PTO-Twin Disc HP 300, 600 Service Manual

7/13/2019 PTO-Twin Disc HP 300, 600 Service Manual

1/197

HyHyHyHyHydrdrdrdrdraulicaulicaulicaulicaulicPPPPPooooowwwwwererererer TTTTTakakakakake-ofe-ofe-ofe-ofe-offffff

Model:

HP300 Series

HP600 Series

Document Number: 1021542

TWIN DISCTWIN DISCTWIN DISCTWIN DISCTWIN DISCINCORPORAINCORPORAINCORPORAINCORPORAINCORPORATEDTEDTEDTEDTED

SerSerSerSerServiceviceviceviceviceManualManualManualManualManual


2/197

NOTICE

Twin Disc, Incorporated makes no warranty or guaranty of any kind,

expressed, implied or otherwise, with regard to the information contained

within this manual. Twin Disc, Incorporated has developed this manual

through research and testing of the information contained therein. Twin

Disc, Incorporated assumes no responsibility for any errors that may

appear in this manual and shall not be liable under any circumstances

for incidental, consequential or punitive damages in connection with, or

arising out of, the use of this manual. The information contained within

this manual is subject to change without notice.


3/197

3Hydraulic Power Take-off Service Manual

Document Number

1021542

Issued

August, 2004

Hydraulic Power Take-off

Service Manual


4/197

4 Hydraulic Power Take-off Service Manual

REVISION AND REISSUE DATA

Original Issue August, 2004

BEFORE YOU START

This manual replaces:

Preliminary Manual #1021542 dated January, 2004 for use with

Hydraulic Power Take-Off model HP300 & HP600.


5/197

5Hydraulic Power Take-off Service Manual

A. Twin Disc, Incorporated warrants all assembled products and parts, (except component products or parts

on which written warranties issued by the respective manufacturers thereof are furnished to the original

customer, as to which Twin Disc, Incorporated makes no warranty and assumes no liability) against defective

materials or workmanship for a period of twenty-four (24) months from the date of original shipment by Twin

Disc, Incorporated to the original customer, but not to exceed twelve (12) months of service, whichever

occurs first. This is the only warranty made by Twin Disc, Incorporated and is in lieu of any and all other

warranties, express or implied, including the warranties of merchantability or fitness for a particular purpose

and no other warranties are implied or intended to be given by Twin Disc, Incorporated.

The original customer does not rely upon any tests or inspections by Twin Disc, Incorporated or on Twin

Disc, Incorporated*s application engineering.

B. The exclusive remedy provided by Twin Disc, Incorporated whether arising out of warranty within the applicable

warranty period as specified, or otherwise (including tort liability), shall at the sole option of Twin Disc,

Incorporated be either the repair or replacement of any Twin Disc, Incorporated part or product found by

Twin Disc, Incorporated to be defective and the labor to perform that work and to remove and reinstall (or

equivalent credit). In this context, labor is defined as the flat rate labor hours established by Twin Disc,

Incorporated in the published Twin Disc Flat Rate Schedule, required to remove, disassemble, inspect,

repair, reassemble, reinstall and test the Twin Disc, Incorporated product only. Under no circumstances,

including a failure of the exclusive remedy, shall Twin Disc, Incorporated be liable for economic loss,

consequential, incidental or punitive damages. The above warranty and remedy are subject to the following

terms and conditions:

1. Complete parts or products upon request must be returned transportation prepaid and also the claims

submitted to Twin Disc, Incorporated within sixty (60) days after completion of the in-warranty repair.

2. The warranty is void if, in the opinion of Twin Disc, Incorporated, the failure of the part or product resulted

from abuse, neglect, improper maintenance or accident.

3. The warranty is void if any modifications are made to any product or part without the prior written consent of

Twin Disc, Incorporated.

4. The warranty is void unless the product or part is properly transported, stored and cared for from the date ofshipment to the date placed in service.

5. The warranty is void unless the product or part is properly installed and maintained within the rated capacity

of the product or part with installations properly engineered and in accordance with the practices, methods

and instructions approved or provided by Twin Disc, Incorporated.

6. The warranty is void unless all required replacement parts or products are of Twin Disc origin or equal, and

otherwise identical with components of the original equipment. Replacement parts or products not of Twin

Disc origin are not warranted by Twin Disc, Incorporated.

C. As consideration for this warranty, the original customer and subsequent purchaser agree to indemnify and

hold Twin Disc, Incorporated harmless from and against all and any loss, liability, damages or expenses for

injury to persons or properly, including without limitation, the original customer*s and subsequent purchaser*s

employees and property, due to their acts or omissions or the acts or omissions of their agents, and employees

in the installation, transportation, maintenance, use and operation of said equipment.

D. Only a Twin Disc, Incorporated authorized factory representative shall have authority to assume any cost orexpense in the service, repair or replacement of any part or product within the warranty period, except when

such cost or expense is authorized in advance in writing by Twin Disc, Incorporated.

E. Twin Disc, Incorporated reserves the right to improve the product through changes in design or materials

without being obligated to incorporate such changes in products of prior manufacture. The original customer

and subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of

prior designs or materials.

F. If failure occurs within the warranty period, and constitutes a breach of warranty, repair or replacement parts

will be furnished on a no-charge basis and these parts will be covered by the remainder of the unexpired

warranty which remains in effect on the complete unit.

January 16, 2002 TDWP0002

TWIN DISCTWIN DISCTWIN DISCTWIN DISCTWIN DISC,,,,,INCORPORAINCORPORAINCORPORAINCORPORAINCORPORATEDTEDTEDTEDTED

EXEXEXEXEXCLCLCLCLCLUSIVE LIMITEDUSIVE LIMITEDUSIVE LIMITEDUSIVE LIMITEDUSIVE LIMITED WWWWWARRANTYARRANTYARRANTYARRANTYARRANTY

GENERAL UNITSGENERAL UNITSGENERAL UNITSGENERAL UNITSGENERAL UNITS


6/197

6 Hydraulic Power Take-off Service Manual


7/1977

Twin Disc, Incorporated Table of Contents

Hydraulic Power Take-off Service Manual

Table of Contents

Introduction .........................................................11General Information .......................................................................... 11

Replacement Parts ............................................................................ 12

Preventive Maintenance/Troubleshooting .................................... 13

Safety .................................................................................................. 14

Sources of Service Information ...................................................... 15

Warranty .............................................................................................. 15

Description and Specifications .........................17General Information .......................................................................... 17

Identifying the HPTO model, serial and BOM numbers ............... 18

Construction Features...................................................................... 19

Specifications .................................................................................... 21

Maximum safe operating speed ................................................. 21

Approximate dry weight ............................................................... 21

Oil Cooling requirements ............................................................. 21

Oil type and oil viscosity .............................................................. 21Oil sump-basic information ......................................................... 22

Oil scavenge pump, oil pump information ................................ 22

Oil pressure specifications ......................................................... 22

Fittings, Hose types ...................................................................... 24

Electronic Module ......................................................................... 24

Output and Input speed sensor air gap..................................... 24

Torque on input and output speed sensor nuts ...................... 24

Remote mounted electronic control cable ................................ 24

Shim tolerance for bearing carrier in idler gear ....................... 24Twin Disc PTO support plate specifications ................................. 25

Torque values for U.S. fasteners ..................................................... 26

Wear limits .......................................................................................... 29

Operation..............................................................31General................................................................................................ 31

General Overview of GP Control Valve with Electronic Interface 32


8/1978

Twin Disc, IncorporatedTable of Contents


GP Control Valve hydraulic portion ................................................ 33

Hydraulic System with GP Control Valve ....................................... 36

GP Control Valve Electronic Control Interface (Profile Module) ....... 38

Clutch Engagement Logic (Closed Loop) ...................................... 39Brake engagement ....................................................................... 39

Power Take-off Clutch engagement........................................... 39

Installation............................................................41Identifying the Twin Disc Power Take-off Model Number............ 41

Identifying the SAE Housing Size .................................................... 42

Prior to Installation ............................................................................ 43

Preliminary Checks ........................................................................... 44

Torsional Input Coupling Installation ............................................. 47HPTO Installation to Engine ............................................................ 51

Final Checks....................................................................................... 56

Check and Adjust Main Pressure ............................................... 56

Check Clutch Operation Pressures ........................................... 58

Plumbing - HP300I, HP300S, HP300S, HP600S .............................. 59

Maintenance .........................................................61Allowable Side Loads........................................................................ 61

Lubrication ......................................................................................... 64Grease Specifications .................................................................. 64

