.0 151-2121 4.8 10.6 151-2382 6.1 13.4
151-2007 6.1 13.4 151-2122 4.9 10.8 151-2383 6.1 13.4
151-2008 6.4 14.1 151-2123 5.1 11.2 151-2385 6.4 14.1
151-2009 6.9 15.2 151-2124 5.2 11.5 151-2386 6.7 14.8
151-2010 5.1 11.2 151-2125 5.4 11.9 151-2387 7.2 15.9
151-2011 5.1 11.2 151-2126 5.6 12.3 151-2389 8.2 18.1
151-2012 5.2 11.5 151-2127 5.8 12.8 151-2421 5.6 12.3
151-2013 5.4 11.9 151-2128 6.1 13.4 151-2423 5.8 12.8
151-2015 5.7 12.6 151-2129 6.6 14.6 151-2425 6.1 13.4
151-2016 5.9 13.0 151-2301 5.9 13.0 151-2426 6.4 14.1
151-2017 6.1 13.4 151-2302 6.1 13.4 151-2427 6.9 15.2
151-2018 6.4 14.1 151-2303 6.1 13.4 151-2429 7.9 17.4
151-2019 6.9 15.2 151-2304 6.2 13.7 151-3401 5.1 11.2
151-2040 4.8 10.6 151-2305 6.4 14.1 151-3402 5.2 11.5
151-2041 4.8 10.6 151-2306 6.7 14.8 151-3403 5.4 11.9
151-2042 4.9 10.8 151-2307 7.2 15.9 151-3407 6.1 13.4
151-2043 5.1 11.2 151-2308 7.7 17.0 151-3408 6.4 14.1
151-2044 5.2 11.5 151-2309 8.2 18.1 151-3409 6.9 15.2
151-2045 5.4 11.9 151-2312 6.1 13.4 151-3702 6.1 13.4
151-2046 5.6 12.3 151-2313 6.1 13.4 151-3703 6.1 13.4
151-2047 5.8 12.8 151-2314 6.2 13.7 151-3704 6.2 13.7
151-2048 6.1 13.4 151-2316 6.7 14.8 151-3706 6.7 14.8
151-2049 6.6 14.6 151-2318 7.7 11.2 151-3707 7.2 15.9
151-2080 5.1 11.2 151-2319 8.2 11.7 151-3708 7.7 17.0
151-2081 5.1 11.2 151-2341 5.6 12.3
151-2082 5.2 11.5 151-2342 5.8 12.8
151-2083 5.4 11.9 151-2343 5.8 12.8
520L0439 • Rev BA • Jan 2014 39

Products we offer: Danfoss Power Solutions is a global manufacturer and supplier of high-quality hydraulic and
electronic components. We specialize in providing state-of-the-art technology and solutions that
 Bent Axis Motors excel in the harsh operating conditions of the mobile off-highway market. Building on our extensive
 Closed Circuit Axial Piston applications expertise, we work closely with our customers to ensure exceptional performance for a
Pumps and Motors broad range of off-highway vehicles.
 Displays We help OEMs around the world speed up system development, reduce costs and bring vehicles to
 Electrohydraulic Power market faster.
Steering Danfoss – Your Strongest Partner in Mobile Hydraulics.
 Electrohydraulics Go to www.powersolutions.danfoss.com for further product information.
 Hydraulic Power Steering
Wherever off-highway vehicles are at work, so is Danfoss.
 Integrated Systems
 Joysticks and Control We offer expert worldwide support for our customers, ensuring the best possible solutions for
Handles outstanding performance. And with an extensive network of Global Service Partners, we also provide
 Microcontrollers and comprehensive global service for all of our components.
Software
Please contact the Danfoss Power Solution representative nearest you.
 Open Circuit Axial Piston
Pumps
 Orbital Motors
 PLUS+1® GUIDE
 Proportional Valves
 Sensors
 Steering
 Transit Mixer Drives
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmueller- Local address:
inverter.com
Turolla
www.turollaocg.com
Valmova
www.valmova.com
Hydro-Gear
www.hydro-gear.com
Daikin-Sauer-Danfoss
www.daikin-sauer-danfoss.com
Danfoss
Power Solutions
Danfoss Danfoss Danfoss (Shanghai) Co. Ltd.
Power Solutions US Company Power Solutions GmbH & Co. OHG Power Solutions ApS Building #22, No. 1000 Jin Hai Rd
2800 East 13th Street Krokamp 35 Nordborgvej 81 Jin Qiao, Pudong New District
Ames, IA 50010, USA D-24539 Neumünster, Germany DK-6430 Nordborg, Denmark Shanghai, China 201206
Phone: +1 515 239 6000 Phone: +49 4321 871 0 Phone: +45 7488 2222 Phone: +86 21 3418 5200
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products
already on order provided that such alterations can be made without subsequential changes being necessary in specifications already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
520L0439 • Rev BA • Jan 2014 www.danfoss.com © Danfoss A/S, 20xx-xx

Hammer Greasing Pump
GREASE STATION
MANUAL
Form No. M1008-PO
Revision 2
August 2001
Page 1
Grease Station
This Page Left Blank Intentionally
Page 2
Grease Station Installation
The Tramac valve, DP-2/3, will drop the autolube pressure signal from the working
pressure of the hammer to the tank pressure in a delay ranging from 1 to 3 seconds.
Due to this quick drop, the autolube pump is re-primed each time the operator stops the
hammer and lubricant is sent to the hammer each time the operator starts up again.
Lube line going to hammer
Grease
Station Drain line going to the tank
(0 psi pressure)
HP Line from the CF port HP Line going to the HP

of Tramac valve inlet of Tramac hammer
The installation of the Tramac valve must be conformed to the above schematic. Be sure
to connect the correct ports of the valve to the correct ports of the correct hoses:
Port 1 must be connected to the HP line going to the HP inlet of the breaker. (usually
through a tee fitting on the CF outlet port of the Tramac control flow valve)
Port 2 must be connected to the HP inlet of the greaser pump.
Port 3 must be connected to the drain circuit of the machine.
Ports 1 and 2 are SAE-8 and Port 3 is SAE-6.
Page 3
H.P. Oil to Hammer
1 Tramac Lube Valve
With the breaker you are

receiving a greaser
assembly and a Tramac
valve, DP-2/3. This valve
3 2 Grease must be inserted into the
Station hydraulic circuit and piped
up according to the
typical schematic diagram
shown to the left.
To
Reservoir Hammer
Valve Details
• 1 = H.P. Oil Inlet Port size is 1/2” SAE O-Ring Boss

• 2 = Work Oil to Autolube Port size is 1/2” SAE O-Ring Boss
• 3 = L.P. Oil To Tank Port size is 3/8” SAE O-Ring Boss
Identifying Numbers on Valve: DPBC-LBN-ECJ

• NOTE: This valve must be installed in the grease circuit to insure that the grease station
works properly.
Page 4
NOTICE
A wrong installation (even for a few seconds of operation) may permanently damage the
cartridge valve.
After the installation, be sure that the delay to release the pressure in the pilot line of the greaser
pump does not exceed 3 seconds. To check that do the following:
• Install a pressure gauge on port 2 of the Tramac valve.
• Run the hammer a few seconds, the pressure reading should be near the working
pressure of the breaker (see owners manual for the proper value).
• Stop the hammer, and check the pressure on the gauge. The cartridge has been
preadjusted at the factory to give the proper pressure drop delay. The pressure
should drop to near zero psi in no more than 3 seconds.
• Basically, the lubrication station is composed of a spring-loaded piston which operates as
follows:
• When circuit is under low pressure, grease comes into the chamber below the piston.
• When circuit is under high pressure, the grease volume contained in chamber is sent to
the breaker.
Filling up the grease station:

• By connecting the filling fitting (ref 310) to a grease pump: Stop the filling when the cover
(ref. 10) is pushed by the piston (ref. 240). Then, release the air pressure inside the tank by
pushing on the relief button.
• By directly filling up the tank: First remove the piston (ref. 240) by using the handle. Fill the
tank with grease up to 2 inches from the top. Reinstall the piston (ref. 240) and release the
air pressure inside the tank by pushing on the relief button. Reprime the pump.
• Fill the hose and the breaker with grease.
• Adjust the pump onto maximum capacity by unscrewing the nut (ref. 90).
• Check pump operation by energizing the breaker control several times and visually confirm
that grease is being pumped into the hammer.
• Readjust the pump capacity.
Adjusting the grease station:
• The volume of grease sent to the hammer can be adjusted by screwing or unscrewing the
nut (ref. 90). The volume may be increased from 0.031 cu in (0.5 CM3) to 0.183 cu in
(3 cm3) by unscrewing the nut (each flat corresponds to 0.012 cu in (0.2 cm3)).
• A properly lubricated breaker will show some grease running down the point. Keep the tool
greased at all times.
Page 5
Grease Station Parts List
Page 6
Grease Station Parts List
Item Part number Ref # Qty. DESCRIPTION DESCRIPTION
86383759 82720 1 Lubricating station Centrals de graissage
1 86379823 81521 1 Grease tank Réservoir de graisse

including: comprenant:
10 86386844 83358 1 (Cover (Couvercle
20 86379971 81536 2 (Spring (Ressort
30 86383791 82737 1 Piston Piston
40 86380144 81562 1 Proximity detector Détecteur de proximité
50 86502275 96094 1 Lubricating pump Pompe de graissage
Fixing Fixation
60 86390614 84188 1 Support Tole support
70 96702303 8494 4 Screw HM12 Vis HM12
80 86225133 1744 4 HFR M12 Nut Ecrou HFR M12
Accessories Accessoires
• 86383775 82726 1 Spare package Pochette de rechange
including: comp.:
A 1 (Lip seal (Joint à lèvres
B 1 (Lip seal (Joint à lèvres
C 1 (O-ring (Joint torique
D 1 (O-ring (Joint torique
E 4 (Tight ring (Bague BS
F 1 (Seal (Joint
G 2 (Lip seal (Joint à lèvres
H 1 (Brass seal (Joint cuivre
86383338 82611 1 Grease bucket (EM 22) Seau de graisse (EM 22)
86357613 75233 1 Oil bucket Seau d’huile
Page 7
Articulation Pin Greasing Pump G3
Instructions
G3 Automatic
Lubrication Pump 3A0414N
EN
For dispensing of NLGI Grades #000 to #2 greases and oil with at least 40cSt. For
Professional Use Only.
Not approved for use in European explosive atmosphere locations.
Part Nos., page 3

5100 psi (35.1 MPa, 351.6 bar) Maximum Working Pressure
Important Safety Instructions

Read all warnings and instructions in this
manual. Save these instructions.
TI14705
Table of Contents
Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Part / Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 3 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Parts - 2 Liter Models . . . . . . . . . . . . . . . . . . . . . . . 80
4 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Parts - 4 Liter and Larger Models . . . . . . . . . . . . . 81
8 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
12 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
16 Liter Models . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Mounting Pattern
Understanding the Model Number . . . . . . . . . . . 7 (For correct mounting configuration, choose
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 either Option 1 or Option 2). . . . . . . . . . . . . 84
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Wall Mounting Template . . . . . . . . . . . . . . . . . . 85
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . 11 Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 86
Choosing an Installation Location . . . . . . . . . . . 12 Graco Information . . . . . . . . . . . . . . . . . . . . . . . 86
System Configuration and Wiring . . . . . . . . . . . 13
Cable Wiring Diagrams . . . . . . . . . . . . . . . . . . . 23
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Connecting to Auxiliary Fittings . . . . . . . . . . . . . 28
Setting Pump Outlet Volume . . . . . . . . . . . . . . . 29
Loading Grease . . . . . . . . . . . . . . . . . . . . . . . . 30
Filling Oil Unit . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Priming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
No Controller Operation . . . . . . . . . . . . . . . . . . . . 32
Quick Setup Guide . . . . . . . . . . . . . . . . . . . . . . . . 34
Pro Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Control Panel Overview (FIG. 13) . . . . . . . . . . . 35
Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Max Model Setup . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Control Panel Overview (FIG. 14) . . . . . . . . . . . 39
Programming the Max Model . . . . . . . . . . . . . . 40
PUMP OFF / REST Setup . . . . . . . . . . . . . . . . 44
DMS™ Models Only . . . . . . . . . . . . . . . . . . . . . 46
Storing Pump Program Settings to the Flash Drive
47
Uploading Pump Program Settings to the Pump 47
Operation / Data Log . . . . . . . . . . . . . . . . . . . . . . . 48
System Event Log . . . . . . . . . . . . . . . . . . . . . . . 48
Error Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Functional Summary . . . . . . . . . . . . . . . . . . . . . 51
Technical Summary . . . . . . . . . . . . . . . . . . . . . . 53
Advanced Programming . . . . . . . . . . . . . . . . . . . . 54
Run Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Time Control . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Max Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Fault / Warning Scenarios . . . . . . . . . . . . . . . . . 65
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
2 3A0414N
Part / Model Numbers

The Part Number is a six-digit unique number that is only used to order the G3 Pump. Directly related to this six digit
Part Number is the configured Graco Model Number. This configured number identifies the distinct features of a spe-
cific G3 Pump. To help you understand each component that makes up the Model Number see Understanding Your
Model Number, page 7. The tables below shows the relationship between each Part Number and its related Model
Number.
2 Liter Models
No Control Models Max Models
Part Part
Model Number Model Numbers
Numbers. Numbers
96G000 G3-G-12NC-2L0000-00C00000 96G017 G3-G-24MX-2L0L00-10CV00R0
96G001 G3-G-24NC-2L0000-00C00000 96G018 G3-G-24MX-2LFL00-10CV00R0
96G002 G3-G-ACNC-2L0000-0D000000 96G019 G3-G-ACMX-2L0L00-1D0V0000
96G003 G3-G-12NC-2L0A00-L0C00000 96G020 G3-G-ACMX-2LFL00-1D0V0000
96G005 G3-G-24NC-2L0A00-L0C00000 96G021 G3-G-12MX-2L0L00-1DMVA2R3
96G006 G3-G-24NC-2FA00-L0C00000 96G023 G3-G-24MX-2L0L00-1DMVA2R3
96G007 G3-G-ACNC-2L0A00-LD000000 96G024 G3-G-24MX-2LFL00-1DMVA2R3
96G008 G3-G-ACNC-2LFA00-LD00000 96G025 G3-G-ACMX-2L0L00-1DMVA2R3
96G050 G3-A-24NC-2L0A00-L0C00000 96G026 G3-G-ACMX-2LFL00-1DMVA2R3
96G059 G3-A-ACNC-2L0A00-LD000000 96G030 G3-G-12MX-2L0L00-10C00000
96G031 G3-G-24MX-2L0L00-10C000R0
Pro Models 96G032 G3-G-ACMX-2L0L00-1D000000
96G035 G3-G-12MX-2L0L05-10CV0000
Part
Model Numbers 96G036 G3-G-24MX-2L0L05-10CV0000
Numbers
96G037 G3-G-ACMX-2L0L00-1D00A000
96G011 G3-G-24PR-2L0L00-R0C00000 96G098 G3-G-12MX-2L0L00-UDMVA1R2
96G012 G3-G-24PR-2LFL00-R0C00000 96G107 G3-A-24MX-2L0L00-1DMVA2R3
96G013 G3-G-ACPR-2L0L00-0D000000 96G110 G3-G-24MX-2L0L00-UDMVA1R2
96G014 G3-G-ACPR-2LFL00-0D000000 96G115 G3-G-24MX-2LFL00-UDMVA1R2
96G027 G3-G-12PR-2L0000-00C00000 G3-A-ACMX-2L0L00-1DMVA2R3
96G122
96G028 G3-G-24PR-2L0000-00C00000
96G125 G3-G-ACMX-2L0L00-UDMVA1R2
96G029 G3-G-ACPR-2L0000-0D000000
96G132 G3-G-ACMX-2LFL00-UDMVA1R2
96G033 G3-G-12PR-2L0L05-00C00000
96G178 G3-G-24MX-2L0L00-0D00A100
96G034 G3-G-24PR-2L0L05-00C00000
96G070 G3-A-24PR-2L0L00-R0C00000
96G079 G3-A-ACPR-2L0L00-0D000000
3A0414N 3
4 Liter Models
Part Part
Numbers. Numbers
96G040 G3-G-24NC-4L0000-00C00000 96G090 G3-G-24MX-4LFL00-10CV00R0
96G042 G3-G-ACNC-4L0000-0D000000
96G092 G3-G-ACMX-4L0L00-1D0V0000
96G044 G3-G-12NC-4L0A00-L0C00000
96G094 G3-G-ACMX-4LFL00-1D0V0000
96G048 G3-G-24NC-4L0A00-L0C00000
96G096 G3-G-12MX-4L0L00-1DMVA2R3
96G051 G3-A-24NC-4L0A00-L0C00000
96G099 G3-G-12MX-4L0L00-UDMVA1R2
96G053 G3-G-24NC-4LFA00-L0C00000
96G055 G3-G-ACNC-4L0A00-LD000000 96G103 G3-G-24MX-4L0L00-1DMVA2R3
96G060 G3-A-ACNC-4L0A00-LD000000 96G108 G3-A-24MX-4L0L00-1DMVA2R3
96G062 G3-G-ACNC-4LFA00-LD000000 96G111 G3-G-24MX-4L0L00-UDMVA1R2
96G113 G3-G-24MX-4LFL00-1DMVA2R3
Pro Models 96G116 G3-G-24MX-4LFL00-UDMVA1R2
96G118 G3-G-ACMX-4L0L00-1DMVA2R3
Part
Model Numbers 96G123 G3-A-ACMX-4L0L00-1DMVA2R3
Numbers
96G068 G3-G-24PR-4L0L00-R0C00000
96G128 G3-G-ACMX-4LFL00-1DMVA2R3
96G071 G3-A-24PR-4L0L00-R0C00000
96G133 G3-G-ACMX-4LFL00-UDMVA1R2
96G073 G3-G-24PR-4LFL00-R0C00000
96G075 G3-G-ACPR-4L0L00-0D000000 96G141 G3-G-12MX-4L0L00-10C00000
96G080 G3-A-ACPR-4L0L00-0D000000 96G143 G3-G-24MX-4L0L00-10C00000
96G082 G3-G-ACPR-4LFL00-0D000000 96G145 G3-G-ACMX-4L0L00-1D000000
96G135 G3-G-12PR-4L0000-00C00000 96G151 G3-G-12MX-4L0L05-10CV0000
96G137 G3-G-24PR-4L0000-00C00000 96G153 G3-G-12MX-4L0L05-U0CV0100
96G139 G3-G-ACPR-4L0000-0D000000 96G155 G3-G-24MX-4L0L05-10CV0000
96G147 G3-G-12PR-4L0L05-00C00000
96G157 G3-G-24MX-4L0L05-U0CV0100
96G149 G3-G-24PR-4L0L05-00C00000
96G159 G3-G-12MX-4L0L05-00C0010M
96G160 G3-G-24MX-4L0L05-00C0010M
96G161 G3-G-12MX-4L0L05-U0C0010M
96G162 G3-G-24MX-4L0L05-U0C0010M
4 3A0414N
8 Liter Models
Part Part
Numbers. Numbers
96G041 G3-G-24NC-8L0000-00C00000 96G093 G3-G-ACMX-8L0L00-1D0V0000
96G043 G3-G-ACNC-8L0000-0D000000 96G097 G3-G-12MX-8L0L00-1DMVA2R3
96G045 G3-G-12NC-8L0A00-L0C00000 96G100 G3-G-12MX-8L0L00-UDMVA1R2
96G049 G3-G-24NC-8L0A00-L0C00000 96G104 G3-G-24MX-8L0L00-1DMVA2R3
96G052 G3-A-24NC-8L0A00-L0C00000 96G109 G3-A-24MX-8L0L00-1DMVA2R3
96G056 G3-G-ACNC-8L0A00-LD000000 96G112 G3-G-24MX-8L0L00-UDMVA1R2
96G061 G3-A-ACNC-8L0A00-LD000000 96G119 G3-G-ACMX-8L0L00-1DMVA2R3
96G124 G3-A-ACMX-8L0L00-1DMVA2R3
Pro Models
Part 96G142 G3-G-12MX-8L0L00-10C00000
Model Numbers
Numbers 96G144 G3-G-24MX-8L0L00-10C00000
96G069 G3-G-24PR-8L0L00-R0C00000 96G146 G3-G-ACMX-8L0L00-1D000000
96G072 G3-A-24PR-8L0L00-R0C00000 96G152 G3-G-12MX-8L0L05-10CV0000
96G076 G3-G-ACPR-8L0L00-0D000000 96G154 G3-G-12MX-8L0L05-U0CV0100
96G081 G3-A-ACPR-8L0L00-0D000000 96G156 G3-G-24MX-8L0L05-10CV0000
96G136 G3-G-12PR-8L0000-00C00000
96G158 G3-G-24MX-8L0L05-U0CV0100
96G138 G3-G-24PR-8L0000-00C00000
96G177 G3-G-24MX-8L0L05-00C0010M
96G140 G3-G-ACPR-8L0000-0D000000
96G148 G3-G-12PR-8L0L05-00C00000
96G150 G3-G-24PR-8L0L05-00C00000
3A0414N 5
12 Liter Models 16 Liter Models

No Control Models No Control Models
Part Part
Model Number Model Number
Numbers. Numbers.
96G057 G3-G-ACNC-120A00-LD000000 96G058 G3-G-ACNC-160A00-LD000000
Pro Models Pro Models
Part Part
Model Numbers Model Numbers
Numbers Numbers
96G077 G3-G-ACPR-120L00-0D000000 96G078 G3-G-ACPR-160L00-0D000000
96G163 G3-G-24PR-120L05-00C00000 96G167 G3-G-24PR-160L05-00C00000
Max Models Max Models
Part Part
Model Numbers Model Numbers
Numbers Numbers
96G105 G3-G-24MX-120L00-1DMVA2R3 96G106 G3-G-24MX-160L00-1DMVA2R3
96G120 G3-G-ACMX-120L00-1DMVA2R3 96G121 G3-G-ACMX-160L00-1DMVA2R3
96G164 G3-G-24MX-120L05-10CV00000
96G166 G3-G-ACMX-160L00-1D0V0000
96G165 G3-G-24MX-120L05-U0CV0100
96G168 G3-G-24MX-160L05-10CV0000
96G169 G3-G-24MX-160L05-U0CV0100
6 3A0414N
Understanding the Model Number

Use the Code Sample provided below to identify each component’s location in the Model Number. The options for
each component that make up the code are provided on the lists below.
NOTE: Some pump configurations are not available. Contact Graco Customer Service or your local Graco distributor
for assistance.
G 3 - G -
Code Sample: a a b b - c c d e f f - g h i j k m n p
G3 - G = Identifies pump as being a G3; G = Grease Code e: Low Level Option

G3 - A = Identifies pump as being a G3; A = Oil
• L = Low Level with Controller
Code aa: Power Source • A = External Low Level
• 0 = No Low Level monitoring
• 12 = 12 Volts DC
• 24 = 24 Volts DC Code ff: Options
• AC = 100 - 240 Volts AC
• 00 = No Options
Code bb: Operation Control • 05 = 5 Pin CPC power cable
• NC = No Controller Code g, h, i, j, k, m, n, p
• PR = Pro (Timer) Control NOTE: Codes g - p relate to a specific location on the
• MX = Max (Cycle) Control G3 pump. See FIG. 1 for these locations.
Code cc: Reservoir Capacity (Liters)
• C = CPC
• 2L = 2 Liters • D = DIN
• 4L = 4 Liters • 1, 2, 3 = Sensor Number
• 8L = 8 Liters • R = Remote Manual Run
• 12 = 12 Liters • M = Machine Count
• 16 = 16 Liters • A = Alarm Output
• L = Low Level
Code d: Follower Plate Installed
• V = Vent Valve
• F = Follower Plate Installed • 0 = Not populated
• 0 = No Follower Plate
DMSTM Models
k
h m
p
n
j All G3 Models
FIG. 1
3A0414N 7
Warnings
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. When
these symbols appear in the body of this manual, refer back to these warnings. Additional, product-specific warnings
may be found throughout the body of this manual where applicable.
WARNING
ELECTRIC SHOCK HAZARD
This equipment must be grounded. Improper grounding, setup, or usage of the system can cause electric
shock.
• Turn off and disconnect power at main switch before disconnecting any cables and before servicing
equipment.
• Connect only to grounded power source.
• All electrical wiring must be done by a qualified electrician and comply with all local codes and
regulations.
EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS from distributor or retailer.
• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment
and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
SKIN INJECTION HAZARD

High-pressure fluid from dispense device, hose leaks, or ruptured components will pierce skin. This may
look like just a cut, but it is a serious injury that can result in amputation. Get immediate surgical treat-
ment.
• Do not point dispense device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow Pressure Relief Procedure in this manual, when you stop dispensing and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.
8 3A0414N
Warnings
WARNING
PRESSURIZED EQUIPMENT HAZARD
Over-pressurization can result in equipment rupture and serious injury.
• A pressure relief valve is required at each pump outlet.
• Follow Pressure Relief Procedure in this manual before servicing.
PLASTIC PARTS CLEANING SOLVENT HAZARD

Many solvents can degrade plastic parts and cause them to fail, which could cause serious injury or
property damage.
• Use only compatible water-based solvents to clean plastic structural or pressure-containing parts.
• See Technical Data in this and all other equipment instruction manuals. Read fluid and solvent
manufacturer’s MSDSs and recommendations.
MOVING PARTS HAZARD

Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhala-
tion of toxic fumes, and burns. This equipment includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
3A0414N 9
Installation
Installation
Grounding
The equipment must be grounded. Grounding reduces the risk of electric shock by providing an escape wire for the
electrical current in the event of malfunction or breakdown. This product is equipped with a cord having an equipment
grounding conductor. The wire with insulation having an outer surface that is green with or without yellow stripes is
the grounding wire.
Component Identification
L
A
Oil Models Grease Models
DMSTM Models
C
Grease Models with Follower
P Plate (2 liter models only)
E
D
I H
F
K
J
96GXXX
G3-G-24NC-2L0A00-L0C00000 B
FIG. 2:
Key:
A Reservoir I Power / Sensor Panel (both sides; only one side shown)
B Adjustable Pump Element (1 included. Can accommodate J Part Number / Model Number example only shown, (see
3 total) pages 3 and 7, Understanding the Model Number, for
C Pressure Relief Valve (Not included / required for each details)
outlet - Available from Graco. See Parts, page 78.) K Power Cord (DIN shown)
D Zerk Inlet Fill Fitting (1 included / grease models only) L Follower Plate (grease models only / not available on all
E Pump Outlet Plug (2 included) grease models)
F Volume Control Spacers (2 included. More spacers = less M Vent Hole for Follower Plate (grease models only / not
output volume per stroke) (also see FIG. 4, page 29) available on all grease models)
G Fuse (DC models only - Not included, not shown. N Fill cap (oil models only)
Available from Graco. See Parts, page 78.) P USB Port (DMS™ Models only)
H Control Panel (Pro and Max models only)
10 3A0414N
Installation
Typical Installation
Divider Installations
D
E
C F
Injector Installations
G E
B
D
H
A Connected to fuse / power E To lube points

B Pressure relief valve (Not included for divider installations/ F - Proximity Switch (Divider Installations)
required for each outlet - user supplied. See Parts, page - Pressure switch (Injector Installations)
78) G Vent valve (Not included / available from Graco. See
C - Cycle indicator sensor cable (Divider Installations) Parts, page 78.)
- Pressure switch cable (Injector Installations) H Return to reservoir
D - Series progressive divider valves (Divider Installations)
- Injectors (Injector Installations)
3A0414N 11
Installation
Choosing an Installation Location
AUTOMATIC SYSTEM ACTIVATION HAZARD

Unexpected activation of the system could result in serious injury, including skin injection and amputation.
This device has an automatic timer that activates the pump lubrication system when power is connected or when exit-
ing the programming function. Before you install or remove the lubrication pump from the system, disconnect and iso-
late all power supplies and relieve all pressure.
• Select a location that will adequately support • Always mount the G3 upright.
the weight of the G3 Pump and lubricant, as
• If the G3 is going to be operated in a tilted or
well as all plumbing and electrical connections.
inverted position for any period of time, you
• Refer to the two mounting hole layouts provided must use a model that includes a follower plate.
in the Mounting Pattern section of this manual, Refer to your model number to confirm if a fol-
page 84. lower plate was installed on your pump. See
page 7, Understanding the Model Number to
NOTE: The two mounting hole layouts provided identify this character in your model number.
in the Technical Data section show the only cor-
• Use the three fasteners (included) to secure the
rect installation patterns to use for mounting the
G3 to the mounting surface.
G3. No other installation configurations should
be used. • Some installations may require an additional
reservoir support bracket. Consult your Graco
• Use designated mounting holes and provided
distributor for assistance with this installation.
configurations only.
12 3A0414N
Installation
System Configuration and Wiring
Fuses
NOTICE
.
Improper installation of the grounding conductor may Fuses (user supplied) are required on all DC mod-
result in a risk of electric shock. This product must be els. To avoid equipment damage:
installed by a qualified electrician in compliance with • Never operate G3 Pump DC models without a
all state and local codes and regulations. fuse installed.
If the product is permanently connected: • A fuse of the correct voltage must be installed in
• it must be installed by a qualified electrician or ser- line with the power entry to the system.
viceman.
Fuse Kits are available from Graco. The following Table
• it must be connected to a grounded, permanent wir-
identifies the correct fuse to use for your input voltage
ing system.
and the corresponding Graco Kit number.
If an attachment plug is required in the end use
application:
Input Voltage Fuse Value Graco Kit No.
• it must be rated for the product electrical specifica-
12 VDC 7.5 A 571039
tions.
• it must be an approved, 3-wire grounding type 24 VDC 4A 571040
attachment plug.
• it must be plugged into an outlet that is properly Recommendations for Using Pump in
installed and grounded in accordance with all local Harsh Environments
codes and ordinances.
• Use pump with CPC style power cable.
• when repair or replacement of the power cord or
• If using a DIN style power or alarm harness with a
plug is required, do not connect the grounding wire
right angle mating connector, make sure the con-
to either flat blade terminal.
nector does not exit the unit in the UP direction.
• Use a corrosion preventative electrical grease on all
contacts.
3A0414N 13
Installation
Alarm Output and Remote Illumination Response

The following tables include graphical representations of the connector as it appears on the unit, a pin-out associated
with the connector and a typical installation wiring diagram. An internal representative wiring diagram is included
where it is deemed useful.
Wire colors provided on these pages only refer to the power cable provided by Graco with this product.
Standard Remote Tri-Color Remote

Illumination Illumination
(via 5 wire CPC power (via illuminated manual run
Alarm Output cable - Kit 571049) input)
Unit in OFF Mode Deactivated (off) Off Off
Unit in ON Mode Deactivated (off) On Green
Toggles On and Off once
Warning Condition Activated (on) Yellow
per second
Toggles On and Off Toggles On and Off once
Fault Condition Red
once per second per second
Fault Condition
Toggles On and Off Toggles On and Off once
(Advanced Programming Red
once per second per second
Setting A7 OFF)
Fault Condition
Toggles On and Off once
(Advanced Programming Activated (on) Red
per second
Setting A7 ON)
Alarm Relay Response
Output Tied to Common
N.O.
No Faults or
Warnings
N.C.
N.O.
Warning
N.C.
N.O.
Fault
(Advanced
Programming A7 N.C.
OFF)
1 second
Fault N.O.
(Advanced
Programming
Setting A7 ON) N.C.
14 3A0414N
Installation
Wiring and Installation Diagrams

The following Table identifies the wiring and installation diagrams provided in this manual. Additional wiring diagrams
for power cords and cables (described on the parts list, page 72) start on page 81.
Diagram Symbol Page #
Power DIN AC 16
Power DIN DC 17
Power CPC DC 18
Inputs 19
Vent Valve Outputs 20
Alarm Outputs 21
Low Level Outputs 22
Kits: 571030, 571031,

Illuminated Manual Run Input
571032, 571033
3A0414N 15
Installation
Power DIN AC
Connector on Housing Pin-out (AC)

(2)
(3) 1 LINE Black

2 NEUTRAL White
3 Not Used Not Used
(4)
4 GROUND Green/Yellow
(1)
Example Wiring Diagram
Black
1
2
White
3
Green/Yellow 4
16 3A0414N
Installation
Power DIN DC
NOTICE
Be sure when power is applied that stirring paddle
rotates clockwise (when viewed from the top). If it is
wired incorrectly paddle could rotate counter-clockwise
which will damage the pump’s internal components. If
this happens, stop the pump immediately and wire unit
correctly.
Connector on Housing Pin-out (DC)

(1)
1 -VDC Black
(3)
2 +VDC White
3 Not Used Not Used
(4) 4 Not Used Green
(2)
Ignition Switch
1
2
Fuse 3
4
12V-pump - 7.5A
24V pump - 4A
3A0414N 17
Installation
Power CPC DC
Connector on Housing Pin-out

(2)
(1)
1 Not Used Not Used
(3)
2 - VDC Black
(7)
3 + VDC White
4 Not Used Not Used
5 Not Used Not Used
(4) (6)
6 Not Used Not Used
7 Not Used Green/Yellow
(5)
Ignition Switch 1
2
3
Fuse 4
5
6
7
12V-pump - 7.5A
24V pump - 4A
18 3A0414N
Installation
Inputs (M12)
See Technical Data, page 81 for ratings.

(1)
(4)
1 SW +
2 Not Used
(2) 3 SW -
4 Signal
(3)

Dry Contacts
1
2
3
4
Sink (NPN) 2 or 3 wire Source (PNP) 2 or 3 wire
1
1
2
2
3
3
4
4
3A0414N 19
Installation
Vent Valve Outputs

See Technical Data, page 81 for ratings.
(3)
1 Not Used
2 Relief+
3 Relief -
(2) (1)
1
2
3
20 3A0414N
Installation
Alarm Outputs
DC example shown. See Technical Data, page 81 for ratings.

(1)
1 N.O.
(3)
2 N.C.
3 COM
(4) 4 Not Used
(2)

1 A Fuse
G3
Alarm +9-30V
1 Amp Max 1
2
3
4
Switch closes on alarm

(shown in non-alarm position)
3A0414N 21
Installation
Low Level Outputs
See Low Level Output Option, page 32 for functional description. See Technical Data, page 81 for ratings.

(4)
(3)
1 Not Used
2 Not Used
(1) 3 LL N.O.
4 LL COM
(2)
G3
1
2
3
4
22 3A0414N
Installation
Cable Wiring Diagrams
Part No. 126217: 3-Wire, 15 ft (4.5m)

(2)
(1)
1 Not Used Not Used
(3)
2 - VDC Black
(7)
3 + VDC White
4 Not Used Not Used
5 Not Used Not Used
(4) (6)
6 Not Used Not Used
7 Not Used Green/Yellow
(5)
Ignition Switch 1
2
3
Fuse 4
5
6
7
12V-pump - 7.5A
24V pump - 4A
3A0414N 23
Installation
Part No.
123750: 5 Wire, 15 ft (4.5 m)
126219: 5 Wire, 20 ft (6.1 m)
126083: 5 Wire, 30 ft (91. m)
PIN PIN Name Wire Color

(2)
(1)
1 Not Used N/A
(3) 2 - VDC Black
(7)
3 + VDC Red
4 LIGHT White
(4) (6) 5 MANUAL Orange
6 Not Used N/A
(5)
7 Not Used Green w/ Yellow

12V-pump - 7.5A
Fuse
24V pump - 4A
L
1
Black
2
Red
3
White 4
5
e
ng
6
ra
O
7
Green w/ Yellow
(Not Used)
24 3A0414N
Installation
Part No. 123358: DIN
Connector on Housing Pin-out (AC)

(2)
(3) 1 LINE Black

2 NEUTRAL White
3 Not Used Not Used
(4)
4 GROUND Green/Yellow
(1)
Black
1
2
White
3
Green/Yellow 4
3A0414N 25
Installation
Part No. 124333: Cable Pin Out (M12) Part No. 124300: Field Wireable Pin Out
(M12)
Wire Colors
Item No. Color Wire Colors
1 Brown Item No. Color
2 White 1 Brown
3 Blue 2 White
4 Black 3 Blue
4 Black

26 3A0414N
Installation
Part No. 124594: 4 Pin Eurofast Field Part No. 124595: 5 Pin Eurofast Field
Wireable Connector Wireable Connector

3A0414N 27
Setup
Setup Connecting to Auxiliary Fittings

Pressure Relief
NOTICE
Relieve pressure in system using two wrenches work- Do not attach unsupported equipment to auxiliary
ing in opposite directions on pump element and pump fittings such as fill ports and pump element. Attach-
element fitting to slowly loosen fitting only until fitting ing unsupported equipment to these fitting can
is loose and no more lubricant or air is leaking from fit- result in irreparable housing damage.
ting. • Always use two wrenches working in opposite
directions when connecting anything to pump
NOTE: When loosening pump element fitting, do NOT element or auxiliary fittings. See FIG. 3 for an
loosen pump element. Loosening pump element will example.
change the output volume.
• Torque pump element fittings to 50 in. lbs (5.6
N•m).
• When connecting pump element into housing
torque to 50 in. lbs (5.6 N•m).
Pressure Relief Valves
A pressure relief valve appropriate for the lubrication

system must be installed close to every pump outlet to
alleviate unintended pressure rises in the system and
protect the G3 pump from damage.
• Only use a pressure relief valve that is rated for no

FIG. 3 more than the working pressure of the G3 pump it is
installed on. See Technical Data, page 81.
• Install a pressure relief valve close to every pump
outlet; before any auxiliary fitting.
NOTE: A pressure relief valve can be purchased from

Graco. See Parts, page 78.
28 3A0414N
Setup
Setting Pump Outlet Volume 3. Tighten pump element fitting. Torque fitting to 50 in.
lbs (5.6 N•m).
NOTE:
• Before making any adjustments to pump volume,
Relieve Pressure following procedure on page 28.
• Only use Graco supplied spacers to control output

volume.
• It may be necessary to repeat this outlet volume

setup procedure after the pump is operating to
re-adjust the volume of dispensed fluids. FIG. 4
1. Use a wrench to turn pump element counter-clock-
wise to loosen. Do not remove entire pump element.
Only back pump element out enough to allow
spacer to be slid on or off.
2. If needed, remove or insert spacers to achieve

required pump output volume. A tool may be
needed to facilitate removal.
Pump volume control is set using either no (0) spac-

ers, 1 or 2 spacers (FIG. 4).
Do not use more than 2 spacers to adjust output vol-

ume.
Output Volume / Minute

No. Spacers cubic inches cubic cm
2 0.12 2
1 0.18 3
0 0.25 4
NOTE:
• The amount of dispensed volume can vary depend-
ing on external conditions such as lubricant temper-
ature and back pressure from downstream
connections.
• Use of these volume adjustment in conjunction with
setting the ON time of the pump will allow for control
of the output volume.
• Use these volume adjustments as a starting point
and adjust as necessary to ensure desired lubrica-
tion dispense.
3A0414N 29
Setup
Loading Grease
To ensure optimal performance from the G3:
• Only use NLGI #000 - #2 greases appropriate for
your application, automatic dispensing, and the
equipment’s operating temperature. Consult with
machine and lube manufacturer for details.
• The reservoir can be filled using a hand operated
pump, pneumatic pump or electric transfer pump.
• Do not overfill (FIG. 6). max fill line
• Do not operate G3 without reservoir attached.
NOTICE FIG. 6
• Always clean fitting (D) with a clean dry cloth 4. Remove fill hose.
prior to filling reservoir. Dirt and/or debris can
damage pump and/or lubrication system. Models with a follower plate:
• Care must be used when filling the reservoir
using a pneumatic or electric transfer pump to 1. Connect fill hose to inlet fitting (FIG. 5).
not pressurize and break the reservoir.
2. For higher viscosity fluids, start pump to rotate stir-
ring paddle during fill to prevent air pockets from
Models without a follower plate: forming in grease.
1. Connect fill hose to inlet fitting (FIG. 5). For models using an external controller, start pump
operation per your controller specifications.
E For Max and Pro models press the

manual run button.
3. Fill reservoir with grease until seal of

follower plate breaches the vent hole (FIG. 7) and
the majority of air is expelled from the reservoir.
FIG. 5
2. For higher viscosity fluids, start pump to rotate stir-

ring paddle during fill to prevent air pockets from
forming in grease. vent hole
For models using an external controller, start pump

operation per your controller specifications.
For Max and Pro models press the

manual run button. FIG. 7
3. Fill reservoir with NLGI grease to max NOTE: Vent port, located in rear of reservoir, should not
fill line. be used as an overfill port/indicator.
NOTE: Vent port, located in rear of reservoir, should not 4. Remove fill hose.
be used as an overfill port/indicator.
30 3A0414N
Setup
Changing Greases
When changing greases, always use compatible fluids
or greases.
Filling Oil Unit

• Only use oil appropriate for your application, auto-
matic dispensing, and the equipment’s operating
temperature. Consult with machine and lube manu-
facturer for details.
• The reservoir can be filled using a hand operated
pump, pneumatic pump or electric transfer pump.
• Do not overfill (FIG. 8). FIG. 9
• Do not operate G3 without reservoir attached.
• Only use oils with at least 40 cSt. 2. Only run pump until air is no longer dispensed with
the lubricant coming out of element fitting (FIG. 10).
FIG. 8
FIG. 10
1. Remove fill cap (a).

