matev 131 7122, 131 7144 Original Operating Manual
matev 131 7122 is an independent live power take off (PTO) designed for John Deere 4020 series tractors. It allows you to extend the tractor's crankshaft to the front and power implements like sweepers and front mowers. This PTO features a robust gearbox, a universal joint shaft and a safety chain for secure operation.
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matev GmbH Nürnberger Str. 50 90579 Langenzenn T +49 (0) 9101 9087 -0 F +49 (0) 9101 9087 -20 [email protected] www.matev.eu Original Operating Manual Independent live power take off FPS-PTO JD 4020 for John Deere series 4020 2000 U/min CCW 2000 U/min CW Version 04/2011 Table of contents Table of contents 1. About this operating manual ................................................................................... 3 2. 2.1. 2.2. 2.3. 2.4. 2.5. Safety ........................................................................................................................ 4 Intended use............................................................................................................... 4 Qualification of personnel ........................................................................................... 4 General safety instructions ......................................................................................... 4 Special safety instructions .......................................................................................... 5 Supplemental provisions............................................................................................. 5 3. 3.1. 3.2. 3.3. Installation ................................................................................................................ 6 Preparatory measures ................................................................................................ 6 Mounting the independent live PTO ............................................................................ 8 Installation is complete ............................................................................................. 16 4. 4.1. 4.2. 4.3. 4.4. 4.5. Operation ................................................................................................................ 17 Coupling and uncoupling implements ....................................................................... 17 Mounting the universal joint shaft ............................................................................. 18 Dismounting the universal joint shaft ........................................................................ 18 Switching the independent live PTO on and off ........................................................ 19 Run-up time of the front PTO shaft system ............................................................... 19 5. 5.1. 5.2. 5.3. Maintenance............................................................................................................ 20 Service ..................................................................................................................... 20 Changing the gear oil ............................................................................................... 20 Repair....................................................................................................................... 21 6. Disposal .................................................................................................................. 21 7. Warranty...................................................................Fehler! Textmarke nicht definiert. 8. List of illustrations ................................................................................................. 22 9. EC Declaration of Conformity ................................................................................ 23 About this operating manual 1. About this operating manual Dear customer! Thank you for purchasing this device, we appreciate your trust. Prior to using this device for the first time read this operating manual carefully and conscientiously all the way through. Keep this operating manual where it is easily accessible. This will enable you to refer to important information and handling instructions as needed. Listings with bullet points are marked as follows: Text Text Text Handling instructions are marked in the sequence in which they should be executed, as follows: 1.1.1. Text 1.1.2. Text 1.1.3. Text . . . This device is subject to change in the interest of technical progress. All information, illustrations, and technical specifications represent the latest status at the time this manual was published. The manufacturer reserves the right to make changes at any time in the interest of technical progress. Page 3 Safety 2. Safety Guidelines and instructions with which you must comply are summarized in this section. Personnel who install, operate and maintain the device, must have read and understood this operating manual. 2.1. Intended use The independent live PTO extends the crankshaft of the tractor to the front. It is used to power sweepers, front mowers, or similar implements that are driven with PTO shafts. This independent live PTO should only be mounted on tractors as specified on the cover sheet. Non-intended use causes: Health hazards for the operator or for third parties Damage to the tractor and the attachments Environmental damage 2.2. Qualification of personnel Only personnel 18 years of age or older, or instructed personnel should install, operate, and maintain the implements. The operator must have read and understood this operating manual. 