Oil Specifications .......................................................................... 65

Oil System ...................................................................................... 65

Torsional Coupling ............................................................................ 66

Overhaul Interval ............................................................................... 67

Periodic Visual Inspection ........................................................... 67

Deflection Alignment Adjustment .................................................... 68

Alignment - U-Joint Installation ........................................................ 70

Disassembly ........................................................73Power Take-off Removal From The Engine ................................... 73

Remove and disassemble the GP Control Valve .......................... 75

Remove the Coupling Housing and disassemble

the Gear Towers ............................................................................ 76


9/1979

Twin Disc, Incorporated Table of Contents


Remove and Front Housing from the Clutch Housing ................. 78

Disassemble the Clutch Housing .................................................... 79

Cleaning and Inspection ....................................83Cleaning and Inspection................................................................... 83

Assembly ..............................................................89Clutch Shaft and Clutch Housing Assembly .................................. 90

Clutch housing .............................................................................. 90

Clutch shaft .................................................................................... 90

Belt Sheave Housing Assembly .................................................... 100

Clutch Assembly .............................................................................. 105

Clutch piston, piston carrier and back plate unit ................... 109

Clutch hub, clutch plates and gear & ring assembly ............ 117

Assemble the Front Housing Unit/Install the Idler Gear ............. 124

Install the Front Housing on the Clutch Housing ........................ 131

Coupling housing ....................................................................... 132

Assemble the Gear Drive Towers ................................................. 135

General information .................................................................... 135

Tower #1 ....................................................................................... 136

Tower #2 ....................................................................................... 143

Assemble the Control Valve Assembly......................................... 144Install the Speed Sensor Pickups ................................................. 151

Output speed sensor.................................................................. 151

Input speed sensor..................................................................... 152

Install the Pump ............................................................................... 153

Plumbing ........................................................................................... 154

HPTO Series Parts Identification List ........................................... 156

Cross Section Views:

HP300I & HP600I .......................................................................... 158

HP300S & HP600S ....................................................................... 159Exploded Views and Illustrations:

HP300S & HP600S Sheave Housing Front Bearing Area ...... 160

HP300S & HP600S Sheave Housing Output Bearing Area.... 161

HP300I & HP600I Rear Bearing Area......................................... 162

HP300I, HP600I, HP300S, HP600S Clutch Area ....................... 163

HP300I, HP600I, HP300S, HP600S Front Bearing Area .......... 164


10/19710

Twin Disc, IncorporatedTable of Contents


HP300I, HP600I, HP300S, HP600S Idler Gear Area ................. 165

HP300I, HP600I, HP300S, HP600S Tower #1 Area................... 166

HP300I, HP600I, HP300S, HP600S Tower #2 Area................... 167

HP300I, HP600I, HP300S, HP600S GP Control Valve Area Illustration ....................................... 168

HP300I, HP600I, HP300S, HP600S

GP Control Valve Area Exploded View (Valve 1020729) ... 169

HP300I, HP600I, HP300S, HP600S

GP Control Valve Area Exploded View (Valve 1021658) ... 170

HP300I, HP600I, HP300S, HP600S Pipes and Fittings ............ 171

HP300I, HP600I, HP300S, HP600S Pipes and Fittings ............ 172

Troubleshooting................................................173Troubleshooting of GP Control Valve & Electronic Interface ... 173Troubleshooting Charts ................................................................. 174

Engineering Drawings ......................................177List of Engineering Drawings ........................................................ 177

Twin Disc Hydraulic Power Take-off Cut-away illustration ....... 178

102668G Sheet 2 of 3: HP300I ........................................................ 179

102668G Sheet 3 of 3: HP300I ........................................................ 180

102668B Sheet 2 of 3: HP300S ...................................................... 181

102668B Sheet 3 of 3: HP300S ...................................................... 182

102668F Sheet 2 of 3: HP600I ........................................................ 183

102668F Sheet 3 of 3: HP600I ........................................................ 184

102668C Sheet 2 of 3: HP600S ...................................................... 185

102668C Sheet 3 of 3: HP600S ...................................................... 186

1020696: Control Valve Assembly ................................................ 187

1020686: HPTO Control Module .................................................... 188

1021292 Sheet 1 of 3: HPTO Plumbing......................................... 189

1021292 Sheet 2 of 3: HPTO Plumbing......................................... 1901021292 Sheet 3 of 3: HPTO Plumbing......................................... 191

1021295: Plumbing Schematic ...................................................... 192


11/19711

Twin Disc, Incorporated Introduction


Introduction

General Information

This publication provides the information necessary for the operation and

maintenance of the Twin Disc, Incorporated equipment specified on the cover

of this manual. Specific engineering details and performance characteristics

can be obtained from the Product Service Department of Twin Disc,

Incorporated, Racine, Wisconsin, USA.

Operation and maintenance personnel responsible for this equipment should

have this manual at their disposal and be familiar with its contents. Applyingthe information in the manual will result in consistent performance from the

unit and help reduce downtime.


12/19712

Twin Disc, IncorporatedIntroduction


Replacement Parts

Parts Lists

See the engineering assembly drawings in Engineering Drawingsand parts

identification and exploded views in the Assembly sectionto facilitate ordering

spare or replacement parts.

Ordering Parts

All replacement parts or products (including hoses and fittings) must

be of Twin Disc origin or equal, and otherwise identical with components

of the original equipment. Use of any other parts or products will void

the warranty and may result in malfunction or accident, causing injury

to personnel and /or serious damage to the equipment.

Renewal parts and service parts kits may be obtained from any authorized

Twin Disc distributor or service dealer.

Note: Do not order parts from the part numbers on the cross-

sectional drawings. These numbers may be referencedfor part identification; however, they should be verified

on the bill of material (BOM) before an order is placed.

BOM numbers are stamped on the unit nameplate.

Parts Shipment

Furnish the complete shipping information and postal address. All parts

shipments made from the factory will be FOB factory location, USA. State

specifically whether the parts are to be shipped by freight, express, etc. If

shipping instructions are not specified, the equipment will be shipped the

best way, considering time and expense. Twin Disc, Incorporated will not beresponsible for any charges incurred by this procedure.

Twin Disc, Incorporated having stipulated the bill of material number on the

units nameplate absolves itself of any responsibility resulting from any

external, internal or installation changes made in the field without the express

written approval of Twin Disc. All returned parts, new or old, emanating from

any of the above-stated changes willnotbe accepted for credit. Furthermore,

any equipment which has been subjected to such changes will notbe covered

by a Twin Disc warranty.


13/19713



Preventive Maintenance/Troubleshooting

Refer to the maintenance and troubleshooting sections of this manual.

Frequent reference to the information provided in this manual regarding dailyoperation and limitations of this equipment will assist in obtaining trouble-

free operation. Schedules are provided for the recommended maintenance

of the equipment and, if observed, minimum repairs (aside from normal wear)

will result.

In the event a malfunction does occur, a troubleshooting table is provided to

help identify the problem area and lists information that will help determine

the extent of the repairs necessary to get a unit back into operation.

Lifting Bolt Holes

Most Twin Disc products have provisions for attaching lifting bolts. The holes

provided are always of adequate size and number to safely lift the Twin Disc

product.

These lifting points must not be used to lift the complete power unit.

Lifting excessive loads at these points could cause failure at the lift

point (or points) and result in damage or personal injury.

Select lifting eyebolts to obtain maximum thread engagement with bolt

shoulder tight against housing. Bolts should be near but should not

contact bottom of bolt hole.


14/19714



Safety

General

Safe practices must be employed by all personnel operating and servicing

this unit. Twin Disc, Incorporated will not be responsible for personal injury

resulting from careless use of hand tools, lifting equipment, power tools, or

unaccepted maintenance/operating practices.

Important Safety Notice

Because of the possible danger to person(s) or property from accidents whichmay result from the use of manufactured products, it is important that correct

procedures be followed. Products must be used in accordance with the

engineering information specified. Proper installation, maintenance, and

operation procedures must be observed. Inspection should be made as

necessary to assure safe operations under prevailing conditions. Proper

guards and other suitable safety codes should be provided. These devices

are neither provided by Twin Disc, Incorporated nor are they the responsibility

of Twin Disc, Incorporated.

To prevent accidental starting of the engine when performing routine

transmission maintenance, disconnect the battery cables from the

battery and remove ignition key from the switch.


15/19715



Sources of Service Information

Each series of manuals issued by Twin Disc, Incorporated is current at the

time of printing. When required, changes are made to reflect advancing

technology and improvements in state-of-the-art.

