Paccar Winch CARCO H50VS User manual

1
LIT2413_R1
11-2008
Printed in U.S.A.
Copyright 2008 PACCAR Winch Division
All Rights Reserved
MODEL H50VS
SERVICE MANUAL
CARCO

2
TABLE OF CONTENTS
FOREWORD...............................................................................................................3
GENERAL SAFETY RECOMENDATIONS .................................................................4
WINCH DESCRIPTION...............................................................................................5
CROSS SECTION.......................................................................................................6
PREVENTATIVE MAINTENANCE ..............................................................................8
OIL RECOMMENDATIONS..................................................................................10
WINCH REMOVALAND INSTALLATION.............................................................11
WIRE ROPE INSTALLATION...............................................................................12
INSTALLATION OF SPIRAL FERRULES.............................................................12
TROUBLESHOOTING GUIDE..................................................................................13
SERVICE PRECAUTIONS........................................................................................17
HYDRAULIC MOTOR GROUP.................................................................................17
WINCH DISASSEMBLY............................................................................................19
FREESPOOL GROUP DISASSEMBLY ....................................................................19
FREESPOOL GROUPASSEMBLY...........................................................................20
LOWER REDUCTION GEAR DISASSEMBLY..........................................................21
LOWER REDUCTION GEAR ASSEMBLY................................................................22
DRUM & BULL GEAR DISASSEMBLY.....................................................................23
DRUM & BULL GEAR ASSEMBLY ...........................................................................25
CARTRIDGE ASSEMBLY SERVICE.........................................................................26
PINION CARRIER SERVICE....................................................................................27
PLANET CARRIER SERVICE...................................................................................28
BRAKE CYLINDER SERVICE ..................................................................................29
METRIC CONVERSION CHART..............................................................................31

3
FOREWORD
Please read and understand this entire manual BEFORE operating or servicing your PACCAR winch. Retain this
manual for future reference.
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.
Whenever a question arises regarding your PACCAR winch, or this manual, please contact your nearest Caterpillar
dealer, or the PACCAR SERVICE DEPARTMENT at:
Phone: [phone], Monday – Friday, 0800 hrs – 1630 hrs CST
FAX: [phone]
Email: [e-mail]
Provide the complete winch MODEL NUMBER and SERIAL NUMBER when making inquiries.
Safety and informational callouts used in this manual include:
This emblem is used to warn against potential or un-
safe practices which COULD result in personal injury,
and product or property damage if proper procedures
are not followed.
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.

4
GENERAL SAFETY RECOMMENDATIONS
Safety for operators and ground personnel is of prime concern. Always take the necessary precau-
tions 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.
1. Read all warning tag information and become familiar
with all controls BEFORE operating the winch.
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.
3. Before starting the tractor, be certain all controls move
freely and are placed in the “Brake-On” (neutral) posi-
tion.
4. Never operate winch controls unless you are properly
seated at the operators station on the tractor and are
sure personnel are clear of the work area.
5. 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.
6. Ground personnel should stay in view of tractor opera-
tor and clear of winch drum. Do not allow ground per-
sonnel near winch line under tension. A safe distance
of at least 1 ½ times the working length of the cable
should be maintained. Never allow anyone to stand
under a suspended load.
7. 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.
8. 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.
9. Use correct size ferrule for cable and pocket in winch
drum. Never use knots to secure or attach cable. The
cable anchor or ferrule pocket in the cable drum is de-
signed 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.
NOTE: We suggest painting the last five wraps of
cable bright red to serve as a visual warning.
Recommended Operating Practices
1. Leather gloves should be used when handling winch
cable.
2. Operate the winch to match line speeds to job condi-
tions.
3. Assure that personnel who are responsible for hand
signals are clearly visible and that the signals to be
used are thoroughly understood by everyone.
4. Inspect winch cable, rigging, winch and tractor at the
beginning of each work shift. Defects should be cor-
rected immediately.
5. Position tractor for straightest line of pull to reduce
wear on winch cable and ensure even spooling.
6. 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.
7. Be sure of tractor ground stability before winching in a
load.
8. Store unused chokers, slings and rigging in a neat and
orderly fashion to prevent damage to equipment or in-
jury to personnel.
9. 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.
FAILURE TO OBEY THE FOLLOWING SAFETY REC-
OMMENDATIONS MAY RESULT IN PROPERTY DAM-
AGE, INJURY OR DEATH.

