INSTALLATION AND PARTS MANUAL

INSTALLATION AND PARTS MANUAL MODEL PA56 WITH ELECTRONIC CONTROLS FOR D6R SERIES III & D6T TRACTORS SEBP4972-06 TABLE OF CONTENTS Mounting Group...2-4 Control Group...6-7 Electric Connections...8-9 Bevel Gear Group...0- Case and Covers...2- Clutch Shaft Group...4-5 Clutch Assembly... 6 Brake Assembly... 7 Fourth Shaft Group... 8 Idler Shaft Group w/freespool... 9 Hydraulic Control Group...20-22 Control Valve Assembly... 2 Cable Drum Group...24-25 Freespool Cylinder Assembly... 26 Pump Group... 27 Accumulator Assembly... 27 Fairlead Assembly... 28 MODEL NUMBER DESCRIPTION PA56 B 0 0 0 0 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 98-25-85 / Fax 98-259-575 www.paccarwinch.com LIT229 R6 7/202

PA56 MOUNTING GROUP D6R III & D6T 2.68 4 7 8 A A 5 2 2 4 6 5B 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

PA56 MOUNTING GROUP D6R III & D6T ITEM NO. PART NO. DESCRIPTION QTY. 9-07 STUD ( - 8 X -/4 G8) 0 2 8S-5654 O-RING 002-455 RETAINING RING 2 4 8-6595 PTO SHAFT 5 8-586 COUPLING 6 7X-0406 CAPSCREW, HEX HEAD ( - 8 X G8 Z) 4 7 4J-5977 NUT, HEX (-/8-7) 4 8-9224 STUD (-/8-7 X 4-/4) 4 9 8-6929 ADAPTER, RH 0 8-690 ADAPTER, LH 8-657 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.

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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8-245 0086 PA56 CONTROL GROUP D6R III & D6T CONTROL GROUP WITHOUT RIPPER CONTROL 25 4 0 8 7 5 B C 7 A 4 4 CONTROL GROUP WITH RIPPER CONTROL NOTES:. TOP OF CONTROLLER SHOULD BEND TOWARD FRONT OF TRACTOR 6

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 SENR846. 2. 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 SEBU7048. 5. 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. 2-2222 DUAL AXIS JOYSTICK CONTROLLER A 285-8466 BOOT B 06428 * CONTROLLER HANDLE DECAL C 285-8465 SWITCH 2 06506 * SPACER, USE W/RIPPER CONTROL 4M-528 CAPSCREW, HEX HD /4-20 X /4 (USE W/SPACER 2) 4 4 249-2804 WIRING HARNESS 5 66-4822 CONTROLLER MOUNTING PLATE 6 8T-994 CAPSCREW, BUTTON HD, 0 X /2, STAINLESS 4 7 8-244 INDICATOR LIGHT, RED 8 8-245 CONTROL CONSOLE DECAL 9 5P-057 WASHER, /4 (USE W/SPACER 2) 4 0 7-898 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 8 4 66-484 CONTROLLER MOUNTING GASKET 5 4P-758 CLIP * PACCAR Winch Division part number. Caterpillar part number not available at time of printing. 7

PA56 ELECTRIC SCHEMATIC D6R III & D6T 8

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 240-6267 UPPER GUARD 2 240-6268 LH GUARD 240-6269 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 4 9 - HARNESS CONNECTION, CONTROL TO MODULE 0 240-627 HARNESS, MODULE TO WINCH 85-2054 CONTROL MODULE 9

PA56 BEVEL GEAR GROUP D6R III & D6T (S/N 0704589 AND BELOW) ITEM PART NO. DESCRIPTION QTY. 9-24 BEARING ASSEMBLY 2 9-67 BEARING LOCKNUT 8T-897 CAPSCREW, HEX HEAD (/2 - X -/4 G8 Z) 6 4 9-68 BEARING LOCKWASHER 5 8-5804 O-RING 6 2-440 DOWEL PIN 7 9-257 RETAINING RING 8 20-768 OIL SEAL 9 8-88 SEAL SPACER SLEAVE 0 8-6589 PUMP DRIVE PINION 8-5854 SHIM GASKET 2 8-7222 BEVEL PINION CARRIER 8-5855 SHIM.005 in. (. mm) 2-AR 4 8-5856 SHIM.007 in. (.8 mm) 2-AR 5 8-5857 SHIM.020 in. (.5 mm) 2-AR 6 7 8-729 BEVEL PINION - 26T (B RATIO) STANDARD SPEED 8-728 BEVEL PINION - 4T (E RATIO) SLOW SPEED 9-227 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) 20 9-29 PLUG, BEVEL PINION - (B RATIO ONLY) * Bevel Gear Set includes one Bevel Pinion and two Bevel Gears. 0

