HPTO12 Installation &

Maintenance
TABLE OF CONTENTS

Application Guidelines and Data .................. 3 Installation Guidelines .................................. 8

Clutch Dimensions & Specifications .................. 3
Application Guidelines - Mechanical ................. 4
Application Guidelines - Hydraulic ................... 5
Oil Requirements ........................................ 6
Application Guidelines – Electrical ................... 6
HPTO Controller – Display Unit ........................ 7
HPTO Controller – Master Unit ........................ 7
Installation ............................................ 8
Recommended Tools/Materials ....................... 8
Mechanical Assembly Procedure ...................... 9
Controller Operation ................................... 11
Maintenance & Troubleshooting ................ 12
Maintenance Intervals ................................. 12
Model Identification & Serial Number ............... 12
Oil Contamination Levels .............................. 13
Auxiliary Components .................................. 13
Schematics & Drawings ........................... 21

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

Safety
Proper 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. Proper 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.

2 08.01.11 B
E-038
 APPLICATION GUIDELINES & DATA
APPLICATION GUIDELINES AND DATA
Clutch Dimensions & Specifications
Nominal Design Torque 3000 lb-ft (4067 Nm)
Maximum Allowable Power 460 hp (298 kW)
Maximum Allowable Operating Speed 2250 rpm
Engine Housing Size #1 or #2 (HPTO12TS2-100 only) - SAE J617c
Flywheel Size 14 or 11-1/2 (HPTO12TS2-100 only) - SAE J620 OCT88
Clutch Model # Weight A B C D E Keyway
454 22.08 15.07 6.875 6.313 Ø3.499-3.500 7/8 X 7/16
HPTO12DD-A100
[206] [560.9] [382.8] [174.6] [160.3] [88.87-88.88] [22.2 X 11.1]
408 19.46 13.55 5.625 4.891 Ø3.542-3.543
HPTO12DS-100 DIN 6885
[185] [494.3] [344.2] [142.9] [124.2] [89.97-89.99]
425 22.08 15.07 6.875 6.313 Ø3.499-3.500 7/8 X 7/16
HPTO12TD-A100
[193] [560.9] [382.8] [174.6] [160.3] [88.87-88.88] [22.2 X 11.1]
410 19.46 13.55 5.625 4.891 Ø3.542-3.543
HPTO12TS-100/101 DIN 6885
[186] [494.3] [344.2] [142.9] [124.2] [89.97-89.99]
399 20.04 14.13 5.500 4.948 Ø3.149-3.150
HPTO12TS2-100 DIN 6885
[181] [509.0] [358.9] [139.7] [125.7] [79.98-80.01]

HPTO12TS-101 SHOWN

08.01.11 B 3
APPLICATION GUIDELINES AND DATA

Application Guidelines - Mechanical

 Belt load and centerline distance should be within limits specified in the provided side load capacity graph
 Belt driven applications require a support plate that is attached to the clutch to eliminate belt load being
transferred to engine housing. Refer to support bracket detail for remaining necessary dimensions
 Always contact belt supplier to determine proper belt tension
 Clutch design torque should be 200% above peak engine torque

4 08.01.11 B
 APPLICATION GUIDELINES & DATA

Application Guidelines - Hydraulic

 Oil coolers are ideally placed in front of the engine’s heat exchanger, opposite the
fan blades, to receive the coolest incoming air
 Oil cooler must be sized to remove at least 2 hp (1.49 kW) of heat from clutch system
 If ambient air temperature is below 32° F (0° C) for extended periods of time, a cold-
weather-bypass may be required to prevent the cooler from bursting

 Oil reservoirs should be as close to the HPTO as possible

 Oil reservoir fluid level cannot be above 4’ (1.22m) from the clutch centerline
 Oil reservoir should be sized such that its capacity is at least twice the maximum flow
rate of the pump which is operating the HPTO
o Example: A pump provides 10 GPM (37.9 LPM) of flow at maximum operating rpm.
The reservoir should then be at least 20 gallons (75.7 L)
 To account for cooler and filter volumes, reservoir levels should be checked after
initial startup and fluid changes
 Reservoirs should be baffled to force the fluid to take the longest path possible from
drain to suction
 Return-to-tank lines should return fluid below the fluid level to prevent splashing and
foaming of the oil

