PTO INSTALLATION ora | OWNER’S MANUAL FOR ALL 6-BOLT AND 8-BOLT MOUNT SERIES OF MUNCIE PTOS Muncie° - Power ProductsWARNING DO NOT ATTEMPT TO INSTALL OR SERVICE ANY POWER TAKE-OFF WITH THE TRUCK ENGINE RUNNING. PUT THE IGNITION KEYS IN YOUR POCKET BEFORE GETTING UNDER THE TRUCK, DO NOT ALLOW TRUCK ENGINE TO BE STARTED WHILE WORKERS, ‘ARE UNDER THE TRUCK. IMMOBILIZE TRUCK WHEELS WITH SUITABLE CHOCKS BEFORE WORKING UNDER TRUCK. BE SURE TO BLOCK ANY RAISED BODY OR MECHANISM BEFORE WORKING ON OR UNDER THE EQUIPMENT. INSTALLED POWER TAKE-OFFS MUST NEVER BE SHIFTED IN OR. OUT OF GEAR BY ANY MEANS EXCEPT BY THE CONTROLS IN THE CAB OF THE TRUCK. STAY CLEAR OF SPINNING DRIVESHAFTS TO AVOID BECOMING ENTANGLED AND INJURED. IT SHALL BE THE RESPONSIBILITY OF THE INSTALLER OF A. MUNCIE POWER TAKE-OFF TO DECIDE WHETHER TO INSTALL GUARDS IN THE PTO AND/OR DRIVELINE AREA BECAUSE OF POTENTIAL EXPOSURE TO DANGER. ‘THIS IS BECAUSE MOST MUNCIE PTOS ARE INSTALLED BY EQUIP- MENT DISTRIBUTORS OR MANUFACTURERS AND THEREFORE, THE RESPONSIBILITY OF THE INSTALLATION IS BEYOND THE CON: TROL OF MUNCIE POWER PRODUCTS. ‘The PTO is supplied with a packet containing warning labels. If you did not receive any, or if you need extra, you may order them, no charge, by phone or |. They are available through your nearest Muncie distributor or at the ber and address 1-800-FOR-PTOS (367-7867) info@munciepower.com ‘© Muncle Power Pro PTO OWNER’S MANUAL FOR ALL 6-BOLT AND 8-BOLT MOUNT MUNCIE PTOS TABLE OF CONTENTS Section 1 PTO Installation PTO Installation Instructions Adapter Plates & Assemblies Adapter Gear Installation... Filler Blocks .... Section 2. Activation Kit Installation Indicator Light Switch Cont PTO Equipped with Magnetic Pick-Up Sensor TG Series Lectra Shift System TG Series Standard Air Shift System TG Series Electric/Air Shit System .. TG Series Air Shift System For Nissan MLS-61A or B 82 Series Double Acting Air Shift System RG, RL Series Standard Air Shift System ‘Automatic Transmission Diagrams .... 5 ich Shit Electric#ydraule Shit System and Super Heavy Electric/Ai and Super Heavy Standard Air Shift System ions & Tests Section 3. Owner's Mani Power Take-Off Warranty’... PTO Shifting Procedure & Precautions 32 Indicator Light Check 1 8A Clutch Shift Operating Notes .. 35 PTO Maintenance .. Cee 35 PTO Torque & Horsepower Ratings « nnnee 86 PTO Troubleshooting Guide ...... ssnnnnennnsnnnesse BTSECTION 1 2. mo 2" x3" PTO Equipped Caution Labet isto be placed within the ¢ PTO INSTALLATION ° PTO INSTALLATION INSTRUCTIONS Always wear safety glasses. Read entire manual before starting installation. 1. There is a packet with the PTO which contains 4 WARNING LABELS. Before make sure the surfaces are free of dirt and grease. Place 3s follows: sseen by anyone who might go under the truck or r to be placed on each side of the vehicle, ‘on the body in a position easily visible by vehicle or near the PTO. Do not paint over NEVER GET iNUNCA SE UNDER THIS META DEBAJO TRUCK IF THE DEL CAMION ENGINE IS CUANDO EL. RUNNING! MOTORIESTE: 7h VENELE wEGUPED WHA ang 7 ENeAnonel POWER TAKE-OFF aI Figure 1.2 There are two (2) 4" X 8" label of the vehicle,gear does not come toa compte stop within a fom see. kage on the truck must be adjusted before installing the Neutral. Determine sound of For manual shift transmissions, drain transmission fluid. For Allison automat ic transmissions, do not drain trans- mmission fluid, but be prepared for a small ‘amount of oll to escape from opening, plate. Place a shop towel in Remove the opening to prevent dirt from getting in the transmission. Examine cover plate. ‘et attached to the ins! ‘cover on the other openi Clean mounting pad. Inspect holes in aperture for thread sealant used on OEM bolts. Clean these inter- ral threads with wire brush to clear the material, Remove shop towel. }» Check transmission for proper PTO driver gear and location, Do not place anything in or near PTO opening while the engine is running, Stop engine and remove keys before proceeding to next operation. ‘Check PTO driver gear for condition. A nick or blem- = ishmay cabs excossve nose when PTOs mounted. 