matev FPS-PTO JD 4020 Installation instructions

matev GmbH
Nürnberger Str. 50
90579 Langenzenn
T [phone]
F [phone]
[e-mail]
www.matev.eu
Version 04/2011
Original Operating Manual
Independent live power take off
FPS-PTO JD 4020
for John Deere series 4020
2000 U/min CCW 2000 U/min CW

Table of contents
Table of contents
1. About this operating manual................................................................................... 3
2. Safety ........................................................................................................................ 4
2.1. Intended use...............................................................................................................4
2.2. Qualification of personnel...........................................................................................4
2.3. General safety instructions......................................................................................... 4
2.4. Special safety instructions..........................................................................................5
2.5. Supplemental provisions............................................................................................. 5
3. Installation ................................................................................................................ 6
3.1. Preparatory measures................................................................................................6
3.2. Mounting the independent live PTO............................................................................8
3.3. Installation is complete.............................................................................................16
4. Operation ................................................................................................................ 17
4.1. Coupling and uncoupling implements.......................................................................17
4.2. Mounting the universal joint shaft .............................................................................18
4.3. Dismounting the universal joint shaft ........................................................................ 18
4.4. Switching the independent live PTO on and off ........................................................19
4.5. Run-up time of the front PTO shaft system...............................................................19
5. Maintenance............................................................................................................20
5.1. Service.....................................................................................................................20
5.2. Changing the gear oil ............................................................................................... 20
5.3. Repair.......................................................................................................................21
6. Disposal .................................................................................................................. 21
7. Warranty...................................................................Fehler! Textmarke nicht definiert.
8. List of illustrations ................................................................................................. 22
9. EC Declaration of Conformity................................................................................ 23

About this operating manual
Page 3
1. About this operating manual
Dear customer!
Thank you for purchasing this device, we appreciate your trust.
Prior to using this device for the first time read this operating manual carefully and con-
scientiously all the way through.
Keep this operating manual where it is easily accessible. This will enable you to refer to
important information and handling instructions as needed.
Listings with bullet points are marked as follows:
Text
Text
Text
Handling instructions are marked in the sequence in which they should be executed, as
follows:
1.1.1. Text
1.1.2. Text
1.1.3. Text . . .

This device is subject to change in the interest of technical progress. All
information, illustrations, and technical specifications represent the latest
status at the time this manual was published. The manufacturer reserves the
right to make changes at any time in the interest of technical progress.

Safety
Page 4
2. Safety
Guidelines and instructions with which you must comply are summarized in this section.
Personnel who install, operate and maintain the device, must have read and understood
this operating manual.
2.1. Intended use
The independent live PTO extends the crankshaft of the tractor to the front. It is used to
power sweepers, front mowers, or similar implements that are driven with PTO shafts.
This independent live PTO should only be mounted on tractors as specified on the cover
sheet.
Non-intended use causes:
Health hazards for the operator or for third parties
Damage to the tractor and the attachments
Environmental damage
2.2. Qualification of personnel
Only personnel 18 years of age or older, or instructed personnel should install, operate,
and maintain the implements. The operator must have read and understood this operat-
ing manual.
2.3. General safety instructions
General safety instructions are explained in this section. These safety instructions are
used in the subsequent sections. In addition to the safety aspect, you will save money
and work time if you follow these safety instructions.

Danger!
Severe injury to the operator or third parties occurs.
Follow the safety instruction.

Attention!
Minor injury to the operator or third parties can occur. The tractor or the
environment can be damaged.
Comply with the safety instruction.

Note!
Important, helpful tips or information for the operator.
Read this note. It facilitates your work.
Attention!
Injuries can occur.
Wear protective work clothing.

Safety
Page 5
2.4. Special safety instructions
Safety instructions are specified in this chapter that are also affixed as stickers on the im-
plements

Attention!
Danger of injury due to moving parts.
Remove the ignition key before performing maintenance tasks on the im-
plement.


Attention!
Injuries can occur due to improper operation. The implement can be dam-
aged.
Read the operating manual all the way through.
Comply with the safety instructions.


Attention!
Injuries due to fluid escaping under high pressure.
Comply with the instructions in the operating manual.

