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NACD Power Take-Off Service Manual

1016070AM

11.5" TP Power Take OffIncludes Installation, Operation, Maintenance and Overhaul Instructions

North American Clutch & DrivelineRockford, Illinois

Phone: (800) 383-9204 (815) 282-7960Fax (815) 282-9160www.naclutch.com


Phone: (800) 383-9204(815) 282-7960

Fax (815) 282-9160www.naclutch.com

NOTICEIMPORTANT INFORMATION

It is imperative that proper installation, maintenance, operation and safety procedures be followed explic-itly regarding products manufactured by North American Clutch & Driveline.

GENERAL:Safe working and operating practices must be employed by all personnel working on, with, or near NACD products. NACD will not be responsible for personal injury.

SAFETY NOTICE:Accidents may result from use of manufactured products, resulting in possible danger to person(s) or property. Therefore, it is important and imperative that correct, safe procedures be followed. Products must be installed, maintained, operated and used in accordance with the engineering information specified. Continual and repeated inspections and observations should be employed as necessary to assure that safe operations and a safe environment exist under prevailing conditions. Use proper guards and other suitable safety equipment, devices and procedures that may be desirable or specified in safety codes, or as necessary to prevent accidental injury to person(s) or property. These devices are neither provided by NACD nor are they the responsibility of NACD.

OWNER / OPERATOR / USER RESPONSIBILITIES:Knowledge of and performance of the procedures specified in this publication are the responsibility of the owner(s), operator(s), user(s) and all person(s) working on or near the products described herein. Follow-ing these procedures and explicit adherence to the information described should ensure safe and reliable use, repair, and operation of products provided by NACD.

WARRANTY:NACD’s limited Warranty is described in detail in this publication. It is the responsibility of the original pur-chaser or manufacturer, successive buyers, users, third parties or employees to make themselves aware of this warranty and all conditions it contains.


Phone: (800) 383-9204 (815) 282-7960Fax (815) 282-9160www.naclutch.com 1

INTRODUCTION General Information

Replacement Parts

Parts Shipment

Preventative Maintenance/Troubleshooting

Safety

Sources of Service Information

Warranty

DESCRIPTION & SPECIFICATIONS General

INSTALLATION Preliminary Checks

Drive Ring Installation

Pilot Bearing Installation

Power Take-Off Installation to Engine Driving Member

Installation Tips

Torque Values for Fasteners

Allowable Side Loads

PREVENTATIVE MAINTENANCE Lubrication

Clutch Adjustment

DISASSEMBLYASSEMBLY

2

2

2

3

3

4

4

5

5

5

6

6

8

8

9

10

12

14

15

15

16

16

19

TABLE OF CONTENTS


Phone: (800) 383-9204(815) 282-7960

Fax (815) 282-9160www.naclutch.com2

INTRODUCTION

General Information

This publication provides the information necessary for the operation and maintenance of the NACD Power Take Off specified on the cover of this manual. Specific engineering details and performance characteristics can be obtained from the EngineeringDepartment of NACD, Rockford, Illinois, 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.

Replacement Parts

Parts Lists

Engineering assembly drawings and bill of materials are provided in appropriate sections of this manual to facilitate ordering spare or replacement parts.

Ordering Parts

All replacement parts or products (including hoses and fittings) must be of NACD origin or equal, and otherwise identical with components of the original equip-ment. 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 NACDdistributor or service dealer.



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. NACD will not be responsible for any charges incurred by this procedure.

NACD, 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 NACD. 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 cov-ered by a NACD warranty.

Preventative Maintenance/Troubleshooting

Frequent reference to the information provided in this manual regarding daily operation and limitations of this equipment will assist in obtaining trouble-free operation. Sched-ules are provided for the recommended maintenance of the equipment and, if observed, minimal repairs (aside from normal wear) will result.

Lifting Bolt Holes

Most NACD products have provisions for attaching lifting bolts. The holes provided are always of adequate size and number to safely lift the NACD product.

These lifting points must not be used to lift the complete power unit. Lifting exces-sive 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.


