DT12 PTO Installation Requirements I. REAR PTO Beginning in late 2016, the DT12 will be available with a rear-facing Power Take-Off (PTO). This PTO is a mechanical drive that attaches to the rear of the transmission and is used to transfer power produced by the engine to an auxiliary component. NOTE: This rear facing PTO is approved for stationary & launch gear use only. The interface is normally closed by a cover plate when not offered.
Figure 2: Rear DT12 PTO drive assembly (option 362-2HB) with cover plate. With the access cover removed, the PTO drive assembly mounting flange offers SAE-B mounting for 2 or 4 bolt configurations and an SAE B-B 15 tooth spline as shown below: Figure 3: PTO drive assembly shown with SAE-B 2 or 4 bolt configuration. The thread type for the 2 or 4 bolt pattern is M14 x 2.0 with a depth of 20mm. It is recommended to use a bolt length that allows for thread engagement of 1-1.
With this configuration: - A transmission cooler will be added to DT12 configuration in SpecPro - Some exhaust configurations are not compatible with DT12 PTO. Please consult with your local vehicle representative to obtain specifics. - Harnesses and controls are included for PTO operation - The pneumatic line is installed - The PTO is ready for operation via dashboard mounted switch - Consult Section 8.28 of the GHG14/17 DDEC13 A&I Manual (DDC-SVC-MAN-0127) for CPC parameterization 2.
Figure 5: Installation of configuration #2 as seen from the rear of the vehicle With this configuration: - A transmission cooler will be added to DT12 configuration in SpecPro - Some exhaust configurations are not compatible with DT12 PTO. Please consult with your local vehicle representative to obtain specifics. - Harnesses and controls are included for PTO operation - The pneumatic line is installed - The PTO is ready for operation via dashboard mounted switch - Consult Section 8.
With this configuration the PTO drive shaft angle must be in the range of 1° to 6°. Bolts and nuts for attaching the driveshaft to this adapter flange are not included in either of the Spicer kits. Use standard torque values to attach bolts to adapter flange based on hardware material and grade. 3. DT12 Hydrocar P89 Rear Mounted PTO with Prep for Hydraulic Pump (1:1 PTO Ratio). This configuration is the same as configuration #1 above, except that the PTO Drive ratio here is 1:1.
With this configuration the PTO drive shaft angle must be in the range of 1° to 6°. Bolts and nuts for attaching the driveshaft to this adapter flange are not included in either of the Spicer kits. Use standard torque values to attach bolts to adapter flange based on hardware material and grade. See Figure 6 above for the installation of the 1350/1410 and 1310 series flange adapter kits to the DT12 Rear PTO. 5. PTO Prep Kit for DT12 Hydrocar P89 Rear Mounted PTO Prep for Driveshaft.
With this configuration: - A transmission cooler will be added to DT12 configuration in SpecPro - Some exhaust configurations are not compatible with DT12 Rear PTO. Please consult with your local vehicle representative to obtain specifics. - Harnesses and controls are included for the Rear PTO which is installed at a later time - The pneumatic airline is NOT installed and would need to be added at the time of PTO install. - Consult Section 8.
Figure 8: Spicer 1310 adapter flange, p/n A9472600417, for Rear PTO. REAR PTO TECHNICAL INFORMATION / INSTALLATION REQUIREMENTS • Engine speed: Vehicle speed during Rear PTO Operation: 1) 0 mph (vehicle is stationary) 2) Launch gear only operation Rear PTO output speed: 850 - 2080 rpm o 1 : 1.
PTO drive shaft angle 1° to 6° Interface (mount) Interface (shaft) Interface (flange drive) 2 or 4 bolt SAE B pad mount SAE BB 15 tooth spline drive Spicer 1350/1410 and Spicer 1310 flange drives Rear PTO rotation Counterclockwise (CCW) looking from rear of DT12 (Requires CW input pump) Figure 9: Rear PTO rotation direction Transmission Oil temperature range: average max.
NOTES: 1) The maximum bending moment of the Rear PTO to the transmission mounting surface must be calculated including the length of unsupported hydraulic hoses, and the weight of the fittings and hydraulic fluid. Support brackets are NOT allowed! 2) The maximum bending moment allowed between the Rear PTO and the DT12 transmission Is 29.5 lb-ft (40 N-m). Unless specific information is available on the pump mounting hardware, please use the following formulas and weights provided below.
PTO OUTPUT SPEED CALCULATION Since the DT12 Rear PTO is driven by the countershaft inside the transmission, there are two effective gear ratios possible, low neutral or high neutral. The low neutral and high neutral are referred to as “split low” and “split high” respectively. There is a data code module in SpecPro that allows for operation to be set to either “split low” or “split high”. This functionality allows the operator to engage the PTO at the desired gear ratio for proper operation.