4 (oe Rock transmission gears by hand to get “fee!” for gear ‘backlash manufactured into transmission gear set. Open the PTO carton and find the mounting kit (studs and enclosed with yi xccept cap screws. Additional instructions may be found on 14 of on supplement sheet enclosed with PTO. Install adapter ‘gear at this point if it is required. (Go to page 1.9 if adapter gear is used) Insta the studs unt the bara ofthe stu is even wth the transmission pad. This typically 10. q1. ). Remove the shifter cover or the inspection cover from the PTO by PTOs which do ‘and rock input Place mounting gasket/shim from your kit over the re studs already installed on the transmission. A thin H Coating of approved transmission oil is recommend- tor which is supplied with the PTO. Do not use a permanent sealant on gasket/shims > because you may need to change them later. Use by approved transmission oil only! S M70 te cs we ose wasn, PES lock tabs and nuts provided. NOTE: The copper washers S Cee ee ee are tos i.e Fe a ed Spr laren aig ween nase eT Seana ie idler shaft cap. Special clearance caps may be used 1e application catalog where known interference exists. ‘gasket/shims and backlash For some Warner W80 applications, a maximum of one thin required. If backlash is too excessive, remove the gasket/shim and use Loctite Gasket Eliminator” sealant Muncie #13M5171 ‘A.20 ounce tube has been supplied with the PTO for these applications. Seth wh arn 14NOTE: Never use silicone type sealant on PTO/transmission mount face as proper backlash cannot be attained. ‘mounting cap screws or nuts to 30-35 Ib-f (6-bolt pad) or 45- rque would be required for stud Fe a torque wrench can not be applied. This can be accom- plished by the installer comparing the tightness of an accessible cap screw (or nut. Tighten this nut wit ‘Then tighten the hard-to-reach Recheck the backlash. The PTO gear should not move more than .012 or less than .006 when all ‘mounting nuts or bolts have been torqued. 14, Repiace shifter cover or inspection cover plate on the PTO. Torque cap Screws to 14-18 Ib.-ft. Double check to make sure the shifter forkis in groove efore tightening cap screws, tuck engine (with transmission and PTO in neutral) for a few sec- n for unnatural noises. Stay ch and remove a gasket/shim. Add sea gasket is used APTO will not always make these noises. Do Not adjust backlash by noise alone, always visually check backlash, Sometime the noise. ling the transmission with lube is the only way to reduce A tight mounted PTO will cause under cutting of gears and result in pre- ‘mature PTO failure, including gear or housing breakage. I OK, repeat test with PTO engaged, 1e as short as possible until trans- ‘ruck without transmission lube. mmission is refiled insmission with manu- ’s approved fluid and for 5 to 10 minutes 19 one tab up housing, Th ing bolts and nuts should be bent up tightly against checked on a regular ba 18. LOCK TABS LOCK TABS are recommended for all 6-bolt PTO installations. They are and provide maximum © 9 © rom mounting parts 82, Lock Tabs are included in all Muncie 6-bolt mounting kts. ‘tab tightly against the flat of the nut or cap sorew. cable shift, page 2.8 f for air shit PTOs, and pat ‘On air system only, you ve any air through the pressure protec tion valve to the PTO system until your main tank pressure exceeds 65 PSI. It your system utilizes a driveline between the PTO and another device and if you have noise in your system that was not there before, the angularty or feline may be the cause. Check driveline angular ity per recommendation on chart and be sure 1.5° to the pump shaft (or driven unit). Driv the yoke ears on the PTO and pump shafts