User Manual - Bezares USA
Contents
1. uonnaed e qe ssed l Pressure Port And Aperture Identification THESE DRAWINGS REPRESENT LEFT AND RIGHT VIEWS OF THE AT 500 MT 600 AND HT CLT 700 PRESSURE PORT ON THE TRANSMISSION Oil return line from cooler AT 540 4 Speed Main pressure 1 8 N P T 90 150 PSI 6 3 10 5 Kg cm MT 640 MT 650 4 amp 5 Speed Oil return line 1 8 125 217 P S I from cooler 8 7 15 2 Kg cm HT 740 HT 750 D Oil return line Main pressure from cooler CLT 750 Oil return line Main pressure from cooler HT 700 Oil return line Main pressure from cooler 5 Mounting Instructions Lubrication Kit PTO AT500 PTO point Lubrication Kit Part N 9018399 Oil From Cooler Gearbox Gearbox point A point C LIST OF CONTENT Shifting Kit Item Description Part N 9019499 1 T Fitting 2 O ring 3 Fitting 4 Hose 5 Fitting 6 Washer Oil Return Line From Cooler INSTALLATION METHOD 1 Install the T fitting 1 into the oil line returning to the transmission from cooler A position 2 Connect the lubrication hose 9018399 to the T fitting 1 by means of fitting 3 3 Connect the lubrication hose to the PTO B position by means of the fitting 3 4 Fit the Pressure hose 9019499 into the main pre2. NS e 1 n 1 EJ SHUM dwy 04 8 Jepjou esn4 uoneuBi Pressure Port and Aperture Identification THESE DRAWINGS REPRESENT LEFT AND RIGHT VIEWS OF THE MD AND HD PRESSURE PORT ON THE TRANSMISION ALLISON 10 BOLT PAD MAIN PRESS PORT 68 TEETH MAIN PRESS PORT 438 20 UNF 2A 10 16 PITCH 438 20 UNF 2A 175 TO 255 P S I 20 PA 175 TO 255 P S I BOTH SIDES 19 2654 HELIX BOTH SIDES 97 TEETH 10 16 PITCH MAIN PRESS PORT ALLISON 20 P A 438 20 UNF 2A 10 BOLT PAD 19 2654 HELIX L H LEFT SIDE ONLY Zi Mounting Instruction Lubrication Kit PTO 3100 Shifting Kit Part N 900899 GEARBOX pointA LIST OF CONTENT ibrication Kit 4 7 gd 4 Item Description Part 9018699 1 Fitting 2 Hose PTO PTO 3 Fitting point C point D 4 Washer 9018699 9018699 900899 To main pressure port Y 900899 To main pressure port INSTALLATION METHOD 1 Remove the gearbox plug in position A and fit the fitting available in the kit 1 2 Remove the protection plug placed on the PTO B 3 Fit the press
3. Allison 1000 2000 2400 5 6 PTO pointA Lubrication Kit part N 9019199 TN Option 1 3 4 16 UNF Option 2 7 8 14 UNF 3 4 5 6 Option 3 1 1 16 12 UNF GEARBOX i PTO GEARBOX point D Z point B point C LIST OF CONTENT Engagement Kit part N 900899 1 Item Description 1 T Fitting 2 O ring INSTALLATION METHOD 3 Fitting 4 Hose 1 Install the T fitting 1 into the oil line 5 Fitting returning to the transmission from cooler 6 Washer point Lubrication Kit 9019199 A Engagement Kit 900899 1 e d V gt 7 Main pressure port 0 438 20UNF Gearbox bottom view 2 Connect the hose 9019199 to the fitting 1 by means of fitting 3 3 Connect the lubrication hose to the PTO A position by means of the fitting 5 and washers 6 4 Fit the Pressure hose 900899 1 into the main pressure to the transmission D position with the fitting 3 5 Fit the Pressure hose on the B position with the fitting 5 and washers 6 PTO After installation of the PTO the transmission should be carefully checked for proper oil level and signs of oil leakage The best check is conducted with the transmission at operating temperature Bru P T O Shifting Procedure amp Precauti
4. Az Hot Shift PTO 2022 0506 3000 3100 3300 Hydraulic Systems 3000 series 3100 series Building our world 1 888 663 1786 pto usa com pto bezares com Gestion 60 3300 series ES 0303 1998 150 9001 Contents SAFETY INFORMATION p 3 FOREWORD a 4 APPLICATION QUESTIONS wsicvsssiccsesesssvssiesarecscttececevesieveeranecesuesevesdvacessneesatunanecuavenstercuecesesseaceassenaentcectanazess 5 1 P T O 3100 FOR WORLD TRANSMISSION SERIES BREAK UP VIEW qe 6 MOUNTING PTO TO TRANSMISSION 7 MOUNTING PTO TO TRANSMISSION 2 5 ntn tnr snnt ttai ato thon nnne 8 SHIFTER COMPONENT INSTALLATION 9 PRESSURE PORT AND OPENING 10 LUBRICATION KIT MOUNTING INSTRUCTION eeeeeeeeeeennee nennen nennen nnne 11 2 P T O 3000 SERIES AT MT HT BREAK UP VIEW 12 MOUNTING PTO TO TRANSMISSION 5 nane ttti rnit ottenere ttai 13 MOUNTING TO TRANSMISSION wesc 14 AUTOMATIC TRANSMISSION PRESSURE LUBE HOSE CONNECTION 15 SHIFTER COMPONENT INSTALLA
