SERVICE MANUAL FOR MODEL PA90VS WINCH FOR D7E General Safety Recommendations Caterpillar

Safety for operators and ground personnel is of prime concern. Always take the necessary precautions to ensure safety to others as well as yourself. To ensure safety, the tractor and winch must be operated with care and concern for the equipment and a thorough knowledge of the machine's performance capabilities. The following recommendations are offered as a general safety guide. Local rules and regulations will also apply.

1. Read all warning tag information and become familiar with all controls BEFORE operating the winch.

2. NEVER attempt to clean, oil or perform any maintenance on the winch with the engine running, unless instructed to do so in this manual.

3. Before starting the tractor, be certain all controls move freely and are placed in the "Brake-On" (neutral) position.

4. NEVER operate winch controls unless you are properly seated at the operators station on the tractor and you are sure personnel are clear of the work area.

5. NEVER attempt to handle winch cable when the hook end is not free. Keep all parts of body and clothing clear of cable rollers, cable entry area of fairleads and winch drum.

6. Ground personnel should stay in view of tractor operator and clear of winch drum. Do not allow ground personnel near winch line under tension. A safe distance of at least 1 1/2 times the working length of the cable should be maintained. NEVER allow anyone to stand under a suspended load.

7. Avoid sudden "shock" loads or attempting to "jerk" a load free. This type of operation may cause heavy loads in excess of rated capacity. which may result in failure of cable and/or winch.

8. Use only GENUINE PACCAR parts. Do not use parts from other winch manufacturers on your PACCAR winch. Do not use PACCAR parts on winches from other manufacturers.

9. Use correct size ferrule for cable and pocket in winch drum. Never use knots to secure or attach cable. The cable anchor or ferrule pocket in the cable drum is designed to provide a self release in the event a back-sliding load must be released from the tractor in an emergency situation. The cable anchor or ferrule alone will NOT support rated line pull. Therefore, a minimum of five (5) complete wraps of cable must be maintained on the winch drum.

NOTE: We suggest painting the last five wraps of cable bright red to serve as a visual warning.

Recommended Operating Practices

1. Leather gloves should be used when handling winch cable.

2. Operate the winch to match line speeds to job conditions.

3. Assure that personnel who are responsible for hand signals are clearly visible and that the signals to be used are thoroughly understood by everyone.

4. Inspect winch cable, rigging, winch and tractor at the beginning of each work shift. Defects should be corrected immediately.

5. Position tractor for straightest line of pull to reduce wear on winch cable and ensure even spooling.

6. When winding winch cable on the winch drum, never attempt to maintain tension by allowing winch cable to slip through hands. Always use "hand-over-hand" technique, being careful to keep hands and clothing away from winch drum and fairlead rollers.

7. Be sure of tractor ground stability before winching in a load.

8. Store unused chokers, slings and rigging in a neat and orderly fashion to prevent damage to equipment or injury to personnel.

9. Do not operate the winch under loads that exceed the maximum rated bare drum line pull. If excessive loads are encountered, use a multi-part line and sheave blocks. Any attempt to exceed the capacity of one winch (such as coupling 2 or more tractors together) is extremely hazardous.

10. The factory approved adaptations for PACCAR winches are designed and intended for use on specific models of crawler tractors. Changing winches between tractors is not possible in some cases because of differences in tractor models. Some changes cannot be approved by PACCAR because of safety limitations. Call a PACCAR dealer or the PACCAR factory prior to attempting winch modifications or before mounting on a different tractor.

11. PACCAR PA90 winches are powered by the tractor hydraulic system. Discharge all retained hydraulic system pressure before removing any hydraulic lines or fittings. Personal injury may result from sudden release of oil pressure.

12. To discharge the winch control system pressure, stop the engine and cycle the winch control lever(s) into all positions five (5) times. Refer to the tractors manufacturers operators or service manual for additional information.

13. On machines having hydraulically, mechanically and/or cable controlled equipment, be certain the equipment is either lowered to the ground or blocked securely before servicing, adjusting and/or repairing the winch. Always apply tractor parking brakes and lower equipment before dismounting the tractor.

14. The winches described in this manual are neither designed nor intended for use or application to equipment used in the lifting or moving of persons.

15. Keep equipment in good operating condition. Perform scheduled servicing and adjustments listed in the "Preventive Maintenance" section of this manual. Use recommended lubricants.

16. An equipment warm-up procedure is recommended for all start-ups and essential at ambient temperatures below +40°F (5°C). Refer to "Warm-Up Procedure" listed in the "Preventive Maintenance" section of this manual.