HEAVY MOTIONS HM589 Series Operating instructions
[INSTALLATION & OWNERS’ MANUAL - POWER TAKE-OFFs]
HM589Series
www.HeavyMotions.com
CONTENTS
SAFETYINFORMATION
PTOSAFETYLABELS
PTOINSTALLATION
CHECKINGBACKLASH
AIRSHIFTINSTALLATION
PTOANDPUMP/DRIVENUNITASSEMBLY
DirectMountPump
PTOMAINTENANCE
PTOOPERATION
1
2
3
6
8
12
12
15
16
PTO589‐IOM‐1512 HeavyMotions,Inc.|HM589SeriesPTOs 1
SAFETYINFORMATION
Pleasereadthismanualcarefullyuntilyouunderstanditbeforeinstallingor
usingthePowerTakeOff(PTO).
ThePTOmustbeproperlymatchedwiththevehicle’stransmissionand
thedrivenequipmentoritcouldcauseseveredamagetotheequipment
and/ormaycauseseriouspersonalinjurytotheoperatorandothers
nearby.
Exposedrotatingdrivingshaftsmusthavesomeformofguardtoensure
safety.
DONOTgounderthevehiclewhentheengineisrunning.
DONOTworkonornearanexposedrotatingshaftwhentheengineis
running.
DONOTuseworn‐outordamagedcomponents.
DONOTworkalonewhileinstalling,repairing,ormaintainingany
equipmentunderthevehicle.
Followtheproperprocedureandusethepropertoolsandsafety
equipment.
TheoperatorshouldreceivepropertrainingregardingthePTOoperation.
2HeavyMotions,Inc.|HM589SeriesPTOsPTO589‐IOM‐1512 2
PTOSAFETYLABELS
1. Frameraillabel.Twoframeraillabelsaresupplied.Placeonthetruck
framerails,oneoneachside,inaplacewhereitcouldbeeasilyseenby
anyonegoingunderthetrucknearthePTO.
2. PTOControlLabel.PlaceclosetothePTOcabincontrolvalveordevice.
3. VisorLabel.Placeonthevisornearthedriver.
PTO589‐IOM‐1512
HeavyMotions,Inc.|HM589Series
PTOs 3
PTOINSTALLATION
1. Draintheoilfromthetransmission
andcleanthecoverplateandthe
surroundingarea.
2. Removethecoverplatefromthe
PTOapertureonthetransmission
(Fig.1).
3. InspectthetransmissionPTOdrive
geartomakesureitisingood
condition.
4. Withyourhand,rockthePTOdrive
gearinthetransmissionandthe
inputgearinthePTOassemblyto
establishtheamountofbacklashin
eachunit.
5. Inordertopreventdirtfrom
enteringthetransmission,putarag
intheaperturehole.
6. Removethegasketonthe
transmissionopeningandcleanthe
apertureusingaputtyknifeorwire
brush(Fig.2).
Fig.1
Fig.2
4
HeavyMotions,Inc.|HM589SeriesPTOs
PTO589‐IOM‐1512 4
7. Installthestudsintothetapped
holesofthetransmission’sPTO
aperture(Fig.3).Makesurethe
studsdonotinterferewiththe
gearsofthetransmission.
8. Torquethestudsto18‐22lbs.ft
(24‐30N.m).Overtighteningthe
studsmaydamagethethreadsin
thetransmissionhousing.
9. Placetheproperamountofgaskets
(Useatleastonegasketbutdonot
stackmorethan3gasketstogether)
(Fig.4).Usuallyone0.020”gasket
willberequired,butmoregaskets
mayberequiredwhenestablishing
properbacklash.Donotusegasket
sealerbecauseyoumayneedto
addorremoveagasketwhen
adjustingthebacklash.
Fig.3
Fig.4
PTO589‐IOM‐1512
HeavyMotions,Inc.|HM589Series
PTOs 5
10. Removetheshiftcoverfromthe
PTOandmountthePTOonthe
transmission(Fig.5).Makesure
thattheoutputshaftisonthe
desiredposition.
