Incorporated: #1019023 Form 2885
Incorporated: #1019023 Form 2885
INCORPORATED
#1019023
Form 2885
2.0 Introduction 5
2.1 Part numbering system ........................................................................... 5
2.2 Locating the part number and serial number .............................................. 5
4.0 Maintenance 7
4.1 Lubrication requirements ...................................................................... 7
4.1.1 Grease specification
4.1.2 Grease specification for special conditions
4.2 Lubrication intervals ............................................................................. 8
4.3 Bearing operating temperature ............................................................... 8
4.4 Clutch adjustment ............................................................................... 8
6.0 Operation 10
6.1 Clutch engagement procedure ................................................................ 10
Page 2 Form No. 2885 Information subject to change without notice Twin Disc Incorporated 414-638-4000
Rev. 04, 01-2003 1328 Racine Street www.twindisc.com
Racine, WI 53403
TABLE OF CONTENTS (continued)
14.0 Warranty 17
Twin Disc Old SAE Clutch Quantity Facing Facing Pilot Release Bearing Notes
(Rockford) Manufacturing Housing Size & Clutch Type Style Bearing Bearing Housing
Part No. Part No. Size Model Plate(s) Type1 Type Code2
1
Ball Bearings-supplied with PTO
Shaft pilot dimensions furnished if pilot bearing not supplied with PTO
.6994 = .6994"/.6990"
.9844 = .9844"/.9840"
2
Used for reference during repair of the PTO
Page 4 Form No. 2885 Information subject to change without notice Twin Disc Incorporated 414-638-4000
Rev. 04, 01-2003 1328 Racine Street www.twindisc.com
Racine, WI 53403
2.0 Introduction 3.0 General Information, Specifications &
Recommendations
Performance of the following procedures by the owner and
T
operator should ensure reliable PTO operation.
M
2.1 Part Numbering System.
Twin Disc, Inc. Power Take-Off part numbers have changed in
the way they were displayed in print over the years, primarily due A
to advances in technology.
O
The part number format for a Twin Disc, Inc. Power Take-Off S L R
Assembly is 040XXXXX, where XXXXX is a 5 digit alpha
number unique to that particular assembly. Sub-assemblies or
Kits are designated 030XXXXX and individual components are
designated 020XXXXX, , where XXXXX is a 5-digit alpha
number unique to that particular sub-assembly, kit or compo- Y
nent. C
Previous numbers may have been displayed as: S.A.E Pilot Bolt Flywheel Housing
4-XXXXX, 40XXXXX, 04-XXXXX, or 4-0XXXXX. The unique Hsg. Diameter O.D. Circle Bolts and Bolt Holes
5-digit number remains unchanged, regardless of how the prefix
No. "T"
may have been written at one time or another.
“A” “S” “R” Qty. Hole Dia. Bolt Size
“3” 16.125 17.75 16.875 12 .433 3/8
2.2 Locating the Part Number and Serial Number.
“4” 14.250 15.88 15.000 12 .433 3/8
Refer to the nameplate for part number and serial number “5” 12.375 14.00 13.125 8 .433 3/8
information. The PTO part number is also located on a small tag
on the mounting flange of the PTO between two of the mounting All dimensions are in inches unless otherwise specified.
holes.
Page 6 Form No. 2885 Information subject to change without notice Twin Disc Incorporated 414-638-4000
Rev. 04, 01-2003 1328 Racine Street www.twindisc.com
Racine, WI 53403
3.7 Alignment Tolerances for Flywheels and Flywheel Hous- Note:
ings. The flywheel and crankshaft of the engine must be held
against either the front or rear of the crankshaft thrust
Check the alignment of the engine flywheel and the engine bearing while the total indicator sweep (TIR) measurement is
flywheel housing. Excessive bore and face runout of the being made.
