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INSTALLATION AND
PARTS MANUAL
MODEL PA90VS
FOR
CATERPILLAR D6R III and D6T
TABLE OF CONTENTS
PA90VS 255 V
LIT2369_R1
1/2008
Printed in U.S.A.
1
General Safety Recommendations
Caterpillar D6R III & D6T
! WARNING !
The hydraulic system may be under high pressure. It
must therefore be depressurized as specified in the
operating instructions before starting any work on
the hydraulic system.
CAUTION
Beware of injuries when attempting to locates leaks.
Always use a piece of paper or cardboard for this
purpose, never you hands. Fluid emerging under
pressure may not be visible but can penetrate the
skin and cause serious injuries which must treated
by a medical professional without delay.
CAUTION
! WARNING !
Hydraulic hose lines must be examined regularly.
The hoses must be replaced if damaged or deformed
and upon expiry of their service life. The hose lines
must comply with technical specifications of the sup-
plier.
2
Mounting Group
Caterpillar D6R III & D6T
USE LOCTITE
USE LOCKTITE #272
#272 OR SIMILAR
OR SIMILAR
THREAD LOCKING
THREAD LOCKING PRODUCT
PRODUCT
3
Mounting Group
Caterpillar D6R III & D6T
INSTALLATION INSTRUCTIONS
CAUTION
CAUTION ! WARNING !
Fill the winch to the proper level with the recommend-
Cleanliness is of utmost importance when working on ed oil BEFORE operating the winch. Component dam-
hydraulic equipment. Contamination may cause dam- age may occur if the winch is operated without oil.
age to close tolerances of the hydraulic components
which may result in erratic operation and reduced ser-
vice life.
1. Ensure that mating surfaces of winch, adapter brackets,
and tractor frame are free of paint, clean and smooth.
NOTE: Mounting winch to tractor as the final step will ease
2. Secure left hand adapter (item 1) and right hand adapter
access to control group and tractor conversion group. In-
(item 2) to winch with 10 capscrews (item 7) and washers
stall complete control group p/n 63652, except direct winch
(item 8); torque to 1363 ft-lbs.
connections, prior to installing winch base unit on tractor.
3. Install studs (item 3) to top mounting holes in tractor
frame on each side (use Loctite 272.)
CAUTION
4
ITEM PART DESCRIPTION QTY
1 103652 * LH MOUNTING BRACKET 1
2 103653 * RH MOUNTING BRACKET 1
3 119-0171 STUD, 1 - 8 UNC X 3.25 LONG 4
4 6V-8190 NUT, HEX 1 - 8 UNC GR 8 4
5 7X-0403 CAPSCREW, 1- 7 UNC X 2.25 GR 8 12
6 8T-5361 WASHER HARDENED 1.00 16
7 105261 * CAPSCREW, 1 - 8 UNC X 4.00 GR 8 10
8 7X-0533 WASHER HARDENED 1-1/4 10
* PACCAR Winch Division part number. Caterpillar part number not
available at time of printing.
5
Tractor Conversion Group
Caterpillar D6R III & D6T
6
Tractor Conversion Group
Caterpillar D6R III & D6T
100
7
Motor Lines Group
1 2 3 4 9 12
10
19 11 10 18
12
Use existing
hardware here
8
Control Group
Caterpillar D6R III & D6T
9
Control Group
Caterpillar D6R III & D6T
ITEM PART # DESCRIPTION QTY
1 9B-0523 SPACER 3/4 OD X 1.00 LONG 2
2 7K-1181 TEE STRAP,BLACK 1
3 170-4891 WIRING HARNESS ASSY 2-PLUG 1
4 83481 * MANIFOLD & CARTRIDGE SUB-ASSY 1
5 226-6583 L-BRACKET ASSEMBLY 1
6 165-0107 WIRING HARNESS ASSY 4-PLUG 1
