Manual
Manual
Owner’s Manual
Power Take-Offs
Offer of Sale
The items described in this document are hereby offered for sale by Parker Hannifin Corporation, its subsidiaries or its authorized distributors. This offer and its acceptance are governed
by the provisions stated in the "Offer of Sale".
Patent Information
The Chelsea® Power Take-Off or its components shipped with this owner’s manual may be manufactured under one or more of the following U.S. patents:
4610175 5228365 4597301 5645363 6151975 6142274 6260682 7159701 B2 7510064
Other patents pending.
General Information
Safety Information............................................................................................................................................................... 1-2
Direct Mount Pump Support Recommendations................................................................................................................ 3
Foreword............................................................................................................................................................................. 4
Chelsea P.T.O. Safety Label Installation.............................................................................................................................. 4
Function of Auxiliary Power Shafts..................................................................................................................................... 6
Spicer® Universal Joint Engineering Data........................................................................................................................... 7
Installation Instructions
Dodge/Sterling Overview.................................................................................................................................................... 8
2007-2009 Dodge/Sterling Heavy Duty Chassis Cab P.T.O................................................................................................ 9-12
Mounting 230, 236, 270, 800, 852 and 885 P.T.O. to Transmission.................................................................................... 13-14
Mounting 231 and 271 P.T.O. to Transmission.................................................................................................................... 15-16
Checking Backlash............................................................................................................................................................. 17
Hose Connection Illustrations............................................................................................................................................. 18-19
GMT P.T.O. Connectors....................................................................................................................................................... 20
Shifter Component Installation Sketch for 270, 271, 800 and 852 Series (Allison)............................................................ 21
Shifter Component Installation Sketch for 270 and 271 Series (Allison 1000, 2000/2400 Series)..................................... 22
Electronic Overspeed Control Installation Sketch for 270, 271, 800 and 852 Series (Allison)............................................ 23
Electric Overspeed Control Installation Sketch for 270 and 271 Series (Allison 1000, 2000/2400 Series)........................ 24
Installation Sketch 12 and 24 Volt without Speed Limiter, 270 Series/AISIN Automatic Transmissions
(models A443, A445 & A450-43LE).................................................................................................................................... 25
Installation Sketch 12 and 24 Volt with Speed Limiter, 270 Series/AISIN Automatic Transmissions
(models A443, A445 & A450-43LE).................................................................................................................................... 26
Manual Air Shift Component Installation Sketch for 230/231, 236 and 885 Series............................................................. 27
Shifter Component Installation Sketch for 230/231 & 236 Series without E.O.C................................................................ 28
Shifter Component Installation Sketch for 230/231 & 236 Series w/E.O.C......................................................................... 29
Shifter Component Installation Sketch for 230/231 Series without E.O.C. (Allison 1000, 2000/2400 Series)..................... 30
Shifter Component Installation Sketch for 230/231 Series w/E.O.C. (Allison 1000, 2000/2400 Series)............................. 31
Air Shift Component Installation Sketch for 230/231 Series with Manual Air Valve (Allison 1000, 2000/2400 Series)....... 32
Shifter Component Installation Sketch for 885 Series w/E.O.C........................................................................................... 33
Shifter Component Installation Sketch for 885 Series without E.O.C.................................................................................. 34
P.T.O./Combo Valve Installation Sketch, 270/271 Series (SK-428)..................................................................................... 35
P.T.O./Combo Valve Installation Sketch, 230/231 & 236 Series (SK-429)........................................................................... 36
Pressure Lube Installation Sketch for 885 Series............................................................................................................... 37
Indicator Light Installation................................................................................................................................................... 37
Dash Drilling Template for 6 & 8 Bolt Air Shift for Williams Valve........................................................................................ 38-39
P.T.O. Openings for Automatic Transmissions..................................................................................................................... 40-42
Circuit Check for Powershift P.T.O....................................................................................................................................... 43
Rotatable Flange Torque Specifications.............................................................................................................................. 44
P.T.O. Shifting Procedure & Precautions............................................................................................................................. 45
Power Take-Off Maintenance.............................................................................................................................................. 46
Offer of Sale........................................................................................................................................................................ 47
Safety Information
These instructions are for your safety and the safety of the end user. Read them carefully until you understand them.
WARNING: A Power Take-Off must be properly matched to the vehicle transmission and to the auxiliary
equipment being powered. An improperly matched Power Take-Off could cause severe damage to the vehicle
transmission, the auxiliary driveshaft, and/or to the auxiliary equipment being powered. Damaged components
or equipment could malfunction causing serious personal injury to the vehicle operator or to others
nearby.
■ Always refer to Chelsea catalogs, literature, and owner’s manuals and follow Chelsea recommendations when
selecting, installing, repairing, or operating a Power Take-Off.
■ Never attempt to use a Power Take-Off not specifically recommended by Chelsea for the vehicle transmission.
■ Always match the Power Take-Off’s specified output capabilities to the requirements of the equipment to be
powered.
■ Never use a Power Take-Off whose range of speed could exceed the maximum.
