BULLETIN NUMBER: 2352

DATE: February 2, 2017

PRODUCT: Skidders winch rebuild

SERIAL NUMBER: Skidders with Carco piston motor winches

SUBJECT: Rebuilding Carco piston motor winches BK120 and BK139

DESCRIPTION: This SNL is implementing a kit to rebuild the Carco piston motor winches
BK120 and BK139. The Rebuilt winch will be transformed to new version of the BK139 with
12T Jaw clutch, cast steel drum and carburized steel side cover.

STAMP BK139
SAME SN xxxxxxx-12T-SD
SN xxxxxxx

REQUIRED ACTION: This SNL introduces the latest kit. The kit uses the improved and
redesigned items such as: 12T Jaw clutch assembly with improved seal ring and piston,
Cast Steel drum, Drive Away clutch piston and ring and Side cover with improved material.

After teardown, all parts that are being replaced must be scrapped. Remaining items must
be thoroughly inspected. All minor scratches must be polished with high grit 1000
sandpaper. Kit items should not be installed on a winch with damaged mating parts.

After leak and pressure tests new stamping to be done on top of the motor housing as
displayed above. Fill the winch with approximately 12 Liter of Dexron III ATF oil. Oil level
must be re-checked after installation of winch on machine.

PROCEDURE:

Before starting work, read and follow all “servicing safety precautions” as listed in
the machine and attachment operating/service manuals and parts catalogs.
• TEARDOWN INSTRUCTIONS…………………………………… STEPS 1-13
• KIT ASSEMBLY INSTRUCTIONS………………………………. .STEPS 14-36
• TESTING INSTRUCTIONS...………………………………………STEP 37

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TEARDOWN:

1. Drain oil and remove small cover with O-rings, bearing and thrust washer.

Front Retaining ring

Fig 1A. Remove small cover Fig 1B. Remove front retaining ring

2. Loosen gear housing cover bolts (turn bolts slowly out until no longer loaded) in cross
pattern to evenly lift the cover. Do not remove cover completely. Remove front retaining
ring, primary sun gear, primary planet carrier and second retaining ring on shaft.

Fig 2A. Loosen bolts Fig 2B. Carefully remove primary sun gear and planetary assembly

3. Remove thrust washer and secondary sun gear.

Fig 3A. Thrust washer Fig 3B. Secondary sun gear

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4. Remove secondary planet carrier assembly and output planetary sun gear.

Fig 4A. Secondary planet carrier assembly Fig 4B. Output sun gear

5. Carefully remove housing cover, springs and output carrier assembly/clutch hub.

Fig 5A. Springs Fig 5B. Output carrier assembly/clutch hub

6. Remove spacer sleeve, shaft and clutch assembly.

Fig 6A. Spacer sleeve Fig 6B. Shaft and clutch assembly to be scrapped

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7. Remove “Drive away” piston and ring gear.

Fig 7A. Remove and scrap drive away piston Fig 7B. Remove large ring gear

8. Remove retainer plate and separator/friction plates pack.

Use piece of sacrificial

material to prevent dents.

DA piston and
Retainer ring plate

Fig 8A. Remove DA piston and retainer ring plate Fig 8B. Remove separator/friction plates pack

9. On the other side of the winch remove piston motor.

Fig 9. Piston motor

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 10. Remove motor shaft spacer and overrunning (Sprag) clutch assembly.

Fig 10A. Motor shaft spacer Fig 10B. Overrunning clutch assembly

11. Using jacking bolts remove motor housing. Some older motor housing may not have
jacking holes. Carefully pry the housing out.

Fig 11. Motor housing

12. Remove bolts and disassemble gear housing, drum, motor housing.

Gear housing

Drum
Assembly

Motor housing

Fig 12A. Remove counter sink socket head bolts Fig 12B. Gear Housing/Drum/Motor housing cover

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 13. Carefully remove lip seals from both sides of the drum. If necessary insert an auxiliary
round plate to pry the lip seals up, by doing this bearing damage is prevented.

Do not use
bearing race
to support
pry bar.

Fig 13. Lip seal

KIT ASSEMBLY:

At this stage all parts must be washed and cleaned.

14. Before starting assembly, inspect every component of the winch. Use 1000-grit
sandpaper to remove scratches especially in critical surfaces that contact seals and
bearings. In case of any concerns, contact Tigercat.
Critical surfaces

Carefully remove deep

Scratches in housing if
exists by using high grit
sandpaper.

Fig 14A. Small lip seal surface Fig 14B. Big lip seal surface Fig 14C.Piston surface

15. Install lip seals from the kit. Apply Loctite 518 to the outer circumference of both seals,
wipe away any excess Loctite that may emerge. Notice orientation of the seals.

Fig 15A. Lip seals orientation Fig 15B. Loctite 518 around seals

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 16. Reassemble gear housing, drum and motor side housing. Drum and gear housing must
be inline when installing the drum to prevent damage to lip seal. Use Loctite 243 (blue)
and Torque the M12 countersink bolts to 70 Ft-lbs. Overrunning clutch housing (motor
will be installed onto this housing) will be installed on motor end housing. See Fig 18B.

