SERVICE MANUAL WINCH MODELS: PA57VS FOR D7R PA58VS

RENR 2099
SERVICE MANUAL
WINCH MODELS:
PA57VS FOR D7R
PA58VS FOR D8R
PA59VS FOR D9R
PACR WINCH DIVISION
PC-261
7/99
Printed in U.S.A.
P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013
PHONE (918) 251-8511 FAX (918) 259-1575
www.paccarwinch.com
Copyright 1999 PACCAR Winch Division
All rights reserved.
TABLE OF CONTENTS
FOREWORD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
GENERAL SAFETY RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
GENERAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
RECOMMENDED OIL
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
WINCH REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
WIRE ROPE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
WINCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
WINCH CROSS-SECTION AND PARTS KEY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
PRIMARY & SECONDARY PLANET CARRIER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . .21
OUTPUT PLANET CARRIER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
DRUM CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
BRAKE HOUSING ASSEMBLY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
OVERRUNNING BRAKE CLUTCH SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
CABLE DRUM SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
WINCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
LOGIC VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
HYDRAULIC CONTROL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
BRAKE CYLINDER LIFTING FIXTURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36
1
FOREWORD
Please read and understand this entire manual BEFORE operating or servicing your PACCAR winch. Retain this manual for future reference.
This manual contains instructions for the service and repair of PACCAR PA57VS, PA58VS and PA59VS hydraulic
winches built for CATERPILLAR. When instructions apply to only one specific winch, the specific winch model designation (i.e., PA57VS only) will appear at the beginning of the pertinent text. If not identified in this manner, the text
applies to ALL above winches.
Some illustrations in this manual may show details or attachments which may be different from your winch. Also, some
components may have been removed for clarity.
Continuing product improvement may cause changes in your winch which may not be included in this manual.
Whenever a question arises regarding your PACCAR winch, please contact your nearest CATERPILLAR dealer, or
the PACCAR WINCH SERVICE DEPARTMENT, Broken Arrow, OK (U.S.A.) at 1-918-251-8511, Monday through
Friday, 0800 hrs through 1630 hrs CST, or by FAX at 1-918-259-1575. Be sure to provide the complete winch SERIAL NUMBER and ARRANGEMENT (AR) NUMBER when making inquiries.
NOTE:
The hydraulic motors and selected gear ratios on PACCAR winches for CATERPILLAR tractors are specifically configured for use on the intended tractor. The winch may not be suitable, or advisable, for use on anything other than the
intended tractor. Contact the PACCAR WINCH SERVICE DEPARTMENT with questions regarding retrofitting your
winch to other tractors.
Safety and informational callouts used in this manual include:
!
CAUTION
CAUTION
!
!
This emblem is used to warn against potential or
unsafe practices which COULD result in personal
injury, and product or property damage if proper
procedures are not followed.
WARNING
CAUTION
!
This emblem is used to warn against unsafe practices which COULD result in severe personal injury
or death if proper procedures are not followed.
2
GENERAL SAFETY RECOMMENDATIONS
11. Use correct size ferrule for cable and pocket in winch
drum. Never use knots to secure or attach cable.
Safety for operators and ground personnel is of prime
concern. Always take the necessary precautions to
ensure safety to others as well as yourself. To ensure
safety, the tractor and winch must be operated with care
and concern by the operator for the equipment, and a
thorough knowledge of the machine’s performance capabilities. The following recommendations are offered as a
general safety guide. Local rules and regulations will also
apply.
!
WARNING
CAUTION
12. Inspect winch cable, rigging, winch and tractor at the
beginning of each work shift. Defects should be corrected immediately.
13. Position tractor for straightest line of pull to reduce
wear on winch cable and ensure even spooling.
14. The cable anchor or ferrule pocket in the cable drum
is designed to provide a self release in the event a
back-sliding load must be released from the tractor in
an emergency situation. The cable anchor or ferrule
alone will NOT support rated line pull. Therefore, a
minimum of five (5) complete wraps of cable must be
maintained on the winch drum. We suggest painting
the last five wraps of cable bright red to serve as a
visual warning.
!
FAILURE TO OBEY THE FOLLOWING SAFETY
RECOMMENDATIONS MAY RESULT IN PROPERTY DAMAGE, INJURY OR DEATH.
1. Read all warning tag information and become familiar
with all controls BEFORE operating the winch.
15. Be sure of tractor ground stability before winching in
a load.
2. Never attempt to clean, oil or perform any maintenance on the winch with the engine running, unless
instructed to do so in this manual.
16. Store unused chokers, slings and rigging in a neat
and orderly fashion to prevent damage to equipment
or injury to personnel.
3. Before starting the tractor, be certain all controls
move freely and are placed in the “Brake-On” (neutral) position.
17. Do not operate the winch under loads that exceed the
maximum rated bare drum line pull. If excessive
loads are encountered, use a multi-part line and
sheave blocks. Any attempt to exceed the capacity of
one winch (such as coupling 2 or more tractors
together) is extremely hazardous.
4. Never operate winch controls unless you are properly seated at the operators station on the tractor and
you are sure personnel are clear of the work area.
5. Operate the winch to match line speeds to job conditions.
18. The factory approved adaptions for PACCAR winches are designed and intended for use on specific
models of crawler tractors. Changing winches
between tractors is not possible in some cases
because of differences in tractor models. Some
changes cannot be approved by PACCAR because
of safety limitations. Call a Caterpillar dealer or the
PACCAR factory prior to attempting winch modifications or before mounting on a different tractor. Use
only GENUINE PACCAR parts. Do not use parts
from other winch manufacturers on your PACCAR
winch. Do not use PACCAR parts on winches from
other manufacturers.
6. Assure that personnel who are responsible for hand
signals are clearly visible and that the signals to be
used are thoroughly understood by everyone.
7. Never attempt to handle winch cable when the hook
end is not free. Keep all parts of body and clothing
clear of cable rollers, cable entry area of fairleads and
winch drum.
8. Leather gloves should be used when handling winch
cable.
9. Ground personnel should stay in view of tractor operator and clear of winch drum. Do not allow ground
personnel near winch line under tension. A safe distance of at least 1 ½ times the length of the cable
should be maintained. Never allow anyone to stand
under a suspended load.
19. The PA57VS, PA58VS and PA59VS winches are
powered by the tractor hydraulic system. Discharge
all retained hydraulic system pressure before removing any hydraulic lines or fittings. Personal injury may
result from sudden release of oil pressure. To discharge the winch control system pressure, stop the
engine and cycle the winch control lever(s) into all
positions five times. Refer to the tractor manufacturers operators or service manual for additional information.
10. When winding winch cable on the winch drum, never
attempt to maintain tension by allowing winch cable
to slip through hands. Always use “hand-over-hand”
technique, being careful to keep hands and clothing
away from winch drum and fairlead rollers.
3
20. On machines having hydraulically, mechanically
and/or cable controlled equipment, be certain the
equipment is either lowered to the ground or blocked
securely before servicing, adjusting and/or repairing
the winch. Always apply tractor parking brakes and
lower equipment before dismounting the tractor.
23. Avoid sudden “shock” loads or attempting to “jerk” a
load free. This type of operation may cause heavy
loads in excess of rated capacity, which may result in
failure of cable and/or winch.
24. Keep equipment in good operating condition.
Perform scheduled servicing and adjustments listed
in the “Preventive Maintenance” section of this manual. Use recommended lubricants.
21. The winches described in this manual are neither
designed nor intended for use or application to equipment used in the lifting or moving of persons.
25. An equipment warm-up procedure is recommended
for all start-ups and essential at ambient temperatures below +40oF (5oC). Refer to “Warm-Up
Procedure” listed in the “Preventive Maintenance”
section of this manual.
22. Install guarding to prevent personnel from getting any
part of their body or clothing caught at a point where
the cable is wrapped onto the drum or drawn through
fairlead guide rollers.
THEORY OF OPERATION
DESCRIPTION OF WINCH
156:1 or 245:1, the planetary reduction group greatly multiplies the motor torque for high line pulls at maximum efficiency and precise load control.
The winch assembly consists of six basic component
groups:
1. Winch case
2. Hydraulic motor and piping
3. Brake housing assembly
4. Cable drum
5. Planetary reduction group
6. Drum clutch group
Planetary Gear
Reduction
BASIC WINCH OPERATION
Brake Valve
Sprag Clutch
Figure 1A
The full output of the tractor implement pump flows
through the tractor implement valve, which controls both
the blade and ripper. The ripper valve section has been
replaced with a special winch section to enhance the
winch performance capabilities. The valve is a four way,
three position valve.