Individual product service bulletins are issued to provide the field with

immediate notice of new service information.

For the latest service information on Twin Disc products, contact any Twin

Disc distributor or service dealer. This can be done on the Twin Disc corporate

web site found at [http://www.twindisc.com]. Provide your model number,

serial number and bill of material number to obtain information on your unit.

If necessary, contact the Product Service Department of Twin Disc,

International S.A., Nivelles, Belgium, or Twin Disc, Incorporated, Racine,Wisconsin, 53405-3698, USA by e-mail at [email protected].

Warranty

Equipment for which this manual was written has a limited warranty. For

details of the warranty, refer to the warranty statement at the front of this

manual.
http://www.twindisc.com/http://www.twindisc.com/http://www.twindisc.com/http://mail%20to:[email protected]/http://mail%20to:[email protected]/http://mail%20to:[email protected]/http://www.twindisc.com/


16/19716




17/19717

Twin Disc, Incorporated Description and Specifications


Description and Specifications

General Information

The Twin Disc Hydraulic Power Take-Off (HPTO) is an engine-mounted

hydraulic power take off that contains an integral clutch for engagement of

the PTO, and a brake to keep the output shaft stopped when the clutch is

not engaged. Some models include an engine driven multiple pump drive to

provide hydraulic fluid for operation of the pto, and other customer

requirements.

These Power Take Offs are controlled by hydraulics through the electroniccontrol module. Both the clutch and the brake are operated by main pressure

oil supply. The bearings, clutches, and gears are lubricated and cooled with

low pressure oil. The output end bearing on straddle units is grease

lubricated.


18/19718

Twin Disc, IncorporatedDescription and Specifications


Identifying the Twin Disc Hydraulic Power Take-Off Model Number

The nameplate identifies the model, bill of material (BOM) and the serial

number of the unit. These numbers are necessary to identify the correct

parts for your transmission.


19/19719



Construction Features

Housings

The HPTO housing consists of a front SAE 1 or SAE 0 engine housing

adapter, and a front and rear housing. The front and rear housings are sealed

together with a gasket. Straddle units have a rear bearing support housing.

Bearings

The input end and pump drive bearings are a combination of ball and

cylindrical roller bearings. The rear main housing bearings are eitherspherical, tapered or cylindrical roller bearings. The rear bearing on straddle

type units is a grease lubricated cylindrical roller design.

Oil Pump Drive

The oil pump is spline driven by the pump drive gear. Customer supplied

auxiliary oil pumps can also be driven by the splined adapters in the pump

drive gears.

Lubrication Features

Oil is directed by the control valve through horizontal drillings in the main

shafts to orifices through which the front and rear bearings on the main shaft

are lubricated. There are also orifices in the shafts through which both clutch

and brake are cooled. The pump drive gears are lubricate by orifices in an

external plumbing circuit. The rear bearing on straddle type units must be

grease lubricated externally.

Suction Strainer and Baffle

A customer supplied serviceable suction strainer should be located between

the customer supplied oil sump and the oil pump. A customer-supplied baffle

installed in the sump allows aerated oil to settle prior to recirculation.


20/19720



Filter Assembly

A customer supplied oil filter must be installed between the heat exchanger

and the control valve. The filter must have a Beta removal efficiency rating

of 2/20/75 for particle sizes 5 micron/13 micron/16 micron. A typical filterelement should say 5 micron nominal or 16 micron absolute.

Gears

All gears are hardened spur gears, and are in constant mesh.

Flexible Torsional Input Coupling

The purpose of the torsional coupling is to transmit power from the engine to

the Power Take Off through a rubber or silicone element that will:

Dampen torsional vibrations.

Change the natural frequencies of a system to move critical

frequencies out of the operating speed range.

Accommodate a certain amount of misalignment.

Absorb shock and reduce noise.

Minimize gear rattle.

Heat Exchanger

The customer supplied heat exchanger is required to maintain the oil in the

hydraulic system of the Hydraulic Power Take Off at the proper temperature.

An air to oil cooler is typical.

The heat exchanger should be capable of dissipating 28,000 BTU/ hr.

Recommended inlet temperature of heat exchanger: 170o F. (77o C.)

Recommended outlet temperature of heat exchanger: 150o F. (66o C.)

Oil flow from standard Twin Disc pump is 0.0085 gal/rev.

Customer-supplied Support Plate Requirement

Twin Disc, Inc. requires that a support plate be used with all HPTOs.

See specifications and figure 2 of this manual.


21/19721



Specifications

Maximum Safe Operating Speed for Twin Disc Hydraulic Power Take-offs

HP300I (in-line) 2100 RPMHP300S (straddle-bearing) 2100 RPM

HP600I (in-line) 2100 RPM

HP600S (straddle-bearing) 2100 RPM

Approximate Dry Weight

Approximate Dry Weight: 590 Kg. (1,300 Lbs.)

Oil Cooling Requirements (see engineering drawing for additional specs.)

Customer supplied, air to oil cooling is typical.

Minimum oil temperature at start up: -40o C. (-40o F.)

Oil temp. at steady operating conditions: 66o C.- 85o C.(150o F.-185o F.)

Maximum oil sump temperature: 93o C. (200o F.)

Oil Type and Oil Viscosity

Oil type and viscosity:

SAE-API service class CD or CC engine oil certified to meet Caterpillar TO-

2 transmission oil specification and/or Allison type C-4 transmission fluid. A

10W, 30W, or 40W can be used, dependent on ambient temperature. Seetable 1.

Note: If SAE 40 viscosity oil is used, all three drain lines

must be used.

Note: Multi-viscosity oils (i.e. 10W-30W, etc.) can be used

under certain conditions, but require TWIN DISC

approval.

-40OC. 38OC. to 66OC. SAE 10

-40OF. 100OF. to 150OF. SAE 10

2OC. 49OC. to 77OC. SAE 30

35OF. 120OF. to 170OF. SAE 30

>40OC. 60OC. to 85OC. SAE 40

>50OF. 140OF. to 185OF. SAE 40

Suggested Oil

Viscosity

Steady Operating

Temperature

Ambient Start-up

Temperature

Table 1 - Recommended Oil Viscosity


22/19722



Oil Sump-Basic Information (See engineering drawing for additional

specs.)

Capacity: Minimum 8 gallons in customer-supplied sump.

Location: Below the HPTO, and allow for gravity drain from at least two

1 1/2 NPTF drain ports.

Breather: (optional) Can be integrated with fill cap.

Breather Ports: When the sump has a breather, a 19.05 mm. (3/4) port

is used to connect a hose from the HPTO to the sump. Do

not integrate with drain ports.

Drain Ports: Use maximum possible diameter drain hoses (1 1/2 inch

diameter) with least restrictive fittings. All three drain hoses

must be used with SAE 40 viscosity oil to prevent overheating

from entrapped oil.

Suction: Use suitable suction screen to prevent pump damage. Use

suitable suction hose to prevent cavitation.

Baffles: Use baffles to allow return oil to settle away from suction

port.

Oil Scavenge Pump (See engineering drawing for additional specs.)

If sump cannot be located below the HPTO, a customer supplied scavenge

pump that is approximately two times the size of the charge pump must be

used to adequately remove the oil from the pto housing.

Oil Pump(See engineering drawing for additional specs.)

Capacity: Oil flow of 8.5 GPM is required at 1000 rpm. Standard Twin

Disc supplied pump supplies 0.0085 gal/rev.

Rotation: The pump rotates in engine speed direction when mounted

on the output side of the pump drive, or opposite engine speed

direction when mounted on the input side of the pump drive.

Oil PressureSee table 2. Oil temperature must be in the normal operating range. The

range of values shown on the chart is based upon specific flow rates,

temperatures and oil used. Contact Twin Disc engineering for guidance

regarding modified parameters.


23/19723



rpm

Limits for HPTO with 0.0085 Gallons/Rev. pump attached to HPTO gear housing

Range

Clutch

Brake

Neutral

Clutch

Neutral

700

2100

Main Clutch Brake Lube Cooling

TempoC.(oF.)

Min.kPa

(psi.)

Act.kPa

(psi.)

Max.kPa

(psi.)

Min.kPa

(psi.)

Act.kPa

(psi.)

Min.kPa

(psi.)

Act.kPa

(psi.)

Min.kPa

(psi.)

Act.kPa

(psi.)

Max.kPa

(psi.)

