Permco 997-01316 PDF

bypassed to tank (as in the case of pressure
compensated valves that bleed a given amount of ow

continuously throughout the entire work cycle), to now
be directed to the work circuit providing full power to
the hydraulic system. This can translate to over 3.5
horsepower loss to tank for traditional compensated
valves verses Permco's bleed valve.
Control of the system when used in an unloader
system setup is accomplished through the use of one
(1) on/off solenoid valve and one (1) speed sensor.
The closed loop input/output digital controller is
used to open and close the solenoid in response to
varying speeds. A microprocessor converts the speed
sensor output into RPM's and sends a signal to the
one (1) on/off solenoid to change its output based
on user selected set points. The on/off solenoid is a
2-way normally open hydraulic cartridge valve which
controls the opening and closing of the unloader
tank port. When activated 100% of the pump flow
is diverted back to tank at very little pressure.
Genesis Digital Hydraulic
Over-Speed Control System
Permco offers a closed loop digital input/output
hydraulic over-speed control and speed sensor that is
used in conjunction with Permco's VERSA-PAK series
refuse pumps. In refuse applications it is usually
required that the vehicle's hydraulic system be able
to operate while in motion. This creates a problem in
that while the pump delivers the required ow at or
near idle RPM's, the operator would have the ability to
substantially over-speed the hydraulic system (and in
turn the mechanics of the truck) while operating the
vehicle at speeds associated with moving (roading) the
vehicle. Permco's Genesis system over-speed control
eliminates this possibility by shutting the pump inlet
ow off (dry valve system) or unloading discharge
ow to tank (unloader system) when a predetermined
over-speed setting is reached, protecting the hydraulic
system, the mechanics of the truck and the pump.
Control of the system when used in a dry valve
system setup is accomplished through the use of two
(2) on/off solenoid valves and one (1) speed sensor.
The closed loop input/output digital controller is
used to open and close these valves in response
to varying speeds. A microprocessor converts the
signal from the speed sensor into RPM's and sends a
signal to the two (2) on/off solenoid valves to change
their output based on user selected set points. One
(1) of the valves is an electric/air, which controls
the opening and closing of the dry valve; the second
valve is a 2-way normally open hydraulic cartridge
valve which controls the opening and closing of
the bleed valve tank port. The solenoid bleed
valve gives the dry valve lubrication flow a direct,
unrestricted path to the hydraulic tank. Unlike other
manufacturer's bleed valves that provide a similar
function, the Permco design is the only one available
that is integral to the pump itself and provides a
positive closure (shutoff) when the pump is told to do
work. This design allows all flow that would have
The speed sensor which threads directly into the gear
housing (provided by Permco) is an active Hall Effect
type, each time a gear tooth passes in front of the
sensor the output changes state generating a steady
pulse train of frequency proportional to target speed,
this pulse train of frequency is read by the digital
controllers microprocessor and converted to RPM's,
when the selected set points RPM's are reached
a signal is sent to the corresponding solenoids to
open or close. This speed sensor has full pressure
capabilities unlike other units on the market. This
minimizes any problems should it see pressure
spikes from the system.
Reliability has been addressed on several levels.
1. First of all, Permco warrants their pumps and
motors for two full years. Dependability is
a very high priority for Permco. We strive to
make it right the rst time.
Efficiency is another aspect about which Permco
is concerned. With the hundreds of thousands
refuse vehicles operating daily, each vehicle must be
running at capacity and at as low of a maintenance
cost as possible. With this new Permco Genesis
system, we have documentation showing increased
productivity and fuel savings over the common
unloader systems.
Because we are controlling the hydraulic system, we
can give the operator hydraulic ow and pressure at
the appropriate time and at the appropriate rate. By
closely controlling the hydraulic system, issues such
as heat and ow saturation of the system are virtually
eliminated.
Gear pumps are an efcient and cost effective means
to supply the required gallons per minute/pressure
for this industrys hydraulic requirements. Other more
expensive pumps are not as tolerant of conditions
that exist in the refuse market. Replacement and
downtimes are minimized because of reliability,
availability, and simplicity of design.
The controller interfaces with a PC
using RS232 communications for conguration of
the module. Windows HyperTerminal can be used to
set or change the RPM ranges from their default
setti ngs; uni t is shipped with complete wiring
harness set.
solenoids controlling the air to the dry valves
go into the dry mode, the corresponding
electric/hydraulic solenoids open, ensuring
a direct path for the fluid back to tank.
Permco
1500 Frost Rd.
P. O. Box 2068
Streetsboro, OH 44241
Phone 330-626-2801
Fax 330-626-2805
e-mail info@permco.com
www.permco.com
that eliminate the possibility of contamination
getting into the front outboard bearing. This
front outboard bearing seal extends the life
of the bearing, but, at the same time, we
also know that contamination getting to that
bearing often shortens the life of the pump.
Rather than eliminating the outboard bearing
as other suppliers have done, we leave the
bearing in to maintain stability but we
protect it to eliminate premature failure.
4. Running hot and cavitation are often
associated with dry valve systems. We have
eliminated these by establishing a positive
bleed valve system eliminating the possibility
of pressure on the discharge side of the
pump in the dry mode. When the electric/air
2. 100% of Permco pumps are factory tested to
eliminate even the possibility of an occasional
problem.
3. Permco uses front outboard bearing seals
The digital controller is a compact
IP67 rated package with plug-
i n connecti ons for remote
mounting. Power supply is 12
or 24 VDC with reverse polarity,
transient surge and over-current
protection provided.

Both the dry valve system and the unloader system
can incorporate Permco's VERSA-PAK pressure
compensated ow control valve, this allows a preset
amount of flow to the hydraulic system with the
excess ow being returned to the suction side (dry
valve system) or returned to tank (unloader system);
this function protects the system's main relief valve
from being ooded so it can better accomplish its
function of controlling system pressure and reduces
the possibility of cavitating the pump at high RPM's (dry
valve system). Because the system never exceeds the
correct ow, it doesn't have the consequential pressure
spikes resulting in cylinder and component failure.
You have a choice. Make it PERMCO.
The Genesis Fuel Saving Systems are tandem (two
pumping sections) P7600 dry valve pumps. The
displacement of the two sections is dependant upon
the desired controlled engine speed and the necessary
GPMs required for proper cycle times. Generally,
for a commercial front loader, for instance,
the requirements are in the 45-60 GPM
range. With a front or rear loader, it
is usually required that the vehicle
be able to operate while in motion.
This creates a problem in that while
delivering the required GPMs at or near
idle RPMs, the operator would have the
ability to substantially over-speed the hydraulic
system (and in turn the mechanics of the truck)
while operating the vehicle at RPMs associated with
moving (roading) the vehicle. Permcos Genesis system
essentially eliminates this possibility by controlling
both sections of the pumping group independently.
Both sections of the pump are controlled independently
by an electronic speed sensor with different speed
settings for each pumping section. At idle speed (600-
850 RPMs) both pumping sections are in the wet
mode, which means that maximum uid is available
to the hydraulic system. At any time the engine RPM
is increased above the 1
st
speed switch setting
(approximately 650 RPMs) the front pumping section
of the pump goes into the dry mode (no uid output).
The back section of the pump is still operational (wet
mode) until the engine reaches the 2
nd
speed switch
setting (approximately 1200 RPMs) when it then also
goes into the dry mode. When the engine then reaches
a speed below approximately 1100 RPMs the back
pumping section returns to the wet mode. When the
engine RPM reaches the setting of the front section
it then returns to the wet mode. At this point both
pumping sections are back into the wet mode.
Control of the system is accomplished through the use
of four (4) on/off solenoids and one (1) speed sensor.
A closed loop input/output digital controller is used to
open and close the solenoids in response to varying
speeds. A microprocessor converts the speed sensor
input teeth/seconds into RPM's and sends a signal
to the four (4) on/off solenoid valves to vary their
output based on user selected set points. Two (2) of
the solenoids are electric/air, which control the dry
valves. The other two (2) solenoids are used as bleed
valves and are independently mounted in the bearing
carrier and port end cover on the discharge side of
the pump. There is a check valve internal to the pump
which allows the front pumping section to combine
with the rear pumping section when both pumping
sections are in the wet mode and/or segregate the
front pumping section when that pumping section is
in the dry mode.
Genesis Pump System
Genesis Pump System:
Low RPM / Fuel $avings
There are many ways that the Genesis fuel saving
system can be tailored to t you system and at the
same time it is reliable, efcient, and one that has
been proven to save fuel.
Reliability has been addressed on several levels.
1.
Permco warrants all their pumps and motors
for a full two years.

Dependability is a very
high priority for Permco. We strive to make it
right the first time.
2. 100% of Permco pumps are factory tested to
eliminate even the possibility of an occasional
problem.
Efficiency is another aspect about which Permco
is concerned. With the hundreds of thousands
refuse vehicles operating daily, each vehicle must
be running at capacity and at as low maintenance
cost as possible. With this new Permco Genesis
system, we have documentation showing increased
productivity and fuel savings over the common
Unloader systems.
Because we are controlling the hydraulic system,
we can give the operator hydraulic operations at
the appropriate time and at the appropriate rate. By
closely controlling the hydraulic system, issues such
as heat and ow saturation of the system are virtually
eliminated.
Gear pumps are an efcient and cost effective means
to supply the required gallons per minute/pressure
for this industrys hydraulic requirements. Other more
expensive pumps are not as tolerant of conditions
that exist in the refuse market. Replacement and
downtimes are minimized because of reliability,
availability, and simplicity of design.
Fuel savings, probably the most important
consideration, will more easily be accomplished
through the use of a dry valve system than other
systems. Permcos Genesis units are currently saving
several gallons of fuel per day over the supplied
unloading systems and other low RPM systems
based on more sophisticated hydraulic components.
Although a tandem dry valve system is the standard
setup system, we can customize your system for
specic needs. A combination dry valve/unloader
system which incorporates a ow control can also
be used. The system can also be setup so that the
pack cycle is completed before a pump or pumping
section is kicked out due to speed settings. Also, the
system can be designed so that only one (1) pumping
section is activated for low ow requirements such as
top doors and tailgates.
The controller interfaces with a PC using
RS232 communications for configuration of the
module. Windows HyperTerminal or Palm OS can
be used to set or change the RPM ranges from their
default settings.
The digital controller is a compact
IP67 rated packaging with plug-
in connections for remote
mounting. Power supply is 12
or 24 VDC with reverse polarity,
transient surge and over-current
protection provided.
Permco
1500 Frost Rd.
P. O. Box 2068
Phone 330-626-2801
Fax 330-626-2805
e-mail info@permco.com
www.permco.com
time, we also know that contamination getting
to that bearing often shortens the life of the
pump. Rather than eliminating the outboard
bearing as other suppliers have done, we
leave the bearing in to maintain stability but
we protect it to eliminate premature failure.
4. Running hot and cavitation are often
associated with dry valve systems. We have
eliminated these by establishing a positive
bleed valve system eliminating the possibility
of pressure on the discharge side of the
pump in the dry mode. When the electric/air
solenoids controlling the air to the dry valves
go into the dry mode, the corresponding
electric/hydraulic solenoids open, ensuring
a direct path for the uid back to tank.
3. Permco uses a front outboard bearing
seal that eliminates the possibility of
contamination getting into the front outboard
bearing. This front outboard bearing seal
extends the life of the pump, but, at the same
Over-Speed Kickout Settings

Single Unloader System

In a Permco Single Unloader System only the D solenoid lead wire is used;
D lead wire is connected to the DC operated 2-way normally open on/off hydraulic cartridge valve that
controls the opening and closing of the unloader tank port.

Under normal operating conditions the operator will engage the pump switch at normal engine idle speed
(600-700 RPM); D solenoid will receive current and close the tank port sending pump flow to the
hydraulic circuit; when the engine RPMs are increased to the 1400 RPM default (D off) setting, D
solenoid will lose current and open the unloader tank port sending pump flow to tank; when the engine
RPMs decrease to the 1000 RPM default (D on) setting, D solenoid will receive current and close the
tank port sending pump flow to the hydraulic circuit.

Simple terminology using default settings is D on at normal engine idle speed (600-700 RPM); D off at
1400 RPM and D back on at 1000 RPM

Speed setting ranges for D solenoid:
D on 800 to 1500 RPM Default Setting 1000 RPM
D off 850 to 2000 RPM Default Setting 1400 RPM

*Specific speed settings can be programmed before shipping.

