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1. tight mounted PTO will cause under cutting of gears and result in premature PTO failure including gear housing breakage If OK repeat test with PTO engaged Caution Keep PTO transmission running time as short as possible until transmission is refilled with lube Do not drive the truck without transmis sion lube Refill transmission with manufacturer s approved fluid and run engine for 5 to 10 minutes to check for leaks Stay clear of rotating com ponents Stop Engine Inspect the cap screws nuts and studs to make sure they are properly tight ened After completing installation installers need to check for leaks and proper mounting torque of PTO fasteners Refer to Step 21 17 18 Install the appropriate shifter kit components including the supplied PTO shift indicator light Refer to page 2 1 for lever shift page 2 2 thru 2 7 for cable shift page 2 8 for the Lectra Shift TG series PTO pages 2 9 thru 2 10 for Air Shift PTOs and pages 2 11 thru 2 20 for Clutch Shift PTOs On air system only you will not receive any air through the pressure pro tection valve to the PTO system until your main tank pressure exceeds 65 PSI If 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 angularity or phasing of your driveline may be the cause Check driveline angularity and reduce total angularity per recommendation on chart a
2. the pin in the groove of the knob 3 Insert screw 4 and tighten with 3 22 allen wrench Push the button cover 5 onto the knob 3 t 6 PN map omo AUTOMATIC TRANSMISSION DIAGRAMS APPLICATION INFORMATION EATON FULLER CEEMAT TRANSMISSIONS TG RG RL 82 amp 83 Series PTOs Right Side Or Bottom Mount Openings Not for Engine Driven Opening Use in addition to the shift system components wa JT ws Supplied With The PTO Eaton Fuller requires the installation of a special wiring harness for PTO indication used in conjunction with their transmission wiring harness The Muncie add on kit includes a special indicator switch and wiring harness which is to be wired as shown Use kit number 48 1434 14 For TG 1 or 4 assembly RL RG 82 all assemblies Use kit number 48 1434 28 for TG 2 or 3 assembly and 83 Series PTOs Switch cluded For Electric Air Shift System PTOs use kit number 48MK1435 14 TG Series 1 or 4 assembly or kit number RI EID ior 48MK1435 23 TG Series 2 or 3 assembly This Kit includes Light the special indicator switch wiring harness indicator light 024 and face plate Engine Driven Opening CS PTO Onh Right Side SAE Bot Opening Suffix Install Tee Here Electrical Bottom SAE BBolt Opening LEFT SIDE VIEW RIGHT SIDE VIEW i Nain Pressure Dual Lube Kit UB NLPT 225 250 PSI ATE Sufix
3. or transmission damage can occur Improper installation tightening or leaks are not the responsibility of Muncie Power Products Inc 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 Replace shifter cover or inspection cover plate and gasket on the PTO Shifter cover gasket can be found in the instruc tion envelope It is required to use a gasket 6 under the shift cover Torque cap screws to 14 18 Ib ft Double check to make sure the shifter fork is in the groove on gear or shift collar before tighten ing cap screws On the TG Series shifter cover the P installation and torqueing of the capscrew should be in an X pattern starting with the center cap screws and crossing the cover during installation 3 Torque the capscrews using the same pattern 4 Start the truck engine with transmission and PTO in neutral for a few seconds and listen for unnatural noises Stay clear of rotating compo nents A whine noise indicates the PTO is mounted too tight Stop engine and add a gasket shim A clatter noise indicates a loose mount Stop engine and remove a gasket shim Add sealant Loctite gasket eliminator if no gasket is used APTO will not always make these noises Do Not adjust backlash by noise alone always visually check back lash Sometimes filling the transmission with lube is the only way to reduce the noise
4. terrain and other external influences We recommend that direct mounted components of any size or weight be supported when these conditions are extreme or unknown This recommendation is based upon our experiences to date Bracket design illustrations and pump recommendations is to be used as a GUIDELINE ONLY Bracket design shown is representative and is not to be duplicated for all applications Any failure 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 constructed A bracket attached to two or more transmission bolts and two pump bolts is required The bracket design should assure that there is no stress or force exerted on the pump or PTO shaft If the vertical supports are greater than 20 degrees off of per pendicular with the jl transmission main shaft then a reinforced Do Z bracket must be LL Le used Reinforce hori zontal members to prohibit flexing at bend or weld Attach the bracket at the pump bolt closest to the center of gravity of the pump gs Most Muncie direct mount flanges offer multiple mounting bolt holes which allow the flange to be rotated to multiple locations on the PTO for improved port loca tion or clearance Be sure to torque the cap screw to 25 ft lb and it is advis able to use a thread locker to secure the
5. 1D Tubing note A pg 2 1 10 Fuse Mounting Bracket 82 Series D Option 48M61261 A 12V Light PTO indicator Light 12v Faceplate 82 SERIES DOUBLE ACTING AIR SHIFT SYSTEM Q OPTION Connect Directly To Air Tank Truck Air Do Not Use Hose Or Tubing EAEE Supply Tank 414 Tubing i x 118 NPT Adapter NN __ JA NPT NDD Pressure Protection Valve y ACC tap 1 8 NPT Elbow mE Positive Indicator Switch Indicator Swit pg 2 1 tid Shipped With PTO on M Connector H 10A Fuse Faceplate MR Mounting Bracket PTO Indicator Light 12 Air Vale RG RL SERIES STANDARD AIR SHIFT SYSTEM NOTE Protective Cap From Air Supply To Cylinders Mounting Bracket 6 Ji J ea 167 2896 Kit Included With Above N Faceplate Air Valve 82 Series Q Option 48M61261 A 12V Light RL Series 48M61260 A 12V Light 241 INSTRUCTIONS FOR PUSH PULL MANUAL AIR VALVE Remove the button cover 5 from the end of the air valve Using 3 32 allen wrench remove screw 4 from knob l Hold red knob 3 to loosen screw Pull the red knob 3 from the valve stem Unscrew the nut 2 from the valve 1 Install the valve 1 through the bracket 6 and 3 face plate 7 using hex nut 2 to hold in place Place knob 3 over the valve stem aligning 2 45
6. ALLISON AUTOMATIC TRANSMISSION 1000 SERIES OR 2000 SERIES When using the Allison transmission for stationary operation it is beneficial to engage the torque converter lock up This allows for a direct comparison of the output shaft speed to engine speed without the affects of the torque converter Muncie requires an electrical connection to the vehicle TCM terminal J106 WTEC 1 or Pin 43 Gen IV reference Allison documentation for PTO enable This noti fies the transmission that a PTO is active and will allow for increased transmission activation pressures and transmission torque converter lock up The Allison automatic transmission special wiring instructions depend on the chassis Please refer to body builder s manuals and special instructions listed there for connection of Muncie PTOs It is required that clutch shifted PTOs mounted to the Allison 1000 series or 2000 series be wired to the Allison trans mission control The PTO enable circuitry provided by Allison allows for full PTO output specifications This means that the PTO enable circuit must be located and connected On GM Medium Duty vehicles C K4500 thru C8500 this accomplished be con necting to the GM PTO control harness Request documentation for the Muncie wiring harness kits 34TK4504 used for clutch shift PTOs or 34TK4505 used for the TG series PTO On Light Duty vehicle C K3600 request installation kit 48TK4461 Pickup chas sis C K2500 C K3500 may not h