Phone: (800) 383-9204(815) 282-7960


Safety

General

Safe practices must be employed by all personnel operating and servicing this unit. NACD 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 NACD nor are they the responsibility of NACD. The maximum safe operating

speeds of this 11.5" triple plate (TP) NACD power take-off is 2800 RPM.

Sources of Service Information

Each series of manuals issued by NACD 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 NACD products, contact any NACD distributor, or contact the sales

department, NACD, PO Box 15130, Rockford, IL 61132-5130, USA or by email at [email protected].



DESCRIPTIONS & SPECIFICATIONS

General

The NACD 11.5" TP Power Take-Off are engine mounted power take-offs that use cast iron two-piece housings and contain an integral triple plate clutch 11 1/2 inches in di-ameter. The engine drives the clutch through a drive ring that is bolted to the engine flywheel and connected to the clutch through internal teeth that mesh with external teeth on the clutch friction plate(s). Clutch engagement and disengagement for most units is accomplished by use of the external hand lever assembly. Some units may use other actuation methods.

Main bearings are lubricated and cooled with grease. Most units use pilot bearings that are pre-lubricated and sealed for life, although some may require periodic re lubrication. Those that require periodic lubrication are lubricated through a grease fitting located in the output end or side of the clutch shaft.

Warranty

Equipment for which this manual was written has a limited warranty. For details of the warranty, refer to the warranty statement at the end of this manual.


Phone: (800) 383-9204(815) 282-7960


INSTALLATION

Preliminary Checks

Note: All measurements must be taken with the engine or motor mounted on its sup-ports after the flywheel and housing have been thoroughly cleaned.

1.

2.

Figure 1: Checking Flywheel Housing Face

3.

4.

Figure 2: Checking Flywheel Housing Bore

5.

6.

Measure and record the engine crankshaft or motor shaft end play using a dial indica-tor. Record this value, as it will be used later. ______________

Attach 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 1.

Rotate the shaft through on entire revolution and note the run out. The total indicator reading must not exceed .008" (.2mm). Apply thrust onto crankshaft in one direction to prevent crankshaft end play from affecting run out measurement.

Reading the indicator so the stem rides on the pilot bore of the flywheel housing. See Figure 2.

Rotate the shaft through one entire revolutionand note the run out. The total indicator reading-should not exceed .008" (.2mm).

Remove the indicator base from the flywheeland attach it to the flywheel housing face. Posi-tion the indicator stem so that it rides where the drive ring will set on the flywheel face.See Figure 3.

Figure 1

Figure 2

6



Figure 3: Checking Drive Ring Surface of Flywheel

7.

8.

Figure 4: Checking Drive Ring Pilot Bore of Flywheel

9.

10.

Figure 5: Checking Pilot Bearing Bore of Flywheel

11.

Rotate the shaft through one entire revolution and note the face run out of the flywheel. The total indicator reading must not exceed .0005".01 mm) per inch (25.4 mm) of flywheel diameter.Apply thrust onto crankshaft in one direction toprevent crankshaft end play from affecting run out measurement.

Readjust the indicator stem so it rides on thedriving ring pilot bore of the flywheel. SeeFigure 4.

Rotate the shaft through one entire revolutionand note the driving ring bore eccentricity. Thetotal indicator reading must not exceed .005"(.13 mm).

Adjust the indicator stem so that it rides onthe pilot bearing bore cavity. See Figure 5.

Rotate the shaft through one entire revolutionand note the pilot bearing bore eccentricity. The total indicator reading must not exceed .005" (.13 mm).

Figure 3

Figure 4

Figure 5

7


Phone: (800) 383-9204(815) 282-7960


Drive Ring Installation

1.

2.

Drive ring attachment screws must be grade 8. Do not use substitutes.

Pilot Bearing Installation

FOR GREASABLE PILOT BEARING ONLY: If a pilot bearing adapter is used on the flywheel, be sure the mating surfaces between the adapter and the flywheel face are sealed, to prevent loss of grease from the pilot bearing grease cavity due to vacuum or centrifugal force. Loctite 515 or equivalent is suggested.

