CS0 & CS SERIES CLUTCH SHIFT PTO PRTS LIST ND SERVICE MNUL FOR THE LLISON WORLD TRNSMISSION U.S. Pat.,,06 Muncie Power Products, Inc.
CS0 & CS SERIES CLUTCH SHIFT PTO EXPLODED VIEW a a MUNCIE POWER PRODUCTS, INC.
CS0 WITH MODEL DTE CODE // ND PRTS LIST ND DESCRIPTION ITEM QTY PRT NUMBER DESCRIPTION 0T6 Input Gear (0) (0T/T) (See Table for additional gears) See Table Input Bearing a See Table Cone Spacer( 0./0.) See Table C Bearing Shim a. 8T Bearing Shim 9T98 Capscrew C, D, T606 Bearing Cover, Closed (CS0) T90 Bear. Cov. w/o Valve Prov. (CS) 6 T608 O-Ring T60 O-Ring 8 0T99 Bearing 9 6T6 Roll Pin 0 T60 Drag Brake Plate T6 Bronze Brake Disc T6 Drag Brake Rotor T600 Snap Ring 0T989 Thrust Race 0T99 Bearing 6 0T69 Bell Gear (0) (T) 0T60 Bell Gear (06) (T) 0T6 Bell Gear (0) (T) 0T6 Bell Gear (08) (0T) 0T6 Bell Gear (0) (8T) 0T6 Clutch Hub (Before /99) 9T6 Clutch Hub ssembly (/99) (Includes: a,b,c) (See Pg 9) a 9T90 Clutch Hub (/99) b 9T9 Clutch Flange (/99) c T9 Snap Ring (/99) d 0T90 Thrust Washer (/99) (Used w/9t6 Only) 8 9T6 Friction Disc 9 9T06 Spacer Disc (Before /99) 6 9T06 Spacer Disc (/99) 0 T6 Spring 9T6 Piston T60 O-Ring T60 O-Ring 9T6 Piston Cup T O-Ring 6 9T8 Set Screw 0T80 Idler Shaft 8 0T9 Housing ( rrangement) 0T9 Housing ( rrangement) 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. 9 06T9 OS B replaces 06T609 06T9 OS C,, X replaces 06T60 06T9 OS D, S replaces 06T60 06T9 OS E, Y, Z replaces 06T60 06T96 OS I replaces 06T68 06T9 OS P replaces 06T699 0 0T Output Bearing 6T06 Woodruff Key T O-Ring T9 Seal T96 Bearing Cov., Open (, B, C, X ) T6 Hyd Flange ( D, P ) T988 Hyd Flange ( Z ) T06 Hyd Flange ( E Only) T600 Hyd Flange ( Y Only) ITEM QTY PRT NUMBER DESCRIPTION continued T68 Hyd Flange ( I Only) T Hyd Flange ( S Only) T8 Hyd Flange ( EW ) 6 9T9 Capscrew ( B, C, X, ) 6 T99 Companion Flange ( C Only) T98 Companion Flange ( Only) T Companion Flange DIN 0 ( 9 ) T009 Washer ( C, Only) 8 T06 Lock Washer ( C,, 9 Only, If Req.) 9 9T0 Capscrew ( C Only) 9T866 Capscrew ( X,, 9 Only) 0 6 9T9 Socket Capscrew D, P, S, Z Hyd 9T86 Socket Capscrew I Hyd 9T Socket Capscrew E, Y Hyd T Cap Plug D, S (Storage Only) T96 Cap Plug E, I, Y, Z (Storage Only) T Cap Plug P (Storage Only) T609 Solenoid ( Volt) T6 Solenoid ( Volt) T68 Pipe Plug 9T6 Set Screw T6 Spring 6 T Gasket T999 Plug 8 T8 Orifice 9 T86 Elbow 0 T86 Hose T6 Tee 9T68 Hose Clamp T68 Washer TK88 Standard Hose Kit TK88 HD For R.S. Installation T6 Hose (Std 8") T6 Hose (HD R.S. ") M680 Elbow 6 T6 Elbow (use as needed) 0MK00 Mounting Bolt Kit (Incl., 8) 0T9 lignment Stud 8 8 9T8 Pt. Capscrew (0mm) 9 9T69 Protector 60 T98 Remote Mount Valve ss y (CS) (See Page ) 6 T09 Cap Plug 6 T09 Cap Plug (CS) N.S. 8TK900 Installation Kit CS0 (V) 8TK Installation Kit CS0 (V) EW Output Incl: TK Hose Kit 8TK0 Installation Kit CS (v) Incl: Shift Kit, Gasket Pack, Stud Kit, Std. Hose Kit 8TK09 Installation Kit CS (v) Incl: Shift Kit, Gasket Pack, Stud Kit, Std. Hose Kit N.S. CS0-GSK Gasket Kit Incl: ()6, (), (), (), (), (), (), ()6 N.S. CS0-RBK* Rebuild Kit Incl: (), ()6, (), ()8, ()9, (), (), (), (), ()8, ()9, (), (), (), ()0, (), (), (),()6 N.S. 8TK0 CS Conversion Kit Includes: TK06 Hose Kit (page 6), T98 Control Valve VDC, T06 Cover Kit, and Solenoid Mounting Hardware. N.S. T0 Cap Plug * Date Code Is Located Under PTO Model Label. * Rebuild kit does not include cone spacer or bearings, these are only sold with input gear. MUNCIE POWER PRODUCTS, INC.
