Twin Disc AM080 User manual

Document Number: 1033752
Pump Drive
Model:
AM080
Operator’s
Manual
TWIN DISC
INCORPORATED ®
T D W
I
N I S
C

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.

Document Number
1033752
Revision B
May 2019
Pump Drive
Operator’s Manual

®
T D W I N I S
C
WARRANTY, LIMITAION OF REMEDIES LIMITATION
OR OTHER WARRANTIES, CONFLICTING TERMS,
MERGER AND INTEGRATION CLAUSE
All sales made subject to the LIMITED TWIN DISC GENERAL WARRANTY, LIMITA-
TIONS OF REMEDIES AND LIMITATION OF ANY OTHER WARRANTIES, including
at http://www.twindisc.com/company/warranty/

III
©2019 Twin Disc, Incorporated Table of Contents
Pump Drive Operator’s Manual #1033752
Table of Contents
Introduction.............................................................1
General Information...............................................................................1
Replacement Parts ................................................................................1
Ordering Parts ...................................................................................... 1
Parts Shipment ..................................................................................... 2
Safety ......................................................................................................2
Warranty .................................................................................................3
Operation.................................................................5
Overview.................................................................................................5
Auxiliary Power Take-off...................................................................... 5
Coupling ................................................................................................ 6
Oil Plug And Breather Diagrams......................................................... 6
Maintenance............................................................9
Lubrication .............................................................................................9
Oil Specications...................................................................................9
Oil Type and Viscosity.......................................................................... 9
Oil Cooling Requirements ................................................................. 10
Oil System ............................................................................................10
Torsional Coupling ..............................................................................10
Overhaul Interval ................................................................................. 11
Periodic Visual Inspection ..................................................................12
Alignment - U-Joint-Type Installation ................................................13
Alignment of In-line Drive “U” Joint Type ........................................ 13
Alignment Measurement Procedure ................................................. 13
Troubleshooting ...................................................15

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Pump Drive Operator's Manual #1033752
©2019 Twin Disc, Incorporated Safety
Safety
These messages convey important information about SAFETY. The safety
alert symbol and signal words described below are followed by safety
messages and appear throughout this manual.
All personnel must read, understand and follow all safety message instructions
prior to operation, maintenance or repair of this unit.
Safety Alert Symbol
This is the safety alert symbol. It is used throughout this
manual to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to
avoid possible injury or death.
Signal Words
Signal words are used with the safety alert symbol to designate a level of
hazard seriousness. The signal words used are DANGER, WARNING,
CAUTION and NOTICE.
DANGER indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
WARNING indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
NOTICE is used to address practices not related to physical
injury.

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©2019 Twin Disc, Incorporated Introduction
Pump Drive Operator’s Manual #1033752
Introduction
General Information
This publication provides the information necessary for the operation and
routine maintenance of the Twin Disc, Incorporated equipment specied
on the cover of this manual. Specic engineering details and performance
characteristics can be obtained from the Product Service Department of
Twin Disc, Incorporated, Racine, Wisconsin, USA.
Operating personnel responsible for this equipment should have this
manual at their disposal and be familiar with its contents. Applying the in-
formation in the manual will result in consistent performance from the unit
and help reduce downtime.
Replacement Parts
Parts Lists
See the engineering assembly drawings in Engineering Drawings section
of the Service Manual to facilitate ordering spare or replacement parts.
Ordering Parts
All replacement parts or products (including hoses and ttings) 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 war-
ranty and may result in malfunction or accident, causing injury to person-
nel 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.
Do not order parts from the part numbers on the engineering draw-
ings. These numbers may be referenced for part identication; how-
ever, they should be veried on the bill of material (BOM) before an
order is placed. BOM numbers are stamped on the unit nameplate.

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©2019 Twin Disc, Incorporated
Introduction
Pump Drive Operator’s Manual #1033752
Parts Shipment
Furnish the complete shipping information and postal address. All parts
shipments made from the factory will be FOB factory location, USA. State
specically whether the parts are to be shipped by freight, express, etc. If
shipping instructions are not specied, the equipment will be shipped the
best way, considering time and expense. Twin Disc, Incorporated will not
be responsible for any charges incurred by this procedure.
Twin Disc, Incorporated, having stipulated the bill of material number on
the unit’s nameplate, absolves itself of any responsibility resulting from
any external, internal or installation changes made in the eld without
the express written approval of Twin Disc. All returned parts, new or old,
emanating from any of the above-stated changes will not be accepted for
credit. Furthermore, any equipment which has been subjected to such
changes will not be covered by a Twin Disc warranty.
Safety
Safe practices must be employed by all personnel operating and servic-
ing 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
which may result from the use of manufactured products, it is important
that correct procedures be followed. Products must be used in accor-
dance with the engineering information specied. 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 pro-
vided. 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
maintenance, disconnect the battery cables from the battery and
remove ignition key from the switch.

