Paccar CARCO 50B Service Manual
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Paccar CARCO 50B Service Manual

Paccar CARCO 50B Service Manual

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CARCO
MODELS 50B & 70A
WITH ELECTRONIC CONTROL
SERVICE
MANUAL
LIT2055 R4
5/2010
Printed in U.S.A.
2010 PACCAR Winch Division
All rights reserved.
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

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  • Page 1 MODELS 50B & 70A WITH ELECTRONIC CONTROL SERVICE MANUAL PACR WINCH DIVISION P.O. BOX 547 BROKEN ARROW, OK U.S.A. 74013 LIT2055 R4 PHONE (918) 251-8511 FAX (918) 259-1575 2010 PACCAR Winch Division 5/2010 www.paccarwinch.com All rights reserved. Printed in U.S.A.

  • Page 3: Table Of Contents

    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.

  • Page 4: General Safety Recommendations

    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.

  • Page 5: Model Description

    ences in tractor models. Some changes cannot be mounting the tractor. approved by CARCO because of safety limitations. Call a CARCO dealer or the CARCO factory prior to 13. The winches described in this manual are neither attempting winch modifications or before mounting on designed nor intended for use or application in the lift- a different tractor.

  • Page 6: Preventive Maintenance & Specifications

    Important: Always refer to the serial number and model MODEL number when requesting information or service parts. Identification 50B, 70A, Plate Serial Number 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 Record the information below for future reference.
  • Page 7 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.
  • Page 8 bolt access cover. Remove the cover, locate the spin-on Stand away from service access of winch and return pressure filter and remove the filter element with a strap Power Shift lever to the BRAKE-ON (neutral) position. wrench. BRAKE RELEASE pressure must return to 0 with the controls in BRAKE-ON (neutral) position.
  • Page 9 6. Winch Cable (wire rope) Shift the control lever to the freespool position (if equipped). Then, with the tractor engine at low idle, place Inspect entire length of wire rope, chokers and hooks Power Shift lever in Reel-In (forward) position. The winch according to wire rope and rigging manufacturers recom- gear train will rotate and warm the oil to operating tem- mendations.
  • Page 10 SPECIFICATIONS Unit weight (without oil, cable or specific tractor adapters) ......1,960 lbs (885 kg) Gear Ratio Available Bevel Gear Ratio 1.00:1...

