Paccar Carco 50b User manual

CARCO<

MODELS 50B & 70A

WITH ELECTRONIC CONTROL

SERVICE

MANUAL

LIT2055 R4

5/2010

Printed in U.S.A.

PACR WINCH DIVISION

P.O. BOX 547 BROKEN ARROW, OK U.S.A.74013

PHONE (918) 251-8511 FAX (918) 259-1575

www.paccarwinch.com

2010 PACCAR Winch Division

FOREWORD

Please read and understand this entire manual BEFORE operating or performing service on your CARCO winch.

Retain this publication for future reference.

This manual contains instructions for the service and repair of CARCO Models 50B & 70A power shift winches with

electronic controls.

Some illustrations in this manual may show details or attachments that may be different from your winch. Also, some

components may have been removed for clarity.

Continuing product improvements may cause changes in your winch, which are not included in this manual. Whenever

a questions arises regarding your CARCO winch or this publication, please contact the CARCO Service Department

at 1-918-251-8511, Monday - Friday, 0800 hrs - 1630 hrs CST, or by fax at 1-918-259-1575, or by e-mail at

winch.service@paccar.com. Provide the complete winch MODEL NUMBER and SERIAL NUMBER when making

inquiries. Refer to MODEL DESCRIPTION section for location of model and serial number.

This complete service manual is available for viewing and/or downloading as a .PDF file on our internet

website - http://www.paccarwinch.com/literaturelist.asp

TABLE OF CONTENTS

GENERAL SAFETY RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

MODEL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

PREVENTIVE MAINTENANCE & SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

CONTROL SYSTEM OPERATION & TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . .9

WINCH REMOVAL & INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

WIRE ROPE INSTALLATION & WELDING SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .28

BEVEL PINION & HYDRAULIC PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

CLUTCH SHAFT SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

CLUTCH ASSEMBLY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

BRAKE ASSEMBLY SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

IDLER SHAFT GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46

FOURTH SHAFT GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

CABLE DRUM GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

CONTROL VALVE SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

ACCUMULATOR SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

WARNING - This emblem is used to warn against haz-

ards and unsafe practices that COULD result in severe

personal injury or death if proper procedures are not

followed.

CAUTION - This emblem is used to warn against

potential or unsafe practices that COULD result in per-

sonal injury and product or property damage if proper

procedures are not followed.

CAUTION

Safety and informational callouts used in this manual include:

This emblem is used to indicate an informational note or service tip.

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 mainte-

nance on the winch with the tractor engine running,

unless specifically instructed to do so in this manual.

3. Before starting the tractor engine, be certain all con-

trols move freely and are placed in the "Brake On"

(neutral) position.

4. Never operate the winch controls unless you are

properly seated at the operator's station on the trac-

tor and you are sure all 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 winch drum, cable rollers and entry area of

fairleads and arches.

6. Ground personnel should stay in clear view of the

tractor operator and clear of the winch drum. Do not

allow ground personnel near a winch line under ten-

sion. A safe distance of 1 ½ times the working length

of the cable should be maintained. Never allow any-

one 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 the rated winch capacity, which

may result in the failure of the cable and/or winch.

8. Use only GENUINE CARCO parts. Do not use parts

from other winch manufacturers on your CARCO

winch. Do not use CARCO parts on winches from

other manufacturers.

9. Use the correct size ferrule for the cable and pocket

in the winch drum. Never use knots to secure or

attach cable to the winch drum, or the hook to the

cable. 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 the rated capacity of

the winch. Therefore, a minimum of five (5) complete

wraps 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 the tractor for the straightest line of pull to

reduce the wear on the winch cable and ensure even

spooling.

6. When winding winch cable on the winch drum, never

attempt to maintain tension by allowing the winch

cable to slip through the hands. Always use the

"hand-over-hand" technique, being careful to keep

hands and clothing away from winch drum and fair-

lead 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 injury 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.

10. The factory approved adaptions for CARCO 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-

GENERAL SAFETY RECOMMENDATIONS

Safety for operators and ground personnel is of prime concern.Always take the necessary precautions to ensure safe-

ty 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 handling and performance capabilities. The

following recommendations are offered only as a guide for the operator. Local rules and regulations will also apply.

Failure to obey the following safety recommendations

may result in property damage, injury or death.

ences in tractor models. Some changes cannot be

approved by CARCO because of safety limitations.

Call a CARCO dealer or the CARCO factory prior to

attempting winch modifications or before mounting on

a different tractor.

11. CARCO power shift winches are equipped with

hydraulic accumulators. Discharge the accumulator

stored oil supply before removing any hydraulic lines

or fittings or servicing winch. Personal injury may

result from the sudden release of oil pressure. To dis-

charge the accumulator, stop the engine, turn the key

switch “on” then slowly cycle the Power Shift control

handle into full Reel-In then Reel-Out positions a min-

imum of five (5) times.

12. 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 the tractor parking brakes

and lower any equipment to the ground before dis-

mounting the tractor.

