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Chelsea PTO Troubleshooting

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The Chelsea P.T.O. is designed and built to meet the rugged demands of the Mobile Equipment Industry. Continue reading for information on diagnostics for your PTO troubleshooting needs. If you need additional assistance give us a call at 877-776-4600 or 407-872-1901, to speak with a Chelsea PTO expert.

You can view this PTO troubleshooting information in PDF format by clicking here.

You can also view our selection of Chelsea PTO parts manuals by visiting our manuals page.

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Chelsea P.T.O.s are designed and built to match a vehicle’s transmission. The gears of a P.T.O. are of the same quality as the transmission’s gears. Successful operation depends on proper specification and installation. Always consult your Chelsea Applications Guide and Installation Manual when working with Chelsea P.T.O.s. Doing this will prevent serious P.T.O. problems.

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WARNING!

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PTO Troubleshooting On The Vehicle:

Performance

The first place to look when troubleshooting a P.T.O. failure is in the application itself.
Repeated or premature failure may be a sign of an incorrect application.
This can be discovered by using
HY25-3000/US Applications Catalog.

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If the P.T.O. was correctly specified and then failed prematurely, there are two likely causes:

Improper installation and/or operator misuse.
An improperly installed P.T.O. can normally be identified immediately by the sound (Noise) it makes.
• It will “Whine” ,“Clatter”, “Click” or “Grind”
• Sometimes, the vehicle itself may contribute enough noise to mask the sound of the P.T.O. and one may not notice the problem

If a problem is allowed to continue, damage to the P.T.O. will result.

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Noise Types:

Set gear backlash min. to .006 – .012.

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Whine – Too tight
Clatter – Too loose

Clicking or Grinding

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Leaks – Root Cause of the Leakage

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Stud Threads

Improper Torque of Fasteners
Improper Stud Installation
Gasket Installation

Seals

Transmission Preparation
Worn Seals

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PTO Troubleshooting On The Workbench:

Performance – Symptoms & Causes

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P.T.O. Operation – Hydraulic System

Erratic Operation
Hard Shifting
Jumping out of Gear

Items to be Examined on the Work Bench

Housing
Gears
Shafts
Bearings
Shifters
Clutches

Housing Damage

[/fusion_text][fusion_separator style_type=”single solid” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” sep_color=”#e10707″ top_margin=”” bottom_margin=”20″ border_size=”” icon=”” icon_circle=”” icon_circle_color=”” width=”25%” alignment=”left” /][/fusion_builder_column][/fusion_builder_row][/fusion_builder_container][fusion_builder_container hundred_percent=”no” hundred_percent_height=”no” hundred_percent_height_scroll=”no” hundred_percent_height_center_content=”yes” equal_height_columns=”no” menu_anchor=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”center center” background_repeat=”no-repeat” fade=”no” background_parallax=”none” enable_mobile=”no” parallax_speed=”0.3″ video_mp4=”” video_webm=”” video_ogv=”” video_url=”” video_aspect_ratio=”16:9″ video_loop=”yes” video_mute=”yes” video_preview_image=”” border_size=”” border_color=”” border_style=”solid” margin_top=”” margin_bottom=”” padding_top=”” padding_right=”15″ padding_bottom=”” padding_left=”15″ admin_toggled=”no”][fusion_builder_row][fusion_builder_column type=”1_2″ layout=”1_2″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” dimension_margin=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_text columns=”” column_min_width=”” column_spacing=”” rule_style=”default” rule_size=”” rule_color=”” class=”” id=””]

One of the most serious problems a P.T.O. can suffer is a cracked case. This condition can lead to oil loss and eventual transmission failure.
Some causes are:

Improper Installation
Poorly Torqued Bolts
Unsupported Direct Mount Pump
Foreign Objects Meshing Between the Gear Teeth
Severe Shock Load
Hitting Obstacles in the Road
Damaged Threads

