matev FPS-JD 3R Engine PTO shaft Operating Manual

matev GmbH
Nürnberger Str. 50
90579 Langenzenn, Germany
T +49 9101 9087 -0
F +49 9101 9087 -20
[email protected]
www.matev.eu
Original Operating Manual
Engine PTO Shaft FPS-PTO JD-3R, from 04/2018
for John Deere, type 3033R, 3038R, 3045R
2000 rpm CCW
1000 rpm CCW
2000 rpm CW
1000 rpm CW
Version
04/2018
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
Qualifications of personnel .......................................................................................... 4
General safety notices ................................................................................................ 4
Special safety notices ................................................................................................. 5
Supplemental provisions ............................................................................................. 5
3.
3.1.
3.2.
3.3.
3.4.
Installation ................................................................................................................. 6
Preparatory measures................................................................................................. 6
Mounting the engine PTO shaft ................................................................................. 10
Connect the electrical system ................................................................................... 13
Installation is complete .............................................................................................. 18
4.
4.1.
4.2.
4.3.
4.4.
Operation ................................................................................................................. 18
Coupling and uncoupling implements ........................................................................ 19
Mounting the universal joint shaft .............................................................................. 20
Dismounting the universal joint shaft ......................................................................... 21
Switching the engine PTO shaft on and off ............................................................... 21
5.
5.1.
5.2.
Maintenance ............................................................................................................ 21
Maintenance ............................................................................................................. 21
Changing the gear oil ................................................................................................ 22
6.
Repair....................................................................................................................... 23
7.
Disposal ................................................................................................................... 23
8.
Guarantee ................................................................................................................ 23
9.
List of illustrations .................................................................................................. 24
10.
Declaration of Conformity ...................................................................................... 25
About this operating manual
1.
About this operating manual
Dear customer! Dear customer!
Thank you for purchasing this implement, we appreciate your trust.
Prior to using this implement 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 implement 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 implements, must have read and understood this operating manual.
2.1.
Intended use
The engine PTO shaft 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
engine PTO shaft 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 implements
 Environmental damage
2.2.
Qualifications 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 notices
General safety notices are explained in this section. These safety notices 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.
Comply with the safety notice.

Attention!
Minor injury to the operator or third parties can occur. The tractor, the grass
collection device or the environment can be damaged.
Comply with the safety notice.

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 notices
The safety instructions specified in this section 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 notice in the operating manual.

Attention!
Increased risk of accident due to 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 re-tightened.
Damage can occur.
2.5.
Supplemental provisions
 Ensure that the speed and the direction of rotation of the engine PTO shaft are suitable for driving the implement before coupling an implement to the tractor.
 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 engine PTO shaft.

Attention!
Injuries can occur.
Wear protective work clothing.

3.1.
Preparatory measures
3.1.1
The prerequisite for using the engine PTO shaft is that the tractor must already be
equipped with the matev front power systems 131 7862 or 131 7881.
3.1.2
In conjunction with the JD frontloader H160 / H165 you need the matev frontloader conversion kit.
Fig. 1: matev frontloader conversion kit
Page 6
Installation
3.1.3
Drive the tractor onto the lift platform. Completely remove the battery with the battery
tray.
Fig. 2: Battery with tray
3.1.4
Dismount all attachment parts from the battery tray. You will need the attachment parts
later.
3.1.5
Make the cut out for the engine PTO shaft in the plastic cover as shown in the diagram
below.
Slide piece,
universal joint
shaft
290
180
50
190
Fig. 3: Cutout for engine PTO shaft
Page 7
Installation
3.1.6
Place the slide piece for the universal joint shaft (flange with 6 bores) radiator and axle. If
the pulley is mounted, the slide piece can no longer be pushed through.
3.1.7
Mount the provided pulley on the pulley on the engine (see Fig. 6). Use the provided Allen screws DIN 912 – M10x20-8.8. Secure the screws with a liquid thread-lock compound. Tighten the screws with a torque of 43 Nm. If the tractor is equipped with an air
conditioning system, then the pulley for the AC compressor must be replaced with the
provided pulley.
On the pendulum axle replace the screw with the threaded pin included in the scope of
delivery.
Then remove the lubricating nipple and mount the extension are shown in the illustrations below. Conclude by mounting the original lubricating nipple on the end piece of the
extension.
Fig. 4: Front axle
Page 8
Screw
Extension
Installation
End piece
Fig. 5: New position of the lubricating nipple
3.1.8
Mount the slide piece of the universal joint shaft on the pulley. Use the provided hex
screws DIN933-M6x16-8.8. Secure the screws with a liquid thread-lock compound.
Tighten the screws with a torque of 9 Nm.
Fig. 6: Belt pulley with universal joint shaft
3.1.9
Slide the splined shaft part of the universal joint shaft onto the slide piece. In this process, ensure correct orientation of the universal joint shaft (white line on the tube)
Page 9
Installation
Fig. 7: Universal joint shaft installed
3.2.
Mounting the engine PTO shaft

