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Wesley Harmon
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1 CS0 & CS Series clutch shift pto parts list and service manual U.S. Pat.,2,0 for the allison world transmission

2 CS0 & CS Series Clutch shift PTO Exploded View

3 parts list and description item qty part number description 0T2 Input Gear (0) (0T/2T) (See Table A for additional gears) 2 2 0T Input Bearing 2a 8T88 Cone Spacer( 0./0.) (See Table B for additional spacers) 8T8 Bearing Shim (See Table C for additional shims) 9T98 Capscrew C, D, 2 T20 Bearing Cover, Closed (CS0) T90 Bear. Cov. w/o Valve Prov. (CS) 2T08 O-Ring 2T20 O-Ring 8 0T99 Bearing 9 2 2T Roll Pin (CS0) 0 2T0 Drag Brake Plate (CS0) 2T2 Bronze Brake Disc (CS0) 2 2T Drag Brake Rotor (CS0) 2T00 Snap Ring 2 0T989 Thrust Race 0T99 Bearing 02T29 Bell Gear (0) (T) 02T220 Bell Gear (0) (T) 02T22 Bell Gear (0) (T) 02T222 Bell Gear (08) (0T) 02T22 Bell Gear (0) (8T) 02T Clutch Hub (Before /99) 9TA Clutch Hub Assembly (/99) (Includes: a,b,c) (See Pg 8) a 9T920 Clutch Hub (/99) b 9T92 Clutch Flange (/99) c 2T9 Snap Ring (/99) d 0T90 Thrust Washer (/99) (Used w/9ta Only) 8 9T Friction Disc 9 9T0 Spacer Disc (Before /99) 9T0 Spacer Disc (/99) 20 2T2 Spring 2 9T Piston 22 2T0 O-Ring 2 2 2T0 O-Ring 2 9T Piston Cup 2 2 2T O-Ring 2 9T8 Set Screw 2 0T80 Idler Shaft 28 0T20 Housing ( Arrangement) 0T202 Housing ( Arrangement) Output Shafts (OS) were changed /99 to accommodate the two-piece clutch hub (). When replacing shaft in PTO prior to /99, clutch hub assembly () and washer (d) must be added to required parts. 29 0T92 OS B replaces 0T09 0T9 OS C, 2, X replaces 0T02 0T9 OS D, S replaces 0T0 0T9 OS E, Y, Z replaces 0T0 0T9 OS I replaces 0T82 0T9 OS P replaces 0T99 0 0T Output Bearing 2T02 Woodruff Key 2 2T O Ring T9 Seal T922 Bearing Cov., Open ( 2, B, C, X ) T Hyd Flange ( D, P, Z ) item qty part number description continued T0 Hyd Flange ( E Only) T00 Hyd Flange ( Y Only) T8 Hyd Flange ( I Only) T Hyd Flange ( S Only) 9T9 Capscrew ( B, C, X, 2 ) T99 Companion Flange ( C Only) T98 Companion Flange ( 2 Only) 2T20092 Washer ( C, 2 Only) 8 2T202 Lock Washer ( C, 2 Only, If Req.) 9 9T2022 Capscrew ( C Only) (CS) 9T82 Capscrew ( X, 2 Only) (CS) 0 9T92 Socket Capscrew D, P, S, Z Hyd 9T8 Socket Capscrew I Hyd 9T Socket Capscrew E, Y Hyd (CS0/) 2T2 Cap Plug D, S (Storage Only) 2T9 Cap Plug E, I, Y, Z (Storage Only) 2T2 Cap Plug P (Storage Only) 2 T092 Solenoid (2 Volt) TA Solenoid (2 Volt) 2T28 Pipe Plug 2 9T Set Screw 2 2T Spring T Gasket 2T999 Plug 8 2T8 Orifice 9 T8 Elbow 0 T8 Hose T2 Tee 2 9T28 Hose Clamp 2T8 Washer TK88 Standard Hose Kit TK88 HD For R.S. Installation T2 Hose (Std 28 ) T2 Hose (HD R.S. ) M80 Elbow T Elbow (use as needed) 20MK00 Mounting Bolt Kit (Incl., 8) 2 20T9 Alignment Stud 8 8 9T8 2 Pt. Capscrew (0mm) 9 9T9 Protector 0 T928 Remote Mount Valve Ass y (CS) (See Page ) 2T029 Caplug 2 2 2T029 Caplug (CS) N.S. 8TK0 Installation Kit (2v) Incl: Shift Kit, Gasket Pack, Stud Kit, Std. Hose Kit 8TK09 Installation Kit (2v) Incl: Shift Kit, Gasket Pack, Stud Kit, Std. Hose Kit N.S. CS0-GSK Gasket Kit Incl: (), (), ()22, (2)2, (2)2, ()2, (), () N.S. CS0-RBK Rebuild Kit Incl: (2)2, (), (), (), ()8, (2)9, (), (), (2), (), ()8, ()9, ()22, (2)2, (2)2, ()0, ()2, (), (2),() N.S. 8TK0 CS Conversion Kit Includes: TK0 Hose Kit (page ), T928 Control Valve 2VDC, TA0 Cover Kit, and Solenoid Mounting Hardware. N.S. 2T02 Caplug * Date Code Is Located Under PTO Model Label.

