PFT-PCV/3000

MAINTENANCE AND REPAIR MANUAL

DIRECT DRIVE
 MAINTENANCE AND REPAIR MANUAL
PFT - PCV / 3000 - DIRECT DRIVE

GENERAL GUIDELINES

• Use the Parts Manual as reference for identification of modules and parts.

• Consult the Torque Chart Table to secure all nuts, screws and general hardware.

• Always think “safety”. Use goggles, gloves (to handle sharp, hot or pointed components),
proper lifting devices and equipment. Always be alert for your safety and for the safety
of others around you.

• Drain oil from transfer case before proceeding with repair work. The coloration, smell,
and contaminants found within the oil may help you determine the type and focus of
the repair work.

• All disassembled components must be thoroughly cleaned with compatible cleaners

prior to reassembling.

• Remove oil seals before proceeding with the registration of bearings.

• All O’rings and oil seals must be lubricated with grease type “A” prior installation and the
drive flanges / splines with graphite grease type “B”. Grease disconnect needle bearing
with grease type “C” (consult grease table).

• Never re-use locking nuts and always evaluate the condition of lock washers and split
pins prior to reassembly.

• This Manual provides disassembling and reassembling instructions for the complete
transfer case. In some cases, the operator performing the work may select an
alternative course based on the specific task on hand.

• While performing a specific maintenance or repair work, always inspect components

as: seals, bearings, gears, shafts, rotating swivel, etc. in order to combine any other
potential work.

• If major repair is necessary, we recommend to remove the transfer case from the
vehicle. If a different approach is followed, please use caution and establish all safety
measures before proceeding.

• When reinstalling a transfer case in a vehicle, follow the OEM installation procedures
and guidelines and remember to replenish the transfer case with lubricating fluid prior
to restart. Follow the serial number plate information for type and amount of fluid.

• If for a remote sequence of events this Manual could not provide you with the answer you
need, please call our Service Department at 330-405-7353 or E-mail us at [email protected].
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PFT - PCV / 3000 - DIRECT DRIVE

TORQUE TABLE
Size Type Torque specifications
M6 8.8 7.5 Ft/lbs 10 Nm
M8 8.8 18.5 Ft/lbs 25 Nm
M10 8.8 37 Ft/lbs 50 Nm
M10 12.9 62.5 Ft/lbs 85 Nm
Always check the nomenclature at the
screw head for reference to torque
values.

GREASE TABLE
Manufacturer Dropp. Penetration Grad.
Type Description
Reference Point ASTM (dmm) NLGI

Multipurpose lithium base

“A” grease brown colored with Agip GR MU 190°C 280 2
medium fiber

Multipurpose lithium base

Mobilgrease 180°C 275 - 305 2
“B” grease with bi-sulfur of
Special
molybdenum.

Longlife EP bearing Bechem-Rhus

“C” 190°C 270 3
grease L 474-3

TABLE 5A
 MAINTENANCE AND REPAIR MANUAL 21
PFT - PCV / 3000 - DIRECT DRIVE

TABLE 1

TABLE 1B
 MAINTENANCE AND REPAIR MANUAL 22
PFT - PCV / 3000 - DIRECT DRIVE

TABLE 2

TABLE 3
Print
All rights reserved.
© Copyright

OMSI Trasmissioni S.p.A OMSI Transmissions, Inc.

Via S.Pietro, 60 9329-J Ravenna Road
Roè Volciano (BS) - Italia Twinsburg, Ohio 44087
Tel: 011-39-0365-556182 U.S.A
Fax: 011-39-0365-63743 Tel: 330-405-7350
E-mail: [email protected] Fax: 330-405-7351
Web site: www.omsitrasmissioni.com E-mail: [email protected]

This manual could be reproduced or copied in full or

partially only with the approval and formal authorization
of OMSI Transmissions, Inc.
Any reproduction, distribution or storage in memory of
electronic media that carries information of any type will
constitute a violation of the rights of the author, and
therefore it will be persecuted to the full extent of the law.