7. TRANS MISSION AND THE AUXILIARY COMPONENTS INCLUDING DRIVESHAFTS AND DRIVEN EQUIPMENT DAMAGED COMPONENTS EQUIPMENT RESULTING IN FAILURE CAN CAUSE SERIOUS PERSONAL INJURY TO OPERATORS AND PERSONS IN THE VICINITY ALWAYS FOLLOW RECOMMENDED PROCEDURES FOR SELECTING INSTALLING OPERATING OR REPAIRING A POWER TAKE OFF AS FOUND IN MUNCIE OWNER S MANUALS SERVICE PARTS LISTS AND SERVICE MANUALS CATALOGS AND APPLICATION GUIDES NEVER USE A MUNCIE PTO ABOVE THE RECOMMENDED OPERATING SPEED OF THE UNIT OR THE SPECIFIED DRIVEN UNI NEVER USE A POWER TAKE OFF THAT HAS NOT BEEN SPECIFIED FOR THE OUTPUT CAPABILITIES FOR THE EQUIPMENT BEING DRIVEN JN ROTATING PTO DRIVE SHAFTS IT IS RECOMMENDED THAT DIRECT COUPLE HYDRAULIC PUMPS BE USED WHENEVER POSSIBLE BUT IF YOUR APPLICATION REQUIRES THE USE OFAN EXPOSED DRIVE SHAFT IT IS THE RESPONSIBILITY OF THE INSTALLER AND PURCHASER TO DETERMINE THE BEST INSTALLATION OF A GUARD ROTATING SHAFT CAN SNAG CLOTHING SKIN HANDS HAIR ETC AND WILL CAUSE SERIOUS INJURY OR DEATH 32 DO NOT GO UNDER THE VEHICLE WHEN THE ENGINE IS RUNNING DO WORK NEAR AN EXPOSED DRIVE SHAFT WITH ENGINE RUNNING AUXILIARY SHAFT CAN BE INSTALLED WITH RECESSED OR PROTRUDING SET SCREWS IF RAISED SQUARE HEAD SET SCREWS ARE CHOSEN THEN BE AWARE THAT THIS IS A CATCH POINT FOR CLOTHES SKIN HAIR HANDS ETC AND SERIOUS INJURY OR DEATH MAY RESULT THE OUTPUT SHAFT OF A PTO WITH INTERN
8. authorized to change this warranty in any way or to grant any other warranty PTO SHIFTING PROCEDURE amp PRECAUTIONS POWER TAKE OFF OPERATION VEHICLE STATIONARY LN WARNING PARKING BRAKE MUST ALWAYS BE SET J WARNING VEHICLE S WHEELS MUST ALWAYS BE CHOCKED LN WARNING TRANSMISSION MUST ALWAYS BE IN NEUTRAL OR PARK WARNING AN OPERATOR MUST ALWAYS IN THE DRIVER S SEAT WHENEVER THE ENGINE IS RUNNING AND THE TRANSMISSION IS IN GEAR IN ORDER TO PREVENT OR STOP ANY UNEXPECTED MOVEMENT OF THE VEHICLE WHICH MAY CAUSE INJURIES TO THE OPERATOR OR OTHERS IN THE VICINITY READ ALL OPERATORS MANUALS AND INSTRUCTIONS FOR THE EQUIPMENT THAT YOU ARE OPERATING ON THIS VEHICLE OBTAIN INSTRUCTIONS AND TRAINING FOR ALL OPERATIONS OF THE EQUIPMENT ON THIS VEHICLE INCLUDING THOSE NOT COVERED BY THIS INSTRUCTION BOOKLET NEVER WORK ALONE WHEN REPAIRING OR GOING UNDER A VEHICLE FOR REPAIR OR MAINTENANCE ALWAYS BLOCK ANY RAISED OR MOVEABLE COMPONENTS OR DEVICES WHEN WORKING ON OR AROUND THE VEHICLE AS SPECIFIED BY THE EQUIPMENT MANUFACTURER WARNING PTOS MAY DRIVE DRIVEN EQUIPMENT WITH AN EXPOSED DRIVE SHAFT WHICH MAY CAUSE SEVERE INJURY OR DEATH IF CONTACTED CARE MUST BE TAKEN WHEN USING PTO FOR ANY SPECIFIC APPLICATION THAT THE PTO HAS BEEN PROPERLY SPECIFIED TO MATCH THE TRANS MISSION AND AUXILIARY EQUIPMENT IMPROPER SPECIFICATION AND INSTALLATION CAN CAUSE SEVERE DAMAGE TO THE VEHICLE
9. c 4m RNET D BK E 2663 PPL F 466 GRNLT G 2522 veL H waT Dash Switch ww K 266 TAN Note ALLISON CONNECTOR PIN WIRE COLOR A PURPLE B YELLOW Le e Faw H BLACK J BLACK K UGHT BLUE E Bottery Ground DASH LIGHT Not Induced w Order 36MK1210A Separately CS6B A68 OR A69 YELLOW WHITE WHITE 3AMAM420 BEN NOT USED ON CS10 OR CS20 247 Follow PTO shifting instructions listed in the PTO Owner s manual for engage ment of CS Series PTOs For stationary operation with vechicel stopped and transmission gear selection in park cruise turned foot off accelerator turn on PTO dash switch For Preset type throttle control push Cruise Control set button to increase throttle to the preset speed programmed into the controller This is 1200 rpm by default Advance only works when Cruise Control is on More information is available in the General Motors Body Builders manuals avail able from GM or on their website at www gmupfitter com 34TK4505 INSTALLATION INSTRUCTIONS FOR TG SERIES PTO ONLY WHITE WHITE 30 G YELLOW HEWHITE On LECTRA SHIFT or E HYDRA SHIFT this is cut and spliced into the connection atthe indicator switch LECTRA SHIFT This wiring har ness does not allow mechani cally shifted PTOs like this
10. equipment for an appropriate amount of time established for proper operation or per the equipment manufacturer s recommendation After shutting down equipment and engine check for leaks Allow unit to sit for 60 minutes then check again for any leaks Fix all found leaks per manufacturer s recommendation Muncie Power Products Inc is not responsible for any damage resulting from installation mounting torque or maintenance of the PTO 22 Complete installation by placing warning labels as indicated on borders of the decals Placement examples are illustrated on pages 1 1 and 1 2 Turn to Section 3 of Owner s Manual ADAPTER PLATES amp 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 Adapter plates mount to the trans mission pad with included gaskets and capscrews The 1 4 plate Adapter Plate has a raised pad to provide proper thread engagement This raised pad is to be mounted toward the transmission opening and the PTO is mounted to the flush side of the plate Mount Towards Transmission ADAPTER GEAR ASSEMBLIES are normally used to reverse the rotation of the PTO output shaft They are also commonly specified to clear mounting obstruc tions Standard adapters will move the PTO outward from the transmission approximately three inches Adapters often reduce the application horsepower ratings and service life Conta
11. 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 filler block surfaces minimum of one 1 gasket is required between each surface Refer to notice supplied with the filler block for more information 1411 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 installing electrical or air activation kits A Vehicle manufacturers may have specific locations for the accessing of electrical power activating hydraulics and air The body builder manual or company repre sentative for the vehicle chassis should be contacted prior to installing electrical or pneumatic systems B Route wires hydraulic activation lines and air lines away from rotating and high temperature components Use appropriate looms and bulkhead pass thrus wherever possible to avoid rubbing through insulation or tubing and causing an electrical short or air leak Follow all Federal Motor Vehicle Safety Standards FMVSS for you
12. push switch into faceplate and bracket so that the green lens on the rocker is up 3 Insert the indicator by aligning the flat with the hole in the faceplate and bracket then push the light into place LECTRA SHIFT INSTALLATION WITH EATON FULLER CEEMAT 48MK1434 14 1 or 4 Assembly 48MK1434 23 2 or 3 Assembly poii 28 WIRING DIAGRAM FOR E HYDRA SHIFT TG SERIES Activation Kit 48TK4686 RE cy u po P POWER source e as IMPORTANT 1 The rocker switch and dash bracket if used is to be mounted in cab within easy k m reach of operator NUN m 3 2 PTO engagement is made by pushing rocker switch fully to the engage position and releas x ing switch immediately upon engagement Indicator light nnn wil tight 3 Dril 750 dia Hole in firewall install black plastic grommet UUUUI pin 37T 39628 in hole and ENGAGEMENT Tun the three wire connector through the grommet and plug into cab harness portion of harness Note the orientation of the connector to insure proper B assembly COVER 4 Plug the rocker switch receptacle onto the switch so that the green wire up matching the position of the green light on the rocker switch as noted in diagram E HYDRA SHIFTER KITS 16 5024 S
13. the supplement sheet enclosed with PTO Install adapter gear at this point if it is required Go to page 1 10 if adapter gear is used PTOS with mounting option 6F have two dowel pins which need to be placed in the mounting pad before mounting PTO Install the studs until the barrel of the stud is even with the transmission pad This typically requires a torque limit of 30 35 Ibs ft 6 bolt pad or 45 50 Ibs ft 8 bolt pad If more torque is required to install the stud to the barrel or to the depth shown in the below table then remove the lock patch from the stud and the transmission mounting holes and use a liquid loctite in its place 242 e 10 11 12 The studs should be engaged to the minimum depth as shown below Stud Dia No Threads Approx Depth 3 8 8 1 2 7 16 8 9 5 8 40mm 9 10 1 2 Remove the shifter cover or the inspection cover plate from the PTO by removing the hex head cap screws on the cover plate With PTOs which do NOT have an inspection cover plate hold the output shaft and rock input gear to get the feel of backlash built into the PTO This feel will be helpful when fitting PTO to trans mission Step 12 Place mounting gasket shim from your kit over the studs already installed on the transmission A thin coating of approved transmission oil is recommended on gasket shims to help seal and to hold them place during installation The PTOs for the Eaton Lightning Transmi
