Installation of the Winch on the D3K2, D4K2, and D5K2 Track-Type Tractors {5163} Caterpillar

Track-Type Tractor

D3K2 (S/N: KF21-UP; KL21-UP; FT31-UP; LT31-UP; JPJ1-UP)

D4K2 (S/N: KM21-UP; KR21-UP; MT31-UP; RT31-UP)

D5K2 (S/N: KW21-UP; KY21-UP; WT31-UP; YT31-UP; RRE1-UP)

Introduction

This Special Instruction provides the procedures for the installation of the winch on the D3K2, the D4K2, and the D5K2 Track-Type Tractors.

The attachment for the Winch Mounting Plate, the attachment for the Winch Hydraulic Arrangement, and the attachment for the cab or canopy Rear Screen needs installed before performing the steps in this Special Instruction. All the required parts are stated in the price list for the machine.

Requirements The machine MUST have one of the following Winch Hydraulic Arrangements on the machine before installing the winch.

• D3K2 - 397-4189 Three-Valve Hydraulic Ar or 397-4193 Four-Valve Hydraulic Ar

• D4K2 - 397-4189 Three-Valve Hydraulic Ar or 397-4193 Four-Valve Hydraulic Ar

• D5K2 - 397-4190 Three-Valve Hydraulic Ar or 397-4194 Four-Valve Hydraulic Ar

Note: All models must have the following installed before installing the winch:

• 393-4250 Protection Screen Gp (Cab) or 393-4251 Protection Screen Gp (Canopy)

• 397-4389 Winch Mounting

Do not perform any of the procedures in this publication until you have completely read all the information.

Removal of Existing Parts from the Machine

Illustration 1	g06024622
(1) Plates (2) Location of hoses for the winch hystat motor (3) Winch mounting plate

Remove plates (1) from the rear of the tractor to access the hydraulic lines for the winch. Remove the lines for the hystat motor from area (2). The reel-out hose will be bolted to the top and the reel-in hose will be bolted to the bottom of area (2).

Preparation of the Winch and the Machine

Illustration 2	g01330463
(4) Mating surface of the winch that needs to be clean (3) Hydrostatic winch

Clean surfaces (4) of the winch that contacts the mating surfaces (5) of the machine. Remove the paint and remove the foreign material from all the mating surfaces. Remove the plugs that protect the threaded bolt holes. Also, remove paint and remove foreign material from the areas of the bolt holes.

Illustration 3	g06026964
The winch is installed onto the tractor in the locations that are shown in illustration 3.

Clean surfaces (5) of the winch that contacts the mating surfaces (4) of the machine. Remove the paint and remove the foreign material from all the mating surfaces. Remove the plugs that protect the threaded bolt holes. Also, remove paint and remove foreign material from the areas of the bolt holes.

Weight of the Components for the Hydrostatic Winch

Refer to Table 2 for the weight of the components. 187-1713 Winch Conversion Group(fourth roller)

Note: Use Tool (A) and a suitable lifting device to lift and balance the winch (3) during the installation procedure.

Illustration 4	g01330541

Position winch (3) at the mounting location on the case of the machine. Leave enough clearance between the winch and the case to install the hose assemblies. The weight of the winch is 610 kg (1345.0 lb).

Location and Identification of the Hose Assemblies and Solenoids for the Winch

Note: Identify the location of the hydraulic connections prior to connecting the four hose assemblies to the winch. Also identify the location of the electrical connections prior to connecting the three connector plug assemblies to the winch.

Illustration 5	g01330578
(6) The first solenoid is for the drive away function. (7) The second solenoid is for the brake function. (8) The third solenoid is for the free spool function. (9) "P2" port connection (10) Case drain connection (11) Reel-out port connection (12) Reel-in port connection

Illustration 6	g01330883
(13) Case opening to access winch hose assemblies.

Note: Connections of the hoses and solenoids are located in Section "Connection of the Hose Assemblies and Solenoids".

The hose assemblies that are required for the installation of the winch were installed on the tractor at the factory. These hose assemblies are secured within the case of the tractor. These hose assemblies are accessible through the opening in the case (13) that is shown in Illustration 6. The lines of the hystat motor are bolted to location (2) that is shown in Illustration 1.