Proceed as follows:

FOR GREASABLE PILOT BEARING ONLY (BEARING HAS A GREASE SHIELD ON 1 SIDE ONLY): Pack the flywheel pilot bearing cavity with grease. Install the pilot bear-ing in the flywheel or adapter with the grease shield of a greasable bearing towards the PTO and clutch. Be sure that the pilot bearing spacer, if used, is in place. Two types of spacers may be used. Spacers may be installed in the flywheel to keep the pilot bearing from going too far into the bore in the flywheel, and a spacer may be used on the pilot end of the PTO shaft between the pilot bearing and the PTO to help maintain proper pilot bearing location in the flywheel bore.

FOR NON-GREASABLE PILOT BEARING ONLY (BEARING HAS 2 GREASE SEALS): Non-greasable, double-sealed pilot bearings require no re-lubrication and may be in-stalled in the flywheel or adapter with either side toward the PTO and clutch. The shaft should have no grease fittings. If it does, remove the grease fitting(s) and replace with pipe plugs as a precaution to insure grease is not forced into the pilot bearing cavity of the flywheel. A build-up of pressure caused by forcing grease into the cavity can cause the pilot bearing to be forced out of the flywheel, resulting in a bearing or shaft failure.

Clean the drive ring and flywheel of any dirt or debris as necessary.

Position the drive ring against the flywheel and secure with eight hex head cap-screws. Torque the capscrews to the proper specifications given in Torque Values for Fasteners.

8



Power Take-Off Installation to Engine or Driving Member

1.

2.

3.

4.

5.

Engine and/or power take-off failure will result form any excessive preloadon components.

6.

Clean the power take-off housing flange, flywheel housing flange, and pilot bearing bore or any debris. Install two alignment studs into the flywheel housing to assist with the power take-off installation.

Install 2 or 3 guide studs in the flywheel housing. Position the power take-off against the flywheel housing, carefully aligning the main shaft pilot with the pilot bearing bore and the driving plates with the drive ring.

Secure the power take-off housing to the flywheel housing with 12 hex-head cap-screws. Torque the capscrews to the proper specifications given in Torque Values for Fasteners.

Note: Power take-off housing to flywheel housing attachment screws must be grade 5 or better.

Rap the output end of the clutch 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.

Measure the crankshaft end play again. The measurement must be the same exact value as recorded from Step 1 under Preliminary Checks. Locate and correct the source or preload if the end play is not the same value.

Install the key on the output shaft and install the drive sheave, chain sprocket, or u-joint flange as the application requires.

Note: A power take-off support plate mounted at the output bearing retainer is con-sidered mandatory for this unit.

9


Phone: (800) 383-9204(815) 282-7960


Installation Tips

Avoid excessive misalignment between the engine and power take-off. Check the fol-lowing if abnormal wear of parts exists:

Verify the power take-off is properly lubricated prior to starting the engine. All serviceable points have a hydraulic ("zerk") grease fitting. See lubrication in Main-tenance for more information. Improper lubrication will result in premature failure of components.

Verify the clutch is adjusted according to the procedure outlined in Clutch Adjustment in Maintenance. Failure to do so will result in premature clutch wear and failure.

NACD will not be responsible for any damage or injury resulting from improper ad-justment and/or lubrication. This includes any accessory drives and loads.

Excessive loads tend to deflect parts to which power take-offs are mounted. A dial indicator can be mounted on a rigid part of the engine or independently on the foun-dation to determine deflection under actual operating conditions.

Readings taken before the drive is installed with the engine standing still and when under operating conditions will indicate the extent of deflection. In no case should the deflection exceed .010" at the bearing carrier. See Figure 6.

Avoid excessive tightening of belts or chains. See Table 5 for allowable side load information.

10



Figure 6: Determining Deflection While Applying Side Loads

The dial indicator should not be applied while the unit is operating. This could re-sult in damage to the dial indicator.

11


Phone: (800) 383-9204(815) 282-7960


Torque Values for Fasteners

Note: All threads and bearing face to be lubricated with light oil film prior to assembly.

