WPT POWER PILOTLESS Installation & Maintenance Manual Download

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PILOTLESS

™

MECHANICAL POWER TAKE-OFF

Installation & Maintenance Manual

”

THRU 14

”

WPT Power Corporation

1600 Fisher Road - Wichita Falls, TX 76305

P.O. Box 8148 - Wichita Falls, TX 76307

Ph. 940-761-1971

www.WPTpower.com

Summary of Contents for PILOTLESS

Page 1: ...LOTLESS MECHANICAL POWER TAKE OFF Installation Maintenance Manual 6 THRU 14 WPT Power Corporation 1600 Fisher Road Wichita Falls TX 76305 P O Box 8148 Wichita Falls TX 76307 Ph 940 761 1971 www WPTpower com ...

Page 2: ...ce Life 3 2 Outboard Support 3 3 Driving Ring 3 4 Installing the Unit 3 5 Clutch Adjustment 4 0 Operation 5 0 Disassembly 6 0 Assembly 7 0 Maintenance 7 1 Maintenance Schedule 8 0 General Storage Guidelines 9 0 Tables Speed and Size Availability SAE Flywheel Housing Dimensions C SP Style Lubrication Schedule Bolt Torque Values 10 0 Appendices Appendix A General Sideload Information OEM Clutch Pack...

Page 3: ...e hazard and are preceded by a safety alert symbol Danger Denotes the most serious injury hazard and is used when serious injury or death WILL result from misuse or failure to follow the specific instructions set forth in this manual Warning Denotes when serious injury or death MAY result from misuse or failure to follow the specific instructions set forth in this manual Caution Denotes when injur...

Page 4: ...tions thoroughly and review until you fully understand all warnings and hazards before proceeding with the work described in this manual Failure to follow the instructions in this manual can result in unreasonable exposure to hazardous conditions and or personal injury and or death Warning Use of improper tools and or methods when installing or servicing this unit can result in accidents causing i...

Page 5: ...ket today Follow the procedures detailed in this Installation Maintenance Manual for years of service When performing installation and maintenance functions refer to the drawings in this manual on pages 6 thru 13 The references on the drawings in this manual DO NOT correspond to the references on the assembly drawing and Bill of Materials Do not use the item numbers from the drawing in this manual...

Page 6: ...LODED VIEWS C Style Ball Bearing sliding sleeve assembly Available in sizes 6 10 Item Description Item Description 1 Retaining Ring 6 Clevis Pin 2 Collar 7 Clevis Pin 3 Ball Bearing 8 Link 4 Retaining Ring 9 Cotter Pin 5 Sliding Sleeve ...

Page 7: ...002_C CLUTCH PACK C Style Ball Bearing Assembly available in sizes 6 10 Item Description Item Description 1 Sliding Sleeve Assembly 5 Spring 2 Adjustment Link Assembly 6 Hub Backplate 3 Floating Plate 7 Pin 4 Friction Disc ...

Page 8: ...tem Description Item Description 1 Nut 11 Clutch Key 2 Washer 12 Shaft 3 Clutch Pack 13 Output Key 4 Driving Ring 14 Bearing 5 HHCS 15 External Retainer Ring 6 Bearing Retainer 16 Cap 7 Hand Lever Assembly 17 Grease zerk 8 Bellhouse 18 Yoke Assembly 9 Nameplate 19 Key Woodruff 10 Bearing 20 Operating Shaft ...

Page 9: ...embly available in sizes 6 10 C Style The C style sliding assembly utilizes a sealed ball bearing design Friction disc sizes range from 6 to 10 with our 1 plate 2 plate or 3 plate options WPT PTOs meet the mounting requirements of SAE J617 and SAE J620 ...

Page 10: ...SLEEVE ASSEMBLY SP Style Ball Bearing assembly available in sizes 11 14 Item Description Item Description 1 Retainer Ring Inner 6 Link 2 Collar 7 Clevis Pin 3 Sealed Ball Bearing 8 Cotter Pin 4 Retainer Ring Outer 9 Plug 5 Sliding Sleeve ...

