Twin Disc HP 300, 600 Service Manual - Morbark

TWIN DISC
INCORPORATED
INCORPORATED
Ser vice
Manual
Hy dr
Hydr aulic
draulic
Power Tak e-of
e-offf
ake-of
Model:
HP300 Series
HP600 Series
Document Number: 1021542

NOTICE
Twin Disc, Incorporated makes no warranty or guaranty of any kind,
expressed, implied or otherwise, with regard to the information contained
within this manual. Twin Disc, Incorporated has developed this manual
through research and testing of the information contained therein. Twin
Disc, Incorporated assumes no responsibility for any errors that may
appear in this manual and shall not be liable under any circumstances
for incidental, consequential or punitive damages in connection with, or
arising out of, the use of this manual. The information contained within
this manual is subject to change without notice.
Document Number
1021542
Issued
August, 2004
Hydraulic Power Take-off

Service Manual
Hydraulic Power Take-off Service Manual 3

REVISION AND REISSUE DATA
Original Issue August, 2004
BEFORE YOU START
This manual replaces:

Preliminary Manual #1021542 dated January, 2004 for use with
Hydraulic Power Take-Off model HP300 & HP600.
4 Hydraulic Power Take-off Service Manual

TWIN DISC
DISC,, INCORPORATED
INCORPORATED
EXCL
EXCLUSIVE LIMITED WARRANTY
CLUSIVE
GENERAL UNITS
A. Twin Disc, Incorporated warrants all assembled products and parts, (except component products or parts
on which written warranties issued by the respective manufacturers thereof are furnished to the original
customer, as to which Twin Disc, Incorporated makes no warranty and assumes no liability) against defective
materials or workmanship for a period of twenty-four (24) months from the date of original shipment by Twin
Disc, Incorporated to the original customer, but not to exceed twelve (12) months of service, whichever
occurs first. This is the only warranty made by Twin Disc, Incorporated and is in lieu of any and all other
warranties, express or implied, including the warranties of merchantability or fitness for a particular purpose
and no other warranties are implied or intended to be given by Twin Disc, Incorporated.
The original customer does not rely upon any tests or inspections by Twin Disc, Incorporated or on Twin
Disc, Incorporated*s application engineering.
B. The exclusive remedy provided by Twin Disc, Incorporated whether arising out of warranty within the applicable
warranty period as specified, or otherwise (including tort liability), shall at the sole option of Twin Disc,
Incorporated be either the repair or replacement of any Twin Disc, Incorporated part or product found by
Twin Disc, Incorporated to be defective and the labor to perform that work and to remove and reinstall (or
equivalent credit). In this context, labor is defined as the flat rate labor hours established by Twin Disc,
Incorporated in the published Twin Disc Flat Rate Schedule, required to remove, disassemble, inspect,
repair, reassemble, reinstall and test the Twin Disc, Incorporated product only. Under no circumstances,
including a failure of the exclusive remedy, shall Twin Disc, Incorporated be liable for economic loss,
consequential, incidental or punitive damages. The above warranty and remedy are subject to the following
terms and conditions:
1. Complete parts or products upon request must be returned transportation prepaid and also the claims
submitted to Twin Disc, Incorporated within sixty (60) days after completion of the in-warranty repair.
2. The warranty is void if, in the opinion of Twin Disc, Incorporated, the failure of the part or product resulted
from abuse, neglect, improper maintenance or accident.
3. The warranty is void if any modifications are made to any product or part without the prior written consent of
Twin Disc, Incorporated.
4. The warranty is void unless the product or part is properly transported, stored and cared for from the date of
shipment to the date placed in service.
5. The warranty is void unless the product or part is properly installed and maintained within the rated capacity
of the product or part with installations properly engineered and in accordance with the practices, methods
and instructions approved or provided by Twin Disc, Incorporated.
6. The warranty is void unless all required replacement parts or products are of Twin Disc origin or equal, and
otherwise identical with components of the original equipment. Replacement parts or products not of Twin
Disc origin are not warranted by Twin Disc, Incorporated.
C. As consideration for this warranty, the original customer and subsequent purchaser agree to indemnify and
hold Twin Disc, Incorporated harmless from and against all and any loss, liability, damages or expenses for
injury to persons or properly, including without limitation, the original customer*s and subsequent purchaser*s
employees and property, due to their acts or omissions or the acts or omissions of their agents, and employees
in the installation, transportation, maintenance, use and operation of said equipment.
D. Only a Twin Disc, Incorporated authorized factory representative shall have authority to assume any cost or
expense in the service, repair or replacement of any part or product within the warranty period, except when
such cost or expense is authorized in advance in writing by Twin Disc, Incorporated.
E. Twin Disc, Incorporated reserves the right to improve the product through changes in design or materials
without being obligated to incorporate such changes in products of prior manufacture. The original customer
and subsequent purchasers will not use any such changes as evidence of insufficiency or inadequacy of
prior designs or materials.
F. If failure occurs within the warranty period, and constitutes a breach of warranty, repair or replacement parts
will be furnished on a no-charge basis and these parts will be covered by the remainder of the unexpired
warranty which remains in effect on the complete unit.
January 16, 2002 TDWP0002

Twin Disc, Incorporated Table of Contents
Table of Contents
Introduction ......................................................... 11
General Information .......................................................................... 11
Replacement Parts ............................................................................ 12
Preventive Maintenance/Troubleshooting .................................... 13
Safety .................................................................................................. 14
Sources of Service Information ...................................................... 15
Warranty .............................................................................................. 15
Description and Specifications .........................17

General Information .......................................................................... 17
Identifying the HPTO model, serial and BOM numbers ............... 18
Construction Features ...................................................................... 19
Specifications .................................................................................... 21
Maximum safe operating speed ................................................. 21
Approximate dry weight ............................................................... 21
Oil Cooling requirements ............................................................. 21
Oil type and oil viscosity .............................................................. 21
Oil sump-basic information ......................................................... 22
Oil scavenge pump, oil pump information ................................ 22
Oil pressure specifications ......................................................... 22
Fittings, Hose types ...................................................................... 24
Electronic Module ......................................................................... 24
Output and Input speed sensor air gap..................................... 24
Torque on input and output speed sensor nuts ...................... 24
Remote mounted electronic control cable ................................ 24
Shim tolerance for bearing carrier in idler gear ....................... 24
Twin Disc PTO support plate specifications ................................. 25
Torque values for U.S. fasteners..................................................... 26
Wear limits .......................................................................................... 29
Operation ..............................................................31
General................................................................................................ 31
General Overview of GP Control Valve with Electronic Interface 32
Table of Contents Twin Disc, Incorporated
GP Control Valve hydraulic portion ................................................ 33

Hydraulic System with GP Control Valve ....................................... 36
GP Control Valve Electronic Control Interface (Profile Module) ....... 38
Clutch Engagement Logic (Closed Loop) ...................................... 39
Brake engagement ....................................................................... 39
Power Take-off Clutch engagement ........................................... 39
Installation ............................................................41
Identifying the Twin Disc Power Take-off Model Number............ 41
Identifying the SAE Housing Size .................................................... 42
Prior to Installation ............................................................................ 43
Preliminary Checks ........................................................................... 44
Torsional Input Coupling Installation ............................................. 47
HPTO Installation to Engine ............................................................ 51
Final Checks....................................................................................... 56
Check and Adjust Main Pressure ............................................... 56
Check Clutch Operation Pressures ........................................... 58
Plumbing - HP300I, HP300S, HP300S, HP600S .............................. 59
Maintenance .........................................................61
Allowable Side Loads........................................................................ 61
Lubrication ......................................................................................... 64
Grease Specifications .................................................................. 64
Oil Specifications .......................................................................... 65
Oil System ...................................................................................... 65
Torsional Coupling............................................................................ 66
Overhaul Interval ............................................................................... 67
Periodic Visual Inspection ........................................................... 67
Deflection Alignment Adjustment .................................................... 68
Alignment - U-Joint Installation ........................................................ 70
Disassembly ........................................................73
Power Take-off Removal From The Engine ................................... 73
Remove and disassemble the GP Control Valve .......................... 75
Remove the Coupling Housing and disassemble
the Gear Towers ............................................................................ 76

Twin Disc, Incorporated Table of Contents
Remove and Front Housing from the Clutch Housing ................. 78

Disassemble the Clutch Housing .................................................... 79
Cleaning and Inspection ....................................83

Cleaning and Inspection................................................................... 83
Assembly ..............................................................89
Clutch Shaft and Clutch Housing Assembly .................................. 90
Clutch housing .............................................................................. 90
Clutch shaft .................................................................................... 90
Belt Sheave Housing Assembly .................................................... 100
Clutch Assembly .............................................................................. 105
Clutch piston, piston carrier and back plate unit ................... 109
Clutch hub, clutch plates and gear & ring assembly ............ 117
Assemble the Front Housing Unit/Install the Idler Gear ............. 124
Install the Front Housing on the Clutch Housing ........................ 131
Coupling housing ....................................................................... 132
Assemble the Gear Drive Towers ................................................. 135
General information .................................................................... 135
Tower #1 ....................................................................................... 136
Tower #2 ....................................................................................... 143
Assemble the Control Valve Assembly......................................... 144
Install the Speed Sensor Pickups ................................................. 151
Output speed sensor.................................................................. 151
Input speed sensor..................................................................... 152
Install the Pump ............................................................................... 153
Plumbing ........................................................................................... 154
HPTO Series Parts Identification List ........................................... 156
Cross Section Views:
HP300I & HP600I .......................................................................... 158
HP300S & HP600S ....................................................................... 159
Exploded Views and Illustrations:
HP300S & HP600S Sheave Housing Front Bearing Area ...... 160
HP300S & HP600S Sheave Housing Output Bearing Area.... 161
HP300I & HP600I Rear Bearing Area......................................... 162
HP300I, HP600I, HP300S, HP600S Clutch Area ....................... 163
HP300I, HP600I, HP300S, HP600S Front Bearing Area .......... 164

Table of Contents Twin Disc, Incorporated
HP300I, HP600I, HP300S, HP600S Idler Gear Area ................. 165

HP300I, HP600I, HP300S, HP600S Tower #1 Area ................... 166
HP300I, HP600I, HP300S, HP600S Tower #2 Area ................... 167
HP300I, HP600I, HP300S, HP600S
GP Control Valve Area Illustration ....................................... 168
GP Control Valve Area Exploded View (Valve 1020729) ... 169
GP Control Valve Area Exploded View (Valve 1021658) ... 170
HP300I, HP600I, HP300S, HP600S Pipes and Fittings ............ 171
HP300I, HP600I, HP300S, HP600S Pipes and Fittings ............ 172
Troubleshooting ................................................173
Troubleshooting of GP Control Valve & Electronic Interface ... 173
Troubleshooting Charts ................................................................. 174
Engineering Drawings ......................................177

List of Engineering Drawings ........................................................ 177
Twin Disc Hydraulic Power Take-off Cut-away illustration ....... 178
102668G Sheet 2 of 3: HP300I ........................................................ 179
102668G Sheet 3 of 3: HP300I ........................................................ 180
102668B Sheet 2 of 3: HP300S ...................................................... 181
102668B Sheet 3 of 3: HP300S ...................................................... 182
102668F Sheet 2 of 3: HP600I ........................................................ 183
102668F Sheet 3 of 3: HP600I ........................................................ 184
102668C Sheet 2 of 3: HP600S ...................................................... 185
102668C Sheet 3 of 3: HP600S ...................................................... 186
1020696: Control Valve Assembly ................................................ 187
1020686: HPTO Control Module .................................................... 188
1021292 Sheet 1 of 3: HPTO Plumbing......................................... 189
1021295: Plumbing Schematic ...................................................... 192

Twin Disc, Incorporated Introduction
Introduction
General Information
This publication provides the information necessary for the operation and
maintenance of the Twin Disc, Incorporated equipment specified on the cover
of this manual. Specific engineering details and performance characteristics
can be obtained from the Product Service Department of Twin Disc,
Incorporated, Racine, Wisconsin, USA.
Operation and maintenance personnel responsible for this equipment should

have this manual at their disposal and be familiar with its contents. Applying
the information in the manual will result in consistent performance from the
unit and help reduce downtime.

Introduction Twin Disc, Incorporated
Replacement Parts
Parts Lists
See the engineering assembly drawings in Engineering Drawings and parts

identification and exploded views in the Assembly section to facilitate ordering
spare or replacement parts.
Ordering Parts
All replacement parts or products (including hoses and fittings) must

be of Twin Disc origin or equal, and otherwise identical with components
of the original equipment. Use of any other parts or products will void
the warranty and may result in malfunction or accident, causing injury
to personnel and /or serious damage to the equipment.
Renewal parts and service parts kits may be obtained from any authorized
Twin Disc distributor or service dealer.
Note: Do not order parts from the part numbers on the cross-
sectional drawings. These numbers may be referenced
for part identification; however, they should be verified
on the bill of material (BOM) before an order is placed.
BOM numbers are stamped on the unit nameplate.
Parts Shipment
Furnish the complete shipping information and postal address. All parts
shipments made from the factory will be FOB factory location, USA. State
specifically whether the parts are to be shipped by freight, express, etc. If
shipping instructions are not specified, the equipment will be shipped the
best way, considering time and expense. Twin Disc, Incorporated will not be
responsible for any charges incurred by this procedure.
Twin Disc, Incorporated having stipulated the bill of material number on the
unit’s nameplate absolves itself of any responsibility resulting from any
external, internal or installation changes made in the field without the express
written approval of Twin Disc. All returned parts, new or old, emanating from
any of the above-stated changes will not be accepted for credit. Furthermore,
any equipment which has been subjected to such changes will not be covered
by a Twin Disc warranty.
Preventive Maintenance/Troubleshooting
Refer to the maintenance and troubleshooting sections of this manual.
Frequent reference to the information provided in this manual regarding daily

operation and limitations of this equipment will assist in obtaining trouble-
free operation. Schedules are provided for the recommended maintenance
of the equipment and, if observed, minimum repairs (aside from normal wear)
will result.
In the event a malfunction does occur, a troubleshooting table is provided to

help identify the problem area and lists information that will help determine
the extent of the repairs necessary to get a unit back into operation.
Lifting Bolt Holes
Most Twin Disc products have provisions for attaching lifting bolts. The holes
provided are always of adequate size and number to safely lift the Twin Disc
product.
These lifting points must not be used to lift the complete power unit.
Lifting excessive loads at these points could cause failure at the lift
point (or points) and result in damage or personal injury.
Select lifting eyebolts to obtain maximum thread engagement with bolt

shoulder tight against housing. Bolts should be near but should not
contact bottom of bolt hole.

Safety
General
Safe practices must be employed by all personnel operating and servicing

this unit. Twin Disc, Incorporated will not be responsible for personal injury
resulting from careless use of hand tools, lifting equipment, power tools, or
unaccepted maintenance/operating practices.
Important Safety Notice
Because of the possible danger to person(s) or property from accidents which

may result from the use of manufactured products, it is important that correct
procedures be followed. Products must be used in accordance with the
engineering information specified. Proper installation, maintenance, and
operation procedures must be observed. Inspection should be made as
necessary to assure safe operations under prevailing conditions. Proper
guards and other suitable safety codes should be provided. These devices
are neither provided by Twin Disc, Incorporated nor are they the responsibility
of Twin Disc, Incorporated.
To prevent accidental starting of the engine when performing routine

transmission maintenance, disconnect the battery cables from the
battery and remove ignition key from the switch.

Sources of Service Information
Each series of manuals issued by Twin Disc, Incorporated is current at the

time of printing. When required, changes are made to reflect advancing
technology and improvements in state-of-the-art.
Individual product service bulletins are issued to provide the field with
immediate notice of new service information.
For the latest service information on Twin Disc products, contact any Twin
Disc distributor or service dealer. This can be done on the Twin Disc corporate
web site found at [http://www.twindisc.com]. Provide your model number,
serial number and bill of material number to obtain information on your unit.
If necessary, contact the Product Service Department of Twin Disc,
International S.A., Nivelles, Belgium, or Twin Disc, Incorporated, Racine,
Wisconsin, 53405-3698, USA by e-mail at service@twindisc.com.
Warranty
Equipment for which this manual was written has a limited warranty. For
details of the warranty, refer to the warranty statement at the front of this
manual.


Twin Disc, Incorporated Description and Specifications
Description and Specifications
General Information
The Twin Disc Hydraulic Power Take-Off (HPTO) is an engine-mounted

hydraulic power take off that contains an integral clutch for engagement of
the PTO, and a brake to keep the output shaft stopped when the clutch is
not engaged. Some models include an engine driven multiple pump drive to
provide hydraulic fluid for operation of the pto, and other customer
requirements.
These Power Take Offs are controlled by hydraulics through the electronic
control module. Both the clutch and the brake are operated by main pressure
oil supply. The bearings, clutches, and gears are lubricated and cooled with
low pressure oil. The output end bearing on “straddle” units is grease
lubricated.

Description and Specifications Twin Disc, Incorporated
Identifying the Twin Disc Hydraulic Power Take-Off Model Number
The nameplate identifies the model, bill of material (BOM) and the serial
number of the unit. These numbers are necessary to identify the correct
parts for your transmission.

Construction Features
Housings
The HPTO housing consists of a front SAE 1 or SAE 0 engine housing

adapter, and a front and rear housing. The front and rear housings are sealed
together with a gasket. Straddle units have a rear bearing support housing.
Bearings
The input end and pump drive bearings are a combination of ball and
cylindrical roller bearings. The rear main housing bearings are either
spherical, tapered or cylindrical roller bearings. The rear bearing on straddle
type units is a grease lubricated cylindrical roller design.
Oil Pump Drive
The oil pump is spline driven by the pump drive gear. Customer supplied
auxiliary oil pumps can also be driven by the splined adapters in the pump
drive gears.
Lubrication Features
Oil is directed by the control valve through horizontal drillings in the main
shafts to orifices through which the front and rear bearings on the main shaft
are lubricated. There are also orifices in the shafts through which both clutch
and brake are cooled. The pump drive gears are lubricate by orifices in an
external plumbing circuit. The rear bearing on straddle type units must be
grease lubricated externally.
Suction Strainer and Baffle
A customer supplied serviceable suction strainer should be located between

the customer supplied oil sump and the oil pump. A customer-supplied baffle
installed in the sump allows aerated oil to settle prior to recirculation.

Filter Assembly
A customer supplied oil filter must be installed between the heat exchanger
and the control valve. The filter must have a Beta removal efficiency rating
of 2/20/75 for particle sizes 5 micron/13 micron/16 micron. A typical filter
element should say 5 micron nominal or 16 micron absolute.
Gears
All gears are hardened spur gears, and are in constant mesh.
Flexible Torsional Input Coupling
The purpose of the torsional coupling is to transmit power from the engine to
the Power Take Off through a rubber or silicone element that will:
Dampen torsional vibrations.
Change the natural frequencies of a system to move critical

frequencies out of the operating speed range.
Accommodate a certain amount of misalignment.
Absorb shock and reduce noise.
Minimize gear “rattle.”
Heat Exchanger
The customer supplied heat exchanger is required to maintain the oil in the
hydraulic system of the Hydraulic Power Take Off at the proper temperature.
An air to oil cooler is typical.
The heat exchanger should be capable of dissipating 28,000 BTU/ hr.
Recommended inlet temperature of heat exchanger: 170o F. (77o C.)
Recommended outlet temperature of heat exchanger: 150o F. (66o C.)
Oil flow from standard Twin Disc pump is 0.0085 gal/rev.
Customer-supplied Support Plate Requirement
Twin Disc, Inc. requires that a support plate be used with all HPTOs.
See specifications and figure 2 of this manual.
Specifications
Maximum Safe Operating Speed for Twin Disc Hydraulic Power Take-offs
HP300I (in-line) 2100 RPM

HP300S (straddle-bearing) 2100 RPM
HP600I (in-line) 2100 RPM
HP600S (straddle-bearing) 2100 RPM
Approximate Dry Weight
Approximate Dry Weight: 590 Kg. (1,300 Lbs.)
Oil Cooling Requirements (see engineering drawing for additional specs.)
Customer supplied, air to oil cooling is typical.