2.3. General safety instructions General safety instructions are explained in this section. These safety instructions are used in the subsequent sections. In addition to the safety aspect, you will save money and work time if you follow these safety instructions. Danger! Severe injury to the operator or third parties occurs. Follow the safety instruction. Attention! Minor injury to the operator or third parties can occur. The tractor or the environment can be damaged. Comply with the safety instruction. Note! Important, helpful tips or information for the operator. Read this note. It facilitates your work. Attention! Injuries can occur. Wear protective work clothing. Page 4 Safety 2.4. Special safety instructions Safety instructions are specified in this chapter that are also affixed as stickers on the implements Attention! Danger of injury due to moving parts. Remove the ignition key before performing maintenance tasks on the implement. Attention! Injuries can occur due to improper operation. The implement can be damaged. Read the operating manual all the way through. Comply with the safety instructions. Attention! Injuries due to fluid escaping under high pressure. Comply with the instructions in the operating manual. Attention! There is an increased risk of accident due to the rotating PTO shaft. Do not enter the work area of the PTO shaft when it is rotating. For your own safety do not wear any loose clothing, belts, or any other loose items. Switch off the implement. Wait until all machine parts have come to a standstill before converting or servicing the implement. Attention! Check all threaded unions prior to using the implement and after using the implement. Loosened connections must be retightened. Damage can occur due to loose connections. 2.5. Supplemental provisions Ensure that the speed and the direction of rotation of the independent live PTO are suitable for driving the implement before coupling to an implement. Always switch off the front PTO shaft and wait until the PTO shaft is no longer turning when you leave the tractor or work on the connected implement. Do not attempt to find a possible leak in the hydraulic system with your fingers. Oil under high pressure can easily penetrate skin and clothing and cause serious injury. Page 5 Installation 3. Installation Danger! Severe injury to the operator or third parties occurs. Switch off the tractor and remove the ignition key before mounting or dismounting the independent live PTO. 3.1. Preparatory measures The prerequisite for using the independent live PTO is that the tractor must already be equipped with the matev front power system 131 7142. 3.1.1. Drive the tractor onto the lift platform. Remove the battery. Remove the mounting bolts of the front floor panel, including the mounting bolts of the radiator on the floor panel. Keep these threaded unions available in a safe place for later use. Remove the condenser of the air conditioning system. Use coolant R 134 A; fill quantity 1.27 kg. Attention! Injuries can occur due to improper operation. The device and the environment can be damaged. If necessary commission an authorized company to empty and fill the condenser of the air-conditioning system. 3.1.2. Drain oil and coolant from the radiators and keep it on hand for later use. Remove the radiators. Fig. 1 Radiators removed Page 6 Installation 3.1.3. Remove the locking hooks of the engine hood, and shorten the locking hooks as shown in the Fig. below. Shorten here Fig. 2 Locking hook Attention! Injuries can occur. Wear protective work clothing. 3.1.4. Make a cutout in the front holding plate of the battery as shown in the diagram below. Fig. 3 Cutout in the holding plate Page 7 Installation 3.1.5. Make a cutout in the floor panel of the tractor as shown in the diagram below. 75 60 Fig. 4 Floor panel with cutout 3.2. Mounting the independent live PTO 3.2.1. Mount the opening handle included in the scope of delivery of this independent live PTO, the locking hook, and the torsion spring on the holding plate. The hole for the heavy-type dowel pin in the locking rod must be bored on site. Position the holding plate in the original position on the tractor and make the cutout for the handle as shown in the Fig. below. Drill Cutout approx. 15x40 Fig. 5 Cutout for the handle of the engine hood locking mechanism 3.2.2. Remove the pulley of the tractor. The original mounting bolts of the pulley will no longer be required. Replace the O-ring Ø38x2 and fasten the pulley included in the scope of delivery of this independent live PTO on the crankshaft of the tractor. To do this use the included clamp ring, the bushing, and the M12 Allen bolt. Use a torque wrench. The tightening torque is 147 Nm. Page 8 Installation O-ring Ø38x2 Pulley Clamp ring Bolt M 12x110, 12.9 Clamping bushing Fig. 6 Mounting parts of the pulley Conical side to the inside Centering collar to the outside Fig. 7 Clamp ring and clamping bushing 3.2.3. Fasten the universal joint shaft to the pulley with the aid of a torque wrench. The tightening torque is 42 Nm. Pulley Bolts M8x16, 12.9 Universal joint shaft Fig. 8 Mounting the universal joint shaft to the pulley Page 9 Installation 3.2.4. Drain the oil from the gearbox and mount the hydraulic hoses on the gearbox. Gearbox Fig. 9 Hydraulic connections on the gearbox 3.2.5. Mount the gearbox on the matev front lift 131 7142. The tightening torque is 50 Nm. Establish the electrical connection. Ensure that the hydraulic connection and the electrical connection are not damaged. Fig. 10 Gearbox on the front power lift 3.2.6. Mount the universal joint shaft on the gearbox using a torque wrench. The tightening torque is 42 Nm. Page 10 Installation Gearbox Bolts M8x16, 12.9 Fig. 11 Universal joint shaft 3.2.7. 