Pa Re Model 23E CATALOGUE No. J267CMODEL 23E PARTS AND INSTRUCTION MANUALGEARMATIC CO, 7400 - 132nd STREET, SURREY, BC. CANADA Var 4x4 PHONE EXCHANGE 604-596-7111 WIRE ADDRESS GEARMATIC, NEW WESTMINSTER, B.C. TELEX 04-351220 FACTORY WARRANTY FOR GEARMATIC PRODUCTS Gearmatic Co., (Hereinafter “Gearmatic”), warrants its products to be free from defects in material and workmanship when installed in an application consistent with Gearmatic instruction manual procedures and specifications for that product. Should any part of said products, within one year from the date of shipment from the Gearmatic factory and under normal use and service, be found to have been defective when shipped, and such product was stored and maintained in factory condition until commencement of service, Gearmatic will repair or replace said part, f.0.b. Surrey, B.C,, Canada, provided such defective part is returned to the location designated by an authorized Gearmatic representative, charges prepaid, and provided further that inspection of the original part establishes the claimed defect to the satisfaction of Gearmatic. Any replacement part supplied by Gearmatic is warranted to be free from defects in material and workmanship lor a period of ninety (90) days after proper installation. Gearmatic’s liability under this warranty is limited to such repair oF replacement, subject to the conditions stated, and Gearmatic shall not in any event be held liable for any damage or delay caused by defective material or workmanship, and no allowances will be made for repairs, replacements, or alterations unless previously authorized in writing by Gearmatic. Gearmatic makes NO WARRANTY of MERCHANTABILITY or FIT- NESS FOR PURPOSE and shall not be liable for any conditions, guaranties or warranties, expressed or implied by law, except those specifically set forth herein. Gearmatic shall! not in any event be liable for any consequential or other damages, loss or expense resulting from any alleged defect in said products. HOW TO ORDER PARTS Order parts from your nearest authorized distributor. Order by part number only and state the serial number of the winch. The serial number is stamped on the manufacturer's name plate attached to the winch base, To determine the correct model number refer to the instructions on page 6.MODEL 23E WINCH SPECIFICATIONS STANDARD DRUM DIMENSIONS Barrel diameter x Flange diameter 164" Barrel length between flanges 10" MAMIXUM LINE PULL on Bare Drum @ 2000 PSI Model 23-S-* = 22,000 Ibs. Model 23.M-* = 18,133 Ibs. Model 23H-* — 11,250 Ibs. LINE SPEED on Bare Drum at Full Load and 90 US GPM Model 23S-* — 110 FPM Model 23M* = 132 FPM Model 23H-* — 220 FPM Maximum operating pressure —~ 2000 PST Maximum allowable oil supply — 90 US GPM Performance Graphs Page 37Index of contents: Winch Specification Description of the carmatic Hydraulic Winch Explanation of Winch Model Number Mounting Instructions Lubrication ‘ Hydraulic Oils Basic Components to be used with Winch Lowering Application Parts List and Drawings Foreword to Servicing Disassembly Instructions Assembly Instructions... Trouble Shooting... i Performance Graphs How to use this Manual Maintenance Procedure Numerical Index PAGE 10 1121 22 2B 29 35 37 38 39Description of the Gearmatic Hydraulic Winch with the Same Speed in Both Directions This Gearmatic Hydraulic Winch consists of a primary drive housing and a final drive hous- ing fastened 10 a winch base by dowel bolts which hold the housings concentric. The winch barrel is carried on anti-friction bearings tween the drive housings. The Primary drive housing contains a hyd: raulic motor which drives the sun gear of a primary planetary reduction, The output of this reduction is transmitted by a shaft which passes through the center of the winch barrel to the sun gear of a final planetary reduction in the final drive housing. The output from the final planetary reduction is transmitted directly to the winch barrel through a spline attaching the final drive planet hub to the winch barrel. The primary housing also contains a metallic disc type friction brake which is attached to the sun gear of the primary planetary reduction by a cam-type over-running clutch. The brake is held engaged by springs and is released by an annular hydraulic cylinder. This cylinder is con- nected to that motor port which is pressurized for reverse rotation, and becomes the exhaust port for forward rotation. In this way the brake is held engaged at all tirnes until the winch is powered in reverse. The brake hub forms the outer race of @ cam: type overrunning clutch and is carried on roller bearing assemblies mounted at each end of the brake hub, and on either side of the cam clutch. The shaft of the primary sun gear forms the inner race for the cam clutch and roller bearings. When the winch is powered in a for ward direction of rotation, the over-running clutch permits the sun gear to run free and the full power from the hydraulic motor is trans: mitted through the entire unit to the winch barrel. When