Parker Chelsea 540 Series Owner'S Manual Download Page 3 | Manualshive

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Parker Chelsea 540 Series Owner'S Manual Download Page 3

Parker Hannifin Corporation

Chelsea Products Division
Olive Branch, MS 38654 USA

Bulletin HY25-1396-M1/US

Contents

Owner’s Manual

Counter Shaft & Thrushaft

General Information

Safety Information

.................................................................. 1-6

Model Number Designations

.................................................... 7

540 Countershaft .................................................................. 7
541 Thrushaft for Fuller ......................................................... 7

Horsepower - Torque - R.P.M. Conversion Chart

.................... 8

Dimensional Drawings

540 Countershaft .................................................................. 9
541 Thrushaft for Fuller ....................................................... 10
540 Countershaft for Volvo ................................................. 11

Operating Instructions

541 Thrushaft for Fuller ....................................................... 12
540 Countershaft for Volvo ................................................. 12
540 Countershaft for Fuller ............................................ 13-15
540 Countershaft for Spicer ........................................... 16-17

Installation Instructions

541 Thrushaft for Fuller .................................................. 18-20
540 Countershaft for Volvo R5 ....................................... 21-26
540 Countershaft for Volvo R6 ....................................... 27-33
540 Countershaft for Fuller ............................................ 34-36
540 Countershaft for Spicer ........................................... 37-41

Airshift Installation Circuits

540/541 Countershaft for Fuller .......................................... 42
540 Countershaft for a Spicer ........................................ 43-48
Requiring Neutral Detent Kit

Wire Shift P.T.O.s

Cable Control Installation Instructions ................................. 49-53

Shift Indicator Continuity Check

............................................... 54

Indicator Light Installation/Dash Drilling Template

................. 55

Dash Drilling Template

Shift Valve and Light 68-P-27 ................................................... 56
Shift Valve and Light 68-P-28 ................................................... 57
Air Shift and Indicator Light 68-P-30 ......................................... 58

P.T.O. Maintenance

..................................................................... 59

Offer of Sale

................................................................................. 60

III

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Summary of Contents for Chelsea 540 Series

Page 1: ...Bulletin HY25 1396 M1 US Owner s Manual Power Take Offs 540Series 541 Series Effective June 2004 Supersedes HY25 1396 M1 US April 2003...

Page 2: ...ely responsible for making the final selection of the products and systems and assuring that all performance safety and warning requirements of the application are met The products described herein in...

Page 3: ...for Fuller 13 15 540 Countershaft for Spicer 16 17 Installation Instructions 541 Thrushaft for Fuller 18 20 540 Countershaft for Volvo R5 21 26 540 Countershaft for Volvo R6 27 33 540 Countershaft fo...

Page 4: ...en equipment from any position that could result in getting caught in the moving machinery Proper Matching of P T O WARNING A Power Take Off must be properly matched to the vehicle transmission and to...

Page 5: ...ge Driven equipment must have separate controls The driven equipment must be left in the disengaged position when not in operation Do not operate the driven equipment until the vehicle is allowed to w...

Page 6: ...s provided Place the owner s manual in the vehicle glove compartment WARNING Operating the P T O with the Vehicle in Motion Some Power Take Offs may be operated when the vehicle is in motion To do so...

Page 7: ...1 The combined weight of pump fittings and hose exceed 40 pounds 2 The combined length of the P T O and pump is 18 inches or more from the P T O centerline to the end of the pump ALSO Remember to pac...

Page 8: ...s Chelsea P T O Safety Label Instructions 1 The two black and orange on white 5 x 7 pressure sensitive vinyl labels part number 379274 must be placed on the vehicle frame rails one 1 on each side in a...

Page 9: ...Parker Hannifin Corporation Chelsea Products Division Olive Branch MS 38654 USA Bulletin HY25 1396 M1 US Safety Information Owner s Manual Counter Shaft Thrushaft 6...

