Professional Documents
Culture Documents
2 10.22.12 I
E-038
Safety
Always follow the operating instructions in this publication. This ensures trouble-free operation and fulfillment of
any rights to claim warranty. Read these instructions before starting any installation or maintenance. These
instructions contain important information about servicing and maintaining your HPTO. Always keep them in a safe
and clean location.
The following notes appear throughout the publication. Please take a moment to review and understand them.
Electrical hazard
Possible consequences: Severe or fatal injuries
Hazardous situation
Possible consequences: Severe or fatal injuries
Important information
Possible consequences: Damage to components or voiding of warranty
Correct installation, maintenance and operation procedures must be followed due to the possible danger to
person(s) or property from accidents that may result from the use of machinery. PT Tech will not be responsible
for personal injury resulting from careless maintenance and working practices.
Safety devices and guards that may be specified in safety codes should be provided. These devices are not
provided nor are the responsibility of PT Tech.
To prevent accidental starting of the engine or electronic damage when performing maintenance,
disconnect battery cables from battery and remove ignition key from switch. Correct lockout/tagout
procedures should always be closely followed.
PT Tech has made provisions for attaching lifting bolts. The holes provided are of adequate size and
quantity to safely lift the product itself. These lifting points must not be used to lift anything other than the
PT Tech product. Lifting excessive loads at these points could result in property damage or personal injury.
Select lifting eyebolts to obtain maximum thread engagement with bolt shoulder tight against housing. Bolts
should not be long enough to bottom out in lifting hole.
Personal injury can result from fluid under pressure. Care must be taken to ensure fluids are contained
during inspections, maintenance, adjusting or repair of the equipment. All pressurized hydraulic
components should be correctly guarded to prevent personal injury.
10.22.12 I 3
SYSTEM OVERVIEW
SYSTEM OVERVIEW
System Overview
Eight components are required to effectively install your PT Tech Hydraulic Power Take-off (HPTO) clutch:
HPTO Unit (model based on desired horsepower capacity) Reservoir
HPTO Controller Gear pump
Manifold Assembly Filter Assembly
Cooler
Torsional Coupling
The items in blue are provided with your HPTO clutch. Items in red are required Auxiliary Components that can
be purchased from PT Tech or from your preferred supplier. Please carefully read this manual so your PT Tech
product is installed correctly for maximum performance.
4 10.22.12 I
SYSTEM OVERVIEW
Auxiliary Components
The following components can be purchased directly from PT Tech or a customer’s preferred source.
* Sauer-Danfoss: 1P3060ASSJBN
(18 cc/rev, A pad, A spline, -16 inlet, -12 outlet)
or
* 1P3072ASSJBN
(22 cc/rev, A pad, A spline, -16 inlet, -12 outlet)
* Prince: SP20B20A9H9L
(20 cc/rev, A pad, A spline, -16 inlet, -12 outlet)
* Honor: 2GG2Q20L
(19.5 cc/rev, A pad, A spline, -16 inlet, -10
outlet)
* Honor: 2GG2U24L
(24 cc/rev, A pad, A spline, -16 inlet, -12 outlet)
Donaldson: P17-0311
Filter element CHYFE-003 Caterpillar: 130-3212
WIX: 557115
* These components are compatible with the HPTO but not available from PT Tech
10.22.12 I 5
SYSTEM OVERVIEW
Component Description
The following illustration is a guide for terminology that will be used throughout this document.
Pump Pad
Spline Insert
Torsional Coupling
(Customer Supplied)
Bellhousing
Clutch
Pump Drive Housing
3X Drain Ports
Support Plate
(Customer Supplied)
6 10.22.12 I
SYSTEM OVERVIEW
HPTO12W-92-100 C 610 89
Clutch Size Assembly Sequential Serial Number
Month Built
Revision Year Built
Letter
Sub-assembly designation
(-91- =Pump Drive Housing) Model Type
(-92- = Clutch)
10.22.12 I 7
HYDRAULICS
HYDRAULICS
Hydraulic Guidelines
Please use the following guidelines to assist your design, selection and installation of your hydraulic system.