5
10. The factory approved adaptions for PACCAR winches
are designed and intended for use on specific models
of crawler tractors. Changing winches between trac-
tors is not possible in some cases because of differ-
ences in tractor models. Some changes cannot be
approved by PACCAR because of safety limitations.
Call the tractor dealer or the PACCAR factory prior to
attempting winch modifications or before mounting on
a different tractor.
11. PACCAR H50 winches are powered by the tractor hy-
draulic system. Turn off engine and discharge all re-
tained hydraulic system pressure before removing any
hydraulic lines or fittings. Personal injury may result
from sudden release of oil pressure.
12. On machines having hydraulically, mechanically and/
or cable controlled equipment, be certain the equip-
ment is either lowered to the ground or blocked se-
curely before servicing, adjusting and/or repairing the
winch. Always apply tractor parking brakes and lower
equipment before dismounting the tractor.
13. The winches described in this manual are neither de-
signed nor intended for use or application to equipment
used in the lifting or moving of persons.
14. 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.
15. Keep equipment in good operating condition. Perform
scheduled servicing and adjustments listed in the “Pre-
ventive Maintenance” section of this manual. Use rec-
ommended lubricants.
16. An equipment warm-up procedure is recommended
for all start-ups and essential at ambient temperatures
below +40°F (5°C). Refer to “Warm-Up Procedure”
listed in the “Preventive Maintenance” section of this
manual.
17. Don’t weld on any part of the winch without PACCAR
Winch Division approval.
WINCH DESCRIPTION
ThePACCAR H50 winchis ahydraulically drivenwinch uti-
lizing a dedicated piston pump for power input. The winch
hydraulic oil pump is usually installed on the tractor trans-
mission pump and the tractor implement pump is installed
on the winch pump in a piggy-back arrangement when
the winch is installed on the tractor. The winch includes
both planetary and standard spur gears as well as a spring
applied, hydraulically released multi-disc static brake for
holding the load secure while in the neutral “Brake-On”
position. The winch case is designed to bolt to the rear
face of the tractor.
When operated in either the Reel-In or Reel-Out direction,
the variable displacement, piston hydraulic motor drives
the gear train. Winch line speed and load control are pro-
portionate to the amount of oil being delivered to the winch
motor by the hydrostatic control system. The winch brake
must be released by pilot pressure through the winch con-
trol valve in both Reel-In and Reel-Out directions.
The Freespool mechanism is a spring-engaged, hydrau-
lically released, splined gear-type connection. As the
control lever is moved into the Freespool position, the oil
is ported through the winch logic valve assembly to re-
lease the brake, and into the freespool cylinder to force
the freespool piston against the coil spring and disengage
the splined connection. This allows the winch cable to be
pulled off the cable drum by hand.
“Drive-Away” mode is controlled by the winch motor. This
function allows the operator to drive the tractor away from
the load while back driving the motor with the winch gear
train. When the control lever is moved into the Drive-Away
position, the winch motor / cartridge valve assembly lim-
its the flow of the hydraulic oil through the motor and the
winch brake to allow for smooth, controlled pay-out of the
winchcable.The maximum back drivenspeed of the winch
motor is limited by a flow control valve set to achieve ap-
proximately 2.6 mph (4.2 km/h) tractor ground speed at
the winch bare drum condition.
An optional three roller or four roller fairlead assembly is
available for applications in which slight side directional
pulls are routinely encountered. Use of a fairlead assem-
bly will help to maximize winch case and wire rope life by
eliminating wear due to contact in these applications.

