ITEM LOC ITEM

DESCRIPTION QTY PART NO COMMENTS

1 HOSE TRANSMISSION TO OIL COOLER 2 16H1112B COOLER IN / OUT
2 HOSE COOLER TUBE TO UNLOADER 1 16H4048C
VALVE
3 EMERGENCY STEER. PUMP TO PORT "EP" 1 MXH006B
4 STEERING PRESSURE TO PORT "OP" 1 MXH007A
5 STEERING ORBITROL TO PORT "STR" 1 MXH008B
6 STEERING ORBITROL "LS" TO PORT "OS" 1 MXH009C
7 STEERING PRESSURE TO RIGHT CYLINDER 1 MXH010A
8 STEERING ORBITROL TO LEFT CYLINDER 1 MXH011A
9 STEERING CROSS OVER HOSES 2 MXH012A
10 LUFF CYLINDER HOSES 4 MXH013C
11 AXLE LOCKOUT RELEASE DRIVERS 1 MXH041-
12 AXLE LOCKOUT LOCK DRIVERS 1 MXH042A
13 AXLE LOCKOUT RELEASE PASS. 1 MXH043-
14 AXLE LOCKOUT LOCK PASS. 1 MXH044-
15 HOSE LUFF CYLINDER PRESSURE 1 MXH086A
BALANCE
16 COUNTER WEIGHT CROSSOVER UP OM906 1 MXH111C
17 COUNTER WEIGHT CROSSOVER DN OM906 1 MXH112C
18 HOSE WINCH V/BANK TO BULKHEAD 1 MXH113D
19 HOSE WINCH V/BANK TO PIPE 1 MXH114D
20 TELE PRIM "IN" V/BANK TO PIPE 1 MXH115C
21 TELE. SEC. V/BANK "OUT" TO PIPE 1 MXH116C
22 TELE. SEC. V/BANK "IN" TO PIPE 1 MXH117C
23 TELE PRIM. OUT V/BANK TO PIPE 1 MXH118C
24 HOSE FILTER RETURN 2" 1 MXH124B
25 HOSE TRANS. CASE COOLER SUCTION 1 MXH126B
26 PUMP LOAD SENSE PIPE TO MAN. OM906 1 MXH143A
27 COUNTER WEIGHT PRESSURE OM906 1 MXH144A
28 HOSE SUCTION MAIN 2" 1 MXH145B
29 HOSE MOTOR BULKHEAD WINCH 1 MXH147A
30 HOSE MOTOR BULKHEAD WINCH 1 MXH148A
31 PUMP PRESSURE TO MANIFOLD OM906 1 MXH154A
32 TELE. PRIMARY OUT HOSE UPPER BOOM 1 MXH156-
33 TELE. PRIMARY IN HOSE UPPER BOOM 1 MXH157-

REF MC25-A-6-067 REV D >1< HYDRAULIC HOSE KIT OM906 3000 GEN4

B E/PUMP 138 BAR WAS 175 D3654 4/05/11 DATE 12/04/2012

C FIX BALLOONS D3743 9/12/11 DRN DT
D SCHEMATIC REVISED FOR NEW WLR 803 WINCH D3785 12/04/12 CKD
REV CHANGE DETAILS CHG NO: DATE APPD

HYDRAULIC HOSE KIT PL-MC25-A-6-067 REV

OM906 3000 GEN4 SHEET 1 OF 1
A.B.N. 86 010 671 048
MAC 25 SERIES III PLMXA6067D D
THIS DRAWING SHALL REMAIN THE PROPERTY OF TEREX LIFTING AUSTRALIA PTY. LTD. & MUST NOT BE DISCLOSED WITHOUT WRITTEN APPROVAL 12/04/2012 11:34:33 AM
 4 5 6

PSM 50 R14 T25 ADJUST FULLY RV6-10-C-0-25/25

SET TO 25 Bar CLOCKWISE
PIN 1 - GREEN/RED PRV1-10-S-0-12/04

PIN 3 - BLACK/ORANGE
TO DASH MOUNTED
NO ORIFICE (M6) PRESSURE GUAGE
G3
PROVISION ONLY t
o
ORIFICE M6 01.0
MC25-H-041
AXLE LOCK RIGHT "REL" DPS2-16-FF-0-160
TO PORT "REL2"
MC25-H-043
.0; 1:4111/Tillal
nn

