INSTALLING NEW CENTER SWITCH
MCH Control Handle
Instructions for Addition or Replacement
of Parts
BLN-95-9057-1 Issued: April 2002
1. Install cam with hub to the outside. (Do not tighten
setscrew.)
2. Install switch so that the switch body is toward the radius
side of the notch in the cam. (See Location of Radius.)
3. Move cam switch until roller is in notch of cam.
4. Tighten switch mounting screws to fasten switch.
5. SEE WARNING. Adjust cam to ensure switch is actuated when the handle is within 3° ±1° of neutral or
detented position.
6. Tighten setscrew on cam.
INSTALLING NEW AUXILIARY SWITCH
1. Determine desired switching angle and mount switch.
2. SEE WARNING. Adjust switch to within ±1° of desired
switching angle.
3. Tighten switch mounting screws. Do not adjust auxiliary
switches by moving cam, as this will destroy center
switch adjustment.
4. Wire as desired.
7. SEE WARNING. Recheck actuating angle of CAM. If
not within 3° ±1° of neutral or detented position, loosen
CAM setscrew and readjust.
8. Wire as desired.
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WARNING
Failure to calibrate switches within the specified angles
may result in the switch being activated when the handle
is not in the proper position. (Example: If the switch is a
center off switch and is not calibrated per specifications,
the machine function controlled by that handle may be
activated when the handle is in the neutral position.)
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WARNING
Failure to calibrate switches within the specified angles
may result in the switch being activated when the handle
is not in the proper position. (Example: If the switch is a
center off switch, and is not calibrated per specifications,
the machine function controlled by that handle may be
activated when the handle is in the neutral position.)
REPLACING EXISTING SWITCHES
1. Identify and record wire positions.
2. Remove wires from switch.
3. Remove switch. (Do not remove cam.)
4. SEE WARNING 1. Install switch, as described above.
5. SEE WARNING 2. Install wires in the original positions.
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WARNING
1. Failure to calibrate switches within the specified angles
may result in the switch being activated when the
handle is not in the proper position. (Example: If the
switch is a center off switch, and is not calibrated per
specifications, the machine function controlled by that
handle may be activated when the handle is in the
neutral position.)
2. Failure to replace wires or electrical components to
their original positions may result in an electrical failure
which could burn out the handle or valve, or cause the
function to be reversed from its original action, or in the
elimination or bypassing of a function.
© Danfoss, 2013-09 BLN-95-9057-1 1
REPLACING SPUR GEAR
3
3
3
1. Identify and record wire positions of switches.
2. Remove wires from switches.
3. Remove cam assembly.
4. Remove switch side plate.
NOTE: On friction-held handles, take precautions to
prevent the loss of the detent spring and ball.
5. Remove spur gear.
6. Install new spur gear by aligning teeth with gear segment. (Do not tighten setscrew.)
7. Electrically null potentiometer. (See “Replacing Potentiometer”, Step 13.)
8. Tighten spur gear setscrew.
9. Replace detent spring and ball. (Friction-held handles
only.)
10. Replace switch side plate.
SEE WARNING 1 below. If the handle has the center
lock option, replace the side plate and check the center
lock action. If it does not function, readjust the side plate
and recheck until it works properly.
SEE WARNING 2 below. Check for free handle movement in both directions. If it does not function, readjust
the side plate and recheck until it works properly.
11. Adjust switches. (See above.)
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WARNING
1. Failure to calibrate the center lock function may result
in the handle passing through the center position
without locking.
2. Failure to ensure free handle movement in both directions may result in limited movement in one direction,
or (if spring returned) may cause the handle to stick in
one direction.
LOCATION OF THE RADIUS
CAM
ASSEMBLY
SWITCH
BODY
RADIUS
LOCATION OF THE #2 SWITCH
#2
COMMON
NORMALLY CLOSED
NORMALLY OPEN
DUAL POTENTIOMETER TERMINALSINGLE POTENTIOMETER TERMINAL
NO. 1 NO. 2
#1
13261323
BLN-95-9057-1
1
+AB—
(2) (3)
3
2
1324
1
3 4
2
+AB—
6
5
1325
2
REPLACING POTENTIOMETER
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1
2
1
2
1
2
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1. Identify and record wire positions on switches and
potentiometer.
2. Remove wires and switches from potentiometer.
3. Remove cam assembly.
4. Remove switch side plate.
NOTE: On friction-held handles, take precautions to
prevent the loss of the detent spring and ball.
5. Remove spur gear.
6. Remove potentiometer.
7. Install new potentiometer. (Do not tighten.)
8. Install spur gear. (Do not tighten.)
9. Adjust gear mesh by sliding potentiometer toward gear
segment to obtain minimum backlash.
10. Tighten potentiometer.
11. SEE WARNING1 below. Rewire potentiometer and
switches to original positions.