6
Lower Reduction
Gear Group
Cartridge
Group
Hydraulic
Motor
Drum Shaft
Bull Gear

7
Typical H50 Hydraulic Schematic
(Hydraulic Winch Control Valve)
TRACTOR WINCH

8
PREVENTATIVE MAINTENANCE
AregularprogramofpreventivemaintenanceforyourPAC-
CAR winch will minimize the need for emergency servicing
and promote long product life and trouble-free service.
The service intervals suggested in this manual will opti-
mize component service life.
GEAR CASE OIL LEVEL
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 de-
tected, the oil level may be checked once every 250 hours
or monthly. The oil level plug is located below the left hand
gear cover toward the rear of the winch. Position the trac-
tor on a flat, level surface and remove the plug. The oil
should be at the bottom of the level plug hole.
Add oil as required through the oil filler plug located above
the lower bearing carrier.
Refer to the recommended oil chart for the proper oil for
your application.
GREASE
There is one grease fitting on each side of the winch case
to which grease should be added every 50 hours. Use
a NLGI #2 EP (extreme pressure) grease with a Lithium
complex base that meets or exceeds NLGI GC or GC/
LB requirements. Pump grease into the upper right drum
bearinggrease fitting untilgrease comesoutthe small vent
hole in the cover. Pump about ½ ounce into the grease
fitting for the second reduction shaft on the left side of the
winch. This will be about 10 strokes with a standard vol-
ume (1.0 to 1.5 grams/stroke) lever operated grease gun.
TRACTOR HYDRAULIC RESERVOIR LEVEL
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 hydrau-
lic oil recommended by the tractor manufacturer.
Change the tractor hydraulic oil in accordance with the
tractor manufacturer’s recommendations.
GEAR CASE OIL CHANGE
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.
Hot oil can cause injury. Make certain the oil has cooled
to a safe temperature (less than 110°F or 43°C) before
servicing the winch.
NOTE: Grease displaced from the second reduction gear
shaft bearings during greasing may drain from the winch
with the oil.
Remove the drain plug located at the bottom left side of
the winch housing. Drain the oil into a suitable container
and recycle or dispose of the used oil in an environmen-
tally responsible manner. Contact your local government
agency for information concerning proper disposal. Install
the plug securely after the oil has been drained. To reduce
oil drain time, remove the filler/vent plug.
Refill the winch to the proper level with the recommended
oil.
Oil capacity: approximately 5 qt. (4.7 L)
DO NOT operate the winch while the oil is drained. Se-
rious damage to internal components may result.
CAUTION
HYDRAULIC OIL FILTER
If a hydraulic oil filter was installed when the winch was
installed on the tractor, replace it on the same interval as
the other tractor hydraulic oil filters.
VENT PLUG
The vent plug is installed in the left hand gear cover.
Whenever the oil is changed, remove the vent plug, clean
in safety solvent and reinstall.
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.
Grease Fitting
Oil Level
Oil Drain
Vent

9
WINCH CABLE (WIRE ROPE)
Inspect the entire length of wire rope and the hook in ac-
cordance with the rigging manufacturer’s recommenda-
tions.
MOUNTING FASTENERS
Check / tighten all winch mounting fasteners to recom-
mended torque after the first 100-250 hours of operation,
then every 1000 operating hours or six (6) months, which-
ever occurs first.
WARM-UP PROCEDURE
The tractor engine should be run in accordance with the
tractor manufacturer’s recommendations to warm up the
hydraulic system, with the winch control in the neutral,
brake-on position. For cold weather operation, use cold
weather oil as recommended in the tractor hydraulic sys-
tem instructions.
The winch should then be operated under a no-load con-
dition, in reel-in and reel-out direction several times to cir-
culate warm hydraulic oil and gear lubricant through the
brake and gear train.
INSPECTION
Every 10,000 hours or four (4) years, whichever occurs
first, the winch should be disassembled for a thorough in-
spection of all wear items. Refer to the disassembly and
assembly sections of this manual for additional informa-
tion.
A warm-up procedure is recommended at each start-
up and is mandatory at ambient temperatures below
+40° F (4° C). Failure to warm-up the tractor/winch
oil may result in temporary brake slippage and loss of
load control due to high back pressures attempting to
release the static brake. This condition may result in
property damage, injury or death.