3. Tighten pump element fitting using two wrenches
2. Pour oil into reservoir to fill line (b). working in opposite directions (FIG. 9).
3. Replace fill cap. Hand tighten cap, securely.
Priming
NOTE: It is not necessary to prime pump every time
pump is filled with lubricant.
Pump only requires priming the first time it is used or if it

is allowed to run dry.
1. Loosen pump element fitting (FIG. 9).
NOTE: When loosening pump element fitting, do NOT

loosen pump element. Loosening pump element will
change the output volume
3A0414N 31
No Controller Operation
The G3 Pump can be controlled using an external, user Low Level Output Option
supplied, power source and controller.
Some G3 pumps without controllers include a Low Level
Refer to the Typical Installation diagrams provided on Output Option. The low level signal is monitored across
page 11 for correct location of the required pump ground PINS 3 and 4. For PIN 3 and 4 locations and wiring
wire and fuses. information the Low Level Outputs diagram, page 22.
NOTE: NOTE: A low level warning is triggered when the con-

troller detects PINS 3 and 4 have momentarily closed.
• When using an external power source and control-
ler, Pump ON (Run) Time should be set for no lon- Grease Pumps
ger than 30 minutes.
When the grease level has reached a low warning level,
• In most cases, Pump OFF (Rest) Time should be PINS 3 and 4 momentarily close (1 time per paddle rev-
twice as long as Pump ON (Run) time. If alternative olution) sending the signal that the fluid has reached a
ON / OFF times are required, contact Graco Cus- low level to the controller.
tomer Service for assistance.
To ensure that a low level condition has been met, 3 or
more low level triggers must be detected within 1 minute
or less.
See FIG. 11 for an illustration of a typical Low Level Out-

put response to low grease level.
Typical Low Level Output Response with Low Level Fluid in Grease Models
200 ms
Closed
Contact
Position
Open
3s
FIG. 11
32 3A0414N
Oil Pumps To ensure that a low level condition has been met, the
low level trigger must be detected for 10 continuous sec-
When the oil level has reached a low warning level,
onds.
PINS 3 and 4 close, sending the signal to the controller
that the fluid has reached a low level.
See FIG. 12 for an illustration of a typical Low Level Out-
put response to low oil level.
Typical Low Level Output Response with Low Level Fluid in Oil Models
Closed
Contact
Position
Open
FIG. 12
3A0414N 33
Quick Setup Guide
Quick Setup Guide

Complete setup instructions for Pro Models begin on page 35 and Max Models begin on page 39.

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34 3A0414N
Pro Model Setup
Pro Model Setup

Control Panel Overview (FIG. 13)
NOTE: Programming instructions begin on page 36.
DISPLAY
• A blinking LED under HH, MM, SS or ## OFF TIME
indicates type of measurement unit you • LED lights when OFF Time sequence is
are setting; i.e., HH is hours. running.
• A blinking number on the display indi- • Value is entered in HH:MM.
cates the G3 is in SETUP MODE. • Displays in HH:MM (hours and minutes)
• In RUN MODE displayed numbers count when > 1 hour.
up or down. See Time ON and Time • Displays in MM:SS (minutes and second)
OFF. when < 1 hour.
• Times pump rest between cycles.
• Counts down from set time to zero.
!
HH MM SS ##
ON TIME ALARM ICONS
• LED lights when ON Time LED next to icon lights when a
sequence is running. fault / warning event occurs dur-
• Display shows time as MM:SS ing a run cycle. See page 65 for
(minutes and seconds). a complete description of these
i.e., 08:30 is 8 minutes: 30 sec- ON OFF alarm scenarios.
onds. MM : SS HH : MM
• Times lubrication cycle.
• Counts down from a set time to
zero.
LOCK ICON
• LED next to icon lights indi-
cating PIN is required to
enter setup.
• In SETUP MODE LED
lights when setting up the
PIN.
PRELUBE
LED next to icon lights indicat-
LEFT DIRECTION ARROW / ing Prelube function is enabled.
RESET
• In SETUP MODE, moves cur-
sor in display one field to the
left.
• In RUN MODE: single press UP and DOWN ARROW RIGHT DIRECTION ARROW /
clears warning. MANUAL RUN / ENTER:
• Hold both the UP and DOWN ARROW but-
• In ALARM MODE: pressing and tons down together for 3 seconds to enter • In SETUP MODE, saves
holding for 3 seconds clears SETUP MODE. entry, moves cursor in display
fault / warning and switches one field to the right or to the
• In SETUP MODE, increases or decreases
cycle to OFF MODE. next setup step.
number values shown in display.
• In RUN MODE starts a man-
ual run cycle.
FIG. 13
3A0414N 35
Pro Model Setup
Instructions Entering a PIN Code to Access Setup Mode

The G3 controller does not require a user to provide a
Powering Units With Controllers PIN code to access the programming features of the
unit. However, Graco understands that some users may
By default, units with controllers are set to want to protect the program settings and therefore, an
operate in a timed mode with 1 minute of option for adding PIN Code authorization is available.
ON time and 8 hours of OFF time. The unit The instructions for setting a PIN Code are provided in
should be powered up in OFF mode, the Advanced Programming section of this manual. See
counting down from the 8 hours. If the unit powers up in page 55.
ON mode and has not been primed, hold the reset but-
ton located on the control panel (example shown on the To enter the PIN Code:
right) for 3 seconds to move to the OFF mode.
1. Press both the UP and
The Pro Model uses a timer to regulate how long a DOWN ARROW buttons for 3
pump cycle runs and the length of time the pump rests seconds.
between cycles.
NOTE: 2. The LED next to the LOCK ICON on

• A blinking number on the display indicates the G3 is the display lights and the 4 zeros
in SETUP MODE. appear on the display indicating the
system requires a PIN Code entry to access the G3
• In RUN MODE numbers on the display do not blink. in SETUP MODE.
• After 60 seconds of no activity, the device returns to
3. The cursor is automatically
RUN MODE in the OFF Time cycle and the OFF
positioned to enter the first
Time restarts counting down the total programmed
character of the PIN Code.
amount of time. It does not resume the countdown
Use the UP and DOWN
from the point where the cycle was interrupted when
ARROW buttons to move up
you entered SETUP MODE.
and down through the numbers 0-9 until the first
number in the PIN code is displayed in the field.
Entering Setup Mode
4. Press the ENTER button to set the num-
Press both the UP and DOWN
ber. The cursor automatically moves to
ARROW buttons together for 3
the next number field.
seconds to enter the SETUP
MODE. 5. Repeat steps 3 and 4 for each PIN Code prompt
field.
NOTE: If the lock LED is
lit after entering Setup If the PIN Code you entered is correct, the first editable
Mode and four 0000’s character on the display will flash.
are displayed, the unit
has a PIN Code lock out NOTE: A blinking field on the display indicates the G3 is
enabled. See Entering a in SETUP MODE. In RUN MODE numbers on the dis-
PIN Code to Access play will not blink.
Setup Mode for instruc-
tions on entering a value.
ON Time
• The LED next to the clock in the ON
field lights, indicating you are setting
the ON Time parameters.
• ON Time is set in Minutes and Seconds (MM : SS).
36 3A0414N
Pro Model Setup
• An LED flashes under 6. After pressing the ENTER button to set

either MM when pro- the last SS field, all the programmed ON
gramming minutes Time information is saved.
OR SS when pro- OR
gramming seconds. The G3 automatically switches to the OFF Time
SETUP MODE.
• In SETUP MODE, the
number displayed in OFF Time
the first field, on the
• The LED next to the clock in the OFF
left side of display
field lights, indicating you are setting
blinks, indicating the
the OFF Time parameters.
device is ready to pro-
gram the ON Time minutes.
• OFF Time is set in Hours and Minutes
• The total amount of ON Time cannot (HH : MM).
exceed 30 minutes. If a value greater
than 30 minutes is entered, the RED • An LED flashes under
alarm LED lights and the value must either HH when pro-
be updated. gramming hours OR
MM when program-
If this time does not meet the application needs, ming minutes. OR
contact Graco Customer Support.
• In SETUP MODE the
Programming ON Time number displayed in
NOTE: When programming a time of less than 10 min- left side of display
utes you must program a leading zero in the first num- blinks, indicating the
ber field and press the ENTER button to save the zero device is ready to pro-
selection. gram the OFF Time hours.
1. To set the ON Time use the • The total amount of OFF Time must be
UP or DOWN ARROW button at least twice as long as the pro-
to scroll through numerals 0 grammed ON Time. If a value less
to 5 until the desired number than twice the ON Time is entered, the
appears in the first MM (min- RED alarm LED lights and the value must be
utes) field. updated.
2. Press the ENTER button to lock in the If this time does not meet the application needs,
selection. The next MM number field to contact Graco Customer Support.
the right flashes indicating it is ready for
programming. Programming OFF Time
3. Use the UP or DOWN NOTE: When programming a time of less than 10
ARROW button to scroll hours you must program a leading zero in the first num-
through numerals 0 to 9 until ber field and press the ENTER button to save the zero
the desired number appears selection.
in the second MM number
field. 1. To set the OFF Time use the
UP or DOWN ARROW button
4. Press the ENTER button to lock in the to scroll through numerals 0
selection. to 9 until the desired number
appears in the first HH (hour)
The next number field to the right field.
flashes and the LED lights under SS; indicating it is
ready to program the seconds fields.
5. Repeat steps 1 - 4 to set the SS (seconds) fields.
3A0414N 37
Pro Model Setup
2. Press the ENTER button to lock in the 4. If you want to set a

selection. The next HH number field to prelube delay time,
the right flashes indicating it is ready for press the DOWN
programming. ARROW button to
change OFF to ON
3. Use the UP or DOWN on the display.
ARROW button to scroll
through numerals 0 to 9 until
the desired number appears
in the second HH number Prelube Delay
field. Prelube Delay can be entered to delay the start of the
pump’s cycle on power up. If prelube is set to ON, a pre-
4. Press the ENTER button to lock in the lube delay time in MM:SS must be entered. By default,
selection. the delay is set to 0 (begin an ON cycle immediately).
The next number field to the right Delaying the prelube function may be desired if other
flashes and the LED lights under MM; indicating it is critical functions or systems of your machine or vehicle
ready to program the minutes fields. are also coming on line during power up.
5. Repeat steps 1 - 4 to set the next MM (minutes)
1. Prelube Delay is set in
fields.
MM:SS (minutes and sec-
6. After pressing the ENTER button to set onds). To set the time use the
the last MM field, the OFF Time informa- UP or DOWN ARROW button
tion is saved. to scroll through numerals 0
to 5 until the desired number
appears in the first MM (minutes) field.
Prelube
The Prelube function determines operation of the pump The maximum length of time Prelube Delay can be
when power is applied. It can be set to OFF or ON. set to is 59:59 (59 minutes:59 seconds).
OFF (default) - The unit resumes its lubrication cycle at 2. Press the ENTER button to lock in the
the point it was at when power was removed. selection. The next MM number field to
ON - The unit begins a pump cycle. programming.
3. Use the UP or DOWN

Setting Prelube
1. After you set the OFF Time information and press through numerals 0 to 9 until
the ENTER button, the G3 automatically switches to the desired number appears
the Prelube setup. in the second MM number
field.
Notice the LED next to the prelube
icon on the G3 display lights indicat- 4. Press the ENTER button to lock in the
ing you are now in the Prelube setup selection.
mode.
The next number field to the right
2. OFF displays. If you flashes and the LED lights under SS; indicating it is
want the prelube ready to program the seconds fields.
cycle to begin imme-
diately, leave this set 5. Repeat steps 1 - 4 to set the SS (seconds) fields.
to OFF.
6. After pressing the ENTER button to set
3. Press the ENTER button to set the the last SS field the G3 automatically
selection. switches to the RUN MODE.
38 3A0414N
Max Model Setup
Max Model Setup

Control Panel Overview (FIG. 14)
NOTE: Programming instructions begin on page 40.
OFF TIME/BACKUP TIME

DISPLAY • LED lights when OFF
• A blinking LED under HH, MM, SS Time/Backup Time is used to con-
trol Pump OFF function.
ON TIME/BACKUP TIME or ## identifies type of measurement
unit you are setting; i.e., HH is • Value is entered in HH:M.
• LED lights when ON
hours. • Displays in HH:MM (hours and
Time/Backup Time is running.
• A blinking number on the display minutes) when > 1 hour.
• Display shows time as MM:SS
indicates the G3 is in SETUP • Times pump rest between cycles.
(minutes and seconds). MODE.
i.e., 08:30 is 8 minutes: 30 sec- • Counts down from set time to
onds.
• In RUN MODE displayed numbers zero.
count up or down. See Time ON and • Can be set up to use as a backup
• Sets the limits for the amount
Time OFF.
of time to complete a cycle or for Machine Count control.
build up pressure before a
warning is activated.
• Counts down from a set time to
zero.
ALARM ICONS
LED next to icon lights when a
CYCLE / PRESSURE SETUP fault / warning event occurs dur-
ing a run cycle. See page 65 for
• Sets either Cycle (C) or Pressure a complete description of these
(P) Monitoring limits for up to 3 alarm scenarios.
sensors.
• Each sensor is set up and con-
trolled independently.
PIN ICON
• LED next to icon lights indi-
MACHINE COUNT cating PIN is required to
enter setup.
• LED lights when Machine Count • In SETUP MODE LED
is used to control Pump OFF lights when setting up the
function. PIN.
• Counts independent machine
operations with a sensor to con-
trol Pump Off duration.
PRELUBE
LED next to icon lights indicat-
• Time OFF function can be used
ing LED lights when Prelube
as a backup for Machine Count.
function is enabled.
LEFT DIRECTION ARROW /

RESET RIGHT DIRECTION ARROW /
• In ADVANCED and SETUP
UP and DOWN ARROW MANUAL RUN / ENTER
MODES, moves cursor in dis- • Hold both the UP and DOWN ARROW but- • In SETUP MODE, saves
play one field to the left. tons down together for 3 seconds to enter entry, moves cursor in display
• In RUN MODE: single press SETUP MODE. one field to the right or to the
clears warning. • In SETUP MODE, increases or decreases next setup step.
• In ALARM MODE: pressing and number values shown in display. • In RUN MODE starts a man-
holding for 3 seconds clears ual run cycle.
fault / warning and switches
cycle to OFF MODE.
FIG. 14
3A0414N 39
Max Model Setup
Programming the Max Model Entering a PIN Code to Access Setup Mode
The G3 controller does not require a user to provide a
Powering Units With Controllers PIN code to access the programming features of the
unit. However, Graco understands that some users may
By default, units with controllers are set to want to protect the programming settings and therefore,
operate in a timed mode with 1 minute of an option for adding PIN Code authorization is available.
ON time and 8 hours of OFF time. The unit The instructions for setting up PIN Code Authorization
should be powered up in OFF mode, are provided in the Advanced Programming section of
counting down from the 8 hours. If the unit powers up in this manual. See page 55.
ON mode and has not been primed, hold the reset but-
ton located on the control panel (example shown on the To enter the PIN Code:
right) for 3 seconds to move to the OFF mode.
1. Press both the UP and
The Pro Model uses a timer to regulate how long a DOWN ARROW buttons for 3
pump cycle runs and the length of time the pump rests seconds.
between cycles.
NOTE: 2. The LED next to the LOCK ICON on

• A blinking number on the display indicates the G3 is the display lights and the 4 zeros
in SETUP MODE. appear on the display indicating the
system requires a PIN Code entry to run the G3 in
• In RUN MODE numbers on the display do not blink. SETUP MODE.
• After 60 seconds of no activity, the device returns to
RUN MODE in the OFF Time cycle and the OFF
positioned to enter the first
Time restarts counting down the total programmed
character of the PIN Code.
amount of time. It does not resume the countdown
Use the UP and DOWN
from the point where the cycle was interrupted when
ARROW buttons to move up
you entered SETUP MODE.
and down through the numbers 0-9 until the first
Entering Setup Mode
Press both the UP and DOWN
ber. The cursor automatically moves to
ARROW buttons together for 3
seconds to enter the SETUP
MODE. 5. Repeat steps 3 and 4 for each PIN Code prompt
field.
NOTE: If the lock LED is
lit after entering Setup If the PIN Code you entered is correct, the first editable
Mode and four 0000’s character on the display will flash.
are displayed, the unit
has a PIN Code lock out NOTE: A blinking field on the display indicates the G3 is
enabled. See the follow- in SETUP MODE. In RUN MODE numbers on the dis-
ing section: Entering a play will not blink.
PIN Code to Access
Setup Mode.
40 3A0414N
Max Model Setup
Setting the Real Time Clock 2. Press the ENTER button to set the
DMS ™
Equipped Models Only month.
NOTE: Set the real time clock prior to plugging the USB The 2-digit date displays indicating the G3 is now
flash drive into the pump. ready to program the date.
Enter the Year: Enter the 2-digit Date:
• The year displays. The first programmable

The first programma- character of the 2-digit
ble character, the date blinks indicating the
decade, blinks indi- device is ready to pro-
cating the device is gram the first digit of the
ready to program the date.
decade digit of the year.
The LED under the # sign lights while setting the date.
• The LED under the # sign lights while setting the
year. 1. Use the UP and DOWN ARROW
buttons to move up and down
1. Use the UP and DOWN arrow but- through the numbers 0-3 until the
tons to move up and down through first digit of the date is displayed in
the number 0-9 until the number the field.
for the current decade is displayed
in the field. 2. Press the ENTER button to accept
the selection. The cursor automati-
2. Press the ENTER button to set the cally moves to the second digit of
decade number. The curser auto- the date.
matically moves to the next field, the
year number. 3. Use the UP and DOWN ARROW
buttons to move up and down
3. Use the UP and DOWN arrow but- through the numbers 0-9 until the
tons to move up and down through second digit of the date is dis-
the number 0-9 until the number played in the field.
for the current year is displayed in
the field. 4. Press the ENTER button to set the
date.
4. Press the ENTER button to set the The time displays indicating the G3 is now ready to
year number. program the time.
The 3-character month displays indicating the G3 is Enter the Time:

now ready to program the month.
• The time displays in 24-Hour format. i.e., 2:45 PM
displays as 14:45.
Enter the Month:
• The clock is set in Hours and Minutes (HH:MM).
• The LED under the

HH lights when set-
ting hours and the
LED under the MM or
1. Set the 3 character month by using lights when setting
the UP and DOWN ARROW but- minutes.
tons to move up and down through
the list of months until the current
month is displayed in the field.
3A0414N 41
Max Model Setup
• The first programmable number of the HH (hour) • The LED next to C/P1 lights, indicat-
filed blinks, indicating the device is ready to program ing which sensor of the pump control
the first digit of the hour. you are programming using either a
specific number of cycles or by mon-
• When programming a time of less then 12 hours, itoring a pressure switch.
you must program a leading zero in the first number
• C / P2 and C / P3 controls functions to the second
field and press the ENTER button to save the zero.
and third sensors (when sensors are used).
1. Use the UP and DOWN ARROW • Only sensor inputs that are available on the unit can
buttons to move up and down be programmed.
through the numbers 0-2 until the
desired number appears in the first NOTE: Field cannot be left blank. If C / P2 and C /
hour (HH) field. P3 are not used, OFF must be entered instead.
2. Press the ENTER button to set the

Cycle (C1, C2, C3) Setup
number.
Cycle controls the number of lube cycles (as monitored
3. Use the UP and DOWN ARROW buttons to move by an external cycle monitor) completed before the
up and down through the numbers 0-9 until the pump rests.
desired number for the second HH number field
appears. NOTE:
4. Press the ENTER button to set the • You must program at least one cycle. Zero is not an
number. available option.
5. The next number field to the right blinks and the 1. Use UP or DOWN arrow but-
LED under the MM lights indicating the G3 is ready ton to toggle display between
to program the minutes fields. OFF / C1 / P1 on the display.
6. Repeat steps 1-4 to set the minutes (MM) fields.

2. When C1 is
on display,
7. After pressing the ENTER button to press the
set the time, the programmed Time ENTER
information is saved. button to
save selec-
tion and begin programming Cycle data.
Programming ON Duration
• OFF, C1 (C2, C3) or • The first number
P1 (P2, P3) displays, displayed after the
identifying the func- “C1” on the dis-
tion you are program- play blinks, indi-
ming. cating the device
is ready to pro-
• Selection of OFF, C1 (C2, C3) or P1 (P2, P3) desig- gram the number of C1 cycles.
nates the way pump run time is controlled:
• The LED under
• C1, C2, C3 - Completing a specific number of the # sign lights
cycles measured by an external prox/cycle when setting the
switch number of cycles.
• P1, P2, P3 - Reaching a specific pressure
threshold measured by an external pressure 3. Program the number
switch - OR, of cycles by pressing the UP
• OFF - A specific duration of time elapses. or DOWN ARROW button to
move up or down through
42 3A0414N
Max Model Setup
number 0-9. 2. When P1

displays,
press
4. The cycle field is a 2 digit number. When ENTER
the correct first numeral of the number button to
displays, press the ENTER button to save
save the number. The cursor automati- selection.
cally moves to the second number field.
3. If your G3 comes equipped with more than one sen-
NOTE: A leading zero (0) must be entered in the sor input, you will automatically be prompted to
first field if the number of cycles is fewer than 10. begin selecting pump control type for the next sen-
sor. Repeat steps 1 - 2 to program P2 and P3.
5. Press the ENTER button, to save the C1
information. If P1 / P2 / P3 is selected the vent valve time is auto-
matically set to 5 minutes. If the unit is used in an
• If your G3 is equipped with injector based system and a sensor input is not
more than one sensor input, used, the user must update the vent valve time in
you will automatically be advanced programming. (See Advanced Program-
prompted to begin selecting ming, A-3 Vent Valve Time, page 56.)
the pump control type for the
next sensor. Repeat steps 1 - 5 to program cycles Input Not Used
for C2 and C3.
Select OFF if your system does not use the applicable
input.
NOTE: If C / P2 and C / P3 are not used, the default
OFF setting must be entered instead. 1. Use UP or DOWN arrow but-
ton to toggle between OFF /
6. After you set the last field and press the C1 / P1 on the display.
ENTER button, the G3 saves the Cycle
information and moves to setting
Backup Time, page 44.
2. When
Pressure Control (P1, P2, P3) Setup OFF is on
the dis-
• For injector systems, monitoring pressure can be play,
used as a way to ensure sufficient pressure has press the
been reached to activate injectors. The pump runs, ENTER
building up enough pressure to cause injectors to button to save selection.
dispense fluid. Pressure continues to build to a pre-
set maximum, activating the (user supplier) pres- If the sensor inputs are available and none are used in
sure switch. Then an external (user supplied) vent the ON Mode, the definition of the entered time is ON
valve opens and pressure reduces, priming the TIME.
injector for the next cycle.
Examples:
• Pressure control is an ON / OFF selection only.
Model G3-G-24MX-2LFL00-1DMVA2R3 has 4 sensors,
1. Use the UP or DOWN arrow so C/P1, C/P2, and C/P3 and Machine Count can all be
button to toggle between OFF programmed.
/ C1/ P1.
Model G3-G-24MX-2LFL00-10CV00R0 has 1 sensor,
only C/P1 is available for programming.
3A0414N 43
Max Model Setup
Backup Time 4. Press the ENTER button to lock in the

selection.
In both Cycle and Pressure Modes, a maximum run
Time (Backup Time) for the lubrication period must be The next number field to the right
set up. If this Time expires before the lubrication is com- flashes and the LED lights under SS; indicating it is
pleted an alarm/warning is triggered and the pump ready to program the seconds fields.
stops.
To determine the Backup Time, Graco recommends the
user verify the length of time it takes to complete a typi- 6. After pressing the ENTER button to set
cal cycle and double that value (to a maximum of 30 the last SS field, all the programmed ON
minutes). Time information is saved.
Backup Time is setup after Cycle or Pressure Sensor The G3 automatically switches to the OFF Time
Setup is complete. SETUP MODE.
NOTE:
PUMP OFF / REST Setup
• The LED next to the clock in the ON field lights, indi-
cating the Backup Time is being programmed. After setting the parameters for either Cycle (C1, C2 or
C3) or Pressure (P1, P2, or P3) ON modes, the OFF or
• BACKUP (ON) Time is set as minutes and seconds pump rest cycle must be set up. There are 3 ways to
(MM:SS) only. control this function:
• The small flashing LED under the MM indicates you
are setting minutes. • Machine Count switch activation, or
• The first field (left side of display) blinks indicating • Machine Count activations limited by a maxi-
the device is ready for you to begin programming. mum Time, or
• A specific set amount of Time (similar to Time
Programming Backup Time Mode).
NOTE: When programming a time of less than 10 min- • If the machine count sensor input is available
utes you must program the leading zero in the first num- and not used in the OFF Mode, the definition of
ber field and press the ENTER button to save the zero the entered time is OFF TIME.
selection.
Machine Count
1. To set the ON Time use the
UP or DOWN ARROW button 1. After you set the last ON Time field
to scroll through numerals 0 and press the ENTER button, the G3
to 5 until the desired number automatically switches to the
appears in the first MM (min- Machine Count setup.
utes) field.
Notice the LED next to 123 on the G3 display lights
2. Press the ENTER button to lock in the indicating you are now in the Machine Count setup
selection. The next MM number field to mode.
programming. 2. Press the UP or DOWN
ARROW button to move up or
3. Use the UP or DOWN down through number 0-9.
the desired number appears 3. When the correct number displays,
in the second MM number press the ENTER button to set the num-
field. ber.
NOTE: If the machine count input is available on the unit

and not used, the value MUST be set to zero (0).
44 3A0414N
Max Model Setup
4. Repeat 2 - 3 to set the remaining fields. • The total amount of Backup Time must
be at least twice as long as the pro-
NOTE: After the Machine Count value is entered, the G3 grammed ON Time. If a value less
can be programmed to backup the machine count input than twice the ON Time is entered, the
with time. RED alarm LED lights and the value must be
updated.
Backup Time Setup
1. The OFF Time LED lights. If this time does not meet the application needs,
contact Graco Customer Support.
Programming Backup Time

NOTE: When programming a Backup Time of less than
10 hours you must program a leading zero in the first
OFF displays. number field and press the ENTER button to save the
zero selection.
1. To set the Backup Time use

the UP or DOWN ARROW
2. Press the UP or DOWN button to scroll through
ARROW button to change numerals 0 to 9 until the
OFF to ON on the display. desired number appears in
the first HH (hour) field.
2. Press the ENTER button to lock in the

3. Press the ENTER button to set the selection. The next HH number field to
selection. the right flashes indicating it is ready for
programming.
Backup Time
• The LED next to the clock in the OFF ARROW button to scroll
field lights, indicating you are setting through numerals 0 to 9 until
the Backup Time parameters. the desired number appears
in the second HH number
• OFF Time is set in Hours and Minutes field.
(HH : MM).
• An LED flashes under selection.
either HH when pro-
gramming hours OR The next number field to the right
MM when program- flashes and the LED lights under MM; indicating it is
ming minutes. OR ready to program the minutes fields.
• In SETUP MODE the 5. Repeat steps 1 - 4 to set the next MM (minutes)
number displayed in fields.
left side of display 6. After pressing the ENTER button to set
blinks, indicating the the last MM field, the OFF Time informa-
device is ready to pro- tion is saved.
gram the Backup Time hours.
7. After selecting ON, refer to page 43.
NOTE: Backup time can be set in HH:MM for the

machine count input.
3A0414N 45
Max Model Setup
Prelube
The maximum length of time Prelube Delay can be
The Prelube function determines operation of the pump set to is 59:59 (59 minutes:59 seconds).
when power is applied. It can be set to OFF or ON.
OFF (default) - The unit resumes its lubrication cycle at selection. The next MM number field to
the point it was at when power was removed. the right flashes indicating it is ready for
programming.
ON - The unit begins a pump cycle.
Setting Prelube ARROW button to scroll
1. After you set the OFF Time information and press
the ENTER button, the G3 automatically switches to
in the second MM number
the Prelube Delay setup.
field.
Notice the LED next to the prelube
icon on the G3 display lights indicat-
selection.
ing you are now in the Prelube setup
mode.
flashes and the LED lights under SS; indicating it is
2. OFF displays. If you
ready to program the seconds fields.
want the prelube
cycle to begin imme- 5. Repeat steps 1 - 4 to set the SS (seconds) fields.
diately, leave this set
to OFF. 6. After pressing the ENTER button to set
the last SS field the G3 automatically
3. Press the ENTER button to set the switches to the RUN MODE.
selection.
DMS™ Models Only

4. If you want to set a
prelube delay time,
press the DOWN
ARROW button to Downloading Data
change OFF to ON
on the display. 1. Plug the USB flash drive into the USB port.
NOTE: The G3 pump stops pumping as soon as the

USB flash drive is plugged into it.
Prelube Delay
Prelube Delay can be entered to delay the start of the 2. The system automatically begins downloading data
pump’s cycle on power up. If prelube is set to ON, a pre- to the USB drive.
lube delay time in MM:SS must be entered. By default,
3. “data” is displayed while the system
the delay is set to 0 (begin an ON cycle immediately).
is downloading files.
Delaying the prelube function may be desired if other 4. When download is finished, “done” is
critical functions or systems of your machine or vehicle displayed.
are also coming on line during power up.
5. G3 pump restarts cycle in the OFF mode.
1. Prelube Delay is set in
MM:SS (minutes and sec- 6. Remove the USB flash drive.
onds). To set the time use the
UP or DOWN ARROW button
to scroll through numerals 0
to 5 until the desired number
appears in the first MM (minutes) field.
46 3A0414N
Max Model Setup
Storing Pump Program Settings 2. The system automatically begins downloading data
to the USB drive.
to the Flash Drive
3. “data” is displayed while the system
The pump program settings file is named: is downloading files.
GRACO/G3Config/g3config.bin. This file cannot be 4. When download is finished, “done” is

modified. Modification of the file or file name may cause displayed.
it to be unusable.
1. Plug the USB flash drive into the USB port.
6. After the download is com-
NOTE: The G3 pump stops pumping as soon as the plete, press and hold the
USB flash drive is plugged into it. RESET button and UP
ARROW button for 3 seconds
2. The system automatically begins downloading data to upload the setup stored in the USB flash drive.
to the USB drive.
7. “data” is displayed while the unit is
3. “data” is displayed while the system uploading the configuration data.
is downloading files.
8. When upload is finished, “done” is
4. When download is finished, “done” is displayed.
displayed.
10. Remove the USB flash drive.
6. After the download is com-
plete, press and hold the UP 11. After the USB flash drive is
and DOWN ARROW button removed, press and hold the
for 3 seconds to store the cur- UP and DOWN ARROW but-
rent setup to the USB flash tons for 3 seconds to enter
drive. the SETUP MODE (see
Entering Setup Mode, page 40).
7. “data” is displayed while the unit is
downloading and storing the configu- 12. In SETUP MODE, set the YEAR, MONTH, DATE
ration on the USB drive. and TIME (see Setting the Real Time Clock, page
41).
8. When configuration is stored, “done”
is displayed. 13. After pressing the ENTER button to set
the TIME, press the RESET button to
9. G3 pump restarts cycle in the OFF mode. exit the SETUP MODE.
10. Remove the USB flash drive. Viewing the UNIT DMS ID Number
1. In RUN mode, press and hold the
Uploading Pump Program DOWN ARROW button.
Settings to the Pump 2. The Unit DMS ID number displays. The

unit continues to normal operation while
1. Plug the USB flash drive into the USB port.
the DMS ID is displayed.
NOTE:
3. Release the DOWN ARROW button after viewing
• The USB flash drive must contain file the DMS ID number.
GRACO/G3Config/g3config.bin.
• The G3 pump stops pumping as soon as the
USB flash drive is plugged into it.
3A0414N 47
Operation / Data Log
Operation / Data Log Sample System Event Log

Example Event Log 1: Pump cycle of a divider valve
During operation the G3 Pump stores information as system with a proximity switch set to detect 5 divider
Log and Summary Files. valve cycles.
Logs contain the following information: G3 System Event Log

DMS ID Number: 0025 (see page 47)
• Log Name Software Part Number: 16F821
• DMS ID Number Software Version: 1019
• Current Software Graco Part Number 09/29/2010 14:1400
• Current Software Version
Date Time Description
• Date and Time of Upload
9/29/2010 14:13:02 Pump Run Off
9/29/2010 14:13:02 C1 Cycle Completed
System Event Log 9/29/2010 14:12:39 C1 Cycle Detected
9/29/2010 14:12:34 C1 Cycle Detected
The System Event Log lists the date and time of the last 9/29/2010 14:12:28 C1 Cycle Detected
800 common system events such as pump cycles, man- 9/29/2010 14:12:23 C1 Cycle Detected
ual run and setting changes. The most recent event is 9/29/2010 14:12:17 Pump Run On
listed first.
The log file is stored in a folder structure created by the

pump DMS ID and download date. If multiple downloads
are done on the same date, the existing files will be writ-
ten over.
The folder structure is as follows:
GRACO/G3_{DMS_id}/{download date - YYYYm-

mDD}/EVENTLOG.CSV
Example: GRACO/G3_00025/20100911/EVENT-
LOG.CSV.
48 3A0414N
Example Event Log 2: Pump cycle of an injector valve Venting Detected In an injector system, the pump on cycle
system with a pressure switch feedback. has completed and the system is cur-
rently venting pressure through the vent
Date Time Description valve.
9/29/2010 13:28:12 Venting Completed Prelube Initiated The pump has entered a prelube delay
9/29/2010 13:23:12 Venting Detected after powering up.
9/29/2010 13:23:11 Pump Run Off Prelube Completed The pump has completed prelube delay
9/29/2010 13:23:11 P1 Pressure Completed and will begin a pump on cycle.
9/29/2010 13:22:20 Pump Run On Successful Pin The pin code was successfully entered
Code Entry and the user has entered setup mode.
Common System Events are listed below.

Pump Run On The pump entered an on cycle and is Error Log
operating and dispensing material.
The Error Log lists Set Time and Clear Time for the last
Pump Run Off The pump entered an off cycle and is
not dispensing. 400 faults and warnings. The most recent event is listed
first.
Pump Run Can- A pump on cycle was cancelled by
celled pressing the cancel button on the front
The log file is stored as:
panel and holding it for 3 seconds.
G3 Power On The pump powered on. GRACO/G3_{DMS_id}/{download date - YYYYm-
G3 Power Off The pump powered off. mDD}/ERRORLOG.CSV
Program Variable The setup mode was entered.
Change Example: GRACO/G3_00025/20100911/ERROR-
C1 Cycle Detected The system is set up to monitor a prox- LOG.CSV.
imity switch on a divider valve using the
C2 Cycle Detected
sensor input (C1, C2, and/or C3) and Sample Error Log
C3 Cycle Detected has detected one divider valve cycle.
G3 Error Log
C1 Cycle Com- The system is set up to monitor a prox-
pleted imity switch on a divider valve using the
sensor input (C1, C2, and/or C3) and Software Part Number:16F821
C2 Cycle Com- Software Version:0205
pleted has achieved the number of counts
required by the system for that input, 12/31/2015 23:04:00
C3 Cycle Com- completing a pump on cycle.
pleted
Date Time Description
P1 Pressure Com- The system is set up to monitor a pres- 12/31/2015 23:03:54 Low Level Cleared
pleted sure switch for an injector system using
12/31/2015 23:03:42 Low Level Fault
P2 Pressure Com- sensor input (P1, P2, and/or P3), the
system has achieved pressure and the 12/31/2015 23:03:32 Low Level Warning
pleted 12/31/2015 23:03:22
switch has activated, completing a P2 Not Detected Cleared
P3 Pressure Com- pump on cycle. 12/31/2015 23:03:22 C1 Not Detected Cleared
pleted 12/31/2015 23:03:19 P2 Not Detected
Machine Count The system is set up to monitor a sen- 12/31/2015 23:03:19 C1 Not Detected
Completed sor on the equipment being lubricated 12/31/2015 23:02:20 Machine Count Not Detected
using the machine count input and has
12/31/2015 23:02:11 Machine Count Not Detected
achieved the number of counts required
by the system for that input, completing
a pump off cycle and initiating a pump
on cycle.
Local Manual Run The manual run button was pressed, ini-
Initiated tiating a pump on cycle.
Remote Manual The remote manual run button was
Run Initiated pressed initiating a pump on cycle.
3A0414N 49
Common Error Log entries are listed below. High Temperature Internal temperature of the unit
Software Fault An internal software error Warning is above the designated oper-
occurred. Contact Graco Cus- ating. Check the unit and sys-
tomer Service. tem to determine that it is
functioning correctly. Operat-
Low Level Warning The unit entered a low level
ing outside of the specified
warning mode and is running
temperature range may cause
low on material. The pump
reduced performance and pos-
continues to dispense material
sible unit failure.
for the duration of the low level
alarm time specified by the Low Temperature Internal temperature of the unit
unit. Warning is below the designated operat-
ing. Check the unit and system
Low Level Fault The alarm time in low level
to determine that it is function-
warning has elapsed. The unit
ing correctly. Operating outside
will not pump until the reservoir
of the specified temperature
is filled and the fault is cleared.
may cause reduced perfor-
Cycle 1 Not Detected In a divider valve system, the mance and possible unit fail-
Cycle 2 Not Detected system has not received the ure.
programmed number of divider
Cycle 3 Not Detected USB Unable to Mount The USB flash drive that was
valve cycles for the specified
installed was unable to connect
input in the programmed
and communicate with the
backup time.
pump.
Pressure 1 Not In an injector system the sys-
USB Unsupported The USB flash drive is unsup-
Detected tem has not received a signal
Device ported. Use a different flash
Pressure 2 Not from the pressure switch in the
drive.
Detected designated backup time.
USB File Not Found The pump program setting file
Pressure 3 Not was not found or created cor-
Detected rectly. Restore the setting file to
System Already Pres- In an injector system the pres- the flash drive.
surized 1 sure switch is activated when USB Folder Navigation The pump program setting file
System Already Pres- the unit enters a pump on was not found or created cor-
surized 2 mode and may not have vented rectly. Restore the setting file to
properly. the flash drive.
System Already Pres-
surized 3 USB Invalid File The pump program settings file
was not found or created cor-
Machine Count Sensor The specified number of
rectly. Restore the setting file to
Failure machine count input activa-
the flash drive.
tions was not received within
the designated backup time. Failed Pin Code Entry A failed attempt was made to
enter the pin code password.
Motor Overcurrent The unit is out of expected
motor current range. Check the
system to determine that it is
functioning correctly (i.e., no
blocked lines). Continued oper-
ation at excessive motor cur-
rents will cause degradation in
pump life.
50 3A0414N
Functional Summary
The Functional Summary contains two types of data. • The second report type, labeled Factory under the
Type heading in the first column of the Sample
• The first report type, labeled User under the Type Functional Summary, covers the cumulative life of
heading in the first column of the Sample Functional the pump from the first day it was put into service
Summary, only provides data compiled since the through present day.
last time the Functional Summary was reset through
present day (see A6 - Clearing the Functional and This is very similar to an odometer in your car.
Technical User Summary, page 58).
The log file is stored as:
This is very similar to the resettable trip odometer in
your car. GRACO/G3_{DMS_id}/{download date - YYYYm-
mDD}/FUNCSUM.CSV
Example: GRACO/G3_00025/20100911/FUNC-
SUM.CSV
Sample Functional Summary
(see page 47)
3A0414N 51
Common Functional Summary Data entries are listed

below.
Number of Cycles The number of lubrication cycles
the unit has started.
Total Run Hours Total amount of hours the pump
has been in the ON mode of the
ON/OFF cycle.
Total Powered On Hours Total number of hours that the
unit has been powered on.
Local Manual Run The number of times the manual
run button was pressed.
Remote Manual Run The number of times the remote
manual run button was pressed.
Average Run Time The average amount of time per
lubrication cycle that the pump
has been running (MM:SS).
Average Cycle 1 Time The average amount of time the
Average Cycle 2 Time unit has been operating before
the specified feedback for the
Average Cycle 3 Time sensor input was received (prox-
imity switch counts in divider
valve systems and pressure
switch activation in injector sys-
tems).
Average Duty Cycle The average percentage of time
the unit has been pumping while
it has been powered on.
Max Duty Cycle The highest percentage of time
for one lubrication cycle that the
unit has been pumping while it
has been powered on.
Total Low Level Faults Total number of low level faults.
Total Cycle Pressure Total number of faults related to
Faults sensor feedback in an injector or
divider valve system.
Total Other Faults Faults other than low level or
sensor feedback.
Total Fault Hours Number of hours the system has
been powered on in fault mode.
Total Low Level Warnings Number of low level warning
conditions.
Total Cycle Pressure Total number of warning condi-
Warnings tions related to sensor feedback.
This is only applicable if fault
retries are used.
Total Other Warnings All other warnings including tem-
perature and motor current.
52 3A0414N
Technical Summary Example: GRACO/G3_00025/20100911/TECH-

SUM.CSV
The Technical Summary contains two types of data.
Common Technical Summary Data entries are listed
• The first report only provides data compiled since below.
the Pump Summary was reset to present day (see Average Input Board The average input voltage mea-
A6 - Clearing the Functional and Technical User Voltage (DC) sured by the internal circuit board.
Summary).
Peak Input Board Voltage The peak input voltage measured
(DC) by the internal circuit board.
This is very similar to the resettable trip odometer in
your car. Average Motor Current The average motor current mea-
sured by the unit.
• The second is a report that covers the cumulative Peak Motor Current The peak motor current mea-
life of the pump from the first day it was put into ser- sured by the unit.
vice to present day. Average Internal Temper- The average internal temperature
ature seen by the unit.
This is very similar to an odometer in your car. Peak Internal Tempera- The peak internal temperature
ture seen by the unit.
The log file is stored as: Low Internal Tempera- The lowest internal temperature
ture seen by the unit.
GRACO/G3_{DMS_id}/{download date - YYYYm-
mDD}/TECHSUM.CSV
Sample Technical Summary
G3 Technical Summary
Software Part Number:16F821
Software Version: 0205
12/27/2010 9:50:51
Latest Values
Temp Voltage
31C 23.877
Type Start Date Average Peak Average Peak Average Peak Low
Board Board Motor Motor Internal Internal Internal
Voltage Voltage Current Current Temp Temp Temp
User 12/21/2010 23.877 23.877 0.062 0.06230C 35C 28C
Factory 9/30/2010 22.804 23.877 1.091 0.36233C 42C -10C
3A0414N 53
Advanced Programming
There are 7 Advanced Programming options. The following Table Identifies each option and when it is used.
Advanced
Model Setting Format/ Description Why Use This?
Option
A1 Max / Pro Lockout Secures setup modes with Prevents unauthorized users to adjusting
Code PIN settings.
(Optional)
A2 Max / Pro Low Level MM:SS (minutes:seconds) To accommodate most lubrication situa-
Alarm Time sets amount of time tions, a conservative amount of time is pro-
between Low Level Warn- grammed between the low level warning
ing to Low Level Fault. and fault to help protect unit from running
Default = 3 minutes dry. If necessary the amount of time the
unit runs before stopping due to a low level
fault can be adjusted.
A3 Max Only Vent Valve MM:SS (minutes:seconds) • In an injector based system that does not
Time sets amount of time vent use a sensor for feedback, determines
valve stays open after Pump the amount of time the system vents.
ON Mode. • Vent time can be modified.
Default = 5 minutes
A4 Max Only Alarm Retry Sets number of automatic Establishes the number of times the unit
retries after a Cycle or Pres- automatically retries lubricating after a
sure Alarm. cycle or pressure alarm to determine if a
temporary or false signal can be cleared.
Default = 0
A5 Max Only Active Changes alarm output Uses alarm output to determine if a unit has
Alarm behavior. an alarm AND/OR loses power.
Default = OFF The output turns ON when power is

applied. It turns OFF when power is lost or
an alarm occurs.
Normal operation (OFF) will only activate

alarm output in an alarm condition when
power is on.
Can change (set to ON) to activate alarm

with power ON and deactivate with power
OFF OR warning.
Used to manage power outage.