12. If the control handle has (2) switches and there is a
resistor in line with the common terminal of the #2
switch, disconnect the common lead. (See Location of
#2 Switch.)
13. SEE WARNING 2 below. Electrically null potentiometer.
the “+” lead from the meter to potentiometer terminal #2.
Divide the original voltage by 2. Turn the #1 potentiometer
shaft until the meter reads that value. Tighten setscrew on
spur gear. Move the “+” lead from the meter to “A” on the
terminal strip, and the “-” from the meter to “B” on the terminal
strip. Rotate the #2 potentiometer shaft until the meter reads
0±.1 volts. Tighten setscrew on spur gear. Move handle to
full stroke in each direction, noting voltages. If the full stroke
voltages are not within 10% of each other, loosen setscrew
on potentiometer #1, rotate the shaft slightly, tighten the
setscrew, and renull potentiometer #2. Repeat if necessary.
If a jumper wire was used between “+” and potentiometer
terminal #1, remove it.
If the handle is a uni-directional device, null the
potentiometer using the following method (see Single
Potentiometer Terminal).
Rotate the handle full clockwise when viewed from the
potentiometer side. If the handle has an end off switch,
jumper from the “+” on the terminal strip to potentiometer
terminal #3. Connect the power lead from the machine to the
“+” terminal, and the ground lead from the machine to the
“-” terminal. Using a voltmeter, connect the “+” from the
meter to potentiometer terminal #2, and the “-” from the meter
to the “-” on the terminal strip. Rotate the potentiometer shaft
slowly to decrease the voltage. When the meter reads
+.2
/
volts, tighten setscrew on spur gear. Recheck reading.
0
-.0
Repeat procedure if necessary. If a jumper wire was used
between “+” and potentiometer terminal #3, remove it.
14. If the common lead from switch #2 was removed,
reconnect it. (See Location of #2 Switch.)
If the handle is a bi-directional device with a single
potentiometer, null the potentiometer using the following
method (see Single Potentiometer Terminal).
Place the handle in the center or detented position. If the
handle has a center off switch, connect a jumper wire from “+”
on the terminal strip to potentiometer terminal #1. Connect
the power lead from the machine to “+” on the terminal strip
and the ground lead from the machine to “-” on the terminal
strip. Using a voltmeter, connect the “+” on the meter to the
“A” on the terminal strip, and the “-” on the meter to “B” on
terminal strip. Rotate the potentiometer until the meter reads
0±.1 volts. Tighten setscrew on spur gear. Recheck the
value at the center position. If not in specification, repeat the
nulling procedure. If a jumper wire was used between
potentiometer terminal #1 and “+”, remove it.
If the handle is a bi-directional device with dual
potentiometers, null the potentiometers using the
following method (see Dual Potentiometer Terminal).
Place the handle in the center or detented position. If the
handle has a center off switch, connect a jumper wire from “+”
on the terminal strip to potentiometer terminal #1. Connect
power from the machine to “+” on the terminal strip, and
ground from the machine to “-” on the terminal strip. Using
a voltmeter, connect “+” to potentiometer terminal #1 and “” to potentiometer terminal #3, and read the voltage. Move
15. Replace detent spring and ball.
16. SEE WARNINGS 3 AND 4 below. Replace switch side
plate.
17. Adjust switches. (See Installing New Center Switch and
Installing New Auxiliary Switch.)
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WARNING
1. Failure to replace wires or electrical components to
their original positions may result in an electrical failure
which could burn out the handle or valve, or cause the
function to be reversed from its original action, or in the
elimination or bypassing of a function.
2. Failure to null potentiometer may result in an uneven
output in each direction. The machine function controlled by the handle may be faster in one direction
than in the other.
3. Failure to calibrate the center lock function may result
in the handle passing through the center position
without locking.
4. Failure to ensure free handle movement in both directions may result in limited movement in one direction,
or (if spring returned) may cause the handle to stick in
one direction.
3
BLN-95-9057-1
REPLACING CENTER SPRING
3
3
3
1. Remove snap ring.
2. Remove washers.
3. Remove bushing.
4. Remove spring.
5. SEE WARNING below. Install new spring. Tabs on
spring may require bending to ensure minimum handle
movement and proper center lock function in the neutral
position.
REPLACING BRAKES
1. Remove snap ring.
2. Remove and discard brake assemblies. Use existing
spring, screw and nut.
3. Mount new brake assemblies.
4. Replace snap ring.
5. Tighten nut and screw (2) full turns after initial contact.
6. Replace bushing.
7. Replace washers, nylon washer to the inside.
8. Replace snap ring.
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WARNING
Failure to calibrate the center lock function may result in
the handle passing through the center position without
locking.