WARNING: During extreme cold weather operation [32°F (0°C) and lower], a disengaged Powershift Power
Take-Off can momentarily transmit high torque that will cause unexpected output shaft rotation. This is caused by
the high viscosity of the transmission oil when it is extremely cold. As slippage occurs between the Power Take-Off
clutch plates, the oil will rapidly heat up and the viscous drag will quickly decrease.
The Power Take-Off output shaft rotation could cause unexpected movement of the driven equipment resulting in
serious personal injury, death, or equipment damage.
WARNING:
■ Rotating auxiliary driveshafts are dangerous. You can snag clothes, skin, hair, hands, etc. This can cause seri-
ous injury or death.
■ Do not go under the vehicle when the engine is running.
■ Do not work on or near an exposed shaft when the engine is running.
■ Shut off the engine before working on the Power Take-Off or driven equipment.
■ Exposed rotating driveshafts must be guarded.
WARNING: We strongly recommend that a Power Take-Off and a directly mounted pump be used to
eliminate the auxiliary driveshaft whenever possible. If an auxiliary driveshaft is used and remains exposed after
installation, it is the responsibility of the vehicle designer and P.T.O. installer to install a guard.
WARNING: Auxiliary driveshafts may be installed with either recessed or protruding set screws. If you
choose a square head set screw, you should be aware that it will protrude above the hub of the yoke and may
be a point where clothes, skin, hair, hands, etc. could be snagged. A socket head set screw, which may not
protrude above the hub of the yoke, does not permit the same amount of torquing as does a square head set
screw. Also, a square head set screw, if used with a lock wire, will prevent loosening of the screw caused by
vibration. Regardless of the choice made with respect to a set screw, an exposed rotating auxiliary driveshaft
must be guarded.
Some Power Take-Offs may be operated when the vehicle is in motion. To do so, the P.T.O. must have been prop-
erly selected to operate at highway speeds and correctly matched to the vehicle transmission and the
requirements of the driven equipment.
If in doubt about the P.T.O. specifications and capabilities, avoid operating the P.T.O. when the vehicle is in motion.
Improper application and/or operation can cause serious personal injury or premature failure of the vehicle, the
driven equipment, and/or the P.T.O.
Always remember to disengage the P.T.O. when the driven equipment is not in operation.
"
Use caution to ensure that bracket does not pre-load pump/P.T.O. mounting
Chelsea strongly recommends the use of pump supports (Support Brackets) in all applications. P.T.O. warranty will
be void if a pump bracket is not used when:
1) The combined weight of pump, fittings and hose exceed 40 pounds [18.14 kg].
2) The combined length of the P.T.O. and pump is 18 inches [45.72 cm] or more from the P.T.O. centerline
to the end of the pump.
ALSO: Remember to pack the female pilot of the P.T.O. pump shaft with grease before installing the
pump on the P.T.O. (reference Chelsea grease pack 379688)
Foreword
This booklet will provide you with information on correct installation of Chelsea® Power Take-Offs (P.T.O.’s).
Proper installation and set up procedures will help you get additional and more profitable miles from your truck
equipment and components.
It is important that you be sure that you are getting the right transmission/P.T.O. combination when you order
a new truck. An inadequate transmission will overwork any P.T.O. in a short period of time. In addition, a
mismatched transmission and P.T.O. combination can result in unsatisfactory performance of your auxiliary
power system from the start.
If you have questions regarding correct P.T.O. and transmission combination, please contact your local
Chelsea® Auxiliary Power Specialist. They can help you select the properly matched components to ensure
correct and efficient applications.
1. The two black and orange on white 5" x 7" pressure sensitive vinyl labels, part number 379274; must be
placed on the vehicle frame rails (one (1) on each side), in a position that would be HIGHLY visible to
anyone that would go under the truck near the P.T.O. rotating shaft. If the vehicle is to be painted after
these labels are installed, cover them with two (2) blank masking covers. Remove the masking covers
after painting.
2. Place the one (1) black and orange on white 3.5" x 5" pressure sensitive vinyl label, part number 379275,
on the visor nearest the operator of the vehicle, this must be placed near the P.T.O. visor label.
3. Place the one (1) red and white with black lettering 3.5" x 7.5" pressure sensitive vinyl label, part number
379915, on the opposite side of the visor from the above label #379275.
4. Place the one (1) white and black heavy duty card, part number 379276, in the vehicle glove box. Again in
a position highly visible to the operator, for example: try to place this card on top of whatever may be in the
glove box.
If you require labels, please order part number 328946X at no charge from your local Chelsea Warehouse or
send request direct to:
Parker Hannifin Corporation
Chelsea Products Division
8225 Hacks Cross Road
Olive Branch, MS 38654
Customer Service: (662) 895-1011
An auxiliary power shaft operates through constantly relative angles between the power source
and the driven accessory, therefore, the length of the auxiliary power shaft must be capable of
changing while transmitting torque. This length change, commonly called “slip movement”, is
caused by movement of the power train due to torque reactions and chassis deflections.