A6 Max / Functional Clears the Functional and Allows user to track lube events from a spe-
DMS™ and Techni- Technical User Summaries cific point (reset), i.e. a month to month
Equipped cal User evaluation.
Models Only Summary
Reset
A7 Max Only Constant Changes alarm output This function changes the behavior of the
Alarm Out- behavior. alarm output in a fault from either toggling
put on Fault once every second or steady on.
Default = OFF
54 3A0414N
Entering Advanced Setup A1 - Setting Up PIN Code

Press the UP ARROW button for 10 sec- A PIN Code can be programmed into the G3 to protect
onds. the settings from inadvertently being changed by unau-
thorized users.
If the G3 was previously set up to require a
PIN Code, the LED next to the LOCK ICON lights, indi- The LED next to the LOCK ICON on the dis-
cating a PIN Code is required. play lights, indicating you have entered the
PIN Mode.
positioned to enter the first 1. The cursor automatically is
character of the PIN Code. positioned to entered the first
Use the UP and DOWN character of the PIN Code.
ARROW buttons to move up Use the UP and DOWN
and down through the numbers 0-9 until the first ARROW buttons to move up
number in the PIN code is displayed in the field. and down through the numbers 0-9 until the first
ber. The cursor automatically moves to 2. Press the ENTER button to set the num-
the next number field. ber. The cursor automatically moves to
3. Repeat steps 1 and 2 for each PIN Code prompt
field.
3. Repeat steps 1 and 2 for each PIN Code prompt
If the PIN Code you entered is correct, the first editable field.
character on the display will flash.
4. The word OFF appears in the
Selecting Advanced Setup Options display. Press the UP or
DOWN ARROW button to
1. Press the UP or DOWN change this to ON.
ARROW button to move up or
down through Advanced
Options A1 - A5. 5. Press the ENTER button to set the PIN
Code and exit Advanced Setup.
2. Press the ENTER button to set the
selection.
3A0414N 55
A2 - Low Level Alarm Time 3. Use the UP or DOWN

Pump ON mode only. ARROW button to scroll
Programs the amount of time in MM: SS (minutes and the desired number appears
seconds) the pump can run between a Low Level Warn- in the second MM number
ing and a Low Level Fault to help protect unit from run- field.
ning dry.
The maximum recommended length of time is 3:00 min- selection.
utes.
Fault, and Low Level LED illuminate. (Max Model Dis- flashes and the LED lights under SS; indicating it is
play shown in illustration below). ready to program the seconds fields.

the last SS field, all the programmed ON
Time information is saved.
Unit exits Advanced Programming.
A-3 Vent Valve Time - (Max Model Only)

The Vent Valve Time is the amount of time the vent
valve stays open after a cycle is completed.
The recommended Vent Valve Time is 5 minutes.
To bypass the Vent Valve Time enter a value of 00:00.
Vent Valve time must be less than the programmed OFF

time (page 37). If it is not set to a value less than the
programmed OFF time, the G3 will automatically adjust
the time to a value 2 seconds less than the set OFF
FIG. 15 time.
To set Vent Valve Time:

NOTE: When programming a time of less than 10 min- NOTE:
utes you must program a leading zero in the first num-
• The LED next to the clock in the OFF
ber field and press the ENTER button to save the zero
field lights and P1, P2, and P3, indi-
selection.
cating the Vent Valve Time is being
programmed.
1. To set the time use the UP or
scroll through numerals 0 to 9
until the desired number
appears in the first MM (min-
utes) field.
• Time is set as minutes and seconds (MM:SS) only.
selection. The next MM number field to
programming.
56 3A0414N
• The small flashing A-4 Alarm Retry (Max Model Only)

LED under the MM
indicates you are Programs the number of times G3 will automatically
setting Minutes. retry running a lubrication cycle after a cycle or pressure
alarm activates. The default setting is 0. For assistance
• The first field (left determining a reasonable number of Alarm Retries to
side of display) blinks program for your application, contact Graco Customer
indicating the device Service or your local Graco distributor.
is ready for you to
begin programming. 1, 2, and 3 and Fault LED’s illuminate.
• When programming a time of less then 10 minutes
you must program a leading zero in the first number
field and press the ENTER button to save the zero
selection.
1. To set the Time use the UP or
scroll through numerals 0 to 5
until the desired number
appears in the first minute
field.

selection. The next minute field to the
right flashes indicating it is ready for
programming.

in the second minute field.
FIG. 16
selection.
To set the Alarm Retry:
5. The next number field 1. The default value
to the right flashes 0000 appears in the
and the LED lights display.
under SS; indicating
it is ready to program
the Seconds fields.
2. Press the UP or DOWN
6. Repeat steps 1 - 4 to set the MM (seconds) fields. ARROW button to move up or
down through number 0-9.
the last seconds field, all the pro-
grammed Time information is saved. 3. When the correct number displays,
press the ENTER button to set the num-
Unit exits Advanced Programming. ber.
4. Repeat 2 - 3 to set the remaining fields.
Press the ENTER button to exit Advanced

Programming.
3A0414N 57
A-5 Active Alarm (Max Model Only) A6 - Clearing the Functional and Technical
Changes the alarm output behavior. Uses output to User Summary (DMS™ Models only)
determine if a fault has occurred.
The Pump Summary shows run details since the last
time the summary was cleared.
Fault and ON LED’s illuminate.
FIG. 17
FIG. 18

1. The default OFF dis-
ARROW button to move
plays.
through Advanced Options
until Advanced Option A6 is
displayed.
2. Press the ENTER button.

ARROW button to change
OFF to ON on the display to 3. “Data” displays.
activate alarm condition.
3. Press the ENTER button to exit 4. Press the RESET but-

Advanced Programming. ton. “Reset” displays.
The summary data is
cleared.
5. Press the RESET or

ENTER button to exit.
58 3A0414N
A-7- Constant Alarm Output on Fault

This function changes the behavior of the alarm output
in a fault from either toggling once every second
(default) or steady on.
Fault and Warning LEDs Illuminate
!
HH MM SS ##
ON OFF
MM : SS HH : MM
C
P1
123
C C
P2
C P
P3
FIG. 19
1. The default OFF is

displayed. The alarm
output will toggle
once a second.

ARROW to change OFF to
ON on the display to change
the alarm output to be on
steady
3. Press the ENTER button to exit

Advanced Programming.
3A0414N 59
Run Mode
Run Mode • When the OFF Time count reaches zero, the G3
Automatic Lubrication Pump turns the pump on and
it runs for the programmed ON Time cycle (FIG. 21).
Time Control (Notice the ON Time LED is now illuminated on the

display.)
After setup is complete, the G3 automatically begins to
run the OFF Time sequence (FIG. 20). • The example shown in FIG. 21 shows an ON Time of
8 minutes and 42 seconds before the lubrication
• The G3 runs the programmed OFF sequence. cycle ends.
(Notice the OFF Time LED on the display lights and

the OFF Time counts down on the display.)
!
HH MM SS ##
• The example shown in FIG. 20 shows an OFF Time
of 1 hour and 32 minutes before the lubrication cycle
begins.
ON OFF
MM : SS HH : MM
!
HH MM SS ##
ON OFF
MM : SS HH : MM
FIG. 21
• When the ON Time count reaches zero, the pump

shuts off again and the system again runs OFF
Time cycle and the OFF Time LED is now again illu-
minated (FIG. 20).
FIG. 20 This sequence repeats itself until the device is
reprogrammed or an alarm occurs.
60 3A0414N
Run Mode
Max Model Pressure Control

• A single triggered count in a pressure based
Lubrication Mode (Pump ON) Controls system (P1). Typically a pressure switch on the
In Max models the Lubrication Mode (Pump ON) can be end of a line of injectors.
controlled by either cycle and/or pressure sensors. • The LED next to the appropriate sensor (C/P1,
C/P2, C/P3) illuminates (FIG. 23 and FIG. 24).
If cycle and/or pressure controls have been set to some-
thing other than OFF the display will alternate between • The display indicates the sensor (P1, P2, P3)
cycles (C1, C2, C3) and/or active sensors (P1, P2, P3) and whether the pressure switch for that sensor
and Backup Time. has been triggered or not.
If cycle or pressure controls have been set to OFF then - 01 = pressure switch has not been triggered
the Lubrication Mode (Pump ON) will be controlled by - 00 = pressure switch is triggered.
On Time (see Time Control, page 60).
The example shown in FIG. 23 shows sensor P1
With cycle and/or pressure controls set, the lubrication with a pressure switch that has been triggered.
cycle (Pump ON) is ended by meeting all required cycle
and/or pressure settings. FIG. 24 (page 62) shows sensor P2 with a pres-
sure switch that has NOT been triggered.
Cycle Control
• A set number of triggered counts in a cycle
based system (C1). Typically a proximity switch
!
HH MM SS ##
connected to a divider valve.
• The LED next to the appropriate sensor (C/P1,
C/P2, C/P3) illuminates.
• The display indicates the sensor (C1, C2, C3) ON OFF
and the remaining cycles for that sensor (FIG.
MM : SS HH : MM
22).
The example shown in FIG. 22 shows sensor C1

C
with 5 cycles remaining. P1
123
C C
P2
C
!
P
P3
HH MM SS ##
ON OFF
MM : SS HH : MM
FIG. 23
C
P1
123
C C
P2
C P
P3
FIG. 22
3A0414N 61
Run Mode
Backup Time
• In both Cycle and Pressure modes a Backup
!
HH MM SS ## Time (maximum run time) has been set.
• The LED(s) next to all programmed sensors
(C/P1, C/P2, C/P3) illuminate.
• The display shows time remaining until a fault.
ON OFF
MM : SS HH : MM The example shown in FIG. 25 shows 14 min-
utes and 33 seconds left until the fault occurs.
• If all cycle and/or pressure requirements are
C
P1 met the unit exits the lubrication cycle (Pump
ON) and enter the rest cycle (Pump OFF).
123
C C
P2
C P
P3
!
HH MM SS ##
ON OFF
FIG. 24
MM : SS HH : MM
C
P1
123
C C
P2
C P
P3
FIG. 25
62 3A0414N
Run Mode
Max Model Backup Time

Rest Mode (Pump OFF) Controls In Machine Count mode, if a Backup Time (maximum
In Max models the Rest Mode (Pump OFF) is controlled rest time) has been set:
by machine counts.
• The LED next to 1-2-3 illuminates (FIG. 27).
If the Machine Count is set to a value greater than 0000 • The display shows the amount of time remain-
and the Backup Time option is activated, the display ing till a fault.
will alternate between Machine Counts and Backup
Time. The example shown in FIG. 27 shows 4 hours
and 17 minutes remaining until a fault occurs.
If Machine Count has been set to a value greater than
0000 and the Backup Time option is NOT activated, the • If the Machine Count requirements are met the
display will only show the number of Machines Counts unit will exit the Rest Mode (Pump OFF) and
remaining. enter the Lubrication Mode (Pump ON).
With machine count set, the Rest Cycle (Pump OFF) is

ended when the machine count reaches zero (0000).
!
HH MM SS ##
Machine Count
• A set number of triggered counts.
• The LED next to 1-2-3 illuminates (FIG. 26).
ON OFF
• The display indicates the number of machine MM : SS HH : MM
counts remaining.
The example shown in FIG. 26 shows the C

remaining number of machine counts is 0045. P1
123
C C
P2
C P
P3
!
HH MM SS ##
ON OFF
MM : SS HH : MM
FIG. 27
C OFF Time
P1
In Max models if the Machine Count is set to 0000 then
123
C C
P2 Reset Mode (Pump OFF) is controlled with OFF Time
C P (see Time Control, page 60).
P3
FIG. 26
3A0414N 63
Run Mode
Additional Controls Prelube Delay

The Prelube function has been selected. Prelube delay
Venting is set to something other than 00:00:
In Max models a Vent Time can be set using the
Advanced Programming mode (page 56). This is typi- • Power to the unit cycles OFF then ON.
cally done in a Pressure Based System (P1) to allow • Unit immediately begins the Prelube Delay
injectors to reset. count down until the lubrication cycle begins.
• Unit vents for a set amount of time (not dis- • The LED next to the clock in the OFF field is illu-
played). minated (FIG. 28).
• The LED’s next to C/P1, C/P2, C/P3 flash while • The Prelube LED lights (FIG. 28).
unit is venting. • The display shows time remaining until lubrica-
• If Machine Count is set, the display will alternate tion cycle begins. The example shown in FIG. 28
between machine counts remaining and backup shows 8 minutes and 14 seconds left until a
time (Max Model Rest Mode, page 63). lubrication cycle begins.
• If Machine Count has been set the LED next to

1-2-3 illuminates (FIG. 26, page 63).
!
• If Machine Count has not been set the display HH MM SS ##
shows OFF Time (See Time Control, page 60).

• If Machine Count has not been set the LED next
to the clock in the OFF field illuminates (See
Time Control, page 60). ON OFF
MM : SS HH : MM
Prelube / Prelube Delay
In all models a power OFF/ON cycle can be controlled
C
with the Prelube and Prelube Delay functions. P1
123
C C
Prelube P2
C P
The Prelube function has been selected. Prelube delay P3
is set to 00:00:
• Power to the unit cycles OFF then ON.

• Unit immediately begins a lubrication cycle.
• Pro Model - display shows ON Time (See Time FIG. 28
Control, page 60).
• Max Model - display shows Cycle/Pres-
sure/Backup Time (See Max Model Lubrication
Mode Controls, page 61).
Manual Run Cycle
To run an extra (non-programmed) lubrica-
tion cycle, push the Manual Start button.
NOTE: Manual Run option is not available while unit is

in Vent Mode.
64 3A0414N
Alarms
Alarms
Any time a Fault / Warning occurs, a combination of LED’s will illuminate to notify you there is a problem and help
identify the kind of Fault / Warning has occurred.
• Faults and Warnings will not automatically clear.
• To clear an fault, press and hold the RESET button on the display button pad for 3 seconds.
• To clear a warning press and immediately release the RESET button.
Fault / Warning Scenarios

The following pages describe the most likely fault / warnings you could receive.
Alarm Type What it Looks Like What it Indicates Solution

Low Level Level of lubricant in Add lubricant to reservoir.
Warning reservoir is low and addi-
! tional lubricant needs to be After lubricant
HH MM SS ##
added. is added,
press the
Unit continues to operate RESET but-
ON OFF
as normal for a limited ton to clear the warning.
MM : SS HH : MM
period of time until a low
level alarm is triggered.
C
P1
123
C C
P2
C P
P3
Low Level Level of lubricant in Add lubricant to reservoir.

Fault reservoir is low and addi-
!
HH MM SS ##
tional lubricant needs to be After lubri-
added. cant is
added press
Unit stops pumping and and hold the
ON OFF
displays amount of accu- RESET button to clear
MM : SS HH : MM mulated time since the fault.
alarm was triggered.
C If repriming pump is
P1
required, the low level
123
C C
P2 alarm time should be
C
P3
P decreased. See A-2:
Advanced Programming,
Low Level Alarm Time
page 56.
3A0414N 65
Alarms
Cycle / System fails to relieve pres- Examine system to deter-

Pressure sure or a lubrication cycle mine if you have a
Warning HH MM SS ##
! was not completed in the plugged or broken line or
user-defined amount of other component failure,
time. i.e., divider valve, injector.
ON OFF
Unit will continue to oper- Press the
MM : SS HH : MM ate for the number of lubri- RESET but-
cation cycles set by the ton to clear
C warning retry parameter warning.
P1
(see Advanced Program-
123
C C
P2 ming, page 54).
C P
P3
If the warning condition

clears itself on the next
automatic lubrication cycle,
the warning is cleared and
the unit continues normal
operation.
Cycle / In pressure mode indi- Examine system to deter-

Pressure cates that unit is over pres- mine if you have a
Fault HH MM SS ##
! surized or a lubrication plugged or broken line or
cycle was not completed in other component failure,
the user-defined amount of i.e., divider valve, injector.
time.
ON OFF
Press and
MM : SS HH : MM In cycle mode indicates hold the
that a cycle was not com- RESET but-
C pleted in the user-defined ton to clear
P1
amount of time. fault.
123
C C
P2
C
P3
P LED corresponding to the
affected sensor input
blinks.
Could be more than one

sensor alarm at the same
time.
66 3A0414N
Alarms
Machine Unit has not received the Examine system to deter-

Count Fault correct number of machine mine if the machine sen-
!
HH MM SS ##
counts in the user defined sor is operating properly.
Backup Time.
Press and
hold the
ON OFF
RESET but-
MM : SS HH : MM ton to clear
fault.
C
P1
123
C C
P2
C P
P3
System An internal fault has Contact Graco Customer

Fault occurred. Service.
!
HH MM SS ##
ON OFF
MM : SS HH : MM
C
P1
123
C C
P2
C P
P3
Motor Cur- The measured motor cur- Examine system to make

rent Warn- rent is above the recom- sure it is operating cor-
ing HH MM SS ##
! mended operating rectly. A blocked line could
maximum value. Continued create excessive motor
use at excessive motor cur- current
rents could reduce life or
ON OFF
cause permanent damage. Examine pump to ensure
MM : SS HH : MM that it is rotating properly.
C If necessary, contact
P1
Graco Customer Service.
123
C C
P2
C P
P3
3A0414N 67
Alarms
Tempera- The internal temperature of Ensure the unit is used in

ture Warning the unit is out of its recom- the correct operating envi-
!
HH MM SS ##
mended operating range. ronment for the specific
temperature: -13° F to
Use of the unit outside of 158° F (-25° C to 70°C).
the recommended temper-
ON OFF
ature range could cause If necessary contact
MM : SS HH : MM degraded system perfor- Graco Customer Service.
mance and possible dam-
C age.
P1
123
C C
P2
C P
P3
USB Error An error occurred during a Read the Troubleshooting

DMS operation. section of this manual
!
HH MM SS ##
(page 69) for error num-
bers and fault descrip-
tions.
ON OFF
MM : SS HH : MM
C
P1
123
C C
P2
C P
P3
68 3A0414N
Troubleshooting
Troubleshooting
Problem Cause Solution

Incorrect/loose wiring Refer to Installation instructions,
Unit does not power on
page 10.
Tripped external fuse due to internal
Contact Graco Customer Service.
component failure
Unit does not power on (DC models Tripped external fuse due to pumping Replace lubricant with pumpable
only) non-cold weather lubricant in cold lubricant, rated for environmental
weather -13°F (-25°C) conditions and application.
Replace fuse.
Unit does not power on (AC models Tripped internal power supply fuse
Contact Graco Customer Service.
only) due to power supply failure
Maximum duty cycle is 33% (2 min- Adhere to allowable duty cycle. Con-
utes OFF for each minute ON) tact Graco Customer Support if other
Can’t set desired ON/OFF times
duty cycles are required for applica-
tion.
Time entered was misinterpreted as Verify the unit was programmed as
MM:SS instead of HH:MM (or visa intended, referencing programming
Unit is not operating based on the
versa) instructions. Note the dot designation
time that was programmed
for hours, minutes, seconds on the
top row of the display.
Reservoir retaining tabs are cracked Replace reservoir.
or broken
Lubricant leaks past seal located on Reservoir is being pressurized during Ensure vent hole is not plugged.
the bottom of the reservoir filling
If problem persists, contact Graco
Customer Service or your local
Graco distributor for assistance.
Unit not pumping during ON cycle, Failed motor Replace unit.
but controller lights and functions
Air is trapped in the reservoir Add grease following Loading Grease
Follower plate is not going down between the follower plate and lubri- instructions, page 30. Ensure air is
cant purged.
Pump takes several minutes before it Pumping non-cold weather lubricant Add 1 stroke adjust spacer and
begins pumping at the highest pump in cold weather -13°F (-25°C) adjust lube cycle time to accommo-
volume setting (no stroke adjust date the difference in pump volume
spacers installed) per stroke.
Tripped internal, resettable fuse due Verify sensor and manual run inputs
Dim display, unit is not operating to internal component failure or sen- have not created a short circuit condi-
sor short circuit condition tion. Cycle power.
Unit indicates a cycle or pressure The ON Time was not entered cor- Refer to programming ON Time,
alarm before the lubrication cycle rectly pages 36 and 42.
could complete
In an Injector System without sensor Vent valve time needs to be config- Refer to Advanced Programming to
feedback, unit does not vent properly ured set ON Time, page 54.
3A0414N 69
Troubleshooting
Problem Cause Solution

Faulty cycle/pressure wiring connec- Unplug cycle/pressure cables from
Display acts erratically tion to unit G3. Plug cables in one at a time to
identify the faulty connection.
Flash drive was removed during Keep the flash drive plugged in until
USB Error 00
operation the unit has completed the operation.
Flash drive unable to mount (initial- • Unplug the flash drive and
ize) re-install.
• Cycle power and re-install the
flash drive.
USB Error 07 • Retry using a different flash
drive.
If any of the above do not rectify the
error, contact Graco Customer Ser-
vice.
Pump program setting file not found Verify that the pump program setting
folder structure and file are stored
USB Error 11 correctly on the flash drive. See Stor-
ing Pump Program Settings to the
Flash Drive, page 47 for instructions.
Pump program settings directory not Verify that the pump program setting
found. folder structure and file are stored
USB Error 12 correctly on the flash drive. See Stor-
ing Pump Program Settings to the
Flash Drive, page 47 for instructions.
Bad pump program settings file The pump programs settings file is
corrupt. Restore file to the flash drive.
USB Error 13 See Storing Pump Program Settings
to the Flash Drive, page 47 for
instructions.
The following operations can be
attempted if another error occurs
using the USB.
• Unplug the flash drive and rein-
stall.
• Cycle power and re-install the
All other USB errors
flash drive.
• Retry using a different flash
drive.
If any of the above do not rectify the
error, contact Graco Customer Ser-
vice.
70 3A0414N
Maintenance
Maintenance
Frequency Component Required Maintenance
Daily and at refill Zerk Fittings Keep all fittings clean using a clean
dry cloth. Dirt and/or debris can dam-
age pump and/or lubrication system.
Daily G3 Pump Unit and Reservoir Keep pump unit and reservoir clean
using a clean dry cloth.
Daily Display Keep display clean using a clean dry
cloth.
Monthly External Wiring Harness Verify external harnesses are secure.
3A0414N 71
Parts
Parts
Ref Part Description Qty Ref Part Description Qty
PADDLE, stirring, 8 Liter models
1 BASE, three pump housing 1
without follower plate - models
3 278142 COVER, bottom, with seal 1 96G039, 96G041, 96G043,
96G045, 96G049, 96G056,
4 115477 SCREW, mach, torx pan hd 9 96G065, 96G069, 96G076,
96G085, 96G089, 96G093,
O-RING, 258, included in Kit
96G097, 96G100, 96G104, 1
13 124396 571042, 571043, 571044, 571045, 2
96G112, 96G119, 96G127,
571069, 571179
96G136, 96G138, 96G140,
O-RING, included in Kit 571069, 96G142, 96G144, 96G146,
124510 1
571179, 571182, 571183 96G148, 96G150, 96G152,
14 PLATE, ricer 1 96G154, 96G156, 96G158,
96G177
15 BEARING, ball 1 PADDLE, stirring, 12 Liter models
PADDLE, stirring, 2 Liter models without follower plate - models
1
without follower plate - models 96G057, 96G077, 96G105,
96G000, 96G001, 96G002, 96G120, 96G163-96G165
96G003, 96G005, 96G007, PADDLE, stirring, 16 Liter models
96G009, 96G011, 96G013, without follower plate - models
16 1 1
96G015, 96G017, 96G019, 96G058, 96G078, 96G106,
96G021, 96G023, 96G121
96G025-96G037, 96G098, PADDLE, stirring, 2 Liter models
96G110, 96G125, included in Kit with follower plate - models
571044, 96G178 96G004, 96G006, 96G008,
PADDLE, stirring, 4 Liter models 96G010, 96G012, 96G014,
1
without follower plate - models 96G016, 96G015, 96G018,
96G038, 96G040, 96G042, 96G020, 96G022, 96G024,
96G044, 96G048, 96G055, 96G026, 96G115, 96G132 included
96G064, 96G066, 96G068, in Kit 571045
96G075, 96G084, 96G088, PADDLE, stirring, 4Liter models
96G092, 96G096, 96G099, with follower plate - models
1
96G103, 96G111, 96G118, 96G046, 96G053, 96G062,
96G126, 96G135, 96G137, 96G073, 96G082, 96G086, 1
96G139, 96G141, 96G143, 96G090, 96G094, 96G101,
96G145, 96G147, 96G149, 96G113, 96G116, 96G128,
96G151, 96G153, 96G155, 96G133
96G157, 96G159, 96G160, PUMP, element, included in Kit
96G161, 96G162 17 1
571041
SPACER, stroke adjust, included in
18 16F368 2
Kit 571041
21 278145 PLUG, pump, 3/4-16 2
72 3A0414N
Parts

PADDLE, low level, models BOARD, circuit, Max, DMS™
96G003-96G008, 96G015-96G026, models 96G098-96G100,
96G033-96G038, 96G044-96G046, 96G110-96G112, 96G115,
96G048, 96G049, 96G053, ‡ 262463 96G116, 96G125-96G128,
96G055-96G058, 96G062, 96G132, 96G133, 96G153,
96G064, 96G065, 96G068, 96G154,96G157, 96G158,
96G069, 96G073, 96G161, 96G162, 96G165
23 278136 96G075-96G078, 96G082, 1 SCREW, machine, flat head, mod-
96G084-96G086, 96G088-96G090, els 96G009-96G037,
96G092-96G094, 96G096-96G101, 96G064-96G066, 96G069-96G072,
96G103-96G106, 96G110-96G113, 96G075-96G082, 96G084-96G086,
96G115, 96G116, 96G088-96G090, 96G092-96G094,
96G118-96G121, 96G125-96G128, 31 119228 2
96G096-96G101, 96G103-96G113,
96G132, 96G133, 96G115, 96G116,
96G141-96G165, 96G177, 96G178 96G118-96G128, 96G132,
SCREW, M6, models 96G133, 96G135-96G148,
96G003-96G008, 96G015-96G026, 96G150-96G165, 96G177, 96G178
96G033-96G038, 96G044-96G046, LABEL, safety, included in Kit
96G048, 96G049, 96G053, 33 16A579 1
571041
96G055-96G058, 96G062,
LABEL, controller blank, models
96G064, 96G065, 96G068,
96G000-96G008, 96G038-96G046,
96G069, 96G073, 16C473 1
96G048-96G053, 96G055-96G062,
27 123025 96G075-96G078, 96G082, 1
96G068, 96G073, 96G149
96G084-96G086, 96G088-96G090,
96G092-96G094, 96G096-96G101, LABEL, overlay, models 96G009,
96G103-96G106, 96G110-96G113, 96G010-96G014, 96G027-96G029,
96G115, 96G116, 96G033, 96G034,
96G118-96G121, 96G125-96G128, 16A578 96G064-96G066, 96G069-96G072, 1
96G132, 96G133, 96G075-96G082, 96G135-96G140,
96G141-96G165, 96G177, 96G178 96G147, 96G148, 96G150,
34 96G163
BOARD, circuit, Pro, models
96G009 - 96G014, LABEL, overlay, models
96G027-96G029, 96G033, 96G015-9G025, 96G030-96G032,
30 96G034, 96G064, 96G065, 96G035-95G037, 96G084-96G086,
258760 1 96G088-96G090,96G092-96G094,
‡ 96G066, 96G069-96G072,
96G075-96G082, 96G135-96G140, 96G096-96G101, 96G103-96G113,
16A073
96G147, 96G148, 96G150, 96G115, 96G116,
96G163 96G118-96G128, 96G132,
96G133,96G141-96G146,
BOARD, circuit, Max, models
96G151-96G162, 96G164,
96G015-96G026, 96G030-96G032,
96G165, 96G177, 96G178
96G035-96G037, 96G084-96G086,
96G088-96G090, 96G092-96G094,
96G096-96G101, 96G103-96G113,
‡ 258697
96G115, 96G116,
96G118-96G128, 96G132,
96G133, 96G141-96G146,
96G151-96G161, 96G164,
96G177, 96G178
3A0414N 73
Parts

WIPER, stirring, models without fol- RESERVOIR, 4 liter, grease,
lower plate - models 96G000, 96G038, 96G040, 96G042,
96G001, 96G002, 96G003, 96G044, 96G046, 96G048,
96G005, 96G007, 96G009, 96G053, 96G055, 96G062,
96G011, 96G013, 96G015, 96G064, 96G066, 96G068,
96G017, 96G019, 96G021, 96G073, 96G075, 96G082,
96G023, 96G025, 96G084, 96G086, 96G088,
96G027-96G045, 96G048, 96G090, 96G092, 96G094,
96G049, 96G055-96G058, 96G096, 96G099, 96G101,
35 1 40a 24B702 1
96G064-96G066, 96G068, 96G103, 96G111, 96G113,
96G069, 96G075-96G078, 96G116, 96G118, 96G126,
96G084, 96G085, 96G088, 96G128, 96G133, 96G135,
96G089, 96G092, 96G093, 96G137, 96G139, 96G141,
96G096-96G100, 96G103-96G106, 96G143, 96G145, 96G147,
96G110-96G112, 96G118-96G121, 96G149, 96G151, 96G153,
96G125-96G127, 96G135-96G165, 96G155, 96G157, 96G159,
96G177, 96G178, included in Kit 96G160, 96G161, 96G162,
571044 included in Kit 571183
WIPER, stirring, models with fol- RESERVOIR, 4 liter, oil, 96G051,
lower plate - models 96G004, 40b 16G020 96G060, 96G071, 96G080, 1
96G006, 96G008, 96G010, 96G108, 96G123
96G012, 96G014, 96G016, RESERVOIR, 8 liter, grease,
96G018, 96G020, 96G022, 96G039, 96G041, 96G043,
96G024, 96G026, 96G046, 96G045, 96G049, 96G056,
1
96G053, 96G062, 96G073, 96G065, 96G069, 96G076,
96G082, 96G086, 96G090, 96G085, 96G089, 96G093,
96G094, 96G101, 96G113, 96G097, 96G100, 96G104,
96G115, 96G116, 96G128, 40a 1
96G112, 96G119, 96G127,
96G132, 96G133 included in Kit 96G136, 96G138, 96G140,
571045 96G142, 96G144, 96G146,
36 LABEL, brand 1 96G148, 96G150, 96G152,
96G154, 96G156, 96G158,
FITTING, zerk, grease, not included 96G178
on models 96G050-96G052, RESERVOIR, 8 liter, oil, 96G052,
37 123741 96G059-96G061, 96G070-96G072, 1 96G061, 96G072, 96G081,
96G079, 96G080, 40b 1
96G109, 96G124, included in Kit
96G107-96G109, 96G122-96G124 571182
RESERVOIR, 2 liter, grease, RESERVOIR, 12 liter, 96G057,
96G000-96G031, 96G033-96G037, 40a 96G077, 96G105, 96G120, 1
96G098, 96G110, 96G115, 96G163, 96G164, 96G165
40a 24E984 96G125, 96G132-96G033-96G037, 1
RESERVOIR, 16 liter, 96G058,
96G098, 96G110, 96G115, 40a 1
96G078, 96G106, 96G121
96G125, 96G132, 96G178,
included in Kit 571042, 571069 SEAL, follower plate, 2 liter models
41 278139 96G004, 96G006, 96G008, 1
RESERVOIR, 2 liter, oil, 96G050,
96G010, 96G012, 96G014
96G059, 96G070, 96G079,
40b 16G021 1 SEAL, follower plate, 4 liter models
96G107, 96G122, included in Kit
571179 96G046, 96G053, 96G062,
96G073, 96G082, 96G086,
16F472 2
96G090, 96G094, 96G101,
96G113, 96G115, 96G116,
96G128, 96G132, 96G133
74 3A0414N
Parts

PLATE, follower, 2 liter models BAFFLE, low level, 8 liter models
42 96G004, 96G006, 96G008, 1 96G045, 96G049, 96G056,
96G010, 96G012, 96G014 96G065, 96G069, 96G076,
PLATE, follower, 4 liter models 96G085, 96G089, 96G093,
96G046, 96G053, 96G062, 96G097, 96G100, 96G104,
† 24F836 1
96G073, 96G082, 96G086, 96G112, 96G119, 96G127,
1 96G142, 96G144, 96G146,
96G090, 96G094, 96G101,
96G113, 96G115, 96G116, 96G148, 96G150, 96G152,
96G128, 96G132, 96G133 96G154, 96G156, 96G158,
ROD, follower plate, 2 liter models 96G177
43 96G004, 96G006, 96G008, 1 BAFFLE, low level, 12 liter models
96G010, 96G012, 96G014 † 24F923 96G057, 96G077, 96G105, 1
ROD, follower, 4 liter models 96G120
96G046, 96G053, 96G062, BAFFLE, low level, 16 liter models
96G073, 96G082, 96G086, † 24F924 96G058, 96G078, 96G106, 1
96G090, 96G094, 96G101, 96G121
96G113, 96G115, 96G116, BEARING, sleeve, models
96G128, 96G132, 96G133 96G003-96G026, 96G033-96G038,
SPRING, compression, 2 liter mod- 96G044-96G046, 96G048,
els 96G004, 96G006, 96G008, 96G049, 96G053,
44 96G010, 96G012, 96G014, 1 96G055-96G058, 96G062,
96G016, 96G018, 96G020, 96G064, 96G065, 96G068,
96G022, 96G024, 96G026 96G069, 96G073,
SPRING, compression, 4 liter mod- 57 117156 96G075-96G078, 96G082, 1
els 96G046, 96G053, 96G062, 96G084-96G086, 96G088-96G090,
96G073, 96G082, 96G086, 96G092-96G094, 96G096-96G101,
1 96G103-96G106, 96G110-96G113,
96G090, 96G094, 96G101,
96G113, 96G115, 96G116, 96G115, 96G116,
96G128, 96G132, 96G133 96G118-96G121, 96G125-96G128,
96G132, 96G133,
BAFFLE, low level, 2 liter models
96G141-96G165, 96G177, 96G178
96G003, 96G005, 96G009,
96G011, 96G013, 96G015, LABEL, models 96G002, 96G007,
45† 24D838 96G017, 96G019, 96G021, 1 96G008, 96G014, 96G032,
96G023, 96G025, 96G030 - 96G037, 96G042, 96G043,
96G037, 96G098, 96G110, 58 196548 96G055-96G062, 96G075-96G082, 1
96G125, 96G178 96G092-96G094, 96G118-96G128,
96G132, 96G133, 96G139,
BAFFLE, low level, 4 liter models
96G140, 96G145, 96G146
96G038, 96G044, 96G048,
96G055, 96G064, 96G068,
96G075, 96G084, 96G088,
96G092, 96G096, 96G099,
† 24E246 96G103, 96G111, 96G118, 1
96G126, 96G141, 96G143,
96G145, 96G147, 96G149,
96G151, 96G153, 96G155,
96G157, 96G159, 96G160,
96G161, 96G162
3A0414N 75
Parts

WASHER, low level, models ADAPTER, reservoir, models
96G003-96G026, 96G033-96G038, 96G038-96G046, 96G048,
96G044-96G046, 96G048, 96G049, 96G051-96G053,
96G049, 96G053, 96G055, 96G057, 96G058,
96G055-96G058, 96G062, 96G060-96G062, 96G064-96G066,
96G064, 96G065, 96G068, 96G068, 96G069,
96G069, 96G073, 96G071- 96G073, 96G075-
60 16D984 96G075-96G078, 96G082, 2 96G078, 96G080-96G082,
96G084-96G086, 96G088-96G090, 96G084-96G086, 96G088-96G090,
96G092-96G094, 96G096-96G101, 96G092-96G094, 96G096,
62 1
96G103-96G106, 96G110-96G113, 96G097, 96G099-96G101,
96G115, 96G116, 96G103-96G106, 96G108,
96G118-96G121, 96G125-96G128, 96G109, 96G111-96G113,
96G132, 96G133, 96G116,
96G141-96G165, 96G177, 96G178 96G118-96G121, 96G123,
RESERVOIR, mid-section, 8 liter 96G124, 96G126-96G128,
models 96G039, 96G041, 96G043, 96G133, 96G135-96G149,
96G045, 96G049, 96G052, 96G151, 96G153, 96G155,
96G056, 96G061, 96G065, 96G157, 96G159- 96G165,
96G069, 96G072, 96G076, 96G177
96G081, 96G085, 96G089, NUT, models 96G050, 96G051,
96G093, 96G097, 96G100, 96G052, 96G059, 96G060,
61 1
96G104, 96G109, 96G112, 96G061, 96G070, 96G071,
96G119, 96G124, 96G127, 96G072, 96G079, 96G080,
66 126417
96G136, 96G138, 96G140, 96G081, 96G107, 96G108,
96G142, 96G144, 96G146, 96G109, 96G122, 96G1223,
96G148, 96G150, 96G152, 96G124, 96G174, 96G175,
96G154, 96G156, 96G158, 96G176
96G177 FLOAT, oil, models 96G050,
RESERVOIR, mid-section, 12 liter 96G051, 96G052, 96G059,
models 96G057, 96G077, 96G105, 2 96G060, 96G061, 96G070,
96G120, 96G163-96G165 96G071, 96G072, 96G079,
67 24N806
RESERVOIR, mid-section, 16 liter 96G080, 96G081, 96G107,
models 96G058, 96G078, 96G106, 3 96G108, 96G109, 96G122,
96G121 96G1223, 96G124, 96G174,
96G175, 96G176
CABLE,15 ft (4.5 m), SOOW
123749 w/7pos, 3 pin, 90 deg (See Wiring 1
Diagram, page 23)
CABLE, 15 ft (4.5 m), SOOW w/7
123750 pos, 5 pin, 90 deg, (See Wiring Dia- 1
gram, page 24)
CABLE, 20 ft (6.1 m), SOOW, w/7
200
125298 pos, 5 pin, 90 deg, (See Wiring Dia- 1
gram, page 24)
CABLE, 30 ft (9.1m) SOOW, w/7
126083 pos, 5 pin, 90 deg, (See Wiring Dia-
gram, page 24)
CABLE, DIN, bare, (See Wiring
123358 1
Diagram, page 25)
76 3A0414N
Parts
Ref Part Description Qty

CABLE, M12, 15 ft., 4 wire, straight
124300 male to flying leads (See Wiring 1
Diagram, page 26)
201
CABLE, M12, 15 ft., 4 wire, straight
124333 male to female (See Wiring Dia- 1
gram, page 26)
CONNECTOR, Eurofast, fem, 1
124301
straight, 4P
CONNECTOR, Eurofast, 4 Pin (see 1
202 124594
wiring diagram, page 27
CONNECTOR, Eurofast, 5 Pin (see 1
124595
wiring diagram, page 27
Replacement Danger and Warning labels, tags and

cards are available at no cost.
Also order Ref 27, Part No. 123025 and Ref 60, Part
No. 16D984
‡ For Pro Models Only - Also order Ref 31, Part No.
119228 and Ref 34, Part No. 16A578
‡ For Max Models Only - Also order Ref 31, Part No.
119228 and Ref 34, Part No. 16A073
† Also order Ref. 57, Part No. 117156 when ordering

this part.
3A0414N 77
Parts
Pressure Relief Valves Fuses

Important Information regarding Pressure Relief
Valve 16C807. Part Description Qty
571039 FUSE, 12 volt DC 1
Pressure Relief Valve 16C807 can only be used on
the G3 Pump. It is not intended for use with any other 571040 FUSE, 24 volt DC 1
products.
The pressure relief valve uses a a

pressure adjustment screw (a) to
b Installation and Repair Kits
set the pressure release point. It
Manual
is not intended as a way to
Kit No. Description Number
relieve pressure during normal
operation, but as a protective 571026 KIT, output union, 3 pump
3A0523
measure in the event there is an 571063 KIT, output union, 2 pump
unintended pressure increase in KIT, return to reservoir NPT,
the system. Do not use this pres- 571028 includes pressure relief valve
sure relief valve a means of 16C807
ti15644 3A0525
relieving pressure in day-to-day, KIT, return to reservoir BSPP,
normal cycle operation. 571071 includes pressure relief valve
a = adjustment screw
b = locking nut 16C807
The pressure adjustment screw
571029 KIT, vent valve, 24 volt DC, NPT
will require periodic adjustments.
Whenever the valve is set/adjusted (after the set point is 571061 KIT, vent valve, 12 volt DC, NPT
3A0526
found) it is important to ensure that the valve is not bot- 24F536 KIT, vent valve, 24 volt DC, BSPP
tomed out and there is at least 1/2 turn of adjustment 24F537 KIT, vent valve, 12 volt DC, BSPP
remaining. This is determined by turning the screw (a) 571030 KIT, remote manual run, 12 volt DC
1/2 turn and then back turning it out again. 571031 KIT, remote manual run, 24 volt DC
KIT, remote manual run, 12 volt DC,
NOTE: Turning adjustment screw (a) clockwise 571032 3A0528
with cable
increases pressure.
KIT, remote manual run, 24 volt DC
571033
with cable
Part Description Qty
571036 KIT, cover with “G” label NA
VALVE, pressure relief, 500-3500 psi KIT, pump element, includes Ref
(3.44 MPa, 34.4 bar - 24.1 MPa, 241 571041 3A0533
17, 18, 33
16C807 bar), Set pressure 3000 psi + 10% 1
KIT, repair, 2 liter reservoir,
(20.68 MPa, 206.8 bar + 10%) 571042
includes Ref 13, 36, 40
Included in Kit 571028
KIT, repair, 2 liter reservoir, for 3A0534
VALVE, pressure relief, 750 psi (5.17
563156 1 571069 models with follower plate, includes
MPa, 51.71 bar)
Ref 13, 36, 40
VALVE, pressure relief, 1000 psi (6.89
563157 1 KIT, replacement, paddle, 2 liter, for
MPa, 68.95 bar)
571044 models without follower plate,
VALVE, pressure relief, 1500 psi includes Ref 13, 16, 35, 57
563158 1
(10.34 MPa, 103.42 bar)
KIT, replacement, paddle, 2 liter, for
VALVE, pressure relief, 2000 psi 571045 models with follower plate, includes
563159 1
(13.78 MPa, 137.89 bar) Ref 13, 16, 35,40a, 42, 57
VALVE, pressure relief, 2500 psi 3A0535
563160 1 KIT, replacement, paddle, 4-16 liter,
(17.23 MPa, 172.36 bar) 571046 for models without follower plate,
VALVE, pressure relief, 3000 psi includes Ref 13, 16, 35, 57
563161 1
(20.68 MPa, 206.84 bar) KIT, replacement, paddle, 4 liter, for
VALVE, pressure relief, 5500 psi 571047 models with follower plate, includes
563190 1
(37.92 MPa, 379.21 bar) Ref 13, 16, 35, 57
78 3A0414N
Parts
Manual
Kit No. Description Number
571058 KIT, output adapter, NPT
3A0522
571070 KIT, output, adapter, BSPP
571060 KIT, fill, zerk, leakproof NA
KIT, repair, reservoir oil, 2 liter mod-
571179
els, includes Ref 13, 36, 40b
KIT, repair, reservoir, oil 4 liter mod-
571182 3A0534
els, includes Ref 13, 36, 40b
KIT, repair, reservoir, grease, 4 liter
571183
models, includes Ref 13, 36, 40b
3A0414N 79
Parts - 2 Liter Models
Parts - 2 Liter Models
40b
Follower Plate
Models Only
Low Level Grease Models Only
40a 45
43
44
35
42
57
27 1
41
60
16
36
23
15
13
14 Low Level Oil Models Only
18 67
3 37
21 1
31
66
33
17 3
34
3
4 2
30
1 Torque to 4 in. lbs (0.45 N.m)
ti15387
80 3A0414N
Parts - 4 Liter and Larger Models
Parts - 4 Liter and Larger Models
Follower Plate
Models Only 40a 40b
43
44
Low Level Grease Models Only