must be in be in phase, alignment, asl Max. | Max. Speed | TIA (RPM) | a" 3500'| 5° 300°} 5° 2500 2000 1500 1000 * For speeds over 2500 RPM contact Muncie for Approval. For installations with angles in the top and side views use this formula to ‘compute the true joint angle (TUA): TWA=VRGBPTO WITH DIRECT COUPLE HYDRAULIC PUMP INSTALLATION Before bolting the pump to the PTO, place (©o not force spline non-seizing compound or grease on the PTO couplings together) shaft and pump shaft 3 mount PTOS are supplied crease, Rousing an os io ing pump wit requrs nopecton fhe pump i ines. Clean any old grease from pump prior ‘or for tandem or multiple section bracket must be installed ‘This recommendation is based upon our experiences to date. Bracket design illus- trations and pump recommendations is to be used as a GUI design shown is representative and Is not to be duplicated all applications. Any lure as a result of damage caused by unsupported weight attached to the PTO will affect any warranty considerations. The drawings below are examples of how the bracket may be construct- ed. A bracket attached to two or more transmission bolts is required. The bracket design should assure that there is Ay no stress or ports: greater than 20 ont punpor thy At PTO shaft. TT 7 If the vertical | — Flos ie oO prohibit flexing at bend or weld, Attach ‘center of gravity of the pump. Pumps without attaching holes or studs are sometimes sup» —f- J ported by welding an eyelet to a hose ax , Installing this into the pump port, and then bracket to it, ct at the pump bolt closest to the Most Muncie direct mount flanges offer ma the flange to be rotated to multiple loca roved port location Or clearance. Be sure to torque the cap screw to 18 ft.lb., and itis advisable to use a thread locker to secure the cap screws (Loctite 241 or NyLoc or equivalent) holes which allow 19. FOR CABLE OR LEVER SHIFT INSTALLATIONS ONLY. attach indicator ight as shown at Battery connection should be an “ACC” tap on fuse panel. Install light in a position which is visible to the operator when operating the PTO and the vehicle. jt is to be connected so that when the PTO is engaged the ‘The indicator light is “OFF” when the PTO Is disengaged. light is “ON" | S3SERIES F" Jn IMPORTANT: 1996 and Later Full Size Light Truck on of the indicator ight through the "On Board Diagnostics” as rood fl ce ght ruck manufactur, Refer tote vette owners manual and body bulder’s manual for locations and functions. For GH Gas Engine, Grounding of the EM is requie 2.12 for wiring indicator switch to the Eaton Fuller CEEMAT transmissions. From btoy lation by placing warning labels as indicated on borders of sment examples are illustrated on pages 1.1 and 1.2. Tum to Section 3 of Owner's Manual.ADAPTER PLATES & ASSEMBLIES ‘See Muncie Quick Reference Catalog for specifications. ADAPTER PLATES are used to convert an SAE 8-bolt aperture to an SAE 6-bolt aperture. ‘mounted to the flush side of the plate. ADAPTER GEAR ASSEMBLIES are normally used to reverse the rotation of the PTO output shaft. They are also commonly fear mounting obstruc- tions. Standard adapters will move the PTO outward from the transmission approx- imately three inches. Adapters often redi ; 09 on 6 BS eater agin ‘Flanged Body - Single Gear ADAPTER GEAR INSTALLATION Before installing the adapter gear be sure to read all ofthe instructions in this book- let for 1g a PTO. 3! the safety instructions listed when installing the ‘adapter as you would for installing the PTO. Make sure that the engine is tured off ‘and wheels are imm fe starting any instal 1. Follow steps 1 through 7 on pages 1.1 through 1.3 of this manual. 2. Before attempting to mount adapter to transmission, bench mount the ‘adapter to the PTO using studs or capscrews in at least the top and bottom stud holes. 3. Using gaskets and spacers (if required) adjust the backlash between the adapter and the PTO so that itis between .008" to .012* inches. 