BLN-95-9057-1
4
REPLACEMENT PARTS
ITEM PART ITEM PART
NUMBER NUMBER DESCRIPTION NUMBER NUMBER DESCRIPTION
1 K00566 Knob Round 1 3/8 Dia. 34 K21567 Switch Actuator
2 K00564 Handle Standard 35 K08357 Boot Sealing Actuator
3 K22078 Boot 36 K08358 Boot Retaining Ring
4 K21549 Screw Metric, M5-13 37 K21580 Handle (2 Halves)
5 K00776 Plastic Case Fastener 38 K08359 Nut Hex Metric M4
6 K00559 Gasket Case Seal 39 K08361 Screw Socket Head Metric M4x10
7 K00754 Plastic Case Without Adj. Holes, 1 Wire Exit Hole 40 K06073 Screw 2-56 x 9/16 (subminiture mounting)
8 K00755 Plastic Case Without Adj. 3 Holes, 1 Wire Exit Hole 41 K00904 Spacer (subminiture mounting)
9 K00557 Leadwire Strain Relief 42 K00902 Nut Plate (subminiture mounting)
10 K03220 Switch and Top Knob Assembly 43 K01300 Switch Micro Subminature (not shown)
11 K00387 Setscrew 4-40 x 1/8 cup point 44 Switch Plate Assembly
12 K28194 Knob Bottom 45 K04821 Ball ss 0.219 dia.
13 K01263 3/18-16 Jam Nut 46 K00387 Set Screw 6-32 x 3/16 Cup Point
14 K21550 Screw Metric Tread Forming M5-16 47 K00544 Cover (top aluminum die cast plate)
15 K00558 Gasket Buna 48 K04820 Spring Detent
16 K02992 Case Assembly Surface Mount 49 Potentiometer Plate Assembly
17 K00562 Collar Boot Retaining 50 K00570 Spur Gear (fits 0.250 dia. shaft)
18 K04459 Cap 51 K00569 Spur Gear (fits 0.125 dia. shaft)
19 K00899 Label 52 K06276 Screw Pan Head 4-40 x 5/16
20 K00616 Spring Center Lock 53 K07220 Screw Thread Forming Metric
21 K03545 Handle Center Lock Tube Assy 54 K00821 Nut Locking 10-32
22 K00635 Boot 55 K02982 Brake Assembly
23 K00636 Plate Top Mount 56 K07213 Retainer Ring
24 K00653 Gasket Neo. Foam 57 Gear Segment Assembly
25 K07194 Setscrew Metric Cup Point M4-5.0 58 K01529 Spring Compression
26 Cam Assembly 59 K04556 Screw Socket Head 10-32 x 1 3/4
27 K00805 Speed Nut 4-40 (V3 mounting) 60 K00567 Bushing Inner Plastic
28 K01445 Screw 4-40 x 5/8 (V3 mounting) 61 K00551 Spring
29 K00548 Switch Micro V3 62 K00568 Bushing Outer Plastic
30 Cable Assembly 63 K00574 Washer Flat Nylon
31 K08355 Switch Micro V3-115 64 K04589 Washer Flat St.
32 K08689 Tape 2-Sided Foam 65 K22038 Hollow Shaft without Welded Nut
33 K08360 Screw Socket Head Metric M4x30 66 K21715 Hollow Shaft with Welded Nut
5
BLN-95-9057-1
REPLACEMENT PARTS
34
35
36
37
32
33
31
2
38
39
(continued)
1
10
11
2
12
3
65
4
6
5
8
7
13
14
15
16
17
9
1707A 1710B
8
VIEW A-A
18
20
21
22
19
24
A
T
F
R
A
23
25
26
2827
29
30
BLN-95-9057-1
1719B 1709B
6
REPLACEMENT PARTS
57
64
49
52
56
(continued)
28
27
40
41
42
FRICTION HANDLE
26
25
47
48
54
55
56
57
58
45
49
29
44
43
46
50 51
1713A
53
49
52
1712A 1714A
FRICTION HANDLE FRICTION HANDLE
59
60
26
47
53
28
27
25
61
62
63
40
41
42
29
43
49
SPRING RETURN HANDLE SPRING RETURN HANDLE SPRING RETURN HANDLE
44
1715B
46
50
51
1716C
7
1717C
BLN-95-9057-1
CUSTOMER SERVICE
NORTH AMERICA
ORDER FROM
Danfoss (US) Company
Customer Service Department
3500 Annapolis Lane North
Minneapolis, Minnesota 55447
Phone: (763) 509-2084
Fax: (763) 559-0108
DEVICE REPAIR
For devices in need of repair or evaluation, include a
description of the problem and what work you believe
needs to be done, along with your name, address and
telephone number.
RETURN TO
Danfoss (US) Company
Return Goods Department
3500 Annapolis Lane North
Minneapolis, Minnesota 55447
EUROPE
ORDER FROM
Danfoss (Neumünster) GmbH& Co.
Order Entry Department
Krokamp 35
Postfach 2460
D-24531 Neumünster
Germany
Phone: +49 4321 871-0
Fax: +49 4321 871-284
BLN-95-9057-1
8
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