HPTO12W

Installation & Maintenance

 Table Of Contents
Safety 3
System Overview........................... 4
System Overview 4
Auxiliary Components 5
Component Description 6
Model Identification & Serial Number 7
Hydraulics ................................... 8
Hydraulic Guidelines 8
Oil Requirements 12
Hydraulic Interface - FX 13
Hydraulic Interface - VG 14
Hydraulic Schematic 15
Manifold Assembly 16
Electrical .................................. 17
Electrical Guidelines 17
HPTO Controller Master Unit 18
HPTO Controller Display Unit 18
Controller Interface 19
Electrical Schematic 20
Initial Startup Checklist 22
Mechanical ................................ 23
Mechanical Guidelines 23
Assembly Guidelines 24
Assembly Procedure 25
Dimensions and Capacities - HPTOFX 27
Dimensions and Capacities - HPTOVG 28
Support Bracket Details 29
Maintenance .............................. 30
Maintenance Intervals 30
Oil Contamination Levels 30
Pump Pad Installation and Orientation 31
Available Kits & Service Parts 32
Detailed Kits Parts List - Clutch 33
Detailed Kits Parts List – Pump Drive Housing 35
Troubleshooting 39

2 10.22.12 I
E-038
 Safety
Always follow the operating instructions in this publication. This ensures trouble-free operation and fulfillment of
any rights to claim warranty. Read these instructions before starting any installation or maintenance. These
instructions contain important information about servicing and maintaining your HPTO. Always keep them in a safe
and clean location.

The following notes appear throughout the publication. Please take a moment to review and understand them.

Electrical hazard
Possible consequences: Severe or fatal injuries

Hazardous situation
Possible consequences: Severe or fatal injuries

Important information
Possible consequences: Damage to components or voiding of warranty

Correct installation, maintenance and operation procedures must be followed due to the possible danger to
person(s) or property from accidents that may result from the use of machinery. PT Tech will not be responsible
for personal injury resulting from careless maintenance and working practices.

Safety devices and guards that may be specified in safety codes should be provided. These devices are not
provided nor are the responsibility of PT Tech.

To prevent accidental starting of the engine or electronic damage when performing maintenance,
disconnect battery cables from battery and remove ignition key from switch. Correct lockout/tagout
procedures should always be closely followed.

PT Tech has made provisions for attaching lifting bolts. The holes provided are of adequate size and
quantity to safely lift the product itself. These lifting points must not be used to lift anything other than the
PT Tech product. Lifting excessive loads at these points could result in property damage or personal injury.

Select lifting eyebolts to obtain maximum thread engagement with bolt shoulder tight against housing. Bolts
should not be long enough to bottom out in lifting hole.

Personal injury can result from fluid under pressure. Care must be taken to ensure fluids are contained
during inspections, maintenance, adjusting or repair of the equipment. All pressurized hydraulic
components should be correctly guarded to prevent personal injury.

10.22.12 I 3
SYSTEM OVERVIEW

SYSTEM OVERVIEW

System Overview
Eight components are required to effectively install your PT Tech Hydraulic Power Take-off (HPTO) clutch:
 HPTO Unit (model based on desired horsepower capacity)  Reservoir
 HPTO Controller  Gear pump
 Manifold Assembly  Filter Assembly
 Cooler
 Torsional Coupling
The items in blue are provided with your HPTO clutch. Items in red are required Auxiliary Components that can
be purchased from PT Tech or from your preferred supplier. Please carefully read this manual so your PT Tech
product is installed correctly for maximum performance.

4 10.22.12 I
 SYSTEM OVERVIEW

Auxiliary Components
The following components can be purchased directly from PT Tech or a customer’s preferred source.

Description PT Tech Part Number Equivalent supplier & part number

Fluid Reservoir – 15 gallon (56.8 L) CHYFR-004 SunSource: SS3149

SAE-A size Hydraulic Gear Pump CHYGP-006 Bosch Rexroth: AZPN12020LDR12MB

(20 cc/rev, A pad, B spline, -16 inlet, -10 outlet)

* Sauer-Danfoss: 1P3060ASSJBN
(18 cc/rev, A pad, A spline, -16 inlet, -12 outlet)
or
* 1P3072ASSJBN
(22 cc/rev, A pad, A spline, -16 inlet, -12 outlet)

* Prince: SP20B20A9H9L
(20 cc/rev, A pad, A spline, -16 inlet, -12 outlet)

* Honor: 2GG2Q20L
(19.5 cc/rev, A pad, A spline, -16 inlet, -10
outlet)

* Honor: 2GG2U24L
(24 cc/rev, A pad, A spline, -16 inlet, -12 outlet)

SAE-B size Hydraulic Gear Pump CHYGP-004 Bosch Rexroth: AZPN12020LDC12MB

(20 cc/rev, B pad, B spline, -16 inlet, -10 outlet)

CHYFC-005 Blissfield: 82010

Oil Cooler
CHYFC-006 AKG Thermal Systems C-8

Filter Assembly with filter element, Donaldson: P17-0773 Filter Head

CHYFA-001-D
filter head & clog indicator Donaldson: P17-0926 Electrical Indicator

Donaldson: P17-0311
Filter element CHYFE-003 Caterpillar: 130-3212
WIX: 557115

* These components are compatible with the HPTO but not available from PT Tech

10.22.12 I 5
 SYSTEM OVERVIEW

Component Description
The following illustration is a guide for terminology that will be used throughout this document.

Pump Drive Housing

Pump Pad
Spline Insert

Torsional Coupling
(Customer Supplied)

Input Speed Pickup

Output Speed Pickup

Bellhousing

Clutch
Pump Drive Housing
3X Drain Ports

Support Plate
(Customer Supplied)

6 10.22.12 I
 SYSTEM OVERVIEW

Model Identification &

Serial Number
All HPTO’s receive a part number and unique serial number when they are assembled at the factory. This
information contains the assembly part number, assembly revision letter and date code in the serial number.
It is important that this information not be painted over, tampered with or removed, as this is the only type
of identification for warranty or replacement parts.

HPTO12W-92-100 C 610 89
Clutch Size Assembly Sequential Serial Number
Month Built
Revision Year Built
Letter
Sub-assembly designation
(-91- =Pump Drive Housing) Model Type
(-92- = Clutch)

Pump Drive Housing

Serial Number Location

Clutch Serial Number

Location

10.22.12 I 7
HYDRAULICS

HYDRAULICS

Hydraulic Guidelines
Please use the following guidelines to assist your design, selection and installation of your hydraulic system.

