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GM PTO Systems; Part 1GM PTOSystems;Part 1Tby Steve Garretthe operation of a Power TakeOff (PTO) is nothing new formost of you. But, as with othervehicle systems, the PTO has undergone a lot of changes in the past fewyears.PTOs provide an inexpensive, reliable and safe way to drive severalvehicle accessories, such as: Winches Road Sanders Dump Boxes Snow Plows Man Lifts Fire and Ambulance Equipment Drills Air Compressors WreckersA PTO unit is commonly boltedto the transmission, transfer case orengine, or in some cases may be operated from an accessory drive belt. Inany case, the PTO is typically a geardriven assembly that directly or indirectly operates a hydraulic pump andPTO hydraulic system.Some systems don’t use a PTOto operate a pump, but rather the PTOoperates a driveshaft, which is thenused to drive a component. Early applications used a lever system to engageand disengage the PTO. On later applications, this operation is typically controlled electronically.With GM applications, many ofthe PTO system components can’t beordered as options when you purchasea new vehicle. Instead, GM uses GMdealers or independent “upfitters” toinstall many of the components requiredto make the PTO system function.GM typically offers two RPO(Regular Production Option) codes thatrelate to the PTO system. RPO UF3designates the vehicle is equipped withfast idle software. The UF3 option1212garrett1208.indd 12PTO Assemblyallows the vehicle to operate at a singleelevated speed when activated. Thisfeature typically increases engine RPM,which improves alternator output, A/Ccooling, and heater performance whenthe vehicle is stationary. This optioncomes with a cab mounted switch, wiring and a PCM or ECM capable of raising idle speed when needed. The fastidle option wasn’t designed to operatethe PTO system.RPO PTO may be ordered on manyapplications. This option provides theupfitter with factory-installed wiringto make installation simpler. In addition, it provides multiple or variableengine speeds to meet current demands.Engine speeds are programmable onsome applications. The factory PTOoption includes: A PTO enable switch Cruise control switches that areused to vary engine speed for PTOoperation Upfitter wiring and connections foran in-cab PTO switch Upfitter interface connector located on the driver’s side of the transmission (passenger side 2007-09applications)A programmable PCM or ECMwith PTO softwareTAC module (on electronic throttlecontrolled systems)PTO module (included in RPOPTO on 2007-08 applications)Some applications also require anRPO M1F option. This option featuresa revised floorpan. The floorpan has akickout design to provide the requiredspace for transmission-mounted PTOs.GM offers PTO installationkits through two suppliers: ChelseaAuxiliary Power Products and MunciePower Products. The PTO installationkits include: Plumbing PTO Heat Shields PTO Control Switch (included inRPO PTO on 2007-08 applicaGEARS December 200811/14/08 9:45:44 AM
We have atransmission solutionfor any vehicle.(Well, almost any)As the technological leader,Precision International’s repair kits are truly state of the part.Name any year, make or model. Give us any transmission problem. Chances are we’ve got a solution. Not just anysolution, but one that will really work and keep on working – backed by solid engineering, the latest specs and ourreputation for giving you and your customers reliable performance and the utmost peace of mind. When you see thePrecision International name on one of our transmission repair kits, you can feel confident you’ve got the very best.All are cross-checked against OEM specs. All changes are noted and made. And we always use OE parts or better.Plus, our huge inventory virtually assures immediate delivery.The best advice on the planetAs the technological leader in transmission repair for over30 years, you can also count on Precision for outstanding techassistance and support, including our hot new websitewww.transmissionkits.com. Just a mouse click away is awealth of information, including continually updated videoseminars from leading transmission expert John Parmenter,question and answer forums,complete parts informationand much more – that canhelp you troubleshoot andsolve virtually any transmissionrepair problem.precision plcd 1208.indd 13Spaceships? No, we haven’t helped repair one of those yet.But who knows what tomorrow will bring. For moreinformation, give us a call.www.transmissionkits.comThe Problem Solvers.14 Todd Court Extension, Yaphank, NY 11980(631) 567-2000 Fax (631) 567-2640 Toll Free: 800-872-6649Florida Office: 6790 Hillsdale Point, Boynton Beach, FL 33437(561) 734-2332 Fax (561) 734-2375E-mail: sales@transmissionkits.com www.transmissionkits.com11/14/08 9:51:24 AM