SEE NOTE 6 SEE NOTE 2 5 4 2 PA56 BEVEL GEAR GROUP D6R III & D6T (S/N 0704590 AND UP) 6 F/2 F SEE NOTE 4 7 8 D D/ 7 0 SEE NOTE SEE NOTE 9 9 20 2 SEE NOTE 5 6 2 4 5 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. (.0 -.0 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. 7-755 BEVEL PINION CARRIER 2 8-6589 PUMP PINION 7K-5448 BEARING CUP 2 4 7K-5449 BEARING CONE 2 5 9-257 RETAINING RING 6 20-768 OIL SEAL 7 8-5804 O-RING 8 8-88 SEAL SPACER 9 9-68 BEARING LOCKWASHER 0 9-67 BEARING LOCKNUT 2-440 DOWEL PIN 2 8-5854 SHIM GASKET 8-5855 SHIM,.005 in. (. mm) 2-AR 4 8-5856 SHIM,.007 in. (.8 mm) 2-AR 5 8-5857 SHIM,.020 in. (.5 mm) 2-AR 6 8T-897 CAPSCREW, HEX HD ( ½ - X ¼ in. G8, Z) 6 7 8-729 BEVEL PINION - 26T (B RATIO) 8-728 BEVEL PINION - 4T (E RATIO) 8 9-227 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) 2 9-29 BEVEL PINION PLUG (USED ON B RATIO ONLY) * Bevel Gear Set includes one Bevel Pinion and two Bevel Gears

WINCH CASE AND COVERS ALSO REFER TO CONTROL CABLE GUARD GROUP ALSO REFER TO CONTROL CABLE GUARD GROUP 6 24-8 UNC LIFTING EYE HOLE (2 PLACES) EYE HOLE (2 PLACES) 0 VIEW A-A 2 20 0 4 6 2 22 4 27 29 2 5 A 4 9 24 A 8 2 SUCTION 9 STRAINER 7 8 7 8 2 5 25 2 7 28 28 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

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 7 8-578 SIGHT GAUGE (INCLUDES ITEM 28) 8 8-6972 WINCH CASE - LOW PTO 9 2-447 SERIAL NUMBER DATA PLATE 0 8-6598 COVER, TOP ACCESS 8-66 GASKET 2 20-754 STRAINER COVER 4 8-6588 COVER, SIDE ACCESS 5 20-754 GASKET 6 8-6298 TIE BOLT 7 8-6597 COVER, LOWER ACCESS 2 8 8-67 GASKET 2 9 8-882 DRAW BAR PIN 20 8-64 SPACER TUBE 2 9-62 LOCKWASHER ( /4) 22 2B-267 NUT, HEX HEAD ( /4 NC) 2 2 B-8822 ELBOW 2 24 6K-797 CAPSCREW, HEX HEAD (/2- X ) SS* 5 25 B-520 COTTER PIN (/8 X IN.) 2 27 6V-5065 O-RING - FOR OIL FILL PLUG 28 9X-4609 O-RING - FOR OIL DRAIN & LEVEL PLUG 2 29 2B-7457 PLUG (/8 NPT SQ HD) 0 5M-624 PLUG (/8 NPT) *SS = SELF-SEALING MATERIAL PREAPPLIED TO THREADS