Joint operating angles are very important in an auxiliary power joint application. In many cases,
the longevity of a joint is dependent on the operating angles. (See chart below)
This information is limited to 1000 through 1310 series applications. For applications requiring a series
larger than 1310, contact your local Chelsea distributor.
Maximum Operating Speed * By Tube Size, Solid Shaft Size, and Length
*(For speed below 500 R.P.M. or over 2500 R.P.M., contact your Chelsea Distributor)
Tubing Dia. & Max. Installed Length in Inches for Given R.P.M.
Wall Thickness Centerline to Centerline of Joints for a Two Joint Assembly
Joint & Shaft or
(W=Welded Centerline of Joint to Centerline of Center Bearing for a Joint & Shaft
S=Seamless) R.P.M. - Revolutions per Minute
500 1000 1500 2000 2500
1.750" X .065" W 117" 82" 67" 58" 52"
1.250" X .095" S 91" 64" 52" 45" 40"
2.500" X .083" W 122" 87" 70" 62" 55"
3.000" X .083" W - - - 85" 76"
Solid Shaft
Diameter
.750" 60" 42" 35" 30" 27"
.812" 62" 44" 36" 31" 28"
.875" 65" 46" 37" 32" 29"
1.000" 69" 49" 40" 35" 31"
1.250" 77" 55" 45" 39" 35"
Dodge/Sterling Overview
P.T.O. Operation
The 3500/4500/5500 Dodge Chassis Cab vehicle, when equipped with either the automatic Aisin 6 speed or
manual G-56 6 speed transmissions, will allow for an aftermarket upfit with a transmission driven P.T.O. (Power
Take-Off). The customer will have the ability to operate the P.T.O. in either a “stationary” or “mobile” mode. The
vehicles will be factory set to the “stationary” mode. In order to select the “mobile” mode a DaimlerChrysler
Dealership is required to modify the vehicles settings using their proprietary Dealer service tool.
Stationary Mode
To operate the P.T.O. in this mode the vehicle must meet the following conditions:
• Be in “park” positions (vehicles equipped with automatic transmission)
• Up fitter provider (on/off) switch has been activated
• Parking brake applied (vehicles equipped with manual transmission)
• Vehicle must be running
• No vehicle, brake or clutch switch faults present
• P.T.O. must be correctly installed using the vehicle provided circuits
The customer has the choice to operate the P.T.O. by utilizing the cruise control switches or by utilizing a remote
control (provided by the P.T.O. supplier). To operate the feature using the cruise control switches the customer
must first activate the up fitter provided on/off switch. Next, the cruise control “on” switch is selected. Following this
step the “set” switch must be depressed. The vehicle is now in the P.T.O. mode and is ready for use. In order to
increase or decrease the engine idle speed, to optimize the P.T.O. function, the “accel” and “decel” cruise switches
can be used respectively. To disengage P.T.O. operation and return to “standard vehicle operation” simply turn the
up fitter provided on/off switch to the off position.
To operate the P.T.O. via a remote switch the customer must make sure the above conditions are met. It is vital
for proper operation that the P.T.O. and remote have been installed correctly paying special attention to ensure
the vehicle provided wiring has been connected properly. This is the responsibility of the installer of the P.T.O. and
switches/remote system. It is the responsibility of the P.T.O. manufacturer to ensure that their electrical (switches
and remote) system is compatible with the vehicle's electrical architecture and software functionality.
Mobile Mode
To operate the P.T.O. in this mode the vehicle must meet the following conditions:
• Dealer selected “mobile” mode activated via Dealer proprietary service tool
• Up fitter provider (on/off) switch has been activated
• Vehicle must be in “park” or “drive” position (vehicles equipped with automatic transmission)
• Parking brake must not be applied
• No vehicle, brake or clutch switch faults present
• Vehicle must be running
• P.T.O. must be correctly installed using the vehicle provided circuits
The customer may choose to use the P.T.O. while the vehicle is moving. To do so the P.T.O. function must be
activated prior to taking the vehicle out of “park”. This is accomplished by activating the up fitter provided P.T.O. on/
off switch. At this point the customer may place the vehicle in a forward or reverse gear and have P.T.O. operation.
To disengage P.T.O. operation and return to “standard vehicle operation” simply turn the up fitter provided on/off
switch to the off position.
NOTE: For application specific information with respect to P.T.O. and pump requirements and additional ve-
hicle information (wiring schematics, preset idle values, engine speed limits, and vehicle hardware and software
requirements) please refer to the Dodge Body Builders Guide by accessing “Wiring Diagrams” and choosing the
appropriate links.
Installation Overview
6. Before mounting the P.T.O. remove the high pressure High Pressure Port 329130-8X
port plug located on the left side (drivers side of Remove Plug and Put Hose Assembly
Fitting 379749 Into Port
transmission) and install part number 379749 male 379749
connector fitting into port. Also install the 90° Male Connector
swivel nut (part number 379703) onto the male
connector (379749) (Fig. 3).