the winch is stopped by moving the control valve to neutral, the cable load causes the cam clutch to “lock up” and the load is then held entirely by the friction brake. When hydraulic oil is supplied to the motor for reverse rotation, the cam clutch will “lock up” and the motor will not rotate until the pressure builds up and releases the brake suffi ciently to permit the primary sun gear and brake plate to rotate as a solid ut This unit can be used to lower any load (up to the designed maximum load) with smooth aceelleration and deceleration. This is achieved by the special design of the automatic friction’ brake. When a load is applied to the cable on the winch barrel it is held by the brake through the cam clutch on the primary sun gear. In order to lower a load with the winch, hydraulic pressure is applied to the reversing side of the motor. This pressure, which is also effective on the brake cylinder, builds up until the brake is released sulliciently to allow it to slip. If the load on the barrel tried to drive the motor faster than the supply of oil will permit (ic. if the motor tries to act as a pump), the hydraulic pressure will decrease in the brake cylinder causing an increase in the effective spring load, resulting in an increase in braking effort. In this way a balanced pressure is supplied to the motor and brake release cylinder according to the load on the winch barrel. The speed of the winch in reverse (and forward) is purely dependent on the volume of oil supplied to the motor through the control valve. This hydraulic winch is also available with the brake active in both directions, designated as “EB” it differs from the “EC” and "EA" units previously described in that it does not contain a cam-type over-running clutch. In this unit the brake plate is connected directly to the primary sun gear and the annular brake cylinder is connected to the forward and reverse hydraulic lines by means of an external port through a shuttle valve allowing pressure from either rota tion to release the brake, Due to the special design of this model, 2 noticeable drop in output torque will be experienced as the output speed is increased. This hydraulic winch is also available with: out the automatic brake for use in special applications.Explanation of Winch Model Number MODEL 23. FINAL DRIVE, aa | $= Standard Ratio 825 to 1 M= Medium Speed Ratio 680 to 1 H= High Speed Ratio 422 to 1 DIRECTION OF DRUM ROTATION (Viewed from Final Drive End) EC = Clockwise Forward Rotation (std.) EA — Anficlockwise Forward Rotation EB — Brake Active in Both Rotations EN — No Brake MOUNTING INSTRUCTIONS General Information Mount the winch on a rigid mounting base. 1 2. Do not weld to any part of the winch. 3. Check alignment of the winch when mounted 4, Use correct type of control valve 5. Use hose and control valve sizes recom: mended. 6. Use oil recommended. 7. Connect vent port ‘O' (Figure ‘A’) directly to the reservoir, EXAMPLE: MODEL 23-5-EC The above model number indicates— 23 = Basic model number indicating the size of the winch. § = The winch has a. standard final drive planetary reduction. EC — When viewed from the, final drive end, when "winching in”. The winch ‘drum rotates. at the same speed in both ‘directions. ‘The automat brake is active in reverse rotation only. J ceed the maximum PSI or GPM stated in the winch specifications. 9. Keep the hydraulic system clean and free from dust and grit at all times. 10. If the winch does not perform according to specifications, check the hydraulic system before dismantling the wineh 11. Read the disassembly and assembly instruc- tions for the winch before removing any part of the winch, 12. Disassemble the winch and sub-assemblies in a work area that is clean and free from dust and grit FIGURE AMOUNTING BASE The Gearmatic Hydraulic Winch must, be mounted on a rigid base which will not deflect due to the cable pull. This base should be ma chined flat on the mounting, surface. ‘Do not weld to any part of the winch, When it is not practical to fasten the winch to a flat ma- chined {ace the following mounting procedure Should be used. Take a piece of Hat mild steel plate of sufficient size to suit the mounting holes In the winch. This plate should have a minimum thickness of 1”. Weld 214" x 204" x /4” thick pads at three corners of the top surface of this plat So that the mounting holes of the winch will be located over these pads. Drill mounting holes Ps" diameter, spaced according to the mounting holes in the winch, Also drill one 234" x 214" x wie" spacer using the same drill. Now weld the mounting plate in its required location so that it forms a rigid base for the winch. If necessary this plate should be braced with ribs welded to the back of the plate. Once the mounting plate has cooled after welding, fasten the winch using "grade 5” capscrews, nuts and lockwashers at the three corners which have the welded pads Measure the clearance, between the mounting plate and winch at the fourth corer. Now g The 2!" 