va 6.5L Diesel w-w/o AC, wi ABS PUMP/CLUTCH ~RESERVOIR INSTALLATION: VIE\JED FROM FRONT /DR. SIDE OF VEHICLE \ \ \ \ g \ \, Y, TO PUMP' \ \ SUCTION

Transcription

1 .Chev/GMC va 6.5L Desel w-w/o AC, wi ABS B Belt Drve Hydraulc Electrc Clutch Solenod Valve Remote Reservor PUMP/CLUTCH ~RESERVOIR INSTALLATION: VIE\JED FROM FRONT /DR. SIDE OF VEHICLE (4 PLACES) /, I.~ j NOTE. USE ALTERNATE FASTENERS ON TRUCKS 'WITH STIF'FENER BET'wEEN BATTERY BOX AND HEAD LAMP 'WEBBING \ \ \ \ g \ \, Y, TO PUMP' \ \ SUCTION \e \ ~ FROM PUMP: ~ 'RELIEF. l \RETURN FROM '\ VAL VE \ TO HOLES ON ACCESSORY G(RDlE 53 (RE(NSTAlL VEHICLE'S RADIATOR HOSE BRACKET BET'WEEN PUMP BRACKET AND ACC. GIRDlD ROUTE THESE THREE HOSES TOGETHER OVER THE TOP or THE RADIATOR SHROUD \ (4 " TO RESERVOIR. RELIEF FROM RESERVOIR. SUCTION l TO VALVE, PRESSURE 09 FISHER ENGINEERING, ROCKLAND, ME 0484 Subject to Change n/96

2 75538 Page w W ~ ~ z o z ~ 0 o a: a: ~ 0. 0 w o 0. W eñ (( :; a: r- ;: Ww Q :J ~~~a: M.,. W 0 z o 00. t- o a:,~ Wr \ "" "- w5~ ú) (/ w ' 0. 0' Q -- ~~v U Iw 0. OJ ~ ~. Q Q ;: a:. o (/ '- ~ ~~ LL (/.. - ~ O~ zw o c: Z ú) llo Q t: ~ w w :: ~~ o.~ -~ ((!: :: ~ OJ '- Q Q.tñ~ ) \ I ( I FISHER ENGINEERING, ROCKLAND, ME 0484 Subject to Change n /96

3 75538 Page 3, PUMP PRESSURE - TO LIFT \,, CYLINDER _ _\ RETURN TO RESERVOIR -.- PLACES TO ~~ 4 PLACES ~ I I VALVE INSTALLATION: LOCATE ON DRIVER'S SIDE FENDER (SHD\.N AS VIE\.ED FROM FRONT J DRIVER'S SIDE OF VEHICLE) (... ~ ~ I $ : ~ $ ~ ~ t l ~....' ~ ~I $ : ~ $ ~ ~ ~ t DRILL FOUR /3' HOLES IN FENDER MOUNT THROUGH THEM. PLACES FISHER ENGINEERING, ROCKLAND, ME 04 Subject to Change 7/96

4 75538 Page 4 TO PASSENGER SIDE ANGLE CYLINDER VAL VE ASSEMBL Y ALL ITEMS ASSEMBLED ( PLACES) FROM PUMP PRESSURE RETURN TO RESERVOIR NOTES:. REMOVE PROTECTIVE: TAPE FROM PART LUBE O-RINGS 'WITH HYDRAULIC OIL BErDRE ASSEMBLY. 3. APPL Y STICK TYPE THREAD SEALER TO ALL HYDRAULIC FITTING THREADS BEf'RE ASSEMBLY. TO LIFT CYLINDER NOTES.. APPLY STICK TYPE THREAD SEALER TO ALL HYDRAULIC fitting THREADS BEroRE ASSEMBLY. 0 PUMP-CLUTCH ASSEMBL Y PRESSURE TO VALVE ("OUT") TORQUE TO B FT -LBS ( PLACES) ø ALL ITEMS ASSEMBLED suet ON FROM RESERVOI R (' N' ) RELIEF TO RESERVOIR FISHER ENGINEERING, ROCKLAND, ME 0484 Subject to Change n/96