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©2019 Twin Disc, Incorporated Introduction
Pump Drive Operator’s Manual #1033752
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 reect advancing
technology and improvements in state-of-the-art.
Individual product service bulletins are issued to provide the eld with im-
mediate 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, Ra-
cine, 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.

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©2019 Twin Disc, Incorporated
Introduction
Pump Drive Operator’s Manual #1033752
NOTES

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©2019 Twin Disc, Incorporated Operation
Pump Drive Operator’s Manual #1033752
Operation
Overview
Twin Disc pump drives provide for simultaneous running of two or more
hydraulic pumps from a single prime mover. All models can be prepared
for various applications.
Auxiliary Power Take-off
The input gear drives, through an idler gear, two output gears, each capa-
ble of driving two auxiliary devices. These output gears rotate in the same
direction of the prime mover at a given ratio, and each is tted with two
mounting plates with two or four mounting holes for auxiliary devices.
Below is showing different tower positions:
A
D
G
Figure 1. Tower Positions

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©2019 Twin Disc, Incorporated
Operation
Pump Drive Operator’s Manual #1033752
A
D
G
Figure 2. Tower Positions
Coupling
The Pump Drive is coupled to the prime mover either directly to the y-
wheel, or remotely through a drive shaft. The prime mover turns the pump
drive input gear and clutch drive ring.
Oil Plug And Breather Diagrams
Table 1. Oil Capacities Based On Tower Position

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©2019 Twin Disc, Incorporated Operation
Pump Drive Operator’s Manual #1033752
Figure 3. Oil Plug And Breather Diagram 1
Figure 4. Oil Plug And Breather Diagram 2

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©2019 Twin Disc, Incorporated
Operation
Pump Drive Operator’s Manual #1033752
Table 2. Tower Ports

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Pump Drive Operator’s Manual #1033752
©2019 Twin Disc, Incorporated Maintenance
Maintenance
Lubrication
Gears and bearings are splash lubricated.
Oil Specications
The pump drive is supplied without oil. Before start up ll pump drive to
level indicated by oil level plug.
Use oil for gears with EP additives, minimum viscosity index 95. Oil type
can be chosen depending on the ambient temperature, on Table 2.
Ensure that the oil temperature, when working, is not higher than 105 °C
(221 °F) with synthetic oil and 80 °C (176 °F) with mineral oil.
Oil Type and Viscosity
Table 1. Oil Type And Viscosity
Multi-viscosity oils (i.e. 10W-30, etc.) can be used under
certain conditions, but require TWIN DISC approval.

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©2019 Twin Disc, Incorporated
Maintenance
Pump Drive Operator’s Manual #1033752
Oil Cooling Requirements (see Engineering Drawings for additional specs.)
Table 2. Oil Cooling Requirements
Customer supplied air to oil cooling is typical
Minimum oil temperature at start-up -40°C (-40° F)
Oil temperature at steady operating
conditions
66°C to -85°C
(150°F to -185°F)
Maximum oil sump temperature 93°C (200°F)
Oil System
Oil Level
The customer supplied sump oil level should be checked daily or every ten
hours.
Oil and Filter Change Interval
With a new unit, change the oil and lter element within the rst 50
hours of operation. Change oil and lter element after each 1000 hours
thereafter or more often if conditions warrant. The oil and lter should be
changed every six months if less than 1000 hours has accumulated since
the last oil change.
For a repaired unit, check the lter element after eight hours of operation.
If the lter is clean, install a new lter element and then change the oil
and lter element after 1000 hours of service. If the lter is dirty, change
the element and operate for another eight hours. Check the lter again.
Continue this cycle until the lter is clean and then change the oil and lter
after 1000 hours of service or more often if conditions warrant.
Torsional Coupling
1. Do not obstruct the ywheel housing vents preventing the free ow
of air for cooling the coupling. The ambient temperature of the air
around the coupling should be between -60°C. (22°F.) and 80°C.
(176°F.). Assure bafes are installed properly so hot air is ported
out of the housing.
2. Visually inspect the element after the rst 100 hours of operation
and every 2000 hours thereafter, or every six months, whichever
comes rst. 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.