  • Page 11: Control System Operation & Trouble Shooting

    CONTROL SYSTEM OPERATION AND TROUBLESHOOTING BASIC OPERATION The winch contains an independent, internal hydraulic The joystick produces a signal by a magnetically induced system. The winch case serves as a reservoir and stores voltage as the control lever is moved near the sensing filtered oil for the internally mounted hydraulic pump.
  • Page 12 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 Discharge accumulator oil supply before removing any circuit components.
  • Page 16 BRAKE ON (NEUTRAL) “CHARGING” REEL IN REEL OUT BRAKE CLUTCH CLUTCH LOW PRESSURE O O O O O O O HIGH PRESSURE ORIFICE ORIFICE ACCUMULATOR 15 PSI FILTER PRESSURE SWITCH 390/410 PSI 315/370 PUMP 15 PSI SUCTION STRAINER ORIFICE BRAKE LUBE BULL GEAR &...
  • Page 17 BREAK ON “UNLOADED” REEL IN REEL OUT CLUTCH BRAKE CLUTCH LOW PRESSURE O O O O O O O HIGH PRESSURE ORIFICE ORIFICE ACCUMULATOR 15 PSI FILTER PRESSURE SWITCH 390/410 PSI 315/370 PUMP 15 PSI SUCTION STRAINER ORIFICE BRAKE LUBE BULL GEAR &...
  • Page 18 BRAKE-OFF REEL IN REEL OUT CLUTCH BRAKE CLUTCH LOW PRESSURE O O O O O O O HIGH PRESSURE ORIFICE ORIFICE ACCUMULATOR 15 PSI FILTER PRESSURE SWITCH 390/410 PSI 315/370 PUMP 15 PSI SUCTION STRAINER ORIFICE BRAKE LUBE BULL GEAR &...
  • Page 19 REEL-IN REEL IN REEL OUT BRAKE CLUTCH CLUTCH O O O O O O O LOW PRESSURE HIGH PRESSURE ORIFICE ORIFICE ACCUMULATOR 15 PSI FILTER PRESSURE SWITCH 390/410 PSI 315/370 PUMP 15 PSI SUCTION STRAINER ORIFICE BRAKE LUBE BULL GEAR &...
  • Page 20 REEL-OUT REEL IN REEL OUT BRAKE CLUTCH CLUTCH LOW PRESSURE O O O O O O O HIGH PRESSURE ORIFICE ORIFICE ACCUMULATOR 15 PSI FILTER PRESSURE SWITCH 390/410 PSI 315/370 PUMP 15 PSI SUCTION STRAINER ORIFICE BRAKE LUBE BULL GEAR &...
  • Page 21 FREESPOOL REEL IN REEL OUT BRAKE CLUTCH CLUTCH LOW PRESSURE O O O O O O O HIGH PRESSURE ORIFICE ORIFICE ACCUMULATOR 15 PSI FILTER PRESSURE SWITCH 390/410 PSI 315/370 PUMP 15 PSI SUCTION STRAINER ORIFICE BRAKE LUBE BULL GEAR &...
  • Page 22 When the freespool operation is completed and the cable drum is stopped, the control lever may then be moved back into the BRAKE ON position. This will clear the signal from the joystick to the control module, which will call for the release of oil pres- FREESPOOL is used for pulling wire rope (cable) off of the sure from the freespool cylinder.
  • Page 23 TROUBLE PROBABLE CAUSE CORRECTIVE ACTION Brake does not hold. Cable 1. Brake assembly worn, damaged 1. Remove and disassemble brake assem- Drum may also be slowly or improperly assembled. bly to check for worn parts or improper turning while in "BRAKE ON". assembly.
  • Page 24 TROUBLE PROBABLE CAUSE CORRECTIVE ACTION (continued) 4. Main pressure solenoid valve 4a. Pressure switch (item 6) in the control (item 10) stuck in the "unload" posi- valve may be stuck in the "open" position tion, or the signal to "charge" is not allowing all oil to flow continuously into the present.
  • Page 25 TROUBLE PROBABLE CAUSE CORRECTIVE ACTION (continued) 5. Control valve defective. 5. Perform electronic and hydraulic tests. 6. Accumulator piston seals leaking. 6. Observe the hole near the rod end of the accumulator body during winch operation. Oil exiting the hole indicates leakage past the piston seals.
  • Page 26 TROUBLE PROBABLE CAUSE CORRECTIVE ACTION (continued) 2d. The check valve (item 9) in the control valve housing may be worn and leaking. Remove the check valve and inspect the valve seat. 2e. If leakage continues and you have ver- ified it is not caused by any of the compo- nents listed above, the problem may be caused by a leaking accumulator holding solenoid valve (item 13).
  • Page 27 TROUBLE PROBABLE CAUSE CORRECTIVE ACTION FREESPOOL will not engage 1. Control system malfunction. 1. Perform electronic and hydraulic tests. or disengage. 2. Problem with freespool cylinder 2. Inspect the freespool cylinder assembly assembly or pressure supply hose. components and hose. Repair or replace as required.
  • Page 28 TROUBLE PROBABLE CAUSE CORRECTIVE ACTION Filter bypass indicator light 1. Filter plugged, remaining in 1. Replace filter, change oil, clean suction remains on. bypass mode. strainer. Cut open pressure filter element if necessary to determine origin of contami- nation and take corrective action as required.