Multi-Disc
Static Brake
Drum Clutch
Hydraulic Motor
Figure 1
The winch case is a structural member of welded construction designed specifically for use in tractor winch
applications. The case supports the output ring gear and
the brake housing assembly. The cable drum revolves on
four large tapered roller bearings. The hydraulic motor is
bolted to the brake housing, which also supports the right
hand cable drum bearings. The output ring gear supports
the left hand cable drum bearings.
The winch control valve is connected to the operator’s
joystick control lever by a series of hydraulic hoses.
Movement of the control lever directs the oil flow to the
winch motor through hydraulic lines. The hydraulic motor
converts the flow and pressure of the tractor hydraulic
system into the mechanical energy needed to drive the
winch gear train.
The planetary reduction group contains three planetary
gear sets driven by the primary sun gear shaft, which is
coupled to the motor shaft by the inner race of the overrunning brake clutch assembly. With a total reduction of
The tractor can walk away from a winch load to reposition
the tractor for another pull by releasing the drum clutch.
The spring applied, hydraulically released multi-disc
4
clutch locks the secondary planetary ring gear to the
winch housing. When released, the ring gear will turn as
the secondary planetary assembly walks around the secondary sun gear, which allows the output planetary
assembly and cable drum to turn free of the remaining
reduction gears, static brake and hydraulic motor. The
cable drum drag observed during brake-off (drum clutch
release) is caused by the rotating output and secondary
planetary gear sets and viscous drag of the friction discs.
The brake-off drag force increases as the tractor ground
speed increases.
REEL-OUT (1)
DUAL BRAKE SYSTEM – DESCRIPTION
LOW PRESSURE
MEDIUM PRESSURE
The dual brake system consists of a dynamic brake system and a static brake system. The dynamic brake system has two operating components:
HIGH PRESSURE
Figure 3
1. Hydraulic Brake valve assembly
2. Hydraulic motor
REEL-OUT (2)
The brake valve is similar to a counter-balance valve. It
contains a check valve to allow free flow of oil to the motor
in the Reel-In direction and a pilot-operated, springloaded spool valve which blocks the flow of oil out of the
motor when the control valve is placed in neutral. When
the control valve is moved into the Reel-Out position, the
spool in the brake valve remains closed until sufficient
pilot pressure is applied to the end of the spool to shift it
against the spring pressure and open a passage. After
the spool valve cracks open, the pilot pressure becomes
flow dependent and modulates the spool valve opening
which controls the Reel-Out speed. See figures 2, 3 & 4.
LOW PRESSURE
MEDIUM PRESSURE
HIGH PRESSURE
Figure 4
REEL-IN
The static brake is released by the brake valve pilot pressure at a pressure lower than that required to open the
pilot operated spool valve in the brake valve assembly.
This sequence assures that dynamic braking takes place
in the brake valve and that little, if any, heat is absorbed
by the friction discs.
The friction brake is a load holding brake only and has
nothing to do with dynamic braking or the rate of release
of a heavy or suspended load.
The overrunning brake clutch is splined to the primary
sun gear shaft between the motor and the primary sun
gear. It will allow this shaft to turn freely in the direction of
Reel-In, and lock up to force the brake discs to turn with
the shaft in the direction of Reel-Out. (Fig. 5 and 6)
LOW PRESSURE
MEDIUM PRESSURE
HIGH PRESSURE
Figure 2
The static brake system has three operating components:
The hydraulic cylinder, when pressurized, will release the
spring pressure on the brake discs, allowing the brake
discs to turn freely.
Spring applied, multiple friction disc static brake
Sprag-type overrunning brake clutch assembly
Hydraulic piston and cylinder
5
upward and firmly lock the shaft to the fully applied friction
brake. (Fig. 6)
STATIC FRICTION BRAKE APPLIED
When the winch is powered in reverse, to Reel-Out the
load, the motor can not rotate until sufficient pilot pressure is present to open the brake valve. The friction brake
within the winch will completely release at a pressure
lower than that required to open the brake valve, typically 350 PSI (2,413 kPa) and 600 PSI (4,137 kPa), respectively. The extent to which the brake valve opens will
determine the amount of oil that can flow through it and
the speed at which the load will Reel-Out. Increasing the
flow of oil to the winch motor will cause the pressure to
rise and the opening in the brake valve to enlarge, speeding up the release of the load. Decreasing this flow causes the pressure to lower and the opening in the brake
valve to decrease, thus slowing the release of the load.
SPRAG
CAMS
Reel-In
Figure 5
With the control valve shifted to neutral, the pressure will
drop and the brake valve will close, stopping the load.
The friction brake will reapply and hold the load after the
brake has closed.
PERMITS FREE SHAFT ROTATION
DURING REEL-IN
The friction brake receives very little wear during the
Reel-Out operation. Most of the heat generated by the
releasing and stopping of the load is absorbed into the
hydraulic oil where it can be readily dissipated.
STATIC FRICTION BRAKE APPLIED
SPRAG
CAMS
CONTROL OPERATION
Reel-Out
HAUL-IN
REEL-IN
PAYOUT
REEL-OUT
LOW-SPEED
LOCK
INDICATOR
WINCH
DISABLE /
ENABLE
Figure 6
LOAD ATTEMPTS TO ROTATE SHAFT
IN OPPOSITE DIRECTION.
BRAKE CLUTCH LOCKS SUN GEAR SHAFT
TO FRICTION BRAKE.
DUAL BRAKE SYSTEM – OPERATION
When pulling in a load (Reel-In), the overrunning brake
clutch, which connects the motor shaft to the primary sun
gear, allows free rotation through the gear train to the
cable drum. The sprag cams lay over and permit the inner
race to turn free of the outer race. (Fig. 5). The friction
brake remains fully applied. The winch, while reeling in a
load, is not affected by any braking action.
BRAKE-ON:
When released, the handle returns to the neutral, brakeon position by spring force. The load is held firm.
REEL-IN:
Moving the control lever in the direction of tractor forward
movement directs oil to the winch motor for cable drum
rotation in the Reel-In direction.
When the Reel-In operation is stopped, the load attempts
to turn the primary sun gear in the opposite direction. This
reversed input causes the sprag cams to instantly roll
6
the maximum displacement position, which will allow the
winch to operate in the maximum line pull, minimum line
speed mode, to enhance precise load control. When
shifted into Low-Lock, the indicator light on the console
adjacent to the joystick will light up. Press the rocker
switch again to disable Low-Lock, and allow the winch to
again operate in the autospeed mode. When in
autospeed, the indicator light will be off.
REEL-OUT:
Moving the control lever in the direction of tractor reverse
movement will cause the cable drum to rotate in the ReelOut direction.
AUTOSPEED MODE:
From the operator’s perspective, this is the simplest
winch control method.
DRUM CLUTCH RELEASE:
Pushing the control lever away from the operator directs
oil to release the winch drum clutch. With the drum clutch
released, the tractor can move away from a load while
using the inherent resistance of the output and intermediate planet gear sets to keep the cable tight on the drum.
The winch line speed, or drum rotation speed, may be
controlled by moving the control lever a very small distance, or by operating the tractor engine, and therefore
the tractor implement pump, at a lower RPM.
The hydraulic motor used with the “autospeed” control
system is a variable displacement, piston-type motor with
an internal load-sense circuit. This circuit contains a small
piston which adjusts the angle of the motor rotating pump
group from minimum to maximum displacement as the
pressure on the motor work ports (A & B) increases due
to the load applied to the winch gear train. When there is
little or no load on the winch, the motor rotating group will
remain at the preset minimum displacement. As the winch
load increases, the pressure at the motor work ports will
increase. This same pressure will also act on the loadsensing piston beneath the “X” and “G” ports. As the loadsense piston moves, it directs oil to the motor rotating
group shift cylinder which increases the motor displacement to provide increased torque, or pulling power, at a
lower line speed.
!
WARNING
CAUTION
!
Do NOT use the drum clutch to position suspended
loads. Sudden load movement may result in personal injury or death. Suspended loads should be controlled by the main winch control valve using Reel-In
or Reel-Out functions.
WINCH DISABLE:
A latching electrical toggle switch is provided to disable
the winch. When the switch is in the lower, latched position, the winch is disabled. Pull the switch handle and
move it to the straight up position to enable the winch system.
In this manner, the motor displacement will automatically
adjust to provide the maximum hydraulic horsepower for
any given line speed and line pull situation.
Leave the switch in the disable position when the winch is
not in use to prevent accidental actuation of the winch
functions.
LOW-SPEED LOCK MODE:
Pressing the rocker switch on top of the control lever will
force the variable displacement motor to shift the piston to
PREVENTIVE MAINTENANCE
A regular program of preventive maintenance for your
PACCAR winch will minimize the need for emergency
servicing and promote long product life and trouble-free
service.