13. The winches described in this manual are neither

designed nor intended for use or application in the lift-

ing 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

the fairlead rollers.

15. Keep equipment in good operating condition. Perform

the scheduled servicing and adjustments defined in

the "Preventive Maintenance" section of this manual.

Use of proper lubricants is crucial.

16. An equipment warm-up procedure is recommended

for all tractor start-ups, and is essential at ambient

temperatures below +40°F (+5°C). Refer to the

"Warm-Up Procedure" listed in the "Preventive

Maintenance" section of this manual.

The CARCO Power Shift Winch is a single drum unit

which mounts on the rear of a crawler tractor. It is driven

by engine power through the tractor PTO (Power Take-

Off). The winch may be operated independently or with

the tractor transmission engaged. When operated prop-

erly, it is capable of utilizing maximum engine horsepow-

er. The winch has equal speed gearing, power-in and

power-out, using multiple-disc oil actuated friction clutch-

es and a spring applied hydraulically released multiple-

disc oil brake.

The winch may be manufactured as a Standard PTO or

Low PTO configuration, depending on tractor application.

In the Standard PTO configuration, the bevel gear group,

clutch and brake components are located in the upper

bores of the winch case.

The Low PTO winch design has the bevel gear group,

clutch and brake components located in the lower bores

of the winch case.

The Model 50B & 70A may have either a 3-shaft or 4-

shaft gear train configuration depending upon the tractor

horsepower, PTO speed and line speed requirements of

the winch application.

The standard Power Shift (PS) Winch is primarily used in

logging, land clearing and general utility applications. The

PS Model has gear ratios which match the cable drum

rotation in Reel-In (forward) to reverse track speeds for

optimum advantage in tractor recovery.

Optional features increase the winches ability to meet

specific application requirements. Options available for

the 50B & 70A series winches include:

• Free Spool

• Gear Ratios

• Three or Four Roller Fairleads

The winch model number is an important reference as to

what optional components were used when the winch

was manufactured. The winch identification plate is locat-

ed on the right hand side of the winch case. The serial

number is also stamped into the upper right hand mount-

ing pad.

MODEL DESCRIPTION

3-Shaft

Standard PTO

shown

Important: Always refer to the serial number and model

number when requesting information or service parts.

The winch model number contains the following configu-

ration data:

MODEL

C 0 0 0 0 0 E

50B, 70A,

Bevel Gear

Ratio

A - 1:1

B - 1.27:1

C - 1.64:1

D - 2.11:1

E - 2.79:1

0 - Overwind

1 - Underwind

0 - Standard Brake

0 - Without Freespool

1 - With Freespool

0 - Four Shaft winch

1 - Three Shaft winch

0 - No Fairlead

3 - Three Roller Fairlead

4 - Four Roller Fairlead

PREVENTIVE MAINTENANCE & SPECIFICATIONS

A regular program of preventive maintenance for your

CARCO 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. The intervals may be grad-

ually increased or decreased with experience of a partic-

ular lubricant and evaluation of your application.

1.Oil Level

Check oil level at the beginning of each work shift, with

Discharge accumulator oil supply before removing any

hydraulic lines or servicing winch. Personal injury may

result from sudden release of oil under pressure. To

discharge the accumulator, stop engine, slowly cycle

Power Shift control handle into full Reel-In position then

full Reel-Out position, a minimum of five (5) times.

CAUTION

WARNING

! !

Identification

Plate

Vent

Plug

Filter

Access

Cover

Oil

Level

Oil Drain

Plug

Serial

Number

E - Electronic Controls

Record the information below for future reference.

Always include the model and serial numbers when

inquiring or ordering parts.

Model No.

Serial No.

In-Service Date

tractor and winch in level position. Oil must be visible in

the upper half of the sight gauge. If an oil level plug is

used in place of the sight gauge, the oil level should be at

the bottom of the level plug hole. Add oil as required

through the fill plug at top of winch case.

2. Oil Change, Filter and Strainer Service

Under normal operating conditions, the oil and pressure

circuit filter should be changed and suction strainer

cleaned after the first 100-250 hours of operation, then

every 1000 hours or six months, whichever occurs first, or

when the filter bypass indicator light remains on after ini-

tial warm up.

To drain oil, place tractor and winch in level position and

remove drain plug located at lower right hand side of

winch case. Drain oil into a suitable container and recycle

or dispose of used oil in an environmentally responsible

manner. Install plug securely after oil has been drained.

After oil has drained, remove four suction strainer cover

capscrews and cover. Remove suction strainer from

winch case then remove metal band and magnetic rods

from suction strainer. Thoroughly wash strainer in clean

safety solvent and blow dry with compressed air, inspect

wire mesh for damage or clogging with debris. Do not

reuse a damaged suction strainer.

All 50B/70A winches serial number 9101599 and up are

equipped with a suction strainer shield which reduces the

potential for pump cavitation when operating on extreme-

ly steep slopes. The suction strainer shield may be

installed on earlier serial number winches. Refer to

CARCO Service Bulletin 97.

