Service Manual: H200 Tail Winch

H200
SERVICE MANUAL
H200 Tail Winch
WRITE WINCH SERIAL NUMBER BELOW

}
First 2 numbers indicate

year manufactured
For serial number location see page 3
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information on the Internet. Most publications and specification sheets are available for downloading.
LIT2753
October 2018 ©2018 PACCAR Inc.
Printed in USA All rights reserved
1
Table of Contents
Foreword...................................................................................................................... 2
Model Identification...................................................................................................... 3
Explanation of Model Number...................................................................................... 4
General Safety Recommendations.............................................................................. 4
Theory of Operation..................................................................................................... 6
Preventive Maintenance............................................................................................. 10
Specifications............................................................................................................. 11
Recommended Planetary Gear Oil............................................................................ 12
Wire Rope Installation................................................................................................ 13
Troubleshooting.......................................................................................................... 14
H200 Major Parts Groups Cross-section................................................................... 19
H200 Major Parts Groups Components..................................................................... 20
Service Precautions................................................................................................... 20
Winch Removal and Installation................................................................................. 21
Winch Disassembly.................................................................................................... 22
Primary Planet Carrier Service................................................................................... 28
Secondary Planet Carrier Service.............................................................................. 29
Third Planet Carrier Service....................................................................................... 30
Output Planet Carrier Service.................................................................................... 31
Drum Clutch Assembly Service.................................................................................. 32
Brake Assembly Service............................................................................................ 34
Brake Assembly Pressure Test.................................................................................. 35
Brake Valve Service................................................................................................... 36
Overrunning Clutch Service....................................................................................... 38
Cable Drum Service................................................................................................... 39
Winch Assembly......................................................................................................... 41
Brake Cylinder Lifting Fixture..................................................................................... 47
FOREWORD
Managing Waste
PACCAR Winch believes in a life-cycle approach to our products. We encourage best practices regarding “Going
Green” — making environmentally responsible decisions to “reduce, reuse, and recycle.”
• At the end of the winch’s useful life, it is highly recommended to drain and recycle any oil remaining in the equipment.
• Please use a metal recycler for winch disposal to reduce landfill waste.
The U.S. Environmental Protection Agency has developed required practices, called “management standards,” for busi-
nesses that handle used oil and metal wastes. Specific guidelines are available at the EPA and API Web sites as well
as your state’s environmental agency Web site:
• https://www.epa.gov/
• http://recycleoil.org/
2
FOREWORD
This service manual has been prepared to provide maintenance information for the CARCO H200 hydraulic winches
built for use on various crawler tractors. Depending on the specific tractor hydraulics, the winches will be configured
with either variable displacement piston motors or fixed displacement vane motors. When instructions apply to only one
specific winch configuration, that designation (such as variable displacement motor only) will appear at the beginning of
the related text. If not identified in this manner, the text applies to ALL H200 winches.
Read this entire publication and retain it for future reference.
For inquiries regarding your CARCO winch or this publication, please contact the CARCO Service Department at
918-251-8511, Monday through Friday, 8:00 a.m. to 4:30 p.m. (CST).
Some illustrations in this manual may show details or attachments different from your winch. Some components have
been removed for illustrative purposes. Drawings in this manual represent a typical unit sold through our distribution
channels. Some winches, particularly those sold directly to original equipment manufacturers, may differ in appearance
and options.
NOTE: The hydraulic motors and selected gear ratios on CARCO H200 winches are specifically configured for use on
the intended tractor. The winch may not be suitable or advisable for use on anything other than the intended tractor.
Contact the CARCO Service Department with questions regarding retrofitting your winch to other tractors.
Safety and informational callouts used in this manual include the following Warnings and Cautions:
! WARNING ! ! CAUTION !
WARNING – This emblem is used to warn against CAUTION – This emblem is used to warn against
hazards and unsafe practice which COULD result in potential or unsafe practices which COULD result
severe personal injury or death if proper procedures in personal injury and product or property damage if
are not followed. proper procedures are not followed.
MODEL IDENTIFICATION
Model numbers, part numbers, and serial numbers

are located on the nameplate. Always refer to the
model number, part number, and serial number
when requesting information or service parts.
There is also another stamped serial number locat-

ed near the top side of winch mounting holes.
3
EXPLANATION OF MODEL NUMBER
H – 200 – 500V
MOTOR MAXIMUM GEAR
RATING RATIO
H Hydraulic motor, two-speed

200 200,000-lb. first-layer line pull
500V 500:1 gear ratio
TO ORDER:
1. List model and serial numbers of the winch.
2. Refer to cross-section drawing (exploded view), select the component(s) needed, and note item number.
3. Find item number on parts list. Show part number, description, and quantity required on your order.
4. Refer to Parts List and show price for each component or assembly.
GENERAL SAFETY RECOMMENDATIONS
Safety for operators and ground personnel is of prime 6. Ground personnel should stay in view of the operator
concern. Always take the necessary precautions to and clear of the winch drum. DO NOT allow ground
ensure the safety of others as well as yourself. To ensure personnel near a winch line under tension. A safe
safety, the tractor and winch MUST be operated with care distance of at least 1-1/2 times the length of the out-
and concern by the equipment operator. The operator stretched cable should be maintained.
MUST also have a thorough knowledge of the machine’s 7. Avoid sudden shock loads or attempting to jerk a load
performance capabilities. free. This type of operation may cause heavy loads, in
excess of rated capacity, which may result in a failure
The following recommendations are offered as a general of the wire rope and/or the winch.
safety guide. Local rules and regulations also apply.
8. Use only GENUINE CARCO parts. Do not use parts
from other winch manufacturers on your CARCO
! WARNING ! winch. Do not use CARCO parts on winches from

other manufacturers.
9. Use correct size ferrule for cable and pocket in winch
Failure to obey the following safety recommendations drum. Never use knots to attach or secure cable.
COULD result in property damage, severe personal The cable anchor or ferrule pocket in the cable drum
injury, or death if proper procedures are not followed. is designed to provide a self-release in the event a
1. Read and understand ALL warning tag information, backsliding load must be released from the tractor in
and become familiar with ALL controls BEFORE an emergency. The cable anchor or ferrule alone will
operating the winch. NOT support rated line pull. Therefore, a minimum of
five complete wraps of cable must be maintained on
2. NEVER attempt to clean oil or perform maintenance
the winch drum.
on a machine with the engine or prime mover running,
unless instructed to do so in this manual.
3. Before starting the tractor, be certain all controls NOTE: We suggest painting the last five wraps of cable
move freely and are placed in the brake-on (neutral) bright red to serve as a visual warning.
position.
4. NEVER operate the winch controls unless you are Recommended Operating Practices
properly positioned at the operator’s station, you are
sure ALL personnel are clear of the work area AND
you are properly trained in the operation of the winch. 1. Wear leather gloves when handling winch cable.
5. Assure that personnel who are responsible for hand 2. Operate the winch to match line speeds to job condi-
signals are clearly visible and that the signals to be tions.
used are thoroughly understood by all involved.
4
GENERAL SAFETY RECOMMENDATIONS
3. Assure that personnel responsible for hand signals 14. The winches described in this manual are neither
are clearly visible and that the signals are thoroughly designed nor intended for use with or application to
understood by everyone. equipment used in the lifting or moving of persons.
4. Inspect winch cable, rigging, winch and tractor at the 15. Install guarding to prevent personnel from getting any
beginning of each work shift. Defects should be cor- part of their body or clothing caught at a point where
rected immediately. the cable is wrapped onto the drum or drawn through
5. Position tractor for straightest line of pull to reduce fairlead guide rollers.
wear on winch cable and ensure even spooling. 16. Keep equipment in good operating condition. Perform
6. When winding winch cable on the winch drum, never scheduled servicing and adjustments listed in the
attempt to maintain tension by allowing winch cable Preventive Maintenance section of this manual. Use
to slip through hands. Always use hand-over-hand recommended lubricants.
technique, being careful to keep hands and clothing 17. An equipment warm-up procedure is recommended
away from winch drum and fairlead rollers. for all start-ups and essential at ambient temperatures
7. Be sure of tractor ground stability before winching in below +40ºF (5ºC). Refer to Warm-up Procedure
a load. listed in the Preventive Maintenance section of this
manual.
8. Store unused chokers, slings, and rigging in a neat
and orderly fashion to prevent damage to equipment 18. Never exceed 4 mph (6.4 km/hour) relative speed be-
or injury to personnel. tween the tractor and the load while in DRIVE-AWAY
mode. This relative limit applies when the tractor and/
9. Do not operate the winch under loads that exceed the
or the load are moving. Limiting the tractor to either
maximum rated bare drum line pull. For excessive
first or second gear typically prevents reaching ex-
loads, use a multipart line and sheave blocks. Any
cessive speed only when the tractor is moving. If the
attempt to exceed the capacity of one winch (such as
load and the tractor are moving, tractor and/or load
coupling two or more tractors together) is extremely
speed must be reduced so that relative speed does
hazardous.
not exceed the speed limit. Exceeding this relative
10. The factory-approved adaptions for CARCO winches speed limit will cause the part of the winch power train
are designed and intended for use on specific mod- connected in DRIVE-AWAY to reach damaging back-
els of crawler tractors. Changing winches between driven rotational speed and cause catastrophic winch
tractors is not possible in some cases because of failure, damage to property connected to winch, other
differ- ences in tractor models. Some changes cannot property damage, personal injury, or death.
be approved by CARCO because of safety limitations. 19. Drive-away should never be used with a suspended
Call a CARCO dealer or the CARCO factory prior to load, such as lowering heavy equipment down a hill.
attempting winch modifications or before mounting on Always use the reel-out function of the winch to lower
a different tractor. a load.
11. CARCO H Series winches are powered by the trac- 20. The correct drum wire rope capacity (length) and
tor hydraulic system. Discharge all retained hydraulic diameter are detailed in Service Bulletin Number
system pressure before removing any hydraulic lines LIT2435 for CARCO Winches, and LIT2436 for Cat-
or fittings. Personal injury may result from sudden erpillar Winches.
release of oil pressure. 21. Do not exceed the rated drum wire rope capacity of
12. To discharge the winch control system pressure, stop the winch. Never use a larger wire rope diameter than
the engine and cycle the winch control lever(s) into specified. Using too long of wire rope, or the wrong
all positions five times. Refer to the tractor manufac- size, can place excessive loads on the winch drum
turer’s service manual for additional information. and gear train. The length of tail chains, chokers, and
other end rigging count toward the maximum allow-
13. On machines having hydraulically, mechanically and/
able rope length, so if such equipment is used, the
or cable controlled equipment, be certain the equip-
rope length must be adjusted accordingly.
ment is either lowered to the ground or blocked
22. Never operate the winch with the wire rope on a higher
securely before servicing, adjusting, and/or repairing
layer than recommended. Never operate winch with
the winch. Always apply tractor parking brakes and
the wire rope outside the drum flange.
lower equipment before dismounting the tractor.
5
THEORY OF OPERATION
DESCRIPTION OF WINCH BASIC WINCH OPERATION
The winch assembly consists of six basic component The CARCO H200 winch contains a hydraulic motor and
groups: gear ratio specifically selected to match the winch to the
hydraulic power of the tractor. This allows the winch to
1. Winch case maximize the available hydraulic horsepower.
2. Hydraulic motor and piping
3. Brake housing assembly The winch motor is operated utilizing the full flow of the
4. Cable drum tractor implement pump via the implement valve, which
5. Planetary reduction group also controls both the blade and ripper. The ripper section
6. Drum clutch may be replaced with a special winch section to enhance
the winch performance capabilities. In any case, the valve
section used will be a four-way, three-position valve.
Typically, the winch control valve is connected to the oper-