MC25-H-143
PSM 1OR 14AP T5D
SV1-8-4-0-00 LOAD SENSE
AXLE LOCK LEFT "REL" SET TO 5 Bar
PIN 1 - LT. GREEN PIPE TO "LS" PORT
TO PORT "REM" PIN 1 - BLACK/WHITE
PIN 2 - BLACK
PIN 3 - BLACK/WHITE
PUSHLOC RETURN DSV2-8-8-0-0
TELE SECONDARY OUT MC25-H-049
TO LOCKOUT LEFT ADJUST TO 160 Bar MC25-H-146
MC25-H-116 MC25-H-114 MC25-H-115 MC25-H-009 PORT "R" TO
PORT "T" TELE SEC. OUT WINCH DOWN TELE PRIM. IN PUMP TO "P" PORT
PORT "OS" TO PILOT CONTROLS "P"
ORIFICE M6 00.5mm
MC2541-044 ORBITROL "LS"
PSP 300 R14 200T
AXLE LOCK LEFT "LK" MC25-H-013
SET TO 200 Bar
TO PORT "LK1" LUFF DOWN
PIN 2 - BLACK
RIGHT
MC25-H-042 PIN 3 - BLACK/ORANGE
MC25-H-013
AXLE LOCK RIGHT "LK"
MC25-H-052 LUFF DOWN
TO PORT "LK2"
RETURN FROM LEFT
MOTION CUT MANIFOLD MC25-H-013
PORT "DR" LUFF UP
LEFT
ORIFICE PUSHLOC RETURN
MC25-H-013
(PROVISION ONLY) TO TANK
LUFF UP
M6 PLUG
RIGHT
PUSHLOC RETURN
TO LOCKOUT RIGHT MC25-H-117 MC25-H-113 MC25-H-118 MC25-H-124 MC25-H-007 MC25-H-006
PORT "T" TELE SEC. IN WINCH UP TELE PRIM. OUT PORT "T" TO PORT "OP" TO EMERGENCY STEER "P"
RETURN FILTER ORBITROL "P" TO "EP" PORT
ORIFICE M6 00.5mm
(E)
II MC25-H-008
ADJUST FULLY ORBITROL "T" TO PORT "STR"
CLOCKWISE

CV3-10-P-0-3

SV4-8-C-0-00 CV3-10-P-0-3
PIN 1 - BLUE/GREY
DPS2-20-PL-0-160
PIN 2 - BLUE/BLACK ORIFICE M6 00.8MM
PARTS LIST : PL-MC25-A-6-051

UNLESS OTHERWISE STATED ALL WELDING TO AS1554 CATEGORY SP AS 1100

AND ALL DIMENSIONS IN (mm) & TOLERENCED TO LIMITS SHOWN.

DATE 08/07/04
n1110

B REPTO 0M906, 3000 GEN4 CHANGES D3048 SR NO 02/01/07 NOMINAL UP TO ABOVE 150 ABOVE 300 ABOVE DO NOT SCALE DRN ' SR
SIZE 150 UP TO 300 UP TO 1000 1000 SHE A7
A ORIFICE CHANGE/RAWHIDE HOSE NOTES D2982 SR YES 12/05/6 SIZE 1.-L) CKD
MACHINING ±0.1 ±0.25 ±0.5 +1 0
CHG
REV CHANGE DETAILS No. BY INTER DATE FABRICATION ±0.5 ±1.0 ±1.5 ±2.5 SCALE 1:5 APPD
Title
HYDRAULIC BANK DRG No.
REV
IS4 TEREX FRANNA INSTALLATION
MAC 25 SERIES III
MC25-A-6-051 B
A.B.N. 86 010 671 048

1 2 3 THIS DRAWING SHALL REMAIN THE SOLE PROPERTY OF TEREX LIFTING AUSTRALIA PTY. LTD. & MUST NOT BE COPIED OR DISCLOSED WITHOUT THEIR WRITTEN APPROVAL. PRODUCT No. : MXA6051B
WLR 803 HOISTING WINCH
OPERATORS MANUAL
Part Number: 16C1522A

16C1522A 1
1 Introduction .................................................................................................... 3
2 Document symbols ........................................................................................ 4
2.1 Symbols relating to the “operator qualification level” .......................... 4
2.2 Symbols relating to “consulting the manual” ....................................... 4
2.3 Mandatory symbols relating to safety ................................................. 5
2.4 Danger symbols relating to safety ....................................................... 5
3 General Characteristics ................................................................................. 6
3.1 Permitted use ...................................................................................... 6
3.1.1 Prohibited uses............................................................................. 6
3.2 Main parts ........................................................................................... 8
3.3 Nameplate .......................................................................................... 9
3.4 Specifications.................................................................................... 11
3.4.1 Winch specifications ................................................................... 11
3.4.2 Airborne noise ............................................................................ 13
3.4.3 Vibrations ................................................................................... 13
4 Safety rules .................................................................................................. 14
4.1 Residual risks ................................................................................... 14
4.2 Workstation ....................................................................................... 15
5 Installation.................................................................................................... 16
5.1 General ............................................................................................. 16
5.2 Ambient conditions for use................................................................ 16
5.3 Assembly of the rope on the drum .................................................... 17
6 Commissioning ............................................................................................ 19
6.1 General warnings .............................................................................. 19
6.2 Trial operation ................................................................................... 19
6.3 Use ................................................................................................... 20
7 Maintenance ................................................................................................ 21
7.1 Service .............................................................................................. 21
7.2 Cleaning............................................................................................ 22
7.3 Routine maintenance ........................................................................ 23
7.3.1 Renewing lubricants / topping up ............................................... 23
7.3.2 Filling and vent plugs.................................................................. 23
7.3.3 Oil filling...................................................................................... 25
7.3.4 Recommended lubricant ............................................................ 25
7.4 Troubleshooting ................................................................................ 26
8 Spare parts .................................................................................................. 27
8.1 How to order spare parts .................................................................. 27