Page 11: ...yle Ball Bearing Assembly available in sizes 11 14 Item Description Item Description 1 Sliding Sleeve Assembly 6 Washer 2 Adjustment Ring 7 Lever 3 Clevis Pin 8 Friction Disc 4 Cotter Pin 9 Center Plate 5 Floating Plate Assembly 10 Hub Backplate ...

Page 12: ...11 14 14 PTO Shown Item Description Item Description 1 Nut 10 Bearing 2 Washer 11 Clutch Key 3 Clutch Pack 12 Shaft 4 Driving Ring 13 Output Key 5 HHCS 14 Cap 6 Bearing Retainer 15 Grease zerk 7 Hand Lever Assembly 16 Yoke Assembly 8 Bellhouse 17 Key Woodruff 9 Nameplate 18 Operating Shaft ...

Page 13: ...embly available to fit 11 14 SP Style The SP style sliding assembly utilizes a sealed ball bearing design Friction disc sizes range from 11 to 14 with our 1 plate 2 plate or 3 plate options WPT PTOs meet the mounting requirements of SAE J617 and SAE J620 ...

Page 14: ...d when installing working or maintaining unit Failure to do so may result in equipment damage personal injury and even death Caution Proper alignment is necessary to ensure that the friction discs track properly Improper alignment will result in poor function and reduced service life Warning Use only the proper quantity and grade of fasteners shown in the drawings Failure to do so may result in fa...

Page 15: ... base on the face of the flywheel and position the dial indicator tip perpendicular to the flywheel housing mounting face Rotate the flywheel 360 degrees while applying force to the crankshaft thrust bearing The total indicator reading should not exceed the values listed in the table shown below in Section 3 1 4 3 1 4 Check flywheel housing bore runout Mount the indicator base on the face of the f...

Page 16: ...haft endplay before installing PTO Using dial indicator as shown in 3 1 5 force the crankshaft back against the rear main bearing and then force the crankshaft to the front of the engine Record the total movement as shown by the dial indicator 3 1 7 Check engine radial play Apply upward radial force by using a prybar to check the radial play in flywheel Consult engine manufactures specifications t...

Page 17: ...he PTO is not moving or deflecting during the installation process see section 3 1 Shim and adjust the support as needed NOTE the outboard support should complement the position of the PTO not change it WARNING Adhere to Table 1 regarding the necessity of an outboard support The outboard support should not restrict flexure of the engine mounts Failure to provide adequate support can result in pers...

Page 18: ...itting until grease just appears at the respective seal surfaces Although the PTO is normally lubricated at the factory this step will ensure that all moving parts are properly lubricated for initial use See Table 6 3 4 2 Remove inspection cover nameplate from the PTO bellhousing and slowly draw the PTO toward the engine this can be done by installing 3 or 4 equally spaced lengths of all thread ro...

Page 19: ...ins tangent to the Arc of Engagement 3 4 9 3 Size of actuator is critical The actuator must be of sufficient size to apply the required amount of force on the handle Too much force can cause permanent deformation of the Sliding Sleeve Assembly Too little force will cause excess slippage damage to the clutch and will eventually damage the Sliding Sleeve Assembly CAUTION Actuator force must be relea...

Page 20: ...r If the engagement force reaches 2 3 of maximum specified torque clutch slips heats excessively or operating lever fails to stay engaged clutch adjustment is required 3 5 1 Remove inspection cover nameplate 3 5 2 Disengage adjustment pin for C style clutches pull pin out For SP style clutches disengage adjustment pin by pushing pin in with a screwdriver C Figure 4 SP 3 5 3 Rotate adjusting ring c...