Single Dry Valve System

In a Permco Single Dry Valve System C and D solenoid lead wires are used;
C lead wire is connected to the DC operated normally open on/off electric/air solenoid that controls the
opening and closing of the dry valve.
controls the opening and closing of the bleed valve tank port.
Both C and D work in conjunction with each other and have the same speed settings.

(600-700 RPM); C and D solenoids will receive current, the dry valve will open and the bleed tank port
will close sending pump flow to the hydraulic circuit; when the engine RPMs are increased to the 1400
RPM default (C and D off) setting, C and D solenoids will lose current closing the dry valve and
opening the bleed valve tank port restricting pump flow to the hydraulic circuit; when the engine RPMs
decrease to the 1000 RPM default (C and D on) setting, C and D solenoids will receive current
opening the dry valve and closing the bleed valve tank port sending pump flow to the hydraulic circuit.

Simple terminology using default settings is C and D on at normal engine idle speed (600-700 RPM);
C and D off at 1400 RPM and C and D back on at 1000 RPM.

Speed setting ranges for C and D solenoid:
C and D on 800 to 1500 RPM Default Setting 1000 RPM
C and D off 850 to 2000 RPM Default Setting 1400 RPM

* Specific speed settings can be programmed before shipping.


Tandem Dry Valve System

In a Permco Tandem Dry Valve System A, B, C and D solenoid lead wires are used;
A lead wire is connected to the DC operated normally open on/off electric/air solenoid that controls the
opening and closing of the dry valve for the front pumping section.
B lead wire is connected to the DC operated 2-way normally open on/off hydraulic cartridge valve that
controls the opening and closing of the bleed valve tank port for the front pumping section.
Both A and B work in conjunction with each other and will have the same speed settings.
C lead wire is connected to the DC operated normally open on/off electric/air solenoid that controls the
opening and closing of the dry valve for the rear pumping section.
controls the opening and closing of the bleed valve tank port for the rear pumping section.
Both C and D work in conjunction with each other and will have the same speed settings.

An internal check valve allows combined or segregated flow between the two (2) pumping sections.

(600-700 RPM); A, B, C and D solenoids will receive current, both dry valves will open and both
bleed tank ports will close sending combined pump flow to the hydraulic circuit (internal check valve open);
when the engine RPMs are increased to the 750 RPM default (A and B off Y0) setting, A and B
solenoids will lose current closing the dry valve and opening the bleed valve tank port restricting front
pumping section flow to the hydraulic circuit (internal check valve closed); the rear pumping section is still
on line at this point; when the engine RPMs are increased to the 1400 RPM default (C and D off) setting,
C and D solenoids will lose current closing the dry valve and opening the bleed valve tank port
restricting rear pumping section flow to the hydraulic circuit; both the front and rear pumping sections are
off line at this point; when the engine RPMs decrease to the 1000 RPM default (C and D on) setting,
C and D solenoids will receive current opening the dry valve and closing the bleed valve tank port
sending flow to the hydraulic circuit (internal check valve closed); the rear pumping section is back on line
at this point; when the engine RPMs decrease to the 700 RPM default (A and B on Y1) setting, A and
B solenoids will receive current opening the dry valve and closing the bleed valve tank port sending
combined pump flow to the hydraulic circuit (internal check valve open); both the front and rear pumping
sections are back on line at this point.

An added pumping section kick-out setting safety feature to prevent engine stall is built into the speed
controller where under normal operating conditions (A, B, C and D on) should the engine experience a stall
situation where the engine RPMs fall below the 400 RPM default (A and B off XO) setting, A and B
on line at this point; when the engine RPMs increase to the 600 RPM default (A and B on X1) setting,
A and B solenoids will receive current opening the dry valve and closing the bleed valve tank port
sending combined pumping section flow to the hydraulic circuit (internal check valve open); both the front
and rear pumping sections are back on line at this point.

Simple terminology using default settings is A, B, C and D on at normal engine idle speed (600-
700 RPM); A and B off at 750 RPM; A and B back on at 700 RPM; C and D off at 1400 RPM;
C and D back on at 1000 RPM; engine stall setting of A and B off at 400 RPM and A and B
back on at 600 RPM.

Speed setting ranges for A, B, C and D solenoid:
A and B off X0 (engine stall) 350 to 650 RPM Default Setting 400 RPM
A and B on X1 (engine stall) X0 + 50 to X0 + 200 RPM Default Setting 600 RPM
A and B off Y0 Y1 200 RPM to Y1 50 RPM Default Setting 750 RPM
A and B on Y1 750 to 1100 RPM Default Setting 700 RPM
C and D off 850 to 2000 RPM Default Setting 1400 RPM
C and D on 800 to 1500 RPM Default Setting 1000 RPM



Tandem Dry Valve/Unloader

In a Permco Tandem Dry Valve/Unloader System A, B and D solenoid lead wires are used;
A lead wire is connected to the DC operated normally open on/off electric/air solenoid that controls the
opening and closing of the dry valve for the front pumping section.
B lead wire is connected to the DC operated 2-way normally open on/off hydraulic cartridge valve that
controls the opening and closing of the bleed valve tank port for the front pumping section.
Both A and B work in conjunction with each other and will have the same speed settings.
controls the opening and closing of the unloader tank port for the rear pumping section.

An internal check valve allows combined or segregated flow between the two (2) pumping sections.

(600-700 RPM); A, B and D solenoids will receive current, the dry valve will open and the bleed tank
port will close on the front pumping section and the unloader tank port will close on the rear pumping
section sending combined pump flow to the hydraulic circuit (internal check valve open); when the engine
RPMs are increased to the 750 RPM default (A and B off Y0) setting, A and B solenoids will lose
current closing the dry valve and opening the bleed valve tank port restricting front pumping section flow to
the hydraulic circuit (internal check valve closed); the rear pumping section is still on line at this point;
when the engine RPMs are increased to the 1400 RPM default ( D off) setting, D solenoid will lose
current opening the unloader tank port sending pump flow to tank; both the front and rear pumping
sections are off line at this point; when the engine RPMs decrease to the 1000 RPM default (D on)
setting, D solenoid will receive current closing the unloader valve tank port sending pump flow to the
hydraulic circuit (internal check valve closed); the rear pumping section is back on line at this point; when
the engine RPMs decrease to the 700 RPM default (A and B on Y1) setting, A and B solenoids will
receive current opening the dry valve and closing the bleed valve tank port sending combined pump flow to
the hydraulic circuit (internal check valve open); both the front and rear pumping sections are back on line
at this point.

An added pumping section kick-out setting safety feature to prevent engine stall is built into the speed
controller where under normal operating conditions (A, B, and D on) should the engine experience a stall
situation where the engine RPMs fall below the 400 RPM default (A and B off XO) setting, A and B
on line at this point; when the engine RPMs increase to the 600 RPM default (A and B on X1) setting,
A and B solenoids will receive current opening the dry valve and closing the bleed valve tank port
sending combined pump flow to the hydraulic circuit (internal check valve open); both the front and rear
pumping sections are back on line at this point.

Simple terminology using default settings is A, B and D on at normal engine idle speed (600-700
RPM); A and B off at 750 RPM; A and B back on at 700 RPM; D off at 1400 RPM; D back on
at 1000 RPM; engine stall setting of A and B off at 400 RPM and A and B back on at 600 RPM.

Speed setting ranges for A, B, C and D solenoid:
A and B off X0 (engine stall) 350 to 650 RPM Default Setting 400 RPM
A and B on X1 (engine stall) X0 + 50 to X0 + 200 RPM Default Setting 600 RPM
A and B off Y0 Y1 200 RPM to Y1 50 RPM Default Setting 750 RPM
A and B on Y1 750 to 1100 RPM Default Setting 700 RPM
D off 850 to 2000 RPM Default Setting 1400 RPM
D on 800 to 1500 RPM Default Setting 1000 RPM

SINGLE UNLOADER
Refuse Pump System with Speed Sensor
Electrical Installation Diagram (12-24 VDC)
W
h
i
t
e
B
l
a
c
k
R
e
d
W
h
i
t
e
B
l
a
c
k
/
W
h
i
t
e
R
e
d
/
W
h
i
t
e
O
r
a
n
g
e
/
W
h
i
t
e
G
r
e
e
n
/
W
h
i
t
e
(
n
o
t

u
s
e
d
)
R
e
d
B
la
c
k
R
e
d
B
l
a
c
k
G
r
a
y
B
l
a
c
k
(
n
o
t

u
s
e
d
)
Solenoid B (not used)
Solenoid A (not used)
Solenoid C (not used)
D
Unl oader
Sol enoi d
9
9
7
-0
1
2
3
8
B
O
X
8
1
2 3 4
5
6
7 9
10
11
12
13
14
15
16
17
18
19
7
8
3
4
4
6
20
16
+
_
Battery
7
+
tery
8
1500 Frost Road
Streetsboro, OH. 44241
Phone: (330) 626-2801
Fax: (330) 626-2805
RS- 232
9
1
9
0
8
21
21
21
3 4 333333 222
a
y
5
a
y
B
l
a
c
k
R
e
d

+

B
l
a
c
k

-
S
e
n
s
o
r
Red
Black
Not Included in Standard
Wiring Harness
Included in Optional
Programming Harness
(997-01238WH-P)
Sensitivity of Electronic Components Require Direct Battery Post Connections
Proper Crimping Tools and/or Soldering Required for Troublefree Connections
Loss of Connection on any Circuit will Shut the System Down
Red
Red
(Secure and seal all unused wire ends to prevent short curcuit)
(999-00948)
(997-01237)
Speed Controller & Harness Set
(997-01238)
Speed Controller Only
(997-01238BOX)
Black & Gray Harness Only
(997-01238WH)
Single Unloader Switch Kit # 999-01407
(Includes Items # 2-4, 6-19 & 21)
Speed Sensor
Regulated Flow
to System
Pump Inlet
(see pump specifications)
Discharge Port
Tank Port, Use 1-1/4" Split Flange
(code 61)
T1 Port, Solenoid Drain 3/8" NPTF (Plumb to Inlet
side of Port End Cover of Pump with 999-00946
Solenoid Drain Hose Kit, not shown)
G
Gauge Port 1/4" NPTF
(plugged)
SINGLE UNLOADER
Single Unloader Valve Installation Diagram
1-1/4" Split Flange (code 61)
and O'ring not included
R
otatio
n
GPM Orifice Plug installed here
(see VERSA-PAK model number
construction for flow settings)
G
Gauge Port
Use 1-1/4" Split flange port to
return excess and unloaded
flow back to tank. Use no
smaller than an 1-1/4" hose.
Returning flow through the
filter is optional.
T1 port (3/8" NPTF) is
plumbed to the 3/8"
ODT port on suction
side of the port end
cover on the Versa-Pak
pump with Solenoid
Drain Hose Assembly
number 999-00946.
T1
Versa-Pak Solenoid installed here.
Do not overtighten. 5 ft. lb. max
Part Number 999-00948.
Logic Element
1500 Frost Road
Phone: (330) 626-2801
Fax: (330) 626-2805
The Versa- Pak Valve may be installed in this manner with the solenoid and/or logic element pointing down or with the
solenoid and/or logic element pointing up. With the solenoid and/or logic element pointing down the return/tank port will
be oriented toward the rear of the vehicle. With the solenoid and/or logic element pointing up the return/tank port will be
oriented toward the front of the vehicle.
1
22
22
23
24
25
23
Speed Sensor 20
(see VERSA-PAK model
number construction for
flow settings)
CCW
Counter-Clockwise Rotation Shown
Items # 1 & 22 thru 25 included with
VERSA-PAK valve if ordered as kit
(Ex: VP100-U45XH2)
Versa-Pak Pump Model Number Construction
VP42 - 4C 0 F L UL (SS)
Pump Model (VP+GPM @ 1200 RPM)
VP28
VP32
VP37
VP42
VP47
Mounting Flange
4B Four Bolt B
2C Two Bolt C
4C Four Bolt C
Shaft
0 1 1/4 C Keyed
6 1 1/4 C Spline
Speed Sensor Machining
Rotation
L Left, CCW
R Right, CW
Function
UL Unloader
Ports
VP28, VP32
1 1/2 X 1 1/4 Split
Flange
VP37, VP42, VP47
2 X 1 1/4 Split Flange
Versa-Pak Valve Model Number Construction
VP100 - U 45 X H2
Valve Model
VP100
Unloader
U Unloader Installed
K Kit Only (Non-Functional - Does not include
Solenoid, Solenoid Plug, T1 Port Plug, or
Regulated Flow Orifice)
Flow Control Setting (GPM)
BL = No Orifice
30, 35, 40, 45, 50,
55, 60, 65, 70, 75, 80
Hose Kit
H2 Solenoid Drain Hose Kit
3/8 (Use with Unloader)
X1 No Hose Kit Included
Switch Kit
X No Switch Kit Included
(order Switch Kit #
999-01407 separately
for digital system)
Versa-Pak Pump Specifications
Model Displ. Max. Min. Max. Inlet Port Discharge Port
Number Cu. In. RPM RPM PSI SAE 4 Bolt SAE 4 Bolt
VP28 6.066 3000 600 3000 1-1/2 1 1/4"
VP32 7.077 3000 600 3000 1-1/2 1 1/4"
VP37 8.088 3000 600 2500 2 1 1/4"
VP42 9.099 2500 600 2500 2 1 1/4"
VP47 10.110 2500 600 2250 2 1 1/4"
1500 Frost Rd
Phone: (330) 626-2801
Fax: (330) 626-2805
Example of System Component Requirements
1500 Frost Rd
Phone: (330) 626-2801
Fax: (330) 626-2805
Single Unloader Wiring Instructions

