INSTALLATION AND PARTS MANUAL

Transcription

1 INSTALLATION AND PARTS MANUAL MODEL PA56 WITH ELECTRONIC CONTROLS FOR D6R SERIES III & D6T TRACTORS SEBP TABLE OF CONTENTS Mounting Group Control Group Electric Connections Bevel Gear Group...0- Case and Covers...2- Clutch Shaft Group Clutch Assembly... 6 Brake Assembly... 7 Fourth Shaft Group... 8 Idler Shaft Group w/freespool... 9 Hydraulic Control Group Control Valve Assembly... 2 Cable Drum Group Freespool Cylinder Assembly Pump Group Accumulator Assembly Fairlead Assembly MODEL NUMBER DESCRIPTION PA56 B E Basic Winch Model Bevel Gear Ratio B-.27: E-2.78: 0-Overwind 0-Standard Brake -With Freespool 0-Four Shaft Winch 0-No Fairlead - Roller Fairlead 4-4 Roller Fairlead E-Electronic Control PRINTED IN U.S.A. 202 PACCAR Inc All Rights Reserved WINCH P.O. Box 547 Broken Arrow, OK 7402 Tel / Fax LIT229 R6 7/202

2 PA56 MOUNTING GROUP D6R III & D6T A A B TRACTOR PTO SHAFT (REF.) 9 0 VIEW A-A C L TRACTOR WINCH MOUNTING HOLES "-8 UNC-2B, 0 PLCS 5 VIEW LOOKING AT TRACTOR REAR FACE 2

3 PA56 MOUNTING GROUP D6R III & D6T ITEM NO. PART NO. DESCRIPTION QTY STUD ( - 8 X -/4 G8) 0 2 8S-5654 O-RING RETAINING RING PTO SHAFT COUPLING 6 7X-0406 CAPSCREW, HEX HEAD ( - 8 X G8 Z) 4 7 4J-5977 NUT, HEX (-/8-7) STUD (-/8-7 X 4-/4) ADAPTER, RH ADAPTER, LH PILOT, PTO 2 5P-2228 CAPSCREW, HEX HEAD (/2 - X G8 Z) 4 7X-05 WASHER, HARDENED (-/8) 4 4 6V-890 NUT, HEX ( - 8) 0 5 W-56 ECOLOGY DRAIN GROUP (INCLUDES ITEMS 5A, B & C) 5A W-57 GUARD 5B 8T-56 WASHER, HARDENED () 8 5C 7X-0400 CAPSCREW, HEX HEAD ( - 8 X -/2 G8 Z) 4 MOUNTING GROUP INSTRUCTIONS. PTO rotation is counterclockwise (CCW) as viewed from the rear of the tractor. Remove the tractor PTO cover. 2. Remove paint, dirt, rust, oil and grease from mounting surfaces of tractor, winch and winch adapters. If this material is left between the mounting surfaces, movement of the clamped members will result in loosening mounting fasteners and possible fastener or mounting component failure.. Coat splines of PTO shaft (4), with multi-purpose grease and install into bevel pinion gear of winch. 4. Install retaining rings (), in coupling (5). Trial fit the coupling onto the tractor PTO shaft and the winch PTO shaft to make certain the splines fit well and there are no rough areas on either shaft that need to be smoothed. Install coupling onto winch PTO shaft with deepest bevel end away from winch. 5. Install O-rings (2), onto PTO pilot (). NOTE: As the same PTO pilot may be used on several adaptations, typically only one O-ring groove will engage and seal in the tractor PTO opening. 6. Apply Loctite 27, 277 or equivalent to threads and install studs (8) into winch adapters (9, 0) to a height of 2-5/8 in. (67 mm). 7. Apply Loctite 242, 24 or equivalent to the threads of capscrews (6), and studs (8). Install the winch adapters (9, 0) onto the winch then install capscrews (6), washers () and nuts (7) onto studs (8). At this time, only lightly hand-tighten the capscrews (6), and nuts (2). 8. Fill winch to proper level with recommended oil. Winch weighs approximately 2500 lb (4 kg) without oil, cable or tractor adapters. Make certain lifting equipment has adequate capacity to eliminate the possibility of damage or injury. Attempting to lift the winch with inadequate equipment may result in personal injury or property damage. DO NOT start the tractor engine until the winch has been filled to the proper level with the recommended oil. Bearing and gear damage may result if the tractor is run without oil in the winch.