Cooler

 Oil coolers must be sized to remove at least 6 hp

(4.5kW) of heat from the system

 If ambient air temperature is below 32° F (0° C) for

extended periods of time, a cold-weather-bypass may
be required to prevent the cooler from bursting

Figure 1
 Oil coolers are ideally placed in front of the engine’s
Preferred Mounting heat exchanger, opposite the fan blades to pull
ambient air through the cooler (Figure 1)

 If a thermostat controlled fan is used it should

monitor inlet oil temperature

 Oil coolers should be oriented so that air does not get

trapped in the system and oil does not drain back to
tank. To avoid this situation inlet and outlet ports
should be oriented upwards or place the inlet at the
bottom and outlet at the top (Figure 2)

Figure 2
 Under extreme high ambient temperature, additional
Unacceptable Mounting cooling may be required

Note: Blue arrows indicate cool oil or air and red

arrows indicate warm oil or air

Figure 3

8 10.22.12 I
 HYDRAULICS

Hydraulic Guidelines (continued)

Reservoir
Location & Oil Levels

3D View  Oil reservoirs should be as close to the HPTO as

Figure 4 possible to minimize hose lengths and away from
the engine’s heat exchanger and other heat sources

 Top of oil reservoir must be below the pump drive

housing drain(s) being used

 To account for cooler and filter volumes, reservoir

levels should be checked after initial startup and
fluid changes

Design & Sizing

 Oil reservoirs should have a baffle that separates
the return port from the suction port. Ideally this
baffle is designed to run the length of the reservoir
so that it gives the oil maximum dwell time to allow
End View foam to settle out. This baffle should also run to the
Figure 5 top of the reservoir to ensure the suction port is as
free of foam as possible (Figure 4 & 6)

 Return and drain flows should be returned below

the reservoir’s fluid level to reduce oil aeration.
These lines should also be slant cut at the bottom
and directed away from reservoir flow to improve
oil dwell time and reduce fluid velocity (Figure 7)
Top View
Figure 6  Reservoir cleanout covers, if used, should allow
access to both sides of the baffle (Figure 5)

 Oil reservoir should be sized such that its capacity is

at least twice the maximum flow rate of the pump
which is operating the HPTO
o Example: A pump provides 8-1/2 GPM (32.2L) of
flow at maximum operating rpm. The reservoir
should then be at least 17 gallons (64.4L)

Side View
Figure 7

10.22.12 I 9
HYDRAULICS

Hydraulic Guidelines (continued)

Pump requirements and pump drive capabilities
Pump requirements for HPTO

 A maximum pump flow of 15 gpm (57 lpm) is allowable at full engine speed

 A minimum pump flow of 3.5 gpm (13.2 lpm) is required at engine idle

 Pump suction hose should be as large in diameter and as short as possible to prevent
pump cavitation. A minimum hose diameter of 1-1/4” (32mm) is recommended.
Consult pump manufacturer to ensure suction head does not exceed their
recommendations for all operating conditions

 Pump inlet port should be no more than one size smaller than the suction hose size
being used
o Example: Pump port should be no smaller than -16 with a -20 suction hose
Pump drive capabilities

 SAE size A through D pump pads are available for use with the HPTO

 SAE size A through C spline inserts are available for use with the HPTO (SAE D size is
default spline in gear)

 Pump drives are available in a 1:1 and 1.27:1 (pump to engine speed) ratio

 If one of the pump drive locations is not being used, a coverplate must be in place to
prevent contaminates from entering unit. Coverplates are available from PT Tech for
all size pump pads

 Maximum unsupported pump load must not exceed 100 lb·ft (136 N·m). See graph
provided to determine if your application is within limits. If load exceeds limits a
support bracket must be used

10 10.22.12 I
 HYDRAULICS

Hydraulic Guidelines (continued)

Hoses, Fittings & Manifold

 Pump drive housing drain hose(s) must be Ø2” (Ø51mm) and free of loops,
restrictions, tight bends or upward slopes that could trap oil inside the HPTO

 If HPTO is mounted at an angle between 20° & 80° from vertical, two drain
hoses must be attached (Figure 8)

 If machine operates on angles, be certain that the pump drive housing drain
hose has adequate slope in worst case scenario

 A pump drive housing drain hose access hole is recommended in the support
plate to eliminate the need for special drain elbows

20°  Hoses should be routed in a fashion that prevents air from being trapped in the
to system
80°
 90° elbows and bulkhead fittings should be avoided in the hydraulic system to
prevent flow loss and pressure increases

 The manifold assembly should be mounted in a way that water and other
contaminates do not enter the electrical connectors of the valves and sensors.
Typically this is achieved by pointing them down or sideways

 The manifold assembly should be mounted in a location that prevents air from
being trapped in the system and is protected from thrown objects, heat sources
and contamination

 Additional hose and fitting sizes are located on the hydraulic schematic
Figure 8 To reservoir

Oil Cleanliness & Filtration

 Baseline oil samples are recommended when the machine is new (Refer to
“Maintenance Section” of this document) for later comparison

 A β16=75 high pressure filter (1000 psi/69 bar working, 2000 psi/138 bar burst) is
recommended

 Recommended Filtration Level ( ISO 4406:1999/SAE J1165) : 15/13/11

(4µm/6µm/14µm), minimum: 19/16/10

 Hoses, coolers and other hydraulic system components should be thoroughly

flushed before initial startup and during fluid changes

10.22.12 I 11
HYDRAULICS

Oil Requirements
Using any fluid other than PT Tech approved oil may significantly affect the performance and function of the
HPTO unit and will void warranty.
• In cold weather conditions, below 32°F (0° C), PT Tech recommends the engine and HPTO hydraulic system
run at low engine idle to allow sufficient time for the hydraulic oil to warm up prior to engaging the clutch
and increasing engine speed. If the HPTO clutch system indicates a pressure fault any time during this
warm up period, follow normal engine shutdown procedures to prevent damage to the HPTO clutch system.
• The HPTO clutch system design specification has an allowable environmental ambient temperature range
of -20° F to 120° F (-29° C to 49° C). If ambient temperatures are below the allowable range, PT Tech
recommends the addition of a reservoir heater.
• High ambient temperatures may require additional cooling
To determine the recommended oil for your application, first select the temperature range below that best
defines the normal ambient air temperature in which the HPTO will be operating.

Below -4° F (-20° C) -4° F to 32° F (-20° C to 0° C) Above 32° F (0° C)

Caterpillar Arctic (Cold Weather)
Mobilfluid LT Mobilfluid 424
TDTO
- Shell Spirax S3 TLV Caterpillar TDTO (10W ONLY)
- ESSO Hydraul 50 Shell Spirax S4 TXM
- - ESSO Hydraul 56
- - Vermeer VMF Ultra Gold

12 10.22.12 I
 HYDRAULICS

Hydraulic Interface - FX

10.22.12 I 13
HYDRAULICS

Hydraulic Interface - VG

14 10.22.12 I
 HYDRAULICS

Hydraulic Schematic

10.22.12 I 15
HYDRAULICS

Manifold Assembly
The manifold assembly (CHYMA-24V-005) is supplied complete with the HPTO12W. Individual valves and sensors are
available from PT Tech upon request. Please note that as of May 2012 manifolds have a colored tag which should
match the color of the clutch controller being used.