flywheel, flywheel housing, and flywheel housing adapters, if
The total indicator reading should not exceed:
used, can adversely affect the performance of the PTO and the
system of which it is a part. A dial indicator will be required to
Clutch Size 10" TT 12" RT
measure which it is a part
Maximum T.I.R. .005" (1.27 mm.) .006" (1.52
3.7.1 Flywheel housing face runout deviation check.
Mount the indicator base on the face of the flywheel and
positionthedial indicator tip 3.7.4 Flywheel pilot bearing bore runout deviation check.
perpendicular to the flywheel
housing mounting flange face. Mount the indicator base on the flywheel housing and
Rotate theflywheel through position the dial indicator tip
360 degrees. so its movement is perpen-
dicular to the pilot bearing
Note:
bore surface of the flywheel.
The flywheel and crankshaft of
Rotate the flywheel through
the engine must be held against
360 degrees.
either the front or rear of the
crankshaft thrust bearing while
The total indicator reading
the total indicator sweep (TIR) measurement is being made.
should not exceed:
The total indicator reading should not exceed: 0.005 inches (0.127 mm)
SAE #3 Housing .008" (.203 mm.)
SAE #4, #5 Housing .006" (.152 mm.) 4.0 Maintenance
Note:
See 3.1 for identification of SAE Housings. 4.1 Lubrication Requirements.
Release bearing:
The release bearing is an automotive-type bearing
that must be replaced if the lubricant has been lost.
Page 8 Form No. 2885 Information subject to change without notice Twin Disc Incorporated 414-638-4000
Rev. 04, 01-2003 1328 Racine Street www.twindisc.com
Racine, WI 53403
Main bearing:
With a hand operated grease gun, add 1 or 2 pumps of Driven Member Asembly
Flywheel
grease while rotating the shaft (by hand), or until
grease weeps from the labyrinth seals around the shaft
at either end of the bearing housing.
Cross shaft:
Pump 1 or 2 shots of grease into each of the grease
fittings located in the PTO housing, near each end of
the cross shaft. Pilot Stub Shaft
Bearing
5.3 Install the Clutch on the Engine Flywheel. Clutch Cover Asembly
5.3.1 Install the pilot bearing in the flywheel. Recom-
mended pilot bearings are non-greasible : (bearing has 2 grease
seals or shields). Non-greasible, double-sealed pilot bearings 5.3.4 Remove the three (3) shipping bolts or blocks from
require no re-lubrication and may be installed with either side the stub shaft in the pilot bearing. The long hub estension
toward the PTO and clutch. The shaft should have no grease should face away from the flywheel.
fittings. If it does, remove the grease fittings(s) and replace
with pipe plugs as a precaution to insure grease is not forced Note:
into the pilot bearing cavity of the flywheel. A build-up of Be sure to locate all 3 shipping devices from each clutch.
pressure by forcing grease into the cavity can cause the pilot They can sometimes fall into the clutch at the time it is bolted
bearing to be forced out of the flywheel, resulting in bearing to the flywheel, and if not removed, can cause failure.
or shaft failure.
5.3.5 Remove the stub shaft.
5.3.2 Install a stub shaft in the driven member assembly
spline and place the driven member on the engine 5.4 Install the PTO housing and the shift lever bracket on
flywheel while piloting. Use the engine manufacturer's the engine.
torque specifications if different from the above.
5.4.1 Simultaneously install the shaft in the driven member
assembly splines and push the housing into place against the
engine flywheel housing. The pilot end of the shaft will enter
Flywheel Driven Member Asembly the pilot bearing as the housing is moved into place.
Caution:
The pilot bearing should have a snug but sliding fit on the
shaft pilot, but do not use abusive force to install the shaft
into the driven member spline or the pilot bearing.
5.5 Correct Shift Lever Installation and Position. 6.1.1 The PTO clutch should normally be engaged with the
engine operating below 1,000 RPM. After the load has been
5.5.1 Install the shift lever or release mechanism. Align the brought up to engine speed, and the clutch is no longer
timing marks on the handle and the end of the PTO cross slipping, the engine speed may be increased to operating
shaft. Slide the lever onto the cross shaft until the locking speed.
finger engages the bracket approximately in the middle of the
finger. 6.1.2 Where high inertia loads must be picked up, engaging
the clutch at 1,000 RPM may result in stalling the engine.