3.2.8. Mount the dismounted radiator and tighten all threaded unions of the mounting bolts and the connections. Fill the radiator. Bore four sink holes for M6 countersunk bolts in the holding plate of the charge-air cooler and mount the small oil cooler of the gearbox. Connect the hydraulic lines. In this process ensure that the lines do not get into the movement zone of the front lift or of the universal joint shaft. Countersunk bolts M6x30 Fig. 12 Mounting the small oil cooler Spacer Small oil cooler Fig. 13 Small oil cooler Page 11 Installation 3.2.9. Fill the gearbox with gear oil up to the oil fill plug. The types of oil that can be used are in section 5.2.5. Fig. 14 Gearbox oil fill plug 3.2.10. Mount the switch-on electronics on the cover plate of the universal joint shaft and fasten the sheet metal instead of the battery holder on the tractor. Fig.15 Cable with switch-on electronics Fig. 16 Switch-on electronics on the universal joint shaft cover 3.2.11. Connect the extension cable to the plug connection on the switch-on electronics. Page 12 Installation Fig. 17 Extension cable 3.2.12. Route the extension cable to a free switch bay in the cab. Remove the cover and connect the switch included with the scope of delivery for this independent live PTO to the cable. Switch Fig. 18 Switch 3.2.13. 3.2.14. Route the brown cable to ground and the red cable to the ignition power. Mount the PTO shaft guard on the gearbox. Fig. 19 PTO shaft guard Page 13 Installation Attention! If you are mounting the independent live PTO in a tractor that has a cab, follow the description in sections 3.2.15 and 3.2.16 3.2.15. Take the left rear tire off of the tractor. 3.2.16. Mount the M10 and M12 spacers in the tapped bores behind the left rear wheel in the gearbox block of the tractor. Install the support plate for the battery on the spacing bolts in the wheel well. Place the battery on the support. Connect the battery. Use the supplied longer cable. Connect the battery to ground at a suitable point. Mount the cover and use it to fasten the battery. Fig. 20 Battery holder in the wheel well Attention! If you are mounting the independent live PTO in a tractor that does not have a cab, follow the description in sections 3.2.17 and 3.2.18 3.2.17. Mount the battery support element under the running board on the tractor. 3.2.18. Place the battery on the support. Connect the battery. Use the supplied longer cable. Connect the battery to ground at a suitable point. Mount the cover and use it to fasten the battery. Page 14 Installation Fig. 21 Electrical connection Attention! If you are mounting the PTO shaft in a tractor with frontloader, follow the description in sections 3.2.19 and 3.2.20 3.2.19. Remove the cross-member of the lower attachment hooks from the frontloader and cut an area out of the middle that matches the supplied conversion part. Fig. 22 Frontloader conversion part 3.2.20. Weld the conversion part onto the cross member in place of the cut out part and paint the weld spot. Re-assemble the frontloader. Fig. 23 Cross member reworked for attachment hooks Page 15 Installation Fig. 24 Frontloader mounted 3.3. Installation is complete 3.3.1. Tighten all threaded unions. To conclude ensure that all cables and hoses have sufficient clearance to moving parts and that no injury hazard exists. Remove all tools and loose parts from the tractor. Attention! There is an increased risk of accident due to the rotating PTO shaft. Do not enter the work area of the PTO shaft when it is rotating. For your own safety do not wear any loose clothing, belts, or any other loose items. Switch off the device. Wait until all machine parts have come to a standstill before converting or servicing the implement. Attention! Injuries due to fluid escaping under high pressure. Comply with the instructions in the operating manual. 3.3.2. Perform a trial run. Switch on the tractor. Ensure that the independent live PTO is at a standstill. Switch on the independent live PTO in idle and listen for unusual noises. Increase the speed to full throttle. Switch off the independent live PTO. Ensure that the independent live PTO is at a standstill. 3.3.3. After the trial run check all bolts, cables, and hoses for firm seat as the concluding step. Page 16 Operation Fig. 25 Tractor with independent live PTO 4. Operation Attention! Before starting up the implement read the instructions on safety and handling for operation of the entire implement and connection to the tractor. 4.1. Coupling and uncoupling implements Note! Comply with the axle loads specified by the tractor manufacturer Attention! There is an increased risk of accident due to the rotating PTO shaft. Do not enter the work area of the PTO shaft when it is rotating. For your own safety do not wear any loose clothing, belts, or any other loose items. Switch off the device. Wait until all machine parts have come to a standstill before converting or servicing the implement. 4.1.1. 4.1.2. 4.1.3. 4.1.4. 4.1.5. Drive the tractor forward in front of the implement. Lower the front lift. Drive slowly toward the implement until the coupling element of the tractor is under the coupling triangle of the implement. Slowly lift the front lift until the implement is slightly lifted. Secure the implement with the appropriate triangle locking mechanism. The triangle locking mechanism depends on the type of implement. Page 17 Operation Attention! Damage can occur to the independent live PTO or to the tractor. Comply with the instructions in the operating manual provided by the manufacturer of the universal joint shaft. Note! Mount the universal joint shaft as described in the original manual supplied by the manufacturer of the universal joint shaft. 