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Pump Drive Operator’s Manual #1033752
©2019 Twin Disc, Incorporated Maintenance
When inspecting the exible coupling, look for evidence or
conditions identied in the following steps:
A. Cracks in the surface of the rubber. May be caused by tor-
sional 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 spongi-
ness 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 ex plate or coupling
plate.
D. Bolt holes in ex 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/nuts -- bent, 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.
Overhaul Interval
A complete overhaul of the unit should be made at the same time that the
engine is overhauled.

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©2019 Twin Disc, Incorporated
Maintenance
Pump Drive Operator’s Manual #1033752
Periodic Visual Inspection
1. Check the mountings for tightness or damage such as cracks.
Tighten loose mountings and replace damaged parts.
2. Check pressure and temperature gauge where applicable.
3. Inspect the oil lines and heat exchanger for leaky connections,
cracks, or other damage. Replace damaged lines.
4. Periodically, inspect the drive line and the input and output shaft oil
seals for leakage. Replace parts as required.

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Pump Drive Operator’s Manual #1033752
©2019 Twin Disc, Incorporated Maintenance
The lifting force established in steps 1 - 3 only needs to be done
for the rst machine of the design type. Any signicant changes
to the weight of the accessories added to the Pump Drive would
require that the lifting force be re-established.
Alignment - U-Joint-Type Installation
Alignment of In-line Drive “U” Joint Type
To realize maximum bearing life, the best possible alignment must be
maintained between the center line of the PTO shaft and the center line of
the pump drive. This may be accomplished as follows:
1. First, and very important, the forks (items 1 and 2, Figure 1) of the
drive shaft between the PTO and the gearbox must lie in the same
plane. This will prevent severe vibrations from occurring in the drive
shaft.
2. Second, the center lines of the PTO shaft and gearbox input shaft
must be offset within the limits recommended by the universal joint
manufacturer to prolong the life of the universal joint needle bearings.
3. Third, and very important, the center lines of the PTO shaft and gear
box input shaft must be parallel. This will further prevent vibrations
which cause premature bearing failure.
4. Proper lubrication of the gearbox clutch is very important for
satisfactory performance. The clutch bearings are lubricated with
lithium -based grease, NLGI-2 grease. The grease selected should be
recommended for anti-friction bearings and have a minimum melting
point of 149° C (300° F). A list of approved lubricants is available upon
request.
Alignment Measurement Procedure
The centerllines of the PTO shaft and input shaft of the pump drive
must be parallel. One method of accomplishing this is shown in Figure
1. To align engine and pump drive by this method, two accurate straight
edges that are at least 36 inches (860 mm) long, and a tape measure are
required.

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©2019 Twin Disc, Incorporated
Maintenance
Pump Drive Operator’s Manual #1033752
1. Place the straight edges horizontally along the face of the PTO and
pump drive hubs.
2. Measure distances A and B. A and B should be equal within 3
mm (0.125 inch) measured 430 mm (18.0 inches) out from the
centerlines of the shaft. If a difference in A and B of more than 3
mm (0.125 inch) is found, the engine should be moved to bring
these distances within 3 mm (0.125 inch).
3. After A and B have been set the straight edges should be rotated
to the vertical position as shown by the dotted lines in the sketch.
Distance C should be equal to distance D within 3 mm (0.125 inch)
measured 430 mm (18.0 inches) out from the center of the shaft.
If C and D vary more than 3 mm (0.125 inch) measured 430 mm
(18.0 inches) from the shaft center the engine should be moved
until the difference is brought within 3 mm (0.125 inch).
4. After setting C and D, A and B should be rechecked and reset if
required. Repeat this procedure until distances A and B, and C and
D are equal to each other within 3 mm (0.125 inch) measured 18
inches (430 mm) from shaft centers.
5. After setting as described above, the engine should be securely
anchored. The PTO shaft centerline and gear head input shaft
centerline will now be within 1 degree of parallel
Figure 1. Alignment Of Pump Drive
Note: All threads and bearing face to be lubricated with light oil lm prior to
assembly.