HENKE HI-GATE, R/H & L/Hhenkemfg.com/wp-content/uploads/2014/08/HIGATE_CAT_140G... · 2016. 4....

HIGATE_CAT_140G & CAT 135-163H_EFF_ALL_8540220-02-043

HENKE HI-GATE, R/H & L/H HENKE MODEL: HG CAT140G, 135H-163H For CAT 140G & 135H-163H Series Graders

PARTS BOOK AND INSTALLATION MANUAL SERIAL NUMBER __________________ VERSION 4.3, APRIL 2016

HENKE MANUFACTURING CORPORATION

MANUFACTURERS OF SNOW REMOVAL EQUIPMENT FOR 95 YEARS 3070 WILSON AVE. LEAVENWORTH, KS 66048 PHONE (913)682-9000 FAX (913)682-0300

WEBSITE ADDRESS: WWW.HENKEMFG.COM EMAIL: [email protected]

http://www.henkemfg.com/

HIGATE_CAT_140G & CAT 135-163H_EFF_ALL_8540220-02-043 of 27

Introduction

Thank you for your purchase of a Henke Hi-Gate for CAT motor graders. This Installation Manual should be read in its entirety before installation is performed to minimize mounting problems. Before beginning your installation, please check that all of the appropriate ship-loose parts and hardware listed in Table 1 were received. In the unlikely event that any parts are missing, please contact Henke Manufacturing Corporation at (913) 682-9000 for replacements.


Table of Contents Introduction ............................................................................................................................. 2

Safety Section ........................................................................................................................... 4

Maintenance ............................................................................................................................ 5

Parts List Tables ........................................................................................................................ 8

Parts Replacement Figures ........................................................................................................ 8

Installment ............................................................................................................................. 12

Installation Instructions .......................................................................................................... 19

Henke Warranty ..................................................................................................................... 26

Dealer Warranty Procedure .................................................................................................... 27

Figures FIGURE 1 – CAT Grader with Henke HI GATE, R/H .............................................................. COVER

FIGURE 2 – Hi-Gate Spring Blade Assembly ................................................................................ 7

FIGURE 3 – Hi-Gate Bearing Assembly ....................................................................................... 8

FIGURE 4 – Hi-Gate Attachment and Hardware Parts View ......................................................... 9

FIGURE 5 – Hi-Gate Attaching Weldments Installation Steps .................................................... 12

FIGURE 6 – Sub-Assembly #1 ................................................................................................... 13



FIGURE 9 – Locating Hi-Gate On Moldboard ............................................................................ 16

FIGURE 10 – Hi-Gate Hydraulic Cylinder and Attaching Weldments - photo .............................. 17

FIGURE 11 – Hi-Gate Spring Blade and Ear Assembly - Photo .................................................... 18

Tables TABLE 1 – Parts Hi-Gate Spring Blade, Parts list .......................................................................... 7

TABLE 2 – Hi-Gate Bearing Assembly ......................................................................................... 8

TABLE 3 – Hi-Gate Attachment and Hardware Parts View, Parts List ......................................... 10

TABLE 4 – Cutting Edges .......................................................................................................... 22

TABLE 5 – Cutting Edge Hardware ........................................................................................... 23

TABLE 6 – Henke Curb Guard & Wear Guards .......................................................................... 24


<<THIS PAGE IS INTENTIONALLY LEFT BLANK>>


IN SEASON MAINTENANCE

Snow removal equipment must be cared for and maintained regularly. Daily or pre-route inspection and maintenance are necessary. Failure to do so may affect efficiency and safety.

A visual inspection must be carried out after every 8 hours of operation. Look for damaged components, bends, cracked welds or hydraulic leaks. REPAIR IMMEDIATELY! It is recommended to re-torque all bolts after the first 8 hours of use and to regularly check for loosened or missing fasteners. Replace any damaged or missing fasteners immediately.

Because of the environment in which snow equipment is expected to operate, hydraulic lines, fasteners, wearable or replaceable items and warning decals may become damaged by snow, ice and road debris. These items must be inspected daily and replaced if necessary to avoid equipment damage or personal injury.

Lubrication of moving parts is of the utmost importance. Exposure to snow, ice, salt and road debris will wash away lubrication quickly and it may be necessary to inspect and reapply lubrication more than once a day.