10
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 suit-
ability of a lubricant, contact the PACCAR Winch Service Department, providing a copy of the product specifications.
o
F -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110
o
F
o
C -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 o C
o
F -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110
o
F
o
C -40 -35 -30 -25 -20 -15 -10 -5 0 5 10 15 20 25 30 35 40 o C
Prevailing Ambient Temperature
! WARNING !
Cold start-up in this ambient temperature range requires extended
equipment warm-up to prevent erratic clutch and brake operation
which may result in property damage, injury or death.
! WARNING !
Cold start-up in this ambient temperature range requires extended
equipment warm-up to prevent erratic clutch and brake operation
which may result in property damage, injury or death.
A - HTF Type C3/C4 SAE 30, CAT TO4 SAE30
B - CAT TO4 SAE 10W30
C - HTF Type C4/C4 SAE 10, CAT TO4 SAE 10W
D - CAT TO4 SAE 5W20 spc.
Basic Oil Requirements
15,000 SUS maximum allowed viscosity at cold start-up; requires extended equipment warm-up.
3,000 SUS maximum allowed viscosity at cold start-up; requires normal equipment warm-up.
60 SUS minimum allowed viscosity at maximum winch operating temperature assuming ambient
plus 80
o
F (27
o
C).
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.
A
B
C
D

11
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 ad-
jacent 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.
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
O-rings and seals specified in the replacement instruc-
tions must not be reused. In general, seals and O-rings
that work under full operating hydraulic pressures, or that
require extensive disassembly to access, should be re-
placed with new parts at the time of reassembly.
WINCH REMOVAL
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 the oil has drained completely.
Support the winch with a suitable hoist or platform, and
remove the fasteners securing the winch to the tractor
mounting brackets, then carefully move the winch away
from the tractor so the hydraulic hoses can be discon-
nected.
Remove the hydraulic hoses from the winch motor and
valve. Remove the motor case drain hose from the motor.
WINCH INSTALLATION
Remove dirt, paint and rust from the mounting surfaces of
the winch and tractor mounting brackets.
Attach the winch control hoses to the motor as defined in
the parts and installation guide.
Align the winch mounting holes with the holes in the mount-
ing brackets, and install and tighten all fasteners to the rec-
ommended torque. Refer to the winch parts and installa-
tion guide.
Fill the winch to the proper level with the recommended
oil.
NOTE: It may be necessary to fill the motor case with
hydraulic oil before start-up to protect against motor
failure due to starting dry.
Start the tractor engine and operate the engine at low
RPM. Alternately place the winch control in the REEL-IN
and REEL-OUT positions until the winch motor hydraulic
circuit is filled with oil and the winch operates smoothly.
Check the tractor hydraulic oil reservoir level and fill as re-
quired.
Before servicing, make sure any trapped oil pressure
in the tractor hydraulic system has been relieved. Per-
sonal injury can result from a sudden release of oil pres-
sure. Relieve trapped pressure by cycling the blade
and winch control levers several times after the trac-
tor engine has been turned off. Relieve any trapped oil
pressure in the hydraulic reservoir by opening the cap.
Ensure that the tractor’s master electrical circuit switch
is off.
Hot oil can cause injury. Make certain the oil has cooled
to a safe temperature (less than 110°F or 43°C) before
servicing the winch.
The H50VS winch weighs approximately 1,400 lbs.
(635 kg) without oil, cable and tractor mounting brack-
ets. Make certain the lifting equipment has adequate
capacity. Attempting to lift the winch with undersized
equipment can result in serious injury or damage to the
winch or other property.
WINCH REMOVAL AND INSTALLATION