42 GPM @ 1200 RPM VP42-4C0FLUL(SS) Pump 42 GPM @ 1200 RPM (With Speed Sensor Machining) CCW Rotation 1
1400 RPM Over-Speed Setting 997-01238 Speed Controller & Harness Set (1400 RPM Over-Speed Kick-Out Setting) (Item # 5) 1
45 GPM Flow Control VP100-U45XH2 VERSA-PAK Valve (45 GPM Flow Control + Unloader Solenoid + Drain Hose) (Includes Items # 1 & 22 thru 25) 1
Switch Kit 999-01407 Single Unloader Switch Kit (Includes Items # 2 thru 4, 6 thru 19 & 21) 1
997-01237 Speed Sensor P7500 Series (Item # 20) 1
System Requirements Required Description Qty,
Components Req'd
The speed sensor (20) is threaded into the pump gear
housing. Torque speed sensor to 8 lb. ft. Run sensor wires,
cut wires to length, allow slack for tie-down. Insert speed
sensor wire colors white, black/white and red/white
(green/white and orange/white are not used) through cable
seals (4), crimp female inserts (17) onto each wire end
(because the speed sensor has 24 gauge wire it is
necessary to double fold the wire ends before crimping),
place in order into shroud assembly (18), push in cable
seals (4), snap cover closed.
(Light is on when switch is engaged indicating power is being
supplied to the system)
42 GPM @ 1200 RPM VP42-4C0FLUL(SS) Pump 42 GPM @ 1200 RPM (With Speed Sensor Machining) CCW Rotation 1
1500 RPM Over-Speed Setting 997-01238 Speed Controller & Harness Set (must note 1500 RPM Over-Speed Kick-Out Setting when ordering) (Item # 5) 1
Switch Kit 999-01407 Single Unloader Switch Kit (Includes Items # 2 thru 4, 6 thru 19, & 21) 1
VP100-UBLXH2 VERSA-PAK Valve (Unloader Solenoid + Drain Hose) (Includes Items # 1 & 22 thru 25) 1
* Specific speed settings can be programmed before shipping, please note when ordering
The switch (15) can be mounted in the dashboard via a
knock-out or mounted to the base of the dashboard
utilizing the dash bracket (12). Mount the dash bracket
(12) utilizing the two (2) 10-24 x " self tapping screws
(11). Peel the backing from the self adhesive nameplate
(13) and place onto the face of the dash bracket (12). Put
the switch guard (14) over the switch (15) and place inside
the opening of the dash bracket (12), support the back of
the dash bracket (12) and push the switch assembly in,
making sure the plastic tabs are securely locked in place.
Run power supply harness wires, cut wires to length, allow
slack for tie-down. Crimp ring terminal (7) onto end of
ground wire (21), attach to ground post of battery, combine
crimp blade terminal (16) onto opposite end of ground wire
and black harness wire (labeled -) and connect to top right
spade terminal on rocker switch (15). Crimp blade terminal
(16) onto end of red harness wire (labeled+) and connect
to bottom left spade terminal on rocker switch (15). Crimp
blade terminal (16) onto end of 12 VDC supply wire (21)
and connect to middle spade terminal on rocker switch
(15), butt splice (8) onto end of fuse wire assembly (9),
butt splice (8) an extension wire (21) to the opposite end
of fuse wire assembly (9), crimp ring terminal (7) onto end
of extension wire (21), attach to positive post of battery,
insert 10 amp fuse (10).
Insert sensor wires (labeled Sensor) through cable seals
(4), crimp male inserts (3) onto each wire end, place in
order into tower assembly (19) (make sure like colors will
mate with like colors in shroud assembly (18)), push in
cable seals (4), snap cover closed, connect shroud and
tower together.
The speed controller black box (5) should be mounted
inside the cab in a protected area. Two (2) 3/8-14 x 1" self
tapping screws (6) w/washer and seal are supplied for
mounting. Insert wiring harness (color coded), run wires to
predetermined locations.
The RS-232 connector programming cable is optional; it is
utilized to hook to a lap top computer for setting speed
control settings and/or troubleshooting. Default settings
are preset to D on at engine idle, D off at 1400 RPM, and
D back on at 1000 RPM. Specific kick-out speed settings
can be programmed before shipping.
D Solenoid (1) is mounted in the Versa-Pak Unloader Valve.
Solenoid comes with shroud (male) assembly fully
attached. Torque Solenoid to 25 lb. ft., and Solenoid Nut to
5 lb. ft. Run solenoid wires, cut wires to length, allow slack
for tie-down. Insert harness cable wires (labeled SOL D)
through cable seals (4), crimp male inserts (3) onto each
wire end, place into tower assembly (2), (placement of red
and black lead wires does not matter, solenoid is not
polarity sensitive), push in cable seals (4), snap cover
closed, connect shroud and tower together.
Single Unloader Switch Kit Components

1500 Frost Rd
Phone: (330) 626-2801
Fax: (330) 626-2805
Item Part Number Description Qty.
No. Req'd
No. Req'd
Switch Kit Part Number 999-01407
2 999-00937 Weather Pack 2 Pin Tower Assembly (Male) 1
3 999-00939 Weather Pack Pins (Male) 5
4 999-00937CS 16G Weather Pack Cable Seals 8
6 900-01271 1/4-14 x 1 Self Tapping Screw W/Washer 2
7 999-00926 18-14G Ring Terminal 2
8 999-00927 16-14G Butt Splice 2
9 999-00928 16 Guage Fuse Holder 1
10 999-00929 10 Amp Fuse 1
11 900-01270 10-18 x 1/2" Self Tapping Screw W/Washer 2
12 999-00932 Switch Bracket 1
13 999-00931 Self Adhesive Face Plate 1
14 999-00933 Switch Guard 1
15 999-00934 Rocker Switch W/Light 1
16 999-00935 Female Blade Terminal 3
17 999-00938 Weather Pack Pins (Female) 3
18 999-00940 Weather Pack 3 Pin Shroud Assembly (Female) 1
21 999-00925-30 30' 16 Gauge Wire (cut to required lengths) 1
SINGLE DRY VALVE
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Solenoid B (not used)
Solenoid A (not used)
C
D
Bl eed
Sol enoi d
9
9
7
-0
1
2
3
8
B
O
X
1 2 3 4
9
10 11 12 13
14
15
16
3
+
_
Battery
11
+
ery
1500 Frost Road
Phone: (330) 626-2801
Fax: (330) 626-2805
RS-232
13
1
3
14
C
Dr y
Val ve
Sol
9
C
Dr y
Val ve
5 6
7
2
2 2 3 4 5 6
8
8
10
11
11
12
17
18
19
20
20
2
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21
22
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Red
Black
Red
Black
Wiring Harness
Programming Harness
(997-01238WH-P)
Red
Red
Red
Red
(997-01238)
(997-01238BOX)
(997-01238WH)
(997-01237)
(999-01148)
(514-00914)
Solenoid D (not used with DVBP Bleed
Valve Port End Cover)
Single Dry Valve Switch Kit # 999-01406
(Includes Items # 2-6, 8-22 & 24-33)
Speed Sensor
G
Air
Tank
SINGLE DRY VALVE
Single Dry Valve Installation Diagram
Vent
R
otation
DVBP = Mechanical Bleed Valve
Bleed port, 3/8" NPT threads,
plumb directly to tank with
minimum 3/8" medium pressure
hydraulic hose, (not included).
Suction Side
Gauge Port
#6, 3/8" O'ring
VCS = Solenoid Side
Bleed Port Rear
VCR = Solenoid Rear
Bleed Port Side
#6 3/8" O'ring Bleed Port,
plumb directly to tank above
fluid level with minimum 3/8"
medium pressure hydraulic
hose, (not included).
1500 Frost Road
Phone: (330) 626-2801
Fax: (330) 626-2805
Speed Sensor
24
25
26
27
28
29 30
31
32
33
34
35
36
37
39
15
9
23
24
24
25
27
27 22
28
15
28
15
33
24 25
25 34
35
Versa-Pak Flow Control
(see Versa-Pak model number
(omit if using dry valve only)
Regulated Flow to System
Discharge Port
Gauge Port 1/4" NPTF
(plugged)
Inlet Port
1-1/4" Split Flange Fitting
(code 61) and O'ring
(not included)
Tank Port, Use 1" NPTF (Plumb to 3/4" NPT
port on back of Dry Valve with 999-00945
Excess Flow Hose Assembly, not shown)
W/Optional Versa-Pak Flow Control
Nut
Ferrule
Tube Insert
Threaded Base
Compression Fitting
25
24
4 24 24 4 24 24 4 24
32 32
9
24
55
31
26
2
225 2
27
25 25
26
288
15
D
1
CCW
Solenoid Sold Separately
(999-01148)
Single Dry Valve Switch Kit # 999-01406
(Includes Items # 2-6, 8-22 & 24-33)
Items # 1 & 34 thru 37 included
with VERSA-PAK valve if ordered
as kit. (Ex: VP100-C45XH1)
Single Dry Valve Installation Diagram (con't)
The Versa-Pak Valve may be installed in this manner with the logic element pointing down or with the logic element
pointing up. With the logic element pointing down the return/tank port will be oriented toward the rear of the vehicle.
With the logic element pointing up the return/tank port will be oriented toward the front of the vehicle.

Gauge Port
GPM Orifice Plug installed here.
Solenoid Plug installed here.
T1
T1 Plug (3/8" NPTF)
installed here.
Use 1" NPTF port to return excess
flow back to inlet side of hydraulic
system. Use Excess Flow Hose
Assembly number 999-00945
installed from here to the 3/4"
NPT port located in the Dry Valve
assembly.
G
Logic Element
Dry Valve Part Numbers
1500 Frost Rd
Phone: (330) 626-2801
Fax: (330) 626-2805
No. Req'd
No. Req'd
39 514-00911-DVA 1-1/2" Dry Valve Assembly (includes mounting bolts) 1 39 514-00278-DVA 2" Dry Valve Assembly (includes mounting bolts) 1
Components Req'd
42 GPM @ 1200 RPM Solenoid Side VP42-4C0FLDV(SS)VCS Pump 42 GPM @ 1200 RPM (With Speed Sensor Machining & Solenoid Location Side) 1
2" Dry Valve 514-00278-DVA 2" Dry Valve (Item 39) (mounting hardware included) 1
Switch Kit 999-01406 Single Dry Valve Switch Kit (Includes Items # 2 thru 6, 8 thru 22, & 24 thru 33) 1
999-01148 Bleed Solenoid (Item # 1) 1
Example of System Component Requirements
42 GPM @ 1200 RPM Solenoid Rear VP42-4C0FLDV(SS)VCR Pump 42 GPM @ 1200 RPM (With Speed Sensor Machining & Solenoid Location Side) 1
1500 RPM Over-Speed Setting 997-01238 Speed Controller & Harness Set (must note 1500 RPM Over-Speed Kick-Out Setting when ordering) (Item # 5) 1
45 GPM Flow Control VP100-C45XH1 VERSA-PAK Valve (45 GPM Flow Control + Excess Flow Hose Kit) (Includes Items # 34 thru 37) 1
2" Dry Valve 514-00278-DVA 2" Dry Valve (Item 39) (Mounting Hardware Included) 1
Switch Kit 999-01406 Single Dry Valve Switch Kit (Includes Items # 2 thru 6, 8 thru 22, & 24 thru 33) 1
42 GPM @ 1200 RPM DVBP VP42-4C0FLDV(SS) Pump 42 GPM @ 1200 RPM (With Speed Sensor Machining & DVBP Mechanical Bleed Valve) 1
2" Dry Valve 514-00278-DVA 2" Dry Valve (Item 39) (mounting hardware included) 1
No Switch Kit 997-01237 Speed Sensor P7500 Series (Item # 23) 1
514-00914 12 VDC Electric/Air Solenoid (used to open and close dry valve) (Item # 9) 1
931-00915 Electric/Air Solenoid Bracket (Item # 26) 1
900-00940 #10-32 x 7/16" Machine Screws (for mounting solenoid bracket to solenoid) (Item # 27) 2
900-00943 #10 Star Washer (for mounting solenoid bracket to solenoid) (Item # 28) 2
514-00559-DVBV Bronze Air Vent (for E/A solenoid vent) (Item # 32) 1
Versa-Pak Pump Model Number Construction
VP42 - 4C 0 F L DV (SS) VCS
Pump Model (VP+GPM @ 1200 RPM)
VP28
VP32
VP37
VP42
VP47
Mounting Flange
4B Four Bolt B
2C Two Bolt C
4C Four Bolt C
Shaft
0 1 1/4 C Keyed
6 1 1/4 C Spline
Speed Sensor Machining
L Left, CCW
R Right, CW
Function
DV Dry Valve

