How to install power take off

1. General rules for PTO installation:

For correct installation of PTOs and all related accessories, it is very important to follow these general rule Always check the PTO instruction manual and any further specific instruction sheets included in the PTO package. Always operate taking into account the gearbox operating manual

Use the appropriate tools and instruments such as torque wrenchs, gauges and thickness gauges
Use only gaskets supplied by the Manufacturer. Use paste gasket only if recommended.
Mastic is forbidden if used together with paper gaskets.
It is advisable to use medium thread locking fluid for locking bolts and studs
Perform all Installation operations with the vehicle standing on a level surface, otherwise oil levels cannot be checked.
Operate with engine and gearbox at ambient temperature.
Check that the PTO is equipped with the correct mounting kit.
Check that clutch works properly, otherwise adjust it. The transmission should stop rotating within 5 to 6 seconds.
Check that the gearbox has no unusual noises or vibrations
2- Use of the PTO:

IMPORTANT: when engaging and disengaging the PTO, always press the clutch pedal!
Working temperature and load conditions
The temperature depends on the way the PTO is used and it is recommended to keep it between the following values Short duration (less than 15 minutes) max.120 °C, long duration
(more than 15 minutes)max 100 °C.
The PTO temperature is affected by various factors; it is possible to reduce overheating by:

Changing the oil more often in case of heavy duty system
When the PTO is side mounted, ensuring that the gear backlash is accurately checked
When the PTO is rear mounted, considering to provide the PTO with a supplementary lubrication kit.
3- Side mounted PTO installation

Empty or reduce the gearbox oil level, check cleanliness.
If oil is dirty or contaminated it should be replaced,
Remove gearbox aperture cover and accurately clean the gearbox aperture surface
Check gearbox gear teeth and the gear backlash
Open the PTO package. Use PTO specific mounting kit and if necessary spacers.
Studs for mounting onto the gearbox:
Accurately check that the holes in the gearbox are threaded. Be careful that studs do not interfere with gears.
-Fit the studs. Picture no. 7 shows a typical mounting example.
- Backlash check between gear tooth and spacer insertion:
- To get a backlash of 0,5mm or 1mm, fit spacers between PTO and gearbox as necessary. Backlash checking can be carried out in two ways:
- In order to avoid the seals sticking to each other, use grease. NEVER use adhesive fluid when the PTO mounting kit requires special gasket USE adhesive fluid only when the PTO mounting kit DOESN'T
involve any gasket.
Notice: Once the nuts have been tightened, the backlash has to be rechecked and the necessary the shiming operation may be repeated.When the installation operation has been completed, fill the gearbox with oil
4.Rear mounted PTO's

Empty or reduce the gearbox oil level, check cleanliness. If oil is dirty or contaminated it should be replaced.
Remove gearbox aperture cover and accurately clean the gearbox aperture surface
If a shaft kit is provided for the application, carefully read the relevant mounting instructions.
PTO mounting. The typical way of mounting is shown in the picture. It is recommended to lock studs or bolts with locking fluid.
-(See tightening torque par. 7).
Notice: In case of a connection to an ISO flange pump: if the oil seal is fitted to the pump, then the pump must be fitted to the gearbox before filling with oil.
When the fitting operation is complete, refill gearbox with oil.
5. General guideline for pumps installation

Basic requirement

Pump shaft must be aligned with PTO (max. allowed concentricity 0.05 mm).
Backlash: pump and PTO shaft must have a minimum radial backlash of 0.1 mm and a axial backlash of 1 to 2 mm.
Clean the PTO-pump contact surfaces.
Fit the pump with its suitable coupling kit, tightening the nuts with a torque spanner. (See tightening torque table par. 7).
Notice: Always check that pump rotation matches PTO rotation. See below:
6 In cab controls installations:
It is possible to fit several kind of controls into the truck cab. Since die control type depends on the system used, a complete detailed installation
procedure cannot be listed. Some specific instructions are mentioned here.
6.1 Controls location safety requirement

A control has to be placed in a visible place, and in a position where it cannot be accidentally operated
The control has to perform only one function.
Identification: in case of electric controls, don't fit them among the standard switches on the dashboard, to avoid possible confusion.
Controls have to be reliable and strong. They must be resistant to stress and reliable overtime in service.
6.2 Mechanical cable control installation

All PTO's can be supplied with a bracket kit suitable for the mechanical cable control. Cable controls can be provided with different kinds of lever or knob controls.