4 PA56 MOUNTING GROUP D6R III & D6T There are two methods that may be used to install the winch with adapters onto the rear face of the tractor: Method A: Involves removing winch guards and covers to gain access to the bevel gears. A. Apply Loctite 27, 277 or equivalent to clean, dry threads and install studs () into rear face of tractor until they bottom in the stud bores but no lower than a height of.80 in. (46 mm) measured from the machined surface of the tractor rear face mounting pads to the end of the stud. A2. Apply general purpose grease to the PTO pilot o-rings. Lift winch into position and install onto rear of tractor taking care to guide the PTO shaft/coupling onto the tractor PTO shaft. It may be necessary to rotate the winch bevel pinion gears to align the winch shaft with the tractor shaft. It will be necessary to remove the guard group and top cover from the winch to gain access to the bevel gears. A. Apply Loctite 242 or 24 to clean dry threads of studs () and install nuts (4). NOTE: Keep the winch in a level position to avoid binding of the PTO pilot and shafts. With the weight of the winch supported by the hoist, use a cross pattern to evenly tighten all mounting fasteners to approximately 25% of the recommended torque. Start the tractor engine and listen for any unusual gear train noise that would indicate binding in the PTO shafts or gear train. If no unusual noises are detected, remove the hoist from the winch and continue to evenly tighten all mounting fasteners to recommended torque. Tighten nuts (7) & (4) to 600 lb.ft. (85 N m) torque. Tighten capscrews (6) to 680 lb ft (920 N m) torque. If torque wrench adapters are not available for tightening the nuts (7, 4) they may be tightened as follows: Tighten nuts with a hand wrench to approximately 00 lb.ft. (6 N m) torque to remove all looseness from the assembly. Mark the position of a wrench flat on each nut, then tighten each nut one () additional wrench flat. Method B: Does not require removal of guards and covers from the winch. B. Apply general purpose grease to the PTO pilot o-rings. Lift winch into position and install onto rear of tractor taking care to guide the PTO shaft/coupling onto the tractor PTO shaft. While the winch is supported on the hoist, slightly rotate the winch case to align the PTO coupling on the winch with the PTO shaft of the tractor. NOTE: Keep the winch in a level position to avoid binding of the PTO pilot and shafts. B2. Apply Loctite 27, 277 or equivalent to clean dry threads and install studs () through winch adapter holes into the tractor rear face. Install the studs till they bottom in the stud bores but no lower than.80 in. (46 mm) measured from the machined surface of the tractor rear face mounting pads to the end of the stud. Apply Loctite 242 or 24 to clean dry threads of studs () and install nuts (4). With the weight of the winch supported by the hoist, use a cross pattern to evenly tighten all mounting fasteners to approximately 25% of the recommended torque. Start the tractor engine and listen for any unusual gear train noise that would indicate binding in the PTO shafts or gear train. If no unusual noises are detected, remove the hoist from the winch and continue to evenly tightening all mounting fasteners to recommended torque. Tighten nuts (7) & (4) to 600 lb.ft. (85 N m) torque. Tighten capscrews (6) to 680 lb ft (920 N m) torque. If torque wrench adapters are not available for tightening the nuts (7, 4) they may be tightened as follows: Tighten nuts with a hand wrench to approximately 00 lb.ft. (6 N m) torque to remove all looseness from the assembly. Mark the position of a wrench flat on each nut, then tighten each nut one () additional wrench flat. After winch is installed on tractor and all fasteners tightened to recommended torque, the bevel pinion must be pried toward the tractor. During installation, the pinion may get driven hard into the bevel gears, taking all end-play out of the pinion bearings and back-lash out of the gear set. Insert a pry bar between the clutch shaft and pinion then pry the pinion toward the tractor. A small amount of gear back-lash should be detected when the pinion moves forward. 4

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6 PA56 CONTROL GROUP D6R III & D6T CONTROL GROUP WITHOUT RIPPER CONTROL B C 7 A 4 4 CONTROL GROUP WITH RIPPER CONTROL NOTES:. TOP OF CONTROLLER SHOULD BEND TOWARD FRONT OF TRACTOR 6