Note!
The gearbox is already filled with oil. Keep this in mind when handling the gearbox.
3.2.1
If this has not yet occurred, mount the front power system as described in the manual,
"Front Power System and Engine PTO Shaft FPS-JD-3R".
3.2.2
Mount the engine PTO shaft on the front power system.
Use the provided spacer bushes for the upper fastening screws.
Page 10
Installation
Spacer bush
Fig. 8: Installation of the engine PTO shaft on the front power system
3.2.3
Fasten the universal joint shaft on the flange of the engine PTO shaft. Use the provided
Allen screws DIN 912-M8x20-8.8. Secure the screws with a liquid thread-lock compound.
Tighten the screws with a torque of 22 Nm.
Fig. 9: Fasten the universal joint shaft on the gearbox flange
Page 11
Installation
3.2.4
Mount the rubber plugs on the provided battery tray.
Cover plate
Rubber grommet
Illustration 10 Battery tray
3.2.5
Mounting the front cover plate on the battery tray
Fig. 11: Mounting the cover plate
3.2.6
Page 12
Mount the battery tray on the tractor.
Installation
3.2.7
Mount the attachment parts that you dismounted from the John Deere battery tray.
Mount the extension between ground cable and frame.
Extension for
ground cable
Fig. 12: Cover plate with cooling hoses mounted
3.2.8
3.3.
Mount the battery. Only connect the battery after complete installation of the engine PTO
shaft.
Connect the electrical system
Fig. 13: PTO shaft switch + cable
Page 13
Installation
3.3.1
Connect PTO shaft switch and cable. Mount the switch on the empty space on the tractor.
Fig. 14: PTO shaft switch (tractor without cab)
Fig. 15: PTO shaft switch (tractor with cab)
Page 14
Installation
3.3.2
Detach the instrument panel on the tractor and lift it off. Find the cable for the engine
PTO shaft. Remove the protective plug with the bridge and connect it to the PTO switch.
Plug connector for
PTO switch
Fig. 16: Cable for engine PTO shaft (tractor without cab)
Plug connector for
PTO switch
Fig. 17: Cable for engine PTO shaft (tractor with cab)
3.3.3
Refasten the instrument panel.
Page 15
Installation
3.3.4
Plug in the provided cable on the engine PTO shaft.
Plug connector
– switch-on
valve
Fig. 18: Plug connector – switch-on valve
3.3.5
The cable for the connection on the engine PTO shaft is at the front, on the right, near
the front axle. Remove the protective cap from the plug and connect the plug connection
to the engine PTO shaft.
Plug connector for
engine PTO shaft
Fig. 19: Plug connection – engine PTO shaft
Page 16
Installation
3.3.6
Check the oil level.
The oil level should be checked before mounting the protective pot. Place the tractor on a
level substrate and open the oil fill plug. The oil level should be directly underneath the fill
opening. Top up oil as needed. Use STOU 10W-30.
Alternatively JD HyGard JDM 20C can be used. When changing the oil type, please execute a complete oil change.
Oil fill opening
Fig. 20: Oil fill plug
Drill the fastening bores in the protective pot. To do this use the aluminum carrier for the
PTO shaft profile guard.
Fasten the protective pot
Aluminum carrier
PTO shaft profile
guard
Fig. 21 PTO shaft guard
3.3.7
Attach the PTO shaft guard.
Page 17
Operation
3.4.
Installation is complete
Check all threaded unions. Then check to ensure that all cables and hoses are sufficiently
far away from moving parts and that no injury hazard exists. Remove all tools and loose
parts from the tractor.
Attention!
Increased risk of accident due to 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, on 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!
Injuries due to fluid escaping under high pressure.
Comply with the notice in the operating manual.