4.2. Mounting the universal joint shaft Danger! Severe injury to the operator or third parties occurs. Switch off the tractor and remove the ignition key before mounting or dismounting the independent live PTO. Attention! There is an increased risk of accident due to the rotating PTO shaft. Do not enter the work area of the PTO shaft when it is rotating. For your own safety do not wear any loose clothing, belts, or any other loose items. Switch off the implement. Wait until all machine parts have come to a standstill before converting or servicing the implement. 4.2.1. 4.2.2. 4.2.3. 4.2.4. 4.2.5. 4.2.6. Press the locking pin on the outer fork and keep it depressed. Slide the outer fork onto the profile stub of the front PTO shaft on the gearbox. Release the locking pin. Slightly move the universal joint shaft back and forth until the locking pin audibly locks in place. Repeat steps 1 to 4 to attach the universal joint shaft to the implement. Hook the safety chain of the universal joint shaft to a fixed part (see Fig 26). Fig. 26 Safety chain on the universal joint shaft 4.3. Dismounting the universal joint shaft Danger! Severe injury to the operator or third parties occurs. Switch off the tractor and remove the ignition key before mounting or dismounting the independent live PTO. Page 18 Operation Attention! There is an increased risk of accident due to the rotating PTO shaft. Do not enter the work area of the PTO shaft when it is rotating. For your own safety do not wear any loose clothing, belts, or any other loose items. Switch off the implement. Wait until all machine parts have come to a standstill before converting or servicing the implement. 4.3.1. 4.3.2. 4.3.3. 4.3.4. 4.3.5. 4.4. Switching the independent live PTO on and off 4.4.1. 4.4.2. 4.4.3. 4.5. Detach the safety chain on both sides. Press the locking pin on the outer fork and keep it depressed. Pull the outer fork down from the profile stub of the PTO shaft on the tractor. Release the locking pin. Repeat steps 2 to 4 to detach the universal joint shaft on the implement. Switch-on the independent live PTO - switch on the switch for the front PTO shaft. Switch on the independent live PTO at approx. 1000 rpm, and do not increase the rpms of the tractor engine when switching on the independent live PTO. Do not switch on the independent live PTO at a speed greater than 1200 rpm. Switch-off the independent live PTO - switch off the switch for the front PTO shaft. Never attempt to loosen a seized front implement by switching the independent live PTO on and off. Run-up time of the front PTO shaft system The run-up time of the front PTO shaft system (only necessary if extremely light or extremely heavy implements will be driven) can be adjusted on the switch-on electronics. If the front PTO shaft system will power an extremely light implement, the run-up time must be long (rotate the set screw counterclockwise) so that the system switches on less abruptly. In the case of powering extremely heavy implements the run-up time should be adjusted as short as possible (turn the set screw clockwise) to reduce wear on the coupling. Set screw Fig. 27 Switch-on electronics Page 19 Maintenance 5. Maintenance 5.1. Service After 5-10 operating hours with a new independent live PTO, or after a repair, check whether all bolts are still tightened to the correct torque. Check the hydraulic lines for leaks. After every 400 operating hours check all threaded connections for correct tightening torque. Check the hydraulic lines for leaks. Lubricate the universal joint shaft. After 1000 operating hours check the oil level. Place the tractor on a horizontal surface and check whether the oil reaches the fill plug. If necessary top-up with oil. After 450 operating hours, or every 6 months change the gear oil. Clean the oil filter in the pump unit. 5.2. Changing the gear oil 5.2.1. 5.2.2. Remove the oil drain plug and drain the oil into a collection container. The oil drain plug is on the underside of the gearbox. Remove the lock ring from the pump unit, loosen the M8 bolt and remove the cover. Retaining ring Oil fill plug M8 bolt Cover Fig. 28 Gearbox 5.2.3. 5.2.4. Remove the oil filter from the pump unit, clean it, for example with compressed air. Replace the oil filter and re-mount the parts that were removed under 5.2.1 and 5.2.2. fill the gearbox with oil up to the oil fill plug. For this use one of the oil types listed below. Page 20 Disposal 5.2.5. Oil types that can be used: 5.3. BP: Shell: Esso: Castrol: Elf: FINA: Mobil: Texaco: Valvoline: Beverol: Total: JD: Autran DX III Fluid 9 Donax TX ATF E 25131 Transmax S Elfmatic G2 syn Elfmatic G3 Finamatic HP Finamatic S6726 Mobil ATF Texamatic 7045 ATF Dextron II-E Dextron II-E (Fina)matic HP Fluide AT 42 Fluidematic Syn Hygard JDMJ 20C Repair If there are faults, problems, or other indications of malfunction, contact your sales consultant or contact the manufacturer directly: matev GmbH Nürnberger Str. 50 90579 Langenzenn Tel.: +49 (0) 9101 9087-0 www.matev.eu [email protected] 6. Disposal The device must be disposed of in accordance with the applicable regulations of the municipality or the country. Take the parts to the collection points for residual waste, special waste, or recycle them depending on material. matev GmbH does not provide any disposal services. 