D3G, D4G and D5G HYSTAT Track-Type Tractors Winch Systems Caterpillar

• The pump has been rebuilt.

• The drum begins to rotate slowly when the winch control is in the BRAKE OFF position.

This adjustment requires a mechanical adjustment and a hydraulic adjustment. You must perform the mechanical adjustment before you perform the hydraulic adjustment.

Refer to Testing and Adjusting, "Tooling Preparation" for additional information for tooling assembly and for alternate methods of testing.

Machine Preparations

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Illustration 1	g00798620

1. Remove four bolts (3) and washers.

2. Remove two footrests (1) .

3. Remove floormat (2) .

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Illustration 2	g00798650

4. Remove six bolts (4) and washers.

5. Remove access panel (5) .

6. Remove the filler cap from the hydraulic tank.

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Illustration 3	g00836976

7. Install vacuum cap (8) onto hydraulic tank (9) .

8. Connect hose (7) to vacuum cap (8). Route the other end of the hose into a suitable container in order to collect any oil that may drain from the hose.

9. Connect air hose (6) to vacuum cap (8) .

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Illustration 4	g00808103

10. Disconnect pilot lines (10). Install plugs on the pilot lines.

11. Remove connectors (11) from the pilot ports.

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Illustration 5	g00837064

12. Install 6V-3965 Fitting (Test) (12) onto each pilot port.

13. Connect each end of the 177-7862 Hose As onto each test fitting.

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Illustration 6	g00808094
The pump is installed on the machine.

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Illustration 7	g00837076
The pump is removed from the machine for clarity.

14. Remove plug (13) from the port "X1"and remove plug (14) from the port "X2".

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Illustration 8	g00808096

15. Install a test fitting assembly (15) for each port.

16. Connect one end of the 177-7862 Hose As to port "X1" and connect the other end of the hose assembly to port "X2".

17. Separate the winch from the machine. Refer to Disassembly and Assembly, "Winch -Remove". Do not disconnect the hydraulic hoses at this time.

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Illustration 9	g00853738

18. Remove the bolts, washers and half flanges in order to disconnect hoses (16) .

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Illustration 10	g00853739

19. Install 122-1951 Cover (18) onto each hose (16) with the following hardware for each hose:
    • four bolts

    • eight washers

    • two half flanges

    • four nuts

20. Install 5P-0046 Covers (17) onto the ports of the piston motor with the following hardware:
    • eight bolts

    • eight washers

    • four half flanges

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Illustration 11	g00799164

21. Connect the hose of 6V-7830 Tetragauge to port "10".

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Illustration 12	g00808193

22. Turn handle (19) of ball valve (20) toward the right side of the machine to the TEST position.

Mechanical Adjustment

1. Enter the machine.

2. Start the engine.

3. Allow the oil to warm up to a minimum temperature of 20 °C (68 °F).

4. Increase engine speed to HIGH IDLE.

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Illustration 13	g00808196

5. Mark the position of set screw (21) .

6. Loosen locknut (22) on set screw (21) .

7. Turn the set screw clockwise until the winch loop pressure at remote pressure tap "10" increases by 200 kPa (30 psi). Mark this position.

Note: The winch loop pressure may decrease before the pressure increases.

8. Turn the set screw back to the original position.

9. Turn the set screw counterclockwise until the winch loop pressure at pressure tap "10" increases by 200 kPa (30 psi). Mark this position.

10. Position the set screw at the midpoint between the two positions that were marked in Step 7 and Step 9.

11. Maintain the position of the set screw while you tighten the locknut.

12. Stop the engine.

13. Remove the jumper hose between the "X1" port and the "X2" port.

14. Remove the tetragauge from port "10".

15. Continue with the hydraulic adjustment.

Hydraulic Adjustment

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Illustration 14	g00857819

1. Install a hose assembly onto port "X1" and install a hose assembly onto port "X2".

2. Install a 8T-0855 Gauge Assembly (0 to 4,000 kPa (0 to 580 psi)) onto the end of each hose assembly.

3. Start the engine.

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Illustration 15	g00815596

4. Loosen lock screw (23) on set screw (24) .

5. Adjust set screw (24) until the pressure at port "X1" is within 200 kPa (30 psi) of the pressure of port "X2".

6. Maintain the position of the set screw while you tighten the lock screw.

Note: This adjustment is sensitive and the adjustment can easily change as you tighten the lock screw.

7. Verify that the pressures of the two ports are within 200 kPa (30 psi) of each other.

   1. Stop the engine.

   2. Exchange the gauges of the two ports.

   3. Start the engine.

   4. Verify that the pressures of the two ports are within 200 kPa (30 psi) of each other.

   5. Stop the engine.

8. Remove the gauges and hoses.

9. Reconnect the pilot lines.

10. Remove the test fitting assemblies and reinstall the plugs.

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Illustration 16	g00798650

11. Install the access panel (5) .

12. Install six bolts (4) and washers.

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Illustration 17	g00798620

13. Install floormat (2) .

14. Align footrests (1) and install four bolts (3) and washers.