Cooler
Figure 1
Oil coolers are ideally placed in front of the engine’s
Preferred Mounting heat exchanger, opposite the fan blades to pull
ambient air through the cooler (Figure 1)
Figure 2
Under extreme high ambient temperature, additional
Unacceptable Mounting cooling may be required
Figure 3
8 10.22.12 I
HYDRAULICS
Side View
Figure 7
10.22.12 I 9
HYDRAULICS
A maximum pump flow of 15 gpm (57 lpm) is allowable at full engine speed
A minimum pump flow of 3.5 gpm (13.2 lpm) is required at engine idle
Pump suction hose should be as large in diameter and as short as possible to prevent
pump cavitation. A minimum hose diameter of 1-1/4” (32mm) is recommended.
Consult pump manufacturer to ensure suction head does not exceed their
recommendations for all operating conditions
Pump inlet port should be no more than one size smaller than the suction hose size
being used
o Example: Pump port should be no smaller than -16 with a -20 suction hose
Pump drive capabilities
SAE size A through D pump pads are available for use with the HPTO
SAE size A through C spline inserts are available for use with the HPTO (SAE D size is
default spline in gear)
Pump drives are available in a 1:1 and 1.27:1 (pump to engine speed) ratio
If one of the pump drive locations is not being used, a coverplate must be in place to
prevent contaminates from entering unit. Coverplates are available from PT Tech for
all size pump pads
Maximum unsupported pump load must not exceed 100 lb·ft (136 N·m). See graph
provided to determine if your application is within limits. If load exceeds limits a
support bracket must be used
10 10.22.12 I
HYDRAULICS
Pump drive housing drain hose(s) must be Ø2” (Ø51mm) and free of loops,
restrictions, tight bends or upward slopes that could trap oil inside the HPTO
If HPTO is mounted at an angle between 20° & 80° from vertical, two drain
hoses must be attached (Figure 8)
If machine operates on angles, be certain that the pump drive housing drain
hose has adequate slope in worst case scenario
A pump drive housing drain hose access hole is recommended in the support
plate to eliminate the need for special drain elbows
20° Hoses should be routed in a fashion that prevents air from being trapped in the
to system
80°
90° elbows and bulkhead fittings should be avoided in the hydraulic system to
prevent flow loss and pressure increases
The manifold assembly should be mounted in a way that water and other
contaminates do not enter the electrical connectors of the valves and sensors.
Typically this is achieved by pointing them down or sideways
The manifold assembly should be mounted in a location that prevents air from
being trapped in the system and is protected from thrown objects, heat sources
and contamination
Additional hose and fitting sizes are located on the hydraulic schematic
Figure 8 To reservoir
Baseline oil samples are recommended when the machine is new (Refer to
“Maintenance Section” of this document) for later comparison
A β16=75 high pressure filter (1000 psi/69 bar working, 2000 psi/138 bar burst) is
recommended
10.22.12 I 11
HYDRAULICS
Oil Requirements
Using any fluid other than PT Tech approved oil may significantly affect the performance and function of the
HPTO unit and will void warranty.
• In cold weather conditions, below 32°F (0° C), PT Tech recommends the engine and HPTO hydraulic system
run at low engine idle to allow sufficient time for the hydraulic oil to warm up prior to engaging the clutch
and increasing engine speed. If the HPTO clutch system indicates a pressure fault any time during this
warm up period, follow normal engine shutdown procedures to prevent damage to the HPTO clutch system.
• The HPTO clutch system design specification has an allowable environmental ambient temperature range
of -20° F to 120° F (-29° C to 49° C). If ambient temperatures are below the allowable range, PT Tech
recommends the addition of a reservoir heater.
• High ambient temperatures may require additional cooling
To determine the recommended oil for your application, first select the temperature range below that best
defines the normal ambient air temperature in which the HPTO will be operating.
12 10.22.12 I
HYDRAULICS
Hydraulic Interface - FX
10.22.12 I 13
HYDRAULICS
Hydraulic Interface - VG
14 10.22.12 I
HYDRAULICS
Hydraulic Schematic
10.22.12 I 15
HYDRAULICS
Manifold Assembly
The manifold assembly (CHYMA-24V-005) is supplied complete with the HPTO12W. Individual valves and sensors are
available from PT Tech upon request. Please note that as of May 2012 manifolds have a colored tag which should
match the color of the clutch controller being used.