VP28, VP32
1 1/2 X 1 1/4 Split Flange
VP37, VP42, VP47
2 X 1 1/4 Split Flange
VP100 - C 45 X H1
Valve Model
VP100
Unloader
C Flow Control
BL = No Orifice
30, 35, 40, 45, 50,
55, 60, 65, 70, 75, 80
Hose Kit
H1 Excess Flow Hose Kit
3/4" (Use with Dry Valve)
Switch Kit
(order Switch Kit #
for digital system)
Versa-Pak Pump Specifications
Model Displ. Max. Min. Max. Inlet Port Discharge Port
Number Cu. In. RPM RPM PSI SAE 4 Bolt SAE 4 Bolt
VP28 6.066 3000 600 3000 1-1/2 1 1/4"
VP32 7.077 3000 600 3000 1-1/2 1 1/4"
VP37 8.088 3000 600 2500 2 1 1/4"
VP42 9.099 2500 600 2500 2 1 1/4"
VP47 10.110 2500 600 2250 2 1 1/4"
1500 Frost Rd
Phone: (330) 626-2801
Fax: (330) 626-2805
Solenoid Location
VCR
VCS
Port End Cover Rear
Port End Cover Side
Rotation
Ports
Blank DVBP Bleed Valve
1500 Frost Rd
Phone: (330) 626-2801
Fax: (330) 626-2805
Single Dry Valve Wiring Instructions
The speed controller black box (7) should be mounted inside
the cab in a protected area. Two (2) 3/8-14 x 1" self tapping
screws (8) w/washer and seal are supplied for mounting. Insert
wiring harness (color coded) and run wires to predetermined
location.
utilized to hook to a lap top computer for setting speed control
settings and/or troubleshooting. Default settings are preset to
D on at engine idle speed, D off at 1400 RPM, and D back on
at 1000 RPM. Specific kick-out speed settings can be
programmed before shipping.
D Bleed Solenoid (1) is mounted in the pump port end cover
with the VCR and VCB options; it is not used with the DVBP
option. A minimum 3/8" medium pressure hydraulic hose (not
included) plumbed direct to tank is required for the VCR, VCB
and the DVBP options. Torque Solenoid to 25 lb. ft. and
Solenoid Nut to 5 lb. ft. Run solenoid wires, cut wires to length,
allow slack for tie-down. Insert bleed solenoid (1) wires through
cable seals (2), crimp female inserts (3) onto each wire end,
place into shroud assembly (4), (placement does not matter),
push in cable seals (2), snap cover closed. Insert harness
cable wires (labeled SOL D) through cable seals (2), crimp male
inserts (6) onto each wire end, place into tower assembly (5),
(placement of red and black lead wires does not matter,
solenoid is not polarity sensitive), push in cable seals (2), snap
cover closed, connect shroud and tower together.
C Electric over Air Solenoid (9) for dry valve should be mounted
inside the cab in a protected area. Install the two (2)
compression fitting assemblies (24) into electric over air
solenoid (9), mount solenoid bracket (26) to electric over air
solenoid (9) utilizing the two (2) #10-32 x 7/16" machine
screws (27) and the two (2) #10 star lock washers (28), mount
the solenoid assembly in a protected area utilizing the two (2)
10-24 x 1/2" self tapping screws w/washer and seal (15). Run
electric over air solenoid wires, cut to length, allow slack for tie -
down. Insert electric over air solenoid (9) wires through cable
seals (2), crimp female inserts (3) onto each wire end, place
into shroud assembly (4), (placement does not matter), push in
cable seals (2), snap cover closed. Insert harness cable wires
(labeled SOL C) through cable seals (2), crimp male inserts (6)
onto each wire end, place into tower assembly (5), (placement
of red and black lead wires does not matter, solenoid is not
polarity sensitive), push in cable seals (2), snap cover closed,
connect shroud and tower together.
The switch (19) can be mounted in the dashboard via a knock-
out or mounted to the base of the dashboard utilizing the dash
bracket (16). Mount the dash bracket (16) utilizing the two (2)
10-24 x " self tapping screws (15). Peel the backing from the
self adhesive nameplate (17) and place onto the face of the
dash bracket (16). Put the switch guard (18) over the switch
(19) and place inside the opening of the dash bracket (16),
support the back of the dash bracket (16) and push the switch
assembly in, making sure the plastic tabs are securely locked
in place. Run power supply harness wires, cut wires to length,
allow slack for tie-down. Crimp ring terminal (10) onto end of
crimp blade terminal (20) onto opposite end of ground wire and
black harness wire (labeled -) and connect to top right spade
terminal on rocker switch (19). Crimp blade terminal (20) onto
end of red harness wire (labeled+) and connect to bottom left
spade terminal on rocker switch (19). Crimp blade terminal (20)
onto end of 12 VDC supply wire (11) and connect to middle
spade terminal on rocker switch (19), butt splice (12) onto end
of fuse wire assembly (13), butt splice (12) an extension wire
(11) to the opposite end of fuse wire assembly (13), crimp ring
terminal (10) onto end of extension wire (11), attach to positive
post of battery, insert 10 amp fuse (14).
The speed sensor (23) is threaded into the pump gear housing.
Torque speed sensor to 8 lb. ft. Run sensor wires, cut wires to
length, allow slack for tie-down. Insert speed sensor wire colors
white, black/white and red/white (green/white and
orange/white are not used) through cable seals (2), crimp
female inserts (3) onto each wire end (because the speed
sensor has 24 gauge wire it is necessary to double fold the
wire ends before crimping), place in order into shroud assembly
(22), push in cable seals (2), snap cover closed.
Insert harness cable wires (labeled Sensor) through cable seals
(2), crimp male inserts (6) onto each wire end, place in order
into tower assembly (21) (make sure like colors will mate with
like colors in shroud assembly (22)), push in cable seals (2),
70-130 PSI inlet air pressure is required to operate the dry
valve. Locate a 1/4" NPT opening on the air tank; install the
1/4" x 1/4" nipple (29) into the opening utilizing a pipe thread
sealant, install the 1/4" internal thread x 1/8" external thread
adapter (30) into the 1/4" x 1/4" nipple (29) utilizing a pipe
thread sealant, install the pressure protection valve (31) onto
the 1/4" internal thread x 1/8" external thread adapter (30)
utilizing a pipe thread sealant, install the compression fitting
assembly (24) into the pressure protection valve (31), install
compression fitting assembly (24) into dry valve (39). Run air
lines (33), cut to length; allow slack for tie-down. Remove nut
and ferrule from compression fitting assembly (24), place nut
over air line (33), push ferrule over air line (33), insert tube
insert (25) into air line (33), place and push air line into
compression fitting (24), gently tighten nut; repeat this process
(Light is on when switch is engaged, indicating power is being
supplied to the system)
Single Dry Valve Switch Kit Components