ator’s joystick control lever by a series of hydraulic hoses.
Movement of the control lever directs the oil flow to the
winch motor through hydraulic lines. The hydraulic motor
converts the flow and pressure of the hydraulic system
into the mechanical energy needed to drive the winch gear
train.
The tractor operator can drive away from a winch load (at
no more than 4 mph (6.4 km/hour) to reposition the tractor
for another pull by releasing the spring-applied, hydraulic-
released drum clutch. When released, the cable drum can
rotate by back driving the final planet carrier, final planet
sun gear, secondary planet carrier and secondary sun
gear and friction discs. The gear train does not back drive
to the load-holding static brake or hydraulic motor when
Figure 1 the drum clutch is released. The drum clutch drag increas-
es as tractor ground speed increases due to the viscous
The winch case is a structural member of welded con- drag of the carrier clutch discs and gear train.
struction designed specifically for use in tractor winch ap-
plications. The case supports the output ring gear and the DUAL BRAKE SYSTEM – DESCRIPTION
brake housing assembly. The cable drum revolves on four
large tapered roller bearings. The hydraulic motor is bolted The dual brake system consists of a dynamic brake sys-
to the brake housing, which also supports the right-side tem and a static brake system. The dynamic brake system
cable drum bearings. The output ring gear supports the has two operating components:
left-side cable drum bearings.
1. Hydraulic Brake Valve Assembly
The planetary reduction group contains four planetary 2. Hydraulic Motor
gear sets driven by the primary sun gear shaft, which is
coupled to the motor shaft by the inner race of the over- The brake valve is similar to a counter-balance valve. It
running brake clutch assembly. With a total reduction of contains a check valve to allow free flow of oil to the motor
500:1, the planetary reduction group greatly multiplies the in the reel-in direction and a pilot-operated, spring-loaded
motor torque for high line pulls at maximum efficiency and spool valve, which blocks the flow of oil out of the mo-
precise load control. tor when the control valve is placed in neutral. When the
6
THEORY OF OPERATION
control valve is moved into the reel-out position, the spool

in the brake valve remains closed until sufficient pilot pres-
sure is applied to the end of the spool to shift it against the
spring pressure and open a passage. After the spool valve
cracks open, the pilot pressure becomes flow dependent
and modulates the spool valve opening which controls the
reel-out speed. See Figures 2, 3, and 4.
The static brake system has three operating components:

Figure 2.
Reel-in 1. Spring-applied, multiple friction disc static brake
2. Sprag-type overrunning brake clutch assembly
3. Hydraulic piston and cylinder
Low pressure The static brake is released by the brake valve pilot pres-
Med. pressure sure at a pressure lower than that required to open the
High pressure pilot-operated spool valve in the brake valve assembly.
This sequence assures that dynamic braking takes place
in the brake valve and that little, if any, heat is absorbed by
the friction discs.
The friction brake is a load-holding brake only and has

nothing to do with dynamic braking or the rate of lowering
of a heavy or suspended load.
The overrunning brake clutch is splined to the primary sun

gear shaft between the motor and the primary sun gear. It
Figure 3. will allow this shaft to turn freely in the direction of reel-in,
Reel-out and lock up to force the brake discs to turn with the shaft
in the direction of reel-out (Figures 5 and 6).
Low pressure
Med. pressure
High pressure
Figure 5. Static fric-

tion brake applied.
Permits free shaft ro-
tation during reel-in.
Figure 4.
Reel-out
Figure 6. Static fric-
tion brake applied.
Load attempts to
Low pressure rotate shaft in oppo-
Med. pressure site direction. Brake
High pressure clutch locks sun
gear shaft to friction
brake.
7
THEORY OF OPERATION
The hydraulic cylinder, when pressurized, will release the REEL-IN

spring pressure on the brake discs, allowing the brake Moving the control lever in the direction of tractor forward
discs to turn freely. movement provides a signal to direct the oil to the winch
motor to pull the cable and load in to the winch. REEL-IN
DUAL BRAKE SYSTEM – OPERATION drum speed is proportional to the amount of lever move-
ment and the amount of load on the on the winch. When
When pulling in a load (reel-in), the overrunning brake released, the lever will return to BRAKE-ON and the winch
clutch, which connects the motor shaft to the primary sun drum will stop and hold the load firm.
gear, allows free rotation through the gear train to the ca-
ble drum. The sprag cams lay over and permit the inner
race to turn free of the outer race (Figure 5). The friction
brake remains fully applied. The winch, while reeling in a
load, is not affected by any braking action.
When the reel-in operation is stopped, the load attempts

to turn the primary sun gear in the opposite direction. This
reversed input causes the sprag cams to instantly roll up-
ward and firmly lock the shaft to the fully applied friction
brake (Figure 6).
When the winch is powered in reverse, to reel-out the

load, the motor cannot rotate until sufficient pilot pressure
is present to open the brake valve. The friction brake with- REEL-OUT
in the winch will completely release at a pressure lower Moving the control lever in the direction of tractor reverse
than that required to open the brake valve, typically 350 movement provides a signal to direct the oil to the winch
PSI (24.1 bar) and 600 PSI (41.4 bar), respectively. The motor to rotate in the direction to power out the cable.
extent to which the brake valve opens will determine the
amount of oil that can flow through it and the speed at REEL-OUT drum speed is proportional to the amount of
which the load will reel-out. Increasing the flow of oil to the lever movement. When released, the lever will return to
winch motor will cause the pressure to rise and the open- BRAKE-ON and the winch drum will stop and hold the load
ing in the brake valve to enlarge, speeding up the release firm.
of the load. Decreasing this flow causes the pressure to
lower and the opening in the brake valve to decrease, thus NOTE: When operating in REEL-OUT mode, the pressure
slowing the release of the load. compensator within the motor is disabled and the winch
will work in high-speed mode ONLY. This feature ensures
With the control valve shifted to neutral, the pressure will control of loads lowered on hillsides, such as yo-yo opera-
drop and the brake valve will close, stopping the load. The tions on pipeline right-of-ways.
friction brake will reapply and hold the load after the brake
has closed. DRUM CLUTCH RELEASE (DRIVE-AWAY)
Depending on the installation of your tractor controls, ei-
The friction brake receives little wear during the reel-out ther pushing the control lever away from the operator to-
operation. Most of the heat generated by the releasing ward the right side of the tractor, or activating the DRIVE-
and stopping of the load is absorbed into the hydraulic oil AWAY switch provides a signal to direct the oil to release
where it can be readily dissipated. the drum clutch. With the drum clutch released, the opera-
tor can slowly drive away from a load using the inherent
CONTROL OPERATION resistance of the final two planetary gear stages to keep a
tight wrap of cable on the drum and prevent cable overrun.
BRAKE-ON (NEUTRAL)
When the winch is not in operation or when the control When DRIVE-AWAY is activated, oil in the drum clutch re-
lever is released, the handle returns to the center or lease cavity is blocked, causing the drum clutch to remain
BRAKE-ON position by spring force. Any load attached to released indefinitely. The control lever must be returned to
the winch cable is held firm. BRAKE-ON, then momentarily moved into any other posi-
tion to cause the drum clutch to reengage and exhaust
the oil back to the reservoir. As long as the DRIVE-AWAY
function is active, an indicator light on the main instrument
panel in front of the operator will remain lit.
8
THEORY OF OPERATION
on the work ports (A and B) increases due to the load ap-

! CAUTION ! plied to the winch gear train. When there is little or no load
on the winch, the motor rotating group will remain at the
preset minimum displacement. As the winch load increas-
Never exceed 4 mph (6.4 km/hour) relative speed be- es, the pressure at the motor work ports will increase. This
tween the tractor and the load while in DRIVE-AWAY same pressure will also act on the load-sensing system in
mode. This relative limit applies when the tractor and/ the motor. As the load-sensing system experiences more
or the load are moving. Limiting the tractor to either pressure, it increases the motor displacement to provide
first or second gear typically prevents reaching ex- increased torque, or pulling power, at a slower line speed.
cessive speed only when the tractor is moving. If the
load and the tractor are moving, tractor and/or load In this manner, the motor displacement will automatically
speed must be reduced so that relative speed does adjust to provide the maximum hydraulic horsepower for
not exceed the speed limit. Exceeding this relative any given line speed and line pull situation.
speed limit will cause the part of the winch power train
connected in DRIVE-AWAY to reach damaging back- LOW-SPEED LOCK MODE (LOW LOCK)
driven rotational speed and cause catastrophic winch Depressing the button near the top of the control lever will
failure, damage to property connected to winch, other force the variable displacement motor to shift the piston
property damage, personal injury, or death. to the maximum displacement position, which will allow
the winch to operate in the maximum line pull, minimum
line speed mode, to enhance precise load control. When
shifted into LOW-LOCK, an indicator light on the main
! WARNING ! operator instrument panel will remain lit. To disable LOW
LOCK, and return to autospeed mode, press the button
DO NOT use the drum clutch release (DRIVE-AWAY) again. The indicator light will be off.
for controlled reeling out of suspended loads. Sudden
release of a load may result in property damage, in- WINCH LOCK-OUT
jury, or death. Use only REEL-OUT to lower any load. Winch lock-out is available on some but not all CAT doz-
ers. If your model is equipped for lock-out, a toggle switch
located on the operator’s right console adjacent to the
winch control lever may be switched to completely lock out
the hydraulic signal to the winch. This can be performed
AUTOSPEED MODE during servicing, or to eliminate the possibility of acciden-
From the operator’s perspective, this is the normal and tal winch actuation when performing general dozing op-
most simple winch control method. erations. When activated, an indicator light on the main
operator instrument panel will remain lit.
The winch line speed, or drum rotation speed, may be
controlled by moving the control lever a small distance or
by operating the tractor engine, and therefore the tractor
implement pump, at a lower RPM.
NOTE: Operating the tractor engine at the lowest idle set-

ting while winching may result in erratic winch operation. ! CAUTION !
Always operate the tractor at high engine idle to provide
the full range of performance from the winch and the The hydraulic motor and gear ratio is configured to
smoothest control. Operating the engine at lower settings match the hydraulic system of a specific tractor. It
will NOT provide slower controlled winching. may not be possible to mount the winch onto a dif-
ferent tractor model. Installation onto a tractor with
The hydraulic motor used with the autospeed control sys- a higher flow hydraulic system could result in over-
tem is a variable displacement, piston-type motor with an speed damage to the motor and winch gear train.
internal load-sense circuit. This circuit contains a small The maximum drum RPM in autospeed, no-load, with
piston which adjusts the angle of the motor rotating group a piston motor, is listed below:
from minimum to maximum displacement as the pressure H200 500:1 9 RPM (+0, -1)
9
PREVENTIVE MAINTENANCE
A regular program of preventive maintenance for your GEAR CASE OIL CHANGE
CARCO winch will minimize the need for emergency ser-
vicing and promote long product life and trouble-free ser-
vice. ! WARNING !
The service intervals suggested in this manual will opti- Hot oil may cause injury. Make certain the oil has
mize component service life. The intervals may be gradu- cooled to a safe temperature (less than 110ºF or
ally increased or decreased with experience of a particular 43ºC) before servicing winch.
lubricant and evaluation of your application.
Change the winch gear case oil after the first 100–250
hours of operation, then every 1,000 hours or six months,
whichever occurs first.
Remove the drain plug located at the bottom of the drum

clutch housing. Drain the oil into a suitable container and
recycle or dispose of the used oil in an environmentally re-
Oil fill sponsible manner. Contact your local government agency
and vent for information concerning proper disposal. Install the plug
securely after draining the oil. To reduce oil drain time, re-
move the filler/vent plug.
Oil level
Refill the winch to the sight glass with the recommended
oil. Allow 15 minutes for oil to flow through the gear train
Oil drain and fill the cable drum cavity before checking the oil level.
GEAR CASE OIL ! CAUTION !