SAE -12 Port Sizes

CHYPV-002
Clutch PWM Valve Gauge port (1/4” NPT)
Pressures range from
0-275 psi (0-19 bar)

CHYPV-004 CHYFV-002
Brake Valve Lube Flow Control Valve
4.0 GPM [15.1 LPM]

CHYSC-004
Sequence Valve
260 psi [18 bar]
SAE -12 Port Sizes
CHYRV-500-001
Pressure Relief Valve
500 psi [34.5 bar]

CHYTS-200-001-D
Temperature Switch
200° F [93° C]

CHYPT-003-D
Pressure Transducer

Pressures range from 230-

550 psi (15.8-37.9 bar)

Gauge port (1/4” NPT)

16 10.22.12 I
 ELECTRICAL
ELECTRICAL

Electrical Guidelines
To avoid any electrical malfunction, the user should always disconnect the wiring harness from the HPTO
controller when welding or performing any electrical maintenance on the equipment. Failure to do so may
result in damage and loss of warranty.
The HPTO controller has been pre-programmed at PT Tech. Failure to understand the specified operating
parameters and conditions prior to initial startup and operation may result in unexpected results and/or
possible damage to equipment. Contact PT Tech prior to initial startup to prevent possible injury or death.

Power
 The HPTO controller must be connected to a 24 Volt DC power source (battery) and will not function correctly if
voltage drops below 20 VDC
 If system voltage is 12 Volts a voltage converter is required (P/N CECVC-002). Contact PT Tech prior to installing
wiring for instructions
 The engine ignition switch should provide power to the ignition input (orange wire connected to pin 1 of grey
plug on master unit of HPTO controller) in all positions except off
 Battery power to the HPTO controller must remain constant regardless of switched power. It also must remain
constant during E-stop conditions
 It is recommended that the machine’s E-stop button not disconnect battery power from the HPTO clutch
controller during an emergency stop situation. A battery positive source should be connected to pin 8 of the
grey “A” plug on the master unit and the engine key switch power must be lost during an E-stop. This will allow
the clutch to stay engaged and the engine to assist in the slowdown of the driven inertia

Wiring & Connectors

 Ensure that all shield/drain wires are connected to the master unit pins per the wiring schematic. Do not ground
shield/drain wires at the sensor end.
 Do not ground shield wires to frame/chassis ground
 If extra wire length is present in wiring harness, cut wires to needed length. Do not coil wires. Coiling the wires
could cause electrical noise and interference
 Plug unused openings in connectors with appropriate sealing plugs to prevent contamination from entering the
connector
 To reduce stress in connectors allow at least 3” (76.2 mm) of wire length from connector to attachment points
or wire bends
 If controller is not mounted inside an electrical enclosure, orient the controller with electrical plugs facing
downwards and run with a “drip loop” to prevent water intrusion into the electrical connectors

Specifications & Options

 The clutch can be engaged/disengaged via three ways:
1) PT Tech display unit
2) Customer supplied momentary switch
3) J1939 interface
 If a customer supplied engage/disengage switch is used the button should be connected to pin 5 of the grey plug
on the master unit of the HPTO controller
 The HPTO controller has an internal resistance that will draw 48mA @ 24 VDC when the remote button is pushed
For customers who choose to use the J1939 functionality of the HPTO controller, a detailed J1939 interface
specification is available from PT Tech upon request

10.22.12 I 17
ELECTRICAL

HPTO Controller
Master Unit
(required)
PT Tech Part Number: CMCMU-008-12WA
 Controller should be oriented with plugs facing down to
keep contaminates out
 Controller should be mounted using rubber isolation
mounts to reduce vibrations
 Protect controller by locating it in a safe location away
from thrown objects
 Controller should not be subjected to temperatures
beyond -20°F (-29°C) and 180°F (82°C)
Beginning May 2012 controller types are distinguished by
label color. Please ensure the correct master unit is
being used
Black Basic R Sky blue Advanced 3
Bluish-green Basic 2 Orange Advanced 4

Clutch Controller
Yellow Advanced 2R

Serial Number Tag HPTO

CMCMU-008-12W
CMCMU-XXX-XXX

PT TECH MADE IN USA

PT TECH MADE IN USA S/N: A1715-CR 10/2010

S/N: A1715-CR 10/2010

Serial Number Date Code Grey (A) plug Black (B) plug
Model Number

HPTO Controller
Display Unit
(optional)
PT Tech Part Number: CMCDU-008

 Mounting studs and nuts included

 Display unit must be grounded using ground

splice in the wiring harness near the master
unit. Do not connect ground wire for display
unit to frame ground

 Display unit must receive power by the yellow

wire, pin 9 of black (B) plug on the master unit

18 10.22.12 I
 Input Speed
Indicates controller is receiving speed Pressure Transducer
signal from input speed pickup or Indicates pressure transducer

10.22.12 I
J1939 CAN is functioning normally

Output Speed J1939 CAN

Indicates controller is receiving speed Indicates controller is receiving
Power signal from output speed pickup communication from CAN
Indicates controller is receiving
switched power

Clutch Engagement
Indicates if the clutch is engaging,
engaged or disengaged

Clutch Engage/Disengage Button

Push and hold for 3 seconds to
engage clutch. Momentary push will
disengage clutch

Clutch Overload Clogged Filter Fault Safety Switch Fault

Oil Pressure Fault Flashes to indicate clutch is Clutch oil filter is Indicates a machine’s
Indicates pressure slipping while engaged. clogged while clutch is safety switch is open.
is not acceptable. Illuminates continuously when engaged. Beacon light This will prevent the
Controller will not clutch has reached thermal also flashes. Clutch clutch from engaging
allow engagement capacity during engagement or will disengage in 15 but will not
or disengage clutch while engaged minutes disengage the clutch

Timed Lockout Oil Temperature Fault RPM Too High Fault Coil Fault
Indicates (3) failed engagements have occurred Clutch oil temperature is above Indicates engine rpm Indicates a
in a row, or the controller detects a clutch 200°F (93°C). Beacon light will must be lowered to solenoid coil on
overload or the clutch has disengaged to prevent flash. Controller will not allow engage or disengage. the manifold is
an engine stall. Controller will not allow another engagement or, if clutch Also indicates if engine not performing
Controller Interface

engagement for 5 minutes and engine must already engaged, speed was increased properly
remain running for that time to count down disengagement will occur in 15 during engagement

19
minutes
ELECTRICAL
ELECTRICAL

Electrical Schematic

20 10.22.12 I
 Electrical Schematic (continued)

10.22.12 I
21
ELECTRICAL
ELECTRICAL

Initial Startup Checklist

After completing the installation of your HPTO, please ensure the system performs as described below

Key On

 Power light illuminated

 Pressure Transducer light illuminated
 J1939 CAN light illuminated (if connected)

Engine Running – Clutch Disengaged

 Power light illuminated
 Pressure Transducer light illuminated
 J1939 CAN light illuminated (if connected)
 Input Speed light illuminated
 Pressure in “G2” port of manifold is at least 230 psi (15.8 bar)

Engine Running – Clutch Engaging
 Power light illuminated
 Pressure Transducer light
illuminated
 J1939 CAN light illuminated (if
connected)
 Input Speed light illuminated
 Output Speed light illuminated
when shaft rotation begins
 Pressure in “G” port of manifold drops
to 0 psi when engage button is pressed
 Clutch engaged light flashes after
button is held for 3 seconds
 Controller “ramps” clutch pressure until
output and input speed are equal
 Pressure in “G2” port increases during
clutch engagement process

