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1 FORD V8 5.0L & 5.8L w-w/o AC _ 7504C Belt Drve Hydraulcs. a: ~-- ~ ~ Q, ~ t. -- ~ ~, ~/~~ ", /~~.. " ''Q,",,_,~. L_~ "" " ~~ \ r-)~)- ) " ~ _ n 'l 1 ) ", 1/ / l ", l, 1;-' =', - ",,, "".. "",..', t, l'~'' ~. ' ~ FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/2/

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3 7504C Page 3 Hydraulcs Parts Lst Ref. Qty n Kt Part Descrpton Ref. Qty n Kt Part Descrpton # A # * Part of 8010 Bolt Bag # A # * Part of 8010 Bolt Bag -40 C -40 C 1 1 A2311 Pump tank assembly 40 2 *8011 Nylon Mountng Te Wrap 2 1 A4466 Control Valve Assembly 42 2 A 1587 Hose Dsconnect Assembly Clevs - VM Dust Plug - ClosurelMale Square Nut - VM 44 1 * 4486 Adapter - Bulkhead 1/4" Npt Clevs Pn - 3/16" x * 4485 Snap Rng - 7/8" Ext. Bowed /16" Push Nut Zp /4" x 90 Swvel Adapter SLC Head - Belt Drve /16-18 wd-rng x 3/8 F P Sw 9 2 A " Control Cable, SLC 50 * 765 1/4 Npt x 90 Deg Street Elbow 10 1 A /2" x 10" Cylnder Assy /4 Npt x 90 Deg Street Elbow Frgd 11 2 A /2" x 12" Cylnder Assy 52 4 * /4 Npt x 90 Deg Unon Elbow Clevs Pn - 1 x 3-5/ *3979 3/8 NPT x 90 Deg Street Elbow Anchor Pn - 1 x *3058 9/16" D.R. to 1/4P Adapter /4" x 1-1/2" Cotter Pn " HP Hose - 1/4P - 3/8P 71 1 *6595 Splt Hose Grommet " HP Hose 3/8P - 3/8P Cauton Label - Cab " HP Hose1/4P to 1/4P Grommet - Rubber, Splt " HP Hose, 1/4P to 1/4P Grommet - Splt Hose " HP Hose, 1/4P to 1/4P *3666 Hose Te, nylon 3/16 x " HP Hose, 1/4P to 1/4P 76 1 * /16" x 1-1/4" (NC) Gr. 5 Cap Screw 22 1 *3677 Fan Spacer, 1/2" /16 x 1-1/2 (NC) Gr. 5 Cap Screw " Fan Belt (not shown) * /16 x 1 (NC) Gr. 5 Cap Screw Drve Sheave * /16 Sp Lk Washer Pump Sheave * /16 (NC) Nut Pump Bracket * /16 Plan Washer Pump Bracket Brace /4 x 1-1/4 (NC) Gr. 5 Cap Screw Brace /4 Sp Lk Washer Valve Plate /4 (NC) Nut Fender Bracket 87 4 *4433 1/2" Specal Washer Hose Support Bracket 90 2 *90659 #12 x3/4" PN HD SM Screw Brace 91 2 * /8 SP LK Washer Ar ntake Bracket 92 2 * /8" (NC) Nut Brace 93 2 * /8" x 1-1/4 (NC) Gr. 5 Cap Screw Saddle Bracket 95 4 *9015 5/16" x 1-1/2" (NF) Gr. 5 Cap Screw Rear Tank Strap 96 4 * /8" x 4-1/4" (NC) Gr. 5 Cap Screw Unversal Brace Rod 97 4 *4268 Spacer Washer 38 *2115 Unversal Brace Tab 98 1 * /16" x 7-1/2" (NC) Gr. 5 Cap Screw Dsconnect Mountng Plate 99 1 * /16" Lock Washer FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/2/96

4 nstallaton nstructons 7504C Page 4 1. Cylnder & Cylnder Hose Assembly A. Usng bench vse to hold lft cylnder (10), remove closure from port. Screw 90 degree swvel adapter (46) nto port. Place lft cylnder wth nstalled adapter between ears on undersde of lft arm and lower headgear ears. Attach cylnder to ears usng clevs pns (12) and cotter pns (15). B. Usng bench vse to hold 32" HP hose (20), nstall female half of hose dsconnect assembly (42) drectly to hose. Then, holdng 36" HP hose (21), nstall brass bar street ell (50) and male half of hose dsconnect assembly (42) on the same hose end. C. Usng a bench vse to hold angle cylnders (11), remove closures from ports and screw brass forged street ells (51) nto ports so that ells are parallel wth cylnder and pont toward lve end. nstall 32" HP hose wth female dsconnect half to drver's sde angle cylnder street ell. nstall other HP hose wth male dsconnect half to passenger sde angle cylnder street ells. nstall angle cylnders to "A" frame on ther respectve sdes so that ells are between cylnders and "A" frame. Secure cylnders wth anchor pns (13) at port end and ram end. Secure anchor pns wth cotter pns (15). 