Attention!
There is an increased risk of accident due to the rotating PTO shaft.
Do not enter the work area of the PTO shaft when it is rotating.
For your own safety do not wear any loose clothing, belts, or any other
loose items. Switch off the implement. Wait until all machine parts have
come to a standstill before converting or servicing the implement.
Attention!
Check all threaded unions prior to using the implement and after using the
implement. Loosened connections must be retightened.
Damage can occur due to loose connections.
2.5. Supplemental provisions
Ensure that the speed and the direction of rotation of the independent live PTO are
suitable for driving the implement before coupling to an implement.
Always switch off the front PTO shaft and wait until the PTO shaft is no longer turn-
ing when you leave the tractor or work on the connected implement.
Do not attempt to find a possible leak in the hydraulic system with your fingers. Oil
under high pressure can easily penetrate skin and clothing and cause serious in-
jury.

Installation
Page 6
3. Installation

Danger!
Severe injury to the operator or third parties occurs.
Switch off the tractor and remove the ignition key before mounting or dis-
mounting the independent live PTO.
3.1. Preparatory measures
The prerequisite for using the independent live PTO is that the tractor must already be
equipped with the matev front power system 131 7142.
3.1.1. Drive the tractor onto the lift platform. Remove the battery. Remove the mounting
bolts of the front floor panel, including the mounting bolts of the radiator on the
floor panel. Keep these threaded unions available in a safe place for later use.
Remove the condenser of the air conditioning system. Use coolant R 134 A; fill
quantity 1.27 kg.

Attention!
Injuries can occur due to improper operation. The device and the environ-
ment can be damaged.
If necessary commission an authorized company to empty and fill the con-
denser of the air-conditioning system.
3.1.2. Drain oil and coolant from the radiators and keep it on hand for later use. Remove
the radiators.
Fig. 1 Radiators removed

Installation
Page 7
3.1.3. Remove the locking hooks of the engine hood, and shorten the locking hooks as
shown in the Fig. below.
Fig. 2 Locking hook
Attention!
Injuries can occur.
Wear protective work clothing.
3.1.4. Make a cutout in the front holding plate of the battery as shown in the diagram be-
low.
Fig. 3 Cutout in the holding plate
Shorten here

Installation
Page 8
3.1.5. Make a cutout in the floor panel of the tractor as shown in the diagram below.
Fig. 4 Floor panel with cutout
3.2. Mounting the independent live PTO
3.2.1. Mount the opening handle included in the scope of delivery of this independent
live PTO, the locking hook, and the torsion spring on the holding plate. The hole
for the heavy-type dowel pin in the locking rod must be bored on site. Position the
holding plate in the original position on the tractor and make the cutout for the
handle as shown in the Fig. below.
Fig. 5 Cutout for the handle of the engine hood lockingmechanism
3.2.2. Remove the pulley of the tractor. The original mounting bolts of the pulley will no
longer be required. Replace the O-ring Ø38x2 and fasten the pulley included in the
scope of delivery of this independent live PTO on the crankshaft of the tractor. To
do this use the included clamp ring, the bushing, and the M12 Allen bolt. Use a
torque wrench. The tightening torque is 147 Nm.
75
60
Cutout approx. 15x40
Drill

Installation
Page 9
Fig. 6 Mounting parts of the pulley
Fig. 7 Clamp ring and clamping bushing
3.2.3. Fasten the universal joint shaft to the pulley with the aid of a torque wrench. The
tightening torque is 42 Nm.
Fig. 8 Mounting the universal joint shaft to the pulley
O-ring Ø38x2
Bolt M 12x110, 12.9
Pulley
Clamp ring
Clamping bushing
Centering collar to the out-
side
Conical side to the inside
Bolts M8x16, 12.9
Universal joint shaft
Pulley

Installation
Page 10
3.2.4. Drain the oil from the gearbox and mount the hydraulic hoses on the gearbox.
Fig. 9 Hydraulic connections on the gearbox
3.2.5. Mount the gearbox on the matev front lift 131 7142. The tightening torque is 50
Nm. Establish the electrical connection. Ensure that the hydraulic connection and
the electrical connection are not damaged.
Fig. 10 Gearbox on the front power lift
3.2.6. Mount the universal joint shaft on the gearbox using a torque wrench. The
tightening torque is 42 Nm.
Gearbox

Installation
Page 11
Fig. 11 Universal joint shaft
3.2.7. Mount the dismounted radiator and tighten all threaded unions of the mounting
bolts and the connections. Fill the radiator.
3.2.8. Bore four sink holes for M6 countersunk bolts in the holding plate of the charge-air
cooler and mount the small oil cooler of the gearbox. Connect the hydraulic lines.
In this process ensure that the lines do not get into the movement zone of the front
lift or of the universal joint shaft.
Fig. 12 Mounting the small oil cooler
Fig. 13 Small oil cooler
Gearbox
Bolts M8x16, 12.9
Small oil cooler
Countersunk bolts M6x30
Spacer

Installation
Page 12
3.2.9. Fill the gearbox with gear oil up to the oil fill plug. The types of oil that can be used
are in section 5.2.5.
Fig. 14 Gearbox oil fill plug
3.2.10. Mount the switch-on electronics on the cover plate of the universal joint shaft and
fasten the sheet metal instead of the battery holder on the tractor.
Fig.15 Cable with switch-on electronics
Fig. 16 Switch-on electronics on the universal joint shaft cover
3.2.11. Connect the extension cable to the plug connection on the switch-on electronics.