Engine Running – Clutch Engaged  Power light illuminated

 Pressure Transducer light illuminated
 J1939 CAN light illuminated (if connected)
 Input Speed light illuminated
 Output Speed light illuminated
 Clutch engaged light illuminated
 Pressure in “G2” port of manifold is 225 psi (15.5 bar)

Engine Running – Clutch Braking  Power light illuminated

 Pressure Transducer light illuminated
 J1939 CAN light illuminated (if connected)
 Input Speed light illuminated
 Output Speed light illuminated until shaft speed drops below 100 RPM
 Pressure in “G2” port fluctuates until shaft is stopped then pressure returns
to at least 230 psi (15.8 bar)

22 10.22.12 I
 MECHANICAL
MECHANICAL

Mechanical Guidelines
 A torsional coupling (customer supplied) is required for connecting the HPTO to the engine’s flywheel
 To avoid system damage and ensure full design life, a torsional vibration analysis is required during the initial
application design. This analysis is the responsibility of the customer and will determine the specific coupling
suitable for the application
 PT Tech recommends Reich torsional couplings. Please contact them for information regarding your application
Reich USA Corporation
P.O. Box 916
300 Route 17 South - Suite H
Mahwah, NJ 07430
T: 201.684.9400
 Belt load and centerline should be within limits specified in the provided belt load graph
 Belt driven applications require a support plate (customer supplied) to be attached to the clutch. Dimensional
details are given within the ‘Mechanical’ section of this document
 Always contact belt supplier to determine correct belt tension

Distance from centerline of

belt to end of shaft

10.22.12 I 23
MECHANICAL

Assembly Guidelines
 Inspect and clean mounting faces and surfaces
 Bolt holes should be clean and free of debris
 Verify flywheel runout tolerance is within engine manufacturer’s specification
 When installing bolts and other fasteners, use permanent thread-locker on the threads and torque to
recommended values
 Assembly should be safely supported at all times until it is firmly secured to the machine

 Ensure that all bolt threads are compatible with equipment. PT Tech follows SAE J620 Oct88 standards

Recommended Tools/Materials
 Torque wrench: 30 – 150 lb·ft (41 – 203 Nm)  Overhead hoist
 Ratchet  Lint-free towels
 Socket set  Recommended oil (see “Oil Requirements”)
 Inch-size wrenches  Brake cleaner (non-chlorinated)
5
 /8-11 & ½-13 UNC eyebolts  Permanent thread-locker (Loctite 262)
 Adjustable crescent wrench  Lifting straps (2000 lb/907 kg minimum capacity)

24 10.22.12 I
 MECHANICAL

Assembly Procedure
The following figures are only provided to make it easier to visualize the process. Discrepancies may occur
depending on HPTO size and version

Flywheel Bolts

SAE-14
½-13 UNC - Grade 8 (M12x1.75 - Grade 12.9)
Torque to 78 lb·ft (108 N·m)

SAE-18
5
/8-11 UNC – Grade 8 (M16x2.0 – Grade 12.9)
Torque to 156 lb·ft (268 N·m)

Bellhousing Bolts

SAE #1
7/16-14 UNC – Grade 8 (M10x1.5 – Grade 12.9)
Torque to 52 lb·ft (62 N·m)

SAE #0
½-13 UNC – Grade 8 (M12x1.75 – Grade 12.9)
Torque to 78 lb·ft (108 N·m)

 Bolt torsional coupling to flywheel

 Align input shaft with spline in torsional coupling and attach bellhousing to engine

10.22.12 I 25
 MECHANICAL

Assembly Procedure (continued)

Output
Speed
Pickup
¾ turns out.
See notes below

Speed
Pickup
¾ turns out.
See notes below

O-ring
Washer

Input Speed Pickup

2.5 turns out

½-13 UNC – Grade 8 Bolts

Torque to 78 lb·ft (105 N·m) Incorrect speed pickup adjustment
may result in damage of speed
pickup and incorrect operation

 Remove two lower most bolts from clutch

 Replace bolts with ½-13 UNC Grade-8 bolts of appropriate length and attach support plate to HPTO
 Shim and attach bottom of support plate to machine frame
 Remove buttonhead capscrew from input speed location and transfer O-ring washer to speed pickup
 Thread speed pickup into input speed location in pump drive housing
 Tighten input speed pickup by hand until speed pickup bottoms out, back out 2.5 turns and lock in place with
jam nut
 Remove buttonhead capscrew from output speed location and transfer O-ring washer to speed pickup
 Thread speed pickup into output speed location in clutch
 Tighten output speed pickup by hand until speed pickup bottoms out, back out 3/4 turn and lock in place with
jam nut. Take care so that the piston inside the clutch is not compressed during adjustment

26 10.22.12 I
 Dimensions and Capacities - HPTOFX

10.22.12 I
27
MECHANICAL
28
Dimensions and Capacities - HPTOVG
MECHANICAL

10.22.12 I
 MECHANICAL

Support Bracket Details (customer supplied)

2X ½-13 UNC Bolts

Torque to 74 lb·ft (100 N·m)

Recommended hydraulic
drain access hole

Plate must be at
least ¾” (19mm) thick

10.22.12 I 29
MAINTENANCE

MAINTENANCE

Maintenance Intervals
Perform all maintenance using standard safety practices and with engine off.
Regular oil changes and samples are recommended to ensure maximum clutch performance and longevity.
Baseline oil samples are suggested to be performed on new machines. These baseline samples can be
beneficial in determining the condition of components and can also aid in troubleshooting if a unit is not
performing correctly.

Frequency What to do?

 Check oil and oil level
 Check hydraulic connections
First 10 hours
 Check all bolted connections
 Baseline oil sample analysis

 Check oil level

Daily  Check pump drive housing and reservoir breathers for clogs or obstructions
 Check ventilation holes in bellhousing for clogs or obstructions

 Replace system oil

 Replace breather at top of HPTO housing (P/N: CHFOB-012-002)
Every 500 hours
 Replace oil filter (See Auxiliary Components for P/N’s)
 Oil sample analysis

1000 hours  Inspect pump drive gears. Contact PT Tech for inspection procedure and additional information

 Internally inspect and service. Rebuild kits and instructions as well as completely rebuilt
5000 hours
clutches are available

Oil Contamination Levels

The following is for reference only and should only be used as a general guideline.
Levels listed below state acceptable amounts ABOVE baseline levels.
Minimum ISO Filtration Level: 19/16/10

Element type Warning Level (ppm) Element type Warning Level (ppm)
Aluminum 10 Molybdenum 5
Antimony 15 Nickel 10
Barium 10 Phosphorus 100
Boron 10 Potassium 10
Calcium 100 Silicon 25
Chromium 10 Silver 10
Copper 25 Sodium 10
Iron 100 Tin 10
Lead 10 Water 250
Magnesium 10 Zinc 100

