Fitting Instructions Kit Nos. 9100, 9110, 9120 MECHANICAL POWER TAKE-OFF

Transcription

1 Fitting Instructions Kit Nos. 9100, 9110, 9120 MECHANICAL POWER TAKE-OFF

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3 Fitting / Operating Instructions Kit Nos. 9100, 9110, 9120 These instructions cover kits from 9/07/1997 i 01 INTRODUCTION 02 GENERAL SPECIFICATION DATA INSTALLATION 03 PTO INSTALLATION COMMISSIONING AND USE 04 PTO OPERATION MAINTENANCE 05 MAINTENANCE AND REPAIRS 06 TROUBLESHOOTING PARTS 07 ASSEMBLY DRAWINGS 08 WARRANTY Superwinch Ltd., Abbey Rise, Whitchurch Road, Tavistock, Devon. Great Britain. PL19 9DR +44 (0) (0) support@superwinch.net Superwinch Inc., Winch Drive, Putnam, Connecticut U.S.A. (860) (860)

4 01 INTRODUCTION INTRODUCTION Please read and understand this owner s manual before installing your P.T.O.. Pay particular attention to the caution notes preceded with the symbol shown here. The notes contain advice for your protection. Correct installation of your P.T.O. is a requirement for proper operation. WARNINGS, CAUTIONS AND NOTES These are given through these instructions in the following form : SYNTHETIC RUBBER Many O ring seals, flexible pipes and similar items, when subjected to fire or heat can become highly corrosive. Handle with seamless industrial gloves only. Should skin contact occur, remove contaminated clothing immediately and obtain medical assistance without delay. Meanwhile, wash the affected area with copious amounts of cold water or limewater for 15 to 60 minutes. RECYCLING AND THE ENVIRONMENT It is illegal to dispose of used oil in the ground, down sewers or drains or into waterways. Dispose of used oil through authorised waste disposal contractors. If in doubt contact your local Authority for advice on disposal facilities. WARNING : Procedures which must be followed precisely in order to avoid the possibility of personal injury. CAUTION : This calls attention to procedures which must be followed to avoid damage to components. NOTE : This calls attention to methods which make a job easier or gives helpful information. Superwinch reserve the right to alter model specifications without prior notice. REPAIRS AND REPLACEMENTS Before you contact Superwinch or your nearest Dealer please have ready the following information : Kit No. Serial No. of P.T.O. Part No. required POISONOUS SUBSTANCES Many liquids and other substances used should under no circumstances be consumed, and should be kept away from open wounds. These substances include (among others) hydraulic oil INTRODUCTION

5 GENERAL SPECIFICATION DATA 02 P.T.O. Type... Mechanical Input / Output Shaft Alignment... Centred, straight through Gear ratio... 1 : 1 Weight... 7 kg (15.5 lbs) GENERAL SPECIFICATION DATA 02-1

6 03 POWER TAKE OFF INSTALLATION OVERVIEW Before beginning the installation of your P.T.O. identify the parts in the following assembly which corresponds to the kit you have purchased: MECHANICAL CENTRE P.T.O. KIT FOR L.R. 90/110 4 CYL. Part No MECHANICAL CENTRE P.T.O LINKAGE KIT P.T.O. FITTING KIT FITTING INST & PARTS LIST MECHANICAL CENTRE P.T.O. KIT FOR L.R. 90/110 V8 Part No MECHANICAL CENTRE P.T.O LINKAGE KIT P.T.O. FITTING KIT FITTING INST & PARTS LIST MECHANICAL CENTRE P.T.O. KIT FOR RANGE ROVER Part No MECHANICAL CENTRE P.T.O LINKAGE KIT P.T.O. FITTING KIT FITTING INST & PARTS LIST 03-1 POWER TAKE OFF INSTALLATION

7 POWER TAKE OFF INSTALLATION Using handbrake fixing indicated as a guide, mark hole in heelboard in accordance with dimensions given. Drill a pilot hole at point marked and open hole to 19mm diameter. Remove sharp edges, treat bare metal and fit the grommet provided. Position replacement gasket against rear transfer box and fit oil catcher assembly into appropriate hole as indicated. Align P.T.O. assembly to rear of transfer box and secure with fixings provided. Remove centre seat panel for access. Remove cover plate and gasket from rear transfer box. Assemble linkage to P.T.O. and engage lever through grommet previously fitted. Fit locknut and knob. NOTE : Bearings must be pre-lubricated with 25ml max of transfer case oil through grub screw hole indicated. Grub screw to be then sealed in position (flush) with P.T.O. casting, with HYLOMAR PL32 or similar. POWER TAKE OFF 03-2