CS0 SERIES CONVERSION TO REMOTE CTIVTION SOLENOID CONVERSION KIT 8TK9 Plug Plug 9 Transmission Main Press Connection Exhaust Line 0 -JIC Exhaust Line Pressure one port, plug other port 8 CL PS IN 6 BLCK RED Blue Green Block Valve must be spaced off any flat surface using washers () to prevent damage to solenoid. CONVERSION KIT - 8TK9 ** 0T6 Pressure Switch ** T8 Wire Harness T0 ⅛" NPT/JIC Fitting T86 ⅛" NPT/JIC Elbow T6 Hose ssembly 6 T6 Straight Branch Tee M680 6-0 Str. Elbow 8 T98 Valve V D.C. 9 T0 Cavity Plug 0 T66 Str. Plug T68 Pipe Plug SOLENOID MOUNTING HRDWRE 9T66 Capscrew T0 Nut T99 Lockwasher T Washer ** Included with original PTO, not included in this kit. TBLE INPUT GER SSEMBLY ITEM & ITEM a (Sold only as assembly) Input Sub Designation Based on Ratio Teeth ssembly Input Gear 0T69 00 0T6 0 0T/T 0T60 006 0T6 06 0T/9T 0T6 00 0T66 0 0T/T 0T6 008 0T6 08 0T/T 0T6 00 0T68 0 0T/6T TBLE C Bearing Shim ITEM (Sold only as kit) 8TK Bearing Shim kit for models with date Code // or later 8TK 86 Bearing Shim kit for models with date Code before // MUNCIE POWER PRODUCTS, INC.
CS0 INSTLLTION KIT - 8TK88 (V) 6M00 Switch Bracket 6T6 Face Plate without light access 0T68 Rocker Switch (v) T699 Fuse ssembly 0T9 Pressure Switch 6 M80 Female Spade Connector M8009 Ring Terminal 8 M88 Female Spade Connector 9 M800 Butt Splice 0 T8 Wire Harness 6 M8000 Wire T6 Grommet N.S. 6MK00 Bolt Kit Incl. w/0t60 & 0T6 N.S. M0 Elbow INSTLLTION KITS For v Option Kit No. 8TK89 (substitute) 0T6 Switch ssembly (Incl. Items # & above & # below) 0T Rocker Switch (V) CS CONVERSION KIT - 8TK0 (V) Use with 8TK88 (N.S.) T0 ⅛" NPT/JIC Fitting T86 ⅛" NPT/JIC Elbow T6 Hose ssembly 6 T6 Straight Branch Tee M680 6 0 Str. Thread Elbow 8 T98 Valve V D.C. 9 T06 Cover ssembly (Includes Bearing & O-Ring (6 & ) as shown on page. N.S. 9T66 Capscrew N.S. CIRCUIT INSTLLTION T0 WHEN Nut USED N.S. WITHOUT T99 OVERSPEED Lockwasher SWITCH For v Option Kit No. 8TK0 (Use with 8TK89) Substitute: 8 T96 Valve V D.C. 9 CS INSTLLTION KIT with REMOTE CTIVTION SOLENOID 8 IN CIRCUIT INSTLLTION WHEN USED PS 6 BLCK RED Blue Green WITH OVERSPEED CL SWITCH CUTION: INSTLL EXHUST FITTING INTO PIPE THRED PORT IN END COVER. USE PIPE THRED SELNT ONLY, DO NOT USE TPE. OVER-TIGHTENING THIS FITTING INTO PORT MY CUSE BLOCKGE ND SOLENOID WILL NOT RELESE PTO CLUTCH PCK. -JIC Transmission Main Press Connection 0 T8 Old Style Harness + CIRCUIT INSTLLTION 