Printed: July 10, 2001. Revision 00

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OPERATION AND MAINTENANCE MANUAL

Model: PFT-PCV/3000

Disconnect Drive

OMSI GAPVAX DRIVE

PART NUMBERS PART NUMBERS RATIO

10810021-05 TRA022324 1 : 1.1

10810074 TRA022307 1 : 1.47

10810074-01 DRI022318 1 : 1.47

OMSI Transmissions, Inc. 9319-A Ravenna Road • Twinsburg, Ohio 44087 U.S.A.
Telephone: 330-405-7350 • Fax: 330-405-7351 • E-mail: [email protected]
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Operation and Maintenance Manual

INDEX
1.0 APPLICATION
2.0 DESCRIPTION
2.1 General description
2.2 Auxiliary hydraulic drive output
2.3 Unit weight
2.4 Identification plate

3.0 TECHNICAL SPECIFICATIONS

3.1 Main drive
3.2 Power take-off outputs
4.0 SHIPPING, HANDLING AND STORAGE
4.1 Shipping and packing
4.2 Packing
4.3 Handling
4.4 Storage

5.0 INSTALLATION
5.1 Drive system design
5.2 Pneumatic control system
5.3 Remote oil reservoir / level indicator
6.0 INITIAL OPERATION
6.1 Oil specifications
6.2 Oil capacity
6.3 Initial oil fill
6.4 Initial start-up
7.0 MAINTENANCE AND INSPECTION
7.1 Oil level inspection
7.2 Oil change
7.3 Maintenance intervals
8.0 TROUBLESHOOTING CHECKLIST

9.0 WARRANTY

10.0 SERVICE
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1.0 APPLICATION
1.1 The PFT-PCV/3000 Transfer Case is used in sewer cleaning combination machines and
vacuum loaders.

2.0 DESCRIPTION
2.1 GENERAL DESCRIPTION
2.1.1 The PFT-PCV/3000 Transfer Case is used to effectively divert the power of the engine to
either the truck’s road mode or the machine’s auxiliary drive systems. The PFT-PCV/3000
series units does not have a provision to operate the machine’s auxiliary drive systems
while in road mode, so the operator would have to choose the engagement control to
either of the systems. Both systems can never be engaged simultaneously.
2.1.2 This Transfer Case is part of a family of modularly designed options that can be selected
to assemble the specific group for your particular drive system application.

2.2 AUXILIARY HYDRAULIC DRIVE OUTPUT

2.2.1 The PFT-PCV/3000 Transfer Case incorporates an intermediate drive output for the
installation of various types of hydraulic pumps for the auxiliary systems of the machine.

2.3 UNIT WEIGHT

2.3.1 The nominal weight of the transfer case is 525 lbs (without oil).

2.4 IDENTIFICATION PLATE

2.4.1 The ID plate is located at the rear−lower of the Transfer Case.

OMSI TRANSMISSIONS, INC.

TYPE PFT-PCV/3000
PART NO. 10810000
SERIAL NO. 0010 0006
RATIO 1:1 OIL 11 QTS.

3.0 TECHNICAL SPECIFICATIONS

3.1 MAIN DRIVE

3.1.1 The main drive shall be engaged and disengaged with the vehicle on a stationary
position. It is controlled by a pneumatic double-acting shifter that allows the power
diversion from the truck transmission into the rear axle drive or PTO outputs.
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Operation and Maintenance Manual

3.1.2 The shifter incorporates a by-pass mechanism that can be used in case of loss of air
pressure or pneumatic system failure.
3.1.3 The double-acting shifter provides a safety system that maintains its position under load
even in the event of pressure loss in the system. It also incorporates an optional switch
that provides a signal when the shifter function is fully actuated.

3.2 TRANSFER CASE OUTPUTS

3.2.1 The Transfer Case outputs are automatically connected when the main drive to the
rear axle is disengaged.

4.0 SHIPPING, HANDLING AND STORAGE

4.1 SHIPPING
4.1.1 The Transfer Case is shipped without oil. Follow the instructions from the identification
plate with regards to the amount and type of oil to be used.
4.1.2 The Transfer Case is painted with a red or black anti-rust primer base. Upon special
requirements, the units may be painted to customer specifications.
4.1.3 The exposed machined components, as flanges and shafts are covered with an anti-
corrosion lubricant. These parts will be protected for regular ambient dry conditions for
approximately 2 months.
4.1.4 The internal components of the transfer case is also covered with an anti corrosion
lubricant which it will provide protection up to start up if maintained in a dry
environment.
4.2 PACKING
4.2.1 The Transfer Case is shipped packed in boxed pallets. It is secured to the pallets by
heavy duty strapping and covered by a plastic enclosure that protects the assembly
during transport.
4.2.2 During the unpacking process, be extremely careful and use caution with the use of
various cutters, levers and other sharp or pointed tools.

4.3 HANDLING
4.3.1 Trained personnel must perform the movement and handling of the units. Always use
adequate equipment for lifting and moving of the components with relation to the
weight (see point 2.4) and packing method.
4.3.2 The packages of the Transfer Case shall never be tilted or turned around during
transport and handling.
4.3.3 Upon receiving, inspect the packages for damages and check the units against the
shipping documents.
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Operation and Maintenance Manual

4.3.4 The handling of the units for final installation must be done with the proper lifting
equipment, as lifting eye provided with the unit, chains and cranes. WARNING: use only
lifting eye with M18x1.5 thread. The handling of the units must be smooth and safe.