41
45
42 36
35
57
61
27 1
60
16
62
13 23
14 15
18
3 37 Low Level Oil Models Only

21 1
31 67
33
34 17 3 66
4 2
30
ti15387
3 2 Torque to 30 in. lbs (3.4 N.m)
3A0414N 81
Technical Data
Technical Data
A
Maximum Working Pressure 5100 psi (35.1 MPa, 351.6 bar)

Power
100-240 VAC 88 - 264 VAC; 0.8 A current, 90 VA Power, 47/63 Hz,
Single phase, inrush/locked rotor, max 40A (1ms)
12 VDC 9 - 16 VDC; 5 A current, 60 W, inrush/locked rotor 12 A
24 VDC 18 - 32 VDC; 2.5 A current, 60 W, inrush/locked rotor 6 A
Outputs - Alarm Relay
Rated Load Resistive: 0.4 A at 125 VAC, 2 A at 30 VDC
Inductive: 0.2 A at 125 VAC, 1 A at 30 VDC
Max Operation Voltage Resistive: 250 VAC, 220 VAC
Inductive: 250 VAC, 220 VDC
Max Operating Current Resistive: 3 A (AC), 3A (DC)
Inductive: 1.5 A (AC), 1.5 A (DC)
Max Switching Capacity Resistive: 50 VA, 60 W
Inductive: 25 VA, 30 W
Min Permissible Load Resistive: 10 µA, 10m VDC
Inductive: 10 µA, 10m VDC
Outputs - Vent Valve
Required Vent Valve Type Normally closed
Output Voltage
100/240 VAC 24 VDC
12 VDC Input Voltage
Max Operating Current 2A
Max Operating Power 48 W
Outputs - Low Level (Dry Contact)(G3 Standard/No Con-
troller units)
Contact Rating 10 Watts Maximum
Switch Rating 200 VDC Maximum
Switching Current 0.5 A Maximum
Carry Current 1.2 A Maximum
Inputs - Cycle Pressure, 1, 2, 3, Machine Count
Required Switch Type Normally open (sink, source, or dry contact)
Sensor Voltage
100/240 VAC 24 VDC
Load Current
100/240 VAC 22mA @ 24 VDC
12 VDC 11mA @ 12 VDC
24 VDC 22mA @ 24 VDC
Maximum Residual Voltage
100/240 VAC 4V
12 VDC 2V
24 VDC 4V
Maximum Off Current
100/240 VAC 1.5 mA
12 VDC 1 mA
24 VDC 1.5 mA
Input Impedance 1.1 K
Response Time 60 ms
Cycle Rate 8.0 Hz (50% duty cycle)
82 3A0414N
Technical Data
Fluid
Grease Models Grease NLGI 000 - #2
Oil Models At least 40 cSt oil.
Pumps Up to 3
Pump Output 0.12 in.3 (2 cm3) / minute per outlet - 2 spacers
0.18 in.3 (3 cm3) / minute per outlet - 1 spacer
0.25 in.3 (4 cm3) / minute per outlet - 0 spacers
Pump Outlet 1/4-18 NPSF. Mates with 1/4-18 NPT male fittings
Reservoir Size 2 Liters
IP Rating IP69K
Sensor Inputs 3 (any of pressure or cycle)
1 (machine count)
Ambient Temps -13°F - 158°F (-25°C to 70°C)
Weight (Dry - includes power cord and plug)
Without follower plate 13.3 lbs (6.03 kg)
With follower plate 14.2 lbs (6.44 kg)
Wetted Parts nylon 6/6 (PA), trogamid T5004-060, zinc plated steel,
carbon steel, alloy steel, stainless steel, nitrile rubber
(buna-N), bronze, nickel plated alnico, chemically lubri-
cated acetal, aluminum, PTFE, Grillamid
Sound Data <60 dB
Dimensions
Height Width Depth
Model
Inches cm Inches cm Inches cm
2L 13.25 33.65 8.00 20.32 9.00 22.86
4L 14.50 36.83 9.25 23.50 10.00 25.40
8L 18.50 47.00 9.25 23.50 10.00 25.40
12L 23.00 58.42 9.25 23.50 10.00 25.40
16L 27.50 69.85 9.25 23.50 10.00 25.40
3A0414N 83
Technical Data
Mounting Pattern
(For correct mounting configuration, choose either Option 1 or Option 2). See P/N 126916 template.
Option 1
0.367inch 7.087 inch
9.3 mm 180.0 mm
2x Ø 0.366 inch
9.3 mm 1.180 inch
30.0 mm
3.268 inch
83.0 mm
3.544 inch
90.0 mm
Option 2
0.722 inch 6.378 inch
18.3 mm 162.0 mm
2x Ø 0.366 inch
0.708 inch
9.3 mm
18.0 mm
3.740 inch
95.0 mm
3.189 inch
81.0 mm
FIG. 29
84 3A0414N
Notes
Notes
3A0414N 85
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into,
given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la
rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite
de ou en rapport, directement ou indirectement, avec les procédures concernées.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.
Phone: 612-623-6928 or Toll Free: 1-800-533-9655, Fax: 612-378-3590
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
For patent information, see www.graco.com/patents.
Original instructions. This manual contains English. MM 3A0414
Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2010, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised November 2012
Electric Motor Data
Nr.: 131426/2013
Curves Date: 14-AUG-2013
PERFORMANCE CURVES RELATED TO SPEED

Three-phase Induction Motor - Squirrel Cage
5.0 10.0
B - Current related to full load current

4.5 9.0
4.0 8.0
3.5 7.0
B
3.0 6.0
A - Torque related to full load torque
2.5 A 5.0
2.0 4.0
1.5 3.0
1.0 2.0
0.5 1.0
0.0 0.0
0 10 20 30 40 50 60 70 80 90 100
Percent of synchronous speed
Customer :
Product code :
Product line : W22 - NEMA PREMIUM EFFICIENCY
Output : 75 HP (55 kW) Duty cycle : S1

Frame : 364/5T Service factor : 1.25
Rated speed : 1775 rpm Design : B
Frequency : 60 Hz Enclosure : IP55 (TEFC)
Rated voltage : 440 V Locked rotor torque : 240 %
Insulation class : F Pull up torque : 200 %
Rated current : 87.9 A Breakdown torque : 260 %
Il/In : 6.4 Code G
Notes:
The figures given herewith are regarded as guaranteed values and applied to sinusoidal power supplied motors, within
permissible tolerances under NEMA MG 1-12.
Performed Checked Revision Approved

cli-camunias AUTOMATICO Nr.: 0 Date: 14-AUG-2013
Nr.: 131426/2013
THERMAL CAPACITY IN OVERLOAD

100000
10000
Time (s)
1000 A
C - Locked rotor (cold)
B - Locked rotor (hot)
100
C
A - Overload
B
10
1.0 2.0 3.0 4.0 5.0 6.0 7.0
I/In
Customer :
Product code :

Il/In : 6.4 Code G
Notes:

Nr.: 131426/2013
PERFORMANCE UNDER LOAD

100 1.0 0.0
C - Slip (%)
C
A
90 0.9 1.0
80 0.8 2.0
70 0.7 3.0
B
60 0.6 4.0
50 0.5 5.0
D - Current at 440V (A)

40 0.4 160
120
A - Efficiency (%)
B - Power factor
80
D
40
0
0 10 20 30 40 50 60 70 80 90 100 110 120 130
Percent of rated output
Customer :
Product code :

Il/In : 6.4 Code G
Notes:

Nr.: 131426/2013
DATA SHEET Date: 14-AUG-2013

Customer :
Product code :
Frame : 364/5T Enclosure : IP55 (TEFC)

Output : 75 HP (55 kW) Mounting : B3R(D)
Frequency : 60 Hz Rotation : Both
Poles : 4 Aprox. weight* : 417 kg
Rated speed : 1775 rpm Moment of inertia : 0.9798 kgm²
Slip : 1.39 % Sound Pressure Level : 67.0 dB(A) (global)
Rated voltage : 440V Foundation loads
Rated current : 87.9 A - Max. traction : 708 kgf
L. R. Amperes : 563 A - Max. compression : 1125 kgf
Il/In : 6.4 Code G
Load Power factor Efficiency (%)
No load current : 31.4 A
100% 0.86 95.4
Rated torque : 30.7 kgfm
75% 0.82 95.0
Locked rotor torque : 240 %
50% 0.73 94.5
Breakdown torque : 260 %
Design : B Bearing Quantity (lubricant)
Insulation class : F Front 6314-C3 27 g
Temperature rise : 80 K Rear 6314-C3 27 g
Locked rotor time : 14 s (hot)
Service factor : 1.25 Lubrication interval: 12000 h
Duty cycle : S1 Grease - MOBIL POLYREX EM
Ambient temperature : -20°C to +40°C
Altitude : 1000 m.a.s.l
Notes:
The figures given herewith are regarded as guaranteed values and applied to sinusoidal power supplied motors, within permissible
tolerances under NEMA MG 1-12. Noise level with tolerance of +3 dB(A). (*) Weight value can be changed without previous
notification.

Hydraulic Pump
ERR100BLS2520NNN3K5NLAIN
Frame J
Series 45
Frame E
Open Circuit Pumps
Data Sheet
Frame F Frame K/L

Introduction
For more than 40 years, Sauer- Features:
Danfoss has been developing state- • Designed for durability and flexibility
of-the-art components and systems –– Heavy-duty tapered roller bearings for long life
for mobile machinery used in –– Single piece rigid housing reduces leak paths and noise
off-highway operations around the –– Designed and manufactured to rigorous standards
world. We have become a preferred for mobile equipment
supplier by offering the best of what –– Displacements ranging from 25 to 147 cm3/rev
really matters: The hardware inside [1.53 - 8.97 in3/rev]
your vehicle application.
• Installation and packaging benefits
Series 45 pumps are a high efficiency –– Compact design minimizes installation space requirements
alternative to traditional open –– Wide range of mounting flanges, shafts, and porting
circuit pumps. Each frame size is options for ease of installation
uniquely designed to optimize –– Robust input shaft bearings to handle large external loads
performance, size, and cost, while –– Low noise for operator comfort
matching the demanding
requirements of the mobile • Wide range of controls:
equipment market. –– Pressure Compensating (PC)
–– Load Sensing (LS)
Series 45 pumps are designed to fit –– Remote Pressure Compensation (RP)
the needs of open circuit systems –– Electric Normally Open On/Off - 12 V / 24 V (NO)
capable of speeds up to 3600 rpm, –– Electric Normally Closed On/Off - 12 V / 24 V (NC)
maximum pressures up to 400 bar, –– Electric Proportional Pressure Control (EPC)
continuous pressures up to 310 bar
[4500 psi]. Series 45 pumps offer a • Application benefits
wide variety of control options with –– Optimized design maximizes efficiency and quiet operation
displacements ranging from 25 to –– PLUS+1™ compliant control options
147 cm3/rev [1.53 - 8.97 in3/rev]. –– Simple design reduces service requirements
–– Optimizes machine power usage to maximize productivity
Series 45 pumps are PLUS+1™ –– Maximizes fuel economy to meet engine emission standards
compliant. With robust designs and
proven reliability in the test lab and
the field, Series 45 pumps set the
standard for market quality.
Sauer-Danfoss pumps are
supported by a global network of
authorized service centers.
Local Address:
11076184 • Rev AC • Oct 2012

Series 45
Open Circuit Pumps
Specifications
Pump model Frame L Frame K Frame J
Maximum displacement cm³/rev [in³/rev] 25 [1.35] 30 [1.83] 38 [2.32] 45 [2.75] 45 [2.75] 51 [3.11] 60 [3.66]
Cont. working pressure 260 [3771] 210 [3046] 260 [3771] 210 [3046] 310 [4496] 310 [4496] 310 [4496]
bar [psi]
Max. working pressure 350 [5075] 300 [4350] 350 [5075] 300 [4350] 400 [5800] 400 [5800] 400 [5800]
Continuous input speed min-1 (rpm) 3200 3200 2650 2650 2800 2700 2600
Theoretical flow l/min [US gal/min] 80 [21.1] 96 [25.4] 100.7 [26.6] 119.2 [31.5] 126 [33.3] 137.7 [36.4] 156 [41.2]
Weight kg [lb] Axial 19 [41.9], Radial 24 [52.9] Axial 22 [48.5], Radial 25 [55.1]
Pump model Frame J (cont.) Frame F Frame E

Maximum displacement cm³/rev [in³/rev] 65 [3.97] 75 [4.58] 74 [4.52] 90 [5.49] 100 [6.1] 130 [7.93] 147 [8.97]
Cont. working pressure 260 [3771] 260 [3771] 310 [4496] 260 [3771] 310 [4496] 310 [4496] 260 [3771]
bar [psi]
Max. working pressure 350 [5075] 350 [5075] 400 [5800] 350 [5075] 400 [5800] 400 [5800] 350 [5075]
Continuous input speed min-1 (rpm) 2500 2400 2400 2200 2800 2200 2100
Theoretical flow l/min [US gal/min] 162 [42.9] 180 [47.5] 177.6 [47.4] 198 [52.8] 245 [64.7] 286 [75.6] 308 [81.4]
Axial 22 [48.5] 29 [63.9] 51.3 [113]
Weight kg [lb]
Radial 25 [55.1] 36 [79.4] 54.9 [121]
Dimensions Frame L/K Frame J

100 [3.9] 257.8 [10.15]
155.2 [6.1]
121.9 [4.8]
178.2 [7.016]
Axial port
mm [in]
62 [2.45]
175.1 [6.9] 146 [5.75] 198.8 [7.83] 160.6 [6.323]
239.8 [9.44]
155.2 [6.1]
211.8 [8.339]
Radial port
mm [in]
62 [2.45]
242.4 [9.54] 160.2 [6.3]

207 [8.15] 190 [7.48]
Dimensions Frame F Frame E

256.4 [10.09] 302.7 max [ 11.92]
262.24 [10.324]
314.9 [12.398]
Axial port
mm [in]
239.74 [9.44] 156.28 [6.15] 275 [ 10.827] 196 [7.72]

314.9 [12.398]
262.24 [10.324]
Radial port
mm [in]
256.04 [10.08] 157 [6.18] 304 [ 11.969] 201 [7.91]
11076184 • Rev AC • Oct 2012 © Copyright 2012, Sauer-Danfoss. All rights reserved. Contents subject to change.
All trademarks in this material are properties of their respective owners
HYDRO CONTROL
MAIN BODY VALVE
EX72
www.hydrocontrol-inc.com
HC-EX72
INDIA
Flow sharing compensated valve
HEAD QUARTERS
Hydrocontrol SpA HC Hydraulic Technologies (P) LTD
Via San Giovanni 481 . 40060 Osteria Grande A5 (B) Ngef Ancillary Indl. Estate
Castel S.Pietro Terme . Bologna - Italy Whitefield Road . Mahadevpura (Po)
Phone +39.051.6959411 (15 linee) Bangalore . 560048
Fax +39.051.946476 India
Phone sales Dep.: +39.051.6959447 Phone +91 (080) 40454707
Fax sales Dep.: +39.051.6958132 Fax +91 (080) 40454703
info@hydrocontrol-inc.com info@hydrocontrol-india.com
U.S.A. CHINA
Hydrocontrol Inc. HC China Sales and Production Facility
1109 Technology Drive . Red Wing, MN 55066 U.S.A Guangzhou Bushi Hydraulic Technology Ltd
Phone +1 (651) 212 6400 . Fax +1 (651 212 6401) Shangwei Shaheshe, Yuehu Village
usa@hydrocontrol-inc-com Xiancun, Xintang Town . Zengcheng City
511335 Guangzhou . Guangdong Province
GERMANY China
Hydrocontrol GmbH Phone +86 (021) 52380695
Rudolf Diesel Str. 1 42477 Radevormwald Fax +86 (021) 52380697
Deutschland fareast@hydrocontrol-inc-com
Phone +49 2195-931123 Fax +49 2195-931124
hans.ley@hydrocontrol-inc.de
FRANCE
HC France SAS
7, Rue des Entrepreneurs . Parc de la Vertonne
44122 Vertou . France
Phone +33 02-40332348 . Fax +33 02-28210034
hc-france@wandoo.fr
EX72-00 04.2013
A global partner for innovative solutions

Functional advantages offered by the EX Family
PATENTED SYSTEM
All the control valves belonging to the EX family work according to a principle designed by Hydrocontrol’s R&D depart-
ment and covered by patents EP1860327 (A1) EP1860327 (B1) US2008282691 (A1) and US7581487 (B2).
The valve LS signal is managed according to innovative tecnique which is an absolute first in the flow sharing world,
ensuring:
• elimination of any LS signal bleed off, which can be observed in most systems currently available commercially, and
is often the cause of poor compensation accuracy, slow response and excessive sensitivity to operating conditions.
• LS signal picking downstream of the local compensator: this will make signal detection “neater’’ improving control
efficiency and accuracy.
RESPONSE RATE
The EX control valve’s strength resides in its quick, prompt response, achieved thanks to the functional advantages built
into our patented system. Even the most critical applications such as excavator bucket shacking and the swift dynamics
of forestry machinery, usually hard to achieve on flow sharing systems, can be successfully implemented by using EX
family products.
ACCURACY AND STABILITY

The unique technical characteristics of the Hydrocontrol’s patent allows for outstanding flow control and compensation
precision, not likely to be affected even by the most diverse operating conditions. Simultaneous functions are never
mutually influenced, not even in the presence of the same load factors (an aspect best highlighted in crawler machi-
nery travelling). System stability itself is greatly benefited by the EX design; the system, also in combination with
traditional overcenter valves, appears well balanced and able to effectively reduce oscillation and dynamic instability.
EFFICIENCY
In addition to the well known advantages typically offered by flow sharing systems which, associated with a variable
pump, will drastically reduce the machine operating consumption, the EX family introduces a number of interesting
options, including pressure relief on the LS signal to further increase energy saving and guarantee top efficiency levels.
FLEXIBILITY
The EX family control valves can be easily adjusted to a variety of applications, thanks to the wide range of available
options and different types of available control systems.
COMPACT DIMENSIONS
The carefully designed features and integrated electrohydraulic control ensure a highly compact and optimised layout. In-
tegrated end plates are available in the final working section, adding to the system dimensional and functional efficiency.
PRIORITY
The EX family allow to install side by side pre-compensated section with post-compensated section. This feauture
allow to establish a priority in the way the oil is directed and increse the number of application where the EX fa-
mily can be applied solving technical difficulties that before required external components. Both Inlets and Outlets
remain common for the pre and post compensated sections making the assembling of the valve particularly convenient.

Flow sharing valve
Quick reference guide
general specifications EX34 EX38 EX46 EX54 EX72

Working section number 1 - 10 1 - 10 1 - 10 1 - 10 1-8
CIRCUIT
Spool stroke (mm) 7 7 8 9 11
Spool pitch (mm) 34 38 46 54 72
RATED FLOW
Pump flow rate (l/min) 130 150 220 300 450
A/B port flow rate (l/min) (*) 80 100 180 250 350
RATED PRESSURE
working pressure inlet port P (bar) 350 350 350 350 350
BACK PRESSURE MAX
Max pressure outlet port T (bar) 10 10 10 10 10
(*) with fixed Pump inlet compensator
option chart EX34 EX38 EX46 EX54 EX72

LS Signal pressure relief valve • • • • •
Pump pressure relief valve • • • • •
LS Signal dump valve (electric 12/24 Vdc) • • • • •
Pump dump valve (electric 12/24 Vdc) • • • •
SPOOLS TYPE
Single acting • • • • •
Double acting • • • • •
Float spool • • • • •
SPOOL ACTUATION
Hydraulic actuation • • • • •
Lever actuation • • • •
Without lever • • • • •
Cloche control • •
Prop. electrohydraulic actuation 12-24 Vdc (*) • • • • •
ON/OFF electrohydraulic actuation 12-24 Vdc (*) • • • • •
CAN BUS interface actuation on development •
SPOOL RETURN ACTION

Return spring • • • • •
Mechanical detent • • • (•) (•)
Hydraulic load limit (•) (•) (•)
Pneumatic control (•) (•) (•)
Spools displacement sensor (HLPS) • • • • •
PORT RELIEF VALVE

Antishock valve • •
Anticavitation valve • • • • •
Antishock and anticavitation valve • • • • •
Plug • • • • •
• = available
(•) = special arrangement available on request
(*) = we recommend to keep the T line for the electrohydraulic cartridges separate from the T line of the valve.
2
EX72-00
Flow sharing valve
General index
4 General specifications
Standard working conditions
Fluid options
Applications
Operating principle
6 Hydraulic schema
Post Compensated system Electrohydraulic control
Pre Compensated system Hydraulic control
7 Order example
Standard thread
Tie-rod kit classification
Painting
9 Dimensions
HC-EX72 with Electrohydraulic control
HC-EX72 with Hydraulic control
11 Typical curves
13 Inlet Section
Order example
Inlet side classification
Valve identification
Valve arrangement
Inlet classification
17 Working section
Order example
Spool identification
Spool flow
Spool actuation classification for Hydraulic control
Spool actuation classification for Electrohydraulic control
Work section arrangement
Auxiliary valves identification
22 Integrated outlet section

Order example
Integrated outlet section classification
24 HC-EX72 Spare parts list

Gasket kits
Trasformation kits
28 Installation and maintenance

Guidelines
General clamping torque
Dimensions - Thread codes
Dimensions - SAE Flange codes
31 General conditions and patents

Product identification
The specifications detailed in this catalogue show standard products. Special applications are available to order subject to contacting our Engineering
Department for an estimate. The data and specifications indicated are to be considered a guide only and Hydrocontrol S.p.A. reserves the right to intro-
duce improvements and modifications without prior notice. Hydrocontrol is not responsible for any damage caused by an incorrect use of the product.
3
EX72-00
hc-EX72 Flow sharing valve
General specification
Standard working conditions
Ambient operating temperature range -40°C / +60°C

Kinematic viscosity range 10 ÷ 300 cSt
Max contamination level 9 (NAS 1638) - 20/18/15 (ISO 4406:1999)
Recommended filtration level b10 > 75 (ISO 16889:2008)
Internal filter (on electroproportional valves pilot line) 30 μm
All information and diagrams in this catalogue refer to a mineral base oil VG46 at 50°C temperature
(32 cSt kinematic viscosity)
Fluid options
Types of fluid (according to IS0 6743/4) Temperature (°C)

Compatible gasket
Oil and Solutions min max
Mineral Oil HL, HM (or HLP acc. to DIN 51524) -25 +80 NBR
Oil in water emulsions HFA +5 +55 NBR
Water in oil emulsions HFB +5 +55 NBR
Polyglycol-based aqueous solution HFC -10 +60 NBR
For special applications and different fluids, please call our Technical Department.
Applications
Flow Sharing valve for 450 l/min inlet flow rate. Suitable applications include drilling machines, wheeled loaders, tele-
scoping cranes, marine cranes and mining and off-shore equipment.
4
EX72-00
Flow sharing valve hc-EX72
Operating principle
The flow sharing technology applied to the standard load sensing system characterizes the new control valves HC-EX.
The valve, completely pressure compensated, guarantees great controllability to all actuations, making workport flow
dependent only on metering area (spool position). When flow saturation occurs the system reacts by implementing an
equal reduction of pressure margin across all spools, generating a proportional reduction of workport flow.
Workport A Workport B
2 1
LEGEND:
1. Inlet line (High pressure)
2. Metering notches
3. Load sensing line
4. Local compensator
5. Metering spool
3 4 5
Single section
Referring to picture it’s possible to remark some aspects of system functionality. Coming from the common inlet line
the main flow, passing across the metering area, reaches local compensator. Metering area, according to the pressure
margin, controls the total amount of flow to the workport selected by the main spool. The load sensing signal, picked
up downstream the local compensator, feeds the common load-sensing line. When a single section is actuated, the
local compensator fully opens to the left side, reaching its complete balanced position. The control of the LS system
is made by the inlet compensator for fixed displacement pump or pump compensator for variable displacement pump.
Multi-section
When two or more sections are actuated only one, characterized by the highest pressure (dominant), is involved in the
LS signal transmission, working as briefly described in the previous paragraph. The other functions (slaves) become
directly dependent on it. The common LS line transfers the information coming from the dominant local compensator
to all dependent compensators. Driven by the LS signal, the unbalanced slave compensators activate the pressure
compensation creating an artificial pressure drop able to keep pressure margin nominally the same on all the spools.
Workport flow becomes only a function of metering area making the system totally load independent.
Flow Sharing function
When saturation occurs the total amount of flow required by actuations is higher than the maximum pump flow rate.
The system is able to keep the nominal pressure margin no more. The actual pressure margin reduces according to
real flow demand. Since all the local compensators feel the same LS signal and the same pressure drop is applied to
different metering areas, then workport flows are reduced proportionally in order to keep all actuations completely
under control.
5
EX72-00
hydraulic schema
Post compensated system Electrohydraulic control
LS
T1 (drain line)
T
B1 A1 B2 A2 B3 A3
Post compensated system Hydraulic control
M LS b1 b2
T1 (drain line)
A1 B1 a1 A2 B2 a2
6
EX72-00
Order example
HC-EX72/2: MR 701 200 KV S37 - W001C 200200 H407L RC1 S35 04 PA 90 05 PB - W001C 200200 H407L RCK1A S35 04 PA 90 05 PB
TYPE:
EX72: product type
/2: working section number
1) INLET ARRANGEMENT:
MR 701 inlet side and valve type
200 setting (bar)
KV S37 inlet position and available thread type
2) WORK SECTION ARRANGEMENT:
W001C 200200 type and spool delivery
H407L spool actuation type
RC1 S35 section type and port threads
04 PA 90 auxiliary valve (port A)
05 PB auxiliary valve (port B)
3) INTEGRATED OUTLET SECTION arrangement:
W001C 200200 type and spool delivery
H407L spool actuation type
RCK1A S35 section type and port threads
04 PA 90 auxiliary valve (port A)
05 PB auxiliary valve (port B)
Ordering row 2 must be repeated for every work section
P 1
M T
B 2
B 3
Standard thread
The connection ports size is indicated by an ordering code common for all Hydrocontrol products. Following table
shows all available connections; for ordering code refer to table on page 30.
Ports sae 3000 (ISO 6162-1) sae 6000 (ISO 6162-2)

P 1”1/4 MA - 1”1/4 UNC
T 1”1/4 MA - 1”1/4 UNC
A-B 1” MA - 1” UNC
7
EX72-00
Tie-rod kit classification
Tie rod kit allows the correct assembly of sectional valves. Tie rod’s length depends on the number of sections; each
valve is assembled with tie rod kits including a tie rod, nut and washer.
Tie rod
Washer Tie rod kit

Nut
tie rod lenght /1 /2 /3 /4 /5 /6 /7 /8

(mm) 232 304 376 448 520 592 664 736
Tie rod clamping torque 110 Nm
Painting
On request, all Hydrocontrol valves can be delivered painted The painting is indicated with the
(RAL 9005 black primer). following value:
Order example of EX72/2 painted:
P006 - /2 - N10
HC-EX72/2
MR 701 200 KV S37 Color black
W001C 200200 H407L RC1 S35 04 PA 90 05 PB section number
W001C 200200 H407L RCK1A S35 04 PA 90 05 PB Painted
P006/2 N10
8
EX72-00
dimensions
HC-EX72 with Electrohydraulic control
185
139.5
87
46.5
72
182 90
152.3 (X) 232 17
164
164
21.4
T B1 B2
341.2
250
118
176
255
123
A1 A2
P
19
62
42
T1
46
42
78
136
131
86.7 17.5 45 81 72 64
195.5 (Y) 297
72
19
26
M14 N°4 fixtures

46.5
LS
type /1 /2 /3 /4 /5 /6 /7 /8
X (mm) 160 232 304 376 448 520 592 664
Y (mm) 225 297 369 441 513 585 657 729
Weights (kg) 52 72 92 112 132 152 172 192
9
EX72-00
dimensions
HC-EX72 with Hydraulic control
185
115
87
46.5
72
90
182 (X) 232 17

b1 b2
100
85
21
T B1 B2
334.1
250
118
176
255
123
A1 A2
P
62
19
42
T1
42
85
95
a1 a2
87
17.5 45 81 72 64
(Y) 297
72
19
26
M14 N°4 fixtures

46.5
LS
type /1 /2 /3 /4 /5 /6 /7 /8
X (mm) 160 232 304 376 448 520 592 664
Y (mm) 225 297 369 441 513 585 657 729
Weights (kg) 52 72 92 112 132 152 172 192
10
EX72-00
typical curves
Inlet compensator Pressure drop (P-T)

Fixed displacement system (KV): pressure drop across the inlet compensator as function of pump flow
30
25
20
pressure [bar]
15
10
0
0 50 100 150 200 250 300 350 400 450 500
flow [l/m]
LS relief valve
Fixed displacement system (KV): LS relief valve characteristic
350
300
250
pressure [bar]
200
150
100
50
0
0 50 100 150 200 250 300 350 400 450 500
flow [l/m]
Post compensated spool flow with variable displacement pumps

Variable displacement systems (JV): spools maximum delivered flow as function of pump DP setting
450
400
350
Spool 340340
300
Flow [l/min]
250
200 Spool 280280
150
Spool 200200
100
50 Spool 160160
0
12 14 16 18 20 22 24 26
Pressure [bar]
11
EX72-00
Post compensated spool flow characteristic

Fixed displacement systems (KV): flow on ports A and B as function of spool stroke, pilot pressure, control current
Inlet flow: 450 l/min - Pump inlet compensator at 15 bar Dp
400
360
Spool 340340
320
280 Spool 280280
240
flow [l/min]
200 Spool 200200
Spool 160160
160
120
80
40
stroke [mm] stroke [mm]

-11 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 +1 +2 +3 +4 +5 +6 +7 +8 +9 +10 +11
12V current [mA] 12V current [mA]

1200 1100 1000 900 800 700 700 800 900 1000 1100 1200
24V current [mA] 24V current [mA]

600 550 500 450 400 350 350 400 450 500 550 600
Hydraulic pilot [bar] Hydraulic pilot [bar]

20,1 17,4 14,8 12,2 9,6 7 7 9,6 12,2 14,8 17,4 20,1
12
EX72-00
inlet section
Order example
MR 701 200 KV S37

MR inlet side
1. 701 valve arrangement
200 setting (bar)
2. KV S37 inlet position and available thread type
P 2
B
1
A
inlet side: pg. 14

MR Flow sharing valve with right inlet section
ML Flow sharing valve with left inlet section
1. valve arrangement: (standard combinations) pg. 15

701 Inlet section with LS pressure relief valve
702 Inlet section with LS pressure relief valve and LS electric dump valve 12 Vdc
703 Inlet section with LS pressure relief valve and LS electric dump valve 24 Vdc
704 Inlet section with LS pressure relief valve and full flow electric dump valve 12 Vdc
705 Inlet section with LS pressure relief valve and full flow electric dump valve 24 Vdc
2. INLET classification: pg. 16

KV S37 Open centre inlet section for fixed displacement pumps (SAE 6000 1”1/4 MA)
JV S37 Closed centre inlet section for variable displacement pumps (SAE 6000 1”1/4 MA)
KV S38 Open centre inlet section for fixed displacement pumps (SAE 6000 1”1/4 UNC)
JV S38 Closed centre inlet section for variable displacement pumps (SAE 6000 1”1/4 UNC)
NOTE: when ordering a relief valve it is necessary to specify factory setting (example 200 bar).
13
EX72-00
Inlet side classification
Flow sharing valve with right inlet section Flow sharing valve with left inlet section
P T
T P
MR ML
Valve identification
Full flow electric - 7

dump valve (12 vdc)
Full flow electric - 8
dump valve (24 vdc)
Full flow - 4
relief plug
Full flow pilot - 3

operated pressure
B
relief valve
2 - LS relief plug
C
A 1 - LS pressure
relief valve
10 - LS plug
11 - LS electric
dump valve (12 vdc)
12 - LS electric
dump valve (24 vdc)
type schema layout description type schema layout description

Full flow electric
7 T P
T P LS pressure dump valve (12 vdc)
1
relief valve Full flow electric
8
dump valve (24 vdc)
2 T P LS relief plug 10 T P LS plug
Full flow pilot

LS electric
3 operated pressure 11
dump valve (12 vdc)
relief valve
T P
Full flow LS electric

4 T P 12
relief plug dump valve (24 vdc)
14
EX72-00
Valve arrangement
4 - Full flow relief plug

Valve combination example: 701 = 1A - 4B - 10C
701 Valve combination

1A LS pressure relief valve in port A
4B Full flow relief plug in port B
B 10C LS plug in port C
The code identifies:

with a number, the type of valve; with a letter its position on
the inlet section.
C
A
NOTE: when ordering a combination type 701, 702,
10 - LS plug 703, 704 and 705 it is necessary to specify pressure
1 - LS pressure relief valve setting.
valve Port - A Port - B Port - C

combination
inlet section 1 2 3 4 7 8 10 11 12
700 • • •
701 • • •
702 • • •
703 • • •
704 • • •
705 • • •
706 • • •
707 • • •
708 • • •
709 • • •
710 • • •
NOTE: Valve combination 700 requires minimum 40 bar difference in setting of full flow and LS relief
valves (see example).
MR 700 200*240 KV G05

700 valve combination
200 setting (bar); LS pressure relief valve
240 setting (bar); Full flow pilot operated pressure relief valve
Dump valve coil specifications

general and technical specifications
Ordering code 413171235 413172432
Supply voltage (Vdc) 12 24
Coil - 12 Vdc = 413171235
Coil resistance R 20 (Ω) 7 28 Coil - 24 Vdc = 413172432
Connector DIN 43650 / ISO 4400
Connector material Nylon
Coil Body Zinc plated steel
ED 100%
Class H coil as from IEC 85 standard
Class H wire (200°C)
Note: mating connector for DIN 43650 can be ordered separately with code 413000313.
Different connector available on request.
15
EX72-00
Inlet classification
Inlet combination and thread available
M LS P
KV S37 M T
P
Open centre
inlet section
for fixed
1 displacement pumps
7/8 10
KV S38 T
The inlet section with KV configuration enables control valve usage with fixed displacement pumps. With this configura-
tion the presence of LS relief valve (valve type 1) is suitable to adjust the system maximum pressure. Full flow electric
dump valve (valve type 7, 8) can also be added as safety device.
M LS P
JV S37 M T
P
Closed centre
4 inlet section
for variable
1 displacement pumps
11/12
JV S38 T
The inlet section with JV configuration enables control valve usage with variable displacement pumps. With this confi-
guration the presence of LS relief valve (valve type 1) is suitable to adjust the system maximum pressure. LS electric
dump valve (valve type 11, 12) can also be added as safety device. An additional full flow relief valve (valve type 3) can
be added to protect the system from pump regulator failures. Additional solution for variable displacement pumps is
available on request to allow a constant reduced free flow in stand by condition through the system: this is sometime
required to guarantee a stand by flow for oil cooling.
NOTE: transformation of the inlet section from closed center to open center and vice versa is possible by
ordering the appropriate kit 320095003 or 320095004 (see page 27)
16
EX72-00
working section
Order example:
W001C 200200 H407L RC1 S35 04 PA 90 05 PB
1. W001C spool type
200200 spool flow
2. H407L spool actuation type
3. RC1 section type
S35 thread type
4. 04 PA 90 auxiliary valve type (port A - handle side)
5. 05 PB auxiliary valve type (port B - end cap side)
P
T
B
3
A
A 1
2
1. spool type: pg. 18 4. auxiliary valve type (port a) pg. 21

W001C 3 positions double-acting 01 PA Antishock valve (port A)
W102C 3 positions double-acting A-B to tank (motor spool) 02 PA Anticavitation valve (port A)
A 4 digit code identify the flow required on port A/B. The- 04 PA Pilot Combined valve (port A)
se flows are available: 160 - 200 - 250 - 280 - 340 l/min 05 PA Prearrangement for auxiliary valve (port A)
Example : W001C - 280280 5. auxiliary valve type (port B) pg. 21
2. spool actuation type: pg. 18 01 PB Antishock valve (port B)
H005A hydraulic actuation (pilot ports on the top) 02 PB Anticavitation valve (port B)
H005C hydraulic actuation (pilot ports on the side) 04 PB Pilot Combined valve (port B)
H407 Without lever + electrohydraulic actuation 12 vdc 05 PB Prearrangement for auxiliary valve (port B)
H408 Without lever + electrohydraulic actuation 24 vdc
3. Section type: pg. 20

RC1 S35 Section arranged for auxiliary valve (1”MA)
RCD1 S35 Section with local LS relief valve arranged for aux. valve (1”UNC)
Note: Sections designed to house auxiliary valve option require double choice on work ports A and B.
Always indicate setting value when using setting auxiliary valve and pilot combined valve:
01 PA (120) - 01 PB (120) - 04 PA (180) - 04 PB (180)
17
EX72-00
Spool identification
W001C T W102C T
3 positions double-acting
3 positions double-acting PAB PAB
A and B to tank (motor spool)
Spool flow
Flow rates delivered to the A and B ports are identified in following table. Rated flows refer to simmetrical spools.
flow rates (l/min)

Spool type
160 200 250 280 340
W001C • • • • •
W102C • • • • •
Classification spool example

w001C - 200200
W001C 3 positions double-acting
200 Flow on port A
200 Flow on port B
NOTE:
- not simmetric spools (such as 160200, 250340...) are available on request; for availability we suggest
to contact our Sales department.
- rated flows are defined for 16 bar ΔP (as per KV inlet arrangement); for different ΔP values on
variable pump systems, refer to diagram (Post compensated spool flow with variable displacement
pumps) or page 12.
Spool actuation classification for Hydraulic control
code description dimensions configuration

87.5 87.5
28.5
28.5
Hydraulic actuation
(pilot ports on the top)
H005A
105 250 105
(only with 460
hydraulic section body)
Port pilot: 1/4” BSP - 9/16” UNF
87.5 87.5
33.5
33.5
Hydraulic actuation
(pilot ports on the sides)
H005C
100 250 100
(only with 450
87.5 87.5
28.5
28.5
Hydraulic actuation
with stroke limiter
H005L
129 250 129
(only with 508
Note:
Recommended control curve for HC Remote Control: A01 for standard spool.
18
EX72-00
Spool actuation classification for Electrohydraulic control
code description dimensions configuration
Without lever +
H407 electrohydraulic actuation
108.8
65.7
(12 vdc)
Without lever +
H408 electrohydraulic actuation 139.5 250
501.5
112
(24 vdc)
Without lever +
electrohydraulic actuation
H407L
108.8
with stroke limiter
65.7
(12 vdc)
Without lever +
electrohydraulic actuation
H408L with stroke limiter
163.5 250 136
549.5
(24 vdc)
proportional electrohydraulic specifications

Feeding reducing pressure (bar) 35
Supply voltage (Vdc) 12 24
Coil resistance R 20 (Ω) 4,7 20,8
ON-OFF control current (mA) 2500 1150
Proportional control current (mA) 600 - 1300 300 - 650
PWM frequency suggested (Hz) 70 - 90
Connector AMP Junior Power Timer
Note: mating connector for AMP Junior Power Timer can be ordered separately with code 413000223
(including 2 m wire).
Different connector available on request.
19
EX72-00
Work section arrangement

Following pages are showing ordering code for post compensated section in their standard version and in combination with some
specific applicable devices.
POST-COMPENSATED section standard
code schema configuration description
RC1
S35
Post compensated
section
Arranged for
auxiliary valves
RC1
S36
B A
POST-COMPENSATED section with local LS relief valve