2. Control Head & Control Cables Note: Dash bracket, hardware, drlng gude and mountng nstructons wl be found n pecular A. Drll three 5/8" holes n the frewall for the control attchments box. cables and wrng harness usng drlng gude as a reference only. Be sure both sdes of the frewall are clear of obstructons before drlng. B. nstall the dash bracket as per dash bracket nstructons. C. Loosen the "jam nuts" on control head end of cables (9) and nstall nto slots n control head (8). (Rase cable centers n begnnng of lower slot.) Snap cable ends onto ball studs and tghten jam nuts to secure cables to control head. Remove the nuts and washers from the valve end of the cables. Route the cables out through the frewall up to top of the drver sde fender well. Attach control head to dash bracket as per dash bracket nstructons. nstall rubber grommets (73) around cables where they pass through the fre wall. 3. Valve & Valve Plate A. Usng a bench vse to hold control valve assembly (2), remove closures from valve ports. Screw the 90 degree swvel adapter unons (47) nto the "n" and "out" ports. Screw qul (55) and shock absorber (49) nto male run tee (48) as lustrated. Screw ths tee assembly nto ths swvel adapter n the "out" port of the valve. Be sure the shock absorber s standng straght up. nstall three 9/16" o-rng to 1/4" ppe adapters (54) n lft and angle ports. nstall one 1/4" brass bar ell (52) to each adapter. When tght, ells should pont at 2 o'clock, away from cable end of valve. B. Mount valve to valve plate (29) usng two 1/4" x 1-114" cap screws, lock washers and nuts located n the valve bag. nstall cap screws from bottom of valve plate, wth lock washer and nut on top of valve. Attach the two long valve leg braces (32) to the two holes n the cable attachng end of valve plate. Attach wth two holes n the cable attachng end of valve plate. Attach wth two 5/16" x 1" cap screws Gr. 5 (NC) (78), lock washer (79) and nut (80). Attach rear leg brace (34) to hole n rear of valve plate on "out" port sde wth one 5/16" x 1" cap screw Gr. 5 (NC) (78), lock washer (79) and nut (80). Attach splt hose (74) to end of valve plate. Place valve plate and legs over smog control vacuum on passenger's sde of vehcle. (Vehcles wth bracket on back of vacuum. The bracket needs to be removed and the bottom hole placed on the top threaded stud.) Vehcles wth plastc hose comng out of top of vacuum: Place valve plate on fre wall sde of vacuum and valve spools pontng toward radator hose. Poston so nothng s chaffng and drl three 11/32" holes n fender. Attach wth three 5/16" x 1" cap screws Gr. 5 (NC) (78), large 1/2" flat washers (87), 5/16" flat washers (81), lock washers (78) and nuts (80). Note: The large vacuum canster wl have to be moved closer to the heater motor and to the engne usng vacuum brace (28), 5/16" x 1" cap screw (78), flat washer (81), lock washer (79) and nut (80). FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/2/96

5 nstallaton nstructons 7504C Page 5 C. nstall control cables to valve plate by renstallng jam nuts and washer son cables. Place control cables n respectve slots of valve plate bulkhead wth one nut and one washer on each sde of bulkhead. Center cables n slots so they are exactly n lne wth valve spool centers. Attach cable clevs (3) to cables usng square nuts (4). Slp cable clevs clevses over spools. nstall clevs pn. Adjust cables so that control head lever s centered between both angle and rase/lower postons. f cable clevs does not allow enough adjustment, reposton cable at valve plate bulkhead. After checkng to see that the valve spools are n the centered poston, tghten cable clevs nuts. Cauton: Valve spools must be free and self centerng when cables and control head are attached. Falure to center spools wl restrct flud flow through valve. Ths may cause hydraulc flud to overheat resultng n pump damage and/or hydraulc hose falure. Hose falures can cause engne fres. When adjusted, the control lever must be n the neutral poston to allow enough spool travel each way for proper valve actuaton. Use three nylon tes to run cables along ar ntake hoses. 4. Drve Sheave nstallaton A. Remove serpentne belt. Remove four 3/8" cap screws from crank shaft pulley. nstall Note: Apply a removable loosenng preventon compound (such as "Lock-tte") to all drve sheave fasteners pror to nstallaton. drve sheave (24) nto center of crank shaft pulley beng certan machned plot of drve sheave seats fully nto crankshaft pulley. Fasten drve sheave to crank shaft wth four 3/8" x 4-1/4" cap screws (96) and spacer washers (97) torqued to 31 ft-bs. B. Remove and dscard four cap screws holdng fan to water pump shaft flange. Place fan spacer (22) between fan and pulley. Renstall fan after nstallng pump bracket. 