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Product: TRACK-TYPE TRACTOR

Model: D3K2 XL TRACK-TYPE TRACTOR FT3
Configuration: D3K2 Small Track Type Tractor FT300001-UP (MACHINE) POWERED BY C4.4 Engine

Disassembly and Assembly

D3K2, D4K2 and D5K2 Track-Type Tractors Machine Systems
Media Number -UENR4090-02 Publication Date -01/05/2015 Date Updated -01/12/2017

i06891654

Winch - Disassemble
SMCS - 5163-015

Disassembly Procedure
Table 1
Required Tools
Tool Part Number Part Description Qty
A 439-3940 Bracket As 2
B 168-0383 Breaker Bar 1
C 183-4799 Fork Assembly 1

Start By:

a. Remove the winch.

1. Drain the winch oil. Refer to Operation and Maintenance Manual, "Winch Oil - Change" for the
correct draining procedure.
 Illustration 1 g06162511

2. Use a suitable lifting device to lift winch (1). The weight of winch (1) is approximately 726 kg
(1600 lb). Position winch (1) on suitable cribbing.

Illustration 2 g06162519

3. Remove bolts (2) and cover (3).

Illustration 3 g06162521
 Note: Put on identifying marks on all the shims as the shims are removed. The identifying
marks will ensure correct installation during assembly.

4. Remove shims (4).

Illustration 4 g06162534

5. Use Tooling (A) and a suitable lift device to remove shaft (5).

Illustration 5 g06162546

6. Remove O-ring seal (6) and O-ring seal (7) from shaft (5).
 Illustration 6 g06162557

7. Remove bearing cone (8).

Illustration 7 g06162563

Personal injury can result from being struck by parts propelled by a

released spring force.

Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to

release the spring force.

8. Remove knob (9).

 Illustration 8 g06162570

9. Remove spring (10).

Illustration 9 g06162573

10. Remove drag pad (11).

 Illustration 10 g06162580

11. Remove insert (12).

Illustration 11 g06162587

12. Position winch (1) on suitable cribbing as Illustrated in Illustration 11.

 Illustration 12 g06162692

13. Remove bolts (13), cover (14), and the gaskets.

Illustration 13 g06162695

Personal injury can result from being struck by parts propelled by a

released spring force.

Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to

release the spring force.

14. Remove nut (15) and setscrew (16).

 Illustration 14 g06162713

15. Remove spring (18) and ball (17).

Illustration 15 g06162751

16. Remove plug (19).

 Illustration 16 g06162759

17. Use Tooling (B) to remove shaft (20).

Illustration 17 g06162783

18. Remove fork (21).

Illustration 18 g06162788

19. Remove stud (22) from fork (21).

 Illustration 19 g06162794

20. Remove bolts (23).

Illustration 20 g06162803

21. Use Tooling (A) and suitable lifting device to remove cover (23). The weight of cover (23) is
approximately 51 kg (112 lb).
 Illustration 21 g06162833

22. Remove bearing cups (24) and ball bearing (25) from cover (23).

Illustration 22 g06162845

23. Remove bearing cone (26).

Illustration 23 g06162847

Note: Put on identifying marks on all the shims as the shims are removed. The identifying
marks will ensure correct installation during assembly.

24. Remove shims (27).

 Illustration 24 g06162859

25. Remove idler shaft (28).

Illustration 25 g06162867

26. Remove retaining ring (29) and idler gear (30) from idler shaft (28).
 Illustration 26 g06162872

27. Remove retaining ring (31) from idler shaft (28).

Illustration 27 g06162875

28. Remove bearing cone (32).

Illustration 28 g06162880

Note: Put on identifying marks on all the shims as the shims are removed. The identifying
marks will ensure correct installation during assembly.

29. Remove shims (33).

 Illustration 29 g06162882

30. Remove intermediate shaft (34) and collar (35).

Illustration 30 g06162885

31. Remove intermediate gear (36).

Illustration 31 g06162903

32. Remove washer (37).

 Illustration 32 g06162908

33. Remove bearing cone (38) and bearing cup (39).

Illustration 33 g06162910

34. Remove bearing cone (40).

Illustration 34 g06162917
 Note: Put on identifying marks on all the shims as the shims are removed. The identifying
marks will ensure correct installation during assembly.

35. Remove shims (41).

Illustration 35 g06162928

36. Remove drum shaft (42).

Illustration 36 g06162934

37. Remove retaining ring (43) from drum shaft (42).

 Illustration 37 g06162939

38. Attach Tooling (A) and suitable lifting device to gear (44). The weight of gear (44) is
approximately 27 kg (60 lb). Remove gear (44).

Illustration 38 g06162948

39. Remove spacer (45).

Illustration 39 g06162951
40. Remove bearing cone (46).

Illustration 40 g06162954

41. Remove bearing cup (47) and lip seal (48).

Illustration 41 g06162959

42. Remove bolts (49) and plates (50).

 Illustration 42 g06162962

43. Remove roller shafts (52) and roller assemblies (51).

Illustration 43 g06162968

44. Orient drum (53) so the ferrule pocket lines up with the recess on frame.

Illustration 44 g06162973

45. Use Tooling (C) and a suitable lifting device to remove drum (53). The weight of drum (53) is
approximately 100 kg (220 lb).
 Illustration 45 g06162985

46. Remove O-ring seal (54).

Illustration 46 g06162986

47. Remove bolts (55) and drum adapter (56).

 Illustration 47 g06162988

48. Remove O-ring seal (57) from drum adapter (56).

Illustration 48 g06163173

49. Position drum (53) on opposite side. Remove lip seal (58).

Illustration 49 g06163229

50. Position winch (1) on suitable cribbing as Illustrated in Illustration 49.

 Illustration 50 g06163226

51. Remove bolts (59) and cover (60).

Illustration 51 g06163248

52. Remove all hoses (61).

 Illustration 52 g06163260

53. Remove bolts (63) and motor (62).

Illustration 53 g06163266

54. Remove bolts (65) and manifold assembly (64) from motor (62).
 Illustration 54 g06163275

55. Remove O-ring seals (66) from manifold assembly (64).

Illustration 55 g06163301

56. Position winch (1) on suitable cribbing as Illustrated in Illustration 55.

 Illustration 56 g06163282

Personal injury can result from being struck by parts propelled by a

released spring force.

Make sure to wear all necessary protective equipment.

Follow the recommended procedure and use all recommended tooling to

release the spring force.

57. Remove bolts (68) and shaft (67).

Illustration 57 g06163317

58. Remove brake assembly (69).

 Illustration 58 g06163327

59. Release piston (70) by applying 207 kPa (30 psi) of air pressure into the passage as indicated.

Illustration 59 g06163333

60. Remove O-ring seal (71) from piston (70).

Illustration 60 g06163335

61. Remove O-ring seal (72).

 Illustration 61 g06163349

62. Remove retaining ring (73) and plate (74).

Illustration 62 g06163356

63. Remove clutch pack (75).

Illustration 63 g06163361
64. Remove spring washer (76).

Illustration 64 g06163362

Note: Put on identifying marks on all the shims as the shims are removed. The identifying
marks will ensure correct installation during assembly.

65. Remove shims (77).

Illustration 65 g06163367

66. Remove ball bearing (78).

 Illustration 66 g06163369

67. Remove retaining ring (79).

Illustration 67 g06163371

68. Remove O-ring seal (80).

 Illustration 68 g06163373

69. Remove plate (81).

Illustration 69 g06163375

70. Remove O-ring seal (82) and O-ring seal (83) from plate (81).

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