CHYPV-004 CHYFV-002
Brake Valve Lube Flow Control Valve
4.0 GPM [15.1 LPM]
CHYSC-004
Sequence Valve
260 psi [18 bar]
SAE -12 Port Sizes
CHYRV-500-001
Pressure Relief Valve
500 psi [34.5 bar]
CHYTS-200-001-D
Temperature Switch
200° F [93° C]
CHYPT-003-D
Pressure Transducer
16 10.22.12 I
ELECTRICAL
ELECTRICAL
Electrical Guidelines
To avoid any electrical malfunction, the user should always disconnect the wiring harness from the HPTO
controller when welding or performing any electrical maintenance on the equipment. Failure to do so may
result in damage and loss of warranty.
The HPTO controller has been pre-programmed at PT Tech. Failure to understand the specified operating
parameters and conditions prior to initial startup and operation may result in unexpected results and/or
possible damage to equipment. Contact PT Tech prior to initial startup to prevent possible injury or death.
Power
The HPTO controller must be connected to a 24 Volt DC power source (battery) and will not function correctly if
voltage drops below 20 VDC
If system voltage is 12 Volts a voltage converter is required (P/N CECVC-002). Contact PT Tech prior to installing
wiring for instructions
The engine ignition switch should provide power to the ignition input (orange wire connected to pin 1 of grey
plug on master unit of HPTO controller) in all positions except off
Battery power to the HPTO controller must remain constant regardless of switched power. It also must remain
constant during E-stop conditions
It is recommended that the machine’s E-stop button not disconnect battery power from the HPTO clutch
controller during an emergency stop situation. A battery positive source should be connected to pin 8 of the
grey “A” plug on the master unit and the engine key switch power must be lost during an E-stop. This will allow
the clutch to stay engaged and the engine to assist in the slowdown of the driven inertia
10.22.12 I 17
ELECTRICAL
HPTO Controller
Master Unit
(required)
PT Tech Part Number: CMCMU-008-12WA
Controller should be oriented with plugs facing down to
keep contaminates out
Controller should be mounted using rubber isolation
mounts to reduce vibrations
Protect controller by locating it in a safe location away
from thrown objects
Controller should not be subjected to temperatures
beyond -20°F (-29°C) and 180°F (82°C)
Beginning May 2012 controller types are distinguished by
label color. Please ensure the correct master unit is
being used
Black Basic R Sky blue Advanced 3
Bluish-green Basic 2 Orange Advanced 4
Clutch Controller
Yellow Advanced 2R
Serial Number Date Code Grey (A) plug Black (B) plug
Model Number
HPTO Controller
Display Unit
(optional)
PT Tech Part Number: CMCDU-008
18 10.22.12 I
Input Speed
Indicates controller is receiving speed Pressure Transducer
signal from input speed pickup or Indicates pressure transducer
10.22.12 I
J1939 CAN is functioning normally
Clutch Engagement
Indicates if the clutch is engaging,
engaged or disengaged
Timed Lockout Oil Temperature Fault RPM Too High Fault Coil Fault
Indicates (3) failed engagements have occurred Clutch oil temperature is above Indicates engine rpm Indicates a
in a row, or the controller detects a clutch 200°F (93°C). Beacon light will must be lowered to solenoid coil on
overload or the clutch has disengaged to prevent flash. Controller will not allow engage or disengage. the manifold is
an engine stall. Controller will not allow another engagement or, if clutch Also indicates if engine not performing
Controller Interface
engagement for 5 minutes and engine must already engaged, speed was increased properly
remain running for that time to count down disengagement will occur in 15 during engagement
19
minutes
ELECTRICAL
ELECTRICAL
Electrical Schematic
20 10.22.12 I
Electrical Schematic (continued)
10.22.12 I
21
ELECTRICAL
ELECTRICAL
Key On
Engine Running – Clutch Engaging Power light illuminated Pressure in “G” port of manifold drops
Pressure Transducer light to 0 psi when engage button is pressed
illuminated Clutch engaged light flashes after
J1939 CAN light illuminated (if button is held for 3 seconds
connected) Controller “ramps” clutch pressure until
Input Speed light illuminated output and input speed are equal
Output Speed light illuminated Pressure in “G2” port increases during
when shaft rotation begins clutch engagement process
22 10.22.12 I
MECHANICAL
MECHANICAL
Mechanical Guidelines
A torsional coupling (customer supplied) is required for connecting the HPTO to the engine’s flywheel
To avoid system damage and ensure full design life, a torsional vibration analysis is required during the initial
