Usage:
A regular program of preventive maintenance for your PACCAR winch will minimize the need for emergency servicing and promote long product life and trouble-free operation.
The service intervals suggested in this manual will optimize component service life. The intervals may be gradually increased or decreased with experience of a particular lubricant and evaluation of your application.
1. Oil Level
Check oil level at the beginning of each work shift with tractor and winch in level position. Oil must be visible in the upper half of the sight gauge. If an oil level plug is used in place of the sight gauge, the oil level should be at the bottom of the level plug hole. Add oil as required through the fill plug at the top of winch case.
2. Oil Change, Filter and Strainer Service
Under normal operating conditions, the oil and pressure circuit filter should be changed and suction strainer cleaned after the first 100-250 hours of operation, then every 1000 hours or six months, whichever occurs first, or when the filter bypass indicator light remains on after initial warm up.
To drain oil, place tractor and winch in level position and remove drain plug located at lower right hand side of winch case. Drain oil into a suitable container and recycle or dispose of used oil in an environmentally responsible manner. Install plug securely after oil has been drained. After oil has drained, remove four suction strainer cover capscrews and cover. Remove suction strainer from winch case then remove metal band and magnetic rods from suction strainer. Thoroughly wash strainer in clean safety solvent and blow dry with compressed air, inspect wire mesh for damage or clogging with debris. Do not reuse a damaged suction strainer.
Install magnetic rods onto suction strainer using metal band. Lubricate o-ring and install in groove on cover. Install strainer, spring and cover into winch case.
NOTE: If the suction strainer shield or shield seal rings are removed for any reason, reinstall them by following the procedure listed below.
1. Install shield. Part number 118-6283, between connector and strainer as shown above, with open side facing downward.
2. Measure distance "X", from shield to strainer cover mounting surface.
3. If "X" dimension is between 0.720 in. and 0.783 in. (18.3-19.9 mm), add one seal, 118-6286, outboard of seal 118-6284.
4. If "X" dimension is greater than 0.783 in. (19.9 mm), add two seals, 118-6286, outboard of seal 118-6284
Refill winch to proper level with recommended oil.
The pressure filter is located behind the right hand, eight-bolt access cover. Remove the cover, locate the spin-on pressure filter and remove the filter element with a strap wrench.
Lubricate the filter gasket and adapter threads with winch oil and install new filter element onto filter head. Tighten 1/2-3/4 turn after seal ring makes contact with filter head.
Start tractor and operate engine at low idle. Correct any leaks.
The filter bypass indicator light may come on for a short time during initial cold start-up but should go out as the oil warms up. If the light stays on, this indicates a restricted filter element, sending unit stuck in the bypass position or accidentally grounded sending unit wire.
3. Control Cable and Pressure Adjustment
While the access cover is removed, it is advisable to check control cable adjustment and hydraulic main relief pressure. Place the Power Shift control lever in the center "Brake-On" (neutral) position. Install the yoke pins into the cable yokes/control valve spools and secure with hitch pins. The yoke pins should slip easily into the bores without any binding. The control valve spools are spring centered. If you notice any binding. turn the cable adjusters in or out until you obtain a "free pin" condition.
Make certain accumulator stored oil supply has been discharged as described earlier. Install an accurate 0-600 psi (0-4137 kPa) gauge onto the -4 J.I.C. gauge port next to the control cables. Start tractor and operate engine at approximately 800-1000 RPM until pressure stabilizes. Maximum pressure during "charging mode should peak at 400 psi (2758 kPa). Pressure will slowly fall back approximately 15-20% from the relief setting then quickly return to 400 psi (2758 kPa) when the valve cycles.
If adjustment is required, locate the adjustment screw hole behind port "P" of the control valve. With a 1/4 in. Allen key, loosen the outer lock screw. Insert a 3/16 in. Allen key through the lock screw and turn the adjusting screw clockwise to increase peak pressure; counterclockwise to decrease peak pressure. Tighten the lock screw.
NOTE: It may be helpful to place the controls in Brake-Off to use some oil in the control circuit and cause the valve to slowly "cycle" so that peak pressure may be more easily observed.
Stop engine, discharge accumulator stored oil supply as described earlier and move hydraulic gauge to the "B" test port on the brake housing. A 1/4 in. NPT adapter will be required.
Start tractor and operate engine at approximately 800-1000 RPM. Place Power Shift lever in the Brake-Off position and observe BRAKE-RELEASE oil pressure. Loosen cable adjuster or cable yoke jam-nut and adjust brake control cable to achieve approximately 300 PSI BRAKE RELEASE pressure.
Stand away from service access of winch and return Power Shift lever to the BRAKE-ON (neutral) position. BRAKE RELEASE pressure must return to 0 with the controls in BRAKE-ON (neutral) position.
NOTE: Optimum BRAKE-RELEASE pressure is the highest pressure you can achieve while ensuring pressure ALWAYS drops to 0 when controls are returned to BRAKE-ON. Excessive heat and accelerated BRAKE-RELEASE pressure does not return to 0.
With controls on Brake-On (neutral) remove gauge from "B" port and securely install plug into brake housing.
Install access cover plate and tighten eight 1/2 in. capscrews/nuts to 75 lb·ft (102 N·m) torque.
4. Vent Plug
The vent is located next to the power shift control cables. It is very important to keep this vent clean and unobstructed. Whenever the oil is changed, remove vent plug, clean in safety solvent and reinstall. Do not replace with a solid plug.
5. Winch Cable (wire rope)
Inspect entire length of wire rope, chokers and hooks according to wire rope and rigging manufacturers recommendations.
6. Mounting Fasteners
Check/tighten all winch mounting fasteners to recommended torque after the first 100-250 hours of operation, then every 1000 operating hours or six (6) months, whichever occurs first.
7. Warm-Up Procedure
Start tractor engine and operate at low idle for five minutes.
Shift the Free Spool lever (if equipped) to the Disengaged position. Then, with the tractor engine at low idle, place Power Shift lever in Reel-in (forward) position. The winch gear train will rotate and warm the oil to operating temperature.
If not equipped with Free-Spool, operate winch alternately in Reel-out and Reel-in with little or no load to warm the oil and lubricate the gear train.