Table 1. U.S. Standard Fine and Coarse Thread Capscrews, Bolts, and Nuts

Table 2. Metric Coarse Thread Capscrews, Bolts, and Nuts

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1

1 1/8

1 1/4

Thread

Diameter

6 - 8

13 - 17

25 - 29

37 - 43

60 - 70

82 - 98

120 - 140

205 - 245

330 - 390

495 - 595

615 - 745

850 - 1000

lb - ft

SAE Grade 5

8 - 11

18 - 23

34 - 39

51 - 58

81 - 95

111 - 132

163 - 190

278 - 332

448 - 528

671 - 806

834 - 1010

1163 - 1355

Nm lb - ft

SAE Grade 8

Nm

10 - 12

20 - 24

35 - 41

55 - 65

83 - 97

120 - 140

165 - 195

295 - 345

470 - 550

715 - 845

1015 - 1185

1375 - 1625

14 - 16

27 - 32

48 - 55

75 - 88

113 - 131

163 - 190

224 - 264

400 - 467

638 - 745

970 - 1145

1377 - 1606

1865 - 2203

Thread

Size

M6

M8

M10

M12

M16

M20

M24

M30

6.5 - 7.5

16 - 18

32 - 36

55 - 63

132 -151

257 - 295

445 - 511

714 - 820

9 -10

21 - 25

43 - 49

74 - 86

179 - 205

348 - 400

603 - 693

987 - 1113

9 -10

23 - 26

44 - 51

77 - 88

189 - 217

364 - 418

626 - 720

1235 - 1421

12 -14

31 - 35

60 - 68

104 - 120

256 - 294

493 - 567

848 - 976

1674 - 1926

lb - ft

10 - 12

25 - 29

51 - 59

89 - 103

219 - 253

429 - 493

737 - 848

1475 - 1697

Nmlb - ft Nmlb - ft

Property Class 8.8 Property Class 10.9 Property Class 12.9

Nm

14 - 16

34 - 40

70 - 80

121 - 139

298 - 342

581 - 669

1000 - 1150

2000 - 2301



Table 3. Tapered Pipe Plugs (with thread lubricant)

Table 4. Straight Threaded Tube Fittings, Hose Fittings, and O-Ring Plugs

NPTF Size (in) Nm ( + or -5%) Nm ( + or -5%)lb-ft (+ or -5%) lb-ft (+ or -5%)

5.5

6.5

16

17

30

34

50

55

55

7.5

9

21.5

23

40.5

46

68

75

75

8.5

10.5

25

27

50

54

80

85

85

11.5

14

34

36.5

68

73

108

115

115

1/16-27

1/8-27

1/4-18

3/8-18

1/2-14

3/4-14

1-11 1/2

1 1/4-11 1/2

1 1/2-11 1/2

NominalThread

Diameter

Nm

( + or -5%)

lb-ft

(+ or -5%)

5/16

3/8

7/16

1/2

9/16

5/8

11/16

3/4

7/8

1 1/16

1 3/16

1 1/4

1 5/16

1 3/8

1 5/8

1 7/8

2 1/2

NominalThread

Diameter

M10x1.0

M12x1.5

M14x1.5

M16x1.5

M18x1.5

M22x1.5

M27x2.0 (IRON)

M27x2.0 (ALUM)

M33x2.0

M42x2.0

M48x2.0

5

11.5

16

20

24.5

24.5

34

40.5

54

75

88

88

108

108

135

162

312

3.5

8.5

12

15

18

18

25

30

40

55

65

65

80

80

100

120

230

Nm

( + or -5%)

lb-ft

(+ or -5%)

26

37

47

58

74

105

179

85

326

347

441

19

27

35

43

55

77

132

63

240

256

325

13


Phone: (800) 383-9204(815) 282-7960


2000

2200

2400

2600

2800

Force lbs.

Distance XShaft

Speed

7220

7030

6860

6700

6570

0”

5680

5510

5370

5240

5120

1”

4340

4210

4110

4010

3920

2”

3540

3440

3350

3280

3210

3”

3010

2930

2860

2790

2730

4”

2630

2560

2500

2450

2400

5”

2350

2290

2240

2190

2140

6”

2100

2040

1990

1940

1890

7”

Allowable Side Loads

Table 1. Allowable Side Load Pulls

Figure 1. Allowable Side Load Pull

L = x F x A126000 x H.P.