8 04 PTO OPERATION OPERATING INSTRUCTIONS To engage the power take off, depress the clutch, pull the selector knob to/from the heel board then release the clutch. For stationary applications the transfer gear lever must be in the neutral position. For continuous running under stationary conditions it is recommended that fourth gear only is selected to reduce the heat generated by the gearbox. Direction of rotation is anti-clockwise when viewed from the rear. For accurate control of engine speed it will be necessary to fit an engine speed governor PTO OPERATION

9 MAINTENANCE AND REPAIRS 05 MAINTENANCE INSTRUCTIONS Every 100 hours of operation or 12 months, whichever is sooner:- Change oil in transfer box gearbox as per manufacturers recommendations. Lightly oil selector linkage. MAINTENANCE AND REPAIRS 05-1

10 06 TROUBLESHOOTING CONDITION POSSIBLE CAUSE CORRECTION LACK OF DRIVE. P.T.O. GENERATING EXCESSIVE NOISE. EXTRANEOUS OIL APPARENT OVERHEATING Dog clutch not fully engaged. Drive Shaft Broken. Sliding Dog broken. Coupling Flange broken. Lack of lubricant. Bearings worn excessively. Other equipment leaking. Worn seal. Damaged Gasket. Damaged Casing. Lack of lubricant. Continuous running under stationary conditions. Check that Link Rod is moving to full extent. Check condition of Clevis Pins / Pivot Bushes and Link Rod. Check Roll Pin is not broken. Check Clevis Pins are not broken. Check for Internal Teeth stripping. Replace. Replace. Replace. Check Transfer Box oil level. Check all oilways for blockages. Replace. Clean area thoroughly. Run PTO and look for source. Replace. Replace. Replace. See above. Allow to cool, select fourth gear TROUBLESHOOTING

11 ASSEMBLY DRAWINGS 07 ASSEMBLY DRAWINGS 07-1

12 LINKAGE KIT FOR L.R. 90/110 4 CYL Part No WASHER LOCKNUT KNOB GROMMET SPLIT PIN PIVOT BUSH LINK ROD OPERATING SHAFT CLEVIS PIN LINKAGE KIT FOR L.R. 90/110 V8 Part No WASHER LOCKNUT KNOB GROMMET SPLIT PIN PIVOT BUSH LINK ROD OPERATING SHAFT CLEVIS PIN LINKAGE KIT FOR RANGE ROVER Part No WASHER LOCKNUT KNOB GROMMET SPLIT PIN PIVOT BUSH CLEVIS PIN LINK ROD OPERATING SHAFT 07-2 ASSEMBLY DRAWINGS

13 MECHANICAL CENTRE P.T.O. KIT FOR LAND ROVER Part No BOLT BALL BEARING BALL BEARING 'O' RING OIL SEAL HEX BOLT M10 x 16mm HEX BOLT M16 x 30mm HEX SET SCREW M5 x 10mm SKT HEAD SET SCREW LOCKNUT M SPRING WASHER M SPRING WASHER M SPRING WASHER M SERRATED WASHER EXTERNAL BALL ROLL PIN WASHER, COPPER, M PIVOT POST SLIDING DOG SELECTOR FORK SELECTOR SHAFT SEALING PLATE SPRING P.T.O. BODY SPACER GASKET CENTRE P.T.O. SHAFT OIL SEAL HOUSING OUTER MUD SHIELD COUPLING FLANGE INNER MUD SHIELD WASHER HEX SET SCREW M8 x 25mm P.T.O. FITTING KIT Part No BOLT SPRING WASHER GASKET OIL CATCHER ASSEMBLY N/S LUBRICATION LABEL N/S WARNING LABEL ASSEMBLY DRAWINGS 07-3

14 MECHANICAL CENTRE P.T.O. KIT FOR RANGE ROVER Part No P.T.O. BODY CENTRE - P.T.O. SHAFT BALL BEARING SPACER BALL BEARING OIL SEAL HOUSING OUTER MUD SHIELD GASKET BOLT M8 x 25mm SPRING WASHER M OIL SEAL COUPLING FLANGE INNER MUD SHIELD WASHER SERRATED WASHER - EXTERNAL HEX SET SCREW SLIDING DOG SELECTOR FORK SELECTOR SHAFT ROLL PIN BALL SPRING WASHER, COPPER, M HEX SET SCREW M10 x 16mm 'O' RING SEALING PLATE SPRING WASHER M HEX SET SCREW M5 x 10mm PIVOT POST 50 7(1) SPRING WASHER M LOCKNUT SKT HEAD SETSCREW 07-4 ASSEMBLY DRAWINGS