 Hoses should be routed in a fashion that prevents air from being trapped in the
system
 90° elbows should be avoided in the hydraulic system to prevent flow loss and
pressure increases
 Hoses, coolers and other hydraulic system components should be thoroughly flushed
before connecting the manifold and during fluid changes
 Drain hose must be Ø 3/4” (Ø 19mm) and free of loops, restrictions or tight bends that
could trap oil inside the HPTO
 Return to tank hose from manifold must not be connected to any other hose or
restriction
 A maximum back pressure of 5 psi (.34 bar) is allowable in drain hose
 A minimum supply pressure of 400 psi (27.6 bar) is required at all times
 A maximum supply pressure of 2500 psi (172.4 bar) is allowable
 A β16=75 high pressure filter is recommended on the manifold inlet line
 Recommended Filtration Level ( ISO 4406:1999/SAE J1165) : 15/13/11
(4µm/6µm/14µm), minimum: 19/16/10
 Normal oil temperature is 150° F (65.5° C) with a max allowable of 200° F (93.3° C)
 Baseline oil samples are recommended when machine is new for later comparison
 To maintain proper lubrication and piston pressure, a 2 GPM (7.6 LPM) minimum
supply to the clutch is required at all times
 Hose and fitting sizes located on hydraulic schematics found later in this document

08.01.11 B 5
APPLICATION GUIDELINES AND DATA

Oil Requirements
Oil type can have a significant effect on performance and function of the HPTO unit and may void
warranty. The fluids listed in the table below are preferred by PT Tech but not required.
When operating the HPTO in low ambient temperatures (below freezing) it is important that oil
kinematic viscosity not exceed 380 cSt. If this viscosity is exceeded, clutch performance may be
affected.
Below 32° F (0° C) Above 32° F (0° C) Locate sales locations in your area
Mobilfluid LT Mobilfluid 424 1-800-662-4525
Caterpillar TDTO (10W ONLY) Caterpillar TDTO (SAE 30 ONLY) 1-800-321-7332
Shell Donax TD Low Vis Shell Donax TD (TD ONLY) 1-800-231-6950
ESSO Hydraul 50 ESSO Hydraul 56 1-800-268-3183
N/A Vermeer VMF Ultra Gold 1-888-837-6337

Application Guidelines – Electrical

To avoid any electrical malfunction, the user should always disconnect the wiring harness from the
controller when welding or performing any electrical maintenance on the equipment. Failure to do so
may result in 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.

 The HPTO controller must be connected to a 24 Volt DC power source (battery) and will not function properly if
voltage drops below 20 VDC
 If system voltage is 12 Volt, do not connect HPTO controller. 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 controller must remain constant regardless of switched power. It also must remain constant
during E-stop conditions
 In the event of an emergency stop, leave the clutch engaged so it can use the engine as a brake. This will bring
the driven inertia to a quicker stop than if the clutch were to disengage. Therefore, it is recommended that
battery power be maintained to the controller during emergency stop situations.
 Do not use shield wires or shield pins on master unit as ground connections
 Do not ground shield wires to frame/chassis ground
 An optional remote engage/disengage momentary type button (customer supplied) can be used in addition to
the button that is integrated into the front of the HPTO display unit to engage/disengage the clutch
 The optional remote engage/disengage button should be connected to pin 5 of the grey plug on the master unit
of the HPTO controller
 The HPTO controller has an internal resistance that will draw 48mA @ 24 VDC when the remote button is pushed
 For customers who choose to use the J1939 functionality of the HPTO controller, a detailed J1939 interface
specification is available from PT Tech upon request
 If extra wire length is present in wiring harness, cut wires to needed length. Do not coil wires. Coiling the wires
could cause electrical noise and interference
 Plug unused openings in connectors with appropriate sealing plugs to prevent contamination from entering the
connector
 To reduce stress in connectors allow at least 3” (76.2 mm) of wire length from connector to attachment points
or wire bends

6 08.01.11 B
 APPLICATION GUIDELINES & DATA

HPTO Controller – Display Unit

 Mounting studs and nuts included

 Display unit must be ground using the
ground splice in wiring harness near the
master unit. Do not ground to frame
 Display unit must be powered by the
yellow wire, pin 9 of black (B) plug on
master unit

HPTO Controller – Master Unit

 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 -40°F (-40°C) and
185°F (85°C)
Clutch Controller
HPTO