Henke SWL AH Case 621B Version 4.3, April 2016 of 27

GROUND ENGAGING COMPONENTS

CUTTING EDGES & GUARDS: Replace any broken cutting edges, unevenly or excessively worn cutting edges, and broken or worn wear guards.

RUNNING GEAR: Replace broken, worn, or missing running gear shoes, and any damaged adjuster leg components. Grease internal threads and sliding members (it’s best to disassemble and grease directly; zerks aren’t as effective at greasing these areas).

HARDWARE: Replace missing or broken bolts. Proper torque is important! Use grade 8

plow bolts for steel cutting edges.

HYDRAULICS

HOSES: Plug or cap any QC fittings or any open hose ends. Inspect hoses for any leaks or

potential leaks. Secure hoses with hose clamps.

CYLINDERS: Check for leaks, and any chrome rod dents or scratches. Apply a light coat of oil or grease on exposed rod surfaces.

FRAME AND MOLDBOARD

JOINTS: Check pins, bushings, and pivot bolts for wear. Make sure all keepers are in

place. Make sure shear bolts and pins are same as original equipment (usually grade 2). Some drivers don’t like replacing shear pins and will install grade 8 replacements to avoid replacing during a storm. These items are designed to shear to protect the driver and the equipment. CHECK WELDMENTS FOR CRACKS.

CABLE AND SHEAVES (IF APPLICABLE)

CABLE: Check cable thoroughly for fraying, kinks, and abnormal wear. Make sure cable is

properly routed and seated in all sheaves. Verify that cable clamps have the proper torque and are in the correct orientation and spacing. Cable shall be checked prior to each use or after every 8 hours, whichever comes first.

SHEAVES: Verify that sheave, bushings and retaining pins are in good condition and adequately greased. Make sure that sheaves, bushings and pins do not have any abnormal wear and rotate without restriction.

REPLACE WORN OR BROKEN PARTS FOUND BY ABOVE INSPECTIONS

END OF SEASON MAINTENANCE


Item No. Qty. Part No. Description

1 1419-0050

419-0082

Main Blade Assembly w/o Top Plate Assembly R/H

Main Blade Assembly w/o Top Plate Assembly L/H

2 1419-0015

419-0081

Top Plate Assembly, R/H

Top Plate Assembly, L/H

3 1

419-0017

419-0055

419-0006

419-0087

Float Blade Assembly, R/H - 6"

Float Blade Assembly, R/H - 8"

Float Blade Assembly, L/H - 6"

Float Blade Assembly, L/H - 8"

4 1 7160029 Rubber Cutting Edge - Hi- Gate

5 1 4100-0039 Retaining Rubber strip - Hi-Gate

6 1 7030049 Toplock Nut, 1-8 GR. C

7 1 7020233 Hex Capscrew, 1-8 x 3.0 GR. 8

8 6 7030084 Toplock Nut, 5/8 - 11 GR. C

9 6 7150002 Plow Bolt 5/8 - 11 x3.0 GR. 8

10 1 7070073 Spring, Higate-Grader

11 1 419-0009 Spring Retaining Assembly

12 3 7030031 Toplock Nut, 1/2 - 13 GR. C

13 3 7040042 Flat Washer, 1/2 Hardened, SAE

14 3 7020130 Hex Capscrew, 1/2-13 x 1.5 GR. 8

TABLE 1 – HI-GATE Spring Blade, Part List

FIGURE 2 – HI-GATE Spring Blade Assembly


Item No. Qty. Part No. Description

1 1 419-0048 Main Blade, HiGate CAT G/H

2 1 419-0015 HiGate Top Plate, R/H

15 4 7030084 Toplock Nut, 5/8-11 GR. C

16 1 7040006 Flat Washer, 5/8 Hardened, SAE

17 1 4100-0032 Plate Bolt-On Horizontal

18 1 419-0004 Bearing Inboard

19 4 7020288 Hex Capscrew 5/8-11 x 2.50 GR. 8

20 1 419-0005 Bearing Outboard

20

TABLE 2 – HI-GATE Bearing, Part List

FIGURE 3 – HI-GATE Bearing Assembly


31

FIGURE 4 – Hi-Gate Attachment and Hardware Parts View


Item

No.Qty. Part No. Description

Associated

Sub-Assy.