  • Page 29: Winch Removal & Installation

    WINCH REMOVAL AND INSTALLATION Two (2) 1 in. - 7 UNC threaded holes are provided in the Before starting any repair procedures, be sure to thor- top of the winch case for installing lifting eyebolts. Make oughly clean the parts to be removed and adjacent areas certain eyebolt has a minimum of 1.25 in.

  • Page 30: Wire Rope Installation & Welding Specifications

    WELDING PROCEDURE The following specifications apply to welding ductile iron to ductile iron or steel to ductile iron when attaching arch- es, fairleads, or guarding to the winch case. Preparation: Attachments should be chamfered to ensure adequate penetration. Weld joints must be free of rust, scale, slag, sand, dirt, grease, oil, paint or moisture.

  • Page 31: Bevel Pinion & Hydraulic Pump Service

    BEVEL PINION AND HYDRAULIC PUMP SERVICE The bevel pinion, bevel gears and hydraulic pump are Remove the ½ in. capscrews which secure the bevel gear turning whenever the tractor PTO shaft is turning. The inspection plate to the top of the winch case. Remove the bevel pinion transmits torque from the PTO shaft to the inspection plate.
  • Page 32 the bevel pinion and seat securely against the pump drive BEVEL PINION CARRIER INSTALLATION pinion. Install bearing cone set spacer on to the bevel pin- ion. Spacer, Bearing Cup Retaining Ring Bearing Cup Bearing Cup Carrier Pinion, Pump Drive Bevel Pinion Seal Sleeve O-Ring Apply LocTite...
  • Page 33 3. Attach pump line to the gauge side of the gate valve or flow meter. Direct the open end of the gate valve/flow meter back into the winch case. Preferred Contact 4. With gate valve/flow meter fully open, operate engine Pattern at 650-700 RPM and measure oil flow by directing oil into a container for 15 seconds.
  • Page 34 PUMP INSTALLATION Lubricate entire pump assembly with recommended oil. Coat the capscrew threads with Loc-tite 242 or equivalent and evenly tighten to 100-110 lb•in by 25 lb•in (11.3-12.4 N•m by 2.8 N•m) increments in a cross pattern. When properly installed, there will be a slight gap, .005- .040 in.

  • Page 35: Clutch Shaft Service

    CLUTCH SHAFT SERVICE DESCRIPTION The clutch shaft assembly contains or supports the two bevel gears, the Reel-In and Reel-Out clutches, the brake hub and the first reduction pinion gear. OPERATION The bevel gears are continuously driven by the bevel pin- ion and, when no clutches are applied, spin freely on nee- dle roller bearings.
  • Page 36 you both move the clutch shaft assembly out through the brake opening. Move the clutch shaft assembly out of the winch case far enough to place a lifting sling between the bevel gears. Using a wood block, bump the end of the clutch shaft at the left hand side of the winch to unseat the brake assem- bly.
  • Page 37 BRAKE ASSEMBLY (REF. PAGE 15) CLUTCH ASSEMBLY (REF PAGE 14) CLUTCH ASSEMBLY (REF PAGE 14) ITEM DESCRIPTION QTY. O-Ring (part of item 14) Bearing Cup Ball Bearing - STD PTO Bearing Cup Bearing Cone Needle Bearing - Inner Race ITEM DESCRIPTION QTY.
  • Page 38 ASSEMBLY Record dimensions M1 and M2, bevel gear mounting dis- tance. The mounting distance has been etched into the Thoroughly clean and carefully inspect all components inside surface of the bevel gears. prior to assembly. If a component’s condition is question- able –...
  • Page 39 Begin the clutch shaft assembly by first installing the Lubricate and install an o-ring (19) and back-up ring (23) brake side components. Install the shim pack, Z (previ- into the inner groove of the shaft with the back-up ring ously determined by the component measurement) onto placed next to the splined thrust bearing spacer (25).
  • Page 40 Install the remaining bevel gear assembly over the bly into the center of the winch case where the bevel gear inner bearing races. bearing carriers (31) are supported by the winch case. Lubricate and install two needle bearings (8) between All 50B/70A winches are fitted with a rollpin (38) driven the bevel gear and bearing races.
  • Page 41 Lubricate and install the o-ring (18) around the bearing carrier cover. Install rotary seal and o-ring (17, 27) into the bore of the cover. Install back-up washer (26) and secure with retain- ing ring (21). Install the bearing carrier assembly (35) into the winch case, carefully aligning the oil port in the cover and shim set with the oil port in the winch case.