Minimum oil temperature at start up: -40o C. (-40o F.)
Oil temp. at steady operating conditions: 66o C.- 85o C.(150o F.-185o F.)
Maximum oil sump temperature: 93o C. (200o F.)
Oil Type and Oil Viscosity
Oil type and viscosity:

SAE-API service class CD or CC engine oil certified to meet Caterpillar TO-
2 transmission oil specification and/or Allison type C-4 transmission fluid. A
10W, 30W, or 40W can be used, dependent on ambient temperature. See
table 1.
Note: If SAE 40 viscosity oil is used, all three drain lines

must be used.
Note: Multi-viscosity oils (i.e. 10W-30W, etc.) can be used

under certain conditions, but require TWIN DISC
approval.
Table 1 - Recommended Oil Viscosity

Ambient Start-up Steady Operating Suggested Oil
Temperature Temperature Viscosity
-40O C. 38OC. to 66OC. SAE 10

-40 F.
O
100 F. to 150 F.
O O
SAE 10
2 C.
O
49 C. to 77 C.
O O
SAE 30
35 F.
O
120 F. to 170 F.
O O
SAE 30
>40 C. O
60 C. to 85 C.
O O
SAE 40
>50O F. 140OF. to 185OF. SAE 40
Oil Sump-Basic Information (See engineering drawing for additional

specs.)
Capacity: Minimum 8 gallons in customer-supplied sump.
Location: Below the HPTO, and allow for gravity drain from at least two
1 1/2 NPTF drain ports.
Breather: (optional) Can be integrated with fill cap.
Breather Ports: When the sump has a breather, a 19.05 mm. (3/4”) port
is used to connect a hose from the HPTO to the sump. Do
not integrate with drain ports.
Drain Ports: Use maximum possible diameter drain hoses (1 1/2 inch
diameter) with least restrictive fittings. All three drain hoses
must be used with SAE 40 viscosity oil to prevent overheating
from entrapped oil.
Suction: Use suitable suction screen to prevent pump damage. Use

suitable suction hose to prevent cavitation.
Baffles: Use baffles to allow return oil to settle away from suction
port.
Oil Scavenge Pump (See engineering drawing for additional specs.)
If sump cannot be located below the HPTO, a customer supplied scavenge

pump that is approximately two times the size of the charge pump must be
used to adequately remove the oil from the pto housing.
Oil Pump (See engineering drawing for additional specs.)
Capacity: Oil flow of 8.5 GPM is required at 1000 rpm. Standard Twin
Disc supplied pump supplies 0.0085 gal/rev.
Rotation: The pump rotates in engine speed direction when mounted

on the output side of the pump drive, or opposite engine speed
direction when mounted on the input side of the pump drive.
Oil Pressure
See table 2. Oil temperature must be in the normal operating range. The
range of values shown on the chart is based upon specific flow rates,
temperatures and oil used. Contact Twin Disc engineering for guidance
regarding modified parameters.
Table 2. Oil Pressure Specification
Limits for HPTO with 0.0085 Gallons/Rev. pump attached to HPTO gear housing
Main Clutch Brake Lube Cooling
rpm Range Min. Act. Max. Min. Act. Min. Act. Min. Act. Max. Temp
kPa kPa kPa kPa kPa kPa kPa kPa kPa kPa
o
C.
(psi.) (psi.) (psi.) (psi.) (psi.) (psi.) (psi.) (psi.) (psi.) (psi.) (oF.)
Clutch
1650 1790 1650 0 276 414
(240) (260) (240) (0) (40) (60)
1650 1790 0 1650 276 414
700 Brake
(240) (260) (0) (240) (40) (60)
1650 1790 0 0 276 414
Neutral
(240) (260) (0) (0) (40) (60)
1650 1790 1650 0 414 552
Clutch
(240) (260) (240) (0) (60) (80)
2100
1650 1790 0 0 414 552
Neutral (240) (260) (0) (0) (60) (80)
Cooling temperature range: Delvac 10W Oil at 29oC. - 35oC. (85oF. - 95oF.) or Mobilkote 501 at 32oC. - 38oC. (90oF. - 100oF.)
Required: Clutch lube pressure = Brake lube pressure within 21 kPa (3 psi)
Rear support is required for testing.
Lube Pressure Port
Brake Pressure Port
Clutch Pressure Port
Main Pressure Port
Lube Pressure Port
Figure 1. Oil pressure pickup points

Fittings (See engineering drawing for additional specs.)
Fittings must meet SAE 514, SAE J476, J518 standards.
Hose Type (See engineering drawing for additional specs.)
Hoses must meet SAE 517 specifications for 100R17 or similar type for
hydraulic applications.
Electronic Control Module
Operating voltage range. 9 to 32 Volts DC

Operating temperature range. -40o C. (-40o F.) to 85o C. (185o F.)
Output Speed Sensor Air Gap
Two turns out from touching the outer diameter of the gear.
Input Speed Sensor Air Gap
One and one half turns out from the outer diameter of the gear.
Torque on input and output speed sensor lock nuts
27 Nm. (20 lb.-ft.)
Remote Mounted Electronic Control Cable
See information contained in Installation section.
Shim Tolerance for bearing carrier (65) in idler gear (58).
Refer to the parts list and exploded view illustration.
The designed shim tolerance is .1016 mm. loose to .0254 mm. tight
(.004” loose to .001” tight).

Twin Disc PTO Support Plate Specifications
C* D
For Straddle-bearing type
E (qty.)
B
F (dia.)
G
Shim to
within
.12 cm.
Engine Bed (.005”)
Frame Width
43.18 cm. (17.0”) min.
For In-Line type
41.91 cm. (16.500”) R
13.49 mm. (17/32”) dia.
thru holes 300 apart on
449.99 mm. (17.716”)
dia. B.C.
Plate
thickness = G
Figure 2. Support plate dimensions
NOTE: One possible mounting method provides installation

ease. Use angle iron to couple the support plate to the
engine frame.
PTO A B C D E F G
Model Bore Bolt Radius Degree Hole Hole Recommended
Thickness
+.127/.025mm Circle Quantity Diameter
(+.005/+.001”)
HPTO300S 238.15 mm 28.58 cm 16.21 cm ** 8 17.46 mm 19.05 mm

9.376” 11.250” 6.38” ** 8 11/16” 3/4”
HPTO600S 238.15 mm 28.58 cm 16.81 cm ** 8 17.46 mm 19.05 mm
9.376” 11.250” 6.62” ** 8 11/16” 3/4”
* Based upon an 8-hole bolt pattern without bolt holes in the 12 and 6 o’clock
positions.
** Angular offset of thru holes (D) must be calculated with respect to orientation of
sheave housing. Holes are evenly spaced, i.e. 360/8 = angular spacing of thru
holes.
NOTE: PTO deflection due to loads imposed by the application

should not exceed .25 mm (.010”). Deflection should
be measured at the support plate pilot with the dial
indicator base mounted on a rigid part of the engine.

Torque Values for U.S. Fasteners
Table 3. - Coarse Thread Capscrews, Bolts and Nuts
Thread SAE Grade 5 SAE Grade 8

Diameter Nm lb-ft Nm lb-ft
1/4 8 - 11 6-8 10 - 12 14 - 16
5/16 18 - 23 13 - 17 20 -24 27 - 32
3/8 34 - 39 25 - 29 35 - 41 48 - 55
7/16 51 - 58 37 - 43 55 - 65 75 - 88
1/2 81 - 95 60 - 70 83 - 97 113 - 131
9/16 111 - 132 82 - 98 120 - 140 163 - 190
5/8 163 - 190 120 - 140 165 - 195 224 - 264
3/4 278 - 332 205 - 245 295 - 345 400 - 467
7/8 448 - 528 330 - 390 470 - 550 638 - 745
1 495 - 595 671 - 806 715 - 845 970 - 1145
1 1/8 615 - 745 834 - 1010 1015 - 1185 1377 - 1606
1 1/4 850 - 1000 1163 - 1355 1375 - 1625 1865 - 2203

Table 4. - Metric Coarse Thread Capscrews, Bolts and Nuts
Thread Property Class 8.8 Property Class 10.9 Property Class 12.9
Size lb-ft Nm lb-ft Nm lb-ft Nm
M6 6.5 - 7.5 9 - 10 9 - 10 12 - 14 10 - 12 14 - 16
M8 16 - 18 21 - 25 23 - 26 31 - 35 25 - 29 34 - 40
M10 32 - 36 43 - 49 44 - 51 60 - 68 51 - 59 70 - 80
M12 55 - 63 74 - 86 77 - 88 104 - 120 89 - 103 121 - 139
M16 132 - 151 179 - 205 189 - 217 256 - 294 219 - 253 298 - 342
M20 257 - 295 348 - 400 364 - 418 493 - 567 429 - 493 581 - 669
M24 445 - 511 603 - 693 626 - 720 848 - 976 737 - 848 1000 - 1150
M30 714 - 820 987 - 1113 1235 - 1421 1674 - 1926 1475 - 1697 2000 - 2301
Table 5. - Tapered Pipe Plugs (with thread lubricant)
In cast iron or steel In aluminum

NPTF Size (in) Nm (+ or - 5%) lb-ft (+ or - 5%) Nm (+ or - 5%) lb-ft (+ or - 5%)
1/16-27 11.5 8.5 7.5 5.5
1/8-27 14 10.5 9 6.5
1/4-18 34 25 21.5 16
3/8-18 36.5 27 23 17
1/2-14 68 50 40.5 30
3/4-14 73 54 46 34
1 - 11 1/2 108 80 68 50
1 1/4 - 11 1/2 115 85 75 55
1 1/2 - 11 1/2 115 85 75 55

Table 6. - Straight Threaded Tube Fittings, Hose Fittings, and O-Rings
Nominal Nominal
Nm lb-ft Nm lb-ft
Thread Thread
(+ or - 5%) (+ or - 5%) (+ or - 5%) (+ or - 5%)
Diameter Diameter
5/16 5 3.5 M10X1.0 26 19
3/8 11.5 8.5 M12X1.5 37 27
7/16 16 12 M14X1.5 47 35
1/2 20 15 M16X1.5 58 43
9/16 24.5 18 M18X1.5 74 55
5/8 24.5 18 M22X1.5 105 77
11/16 34 25 M27X2.0 179 132
IN IRON
3/4 40.5 30
M27X2.0 85 63
7/8 54 40 IN ALUM.
1 1/16 75 55 M33X2.0 326 240
1 3/16 88 65 M42X2.0 347 256
1 1/4 88 65 M48X2.0 441 325
1 5/16 108 80
1 3/8 108 80
1 5/8 135 100
1 7/8 162 120
2 1/2 312 230

Wear Limits
The following list maximum diameters sizes for bearing bores and minimum
diameters for bearing journals and seal contact surfaces.
Table 7. Bearing Bores and Bearing Journals

Maximum Diameter Maximum Diameter
Item mm. inches Item mm. inches
A Bearing Bore 150.0251 5.9065 D Bearing Bore 215.9762 8.5030
B Bearing Bore E Bearing Bore 125.0112 4.9217
Hsg. #1020659 215.0466 8.4664 H Bearing Bore
Hsg. #1020659b 215.0466 8.4664 SAE “A” size 90.0227 3.5442
Hsg. #1020659c 215.9762 8.5030 SAE “B” size 90.2767 3.5542
C Bearing Bore SAE “C” size 90.2767 3.5542
Hsg. #1019124 160.0225 6.3001 Minimum Diameter
Hsg. #A7576 170.0378 6.6944 Item mm. inches
Hsg. #1020654 215.0466 8.4664 F Bearing Journal 100.0023 3.9371
G Bearing Journal 50.0024 1.9686
Front Housing
Clutch Housing Belt Sheave
Housing
C
Bearing Bore
B
A Bearing Bore
SAE Mounting
Bearing Bore Plate
Gear & Drive
Ring Asy. H
Model I Bearing Carrier Bearing Bore
Driven Gear
F
E Bearing
Bearing Bore Journal
G
D
Bearing
Bearing Bore
Journal
Table 8. Bearing Journals and Seal Contact Surfaces on Shafts
Bearing Journal Seal Contact Surface Bearing Journal

J K L
Shaft Minimum Diameter Minimum Diameter Minimum Diameter
Part Number mm. inches mm. inches mm. inches
#1020660b 120.523 4.7450 130.0988 5.1220 120.0581 4.7267
#1020678c 71.374 2.8100 130.0988 5.1220 120.0581 4.7267
#1020678d 80.010 3.1500 130.0988 5.1220 120.0581 4.7267
#1020678e 80.010 3.1500 130.0988 5.1220 120.0581 4.7267
#1020678f n/a n/a n/a n/a 139.7406 5.5016
#1020678g n/a n/a n/a n/a 139.7406 5.5016
Bearing Journal Seal Contact Surface Seal Contact Surface Seal Contact Surface
M N P Q
Shaft Minimum Diameter Minimum Diameter Minimum Diameter Minimum Diameter
Part Number mm. inches mm. inches mm. inches mm. inches
#1020660b 70.1010 2.7563 107.7341 4.2415 101.4095 3.9925 95.0595 3.7425
#1020678c 70.1010 2.7563 107.7341 4.2415 101.4095 3.9925 95.0595 3.7425
#1020678d 70.1010 2.7563 107.7341 4.2415 101.4095 3.9925 95.0595 3.7425
#1020678e 70.1010 2.7563 107.7341 4.2415 101.4095 3.9925 95.0595 3.7425
#1020678f 70.1010 2.7563 107.7341 4.2415 101.4095 3.9925 95.0595 3.7425
#1020678g 70.1010 2.7563 107.7341 4.2415 101.4095 3.9925 95.0595 3.7425
P Q
Seal Contact Seal Contact
Surface Surface
M
N Bearing Journal
Seal Contact
Surface
Shaft L
Typical Bearing
Model 300S & 600S
Shaft Journal
Shaft
K Typical
J Seal Contact Model 300I & 600I
Shaft
Bearing Journal Surface

Twin Disc, Incorporated Operation
Operation
General
A Flexible Torsional Input Coupling is bolted to the engine flywheel. The

coupling’s internal spline meshes with an external spline on the drive gear.
External teeth on a series of Clutch Friction Plates are in constant contact with
internal teeth of the drive gear. These and related components comprise the
basic input drive portion of the Power Take-off and are in rotation at engine
speed whenever the engine is running.
A series of internally splined Steel Clutch Plates are located between the Clutch
Friction Plates. Their internal teeth mesh with external teeth on the Clutch Hub,
which is, in turn, splined to the Clutch Shaft. These and related components
comprise the basic output portion of the Power Take-off and are in rotation
when partial or full clutch is engagement occurs (see below).
The Back Plate is contained within the Clutch Piston forming an operating cavity
into which high-pressure oil is directed by the GP Control Valve. A Piston Carrier,
located inside the Clutch Piston separates the clutch-engagement side from
the brake-engagement side of the cavity.
Multiple accessory drives (on some models) are in rotation whenever the engine
is running. Their output speed is always the same as engine speed.
The General Purpose (GP) Control Valve with its electronic interface is used to
obtain brake engagement, coast, and clutch engagement in this hydraulic power
take off. When these positions are selected by the operator, and the proper
conditions exist, the control valve directs high-pressure oil through internal
passages to instantaneously and smoothly apply the brake, or to engage the
hydraulic clutch. The pressure-rate of rise, controlled by the electronic module,
provides a rapid, smooth, clutch engagement.
On initial startup and service, closely monitor the pressure while starting
the engine to ensure that the pump primes. Do not run the engine for
longer than 10 seconds if measurable main pressure does not register.
Power Take-off Service Manual 31

Operation Twin Disc, Incorporated
General Overview of GP Control Valve with Electronic Interface
The General Purpose (GP) control valve is a hydraulic valve assembly designed
for use with this power take-off, that includes a remotely mounted electronic
interface control module. The valve assembly contains electrical-current-
controlled proportional cartridges.
32 Power Take-off Service Manual

GP Control Valve Hydraulic Portion
The hydraulic portion of the GP Control Valve is made up of two blocks, a lower
main regulator valve body, and an upper valve body. These valve bodies contain
two electrically-actuated proportional valves, and a hydraulic pressure regulator
(consisting of a pilot relief valve assembly and a main spool valve assembly).
Separate identical proportional valves are used for the brake and the clutch
engagement. When the power take-off clutch is selected to be engaged, the
control valve directs high-pressure oil through internal passages to operate the
clutch. When brake engagement is selected, the brake control valve directs
high-pressure oil to operate the brake. (The clutch and brake are never engaged
at the same time.) The pressure-rate of rise (profile) is controlled electronically
by the GP Control Valve electronic interface to provide a rapid, smooth, oil
pressure increase in the clutch or brake hydraulic passages during engagement.
The proportional valve coils are low resistance devices that are electrical
current driven. The use of an uncontrolled power source may supply
too much current and damage the proportional valve.
Note: Installations with this valve must include an oil filter

with the proper filtering characteristics. This valve
requires a filtration level of 16 micron at an efficiency
of 98% (beta ratio = 75) or better. Besides the valve's
requirement on filtration, the filter must meet the
requirements of the power take-off (operating
pressure, flow, etc.)

Figure 3. Hydraulic Schematic (GP control valve)

Figure 4. Top Hydraulic Valve Body Assembly
Valve section
used with valve
assembly 1020729
Valve section
used with valve
assembly 1021658
Pressure Regulator
Figure 5. Main Regulator Hydraulic Valve Assembly

Hydraulic System with GP Control Valve
The oil pump draws oil from the oil sump and discharges it to the heat exchanger,
and on through the oil filter. Filtered oil enters the control valve through the inlet
port. The incoming oil is supplied to the main pressure regulating relief pilot
valve and the main regulating valve cartridge, satisfying the main pressure
requirements of the HPTO and cascading all remaining oil flow into the
lubrication circuit. Oil not used for clutch or brake engagement flows past the
regulator piston to become lubrication oil. Lubrication oil flows through the
lubrication oil circuit in the pto to lubricate and cool the clutches and bearings.
Main pressure is supplied to the inlet of each proportional valve. Prior to

engagement, the areas behind the clutch piston and brake piston are open to
sump when the solenoids are not energized. The clutch and brake are
hydraulically disengaged, but springs in the clutch unit cause the brake to be
mechanically engaged. (The clutch is disengaged at that time.)
When the clutch is commanded to engage, the proportional valve directs main
pressure to a passageway in the clutch shaft. The oil is directed between the
carrier and the apply piston. The apply pistons for the power take off clutch and
the brake are connected so that when the clutch is hydraulically applied, the
apply piston for the brake is pulled away from the clutch plate(s), preventing
brake engagement. The clutch engagement, including the rate-of-rise, is
controlled electronically utilizing a closed loop logic that is programmed into
the HPTO Control Module.
Clutch release occurs when the proportional valve is de-energized. (At that
time, the springs in the clutch unit will mechanically engage the brake.
The electronic interface portion of the control valve allows only one proportional
valve to be energized at a time, thus, apply oil can only be supplied to either the
brake or the clutch at one time, and the oil from the disengaged unit is vented to
sump (atmospheric pressure). The pto clutch release springs move the clutch’s
apply piston to the disengaged position minimizing clutch plate drag.
See the Hydraulic Piping Diagram on the following page.
Note: The breather (108) that is located on the top of the

pump drive tower can be moved to the sump,
provided that a line is connected from the vent
location on the pump tower to the sump, and the
sump breather is located in a baffled “quiet” area
where the oil flow path does not affect the sump area
by the breather.

Pump Outlet 1”Hose 1”Hose

Port
Pump Inlet
Port Breather
3/4”Hose
Valve Inlet Port

1 1/4”Hose
1 1/2-11 1/2 NPTF
Thread
1 1/2-11 1/2 NPTF
Thread 1 1/2”Hose
1 1/2”Hose
1 1/2-11 1/2 NPTF
Thread
Pump Pump Outlet Port
Pump Inlet Port
Valve Inlet Port
Control Valve
Assembly
Drain Port
Figure 6. Hydraulic Piping Diagram

GP Control Valve Electronic Control Interface (Profile Module)
The electronic portion of the GP Control Valve must be remotely mounted from
the hydraulic portion of the GP Control Valve, because of the ambient
temperature in most applications.
If the ambient temperature of this mounting location exceeds 82oC.

(180oF.), the Electronic Control Interface must be relocated to a cooler
area. See Remote Mounted Electronic Control Cable in the Installation
Section of this manual
This module contains the electronic circuitry to control the proportional cartridges
that are used to engage the clutch and brake, based on the commands from
the operator, and the programmed logic. Clutch apply pressure rate of rise
(profile) is factory set with the use of internal circuitry. Closed loop logic is used
for all clutch engagements. There are no user adjustments on the HPTO Profile
Module. All electrical wiring for the Hydraulic Power Take Off system controls
are routed through this interface module. The machine’s battery power (12 vdc
or 24 vdc) is supplied to the electronic interface only, and never directly to the
hydraulic proportional valves. Two red led lights are used to identify the
proportional cartridge valve that is energized, and a green led is used to identify
when power is provided to the electronic module. Flashing lights are used in
troubleshooting. Engine speed and clutch output speed sensors are required
for the control logic. The following figure shows the Electronic HPTO Module.
Do not connect valve coils directly to battery power supply voltage.

Use an approved Twin Disc Control System.
Figure 7. Electronic HPTO Module

Clutch Engagement Logic (Closed Loop)
Brake Engagement
Any time that the PTO Output Speed is below a preset speed, and the Power
Take Off Clutch is not commanded to be on, the Brake Valve Coil will be
commanded on by a pre-programmed profile. When the clutch is engaged,
the brake will be commanded to be off. Also, if the PTO Output Speed increases
at any time a small amount above this preset speed, the Brake Valve Coil will
be commanded off.
Power Take Off Clutch Engagement
Any time that the customer supplied PTO Engage Switch is closed, indicating
that the operator wishes to engage the Power Take Off, the Control Module
commands the brake to be off and begins two simultaneous logic processes.
These are a Clutch Engagement process, and a Clutch Lockup Check process.
Input Speed and Output Speed are monitored continuously. The following briefly
describes the steps in the processes.
The engine must be below a preset speed before any clutch engagement will
be commanded. If the engine speed is proper, the clutch is engaged at a
preset level, while engine speed and output speeds are monitored. The clutch
pressure will be increased as fast as possible without reducing the engine
speed below a preset speed. If no output speed is detected, the PTO clutch
will be disengaged and reapplied. If no output speed is detected after four
attempts, the warning relay will be closed, and no further engagements
attempted for five minutes, allowing the clutch components to cool sufficiently.
Do not shut off the power to bypass the five minute cool down period.
Mechanical damage can occur if the clutch is not allowed to cool after
each engagement. After five minutes, turn off the engine and determine
why the output did not rotate.
After five minutes, another clutch engagement can be attempted. The

PTO Engagement Switch must be turned off to reset the warning relay.
If an input speed sensor failure is detected, engagements of the PTO Valve

Coil will not be allowed.
If an output speed sensor failure is detected, engagements of the Brake Valve

Coil will not be allowed.


