- - 55, 56, 57, 58 & 59 TOWING WINCHES Page 1 of 21 Testing and Adjusting 55, 56, 57, 58 & 59 TOWING WINCHES Media Number -SENR7217-01 Publication Date -01/10/1977 Date Updated -12/10/2001 Testing And Adjusting Introduction When making an analysis of winch performance, be sure that the operation of the following components is correct. The tractor engine: horsepower and engine rpm. The tractor torque converter (power shift machines): oil pressures and leakage. The output of the winch pump: See SPECIFICATIONS. The control linkage for the winch control valve: no damage to the flexible cables or no loose connections. The hydraulic control pressure: See OPERATIONAL CHECKS (Hydraulic). The input clutch: the capacity of the clutch must be enough to stall the engine (direct drive) or the torque converter (power shift). The directional clutches: they must have the capacity to keep the drum from turning when pulling a maximum load on the cable; in free spool, both directional clutches must release so that the drum can turn when the cable is pulled. The winch gears: make sure that the gears installed are correct for the specific arrangement. (See the following chart.)
Page 2 of 21 LOCATION OF GEARS 1. Gear on input clutch. 2. Transfer gear. 3. Pinion. 4. Bevel gears. 5. Transfer gear (early 55 and 56 low speed winches). 6. Transfer gear (early 55 and 56 low speed winches). 7. Transfer gear (early 55 and 56 low speed winches). 8. Drum drive gear (early 55 and 56 low speed winches). 9. Transfer gear. 10. Transfer gear. 11. Transfer gear. 12. Drum drive gear. 13. Drum. 14. Planetary gear set (57, 58 and 59 Winches only).
Page 3 of 21 Operational Checks (Mechanical) PROBLEM 1: Winch drum does not reel in or reel out. 1. Control linkage does not have correct adjustment or has a failure. 2. Failure of hydraulic pump or hydraulic lines. 3. Failure of power take-off shaft or shaft coupling. 4. Input clutch discs and plates are worn. 5. Mechanical failure of transfer gears from input clutch. 6. Mechanical failure of bevel gear or pinion. 7. Mechanical failure of one or more drum drive gears. 8. Directional clutches do not release. 9. Low pressure to the input clutch (but not zero) due to failure of one or more seals (1) through (7). 10. Low pressure of the control system. See OPERATIONAL CHECKS (Hydraulic).
Page 4 of 21 INPUT CLUTCH CROSS-SECTION 1. Plastic ring seal. 2. Plastic ring seal. 3. O-ring seals. 4. O-ring seals. 5. O-ring seals. 6. Metal ring seals. 7. O-ring seals. PROBLEM 2: Winch drum will "reel out" but will not "reel in." 1. Leakage of seal in manifold on tube (8). 2. Leakage past seal (20). 3. Leakage past seals (18). 4. Discs and plates (17) of the directional clutch have been too hot and are bent. 5. Failure of spring or springs (11). 6. Retaining ring (13) out of groove. 7. Leakage past seals (12).
Page 5 of 21 OIL MANIFOLD AND BEVEL GEAR SHAFT 8. Oil tube. 9. Oil tube. BEVEL GEAR SHAFT ASSEMBLY 10. Seals. 11. Springs. 12. Seals. 13. Retaining ring. 14. Seal. 15. Springs. 16. Discs and plates of left directional clutch. 17. Discs and plates of right directional clutch. 18. Seals. 19. Seal. 20. Seal. PROBLEM 3: Winch drum will "reel in" but will not "reel out." 1. Leakage past seal in manifold on tube (9). 2. Leakage past seal (19). 3. Leakage past seals (10). 4. Discs and plates (16) of the directional clutch have been too hot and are bent. 5. Failure of spring or springs (15). 6. Leakage past seals (14). PROBLEM 4: Winch drum will not turn with "brake off."