1650 1790 1650 0 276 414

(240) (260) (240) (0) (40) (60)

1650 1790 0 1650 276 414

(240) (260) (0) (240) (40) (60)

1650 1790 0 0 276 414

(240) (260) (0) (0) (40) (60)

1650 1790 1650 0 414 552

(240) (260) (240) (0) (60) (80)

1650 1790 0 0 414 552(240) (260) (0) (0) (60) (80)

Cooling temperature range: Delvac 10W Oil at 29oC. - 35oC. (85oF. - 95oF.) or Mobilkote 501 at 32oC. - 38oC. (90oF. - 100oF.)

Required: Clutch lube pressure = Brake lube pressure within 21 kPa (3 psi)

Rear support is required for testing.

Table 2. Oil Pressure Specification

Lube Pressure Port

Brake Pressure Port

Clutch Pressure Port

Main Pressure Port

Lube Pressure Port

Figure 1. Oil pressure pickup points


24/19724



Fittings(See engineering drawing for additional specs.)

Fittings must meet SAE 514, SAE J476, J518 standards.

Hose Type(See engineering drawing for additional specs.)

Hoses must meet SAE 517 specifications for 100R17 or similar type for

hydraulic applications.

Electronic Control Module

Operating voltage range. 9 to 32 Volts DC

Operating temperature range. -40o C. (-40o F.) to 85o C. (185o F.)

Output Speed Sensor Air Gap

Two turns out from touching the outer diameter of the gear.

Input Speed Sensor Air Gap

One and one half turns out from the outer diameter of the gear.

Torque on input and output speed sensor lock nuts

27 Nm. (20 lb.-ft.)

Remote Mounted Electronic Control Cable

See information contained in Installation section.

Shim Tolerance for bearing carrier (65) in idler gear (58).

Refer to the parts list and exploded view illustration.

The designed shim tolerance is .1016 mm. loose to .0254 mm. tight

(.004 loose to .001 tight).


25/19725



HPTO300S 238.15 mm 28.58 cm 16.21 cm ** 8 17.46 mm 19.05 mm

9.376 11.250 6.38 ** 8 11/16 3/4

HPTO600S 238.15 mm 28.58 cm 16.81 cm ** 8 17.46 mm 19.05 mm

9.376 11.250 6.62 ** 8 11/16 3/4

* Based upon an 8-hole bolt pattern without bolt holes in the 12 and 6 oclockpositions.

** Angular offset of thru holes (D) must be calculated with respect to orientation of

sheave housing. Holes are evenly spaced, i.e. 360/8 = angular spacing of thru

holes.

NOTE:PTO deflection due to loads imposed by the application

should not exceed .25 mm (.010). Deflection should

be measured at the support plate pilot with the dial

indicator base mounted on a rigid part of the engine.

PTO

Model

A

Bore+.127/.025mm

(+.005/+.001)

B

Bolt

Circle

C

RadiusD

Degree

E

Hole

Quantity

F

Hole

Diameter

GRecommended

Thickness

Twin Disc PTO Support Plate Specifications

Figure 2. Support plate dimensions

NOTE: One possible mounting method provides installationease. Use angle iron to couple the support plate to the

engine frame.

G

B

C* D

E (qty.)

A

Width

43.18 cm. (17.0) min.

Shim to

within

.12 cm.

(.005)Engine BedFrame

F (dia.)

For Straddle-bearing type

For In-Line type

Platethickness = G

41.91 cm. (16.500) R13.49 mm. (17/32) dia.thru holes 300apart on449.99 mm. (17.716)

dia. B.C.


26/19726



1/4 8 - 11 6 - 8 10 - 12 14 - 16

5/16 18 - 23 13 - 17 20 -24 27 - 32

3/8 34 - 39 25 - 29 35 - 41 48 - 55

7/16 51 - 58 37 - 43 55 - 65 75 - 88

1/2 81 - 95 60 - 70 83 - 97 113 - 131

9/16 111 - 132 82 - 98 120 - 140 163 - 190

5/8 163 - 190 120 - 140 165 - 195 224 - 264

3/4 278 - 332 205 - 245 295 - 345 400 - 467

7/8 448 - 528 330 - 390 470 - 550 638 - 745

1 495 - 595 671 - 806 715 - 845 970 - 1145

1 1/8 615 - 745 834 - 1010 1015 - 1185 1377 - 1606

1 1/4 850 - 1000 1163 - 1355 1375 - 1625 1865 - 2203

Thread

Diameter Nm lb-ft Nm lb-ft

SAE Grade 5 SAE Grade 8

Table 3. - Coarse Thread Capscrews, Bolts and Nuts

Torque Values for U.S. Fasteners


27/19727



Table 4. - Metric Coarse Thread Capscrews, Bolts and Nuts

M6 6.5 - 7.5 9 - 10 9 - 10 12 - 14 10 - 12 14 - 16

M8 16 - 18 21 - 25 23 - 26 31 - 35 25 - 29 34 - 40

M10 32 - 36 43 - 49 44 - 51 60 - 68 51 - 59 70 - 80

M12 55 - 63 74 - 86 77 - 88 104 - 120 89 - 103 121 - 139

M16 132 - 151 179 - 205 189 - 217 256 - 294 219 - 253 298 - 342

M20 257 - 295 348 - 400 364 - 418 493 - 567 429 - 493 581 - 669

M24 445 - 511 603 - 693 626 - 720 848 - 976 737 - 848 1000 - 1150

M30 714 - 820 987 - 1113 1235 - 1421 1674 - 1926 1475 - 1697 2000 - 2301

Property Class 8.8 Property Class 10.9 Property Class 12.9

lb-ft Nm

Thread

Size lb-ft Nmlb-ft Nm

Table 5. - Tapered Pipe Plugs (with thread lubricant)

1/16-27 11.5 8.5 7.5 5.5

1/8-27 14 10.5 9 6.5

1/4-18 34 25 21.5 16

3/8-18 36.5 27 23 17

1/2-14 68 50 40.5 30

3/4-14 73 54 46 34

1 - 11 1/2 108 80 68 50

1 1/4 - 11 1/2 115 85 75 55

1 1/2 - 11 1/2 115 85 75 55

NPTF Size (in) Nm (+ or - 5%) lb-ft (+ or - 5%) Nm (+ or - 5%) lb-ft (+ or - 5%)

In cast iron or steel In aluminum


28/19728



Table 6. - Straight Threaded Tube Fittings, Hose Fittings, and O-Rings

5/16 5 3.5

3/8 11.5 8.5

7/16 16 12

1/2 20 15

9/16 24.5 18

5/8 24.5 18

11/16 34 25

3/4 40.5 30

7/8 54 40

1 1/16 75 55

1 3/16 88 65

1 1/4 88 65

1 5/16 108 80

1 3/8 108 80

1 5/8 135 100

1 7/8 162 120

2 1/2 312 230

Nominal

Thread

Diameter

Nm

(+ or - 5%)

lb-ft

(+ or - 5%)

M10X1.0 26 19

M12X1.5 37 27

M14X1.5 47 35

M16X1.5 58 43

M18X1.5 74 55

M22X1.5 105 77

M27X2.0 179 132

IN IRON

Nominal

Thread

Diameter

Nm

(+ or - 5%)

lb-ft

(+ or - 5%)

M27X2.0 85 63IN ALUM.

M33X2.0 326 240

M42X2.0 347 256

M48X2.0 441 325


29/19729



A Bearing Bore 150.0251 5.9065

B Bearing Bore

Hsg. #1020659 215.0466 8.4664

Hsg. #1020659b 215.0466 8.4664

Hsg. #1020659c 215.9762 8.5030

C Bearing Bore

Hsg. #1019124 160.0225 6.3001

Hsg. #A7576 170.0378 6.6944

Hsg. #1020654 215.0466 8.4664

mm. inches

Table 7. Bearing Bores and Bearing Journals

Maximum Diameter

Item

D Bearing Bore 215.9762 8.5030

E Bearing Bore 125.0112 4.9217

H Bearing Bore

SAE A size 90.0227 3.5442

SAE B size 90.2767 3.5542

SAE C size 90.2767 3.5542

mm. inches

Maximum Diameter

Item

F Bearing Journal 100.0023 3.9371

G Bearing Journal 50.0024 1.9686

mm. inches

Minimum Diameter

Item

G

Bearing

Journal

E

Bearing Bore

C

Bearing Bore

B

Bearing BoreA

Bearing Bore

F

Bearing

Journal

HBearing Bore

D

Bearing Bore

Clutch Housing

Gear & Drive

Ring Asy.