The connector plug assemblies that are required for the installation of the winch were installed on the tractor at the factory. These connector plug assemblies are secured within the case of the tractor. These connector plug assemblies are accessible through the opening in the case (13) that is shown in Illustration 6.

Note: Remove the caps, the bolts, and the covers from the areas that are shown in Illustration 5.

Note: Save all the caps, covers, bolts, and plugs in case the winch is removed in the future.

Procedure to Apply a Vacuum to the Hydraulic Tank

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Personal injury can result from hydraulic oil pressure and hot oil. Hydraulic oil pressure can remain in the hydraulic system after the engine has been stopped. Serious injury can be caused if this pressure is not released before any service is done on the hydraulic system. Make sure all of the work tools have been lowered to the ground, and the oil is cool before removing any components or lines. Remove the oil filler cap only when the engine is stopped, and the filler cap is cool enough to touch with your bare hand.

Note: To prevent oil leakage, apply a vacuum to the hydraulic oil tank. Do not exceed 7 kPa (1 psi) of vacuum pressure. Exceeding 7 kPa (1 psi) may damage the hydraulic tank. Capture any oil that is lost during the installation of the hose assemblies.

Illustration 7	g01333371

Illustration 7 shows Tool (B) that is properly installed onto the hydraulic tank.

Perform the following steps to create a vacuum on the hydraulic system.

1. Remove the cap from the hydraulic oil tank.

2. Install the Tool (B) onto tank (16).

3. Attach hose (15) to Tool (B).

4. Put the end of hose (15) into a suitable container for the collection of oil.

5. Connect air hose (14) onto Tool (B).

6. Dispose of any oil that was lost in a proper manner.

Note: Check that the vacuum is functioning properly on the oil tank prior to opening the hydraulic hose assemblies.

Connection of the Hose Assemblies and Solenoids

Illustration 8	g06026970
(17) Hose assembly for the "P2" port (18) Plug assembly (19) Hose assembly for the case drain (20) Hose assembly (21) Hose assembly (22) Eight 8T-4182 Bolts (23) Eight 8T-4121 Hard Washers (24) Four 8T-9403 Half Flanges (25) Two 122-1951 Covers (26) Eight 8T-4133 Nuts (27) Plug assembly

Illustration 9	g06026973
(28) Connector plug assembly (Orange and black wires) (29) Connector plug assembly (Black and blue wires) (30) Connector plug assembly (Yellow and orange wires)

Illustration 10	g06016529
(6) The first solenoid is for the drive away function. (7) The second solenoid is for the brake function. (8) The third solenoid is for the free spool function. (17) Hose assembly (19) Hose assembly (20) Hose assembly (21) Hose assembly

Note: Connect hose assemblies (20) and (21) first.

Note: Orient the hose assemblies to avoid contact and rubbing.

1. Remove the following items from hose assemblies (20) and (21).

   • Four bolts (22)

   • Four washers (23)

   • Two half flanges (24)

   • Cover (25)

   • Four nuts (26)

2. Connect hose assembly (21) to the upper drive motor port on the hystat motor. Use four 8T-4121 Hard Washers (23), four 8T-4182 Bolts (22), and two 8T-9403 Half Flanges (24) to fasten hose (21) to the winch. Tighten four 8T-4182 Bolts (22) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Refer to Illustration 10.

3. Connect hose assembly (20) to the lower drive motor port on the hystat motor. Use four 8T-4121 Hard Washers (23), four 8T-4182 Bolts (22), and two 8T-9403 Half Flanges (24) to fasten hose (20) to the winch. Tighten four 8T-4182 Bolts (22) to a torque of 55 ± 10 N·m (41 ± 7 lb ft). Refer to Illustration 10.