4. After spacing between PTO and adapter is adjusted remove the adapter from the adapter to ‘the backlash of the adapter fo the transmission so that itis 006" to inches. Refer to steps 8 through 12 on pages 1.3 and 1.4 for addition- 5. Using the Gasket Packs created from earlier steps, mount the PTO to the ‘adapter using all six studs stud holes and return to the instructions on page 1.3, step 8 and continue the installation until completed, FILLER BLOCKS/SPACERS FILLER BLOCKS are often required in transmission applications where it is necessary to use a spacer to adapt the PTO to a particular transmission. Two filler blocks may be used in combination with one or more gaskets between the filer block surfaces. A minimum of ‘one (1) gasket is jeen each surface. Refer to notice supplied with 3 block for more information.SECTION 2 ACTIVATION KIT INSTALLATION ALL INSTALLERS MUST READ THE FOLLOWING ACTIVATION KIT INSTALLATION INSTRUCTIONS IMPORTANT: Disconnect vehicle battery and bleed air tanks with engine ‘stopped prior to ins ‘trical or air activation kits. facturers may have specific locations for the accessing of electrical Power and ait. The body builder mar le chassis should be contacted prior B. Route wires and airlines away from rotating and high temperature components. Use appropriate looms and bulkhead pass-thrus wherever possible to avoid nu ough insulation or tubing and causing an electrical short oF ar leak, C. Foliow aii Federal Motor Vehicle Safety Standards (FMVSS) for your vehicle. D. here electrical grounds are indicated, be sure that they are ith straight paths to the vehicle battery ground. (Many vehicle cabs are ‘rom the vehicle frame and a weak ground isa very common cause heck with the vehicle manufacturers for the proper {ground location or connect directly to battery. E. when instalng hydraulic components, be certain to folow common instalation and testing procedures. If you are not familar wth acceptable installation proce- dures request instructions and guidance from the hydraulic equipment supple n SG, TG, RG, RL, RX, 82, 83 nkage and hook-up to the PTO. this purpose. The PTO is designed wit disengage positions, ler of the linkage. Eye Bolt 121.0. 56 62 Jam Nut Tighten after shiting austments have been made. Note: On the RX Series PTOs the indicator light will go off only in one of the two Neutral postions. Refer to the Parts and Service Manual for these PTOs. CABLE SHIFT INSTRUCTIONS 0 Hite 898 TG SERIES PTI Figure 2.2 Figure 2.3 rolled PTOs are designed to be shifted only by wire hment of lever control linkage to a cable control ‘damage to shifting components and, subsequently, the transmission. The unauthorized attachment of the lever control linkage to a cable ‘control mechanism may cause the PTO to engage unintentionally due to linkage bounce or fal, 22CABLE SHIFT INSTALLATION INSTRUCTIONS In not running when instaling or adjusting cable control. After ‘cable from shipping liner ‘Make sure cable has free travel. + Find a suitable location for the control cable and the indicator ight. The cable control should be 0 that the operator has easy access to push in and pull out the control without obstruction or interference by other controls ‘or components in the cab. ny .« Drill a 1/2" hole in dash or control bracket (not provided). (2 Install the control head through the hole and attach with the lock washer and ruts provided. ca Knob can be screwed into place, using the jam nut to secure. Figure 2.4 23 5. Route the length of cable through the floorboard all and to the PTO. The cable needs to be routed cles ito /stems, and rotat- ing and moving components. When routing the control cable avoid kinking the cable and do not bend to radius of less than 6° Critical area: Do not place ‘cable In-a bind in this area. sable head to make a ‘bend when going thru ard. eet ee cine ener Minimum bend radius this point. 