For example, the Rear PTO speed with a DT12-DA (DH) Split Low with the 1:1 PTO Ratio would be: (Engine RPM) x (Engine:PTO Ratio) = 850 rpm x 0.78 = 663 rpm Similarly, the Rear PTO speed with a DT12-OC (OHE & OV) Split High with the 1:1.32 PTO Ratio would be (Engine RPM) x (Engine:PTO Ratio) = 850 rpm x 1.
II. BOTTOM PTO’s Auxiliary equipment require power take-offs, either when the truck is stationary or when it is in motion. Various power take-off alternatives can be chosen, depending on the bodywork. The work is generally carried out by equipment which is powered by a hydraulic motor. The hydraulic motor, together with a pump and associated equipment, form the basis of the hydraulic system. The pump, which provides the hydraulic pressure and flow to the motor, is the heart of the hydraulic system.
BOTTOM PTO OPERATION 1) Running Bottom PTO during normal vehicle operation. Operation of the Bottom PTO during normal vehicle operation (while driving the vehicle with the transmission shifting gears normally) is NOT ALLOWED at this time. NOTE: This Bottom PTO is approved for launch gear and stationary use only. 2) Moving of the vehicle with Bottom PTO engaged (Launch Gear Use). NOTE: Launch gear PTO operation requires Citrine CEAA+ level software or newer.
CHELSEA BOTTOM PTO’S See the table below for the maximum allowed torque for permanent and intermittent operation.
Figure 11: Model Chart for the Chelsea 823 PTO and the DT12-DC (DHE & DV). Figure 12: Model Chart for the Chelsea 823 PTO and the DT12-OC (OHE & OV). Figure 13: Model Chart for the Chelsea 823 PTO and the DT12-OD (OVX).
Below are the model charts for the Chelsea 880 PTO for the various DT12 variants. Figure 14: Model Chart for the Chelsea 880 PTO and the DT12-DC (DHE & DV). Figure 15: Model Chart for the Chelsea 880 PTO and the DT12-OC (OHE & OV). Figure 16: Model Chart for the Chelsea 880 PTO and the DT12-OD (OVX).
Below are the model charts for the Chelsea 680 PTO for the various DT12 variants. Figure 17: Model Chart for the Chelsea 680 PTO and the DT12-DC (DHE & DV) Figure 18: Model Chart for the Chelsea 680 PTO and the DT12-OC (OHE & OV). Figure 19: Model Chart for the Chelsea 680 PTO and the DT12-OD (OVX).
Below are the model charts for the Chelsea 489 PTO for the various DT12 variants. Figure 20: Model Chart for the Chelsea 489 PTO and the DT12-DC (DHE & DV). Figure 21: Model Chart for the Chelsea 489 PTO and the DT12-OC (OHE & OV). Figure 22: Model Chart for the Chelsea 489 PTO and the DT12-OD (OVX).
CHELSEA BOTTOM PTO ASSEMBLY & INSTALLATION 1. PTO Adapter Selection The Chelsea Bottom PTO needs a separate adapter to mate the Bottom PTO to the transmission input shaft. This adapter is different for each of the transmission variants; there is also one for low power and another for high power Bottom PTO’s. Below is a summary of the Bottom PTO adapters.
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4. Adapter to PTO Installation & Backlash Adjustment Use the below procedure to properly mate the PTO Adapter to the PTO and adjust the backlash. On a workbench, insert qty=1 thick gasket onto either the PTO Adapter or PTO Housing. Mate the PTO Adapter to the PTO Housing with qty=8 M12 (0.438”) hex head bolts and nuts. Torque the bolts to 54-61 Nm (40-45 lb-ft). With a dial indicator, measure the backlash between the PTO gear and the adapter gear. Acceptable backlash measurement is 0.15-0.30 mm (.
5. Gasket & PTO Adapter Installation Use the below procedure to properly install the DT12 Bottom PTO Adapter Gasket between the transmission and the Bottom PTO adapter. Beginning with 1 thin gasket, install the adapter gasket over the studs and dowel pins. Ensure the offset is towards the rear of the transmission. Figure 29: Bottom PTO adapter/transmission gasket installation Position PTO Adapter so that the ribs are towards the front of the transmission.
Install PTO Adapter over studs and dowel pins. Rotate the adapter gear to mesh with the transmission K1 gear. Install locking nuts with washers, and torque to 40-45 Nm (30-33 lb-ft) to secure the adapter in place. With dial indicator, measure the backlash between the adapter gear and the transmission K1 gear. Acceptable backlash measurement is 0.15 - 0.30mm (0.006” – 0.012”). If backlash is < 0.15mm (0.006”), repeat assembly with a thick gasket.
