Edbro PTO 01-01 User manual

SETTING THE INDUSTRY STANDARD
Edbro plc
Nelson Street, Bolton BL3 2JJ, UK
Tel: [phone] Fax: [phone]
Spares fax: [phone]
Web: www.edbro.com
Technical specificaons are subject to change without noce.
Rev1, July 2011
General Installaon Guide for PTO’s PTO 01-01
1 - ATTENTION: SAFETY INFORMATION
- The PTOs should be mounted by qualied personnel.
- Use suitable tools and measurement instruments.
- Use personal protection and precautions set out by current regulation on safety in the workplace.
- Ensure the system or the PTO cannot involuntarily be started up.
- Do not assemble the PTO or parts of the PTO or conduct maintenance work when the engine is on.
- Ensure all the components have been assembled properly and the level of oil in the gear box has been topped up before starting up the
vehicle: Incorrect assembly of the PTO may cause the PTO and/or the gearbox to break and damage other parts of the vehicle.
- The splined shaft (male or female) protruding from the PTO rotates with no protection when the pump has not been assembled.
Avoid any contact between the shaft and any object and, more importantly, protect the working area to prevent contact with body parts or
clothing.
- Install the pump or the cardan shaft only when the engine is o and the PTO has been disconnected.
- The gearbox or the PTO may attain high very temperatures after prolonged use of the vehicle or the PTO. It is therefore necessary to take
all the necessary precaution measure to prevent burns. Wait for the mechanical parts to cool down to temperatures appropriate for skin contact
- Some PTOs are considerably heavy and to assemble and disassemble them it is necessary to use adequate lifting or resting sys
prevent crushing hazards, it may be necessary for two people to carry out the operation.
- Any waste oil that has not been used should be processed according to the directives included in the current regulation on the disposal of special waste.
MOST COMMON PTO SHAFT
OUTLET VERSION
Male shaft 6x21x25 (ISO14)
Rear outlet
Male shaft 6x21x25 (ISO14)
Front outlet
VERSION 13 VERSION 14
VERSION 15
Male shaft 8x32x36 (ISO14) Rear outlet
This version always requires
the ange (114...)
Female hub 8x32x36 (ISO14)
Rear outlet
VERSION 17
ASSEMBLY OF THE RIGHT SIDE
ASSEMBLY OF THE LEFT SIDE
ASSEMBLY OF THE REAR
ASSEMBLY OF THE UPPER PART
ASSEMBLY OF THE LOWER PART
2 - INDICATIVE ASSEMBLY POSITIONS OF THE PTOS
OUTLET REAR SHAFT
CLOCKWISE
ANTICLOCKWISE
CLOCKWISE rotation
Application - LEFT pump
ANTICLOCKWISE rotation
Application - RIGHT pump
RULES APPLYING TO THE DIRECTION
OF ROTATION OF THE PTO
OUTPUT SHAFT
OUTLET FRONT SHAFT

SETTING THE INDUSTRY STANDARD
Edbro plc
Nelson Street, Bolton BL3 2JJ, UK
Tel: [phone] Fax: [phone]
Spares fax: [phone]
Web: www.edbro.com
Technical specificaons are subject to change without noce.
Rev1, July 2011
General Installaon Guide for PTO’s PTO 01-01
3 - GENERAL INFORMATION TO MOUNT POWER TAKE-OFFS
- Carefully follow these general assembly instructions, both as far as the safety precautions and the assembly stages of the PTOs are concerned.
- The general indications do not replace specic instructions contained in the PTOs, in the assembly kit or in the various assembly accessories
(adapters, auxiliary shafts, etc).
- It is necessary to also follow any instructions related to the vehicle gearbox.
- Install the PTO with the vehicle placed on a at surface, so that oil levels in the gearbox can be checked correctly.
- Only use the components contained in the PTO packaging and related accessories (assembly kit, auxiliary shafts, adapters).
- Only use gaskets supplied.
- Do not use sealing paste, unless explicitly indicated in the specic instructions.
- It is advisable to use a medium-strength threadlocker to tighten the studs and screws.
- Before assembling the PTO, check that the vehicles clutch and transmission work correctly and that the gearbox does no produce any
anomalous noises or issues in selecting gears.
TIGHTENING TORQUE (see note)
Thread diameter - Screw (mm) M8 M10 M12 UNC 3/8 UNC 7/16
Screws and nuts torque (Nm) 25 50 80 25 60
Studs torque (Nm) 6 10 18 10 20
For some aluminium gearboxes the tightening torque needs to be reduced
by 30%.