4 CS0 SERIES CONVERSION TO REMOTE ACTIVATION SOLENOID CONVERSION KIT 8TK92 Plug Plug 9 Transmission Main Press Connection Exhaust Line 0 -JIC Exhaust Line Pressure one port, plug other port 8 CL PS IN BLACK RED Blue Green A 2 Block Valve must be spaced off any flat surface using washers() to prevent damage to solenoid. 2 CONVERSION KIT - 8TK92 ** 0T2 Pressure Switch 2** T82 Wire Harness T0 /8 NPT/JIC Fitting 2 T8 /8 NPT/JIC Elbow T2 Hose Assembly T2 Straight Branch Tee M80 /-20 Str. Elbow 8 T928 Valve 2V D.C. 9 2T02 Cavity Plug 0 2 2T2 Str. Plug 2T28 Pipe Plug SOLENOID MOUNTING HARDWARE 2 2 9T2 Capscrew 2 22T0 Nut 2 2T99 Lockwasher 2 2T2 Washer ** Included with original PTO, not included in this kit. TABLE A INPUT GEAR ASSEMBLY ITEM (Sold only as assembly) Input Sub Designation Based on Ratio Teeth Assembly Input Gear 0TA9 A00 0T2 0 0T/2T 0TA20 A00 0T2 0 0T/29T 0TA2 A00 0T2 0 0T/T 0TA22 A008 0T2 08 0T/T 0TA2 A00 0T28 0 0T/T tables a, b, c TABLE B Cone Spacer ITEM 2a PART NO. thickness 8T88 0./0. 8T82 0.0/0.8 8T8 0./0. 8T8 0./0.2 8T8 0./0.29 8T8 0.28/0.2 8T8 0.2/0.2 8T /0.20 8T89 0.9/0. 8T80 0./0. 8T890 0./0. 8T89 0.0/0.08 8T /0.0 TABLE C Bearing Shim ITEM PART NO. thickness 8T 0.00/0.80 8T8 0./0. 8T2 0.0/0.0 8T80 0.2/0.0 8T 0.00/0.80 8T829 0./0. 8T /0.0 8T /0.0 8T / T82 0.2/0.2 8T /0.20 8T8 0.20/0.20