4. Remove plug assembly (18) from hose assembly (17). Refer to Illustration 8 for location.

5. Remove plug assembly (27) from hose assembly (19). Refer to Illustration 8 for location.

6. Connect hose assembly (19) to case drain (10). Refer to Illustration 5 and 10 for location.

7. Connect hose assembly (17) to the "P2" port (9). Refer to Illustration 5 and 10 for location.

8. Connect connector plug assembly (28) to solenoid (6). Refer to Illustration 5 and 9 for location.

9. Connect connector plug assembly (30) to solenoid (7). Refer to Illustration 5 and 9 for location.

10. Connect connector plug assembly (29) to solenoid (8). Refer to Illustration 5 and 9 for location.

11. Remove tool (B) and install the cap onto the hydraulic tank.

Installation of the Winch to the Case

Note: Check the location of the hoses. Orient the hose assemblies to avoid contact and rubbing.

1. Position the winch onto the case.

2. Align the bolt holes of the winch with the threaded bolt holes in the case.
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   Illustration 11	g01333878
   (31) Mounting bolts for the winch

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   Illustration 12	g01333886
   (31) Mounting bolts for the winch (32) Cover mounting bolt

3. Remove bolt (32) from the access cover. This removal will allow clearance for Tool (C). Install the mounting bolts that secure the winch to the case.
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   Illustration 13	g00837182

4. Position Tool (C) onto each bolt (31). A suitable wood block with Tool (C) is needed to tighten the mounting bolts on the top left side of the winch. Refer to Illustration 13 for tool position. Refer to Illustration 12 and 11 for bolt locations.
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   Illustration 14	g01333898
   Winch installation. This illustration shows the lower side of the winch that is bolted to the case.

5. Use Tool (C) to tighten bolts (31) to a torque of 900 ± 100 N·m (664.0 ± 74.0 lb ft).

6. Use Tool (D) to tighten only bolt (33) to a torque of 900 ± 100 N·m (664.0 ± 74.0 lb ft).

   Note: No special positioning of the tool is required.

7. Install bolt (32) onto the original location on the machine.

8. Remove the lifting device from the winch.

Note: Check the oil level in the winch before proceeding. Refer to Operation and Maintenance Manual, SEBU8498, "Winch Oil Level - Check" to check the oil level in the winch. Fill the winch with oil to the correct level. Refer to Operation and Maintenance Manual, SEBU8498, "Winch Oil - Change" to fill the winch.

Testing the Operating System of the Winch (Option)

Note: Check all fluid levels before testing of the winch and several times during testing of the winch.

Reference: Refer to Testing and Adjusting, UENR1357 for the procedure to test the winch after installation.

Setting Up the Winch In ET

The software program that will be used for this test procedure is the Caterpillar Electronic Technician (ET) . The Caterpillar Electronic Technician (ET) is a software program that can be used on an IBM compatible personal computer. Refer to the Service Manual, JEBD3003 for the requirements to install Caterpillar Electronic Technician (ET).

Installing the Rear Winch

1. Open the software program (ET). Install 461-4351 (or latest) software on the auxiliary ECM.

2. Select the machine control ECM from the ECM list.

   Note: Make sure that the machine has the latest ECM software installed.

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   Illustration 15	g01419205

3. The "Rear Attachment Installation Status" will be set to "Winch Pump" or "Winch Pump with 4th Function".
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   Illustration 16	g01419380

4. Select "Rear Attachment Installation Status". Then select the "Change" button.
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   Illustration 17	g01419211

5. Select the drop-down menu in the "New Value" box. Then select "Winch". Then select "OK".

   Note: If the machine has a standard 3-bank implement valve, change the status to "Winch".

   Note: If the machine has an optional 4-bank implement valve, change the status to "Winch with 4th Function".

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   Illustration 18	g01419213

6. The winch will be set up once the screen appears in Illustration 18.

   Note: If the machine has a standard 3-bank implement valve, the "Rear Attachment Installation status" will display "Winch".

   Note: If the machine has an optional 4-bank implement valve, the "Rear Attachment Installation status" will display "Winch""Winch with 4th Function".