Page 21: ...289 295 391 125 165 57 75 21 533 Table 2 3 5 6 Make sure lock pin is proper engaged after completing adjustment 3 5 7 Replace inspection cover nameplate NOTE New friction discs require frequent adjustments during an initial break in period Please recheck clutch adjustment after the first 10 hours of operation Clutch Adjustment Frequency 3 5 8 As clutch wears the hand lever force required to engage...

Page 22: ...ay have to be operated at higher speeds while engaging the clutch However with a combination of clutch control and careful use of engine speed a much smoother transition can be achieved by allowing the clutch to slip Variations in engine revs are not immediately translated into changes in drive shaft rotation speed but rather the friction on the clutch plate allows the drive shaft to gradually equ...

Page 23: ...rom the flywheel housing If the PTO doesn t separate gently pry the flanges apart until the housing is removed from the engine flywheel housing pilot diameter 5 2 Remove the clutch from the PTO 5 2 1 Bend hub lock washer tab away from hub locknut 5 2 2 Remove hub locknut 5 2 3 Remove hub lock washer 5 2 4 Remove the clutch hub assembly using a gear puller and the tapped holes that are provided in ...

Page 24: ... 7 Let bearing cool before next step 6 1 1 8 Turn shaft over to install second tapered roller bearing from the other end if required 6 1 1 9 Heat second tapered roller bearing to 170 F 20 F Then demagnetize bearing 6 1 1 10 Install second tapered roller bearing on shaft until against shoulder NOTE this operation must be done quickly If bearing does not drop on shaft easily remove bearing immediate...

Page 25: ...late assembly Place spring adjusting lock pin into floating plate then screw adjusting ring on hub to secure floating plate 6 1 3 7 Assemble finger levers to floating plate using spring washers clevis pins and cotter pins See Figure 8 9 for direction of clevis pins and positioning of cotter pins IMPORTANT ORIENT ALL CLEVIS PINS AS SHOWN Figure 8 6 1 3 8 Assemble lever links clevis pins and cotter ...

Page 26: ...embly to adjusting ring assembly using clevis pins and cotter pins See Figure 8 9 for direction of clevis pins and positioning of cotter pins 6 1 3 16 Place spring adjusting lock pin into adjusting ring Retract pin and put a wire paper clip through the pin hole 6 1 3 17 Screw adjusting ring assembly onto hub threads to secure floating plate 6 1 3 18 Brush anti seize lubricant on shaft for easy ass...

Page 27: ... in a safe position Failure to do so could result in serious injury or may cause death Warning Do not disassemble install or perform maintenance work on the unit without making sure that the entire manual is read and understood Failure to do so could result in serious injury or may cause death Caution Examine the unit for wear of the friction material and the wear plates Failure to perform this e ...

Page 28: ...1 2 During normal operation apply grease to the lever operating shaft one shot per 100 hours of operation Grease the main bearings located on the clutch shaft as shown in Chart 1 below 7 1 3 Amount and frequency of lubrication are only a recommendation Actual requirements will vary due to load and operating conditions New units should be monitored for heat and wear for a period of time to determin...

Page 29: ...ts should be maintained as follows o No exposure to rainwater o Temperatures 32F 0C to 110F 43C o Below 50 average humidity o Average sunlight Hazards that require additional protection o Dust and debris o Oil water salt water acids or other chemicals o Any other foreign items which may damage the product o Other measures include covering the product to prevent ingress of foreign matter Long Term ...

Page 30: ... 25 184 2 8 500 215 90 7 875 200 02 6 5 16 18 NC 7 8 12 206 2 8 750 222 25 9 500 241 30 8 5 16 18 NC 8 8 88 225 6 9 625 244 48 10 375 263 52 6 3 8 16 NC 10 10 88 276 4 11 625 295 28 12 375 314 32 8 3 8 16 NC 11 12 38 314 5 13 125 333 38 13 875 352 42 8 3 8 16 NC 14 16 12 409 4 17 250 438 15 18 375 466 72 8 1 2 13 NC FLYWHEEL HOUSING DIMENSIONS Housing size D E N2 H2 6 10 500 266 70 11 250 285 75 8...