Oil
Fill
Oil
Level
The service intervals suggested in this manual will optimize component service life. The intervals may be gradually increased or decreased with experience of a particular lubricant and evaluation of your application.
GEAR CASE OIL
The winch assembly should be visually inspected for
leaks at the beginning of each workday. If oil leaks are
found, the gear case oil level must be checked. If no leaks
are detected, the oil level may be checked once every
250 hours or monthly. The oil level plug is located at the
Oil
Drain
7
horizontal centerline on the drum clutch housing. Position
the tractor on a flat, level surface and remove the plug.
The oil should be at the bottom of the level plug hole.
VENT PLUG
The vent plug is installed in the oil filler plug located near
the top of the drum clutch housing. Whenever the oil is
changed, remove the vent plug, clean in safety solvent
and reinstall.
Add oil as required through the oil filler plug located near
the top of the drum clutch housing. Add oil slowly, as the
oil must pass through the gear train and fill the drum cavity.
Refer to the recommended oil chart for the proper oil for
your application.
Note: Do not replace the vent plug with a solid plug. The
normal expansion of the gear oil during operation will
cause a build-up of pressure in the gear case, which may
lead to seal leakage.
TRACTOR HYDRAULIC RESERVOIR LEVEL
WINCH CABLE (WIRE ROPE)
The tractor hydraulic oil reservoir level should be checked
at the sight glass daily, or in accordance with the tractor
manufacturer’s recommendations. Use the type of
hydraulic oil recommended by the tractor manufacturer.
Inspect the entire length of wire rope and the hook in
accordance with the rigging manufacturer’s recommendations.
MOUNTING FASTENERS
Change the tractor hydraulic oil and filter every 1000
hours or in accordance with the tractor manufacturer’s
recommendations.
Check / tighten all winch mounting fasteners to recommended torque after the first 100-250 hours of operation,
then every 1000 operating hours or six (6) months,
whichever occurs first.
GEAR CASE OIL CHANGE
WARM-UP PROCEDURE
Change the winch gear case oil after the first 100-250
hours of operation, then every 1000 hours or six (6)
months, whichever occurs first.
!
WARNING
CAUTION
The tractor engine should be run in accordance with the
tractor manufacturer’s recommendations to warm up the
hydraulic system. Use cold weather oil as recommended
in the tractor hydraulic system instructions.
!
FAIRLEAD ROLLERS
Hot oil may cause injury. Make certain the oil has
cooled to a safe temperature before servicing.
Grease the fairlead rollers at the beginning of each workday. The vertical rollers have grease fittings at the top and
bottom. The horizontal rollers have only one grease fitting. Apply grease until a small amount pushes out
around the shaft.
Remove the drain plug located at the bottom of the drum
clutch housing. Drain the oil into a suitable container and
recycle or dispose of the used oil in an environmentally
responsible manner. Install the plug securely after the oil
has been drained. To reduce oil drain time, remove the
filler/vent plug.
Use a high quality type 12-hydroxy stearate lithium based
product, which contains an EP additive, such as Moly,
and meets or exceeds an NGLI Grade 2 specification.
Refill the winch to the proper level with the recommended
oil. Allow 15 minutes for the oil to flow through the gear
train and fill the cable drum cavity before checking the oil
level.
Oil capacity:
INSPECTION
Every 10,000 hours or four (4) years, whichever occurs
first, the winch should be disassembled for a thorough
inspection of all wear items. Refer to the Service Manual
for additional information.
approximately 16 qt. (15 L)
!
CAUTION
CAUTION
!
Do NOT operate the winch while the oil is drained.
Serious damage to internal components may result.
8
GENERAL SPECIFICATIONS
Unit Weight w/o Oil, Cable or Tractor Adapters . . . . . . . . . . . . . . . . . . . . . . . . . . .Approximately 4,025 lb (1,826 kg)
Cable Drum Dimensions
Barrel Diameter . . . . . . . . . . . . .12.50 in. (318 mm)
Flange Diameter . . . . . . . . . . . .24.00 in. (610 mm)
Barrel Length . . . . . . . . . . . . . .13.25 in. (337 mm)
Overall Gear Ratio
PA57VS/D7R D/S . . . . . . . . . . . . . . . . . . . . . .156:1
PA57VS/D7R PS, PA58VS, PA59VS . . . . . . .245:1
Gear Case Oil Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 qt (15 L)
Static Brake Release Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .approximately 305 psi (2,103 kPa)
Drum Clutch Release Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . .approximately 225 - 390 psi (1,550 - 2,690 kPa)
Cable Storage Capacity
1-1/4 in. (32 mm)
Layer
Ferrule Part No. 131-7404
ft
M
1
38
11.6
2
83
25.3
3
135
41.2
4
193
58.8
5
-----
1-1/8 in. (29 mm)
Ferrule Part No. 131-7403
ft
M
42
12.8
90
27.4
145
44.2
207
63.1
276
84.1
1 in. (25 mm)
Ferrule Part No. 131-7402
ft
M
46
14.0
99
30.2
159
48.5
226
68.9
300
91.4
RECOMMENDED OIL
We have published the following specification to help determine which lubricant is best suited to your application.
The oil must possess high temperature oxidation stability, rust and corrosion protection, good dispersant and detergent characteristics, anti-wear additives and remain compatible with nitrile base seals.
Your lubricant supplier should assure you that his product meets this specification. If there is any doubt as to the suitability of a lubricant, contact the PACCAR Winch Service Department, providing a copy of the product specifications.
PREVAILING AMBIENT TEMPERATURE
oF
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
80
90
100
110 oF
SAE 0W-30
SAE 5W-30
SAE 30
SAE 50
oC
-50
-40
!
-30
-20
WARNING
CAUTION
-10
0
10
20
30
40 oC
Caterpillar TDTO or Caterpillar TO-4
!
Cold start-up in the shaded range of each oil type requires extended equipment warm-up to prevent erratic clutch and brake operation which may result in property damage, injury or death.
SAE 30 - Recommended for most
applications, and factory fill.
WINCH REMOVAL AND INSTALLATION
During disassembly, care should be taken not to damage
seals and o-rings that are to be reused. Replace any such
parts that are damaged or otherwise defective. Certain orings and seals specified in the replacement instructions
must not be reused. In general, seals and o-rings that
work under operating hydraulic pressures, or that require
extensive disassembly to replace, should be replaced
with new parts at the time of reassembly.
Cleanliness around all hydraulic components is of utmost
importance. Before starting any repair procedures, be
sure to thoroughly clean the parts to be removed, as well
as adjacent areas on the tractor, to avoid entry of dirt into
the winch and winch control system. Do not leave any
ports or access openings exposed to the weather. Seal or
cap the openings to prevent entry of dust, moisture or
other foreign material. Cap or plug all exposed hydraulic
ports and fittings.
9
WINCH REMOVAL
!
remove the nuts and bolts securing the winch to the tractor adapters, and move the winch away from the tractor.
WARNING
CAUTION
!
WINCH INSTALLATION
Before servicing, make sure any trapped oil pressure
in the tractor hydraulic system has been relieved.
Personal injury may result from a sudden release of
oil pressure. Relieve trapped pressure by cycling the
blade and winch control levers several times after the
tractor engine has been turned off. Relieve any
trapped oil pressure in the hydraulic reservoir by
opening the fill cap. Turn the tractor’s master electrical circuit switch off.
!
WARNING
CAUTION
WARNING
CAUTION
!
!
Winch weighs approximately 4,025 lb. (1,826 kg)
without oil, cable and tractor adapters. Make certain
the lifting equipment has adequate capacity.
Attempting to lift the winch with inadequate equipment may result in personal injury or damage to the
winch or property.
Remove dirt, paint and rust from the mounting surfaces of
the winch and tractor adapters.
!
Hot oil may cause injury. Make certain the hydraulic
oil has cooled to a safe temperature before servicing.
Align the winch mounting holes with the adapter mounting
holes, and install and tighten all fasteners to the recommended torque.
Place the tractor and winch in a level position and drain
the oil from the winch into a suitable container. Install the
drain plug securely after oil has drained completely. Note:
Due to the configuration of the cable drum, a small
amount of oil will remain within the drum cavity.
Attach the winch control hoses to the motor, as defined in
the Parts and Installation Manual.
Fill the winch to the proper level with the recommended
oil. Allow 15 minutes for the oil to flow through the gear
train and fill the drum cavity before checking the oil level.
Remove the winch motor hoses from the motor and brake
valve. Remove the motor shift hose from the motor “X”
port. Remove the motor drain hose from the motor.
Remove the drum clutch hose from the elbow on the RH
side of the winch case.