Twin Disc, Incorporated Installation
Installation
Identifying the Twin Disc Power Take-off Model
The nameplate identifies the model, bill of material (BOM) and the serial number
of the unit. These numbers are necessary to identify the correct parts for your
transmission.
Power Take-Off Service Manual 41

Installation Twin Disc, Incorporated
Identifying the SAE Housing Size
B C
Figure 8. Basic dimensions for SAE housings
Table 9. SAE Housing Identification

A B C D
SAE Housing Housing Bolt Circle Bolt Holes
Housing Pilot Diameter Flange O.D. Diameter Dia.
Size Qty.
mm. inches mm. inches mm. inches mm. inches
00 787.40 31.000 876.3 34.50 850.90 33.500 16 13.49 .531

0 647.70 25.500 711.2 28.00 678.18 26.750 16 13.89 .547
1 511.18 20.125 552.5 21.75 530.23 20.875 12 12.29 .484
42 Power Take-Off Service Manual

Prior to Installation
The Twin Disc Hydraulic Power Take Off mounts directly onto the flywheel
of the engine. Flywheel-to-Power take off interference is possible due
to mismatch of components or other reasons. Therefore, engine
crankshaft endplay as well as flywheel alignment checks must be made
before the Hydraulic Power Take Off is installed.
After installation of the Hydraulic Power Take Off, the crankshaft endplay should
be measured again. The endplay at the second measurement should be the
same as the first. A difference in these two endplay measurements could be
an indication of interference. Consequently, the Hydraulic Power Take Off should
be removed and the source of interference found and corrected.
Twin Disc will not be responsible for system damage caused by engine to Twin
Disc Hydraulic Power Take Off interference regardless of the cause of
interference. This engine crankshaft endplay check is considered mandatory.
The power take off housing flange and pilot, the engine flywheel and the flywheel
housing must be checked for trueness. Clean the engine flywheel and flywheel
housing mounting surfaces thoroughly before any measurements are made.
Filtration prior to start-up (new or rebuilt unit)

1) Proper cleaning of hydraulic hoses prior to installing them on the HPTO.
2) Insure cooler has been flushed and is indeed clean.
3) Always install a filter at the inlet of the valve body in case residual debris
was missed in the cooler after cleaning.
4) At first start-up with new or rebuilt HPTO, check main and lube pressure
to ensure pump has primed and producing oil pressure.

Preliminary Checks
Refer to Identifying the SAE Housing size in table 9.
Note: All measurements must be taken with the engine or

motor mounted on its supports after the flywheel and
housing have been thoroughly cleaned.
1. Measure and record the engine crankshaft or motor shaft endplay using
a dial indicator. Record this value, as it will be used later._______
2. Bolt the indicator to the flywheel so the indicator is perpendicular to the

flywheel housing face and the indicator stem rides on the flywheel housing
face. See Figure 9.
Figure 9. Checking Flywheel Housing Face
3. Rotate the shaft through on entire revolution and note the runout. The
total indicator reading (T.I.R.) must not exceed:
SAE #0 Housing .41 mm. (.016”).
SAE #1 Housing .30 mm. (.012”).
Note: The flywheel and crankshaft of the engine must be

held against either the front or rear of the crankshaft
thrust bearing while the total indicator sweep (T.I.R.)
is being made.

4. Readjust the indicator so the stem rides on the pilot bore of the flywheel
housing face. See Figure 10.
Figure 10. Checking Flywheel Housing Bore
5. Rotate the shaft through one entire revolution and note the runout. The
total indicator reading (T.I.R.) should not exceed:
SAE #0 Housing .41 mm. (.016”).
SAE #1 Housing .30 mm. (.012”).
6. Remove the indicator base from the flywheel and bolt it to the flywheel
housing face. Position the indicator stem so that it rides where the drive
ring will set on the flywheel face. See Figure 11.
Figure 11. Checking Driving Ring Surface of Flywheel
7. Rotate the shaft through one entire revolution and note the face runout of
the flywheel. The total indicator reading (T.I.R.) must not exceed .01mm.
(.0005”) per 25.4 mm. (per inch) of flywheel diameter.
Note: The flywheel and crankshaft of the engine must be

held against either the front or rear of the crankshaft
thrust bearing while the total indicator sweep (T.I.R.)
is being made.
8. Readjust the indicator stem so it rides on the torsional input coupling

pilot bore of the flywheel. See Figure 12.
Figure 12. Checking Torsional Input Coupling Pilot Bore of Flywheel
9. Rotate the shaft through one entire revolution and note the torsional input
coupling bore eccentricity. The total indicator reading (T.I.R.) must not
exceed .13 mm. (.005”).

Torsional Input Coupling Installation
Refer to the cleaning and inspection section of this manual before proceeding.
1. Clean the flywheel and the input coupling face and outside pilot diameter
of any dirt or debris as necessary.
2. Use crocus cloth or emery cloth to remove any surface imperfections

such as nicks, burrs, and sharp edges on the O.D. or the surface that
will be mounted against the flywheel face.
3. Use crocus cloth or emery cloth to remove any surface imperfections

such as nicks, burrs, and sharp edges in the I.D. of the flywheel pilot
bore or on the face that will be in contact with the input coupling.
4. Position the input coupling against the flywheel, piloted in the mounting
bore, and secure with eight hex-head capscrews. Torque the capscrews
to the proper specifications given in Torque Values for U.S. Fasteners
in the Description and Specifications section of this manual.
Torsional Input Coupling attachment screws must be grade 8. Do not

use substitutes.
Be sure the internal retaining ring is properly installed inside the

torsional input coupling hub. See Engineering Drawings section of this
manual for correct ring location.

Assembly Instructions for CENTAFLEX - R on Flange Mounted

transmission. Information Taken from CENTA Drawing 26-60062-91-3.
1. Bolt flywheel flange onto flywheel and tighten bolts as follows.
Mounting Bolt
Flywheel
Flywheel Flange portion of

the Torsional Input Coupling
Figure 13. Assemble Flywheel Flange to Flywheel
Table 10. Centa Tightening Torque Chart
Thread Property Class 8.8

Size Nm ft.-lbs.
M10 50 37
M12 85 63
M16 215 159
Tightening torque is for slightly oiled bolts, tolerance is + or - 5%.

Securing of the bolts by adhesives (e.g. Loctite) is possible.

2. Place rubber rollers in the deepest section of the cam in the output hub.
Normally they stick there by friction.
Figure 14. Insert Rollers and Note Alignment
3. In case they do not stick, place a tape or a cord with a slip knot around
all rollers close to the gear side. Leave the end of the tape or cord long
enough so that it extends outside the flange. Turn the two coupling halves
so that the arrows of both halves are opposite one another. See Figure
14 (View X).
Flywheel Flange portion of

the Torsional Input Coupling
Flywheel
Tape or Cord
Rollers
Internal portion of the

Torsional Input
Coupling
Figure 15. Coupling into Flywheel Flange

4. Then push the output side of the coupling with the hub into the outer
flange. If necessary apply lubricant on the outer flange. Suitable
lubricants are soap water, detergents, etc. DO NOT USE OIL OR
GREASE. If tape or a cord was used, push the coupling only half way
together and remove the tape or cord. Then complete the installation.
Remove
Tape or Cord
Figure 16. Assemble part way and remove the tape or cord.
Figure 17. Final Assembly

HPTO Installation to Engine
Refer to the cleaning and inspection section of this manual before proceeding.
When mounting the engine and Hydraulic Power Take Off in the machine,
the six mounting bolts on each side of the mounting pads of the In-Line
power take off must be used. The power take off mounting brackets
should not be used to support the engine. A support plate must be
used to support the output end of the Straddle Bearing Units. Failure
to follow this guideline may result in damage to the power take off or
the engine flywheel housing.
See Engineering Drawings for installation dimensions and the locations of the
required connections for power take off installation.
HP300I HP300S HP600I HP600S
The connections include the following:
Output shaft connection
Electrical connection for Control Module
Oil connection to the oil pump and heat exchanger
Oil connection from the heat exchanger to the oil filter
Speed pickups and pressure gauges
1. Clean the PTO housing flange, flywheel housing flange of any debris.
2. Make sure the housing flange and flywheel housing flange are free of
surface imperfections such as nicks, burrs, and sharp edges. Remove
them using fine emery cloth or crocus cloth.
3. Install a minimum of 3 guide studs in the flywheel housing, located

approximately 120o apart. Using a suitable hoist, position the PTO on
the guide studs and slide it against the flywheel housing, carefully aligning
the teeth of the drive gear (12) with the internal teeth of the coupling (1).
Do not force the pto unit onto the engine. If any resistance is noted,
identify and correct all sources of interference.
4. Secure the PTO housing to the flywheel housing with 12 hex-head

capscrews (SAE #1 housing) or 16 capscrews (SAE #0 housing) .
Torque the capscrews to the proper specifications given in Torque
Values for U.S. Fasteners in the Description and Specifications
section of this manual.
Note: PTO housing to flywheel housing attachment screws

must be grade 5 or better.
5. Rap the end of the output shaft with a soft hammer to remove any preload
on the main bearings and/or pilot bearing.
Note: This step must not be omitted. Bearing failure may

result.
6. Measure the crankshaft endplay again. The measurement must be the

same value as recorded from step 1 under Preliminary Checks. Locate
and correct the source of preload if the endplay is not the same value.
Engine and/or PTO failure will result from any excessive preload on
components.
7. Install the drive sheave, u-joint flange or other driven components as the
application requires.
HP300S and HP600S only: (Models 300I & 600I skip to step 8.)
Note: Straddle bearing units only - refer to V-belt installation in
the maintenance section and the Engineering Drawings
towards the back of this manual. (Proceed at step 8.)
HP300S, HP600S, HP300I and HP600I

8. A PTO support plate mounted at the output bearing retainer must be
used. Install the support plate. Refer to Support Plate Specifications
in the Description and Specifications section and the Engineering
Drawings towards the back of this manual.
9. Measure and adjust for proper deflection and alignment. (See

instructions near back of this section.)
10. Attach hoses, hose fittings and other plumbing circuit components
including the sump, oil filter and heat exchanger. (See plumbing
illustrations near back of this section.)
11. Attach the speed pickup(s) and pressure gauge(s). (See details
contained in drawings in the Engineering Drawings section of this
manual.)
12. Mount the Electronic Control Module.

The Electronic Control Module must be remotely mounted from the
Hydraulic Power Take Off unit because of the possible temperatures
reached at the power take off. See Figure 18 .
Figure 18. Electronic Control Module

13. Attach all electrical connections for the Control Module.
Figure19. Wiring Schematic

14. Attach the optional cables for remotely locating the control module are
listed in the table 11.
Length
Figure 20. Cable for remote control operation
Electrical Controls: All electrical wires and connectors must be

adequately supported to prevent rubbing, chafing, or distress from
relative movement. All electrical connections must be tight and free
from any corrosion. See Figure 18 for the wiring connector.
Table 11. Cable Lengths
Part Length Part Length

Number millimeters inches Number millimeters inches
1021351A 1500 59 1021351R 6000 236
1021351B 1800 71 1021351S 6300 248
1021351C 2100 83 1021351T 6600 260
1021351D 2400 94 1021351U 6900 272
1021351E 2700 106 1021351V 7200 283
1021351F 3000 118 1021351W 7500 295
1021351G 3300 130 1021351X 7800 307
1021351H 3600 142 1021351Y 8400 331
1021351J 3900 154 1021351Z 9000 354
1021351K 4200 165 1021351AA 9600 378
1021351L 4500 177 1021351AB 10200 402
1021351M 4800 189 1021351AC 10800 425
1021351N 5100 201 1021351AD 11400 449
1021351P 5400 213 1021351AE 12000 472
1021351Q 5700 224 1021351AF 12600 496

Final Checks
Before starting the engine, be sure the sump is properly filled with oil and the
rear main bearing is properly greased. See Description and Specifications
and Maintenance sections for the proper oil specification and filling procedure.
Monitor the pressure while starting the engine to ensure that the pump
primes. Do not run the engine for longer than 10 seconds if the pump
does not prime, resulting in measurable main pressure.
Check and Adjust Main Pressure (as needed)
It is recommended that following the servicing of the valve assembly a procedure

be followed to ensure the flushing of oil through the valve assembly, followed by
adjustment of the main pressure.
1. Install a main pressure gauge into the port on top of the Top Valve body.
Top View
Main Pressure
Port
Pilot Relief Valve
Assembly
Valve Inlet Port
Valve assembly
Side View 1020729 is
illustrated.
Figure 21. Main Pressure Port in Valve Body
2. Remove protective cover cap located at the end of the pilot relief valve
assembly. This will expose a 1/4" hex head adjustment screw. Loosen
the jam nut on the stem.

Used with valve

assembly
1020729
Cap
Used with valve
assembly
1021658
Jam Nut
Figure 22. Pilot Relief Valve Assembly/Pressure Regulator
The Hydraulic Power Take-Off must be in the disengaged position before

the engine is started.
3. Turn this adjustment screw counterclockwise until it reaches a positive

stop. This allows the engine to be started and flush any debris past the
relief valve.
4. Start engine with the HPTO control in set in the disengaged position.
Main pressure should be approximately 689 kPa (100 psi.) or less. Allow
the fluid to flush the valve for approximately 1 minute.
Monitor the pressure while starting the engine to ensure that the pump
primes. Do not run the engine for longer than 10 seconds if measurable
main pressure does not register.
5. Turn the 1/4" hex head adjustment screw clockwise to achieve the main
pressure setting. A helpful practice is to turn the screw approximately
35 kPa (approximately 5 psi.) beyond the desired setting and then adjust
for the target pressure. This aids in reducing variance in pressure setting
due to torsional wind-up of the internal pressure spring.
Note: If main pressure is to be set with cold oil, adjust the

main pressure to approximately 35 - 70 kPa (5 - 10
psi.) higher than the desired hot oil value.
6. Tighten the jam nut to a torque of 20 Nm. (15 ft.-lb.), install the protective
cap, and torque it to14 Nm. (10 ft.-lb.)

Check Clutch Operation and Pressures
7. After the engine and Hydraulic Power Take-Off are warmed up, check
oil pressures in accord with the pressures shown in the Oil Pressure
Specification table in the Description and Installation section of this
manual.
Note: Read and become completely familiar with the Power

Take-Off Clutch Engagement explanation in the
Operation Section of this manual.
8. Engage the clutch. Automatic brake disengagement should allow shaft

rotation to reach full speed.
Note: Read and become completely familiar with the Brake

Engagement explanation in the Operation Section
of this manual.
9. Disengage the clutch. Check to be sure shaft rotation slows to a stop

when the clutch is disengaged. Automatic brake engagement will
eventually stop shaft rotation when the clutch is disengaged.

Plumbing - HP300I, HP300S, HP600I, HP600S

Pump Outlet 1”Hose 1”Hose
Port
Pump Inlet
Port Breather
3/4”Hose
Valve Inlet Port

1 1/4”Hose
1 1/2-11 1/2 NPTF
Thread
1 1/2-11 1/2 NPTF
Thread 1 1/2”Hose
1 1/2”Hose
1 1/2-11 1/2 NPTF
Thread
Pump Pump Outlet Port
Pump Inlet Port
Valve Inlet Port
Control Valve
Assembly
Drain Ports

Twin Disc, Incorporated Maintenance
Maintenance
Allowable Side Loads

CENTERLINE
S OF SIDE
LOAD
126,000 x H.P.
L= x F x LF
NxD
Figure 22. Allowable Side Pull and Formula to Determine Applied Load
Formula values for Figure 22.
L = actual applied load (Lbs.)
N = shaft speed (RPM)
D = pitch diameter (in.) at sheave, etc.
F = load factor
− 1.0 for chain or gear drive − 2.5 for all V belts
− 1.5 for timing belts − 3.5 for flat belts
LF = 2.1 for reciprocating compressors and other severe shock drivers

and 1.8 for large inertia type drive (crushers, chippers, planers)
A support plate must be attached at the rear of the PTO.
Note: HP300I and HP600I Hydraulic Power Take-offs are

recommended for in-line, not side-loaded,
applications.

Maintenance Twin Disc, Incorporated
Allowable Side Loads HP300S
Side Load Chart - HPTO 300S
15000
14000
13000
Maximum Load, Lbs.
12000
11000
10000
9000
127 (5.0) 152.4 (6.0) 177.8 (7.0) 203.2 (8.0) 228.6 (9.0) 254 (10.0)
"X" Distance, mm. (inches)
1500 RPM 1800 RPM 2100 RPM 2400 RPM
Table 12 - HP300S Side Load Capacity Values

“S” Dimension
127.0 mm. 152.4 mm. 177.8 mm. 203.2 mm. 228.6 mm. 254.0 mm.
RPM 5.0 inches 6.0 inches 7.0 inches 8.0 inches 9.0 inches 10.0 inches
N 47149 52931 60493 65385 56934 50485
1500
Lbs. 10600 11900 13600 14700 12800 11350
N 44480 50040 56834 61827 54043 47816
1800
Lbs. 10000 11250 12800 13900 12150 10750
N 42478 47816 54488 59158 51597 45814
2100
Lbs. 9550 10750 12250 13300 11600 10300
N 40744 45814 52486 56934 48595 44035
2400
Lbs. 9160 10300 11800 12800 11150 9900

Allowable Side Loads HP600S
Side Load Chart - HPTO 600S
22000
20000
Maximum Load, Lbs.
18000
16000
14000
127.0 (5.0) 152.4 (6.0) 177.8 (7.0) 203.2 (8.0) 228.6 (9.0) 254.0 (10.0) 279.0 (11.0)
"X" Distance, mm. (inches)
"1200 RPM" 1800 RPM 2100 RPM
Table 13 - HP600S Side Load Capacity Values

“S” Dimension
127.0 mm. 152.4 mm. 177.8 mm. 203.2 mm. 228.6 mm. 254.0 mm. 279.0 mm.
RPM 5.0 inches 6.0 inches 7.0 inches 8.0 inches 9.0 inches 10.0 inches 11.0 inches
N 79619 87181 96966 97856 90274 82510 74726

1200
Lbs. 17900 19600 21800 22000 20700 18560 16800
N 70278 77396 56834 87626 82288 73837 66720
1800
Lbs. 15800 17400 19300 19700 18500 16600 15000
N 67165 73837 54488 83622 78730 70723 64051
2100
Lbs. 15100 16600 18400 18800 17700 15900 14400

Lubrication
Refer to Engineering Drawings and figure 23 below for location of fittings.
Grease Specifications (rear-straddle type - HP300S & HP600S)
NLGI grades 0, 1, or 2 with allowable continuous use up to 135o C.

(275o F.) are acceptable. Recommended greases include Mobilgrease
XHP 222, Mobilgrease CM-S, Mobilux EP-2 or equivalent.
Grease Specifications (rear-straddle type - HP300S & HP600S)
Add 1cc every 10 hours of use. See figure 23 for location of grease fitting.
Lubrication Point
Hydraulic PTO (Rear StraddleType)
Enlarged View Lubricate the rear

(Typical) Main Bearing (grease)
Side View (Typical) Rear View (Typical)
Figure 23. Location of lubrication points

Note: The remaining portion of the HPTO Straddle-Bearing

unit is oil-lubricated. HPTO In-Line units are oil-
lubricated and require no grease lubrication.
Oil Specifications
See specifications contained in Description and Specifications section.
Oil System
Oil Level
The customer supplied sump oil level should be checked daily or every 10
hours. A dipstick or sight glass is the preferred means of checking oil level.
Oil and Filter Change Interval

With a new unit, change the oil and filter element within the first 50 hours of
operation. Change oil and filter element after each 1000 hours thereafter or
more often if conditions warrant. The oil and filter should be changed every six
months if less than 1000 hours has accumulated since the last oil change.
For a repaired unit, check the filter element after eight hours of operation. If the
filter is clean, install a new filter element and then change the oil and filter element
after 1000 hours of service. If the filter is dirty, change the element and operate
for another eight hours. Check the filter again. Continue this cycle until the filter
is clean and then change the oil and filter after 1000 hours of service or more
often if conditions warrant.
Oil Suction Strainer

Remove and clean the pump suction strainer at every oil change or sooner if
necessary. The suction strainer is customer provided, and should be located
in the suction line near the sump.

