INSTALLATION AND PARTS MANUAL

Transcription

1 INSALLAION AND PARS MANUAL FOR D8R SERIES II RACORS ABLE OF CONENS Foreword Installation Instructions Winch Mounting and Motor Lines Group Drawing Pilot Lines and Winch Lines Group Drawing Manifold Assembly Hydraulic Circuit Motor Group Brake Valve Assembly MODEL NUMBER DESCRIPION H110VS 245 V 65/33 3 Basic Overall Motor ype Motor Size Fairlead Winch Gear Ratio V - Variable Cu. In. 3-3 roller Model 245:1 Displacement Displacement 4-4 roller per revolution 6.5 cu in. (High) 3.3 cu in. (Low) PRINED IN U.S.A. COPYRIGH 2003 PACCAR WINCH DIVISION. ALL RIGHS RESERVED. PACR WINCH DIVISION P.O. BOX 547 BROKEN ARROW, OK U.S.A PHONE (918) FAX (918) LI2139 REV 2 10/2003

2 WINCH INSALLAION FOREWORD his manual includes parts listings and installation information for the H110VS winch for use on the CAERPILLAR D8R Series II tractor. Continuing product improvement may cause changes in your PACCAR built winch, which may not be included in this manual. If a question arises regarding your winch or this manual, contact your nearest CA dealer, or the PACCAR WINCH DIVISION PRODUC SUPPOR DEPARMEN at , Monday Friday, 0800 hrs 1630 hrs CS, or by fax at Please provide the complete winch MODEL number and SERIAL number when making inquiries. INSALLAION INSRUCIONS CAUION Cleanliness is of utmost importance when working on hydraulic equipment. Contamination may cause damage to close tolerance hydraulic components, which may result in erratic operation and reduced service life. tractor master electrical switch off. 1. Drain the tractor hydraulic oil into a suitable container. Recycle or dispose of used oil in an environmentally responsible manner. Securely install the hydraulic reservoir drain plug after draining. 2. Clean all paint, oil, grease, rust and dirt from the mounting surfaces of the winch, winch adapter brackets and tractor rear face. Personal injury can result from the sudden release of hydraulic oil under pressure or hot oil. Hydraulic oil pressure can remain in the hydraulic system after the tractor engine has been stopped. Serious injury can be caused if this pressure is not released before performing any service on the hydraulic system or equipment. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with the bare hand. Winch weighs approximately 3,950 lb (1,790 kg), without wire rope and mounting adapters. Make certain that lifting equipment has adequate capacity. Failure to use adequate lifting equipment may result in property damage, personal injury or death. NOE: Refer to the appropriate Caterpillar service manuals for additional information regarding service procedures to the tractor. o prepare the tractor for service, lower the blade to the ground. urn the engine off and relieve any oil pressure in all tractor circuits as required. Relieve oil pressure in the hydraulic reservoir by opening the fill cap. urn the Winch adapters weigh approximately 340 lb (154 kg) each. Make certain that lifting equipment has adequate capacity. Failure to use adequate lifting equipment may result in property damage, personal injury or death. 3. Attach winch adapters, items 21 and 22, to the tractor rear face with bolts, item 20. Apply Loctite 272 or equivalent to bolt threads. Leave bolts loose at this time to aid alignment of winch to adapters. 4. Carefully hoist the winch and install to the winch adapters, using bolts, item 20. Apply Loctite 272 or equivalent to bolt threads. 5. orque all winch mounting bolts to 1,100 lb ft (1,500 N m). 6. Remove and discard the motor port cover plate and bolts on the upper port of the winch motor. 7. Attach one end of the REEL-OU hose, item 5, to the manifold at the upper motor port. Use split flange halves, item 1, D-ring, item 4, and fasteners, items 2 and 3. orque bolts to 50 lb ft (70 N m). Attach the opposite end to the LH port of the manifold, utilizing hardware previously defined and new D-ring, item Attach one end of the REEL-IN hose, item 7, to the port in the brake valve on the lower motor port, utiliz- 2