Installation
Page 13
Fig. 17 Extension cable
3.2.12. Route the extension cable to a free switch bay in the cab. Remove the cover and
connect the switch included with the scope of delivery for this independent live
PTO to the cable.
Fig. 18 Switch
3.2.13. Route the brown cable to ground and the red cable to the ignition power.
3.2.14. Mount the PTO shaft guard on the gearbox.
Fig. 19 PTO shaft guard
Switch

Installation
Page 14

Attention!
If you are mounting the independent live PTO in a tractor that has a cab,
follow the description in sections 3.2.15 and 3.2.16
3.2.15. Take the left rear tire off of the tractor.
3.2.16. Mount the M10 and M12 spacers in the tapped bores behind the left rear wheel in
the gearbox block of the tractor. Install the support plate for the battery on the
spacing bolts in the wheel well. Place the battery on the support. Connect the bat-
tery. Use the supplied longer cable. Connect the battery to ground at a suitable
point. Mount the cover and use it to fasten the battery.
Fig. 20 Battery holder in the wheel well

Attention!
If you are mounting the independent live PTO in a tractor that does not
have a cab, follow the description in sections 3.2.17 and 3.2.18
3.2.17. Mount the battery support element under the running board on the tractor.
3.2.18. Place the battery on the support. Connect the battery. Use the supplied longer ca-
ble. Connect the battery to ground at a suitable point. Mount the cover and use it
to fasten the battery.

Installation
Page 15
Fig. 21 Electrical connection

Attention!
If you are mounting the PTO shaft in a tractor with frontloader, follow the
description in sections 3.2.19 and 3.2.20
3.2.19. Remove the cross-member of the lower attachment hooks from the frontloader
and cut an area out of the middle that matches the supplied conversion part.
Fig. 22 Frontloader conversion part
3.2.20. Weld the conversion part onto the cross member in place of the cut out part and
paint the weld spot. Re-assemble the frontloader.
Fig. 23 Cross member reworked for attachment hooks

Installation
Page 16
Fig. 24 Frontloader mounted
3.3. Installation is complete
3.3.1. Tighten all threaded unions. To conclude ensure that all cables and hoses have
sufficient clearance to moving parts and that no injury hazard exists. Remove all
tools and loose parts from the tractor.

Attention!
There is an increased risk of accident due to the rotating PTO shaft.
Do not enter the work area of the PTO shaft when it is rotating.
For your own safety do not wear any loose clothing, belts, or any other
loose items. Switch off the device. Wait until all machine parts have come to
a standstill before converting or servicing the implement.

Attention!
Injuries due to fluid escaping under high pressure.
Comply with the instructions in the operating manual.
3.3.2. Perform a trial run. Switch on the tractor. Ensure that the independent live PTO is
at a standstill. Switch on the independent live PTO in idle and listen for unusual
noises. Increase the speed to full throttle. Switch off the independent live PTO.
Ensure that the independent live PTO is at a standstill.
3.3.3. After the trial run check all bolts, cables, and hoses for firm seat as the concluding
step.

Operation
Page 17
Fig. 25 Tractor with independent live PTO
4. Operation

Attention!
Before starting up the implement read the instructions on safety and han-
dling for operation of the entire implement and connection to the tractor.
4.1. Coupling and uncoupling implements

Note!
Comply with the axle loads specified by the tractor manufacturer

Attention!
There is an increased risk of accident due to the rotating PTO shaft.
Do not enter the work area of the PTO shaft when it is rotating.
For your own safety do not wear any loose clothing, belts, or any other
loose items. Switch off the device. Wait until all machine parts have come to
a standstill before converting or servicing the implement.
4.1.1. Drive the tractor forward in front of the implement.
4.1.2. Lower the front lift.
4.1.3. Drive slowly toward the implement until the coupling element of the tractor is under
the coupling triangle of the implement.
4.1.4. Slowly lift the front lift until the implement is slightly lifted.
4.1.5. Secure the implement with the appropriate triangle locking mechanism. The trian-
gle locking mechanism depends on the type of implement.