30 10.22.12 I
 MAINTENANCE

Pump Pad Installation

and Orientation
1. Clean any gasket residue off of housing. Avoid getting debris or solvent inside the housing. Surface must be
clean and dry before installation of new gasket or O-rings.
2. Align bearing with pilot opposite while aligning teeth with idler gear. Push until seated against pilot’s
shoulder. If desired, gear may be inverted during installation to put opposite gear faces in service
3. Install gasket or O-rings to pump pad. Install pump pad into housing.
NOTE: If pump pad has slots machined near the bearing bore its orientation is critical! For FX pad locations 1 &
3, align center slot so it is pointing towards clutch shaft. For pad locations 2 & 4, align center slot so it is
pointing towards the lifting hole. If other pump pad rotation is necessary for pump alignment, slots should
be pointing towards the center of the housing. VG housings should have the slots pointed towards the
centerline of the clutch.
4. Secure pump pad to housing using (4) flathead bolts (SAE-D pump pad uses studs). Use permanent
threadlocker (Loctite 262) and torque to 95 lb-ft [129 N-m]
5. Assemble O-rings to pump and reinstall pump. Torque fasteners to manufacturer’s specifications

Pilot’s shoulder

Idler Gear

Orient slots as shown

Lifting hole

Pump pad location number

are cast into housing

10.22.12 I 31
MAINTENANCE

Available Kits & Service

Parts
HPTO12W-60-100 Output Shaft Seal Kit
Clutch Kits HPTO12W-63-100 Complete Clutch Rebuild Kit
HPTO12W-64-100 Brake Rebuild Kit
HPTOFX-60-100 Input Shaft Seal Kit
HPTOFX-61-100 Pump Pad Field Kit – SAE A
HPTOFX-61-101 Pump Pad Field Kit – SAE B
HPTOFX-61-102 Pump Pad Field Kit – SAE C
HPTOFX-61-103 Pump Pad Field Kit – SAE D
HPTOFX-62-100 FX Housing Seal Kit
HPTOFX-63-100 Pump Drive Gear Kit
HPTO15FX-64-100 Clutch Cup Kit
Pump Drive HPTO15FX-64-101 Clutch Cup Kit - Speed Increase
Housing Kits HPTOFX-65-100 Idler Gear Kit
HPTOFX-65-101 Idler Gear Kit - Speed Increase
HPTOFX-66-100 Input Shaft Kit
HPTOFX-67-100 #0 Bellhousing Kit
HPTOFX-67-101 #1 Bellhousing Kit
HPTO15FX-68-100 Complete Flex Housing Rebuild Kit
HPTO15FX-68-102 Complete Flex Housing Rebuild Kit – Speed Increase
HPTO14VG-68-100 Complete VG Housing Rebuild Kit
HPTO14VG-68-102 Complete VG Housing Rebuild Kit – Speed Increase
CECSP-003-D Speed Pickup
CHFOB-012-002 Breather
CHFOB-012-002-KIT Breather Riser Kit
HPTOFX-13-100 Spline Insert - SAE A
Service Parts HPTOFX-13-101 Spline Insert - SAE A-A
HPTOFX-13-102 Spline Insert - SAE B
HPTOFX-13-103 Spline Insert - SAE B-B
HPTOFX-13-104 Spline Insert - SAE C – Standard Length
HPTOFX-13-105 Spline Insert - SAE C – Short

32 10.22.12 I
 MAINTENANCE

HPTO12W-60-100

HPTO12W-63-100

HPTO12W-64-100
Detailed Kits Parts List - Clutch

CAC-028I-7218BECBY Angular Contact Bearing ●

COR-B103-2170 O-ring ● ● ●
COR-B139-2280 O-ring ●
CPP-BS250-6250B Polypak Seal ●
CPP-BS250-8000B Polypak Seal ●
CQR-B139-Q4260 Quad Ring Seal ● ●
CQR-B139-Q4263 Quad Ring Seal ● ●
CRR-XXMI-DNH150 Double-wound Retaining Ring ●
CRR-XXMI-X775 Retaining Ring ● ● ●
CSS-V034-42474 Shaft Seal ● ● ●
HBH08-O6F04-XX Button-head Capscrew ●
HBH08-08C08-XX Button-head Capscrew ●
HFW08-08XXX-XZ Flat Washer ●
HHD08-08C12-XX Hexhead Capscrew ●
HLWXX-38XXX-XX Locknut Washer ●
HLWXX-41XXX-XX Locknut Washer ●
HOWXX-06XXX-XX O-ring Washer ●
HOWXX-08XXX-XX O-ring Washer ●
HPTO12W-10-100 Pressure Plate ●
HPTO12W-18-100 Seal Ring ●
HPTO12W-19-100 Brake Rotor ● ●
HPTO12W-20-100 Seal Cover ● ●
HPTO12W-22-100 Brake Piston ● ●
HPTO12W-23-100 Endplate Friction Assembly ●
HPTO12W-25-100 Torque Reaction Tab ● ● ●
HPTO12W-40-100 Bearing/Spacer Set ●
HPTO14DD-07-102 Separator Plate ●
HPTO14DD-23-105 Friction Material Assembly ●
HSM05-08C28-FA Hexhead Capscrew ●
HSSFT-08C04-XX Set Screw ●
SP93-10D04-120X Die Spring – Red ●

10.22.12 I 33
MAINTENANCE

34 10.22.12 I
 MAINTENANCE

HPTO14VG-68-102
HPTO14VG-68-100
HPTO15FX-64-100
HPTO15FX-64-101

HPTO15FX-68-100
HPTO15FX-68-102
HPTOFX-60-100
HPTOFX-61-100
HPTOFX-61-101
HPTOFX-61-102
HPTOFX-61-103
HPTOFX-62-100
HPTOFX-63-100

HPTOFX-65-100
HPTOFX-65-101
HPTOFX-66-100
HPTOFX-67-100
HPTOFX-67-101
Detailed Kits Parts List
– Pump Drive Housing