7 234-3422 HOSE ASSY -12 ORFS 90° X 53 LONG X -8 ORFS 1
8 234-3425 GUARD, REAR HYD ACCES 1
9 239-5235 BRACKET ASSY, HYD MANIFOLD 1
10 258-5488 HOSE ASSY -12 FLANGE 68° X 46.5 LONG X -16 FLANGE 2
11 126-0810 INDICATOR LIGHT 1
12 260-6479 CLIP-HALF USED WITH P/N 7G-3834 1
13 148-8336 ADAPTER, STRAIGHT -6 ORB X -6 ORFS 4
14 148-8340 ADAPTER, STRAIGHT -8 ORB X -8 ORFS 1
15 137-4398 CAPSCREW, BUTTON HD M6 1.0 X 25L STAINLESS 4
16 106580 * TEE -10 ORB X -12 ORFS X -12 ORFS 1
18 PA1P3702 * SEAL, CAT D-RING, -12 2
19 1P-3703 D-RING, SPLIT FLG 2
20 1S-0994 HOSE CLAMP, -8 HOSE 2
21 4P-7581 CLIP, USE WITH TIE-STRAP 1
23 5P-1075 WASHER, HARDENED 3/8 6
24 6V-0400 FLANGE HALF, HYDRAULIC PORT 8
25 7G-3832 GROMMET, 2-HOSE 1
26 7G-3834 CLIP-HALF, USED WITH P/N 260-6479 1
27 8T-4121 WASHER; M10 HARDENED 1
28 8T-4136 CAPSCREW, HEX HD M10 X 1.50 X 25L GR 10.9 3
29 8T-4184 CAPSCREW, HEX HD M12 X 1.75 X 45L GR 10.9 16
30 8T-4195 CAPSCREW, HEX HD M10 X 1.50 X 30L GR 10.9 2
31 8T-4223 WASHER, HARDENED M12 18
32 8T-4139 CAPSCREW, HEX HD M12 X 1.75 X 30L GR 10.9 2
33 106633 * CAPSCREW, HEX HD M10 X 1.50 X 60L GR 10.9 2
34 227-3179 HOSE ASSY, -16 FLANGE 110° X 22.9 LONG X -20 FLANGE 22° 1
35 226-3509 HOSE ASSY, -4 ORFS X 23 LONG X -4 ORFS 45° 1
36 106584 * HOSE ASSY, -6 ORFS X 16.5 LONG X -6 ORFS 45° 1
37 105828 * HOSE ASSY, -6 ORFS 90° X 17 LONG X -6 ORFS 1
38 228-7946 HOSE ASSY, -4 ORFS X 11.50 LONG X -4 ORFS 90° 1
39 228-7948 HOSE ASSY, -4 ORFS X 17.5 LONG X -4 ORFS 90° 1
40 106585 * HOSE ASSY, -6 ORFS X 57.25 LONG X -6 ORFS 45° 1
41 156-8018 HOSE ASSY, -6 ORFS 90° X 61 LONG X -6 ORFS 1
42 148-8326 ADAPTER, STRAIGHT -4 ORB X -4 ORFS 1
43 6V-9850 ELBOW, 90° -6 ORS X -6 ORFS SWIVEL NUT 1
44 6V-8627 ELBOW, 90° -6 ORB X -4 ORFS 2
45 148-8369 ELBOW, 90° -4 ORB X -4 ORFS 2
46 148-8378 ELBOW, 90° -6 ORB X -6 ORFS 1
47 4D-6466 CLIP, DOUBLE HOSE 9/16 1
48 4J-0520 O-RING, -219 N90 1
49 8M-4986 O-RING, -222 N70 1
50 4S-1936 CLIP, SINGLE HOSE 9/16 2
51 160-0766 CONTROL, JOYSTICK 1
52 164-9928 DECAL, LOCK IN LOW 1
53 164-9930 DECAL, CONTROL 1
* PACCAR Winch Division part number. Caterpillar part number not available at time of printing.
10
Control Group
Caterpillar D6R III & D6T
11
Motor Group
Caterpillar D6R III & D6T
12
Brake Valve
Caterpillar D6R III & D6T
D6T
21 1 22
3
19
12 12
11
14
9
16
20
13
15
5
8 2 10 7 4
QTY
ITEM NO. PART NO DESCRIPTION D6R III D6T
-- 126-2864 BRAKE VALVE ASSY 1 --
-- 83577 * BRAKE VALVE ASSY -- 1
1 126-2467 BRAKE VALVE HOUSING 1 1
2 242-7228 VALVE SPRING RETAINER 1 1
3 296-4278 PLUG, SPRING RETAINER 1 1
4 9S-8008 PLUG 1 1
5 126-0819 SPOOL, LOW PRESSURE 1 1
6 126-2454 STOP, SPOOL 1 1
7 7M-8485 O-RING 1 1
8 242-7226 CHECK VALVE POPPET 1 1
9 126-2453 PILOT ORIFICE 1 1
10 126-0817 CHECK VALVE SPRING 1 1
11 242-7227 DIE SPRING 1 1
12 3D-2824 O-RING 2 2
13 4J-5268 O-RING 1 1
14 24194 * O-RING -- 1
15 126-3349 BACK-UP RING 1 1
16 24196 * BACK-UP RING -- 1
19 155-3624 HEX HEAD PLUG (-4SAE) 1 1
20 25403 * SHIPPING PLUG HYD 1 1
21 75288 * SHIPPING PLUG 1 1
22 8J-7269 SHIM, VALVE SPRING 1 1
* PACCAR Winch Division part number. Caterpillar part number not available at time of printing.