Take into account, when fitting the lever into a suitable place that there is sufficient clearance to allow unrestricted lever movement PTOs are usually DISENGAGED when the KNOB IS PUSHED or the LEVER IS LOWERED
When the cable is installed, avoid tight bends. Choose as a straight a line as possible for the cable. A very tortuos line means greater operating forces and backlash.
SETTING
This operation has to be carried out with the PTO movement determining the two end stroke positions. Check the Positions of the control lever and set the cable in such a way that movement of the lever / knob gives full PTO Engagement / disengagement.
Notice: PTO engagement has to be complete. Partial engagement may lead to a PTO breakdown.
It is recommended that the cable bolt is locked with loctite 242 or similar product in order to avoid possible slackening. Examples of cable connection

6.3 Air controls
The following recommendations only refer to the PTO engagement-disengagement control

Lamp and pressure switch: even though air controls are equipped with a pressure switch, this device doesn't signal that the PTO is engaged, just that the air line is pressurized. It is therefore
recommended to use a PTO equipped with switch kit
Air treatment: For efficient operation air controls require clean and dry air. Check the technical features of the air controls and the air treatment device available on the vehicle.
Check that the air pressure in the PTO air connector is between 6/11 bar.
Electro-pneumatic controls: are pneumatic controls operated by an electric solenoid. Follow procedures for general airand electric installations.

6.4 Electrical controls and devices

There is quite a wide range of electrical controls not included in the scope of this manual. Please refer to electric circuits manuals. Main recommendations concerning electrical controls are:

Always protect the circuit with fuses (10 A).
Clearly identify the controls; this is valid for those controls fitted on the dashboard in order to avoid unintentional operation.
7. After installation checks:

Once the installation phase is complete, the following checks are recommended.
Engagement / disengagement:
Perform soon after engine start. If a clash is heard, this may be due to one of the following check

Clutch not working properly
There's no or insufficient air pressure.
Oil Level Check: Carry out an oil check when the engine is still cold and top up if necessary. Check to be carried out after 15-20 minutes operation.

Oil Leak: Be sure that there are no leaks between gearbox aperture PTO mounting flange and PTO output. In the case of a leak, check tightness.
Noise check: To be carried out under all the working conditions, with PTO engaged, gearbox in neutral position. In case of a side mounted PTO, an excessive noise may mean a wrong backlash according the following:

High pitched noise: backlash is too tight.
Rattle noise: excessive backlash.
Tightening bolts check: Normally bolts tend to loosen because of the seal setting. It is recommended that all blots and nuts are checked after a few hours of work checking the tightening by means of a torque wrench. With side mounted PTO's, recheck the Cardan shafts generate torsional and axial vibrations.
The higher the cardan angle is, the higher are the potential vibrations. Vibrations may adversely affect the bearings of the components connected by the shaft and may reduce the bearings life. To correctly install the drive shaft the following instructions should be followed:
8. Drive shafts installation

Cardan shafts generate torsional and axial vibrations.
The higher the cardan angle is, the higher are the potential vibrations. Vibrations may adversely affect the bearings of the components connected by the shaft and may reduce the bearings life. To correctly install the drive shaft the following instructions should be followed:

Transmission must be square and in line. The two connecting flanges
should be parallel and both angular inclinations should be the same
Total angle of the universal joints must be between 2° and 8°.
Drive shaft must be dynamically balanced.
Do not remove counterweights and do not change the single components of the shaft to avoid creating new unbalance. In case of loss or replacement of single components, the shaft must be balanced again.
Accurately check that the drive shaft full extension is sufficient and doesn't cause end stroke bumps in the application.
In case of heavy duty “applications contact our technical department and always follow the shaft manufacturer instruction leaflet.
NOTICE: With the cardan shaft use only pumps equipped with ISO flange. Do not exceed an 8° angle.

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