Driven Gear

Belt Sheave

Housing

Front Housing

Model I Bearing Carrier

SAE Mounting

Plate

Wear Limits

Refer to the parts list and exploded view illustration.

The following list maximum diameters sizes for bearing bores and minimumdiameters for bearing journals and seal contact surfaces.


30/19730



#1020660b 70.1010 2.7563 107.7341 4.2415 101.4095 3.9925 95.0595 3.7425

#1020678c 70.1010 2.7563 107.7341 4.2415 101.4095 3.9925 95.0595 3.7425

#1020678d 70.1010 2.7563 107.7341 4.2415 101.4095 3.9925 95.0595 3.7425

#1020678e 70.1010 2.7563 107.7341 4.2415 101.4095 3.9925 95.0595 3.7425

#1020678f 70.1010 2.7563 107.7341 4.2415 101.4095 3.9925 95.0595 3.7425

#1020678g 70.1010 2.7563 107.7341 4.2415 101.4095 3.9925 95.0595 3.7425

mm. inches

Bearing JournalM

Minimum DiameterShaft

Part Number mm. inches

Seal Contact SurfaceN

Minimum Diameter

mm. inches

Seal Contact SurfaceP

Minimum Diameter

mm. inches

Seal Contact SurfaceQ

Minimum Diameter

Table 8. Bearing Journals and Seal Contact Surfaces on Shafts

Shaft

TypicalModel 300S & 600S

Shaft

J

Bearing Journal

K

Seal Contact

Surface

L

BearingJournal

N

Seal Contact

Surface

P

Seal Contact

Surface

Q

Seal Contact

Surface

M

Bearing Journal

ShaftTypical

Model 300I & 600I

Shaft

#1020660b 120.523 4.7450 130.0988 5.1220 120.0581 4.7267

#1020678c 71.374 2.8100 130.0988 5.1220 120.0581 4.7267

#1020678d 80.010 3.1500 130.0988 5.1220 120.0581 4.7267

#1020678e 80.010 3.1500 130.0988 5.1220 120.0581 4.7267

#1020678f n/a n/a n/a n/a 139.7406 5.5016

#1020678g n/a n/a n/a n/a 139.7406 5.5016

mm. inches

Bearing Journal

J

Minimum DiameterShaftPart Number mm. inches

Seal Contact Surface

K

Minimum Diametermm. inches

Bearing Journal

L

Minimum Diameter


31/19731

Twin Disc, Incorporated Operation

Power Take-off Service Manual

Operation

General

A Flexible Torsional Input Coupling is bolted to the engine flywheel. The

couplings internal spline meshes with an external spline on the drive gear.

External teeth on a series of Clutch Friction Plates are in constant contact with

internal teeth of the drive gear. These and related components comprise the

basic input drive portion of the Power Take-off and are in rotation at engine

speed whenever the engine is running.

A series of internally splined Steel Clutch Plates are located between the ClutchFriction Plates. Their internal teeth mesh with external teeth on the Clutch Hub,

which is, in turn, splined to the Clutch Shaft. These and related components

comprise the basic output portion of the Power Take-off and are in rotation

when partial or full clutch is engagement occurs (see below).

The Back Plate is contained within the Clutch Piston forming an operating cavity

into which high-pressure oil is directed by the GP Control Valve. A Piston Carrier,

located inside the Clutch Piston separates the clutch-engagement side from

the brake-engagement side of the cavity.

Multiple accessory drives (on some models) are in rotation whenever the engine

is running. Their output speed is always the same as engine speed.

The General Purpose (GP) Control Valve with its electronic interface is used to

obtain brake engagement, coast, and clutch engagement in this hydraulic power

take off. When these positions are selected by the operator, and the proper

conditions exist, the control valve directs high-pressure oil through internal

passages to instantaneously and smoothly apply the brake, or to engage the

hydraulic clutch. The pressure-rate of rise, controlled by the electronic module,

provides a rapid, smooth, clutch engagement.

On initial startup and service, closely monitor the pressure while starting

the engine to ensure that the pump primes. Do not run the engine for

longer than 10 seconds if measurable main pressure does not register.


32/19732

Twin Disc, IncorporatedOperation


General Overview of GP Control Valve with Electronic Interface

The General Purpose (GP) control valve is a hydraulic valve assembly designed

for use with this power take-off, that includes a remotely mounted electronic

interface control module. The valve assembly contains electrical-current-controlled proportional cartridges.


33/19733



GP Control Valve Hydraulic Portion

The hydraulic portion of the GP Control Valve is made up of two blocks, a lower

main regulator valve body, and an upper valve body. These valve bodies containtwo electrically-actuated proportional valves, and a hydraulic pressure regulator

(consisting of a pilot relief valve assembly and a main spool valve assembly).

Separate identical proportional valves are used for the brake and the clutch

engagement. When the power take-off clutch is selected to be engaged, the

control valve directs high-pressure oil through internal passages to operate the

clutch. When brake engagement is selected, the brake control valve directs

high-pressure oil to operate the brake. (The clutch and brake are never engaged

at the same time.) The pressure-rate of rise (profile) is controlled electronically

by the GP Control Valve electronic interface to provide a rapid, smooth, oil

pressure increase in the clutch or brake hydraulic passages during engagement.

The proportional valve coils are low resistance devices that are electrical

current driven. The use of an uncontrolled power source may supply

too much current and damage the proportional valve.

Note: Installations with this valve must include an oil filter

with the proper filtering characteristics. This valve

requires a filtration level of 16 micron at an efficiency

of 98% (beta ratio = 75) or better. Besides the valve's

requirement on filtration, the filter must meet therequirements of the power take-off (operating

pressure, flow, etc.)


34/19734



Figure 3. Hydraulic Schematic (GP control valve)


35/19735



Figure 4. Top Hydraulic Valve Body Assembly

Figure 5. Main Regulator Hydraulic Valve Assembly

Valve sectionused with valve

assembly 1020729

Pressure Regulator

Valve sectionused with valve

assembly 1021658


36/19736



Hydraulic System with GP Control Valve

The oil pump draws oil from the oil sump and discharges it to the heat exchanger,

and on through the oil filter. Filtered oil enters the control valve through the inletport. The incoming oil is supplied to the main pressure regulating relief pilot

valve and the main regulating valve cartridge, satisfying the main pressure

requirements of the HPTO and cascading all remaining oil flow into the

lubrication circuit. Oil not used for clutch or brake engagement flows past the

regulator piston to become lubrication oil. Lubrication oil flows through the

lubrication oil circuit in the pto to lubricate and cool the clutches and bearings.

Main pressure is supplied to the inlet of each proportional valve. Prior to

engagement, the areas behind the clutch piston and brake piston are open to

sump when the solenoids are not energized. The clutch and brake arehydraulically disengaged, but springs in the clutch unit cause the brake to be

mechanically engaged. (The clutch is disengaged at that time.)

When the clutch is commanded to engage, the proportional valve directs main

pressure to a passageway in the clutch shaft. The oil is directed between the

carrier and the apply piston. The apply pistons for the power take off clutch and

the brake are connected so that when the clutch is hydraulically applied, the

apply piston for the brake is pulled away from the clutch plate(s), preventing

brake engagement. The clutch engagement, including the rate-of-rise, is

controlled electronically utilizing a closed loop logic that is programmed into

the HPTO Control Module.

Clutch release occurs when the proportional valve is de-energized. (At that

time, the springs in the clutch unit will mechanically engage the brake.

The electronic interface portion of the control valve allows only one proportional

valve to be energized at a time, thus, apply oil can only be supplied to either the

brake or the clutch at one time, and the oil from the disengaged unit is vented to

sump (atmospheric pressure). The pto clutch release springs move the clutchs

apply piston to the disengaged position minimizing clutch plate drag.

See the Hydraulic Piping Diagram on the following page.

Note: The breather (108) that is located on the top of the

pump drive tower can be moved to the sump,

provided that a line is connected from the vent

location on the pump tower to the sump, and the

sump breather is located in a baffled quiet area

where the oil flow path does not affect the sump area

by the breather.


37/19737



Figure 6. Hydraulic Piping Diagram

Pump Inlet Port

Pump Outlet Port

Valve Inlet Port

Drain Port

Control ValveAssembly

Pump

3/4Hose

1Hose1Hose

1 1/4Hose

1 1/2Hose

1 1/2Hose

1 1/2-11 1/2 NPTF

Thread

1 1/2-11 1/2 NPTFThread


Pump InletPort

Pump OutletPort

Valve Inlet Port

Breather


38/19738



GP Control Valve Electronic Control Interface (Profile Module)

The electronic portion of the GP Control Valve must be remotely mounted from

the hydraulic portion of the GP Control Valve, because of the ambient

temperature in most applications.