Note on the tightening torque: the tightening torques reported are only
means as a guide and do not replace the indications given by the vehicle’s
manufacturer of the gearbox manufacturer.
TABLE 3
4.5 - If the PTO needs to be mounted
with studs, insert them (with the
short thread side) in the threaded
holes of the gearbox, using a
medium-strength threadlocker (LOC-
TITE 243, LOXEAL 55-03 or similar).
Tighten the studs using a torque like
the one indicated in TABLE 3 Chap.3 .
If the gearbox has feed-through
threaded holes, the threadlocker
should also have a sealing action
and it is necessary to check that the
studs do not interfere with the gea-
ring of with parts inside the gearbox.
4.1 - Unscrew the drain plug
and remove the oil from the gear-
box. Screw the drain plug back
with the tightening torque indicated
in the gearbox’s operating manual.
4.2 - Identify the suitable gearbox
opening to mount the PTO and remo-
ve the cover with the related gasket.
4 - INSTALLATION OF SIDE MOUNT PTOS
4.3 - Check that the gearing is compa-
tible with the PTO’s gearing in terms of
position, inclination of the tooth and te-
ethsize.Thisneedstobecarriedoutasan
additional check that the right PTO has
been selected for the specied gearbox.
4.4 - Clean the surface of the ope-
ning, make sure no foreign mat-
ter is introduced in the gearbox.
4.6 - Position the sealing gasket.
4.7 - Install the PTO and tighten the nuts
with lower torque compared to the
nd xing torque.
4.9 - Once the optimal clearance
has been dened
tighten the nuts or the screws of the
PTO fully home with the tightening
torque shown in TABLE 3 Chap.3 .
4.10 - Top up the oil in the gearbox
bearing in mind that usually a side
mount PTO uses up approximately
0.5–0.8litresofoil. Installthecontrol
system. Start up the vehicle and en-
gage the PTO. Conduct the checks as
illustrated in the paragraphs below.
(A)
4.8 - Check, through the inspection hole
(indicated by the arrow) the clearan-
ce between the gearings. The clearan-
ce should be between 0.15 and 0.3 mm
(A) . The clearance is controlled manually
and therefore it cannot be precise. This is
why it is necessary to proceed by attem-
pts until the optimal clearance is achieved.

SETTING THE INDUSTRY STANDARD
Edbro plc
Nelson Street, Bolton BL3 2JJ, UK
Tel: [phone] Fax: [phone]
Spares fax: [phone]
Web: www.edbro.com
Technical specificaons are subject to change without noce.
Rev1, July 2011
General Installaon Guide for PTO’s PTO 01-01
5 - INSTALLATION OF REAR MOUNT PTOS
It is necessary to check and follow the specic instructions contained in the adapters and the auxiliary shafts.
tions contained in the adapters and the auxiliary shafts. The indications below are meant as a guide.
5.1 - Empty the oil of the gearbox (for some gearboxes there is no need to empty the oil as the level does not reach the rear appertue (check the gear box’s operating manual)
5.2 - Identify the rear opening and remove its cover and gasket. The gasket removed should not be used to assemble the PTO.
5.3 - Clean the surface of the apertue, make sure no foreign matter is introduced in the gearbox
5.4 - If necessary, install the auxiliary shaft and/or adapters following the specic instructions with special care for cases where it is necessary to adjust the bearings with
cone-shaped rollers.
5.5 - If the PTO needs to be assembled with studs, insert them (fron the short thread side) in the threaded holes using a medium-strength threadlocker
(LOCTITE 243, LOXEAL 55-03 or similar). Tighten the studs using a torque as indicated in TABLE 3 .
If the gearbox has feed-through threaded holes, the threadlocker should also have a sealing action.
5.6 - Install the PTO on the gearbox and tighten the nuts or screws with the tightening torque indicated in the table.
5.7 - Top up the oil in the gearbox bearing in mind the oil required by the PTO.
5.8 - Install the tting and the air coupling pipe.
For rear PTO with 2 wheel it is recommended, to optimise the lubrication of internal parts, to suit the assembly positions indicated.
PTO Vertical ASSEMBLY
-Low outlet
PTO Horizontal
ASSEMBLY
PTO Vertical ASSEMBLY
-High outlet
6 - PREPARATION OF REAR PTOS
Some PTOs feature an engaging coupling
separated from the PTO and which changes
according to the gearboxes where
it needs to be installed.
6.1 - Use the circlip pliers to remove
the circlip from the seat of the central pin.