5.5.2 Tighten the shift lever bolt to secure the lever to the Heavy inertia loads may be brought up to speed by a series of
cross shaft. short engagements and disengagements at intervals long
enough to prevent excessive heat build up in the facings.
5.5.3 Check to insure proper clutch operation. Under extreme circumstances, the engine may have to be
operated at higher speeds while engagement occurs, but
Caution: UNDER NO CIRCUMSTANCES should the clutch be
Always be sure the engine is shut off and secured against acci slipped for more than a second or two without either fully
dental start up when working on the clutch or Power Take-Off engaging the clutch or completely disengaging the clutch to
area. permit it to cool.
5.5.3.1 With the timing marks properly aligned and the shift
lever locked into the rear slot of the shift lever bracket, a gap
7.0 Exploded Views -
should exist between the relrease bearing face and the clutch
cover assembly levers. - CURRENTLY NOT AVAILABLE -
5.5.3.2 With the shift lever locked in the front notch, the
clutch should be completely disengaged and the output shaft
should turn freely.
5.5.4 Be sure the shift lever securely locks into both notches
of the shift lever bracket.
Page 10 Form No. 2885 Information subject to change without notice Twin Disc Incorporated 414-638-4000
Rev. 04, 01-2003 1328 Racine Street www.twindisc.com
Racine, WI 53403
8.0 Disassemble the Power Take-Off The following illustrate standard bearing and bearing housing
configurations found in Twin Disc, Inc.® power take-offs.
“Specials” have been designed and sold, but they are only slight
variations of these standard configurations.
8.1 Remove All Accessories or Drives Attached to the
Bell Housing (T1)
Output Shaft. Lockwasher (T52)
8.1.1 If the handle must be removed to permit removal of the Bolt (T51)
power take-off from the engine, loosen the bolt which fastens
the handle to the cross-shaft. Bearing Retainer (T10)
8.2.3 Remove the mounting bolts, removing those located Lock Bolt (T12)
near the top last. The PTO should separate from the flywheel
housing. If the PTO doesn’t separate, install two bolts in the Adjustment Lock (T11)
threaded holes in the flange.
Bearing Retainer (T10)
#
3, #4, #5 Housing 3/8" - 16 bolts
External Snapring (T29)
Tighten the bolts alternately and evenly until the housing is
removed from the engine flywheel housing pilot diameter.
Main Bearing (T9)
8.2.4 Exercise caution when removing the PTO from the
engine to avoid damage to the grease fittings and shaft. Configuration B
8.3 Remove the Clutch From the Flywheel. Bell Housing (T1)
Lockwasher (T13)
8.3.1 It is helpful to use a stub shaft in the driven member
assembly splines to help contain the components as the bolts Lock Bolt (T12)
are removed. (See illustrations in section 5.3.)
Bearing Retainer (T10)
8.3.2 Remove the six (6) mounting bolts at the outer flange of
the cover assembly. The driven member assembly will also be
removed as the cover assembly is unbolted. Drive Shaft (T8)
Configuration C
8.4.1 Remove the release sleeve and bearing assembly from the Caution:
bearing retainer "tube". Place a block of wood beneath the shaft to prevent
it from being damage as it falls loose.
Configuration A: Proceed at 8.4.6
8.4.8 Lift the drive shaft (T8) with bearing (T9) from the 9.0 Inspect the Power Take-Off Components
bearing housing (a hoist may be needed).