213" x %e" spacer to fill this measured Clearance, install this spacer and the remaining capscrew, nut and lockwasher, and tighten all Capscrews securely. Check the alignment of the Wrinch as stated below and tack weld the ground Spacer to the mounting plate so that it will not ‘Be lost when the winch is removed for servicing in the future. CHECK THE ALIGNMENT OF THE WINCH (Ref. Figure ‘A’) Measure clearance ‘Y’ with feeler gauges, at points 'V" and "Was indicated on Figure ‘A’ Measure clearance ‘Z' at, points ‘V' and "W" also indicated on Figure, ‘A’. For good alignment Clearance "Y" should be equal when measured at points, "V" and 'W" within ,005". Clearance “2, Bhould also be equal when measured at 'V' and AW" within 005", Clearance "Y’ does not require to be equal to clearance °Z’, IE the clearances measured at "Vand ‘W' are not within 005", Install shims under one corner of the winch base Until clearances ‘V’ and ‘W’ are within .005" when the winch is bolted solidly to its mounting, LOCATION OF OIL LEVEL PLUG ‘S’ IN FINAL DRIVE COVER (Ref. Figure ‘A’) The oil Jevel plug ‘S" should be located at the bottom of the final drive cover when the winch is mounted in position. If plug ‘S' is not in the Tequired location remove the cover according (0 the disassembly instructions for the final drive assembly and replace as required. Rcfill with SAE, 90 transmission oil to the level of the filler plug. LOCATION OF MOTOR PORTS ‘R' AND VENT PORT ‘Q’ (Ref. Figure ‘A’) When the winch, ig mounted in its required location, vent port ‘Q' must be located within 45 degrees of top dead centre. This insures that the primary housing will always be filled with oil to the required minimum level. Vent port ‘Q’ and the motor ports ‘R’ can be moved to any desired angle to suit a particular installation by using the following procedure. _ First check, tha all oil has been drained, From the primary housing by removing the '4” pipe plug?U"itom the underside of the primary hous. Tngr also remove the top '%” pipe plug allowing air'to enter the housing, Remoye the spring cover which contains port “Q' by slackening capscrews “I” half a turn at a time, progressively ‘around in a clockwise or counter clockwise direction. Care must be used to insure that the spring cover is removed evenly as it carries the full spring load for the brake. When all the spring load has been removed from. the spring cover it can be withdrawn from the winch, In most cases there will be a spring in ever: hole provided. but in certain applications fewer Ss] gs are req d and it is snportant that they be located symmetrically when they are replaced. Note and mark any hole that does not contain a spring and then remove all the springs. ‘The motor assembly can now be rotated inside the primary housing until the motor ports 'R’ are turned to the required location. Replace the springs in their holes as marked, so that they form the same symmetrical pattern, as before. Now replace the spring cover with capserews “Y'so that port ‘Q' is in the required location. Tighten the capscrews evenly by one half turn at a time, progressively as before. Care must be sed to insure that the spring cover remains par- allel to the end of the primary housing as it is tightened into place. Torque load capscrews ‘T’ to 50 Ibs. fi. LUBRICATION The final drive assembly is to be filled with SAE 90 transmission oil to the level of the filler plug ’S' ‘The primary drive assembly is to be filled through port“Q' with the same oil as is used in the hydraulic system. ‘The drum bearing at the primary drive end is prepacked with bearing grease on assembly and does not require further attention.HYDRAULIC OILS General Application Any good quality hydraulic oil may be used in the hydraulic system. The following sp tions will serve as a guide i ng suitable oils. select For a tractor winch installation or similar tow ing application any good HYDRAULIC OIL may be used. To express these oils in general terms, for areas where the minimum climatic tempera. is above 32°F. a hydraulic oil having @ ht equivalent to an SAB rating of 1OW will be satisfactory. When the mini perature is between 0° F. and 32" F, use a hydraw: lic oil having a weight equivalent to an SAE rat num climatic tem: ing of SW, For low temperature climates below 0° F, consult the local oil company representative for a hydraulic oil having a maximum viscosity of 3,000 SSU's at the minimum temperature encountered. Oils having 150 10 250 SSU viscosity at 100° F. and a viscosity index of 100 or greater will give good results under normal temperature condi- tions, The use of an oil having a high viscosity index will minimize cold-start trouble and redu the length of w: index will mini mmup periods. A high viscosity nize changes in viscosity with corresponding changes in temperature. Under continuous operating conditions the tem: perature of the oil at any point in the system must not be allowed to exceed 180° F, It is recom: mended that the pump inlet temperature be limited to 130° F, Definite operativnal advantages will be