CLUTCH SHAFT GROUP 4

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 9-240 BEARING CUP 2 20-765 BEARING CONE 9-2206 NEEDLE BEARING - INNER RACE 4 4 24-049 THRUST BEARING 2 5 9-2208 NEEDLE BEARING 4 6 009-690 BEARING CONE 7 5P-2228 CAPSCREW, HEX HEAD (/2 - X GD8 Z) 6 8 7X-026 CAPSCREW, HEX HEAD (/2 - X GD8 Z) 6 9 20-76 THRUST BEARING RACE 4 0 64-566 PLUG 2 40-97 ORIFICE PLUG 2 2 8M-447 O-RING 8 20-7629 O-RING 2 4 H-9696 O-RING 2 5 2H-927 O-RING 4 6 9-550 BACK-UP RING 4 7 9-66 RETAINING RING 2 8 2D-698 RETAINING RING 2 9 9-628 BACK-UP WASHER 2 20 9-29 TEFLON SEAL 2 2 8-5858 BEVEL GEAR SPACER 2 22 27-8445 SPACER, INNER RACE 2 ITEM PART NO DESCRIPTION QTY 2 9-000 SHIM 2 24 9-00 SHIM 2 25 2-6 CLUTCH ASSEMBLY (SEE PAGE 6) 2 26 8-5844 BEARING CARRIER 2 27 9-27 BEARING RETAINER 2 28 47-2728 SHAFT, ROTARY SEAL 2 29 8-7225 CLUTCH SHAFT 0 2-2447 CLUTCH SHAFT CARRIER 8-844 BRAKE HUB 2 8-6582 PINION 4 8-6647 SHIM.005 4 5 8-6599 SHIM.007 4 6 8-6600 SHIM.020 4 7 20-766 O-RING SLEEVE 4 8 27-8444 BRAKE SPACER 4 9 9-0094 SHIM 2 40 48-8407 PLUG, O-RING BOSS-HEX HD 4 270-5244 SIGHT GAUGE 42 9-29 BALL BEARING 2 4 4H-440 SPRING PIN 2 5

CLUTCH ASSEMBLY (SLOTTED HOUSING) Slotted Housing (Winch S.N. 0005 and higher) ITEM PART NO. DESCRIPTION QTY. - 2-6 CLUTCH ASSEMBLY - INCLUDES - 8 8-726 PLUG (-4 ORB) 2 2 Y-9267 STEEL CHECK BALL (.25 in.) 2-640 SPRING 8 4 H-6227 O-RING 5 9F-99 O-RING 6 9-295 RETAINING RING 7 2-64 RETAINING RING 8 295-797 SPRING RETAINER 9 8-5849 CHECK VALVE SEAT 0 2-64 PRESSURE PLATE 2-69 CLUTCH HOUSING * 2 6-645 DISC - FRICTION 5 6-644 DISC - STEEL.04 in. (2.64 mm) 5 4 6-649 CLUTCH PISTON 5 J-754 O-RING 2 6 62-275 BACKUP RING 7 62-2754 BACKUP RING 8 2-2245 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, 6-645 interchangeable with 8-6547. Use all of one part number. 6

BRAKE ASSEMBLY (SLOTTED HOUSING) Slotted Housing (Winch S.N. 000878 and higher) ITEM PART NO. DESCRIPTION QTY. - 2-60 BRAKE ASSEMBLY, STD - INCLUDES - 20 009-69 BEARING CUP 2 4L-6454 CAPSCREW, HEX HEAD (/8-6 X G8 Z) 2 48-8407 PLUG, HEX SOCKET (-6 ORB) 4 9-577 O-RING 5 5F-44 O-RING 6 Y-9267 STEEL BALL 7 9-586 O-RING 8 2-445 RETAINING RING 9 2-68 PRESSURE PLATE 0 2-64 RETAINING RING 2-62 PRESSURE PLATE 2 S-69 O-RING 2-6 BRAKE PISTON 4 2-67 BRAKE HOUSING - CURRENT (REQUIRES OF ITEM 6) 5 6-645 DISC - FRICTION - BRONZE * 8 6 6-644 DISC - STEEL -.04 in. (2.64 mm) 8 7 2-66 BRAKE CARRIER 8 9-267 BRAKE SPRING 2 * 6-645 Friction Disc interchangeable with 8-6547. Use all of one part number. 7

FOURTH SHAFT GROUP ITEM PART NO. DESCRIPTION QTY. 9-27 ROLLER BEARING 2 2 9-572 THRUST WASHER -.062 in. (.58 mm) 8-665 CLUSTER GEAR 7/7 TEETH 4 8M-4986 O-RING 2 5 8-6297 SPACER 6 8-65 COUNTERSHAFT PIN 7 8-6287 THRUST WASHER -.27 in. (5.5 mm) 8