N x D

L = Actual Applied Load (lbs.)HP = HorsepowerN = Shaft Speed (rev./min.)D = Pitch Diameter of Pulley, etc. (in.)F = Load Factor (see below)

A = 1.0 for low & moderate duty drives1.4 for severe duty shock loads or large inertia loads (reciprocating compressors, crusher, chippers, planers, etc.)

1.0 for chain2.5 for V belt drive3.5 for flat belt drive

14



LUBRICATION

Use NLGI Grade 2 grease with a minimum 300°F (149°C) drop point for all lubrication.

Operating Shaft Fittings

Grease every 500 hours of operation. Add one or two pumps of grease from a hand operated grease gun.

Throwout Collar

Using a hand operated grease gun, add 1 or 2 pumps of grease per 500 hours of operation (or add grease until grease begins to weep from the ID of the bearing and from between the release sleeve and the shaft). Rotate the shaft (by hand) while adding grease.DO NOT OVER GREASE!

Main Bearings

Apply 1 cc. of grease (one shot from a grease gun) every 6 months or 100 hours (whichever occurs first) through the fitting in the main bearing housing.

Do not over grease. Excess grease can cause the main bearings to overheat.

Pilot Bearings

The pilot bearing supplied with most NACD power take-off units are pre-lubricated and sealed for life. No maintenance is required. Inspection is recommended every two years or when the power take-off is removed from the driving component for servicing. If the pilot bearing supplied with your power take-off is to be periodically lubricated, add one shot of grease from a grease gun every 100 hours through the fitting in the output end of the clutch shaft. DO NOT OVER GREASE!

15


Phone: (800) 383-9204(815) 282-7960


Clutch Adjustment

Note: New power take-offs must have clutch adjustment checked before being placed into service and after the first 4 to 8 hours of operation. This includes any power take-offs with new driving plates. New plates have a wear in period and the clutch may re-quire several adjustments before the new plates are worn in.

The clutch must be adjusted if it overheats, does not pull, or the operating lever jumps from the engaged position.

Adjustment measurements are made by fitting a torque wrench with a 1 1/2" socket over the hex end located at the bottom of the hand lever. Grasp only the torque wrench when making measurements.

1.

2.

3.

DISASSEMBLY

Power Take-Off Disassembly

1.

2.

3.

4.

Disconnect any power engagement devices from the operating shaft if so equipped.

Remove the hand hole plate from the housing and turn the clutch shaft assembly until the adjusting ring lock pin can be reached.

Depress the adjusting ring lock pin and turn the adjusting yoke or ring to the right (or clockwise when looking at the flywheel) until the operating shaft requires 240-300 ft.-lb or 325-410 Nm of peak torque to engage the clutch.

Remove all attached parts from the output end of the power take-off.

Remove the hex-head capscrew securing the hand lever to the operating shaft.

Remove the twelve hex-head capscrews securing the power take-off to the engine fly-wheel housing. Use two 3/8-16UNC x 1 1/2 bolts for pusher screws in the two tapped holes provided in the housing flange. Remove the power take-off from the engine.

Remove the 8 hex-head capscrews securing the drive ring to the engine flywheel.

16



Clutch Disassembly

1.

2.

3.

4.

5.

6.

7.

8.

9.

Support the power take-off with the clutch end facing up on a bench. Use wooden blocks under the power take-off.

Remove the pilot bearing from the clutch shaft using a standard bearing puller.

Use a 15/16" wrench to remove the jam nut and lock washer from the hose fitting located in the power take-off housing. Push the fitting and hose into the power take-off housing.

Straighten the bent portion of the hub nut lock washer. Use a 4" wrench or socket to remove the hub nut from the clutch shaft.

Use a gear puller with threaded legs for 1/2-13UNC tapped holes to pull the clutch assembly from the clutch shaft. Install the puller so the threaded legs screw into the holes provided in the hub-and-back plate and the jackscrew exerts force on the end of the clutch shaft.