Serial Number Tag

CMCMU-008-XXX
Model Number CMCMU-XXX-XXX

PT TECH MADE IN USA

PT TECH MADE IN USA S/N: A1715-CR 10/2010

S/N: A1715-CR 10/2010

Serial Number Date

Grey (A) plug Black (B) plug

08.01.11 B 7
INSTALLATION
INSTALLATION

Recommended Tools/Materials
 Torque wrench: 30 – 80 lb·ft (41 – 108 N·m)  Overhead hoist
 Ratchet  Lint-free towels
 Socket set  Mobilfluid 424 oil
 Inch-size wrenches  Brake cleaner
 ½-13 UNC eyebolts  Permanent thread-locker (Loctite 262)
 Adjustable crescent wrench  Lifting straps

Installation 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
 Do not follow standard industry practice by locking the disc pack together. Also do not plug manifold drain
port and pressurize or else internal damage will occur
 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

Drive Ring Serial Number Location

Rubber Inspection Hole Plug

Eyebolt
PWM Valve

Manifold

Pressure Transducer

Bellhousing
Support Plate
Speed Pickup

On/Off Valve

8 08.01.11 B
 INSTALLATION
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
Torque to 74 lb·ft (100 N·m)

Rubber Plug

Access hole

Bellhousing Bolts Speed Pickup

SAE #1
7/16-14 UNC
Torque to 49 lb·ft (66 N·m)

1. Bolt drive ring to flywheel

2. Remove rubber plugs from access holes (save these for re-use)
3. Align teeth of the 3 friction plates with the teeth in the drive ring while mounting bellhousing to engine. A
screwdriver can be used to align the teeth through the access holes
4. Bolt bellhousing to engine
5. Ensure that there is a metal drive ring tooth directly centered in the speed pickup hole
6. Thread speed pickup into input speed location in bellhousing
7. Tighten by hand until speed pickup bottoms out, back out 2-1/2 turns and lock in place with jam nut

08.01.11 B 9
INSTALLATION

5
/8-11 UNC Bolts
1-1/2” (38.1mm) Minimum Length
Torque to 148 lb·ft (100 N·m)

8. Attach support plate to clutch using 5/8-11 UNC Grade-8 bolts of 1-1/2” (38.1mm) minimum length. 3/4”
(19mm) of thread depth is provided in the clutch
9. Shim and attach bottom of support plate to machine frame
10. The hydraulic manifold has been preinstalled on the HPTO by PT Tech. Do not remove. See schematic at the
end of this document for connection details
11. Follow controller instructions and hydraulic guidelines to complete the HPTO installation

10 08.01.11 B
 INSTALLATION

Controller Operation

Key On

 Power light illuminated

 Pressure Transducer light illuminated
 J1939 CAN light illuminated (if connected)

Engine Running – Clutch Disengaged

 Power light illuminated
 Pressure Transducer light illuminated
 J1939 CAN light illuminated (if connected)
 Input Speed light illuminated
 Pressure in “G” port of manifold is 220 psi

Engine Running – Clutch Engaging  Power light illuminated

 Pressure Transducer light illuminated
 J1939 CAN light illuminated (if connected)
 Input Speed light illuminated
 Pressure in “G” port of manifold drops to 0 psi when engage
button is pressed
 Clutch engaged light flashes after button is held for 3 seconds
 Controller “bumps” clutch until output and input speed are equal
 Pressure in “G” port fluctuates during clutch engagement process

Engine Running – Clutch Engaged

 Power light illuminated
 Pressure Transducer light illuminated
 J1939 CAN light illuminated (if connected)
 Input Speed light illuminated
 Pressure in “G” port of manifold is 220 psi

08.01.11 B 11
MAINTENANCE & TROUBLESHOOTING
MAINTENANCE & TROUBLESHOOTING

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 properly.

Frequency What to do?

 Check oil and oil level
 Check hydraulic connections
First 10 hours
 Check all bolted connections
 Baseline oil sample analysis
Daily  Check oil level
 Replace system oil
Every 500 hours  Replace oil filter (P/N: CHYFE-003)
 Oil sample analysis
5000 hours  Internally inspect and service

Model Identification & Serial Number

All HPTO’s receive a part number and unique serial number when they are assembled at the factory. This
information contains the assembly part number, assembly revision letter and date code in the serial number.
It is important that this information not be painted over, tampered with or removed, as this is the only type
of identification for warranty or replacement parts.

