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Transcription

1 L~. SYSTEM FORD V8 5.0L w-w/o AC V8 5.8L w-w/o AC D Belt Drve Hydraulcs SLC Underhood Valve Q) CJ ~ Q) a: ~ "'~._.~;: ~ ~ OOr- ~ ~~ ~ l f""~,."." j~;~// ~~ "y" 'QQ.~.....\ ' ' co '.. -.~. : : ".. ~ l' ~,,:.Ø ~ ~ C) - C ~.~ ~ o Q) 0 ~.., è~ ~ l(~ ~"'~a "~ - ~ ts 6437 FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/8/97

2 ~? ~ / \/ / / / ~-- / l- (\ ~ Wr \\ \ \\ 7520D Page 2 '\ "' ~ "' \ FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/8/97

3 ~ 7520D Page 3 DR. SDE ANGLE CYL (CYL "A")-- PASS. SDE ANGLE CYL (CYL "B")-- 54 èg RASE CYLNDER- fí----! \! -~ (3 PLACES) :: y R E TU R N TO PUMP NOTE: DO NOT USE THE HYDRAULC FLTER N THS NSTALLATON CONTROL CABLE J / (/ ~ FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/8/97

4 7520D Page 4 Qty Parts Lst Ref # A D Part # Descrpton 1 1 A2311 Pump Tank assembly 2 1 A Control Valve Assembly Clevs Square Nut Clevs Pn - 3/1611 x /1611 Push Nut Zp SLC Head - Belt Drve 9 2 A SLC Cable /211 x 1011 Cylnder Assy - XL /211 x 1211 Cylnder Assy - XL Clevs Pn x 3-5/ Anchor Pn x /411 x 1-1/211 Cotter Pn Hp Hose - 1/4P - 318P Hp Hose 3/8P-3/8P Hose Hp 1/4P - 1/4P Hose Hp 1/4P - 1/4P Hose Hp 1/4P - 1/4P Hose Hp 1/4P - 1/4P 22 1 *3677 Fan Spacer - 1/ Fan Belt, 5511 (not shown) (4L 550) Drve Sheave Pump Sheave Pump Bracket Pump Bracket Brace Brace Valve Plate Fender Bracket Hose Support Bracket Brace Ar ntake Bracket Brace Saddle Bracket - Unversal Rear Tank Strap Unversal Brace Rod 38 1 *2115 Unversal Brace Tab 40 2 *8011 Nylon Mountng Te Wrap Hose Dsconnect Assembly *1588 Dust Plug - Closure/Male 44 1 * 4486 Adapter - Bulkhead 1/411 Npt 45 3 * 4485 Snap Rng - 7/811 External Bowed /16 w/o-rng x 3/8 F P Swvel /4 Npt x 90 Street Elbow Frgd 51 1 * /4 Npt x 90 Unon Elbow 52 1 *3979 3/811 Npt x 90 Street Elbow 53 3 * /16 O-Rng to 1/4 Npt 90 Elbow 56 1 *8599 QD/Electrc - Long 57 1 * QD - Long 59 8 *8324 Hose Te - 3/1611 x 1411 NC FASTENER TORQUE CFT -LB) DAMETER- GRADE THREADS 0ø~..'1' PER NCH G2 G5 G8 1/ / / / / / / / / FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/8/97