  • Page 42: Clutch Assembly Service

    CLUTCH ASSEMBLY SERVICE gear to turn free of the clutch shaft which is now locked NOTE: In April of 2001 Carco began using a new by the spring applied brake. slotted housing clutch assembly in all 50B/70A winches (Serial Number 0100513 and higher). REMOVAL Basic service instructions are unchanged from the Right hand or left hand clutch removal may be accom-...
  • Page 43 ITEM DESCRIPTION QTY. PLUG (-4 ORB) Slotted STEEL CHECK BALL Clutch SPRING Assembly O-RING O-RING RETAINING RING RETAINING RING SPRING RETAINER CHECK VALVE SEAT PRESSURE PLATE CLUTCH HOUSING ITEM DESCRIPTION QTY. DISC - FRICTION DISC - STEEL CLUTCH PISTON O-RING BACKUP RING BACKUP RING WAVE SPRING...
  • Page 44 Install the steel check-ball (2) into the back side of clutch housing (11). Lightly coat threads of check valve seat (9) with Loc-tite 242 and install flush with the surface of the clutch housing. Make certain that the steel ball moves freely and no thread locking compound is in seat area.

  • Page 45: Brake Assembly Service

    Remove the screwdrivers and push the pressure holes to push the clutch piston against clutch discs and plate down against the disc. Again, measure from hold them in position. Only tighten the capscrews enough the top of the pressure plate to the top of the disc. to keep the clutch discs from moving in the housing.
  • Page 46 Remove the six ½ in. capscrews securing the brake Inspect the steel discs (16) for scoring and warping. assembly to the winch case. Do not remove the two 3/8- Replace steel discs if they are not flat beyond .015 in. (.4 in.
  • Page 47 Locate the external brake release port next to the “B” cast into the bearing carrier. The port is -6 ORB on current units. Attach a hand pump with an accurate 0-500 psi (0- One brake spring must “nest” within the shallow cavity 3450 kPa) gauge teed into the line.

  • Page 48: Idler Shaft Group

    IDLER SHAFT GROUP NO GASKET USE RTV SEALANT ITEM DESCRIPTION QTY. ITEM DESCRIPTION QTY. BEARING FREESPOOL CYLINDER ASSEMBLY BEARING ROLL PIN CAPSCREW (1/2 - 13 X 1-1/4 G8 Z) CYLINDER STUD CAPSCREW (1/2 - 13 X 2 G8 Z) SPRING THRUST BEARING CAPSCREW (1/4 NC X 2 SOC.
  • Page 49 Note: All electronically controlled winches are con- figured with factory supplied freespool. The idler shaft group and freespool components, which include the first reduction gear, second reduction pinion and freespool linkage, are located on the LH side of the winch, when viewed from the rear. REMOVAL Drain the oil from the winch as described in the "Preventive Maintenance"...
  • Page 50 Together, remove the second reduction pinion and first reduction pinion with new winch oil, and install the bush- reduction gear from the winch case. Press the pinion from ing over the pinion. the gear and bearings. Install the freespool clutch collar over the first reduction Inspect the bushing in the first reduction gear for scoring gear with the beveled side of the collar facing down or excessive wear.
  • Page 51 Apply silicon sealant, RTV 730 or equivalent, to the seal- ing surface of the large diameter second reduction gear bearing carrier cover and install it onto the winch case. Apply thread sealant to the capscrews and install them finger tight. DO NOT tighten the capscrews at this time. Lubricate and install the O-ring into the groove in the bearing carrier.