The thread puller holes are not to be used as jackscrews.

Remove the clutch puller from the clutch shaft. Remove the key.

Set the clutch assembly on a bench with the sliding sleeve assembly facing upward. Remove the grease fitting from the hose fitting. Remove the hose from the collar assembly.

Straighten and remove the 4 cotter pins from the 4 headed pins. Remove the pins from the levers and the floating plate. Remove the two spring washers at each lever location and remove the levers and collar assembly from the floating plate as an assembly.

Straighten and remove the 8 cotter pins from the headed pins. Remove the pins, lever links, and levers from the assembly.

17


Phone: (800) 383-9204(815) 282-7960


10.

11.

12.

Clutch Shaft and Housing Disassembly

1.

2.

3.

4.

5.

6.

7.

See Ball Bearing Collar Disassembly for details regarding the ball bearing collar disassembly.

Depress the adjusting ring lock pin with a screwdriver and unscrew the adjusting ring, removing it from the hub and the back plate. Remove the adjusting ring lock pin and spring from the floating plate.

Remove the floating plate. Three driving plates and two center plates.

Turn the power take-off housing with attached parts over on the bench. Support the housing so the output end of the clutch shaft faces up and is free to rotate.

Remove the two round head machine screws securing the nameplate to the clutch housing. Remove the plate.

Remove the two grease fittings only if replacement of the parts is necessary.

Set the clutch shaft with attached parts in a large vise with the clutch end of the shaft facing up, gripping the rear cast section of the bearing carrier in the vise. Remove the hex-head caps crew, lock washer, and retainer lock from the bearing carrier.

Note: Some units may use an internal snap ring.

Remove the bearing retainer from the bearing carrier. Lift the clutch shaft from the bear-ing retainer. The forward bearing cup will come out with the shaft and bearing cones.

Use an arbor press or bearing puller to remove the bearing cones from the clutch shaft only if replacement is necessary. The bearing cones remove in opposite direc-tions from the shoulder machined on the clutch shaft.

Remove the rear bearing cup from the bearing carrier by removing the two plugs from the bearing carrier and tapping the race from the bearing carrier through the holes using blunt punch. Remove the race only if replacement is necessary.

18



8.

9.

Ball Bearing Collar Disassembly

1.

2.

3.

4.

Ball Bearing Collar Assembly

1.

2.

3.

4.

5.

Remove the grease fitting from the bearing carrier only if replacement is necessary.

Set the clutch housing on the bench with the input end facing upward. Remove the two hex-head capscrews and lock washers from the throwout yoke. Tap one end of the shaft gently to expose one of the Woodruff keys. Remove the key. Do the same on the other side of the shaft to remove the other key.

Remove the internal snap ring from the inside of the bearing carrier.

Remove the external snap ring from the release sleeve.

Using a split plate, support beneath the bearing carrier on the bed of a press. Press the release sleeve from the bearing and bearing carrier.

Remove the snap ring from the sleeve.

Clean the sleeve with a degreasing solvent.

Install the release bearing in the carrier (gently tap the bearing into the carrier if nec-essary). Install the internal snap ring.

On the bed of a press, support beneath the inner race of the release bearing. Press the release sleeve into the bearing until the shoulder of the release sleeve stops against the bearing inner race.

Install external snap ring in the groove of the release sleeve to retain the bearing.

Pack the bearing with grease before installing collar assembly on the clutch.

19


Phone: (800) 383-9204(815) 282-7960


Clutch Shaft and Housing Assembly

1.

2.

3.

4.

5.

6.

7.

8.

9.

Clean the bearing cones and clutch shaft with isopropyl solvent to remove any oil or grease residue.

Note: Do not use any oil or paraffin based solvents.

Use an arbor press to install the two bearing cones on the clutch shaft. Install the cones one from each end with the black faces butting against the shoulder on the clutch shaft.

Note: An alternative method to install the bearing cones is to heat them in an oven at 275° F for one hour and install them immediately on the clutch shaft. Let the bearing cones cool to room temperature after installation. Apply force as the bear-ing cools ensuring that it remains seated.