12
WIRE ROPE INSTALLATION
All winches are rated at bare drum line pull. As the cable
drumfills,thelinepullwill decrease (loss of leverage) while
thelinespeedincreases(largercircumference).Therefore,
it is recommended to install the minimum length of cable
possible for use in your application to allow the winch to
operate on the lower layers (smaller diameter) and deliver
the maximum amount of line pull.
Using larger diameter cable will not always increase
strength as the larger cable may be more vulnerable to
bending fatigue failure than the smaller rope. Consult your
wire rope supplier for their recommendations for the style
of wire rope and other rigging best suited to your applica-
tion.
Winch cable anchors (ferrule and ferrule pocket) are
NOT designed to hold full rated load. Winch loads ap-
plied directly to the cable anchor may allow the cable
to pull free, resulting in the sudden loss of load control
and property damage, injury or death.A minimum of five
(5) wraps of cable must remain on the drum barrel to
achieve full rated load. Do NOT use knots to secure or
attach the winch cable. It is suggested that the last five
(5) wraps of cable be painted bright red to serve as a
visual warning.
INSTALLATION OF SPIRAL FERRULES
Re-usable, field-installable spiral ferrules are available from the factory or from your wire rope supplier. These ferrules
are for use with six (6) strand, IWRC (Independent Wire Rope Core) type wire rope.
Step One
Insert the cable through the small opening and out the large opening of the ferrule. Spread the strands and insert the
wedge halves between the strands and over the core. Lay separate strands in the individual grooves in the wedges.
Step Two
Tap the wedges and cable into the ferrule, leaving approximately 3/8 in. (10 mm) extending beyond the ferrule end.
The first load applied will seat the cable and wedges securely within the ferrule.

13
If a hoist exhibits any sign of:
- Erratic operation such as poor load control, load creeping down or chattering.
- Unusual noise.
- Gear oil leaks
- A sudden rise in wear particles from oil analysis
The hoist MUST be removed from service until the problem has been corrected. If a hoist has been subjected to a
sudden heavy load (shock-load) or overload, the hoist must be removed from service, disassembled and all internal
components thoroughly inspected for damage. Continued operation with a defect may result in loss of load control,
property damage, injury or death.
TROUBLESHOOTING
The following troubleshooting section is provided as a general guide. You may also need to contact the Origi-
nal Equipment Manufacturer (OEM) for additional information.
A
The winch will not smoothly reel-out or
reel-in the load. A. Check the brake cylinder seal as
follows:
Disconnect the small hose from
the brake release port. Connect a
handpumpwithanaccurategauge
and shut-off valve to the -4 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 dur-
ing the five (5) minutes, the brake
housing assembly should be dis-
assembled for inspection of the
brake cylinder and piston sealing
surfaces and replacement of the
seals. Refer to “Brake HousingAs-
sembly Service” for more informa-
tion.
Disassemble the brake housing
assembly to inspect the brake
discs. Replace the brake discs as
required.
1. The multi-disc static brake may not
be releasing as a result of a defec-
tive brake cylinder seal.
NOTE: If the brake cylinder seal
is defective, you may notice
oil leaking from the winch vent
plug as hydraulic oil fills the
gear cavity.
2. The multi-disc static brake will not
release as a result of damaged
brake discs.
TROUBLE PROBABLE CAUSE REMEDY

14
B
Oil leaking from the vent plug. A. Same as A2.
A. Hydraulic motor case drain pres-
sure must not exceed 40 PSI (2.8
kg/cm2). Inspect the hydraulic sys-
tem for a restriction.
B. Oil analysis may indicate contami-
nation, 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.
A. Disconnect the drum clutch re-
lease hose from the drum clutch
housing. Connect a hand pump
with an accurate gauge and shut-
off valve to the -6 adapter.
B. Apply 250 psi (1,724 kPa) to the
drum clutch. Close the shut-off
valve and let stand for 5 minutes.
C. If there is a loss of pressure dur-
ing the 5 minutes, the freespool
piston must be removed and dis-
assembled for inspection of the
seals and sealing surfaces. Refer
to “Freespool Group Service” sec-
tion of this manual for additional
information.
1. Same as A2.
2. Motor seal may be defective as a
result of high hydraulic motor case
drain pressure or contaminated
oil.
3. The freespool piston seals may be
leaking.
TROUBLE PROBABLE CAUSE REMEDY
C
The brake will not hold a load with
the control lever in neutral. A. Install gauge at brake release port to check pressure when joystick is
in neutral.
A. Same as A3A.
A. Same as C1A.
1. Excessive system pressure acting
on the brake release port.
2. Friction brake will not hold due to
worn or damaged brake discs.
3. Defective 3-way valve in valve
manifold on motor.