17 1 REFERENCE Plate, Bolt-On Horizontal 2

23 1 4100-0087 Mount Plate, Left 1

24 1 7020082 Hex Capscrew, 3/4-10 X 3.50 GR. 8 1

25 2 7040007 Flat Washer, 3/4 Hardened, SAE 1

26 2 7030030 Toplock Nut, 3/4-10 GR. C 1

27 1 4100-0088 Mount Spacer 1

28 1 7050102 Clevis Pin, 1 X 6 3

29 2 7050003 Cotter Pin, 3/16 X 2.0 3

30 1 4100-0095 Cylinder Ear I/B CAT HiGate 3

31 1 7080560 Higate Hydraulic Cylinder 1&3

32 1 4100-0094 Cylinder Ear O/B CAT HiGate 3

33 1 7050101 Clevis Pin, 1.0 X 5.0 2

34 2 4100-0091 Curved Triangular Gusset 2

35 1 4100-0150 Upper Bolt-On Mount Plate 2

36 1 N/A CAT G/H Moldboard 2

37 1 7020080 Hex Capscrew, 3/4-10 X 3 GR. 8 3

38 1 4100-0153 Cylinder Anchor Plate, Bolt-On 3

39 1 4100-0155 Brace, Lower 3

40 2 4100-0152 Gusset, Lower 3

41 1 4100-0154 Rectangular Gusset 3

42 1 4100-0151 Lower Bolt-On Mount Plate 3

43 1 4100-0160 Straight Edge, Triangular Gusset 1

44 1 4100-0159 Notched Gusset 1

45 5 N/A Existing Moldboard Nut 2&3

46 5 7150002 Plow Bolt 5/8" 2&3

NOTE 1 1

419-0048

419-0077

419-0002

419-0084

Mainblade & Slide HiGate

Cat G/H - 6" RH - w/HWR


Cat G/H - 8" RH - w/HWR


Cat G/H - 6" LH - w/HWR


Cat G/H - 8" LH - w/HWR

TABLE 3 – Hi-Gate Attachment and Hardware Parts View, Parts List


FIG

UR

E 5

– H

i-G

ate

Att

ach

ing

Weld

men

ts In

sta

llati

on

Ste

ps


FIGURE 6 – Sub-Assembly #1


FIGURE 7 – Sub-Assembly #2


FIG

UR

E 8

– S

ub

-Assem

bly

#3


FIG

UR

E 9

– L

ocati

ng

Hi-

Gate

on

Mo

ldb

oard


FIG

UR

E 1

0 –

HI-

GA

TE

Sp

rin

g B

lad

e a

nd

Ear

Asse

mb

ly -

Ph

oto


Note

: T

his

im

age

is

outd

ated

. Y

our

HiG

ate

has

a new

more

sta

ble

low

er

cyli

nder

bra

ce.

FIG

UR

E 1

1 –

Hi-

Gate

Hyd

rau

lic C

yli

nd

er

an

d A

ttach

ing

Weld

men

ts -

Ph

oto


Mounting Instructions for RH Hi-Gate on CAT 140 G & 135H-163H Graders

1) Preparation of Hi-Gate for mounting

a) Before welding, disconnect electrical system components as directed in the motor grader manual.

b) Remove 5 right hand outboard bolts along curved end of moldboard

2) Installation and mounting of Hi-Gate to motor grader moldboard.

Step 1: Attach Hi-Gate mounting plates to motor grader moldboard (See Fig. 5, Step 1)

3. Temporarily bolt 4100-0088 and 4100-0087 (Items 27 & 23, Fig.4) to moldboard.

4. Temporarily bolt 4100-0151 and 4100-0150 (Item 35 & 42, Fig.4) to CAT moldboard’s five right hand outboard end holes using provided 7150002 Plow Bolts & existing 5/8” Moldboard Nuts removed in the preparation step.

5. Temporarily bolt 4100-0153 (Item 38, Fig. 4) to moldboard lower rib outboard holes, with arrow shaped end of plate pointing inboard.