15 GUARANTEE 08 Superwinch Limited Warranty Valid World Wide LIMITED WARRANTY. Superwinch ( Seller ) warrants to the original buyer ( you ) all parts and components except wire rope to be free from defects in materials and workmanship for a period of (one) 1 year from the provable date of purchase. Any Superwinch product which is defective will be repaired or replaced without charge to you, upon compliance with these procedures. The warranties set forth herein are exclusive and in lieu of all other warranties, whether oral or written, express or implied. LIMITED WARRANTY PERFORMANCE PROCEDURE. Upon discovery of a defective Superwinch product, you shall mail to the Seller at his factory or any Factory Authorised Service Centre written notice of such defect and mail, ship or otherwise deliver the defective Superwinch, postage or shipping prepaid. Repairs or replacements by Seller under this limited Warranty will normally be accomplished within fifteen (15) business days after receipt of the defective Superwinch. Seller or its Authorised Agents may make reasonable charges for parts and labour for repairs not covered by this limited warranty. WARRANTY AND REMEDY LIMITATIONS AND EXCLUSIONS. Repair and/or replacement of the defective Superwinch or component thereof as provided herein is the exclusive remedy for the Buyer. The following exclusions or limitations of warranties and limitations of remedies shall be expressly applicable: A. Express warranties. Seller Warrants that the Superwinch is as described in the Superwinch Owner s Manual provided herewith; no other express warranty is made in respect to the Superwinch. If any model or sample was shown to the Buyer, such model or sample was used for illustrative purposes only, and shall not be construed as a warranty that the Superwinch will conform to the sample or model. SELLER MAKES NO EXPRESS WARRANTY WITH RESPECT TO WIRE ROPE INCORPORATED IN THE PRODUCT. B. Implied Warranties. THE IMPLIED WARRANTY OF MERCHANTABILITY AND ALL OTHER IMPLIED WARRANTIES SHALL ONLY EXTEND FROM THE PROVABLE DATE OF PURCHASE FOR ONE (1) YEAR. THE WIRE ROPE IS SOLD AS IS, WITHOUT ANY IMPLIED WARRANTIES. SOME STATES WITHIN THE USA DO NOT ALLOW LIMITATIONS ON HOW LONG AN IMPLIED WARRANTY LASTS, SO THE ABOVE LIMITATION MAY NOT APPLY TO YOU. C. Incidental and Consequential Damages. SUBJECT TO SELLER S LIMITED WARRANTY OBLIGATIONS SET FORTH HEREIN, SELLER SHALL NOT BE RESPONSIBLE FOR INCIDENTAL DAMAGES OF ANY KIND, OR FOR CONSEQUENTIAL DAMAGES TO PROPERTY, LOSS OF PROFITS AND LOSS OF USE WHICH MAY BE CAUSED BY ANY DEFECT IN, OR MALFUNCTION, OR FAILURE OF ENCLOSED SUPERWINCH. SOME STATES WITHIN THE USA DO NOT ALLOW EXCLUSION OR LIMITATION OF INCIDENTAL OR CONSEQUENTIAL DAMAGES, SO THE ABOVE LIMITATION OR EXCLUSION MAY NOT APPLY TO YOU. D. Condition of Warranty. Seller shall not be required to comply with its warranty duties provided herein if the defect, malfunction, or failure of the Superwinch was caused by damage (not resulting from defective or malfunctioning components) or unreasonable use by you. Unreasonable use shall include, but is not limited to, installation or use of the Superwinch without compliance with the instructions contained in the Superwinch Owner s Manual for the particular model number. Seller s liability under this warranty or for any loss or damage to the Superwinch product shall not exceed the cost of correcting defects in or replacing the Superwinch product, and upon expiration of the warranty period, all such liability shall terminate. The agents, dealers and employees of the Seller are not authorised to make modifications to this warranty, or additional warranties binding on the Seller. Accordingly additional statements, whether oral or written, do not constitute warranties and should not be relied upon. LEGAL REMEDIES OF BUYER. This Limited Warranty gives you specific legal rights, and you may also have other rights which vary from State to State within the USA and from country to country. You may also have implied warranty rights. In the event of a problem with Limited Warranty service or performance, the Buyer may be able to go to small claims court, a state Court or a federal district court in the USA or to appropriate jurisdictions outside the USA. INQUIRES. Any enquiries regarding compliance with the warranties provided herein may be addressed in writing to: Superwinch Ltd., Abbey Rise, Whitchurch Road, Tavistock, Devon PL19 9DR, UK. or to: Superwinch Inc., Winch Drive, Putnam, CT 06260, USA GUARANTEE 08-1

16 This Manuals Part No. is : 8854 Issue No Superwinch Ltd., Abbey Rise, Whitchurch Road, Tavistock, Devon. Great Britain. PL19 9DR +44 (0) (0) support@superwinch.net Superwinch Inc., Winch Drive, Putnam, Connecticut U.S.A. (860) (860)