6. The lever on the PTO shifter assembly is designed so that it can be moved fer, also must be positioned so that when you pull on. 1@ PTO engages. (The RG Series should have a detent px tead of pushing all the way in for neutral.) 2425 3 To adjust tho lever, mark the poston ofthe lever wi the cable Would pull the lever Remove the shift cover from the PTO Remove the locking capscrew rom the co serrated post. Lineup te lever with your mar. Lineup the post making ue thet the poppet and the shit pate poston, Replace the aking canse and tue 18 Pata si ver assembly. Double check te tal ‘ei ez ae ath station by refering back to step 7 on ~ ighton Sq. head ENGAGED Lever should Move lever tc disengaged the cable knob fully disengaged position. 9. Referring to Figs. 2.1, 2.2, 2.3 on page 2.2, install the appropriate brackets, ‘clamps, and hardware. If the cable is too long, remove the inner wire and cut casing (oniy) to length with a ‘hacksaw or large side cutters. cables are required - they are ible from your nearest Muncie Independent Master Warehouse. DELUXE (PT-65) PTO CABLE Abrasive power cutting equipment is recom- mended for shortening this type of control cable. Do not use a bolt ing tool by using a hardwood block of any convenient length as sm. The hole should be of a size just large enough for the through, have a fine tooth blade (no less than 32 teeth per inch). Remove the inner wire before cutting conduit by puling the control knob end able end by unscrewing it from 10. itis recommended that the control cable casing be securely anchored, with cable clamps, approximately every 30°, to the frame and/or cab to prevent shifting. Cable mounting clamps can be purchased from Incie Independent Master Warehouse. (part no. MT306-4) light and warning labels it must be installed so that itis visible to the opera- le seated in the driver's seat. Additional indicatorINDICATOR LIGHT SWITCH CONTINUITY CHECK TG SERIES LECTRA SHIFT SYSTEM ‘ae Sith pts Dash Bracket ae Figure 28 Figue 28 | Performing @ continuity check on the indicator switch will verity that the indicator ‘switch is functioning and that the PTO is properly assembled. 1. Using a muitime inect one lead to the spade terminal on the indicator ‘switch mounted to the PTO. 2. Connect the other lead to a bare metal portion of the PTO or shifter (Figure 2.5). 'S. if the PTO is mounted on a vehicle, be sure that the engine is stopped, and the vehicle is safely immobilized to prevent any movement. 4, Engage the PTO. The meter will show continuity (Figure 2.6). 5. shift PTO to the disengage position. The meter should return to normal ‘This continuity check may be performed on any Muncie PTO. Only the air shifted ‘models will require an air source to engage the PTO. PTO EQUIPPED WITH MAGNETIC PICK-UP SENSOR 1, Mount the shift cover to the PTO (as required) ‘37TK3899 OR 31713879 SPEED SENSOR KT ] | in the pick-up opening. ick-up until wards 12 tum, Rotate gear to make sure it clears. 5. Hold pick-up and tighten jam nut to hold in place. 6. Re-Check gear for rotation, 27TG SERIES STANDARD AIR SHIFT SYSTEM TG SERIES AIR SHIFT SYSTEM 481k4027 “N" shitt Option - Vehicles 1999 & at FOR NISSAN MLS-61A OR B Insite st Pug atl 0EM Weg Hs Tie Te dah la TG SERIES ELECTRIC/AIR SHIFT SYSTEM sewatac M24 YeMEE Ae 29 2.82 SERIES DOUBLE ACTING AIR SHIFT SYSTEM (D OPTION) Cone Diet ee Sua Tank ame WANT Niple Pressure (IFT SYSTEM (Q OPTION) ee | 1) ‘WB NPT. Bow nee RG, RL SERIES STANDARD AIR SHIFT SYSTEM. NOTE: Protective Cap From. Ae Supply To ri a Be ‘ie mer es en a ponees fesse SRarvnn Ph vO EATON FULLER CEEMAT TRANSMISSIONS: ‘TG, RG, RL, 82 & 83 Series PTOS rrmmronconn — LU Engine Driven PTO Opening). ‘Adlon To The Shit System ‘Components Supplied With The PTO. Eaton Fuller requires the Shift System PTOs use kit number 4 assembly) oF Kt numb 4a indicator switch, wiring barnes, indicator ght and face pat. AUTOMATIC