CAC-009I-3306E Angular Contact Bearing ● ● ● ● ● ●

CAC-028I-7218BECBY Angular Contact Bearing ● ● ● ● ●
CBB-017I-0004 Ball Bearing ● ● ● ● ●
CECSP-003-D Speed Pickup ● ● ● ●
CHFOB-012-002 Breather ● ● ● ●
CHFPL-032-002 Plastic Cap/Plug ● ● ● ●
COR-B070-2031 O-Ring ● ● ● ●
COR-B103-2114 O-Ring ● ● ● ●
COR-B103-2166 O-Ring ● ● ● ● ● ● ●
COR-B103-2171 O-Ring ● ● ● ● ● ● ● ● ●
COR-B103-2242 O-Ring ●
COR-B139-2225 O-Ring ● ●
COR-B139-2228 O-Ring ●
COR-B139-2236 O-Ring ●
COR-B139-2250 O-Ring ●
COR-B139-2280 O-Ring ● ● ● ● ● ● ● ● ● ●
CRR-XXHE-5100118 Retaining Ring ● ● ● ● ● ●
CRR-XXLI-X287 Retaining Ring ● ● ● ●
CSS-V034-42474 Shaft Seal ● ● ● ● ● ● ●
HBH08-06F04-XX Buttonhead Capscrew ● ●
HBH08-06F08-XX Buttonhead Capscrew ● ●
HBSCR-20MXX-XX Belleville Washer ● ● ● ●
HFS08-05C06-XX Flathead Socket Capscrew ● ●
HFS08-10C08-XX Flathead Socket Capscrew ● ● ●
HHD05-06C06-XX Hexhead Capscrew ● ●
HHD08-10C12-XX Hexhead Capscrew ● ● ● ● ● ●
HNTHN-12CXX-XX Hex Nut ● ● ● ●
HOWXX-06XXX-XX O-Ring Washer ● ● ● ●
HOWXX-16XXX-XX O-Ring Washer ● ● ● ●
HPTOFX-02-100 Bellhousing - #0 ●
HPTOFX-02-101 Bellhousing - #1 ●
HPTOFX-03-103 Pump Pad Kit – SAE D ●
HPTOFX-03-A Pump Pad – SAE A ●
HPTOFX-03-B Pump Pad – SAE B ●
HPTOFX-03-C Pump Pad – SAE C ●
HPTOFX-04-100 Clutch Body ● ● ● ● ● ●
HPTOFX-08-100 Input Shaft ●
HPTOFX-17-100 Bearing Sleeve ● ● ● ●
HPTOFX-18-100 Idler Gear Retainer ● ● ● ●
HPTOFX-30-100 Pump Pad Gasket ● ● ●
10.22.12 I 35
MAINTENANCE

HPTO14VG-68-102
HPTO14VG-68-100
HPTO15FX-64-100
HPTO15FX-64-101

HPTO15FX-68-100
HPTO15FX-68-102
HPTOFX-60-100
HPTOFX-61-100
HPTOFX-61-101
HPTOFX-61-102
HPTOFX-61-103
HPTOFX-62-100
HPTOFX-63-100

HPTOFX-65-100
HPTOFX-65-101
HPTOFX-66-100
HPTOFX-67-100
HPTOFX-67-101
Detailed Kits Parts List
– Pump Drive Housing

HPTOFX-50-100 Idler Gear ● ●

HPTOFX-50-101 Idler Gear – Speed Increase ● ●
HPTOFX-51-100 Pump Drive Gear ● ● ● ● ●
HPTOFX-52-100 Input Pinion ● ● ●
HPTOFX-52-101 Input Pinion – Speed Increase ● ● ●
HPTOVG-10-100 Idler Shaft ● ●
HPTOVG-11-100 Idler Clamp Plate ● ●
HPTOVG-12-100 Idler Hub ●
HPTOVG-13-100 Shipping Plate – w/breather hole ● ●
HPTOVG-15-100 Pump Pad Gasket – A-size ● ● ●
HPTOVG-16-100 Coverplate – A-size ● ●
HPTOVG-50-100 Idler Gear – Speed Increase ●
HSH08-05F08-XX Sockethead Capscrew ● ● ● ● ● ●
HSH08-08C08-XX Sockethead Capscrew ● ● ● ●
HSH08-10C10-XX Sockethead Capscrew ● ●
HSM05-08C28-FA Orange Hexhead Capscrew ● ● ● ● ● ● ● ● ● ●

36 10.22.12 I
 MAINTENANCE

10.22.12 I 37
MAINTENANCE

38 10.22.12 I

Troubleshooting
Please use the logic trees on the following pages to aid in understanding the functions of the HPTO and
troubleshooting any problems that may occur.
Illuminated Illuminated
continuously with continuously
engine running with key off
Normal when ignition switch is Pin 1 of grey (A) plug on Controller not receiving
in every position other than master unit is receiving switched power from
"Off" continuous power, not
switched power
Check ignition switch
wiring
If using a voltage
voltage in wire connected to
converter, check
voltage converter
wiring is correct
10.22.12 I
MAINTENANCE
Power
Not illuminated Flashing in Flashing randomly
with engine rhythm with (flickering) with
running engine running engine running
Controller receiving power Poor battery ground
less than 20 volts
ignition switch
Check battery voltage. Check for damage in wire
Check 5 amp fuse on wire Charge or replace if connected to pin 7 of grey
connected to pin 8 of necessary (A) plug on master unit
grey (A) plug on master unit
With ignition on, test
Check that wire connected
to pin 7 of grey (A) plug on
pin 1 of grey (A) plug on
master unit. If no voltage, master unit is connected to
(-) terminal of battery
check wire for damage and
inspect ignition switch
terminals
A proper battery ground will
measure 0 VDC and less
Check that wire connected
than 1 Ω of resistance
to pin 8 of grey (A) plug on
master unit is directly
connected to (+) battery
terminal and is damage free
Check that wire connected
to pin 7 of grey (A) plug on
master unit is directly
connected to (-) battery
terminal and is damage free
Check that wire connected
to pin 1 of grey (A) plug on
master unit is not losing
momentary power when
engine is cranking
Check that wires connected
to pins 7 & 8 of grey (A)
plug on master unit are not
losing connection
Permanent damage occured
from welding or lightning
strike, replace controller
39
MAINTENANCE
Input Speed
Illuminated
continuously
Normal when engine running
Output Speed
Illuminated Not illuminated or
continuously flashing randomly
(flickering)
Normal while the output shaft of Controller not receiving signal
the HPTO unit is spinning from the output speed pickup
Check the speed pickup adjustment (see
Mechanical Assembly Procedure section of
this document)
Check the wires running from the speed
pickup to the master unit for damage.
These wires must be shielded
Check that the drain wire (clear insulation)
is connected to pin 3 of black (B) plug on
master unit. This wire must not be
connected to the chassis frame
Remove speed pickup and inspect probe
end for damage
Remove speed pickup from clutch housing
and disconnect from wiring harness. Check
resistance between red and black wires
(pins 1 & 2). Resistance should measure
900 Ω (+/- 90 Ω)
Replace speed pickup
40
Not illuminated or
flashing randomly
(flickering)
Controller not receiving signal
from input speed pickup
Check the speed pickup adjustment (see
Mechanical Assembly Procedure section of
this document)
Check the wires running from the speed
pickup to the master unit for damage.
These wires must be shielded
Check that the drain wire (clear insulation)
is connected to pin 12 of grey (A) plug on
master unit. This wire must not be
connected to the chassis frame
Remove speed pickup and inspect probe
end for damage
Remove speed pickup from clutch housing
and disconnect from wiring harness. Check
resistance between red and black wires
(pins 1 & 2). Resistance should measure
900 Ω (+/- 90 Ω)
Replace speed pickup
Flashing in rhythm
The controller has seen a loss of the output
speed signal while engaging or running or the
controller has seen no output speed after a
full engagement attempt (and aborted by
clutch overload fault)
Check the speed pickup adjustment (see
Mechanical Assembly Procedure section of
this document)
Check the wires running from the speed
pickup to the master unit for damage.
These wires must be shielded
Check that the drain wire (clear
insulation) is connected to pin 3 of black
(B) plug on master unit. This wire must not
be connected to the chassis frame
Remove speed pickup and inspect probe
end for damage
Remove speed pickup from clutch housing
and disconnect from wiring harness.
Check resistance between red and black
wires (pins 1 & 2). Resistance should
measure 900 Ω (+/- 90 Ω)
Replace speed pickup
10.22.12 I