The winch assembly should be visually inspected for leaks DO NOT operate the winch while the oil is drained.
at the beginning of each workday. If you find oil leaks, Serious damage to internal components may result.
check the gear case oil level. If no leaks are detected, the
oil level may be checked once every 250 hours or monthly. Oil capacity: approximately 35 qt. (33 L).
The oil level plug is located at the horizontal centerline on
the drum clutch housing. Position the tractor on a flat, level VENT PLUG
surface and remove the plug. The oil should be at the bot-
tom of the level plug hole. The vent plug is installed in the oil filler plug located near
the top of the drum clutch housing. Whenever the oil is
Add oil as required through the oil filler plug located near changed, remove the vent plug, clean in safety solvent
the top of the drum clutch housing. Add oil slowly, because and reinstall.
the oil must pass through the gear train and fill the drum
cavity. NOTE: Do not replace the vent plug with a solid plug.
The normal expansion of the gear oil during operation will
Refer to the recommended oil chart for the proper oil for cause a build-up of pressure in the gear case, which may
your application. lead to seal leakage.
TRACTOR HYDRAULIC RESERVOIR LEVEL WINCH CABLE (WIRE ROPE)
Check the tractor hydraulic oil reservoir level at the sight Inspect the entire length of wire rope and hook in accor-
glass daily or in accordance with the tractor manufactur- dance with the rigging manufacturer’s recommendations.
er’s recommendations. Use the type of hydraulic oil rec-
ommended by the tractor manufacturer. MOUNTING FASTENERS
Change the tractor hydraulic oil and filter every 1,000 Check all winch-mounting fasteners and tighten to recom-
hours or in accordance with the tractor manufacturer’s mended torque after the first 100–250 hours of operation,
recommendations. then every 1,000 operating hours or six months, which-
ever occurs first.
10
PREVENTIVE MAINTENANCE
WARM-UP PROCEDURE grease until a small amount pushes out around the shaft.
Use a high-quality 12-hydroxy stearate lithium-based
The tractor engine should be run in accordance with the product, which contains an EP additive, such as Moly, and
tractor manufacturer’s recommendations to warm up the meets or exceeds an NLGI Grade 2 specification.
hydraulic system. Use cold-weather oil as recommended
in the tractor hydraulic system instructions. INSPECTION
FAIRLEAD ROLLERS Disassemble winch every 10,000 hours or four years,

whichever occurs first, for a thorough inspection of all
Grease the fairlead rollers at the beginning of each work- wear items. Refer to the disassembly and assembly sec-
day. Roller shafts have grease fittings at both ends. Apply tions of this manual for additional information.
SPECIFICATIONS
Base unit weight: 7,040 lbs. (3,193 kg) RECOMMENDED OIL

Gear ratio: 500:1
Motor: two-speed hydraulic; 6.53 cu.in./rev. low-speed; The following specifications will help determine which
3.00 cu.in./rev. high-speed; lubricant is best suited to your application. The oil must
3,500 PSI start of compensation possess high-temperature oxidation stability, rust and cor-
Rope diameter: 1.5 in. (38 mm) rosion protection, good dispersant and detergent charac-
Rope storage: 210 ft. (64 m) teristics, antiwear additives, and remain compatible with
Drawbar: Ø3-inch pin, 4.5-inch opening nitrile-based seals.
Cable drum barrel diameter: 15 in. (381 mm)
Cable drum flange diameter: 28.37 in. (721 mm) Your lubricant supplier should assure you that his product
Cable drum barrel length: 14.87 in. (378 mm) meets this specification. If there is any doubt of the suit-
Bare drum rated line pull*: 200,000 lbs. (90,718 kg) ability of a lubricant, contact the PACCAR Winch Service
Bare drum rated line speed: 37.1 ft./min. (11.3 meters Department, providing a copy of the product specifications.
min.)
Gear oil capacity: 35 pints / 17.5 qt. (16.5 L)
Static brake-release pressure: approx. 305 PSI (21 bar)
Drum clutch-release pressure: 215–350 PSI (15–24 bar)
* NOTE: Actual performance varies. The tractor's hydrau-

lic system characteristics determine maximum line pull
and speed.
11
RECOMMENDED PLANETARY GEAR OIL
Field experience, supported by engineering endurance tests, indicates that the use of the proper gear oil and a
program of regular preventive maintenance will help provide extended gear-train life and reliable winch-brake perfor-
mance. For this reason, CARCO has published the following specifications to assist in determining which lubricant is
best suited to your application.
For simplicity, CARCO has listed available products in each temperature range that have been tested and found to
meet our specifications. This is not to say that other lubricant brands would not perform equally as well.
If the following lubricant brands are not available in your area, make certain your lubricant vendor supplies you with
oil equivalent to those products listed below.
RECOMMENDED GEAR OIL

PREVAILING AMBIENT TEMPERATURE
oF -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 oF
Use gear oil detailed in Range A
Use gear oil detailed in Range B
Use gear oil detailed in Range C
oC -40 -30 -20 -10 0 10 20 30 40 50 oC
SHADED TEMPERATURE RANGE IN THE CHART ABOVE NOT RECOMMENDED FOR SEVERE APPLICATIONS SUCH AS SUSTAINED
FAST DUTY CYCLES OR FREQUENT WINCHING.
Winches are factory filled with Mobilgear 600 XP 150 or equivalent. Consult your oil supplier for other equivalent
oils if required.
Mobil Shell Chevron Texaco
Range A Mobilgear 600 XP 220 Omala S2 G 220 Gear Compounds EP 220 Meropa 220
Range B Mobilgear 600 XP 150 Omala S2 G 150 Gear Compounds EP 150 Meropa 150
Range C Mobilgear SHC 150 Omala S4 GX 150
Unless otherwise specified, it is recommended to change gear oil after the first 100 hours or two months of machine
operation, then every 1,000 hours or six months, whichever occurs first. The gear oil should also be changed when-
ever the ambient temperature changes significantly and an oil from a different temperature range would be more
appropriate.
A warm-up procedure is recommended at each start-up and is essential at ambient temperatures below +40ºF (4ºC).
The prime mover should be run at its lowest recommended RPM with the hydraulic winch control valve in the neutral
position allowing sufficient time to warm up the system. The winch should then be operated at low speeds; raise and
lower several times to prime all lines with warm hydraulic oil and to circulate gear lubricant through the planetary gear
sets.
! WARNING !
Cold start-up in the ambient temperature range requires extended equipment warm-up to prevent erratic clutch
and brake operation which may result in property damage, injury, or death. Failure to properly warm up the winch,
particularly under low ambient temperature conditions, may result in temporary brake slippage due to high back pres-
sures attempting to release the brake. This also could result in property damage, severe personal injury, or death.
12
! WARNING !
Failure to use the proper type and viscosity of planetary gear oil may contribute to intermittent brake clutch slippage,
which could result in property damage, severe personal injury, or death. Some gear lubricants contain large amounts
of extreme-pressure (EP) and antifriction additives, which may contribute to brake clutch slippage or damage to brake
friction discs or seals. NOTE: DO NOT use oil that is labeled as meeting “API Service GL-5.” Oil viscosity, af-
fected by ambient temperature, is also critical to reliable brake clutch operation. Our tests indicate excessively heavy
or thick gear oil may contribute to intermittent brake clutch slippage. Make certain the gear oil viscosity used in your
winch is correct for your prevailing ambient temperature.
WIRE ROPE INSTALLATION
All winches are rated at bare drum line pull. As the INSTALLATION OF SPIRAL FERRULES
cable drum fills, the line pull will decrease (loss of lever-
age) as the line speed increases (larger circumference). Reusable, field-installed spiral ferrules are available from
Therefore, install the minimum length of cable possible your CARCO or wire rope dealer. The ferrules are for use
for your application so that the winch will operate on lower with standard six-strand, Independent Wire Rope Core
layers (smaller diameter) and deliver the maximum line (IWRC)-type wire rope.
pull.
Using larger cable will not always increase strength, as
the larger cable may be more prone to bending fatigue Step 1
failure than smaller wire rope. Consult your wire rope sup-
plier for his recommendations for the wire rope and other
rigging which best suits your application.
Insert cable through the small opening of the fer-

rule. Spread strands and insert spiral wedges between
strands and core. Lay strands in individual grooves in
spiral wedges.
! WARNING !
Step 2
Winch cable anchors (ferrules and ferrule pocket)
are NOT designed to hold rated loads. Winch loads
applied directly to the cable anchor may cause the
cable to pull free and result in the sudden loss of load
control and cause property damage, personal injury, Tap wedges and cable into the ferrule leaving approxi-
or death. A minimum of five wraps of cable must mately 3/8 inch (10 mm) extending from the top. The first
be left on the drum barrel to achieve rated load. load will seat cable and wedges securely in the ferrule.
Do not use knots to secure or attach winch cable. We
suggest that the last five wraps of cable be painted
Do not exceed the rated drum wire rope capacity of the winch.
bright red to serve as a visual warning.
Never use a larger wire rope diameter than specified. Using too
long of wire rope, or the wrong size, can place excessive loads
on the winch drum and gear train. The length of tail chains, chok-
ers, and other end rigging count toward the maximum allowable
rope length, so if such equipment is used, the rope length must
be adjusted accordingly.
Never operate the winch with the wire rope on a higher layer
than recommended. Never operate winch with the wire rope out-
side the drum flange.
13
TROUBLESHOOTING
After troubleshooting the winch and its hydraulic system as covered in the Troubleshooting section of this manual, and
the problem is determined to be in the winch, disassemble the winch according to the Winch Disassembly section of
this manual.
TROUBLE PROBABLE CAUSE REMEDY