Torsional Coupling
1. Do not obstruct the flywheel housing vents preventing the free flow of air
for cooling the coupling. The ambient temperature of the air around the
coupling should be between -6oC. (22oF.) and 80oC. (176oF.). Assure
baffles are installed properly so hot air is ported out of the housing.
2. Visually inspect the element after the first 100 hours of operation and
every 2000 hours thereafter, or every six months, whichever comes first.
Torsional vibration, misalignment, degradation by contaminants (oil),
heat, ultraviolet radiation, and excessive system torque can cause cracks
or other signs of distress to appear on the surface of the rubber. The
above-described items affect the life of the coupling element.
When inspecting the flexible coupling, look for evidence or conditions

identified in the following steps:
A. Cracks in the surface of the rubber. May be caused by torsional

vibrations, excessive misalignment or exposure to contaminants
(heat, petroleum products, chemicals, ozone, ultraviolet radiation,
etc.) excessive system torques.
B. Deterioration of the rubber element, as evidenced by sponginess

or by black carbon-like dust on rubber surface. May be caused
by contaminants or excessive heat, either external or internal to
the coupling.
C. Cracked, bent or otherwise damaged flex plate or coupling plate.
D. Bolt holes in flex plate or coupling plate are elongated oval

shaped, not round. This could be caused by improperly
assembled parts, loose parts, vibration or improperly torqued
parts.
E. Bolts/nuts—bent, worn or stripped threads.
3. Inspect the hub, looking for the following:
A. Damaged or worn splines.
B. Cracked parts.
4. Replace any defective parts including defective fasteners that are found.

Overhaul Interval
A complete overhaul of the unit should be made at the same time that
the engine is overhauled.
Periodic Visual Inspection
1. Check the mountings for tightness or damage such as cracks.

Tighten loose mountings and replace damaged parts.
2. Check pressure and temperature gauge where applicable.
3. Inspect the oil lines and heat exchanger for leaky connections,
cracks, or other damage. Replace damaged lines.
4. Periodically, inspect the drive line and the input and output shaft
oil seals for leakage. Replace parts as required.

Deflection Alignment Adjustment
1. Proper alignment of an engine and the Hydraulic Power Take Off is

critical, both during the initial installation and following the reinstallation
after removal for servicing. The following steps may be taken to secure
proper power take off alignment.
2. When reinstalling a Hydraulic Power Take Off after a repair, or when

installing a new Hydraulic Power Take Off to an engine already mounted
in the bed rails, the flywheel housing should be checked for deflection
using the following procedure:
3. Install the mounting brackets on the side mounting pads of the Hydraulic
Power Take Off. Install the driving ring on the engine flywheel. Bolt an
indicator to the engine block and set the indicator stem on the engine
flywheel housing
Support plate
Figure 24. Hydraulic Power Take Off Alignment (In-line version illustrated)
4. Set the indicator gauge at zero (0). Lift the Hydraulic Power Take Off
with a hoist, or other suitable means, and place the unit in position against
the engine flywheel housing. Secure the flange of the Hydraulic Power
Take Off housing to the engine flywheel housing.

5. Use a feeler gauge between each mounting bracket and engine bed
rail. Add shims between the brackets and bed rails to equal the feeler
gauge readings.
6. Carefully release the lifting force on the Power Take Off while observing
the indicator. The indicator gauge must remain steady at the zero mark.
Torque the mounting bracket to bed rail bolts to the proper rating. If the
reading moves from zero, lift the Hydraulic Power Take Off and insert
additional shims.
7. Continue this procedure until the Hydraulic Power Take Off is completely
at rest on the bed rails and the gauge maintains a steady zero reading.
8. After obtaining the correct zero reading, indicating no distortion of the

engine flywheel housing, secure the mounting brackets to the engine
bed rails.
Verify the PTO is properly lubricated prior to starting the engine. All
bearings within the main unit are oil lubricated, supplied by the oil charge
pump feeding the HPTO. Be sure to check oil pressures in accord with
Table 2 in the Description and Specifications section of this manual.
The rear main bearing of HP300S and HP600S (straddle bearing designs)
are lubricated by grease and have a hydraulic (“zerk”) grease fitting.
See Lubrication in the Maintenance section for more information.

Alignment - U-Joint-Type Installation
Refer to figure 25 on next page.
To realize the longest possible life of the power take-off bearings, the best
possible alignment must be maintained between the center line of the power
take-off shaft and the center line of the driven unit shaft.
1. It is extremely important that the forks of the drive shaft between the pto
and the driven unit lie in the same plane. This will prevent severe
vibrations from occuring in the drive shaft.
2. The center lines of the pto shaft and the driven unit input shaft must be
offset within the limits recommended by the u-joint manufacturer to
prolong the life of the universal joint needle bearings.
3. It is extremely important that the center lines of the pto shaft and driven
unit input shaft be parallel. This will further prevent vibrations which cause
premature pto bearing failure.
4. Proper lubrication of the pto is important for satisfactory service. Refer

to lubrication specifications in the Maintenance section.
Align the centerlines of the pto shaft and the input shaft of the driven
unit. (One possible method is described below.)
5. To align the engine and gear head by this method, two accurate straight
edges at least 91 cm. (36”) long and a tape measure are required.
6. Place the straight edges horizontally along the face of the pto and gear
head hubs. Measure distances A and B. These two distances should
be equal within 3.17 mm. (.125”) at a point 45.7 cm. (18”) from the
centerline of the shaft. Move the engine and/or driven unit to obtain this
specification.
7. Rotate the shafts so the straight edges are in a vertical position. Measure
the distances C and D as was done for A and B in step 2. These two
distances should be equal within 3.17 mm. (.125”) at a point 45.7 cm.
(18”) from the centerline of the shaft. Move the engine and/or driven unit
to obtain this specification.

PTO Vertical Position

Horizontal Position
Engine 45.7cm C
(18”) Fork Parallel Centerlines
A
45.7cm
(18”)
Fork
D Driven
Unit
Figure 25. Alignment - U-Joint-Type Installation
8. Secure the engine and driven unit. Recheck A and B, C and D as

described in steps 5 through 7 above. All measurements must be within
the specifications. If not, repeat steps 5 through 7 until specifications
are met.


Twin Disc, Incorporated Disassembly
Disassembly
Power Take-off Removal From The Engine
Refer to the exploded view illustrations near the back of this manual.
1. Disconnect all electrical and electronic connections. Remove all oil hoses
and cap all open fittings to prevent oil from leaking out. Remove all
attached parts from the output end of the power take-off.
Models HP300S and HP600S: (Models HP300I and HP600I skip to step
13.)
2. Remove the support plate from the output end of the power take-off.
3. Attach lifting equipment to the belt sheave housing (46) and take out the
slack just enough to begin to support the weight of the housing. Do not
apply too much force.
Lifting devices and their capacity must be capable of supporting the

weight of the power take-off and all attached devices and equipment.
Suspend the pto with the lifting devices securely attached at 3 positions
(minimum) so it remains with the main drive shaft in a horizontal position
until it is safely lowered and resting on a secure bed.
4. Remove the hex-head capscrews (53) securing the rear bearing retainer
(50) to the belt sheave housing (46). Remove the rear bearing retainer
with the grease fitting (49).
Models HP300S only: (Model HP600S skip to step 9.)

5. Remove the snapring (52) from the output shaft (12).
6. Remove 12 hex head screws (47) securing the belt sheave housing
(46) to the clutch housing (37).
7. Separate the sheave housing from the clutch housing (37), slide it off
the shaft and set it aside. The roller bearing (51) will be removed with
the sheave housing.
8. Remove the roller bearing (51) from the sheave housing. (Proceed to
step 12.)
Disassembly Twin Disc, Incorporated
Models HP600S only:

9. Remove 12 hex head screws (47) securing the belt sheave housing
(46) to the clutch housing (37).
10. Separate the sheave housing from the clutch housing (37), slide it off
the shaft and set it aside. The outer race of the spherical roller bearing
(51) will be removed with the sheave housing.
11. Remove the outer race (51) from the sheave housing. (Proceed to step
12.)
Note: The inner race of bearing (51) will be removed later, if it

must be replaced.
Models HP300S and HP600S

12. Remove the belt sheave (customer component) and the output key (55).
(Proceed to step 13.)
All Models:
13. Attach lifting equipment to the power take-off and take out the slack just
enough to begin to support the weight of the pto. Do not apply too much
force.

weight of the power take-off and all attached devices and equipment.
Suspend the pto with the lifting devices securely attached at 3 positions
(minimum) so it remains with the main drive shaft in a horizontal position
until it is safely lowered and resting on a secure bed.
14. Remove all bolts, brackets and devices supporting the power take-off
to the bed frame.
15. Remove the bolts securing the coupling housing (2) to the engine.
16. Carefully pull the hydraulic power take-off back from the engine and move
to the disassembly area.
17. Remove the bolts securing the flexible coupling (1) to the flywheel.
Remove the coupling.
18. Do not remove the internal snapring (10) from the I.D. of the coupling
spline unless visible damage has occured.

Remove and disassemble the GP Control Valve
Refer to the parts list and exploded view illustrations.
1. Support the power take-off on a bench with the GP control valve up. Use
fixtures or blocks under the power take-off to secure the unit in position.
2. Remove six hex head capscrews (113) securing the (top) valve body
(134) to the main regulator (center) valve body (115). Remove the valve
body and the gasket (114).
3. Remove four socket head capscrews (127) securing the main regulator
valve body (115) to the ditch plate (131). Remove the valve body and
the gasket (133).
4. Remove the 6 socket head capscrews (130) securing the ditch plate
(131) to the clutch housing (37). Remove the ditch plate and ditch plate
gasket (137).
Note: Do not remove the ditch plate unless visible damage has
occured.
5. Remove the socket head capscrew (123) and lock plate (122) and
remove the proportional valve assemblies (125) from the valve body.
6. Remove plug (126) from the valve body.
7. Using a wrench on the hex body of the hydraulic relief valve (124), remove
it from the valve body.
Alternate design center section.
8. Remove four hex head capscrews (146 & 154) from the covers. Remove
the covers (145 & 153), hex nut (155), piston (152), spool (147), springs
(149 & 150), washer (148) and o-ring (151).
9. Remove the filter (142) and valve (143) from the valve body (115).
10. Remove all remaining plugs, fittings, gaskets and o-rings.

Remove the Coupling Housing, and disassemble the Gear Towers
Remove the coupling housing.

1. Remove 13 hex head capscrews (5) and remove the coupling housing
from the front housing (6).
Disassemble the first tower.
Note: The gear towers may be configured to utilize one, two,

three or four of the available drives. Those drives not used
will be covered with steel plates and gaskets. the
procedure below describes a typical gear tower
configuration. The HPTO you are working on may be
different, but the procedure will remain approximately the
same for all configurations.
2. Remove all pipes and fittings from the gear towers.
3. If a pump is mounted on the tower, remove 4 hex head capscrews (102)

and pull the pump (109) and gasket (101) from the tower.
4. If there is no pump mounted on the tower, remove 4 hex head capscrews

(102) and remove the cover (104) with gasket (101) from the tower.
5. Remove 6 hex head capscrews (99) with copper washers (100) and
remove the SAE mounting plate (98) with plate gasket (97) from the
tower.
6. Remove the driven gear (103) with ball bearings (96 & 105 ) from the
housing.
7. Remove 4 hex head capscrews (95) and remove the cover (93) with
cover gasket (92) from the other side of the tower.
tower.
9. Using a bearing puller, remove the ball bearings ( 96 & 105) from the
driven gear (103).

Disassemble the second tower (in the same manner as steps 2 through 9).
10. If a pump is mounted on the tower, remove 4 hex head capscrews (102)
and pull the pump (109) and gasket (101) from the tower.
11. If there is no pump mounted on the tower, remove 4 hex head capscrews
(82) and remove the cover (94) with gasket (81) from the tower.
gear tower.
13. Remove the driven gear (83) with ball bearings (76 & 84) from the
housing.
14. Remove 4 hex head capscrews (75) and remove the cover (74) with
cover gasket (73) from the other side of the tower.
tower.
16. Using a bearing puller, remove the ball bearings ( 76 & 84) from the
driven gear (108).

Remove the Front Housing from the Clutch Housing
1. Position the HPTO with the front housing up.
2. Remove 12 hex head capscrews (4) securing the front housing to the
clutch housing (37).
3. Using a hoist, carefully lift the front housing off the unit.
Do not damage the idler gear (58), nor the splines of the gear and drive
rings assy. (9) when the housing is being removed.
4. Remove the housing gasket (56).
Remove the idler gear

5. Remove pipe plug (67) and drive out the dowel pin (66).
6. Remove three 12 pt. capscrews (68) from the housing and idler gear.
7. Remove the idler gear (58) with the bearing carrier (65), bearing (63),
shims (57) and other components from the housing.
8. Remove 4 hex head capscrews (62), 4 hex head capscrews (60), and
the idler gear washers (61 & 59) from the idler gear (58).
8. Remove the bearing carrier snapring (64) from the bearing carrier (65).
9. Press the bearing carrier out of the idler gear.

Disassemble the Clutch Housing
1. Remove pipe plug (3) from the input end of the gear and drive ring assy.
(9).
2. Using a hoist and eyebolts, lift off the gear and drive ring assy.
Note: The cylindrical bearing (11) outer race will be removed

with the gear and drive ring assembly. The cylindrical
bearing’s inner race will stay with the shaft.
3. Remove the cylindrical bearing (11) outer race from the gear and drive
ring assy. (9).
4. Using a bearing puller, remove the outer race of cylindrical bearing (11)
from the shaft.
5. Remove the external snapring (15) from the shaft.
6. Lift off the clutch hub (16).
7. Lift off the stack of clutch friction plates (18) and steel clutch plates (17).
8. Using a hoist and eyebolts, lift off the clutch piston (22). The piston carrier
(20) and back plate (26) will be lifted off at the same time.
9. Locate and dowel pin (33), which is located in the pocket of the shaft
between the piston carrier and the shaft.
10. Turn the clutch piston over on a bench. Remove the internal snapring
(25) from the clutch piston.
Note: The 9 springs (23) may have to be compressed to allow

removal of the snapring.
11. Support under the piston carrier. Using a soft mallet, carefully tap the
clutch piston down off the carrier.
12. Remove the back plate (26), 9 springs (23) and o-rings
Note: Do not remove the 3 anti-rotation pins (29) unless

damaged.

13. Remove the last friction plate (28).
14. Do not remove the 3 dowel pins (27) unless they are damaged.
15. Turn the clutch housing unit over. Securly support the clutch housing unit
with the output end of the shaft up.
Models HP300S and HP600S only: (Models HP300I and HP600I skip to
step 30.)
16. Remove 6 hex head capscrews (43) and remove the front bearing
retainer (44) with the oil seal (45).
17. Remove the oil seal (45) from the retainer.
18. Remove the retainer gasket (40).
Model 300S only: (Models HP600S skip to step 25.)

19. Remove the spacer (41) and second retainer gasket (40).
20. Attach a hoist to the end of the shaft. Lift the shaft out of the clutch housing.
The spherical bearing (38) will be removed with the shaft.
21. Remove 4 seal rings (34) from the shaft (12).
22. Remove the snapring (35) and the bearing spacer (36) from the shaft
(12).
23. Place the shaft and bearing in a press with press with the input end up
and plates supporting beneath the inner race of the spherical bearing.
Press the shaft out of the bearing.
24. Remove the pipe plug (39) and pipe plug (48) from the clutch housing
(37).
Note: Remove the pipe plug (39) ONLY to clean the passageway
in the event a catastrophic failure has occurred within the
HPTO.
Note: Do not remove the dowel pins (42), the housing spacer
(140) or dowel pins (141) unless they are damaged.
Models HP600S only:

25. Remove inner race of bearing (51) from the end of the clutch shaft (12).
Note: Remove the bearing race ONLY if it must be replaced.

The inner race of bearing (38) will be removed with the shaft.
28. Place the shaft and bearing in a press with press with the input end up
and plates supporting beneath the inner race of the bearing. Press the
shaft out of the bearing.
29. Remove the pipe plug (39) and pipe plug (48) from the clutch housing
(37).
Note: Remove the pipe plug (39) ONLY to clean the passageway
in the event a catastrophic failure has occurred withing
the HPTO.
Note: Do not remove the dowel pins (42), the housing spacer
(140) or dowel pins (141) unless they are damaged.
Models HP300I and HP600I only:

30. Remove 6 hex head capscrews (47) and remove the front bearing
retainer (46) with the oil seal (45).
31. Remove the oil seal (45) from the retainer.
32. Tap the bearing outer race (38) out of the retainer bore.
The double cup bearing assembly (38) will be removed with the shaft.
35. Using a small chisel, bend the tab(s) of the bearing lock washer (110)
out of the slot (s) of the bearing lock nut (111).
36. Remove the bearing lock nut.
37. Remove the double cup bearing (38), including 2 cups, 2 cones and the
spacer from the shaft


Twin Disc, Incorporated Cleaning and Inspection
Cleaning and Inspection
Cleaning and Inspection
Note: Replace all oil seals, gaskets, o-rings, piston rings, seal
rings, snap rings, etc. as a part of any maintenance or
overhaul procedure. Replace shims that are damaged or
destroyed in disassembly.
General.
1. Clean all parts using EPA/OSHA-approved solvents or by steam

cleaning. Parts must be dried and oiled immediately.
Note: Do not steam clean clutch friction plates. If they are worn
beyond use, replace them.
2. Examine all parts carefully for grit, dirt and abrasives and reclean them
if necessary.
3. Clean all oil passages by working a piece of wire back and forth through
them, and then flushing them with cleaning solvent.
4. Use clean solvent to flush oil pumps, valves, etc.
5. Flush all hoses, tubing, coolers, etc. particularly if the unit is being
disassembled because of an internal failure.
6. De-burr the housing and bearing carrier with a stone or file in the vicinity
of all pusher screw locations.
7. For previously sealed joints and joint surfaces, scrape surfaces to remove
old gasket material or sealant.
8. Clean surfaces with solvent to remove oil and grease residue.
9. Test for clean surfaces by applying a few drops of cool water to the
surfaces. Parts are sufficiently clean if water covers the surface in a film.
If the water puddles or forms beads, use fresh solvent and reclean. These
reactions indicate presence of an oil or other lubricant film.
Cleaning and Inspection Twin Disc, Incorporated
Bearings.
Note: Twin Disc, Inc. recommends replacing all used bearings

as a normal practice during repair or rebuild of the HPTO.
However, if the bearing will be reused, the following
provides pertinent information prior to the bearing’s reuse.
10. Thoroughly wash bearings in clean solvent if they have been in service.
Soak bearings in solvent if they are particularly dirty.
If a permanently-sealed bearing is used, never soak it in solvent.

(Permanently-sealed bearings were not originally used in the HPTO
design, but later engineering changes may have incorporated their use.)
Never dry bearing with compressed air. Do not spin bearings while they
are not lubricated. Oil bearings with SAE 10 engine oil immediately after
cleaning. Be sure bearings are oiled before inspection. Protect clean
bearings, whether they are new or have been in service, from dirt, dust,
grit or any other contaminant.
11. Inspect bearings for roughness of rotation. Replace the bearing if

roughness is found.
12. Inspect bearings for corrosion, scored, scratched, cracked, pitted or

chipped races, and for indication of excessive wear of balls or rollers. If
one of the these defects is found, replace the bearing.
Preventing Entrance of Dirt Into Bearings.
13. Dirt and grit in bearings are often responsible for bearing failure.
Consequently, it is important to keep bearings clean. Do not remove
grease from new bearings. Keep the wrapper on new bearings until
immediately before they are to be installed. Do not expose new clean
bearings until they are ready to be used in the assembly. Keep them
wrapped in clean lint-free cloth or paper to keep out dust and debris.
Protect bearings from contamination even after they are installed on the
shaft or in the bore.

Housings, Cast Parts and Machined Surfaces.
14. Replace cast parts or housings that are cracked.
15. Inspect bearing bores for grooved, burred or galled conditions that would
indicate that the bearing has been turning in its housing. If the damage
cannot be repaired to like-new condition with a fine crocus cloth, replace
the part. Bore diameters must not exceed the maximum dimension
shown under wear limits in the Description and Specifications
16. Inspect bearing journals for grooved, burred or galled conditions that
would indicate that the bearing inner race has been turning on the journal.
If the damage cannot be repaired to like-new condition with a fine crocus
cloth, replace the part. Bearing journals must not be less than the
minimum diameters shown under wear limits in the Description and
Specifications section of this manual.
17. Inspect oil passages for obstructions. If an obstruction is found, remove

it with compressed air or by working a wire or wire brush back and forth
through the passage and flushing it with solvent.
18. Inspect machined surfaces for burrs, nicks or scratches that have
material that extends above the surface, and foreign matter. If such
defects cannot be removed with crocus cloth or a soft stone, replace the
part.
19. Inspect threaded openings for damaged threads. Chase damaged

threads with a tap of the correct size.
20. Inspect dowel pins and dowel pin holes for wear or damage. Replace
defective dowels. If a dowel pin hole is worn, re-bore and sleeve the
hole when possible. If this cannot be done accurately, replace the part.
Note: This applies where a matched set of parts is not involved.
Shafts, seal lip contact surfaces and bearing journals.
21. Inspect bearing journals for grooved, burred or galled conditions that
would indicate that the bearing inner race has been turning on the journal.
If the damage cannot be repaired to like-new condition with a fine crocus
cloth, replace the part. Bearing journals must not be less than the
minimum diameters shown under wear limits in the Description and

22. Inspect seal ring and seal lip contact surfaces. Look especially for
scratches or nicks that intersect with or cross the contact area. If they
cannot be removed using a very fine crocus cloth, replace the part. Seal
contact area diameters must not be less than the minimum dimension
shown under wear limits in the Description and Specifications
23. Be sure the seal ring grooves and snapring grooves have straight sides,
especially if a bearing failure has occurred. See figure 27.
Straight sides Damaged Wall
Undamaged Groove Damaged Groove
Figure 27. Inspect sealring grooves and snapring grooves
24. Inspect threaded openings for damaged threads. Chase damaged

threads with a tap of the correct size.
Valve Seats.
25. Inspect valve seats for burrs, nicks and scratches. If they cannot be
removed with very fine crocus cloth, replace the part. Check to be sure
that the valve is seating properly after reworking the valve seat.
Splined parts.
26. Inspect splines for stripped, twisted, chipped or burred splines. Remove
burrs with a soft stone. If wear exists on the sides of the tooth, replace
the part. Replace the part if other defects are found.
Springs.
27. Inspect the springs for broken or distorted coils. Replace the spring if
these or other defects are found.