9.1 Ball Bearings:
8.5 Remove the Main Bearings From the Drive Shaft. 9.1.1 (Greasible type with 1 shielded side and 1 open side
ONLY.) Visually examine for indications of wear, corrosion,
Wash the bearings and bearing cups with clean fuel oil or or pitting on balls and races. Apply clean, lightweight engine
solvent. Dry and carefully examine for wear, corrosion or oil and slowly rotate the outer race while holding the inner race.
rough spots. Replace if no longer usable. The balls must roll free. Rough or sticking spots must be
checked to be sure they are not particles of dirt. If they are,
Configuration A and B only: Proceed to 8.5.4 clean and check again. If not dirt, replace the bearing.
Caution:
Place a block of wood beneath the shaft to prevent it 9.2 Tapered Roller and Spherical Roller Bearings:
from being damaged as it falls loose.
9.2.1 Visually examine for indications of wear, corrosion,
brinelling or pitting on races or rollers. Rollers must not have
8.5.3 Turn the shaft over and repeat steps 8.5.1 and 8.5.2 to flat spots or pitting. (Tapered roller bearing) cups and cones
remove the remaining bearing (T9). must not exhibit signs of pitting, scuffing or tracking. Lightly
oil the races with clean oil, hold one race stationary while slowly
CONFIGURATION A and B only: rotating the other race against it. Rough spots or sticking
8.5.4 Remove external snapring (T29). indicate need for replacement. Races must be smooth and
unworn.
8.5.5 Support beneath bearing (T9) on the bed of a press.
Page 12 Form No. 2885 Information subject to change without notice Twin Disc Incorporated 414-638-4000
Rev. 04, 01-2003 1328 Racine Street www.twindisc.com
Racine, WI 53403
9.3 Bell Housing: detrimental until it inhibits smooth rotation during clutch
engagement or allows moisture, dirt, or other corrosives to
9.3.1 Check the bearing fit. Bearing races usually are designed enter the housing. This can be prevented by ample greasing
with a sliding or slightly snug fit in the housing bore. They through the grease fittings to keep the cross shaft lubed.
should not have side movement in the bore. Labyrinth seal
bores at the output end of the housing should be round, not 9.5.2 Woodruff key slots must hold the keys straight. If the
worn oval, and should be approximately .020" - .025" (.508 release yoke has been loose on the cross shaft the keyways may
mm - .635 mm.) diameter larger than the drive shaft. have one side worn at an angle.
9.3.2 Threads for the bearing retainer (configurations B and 9.5.3 Splines should not be worn enough to prevent the shift
C) should not be damaged. lever from clamping tight.
9.3.3 If a bearing failure has occurred, be sure the bearing has 9.6 Clutch Release Yoke:
not spun in the housing, destroying the shoulder or bore
contacted by the bearing. 9.6.1 Keyways must not be worn excessively.
9.3.4 (Configurations B and D only): Although the moveable 9.6.2 Replace if width of cradles is over: .760" (19.30 mm.).
bearing retainer will compensate for small amounts of shoulder
wear, it is imperative the bearing contact the housing only at the 9.6.3 The release yoke must clamp tight onto the cross shaft.
O.D. of the race, and not anywhere else on the bearing in its
assembled and adjusted position. 9.7 Drive shaft
9.3.5 The mounting pilot O.D. and mounting face must be 9.7.1 Pilot bearing journal must not be worn. A new pilot
free of protruding metal, rust, corrosion etc., which would bearing should have a sliding-but-snug fit or tight fit. Replace
prevent the housing from locating properly in the flywheel if the diameter of the pilot is less than shown below. Various
housing bore or against the bearing housing face. An improper basic sizes are shown.
fit causes misalignment. Misalignment is a major cause of
power take-off failure.
Pilot Diameter Minimum
9.3.6 Cross shaft holes should not be worn more than New Dimension (Worn)
.015" (.381 mm) out of round. A little wear does not render .6694" - .6690" .6690"
the parts unserviceable, but excessive wear can cause binding of .7875" - .7871" .7871"
the cross shaft under load during clutch engagement. .9844" - .9840" .9840"
9.9.1 The driven member assembly is not considered field 10.1.7 Turn the shaft over in the press. Press the second
rebuildable. Do not disassemble. bearing onto the drive shaft as in 10.1.4 thru 10.1.6.