IDLER SHAFT GROUP WITH FREESPOOL NO GASKET USE RTV SEALANT ITEM PART NO. DESCRIPTION QTY 9-060 BEARING ASSEMBLY 2 4-5870 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) 2 5 20-76 THRUST WASHER 6 8-655 ADJUSTER 7 8T-98 CAPSCREW (/2 - - /4 GD 8 Z) 2 8 9-270 BUSHING 9 8-6584 SECOND REDUCTION PINION 0 8-7224 FIRST REDUCTION GEAR 8-6585 CLUTCH COLLAR 2 8-697 CARRIER 8-5859 LOCK PLATE 4 9-547 O-RING 5 8-242 FREESPOOL CYLINDER ASSEMBLY (SEE PAGE 26) 6 5H-8985 ROLL PIN 7 8-249 CYLINDER STUD 8 8-2420 SPRING 9 8-242 BOLT RETAINER 20 6-7209 CAPSCREW, SOCKET HEAD (/8-6 X 4 -/4 GD 8 Z) 2 064-609 SET SCREW, SOCKET HEAD (/2-20 X ) 2 9

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 6 5 6 Install strainer shield (item 49) with open side facing downward. Measure from strainer shield to cover mounting surface. If distance is.720 in. -.78 in. (8. - 9.9 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

.25 TO.75 4 29 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") (26752-45 ELBOW) (#2-44 45-DEGREE ELBOW) PUMP (24 ) (2") (#B-77 AND #H-9779 ADAPTER) (69047-45 ELBOW) ACCUMULATOR (22.5") (26") BRAKE FREESPOOL CYLINDER RIGHT CLUTCH (BRAKE SIDE) LEFT CLUTCH (GEAR SIDE) 2

HYDRAULIC CONTROL GROUP - LOW PTO ITEM PART NO. DESCRIPTION QTY. 74-04 CONTROL VALVE (SEE CONTROL VALVE ASSEMBLY, PG. 2) 2 G-8878 FILTER ELEMENT 8-702 ACCUMULATOR (REFER TO ACCUMULATOR ASSEMBLY) 4 8-2405 WIRING HARNESS 5 9-264 STRAINER 6 8-6265 CONNECTOR 7 9-55 COMPRESSION SPRING 8 8-628 STRAINER SHIELD 9 8-6284 SEAL RING,.25 in. (6.4 mm) 0 8-6286 SEAL RING,.06 in. (.5 mm) -2 AR * 8M-4986 O-RING 2 8-2406 RETAINER FLANGE 8-2407 MACHINE SCREW, BUTTON SOC. HEAD (#0 - /4) 4 7X-0292 CAPSCREW, HEX HEAD (/8-6 X 4 /2 G8 Z) 2 5 00-794 ELBOW, 45 o ORB -8 5 6 9-05 HOSE, -8, 24 in. (60 mm) B, F, CR, A 4 7 29-870 HOSE, -4, 22.5 in. (572 mm) F/S 8 06-946 ADAPTER /4 NPT -8 4 9 9-020 HOSE, -8, 50 in. (270 mm) CL 20 8-2408 HOSE, -8, 29 in. (77 mm) PUMP TO FILTER 2 8-240 HOSE, -4, 6 in. (94 mm) GAUGE 22 7K-997 ELBOW, 90 o -4, GAUGE PORT 2 8L-6557 ADAPTER, -4 24 00-794 ELBOW, 45 o -4 25 7-848 HOSE, -4, 26 in. (660 mm) F/S 26 J-752 ADAPTER, ORB -4 2 28 00-7948 ELBOW, 90 o ORB -8 29 8M-0547 ELBOW, 90 o -8 4 0 9-022 HOSE, -4, 60 in. (524 mm) LUBRICATION J-755 UNION, -4 2 2 8-2409 LUBRICATION TUBE 9-06 CLAMP 2 4 8-6270 CLAMP 5 2H-740 CAPSCREW, HEX HEAD (/4-6 X /4 G8 Z) 6 8-242 HOSE CLAMP 7 9S-8752 NUT, HEX (/8-6) 8 4B-4278 WASHER (/8) 9 4K-8864 HOSE CLAMP 40 B-4506 LOCKWASHER (/8) 2 4 8-6264 SUCTION HOSE 42 9M-7958 CLAMP 4 58-650 QUICK DISCONNECT, GAUGE PORT 44 27-7025 SLEEVE, GAUGE PORT 45 B-8822 ELBOW, 90 o (/8 NPT) VENT PORT, INSIDE 46 8-6 ACCUMULATOR BRACKET 47 8-608 MOUNTING ANGLE 48 9-0549 STUD (/2 - X 2 /4) 2 49 6V-888 NUT, HEX (/2 - ) 2 50 8T-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