Start the tractor engine and operate the engine at low
rpm. Alternately place the winch control in the Reel-In,
then the Reel-Out position until the winch motor hydraulic
circuit is filled with oil and the winch operates smoothly.
Check the tractor hydraulic oil reservoir and fill to the
proper level as required.
Support the winch with a suitable hoist or platform and
WIRE ROPE INSTALLATION
All winches are rated at bare drum line pull. As the cable drum fills, the line pull will decrease (loss of leverage) as the
line speed increases (larger circumference). Therefore, install the minimum length of cable possible for your application so the winch will operate on lower layers (smaller diameter) and deliver the maximum line pull.
Using larger cable will not always increase strength as the larger cable may be more prone to bending fatigue failure
than smaller wire rope. Consult your wire rope supplier for his recommendations for the wire rope and other rigging
which best suits your application.
!
WARNING
CAUTION
!
Winch cable anchors (ferrules and ferrule pocket) are NOT designed to hold rated loads. Winch loads
applied directly to the cable anchor may cause the cable to pull free and result in the sudden loss of load
control and cause property damage, injury or death. A minimum of 5 wraps of cable must be left on the
drum barrel to achieve rated load. Do not use knots to secure or attach winch cable. We suggest that
the last 5 wraps of cable be painted bright red to serve as a visual warning.
10
INSTALLATION OF SPIRAL FERRULES
Re-useable, field installed spiral ferrules are available from your Caterpillar or wire rope dealer. These ferrules are for
use with six strand, IWRC (Independent Wire Rope Core) type wire rope. Refer to Specifications on page 9.
Step One
Step Two
Tap wedges and cable into ferrule leaving approximately 3/8 in. (10 mm) extending from the top. The first load
will seat the cable and wedges securely in the ferrule.
Insert cable through the small opening of the ferrule.
Spread strands and lay them in individual grooves in spiral wedges.
TROUBLE SHOOTING
!
WARNING
CAUTION
TROUBLE
A
The winch will not lower a
suspended load, or not
release the load smoothly.
!
If a winch exhibits any sign of erratic operation, or load control difficulties
(i.e., load creeping or chattering) appropriate trouble shooting tests and
needed repairs should be performed immediately. Continued operation
under any of the above conditions may result in loss of load control, property damage, serious personal injury or death.
PROBABLE CAUSE
REMEDY
1. The problem could be a plugged
pilot orifice in the brake valve. A
plugged orifice may prevent the spool
from moving or prevent the spool from
moving smoothly, causing jumping or
chattering as the load is released.
A. Disassemble the brake valve. Clean
and inspect all parts. Make certain the
.020 in. (0.5 mm) pilot orifice is not
obstructed.
2. The multi disc static brake may not
be releasing as a result of a defective
brake cylinder seal. NOTE: If the
brake cylinder seal is defective, you
may notice oil leaking from the winch
vent plug.
A. Check the brake cylinder seal as follows:
Disconnect the small hose from the brake
release port. Connect a hand pump with
an accurate gauge and shut-off valve to
the –4 ORFS fitting in the brake release
port.
Apply 1000 PSI (70.3 kg/cm2) to the brake.
Close the shut-off valve and let stand for
five (5) minutes.
If there is any loss of pressure during the
five (5) minutes, the brake housing
assembly should be disassembled for
inspection of the brake cylinder and piston
sealing surfaces and replacement of the
seals. Refer to “Brake Housing Assembly
Service” for more information.
11
TROUBLE
PROBABLE CAUSE
REMEDY
TROUBLE “A” CONTINUED
FROM PREVIOUS PAGE
3. The multi disc static brake will not
release as a result of damaged brake
discs.
A. Disassemble the brake housing assembly to inspect the brake discs. Replace the
brake discs as required.
1. Same as A2.
A. Same as A2.
2. Motor seal may be defective as a
result of high system back pressure or
contaminated oil.
A. System back pressure must not
exceed 40 PSI (2.8 kg/cm2). Inspect the
hydraulic system for a restriction.
B
Oil leaking from the vent plug.
B. Oil analysis may indicate contamination, which could result in a worn motor
shaft seal. Thoroughly flush the entire
hydraulic system and install new filters
and oil. Install a new motor seal.
3. The drum clutch piston seals may
be leaking.
A. Disconnect the drum clutch release
hose from the drum clutch housing.
Connect a hand pump with an accurate
gauge and shut-off valve to the –6
adapter.
B. Apply 500 psi (3,450 kPa) to the drum
clutch. Close the shut-off valve and let
stand for 5 minutes.
C. If there is a loss of pressure during the
5 minutes, the drum clutch housing must
be removed and disassembled for inspection of the seals and sealing surfaces.
Refer to “Drum Clutch Service” section of
this manual for additional information.
C
The brake will not hold a load
with the control lever in neutral.
1. Excessive system back pressure
acting on the brake release port.
A. Same as B2A.
2. Friction brake will not hold due to
worn or damaged brake discs.
A. Same as A3A.
3. Brake clutch may be slipping.
A. Improper planetary gear oil may cause
the brake clutch to slip. Drain the old gear
oil and flush the winch with a mild solvent. Thoroughly drain the cleaning solvent, and refill the winch with the recommended planetary gear oil listed in the
“Preventive Maintenance” section, or in
Service Bulletin 92.
B. Overrunning brake clutch may be damaged or worn. Disassemble and inspect
as described in “Overrunning Brake
Clutch Service”.
12
TROUBLE
PROBABLE CAUSE
TROUBLE “C” CONTINUED
FROM PREVIOUS PAGE
4. If winch was field installed, check to
see that the proper stack valve section was used (motor spool required).
D
The winch will not pull the
rated load.
REMEDY
5. Drum clutch discs may be worn.
A. Disassemble and inspect drum clutch
components as described in “Drum
Clutch Service” section.
1. The hydraulic system relief valve
may be set too low. The relief valve
may need replacement or repair.
A. Check system relief pressure as follows:
Install an accurate gauge into the tractor
pump pressure port per the tractor manual.
Apply a stall pull load on the winch while
monitoring the pressure.
Compare the gauge reading to the winch
specifications. Adjust the relief valve as
required, if necessary.
NOTE: Refer to the tractor service manual for more information regarding the system relief valve.
E
The winch runs hot.
2. Be certain the hydraulic system
temperature is not more than 200° F
(93° C). Excessive hydraulic oil temperatures increase motor and pump
internal leakage.
A. Check system relief valve, per D1A.
3. Winch line pull rating is based on
1st layer of wire rope.
A. Refer to winch performance data for
more information.
4. Same as C5
A. Same as C5A.
5. Hydraulic motor locked in high
speed, small displacement position.
A. Send motor to qualified motor service
center.
1. Be certain the hydraulic system
temperature is not more than 200°F
(93°C). Excessive hydraulic oil temperatures may be caused by:
A. Same as D2A.
B. Same as E2A.
B. Plugged heat exchanger (where used).
Thoroughly clean exterior and flush interior of heat exchanger.
C. Too low or too high oil level in hydraulic
reservoir.
Fill / drain reservoir to proper level.
D. Same as D1A
13
TROUBLE
PROBABLE CAUSE
TROUBLE “E” CONTINUED
FROM PREVIOUS PAGE
REMEDY
E. Tractor hydraulic pump not operating
efficiently.
Tractor low on horsepower or RPM. Tune
/ adjust tractor engine for optimum performance. See tractor service manual for
more information.
Check suction line for damage.
Pump worn or damaged. Inspect / replace
pump as needed. See tractor service
manual for more information.
F
Winch “chatters” while pulling
rated load.
G
Winch fails to operate with
“Disable Switch” toggled to
“Enable” mode.
H
Winch continues to operate
with “Disable Switch” toggled
to “Disable” mode.
2. Excessively worn or damaged
internal winch components.
A. Disassemble winch for inspection /
replacement of worn or defective components.
1. Same as D1.
A. Same as D1A.
2. Hydraulic oil flow to motor may be
too low.
A. Same as E1B, C, D and E.
3. Controls being operated too quickly or not smoothly.
A. Conduct operator training as required.
1. Switch may not be located in proper position
A. Pull switch and move to top position
for enable mode.
2. Contacts may be corroded, connections may be loose, or wiring may
be scuffed or frayed creating a short/
open circuit.
A. Check contacts, connections and
wiring.
3. Power supply may be faulty
A. Measure voltage across pins on power
leads. Correct voltage is 22 to 27 volts.
4. “Disable Solenoid” may be faulty.
A. Disconnect power leads from solenoid.
Use an accurate ohmeter to check resistance across the coil. Resistance should
be 38 to 40 ohms. Replace the coil or
solenoid as required. See logic valve
service.