D6R III
21 1 22
3
19
12 12
11
20
13
15
5
8 2 10 7 4
13
WINCH HOUSING AND FAIRLEAD GROUPS
PA90VS
QTY .
ITE M NO. P AR T NO. DE S C R IP TION 3-R OL L E R 4-R OL L E R
601 126-0836 V E R T IC AL R OLLE R 2 2
602 126-0835 V E R T IC AL S HAF T AS S E MB LY 2 2
603 126-0794 B US HING 6 8
604 102793 * HOR IZONT AL R OLLE R 1 2
605 102792 * HOR IZONT AL S HAF T AS S E MB LY 1 2
606 4L-6454 C AP S C R E W (3/8 - 16 X 21 IN., G D8, HE X HD) 3 4
607 8T -4896 W AS HE R , HAR D (3/8) 3 4
608 126-0806 W AS HE R , HAR D (2 IN.) 6 8
609 3B -8489 G R E AS E F IT T ING 6 8
--- 63433 * 4T H R OLLE R G R OUP (INC LUDE S IT E MS 603 - 609 NE E DE D F OR ONE C OMP LE T E R OLLE R INS T ALLAT ION) OP T . ---
* P AC C AR W inch Divis ion part number. C aterpillar part number not available at time of printing.
14
WINCH HOUSING AND FAIRLEAD GROUPS
PA90VS
15
OUTPUT PLANET CARRIER ASSEMBLY
PA90VS
16
INTERMEDIATE PLANET CARRIER ASSEMBLY
PA90VS
21
17
19
20
15
16
18
38
17
CARRIER CLUTCH ASSEMBLY
PA90VS
* PACCAR Winch Division part number. Caterpillar part number not available at time of printing
18
SPRAG CLUTCH ASSEMBLY
PA90VS
53 52
51
54 49
51
52
50
55 53
19
BRAKE HOUSING ASSEMBLY
PA90VS
20
BRAKE HOUSING ASSEMBLY
PA90VS
21
RECOMMENDED FASTENER TORQUE
Higher or lower torque values for special applications will be specified; such as the use of spanner nuts, nuts on shaft
ends, jam nuts and where distortion of parts or gaskets is critical.
Lubricated torque values based on use of SAE 30wt engine oil applied to threads and face of bolt or nut.
Avoid using thread lubricants as the applied torque may vary by 10 - 40%, depending upon the product used.
Q
Torque (LB-FT) Torque (LB-FT)
Bolt Dia. Thds Per Grade 5 Grade 8 Bolt Dia. Thds Per Grade 5 Grade 8
Inches Inch Dry Lubed Dry Lubed Inches Inch Dry Lubed Dry Lubed
20 10
1/4 8 6 12 9 3/4 265 200 380 280
28 16
18 9
5/16 17 13 24 18 7/8 420 325 600 450
24 14
16 8
3/8 31 23 45 35 1 640 485 910 680
24 14
14 7
7/16 50 35 70 50 1 1/8 790 590 1290 970
20 12
13 7
1/2 75 55 110 80 1 1/4 1120 835 1820 1360
20 12
12 6
9/16 110 80 150 110 1 3/8 1460 1095 2385 1790
18 12
11 6
5/8 150 115 210 160 1 1/2 1940 1460 3160 2370
18 12
To convert lb•ft to kg•m, multiply lb•ft value by 0.1383.
22
METRIC CONVERSION TABLE
English to Metric Metric to English
LINEAR
inches (in.) X 25.4 = millimeters (mm) millimeters (mm) X 0.3937 = inches (in.)
feet (ft.) X 0.3048 = meters (m) meters (m) X 3.281 = feet (ft.)
miles (mi.) X 1.6093 = kilometers (km) kilometers (km) X 0.6214 = miles (mi.)