Figure 3
Figure 4
Figure 5
11
High Pressure Port
Remove Plug and Put Fitting
14-Gauge Wire
379749 Into Port
(Black) With Ring
1 2 3 4 Connector
Connect to
Upfitter Jumper 5 6 8
7
(See Page 12) * Passenger Side View 379749
Male Connector
Low Pressure Port
329457X
Connect To Unterminated Wires Near Remove Plug and Put Fitting
Harness Assembly
Master Cylinder (See Page 12) 379749 Into Port
Wiring Charts - Model Year 2007-2009 Dodge Chassis Cab, 6.7L w/Aisin Transmission
2007 Wiring Chart
Chelsea Wire Connected to Dodge Wire Location
1 Orange * K425 Orange w/Brown Stripe Terminal #9, 10-way Connector on Bellhousing
2 Violet 1 * V937 Violet w/Brown Stripe Terminal #8, 10-way Connector on Bellhousing
3 Violet 2 G425 Violet w/Yellow Stripe Upfitter Jumper Connector**
4 Pink F922 Pink w/Red Stripe Upfitter Jumper Connector**
5 Orange K427 Orange w/Lt. Green Stripe Unterminated Wires Near Master Cylinder
6 Pink F922C Pink w/Red Stripe Unterminated Wires Near Master Cylinder
7 Black Z914 Black Unterminated Wires Near Master Cylinder
8 Violet G425 Violet w/Yellow Stripe Unterminated Wires Near Master Cylinder
Chelsea Wire Connected to Location
9 Black w/ring Terminal Pressure Switch P.T.O.
10 Violet w/ring Terminal Pressure Switch P.T.O.
11 Black w/Butt Connector P.T.O. Solenoid - Black Wire Remotely Mounted On Vehicle
12 Red w/Butt Connector P.T.O. Solenoid - Red Wire Remotely Mounted On Vehicle
* NOTE: These two wires must be cut from Dodge 10 way connector. Do not cut any other wires.
** NOTE: Stored in Vehicle Glove Box. Connect to Mating Plug under Instrument Panel Near Grommet.
36"
4" TYP
5
36" 6
7
8
9
10 11 12
Mounting P.t.o. to Transmission for 230, 236, 270, 800, 852 and 885 Series
2. Discard the cover plate and cover plate gasket, then clean the
aperture pad using a putty knife or wire brush (Fig 2).
3. Install the proper studs in the P.T.O. aperture pad using a stud driver
or wrench (Fig 3).
NOTE: Avoid contact of Permatex with automatic transmission fluid in Figure 1
automatics. Always check to be sure that the studs do not interfere
with transmission gears.
4. Tighten the studs to 17 - 19 Lbs. ft. (2.38 - 2.66 kg. meters) and then
torque the capscrews to 32 - 37 Lbs. ft. (4.43 - 5.12 kg. meters) for
the 6 or 8 bolts (Fig 4).
5. For the 230, 236, 800, and 852 series, place one thick gasket .020" Figure 2
(.50 mm) and one thin gasket .010" (.25 mm) over the studs. For the
270 series with the AJ gear pitch designation (i.e.: 270XBAJP-B3XD)
use the special 35-P-41 gasket that comes with the P.T.O. When the
35-P-41 gasket is installed with the 270 series, the need for
backlash adjustment is greatly reduced.
The 250 Series requires (1) 35-P-41 gasket for installation and no
backlash to check (Fig 5).
● When mounting a P.T.O. use gaskets between all mounting
surfaces. Figure 3
● Do not stack more than 3 gaskets together.
● Usually, one thick gasket .020" (.50 mm) will be required.
● Remember the lubricant in the transmission also lubricates the
Figure 4
Figure 5
NOTE: Self locking nuts do not require lock washers (Fig 7).
Figure 6
7. Fasten the P.T.O. to the transmission. Torque the self locking nuts to
their proper specifications (Fig 8).
● 379744: 3/8"-24 for six bolt applications 35-40 Lbs. ft.
(4.83-5.52 kg.m)
● 379745: 7/16"-20 for eight bolt applications 55-60 Lbs. ft.
(7.59-5.52 kg.m)
Torque capscrews to their proper specifications.
Figure 7
7a. The 236 Series has an inspection plate that can be removed to
check for proper backlash. Refer to page 12 for checking backlash
procedure.
8. There are two (2) large drilled and tapped holes on the 230, 270 and
800 Series P.T.O. housing (See Fig 9). These two holes come with
plugs installed. (Fig 9) The 852 Series has one (1) drilled and tapped
hole in the inspection plate. Figure 8
9. One of the plugs will be used for the dump line from the
solenoid to the housing of the 270, 800 and 852 series. The 230 and
885 Series are air shifted and does not require the dump line. The
one hole in the 852 will be used for the dump line from the solenoid
valve.
The second plug, which is positioned over the input gear, must be
removed and replaced with a transducer if you are using the Chelsea
Electronic Overspeed Control. If you are not using an Electronic Figure 9
Overspeed Control, the plug will remain in the housing (Fig 10). After
checking backlash, continue with the plumbing and wiring of the
controls.