5 Installation kits CS0 INSTALLATION KIT - 8TK882 (2V) 0T20 Switch Ass y (includes,2,,) MA00 Switch Bracket 2 T2 Face Plate without light access 0T8 Rocker Switch (2v) T299 Fuse Assembly 0T9 Pressure Switch M820 Female Spade Connector M8009 Ring Terminal 8 2 M88 Female Spade Connector 9 M8002 Butt Splice 0 T0902 Wire Harness M8000 Wire 2 T Grommet N.S. MK00 Bolt Kit Incl. w/0t20 & 0T N.S. M022 Elbow For 2v Option Kit No. 8TK89 (substitute) 0T Switch Ass y (includes & 2 above and below. 0T2 Rocker Switch (2V) CS0 INSTALLATION KIT with DIRECT ACTIVATION SOLENOID (No Hose Kit required) CS INSTALLATION KIT with REMOTE ACTIVATION SOLENOID CS CONVERSION KIT - 8TK0 (2V) Use with 8TK882 (N.S.) T0 /8 NPT/JIC Fitting 2 T8 /8 NPT/JIC Elbow T2 Hose Assembly T2 Straight Branch Tee M80 / 20 Str. Thread Elbow 8 T928 Valve 2V D.C. 9 TA0 Cover Assembly (Includes Bearing & o-ring ( & ) as shown on page 2. N.S. 2 9T2 Capscrew N.S. 2 22T0 Nut N.S. 2 2T99 Lockwasher For 2v Option Kit No. 8TK02 (Use with 8TK89) Substitute: 8 T9 Valve 2V D.C. 9 8 CL PS IN BLACK RED CAUTION: INSTALL EXHAUST FITTING INTO PIPE THREAD PORT IN END COVER. USE PIPE THREAD SEALANT ONLY, DO NOT USE TAPE. OVER-TIGHTENING THIS FITTING INTO PORT MAY CAUSE BLOCKAGE AND SOLENOID WILL NOT RELEASE PTO CLUTCH PACK. Blue Green A -JIC Transmission Main Press Connection 0 T82 Old Style Harness + A CIRCUIT INSTALLATION When used without Overspeed Switch RED light in rocker switch is to turn "ON" when PTO is engaged and to turn "OFF" when PTO is disengaged. * Battery Ground 0 2 2v DC Neg. Ground Green Red Black Blue * A 2 SPD-00A CIRCUIT INSTALLATION When used with Overspeed Switch Red Green Black Black Blue * * GREEN 2V DC Neg. Ground * Battery Ground YELLOW Red White * 9 CTO Tach Output 8 + ** ** Faceplate (M00) and 2V light assembly (2MSRRV) are available in their own separate kit (TK9). Sold Separately + RED light in rocker switch is to turn "ON" when PTO is engaged and to turn "OFF" when PTO is disengaged. PG-

6 Accessory kits installation hose kit TK88 Hose kit - Standard 28 TK88 Hose kit - For top r.s. HD Series TK Hose kit - special T2 Hose Assembly - Std. 28 T2 Hose Assembly - HD Top T98 Hose Assembly - Special 2 M80 Elbow (Transmission) REPLACEMENT PARTS - BEFORE 2008 T Elbow (use as needed) (TK88 & TK only) 2 TK0 Hose kit for CS series T2 Hose Assembly - Std M80 Elbow (Transmission) T Elbow (use as needed) N.S. 2 T8 Elbow N.S. T2 Tee Fitting 2 20 ft.lb. B A - ft.lb. Solenoid Valve T928 (2V) - w/ T092 Solenoid T9 (2V) - w/ T Solenoid 8 22T929 Nut 2 T9088 2v Coil (Delta) T899 2v Coil (Delta) T99 Valve 2 2T908 O-ring * N.A. Manifold Blk(CS) 2 SPEED SENSOR KIT * (Not Sold Separately) TK8 SPECIAL OPTION U PS CL T08 Mag Pickup 2 2T09 Jam Nut MA Wiring Harness 2T099 Flat Washer 2T O-ring BLOCK TYPE VALVE FOR CS/CS2 T928 2V VALVE W/BLOCK (INCL. T092) T9 2V VALVE W/BLOCK (INCL. TA) 20MK00 BOLT KIT FOR CS0 2 mm 0mm w/lw QTY PART NO. DESCRIPTION 9T02 2pt. Capscrew - 0mm 2 9T2 2pt. Nordlock Capscrew - 2mm 2 20T9 Alignment Washer Stud 2T00 Nordlock Washer 2 mm 0mm w/lw Outside Nordlock Washer Mount two Mount halves two halves of 8of washer with washer insides with insides facing. facing. Inside Mount two halves Bolt kit The Outside two(2) 2mm long capscrews are to be Inside used in positions and as shown in diagram (Fig. ). The six() 0mm long capscrews and six() special lock washers are used in positions 2,,,,, & 8. Torque to lb.ft. 2 Figure. - CAPSCREW PLACEMENT 8 important The CS0 includes the mounting kit, special shim/gasket, high pressure hose hookup kit, wiring harness, dash bracket kit, and installation instructions. The PTO is available with a pulse generator (pick-up) for use with the Muncie Digital Tachometer - 8MK2000 (request MP92-0) or use with the Muncie digital switch SPD-00A to control the engagement or overspeed protection of the PTO. Contact your Muncie Application Specialist for assistance with these options.