Use a piece of steel tubing slightly smaller in diameter than the outer diameter of the rear main bearing cup to press the cup into the bearing carrier, back face of the cup rearward. Press the cup to the bottom of the bore.

Set the bearing carrier in a large bench vise, output end down.

Coat the bearing rollers and both bearing cups with a light film of SAE 10 oil.

Install the clutch shaft with bearing cones into the bearing carrier, output end down.

Install the forward bearing cup into the bearing carrier. Use the same tubing as in step 3.

Install the bearing retainer into the bearing carrier until it seats against the forward bearing cup (no end play)

Tighten the bearing retainer until there is 60 in.-lbs (6.8 N-m) of uniform drag torque on the shaft while rotating, for new bearings.

Note: The drag must be constant. Rotate the shaft until the torque is constant or dis-assemble the carrier and clutch shaft assembly and look for the cause of high spots.

Tighten the bearing retainer enough to produce 30 in-lbs. of uniform drag torque on the shaft or used bearings. Follow the remainder of the procedure as written.

20



10.

11.

12.

13.

14.

15.

16.

17.

18.

Mark the 4th notch on the bearing retainer clockwise from the lock slot on the bear-ing carrier. Use the slot in line with or clockwise from the lock slot on the bearing carrier as the first slot.

Remove the bearing retainer, front bearing cup and shaft assembly from the bearing carrier.

Pack the bearing rollers and cage with about 4 ounces of a good NLGI Grade 2 lithium base grease with a minimum 300° F (149°C) drop point.

Spread a light coat of grease on the face of both bearing cups, the seal surface on the bearing carrier and the inner diameter of the bearing retainer.

Install the shaft assembly in the bearing carrier.

Install the forward bearing cup and bearing retainer into the bearing carrier.

Tighten the retainer until snug, then loosen the retainer until the mark on the retainer made previously in step 10 lines up with the lock slot on the bearing carrier.

Install the retainer lock and secure it to the bearing carrier with the lock washer and caps crew. Refer to the proper torque values given in Torque Values for Fasteners in Installation.

Set the clutch housing on a bench with the input end facing up. Install the operating shaft halfway into the clutch housing. Slip the throwout yoke on to the operating shaft and push the shaft through the opening on the other side of the clutch housing far enough to expose one of the Woodruff key slots at the center of the operating yoke.

21


Phone: (800) 383-9204(815) 282-7960


19.

20.

21.

22.

23.

24.

25.

26.

27.

Clutch Assembly

1.

2.

3.

Note: Install the yoke with the retainer bolt threads facing the output side of the power take-off housing.

Install one Woodruff key in the operating shaft.

Push the operating shaft the other way to expose the other key slot in the center of the operating shaft.

Install the other Woodruff key.

Center the operating yoke and shaft in the power take-off housing and install the two hex-head capscrews with the lock washers. Torque the capscrews to the proper specifications given in Torque Values for Fasteners in Installation.

Set the power take-off housing so the input end is facing down and is blocked at least 5 inches above the bench or floor.

Install the clutch shaft assembly into the power take-off housing so the grease zerk hole on the bearing carrier faces up and is perpendicular to the operating shaft.

Secure the bearing carrier to the power take-off housing with six lock washers and six capscrews. Torque the capscrews to the proper specifications given in Torque Values for Fasteners in Installation.

Install the grease fitting in the bearing carrier if it was removed previously.

Add 3 cc's of grease (or 3 shots of grease from a grease gun) at the fitting on the bearing carrier.

Set the hub-and-back plate on a bench with the splined section facing up.

Install a driving plate on the hub-and-back plate. Install one center plate so it rests flat on the driving plate. Install a second drive plate and center plate, respectively, over the first center plate. Install the third driving plate over the second center plate.

Install the floating plate over the third driving plate.

22



4.

5.

6.

7.

Power Take-Off Assembly

1.

2.

3.

4.

5.

6.

7.

8

Install the adjusting lock pin spring in the bore provided in the floating plate.

Install the adjusting lock pin and press the pin and spring with a flat blade screwdriver while installing the adjusting ring halfway down the hub thread.