14. 5 psi Improper method Make sure vehicle clutch of shifting causing S adjusted to allow the rive gear to stop damage to the before shifting or that the Section 3 shift collar proper shift procedure is followed Worn or damaged Repair or replace shift control components Shift fork is out of Reassemble onto PTO shift collar correctly PTO doesn t Faulty air valve Repair or replace Usually a result of con disengage tamination or dirty valve Keep air system bled and valves free of dirt Worn or damaged Repair or replace shift control components Shift fork is out of Reassemble onto PTO shift collar correctly 37 PTO TROUBLESHOOTING GUIDE continued PROBLEM POSSIBLE CAUSE REMEDY PREVENTION LECTRA SHIFT PTOS PTO doesn t Loose connection Review wiring diagrams Make sure wires are prop engage in Section 2 erly supported and connec tions are properly made Poor improper ground Make all grounds to the Control module is very ing of electrical circuit vehicle battery sensitive to proper ground Blown fuse Replace fuse with Make proper connections proper rating Improper shifting Make sure vehicle clutch is adjusted to allow the PTO See Section 3 drive gear to stop before shifting or that the proper shift procedure is followed Worn or damaged Repair or replace shift control components CLUTCH SHIFT PTOS
15. 500 82 05 95 70 8 500 678 2500 08 85 63 4 450 610 2500 09 78 58 2 410 556 2500 10 78 582 410 556 2500 12 71 52 9 375 508 2500 13 n 529 375 508 2500 15 67 49 9 350 415 2500 19 57 425 300 407 2500 83 05 95 70 8 500 678 2500 06 95 70 8 500 678 2500 12 n 529 375 508 2500 3 6 PTO TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE REMEDY PREVENTION CABLE SHIFT PTOS Hard Cable inner member Thaw in garage Route cable away from Shifting frozen Toad spray and seal end from moisture Sharp bend in cable Straighten inner member Keep bends larger than or replace cable the minimum bend radius Avoid short cable runs Improper shifting Make sure vehicle clutch is See Section 3 adjusted to allow the PTO drive gear to stop before shifting or that the proper shift procedure is followed Worn or damaged Repair or replace Do not connect lever shift control components rods to cable shifters Delayed Loose linkage or Repair or replace Routine maintenance or partial attachment Loose engage or missing cable ment clamps AIR SHIFT PTOS PTO doesn t Contaminated air Remove contaminants Bleed air system more engage lines from air cylinder often Air pressure not Wait until system Systems are designed with high enough pressure is above 65 psi 2 pressure protection valve bef ing PTO Which does not allow air to the PTO until the system pressure exceeds 6
16. AL CLUTCH PACKS MAY ROTATE IN COLD TEMPERATURES WITH THE PTO DISENGAGED PTO SHAFT ROTATION CAN CAUSE SUDDEN MOVEMENT OF THE OUTPUT SHAFT AND ATTACHED DRIVE SHAFT LEADING TO PERSONAL INJURY OR DEATH ALLOW TRANSMISSION TO OPERATE FOR A FEW MINUTES BEFORE ENGAGING PTO ALLOW PTO TO OPERATE FOR A FEW MINUTES BEFORE ACTUATING APPLI CATION CONTROLS SOME O E M CHASSIS MANUFACTURERS HAVE INTEGRATED ELECTRONIC CONTROLS WHICH REQUIRE CERTAIN CONDITIONS TO BE MET BEFORE ENGAGING A PTO THESE INCLUDE BUT ARE NOT LIMITED TO SETTING PARKING BRAKE FOOT OFF SERVICE BRAKE ENGINE AT IDLE FOOT OFF ACCELERATOR PEDAL AND OR TRANSMISSION SELECTOR IN PARK OR NEUTRAL 1 Mechanical Transmission A A power take off is and should be operated as an integral part of the main transmission 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 TG SH RL RG RX 82 83 Series PTOs On automatic transmissions the gears in the transmission turn when the transmission is in neutral therefore gear clashing will occur if the power take off is shifted into gear engaged or out of gear disengaged at this time With Converter Driven Gear A Engine idle With the operator seated in the driver s seat and while activating the vehicle s brake shift transmission lever i
17. F DURING THIS TEST JUMPER WIRE 4 The bulb in the rocker switch is a long lasting bulb It is not replaceable You will need to replace switch if bulb fails 3 5 PTO TORQUE amp HORSEPOWER RATINGS Intermittent service refers to an On Off operation under load If maximum horsepower and or torque is used for extended periods of time 5 minutes or more this is considered Continuous Service and the horsepower rating of the PTO should be reduced by multiplying the value below by 70 INTERMIT INTERMIT PTO SPEED HPO1000 KW 1000 TORQUE TORQUE MAX SERIES RATIO RPM RPM _LBS FT NM SPEED 56 10 25 18 6 130 176 2500 TG 04 54 40 3 285 386 2500 05 51 38 270 366 2500 06 47 35 245 332 2500 07 44 32 8 230 312 2500 08 44 32 8 230 312 2500 09 39 29 205 278 2500 12H 40 29 8 210 285 2500 13H 40 29 8 210 285 2500 15H 37 27 6 195 264 2500 18H 33 24 6 175 237 2500 SH 05 76 57 400 542 2500 07 76 57 400 542 2500 09 n 53 375 508 2500 12 62 46 325 441 2500 13 62 46 325 441 2500 cs 03 57 42 5 300 407 2500 04 57 42 5 300 407 2500 05 57 42 5 300 407 2500 06 57 42 5 300 407 2500 07 57 42 5 300 407 2500 09 52 38 8 275 373 2500 12 52 38 8 275 373 2500 14 52 38 8 275 373 2500 RG 13 26 19 4 140 190 2500 RL 03 38 283 200 271 2500 05 38 28 3 200 271 2500 RX ALL 26 19 4 140 190 2
18. ORKING UNDER TRUCK BE SURE TO BLOCK ANY RAISED BODY OR MECHANISM BEFORE WORKING ON 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 EQUIPMENT DISTRIBUTORS OR MANUFACTURERS AND THEREFORE THE RESPONSIBILITY THE INSTALLATION IS BEYOND THE CONTROL OF MUNCIE POWER PRODUCTS OBTAIN PROPER TRAINING BEFORE OPERATING THIS MACHINERY Z PO NOT INSTALL OR OPERATE EQUIPMENT WHICH HAS NOT BEEN PROPERLY SPECIFIED FOR YOUR EQUIPMENT AX ALLOW THE VEHICLE PTO AND DRIVEN EQUIPMENT TO WARM UP WHEN OPERATING IN WEATHER WHERE TEMPERATURES ARE NEAR OR BELOW 2 5007 INSTALL SEPARATE CONTROLS FOR AND DRIVEN EQUIPMENT ALWAYS INSTALL THE SAFETY LABELS PROVIDED AND PLACE THE OWNER S MANUAL IN THE VEHICLE GLOVE COMPARTMENT 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 email or mail They are available through your nearest Muncie distributor or at the number and address below 1 800 FOR PTOS 367 7867 Muncie
19. PEED Lube Fiting io 43478840 Required Must be ordered separately MT 600 4 amp 5 SPEED SERIES Lobe Fitting Mo 3M78370 Required Mast te ordered separately LEFT PROFILE unm pnessune pont uam enessune ponr e Ta NPT 125217 PS cube rap se O RING pin HT 740 HT 750D Lube A3M78897 Required Most be ordered separately M N PRESSURE PORT ALLISON AUTOMATIC TRANSMISSION 1000 SERIES 2000 SERIES AND 2400 SERIES 4 Bolt Mount 2 Housing 2 Bolt Mount 3 Housing SIDE VIEW Locate Main Pressure Tap on Bottom of Transmission Converter GM Only Applications Use Lube Tap Kit 43TK4497 on C3500 C5500 Chassis Use Lube Tap Kit 43TK4503 on 08500 C8500 Chassis On GM3600 Cab Chassis the cooling lines enter the side of the transmission case use 43TK4497 for lubrication line installation Main Pressure P 100 260 PSI 44 20 UNF 2A 4 43736431 Fitting and 43736445 Elbow Fitting Required BOTTOM VIEW Tee or Tap Into Return Cooler Port for PTO Pressure Lubrication Where Required SAE 8 1000 Series 3 Housing use 43M78840 Tee Fitting SAE 12 1000 or 2000 Series 2 Housing use 43M78970 Tee Fitting Chassis Info International Hino Mitsubishi Remove factory elbow in lubrication return port and drill and tap 1 8 NPT port Thoroughly clean and reinstall chassis lines 215