1500 Frost Rd
Phone: (330) 626-2801
Fax: (330) 626-2805
No. Req'd
No. Req'd
2 999-00937CS 16G Weather Pack Cable Seals 14
3 999-00938 Weather Pack Pins (Female) 7
6 999-00939 Weather Pack Pins (Male) 7
8 900-01271 1/4-14 x 1 Self Tapping Screw W/Washer 2
9 514-00914 Electric/Air Solenoid (to operate dry valve) 1
10 999-00926 18-14G Ring Terminal 2
11 999-00925-20 20' 16 Gauge Wire (cut to required lengths) 1
12 999-00927 16-14G Butt Splice 2
13 999-00928 16 Guage Fuse Holder 1
14 999-00929 10 Amp Fuse 1
15 900-01270 10-18 x 1/2" Self Tapping Screw W/Washer 4
16 999-00932 Switch Bracket 1
17 999-00931 Self Adhesive Face Plate 1
18 999-00933 Switch Guard 1
19 999-00934 Rocker Switch W/Light 1
20 999-00935 Female Blade Terminal 3
24 514-00306-CF Compression Fitting, (Base, Nut & Ferrule) 4
25 999-01341 Tube Insert 4
26 931-00915 E/A Solenoid Bracket 1
27 900-00940 #10-32 x 7/16" Machine Screw 2
28 900-00943 #10 Star Washer 2
29 999-00930 1/4" x 1/4" NPT Nipple 1
30 999-00924 1/4" Int. x 1/8" Ext. NPT Adapter 1
31 PP1204 Pressure Protection Valve 1
32 514-00559-DVBV Bronze Air Vent 1
33 514-00268-PT Air Line 17.5' (cut to required length) 2
TANDEM DRY VALVE
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Sol enoi d
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9
7
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1
2
3
8
B
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1 2 3 4
9
10 11 12 13
14
15
16
3
+
_
Battery
+
ery
1500 Frost Road
Phone: (330) 626-2801
Fax: (330) 626-2805
RS-232
13
14
C
Dr y
Val ve
Sol
Dr y
Val ve
5 6
7
2
2 2 3 4 5 6
8
8
10
11
11
17
18
19
20
20
2
2
6
21
22
23
C
B
Bl eed
Sol enoi d
1 2 3 4
9
10
A
Dr y
Val ve
Sol
Dr y
Val ve
5 6 2
2 2 3 4 5 6
12
Dr y
C
Dr y
9 2
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A
Dr y
9 2
5 6 2
2 5 6 2 5 6
5 6 2
2 5 6
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Red + Black -
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Wiring Harness
Programming Harness
(997-01238WH-P)
Red
Black
Red
Black
Red
Black
Red
Black
Loss of Connections on any Circuit will Shut the System Down
Red
Red
Red
Red
Red
Red
Red
Red
(999-01148)
(999-01148)
(514-00914)
(514-00914)
(997-01238WH)
(997-01238)
(997-01238BOX)
(997-01237)
Tandem Dry Valve Switch Kit # 999-01414
(Includes Items # 2-6, 8-22, 24-32 & 34)
Speed Sensor
Vent
Vent
1500 Frost Road
Phone (330) 626-2801
Fax (330) 626-2805
VCS = Solenoid Side
Bleed Port Rear
VCR = Solenoid Rear
Bleed Port Side
minimum 3/8" medium
pressure hydraulic hose,
(not included).
B Solenoid
D Solenoid
A C
Dry Dry
Valve Valve
Sol Sol
minimum 3/8" medium
(not included).
minimum 3/8" medium
(not included).
Discharge Port
Inlet Port
Speed Sensor
90 Degree Port
Adapter Plate
eno B Sole
ng 8" O'rin
directly t
TANDEM DRY VALVE
Tandem Dry Valve Installation Drawing
B
D
D
Nut
Ferrule
Tube Insert
Threaded Base
Compression Fitting
1
1
1
23
9
9
15
24
24
24
24
24
24 24
24
25
25
25
25
26
26
27 27 27
27
28
28 28
28
29 30
31
32 32
33
34
34
34
34
35
35
36
25 25
25 25
15 15
15
24 244 24 24 24
25
15
27
28 28
26
34
15
24
1
26
30
24
25
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Air
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Counter Clockwise Rotation Shown
(999-01148)
(999-01148)
Sold Separately
(1317-24-24) 1-1/2"
(1317-24-24) 2"
Sold Separately
(Item # 33, not included
in switch kit)
(999-01148)
Tandem Dry Valve Switch Kit # 999-01414
(Includes Items # 2-6, 8-22, 24-32 & 34)
1500 Frost Rd
Phone (330) 626-2801
Fax (330) 626-2805
No. Req'd
No. Req'd
No. Req'd
No. Req'd
Port Rotation Plate Part Numbers
35 1317-24-24 Port Rotation Plate Kit for 1-1/2" Dry Valve 1 35 1317-32-32 1
Components Req'd
Examples of System Component Requirements
Port Rotation Plate Kit for 2" Dry Valve
50 GPM @ 700 RPM Solenoid Side P7600B467VCSXVCSSTG22-6CVCNM22-1DV Pump 50 GPM @ 700 RPM (With Speed Sensor Machining & Solenoid Location Side of Port End Cover) CCW 1
750 & 1400 RPM Over-Speed Setting 997-01238 Speed Controller & Harness Set (750 & 1400 RPM Over-Speed Kick-Out Setting) (Item # 7) 1
2" Dry Valve 514-00278-DVA 2" Dry Valve (Item # 36) (mounting hardware included) 2
Switch Kit 999-01414 Tandem Dry Valve Switch Kit (Includes Items # 2 thru 6, 8 thru 22, 24 thru 32 & 34) 1
Port Rotation Plates 1317-32-32 Port Rotation Plate Kit for 2" Dry Valve (Item # 35) (mounting hardware included) 2
45 GPM @ 700 RPM Solenoid Rear P7600B467VCRXVCSSTG20-6CVCNM20-1DV Pump 45 GPM @ 700 RPM (With Speed Sensor Machining & Solenoid Location Rear of Port End Cover) CCW 1
Switch Kit 999-01414 Tandem Dry Valve Switch Kit (Includes Items # 2 thru 6, 8 thru 22, 24 thru 32 & 34) 1
* One (1) Dry Valve required per section
* One (1) Port Rotation Kit required per Dry Valve
45 GPM @ 700 RPM Solenoid Rear P7600B467VCRXVCSSTG20-6CVCNM20-1DV Pump 45 GPM @ 700 RPM (With Speed Sensor Machining & Solenoid Location Rear of Port End Cover) CCW 1
No Switch Kit 997-01237 Speed Sensor P7500 Series (Item # 23) 1
Tandem Dry Valve Model Number Construction
Genesis Pump Specifications
Gear Displ. Max. Min. Max. Inlet Port Discharge Port
Housing Cu. In. RPM RPM PSI SAE 4 Bolt SAE 4 Bolt
1-1/4" 5.055 3000 600 3000 1-1/2" 1-1/4"
1-1/2" 6.066 3000 600 3000 1-1/2" 1 1/4"
1-3/4" 7.077 3000 600 3000 1-1/2" 1 1/4"
2" 8.088 3000 600 2500 2" 1 1/4"
2-1/4" 9.099 2500 600 2500 2" 1 1/4"
2-1/2" 10.110 2500 600 2250 2" 1 1/4"
1500 Frost Rd
Phone (330) 626-2801
Fax (330) 626-2805
P 7600 B 4 67 VCR X VCSSTG 20 - 6 CVC NM 20 - 1 DV
A B C D E F G H I J K L M N
A = Pump
B = Series
C = Unit Code
D = Rotation
3 = Right CW
4 = Left CCW
E = Mounting Flange
67 = Four Bolt "C"
F = Port End Cover Solenoid Location
7600
B = Multiple
VCR = Solenoid Rear-Bleed Port Side
VCS = Solenoid Side-Bleed Port Rear
G = Studs
X = Extended Studs
H = Front Gear Housing
VCSSNT = Solenoid & Speed Sensor Machining
I = Front Gear Housing Size
12 = 1-1/4"
15 = 1-1/2"
17 = 1-3/4"
20 = 2"
22 = 1-1/4"
25 = 2-1/2"
O
J = Shaft
00 = 1-1/4" Keyed (PL Factor 8300)
6 = 1-1/4" "C" Spline (PL Factor 12,000)
K = Bearing Carrier
BVC = CW Rotation
CVC = CCW Rotation
L = Rear Gear Housing Porting
NL = CCW 1-1/4" x 1-1/2" Split Flange
NM = CCW 1-1/4" x 2" Split Flange
NO = CW 1-1/2" x 1-1/4" Split Flange
NP = CW 2" x 1-1/4" Split Flange
M = Rear Gear Housing Size
N = Connecting Shaft
1 = Standard Connecting Shaft
O = Function
DV = Dry Valve
12 = 1-1/4"
15 = 1-1/2"
17 = 1-3/4"
20 = 2"
22 = 1-1/4"
25 = 2-1/2"
CCW Blank x 1-1/2" Split Flange
VCSSND = Solenoid & Speed Sensor Machining
CW 1-1/2" x Blank Split Flange
VCSSTG = Solenoid & Speed Sensor Machining
CCW = Blank x 2" Split Flange
VCSSTH = Solenoid & Speed Sensor Machining
CW 2" x Blank Split Flange
1500 Frost Rd
Phone (330) 626-2801
Fax (330) 626-2805
Tandem Dry Valve Wiring Instructions
The speed controller black box (7) should be mounted
inside the cab in a protected area. Two (2) 3/8-14 x 1" self
tapping screws (8) w/washer and seal are supplied for
mounting. Insert wiring harness (color coded) and run wires
to predetermined locations.
utilized to hook to a lap top computer for setting speed
control settings and/or troubleshooting. Default settings
are preset to A, B, C, & D on at engine idle speed (600-
700 RPM), A & B off at 750 RPM, A & B back on at 700
RPM with an engine stall setting for A & B off at 400 RPM,
C & D off at 1400 RPM, and C & D back on at 1000 RPM.
Specific kick-out speed settings can be programmed before
shipping.
D Bleed Solenoid (1) is mounted in the pump port end
cover with the VCR and VCB options. A minimum 3/8"
medium pressure hydraulic hose (not included) plumbed
direct to tank is required for the VCR, VCB and the DVBP
options. Torque Solenoid to 25 lb. ft., and Solenoid Nut to
5 lb. ft. Run solenoid wires, cut wires to length, allow slack
for tie-down. Insert bleed solenoid (1) wires through cable
seals (2), crimp female inserts (3) onto each wire end,
place into shroud assembly (4), (placement does not
matter), push in cable seals (2), snap cover closed. Insert
harness cable wires (labeled SOL D) through cable seals
(2), crimp male inserts (6) onto each wire end, place into
tower assembly (5), (placement of red and black lead wires
does not matter, solenoid is not polarity sensitive), push in
tower together.
C Electric over Air Solenoid (9) for rear pump section dry
valve should be mounted inside the cab in a protected
area. Install the two (2) compression fitting assemblies
(24) into electric over air solenoid (9), mount solenoid
bracket (26) to electric over air solenoid (9) utilizing the two
(2) #10-32 x 7/16" machine screws (27) and the two (2)
#10 star lock washers (28), mount the solenoid assembly
in a protected area utilizing the two (2) 10-24 x 1/2" self
tapping screws w/washer and seal (15). Run electric over
air solenoid wires, cut to length, allow slack for tie-down.
Insert electric over air solenoid (9) wires through cable
harness cable wires (labeled SOL C) through cable seals
tower together.
B Bleed Solenoid (1) is mounted in the pump bearing
carrier, a minimum 3/8" medium pressure hydraulic hose
(not included) plumbed direct to tank is required for this
bleed solenoid. Torque Solenoid to 25 lb. ft., and Solenoid
Nut to 5 lb. ft. Run solenoid wires, cut wires to length,
allow slack for tie-down. Insert bleed solenoid (1) wires
through cable seals (2), crimp female inserts (3) onto each
wire end, place into shroud assembly (4), (placement does
not matter), push in cable seals (2), snap cover closed.
Insert harness cable wires (labeled SOL B) through cable
seals (2), crimp male inserts (6) onto each wire end, place
into tower assembly (5), (placement of red and black lead
wires does not matter, solenoid is not polarity sensitive),
push in cable seals (2), snap cover closed, connect shroud
and tower together.
A Electric over Air Solenoid (9) for front pump section dry
valve should be mounted inside the cab in a protected
area. Install the two (2) compression fitting assemblies
(24) into electric over air solenoid (9), mount solenoid
bracket (26) to electric over air solenoid (9) utilizing the two
(2) #10-32 x 7/16" machine screws (27) and the two (2)
#10 star lock washers (28), mount the solenoid assembly
in a protected area utilizing the two (2) 10-24 x 1/2" self
tapping screws w/washer and seal (15). Run electric over
air solenoid wires, cut to length, allow slack for tie-down.
Insert electric over air solenoid (9) wires through cable
harness cable wires (labeled SOL A) through cable seals
tower together.
The speed sensor (23) is threaded into the pump gear
housing. Torque speed sensor to 8 lb. ft. Run sensor wires,
cut wires to length, allow slack for tie-down. Insert speed
sensor wire colors white, black/white and red/white
(green/white and orange/white are not used) through cable
seals (2), crimp female inserts (3) onto each wire end
(because the speed sensor has 24 gauge wire it is
necessary to double fold the wire ends before crimping),
place in order into shroud assembly (22), push in cable
seals (2), snap cover closed. Insert harness cable wires
(labeled Sensor) through cable seals (2), crimp male
inserts (6) onto each wire end, place in order into tower
assembly (21) (make sure like colors will mate with like
colors in shroud assembly (22)), push in cable seals (2),
snap cover closed, connect shroud and tower together.
1500 Frost Rd
Phone (330) 626-2801
Fax (330) 626-2805
Tandem Dry Valve Wiring Instructions
continued
The switch (19) can be mounted in the dashboard via a
knock-out or mounted to the base of the dashboard
utilizing the dash bracket (16). Mount the dash bracket
(16) utilizing the two (2) 10-24 x " self tapping screws
(15). Peel the backing from the self adhesive nameplate
(17) and place onto the face of the dash bracket (16). Put
the switch guard (18) over the switch (19) and place inside
the opening of the dash bracket (16), support the back of
the dash bracket (16) and push the switch assembly in,
making sure the plastic tabs are securely locked in place.
Run power supply harness wires, cut wires to length, allow
slack for tie-down. Crimp ring terminal (10) onto end of
crimp blade terminal (20) onto opposite end of ground wire
and black harness wire (labeled -) and connect to top right
spade terminal on rocker switch (19). Crimp blade terminal
(20) onto end of red harness wire (labeled+) and connect
to bottom left spade terminal on rocker switch (19). Crimp
blade terminal (20) onto end of 12 VDC supply wire (11)
and connect to middle spade terminal on rocker switch
(19), butt splice (12) onto end of fuse wire assembly (13),
butt splice (12) an extension wire (11) to the opposite end
of fuse wire assembly (13), crimp ring terminal (10) onto
end of extension wire (11), attach to positive post of
battery, insert 10 amp fuse (14).
(Light is on when switch is engaged, indicating power is
being supplied to the system)
valves. Locate a 1/4" NPT opening on the air tank; install
the 1/4" x 1/4" nipple (29) into the opening utilizing a pipe
thread sealant, install the 1/4" internal thread x 1/8"
external thread adapter (30) into the 1/4" x 1/4" nipple
(29) utilizing a pipe thread sealant, install the pressure
protection valve (31) onto the 1/4" internal thread x 1/8"
external thread adapter (30) utilizing a pipe thread sealant,
install the Tee fitting (33) not supplied into the pressure
protection valve outlet utilizing a pipe thread sealant,
install the compression fitting assemblies (24) into the
Tee fitting (33), install compression fitting assembly (24)
into each dry valve (39). Run air lines (34), cut to length;
allow slack for tie-down. Remove nut and ferrule from
compression fitting assembly (24), place nut over air line
(34), push ferrule over air line (34), insert tube insert (25)
into air line (34), place and push air line into compression
fitting (24), gently tighten nut; repeat this process for all
compression fitting assemblies.
Tandem Dry Valve Switch Kit Components