Fig 16A. Carefully install drum on gear housing Fig 16B. Install motor end housing onto drum
17. Ensure the overrunning clutch housing critical surfaces where bearing and seal sit are
already polished and washed. Apply silicone around bolt pattern circumference.

Fig 17A. Polish and wash critical surfaces Fig 17B. Silicone bolt pattern circumference
18. Lubricate lips seals with ATF oil. Reinstall motor housing into motor end housing
(ensure motor bolts are aligned with serial number plate). Apply Loctite 243 to bolts
and torque to 80 Ft-lbs.

Fig 18A. Before mounting housing Lubricate lip seals Fig 18B. Motor bolts aligned with S/N plate

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19. Put the winch assembly on work bench with gear housing facing the top. All O-rings
must be lubricated with ATF oil before installation.
Install centering O-ring and the thick spacer plate from service kit into gear housing until
spacer plate bottoms out. Apply ATF oil to spacer plate

Fig 19A. Centering O-ring. See below section drawing Fig 19B. Gear oil on spacer plate

20. Install separator/friction plate’s pack from service kit as per picture below. When
installing apply ATF oil in between every plate. Use auxiliary pictures and kit drawing.

Use ATF oil between

each plate and
separator plate.
Half of the
thickness of Centering
the first thick O-ring
friction plate
must be
engaged
with housing

Fig 20A. Separator/friction plates Fig 20B. Gear oil between plates

21. Install ring gear.

16 Tab
friction
plates
3X

Fig 21A. Clutch pack all in place Fig 21B. Complete clutch pack and Ring gear

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22. Install inner and outer retainer plate O-rings. Install drive away piston O-ring and
backup ring. Preassemble D/A piston and retainer plate before installing into gear
housing (All these components must be taken from service kit). Notice the orientation
of back up ring.

Verify this
dimension

1.5”

D/A piston
220316

Fig 22A. O-rings/backup ring installation Fig 22B. D/A piston– Retainer plate sub assembly

23. Use a rubber mallet to install Piston/Retainer plate sub assembly into gear housing until
retainer plate bottoms out. Lubricate O-rings with ATF oil to ease installation. Ensure
the installation process does not damage the O-rings.

Fig 23A. Lubricate O-rings Fig 23B. D/A Piston/Retainer plate installation

24. Install jaw clutch assembly from service kit into gear housing. Spline section of the jaw
clutch shaft will engaged to internal spline of drum. Install bronze spacer from service
kit into jaw clutch assembly. Reinstall spacer sleeve.

Fig 24A. Jaw clutch into gear housing Fig 24B. Spacer sleeve (steel) & Bronze spacer

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 25. Reinstall springs. Pre assemble clutch hub assembly from service kit and existing
output carrier assembly as shown below. Use retaining rings from service kit to lock
clutch hub in place.

New 12T Jaw

clutch hub
Remove 18
springs as shown
and install 42
springs. See kit
drawing for detail.

Fig 25A. Install 42 springs (see kit drawing) Fig 25B. Clutch hub/output carrier assembly
26. Install output carrier/clutch hub assembly into gear housing. Install thrust washer from
service kit onto clutch hub and lubricate bearing.

Bronze thrust
washer

Fig 26A. Output carrier/clutch hub asy. into gear housing Fig 26B. Thrust washer onto clutch hub
27. Install output sun gear from service kit. Install gear housing cover O-ring and drop the
existing cover onto gear housing.

Apply bead
of silicone
on Housing

Install O ring
On cover
Fig 27A. Output sun gear Fig 27B. Gear housing cover O-ring & Silicone bead

Old bolts as temporary

fasteners.
Apply
silicon
between
housing
and
cover

Fig 27C. Temporary fastening the side cover by using 4 to 6 old bolts

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Use 4 to 6 old bolts to keep the cover and housing together. The cover will be completely
bolted with new bolts and spacers once gear housing assembly and shaft are assembled.
Temporary Bolts should be snug but not tight to let the friction plates move when installing the
shaft. Using the old bolts ensures the new bolts are not deformed during gradual clamping the
large side cover.

28. Reinstall secondary planet carrier assembly, secondary sun gear with O-ring and thrust
washer

Fig 28A. Secondary planet carrier Fig 28B. Secondary sun gear w/o-ring and thrust washer

29. Reinstall primary planet carrier. Install new small cover from service kit with thrust
washer temporarily in order to put the winch in horizontal position so the parts don’t fall
out.
Temporary
install
small
cover.

Fig 29A. Primary planet carrier assembly. Fig 29B. Temporary installation of Side cover

30. Turn the winch 90 degree and put it on bench in horizontal position.

. Fig 30B. Winch assy. horizontal position

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31. Remove the small cover. On new shaft from kit install O-rings and wrap the end of the
shaft with electrical tape (where the O-ring sits) to prevent damage during installation.
Insert new shaft into winch assembly from motor side as shown. Shaft must be placed
all the way in.