1. Switch may not be located in proper position
A. Move switch to the lower, angled position for “Disable”.
2. Same as G4.
A. Same as G4A.
3. Check “Disable Solenoid
Cartridge” for contamination blocking
the valve in the open position.
A. Re-seal or replace the cartridge as
required.
14
TROUBLE
J
The wire rope does not spool
smoothly on the cable drum.
PROBABLE CAUSE
REMEDY
1. Incorrect wire rope lay being used.
There is a distinct advantage in
applying wire rope of the proper
direction of lay. When the load is
slacked off, the remaining coils on
the drum will stay closer together and
maintain an even layer. If rope of
incorrect lay is used, the coils will
spread apart each time the load is
removed. Then, when reeling in is
resumed, the wire rope has a tendency to criss-cross and overlap on the
drum. The possible result is flattened
and crushed wire rope, ultimately
resulting in diminished rope life.
A. Consult your wire rope distributor for
recommendation of the wire rope best
suited for your specific application.
2. The winch may have been overloaded, causing permanent set in the
wire rope.
A. Replace the wire rope and conduct
operator training as required.
WINCH DISASSEMBLY
SERVICE PRECAUTIONS
• Before any part is removed from the winch, all service instructions should be read and understood.
• Work in a clean, dust free area, as cleanliness is of utmost importance when servicing hydraulic equipment.
• Inspect all replacement parts, prior to installation, for any damage that may have occurred in shipment.
• Use only genuine PA57, PA58 or PA59 winch replacement parts, which may be obtained through your CAT dealer.
Never reuse expendable parts such as o-rings.
• Inspect all machined surfaces for excessive wear or damage…before reassembly operations are begun.
• Lubricate all o-rings and oil seals with gear oil prior to installation.
• Use a sealing compound on the outside surfaces of oil seals. If using a thread sealant, avoid getting excess sealant
inside parts or passages that conduct oil.
• Thoroughly clean all parts in a good grade of safety solvent. Wear protective clothing as required.
After trouble shooting the winch and its hydraulic system as covered in the “Trouble Shooting” section of this manual,
and the problem is determined to be in the winch, use the following procedure to disassemble the winch.
An overall cross-section of the winch, and a parts key is provided for reference on the following two pages.
Disassembly instructions begin on page 18.
15
Winch Cross-Section
156:1 Ratio
Hose routed through
tube in Housing (item 1)
7
16
Parts Key
Refer to appropriate Installation and Parts Manual
for part numbers.
245:1 Ratio
Item
No.
1
2
3
4
5
6
7
8
19
27
39
43
44
45
46
47
48
49
50
51
52
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
140
17
Description
Winch Housing
Cable Drum
Bearing Cone
Bearing Cup
Spacer Ring
Retaining Ring
Oil Seal
Output Planet Carrier Assembly
Secondary Planet Carrier Assembly
Drum Clutch
Hose
Retaining Ring
Secondary Sun Gear
Thrust Washer
Output Sun Gear
Output Ring Gear
O-ring
Capscrew. Hex Head
Washer
Spring
Primary Planet Carrier Assembly
Thrust Bearing Race
Thrust Bearing
Thrust Bearing Race
Intermediate Shaft
Primary Sun Gear/Shaft
Thrust Bearing Race
Thrust Bearing
Retaining Ring
Primary Planet Ring Gear/End Cover
Thrust Bearing Race
Thrust Bearing
O-ring
Capscrew. Hex Head
Washer, Hardened
Brake Housing Assembly
O-ring
Qty.
1
1
4
4
2
2
2
1
1
1
1
1
1
1
1
1
1
46
46
20
1
1
1
1
1
1
2
1
2
1
2
1
1
10
10
1
1
1. Remove the wire rope from the cable drum BEFORE
disconnecting the hydraulic lines from the motor.
Springs
(Note location
of four empty
holes)
2. Drain the gear case oil as described in the “Preventive
Maintenance” section of this manual.
Lifting eye-bolt
1/2 - 13 threads
6. Remove the springs from the drum clutch piston.
!
4. Remove the capscrews that secure the end cover / primary ring gear to the drum clutch housing. Remove the
end cover / ring gear from the winch.
CAUTION
CAUTION
!
Needle roller thrust bearings are used throughout the
planetary reduction group. Handle these bearings with
care. If dropped, the metal cage separating the rollers
may be damaged, which will result in bearing failure,
and possible damage to winch components, if reused.
3. Remove the hose guard from the LH side of the winch
and disconnect the drum clutch hose.
!
CAUTION
CAUTION
7. Remove the primary sun gear, secondary sun gear and
thrust bearings.
!
The end cover / primary ring gear retains the springs
that keep the drum clutch applied. Remove the capscrews slowly, in a criss-cross pattern to allow the slow
release of spring tension on the end cover. Failure to
follow this procedure may result in injury or damage to
clutch parts.
5. Remove the primary planet carrier assembly, if necessary. (It may have been removed with the end cover / ring
gear.)
7A. Remove the secondary planet carrier assembly and
the intermediate shaft.
18
!
CAUTION
CAUTION
!
The drum clutch housing weighs approximately 335 lbs
(152 kg). Make certain lifting equipment has adequate
capacity.
10. Use a hoist to support the output plant carrier assembly, and remove it from the winch.
11. Remove the spiral retaining ring, which secures the
output planet carrier to the drum drive shaft.
12. Remove the drum drive shaft from the carrier assembly.
8. Support the drum clutch housing with a hoist and
remove the capscrews securing the drum clutch housing
to the output ring gear. Remove the drum clutch housing
from the ring gear, and move it to a suitable work surface.
Jackscrew holes are provided to aid removal.
13. Remove the 3/8” bolt securing the vertical fairlead
roller shaft assembly to the top of the winch case.
!
CAUTION
CAUTION
!
The vertical roller assembly weighs approximately 100
lbs (45 kg). Make certain lifting equipment has adequate capacity.
9. Remove the output planetary sun gear and thrust
washer. Install a 5/8 - 11 lifting eye-bolt into the output
planet carrier.
!
CAUTION
CAUTION
!
The output planet carrier assembly weighs approximately 295 lbs (134 kg). Make certain lifting equipment has adequate capacity.
14. Carefully remove the vertical shaft from the winch
case. The vertical roller must be supported to prevent it
from falling out of position with the shaft removed.
Remove the roller assembly, and the spacer washers at
each end.
19
!
CAUTION
CAUTION
tied through the holes in the top plate of the winch case.
Also support the drum by placing wood blocks under the
drum flanges.
!
The horizontal roller assembly weighs approximately
72 lbs (33 kg). Make certain lifting equipment has adequate capacity.
17. If removal of the output ring gear is necessary,
remove the capscrews securing the output ring gear to
the case. Install a 5/8 - 11 eyebolt into the lifting eye hole
in the mounting flange, and remove with a hoist.
Jackscrew holes are provided to aid removal. Refer to the
“Cable Drum Service” section for drum bearing and seal
replacement information.
!
CAUTION
CAUTION
!
The motor cover weighs approximately 95 lbs (43 kg).
Make certain lifting equipment has adequate capacity.
15. Support the horizontal fairlead roller using rope or
some other positive retention method. Remove the bolt
and spring washer securing the horizontal roller shaft
assembly to the winch case LH wall. Carefully remove the
roller shaft and spacer washers from the RH side of the
winch. Remove the horizontal roller from the winch.
!
CAUTION
CAUTION
!
18. Remove the motor cover. Due to the size of the cover,
an access hole and weld nut is provided on the top of the
cover to allow installing an eyebolt (1/2 - 13 thread) and
lifting with a hoist.
The cable drum is supported in the winch case by
bearings on the output ring gear and the brake housing. If either of these components is removed, and
the drum is not supported externally as described
above, the cable drum may come loose in the case.
The cable drum weighs approximately 540 lb. (245
kg). Injury or damage to parts may occur if precautions are not taken.
19. Disconnect the brake release line from the long
adapter on the brake housing.
16. Support the cable drum to the winch case with a suitable hoist. As an alternate method, use a heavy duty rope
20
!
CAUTION
CAUTION
!
The motor assembly weighs approximately 110 lbs (50
kg). Make certain lifting equipment has adequate
capacity.
21. Remove the capscrews securing the brake housing to
the winch case. Support the brake housing with a hoist
and carefully remove the brake housing from the winch
case.
22. Support the cable drum with a hoist and lifting strap,
remove the supporting rope, and remove the cable drum
through the rear of the case.
20. Support the hydraulic motor with a hoist and lifting
strap, and remove the motor mounting bolts. Carefully
remove the motor.
23. Clean and inspect all components and subassemblies
at this time. Refer to the appropriate sub-assembly service section of this manual for specific repair procedures.