5 Part Lst Electrc Clutch Common Hydraulc Kt Ref # Assy Comp Qty Part # Descrpton 0 Pump-Clutch Assembly Pump Assembly 3 Electrc Clutch 4 9 Pump Plate /4 x 3/4 (NC) Gr.5 Cap Screw /4 Lock Washer /6 x -/4 (NF) Gr.5 Cap Screw /6 Lock Washer /6 Plan Washer /6 Hex Nut /3 x / Sprng Pn 8389 Ol Reservor Valve Assembly--Elec Clutch/Sol 4 79 Valve Manfold Assy Sol Valve Bracket Mountng Plate - Valve /8 Nptm to /4 NPT Swvel Adapter /8 Nptm to /4 NPT Reducng Adapt /4 x 3-/ (NC) Gr.5 Cap Screw /4 Lock Washer /4 Plan Washer 90 3/8 x -/ (NC) Gr.5 Cap Screw /8 Lock Washer /8 (NC) Nut a-rng a-rng Dash Bracket Bag (not shown) " Lft Cylnder Assy - XL 9 07 " Angle Cylnder Assy - XL Flter Kt Control Hamess--Clutch & Solenod Valve 3 89 Solenod Control Bolt Bag for Clevs Pn - 00 x 3-5/ Anchor Pn - ad x Bolt Bag - Part of /4 x -/ Cotter Pn /4-6 O-Rng to 3/8 NPT Swvel Elbow /4" Hex Male Npple, /4 NPT x 90 Unon Elbow Qul - /4 NPT to 3/8 I D Hose Qul- 3/8 NPT to /D Hose /4 Npt x 90 Street Elbow Hose Dsconnect Assembly Dust Plug - Closure/Male Grommet - Rubber, Splt Grommet - Splt Hose (not shown) Delectrc Grease Tube (not shown) M 560 n-lne Connector Female Connector (not shown) Male Connector (not shown) Page 5 FISHER ENGINEERING, ROCKLAND, ME 0484 Subject to Change n /96

6 75538 Page 6 Ref' Assy Comp Part Lst Electrc Clutch Pecular Hydraulc Kt Qty Part # Descrpton Hose - 36" HP, /4P to /4P Hose - " HP, /4P to /4P Hose - 78" HP /4P to /4P Hose - 66" HP /4P to I4P Hose - 30" HP /4P to 3/8P 3/8" Hose - 66" LP 3/8" Hose - 54 LP /" Hose - 58 LP 54 V-Belt (not shown) Drve Sheave Pump Bracket Reservor Bracket Reservor Brace Valve Plate - Sol valve Brace - Short Cauton Label Bolt Bag for 7553B /4 x 45 Deg Street Elbow Qul- /4 Nptf to 3/8 ID Hose /4 NPT x 90 Deg SVV ADT Unon /4 NPT x 90 Deg Street Elbow /4 x 45 Deg Street Swvel Bracket - Cable Boot Cable Boot Bulkhead Adapter 7/8" Snap Rng - External Bowed QD/Electrc Grle Plate (short) QD Grle Plate (short) Stand off Leg 4 x / (NC) Button Head Cap Screw /4 (NC) Locknut Te Wrap - 3/6 x 4 Te Wrap - 3/6 x 8 (not shown) Fan Spacer -.5 Splt Hose Grommet (3/8 x 6) 38 x -/4 (NC) Gr.5 Cap Screw ZP 3/8 Lock Washer 3/8 Plan Washer 5/6 x (NC) Gr.5 Cap Screw 5/6 Lock Washer 5/6 (NC) Nut 5/6 Plan Washer M0 x.5 x 90 Hx CS Gr. 0.9 Ny P M 0 SP Lock Washer ZP M8 x.5 x 50 Ob End Stud G0.9 M0 x.5 x 30 HX CS G8.8 ZP/PL M8 x.5 x 30 HX CS G8.8 ZP/PL M8 x.5 Hx Nut G8.8 ZP/PL M8 SP LK Washer ZP/PL FISHER ENGINEERING, ROCKLAND, ME 044 Subject to Change n/96