Another feature not commonly found in flow sharing systems is the possibility to have a Load Sensing relief valve on
individual sections. The purpouse to use a local LS relief instead of a standard port shock relief is to improve the effi-
ciency of the system. When a standard port shock relief is used, the full flow across the relief will be directed to tank,
if the pressure system exceeds the setting.
By using a local LS relief, only a very minimal part of oil will be directed to tank in the same condition, with great ad-
vantage for the system efficiency. Furthermore, by saving oil from going to tank, more oil will be available for simul-
taneous operations and this will improve the performance of the machine.
The pressure limitation generated by the local LS relief applies to both section ports, A and B.
The local pressure limitation works properely if the section is actuated alone or if the section is the most
charged.
The local LS relief can be easily installed as a retrofit too.
RCD1
S35
Post compensated
section with
Local Load Sensing
relief valve
Arranged for
auxiliary valves
RCD1
S36 Local LS
relief valve Local LS relief valve
B A
Note:
LS relief valve works on both ports; setting for A and B ports is the same
LS relief valve setting must be specified as follow: RCD1 S35 (120)
20
EX72-00
Auxiliary valve identification
Setting range (bar)

code description schema sonfiguration
type at full flow type at min. flow
A 60 / 100 A 10-A / 60-A
Antishock B 101 / 160 B 61-A / 130-A
01 PA valve
(port A) C 161 / 250 C 131-A / 250-A
D 251 / 350 D 251-A / 350-A
Anticavitation
02 PA valve
(port A)
Pilot combined
04 PA valve A 50 / 300
(port A)
Prearrangement
05 PA for auxiliary valve
(port A)
Setting range (bar)

code description schema sonfiguration
type at full flow type at min. flow
A 60 / 100 A 10-A / 60-A
Antishock B 101 / 160 B 61-A / 130-A
01 PB valve
(port B) C 161 / 250 C 131-A / 250-A
C 251 / 350 C 251-A / 350-A
Anticavitation
02 PB valve
(port B)
Pilot combined
04 PB valve A 50 / 300
(port B)
Prearrangement
05 PB for auxiliary valve
(port B)
Auxiliary valve - Setting range
Sections designed to house auxiliary valve option require double choise on work ports A and B.
Always indicate setting value when using antishock valve or pilot combined valve:
01 PA (120) = setting at full flow / 01 PA (120-A) = setting at min. flow
04 PA (120) = setting at full flow / 04 PA (120-A) = setting at min. flow
21
EX72-00
integrated outlet section
Order example:
W001C 200200 H407L RCK1A S35 04 PA 90 05 PB
1. W001C spool type
200200 spool flow
2. H407L spool actuation type
3. RCK1A integrated outlet section type
S35 thread type
4. 04 PA 90 auxiliary valve type (port A - handle side)
5. 05 PB auxiliary valve type (port B - end cap side)
P
T
B 3
1
2
1. spool type: pg. 18 4. auxiliary valve type (port a) pg. 21

W001C 3 positions double-acting 01 PA Antishock valve (port A)
W102C 3 positions double-acting A-B to tank (motor spool) 02 PA Anticavitation valve (port A)
A 4 digit code identify the flow required on port A/B. The- 04 PA Pilot Combined valve (port A)
se flows are available: 160 - 200 - 250 - 280 - 340 l/min 05 PA Prearrangement for auxiliary valve (port A)
Example : W001C - 280280
5. auxiliary valve type (port B) pg. 21
2. spool actuation type: pg. 18
01 PB Antishock valve (port B)
H005A hydraulic actuation (pilot ports on the top) 02 PB Anticavitation valve (port B)
H005C hydraulic actuation (pilot ports on the side) 04 PB Pilot Combined valve (port B)
H407 Without lever + electrohydraulic actuation 12 vdc 05 PB Prearrangement for auxiliary valve (port B)
H408 Without lever + electrohydraulic actuation 24 vdc
3. Section type: pg. 20
RCK1A S35 Integrated outlet section arranged for auxil. valve (1”MA)
RCK1A S36 Integrated outlet section arranged for auxil. valve (1”UNC)
Note: Sections designed to house auxiliary valve option require double choice on work ports A and B.
Always indicate setting value when using setting auxiliary valve and pilot combined valve:
01 PA (120) - 01 PB (120) - 04 PA (180) - 04 PB (180)
22
EX72-00
Integrated oulet section classification
B
RCK1A
LS Drain A
S35
Integrated
outlet section
with LS drain - upper
Arranged for
auxiliary valves
RCK1A
S36
T1
B
RCK1C
S35 A
Integrated
outlet section
with LS drain - side
LS Drain
Arranged for
auxiliary valves
RCK1C
S36
23
EX72-00
ex72 spare parts list

4
12
6 P
2 7
T
19
15 11
B 9
8
A
17
19
15
B
A 18 10
5
17 3
13
21 18
20 16
14
13
16
14
Rif. Description Order code Q.ty Type Note
1 LS pressure relief valve 1
2 LS plug 430059003 1
LS electric dump valve (12 vdc) (**) 915040410 1
LS electric dump valve (24 vdc) (**) 915040411 1
3 Full flow pilot operated pressure relief valve 1

Full flow relief plug 430195001 1
4 kit RDP 320095002 1
5 Plug kit 1/4”G DIN 3852 E 430000017 2 (q.ty = 1 for JV version)
6 Inlet compensator spring 421803271 1
7 Assembly inlet Compensator Spool 433095001 1 only for KV

433095002 1 only for JV
8 Inlet compensator plug kit 430095005 1 only for KV

430095004 1 only for JV
9 Valve 430085005 1 only for KV

430085046 1 only for JV
10 Plug kit 7/16-20 UNF 320062013 1
11 Assembly LS valve kit 430095008 1
12 Assembly spring kit 430098003 1
13 3 positions double-acting spool 421295007 1 W001C-200200 spool 200 l/min

421295009 1 W001C-250250 spool 250 l/min
421295005 1 W001C-280280 spool 280 l/min
421295001 1 W001C-340340 spool 340 l/min
3 positions double-acting spool A-B to tank (motor spool) 421295019 1 W102C-160160 spool 160 l/min
421295008 1 W102C-200200 spool 200 l/min
421295015 1 W102C-250250 spool 250 l/min
421295006 1 W102C-280280 spool 280 l/min
421295002 1 W102C-340340 spool 340 l/min
24
EX72-00
Rif. Description Order code Q.ty Type Note
14 Without lever + electr. actuation with stroke limiter (front) 320395004 1 H407L=H408L
15 Without lever + electr. actuation with stroke limiter 24 Vdc (rear) 322095005 1 H408L
Without lever + electr. actuation with stroke limiter 12 Vdc (rear) 322095008 1 H407L
16 Section compensator plug kit 430095002 1
17 Section compensator kit 320095001 1
18 Antishock valve setting on port A (*) 84433 1 01 PA setting 100 bar

85005 1 01 PA setting 150 bar
85007 1 01 PA setting 200 bar
Anticavitation valve setting on port A 915088801 1 02 PA

Pilot combined valve setting on port A (*) 84438 1 04 PA setting: 100 bar
84439 1 04 PA setting: 200 bar
84440 1 04 PA setting: 300 bar
Prearrangement for auxiliary valve on port A 430488001 1 05 PA
19 Antishock valve setting on port A (*) 84433 1 01 PB setting 100 bar

85005 1 01 PB setting 150 bar
85007 1 01 PB setting 200 bar
Anticavitation valve setting on port B 915088801 1 02 PB

Pilot combined valve setting on port B (*) 84438 1 04 PB setting: 100 bar
84439 1 04 PB setting: 200 bar
84440 1 04 PB setting: 300 bar
Prearrangement for auxiliary valve on port B 430488001 1 05 PB
20 Plug kit LS drain 300037002 1
21 Tie rod kit EX72/1 300195003 4

Tie rod kit EX72/2 300195002 4
Tie rod kit EX72/3 300195008 4
Tie rod kit EX72/4 300195001 4
Tie rod kit EX72/5 300195007 4
Tie rod kit EX72/6 300195004 4
Tie rod kit EX72/7 300195005 4
Tie rod kit EX72/8 300195006 4
Note
(*) = for different settings please contact our Sales Dpt.

Coil - 12 Vdc = 413171235
(**) = electric dump valve coil can be ordered Coil - 24 Vdc = 413172432
separately as spare part: (see drawing)

Ordering code Coil 12 vdc: 413171235
Ordering code Coil 24 vdc: 413172432
60 Nm
30 Nm
25
EX72-00
Gasket kits
4
1
1 4
3
2
3
2
inlet and work section
Rif. order code Description Q.ty
1 412010122 O.R. 70SH 6,07 x 1,78 (2-10) 2
2 412020905 O.R. 90SH 13,87 x 3,53 5
3 612020501 O.R. 90SH 50,39 x 3,53 2
4 412020904 O.R. 90SH 29,74 x 3,53 1
Complete Gasket kit: order code - 350995001
26
EX72-00
Trasformation kits
Transformation on the inlet section from open center to closed center is possible by ordering the complete kit code:
320095003 (transformation kit from KV to JV)
open center configuration (JV)

variable pump
Spool assembly - 433095001
order code Description Q.ty
430095005 Inlet compensator kit 1
P
430085046 Valve kit 1
M T 433095001 Spool assembly 1
Complete transformation kit:

order code - 320095003
Valve kit - 430085046
Inlet compensator kit - 430095005
Transformation on the inlet section from closed center to open center is possible by ordering the complete kit code:
320095004 (transformation kit from JV to KV)
open center configuration (KV)

Fixed pump
order code Description Q.ty
430000017 Plug G1/4” 1
Spool assembly - 433095002
430095004 Inlet compenator plug kit 1
P
M T 430085005 Plug kit 1
433095002 Spool assembly 1
Complete transformation kit:

order code - 320095004
Plug kit - 430085005
Inlet compensator kit - 430095004
Plug G1/4” - 430000017
27
EX72-00
installation and maintenance
Guidelines
- Mount the control valve securely to a flat surface (recommended 3 point fixing); at the time do not use a hammer
to positioning by hitting.
- When handling the control valve, be careful not hold the pilot cover or return spring cap of the spool or accessory
valves such as main relief valves and anti-shock relief valves.
- Clean piping materials sufficiently before use.
- Make sure to prevent the port openings from being entered with dust or foreign matters.
- Tighten the port connectors surely with the recommended fastening torques.
- Do not direct the jet of a pressure washing unit directly to the valve.
General clamping torque
The following table provides the main tightening torques of the distributor HC-EX72; are highlighted in 3 separate
drawings depicting the inlet section, the working section and the integrated outlet section.
Inlet Section
Plug - Hex.30
60/65 Nm
Plug - Hex.10
120 Nm
Nut - Hex.19
15/20 Nm
Valve - Hex.24
40/45 Nm
Valve - Hex.30
60/65 Nm
Plug - Hex.10
Valve - Hex.30 120 Nm
60/65 Nm
Plug - Hex. 6 Plug - Hex.36

Plug - Hex.5
30 Nm 120 Nm
20 Nm
28
EX72-00
Work Section
Plug - Hex.32
80 Nm
Valve - Hex.32
Plug - Hex.10 80 Nm
80 Nm
Nut - Hex.19
20 Nm
Plug - Hex.10
80 Nm
Screw - Hex.6
25 Nm
Integrated Outlet Section
Plug - Hex.32
80 Nm
Valve - Hex.32
Plug - Hex.10 80 Nm
80 Nm
Nut - Hex.19
20 Nm
Plug - Hex.6
30 Nm
Plug - Hex.10
80 Nm
Screw - Hex.6
25 Nm
29
EX72-00
Flow sharing valve
Dimensions - Thread codes
The connection ports size is indicated by an ordering code common for all Hydrocontrol products. Following table
shows all available connections.
METRIC thread (iso 9974-1)
Type M18x1,5 M22x1,5 M27x2
Code M01 M02 M03
BSP thread (ISO 1179-1)

Type 1/4” 3/8” 1/2” 3/4” 1” 1”1/4 1”1/2 2”
Code G02 G03 G04 G05 G06 G07 G08 G09
UN / UNF thread (ISO 11926-1)

9/16” 18 UNF 3/4” 16 UNF 7/8” 14 UNF 1”1/16 12 UNF 1”5/16 12 UNF 1”5/8 12 UNF
Type
SAE6 SAE8 SAE10 SAE12 SAE16 SAE20
Code U02 U03 U04 U05 U06 U07
Dimensions - SAE Flange codes
D
A
C
sae / 3000 flange (iso 6162-1)

3/4” 3/4” 1” 1” 1”1/4 1”1/4 1”1/2 1”1/2 2” 2” 3” 3”
Type
(MA) (UNC) (MA) (UNC) (MA) (UNC) (MA) (UNC) (MA) (UNC) (MA) (UNC)
Code S03 S04 S05 S06 S07 S08 S09 S10 S11 S12 S15 S16
A 19 19 25 25 32 32 38 38 51 51 76 76
B 47,6 47,6 52,4 52,4 58,7 58,7 69,9 69,9 77,8 77,8 106,4 106,4
C 22,3 22,3 26,2 26,2 30,2 30,2 35,7 35,7 42,9 42,9 61,9 61,9
D M10 3/8-16 M10 3/8-16 M10 7/16-14 M12 1/2-13 M12 1/2-13 M16 5/8-11
sae / 6000 flange (iso 6162-2)

3/4” 3/4” 1” 1” 1”1/4 1”1/4 1”1/2 1”1/2
Type
(MA) (UNC) (MA) (UNC) (MA) (UNC) (MA) (UNC)
Code S33 S34 S35 S36 S37 S38 S39 S40
A 19 19 25 25 32 32 38 38
B 50,8 50,8 57,2 57,2 66,6 66,6 79,3 79,3
C 23,8 23,8 27,8 27,8 31,8 31,8 36,5 36,5
D M10 3/8-16 M12 7/16-14 M14 1/2-13 M16 5/8-11
30
EX72-00
Flow sharing valve
general conditions and patents
Product identification
All Hydrocontrol products have an identifying plate placed in specific position.
Serial number:
Serial number
000807500 Serial number It univocally identifies the physical valve: this provides
Product code
an easy way to find all sales and production details.
44612 Product code
Product code:
It is a number univocally identifying the configuration
Made in Italy and pressure settings of a valve.
Introduction
These general conditions apply to all general supplies from Hydrocontrol s.p.a., after receiving orders from the Custo-
mer. Should commercial terms such as EXW, DDP, etc be mentioned, of course the Incoterms of the International Cham-
ber of Commerce must be referred to, according to the test existing when the general supply conditions are agreed on.
Management of orders
No Customer’s order is binding to Hydrocontrol s.p.a. if Hydrocontrol s.p.a. has not confirmed the order in writing.
Hydrocontrol s.p.a. commits to supplying the orders in compliance with the order confirmation that has been is-
sued. Any disagreement with the content of the order confirmation must be communicated in writing to Hydrocon-
trol s.p.a. within and no later than 5 days from the delivery of the order confirmation. The Customer commits to
paying for the goods supplied by Hydrocontrol s.p.a., according to the prices indicated on the order confirmation.
Payment conditions
The Parties agree on the payment terms at the beginning of the supply. The terms will be indicated on the order con-
firmation. Should the Customer be late with the payments, Hydrocontrol S.p.a. will be entitled to require the payment
of interests on arrears based on the exiting Prime Rate increased by 2%. Should there be any payment delay, Hydro-
control s.p.a. will be entitled not to process the Customer’s purchase order, even if it has already been confirmed.
Delivery and shipment

The goods are always supplied Ex Works, even when Hydrocontrol s.p.a. agrees with the Customer that the shi-
pment, or a part of it, will be arranged by Hydrocontrol s.p.a. It is agreed that the Customer will bear the risk of
goods deterioration or damaging from the moment the goods are handed by Hydrocontrol s.p.a. to the first carrier.
Product characteristics
Hydrocontrol s.p.a. commits to supplying good quality products, compliant with the technical specifications declared
on the technical tables and on the catalogue. Hydrocontrol s.p.a, even without notice, at its own discretion, reserves
the right to modify the products as necessary, without these changes altering the main characteristics of the products.
Claims
Any claims about defects on delivered products (just as an example: claims about the packaging, the number, the
quantity or the external product characteristics) will have to be notified to Hydrocontrol s.p.a. in writing, within
and no later than 7 days from reception of the goods, otherwise the claims will be considered as null and void.
Occult defects (the defects of the goods that cannot be spotted with a careful control of the goods received by
the Customer), will have to be notified in writing to Hydrocontrol s.p.a. within 7 days from the discovery of the
defect, and anyhow no later than 12 months from the delivery of the goods, otherwise the claim will be consi-
dered as null and void. Even in case of claim or objection, the Customer will never be entitled to suspend or de-
lay the payments to Hydrocontrol s.p.a. for the products subject to claim or objection nor for any other supply.
31
EX72-00
Flow sharing valve
general conditions and patents
Warranty
Should the products supplied by Hydrocontrol not be compliant or have the required quality and should this defect
be due to Hydrocontrol, Hydrocontrol s.p.a. commits, at its choice, to replace or repair the faulty products, as long
as the defect or lack of compliance is notified to Hydrocontrol s.p.a. in writing, as specified at point 6, within and
no later than 18 months from product delivery. On the products that have been fixed or replaced in accordance
with what specified above, the above-mentioned warranty applies. The 12 month duration starts from the date of
repair or replacement. In case of defects, lack of quality or in case of lack of compliance for the supplied products,
with the exception of fraud or serious offence, Hydrocontrol s.p.a. only commits to repairing or replacing the faul-
ty products, according to what specified above. This warranty replaces any other Supplier’s warranty or liability
established by the law. This warranty excludes any other liability contractual or extra-contractual by Hydrocontrol
s.p.a. on the products supplied by Hydrocontrol (as a mere example: damage refund, loss of profit, product recall
campaign, etc). Hydrocontrol s.p.a. has signed a product civil liability police, with a suitable maximum coverage.
Ownership retention
The products supplied by Hydrocontrol s.p.a. will be owned by the latter until Hydrocontrol receives the complete
payment for the supplied goods.
Obligation confidentiality
Hydrocontrol s.p.a. commits to not disclosing the technical and commercial information it receives from the Customer,
unless this information has already been publicly disclosed.
Patents
The Customer is not allowed to use the provided Products, or a part of them, their descriptions or drawings protected or
not protected by Patent or registered trademark in order to design or make similar products, unless Hydrocontrol s.p.a.
previously issues its written authorization. Should Hydrocontrol s.p.a. give its written authorization, all patents, trade-
marks, registered designs, copyrights and intellectual property rights related or connected to the Products provided by
Hydrocontrol s.p.a. will stay Hydrocontrol’s property. The Customer commits to respecting the highest confidentiality.
Applicable law and court of jurisdiction

Hydrocontrol s.p.a.’s supplies are regulated by these General Supply Conditions and, for anything not defi-
ned here, by the Italian law. Any controversy related, generated or connected to the supply of Products by
Hydrocontrol s.p.a., where Hydrocontrol s.p.a. is involved, will be exclusively dealt with by the Court of Bologna.
32
EX72-00
www.hydrocontrol-inc.com
HC-EX72
INDIA
Flow sharing compensated valve
HEAD QUARTERS
Hydrocontrol SpA HC Hydraulic Technologies (P) LTD
Via San Giovanni 481 . 40060 Osteria Grande A5 (B) Ngef Ancillary Indl. Estate
Castel S.Pietro Terme . Bologna - Italy Whitefield Road . Mahadevpura (Po)
Phone +39.051.6959411 (15 linee) Bangalore . 560048
Fax +39.051.946476 India
Phone sales Dep.: +39.051.6959447 Phone +91 (080) 40454707
Fax sales Dep.: +39.051.6958132 Fax +91 (080) 40454703
info@hydrocontrol-inc.com info@hydrocontrol-india.com
U.S.A. CHINA
Hydrocontrol Inc. HC China Sales and Production Facility
1109 Technology Drive . Red Wing, MN 55066 U.S.A Guangzhou Bushi Hydraulic Technology Ltd
Phone +1 (651) 212 6400 . Fax +1 (651 212 6401) Shangwei Shaheshe, Yuehu Village
usa@hydrocontrol-inc-com Xiancun, Xintang Town . Zengcheng City
511335 Guangzhou . Guangdong Province
GERMANY China
Hydrocontrol GmbH Phone +86 (021) 52380695
Rudolf Diesel Str. 1 42477 Radevormwald Fax +86 (021) 52380697
Deutschland fareast@hydrocontrol-inc-com
Phone +49 2195-931123 Fax +49 2195-931124
hans.ley@hydrocontrol-inc.de
FRANCE
HC France SAS
7, Rue des Entrepreneurs . Parc de la Vertonne
44122 Vertou . France
Phone +33 02-40332348 . Fax +33 02-28210034
hc-france@wandoo.fr
EX72-00 04.2013

Pressure and Temperature Switches
SW 2000
TW 2000
Dialog User Level (continued) Operating Instructions
Dialog Value Function/Description Dual pressure switch Switch 2000
item
Dual Temperature Switch TempSwitch 2000
Only models with analog output:
* 0 ... xxx Scale the analog output - start value (e. g. 0 bar = 4 mA)
* 0 ... xxx Scale the analog output - end value (e. g. 400 bar = 20 mA)
(output signal start value always corresponds to the display initial value, e. g. 0
bar = 4mA)
Maximum turn-down 4 : 1, i.e. at values below 25 % of the measuring range
the analog output is switched off
0 ... xxx Display of peak value „Max“ (xxxx: = max. 125 % f. s.)
Delete the maximum value memory
= no deletion
= delete value
Error display:
= no error 1 Intended Applications .................................................................................................... 2
= exceeding pos. measuring range 2 Safety Instructions ......................................................................................................... 2
= exceeding neg. measuring range 3 Standards ........................................................................................................................ 3

4 Warranty/Guaranty ......................................................................................................... 3
= sensor error
5 Installation/Commissioning .......................................................................................... 3
= error switching output 1
6 Maintenance/Cleaning ................................................................................................... 4
= error switching output 2 7 Technical Data ................................................................................................................ 5
= data error (EEProm) 8 Operation......................................................................................................................... 6
= program error 9 Programming .................................................................................................................. 6
10 User Level Dialog Switch 2000/TempSwitch 2000 ...................................................... 7
= calibration error
= error analog out
IMPORTANT
Barksdale GmbH
When changing units from psi to bar or bar to psi, the switching point values must be changed Dorn-Assenheimer Straße 27
accordingly.
D-61203 Reichelsheim Art. no.: 923-1440
* Flashing of the mean segment signals a negative setting value.
Tel.: +49 (6035) 949-0 Index O, 10.05.2011
Fax: +49 (6035) 949-111 and 949-113 Software-Version: V 2.1 and higher
email: info@barksdale.de Specifications are subject to changes

without notice!
Internet: www.barksdale.de
8 1
1 Intended Applications 3 Standards
The dual pressure switch monitors system pressures and has up to two switching outputs and one The standards applied during development, manufacture and configuration are listed in the CE
analog output. conformity and manufacturer's declaration.
The dual temperature switch monitors media temperature into which the probe is immersed and has
up to two switching outputs and one analog output. 4 Warranty/Guaranty
Warranty
DANGER Our scope of delivery and services is governed by the legal warranties and warranty periods.
Terms of guaranty
The switch may only be used in the specified fields of application.
The temperature ranges must be within the permissible limits. The stated pressures and electrical We guaranty for function and material of the dual pressure and temperature switch under normal
load values must not be exceeded. operating and maintenance conditions in accordance with the statutory provisions.
Observe also the applicable national safety instructions for assembly, commissioning and Loss of guaranty
operation of the switch. The agreed guaranty period will expire in case of:
The switch is not designed to be used as the only safety relevant element in pressurized systems  incorrect use,
according to PED 97/23/EC.  incorrect installation or
 incorrect handling or operation contrary to the provisions of these operating instructions.
2 Safety Instructions No liability is assumed for any damage resulting therefrom, or any consequential damage.
The safety instructions are intended to protect the user from dangerous situations and/or material
damage. 5 Installation/Commissioning
In the operating instructions the seriousness of the potential risk is designated by the following
signal words: DANGER
Only install or uninstall the switch when deenergized (electrically and hydraulically/
DANGER pneumatically).
Refers to imminent danger to men. Pressure connection and electrical connection must be carried out by trained or instructed
personnel according to state-of-the-art standards.
Nonobservance may result in fatal injuries.
The switch must only be installed in systems where the maximum pressure Pmax or the maximum
temperature Tmax is not exceeded (see type label).
WARNING
Refers to a recognizable danger. WARNING

Nonobservance may result in fatal injuries, and destroy the equipment or plant parts. Be aware of the fact that in case of operation with higher temperatures the casing surface may
become very hot!
CAUTION
CAUTION
Refers to a danger.
Nonobservance may result in light injuries and material damage to the switch and/or to the plant. Mount the pressure switch from bottom to the fitting with a wrench hex 36 (1/4“) resp. 19 with
45 Nm torque.
IMPORTANT Do not put the switch into operation when the switch itself or the connection cable is damaged.
Jolts and heavy vibrations must be avoided during transport. Even if the switch casing remains
Refers to important information essential to the user. undamaged, inside parts may be damaged and cause malfunctions.
Disposal
The switch must be disposed of correctly in accordance with the local regulations for
electric/electronic equipment.
The switch must not be disposed of with the household garbage!
2 3
Electrical connection is to be carried out dependent on the type of switch (see type label) 7 Technical Data
according to the chart below. Wrong assignment of the connections may cause malfunctions or
incorrect switch outputs. Switch 2000 TempSwitch 2000
Measuring element Piezoresistive pressure sensor with Pt 100 (class B) according to
Plug Model with 1 Model with 2 Model with 1 Model with 2 internal special steel diaphragm DIN IEC 751
M 12x1 switching switching switching switching
4/5-pin output outputs output and 1 output and 1 Measuring ranges 0 ... 10 bar to 0 ... 600 bar 0 ... +100 °C to -30 ... +150 °C
analog output analog output 0 ... 150 psi to 0 ... 9000 psi +32 ... +212 °F to -22 ... +302 °F
relative pressure
Pin 1 +Ub (15 ... 32 V DC) +Ub (15 ... 32 V DC) +Ub (15 ... 32 V DC) Ub (15 ... 32 V DC)
brown (15 ... 28 V DC)* (15 ... 28 V DC)* (15 ... 28 V DC)* (15 ... 28 V DC)* Display 3-digit 7-segment LED display, red, digit height 10 mm
- SP2 (0.5 A max.) Analog Analog Transistor switching 1 or 2 x NO/NC function (programmable),
Pin 2
(0.4 A)* outputs PNP adjustable switching time delay 0 ... 9.9 s
white
Operating temperature -10 ... +70°C / +14 ... +158 °F
Pin 3 0V 0V 0V 0V
range
blue
Media temp. range -25 ... +100°C / -13 ... +212 °F -30 ... +150°C / -22 ... +302 °F
Pin 4 SP1 (0.5 A max.) SP1 (0.5 A max.) SP1 (0.5 A max.) SP1 (0.5 A max.)
black (0.4 A)* (0.4 A)* (0.4 A)* (0.4 A)* Process connection G 1/4 G 1/4
(fitting "A" without 1/4" – 18 NPT 1/4" – 18 NPT
Pin 5 - - - SP2 (0.5 A max.) adapter) 7/16 – 20 SAE
grey (0.4 A)*
Protection system/class Nema 4, IP65/III
* cULus version
Electrical connection 4-pin plug, M 12x1
Auxiliary power 15 ... 32 V DC / 15 ... 28 V DC (cULus version)
For further technical data and options please refer to the data sheets
Operating and display elements/Dimensions Dimensions (example) in mm (inch)
12 (0.47) 118 (4.64)

12 (0.47) Dual pressure switch
Switch 2000
 35 (1.38)
Item 1: LEDs
M 12x1
WARNING
hex 36
"A"
AL (yellow) – alarm
Check the switch regularly for functioning. S1 (green) – switching point 1
If the switch does not work properly, stop operation immediately! S2 (green) – switching point 2
Item 2: Plastic film keys

12 (0.47) 110 (4.33) 17 (0.66)
Dialog item "change to value/to
IMPORTANT function", acknowledge inputs
12 (0.47)
1 2 Change dialog items/functions,
Only TempSwitch 2000
6 (0.24)
change numerical values
When the rotatable display is adjusted, the switch has to be fixed with the threaded pin at the front
side with a 3 Nm torque.
6 Maintenance/Cleaning
 30 (1.18)
M 12x1
hex 19
Dual Temperature Switch
"A"
The switch requires no maintenance. TempSwitch 2000
CAUTION
The plastic film keys may be damaged by the use of unsuitable cleaning agents. Do not use any
cleaning agents containing solvents or abrasive additives.
4 5
8 Operation 10 User Level Dialog Switch 2000/TempSwitch 2000
The switch must be installed and operated only by authorized persons. Do not use any hard objects for
Dialog Value Function/Description
making entries. After being switched on the Switch 2000 / TempSwitch 2000 runs through a self-test.
item
Operation via three plastic film keys is menu-driven. These keys must not be touched with hard objects! If
an error is recognized during the self-test or during operation, this is signalled by the (yellow) flashing 0 ... 400 Display of the actually measured value
alarm LED (AL).
The error can be read out in the menu . The green LEDs S1 and S2 signal the activity of the two Select the display unit Switch 2000 TempSwitch 2000
switching points.
= mbar = psi x 10 = hPa = °Celsius
9 Programming
= bar = psi = mPa = °Fahrenheit
1 After switching on with change to the first dialog item.
Activation of the unit display
2 Change dialog item Select the desired dialog item with or (see chap. 10).
= unit display on (every 30 s)
3 Activate dialog item Activate the desired dialog item with to change the corresponding value or
Value input/function the desired function. = no unit display
selection
4 Change value = window technology = error output
Select the individual digits with .
Change the numerical value with or and acknowledge with . = standard evaluation
If the entered value is within the permissible range, the system changes to the * 0 ... xxx Switch-on point for SP1; if the ON value is smaller than the OFF value the
dialog item after input of the last digit, otherwise the 1st digit will flash again. switching point evaluation is falling
5 Change function Change the function with or and acknowledge with . 0 ... xxx Switch-off point for SP1
*
Activate key lock Simultaneously press + for at least 5 s. The display must not change 0.0 s ... 9.9 s Switch-on delay for SP1 in seconds
during this time. When key lock is activated appears in the display e. g.
*. 0.0 s ... 9.9 s Switch-off delay for SP1 in seconds
Key lock active Values or functions are displayed, but cannot be changed. appears in the Inversion of switching output SP1
display when an attempt is made to make a change.
= high-level-fail-save (normally open function)
Deactivate key lock Simultaneously press + for at least 5 s. The display must not change
= low-level-fail-save (normally closed function)
during this time. When key lock is deactivated appears in the display
e. g. *.
Only models with 2nd switching contact:
Return to measuring If no entry is made for 2 minutes, the switch automatically returns to the
mode measuring mode without accepting the entries. = window technology = error output
Terminate Press for at least 5 s to change to the measuring mode. = standard evaluation
programming
* 0 ... xxx Switch-on point for SP2; if the ON value is smaller than the OFF value the
* Software versions no.
switching point evaluation is falling
* 0 ... xxx Switch-off point for SP2
0.0 s ... 9.9 s Switch-on delay for SP2 in seconds

0.0 s ... 9.9 s Switch-off delay for SP2 in seconds
Inversion of switching output SP2
= high-level-fail-save (normally open function)
= low-level-fail-save (normally closed function)
6 7
Pressure Switch
SPA2-4M-C-HC
www.switchingssi.com
TABLE OF CONTENTS
PRESSURE
SPA ......................................................................... 4
SWA ........................................................................ 6
SMA ........................................................................ 8
SDCA..................................................................... 10
PRESSURE
SKBA ..................................................................... 12
SKDA..................................................................... 14
SPAL ..................................................................... 16
SLF ....................................................................... 18
SPAH ..................................................................... 20
DIFFERENTIAL
DSPA ..................................................................... 22 DIFFERENTIAL
VACUUM
SVA ....................................................................... 24
VACUUM
SPVL ..................................................................... 26
TEMPERATURE
S1TAF .................................................................... 28
TEMPERATURE
S2TAF ................................................................... 30
TRANSDUCER
TG......................................................................... 32
TRANSDUCER
TC ......................................................................... 34
LEVEL
LF1 ....................................................................... 36
LF2 ....................................................................... 37
LEVEL SWITCH CHART ............................................. 38 LEVEL
LEVEL SWITCH SPECIFICATION ................................. 39
VE ......................................................................... 40
LSM....................................................................... 41
MISC
OPTIONS - DESCRIPTION ......................................... 42
OPTIONS - AVAILABILITY ......................................... 43 MISC
MATERIAL COMPATIBILITY ........................................ 44
ELECTRICAL CONFIGURATION ................................... 45
GLOSSARY ......................................................... 46
SPA
DESCRIPTION
A compact pressure switch utilizing a high quality snap
action micro switch for applications in which price and size
are of concern. Suitable for pneumatic, water, and low
pressure hydraulic applications. Its modular design allows
for a variety of electrical and mechanical terminations.
FEATURES APPLICATIONS
• Low pressure switch • Pneumatic system control
PRESSURE
• Factory set or field adjustable • Low pressure filter monitoring

• Compact size • Car washes
• Cost effective • Gate control
* UL available for certain models
Specifications Pressure Range

Electrical 5A [12/24 VDC, 125 VAC] or 3A [250 VAC] Adjustment Range
Model
Switch Type Snap Action PSI BAR
Protection DIN 43650A - IP65, Terminals - IP00 1 3-7 0.2 - 0.5
Temperature Range -20°F to 180°F (-29°C to 82°C) Nitrile 2 5 - 30 0.3 - 2.1
Mechanical Range 1,000,000 Cycles @ 75 PSI (5.2 BAR) 3 25 - 150 1.7 - 10
Diaphragm Material Standard: Nitrile Optional: Viton, EPDM, HNBR
Housing Material Brass (Optional Stainless Steel)
Maximum Overpressure 350 PSI (24 BAR)
Repeatability +/- 2% of full set point range at 20°C (68°F)
Differential 6 - 20% of setting
Weight 0.26 lbs (0.12 kg)
Dimensions 29
1.13
50 3/32" ALLEN WRENCH
ADJUSTMENT SCREW
1.97
78
3.07
3.29
84
2.04
2.09
1.61
2.09
52
53
1.61
53
41
41
H HC HCR SP FL
Din Male Only DIN 43650A Right angled DIN 1/4” Spades Flying Leads
43650A
Wiring Code
FLDR / FLDP
FLYING DIN 43650 FLWF / FLWM
CONTACT DEUTSCH
LEADS TYPE WEATHERPACK
RECEPTACLE / PLUG
COMMON BLACK PIN 1 PIN A PIN A / PIN 1
NORMALLY CLOSED BLUE PIN 2 PIN C PIN C / PIN 2
NORMALLY OPEN RED PIN 3 PIN B PIN B / PIN 2
4 www.switchingssi.com
SPA
Ordering Information
1 2 3 4 5
Field Adjustable SPA - 2 - 2M - C - HC - 1

1 2 3 4 5
Factory Preset SPF - 30F - 2M - C - HC - 1
1 - Pressure Selection:
PRESSURE
Field Adjustable - Select Model Code Insert set point value XXX followed by: R, F, BR, or BF
Adjustment Range Setpoint Direction Description

Model
PSI BAR R PSI Rising Pressure
1 3-7 0.21 - 0.5 OR F PSI Falling Pressure
XXXX
2 5 - 30 0.3 - 2.1 BR BAR Rising Pressure
3 25 - 150 1.7 - 10 BF BAR Falling Pressure
2 - Thread Options:
2M - 1/8 NPT male
4M - 1/4 NPT male
2G - 1/8 BSPP male, G1/8
4S - 7/16-20 SAE male, with O-ring seal
M10 - M10 X 1.0 male
M12 - M12 X 1.5 male
3 - Circuit:
A - SPST (Normally Open)
B - SPST (Normally Closed)
C - SPDT (Single Pole Double Throw : Normally Open and Normally Closed)
4 - Electrical Termination:
H - DIN 43650A - connector type - male half only (only available in SPDT option)
HC - DIN 43650A - connector type (only available in SPDT option)
HR - 90 Degree DIN 43650A - connector type - male half only (only available in SPDT option)
HCR - 90 Degree DIN 43650A - connector type (only available in SPDT option)
HN - DIN 43650A 1/2” NPT Conduit (only available in SPDT option)
HNR - 90 Degree DIN 43650A 1/2” NPT Conduit (only available in SPDT option)
FL - Flying Lead 18” long, 18 AWG
FLWF - Flying Lead Weatherpack connector, female, 10” long leads
FLWM - Flying Lead Weatherpack connector, male, 10” long leads
FLDP - Flying Lead Deutsch connector, plug, 10” long leads
FLDR - Flying Lead Deutsch connector, receptacle, 10” long leads
SP - 1/4” Spade
5 - Options:
1 - Viton® Diaphragm
2 - EPDM Diaphragm
3 - 316 Stainless Steel Housing
4 - HNBR Diaphragm
7 - Gold Contact, Snap Action Microswitch @ 20 mA/12 VDC
8 - 10 amp, Snap Action Microswitch @ 10(2) 125 VAC (inductive), 6(2) 250 VAC (inductive)
20 - Seal Adjustment Screw
OC - Oxygen Cleaned Switches
Note: Please see page 42 for other available options
SR - Snubber
www.switchingssi.com 5
SWA
DESCRIPTION
A very compact pressure switch suitable for OEM applications.
Available with a WRAS approved EPDM diaphragm for potable
water use. Features a high quality snap action micro switch
for years of trouble free operation.
FEATURES APPLICATION
• Very Compact • Water pressure boost pumps
PRESSURE
• Factory set or field adjustable • Filter monitoring

• Internally vented option
• WRAS approved EPDM
diaphragms available

Model
Protection DIN 43650A - IP65, Flying Leads - IP64 1 7 - 21 0.5 - 1.5
Temperature Range -20°F to 180°F (-29°C to 82°C) Nitrile
2 15 - 35 1.0 - 2.4
Standard: Nitrile
Diaphragm Material 4 30 - 100 2.1 - 6.9
Optional: Viton, EPDM, HNBR
3/32" ALLEN WRENCH

ADJUSTMENT SCREW
Dimensions 29
1.13
46 78
1.82 3.07
1.85
47
1.82
1.82
1.33
1.33
46
46
34
34
HR HCR SP FL
Right angled DIN Right angled DIN 1/4” Spades Flying Leads
43650A male only 43650A
Wiring Code
FLDR / FLDP
CONTACT DEUTSCH
RECEPTACLE / PLUG
SWA
1 2 3 4 5
Field Adjustable SWA - 2 - 2M - C - FL - 1

1 2 3 4 5
Factory Preset SWF - 30F - 2M - C - FL - 1
PRESSURE
Adjustment Range Setpoint Direction Description

Model
PSI BAR R PSI Rising Pressure
1 7 - 21 0.5 - 1.5 OR F PSI Falling Pressure
XXXX
2 15 - 35 1.0 - 2.4 BR BAR Rising Pressure
4 30 - 100 2.1 - 6.9 BF BAR Falling Pressure
2 - Thread Options:
2M - 1/8 NPT male
4M - 1/4 NPT male
3 - Circuit:
HNR - 90 Degree DIN 43650A 1/2” Female Conduit (only available in SPDT option)
FLWM - Flying lead Weatherpack connector, male, 10” long leads
SP - 1/4” Spade
5 - Options:
2 - EPDM Diaphragm
4 - HNBR Diaphragm
SR - Snubber
SMA
DESCRIPTION
A versatile pressure switch suitable for many hydraulic
and pneumatic applications. It utilizes a proven piston/
diaphragm design to provide excellent accuracy and high
proof pressures with zero leakage. Various electrical
terminations are available utilizing a high quality snap action
micro switch.
• Snap action micro switch • Hydraulic system control
PRESSURE
• Factory set or field adjustable • Material handling equipment

• Diaphragm/piston design for • Lubrication systems
longevity • Garbage compactors
• Wide adjustment range
• High proof pressures

Model
Protection DIN 43650A - IP65, Terminals - IP00 3 10 - 35 0.7 - 2.4
4 30 - 120 2.0 - 8.0
Mechanical Range 1,000,000 Cycles @ 1000 PSI (69 BAR)
5 75 - 300 5.2 - 21
Diaphragm Material Standard: Nitrile Optional: Viton, EPDM
6 300 - 1200 21 - 83
Housing Material Zinc Plated Steel (Optional Stainless Steel)
9000 PSI (620 BAR) 7 1000 - 3000 69 - 207
Maximum Overpressure
4700 PSI (324 BAR) for SMA-3 model 8 2000 - 5000 138 - 345
Dimensions 3/32" ALLEN WRENCH

ADJUSTMENT SCREW
29
1.13
50
1.97
78
46
1.25
3.07
32
1.82
3.68
94
2.43
2.47
2.47
2.47
62
63
63
2.00
2.00
63
51
51
H HC HR HCR SP FL
Din Male Only DIN 43650A Right angled DIN Right angled DIN 1/4” Spades Flying Leads
43650A male only 43650A
Wiring Code
FLDR / FLDP
CONTACT DEUTSCH
RECEPTACLE / PLUG
SMA
1 2 3 4 5
Field Adjustable SMA - 4 - 2M - C - HC - 1
1 2 3 4 5
Factory Preset SMF - 30F - 2M - C - HC - 1
PRESSURE
Adjustment Range
Model
PSI BAR
3 10 - 35 0.7 - 2.4
Set point Direction Description
4 30 - 120 2.0 - 8.0

R PSI Rising Pressure
5 75 - 300 5.2 - 21 OR XXXX

F PSI Falling Pressure
6 300 - 1200 21 - 83
BR BAR Rising Pressure
7 1000 - 3000 69 - 207

BF BAR Falling Pressure
8 2000 - 5000 138 - 345
2 - Thread Options:
2M - 1/8 NPT male
4M - 1/4 NPT male
4SLN - 7/16-20 SAE male, with O-ring seal, adjustable
M10 - M10 X 1.0 male
M12 - M12 X 1.5 male
3 - Circuit:
SP - 1/4” Spade
5 - Options:
2 - EPDM Diaphragm
4 - HNBR Diaphragm
SR - Snubber Note: Please see page 42 for other available options
SDCA
DESCRIPTION
A robust pressure switch with full metal stops for demanding
applications. Features a heavy steel body providing high
proof pressures as well as an outstanding burst pressure
rating. Excellent for hydraulic applications that may see
system pressure shock.
• Snap action micro switch • Industrial equipment
PRESSURE
• Factory set or field adjustable • Scissor lifts

• Full metal stops • Presses
• High proof pressure • Cranes

Model
Protection DIN 43650A - IP65, Terminals - IP00 2 15 -75 1.2 - 5.2
3 50 - 150 3.4 - 10
4 150 - 650 10 - 44
5 500 - 1750 34 - 120
Maximum Overpressure 12000 PSI (827 BAR) 6 1500 - 6000 103 - 413