7 PA56 CONTROL GROUP D6R III & D6T CONTROL INSTALLATION INSTRUCTIONS These control installation instructions are provided as a general guide. Tractor options, application requirements or local regulations may require deviation from these recommendations. Stop engine, turn key switch and master power switch off. CAUTION Avoid routing the wiring harness near moving shafts or linkages, which may cause damage to the wiring harness or restrict free movement of tractor components.. Attach dual axis controller (), to controller mounting plate (5), with button head capscrews (6). 2. Remove RH tractor console.. Install harness (4), in tractor as shown. Connect winch and control module ends of harness. Secure winch end of harness with strap, capscrew, washer and wire tie strap (, 2,, 5), as shown. Secure harness at console wall with wire tie straps, as shown. 4. Install decal, and indicator light (7, 0), onto console. 6. Attach dual axis controller and mounting plate to console cover with existing Caterpillar fasteners. 7. Connect controller to control module and secure harness with wire tie straps (). 8. Connect harness spade connectors to indicator light. Red wire must be connected to positive terminal of indicator light. 9. Insure tractor power is off. Connect harness to tractor power supply circuit -pin plug, which is located on right rear side of the fuel tank. 0. Install control decal (8) onto console cover.. Fill the winch to the proper level with recommended oil. Refer to the specifications found in the Operation and Preventive Maintenance Manual, publication SEBU7048 or Service Manual, publication SENR Start the tractor and operate the engine at low RPM for several minutes to allow the winch control system pressure to stabilize. Operate the winch in brake-off for approximately one minute then all functions as instructed in the Operation and Preventive Maintenance Manual, publication SEBU If tractor is equipped with a ripper control assembly, modify console as shown and install spacer (2) with capscrews and washers (, 9) as shown. Install console cover. ITEM NO. PART NO. DESCRIPTION QTY DUAL AXIS JOYSTICK CONTROLLER A BOOT B * CONTROLLER HANDLE DECAL C SWITCH * SPACER, USE W/RIPPER CONTROL 4M-528 CAPSCREW, HEX HD /4-20 X /4 (USE W/SPACER 2) WIRING HARNESS CONTROLLER MOUNTING PLATE 6 8T-994 CAPSCREW, BUTTON HD, 0 X /2, STAINLESS INDICATOR LIGHT, RED CONTROL CONSOLE DECAL 9 5P-057 WASHER, /4 (USE W/SPACER 2) FILTER BYPASS DECAL 5M-062 CAPSCREW, HEX HD, /8-6 X /4 GD 8 Z 2 8T-4896 WASHER, /8 7K-8 WIRE TIE STRAP, BLACK CONTROLLER MOUNTING GASKET 5 4P-758 CLIP * PACCAR Winch Division part number. Caterpillar part number not available at time of printing. 7

8 PA56 ELECTRIC SCHEMATIC D6R III & D6T 8

9 Module and Harness Installation PA56 CONTROL MODULE D6R III & D6T. Mount module by installing self-tapping screw (item 8) using Loctite 222, 242, or equivalent low or medium strength thread locker. 2. Insert wiring harness (pn# 29-74) to winch and control module connectors (9 & 0), as well as in-cab mounted control group. Bundle loose wiring harness leads and secure with tie strap ITEM PART NO. DESCRIPTION QTY UPPER GUARD LH GUARD RH GUARD 4 5P-076 HARDENED WASHER 0 5 5P-2228 CAPSCREW,/2- X HEX HEAD GD8 Z 6 8T-897 CAPSCREW,/2- X /4 HEX HEAD GD8 Z 8 7 5P-2566 CAPSCREW, /2- X /2 HEX HEAD GD8 Z 8 7H-454 SELF TAPPING SCREW HARNESS CONNECTION, CONTROL TO MODULE HARNESS, MODULE TO WINCH CONTROL MODULE 9

10 PA56 BEVEL GEAR GROUP D6R III & D6T (S/N AND BELOW) ITEM PART NO. DESCRIPTION QTY BEARING ASSEMBLY BEARING LOCKNUT 8T-897 CAPSCREW, HEX HEAD (/2 - X -/4 G8 Z) BEARING LOCKWASHER O-RING DOWEL PIN RETAINING RING OIL SEAL SEAL SPACER SLEAVE PUMP DRIVE PINION SHIM GASKET BEVEL PINION CARRIER SHIM.005 in. (. mm) 2-AR SHIM.007 in. (.8 mm) 2-AR SHIM.020 in. (.5 mm) 2-AR BEVEL PINION - 26T (B RATIO) STANDARD SPEED BEVEL PINION - 4T (E RATIO) SLOW SPEED BEVEL GEAR SET - /26T (B RATIO)* STANDARD SPEED 9-22 BEVEL GEAR SET - 9/4T (E RATIO)* SLOW SPEED 8 6F-0249 O-RING - (B RATIO ONLY) 9 J-647 RETAINING RING - (B RATIO ONLY) PLUG, BEVEL PINION - (B RATIO ONLY) * Bevel Gear Set includes one Bevel Pinion and two Bevel Gears. 0