GM PTO Systems; Part 1PTO Fast Idle tions)PTO Interface Harness (includedin RPO PTO on 2007-08 applications)Load Engagement Switch (someapplications)PTO Solenoid (some applications)The PTO installation kit allows thePTO system to be installed on properlyequipped 4L80E, LCT 1000 and the ZF6-speed manual transmission applications.PTO ComponentsPTO Drive Gear — Not allapplications are equipped to handle aPTO. The LCT 1000 may or may notbe equipped with a PTO drive gear,depending on the year and application.These models are equipped for PTOoperation: All 2001-2006 8.1 RPO L18 (VINcode G) and 2001-2004 6.6 RPOLB7 (VIN code 1) All 2004-2008 6.6 RPO LLY (VINcode 2), 2006-2008 6.6 RPO LBZ(VIN code D), 2007-2008 6.6 RPOLMM (VIN code 6) and 2007 8.1RPO L18 (VIN code G) Trucks with RPO ZW9 don’t have aPTO drive gear unless they’re 2007and prior model years equippedwith an 8.1L, RPO L18.If the application isn’t equipped fora PTO, the PTO gear may be ordered aspart of a rotating housing assembly. The2001-05 rotating assembly is GM partnumber 29540518. The 2006-and-laterrotating assembly is GM part number29542802.1412garrett1208.indd 14NOTE: GM doesn’t recommendinstalling a PTO on non-factory PTOapplications on 2007-and-later vehicles. 2007-and-later applications haveundergone significant changes and adding a PTO is no longer a cost effectivechoice.PTO Control Switch — The PTOswitch generally uses two or three positions: Off, On and on some applicationsSet. The PTO switch acts as the maincontrolling component for the GM PTOsystem.PTO Interface Connector — Thisconnector is located on a bracket on thedriver’s side of the transmission (passenger side 2007-09 applications). Theinterface connector provides access tothese circuits: PTO engine shutdown (LightBlue) PTO remote enable switch(Light Green) Ground (Black) PTO feedback (Yellow) PTO relay control (White) Cruise control switch (DarkBlue)PCM/ECM — The PCM/ECM forPTO applications can be programmedto control the PTO as well as engineRPM (2006 and earlier). Two modes ofPTO operation are typically available: Preset — In this mode the PCMtypically uses one of two presetPTO operating speeds. Variable — This mode allows variable PTO speed while the vehicleis stationary or moving.PTO Relay — The PTO relayis controlled by the PCM/ECM. ThePCM/ECM receives input from thePTO switch. When the PTO is commanded on or off, the PCM/ECM willcorrespondingly command the relay onor off when the required parametershave been met.The PTO relay is mounted in theunderhood fuse box (UBEC). Theengine 1 fuse and the PTO switchtypically control the power to the relaywinding, while the PCM/ECM controlsthe relay ground.NOTE: The PTO relay is an upfitter-installed device on some later modelapplications and is now controlled bythe Power Take Off Module (PTOM).Cruise Control Switch — Onvehicles that are equipped with cruisecontrol, the cruise control switchassembly is typically used to controlPTO operation. The switch can be usedto turn the PTO on and off, and set thePTO speed.TCC — Several automatic transmission applications apply the TCCduring PTO operation. This typicallyoccurs when the vehicle is in park andthe engine speed is above 1100 RPMwith the PTO engaged.Brake Switch/Clutch Switch —The brake switch/clutch switch is usedto cancel PTO operation as a safetyprecaution on factory applications. Onsome applications (typically diesel)when the brake/clutch is released, thesystem will resume operation. Otherapplications require the operator todepress the set switch or touch theresume button on the cruise controlswitch to resume operation.TAC Module — On electronic,throttle-controlled applications, theThrottle Actuator Control (TAC) module is used to regulate engine RPM.Based on data received from the PCM/ECM, the TAC module will raise orlower engine RPM to meet the demand.This is accomplished as the TAC module changes the commands to the TACmotor.PTO Solenoid — The PTO solenoid is an upfitter-installed device.Many systems require a solenoid forclutch activated PTOs. The PTO relayprovides the solenoid with power whenthe relay is energized by the PCM/ECM.Load Engagement Switch — LikeGEARS December 200811/14/08 9:46:01 AM
the PTO solenoid, the load engagementswitch is an upfitter-installed device.The switch is typically wired into thepower feed for the PTO solenoid andmust be closed before the PTO willengage.PTO Module — Introduced forthe 2007 model year, the PTO module(PTOM) provides these functions: Replaces many of the functionspreviously performed by the PCM/ECM Receives input from the PTOswitch Controls the PTO relay Processes requests to the ECM/PCM and BCM regarding remotestarting and engine shutdown Shares information and data withthe BCM, ECM/PCM, IPC andTCM regarding desired PTO operation Processes information from theTCM regarding transmission temperature and gear position Requests the IPC to display information and messages regardingPTO operationGEARS December 200812garrett1208.indd 15PTO System 2007-2008Body Control Module (BCM)— The BCM is now part of the PTOsystem (2007 and later). The BCMstores the PTO configuration; if thefactory preset configuration needs tobe changed, the BCM will have to bereprogrammed using a scan tool. Thisincludes the default modes of opera-tion. In addition, the BCM acts as themaster controller for many functions,including remote start.Modes of OperationSeveral modes of operation may beavailable, depending on vehicle application and content. These include:1511/14/08 9:46:16 AM