Differential 7 - 30 % of setting
1/8" ALLEN WRENCH

Dimensions ADJUSTMENT SCREW
UNDERNEATH LID
77
45
3.03
1.78
2.82
2.82
72
72
1.24
HCR HR
Right angled DIN Right angled DIN
43650A 29 43650A male only
Wiring Code 1.13
CONTACT DIN 43650 TYPE

COMMON PIN 1
NORMALLY CLOSED PIN 2
NORMALLY OPEN PIN 3
SDCA
1 2 3 4 5
Field Adjustable SDCA - 2 - 2M - C - HC - 1

1 2 3 4 5
Factory Preset SDCF - 50F - 2M - C - HC - 1
PRESSURE
1 - Pressure Selection
Adjustment Range
Model Set point Direction Description
PSI BAR
2 15 - 75 1.2 - 5.2
3 50 - 150 3.4 - 10 OR XXXX
4 150 - 650 10 - 44
5 500 - 1750 34 - 120
6 1500 - 6000 103 - 413
2 - Thread Options:
4M - 1/4 NPT male
4MF - 1/4 NPT female
4GF - 1/4 BSPP female, G1/4
3 - Circuit:
C - SPDT (Single Pole Double Throw)
HCR - 90 Degree DIN 43650A PG9/PG11- connector type (only available in SPDT option)
5 - Options:
2 - EPDM Diaphragm
3 - 316 Stainless Steel Process Connection and Housing
3A - 316 Stainless Steel Process Connection
4 - HNBR Diaphragm
7 - Gold Contact, Snap Action Microswitch @ 20mA@ 12Vdc
SR - Snubber
SKBA
DESCRIPTION
A miniature pressure switch with high proof pressures ideal
for mobile and other harsh applications. It is a well sealed
design that offers ingress protection to IP68 when paired
with the flying lead option. It is offered with a variety of
mechanical and electrical terminations for easy integration.
• Silver nickel alloy contacts • Industrial tools
PRESSURE
• Diaphragm/piston combination • Garbage trucks

• High ingress protection • Brake pressure switch
• Compact body
• Gold contact available

Electrical 100 VA, 42 VDC Adjustment Range
Model
Switch Type Blade Contact PSI BAR
Protection Exposed Terminals - IP00 (IP68 Available) 1 1.5 - 20 0.1 - 1.4
2 20 - 120 1.4 - 8.2
3 90 - 250 6.2 - 17
Standard: Nitrile
Diaphragm Material 4 250 - 950 17 - 65
Housing Material Zinc Plated Steel (Optional Stainless Steel) 5 700 - 1900 48 - 131
Maximum Overpressure 9000 PSI (600 BAR) 6 1000 - 3000 69 - 206
Repeatability +/- 3% of full set point range
Dimensions
IP68 CAP IS STANDARD WITH
FLYING LEAD OPTION
14
.56
1.97
50
1/8" ALLEN WRENCH

ADJUSTMENT SCREW 44
1.71
SP FL
1/4” Spades Flying Leads
Wiring Code
FLDR / FLDP
FLYING FLWF / FLWM
CONTACT DEUTSCH
LEADS WEATHERPACK
RECEPTACLE / PLUG
COMMON BLACK PIN A PIN 1
NORMALLY CLOSED BLACK PIN B PIN 2
NORMALLY OPEN BLACK PIN B PIN 2
SKBA
1 2 3 4 5
Field Adjustable SKBA - 2 - 2M - B - SP - 1

1 2 3 4 5
Factory Preset SKBF - 30F - 2M - B - SP - 1
PRESSURE
Adjustment Range
PSI BAR
1 1.5 - 20 0.1 - 1.4
2 20 - 120 1.4 - 8.2 XXXX
3 90 - 250 6.2 - 17
OR BR BAR Rising Pressure
4 250 - 950 17 - 65
5 700 - 1900 48 - 131
6 1000 - 3000 69 - 206
2 - Thread Options:
2M - 1/8 NPT male
4M - 1/4 NPT male
M10 - M10 X 1.0 male
M12 - M12 X 1.5 male
3 - Circuit:
FL - Flying Lead 18” long, 18 AWG, IP68 Cap is standard with this option
SP - 1/4” Spade
5 - Options:
2 - EPDM Diaphragm
4 - HNBR Diaphragm
7 - Gold Contact, 0.4 VA, 30 VDC
30 - Rubber Boot - Removable (Excludes IP68 Cap if selected)
SR - Snubber
SKDA
DESCRIPTION
One of the smallest switches in the market offering an
integrated Deutsch receptacle. Plug in a mating Deutsch
DT06-2S plug for an instant solution to the constant water
spray present in mobile applications.
• Silver Nickel alloy contacts • Mobile equipment
PRESSURE
• Direct blade contact • Street sweepers

• Diaphragm/Piston combination • Cement trucks
• Integrated Deutsch receptacle • Aerial booms
• Gold contact available

Electrical 100 VA, 42 VDC Adjustment Range
Model
Switch Type Blade Contact PSI BAR
Protection IP67 1 1.5 - 14.5 0.1 - 1.0
Mating Connector DT06-2S
2 14.5 - 145 1.0 - 10
3 50 - 350 3.4 - 24
4 250 - 1000 17 - 69
Standard: Nitrile
Diaphragm Material
Optional: Viton, EPDM, HNBR 5 500 - 2175 34 - 150
Repeatability +/- 3% of full set point range
Dimensions
DT04-2P, 2 POLE RECEPTACLE

MATING: DT06-2S, 2 POLE PLUG
1.5 mm ALLEN WRENCH
ADJUSTMENT SCREW
24
.94
31
1.22
53
2.10
Wiring Code
DEUTSCH
CONTACT
RECEPTACLE
COMMON PIN A
NORMALLY CLOSED PIN B
NORMALLY OPEN PIN B
SKDA
1 2 3 4 5
Field Adjustable SKDA - 2 - 2M - B - DR - 1

1 2 3 4 5
Factory Preset SKDF - 30F - 2M - B - DR - 1
PRESSURE
1 - Pressure Selection
Adjustment Range
Model
PSI BAR Set point Direction Description
1 1.5 - 14.5 0.1 - 1.0
2 14.5 - 145 1.0 - 10
OR F PSI Falling Pressure
XXXX
3 50 - 350 3.4 - 24
4 250 - 1000 17 - 69
5 500 - 2175 34 - 150
2 - Thread Options:
2M - 1/8 NPT male
4M - 1/4 NPT male
M10 - M10 X 1.0 male
M12 - M12 X 1.5 male
3 - Circuit:
DR - Integrated Deutsch Receptacle - Mates with DT06-2S
5 - Options:
2 - EPDM Diaphragm
4 - HNBR Diaphragm
7 - Gold Contact, 0.4 VA, 30 VDC
SR - Snubber
SPAL
DESCRIPTION
A simple and common pressure switch utilizing a polyimide
diaphragm for extended duty applications. It is used in many
automotive applications for monitoring of engine functions
and auxiliary devices.
• Gold plated silver alloy contacts • Oil pressure switch
PRESSURE
• High current ratings • Fuel pressure switch

• Works well in extreme • Exhaust pressure switch
temperatures • Air brake switch
• Very economical

Resistive Inductive Adjustment Range
Model
15 AMP - 6 VDC 1 AMP - 120 VAC PSI BAR
Electrical 1A 0.5 - 1.0 0.03 - 0.07
8 AMP - 12 VDC 0.5 AMP - 240 VAC
2A 1.1 - 3.0 0.08 - 0.21
4 AMP - 24 VDC
3A 3.1 - 7.0 0.21 - 0.49
Switch Type Blade Contact
4A 8.0 - 13 0.55 - 0.90
Protection Terminals - IP00
5A 14 - 24 0.97 - 1.65
Temperature Range -40°F to 248°F (-40°C to 120°C) Polyimide Film
Mechanical Range 1,000,000 Cycles @ 75 PSI (5.2 BAR) 6A 25 - 50 1.72 - 3.45
Standard: Polyimide Film 7A 51 - 90 3.52 - 6.20

Diaphragm Material Optional: EPDM (must be selected when in 8A 91 - 150 6.27 - 10.34
contact with water)
Brass, Glass Reinforced Polyester
Housing Material * Model 1H to 5H has an overpressure of 500 PSI
(Optional Stainless Steel)
Adjustment Range
Model 1A to 5A - 150 PSI (3.5 BAR) Model
Maximum Overpressure Model 6A to 8A - 250 PSI (17 BAR) PSI BAR
Model 1H to 5H - 500 PSI (34 BAR)
1H 10 - 35 0.69 - 2.41
Weight 0.14 lbs (0.06 kg) 2H 35 - 75 2.41 - 5.17
3H 75 - 150 5.17 - 10.34
Dimensions 4H 150 - 250 10.34 - 17.24
37 5H 250 - 400 17.24 - 27.58
1.5
1.7
42
5 mm Adjustment Screw
Wiring Code
FLDR / FLDP
FLYING FLWF / FLWM
CONTACT DEUTSCH
LEADS WEATHERPACK
RECEPTACLE / PLUG
COMMON BLACK PIN A PIN A / PIN 1
NORMALLY CLOSED BLUE PIN C PIN C / PIN 2
NORMALLY OPEN RED PIN B PIN B / PIN 2
SPAL
1 2 3 4 5
Field Adjustable SPAL - 2A - 2M - B - FL - 3

1 2 3 4 5
Factory Preset SPFL - 30F - 2M - B - FL - 3

1 2 3 4 5
Factory Preset (Select this ordering code if you

SPFLH - 30F - 2M - B - FL - 3 require a factory set switch with
PRESSURE
the high overpressure option.)
Field Adjustable - Select Model Code
Adjustment Range
Model
PSI BAR
1A 0.5 - 1.0 0.03 - 0.07
2A 1.1 - 3.0 0.08 - 0.21 Insert set point value XXX followed by: R, F, BR, or BF
3A 3.1 - 7.0 0.21 - 0.49 OR Set point Direction Description
4A 8.0 - 13 0.55 - 0.90
5A 14 - 24 0.97 - 1.65
6A 25 - 50 1.72 - 3.45 XXXX
7A 51 - 90 3.52 - 6.20
8A 91 - 150 6.27 - 10.34
1H 10 - 35 0.69 - 2.41 *If you require a factory preset switch with an
overpressure higher than 250 PSI, please select
2H 35 - 75 2.41 - 5.17
the model code SPFLH.
3H 75 - 150 5.17 - 10.34
4H 150 - 250 10.34 - 17.24
5H 250 - 400 17.24 - 27.58
2 - Thread Options:
2M - 1/8 NPT male
4M - 1/4 NPT male
3 - Circuit:
D - SPDT (Single Pole Double Throw : Normally Open and Normally Closed)
E - SPDT (Single Pole Double Throw, Adjustable Differential)
SP - 1/4” Spade
TS - Terminal Screws, #8-32
5 - Options:
2 - EPDM Diaphragm
3 - Stainless Steel Housing
30 - Rubber Boot - Removable
SLF
DESCRIPTION
A basic snap disc design pressure switch for control
applications. It has the ability to automatically reset pressure
at various desired settings. Its main uses are in the air
conditioning and refrigeration field.
• Stainless steel diaphragm • Air conditioning
PRESSURE
• Compact size • Refrigeration

• Low cost
• Factory adjusted differential
• Preset differential

Electrical 2A [12/24 VDC] or 120/240 VAC, 375 VA Set Point
Switch Type Snap Disc PSI BAR
Protection Terminals - IP00 2 - 650 0.1 - 45
Temperature Range -40°F to 180°F (-40°C to 82°C) Stainless Steel
*Factory Set Only
Mechanical Range 100,000 Cycles
Diaphragm Material Standard: Stainless Steel
Housing Material Brass
500 PSI (35 BAR) for set points up to 145 PSI (10 BAR)
Maximum Overpressure 770 PSI (55 BAR) for set points 146 PSI to 290 PSI (10.1 BAR - 20 BAR)
1200 PSI (85 BAR) for set points 291 PSI to 630 PSI (20.1 BAR - 45 BAR)
Dimensions
13
.53
22
10 .85
.39
1.22
1.04
31
26
.83
21
FL SP
Flying Leads 1/4” Spades
SLF
Wiring Code
PRESSURE
FLDR / FLDP
FLYING FLWF / FLWM
CONTACT DEUTSCH
LEADS WEATHERPACK
RECEPTACLE / PLUG
COMMON BLACK A PIN 1

NORMALLY CLOSED BLACK B PIN 2
NORMALLY OPEN BLACK B PIN 2
1 2 3 4
Factory Preset SLF - 30R/25F - 2M - A - FL
1 - Pressure Selection 2 - Thread Options:

Insert rising and falling set point
2M - 1/8 NPT male
value XXX followed by: R, F, BR, or BF
2F - 1/8 NPT female
Set point Direction Description 4M - 1/4 NPT male
R PSI Rising Pressure 4MF - 1/4 NPT female
XX/XX 2G - 1/8 BSPP male, G1/8
2BF - 1/8 BSPP female, G1/8
4GF - 1/4 BSPP female, G1/4
3 - Circuit: 4 - Electrical Termination:

A - SPST (Normally Open) FL - Flying Lead 18” long, 18 AWG
B - SPST (Normally Closed) Flying Lead Weatherpack connector,
FLWF -
female, 10” long leads
Flying Lead Weatherpack connector,
FLWM
male 10” long leads
Flying Lead Deutsch connector
FLDP -
plug, 10” long leads
Flying Lead Deutsch connector
FLDR -
receptacle, 10” long leads
SP - 1/4” Spade
TS - Terminal Screw, #8-32
SPAH
DESCRIPTION
A small open type construction switch suitable for use in the
electrical appliance market. Its high current ratings allow
direct control of heating elements and motor loads without
the use of an additional relay. It is ideal for high volume
requirements.
• Very high current rating • Household appliances
PRESSURE
• Compact size • Motor switching

• Open type construction • Heating element switching

16A, 125/250 VAC Adjustment Range
Electrical Model
21A, 125/250 VAC
PSI BAR
Switch Type Snap Action
Protection Terminals - IP00 1 3-9 0.2 - 0.6
Temperature Range -20°F to 257°F (-29°C to 125°C) Stainless Steel 2 7 - 20 0.5 - 1.5
Diaphragm Material Standard: Stainless Steel 3 17 - 36 1.2 - 2.5
Housing Material Brass , Glass reinforced polyester 4 29 - 58 2.0 - 4.0
Model 1 - 43 PSI (3 BAR) 5 43 - 100 3.0 - 6.9
Model 2 - 58 PSI (4 BAR)
Model 3 - 72 PSI (5 BAR) 6 70 - 130 4.8 - 9.0
Maximum Overpressure
Dimensions
SP
Wiring Code 1/4” Spades
CONTACT SP
COMMON COM
NORMALLY CLOSED NC
NORMALLY OPEN NO
SPAH
1 2 3 4 5
Field Adjustable SPAH - 2 - 2M - C1 - QC1 - T1

1 2 3 4 5
Factory Preset SPFH - 30F - 2M - C1 - QC1 - T1
PRESSURE
Adjustment Range
Model
PSI BAR
1 3-9 0.2 - 0.6
2 7 - 20 0.5 - 1.5
3 17 - 36 1.2 - 2.5
OR XXXX
4 29 - 58 2.0 - 4.0
5 43 - 100 3.0 - 6.9
6 70 - 130 4.8 - 9.0
2 - Thread Options:
2M - 1/8 NPT male
4M - 1/4 NPT male
3 - Circuit:
C1 - SPDT (Single Pole Double Throw) - 15A, 125/250 VAC
C2 - SPDT (Single Pole Double Throw) - 21A, 125/250 VAC
QC1 - Quick Connect 4.8 mm
QC2 - Quick connect 6.35 mm
5 - Temperature Selection:
T1 - 85°C
T2 - 125°C
DSPA
DESCRIPTION
An economical differential switch utilizing a simple and
reliable design. It is used for many monitoring applications
such as a filter change indicator. Constructed of an anodized
aluminium body with steel ports for durability.
• Snap action micro switch • Filter element monitoring
• Factory set or field adjustable • Fluid control
• Diaphragm design • Water treatment applications

DIFFERENTIAL

Model
Protection DIN 43650A - IP65, Terminals - IP00 1 10 - 30 0.7 - 2.0
2 25 - 60 1.7 - 4.0
Mechanical Range 1,000,000 Cycles @ 75 PSI (5.2 BAR)
Standard: Nitrile
Diaphragm Material
Housing Material Anodized Aluminum Housing
Dimensions
50 DIN43650A
1.97
73
2.87
32 32
1.25 1.25
5/64" ALLEN WRENCH 48 67

ADJUSTMENT SCREW 1.90 2.64
HC H
Wiring Code DIN 43650A Din Male Only
CONTACT DIN 43650 TYPE
COMMON PIN 1
NORMALLY CLOSED PIN 2
NORMALLY OPEN PIN 3
DSPA
1 2 3 4 5
Field Adjustable DSPA - 2 - 4M-4M - C - HC - 1

1 2 3 4 5
Factory Preset DSPF - 30F - 4M-4M - C - HC - 1
Adjustment Range
Model R PSI Rising Pressure
PSI BAR
OR F PSI Falling Pressure
1 10 - 30 0.7 - 2.0 XXXX
2 25 - 60 1.7 - 4.0
DIFFERENTIAL
2 - Thread Options for both process connections:

4M - 1/4 NPT male , Plated Steel
4G - 1/4 BSPP male, G1/4, Plated Steel
3 - Circuit:
HC - DIN 43650A PG9/PG11 - connector type (only available in SPDT option)
5 - Options:
2 - EPDM Diaphragm
4 - HNBR Diaphragm
7 - Gold Contact, Snap Action Microswitch @ 20 mA / 12 VDC
SVA
DESCRIPTION
A compact vacuum switch utilizing a high quality snap action
micro switch for applications in which price and size are of
concern. It is used for pneumatic, water and low pressure
applications. Its modular design allows for a variety of
electrical and mechanical terminations.
• Snap action micro switch • Vacuum generators
• Factory set or field adjustable • Industrial automation
• Diaphragm design • Pick and place units
• WRAS approved EPDM • Engine load monitoring
diaphragms available

MODEL
Switch Type Snap Action inHg Millibar
Protection DIN 43650A - IP65, Terminals - IP00 1 5-30” 170 - 1020
Mechanical Range 1,000,000 Cycles @ 75 PSI (5.2 BAR)
VACUUM

Dimensions 29
1.13
50 3/32" ALLEN WRENCH
ADJUSTMENT SCREW
1.97
78
3.07
3.29
84
2.04
2.09
1.61
2.09
52
53
1.61
53
41
41
H HC HCR SP FL
Din Male Only DIN 43650A Right angled DIN 1/4” Spades Flying Leads
43650A
Wiring Code
FLDR / FLDP
CONTACT DEUTSCH
RECEPTACLE / PLUG
SVA
1 2 3 4 5
Field Adjustable SVA - 1 - 2M - C - HC - 1

1 2 3 4 5
Factory Preset SVF - 25F - 2M - C - HC - 1
Field Adjustable - Select Model Code Insert set point value XXX followed by: R, F, MR, or MF

Adjustment Range R inHg Rising Vacuum
Model
inHg Millibar OR F inHg Falling Vacuum
XXXX
1 5 - 30” 170 - 1020 MR Millibar Rising Vacuum
MF Millibar Falling Vacuum
2 - Thread Options:
2M - 1/8 NPT male
4M - 1/4 NPT male
VACUUM
M10 - M10 X 1.0 male
M12 - M12 X 1.5 male
3 - Circuit:
C - SPDT (Single Pole Double Throw)
HNR - 90 Degree DIN 43650A 1/2” Female Conduit (only available in SPDT option)
SP - 1/4” Spade
5 - Options:
2 - EPDM Diaphragm
4 - HNBR Diaphragm
7 - Gold Contact, Snap Action Microswitch @ 20 mA / 12 VDC
20 - Seal adjustment Screw
SR - Snubber
SPVL
DESCRIPTION
This compact, simple vacuum switch is suitable for many
applications. It is designed for easy installation and quick
access to the set point. It is available in factory set or
adjustable ranges.
• Gold plated silver alloy contacts • Vacuum generators
• High current ratings • Industrial automation
• Works well with extreme • Engine load monitoring
temperature
• Economical

Resistive Inductive Adjustment Range
Model
15 AMP - 6 VDC 1 AMP - 120 VAC inHg Millibar
Electrical 1 1.1 - 3 37 - 101
8 AMP - 12 VDC 0.5 AMP - 240 VAC
2 4-8 135 - 270
4 AMP - 24 VDC
3 9 - 17 305 - 575
VACUUM
Switch Type Blade Contact

4 18 - 22 610 - 745
Protection Terminals - IP00
Temperature Range -40°F to 248°F (-40°C to 120°C)
Diaphragm Material Standard: Flurosilicone elastomer
Brass, Glass Reinforced Polyester
Housing Material
(Optional Stainless Steel)
Maximum Operating Pressure 30 inHg Vacuum
Burst Pressure 150 PSI (10.3 BAR)
Dimensions
37
1.5
1.7
42
5 mm Adjustment Screw
Wiring Code
FLDR / FLDP
FLYING FLWF / FLWM
CONTACT DEUTSCH
LEADS WEATHERPACK
RECEPTACLE / PLUG
COMMON BLACK PIN A PIN A / PIN 1
NORMALLY CLOSED BLACK PIN C PIN C / PIN 2
NORMALLY OPEN BLACK PIN B PIN B / PIN 2
SPVL
1 2 3 4 5
Field Adjustable SPVL - 2 - 2M - A - SP - 2

1 2 3 4 5
Factory Preset SPVF - 17F - 2M - A - SP - 2
Field Adjustable - Select Model Code Insert set point value XXX followed by: R, F, MR, or MF
Adjustment Range
inHg Millibar
R inHg Rising Vacuum
1 1.1 - 3 37 - 101
F inHg Falling Vacuum
2 4-8 135 - 270 OR XXXX
MR Millibar Rising Vacuum
3 9 - 17 305 - 575
MF Millibar Falling Vacuum
4 18 - 22 610 - 745
2 - Thread Options:
2M - 1/8 NPT male
VACUUM
4M - 1/4 NPT male
3 - Circuit:
SP - 1/4” Spade
TS - Terminal Screws, #8-32
5 - Options:
2 - EPDM Diaphragm
20 - Seal adjustment Screw
S1TAF
DESCRIPTION
A bimetal temperature switch with grounded body
switching and built in thermistor output. It is used for
mobile or automotive applications where a switch and
indicator output are both required.
• Temperature switch and sensor • Coolant temperature switch/sensor
• Compact size • Lubrication systems
• Low differential • Oil reservoir temperature switch/senso
Specifications Temperature
5A [12/24 VDC, 125 VAC] Temperature Set point
Electrical
3A [250 VAC] °F °C
Switch Type Bimetal
77 - 293 25 - 145
Protection Terminals IP00, Body IP65
Temperature Range 77°F to 293°F (25°C to 145°C)
Temperature Differential 10°F (5°C)
Temperature Exposure Limit 300°F (149°C)
Maximum Overpressure 350 PSI (24.1 BAR)
TEMPERATURE
Dimensions
PIN 1 PIN 2
0.18" 0.25"
22
.86
NTC
11
.42 19
.76 33
30 1.29
1.18
70
69 2.76
2.72
S1TAF
Wiring Code
FLDR / FLDP
FLYING FLWF / FLWM
CONTACT SPADE DEUTSCH
LEADS WEATHERPACK
RECEPTACLE / PLUG
PIN 1 - NORMALLY CLOSED 0.18” RED PIN A PIN 1
PIN 1 - NORMALLY OPEN 0.18” RED PIN A PIN 1
PIN 2 - NTC 0.25” BLACK PIN B PIN 2
1 2 3 4 5
Factory Preset S1TAF - 120F - 4M - B - SP - 3
1 - Temperature Selection
Insert set point value XXX followed by: R, F

R Fahrenheit Rising
XXXX
F Fahrenheit Falling
2 - Thread Options:
TEMPERATURE
4M - 1/4 NPT male
6M - 3/8 NPT male
8M - 1/2 NPT male
3 - Circuit:
A - SPST (Normally Open), NTC 2000
B - SPST (Normally Closed), NTC 2000
SP - 1/4” Spades
J - Junior Power Connector AMP 106462/1
5 - Options:
S2TAF
DESCRIPTION
A bimetal temperature switch with brass body and an
internal sensing cavity. Its unique design allows for sensing
of the fluid temperature without the need of a probe. This
compact bimetallic temperature switch will meet most
industrial applications.
• Factory set • Hydraulic reservoir safety switch
• High current rating • Coolant temperature switch
• Reliable differential
• Compact size
Specifications Temperature
120 VAC - 15A Resistive Temperature Set point
240 VAC - 10A Resistive °F °C
Electrical
12VDC - 12A Resistive
24 VDC - 6A Resistive 77 - 293 25 - 135
Switch Type Bimetal
Protection DIN 43650A - IP65, Terminals - IP00
Temperature Range 77°F to 293°F (25 °C to 145°C)
Temperature Differential 25°F (12°C)
Temperature Exposure Limit 300°F (149°C)
TEMPERATURE
Maximum Overpressure 350 PSI (24.1 BAR)

Dimensions
2.37
60
1.12
28
.88
22
.74
19
-INTERNAL SENSING CAVITY

-PROBE IS OPTIONAL
FL SP H HC
Flying Leads Spades Din Male Only DIN 43650A
Wiring Code
FLDR / FLDP
CONTACT DEUTSCH
RECEPTACLE / PLUG
COMMON RED PIN 1 PIN A PIN 1
NORMALLY CLOSED RED PIN 2 PIN B PIN 2
NORMALLY OPEN RED PIN 2 PIN B PIN 2
S2TAF
1 2 3 4 5
Factory Preset S2TAF - 140F - 4M - B - HC - 3
1 - Temperature Selection:
Insert set point value XXX followed by: R, F.

R °F Rising temperature
XXXX
F °F Falling temperature
2 - Thread Options:
4M - 1/4 NPT
6M - 3/8 NPT
8M - 1/2 NPT
8S - 3/4-16 SAE
3 - Circuit:
TEMPERATURE
H - DIN 43650A - connector type - male half only
HC - DIN 43650A - connector type
SP - 1/4” Spade
5 - Options:
NOTE: For probe length requirements, please consult factory.

Standard switch is designed with an internal sensing cavity
TG
DESCRIPTION
A general purpose low cost industrial transducer suitable
for a wide range of applications. Available in either 0.5%
or 0.25% accuracy. It utilizes diffused silicone, ceramic and
strain gauge technologies.
• Low Cost • Industrial Equipment
• Temperature Compensation • Safety Monitoring
• Voltage and Current output • Mobile Equipment
models available
Specifications Dimensions
Accuracy 0.5% FS, 0.25% FS
Pressure Range Vacuum to 10,000 PSI (700 BAR)
Proof Pressure 150% FS
Burst Pressure 300% FS
Fatigue Life 100,000,000 cycles
0.1%/FS/year for < 725 PSI (50 BAR)
Long Term Drift
0.2%/FS/year for ≥ 725 PSI (50 BAR)
Thermal Error 0.02%/FS/°C 34
1.34
Compensated Temperatures 32°F to 149°F (0°C to 65°C)
Operating Temperatures -4°F to 176°F (-20°C to 80°C)
TRANSDUCER
Storage Temperature Rating -40°F to 257°F (-40°C to 125°C)

Standard: SS304 26
Process Connection 1.02
Optional: SS316
90 67
10g (20-2000Hz) for ≤ 58 PSI (4 BAR) 90
Vibration 3.54 3.55 2.64
20g (20 - 500Hz) for ranges > 58 PSI (4 BAR)
Shock 100g (11ms)
Voltage Output 0-5V, 0.5-4.5V, 0-10V
Supply Voltage for Voltage
16 - 36 VDC
Output
Current Output 4-20mA
Supply Voltage for Current 10 19
12V - 32VDC 0.39 0.75
Output
Max. Loop Resistance 500 Ω
TG
1 2 3 4 5 6
Example TG - 1V1B - A - 3 - HC - 4M - A2
1 - Measuring Range:
Code Description Code Description

1V0B -1 to 0 BAR 1V0P 30 inHg to 0 inHg
1V1B -1 to 1 BAR 1V1P 30 inHg - 15 PSI
001B 1 BAR 001P 15 PSI
002B 2 BAR 003P 30 PSI
005B 5 BAR 006P 60 PSI
010B 10 BAR 010P 100 PSI
020B 20 BAR 015P 150 PSI
050B 50 BAR 020P 200 PSI
100B 100 BAR 030P 300 PSI
200B 200 BAR OR 050P 500 PSI
350B 350 BAR 060P 600 PSI
400B 400 BAR 075P 750 PSI
600B 600 BAR 100P 1000 PSI
700B 700 BAR 150P 1500 PSI
200P 2000 PSI
Note: Other ranges available. 300P 3000 PSI
Please consult factory. 500P 5000 PSI
600P 6000 PSI
750P 7500 PSI
10KP 10000 PSI
2 - Gauge Standard:
A - Absolute
TRANSDUCER
G - Gauge
3 - Output:
2 - 4 -20 mA, 2 wire
3 - 0 - 10 V, 3 wire
4 - 0.5 - 4.5 V
5 - 0 - 5.0 V
4 - Electrical Connection:
HC - DIN 43650A - connector type
HCC2 - DIN 43650A - with 2 meters of cable
M12 - M12, 4 pin
C2 - Shielded Cable, 2 meter
5 - Process Connection
4M - 1/4” NPT male
4G - 1/4” BSPP male, G1/4
6 - Accuracy
A2 - 0.5%
A3 - 0.25%
TC
DESCRIPTION
A compact pressure transducer suitable for mobile
applications. It shares many features of the TG series, but in
a more compact body. This product would be a great choice
for tight spaces.
• Compact Style • Road Maintenance Vehicles
• Temperature Compensation • Cranes
• Stainless Steel Construction • Automation process
Specifications Dimensions
Accuracy 0.5% FS
Pressure Range Vacuum to 10,000 PSI (700 BAR)
Proof Pressure 150% FS
Burst Pressure 300% FS
Fatigue Life 100,000,000 cycles
0.1%/FS/year for < 725 PSI (50 BAR)
Long Term Drift
0.2%/FS/year for ≥ 725 PSI (50 BAR)
Thermal Error 0.02%/FS/°C
Compensated Temperatures 32°F to 149°F (0°C to 65°C)
Operating Temperatures -4°F to 176°F (-20°C to 80°C)
22
TRANSDUCER
Storage Temperature Rating -40°F to 257°F (-40°C to 125°C) 0.87

Standard: SS304 70 65 47
Process Connection 2.76 2.58 1.85
Optional: SS316
10g (20-2000Hz) for ≤ 58 PSI (4 BAR)
Vibration
20g (20 - 500Hz) for ranges > 58 PSI (4 BAR)
Shock 100g (11ms)
Voltage Output 0-5V, 0.5-4.5V, 0-10V
Supply Voltage for Voltage
16 - 36 VDC 19
Output 10 0.75
Current Output 4-20mA 0.39
Supply Voltage for Current

12V - 32VDC
Output
Max. Loop Resistance 500 Ω
TC
1 2 3 4 5 6
Example TC - 050P - A - 4 - M2 - 4M - A2
1 - Measuring Range:
001B 1 BAR 1V0P 30 inHg to 0 inHg
002B 2 BAR 1V1P 30 inHg to 15 PSI
005B 5 BAR 001P 15 PSI
010B 10 BAR 003P 30 PSI
020B 20 BAR 006P 60 PSI
050B 50 BAR 010P 100 PSI
100B 100 BAR 015P 150 PSI
200B 200 BAR 020P 200 PSI
350B 350 BAR OR 030P 300 PSI
400B 400 BAR 050P 500 PSI
600B 600 BAR 060P 600 PSI
700B 700 BAR 075P 750 PSI
100P 1000 PSI
Note: Other ranges available. 150P 1500 PSI
Please consult factory. 200P 2000 PSI
300P 3000 PSI
500P 5000 PSI
600P 6000 PSI
750P 7500 PSI
10KP 10000 PSI
2 - Gauge Standard:
A - Absolute
G - Gauge
TRANSDUCER
3 - Output:
2 - 4 - 20 mA, 2 wire
3 - 0 - 10 V, 3 wire
4 - 0.5 - 4.5 V
5 - 0 - 5.0 V
4 - Electrical Connection:
M2 - DIN 43650C (Mini DIN)
M2C2 - DIN 43650C (Mini DIN) with 2 meter cable
M12 - M12, 4 pin
5 - Process Connection
4M - 1/4” NPT male
4G - 1/4” BSPP male, G1/4
6 - Accuracy
A2 - 0.5%
LF1
DESCRIPTION
A rapid fluid level switch suitable for use with contaminated
fluid. Rod height can be easily cut to length for fast
implementation into your system.
• Rapid level float switch • Hydraulic unit
• User can easily customize length • Coolant tanks
of rod • Storage tanks
• Can be used in the presence of
dirty liquids or ferrous particles
due to lack of magnet
• Materials suitable for high
temperatures
Specifications
1A, 20W, 20VA, 150 VDC/VAC Single Pole Double Throw Contact
Electrical
0.5A, 30W, 500VDC
Switch Type Reed Switch
3 2
Protection DIN 43650 PG9 - IP65
Rod Material Stainless Steel (Optional Reinforced Rods Brass)
Rod Length 500 mm or 1000 mm 1
Maximum Pressure 145 PSI (10 BAR)
1 2 3 4
Example LF1 - R - F3 - S2 - A500
1 - Rod Type:
Blank - Stainless Steel Standard Rod
R - Reinforced Rod (Brass material)
2 - Thread Options:
F3 - 3 Hole Flange
T3 - 1-1/4 NPT
LEVEL
3 - Circuit:
S2 - SPDT (Single Pole Double Throw)
4 - Control Rod Length:

A500 - Standard rod length 500 mm
* Rods can be cut to specific length. Please see pg 38 for cutting chart
LF2
DESCRIPTION
A rapid fluid level switch suitable for use with contaminated
fluid. Rod height can be easily cut to length for fast
implementation into your system. It has two rods to monitor
two fluid levels.
• Rapid level float switch • Process tank
• User can easily customize length • Batch monitoring
of rod • Storage tanks
• Can be used in the presence of
dirty liquids or ferrous particles
due to lack of magnet
• Materials suitable for high
temperatures
Specifications
1A, 20W, 20VA, 150 VDC/VAC Single Pole Double Throw Contact
Electrical
0.5A, 30W, 500VDC
Switch Type Reed Switch
3 2
Protection Junction Box - IP65
Rod Material Stainless Steel (Optional Reinforced Rods Brass)
Rod Length 500 mm or 1000 mm 1
Maximum Pressure 145 PSI (10 BAR)
1 2 3 4 5
Example LF2 - R - F3 - S2-S2 - A500 - B400
1 - Rod Type:
BLANK - Stainless Steel Standard Rod
R - Reinforced Rod (Brass material)
2 - Thread Options:
F3 - 3 Hole Flange
T3 - 1-1/4 NPT
LEVEL
3 - Circuit:
S2 - S2 - SPDT (Single Pole Double Throw)
4 - Lower Control Rod Length:

5 - Upper Control Rod Length:

B400 - Standard rod length 400 mm * Minimum distance between the two points to be controlled is 90mm
B900 - Standard rod length 900 mm ** Rods can be cut to specific length. Please see pg 38 for cutting chart
LEVEL SWITCH CHART
Rod Cutting For Min Rod Cutting for Max

Control Value L Control Value L1
Level A Level B
(mm) (mm)
(mm) (mm)
120 116
140 137
160 158
220 221 120 131
240 242 140 152
260 263 160 173
280 284 180 194
300 305 200 215
320 326 220 236
A
L
340 347 240 257

360 368 260 278
380 389 280 299
400 410 300 320
420 431 320 341
440 452 340 362
460 473 360 383
480 494 380 404
H
500 515 400 425

520 511 420 421
540 532 440 442
560 553 460 463
580 574 480 484
600 595 500 505
620 616 520 526
640 637 540 547
660 658 560 568
680 679 580 589
700 700 600 610
720 721 620 631
740 742 640 652
B
760 763 660 673

L1
780 784 680 694

800 805 700 715
A
L
820 826 720 736

H1
840 847 740 757

860 868 760 778
880 889 780 799
900 910 800 820
920 931 820 841
H
LEVEL
940 952 840 862

960 973 860 883
980 994 880 904
1000 1015 900 925
H = 60 for L = 120 to 500

H = 90 for L = 501 to 1000
H1= 70 for L1 = 120 to 1000
LEVEL SWITCH SPECIFICATION
Wiring Code - LF1 Wiring Code - LF2

CONTACT DIN 43650 TYPE CONTACT JUNCTION BOX
COMMON PIN 1 COMMON YELLOW
NORMALLY CLOSED PIN 2 NORMALLY CLOSED BLUE
NORMALLY OPEN PIN 3 NORMALLY OPEN WHITE
LF1 LF2
15
33
1
55
43
2
2
15
1
80
3
35
L1
1
Stainless Steel Maximum Level
Control Rod
2
4
L
L
0.2
70
3
1
Stainless Steel Minimum Level

H
Control Rod
30
1
BASE ULTRASONIC WELDING
FIXING SCREWS SEAT F3 Mounting Pattern:
MAGNET SEAL
M4
BODY
LEVEL
UNION
S/STEEL CONTROL ROD 43

1.7
SILICONE SHEATH
FLOAT
VE
DESCRIPTION
A visual level switch that can be installed into the side of a
reservoir. This easy to install switch is affordable and reliable.
It comes with the option of two lengths and the option of a
temperature probe.
• Compact size • Water tank
• Easy to install • Hydraulic units
• Visual indicator • Level monitoring
Specifications Wiring Code

Electrical 1A, 20W, 20 VA. 150 VDC/VAC CONTACT DIN 40050
Electrical Connection DIN 40050 COMMON PIN 3
Protection IP65 NORMALLY CLOSED PIN 2
NORMALLY OPEN PIN 1
Tube Material Methacrylate Tube
Mounting Method M12 Screws
Maximum Overpressure 72.5 PSI (5 BAR)
WASHER
Dimensions
LEVEL
Description 5” Visual/Electrical Gauge 10” Visual/Electrical Gauge

Single Pole Double Throw VE-127-M12-SPDT VE-254-M12-SPDT
Single Pole Double Throw with
VE-127-M12-SPDT-T VE-254-M12-SPDT-T
Temperature Probe
LSM
DESCRIPTION
A compact level switch that can be installed into the side
of a reservoir. This easy to install switch is affordable and
reliable.
• Compact size • Water tank
• Easy to install • Hydraulic units
• Economical • Level monitoring
Specifications Wiring Code

Electrical 2A, 40W, 40 VA. 230VDC/VAC CONTACT DIN 43650 TYPE
Electrical Connection DIN 43650 PG9 COMMON PIN 1
Protection IP65 NORMALLY CLOSED PIN 2
Temperature Range -4°F to 176°F (-20°C to 80°C) NORMALLY OPEN PIN 2
Tube Material Polyamide 11/12
Mounting Method Flange 4 Holes (Diameter: 5.3 mm)
Maximum Pressure 43.5 PSI (3 BAR)
LEVEL
1 2
Example LSM - A - 1
1 - Circuit 2 - Optional Material

A - Normally Closed 1 - PVDF (for aggressive liquids)
B - Normally Open
OPTIONS
MODEL
- DESCRIPTION
SERIES
1 2 3 4 5
Field Adjustable SMA - 4 - 2M - C - HC - 1

1 2 3 4 5
Factory Preset SMF - 30F - 2M - C - HC - 1
2 - Thread Options:
2M - 1/8 NPT male
4M - 1/4 NPT male
4SLN - 7/16-20 SAE male, with O-ring seal, adjustable
8S - 3/4 - 16 SAE male, with O-ring seal
8J - 3/4-16 JIC 37° Flare
M10 - M10 X 1.0 male
M12 - M12 X 1.5 male
HC-5A - DIN 43650A - connector type with light 12 VDC
HC-5B - DIN 43650A - connector type with light 24 VDC
HC-5C - DIN 43650A - connector type with 110/230 VAC
HN - DIN 43650A 1/2” Female Conduit (only available in SPDT option)
HNR - DIN 43650A 1/2” Female Conduit (only available in SPDT option)
FLDP - Flying Lead Deutsch connector, plug, 10” long leads (male)
FLDR - Flying Lead Deutsch connector, receptacle, 10” long leads (female)
FLCM - Flying Lead Metripack, male, 150 Series
FLCF - Flying Lead Metripack, female, 150 Series
FLPM - Flying Lead Metripack, male, 280 Series
FLPF - Flying Lead Metripack, female, 280 Series
SP - 1/4” Spade
TS - Terminal Screw
5 - Options:
2 - EPDM Diaphragm
4 - HNBR Diaphragm
7 - Gold Contact
35 - Bonded Seal
MISC
45 - O-ring seal for M10 and M12 thread

SR - Snubber
SL - Split Flex Loom
HS - Heat Shrink
OPTIONS - AVAILABILITY
● - Standard
Thread Options
ο - May require minimum quantity
2G 4G 4GF 4GB 2M 4M 4MF 4MB 6M 8M 4S 4SLN 6S 8S M10 M12 8J
Oring Male,
Male, Brass
Male, Brass
Oring Male
Oring Male
Oring Male
3/4-16 JIC
Adjustable
M10 x 1.0
M12 x 1.5
1/8 BSPP
7/16 SAE
7/16 SAE
9/16 SAE
1/4 BSPP
1/4 BSPP
1/4 BSPP
37° Flare
1/4 NPT
1/4 NPT
3/4 SAE
1/8 NPT
1/4 NPT
3/8 NPT
1/2 NPT
MODEL
Female
Female
Male
Male
Male
Male
Male
Male
Male
Male
Male
OPTIONS
SPA ● ● ● ● ● ● ● ●
SWA ● ● ● ● ο ο ο ο
SPAL ● ● ● ●
SLF ● ● ● ● ● ●
SMA ο ● ● ● ● ● ● ● ● ο
SPAH ● ● ● ●
SDCA ● ● ● ● ● ο
SKBA ● ● ● ● ● ● ● ● ο
SKDA ● ● ● ● ● ● ● ● ο
DSPA ● ● ● ●
SVA ● ● ● ● ● ● ● ●
SPVL ● ● ● ●
S1TAF ο ● ● ● ο
S2TAF ο ● ● ● ο ● ●
TG ● ● ●
TC ● ● ●
Miscellaneous Options
1 2 3 4 7 8 9 20 30 35* 45 SL HS
Heat Shrink
Microswitch
Deadband
M10, M12
Split Flex
Seal Adj.
Stainless
MODEL
Contact
threads
Bonded
Rubber
VITON
O-ring
Screw
HNBR
EPDM
Loom
Steel
Wide
Boot
Gold
Seal
Seal
Seal
10A
OPTIONS
SPA ● ● ● ● ● ● ● ● ● ● ● ●
SWA ● ● ο ● ● ● ● ● ● ● ● ●
SPAL ο ● ● ● ● ● ● ●
SLF ● ● ● ●
SMA ● ● ● ● ● ● ● ● ● ● ● ●
SPAH
SDCA ● ● ο ● ● ● ● ● ● ●
SKBA ● ● ο ● ● ● ● ● ● ● ●
SKDA ● ● ο ● ● ● ● ● ●
DSPA ● ● ο ● ● ● ● ● ● ●
SVA ● ● ● ● ● ● ● ● ● ● ● ●
SPVL ● ●
S1TAF ● ●
S2TAF ● ●
TG ● ●
MISC
TC ● ●
* Only available for threads: M10, M12, 1/8 BSPP, 1/4 BSPP
MATERIAL COMPATIBILITY
Media Nitrile EPDM Viton Media Nitrile EPDM Viton

Acetic Acid X Hydraulic Oil (PET Base) X
Acetone X Hydrocarbons X
Acetylene X Hydrogen X
Air X Hydrogen Sulphide X
Alcohols X Isopropanol X
Alkalies (weak) X JP-3-6 X
Alkalies (strong) X Kerosene X
Ammonia (Anhydrous) X LPG X
Ammonia (Hydroxide) X Lube Oil (PET Base) X
Asphalt X Methanol X
Automotive Oils X MEK X
Beer X Mineral Oil X
Benzene X Motor Oils X
Boric Acid X Naptha X
Brake Fluid X Natural Gas X
Bunker Oil X Nitric Acid X
Butane X Nitrogen X
Butyl Cellosolve X Oleum Spirits X
Carbon Dioxide X Oxygen X
Carbon Monoxide X Ozone X
Cellube X Cruide Oil X
Chlorobenzene X Phosphoric Acid X
Citric Acid X Propane X
Coke Oven Gas X Propanol X
Coolanol X Pydral (135, 150, A200)
Diesel Fuels X Shell Iris 902 X
Di-Ester Lube (MIL-L-7808) X Silicone Greases X
Dowtherm A&E X Silicone Oils X
Ethanol X Skydrol 500 & 7000 X
Ether X Soap Solutions X
Ethylene X Steam below 320°F X
Ethylene Glycol X Stoddard Solvent X
Freon 11, 12, 112, 114 X Sulfuric Acid X
Freon 22 X Toluene X
Fyrquel X Transmission Fluid A X
Fuel Oil X Trisodium Phosphate X X
Gasoline X Turpentine X
Glycerin X Water to 220°F (104°C) X
Helium X Water to 302°F (150°C) X
Hexane X
MISC
ELECTRICAL CONFIGURATION
FLDR - Deutsch DT04-2P FLDP - Deutsch DT06-2S FLDR - Deutsch DT04-3P FLDP - Deutsch DT06-3S
(Receptacle, 2 Tower) (Plug, 2 Tower) (Receptacle, 3 Tower) (Plug, 3 Tower)
Only available for SPST Only available for SPST Only available for SPDT Only available for SPDT
FLWF - Weather Pack FLWM - Weather Pack FLWF - Weather Pack FLWM - Weather Pack
(Female, 2 Tower) (Male, 2 Tower) (Female, 3 Tower) (Male, 3 Tower)
Only available for SPST Only available for SPST Only available for SPDT Only available for SPDT
HC HN FL SP
DIN 43650 Form A DIN 43650A 1/2” Conduit Flying Leads 1/4” Spade Terminals
Only available for SPDT Only available for SPDT
Note: Other electrical options are available.