7 Installaton Instructons Page 7 Note: The 0850 Fsh-Stk /ClutchRelay Kt s requred for nstallatons that wl use the 9400 Fsh-Stk Push Button Hand-Held Control.. Cylnder and Cylnder Hose Assembly A. Attach female half of dsconnect (44) and a /4" Npt 450 street elbow (87) to " Hp Hose (7). Usng bench vse to hold lft cylnder (8), remove closure from port and screw the other end of the hose drectly nto ths port. Place lft cylnder wth hose pontng to passenger-sde nto ears on lft arm and upper gear. Secure wth clevs pns (34) and cotter pns (37). B. Attach male half of quck dsconnect (44) to one end of a 36" Hp hose (70). Place a dust cover (45) on the end of the other 36" Hp Hose (70) and put another male half of a dsconnect (44) on ths hose. C. Usng a bench vse to hold angle cylnders (9), remove closures from ports. Screw brass forgeçlstreet ells (43) nto ports. Ells should pont forward toward lve end of cylnder and slghtly upward as they wl be nstalled on the A-frame. The drver-sde cylnder uses the 36" HP hose wth the dust cover and male dsconnect half. The passenger-sde uses the 36" Hp hose wth the male dsconnect half and no dust cover. Ths male half wl be plugged nto the female half on the lft cylnder for storage. Install cylnders to ther respectve sdes so that ells are between the cylnders and the A-frame. Secure cylnders wth anchor pns (35) at both ends, wth cotter pns (37) n each anchor. loosenng preventon compound (such as "Lock-tte") to an drve sheave fasteners pror to nstallaton. Note: Apply a removable. Drve Sheave Installaton A. Remove top secton of fan shroud, loosen serpentne belt from dler pulley and remove fan. Save fasteners. Remove and dscard cap screws holdng the vehcle crank pulley to the crankshaft. Poston drve sheave (79) over holes n crank pulley and fasten drve sheave and crank pulley to crankshaft usng four M0 x.5 x 90 Gr. 0.9 Nylock cap screws () and four M00ck washers (3). Torque these fasteners to 7 N-m (53 ft-ibs) whle makng sure lock washers seat properly on the sheave. Cauton: Before nsertng bushng, check center of crankshaft for rust or any foregn materal and remove. METRIC - COARSE FASTENER TORQUE (N-M) GRADE NOM. SIZE- 0 r6 PITCH..'.. B.B ' al0 B. Remove and dscard the four studs from the water pump shaft flange. Install the four longer M8 studs (4) by screwng the end wth the short thread nto the holes n the water pump shaft flange. Replace the water pump sheave over the studs, add the fan spacer (03) and renstall the fan wth the orgnal nuts torqued to 36 N-m (7 ft-lbs). 3. Pump-Clutch Assembly and Pump Bracket A. The pump plate (4) needs to be modfed. Cut the end of the pump plate off as shown n the lustraton to the rght. Remove any slag or burrs left on the plate from the cuttng process. Remove and save the two bolts holdng the pump to the pump plate. Rotate the pump n the plate as shown n the lustraton on page. The relef port should pont toward the mountng slots. Attach the pump plate to the pump. CUT PUMP PLATE AS SHOWN FOR PROPER FIT-UP TO PUMP BRACKET 6 / FISHER ENGINEERING, ROCKLAND, ME 0484 Subject to Change n /96