11. Installthewashersandnuts(Fig.
6).Torquethenutsto:
30‐37lbs.ft(40‐50N.m)on
6‐boltapplications
50‐60lbs.ft(68‐80N.m)on
8‐boltapplications.
Fig.5
Fig.6
6
HeavyMotions,Inc.|HM589SeriesPTOs
PTO589‐IOM‐1512 6
CHECKINGBACKLASH
1. RemovethePTOshiftcoverifitisstillonthePTO.
2. MountthedialindicatoronthebodyofthePTOorthebodyofthe
transmissionsoitmeasuresthemovementofthePTOinputgear.See
Figure7fortheproperlocationofthedialindicatorcontactpoint.Two
commontypedialindicatorsshown.
Fig.7.
3. MakesurethatthePTOdrivegearinthetransmissioncannotmove.
Holditwithascrewdriverorbar.
PointerIndicatesSide
Movement(0.006”/0.012”)
PlungerTypePointer
IndicatesDepth
RockPTO
InputGear
GasketPack
IndicatorOptions
PTO589‐IOM‐1512 HeavyMotions,Inc.|HM589SeriesPTOs 7
4. MovethePTOinputgearbackandforthwithyourhand.Readinthedial
indicatorthemeasurementofthebacklash.
5. Theproperbacklashshouldbe0.006”to0.012”(0.15mmto0.30mm).If
thebacklashisoutsidethisrange,adjustitbyaddingorremoving
gaskets.
Ifthebacklashistoolarge,removegasketsorselectathinner
gasket.
Ifthebacklashistoosmall,addgasketsorselectathickergasket.
8
HeavyMotions,Inc.|HM589SeriesPTOs
PTO589‐IOM‐1512 8
AIRSHIFTINSTALLATION
1. Placetheshiftcovergasket
onthePTOaperture(Fig.8).
Donotusesiliconeonthe
gasket.
2. InstallthePTOshiftcoverso
thattheforkisonthesame
sideoftheoutputshaft.
3. Makesuretheforkslides
intotheoutputgeargroove
(Fig.10).
Fig.8
Fig.9
Fig.10
Fork
Groove
PTO589‐IOM‐1512
HeavyMotions,Inc.|HM589Series
PTOs 9
4. ApplyadropofLoctite290
oneachcoverbolt.Install
bolts(Fig.11).
5. Torqueboltsto16‐20lbs.ft
(22‐27N.m).
6. Screwtheairfittingintothe
shiftcover(Fig.12).
7. Installthenylontubingthat
comesfromthecabin
controlvalveintothefitting
(Fig.12)
Important:
Makesuretheairsystem
hasinstalledapressure
protectionvalvebetween
theairsourceandthe
cabincontrolvalve.It
shouldopenat60‐70PSI.
Connectthepressure
protectionvalvedirectly
totheairsupplyusinga
nipple.Donotusetubing.
Fig.11
Fig.12
Wheninstallingthenylon
tubing,avoidsharpangles,
sharpedges,exhaustand
manifoldsystems.
Nylon
Tube
Fitting
10
HeavyMotions,Inc.|HM589SeriesPTOs
PTO589‐IOM‐1512 10
9. Connectthenylontubetothecabinsinglecontrolvalveorcombo
controlvalveairoutput(Seetheschematicsuppliedwiththevalve).
10. Connecttheswitchconnectorwiretothesinglecontrolvalveorcombo
valveindicatorlightconnectorsusingbuttconnectors(Seethe
schematicsuppliedwiththevalve).
8. Connecttheswitch
connectorintotheindicator
switch(Fig.13).
Fig.13
Indicator
Switch
Switch
Connector
PTO589‐IOM‐1512
HeavyMotions,Inc.|HM589Series
PTOs 11
Fig.14
DONOTFORGETTOREFILLTHETRANSMISSIONWITHCLEANOILUP
TOTHEPROPERLEVEL.