11 SEE NOTE 6 SEE NOTE PA56 BEVEL GEAR GROUP D6R III & D6T (S/N AND UP) 6 F/2 F SEE NOTE D D/ 7 0 SEE NOTE SEE NOTE SEE NOTE SEE NOTE 7 SEE NOTE 4 NOTES:. Clean bevel and pump pinions with Loctite solvent. Verify press fit before assembly. Apply Loctite 609 or equal to surfaces indicated in Detail A. Press pump drive pinion, item 2, onto bevel pinion and seat securely against shoulder. Allow proper cure time for Loctite before usage. 2. Apply a thin coat of multi-purpose grease to rollers. Do not pack solid.. Tighten nut to ensure parts are fully seated. Loosen nut to set the rolling torque of 0 lb-in (. N-m). Pinion must turn smoothly by hand. 4. Shim as required for tooth contact pattern as shown. The pattern height should be about / the whole depth, located midway between tip and root. It should be about ½ the face width shifted toward the toe. Set the backlash to.004 to.02 in. ( mm). 5. Apply approximately /6 (5 mm) bead of silastic sealant (RTV 72) to pilot diameter as indicated. 6. Clean with Loctite solvent and apply Loctite 242 to dowel pin and insert into winch case. 7. Clean with Loctite solvent and apply Loctite 242 to threads. Torque to 75 to 8 ft-lb (02 - N-m). ITEM NO. PART NO. DESCRIPTION QTY BEVEL PINION CARRIER PUMP PINION 7K-5448 BEARING CUP 2 4 7K-5449 BEARING CONE RETAINING RING OIL SEAL O-RING SEAL SPACER BEARING LOCKWASHER BEARING LOCKNUT DOWEL PIN SHIM GASKET SHIM,.005 in. (. mm) 2-AR SHIM,.007 in. (.8 mm) 2-AR SHIM,.020 in. (.5 mm) 2-AR 6 8T-897 CAPSCREW, HEX HD ( ½ - X ¼ in. G8, Z) BEVEL PINION - 26T (B RATIO) BEVEL PINION - 4T (E RATIO) BEVEL GEAR SET - /26T (B RATIO)* (NOT SHOWN) 9-22 BEVEL GEAR SET - 9/4T (E RATIO)* (NOT SHOWN) 9 6F-0249 O-RING (USED ON B RATIO ONLY) 20 J-647 RETAINING RING (USED ON B RATIO ONLY) BEVEL PINION PLUG (USED ON B RATIO ONLY) * Bevel Gear Set includes one Bevel Pinion and two Bevel Gears

12 WINCH CASE AND COVERS ALSO REFER TO CONTROL CABLE GUARD GROUP ALSO REFER TO CONTROL CABLE GUARD GROUP UNC LIFTING EYE HOLE (2 PLACES) EYE HOLE (2 PLACES) 0 VIEW A-A A A 8 2 SUCTION 9 STRAINER STANDARD PTO NOTES: 2 4 APPLY FEL-PRO C648F SEALANT TO BOLTS TO PREVENT THREAD CORROSION. TIGHTEN FASTENERS TO 75 LB FT (0.4 Kg M) TORQUE. APPLY RTV 72 SILASTIC SEALANT TO BOTH SIDES OF GASKETS (, 5 & 8) AND DRIVE SCREWS (2). TIGHTEN HEX NUT (22) UNTIL LOCKWASHER (2) IS FLATTENED AND THEN TURN ONE FLAT. LOW PTO 2

13 WINCH CASE AND COVERS ITEM PART NO. DESCRIPTION QTY. 5P-2228 CAPSCREW, HEX HEAD (/2- X G8 Z) 2 2 7H-454 DRIVE SCREW 4 5P-946 PLUG, DRAIN (MAY BE SUBSTITUTED FOR ITEM 7) 4 5P-40 PLUG, OIL FILL (INCLUDES ITEM 27) 5 6L-9965 O-RING 2 6 5F-544 VENT PLUG SIGHT GAUGE (INCLUDES ITEM 28) WINCH CASE - LOW PTO SERIAL NUMBER DATA PLATE COVER, TOP ACCESS 8-66 GASKET STRAINER COVER COVER, SIDE ACCESS GASKET TIE BOLT COVER, LOWER ACCESS GASKET DRAW BAR PIN SPACER TUBE LOCKWASHER ( /4) 22 2B-267 NUT, HEX HEAD ( /4 NC) 2 2 B-8822 ELBOW K-797 CAPSCREW, HEX HEAD (/2- X ) SS* 5 25 B-520 COTTER PIN (/8 X IN.) V-5065 O-RING - FOR OIL FILL PLUG 28 9X-4609 O-RING - FOR OIL DRAIN & LEVEL PLUG B-7457 PLUG (/8 NPT SQ HD) 0 5M-624 PLUG (/8 NPT) *SS = SELF-SEALING MATERIAL PREAPPLIED TO THREADS

14 CLUTCH SHAFT GROUP 4

15 CLUTCH SHAFT GROUP NOTES: 2 Bearing cone (item 6) must seat against shoulder on clutch shaft (item 29). Bearing cone (item 2) must seat fi rmly against the fi rst reduction pinion (item 2), such that no axial clearance remains between all other components of the clutch shaft. 5 Select shims (item 4, 5, & 6) to produce clutch shaft group axial clearance from.005 to.00 inch. Equalize bevel gear backlash by transfering shims (item 4, 7 & 8) from one side to the other. 6 Torque fasterners to 75-8 lb-ft. 8 Assemble cover (item 0) to clutch shaft before installing seal (item 20) (to prevent seal damage because of short cover pilot). ITEM PART NO DESCRIPTION QTY BEARING CUP BEARING CONE NEEDLE BEARING - INNER RACE THRUST BEARING NEEDLE BEARING BEARING CONE 7 5P-2228 CAPSCREW, HEX HEAD (/2 - X GD8 Z) 6 8 7X-026 CAPSCREW, HEX HEAD (/2 - X GD8 Z) THRUST BEARING RACE PLUG ORIFICE PLUG 2 2 8M-447 O-RING O-RING 2 4 H-9696 O-RING 2 5 2H-927 O-RING BACK-UP RING RETAINING RING 2 8 2D-698 RETAINING RING BACK-UP WASHER TEFLON SEAL BEVEL GEAR SPACER SPACER, INNER RACE 2 ITEM PART NO DESCRIPTION QTY SHIM SHIM CLUTCH ASSEMBLY (SEE PAGE 6) BEARING CARRIER BEARING RETAINER SHAFT, ROTARY SEAL CLUTCH SHAFT CLUTCH SHAFT CARRIER BRAKE HUB PINION SHIM SHIM SHIM O-RING SLEEVE BRAKE SPACER SHIM PLUG, O-RING BOSS-HEX HD SIGHT GAUGE BALL BEARING 2 4 4H-440 SPRING PIN 2 5