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Gear Damage

PTO gear damage generally takes place in the tooth or spline. The first parts to inspect should be the gears. Check the surface of the gear teeth for signs of pitting. Once pitting of the gear surfaces has begun, there is nothing that can stop it. Another possible problem during vehicle operation is “shock load”. Deep Mesh Pattern Caused by Improper Backlash Adjustment. Worn PTO gears can easily be affected by “shock load”. If you neglect to replace gears that are worn, they can eventually lead to broken gear teeth. Sometimes a gear will chip a tooth because of mishandling or improper shifting. Undershifting allows incomplete gear tooth contact with the driver gear. This means only part of the tooth width is transmitting the torque and R.P.M. during P.T.O. operation.

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Check the surface of the gear teeth for signs of pitting.

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PTO “shock-load” gear damage

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”1_5″ layout=”1_5″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” dimension_margin=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_imageframe image_id=”1430″ max_width=”” style_type=”none” stylecolor=”” hover_type=”liftup” bordersize=”” bordercolor=”” borderradius=”” align=”center” lightbox=”yes” gallery_id=”” lightbox_image=”https://www.chelseaptopart.com/wp-content/uploads/2018/07/broken-gear-teeth.png” alt=”broken PTO gear teeth” link=”” linktarget=”_self” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]https://www.chelseaptopart.com/wp-content/uploads/2018/07/broken-gear-teeth-300×222.png[/fusion_imageframe][fusion_text columns=”” column_min_width=”” column_spacing=”” rule_style=”default” rule_size=”” rule_color=”” class=”” id=””]

Broken gear teeth

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”1_5″ layout=”1_5″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” dimension_margin=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_imageframe image_id=”1431″ max_width=”” style_type=”none” stylecolor=”” hover_type=”liftup” bordersize=”” bordercolor=”” borderradius=”” align=”center” lightbox=”yes” gallery_id=”” lightbox_image=”https://www.chelseaptopart.com/wp-content/uploads/2018/07/chipped-PTO-gear-tooth.png” alt=”chipped PTO gear tooth” link=”” linktarget=”_self” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]https://www.chelseaptopart.com/wp-content/uploads/2018/07/chipped-PTO-gear-tooth-300×222.png[/fusion_imageframe][fusion_text columns=”” column_min_width=”” column_spacing=”” rule_style=”default” rule_size=”” rule_color=”” class=”” id=””]

Chipped gear teeth

[/fusion_text][/fusion_builder_column][fusion_builder_column type=”1_5″ layout=”1_5″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” dimension_margin=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_imageframe image_id=”1432″ max_width=”” style_type=”none” stylecolor=”” hover_type=”liftup” bordersize=”” bordercolor=”” borderradius=”” align=”center” lightbox=”yes” gallery_id=”” lightbox_image=”https://www.chelseaptopart.com/wp-content/uploads/2018/07/incomplete-gear-tooth-contact.png” alt=”Incomplete PTO gear tooth contact” link=”” linktarget=”_self” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]https://www.chelseaptopart.com/wp-content/uploads/2018/07/incomplete-gear-tooth-contact-300×222.png[/fusion_imageframe][fusion_text columns=”” column_min_width=”” column_spacing=”” rule_style=”default” rule_size=”” rule_color=”” class=”” id=””]