Clutch Plates.
28. Inspect clutch plates, both friction plates and steel plates, for signs of
overheating, pitting or excessive wear. Plates must be flat, not dished,
distorted or bent. Inspect the steel clutch plates for wear on the external
teeth. If wear exists on the sides of the tooth, replace the part. Replace
the plates if these or other defects are found.
Gears.
29. Inspect gears for scuffed, nicked, burred or broken teeth. Inspect gear
teeth for wear that may have destroyed the original tooth shape. Inspect
internal bores or splines for wear or damage. If these or other defects
cannot be removed with fine crocus cloth or a soft stone, replace the
gear.
Flexible Hoses.
30. Inspect all hoses for cracks and sponginess. Replace damaged hoses.
Pipes and Pipe Fittings
31. Inspect all metal pipes for cracks and damage. If the pipe has been
distorted or bent, especially if it has a crease or sharp bend in it, replace
the pipe. Replace damaged pipe plugs or pipe fittings that have been
damaged. Inspect for stripped threads and broken fittings. Replace all
damaged parts.


Twin Disc, Incorporated Assembly
Assembly
Assembly Hint:
Several components must be heated in an oven at 121° C. (250°
F.) for one hour prior to assembly. Other components must be
frozen in a freezer or dry ice for one hour prior to assembly. It is
recommended that these components be prepared (heated or
frozen) in advance of beginning the assembly process to avoid
costly delays. Those components are:
To be heated:
(HP300S & HP600S only).
Inner race of bearing (38). See figure 29.
(HP300I & HP600I only.)

Bearing (38). See Assembly step #10. (Clutch housing)
(HP600S only).
(HP300S, HP600S, HP300I & HP600I).

Bearing (8). See figure 83.
To be frozen:
(HP300S & HP600S only).
Dowel pins (42). See figure 40.
(HP300S, HP600S, HP300I & HP600I).

Dowel pin (66). See figure 95

Assembly Twin Disc, Incorporated
Clutch Shaft and Clutch Housing Assembly
Clutch housing.

1. Position the clutch housing (37) so the bearing bore (output end) is up.
HP600S only: (HP300S-skip to step 6, HP300I & HP600I-skip to step 10.)

2. Tap or press the bearing outer race (38) straight into the bore with the
back end of the bearing up. See figure 28. (Proceed to step 3.)
Be sure to tap or press only on the outer race of the bearing. Do not
Bearing
contact the rollers. If the rollers become damaged, replace the bearing.
Figure 28. Install the bearing in the clutch housing (HP600S)
Clutch shaft.
HP600S only
3. Clean the bearing race I.D. (38) and clutch shaft (12) with EPA/OSHA-
approved solvent to remove any oil or grease residue.
4. Position the clutch shaft (12) with the input end up.

5. Heat the inner race of the bearing (38) in an oven at 121° C. (250° F.) for
one hour and install it immediately on the clutch shaft. Install the race
from the input end of the shaft. See figure 29. The wide end of the
bearing race must rest tightly against the shoulder of the shaft. Let the
bearing race cool to room temperature after installation while continuing
to apply downward force as it cools. This is necessary to ensure that it
remains properly seated. (Proceed to step 18.)
Note: An alternate method to install the bearing race is to use

an arbor press to install the inner race of bearing (38) on
the clutch shaft (12). Use a flat plate on top of a piece of
steel tubing approximately 25 cm. (10 inches) long. The
inside diameter of the tube must be just slightly larger than
the O.D. of the bearing journal on the shaft. Press the race
straight onto the shaft until it stops solidly against the shaft
shoulder.
Small end
of race.
Wide end
of race.
Figure 29. Install the bearing inner race on the shaft.
HP300S only:
6. Clean the bearing (38) and clutch shaft (12) with EPA/OSHA-approved
solvent to remove any oil or grease residue.
7. Heat the bearing (38) in an oven at 121° C. (250° F.) for one hour and
install it immediately on the clutch shaft. Install the from the input end of
the shaft. Let the bearing cool to room temperature after installation
while continuing to apply downward force as the bearing cools. This is
necessary to ensure that it remains properly seated.
Note: An alternate method to install the bearing (38) is to use

an arbor press to install it on the clutch shaft (12). Use a
flat plate on top of a piece of steel tubing approximately

27 cm. (10.5 inches) long. The inside diameter of the tube

must be just slightly larger than the O.D. of the bearing
journal on the shaft. Press the bearing straight onto the
shaft until it stops solidly against the shaft shoulder.
8. After the race has cooled, install spacer (36) resting against the race.
9. Securely install the snap ring (35) in the groove against the race.
(Proceed to step 18.)
Note: Prior to installation, feel the two edges of the I.D. of the
snap ring to locate the sharpest edge. Install the snap ring
so that sharpest edge is toward the input end of the shaft,
away from the bearing and spacer.
Be sure the snap ring is completely and securely seated

all the way around the groove.
HP300I and HP600I only:

10. Support the clutch shaft (12) with the output end up. Heat the bearing
(38) in an oven at 121° C. (250° F.) for one hour.
Note: The bearing (38) used in HP300I and HP600I is a double

-cup assembly. The components are furnished in matched
sets. Do not mix or substitute components from other
bearings.
11. Quickly and carefully install the bearing cone, then a bearing cup,
followed by the bearing spacer, a second bearing cone and the second
bearing cup on the shaft. Immediately install the bearing lock washer
(110) and the bearing lock nut (111) on the shaft and securely tighten it
against the bearing. This is necessary to ensure that it remains properly
seated tightly against the shoulder on the shaft while it is cooling to room
temperature. Periodically retighten the nut to continue to apply downward
force as the bearing cools.
12. After the bearing has cooled to room temperature, usually requiring
several hours, the nut must again be retightened. Using a spanner wrench
or a large chisel and mallet, tighten the nut further.

13. Use a .0381 mm. (.0015”) feeler gage to insure there is no gap between
the bearing’s inner race and the shaft shoulder. Check all around the
circumference of the shoulder. The feeler gage must not fit anywhere in
the gap.
Note: If the feeler gage reveals that the bearing is not tightly
seated against the shoulder, the nut must be tightened
more or the bearing must be seated in a press, using a
heavy metal tube with an I.D. just slightly larger than the
diameter of the shaft to press the bearing down further
and eliminate the gap.
The tube must press only against the inner race of the bearing.
14. Next use the .0381 mm. (.0015”) feeler gage to insure there is no gap
on either side of the bearing lock washer, between the lock washer and
the upper bearing cone, or between the lock washer and lock nut. Again,
check all around the circumference and use a spanner wrench or a large
chisel and mallet to tighten the nut to eliminate both gaps, if they exist.
15. When it is insured that no gap exists in any of the three locations
described above, find the lock washer tab that most closely aligns in the
middle of one of the four notches in the lock nut. Matchmark the tab and
it nearest slot.
16. Tighten the nut a partial turn more, just until a different notch
becomes aligned with a tab.
17. Using a hammer and chisel, carefully bend that tab of the bearing lock
washer (110) up into the notch of the bearing lock nut (111). (Proceed to
step 18.)
18. Install four seal rings (34) in the grooves of the shaft. See figure 30.
Lubricate the seal rings with an assembly lubricant to help prevent
breakage when the shaft is installed into the clutch housing later in this
procedure.

Figure 30. Install the seal rings on the shaft
Note: After installation, rotate the seal rings in the grooves so

the split lines of adjacent seal rings are 180o apart. See
figure 31.
Split lines must

be 180o apart. Split lines must
be 180o apart.
Figure 31. Position the seal rings in the grooves

19. Position the clutch housing (37) so the bearing bore (output end) is up.
Lubricate the seal ring bore of the housing to help prevent damage to
the seal rings (34) as the shaft is installed into the housing.
20. Using lifting equipment attached to the output end of the clutch shaft
(12) lower the shaft unit into the clutch housing, taking special precautions
to prevent damage to the seal rings (34) as they enter the housing bore.
See figure 32. Gently lower the shaft until it stops.

weight of the item being lifted.

Note: HP600S: the shaft will be stopped when the bearing races
come in contact with each other.
HP300S: the shaft will be stopped when the bearing (38)

seats in the housing bearing bore.
HP300I and HP600I: the shaft will be stopped when the

bearing race stops in the clutch housing bore.
Lubricate seal Do not damage

rings to prevent seal rings.
damage during
assembly.
(Model HP300S
is shown in
illustration.)
Figure 32. Install the shaft in the clutch housing.
21. Install the (orifice) plug (48) in the clutch housing threaded hole
immediately adjacent to the O.D. of the bearing (38). Install plug (39) in
the housing if it was previously removed. See figure 33.
Pipe Plug (48)
Pipe Plug (39)
Figure 33. Install the orifice plug (48) and plug (39) in the clutch housing.
HP600S and HP300S only: (HP300I & HP600I-skip to step 27.)

22. Install oil seal (45) in the front bearing retainer (44). Coat the O.D. of the
seal with sealant M2828 before installation. Rest the oil seal in the
bore; the seal lip should be down, with the outer shell of the oil seal up.
See figure 34. Use a flat steel plate slightly larger in diameter than the
O.D. of the seal. Using the flat plate on top of the seal, press the seal
straight into the bore until the steel plate stops against the surface of the
carrier. The rear of the outer shell of the seal should be flush with the
surface. Pre-lubricate the seal lip with clean No. 30 engine oil.
Note: Press only against the outer shell of the seal. Do not
damage the seal lip.
Flat plate
Flat plate will stop Oil seal (45)

against back of
Bearing
bearing carrier.
retainer (44)
Figure 34. Install the oil seal in the bearing carrier (HP300S & HP600S).
23. Place gasket (40) in position on the clutch housing. See figures 35 &
36.
The gasket must be positioned so the notch in the gasket is aligned

with the (orifice) plug (48). See figures 35 & 36. THE ORIFICE IN THE
PLUG MUST NOT BE COVERED, which would prevent lubricating oil
flow to the bearing.
Align the notch

with the orifice
fitting (48).
Figure 35. Install the gasket with the notch aligned with the orifice.

Align the notch

with the orifice
fitting (48).
Figure 36. Install the gasket with the notch aligned with the orifice.
HP300S only: (HP600S-skip to step 26.)

24. Place the spacer (41) on top of the first gasket (40). Again, align the
notch with the notch in the gasket and the orifice fitting.
25. Place a second gasket (40) on the spacer. Align the notch as described
above. (Proceed to step 26.)
HP600S and HP300S only:

26. Place the bearing carrier (44) on top of the gasket, install 6 hex head
capscrews (43) to secure the bearing carrier to the clutch housing. See
figure 37. Torque the capscrews to the proper specifications given in
Torque Values for U.S. Fasteners in the Description and
Do not cut the seal lip as is passes over the keyway of the shaft.
Figure 37. Install the bearing retainer (44) (HP300S & HP600S).

HP600I and HP300I only:

27. Install oil seal (45) in the bearing carrier (44). Coat the O.D. of the seal
with sealant M2828 before installation. Rest the oil seal in the bore; the
seal lip should be down, with the outer shell of the oil seal up. Use a flat
steel plate slightly larger in diameter than the O.D. of the seal. See figure
38. Using the flat plate on top of the seal, press the seal straight into the
bore until the steel plate stops against the surface of the carrier. The
rear of the outer shell of the seal should be flush with the surface. Pre-
lubricate the seal lip with clean No. 30 engine oil.
Flat Plate
Flat plate will stop Oil Seal (45)
against back of
Bearing
bearing carrier.
Carrier (44)
Figure 38. Install the oil seal in the bearing carrier (HP300I & HP600I).
28. Install the pipe plug (39) in the threaded hole near the bolt circle. See
figure 39. Install the shaft in the clutch housing.
Note: Check to be sure the plug is below the surface.
Pipe Plug (39)
Figure 39. Install the pipe plug (39).

29. Install the o-ring seal (132) on the groove on the pilot of the bearing
carrier. Lubricate the o-ring with assembly lubricant to help prevent it
from being damaged during assembly.
30. Using a hoist and lifting equipment, place the bearing retainer in position
on the shaft and clutch housing.
Use extreme caution to prevent damaging the o-ring and oil seal.
31. Install 6 hex head capscrews (47) to secure the bearing carrier (44) to
the clutch housing (37). Torque the capscrews to the proper specifications
given in Torque Values for U.S. Fasteners in the Description and

Belt Sheave Housing Assembly
HP600S and HP300S only:
Note: HP300I & HP600I do not use belt sheave housings.
Note: Freeze dowel pins (42), and dowel pins (141) if used, in
a freezer or dry ice for approximately 1 hour prior to
installation.
1. Multiple dowel pin holes are provided to allow orientation of the belt
sheave housing in any of several desired positions. If not already
installed, drive 2 dowel pins (42) in the appropriate dowel pin holes to
properly position the belt sheave housing for the application.
2. If used, install the housing spacer (140), locating it on the appropriate

dowel pins (42). See figure 40.
Housing
spacer
Figure 40. Install the housing spacer (140) (HP300S & HP600S).
3. Install two dowel pins (141) in the housing spacer, if used, locating them
in the same holes as dowel pins (42). Again, leave 1/2 of each dowel
pin protruding from the surface.

4. Using a hoist and lifting equipment, install the belt sheave housing (46)
on the clutch housing, carefully aligning it on the dowel pins (42 or 141).
See figure 41. Secure with 6 hex head capscrews (47). Tighten the
capscrews alternately and evenly. Torque the capscrews to the proper
specifications given in Torque Values for U.S. Fasteners in the
Description and Specifications section of this manual.
Belt
Sheave
Housing
Dowel Dowel
Pin (141) Pin (141)
Figure 41. Install the belt sheave housing (HP300S & HP600S).
HP600S only: (HP300S-skip to step 10.)

from the output end of the shaft. See figure 42. The wide end of the
bearing race must rest tightly against the shoulder of the shaft. Let the
bearing race cool to room temperature after installation while continuing
to apply downward force as it cools. This is necessary to ensure that it
remains properly seated.

Rear bearing
inner race
Figure 42. Install the output bearing race (HP600S only).
6. After the bearing inner race is cool, install the outer race of the output
bearing (38) in the bore of the belt sheave housing (46). Tap into the
bore but leave the race extending above the surface approximately 12.7
mm. (1/2”). See figures 43 & 44. It will be properly positioned when the
bearing retainer (50) is installed and securely bolted to the sheave
housing.
Note: Tap only against the outer race of the bearing. Do not
damage the bearing rollers.
Rear bearing
outer race
Figure 43. Install the output bearing race (HP600S).
Leave the
rear bearing
approx. 12.7
mm. (1/2”)
above the
surface.
Figure 44. Leave the output bearing extending out of the bore ( HP600S).
7. Place the rear bearing retainer (50) in position on top of the bearing,
aligning the bolt holes and orienting the grease fitting (49) at the top 12
o’clock position. See figure 45.
Rear
bearing
retainer
Figure 45. Install the rear bearing retainer ( HP600S).
8. Install 6 hex head capscrews (53) to secure the bearing retainer to the
sheave housing. Tighten the screws alternately and evenly to draw the
rear bearing race into the bore while the retainer is tightened against
the sheave housing. Torque the capscrews to the proper specifications
9. Install the grease fitting (49).
HP300S only:
10. Install the rear bearing (51) in the bore of the belt sheave housing (46).
Tap the bearing to the bottom of the bore. See figure 46.
Note: Tap only against the outer race of the bearing. Do not
damage the bearing rollers.
Figure 46. Install the rear bearing (HP300S ).

11. Install snap ring (52) in the groove on the shaft to retain the rear bearing
(51).
so that sharpest edge is toward the input end of the shaft,
away from the bearing and spacer.

12. Place the rear bearing retainer (50) in position on top of the bearing,
aligning the bolt holes and orienting the grease fitting (49) at the top 12
o’clock position. See figure 47.
Rear Hex Head

bearing Capscrews
retainer
Hex Head
Capscrews
Figure 47. Install the rear bearing retainer ( HP300S).
13. Install 6 hex head screws (53) to secure the bearing retainer to the sheave
housing. Tighten the screws alternately and evenly to tighten the retainer
against the sheave housing. Torque the capscrews to the proper
14. Install the pipe plug (54) in the threaded hole in the inside of the sheave
housing.
15. Install the grease fitting (49).

Clutch Assembly
HP300S, HP600S, HP600I and HP300I:

1. Turn the unit over so the front of the clutch housing is up. See figure 48.
Note:
Typical HP300S or
HP600S model is
illustrated.
Figure 48. Turn the unit over with the clutch housing up.
2. If 4 anti-rotation dowel pins (27) were removed, install them in the dowel
holes on the inside of the clutch housing. The dowels must be installed
with 10.92 mm. (.430 inches) max. extending above the surface of the
clutch housing. See figures 49, 50 & 51.
Note: Freeze dowel pins (27) in a freezer or dry ice for

approximately 1 hour prior to installation.

Anti-rotation
Installation tool Dowel Pins
with dowel pin
in place ready
to be installed.
Figure 49. Dowel pins (27) and installation tool.
10.92 mm. (.430”) Max. Clutch housing

surface
Dowel Pin
Figure 50. Position the dowel pin in the clutch housing hole.
Anti-rotation
Dowel Pin
Figure 51. Install 4 anti-rotation dowel pins (27).

3. Place 1 friction plate (28) inside the clutch housing (37) with the external
teeth meshing with the 4 dowel pins. See figures 52, 53, & 54.
Friction Plate
Figure 52. Install friction plate (28).
Dowel pin
Figure 53. Friction plate teeth aligned with dowel pins.
Friction plate
Dowel pin Dowel pin
Figure 54. Friction plate installed and aligned on dowel pins.

4. Install the pin (33) in the pocket in the side of the shaft. Stick the pin in
the groove using an assembly grease. The grease will hold the pin in
place during assembly. Mark the shaft with a black marker to indicate
the location of the pin during further assembly procedures. See figures
55 & 56.
Mark the
shaft.
Pin (36)
Assembly
Grease
Figure 55. “Stick the pin (33) in the hole of the shaft. Mark the shaft.
Be sure to
also
matchmark
the shaft near
the splines.
Figure 56. Matchmark the shaft in line with dowel pin (33).

Clutch Piston, Piston Carrier and Back Plate Unit.
Note: If previously were removed, freeze dowel pins (29) in a

freezer or dry ice for approximately 1 hour prior to
installation.
5. Position the piston carrier (20) with the notch down. Brace beneath the
carrier at a location just outside the 3 pin holes. When frozen, quickly
press three dowel pins (29) in the piston carrier (20). See figures 57 &
58.
Side without
the notch is
up.
Support just Press tight

outside the against the
dowel pin surface.
holes.
Figure 57. Install dowels in piston carrier.
Notch
Dowel is
installed from
the side
without the
notch.
Figure 58. Dowels installed from side opposite the notch.
6. Place the piston carrier in the clutch piston (22) (before the o-rings are
installed). The three dowels must enter the holes in the clutch piston.
See figure 59.
Note: The clutch piston is installed in the piston carrier before

the seal rings are installed ONLY for the purpose of
alignment and match-marking the parts. The seal rings
must be installed for final assembly.

Large end of
dowel pins
must enter
holes in the
piston.
Figure 59. Dowels must enter holes in the clutch piston.
7. Matchmark the piston carrier (20) and clutch piston (22) to facilitate later
assembly. See figure 60. (Before the o-rings are installed.)
Matchmark
the piston
carrier and
clutch piston.
Figure 60. Matchmark the clutch piston and piston carrier.
8. Remove the match-marked piston carrier from the clutch piston. Install
one seal ring (19) and one seal ring (21) on the piston carrier (20). Be
careful the seal rings are not damaged during installation. Lubricate the
seal rings with an assembly lubricant in preparation for further assembly.
See figure 61.
Note: Install the smaller of the seal rings in the groove on the
side opposite the notch.
Note: The remaining seal ring (19) will not be installed at this
time, to avoid damage that can occur during assembly.

Install one seal ring

(19) in the groove on
the piston carrier.
Do not install 2nd

seal ring here until
later in this assembly
procedure.
Install seal ring Notch.