Figure 10
1. Remove the 6 bolt cover and gasket from the 6 bolt aperture.
Clean the 6 bolt aperture as in step 2 on page 9 (Fig 1).
3. Next, fasten the special mounting plate onto the opening with
the three (3) socket head bolts. The three socket head bolts
Figure 1
always go in the three holes closest to the two (2) welded-on
nuts. Figure 3 shows the plate position for a P.T.O. with a “5”
assembly arrangement. Torque the three socket head bolts
to 300 in. lbs. (3.5 kg. meters) using an inch pound torque
wrench.
4. Place the special gasket on the plate (Fig 4). Again, the gas-
ket and plate can be mounted in two (2) positions depending
on your assembly arrangement. See step 3.
Figure 2
5. Place the 231 or 271 on the plate (Fig 5). There are 5 (five)
capscrews that hold the 271 to the transmission and plate.
Make sure all 5 capscrews that go through the plate and into
the transmission have copper gasket washers under them.
Figure 3
Figure 4
Figure 5
Figure 8
Checking Backlash
Powershifts
P.t.o. Hose Connection Illustrations
C
230 Series
C
231 Series
A
A. High Pressure Line From Valve. B
B. Dump Line to P.T.O. From 3 Way Valve.
C. Lubrication Line From Transmission.
Attach to Either End of IDLER Shaft.
C
270 Series
B 800-4
800 Series
A
A. High Pressure Line From Valve.
B. Dump Line to P.T.O. From 3 Way Valve.
B
C. Lubrication Line From Transmission.
Attach to Either End of IDLER Shaft. C
852 Series
Powershifts
P.t.o. Hose Connection Illustrations (Continued)
236 Series
In order for the customer to utilize the full capability of the P.T.O./transmission, Chelsea has designed a wiring har-
ness that must be used between the GM P.T.O. connector and the Chelsea Power Take-Off. These are for P.T.O.
Non E.O.C. applications only.
The main purpose of the wiring harness on the Allison 1000, 2000/2400 transmissions will be to engage the
torque converter lock-up clutch. The harness will also allow the end-user to utilize the stalk-mounted cruise control
to control Power Take-Off R.P.M.
See wiring harness part number 379924 for the 270/230 Series Power Take-Offs.
Model year 2003 and higher GM “C” Series Wiring Harness for 270 Series
Part Number 379924
NOTE: For 2006 Model Year Chev. Kodiak and GMC Topkick C4500-C7500 Series with 6.6L Diesel or 8.1L Gas
engines and Allison 1000/2200/2300 Series transmission. The P.T.O. may not operate properly due to a GM
change in feedback logic in the TCM. Please refer to GM UI Bulletin#76 REV. 1 dated 6/09/2006 or latest revision
for complete details.
Shifter Component Installation Sketch for 270, 271, 800 and 852 Series
(Allison)12 and 24 Volt without E.o.c. (SK-225 Rev L)
Color Code
Brown
Green
Solenoid Valve
379686-1
379686-2
Voltage
12 V
24 V
Transmission
300 PSI
300 PSI
Hose Assembly
328075X
Hose Assembly
329087X
328075X
Hose Assembly
IN CYL
12 and 24 Volt without E.o.c. (SK-329 Rev L)
22
329075-2X
Hose Assembly
Owner’s Manual
Powershift P.T.O.s
Electronic Overspeed Control Installation Sketch for 270, 271, 800 and 852 Series
(Allison) (SK-224 Rev J)
IN CYL
Hose Assembly
329087X
*
(Allison 1000, 2000/2400) (SK-328 Rev K)
24
IN CYL
329075-2X
Hose Assembly
Owner’s Manual
Powershift P.T.O.s
328075X
Hose Assembly
Electronic Overspeed Control Installation Sketch for 270 and 271 Series
.O.
379686-1 12V (Gr) Port A
379686-2 24V (Blk) On Closed
)
Bearing Cap
Installation Sketch
Bulletin HY25-1240-M1/US
V
EXH 379547
Por t-A
379449 Port B To Low Pressure Port
m
Screened Pressure On Transmission and To P.T.O.
Switch
Fro
379280 Idler Shaft Lube Port “C”
379252
378881 378978 12V Butt Connector
Rocker 379005 24V
Switch Indicator Light
Ground 329130-5X
High Pressure
25
379336 Hose Assembly 379749
Switch Bracket Male Connector
R
379257
Splice Remove Cover on Transmission
Connector before Installing P.T.O.