HPTO12TS-100 C 610 89
Clutch Size Assembly Sequential Number
Month Built
Revision Year Built
Drive Configuration
Letter
(D = Driveshaft, T = Belt)
Shaft Length Model Type
(D = Long, S = Short)

Serial Number Location

12 08.01.11 B
 MAINTENANCE & TROUBLESHOOTING

Oil Contamination Levels

The following is for reference only and should only be used as a general guideline.
Levels listed below state amounts above baseline levels.
Minimum ISO Filtration Level: 19/16/10

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

Auxiliary Components
The following components can be purchased directly from PT Tech or a customer’s preferred source.
Description PT Tech Part Number Equivalent supplier & part number
Fluid Reservoir – 15 gallon (3.79 L) CHYFR-004 SunSource: SS3149
SAE-B size Hydraulic Gear Pump CHYGP-004 Bosch Rexroth: AZ-P-N-12-020-LDC12MB
Oil Cooler CHYFC-005 Blissfield: 82010
Filter Assembly with filter, head & clog Donaldson: P17-0773 Head
CHYFA-001-D
indicator Donaldson: P17-0926 Electrical Indicator
Donaldson: P17-0311
Filter CHYFE-003 Caterpillar: 130-3212
WIX: 557115
Sun Hydraulics: RSFC-LBN-BCL set @ 400 psi
Sequence Valve: 0-30 GPM (0-113.6 LPM) CHYSC-002
(27.6 bar)

08.01.11 B 13
14
Output Speed
Not used on this clutch model
Input Speed
Indicates controller is
receiving speed signal from
speed pickup or J1939 CAN
Power
Indicates controller is
receiving switched power
J1939 CAN
Indicates controller is
receiving communication
from CAN
Pressure Transducer
Indicates controller is Clogged Filter Fault
receiving pressure signal Not used on this clutch model
from pressure transducer
Safety Switch Fault
MAINTENANCE & TROUBLESHOOTING

Indicates a machine’s safety

Clutch Engagement switch is open. This will
Indicates if the clutch is prevent the clutch from
engaging, engaged or engaging but will not
disengaged disengage the clutch

Clutch Engage/Disengage Button

Push and hold for 3 seconds to
engage clutch. Momentary push will
disengage clutch.
Oil Pressure Fault
Indicates clutch is not
receiving acceptable pressure
Not used on this clutch model
Timed Lockout
Indicates 3 failed
engagements have occurred
or the clutch has disengaged
to prevent an engine stall.
The controller will not allow
Clutch Overload
Indicates engine rpm must be
Oil Temperature Fault
Not used on this clutch model
Coil Fault
Indicates a solenoid coil on
the manifold is not
performing properly
RPM Too High Fault
lowered to engage or
disengage. Also indicates if
engine speed was increased
during engagement

08.01.11 B
another engagement attempt
for 5 minutes

Illuminated Illuminated
continuously with continuously
engine running with engine off
Normal when ignition switch is Pin 1 of grey (A) plug on Controller not receiving
in every position other than master unit is receiving switched power from
"Off" continuous power, not
switched power
Check ignition switch
wiring
If using a voltage
voltage in wire connected to
converter, check
voltage converter
wiring is correct
08.01.11 B
MAINTENANCE & TROUBLESHOOTING
Power
Not illuminated Flashing in Flashing randomly
with engine rhythm with (flickering) with
running engine running engine running
Controller receiving power Poor battery ground
less than 20 volts
ignition switch
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
grey (A) plug on master unit
With ignition on, test
Check that wire connected
to pin 7 of grey (A) plug on
pin 1 of grey (A) plug on
master unit. If no voltage, master unit is connected to
(-) terminal of battery
check wire for damage and
inspect ignition switch
terminals
A proper battery ground will
measure 0 VDC and less
Check that wire connected
than 1 Ω of resistance
to pin 8 of grey (A) plug on
master unit is directly
connected to (+) battery
terminal and is damage free
Check that wire connected
to pin 7 of grey (A) plug on
master unit is directly
connected to (-) battery
terminal and is damage free
Check that wire connected
to pin 1 of grey (A) plug on
master unit is not losing
momentary power when
engine is cranking
Check that wires connected
to pins 7 & 8 of grey (A)
plug on master unit are not
losing connection
Permanent damage occured
from welding or lightning
strike, replace controller
15
MAINTENANCE & TROUBLESHOOTING