NOTE: It is recommended that a brake cylinder lifting
fixture, similar to the one shown on page 36, be fabricated and used in the removal and installation of the brake
cylinder assembly. The fixture is fastened at the two
motor mounting holes and will assist in balancing the
assembly as it is removed or installed.
PRIMARY & SECONDARY PLANET CARRIER SERVICE
SECONDARY PLANET CARRIER
DISASSEMBLY
2. Slide the planet shaft clear of the carrier wall. Use a
punch to drive the roll pins from the planet shafts. Do not
reuse the roll pins.
1. Remove the planet pins by driving the roll pins into the
center of the planet shafts.
3. Remove the planet shafts, bearings, spacers, thrust
washers and gears. Thoroughly clean all parts and
inspect for damage and wear. The bearing rollers should
not exhibit any irregularities. If the rollers show any sign
of spalling, corrosion, discoloration, material displace21
ment or abnormal wear, the bearing should be replaced.
Likewise, the bearing cage should be inspected for
unusual wear or deformation, particularly the cage separator bars. If there is any damage that will impair the ability of the cage to separate, retain and guide the rollers
properly, the bearing must be replaced. The thrust washer contact areas must be free of any surface irregularities
that may cause abrasion or friction. The gears and planet
shafts should be inspected for abnormal wear or pitting.
Replace as needed.
Carefully align the pin hole in the carrier with the hole in
the planet shaft, and drive a new roll pin into place.
Always use new roll pins. Approximately 1/2 of the rollpin
should engage the shaft and 1/2 should engage the carrier.
Note that the roll pin is slightly recessed in the carrier
when properly installed. With a center punch, stake the
carrier next to the pin hole. This will distort the hole so the
pin will not back out. Repeat these steps for each of the
three planet gears.
ASSEMBLY
PRIMARY PLANET CARRIER
Insert two (2) bearings and a bearing spacer into a gear,
with the spacer between the bearings. Place a thrust
washer on each side of the gear, and position into an
opening in the carrier. Slide the planet shaft through the
carrier, and into and through the gear and thrust washers.
To service the primary planet carrier, the steps are the
same as for the secondary carrier except there is only
one bearing for each gear, and no bearing spacer.
OUTPUT PLANET CARRIER SERVICE
DISASSEMBLY
ASSEMBLY
Remove the planet gear shafts by driving the roll pins into
the center of the shafts, then push the shafts out of the
planet carrier while supporting the planet gear.
Support the planet gear on one of the thrust washers and
install twenty (20) rollers at one end of the bore. A light
coating of grease on the bore, and on the rollers will aid
retention of the rollers in the bore during assembly. Install
the bearing spacer, then install the remaining twenty (20)
rollers in the bore. Repeat this procedure for all three output planet gears.
Each gear contains two (2) sets of twenty (20) loose bearing rollers, separated by a bearing spacer. Carefully
remove the rollers and spacers for inspection. Thoroughly
clean all parts and inspect for damage or abnormal wear,
as was done for the primary and secondary planet
assemblies.
Move the gear assembly and the supporting thrust washer into place in one of the planet gear openings in the carrier. Carefully slide the gear and washer into alignment
with the planet shaft bore. Install the second thrust washer on the upper side of the gear.
Slide the planet shaft through the carrier assembly, into
and through the gear assembly and thrust washers.
Carefully align the roll pin hole in the carrier with the hole
in the planet shaft and drive a new roll pin into place.
Always use new roll pins. Approximately 1/2 of the rollpin
should engage the shaft and 1/2 should engage the carrier.
Make certain the roll pin is slightly recessed in the carrier
and stake into place as described for the primary and secondary planet assemblies.
22
DRUM CLUTCH SERVICE
DISASSEMBLY
6. Place each friction disc on a clean, flat surface, and
check for distortion using a straightedge. The friction
material should appear evenly across the entire surface,
with visible grooves. Replace the friction discs if the
splines are worn to a point, if the disc is distorted, or if the
friction material is worn unevenly.
1. Place the drum clutch housing on a suitable work surface, small end down.
7. Place each steel divider plate on a clean, flat surface
and check for distortion using a straightedge. Check both
surfaces for signs of material transfer or heat. Replace
the steel divider plate if the splines are worn to a point or
if the disc is distorted or heat discolored.
0
90
10
20
80
1
0
30
70
40
60
50
2. Remove the spiral retaining ring from the housing.
8. Check the clutch spring free length; minimum free
length is 2 3/8 in. (60.3 mm). Check the springs for any
sign of cracking or other failure. If a single clutch spring
must be replaced for any reason, then ALL clutch springs
must be replaced.
!
CAUTION
CAUTION
!
Failure to replace the clutch springs as a complete
set may result in uneven drum clutch application
pressure, and accelerated and repeated drum clutch
and clutch spring failure.
3. Remove the pressure plate, clutch hub and friction
discs and divider plates from the assembly.
ASSEMBLY
1. Place the drum clutch housing on a clean, level surface
with the large end down. Be sure that the spacer ring is in
place in the spline groove.
4. Support the drum clutch housing approximately 1”
above the work surface and drive the piston out of the
housing using a rubber mallet.
2. Install new o-rings on the clutch piston. Lubricate the orings and install the clutch piston into the housing. Use a
rubber mallet, if needed, to seat the piston seals into the
housing.
5. Thoroughly clean and inspect all parts at this time.
Check the piston sealing surfaces for any scoring which
could damage the seals. Make certain the brake release
port is free of any contamination.
23
3. Carefully lift the housing so that the piston does not fall
out and turn the assembly over so that the piston is facing downward.
4. Lubricate the friction discs with winch oil prior to
assembly. Install a steel divider plate into the housing
against the clutch piston. Next, install a friction disc on top
of the divider plate. Continue alternating the clutch discs
into the housing until all plates have been installed. The
top part must be a friction disc, which will rest against the
pressure plate.
5. Align the inside splines on the friction plates, and install
the clutch hub into the assembly. Make sure the smooth
face of the clutch hub faces toward the pressure plate.
6 Install the pressure plate. Tap the pressure plate as
needed to move the piston / clutch assembly to enable
installation of the retaining ring. Install the spiral retaining
ring.
BRAKE HOUSING ASSEMBLY SERVICE
Refer to Brake Housing Assembly Drawing and Parts Key on following page
DISASSEMBLY
Press Here
Retaining
Ring
Press Table
1. Place the brake housing assembly on a suitable work
surface with the motor end down. Remove the retaining
ring and thrust bearings (items 80, 93 & 94) from the
brake shaft.
3. Using a large socket or piece of tubing that will clear
the brake shaft, apply only enough force with the press
against the spring retainer (item 87) to permit removal of
the retaining ring (item 95) from the housing. Remove the
spring retainer, brake springs(item 86), brake piston (item
85), brake cylinder (item 92) and over-running brake
clutch (item 75) from the housing.
2. Turn the brake housing assembly over on the table of
a hydraulic press with the motor end up. Be certain to
support the housing on the press table and not damage
the end of the brake shaft or brake retainer.
24
Brake Housing
Assembly and
Parts Key
ITEM NO.
74
75
80
82
83
84
85
86
87
88
89
90
DESCRIPTION
Brake Housing
Brake Clutch Assembly
Retaining Ring
Disc - Steel
Disc - Friction
Spacer
Brake Piston
Spring
Spring Retainer
O-Ring
O-Ring
O-Ring
QTY.
1
1
1
11
10
1
1
13
1
1
1
1
ITEM NO.
91
92
93
94
95
96
97
98
99
100
101
DESCRIPTION
O-Ring
Brake Cylinder
Bearing Race
Thrust Bearing
Retaining Ring
Brake Retainer
Back-up Ring
Back-up Ring
Back-up Ring
Back-up Ring
Pipe Plug
QTY.
1
1
2
1
2
1
1
1
1
1
1
5. Thoroughly clean and inspect all parts at this time.
Check the brake piston and brake cylinder sealing surfaces for any scoring which could damage the seals.
Make certain the brake release port is free of any contamination.
4. Turn the housing over with the motor end down.
Remove the large retaining ring and the brake retainer
from the housing. Remove the brake discs and spacer
plate.
25
6. Check the cable drum oil seal and bearing surfaces on
the brake housing (item 74) for any wear or damage.
7. Place each friction disc (item 83) on a clean, flat surface, and check for distortion using a straightedge. The
friction material should appear evenly across the entire
surface, with visible grooves. Replace the friction discs if
the splines are worn to a point, if the disc is distorted, or
if the friction material is worn unevenly.
8. Place each steel disc (item 82) on a clean, flat surface
and check for distortion using a straightedge. Check both
surfaces for signs of material transfer or heat. Replace
the steel divider plate if the splines are worn to a point or
if the disc is distorted or heat discolored.