1500 Frost Rd
Phone: (330) 626-2801
Fax: (330) 626-2805
No. Req'd
No. Req'd
2 999-00937CS
16G Weather Pack Cable Seals
22
3 999-00938
Weather Pack Pins (Female)
11
4 999-00936
Weather Pack 2 Pin Shroud Assembly (Female)
4
5 999-00937
Weather Pack 2 Pin Tower Assembly (Male)
4
6 999-00939
Weather Pack Pins (Male)
11
8 900-01271
1/4-14 x 1 Self Tapping Screw W/Washer
2
9 514-00914
Electric/Air Solenoid (to operate dry valve)
2
10 999-00926
18-14G Ring Terminal
2
11 999-00925-20
20' 16 Gauge Wire (cut to required lengths)
1
12 999-00927
16-14G Butt Splice
2
13 999-00928
16 Guage Fuse Holder
1
14 999-00929
10 Amp Fuse
1
15 900-01270
10-18 x 1/2" Self Tapping Screw W/Washer
6
16 999-00932
Switch Bracket
1
17 999-00931
Self Adhesive Face Plate
1
18 999-00933
Switch Guard
1
19 999-00934
Rocker Switch W/Light
1
20 999-00935
Female Blade Terminal
3
21 999-00940
1
22 999-00941
1
24 514-00306-CF
Compression Fitting, (Base, Nut & Ferrule)
8
25 999-01341
Tube Insert
8
26 931-00915
E/A Solenoid Bracket
2
27 900-00940
#10-32 x 7/16" Machine Screw
4
28 900-00943
#10 Star Washer
4
29 999-00930
1/4" x 1/4" NPT Nipple
1
30 999-00924
1/4
"
Int. x 1/8
"
Ext. NPT Adapter
1
31 PP1204
Pressure Protection Valve
1
32 514-00559-DVBV
Bronze Air Vent
2
34 514-00268-PT
Air Line 17.5' (cut to required length)
2
TANDEM DRY VALVE/UNLOADER
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Battery
11
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tery
1500 Frost Road
Phone: (330) 626-2801
Fax: (330) 626-2805
RS-232
14
17
18
19
20
C
B
Bl eed
Sol enoi d
1
2 3 4
A
Dr y
Val ve
Sol
Dr y
Val ve
5
6
2 3 4
6
Dr y
A
Dr y
4
D
Unl oader
Sol enoi d
2 3 4
D
Unl oader
Sol enoi d
Solenoid C (not used)
7 8 9 4
8 9 4 10
11
15
13
12
21
21
12
4
3
22
23
8
4
24
2 3 4 22 33 44
2 3 4
1 122 13
2 3 4
122 13
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5
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Red + Black -
S
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r
Red
Black
Red
Red
Red
Red
Red
Red
Red
Red
Black
Black
Wiring Harness
Programming Harness
(997-01238WH-P)
(997-01238)
(997-01238BOX)
(997-01238WH)
(997-01237)
(514-00914)
(999-01148)
(999-00948)
Tandem Dry Valve/Unloader Switch Kit # 999-01413
(Includes Items # 2-4, 6, 8-23 & 25-34)
Speed Sensor
Vent
1500 Frost Road
Phone (330) 626-2801
Fax (330) 626-2805
B Solenoid A
Dry
Valve
Sol
minimum 3/8" medium
(not included).
Discharge Port
(
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m
p

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c
i
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)
Inlet Port
90 Degree Port
Adapter Plate
Tandem Dry Valve/Unloader Installation Diagram
B
G
1
Air
Tank
25
Vent
t
eed Port,
tank with
edium
c hose,
Speed Sensor
e
r
90 Degre
Adapter
Regulated Flow to System 1-1/4" Split Flange (code 61)
and O'ring not included)
T1 Port, Solenoid Drain 3/8" NPTF
Plumb to Inlet Side of Port End Cover
With 999-00946 Solenoid Drain Hose
(not shown)
Nut
Ferrule
Tube Insert
Threaded Base
Compression Fitting
16
16
25
25
25
25 26
26
26
26
27
28
28
29
29
30 31
32
33
10
34
26
35
36
36
37
37
38
39
41
7
24
7
16
22
22
Air A
Tan Tan
25
0
16
30 31
227
3
32
34
16 1
40
(optional)
9 29
10
29 229 2
l
r
l
A
r
o
25 25
10
26
28 2
29 2
Val VV
Dr
V l V
A
Dr
S
9 29
5 255 25
26
28 28 228 2
ve
ry
A
ry
ol
34
(999-01148)
(1317-24-24) 1-1/2"
(1317-32-32) 2"
(see VERSA-PAK model
number construction for
flow settings)
Tandem Dry Valve/Unloader Switch Kit # 999-01413
(Includes Items # 2-4, 6, 8-23 & 25-34)
Items # 1 & 36 thru 40 included with
VERSA-PAK valve if ordered as kit
(Ex: VP100-U50XH2)
Tandem Dry Valve/Unloader Installation Diagram
GPM Orifice Plug installed here.
G
Gauge Port
Use 1-1/4" Split flange port to
return excess and unloaded
flow back to tank. Use no
smaller than an 1 1/4" hose.
Returning flow through the
filter is optional.
T1 port (3/8" NPTF) is
plumbed to 3/8"
ODT port on suction
side of the port end
cover of the tandem
pump with Solenoid
Drain Hose Assembly
number 999-00946.
T1
Versa-Pak Solenoid installed here.
Do not overtighten. 5 ft. lb. max
Part Number 999-00948.
Logic Element
1500 Frost Road
Phone (330) 626-2801
Fax (330) 626-2805
The Versa- Pak Valve may be installed in this manner with the solenoid and/or logic element pointing down or with the
solenoid and/or logic element pointing up. With the solenoid and/or logic element pointing down the return/tank port will
be oriented toward the rear of the vehicle. With the solenoid and/or logic element pointing up the return/tank port will be
oriented toward the front of the vehicle.
1
1
40
1500 Frost Rd
Phone (330) 626-2801
Fax (330) 626-2805
No. Req'd
No. Req'd
No. Req'd
No. Req'd
Port Rotation Plate Part Numbers
35 1317-24-24 Port Rotation Plate Kit for 1-1/2" Dry Valve 1 35 1317-32-32 1
Examples of System Component Requirements
Port Rotation Plate Kit for 2" Dry Valve
* One (1) Dry Valve required per section
* One (1) Port Rotation Kit required per Dry Valve
50 GPM @ 700 RPM P7600B467ZUXVCSSTG22-6CVCNM22-1DVUL Pump 50 GPM @ 700 RPM (With Speed Sensor Machining) CCW Rotation 1
50 GPM Flow Control VP100-U50XH2 VERSA-PAK Valve (50 GPM Flow Control + Unloader Solenoid + Drain Hose Kit) (Includes Items # 1 & 36 thru 40) 1
Switch Kit 999-01413 Tandem Dry Valve/Unloader Switch Kit (Includes Items # 2 thru 4, 6, 8 thru 23, & 25 thru 34) 1
Switch Kit 999-01413 Tandem Dry Valve/Unloader Switch Kit (Includes Items # 2 thru 4, 6, 8 thru 23, & 25 thru 34) 1
Port Rotation Plate 1317-32-32 Port Rotation Plate Kit for 2" Dry Valve (Item # 35) (mounting hardware included) 1
VP100-UBLXH2 VERSA-PAK Valve (Unloader Solenoid + Drain Hose Kit) (Includes Items # 1 & 36 thru 40) 1
Components Req'd
Port Rotation Plate 1317-32-32 Port Rotation Plate Kit for 2" Dry Valve (Item # 35) (mounting hardware included) 1
No Switch Kit VP100-UBLXH2 VERSA-PAK Valve (Unloader Solenoid + Drain Hose Kit) (Includes Items # 1 & 36 thru 40) 1
Tandem Dry Valve/Unloader Model Number Construction
Genesis Pump Specifications
Gear Displ. Max. Min. Max. Inlet Port Discharge Port
Housing Cu. In. RPM RPM PSI SAE 4 Bolt SAE 4 Bolt
1-1/4" 5.055 3000 600 3000 1-1/2" 1-1/4"
1-1/2" 6.066 3000 600 3000 1-1/2" 1 1/4"
1-3/4" 7.077 3000 600 3000 1-1/2" 1 1/4"
2" 8.088 3000 600 2500 2" 1 1/4"
2-1/4" 9.099 2500 600 2500 2" 1 1/4"
2-1/2" 10.110 2500 600 2250 2" 1 1/4"
1500 Frost Rd
Phone (330) 626-2801
Fax (330) 626-2805
P 7600 B 4 67 ZU X VCSSTG 20 - 6 CVC NM 20 - 1 DV UL
A B C D E F G H I J K L M N
A = Pump
B = Series
C = Unit Code
D = Rotation
3 = Right CW
4 = Left CCW
E = Mounting Flange
67 = Four Bolt "C"
F = Port End Cover
7600
B = Multiple
X = Extended Studs
H = Front Gear Housing
VCSSNT = Solenoid & Speed Sensor Machining
I = Front Gear Housing Size
12 = 1-1/4"
15 = 1-1/2"
17 = 1-3/4"
20 = 2"
22 = 1-1/4"
25 = 2-1/2"
O P
J = Shaft
00 = 1-1/4" Keyed (PL Factor 8300)
6 = 1-1/4" "C" Spline (PL Factor 12,000)
K = Bearing Carrier
BVC = CW Rotation
CVC = CCW Rotation
L = Rear Gear Housing Porting
NL = CCW 1-1/4" x 1-1/2" Split Flange
NM = CCW 1-1/4" x 2" Split Flange
NO = CW 1-1/2" x 1-1/4" Split Flange
NP = CW 2" x 1-1/4" Split Flange
M = Rear Gear Housing Size
N = Connecting Shaft
1 = Standard Connecting Shaft
O = Function Front Section
DV = Dry Valve
12 = 1-1/4"
15 = 1-1/2"
17 = 1-3/4"
20 = 2"
22 = 1-1/4"
25 = 2-1/2"
CCW Blank x 1-1/2" Split Flange
VCSSND = Solenoid & Speed Sensor Machining
CW 1-1/2" x Blank Split Flange
VCSSTG = Solenoid & Speed Sensor Machining
CCW = Blank x 2" Split Flange
VCSSTH = Solenoid & Speed Sensor Machining
CW 2" x Blank Split Flange
P = Function Rear Section
UL = Unloader
UZ = Bleed Port CW
ZU = Bleed Port CCW
G = Studs
VP100 - U 50 X H2
Valve Model
VP100
Unloader
U Unloader Installed
BL = No Orifice
30, 35, 40, 45, 50,
55, 60, 65, 70, 75, 80
Hose Kit
H2 Solenoid Drain Hose Kit
3/8 (Use with Unloader)
Switch Kit
(order Switch Kit #
for digital system)
1500 Frost Rd
Phone (330) 626-2801
Fax (330) 626-2805
1500 Frost Rd
Phone (330) 626-2801
Fax (330) 626-2805
Tandem Dry Valve/Unloader Wiring Instructions
The speed controller black box (5) should be mounted inside
the cab in a protected area. Two (2) 3/8-14 x 1" self tapping
screws (6) w/washer and seal are supplied for mounting. Insert
wiring harness (color coded) and run wires to predetermined
locations.
utilized to hook to a lap top computer for setting speed control
settings and/or troubleshooting. Default settings are preset to
A, B & D on at engine idle speed (600-700 RPM), A & B off at
750 RPM; A & B back on at 700 RPM with an engine stall
setting for A & B off at 400 RPM, D off at 1400 RPM, and D
back on at 1000 RPM. Specific kick-out speed settings can be
programmed before shipping.
D Solenoid (1) is mounted in the Versa-Pak Unloader Block.
Solenoid comes with shroud (male) assembly fully attached.
Torque Solenoid to 25 lb. ft., and Solenoid Nut to 5 lb. ft. Run
solenoid wires, cut wires to length, allow slack for tie-down.
Insert harness cable wires (labeled SOL D) through cable seals
(4), crimp male inserts (3) onto each wire end, place into tower
assembly (2), (placement of red and black lead wires does not
matter, solenoid is not polarity sensitive), push in cable seals
(4), snap cover closed, connect shroud and tower together.
B Bleed Solenoid (7) is mounted in the pump bearing carrier, a
minimum 3/8" medium pressure hydraulic hose (not included)
plumbed direct to tank is required for this bleed solenoid.
Torque Solenoid to 25 lb. ft., and Solenoid Nut to 5 lb. ft. Run
solenoid wires, cut wires to length, allow slack for tie-down.
Insert bleed solenoid (7) wires through cable seals (4), crimp
female inserts (8) onto each wire end, place into shroud
assembly (9), (placement does not matter), push in cable seals
(4), snap cover closed. Insert harness cable wires (labeled SOL
B) through cable seals (4), crimp male inserts (3) onto each
wire end, place into tower assembly (2), (placement of red and
black lead wires does not matter, solenoid is not polarity
sensitive), push in cable seals (4), snap cover closed, connect
shroud and tower together.
valves. Locate a 1/4" NPT opening on the air tank; install the
1/4" x 1/4" nipple (30) into the opening utilizing a pipe thread
sealant, install the 1/4" internal thread x 1/8" external thread
adapter (31) into the 1/4" x 1/4" nipple (30) utilizing a pipe
thread sealant, install the pressure protection valve (32) onto
the 1/4" internal thread x 1/8" external thread adapter (31)
utilizing a pipe thread sealant, install the compression fitting
assemblies (25) into the pressure protection valve (32), install
compression fitting assembly (25) into dry valve (41). Run air
lines (34), cut to length; allow slack for tie-down. Remove nut
and ferrule from compression fitting assembly (25), place nut
over air line (34), push ferrule over air line (34), insert tube
insert (26) into air line (34), place and push air line into
compression fitting (25), gently tighten nut; repeat this process
for all compression fitting assemblies.
The speed sensor (24) is threaded into the pump gear housing.
Torque speed sensor to 8 lb. ft. Run sensor wires, cut wires to
length, allow slack for tie-down. Insert speed sensor wire colors
white, black/white and red/white (green/white and
orange/white are not used) through cable seals (4), crimp
female inserts (8) onto each wire end (because the speed
sensor has 24 gauge wire it is necessary to double fold the
wire ends before crimping), place in order into shroud assembly
(23), push in cable seals (4), snap cover closed. Insert harness
cable wires (labeled Sensor) through cable seals (4), crimp
male inserts (3) onto each wire end, place in order into tower
assembly (22) (make sure like colors will mate with like colors
in shroud assembly (23)), push in cable seals (4), snap cover
closed, connect shroud and tower together.
A Electric over Air Solenoid (10) for front pump section dry valve
should be mounted inside the cab in a protected area. Install
the two (2) compression fitting assemblies (25) into electric
over air solenoid (10), mount solenoid bracket (27) to electric
over air solenoid (10) utilizing the two (2) #10-32 x 7/16"
machine screws (29) and the two (2) #10 star lock washers
(28), mount the solenoid assembly in a protected area utilizing
the two (2) 10-24 x 1/2" self tapping screws w/washer and
seal (16). Run electric over air solenoid wires, cut to length,
allow slack for tie-down. Insert electric over air solenoid (10)
wires through cable seals (4), crimp female inserts (8) onto
each wire end, place into shroud assembly (9), (placement
does not matter), push in cable seals (4), snap cover closed.
Insert harness cable wires (labeled SOL A) through cable seals
(4), crimp male inserts (3) onto each wire end, place into tower
assembly (2), (placement of red and black lead wires does not
matter, solenoid is not polarity sensitive), push in cable seals
(4), snap cover closed, connect shroud and tower together.
The switch (20) can be mounted in the dashboard via a knock-
out or mounted to the base of the dashboard utilizing the dash
bracket (17). Mount the dash bracket (17) utilizing the two (2)
10-24 x " self tapping screws (16). Peel the backing from the
self adhesive nameplate (18) and place onto the face of the
dash bracket (17). Put the switch guard (19) over the switch
(20) and place inside the opening of the dash bracket (17),
support the back of the dash bracket (17) and push the switch
assembly in, making sure the plastic tabs are securely locked
in place. Run power supply harness wires, cut wires to length,
allow slack for tie-down. Crimp ring terminal (11) onto end of
crimp blade terminal (21) onto opposite end of ground wire and
black harness wire (labeled -) and connect to top right spade
terminal on rocker switch (20). Crimp blade terminal (21) onto
end of red harness wire (labeled+) and connect to bottom left
spade terminal on rocker switch (20). Crimp blade terminal (21)
onto end of 12 VDC supply wire (12) and connect to middle
spade terminal on rocker switch (20), butt splice (13) onto end
of fuse wire assembly (14), butt splice (13) an extension wire
(12) to the opposite end of fuse wire assembly (14), crimp ring
terminal (11) onto end of extension wire (12), attach to positive
post of battery, insert 10 amp fuse (15).