Illuminated
continuously
Normal when switched power is
coming from ignition switch
Illuminated
continuously
Normal when controller is
connected to a J1939 CAN and
ignition switch is in every
position other than "Off"
10.22.12 I
Pressure Transducer
J1939 CAN
Not
illuminated
Normal if controller is not
connected to a J1939 CAN
Determine if the controller is
connected to a J1939 CAN. If
there are no wires attached
to pins 7 & 8 of the black (B)
plug on the master unit the
controller is not connected to
a J1939 CAN
MAINTENANCE
Not
illuminated
Controller not receiving good
signal from pressure transducer
Inspect wires from pressure transducer to
master unit for damage
With ignition on and engine off, test voltage in
red wire connected to pin 10 of the black (B)
plug on the master unit. Also test the voltage in
the red wire (pin 2) on the pressure transducer.
These voltages should be 12V DC, +/- 1V. If not,
inspect wiring for damage or replace master
unit
With ignition on and engine off, test voltage in
white wire connected to pin 12 of the black (B)
plug on the master unit. This voltage should be
greater than 0.85V DC. If not, inspect wiring
for damage or replace pressure transducer
Verify correct wires are running to transducer
(see schematic at the end of this document)
Replace pressure transducer
Flashing in
rhythm
Controller is connected to but not Controller was connected to a J1939
receiving signal from J1939 CAN CAN and has lost communication or
there was a communication error.
(during this time the controller will
If there are wires connected to use the input speed sensor installed
pins 7 & 8 of the black (B) plug on the HPTO if one is detected)
on the master unit, inspect
them for damage
Turn ignition switch off and
SAE J1939 networks require a restart engine. If J1939 CAN
120Ω terminating resistor be communication is re-established
installed at each end of the light will stay continuously
main J1939 trunk. Verify they illuminated
are installed properly. Contact
machine's OEM for assistance
Inspect wires connected to pins 7
& 8 of the black (B) plug on the
There may be a problem with master unit for damage
the engine's CAN. Contact the
engine manufacturer for service
and troubleshooting SAE J1939 networks require a
120Ω terminating resistor be
installed at each end of the main
J1939 trunk. Verify they are
installed properly. Contact
machine's OEM for assistance
There may be a problem with the
engine's CAN. Contact the engine
manufacturer for service and
troubleshooting
41
MAINTENANCE

Clutch Engagement
Flashes during engagement Flashes after holding start button
Not flashing after holding
and then is illuminated for 3 seconds but clutch does not
start button for 3 seconds
continuously engage after 30 seconds

Normal with a successful Clutch is not engaging
engagement
Check that the voltage stamped on the
side of the coils is 24V and that the
system voltage is 24V DC. If system
voltage is 12V DC, contact PT Tech
During engagement the Power,
Pressure Transducer and Input Speed
lights must be continuously
illuminated. If they are not lit or are
flickering the clutch will not engage.
Refer to those light's troubleshooting
sections for more information
The controller must receive a minimum
of 20V DC from the (+) terminal of the
battery to pin 8 of the grey (A) plug on
the master unit. While cranking the
engine the voltage may be dropping
below 20V
Clutch is not engaging and oil pressure
light is flashing in rhythm
Check that the voltage stamped on the
side of the coils is 24V and that the
system voltage is 24V DC. If system
voltage is 12V DC, contact PT Tech
Check for oil leaks or low fluid level in
the reservoir
Install a flow meter at the inlet port of
the manifold and verify that at least 3.5
GPM (13.2 LPM) is being supplied during
engagment
Refer to 'Oil Pressure' light
troubleshooting section

Oil Pressure
Not Continuously illuminated Illuminated Flashing in
illuminated and Pressure Transducer is continuosly rhythm
not illuminated
There is currently an oil There was a pressure loss while
There is a problem with the pressure fault in the system - the clutch was engaging or
Normal shut engine off immediately
Pressure Transducer engaged.

Refer to Pressure
Transducer
troubleshooting section
Do not run the engine while a pressure fault is
occurring. A pressure fault could starve the
clutch of necessary lubrication oil. Shutdown
the system and locate the cause of the
pressure fault to avoid possible damage to vital
HPTO components.
Check all hoses, filters, coolers, etc. for leaks or damage Push the Engage/Disengage button
for 1 second. If there is still a
Check oil reservoir fluid level pressure fault, the light will
illuminate continuously and stop
1. Install a 0-1000 psi (0-169 bar) pressure gauge into flashing. Refer to "Illuminated
"G1" on the inlet port (1/4" NPT) of the manifold. Continuously" troubleshooting
2. With the engine running and clutch disengaged the
Push the Engage/Disengage button
dial should read at least 230 psi (15.8 bar).
for 1 second. If the light goes out,
3. If this condition is not true, there is a Brake valve there is no longer a pressure fault
problem, a pressure transducer problem or a wiring
problem
Check that the pressure transducer
light is not turned off. If it is off,
1. Install a 0-500 psi (0-24.5 bar) pressure gauge into the refer to "Pressure Transducer"
manifold at the location stamped “G2” (¼” NPT). troubleshooting
2. With the engine running, the clutch disengaged and
the output stopped, the dial on the pressure gauge Check that the Power light is not
should read at least 230 psi (15.8 bar). flashing. If it is flashing, refer to
"Power" troubleshooting
3. If this condition is not true there is a problem with
the Brake valve or shuttle valve in the manifold. The Check that both coils are
pressure in the G2 port should be 225 psi when the connected to the valves
clutch is fully engaged. If this is not true then the
Clutch valve, Brake valve or shuttle valve could be
faulty. It is normal during the process of engaging (with Check all hoses, filters, coolers,
the Clutch Engagement light flashing) for the pressure at etc. for leaks or damage
the G2 port to be low and slowly increase during the
process of engaging. Check oil reservoir fluid level

Check for sources of oil

1. Install a 0-500 psi (0-24.5 bar) pressure gauge into contamination
the manifold at the location stamped “G2” (¼” NPT).
2. With the engine running, the clutch disengaged and
the output stopped, the dial on the pressure gauge
should read at least 230 psi (15.8 bar).
3. Check the controller display to see if the “Pressure
Transducer” light is illuminated. If the pressure gauge
indicates that the pressure is good but the light is off,
then the pressure transducer may be bad or there is a
problem with the wiring.