application design. This analysis is the responsibility of the customer and will determine the specific coupling
suitable for the application
PT Tech recommends Reich torsional couplings. Please contact them for information regarding your application
Reich USA Corporation
P.O. Box 916
300 Route 17 South - Suite H
Mahwah, NJ 07430
T: 201.684.9400
Belt load and centerline should be within limits specified in the provided belt load graph
Belt driven applications require a support plate (customer supplied) to be attached to the clutch. Dimensional
details are given within the ‘Mechanical’ section of this document
Always contact belt supplier to determine correct belt tension
10.22.12 I 23
MECHANICAL
Assembly Guidelines
Inspect and clean mounting faces and surfaces
Bolt holes should be clean and free of debris
Verify flywheel runout tolerance is within engine manufacturer’s specification
When installing bolts and other fasteners, use permanent thread-locker on the threads and torque to
recommended values
Assembly should be safely supported at all times until it is firmly secured to the machine
Ensure that all bolt threads are compatible with equipment. PT Tech follows SAE J620 Oct88 standards
Recommended Tools/Materials
Torque wrench: 30 – 150 lb·ft (41 – 203 Nm) Overhead hoist
Ratchet Lint-free towels
Socket set Recommended oil (see “Oil Requirements”)
Inch-size wrenches Brake cleaner (non-chlorinated)
5
/8-11 & ½-13 UNC eyebolts Permanent thread-locker (Loctite 262)
Adjustable crescent wrench Lifting straps (2000 lb/907 kg minimum capacity)
24 10.22.12 I
MECHANICAL
Assembly Procedure
The following figures are only provided to make it easier to visualize the process. Discrepancies may occur
depending on HPTO size and version
Flywheel Bolts
SAE-14
½-13 UNC - Grade 8 (M12x1.75 - Grade 12.9)
Torque to 78 lb·ft (108 N·m)
SAE-18
5
/8-11 UNC – Grade 8 (M16x2.0 – Grade 12.9)
Torque to 156 lb·ft (268 N·m)
Bellhousing Bolts
SAE #1
7/16-14 UNC – Grade 8 (M10x1.5 – Grade 12.9)
Torque to 52 lb·ft (62 N·m)
SAE #0
½-13 UNC – Grade 8 (M12x1.75 – Grade 12.9)
Torque to 78 lb·ft (108 N·m)
10.22.12 I 25
MECHANICAL
Output
Speed
Pickup
¾ turns out.
See notes below
Speed
Pickup
¾ turns out.
See notes below
O-ring
Washer
26 10.22.12 I
Dimensions and Capacities - HPTOFX
10.22.12 I
27
MECHANICAL
28
Dimensions and Capacities - HPTOVG
MECHANICAL
10.22.12 I
MECHANICAL
Recommended hydraulic
drain access hole
Plate must be at
least ¾” (19mm) thick
10.22.12 I 29
MAINTENANCE
MAINTENANCE
Maintenance Intervals
Perform all maintenance using standard safety practices and with engine off.
Regular oil changes and samples are recommended to ensure maximum clutch performance and longevity.
Baseline oil samples are suggested to be performed on new machines. These baseline samples can be
beneficial in determining the condition of components and can also aid in troubleshooting if a unit is not
performing correctly.
1000 hours Inspect pump drive gears. Contact PT Tech for inspection procedure and additional information
Internally inspect and service. Rebuild kits and instructions as well as completely rebuilt
5000 hours
clutches are available
Element type Warning Level (ppm) Element type Warning Level (ppm)
Aluminum 10 Molybdenum 5
Antimony 15 Nickel 10
Barium 10 Phosphorus 100
Boron 10 Potassium 10
Calcium 100 Silicon 25
Chromium 10 Silver 10
Copper 25 Sodium 10
Iron 100 Tin 10
Lead 10 Water 250
Magnesium 10 Zinc 100
30 10.22.12 I
MAINTENANCE
Pilot’s shoulder
Idler Gear
10.22.12 I 31
MAINTENANCE
32 10.22.12 I
MAINTENANCE
HPTO12W-60-100
HPTO12W-63-100
HPTO12W-64-100
Detailed Kits Parts List - Clutch
10.22.12 I 33
MAINTENANCE
34 10.22.12 I
MAINTENANCE
HPTO14VG-68-102
HPTO14VG-68-100
HPTO15FX-64-100
HPTO15FX-64-101
HPTO15FX-68-100
HPTO15FX-68-102
HPTOFX-60-100
HPTOFX-61-100
HPTOFX-61-101
HPTOFX-61-102
HPTOFX-61-103
HPTOFX-62-100
HPTOFX-63-100
HPTOFX-65-100
HPTOFX-65-101
HPTOFX-66-100
HPTOFX-67-100
HPTOFX-67-101
Detailed Kits Parts List
– Pump Drive Housing
HPTO14VG-68-102
HPTO14VG-68-100
HPTO15FX-64-100
HPTO15FX-64-101
HPTO15FX-68-100
HPTO15FX-68-102
HPTOFX-60-100
HPTOFX-61-100
HPTOFX-61-101
HPTOFX-61-102
HPTOFX-61-103
HPTOFX-62-100
HPTOFX-63-100
HPTOFX-65-100
HPTOFX-65-101
HPTOFX-66-100
HPTOFX-67-100
HPTOFX-67-101
Detailed Kits Parts List
– Pump Drive Housing
36 10.22.12 I
MAINTENANCE
10.22.12 I 37
MAINTENANCE
38 10.22.12 I
MAINTENANCE
Troubleshooting
Please use the logic trees on the following pages to aid in understanding the functions of the HPTO and
troubleshooting any problems that may occur.