AREA
2 2 2
inches (sq.in.) X 645.15 = millimeters (mm ) millimeters 2 (mm 2) X 0.000155 = inches 2 (sq.in.)
feet 2 (sq.ft.) X 0.0929 = meters 2 (m 2) meters 2 (m 2) X 10.764 = feet 2 (sq.ft.)
VOLUME
inches 3 (cu.in.) X 0.01639 = liters (l) liters (l) X 61.024 = inches 3 (cu.in.)
quarts (qts.) X 0.94635 = liters (l) liters (l) X 1.0567 = quarts (qts.)
gallons (gal.) X 3.7854 = liters (l) liters (l) X 0.2642 = gallon (gal.)
inches 3 (cu.in.) X 16.39 = centimeters 3 (cc) centimeters3 (cc) X 0.06102 = inches 3 (cu.in.)
feet 3 (cu.ft.) X 28.317 = liters (l) liters (l) X 0.03531 = feet 3 (cu.ft.)
feet 3 (cu.ft.) X 0.02832 = meters 3 (m 3) meters3 (m3) X 35.315 = feet 3 (cu.ft.)
fluid ounce (fl.oz.) X 29.57 = millileters (ml) milliliters (ml) X 0.03381 = fluid ounce (fl.oz.)
MASS
ounces (oz.) X 28.35 = grams (g) grams (g) X 0.03527 = ounces (oz.)
pounds (lbs.) X 0.4536 = kilograms (kg) kilograms (kg) X 2.2046 = pounds (lbs.)
tons (2000 lbs.) X 907.18 = kilograms (kg) kilograms (kg) X 0.001102 = tons (2000 lbs.)
tons (2000 lbs.) X 0.90718 = metric tons (t) metric tons (t) X 1.1023 = tons (2000 lbs.)
tons (long) (2240 lbs.) X 1013.05 = kilograms (kg) kilograms (kg) X 0.000984 = tons (long) (2240 lbs.)
PRESSURE
o
inches Hg (60 F) X 3600 = kilopascals (kPa) kilopascals (kPa) X 0.2961 = inches Hg (60 oF)
pounds/sq.in. (PSI) X 6.895 = kilopascals (kPa) kilopascals (kPa) X 0.145 = pounds/sq.in. (PSI)
pounds/sq.in. (PSI) X 0.0703 = kilograms/sq.cm. (kg/cm 2) kilograms/sq.cm. (kg/cm2) X 14.22 = pounds/sq.in. (PSI)
pounds/sq.in. (PSI) X 0.069 = bars bars X 14.5 = pounds/sq.in. (PSI)
o o
inches H 2O (60 F) X 0.2488 = kilopascals (kPa) kilopascals (kPa) X 4.0193 = inches H 2O (60 F)
bars X 100 = kilopascals (kPa) kilopascals (kPa) X 0.01 = bars
POWER
horsepower (hp) X 0.746 = kilowatts (kW) kilowatts (kW) X 1.34 = horsepower (hp)
ft.-lbs./min. X 0.0226 = watts (W) watts (W) X 44.25 = ft.-lbs./min.
TORQUE
pound-inches (in.-lbs.) X 0.11298 = newton-meters (N-m) newton-meters (N-m) X 8.851 = pound-inches (in.lbs.)
pound-feet (ft.-lbs.) X 1.3558 = newton-meters (N-m) newton-meters (N-m) X 0.7376 = pound-feet (ft.-lbs.)
pound-feet (ft.-lbs.) X .1383 = kilograms/meter (kg-m) kilogram/meter (kg-m) X 7.233 = pound-feet (ft.-lbs.)
VELOCITY
miles/hour (m/h) X 0.11298 = kilometers/hour (km/hr) kilometers/hour (km/hr) X 0.6214 = miles/hour (m/h)
feet/second (ft./sec.) X 0.3048 = meter/second (m/s) meters/second (m/s) X 3.281 = feet/second (ft./sec.)
feet/minute (ft./min.) X 0.3048 = meter/minute (m/min) meters/minute (m/min) X 3.281 = feet/minute (ft./min.)
TEMPERATURE
o o o
Celsius = 0.556 ( F - 32) Fahrenheit = (1.8 X oC) + 32