3 WINCH INSALLAION ing adapter, item 6. Attach the opposite end to the RH port of the manifold, utilizing the hardware defined previously and new D-ring, item Install MOOR SHIF hose, item 9, to the 4 elbow in the X port on the forward side of the winch motor. Install the opposite end to the X port on the lower surface of the manifold, using 4 elbow, item Install DRUM CLUCH RELEASE hose, item 10, between the elbow located on the RH side of the winch case and the port of the manifold, using 6 elbow, item Install MOOR DRAIN hose, item 12, between the 8 elbow located on top of the motor, and to the port on the manifold, utilizing the 8 elbow, item Route the hoses approximately as shown and bundle them together utilizing the clips, 16 and 17, fasteners, items 14 and 18, and spacer, item 15. Attach the clip set to the winch case and tighten the bolt snugly. CAUION Fill winch with to proper level with recommended oil BEFORE operating. Component damage may occur if winch is operated without oil. NOE: After winch and controls installation has been completed, refill the tractor hydraulic reservoir with the proper lubricant. Refer to the appropriate Caterpillar service literature for the oil specs. Start the tractor engine and operate at low engine idle to purge air from the hydraulic lines. Operate the winch in all functions to verify proper operation. Check all connections for leaks and make any needed repairs. Check the hydraulic oil reservoir level. Add oil as needed to maintain the level at the FULL mark on the sight gauge. IEM NO. PAR NO. DESCRIP ION QY SPLI FLANGE HALF BOL (7/16-14 UNC X 2-3/4 G8) WASHER, HARD (7/16) D-RING HOSE AS ADAPER HOSE AS HOSE AS HOSE AS ADAPER HOSE AS ADAPER BOL (1/2-13 UNC X 3 G8) SPACER 1 16 PA6D7573 CLIP CLIP WASHER, HARD (1/2) ADAPER BOL (1-1/4-7 UNC X 3-1/2 G8) RH ADAPER LH ADAPER DRAWBAR PIN COER PIN 2 3

4 MOUNING GROUP/MOOR LINES GROUP MOOR CASE DRAIN POR (REF) 12 DEAIL C NO O SCALE C 18 4 DEAIL A NO O SCALE 5 D D A R/O R/O DEAIL B NO O SCALE R/I B R/I 13 X REF: MANIFOLD ASSEMBLY MOUNING POSIION WINCH MOUNING HOLES 1-1/4-7 UNC HOLES 14 PLACES, AS SHOWN RACOR REAR FACE 6 VIEW D D NO O SCALE 7 4

5 PILO LINES AND WINCH LINES GROUP F SEE NEX PAGE IMPLEMEN CONROL LEVER D F DOZER CONROL LEVER H CSEE NEX PAGE C SECION D-D D E G SEE NEX PAGE G SEE NEX PAGE (2) (2) H E B A (8) (8) (2) (4) (4) (4) LEF SIDE VIEW (2) 167 A B (8) (8) (2) (4) R/I POR R/O POR (2) (4) (8) (8) POR "P" POR "" POR "" 142 POR "X" SECION A-A SECION B-B 203 AUXILIARY VIEWS AA BB CC DD EE FF GG HH MANIFOLD MANIFOLD CONSOLE BOOM CONSOLE FRON OP INERIOR OP VALVE BOOM ACCUMULAOR IEM 117 NO SHOWN FOR CLARIY SECION H-H 5

6 PILO LINES AND WINCH LINES GROUP SECION F-F FROM PREVIOUS PAGE SECION E-E FROM PREVIOUS PAGE LOW LOCK LED JOYSICK SWICH #1 BLACK ORANGE DOZER PILO VALVE AACH O BRACKE ASM. FROM BAERY WIRING GP. CONROL POR 1 (IEM 107) SUPPLY POR (IEM 120) ANK POR (IEM 121) CONROL POR 2 (IEM 115) BALL VALVE P ACCUMULAOR SECION C-C FROM PREVIOUS PAGE CONROL POR 4 (IEM 117) (2) SECION G-G FROM PREVIOUS PAGE PURPLE BLACK (3) 1 #2 + - ORANGE RED #2 #1 +24V DISABLE SWICH POWER RED BLACK #2 #1 #1 #4 LOW LOCK SOLENOID DISABLE SOLENOID ELECRICAL CIRCUI NOES: Install low speed light next to existing light on console cover. For installation of decals on plastic parts, clean area with isopropyl alcohol and apply decal as soon as area dries (3)