Page 10: ...on page for Ratios available on each P T O Output XV Spicer 1410 Flange XK S A E B 2 or 4 Bolt XR Chelsea Special Shifter Type A Air AK Volvo R5 540 L AT Y XV 541Thrushaft for Fuller Basic Model 540 T...

Page 11: ...n 100 HP at 1750 R P M Then with a straight edge on HP scale at 100 Left Side and on R P M scale at 1750 Find Answer on T scale 300 pounds feet torque Middle Formula HP x 5252 T pounds Feet Torque R P...

Page 12: ...200 03mm 80 01mm 71 12mm 8 375 3 150 Not Applicable AD 212 73mm 80 01mm 8 375 3 150 Not Applicable AE 212 73mm 80 01mm 8 135 3 150 2 800 AQ 206 63mm 80 01mm 71 12mm B1 is for P R Ratios B2 is for S R...

Page 13: ...lletin HY25 1396 M1 US Dimensional Drawings Owner s Manual Counter Shaft Thrushaft 541 Thrushaft for Fuller 10 500 12 70 2 402 60 94 6 493 164 92 5 616 142 70 5 101 129 57 2 809 71 35 10 437 2 510 mil...

Page 14: ...n Olive Branch MS 38654 USA 11 Bulletin HY25 1396 M1 US Dimensional Drawings Owner s Manual Counter Shaft Thrushaft 540 Countershaft for Volvo 540 AK Dimensions 540 AL Dimensions 5 250 7 105 5 125 2 8...

Page 15: ...the Countershaft P T O 1 Disengage the vehicle clutch and stop the vehicle 2 Set the parking brakes and place the main transmission in neutral 3 Engage the Countershaft P T O 4 The light mounted next...

Page 16: ...pped with the Rear Mount Countershaft P T O Neutral Interlock System CAUTION Failure to comply with the proper shifting or operating sequences may result in premature P T O failure with possible damag...

Page 17: ...6 Move the Extended Rear Countershaft P T O Control to the In position 7 Slowly release the clutch pedal to engage the P T O for stationary operation To Engage P T O for Stationary Operation 1 For ve...

Page 18: ...esult See Trouble Shooting 540 Countershaft for Fuller 2 It is now safe to release the clutch pedal 3 Release parking brakes to prepare for operating the vehicle in the mobile mode CAUTION To avoid im...

Page 19: ...P T O is engaged 8 Select main transmission into desired gear position a The relative speed of the countershaft P T O output shaft to engine speed can be changed by selecting different main transmiss...

Page 20: ...T O is engaged 5 Release the clutch The countershaft P T O will now start to rotate D To Disengage on Spicer 1107 1310 1352 1362 1364 1372 1374 1410 1452 1453 1462 and 1463 1 Disengage the vehicle cl...

Page 21: ...ansmission rear cover CAUTION THE OIL MAY BE HOT Remove the Welsh Plug from the P T O drive access hole Fig 1 Lubricate the O Ring supplied with Parker O Lube Install the O Ring in the groove in the P...

Page 22: ...rews one long and two short and torque them to 30 35 ft lbs Fig 4 Lubrication Install the oil strainer and the 90 elbow in the transmission rear cover drain hole Fig 5 6 Fig 4 Fig 5 Fig 6 Bulletin HY2...

Page 23: ...he clamp supplied and the capscrew in the transmission rear cover Fig 8 Remove the pipe plug in P T O case and fill the P T O with trans mission oil up to the pipe plug Fig 9 Be sure to replace the pi...

Page 24: ...oil drain plug Note Use caution when draining the transmission the oil may be hot Fig 2 Now as shown in Fig 3 remove the Snap ring lockwasher and nut from the transmission output shaft Now you are re...

Page 25: ...8 10 stud B in the lower left hand bolt hole as shown in Fig 5 Then torque all three studs to 37 41 ft lbs Now install the 35 P 53 mounting gasket over the studs and onto the transmission Make sure th...

Page 26: ...tall the roller bearing 560964 in the countershaft as shown in Fig 8 Place the 31 P 76 thrust washer next to the input gear Now place the 57 P 22 clutch in the 540 AK housing with its clutch teeth eng...