  • Page 52: Fourth Shaft Group

    FOURTH SHAFT GROUP Remove the six capscrews then remove the left-hand Low PTO, 4 Shaft clutch shaft bearing carrier. Retain the shim set for Winch Shown reassembly. Remove the first reduction drum drive gear, second reduction gear and pinion, freespool shift rail and yoke, if equipped with freespool.
  • Page 53 ASSEMBLY Lubricate and install new o-ring (4) into the groove on the Install the first and second reduction gears and freespool countershaft pin (6). Lubricate and install two roller bear- linkage, if equipped. Refer to the “Idler Shaft Group” sec- ings (1) separated by a spacer (5) into the bore of the tion for additional information.

  • Page 54: Cable Drum Group

    CABLE DRUM GROUP ITEM DESCRIPTION QTY. BALL BEARING BEARING CUP BEARING CONE CAPSCREW, HEX HEAD (1/2 - 13 X 1 G5 SS) CAPSCREW, HEX HEAD (1/2 - 13 X 1 1/4 G5) DISASSEMBLY O-RING RETAINING RING, EXTERNAL RETAINING RING, INTERNAL OIL SEAL CAPSCREW, SOCKET HEAD (1/2 - 13 X 1 G8 SS) CABLE DRUM...
  • Page 55 CAUTION Hot oil may cause injury. Make certain the oil has Use a pry bar between the bearing carrier cover and the cooled to a safe temperature (less than 110°F/43°C) second reduction drum drive gear to unseat the ball before servicing the winch. bearing from cover.
  • Page 56 remove the drum bearing carrier. 75 lb•ft (102 N•m) torque. Remove capscrews (4) from the left hand drum bearing Attach a dial indicator to the left hand bearing carrier and carrier (15) and lube tube clamps. Using jackscrews, position the indicator stem against the retaining ring (8) in remove the drum bearing carrier.

  • Page 57: Control Valve Service

    CONTROL VALVE SERVICE 7. Remove the two (2) check valve assemblies from the Make certain that all applicable troubleshooting proce- valve housing through the front, or forward, face of the dures have been completed BEFORE removing or disas- sembling the control valve. Refer to the "Control System valve.
  • Page 58 NEAR PORT "P" SIDE PORT "PS" 1.63 ±.12 PORT "AG" PORT "FSG" SYSTEM FLOW TORQUE VALUE · · ITEM NO. DESCRIPTION QTY. CONTROL VALVE HOUSING FILTER HEAD UNION ELBOW PLUG, HEX HD ELBOW PRESSURE SWITCH STUD RELIEF VALVE SOLENOID VALVE (C1, C2, F/S) SOLENOID VALVE (BRAKE) COIL, SOLENOID (C1, C2, F/S, BRAKE) SOLENOID VALVE (MAIN PRESSURE)
  • Page 59 3. Install the filter head assembly into the valve housing, 2. Place the control lever into the BRAKE-OFF position after all solenoids have been installed. and record the pressure. When a winch function is selected, the main pressure, controlled by the relief 4.

  • Page 60: Accumulator Service

    ACCUMULATOR SERVICE The accumulator stores oil at system pressure. The pri- mary function of the accumulator is to cushion pressure surges in the hydraulic system and aid in brake release Discharge accumulator oil supply before removing any and clutch application. The accumulator also stores hydraulic lines or servicing winch.
  • Page 61 3. Slowly release pressure on the press and remove rod guide (3), spring (4) and piston/rod assembly. TIP: The cast iron piston ring (6) will attempt to expand into the retaining ring groove when the piston is removed from the tube. To reduce the chances of this happening, pack the groove with heavy grease and withdraw the piston rod assembly quickly past the groove.

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Carco 70a

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