Power
Illuminated Illuminated Not illuminated Flashing in Flashing randomly
continuously with continuously with engine rhythm with (flickering) with
engine running with key off running engine running engine running
Normal when ignition switch is Pin 1 of grey (A) plug on Controller not receiving Controller receiving power Poor battery ground
in every position other than master unit is receiving switched power from less than 20 volts
"Off" continuous power, not ignition switch
switched power Check battery voltage. Check for damage in wire
Check 5 amp fuse on wire Charge or replace if connected to pin 7 of grey
connected to pin 8 of necessary (A) plug on master unit
Check ignition switch
grey (A) plug on master unit
wiring
10.22.12 I 39
MAINTENANCE
Input Speed
Illuminated Not illuminated or
continuously flashing randomly
(flickering)
Normal when engine running Controller not receiving signal
from input speed pickup
Output Speed
Illuminated Not illuminated or Flashing in rhythm
continuously flashing randomly
(flickering)
Normal while the output shaft of Controller not receiving signal The controller has seen a loss of the output
the HPTO unit is spinning from the output speed pickup speed signal while engaging or running or the
controller has seen no output speed after a
full engagement attempt (and aborted by
clutch overload fault)
Check the speed pickup adjustment (see
Mechanical Assembly Procedure section of
this document)
Check the speed pickup adjustment (see
Mechanical Assembly Procedure section of
Check the wires running from the speed this document)
pickup to the master unit for damage.
These wires must be shielded
Check the wires running from the speed
pickup to the master unit for damage.
Check that the drain wire (clear insulation) These wires must be shielded
is connected to pin 3 of black (B) plug on
master unit. This wire must not be
connected to the chassis frame
Check that the drain wire (clear
insulation) is connected to pin 3 of black
Remove speed pickup and inspect probe (B) plug on master unit. This wire must not
end for damage be connected to the chassis frame
40 10.22.12 I
MAINTENANCE
Pressure Transducer
Illuminated Not
continuously illuminated
J1939 CAN
Illuminated Not Flashing in
continuously illuminated rhythm
Normal when controller is Normal if controller is not Controller is connected to but not Controller was connected to a J1939
connected to a J1939 CAN and connected to a J1939 CAN receiving signal from J1939 CAN CAN and has lost communication or
ignition switch is in every there was a communication error.