(21) in the large
groove of the
piston carrier.
Figure 61. Install seal rings on the piston carrier.
9. Generously lubricate the bore of the clutch piston (22) and the seal rings.
Place the piston and piston carrier on the bed of a press. Perfectly
align the matchmarks and press the piston carrier in the clutch piston.
Press the piston carrier to the bottom of the bore. See figures 59 & 60.
10. Install the back plate (26) (before the seal ring (24) is installed, aligning
the dowel pin holes. Matchmark the back plate and clutch piston (22).
See note in step 8 above.
11. Now remove the back plate and install the 2nd seal ring (19). See figure
61.
12. Install the seal ring (24) in the external groove of the back plate (26). Be
careful the seal ring is not damaged during installation. Lubricate the
seal ring with an assembly lubricant in preparation for further assembly.
See figure 62.
Seal ring.
Back
Plate.
Figure 62. Install the seal ring on the back plate.

13. Install the nine springs (23) in the back plate (26). See figure 63.
Note: It is imperative that the springs “stick” in the holes. Use an

oil-soluble assembly grease to hold the springs in the
holes during assembly.
Use assembly Springs

grease to
“stick” the
springs in the
pockets. Seal ring
(24)
Figure 63. “Stick” the springs in the back plate.
14. Install the back plate (26) in the clutch piston (22), aligning the marks so
the dowel pins enter the 3 pockets. Press the back plate down as far as
it will go. Using a small arbor press, compress the springs until the back
plate is below the snap ring groove. See figure 64.
Note: If the dowels are not perfectly aligned with the holes in the
clutch piston, the back plate cannot be moved to a point
below the snap ring groove.
Do not damage the dowel pins or dowel pin holes in the clutch piston. If
excessive resistance is met while compressing the back plate into the
clutch piston, the dowels may not be properly aligned with the holes.
Relieve the pressure on the back plate, align the matchmarks and
reinstall. It may be necessary to repeat steps 9 thru 14 to more precisely
match-mark the parts.

Press tool Press tool
Snapring (25)
Figure 64. Compress the springs.
15. While holding the back plate in that position install the internal snap ring
(25) in the groove of the clutch piston. See figure 65.
Note: Be sure the snap ring is completely and securely seated

Snapring
securely
seated in
groove.
Figure 65. Install the snap ring in the clutch piston.
Note: A pre-check of piston function and a check for leaks with

air pressure is advised.
16. Check to be sure the seals have not been damaged during assembly
and the clutch functions properly. Direct approximately 30 p.s.i. air into
the clutch pressure passageway in the I.D. of the piston carrier. See
figure 66. Listen and look for signs of leakage in the clutch area. Use
approximately 207 kPa. (30 psi.) air pressure to operate the piston and
check for air leaks.

Clutch
pressure port
Sealring
grooves
Notch
Figure 66. Location of clutch pressure port in the I.D. of the piston carrier.
17. Turn the clutch piston unit over. Install seal rings (30, 31 and 32) in the
grooves located in the bore of the piston carrier (20). Be careful the
seal rings are not damaged during installation. Lubricate the seal rings
with an assembly lubricant in preparation for further assembly. See
figures 66, 67 & 68.
Seal ring
Figure 67. Install seal rings in the I.D. of the piston carrier.
Mark the
Seal ring
Piston Carrier.
Seal ring
grooves
Notch
Figure 68. Install seal rings in the clutch piston bore.

18. Locate the notch in the I.D. of the piston carrier. See figures 66 & 68.
That notch will fit over the pin that was “stuck” in the shaft with grease in
a previous step. See figure 55. Place a mark on the piston carrier to
indicate the location of the notch. Align the piston carrier notch with the
black mark previously drawn on the shaft and install the piston carrier
unit on the shaft. See figure 69.
Note: Use lifting equipment to lower the unit onto the shaft.
Do not force the clutch piston unit into position. Use a slight rocking
motion to “help” the seal rings move over the shoulders on the shaft.
DO NOT MOVE THE PART ROTATIONALLY. A slight imperfection on the
shoulder could cause the seal rings to be cut during assembly.
Align
matchmarks
Figure 69. Align the matchmarks during assembly.
Figure 70. Install the piston carrier on the shaft.

Note: Check carefully to be sure the dowel pin (36) was not
dislodged from its pocket during assembly. When properly
seated, the top edge at the I.D. of the piston carrier will be
located even with the shoulder of the clutch shaft and the
dowel pin will prevent rotation of the clutch piston assembly
on the shaft. See figure 71.
Shaft
shoulder Piston carrier
top surface
Figure 71. Check to be sure clutch piston unit is properly seated.
19. Check to be sure seals have not been damaged during assembly and
the clutch functions properly. See figure 72. Plumb an air source into
the clutch pressure port located in the side of the clutch housing (37).
Use approximately 207 kPa. (30 psi.) of air pressure. While pressurizing
the port, listen and look for signs of leakage in the clutch area.
Assembly hint:
Add a small amount of oil in the pressure port to help seal the
shaft rings.
Plumb air into
the clutch
pressure port
to test.
Figure 72. Check for pressure leaks.

Clutch Hub, Clutch Plates and Gear & Ring Assembly.
See assembly hint in step 23 and note in step 24 before proceeding.
20. Place the clutch hub on the bench (or in an assembly fixture similar to
the one described in step 24 below) with the splined portion up. Install
one clutch friction plate (18) on the hub. Visually center the plate on the
hub.
21. Install one steel clutch plate (17) on the top of the friction plate. Use the
steel plate to center the friction plate more exactly.
22. Alternately install the remaining 7 friction plates and 7 steel clutch plates
on the clutch hub until a total of 8 friction and 8 steel plates are on the
stack. A steel clutch plate will be the top plate on the stack.
23. Perfectly align the stack of plates before assembly onto the clutch shaft.
Assembly hint:
The gear and drive ring assembly (9) may be used as an alignment
guide. Carefully place the clutch hub with the plate stack into the
gear and drive ring assembly, meshing the external teeth and
visually centering the plates and hub in the process.
24. While preventing the plates from moving relative to each other and the
clutch hub, turn the hub over and place the stack on the clutch shaft.
Note: Although the plates may also be aligned using 2 or 3 dowel

pins, small rods or flat plates spaced evenly in the teeth to
align the plates, a fixture similar to the one in figures 73
& 74 may be used to aid this process. The black “handles”
are attached to tubes that rotate. The bottom end of each
tube has a “foot” that retains the plates and clutch hub.
The I.D. of the fixture housing is splined to locate the friction
plates. After the components are installed on the clutch
shaft, rotate the “handles” to release the plates and remove
the fixture.

Figure 73. Fixture being used for assembly.
Fixture
Handles
rotate
Figure 74. Using an alignment and installation fixture for installation.
25. While compressing the springs (23) install the external snap ring (15) to
retain the hub and plates on the clutch shaft. See figure 75.
Note: The following installation (see figures 75 & 76) shows a

simple method of holding the springs in a compressed
position to allow for installation of the snap ring. A threaded
rod was installed in the hole in the end of the clutch shaft.
A straddle fixture was used to press against the piston
carrier. Spacers were used on the threaded rod beneath
a washer and nut. When the nut is tightened against the
spacers, the straddle fixture presses against the piston
carrier to compress the springs.

Spacers
Straddle
Fixture
Rod threaded
into end of
clutch shaft
Figure 75. Compress the springs to install the snap ring (15)
Figure 76. Install the snap ring (15)
from the input end of the shaft. See figures 77 & 78. The wide end of
the bearing race must rest tightly against the shoulder of the shaft. Let
the bearing race cool to room temperature after installation while
continuing to apply downward force as it cools. This is necessary to
ensure that it remains properly seated.
Inner race of
the bearing
Figure 77. Bearing inner race.

Bearing
outer race
Bearing
inner race
Figure 78. Install the bearing inner race.
27. If previously removed, install the pipe plug (13) and press two ball plugs
(14) in the end of the clutch shaft (12). See figure 79.
Pipe plug Ball plug
Ball plug
Figure 79. Ball plugs and pipe plug.
Assembly hint:
If carefully used in a manner that prevents damage of the
components, the gear and ring assembly may be used as a tool
to align the friction plates prior to installation of the bearing outer
race.

28. Apply assembly grease to the bore of the gear and ring assembly (9) to
prevent the outer race from falling out during further assembly. See figure
80. Install the outer race of the bearing (11) in the bore of the gear and
ring assembly (9). See figure 81.
Generously
apply
assembly
grease in the
bore to hold
the race
during further
assembly
Figure 80. Apply assembly grease the gear and drive ring bore.
Bearing outer
race
Figure 81. Install the bearing outer race in the gear and drive ring bore.
Note: The friction plates (18) must be perfectly aligned and

centered before the gear and drive ring assembly (9) is
installed. A pair of straight edged measurement scales,
flat plates or metal dowel rod may be used to perfectly
align the teeth and center the plates for further assembly.
29. Install the gear and drive ring assembly (9) on the clutch shaft. The internal
teeth must mesh with the teeth of the clutch friction plates (18). The inner
and outer races of the bearing (11) will position the components when
they come into contact. See figure 82.

Lower the unit gently onto the shaft to prevent damage to the bearing.
DO NOT FORCE the gear and drive ring assembly into position on the
shaft. If resistance is met, the external teeth of the clutch friction plates
may be misaligned. STOP, realign the plates and continue to install the
gear and drive ring assembly.
Use lifting
equipment.
Do not Gear and

damage the drive ring
bearing. assembly
Carefully
Bottom plate. mesh the
teeth.
Figure 82. Install the gear and drive ring assembly on the shaft.
Warning:
Check the bottom plate to make sure its teeth are engaged inside the
gear and ring assembly. This can be done both visually and by feeling
all around the circumference of the gear and drive ring assembly with
the hands to be sure the teeth do not protrude in any area.

30. Heat the bearing (8) in an oven at 121° C. (250° F.) for one hour and
install it immediately on the clutch shaft. Install the race from the input
end of the shaft. Install the bearing on the gear and drive ring assembly
(9) See figure 83. Let the bearing race cool to room temperature after
installation while continuing to apply downward force as it cools. This is
necessary to ensure that it remains properly seated.
Bearing
Figure 83. Install the bearing (8).

Assemble the Front Housing Unit/Install Idler Gear
Front housing
1. Apply a thread sealant on the pipe plug (orificed) (85) and install it in the
bottom of the manifold hole in the front housing (6). See figure 84.
Pipe plug
(orifice) (85)
Figure 84. Install the (orifice) plug.
2. Position the front housing on the bench with the output end up. Place
the bearing carrier (65) in the housing. Align the three bolt holes, but it is
not imperative that they be perfectly aligned until later assembly.
Note: Be sure the surfaces of the front housing and the bearing
carrier are clean.
3. Using a feeler gauge, measure the shim gap between the top of the
bearing carrier and the under side of the housing. See figure 85. Record
the width of the gap as determined by the feeler gage reading.
Use feeler
gauge to
measure
Front
the gap.
housing (6)
Bearing
carrier (65)
Figure 85. Measure for shims.

4. Select shims (57) equal to the amount of the gap. Set the shims aside
for later installation. Refer to Shim Tolerance for bearing carriers (65)
in idler gear (58) in the Description and Operation section for exact
designed shim tolerance.
5. Press the bearing (63) in the idler gear (58). See figures 86 & 87.
Press until the bearing is flush with the surface of the gear.
Note: Press only against the outer race of the bearing.
Pressing tool
Bearing (63)
Pressing tool
Tool stops against Bearing (63)
surface of idler gear.
Figure 86. Install the bearing (63) in the idler gear (58).
Bearing is
flush with
surface of
gear.
Figure 87. Bearing (63) installed flush with the idler gear (58) surface.

6. Press the bearing carrier (65) into the bearing (63). See figure 88.
Press until the shoulder is tight against the I.D. of the bearing.
Support beneath the inner race of the bearing before pressing in the
bearing carrier. Failure to do so may cause the bearing to be damaged,
resulting in premature, catastrophic failure.
Bearing
carrier
Figure 88. Installed the bearing carrier.
7. Place the idler gear washer (59) on the gear and secure with four hex
head capscrews (60). See figures 89 & 90. Torque the capscrews to
the proper specifications given in Torque Values for U.S. Fasteners
in the Description and Specifications section of this manual.
Assembly Hint:
Rest the lower end of the bearing carrier on the bed of the press
and hold tight with the press ram while tightening the capscrews.
Idler gear
Press ram washer (59)
Hex head
capscrew (60)
12345678
12345678
Press ram 12345678
12345678
Support directly
123456789012345678
123456789012345678 beneath the
Bearing 123456789012345678
123456789012345678 bearing carrier.
carrier
Figure 89. Install the idler gear washer (59).
Figure 90. Hold the unit while torquing the hex head capscrews (60).
8. Turn the gear over on the bed of the press. Install the other idler gear
washer (61) on the gear and secure with four hex head capscrews (62).
Assembly Hint:
Again, rest the lower end of the bearing carrier on the bed of the
press and hold tight while tightening the capscrews.
9. Install the snap ring (64) on the bearing carrier (65). See figure 91.
so that sharpest edge is up, away from the gear.

Snap ring (64)
Sharp side Snap ring

of snap ring groove
to be up.
Figure 91. Install the snap ring.

10. Place the idler gear unit in position in the front housing (6). Align the
three bolt holes with the holes in the housing. See figure 92.
Note: The wide shoulder of the bearing carrier must be up,

toward the output side of the front housing (6).
11. Place the proper amount of shims (57) as previously determined by

measuring the shim gap on top of the bearing carrier. Align the bolt
holes in the shims with the holes in the bearing carrier and front housing.
See figure 92.
Align holes Output side

with 2 large of front
punches. housing (6)
is up.
Install
shims (57).
Wide side
of bearing
carrier (65)
Figure 92. Place the gear unit and shims in the housing.
12. Place two large punches or tapered rods into the bolt holes as alignment
tools while the first of three 12 pt. capscrews (68) is installed.
Raise the housing to gain access to the under side (input side) of the
housing. See figures 93 & 94. Coat the threads of the first capscrew
with thread sealant and install it in one of the three bolt holes. Hand
tighten.
Figure 93. Raise the housing for access to the lower side.

13. Remove one of the alignment tools and install a second 12 pt. capscrew
(68). Again, use thread sealant on the threads before it is installed. Hand
tighten.
14. Remove the second alignment tool and install the remaining 12 pt.
capscrew (68) with sealant on the threads. Hand tighten.
15. Torque the capscrews to the proper specifications given in Torque

section of this manual. See figure 94. Lower the housing to rest securely
on the bench.
Thread
sealant
12 pt.
capscrews
Torque
(68)
wrench
Figure 94. Install, tighten and torque three 12 pt. capscrews (68).
16. Freeze the dowel pin (66) in a freezer or dry ice for one hour. When the
dowel is frozen, quickly install and drive the dowel into the hole in the
middle of the three 12 pt. capscrews. See figure 95.
Note: Lubricate the dowel pin hole with anti-seize compound

prior to installing the dowel pin.
Dowel pin
must be
installed
below the
surface.
Capscrew
holes
Figure 95. Insure that the dowel is below the surface.

17. Coat the threads of pipe plug (67) and install it in the threaded hole at
the front side of the dowel pin hole.
18. Coat the threads on both ends of the pipe nipple (87) and install it in the
housing. Install the manifold (86) on the pipe nipple. Rotate the manifold
so it’s bottom side will be parallel to a horizontal centerline when the
HPTO is installed on the engine. See figure 96.
Bottom of
manifold to be
horizontal
Imaginary
horizontal line.
Manifold (86)
Bottom of
manifold
Pipe nipple
(87)
Figure 96. Install manifold (86).

Install the Front Housing on the Clutch Housing
Turn the front housing over on the bench with the front side up.
1. Install guide dowels in two threaded holes of the front housing (6). See
figure 97. Locate the guides 180o apart.
2. Install the gasket (56) on the clutch housing (37). See figure 97. Align
the holes. Use a small amount of assembly grease to “stick” the gasket
on the housing so it does not move during assembly.
3. Using lifting equipment, and with the housing suspended in a horizontal

position, install front housing (6) on the clutch housing (37). See figures
97 & 98. Be sure the front housing is aligned so the gear towers will be
at the top of the unit (see note below) aligned with the control valve
assembly when the HPTO is installed on the engine.
Note: Suspend the front housing in a perfect horizontal position.

Use hoisting equipment attached at three points as shown
in figure 97.
Note: As the gear housing is lowered onto the clutch housing,

the guides dowels will first enter the bolt holes in the clutch
housing. Then the bearing (8) will enter the bore of the
gear housing and the idler gear will contact the teeth of
the gear and drive ring assembly. Rotate the idler gear so
the teeth mesh properly. When properly aligned the gear
housing will rest properly on the clutch housing.
Note: On some applications the gear housing is rotated as much

as two (2) bolt holes from the top. (See caution and
warning that follow.)
Regarding repositioning of the gear housing: DO NOT ROTATE MORE

THAN two (2) bolt holes from the top as described in step 3 above. To
do so would cause the drain holes to be mislocated at the bottom of the
housing and would prohibit proper gravity drainage of the oil from the
housing.
Units that do not drain properly will overheat, resulting in malfunction

and/or catastrophic failure.
Suspend from
three points.
Gasket is “stuck”
to underside with
grease. (May also
Guide be placed on the
dowel clutch housing but
do not damage
with the guide
pins.)
Figure 97. Hoist equipment should be attached at three points.
Front
housing
Guide dowel
Clutch
housing
Figure 98. Guide dowels enter holes in clutch housing.
4. Install 12 hex head capscrews (4) from the bottom side to secure the
housing. Torque the capscrews to the proper specifications given in
Coupling Housing
5. Install the coupling housing (2) on the front housing. See figure 99.
Secure with 13 hex head capscrews (5). Torque the capscrews to the
proper specifications given in Torque Values for U.S. Fasteners in
the Description and Specifications section of this manual.

Coupling
housing
Front
housing
Figure 99. Install the coupling housing.
6. Install the oil seal (7) in the bore of the front housing (6). Coat the O.D. of
the seal with sealant M2828 before installation. Rest the oil seal in the
bore; the seal lip should be down, with the outer shell of the oil seal up.
See figure 100. Press the seal straight into the bore until the assembly
tool stops against the surface of the carrier. The rear of the outer shell of
the seal should be flush with the surface. Pre-lubricate the seal lip with
clean No. 30 engine oil.
Assembly Hint:
Figure 100 shows an assembly tool that will safely and correctly
install the oil seal. It consists of two parts, an inner shaft protector
and seal lip guide that fits over the end of the shaft and an outer
component that is designed to contact the outer shell of the seal.
The outer component must have an O.D. greater than the O.D. of
the seal so the tool will be stopped by the surface of the housing
to properly locate the seal.
If such tool is not available, it is recommended that a flat ring with

an I.D. slightly larger in diameter than the seal lip and O.D. slightly
larger than the O.D. of the seal be used to install the seal. Press
or tap on the flat plate working 360o around the ring a little at a
time until the ring stops against the surface of the housing.
Do not tap directly on the seal housing to install it. The seal housing will
become damaged and bent, resulting in oil leaks.

Outer O.D. must be

component of larger than
assembly tool O.D. of the oil
Inner seal.
component of
assembly tool Press oil seal
flush with
housing
Hex head
surface.
capscrews (5)
Figure 100. Install the oil seal.
7. Install the pipe plug (3) in the end of the shaft (12). See figure 101.
Pipe plug
Figure 101. Install the pipe plug.

Assemble the Gear Drive Towers
General Information
Note: HPTOs that are designed with gear drive towers may be
equipped to drive from either the front or rear of either of
the towers, depending upon the BOM and design
parameters of the installation. In such cases, one, two,
three and/or four drives may be used. Refer to the BOM
for your unit for exact design features.
Note: The SAE plates are of two basic designs; flat and
contoured. See figure 102.
Narrow Wide
thickness thickness
Flat design “Countoured” design

(plate side illustrated) (bearing side illustrated)
Figure 102. SAE plate configurations.
Note: The SAE plates are of two basic thicknesses; a wide

thickness and a narrower thickness. One wide SAE plate
and one narrow SAE plate are used on each tower. See
figures 102 & 103.
Wide
SAE plate Use one wide SAE
plate and one
narrow SAE plate
on each tower.
Narrow
SAE plate
Figure 103. Top view of tower with wide and narrow SAE plates.

Note: The SAE plates are available in several SAE sizes “A,”
“B,” and “C.” Flat designs and contoured designs are not
necessarily available in all SAE sizes. Refer to the BOM
for your unit for exact design features.
Note: Driven gears have a “long” side and a “short” side. It is

imperative that the “long” side of the gear be installed
on the side with the wider SAE plate.
Note: The assembly procedure as described below refers to

typical tower configurations. The procedure describes a
typical installation and is applicable to any of the
configurations or combinations of components. The
photos used show typical contoured SAE plates being
used at both front and rear positions of both towers.
Refer to the specific BOM for your HPTO; the drives may
be designed with the drives in different locations.
Hex head
Cover
capscrew
Gasket
SAE Mounting
Plate
Hex head
capscrew Gasket
Copper
washer
Figure 104. SAE mounting plate and associated components.
Tower #1
1. Install two guide dowels in the front housing (6), 1800 apart from one
another. See figure 105.