5. Item Description Lubrication Kit 9041499 1 Fitting 1 2 UNF Engagement hose Fitting M10x1 Washer Lubrication hose Fitting 1 8 BSP Au INSTALLATION METHOD 1 Remove the gearbox plug in A and position 2 Remove the protection plugs placed on the PTO in B and D position Engagement kit PTO 9041399 3 Fit the engagement kit 9041399 in A and B position A 4 Fit the lubrication kit 9041499 in C 2 D position Dezaresusa Mounting Instructions Lubrication Kit PTO AISIN AS69RC DODGE RAM Vehicles 7 Engagement Kit Part N 9041399 GEARBOX PTO point pele E Lubrication Kit Part N 9041499 GEARBOX PTO point C pa GEARBOX viewed from left side f LIST OF CONTENT Item Description 1 Fitting 1 2 UNF Engagement hose Fitting M10x1 Washer Lubrication hose Fitting 1 8 BSP Lubrication kit 9041499 INSTALLATION METHOD 1 Remove the gearbox plug in A and position 2 Remove the protection plugs placed on the PTO in and D position 3 Fit the engagement kit 9041399 42 Engagement kit in A and B position uL 9041399 4 Fit the lubrication kit 9041499 in DOza est sa C and D position Mounting Instructions Lubrication Kit PTO Oil from cooler
6. TION SKETCH essen 16 PRESSURE PORT AND OPENING 17 LUBRICATION KIT MOUNTING INSTRUCTION AT500 MT 600 HT 700 18 19 20 3 P T O 3300 SERIES ALLLISON AISIN BREAK UP VIEW 21 SHIFTER COMPONENT INSTALLATION 22 AISIN LUBRICATION KIT MOUNTING INSTRUCTION eere 23 AISIN AS69RC LUBRICATION KIT MOUNTING INSTRUCTION 24 ALLISON 1000 2000 2400 TRANSMISSION SERIES 25 PTO SHIFTING PROCEDURE amp PRECAUTIONS jccissscsscccsescesscsussecsseseoceseiscassesssncrsastsctsesscesabesecsasessesieasoenss 26 PEE 27 Zi Safety Information TO PREVENT POSSIBLE INJURY OR DEATH DO NOT go underneath the vehicle with the engine running DO NOT attempt to work on an installed Power Take Off with the engine running DO NOT operate the controls of the Power Take Off or other driven equipment from underneath the vehicle with the engine running DO NOT operate the controls of the Power Take Off or other driven equipment in any position that could result in getting caught in the moving machinery Make sure to block any moving or raised device that may injure a person
7. er To help you select the proper type size and design of P T O it is advisable to discuss your specific requirements with a Bezares P T O specialist They know their products and Power Take Offs They can inform you about everything you need to know about power at the right time before you specify components Br Aplication Questions Here are some of the questions that are relevant to the Proper Selections of a Transmission mounted Power Take Offs What is the make and model of your transmission Which P T O opening will be used What accessory is to be driven How much horsepower is required to drive the accessory What is the required rotation of the au PWN What is the required P T O output shaft speed as a percent of engine speed Once all of the answer to these questions have been determined a transmission mounted P T O can be selected to meet the horsepower speed and rotation that you require Having made the selection of a P T O you are ready to start the installation Br 1 P T O 3100 For World Transmission CCZACSUSA Mounting P T O To Transmission 1 Drain the oil from the transmission and the PTO aperture cover plate 2 Discard the cover plate and cover plate gasket then clean the aperture pad using a putty knife or wire brush Note Stuff a rag in the aperture opening to prevent dirt from entering the transmission while you are c
8. he disengaged position when not in operation Driven equipment must not be operated until the vehicle is allowed to warm up Bru Notes 27634 Commerce Oaks Drive L Oak Ridge north Texas 77385 1 888 663 1786 DeZa GsL Sa BZUM3000 07 2015
9. lation Sketch 5 LOH HOLAMS NOLLVTIV LSNI 6688906 LIM NOILVTIVLSNI 6668906 Ave jaued 5 6628506 N d U23IMS 016206 Avz 10 06 ET AZ peu ____ 62 gt 20501005 N d T Se 2 3 666506 N d U211MS 9JnssaJd 22218 K NS 06 906 Avz N d 9 e amp 04328 3 mene 6616606 N d Suono euuo M 66c6S06 N d 189UJUJO45 L 026 JOPaUUOD 5524 dwy 01 8 asn4 10 uoniubi l Shifter Instructions Lubrication Kit PTO AISIN Engagement Kit Part N 9041399 GEARBOX PTO point A point B Lubrication Kit Part N 9041499 GEARBOX PTO point C point D 5 E iil WITT GEARBOX GEARBOX Viewed from top side Viewed from left side LIST OF CONTENT