CONTROL VALVE ASSEMBLY - 74-04 8 9 0 2 4 20 6 6 7 5 20 6 9 4 2 4 5 6 7 8 4 2 4 2 7 8 ITEM PART NO DESCRIPTION QTY 74-0 CONTROL VALVE - INCLUDES 2-9 & HOUSING 2 8-62 FILTER HEAD 8-247 UNION 4 8-248 ELBOW, 90º -8 5 55-624 HEX HEAD PLUG (-4 ORB) 5 6 J-752 ADAPTER, -4 ORB 2 7 9L-849 CAP, -4 8 7-755 PRESSURE SWITCH 9 J-8668 STUD (/8-6 X 2) 0 9S-8752 NUT-HEX (/8) 2 40-8 RELIEF VALVE 294-762 SEAL KIT 2 40-76 SOLENOID VALVE, CLUTCH & F/S - W/O COIL 294-76 SEAL KIT 40-78 PROPORTIONAL BRAKE SOLENOID VALVE - W/O COIL 40-77 SEAL KIT 4 40-79 COIL FOR 2 & 4 5 40-80 MAIN PRES. SOLENOID VALVE - W/O COIL 40-8 SEAL KIT 6 40-82 COIL FOR 5 & 9 2 7 40-95 CHECK VALVE 2 40-94 SEAL KIT 2 8 2U-75 CHECK VALVE RETAINER 2 9 74-070 SOLENOID VALVE, ACCUMULATOR, ISOLATOR - W/O COIL 00-575 SEAL KIT FOR 9 20 7K-997 ELBOW, 90º -4 2 2 74-04 CONTROL VALVE ASSEMBLY - ALL ITEMS ABOVE 2

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

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 2 7 2-446 RETAINING RING, EXTERNAL 2 8 7M-2275 RETAINING RING, INTERNAL 9 8-5866 OIL SEAL 2 8-7229 CABLE DRUM 2 8-725 SECOND REDUCTION GEAR 8-658 SECOND REDUCTION GEAR SHAFT 4 8-6968 BEARING CARRIER, COVER 5 8-6975 BEARING CARRIER, DRUM 2 6 8-5847 SHIM SET ( pair each,.005,.007,.020 in. (.,.8,.5 mm) -2 AR 7 8-627 FERRULE - /4 IN. (9 mm) WIRE ROPE 8-6275 FERRULE - 7/8 IN. (22 mm) WIRE ROPE 8-6276 FERRULE - IN. (25 mm) WIRE ROPE 8 ----- NO GASKET, USE DOW RTV 72 OR EQUIVALENT -- 9 8-2400 VALVE MOUNTING PLATE AR - AS REQUIRED SS - SELF SEALING 25

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. - 8-242 FREESPOOL CYLINDER ASSEMBLY 8-24 YOKE 2 8-244 CYLINDER RETAINER 8-245 FREESPOOL CYLINDER 4 6L-596 CAPSCREW, SOC. HEAD (/4-20 x 2 GD 8 Z) 5 8-246 SPRING 6 8-247 SPRING GUIDE 7 8M-447 O-RING 8 8-248 CYLINDER ROD 9 S-92 O-RING 0 4L-724 CAPSCREW, SOC. HEAD (/4-20 x /4 GD 8 Z) J-752 ADAPTER 26

PUMP GROUP REFER TO BEVEL PINION GROUP ITEM PART NO. DESCRIPTION QTY 8-6979 PUMP ASSEMBLY 2 2-44 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 - 8-702 9 7 6 5 8 4 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 2 096-89 RETAINING RING NSS ROD GUIDE 4 NSS SPRING 5 NSS PISTON 6 9-0554 CAST IRON PISTON RING 7 SEAL (PACCAR P/N 07956) 8 NSS BARREL ASSEMBLY 9 NUT (PACCAR P/N 22702) - 2-44 SEAL KIT (CONTAINS 2, 6 & 7) NSS = Not Serviced Separately 27