2 16C1522A
 1 Introduction
Crane Owners and Operators:
Terex appreciates your choice of our product for your application. Our number
one priority is user safety which is best achieved by our joint efforts. We feel
that you make a major contribution to safety if you as equipment users and
operators:

1. Comply with OH&S, Federal, State and Local Regulations.

2. Read, Understand and Follow the instructions in this and other
manuals supplied with this product.
3. Use Good, Safe Work Practices in a common sense way.
4. Only have trained operators – directed by informed and
knowledgeable supervision – operating this product.

If there is anything in this manual that is not clear or which you believe should
be added, please send your comments to Terex Product Support.

Your safety is our priority.

16C1522A 3
 2 Document symbols

2.1 Symbols relating to the “operator qualification level”

Machine operator: operator with no specific skills, capable of

performing simple tasks only, i.e. running the system with its controls.

Lifting and transport equipment operator: operator trained for

driving and using material and machine lifting and transport gear (the
instructions of the manufacturer of these must be scrupulously followed) in
accordance to the laws in force in the machine user's country.

Maintenance mechanic: qualified technician capable of running the

machine in normal conditions; running it with guards deactivated using a
deadman control; carrying out adjustments, maintenance or repair work on
mechanical components.

Manufacturer’s technician: qualified technician provided by the

manufacturer to carry out complicated operations in particular situations, as
established with the user. Specialised mechanical and/or electric and/or
software technicians are available according to need.

2.2 Symbols relating to “consulting the manual”

IMPORTANT
Texts highlighted by this symbol indicate a potential danger for the machine
and draw attention to the damage that such danger may cause to the machine
and/or to the operator.

4 16C1522A
 TO SAFEGUARD THE ENVIRONMENT
Texts highlighted by this symbol contain warnings relating to the environment.

NOTE
Texts highlighted by this symbol contain additional information.

2.3 Mandatory symbols relating to safety

Always wear protective gauntlets:

this symbol means that operators should be wearing protective gauntlets for
electrical/thermal insulation.

Always wear accident-prevention footwear:

this symbol means that the operator must be wearing accident-prevention
footwear.

2.4 Danger symbols relating to safety

Danger of hand/arm and leg/foot crushing:

this symbol instructs operators to pay particular attention towards mechanical
components that could cause hand/arm and leg/foot crushing in the event of
unexpected movements or imprudent manoeuvres of the operators
themselves.

16C1522A 5
 3 General Characteristics

3.1 Permitted use

 The WLR 803 winch has been designed and built for hoisting.
 The machine is designed for use in normal industrial environments.
 The machine must be run by persons that have been trained
concerning the characteristics of the same and that are familiar with the
contents of this manual.
 The machine is automatic since it does not call for the presence of an
operator during its work cycle.

3.1.1 Prohibited uses

The machine cannot be used either partially or totally:

 for lifting or towing people;
 without its guards and/or with its safety devices deactivated, out-of-
order or missing;
 unless it has been correctly installed;
 in dangerous conditions or when it is malfunctioning;
 improperly or by untrained personnel;
 for uses not complying with the specific standard;
 in the event of supply defects;
 if maintenance has been badly conducted;
 unless the appropriate personal protective equipment is worn;
 unless operators are suitably trained and informed, concerning
safety at work;
 after unauthorised modifications;
 with material and/or tools differing from those indicated for normal
machine operation;
 at an ambient temperature lower than –20°C or higher than 50°C;
 unless all instructions are observed.

The machine cannot be used in any of the following conditions:

 in environments where temperature is lower than -20°C and higher

than 50°C;
 in environments where relative humidity is lower than 10% or higher
than 85%;
 in submerged or semi-submerged places;
 in explosive or potentially explosive environments and areas
where there is a risk of fires.

6 16C1522A
 Any deviation from the above mentioned specifications calls for a
specific written authorisation by Terex Australia Pty Ltd.
 Any modification that has not been authorised by Terex, that
alters the functions of the machine and consequently modifies the
risks and/or generates additional ones, will be made at the
exclusive responsibility of the person/company making that
modification.
 Should these modifications be made without the manufacturer's
authorisation, any warranty issued by Terex Australia Pty Ltd will
be invalidated.