Page 6 of 21 1. Discs and plates (16) and (17) of the directional clutches have been too hot and are bent. 2. Hydraulic control valve is not working correctly. See OPERATIONAL CHECKS (Hydraulic). PROBLEM 5: On power shift tractor, the torque converter stalls. 1. Discs and plates of input clutch have been too hot and are bent so that input clutch will not release. 2. Linkage for the hydraulic control of the winch does not have correct adjustment. 3. The hydraulic control valve is not working correctly. See OPERATIONAL CHECKS (Hydraulic). PROBLEM 6: On direct drive tractor, the engine stops when tractor flywheel clutch and winch are engaged. See Probable Causes of Problem 5. PROBLEM 7: Oil leak between drum and winch case. 1. Leakage past seals (22) or seal (23). 2. Leakage past seal (21).
Page 7 of 21 CROSS-SECTION OF DRUM AND DRIVE GEARS 21. Seal. 22. Seal. 23. Seal. PROBLEM 8: Tooth wear on the two bevel gears shows different wear pattern. 1. Bevel gear shaft assembly not centered in respect to the bevel pinion gear. PROBLEM 9: Both bevel gears have similar wear pattern but show poor tooth contact. 1. Incorrect gear tooth clearance (backlash) between bevel pinion gear and bevel gears. Operational Checks (Hydraulic)
Page 8 of 21 Pressure Tests HYDRAULIC CONTROL VALVE (Typical Example) 1. Pressure tap for input clutch pressure. 2. Pressure tap for directional clutch pressure. 3. Pressure tap for lubrication circuit pressure. CONTROL CONSOLE (Typical Example) A, B, C, D, E, and F. Hand control lever positions. Control Valve With Sequence Valve and Later Control Valves Without Sequence Valve Install 0 to 600 psi (0 to 4150 kpa) pressure gauges in pressure taps (1) and (2). Install a 0 to 60 psi (0 to 415 kpa) pressure gauge in tap (3). Start the tractor engine. With the engine at high idle and the winch control lever in Position (B), the gauge reading at tap (3) must be approximately 40 psi (280 kpa). The gauge readings at taps (1) and (2) must be 0 psi (0 kpa). Pull the control lever slowly in the direction of Position (E). The gauge reading at tap (1) must go up immediately until it is 250 ± 15 psi (1720 ± 105 kpa). The gauge reading at tap (2) must become larger with any force increase on the control lever. The maximum gauge reading at tap (2) must be 250 ± 15 psi (1720 ± 105 kpa). The gauge reading at tap (1) must read approximately 250 psi (1720 kpa).
Page 9 of 21 Because inching of the cable is done at the low idle setting of the engine, the pressure readings at low idle are important. At low idle, the pressure at tap (1) must be 230 psi (1585 kpa) minimum and at tap (2) must be 220 psi (1520 kpa) minimum. When the force on the hand control lever is less than 19 lb. (85 N), the gauge reading at tap (2) can be less than 250 psi (1720 kpa) when the gauge reading at tap (1) is 250 psi (1720 kpa). During the time of pressure increase at pressure taps (1) and (2), the gauge reading at tap (3) can be near 0 psi (0 kpa). Control Valve Without Sequence Valve (Earlier Winches) Install 0 to 600 psi (0 to 4150 kpa) pressure gauges in pressure taps (1) and (2). Install a 0 to 60 psi (0 to 415 kpa) pressure gauge in tap (3). Start the tractor engine. With the engine at high idle and the winch control lever in Position (B), the gauge reading at tap (3) must be approximately 40 psi (280 kpa). The gauge readings at taps (1) and (2) must be 0 psi (0 kpa). Pull the control lever slowly in the direction of Position (E). The gauge reading at tap (1) must go up immediately until it is 300 ± 15 psi (2050 ± 105 kpa). The gauge reading at tap (2) must become larger with any force increase on the control lever. The maximum gauge reading at tap (2) must be 275 ± 15 psi (1900 ± 105 kpa). The gauge reading at tap (1) must read approximately 300 psi (2050 kpa). Because "inching" of the cable is done at the low idle setting of the engine, the pressure readings at low idle are important. At low idle, the pressure at tap (1) must be 265 psi (1825 kpa) minimum and at tap (2) must be 220 psi (1520 kpa) minimum. When the force on the hand control lever is less than 19 lb. (85 N), the gauge reading at tap (2) can be less than 275 psi (1900 kpa) when the gauge reading at tap (1) is 300 psi (2050 kpa). During the time of pressure increase at pressure taps (1) and (2), the gauge reading at tap (3) can be near 0 psi (0 kpa). PRESSURE CONTROL VALVE WITHOUT SEQUENCE VALVE 4. Load piston. 5. Spring assembly. 6. Spring (only in early valves). 7. Spool. 8. Slug. 9. Spring. 10. Spring assembly. 11. Spool. 12. Slug. 13. Spring.