10. leaning it 3 Install the proper studs and pins furnished with the PTO in the pto aperture pad See also specific mounting instruction furnished with the PTO 4 Place the steel gasket over studs using grease if necessary to keep it in place The ribbed surface should face towards the installer Fit at least 4 nuts in each corner before checking the backlash Check the suitable backlash It should be between 0 006 and 0 015 Dezaresusa Mounting To Transmission 5 Fasten the PTO to the transmission by means of the bolts and remaining nuts 6 Install the lubrication and engagement hoses see specific mounting instructions pag 11 7 Fasten the high pressure line to the transmission and checking for proper oil level and signs of oil leakage the best check is conducted with the transmission at operating temperature 8 Finally install the electrical connection Zi Shifter Component 3100 Series Installation Sketch 66 8606 N d 16206 Avc 210206 5 LOH HOL3PIS NOLLVTIVLSNI N d 6668506 6688906 N d NOLLVTIVLSNI Bru jeued 1ueuunuisur puno46 666S06 N d eJnsseJd 6626S06 N d Pwu 0 C IM 7 jeuJu1046 19 9 99 5594 06 7906 vC 0622906 cL N d
11. ons CAUTION This vehicle is equipped with a Power Take Off Shut engine off before working on the Power Take Off or getting below the vehicle Consult the operating instructions before using the P T O see sun visor POWER TAKE OFF OPERATION VEHICLE STATIONARY Automatic Transmission with Power Shift 0 5 Engage the P T O with the engine at idle speed NOTE Power Shift P T O s The engine must be at idle or below 1000 RPM when the is engaged See the transmission manufacturer s instructions for special procedures IMPORTANT Failure to follow the proper shifting or operating sequences will result in premature P T O failure with possible damage to other equipment Warning Cold Weather Operation of Power Shift P T O s During extreme cold weather operation 32 F 0 C and lower a disengaged Power Shift Power Take Off can momentarily transmit high torque that will cause unexpected output shaft rotation This is caused by the high viscosity of the transmission oil when it is extrememly cold As slippage occurs between the Power Take Off clutch plates the oil will rapidly heat up and the viscous drag quickly decreases The Power Take Off output shaft rotation could cause unexpected movement of the driven equipment resulting in serious personal injury death or equipment damage To avoid personal injury or equipment damage Driven equipment must have separate controls Driven equipment must be left in t
12. ructions 6 After fastening the high pressure line to the transmission circuit need to be checked for proper oil level and signs of oil leakage The best check is conducted with the transmission at operating temperature 7 Finally install the electrical circuit Zi Automatic Transmission 5 Pressure Lube Hose Connection Tee Connection To Idler pin in PTO Pressure Lube Hose 9018399 COCH To cooler Return TRANSMISSION AT 500 MT 600 HT 700 T CONNECTION P N FI511 FI511 FI521 TRANSMISSION 1000 2000 2400 T CONNECTION P N FI831 FI401 Br Shifter Component 3000 Series Installation Sketch 6628506 N d 16006 8 014 1 1 LOH HOL3 S NOILVTIVLSNI 10506 AZL 6668906 6688506 LIM NOLLVTIVISNI Jo3e ipu 14617 pau Ave lt LZOSOLOOZ N d AML 2 666906 N d 9 9 U211MS 91 55944 6626506 N d ania PHUM 5 0 01 8 V asn4 EX 06 2906 0622906 N d 9 e 04329 3 JO 10328uuo 5
13. ssure to the transmission C position with the fitting 3 Main Pressure Rear view 5 Fit the Pressure hose on the D position with the fitting 5 and washers 6 f After installation of the PTO the transmission should be carefully checked for proper oil level and signs of oil leakage The best check is conducted with the transmission at operating temperature Mounting Instructions Lubrication Kit PTO MT600 Oil From Cooler Lubrication Kit Part N 9018399 GEARBOX point LIST OF CONTENT Shifting Kit Item Description Part N 9019499 1 T Fitting 2 O ring 3 Fitting 4 Hose 5 Fitting 6 Washer INSTALLATION METHOD 1 Install the T fitting 1 into the oil line returning to the transmission from cooler A position 2 Connect the hose 9018399 to the fitting 1 by means of fitting 3 3 Connect the lubrication hose to the PTO B position by means of the fitting 3 4 Fit the Pressure hose 9019499 into the main pressure to the transmission C position with the fitting 3 MAIN PRESSURE Oil Return Line on 5 Fit the Pressure hose the 0 position Rear view with the fitting 5 and washers 6 After installation of the PTO the transmission should be carefully Az checked for proper oil level and signs of oil leakage The best check is conduc