20. PTO doesn t Contaminated air Remove contaminants Bleed air system more engage lines from air cylinder often Air pressure not Wait until system pres Electri Air systems are high enough sure is above 65 psi designed with a pressure before engaging PTO or protection switch which 80 psi for the Electric Air does not allow current to system the PTO valve until system pressure exceeds 80 psi Airlines are too long Re route lines directly Follow installation to air tanks diagrams Hydraulic line con Review installation dia nected to wrong port grams in Section 2 Burned or extremely Replace worn worn clutch pack Components Engine RPM too Adjust SPD per INO7 04 high SPD PTO doesn t Hydraulic or air lines Re route lines Refer to installation disengage connected to wrong diagrams in Section 2 ports on valve control Faulty air or hydrau Repair or replace Sometimes a result of lic valve contamination or dirty valve Keep air system bled and valves free of dirt Burned or extremely Repair or replace Follow proper engagement worn clutch pack components procedures in Section 3 Misadjusted drag brake Adjust brake with adjust ment screws see Section 2 38
21. Power Products Inc P O Box 548 Muncie IN 47308 0548 info munciepower com AA This symbol warns of personal injury Muncie Power Products Inc 2008 E 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 amp Assemblies Adapter Gear Installation Filler Blocks 1 11 140 341 Section 2 Activation Kit Installation Activation Kit Installation Instructions Lever Shift Control Cable Shift Instructions Indicator Light Switch Continuity Check PTO Equipped with Magnetic Pick Up Sensor TG Series Lectra Shift System TG Series Wiring Diagram for E Hydra Shift TG Series Standard Air Shift System TG Series Electric Air Shift System 82 Series Double Acting Air Shift System RG RL Series Standard Air Shift System Automatic Transmission Diagrams Clutch Shift and SH Series Electric Air Shift System Clutch Shift and SH Series Standard Air Shift System Clutch Shift Electric Hydraulic Shift System Clutch Shift Instructions amp Tests 2 10 2 10 22 11 B1 2 12 2 18 2 20 24221 2 22 Section 3 Owner s Manual Power Take Off Warranty PTO Shifting Procedure amp Precautions Clutch Shift Operating Notes PTO Maintenance Indicator Light Check PTO Torque amp Horsepower Ratings PTO Troubleshooti
22. PrOGear AND TRANSMISSION INC If you have any questions about any Munice Product do not hesitate to call us so we can help you with finding the right PTO part or anything else you may need 906 West Gore St Orlando FL 32805 USA Contact Us 1 866 776 4600 1 407 872 1901 Fax 1 407 872 6235 KEEP IN VEHICLE READ OPERATING INSTRUCTIONS INSTALLATION and OWNER S MANUAL FOR ALL 6 BOLT AND 8 BOLT MOUNT SERIES OF MUNCIE PTOS Muncie K Power Products Muncie Power Products Inc Member of the Interpump Hydraulics Group General Offices and Distribution Center P O Box 548 Muncie IN 47308 0548 765 284 7721 FAX 765 284 6991 E mail info munciepower com Web site http mww munciepower com Drive Products Exclusive Agents for Canada ISO Certified by an Accredited Registrar 184 03 Rev 9 08 Printed in the U S A ZA warnine READ MANUAL COMPLETELY INCLUDING THESE WARNINGS AND OPERATOR S INSTRUCTIONS IN SECTION 3 READ AND UNDERSTAND ENTIRE MANUAL BEFORE INSTALLATION OR OPERATION OF PTO AND DRIVEN EQUIPMENT ALWAYS DISENGAGE THE PTO WHEN THE DRIVEN EQUIPMENT IS NOT IN OPERATION 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 W
23. Required for Continuous e Labe Tap Port B rer Duty or High Cyc is Location For Engine oan Driven Powerclutch PTO Only 242 EATON FULLER ULTRA SHIFT PTO w 18 Connector There two different automated manual transmissions provided by UE y EEH Eaton Fuller The Medium Duty 6 speed Ultra Shift and the Heavy _ i le 10 speed Ultra Shift Both trans missions require connection to the transmission control module TCM as shown is the diagram To insure that the vehicle is properly specified for PTO use contact the chassis dealer Refer to the Eaton installation manual for specific instructions WIRING DIAGRAM FOR EATON FULLER AUTOMATED Connector DM3 or AW3 MANUAL TRANSMISSIONS uror orem Locate wire connected to the F1 on the 18 way con Ifa wire is present then obtain the Eaton document nector on the transmission control module middle position Chassis dealer body builder information should be able to help you find this information TRIG 0082 6 spd Version or TRIG 2500 10 spd E Version Front View Temas 918 Review their instructions for obtaining the Packard Delphi terminal described in the PTO section ofthe Eaton document Muncie recommends the installation be wired as shown by using standard Normally Open automo tive relay Follow t
24. SHIFT mo AT No eas IR SHIFT SYSTEM or SH Series PTOS Rot stp wt Rt CS amp SH Series Kit No 48TK3926 12 Volt System Kit No 48TK3929 24 Volt System SYSTEM PROTECTION DEVICE CS Series Only SPD 1000A shown is sold separately Refer to INO7 04 when making this installation FOOTNOTES 1 Green light in rocker switch is to turn ON when PTO is engaged and to turn OFF when PTO is disengaged Solenoid valve should be mounted on firewall to protect it from corrosive environment Air System Users You will not receive any air through the pressure protection valve to the PTO system until your main tank pressure exceeds 65 PSI Some chassis have dual air systems Be sure to connect to the MAIN air suppl manufacturer Hydraulic hoses and hose ends not supplied with star rately Street Tee provided for clearance mount of pressur unused part s Connection to positive battery ACC tap as identifie 2 20 7 m 6 L3 V ly tank or to the connection specified by the vehicle 4 indard installation kit Order Muncie 131 2 0001 sepa switch or for CS6G installation be sure to plug d by chassis manufacturer See note A on pg 2 1 CLUTCH SHIFT ELECTRIC HYDRAULIC SHIFT SYSTEM For Hydraulic Shifting CLUTCH SHIFT Series P
25. TO on Automatic Transmissions OPTIONAL foseasey To Lube Tap Required On Automatic Transmissions ketno f2VOLT SYSTEM FACE PLATE WIRING PIGTAIL Cocos T 4 TCM ALLISON nj if ING TERA Te eria Noreo siste Do not mount solenoid to a flat surface without spacing the block with washers Damage to valve will occur if coil is allowed to bind against any surfaces CLUTCH SHIFT amp SH HEAVY ELECTRIC AIR SHIFT SYSTEM For Use When Air Shifting CLUTCH SHIFT or SH Series PTOs Connect Directly to Air Tank OPTIONAL Do Not Use Hose or Tubing Fa zm Z euma Required On Automatic 2 Transmissions swe ren onion KI wo caro va Dresses Saraq e reune 3 MENS eden ron D wna era d A uF no damit GV AXE E iste nore nores IDA FUSE ASSEMBLY 221 CLUTCH SHIFT INSTRUCTIONS amp TESTS 1 install the appropriate shifter kit components described on pages 2 11 2 16 On Allison Aisin Eaton Fuller CEEMAT and JATCO Automatic installations be sure that the lube orifice fitting is installed in the housing port as shown on 1 Use only the fitting supplied with your kit to assure proper transmission func tion Allison transmissions with neutral lock up should be installed on a circuit se
26. Turn the pick up back wards 2 turns Rotate gear to make sure it clears Hold pick up and tighten jam nut to hold in place Re Check gear for rota tion 16TK3833 OR 31TK3873 SPEED SENSOR KIT Pulse Generator 31735108 Seal Nut 21735109 Gam Nut seal mount towards fat washer or PTO Flat Washer _ 21136099 0 Ring 12T35774 27 TG SERIES LECTRA SHIFT SYSTEM rust 9 DASH BRACKET cu IMPORTANT 1 The dash bracket is to be mounted in cab within easy reach of operator 2 The control relay should be mounted firewall in engine compartment 3 10 ga wires from battery to relay and from relay to solenoid should not be lengthened 4 PTO engagement is made by pushing rocker switch fully to the engage position and releas TEVDG ing switch immediately upon engagement 1 Excessive repeated shifting of PTO can overheat solenoid and prevent engagement until alowed to cool down Drill 825 dia hole in firewall near where control relay is mounted Install back plastic grommet P N 37735674 in hole and run the four wire connector through the grommet and plug into cab harness portion of harness Plug the rocker switch receptacle onto the switch so that the green wire is up matching the position of the green light onthe rocker switch SWITCH AND LIGHT INSTALLATION 1 Remove protective film from faceplate 2 Lay faceplate on switch bracket and