If the ambient temperature of this mounting location exceeds 82oC.

(180oF.), the Electronic Control Interface must be relocated to a cooler

area. See Remote Mounted Electronic Control Cable in the Installation

Section of this manual

This module contains the electronic circuitry to control the proportional cartridges

that are used to engage the clutch and brake, based on the commands from

the operator, and the programmed logic. Clutch apply pressure rate of rise(profile) is factory set with the use of internal circuitry. Closed loop logic is used

for all clutch engagements. There are no user adjustments on the HPTO Profile

Module. All electrical wiring for the Hydraulic Power Take Off system controls

are routed through this interface module. The machines battery power (12 vdc

or 24 vdc) is supplied to the electronic interface only, and never directly to the

hydraulic proportional valves. Two red led lights are used to identify the

proportional cartridge valve that is energized, and a greenled is used to identify

when power is provided to the electronic module. Flashing lights are used in

troubleshooting. Engine speed and clutch output speed sensors are required

for the control logic. The following figure shows the Electronic HPTO Module.

Do not connect valve coils directly to battery power supply voltage.

Use an approved Twin Disc Control System.

Figure 7. Electronic HPTO Module


39/19739



Clutch Engagement Logic (Closed Loop)

Brake Engagement

Any time that the PTO Output Speed is below a preset speed, and the Power

Take Off Clutch is not commanded to be on, the Brake Valve Coil will be

commanded on by a pre-programmed profile. When the clutch is engaged,

the brake will be commanded to be off. Also, if the PTO Output Speed increases

at any time a small amount above this preset speed, the Brake Valve Coil will

be commanded off.

Power Take Off Clutch Engagement

Any time that the customer supplied PTO Engage Switch is closed, indicatingthat the operator wishes to engage the Power Take Off, the Control Module

commands the brake to be off and begins two simultaneous logic processes.

These are a Clutch Engagement process, and a Clutch Lockup Check process.

Input Speed and Output Speed are monitored continuously. The following briefly

describes the steps in the processes.

The engine must be below a preset speed before any clutch engagement will

be commanded. If the engine speed is proper, the clutch is engaged at a

preset level, while engine speed and output speeds are monitored. The clutch

pressure will be increased as fast as possible without reducing the engine

speed below a preset speed. If no output speed is detected, the PTO clutchwill be disengaged and reapplied. If no output speed is detected after four

attempts, the warning relay will be closed, and no further engagements

attempted for five minutes, allowing the clutch components to cool sufficiently.

Do not shut off the power to bypass the five minute cool down period.

Mechanical damage can occur if the clutch is not allowed to cool after

each engagement. After five minutes, turn off the engine and determine

why the output did not rotate.

After five minutes, another clutch engagement can be attempted. The

PTO Engagement Switch must be turned off to reset the warning relay.

If an input speed sensor failure is detected, engagements of the PTO Valve

Coil will not be allowed.

If an output speed sensor failure is detected, engagements of the Brake Valve

Coil will not be allowed.


40/19740




41/19741

Twin Disc, Incorporated Installation

Power Take-Off Service Manual

Identifying the Twin Disc Power Take-off Model

The nameplate identifies the model, bill of material (BOM) and the serial number

of the unit. These numbers are necessary to identify the correct parts for your

transmission.

Installation


42/19742

Twin Disc, IncorporatedInstallation


Identifying the SAE Housing Size

Figure 8. Basic dimensions for SAE housings

Table 9. SAE Housing Identification

00 787.40 31.000 876.3 34.50 850.90 33.500 16 13.49 .531

0 647.70 25.500 711.2 28.00 678.18 26.750 16 13.89 .547

1 511.18 20.125 552.5 21.75 530.23 20.875 12 12.29 .484

SAE

HousingSize

A

Housing

Pilot Diameter

B

Housing

Flange O.D.

C

Bolt Circle

Diameter

D

Bolt Holes

Qty.Dia.

mm. inches mm. inches mm. inches mm. inches

A

B

D

C


43/19743



Prior to Installation

The Twin Disc Hydraulic Power Take Off mounts directly onto the flywheel

of the engine. Flywheel-to-Power take off interference is possible due

to mismatch of components or other reasons. Therefore, engine

crankshaft endplay as well as flywheel alignment checks must be made

before the Hydraulic Power Take Off is installed.

After installation of the Hydraulic Power Take Off, the crankshaft endplay should

be measured again. The endplay at the second measurement should be the

same as the first. A difference in these two endplay measurements could be

an indication of interference. Consequently, the Hydraulic Power Take Off should

be removed and the source of interference found and corrected.

Twin Disc will not be responsible for system damage caused by engine to Twin

Disc Hydraulic Power Take Off interference regardless of the cause of

interference. This engine crankshaft endplay check is considered mandatory.

The power take off housing flange and pilot, the engine flywheel and the flywheel

housing must be checked for trueness. Clean the engine flywheel and flywheel

housing mounting surfaces thoroughly before any measurements are made.

Filtration prior to start-up (new or rebuilt unit)

1) Proper cleaning of hydraulic hoses prior to installing them on the HPTO.

2) Insure cooler has been flushed and is indeed clean.

3) Always install a filter at the inlet of the valve body in case residual debris

was missed in the cooler after cleaning.

4) At first start-up with new or rebuilt HPTO, check main and lube pressure

to ensure pump has primed and producing oil pressure.


44/19744



Preliminary Checks

Refer to Identifying the SAE Housing size in table 9.

Note: All measurements must be taken with the engine or

motor mounted on its supports after the flywheel and

housing have been thoroughly cleaned.

1. Measure and record the engine crankshaft or motor shaft endplay using

a dial indicator. Record this value, as it will be used later._______

2. Bolt the indicator to the flywheel so the indicator is perpendicular to theflywheel housing face and the indicator stem rides on the flywheel housing

face. See Figure 9.

Figure 9. Checking Flywheel Housing Face

3. Rotate the shaft through on entire revolution and note the runout. The

total indicator reading (T.I.R.) must not exceed:

SAE #0 Housing .41 mm. (.016).SAE #1 Housing .30 mm. (.012).

Note: The flywheel and crankshaft of the engine must be

held against either the front or rear of the crankshaft

thrust bearing while the total indicator sweep (T.I.R.)

is being made.


45/19745



4. Readjust the indicator so the stem rides on the pilot bore of the flywheel

housing face. See Figure 10.

Figure 10. Checking Flywheel Housing Bore

5. Rotate the shaft through one entire revolution and note the runout. The

total indicator reading (T.I.R.) should not exceed:

SAE #0 Housing .41 mm. (.016).

SAE #1 Housing .30 mm. (.012).

6. Remove the indicator base from the flywheel and bolt it to the flywheel

housing face. Position the indicator stem so that it rides where the drive

ring will set on the flywheel face. See Figure 11.

Figure 11. Checking Driving Ring Surface of Flywheel

7. Rotate the shaft through one entire revolution and note the face runout of

the flywheel. The total indicator reading (T.I.R.) must not exceed .01mm.

(.0005) per 25.4 mm. (per inch) of flywheel diameter.

Note: The flywheel and crankshaft of the engine must be

held against either the front or rear of the crankshaft

thrust bearing while the total indicator sweep (T.I.R.)

is being made.


46/19746



8. Readjust the indicator stem so it rides on the torsional input coupling

pilot bore of the flywheel. See Figure 12.

Figure 12. Checking Torsional Input Coupling Pilot Bore of Flywheel

9. Rotate the shaft through one entire revolution and note the torsional input

coupling bore eccentricity. The total indicator reading (T.I.R.) must not

exceed .13 mm. (.005).


47/19747



Torsional Input Coupling Installation

Refer to the cleaning and inspection section of this manual before proceeding.

1. Clean the flywheel and the input coupling face and outside pilot diameterof any dirt or debris as necessary.

2. Use crocus cloth or emery cloth to remove any surface imperfections

such as nicks, burrs, and sharp edges on the O.D. or the surface that

will be mounted against the flywheel face.

3. Use crocus cloth or emery cloth to remove any surface imperfections

such as nicks, burrs, and sharp edges in the I.D. of the flywheel pilot

bore or on the face that will be in contact with the input coupling.

4. Position the input coupling against the flywheel, piloted in the mounting

bore, and secure with eight hex-head capscrews.Torque the capscrews

to the proper specifications given in Torque Values for U.S. Fasteners

in the Description and Specifications section of this manual.