Calibration of the Solenoid for the Winch

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Illustration 19	g01419382

1. The screen will show that the "Winch Spool In Solenoid" is not calibrated. The screen will also show that the "Winch Spool Out Solenoid" is not calibrated.
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   Illustration 20	g01419215

2. Select the "Service" menu to begin the calibration procedure. Then select "Calibrations". A second menu will be displayed. Select "Implement Valve Solenoid Calibrations (Pressure-Based)" from the second menu.
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   Illustration 21	g01419219

3. The next screen is the initial calibration screen. Once "Winch Solenoid Calibrations" has been selected, the screen displays the instructions for calibration. The top display area displays status parameters that are monitored during the calibration. The middle display area displays information about the status of the calibration. The display area on the bottom will display the conditions for the setup and the display area on the bottom will also display the instructions for the calibration.

4. The display area will show the following conditions for the setup:

   • Engage the parking brake.

   • Operate the engine at high idle.

   • Place the "Implement Lockout Switch" to "Not Locked Out".

   • Warm the hydraulic oil to a minimum of 15 °C (59 °F) and a maximum of 90 °C (194 °F).

5. Press the "Next>" button to start the calibration. If the conditions for the setup are not correct, the condition that is not correct will be display in the middle display area. The calibration will not start. When the conditions are correct, press the "Next>" button to start the fill calibration.

6. The calibration procedure continues unless the ECM determines that one of the conditions is not met. The middle display area will display a message to alert you of the error. You can correct the error that is described in the middle display area or you can cancel the calibration by pressing the "Cancel" button. The Electronic Technician will display a message in the middle display area to alert you of the problem.

7. If the solenoid calibration needs to be restarted, press the "Restart" button.
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   Illustration 22	g01353331

8. Once the calibration has been successfully completed, select "FINISH".

Calibration for the Winch Control Lever

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Illustration 23	g01419387

1. The screen will show that the "Auxiliary Lever" may need calibrated.
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   Illustration 24	g01419220

2. Select the "Service" menu to begin the calibration procedure. Then select "Calibrations". A second menu will be displayed. Select "Implement Operator Control Calibrations" from the second menu.
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   Illustration 25	g01353428

3. Select "Auxiliary Control Lever". You will need to make sure that "Blade Control Lever" and "Blade Control Handle Thumb Rocker" are not selected. Select "Begin".
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   Illustration 26	g01353553

4. The next screen is the initial calibration screen. Once "Auxiliary Control Lever" has been selected, the screen displays the instructions for calibration. The top display area displays status parameters that are monitored during the calibration. The middle display area displays information about the status of the calibration. The display area on the bottom will display the conditions for the setup and the display area on the bottom will also display the instructions for the calibration.

5. The display area will show the following conditions for the setup:

   • Engage the parking brake.

   • The engine must be at 0 RPM.

   • Place the "Implement Lockout Switch" to "Locked Out".

6. Press the "Next>" button to start the calibration. If the conditions for the setup are not correct, the condition that is not correct will be display in the middle display area. The calibration will not start. When the conditions are correct, press the "Next>" button to start the fill calibration.

7. The calibration procedure continues unless the ECM determines that one of the conditions is not met. The middle display area will display a message to alert you of the error. You can correct the error that is described in the middle display area or you can cancel the calibration by pressing the "Cancel" button. The Electronic Technician will display a message in the middle display area to alert you of the problem.

8. If the calibration needs to be restarted, press the "Restart" button.
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   Illustration 27	g01353655

9. Once the calibration has been successfully completed, select "FINISH".

Note: Check the winch to make sure that all connections are correct before installing the winch onto the machine.

Installation of the Fairlead Group (Option)

A Winch Fairlead Group is used in applications that encounter slight side directional pulls. A Winch Fairlead Group improves the life of the winch case and the life of the winch cable due to reduced mechanical friction in these applications.

A Winch Conversion Group that has the fourth roller for the Winch Fairlead Group is an option. The fourth roller is attached to the lower portion of the fairlead assembly.

Note: Shims are required to eliminate the clearances between the winch arrangement and the winch fairlead. Position the winch fairlead on the winch arrangement. Measure the clearances from the outside of the lower bolt holes of the winch arrangement to the inside lower bolt hole of the winch fairlead. Use a combination of shims to eliminate these clearances prior to installing the mounting bolts.

Note: The top of the winch fairlead must be shimmed in the same manner as the bottom of the winch fairlead.