2. Lay the brake housing onto its side and install the overrunning brake clutch assembly (item 75) into the housing.
Install the thrust bearing set (items 93 & 94) with the needle roller bearing between the two thrust races, and
secure with the retaining ring (item 95).
9. Check the brake spring free length; minimum free
length is 1-7/16 in. (36.5 mm). Check the springs for any
sign of cracking or other failure. If a single brake spring
must be replaced for any reason, then ALL brake springs
must be replaced.
!
CAUTION
CAUTION
3. Place the brake housing on the table of a hydraulic
press with the motor end up. Be certain to support the
housing on the press table and not damage the end of the
brake shaft or brake retainer.
!
Failure to replace the brake springs as a set may
result in uneven brake application pressure, and
accelerated and repeated brake system and brake
spring failure.
ASSEMBLY
4. Lubricate the friction discs (item 83) in clean oil, using
the same oil intended for the winch. Install a steel disc
(item 82) against the brake retainer, then install a friction
disc. Continue assembly in this alternating fashion until all
brake discs are installed – 10 friction discs and 11 steel
discs.
5. Install the brake plate spacer (item 84) on top of the
last steel disc.
1. Place the brake housing on a suitable work surface
with the motor end down. Install the brake retainer (item
96) and retaining ring (item 95) into the brake housing.
26
Brake Housing
Backup Rings
Retaining Ring
Brake Piston
O-Rings
Backup Rings
Brake Cylinder
Location of O-Rings and Backup Rings
6. Install O-rings (items 89 thru 90) and backup rings
(items 97 thru 99) into the brake housing and brake cylinder (item 92) grooves. Lightly lubricate the brake housing
bore with multi-purpose grease and carefully install the
brake cylinder into the housing. Take the proper precautions to avoid cutting the O-rings during assembly. Make
sure the brake cylinder is located against the splines
inside the housing.
Completed Brake Housing Assembly
8. Install the brake springs (item 86) into the holes in the
piston. Place the spring retainer (item 87) over the
springs. Using a large socket or piece of tubing that will
clear the brake shaft, apply only enough force with the
press to permit installation of the retaining ring (item 95).
7. Install the O-ring (item 91) and backup ring (item (100)
into the brake piston (item 85) grooves. Lightly lubricate
the outside surfaces of the brake piston with multi-purpose grease and install the piston into the cylinder. Take
the proper precautions to avoid cutting the o-rings during
assembly.
Connect hand
pump here
BRAKE ASSEMBLY PRESSURE TEST
Install the long fitting into the brake release port of the
brake housing. Connect a hand pump with an accurate
gauge and a shut-off valve. Apply 1,000 PSI (6900kPa)
to the brake. Close the shut-off valve and let the unit
stand for five (5) minutes. If after five (5) minutes, there is
any pressure loss, the brake assembly should be disassembled for inspection of the sealing surfaces and brake
piston seals.
27
OVERRUNNING BRAKE CLUTCH SERVICE
DISASSEMBLY
aged or shows excessive wear, there is no need for further disassembly. If further disassembly is required,
remove the remaining sprag bearing as defined above.
Brake Shaft
Snap Ring
Brake shaft freewheels clockwise looking at this end.
1. Remove the snap ring and thrust washer from the
brake shaft. While slowly rotating the brake shaft within
the sprag assembly, pull the brake shaft free of the outer
brake race and sprag assembly.
5. Thoroughly clean and inspect all brake clutch parts
before re-assembly.
2. Closely inspect the polished outer surface of the brake
shaft for scoring, wear, discoloration due to excessive
heat, or indentions caused by the sprag cams. The entire
brake clutch assembly MUST be replaced if any damage
is found.
!
WARNING
CAUTION
!
The polished surfaces of the races and sprag cams
must be perfectly smooth to insure positive engagement of the sprag assembly. The slightest defect
may reduce the effectiveness of the brake clutch,
which could result in loss of load control, property
damage, severe personal injury or death. It is generally recommended to replace the entire brake clutch
assembly if any component is defective.
ASSEMBLY
1. Press a bronze sprag bearing into one end of the outer
brake race, using a mechanical or hydraulic press. A flat
plate of approximately the same diameter as the bearing
flange outside diameter should be placed between the
press and the bearing during installation to protect the
bearing. Make sure the bearing flange is located squarely against the shoulder in the outer race.
3. Use a screwdriver to remove the bronze sprag bearing
from one end of the sprag assembly. There are four special cut-outs on the inside face of the bearing for this purpose. Be careful not to damage the inside surface of the
bearing. If the inside surface is damaged or shows wear,
it should be replaced.
2. Turn the assembly over and install the two sprag
clutches into the bore of the outer race. Slowly rotate the
sprag clutch to aid installation.
4. Slide the sprag clutches out of the outer brake race.
Inspect each sprag clutch closely for abnormal wear,
cracks, pitting or corrosion. Check the small clips for
breakage or bright spots, which indicate excessive wear.
Unless the outer race or remaining sprag bearing is dam-
3. Press the remaining bearing into the outer race. Again,
make sure the bearing is located squarely against the
shoulder in the outer race.
28
4. Install a thrust washer onto brake shaft against the
motor coupling end. Lubricate the brake shaft outer surface with winch oil.
left hand with the motor coupling toward you. Grasp the
motor coupling end of the brake shaft with your right
hand, and turn it in a CLOCKWISE direction – the same
direction the cable drum turns to reel-in wire rope. If the
brake shaft will not rotate freely in this direction, the sprag
clutches and outer brake race have been installed incorrectly and must removed, turned over and reinstalled.
5. Slide the brake shaft through the sprag clutch assembly. Rotate the brake shaft in the freewheeling direction to
start it through the sprag assembly. If the brake shaft will
not start through the bearings, the bearings may have
been damaged and should be replaced.
7. Once you have verified that the brake clutch has been
assembled for the correct rotation, install the remaining
thrust washer and the retaining ring.
6. Make sure the brake clutch is assembled for the correct
direction of free rotation. Hold the outer brake race in your
CABLE DRUM SERVICE
DISASSEMBLY
!
CAUTION
CAUTION
!
The cable drum is supported in the winch case by
bearings on the output ring gear and the brake housing. If either of these components is removed, and
the drum is not supported externally as described
above, the cable drum may come loose in the case.
The cable drum weighs approximately 540 lb. (245
kg). Injury or damage to parts may occur if precautions are not taken.
1. Remove the cable drum as described on pages 17
through 20 of this manual.
2. Place the cable drum on a suitable work surface. The
seals must be removed to gain access to the drum bearings. Next, remove the spiral retaining ring and the spacer ring from the drum. Inspect the drum bearings while
installed in the drum. If scored, heat discolored or damaged in any other way, they should be removed and
replaced.
3. To remove the drum bearings, drive the bearing cones
from the drum bore using a long, soft metal punch.
Remove the inner bearing cups using a multi-jaw puller or
by welding pulling lugs directly to the cups. Either method
will destroy the bearing cups and require replacement.
NOTE: The bearings should only be removed if replacement is necessary as unintentional damage may occur
during the removal process.
ASSEMBLY
1. Chill the inner bearing cup in dry ice to shrink the diameter to aid installation. Install the bearing cup into the
cable drum bearing bore. Use a .002 in. (.05 mm) feeler
gauge to make certain the cup is fully seated against the
drum barrel shoulder.
29
2. Lubricate the bearing cones with winch oil and install
into the bearing cup. The bearing cones will be back-toback with the large end of the cones in contact with each
other.
7. To maintain alignment, alternately install the ring gear
and then the brake housing assembly into the cable drum
bearings. The bearings have a snug slip-fit which requires
extreme care during installation.
3. Chill the outer bearing cup, as previously described,
and install into the drum against the bearing cones. Take
care during assembly to avoid damaging the bearing
cage on the cone.
8. Make sure all bolt holes are properly aligned before the
ring gear and brake housing assembly enter the winch
case pilot bore. Locate the lifting eye boss on the ring
gear housing at the top-most position. Locate the brake
release port on the brake housing in the upper LH quadrant, and the two-bolt motor mounting pattern vertical.
4. Install the spacer ring, then the spiral retaining ring into
the cable drum.
9. Install the hydraulic motor assembly and planetary
reduction group. Make sure all bolts are torqued to the
proper values.
5. Apply non-hardening sealing compound to the outside
surface of the seal housing at installation. With the drum
seal properly positioned in the drum bore, place a large
steel plate over the seal for protection and press or drive
it into place.
10. Refill the winch to the proper level with the recommended oil.
6. Support the cable drum into place within the winch
case. NOTE: The wire rope anchor pocket is always
located on the right hand (motor) side of the winch.