(Light is on when switch is engaged, indicating power is being
supplied to the system).
Tandem Dry Valve/Unloader Switch Kit Components

1500 Frost Rd
Phone: (330) 626-2801
Fax: (330) 626-2805
No. Req'd
No. Req'd
2 999-00937
3
3 999-00939
Weather Pack Pins (Male)
9
4 999-00937CS
16G Weather Pack Cable Seals
16
6 900-01271
1/4-14 x 1 Self Tapping Screw W/Washer
2
8 999-00938
Weather Pack Pins (Female)
7
9 999-00936
2
10 514-00914
Electric/Air Solenoid (to operate dry valve)
1
11 999-00926
18-14G Ring Terminal
2
12 999-00925-20
20' 16 Gauge Wire (cut to required lengths)
1
13 999-00927
16-14G Butt Splice
2
14 999-00928
16 Guage Fuse Holder
1
15 999-00929
10 Amp Fuse
1
16 900-01270
10-18 x 1/2" Self Tapping Screw W/Washer
4
17 999-00932
Switch Bracket
1
18 999-00931
Self Adhesive Face Plate
1
19 999-00933
Switch Guard
1
20 999-00934
Rocker Switch W/Light
1
21 999-00935
Female Blade Terminal
3
22 999-00941
1
23 999-00940
1
25 514-00306-CF
Compression Fitting, (Base, Nut & Ferrule)
4
26 999-01341
Tube Insert
4
27 931-00915
E/A Solenoid Bracket
1
28 900-00943
#10 Star Washer
2
29 900-00940
#10-32 x 7/16" Machine Screw
2
30 999-00930
1/4" x 1/4" NPT Nipple
1
31 999-00924
1/4" Int. x 1/8" Ext. NPT Adapter
1
32 PP1204
Pressure Protection Valve
1
33 514-00559-DVBV
Bronze Air Vent
1
34 514-00268-PT
Air Line 17.5' (cut to required length)
1

1
Basic Function of Black Box

The Permco Black Box is a micro-processor controlled electronic switching system that
determines when to switch power on or off based on RPMs. These RPMs come from an
electronic signal or pulse generated by the rotating gears of the pump/motor. A sensor threaded
into the pump or motor and connected to the black box sends these pulses to the micro-processor
of the black box indicating the rotating speed of the pump or motor.

The system is simple in theory. It only knows two things. How fast the pump/motor is going and
when to turn power on or off based on the data you enter into it along with the pulses coming from
the pump/motor sensor. As long as power is applied and a rotation is sensed, then nothing else
can go wrong. If you follow the instructions for programming and connecting the Black Box to the
system properly, you should not have any problems.

The Black Box retains all settings even when power is removed. Once the system senses rotation
the Black Box will cycle the circuits on an off until power is removed from the system. Should you
need the Black Box to shut down the system completely upon the sense of a particular RPM and
stay off until power is cycled off and on again, the Black Box can be factory programmed to do so.

Following the preparation section below are some items to check for and some troubleshooting tips
in the event the system is not operating correctly.

Preparing the Black Box for Speed Setting Values

The black box comes preprogrammed from the factory with default speed settings. If specific
speed settings are required it is recommended they be factory programmed before shipment. The
following items are needed to reprogram the speed settings on the black box to enable it to work
with your vehicle or system.

Reprogramming the black box without factory approval will void the warranty.

1. A Personal Computer (PC), or Laptop Computer with a terminal emulation software
installed such as Windows Hyper Terminal or Pro-Com will be needed. The instructions
below explain how to set up the Black Box using Windows Hyper Terminal. If you use
any other computer, Mac with terminal emulation software, or a dumb terminal using
ASCII, or ADDS emulation, you simply must be able to make the appropriate
communications software settings.

2. Programming/troubleshooting cable, 6 foot in length; Permco part number, 997-
01238WH-P

x Although it is assumed that you will program the Black Box before it is installed in
the vehicle, you can program the Black Box once installed in the vehicle. You will
need to remove the sensor connector and connect the programming cable, part
number 997-01238WH-P. (The Black Box comes preprogrammed from the factory
with industry standard speed kick out settings; specific settings can be
programmed before shipping).

x Once power is removed from the Black Box, the settings will remain until changed
again.

2
Advanced Port Settings Instructions

Windows 95/98/2000/XP

1. Right Click on My Computer (From Desktop)
2. Click on properties
3. WIN98/95 Click on device Manager
Go to step 4
3. WIN2000/XP Click on Hardware
Click on Device Manager
4. Click on + next to Ports (COM & LPT)
5. Dbl Click on the port you are adjusting
6. Click on Port Settings
7. Click on Advanced
8. Move the sliders to 75%
9. Click on OK until you close everything
x The following steps are common for Windows Hyper Terminal and necessary to
establish communications between your computer and the Black Box.

x 1.) Connect the programming cable (997-01238WH-P) to your laptop or PC 9 or 25 pin
Com port, normally located at the back of your laptop or PC to the Black Box 9 pin
connector.

x 2.) Open Hyper Terminal
(Usually located under Programs, Accessories\Communications.)

x Connection Description: New Connection
Name: Permco Black Box (Whatever you want)
Icon: (doesnt matter)
Click Ok

x Phone Number, or Connect to: Permco
Connection Using: Select the Com port you connected the serial cable to in step 1.
Click Ok

x COM# Properties: Port Settings
Bits per Second: 9600
Data Bits: 8
Parity: None
Stop Bits: 1
Flow Control: None

x Optimal Advanced Port Settings:
Use FIFO buffers: Selected
Receive buffer: 75%
Transmit buffer: 75%
Click Ok

x 3.) Applying power to the black box will
begin the speed sense function using the
pre-set trip points. To modify these trip points, you will need to press any key on the
computer within a few seconds of applying power to the Black Box. If you need to reset
the Black Box or start again, simply remove power to the Black Box and re-apply it.

Programming the Black Box

The following are the Black Box Menu Options

M Main Menu
From anywhere in the system, pressing M will bring you to this menu.
A Information about the Black Box
Short description about the Black Box.
H Help definitions
A short example of how the Black Box works.
R Read the present trip point settings
This displays the current Trip Point settings.

3
D Set all trip point back to default settings
Resets all previously set trip points to the default settings.
(Aoff =400, Aon = 600, Boff = 750, Bon = 700, Coff = 1400, Con = 1000)
T Change the trip point settings
Allows you to modify the default settings for Aoff, Aon, Boff, Bon, Coff, Con. To
bypass or leave a setting unchanged, you would press the1 key to move on to the
next setting.
S Change the Startup Timer
This allows you to modify the timers start up time. This is the time the Black Box
waits once powered up before it activates the system.
X Exit setup
This exits the setup process and resumes the countdown to activate the system.

Last minute Checks for Connecting the Black Box to Your Vehicle

* Always consult the appropriate wiring diagram for your application. These
diagrams can be obtained by contacting the factory.

1. Leave some slack in the wires to ensure that the wires do not become
disconnected at either end, making sure the wires are properly tied down to avoid
snagging and disconnection.
2. If available, use only Weather Pack connectors, pins, and crimping tools to
connect each cable to the appropriate mating end. You will find all the appropriate
connectors and pins in your Permco switch kit, which can be purchased
separately. Soldering is recommended for trouble free connections.
3. When installing the sensor (997-01237, 7500/7600 series, or 997-01316,
5000/5100/257 series) in the pump, take care in making sure that you only use
7-1/2 to 8 lb. ft. of torque when tightening.
4. When installing the Solenoid in the pump, take care in making sure that you only
use 25 lb. ft. of torque maximum when tightening.
5. When tightening the solenoid coil nut, take care in making sure that you only use
4 5 lb. ft. of torque maximum when tightening.
6. Sensitivity of the electronic components requires direct battery post connections
for (+) positive and (-) ground. It is not recommended to utilize the fuse panel for
(+) positive and (-) ground connections, a millisecond of interrupted power on
these circuits will shut the system down and will be problematic for the system.
7. On all systems the speed sensor should be mounted on the belly side or the
bottom of the pump. Should the sensor be located on top, take extra precautions
to protect the wire leads coming from the sensor. Tie them down and protect
them from becoming stepped on or tangled.

Failure to observe the previous steps or properly install the electrical circuitry will result in
improper functioning of the system. Improperly crimped wires, unprotected (bare) wires
and connections could lead to failure and damage to the system. Using incorrect torque
(over tightening) of the solenoids, solenoid coils and speed sensors can adversely affect
the current draw, this can trip the circuit and will lead to damaged coils and solenoids,
although the system will seem to function properly, the coils will eventually burn out and
fail. This will not only result in damage to the system, but will also void the warranty.

4

Troubleshooting:

Should the system fail to function properly, please check the following items before calling
the plant for assistance.

1. Connect a laptop to the Black Box and speed sensor using the
programming/troubleshooting cable, Permco part number 997-01238WH-P (sold
separately). Verify that the RPMs match that of the tachometer of the vehicle, and
check for any error messages that appear when the system is running. See the
above steps to connect your laptop to the black box. Over-current or a short in the
circuit of the system will result in the system shutting down. The system will display
such messages should this situation occur.