8 Installaton Instructons Page 8 B. Lookng down on the pump-clutch assembly () wth the 'n' sucton port up, nstall a 3/4 o.nng to 3/8 Npt swvel elbow (38) nto the pressure 'out' port. Poston the 3/8 Npt swvel elbow (38) to 5:00 wth the pump shaft as a :00 reference. Install the other 3/4 o-rng to 3/8 Npt swvel elbow (38) nto the sucton 'n' port. Poston t to 0:00. Lock the fttngs n ther proper orentaton wth the jam nuts. Attach a /" qul (4), from the common kt, nto the sucton fttng. Install the 58" long /" LP hose (77) onto the qull. Install the /4" hex male ppe npple (39) nto the relef port and attach the /4" unon elbow (40) so that the elbow outlet ponts toward the back of the pump. Inserr the 3/8 qul (4) nto the elbow (40). Attach the 66" long 3/8" LP hose (75) onto the qull. Screw the 38" end of the 30" /4" to 3/8" HP hose (74) nto the pressure fttng. Make sure all fttngs are tght. C. Remove and dscard the two vehcle fasteners on the drver-sde of the engne that are holdng the top radator hose bracket. Algn the pump bracket (80) over the two unused tapped holes and the two holes just vacated. Poston the radator hose bracket between the pump bracket and the accessory grdle and attach the pump bracket usng four M 0 x.50 x 30 cap screws (5) and M 0 lock washers (3). Tghten all fasteners. D. Mount the pump-clutch assembly to the pump bracket usng the bottom 3/8 x -/4 (NC) Gr. 5 CËP screw (05),3/8 flat washer (07) and 3/8 lock washer (06) only at ths tme. Place the 54" V-belt (78) over the drve sheave, rotate the pump assembly down and place the belt over the clutch sheave. Rotate the pump assembly back up and nstall the top 3/8 x -/4 (NC) Gr. 5 cap screw (05),3/8 flat washer (07) and 3/8 lock washer (06). Tghten the V-belt beng careful to poston the pump plate so as to leave adequate space between the V-belt and other engne components, partcularly the center hub of the power steerng sheave. Tghten all fasteners. 4. Solenod Control and Harness Installaton INote: Use delectrc grease (48) to prevent corroson on all under hood electrcal connectons. l Fl receptacles and lghtly coat rng termnals and blades before assembly. A. Check both sdes of fre wall for wres and ' hot or movng engne parts. Then, on the drver sde, drl a 5/8" hole n the fre wall for the control harness (3). B. Install the solenod control (3) and dash bracket as per the nstructons found n the dash bracket bag (7) located n the common hydraulc bolt bag. C. Remove negatve battery cable from battery. Warnngl Dsconnect battery before nstallng, removng or replacng electrcal components. D. Insert the control harness (3) through the hole dnlled n the fre wall. Attach the connector to the plug on the solenod control. Connect the red wre from the fuse holder to a crcut whch s on' only when the /"',.,, /" TO HEADLAMP RELAY TERMINAL *85 (EITHER OND! TO BLACK/ORANGE 'WIRE ON VEHICLE HARNESS REMOVED rrom TERMINAL *'85 gnton key s on. Use an n-lne connector (49). Route the man porton of harness (whte, green, blue and black wres) to the valve. Place a grommet (46) around control harness where t passes through fre wall. Remove the plastc cover from the valve. Install the solenod wres accordng to the nstructons nsde the cover. Install the cover wth the harness stran relef n place nsde. Attach orange/black (black) wre wth rng termnal extng loom near valve to a good vehcle ground. Route the porton of the harness wth the brown/red and black/orange wres wth female spade termnals to electnc clutch. Note: Install the 0850 Fsh-Stk /Clutch Relay Kt at ths tme, f necessary. FISHER ENGINEERING, ROCKLAND, ME 0484 Subject to Change n/96