A
Winch will not smoothly reel-out 1. The problem could be a plugged A. Disassemble the brake valve. Clean
the load, or smoothly lower a sus- pilot orifice in the brake valve. and inspect all parts. Make certain the
pended load. A plugged orifice may prevent .020 inch (0.5 mm) pilot orifice is not
the spool from moving or prevent obstructed.
the spool from moving smoothly,
causing jumping or chattering as
the load is released.
2. The multidisc static brake may not A. Check the brake cylinder seal as fol-
be releasing as a result of a defec- lows:
tive brake cylinder seal.
Disconnect the small hose from the brake
NOTE: If the brake cylinder seal is release port. Connect a hand pump with
defective, you may notice oil leak- an accurate gauge and shut-off valve to
ing from the winch vent plug as the –4 fitting in the brake release port.
hydraulic oil fills the gear cavity.
Apply 1,000 PSI (68.9 bar) to the brake.
Close the shut-off valve and let stand for
five minutes.
If there is any loss of pressure during the

five minutes, the brake housing assem-
bly should be disassembled for inspec-
tion of the brake cylinder and piston
sealing surfaces and replacement of the
seals. Refer to Brake Housing Assembly
Service for more information.
3. The multidisc static brake will not A. Disassemble the brake housing
release as a result of damaged assembly to inspect the brake discs.
brake discs. Replace the brake discs as required.
B
Oil leaks from vent plug. 1. Same as A2. A. Same as A2A.
2. Motor seal may be defective as a A. Case drain circuit back pressure must
result of high system back pres- not exceed 30 PSI (2 bar) measured at
sure or contaminated oil. the case drain port. Inspect the hydraulic
system for a restriction.
B. Oil analysis may indicate contamina-

tion, which could result in a worn motor
shaft and seal. Thoroughly flush the
entire hydraulic system and install new
filters and oil. Install a new motor seal or
replace the motor as needed.
14
TROUBLESHOOTING

B
TROUBLE “B” CONTINUED 3. The drum clutch piston seals may A. Disconnect the drum clutch release
FROM PREVIOUS PAGE be leaking. hose from the drum clutch housing.
Connect a hand pump with an accu-
rate gauge and shut-off valve to the –6
adapter.
B. Apply 500 PSI (34.5 bar) to the drum

clutch. Close the shut-off valve and let
stand for five minutes.
C. If there is a loss of pressure during

the five minutes, the drum clutch hous-
ing must be removed and disassembled
for inspection of the seals and sealing
surfaces. Refer to Drum Clutch Service
section of this manual for additional infor-
mation.
C
Brake will not hold a load with the 1. Excessive system back pressure A. The pressure at the lowering port of
control lever in neutral. acting on the brake release port. the motor is also directed to the brake
release port. This pressure must drop
below 50 PSI (3.4 bar) when the con-
trols are returned to neutral, BRAKE-ON.
Trace the hydraulic circuit back to the
reservoir to locate source of back pres-
sure.
2. Friction brake will not hold due to A. Same as A3A.

worn or damaged brake discs.
3. Brake clutch may be slipping. A. Improper planetary gear oil may cause
the brake clutch to slip. Drain the old gear
oil and flush the winch with a mild sol-
vent. Thoroughly drain the cleaning sol-
vent, and refill the winch with the recom-
mended gear oil listed in the Preventive
Maintenance section.
B. Overrunning brake clutch may be worn

or damaged. Disassemble and inspect as
described in Overrunning Brake Clutch
Service section of this manual.
4. If winch was field installed, check
to see that the proper stack valve
section was used (motor spool
required).
5. Drum clutch discs may be worn. A. Disassemble and inspect drum clutch
components as described in Drum Clutch
Service section.
15
TROUBLESHOOTING

D
Winch will not pull the rated load. 1. The hydraulic system relief valve A. Check system relief pressure as fol-
may be set too low. The relief lows:
valve may need repair or replace-
ment. Install an accurate gauge into the trac-
tor 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 necessary.
NOTE: Refer to the tractor service man-

ual for more information regarding the
system relief valve.
2. Be certain the hydraulic system A. Check system relief valve, per D1A.
temperature is not more than
200ºF (93ºC). Excessive hydraulic B. Same as E2A.
oil temperatures increase motor
and pump internal leakage.
3. Winch line pull rating is based on A. Refer to winch performance data for
first layer of wire rope. more information.
4. Same as C5. A. Same as C5A.
5. Hydraulic motor locked in high A. Send motor to qualified motor service

speed, small displacement posi- center.
tion.
16
TROUBLESHOOTING

E
Winch runs hot. 1. Be certain the hydraulic system Same as D1A.

temperature is not more than
200ºF (93ºC). Excessive hydraulic
oil temperatures may be caused
by:
A. Plugged heat exchanger (where A. Thoroughly clean exterior and flush

used). interior of heat exchanger.
B. Too low or too high oil level in B. Fill or drain reservoir to proper level.
hydraulic reservoir.
C. Tractor hydraulic pump not operat- C. Tractor low on horsepower or RPM.

ing efficiently. Tune-up or adjust tractor engine for opti-
mum performance. See tractor service
manual for more information.
Check suction line for damage.
Pump worn or damaged. Inspect or

replace pump as needed. See tractor
service manual for more information.
2. Excessively worn or damaged A. Disassemble winch for inspection or

internal winch components. replacement of worn or defective compo-
nents.
! WARNING !
If a winch exhibits any sign of erratic operation or
load-control difficulties (such as load creeping or
chattering), appropriate troubleshooting tests and
repairs must be performed immediately. Continued
operation under any of these conditions may result
in loss of load control, property damage, serious per-
sonal injury, or death.
17
TROUBLESHOOTING

F
Winch chatters while pulling rated 1. Same as D1. A. Same as D1A.

load.
2. Hydraulic oil flow to motor may be A. Same as E1B, C, D; operate engine at
too low. full throttle.
3. Controls operated too quickly or A. Conduct operator training as required.

not smoothly.
G
Wire rope does not spool smooth- 1. Incorrect wire rope lay used. There A. Consult your wire rope supplier for rec-
ly on the cable drum. is a distinct advantage in applying ommendation of the wire rope best suited
wire rope of the proper direction for your specific application.
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 reeling in is
resumed, the wire rope has a ten-
dency to crisscross and overlap
on the drum. The possible result
is flattened and crushed wire rope,
ultimately resulting in diminished
rope life.
2. The winch may have been over- A. Replace the wire rope and conduct
loaded, causing permanent set in operator training as required.
the wire rope.
18
H200 MAJOR PARTS GROUPS CROSS-SECTION
Part number 88141
19
H200 MAJOR PARTS GROUPS COMPONENTS
Part number 88141
ITEM DESCRIPTION PART NO. QTY.

NO.
000 Ratio group, H200-500 63418 1
100 Miscellaneous parts group H200 63420 1
200 Fairlead group 65297 1
300 Brake assembly, V 83107 1
400 Overrunning clutch assembly, V 83109 1
500 Hydraulic motor group H200A 63940 1
ADDITIONAL REFERENCE
PUBLICATION
For cross-section diagrams and

complete list of components, please
refer to LIT2750: Parts List for H200
tail winches.
SERVICE PRECAUTIONS
1. Before removing any part from the winch, read and understand all service instructions.
2. Work in a clean, dust-free area because cleanliness is of utmost importance when servicing hydraulic equipment.
3. Inspect all replacement parts, prior to installation, for any damage that may have occurred in shipment.
4. Use only genuine CARCO winch replacement parts, which may be obtained through your CARCO dealer. Never
reuse expendable parts such as O-rings.
5. Inspect all machined surfaces for excessive wear or damage before starting reassembly operations.
6. Lubricate all O-rings and oil seals with gear oil prior to installation.
7. Use a sealing compound on the outside surfaces of oil seals. If using a thread sealant, avoid getting excess sealant
inside parts or passages that conduct oil.
8. Thoroughly clean all parts in a quality grade of safety solvent. Wear protective clothing as required.
9. This winch and its components are very heavy. Use extreme caution when disassembling and reassembling. It is
recommended to use a certified crane with lifting gear capable of lifting the weights listed in this manual.
10. It is highly recommended that all disassembly and reassembly be performed in a vertical fashion. This will aid in
better axial alignment and prevent unnecessary damage.
20
WINCH REMOVAL AND INSTALLATION
Cleanliness around all hydraulic components is of utmost