Please refer to page 42 or consult factory.
MISC
GLOSSARY
Terminology
Accuracy is the maximum allowable set point deviation of a
Accuracy (Repeatability) single pressure or temperature switch under one given set
of environmental and operational conditions.
The actuation point (sometimes called set point) is the
exact point at which the electrical circuit controlled by
Actuation Point and the switching element is opened (or closed) on increasing
Deactuation Point pressure or temperature. The deactuation point is the
opposite of the point at which the electrical circuit is closed
(or opened) on decreasing pressure or temperature.
It is the range within which a switch can be set from lowest
Adjustable Range
to highest set point.
A temperature sensing device that contains a bimetallic
Bimetal Temperature Switch strip. It has a specified temperature set point for which the
switch will open or close the circuitry.
A pressure switch that is not operated by a microswitch,
Blade Contact but rather the circuitry is opened or closed through a piece
of metal that bridges the two terminals.
Sometimes referred to as “hysteresis”, is the change in
Dead Band Differential pressure between the actuation and deactuation set
points.
The membrane of flexible material (Buna, EPDM, Viton®),
Diaphragm
which is deflected by input pressure.
A sensor which has been designed to permit adjustment or
Field Adjustable
calibration of set points in field applications.
In engineering terms, a liquid or gas which tends to conform
Fluid to the shape of its container, and which alters its shape in
response to applied force.
A form of differential pressure measurement which uses
Gauge Pressure
atmospheric pressure (14.7psia) as the zero reference.
Gold switching elements provide high corrosion resistance
Gold Contacts
and high reliability when switching low voltage circuits.
In a circuit, the opposition to flow of alternating current,
Impedance consisting of ohmic resistance, inductive reactance, and
capacitive reactance.
Load from electrical devices which are made of wound or
coiled wire. Current passing through the windings creates a
Inductive Load magnetic field which produces mechanical work. When an
inductive circuit is switched open, energy stored in the coil
can reverse flow, sparking at the switch contact surfaces.
Rated pressure above the normal system pressure,
Maximum System Pressure
including surges or spikes.
MISC
MODEL
GLOSSARY
SERIES
Terminology
Is one in which the terminals are wired so that current
Normally Closed Switching
can flow through the switching element until pressure is
Element
applied to open the electrical circuit.
Is one in which the terminals are wired so that no current
Normally Open Switching
can flow through the switching element until the pressure
Element
is applied to close the electrical circuit.
Minimum and maximum pressure for which a sensor has
Pressure Range
been calibrated or specified.
Proof Pressure (normally 1-1/2 times system pressure) is
Pressure, Proof the maximum static pressure which can be applied to any
switch without causing permanent degradation.
That portion of the pressure switch that is in contact with
and moves as a result of a change in pressure of the fluid.
Pressure Sensing Element
The most common type of pressure sensing elements are
diaphragms, bellows, bourdon tubes, and pistons.
An instrument that upon the increase or decrease of a
pressure or vacuum, opens or closes one or more electrical
Pressure Switch
switching elements at a predetermined actuation point
(setting).
Is an electrical switch operated by an applied magnetic
Reed Switch field. It consists of a pair of contacts, either normally open
or normally closed, in a hermetically sealed glass tube.
Load from devices which use electrical resistance to
Resistive Load produce heat or light. Restive loads cause current to flow
in only one direction through a circuit.
The point at which motion of the pressure or vacuum
Set Point or temperature sensing element causes the switch to
function.
A SPDT switching element has one normally open, one
Single Pole Double Throw normally closed and one common terminal. Three terminals
(SPDT) mean that the switch can be wired with the circuit either
normally open (N/O) or normally closed (N/C) or both.
A mechanically operated electric switch which, once its
actuator has reached its operating (or release) point,
Snap-Action Switch
immediately transfers to its opposite position without
further travel of the actuator.
MISC
Switching Solutions Inc.
380 Four Valley Drive,
Concord, Ontario, Canada, L4K 5Z1
Toll Free: 1-877-774-8808
Phone: (905)303-8700
Fax: (905)303-7130
Released: May 2012

switchingssi
www.switchingssi.com
Controller Danfoss
MC-050-10
MAKING MODERN LIVING POSSIBLE
Data Sheet
PLUS+1® Controllers
MC050-010 and MC050-012
Mobile Machine Management

The MC050-010 and MC050-012 controllers are
elements of the flexible, powerful, expandable, and
affordable PLUS+1 family of mobile machine
management products. These devices are
general-purpose controllers that are equally suited
for use as members of a distributed machine
control system, with intelligence in every node, or
as stand-alone controllers.
Product Highlights
The MC050-010 employs a Digital Signal Processor
(DSP), providing the controller with extremely fast
single cycle processing speed and 256K internal
flash. The MC050-012 has an application key that
enables the use of Danfoss developed GUIDE
machine control solutions. The same GUIDE HWD
file is used with both controllers.
Application Development
Users develop MC050-010 and MC050-012
applications with PLUS+1 GUIDE. This Microsoft®
Windows® based development environment
features a user-friendly, field proven, icon-based
graphical programming tool, application
downloader, and service/diagnostic tool.
Features yy User-programmable with PLUS+1 GUIDE (Graphical yy 16 outputs

User Integrated Development Environment) –– (10) universal (PWMOUT/DOUT/PVGOUT) that
yy 50 pins: (1) Deutsch® DRC connector are user-defined as either:
yy 32 bit fixed-point DSP running at 150 MHz Digital: (3 A), configurable as source or sink;
yy 12 bit analog-to-digital converter PWM: (30 to 4000 Hz), configurable as open or
yy 22 inputs closed loop with current control;
–– (6) universal (DIN/AIN/FreqIN) that are Analog voltage: open loop PWM at 4000 Hz
user-defined as either: –– Any PWMOUT/DOUT/PVGOUT can be used to
Analog: with configurable ranges provide reference power to one PVG valve
0 to 5.25 Vdc (with over range protection) or –– (3) digital (DOUT) (3 A), configurable as source
0 to 36 Vdc; only
Digital: pull up (5 Vdc), pull down (0 Vdc) or –– (3) digital/PVG power supply (DOUT/PVG Pwr)
pull to center (2.5 Vdc); –– (3 A), user-configurable; one DOUT/PVG Pwr will
Frequency (timing): 1 Hz to 10 kHz power up to three PVGs
–– (6) digital (DIN) configurable as pull up yy 9 to 36 Vdc power supply, monitored internally
(5 Vdc), pull down (0 Vdc) yy 2 CAN 2.0 B ports, the fixed range analog input can
–– (4) digital/analog (DIN/AIN) that are user- be configured as the shield pin
defined as either: yy Power supply for external sensors rated at 5 Vdc to
Digital: pull up (5 Vdc), pull down (0 Vdc) or pull 450 mA, monitored and regulated internally
to center (2.5 Vdc); yy 2 LEDs under user control
Analog: 0 to 5.25 Vdc or 0 to 36 Vdc yy 3 mounting alternatives: stack, end, or side
–– (4) analog (AIN/Temp/Rheo) 0 to 5.25 Vdc or yy MC050-012 contains application key required to run
0 to 10,000 ohm rheostat Danfoss developed machine control application
–– (2) fixed range analog (AIN/CAN shield) 0 to software
5.25 Vdc or CAN shield pin yy CE compliant
520L0714 • Rev OB • Apr2014

Data Sheet PLUS+1® Controllers MC050-010 and MC050-012
Dimensions and Pin Assignments MC050-010 and MC050-012 50 Pin Connector

MC050-010 and MCO50-012 Mounting Dimensions
1 2 3 4 5 6 7 8 9 10
in Millimeters [Inches] 11 12 13 14 15 16 17 18 19 20
114.4 [4.50] 21 22 23 24 25 26 27 28 29 30
31 32 33 34 35 36 37 38 39 40
41 42 43 44 45 46 47 48 49 50
2198B
Connector
35.7 [1.41] Pin Controller function Pin Controller function
C1-P1 Power ground - C1-P26* DIN/AIN/FreqIN
C1-P2 Power supply + C1-P27 AIN/Temp/Rheo
159.7 [6.29] C1-P3 CAN0 + C1-P28 AIN/Temp/Rheo
144.5 [5.69] C1-P4 CAN0 - C1-P29 AIN/Temp/Rheo
C1-P5 AIN/CAN0 shield C1-P30 AIN/Temp/Rheo
32.4 [1.27] C1-P6 DIN C1-P31 DOUT
C1-P7 DIN C1-P32 DOUT
C1-P8 5 Vdc sensor power + C1-P33 DOUT
147.5 [5.81] 139.11 [5.50] C1-P9 Sensor power ground - C1-P34 DOUT/PVG Pwr
193.8 [7.63]
C1-P10 DIN C1-P35 DOUT/PVG Pwr
C1-P11 DIN C1-P36 DOUT/PVG Pwr
C1-P12 DIN C1-P37 PWMOUT/DOUT/PVGOUT
C1-P13 DIN C1-P38 PWMOUT/DOUT/PVGOUT
C1-P14 DIN/AIN C1-P39 PWMOUT/DOUT/PVGOUT
C1-P18 DIN/AIN/FreqIN C1-P43 PWMOUT/DOUT/PVGOUT
51.6 [2.03] C1-P19 DIN/AIN/FreqIN C1-P44 PWMOUT/DOUT/PVGOUT
47.1 [1.85]
C1-P20 CAN1 + C1-P45 PWMOUT/DOUT/PVGOUT
C1-P21 CAN1 - C1-P46 PWMOUT/DOUT/PVGOUT
2197A
C1-P22 AIN/CAN1 shield C1-P47 Power supply +
CCaution
PCB damage may occur. All device power supply + pins must be C1-P23 DIN/AIN/FreqIN C1-P48 Power supply +
connected to battery +. C1-P24 DIN/AIN/FreqIN C1-P49 Power supply +
C1-P25 DIN/AIN/FreqIN C1-P50 Power supply +
CCaution * Recommendation is to not use pin C1p26 as a frequency input. If used,
This device is not field serviceable. Opening the device housing recommendation is to disable internal filtering and use filter inside the application
will void the warranty. instead.
Use care when wiring mating connector. Above pinouts are for
Specifications device pins.
Product Parameters
Supply voltage 9 to 36 Vdc Product Part Number
Operating temperature (ambient) -40°C to 70°C [-40°F to 158°F] MC050-010 10100900
Storage temperature -40°C to 85°C [-40°F to 185°F] MC050-012 11013734
Programming temperature 0°C to 70°C [32°F to 158°F]
Related Products Part Numbers
IP rating IP 67
(with mating connector attached) CG150 CAN/USB Gateway 10104136
EMI/RFI rating 100 V/M Deutsch® mating connector 10102024 10100946
bag assembly (16 to 20 AWG) (20 to 24 AWG)
Weight 0.53 kg [1.16 lb]
PLUS+1 GUIDE 10101000
Vibration IEC 60068-2-64 single user license
Shock IEC 60068-2-27 test Ea
Maximum current, sourcing 40 A Danfoss comprehensive technical information on line at:
Maximum current, sinking 8A www.danfoss.com
Danfoss
Power Solutions Trading
Danfoss Danfoss Danfoss (Shanghai) Co. Ltd.
Power Solutions (US) Company Power Solutions GmbH & Co. OHG Power Solutions ApS Building #22, No. 1000 Jin Hai Rd
2800 East 13th Street Krokamp 35 Nordborgvej 81 Jin Qiao, Pudong New District
Ames, IA 50010, USA D-24539 Neumünster, Germany DK-6430 Nordborg, Denmark Shanghai, China 201206
Phone: +1 515 239 6000 Phone: +49 4321 871 0 Phone: +45 7488 2222 Phone: +86 21 3418 5200
Danfoss can accept no responsibility for possible errors in catalogues, brochures and other printed material. Danfoss reserves the right to alter its products without notice. This also applies to products
already on order provided that such alterations can be made without changes being necessary in specifications already agreed.
All trademarks in this material are property of the respective companies. Danfoss and the Danfoss logotype are trademarks of Danfoss A/S. All rights reserved.
520L0714 • Rev OB • Apr2014 www.danfoss.com © Danfoss A/S, 2014-04

Joystick
JS6000-XY-CAN-HSPN1N-J331-A200N-NRNNNNN
JS6000
Joystick Base
Technical
Information
JS6000 Joystick Base
Revisions
Revision History Table of Revisions

Date Page Changed Rev.
7 June, 2010 9, 29, 30 Single or Dual Axis Options images; Dimensions and Installation KA
— revised dimensions to include18 pin connector, added
recommended mounting panel cut-out illustration, and updated
installation instructions.
26 Feb, 2010 9, 27, 38 Axis base image, A Grip Front Plate Diagram illustration, JA
Environmental Characteristics
16 Sep, 2009 Various Content update IA
04 Jan, 2008 26 A grip front plate diagram updated HA
14 Nov, 2007 3, 6, 7, 13, 17 Grip options model code details; GA
mechanical options: friction hold torque
28 Jun, 2007 15, 32, 36 Corrected temperature and length conversion FA
27 Jun, 2007 Various Text changes and addition of CAN+ EA
24 Apr, 2007 Various Text changes D
22 Feb, 2006 Various Text changes C
28 Nov, 2005 Various Feature updates B
26 May, 2005 33 Hall sensor pinouts A
17 Dec, 2004 Initial release
© 2010 Sauer-Danfoss. All rights reserved.
Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.
Sauer -Danfoss reserves the right to alter its products without prior notice. This also applies to products already
ordered provided that such alterations can be made without affecting agreed specifications. All trademarks
in this material are properties of their respective owners. Sauer-Danfoss, the Sauer-Danfoss logotype, the
Sauer-Danfoss S-icon, PLUS+1™, What really matters is inside® and Know-How in Motion™ are trademarks of the
Sauer-Danfoss Group.
2 520L0760 • Rev KA • June 2010

Contents
General Information Product Overview........................................................................................................................................... 5

Features and Options..................................................................................................................................... 5
Product Configuration Product Configuration Model Code......................................................................................................... 6

Base Model Code............................................................................................................................................. 7
Grip Model Code............................................................................................................................................. 8
Model Code Details Code B: Single or Dual Axis Options........................................................................................................ 9

Code C: Shaft Sensor/Output Options..................................................................................................10
Potentiometer Sensor............................................................................................................................10
Dual Potentiometer Outputs Per Axis..............................................................................................11
Hall Effect Sensor.....................................................................................................................................12
Controller Area Network (CAN) Output...........................................................................................12
Pulse Width Modulated (PWM) Output...........................................................................................12
Code D: Centering Return Spring Options..........................................................................................13
Code E: Hardware Configuration............................................................................................................13
Code F: Mechanical Options.....................................................................................................................14
Code G: Microswitch Option....................................................................................................................16
Code H: Electrical Interface Options......................................................................................................17
Analog..........................................................................................................................................................17
CAN 2.0B, J1939 Protocol......................................................................................................................17
CANopen 2.0B, J1939 Protocol...........................................................................................................17
PWM ............................................................................................................................................................17
Code I, J, K,L Grip Options..........................................................................................................................18
JS6000 CAN Messages CAN Option.....................................................................................................................................................19

CAN+ Option..................................................................................................................................................19
CAN+ External Inputs..................................................................................................................................19
Analog Inputs (AIN).................................................................................................................................19
Digital Inputs (DIN)..................................................................................................................................19
CAN Message Protocol SAE J1939 CAN Message Specification..................................................................................................21

SAE J1939 Basic Joystick Message.....................................................................................................21
Data Field....................................................................................................................................................21
Basic Joystick Message Data Field Descriptions...........................................................................22
SAE J1939 Extended Joystick Message............................................................................................25
SAE J1939 Error (DM1) Messages.......................................................................................................26
SAE CANopen Protocol Information.......................................................................................................26
A Grip Button and Rocker CAN Naming Conventions.....................................................................27
Top and Operator Present Switch Naming Conventions...........................................................27
Proportional Rocker Naming Conventions.....................................................................................27
MG Grip Button CAN Naming Conventions.........................................................................................28
520L0760 • Rev KA • June 2010 3

Contents
Product Installation Dimensions and Installation......................................................................................................................29

Dimensions................................................................................................................................................29
Recommended Mounting Panel Cut-out........................................................................................29
Installation..................................................................................................................................................30
Recommended Wiring Practice................................................................................................................30
Joystick Safety................................................................................................................................................31
JS6000 Connector Pin Assignments General Information.............................................................32
Pin Assignments............................................................................................................................................32
CAN Output Connector Pin Assignments.......................................................................................32
CAN Output Mating Connector Deutsch® DTM06-6S................................................................32
CAN+ and PWM Output Connector Pin Assignments................................................................33
CAN+ and PWM Output Mating Connector Deutsch® DT16-18SB........................................33
Potentiometer Sensor with Analog Output Connector Pin Assignments...........................34
Analog Output Mating Connector ...................................................................................................34
Hall Effect Sensor with Analog Output Pin Assignments . .......................................................35
Specifications Mechanical Characteristics........................................................................................................................36

Electrical Characteristics.............................................................................................................................36
Microswitch Characteristics.......................................................................................................................37
Sensor Power Supply Ratings...................................................................................................................38
Environmental Characteristics..................................................................................................................38
4 520L0760 • Rev KA • June 2010

General Information
Product Overview The JS6000 Joystick Base has been specially developed to meet the harsh operating
requirements of today’s mobile machines. The JS6000 features metal construction with
a large diameter stainless steel operating shaft, an innovative ball and socket gimbal
design manufactured from pressure die cast zinc alloys, a custom high strength material
for the center return cone, and optional contactless Hall effect sensing technology.
The CAN+ version of the JS6000 base allows the value and state of up to eleven digital
or seven digital and four analog inputs from external-to-the-joystick sources to be
broadcast along with joystick Controller Area network (CAN) messages.
The Pulse Width Modulation (PWM) version of the JS6000 base can be used to directly
drive a valve, such as the H1 hydrostatic transmission, without an intermediate
microcontroller. This version allows joystick operating parameters (e.g. ramp rates,
button function assignments, output characteristics) to be configured using the
PLUS+1 GUIDE Service Tool interface. Refer to JS6000 PWM User Manual, 11060942 for
instructions and information required to configure JS6000 PWM joystick options.
The flexible design of the JS6000 offers many options, making it the right choice for
applications that require more than a simple dual axis joystick with spring return to
center. This technical manual describes the many different features that can be selected
to configure the right product for a specific application.
F101 445
Features and Options • Hall effect or potentiometer sensing (model dependent)

• One or two sensors per axis for redundancy
• Single or dual axis
• Mechanical direction switches
• 2 centering spring forces
• 3 available friction-hold options
• Output options:
–– Analog
–– CAN 2.0B, J1939 protocol
–– CANopen protocol
–– High current PWM
• Multiple grip options:
–– HKN — plain knob
–– MG — with operator trigger and hand rest
–– A— configurable ergonomic
–– Custom designed grips
• External-to-joystick analog and digital information included in JS6000 CAN+messages
520L0760 • Rev KA • June 2010 5
Product Configuration
Product Configuration Use the JS6000 product configuration model code to specify particular features when
Model Code ordering a JS6000 joystick. The model code begins with the product family name:
JS6000. Fill in the remaining fields to configure the product with the desired features.
The model code includes both joystick base and joystick grip information. This technical
manual provides information required to configure the base portion of the joystick. The
Sauer-Danfoss manual JS1000, JS6000 Joystick Grips Technical Information 520L0872
provides information required to configure JS6000 joystick grips.
Product Configuration Model Code Example

J S 6 0 0 0 X Y H M M H S N L N J 3 3 1 A 0 H 0 R V N N N N N N N N
6 520L0760 • Rev KA • June 2010

Base Model Code JS6000 Product Configuration Model Code Example

A B C D E F G H I J K L M N O P Q R S
Base Grip
A Product Series
Code Description
JS6000 Series JS6000 Joystick
B Operational Axis Options

Code Description
XY Bi-directional: X and Y axis
NY Uni-directional: Y axis only (required for friction-holding)
C Shaft Position Sensing and Output Options

Code Description
PRR Potentiometer: single output per axis; Vo = 10 to 90% of Vs; ±1.5° neutral threshold
PQQ Potentiometer: single output per axis; Vo = 25 to 75% of Vs; ±1.5° neutral threshold
PSS Potentiometer: single output per axis; Vo = 10 to 90% of Vs; ±5° neutral threshold
PTT Potentiometer: single output per axis; Vo = 25 to 75% of Vs; ±5° neutral threshold
PUU Potentiometer: dual output per axis; Vo = 10 to 90% of Vs; ±1.5° neutral threshold
HMM Hall effect: dual sensors per axis; Vs = 5 VDC; Vo = 0.5 to 4.5 VDC
CAN* Hall effect: dual sensors per axis; Vs = 9 to 36 VDC; CAN 2.0B J1939 communication, 6 pin connector
CANopen* Hall effect: dual sensors per axis; Vs = 9 to 36 VDC; CANopen 2.0B J1939 communication, 6 pin connector
CPL Hall effect: dual sensors per axis; Vs = 9 to 36 VDC; CAN 2.0B communication, 18 pin connector
PWM Hall effect: dual sensors per axis; Vs = 9 to 36 VDC; high current PWM and digital outputs
* See H1 Electrical Interface Options, page 17.
D Centering Spring Options

Code Description
H Heavy force
M Medium force
F Friction-hold (position maintained, center detent)
E Gate Pattern Options

Code Description
S Square, full output at 45 degree
F Mechanical Options
Code Description
NL No mechanical option; spring return to center only
FB Friction-held in Y axis; no X axis; center detent; 1.25 N•m [0.92 lb•ft] friction-hold force;
2.5 N•m [1.66 lb•ft] breakout force
FC Friction-held in Y axis; no X axis; center detent; 1.25 N•m [0.92 lb•ft] friction-hold force;
HC Friction-held in Y axis; no X axis; center detent; 2.25 N•m [1.66 lb•ft] friction-hold force;
G Direction (Microswitch) Options

Code Description
N No switches
Y Microswitches installed
520L0760 • Rev KA • June 2010 7

Grip Model Code JS6000 Product Configuration Model Code Example
A B C D E F G H I J K L M N O P Q R S
1 2 3 4
H1 Electrical Interface Options

Code Description
S Analog (DC voltage output)
J CAN, SAE J1939 protocol
W PWM output
P CANopen protocol (default: 125 Kbit band rate)
H2, 3 CAN Source Address*

Code Description
NN None—use with analog outputs when H1 = S
33 Source address = 0x 33 (use this source address with PWM outputs.)
34 Source address = 0x 34
H4 Joystick Output Type

Code Description
N None—use with analog and PWM outputs
1 CAN full scale output = 1000 counts
I, J, K, L, M, N, O, P, Q, R, S Grip Options
The Sauer-Danfoss manual JS1000, JS6000 Joystick Grips Technical Information 520L0872
provides information required to configure the JS6000 joystick grip.
* Consult the factory if additional source addresses are required.
8 520L0760 • Rev KA • June 2010

Model Code Details
Code B: Single or Dual JS6000 Product Configuration Model Code - B

Axis Options
B
J S 6 0 0 0
Code B designates the number of operational axes.
Single Axis Base Dual Axis Base

NY with friction hold option in the configuration code. XY in the configuration code.
+X Axis
-Y Axis -Y Axis
+Y Axis +Y Axis
-X Axis
Orientation Mark
(lift boot)
2456B
X and Y Operation (or movement).
20° ± 0° 20° ± 0°
20° ± 0° 20° ± 0° 20° ± 0° 20° ± 0°
20° ± 0° 20° ± 0°
P200 001
520L0760 • Rev KA • June 2010 9

Model Code Details
Code C: Shaft Sensor/ JS6000 Product Configuration Model Code C

Output Options C
J S 6 0 0 0 X Y P R R
Code C designates the shaft sensing technology; potentiometer or Hall effect; and the electrical output characteristics of the joystick base.
C Shaft Position Sensing and Output Options

Code Description
PRR Potentiometer: single output per axis; Vo = 10 to 90% of Vs; ±1.5° neutral threshold
PQQ Potentiometer: single output per axis; Vo = 25 to 75% of Vs; ±1.5° neutral threshold
PSS Potentiometer: single output per axis; Vo = 10 to 90% of Vs; ±5° neutral threshold
PTT Potentiometer: single output per axis; Vo = 25 to 75% of Vs; ±5° neutral threshold
PUU Potentiometer: dual output per axis; Vo = 10 to 90% of Vs; ±1.5° neutral threshold
HMM Hall effect: dual sensors per axis; Vs = 5 VDC; Vo = 0.5 to 4.5 VDC
CAN* Hall effect: dual sensors per axis; Vs = 9 to 36 VDC; CAN 2.0B J1939 communication, 6 pin connector
CANopen* Hall effect: dual sensors per axis; Vs = 9 to 36 VDC; CANopen 2.0B J1939 communication, 6 pin connector
CPL Hall effect: dual sensors per axis; Vs = 9 to 36 VDC; CAN 2.0B communication, 18 pin connector
PWM Hall effect: dual sensors per axis; Vs = 9 to 36 VDC; high current PWM and digital outputs
* See H1 Electrical Interface Options, page 17.
Potentiometer Sensor
The potentiometer sensor electrical connections are made via a 16 pin AMP® 040 series
MULTILOCK connector mounted on the base of the unit.
Potentiometer outputs are ratiometric. The output value is dependent on the supply
voltage. When the joystick handle returns to center, the output will be between 48% and
52% of supply voltage (Vs).
Potentiometer Sensor Specifications

Minimum load impedance 1 MΩ recommended
Maximum wiper current 5 mA
Supply voltage < 36 Vdc
Center tap/switch alignment Within 0.5º
Potentiometer electrical angle ± 18º
Center tap angle ± 2.5º
Insulation resistance at 50 Vdc >50 MΩ
Center Tap
A center tap is standard on all potentiometer tracks, where 50% of the supply voltage
can be supplied to force the sensor voltage to this known reference. When the center tap
is not connected there will be a center dead band (where the voltage output does not
change on initial deflection) and the output voltage will be between 48 and 52% of the
supply voltage.
Directional Potentiometer Switches

Potentiometer tracks have directional and normally closed (center on) position switches
that operate at the angles shown in the table below. Switch outputs are independent
of the proportional potentiometer elements on each axis and can be terminated by the
customer to provide directional or center on/off data to the control system.
Directional Potentiometer Switches Specifications

Maximum load current 200 mA resistive
Maximum supply voltage < 36 Vdc
10 520L0760 • Rev KA • June 2010

Model Code Details
Code C: Shaft Sensor/ Directional Potentiometer Switch Circuit Diagram

Output Options Handle Direction Switch Handle Direction Switch
(continued)
Pot Pot
Back Forward Left Right
Center Tap Center Tap
16 Pin Connector 16 Pin Connector
13 14 9 12 11 10 16 1 7 8 3 6 5 4 2 15
Y-axis Pin Numbering X-axis Pin Numbering

– Wiper Symbol
Potentiometer Track 0utputs

Minimum output Maximum output
Switch track angle Resistance kΩ Order code
Voltage (% Vs) Voltage (% Vs)
10 ± 2 90 ± 2 ±1.5º 1.6 to 2.4 R
25 ± 2 75 ± 2 ±1.5º 2.2 to 3.6 Q
10 ± 2 90 ± 2 ±5º 1.6 to 2.4 S
25 ± 2 75 ± 2 ±5º 2.2 to 3.6 T
Warning
Potential uncommanded machine movement. When a JS6000 joystick with the 25% to
75% potentiometer output option (designated Q or T) is used to directly drive a PVG
valve, if the power or ground side of the joystick is lost, there is a risk of the valve going
full on in one direction or the other. To avoid the possibility of unintended machine
motion, the PVG valve must have Active Fault Monitoring.
Dual Potentiometer Outputs Per Axis

Dual potentiometer outputs are available that feature independent power inputs and
sensor outputs. The secondary potentiometer output connections are via an 8 pin AMP®
connector. Secondary potentiometer outputs do not provide secondary directional and
center switches.
Hall sensing and dual potentiometer outputs are not available together.
Dual Potentiometer Track Selection

Minimum output Maximum output
Switch track angle Resistance kΩ Order code
Voltage (% Vs) Voltage (% Vs)
10 ± 2 90 ± 2 ±1.5º 1.6 to 2.4 U
520L0760 • Rev KA • June 2010 11

Model Code Details
Code C: Shaft Sensor/ Hall Effect Sensor

Output Options The Hall effect sensor option includes dual sensors per axis. The sensors can be supplied
(continued) from two separate regulated 5 V supplies for a higher degree of redundancy, or can be
supplied from a single regulated 5 V supply.
Hall effect sensing electrical connections are made via a 12 pin AMP® 040 series
MULTILOCK connector on the base of the unit.
JS6000 Hall effect sensors are affected by temperature. Output values change
temporarily by 2.6% and permanently by 0.6% when subjected to a -40°C (-40°F) to 80°C
(176°F) operating temperature range cycle.
Hall Effect Sensor Specifications

Supply voltage (Vs) 5 Vdc regulated
Minimum output voltage 10% ± 4% Vs
Center voltage 50% ± 2% Vs
Maximum output voltage 90% ± 4% Vs
Controller Area Network (CAN) Output

Three versions of JS6000 CAN joysticks are available:
CAN (Configuration Model Code CAN)

CAN 2.0bB J1939 protocol and CANopen 2.0B J1939 protocol (reference product
configuration model code, under H1 designator, see page 17).
CAN+ (Configuration Model Code CPL)

Broadcasts joystick shaft position, grip switch states, grip proportional rocker position
and the state and value of up to 11 digital (DIN) or 7 digital (DIN) and 4 analog (AIN)
inputs from sources external to the joystick. The CAN+ option joystick base has an 18 pin
Deutsch connector.
Pulse Width Modulated (PWM) Output

One version of the JS6000 PWM joystick is available.
PWM (Configuration Model Code PWM)

Has two bi-directional PWM channels and six Digital Ouputs. The PWM option joystick
base has an 18 pin Deutsch connector.
12 520L0760 • Rev KA • June 2010

Model Code Details
Code D: Centering JS6000 Product Configuration Model Code D

Return Spring Options
D
J S 6 0 0 0 X Y H M M H
Code D designates centering spring force options.
The center spring returns the joystick to its center position when released by the
operator and provides the physical resistance to movement when the joystick is
operated. Two levels of spring force are available: heavy and medium. Spring force is
selected by choosing a letter from the order character column of the following table.
Warning
Potential uncommanded machine movement. The spring choice affects the joystick’s
ability to resist system vibrations. Each of the following springs give a different product
harmonic range. This, in combination with critical mass differences as a result of
grip choice, results in each system (joystick and machine) having different vibration
characteristics. With this in mind, please consider the vibration range of the system and
determine whether any resonance exists in the joystick. Resonance causes dither and
could cause the joystick to leave neutral.
Centering Spring Selection

Spring option Breakout force on axis Force at full deflection Order code
Heavy duty spring 12 to 19 N [2.7 to 4.3 lbf ] 31 to 47 N [6.7 to 10.6 lbf ] H
Medium duty spring 6 to 8.5 N [1.3 to 1.9 lbf ] 15 to 23 N [3.4 to 5.2 lbf ] M
The above forces are measured 55 mm (2.17 in) from the joystick mounting surface and are perpendicular
to the shaft.
Code E: Hardware JS6000 Product Configuration Model Code E

Configuration
E
J S 6 0 0 0 X Y H M M H S
Code E designates hardware configuration.
JS6000 joysticks have a square gate pattern as the standard configuration. This is
designated as S in the configuration code and includes a standard label.
Gate Selection
Gate option Characteristics Order code
Square ± 20º mechanical travel (on axis) S
The square gate offers full X and Y outputs when the joystick is moved to the corner positions.
520L0760 • Rev KA • June 2010 13

Model Code Details
Code F: Mechanical JS6000 Product Configuration Model Code F

Options
F
J S 6 0 0 0 X Y H M M H S N L
Code F designates joystick mechanical options.
JS6000 joysticks are available with a friction-hold option. With this option, the joystick
handle position will remain in a position set by the operator and will not automatically
return to center. This option is only available in a single (Y) axis configuration. Four levels
of friction/breakout from center force are available.
Friction-hold Selection
Friction-hold torque Center detent breakout torque Order code
No mechanical options NL
1.25 N•m (0.92 lb•ft) 2.50 N•m (1.84 lb•ft) FB
1.25 N•m (0.92 lb•ft) 3.25 N•m (2.40 lb•ft) FC
2.25 N•m (1.66 lb•ft) 4.00 N•m (2.95 lb•ft) HC
JS6000 FB Option
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
Torque (N.m)
0.5
0.0
21 20 19 18 1716 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
-0.5
-1.0
-1.5
-2.0
-2.5
-3.0
-3.5
-4.0
-4.5
-5.0
Angle (°)
2458
14 520L0760 • Rev KA • June 2010

Model Code Details
Code F: Mechanical JS6000 FC Option

Options (continued)
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
Torque (N.m)
0.5
0.0
21 20 19 18 1716 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
-0.5
-1.0
-1.5
-2.0
-2.5
-3.0
-3.5
-4.0
-4.5
-5.0
Angle (°)
2459
JS6000 HC Option
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
Torque (N.m)
0.5
0.0
21 20 19 18 1716 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
-0.5
-1.0
-1.5
-2.0
-2.5
-3.0
-3.5
-4.0
-4.5
-5.0
Angle (°)
2460
520L0760 • Rev KA • June 2010 15

Model Code Details
Code G: Microswitch JS6000 Product Configuration Model Code G

Option
G
J S 6 0 0 0 X Y H M M H S N L N
Code G designates joystick microswitch options.
Optional microswitch outputs can replace the low current directional potentiometer
switches on the potentiometer tracks. Microswitch outputs are on the 16 pin connector
(potentiometer option). There are two switches per axis and the microswitches are
configured as normally open, with the handle centered. The microswitch joystick shaft
direction indication feature is not available with the dual potentiometer sensing option.
Optional microswitches are also available with the Hall effect sensing option.
Microswitch outputs, in this case, are on the 8 pin connector.
Optional microswitches are only available on analog output joysticks with the spring-
return-to-center mechanical operation.
Optional microswitches are not available on BMM, CAN, CPL, or PWM output joysticks.
The Honeywell® microswitch electrical details follow. These details are taken directly
from the switch manufacturer’s specification. Further information is available from
www.honeywell.com.
• Microswitch operates at a mechanical deflection of 2 to 5 degrees in any direction

• Contact ratings are 3 A at 125 Vac, 2 A at 30 Vdc
• Life rating is 100,000 cycles minimum at 1 A 12 Vdc
• Temperature range is -25°C to 85°C [-13°F to 185°F] (when fitted, the joystick
temperature is limited to this range)
With the microswitch option, choose the letter from the order character column of the
following table. The choice is either Y for microswitch N for none.
Microswitch Option
Microswitch option Mechanical function description Order code
Without microswitch No switches N
Microswitch Microswitches installed Y
16 520L0760 • Rev KA • June 2010

Model Code Details
Code H: Electrical JS6000 Product Configuration Model Code H

Interface Options
H
J S 6 0 0 0 X Y H M M H S N L N J 3 3 1
Code H designates joystick output options.
1 2 3 4
JS6000 joystick base signal outputs are available in analog voltage, PWM, or Controller
Area Network (CAN) versions.
Analog
The analog output option gives a direct voltage output from the joystick’s shaft sensors,
position switches and grip functions. No signal conditioning is performed. The PWM
output option provides a conditioned output from the joystick’s shaft sensors, position
switches, and grip functions. Output characteristics are configured using the PLUS+1
GUIDE Service Tool.
CAN 2.0B, J1939 Protocol

The CAN J1939 output option provides conditioned joystick output information in 2.0B,
J1039 message protocol.
CANopen 2.0B, J1939 Protocol

The CANopen output option provides conditioned joystick output information in 2.0B,
CANopen message protocol.
PWM
The PWM output option provides high voltage outputs for directly driving valves. The
CAN port is active on the PWM version, but it is not designed to be used on a CAN bus in
a system with other devices. The CAN bus is only to be used for configuration and data
logging while connected to a PC running the PLUS+1 GUIDE Service Tool.
H1 Electrical Interface Options H4 CAN Proportional Output

S Analog voltage N None (if Analog or PWM)
J CAN 2.0B, J1939 protocol 1 CAN full scale output = 1000 counts
P CAN 2.0B, CANopen protocol
W PWM
H2, 3 Joystick Location/CAN Source Address*

Code Description
NN None—use when H1 = S
* Source addresses are factory set. Additional addresses are available upon request.
520L0760 • Rev KA • June 2010 17

Model Code Details
Code I, J, K,L Grip Options JS6000 Product Configuration Model Code I
I J K L M N O P Q R S
J S 6 0 0 0 X Y H M M H S N L N W 3 3 1 A 0 H 0 R V N N N N N N N N
1 2 3 4
The Sauer-Danfoss manual JS1000, JS6000 Joystick Grips Technical Information 520L0872
provides instructions and information required to specify JS6000 joystick grip options.
18 520L0760 • Rev KA • June 2010

JS6000 CAN Messages
CAN Option Joysticks CAN J1939 protocol option, designated as model code CAN, broadcasts two
J1939 messages to communicate device information: Basic Joystick Message 1 (BJM1)
and Extended Joystick Message 1 (EJM1). The two CAN options available are:
• CAN 2.0B, J1939 Protocol Option

• CAN 2.0B, CANopen Protocol Option
CAN+ Option Joysticks with the CAN+ option, designated as model code CPL, allow eleven external
inputs that are not associated with the joystick shaft position or grip functions to be read
by the joystick’s microcontroller and broadcast by the joystick’s CAN transceiver.
CAN+ joysticks broadcast four CAN messages. Basic Joystick Message 1 and Extended
Joystick Message 1 have the same data content as the CAN option, above. External
digital input (DIN) and analog input (AIN) input information is contained in Basic Joystick
Message 3 and Extended Joystick Message 3. The data field format for Basic Joystick
Message 3 and Extended Joystick Message 3 is the same as that for Basic Joystick
Message 1 and Extended Joystick Message 1.
CAN+ External Inputs Analog Inputs (AIN)