16 CLUTCH ASSEMBLY (SLOTTED HOUSING) Slotted Housing (Winch S.N and higher) ITEM PART NO. DESCRIPTION QTY CLUTCH ASSEMBLY - INCLUDES PLUG (-4 ORB) 2 2 Y-9267 STEEL CHECK BALL (.25 in.) SPRING 8 4 H-6227 O-RING 5 9F-99 O-RING RETAINING RING RETAINING RING SPRING RETAINER CHECK VALVE SEAT PRESSURE PLATE 2-69 CLUTCH HOUSING * DISC - FRICTION DISC - STEEL.04 in. (2.64 mm) CLUTCH PISTON 5 J-754 O-RING BACKUP RING BACKUP RING WAVE SPRING 4 * Item includes a a basic housing with two (2) (2) steel balls Y-9267 driven into into cross-drilled passages. ** Item 2 Friction Disc, interchangeable with Use all of one part number. 6

17 BRAKE ASSEMBLY (SLOTTED HOUSING) Slotted Housing (Winch S.N and higher) ITEM PART NO. DESCRIPTION QTY BRAKE ASSEMBLY, STD - INCLUDES BEARING CUP 2 4L-6454 CAPSCREW, HEX HEAD (/8-6 X G8 Z) PLUG, HEX SOCKET (-6 ORB) O-RING 5 5F-44 O-RING 6 Y-9267 STEEL BALL O-RING RETAINING RING PRESSURE PLATE RETAINING RING 2-62 PRESSURE PLATE 2 S-69 O-RING 2-6 BRAKE PISTON BRAKE HOUSING - CURRENT (REQUIRES OF ITEM 6) DISC - FRICTION - BRONZE * DISC - STEEL -.04 in. (2.64 mm) BRAKE CARRIER BRAKE SPRING 2 * Friction Disc interchangeable with Use all of one part number. 7

18 FOURTH SHAFT GROUP ITEM PART NO. DESCRIPTION QTY ROLLER BEARING THRUST WASHER in. (.58 mm) CLUSTER GEAR 7/7 TEETH 4 8M-4986 O-RING SPACER COUNTERSHAFT PIN THRUST WASHER -.27 in. (5.5 mm) 8

19 IDLER SHAFT GROUP WITH FREESPOOL NO GASKET USE RTV SEALANT ITEM PART NO. DESCRIPTION QTY BEARING ASSEMBLY BEARING ASSEMBLY 8T-897 CAPSCREW, HEX HEAD (/2 - - /4 GD 8 Z) 2 4 A-460 CAPSCREW, HEX HEAD (/2 - X 2 GD 8 Z) THRUST WASHER ADJUSTER 7 8T-98 CAPSCREW (/2 - - /4 GD 8 Z) BUSHING SECOND REDUCTION PINION FIRST REDUCTION GEAR CLUTCH COLLAR CARRIER LOCK PLATE O-RING FREESPOOL CYLINDER ASSEMBLY (SEE PAGE 26) 6 5H-8985 ROLL PIN CYLINDER STUD SPRING BOLT RETAINER CAPSCREW, SOCKET HEAD (/8-6 X 4 -/4 GD 8 Z) SET SCREW, SOCKET HEAD (/2-20 X ) 2 9

20 HYDRAULIC CONTROL GROUP - LOW PTO SEE DETAIL H SEE DETAIL F FS A T A B CR 29 T B CR CL SECTION C-C SECTION B-B C B E D SECTION F-F ELBOW POINTED DOWN F F G DETAIL H NOTES: Apply Loctite 242 to clean dry threads. G 2 Trim clamp end a minimum amount to clear bottom of case wall so clamp cannot rotate out of position. 5 4 Apply Loctite 609 to external threads. Bend lubrication tube (item 4) as required to direct oil stream as indicated. C B E D Install strainer shield (item 49) with open side facing downward. Measure from strainer shield to cover mounting surface. If distance is.720 in in. ( mm), add one seal (item 57) outboard of seal (item 49). If distance is greater than.78 in. (9.9 mm), add two seals (item 57) 20