Page 10 of 21 PRESSURE CONTROL VALVE WITH SEQUENCE VALVE 4. Load piston. 5. Spring Assembly. 7. Spool. 8. Slug. 9. Spring. 10. Spring Assembly. 11. Spool. 12. Slug. 13. Spring. PROBLEM 1: No oil pressure at pressure taps (1), (2), and (3). 1. Very low oil level or no oil in winch. 2. Failure of oil pump or pump drive. 3. Failure of an oil line. PROBLEM 2: Oil pressure at pressure tap (3) is too high. 1. Lubrication valve in filter base will not open or will not open completely. 2. Oil flow through the filter element is stopped. PROBLEM 3: Oil pressure at pressure tap (3) is too low. 1. Low oil flow (See Problem 1). 2. Failure of lubrication valve spring. 3. Oil leakage in clutch and/or lubrication circuits a. If leak is in lubrication circuit, oil pressure at pressure taps (1) and (2) will be normal. b. If leak is in input clutch circuit, oil pressure at pressure taps (1) and (2) will be low. c. If leak is in directional clutch circuit, oil pressure at pressure tap (2) will be too low. PROBLEM 4: Oil pressure at pressure tap (1) is zero. 1. Load piston (4) or spool (7) does not move. 2. No oil flow to load piston through oil passage (15). a. Sequence valve (14) does not move. b. There is no pressure in the directional clutch. (See Problem 7). PROBLEM 5: Oil pressure at pressure tap (1) is too high.
Page 11 of 21 1. Wrong spring assembly (5) installed at this location. 2. Spring (6) is keeping spring assembly (5) from pushing load piston (4) against left stop. 3. Too much oil leakage past slug (8). 4. Wrong spring (9) installed. PROBLEM 6: Oil pressure at pressure tap (1) is too low. 1. Failure of spring assembly (5). 2. Load piston (4) does not have full travel. 3. There is an oil leak in the circuit of the input clutch. PROBLEM 7: Oil pressure at pressure tap (2) is zero. 1. Failure of control cable or linkage. 2. Spool (11) will not move. PROBLEM 8: Oil pressure at pressure tap (2) is too high. 1. Wrong spring assembly (10) installed. 2. Too much oil leakage past slug (12). PRESSURE CONTROL VALVE 4. Load piston. 14. Sequence valve. 15. Ports of oil passage to load piston. PROBLEM 9: Oil pressure at pressure tap (2) is too low. 1. Failure of spring assembly (10). 2. There is an oil leak in the circuit of the directional clutch. PROBLEM 10: Oil pressure at pressure taps (1), (2), and (3) goes up and down.