Tosingleor
combocabin
controlvalve
airoutput.
Tosingleor
combocabin
controlvalve
indicatorlight.
12
HeavyMotions,Inc.|HM589SeriesPTOs
PTO589‐IOM‐1512 12
PTOANDPUMP/DRIVENUNITASSEMBLY
DirectMountPump
1. Greasetheinnersplines
surfaceofthePTOoutput
shaftwithanti‐fretting,high
temperature,highpressure
grease.
2. Installthepumpintothe
PTO(Fig.15).Aftermaking
thepumpandPTOsplines
match,insertthepump
ensuringthatthecontact
withtheflangeopeningis
good.
3. Rotatethepumpsothatthe
holesfortheboltsonthe
pumpflangeandonthePTO
flangearealigned(Fig.16).
Fig.15
Fig.16
PTO589‐IOM‐1512
HeavyMotions,Inc.|HM589Series
PTOs 13
4. ApplyadropofLoctite290
oneachbolt,installwashers
andbolts(Fig.17).
5. Tightentheboltsin
oppositeangles,notin
sequence.Torqueboltsto
60‐70lbs.ft(82‐94N.m).
Fig.17
14
HeavyMotions,Inc.|HM589SeriesPTOs
PTO589‐IOM‐1512 14
Important:Useapumpbracketontherearofthepumptohelpsupportthe
weightofthepumpif:
Thecombinedweightofthepump,itsfittings,andhosesexceeds
40pounds(18Kg).
6. ThedistancebetweenthecenterlineofthePTOtotheendofthepump
is18inches(45cm)orlonger(Distance“D”Fig.18).
Fig.18
Thebracketmustbeattachedtoatleast2transmissionboltlocations
andatleast2pumplocations.Makesurethatthebracketdoesnot
preloadthepump/PTOmounting.
D
PTO589‐IOM‐1512 HeavyMotions,Inc.|HM589SeriesPTOs 15
PTOMAINTENANCE
Toensureasafeandtroublefreeoperation,theownerand/oroperatormust
performthefollowingperiodicmaintenance:
Daily:
Lookforairleaks,hydraulicleaks,andmakesurethemechanismsare
workingproperly.Performrepairsasrequired.
Monthly:
Tightenallair,hydraulicandhardwaretothepropertorque.
DirectMount:EnsurethatthePTOandPumpshaftsplinesareproperly
greased.Useanti‐fretting,hightemperature,highpressuregreaseonly.
RemoteMount:CheckthePTOdrivelinecomponentsforanoutofphase
condition,excessivevibration,excessiveu‐jointanglesorwornparts.
Performrepairsasrequired.
16HeavyMotions,Inc.|HM589SeriesPTOsPTO589‐IOM‐1512 16
PTOOPERATION
Important:FailuretofollowtheproperPTOoperationwillresultinpremature
PTOfailure.
StationaryApplications:ChockthewheelsbeforeengagingthePTO.
ManualTransmissions:
1. Pushintheclutchpedaltodisengagetransmissionandwaitafew
secondssothetransmissionstopsturning.
2. Shiftthetransmissionintoneutral.
3. EngagethePTOusingthedashmountedvalve.
4. Letclutchpedalout.
AutomaticTransmissions:
1. Letengineidle.
2. Applybrakes.
3. Placeshiftselectorinanydriverange.
4. EngagethePTOusingthedashmountedvalve.
5. Shifttransmissiontoneutralorpark.
NOTE:ExpectaslightincreaseinPTOnoiselevelasoilthinsoutatoperating
temperature.
PTO589‐IOM‐1512 HeavyMotions,Inc.|HM589SeriesPTOs 17
HeavyMotions,Inc.
Tollfree:1‐866‐865‐8889
Tel:909‐627‐1000
Fax:909‐498‐0468
www.HeavyMotions.com
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