2. Install the gasket (69) on the front side of the tower. See figures 105
and 106.
Gasket Use guide

dowels to
align the
gasket and
SAE plate.
Figure 105. Install guide dowels to align the SAE plate.
3. Locate the SAE mounting plate (70) on the guide bolts. See figure
106.
Note: The hole for the fitting must be toward the outside.
Note location
of hole for
the fitting.
Figure 106. Set the SAE mounting plate in position on the guides.
4. Carefully tap the SAE plate down tight against the gasket. See figure
107.
Figure 107. Tap the SAE mounting plate into position.

5. Install 5 hex head capscrews (71) with copper washers (72) to secure
the plate to the housing. See figure 108. Torque the capscrews to 48.8
Nm. (36 lb. ft.).
Assembly Hint:
Do not install the copper washer and hex head capscrew nearest
the hole for the fitting until after the fitting is installed. The head of
the capscrew will interfere with the fitting as is rotated into the
hole. See illustrations in figure 109.
Hex head
capscrew
Copper
washer
Figure 108. Install one copper washer with each hex head capscrew.
6. Install the pipe fitting in the hole. See figure 109.
Capscrew
prevents
rotation of
Fitting the fitting
Figure 109. Install the fitting before the hex head capscrew and washer.
7. Install the last hex head capscrew (71) with copper washer (72). See
figure 109. Torque the capscrew to 48.8 Nm. (36 lb. ft.)
8. Install the cover (74) with gasket (73) on the plate. Install 4 hex head
capscrews (75) to secure the plate to the SAE mounting plate (70). See
figure 110. Torque the capscrews to the proper specifications given in

Cover
SAE
Typical mounting plate
4-bolt cover
Note:
2-bolt cover
is shown.
Figure 110. Install the fitting before the hex head capscrew and washer.
9. Identify the “long” and “short” ends of the driven gear (83). See figures
111 & 112.
Long Short
End End
Bearing Bearing
journal journal
Long Short
Figure 111. Identify the long and short ends of the driven gears.
Bearing Bearing
Driven Gear
Figure 112. Driven gear and bearings

10. Press the bearing (63) onto the long end of the driven gear (83). See
figure 113. Press the bearing tight against the shoulder on the gear
Press only against the inner race of the bearing to prevent damage that
may result in premature catastrophic failure.
Assembly Hint:
Figure 113 shows a metal pipe being used as a press tool. The
I.D. of the tool is just slightly larger than the I.D. of the bearing
inner race and the O.D. of the tool does not contact the bearing
balls, cages or outer race.
Press tool
Bearing
Gear
Figure 113. Press the first bearing on the gear.
11. Press the bearing (84) onto the short end of the driven gear (83). See
figures 114 & 115. Press the bearing tight against the shoulder on the
gear.
Press tool
2nd Bearing
Gear
1st Bearing
Figure 114. Install the 2nd bearing on the driven gear.

2nd Bearing
1st Bearing
Figure 115. Both bearings seated on the gear.
12. Install the driven gear into the front SAE mounting plate through the hole.
See figure 116. The long end of the gear must be toward the side with
the wide SAE plate. See information with figures 111 & 112.
Note: When the bearing on the lower side of the driven gear is
properly seated in the bearing bore of the SAE plate, the
teeth of the driven gear will be located in the middle of the
teeth of the idler gear. See figures 116 & 117. If they are
not aligned so contact is in the middle of the tooth, the
driven gear is improperly installed or the wrong SAE plate
is installed on the front side of the tower.
Idler gear
teeth
Driven gear
teeth
Figure 116. Install the driven gear in the housing.

Idler gear
teeth
Driven gear
teeth
Figure 117. Gear teeth must mesh properly.
13. Install two guide dowels in the front housing (6), 1800 apart from one
another. See figure 116.
14. Install the gasket (96) on the back side (sheave housing side) of the
Tower. See figure 116.
15. Locate the SAE mounting plate (93) on the guide bolts. Similar to figure
106.
Note: The hole for the fitting must be toward the outside.
16. Carefully tap the SAE plate down tight against the gasket. Similar to
figure 107.
17. Install 5 hex head capscrews (94) with copper washers (95) to secure
the plate to the housing. Similar to figure 108. Torque the capscrews
to 48.8 Nm. (36 lb. ft.).
Assembly Hint:
Do not install the copper washer and hex head capscrew nearest
the hole for the fitting until after the fitting is installed. The head of
the capscrew will interfere with the fitting as is rotated into the
hole. Similar to illustrations in figure 109.
18. Install the pipe fitting in the hole. Similar to figure 109.
19. Install the last hex head capscrew (94) with copper washer (95). Similar
to figure 109. Torque the capscrew to 48.8 Nm. (36 lb. ft.)

20. Install the cover (97) with gasket (96) on the plate. Install 4 hex head
capscrews (98) to secure the cover to the SAE mounting plate (93).
Similar to figure 110. Torque the capscrews to the proper specifications
Note: Do not install the pump (109) at this time. It will be installed
later.
Tower #2
21. Assemble the components of Tower #2. Follow the instructions as

previously described in steps 1 through 20 for the first pump tower.
See figures 102 through 117.

Assemble the Control Valve Assembly
Position the HPTO with the towers and control valve area up.
1. If it was removed, install the ditch plate (131) onto the clutch housing
with ditch plate gasket (142). See figures 118 & 119. Secure with 6
socket head capscrews (130). Torque the capscrews to the proper
Note: Be sure the gasket is properly aligned so no hole or port

is restricted or covered.
Ditch plate
gasket
Clutch
housing
Ditch plate
Figure 118. Install the ditch plate and gasket.
Figure 119. Ditch plate and gasket installed.
Assembly 1020729 only: (Assembly 1021658-skip to step 9.)

2. Install the hydraulic relief valve (124) and plug (126) in the center section

of the control valve assembly. See figure 120. Tighten securely.
Note: The hydraulic pressure will be adjusted later as described

in the Installation section of this manual.
For valve assembly 1020729

o-ring
Pipe Plug Elbow
Plug Hydraulic
Relief Valve
Gasket
Figure 120. Assemble the regulator section. (Assembly 1020709)
3. Lubricate the o-ring on the elbow fitting (112) with an assembly grease.
See figure 121. Install the fitting in the center section of the control valve
assembly. Tighten securely. The fitting should point horizontally toward
the right side (viewed from the rear) of the HPTO .
Note: Be careful to prevent damage to the o-ring during

assembly.
4. Install the main regulator (center section) valve body (115) onto the ditch
plate with gasket (133). See figure 121. Secure with 4 socket head
capscrews (127). Torque the capscrews to the proper
specifications given in Torque Values for Fasteners in Table 8 of
the Installation section.


Assembly hint:
See figure 121. Install the four socket head capscrews (127)
into the ditch plate and install the gasket (133) on the plate aligned
on the capscrews to assist in being sure the gasket is properly
positioned and aligned.
Elbow fitting
Capscrew Gasket
Ditch plate
Center
(main regulator)
section
Figure 121. Install the elbow fitting and gasket on the valve body.
5. Lubricate the o-rings of the two 3-way proportional valves (125) with an
assembly grease. See figure 122. Install the proportional valves in the
top section of the control valve assembly. Use a twisting motion while
pushing each valve into the bore. Position the connectors horizontally,
pointing directly opposite each other. Secure with lock plate (122) and
hex head capscrew (123). Torque the capscrews to the proper
Note: Be careful to prevent damage to the o-rings during

assembly.
Pipe Plug
Pipe Plug
Cartridge
Plug o-rings
3-way Proportional
Pipe Plug Valve o-rings
Gasket
Figure 122. Install the 3-way proportional valves.

6. Lubricate the o-rings of the valve cartridge plug (128) with an assembly
grease. Install the cartridge in the top section of the control valve
assembly.

assembly.
7. Install the (top section) valve body (134) onto the center (main regulator)
valve body section with gasket (114). See figure 123. Secure with 6
hex head capscrews (113). Torque the capscrews to the proper
specifications given in Torque Values for Fasteners in Table 8 of the
Installation section.

Assembly hint:
See figure 123. Install the six socket head capscrews (113) into
the valve body and install the gasket (114) on the plate aligned
on the capscrews to assist in being sure the gasket is properly
positioned and aligned.
3-way
Capscrew proportional
valves
Gasket
Top valve Center

section (main regulator)
section
Figure 123. Install the top valve body and gasket.
8. Install the remaining pipe plugs, in the control valve assembly. See figure
124.

Top section
Pipe plug
Lock plate
Center
Proportional section (main
valve regulator)
Ditch plate
Hydraulic
relief valve
Figure 124. Install the remaining plugs. (Early design)
Valve assembly 1021658 only:

9. Install the filter (142) in the end of the body (115). See figure 125.
157 142
144
145
146
143
158
115
147
148
150 149
151
152
154 153
155
156
Figure 125. Assemble the regulator section. (Assembly 1021658)
10. Install the valve (143) in the hole in the body.
11. While holding the filter and valve in the body install the cover (145) with
gasket (144) and secure with four hex head capscrews (146). Torque
the capscrews to the proper specifications given in Torque Values
for Fasteners in Table 8 of the Installation section.
12. Install the o-ring (151) on the piston and thread the piston into the cover
(153). Place the inner spring (150), outer spring (149), washer (148) on
the spool (147). See figure 126.

Cover Spool Springs Piston Jam Nut Cap
Figure 126. Pressure regulator (Used with assembly 1021658)
13. Lubricate the o-ring with oil or an assembly lubricant and install the piston
unit into the body. Secure with four hex head capscrews (154). Torque
the capscrews to the proper specifications given in Torque Values
for Fasteners in Table 8 of the Installation section.
Note: Be careful to prevent damage to the o-ring during

assembly.
14. Install the jam nut (155) and hand-tighten it against the cover. Install the
cap (156) and hand-tighten.
Note: The hydraulic pressure will be adjusted later as described

in the Installation section of this manual.
15. Lubricate the o-rings of the two 3-way proportional valves (125) with an
assembly grease. See figure 126. Install the proportional valves in the
top section of the control valve assembly. Use a twisting motion while
pushing each valve into the bore. Position the connectors horizontally,
pointing directly opposite each other. Secure with lock plate (122) and
hex head capscrew (123). Torque the capscrews to the proper

assembly.

125
125
123
122
134
116
113
159
118
114
Figure 127. Assemble the top valve section. (Used with assembly
1021658.)
16. Install the (top section) valve body onto the center (main regulator) valve
body section with gasket (114) between the sections. See figures 126
& 127. Then, install both sections on the ditch plate with gasket (133)
between the center section and the ditch plate.
Note: Be sure both gaskets are properly aligned so no hole or

port is restricted or covered.
Assembly hint:
Install the six socket head capscrews (113) through the top valve
body and install the gasket (114) aligned on the capscrews to
assist in being sure the gaskets are properly positioned and
aligned. Then install the center section on the capscrews followed
by the gasket (133). Finally, place the whole unit on the ditch
plate.
17. Lubricate the o-rings of the directional control valve (159) with an
assembly grease. Install the valve in the top section of the control valve
assembly. Torque the valve to 36 N-m (26.5 ft.-lbs.)

assembly.
18. Install the remaining pipe plugs, in the control valve assembly. See figure
127.

Install the Speed Sensor Pickups
Output speed sensor
1. View into the output speed sensor in the hole in the side of the clutch
housing just below the control valve. See figure 128. Rotate the main
output shaft so a tooth on the O.D. of the gear and ring assembly (9) is
directly aligned with the center of the hole. Install the speed sensor until
it just touches the tooth. Then back it out as specified in the Description
and Specification section of this manual.
Speed
sensor
Double
lock nuts
Figure 128. Install the output speed sensor.
2. Mark the exact location of the speed sensor. Then back it out an additional
6 turns so thread sealant MA908 can be applied to the threads.
3. Apply thread sealant MA908 to the threads. Thread the sensor back to
the original position.
4. Tighten the lock nut closest to the housing. Torque the nut to the
specifications contained in the Description and Specification section
of this manual. Then tighten the second lock nut against the first and
torque it as specified in the Description and Specification section
of this manual.

Input speed sensor
5. View into the driven gear speed sensor in the hole in the side of tower
#2. See figure 129. Rotate the driven gear so a tooth is directly aligned
with the center of the hole. Install the speed sensor until it just touches
the tooth. Then back it out as specified in the Description and
Specification section of this manual.
Speed
sensor
Tower
#2
Double
lock nuts
Figure 129. Install the input speed sensor.
6. Mark the exact location of the speed sensor. Then back it out an additional
6 turns so thread sealant MA908 can be applied to the threads.
7. Apply thread sealant MA908 to the threads. Thread the sensor back to
the original position.
8. Tighten the lock nut closest to the housing. Torque the capscrews to the
proper specifications given in the Description and Specifications section
of this manual. Then tighten the second lock nut against the first and
torque the capscrews to the proper specifications given in the

Install the Pump
1. If used, install the pump (109), meshing the splines of the pump and
driven gear (83). Position the pump with the long flange section at the
bottom.
2. Secure the pump to the front housing using 4 hex head capscrews (82).

Plumbing
1. The various applications may use slightly different pump and gear tower
locations, which result in slightly different plumbing configurations. Refer
to the engineering drawings at the back of this manual and the typical
plumbing illustrations near the back of this section for exact plumbing
components and configurations. See figures 130 through 134.
Note: The illustrations below show various fittings, plumbing

configurations, and components to complete the assembly
of the HPTO. These illustrations are provided as a
convenience to clarify questions not specifically covered
in this manual.
It is likely that the HPTO you are working on is not the

same model or BOM illustrated. Refer to the engineering
drawings for your specific unit.
Figure 130. Typical installation of components.
Ditch plate
Double
lock nuts

Speed
sensor
Speed
sensor
Speed
sensor

HPTO Series Parts Identification List
Item Description Qty. Item Description Qty.

1 Coupling, flexible 1 42 Pin, dowel, 12mm. x 24mm. 2
2 Housing, coupling 1 43 Capscrew, hex. hd. 1/2” - 13 x 1.75 6
3 Plug, pipe 1-11 1/2 NPTF 1 44 Retainer, bearing, front bearing 1
4 Capscrew, hex. hd. 7/16”-14 x 1.38” 12 45 Seal, radial 1
5 Capscrew, hex. hd. 1/2”-13 x 1.25” 13 46 Carrier, bearing (Model I) 1
6 Housing, front 1 46 Housing, belt, sheave (Model S) 1
7 Seal, radial 1 47 Capscrew, hex. hd. 1/2” - 13 x 1.25 6
8 Bearing, ball 1 48 Plug, pipe, clutch housing 1
9 Gear & drive ring assy. 1 49 Fitting, grease 1
10 Ring, snap, internal (service) 1 50 Retainer, bearing, rear bearing 1
11 Bearing, cylindrical 1 51 Bearing, spherical 1
12 Shaft 1 52 Ring, bearing 1
13 Plug, pipe, shaft 1 53 Screw, hex. hd. M12 x 1.75 6
14 Plug, ball, shaft 2 54 Plug, pipe, 1/8 1
15 Ring, external snap, shaft 1 55 Key, output 1
16 Hub, clutch 1 56 Gasket 1
17 Plate, steel, clutch 8 57 Shims A/R
18 Plate, friction, clutch 8 58 Gear, idler 1
19 Ring, seal 2 59 Washer, idler gear 1
20 Carrier, piston 1 60 Capscrew, hex. hd. 3/8”-24 x 5/8” 4
21 Ring, seal 1 61 Washer, idler gear 1
22 Piston, clutch 1 62 Capscrew, hex. hd. 3/8”-24 x 5/8” 4
23 Spring 9 63 Bearing, Roller 1
24 O-ring, plate 1 64 Ring, snap, bearing carrier 1
25 Ring, internal snap, piston 1 65 Carrier, bearing 1
26 Plate, back 1 66 Pin, dowel, 3/8” x .250” 1
27 Pin, dowel, .157” x 1.0” 4 67 Plug, pipe, 1/4 1
28 Plate, friction, clutch 1 68 Capscrew, 12 pt. 3/8”-11 x 3.50” 3
29 Pin, anti-rotation, piston 4 69 Gasket, plate 1
30 O-ring, shaft 1 70 Plate, SAE mounting 1
31 O-ring, shaft 1 71 Capscrew, hex. hd. 3/8” - 16 x 1.25 6
32 O-ring, shaft 1 72 Washer, copper 6
33 Pin, dowel, 1/4 x .38 1 73 Gasket, cover 1
34 Ring, seal 1 74 Cover 1
35 Ring, spacer 1 75 Capscrew, hex. hd. 2” - 13 x 1.0 4
36 Spacer, bearing 1 76 Bearing, Ball 1
37 Housing, clutch 1 77 Gasket, plate 1
38 Bearing, double cup assy (Model I) 1 78 Plate, SAE mounting 1
38 Bearing, spherical (Model S) 1 79 Capscrew, hex. hd. 3/8” - 16 x 1.75 6
39 Plug, pipe, clutch housing 1 80 Washer, copper 6
40 Gasket, spacer 2 81 Gasket, cover 1
41 Spacer 1 82 Capscrew, hex. hd. 1/2” - 13 x 1.25 4

HPTO Parts Identification List
Item Description Qty. Item Description Qty.

83 Gear, driven 1 121 O-ring 1
84 Bearing, Ball 1 122 Plate, lock 1
85 Plug, pipe 1 123 Capscrew, socket hd. M6 X 1.0 X 16.0 1
86 Manifold 1 124 Valve, cartridge, hydraulic relief 1
87 Nipple, pipe 1 125 Valve assy. 3-way proportional valve 2
88 Gasket, plate 1 126 Plug 1
89 Plate, SAE mounting 1 127 Capscrew, socket hd. M10 X 1.5 X 50.0 4
90 Capscrew, hex. hd. 3/8” - 16 x 1.25 6 128 Valve, cartridge, plug 1
91 Washer, copper 6 129 Plug, pipe, valve body 1
92 Gasket, cover 1 130 Capscrew, socket hd. 3/8”-16 6
93 Cover 1 131 Plate, ditch 1
94 Cover 1 132 O-ring, carrier 1
95 Capscrew, hex. hd. 2” - 13 x 1.0 4 133 Gasket, ditch plate 1
96 Bearing, Ball 1 134 Body, valve 1
97 Gasket, plate 1 135 Cover, inspection 1
98 Plate, SAE mounting 1 136 Screw, cover, M6 hex. hd. 4
99 Capscrew, hex. hd. 3/8” - 16 x 1.75 6 137 Gasket, ditch plate-to Clutch Hsg. 1
100 Washer, copper 6 138 Plug, pipe, 1/4 1
101 Gasket, cover 1 139 Reducer, pipe 1
102 Capscrew, hex. hd. 1/2” - 13 x 1.25 4 140 Housing Spacer 1
103 Gear, driven 1 141 Dowel Pin 2
104 Cover 1 142 Filter 1
105 Bearing, Ball 1 143 Valve 1
106 Fitting, elbow 1 144 Gasket 1
107 Fitting, elbow 1 145 Cover 1
108 Breather 1 146 Capscrew, hex hd. 4
109 Pump 1 147 Spool 1
110 Washer, bearing lock 1 148 Washer 1
111 Nut, bearing lock 1 149 Spring, outer 1
112 Fitting 1-1/16-20 to M27 X 2 elbow 1 150 Spring, inner 1
113 Capscrew, hex hd. M10 X 1.5 X 70.0 6 151 O-ring, piston 1
114 Gasket, cartridge valve body 1 152 Piston 1
115 Body, valve, main regulator 1 153 Cover 1
116 Plug, o-ring M12 X 1.5 1 154 Capscrew, hex hd. 4
117 Plug, o-ring M12 X 1.5 1 155 Nut, hex 1
118 Plug, o-ring M12 X 1.5 1 156 Cap 1
119 O-ring 1 157 Plug 1
120 O-ring 1 158 Plug 1

Models HP300I & HP600I Cross-Section View
Gear Tower Area

(see following pages)
GP Control
Front Valve Area
Bearing Area (see following
(see following pages) pages)
Rear Bearing Area

2
10 55
9
12
Clutch
Area
(see following
pages)
37
135 136 6 56 4
Note: Some parts not shown

Models HP300S & HP600S Cross-Section View
Gear Tower Area

Front
Bearing GP Control
Area Valve Area
(see following
pages)
(see following Sheave Housing
pages) Output Bearing Area
Sheave Housing
2 Front Bearing Area
1 (see following pages)
5
10
Clutch
Area 12 55
(see following
pages)
135 136 6 56 4 37 46 42 47
Pin
Note: Some parts not shown

Models HP300S & HP600S Sheave Housing Front Bearing Area

Exploded View
Note: Typical unit illustrated.
37
48
40
41
Approximate area shown.
40
42
140
141
33
35
36
45
43
39
42
141
34
12
38
44
46

Models HP300S & HP600S Sheave Housing Output Bearing Area

Exloded View
12
54
46
51
52
49
50
53

Models HP300I, HP600I, Rear Bearing Area Exploded View
37
39
12
55
38
110
111
34
132
46
45
47

Models HP300I, HP600I, HP300S & HP600S Clutch Area Exploded

View
11
15
16
17
18
23
22
29
19
21
30 28
31
32
20
19
26
24
27
25

Models HP300I, HP600I, HP300S & HP600S Front Bearing Area

Exploded View
Not shown
(In Tower)
108 Breather
138 Plug, pipe
139 Reducer, pipe
85
7
8
11
12

Models HP300I, HP600I, HP300S & HP600S Idler Gear Area

Exploded View
67
68
64
65 Approximate area shown.