Page 12 of 21 1. Low oil level is causing pump cavitation. PROBLEM 11: Hose failure caused by high oil pressure. 1. Spools (7) or (11) do not move. 2. Spring assembly (5) and spring (6) do not let load piston (4) have full travel or the spring rate is not correct. Adjustment Of Winch Control Linkage NOTICE Do not make an adjustment to the linkage with the engine running. NOTE: To check for correct adjustment of control linkage, go to Step 12. HYDRAULIC CONTROL VALVE (TYPICAL EXAMPLE) 1. Cable. 2. Bolt. 3. Cable. 4. Bolt. 5. Rod end. A. Distance between the rod end and the end of the threads on the cable is.50 in. (12.7 mm). 1. Remove bolt (2) and the nut. 2. Make an adjustment to cable (1) so that distance (A) between the rod end and the end of the threads on cable (1) is.50 in. (12.7 mm). 3. Put rod end (5) in position on the lever and install bolt (2) and the nut. 4. Tighten the nut against rod end (5) to a torque of 30 ± 5 lb. in. (3.4 ± 0.6 N m).
Page 13 of 21 5. Put control lever (7) in position (C). 6. Loosen nut (10) and disconnect rod end (9) from the control lever. Make an adjustment to rod end (9) until dimensions (H) and (I) are the same when the control lever is in position (C). 7. Install rod end (9) on the control lever. Tighten nut (10) against the rod end to a torque of 30 ± 5 lb. in. (3.4 ± 0.6 N m). ILLUSTRATION OF CONTROL PANEL 6. Spring clip. B, C, D, E, F and G. Positions of the control valve.
Page 14 of 21 CONTROL LINKAGE (TYPICAL EXAMPLE) 1. Cable. 3. Cable. 7. Control lever. 8. Rod end. 9. Rod end. 10. Nut. 11. Nut. 8. Loosen nut (11). Move the control lever to position (E). Install a 0 to 600 psi (0 to 4150 kpa) pressure gauge in the pressure tap for the brake. Start the tractor engine. Make an adjustment to cable (3) until the pressure at the brake tap is 185 ± 5 psi (1270 ± 35 kpa). Move the control lever into spring clip (6). If the control lever is not held by the spring clip, make an adjustment to cable (3) until the control lever is held. At this time the pressure must not be less than 160 psi (1100 kpa). 9. Tighten nut (11) against rod end (8) to a torque of 30 ± 5 lb. in. (3.4 ± 0.6 N m). 10. Do not tighten nut (12). Install on the threads until there is a minimum amount of free movement in bellcrank (13) and the bellcrank is free to turn. 11. Move the control lever to all positions, make sure the threads on the cables do not come in contact with the rubber seals. If the threads come in contact with the rubber seals, make an adjustment to the cables again.
Page 15 of 21 CONTROL LINKAGE (TYPICAL EXAMPLE) 6. Spring clip. 7. Control lever. 12. Nut. 13. Bellcrank. H. and I. Dimensions from positions of control valve. HYDRAULIC CONTROL VALVE (Typical Example) J. Pressure tap for input clutch pressure. K. Pressure tap for direction clutch pressure (brake). 12. Make a check of the adjustment of the control linkage as follows: a. Install 0 to 600 psi (0 to 4150 kpa) pressure gauges in pressure taps (J) and (K). b. Start and run the tractor engine at high idle. c. Move the control lever for the winch to the "BRAKE OFF" position. d. Run the tractor engine at high idle until the oil in the winch is at the normal temperature of operation. e. Move the control lever to "BRAKE ON" position (C).