16C1522A 7
 3.2 Main parts

A. Drum
B. Hydraulic motor
C. Motor support
D. Bearing support
E. Pressure roller

8 16C1522A
 3.3 Nameplate

The machine's identification data can be found on the plate fastened to the
machine.

For no reason may the information printed on the plate be

altered.

Refer the "Serial Number" of the system every time you contact
Terex for information or spare parts.

16C1522A 9
The identifications plate bears the following information:

1) Serial Number
2) Item
3) Family/Out/i/In.
4) Bar code
5) Made in Italy
6) Rope diameter
7) Rope strength
8) F.E.M.
9) Info
10) kW
11) Volt
12) Hz
13) Weight
14) Max pressure
15) Max oil flow
16) Max line pull first layer
17) Max line pull top layer
18) Layer
19) Speed rope first layer
20) Speed rope top layer
21) Layer

10 16C1522A
3.4 Specifications

3.4.1 Winch specifications

16C1522A 11
12 16C1522A
 3.4.2 Airborne noise
Sound pressure level: less than 70 db(A).

3.4.3 Vibrations
The machine does not create vibrations that put the health of operators at risk
or that disturb machines installed nearby.

IMPORTANT!
Increased shaking may indicate malfunctioning of the machine. In this
situation, stop the machine and perform the necessary checks.

16C1522A 13
 4 Safety rules

IMPORTANT!
The machine is supplied without guards since it is usually incorporated
into a complex line.
The final manufacturer of the assembly is responsible for supplying and
installing all fixed and movable guards to prevent accidents in
dangerous positions, with the exception of those indicated in
"RESIDUAL RISKS": for example, the exit area from the rope drum.
These areas must be highlighted by applying safety labels that are easy
to understand.

4.1 Residual risks

A. Personal protective equipment (PPE)

Should it be necessary for operational or servicing reasons to work on the

system manually, operators must wear the necessary Personal Protective
Equipment, namely:
- Gloves resisting heat
- Non-slip footwear

B. Unexpected / accidental machine starting

The relevant risk is avoided by instructing the operator concerning the

practices to follow in this event:
- in the event of any maintenance work, inform the person in charge so as to
prevent any accidental starting of the machine.

C. Danger of entanglement / crushing

In the rope winding area, there is a risk of entanglement / crushing. Do not

approach this area during operation.

14 16C1522A
D. Danger of collision

When working in the rope towing area, there is a risk of rope failure. Keep at a
safe distance from the towing area during operation

4.2 Workstation

During operation, the operator must keep at a safe distance

from the winding and towing areas.

16C1522A 15
 5 Installation

5.1 General
Machine installation is a complex operation that gives rise to various risks; this
operation is generally performed by Terex or by qualified technicians
authorised by the same. The installation of the winch to the crane boom can
require modification when installed on certain cranes. Please contact Terex
service, see section 7.1, for further information and procedures regarding your
winch installation.

Please be informed that installation of machines is not at the

care of Terex. Therefore, the latter refuses any liability in the event that
the instructions are not followed.

5.2 Ambient conditions for use

The machine has been designed and built for use in various climates, in non-
explosive environments or potentially explosive ones, with the following
temperature and humidity:
Temperature min. -20°C max. +50°C;
Humidity min. 10% max. 85%.

16 16C1522A
 5.3 Assembly of the rope on the drum

The winch is generally supplied installed on a crane with rope

installed. If the winch is supplied as a spare part the rope will be
separated from its drum. Assembly of the rope must be performed by
the operator or by a qualified technician, following the instructions of
the rope manufacturer, after running the winch according to Section 6.2

Before mounting the rope, pull away the pressure roller from the drum and fix
it by means of two pins put into the proper holes “A”

16C1522A 17
Pass the end of the rope “A” outward through the slot on the drum plate, then
pass the rope under the two clamps “B” positioned by the two pins “D” in the
pocket “C”. Fix the rope with the two clamps “B” by tightening the four screws
“E” (M8, tool size 13 mm, tightening torque 25 Nm). The newer versions of the
winch use cap head screws “F” (M8, allen key 6 mm, tightening torque 25
Nm).

18 16C1522A
 6 Commissioning

6.1 General warnings

Before starting up the machine, read this manual with care and
make sure to have understood its contents.

 For more information or explanations, contact Terex.

 Persons in charge of running and servicing the machine must possess
the specific competences described in this manual as well as the
psychological and physical abilities needed to use the machine.
 The following paragraphs provide instructions for putting the machine
into service.

Before putting the machine into service (only required if winch is installed as a
spare part for an existing crane):

 Check the level of lubricant.