obtained by operating betow 130° F Contact the factory if in doubt regarding the selection of hydraulic vil BASIC COMPONENTS TO BE USED WITH THE WINCH Control Valve The control valve used 10 operate this winch must be a four-way, spring return ( neutral, open centte valve, having a motor spool, that is, all ports must be open to the reservoir when the valve spool is in the neut valve should have good metering characteristics in order to provide smooth winch control, and have a built-in relief valve suitable for the maxi mum operating pressure. The use of a long con: 1 position. This control trol valve handle will provide better control, The control valve must have port sizes suitable for the hoses recommended under the heading "Hose Sizes" (Page 9). When the winch control valve is to be inst between the pump and an ¢: led g control valve, it will be necessary to use a control valve for the inch which has a “high pressure carryover" or “Power Beyond” Port.Pump For maximum pump life it is important that the manufacturer's recommendations for maxi- mum PSI and R.P-M. are not exceeded. When a V belt, or similar drive is to be used to drive the pump, consult the pump manufacturer for the maximum overhang load which is permissible on the pump shaft. Filter When these winches are installed with their own hydraulic system or when there is no filter in the existing circuit, a partial flow micro filter should be installed in the return Tine between the control valve and the reservoir. This filter should trap particles over 10 microns in size. SERVICING SCHEDULE FOR FILTER The original filter cartridge should be replaced after 50 hours operation, ‘Average Atmosphere—Replace after each 500 hours. Dirty Atmosphere — Replace after each 250 hours. The above schedule is for an open system equipped with a micro air breather. Open sys tems without micro air breathers are not recom: mended, Visual inspection can not be used to determine when the cartridge should be replaced. Particles below 40 microns are not visible to the human eye. Reservoi The reservoir should be fabricated from clean scale-free material and be made as large as is practicable to provide cooling for the oil. The actual size of the reservoir will depend on the application for which the winch is used but should not be less than 4 of the pump capacity. That is, if the pump delivers 90 GPM, the mini- mum reservoir capacity will be 30 gallons. The reservoir requires to have a filler cap with a built-in micro air breather and a permanently installed fine mesh oil screen having a minimum of 2000 meshes per square inch. A dip stick or sight glass to indicate maximum and minimum oil levels is also required. The return line must enter the reservoir at a point which will be below the surface of the oil at all times. The return oil should be suitably baffled to prevent excessive turbulence in the tank. The addition of a mag- netic plug in the bottom of the reservoir is recom- mended for trapping steel particles. This plug can also serve as a drain for the reservoir. A sealed inspection cover should also be installed on the reservoir for the purpose of cleaning the inside after fabrication, and for future inspection. One additional port requires to be provided in the reservoir so that oil entering through this port will do so just below the minimum oil level, this port is required for the vent line which is to be connected to port “Q’ on the winch (%" N.P.T.) The reservoir should be located close to and above the pump if possible, clear of other equip- ment to provide good air circulation around the reservoir for cooling. Hose Sizes In order to maintain maximum efficiency in the winch, select the size of hydraulic fines from Table | according to the maximum volume of oil to be used in the winch. If the hydraulic lines used are too small they may cause sufficient back pressure at the motor to release the brake (see paragraph 3 of Description of Gearmatic Winch, page 5) ‘The sizes shown in Table 1 are to be used as a guide only. If trouble is experienced due to the tse of long hoses it will be necessary to use hoses which are one size larger. TABLE 1 vonune | __ Mimo Sega Hee us gnu ts] oasina eweim 41 to 65, 1%" LD. 1%" LD. | eet : won] mi | ow | win ——ico ai orcanren win FILLER seneen aan PLie. ww MAGNET LeveL sich uass HEAT EXCHANGER “ ppeicnnion RELIEF vauve port? pont at : syoRAULiC “I +t ,eressune_|{ | epessuse < c ScowTwOL_vaLVE FIGURE 8 LOWERING APPLICATION In all lowering applications, it is necessary to circulate oil through the primary housing. This provides cooling for the brake and also insures that the primary housings completely filled with oi Figure ‘B’ illustvates the basic hydraulic circuit for 2 lowering application, Oil iy circulated through the primary housing so that it enters at port'P" and leaves at port ‘O° The hose used for The circulation lines 10 ports ‘P' and 'Q" can be Jow pressure hose with “push on” fittings. Figure 'B illustrates a partial flow micro filter being used to filter the oil and