Powershift P.T.O.s
Battery
Top View Left View
Line Pressure
Lube Pressure
379254-13
379686-2 24V (Blk) Over Gear Tooth
14-Gauge 329087X
379449 (Blue) Wire Hose Assembly 329087X Hose Assembly
Screened w/Ring Connect to Low Pressure Port on
Fitting Connector Transmission and to P.T.O. Idler Shaft
379280 Fitting
Lube Port “C”
379547
379254-3 500357-1 Lock Washers Pressure
14-Gauge
Switch
(Green) 379258
Wire Mounting 500457-6 Mounting Screw
w/Butt Bracket 379254-14
Connector 14-Gauge (Black) Wire
14-Gauge (Green) Wire w/ w/2 Ring Connectors
Butt Connector
Connector with 2-Wire
Shielded Cable
Ground Battery
Ground Drill 1.0" Hole
in Firewall 329130-5X
26
14-Gauge (Black) Wire 9 Amp Fuse & Holder Hose Assy
w/Ring Connector 14 Gauge (Red) Wire 379749
379749 Male Connector
Male Connector
Mounting Bracket
Supplied w/Speed 379265 To High Pressure
Limiter Grommet Port
To Low Pressure Port
Rear View
Powershift P.T.O.s
Line Pressure
Lube Pressure
▼
Installation Sketch 12 and 24 Volt with Speed Limiter, 270 Series/AISIN Automatic
Manual Air Shift Component Installation Sketch for 230, 231, 236 and 885 Series with
Manual Air Valve (SK-246 Rev F)
Warning: Connect directly to air supply. Do not use tubing between air supply and pressure protection valve.
To 230, 231, 236 Series
P.T.O. Inlet Port
Installation Kit 328388-57X
Shifter Component Installation Sketch for 230, 231 and 236 Series 12 and 24 Volt without
E.o.c. (SK-226 Rev G)
Warning: Connect directly to air supply. Do not use tubing between air supply and pressure protection valve.
Shifter Component Installation Sketch for 230, 231 and 236 12 and 24 Volt
w/E.o.c. (SK-227 Rev C)
Warning: Connect directly to air supply. Do not use tubing between air supply and pressure protection valve.
30
Owner’s Manual
Powershift P.T.O.s
500457-6 Screw
31
Owner’s Manual
Powershift P.T.O.s
Shifter Component Installation Sketch for 230 and 231 12 and 24 Volt with E.o.c.
Warning: Connect directly to air supply. Do not use tubing between air supply and pressure protection valve.
Bulletin HY25-1240-M1/US Owner’s Manual
Installation Sketch Powershift P.T.O.s
Air Shift Component Installation Sketch for 230 and 231 Series with Manual Air Valve
without E.O.C. (Allison 1000, 2000/2400) (SK-339 Rev D)
Warning: Connect directly to air supply. Do not use tubing between air supply and pressure protection valve.
2005 and Later - Connect to 43 (TCM) or Wire #143.
NOTE: * Pre - 2005-Connect to J1-6 (TCM) or Wire #106
*
328388-57X Air Shift Installation Kit
329336-2X J1-6 Wire Kit
Shifter Component Installation Sketch for 885 Series 12 and 24 Volt w/E.O.C.
(SK-302 Rev C)
Warning: Connect directly to air supply. Do not use tubing between air supply and pressure protection valve.
328388-52X Air Shift Kit 12V w/ E.O.C.
328388-53X Air Shift Kit 24V w/ E.O.C.
Shifter Component Installation Sketch for 885 Series 12 and 24 Volt without E.O.C.
(SK-301 Rev D)
Warning: Connect directly to air supply. Do not use tubing between air supply and pressure protection valve.
328388-50X Air Shift Kit 12V w/o E.O.C.
328388-51X Air Shift Kit 24V w/o E.O.C.
379258 Battery
Bracket 379257
328075X
Hose 500457-6 *379254-17 Instant Connector
Assembly (2) Screw (2) 14-Gauge Wire
with Fork Terminal
379254-3
14-Gauge Wire (Green)
500357-7 with Butt Connector 379900
Washer (2) Fuse Holder Ass’y
Valve Port Exhaust w/10 Amp Fuse
379449 .250-18 NPTF
Screen Adapter 379686-1 (12 Volt)
Solenoid Valve
Red
329075-2X
Blue 379547X w/wires
Hose Assembly
Pressure Switch
Red
Ground
378966
Warning: Connect directly to air supply. Do not use tubing between air supply and pressure protection valve.
Street Tee 380009
1/8-27 NPTF 379254-14 Female Connector
14-Gauge Wire (Black)
with Ring and 379664
379486 Bullet Connector 379252 Red L.E.D. Light
90° Fitting Butt Connector To P.T.O. Air Control Valve
w/O-Ring
To Pressure Switch #2
379254-13
379547 (#2) 14-Gauge Wire (Blue)
Caution: When installing nylon tubing avoid sharp angles, exhaust and manifold systems.