TRANSMISSION DIAGRAMS ‘APPLICATION INFORMATION ALLISON TRANSMISSION RIGHT PROFILE MODEL LEFT PROFILE gnc gon {82 Series (Q Option) 48N161261-A (12V Light) RG, RL Series 48N61260-A (12V Light) 2a 21AUTOMATIC TRANSMISSION DIAGRAMS APPLICATION INFORMATION EATON FULLER CEEMAT TRANSMISSION ge in ig @hosae “AT Sut Insta Tee Hoe Pot sie pia Becial Camecar Bote SAE at Opening LET SE ViEW AIGHT SIDE VW 4374004 Dal Lube Ka agure forContnucus Duty a High Oye Doplcaions 4JATCO AUTOMATIC TRANSMISSION PTO Lubrication (Pot "8" 18 PTO Main Pressure (Port “P") ‘V8-28 BSPT Requires Fting 43737429 50-70 PS! at de AUTOMATIC TRANSMISSION DIAGRAMS. APPLICATION INFORMATION AISIN AUTOMATIC TRANSMISSION MODELS 450-43LE, A443, A445 Man Psu (PtP 2 ‘WED FROM EF SE ALLISON AUTOMATIC TRANSMISSION +1000 SERIES”, 2000 SERIES", AND 2400 SERIES™ ioe vw Lv oa ts Pressure Tp Sof tosnsson ametCLUTCH SHIFT ELECTRIC/HYDRAULIC SHIFT SYSTEM sYSTEM For Hydraulle Shifting CLUTCH SHIFT Series PTO on Automatic Transmissions CLUTCH SHIFT & SUPER HEAVY STANDARD AIR SHIFT S) iting CLUTCH SHIFT or SUPER HEAVY Series PTOs na vekt CS & SH Series eee Kit No. 48TK3926 No, erkaaa0 (12a System) (24'Volt System) ‘Kit No. 48TK3929 (24 Vor System) CLUTCH SHIFT & SUPER HEAVY ELECTRIC/AIR SHIFT SYSTEM ES For Use When Air Shifting CLUTCH SHIFT or SUPER HEAVY Series PTOs ELECTRONIC OVERSPEED SWITCH (CS Series Only) 0S-110 or E0S-111 shown is sold separately ‘Refer to the EOS owner's manual when making this instalation ‘at No. it No, 48TK9991 (24 Ve SH Series OnlyCLUTCH SHIFT INSTRUCTIONS & TESTS 1. install the appropriate shifter kit components described on pages 2.15 & 2.16. (On Allison, Eaton Fuller CEEMAT and JATCO Automatic installations be sure that the lube orice fitting is installed inthe housing port as shown on 2.15 & 2.16, Use ‘only the fiting supplied with your kt to assure proper transmission function. Alison transmissions with neutral lock-up should be installed on a circuit separate ‘of PTO shift circuit. The circuits are supplied by the transmission main pressure and should be teed together at, and closest to, the main pressure port (port P) on 2.13. 22. with ignition switch on (but engine not running) turn on the PTO control switch and listen for solenoid valve. You should be able to hear valve snap open. If not, check for a poor ground connection. The ground must be a bare metal contact to frame. SECTION 3 OWNER’S MANUAL ‘3. start engine and engage switch. If ‘check pressures as follows: 1. Stop engine. d. Start engine. Stay clear of rotating compo- rents. Place PTO switch in engage position. «If either gauge registers less than 90 PSI, or if there is more than 50 PSI difference at ‘any engine speed, check for obstructions in the hoses or the screen adapter. On the hydraulic system if gauge registers 50 PSI or less, you may nected to the wrong port on t information for the main pressure tap loc 4. Complete installation by placing warnit of the decals. Placement examples ar Upon installation, the Clutch Shift output shaft may operate in the off position, If this ‘occurs, double check plumbing for restrictions in the lines. If OK, adjustment of the {drag brake may be required. Ciutch Shift requires a minimal load on the output shaft. ‘The CS6 & CSB PTO is equipped with an internal drag brake as standard. The brake 's adjustable, should the output shaft continue to tun once PTO is disengaged. Note: This brake will not stop shaft if there is a catastrophic fallure with PTO clutch pack. See page 3.8 for more information. . Drag Brake Adjustment Procedure: 1. Stop engine. el ‘2. Locate adjustment screws on the. a ‘end cover per the diagram. f 3. Using 8/16" Allen wrench tum each # of the set screws 1/4 turn clockwise, ‘COVER END View 4. Move away from under the vehicle and away from possible moving compo- nents and restart the engine. Look for the output shaft to stop turning. Ifthe shaft continues, then shut the engine off and repeat steps 2 thru 4. 