57
62
61
63
58
59
66
60

Models HP300I, HP600I, HP300S & HP600S Tower #1 Area Exploded

View
71
72
75
74
73
70
69
84
83
106 Elbow fitting

not shown
87
86
77
76
78
81
94
82
80
79

Models HP300I, HP600I, HP300S & HP600S Tower #2 Area Exploded

View
102 6
103
75
74
104
101
100
97
96
107 Elbow fitting

not shown
77
98
91 Cover not shown.

(NOt used if a pump
is used in this
location
78
80
79
86
87
81
6 109
82

Models HP300I, HP600I, HP300S & HP600S GP Control Valve Area

Illustration
113
126
134
112
114
115
Approximate area shown. 116
133
131
130 143
124 125 113 126 113 134 114 115
129
51
Lock Plate
51
113 122 123 113
116 128
119
51 120 112
51
128
125
51
112
130
117
129
124 127 124
121 112


Exploded View - (Valve assembly 1020729 is illustrated)
113
116
128
117
134
122
118
123
114
125 125
127
112
129
115
124
126
133
130
131
137


Exploded View - (Valve assembly 1021658 is illustrated)
125
125
123
122
134
116
113
126
118
114
157 142
144
145
146
143
158
115
147
148
149
150
151
152
153
155
154
156

Models HP300I, HP600I, HP300S & HP600S Pipes and Fittings

Illustrations

Models HP300I, HP600I, HP300S & HP600S Pipes and Fittings

Illustrations
Note: Typical units illustrated.

Twin Disc, Incorporated Troubleshooting
Troubleshooting
Troubleshooting of GP Control Valve with Electronic Interface
The HPTO is one part of a complete power package. Problems in the input
power system or the output power delivery components can cause problems to
develop in the HPTO. It is therefore important that the entire power package
be considered when problems are encountered.
Electronic Interface LED Indicators
The electronic interface control modules have one green and two red LED
indicator lights. The green power light is illuminated whenever the input power
is more than 9.0 volts.
The following table lists the reasons for the various conditions where lights are
illuminated. This should guide in troubleshooting problems. See the wiring
schematics in the Installation Section.
Troubleshooting Tables begin on the next page.
Table 14. LED Light Status
Light Status Profile Generator

(Non trolling)
Green light on Supply Voltage > 9.0 Volts
Red light on Valve coil commanded on
One red light flashing Open circuit in an energized
valve coil circuit, or Valve coil
leads shorted together, or Low
coil current
Both red lights flashing Not applicable
simultaneously
Both red lights flashing Either or both speed signals
alternately missing

Troubleshooting Twin Disc, Incorporated
Table 15. Troubleshooting Chart --- GP Valve Equipped HPTO
Symptom Cause Remedy

1. Low main oil pressure 1-1 Part ially clogged oil 1-1 Remove and clean oil
strainer strainer.
1-2 Contamination on Pilot 1-2 Disassemble the Pilot
Relief Val ve seat. Relief Valve and clean.
Service the transmission
oil filter.
1-3 Contamination in Main 1-3 Clean or replace the Main
Valve Cartridge Val ve Cartridge, and
service the transmission
oil filter.
1-4 Broken piston rings on 1-4 Remove the collector and
clutch shaft(s). inspect piston rings.
1-5 Damaged or worn oil pump 1-5 Replace damaged or worn
assembly. oil pump assembly (pump
is not serviceable).
1-6 Engine idle speed too low. 1-6 Raise engine speed.
2. No oil pressure, or erratic 2-1 Oil pump suction strainer 2-1 Remo ve and clean
low pressure at control plugged. strainer.
valve.
2-2 Oil level low. 2-2 Check oil level and
correct.
2-3 Air leak on suction side of 2-3 Correct cause of air leak.
pump.
2-4 Pump dri ve broken. 2-4 Disassemble and repair as
required.
2-5 Pilot Relief Valve or Main 2-6 Remove, disassemble,
Regulating Val ve stuck in clean and repair the Pilot
open position Relief Valve. Remove,
clean, or replace the Main
Regulating val ve. This
v alv e c ann ot be
disassembled.
2-6 Oil pump defective 2-7 Replace oil pump.
2-7 Leaking heat exchanger 2-7 Replace heat exchanger

has caused oil to be lost
externally.

Twin Disc, Incorporated Troubleshooting
Table 15. Troubleshooting Chart (continued)--- GP Valve Equipped HPTO
Partially clogged oil Remove and clean oil

1. Low main oil pressure 1-1 1-1
strainer strainer.
Disassemble the Pilot
Contamination on Pilot Relief Valve and clean.
1-2 1-2
Relief Val ve seat. Service the transmission
oil filter.
Clean or replace the
Contamination in Main Main Valve Cartridge,
1-3 1-3
Valve Cartridge and service the
transmission oil filter.
Broken piston rings on Remove the collector

1-4 1-4
clutch shaft(s). and inspect piston rings.
Replace damaged or
Damaged or worn oil worn oil pump assembly
1-5 1-5
pump assembly. (pump is not
serviceable).
Engine idle speed too

1-6 1-6 Raise engine speed.
low.
No oil pressure, or
Oil pump suction strainer Remove and clean
2. erratic low pressure at 2-1 2-1
plugged. strainer.
control valve.
Check oil le vel and
2-2 Oil level low. 2-2
correct.
Air leak on suction side of
2-3 2-3 Correct cause of air leak.
pump.
Disassemble and repair

2-4 Pump dri ve broken. 2-4
as required.
Remove, disassemble,
clean and repair the Pilot
Pilot Relief Valve or Main Relief Valve. Remove,
2-5 Regulating Val ve stuck in 2-6 clean, or replace the
open position Main Regulating valve.
This valve cannot be
disassembled.
2-6 Oil pump defective 2-7 Replace oil pump.

Leaking heat exchanger
2-7 has caused oil to be lost 2-7 Replace heat exchanger
over board.

Troubleshooting Twin Disc, Incorporated
Table 15. Troubleshooting Chart (continued)--- GP Valve Equipped HPTO
Remove clutch plates.

6. No neutral. 6-1 Clutch plates warped. 6-1
Overhaul unit.
Faulty Proportional Replace Proportional

7. Harsh engagement. 7-1 7-1
Valve. Valve.
Profile Generator Replace Profile

defective or out of Generator. Adjust if
7-2 7-2
adjustment. proper equipment is
available.
Pump flow output too

8. Low lube oil pressure. 8-1 8-1 Replace pump.
low.
Remove, clean, inspect,

Pump suction strainer
8-1 8-2 and install the suction
plugged.
screen.
Air leak on suction side Inspect and correct
8-3 8-3
of pump. cause of suction leaks.
Remove and clean or

Lube relief valve
8-4 8-4 replace parts as
malfunction.
necessary.
Replace damaged
8-5 Broken piston rings. 8-5
piston rings.
Oil spilling out of

9. 9-1 Oil level too high. 9-1 Adjust oil level.
breather.
9-2 Wrong type of oil. 9-2 Draw and refill with
recommended oil.
Low Clutch Apply

10. 10-1 Low Main Pressure
Pressure 10-1 See Paragraph 1.
Defective Proportional Replace Proportional

10-2 10-2
Valve. Valve

Twin Disc, Incorporated Engineering Drawings
Engineering Drawings
The engineering drawings included are listed below.
Note: All part numbers listed in the following engineering

drawings are for reference only. Please refer to your bill
of material for part numbers specific to your model.
q Twin Disc Hydraulic Power Take-off Cutaway
q 1020668G HP300I: Sheet 2 of 3 Contact your

Authorized Twin Disc Dealer
q 1020668G HP300I: Sheet 3 of 3 for the latest BOM and
engineering drawings.
q 1020668B HP300S: Sheet 2 of 3
q 1020668B HP300S: Sheet 3 of 3
q 1020668F HP600I: Sheet 2 of 3
q 1020668F HP600I: Sheet 3 of 3
q 1020668C HP600S: Sheet 2 of 3
q 1020668C HP600S: Sheet 3 of 3
q 1020696 Control Valve Assembly
q 1021658 Control Valve Assembly
q 1020686 HPTO Control Module
q 1021292 Sheet 1 of 3 HPTO Plumbing
q 1021295 Piping Diagram
q X216923BU Gear Group (Sae C)

q X216923BV Gear Group (Sae B)
q X216923BX Gear Group (Sae B & C)

Engineering Drawings Twin Disc, Incorporated
Twin Disc Hydraulic Power Take-Off Cut-away Illustration

NOTES:
SCREW, MA961X (6) A. PROPORTIONAL CONTROL VALVE OPERATION.
PLUG, MA1038B "O"RING, A2916JT (2) PLATE, 1018175
1. WARNING DO NOT CONNECT VALVE COIL DIRECTLY
MAIN PRESSURE CHECK TO BATTERY/POWER SUPPLY VOLTAGE.
M12x1.5 THD. CONFORMS PORT "B" SCREW, MA1100B 2. OPERATION TO BE PERFORMED WITH ONLY TWIN DISC
TO ISO 6149 CONTROL SYSTEMS OR MODULES.
PROPORTIONAL VALVE, B. MANUAL DIRECTIONAL CONTROL VALVE OPERATION.
SEE CHART (2) 1. WITH MANUAL DIRECTIONAL CONTROL VALVE IN 5
BODY, 1020519 SEE NOTE "A" CENTERED POSITION, PUSH TO ENGAGE PORT "A".
2. WITH MANUAL DIRECTIONAL CONTROL VALVE IN
CENTERED POSITION, PULL TO ENGAGE PORT "B".
C. MANUAL DIRECTIONAL CONTROL VALVE MODE SWITCH.
VALVE, SEE CHART (TORQUE TO 36 N-m) 1. SWITCH IS NORMALLY CLOSED WHEN MANUAL DIRECTIONAL
(1021000A SHOWN) CONTROL VALVE IS IN THE CENTERED POSITION AND
OPEN WHEN LEVER IS ACTUATED FROM CENTERED POSITION.
2. CURRENT = 20 AMPS MAX.
3. FOR WIRING SCHEMATIC, REFER TO CONTROL MODULE
SEE NOTE "C" DRAWING.
PLUG, MA1038B (2) D. PRESSURE REGULATOR ADJUSTMENT.
CLUTCH PRESSURE PORT 1. REMOVE 1002144 CAP AND LOOSEN 1002145 NUT.
M12x1.5 THD. CONFORMS 2. CLOCKWISE ROTATION OF 1020939A PISTON INCREASES
TO ISO 6149 PRESSURE. COUNTER CLOCKWISE DECREASES PRESSURE.
3. LOCK PISTON IN PLACE USING JAM NUT AND REPLACE CAP.
GASKET, 1020531 E. REFER TO MARINE TRANSMISSION ASSEMBLY DRAWING OR 4
SEE NOTE "B" FILTER, P10786 BILL OF MATERIAL FOR VALVE MOUNTING AND SCREWS.
F. APPLY ANAEROBIC SEALANT MEETING M2828 REQUIREMENTS
GASKET, 1021663 AROUND CORE PLUG, JUST BEFORE FINAL ASSEMBLY. REFER TO
S774 FOR FURTHER INFORMATION.
PORT "A" COVER, 1021662 G. MODIFICATION KIT TO UPGRADE EXISTING 1020729/1020696
SERIES VALVE ASSEMBLIES TO 1021658 SERIES VALVE ASSEMBLY.
PLUG, SEE CHART
OPTIONAL INLET PORT
M27x2.0 THD. CONFORMS SCREW, MA960M (4) B
TO ISO 6149
COVER, 1021661
SPOOL, 1021660
3
SCREW, MA960A (4)
VALVE, 1020942
WASHER, A2782AV BODY, 1021659
SEE CHART
CAP, 1002144 SPRING(S)
SEE NOTE "D" SEE CHART STAMP VALVE ASSEMBLY
IDENTIFIER HERE
NUT, 1002145 RING, A2916LV
2
PISTON, 1020939A A B
VALVE VALVE PRESSURE CORE MODIFICATION
ASSEMBLY ASSEMBLY BOM kPa SPRING(S)
PLUG PROPORTIONAL
KIT
PART NO. IDENTIFIER VALVE SENSOR PLUG PLUG SEE NOTE VALVE
(psi) "F" SEE NOTE "G"
1021658A A 43110 1795-2205
(260-320)
201341ZC 1021000A NONE M2051S MA1038E NONE 1020520 K1417
201341ZD
1021658B B 43111 1585-1795
(230-260)
201341ZC 1021000A NONE M2051S MA1038E NONE 1018528 K1418
SUMP
MAIN (CP) 1021658C C 43112 2205-2760

(320-400)
201341ZC
201341ZE 1021000A NONE M2051S MA1038E NONE 1020520 K1420
1021658D D 43195 1795-2205 201341ZC 1021000A 1016122A NONE MA1038E NONE 1020520 K1417
PORT "A"
LUBE (IP)
PORT "B" (260-320) 201341ZD
1021658E E 43196
1585-1795
(230-260) 201341ZC 1021000A1016122A NONE MA1038E NONE 1018528 K1418
CL CL
SUMP
2205-2760 201341ZC 1020520
1021658F F 43197 (320-400) 201341ZE 1021000A 1016122A NONE MA1038E NONE K1420
1021658G G 43198 1585-1795
201341ZC 1020542 NONE M2051S MA1038E PORT
M1945E 1018528 K1419
(230-260) "A"
1021658H H 43199 1585-1795
(230-260)
201341ZC 1021000A NONE M2051S MA1185A NONE 1018528 K1418
J 43200 1585-1795 1020542
1021658J (230-260) 201341ZC NONE M2051S MA1053Q NONE 1018528 K1418 1
TWIN DISC
DATE
BOTTOM VIEW SCALE

5-04-04
INCORPORATED
SCALE = HALF WEIGHT WR
2
FIRST USE MATERIAL HEAT TREAT
FULL RACINE, WI 53403 - USA
METRIC
UNLESS OTHERWISE SPECIFIED DRN.
ASSY. 1020391 D. MEYERS
1021658
MACHINED DIMENSIONS 2
kg Nm
X. ±0.75
MODEL MG-5222DC CHK.
B A2 ECN12561 7-28-04 X.X
X.XX
±0.25
±0.13 NOTICE! THIS PRINT CONTAINS PROPIETARY INFORMATION AND IS NOT TO BE USED IN ANY SIMILAR TO NAME ALC
VALVE ASS'Y.
MANNER DETRIMENTAL TO THE INTEREST OF
A B3 ECN12537 6-28-04 ALL ANGULAR TOLERANCES ±1°
GEOMETRIC TOLERANCING
TWIN DISC, INCORPORATE
THIRD ANGLE
PROJECTION APPD.
DWG SHT. REV
REV SHEET ZONE CH. NO. DATE REV SHEET ZONE CH. NO. DATE PER ASME Y14.5M 1994
THIS NOTICE IS NOT INTENDED TO NULLIFY OR LIMIT RIGHTS GRANTED TO THE U.S.
GOVERNMENT OR OTHERS BY CONTRACT. WTW SIZE A1 1 of 1 B
F E D C B A
OIL SPECIFICATIONS: Use only SAE-API service class CD or CC engine oil certified
to meet Caterpillar TO-2 transmission oil specification and/or Allison type C-4
transmission fluid. Oil viscosity is dependent on ambient temperature and resulting
operating temperatures. See manual for recommendations. Multi-viscosity oils can be
used, but require Twin Disc approval.
SUMP: Customer supplied. Minimum size, 8 gallons. Use baffles to allow return oil to
settle away from suction port. Recommended to be mounted below HPTO and allow for
gravity drain from 1-1/2" drain ports. If the sump cannot be mounted below the HPTO, a
scavenge pump that is 1.5 – 2 times the size of the charge pump must be used. Three
drain ports are provided under the HPTO. Connecting all 3 ports may be required if
drainage hoses are to long and tightly bent.
Warning: Insufficient drainage will cause unit to overheat and oil will flow out from
breather.
FILTRATION: Customer supplied. The HPTO contains electronically controlled

proportional pressure valves, thus filtration must meet the following criteria: Beta
removal efficiency rating 2/20/75 for particle sizes 5micro/13micro/16micro. A typical
filter element should say "5 micro nominal" or "16 micro absolute".
COOLING REQUIREMENTS: Customer supplied, air to oil cooling is typical.

-Minimum oil temperature at start-up: -40F.
-Oil temperature at steady operating conditions: 100F-185F.
- Recommended inlet temperature of H.E. to be 170F.
- Recommended outlet temperature of H.E. to be 150F.
-Oil flow to H.E. from HPTO: Pump specific (0.0085 GAL/REV theoretical for the
standard Twin Disc pump)
- The equivalent heat generation of the HPTO is 28000 BTU/hr continuous. Due to
deterioration in cooling capacity in a dust-heavy environment; Twin Disc recommends
that a larger heat exchanger be considered when feasible.
-Peak oil pressure at H.E.: 265PSI.
CHARGE PUMP SPECIFICATIONS: Twin Disc or customer supplied. 15 GPM

maximum flow required. Oil flow of 8.5 GPM is required at 1000 rpm. Pump rotation is
CW on output side, or CCW when mounted on engine side.
MAINTENANCE REQUIREMENTS: All bearings within the main unit are oil
lubricated. The output bearing of the straddle bearing housing unit is grease lubricated.
Grease is to have operating temperature suitable up to 275F continuous use. NLGI grades
0,1, or 2 are acceptable. Recommended greases would be Mobilgrease XHP 222,
Mobilgrease CM-S, Mobilux EP-2 or equivalent. Add 1cc Every 10 hours.
HOSE TYPE: Hoses must meet SAE517 specification for 100R17 or similar type for
hydraulic applications.
FITTINGS: Fittings selected must meet SAE J514, SAE J476, J518 standards.
#1021542 0804
TWIN DISC, INCORPORATED RACINE, WISCONSIN 53403, U.S.A. 262-638-4000/262-638-4482 (FAX) WWW.TWINDISC.COM

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TWIN DISC

Document Number: 1021542

Hydraulic Power Take-off

Hydraulic Power Take-off Service Manual 3

Original Issue August, 2004

BEFORE YOU START

This manual replaces:

4 Hydraulic Power Take-off Service Manual

January 16, 2002 TDWP0002

Hydraulic Power Take-off Service Manual 5

Description and Specifications .........................17

GP Control Valve hydraulic portion ................................................ 33

8 Hydraulic Power Take-off Service Manual

Remove and Front Housing from the Clutch Housing ................. 78

Cleaning and Inspection ....................................83

Hydraulic Power Take-off Service Manual 9

HP300I, HP600I, HP300S, HP600S Idler Gear Area ................. 165

Engineering Drawings ......................................177

10 Hydraulic Power Take-off Service Manual

Operation and maintenance personnel responsible for this equipment should

Hydraulic Power Take-off Service Manual 11

See the engineering assembly drawings in Engineering Drawings and parts

All replacement parts or products (including hoses and fittings) must

Refer to the maintenance and troubleshooting sections of this manual.

Frequent reference to the information provided in this manual regarding daily

In the event a malfunction does occur, a troubleshooting table is provided to

Lifting Bolt Holes

Select lifting eyebolts to obtain maximum thread engagement with bolt

Hydraulic Power Take-off Service Manual 13

Safe practices must be employed by all personnel operating and servicing

Important Safety Notice

Because of the possible danger to person(s) or property from accidents which

To prevent accidental starting of the engine when performing routine

14 Hydraulic Power Take-off Service Manual

Sources of Service Information

Each series of manuals issued by Twin Disc, Incorporated is current at the

Hydraulic Power Take-off Service Manual 15

16 Hydraulic Power Take-off Service Manual

Description and Specifications

The Twin Disc Hydraulic Power Take-Off (HPTO) is an engine-mounted

Hydraulic Power Take-off Service Manual 17

Identifying the Twin Disc Hydraulic Power Take-Off Model Number

18 Hydraulic Power Take-off Service Manual

The HPTO housing consists of a front SAE 1 or SAE 0 engine housing

Oil Pump Drive

Suction Strainer and Baffle

A customer supplied serviceable suction strainer should be located between

Hydraulic Power Take-off Service Manual 19

Flexible Torsional Input Coupling

 Dampen torsional vibrations.

 Change the natural frequencies of a system to move critical

 Accommodate a certain amount of misalignment.

 Absorb shock and reduce noise.

 Minimize gear “rattle.”

The heat exchanger should be capable of dissipating 28,000 BTU/ hr.

Recommended inlet temperature of heat exchanger: 170o F. (77o C.)

Recommended outlet temperature of heat exchanger: 150o F. (66o C.)

Oil flow from standard Twin Disc pump is 0.0085 gal/rev.

Customer-supplied Support Plate Requirement

Dampen torsional vibrations.

Change the natural frequencies of a system to move critical

Accommodate a certain amount of misalignment.

Absorb shock and reduce noise.

Minimize gear “rattle.”