Pressure Switch with Ring Connector
Main Pressure Actuation Pressure
from Transmission to P.T.O. 379664
Red L.E.D. 12 Volt
Cab
Indicator Light Assembly
To
Pressure
Switch (#2)
378414
Pressure Protection
Valve
Opens at 70 PSI
379042
378416 Male Connector
Hex Nipple
379044-7
Nylon Tubing
379044-7
Air Supply
1/4" Nylon Tubing
380009
Female Connector
379042
Male Connector
379547X (#1)
Pressure Switch
NOTE: * Pre - 2005-Connect to J1-6 (TCM) or Wire #106
379042
2005 and Later - Connect to 43 (TCM) or Wire #143. Male Connector
Kits (Order Seperately)
329365X - Hose Kit
329366-1X - J1-6 Feedback Kit
329297X - Fitting Kit (Allison 1000, 2000/2400 only) To Dump Pump To Dump Pump
Shifter “Lower Port” Shifter “Raise Port”
Air Shift Installation Kits: 328388-87X - 12V “S” Shifter
328388-88X - 12V “T” Shifter
378414
Pressure
Protection Valve
Opens at 70
378416 379042
P.S.I. 500750-1
Installation Sketch
Bulletin HY25-1240-M1/US
Air Supply
70-140 P.S.I. 379044-7 *379254-17
1/4" Nylon Tubing Wire with Fork Connector
379044-7
Nylon Tubing
379042
Note: Direction of Arrows Connector 379042 379042
Male Connector 379254-13 Wire
Male Connector 379254-15 Wire 14 Gage Blue
14 Gage Blue
379044-7
Plastic Tubing 378966 Street Tee
36
379252
379042 Butt Connector
Connector Actuation
Pressure to
P.T.O.
379042
Connector 379131-1 Connect to Ground
Recucer
Powershift P.T.O.s
379900
Pilot Fuse Holder Ass’y
.270 w/10 AMP Fuse
379131-1
Reducer 379042
Connector
Normally “On”
Dash Drilling Template for 6 & 8 Bolt Air Shift for Williams Valve (SK-204 Rev C)
Dash Drilling Template for 6 & 8 Bolt Air Shift for Williams Valve (SK-204 Rev C)
HT-740
78T
HT-750D
T Fitting 378897
5.6
[142.24]
Main Pressure
1/8 N.P.T. 90-175 P.S.I.
3.5 6.3-12.2 Kg/cm2
Lube Tap [88.9]
1 15/16 O-Ring 35-45 P.S.I.
2.4-3.2 Kg/cm2
CLT-750 40T
T Fitting 378897
78T
5.6
[142.24] 64T
Main Pressure
1/8 N.P.T. 90-270 P.S.I.
6.3-19 Kg/cm2
Lube Tap 3.5
1 15/16 O-Ring 35-45 P.S.I. [88.9]
2.4-3.2 Kg/cm2
78T
8.46
6.7 [214.8]
[170.18]
Main Pressure
Lube Tap 2.00 1/8 N.P.T. 90-240 P.S.I.
6.2
1/8 N.P.T. 5-15 P.S.I. [50.8] 7.7-16.8 Kg/cm2
[157.48]
.35-1.05 Kg/cm2
78T
6.7
[170.18]
2.00
6.2 [50.8]
[157.48]
Lube Tap Main Pressure
1/8 N.P.T. 5-15 P.S.I. 1/8 N.P.T. 110-240 P.S.I.
.35-1.05 Kg/cm2 7.7-16.8 Kg/cm2
.6
[15.24]
1.6
[40.64]
Lube Tap
1/4 N.P.T. 15-35 P.S.I.
1.05-2.4 Kg/cm2
8000 Series
43T
Lube Tap Main Pressure
6.7
1/8 N.P.T. 5-15 P.S.I. 1/4 N.P.T. 140-230 P.S.I.
[170.18]
.35-1.05 Kg/cm2 9-15 Kg/cm2
38T
6.2
[157.48]
6 Speed
3341-3441 5.1
[129.54]
T Fitting 378840
4.7
[119.38]
Tee Purchased
D Separately
.032" ORIFICE *
“C” Hose
E
Chart I
Dimensional Information
Tee
Fitting 378840 378880 378970 378897
D .750"-16 U.N.F. 2A .875"-14 U.N.F. 2A 1.062"-12 U.N.F. 2A 1.312"-12 U.N.F. 2A
E .250"-18 N.P.T.F. .250"-18 N.P.T.F. .250"-18 N.P.T.F. .250"-18 N.P.T.F.
F .750"-16 UNF-2B .875"-14 U.N.F. 2B 1.062"-12 U.N.F. 2B 1.312"-12 U.N.F.-2B
* NOTE: The .032" [0.81mm] orifice is built into all pressure lubed idler shafts. No additional orifices are
required when using these pressure lubed shafts.
NOTE: Check Thread Size on Cooler Port Fitting to Determine Correct “T” Fitting
Circuit Check for Powershift P.T.O. for 270, 271, 800 and 852 Series on Automatic
Transmissions
Perform the following steps. Record the results when installing the P.T.O. originally, as a replacement, or while
troubleshooting.
1. Install 2 Pressure Gauges in the circuit as shown: 300 - 400 PSI Gauges for Allisons.
2. With the Solenoid Valve “Off,” record the pressures at inlet to Solenoid Valve for the transmission both cold
(ambient) and at the operating temperature for engine idle R.P.M. and engine maximum R.P.M.
Before 378965 Screen Adapter @ “In” Between 378966 Screen Adapter and For Allisons should be 90-270 PSI.
Port of Solenoid Valve. P.T.O. Port.