 Check the tightness of all the nuts and bolts.
 Make sure that the hydraulic circuit has the features described in the
relative paragraph.
 Make sure the drum is turning in the right direction.

6.2 Trial operation

All information relating to pressure, oil flow rate and speed is

given in the winches' technical specifications tables.

Note the below is only required if winch is installed as a spare part for an
existing crane.

Before winding the rope around the installed winch, run the latter in both
directions for a few minutes. After winding the rope perform a trial lifting cycle
with a light load. Check correct operation of the brake of the load during its
upward movement. Make sure that the load is lowered in a smooth,
controllable and jerk-free manner.

16C1522A 19
 6.3 Use

Before using the winch, make sure that the rope is in perfect
working order. If it is crushed or frayed, replace it immediately

Leave at least 2 coils of rope around the drum

Never use the winch beyond its maximum pulling capacity.

Unexpected breakage of the taut rope or any failure that causes

the hook to release the load will result in a particularly dangerous
"whiplash" action. For this reason, never stand in the operating radius
of the rope.

Never guide the rope with your hands while the winch is
running.

20 16C1522A
 7 Maintenance
7.1 Service

Terex will service your winch at the standard service intervals of the crane it is
installed on. See section 7.3 for routine maintenance that can be carried out
by the customer.

Please contact the service department if you have any questions about your
winch. Please note the crane model number, crane serial number and winch
family (WLR803) in all your correspondence.

Service Centres

Brisbane
585 Curtin Avenue East
Eagle Farm, QLD 4009
P: (07) 3868 9600

New South Wales

114 Hassall Street
Wetherill Park, NSW 2164
P: (02) 8786 4444

Western Australia
39 Catalano Road
Canningvale, WA 6155
P: (08) 9232 0000

Victoria
187 Osborne Avenue
Clayton South, VIC 3169
P: (03) 9551 8644

16C1522A 21
 7.2 Cleaning

Perform cleaning with the machine isolated from all energy

supplies. Never clean the machine and its components with solvents,
corrosive liquid or abrasive objects.
If you are using the winch in corrosive environments, containing rough
polluting particles and/or very fine dust, wash the winch with water and
suitable fluids to prevent dirt depositing and damaging important
components such as nuts and bolts, rings and washers.
Plan maintenance correctly so as to prevent excessive wear and tear of
the winch.

When using a high pressure washer for cleaning do not direct

water at the pressure rollers “A” and 2 speed solenoid connector “B”.

22 16C1522A
 7.3 Routine maintenance

7.3.1 Renewing lubricants / topping up

REMOVAL OF ANY OIL INSIDE THE REDUCTION GEAR

SHOULD BE STORED IN APPROPRIATE CONTAINERS READY TO BE
HANDED OVER TO AUTHORISED WASTE DISPOSAL CENTRES, IN
ACCORDANCE TO THE LAWS IN FORCE.

For checking, topping up and renewing, use the special plugs provided (see
technical data sheet). Replace seals under the plugs every time you unscrew
them for inspections. For recommended lubricants see section 7.3.4

It is recommended to replace the lubricant when it is warm to prevent sludge

forming. When renewing oil, it is recommend to wash the reduction gear with
a suitable fluid, as indicated by the lubricant manufacturer.

Irrespective of the hours of work, the level of lubricant should be checked

every 20/30 calendar days.

Irrespective of the type of work, regularly check the winch, the condition and
level of lubricant and if necessary top up.

7.3.2 Filling and vent plugs

It is important to regularly check operation of the oil filling and

vent plugs to prevent vent clogging from causing pressure to rise in the
reduction gear and temperature of oil to increase.

16C1522A 23
 A. Winch vent plug
B. Motor drain port
C. Winch oil level/filling plugs
D. Winch oil drain

Every time lubricant is renewed or topped up, push the inner section of the
plug with a pin until you overcome the resistance of the compression spring
on the closing diaphragm (max. 0.1-0.2 kg); to make sure that there are no
obstructions, blow compressed air (max. 0.5 bar) from the inner to the outer
side of the plug.

It is recommended to perform this operation regularly

irrespective of whether oil is renewed or not.

24 16C1522A
 7.3.3 Oil filling

For oil filling follow the instructions below:

 Remove vent plug “A” and filling/level plugs “C”
 The winch may contain a small amount of protective oil. Remove it by
opening the drain plug “D”, then close the drain plug.
 Fill the winch with oil by a pump through one of the two plugs “C”. Fill
the winch until the oil comes out from the opposite plug “C”. Oil
quantity: about 4.5 litres.
 Remove the pump and close all the plugs.

After oil filling, remove the warning tag: “Fill the gearbox with
oil before use”

7.3.4 Recommended lubricant

Winch gearbox and brake – Castrol Alpha SP 320, 4.5 Litres

Note gearbox and brake are common.