create a back pressure to Cause circulation through the winch. The pres sure in the primary housing duc to the circula. tion oil mnust not exceed 15 P'S [The filter should be installed close to the reservoir and the cireulat- ing line to port 'P’ should be connected from a point close to the oil filter as shown. Port “Q" Should be connected directly to the reservoir as Shown, Once the hydraulic circuit has been com pleted, bleed all aiv from the primary housing 10 before running the winch. This is done by slack ening the '4__ pipe plug ‘U" (Figure A) on top of the primary housing while oi is being circulated through the housing. In installations where the amount of heat absorbed by the oil is greater than the cooling capacity of the reservoir and the other compo: ents, it is necessary to install a heat exchanger as shown by dotted lines on Figure ‘B’. All the oil 1. ing the control valve passes through the heat Cacuanger before returning to the reservoir. The hheat exchanger illustrated on Figure ‘B’ is a water Cooled unit. The volume of water entering the heat exchanger is regulated by a thermostatic valve which is controlled by the temperature of the oil in the reservoir. When it iy vet practical to use a water cooled unit an air cooled heat ex- changer may be used. The temperature of the oil fat any point in the system must not be allowed to exceed 180°F, It is recommended that the pump inlet temperature be limited to 130°F. Defic hite operational advantages will be obtained by operating below 130°F. During low speed lowering, it is recommended that the hydraulic pump be eperated at maxirsum GPM to avoid brake chatter,SECTIONAL DRAWING OF COMPLETE WINCH sodei 23-s-ec FiGURE &Location Ase PART No DRUM AND WINCH BASE ASSEMBLY Model 23-S-*, Model 23-M-* and Model 23-H-* ‘i Weight ttemNo. | Part No. Description No.Rea'd | y, V0 1 50478 Ball Bearing 1 2 0 2 30328 ‘O' Ring 1 _ 3 A22008 ‘Small Seal Ring 1 oO 8 4 50482 ‘Oil Seal 1 oO 45 5 50276 Drum Bushing 1 _ 6 ALLO41 Dowel Bolt 14 oO 4 7 50098 Lock Washer 4 8 50099 Hex, Nut 14 0 Ha 9 50123 Hondu 1 8 10 50875 Snap Ring 1 a n 530352 ‘0’ Ring 1 es 12 22000 Faper Seal Ring 1 ° 8 13, ‘See page 13 Sun Gear Shaft 1 9 8 4 50483 Oil Seal 1 0 6 AS. 22002 Large Seal Ring 1 2 oO 16 50333 | -o Ring 1 ae 7 50479 Snap Ring 1 - 18 50480, Ball Bearing (50479 Included) I 4 8 19 See page 13 | Winch Base 1 136 0 20 See page 13. | Drum (50276 Included) \ 165 ° Not Shown | S049 | Wire (Shipping Only) 1 7 L | 2 WHEN ORDERING PARTS, BE SURE TO STATE THE SE IAL NUMBER OF WINCHSm art “a “a tnt Description No. Read *B22135X-* Sun Gear Shaft Het *| ° B22004X | Sun Gear Shaft [1 Tell 13 (*B22036X-* Sun Gear Shaft Jd el |e B22 101X-* Sun Gear Shaft ae . ele . a *B22136X-" ‘Sun Gear Shaft 1 . . _| D22050X___| Winch Base 1 oo is \-onnosix Winch Base eae Le Ga | | €22196X Winch Base T | [elele | C22197X-* Winch Base [ejeie [ Hatt ag 1 €22000X | Brum 1 : : Vre2z041x-*-*2*| Drum 1 Lelele =e] * Additional information to be inserted before Part Number is complete. On the following parts the Part Numbers must be completed as follows: APTS B22135% 1B22036X.t B22101X-3 B22136X-¢ Ise cen ee Se) CEC between flanges in inches | WINCH BASES D22051X- C22197X 4 Insert drum length measured | a between flanges in inches bru cxmixges DRUM fs For Model 23-"-E¢, insert ‘C! | ‘ for Yad 8g | IT overt measured barrel diameter ———— Insert measured flange diameter \ Tnocrt acre! length measured between flanges —> WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NUMBER OF WINCH 13w PRIMARY DRIVE ASSEMBLY Model 23-*-EC ; ee Assembly | D22033XEC | Primary Drive Assembly 1 3 0 1 50468 | Capscrew 2 0 25 2 50392 Seal Washer 2 = 3 50465 Spring Cover 1 9 o 4 50346 ORi 1 a 5 50462 Brake Spring 18 0 35 6 50343 ‘O-Ring 1 - 7 B22005 Snap Ring 1 ° 6 8 D22093xC Motor Assembly 1 145 0 9 50461 Brake Plate 1 2 12 10 A22076 Spacer 1 1 2 u ‘A22073XC Brake Hub Assembly 1 7 0 12 50833, Snap Ring 2 - B B22045 Brake Ring i 8 8 4 22059 Primary Planet Assembly 1 1B 9 15 50328 0. 1 pe 16 50454 Oil Seal 1 0 4 7 22085, Seal Ring 1 2 0 18 50492 Snap Ring 1 0 25 19 50476 Pipe Plug 1 0 3 20 €22190 Primary Drive Housin 1 ” 0 21 50428 Pipe Plug 1 ae 2 22084 Split Flange Set (for 12” Hoses) 1 10 B22085 Split Flange Set (for 114" Hoses) 1 10 23 50100 Lock Washer 6 — pry 50611 Capscrew 6 o 1s Model 23-*-EA tem No. | Part No. j Description No. Reg'd Ree Assembly D22033XEA | Primary Drive Assembly | 1 ai 0 (This assembly includes all parts listed under 1D22033XEC except Items 8 and 11 change to the part numbers listed below.) 