9.9.2 Splines must not be worn. The spaces between the teeth
are approximately the same width as the width of the tooth 10.2 Install the Drive Shaft in the Bearing Housing.
when new.
Configurations B and C: Proceed at 13.2.9
9.9.3 The assembly must not be oily.
Page 14 Form No. 2885 Information subject to change without notice Twin Disc Incorporated 414-638-4000
Rev. 04, 01-2003 1328 Racine Street www.twindisc.com
Racine, WI 53403
10.2.9 Install one bearing cup in the bore. (If necessary, gently 11.0 Adjust the Main Bearing End Play
tap the cup to the bottom of the bore.)
11.1 (CONFIGURATIONS A and B ONLY):
10.2.10 Install the shaft and bearing in the bore. This is a ball bearing design. No adjustment is required.
10.2.11 Place the second bearing cup onto the exposed bearing 11.2 (CONFIGURATION C only):
cone. (If necessary, gently tap on the outer edge of the cup using
a hard wood dowel to seat the cup against the bearing cone. 11.2.1 Support the PTO with a sling and chain hoist as
Under no circumstances should abusive force be used. Exces- illustrated.
sive force can damage the roller surface of the bearing cup,
causing bearing failure.) 11.2.2 Raise the PTO high enough for access to the output end
of the drive shaft. Using a soft, but heavy mallet against a hard
10.2.12 Thread the bearing retainer (T10) into the bearing wood block, strike the end of the shaft to seat the front bearing
housing until it is snugly tightened against the bearing cup. cup.
Rotate the drive shaft while tightening the bearing retainer to
determine when “zero” bearing clearance exits. When the 11.2.3 Lower the PTO and repeat the procedure in 11.2.2 on
bearing cups are seated the “zero” point will be noted by the the front end of the drive shaft to seat the rear bearing cup.
increased effort required to rotate the drive shaft.
10.2.14 Position the adjustment lock (T11) tab in a notch, 11.2.5 Attach a dial indicator to the shaft as shown. Position
align the bolt hole with the hole in the housing, and install the the point on a smooth surface inside the bell housing, as close
adjustment lock bolt and lockwasher (T12 and T13). to the shaft as possible (but not on the bearing retainer). Set the
dial indicator to “0”.
10.3 Install the cross shaft and clutch release yoke Clamp bar to Clamp bar to
housing housing
flange here flange here
10.3.1 Lubricate the cross shaft holes in the bell housing. Slide
the cross shaft (T14) through one hole.
10.3.2 Slide the clutch release yoke (T17) onto the cross shaft.
The bolt holes (unthreaded end) should face outward (toward
the flywheel). Slide the cross shaft through the release yoke and
into the other cross shaft hole in the bell housing.
10.3.4 Slide the cross shaft and woodruff keys into the keyways
of the release yoke until the keys are centered on the yoke.
10.3.5 Install (2) bolts and lock washers (T18 & T19) in the
clutch release yoke. Tighten and torque to 17-20 ft. lbs. (23-
27 Nm).
12.1 Check to be sure the clutch and housing are installed properly
and in alignment. If the readings exceed the maximum T.I.R.
(total indicator reading), repeat installation of the clutch and/
or housings to bring the readings into specifications.
12.1.3 Move the tip to read the O.D. of the housing pilot and
repeat as in 15.11.2. Maximum runout must not exceed:
12.2 Install the grease hose through the hole in the side of the housing.
Install and tighten the lock nut (T6).