position other than "Off" (during this time the controller will
Determine if the controller is If there are wires connected to use the input speed sensor installed
connected to a J1939 CAN. If pins 7 & 8 of the black (B) plug on the HPTO if one is detected)
there are no wires attached on the master unit, inspect
to pins 7 & 8 of the black (B) them for damage
plug on the master unit the
controller is not connected to Turn ignition switch off and
a J1939 CAN SAE J1939 networks require a restart engine. If J1939 CAN
120Ω terminating resistor be communication is re-established
installed at each end of the light will stay continuously
main J1939 trunk. Verify they illuminated
are installed properly. Contact
machine's OEM for assistance
Inspect wires connected to pins 7
& 8 of the black (B) plug on the
There may be a problem with master unit for damage
the engine's CAN. Contact the
engine manufacturer for service
and troubleshooting SAE J1939 networks require a
120Ω terminating resistor be
installed at each end of the main
J1939 trunk. Verify they are
installed properly. Contact
machine's OEM for assistance
10.22.12 I 41
MAINTENANCE
Clutch Engagement
Flashes during engagement Flashes after holding start button
Not flashing after holding
and then is illuminated for 3 seconds but clutch does not
start button for 3 seconds
continuously engage after 30 seconds
Normal with a successful Clutch is not engaging Clutch is not engaging and oil pressure
engagement
light is flashing in rhythm
Check that the voltage stamped on the
side of the coils is 24V and that the
system voltage is 24V DC. If system
voltage is 12V DC, contact PT Tech Check that the voltage stamped on the
side of the coils is 24V and that the
During engagement the Power, system voltage is 24V DC. If system
Pressure Transducer and Input Speed voltage is 12V DC, contact PT Tech
lights must be continuously
illuminated. If they are not lit or are
flickering the clutch will not engage. Check for oil leaks or low fluid level in
Refer to those light's troubleshooting the reservoir
sections for more information
Install a flow meter at the inlet port of
the manifold and verify that at least 3.5
The controller must receive a minimum GPM (13.2 LPM) is being supplied during
of 20V DC from the (+) terminal of the engagment
battery to pin 8 of the grey (A) plug on
the master unit. While cranking the
engine the voltage may be dropping Refer to 'Oil Pressure' light
below 20V troubleshooting section
Oil Pressure
Not Continuously illuminated Illuminated Flashing in
illuminated and Pressure Transducer is continuosly rhythm
not illuminated
There is currently an oil There was a pressure loss while
There is a problem with the pressure fault in the system - the clutch was engaging or
Normal shut engine off immediately
Pressure Transducer engaged.
Refer to Pressure Check all hoses, filters, coolers, etc. for leaks or damage Push the Engage/Disengage button
Transducer for 1 second. If there is still a
troubleshooting section Check oil reservoir fluid level pressure fault, the light will
illuminate continuously and stop
1. Install a 0-1000 psi (0-169 bar) pressure gauge into flashing. Refer to "Illuminated
"G1" on the inlet port (1/4" NPT) of the manifold. Continuously" troubleshooting
Do not run the engine while a pressure fault is 2. With the engine running and clutch disengaged the
Push the Engage/Disengage button
dial should read at least 230 psi (15.8 bar).
occurring. A pressure fault could starve the for 1 second. If the light goes out,
3. If this condition is not true, there is a Brake valve there is no longer a pressure fault
clutch of necessary lubrication oil. Shutdown problem, a pressure transducer problem or a wiring
the system and locate the cause of the problem
Check that the pressure transducer
pressure fault to avoid possible damage to vital light is not turned off. If it is off,
1. Install a 0-500 psi (0-24.5 bar) pressure gauge into the refer to "Pressure Transducer"
HPTO components. manifold at the location stamped “G2” (¼” NPT). troubleshooting
2. With the engine running, the clutch disengaged and
the output stopped, the dial on the pressure gauge Check that the Power light is not
should read at least 230 psi (15.8 bar). flashing. If it is flashing, refer to
"Power" troubleshooting
3. If this condition is not true there is a problem with
the Brake valve or shuttle valve in the manifold. The Check that both coils are
pressure in the G2 port should be 225 psi when the connected to the valves
clutch is fully engaged. If this is not true then the
Clutch valve, Brake valve or shuttle valve could be
faulty. It is normal during the process of engaging (with Check all hoses, filters, coolers,
the Clutch Engagement light flashing) for the pressure at etc. for leaks or damage
the G2 port to be low and slowly increase during the
process of engaging. Check oil reservoir fluid level
42 10.22.12 I
MAINTENANCE
Oil Temperature
Not Illuminated
Illuminated continuously
Filter Clog
Not Illuminated
Illuminated
continuously
Normal
The HPTO oil filter is The HPTO filter was just
clogged replaced and an oil filter
fault is still being indicated
10.22.12 I 43
MAINTENANCE
Safety Switch
Illuminated
Not Illuminated
continuously
By default, the safety switch feature only prevents the clutch from
being engaged. It will not disengage the clutch if a switch is
activated. This feature may be enabled using HPTO ProLink
Coil
Illuminated Flashing in
Not Illuminated
continuously rhythm
Normal Problem with Brake coil or its wiring Problem with Clutch coil or its wiring
Check that the wires from pins 7 & 10 of Check that the wires from pins 7 & 9 of the
Refer to ‘Manifold Assembly’ for the grey (A) plug on the master unit are grey (A) plug on the master unit are not
not damaged or connected together damaged or connected together
Brake vs. Clutch Coil location.