6. Position gussets 4100-0152 (Qty. 3), 4100-0154, and 4100-0155 (Items 39, 40, and 41 respectively, Fig 4) between the two bolted-on plates 4100-0153, and 4100-0151 as shown in Figure 5, Step 1, and Figure 8. Tack loose pieces to bolt-on plate 4100-0151 (Item 42, Fig. 4)and to each other, with plenty of clearance for bolt removal. Do Not tack pieces to outer plate 4100-0153 yet. See Figure 8 for placement and measurements. DO NOT TACK ANYTHING TO MOLDBOARD!

7. Remove bolt on plate 4100-0153 and plate 4100-0151 (with tacked-on sub-assembly). Fully weld around small pieces onto plate 4100-0151 using 5/16” Fillet Weld. DO NOT WELD ANYTHING TO MOLDBOARD!

8. Re-attach plate 4100-0151 with welded on pieces and plate 4100-0153 and fully tighten in place, they will not need to be taken off again from this point forward.

9. Tack and fully weld plate 4100-0153 to complete sub-assembly #3 (See Figure 8) on the moldboard using 5/16” fillet welds. See Figure 5, Step 1 for final appearance. DO NOT WELD ANYTHING TO MOLDBOARD!

Step 2: Attach Bearing Ears and Cylinder Ears for Hi-Gate mounting (See Fig. 5, Step 2)

10. Install 419-0004 (Item 18, Fig.3) and 419-0005 (Item 20, Fig.3) into Hi-Gate Top Plate Assembly 419-0015 tube.


11. Align and bolt together 419-0032 (Item 22, Fig.4) and 419-0004 (Item 18, Fig. 3) using hardware 7020288 bolts (Qty. 4), 7040006 washers (Qty. 4), and 7030084 nuts (Qty. 4) (Items 19, 16, and 15 respectively, Fig. 3).

12. Pin base end of cylinder 7080590 (Item 31, Fig. 4) to loose cylinder ears 4100-0094 and 4100-0095 (Items 32 & 30, Fig. 4) using clevis pin 7050102 and cotter pin 7050003 (Items 28 & 29, Fig. 4.

Step 3: HiGate Position on Moldboard (See Fig. 9 and Fig. 5, Step 3)

13. Using a forklift and chain lift gate using chain ear on top of moldboard. 14. Position Hi-Gate relative to moldboard as shown in figure 9. Ensure 419-0004 and

419-0005 (Items 18 and 20, Fig. 3) are level. TIP: Use extra pieces of angle iron tacked in place to gate and moldboard to hold gate in place while installing bracing at rear of moldboard. Do not let slack on chain holding up moldboard. This will ensure gate does not move during installation.

Step 4: Attaching Final Gussets and Cylinder. (See Fig. 6, and 7, and Fig. 5, Step 4)

15. With Hi-Gate positioned correctly, position 4100-0160 & 4100-0159 (Items 42 &44, Fig. 4) gussets under Bolt-On Plate 4100-0032 (Item 22, Fig. 4) and against Bolt-On Plate 4100-0087 (Item 23, Fig. 4). Tack gussets to plates so that bolts are easily removable and bearing 419-0004 rests loosely in tube of top plate assembly (Item 2, Fig. 3). See Figure 6 for sub-assembly #1 final visual.

[DOES ITEM 21 GET WELDED TO MOLDBOARD?]

16. Position 4100-0091 (Qty.2) (Item 34, Fig. 4) under Bearing 419-0005 (Item 20, Fig.

3) and against Bolt-On Plate 4100-0150. Tack gussets 4100-0091 to 419-0005 and 4100-0150 so that bolts are easily removable, and bearing 419-0005 rests loosely in tube of top plate assembly (Item 2, Fig. 3). See Figure 7 for sub-assembly #2 final visual.

17. Make sure all dimensions are still being held from Figure 9 AND that Hi-Gate is flush with CAT moldboard.

18. Fully extend cylinder (Item 31, Fig. 4) and make sure that both cylinder ends are aligned to one another.

19. Install rod end to Hi-Gate with clevis pin 7050101 and cotter pin 7050003 (Items 33 & 29, Fig. 4).

20. Position and tack loose cylinder base-ears 4100-0095 and 4100-0094 to plate 4100-0153. Make sure all dimensions are being held in figure 9. Make sure tack welds allow cylinder to swing down freely and be sure that cylinder maintains perpendicularity to Hi-Gate pivot. This will prevent side-loading of cylinder.