Torsional Input Coupling attachment screws must be grade 8. Do not

use substitutes.

Be sure the internal retaining ring is properly installed inside the

torsional input coupling hub. See Engineering Drawings section of this

manual for correct ring location.


48/19748



Assembly Instructions for CENTAFLEX - R on Flange Mounted

transmission. Information Taken from CENTA Drawing 26-60062-91-3.

1. Bolt flywheel flange onto flywheel and tighten bolts as follows.

Figure 13. Assemble Flywheel Flange to Flywheel

Table 10. Centa Tightening Torque Chart

Property Class 8.8Thread

Size ft.-lbs.Nm

M10 50 37M12 85 63

M16 215 159

Tightening torque is for slightly oiled bolts, tolerance is + or - 5%.

Securing of the bolts by adhesives (e.g. Loctite) is possible.

FlywheelMounting Bolt

Flywheel Flange portion ofthe Torsional Input Coupling


49/19749



2. Place rubber rollers in the deepest section of the cam in the output hub.

Normally they stick there by friction.

Figure 14. Insert Rollers and Note Alignment

3. In case they do not stick, place a tape or a cord with a slip knot around

all rollers close to the gear side. Leave the end of the tape or cord long

enough so that it extends outside the flange. Turn the two coupling halves

so that the arrows of both halves are opposite one another. See Figure

14 (View X).

Figure 15. Coupling into Flywheel Flange

Flywheel

Tape or Cord

Flywheel Flange portion ofthe Torsional Input Coupling

Rollers

Internal portion of theTorsional Input

Coupling


50/19750



4. Then push the output side of the coupling with the hub into the outer

flange. If necessary apply lubricant on the outer flange. Suitable

lubricants are soap water, detergents, etc. DO NOT USE OIL OR

GREASE. If tape or a cord was used, push the coupling only half way

together and remove the tape or cord. Then complete the installation.

Figure 16. Assemble part way and remove the tape or cord.

Figure 17. Final Assembly

RemoveTape or Cord


51/19751



HPTO Installation to Engine

Refer to the cleaning and inspection section of this manual before proceeding.

When mounting the engine and Hydraulic Power Take Off in the machine,

the six mounting bolts on each side of the mounting pads of the In-Line

power take off must be used. The power take off mounting brackets

should not be used to support the engine. A support plate must be

used to support the output end of the Straddle Bearing Units. Failure

to follow this guideline may result in damage to the power take off or

the engine flywheel housing.

See Engineering Drawings for installation dimensions and the locations of the

required connections for power take off installation.

HP300I HP300S HP600I HP600S

The connections include the following:

Output shaft connection

Electrical connection for Control Module

Oil connection to the oil pump and heat exchanger

Oil connection from the heat exchanger to the oil filter

Speed pickups and pressure gauges

1. Clean the PTO housing flange, flywheel housing flange of any debris.

2. Make sure the housing flange and flywheel housing flange are free of

surface imperfections such as nicks, burrs, and sharp edges. Remove

them using fine emery cloth or crocus cloth.

3. Install a minimum of 3 guide studs in the flywheel housing, located

approximately 120o apart. Using a suitable hoist, position the PTO on

the guide studs and slide it against the flywheel housing, carefully aligning

the teeth of the drive gear (12) with the internal teeth of the coupling (1).

Do not force the pto unit onto the engine. If any resistance is noted,


52/19752



identify and correct all sources of interference.

4. Secure the PTO housing to the flywheel housing with 12 hex-head

capscrews (SAE #1 housing) or 16 capscrews (SAE #0 housing) .

Torque the capscrews to the proper specifications given in TorqueValues for U.S. Fasteners in the Description and Specifications

section of this manual.

Note: PTO housing to flywheel housing attachment screws

must be grade 5 or better.

5. Rap the end of the output shaft with a soft hammer to remove any preload

on the main bearings and/or pilot bearing.

Note: This step must not be omitted. Bearing failure may

result.

6. Measure the crankshaft endplay again. The measurement must be the

same value as recorded fromstep 1 under Preliminary Checks.Locate

and correct the source of preload if the endplay is not the same value.

Engine and/or PTO failure will result from any excessive preload on

components.

7. Install the drive sheave, u-joint flange or other driven components as the

application requires.

HP300S and HP600S only: (Models 300I & 600I skip to step 8.)

Note: Straddle bearing units only - refer to V-belt installation in

the maintenance section and the Engineering Drawings

towards the back of this manual. (Proceed at step 8.)

HP300S, HP600S, HP300I and HP600I

8. A PTO support plate mounted at the output bearing retainer must be

used. Install the support plate. Refer to Support Plate Specificationsin the Description and Specifications sectionand the Engineering

Drawingstowards the back of this manual.

9. Measure and adjust for proper deflection and alignment. (See

instructions near back of this section.)

10. Attach hoses, hose fittings and other plumbing circuit components

including the sump, oil filter and heatexchanger. (See plumbing

illustrations near back of this section.)


53/19753



11. Attach the speed pickup(s) and pressure gauge(s). (See details

contained in drawings in the Engineering Drawings section of this

manual.)

12. Mount the Electronic Control Module.The Electronic Control Module must be remotely mounted from the

Hydraulic Power Take Off unit because of the possible temperatures

reached at the power take off. See Figure 18 .

Figure 18. Electronic Control Module


54/19754



Figure19. Wiring Schematic

13. Attach all electrical connections for the Control Module.


55/19755



1021351A 1500 59

1021351B 1800 71

1021351C 2100 83

1021351D 2400 941021351E 2700 106

1021351F 3000 118

1021351G 3300 130

1021351H 3600 142

1021351J 3900 154

1021351K 4200 165

1021351L 4500 177

1021351M 4800 189

1021351N 5100 201

1021351P 5400 213

1021351Q 5700 224

1021351R 6000 236

1021351S 6300 248

1021351T 6600 260

1021351U 6900 2721021351V 7200 283

1021351W 7500 295

1021351X 7800 307

1021351Y 8400 331

1021351Z 9000 354

1021351AA 9600 378

1021351AB 10200 402

1021351AC 10800 425

1021351AD 11400 449

1021351AE 12000 472

1021351AF 12600 496

Part

Number

Part

Number

Length

millimeters inches

Length

millimeters inches

Table 11. Cable Lengths

Length

14. Attach the optional cables for remotely locating the control module are

listed in the table 11.

Figure 20. Cable for remote control operation

Electrical Controls: All electrical wires and connectors must be

adequately supported to prevent rubbing, chafing, or distress fromrelative movement. All electrical connections must be tight and free

from any corrosion. See Figure 18 for the wiring connector.


56/19756



Final Checks

Before starting the engine, be sure the sump is properly filled with oil and the

rear main bearing is properly greased. See Description and Specifications

and Maintenance sections for the proper oil specification and filling procedure.

Monitor the pressure while starting the engine to ensure that the pump

primes. Do not run the engine for longer than 10 seconds if the pump

does not prime, resulting in measurable main pressure.

Check and Adjust Main Pressure (as needed)

It is recommended that following the servicing of the valve assembly a procedure

be followed to ensure the flushing of oil through the valve assembly, followed byadjustment of the main pressure.

1. Install a main pressure gauge into the port on top of the Top Valve body.

Figure 21. Main Pressure Port in Valve Body

2. Remove protective cover cap located at the end of the pilot relief valve

assembly. This will expose a 1/4" hex head adjustment screw. Loosen

the jam nut on the stem.

Top View

Side View

Main PressurePort

Valve Inlet Port

Pilot Relief ValveAssembly

Valve assembly1020729 isillustrated.


57/19757



Figure 22. Pilot Relief Valve Assembly/Pressure Regulator

The Hydraulic Power Take-Off must be in the disengaged position before

the engine is started.

3. Turn this adjustment screw counterclockwise until it reaches a positive

stop. This allows the engine to be started and flush any debris past the

relief valve.

4. Start engine with the HPTO control in set in the disengaged position.

Main pressure should be approximately 689 kPa (100 psi.) or less. Allow

the fluid to flush the valve for approximately 1 minute.

Monitor the pressure while starting the engine to ensure that the pump

primes. Do not run the engine for longer than 10 seconds if measurable

main pressure does not register.

5. Turn the 1/4" hex head adjustment screw clockwise to achieve the main

pressure setting. A helpful practice is to turn the screw approximately

35 kPa (approximately 5 psi.) beyond the desired setting and then adjust

for the target pressure. This aids in reducing variance in pressure setting

due to torsional wind-up of the internal pressure spring.