8 | D22093XA_ | Motor Assembly 1 145, 0 " A22073KA Brake Hub Assembly 1 7 0 WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NUMBER OF WINCHModel 23-*-EB em No, | Patt No. Description No. Req'd - —_t_-—_—_ —— 1 Assembly | D22054XEB Primary Drive Assembly fen | au 0 (This assembly includes all parts listed under 1D22033XEC except Item 8 changes to the part no, | listed below. Items 25, 26 and 27 are added. Item 11 | is not required.) | 8 D22093KBP | Motor Assembly 1 145 0 23 22081 Brake Hub 1 3 8 6 22082 Primary Sun Gear 1 } 4 2 2 Snap Ring 1 | a Model 23. Hem No. Deseri | No. Read Weight Seer Poa | Assembly | D2208SXEN Primary Drive Assembly 1 31 0 | (This assembly includes all parts listed under 1D22033XEC except Item 8 changes to the part no. listed below. Items 25, 26 and 27 are added. Items 5, 9, 11, 12 and 13 are not required.) | 8 122093KN. Motor Assembly fea | 145 o 25 22081 Brake Hub ; 2 8 26 | A22082 Primary Sun Gear 1 1 2 27 | -50580 |__ Snap Ring 1 4. When ordering replacement motor assemblies for Winches serial number 23-521 and down, order Motor Assembly D22093XC and Brake Plate 50461. When installing the new motor discard the Pressure Plate B22047 and the Backing Plate C2011. When ordering replacement Brake parts order as follows: Brake Plate 52995 (Radial Grooves) is to be used with Motor Assembly D22034XC (Serial Number 23.521 and down). Brake Plate 50461 (no Radia Grooves is to be used with Motor Assembly D22093XC (Serial Number 23-522 and up). 15BRAKE HUB ASSEMBLY i Weight tom No. | Part No. No. Req'd es ae Assembly | A22073X 1 7 15 1 B22046 Primary Sun Gear f 2 3 2 a2079 | Roller oo = 3 822077 Snap Ring 2 ° 1 4 22051 Cam Lock 28 _ 5 22080 Garter Spring 2 ae 6 422073 Brake Hub 1 3 1s 7 422078 Spacer 2 ° 1 8 50832 Snap Ring 1 = PRIMARY PLANET HUB ASSEMBLY tom No. Dose Assembly | C22059X Primary Planet Assembly 1 18 9 1 50573 Pin 3 _ 2 422072 Primary Planet Pin 3 0 7 3 30829 Bearing 3 0 35 4 22078 Primary Planet Gear i aetstoe acer 0 5 Al1018, Thrust Plug 3 0 os 6 22074 Bushing 1 0 4 1 22019 ‘Thrust Pad 1 0 45 8 50306 ORing 1 a 9 22059 Primary Planet Hub 1 8 ae WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NUMBER OF WINCHMOTOR ASSEMBLY Model 23-*-EC Item No. | PartNo. Description Assembly | D22093XC Motor Assembly 1 E2042 Motor Housing 2 B22088X Cartridge Assembly 3 A22104 Snap Ring 4 50367 Backup Washer 5 50337 O-Ring 6 €22189X. /4{H%6" Brake Piston (includes 8 of Item 1 7 50339 O-Ring 8 30368 | Back-up Washer 9 B22086 Motor Shaft 10 50537 Pilot Ring u 50310 O-Ring 2 50831 Pin 3 50328 ORing 4 50134 Snap Ring 15 50589 Bearing 16 1295 ORing 7 €22096C Shaft End Cover 18 30830 Cap Screw 19 50428 |__ Pipe Plug Winches Serial Number 23-521 and down use Motor Assembly D22034XC. The following parts are to be used in the Motor Assembly D22034XC: Pin $0395), Motor Housing E22009C and one Pin 50395, Model 23-*-EA tem Ne. Part No. Description Assembly | D22093KA Motor Assembly | (This assembly includes all parts as listed above | the part numbers listed below.) 220424 Motor Housing €220964, Shaft End Cover under D22093XC except Items 1 and 17 change to WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NUMBER OF WINCHModel 23-*-EB Assembly | D22093XBP Motor Assembly 144 0 (This_assembly includes all parts listed under D22093XC except Item Numbers 1 and 17 change | to the part numbers listed below. Items 21 to 27 | are added.) 1 220428 | Motor Housing 1 n 0 7 €22096B Shaft End Cover 1 18 0 2 | 50827 Tube 1 = 2 50796 Elbow 5 o 15 23 50826 Nut 6 0 07 24 50936 Tube 1 a 25 50835 | valve 1 1 0 2% 50834 | Cap Screw 2 ae 7 50912 Male Connector 1 = 28 | 50828 Tube 1 = Model 23-*-EN Taare aaa Weight mene | fn . tbe om Assembly | D22093XN_ | Motor Assembly 1 145 o j (This assembly includes all_ parts listed under i 1D22093XC except Items 1 and 17 change to the [tem No’s listed below and Items 3, 4, 5, 6, 7, 8, 12 and 16 are not required.) i 1 £22042 Motor Housing 1 R 0 7 €22096 Shaft End Cover 1 18 0 WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NU/ 18CARTRIDGE ASSEMBLY temo. | panne | Description No. Reqd Assembly | 522088% Cartridge Assembly 1 1 50413 Pin 2 2 50278 Backup Washer 2 3 50277 ORing 2 4 5oaz | Capscrew 2 o 1 Sub Ass’y } A2ziis Plate Assembly (consists of items 5 and 6) 1 7 3 5 50817 Plate 1 7 0 6 Soaia Bushing 1 ° 1 7 50418 Gam Bios 1 4 3 ; fane Kit Soe ee ee rece (consists of items 8 and 9) 7 8 50415 vane 10 ° 2 9 s0di6 Spring 40 10 50411 Pin 2 ° 1 n 50410 Rotor i 6 1 2 50409 Plate 1 7 o B 50430 Seal Ring 1 TERT ETT] Tit pane WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NUMBER OF WINCH Taiete winer KE | toma W | RUE TaIvY DRIVE ASEM | bana Wf zaI3a (6 meer) suept_| szeraeox UPAPY Gave ASSERT | Buna W | 209% (40 eter) sutyt_| nzziopox aon ASSL Tune wT Aras sutyt_| azerasex Tina, GRE ASSO nao (stersre) aL onTve ASSEPRLY (ear iereefet). Site Tain ASSERLY ‘seas aie A gerates Hot Aapticatte Blake Zettdad’ tor use wien Hydrate 081 FEUTWL" for ose wth Peosghate Exton Putas 19FINAL DRIVE ASSEMBLY Model 23-S-* tem No. Part No, Description No. Req'd i i ‘Assembly Final Drive Assembly 1 Is 0 1 22001 Final Housing t 75 0 2 €22006xS I Planet Assembly (Std) 1 08 0 3 822000, Plate 1 1 8 4 si775 ‘over i %» 5 50346 ‘O' Ring U 6 30463 Snap Ring 1 6 6 7 50477 Pipe Plug 1 0 4 10 50428 Pipe Plug 1 Model 23-M-* Item No. Part No. Description No. Rea ibe creates Assembly C2216 Final Drive Assembly Hanae Rens: 0 (This assembly includes all parts listed above under €22029XS except Item 2 changes 10 the part number as shown below.) 