21. Remove cylinder from Hi-Gate and Moldboard leaving base-ears tacked to sub-assembly #3.


22. Remove created sub-Assemblies 1 & 2 from Moldboard and weld all tacked parts

together with 5/16” fillet welds. (Sub-Assemblies had shown in figure 6 & 7).

23. Weld tacked base-ears to plate 4100-0153 with 5/16” fillet welds.

C. Plumbing of Hydraulics to Hi-Gate cylinder

24. Re-Install finished sub-assemblies and cylinder in place on CAT moldboard.

25. Run hoses out to cylinder; be sure that hoses have plenty of slack to allow moldboard proper freedom of movement.

D. Final Inspection and test

26. Cycle cylinder up and down to verify that Hi-Gate is operating properly.

27. WARNING: MAKE SURE NO-ONE GETS BETWEEN HI-GATE AND MOTOR GRADER MOLDBOARD, OR HI-GATE AND GROUND, DEATH OR SEROUS INJURY CAN OCCUR.


TABLE 4 – Cutting Edges

10FT. 7150088

SNOW BASKET1” THICK

X10" Tall CP

16FT. 3500-0016 1300-0402

12FT. 3500-0012 1300-0396

RUBBER

Notes 5&6

1 ½” THICK

X10” Tall CPRETAINING STRIP

CARBIDE 3/4” THICK

4FT.X5” TALL 7150123

4FT.X8” TALL 7150164

8FT. 3500-0008 3500-0026

9FT. 7150053

CP 8”

STEEL1/2” THICK 5/8” THICK 3/4” THICK

12FT. 7150019 7150056 Call

9FT. 7150013 7150045 71500468FT. 7150172 Call Call

11FT. 3500-0011 1300-03953FT.X8” TALL 7150163

10FT. 3500-0010

Call

8FT.

6FT.X6” TALL 7150124

14FT. 3500-0014 1300-04014FT.X6” TALL 7150025

7150052

1300-03943FT.X6” TALL 7150035

10FT. Call Call 7150050

3FT.X5” TALL Call 9FT. 3500-0009 1300-2223

CP 10"


7150169 Call

4FT. 7150187 Call Call

11FT. 7150018


10FT. 7150017 Call 7150171

CP 6”


3FT. 7150021 Call


7150044 7150049

12FT. 7150010 7150082 7150032

12FT. 715001611FT. 7150009 7150089 7150031

7150043 7150047

10FT. 7150008 7150090 7150197 11FT. 7150015 7150040 7150048

9FT. Call Call 7150036 10FT. 7150014

7150081 7150055

7FT. Call Call 7150028 8FT. 7150012 Call 7150042

6FT. Call Call 7150004 6FT. 7150005

3FT. 7150037 7150078 Call

7150079 Call

5FT. 7150007 7150184 7150026 5FT. 7150011 Call 7150054

4FT. 7150154 7150129 7150072 4FT. 7150038

NOTES:

1. For Cutting Edges Not Listed Call Henke Manufacturing at 1-888-682-9010.

2. Except as noted, all cutting edges have 1.5" gauge line (distance from top edge to center of holes)

3. "CP" = Center Punched

4. All edges shown are punched for 5/8" bolts.

5. For rubber cutting edges, 6" tall center punched steel edges, Items 7150186 & 7150187 may be used to

provide proper support behind the rubber edge.

6. Henke's rubber cutting edges feature a minimum tensile strength of 2000 psi and a maximum DIN rating

of 150, and last much longer in service than lower quality rubber cutting edges available from some other

suppliers.

7.Polyurethane cutting edges also available - call for price and availability.

5FT.X8” TALL 7150097

1/2” THICK 5/8” THICK 3/4” THICK

2FT. Call 7150119 7150189 2FT. 7150039 7150077

6" STEEL 1/2" THICK 5/8" THICK 3/4" THICK 8” STEEL

Call

3FT. 7150153 7150120 7150073


TABLE 5 – Cutting Edge Hardware

HENKE CUTTING EDGES

HENKE CUTTING EDGES

TYPE LENGTH PART NO. USES/NOTES

2” 7150001

2 ½” 7150003

3” 7150002

3 ½” 7150103

4” 7150105

4 ½” 7150106

5” 7150108

6” 7150107

3” 7020280

4” 7020287

5” 7020359

6” 7020363

4” 7020064

4 ½” 7020128

5” 7020295

NYLOCK NUT

5/8-11 GRADE 8N/A 7030095

USE WITH RUBBER OR

POLY CUTTING EDGES

TOPLOCK NUT

5/8-11 GRADE CN/A 7030084

USE WITH STEEL OR

CARBIDE CUTTING EDGES

PLOWBOLTS

5/8-11 GRADE 8

FOR STANDARD CUTTING

EDGES AND WEAR

GUARDS

CARRIAGE

BOLTS

5/8-11 GRADE 8

FOR SOME WRAPAROUND

CURB GUARDS

(SQUARE HOLES, NOT

COUNTER SUNK)