importance. Before starting any repair procedures, thor-
oughly clean the parts to be removed, as well as adjacent ! WARNING !
areas of the tractor, to avoid entry of dirt into the winch and
winch control system. Do not leave any ports or access Winch weighs approximately 7,040 lbs. (3,193 kg)
openings exposed to the weather. Seal or cap the open- without oil, cable and tractor adapters. Make cer-
ings to prevent entry of dust, moisture or other foreign ma- tain the lifting equipment has adequate capacity. At-
terial. Cap or plug all exposed hydraulic ports and fittings. tempting to lift the winch with inadequate equipment
may result in personal injury and product or property
During disassembly, be careful not to damage seals and damage.
O-rings to be reused. Replace any damaged or defective
parts. Certain O-rings and seals specified in the replace-
ment instructions must not be reused. In general, seals and Support the winch with a suitable hoist or platform and
O-rings that work under operating hydraulic pressures, or remove the nuts and bolts securing the winch to the tractor
that require extensive disassembly to replace, should be adapters, and move the winch away from the tractor.
replaced with new parts at the time of reassembly.
WINCH INSTALLATION
WINCH REMOVAL
For first-time installation, contact PACCAR Winch Engi-
neering for your specific tractor. A detailed scope of work
! WARNING ! is put forth in this document and describes all tractor modi-
fications and adaptation.
Before servicing, make sure any trapped oil pressure Remove dirt, paint and rust from the mounting surfaces of
in the tractor hydraulic system has been relieved. the winch and tractor adapters.
Personal injury may result from a sudden release of
oil pressure. Relieve trapped pressure by cycling the Align the winch-mounting holes with the adapter mounting
blade and winch control levers several times after holes, and install and tighten all fasteners to the recom-
turning off the tractor engine. Relieve any trapped oil mended torque.
pressure in the hydraulic reservoir by opening the fill
cap. Be sure to activate the winch or tractor hydrau-
lic system lock-out toggle switch(es) or as directed in
the tractor service manual.
! CAUTION !
Failure to fill the motor case with hydraulic oil before
operating the winch may result in serious damage to
! WARNING ! the motor.
Hot oil may cause injury. Make certain the oil has
Fill the hydraulic motor case, through the motor case drain
cooled to a safe temperature (less than 110ºF or
port, with tractor hydraulic oil. Attach the winch control
43ºC) before servicing winch.
hoses to the motor, as defined in the parts and installation
Place the tractor and winch in a level position and drain manual.
the oil from the winch into a suitable container. Install the
drain plug securely after oil has drained completely. Fill the winch to the proper level with the recommended oil.
Allow five minutes for the oil to flow through the gear train
NOTE: Due to the configuration of the cable drum, a small and fill the drum cavity before checking the oil level.
amount of oil will remain within the drum cavity.
Start the tractor engine and operate the engine at low
Remove the winch motor hoses from the motor and brake RPM. Alternately, place the winch control in the reel-in,
valve. Remove the motor shift hose from the motor X port. then the reel-out position until the winch motor hydraulic
Remove the motor drain hose from the motor. Remove the circuit is filled with oil and the winch operates smoothly.
drum clutch hose from the elbow on the right of the winch Check the tractor hydraulic oil reservoir and fill to the prop-
case. er level as required.
21
WINCH DISASSEMBLY
1. Remove the wire rope from the cable drum BEFORE disconnecting the hydraulic lines from the winch motor.
2. Drain the gear case oil as described in the Preventive Maintenance section of this manual.
Oil fill
and vent
Oil level
Oil drain
3. Disconnect hydraulic and electrical lines from the winch to the tractor. Take precautions so that hydraulic oil does
not leak from the tractor hydraulic lines onto the ground. Cap or plug all connectors and ports to prevent leakage
and contamination.
4. Using caution, remove the winch from the tractor mounting brackets. Take note of the weight of the base winch from
the Specifications section of this manual. Use an appropriately sized crane and lifting equipment that can handle
the weight. It is recommended to use a lift plan to ensure safety during disassembly.
5. Remove the hose guard (Item 179) from the left of the winch and disconnect the drum clutch hose.
6. Remove the cap screws and washers (171, 172) that secure the end cover (167) to the ring gear assembly. Remove
the cover and inspect or replace O-ring (170). Remove the thrust bearing set (159 thrust race, 160 needle bearing,
and 161 thrust washer) from around the primary planet carrier hub. Remove the 20 drum clutch springs (151).
7. Remove retaining rings (166) and primary sun gear (63). Remove the primary carrier assembly (600). Remove the
thrust bearing set (2x 168 thrust washers, 169 thrust bearing). Refer to the Primary Carrier Assembly Service sec-
tion of this manual for service procedures.
! CAUTION !
Needle roller thrust bearings are used throughout the
planetary reduction group. Handle these bearings
with care. If dropped, the metal cage separating the
rollers may be damaged, which will result in bearing
failure and possible damage to the winch gear train
if reused.
22
WINCH DISASSEMBLY
Drum clutch
hose
600
166
179
167 63 168,169
159,160,161
151
170
171,172
8. Remove the secondary sun gear (Item 44) and inspect snap ring (143).
9. Remove the secondary carrier assembly (700). Remove thrust bearing set (2x 164 thrust race, 165 needle roller
bearing). Refer to the Secondary Carrier Assembly Service section for service procedures.
10. Remove the intermediate shaft (62). The intermediate shaft weighs approximately 28 lbs. (13 kg).
11. Remove the cap screws and washers (113, 116) that secure the drum clutch assembly (950) to the ring gear (16).
Remove the drum clutch assembly (950). Use caution because the drum clutch assembly weighs approximately
620 lbs. (281 kg). Refer to the Drum Clutch Assembly Service section of this manual for service procedures.
! CAUTION !
The primary planet carrier assembly (600) weighs
approximately 16 lbs. (7 kg). The secondary planet
carrier assembly (700) weighs approximately 35
lbs. (16 kg). The third planet carrier assembly (800)
weighs approximately 136 lbs. (62 kg). The output
planet carrier assembly (900) weighs approximately
370 lbs. (168 kg). The drum clutch assembly (950)
weighs approximately 615 lbs. (279 kg). The drum
shaft (22) weighs approximately 110 lbs. (50 kg).
Damage to parts or personal injury can occur if pre-
cautions are not taken. Make certain lifting equip-
ment has adequate capacity.
23
WINCH DISASSEMBLY
175
164,165
16
800 21
950
46
700
44 113,116
143
12. Remove the third sun gear (46) and the third carrier assembly (800). Use caution because the third carrier assembly
weighs approximately 136 lbs. (62 kg). Refer to the Third Carrier Assembly Service section for service procedures.
13. Remove thrust washer (21). Remove the two socket-head cap screws (175) from ring gear (16). Remove ring gear
(16). The ring gear weighs approximately 171 lbs. (78 kg).
14. 1/2 -13 threaded bolt holes are machined into the output planet carrier pins to aid in removal. Remove output planet
carrier assembly (900) and drum shaft (22). Refer to the Output Planet Carrier Assembly Service section of this
manual for service procedures. The output planet carrier assembly (900) weighs approximately 370 lbs. (168 kg).
Jack hole
1"-8
117,118
14
Use 1/2-13
eyebolt
112
147
22
145 146
900
24
WINCH DISASSEMBLY
15. Remove thrust washer (Item 145) and wear plate (146), then inspect for wear or damage.
16. Support the drum in the winch housing by using wooden blocks or other suitable means. Once either the support
adapter (147) or the brake (300) has been removed, the drum will no longer be supported in the frame. Make sure
the drum is supported by means so that it remains stable in the housing during disassembly.
17. Remove cap screws and washers (117, 118) from the support adapter (147). It is necessary to remove the output
ring gear (14) and support adapter (147) at the same time. There are two 1”-8 threaded, “Jack” holes located 180
degrees apart on the support adapter. If necessary, utilize these holes to remove the support adapter by using 1”-8
size bolts and prying the support adapter off of the winch housing. If necessary, take apart the output ring gear (14)
and support adapter (147) by removing the socket-head cap screws (112) from the backside of the support adapter.
! CAUTION ! ! CAUTION !
The support adapter (147) weighs approximately The motor cover (137) weighs approximately 108 lbs.
600 lbs. (272 kg.) The output ring gear (14) weighs (49 kg). The hydraulic motor assembly (500) weighs
approximately 320 lbs. (145 kg). Damage to parts approximately 110 lbs. (50 kg). The brake assembly
or personal injury can occur if precautions are not (300) weighs approximately 140 lbs. (64 kg). The ca-
taken. Make certain lifting equipment has adequate ble drum (102) weighs approximately 1,000 lbs. (454
capacity. kg). Damage to parts or personal injury can occur if
precautions are not taken. Ensure lifting equipment
has adequate capacity.
18. Remove the motor cover (137) from the winch. Install a 1/2-13 eyebolt into the lifting hole in the top center of the
cover and lift with a hoist or overhead crane. The motor cover weighs approximately 108 lbs. (49 kg).
400
300
133,132
500
137
150
Lifting hole
19. Disconnect the brake release hose (150) from the long adapter on the brake housing (300).
20. Support the hydraulic motor assembly (500) securely with a lifting strap and hoist. Remove the cap screws and
washers (167, 168) that fasten the solenoid manifold valve (162) from the winch. Remove the motor mounting fas-
teners (133, 132). Carefully remove the hydraulic motor from the winch. The hydraulic motor weighs approximately
97 lbs. (44 kg).
25
WINCH DISASSEMBLY
21. Remove the overrunning clutch (Item 400) from inside the brake assembly (300). Refer to the Overrunning Clutch
Service section of this manual for service procedures.
22. Make sure the drum is well supported in the winch housing before removal of the brake assembly.
23. Remove the cap screws and washers (149, 150) securing the brake assembly (300) to the winch housing. Carefully
remove the brake assembly from the winch case. Refer to the Brake Assembly Service section for service proce-
dures. The brake assembly (300) weighs approximately 140 lbs. (64 kg).
NOTE: To aid handling, a brake cylinder lifting fixture similar to that illustrated in the back of this manual may be fabri-
cated. The fixture is fastened to the two motor-mounting holes and will assist in balancing the assembly during removal
and installation.
24. Remove the cable drum assembly through the rear opening of the winch housing. Refer to the Cable Drum Service
section of this manual for specific service procedures. The cable drum (102) weighs approximately 1,000 lbs. (454
kg).
25. To remove each vertical roller assembly (201), place a wide-band sling or other positive-retention method under
the roller. Remove cap screws (207) and clip (205) that secure the vertical roller shaft (204) to the top of the winch
housing. Remove the vertical roller shaft from the housing. Remove the vertical roller assembly (203) and spacer
washers (206) at each end.
207
205
204
207 204
205
203
201
202
206
205 206
207
26
WINCH DISASSEMBLY
26. Support the horizontal fairlead roller assembly (Item 201) with a wide-band sling or other positive-retention method.
Remove the cap screws (207) and clip (205) that secure the roller assembly to the winch housing. Carefully remove
the roller shaft (202) from the housing. Remove the roller assembly (201) and spacer washers (206) from each end
of the roller assembly.
The cable drum is supported in the winch housing The horizontal roller assembly weighs approximately
by bearings on the output ring gear and the brake 75 lbs. (34 kg). The vertical roller assembly weighs
housing. If either of these components is removed, approximately 100 lbs. (45 kg). Damage to parts
and the cable drum is not supported externally as de- or personal injury can occur if precautions are not
scribed in the text, the cable drum may come loose taken. Make certain lifting equipment has adequate
in the housing. The cable drum weighs approximately capacity.
1,000 lbs. (454 kg). Damage to parts or personal in-
jury can occur if precautions are not taken. Ensure
lifting equipment has adequate capacity.
27
PRIMARY PLANET CARRIER SERVICE
DISASSEMBLY ASSEMBLY
1. Apply light pressure to the thrust ring (Item 10) and re- 1. Install the bearing (57) into a planet gear (54). Place a
move the retaining ring (11). Then remove thrust ring, thrust washer (56) on each side of the gear and insert
brake plates, friction discs, and wave springs (7,8,9) the gear assembly into an opening in the carrier (53).
from the carrier. Slide the planet shaft through the carrier, and into and
through the gear and thrust washers.
2. Remove the planet gear shafts (55) by driving the roll
pins (58) into the center of the shafts. Slide the planet 2. Carefully align the pin hole in the carrier (58) with the
gear shafts out of the carrier. Use a punch to drive the hole in the planet shaft, and drive a NEW roll pin into
roll pins out of the gear shafts. DO NOT reuse the roll place. The roll pin should be recessed into the carrier
pins; replace with new during reassembly. to a depth of .35 inch (9 mm). Using a center punch,
stake the carrier next to the pin hole. This will distort
3. Remove the planet gears, bearings, and thrust wash- the hole so that the roll pin will not back out in service.
ers (54,56,57) from the carrier (53).
3. Repeat for each of the planet gears.
4. Thoroughly clean and inspect all planetary compo-
nents for abnormal wear or damage. The bearing roll- 4. Install the thrust ring (10) into the carrier on top of the
ers should not exhibit any irregularities. If rollers show clutch pack.
any sign of spalling, corrosion, discoloration, mate-
rial displacement, or other abnormal wear, replace
bearing(s). Inspect the bearing cage for unusual wear
or deformation, particularly the cage separator bars.
If there is any damage that will impair the ability of
the cage to separate, retain, guide the rollers properly,
the bearing MUST be replaced. The thrust washer
contact areas must be free of serious surface irregu-
larities that may cause abrasion or friction. The gears
and planetary shafts should be inspected for abnormal
wear or pitting. Replace all components as required.
NOTE: Use care in handling the carrier to prevent damag-

ing the hub on the gear side of the carrier, because this is
a bearing surface.
PRIMARY PLANET CARRIER ASSEMBLY

