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SERVICE INSTRUCTIONS
CONTINUED
172 REV.030429
5)
Remove pipe plug item 755, and verify that circulation hole in piston is clear and unobstructed. Re-install pipe
plug item 755.
6)
Thoroughly inspect the brake piston outer diameters and brake housing inner bores for scoring caused by
hydraulic fluid contamination. Minor surface damage may be repaired by polishing with a fine emery cloth.
7)
Remove coupling fastener item 738, from center of brake shaft item 730.
8)
Pull the brake shaft item 730, and complete brake hub assembly from the brake housing.
9)
Disassemble brake hub assembly by removing circlip item 727, from brake shaft item 730. Remove brake shaft
from brake hub assembly. Remove sprag clutch aligners item 722 and item 724, and sprag clutch item 723,
from brake hub.
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 BRAKE SHAFT,
SPRAG CLUTCH AND BRAKE HUB AS A SET.
10) Thoroughly inspect brake shaft item 730, and brake hub item 720, particularly the surfaces where the sprag
clutch item 723, engages. If any indentation or surface damage is detected, replace brake hub, sprag clutch
and brake shaft as a set.
11) Remove the 14 divider plates item 713, together with 13 brake plates item 715, and inspect for damage or wear.
Plates should not show heat discoloration. Paper material on friction plates should be intact and smooth. If any
damage is detected, replace friction and divider plates as a set. Check oil for contamination if plates are in poor
condition.
DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING
CAPACITY AND ALLOW THE LOAD TO DROP CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. DO NOT USE SOLVENT TO
CLEAN THE FRICTION PLATES. PERFORM THOROUGH
INSPECTION AND, IF NECESSARY, REPLACE FRICTION
AND DIVIDER PLATES AS A SET.
12) Remove brake spacer item 712, two thrust washers item 615, and thrust bearing item 617.
13) Remove bronze washer item 706. Remove and discard oil seal item 711, and backup washer item 710.
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 final drive or freespool mechanism of the Model R5.
DISASSEMBLY OF FINAL DRIVE ASSEMBLY:
If a failure occurs in the mechanism located inside the final drive housing, or the winch has to be disassembled
beyond the point described in the preceding chapter, proceed as follows:
1)
Remove the drain plug item 121, from the freespool housing item 250, and drain the lubricating oil from the final
drive assembly and the cable drum interior. In order to drain all of the oil out of the cable drum interior, the winch
should be tipped to an angle and the filler plug item 503, removed.
DANGER
DANGER