7 CS0 & CS disassembly and reassembly DENOTES SPECIAL SERVICE PROCEDURES (Reference Exploded View on page 2) disassembly procedure. Remove the CS0 input gear, by removing the set screw in the pad and driving the idler shaft from the housing. (2,2) 2. Remove the set screws () from the bearing cover () which hold the drag brake springs (). Position the housing so that the springs fall from housing.. Remove the four large socket capscrews () which hold the back cover to the PTO housing.. Position the housing against a bench block and hit the end of the output shaft with a soft face hammer to remove the entire output shaft assembly with bearing cover ().. Remove the two pipe plugs () from the bearing cover. This exposes the ball bearing assembly within the cover.. Using a / punch and alternating between the two holes, drive the bearing and shaft assembly from the bearing cover.. Using a bearing puller remove the rear bearing (8) by grabbing the drag brake plate (0) and removing both pieces. The bronze brake disk () can be removed. 8. Insert four /-20 capscrews into the drag brake rotor (2) until they just touch the back of the bell gear. Using an X pattern screw the capscrews in at / turn intervals until the brake rotor is free of the output shaft (29). 9. The piston and clutch pack may be serviced without removal of the drag brake. Using snap ring pliers, remove the snap ring () located on the output shaft end while gently pushing on the piston cup (2). 0. Pull the piston cup (2) from the shaft and the piston (2) will go with it.. Tap the piston cup on a wood surface to remove the piston. 2. Remove the spring (20). The clutch friction discs (8) and spacer discs (9) and inner clutch hub () can be removed by pointing the shaft end down.. With the drag brake removed, the snap rings () on this end of the bell gear can be removed with snap ring pliers. This allows the bell gear to be removed towards the closed end. The internal bearing () of the bell gear can easily be removed. Reassembly procedure. The reassembly of the unit is made in reverse of the disassembly. The re-use of seals, o-rings and snaprings are not recommended.. Be sure to lubricate the o-rings and all bearings upon installation. It is important to position drag brake plate so that input gear clears. This is the reason for the flat sides of the plate. Torque capscrews to the values shown or to the following values. / capscrews - 8 ft. lb. /8 capscrews - ft. lb. / set screw - 9 ft. lb. The Input Gear is replaced as a set which includes the gear, cone spacer, & bearings. See Table A. Slide this sub-assembly into the housing to line up the idler shaft. Tap the idler shaft into the housing and through both bearing races. 8 Tap the idler shaft in the reverse direction so that it is flush with the bearing in this assembly. Insert the thickest shim that can be installed by hand in the gap between the bearing and housing. Remove shim and select the next thicker shim and drive it into the gap. Rotating the gear to make sure it easily rotates. The recommended bearing pre-load is.002 to.00 loose. (The cone spacer sets this per-load and measurement is not required.) 9 Tap the idler shaft into position and install set screw. solenoid valve installation (CS0 ONLY) 20 Separate the coil from the valve assembly. Insert the valve cartridge into the rear cover and torque to 20 ft. lb. 2 Slip one o-ring and the coil over the valve. Slip the second o-ring on. 22 Place thread locking compound on the post threads and install nut. Torque the nut to ft. lb. max. 2 Place thread sealant on pipe plugs. Torque 0- ft. lb. drag brake adjustment (CS0 ONLY) 2. When installing the rear cover be sure to align the roll pins in the drag brake plate with the holes in the rear cover. NOTE: It is important that one of the flat edges of this plate is positioned towards the input gear. 2. After the cover has been attached to the housing insert the springs into the holes. 2. Insert the setscrew over the spring and turn the screw four () full turns. 2. Follow the test and adjustment procedures in the CS0 owners manual. DRAG BRAKE AND BELL GEAR REMOVAL SET SCREW ADJUSTMENT DRAG BRAKE TAPER ROLLER BEARINGS 29 /-20UNC 8 9 DROP-IN SOLENOID 2 2a 2c 22 2b 20 8 SET SCREW ADJUSTMENT DRAG BRAKE 2