5 Parts Lst Qty Ref # A D Part # Descrpton 60 1 *8476 1/411 x 45 degree Street Elbow 65 1 *8741 Bracket - Cable Boot 66 1 *8284 Boot 71 1 *6595 3/411 Splt Hose Grommet Cauton Label - Cab Grommet - Rubber, Splt Grommet - Splt Hose *3666 Hose Te, nylon 3/1611 x /1611 x 1-1/411 (NC) Gr. 5 Cap Screw /1611 x 1-1/211 (NC) Gr. 5 Cap Screw * /1611 x 111 (NC) Gr. 5 Cap Screw * /1611 Sp Lk Washer ZP * /1611 (NC) Nut * /1611 Flat Washer /411 x 1-1/411 (NC) Gr. 5 Cap Screw /411 Sp Lk Washer /411 (NC) Nut 87 4 *4433 1/211 Specal Washer 90 2 * /1611 x 7-1/211 (NC) Gr. 5 Cap Screw 91 2 * /811 Lock Washer 92 2 * /811 (NC) Nut 93 2 * /811 x 1-1/411 (NC) Gr. 5 Cap Screw /1611 x 1-1/211 (NF) Gr. 5 Cap Screw 96 4 * /811 x 4-1/411 (NC) Gr. 5 Cap Screw 97 4 *4268 Spacer Washer 98 1 * /1611 x 7-1/211 (NC) Gr. 5 Cap Screw 99 1 * /1611 Lock Washer A uses Bolt bag 5425 * Part of 8705 Bolt Bag 7520D Page 5 nstallaton nstructons 1. Cylnder and Cylnder Hose Assembly A. Attach female half of dsconnect (42) and a 1/411 Npt 45 degree street ell (60) to 2211 Hp Hose (20). Usng bench vse to hold lft cylnder (10), remove closure from port and screw the other end of the hose drectly nto ths port. Place lft cylnder wth hose pontng to passenger sde nto ears on lft arm and upper gear. Secure wth clevs pns (12) and cotter pns (15). B. Attach male half of quck dsconnect (42) to one other end of a 3611 Hp hose (21). Place a dust cover (43) on the end of the other 3611 Hp Hose (21) and put another male half of a dsconnect (42) on ths hose. C. Usng a bench vse to hold angle cylnders (11), remove closures from ports and screw brass forged street ells (51) nto ports. Pont forward toward lve end of cylnder and slghtly upward as they wll be nstalled on the A-Frame. The drver sde cylnder uses the 3611 Hp hose (21) wth the dust cover and male dsconnect half. The passenger sde uses the 3611 Hp hose (21) wth the male dsconnect end and no dust cover. nstall cylnders to ther respectve sdes so that ells are between the cylnders and the A-frame. Secure cylnder wth anchor pns (13) at both ends, wth cotter pns (15) n each anchor. FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/8/97

6 nstallaton nstructons 7520D Page 6 2. Control Head and Control Cables Note: Dash bracket, hardware, drlng gude and mountng nstructons wl be found n pecular attachments box. A. Drl two 5/811 holes n the frewall for the control cables and wrng harness usng drllng gude as a reference only. Be sure both sdes of the frewall are clear of obstructons before drllng. B. nstall the dash bracket as per dash bracket nstructons. C. Loosen the jam nutsll 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 and 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 lnll and loutll ports. nstall three 9/1611 o-rng to 1/411 Npt 90 elbows (54) n lft and angle ports. When tght, elbows should pont at 2 o'clock, away from cable end of valve. B. Mount valve to valve plate (29) usng two 1/411 x 1-3/411 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 5/1611 x 111 cap screws Gr. 5 (NC) (78), lock washers (79) and nuts (80). Attach rear leg brace (34) to hole n rear of valve plate on lout" port sde wth one 5/1611 x 111 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 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 11/3211 holes n fender. Attach wth three 5/1611 x 111 cap screws Gr. 5 (NC) (78), large 1/211 flat washers (87), 5/1611 flat washers (81), lock washers (79) and nuts (80). Note: The large vacuum canster wl have to be moved closer to heater motor and to the engne usng vacuum brace (28),5/1611 x 111 cap screw (78), flat washer (81), lock washer (79) and nut (80). C. nstall control cables to valve plate by renstallng jam nuts and washers on 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 that 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 (5) through clevs and spool and secure wth push nut (6) on clevs pn. Adjust cables so control 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 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 (75) to FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/8/97

7 nstallaton nstructons 7520D Page 7 4. Drve Sheave nstallaton Note: Apply a removable loosenng preventon compound (such as Lock-ttell) to all drve sheave fasteners pror to nstallaton. A. Remove serpentne belt. Remove four 3/811 cap screws from crank shaft pulley. nstall drve sheave (24) nto center of crankshaft pulley beng certan machned plot of drve sheave seats fully nto crankshaft pulley. Fasten drve sheave to crankshaft wth four 3/811 x 4-1/411 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 and secure wth four 5/1611 x 1-1/211 (NF) Gr. 5 cap screws (95) and lock washers (79) torqued to 18 ft-bs. 5. Pump Tank and Pump Bracket Cauton: Pump tank fl must be vertcal to engne. A. Remove two cap screws holdng the catalyst flter contaner to the drver-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 15/3211 hole wth ppe spacer lnes up wth the hole from whch bolt was removed. Fasten tab wth prevously removed nut. nstall 7/1611 x 7-1/211 cap screw (98) and 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 3/811 lock washer (91) and nut (92). On some models cap screw may have to be removed. Replace wth one 3/811 x 1-1/411 cap screw (NC) Gr. 5 ZP (93) and lock washer (81). Place opposte end of brace on pump bracket tab and fasten wth one 5/1611 x 111 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 5.0L engne, remove A/C or dler mount. Holdng A/C or dle pulley, 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 engne, 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 (NC) (92). C. For Vehcles wth 5.8L Engne: Note: Plastc nner fender well must be pulled outward to provde clearance for Fsher hydraulc pump. Place fender bracket (30) n drver-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 111 cap screw (78) flat washer (81) and 1/211 specal washer (87) out through nsde of fender and fasten to bracket wth a 5/1611 lock washer (79) and nut (80). D. Holdng pump tank (1) n bench vse, screw a 3/811 brass bar street ell (53) nto return port on pump tank. nstall a 1/411 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 5/1611 x 1-1/211 cap screw (77), lock washer (79) and nut (80). Do not fully tghten. Fasten the hose support bracket (31) on the back sde of pump bracket wth the lower saddle bracket FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/8/97