15
D
The winch will not pull the rated load. 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 neces-
sary.
NOTE: Refer to the tractor ser-
vice manual for more informa-
tion regarding the system relief
valve.
A. Check system relief valve, per
D1A.
B. Same as E2A.
A. Refer to winch performance data
for more information.
A. Send motor to qualified motor ser-
vice center.
A. See section “A”
1. The hydraulic system relief valve
may be set too low. The relief valve
may need replacement or repair.
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.
3. Winch line pull rating is based on
1st layer of wire rope.
4. Hydraulic motor locked in high
speed, small displacement posi-
tion.
5. Winch brake not releasing.
TROUBLE PROBABLE CAUSE REMEDY
E
The winch runs hot. A. Same as D2A.
B. Plugged heat exchanger (where
used).
Thoroughly clean exterior and
flush interior of heat exchanger.
C. Too low or too high oil level in hy-
draulic reservoir.
Fill/drain reservoir to proper level.
D. Same as D1A.
E. Tractor hydraulic pump not operat-
ing efficiently.
Tractor low on horsepower or
RPM. Tune / adjust tractor engine
for optimum performance. See
tractor service manual for more in-
formation.
1. Be certain the hydraulic system
temperature is not more than 200°
F (93° C). Excessive hydraulic oil
temperatures may be caused by:

16
TROUBLE “E” CONTINUED FROM
PREVIOUS PAGE Check suction line for damage.
Pump worn or damaged. Inspect
/replace pump as needed. See
tractor service manual for more in-
formation.
A. Disassemble winch for inspection
& replacement of worn or defective
components.
2. Excessively worn or damaged in-
ternal winch components.
TROUBLE PROBABLE CAUSE REMEDY
F
Winch “chatters” while pulling rated
load. A. Same as D1A.
A. Same as E1B, C, and E.
A. Conduct operator training as re-
quired.
A. See section “A”
1. Same as D1.
2. Hydraulic oil flow to motor may be
too low.
3. Controls being operated too quick-
ly or not smoothly.
4. Winch brake not fully releasing
G
The wire rope does not spool
smoothly on the cable drum. A. Consult your wire rope distributor for recommendation of the wire
rope best suited for your specific
application.
A. Replace the wire rope and conduct
operator training as required.
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 reel-
ing 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 dimin-
ished rope life.
2. The winch may have been over-
loaded, causing permanent set in
the wire rope.

17
SERVICE PRECAUTIONS
After troubleshooting 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 as needed.
• 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.
• Use only genuine factory replacement parts, which may be obtained through your heavy equipment dealer. Never
re-use expendable items, such as O-rings.
• Inspect all machined surfaces for excessive wear or damage before reassembly operations start.
• Lubricate all O-rings and oil seals with clean gear oil prior to installation.
• Use a sealing compound on the outside surfaces of oil seals. If using a thread sealant on fasteners or fittings, 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.
Hydraulic Motor Group
(Hydraulically Operated Winch Control Valve)
The typical hydraulic schematic is on pg.7
Contamination of the hydraulic system will shorten the life of the components and system. Work in a clean dust-free
area when servicing any part of the hydraulic system.
Freespool
Hose
Winch Control
Valve
Drive-Away
Valve
Drive-Away
Hose Brake Release
Hose Tank Hose