4.4 STORAGE
4.4.1 Whenever the Transfer Case is required to be in stock for a period over two months, the
external components as drive flanges, pump flanges, shafts, adapters, machined
mounting surfaces, must be covered with an oil base protection lubricant.
NOTE: Store Transfer Case in a dry environment at a constant temperature whenever
possible.
4.4.2 The internal components of the Transfer Case are designed to minimize corrosion build
up. In addition, all components are greased and lubricated at assembly. Although,
when the Transfer Case is stored for a period of over twelve months, the oil seals, clutch
operation and rotating components must be checked carefully before use.

5.0 INSTALLATION

5.1 DRIVE SYSTEM DESIGN

5.1.1 The Transfer Case must be positioned within the vehicle’s chassis to conform with
proper drive train design.
5.1.2 To maximize the lubrication of the internal components, we recommend that the
Transfer Case is installed straight in an upright position. Avoid lateral inclination when
possible. If your application requires that the unit be positioned at a lateral incline,
please consult our Engineering Department.
5.1.3 The inclination of the Transfer Case front-to-rear must be designed to suit drive line
operating angles. Do not exceed 5° rear incline.

5.2 PNEUMATIC CONTROL SYSTEM

5.2.1 In order to optimize the pneumatic control system and extend the life of its
components, we recommend the installation of an air drier and oil lubricator in the air
supply system.

5.3 REMOTE OIL RESERVOIR / LEVEL INDICATOR

5.3.1 We highly recommend the installation of the optional remote oil reservoir / level
indicator to facilitate oil level inspection and re-filling when required.
5.3.2 The oil reservoir / level indicator can be mounted at the outside of the chassis rails. The
operator has the full view of the oil level in the Transfer Case through the large sight eye
of the remote reservoir.
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Operation and Maintenance Manual

6.0 INITIAL OPERATION

6.1 OIL SPECIFICATION

6.1.1 The oil type must be: ATF (Automatic Transmission Fluid) DEXRON III.

6.2 OIL CAPACITY

6.2.1 The approximate capacity of oil is ~ 11 quarts.
6.3 INITIAL OIL FILL
6.3.1 The Transfer Case is shipped without oil. Before the unit is placed in operation, fill to the
proper level with the recommended type of oil. The oil used must be perfectly clean
and free contamination.
6.3.2 Mixing oils and/or using other types of oils will drastically affect the operation and
performance of the unit and it will void the warranty.
6.3.3 The initial oil fill must be performed as follows: A) Pour approximately 1/2 quart of oil in
the disconnect housing. The oil will seek its own level and any additional oil will be
automatically drained into the main housing of the Transfer Case. B) Fill the Transfer
Case housing until the proper amount of oil is shown at the oil level sight eye.

6.4 INITIAL START-UP

6.4.1 Engage the Transfer Case and run for ~ 5 minutes at idle speed.
6.4.2 Shut off engine, allow the oil to set after covering all internal surfaces, and inspect level
through the sight eye.
6.4.3 Add more oil as necessary in order to fill the entire plumbing of the lubrication system.
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PFT-PCV-3000 Disconnect Drive

Operation and Maintenance Manual

7.0 MAINTENANCE AND INSPECTION

IMPORTANT: Before performing any maintenance and inspection of the Transfer

Case and drive system components, you must shut off the vehicle,
remove the keys from ignition and secure them, engage parking brake
and chuck wheels, and be sure that ground and surrounding areas are
clear, ready and safe.

7.1 OIL LEVEL INSPECTION

7.1.1 The oil level can be visually checked through the sight glass located at the rear-lower
portion of the Transfer Case housing or through the sight glass of the optional remote oil
reservoir / level indicator mounted at the outside of the chassis rails.
7.1.2 The oil level must be inspected weekly and/or before and after a long travel / severe
work condition.
7.1.3 The inspection must be done with the truck shut off and on level ground. For best
results, the oil must be cold when inspecting its level.
7.1.4 If the oil level is below the center point of the sight glass, re-fill immediately to correct
level.