Check for sources of oil contamination

42 10.22.12 I
 MAINTENANCE

Oil Temperature
Not Illuminated
Illuminated continuously

HPTO oil system temperature has

Normal
exceeded 200F (93° C)

Check the cooler for debris that may

be blocking the flow of air across the
cooler

Check that the drain line on the

bottom of the HPTO housing flows
directly to the reservoir with no
loops or slopes in the drain line that
would prevent oil from gravity
flowing back to the reservoir

Check that the breather on top of

the HPTO housing is clean and
replaced with every oil change

Check the oil reservoir's breather is

clean. Replace if necessary

Check that the capacity of the

cooler meets PT Tech
specifications
Check the continuity across the
pressure switch leads. If the
temperature of the oil is below 200
F (93° C), then there should be
continuity across the leads

Check that there are no cut wires

leading from the controller to the
temperature switch

Contact PT Tech to order a

replacement temperature switch

Filter Clog
Not Illuminated
Illuminated
continuously
Normal
The HPTO oil filter is The HPTO filter was just
clogged replaced and an oil filter
fault is still being indicated

Check the continuity across

Shutdown engine and the filter switch leads. If the
replace spin-on oil filter filter has just been changed
then there should be
continuity across the leads

Check that there are no cut

wires leading from the
controller to the filter switch

Contact PT Tech to order a

replacement filter switch

10.22.12 I 43
MAINTENANCE

Safety Switch
Illuminated
Not Illuminated
continuously

There is a safety switch fault on the machine

Normal preventing the clutch from engaging

Correct the safety hazzard on the machine

Inspect the wire connected to pin 4 of the grey (A)

plug on the master unit for damage

If a safety switch is present, ensure that it is

receiving power, has a good ground and is in good
working order

1. Trace the wire from pins 1 & 4 of the grey (A)

plug on the master unit to the safety switch(es)
on the machine.
2. If no switch is present, connect the two wires
together so the controller is receiving power at
pin 4 when the system is powered on

Never intentionally bypass a safety

switch using this procedure

By default, the safety switch feature only prevents the clutch from
being engaged. It will not disengage the clutch if a switch is
activated. This feature may be enabled using HPTO ProLink

Coil
Illuminated Flashing in
Not Illuminated
continuously rhythm

Normal Problem with Brake coil or its wiring Problem with Clutch coil or its wiring

Check that the wires from pins 7 & 10 of Check that the wires from pins 7 & 9 of the
Refer to ‘Manifold Assembly’ for the grey (A) plug on the master unit are grey (A) plug on the master unit are not
not damaged or connected together damaged or connected together
Brake vs. Clutch Coil location.

Check that the voltage stamped on the side Check that the voltage stamped on the side
of the coils is 24V and that the system of the coils is 24V and that the system
voltage is 24V DC. If system voltage is 12V voltage is 24V DC. If system voltage is 12V
DC, contact PT Tech DC, contact PT Tech

Disconnect the coil from the wiring harness.
Using an Ohmmeter, check the resistance
across the two pins in the Deutsch electrical
connector of the coil.
Coil should be 34 Ω (+/- 1 Ω) when coil is at
68° F (20° C)
Disconnect the coil from the wiring harness.
Using an Ohmmeter, check the resistance
across the two pins in the Deutsch electrical
connector of the coil.
Coil should be 34 Ω (+/- 1 Ω) when coil is at
68° F (20° C)

Check all wires and pins in the Metripak & Check all wires and pins in the Deutsch
Deutsch electrical connectors that are electrical connectors that are attached to
attached to the coil and master unit for the coil and master unit for damage.
damage.

44 10.22.12 I
 MAINTENANCE

RPM
Not Illuminated Illuminated continuously Flashing in rhythm Flashing in
Illuminated continuously while while attempting to while attempting rhythm while
attempting to engage disengage to engage engaged
Normal
The engine The engine speed Engine speed is The engine Input speed Normal if the
Engine speed is speed was signal was lost driven equipment
speed is over is over 1200 rpm below 1200 rpm
below 1050 rpm increased for more than 2 becomes jammed
1050 rpm
Check engine above 1430 seconds during or has caused a
Refer to "Input during clutch clutch shock load in the
Refer to "Input Check engine speed and Speed"
reduce speed engagement engagement system. The HPTO
Speed" speed and troubleshooting
troubleshooting reduce to under 1200 controller will
section attempt to
section speed to rpm Do not attempt to
increase engine 1. Push the disengage if input
under 1050 Engage/Disengage
rpm speed while clutch speed drops below
is in the process of button for 1 500 rpm to
engaging second to clear prevent an engine
the fault stall
1. Push the 2. Push and hold
Engage/Disengage Engage/Disengage
button for 1 button for 3
seconds to engage 1. Push the
second to clear Engage/Disengage
the fault the clutch
button for 1
2. Push and hold second to clear
Engage/Disengage the fault
button for 3 Refer to "Input
Speed" 2. Push and hold
seconds to engage Engage/Disengage
the clutch troubleshooting
section button for 3
seconds to engage
the clutch

Clutch Overload
Not Illuminated Flashing randomly
Illuminated continuously (flickering)
Normal
Controller will not allow Too much difference between input Too much difference between
engagement and output speed while attempting to input and output speed while
engage clutch or while clutch engaged clutch engaged

Wait for clutch overload
light to go out then
reattempt engaging
clutch
Turn off engine and check driven
equipment for jam conditions.
Rotor may be partially jammed and
preventing a complete system
startup
Turn off engine and check driven
equipment for jam conditions. Rotor
may be partially jammed and
preventing a complete system
startup

If the rotor rotates freely, verify that
the “Output Speed” is illuminating
once the output shaft of the clutch
starts turning. If not, refer to
Troubleshooting Section titled,
“Output Speed”.
Refer to input speed and output
speed troubleshooting sections
Refer to input speed and output
speed troubleshooting sections
Check machine driveline components
for damage
Clutch may be worn out. Consider
hours of operation, as clutch may
need service

Check machine driveline components

for damage

Clutch may be worn out. Consider

hours of operation, as clutch may
need service

10.22.12 I 45
MAINTENANCE
Timed Lockout
Not illuminated
Normal
3 failed engagements have
occurred in a row
While the clutch was in the
process of engaging engine
speed goes to zero
Engine speed was increased
during clutch engagement
process
Engage/disengage button
was pushed during clutch
engagement process
46
Illuminated
continuously
Immediate lockout while
Immediate lockout during
engagement engaged
A clutch overload
A clutch overload condition has occurred.
condition has occurred.
Engine will need to run
Engine will need to run for 5 minutes before
for 5 minutes before another engagement can
another engagement can be attempted
be attempted
The controller has
prevented an engine
stall. Engine will need to
run for 5 minutes before
another engagement can
be attempted
10.22.12 I
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01.31
REV DATE INITIALS CHANGES MADE
A - TAC Initial release
B - TAC Production release updates
C - TAC Added AKG cooler to aux. components section
Updated oils, added hydraulic information, updated
D - TAC
customer drawing
Added pump suction line details, consolidated support
E 10/14/11 TAC
bracket details
F 2/24/12 TAC Reformatted
G 4/30/12 TAC Added new manifold
H 5/31/12 CGK Updated gasket kit for FX housing
I 10/22/12 NEY Updated Kits and Maintenance Section
 HEADQUARTERS – USA
1441 Wolf Creek Trail, P.O. Box 305
Sharon Center, OH 44274-0305
U.S.A.
T: 330.239.4933 (ask for HPTO Sales or Service)
F: 330.239.2012
www.pttech.com

16 Atlas Road, Hermitage Industrial Estate

Coalville, Leicestershire, LE67 3FL
UK
T: +44 (0) 1530 832888 when calling from Europe
T: 011 44 1530 832888 when calling from USA

Document subject to change without notice

01.31