18
DISASSEMBLY
1. Remove the winch from the tractor to access the hy-
draulic motor group and hoses. (See Winch Removal
on pg. 12)
2. Tag the hoses form the tractor to the winch for reas-
sembly and then disconnect hoses from the winch con-
trol valve, drive-away valve, and hydraulic motor.
3. Remove the components needed for servicing.
4. Remove the bolts securing the hydraulic motor to the
winch and remove the hydraulic motor by pulling it
straight out from the cartridge assembly. If the motor
coupling comes out with the motor, refer to the assem-
bly section for installation instructions before installing.
ASSEMBLY
1. Ensure the motor and valve subassemblies are assem-
bled and ready for installation in the winch. Ensure the
bulkhead fitting for winch freespool is installed.
NOTE: Some hose connections will be difficult to tight-
en after the hydraulic motor is installed. Before install-
ing the motor, check for tightness hoses and fittings
that may be difficult to get to with the motor in place.
2. Install a new o-ring on the motor pilot and install the
motor in the winch engaging the motor splines with the
splines of the motor coupling.
3. Install new o-rings between the drive-away valve and
the motor and install the valve on the motor.
4. Install new o-rings between the winch control valve and
the motor and install the valve on the motor.
5. Reconnect the brake release, freespool, drive-away,
and tank hose.
6. The remaining hose connections between the tractor
and the winch will be connected when the winch is in-
stalled on the tractor.
The hydraulic group consists of the hydraulic motor, winch control valve, drive-away valve, and hoses and fittings. Ports
to measure loop pressure on the drive-away valve can be accessed at the lower right winch case cover, but the winch
must be removed from the tractor for most service on the hydraulic group.
NOTE: Some hose connections and fittings may be difficult to tighten after the hydraulic motor and valves are installed.
Before installing the motor and valves, check fittings for tightness and install and tighten any hoses that will be difficult
to access after installation.
Drive-away Valve Drawing

19
WINCH DISASSEMBLY
FREESPOOL GROUP
DISASSEMBLY
1. Bleed the pressure from the tractor hydraulics by cy-
cling the joystick with power on but with the tractor en-
gine off.
2. Drain the oil from the winch.
3. Loosen but leave threaded in position bolt (703) at 12
o’clock position on gear cover (701). Remove remain-
ing bolts (703) from gear cover (701). Remove bolts
(613) from gear shaft. Support the gear cover (701),
remove loosened bolt (703), and remove gear cover
(701).
4. Remove o-ring (713) and gasket (702) from the gear
cover. Replace o-ring and gasket.
The gear cover weighs 47 lbs. Ensure the gear cover is
supported before removing all of the fasteners holding it
to the winch case. Failure to support the gear cover may
result in personal injury or property damage.
CAUTION
Ensure the winch oil is cool and hydraulic pressure is
released before any work is done on the winch. High
pressure oil and hot oil can cause death or personal
injury.

20
5. Use compression tool and the two ½”-13 tapped holes
in the bull gear (601) to compress spring (711) behind
freespool clutch (709), and remove retaining ring (712)
with retaining ring pliers. Carefully release tension on
spring by backing off compression tool and remove
freespool clutch (709) and spring (711) from drum
shaft.
6. Remove piston (706), back-up ring (708), and o-ring
(707) from gear cover (701). Replace o-ring and back-
up ring.
FREESPOOL GROUP
ASSEMBLY
Wash all parts in solvent before assembly.
1. Place spring (711) in drum shaft (202). Slide freespool
clutch (709) onto bull gear (601).
2. Place retaining ring (712) on freespool clutch (709). In-
stall compression tool in position using the two ½”-13
tapped holes in the bull gear (601).
3. Compress spring (711) and install retaining ring (712)
using retaining ring pliers.
4. Install o-ring (707) and back-up ring (708) on piston
(706). Install piston (706) in gear cover (701).
5. Install new o-ring (713) in gear cover (701). Position
gear cover (701) with a new gasket (702) on winch and
secure with capscrews (703) and lockwashers (704).
Torque capscrews to chart specification.
6. Install capscrews (613) and lockwashers (614) in gear
cover to support the gear shaft (607).
7. Fill the winch with oil prior to operating.
Exercisecaution when compressingthe freespool clutch
spring, removing the retaining ring, and releasing the
tension on the freespool clutch spring. Death or person-
al injury can result from parts propelled by spring force.