NOTE: If the suction strainer shield or shield seal

rings are removed for any reason, reinstall them by

following the procedure listed below:

1. Install shield. Part Number 29020, between connector

and strainer as shown above, with open side facing

downward.

2. Measure distance “X”, from shield to strainer cover

mounting surface.

3. If “X” dimension is between 0.720 in. and 0.783 in.

(18.3 – 19.9 mm), add one seal, 29023, outboard of

seal 29021.

4. If “X” dimension is greater than 0.783 in. (19.9 mm),

add two seals, 29023, outboard of seal 29021.

Seal 29021 is .25 in. (6.4 mm) thick

Seal 29023 is .06 in. (1.5 mm) thick

Install magnetic rods onto suction strainer using metal

band. Lubricate o-ring and install in groove on cover.

Install strainer, spring and cover into winch case.

Refill winch to proper level with recommended oil.

Winches adapted to Komatsu power shift tractors are

equipped with an adapter gear box (drop box) assembly.

Later units are lubricated with a captive supply of 90-wt.

gear oil which should be drained through a plug found at

the bottom of the housing. Refill gear box to the oil level

plug found approximately 1/3 of the housing length from

the bottom with 90-wt. gear oil which meets API specifi-

cation GL5 or MIL-L-2105C.

The pressure filter is located behind the right hand, eight-

Hot oil may cause severe injury. Make certain the oil

has cooled to a safe temperature (less than 110°F or

43°C) before servicing.

Shield 29020

Seal 29021

Seal 29023

To prevent serious damage to the winch, DO NOT run

engine while oil is drained from the winch.

CAUTION

Oil Fill

Plug

Suction

Strainer

bolt access cover. Remove the cover, locate the spin-on

pressure filter and remove the filter element with a strap

wrench.

Lubricate the filter gasket and adapter threads with winch

oil and install new filter element onto filter head. Tighten

½ - ¾ turn after seal ring makes contact with filter head.

Start tractor and operate engine at low idle. Correct any

leaks.

The filter bypass indicator light may come on for a short

time during initial cold start-up but should go out as the oil

warms up. If the light stays on, this indicates a restricted

filter element, sending unit stuck in the bypass position or

accidentally grounded sending unit wire.

3. Control Cable and Pressure Adjustment

While the access cover is removed, it is advisable to

check control cable adjustment and hydraulic main relief

pressure. Place the Power Shift control lever in the cen-

ter “Brake-On” (neutral) position. Install the yoke pins into

the cable yokes/control valve spools and secure with

hitch pins. The yoke pins should slip easily into the bores

without any binding. The control valve spools are spring

centered. If you notice any binding, turn the cable

adjusters in or out until you obtain a “free pin” condition.

Make certain accumulator stored oil supply has been dis-

charged as described earlier. Install an accurate 0-600

psi (0-4137 kPa) gauge onto the – 4 J.I.C. gauge port

next to the control cables. Start tractor and operate

engine at approximately 800-1000 RPM until pressure

stabilizes. Maximum pressure during “charging” mode

should peak at 400 psi (2758 kPa). Pressure will slowly

fall back approximately 15-20% from the relief setting

then quickly return to 400 psi (2758 kPa) when the valve

cycles.

If adjustment is required, locate the adjustment screw

hole behind port “P” of the control valve. With a ¼ in.Allen

key, loosen the outer lock screw. Insert a 3/16 in. Allen

key through the lock screw and turn the adjusting screw

clockwise to increase peak pressure; counterclockwise to

decrease peak pressure. Tighten the lock screw.

TIP: It may be helpful to place the controls in

Brake-Off to use some oil in the control circuit and

cause the valve to slowly “cycle” so that peak pres-

sure may be more easily observed.

Stop engine, discharge accumulator stored oil supply as

described earlier and move hydraulic gauge to the “B”

test port on the brake housing. A ¼ in. NPT adapter will

be required.

Start tractor and operate engine at approximately 800-

1000 RPM. Place Power Shift lever in the Brake-Off posi-

tion and observe BRAKE-RELEASE oil pressure. Loosen

cable adjuster or cable yoke jam-nut and adjust brake

control cable to achieve approximately 300 PSI BRAKE-

RELEASE pressure.

Stand away from service access of winch and return

Power Shift lever to the BRAKE-ON (neutral) position.

BRAKE RELEASE pressure must return to 0 with the

controls in BRAKE-ON (neutral) position.

TIP: Optimum BRAKE-RELEASE pressure is the

highest pressure you can achieve while ensuring

pressure ALWAYS drops to 0 when controls are

returned to BRAKE-ON. Excessive heat and accel-

erated brake and hydraulic component wear will

result if BRAKE-RELEASE pressure does not

return to 0.

With control in Brake-On (neutral) remove gauge from “B”

port and securely install plug into brake housing.