27. Visor Label The Visor Label 4 x 6 1 2 is to be placed on the visor on the operator s side of the vehicle See Figure 1 2 Do not mount this label on the same side of the visor as the air bag warn ing label if so equipped Vehicles with hydraulic dump pumps are supplied with a Warning label to be mounted in clear view of the operator while seated in the driver s seat rower et oro 2805 Em THIS VEHICLE IS EQUIPPED WITH A POWER TAKE OFF AND HYDRAULIC DUMP PUMP FALURE TODSENCATE IEPTO AND DUMP PUMP es nr REGUIPED CAN RESULT IN ECLIEWEN DAADE ANVOR SERIOUS A WARNING ADVERTENCIA THIS VEHICLES ESTE VEHICULO ESTA EQUIPPED WITHA EQUIPADO CON UNA POWER TAKEOFF TOMA DE FUERZA e MORS o ena rane TO mummo pucr assasi ESTE VEHICULO EST EQUIPADO CON UNA DE FUERZA Y BOMBA DEVOLTEO TLNOPESACTVAE TANTO DE FUERZA COMO PUEDA RESULTAR EN DANO ALEQUPO V O HERIDAS Figure 1 2 12 Manual Transmissions While driving the truck into the work bay note if a delay is required between depressing the clutch and shifting the main transmission gear selection If the gear does not come to a complete stop within a few seconds the clutch linkage on the truck must be adjusted before installing the PTO Run trans mission in neutral Determine sound of transmission before the PTO is installed A transmission no
28. acement examples are illustrated on pages 1 1 and 1 2 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 Clutch Shift requires a minimal load on the output shaft The CS6 amp CS8 PTO is equipped with an internal drag brake as standard The brake is adjustable should the output shaft continue to turn once PTO is disengaged Note This brake will not stop shaft if there is a catastrophic failure with PTO clutch pack See Section 3 for more information Drag Brake Adjustment Procedure 1 2 e 222 Stop engine E Locate adjustment screws on the pads bel end cover per the diagram Fo ail otar atos p Using 3 16 Allen wrench turn each 00 not paint these screws of the set screws 1 4 turn clockwise For USO F85 184 amp 185 PTOS install spring per hole in COVER END VIEW 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 If the shaft continues then shut the engine off and repeat steps 2 thru 4 SECTION 3 OWNER S MANUAL POWER TAKE OFF WARRANTY The Muncie Power Take Off is warranted to be free of defects in materi al or workmanship and to meet Muncie s standard written specifications at the time of sale Muncie s obligation and liability under this warr
29. and is supplied with PTO The CS6B SH6B A6907 series and TG6B A69 Series uses the 23M60270 spacer and requires gasket shims and backlash checks as described below Special Instructions for Allison 1000 amp 2000 Series Transmission Installations Noise can occasionally be emitted from the PTO when installed on the Allison 1000 2000 Series transmissions that may be objectionable to the operator The following instructions assist in reducing this noise Noise emitting when the unit is disengaged and the reduced or extinguished when unit is engaged is common for this installation and is not a signal of advanced failure Muncie Power Products does not consider this noise to be a warrantable condition TG SERIES When installing the TG series note that the PTO is provided with several gaskets and a steel spacer 23M60270 Install the PTO using two 020 thick gaskets provided using one on each side of the spacer Check the backlash Backlash measurement should be in the range 010 to 024 If the PTO is noisy in the off mode but quiet when engaged then remove PTO and re install with all of the gaskets provided CS6 SERIES CS6B A68 03 thru 05 ratios When installing the PTO use one of the two 13M13541 gaskets If PTO is noisy in the off mode and quiet when engaged then remove PTO and re install using both 13M13541 gaskets provided CS6B A69 07 ratio Install the PTO using two 020 thick gaskets provid ed using one on each si
30. anty is expressly limited to repairing or replacing at Muncie s option within one year after date of original installation any defective part or parts or any product not meeting the specifications 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 INDIRECT 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 If requested by Muncie products or parts for which a warranty claim is made are to be returned transportation prepaid to a Muncie Service Center Any installation or use not in accordance with catalogue or package instructions other improper use operation beyond capac ity substitution of parts not approved by Muncie use with equip ment other than the equipment on which the Power Take Off is first installed or alteration or repair made to the Power Take Off other than at a Muncie Service Center shall void this warranty No employee or representative of Muncie is
31. ave proper electrical connections contact GM upfitter s group for assistance International Truck and Engine Corp has a specific PTO control which makes the appropriate connection when the correct activation option is ordered with the vehicle PTO options are specified through the truck chassis dealer CS6B GA6B Series Depending on the Chassis used connection to the PTO enable terminal can be accomplished be attaching a wire to the switched power from the PTO rocker switch and connecting it to the J106 terminal WTEC II or Pin 43 Gen IV GM chassis wiring harnesses are available for connection to this circuit requires GM PTO option to be installed GM6B Series Installation of this PTO is described in IN 01 03 and is not contain in this docu ment This PTO is made for the GM 3600 chassis and comes with wiring which already controls the J106 WTEC 1 or Pin 43 Gen IV circuit TG Series Cable lever and air shifted PTOs can be install with either a two terminal switch or the use of a standard automotive relay as shown on the diagrams Diagram 1 or Diagram 2 0 Banery round Toten kai g From Batery From Batory Acc ip ASC Mean A pr 246 GM THROTTLE ADVANCE C4500 SERIES THRU C8500 SERIES BLT MUNCIE COANECTOR Upfitter Wire Chart PIN WIRE Cor a NC B 48 BULT
32. cap screws Loctite 241 or NyLoc or equivalent 19 Greaseable hydraulic output shaft option 20 21 PTOs with the G special feature option have a grease zerk fitting behind a cover the closed end cap of the output shaft Grease needs to be added after the pump has been installed using a grease gun Use a high temperature high pressure EP type grease FOR CABLE OR LEVER SHIFT INSTALLATIONS ONLY For CLUTCH SHIFT installations skip to pages 2 12 2 21 Using the metal plate as a template drill holes in dash near cable knob and attach indicator light as shown at right 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 Sill The indicator light is to be connected so that when the PTO is engaged the light is ON and the light is OFF when the PTO is disengaged 83 SERIES Do not install any other electri cal devices to Muncie indicator switches or to pressure switches Cg 8 See page 2 12 for wiring indicator switch to the Eaton Fuller CEEMAT transmissions lli Complete installation by placing warning labels as indicated on borders of the decals Placement examples are illustrated on pages 1 1 and 1 2 Turn to Section 3 of Owner s Manual After complete installation installers needs to check for leaks and proper mounting torque of fasteners Operate the
33. ct Muncie for specific infor mation regarding your application Solid Body Single Gear Angular Cluster Gear Flanged Body Single Gear Vertical Offset Gear 110 ADAPTER GEAR INSTALLATION Before installing the adapter gear be sure to read all of the instructions in this booklet for installing a PTO Follow all the safety instructions listed when installing the adapter as you would for installing the PTO Make sure that the engine is turned off and wheels are immobilized before starting any installation 1 2 Follow steps 1 through 7 on pages 1 1 through 1 3 of this manual Before attempting to mount adapter to transmission bench mount the adapter to the PTO using studs or capscrews in at least the top and bot tom stud holes Using gaskets and spacers if required adjust the backlash between the adapter and the PTO so that it is between 006 to 012 Some adapt ers are supplied with gasket eliminator instead of gaskets Apply a bead evenly around the surface of the mounting pad Atter spacing between PTO and adapter is adjusted remove the adapter from the PTO and carefully save the Gasket Pack you have just created Mount the adapter to the transmission using at least the top and bottom stud holes Adjust the backlash of the adapter to the transmission so that it is 006 to 012 inches Refer to steps 8 through 12 on pages 1 3 and 1 4 for additional instructions on backlash Using the Gasket Packs created
