Make certain that all applicable troubleshooting procedures have been completed BEFORE removing or disassembling the control valve. Refer to the "Control System Operation and Troubleshooting" section of this manual for more information. All repairs to the control valve must be performed in a clean work environment.
Control Valve Removal and Disassembly
1. Stop the tractor engine. With the key switch in ON position, discharge the accumulator stored oil supply by slowly cycling the joystick control lever into full REEL-IN then REEL-OUT positions as a minimum of (5) times.
2. Remove the filter and valve access cover from the RH side of the winch case.
3. Remove the filter element from the filter head. Carefully tag all hoses to aid assembly then remove all of the hoses from the control valve. Disconnect the wiring harness from the solenoids at all connections. The wires are color keyed. Refer to the "Control System Operation and Troubleshooting" section of this manual for wire color/function and connection point information.
4. Remove the pump supply hose from the filter head. Remove the two (2) capscrews that secure the valve to the mounting bracket and remove the valve assembly from the winch case.
5. Place the valve on a clean work surface and remove the filter head assembly from the valve.
- a. Carefully bend the lock tab down and away from the retaining nut.
- b. Remove the retainer nut from the top of the solenoid and lift the coil off of the cartridge.
- c. Remove the solenoid valve cartridge from the valve housing.
- b. Remove the retainer nut from the top of the solenoid and lift the coil off of the cartridge.
6. The solenoid valves may be removed from the valve housing by first removing the solenoid coil from the valve cartridge.
7. Remove the two (2) check valve assemblies from the valve housing through the front, or forward, face of the valve. Build the special spanner socket, defined below, for use in removing the check valves.
8. Thoroughly clean and inspect all parts of the control valve. Replace the check valve assembly if there is any damage to the sealing surfaces of the stem and housing.
Assembly and Installation
1. Install new O-rings and back-up rings on the solenoid valves before installation. Seal kits are available for all of the valve cartridges. Lubricate the seals with new winch oil prior to assembling.
2. Unless you are installing new components, carefully install the solenoid valve cartridges back into the valve housing bores they were originally removed from. Tighten the valve cartridges to the torque values listed in the chart on page 55.
3. Install the filter head assembly into the valve housing, after all solenoids have been installed.
4. Install the valve/filter sub-assembly into the winch case. Install the two (2) capscrews that secure the valve to the mounting bracket. Evenly tighten the capscrews to 35 lb-ft (47 N·m) torque. Install the pump supply hose onto the filter head assembly.
5. Lubricate the seal and install the filter element onto the filter head. Tighten the filter 3/4 turn, by hand, after the seal makes contact with the filter head. Attach the wiring harness leads to the proper solenoid and pressure switch contact points. Refer to the wiring diagram on page 10 of this manual. Attach the grounding terminal (black wire) to the upper RH corner of the valve housing with the machine screw. Install all of the hydraulic hoses onto the valve assembly, then fill the winch to the proper level with the recommended oil.
Pressure Adjustment
1. Install an accurate 0-600 PSI (0-4140 kPa) pressure gauge to the main pressure tap on the front of the winch. Start the tractor engine and operate approximately 800 RPM for about (5) minutes to purge the air from the hydraulic lines. The standby oil pressure should charge up to 340 PSI (2345 kPa), then slowly fall back to 290 PSI (2000 kPa). This pressure is controlled by the pressure switch signaling the main pressure solenoid, and is not adjustable.
2. Place the control lever into the BRAKE-OFF position and record the pressure. When a winch function is selected, the main pressure, controlled by the relief valve, should be 390-410 PSI (2690-2830 kPa) at low idle. If the main pressure is not within this range, loosen the jam nut on the relief valve and turn the adjusting screw. A 1/4 in. Allen wrench is required for this adjustment. After making adjustments, retighten the jam nut. Shut the tractor engine off, turn the tractor key switch to the ON position, and discharge the accumulator stored oil supply by slowly cycling the control lever between REEL-IN and REEL-OUT five (5) times.
3. Remove the pressure gauge from the main pressure tap then install the filter/valve access cover with a new gasket as required. Tighten the cover fasteners to 75 lb-ft (100 N·m).