Discharge accumulator stored oil supply as described

earlier. Remove pressure filter element to gain access to

accumulator. Install gauge assembly to accumulator and

observe pressure. Recharge unit to 190-210 psi (1310-

1448 kPa) with dry nitrogen. If the accumulator will not

hold a gas charge, then the unit should be replaced by

the spring/piston type accumulator. Order kit P/N 62138,

reference Carco Service Bulletin 95. The spring/piston

accumulator requires no periodic service.

Reinstall the filter element as described earlier.

Install access cover plate and tighten eight ½ in. cap-

screws/nuts to 75 lb•ft. (102 N•m) torque.

4. Vent Plug

The vent is located next to the power shift control harness

on all 50B & 70A model winches. It is very important to

keep this vent clean and unobstructed. Whenever the oil

is changed, remove vent plug, clean in safety solvent and

reinstall. Do not replace with a solid plug.

5. PTO Shaft

Winches adapted to J.I. Case, John Deere and Komatsu

powershift tractors are driven by a long, automotive-type

driveline PTO shaft.

The PTO shaft u-joints, slip-joint, flanges and fasteners

must be inspected, tightened and lubricated as required

at least once every three months or 500 tractor hours,

whichever occurs first.

Inadequate PTO shaft maintenance may result in the

accelerated wear of the PTO shaft, U-joint, bearings and

the adapter gear box components.

Maintenance of the PTO shaft assembly is essential to

reliable winch operation. As the PTO shaft turns at

approximately engine speed and torque, a failure of a u-

joint, shaft or adapter gear box component may result in

property damage or injury.

CAUTION

6. Winch Cable (wire rope)

Inspect entire length of wire rope, chokers and hooks

according to wire rope and rigging manufacturers recom-

mendations.

7. 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,

whichever occurs first.

8. Warm-Up Procedure

Start tractor engine and operate at low idle for five min-

utes.

Shift the control lever to the freespool position (if

equipped). Then, with the tractor engine at low idle, place

Power Shift lever in Reel-In (forward) position. The winch

gear train will rotate and warm the oil to operating tem-

perature.

If not equipped with Free Spool, operate winch alternate-

ly in Reel-Out and Reel-In with little or no load to warm

the oil and lubricate the gear train.

A warm-up procedure is recommended at each start-up

and is essential at ambient temperatures below +40°F

(4°C). Failure to warm-up winch hydraulic system may

result in erratic clutch/brake operation which may result

in property damage, injury or death.

Do not shift Freespool lever and attempt to engage

cable drum while the cable drum or gear train is rotat-

ing. Winch gear train damage may result.

CAUTION

Basic Oil Requirements

15,000 SUS maximum allowed viscosity at cold start-up; requires extended equipment warm-up. 3,000 SUS maxi-

mum 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°F (27°C).

Oil must possess high temperature oxidation stability, rust corrosion protection, good dispersant and detergent char-

acteristics, anti-wear additives and remain compatible with nitrile base seals.

RECOMMENDED OIL

We have published the following specifications to help you determine which lubricant is best suited to your application.

Your lubricant supplier should assure you his product meets this specification. If there is any doubt as to the suitabil-

ity of a lubricant, contact the Carco Winch Service Department, providing a detailed copy of the product specifications.

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.

SPECIFICATIONS

Unit weight (without oil, cable or specific tractor adapters) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1,960 lbs (885 kg)

Gear Ratio Available

Bevel Gear Ratio 1.00:1 1.27:1 1.64:1 2.11:1 2.78:1

Overall Ratio (3-Shaft Gear Train) 22.3:1 28.3:1 36.6:1 47.0:1 62.2:1

Overall Ratio (4-Shaft Gear Train) 40.4:1 51.4:1 66.3:1 85.3:1 112.8:1

Multiply above overall ratios by 1.29 for the adapter gear box used on Komatsu Power Shift tractors.

Barrel Diameter 10 in. (254 mm) 3/4 in. (19 mm) 319 ft (97 m)

Flange Diameter 19-7/8 in. (504 mm) 7/8 in. (22 mm) 226 ft (69 m)

Barrel Length 12-3/8 in. (314 mm) 1 in. (25 mm) 154 ft (47 m)

Throat Clearance approx. 9 in. (229 mm)

3/4 in. (19 mm) 29424

7/8 in. (22 mm) 29425

1 in. (25 mm) 29426

Cable Drum Dimensions

Cable Storage Capacity

Cable Ferrule Part Numbers

Cable Ferrule Dimensions

A - 2-3/16 in. (56 mm)

B - 2-1/32 in. (52 mm)

C - 2-5/8 in. (67 mm)

D - To match cable diameter

Dry Lubed Dry Lubed Dry Lubed Dry Lubed

Torque (LB-FT)

Grade 5

Grade 8

1/4

5/16

3/8

7/16

1/2

9/16

5/8

110

150

110

150

115

210

160

265

200

Torque (LB-FT)

Grade 5

Grade 8

380

280

7/8

420

325

600

450

3/4

680

1 1/8

790

590

1290

970

640

1120

835

910

485

1460

1820

1360

1 3/8

1460

1095

2385

1790

1 1/4

3160

2370

Bolt Dia.