5. Pump and Pump Bracket Cauton: Pump tank fl must be vertcal to engne. A. Remove the two cap screws holdng the catalyst flter contaner to the drver's sde fender well. Remove flexble plastc ppe from molded plastc ar ntake duct. Lft and place contaner up out of the way. B. Remove and save nut from stud on bracket holdng dler pedestal (or ar condtoner) and power steerng pump. Also remove outer bolt from bracket. Poston pump bracket (26) behnd serpentne belt and place proper hole n tab on end of pump bracket over stud so that the 15/32" hole wth the ppe spacer lnes up wth the hole from whch the bolt was removed. Fasten tab wth prevously removed nut. nstall 7/16" x 7-1/2" cap screw (98) and 7/16" lock washer (99) n hole n pump bracket wth ppe spacer. Place cropped end of pump bracket brace (27) onto front exhaust manfold stud and fasten wth a 3/8" lock washer (91) and nut (92). On some models cap screw may have to be removed. Replace wth one 3/8" x 1-114" cap screw (NC) Gr. 5 ZP and lock washer. Place opposte end of brace on pump bracket tab and fasten wth one 5/16 x 1 Gr. 5 cap screw (78), lock washer (79) and nut (80). Tghten all fasteners. Remove rear bolt on dler pulley bracket or ar condtoner (f equpped) and nstall unversal brace tab (38). Renstall bolt and serpentne belt at ths tme. On 5.0 L engne, remove AlC or dler mount holdng AlC or dle pulley. nstall a 3/8 x 1-1/4 cap screw (93) from back of bracket. Renstall mount and nstall a 3/8 x 1-1/4 cap screw (93) from back of bracket. Renstall mount and nstall pump bracket same as above nstructons. On 5.8L, 3/8 x 1-1/4 (93) cap screw can be nstalled wthout removng mount. Fasten cap screw wth one 3/8 lock washer (91) and nut (92). Renstall fan and secure wth four 5/16" x 1-1/211 (NF) Gr. 5 cap screws (95) and lock washers (79) torqued to 18 ft-bs. C. For vehcles wth 5.8L engne. Plastc nner fender well must be pulled outward to provde clearance for Fsher hydraulc pump. Place fender bracket (30) n drver's sde fender well around col sprng bracket (F-150 models) or shock mount bracket (F-250, F-350 models). Poston bracket where, wth nner fender attached to t, adequate clearance wl result. Usng hole n bracket as gude, drl a 11/3211 hole through nner fender. nstall a 5/1611 x 1" cap screw (78), flat washer (81) and 1/211 specal washer (87) out through nsde of fender and fasten to bracket wth a 5/16 lock washer (79) and nut (80). "\ FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/2/96

6 nstallaton nstructons 7504C Page 6 D. Holdng pump tank (1) n bench vse, screw 3/8" brass bar street ell (53) onto return port on pump tank. nstall a 1/4" Brass bar ell (52) onto pressure port. Both fttngs should face upward. nstall pump sheave (25) onto shaft usng lock nut and key suppled wth pump. Remove pump from vse and nstall saddle bracket (35) on over front of pump. Secure wth a 5/16 x 1 Gr. 5 cap screw (78), flat washer (81), lock washer (79) and nut (80). Do not fully tghten. Fasten the support hose bracket (31) on the back sde of pump bracket wth the lower saddle bracket hardware (one 5/16" x 1-1/4" (NC) Gr. 5 cap screw (76), flat washer (81) lock washer (79) and nut (80).) Do not fully tghten. Use the upper hole n the hose support bracket on 5.0L engnes and the lower hole on 5.8L engnes. nstall 3/4" splt hose grommet (71) onto power steerng hose beneath the hose support bracket. Secure power steerng hose and splt hose grommet to hose support bracket. Secure power steerng hose and splt hose grommet to hose support bracket to mnmze hose twst and maxmze hose bend radus. Tghten V-belt and saddle bracket fasteners. Adjust for proper belt tenson by pvotng saddle bracket on top bolt. Cauton: There should be a mnmum of 1/2" clearance between hose support bracket and drve sheave V-belt. Bend bracket to ncrease clearance f necessary. E. Algn sheaves and tghten 1-1/2" saddle bracket fastener. nstall rear tank strap (36) on rear of pump tank. Check length of unversal brace rod (37) and cut to length as needed. nstall one 5/16" nut (80) and flat washer (81) onto brace rod and nsert brace rod through prevously