Install O-rings
on shaft from
kit

Fig 31A. Shaft O-rings and electrical tape at the end. Fig 31B. Shaft installation from motor side

32. Reinstall the overrunning clutch assembly. Note orientation. Sprag clutch should be
only capable of turning in direction shown below.

Motor housing

Overrunning
(Sprag) clutch

Spacer

Retaining ring

Fig 32A. Orientation overrunning clutch assembly. Fig 32B. Overrunning (sprag) clutch direction of rotation

33. Install “back retaining ring”, reinstall primary sun gear and install “front retaining ring”
onto shaft.

Once front retaining ring is installed proceed to remove electrical tape.

NOTE: After electrical tape is removed, use 1000-grit sandpaper to carefully rectify
sharp edge at the very end of the shaft to prevent O-ring damage when installing small
cover.

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 Break
sharp edge
(if exists)
and clean
the shaft
end before
installing
the shaft

Fig 33A. New Spacer washer at the end of shaft. Fig 33B. Using 1000 grit sand paper break the sharp corner.

Temporary bolts to be
replaced with proper
bolt/washer/spacer

Bolt
Washer
Spacer

Fig 33C. Remove tape after front ring installation Fig 33D. Install Bolts and spacers from kit replace temporary bolts.

Use new bolts and spacers with washers and install them on side cover. Apply Loctite 243
(Blue) to new bolts and torque in criss-cross pattern to final torque 80 Ft-Lbs. Remove the
temporary bolts and install new bolts with spacers plus washer. Apply Loctite and fully
torque.

34. Reinstall thrust washer onto new small cover from service kit, Install cover O-rings and
bearing. Make extra attention when installing small shaft O-ring.
Before installation of small cover, apply silicone bead around bolt pattern
circumference. Apply Loctite 243 to bolts and torque 80 Ft-Lbs.

Apply
silicon
between
housing
and
cover

Fig 34A. Small cover internal components Fig 34B. Small shaft O-ring Fig 34C. New small cover installed

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35. Reinstall motor spacer, install motor O-ring onto piston motor.
Before proceeding with motor installation, apply silicone around bolt pattern
circumference. Apply Loctite 243 to bolts and torque to 400 Ft-Lbs.

Fig 35A. Reinstall motor shaft spacer. Fig 35B. Motor O-ring.

36. Before testing reinstall all fittings and plugs. Do not fill the winch with oil at this stage.
Winch will be filled with ATF Dexron III oil after leak tests.

Port “O”
Oil Fill port

Port “F”
Free spool
port

Port “B”
Oil
Drive Away
drain
(Brake off)
port Plug

Fig 36. Fittings & plugs

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TESTING:

37. TESTING WILL BE DONE IN 4 STEPS. THESE TESTS MUST BE DONE IN

SEQUENTIAL ORDER

37.1 AIR LEAK TEST: Before filling with ATF oil, fill the winch through fill port (“O”) with
compressed air @ 10 PSI and shut the valve off. Ensure the FS and DA ports are
opened. If there is pressure drop after 20 minutes, internal seals must be inspected.
Otherwise, let the air out and carry on testing.

Port “O”

Fig 37.1 Air leak test

37.2 BRAKE-OFF LEAK TEST: Using a hand pump (i.e. ENERPAC) with reliable shut off
valve pressurize through Brake-off port (“B”) @ 680 PSI, shut the valve off. If there is
pressure drop after 20 minutes, internal seals must be inspected. Otherwise, relieve
pressure and carry on testing.

Port “B”

Fig 37.2 Brake-off leak test

37.3 FREE SPOOL LEAK TEST: Using a hand pump (i.e. ENERPAC) with reliable shut
off valve pressurize through free spool port (“F”) @ 680 PSI, shut the valve off. If there
is any pressure drop after 20 minutes, internal seals must be inspected. Otherwise,
relieve pressure and carry on testing.

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 Port “F”

Fig 37.3 Free spool leak test

37.4 DRUM FREE ROTATION TEST: Connect both Brake-off (“B”) and Free spool
(“F”). Using a hand pump (Like Enerpac) slowly increase the pressure while turning
the drum (use a nylon rope or pull on the ferrule pocket to simulate the drum when it is
under cable tension). Drum should be free to rotate before pressure reaches 550 PSI.
Repeat 3 times and record free rotation pressure. If free rotation pressure is greater
than 550 PSI contact Tigercat Service.

Both Ports
“B” and “F”

Fig 37.4 Drum free rotation test

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PARTS INFORMATION:

DESCRIPTION PART NUMBER QUANTITY

KIT, SERVICE, WINCH, 12T, SD, BK120 TO BK139 75874B 1

(Latest revision of the kit should be used)

PARTS ORDERING PROCEDURE: Contact the Tigercat Parts Department to order.

REIMBURSEMENT POLICY: Not Applicable

This Service News Letter presents improvements offered to update machines to the
latest design or technology. These improvements are offered on an optional basis
and no Reimbursement Policy is offered.

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