Inches

Thds Per

Inch

Bolt Dia.

Inches

Thds Per

Inch

1 1/2

1940

To convert lb•ft to kg•m, multiply lb•ft value by 0.1383.

RECOMMENDED FASTENER TORQUE

Higher or lower torque values for special applications will be specified; such as the use of spanner nuts, nuts on

shaft ends, jam nuts and where distortion of parts or gaskets is critical.

Lubricated torque values based on use of SAE 30wt engine oil applied to threads and face of bolt or nut.

Avoid using thread lubricants as the applied torque may vary by 10 - 40%, depending upon the product used.

Hydraulic System

Oil Capacity (Standard PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 qt (74 L)

Oil Capacity (Low PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 qt (63 L)

Differential Unloading Valve Cut-out Pressure . . . . . . . . . . . . . . . . . . . . . .390-410 psi (2,690-2,830 kPa)

Typical Operating Oil Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . .Up to Ambient Plus 80°F (26.7°C)

Adapter Gear Box Oil Capacity and Type (Komatsu Adaptions Only)

50B & 70A . . . . . . . . . . . . .1.8 qt (1.7 L) . . . . . . . . . . . . . . . . . . . . . . . . . .90 wt API-GL5 Gear Oil

CONTROL SYSTEM OPERATION AND TROUBLESHOOTING

BASIC OPERATION

The winch contains an independent, internal hydraulic

system. The winch case serves as a reservoir and stores

filtered oil for the internally mounted hydraulic pump. The

pump is driven by a gear pressed onto the bevel pinion

gear, and supplies oil as long as the tractor PTO shaft is

turning. Oil from the pump is then routed through a pres-

sure filter then directed to the control valve where a

stand-by system pressure is maintained at 320-410 PSI

(2210-2830 kPa).

The system oil pressure is routed through the control

valve body to the solenoid actuated valve cartridges.

When energized by the electronic control system, the

solenoids direct oil to apply the Reel-In and Reel-Out

clutches, release the spring-applied brake and shift the

spring-engaged freespool mechanism. The electronic

winch control system includes a sealed, solid-state joy-

stick control lever and a sealed, solid-state control mod-

ule installed under the RH console of the tractor, an elec-

tric solenoid operated control valve installed within the

winch case, with a wiring harness connected between

them.

The hydraulic control system is equipped with an accu-

mulator. The spring-loaded accumulator stores a small

amount of oil at system pressure to assist the application

of the clutches and release of the brake under all operat-

ing conditions. The stored oil supply may also be used to

release the spring-applied brake whenever the tractor

engine or torque converter is stalled. The accumulator-

stored oil supply is continuously refilled by the pump and

pressure maintenance system in the control valve when-

ever the PTO shaft is turning.

On tractors that supply PTO power through a torque con-

verter, it is possible to cause the torque converter to stall

if the tractor engine speed is too low. It is important that

engine idle speeds be set to factory specifications to

maintain proper operation.

The solid-state joystick control lever has no contact points

to wear out or need adjustment, aside from the small

push-button switch on the top of the lever. This button

MUST be depressed to enable the electronic control sys-

tem to perform any winch function. This feature prevents

accidental or unwanted winch actuation.

The joystick produces a signal by a magnetically induced

voltage as the control lever is moved near the sensing

devices on the circuit board beneath the lever. The small,

induced voltage is transmitted to the control module

mounted beneath the console. The job of the control

module is to receive 24V DC power from the tractor, filter

this power supply to protect the electronics, then produce

the correct combination of 24V DC signals to energize the

appropriate solenoid cartridges in the control valve. The

control valve is mounted inside the winch case behind the

large access cover on the RH side. When energized by

the control module, the solenoids send control oil pres-

sure to perform the specific winch functions based on the

position of the joystick lever. An additional terminal built

into the winch end of the wiring harness allows for diag-

nostics and troubleshooting of electrical problems and

components. A small red indicator light, installed next to

the joystick, will illuminate to indicate that the hydraulic oil

filter is beginning to bypass and should be serviced if the

light remains on.

A small volume of oil is stored in the spring-type accumu-

lator at control system pressure. This stand-by pressure

ensures quick response to the operator's commands,

regardless of engine speed or winch load. The stand-by

pressure is maintained by the joint operation of a pres-

sure switch and a main pressure control solenoid valve.

The pressure switch will be closed and send current to

the main pressure solenoid until stand-by pressure reach-

es 370 PSI (2550 kPa). When the cutout pressure is

reached, the pressure switch de-energizes the solenoid

valve. The stand-by pressure is contained in the control

valve housing by a check valve, and slowly decreases to

315 PSI (2170 kPa), where it will close the pressure

switch contacts and start the charging process again.

When the operator selects a winch function, the pressure

switch is not used and the control module activates the

main pressure solenoid. A relief valve limits the main sys-

tem pressure to approximately 400 PSI (2760 kPa) during

clutch and brake actuation.

