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CARCO

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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

All rights reserved.

Содержание CARCO 50B

Страница 1: ...ECTRONIC CONTROL SERVICE MANUAL LIT2055 R4 5 2010 Printed in U S A PACRWINCH 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...

Страница 2: ......

Страница 3: ...odel 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 GENE...

Страница 4: ...raps 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 ti...

Страница 5: ...ventive 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 Ta...

Страница 6: ...gested 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 L...

Страница 7: ...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 follow...

Страница 8: ...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 ad...

Страница 9: ...ty 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 Requirement...

Страница 10: ...45 35 70 50 23 31 50 35 80 110 80 150 110 110 55 75 150 115 210 160 14 20 13 20 12 18 11 18 265 200 Torque LB FT Grade 5 Grade 8 380 280 7 8 9 14 420 325 600 450 3 4 10 16 680 1 1 8 7 12 790 590 1290...

Страница 11: ...r 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 indu...

Страница 12: ...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 ne...

Страница 13: ...WIRING HARNESS 70A for D6R Series II 11...

Страница 14: ...12 WIRING HARNESS 50B for D5N D6N...

Страница 15: ...OW 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 2 1 PIN NO RED GREEN TO FILTER LIGHT LED BLACK RED BLACK ORANGE 24 VDC 24...

Страница 16: ...ed 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...

Страница 17: ...s 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 availa...

Страница 18: ...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...

Страница 19: ...uence 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...

Страница 20: ...4 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 control system oil pressure from stand by pr...

Страница 21: ...is sent to the control mod ule 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...

Страница 22: ...oper ating Voltage readings at the diagnostic connector on the wiring harness Key switch on Pin 11 is ground Refer to diagnostic plug drawing on previous page for pin number BRAKE ON Neutral 24Volts...

Страница 23: ...corrective action for A2 Also disas semble clutch assembly to check for worn parts Determine the root cause of failure C Tractor torque converter stalls out when attempting to REEL IN or REEL OUT 1 B...

Страница 24: ...ay be tested with an Ohm meter across the terminals A reading of no more than 25 Ohms at 70 F 21 C is required The resistance should decrease with increased temperature 5 Drain oil remove small side i...

Страница 25: ...fective Install a gauge at the pressure tap on the front of the winch and record the pressure The pressure should increase to approximately 370 PSI 2550 kPa then fall slowly back to approx imately 315...

Страница 26: ...pressure solenoid valve item 10 Refer to corrective action D4b G Winch runs noisy 1 Improper bevel gear pinion back lash 2 Defective gear train bearing s and or gear s 1 Establish clutch shaft end pl...

Страница 27: ...DC Replace solenoid s or correct electronic control system as required Check the resistance of the coil s If the resistance across the terminals of the coil s with the wires removed is less than 25 Oh...

Страница 28: ...round seeking circuit The light will be on if the wire has chaffed and shorted to ground or if the switch is stuck in the bypass position Replace the sending switch as required N Brake will not releas...

Страница 29: ...itch ON then slowly cycle the joystick lever into full REEL IN and REEL OUT positions a minimum of five 5 times The tractor electrical system MUST be ON during this procedure Two 2 1 in 7 UNC threaded...

Страница 30: ...50 Fe 43 75 Mechanical properties tensile strength 65 000 84 000 psi 448 000 579 000 kPa yield strength 45 000 65 000 psi 310 000 448 000 kPa elongation 15 25 Flux cored wire Composition Ni 50 00 Fe...

Страница 31: ...cks under the pump drive pinion 10 as close to the bevel pinion gear as possible Press the bevel pinion 16 free of the bearing cone and pump drive pinion Support the carrier in a vice and remove the o...

Страница 32: ...rdening sealant to the outside sur face of the oil seal 8 and install the oil seal firmly against the retaining ring 7 Install the bearing lockwasher 4 and locknut 2 onto the bevel pinion Tighten the...

Страница 33: ...pplied 350 psi 2413 kPa load to the pump Again record the flow for 15 seconds The minimum acceptable pump flow is 2 gpm US 7 6 lpm at 650 700 RPM PTO speed and 350 psi 2413 kPa Two quarts per 15 secon...

Страница 34: ...ation the most common install the pressure adapter into A port B For clockwise cw bevel pinion rotation install the pressure adapter into B port NOTE Determine direction of bevel pinion rotation when...

Страница 35: ...tion discs slip freely between the brake steel discs The bevel gears and center portion of the clutch shaft are supported by two large ball bearings while the ends of the shaft are supported by two ta...

Страница 36: ...nts in the order in which they were removed Remove the rotary seal shafts 24 and bearing retainers 22 from each end of the clutch shaft With a gear puller remove the pinion gear 28 and bear ing cone 5...

Страница 37: ...tains item 1 2 15 Plug contains item 1 1 16 O Ring 8 17 O Ring 2 18 O Ring 2 19 O Ring 4 20 Retaining Ring 2 21 Retaining Ring 2 22 Bearing Retainer 2 23 Back up Ring 4 24 Rotatry Seal Shaft 2 ITEM DE...

Страница 38: ...er 30 R1 thru R4 4 Needle Bearing Inner Race 6 M1 M2 2 Bevel Gear Shim Pack Thickness Z B1 B2 M1 M2 S1 S2 S3 S4 R1 R2 R3 R4 The basic shim pack supplied through Service Parts is 120 in 3 05 mm thick R...