8 PTO TYPE Clutch Shift CS model number construction MOUNTING 0-Bolt Mount 0 0-Bolt Mount with Remote Solenoid trans. CS Gear data Allison 0.P RH - A0 speed ratio 0 -.: 0 -.: 0 -.2: : 0 -.9: PTO assembly arrangements CS 0 A0 0 H B X special features X - None (Pressure Lube is standard on all units) B - Hose kit (HD Trans. R.S.) D - Pulse Generator & SPD-00A U - Pulse Generator - Activation Hose - Less Activation Hose (CS0) output type B - -/ Round /KW C - -/ 20 Spl. (0 Companion Flange) D - SAE B 2& Bolt E - SAE C 2& Bolt I - DIN 2 P - SAE B&B 2& Bolt S - SAE B 2 Bolt Y - SAE C 2 Bolt 2 - DIN Companion Flange Assembly arrangement or SHIFTER TYPE H - 2 Volt Electric/Hydraulic J - 2 Volt Electric/Hydraulic NO. Assembly NO. Assembly CS0 CLUTCH HUB REPLACEMENT Effective April 999 the clutch hub supplied in the CS0 Series PTO has the two piece clutch hub as shown on this page. The two piece hub consists of a splined hub and a flange which is held together by a snap ring. Because of this design change the clutch pack stack up has changed as shown on page 2. Begin by assembling the new Clutch Hub:. Place the flange (b) on to the Clutch Hub (a) so that the recessed area of the flange is against the splines. Fig.. 2. Using snap ring pliers install the Snap Ring (c) on to the Clutch Hub (a).. The New Clutch Hub requires a new output shaft. Select the appropriate shaft and install the Thrust Washer (d) against the splines on the out put shaft (29). Fig. 2.. Hold thrust washer in place with the Snap Ring (). 0T92 = 0T09X ( B ) 0T9 = 0T0X ( S, D ) 0T = 0T82X ( I ) 0T9 = 0T02X ( C, X, 2 ) 0T9 = 0T0X ( E, Y ) 0T9 = 0T99X ( P ) Current Inventory that has been reworked will have an X marked on the shaft by the part number.

9 dimensions in inches (mm) CS0 CS STD -/ Round keyed shaft ( B OPtion) -/2 0 spline w/0 Series flange ( C OPTION) SAE B 2& Bolt /8 spline ( D OPTION) SAE C 2& Bolt -/ spline ( E OPTION) DIN 2 MM 8 spline ( I OPTION) SAE B&B 2& Bolt spline ( P OPTION) SAE B 2 Bolt /8 spline ( S OPTION) SAE C 2-Bolt -/ spline ( Y OPTION) -/2 0 spline w/din 00 Flange ( 2 OPTION)

10 SP9-0 (Rev. 0-09) Printed in the U.S.A Member of the Interpump Hydraulics Group General Offices and Distribution Center P.O. Box 8 Muncie, IN () 28-2 FAX () info@munciepower.com Web site Drive Products, Exclusive Agents for Canada, ISO Certified by an Accredited Registrar

CS41 SERIES CLUTCH SHIFT PTO

CS41 SERIES CLUTCH SHIFT PTO PARTS LIST AND SERVICE MANUAL Patent #2004200334 Muncie Power Products, Inc. CS41 SERIES CLUTCH SHIFT PTO EXPLODED VIEW 46 2 MUNCIE POWER PRODUCTS, INC. PARTS LIST AND DESCRIPTION