GM PTO Systems; Part 1Preset Mode/Stationary Mode —This mode is used for stationary operation. Preset mode provides a defaultstandby speed of 800-850 RPM, andtwo preset PTO speeds: 1250 RPM and1700 RPM. Maximum engine speed forPTO operation is typically set at 2200RPM.To operate the PTO in preset mode,these conditions must be present: Engine running Transmission in park or neutral Park brake set on manual transmission applications VSS 0 MPH Foot off the brake or clutch PTO switch onWith these conditions met, engineRPM will increase to standby speed.The LED on the PTO switch willflash, indicating the PTO is attempting to engage. Once the LED changesto a steady state, the PTO should beengaged.Variable Modes — Variable modecan be used for stationary or mobileapplications. This mode allows the PTOto be controlled in 100 RPM increments. Variable mode allows the operator to “Tap Up” or “Tap Down” thePTO speed by using the set and resumecruise control switches. Applicationsnot equipped with cruise control won’thave the “Tap” features.Variable mode can be operatedwith the vehicle stationary or in motion.If the vehicle is in motion, the system will allow the driver to attainthe desired engine RPM (not vehiclespeed) for PTO operation.To operate the PTO in variablemode, these conditions must be present: Engine running Foot off the brake or clutch PTO switch on Engine RPM raised to standbyspeedFrom here, you’ll be able to obtainthe desired engine RPM by pressingthe accelerator pedal. Then press theset button on the PTO switch or cruisecontrol switch to retain the desired setspeed.The LED on the PTO switch willflash when the PTO is attempting toengage. The LED will change to a1612garrett1208.indd 16steady state when the PTO has engaged.The set and resume buttons can now beused to adjust engine speed in 100 RPMincrements.NOTE: Engine RPM must begreater than PTO standby speed butlower than the maximum PTO engineRPM for the system to function.NOTE: For the system to functionthe PCM must be programmed for thevariable mode. If the system wasn’tfactory equipped (RPO PTO), you’llneed to reprogram the PCM/ECM forPTO function with your scan tool.Fast Idle Mode — This mode istypically used on vehicles that don’t usea PTO, but have need for a higher-thannormal idle speed when the vehicle isstationary. A typical application for fastidle mode would be an ambulance. Aswith a PTO system, to make the vehicleoperate in fast idle mode, additionalequipment is necessary.On many applications (RPO UF3),an 8-pin PTO connector is locatedbehind passenger air bag switch inthe dash. The connector is typicallytaped to the IP harness. If the connector is present, a GM accessory kit isavailable to make the fast idle modeinstallation easier. The accessory kitis available under GM part number12497678. Some applications may nothave the connector, so hard wiring willbe required.Once the kit is installed or thesystem hardwired, the PCM may needto be programmed to enable fast idleoperation. You’ll need to program thesefactory default parameters into thePCM/ECM with your scan tool: Fast idle/PTO switch onPress the set button on the cruisecontrol or PTO switchThis should force the engine idle toincrease. On some applications, pressing the resume/accelerate button onthe cruise control will allow the enginespeed to “tap up” while touching the setbutton will decrease fast idle speed.Major changes have occurred forthe 2007-2009 model year applications.These include: Kit 12497678 is no longer requiredif the vehicle is ordered with RPOPTO. A new, dedicated, in-cab multifunction switch is included in thePTO factory package. A dedicated upfitter connector nowappears on all applications. A dedicated PTO module controlsPTO operation. A remote enable switch providesremote on/off control of the PTO. A remote engine start and shutdown feature can be programmedto operate with a scan tool. Automatic engine shutdown feature warns the driver by honkingthe horn prior to shutdown. Thisfeature monitors oil level, oil pressure, coolant level, transmissionfluid temperature, fuel level anddiesel particulate filter regeneration. Tap Up/Tap Down is no longeraccomplished using the cruisecontrol switch. The multifunctionswitch now provides the Tap Up/Tap Down functions for the PTOsystem. New transmissionPTO Max Engine Speed2200-4400 RPM (Factory default 2200 RPM)calibrations preventPTO Standby Speed800-1200 RPM (Factory default 800 RPM)shift business duringPTO Set Speed1250-1400 RPM (Factory default 1250 RPM)mobile PTO operaPTO Resume Speed1700 RPMtion.PTO Max Engage Speed 1000-1800 RPM (Factory default 1000 RPM) Remote tachometerand PTO status LEDsPTO ShutdownNOallow for easy sysPTO Engage RelayNOtem monitoring whenPTO FeedbackNOyou’re out of the cab(2009).With the kit installed and the programming complete, the fast idle funcWell as you can see, the PTO systion should operate. To engage fast idle,tem is a complex animal. Until nextthese conditions must be met:time, remember: “Success doesn’t come Park range (neutral on M/T)to you you go to it.” Park brake set (M/T)GEARS December 200811/14/08 9:46:34 AM
964 East Market St., Crawfordsville, IN 47933 Toll Free: 800-729-7763 Fax: 765-364-4576 Email: raypt@raybestospowertrain.com* Raybestos Powertrain warrants that each electrical component manufactured or supplied by Raybestos Powertrain will be free from defects in material or factory workmanship for fiveyears or 50,000 miles from the date of sale. Please refer to Raybestos Powertrain’s website (www.raybestospowertrain.com) and catalog for details and limitations.Raybestos placed1107.indd 211/14/08 3:37:23 PM
A PTO unit is commonly bolted to the transmission, transfer case or engine, or in some cases may be oper-ated from an accessory drive belt. In any case, the PTO is typically a gear-driven assembly that directly or indi-rectly operates a hydraulic pump and PTO hydraulic system. Some systems don’t use a PTO
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