HEX BOLTS

RUBBER AND POLY

CUTTING EDGES (USE

NYLOCK NUTS ONLY)


TABLE 6 – Henke Curb Guards & Wear Guards

Wrap-Around Curb Guards, Steel

7150122 6”, Left

7150121 6”, Right

7150117 8”, Reversible

Wrap-Around Curb Guards, Chrome-Carbide Weld Deposit on Wrap-Around Corner

7150125 6”, Left

7150126 6”, Right

7150115 8”, Left

7150118 8”, Right

Wrap-Around Curb Guard + Wear Guard, Chrome-Carbide Weld Deposit on Wrap-Around Corner + on Bottom Wear Edge

7150113 6”, Left

7150114 6”, Right

7150130 8”, Left

7150131 8”, Right

Bolt-On Curb Guards (Bolts to Outside of End Rib)

139-1046 Bolt-On Guard Assy.

1300-1633 Optional spacer (Required for

Tripedge applications)

Henke Wear Guards and Wear Shoes

Wear Guards, Standard Length (9”), with Chrome-Carbide Weld Deposit (Mount in front of cutting edge)



Wear Guards, Long Length (21”), with Chrome-Carbide Weld Deposit (Mount in front of cutting edge)



Cast Wear Shoes

(Mount behind cutting edge)

7140004

Wear shoe for 6” cutting edges, or 8” center-punched edges

7140002 Wear shoe for 8” cutting edges

Bottom Angle Saver (Mount behind of Bottom Angle)

199-0280

Bottom Angle Saver with Carbide Strip


Henke Standard Warranty Policy


Dealer Warranty Procedure

For units delivered within the past 12 months, report any warranty problems needing

repair to our Product support department. Please have information ready regarding:

1. Henke unit model and serial number, 2. Model of equipment Henke unit is attached to (prime mover) 3. Description of the problem and any helpful information by the

end user. (Photos are always helpful). Measurements or photos may be requested by Henke engineering for any issues regarding prime mover proximity and clearance, or any other unique considerations of fit and adaptability. These may be necessary for a proper repair recommendation and procedure. Henke will respond with a written labor hour allowance for Henke participation on a faxed claim form and will ship any required replacement parts. If necessary, a repair procedure will be included on the claim form. A parts invoice will be generated to confirm shipment of the replacement parts.

If defective parts are needed for analysis, Henke will request their return.

Any such returned items are to be labeled with the claim number and returned to: Henke Manufacturing Corp.

ATTN: Product Support

3070 Wilson Ave.

Leavenworth, KS. 66048

RGA#_____________ The dealer should perform repairs as agreed on a dealer warranty repair order. Return the claim form with a copy of the dealer warranty repair order and service report. Credit as agreed will be issued to the dealer upon receipt of the dealer warranty repair order invoice (Pro-forma invoice), and upon receipt, inspection and warranty confirmation of the returned parts if any. Parts & Service Assistance Parts and service assistance is available, Monday through Friday, from 8:00 am to 5:00 pm, CST. Call 913-682-9000.

Our web site, www.henkemfg.com, is a quick source for parts pricing, and many common

parts diagrams.

Parts purchase orders may be faxed in at any time to 913-682-0300. Faxed orders are encouraged, as they help insure order accuracy and follow up. Include any special instructions, such as drop ship addresses on your order.

HENKE HI-GATE, R/H & L/Hhenkemfg.com/wp-content/uploads/2014/08/HIGATE_CAT_140G... · 2016. 4....

Documents

Transcript of HENKE HI-GATE, R/H & L/Hhenkemfg.com/wp-content/uploads/2014/08/HIGATE_CAT_140G... · 2016. 4....