16C1522A 25
 7.4 Troubleshooting

If the winch is not working properly, check the troubleshooting

table to locate the cause and the solution, if any.
If the problem cannot be solved, contact Terex Technical Support,
National Free Call 24 / 7 PH: 1800 837 395 (1800TEREXL)

26 16C1522A
 8 Spare parts
8.1 How to order spare parts
The Customer must purchase only original spare parts. Removal and refitting
must be performed in accordance to the manufacturer's instructions.

ORDERING SPARE PARTS

When ordering spare parts from Terex Australia Pty. Ltd., always indicate:

 CRANE SERIAL No e.g. 4000

 CRANE MODEL No e.g. AT-20
 WINCH FAMILY e.g. WLR803
 DESCRIPTION e.g. Seal kit
 QUANTITY e.g. 1

Winch spare part information can be found on the Docware electronic

catalogue (CD) included with your crane. If your winch was supplied
individually (i.e. not assembled to a crane) you will need to contact spare parts
for further information.

Enquiries and orders relating to spare parts should be made to:

Spare Parts
585 Curtin Avenue East
Eagle Farm, QLD 4009
P: (07) 3868 9600

16C1522A 27
 [1.69]

420 Mobile Piston Pump

Technical Bulletin ADU041
ADU049
ADU062
Model Codes
420 Mobile Piston Pump

ADU 062 R 08 AB 1 0 A 43 14 00 A 1 AB 1 00 CD 0 A

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31

1 2 3 Pump Series 10 11 Main Ports 15 16Pressure Control 23 24 Auxiliary Rear Mount

ADU – 420 Family Open AA – Rear Ports, 4 Bolt Flange Setting Code 00 – No Rear Mount
Circuit Piston 2” Inlet; 1” Outlet 28 – 206.8-213.7 bar AA – 9T No Coupling Needed
(Code 61) [3000-3100 lbf/in2] AB – SAE A 2 bolt with
4 5 6 Pump Displacement AB – Side Ports, 4 Bolt Flange 43 – 275.8-282.7 bar 11T Coupling
041 – 41.0 cm3/r [2.50 in3/r] 2” Inlet; 1” Outlet [4000-4100 lbf/in2] AC – SAE B 2 bolt with
049 – 49.2 cm3/r [3.00 in3/r] (Code 61) 13T Coupling
17 18Flow Control
062 – 62.3 cm3/r [3.80 in3/r] 25
12 Drain Ports Setting Code Shaft Seal
7 Pump Rotation 1 – .875-14 UNF-2B O-Ring 00 – No Flow Control Setting 0 – No Shaft Seal
R – Right Hand (Clockwise) Port on Top 14 – 12.41-15.17 bar 1 – Polyacrylate (standard)
Right Side Suction; Left 2 – .875-14 UNF-2B O-Ring [180-220 lbf/in2] 2 – Fluorocarbon
Side Pressure Port Port on Bottom 24 – 22.75-25.51 bar 3 – Double Fluorocarbon
L – Left Hand [330-370 lbf/in2] 26 27
(Counter-clockwise) 13 Diagnostic Ports Pump Special
Left Side Suction; Right 0 – No Diagnostic Ports 19 20Secondary Features
Side Pressure Port Pressure Setting 00 – No Special Features
14 Control Type 00 – No Pressure Setting 28 29
8 9 Front Mount and Shaft A – Pressure/Flow Paint
02 – 2 Bolt B with straight Compensator With 21Control Special Features 00 – No Paint
keyed shaft, 25.4mm SAE O-Ring Port 0 – No Special Features CD – Blue Primer
(1.00 in.) dia. B – Pressure/Flow A – Load Sense Bleed 30 Identification
05 – 2 Bolt B with 13T spline Compensator With Metric Down Orifice
shaft, 22.2mm (.88in.) dia. O-Ring Port 0 – Standard
08 – 2 Bolt B with 15T spline C – Pressure 22Displacement Option
shaft, 25.4mm Compensator Only 31 Design Level
1 – Standard Displacement
(1.00 in.) dia. 2 – External Manual A – First Design
Stroke Adjust

Features Pump Performance Data

- SAE B-B, 2 Bolt Mount, - Standard SAE splined DISPLACEMENT 041 049 062
Cradle Swashplate and keyed shaft options (cc/rev) 41.0 49.2 62.3
(in/rev) 2.50 3.00 3.80
- Clockwise and Counter- - End and Side Ports PRESSURE (BAR)
Clockwise rotation in Tube and Flange styles
Continuous 280 280 280
Intermittent 320 320 320
- Pressure Compensator & - Optional diagnostic ports Peak 350 350 350
Pressure/Flow Comp.
SPEED CAPABILITY
pump control types - Alternate Drain Port
locations Rated 2750 2650 2600
Standby 3600 3600 3600
- Auxiliary thru-drive pad Minimum 600 600 600
for multiple pump use
INLET CONDITIONS
(RATED SPEED)
7.4 psig (1.5 bar) 2950 2850 2800
0 psig (1.0 bar) 2750 2650 2600
5" Hg (.85 bar) absolute 2550 2450 2400
DYNAMIC RESPONSE
(MSEC)
Response (off stroke) 25 25 30
Recovery (on stroke) 90 90 100
Load Sense Recovery 100 100 120
STANDBY POWER
LOSS (HP) 4.5 4.5 5
DRY WEIGHT (LBF) 46 46 48