PART NUMBER 82090
ITEM DESCRIPTION QTY.
NO.
53 Primary planet carrier 1
54 Primary planet gear 3
55 Primary planet gear shaft 3
56 Thrust bearing 6
57 Roller bearing 3
58 Spirol pin 3
28
SECONDARY PLANET CARRIER SERVICE
1. The preferred method of removing the planet gear pin 1. Liberally coat the bore of a planet gear (21) with a
(Item 22) is to first remove the roll pin (26). This can good grade of oil soluble grease.
usually be done by inserting a punch into the hole in
the end of the shaft and forcing the roll pin up and out 2. Support the planet gear on a thrust washer (23). With
of the hole through the carrier (20). the gear centered on the thrust washer, install roller
bearing (24) into the bore. Install the remaining thrust
If the roll pin cannot be easily removed, and must be washer onto the planet gear.
sheared, please observe the following:
3. Carefully install the entire gear assembly, including the
Use a pipe or tube section large enough to support the thrust washers on the top and bottom surface, install it
area around the planet gear shaft. Also, ensure the entire into the planet carrier opening. Insert the planet gear
carrier assembly is supported at the same level. When ad- shaft into the gear bore and align the small hole in the
equately supported, drive or press the gear shaft out of the shaft with the hole in the edge of the carrier.
carrier while shearing the roll pin.
4. Drive a roll pin into the carrier and planet gear shaft.
When installed properly, approximately half of the roll
! CAUTION ! pin should engage the shaft and half should engage
the carrier. Once installed, use a center punch and
The secondary planet carrier assembly weighs ap- stake the carrier next to the pinhole to distort the car-
proximately 35 lbs. (16 kg). Make certain lifting equip- rier hole so the roll pin will not back out in service.
5. Repeat steps 2 through 5 for the remaining planet
2. Slide the planet pin (22) out of the carrier. gears.
3. Slide the planet gear (21) out of the carrier and care-
fully remove the roller bearings (24). Use a clean shop
towel or other means to keep from dropping the roll-
ers. Repeat for all planet gears.
4. Thoroughly clean all parts and inspect for wear or

damage. The bearing rollers should be inspected for
signs of spalling, corrosion, discoloration, material
displacement, or abnormal wear. Inspect the planet
gears and shafts for pitting or wear. Replace all com-
ponents as required.
SECONDARY PLANET CARRIER ASSEMBLY

PART NUMBER 82071
NO.
020 Secondary planet carrier 1
021 Output planet gear 3
022 Planet pin 3
023 Thrust bearing 6
024 Roller bearing 6
025 Bearing spacer 3
026 Spirol pin 3
29
THIRD PLANET CARRIER SERVICE
1. Replace final sun gear (95) by first inserting snap ring

! CAUTION ! (42).
The third planet carrier assembly weighs approxi- 2. For each gear, replace two sets of bearing cups (21),
mately 137 lbs. (62 kg). Make certain lifting equip- bearing cones (70), and bearing spacer (19). Replace-
ment has adequate capacity. ment of parts is similar to replacing the primary and
secondary planet assemblies.
1. Remove the planet pin (Item 51) by removing the re-
taining rings (52), then push the shafts out of the plan- 3. Replace planet gears (15) in carrier (43).
et carrier (43) while supporting the planet gear (15).
4. Replace the planet pin (51) by first replacing the re-
2. Remove planet gears (15) from carrier (43). taining rings (52). Insert the shafts into the planet car-
rier (43) while supporting the planet gear (15).
3. Each gear contains two sets of bearing cups (21) and
bearing cones (70) separated by a bearing spacer
(19). Carefully remove the bearing cups and spacers
for inspection. Thoroughly clean all parts and inspect
for abnormal wear or damage, as was done for the
primary and secondary planet assemblies.
4. Remove final sun gear (95) by removing snap ring

(42).
THIRD PLANET CARRIER ASSEMBLY

PART NUMBER 83136
NO.
15 Primary planet gear 3
19 Bearing spacer 3
20 Snap ring 3
21 15287 Bearing cup 6
42 Snap ring 1
43 Carrier, primary planet 1
51 Pin, primary planet 3
52 Retaining ring, internal 3
70 Bearing cone 6
95 Sun gear (final) 1
30
OUTPUT PLANET CARRIER SERVICE
1. Support the planet gear (15) on one of the thrust
! CAUTION ! washers (54) and install 21 rollers (53) at one end of

the bore. Applying a light coating of grease on the bore
and on the rollers aids in retention during assembly.
The output carrier assembly weighs approximately Install the bearing spacer (55) and the remaining 21
370 lbs. (167.8 kg). Make certain lifting equipment rollers (53). Repeat for all five output planet gears.
has adequate capacity.
2. Move the gear assembly and supporting thrust washer
into place in one of the planet gear openings in the
1. Remove the planet pins (Item 9) by removing the snap carrier. Carefully slide the gear and washer into align-
rings (10). Push the shafts out of the planet carrier (8) ment with the planet shaft bore. Install the second
while supporting the planet gear (15). thrust washer (54) on the upper side of the gear.
2. Each gear contains two sets of 21 rollers (53) separat- 3. Slide planet pin (9) through the carrier assembly, into
ed by a bearing spacer (55). Carefully remove rollers and through the gear assembly and thrust washers.
and spacers for inspection. Thoroughly clean all parts
and inspect for abnormal wear or damage. 4. Install snap ring (10) into the planet carrier to secure
planet pin. Repeat for all gear assemblies.
FINAL PLANET CARRIER ASSEMBLY

PART NUMBER 82437
NO.
08 Carrier, final planet 1
09 Pin, final planet 5
10 Snap ring 5
15 Gear, final planet 5
53 Roller 210
54 Thrust washer 10
55 Spacer, bearing 5
31
DRUM CLUTCH ASSEMBLY SERVICE
1. Place the ring gear housing (28) on a clean work sur-

! CAUTION ! face with the large end facing down.
The drum clutch assembly weighs approximately 620 2. Install new quad rings (34,35) into the clutch piston
lbs. (281 kg). Ensure lifting equipment has adequate (29) grooves. Lubricate the O-rings liberally and install
capacity. the piston into the ring gear housing. Apply even pres-
sure to the piston to seat the piston seals into the ring
gear and press the piston into place. Be sure to seat
the piston into the bottom of the ring gear bore.
! CAUTION ! 3. Flip the clutch housing over and install spacer ring
The ring gear housing weighs approximately 260 (39). Insert clutch plates beginning with separator
lbs. (118 kg). Make certain lifting equipment has ad- plate (31) and then brake plate (30).
equate capacity.
4. Install clutch hub (36).
1. Remove the clutch springs (Item 151). 5. Place the pressure plate (32) into the clutch housing.
2. Check the clutch spring (151) free length; minimum 6. Install retaining ring (33) into the groove. Make certain
free length should be 2.5 inches (63.5 mm). Check the retaining ring is fully seated into the bottom of the
the springs for signs of cracks or other failure. If any groove.
spring must be replaced for any reason, then ALL
clutch springs must be replaced.
3. Remove the piston (29). Discard the quad rings (34, ! CAUTION !
35).
The clutch housing weighs approximately 260 lbs.
4. Remove spacer ring (39) and clutch plates (30,31). (118 kg). Make certain lifting equipment has ade-
quate capacity.
5. Remove clutch hub (36), pressure plate (32), and
retaining ring (33). Thoroughly clean all parts and in-
spect for wear or damage. Check the piston sealing
surfaces for any scoring could damage seals or create
any sealing problems. Make certain the clutch pres-
sure port is open and free of contamination.
! CAUTION !
Failure to replace the clutch springs as a complete
set may result in uneven clutch application pressure,
and accelerated and repeated drum clutch and clutch
spring failure.
32
DRUM CLUTCH ASSEMBLY SERVICE
DRUM CLUTCH ASSEMBLY

PART NUMBER 83137
ITEM DESCRIPTION PART QTY.
NO. NO.
028 Clutch housing 111362 1
029 Clutch piston 29309 1
030 50461 Brake plate 72180 8
031 50497 Divider plate 72204 8
032 Pressure plate 29292 1
033 Retaining ring 29303 1
034 Quad-ring 106885 1
035 Quad-ring 106886 1
036 Clutch hub 29246 1
038 16574-0012 Sight gauge 70193 1
039 Spacer ring 100135 1
040 Plug, magnetic 40161 1
041 Fill-vent plug 29678 1
042 Relief valve 1-5 PSI 10074 1
33
BRAKE ASSEMBLY SERVICE
DISASSEMBLY 8. Check the cable drum bearing and seal surfaces on

the outside of the brake housing for excessive wear
or damage.
! CAUTION ! 9. Place each friction disc on a clean, flat surface and
check for any distortion using a straightedge. The fric-
The brake assembly weighs approximately 140 lbs. tion material should appear evenly across the entire
(64 kg). Make certain lifting equipment has adequate surface, with visible grooves. Replace the discs if the
capacity. splines are worn to a point, if there is any distortion, or
if the friction material is worn unevenly.
1. Place the brake assembly on a press table with the
motor end, or large end, down. Apply pressure to the 10. Place each steel disc on a clean, flat surface and
spring retainer (Item 315) to force the retainer just check for any distortion using a straightedge. Check
clear of the retaining ring (316). Remove the retain- both surfaces for signs of material displacement or
ing ring. Slowly release the force applied to the spring heat. Replace the steel discs if the splines are worn to
retainer. a point or if the discs are distorted or heat damaged.
2. Remove the spring retainer and 16 brake springs 11. Check the brake spring free length; minimum free
(313). length should be 1.44 inch (36.5 mm). Check the
springs for any sign of cracks or other failure. If a sin-
3. Turn the brake housing over so that the motor end gle brake spring must be replaced for any reason,
now faces upward. then ALL brake springs must be replaced.
4. Remove the retaining ring (304) from the brake hous-

ing. It may be necessary to tap the brake spacer (305)
downward to provide clearance to easily remove the
retaining ring.
5. Remove the spacers (305) and brake discs (306, 307)

from the housing. ! CAUTION !
6. Tap the piston downward to remove the piston. Dis- Failure to replace the brake springs as a set may re-
card the O-rings and backup rings (309, 310, 311, sult in uneven brake application pressure, and accel-
312). erated and repeated brake system and brake spring
failure.
7. Thoroughly inspect and clean all parts at this time.
Check the brake piston and housing bore sealing sur-
faces for any scoring which could damage the seals or
create any sealing problems. Make certain brake re-
lease pressure port is clear and free of contamination.
34
BRAKE ASSEMBLY SERVICE
ASSEMBLY 6. Lubricate the O-rings and backup rings (309, 310, 311,
312) with light grease or petroleum jelly. Install O-rings
and backup rings into the piston grooves. Be sure to
! CAUTION ! install the backup rings to the outside of the O-rings
toward the ends of the piston. Ensure the concave
The brake housing weighs approximately 110 lbs. (50 surface of the backup rings is against the O-rings.
kg). Ensure lifting equipment has adequate capacity.
7. Install the piston (308) into the brake housing bore. Ap-
1. Place the brake housing on a clean, flat surface with ply light, even pressure to the piston to seat it against
the motor end, or large end, facing up. the brake plate spacer.
2. Install a brake spacer (Item 305) into the bottom of the 8. Insert the spring spacer (314) into piston bore. Insert
splined bore. 16 brake springs (313) into the spring pockets created
by the spacer. Two openings will remain in the spacer.
3. Lubricate the friction discs in clean oil, using the same Ensure that openings are located 180 degrees apart.
oil as that intended for the winch gear cavity. Install a
steel brake disk (306) on top of the brake plate spac- 9. Install the spring retainer (315) on top of the brake
er. Next, install a friction disc (307). Then alternate springs. Using a press, apply even pressure to the re-
steel and friction discs until the last steel disc is placed tainer to force it just below the bottom face of the re-
on top – nine steel discs and eight friction discs total. taining ring groove and install the retaining ring (316).
Ensure retaining ring is fully seated in the groove be-
4. Install the second brake plate spacer (305) on top of fore removing the pressure from the retainer.
the last steel brake disc. Install the retaining ring (304)
into the groove above the spacer. Make certain the BRAKE ASSEMBLY PRESSURE TEST
retaining ring is fully seated into the groove.
Install the long tube fitting into the brake release port of
5. Turn the brake housing over and rest it on the motor the brake housing. Connect a hand pump with an accurate
end. Make certain the brake plates and spacers are gauge 0–2,000 PSI (0–137.9 bar) and a shut-off valve to
resting flat on the bottom of the bore and are not hung the fitting. Apply 1,000 PSI (68.9 bar) to the brake. Close
up or held out of position. Insert the overrunning brake the shut-off valve and let the unit stand for 3 to 5 minutes.
clutch assembly to more closely align the splines of If there is any pressure loss, the brake assembly should
the friction discs. Either support the brake clutch as- be disassembled for inspection of the sealing surfaces
sembly in position with a spacer on the table or re- and brake piston seals, and repaired as needed. Perform
move it completely. this test after any repair to brake assembly.
302 305 304