• All external analog inputs must be powered by the JS6000 joystick 5 Vdc regulated
power supply (connector pin 8).
• No calibration, error checking or software filtering is performed on analog data
received from external inputs.
• External analog data is scaled in raw form from 0 to 1000 counts.
• Data associated with CAN+ pins 9, 10,11 and 12 is broadcast in both Basic Joystick
Message 3 and Extended Joystick Message 3. For analog inputs use the appropriate
data bytes in Basic Joystick Message 3 or Extended Joystick Message 3.
Digital Inputs (DIN)

• External inputs are pull-down and must be powered by a voltage source <32 Vdc. Low
state is interpreted as <0.97 Vdc. High state is interpreted as >4.00 Vdc.
• Data associated with CAN+ pins 9, 10, 11, 12 is broadcast in both BJM3 and EJM3. For
digital inputs use the appropriate data bytes in BJM3.
See Sauer-Danfoss publication JS6000 PWM Service Tool User Manual, 11060942 for
technical details on the JS6000 PWM Joystick Base and complete details regarding
the use of the PLUS+1 GUIDE Service Tool interface for troubleshooting and configuring
the device.
Obtain free Service Tool software license and download the P1D file at:
http://www.sauer-danfoss.com/Products/MobileElectronics/PLUS1Guide/
PLUS1GuideDownloads/ PLUS1GUIDEServiceToolSoftwareLicense/index.htm
520L0760 • Rev KA • June 2010 19

JS6000 CAN Messages
CAN+ External Inputs External Input Pin Assignment/J1939 Basic Joystick Message 3 Designation
(continued)
CAN+ connector CAN+ function Corresponding J1939 BJM3
pin number data field designation
7 5 Vdc sensor power (0 = 0 Vdc, 1000 = 5.25 Vdc) X-Axis Position
9 External input pin 9 AIN. Use if pin 9 data is required in Y-Axis Position
analog form (0 = 0 Vdc, 1000 = 5.00 Vdc)
9 External input pin 9 DIN status. Use if pin 9 data is Button 1
required in digital form
13 External input pin 13 status Button 5
6 External input pin 6 status (see Warning statement below) Button 11
Warning
Potential uncommanded machine movement. JS6000 CAN+ Joysticks fitted with an
operator present switch have an internal connection between the operator present
switch and pin 6. The operator present switch status is broadcast in BJM1 and BJM3.
Unintended machine motion may result if an external DIN is applied to pin 6 with a
joystick that has a grip with operator present switch.
External Input Pin Assignment/J1939 Extended Joystick Message 3 Designation

CAN+ connector Corresponding J1939 EJM3
CAN+ function
pin number data field designation
10 External input pin 10 AIN. Use if pin 10 data is required in Grip X-Axis
11 External input pin 11 AIN. Use if pin 11 data is required in Grip Y-Axis
12 External input pin 12 AIN. Use if pin 12 data is required in Grip Theta-Axis
20 520L0760 • Rev KA • June 2010

CAN Message Protocol
SAE J1939 CAN Message SAE J1939 Basic Joystick Message

Specification The JS6000 joystick uses the SAE J1939 basic joystick message to transfer information
about the measured status of the X and Y axes of a joystick, the state of switches on the
joystick grip, and the state of external-to-the-joystick digital inputs.
Basic Joystick Message Structure

Basic
Source
message Priority Base PGN PDU format PDU specific Data field
address
number
Dec hex Dec hex Dec hex Dec hex
1 3 64982 FDD6 253 FD 214 D6 * * 8 bytes
3 3 FDDA FD DA * * 8 bytes
* Depends on position specified in master model code. See H2, 3 Joystick Location/CAN Source Address, page 17.
• Message transmission rate: 20 ms

• CAN bus baud rate: 250kbps
The resulting SAE J1939 basic joystick message PGN on the CAN bus is:
0xCFDD6 __ __ or 0xCFDDA __ __
* *
* = joystick source address (hex)
Data Field
The data field contains the joystick’s output information. SAE J1939 data fields contain 8
bytes of data.
Information in the Data Field

Byte# 0 1 2 and so on
Bit# 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8
520L0760 • Rev KA • June 2010 21

SAE J1939 CAN Message Basic Joystick Message Data Field Descriptions
Specification
(continued) Basic Joystick Message Parameters and Data Field Locations
Start position Length Parameter name
(byte/bit) (bits)
0/1 2 Joystick X-axis neutral position status
0/3 2 Joystick X-axis lever left negative position status
0/5 2 Joystick X-axis lever right positive position status
0/7 through 1/1-8 10 Joystick X-axis position (Byte 0 Bit 7 is LSB. Byte 1 Bit 8 is MSB)
2/1 2 Joystick Y-axis neutral position status
2/3 2 Joystick Y-axis lever back negative position
2/5 2 Joystick Y-axis lever forward positive position
2/7 through 3/1-8 10 Joystick Y-axis position (Byte 2 Bit 7 is LSB. Byte 3 Bit 8 is MSB)
4/5 2 Joystick Y-axis detent position status
4/7 2 Joystick X-axis detent position status
5/1 2 Grip button 4 pressed status
7/5 2 Grip button 10 presses status
Button naming convention: Refer to the illustrated A Grip Button and Rocker CAN Naming
Conventions, page 27, for button and proportional input definitions.
Data Field Examples

Byte 0
Bit 8 7 6 5 4 3 2 1
The 2 LSB* of X-axis X-axis lever right X-axis lever left X-axis neutral
position positive status negative position status position status
*Least Significant Bit
Byte 1
Bit 8 7 6 5 4 3 2 1
MSB* X-axis position
*Most Significant Bit
Byte 2
Bit 8 7 6 5 4 3 2 1
The 2 LSB* of Y-axis X-axis lever forward Y-axis lever back Y-axis neutral
position status positive status negative position status position status
*Least Significant Bit
22 520L0760 • Rev KA • June 2010

SAE J1939 CAN Message Basic Joystick Message Data Field Descriptions (continued)
Specification
(continued) Joystick X-axis Neutral Position Status Information in the Data Field
Reports when the current joystick Bit status Remarks
position is in the neutral position for the 00 Not in neutral position
X-axis of travel. 01 In neutral position
10 Error indicator
11 Not available
Joystick X-axis Handle Left Negative Information in the Data Field

Position Status Bit status Remarks
Reports when the current joystick 00 Not on negative side of neutral
position is on the negative travel side 01 On negative side of neutral
(back, left, counterclockwise, down) 10 Error indicator
relative to the neutral position for the 11 Not available
X-axis.
Joystick X-axis Handle Right Positive Information in the Data Field

Reports when the current joystick 00 Not on positive side of neutral
position is on the positive travel side 01 On positive side of neutral
(forward, right, clockwise, up) relative to 10 Error indicator
the neutral position for the X-axis. 11 Not available
Joystick X-axis Position Status

The position of the joystick in the relative motion of travel from the neutral position. The
position value of 0 is always neutral. The output range of the joystick handle at the end
of travel is factory set according to the option specified in the electrical interface options
section of the master model code.
The master model code specifies that the full-scale output at the end of each linear zone
will be 1000 counts.
Warning
Potential uncommanded machine movement. Per the SAE J1939-71 standard, if
the JS6000 joystick internal diagnostics detect a shaft position measurement error,
the joystick output will be set to a value of 1022 counts regardless of shaft position.
Application software should be written to recognize this error condition to avoid the
possibility of unintended machine motion.
Per the SAE J1939-71 standard, if a specific joystick axis is not available, the basic
joystick message for the unavailable axis will indicate an output value of 1023 counts.
Application software should be written to recognize this condition to avoid the
520L0760 • Rev KA • June 2010 23

SAE J1939 CAN Message Basic Joystick Message Data Field Descriptions (continued)
Specification
(continued) Joystick Y-axis Neutral Position Status Information in the Data Field
Reports when the current joystick Bit status Remarks
position is in the neutral position for the 00 Not in neutral position
Y-axis of travel. 01 In neutral position
10 Error indicator
11 Not available
Joystick Y-axis Handle Back Negative Information in the Data Field

Reports when the current joystick position 00 Not on negative side of neutral
is on the negative travel side (back, left, 01 On negative side of neutral
counterclockwise, down) relative to the 10 Error indicator
neutral position for the Y-axis. 11 Not available
Joystick Y-axis Handle Forward Positive Information in the Data Field

Reports when the current joystick position 00 Not on positive side of neutral
is on the positive travel side (forward, 01 On positive side of neutral
right, clockwise, up) relative to the neutral 10 Error indicator
position for the Y-axis. 11 Not available
Joystick Y-axis Position Status

The position of the joystick in the relative motion of travel from the neutral position. The
position value of 0 is always neutral. The output range of the joystick handle at the end
of travel is factory set according to the option specified in the electrical interface options
section of the master model code.
The master model code specifies that the full-scale output at the end of each linear zone
will be 1000 counts.
Warning
Potential uncommanded machine movement. Per the SAE J1939-71 standard, if
the JS6000 joystick internal diagnostics detect a shaft position measurement error,
the joystick output will be set to a value of 1022 counts regardless of shaft position.
Application software should be written to recognize this error condition to avoid the
Per the SAE J1939-71 standard, if a specific joystick axis is not available, the basic
joystick message for the unavailable axis will indicate an output value of 1023 counts.
Application software should be written to recognize this condition to avoid the
Joystick Button 1-8 Pressed Status
Bit status Remarks
00 Button not pressed
01 Button pressed
10 Error indicator
11 Not available (no button installed)
24 520L0760 • Rev KA • June 2010

SAE J1939 CAN Message SAE J1939 Extended Joystick Message

Specification The JS6000 joystick uses the SAE J1939 extended joystick message to transfer
(continued) information about the measured status of up to 3 additional proportional input
functions on the joystick grip, and external-to-the-joystick analog inputs. The joystick
base X and Y-axis information is available in the basic joystick message. The extended
joystick message structure is as follows:
Extended Joystick Message Structure

Extended
Source
message Priority Base PGN PDU format PDU specific Data field
address
number
Dec hex Dec hex Dec hex Dec hex
1 3 64983 FDD7 253 FD 215 D7 * * 8 bytes
3 FDDB FD DB * * 8 bytes
* Depends on position specified in master model code. See H2,3 Joystick Location/CAN Source Address, page 17.
• Message transmission rate: 20 ms

• CAN bus baud rate: 250kbps
The resulting SAE J1939 basic joystick message PGN on the CAN bus is:
0xCFDD7 __ __ or 0xCFDDB __ __
* *
* = joystick source address (hex)
Extended Joystick Message Parameters and Data Field Locations

Start position Length Parameter name
(byte/bit) (bits)
0/1 2 Grip X-axis neutral position status
0/3 2 Grip X-axis lever left negative position status
0/5 2 Grip X-axis lever right positive position status
0/7 through 1/1-8 10 Grip X-axis position
2/1 2 Grip Y-axis neutral position status
2/3 2 Grip Y-axis lever back negative position
2/5 2 Grip Y-axis lever forward positive position
2/7 through 3/1-8 10 Grip Y-axis position
6/5 2 Grip Y-axis detent position status-not available
6/7 2 Grip X-axis detent position status-not available
Data field descriptions and output ranges for extended joystick messages are similar to
those for base X and Y-axis basic joystick messages.
Grip Proportional Input Naming Convention

Proportional input location Extended joystick message designation
Horizontal orientation, top Y-axis
Horizontal orientation, bottom X-axis
Vertical orientation, left side X-axis
Vertical orientation, right side Y-axis
Refer to the A Grip Button and Rocker CAN Naming Conventions, page 27, for proportional
input naming conventions.
520L0760 • Rev KA • June 2010 25
SAE J1939 CAN Message SAE J1939 Error (DM1) Messages

Specification SAE J1939 DM1 error messages are supported by JS6000 software.
(continued) See the tables below for SPN and FMI information.
Failure: Voltage Too High

Message Axis SPN FMI
BJM1 X 2660 3
BJM1 Y 2661 3
BJM1 Grip X 2662 3
BJM1 Grip Y 2663 3
BJM1 Grip Theta 2664 3
Failure: Voltage Too Low

BJM1 X 2660 4
BJM1 Y 2661 4
BJM1 Grip X 2662 4
BJM1 Grip Y 2663 4
Failure: Input Not Calibrated

BJM1 X 2660 13
BJM1 Y 2661 13
BJM1 Grip X 2662 13
BJM1 Grip Y 2663 13
Failure: Redundant Input Failure

BJM1 X 2660 14
BJM1 Y 2661 14
BJM1 Grip X 2662 14
BJM1 Grip Y 2663 14
Sensor Power Fault (CAN+ Only)

Message Power Fault SPN FMI
Sensor power too high 3509 3
Sensor power too low 3509 4
SAE CANopen Protocol JS6000 joysticks do not support SAE J1939 dynamic addressing, since the joystick
Information source addresses are hard-coded (static). However, JS6000 joysticks are compliant
with SAE J1939 address claiming protocol (in the unlikely event another node on the
SAE J1939 bus claims an identical source address to the JS6000, the JS6000 may cease
communication on the bus, depending on the message priority of the other node).
When you want to use CANopen Joystick, go to http://www.sauer-danfoss.com/

Products/MobileElectronics/Joysticks/index.htm, and click on CANopen EDS to open
CANopen Object Dictionary
26 520L0760 • Rev KA • June 2010

A Grip Button and A Grip Front Plate Diagram

Rocker CAN Naming
Conventions A000 A0B0* A1R0 A200 A2H0
3 2
A00T A1RT A20T A2HD
X Y 3 Y 3 2
A00D A1RD A20D
X
A00B A1RB A20B
A0R0 A0H0 A1L0 A2R0 3 A300 3 2

A0RT Y A0HD A1LT X 1 A2RT Y A30T
A0RD X A1LD A2RD 4 A30D 1
A0RB A1LB A2RB A30B
A0L0 A100 A1H0 A2L0 A400

2 2 3 2
A0LT A10T A1HD A2LT A40T
X X
A0LD A10D A2LD 1 A40D 4
1 1
A0LB A10B X A2LB A40B
A3R0 3 A3L0 2 A500 3 2 A600 3 2

A3RT Y A3LT X A50T 5 A60T 5
5 6 4 1 4 1
A3RD A3LD A50D A60D
4 1 6
A3RB A3LB A50B A60B
* For CAN and CAN+ output models, include grip configurations: A0BD, A0BB, A0BT.
2247B
Top and Operator Present Switch Naming Conventions

Top and operator present switch state information is broadcast on J1939 Basic Joystick
Message 1 (BJM1)
Switch State Information

Top switch BJM1 button 7
Operator present switch BJM1 button 8
Proportional Rocker Naming Conventions

Grip rocker proportional output information is broadcast on J1939 Extended Joystick
Message 1 (EJM1) using the X and Y axis data bits. See the above diagram for
proportional rocker output X and Y naming conventions.
Each rocker switch also has two switch states—one for each end of travel. Rocker
switch state information is broadcast on BJM1 concurrently with proportional output
information. See the above diagram for rocker switch naming conventions.
520L0760 • Rev KA • June 2010 27

MG Grip Button CAN MG Grip Button CAN Naming Conventions

Naming Conventions
Operator Present Switch

CAN Grip Button 8
Switch 1 Position
CAN Grip Button 1

CAN Grip Button 8
Switch 1 Position
CAN Grip Button 1
Switch 2 Position
CAN Grip Button 2

CAN Grip Button 8
2461
28 520L0760 • Rev KA • June 2010

Product Installation
Dimensions Dimensions
and Installation mm [in] Ø11.93/12.00
105.6 [4.16]
[0.46968/0.4724]
61 [2.401] Ø9.518/9.531
(mounting screw centers) [0.37472/0.37523]
(4 places) Friction-held Boot
Ø3.218/3.2
[0.12669/0.126]
(typical)
[ 1.26]
32.0
[0.382]
9.7
[0.59]
15.0
Joystick Spring
Mounting Return
Surface Boot
165 [6.496] (maximum)
75.6 [02.98] (maximum)

"Forward"
Orientation Mark
101.6 [04.0] (maximum)
80.00 [3.15]
P108 303
Mating Connector (18 pin)

with Lead Wires Attached
The JS6000 is designed to be installed from the panel below, through a 68 mm [2.677 in]
diameter hole.
Recommended Mounting Panel Cut-out

61.00 [2.40]
30.50 [1.20]
Ø6.30 ± 0.12
Ø0.249 ± 0.00079
Ø72.50 ± 0.50
30.50 [1.20]
Ø2.85 ± 0.020
61.00 [2.40]
Mounting screw: M6 X 20 mm,

pan head, thread forming (tri-lobe). P108 304
520L0760 • Rev KA • June 2010 29

Dimensions Installation
and Installation Drive mounting screws to a maximum torque of 5 N.m [44.25 lbf.in] when clamped
(continued) against a 3.0 to 6.0 mm [0.118 to 0.236 in] thick panel. The joystick flange mounting hole
depth is 12.6 mm [0.496 in]. For through-hole mounting, drive the screws at a torque of
3.5 N.m [30.98 lbf.in] directly through the blind cast holes to remove the cast covers.
Use fit and seal for fitting and sealing of the joystick into the mounting panel using the
screws supplied. Note the following:
• The panel material type, thickness, strength and rigidity. Install in a panel with a
minimum thickness of 3.0 to 6.0 mm [0.118 to 0.236 in]. This allows the mounting
screws to correctly clamp the sealing boot.
• Apply the specified screw torque to ensure sufficient and even clamping force on
the sealing boot.
• The mounting flange of the joystick should be connected to the vehicle
chassis ground.
Recommended Wiring • Protect all wires from mechanical abuse.

Practice
• Use 85°C [185°F] wire with abrasion resistant insulation.
• Use a wire gauge that is appropriate for the joystick electrical mating connector.
• Separate high current wires such as feeds to solenoids, lights, alternators, or fuel
pumps from control wires. Recommended minimum separation is 300 mm [11.8 in].
• Run wires along the inside of or close to metal machine frame surfaces where
possible. This simulates a shield which minimizes the effects of EMI/RFI radiation.
• Do not run wires near sharp metal corners. Run wires through grommets when
rounding a corner.
• Provide strain relief for all wires.
• Avoid running wires near moving or vibrating components.
• Avoid long, unsupported wire spans.
• All sensors have dedicated wired power sources and ground returns: use them.
• Twist sensor lines about one turn every 100 mm [3.94 in].
• Use wire harness anchors that will allow wires to float with respect to the machine
frame rather than rigid anchors.
• The mounting flange of the joystick base should be electrically connected to the
machine reference ground plane.
30 520L0760 • Rev KA • June 2010

Joystick Safety For a system to operate safely it must be able to differentiate between commanded
and uncommanded inputs. Take steps to detect and manage joystick and system
failures that may cause an erroneous output.
For safety critical functions Sauer-Danfoss recommends you use an independent

momentary action system enable switch. You can incorporate this switch into the
joystick as an operator presence switch or can be a separate foot or hand operated
momentary switch. Disable all joystick functions that the joystick controls when this
switch is released.
Ensure the control system looks for the appropriate system enable switch input before
the joystick is displaced from its neutral position. Enable functions only after receiving
this input.
Applications using CAN joysticks should continuously monitor for the presence of
the CAN messages on periodic basis. Messages are to be checked frequently enough for
the system or operator to react if the CAN messages lose priority or are no
longer received.
PWM joystick outputs will return to zero output if the joystick’s embedded
microcontroller detects a measurement error between the redundant shaft position
sensors. Applications using the PWM joystick option should be designed to ensure a
safe machine state exists in the event a joystick output goes to zero due to an error.
520L0760 • Rev KA • June 2010 31

JS6000 Connector Pin JS6000 Joystick base pin assignments are a function of the following options:
Assignments General • Type of shaft position sensor (potentiometer or Hall)
Information • Electrical output (analog or CAN)
• Grip type
Base pin and connector assignments are different for the potentiometer and Hall sensor
options.
In all cases, grip pin assignments are dependent on the type of grip and the number of
grip options that are selected.
For CAN Output Connector Pin Assignments, see below.
For CAN+ and PWM Output Connector Pin Assignments, refer to page 33.
For Potentiometer Sensor with Analog Output Pin Assignments, refer to page 34.
For Hall Effect Sensor with Analog Output Pin Assignments, refer to page 35.
Pin Assignments CAN Output Connector Pin Assignments
Pinout and Wiring Information Pin Location

Pin 6
Pin CAN output Pin 1
1 Ground
2 Power
3 CAN high
4 CAN low
5 CAN shield
6 No connection
2239
CAN Output Mating Connector Deutsch® DTM06-6S

Sauer-Danfoss provides mating connector kits (bag assemblies) for JS6000 joysticks. The
bag assembly contains loose parts you must assemble. The connector with wire harness
features a fully assembled connector with an unterminated wire harness.
Mating Connector Assemblies

Type Sauer-Danfoss material number
Connector bag assembly 10101551
Connector with 400 mm [15.75 in] wire harness 10101557
32 520L0760 • Rev KA • June 2010

Pin Assignments CAN+ and PWM Output Connector Pin Assignments

(continued)
Pin Location
Pin 13
Pin 1
Pin 6
Pin 18
2457
CAN+ Output Connector PWM Output Connector

Pinout and Wiring Information Pinout and Wiring Information
Pin CAN output Pin CAN output
1 Ground - 1 Ground -
2 Power + 2 Power +
3 CAN high 3 CAN high
4 CAN low 4 CAN low
5 CAN shield 5 PWM Valve Out 1 +
6 Operator present/DIN11 6 PWM Valve Out 1 -
7 Sensor ground - 7 PWM Valve Out 2 +
8 5 Vdc sensor power + 8 PWM Valve Out 2 -
9 AIN1/DIN7 9 AIN / CAN Shield
10 AIN2/DIN8 10 DIN
11 AIN3/DIN9 11 DOUT1
12 AIN4/DIN10 12 DOUT2
13 DIN1 13 DOUT3
14 DIN2 14 DOUT4
15 DIN3 15 Operator Presence +
16 DIN4 16 Operator Presence -
17 DIN5 17 DOUT5
18 DIN6 18 DOUT6
CCaution
Joystick electronics damage may occur possibly causing the joystick to non-function. Do
not connect battery power to operator presence + or operator presence -.
CAN+ and PWM Output Mating Connector Deutsch® DT16-18SB

Sauer-Danfoss provides mating connector kits (bag assemblies) for JS6000 joysticks. The
bag assembly contains loose parts you must assemble. The connector with wire harness
features a fully assembled connector with an unterminated wire harness.
Mating Connector Assemblies

Connector bag assembly 11012648
Connector with 400 mm [15.75 in] wire harness 11012646
520L0760 • Rev KA • June 2010 33

Pin Assignments Potentiometer Sensor with Analog Output Connector Pin Assignments
(continued)
Shaft Position Output
Pin Location 16 Pin Connector
Pin 1
Pin 9
Grip Output
12 Pin Connector
Pin 7
Pin 1
Pin 1
Redundant Sensor Output Pin 5
8 Pin Connector 2240
16 Pin Sensor Connections* 8 Pin Redundant Sensor Connections

Pin Pin allocation description Pin allocation description for redundant
Pin
1 N/O signal Y-axis direction switch forward potentiometer sensor
2 N/C signal X-axis direction switch center 1 Second Y axis + supply voltage
3 X-axis ground 2 Second Y-axis center tap + supply voltage
4 X-axis position signal 3 Second Y-axis position signal
5 X-axis + supply voltage 4 Second Y-axis ground
6 X-axis center tap + supply voltage 5 Second X-axis + supply voltage
7 X-axis direction switches + supply voltage 6 Second X-axis position signal
8 N/O signal X-axis direction switch left 7 Second X-axis center tap + supply voltage
9 Y-axis ground 8 Second X-axis ground
10 Y-axis position signal
11 Y-axis + supply voltage For 12 pin grip output connections see
12 Y-axis center tap + supply voltage Sauer-Danfoss manual JS1000, JS6000
13 Y-axis direction switches + supply voltage Joystick Grips Technical Information
14 N/O signal Y-axis direction switch back 520L0872 for grip connector pin out
15 N/O signal X-axis direction switch right assignments.
16 N/C signal Y-axis direction switch center
* Refer to page 10 for additional details referencing potentiometer measurement and switch track connections.
Analog Output Mating Connector

Sauer-Danfoss provides mating connector kits (bag assemblies) for JS6000 joysticks.
The bag assembly contains loose parts you must assemble. The connector with 400 mm
leads features a fully assembled connector with an unterminated wire harness.
Bag Assemblies
16 pin + contacts 10101552
12 + 8 pin + contacts 10101023
Wire Harness
16 pin with 400 mm [15.75 in] leads 10101556
34 520L0760 • Rev KA • June 2010

Pin Assignments Hall Effect Sensor with Analog Output Pin Assignments
(continued) Grip Output
Pin Assignments 16 Pin Connector
Pin 1
Pin 9
Shaft Position Output

12 Pin Connector
Pin 7
Pin 1
Directional and Microswitch Output Pin 1

Pin 5
8 Pin Connector 2241
12 Pin Shaft Position Connections 8 Pin Microswitch and Directional Switch

Pin Pin allocation description Connections
1 Hall 3 and 4 5 Vdc + supply Pin Pin allocation description
2 Hall 3 and 4 ground 1 Joystick forward common
3 Hall 1 and 2 5 Vdc + supply 2 Forward switch output
4 Hall 1 and 2 ground 3 Backward switch output
5 Hall 3 forward/backward output 4 Switch backward common
6 Hall 2 left/right output 5 Switch left common
7 Hall 4 left/right output 6 Left switch output
8 Hall 1 forward/backward output 7 Right switch output
9 Not connected 8 Switch right common
10 Not connected
11 Not connected
12 Not connected
For 12 pin grip output connections see Sauer-Danfoss manual JS1000, JS6000 Joystick
Grips Technical Information 520L0872, for grip connector pin out assignments.
520L0760 • Rev KA • June 2010 35

Specifications
Mechanical Mechanical Characteristics

Characteristics Shaft mechanical angle limits ± 20˚
Shaft maximum overload 5 cycles only at 490 N [110.15 lbf ] measured 130 mm [5.12 in]
above mounting surface
Shaft maximum operating load 390 N [87.67 lbf ] measured 130 mm [5.12 in]
above mounting surface
Shaft maximum downward loading 2450 N [550.76 lbf ]
Shaft maximum torque 15 N.m [11.06 lbf.ft]
Base mechanical life (X and Y axis only) > 7.5 million operating cycles
Base only mass 0.75 kg [1.65 lbf ]
Breakout Load On Axis

Medium duty spring 6 to 8.5 N [1.349 to 1.911 lbf ]
Heavy duty spring 12 to 19 N [2.698 to 4.271 lbf ]
Load At Full Deflection

Medium duty spring 15 to 23 N [3.37 to 5.17 lbf ]]
Heavy duty spring 31 to 47 N (6.97 to 10.57 lbf )
Electrical Characteristics Potentiometer Sensor with Analog Output

Supply voltage (Vs) 9 to 36 Vdc
Maximum survival voltage 36 Vdc
Maximum wiper current 5 mA
Maximum load current 200 mA resistive
Center tap/switch alignment Within 0.5˚
Potentiometer electrical angle ± 18˚
Center tap angle ± 2.5˚
Insulation resistance at 50 Vdc > 50 MΩ
Minimum load impedance 1 MΩ recommended
Potentiometer Output Options

Minimum voltage Maximum voltage Switch track angle Resistance Model code order
(% Vs) (% Vs) (°) (kΩ) character
10 ± 2 90 ± 2 ± 1.5 1.6 to 2.4 R
25 ± 2 75 ± 2 ± 1.5 2.2 to 3.6 Q
10 ± 2 90 ± 2 ±5 1.6 to 2.4 S
25 ± 2 75 ± 2 ±5 2.2 to 3.6 T
Dual Potentiometer Output

Minimum voltage Maximum voltage Switch track angle Resistance Model code order
(% Vs) (% Vs) (°) (kΩ) character
10 ± 2 90 ± 2 ± 1.5 1.6 to 2.4 U
36 520L0760 • Rev KA • June 2010

Specifications
Electrical Characteristics Hall Effect Sensor with Analog Output

(continued) Supply voltage (Vs) 5 ± -0.5 Vdc
Maximum survival supply voltage 18 Vdc
Maximum current draw (base only) 90 mA
Minimum output voltage 10% ± 4% Vs
Center voltage 50% ± 2% Vs
Maximum output voltage 90% ± 4% Vs
Hall Effect Sensor with CAN Output Option

Maximum current draw (base only) 90 mA
Supports CAN 2.0B with SAE J1939 message protocol
Hall Effect Sensor with PWM Output Option

Maximum survival voltage 40 Vdc
Maximum current draw (base only) 13 amps
Valve outputs 2.5 amps maximum
Digital outputs 3.0 amps maximum
Maximum output current 13.0 amps
External-To-Joystick Digital Inputs

Property Minimum Maximum Comments
Allowed voltage at pin 0 Vdc 36 Vdc
Rising voltage threshold 2.48 Vdc 3.5 Vdc Digital input will be read as high if
voltage is greater than 3.5 Vdc
Falling voltage threshold 1 Vdc 2.25 Vdc Digital input will be read as low if
voltage is less than 1 Vdc
CAN output latency 6 ms 24 ms Based on update rate of
application software
Response to voltage below Non-damaging, non-latching:
minimum reading saturates to low limit
Response to voltage above Non-damaging; non-latching:
maximum reading saturates to high limit
External-To-Joystick Analog Inputs

Property Minimum Maximum Comments
Allowed voltage at pin 0 Vdc 36 Vdc
0 Vdc 25 Vdc AIN/CAN_Shld on PWM version
Maximum discernable voltage 4.915 Vdc 5.085 Vdc
Minimum discernable voltage 0 mVdc 85 mVdc
Response to input below Effect on other inputs; non
minimum voltage damaging, non-latching; reading
saturates to low limit
Response to input above Effect on other inputs; non
maximum voltage damaging, non-latching; reading
saturates to high limit
Response to open input Pull down = 0 Vdc
520L0760 • Rev KA • June 2010 37

Specifications
Microswitch Microswitch Characteristics

Characteristics Mechanical deflection 0 to 5°
Contact ratings 3 A at 125 V AC, 2 A at 30 Vdc
100,000 cycles minimum at a cycling frequency of
Service life
1 Hz at 1 A 12 Vdc
Sensor Power Supply Sensor Power Supply Ratings

Ratings Property Minimum Maximum Comments
Output current 50 mA
Output voltage 4.85 Vdc 5.15 Vdc
Output short circuit voltage 36 Vdc
Environmental Environmental Characteristics

Characteristics -40°C to +80°C [-40°F to 176°F]
Operating temperature
With microswitches: -25°C to 80°C [-13°F to +176°F]
-40°C to +85°C [-40°F to 185°F]
Storage temperature
With microswitches: -25°C to +80°C [-13°F to +176°F]
Potentiometer: IP 40 below panel (grip dependent above)
Joystick base Ingress Protection (IP) rating Hall: IP 40 below panel (grip dependent above)
CAN, CAN+, PWM: IP 66 below panel (grip dependent above)
EMI/RFI Rating 100 V/m
Frequency range 10 to 200 Hz
Level 3.6 G rms
(Duration 2 hours each axis)
Vibration (sinusoidal)
Frequency range 10 to 200 Hz
Level ± 3 G Peak
(Duration 1 hour each axis random)
Level 20 G type 1/2 sine 6 ms
Shock
Number of shocks: 1350 each axis
38 520L0760 • Rev KA • June 2010

Notes
520L0760 • Rev KA • June 2010 39

Our Products Sauer-Danfoss Mobile Power and Control Systems
– Market Leaders Worldwide
Open circuit axial piston pumps
Sauer-Danfoss is a comprehensive supplier providing complete
Gear pumps and motors systems to the global mobile market.
Fan drive systems
Sauer-Danfoss serves markets such as agriculture, construction,
Closed circuit axial piston pumps road building, material handling, municipal, forestry, turf care, and
and motors many others.
Bent axis motors
We offer our customers optimum solutions for their needs and
Hydrostatic transmissions develop new products and systems in close cooperation and
partnership with them.
Transit mixer drives
Hydrostatic transaxles Sauer-Danfoss specializes in integrating a full range of system
components to provide vehicle designers with the most advanced
Electrohydraulics
total system design.
Integrated systems
Sauer-Danfoss provides comprehensive worldwide service for its
Microcontrollers and software
products through an extensive network of Global Service Partners
PLUS+1™ GUIDE strategically located in all parts of the world.
Displays
Joysticks and control handles Local address:
Sensors
Orbital motors
Inverters
Electrohydraulic power steering
Hydraulic power steering
Hydraulic integrated circuits (HIC)
Sauer-Danfoss (US) Company Sauer-Danfoss ApS
Cartridge valves 2800 East 13th Street DK-6430 Nordborg, Denmark
Ames, IA 50010, USA Phone: +45 7488 4444
Directional spool valves Phone: +1 515 239-6000 Fax: +45 7488 4400
Fax: +1 515 239 6618
Proportional valves Sauer-Danfoss-Daikin LTD.
Sauer-Danfoss GmbH & Co. OHG Shin-Osaka TERASAKI 3rd Bldg. 6F
Postfach 2460, D-24531 Neumünster 1-5-28 Nishimiyahara, Yodogawa-ku
Krokamp 35, D-24539 Neumünster, Germany Osaka 532-0004, Japan
Phone: +49 4321 871-0 Phone: +81 6 6395 6066
Fax: +49 4321 871 122 Fax: +81 6 6395 8585
520L0760 • Rev KA • June 2010 www.sauer-danfoss.com

Oil Level Sensor MP Filtri
RL-G1-T3 S1 A A500
Level Float Switch - RL Series
Description
Rapid Level Float Switch. Revolutionary Can be used in heavily contaminated fluids and
new series of electro-magnetic level gauges. refrigerating oils. Tolerates the presence of
metallic particles.
Packed in "Kit" form. Only a few seconds
are required to obtain the desired length: just Multiple switching options are available to
cut the control rod to length. customize your system.
5-4
There are no electrical components Models suitable for high temperatures and
submersed in the fluid. corrosive liquids are available.
Technical Data
Wiring Schematics: S1 1
S2 2 3
S3 ELECTRICAL CONNECTOR
(absence of fluid) LOCATION
1
3
2
1 SEAL
PACKING
OR
GASKET
2
2 POSITION
SWITCH (S2)
S3=S1+S1
1 POSITION
Switch Specifications: Open or closed contacts switch SWITCH (S1)
Standard: 3A. 60W. 60 V.A. 250V MAGNET
On request: 5A. 250 V.A 250V
Exchange Contact 1 A 30W. 60 V.A. 220V

Switch:
COMPRESSION
Mounting Pattern F3: JOINT
CONTROL ROD
(WITH FLOAT
AND MAGNET
ASSEMBLED)
Ø34.6 QUICK
MOUNTING
ROD/FLOAT
CONNECTOR
LR - F3
FLOAT
(IN PLASTIC)
Each level is supplied outfitted with screws and

oiltight gasket
How To Cut The Rapid Level Rod
L/L1 A B
120 116 116

140 137 137
160 158 158
180 179 179
200 200 200
220 221 221
240 242 242
5-5
260 263 263
280 284 284
300 305 305
320 326 326
340 347 347
360 368 368
380 389 389
400 410 410
420 431 431
440 452 452
L/L1 A B
460 473 473
480 494 494 840 874 872
500 515 515 860 868
520 511 536 880 889
540 532 557 900 910
560 553 578 920 931
580 574 599 940 952
600 595 620 960 973
620 616 641 980 994
640 637 662 1000 1015
660 658 683
L = Liquid Level in mm
680 679 704
A = Minimum Rod Level in mm
700 700 725 B = Maximum Rod Level in mm
720 721 746
H = 60 (L = 120:500 mm)
740 742 767 H = 90 (L = 501:1000 mm)
760 763 788 H1 = 70 (L = 120:1000 mm)
H1 = 33 (L = 85 mm)
780 784 809
800 805 830
When measuring length of rod for cutting,
820 826 851 Don't forget to keep the rod extended!
RL/G1 Series - Single Float
Description CONNECTOR
28mm
15mm
REED-
CARRYING
Packed in a kit form which includes the head/ HEAD
connector assembly, control rod and float. (NYLON
GLASS)
Switches are in the head assembly thus there

are no wires to position inside the control
L
rod. The control rod is stainless steel and can
be cut to length easily. CONTROL
1-1/4" NPT 5-6
ROD
(STAINLESS 55mm
STEEL)
The float is fixed to the control rod and does
not contain any magnets. This eliminates the
collection of ferrous material present in some
fluids. Level FLOAT
(PLASTIC)
The control rod and float move as one piece

into the head assembly to actuate the
switches. For lengths over 500 mm or in systems with
turbulence in the tank, specify type "R"
Standard model is supplied with control rod reinforced rods.
closing the switch with falling oil level. If
you need open contacts add "A" to the Mounting connection: T3: 1-1/4" NPT thread
F3: Flange 3 mounting
standard code. ie: RLG1-F3-S3 "A"
holes
RL/G2 Series - Double Float

28mm
Description 15mm
L1
The RL/G2's head accepts two control rods. For lengths over 500mm
Each control rod activates a separate switch. or in systems with
Each switch can be wired with S1, S2, S3, turbulence in the tank,
configuration. This option allows a wide specify the "R"
L
variety of signal options. reinforced rod.
The standard model is supplied with control Mounting Connection:

rod 1 closing the switch contacts with falling T3 = 1-1/4" NPT thread
oil level and control rod 2 closing the switch F3 = Flange, CONTROL ROD
IN STAINLESS
contacts with rising oil level. 3 mounting holes. STEEL UPPER
LEVEL
CONTROL ROD IN
For open switch contacts add "A" to the STAINLESS STEEL
LOWER LEVEL
standard code.
RL/L Series - Side Mount
Description
Rapid Level lateral electro-magnetic levels
packed in "Kit" form.
This model mounted on the side of the tank,

has the same basic design as the tank top
version.
5-7
Unlike the tank top models, the distance
between the first and second signal is not
fixed. As the length of the control rod
increases the distance between the two
signals increases (see graph).
Example using graph:
The hydraulic pump is allowed to operate through the cross hatched range. When the oil level reaches
line 1 a low oil level warning signal is generated. When the oil level drops to line 3 the system is
automatically shut down.
Ordering Information RL Series
Single Float
RL-G1 - F3 S1A A500
SERIES CONTROL ROD (LOWER)
RL-G1 One Float Type A500 Standard Rod 500mm
RL-L Single Float Side Mounting A1000 Standard Rod 1000mm
5-8
ROD TYPE WIRING SCHEME
Condition in the absence of liquid
- Standard Rod
Normally Closed Normally Open
R Reinforced rod
S1 S1A
N/A for RL-L N/A for RL-L
FASTENING TYPE
S2 S2A
F3 3 Hole flange
S3 S3A
T3 1-1/4" NPT
Consult MP Filtri for high temperature and
corrosive liquid options
Double Float
RL-G2 R F3 S1A S1 A1000 B900
SERIES CONTROL ROD (UPPER)
RL-G2 Double Float Type B400 Standard Rod 400mm
B900 Standard Rod 900mm
WIRING SCHEME RL-G2 LOWER FLOAT WIRING SCHEME RL-G2 UPPER FLOAT
Condition in the absence of liquid Condition in the presence of liquid
Normally Closed Normally Open Normally Closed Normally Open

S1 S1A S1 S1A
S2 S2A S2 S2A
S3 S3A S3 S3A

Hydraulic Boom 1093 - Model TR-14 New

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Hydraulic Boom 1093 - Model TR-14 New

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♦♦ OPERATION AND MAINTENANCE MANUAL

TRAMAC CORPORATION TRAMAC EQUIPEMENT LTD

Rev: New Page 1 of 54

Rev: New Page 3 of 54

Figure 2-1 Boom Installation Side View ................................................. 7

Rev: New Page 4 of 54

The rock breaker system includes the following main assemblies:

• Breaker boom assembly TR-14

• Hydraulic breaker tool

• Electric powered hydraulic power pack

• Electric local control station

1.1 TR-14 HYDRAULIC BOOM DESCRIPTION

• Hydraulic System and Cylinders

Rev: New Page 5 of 54

1.2 HYDRAULIC POWER PACK DESCRIPTION

1.3 ELECTRICAL CONTROLS

Rev: New Page 6 of 54

2 DATA SHEET & SPECIFICATIONS

2.1 Boom Specifications

Figure 2-1 Boom Installation Side View

Rev: New Page 7 of 54

Figure 2-2 Boom Reach Diagram

Type of swing: Slewing Ring with two (2) planetary reducer /

Controls: From operator cabins (24 volt electric joysticks)

Breaker Model: V1200 (supplied by other)

2.2 Hydraulic Power Unit

Rev: New Page 9 of 54

3.1 BOOM INSTALLATION

4) Install the neoprene washers and then steel washers in place;

5) Screw the nuts over the anchors and tighten;

7) Link and connect the rest of the boom;

8) Install the breaker and tool according to breaker's manufacturer specifications;

hoses have been furnished to complete the installation.

3.2 HYDRAULIC POWER UNIT INSTALLATION

3.3 HYDRAULIC HOSE CONNECTIONS

6) Re-connect all hoses between sections of the boom

Rev: New Page 11 of 54

Figure 3-1 HPU Hydraulic Connections to Boom

3.4 ELECTRICAL INSTALLATION

Rev: New Page 12 of 54

Figure 4-1 Hydraulic Schematic

Rev: New Page 13 of 54

Figure 4-2 Electrical Block Diagram

Rev: New Page 14 of 54

5.1 Before start-up:

4. Verify that no hydraulic hose has been pinched or improperly routed;

5. Check that all hydraulic hose has been properly tightened;

5.2 Start-up procedure:

POWER UNIT OIL COOLER

Figure 5-1HPU Control Panel

LOW OIL FILTER ALARM OIL COOLER OIL HEATER LUBRIFICATION

POWER UNIT STOP START

Figure 5-2 Hydraulic Power Unit Control Panel

Rev: New Page 16 of 54

HAMMER TILT BOOM

Figure 5-3 Manual Hydraulic Control Valves

Figure 5-4 Operator Console

9. Re-verify position of mechanical stoppers to prevent any accident or damage.

6.1 PRESSURE ADJUSTMENTS:

Each pump shall be adjusted individually.

6.1.1 Load Sensing Pump No 1 Pressure Setting

4. Lock the load sensing adjustments.

6.1.2 Main Pump No 1 Pressure Setting

Rev: New Page 18 of 54