Illustration 28	g01333922
The bolt holes (34) and (35) in the winch must align with the bolt holes in the fairlead group. The shims are positioned at locations (E) that are between the winch arrangement and the fairlead group.

Illustration 29	g01333949

1. Use a suitable lifting device to position fairlead group (36) on winch (3).

2. Align the bolt holes in the fairlead group with the bolt holes (34) and (35) in the winch.
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   Illustration 30	g01333984

3. Use 215-1850 Threaded Rod (37) to secure the upper part of the fairlead group to the winch at bolt hole (34). Refer to Illustration 28.

   Note: Install shims to eliminate any gaps between the fairlead group and the winch.

4. Install hard washer (38) and nut (39) to each end of threaded rod (37). Tighten nuts (39) to a torque of 3100 ± 350 N·m (2290 ± 260 lb ft).

5. Measure the clearances from the outside of the lower bolt holes of the winch arrangement to the inside lower bolt hole of the winch fairlead.

6. Use a combination of shims (E) to eliminate these clearances prior to installing the mounting bolts. Refer to Table 4 for a description of the shims that are available.

7. Position the required combination of shims between the fairlead group and the winch.

8. Install bolts (42) through the bolt holes in the fairlead group, the bushings, the shims, and bolt holes (35) in the winch. Install washer (41) and nut (40) onto each bolt. Tighten nuts (40) to a torque of 900 ± 100 N·m (665 ± 75 lb ft). Refer to Illustration 30.
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   Illustration 31	g01419179

9. Place 215-1866 Keeper (43), 5S-7379 Bolt (44), and 8T-4896 Hard Washer (45) onto the machine. Torque the bolts to 47 ± 9 N·m (35 ± 7 lb ft).
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   Illustration 32	g01419181

10. Place two 215-1867 Keepers (46), 5S-7379 Bolt (44), and 8T-4896 Hard Washer (45) onto the machine. Torque the bolts to 47 ± 9 N·m (35 ± 7 lb ft).

Illustration 33	g01334013
Fairlead Group (36) is installed onto winch (3).

Installation of the Winch Cable

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Personal injury or death can result from unexpected movement of objects. Be sure all persons are clear of cable and objects before a machine is winched or moved. A safe distance of at least one and a half times the working length of the cable should be maintained. The tail end of a moving object can throw debris at bystanders. A minimum of five complete wraps of cable must be maintained on the winch drum. Do not handle a load with a winch drum that has less than five wraps.

Note: The cable ferrule or the cable anchor assembly will not support the rated loaded capacity. Therefore, maintain a minimum of five wraps of the cable on the drum of the winch.

Note: Consult your local Caterpillar dealer for winch cables and ferrules.

1. Unwrap the winch cable. Place the ferrule end toward the winch.

   Note: Prior to installing the cable onto the drum of the winch, use red paint to identify the first 4.6 m (15 ft) of the cable. The first five wraps of the cable around the winch drum are the 4.6 m (15 ft) of the cable that is painted red. This method of identification is used to warn the operator not to unwrap the last five lines of cable that are wrapped around the drum of the winch.

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   Illustration 34	g01334023

2. Remove bolt (47) and the retaining clip from the winch drum (48).
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   Illustration 35	g01334025
   Typical example of a ferrule (49) that is used with a winch cable

3. Position the ferrule (49) into the opening of drum (48). Install the retaining clip and bolt (47) to secure the ferrule and the winch cable to the drum. Tighten bolt (47).

4. Lay the cable in a straight line.

   Note: Use Tool (F) to connect the cable to a heavy object. The cable should be attached to a heavy object that weighs approximately 68.0 kg (150 lb). The heavy object is pulled toward the machine. The machine should not move during the installation of the cable onto the drum of the winch.

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   Illustration 36	g01334028

   Note: Maintain tension on the cable while the cable is wound around the winch drum.

5. The first roll of the cable (50) starts from the right side of the drum (48). Continue this process from the left side over the first roll and repeat until the cable is wound on the drum completely. Refer to Illustration 36.

6. When the winch cable is wound on the drum, remove Tool (F) to disconnect the winch cable from the heavy object. Slowly reel in the remaining cable.