3.4.1
Reconnect the battery.
3.4.2
Perform a trial run. Switch on the tractor. Ensure that the engine PTO shaft is at a standstill. Switch on the engine PTO shaft in idle and listen for unusual noises. Increase the
speed to full throttle. Switch off the engine PTO shaft. Ensure that the engine PTO shaft
is at a standstill.
3.4.3
After the trial run check all bolts, cables, and hoses for firm seat as the concluding step.
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.

Page 18
Operation
Attention!
The total power of the front implements must not be exceeded, depending
on the gearbox, otherwise the front PTO shaft could be damaged.

CW
Rotational speed on
the gearbox output
1000 rpm
CCW
2000 rpm
max. power
4.1.
1000 rpm
2000 rpm
47 kW
max. continuous power
30 kW
30 kW
21 kW
33 kW
Rotational speed on
the gearbox output
1000 rpm
2000 rpm
1000 rpm
2000 rpm
Coupling and uncoupling implements

Note!
Comply with the axle loads specified by the tractor manufacturer
Attention!
Increased risk of accident due to 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.

4.1.1
Drive the tractor forward in front of the implement.
4.1.2
Lower the front power system.
4.1.3
Drive slowly toward the implement until the coupling triangle of the tractor is under the
coupling triangle of the implement.
4.1.4
Slowly lift the front power system until the implement is slightly lifted.
4.1.5
Secure the implement with the appropriate triangle locking mechanism. The triangle locking mechanism depends on the type of implement.
Attention!
Damage can occur to the engine PTO shaft 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.
Page 19
Operation
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 engine PTO shaft.
Attention!
Increased risk of accident due to 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
Press the locking pin on the outer fork and keep it depressed.
4.2.2
Slide the outer fork onto the profile stub of the front PTO shaft on the gearbox.
4.2.3
Release the locking pin.
4.2.4
Slightly move the universal joint shaft back and forth until the locking pin audibly locks in
place.
4.2.5
Repeat steps 1 to 4 to attach the universal joint shaft to the implement.
4.2.6
Hook the safety chain of the universal joint shaft to a fixed part (see Fig. 22).
Fig. 22 Safety chain on the universal joint shaft
Page 20
Maintenance
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 engine PTO shaft.
Attention!
Increased risk of accident due to 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
Detach the safety chain on both sides.
4.3.2
Press the locking pin on the outer fork and keep it depressed.
4.3.3
Pull the outer fork down from the profile stub of the PTO shaft on the tractor.
4.3.4
Release the locking pin.
4.3.5
Repeat steps 2 to 4 to detach the universal joint shaft on the implement.
4.4.
Switching the engine PTO shaft on and off
4.4.1
Switching on the engine PTO shaft: switch on the engine PTO shaft at approx. 1000 rpm,
and do not increase the rpm of the tractor engine when switching on the engine PTO
shaft. Do not switch on the engine PTO shaft at a rotational speed greater than 1200
rpm.
4.4.2
Switching off the engine PTO shaft: switch off the switch for the front PTO shaft.
4.4.3
Never attempt to loosen a seized front implement by switching the engine PTO shaft on
and off.
5.
Maintenance
5.1.
Maintenance
 After 5-10 operating hours with a new engine PTO shaft, or after a repair, check
whether all bolts are still tightened to the correct torque
 Change the oil after 50 operating hours. Use STOU 10W30. Alternatively JD HyGard
JDM J20C can be used.
Page 21
Maintenance
 After 100 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.
 The universal joint shaft must be lubricated every 250 operating hours, however at the
latest after 1 month.
 After every 400 operating hours check all threaded connections for correct tightening
torque. Check the hydraulic lines for leaks
 Change the gear oil after 500 operating hours. Clean the oil filter in the pump unit.
5.2.
Changing the gear oil
5.2.1
Place the tractor on a level surface
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.
Clean the oil drain plug and screw the oil drain plug back in.
5.2.3
Unscrew the screw on the cover for the oil filter and remove the cover.
Oil filter
Fig. 23: Replacing the oil filter
5.2.4
Replace the oil filter.
5.2.5
Remove the oil fill plug and fill with STOU 10W-30 (alternatively HyGard JDMJ 20C).
The oil level is correct, when the oil is on the lower edge of the oil fill opening.
Remount the oil fill plug.
Page 22
Repair
6.
Repair
Never open the gearbox on your own.