Attention: DO NOT EXPAND THE CIR-
CLIP MORE THAN IT NEEDS TO BE
TO AVOID PERMANENT WARPING.
6.2 - Insert the coupling in the seat of the
PTO
6.3 - Use the pliers to reposition
the circlip in the seat of the pin,
checking that this is secure.
Attention: DO NOT EXPAND THE CIR-
CLIP MORE THAN IT NEEDS TO BE
TO AVOID PERMANENT WARPING
ATTENTION: incorrect positioning of the cir-
clip or warping of the circlip during assem-
bly may cause the PTO to fail to disengage.
6.4 - Proceed to install the PTO, as il-
lustrated in the previous paragraph.

SETTING THE INDUSTRY STANDARD
Edbro plc
Nelson Street, Bolton BL3 2JJ, UK
Tel: [phone] Fax: [phone]
Spares fax: [phone]
Web: www.edbro.com
Technical specificaons are subject to change without noce.
Rev1, July 2011
General Installaon Guide for PTO’s PTO 01-01
7 - CHECKS
7.1 - Checking the coupling
Connect and disconnectthePTOafew times (follow the paragraph HOW TO USE THE PTO) to check the coupling system is working properly
Any anomalous noise produced during couplingis only dueto thefact that the PTO’s gearings are not completely still and therefore to the fact that the vechile’s
clutch isnot workingproperly. Eitherthe clutchpedal hasnot beenfully pressedor onehas notwaited thetime necessaryfor thegearbox’s gearings to stop.
7.2 - Checking noise levels for lateral PTOs
- If the PTO does not produce anomalous noises or noises that are not that dierent from those of the clutch, this means that the assembly and
the teeth clearance are correct;
- If the PTO produces a screeching noise (whistle) this means that the PTO has been assembled with insucient clearance between the teeth.
In this case it is necessary to disassemble the PTO and add a gasket between the surface of the PTO and that of the gear box;
- If the PTO produces a beating, this means that the PTO has been assembled with excessive clearance between the teeth. In this case it is
necessary to disassemble the PTO and remove a gasket or use a thinner gasket.
For the purposes of the durability of the PTO it is generally preferable to have a slightly higher clearance between the teeth rather than a low one.
7.3 - Leak check
After it has been operating for a few minutes, stop the vehicle and check there are no oil leaks from the surface connecting the gearbox to the
PTO or from other parts of the PTO.
7.4 - Clamping check
After a few minutes of operation, check the that the threaded parts have been tightened.
Checks related to noise levels, leaks and clamping should also be conducted when the vehicle is hot.
8 - PTO FOR DIRECT ASSEMBLY ON THE PUMP
shown in TABLE 3
2 - Move the pump away from
the PTO by 10mm.
3 - Screw the nuts a few mm. 4 - Push the pump against the
PTO and tighten the nuts fully
home. The tightening torque
1 - Install the pump on the PTO
with the sealing gasket supplied
with the assembly kit
To prevents splines from wear please grease pump shafts and / or couplings.
9 - HOW TO USE THE PTO
The procedure applies to PTOs installed on NON-automatic gearboxes.
For PTOs installed on automatic gearboxes, please refer to the related instructions.
PTO engagement procedure must be always carried with vehicle stationary and parking brake applied.
ATTENTION: incorrect connection or disconnection causes premature damaging to the internal organs of the PTO.
Therefore CAREFULLY follow the indicated instructions.
9.1 CONNECTING THE PTO
-Press the clutch pedal and keep it pressed for a few seconds to stop the gears from turning.
- Activate the PTO control.
- The PTO engages (the actual coupling is conrmed when the related PTO CONNECTION indicator, if any, turns on).
- SLOWLY release the clutch pedal.
9.2 DISCONNECTING THE PTO
- Press the clutch pedal and keep it pressed for a few seconds.
- Bring the PTO control back to the o position.
- The PTO disengages (the actual coupling is conrmed when the related PTO CONNECTION indicator, if any, turns o).
- Release the clutch pedal.
WARNING: when the vehicle is on the move the PTO must be always OFF.
MOUNTING INSTRUCTIONS FOR ISO PUMPS ON ISO PTO’S WITHOUT BEARING
1 - Mount loose gear and circlip
on the pump’s shaft 2 - After mounting PTO on the gearbox, screw the studs
(pos.A) onto the PTO. Place the intermediate gasket and
then fit the PTO assembly (fig 1) onto the PTO. Fix the pump
applying the tightening torque indicated in TABLE 3.