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 200-00 LB FT (27-407 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 8-72 4 ROLLER FAIRLEAD ASSEMBLY 8-695 FAIRLEAD FRAME 2 8-6649 ROLLER - VERTICAL 2 2 9-274 BEARING CONE 6 8 4 K-96 BEARING CUP 6 8 5 8-580 DUST GUARD ASSEMBLY 6 8 6 9-286 GREASE RETAINER 4 4 7 24-076 ROLLER - HORIZONTAL 2 8 8-6648 SHAFT - VERTICAL 2 2 9 8-6604 SHAFT - HORIZONTAL 2 0 9-22 WASHER 4 205-8260 LOCK NUT 4 2 8T-98 CAPSCREW, HEX HEAD (/2 - X /4) 4 B-8489 GREASE FITTING 5 6 6 20-764 WASHER -.00 in. (.8 mm) 5 6 7 8-6298 TIE BOLT 8 9-62 LOCK WASHER ( /4) 9 2B-267 NUT, HEX ( /4-5) 20 2-440 SHIM -.25 in. (.8 mm) 6-AR 6-AR 2 20-756 SPACER 4 74-4770 4th ROLLER KIT (CONTAINS ONE EACH 7, 9, 0,, 2,, 2 AND TWO EACH, 4 & 5) - AR - AS REQUIRED 28

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 0.048 = meters (m) meters (m) X.28 = feet (ft.) miles (mi.) X.609 = kilometers (km) kilometers (km) X 0.624 = miles (mi.) AREA inches 2 (sq.in.) X 645.5 = millimeters 2 (mm 2 ) millimeters 2 (mm 2 ) X 0.00055 = inches 2 (sq.in.) feet 2 (sq.ft.) X 0.0929 = meters 2 (m 2 ) meters 2 (m 2 ) X 0.764 = feet 2 (sq.ft.) VOLUME inches (cu.in.) X 0.069 = liters (l) liters (l) X 6.024 = inches (cu.in.) quarts (qts.) X 0.9465 = liters (l) liters (l) X.0567 = quarts (qts.) gallons (gal.) X.7854 = liters (l) liters (l) X 0.2642 = gallon (gal.) inches (cu.in.) X 6.9 = centimeters (cc) centimeters (cc) X 0.0602 = inches (cu.in.) feet (cu.ft.) X 28.7 = liters (l) liters (l) X 0.05 = feet (cu.ft.) feet (cu.ft.) X 0.0282 = meters (m ) meters (m) X 5.5 = feet (cu.ft.) fluid ounce (fl.oz.) X 29.57 = millileters (ml) milliliters (ml) X 0.08 = fluid ounce (fl.oz.) MASS ounces (oz.) X 28.5 = grams (g) grams (g) X 0.0527 = ounces (oz.) pounds (lbs.) X 0.456 = kilograms (kg) kilograms (kg) X 2.2046 = pounds (lbs.) tons (2000 lbs.) X 907.8 = kilograms (kg) kilograms (kg) X 0.0002 = tons (2000 lbs.) tons (2000 lbs.) X 0.9078 = metric tons (t) metric tons (t) X.02 = tons (2000 lbs.) tons (long) (2240 lbs.) X 0.05 = kilograms (kg) kilograms (kg) X 0.000984 = tons (long) (2240 lbs.) PRESSURE inches Hg (60 o F) X 600 = kilopascals (kpa) kilopascals (kpa) X 0.296 = inches Hg (60 o F) pounds/sq.in. (PSI) X 6.895 = kilopascals (kpa) kilopascals (kpa) X 0.45 = pounds/sq.in. (PSI) pounds/sq.in. (PSI) X 0.070 = kilograms/sq.cm. (kg/cm 2 ) kilograms/sq.cm. (kg/cm2) X 4.22 = pounds/sq.in. (PSI) pounds/sq.in. (PSI) X 0.069 = bars bars X 4.5 = pounds/sq.in. (PSI) inches H 2O (60 o F) X 0.2488 = 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 0.746 = kilowatts (kw) kilowatts (kw) X.4 = horsepower (hp) ft.-lbs./min. X 0.0226 = watts (W) watts (W) X 44.25 = ft.-lbs./min. TORQUE pound-inches (in.-lbs.) X 0.298 = 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 0.776 = 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 0.298 = kilometers/hour (km/hr) kilometers/hour (km/hr) X 0.624 = miles/hour (m/h) feet/second (ft./sec.) X 0.048 = meter/second (m/s) meters/second (m/s) X.28 = feet/second (ft./sec.) feet/minute (ft./min.) X 0.048 = meter/minute (m/min) meters/minute (m/min) X.28 = feet/minute (ft./min.) TEMPERATURE o Celsius = 0.556 ( 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) = 0.000.00 or 0-6 29