2a POWER TAKE-OFF WARRANTY ‘The Muncie Power Take-Off is warranted to be free of defects in me cor workmanship and to meet Muncie’s standard written speciticatior ‘and liability une we cing, at Muncie's option, within one ‘any defective part or parts or any THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. MUNCIE MAKES NO WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR ANY PARTICULAR PURPOSE. MUNCIE’S OBLIGATION UNDER THIS WARRANTY SHALL NOT INCLUDE ANY TRANSPORTATION CHARGES OR COSTS OF INSTALLATION OR ANY LIABILITY FOR DIRECT, INDI- RECT SPECIAL, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OR DELAY. THE REMEDIES SET FORTH HEREIN ARE EXCLUSIVE, AND MUNCIE’S LIABILITY WITH RESPECT TO ANY CONTRACT ‘OR SALE OR ANYTHING DONE IN CONNECTION THEREWITH, WHETHER IN CONTRACT, IN TORT, UNDER ANY WARRANTY, OR OTHERWISE, SHALL NOT, EXCEPT AS EXPRESSLY PROVIDED HEREIN, EXCEED THE PRICE OF THE PRODUCT OR PART ON WHICH SUCH LIABILITY IS BASED. . products or parts for which a warranty claim is n prepaid to a Muncie Service ‘accordance with catalogue or ‘ther improper use, operation beyond capacity it other If requested by Mun warranty. No employee or representative ized to change this warranty in any way or to grantPTO SHIFTING PROCEDURE & PRECAUTIONS 3. Automatic Transmission/Transfer Case Mounted PTO coe OFF A. Shift transmission into park. JER TAKE: : ne B. Caution: Apply parking brake and block wheels. Note: Applying park- ing brake does not insure that vehicle will not move when transfer case is in neutral. ite PTO output shaft. Caution: Do not cr reverse while PTO is opera- ay occur To Disengage PTO: F. Shut off engine with transmission in drive mode. selector to park. J. Remove wheel blocks and release parking brake. KK. Shift transfer case into engaged mode. 1. Mechanical Transmission L. Vehicle can now be driven. ‘A. A power take-off is, and should be, operated as an integral part of the Failure to follow proper shifting or operating sequences will result in main transmission. premature PTO failure with possible damage to the equipment. B. Before shifting the Power Take-Off into or out of gear disengage the clutch and wait for transmission or PTO gears to stop rotating, 2. Automatic Transmission with Manual Shift PTOs (includes Air Shift) — ‘Manual Shift PTOs include SG, G, SH, RL, RG, RX, 82, 83 Series PTOs — On automatic transmissions, the gears in jon turn when the transmission is in neutral, therefore, gear ‘occur if the power take-off is shifted into gear or out of gear at ths time. With Converter Driven Gear: A. Engine idle. With the operator the driver's seat and while acti- vating the vehicle's brake, ission lever into any of the drive positions. (This will stop transmission gear from turning.) B. Shit power take-off into or out of goa. G. Ifthe PTO does not engage release the PTO to the disengage position, shift the transmission to neutral and repeat the above steps from step A. D. Shift transmission into park or neutral. (This wil start transmission gears turing) If you hear @ grinding or ratcheting sound turn PTO off and repeat these procedures from step A. 32 33INDICATOR LIGHT CHECK Procedure for checking the PTO Indicator Switch is found on Page 2.7 a4 PTO LIGHT 410A FUSE STOP ENGINE. TRUCK IS NOT TO BE RUNNING WHEN PREFORMING THIS TEST. STOP ENGINE. TRUCK |S NOT TO BE RUNNING WHEN PREFORMING THIS TEST. ROCKER SWITCH IS TO BE TURNED OFF DURING THIS TEST. JUMPER WIRE é JUMPER WIRE Temporarily ground the connector to check bulb. CLUTCH SHIFT OPERATING NOTES CLUTCH SHIFT PTOs should not be engaged (turned “ON”) under heavy load and/or at engine speeds over 1200 RPM. If your operators are careless or n {gent in this respect, you can safeguard your equipment with one or more Muncie protective systems. Consult your Muncie product Iterature or call your nearest Muncie Power