2 EATON Hydraulics 420 Mobile Piston Pump E-PUPI-TB001-E January 2003

 Pump
Installation –
Rear Ported Case Drain Top
122.7
7/8-14 UNF-2B SAE
420 Mobile Piston Pump (M22 X 1.5 Metric Optional) [4.83]
O-Ring Port
(Shown Plugged)

42.9
[1.69]

2X 13.6
ATTENTION: [.54]
Removal of the pressure
adjustment screw cover may
void the warranty on this For compensator
assembly configuration see
26.19 42.88 separate compensator
[1.031] [1.688] installation drawing
Pressure
port -C For shaft configuration
1.00 SAE see separate shaft
4 bolt installation
Suction drawing
split flange port -D
port standard 2.00 SAE 4
pressure bolt split flange
series port standard
(code 61) pressure series
(code 61)

52.37
[2.062] 77.77
[3.062]

101.57±0.02
4X .500-13 UNC-2B [3.999±.001]
41.1
[1.62] 38.1 19.6 MIN 9.4
[8.58]
4X .375-16 UNC-2B [1.50] [.77] [.37]
(M10 X 1.5-6H optional)
14 MIN
[.55]
97.3
[3.83]
119.1
[4.69]
2X Ø14.2 79.2
77.5 [.56] [3.12]
[3.05] (case drain)

73.9
73.8 72.1 [2.91]
[2.91] [2.84]
(case drain)

Case Drain Bottom 7/8-14 UNF-2B SAE

(M22 X 1.5 Metric Optional) [5.75]
O-Ring Port (Shown Plugged)

EATON CORPORATION Hydraulics 420 Mobile Piston Pump E-PUPI-TB001-E January 2003 3
Pump
Installation –
Case Drain Top
Side Ported 7/8-14 UNF-2B SAE
420 Mobile Piston Pump (M22 X 1.5 Metric Optional)
O-Ring Port 122.7
(Shown Plugged) [4.83]

73.8
[2.91] 42.9

74.7
[2.94]

ATTENTION:
Removal of the pressure
adjustment screw cover may 2X 13.7
void the warranty on this [.54]
assembly
Suction For compensator
port -D configuration see
2.00 SAE 4 separate compensator
bolt split installation drawing
flange
port For shaft configuration
standard see separate shaft
pressure installation 119.1
series drawing [4.69]
(code 61) 79.2
[3.12]
(case drain)

77.77
[3.062]
72.1 74.7
2X Ø14.2 [2.84] [2.94]
[.56] (case drain)

[8.59] 146.1
42.88 [5.75]
[1.688]
4X .500-13 UNC-2B
(M12 X 2.5-6H optional)
19.6
[.77] MIN Pressure
port -C
256.2 1.00 SAE
[10.09] 4 bolt
97.3 9.4 split flange
[3.83] [.37] port standard
pressure

(code 61)
71.4
[2.81]
52.37
[2.062]
71.4 [3.999±.001]
[2.81]

240.9
[9.49] [8.34] 26.19
[1.03] 4X .375-16 UNC-2B
Case Drain Bottom 7/8-14 UNF-2B SAE (M10 X 1.5-6H optional)
(M22 X 1.5 Metric Optional) 14
O-Ring Port (Shown Plugged) MIN
[.55]

4 EATON Hydraulics 420 Mobile Piston Pump E-PUPI-TB001-E January 2003

 Pump
Installation –
Thru-drive
SAE A Option Case Drain Top
420 Mobile Piston Pump 7/8-14 UNF-2B
(M22 X 1.5 Metric Optional)
O-Ring Port 122.7

74.7
[2.94]

ATTENTION:
Removal of the pressure adjustment
screw cover may void the warranty
on this assembly
For compensator
configuration see
A separate compensator
Suction installation drawing
Port -D 2.00
SAE 4 Bolt 119.1
Standard [4.69]
Pressure 79.2
Series 2X Ø 14.2
[.56] [3.12]
(Code 61) (case

77.77
[3.062] 72.1
[2.84]
(case drain)