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 v DC Neg. Ground Green Black Blue Red * 9 6 + 0 SPD-00 Red CIRCUIT INSTLLTION When used with Overspeed Switch Green Black Black Blue * * GREEN V DC Neg. Ground * Battery Ground YELLOW Red White * 6 9 CTO Tach Output 8 + ** ** Faceplate (6M006) and V light assembly (MSRRV) are available in their own separate kit (6TK9). Sold Separately + RED light in rocker switch is to turn "ON" when PTO is engaged and to turn "OFF" when PTO is disengaged. 6 MUNCIE POWER PRODUCTS, INC. PG-
CCESSORY KITS INSTLLTION HOSE KIT TK88 HOSE KIT - STNDRD 8" TK88 HOSE KIT - FOR TOP R.S. HD SERIES " TK HOSE KIT - SPECIL " T6 Hose ssembly - Std. 8" T6 Hose ssembly - HD Top " T986 Hose ssembly - Special " SCREW-IN SOLENOID M680 VLVE Elbow (Transmission) REPLCEMENT PRTS - BEFORE 008 T6 Elbow (use as needed) (TK88 & TK only) TK06 HOSE KIT FOR CS SERIES T6 Hose ssembly - Std. 8" M680 Elbow (Transmission) T6 Elbow (use as needed) N.S. T86 Elbow N.S. T6 Tee Fitting P.N. DESCRIPTION T609 V CRTRIDGE T6 V CRTRIDGE 0 ft.lb. B - ft.lb. SOLENOID VLVE T98 (V) - w/ T609 Solenoid T96 (V) - w/ T6 Solenoid 8 T99 Nut T9088 v Coil (Delta) T899 v Coil (Delta) * T9 Valve T908 O-Ring * N.. Manifold Blk(CS) SPEED SENSOR KIT * (Not Sold Separately) TK8 SPECIL OPTION U PS CL T08 Mag Pickup T09 Jam Nut M Wiring Harness T6099 Flat Washer T O-Ring it lock sher BLOCK TYPE VLVE FOR CS/CS 0MK00 BOLT KIT FOR CS0 QTY PRT NO. DESCRIPTION 6 9T066 pt. Capscrew - 0mm 9T pt. Nordlock Capscrew - mm 0T9 lignment Washer Stud 6 T060 Nordlock Washer mm 0mm w/lw Outside Bolt Kit T98 V VLVE W/BLOCK (INCL. T609) T96 V VLVE W/BLOCK (INCL. T6) mm 0mm w/lw Nordlock mm 0mm w/lw Washer Nordlock Washer Mount two Mount halves two halves of 8of washer with washer insides with insides facing. facing. Inside 6 Mount two halves * Is Not Sold Separately BOLT KIT The Outside two() mm long capscrews are to be Inside used in positions and as shown in diagram (Fig. ). The six(6) 0mm long capscrews and six(6) special lock washers are used in positions,,, 6,, & 8. Torque to lb.ft. Outside Figure. - CPSCREW PLCEMENT 8 6 Inside IMPORTNT 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 - 8MK000 (request MP9-0) or use with the Muncie digital switch SPD-00D to control the engagement or overspeed protection of the PTO. Contact your Muncie pplication Specialist for assistance with these options. MUNCIE POWER PRODUCTS, INC.