The wiring harness provides the vital connection between

the control module and the control valve. The connecting

pins and sockets are numbered for identification and trou-

ble-shooting. The pin and socket numbers are referenced

in the following descriptions of winch functions.

CONTROL OPERATION

A thorough understanding of the control system is need-

ed before any trouble-shooting is begun. Please review

the following descriptions of the control system to

become familiar with the interaction of all of the control

circuit components.

All control diagnostic tests should be performed with an

accurate 0-600 PSI (0-7000 kPa) hydraulic pressure

gauge and an accurate digital or analog multi-meter. A

diagnostic connector is incorporated into the wiring har-

ness and may be found near the winch end of the har-

ness. The main hydraulic test port is located on the RH

side of the winch case next to the wiring harness con-

nector. A female quick disconnect coupler is required for

using the gauge.

Discharge accumulator oil supply before removing any

hydraulic lines or servicing winch. Personal injury may

result from sudden release of oil pressure. To discharge

the accumulator, stop the engine, turn the key switch on,

then slowly cycle the joystick lever into full REEL-IN and

REEL-OUT positions a minimum of five (5) times.

NOTE: The tractor electrical system must be ON.

WIRING HARNESS

(70A for D6R Series II)

WIRING HARNESS

(50B for D5N/D6N)

BLACK

RED

BLUE

WHITE/BLACK ST

BROWN

WHITE

ORANGE

GREEN

BLACK

RED

BLUE

WHITE/BLACK ST

BROWN

WHITE

ORANGE

GREEN

TAN

BLACK

123456789101112

BLACK

RED

BLUE

WHITE/BLACK ST

BROWN

WHITE

ORANGE

GREEN

TAN

BARE

RED

BLACK

BLUE

WHITE/BLACK ST

BROWN

YELLOW (OPT)

WHITE

ORANGE

GRAY (OPT)

TAN

1 RED

2 BLACK

3 ORANGE

4 PURPLE

5 BLUE

6 YELLOW

+5V

GND

DECODE

ENABLE

Y AXIS

X AXIS

CONNECTOR

RED

GREEN TO FILTER LIGHT LED

BLACK

RED BLACK -

ORANGE + (-) 24 VDC

(+) 24 VDC

9 AMP

SYSTEM FLOW

REEL IN

BRAKE

REEL OUT

FREESPOOL

LTR

CONNECTOR CONNECTOR

WINCH

DIAGNOSTIC

CONNECTOR

PIN NO. ---

FUNCTIONS

315/370

PSI

CC ISOLATION

BLACK

TRACTOR HARNESS

SYS

FILTER BYPASS

INDICATOR

GROUND ONTO

VALVE HOUSING

CONTROL

MODULE

EXTERNAL HARNESS

HARNESS WITHIN WINCH CASE

POWER

SUPPLY

CONNECTOR

JOYSTICK

CONTROL

VALVE

WIRING HARNESS

(Early D6R, D5M/D6M)





























390/410 PSI

15 PSI

FLG L

BRAKE LUBE

& COOLING

ORIFICE

LUBE

315/370

PSI

C2 BR C1

15 PSI

REEL OUT

CLUTCH

BRAKE

REEL IN

CLUTCH





ORIFICE ORIFICE

PRESSURE

SWITCH

ACCUMULATOR

BULL GEAR

PUMP

FILTER

SUCTION

STRAINER

C2 BR C1

SYS

OOOOOOO LOW PRESSURE

 HIGH PRESSURE

GREEN (9)

FILTER

HEAD

RED (1)

BROWN (4)

ORANGE (7)

BLACK (11) - GROUND

BLUE (2)

WHITE (6)

WHITE W/ BLACK STRIPE (3)

BLACK (11) - GROUND

12 11 10 9 8 7

321

(-) GROUND

(+) 24 VDC (+) 24 VDC, SLOWLY

CYCLING ON-OFF

(ON WHILE CHARGING,

BREAK-ON (NEUTRAL) "CHARGING"

When "charging", 24 volts DC will be seen at the red and

blue wire within the winch case, and at terminals 1 and

2 at the diagnostic connector. The blue wire and pin 2

will be de-energized when the circuit is "unloaded".

The pressure maintenance system operates continuous-

ly to maintain a stand-by supply of oil pressure for the

control system. The pressure maintenance system con-

sists of the following components:

Item 9 - Check Valve

Item 10 - Main Pressure Solenoid Valve

Item 11 - Stand-by System Pressure Switch

Item 13 - Accumulator Holding Cartridge (not

found on early units)

Item A - Accumulator

Oil from the pump passes through the filter and enters

the valve housing, passing through the check valve (9)

and holding cartridge (13) on its way to the accumulator

(A). When charging first occurs, the pressure switch (11)

contacts are closed producing a signal to energize the

main pressure solenoid (10) to block the flow of oil to the

lubrication circuit.At this time, all of the oil from the pump

is directed to fill the accumulator and the pressure

gallery in the control valve.