Page 31: ...Page 31 of 39 WIM TD 002_C Figure 11 SAE Flywheel and Housing Drawing ...

Page 32: ... 5 0 008 inches 0 203mm 6 0 007 inches 0 178mm Table 5 C SP Style Lubrication schedule Component Interval Lubrication Main Bearings See Chart 1 Section 7 1 2 NLGI 2 lithium based grease Operating Shaft Approx 1 to 3 shots every 3 months or 100 hours of Operation NLGI 2 lithium based grease Sliding Sleeve Sealed Ball Bearings Inspect every 2 years or 2000 hours Seal for Life Discard as Required TAB...

Page 33: ...AP SCREWS Grade 8 BOLT SIZE As Received Lubricated INCHES lbf ft lbf in N m lbf ft lbf in N m 1 4 8 100 11 6 80 9 5 16 17 200 23 13 160 18 3 8 30 360 41 24 288 32 7 16 48 570 64 38 456 51 1 2 83 990 112 66 792 89 9 16 107 1285 145 85 1028 116 5 8 143 1714 194 114 1371 155 3 4 256 3070 347 204 2456 277 7 8 417 5000 565 333 4000 452 1 625 7500 848 500 6000 678 HEX HEAD CAP SCREWS Grade 5 BOLT SIZE A...

Page 34: ...8 1115 617 7407 837 30 1117 13408 1515 838 10054 1136 33 1520 18240 2061 1140 13682 1546 36 1952 23426 2647 1464 17567 1985 39 2527 30320 3426 1895 22736 2569 10 9 Class Bolt Size Dry Lubricated lbf ft lbf in N m lbf ft lbf in N m 5 6 5 77 9 8 8 4 9 58 4 6 6 6 11 1 133 15 8 3 100 11 3 8 26 9 323 36 5 20 2 242 27 3 10 53 3 639 72 2 39 9 480 54 2 12 92 9 1115 126 69 7 836 94 5 14 148 1770 200 111 13...

Page 35: ...N Tables 6 HARDWARE TIGHTENING DESCRIPTION THREADLOCKER TORQUE SPECIFICATION OR REFERENCE NAMEPLATE BOLTS NONE Table 7 BELLHOUSING TO BEARING CARRIER BOLTS LOCTITE 242 OR EQUAL OR NONE IF LOCKING WASHER IS USED BEARING RETAINER LOCK BOLT HUB NUT BEND LOCKING TAB OVER NUT FLAT AFTER TIGHTENING 90 110 lbf ft 122 149 Nm ...

Page 36: ...Sideload ratings for WPT Mechanical PTOs is on the drawing supplied with the unit These ratings are applicable when used in conjunction with WPT Power s Product Selection Calculations located in the Power Drivetrain Product catalog WLB 00 001 This catalog can be found by contacting WPT Power or by visiting www WPTpower com For questions regarding Sideload contact WPT Power Applications Engineering...

Page 37: ...ual 2 Torque specification for hub nut see Appendix A Aligning the Friction Discs and Assembling with the Engine 1 See section 3 3 Installation in this manual 2 Disengage the PTO after mounting to the Engine is complete Maintenance 1 Maintenance schedule See section 7 1 in this manual 2 Lubrication See section 7 1 in this manual 3 Clutch Adjustment See section 3 5 in this manual Clutch Operation S...

Page 38: ...rn drive ring Inspectdrive ringteeth and replaceas needed Engagement speed is too high Reduce to 1100 r min Improper alignment Check alignment adjust as needed No support outboard support plate Check if unit requires outboard support install if needed High inertia or shock load starts Contact WPT Power Applications Engineering for support PTO Self Engages Improper engagement torque Check engagemen...

Page 39: ...Page 39 of 39 WIM TD 002_C WPT Power Corporation 1600 Fisher Road Wichita Falls TX 76305 P O Box 8148 Wichita Falls TX 76307 Ph 940 761 1971 www WPTpower com ...

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