9 Installaton Instructons Attach female spade termnals to clutch plug (brown/red to black wth whte strpe and black/orange to black). Fasten other black/orange wre wth female spade connector to head lamp relay and male spade connector to black/orange ground wre from vehcle harness. See Dagram. Note: The relay and vehcle harness are found n the pecular lght kt. E. Install plow headlamps accordng to the lght kt nstructons. Stretch the rectangular openng of the plug cover strap (from lght kt) over grlle connector ends of the long battery cable (from hydraulcs box) and vehcle harness (from lght kt). Place the plug cover over the mold on the harness. F. Reconnect negatve battery cable to battery termnal. BEFORE a ~ am ~30 /86 85 HEADLAMP RELAYS '" ~ :: 86 n 85 U30 BLACK/ORANGE FROM FE VEHICLE HARNESS AFTER Page 9 'í ~ am ~30 /8685 HEADLAMP RELAYS "'~: 86 lo 85 Dagram BLACK/ORANGE rrom FE CLUTCH HARNESS CONNECT BLACK/ORANGE FROM FE VEHICLE HARNESS 5. Valve and Valve Plate A. Fasten the solenod valve assembly (3) to the valve plate (83) wth two 5/6 x (NC) Gr. 5 cap screws (08), lock washers (09), and nuts (0), as per the lustraton. Fasten the four valve plate brackets (84) to the valve plate, as per the lustraton, usng 5/6 x (NC) Gr. 5 cap screws (08), lock washers (09), and nuts (0). Tghten the fasteners. B. The valve plate assembly wl be mounted to the drver-sde fender n the openng behnd the battery. The valve cover wl pont toward the fre wall. Set the valve assembly n ths space and mark the fender for the locton of the mountng holes. Drll four /3" holes n the fender, as marked, and attach the valve plate assembly to the fender wth four 5/6 x (NC) Gr. 5 cap screws (08), flat washers (), lock washers (09) and nuts (0). C. Screw two 90 swvel fttngs (89) nto the two angle cylnder ports and the lft cylnder port wth the fttngs ponted as per the lustraton. Screw a 45 swvel fttng (9) nto the pressure port. Screw a 3/8" qul (88) nto a 90 street elbow (90) and screw the street elbow nto the return port. Poston these fttngs accordng to the lustraton. NC FASTENER TORQUE (FT -LB) DIAHETER- GRADE THREADS 0ø J... PER INCH G G5 G8 / / / / /6-66 HO 65 5/ / / Ol Reservor Cauton: Reservor tank fll must be vertcal to engne. A. Attach the remote reservor bracket (8) to the passenger sde battery box usng the two exstng holes n the webbng below the battery. The bracket wl need to be placed behnd the ar-condtonng "hgh sde" lne. Attach the bracket wth two 5/6 x cap screws (08), lock washers (09) and nuts (0). On some vehcles the holes under the battery, whch are used to mount the remote reservor, are already beng used to hold a stffener between the battery box and the head lamp webbng. In ths case remove the battery and battery box wth the stffener attached. Replace the two fasteners holdng the stffener to the battery box wth two M8 X.5 X 30 cap screws (6) and a 5/6" flat washer () under the head of the fastener. These fasteners wl be used as the mountng "studs" for the reservor mountng bracket. Renstall the battery box and battery. Instan the remote reservor bracket (8) to the two "studs" wth M8 nuts (7) and M8 lock washers (8). FISHER ENGINEERING, ROCKLAND, ME 0484 Subject to Change n/96