7 PILO LINES AND WINCH LINES GROUP IEM NO. PAR NO. DESCRIP ION QY. 1 PA JOYSICK CONROL AS INDICAOR LIGH, GREEN PA HOSE AS PA HOSE AS PA HOSE AS PA HOSE AS PA UBE AS PA UBE AS PA HARNESS CONNECOR PA ELBOW ELBOW ELBOW BOL (3/8-16 x 1 in. G8) PA5K5338 CLIP BOL (3/8-16 x 1-3/4 G8) HEX NU (3/8-16) PA8M2773 CLIP WASHER, HARD (3/8) SRAP PA HOSE AS MANIFOLD & CARRIDGE AS. (REFER O PAGE X) PA HARNESS PA HOSE AS PA HOSE AS ADAPER PA REDUCER, ORFS PA EE, ORFS SEAL, D-RING SPLI FLANGE HALF SPLI FLANGE HALF O-RING BOL (7/16-14 X 1-3/4 G8) PA81891 CLIP PA81892 CLIP WASHER, HARD (7/16) BOL (3/8-16 X 1-1/4 G8) PA HOSE AS CONROL VALVE SECION PA ROD PA4J0522 O-RING PA4J8997 O-RING PA6V0913 O-RING PA6V5555 O-RING 2 - PA DECAL 1 - PA DECAL 1 7

8 MANIFOLD ASSEMBLY (1.06 MAX) (1.85) 11 6 R/I POR 1.0 SPLI FLG. POR "P" -6 ORB R/O POR 1.0 SPLI FLG. 1 (1.81 (.66) POR "X" -4 ORB POR "" -8 ORB (3.00) POR "" -6 ORB (7.75) REF.-DUAL SPLI FLANGE PAERNS X RI -16 RO -16 P -8-6 RI -16 RO -16 HYDRAULIC CHAR IEM NO. PAR NO. DESCRIP ION QY MANIFOLD AND CARRIDGE AS SOLENOID VALVE AND ERMINAION AS. - LOW RANGE LOCK SOLENOID VALVE CARRIDGE AS SEAL KI (FOR 29820) COIL (FOR 29820) MANIFOLD PLAE WASHER, HARD (1/2) BOL (1/2-13 X 1-1/4 G8) 2 6 PA4P8571 CLIP 1 7 PA5P8167 BOL (3/8-16 x 5/8 G8) WASHER, HARD (3/8) RECEPACLE (FOR 82213) WEDGE, CONNECOR (FOR 82213) CONAC PIN (FOR 82213) 2 8

9 HYDRAULIC CIRCUI BRAKE VALVE WINCH HYDRAULIC SYSEM X REEL-IN "BR" REEL-OU "BR" "DRAIN" X WINCH BRAKE DRUM CLUCH "" CABLE DRUM PA57VS & PA58VS WINCHES MANIFOLD RACOR HYDRAULIC SYSEM B B P A PILO PRESSURE SUPPLY WINCH CONROL SECION (MOOR SPOOL) EXISING RACOR CONROL VALVE (SIMPLIFIED CIRCUI) RI RI RO RO X P 9

10 MOOR GROUP IEM NO. PAR NO. DESCRIP ION QY HYD MOOR, 3.34 CID / 3100 PSI CAPSCREW, 3/4-10 UNC X 1-3/4 G WASHER, HARD (3/4) CAPSCREW, 7/16-14 UNC X 3 in. G8, HEX SOCKE BRAKE VALVE AS (REFER O PAGE X) O-RING O-RING ADAPER BLOCK ADAPER, MERIC EE ELBOW, ADAPER HOSE AS HOSE AS ELBOW, SPACER CHECK VALVE ELBOW, ELBOW, HOSE AS EE HOSE AS ELBOW, HOSE AS EE BRACKE CAPSCREW, 1/4-20 UNC X 1-3/4 G HEX NU, 1/4-20 UNC WASHER, HARD (1/4) 2 10

11 BRAKE VALVE ASSEMBLY SAE -12 O-RING BOSS (1 1/16-12 SR HRD) BRAKE POR SAE -4 O-RING BOSS (7/16-20 SR HRD) ASSEMBLY INSRUCI0NS 1. ighten plug, item 19, to 25 lb ft (34 N m) torque. 2. ighten plugs, items 2, 3, and 4, to 40 lb ft (54 N m) torque. IEM NO. PAR NO. DESCRIP ION QY BRAKE VALVE AS. 1 1 NSS BRAKE VALVE HOUSING VALVE SPRING REAINER SPRING REAINER PLUG 1 5 NSS SPOOL SPOOL SOP O-RING CHECK VALVE POPPE PILO ORIFICE CHECK VALVE SPRING SPRING, MAIN SPOOL O-RING O-RING BACK-UP RING PLUG SHIM, SPOOL SPRING AR NSS - NO SERVICE SEPARAELY AR - AS REQUIRED 11