7.2 OIL CHANGE

7.2.1 When replacing the oil, be sure to drain the old oil completely.
7.2.2 Use only the recommended type of oil. Mixing oils will drastically affect the lubrication
and life of components.
7.2.3 The oil must be replaced after the first 100 hours of operation.
7.2.4 Oil changes must be done when the oil is still hot. The oil can be drained by removing
the drain plug. To accelerate the draining process, it is recommended to also remove
the fill plug.
Always clean the magnetic drain plug before reinstalling it.
7.2.5 Subsequent oil changes are recommended at intervals of 500 hours and/or 12 months,
whichever comes first.
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PFT-PCV-3000 Disconnect Drive

Operation and Maintenance Manual

8.5 MAINTENANCE INTERVALS

PERIOD OPERATION
Inspect air system for leaks. Be sure that there is at least 110 PSI to
operate shifter controls.
DAILY
During the first week of operation, the oil level and filter indicator must
be checked on a daily basis.
Inspect oil level.
MONTHLY Check PTO surrounding areas for interference and clearance of
structure and plumbing.
Inspect all mounting hardware and re-torque as necessary to proper
specifications.
BI-YEARLY Inspect oil seals and check for any sign of oil throughout the body of
the PTO.
Inspect entire Transfer Case housing and seals for leaks.

Change oil (every 12 months or 500 hours of operation, whichever

YEARLY comes first).
Inspect entire Transfer Case housing and seals for leaks.
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PFT-PCV-3000 Disconnect Drive

Operation and Maintenance Manual

9.0 TROUBLESHOOTING CHECKLIST

This troubleshooting checklist was design for quick reference of potential subjects
affecting the operation of the Transfer Case.
If your actual condition cannot be found on the following list, please contact our
Service Department immediately.

Condition Probable Cause Remedy

Leakage at seals, drain Inspect Transfer Case and
Excessive use of oil.
plug. repair as required.
Inspect the angularity of drive
shafts and re-position drive
Excessive drive shaft angles.
Severe vibration and components to allow correct
loud noise coming drive line specifications.
out of drive shafts.
Re-install drive shafts with
Drive shafts out of face.
proper joint facing.
Check air system and be sure
Main drive does not Insufficient air pressure at
to provide at least 110 PSI to
engage / disengage. shifter.
the shifter ports.
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Operation and Maintenance Manual

10.0 WARRANTY

OMSI Transmissions, Inc., hereinafter called OTI, warrants its products from defects and
faulty workmanship for a period of 12 (twelve) months from the date of acceptance by the
purchaser. Date of acceptance shall be defined as the time that the products are
received by the purchaser. Acceptance of the products shall imply agreement to the
terms and conditions of this warranty.

In order for the warranty to take effect, it shall be evident and proven to OTI that its
products were subject to normal use and adequate maintenance. OTI reserves the right to
request the unit/s and/or component/s to be returned, freight pre-paid, for analysis before
proceeding with any Warranty Claim. The purchaser shall be responsible for payment of the
replaced components until the evaluation and analysis are completed by OTI and it is
determined that warranty applies.

This warranty will not cover failures caused by operating the product in excess of its
design and specifications, abuse, insufficient and/or lack of maintenance, alterations and
modifications to the product as supplied by OTI.

Any components replaced during the period of the warranty will be warranted only
during the period of the initial warranty, and no extensions shall be made, unless in writing by
OTI in addition to the provision of the terms of the original warranty.

This warranty does not provide allowances for freight, travel time and labor. OTI’s
liability under this warranty is limited to the repair and/or replacement, at its discretion, of its
products. OTI shall not be held liable for losses, damages, and other charges incurred by the
user as a result of product failure. Any components replaced by OTI will be shipped F.O.B.
Twinsburg, Ohio.

OTI reserves the right to make design changes and modifications to its products
specifications without inferring that previous designs and specifications were not fit for the
applications intended for at the time. OTI shall not be obligated to perform retrofits and/or
modifications to products manufactured prior to the incorporation of the new design and
specifications.

This shall be the only warranty in effect, and no one shall be authorized to supersede
or modify the terms and provisions within, except in writing by OTI. There are no other
warranties applicable, expressed or implied, including warranties of fitness or
merchantability for a particular purpose or use.

OMSI Transmissions, Inc.

9319-A Ravenna Road
Twinsburg, Ohio 44087 U.S.A.
Effective: March 3, 2000
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11.0 SERVICE

We at OMSI Transmissions, Inc. are committed to service and customer support. You’ll have
our assurance that in the event of a problem situation, you will be able to count on our
intervention to help determine the reason while providing with the necessary and prompt
means to correct the condition and get you and / or your customer back in business.
We strongly believe that our quality products have to be matched with a quality
service support.

O M S I T R A N S M I S S I O N S, I N C.
We can put your transmission project in high gear . . .
SM
. . . and we’ll do our best to keep you running.