2. Check for loose or open connections. If you purchased the system with the switch
kit, make sure that you utilize the Weather Pack connectors that came with the kit.
This is very important. Also, it is very important to use Weather Pack brand
crimpers for crimping the wires to the Weather Pack connectors. Failure to do so
will result in loose and improper connections. Soldering is recommended for trouble
free connections.

3. If during installation, you did not connect the power and ground leads directly to the
battery post, attempt this. Utilizing the fuse panel for connections is not
recommended; a millisecond of interrupted power on these connections will shut the
system down. It is very important that the power and ground source for the Black Box
not be interrupted or dirty.

4. Check your current draw to the solenoid leads (1.75 amps maximum per circuit).
The internal digital over-current protection (7 amps system total) reacts much quicker
than fuses. Current spikes, which may not blow a fuse, will trip the internal over-
current protection resulting in the black box temporarily shutting down until the over-
current situation is resolved.

5. If using Permcos switch kit, verify that the 12 volt power source is connected to the
center tab on the system switch and that the ground lead is connected to the tab
directly behind the light on the switch. The switched power is connected to the third
tab or the tab located opposite the ground tab. The switch may be functioning
properly even though the light is not on. The Black Box does not require that the
ground source be connected to the switch. Connecting ground to the switch only
provides the ground source for the switch light.

6. Recheck torque values on all solenoids, solenoid coils and speed sensors; over
tightening distorts the solenoid tubes and increases current draw; over tightening of
the speed sensor will crack the diaphragm and damage the circuit board. If utilizing
Mac valves or other types of solenoids not supplied by Permco an over-current
draw situation can occur; this will result in the system shutting down and cause
damage to the electronic components.

7. If your system incorporates a dry valve make sure you have a sufficient clean air
supply to the electric over air solenoids and dry valves; 70-130 PSI required.
997-01238BOX Troubleshooting
Basic Function of the Black Box
The Permco Black-Box is a micro-
processor controlled electronic
switching system that determines
when to switch power on or off
based on RPMs. These RPMs
come from an electronic signal or
pulse generated by the rotating
gears of the pump/motor. A
sensor attached to the pump or
motor and connected to the Black-
Box sends these pulses to the
micro-processor of the Black-Box
indicating the rotating speed of the
pump or motor.
The system is simple in theory. It only knows two things. How fast the pump/motor is
turning using the pulses from the sensor, and when to turn power on or off based on
the pulses and the data you enter into it when initially setting it up. As long as power
is applied and a rotation is sensed, then nothing else can go wrong.
The Black-Box retains all settings even when power is removed. Once the system
senses rotation the Black-Box will cycle the circuits on and off until power is removed
from the system. Should you need the Black-Box to shut down the system completely
upon the sensing of a particular RPM and stay off until power is cycled off and on again,
the Black-Box can be factory programmed to do so. (See Latching Software)
Basic logic of the circuit
Power is directed to the 4 electrical circuits through programmable logic stored in
Random Access Memory (RAM) located on the circuit board based on settings input
during initial setup. There are several conditions that must be met for these circuits to
act properly
1. The speed sensor connected to the black connector on the Black-Box,
MUST sense the rotation of the internal gears of the pump. If there is no
1
rotation, then power will be removed from all 4 circuits (A/B & C/D). If
rotation falls below the preset value, then power will be removed from the
circuit related to that value.
2. Should the internal overload protection circuit sense a short on any one of
the four circuits (A/B & C/D), or an over-current of 1.75 amps per circuit, or
7 amps total, power will be removed from all four of the circuits. The Black-
Box will continue to operate, checking for a corrected state. Once the
problem has been eliminated through fixing the short, or resolving the over-
current, and a corrected state is detected, the system will resume normal
operation.***
Special Note: Normal fuses react to an over-current condition much more slowly
than an electronic circuit breaker, which is built into the Black-Box. An over-current
condition of just amp or less for a split second will trip the over-current protection
circuitry where a fuse may take several seconds to blow. Circuits containing solenoids
should be protected with an fly-back diode, which will stop the back-rush of high
voltage created by the coil of solenoids when power is removed from the solenoid. The
Black-Box has this fly-back diode built into the circuitry. See attached diagram.
*** This circuitry can be bypassed by shorting the grey, color banded resister located
to the right of LEDs 3&4, which is labeled R9. Should it be determined to do this, it is
highly recommended that you replace the supplied 10 amp fuse with a 7 amp fuse to
make sure you dont burn up the Black-Box if there is a failed electrical system. Doing
so will void the warranty.
When measuring voltage from any of the four circuits (A/B & C/D), you should see at
least 12 volts (with power applied and rotation sensed). You will notice that the polarity
on these circuits appears backwards. Positive voltage comes through the black lead
and negative through the red. This is only a concern should you have a solenoid that is
sensitive to polarity. If this is the case, be sure to properly wire the solenoids. Some
solenoids may not be polarity sensitive, but one lead may be tied into chassis ground
and this could cause problems. The Solenoids in the valves Permco uses were selected
because they are not polarity sensitive, nor does either of the leads tie into chassis
ground.
Considering the above, solenoids or other
devices connected to the Black-Box must be
connected to both leads of the circuit. DO
NOT connect one lead from the solenoid to the
Black-Box, and the other to the chassis or
ground. This will cause a failed circuit and could
cause permanent damage to the Black-Box.
2
The electronic components internal to the Black-Box require that the applied voltage
and grounding connections be wired directly to the battery posts. Taking the applied
voltage and grounding from a fuse panel, or from the chassis will not guarantee proper
operation of the hydraulic system.
It is Highly recommended that all bleed valves and air valves used in your system, are
ones designed for the system by Permco.
Light Emitting Diodes (LED) located on circuit board
LED 1 through 4 - These green LEDs
when lit, are indicating that power is being
supplied to the solenoid circuits. Once an
over-speed condition is met, or voltage to the
system is removed, power will be removed
from the solenoid circuits and the LEDs will go
out.
LED 5 - This green LED is a power indicator
telling you that the power to the Black-Box is
turned on.
LED 6&7 - These are not used for
troubleshooting
LED 8 - This LED blinks bright red when the
microprocessor is functioning properly.
LED 9 - This red LED blinks with the pulse of the signal coming from the RPM sensor.
At normal engine idle, LEDs 1 through 4 will come on within 1 2 seconds, once the
RPM sensor senses movement of the internal pump gears. If LED 9 does not come on,
then you can assume that there is a problem with the sensor, or the depth position of
the sensor in the pump. To operate normally, there must be a minimum air gap of .030
and a maximum air gap of .100 between the face of the gear tooth and the face of the
sensor. Permcos manufacturing standard allows for an air gap of .040 - .050.
As the pump is rotating, LED 9 may appear to be glowing continuously because the
pulse is faster than the human eye can detect.
3
Line Output Specifications
Although there are four lines, both A and B work together, and C and D work together.
Line Default Range
Aoff/Boff (X0) 400 RPM 350 650 RPM
Aon/Bon (X1) 600 RPM X0 + 50 to X0 +200 RPM
Aoff/Boff (Y0) 750 RPM Y1 -200 to Y1 -50RPM
Aon/Bon (Y1) 700 RPM 750 1100 RPM
Con/Don 1000 RPM 800 RPM 1100 RPM
Coff/Doff 1400 RPM 850 RPM 2000 RPM (Coff > Con)
The above chart reflects Hysteresis logic (example below). This logic says that once the
RPM reaches a predetermined level, the system will power off until the RPM decreases
beyond the lower setting.
4
Sensors: There are two types of sensors. One is for the 7500/7600 series, and the
other is for the 197/257/2100/2500/3000/3100/3700/5000/5100/5151/ series. The
only difference is size. The operational characteristics of both are the same.
Both have 5 leads and a metal braded shield.
(Used only for strength and rigidity.)
1. White Signal from sensor to Black-
Box
This lead connects to the white lead
of the sensor lead on the Black-Box.
2. White with red stripe Positive
voltage
This lead connects to the red lead of
the sensor lead on the Black-Box.
3. White with black stripe Negative
voltage
This lead connects to the black lead of the sensor lead on the Black-Box.
Permco PN: 997-01237
7500/7600 Series Sensor
4. White with green stripe Future temperature sensor
Presently no connection
5. White with orange strip Future temperature sensor
Presently no connection
x The port in the gear housing or the pump/motor is machined using the wall of
the gear bore as a reference point. This assures that the air gap between the
face of the sensor and the tips of the gear is accurate.
x The sensor is sensitive to excessive heat. Temperatures upwards to 300q
Fahrenheit, will cause damage to the sensor.
x The sensor was designed specifically for the gears that Permco uses and not
meant for use in other applications.
x Pressures above 4250 psi will damage the sensor.
Software
There are two versions of software available.
x Standard Which provides the on/off/on switching as determined by the
settings input during the initial set up. (Specifically designed for typical refuse
systems.)
x Latching This reacts the same as the standard version, except that solenoids
C/D will force complete shutdown of the system requiring a power cycle off/on
should the upper RPM setting be reached as determined during initial setup.
5
What if.
Rpms are in the acceptable range but the solenoids will not open/close.
x Poor electrical connection to the Black-Box.
x Short in system
x Failed sensor.
1. Make sure your applied voltage and grounding is wired directly to the
battery. Verify that you have 12 volts to the switch. Verify that all
connections are tight.
2. With the engine running, connect the laptop to the system using the
programming/test cable, checking for error messages due to an over-
current situation, or a possible short.
3. Verify that you are getting a signal from the sensor by either using a
laptop to check RPMs, or remove the cover from the Black-Box and check
to see that LED 9 is either blinking quickly or solid red.
4. Using the sensor test tool described later, determine that the sensor is
actually functioning.
System continually cycles on and off during normal operation.
x Short in one or more of the solenoid circuits
x Poor electrical connection to the Black-Box.
x Failing sensor
1. With the engine running, connect the laptop to the system using the
programming/test harness checking for error messages due to an over-
current situation, or a possible short.
2. Make sure your applied voltage and grounding is wired directly to the
battery. Verify that you have 12 volts to the switch. Verify that all
connections are tight.
3. Verify signal pulse from the sensor by checking RPMs using a laptop or by
checking the status of LED 9 on the circuit board.
4. Using the sensor test tool described later, determine that the sensor is
actually functioning.
6
7
Band on Diode
Solenoid
Black Box
-12 VDC +12 VDC
Fly-back Diode
Devices containing solid state components can be damaged or caused to
malfunction when used in systems which incorporate inductive leads (e.g.
relays, solenoids, etc.) that can generate reverse voltage spikes.
To reduce the potential for this type of damage, install a properly sized fly-back
or clamping diode across all inductive loads such as in the above example.
A typical diode is 1N4005 which is readily available from retail sources such as
Radio Shack.
8
Red
White
Black
+12vdv
-12vdv
Sensor
Using a 1000 ohm resistor, connect either end to the white wire of the sensor, con-
nect the negative lead of a 12v LED to the other end of the resistor. Connect the
other lead of the LED to the Red on White wire.
Connect a 12 volt power supply to the appropriate leads and pass the tip of a screw
driver or other metal object past the face of the sensor. If the LED lights as the metal
object passes the face of the sensor, then the sensor is ok.
Sensor Test Tool
White
Red
Black
Sensor
-12vdv +12vdv
Connection Diagram
Schematic Diagram
Resistor - LED +
1500 Frost Road
Phone (330) 626-2801
Fax (330) 626-2805
7500/7600 Series Speed Sensor
Permco Part Number 997-01237
1500 Frost Road
Phone (330) 626-2801
Fax (330) 626-2805
197/257/2100/3000/5000 Series Speed Sensor
1500 Frost Road
Phone (330) 626-2801
Fax (330) 626-2805
Permco Part Number 997-01316
Below is a 7500/7600 housing pictured with a SPECIAL 3/8 JIC port on the top. While this port is a
standard JIC port, IT REQUIRES EXACT PLACEMENT IN THE HOUSING and must be done according to the
drawing. The port is designed to accommodate our new speed sensor part number 997-01237 which is
used with our new speed control box part number 997-01238. You would also need a wiring harness
part number 997-01238WH. For more information please refer to the Genesis brochure which is available
as a PDF or in hard copy.The code for this new housing is SS. Example, P7600A467ZD(SS)NM17-00DVBP.
Copyri ght 2 0 0 6 Per mco
Bull e t in # GS0 6- 1 0 0 A

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What is the purpose of the speed sensor?

How does the speed control system work?

bypassed to tank (as in the case of pressure

compensated valves that bleed a given amount of ow

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