Paccar Winch CARCO H50VS Service Manual Download

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TABLE OF CONTENTS

FOREWORD ...............................................................................................................3

GENERAL SAFETY RECOMENDATIONS .................................................................4

WINCH DESCRIPTION ...............................................................................................5

CROSS SECTION.......................................................................................................6

PREVENTATIVE MAINTENANCE ..............................................................................8
OIL RECOMMENDATIONS ..................................................................................10
WINCH REMOVAL AND 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 GROUP ASSEMBLY ...........................................................................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

Summary of Contents for CARCO H50VS

Page 2: ...RAL FERRULES 12 TROUBLESHOOTING GUIDE 13 SERVICE PRECAUTIONS 17 HYDRAULIC MOTOR GROUP 17 WINCH DISASSEMBLY 19 FREESPOOL GROUP DISASSEMBLY 19 FREESPOOL GROUP ASSEMBLY 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 ...

Page 3: ... dealer or the PACCAR SERVICE DEPARTMENT at Phone 918 251 8511 Monday Friday 0800 hrs 1630 hrs CST FAX 918 259 1575 Email winch service paccar com 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 pr...

Page 4: ...CAR 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 pul...

Page 5: ...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 desig...

Page 6: ...6 Lower Reduction Gear Group Cartridge Group Hydraulic Motor Drum Shaft Bull Gear ...

Page 7: ...7 Typical H50 Hydraulic Schematic Hydraulic Winch Control Valve TRACTOR WINCH ...

Page 8: ...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 c...

Page 9: ...e 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 disas...

Page 10: ...erature 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 C...

Page 11: ...f 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 necess...

Page 12: ...r 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 ...

Page 13: ...he 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 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 assemble...

Page 14: ...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...

Page 15: ... 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 e...

Page 16: ... 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...

Page 17: ...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 solve...

Page 18: ...th 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 fr...

Page 19: ...om 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...

Page 20: ...tch 709 In stall compression tool in position using the two 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 a...

Page 21: ... the retaining ring 611 from the groove in the 1st reduction gear 605 LOWER REDUCTION GEAR DISASSEMBLY The 1st reduction gear 605 weights 38 lbs and 2nd reduction gear 606 weighs 22 lbs Use necessary lift ing equipment to support them in the winch case CAUTION 2 Insert a screwdriver between the splines of the 1st re duction gear 605 and the 2nd reduction gear 606 Slowly pry against the back of the...

Page 22: ...ring 618 on shaft 607 Place thrust race 609 on the shaft Slide bearings 608 and 607 into the gear 606 The bearings must be installed in the correct order refer to drawing on p 21 3 Place washer 618 on gear 606 and install retaining ring 612 in the groove in gear 606 Install new o ring 616 on shaft 4 Place 1st reduction gear 605 in the winch case Roll the gear forward on the pinion and install the ...

Page 23: ...ch drum 201 with an overhead hoist and lifting strap DRUM AND BULLGEAR DISASSEMBLY 2 Remove bearing cover capscrews 222 and lockwash ers 223 bearing cover 221 and gasket 212 The winch drum weighs approximately 240 lbs 109 kg Ensure rigging for lifting or supporting the drum is properly rated Death or personal injury may result if the winch drum is not properly supported ...

Page 24: ...m of the fairlead assembly away from the winch to provide clearance for removing the drum from the winch case Tighten the upper bolts to hold the fair lead assembly in position and then remove the drum 10 Remove washers 219 and seals 208 from both sides of the winch drum 3 Remove socket head capscrew 206 which secures the locknut 205 in position User a spanner wrench to remove the locknut 205 4 In...

Page 25: ...to the bearing sleeve 207 Install a new o ring 218 on the bearing sleeve 207 8 Install bearing 602 into bull gear 601 and install retaining ring 603 in bull gear 601 Install retain ing ring 612 and the second bearing 602 in the bull gear 601 9 Install drum shaft 202 into bull gear 601 Slide bearing 204 onto the drum shaft 202 10 Use a lifting link in one of the 1 2 13 tapped hole in the bull gear ...

Page 26: ... cylinder 310 Install two of the longer bolts 302 removed in Step 1 in place of the two bolts just removed and leave about 5 8 inch protruding 4 Pull on the bolts to remove the cartridge assembly from the winch case 5 Place the cartridge assembly on a work bench for fur ther disassembly Refer to disassembly instructions for Brake Cylinder Plan et Carrier and Pinion Carrier for further disassembly ...

Page 27: ...nd two bearings 363 and 364 from the bearing carrier 361 5 Use bearing pullers to remove the bearings 363 and 364 from the pinion 362 6 Remove and discard o ring 365 from bearing car rier 361 362 364 363 PINION CARRIER ASSEMBLY 1 Use an induction heater to heat the inner race of bear ing 364 and install on pinion 362 2 Heat bearing 363 and install on pinion 364 3 Use a hydraulic press to install t...

Page 28: ...y cause abrasions or friction The gears and shafts should be inspected for abnormal wear or pitting Replace if necessary ASSEMBLY 1 Place the output planet carrier on workbench with splined coupling side down Install output thrust plate in center of carrier 2 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 a...

Page 29: ...d be offset away from the opening in the retaining ring to provide clearance for the retaining ring pliers 2 Compress the brake pack Carefully remove the re taining ring 323 Slowly back off the compression tool to remove the force on the brake springs and then remove the compression tooling Spring force is applied to the brake cylinder Parts pro pelled by released spring force can result in death ...

Page 30: ...ease will hold the compo nents in position on the spring backup plate 313 5 Install the piston seal 316 and a new o ring 322 on the brake retainer 321 The spring o ring in the seal must be installed toward the external teeth of the brake retainer 321 6 Place the brake retainer 321 on a clean work sur face with the external teeth down Apply a light coat of gear oil to the friction surface of the fr...

Page 31: ...es Hg 60 o F pounds sq in PSI X 6 895 kilopascals kPa kilopascals kPa X 0 145 pounds sq in PSI pounds sq in PSI X 0 0703 kilograms sq cm kg cm 2 kilograms sq cm kg cm2 X 14 22 pounds sq in PSI pounds sq in PSI X 0 069 bars bars X 14 5 pounds sq in PSI inches H 2O 60 o F X 0 2488 kilopascals kPa kilopascals kPa X 4 0193 inches H 2O 60 o F bars X 100 kilopascals kPa kilopascals kPa X 0 01 bars horse...

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