2 c22006XM Final Planet Assembs _ - (Medium Speed) 1 65 a Model 23-H-* Item No. Part No. Description No. Req'd eee ‘Assembly | €22029KH Final Drive Assembly “1 173 0 (This assembly includes all parts listed above under €22029XS except Tern 2 is replaced by Item 8.) 8 B22009X Final Planet Assembly (High Spe i 61 ° + Added on Winches Serial Number 231723 and up. oo WHEN ORDE! IG PARTS, BE SURE TO STATE THE SERIAL NUMBER OF WINCHFINAL PLANET ASSEMBLY Model 23-S-* (For Units equipped with Free Fall, see Free Fall Manual J341) ana a Weight tem No. Part No. Description No.Rea’d | ibe ee Assembly | ©22006X5) Final Planet Assembly (Std) T 8 0 1 50472 Final Planet Pin 3 1 8 2 50473, Ball Bearing 6 1 0 3 50474 Snap Ring 6 _ 4 50471 Final Planet Gear 3 9 8 5 50451 Pin 3 a 6 €22006S Final Planet Hub 1 30 0 Model 23-M-* A Weight Item No. Part No. Descr . . art No. 8 No. Req'd eee Assembly | C22006XM Final Planet Assembly i 65 0 | ~“Cthis assembly includes all parts as listed above under €22006XS except Trems 4 and 6 change as shown below.) 4 822134 Final Planet Gear 1 9 4 6 €22006M Final Planet Hub 1 30 0. Model _23-H-* : # : Weight tom No. Part No. Description No.Req’d | gy ze, Assembly | _B22009X Final Planct Reduction (High Speed) (items 7 to 14 inclusive) 1 6 0 Sub-Ass'y | €22006XH Final Planet Assembly (Items 7 to 12 inclusive) 1 56 8 7 50472 Final Planet Pin 3 1 8 8 50473 Ball Bearing 6 1 0 ° 50474 Snap Ring 6 - 10 1822008 Final Planet Gear 3 5 0 u 50451 Pin 3 aa 12 220061 Final Planet Hub 1 30 o 8 422031 Retainer Ring 1 0 os 4 422030 Sun Gear 1 4 8 WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NUMBER OF WINCHFOREWORD TO SERVICING The following service instructions have been arranged to provide the best methods for assembly and disassembly of the Gearmatic Model 23E winch. It is suggested that before any work is done on this unit, all the steps for disassembly and assembly should be read and understood. Expendable parts such as oil seals, back-up washers and ‘O' rings, should never be re-used even though inspection may show these as being serviceable for future use. The cost of these items is negligible compared to the labour involved in replacing such items if they do not function properly. All replacement parts should be given your final inspection to insure that no damage has resulted after the final factory inspection was made. Cleanliness is of prime importance when any part of this winch is to be assembled or disassembled. Before commencing disassembly be sure that a clean work area with a dust and grit free work bench is available. For ease of assembly and disassembly and in order to avoid damage to some elements in the winch, it is recommended that when possible, the winch should be removed from its mounting base. The reasons for this, will become evident once the following instructions have becn studied, General Before reassembly of the winch be sure that all parts are perfectly clean, and that all machined surfaces of the winch parts are in good condition and free from damage or excessive wear. During reassembly lubricate all ‘O" before installation. ngs and oi! seals with grease In the following assembly, disassembly and inspection instructions, the numbers in brackets refer to the item numbers on the exploded parts drawing illustrated on the reference page stated beside the heading for each section.DISASSEMBLY INSTRUCTIONS To Remove the Final Drive Assembly €22029XS, C22029XH or €22216X (Ref. Page 12 and 13) Model 23-S-*, Model 23-H-* or M I 3 lodel 23-M-* Disassemble the final drive assembly accord: ing to the following instruction on this page. Remove the seven nuts (8) and washers (7) from the final drive end of the winch, If the primary drive assembly has already been removed from the winch base, and if the drum (20) has standard flange diameter as listed in the winch specifications, remove the drum (20), Support the drum under, the centre of the barrel and drive it off the final housing by tapping the inside face of the drum flange opposite to the final housing, When the drum has been removed proceed according to step 5 If the primary, drive assembly has not been removed or if the drum has a flange diameter that is larger than the standard Mange, re- move the final housing (1), (page 20) from the winch base and drum as follows. For final housings with tapped puller, holes in the flange, use two 14" N.C. x 2° cap- screws as jacks and pull the housing off the dowel bolis (6). For final housings with cast slots under the edge of the flange, use two heel bars and re- move the housings from the dowel bolts (6). To Remove the Primary Drive Assembly D22033XEC, D22033XEA, 22054XEB or D22055XEN (Ref. Page 12 and 13) Model 23-*-EC, Model 23-*-EA, Model 23-*-EB or Model 23-*-EN Disassemble the primary drive assembly according to the instructions on page 24. Do not remove this assembly as a unit as dam- age may be caused to the seal diameter of the primary planet hub (14), (page 14) and tapered seal diameter of the’ taper seal ring (12) on the sun gear shaft (13) Once the primary drive assembly has been disassembled, remove the hex nuts (8) and washers (7) If the final drive assembly has already been removed from the winch base and if the drum (20) has standard flange diameter as listed in the winch specifications, remove the drum (20). Support the drum under the centre of the barrel and drive it off the pri mary housing by tapping the inside face of the drum flange opposite to the primary housing. 