12.3 Install the grease fitting (T7) in the end of the grease hose.
Page 16 Form No. 2885 Information subject to change without notice Twin Disc Incorporated 414-638-4000
Rev. 04, 01-2003 1328 Racine Street www.twindisc.com
Racine, WI 53403
TWIN DISC, INCORPORATED
EXCLUSIVE LIMITED WARRANTY
GENERAL UNITS
A. Twin Disc, Incorporated warrants all assembled products and parts, (except component products or parts on which written warranties
issued by the respective manufacturers thereof are furnished to the original customer, as to which Twin Disc, Incorporated makes no
warranty and assumes no liability) against defective materials or workmanship for a period of twenty-four (24) months from the date of original
shipment by Twin Disc, Incorporated to the original customer, but not to exceed twelve (12) months of service, whichever occurs first. This is the
only warranty made by Twin Disc, Incorporated and is in lieu of any and all other warranties, express or implied, including the warranties
of merchantability or fitness for a particular purpose and no other warranties are implied or intended to be given by Twin Disc,
Incorporated.
The original customer does not rely upon any tests or inspections by Twin Disc, Incorporated or on Twin Disc, Incorporated*s
application engineering.
B. The exclusive remedy provided by Twin Disc, Incorporated whether arising out of warranty within the applicable warranty period as
specified, or otherwise (including tort liability), shall at the sole option of Twin Disc, Incorporated be either the repair or replacement
of any Twin Disc, Incorporated part or product found by Twin Disc, Incorporated to be defective and the labor to perform that work
and to remove and reinstall (or equivalent credit). In this context, labor is defined as the flat rate labor hours established by Twin Disc,
Incorporated in the published Twin Disc Flat Rate Schedule, required to remove, disassemble, inspect, repair, reassemble, reinstall and
test the Twin Disc, Incorporated product only. Under no circumstances, including a failure of the exclusive remedy, shall Twin Disc,
Incorporated be liable for economic loss, consequential, incidental or punitive damages. The above warranty and remedy are subject
to the following terms and conditions:
1. Complete parts or products upon request must be returned transportation prepaid and also the claims submitted to Twin Disc,
Incorporated within sixty (60) days after completion of the in-warranty repair.
2. The warranty is void if, in the opinion of Twin Disc, Incorporated, the failure of the part or product resulted from abuse,
neglect, improper maintenance or accident.
3. The warranty is void if any modifications are made to any product or part without the prior written consent of Twin Disc,
Incorporated.
4. The warranty is void unless the product or part is properly transported, stored and cared for from the date of shipment to
the date placed in service.
5. The warranty is void unless the product or part is properly installed and maintained within the rated capacity of the product
or part with installations properly engineered and in accordance with the practices, methods and instructions approved or
provided by Twin Disc, Incorporated.
6. The warranty is void unless all required replacement parts or products are of Twin Disc origin or equal, and otherwise identical
with components of the original equipment. Replacement parts or products not of Twin Disc origin are not warranted by Twin
Disc, Incorporated.
C. As consideration for this warranty, the original customer and subsequent purchaser agree to indemnify and hold Twin Disc, Incorporated
harmless from and against all and any loss, liability, damages or expenses for injury to persons or properly, including without limitation,
the original customer*s and subsequent purchaser*s employees and property, due to their acts or omissions or the acts or omissions of
their agents, and employees in the installation, transportation, maintenance, use and operation of said equipment.
D. Only a Twin Disc, Incorporated authorized factory representative shall have authority to assume any cost or expense in the service, repair
or replacement of any part or product within the warranty period, except when such cost or expense is authorized in advance in writing
by Twin Disc, Incorporated.
E. Twin Disc, Incorporated reserves the right to improve the product through changes in design or materials without being obligated to
incorporate such changes in products of prior manufacture. The original customer and subsequent purchasers will not use any such
changes as evidence of insufficiency or inadequacy of prior designs or materials.
F. If failure occurs within the warranty period, and constitutes a breach of warranty, repair or replacement parts will be furnished on a
no-charge basis and these parts will be covered by the remainder of the unexpired warranty which remains in effect on the complete
unit.
TWIN DISC, INCORPORATED RACINE, WISCONSIN 53403, U.S.A. 262-638-4000/262-638-4482 (FAX) WWW.TWINDISC.COM