NO.
301 301 Brake housing 1
302 Ball, steel 1
303 Pipe plug 1
316 304 Ring, internal retaining 1
303
315 305 Brake plate spacer 2
313 306 Brake disc 9
314 307 Friction disc 8
308 Brake piston 1
309 O-ring 1
310 Backup, O-ring 1
311 O-ring 1
312 Backup ring 1
313 Spring 16
314 Spring spacer 1
308 312 311 309 310 306 307 315 Spring retainer 1
316 Retaining ring 1
35
BRAKE VALVE SERVICE
The brake valve is a reliable hydraulic valve with internal DISASSEMBLY

components manufactured to close tolerances. Due to
the close tolerances and mating of components, the valve 1. Remove the pilot orifice (Item 9) from the brake re-
housing, spool, piston and check poppet are not available lease (BR) port using a 5/32-inch Allen wrench.
as replacement parts.
Before disassembling the brake valve, be sure you have

conducted all applicable troubleshooting operations and
are certain the brake valve is causing the malfunction.
Thoroughly clean the outside surfaces of the valve and

work in a clean dust-free area, because cleanliness is of
utmost importance when servicing hydraulic components.
2. Remove the plug (19) from the drain port.
3. Remove the spool spring retainer (3) and spool spring

(11). Check spring free length. Replace spring if less
than 1-15/16 inches (49.2 mm) long.

NO.
1 Valve housing, NSS 1
2 Check valve retainer 1
3 Spring retainer 1
4 Plug 1
5 Spool, NSS 1
6 Damper piston, NSS 1
7 O-ring 1
8 Check valve poppet, NSS 1
9 Pilot orifice 1
10 Check valve spring 1
11 Spool spring 1
12 O-ring 2
13 O-ring 1
14 O-ring 1
15 Backup ring 1
16 Backup ring 1
19 Plug 1
22 Shim AR
NSS - Not serviced separately. Replace complete
valve assembly.
AR - As required.
36
BRAKE VALVE SERVICE
4. Remove spool plug (Item 4) and carefully remove ASSEMBLY

spool (5).
1. Install new O-rings on the plug and spring retainers.
2. Install new O-rings and backup rings on the spool. It

is important that the backup ring is on the correct side
of its O-ring. Take care not to cut the O-ring during
assembly. Let the spool set for 10 minutes before in-
stalling them in their respective bores. This will allow
the O-ring to return to their original size after being
stretched.
3. Lubricate the spool bore and spool O-rings with hy-

5. Remove the check valve spring retainer (2), spring draulic oil. Carefully install the spool into the valve
(10), and check valve poppet (8). Check spring free housing. Always install the spool from the plug end as
length. Replace spring if less than 1-1/2 inches (38.1 shown to minimize the possibility of damaging the O-
mm) long. ring. Install the plug, spool spring and spring retainer.
4. Install the check valve poppet, spring and check valve

spring retainer.
5. Install the solid plug into the drain port.
6. Install the pilot orifice into the valve housing.
7. The brake valve is complete and ready to be installed

on winch motor.
CLEAN AND INSPECT
1. Discard all O-rings and backup rings. Clean all parts

in solvent and blow dry. Inspect polished surfaces of
spool for damage that may cause binding or leakage.
Inspect spool bore in valve housing for damage or
scoring. Inspect check valve seat in valve housing and
check valve poppet. If the spools, bores, or valves are
damaged, the entire valve must be replaced because
these parts are not serviced separately.
2. Inspect the .020-inch orifice in the pilot orifice (9) to be

certain it is open.
37
OVERRUNNING CLUTCH SERVICE
401 406 403

402
ITEM DESCRIPTION
NO.
401 Inner race
405
402 Outer race
404 403 Overrunning clutch
404 Ball bearing
405 Retaining ring
406 16314-137 Retaining ring
404
405
NOTE: Outer race, inner race, and overrunning clutch
are NOT SOLD individually as replacement parts. If any
of these parts require replacement, the entire overrunning ! WARNING !
clutch assembly must be replaced. Use a marking pen to
carefully note the relative orientation between the inner Failure to assemble the overrunning clutch assem-
and outer races, and the direction of free rotation of the bly with all parts oriented correctly may result in re-
inner race. The clutch MUST be reassembled correctly for duced brake effectiveness, which may lead to loss of
proper winch operation. load control and result in property damage, injury, or
death.
! WARNING ! ASSEMBLY
The polished surfaces of the inner and outer race and 1. If both bearings have been removed from the inner
the overrunning cams must be perfectly smooth to race, install one of them now.
insure positive engagement of the clutch. The slight-
est defect may reduce clutch effectiveness, which 2. Install the overrunning clutch onto the inner race. Ro-
may lead to loss of load control and result in property tate the inner race slightly to get the clutch started
damage, injury, or death. Replace the entire clutch onto the inner race.
assembly if any component is defective. For these
reasons, the overrunning clutch assembly should be 3. Install the other bearing onto the inner race.
disassembled for inspection only if the winch has ex-
hibited any unusual operation that would point toward 4. The outer race should have one retaining ring installed
a clutch malfunction, or the overrunning clutch as- in one end. Carefully slide the inner race, with bear-
sembly shows external signs of mechanical damage. ings and clutch, into the outer race. Install the other
retaining ring into the outer race.
DISASSEMBLY
1. Remove one of the retaining rings (405) from the outer

race. Push the inner race (401), bearings (404), and
overrunning clutch (403) through the outer race (402).
2. Use a small punch and hammer to carefully tap one

of the bearings off of the inner race. The overrunning
clutch can now be removed from the inner race. Close-
ly inspect the overrunning clutch and the polished
surfaces of the inner and outer race for wear, cracks,
pitting, corrosion, or mechanical damage. Closely in-
spect the bearings for any signs of wear, corrosion,
pitting, heat discoloration, or damage.
38
CABLE DRUM SERVICE
1. Chill the inner bearing cup in dry ice to shrink the di-
! CAUTION ! ameter to aid installation. Install the bearing cup into
the cable drum bearing bore. Use a .002 inch (.05 mm)
feeler gauge to make certain the cup is fully seated
Cable drum weighs approximately 1,000 lbs. (454
against the drum barrel shoulder.
kg). Personal injury or damage to parts may occur if
precautions are not taken.
2. Lubricate the bearing cones with winch oil and install
into the bearing cup. The bearing cones will be back-
1. Remove the cable drum as described in Winch Disas- to-back with the large end of the cones in contact with
sembly section of this manual. each other.
2. Place the cable drum on a suitable work surface. The 3. Chill the outer bearing cup, as previously described,
seals (Items 111, 107) must be removed to gain ac- and install into the drum against the bearing cones.
cess to the drum bearings. Next, remove the spiral Take care during assembly to avoid damaging the
retaining ring (105). Inspect the drum bearings (110, bearing cage on the cone.
103) while installed in the drum. If scored, heat dis-
colored, or damaged in any other way, they should be 4. Install the spacer ring, then the spiral retaining ring
removed and replaced. into the cable drum.
NOTE: The bearings should be removed only if replace- 5. Apply nonhardening sealing compound to the outside
ment is necessary as unintentional damage may occur surface of the seal housing at installation. With the
during the removal process. drum seal properly positioned in the drum bore, place
a large steel plate over the seal for protection and
3. To remove drum bearings (110, 103), drive the bear- press or drive it into place. The cable drum is ready for
ing cones from the drum bore using a long, soft metal installation as described on the following page.
punch. Remove inner bearing cups using a multijaw
puller or by welding pulling lugs directly to the cups. 6. To maintain alignment, alternately install the ring gear
Either method will destroy bearing cups and require and then the brake housing assembly into the cable
replacement. drum bearings. The bearings have a snug slip-fit which
requires extreme care during installation.
39
CABLE DRUM SERVICE