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, Germany
Tel.: +49 9101 9087-0
www.matev.eu
[email protected]
7.
Disposal
The implement 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.
8.
Guarantee
The general terms and conditions of matev GmbH apply.
Page 23
List of illustrations
9.
List of illustrations
Fig. 1: matev frontloader conversion kit .........................................................................................................6
Fig. 2: Battery with tray ..................................................................................................................................7
Fig. 3: Cutout for engine PTO shaft ...............................................................................................................7
Fig. 4: Front axle ............................................................................................................................................8
Fig. 5: New position of the lubricating nipple .................................................................................................9
Fig. 6: Belt pulley with universal joint shaft ....................................................................................................9
Fig. 7: Universal joint shaft installed ........................................................................................................... 10
Fig. 8: Installation of the engine PTO shaft on the front power system ...................................................... 11
Fig. 9: Fasten the universal joint shaft on the gearbox flange .................................................................... 11
Illustration 10 Battery tray ........................................................................................................................... 12
Fig. 11: Mounting the cover plate ............................................................................................................... 12
Fig. 12: Cover plate with cooling hoses mounted ....................................................................................... 13
Fig. 13: PTO shaft switch + cable ............................................................................................................... 13
Fig. 14: PTO shaft switch (tractor without cab) .......................................................................................... 14
Fig. 15: PTO shaft switch (tractor with cab)................................................................................................ 14
Fig. 16: Cable for engine PTO shaft (tractor without cab) .......................................................................... 15
Fig. 17: Cable for engine PTO shaft (tractor with cab) ............................................................................... 15
Fig. 18: Plug connector – switch-on valve .................................................................................................. 16
Fig. 19: Plug connection – engine PTO shaft ............................................................................................. 16
Fig. 20: Oil fill plug ...................................................................................................................................... 17
Fig. 21 PTO shaft guard ............................................................................................................................. 17
Fig. 22 Safety chain on the universal joint shaft ......................................................................................... 20
Fig. 23: Replacing the oil filter .................................................................................................................... 22
Page 24
Declaration of Conformity
10.
Declaration of Conformity
EC Declaration of Conformity for a machine to confirm compliance with the Machinery Directive
2006/42/EC, the EMC Directive 2004/108/EC, and with the statutory regulations issued for their implementation.
The manufacturer
matev GmbH
Nürnberger Str. 50
90579 Langenzenn, Germany
declares that the machine
Engine PTO Shaft FPS-PTO JD-3R
131 8666 / 131 8667 / 131 8668 / 131 8669
Type John Deere 3033R/3038R/3045R
complies with the provisions of the Machinery Directive 2006/42/EC, The EMC Directive 2004/108/EC
and with the national statutory regulations for their implementation.
The signer is authorized to compile the technical documents.
The address is the address of the manufacturer.
Date / signature
April 2018
Name of signer
Information concerning the signer
..............................................
Georg Hemmerlein
Managing Director
Page 25
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