Page 27: ...g 10 Fig 11 540 AK Countershaft for Volvo R5 Install the 540 AK over the studs as shown in Fig 10 Make sure the 500365 26 washer is placed first on the 378431 26 Hex Head Screw and then the 379164 con...

Page 28: ...ne sleeve will be exposed Fig 13 Put the 500357 11 lockwasher and 501146 3 Hex Nut on the two right side studs and the lower left stud Torque all three to 35 40 ft lbs Fig 14 Now replace the companion...

Page 29: ...with 8 ounces 220 ML of transmission fluid Remember to replace the pipe plug after filling the counter shaft P T O Fig 16 Remember to fill the transmission with oil and check the oil level within the...

Page 30: ...oil drain plug Fig 2 Note Use caution when draining the transmission as the oil may be hot Now as shown in Fig 3 remove the Snap ring lockwasher and nut from the transmission output shaft Now you are...

Page 31: ...asket Fig 4 Install the 90 elbow and oil strainer that is furnished in the mounting kit for the 540 AL countershaft Fig 5 Support the countershaft and install the lube line onto the 90 elbow Fig 6 Bul...

Page 32: ...ow fill the transmission with 4 gallons 15 liters of oil Remember to replace the fill plug Fig 7 Install the two studs A in the lower bolt holes as shown in Fig 8 Then torque the studs to 37 41 ft lbs...

Page 33: ...P 54 spring from the 540 AL mounting kit over the countershaft extension Fig 10 Now install the roller bearing 560964 in the countershaft as shown in Fig 11 Place the 31 P 76 thrust washer next to th...

Page 34: ...ll the 540 AL over the studs as shown in Fig 13 Make sure the 500365 26 washer is placed first on the 378431 26 Hex Head Screw and then the 379164 cone lock sleeve is placed on Now you can install the...

Page 35: ...tructions Owner s Manual Counter Shaft Thrushaft Note Once the 378431 26 Hex Head Screws are torqued down the cone sleeve will be exposed as shown in Fig 16 Place the 500357 11 lockwasher and 501146 3...

Page 36: ...air shift cover and plumb air circuit per sketch Fig 19 Now replace the companion flange and tighten the nut until the lockwasher fits and the lockring can be installed Fig 20 Note Check Transmission...

Page 37: ...Shaft Thrushaft 1 Remove drain plug and drain oil from transmission After oil is all drained out immediately re install drain plug 2 Remove extended countershaft bearing cover and gasket from transmis...

Page 38: ...Install spring over extended countershaft of transmission Make sure the spring is in stalled against the bearing in the transmission 6 Now install the P T O to the transmission Put the two nuts and lo...

Page 39: ...ter Shaft Thrushaft 7 The 540 P T O should be filled with oil After the initial filling the P T O will be lubricated with oil from the transmission Note Refill transmission to the proper oil level aft...

Page 40: ...ons Owner s Manual Counter Shaft Thrushaft 2 Install the two 379054 83 studs Torque to 32 37 ft lbs 5 Mesh 57 P 17 clutch with input gear face in 540 housing 540 Countershaft for Spicer 37 Studs Studs...

Page 41: ...put Bearing Designation Cap Gasket AB 22 P 61 AC 22 P 61 AF 22 P 68 AG 22 P 61 AH 22 P 68 Note The lube holes MUST line up with the transmission holes as shown 4 Install spring over counter shaft exte...

Page 42: ...oles within the bearing cap of the output shaft see step 2 for locating studs Possible installations Left side sift cover up or left Right side shift cover down or right Note When mounting the P T O o...

Page 43: ...s Manual Counter Shaft Thrushaft 7 Slide 378448 14 bolts thru the 379164 cone sleeves Place both assemblies in 540 P T O 8 Install 500357 11 lockwashers and 501146 3 nuts on two exposed 379054 83 stu...

Page 44: ...s shown 10 Add same lube as used in mating transmission per the following amounts per position Shown in the chart at bottom of this page 11 Install the two 379042 male connectors in air shift cover an...