Input Speed
Illuminated Not illuminated or
continuously flashing randomly
(flickering)
Normal when engine running Controller not receiving signal
from input speed pickup

Check the speed pickup adjustment (see

Mechanical Assembly Procedure section of
this document)

Check the wires running from the speed

pickup to the master unit for damage.
These wires must be shielded

Check that the drain wire (clear insulation)

is connected to pin 12 of grey (A) plug on
master unit. This wire must not be
connected to the chassis frame

Remove speed pickup and inspect probe

end for damage

Remove speed pickup from clutch housing

and disconnect from wiring harness. Check
resistance between red and black wires
(pins 1 & 2). Resistance should measure
900 Ω (+/- 90 Ω)

Replace speed pickup

Output Speed
Not illuminated

Normal. This feature is not used on

this clutch model

16 08.01.11 B

Illuminated
continuously
Normal when switched power is
coming from ignition switch
Illuminated
continuously
Normal when controller is
connected to a J1939 CAN and
ignition switch is in every
position other than "Off"
08.01.11 B
Pressure Transducer
J1939 CAN
Not
illuminated
Normal if controller is not
connected to a J1939 CAN
Determine if the controller is
connected to a J1939 CAN. If
there are no wires attached
to pins 7 & 8 of the black (B)
plug on the master unit the
controller is not connected to
a J1939 CAN
MAINTENANCE & TROUBLESHOOTING
Not
illuminated
Controller not receiving good
signal from pressure transducer
Inspect wires from pressure transducer to
master unit for damage
With ignition on and engine off, test voltage in
red wire connected to pin 10 of the black (B)
plug on the master unit. Also test the voltage in
the red wire (pin 2) on the pressure transducer.
These voltages should be 12V DC, +/- 1V. If not,
inspect wiring for damage or replace master
unit
With ignition on and engine off, test voltage in
white wire connected to pin 12 of the black (B)
plug on the master unit. This voltage should be
greater than 0.85V DC. If not, inspect wiring
for damage or replace pressure transducer
Verify correct wires are running to transducer
(see schematic at the end of this document)
Replace pressure transducer
Flashing in
rhythm
Controller is connected to but not Controller was connected to a J1939
receiving signal from J1939 CAN CAN and has lost communication or
there was a communication error.
(during this time the controller will
If there are wires connected to use the input speed sensor installed
pins 7 & 8 of the black (B) plug on the HPTO if one is detected)
on the master unit, inspect
them for damage
Turn ignition switch off and
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
There may be a problem with the
engine's CAN. Contact the engine
manufacturer for service and
troubleshooting
17
MAINTENANCE & TROUBLESHOOTING

Clutch Engagement

Flashes during engagement Not illuminated after Flashes after holding start
and then is illuminated holding start button for 3 button for 3 seconds but clutch
continuously seconds does not 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 Check that the voltage stamped on the
system voltage is 24V DC. If system side of the coils is 24V and that the
voltage is 12V DC, contact PT Tech system voltage is 24V DC. If system
voltage is 12V DC, contact PT Tech

During engagement the Power, Pressure
Transducer and Input Speed lights must
be continuously illuminated. If they are
not lit or are flickering the clutch will
not engage. Refer to those light's
troubleshooting sections for more
information
Check for oil leaks or low fluid level in
the reservoir
Install a flow meter at the inlet port of
the manifold and verify that at least 2.0
GPM (7.6 LPM) is being supplied during
engagment

The controller must receive a minimum

of 20V DC from the (+) terminal of the
battery to pin 8 of the grey (A) plug on Check that oil viscosity does not exceed
the master unit. While cranking the 380 cSt
engine the voltage may be dropping
below 20V

Oil Pressure
Not Continuously illuminated Illuminated
and Pressure Transducer Flashing in
illuminated continuosly rhythm
is not illuminated

Normal There is a problem with the There is currently an oil pressure There was a pressure loss while the
Pressure Transducer fault in the system - shut engine clutch was engaging or engaged.
off immediately