10 Installaton Instructons Page 0 Note: Be sure to solate and secure the ar-condtonng "hgh sde" lnes from the reservor bracket to elmnate rubbng. Temporarly attach the remote reservor () and remote reservor brace (8) to the remote reservor bracket (8) wth two 5/6 x cap screws (08), lock washers (09) and nuts (0). Poston the reservor so there s no contact wth any vehcle equpment. The postve battery connectons may need to be repostoned to elmnate any rubbng on the reservor. Locate a fastenng pont between the battery and the ar flter box for the reservor brace (8) and mark the fender. Drl a /3" hole as marked and fasten the brace to the fender wth a 5/6 x cap screw (08), flat washer (), lock washer (09) and nut (0). Tghten all fasteners. Screw a /" qul (4), from the common kt, nto the threaded port of the reservor. B. Tghten the serpentne belt and renstall the top half of the radator shroud. The clp holdng the negatve battery cable, that goes across the top of the shroud, should be fastened wth the outer shroud hold down bolt on the drver sde n order to keep t away from the hydraulc pump clutch. 7. Hydraulc Hose Installaton Cauton: Keep hoses away from hot or movng engne components. Faure to do so may cause hose to burst resultng n a possble engne fre. Note: Do not shorten LP hoses. Bends n all hoses must have suffcent radus to prevent crmpng. A crmped hose may cause overheatng of the hydraulc system, hose falure, and possbleengne fre. J A. Route the loose end of the pump pressure hose (74) to the 45 swvel fttng n the pressure port on the valve and tghten the fttng. Route the loose end of the pump relef hose over the top of the radator shroud to the top 3/8" qul on the reservor. Route the pump sucton hose over the top of the radator shroud and nstall t onto the " qul screwed nto the reservor. Install one end of the 54" 3/8" LP hose (76) onto the bottom 3/8" qul of the reservor. Route the loose end over the top of the shroud and nstall t onto the qul n the return port on the valve. B. Install the n-lne return flter accordng to the nstructons locted n the flter kt (30). The flter kt s located n the common hydraulc kt. The best locaton for the flter s on the drver-sde of the vehcle between the valve and the top radator hose. Use the plastc tes (0) to bundle and/or solate any hoses from movng or hot engne and vehcle parts. C. Remove the grlle and route the three cylnder hoses (7,7, 73) through the gap between the head lamp webbng and the drver-sde fender. Route the three hoses over the drver-sde battery to the valve. The 66" hose (73) goes to the drver-sde angle cylnder port. The two 78" hoses (7) go to the passenger-sde angle port and the lft cylnder port. When the hoses are tghtened nto the approprate valve ports, place a length of the splt radator hose (47), from the common kt, between the cylnder hoses and the head lamp webbng. Ths s very mportant due to the sharp edge of the head lamp webbng. D. Attach the female half of a quck dsèonnect (QD) (44) to one hole n the two QD grle plate (97) wth a snap rng (95). Attch the bulk head adapter (94) to the other hole n ths grle plate wth another snap rng (95). If the vehcle does not need the stand off legs on the grle plates, nstall a /4 x 90 degree swvel fttng (89). wth dust plug (45), nto the female QD. Install a /4 x 90 swvel fttng (89), wth dust plug (45), nto the bulk head adapter. Install a male ad half (44) to the bulk head adapter (94). Attach the passenger-sde angle cylnder hose to the female ad and the lft cylnder hose to the bulk head adapter. Attach the grlle plate assembly to the grlle wth plastc tes (0). The female ad should be placed toward the outsde of the vehcle. I Note: wth Some four GMC /4 models x / socket wth a head fne mesh cap screws grje may (9) have and locknuts to use stand (93) off on legs each (86) grle fastened plate. FISHER ENGINEERING, ROCKLAND, ME 0484 Subject to Change n/96

11 Installaton Instructons Page E. Attach a female ad half (44) to the QD/Electrc grle plate (96) wth a snap rng (95). If the vehcle does not need the stand off legs on the grle plates, put a dust plug (45) on the end of a 90 degree swvel fttng (89) and screw t nto the female QD. Screw the drver-sde angle cylnder hose (73) nto the 90 fttng. Slde the head lamp connector nto the slot on ths grle plate. Attach the grlle plate assembly to the grle wth plastc tes. The QD should be placed to the outsde of the vehcle. Renstall the grle. F. Install cable boot bracket (9) on drver-sde headgear brace, between brace and fasteners. Insert cable boot (93) on over bracket. G. Algn all the fttngs on the valve and make sure they are tght. 8. OPERATIONS A. Check all fttngs and fasteners for tghtness. Secure hoses wth nylon te wraps (0). Place Cauton Label (85) on the dash besde the control. B. Attach the hose dsconnects, push lft arm all the way down and fll reservor wth FISHER. Hgh Penormance Hydraulc Flud (recommended for superor cold-weather performance) or type "A" automatc transmsson flud. Start engne. Lft and angle blade several tmes. If blade angles opposte from control lever poston, reverse the two angle hoses at the valve. Rase front end of vehcle untl plow s clear of ground, wth lft cylnder fully retracted. Check reservor ol level. Angle blade (wth lft cylnder retracted) to remove ar from system. Recheck reservor ol level. Note: The nstaller must nform the end user of the proper procedure for removng any resdual hydraulc pressure that may be trapped n the rase or angle hoses. The plow wl be much easer to nstall or remove f the proper procedures are followed. Before couplng or uncouplng the hydraulc dsconnects you must turn off the engne and then turn the key to the Ron" poston (the red LED lght wl be lt). Move the control to the four plowng postons. Actvate lower/float before removng or nstallng the plow. FISHER ENGINEERING, ROCKLAND, ME 0484 Subject to Change n96