21 .25 TO CL 2 CLIP TO FS HOSE, ITEM 25 ORIENT AS SHOWN (BLUE) RED BROWN ORANGE PS BR FS BLACK BLUE FILTER HEAD WHITE 2 C2 8 C GREEN BLACK WHITE W/ BLACK STRIPE TO GAUGE PORT ON HOUSING FACE (6") A A SEE NOTE 7 VIEW A-A B C2 C FS A F L (28") TO LUBE TUBE ON GEAR SIDE 9 (24") (24") (50") (24") (60") ( ELBOW) (# DEGREE ELBOW) PUMP (24 ) (2") (#B-77 AND #H-9779 ADAPTER) ( ELBOW) ACCUMULATOR (22.5") (26") BRAKE FREESPOOL CYLINDER RIGHT CLUTCH (BRAKE SIDE) LEFT CLUTCH (GEAR SIDE) 2

22 HYDRAULIC CONTROL GROUP - LOW PTO ITEM PART NO. DESCRIPTION QTY CONTROL VALVE (SEE CONTROL VALVE ASSEMBLY, PG. 2) 2 G-8878 FILTER ELEMENT ACCUMULATOR (REFER TO ACCUMULATOR ASSEMBLY) WIRING HARNESS STRAINER CONNECTOR COMPRESSION SPRING STRAINER SHIELD SEAL RING,.25 in. (6.4 mm) SEAL RING,.06 in. (.5 mm) -2 AR * 8M-4986 O-RING RETAINER FLANGE MACHINE SCREW, BUTTON SOC. HEAD (#0 - /4) 4 7X-0292 CAPSCREW, HEX HEAD (/8-6 X 4 /2 G8 Z) ELBOW, 45 o ORB HOSE, -8, 24 in. (60 mm) B, F, CR, A HOSE, -4, 22.5 in. (572 mm) F/S ADAPTER /4 NPT HOSE, -8, 50 in. (270 mm) CL HOSE, -8, 29 in. (77 mm) PUMP TO FILTER HOSE, -4, 6 in. (94 mm) GAUGE 22 7K-997 ELBOW, 90 o -4, GAUGE PORT 2 8L-6557 ADAPTER, ELBOW, 45 o HOSE, -4, 26 in. (660 mm) F/S 26 J-752 ADAPTER, ORB ELBOW, 90 o ORB M-0547 ELBOW, 90 o HOSE, -4, 60 in. (524 mm) LUBRICATION J-755 UNION, LUBRICATION TUBE 9-06 CLAMP CLAMP 5 2H-740 CAPSCREW, HEX HEAD (/4-6 X /4 G8 Z) HOSE CLAMP 7 9S-8752 NUT, HEX (/8-6) 8 4B-4278 WASHER (/8) 9 4K-8864 HOSE CLAMP 40 B-4506 LOCKWASHER (/8) SUCTION HOSE 42 9M-7958 CLAMP QUICK DISCONNECT, GAUGE PORT SLEEVE, GAUGE PORT 45 B-8822 ELBOW, 90 o (/8 NPT) VENT PORT, INSIDE ACCUMULATOR BRACKET MOUNTING ANGLE STUD (/2 - X 2 /4) V-888 NUT, HEX (/2 - ) T-422 LOCKWASHER (/2) 2 5 8T-904 CAPSCREW, HEX HEAD (5/6-8 X 7/8 G8 Z) 2 52 B-4505 LOCKWASHER (5/6) 2 5 0S-59 CAPSCREW, SOC. HEAD (/8-6 X /2 G8) 54 0S-64 CAPSCREW, HEX HEAD (/4-20 X /2 G8 Z) 55 B-4504 LOCKWASHER (/4) AR - AS REQUIRED 22

23 CONTROL VALVE ASSEMBLY ITEM PART NO DESCRIPTION QTY 74-0 CONTROL VALVE - INCLUDES 2-9 & HOUSING FILTER HEAD UNION ELBOW, 90º HEX HEAD PLUG (-4 ORB) 5 6 J-752 ADAPTER, -4 ORB 2 7 9L-849 CAP, PRESSURE SWITCH 9 J-8668 STUD (/8-6 X 2) 0 9S-8752 NUT-HEX (/8) RELIEF VALVE SEAL KIT SOLENOID VALVE, CLUTCH & F/S - W/O COIL SEAL KIT PROPORTIONAL BRAKE SOLENOID VALVE - W/O COIL SEAL KIT COIL FOR 2 & MAIN PRES. SOLENOID VALVE - W/O COIL 40-8 SEAL KIT COIL FOR 5 & CHECK VALVE SEAL KIT 2 8 2U-75 CHECK VALVE RETAINER SOLENOID VALVE, ACCUMULATOR, ISOLATOR - W/O COIL SEAL KIT FOR K-997 ELBOW, 90º CONTROL VALVE ASSEMBLY - ALL ITEMS ABOVE 2