34. de of the 23M60270 spacer provided with PTO Check the backlash Backlash measurement should be in the range 010 to 024 If the PTO is noisy in the off mode but quiet when engaged then remove PTO and re install with all of the gaskets provided GM6B GA6B SERIES Install PTO using both 13M13541 gaskets provided See INO3 01 Notice For some Warner W80 applications a maximum of one thin gasket shim 010 is required If backlash is too excessive remove the gasket shim and use Loctite Gasket Eliminator sealant Muncie 13 61717 A 20 ounce tube has been supplied with the PTO for these my il applications Use of a dial indicator can greatly improve the quality of the installation 8 Eee Mount the indicator so that the plung tuve er aligns with a tooth on the PTO input Gear Hold the transmission gear with screw driver or bar and rock the PTO gear back and forth with your hand The 13 14 15 16 total movement on the dial indicator should be between 006 012 Check the backlash at different points around drive gear to find the worst condi tion NOTE Never use silicone type sealant on PTO transmission mounting surface as proper backlash cannot be attained Torque all the mounting cap screws or nuts to 40 45 Ib ft 6 bolt pad or 50 55 Ib ft 8 bolt pad unless noted in a separate stud kit instruction Failure to properly tighten capscrews or nuts can lead to leaks PTO and
35. ded for shortening this type of control cable Do not use a bolt cutter or similar tool Described here is a hand method for cutting cables where abrasive power cutting equipment is not available Make a holding tool by using a hardwood block of any conve nient length as shown in the dia gram The hole should be of a size just large enough for the conduit to easily slip through The hacksaw should have a fine tooth blade no less than 32 teeth per inch Remove the inner wire before cutting conduit by pulling the con trol knob end from the control head Remove the installed cable end by unscrewing it from the cable conduit and saving it for reinstallation It is recommended that the control cable casing be securely anchored with cable clamps approximately every 30 to the frame and or cab to prevent movement during shifting Cable mounting clamps can be pur chased from your nearest Muncie Independent Master Warehouse part no MT306 4 1 Install the indicator light and warning labels by referring to steps 19 amp 20 on page 1 9 of this instruction booklet The indicator light is to be ON when the PTO is engaged and OFF when the PTO is disengaged Do not install other electrical devices to the Muncie indicator light Switch Install cable so that you pull to engage and fully pushed in to disengage The PTO indicator light must be installed so that it is visible to the oper ator of the vehicle while seated in the drive
36. ed ON under heavy load and or at engine speeds over 1200 RPM If your operators are careless or neg ligent in this respect you can safeguard your equipment with one or more Muncie protective systems Consult your Muncie product literature or call your nearest Muncie Power Center for information on the SPD 1000A System Protection Device which prevents engagement of your CLUTCH SHIFT PTO above safe speeds The red overspeed light on the PTO control switch panel is for use with the SPD 1000A and will indicate an overspeed condition when wired according to instruc tions in the SPD 1000A Installation Manual Upon installation CLUTCH SHIFT output shaft may rotate while in the off position If this occurs recheck plumbing for restrictions in the lines If the plumbing is okay adjustment of drag brake will be required The Clutch Shift requires a minimal load on the output shaft See your PTO installer or refer to page 2 20 for adjustment instructions The CB Series does not require adjustment PTO MAINTENANCE The Power Take Off being an integral part of the transmission should be serviced at the same intervals as the transmission Transmission fluid changes should follow the interval recommended by the vehicle manufacturer for severe service Transmission oil level is important Checking for PTO leaks and checking the transmission oil level should be done on a regular basis Check for leaks upon delivery of the vehicle and after initial o
37. ed so that when you pull on the control knob that the PTO engages The RG Series should have a detent position for neutral instead of pushing all the way in for neutral 24 8 To adjust the lever mark the position of the lever where it s engaged when the cable would pull the lever Remove the shift cover from the PTO Remove the locking capscrew from the control lever Lift the lever from the serrated post Line up the lever with your mark Line up the serrated hole and post making sure that the poppet and the shift plate are in their respective positions Replace the locking capscrew and torque to 18 ft lb Reinstall shift cover assembly Double check the installation by referring back to step 7 on the previous page 2 4 DISENGAGE mmm DISENGAGED With lever in disengage position tighten Sq head T set screw ENGAGED Lever should Cut off excess wire not hit easing Move lever to its fully disengaged position and the cable knob to its fully disengaged position 25 10 1 28 9 Referring to Figs 2 1 2 2 2 3 on page 2 2 install the appropriate brackets clamps and hardware STANDARD PTO CABLE If the cable is too long remove the inner wire and cut casing only to length with a hacksaw or large side cutters If longer cables are required they are available from your nearest Muncie Independent Master Warehouse DELUXE PT 65 PTO CABLE Abrasive power cutting equipment is recommen
38. etent ball and spring to locate the engage and dis engage positions but it is not designed to lock into these positions A neutral detent to prevent unintentional or accidental engagement must be installed on the external shift linkage This detent must be included by the installer of the linkage Ke Bolt Tighten after shifting 1 2 1 0 adjustments have been made ae Nut 24 CABLE SHIFT INSTRUCTIONS TG SERIES PTO Ne Figure 2 1 Figure 2 2 RG SERIES PTO Figure 2 3 WARNING All cable shift controlled PTOs are designed to be shifted only by wire cable The unauthorized attachment of lever control linkage to a cable control mechanism may cause 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 flail 22 CABLE SHIFT INSTALLATION INSTRUCTIONS Be sure vehicle in not running when installing or adjusting cable control After removing the cable from shipping liner being very careful to hold cable so that it cannot uncoil and cause injury straighten cable at crimp that has resulted from being coiled Make sure cable has free travel before installing Remove Cable from shipping liner so that it cannot uncoil and cause injury The coiling of the cable causes a kink at the crimp Straighten this before install ing cab
39. he recommended wiring shown JATCO AUTOMATIC TRANSMISSION PTO Lubrication Port B 1 8 28 BSPT Requires Fitting 43737429 Eyl PTO Main Pressure Port P 1 8 28 BSPT Requires Fitting 43137429 50 70 PSI at Idle 1 8 28 BSPT Requires Fitting 43737429 50 70 PSI at Idle 2 7813 AISIN AUTOMATIC TRANSMISSION MODELS 450 43LE A443 A445 5 SPEED PTO Lube Tap Port B Main Pressure Port P 1 2 20 UN SE SAE 2 56 PSI 1 2 20 UNF 2B SAE 5 Use 43137557 amp 43735867 _ 81 120 PSI Use 43137557 VIEWED FROM LEFT SIDE AISIN AUTOMATIC TRANSMISSION 6 SPEED For Dodge Sterling Bullet 2007 and later using separate instructions INO7 03 Pressure Lube Port 4 22 PSI 5 de aa Main Pressure 116 080 SS Ports 20 UNF 2B SAE 5 Use 43737557 to convert to 1 8 NPT Locate the two pressure ports on the Left side of the Aisin 6 speed automatic transmission Connect Main Pressure to port 1 on CS6 solenoid valve as shown in the Electric Hydraulic Clutch shift instructions Connect the pressure lubrication hose the Pressure Lube Port P as shown in the Electric Hydraulic Clutch shift instructions 244 AUTOMATIC TRANSMISSION DIAGRAMS APPLICATION INFORMATION ALLISON TRANSMISSION RIGHT PROFILE TAP PORT 8 TM RING 2630 9 51 MODEL AT 540 4 S