CS0 & CS DISSSEMBLY ND RESSEMBLY DENOTES SPECIL SERVICE PROCEDURES (Reference Exploded View on page ) DISSSEMBLY PROCEDURE Remove the CS0 input gear, by removing the set screw in the pad and driving the idler shaft from the housing. (6, ) 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. 6 Using a ¼" 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 ¼-0 capscrews into the drag brake rotor () until they just touch the back of the bell gear. Using an X pattern screw the capscrews in at ¼ turn intervals until the brake rotor is free of the output shaft (9). 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 (). 0 Pull the piston cup () from the shaft and the piston () will go with it. Tap the piston cup on a wood surface to remove the piston. Remove the spring (0). 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. RESSEMBLY 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. 6 capscrews - 8 ft.lb. 8 capscrews - 6 ft.lb. ¼ set screw - 9 ft.lb. 6 The Input Gear is replaced as a set which includes the gear, cone spacer, and bearings. See Table. 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. DRG BRKE ND BELL GER REMOVL 6 SET SCREW DJUSTMENT DRG BRKE 8 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.00" to.006" 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 VLVE INSTLLTION (CS0 ONLY) 0 Separate the coil from the valve assembly. Insert the valve cartridge into the rear cover and torque to 0 ft.lb. Slip one O-Ring and the coil over the valve. Slip the second O-Ring on. Place thread locking compound on the post threads and install nut. Torque the nut to ft.lb. max. Place thread sealant on pipe plugs. Torque 0-6 ft.lb. DRG BRKE DJUSTMENT (CS0 ONLY) 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. fter the cover has been attached to the housing insert the springs into the holes. 6 Insert the setscrew over the spring and turn the screw four () full turns. Follow the test and adjustment procedures in the CS0 operator s manual. 0 TPER ROLLER BERINGS 6 6 9 /-0UNC 8 9 DROP-IN SOLENOID a c b 0 8 SET SCREW DJUSTMENT DRG BRKE 8 MUNCIE POWER PRODUCTS, INC.
PTO TYPE Clutch Shift CS MODEL NUMBER CONSTRUCTION MOUNTING 0-Bolt Mount 0 0-Bolt Mount with Remote Solenoid TRNS. CS GER DT llison 0.6P RH - 0 SPEED RTIO 0 -.: 06 -.6: 0 -.: 08 -.8: 0 -.9: PTO SSEMBLY RRNGEMENTS CS 0 0 0 H B X SPECIL FETURES X - None (Pressure Lube is standard on all units) B - Hose kit (HD Trans. R.S.) D - Pulse Generator & SPD-00 U - Pulse Generator - " ctivation Hose - Less ctivation Hose (CS0) OUTPUT TYPE B - -¼ Round 6 KW C - -¼ 0 Spl. (0 Companion Flange) D - SE B - &-Bolt E - SE C - &-Bolt I - DIN 6 P - SE B&B - &-Bolt S - SE B -Bolt V - Special for Extended Shaft Y - SE C -Bolt - DIN Companion Flange Z - SE B Flange w/se C Shaft 9 - DIN 0 Comp. Flange SSEMBLY RRNGEMENT or SHIFTER TYPE H - Volt Electric/Hydraulic J - Volt Electric/Hydraulic NO. SSEMBLY NO. SSEMBLY CS0 CLUTCH HUB REPLCEMENT Effective pril 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. 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... 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 (9). Fig... Hold thrust washer in place with the Snap Ring (). 06T9 = 06T609X ( B ) 06T9 = 06T60X ( S, D ) 06T66 = 06T68X ( I ) 06T9 = 06T60X ( C, X, ) 06T9 = 06T60X ( E, Y ) 06T9 = 06T699X ( P ) Current Inventory that has been reworked will have an X marked on the shaft by the part number. 9 MUNCIE POWER PRODUCTS, INC. 9
DIMENSIONS IN INCHES (MM) CS0 CS STD ¼" ROUND KEYED SHFT ( B OPTION) ½" 0 SPLINE W/0 SERIES FLNGE ( C OPTION) SE B &-BOLT 8" SPLINE ( D OPTION) SE C - &-BOLT ¼" SPLINE ( E OPTION) DIN 6 6MM 8 SPLINE ( I OPTION) SE B&B - &-BOLT " SPLINE ( P OPTION) SE B -BOLT 8" SPLINE ( S OPTION) SE C -BOLT ¼" SPLINE ( Y OPTION) ½" 0 SPLINE W/DIN 00 FLNGE ( OPTION) 0 MUNCIE POWER PRODUCTS, INC.
C L SE B FLNGE W/SE C SHFT ( Z OPTION) 6. 8.8.6. ½- UNC-B ( PLCS) EQ. SP.. [6.0] DI. B.C. 0.8. SPECIL FOR EXTENDED SHFT ( V OPTION).00 [0.] PILOT DI. ½- UNC-B ( PLCS) EQ. SP..00 [.0] DI. B.C. 6 9 0.69 6..998 0. MUNCIE POWER PRODUCTS, INC.
Member of the Interpump Group SP9-0 (Rev. 0/) 0 East Jackson Street Muncie, Indiana 0 800-6-86 Fax 6-8-699 info@munciepower.com www.munciepower.com Specifications are subject to change without notice. Visit www.munciepower.com for warranties and literature. ll rights reserved. Muncie Power Products, Inc. (009)