Lubricate the bearing and seal contact surfaces of the
output ring gear and brake housing.
30
WINCH ASSEMBLY
4. Install the hydraulic motor onto the brake housing,
making sure to properly align the splines in the brake
shaft. Apply a light coat of multi-purpose grease to the
motor pilot O-ring.
Retaining Rings
Thrust
Washer
Counter-bore
1. If the cable drum has been removed, support the drum
securely between the winch case walls. The cable pocket end, or wide flange, must be located to the motor side,
(right hand side), of the case.
2. Install the output ring gear into the large bore on the LH
side of the winch case. Apply a light coating of multi-purpose grease to the seal land on the ring gear pilot. Locate
the lifting eye boss at the topmost position. Tighten the
capscrews to 120 lb-ft (163 N-m) torque.
5. Make certain both mid-position retaining rings are seated in the grooves of the drum drive shaft and install the
shaft into the output planet carrier with the thrust washer
counterbore facing the planet gears. Install the spiral
retaining ring into the outermost groove in the drum drive
shaft.
3. Install the brake housing assembly into the small bore
on the RH side of the winch case. Apply a light coating of
multi-purpose grease to the seal land of the brake housing pilot. Be careful not to damage the oil seal in the cable
drum during installation. Locate the brake release port in
the upper LH quadrant, and the two-bolt motor mounting
pattern vertical. Tighten the capscrews to 120 lb-ft (163
N-m) torque.
6. Install the output planet carrier assembly into the output ring gear while aligning the planet carrier and drum
shaft splines.
31
10. Install the secondary planet carrier assembly into the
drum clutch hub, while aligning the planet carrier and output sun gear teeth.
7. Apply multi-purpose grease to the thrust washer and
install it into the counterbore in the drum drive shaft.
8. Install the intermediate shaft through the cable drum
into the brake shaft. Install the output sun gear over the
intermediate shaft into the output planet carrier assembly.
Be sure to insert the large end of the output sun gear
toward the cable drum.
11. Install the secondary and primary sun gears on the
intermediate shaft. Make certain that the thrust bearing
sets are properly installed, and the thrust washers are
located on both sides of the thrust bearings.
9. Lubricate the o-ring on the pilot of the drum clutch
housing and install the drum clutch assembly onto the
output ring gear. The drum clutch housing includes the
drain plug, which must be located at the bottom of the
assembly after installation. Evenly tighten the capscrews
to 120 lb-ft (163 N-m) torque.
12. Install the primary planet carrier thrust bearing set
onto the inboard hub of the primary planet carrier. Again,
make certain that the thrust washers are located on either
side of the thrust bearings. Install the primary planet carrier assembly over the primary sun gear, while aligning
the planet carrier and secondary sun gear teeth.
32
15. Attach the drum clutch release hose to the release
port on the drum clutch housing. Install the hose guard to
the winch case.
13. Install the clutch springs into the drum clutch piston.
Be sure to locate the springs such that the remaining four
(4) open spring pockets are evenly spaced.
16. Install the horizontal fairlead shaft and roller assemblies. Insert the spacer washers at both ends of the roller
assembly between the roller and the case wall. Be sure to
install the spring washer with the large diameter contacting the housing wall.
17. Install the vertical fairlead roller and shaft assemblies.
Insert the spacer washers at both ends of the roller
assembly between the roller and the case wall.
18. Grease the fairlead rollers as specified in the
“Preventive Maintenance” section in this manual. Refill
the winch to the proper level with the recommended oil.
19. Install all motor plumbing then refill the tractor
hydraulic reservoir as recommended in the tractor
Operation and Preventive Maintenance manual.
14. Lubricate the o-ring on the pilot of the end cover / primary ring gear. Install the end cover / primary ring gear to
the drum clutch housing. Rotate the end cover slowly until
the ring gear teeth properly mesh with the primary planet
gear teeth. A slight amount of upward pressure may aid
the alignment of the gear teeth during installation.
Tighten the capscrews to 120 lb-ft (163 N-m) torque.
!
CAUTION
CAUTION
20. Start the tractor and refill the reservoir as required.
Operate the winch, with no load, in both directions to
purge air from the lines. Check all plumbing for leaks and
repair as required.
21. Install the motor cover. Evenly tighten the capscrews
to 75 lb-ft (102 N-m) torque.
!
Do not install and tighten the end cover/ring gear
capscrews until you are certain the gear teeth are
properly aligned. Damage to the ring gear teeth
and/or primary planet gears may result if the gear
teeth are not properly aligned. Do not attempt to pull
the cover into alignment with the capscrews. The
cover will go into place and seat evenly against the
springs when the gear teeth are properly aligned.
33
LOGIC VALVE SERVICE
The logic valve contains a pressure reducing valve, relief valve and flow control valve cartridges that comprise the
pressure maintenance system for the winch pilot control system. The logic valve also contains a quick disconnect
pressure tap for checking the pilot circuit oil pressure.
An electric solenoid valve is installed in the logic valve to provide a pilot pressure signal to the winch motor “X” port
when the “Low-Lock” rocker switch on the control lever is actuated. When the “X” port is pressurized, the motor displacement will remain at the maximum for enhanced load control.
The other solenoid valve is used to enable/disable the winch pilot control circuit. This solenoid is energized by the
toggle switch mounted on the winch joystick control module.
Follow the procedure below to check/adjust the winch pilot circuit relief pressure:
1. Stop the engine and lower the blade to the ground. Relieve trapped oil pressure in the hydraulic system by cycling
all hydraulic controls then return them to neutral.
2. Install an accurate hydraulic gauge to the quick disconnect pressure tap on the logic valve at the port labeled “G”.
3. Start the engine and operate at high idle. Enable the winch circuit by actuating the toggle switch on the winch joystick control module. The stand-by oil pressure when the winch is NOT in use should be 350-450 psi (2400-3100
kPa) as controlled by the tractor hydraulic system.
4. Place the winch joystick control lever in the Drum Clutch Release position and note the pilot circuit oil pressure.
Adjust the pressure reducing valve to achieve 575-675 psi (3965-4655 kPa). On D7R-PS (non-differential steer),
adjust the relief valve pressure to 400 psi (2760 kPa).
5. Stop the engine, relieve trapped pressure as mentioned earlier, and remove the test gauge.
6
PARTS KEY
Item
1
2
3
4
5
6
7
Description
Qty.
Valve Body
1
Solenoid Valve - Low Range
1
Solenoid Valve - Disable
1
Plug
3
Relief Valve (600 psi - 4140 kPa) ** 1
Pressure Reducing Valve *
1
Flow Control Valve *
1
3
2
7
P
G
4
* Not used on D7R-PS (non-differential
steer); cavity plug installed in valve port
5
** Set at 400 psi (2760 kPa) on D7R-PS
(non-differential steer)
1
T
T
T
T
Assembly Notes:
1. Tighten valve cartridges 5, 6 and 7 with a 7/8 inch socket to 30 - 35 lb•ft (41 - 47 N•m) torque.
2. Tighten solenoid valve bodies 2 and 3 with a 7/8 inch wrench to 15 - 20 lb•ft (20 - 27 N•m) torque.
3. To aid assembly, the coil may be removed from the solenoid valve by removing the retainer nut with a 3/4 inch
wrench. After assembly, carefully tighten the coil retainer nut to 5 lb•ft (8 N•m) torque.
34
Brake
Valve
35
Cable
Drum
Winch
Drum
Clutch
“Drain”
“BR”
“DC”
Winch
Brake
“BR”
800
psi
1
4
600
psi
A2
0-600
B1
20-297
Logic Valve
24 VDC
Reel-Out
Reel-In
Winch Hydraulic System
P
B2
20-297
3.0
gpm
T
3
Tractor Reservoir
Existing Tractor
Control Valve
(Simplified
Circuit)
Winch Control
Section
(Motor Spool)
Tractor Hydraulic System
HYDRAULIC CONTROL CIRCUIT
ELECTRICAL CIRCUIT
#2
#2
BLACK
ORANGE
#1
PURPLE
BLACK
Joystick
Switch
#1
Ground
+24 VDC
ORANGE
RED
Power
Disable
Switch
RED
BLACK
#2
#1
#1
Low Lock
Solenoid
2.0
#4
Disable
Solenoid
BRAKE CYLINDER
LIFTING FIXTURE
0.5
0.8125 Diam.
All dimensions in inches
12.0
1.0
Diam.
12.0
9.843
This piece can be a solid bar or piece
of heavy wall pipe or tubing.
Attach fixture to Brake Cylinder at the two holes
used for the hydraulic motor. Use two 3/4 - 10
grade 5 capscrews, 1 1/4 inches long.
0.8125 Diam.
36
37