7. Warranty The general terms and conditions of matev GmbH apply. Page 21 List of illustrations 8. List of illustrations Fig. 1 Radiators removed ......................................................................................................................... 6 Fig. 2 Locking hook .................................................................................................................................. 7 Fig. 3 Cutout in the holding plate .............................................................................................................. 7 Fig. 4 Floor panel with cutout ................................................................................................................... 8 Fig. 5 Cutout for the handle of the engine hood locking mechanism .......................................................... 8 Fig. 6 Mounting parts of the pulley............................................................................................................ 9 Fig. 7 Clamp ring and clamping bushing ................................................................................................... 9 Fig. 8 Mounting the universal joint shaft to the pulley ................................................................................ 9 Fig. 9 Hydraulic connections on the gearbox .......................................................................................... 10 Fig. 10 Gearbox on the front power lift .................................................................................................... 10 Fig. 11 Universal joint shaft .................................................................................................................... 11 Fig. 12 Mounting the small oil cooler ...................................................................................................... 11 Fig. 13 Small oil cooler ........................................................................................................................... 11 Fig. 14 Gearbox oil fill plug ..................................................................................................................... 12 Fig.15 Cable with switch-on electronics .................................................................................................. 12 Fig. 16 Switch-on electronics on the universal joint shaft cover ............................................................... 12 Fig. 17 Extension cable .......................................................................................................................... 13 Fig. 18 Switch ........................................................................................................................................ 13 Fig. 19 PTO shaft guard ......................................................................................................................... 13 Fig. 20 Battery holder in the wheel well .................................................................................................. 14 Fig. 21 Electrical connection................................................................................................................... 15 Fig. 22 Frontloader conversion part ........................................................................................................ 15 Fig. 23 Cross member reworked for attachment hooks ........................................................................... 15 Fig. 24 Frontloader mounted .................................................................................................................. 16 Fig. 25 Tractor with independent live PTO .............................................................................................. 17 Fig. 26 Safety chain on the universal joint shaft ...................................................................................... 18 Fig. 27 Switch-on electronics.................................................................................................................. 19 Fig. 28 Gearbox ..................................................................................................................................... 20 Page 22 EC Declaration of Conformity 9. EC Declaration of Conformity EC Declaration of Conformity for a machine to confirm compliance with the Machinery Directive 2006/42/EC and with the statutory provisions issued for the implementation of the Machinery Directive. The manufacturer matev GmbH Nürnberger Str. 50 90579 Langenzenn declares that the machine Independent live PTO Code number 131 7122 and 131 7144 Type John Deere 4520/4720 complies with the provisions of the Machinery Directive 2006/42/EC and with the implementing national statutory provisions. The signer is authorized to compile the technical documents. The address is the address of the manufacturer. Date / Signature Name of signer Signer information April 2011 ........................................... Georg Hemmerlein Managing Director Page 23 ">

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Key features
- Independent live PTO
- For John Deere 4020 series tractors
- Extends crankshaft to the front
- Powers front mounted implements
- Robust gearbox
- Universal joint shaft
- Safety chain
Frequently asked questions
It's an independent live PTO for John Deere 4020 series tractors, extending power to the front for implements.
It can power implements like sweepers and front mowers that are driven by PTO shafts.
You can adjust it on the switch-on electronics by turning the set screw clockwise for shorter run-up time or counterclockwise for a longer one.
Refer to section 5.2.5 in the manual for a list of suitable oil types.