Check that the voltage stamped on the side Check that the voltage stamped on the side
of the coils is 24V and that the system of the coils is 24V and that the system
voltage is 24V DC. If system voltage is 12V voltage is 24V DC. If system voltage is 12V
DC, contact PT Tech DC, contact PT Tech
Disconnect the coil from the wiring harness. Disconnect the coil from the wiring harness.
Using an Ohmmeter, check the resistance Using an Ohmmeter, check the resistance
across the two pins in the Deutsch electrical across the two pins in the Deutsch electrical
connector of the coil. connector of the coil.
Coil should be 34 Ω (+/- 1 Ω) when coil is at Coil should be 34 Ω (+/- 1 Ω) when coil is at
68° F (20° C) 68° F (20° C)
Check all wires and pins in the Metripak & Check all wires and pins in the Deutsch
Deutsch electrical connectors that are electrical connectors that are attached to
attached to the coil and master unit for the coil and master unit for damage.
damage.
44 10.22.12 I
MAINTENANCE
RPM
Not Illuminated Illuminated continuously Flashing in rhythm Flashing in
Illuminated continuously while while attempting to while attempting rhythm while
attempting to engage disengage to engage engaged
Normal
The engine The engine speed Engine speed is The engine Input speed Normal if the
Engine speed is speed was signal was lost driven equipment
speed is over is over 1200 rpm below 1200 rpm
below 1050 rpm increased for more than 2 becomes jammed
1050 rpm
Check engine above 1430 seconds during or has caused a
Refer to "Input during clutch clutch shock load in the
Refer to "Input Check engine speed and Speed"
reduce speed engagement engagement system. The HPTO
Speed" speed and troubleshooting
troubleshooting reduce to under 1200 controller will
section attempt to
section speed to rpm Do not attempt to
increase engine 1. Push the disengage if input
under 1050 Engage/Disengage
rpm speed while clutch speed drops below
is in the process of button for 1 500 rpm to
engaging second to clear prevent an engine
the fault stall
1. Push the 2. Push and hold
Engage/Disengage Engage/Disengage
button for 1 button for 3
seconds to engage 1. Push the
second to clear Engage/Disengage
the fault the clutch
button for 1
2. Push and hold second to clear
Engage/Disengage the fault
button for 3 Refer to "Input
Speed" 2. Push and hold
seconds to engage Engage/Disengage
the clutch troubleshooting
section button for 3
seconds to engage
the clutch
Clutch Overload
Not Illuminated Flashing randomly
Illuminated continuously (flickering)
Normal
Controller will not allow Too much difference between input Too much difference between
engagement and output speed while attempting to input and output speed while
engage clutch or while clutch engaged clutch engaged
Wait for clutch overload Turn off engine and check driven
light to go out then Turn off engine and check driven
equipment for jam conditions. equipment for jam conditions. Rotor
reattempt engaging Rotor may be partially jammed and
clutch may be partially jammed and
preventing a complete system preventing a complete system
startup startup
If the rotor rotates freely, verify that Refer to input speed and output
the “Output Speed” is illuminating speed troubleshooting sections
once the output shaft of the clutch
starts turning. If not, refer to Check machine driveline components
Troubleshooting Section titled, for damage
“Output Speed”.
Clutch may be worn out. Consider
Refer to input speed and output hours of operation, as clutch may
speed troubleshooting sections need service
10.22.12 I 45
MAINTENANCE
Timed Lockout
Illuminated
Not illuminated continuously
46 10.22.12 I
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01.31
REV DATE INITIALS CHANGES MADE
A - TAC Initial release
B - TAC Production release updates
C - TAC Added AKG cooler to aux. components section
Updated oils, added hydraulic information, updated
D - TAC
customer drawing
Added pump suction line details, consolidated support
E 10/14/11 TAC
bracket details
F 2/24/12 TAC Reformatted
G 4/30/12 TAC Added new manifold
H 5/31/12 CGK Updated gasket kit for FX housing
I 10/22/12 NEY Updated Kits and Maintenance Section
HEADQUARTERS – USA
1441 Wolf Creek Trail, P.O. Box 305
Sharon Center, OH 44274-0305
U.S.A.
T: 330.239.4933 (ask for HPTO Sales or Service)
F: 330.239.2012
www.pttech.com