Install the collar assembly to the floating plate using 4 headed pins, 8 spring washers, and 4 cotter pins. Spread the ends of the cotter pins.

Install the hose assembly into the collar.

Set up and support the main housing assembly with attached parts on the bench with the input side facing up.

Install two 1/2-13UNC eyebolts in the front of the clutch assembly.

Lower the clutch assembly over the clutch shaft while:

A. Aligning the trunnions on the collar with the throwout yoke. B. Aligning the shaft keyway with the keyway in the hub-and-back plate

Install the key between the clutch and main shaft with a soft hammer.

Note: Do not use excessive hammer force when installing the key.

Install the hub nut lock washer over the clutch shaft, indexing its lower tab in the notch on the hub-and-back plate. Install the hub nut and tighten to 30 ft.-lb.

Tighten the hub an additional 1/2 turn clockwise then bend the hub nut lock washer against a flat on the nut.

Route the hose assembly away from all moving parts and push the end fitting through the hole provided in the clutch housing.

Install the lock washer and jam nut to retain the end fitting against the housing.

23


Phone: (800) 383-9204(815) 282-7960


9.

10.

11.

Confirm that the hose assembly is not twisted or applying preload to the collar assembly.

Install the pilot bearing according to Pilot Bearing Installation in Installation.

Adjust the clutch according to Clutch Adjustment in Maintenance.

Install the power take-off according to Installation.

24



North American Clutch & Driveline warrants all assembled products and parts to the original customer. For Power Take-Off products and parts, such warranty shall extend for a period of twenty-four (24) months from the date of original shipment by NACD to the original customer, but not to exceed twelve (12 months of service or one thousand five hundred (1,500) hours of service, whichever occurs first. The warranty set forth above is exclusive and North American Clutch & Driveline, Inc. makes no other warranty, express or implied. NACD hereby expressly disclaims any and all other warranties including warranties of merchatability or fitness for a particular purpose.

Limitation of Remedies and Liability: The remedies provided herein are buyer’s sole and exclusive remedies. In no event shall NACD be liable for any direct, indirect, special, punitive, incidental or consequential damages including, but not limited to, loss of revenue or profit, loss of use of the product, cost of capital, cost of substitute equipment or facilities, cost of cover, downtime costs, claims of any third parties, including buyers’ customers, or any other costs whatsoever, whether based on contract, warranty, tort (including negligence) or any other legal theory.

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 NACD �� within sixty (60) days after completion of the in-warranty repair.� 2. The warranty is void if, in the opinion of NACD, the failure of the part or product resulted from abuse, neglect, improper mainte�� nance or accident.� 3. The warranty is void if any modifications are made to any product or part without the prior written consent of NACD.� 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 NACD.� 6. The warranty is void unless all required replacement parts or products are of NACD origin or are NACD authorized replacement �� parts, and otherwise identical with components of the original equipment. Replacement parts or products not of NACD origin �� are not warranted by NACD.

As considered for this warranty, the original customer and subsequent purchaser agree to indemnify and hold NACD harmless from and against all and any loss, liability, damages or expenses for injury to persons or property, 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.

Only an NACD 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 NACD.

NACD 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.

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.

LIMITED NACD GENERAL WARRANTY, LIMITATIONS OF REMEDIESAND LIMITATIONS OF OTHER WARRANTIES

A.

�.

C.

*Note: The above constitutes the basic NACD General Limited Warranty and may be supplemented by additional published

warranty terms dependent upon the product involved. Supplementary warranty terms are available upon request.

NOTICE

NACD makes no warranty or guarantee of any kind, expressed, implied or other-wise, with regard to the information contained within this manual. NACD assumes no responsibility for any errors that may appear in this manual and shall not be li-able under any circumstances for incidental, consequential or punitive damages in connection with, or arising out of, the use of this manual. The information con-tained within this manual is subject to change without notice.

North American Clutch & Driveline

P.O. Box 15130Rockford, IL. 61132

Phone: (800) 383-9204Fax: (815) 282-9160

www.naclutch.com

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