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REMOVAL OF HYDRAULIC MOTOR ASSEMBLY:
If disassembly of the hydraulic motor is not necessary, proceed as follows:
1)
Remove 12 hex head capscrews item 537, with lockwashers item 541, from motor adaptor item 800. (Since
brake springs item 752, apply pressure against the inside of motor adaptor, it is recommended that hex
capscrews are unscrewed, one turn at a time, until spring pressure has been released.) Complete motor
assembly, including motor adaptor, can now be removed from brake housing assembly.
2) Remove and discard three O-rings item 801, and O-ring item 707. (O-rings item 801, seal pressure transfer
hole for automatic brake release and are situated on flange of brake housing.)
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:
1) After motor assembly has been removed, all parts of brake assembly are accessible. Remove 14 brake
springs item 752. Thoroughly examine springs for damage and measure overall length. Overall spring length
should be 2.27 inch. If any spring measures less than 2.21 inch, replace all springs as a set.
2) Pull motor drive shaft item 730, and complete brake hub assembly from brake housing.
3) Disassemble brake hub assembly by removing circlip item 727, from motor drive shaft. Remove motor drive shaft from
brake hub item 720. Remove sprag clutch aligners items 722 and 724, and sprag clutch item 723, from brake hub.
SERVICE INSTRUCTIONS CONTINUED
MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE MOTOR DRIVE
SHAFT AND BRAKE HUB, WILL RESULT IN BRAKE FAILURE AND ALLOW THE LOAD TO
DROP, CAUSING PROPERTY DAMAGE, SEVERE INJURY OR DEATH. THOROUGHLY
INSPECT THESE AREAS AND, IF NECESSARY, REPLACE MOTOR DRIVE
SHAFT, SPRAG CLUTCH AND BRAKE HUB AS A SET.
4) Thoroughly inspect motor drive shaft item 730, and brake hub item 720, particularly surfaces where sprag
clutch item 723, engages. If any indentation or surface damage is detected, replace brake hub, sprag clutch
and motor drive shaft as a set.
5) Pull brake piston item 750, out of brake housing using two 5/8-11NC bolts screwed into two puller holes in
piston and discard O-rings item 751 and item 753.
6) Thoroughly examine inner bores of brake housing and outer diameters of brake piston for scoring caused by
hydraulic fluid contamination. Minor surface damage may be repaired by polishing with a fine emery cloth.
DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING CAPACITY AND
ALLOW THE LOAD TO DROP, CAUSING PROPERTY DAMAGE, SEVERE INJURY OR
DEATH. SOLVENT MAY DAMAGE THE FRICTION PLATES. DO NOT USE SOLVENT TO
CLEAN THE FRICTION PLATES. PERFORM THOROUGH INSPECTION AND,
IF NECESSARY, REPLACE FRICTION AND DIVIDER PLATES AS A SET.
7) Remove five friction plates item 715, together with six divider plates item 713, and inspect for damage or wear.
Plates should be flat and smooth. Plates should not show heat discoloration. Paper material on friction
plates should be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
8) Remove brake spacer item 712.
9) Oil seal item 607, and backup washer item 606, which seals brake housing from cable drum interior, can now
be removed and discarded.
All parts have now been removed from the brake housing and there is no need for further disassembly, unless
a failure has been analysed in the remaining winch assembly.
DANGER
DANGER
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