Page 16 of 21 f. Slowly move the control lever toward "BRAKE OFF" (E) until the control lever just makes contact with spring clip (6). g. At this point, the pressure at pressure tap (K) for the brake must be 185 ± 5 psi (1270 ± 35 kpa) and the pressure at pressure tap (J) for the input clutch must be 300 ± 15 psi (2050 ± 105 kpa). If the pressures are not correct, make an adjustment to cable (3). See Step 8. h. Move the control lever into spring clip (6). The control lever must be held by the spring clip. If the control lever is not held by the spring clip, make an adjustment to cable (3) until the control lever is held. At this time, the pressure at tap (K) must not be less than 160 psi (1100 kpa). i. Move the control lever to "BRAKE ON" position (C). At this point, the pressures at tap (J) and tap (K) must be 0 psi (0 kpa). j. Move the control lever to position (B): On earlier winches without a sequence valve, the pressures at taps (J) and (K) must be 0 psi (0 kpa). On later winches with a sequence valve, the pressure at tap (J) must be 0 psi (0 kpa). It is possible that the pressure at tap (K) is 60 psi (415 kpa) maximum. k. Move the control lever to position (D): On earlier winches without a sequence valve, the pressures at taps (J) and (K) must be 0 psi (0 kpa).on later winches with a sequence valve, the pressure at tap (J) must be 0 psi (0 kpa). It is possible that the pressure at tap (K) is 60 psi (415 kpa) maximum. 13. If the pressures in Steps j and k are not correct, make an adjustment to cable (1). Adjustment Of Drum Disconnect 55 And 56 Winch Drum Disconnect Adjustment for D5 and D6C 1. Put lever (2) in position (A).
Page 17 of 21 ADJUSTMENT OF DRUM DISCONNECT 1. Plate. 2. Lever. 3. Rod end. 4. Cable. A. Drum disconnect lever not activated position. B. Drum disconnect lever activated position (free spool). 2. With rod end (3) installed on cable (4) and plate (1), make sure there is.50 in. (12.7 mm) of thread showing on cable (4). 3. Install the nut and rod end (5) on cable (4). 4. Adjust rod end (5) until it can be installed in lever (2) and tighten nut (6).
Page 18 of 21 CABLE CONNECTIONS AT VALVE 4. Cable. 5. Rod end. 6. Nut. 7. Spacer and clamp. 5. Install the spacer and clamp (7). 6. Move lever (2) to position (B). 7. Check to see if the valve spool has moved out a minimum of.50 in. (12.7 mm); if it has not, adjust rod end (5). 8. Remove plug (8) and install a pressure gauge. With the engine speed at low idle and lever (2) in position (B), the oil pressure must be 265 to 315 psi (1825 to 2155 kpa). LOCATION TO CHECK OIL PRESSURE 8. Plug. Drum Disconnect Adjustment for D5B and D6D Tractors 1. Make an adjustment to rod end (8) so that ten threads show above nut (9).
Page 19 of 21 2. Tighten locknut (10). 3. Move drum disconnect lever (3) to the DISCONNECT position. ADJUSTMENT OF DRUM DISCONNECT 1. Plate. 2. Rod ends. 3. Drum disconnect lever. 4. Two stop bolts. 5. Stop. 6. Horizontal position for plate (1). 7. Two locknuts. 8. Rod end. 9. Nut. 10. Locknut. 11. Rod end. 12. Locknut. 4. Check to see that the valve spool is pushed in.39 in. (9.7 mm). If not, adjust rod end (11) and tighten locknut (12). 5. Adjust the two stop bolts (4) so that the drum disconnect lever will move 90, (from disconnect position to connect position. 6. Tighten locknuts (7).
Page 20 of 21 7. With the drum disconnect lever in the DISCONNECT position, make an adjustment to the rod ends (2) so that plate (1) is in horizontal position (6) on stop (5). DRUM DISCONNECT LEVER IN CONNECT POSITION 3. Drum disconnect lever in CONNECT position. 8. Check to see that the winch drum will turn by hand when the drum disconnect lever is in the DISCONNECT position. 9. Run the engine at half engine speed and put drum disconnect lever in DISCONNECT position. Check winch oil pressure. Oil pressure must be 265 to 315 psi (1825 to 2155 kpa).
https://sisweb.cat.com/sisweb/sisweb/techdoc/techdoc_print_page.jsp?returnurl=/sisweb/si Page 21 of 21 DRUM DISCONNECT LEVER IN DISCONNECT POSITION 3. Drum disconnect lever in DISCONNECT position.