Incomplete gear tooth contact

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Shaft Damage

[/fusion_text][fusion_separator style_type=”single solid” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” sep_color=”#e10707″ top_margin=”” bottom_margin=”20″ border_size=”” icon=”” icon_circle=”” icon_circle_color=”” width=”25%” alignment=”left” /][/fusion_builder_column][fusion_builder_column type=”1_2″ layout=”1_2″ spacing=”” center_content=”no” link=”” target=”_self” min_height=”” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” background_color=”” background_image=”” background_position=”left top” background_repeat=”no-repeat” hover_type=”none” border_size=”0″ border_color=”” border_style=”solid” border_position=”all” padding_top=”” padding_right=”” padding_bottom=”” padding_left=”” dimension_margin=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=”” last=”no”][fusion_imageframe image_id=”1439″ max_width=”” style_type=”bottomshadow” stylecolor=”” hover_type=”liftup” bordersize=”” bordercolor=”” borderradius=”” align=”none” lightbox=”no” gallery_id=”” lightbox_image=”” alt=”PTO torsional overload” link=”” linktarget=”_self” hide_on_mobile=”small-visibility,medium-visibility,large-visibility” class=”” id=”” animation_type=”” animation_direction=”left” animation_speed=”0.3″ animation_offset=””]https://www.chelseaptopart.com/wp-content/uploads/2018/07/PTO-torsional-overload.png[/fusion_imageframe][fusion_text columns=”” column_min_width=”” column_spacing=”” rule_style=”default” rule_size=”” rule_color=”” class=”” id=””]

P.T.O. shafts are also vulnerable to operating abuse, torsional overload, bending fatigue failure.

When inspecting a P.T.O. output shaft, always inspect the keyway.

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PTO shaft damage can occur misapplication overloads and shock loads.

Fretting corrosion is another type of damage your PTO shafts can experience. It appears as a rusting and wearing of the pump shaft splines. Fretting corrosion is caused by many factors and without proper maintenance, the anti-fretting grease can only reduce, but not eliminate, its effect on components.

Shifting Problems

If you experience that your P.T.O. is hard to shift, remember, a lever-operated shift linkage should not be connected to a wire shift cover. The mechanical advantage of the lever is often too great for the wire shift cover and could severely damage it. Also inversely, don’t use a cable with a lever shift cover. The cable isn’t capable of transmitting the force necessary to shift a lever mechanism.

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Most shifting complaints are caused by improper shifting procedure or incorrect linkage installation.

Shifting problems can also be caused by a worn or elongated shifter poppet hole.

Seals and O-Rings may cause special problems in P.T.O. operations.

Remember, when troubleshooting any clutch-operated P.T.O., carefully inspect all components for wear or damage. Burnt clutch plates, welded clutch pack, or a burnt driving hub are three easily identifiable conditions that lend themselves to failure analysis.

A sure sign of potential trouble with a clutch operated P.T.O. is erratic operation.

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The 3 most common complaints:

Noise

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Listen carefully for a whine or high pitched sound. This could indicate issues with the gears being too tight, bearings or hydraulics. A rattle could indicate issues with the gears too loose or torsional vibrations.

Engagement Problems

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Powershift PTO engagement problems could be from blocked hoses or fittings, bad connections or ground or the solenoid. Mechanical PTO engagement problems could originate from low air pressure, improper cable installation or back lash too tight.

Disengagement Problems

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Experiencing disengagement problems with powershift PTOs could indicate issues with blocked hoses or fittings, frozen clutch pack or the solenoid.

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Prevention

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Prevention is the best cure for P.T.O. case damage. Always torque the P.T.O. flange bolts in sequence and the proper specifications
Also, be sure to check the weight of the direct mount pump and, if it is over forty pounds, make a support bracket for it.

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Chelsea strongly recommends the use of pump supports (Support Brackets) in all applications. Also remember to pack the female pilot of the PTO pump shaft with grease before installing the pump on the PTO.

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Chelsea PTOs are designed and built to match a vehicle’s transmission, the gears of a PTO are of the same quality as the transmission’s gears. Successful operation depends on proper specification and installation.

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Chelsea PTO Troubleshooting

PTO Troubleshooting On The Vehicle:

Performance

Noise Types:

Leaks – Root Cause of the Leakage

PTO Troubleshooting On The Workbench:

Performance – Symptoms & Causes

Housing Damage

Gear Damage

Shaft Damage

Shifting Problems

The 3 most common complaints:

Noise

Engagement Problems

Disengagement Problems

Prevention

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