A
42.88 [8.59] For shaft [5.75]
[1.688] configuration
4X .500-13 UNC-2B see separate shaft
(M12 X 1.75-6H optional) installation drawing
19.6 MIN
[.77]
Ø ±0.02
±0.01] .375-16 UNC-2B
7.9 19 MIN
[.31] ]
287.3 Groove to accept
[11.31] 2 X 13.6 9.4 an AS 568A size 042
[.54] [.37] (1/16 X 3-1/4 ID)
O-Ring
3X .375-16
71.4 UNC-2B
[2.81] THRU
106.38
172.7 57 ±0.02 [4.188]
[6.80] ±.001] 86.4
[3.40]
71.4
[2.81]

106.38
1
[4.188]
Case Drain Bottom 97.3 For output shaft
7/8-14 UNF-2B SAE [3.83] configuration see VIEW A-A
(M22 X 1.5 Metric Optional) separate output
O-Ring Port (Shown Plugged) shaft installation drawing

EATON CORPORATION Hydraulics 420 Mobile Piston Pump E-PUPI-TB001-E January 2003 5
Pump
Installation – Case Drain Top
7/8-14 UNF-2B SAE
Thru-drive (M22 X 1.5 Metric Optional)
SAE B Option O-Ring Port 122.7
[4.83]
420 Mobile Piston Pump

74.7
[2.94]

ATTENTION:
Removal of the pressure
adjustment screw cover may
void the warranty on this
assembly

For compensator
A configuration see
Suction port -D separate compensator
2.00 SAE 4 installation drawing
bolt split
flange port 119.1
standard [4.69]
pressure
series
(code 61) 2X Ø14.2 79.2
[.56] [3.12]
(case

77.77
[3.062]
72.1
[2.84]

218.2
A 42.88 [8.59]
For shaft 146.1
[1.688] configuration see [5.75]
4X .500-13 UNC-2B separate shaft
(M12 X 1.75-6H optional) installation
19.6 MIN drawing
[.77]

Ø101.68±0.02
[4.003±.001]
10.4
287.3 [.41]
[11.31] 2X 13.6 9.4
[.37] Groove to accept
an AS 568A size
045 (1/16 X 4 ID)
71.4 O-Ring
[2.81] 4X .500-13
UNC-2B THRU
172.7 ±0.02 146.1
[6.80] 9±.001] [5.75]

71.4 86.4
[2.81] [3.40]

Case Drain Bottom 97.3 For output shaft

7/8-14 UNF-2B SAE [3.83] configuration see 146.1
(M22 X 1.5 Metric Optional) separate output shaft [5.75]
O-Ring Port (Shown Plugged) installation drawing VIEW A-A

6 EATON Hydraulics 420 Mobile Piston Pump E-PUPI-TB001-E January 2003

Pump Control
Installation
420 Mobile Piston Pump

Load Sense Port

7/16-20 UNF-2B SAE
(M14 X 1.5 Metric Optional)
O-Ring Port 74.7
96.6 [2.94]
[3.81]

139.5
122.2 [5.49]
[4.81] 94.5
[3.72]

163.9
[6.45]
229.3 [9.03]
.03]
210 bar [[3000
3000 psi]
or less
251.5 [9.90]
210 bar [3000 psi]
or greater

6.31±.04
[.248 -.002 ]
Shaft Installation Key width

08 Code 05 Code 02 Code 46.0

(1.81)
46.0 41.3
(1.81) (1.62)
(1.12)
3(.12)

+.11
28.16 -.12
[1.108 +.005
-.004 ]

+.007
ø25.393
3-.006
[.9998 +.0002 ]
-.0003

ø 24.912 [.9808] 15 Tooth 30° ø 21.737 [.8558] 13 Tooth 30°

Flat Root Side Fit 16/32 Flat Root Side Fit
Class 5 Spline 16/32 Class 5 Spline per
per ANSI B92.1 (Modified) Fits
Fits 15 Tooth 30° 13 Tooth 30°
Flat Root Side Fit Fit 16/32 Internal Splines per
16/32 Internal Splines SAE J498b Class 1 or
per SAE J498b Class 1 ANSI B92.1 Class 5
or ANSI B92.1 Class 5

EATON Hydraulics 420 Mobile Piston Pump E-PUPI-TB001-E January 2003 7

Eaton Eaton Eaton
14615 Lone Oak Road 20 Rosamond Road 46 New Lane, Havant
Eden Prairie, MN 55344 Footscray Hampshire PO9 2NB
USA Victoria 3011 England
Tel: 952 937-9800 Australia Tel: (44) 23 92 486 451
Fax: 952 974-7722 Tel: (61) 3 9319 8222 Fax: (44) 23 92 487 110
www.hydraulics.eaton.com Fax: (61) 3 9318 5714

© 2003 Eaton Corporation

All Rights Reserved
Printed in USA
Document No. E-PUPI-TB001-E
January 2003