Page 45: ...ctly to air supply Do not use tubing between air supply and pressure protection valve Caution When installing nylon tubing avoid sharp angles exhaust and manifold systems Important When this installat...

Page 46: ...HY25 1396 M1 US Airshift Installation Circuits Owner s Manual Counter Shaft Thrushaft 43 Bulletin HY25 1396 M1 US Airshift Installation Circuits Owner s Manual Counter Shaft Thrushaft 1420 3A 3B and...

Page 47: ...HY25 1396 M1 US Airshift Installation Circuits Owner s Manual Counter Shaft Thrushaft 45 Owner s Manual Counter Shaft Thrushaft 1412 3A 1414 2A 1414 3A Air Plumbing Diagrams for Spicer Bulletin HY25 1...

Page 48: ...1 US Airshift Installation Circuits Owner s Manual Counter Shaft Thrushaft 47 Owner s Manual Counter Shaft Thrushaft Bulletin HY25 1396 M1 US Airshift Installation Circuits 1007 2A 2B 3A 1207 2B 2D an...

Page 49: ...ment 2 CAUTION Before drilling any holes make sure there is adequate room on both sides through dash wall drill a 1 2 5 diameter hole for the control cable 1 3 Install the control cable on the dash us...

Page 50: ...et and or spring into the transmission if the shifter post assembly should be pushed through the cover when reinstalling the lever 9 Shift the P T O to the engaged position to see how much of the cabl...

Page 51: ...ble Control Installation Instructions Continued 11 Push the wire back through and install the cable using the hardware from the previously mentioned wire control parts bag 328380X 12 Cut the excess wi...

Page 52: ...y 15 Shift the P T O The following should be adhered to 15A CABLE IN P T O DISENGAGED LIGHT OUT 15B CABLE OUT P T O ENGAGED LIGHT ON NOTE The P T O should be checked for continuity as per the instruct...

Page 53: ...T O will always be engaged when all the way in or out 3 Follow step 7 and 8 4 In step 9 shift the P T O from forward to reverse or vice versa to determine the amount of travel needed and the length o...

Page 54: ...the other probe make contact with the shifter cover or housing see Figs 1 2 3 Actuate shifting device and the meter or light should be actuated when P T O gear is engaged see Figs 3 4 4 Shift unit out...

Page 55: ...Chelsea Products Division Olive Branch MS 38654 USA Bulletin HY25 1396 M1 US Indicator Light Installation Owner s Manual Counter Shaft Thrushaft 55 Indicator Light 68 P 18 Indicator Light Installatio...

Page 56: ...Parker Hannifin Corporation Chelsea Products Division Olive Branch MS 38654 USA 56 Bulletin HY25 1396 M1 US Dash Drilling Template Owner s Manual Counter Shaft Thrushaft Shift Valve and Light 68 P 27...

Page 57: ...Parker Hannifin Corporation Chelsea Products Division Olive Branch MS 38654 USA 57 Bulletin HY25 1396 M1 US Dash Drilling Template Owner s Manual Counter Shaft Thrushaft Shift Valve and Light 68 P 28...

Page 58: ...rker Hannifin Corporation Chelsea Products Division Olive Branch MS 38654 USA 58 Bulletin HY25 1396 M1 US Dash Drilling Template Owner s Manual Counter Shaft Thrushaft Air Shift Indicator Light 68 P 3...

Page 59: ...on the P T O internal splines as well as the pump external splines Fretting corro sion appears as a rusting and wearing of the pump shaft splines Severe duty applications which require long P T O runn...

Page 60: ...ays or failures in delivery of carriers or suppliers shortages of materials and any other cause beyond Seller s control 12 Entire Agreement Governing Law The terms and conditions set forth herein toge...

Page 61: ...Parker Hannifin Corporation Chelsea Products Division 8225 Hacks Cross Road Olive Branch Mississippi 38654 USA Tel 662 895 1011 Fax 662 895 1019 www parker com chelsea FP 01 05 5C...

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