Страница 39: ...e back up ring 23 next to the o ring Install the brake hub spacer 36 onto the clutch shaft next to the clutch housing The spacer should hold the o ring and back up ring into the clutch housing Install...

Страница 40: ...one Apply Loc tite 271 or equivalent to the threads and pilot shoulder of the shaft and tighten to 40 lb ft 54 N m torque Tighten the current design to 130 lb ft 175 N m torque INSTALLATION Place the...

Страница 41: ...ervice for installation instructions and procedure for obtaining cor rect tooth contact pattern With correct bevel gear tooth contact pattern established move clutch shaft assembly to the right brake...

Страница 42: ...locked by the spring applied brake REMOVAL Right hand or left hand clutch removal may be accom plished with a winch mounted to the tractor However if both clutch assemblies are to be inspected for re...

Страница 43: ...ve O Rings and back up rings from the piston Replace O Rings and or back up rings upon reassembly Remove the check valve seat 9 and steel ball 2 from the back side of clutch housing 11 Inspect for wea...

Страница 44: ...teeth or lugs on outer diameter until a total of five friction discs and four steel discs are installed Slotted Housing Install the discs by starting with a steel separator disc 13 lugs on outside di...

Страница 45: ...r normal conditions no periodic brake adjustment is required STANDARD BRAKE The brake may be used on an intermittent basis to lower a load However partially releasing the brake and lower ing the load...

Страница 46: ...riction material is worn unevenly Inspect the steel discs 16 for scoring and warping Replace steel discs if they are not flat beyond 015 in 4 mm heat discolored or show signs of friction material tran...

Страница 47: ...brake should be fully released at approximately 230 250 psi 1590 1720 kPa Continue to increase pressure to 350 psi 2410 kPa Close the hand pump valve and let stand for five minutes If there is any lo...

Страница 48: ...13 X 2 G8 Z 1 18 SPRING 1 5 THRUST BEARING 2 19 CAPSCREW 1 4 NC X 2 SOC HEAD 3 6 ADJUSTER 1 20 CYLINDER ROD 1 7 CAPSCREW 1 2 13 X 3 4 G8 Z 1 21 CYLINDER 1 8 BUSHING 1 22 O RING 1 9 PINION 1 23 SPRING...

Страница 49: ...adjuster counter clockwise CCW and remove it from the bearing carrier Remove and discard the O ring from the carrier Remove the capscrews from the large diameter second reduction shaft bearing carrie...

Страница 50: ...ction gear and clutch collar assembly over the bush ing aligning the second reduction pinion teeth with the splined collar teeth The clutch collar MUST be installed with the chamfered edge toward the...

Страница 51: ...ll the bearing carrier to the winch case Apply thread sealant to the capscrews and torque evenly to 75 lb ft 102 N m Using a pry bar or a screwdriver approximately 18 in 460 mm in length turn the thre...

Страница 52: ...rew into the end of the countershaft pin 6 to serve as a handle Support the cluster gear 3 and remove the countershaft pin Thoroughly clean all parts and inspect for damage and wear The bearing roller...

Страница 53: ...the inner case wall then fully install the countershaft pin Rotate the countershaft pin so that the slotted end is properly positioned to permit clutch shaft bearing carrier installation Install the...

Страница 54: ...NG CARRIER COVER 1 15 BEARING CARRIER DRUM 1 16 SHIM SET 2 pair each 005 007 020 in 2 FERRULE 3 4 IN 19 mm WIRE ROPE 1 FERRULE 7 8 IN 22 mm WIRE ROPE 1 FERRULE 1 IN 25 mm WIRE ROPE 1 18 NO GASKET Use...

Страница 55: ...ter bear ing carrier cover 14 and remove the cover Remove the 2nd reduction drum drive gear and shaft assembly 12 13 from the winch Remove the shift rail and freespool shift collar and yoke assembly f...

Страница 56: ...the retaining ring 8 in the cable drum bore With a large screwdriver pry drum from side to side to check for end play of 005 010 in 13 25 mm Add or remove shims 16 as required while keeping the cable...

Страница 57: ...ling the joystick control lever into full REEL IN then REEL OUT positions as a minimum of 5 times 2 Remove the filter and valve access cover from the RH side of the winch case 3 Remove the filter elem...

Страница 58: ...EAD 1 3 UNION 1 4 ELBOW 1 15 20 5 PLUG HEX HD 5 5 5 7 6 ELBOW 2 5 5 7 7 CAP 1 8 PRESSURE SWITCH 1 5 5 7 9 STUD 1 10 NUT 2 11 RELIEF VALVE 1 25 35 12 SOLENOID VALVE C1 C2 F S 3 50 70 13 SOLENOID VALVE...

Страница 59: ...ressure switch signaling the main pressure solenoid and is not adjustable 2 Place the control lever into the BRAKE OFF position and record the pressure When a winch function is selected the main press...

Страница 60: ...tor 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 and clutch application The accumulator also st...

Страница 61: ...e tightened to 120 lb ft 163 N m torque 5 Lubricate tube and piston seals with winch lubricant Install an automotive type piston ring compressor around the piston making certain the step cut piston ri...

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