8 nstallaton nstructons 7520D Page 8 hardware (one 5/1611 x 1-1/411 (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 the 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 wth two te wraps (75). nstall 5511 V-belt (23) onto nstalled drve and pump sheaves. Poston the power steerng hose and support bracket to mnmze hose twst and maxmz.e hose bend radus. Tghten V-belt and saddle bracket fasteners. Adjust for proper belt tenson by pvotng saddle bracket on top bolt. Note: There should be a mnmum of 1/211 clearance between hose support and drve sheave V-belt. Bend bracket to ncrease clearance f necessary. E. Algn sheaves and tghten 1-1/211 saddle bracket fastener. nstall rear tank strap (36) on over rear of pump tank. Check the length of unversal brace rod (37) and cut to length as needed. nstall one 5/1611 nut (80) and flat washer (81) onto brace rod and nsert brace rod through prevously nstalled unversal brace tab. Bend tab as needed. Connect brace rod to tank strap wth one 1/411 x 1-1/411 cap screw (84), lock washer (85) and nut (86). Fasten other end of brace rod to brace tab wth a 5/1611 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 frewall, slde top of bracket between catalyst brace and tab on reservor. Rotate bracket counter clockwse and slde lower slot 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 1/411 end of 72" Hp hose (16) to the 1/411 brass ell on pump tank and one end of 6911 Hp hose (17) nto the 3/811 street ell on pump tank. Remove two rear rubber hood seal to frewall 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 engne fre. nstall the end of the 6911 Hp hose (17) nto the "out" port of the valve, and the end of the 7211 Hp hose (16) nto the "nll port. nstall 6611 HP hose (18) to elbow n angle port closest to cables on valve. Pass ths hose by the battery and out through the core support near the radator. Pass the hose out through the grle low and about 1411 off center on the drver-sde. Attach a female ad half to the long ad/electrc grle plate (56) wth a snap rng (45). Pass the 6611 hose through a rubber dust cover (43) and attach t to the female dsconnect half. Put a dust cover on the plug of the vehcle harness and slde t nto the slot of the grle plate. Attach the grle plate to the grle wth four long te wraps (59). Note: Do not nstall the hydraulc flter n ths nstallaton. B. Attach a 4211 hose (19) to the rase port elbow and one 4211 hose (19) to the angle port elbow farthest from the cables. Pass these hoses out through the core support by the radator, low about 14" off center on the passenger sde of the grle. Attach a bulkhead adapter (44) to one hole of the long ad/ad grlle plate (57) wth a snap rng (45). Attach a male half of a ad to ths adapter. Secure a female ad half to the other hole n the grle plate wth a snap rng (45). Slde a rubber dust cover over the end of the rase hose and attach ths to the male dsconnect on the n-board sde of the grle plate. Slde a dust cover over the angle hose and attach t to the female ad half on the outboard sde of the plate. Slde the plate back to the grlle and attach t wth four long te wraps (59). FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/8/97

9 nstallaton nstructons 7520D Page 9 c. nstall cable boot bracket (65) on drver-sde headgear brace, between brace and fasteners. nsert cable boot (66) on over bracket. 7. Operatons A. Check all fttngs and fasteners for tghtness. Secure hoses wth nylon te wraps (75). Be sure hoses clear battery post. Place cauton label (72) on the dash besde the control head. B. Fl reservor wth FSHER~ Hgh Performance Hydraulc Flud (recommended for superor cold-weather performance) or type "All 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 valve. 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..j FSHER ENGNEERNG, ROCKLAND, ME Subject to Change 4/8/97