MUNCIE BOTTOM PTO’S See the table below for the maximum allowed torque for permanent and intermittent operation. Table 5: Info table on released Muncie Bottom PTO variants The Muncie PTO model number provides a lot of information about the PTO and how it is configured in the application.
Below are the model number charts for the Muncie Bottom PTO’s for the DT12 variants.
MUNCIE BOTTOM PTO ASSEMBLY & INSTALLATION 1. PTO Adapter Selection The Muncie Bottom PTO needs a separate adapter to mate the PTO to the transmission input shaft. This adapter is different for the different transmission variants. Below is a summary of the Muncie Bottom PTO adapters. Table 6: Muncie Bottom PTO adapter variants The DT12 Bottom PTO hardware and Installation Kits are available through your Muncie Power parts provider. 2.
Apply a thin coating of approved transmission oil on both sides of the gasket to be installed between the transmission and the PTO adapter – this will help hold it in place during the installation process. Install the adapter on the transmission using the thicker gasket (0.020”) included with the installation kit, and torque the qty=8 M12x30 cap screws to 50 lb-ft (68 N-m).
NOTE: It is critical that the edge-molded gasket is used against the PTO Adapter – failure to do so may result in oil leakage! Figure 35: Installation of the Muncie PTO to the PTO Adapter and transmission NOTE: See Muncie PTO Operators Manual, IN84-03, for further PTO Installation details, activation kit instructions, as well as warranty and maintenance information. PTO POWER SPLIT The term PTO Power Split refers to the simultaneous operation of the Rear and Bottom PTO’s.
BOTTOM MOUNTED PTO SUPPORT REQUIREMENTS A Bottom PTO support bracket must be used if either of the two conditions below are met: 1. The combined weight of the pump, fittings and hoses exceeds 40 lbs (18.1 kg) 2. The combined length of the PTO and pump is 18 inches or more from the PTO centerline to the end of the pump.
Figure 38: Example DT12 Bottom PTO support bracket Figure 39: Bottom PTO support bracket mounting boss locations The required size and thread pitch for the Bottom PTO support bracket bolts is M10 x 25. The thread depth in the hole in the block is 25mm, the drilled depth is 30mm. Below are the dimensions on the DT12 mid-housing if a support bracket is required.
Figure 40: Mid-housing dimensions (in mm) for Bottom PTO Support Bracket Below are the dimensions on the DT12 rear housing if a support bracket is required.
Here are some examples of actual Bottom PTO support brackets: Figure 42: Actual Bottom PTO support bracket, pic 1 Figure 43: Actual Bottom PTO support bracket, pic 2 The mating piece to the 90 degree connection off of the Bottom PTO pump shown in the above pictures must also be supported.
RESONANCE FREQUENCIES & PTO OPERATION SPEEDS Beside the torsional excitation of the system by engine combustion or driveshafts the resonance frequency of the system is also a major concern. To avoid critical operation conditions and/or damages of powertrain components the pto operation rpm has to stay away from natural frequencies. The recommended PTO Torque by engine speed is shown in the graph below.
PTO DRIVESHAFT INSTALLATION Maximum torque can only be applied if the operation is completely oscillation and shock free. To keep the excitation as low as possible, the following requirements must be met.
In either of the above driveshaft angle configurations, if a driveshaft bend angle > 6° is not avoidable, follow the instructions below for large Joint Bend Angles. JOINT BEND ANGLES In addition to the driveshaft installation pattern, the joint bend angle significantly effects the driveshaft acceleration and additional dynamic torque load. The minimum bend angle requirement is shown below.
SHOCK LOAD (DYNAMIC TORQUE) Maximum torque can only be applied if the operation is completely oscillation and shock free. The dynamic toque or shock load varies by application, but the system has to be dimensioned and set-up to handle the highest combination of static plus dynamic torque. The following overview is only an example, please verify the specifics of your application meet the appropriate dynamic factor. The Operation Torque plus the shock overload MUST be less than the PTO torque limit.
Engineering Change Log Technical Content / Publisher Owner Rev. # Rev. Date Description of Revisions C. Grissom R01 12OCT16 C.Grissom R02 27OCT16 C.Grissom R03 07DEC16 C.Grissom R04 19DEC16 C.Grissom R05 23JAN17 C.Grissom R06 08APR17 C.Grissom C.Grissom C.Grissom R07 R08 R09 03MAY17 19MAY17 25OCT17 C.Grissom R10 16APR18 C.Grissom / J.Adelsperger R11 10JUL20 R12 31MAR21 R13 30SEP21 Initial release. Added notes to PTO configurations 1 & 2.