14. ted with the transmission at operating temperature Mounting Instructions Lubrication Kit PTO HT700 Oil From Cooler PTO point B Lubrication Kit Part N 9018399 GEARBOX point A GEARBOX PTO point C point D LIST OF CONTENT Shifting Kit Item Description Part N 9019499 1 T Fitting 2 O ring 3 Fitting 4 Hose 5 Fitting 6 INSTALLATION METHOD 1 Install the T fitting 1 into the oil line returning to the transmission from cooler A position 2 Connect the lubrication hose 9018399 to the T fitting 1 by means of fitting 3 3 Connect the lubrication hose to the PTO B position by means of the fitting 3 4 Fit the Pressure hose 9019499 into the main pressure to the transmission C position with the fitting 3 Oil return line from cooler 5 Fit the Pressure hose on the D position Main Pressure with the fitting 5 and washers 6 Rear view f After installation of the PTO the transmission should be carefully checked for proper oil level and signs of oil leakage The best check is conducted with the transmission at operating temperature INPUT GEAR A AND Z RATIO 65 INPUT GEAR B RATIO ONLY 62 3 PTO 3300 SERIES pressure from cooler C oil return line port Bru 5 Shifter Component 3300 Series Instal
15. ure Hose 900899 on the A and B position by means of the hose and fitting 3 4 Fit the Lube hose 9018699 on the C and D position with the fitting 3 and washers 4 77 SERIES HD Rear View 2 P T O 3000 Series MT HT main pressure 5 pages Lo 5 ESAE ow Mounting P T O To Transmission 1 Discard the cover plate and cover plate gasket then clean the aperture pad using a putty knife or wire brush Note Stuff a rag in the aperture opening to prevent dirt from entering the transmission while you are cleaning it 2 Install the proper studs furnished with the PTO in the PTO aperture pad See also specific mounting instructions furnished with the PTO DO NOT USE SEALING COMPOUNDS IN AUTOMATIC TRANSMISSIONS 3 Place the correct number of gaskets over studs Do not use paste between because you may want to add or subtract gasket to obtain proper backlash Do not use more than 3 gaskets together Usually one gaskets 0 020 0 5 mm will be required 4 Install the lubrication and engagement hoses specific instructions for each transmission pag 18 19 20 Lubrication hose is connected to point coming from cooler AL Mounting To Transmission 5 Install the PTO to the transmission by means of the bolts and remaining nuts Torque to 30 35 Ib ft 41 47Nm See specific mounting inst
16. working on or under the truck A lever or its linkage may be accidentally moved causing movement of the device which could cause injury to a person near the device Because most of our Bezares Power Take Offs and P T O drive lines are sold through distributors the product applications and the resulting degree of exposure to danger of the operators are beyond the knowledge and controls of BZ U S A Therefore the proper installation of the P T O and its associated equipment and the decisions of whether to install guards and or warning signs shall be the responsibility of the designers or installers NEVER GET ji NUNCA SE UNDER THE META DEBAJO TRUCK IF DEL CAMI N THE ENGINE CUANDO EL IS RUNNING MOTOR EST You may be hurt or killed EN MARCHA Az Foreword Since it is our major objective to show you how to get additional and more profitable miles from truck tractor and trailer components we want to provide you with information on the installation of 3000 3100 and 3300 Series We all realize that an inadequate transmission will overwork any Power Take Off a very short period of time In addition a mismatched transmission P T O combination can result in unsatisfactory performance of the equipment right from the start Before you order new trucks be sure that you re getting the right transmission P T O combination It is of vital importance for efficient performance to have adequate pow
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