NO.
102 Cable drum 1
103 Bearing, tapered roller set 2
105 Spacer ring 1
107 Oil seal 1
110 Bearing, spherical 1
111 Oil seal 1
40
WINCH ASSEMBLY
The cable drum is supported in the winch housing The support adapter (147) weighs approximately
by bearings on the output ring gear and the brake 600 lbs. (272 kg.) The output ring gear (14) weighs
housing. If either of these components is removed, approximately 320 lbs. (145 kg). Damage to parts
and the cable drum is not supported externally as de- or personal injury can occur if precautions are not
scribed in the text, the cable drum may come loose taken. Make certain lifting equipment has adequate
in the housing. The cable drum weighs approximately capacity.
1,000 lbs. (454 kg). Damage to parts or personal in-
jury can occur if precautions are not taken. Ensure
lifting equipment has adequate capacity.
1. If the cable drum has been removed, support the drum securely between the winch housing walls with a suitable
hoist and chain. The cable pocket end, or wide flange, must be located to the motor side or right side of the housing.
The cable drum weighs approximately 1,000 lbs. (454 kg).
Jack hole
1"-8
117,118
14
Use 1/2-13
eyebolt
112
147
22
145 146
900
2. Install the support adapter/output ring gear assembly into the bore on the left of the housing using cap screws and
washers (117, 118). Apply a light coating of multipurpose grease to the seal and on the support adapter pilot. Be
careful not to damage the oil seal in the cable drum during installation. Tighten cap screws to 900 ft-lbs. (1220 N-m).
NOTE: Torque requirements are based on plain and dry conditions with zinc coatings.
! CAUTION !
The motor cover (137) weighs approximately 108 lbs. (49 kg). The hydraulic motor assembly (500)
weighs approximately 110 lbs. (50 kg). The brake assembly (300) weighs approximately 140 lbs. (64
kg). The cable drum (102) weighs approximately 1,000 lbs. (454 kg). Damage to parts or personal
injury can occur if precautions are not taken. Ensure lifting equipment has adequate capacity.
41
WINCH ASSEMBLY
3. Install the brake assembly into the bore on the right of the housing using the cap screws and washers (Items 149,
150). Apply a light coating of multipurpose grease to the seal and on the brake housing pilot. Be careful not to dam-
age the oil seal in the cable drum during installation. Position the brake housing so that the brake release port is
located in the upper left quadrant, and the two-bolt motor mounting pattern is vertical. Tighten cap screws to 106
ft-lbs. (144 N-m).
400
300
133,132
500
137
150
Lifting hole
4. Install the overrunning clutch into the brake assembly. Insert the long end of the inner race inward toward the gear-
ing. Ensure that the inner race turns freely in the clockwise direction when looking at the input or motor shaft end.
! WARNING !
Failure to assemble the overrunning clutch with all
parts oriented correctly may result in reduced brake
effectiveness, which may lead to loss of load control
and result in property damage, injury, or death.
5. Apply a light coat of multipurpose grease to the motor pilot O-ring and install onto the motor pilot.
6. Install the hydraulic motor assembly (500) into the brake housing, making sure to align the splines in the overrun-
ning clutch. Position the motor so that it angles toward the tractor. Tighten cap screws to 280 ft-lbs. (380 N-m). Using
cap screws and washers (167, 168), fasten the solenoid manifold valve (162) to the winch mounting bracket.
7. Install the thrust washers (145, 146) and drum shaft (22). Rotate the shaft to engage the drum splines. The drum
8. Install the output planet carrier assembly (900) into the output ring gear, aligning it with the drum drive shaft splines
(22). The output planet carrier assembly (900) weighs approximately 370 lbs. (168 kg).
9. Install the lightly greased O-ring (148) onto the third-stage ring gear (16). Install the third-stage ring gear (16). The
ring gear weighs approximately 171 lbs. (78 kg).
10. Install thrust washer (21).
42
WINCH ASSEMBLY
11. Install the third planet carrier assembly (800). The third planet carrier assembly weighs approximately 136 lbs. (62 kg).
175
164,165
16
800 21
950
46
700
44 113,116
143
12. Install the intermediate shaft (62) through the cable drum and into the brake clutch. Make certain the shaft is fully
inserted into the brake clutch inner race. The intermediate shaft weighs approximately 28 lbs. (13 kg).
13. Install the third sun gear (46).
14. Install the lightly greased O-ring (120) onto the drum clutch assembly (950). Install the drum clutch assembly. Use
the cap screw and washer (113, 116). Torque the cap screws to 376 ft-lbs. (414 N-m).
15. Install thrust bearing set (2x 164 thrust race, 165 needle roller bearing). Use a light coat of multipurpose grease on
the thrust bearing set.
16. Install the secondary planet carrier assembly (700) and then the secondary sun gear (44). Install snap ring (143) to
sun gear before installation.
! CAUTION !
The primary planet carrier assembly (600) weighs
approximately 16 lbs. (7 kg). The secondary planet
carrier assembly (700) weighs approximately 35
lbs. (16 kg). The third planet carrier assembly (800)
weighs approximately 136 lbs. (62 kg). The output
planet carrier assembly (900) weighs approximately
370 lbs. (168 kg). The drum clutch assembly (950)
weighs approximately 615 lbs. (279 kg). The drum
Damage to parts or personal injury can occur if pre-
cautions are not taken. Make certain lifting equip-
43
WINCH ASSEMBLY
17. Install the thrust bearing set (2x 168 thrust washers, 169 thrust bearing). Install the first of two retaining rings (Item
166) onto the intermediate shaft. Use a light coat of multipurpose grease on the thrust bearing set.
18. Install the primary planet carrier assembly.
Drum clutch
hose
600
166
179
167 63 168,169
159,160,161
151
170
171,172
19. Install the primary sun gear (63) and the final retaining ring (166).
20. Install the thrust bearing set (159 thrust race, 160 needle bearing, and 161 thrust washer) around the primary planet
carrier hub. Use a light coat of multipurpose grease on the thrust bearing set.
21. Install the 20 drum clutch springs (151) into the drum clutch assembly.
22. Install O-ring (170) to the end cover (67) and then install the end cover using cap screws and washers (171 and
172). Make certain the thrust bearings and washers remain in position until the cover is properly located. Tighten
cap screws to 106 ft-lbs. (144 N-m).
23. Reinstall the drum clutch hose and drum clutch hose cover (179). Install the stud (178) and use hex nut (177) under
the cover as a spacer. Install the cover and then install the nut and washer (172, 177). Torque the nuts to 75 ft-lbs.
(102 N-m).
! CAUTION !
The horizontal roller assembly weighs approximately
75 lbs. (34 kg). The vertical roller assembly weighs
approximately 100 lbs. (45 kg). Damage to parts
or personal injury can occur if precautions are not
taken. Make certain lifting equipment has adequate
capacity.
44
WINCH ASSEMBLY
24. Install the horizontal fairlead shaft and roller assembly into the winch housing. Insert the shaft in to the housing from
the left, or gear side. Make certain spacer washers are installed at both ends of the fairlead roller. Install the clip,
cap screws, and washers. Tighten cap screws to 212 ft-lbs. (287 N-m).
207
205
204
207 204
205
203
201
202
206
205 206
207
25. Install the vertical fairlead rollers and shaft assemblies. Insert the shafts from the top of the housing. Make cer-
tain the spacer washers are installed at both ends of the fairlead roller. Install the clips, cap screws, and washers.
Tighten cap screws to 212 ft.-lbs. (287 N-m).
26. Grease the fairlead rollers as specified in the Preventive Maintenance section of this manual.
27. Install winch to winch mounting brackets. It is highly recommended to use new capscrews and flat, hardened
washers. The hex head capscrews are 1-1/4 inch UNC-2A, Grade 8 steel, zinc plated. The capscrews should be
inspected for correct threads per inch with a gauge or an identical size and grade nut. Depending on your applica-
tion, the length of capscrew will differ. Measure the length of the capscrew to determine your application needs. It is
also recommended that you clean and inspect the threads in the mounting bracket for correct threads per inch and
any damage. Use a new capscrew of identical size as listed above to check each thread for proper fit.
If assembled “dry,” tighten capscrews to 1,360 ft-lbf. Anaerobic thread-locking compound or antiseize compound is
permitted on capscrews per customer preference. If antiseize compound is used, the torque specifications above must
be reduced as directed by the antiseize compound manufacturer’s specification. Use only antiseize compounds that
provide specific guidance on torque reduction.
45
WINCH ASSEMBLY
! WARNING !
Incorrect fastener tightening, both under and over
tightening, can result in failure of the winch mounting
fastener(s), loss of winch, loss of load, other property
damage, and/or personal injury or loss of life.
28. Fill the winch to the proper level with the recommended oil as specified in the Preventive Maintenance section.
Oil fill
and vent
Oil level
Oil drain
29. Prefill the hydraulic motor with clean hydraulic oil through the tank port on top of the motor.
30. Install any remaining hydraulic plumbing and refill the tractor hydraulic oil reservoir if required. Refer to the tractor
operation and maintenance manual for procedures and recommendations.
31. Start the tractor engine and cycle the winch in both directions, with no load, a few times to purge air from the lines.
Check all fittings and connections for leaks and repair or retighten as necessary. Turn the tractor engine off when
testing is complete.
32. Check the tractor hydraulic reservoir level and refill as needed.
33. Install the motor assembly cover. Tighten cap screws to 106 ft-lbs. (143 N-m).
34. Reinstall the wire rope onto the drum. Refer to the Wire Rope Installation section of this manual.
46
BRAKE CYLINDER LIFTING FIXTURE
2.0 0.5
LIFTING FIXTURE
0.8125
Diameter
All dimensions in inches
1.0 12.0
Diameter
12.0 9.843
This This
piecepiece
can be
cana be
solid bar orbar
a solid piece of heavy
or piece
wall pipe or tubing.
of heavy wall pipe or tubing.
Attach fixture to brake cylinder at the two holes
used for the hydraulic motor. Use two 3/4-10
Attach5 fixture
Grade to brake
capscrews, cylinder
1-1/4 inchesatlong.
the two holes
0.8125 used for the hydraulic motor. Use two 3/4 - 10
Diameter G rade 5 capscrews, 1-1/4 inches long.
47
LIT2753
October 2018 ©2018 PACCAR Inc.
Printed in USA All rights reserved
48

Service Manual: H200 Tail Winch

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Service Manual: H200 Tail Winch

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H200

WRITE WINCH SERIAL NUMBER BELOW

First 2 numbers indicate

Read this entire publication and retain it for future reference.

Model numbers, part numbers, and serial numbers

There is also another stamped serial number locat-

H Hydraulic motor, two-speed

GENERAL SAFETY RECOMMENDATIONS

! WARNING ! winch. Do not use CARCO parts on winches from

DESCRIPTION OF WINCH BASIC WINCH OPERATION

Typically, the winch control valve is connected to the oper-

control valve is moved into the reel-out position, the spool

The static brake system has three operating components:

The friction brake is a load-holding brake only and has

The overrunning brake clutch is splined to the primary sun

Figure 5. Static fric-

The hydraulic cylinder, when pressurized, will release the REEL-IN

When the reel-in operation is stopped, the load attempts

When the winch is powered in reverse, to reel-out the

on the work ports (A and B) increases due to the load ap-

NOTE: Operating the tractor engine at the lowest idle set-

Remove the drain plug located at the bottom of the drum

GEAR CASE OIL ! CAUTION !

TRACTOR HYDRAULIC RESERVOIR LEVEL WINCH CABLE (WIRE ROPE)

FAIRLEAD ROLLERS Disassemble winch every 10,000 hours or four years,

Base unit weight: 7,040 lbs. (3,193 kg) RECOMMENDED OIL

* NOTE: Actual performance varies. The tractor's hydrau-

RECOMMENDED GEAR OIL

Use gear oil detailed in Range A

Use gear oil detailed in Range B

Use gear oil detailed in Range C

oC -40 -30 -20 -10 0 10 20 30 40 50 oC

Mobil Shell Chevron Texaco

Range C Mobilgear SHC 150 Omala S4 GX 150

WIRE ROPE INSTALLATION

Insert cable through the small opening of the fer-

TROUBLE PROBABLE CAUSE REMEDY

If there is any loss of pressure during the

Oil leaks from vent plug. 1. Same as A2. A. Same as A2A.

B. Oil analysis may indicate contamina-

TROUBLE PROBABLE CAUSE REMEDY

B. Apply 500 PSI (34.5 bar) to the drum

C. If there is a loss of pressure during

2. Friction brake will not hold due to A. Same as A3A.

B. Overrunning brake clutch may be worn

TROUBLE PROBABLE CAUSE REMEDY

Apply a stall pull load on the winch while

Compare the gauge reading to the winch

NOTE: Refer to the tractor service man-

4. Same as C5. A. Same as C5A.

5. Hydraulic motor locked in high A. Send motor to qualified motor service

TROUBLE PROBABLE CAUSE REMEDY

Winch runs hot. 1. Be certain the hydraulic system Same as D1A.

A. Plugged heat exchanger (where A. Thoroughly clean exterior and flush

C. Tractor hydraulic pump not operat- C. Tractor low on horsepower or RPM.

Check suction line for damage.

Pump worn or damaged. Inspect or

2. Excessively worn or damaged A. Disassemble winch for inspection or

TROUBLE PROBABLE CAUSE REMEDY

Winch chatters while pulling rated 1. Same as D1. A. Same as D1A.

3. Controls operated too quickly or A. Conduct operator training as required.

ITEM DESCRIPTION PART NO. QTY.

For cross-section diagrams and