40. ise may be more noticeable after PTO is installed Stop engine For manual shift transmissions drain transmission fluid For Allison auto matic transmissions do not drain trans mission fluid but be prepared for a small amount of oil to escape from opening Remove cover plate Place a shop towel in the opening to prevent dirt from get ting in the transmission Examine cover plate If there is a mag net attached to the inside reinstall this cover on the other opening Clean mounting pad Inspect bolt holes in aperture for thread sealant used on OEM bolts Clean these internal 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 blemish may cause excessive noise when PTO is mounted Rock transmission gears by hand to get feel for gear backlash manufactured into transmission gear set Open the PTO carton and find the mounting kit studs and cap screws enclosed with your PTO Visual inspection of the PTO will indicate which mounting holes in the PTO will not accept cap screws Install the enclosed studs in the transmission housing holes that correspond to those PTO holes which will not accept cap screws Additional instructions may be found on
41. le Make sure cable has free travel 22 Find suitable location for the control cable the indicator light cable control should be installed so 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 Drill a 1 2 hole in dash or contro bracket not provided Install the control head through the hole and attach with the lock washer and nuts provided 4 Knob can be screwed into place using the jam nut to secure Dash or bracket N Knob Lockwasher Figure 2 4 23 5 Route the length of cable through the floorboard or firewall and to the PTO The cable needs to be routed clear of manifold exhaust systems 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 Floorboard Critical area Do not place cable in a bind in this area Build up cable bead to make a smoother bend when going thru Bracket a floorboard Start bend radius after this point y Minimum bend radius is 6 6 The lever on the PTO shifter assembly is designed so that it can be moved to allow the cable approach to be from the front or the back of the PTO This should be determined by the routing method causing the least amount of bends and the shortest cable length T The lever also must be position
42. nd be sure the PTO shaft is parallel within 1 5 to the pump shaft or driven unit Drivelines must be in phase that is the yoke ears on the PTO and pump shafts must be in alignment as illustrated below PTO with Direct Couple Hydraulic Pump Installation Max Max Speed TJA RPM A 3500 5 3000 5 2500 Yd 2000 8 1500 11 1000 12 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 TJA TJA 2 B FOR CABLE OR LEVER SHIFT INSTALLATIONS ONLY Before bolting the pump to the PTO place non seizing compound or grease on the PTO shaft and pump shaft Do not force spline couplings together All Muncie direct mount PTOs are supplied with the appropriate grease Reusing an existing pump will require inspection of the i pump splines Clean any old grease from pump prior to installation When mounting hydraulic pumps weigh ing over 40 Ibs exceeding 12 in length or for tandem multiple section pumps a rigid support bracket must be installed It should be attached to the rear of the pump and to the transmission to support the pump and to inhibit movement in all directions Weight includes fittings oil and unsupported hose sec tions This requirement does not take into account the system duty cycles vehicle vibrations application
43. ng Guide SECTION 1 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 adhering the labels make sure the surfaces are free of dirt and grease Place the labels supplied as follows There are two 2 labels which measure approximately 4 x 8 which are to be placed on the outside of the vehicle frame rail making them easy to be seen by anyone who might go under the truck or near the PTO One label is to be placed on each side of the vehicle Should the body installed on the chassis cover the frame rail place the label on the body in a position easily visible by anyone who might go under the vehicle or near the PTO Do not paint over labels ADANGER APELIGRO NEVER GET iNUNCA SE UNDER THIS META DEBAJO TRUCKIF ez DEL CAMI N THE ENGINE CUANDA EL IS RUNNING You may be MOTOR ESTE hurt or killed EN MARCHA Figure 1 1 There are two 2 4 X 8 labels supplied and one is to be placed on each side of the vehicle 2 The 2 x 3 PTO Equipped Caution Label is to be placed within the cab of the vehicle and in easy view of the vehicle operator It should be located near the PTO control when the control is installed in the vehicle dash See Figure 1 2 This label directs the operator to read the PTO operat ing instructions on the
44. nto any of the drive positions This will stop transmission gear from turning B Shift power take off into or out of gear C If the 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 will start transmission gears turning If you hear a grinding or ratcheting sound turn PTO off and repeat these procedures from step A S Automatic Transmission Transfer Case Mounted PTO Also SS66 Splitshaft PTO A Shift transmission into park B Caution Apply parking brake and block wheels Note Applying parking brake does not insure that vehicle will not move when trans fer case is in neutral C Engage PTO 33 D Shift transfer case into neutral E Shift transmission into drive to activate PTO output shaft Caution Do not place the transmission selector in park or reverse while PTO is operational as damage to PTO or driven unit may occur To Disengage PTO Shut off engine with transmission in drive mode Disengage PTO Shift transmission selector to park Restart engine Remove wheel blocks and release parking brake Shift transfer case into engaged mode Vehicle can now be driven Failure to follow proper shifting or operating sequences will result in premature PTO failure with possible damage to the equipment CLUTCH SHIFT OPERATING NOTES CLUTCH SHIFT PTOs should not be engaged turn
45. one to be activated by the GM Rocker Switch It will only assist in the engine throttle advance of the application Install PTO controls separate of the installation Follow PTO shifting instructions listed in this PTO owner s manual for engagement of manual shift type PTOs Engage PTO first For stationary operation throttle advance with vehicle stopped and transmission gear selection in Park parking brake set foot off accelerator and turn on PTO Dash Switch For Preset type throttle control push Cruise Control set button to increase throttle to the preset speed programmed into the controller This is 1200rpm by default E HYDRA SHIFT 248 Advance only works when Cruise Control is More information is available in the General Motors Body Builders manuals avail able from GM or on their website at www gmupfitter com MERCEDES AGS AUTOMATED TRANSMISSION WARNING PTOS MOUNTED TO THE MERCEDES AGS TYPE TRANSMIS SION WILL NOT FUNCTION UNLESS VEHICLE IS PROPERLY SPECIFIED THE MERCEDES AGS SERIES TRANSMISSION REQUIRES THE PTO TO BE INSTALLED THROUGH THE PROVIDED PTO ACTIVATION AIR SOLE NOID CONTROL THE PTO MUST BE AIR SHIFT OPTION WHETHER IT IS A MECHANICAL TYPE TG SH RS4S SERIES OR CLUTCH SHIFT CS6 SERIES TYPE THE VEHICLE NEEDS TO BE SPECIFIED FOR PTO USE FROM TIME OF ORDER CONTACT DEALER FOR PTO CONNECTION LOCATIONS 249 CLUTCH SHIFT amp SH STANDARD For Use When Air Shifting CLUTCH
46. parate 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 as shown on diagrams found on pages 2 11 thru 2 17 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 Start engine and engage PTO with switch If PTO fails to operate or will not develop enough torque to operate your equipment check pressures as follows a Stop engine b Install 400 PSI pressure gauge at PTO piston port Fig 150 PSI gauge for air systems c Install a second 400 PSI pressure gauge in front of screen adapter at solenoid valve Fig B 150 PSI gauge for air systems d Start engine Stay clear of rotating components Place PTO switch in engage position e 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 f On the hydraulic system if gauge Fig B registers 50 PSI or less you may be connected to the wrong port on the transmission Recheck the transmission information for the main pressure tap location on your model 4 Complete installation by placing warning labels as indicated on bor ders of the decals Pl