24 CABLE DRUM GROUP INSTALL GEAR, ITEM 2, WITH GROOVE TOWARD OUTSIDE REFER TO IDLER SHAFT GROUP 24

25 CABLE DRUM GROUP QTY. ELECTRONIC ITEM PART NO. DESCRIPTION CONTROLS 8M-20 BALL BEARING 2 4F-204 BEARING CUP 2 5P-26 BEARING CONE 2 4 6K-797 CAPSCREW, HEX HEAD (/2 - X G5 SS) 2 5 5P-2566 CAPSCREW, HEX HEAD (/2 - X /2 G8 Z) 6 S-69 O-RING RETAINING RING, EXTERNAL 2 8 7M-2275 RETAINING RING, INTERNAL OIL SEAL CABLE DRUM SECOND REDUCTION GEAR SECOND REDUCTION GEAR SHAFT BEARING CARRIER, COVER BEARING CARRIER, DRUM SHIM SET ( pair each,.005,.007,.020 in. (.,.8,.5 mm) -2 AR FERRULE - /4 IN. (9 mm) WIRE ROPE FERRULE - 7/8 IN. (22 mm) WIRE ROPE FERRULE - IN. (25 mm) WIRE ROPE NO GASKET, USE DOW RTV 72 OR EQUIVALENT VALVE MOUNTING PLATE AR - AS REQUIRED SS - SELF SEALING 25

26 FREESPOOL CYLINDER ASSEMBLY NOTE: APPLY LOCTITE 242 OR 24 TO CLEAN DRY THREADS OF ITEMS 4 & 0 AND TIGHTEN TO LB FT (8 N m) ITEM PART NO. DESCRIPTION QTY FREESPOOL CYLINDER ASSEMBLY 8-24 YOKE CYLINDER RETAINER FREESPOOL CYLINDER 4 6L-596 CAPSCREW, SOC. HEAD (/4-20 x 2 GD 8 Z) SPRING SPRING GUIDE 7 8M-447 O-RING CYLINDER ROD 9 S-92 O-RING 0 4L-724 CAPSCREW, SOC. HEAD (/4-20 x /4 GD 8 Z) J-752 ADAPTER 26

27 PUMP GROUP REFER TO BEVEL PINION GROUP ITEM PART NO. DESCRIPTION QTY PUMP ASSEMBLY ELBOW, 45-8 PRESSURE SIDE B-77 ELBOW, 45 SUCTION 4 H-9779 BARBED HOSE ADAPTER 5 B-4504 LOCKWASHER (/4) 4 6 4M-5282 CAPSCREW, HEX HEAD (/4-20 X /2 G8) 2 7 7X-0266 CAPSCREW, HEX HEAD (/4-20 X G8) 2 ACCUMULATOR ASSEMBLY VENT HOLE 2 /4-6, -8 O-RING BOSS PORT WARNING CAUTION!!! DANGER - 2,000 LB (900 KG) SPRING PRELOAD! USE PRESS FOR DISASSEMBLY PER SERVICE INSTRUCTIONS. SEVERE PERSONAL INJURY OR DEATH MAY RESULT IF ROD GUIDE REMOVAL IS ATTEMPTED WITHOUT A PRESS. ITEM PART NO. DESCRIPTION QTY NSS ROD RETAINING RING NSS ROD GUIDE 4 NSS SPRING 5 NSS PISTON CAST IRON PISTON RING 7 SEAL (PACCAR P/N 07956) 8 NSS BARREL ASSEMBLY 9 NUT (PACCAR P/N 22702) SEAL KIT (CONTAINS 2, 6 & 7) NSS = Not Serviced Separately 27

28 FAIRLEAD ASSEMBLY Standard -roller fairlead consists of two vertical rollers, and one horizontal roller in the top position. 4 Horizontal Roller(s) A A Four roller fairlead adds a second horizontal roller in the bottom position. Vertical Rollers 6 2 View A-A NOTES: 2 4 WHILE TURNING ROLLER, TIGHTEN NUT. WHEN ROLLER WILL NO LONGER TURN, BACK OFF NUT /8 TURN. SHIM BOTH SIDES AS REQUIRED TO REDUCE END PLAY TO LESS THAN O.00 in. (0.8 mm). TIGHTEN NUT TO LB FT ( N m) TORQUE. WHEN INSTALLING FAIRLEAD ON WINCH IN FIELD, REMOVE ORIGINAL CABLE GUARD SPACER TUBE AND RE-USE UPPER TIE BOLT (8-6298), LOCKWASHER (9-62) AND NUT (2B-267). THOROUGHLY PACK ALL FAIRLEAD BEARINGS WITH MULTI-PURPOSE GREASE ON ASSEMBLY. ITEM PART NO. DESCRIPTION QUANTITY ROLLER 4 ROLLER 8-72 ROLLER FAIRLEAD ASSEMBLY ROLLER FAIRLEAD ASSEMBLY FAIRLEAD FRAME ROLLER - VERTICAL BEARING CONE K-96 BEARING CUP DUST GUARD ASSEMBLY GREASE RETAINER ROLLER - HORIZONTAL SHAFT - VERTICAL SHAFT - HORIZONTAL WASHER LOCK NUT 4 2 8T-98 CAPSCREW, HEX HEAD (/2 - X /4) 4 B-8489 GREASE FITTING WASHER -.00 in. (.8 mm) TIE BOLT LOCK WASHER ( /4) 9 2B-267 NUT, HEX ( /4-5) SHIM -.25 in. (.8 mm) 6-AR 6-AR SPACER th ROLLER KIT (CONTAINS ONE EACH 7, 9, 0,, 2,, 2 AND TWO EACH, 4 & 5) - AR - AS REQUIRED 28

