SERVICE MANUAL FOR MODEL PA90VS WINCH FOR D7E Winch Assembly Caterpillar

If the cable drum was removed, support the drum securely between the winch case walls with a suitable chain and hoist. The cable anchor pocket must be located on the RH, or motor, side of the winch.

Install the output ring gear into the LH side of the winch case. Locate the eyebolt as close to top dead center as possible. Ensure the bearing cone is properly positioned on the hub of the ring gear before completing the assembly. Align the mounting holes. Install the fasteners and torque the capscrews to 120 ft·lbs (163 N·m).

Remove the eyebolt from the ring gear and install the capscrew into the eyebolt hole.

Install the output planetary assembly into the ring gear while aligning the planet gear and drum shaft splines.

Install the output sun gear through the drum shaft and into the planet gears.

Install the O-ring into the groove on the end cover pilot. Lubricate the O-ring with a light coating of grease or petroleum jelly and install the end cover onto the ring gear. Torque the capscrews to 120 lb·ft (163 N·m).

Install the retaining ring into the groove on the end of the output sun gear.

Install the intermediate planetary assembly into the cable drum. Align the splines on the planet carrier with the splines on the end of the output sun gear.

Install the retaining ring into the I.D. groove of the cable drum.

Install the thrust ring into the cable drum. Ensure the hub is facing the motor end.

Install the carrier clutch assembly into the cable drum. The intermediate sun gear splines will have to be aligned with the intermediate planet gears.

Apply a thin layer of grease to the hub and face of the clutch carrier. Install the thrust washer, needle roller bearing and thrust race. Ensure the counterbored side of the thrust race is facing the planet gear set. A thin coating of grease on each of these components will aid retention during assembly.

Lubricate the bearing cone with new winch oil. Place the cone in the bearing cup.

Apply non-hardening sealing compound to the outside surface of the seal housing. Properly position the seal in the drum bore. Place a large steel plate over the seal and press or drive into position within the bore.

NOTE: A large plate or mandrel will help to maintain proper alignment and protect the seal from unintentional damage during installation.

Install the primary sun gear into the planet gears.

Method for Setting PA90VS Shimstack

1. Install bearing cup, bearing cone, and drum seal into output ring gear end of cable drum. Install bearing cup into motor end of cable drum. Do not install the bearing cone or drum seal on the motor end of the drum at this time.

2. Set the cable drum into winch housing and install output ring gear. Rotate winch housing so that the hydraulic motor side is up. Rotate and tap the cable drum so that the drum is fully seated on the output ring gear.

3. Install bearing cone into drum. Do not install drum seal at this time.

4. Lay a 42 in. (10.7 cm) length of 1/8 in. (3.2 mm) solder between the brake housing pilot bore and bolt patter on the winch housing. Overlap the ends approximately 3 inches (7.6 cm.) Use solder or babbit only.

5. Install the brake housing assembly and tighten bolts with washers as follows: (Do not use an impact wrench) Hand tighten all the bolts in a criss-cross pattern and rotate the cable drum. Repeat tightening pattern using a torque wrench to 40 ft·lbs (54 N·m), 65 ft·lbs (88 N·m) and 100 ft·lbs (135 N·m) respectively. Rotate the cable drum between each tightening.

6. Remove bolts, washers, and brake housing assembly.

7. Measure the thickness of solder using a micrometer in a minimum of 5 places, evenly spaced around the flattened solder, and record the readings. Do not measure within 3 in. (7.6 cm.) of the ends of the solder as the readings are inaccurate.

8. To determine the total thickness of the shim stack, calculate the average thickness and round up to the nearest thousand of an inch. Add .003 in. - .005 in. (.08 - .13 mm) to obtain the total shim stack thickness.

9. Remove the bearing cone and install the ratio group.

10. Re-install the bearing cone and install the drum seal into the motor end of cable drum.

11. Install the required combination of shims to equal the total shim stack thickness. Install the brake housing assembly.

12. Install bolts with washers and tighten in the numbered order shown to 80 ft·lbs (108 N·m) using a torque wrench (do not use an impact wrench). Rotate the cable drum and check the torque at each bolt.

Locate the brake release (BR) port at the top. Align the mounting holes. Install the fasteners and torque the capscrews to 120 lb·ft (163 N·m).

Install the brake clutch into the brake housing with the short end of the inner race toward the motor.

When installed correctly, the inner race of the brake clutch should turn freely in the SAME direction the cable drum turns in REEL-IN. To verify direction, hold the outer race of the assembly in one hand and turn the inner race with the other hand.

If the brake clutch freewheels in the wrong direction, disassemble the brake clutch and reverse the inner race. Refer to the "Brake Clutch Service" section of this manual for further information.

Install a new O-ring on the motor pilot and lubricate with grease or petroleum jelly.

Install the hydraulic motor assembly into the brake clutch inner race. Ensure the motor seats fully into the pilot bore. Torque the fasteners to 230 lb·ft (312 N·m).

Attach the brake release hose to the brake release "BR" port on the brake housing.

Install the horizontal fairlead roller and shaft assemblies. Install the shaft assembly from the LH side of the case. Insert the spacer washers at both ends of the shaft assembly between the roller and the case wall. Torque the bolt to 45 lb·ft (61 N·m).

Install the vertical fairlead roller and shaft assemblies. Install the shaft assembly from the top of the case. Insert the spacer washers at both ends of the shaft assembly between the roller and the case wall. Torque the bolt to 45 lb·ft (61 N·m).

Grease the fairlead rollers as specified in the "Preventive Maintenance" section of this manual.

Refill the winch to the proper level with the recommended oil. Refer to the "Preventive Maintenance" section of this manual for further information.

Install the winch onto the tractor. Refer to your "Parts and Installation" manual for the recommended procedure.

Once installed on the tractor, refill the tractor hydraulic reservoir as required. Refer to your tractor maintenance manual for recommendations and proper procedures.

Start the tractor engine and operate the winch with NO LOAD in both directions to purge air from the lines. Check all plumbing for leaks and make any necessary repairs.

Install the motor cover and torque the capscrews to 75 lb·ft (102 N·m).