47. peration of your equip ment Loss of any oil can significantly affect or damage a transmission or PTO Muncie Power Products Inc is not responsible for damage resulting from improper fastener installation mounting torque or maintenance of the PTO PAS rom The Power Take Off is also part of a system The PTO system may include the activa tion control parts a driveshaft or hydraulic pump This PTO system requires periodic checks and service Typically the interval for maintenance checks of the PTO system depends on the application of the system Every time the chassis is lubricated or a mechanic is under the vehicle the PTO system should be checked and serviced For severe duty PTO system applications it is recommended that the system be checked for service every 100 hours of use this guideline can be adjusted based on past 34 service history once you have it established Service should include checking and lubricating direct mount pump shaft connections PTO gears can be checked for wear by removing the inspection or shifter cover If pitting galling 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 loose mounting hardware studs cap screws nuts Recheck the cable or lever connections for proper adjustment and tighten any loose connections At regular maintenance intervals check adjustmen
48. r vehicle D Where electrical grounds are indicated be sure that they are good grounds with straight paths to the vehicle battery ground Many vehicle Cabs are insulated from the vehicle frame and a weak ground is a very com mon cause for malfunctions Check with the vehicle manufacturers for the proper ground location or connect directly to battery E When installing hydraulic components be certain to follow common installation and testing procedures If you are not familiar with acceptable installation proce dures request instructions and guidance from the hydraulic equipment supplier F Note that when installing the PTO air systems the installation of a pressure protection valve is required at the air tank This valve is not a pressure regula tor it is a pressure check valve which does not allow air to the PTO system until the system air pressure exceeds approximately 65 PSI Cold weather start conditions require that the transmission be started and warmed prior to engaging and using equipment Hydraulic pumps should be run at idle and under no load conditions to allow oil to warm before activating hydraulic system LEVER SHIFT CONTROL Install indicator light as described on page 1 8 step 19 Muncie PTOs with lever shift options available on RG RL 82 83 Series only require the customer to provide the linkage and hook up to the PTO The PTO is provided with an eye bolt for this purpose The PTO is designed with d
49. r s seat Additional indicator lights may need to be purchased to comply with this requirement INDICATOR LIGHT SWITCH CONTINUITY CHECK Figure 2 5 Figure 2 6 Performing a continuity check on the indicator switch will verify that the indicator switch is functioning and that the PTO is properly assembled 1 Using a multimeter connect one lead to the spade terminal on the indica tor switch mounted to the PTO 2 3 Figure 2 5 Connect the other lead to a bare metal portion of the PTO or shifter 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 Figure 2 5 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 2 Align the internal gear tooth so that tip is centered the pick up opening Install the jam nut with the seal in the nut facing the PTO and back it down the pick up close to the wire end Place washer then the o ring on the pick up so that the o ring will be against the PTO cover Screw in the pick up until the tip gently touches the top of the gear tooth 4
50. ssion are designed to be mounted without gasket shims and require the use of a gasket eliminator which is sup plied with the PTO Do not use a permanent sealant on gasket shims because you may need to change them later Use 9 approved transmission oil only E Position the PTO on the studs and start the nuts provided onto the studs Do Not Tighten Yet Check for gaps between the PTO and transmission and make sure gear teeth are properly meshed and then tighten the top and bottom nuts or cap screws On some transmission models the TG Series PTO may encounter interference with the idler shaft cap Special clearance caps may be used and are listed in the application catalog where known interference exists Check the backlash on the input gear gear that meshes with transmission gear by feeling through the inspection hole or shift cover opening previously uncovered in step 9 The amount of rotational movement of the PTO gear should be only 006 to 012 As a reference the thin gasket shim in your installation kit is 010 thick The thin gasket shim 010 thick will change the backlash approx 006 The amount of movement of the input gear would only be about the same distance as this gasket shim thickness At least one gasket shim must be used Do not stack more than 4 gasket shims together On Allison transmissions Series AT 500 MT 600 HT 700 1000 2000 2400 only the single 030 gasket shim 13M13541 should be required
51. tandard 1 or 4 Assembly 16TK5025 Standard 2 or 4 Assembly oy 16TK5026 Allison 1000 2000 1 or 4 Assembly 16TK5027 Allison 1000 2000 2 or 3 Assembly 29 TG SERIES STANDARD AIR SHIFT SYSTEM 48M61250 A 12V Light 48M62450 A 24V Light Connect Dir To Air Tank Truck Air Bonet ae tn 0 1 8 Elbow WE RPT Nipple Press Protection Valve 6 ID Tubing ACC tap note A pg 2 1 Indicator Switch Ej Bact Connector Fuse Assembly 18 NPT Elbow PTO Switch Bracket Indicator L Air Vah And Faceplate Ugh ane TG SERIES ELECTRIC AIR SHIFT SYSTEM 48M61200 A 12V Solenoid amp Switch 48M62400 A 24V Solenoid amp Switch ENPI Nipple Connect Directly To 1 4 NPT Adapter Air Tank Do Not Use Solenoid Hose Or Tubing vehi Tubing VUE NPT Elbow 18 gauge wire Fuse Assembiy Bootes Connector Do Not Use The Shift With Any Overspeed vs Prolecton Device N Spade Connector seen ey 240 82 SERIES DOUBLE ACTING AIR SHIFT SYSTEM D OPTION Connect Directly To Air Tank Truck Air Do Not Use Hose Or Tubing Supply Tank 4 4 NPT Adapter 1 4 Nipple Pressure Protection VE Elbow VB NPT Elbow __ Positive Indicator Switch H Shipped With PTO Booted Connector Air Valve ACC tap 1 4
52. ts and lubricate moving parts tighten and repair the connections mounting hardware cable or lever linkages It is recommended that the operator owner do a visual inspection for leaks under and around the vehicle and equipment on at least a weekly basis Any leaks found should be corrected immediately Pumps that are mounted directly to the PTO output require the application of an anti seize or a high temperature high pressure grease Muncie PTOs are initially supplied with the required grease The purpose of this grease is to help make the PTO easier to service and to reduce the effects of fretting corrosion on the mat ing PTO and pump shafts PTO applications under severe duty cycles and or high torque requirements may require servicing this shaft connection by periodically re greasing the shafts Vehicles with low speed diesel engines are also severe applications due to the vibrations inherent in these vehicles Fretting corrosion cannot be stopped by applying grease the grease is only a deterrent INDICATOR LIGHT CHECK Procedure for checking the PTO Indicator Switch is found on Page 2 7 PTO LIGHT 10 FUSE LH 4 JUMPER WIRE STOP ENGINE TRUCK IS NOT TO BE RUNNING amp WHEN PREFORMING THIS TEST Temporarily ground the connector to check bulb STOP ENGINE Temporarily ground the TRUCK IS NOT TO BE RUNNING terminal to check bulb WHEN PREFORMING THIS TEST ROCKER SWITCH IS TO BE TURNED OF

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