Refer to Pressure Transducer

Check all hoses, filters, coolers, etc.
troubleshooting section
for leaks or damage
Push the Engage/Disengage button for 1
second. If there is still a pressure fault,
Check oil reservoir fluid level
the light will illuminate continuously and
stop flashing. Refer to "Illuminated
1. Install a 2000 psi (138 bar) pressure Continuously" troubleshooting
gauge into a tee fitting in hose at the
inlet port of the manifold.
2. With the engine running the dial Push the Engage/Disengage button for 1
should read at least 400 psi (27.6 second. If the light goes out, there is no
bar). longer a pressure fault
3. If this condition is true, there is a
PWM valve problem, a pressure
transducer problem or a wiring Check that the pressure transducer light
problem is not turned off. If it is off, refer to
"Pressure Transducer" troubleshooting
1. Install a 300 psi (20.7 bar) pressure
gauge with an SAE #4 o-ring fitting
into the "G" port in the manifold. Check that the Power light is not
2. With the engine running and the flashing. If it is flashing, refer to "Power"
clutch disengaged, the gauge should troubleshooting
read 220 psi (15.2 bar).
3. If this condition is not true there is Check that both coils are connected to
a problem with the PWM valve. the valves
Note: The pressure in this port should
be 220 psi (15.2 bar) when the Check all hoses, filters, coolers, etc. for
clutch is engaged and disengaged. leaks or damage
Pressure will vary between 0-220 psi
(0-15.2 bar) during clutch
engagement Check oil reservoir fluid level

Check for sources of oil contamination Check for sources of oil contamination

18 08.01.11 B
 MAINTENANCE & TROUBLESHOOTING

Oil Temperature
Not illuminated

Normal. This feature is not used on

this clutch model

Filter Clog
Not illuminated

Normal. This feature is not used on

this clutch model

Safety Switch
Illuminated
Not Illuminated
continuously

There is a safety switch fault on the machine

Normal preventing the clutch from engaging

Correct the safety hazzard on the machine

Inspect the wire connected to pin 4 of the grey (A)

plug on the master unit for damage

If a safety switch is present, ensure that it is

receiving power, has a good ground and is in good
working order

1. Trace the wire from pins 1 & 4 of the grey (A)

plug on the master unit to the safety switch(es)
on the machine.
2. If no switch is present, connect the two wires
together so the controller is receiving power at
pin 4 when the system is powered on

Never intentionally bypass a safety

switch using this procedure

Safety switch feature only prevents the clutch from being engaged.
It will not disengage the clutch if a switch is activated.

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MAINTENANCE & TROUBLESHOOTING

Coil
Illuminated Flashing in
Not Illuminated
continuously rhythm

Normal Problem with On/Off coil or its wiring Problem with PWM coil or its wiring

Check that the wires from pins 7 & 10 of Check that the wires from pins 7 & 9 of the
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

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.
Using an Ohmmeter, check the resistance
across the two pins in the Deutsch electrical
connector of the coil.
Silver coils should be 29.3 Ω (+/- 1 Ω)
Black coils should be 26.2 Ω (+/- 1 Ω)
Disconnect the coil from the wiring harness.
Using an Ohmmeter, check the resistance
across the two pins in the Deutsch electrical
connector of the coil.
Silver coils should be 29.3 Ω (+/- 1 Ω).
Black coils should be 26.2 Ω (+/- 1 Ω)

Check all wires and pins in the Deutsch Check all wires and pins in the Deutsch
electrical connectors that are attached to electrical connectors that are attached to
the coil and master unit for damage. the coil and master unit for damage.

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 is Engine speed is The engine Input speed signal
Engine speed is speed was Normal if the
speed is over over 1200 rpm below 1200 rpm was lost for more
below 1050 rpm increased above driven equipment
1050 rpm than 2 seconds
1050 during becomes jammed
during clutch or has caused a
Check engine Refer to "Input clutch engagement
Refer to "Input Check engine speed and Speed" engagement shock load in the
Speed" speed and reduce speed to troubleshooting system. The HPTO
troubleshooting reduce speed under 1200 rpm section 1. Push the controller will
section to under Do not attempt to attempt to
Engage/Disengage
1050 rpm increase engine disengage if input
button for 1
speed while clutch speed drops below
second to clear
is in the process of 500 rpm to prevent
the fault
engaging an engine stall
2. Push and hold
1. Push the Engage/Disengage
Engage/Disengage button for 3
button for 1 seconds to engage
second to clear the clutch
the fault
2. Push and hold Refer to "Input
Engage/Disengage Speed"
button for 3 troubleshooting
seconds to engage section
the clutch

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SCHEMATICS & DRAWINGS

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SCHEMATICS & DRAWINGS

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