Genter for information on the EOS: {08-111 Electronic Overspeed Switch which pre~ vents engagement of your CLUTCH SHIFT PTO above safe speeds. t on the control switch panel is for use with the EOS-110 or stallation Manual Upon installation, CLUTCH SHIFT output shart may rotate while in the off position. restrictions in t ‘Ok, adjustment of ‘The Power Take-Off, being an integral part of the transmission, should be serviced jon. Transmission fluld changes should follow Vehicle manufacturer for severe service. t. Checking for PTO leaks and checking the trans- ‘be done on a regular basis. ‘The Power Take-Offs also part of a system. The PTO system may include the activa- ton control parts, a driveshatt, or hydraulic pump. This PTO system requires periodic {or service every 100 hours of vice history once you have It established). Service should include checking ‘cating direct mount pump shaft connections. PTO gears can be checked for removing the inspection or shifter cover. If piting, galing, cracking, or deformation of the gears or splines has occurred, then the PTO needs to be rebuilt or replaced. Within the first week of use, recheck the installation of the PTO. Check for leaks and iment and tighten any k justments and lubricate moving parts, tighten and repair hi ‘cable or lever linkages. 1 speed diesel engines are also severe appl ‘to the vibrations inherent in these vehicles. Fretting corrosion cannot be: applying grease, the grease is only a deterrent. 35PTO TORQUE & HORSEPOWER RATINGS PTO TROUBLESHOOTING GUIDE Intrmitent service retest an n-Ot operation under lod. maximum horsepower andor torque PROBLEM | POSSIBLECAUSE | REMEDY PREVENTION CABLE SHIFT PTOS Hard cable inner member | Thaw in garage Route cable away fom | INTERN. Satng | frozen road spray and stl end rro_ | sree waro00 | Tonaue | Torque | Max. from moisture SERIE i, FT. = mu | sr | om | Se Sharp bend in cable | Straighten inner member | Kaep bends larger than 3 70 ves_[ | 6 | 2500 ovreplace cable the rinimum bod rads 76 203) 250 ‘Avo shor cable runs % 2500 Improper siting See page 3.2 35 2500 a 2500 | 28 2500 2 200 Worn or damaged Do not connect lever 0 Bs Ed shit conto camponents to abl shiters 738 2500 En 2500 Delayed or | Loose linkage or | Repair or replace Routine maintenance 246 2500 paral | atachment Loose or a 7 250 engagement | missing cable camps 7 250 3 at [a sarr Pros 6 2500 TO doesnt | Contaminated air Bleed ar system more ra ~ 2500 engage | lines often w Bs 2500 Air pressure not Systems are designed w 25; 2500 high enoogh gel] sprue ptcion Before enna wih eo alow at 28 ea i these fas 2500, press exes 8 ey 2500 Improper method of | Make sure vec cc is | Seepage 2 Sh El shifting causing | adjusted to allow the PTO maa 00 damage tthe FTO. | dive gear to stop before aS ‘34 230 shit coer shifig or hat the AL 703 750 Shit procedure flowed aa 250 mm aa 2500 2 708 250 Aeassomble onto PTO 34 2500 camtecty 382 2500 —— maa = Fauty ar vale | Repair or place 329) 00 29) 2500, aa 2300, Worn or dumaped 25 2300 shit conto ® mae ea Shit forks out ot | Reasomble onto PTO 708 2500 shit eaar camcty 7 S29 2500PTO TROUBLESHOOTING GUIDE Continued ydraulic tine con- ‘ected to wrong port Engine RPM too high (€0) Adjust EOS per INBE-Ot PROBLEM | POSSIBLE CAUSE | REMEDY PREVENTION LECTRA SHIFT PTOS Loose connection | Review wiring diagram | Make sure wires ar prop- on Page 28, erty supported an connec: tion are propery made oorimproprground-| Make all grounds tothe | Control module i very Ing of elctial circuit | vehicle battery sensitive to proper ground Blown fuse Replace fuse with Make proper connections Improper si See page 32 shi ‘CLUTCH SHIFT PTOS PTO doesn't Bleed air system more engage often ctriciir systems are high enough Bir lines are too long Burned or extremely worn clutch pack saute crag bree Reroute lines components ‘Adjust per page 2.17 jw proper engagement Drocadures. See page 3.5, 38