Operation
Page 18

Attention!
Damage can occur to the independent live PTO or to the tractor.
Comply with the instructions in the operating manual provided by the manu-
facturer of the universal joint shaft.

Note!
Mount the universal joint shaft as described in the original manual supplied
by the manufacturer of the universal joint shaft.
4.2. Mounting the universal joint shaft
Danger!
Severe injury to the operator or third parties occurs.
Switch off the tractor and remove the ignition key before mounting or dis-
mounting the independent live PTO.
Attention!
There is an increased risk of accident due to the rotating PTO shaft.
Do not enter the work area of the PTO shaft when it is rotating.
For your own safety do not wear any loose clothing, belts, or any other
loose items. Switch off the implement. Wait until all machine parts have
come to a standstill before converting or servicing the implement.
4.2.1. Press the locking pin on the outer fork and keep it depressed.
4.2.2. Slide the outer fork onto the profile stub of the front PTO shaft on the gearbox.
4.2.3. Release the locking pin.
4.2.4. Slightly move the universal joint shaft back and forth until the locking pin audibly
locks in place.
4.2.5. Repeat steps 1 to 4 to attach the universal joint shaft to the implement.
4.2.6. Hook the safety chain of the universal joint shaft to a fixed part (see Fig 26).
Fig. 26 Safety chain on the universal joint shaft
4.3. Dismounting the universal joint shaft
Danger!
Severe injury to the operator or third parties occurs.
Switch off the tractor and remove the ignition key before mounting or dis-
mounting the independent live PTO.

Operation
Page 19
Attention!
There is an increased risk of accident due to the rotating PTO shaft.
Do not enter the work area of the PTO shaft when it is rotating.
For your own safety do not wear any loose clothing, belts, or any other
loose items. Switch off the implement. Wait until all machine parts have
come to a standstill before converting or servicing the implement.
4.3.1. Detach the safety chain on both sides.
4.3.2. Press the locking pin on the outer fork and keep it depressed.
4.3.3. Pull the outer fork down from the profile stub of the PTO shaft on the tractor.
4.3.4. Release the locking pin.
4.3.5. Repeat steps 2 to 4 to detach the universal joint shaft on the implement.
4.4. Switching the independent live PTO on and off
4.4.1. Switch-on the independent live PTO - switch on the switch for the front PTO shaft.
Switch on the independent live PTO at approx. 1000 rpm, and do not increase the
rpms of the tractor engine when switching on the independent live PTO. Do not
switch on the independent live PTO at a speed greater than 1200 rpm.
4.4.2. Switch-off the independent live PTO - switch off the switch for the front PTO shaft.
4.4.3. Never attempt to loosen a seized front implement by switching the independent
live PTO on and off.
4.5. Run-up time of the front PTO shaft system
The run-up time of the front PTO shaft system (only necessary if extremely light or ex-
tremely heavy implements will be driven) can be adjusted on the switch-on electronics. If
the front PTO shaft system will power an extremely light implement, the run-up time must
be long (rotate the set screw counterclockwise) so that the system switches on less
abruptly. In the case of powering extremely heavy implements the run-up time should be
adjusted as short as possible (turn the set screw clockwise) to reduce wear on the cou-
pling.
Fig. 27 Switch-on electronics
Set screw

Maintenance
Page 20
5. Maintenance
5.1. Service
After 5-10 operating hours with a new independent live PTO, or after a repair,
check whether all bolts are still tightened to the correct torque. Check the hydraulic
lines for leaks.
After every 400 operating hours check all threaded connections for correct tighten-
ing torque. Check the hydraulic lines for leaks. Lubricate the universal joint shaft.
After 1000 operating hours check the oil level. Place the tractor on a horizontal sur-
face and check whether the oil reaches the fill plug. If necessary top-up with oil.
After 450 operating hours, or every 6 months change the gear oil. Clean the oil fil-
ter in the pump unit.
5.2. Changing the gear oil
5.2.1. Remove the oil drain plug and drain the oil into a collection container. The oil drain
plug is on the underside of the gearbox.
5.2.2. Remove the lock ring from the pump unit, loosen the M8 bolt and remove the
cover.
Fig. 28 Gearbox
5.2.3. Remove the oil filter from the pump unit, clean it, for example with compressed air.
5.2.4. Replace the oil filter and re-mount the parts that were removed under 5.2.1 and
5.2.2. fill the gearbox with oil up to the oil fill plug. For this use one of the oil types
listed below.
Oil fill plug
Retaining ring
M8 bolt
Cover