Note: If main pressure is to be set with cold oil, adjust the

main pressure to approximately 35 - 70 kPa (5 - 10

psi.) higher than the desired hot oil value.

6. Tighten the jam nut to a torque of 20 Nm. (15 ft.-lb.), install the protective

cap, and torque it to14 Nm. (10 ft.-lb.)

Cap

Jam Nut

Used with valveassembly1020729

Used with valveassembly1021658


58/19758



Check Clutch Operation and Pressures

7. After the engine and Hydraulic Power Take-Off are warmed up, check

oil pressures in accord with the pressures shown in the Oil Pressure

Specification table in the Description and Installationsection of thismanual.

Note: Read and become completely familiar with the Power

Take-Off Clutch Engagement explanation in the

Operation Sectionof this manual.

8. Engage the clutch. Automatic brake disengagement should allow shaft

rotation to reach full speed.

Note: Read and become completely familiar with the Brake

Engagement explanation in the Operation Section

of this manual.

9. Disengage the clutch. Check to be sure shaft rotation slows to a stop

when the clutch is disengaged. Automatic brake engagement will

eventually stop shaft rotation when the clutch is disengaged.


59/19759



Plumbing - HP300I, HP300S, HP600I, HP600S

Pump Inlet Port

Pump Outlet Port

Valve Inlet Port

Drain Ports

Control ValveAssembly

Pump

3/4Hose

1Hose1Hose

1 1/4Hose

1 1/2Hose

1 1/2Hose




Pump InletPort

Pump OutletPort

Valve Inlet Port

Breather


60/19760




61/19761

Twin Disc, Incorporated Maintenance


Maintenance

Allowable Side Loads

Figure 22. Allowable Side Pull and Formula to Determine Applied Load

Formula values for Figure 22.

L = actual applied load (Lbs.)

N = shaft speed (RPM)

D = pitch diameter (in.) at sheave, etc.

F = load factor

1.0 for chain or gear drive 2.5 for all V belts

1.5 for timing belts 3.5 for flat belts

LF = 2.1 for reciprocating compressors and other severe shock drivers

and 1.8 for large inertia type drive (crushers, chippers, planers)

A support plate must be attached at the rear of the PTO.

Note: HP300I and HP600I Hydraulic Power Take-offs are

recommended for in-line, not side-loaded,

applications.

L=126,000 x H.P.

N x Dx F x LF

CENTERLINE

OF SIDE

LOAD

S


62/19762

Twin Disc, IncorporatedMaintenance


Allowable Side Loads HP300S

127.0 mm. 152.4 mm. 177.8 mm. 203.2 mm. 228.6 mm. 254.0 mm.

5.0 inches 6.0 inches 7.0 inches 8.0 inches 9.0 inches 10.0 inches

47149 52931 60493 65385 56934 50485

10600 11900 13600 14700 12800 11350

44480 50040 56834 61827 54043 47816

10000 11250 12800 13900 12150 10750

42478 47816 54488 59158 51597 45814

9550 10750 12250 13300 11600 10300

40744 45814 52486 56934 48595 44035

9160 10300 11800 12800 11150 9900

RPM

1500N

Lbs.

N

Lbs.

N

Lbs.

N

Lbs.

1800

2100

2400

S Dimension

Table 12 - HP300S Side Load Capacity Values

Side Load Chart - HPTO 300S

9000

10000

11000

12000

13000

14000

15000

127 (5.0) 152.4 (6.0) 177.8 (7.0) 203.2 (8.0) 228.6 (9.0) 254 (10.0)

"X" Distance, mm . (inches)

Maximu

mL

oad,

Lbs.

1500 RPM 1800 RPM 2100 RPM 2400 RPM


63/19763



Allowable Side Loads HP600S

Table 13 - HP600S Side Load Capacity Values

127.0 mm. 152.4 mm. 177.8 mm. 203.2 mm. 228.6 mm. 254.0 mm. 279.0 mm.

5.0 inches 6.0 inches 7.0 inches 8.0 inches 9.0 inches 10.0 inches 11.0 inches

79619 87181 96966 97856 90274 82510 74726

17900 19600 21800 22000 20700 18560 16800

70278 77396 56834 87626 82288 73837 66720

15800 17400 19300 19700 18500 16600 15000

67165 73837 54488 83622 78730 70723 64051

15100 16600 18400 18800 17700 15900 14400

RPM

1200N

Lbs.

N

Lbs.

N

Lbs.

1800

2100

S Dimension

Side Load Chart - HPTO 600S

14000

16000

18000

20000

22000

127.0 (5.0) 152.4 (6.0) 177.8 (7.0) 203.2 (8.0) 228.6 (9.0) 254.0 (10.0) 279.0 (11.0)

"X" Distance, mm. (inches)

Maximu

mL

oad,

Lbs.

"1200 RPM" 1800 RPM 2100 RPM


64/19764



Lubrication

Refer to Engineering Drawings and figure 23 below for location of fittings.

Figure 23. Location of lubrication points

Grease Specifications (rear-straddle type - HP300S & HP600S)

NLGI grades 0, 1, or 2 with allowable continuous use up to 135o C.

(275o F.) are acceptable. Recommended greases include Mobilgrease

XHP 222, Mobilgrease CM-S, Mobilux EP-2 or equivalent.

Grease Specifications (rear-straddle type - HP300S & HP600S)

Add 1cc every 10 hours of use. See figure 23 for location of grease fitting.

Lubrication Point

Hydraulic PTO (Rear StraddleType)

Rear View (Typical)

Lubricate the rearMain Bearing (grease)

Side View (Typical)

Enlarged View(Typical)


65/19765



Note: The remaining portion of the HPTO Straddle-Bearing

unit is oil-lubricated. HPTO In-Line units are oil-

lubricated and require no grease lubrication.

Oil Specifications

See specifications contained inDescription and Specifications section.

Oil System

Oil LevelThe customer supplied sump oil level should be checked daily or every 10

hours. A dipstick or sight glass is the preferred means of checking oil level.

Oil and Filter Change IntervalWith a new unit, change the oil and filter element within the first 50 hours ofoperation. Change oil and filter element after each 1000 hours thereafter or

more often if conditions warrant. The oil and filter should be changed every six

months if less than 1000 hours has accumulated since the last oil change.

For a repaired unit, check the filter element after eight hours of operation. If the

filter is clean, install a new filter element and then change the oil and filter element

after 1000 hours of service. If the filter is dirty, change the element and operate

for another eight hours. Check the filter again. Continue this cycle until the filter

is clean and then change the oil and filter after 1000 hours of service or more

often if conditions warrant.

Oil Suction StrainerRemove and clean the pump suction strainer at every oil change or sooner if

necessary. The suction strainer is customer provided, and should be located

in the suction line near the sump.


66/19766



Torsional Coupling

1. Do not obstruct the flywheel housing vents preventing the free flow of air

for cooling the coupling. The ambient temperature of the air around the

coupling should be between -6oC. (22oF.) and 80oC. (176oF.). Assurebaffles are installed properly so hot air is ported out of the housing.

2. Visually inspect the element after the first 100 hours of operation and

every 2000 hours thereafter, or every six months, whichever comes first.

Torsional vibration, misalignment, degradation by contaminants (oil),

heat, ultraviolet radiation, and excessive system torque can cause cracks

or other signs of distress to appear on the surface of the rubber. The

above-described items affect the life of the coupling element.

When inspecting the flexible coupling, look for evidence or conditionsidentified in the following steps:

A. Cracks in the surface of the rubber. May be caused by torsional

vibrations, excessive misalignment or exposure to contaminants

(heat, petroleum products, chemicals, ozone, ultraviolet radiation,

etc.) excessive system torques.

B. Deterioration of the rubber element, as evidenced by sponginess

or by black carbon-like dust on rubber surface. May be caused

by contaminants or excessive heat, either external or internal to

the coupling.

C. Cracked, bent or otherwise damaged flex plate or coupling plate.

D. Bolt holes in flex plate or coupling plate are elongated oval

shaped, not round. This could be caused by improperly

assembled parts, loose parts, vibration or improperly torqued

parts.

E. Bolts/nutsbent, worn or stripped threads.

3. Inspect the hub, looking for the following:

A. Damaged or worn splines.

B. Cracked parts.

4. Replace any defective parts including defective fasteners that are found.


67/19767


Powe

Documents

PTO-Twin Disc HP 300, 600 Service Manual