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SERVICE INSTRUCTIONS CONTINUED
DISASSEMBLY OF FREE FALL ASSEMBLY:
NOTE: All instructions which refer to controlled free fall also apply to combined free fall.
If a failure occurs in free fall section of the winch, proceed as follows:
1) Remove drain plug item 503, from end cover item 240, and drain lubricating oil from free fall housing and
end cover. The oil will drain quicker if the filler plug item 503, is removed from cable drum item 500.
2) If controlled free fall model, winch includes metering pump at back of free fall end cover item 240. If a failure
has occurred in metering pump, pump can be serviced without disassembling remainder of free fall
assembly. If not servicing pump, proceed to 3).
DISASSEMBLY OF METERING PUMP:
The metering pump can be replaced as a sub-assembly or serviced. If replacing as a sub-assembly, proceed
to
h)
. If servicing, be sure to have a pump seal kit on hand (Part No. 23031). Proceed as follows:
a)
Remove metering tube assembly item 216, from port end cover item 180, and free fall end cover item 240.
b)
Remove four hex capscrews item 197, and lockwashers item 199, from metering pump assembly.
IMPORTANT: Failure to exercise care when removing port end cover or gear housing could
permanently damage machined surfaces of pump components. Take care not to
damage machined surfaces of pump components at disassembly.
c)
Remove port end cover item 180, from gear housing item 242.
d)
Remove gear set item 224, and thrust blocks item 235.
e)
Remove and discard channel seals item 225, and backup seals item 184.
f)
Carefully pry gear housing item 242, off metering pump adaptor item 246. Dowel pins item 191, may
stay in gear housing.
g)
Discard section seals item 205.
Section seals, channel seals and backup seals in metering pump are not part of winch seal kit. Seal kit for
metering pump can be ordered from factory under Part No. 23031.
h)
To remove metering pump adaptor item 246, along with stopper item 140, unscrew four capscrews item
209, and lockwashers item 211. Remove and discard O-ring item 241.
i)
Remove metering pump shaft item 190.
3) Remove 18 hex head capscrews item 239, with lockwashers item 237, and separate free fall clutch assembly
from free fall housing item 200.
IMPORTANT: Internal gear item 330, may come off of planet gears at this time. If this occurs, care must be
taken to ensure the part does not slide out of ball bearing item 103, and drop.
4) Remove internal gear item 330.
5) EMERGENCY FREE FALL:
5a) Inspect sungear stopper item 344, for excessive wear. Replace if less than 1.54 inch thick.
CONTROLLED FREE FALL:
5a) Inspect hub stopper item 126, for excessive wear. Replace if less than 0.50 inch thick.
5b) Remove metering pump connector item 248.
5c) Inspect sungear stopper item 344, for excessive wear. Replace if less than 0.22 inch thick.
6) Pull final planet assembly off of cable drum hub item 500, and inspect for wear or damage. (Free fall end cover
capscrews item 239, can be screwed into two tapped pulling holes in planet hub to assist with removal of
final planet hub assembly.)
7) Inspect three final planet gears, item 320, for damage or wear. If it is necessary to remove final planet gears,
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