Transmission Transmission
R.p.m. Cold (Ambient) At Operating Temperature
Circuit Check for Powershift P.T.O. for 270, 271, 800 and 852 Series on
Automatic Transmissions
3. With the Solenoid Valve “On,” record the corresponding pressures at the 2 gauges with the transmission
both cold (ambient) and at the operating temperature for engine idle r.p.m. and engine maximum rpm.
Transmission Transmission At
Engine Cold (ambient) Operating Temperature
If at any time the above pressures are below 90 PSI or there is a 50 PSI or more difference in two of the
corresponding readings in Part 3:
(a) Check the circuit for correct installation.
(b) Check hoses and screens for obstruction.
4. Remove the “B” line from the P.T.O. with the Solenoid Valve “On.” No oil should appear from the line. Then turning
the Solenoid Valve to “Off” should dump the oil from the P.T.O. Clutch Pack through this line.
5. Remove the “C” line from the P.T.O. Idler
Shaft end, and confirm that oil is running
to this shaft for lubrication.
Retain the findings of these tests for future
comparison. Re-check the oil level in the
transmission after testing is complete.
This concludes your installation and circuit
checks. Make sure all lines are reconnected
(lube lines and pressure solenoid lines).
Fig. 1 Fig. 2
The rotatable flange is shipped loose with the P.T.O. units for ease of installation. After determining the
flange position, attach the flange to the P.T.O. bearing cap using the capscrews provided in the bag kit.
Bag kit number 328170-207X (6-bolt family) will contain (3) capscrews (378447-6) and 328170-208X
(230/231, 236 and 270/271 Series) will contain (4) capscrews for attaching the flange to the P.T.O.
bearing cap. After installing the capscrews make sure to torque the screws to 16-20 Lbs. ft.
Consideration should be taken on the size and weight of the pump being installed. (see pages 3 and 4)
▼▼
▼
RA Flange Shown
NOTE: Reinstalling or tightening of a rotatable flange after it has become loose is not recommended. If a
P.T.O. has run for a length of time after the flange has become loose, the flange and / or bearing cap may not
be to manufacturing tolerance.
P.t.o. Shifting Procedure & Precautions for 1000, 2000/2400, AT, MT & HT
Series Transmissions
CAUTION: This vehicle is equipped with a Power Take-Off. Shut the engine off before working on the
Power Take-Off or getting below the vehicle.
NOTE: Powershift P.T.O.: The engine must be at idle or below 1,000 r.p.m. when the P.T.O. is initially
engaged. See the transmission manufacturer’s instructions for special procedures.
IMPORTANT: Failure to follow proper shifting or operating sequences will result in premature P.T.O. failure
with possible damage to other equipment.
NOTE: There is a torque converter lock up feature available with the 1000/2000/2400 Series transmis-
sions. The torque converter lock up feature comes on and is controlled by the Transmission Control Module
(TCM) at 1100 engine R.P.M. when a signal is provided to the “P.T.O. Enable” circuit of the TCM by the
P.T.O. switch. Lock up will only come on in the “NEUTRAL” and “PARK” positions. The lock up clutch does
not come on automatically in “DRIVE” at 1100 R.P.M.
Due to the normal and sometime severe torsional vibrations that Power Take-Off units experience, operators
should follow a set maintenance schedule for inspections. Failure to service loose bolts or Power Take-Off leaks
could result in potential auxiliary Power Take-Off or transmission damage.
Periodic P.T.O. MAINTENANCE is required by the owner/operator to ensure proper, safe and trouble free
operation.
Daily: Check all air, hydraulic and working mechanisms before operating
P.T.O. Perform maintenance as required.
Monthly: Inspect for possible leaks and tighten all air, hydraulic and
mounting hardware, if necessary. Torque all bolts, nuts, etc. to
Chelsea specifications. Ensure that splines are properly
lubricated, if applicable. Perform maintenance as required.
With regards to the direct mounted pump splines, the P.T.O. requires the application of a specially formulated
anti-fretting, high pressure, high temperature grease. The addition of the grease has been proven to reduce the
effects of the torsional vibrations, which result in fretting corrosion on the P.T.O. internal splines as well as the
pump external splines. Fretting corrosion appears as a “rusting and wearing” of the pump shaft splines. Severe
duty applications, which require long P.T.O. running times and high torque may require more frequent regreasing.
Applications such as Utility Trucks that run continuously and are lightly loaded also require frequent regreasing
due to the sheer hours of running time. It is important to note that service intervals will vary for each and every
application and is the responsibility of the end user of the product. Chelsea also recommends that you consult
your pump owners manuals and technical services for their maintenance guidelines. Fretting corrosion is caused
by many factors and without proper maintenance; the anti-fretting grease can only reduce its effects on
components.
Chelsea offers the grease to our customers in two packages. The first is a 5/8 fluid ounce tube (379688), which is
included with every applicable P.T.O., and the second is a 14-ounce grease cartridge (379831). Chelsea also
offers greaseable shafts for most all output designators.
Warranty: Failure to comply entirely with the provisions set forth in the appropriate
Owner’s Manual will result in voiding of ALL Warranty consideration.
FP 07/09 4M