CONTROL VALVE DIAGNOSTICS PLUG

BRAKE ON (NEUTRAL) “CHARGING”





























390/410 PSI

15 PSI

FLG L

BRAKE LUBE

& COOLING

ORIFICE

LUBE

315/370

PSI

C2 BR C1

15 PSI

REEL OUT

CLUTCH

BRAKE

REEL IN

CLUTCH





ORIFICE ORIFICE

PRESSURE

SWITCH

ACCUMULATOR

BULL GEAR

PUMP

FILTER

SUCTION

STRAINER

C2 BR C1

SYS

OOOOOOO LOW PRESSURE

 HIGH PRESSURE

RED (1)

BROWN (4)

ORANGE (7)

BLACK (11) - GROUND

BLUE (2)

WHITE (6)

WHITE W/ BLACK STRIPE (3)

BLACK (11) - GROUND

GREEN (9)

FILTER

HEAD

12 11 10 9 8 7

321

(-) GROUND

(+) 24 VDC (+) 24 VDC, SLOWLY

CYCLING ON-OFF

(ON WHILE CHARGING,

When the pressure at the pressure switch (11) reaches

approximately 370 PSI (2550 kPa), the switch opens and

the main pressure solenoid (10) is de-energized. In the

de-energized position, the main pressure solenoid valve

(10) allows pump oil to flow through the lube circuit and

return to the winch sump. The oil stored in the accumu-

lator is trapped by the check valve (9) and the accumu-

lator holding cartridge (13). This oil is available for clutch

application and brake release.

When the pressure at the pressure switch (11) decreas-

es to approximately 315 PSI (2170 kPa), either through

system demand or internal system leakage, the pres-

sure switch (11) contacts will close producing a signal to

energize the main pressure solenoid valve (10). When

energized, the main pressure solenoid valve (10) blocks

the flow of oil to the lube circuit and the pump will refill

the accumulator to approximately 370 PSI (2550 kPa).

In the "unloaded" mode, the main pressure solenoid is

de-energized and the oil from the pump is flowing back

to sump through the lube circuit. There is very little load

on the winch pump at this time, thus reducing wear and

heat.

CONTROL VALVE DIAGNOSTICS VALVE

BREAK ON “UNLOADED”

















390/410 PSI

15 PSI

FLG L

BRAKE LUBE

& COOLING

ORIFICE

LUBE

315/370

PSI

C2 BR C1

15 PSI

REEL OUT

CLUTCH

BRAKE

REEL IN

CLUTCH





ORIFICE ORIFICE

PRESSURE

SWITCH

ACCUMULATOR

BULL GEAR

PUMP

FILTER

SUCTION

STRAINER

C2 BR C1

SYS

OOOOOOO



LOW PRESSURE

HIGH PRESSURE















RED (1)

BROWN (4)

ORANGE (7)

BLACK (11) - GROUND

BLUE (2)

WHITE (6)

WHITE W/ BLACK STRIPE (3)

BLACK (11) - GROUND

GREEN (9)

FILTER

HEAD

12 11 10 9 8 7

321

(-) GROUND

(+) 24 VDC (+) 0 TO 24 VDC

CONTROL VALVE DIAGNOSTICS PLUG

BRAKE-OFF

During BRAKE-OFF, 24 volts DC will be seen at the red and

blue wires within the winch case, and at pins 1 and 2 of the

diagnostics connector on the wiring harness. As the joystick

lever moves from the BRAKE-ON position into the full BRAKE-

OFF position, the voltage at the brown wire and pin 4 increase

proportionally from 0 to 24 volts DC.

To release the spring-applied brake requires the following com-

ponents:Item 2 - Brake Control Solenoid

Item 6 - Relief Valve

Item 10 - Main Pressure Solenoid Valve

Item 13 - Accumulator Holding Valve

Item A - Accumulator

In BRAKE-OFF, only the brake is released; the directional

clutches are not affected. The brake circuit is unique in that the

brake release oil pressure is proportional to the movement of

the joystick lever into the BRAKE-OFF position. All other winch

functions receive full control pressure, 400 PSI (2760kPa) and

full 24 volts DC to the solenoid valves. The main pressure sole-

noid valve (10) and the accumulator holding valve (13)

receives 24 volts DC through the blue wire within the winch

case. The full flow of the pump is directed to the oil pressure

gallery in the control valve. The pressure switch (11) is not

used to control the maximum control system oil pressure when

a winch function is selected. Instead of the pressure switch

(11), the relief valve (6) limits the maximum pressure in the

control circuit to approximately 400 PSI (2760 kPa).

After first pressing the enable switch, the movement of the joy-

stick lever toward the BRAKE-OFF position will cause an

increase in the voltage sent to the brake control solenoid (2)

through the brown wire and pin 4 on the diagnostics plug. As

voltage increases, the valve opens further to send higher con-

trol pressure to release the spring-applied brake. When the joy-

stick lever is placed in the full BRAKE-OFF position, full 24 volt

DC current is sent to the control valve and full 400 PSI (2760

kPa) oil pressure is sent to fully release the brake.