29 METRIC CONVERSION TABLE MULTIPLY: BY: TO GET: MULTIPLY: BY: TO GET: LINEAR inches (in.) X 25.4 = millimeters (mm) millimeters (mm) X 0.97 = inches (in.) feet (ft.) X = meters (m) meters (m) X.28 = feet (ft.) miles (mi.) X.609 = kilometers (km) kilometers (km) X = miles (mi.) AREA inches 2 (sq.in.) X = millimeters 2 (mm 2 ) millimeters 2 (mm 2 ) X = inches 2 (sq.in.) feet 2 (sq.ft.) X = meters 2 (m 2 ) meters 2 (m 2 ) X = feet 2 (sq.ft.) VOLUME inches (cu.in.) X = liters (l) liters (l) X = inches (cu.in.) quarts (qts.) X = liters (l) liters (l) X.0567 = quarts (qts.) gallons (gal.) X.7854 = liters (l) liters (l) X = gallon (gal.) inches (cu.in.) X 6.9 = centimeters (cc) centimeters (cc) X = inches (cu.in.) feet (cu.ft.) X 28.7 = liters (l) liters (l) X 0.05 = feet (cu.ft.) feet (cu.ft.) X = meters (m ) meters (m) X 5.5 = feet (cu.ft.) fluid ounce (fl.oz.) X = millileters (ml) milliliters (ml) X 0.08 = fluid ounce (fl.oz.) MASS ounces (oz.) X 28.5 = grams (g) grams (g) X = ounces (oz.) pounds (lbs.) X = kilograms (kg) kilograms (kg) X = pounds (lbs.) tons (2000 lbs.) X = kilograms (kg) kilograms (kg) X = tons (2000 lbs.) tons (2000 lbs.) X = metric tons (t) metric tons (t) X.02 = tons (2000 lbs.) tons (long) (2240 lbs.) X 0.05 = kilograms (kg) kilograms (kg) X = tons (long) (2240 lbs.) PRESSURE inches Hg (60 o F) X 600 = kilopascals (kpa) kilopascals (kpa) X = inches Hg (60 o F) pounds/sq.in. (PSI) X = kilopascals (kpa) kilopascals (kpa) X 0.45 = pounds/sq.in. (PSI) pounds/sq.in. (PSI) X = kilograms/sq.cm. (kg/cm 2 ) kilograms/sq.cm. (kg/cm2) X 4.22 = pounds/sq.in. (PSI) pounds/sq.in. (PSI) X = bars bars X 4.5 = pounds/sq.in. (PSI) inches H 2O (60 o F) X = kilopascals (kpa) kilopascals (kpa) X 4.09 = inches H 2O (60 o F) bars X 00 = kilopascals (kpa) kilopascals (kpa) X 0.0 = bars POWER horsepower (hp) X = kilowatts (kw) kilowatts (kw) X.4 = horsepower (hp) ft.-lbs./min. X = watts (W) watts (W) X = ft.-lbs./min. TORQUE pound-inches (in.-lbs.) X = newton-meters (N-m) newton-meters (N-m) X 8.85 = pound-inches (in.lbs.) pound-feet (ft.-lbs.) X.558 = newton-meters (N-m) newton-meters (N-m) X = pound-feet (ft.-lbs.) pound-feet (ft.-lbs.) X.8 = kilograms/meter (kg-m) kilogram/meter (kg-m) X 7.2 = pound-feet (ft.-lbs.) VELOCITY miles/hour (m/h) X = kilometers/hour (km/hr) kilometers/hour (km/hr) X = miles/hour (m/h) feet/second (ft./sec.) X = meter/second (m/s) meters/second (m/s) X.28 = feet/second (ft./sec.) feet/minute (ft./min.) X = meter/minute (m/min) meters/minute (m/min) X.28 = feet/minute (ft./min.) TEMPERATURE o Celsius = ( o F - 2) o Fahrenheit = (.8 X o C) + 2 COMMON METRIC PREFIXES mega (M) 6 =,000,000 or 0 deci (d) = 0. or 0 - kilo (k) =,000 or 0 centi (c) = 0.0 or 0-2 hecto (h) = 00 or 0 2 milli (m) = 0.00 or 0 - deka (da) = 0 or 0 micro (m) = or