nstalled brace tab, Bend tab as needed. Connect brace rod to tank strap wth one 1/4" x 1-114" cap screw (84), lock washer (85) and nut (86). Fasten other end of brace rod to brace tab wth a 5/16" flat washer (81), lock washer (79) and nut (80). Use brace rod to adjust algnment of drve and pump sheaves. Check belt for proper tenson. F. Loosen the two brass colored nuts on coolant reservor and catalyst flter contaner brace. Wth long leg of ar ntake bracket (33) towards fre wall, slde top slot of bracket between catalyst brace and tab onto remanng fastener. Tghten fasteners. Renstall catalyst flter contaner. The contaner should be restng on top of the ar ntake bracket. 6. Hydraulc Hose nstallaton A. Attach 1/4" end of 72" HP hose (16) to 1/4" brass bar elbow on pump tank and one end of the 69" HP hose (17) nto the 3/8" street ell on pump tank. Remove two rear rubber hood seal to fre wall screws that are approxmately ffteen nches apart and centered on vehcle. Replace wth two nylon mountng te wraps (40) and #12 sheet metal screws (90). Route both HP hoses from pump to valve. Secure wth prevously nstalled te wraps. Cauton: Keep hoses away from hot or movng engne components. Falure to do so may cause hose to burst resultng n a possble nstall the end of the 69" HP hose (17) nto the "out" port of the valve and the end of the 72" HP hose (16) nto the "n" port. Note: Do Not nstall the hydraulc flter n ths nstallaton. B. nstall 54" HP hose (18) to brass ell n lft cylnder port of valve (Spool #1). nstall two 60" hoses (19) to brass ells n angle ports of valve (Spool #2). On vehcles wthout ar condtonng, hoses may be routed out between radator and radator web, then through the grl near the center of vehcle. f vehcle s equpped wth ar condtonng, a 1-7/8" hole must be drled through the radator web on passenger's sde nboard of battery. nstall splt hose grommet (74) around hole. Route 60" and 54" hoses out through ths hole and through grl near center of vehcle. Attach 54" hose (18) to prevously nstalled 90 degree swvel adapter on lft cylnder, Turn brass ell's and te hoses to prevent hoses from rubbng battery or metal on radator web. FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/2/96

7 nstallaton nstructons 7504C Page 7 7. Dsconnect Assembly A. Wth dsconnect mountng plate (39) held n bench vse, nstall dsconnect halves as shown n lustraton. Bulkhead adapter (44) and male dsconnect half (42) go n bottom hole. Female dsconnect half (42) goes n the top hole. Secure both wth 7/8" snap rngs (45). Attach mountng plate to back of drver's sde headgear post wth two 5/16 x 1 cap screws (78), lock washers (79) and nuts (80). nstall dust plugs (43) over ends of hoses routed to front of vehcle n the prevous step. Connect 60" rght angle hose (spool #2, Cyl. B) to back of female dsconnect nstalled n top hole of dsconnect bracket. Connect 60" left angle hose (Spool #2, Cyl. A) to bottom (male) dsconnect. Tghten by holdng hoses and rotatng the dsconnect halves n the bracket. 8. Operatons A. Check all fttngs and fasteners for tghtness. Secure hoses wth nylon te wraps (75). Place cauton label (72) on the dash besde the control head. B. Fl reservor wth type "A" automatc transmsson flud. Start the engne, lft and angle the blade. f the blade angles opposte from the control lever poston, reverse the two Hp hose connectons on the back of the dsconnect bracket. Rase the front end of the vehcle untl the plow s clear of the ground wth the lft cylnder fully retracted. Check the reservor ol level. Angle the blade (wth the lft cylnder retracted) to remove ar from the system. Recheck the reservor ol level. Note: The nstaller must nform the end user of the proper procedure for removng any resdual hydraulc pressure that may be trapped n the rase or angle hoses. The plow wl be much easer to nstall or remove f the proper procedures are followed. Before couplng or uncouplng the hydraulc dsconnects you must frst turn off the gnton. Move the control to all four plowng postons and return the control to lower. You may then remove or nstall the plow. ~ FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/2/96