When the joystick lever is released, the electrical signal to the

solenoids is lost, the solenoid valves exhaust the control oil

pressure to the winch sump, and the spring-applied brake

reapplies to hold the load. The control valve returns to the

BRAKE-ON mode and the pressure maintenance system

begins slowly cycling to maintain a stand-by supply of control

oil pressure.

BRAKE-OFF

Voltage is proportional to control handle move-

ment. If a test light is used, brightness will be

proportional to control handle movement.

















390/410 PSI

15 PSI

FLG L

BRAKE LUBE

& COOLING

ORIFICE

LUBE

315/370

PSI















BR C1

15 PSI

REEL OUT

CLUTCH

BRAKE

REEL IN

CLUTCH





ORIFICE ORIFICE

PRESSURE

SWITCH

ACCUMULATOR

BULL GEAR

PUMP

FILTER

SUCTION

STRAINER

C2 BR C1

SYS

OOOOOOO



LOW PRESSURE

HIGH PRESSURE

REEL-IN

GREEN (9)

FILTER

HEAD

RED (1)

BROWN (4)

ORANGE (7)

BLACK (11) - GROUND

BLUE (2)

WHITE (6)

WHITE W/ BLACK STRIPE (3)

BLACK (11) - GROUND

12 11 10 9 8 7

321

(-) GROUND

(+) 24 VDC

CONTROL VALVE DIAGNOSTICS PLUG

REEL-IN

During REEL-IN, 24 volts DC will be seen at the red, blue,

brown and white with black stripe wires within the winch case,

and at pins 1, 2, 3 and 4 of the diagnostics connector on the

tractor wiring harness.

To apply the REEL-IN clutch and release the spring-applied

brake requires the following components:

Item 1 - C2 Clutch Control Solenoid

Item 2 - Brake Control Solenoid

Item 6 - Relief Valve

Item 10 - Main Pressure Solenoid

Item 13 - Accumulator Holding Valve

Item A - Accumulator

With the enable button pressed and the joystick lever moved to

the REEL-IN position, a signal is sent to the control module to

initiate a sequence of 24 volt DC signals to energize the prop-

er solenoids of the control valve within the winch case. The

main pressure solenoid valve (10) is energized to bring the

control system oil pressure from stand-by pressure up to full

pressure, 400 PSI (2760 kPa), by blocking the path to the lube

circuit. The control system pressure is limited by the relief valve

(6). The accumulator holding solenoid valve (13) is opened to

allow the stored oil in the accumulator to enter the pressure

gallery of the control valve. This action improves the response

time and consistency of the REEL-IN clutch. The brake control

solenoid (2) will be energized to begin the release of the brake

as the C2 clutch control solenoid (1) is energized to begin the

application of the REEL-IN clutch. The timing of the brake

release and clutch application is electronically controlled to

provide a shift with a minimal amount of load "fall-back" for

good load control while minimizing clutch/brake disc scrubbing

due to overlap.

When the joystick lever is released and returned to BRAKE-

ON, the signal to the control module is cleared and the 24-volt

DC signals to energize the solenoids are switched off. The

clutch releases as the brake applies to hold the load. The pres-

sure maintenance system will return to slowly cycling to main-

tain a stand-by supply of control oil pressure.

BR C1

15 PSI

REEL OUT

CLUTCH

BRAKE

REEL IN

CLUTCH





ORIFICE ORIFICE

PRESSURE

SWITCH

ACCUMULATOR

BULL GEAR

PUMP

FILTER

SUCTION

STRAINER

C2 BR C1

SYS

OOOOOOO



LOW PRESSURE

HIGH PRESSURE

















390/410 PSI

15 PSI

FLG L

BRAKE LUBE

& COOLING

ORIFICE

LUBE

315/370

PSI















GREEN (9)

FILTER

HEAD

RED (1)

BROWN (4)

ORANGE (7)

BLACK (11) - GROUND

BLUE (2)

WHITE (6)

WHITE W/ BLACK STRIPE (3)

BLACK (11) - GROUND

12 11 10 9 8 7

321

(-) GROUND

(+) 24 VDC

REEL-OUT

CONTROL VALVE DIAGNOSTICS PLUG

REEL-OUT

For REEL-OUT, 24 volts DC will be present at the red, blue,

brown and orange wires within the winch case, and at pins 1,

2, 4 and 6 of the diagnostics connector on the wiring harness.

To apply the REEL-OUT clutch and release the spring-applied

brake requires the following components:

Item 2 - Brake Control Solenoid

Item 3 - C1 Clutch Control Solenoid

Item 6 - Relief Valve

Item 10 - Main Pressure Solenoid

Item 13 - Accumulator Holding Valve

Item A - Accumulator

With the enable button pressed and the joystick lever moved to

the REEL-OUT position, a signal is sent to the control module

to initiate a sequence of 24 volt DC signals to energize the

proper solenoids of the control valve within the winch case.

The main pressure solenoid valve (10) is energized to bring the