4. If the final drive assembly has not been re- moved or if the drum has a flange diameter that is larger than the standard flange, re- move the primary housing (20), (page 14), from the winch base and drum as follows: 5. For primary housings with tapped. puller holes in the lange, use two 44” N.C. x 2" cay screws as jacks and pull the housing off the dowel bolis (6) For primary housings with cast slots under the edge of the flange, use two heel bars and remove the housings from the dowel bolts (6). é a ¥ FIGURE D a To Disassemble the Final Drive Assembly C22029XS, €22029XH or €22029XM (Ref. Page 12, 20, 21) Model 23-S-* and Model 23-M-* ASSEMBLY C22029XS and C22216X 1. Remove snap ring (6) 2. Remove the end cover (4) using a heel bar under the lug provided below the filler plug. boss. Remove and discard ‘O" ring (5) from the end cover (4). 3. Remove the thrust plate (3) from the final planet assembly (2). 4. Remove the final planet assembly (2). Using two pinch bars under the rim of the planet hub and against the end of the final housin, (1) pull the final planet assembly (2) ‘of the splined end of the drum (Figure ‘D’). Care must be taken not to damage the pilot bore in the final housing (1) that carried the end cover (4). 5. Remove the sun gear shaft (13) and remove and discard ‘O' ring (1) from the sun gear shaft (13). Model 23-H-* ASSEMBLY C22029XH 1. Remove the snap ring (6), 2, Remove the end cover (4) using a heel bar under the lug provided below the filler plug boss. Remove and discard ‘O’ ring (5) from the end cover (4). 3. Remove the thrust plate (3) from the final planet assembly (Bc). 234. Remove the sun gear shaft and remove and discard ‘O' ring from the sun gear shaft, The sun gear (8a) and retainer ring (8b) will be permored with the sun gear shaft as an as- sembly. 5. Remove the final planet assembly {80 Using two pinch bars under the rim of the janet hub and against the end of the final fousing (1). pull'the final planet assembly (8c) off the splined end of the drum (Figure “D’). Care must be taken not to damage the pilot bore in the final housing (1) that car- Fed the end cover (4). Inspection of Parts for Final Drive Assembly €22029XS. C22029XH or C22216X Model 23-S-*, Model 23-H-* or Model 23-M-* 1. Discard °O" ring (5) 2) Wash all parts in a suitable solvent and dry thoroughly with compressed air or clean gloths, WARNING: Do not dry the final planet as- sembly (2). or (8c) with compressed air as this may drive particles of dirt into the ball bearings which carry the plat 3. Check snap ri a forms a true circle, if bent or damaged replace with a new part. 4, Check for wear at the centre of the thrust plate (3). The original thickness at, the cen- tre of the thrust plate was, 1363", if the wear is greater than Se" replace the thrust plate (3). 5. Check that the planet gears run freely in the final planet assembly (2) or (8c). For dis: assembly. instructions and inspection of parts in the final planet assembly (2) or (8c) see page 23. 6. Inspect the gear teeth in the final housing (1). If the wear is greater than 015” when compared to the unworn part of the teeth, replace the final housing (1). Check the large pilot bore at the end of the final hous- ing (1) used to carry the end cover (4) Remove all roughness and scores carefully using a scraper and extra fine emery cloth so that ‘O° ring (5) will seal on this diameter 7. Inspect the sun gear shaft (13). Check the ear teeth for wear by comparing the tooth Shickness at the worn area of the teeth with the tooth thickness at the unworn end. If the wear is greater than .012” replace the sun gear shaft (13). 8. Inspect the taper seal ring (12), if the tapered diameter has any roughness’ or scratches remove the tapered seal ring (12) from the shaft by using a punch between the gear teeth to drive the ring off the shaft. Replace with a new taper seal ring (12) NOTE: If any one of the gears in this as sembly requires to be replaced because of tooth wear, all gears in the assembly should be replaced. 24 10. Before removing the To Disassemble the Primary Drive Assembly D22033XEC, D22033XEA, D22054XEB or D22055XEN (Ref. Page 14 and 15) Model 23-*-EC, Model 23-*-EA, Model 23-*-EB or Model 23-*-EN 1. Clean all dust and dirt away from the motor ports and, vent port ‘and’ disconnect, the yydraulic hoses. Mark the location of the spring cover (3) with respect to the housiny (2)"and location of spring cover (3) with respect to the motor assembly (8) this will insure that the motor ports and vent port are located correctly on reassembly. 2. Drain the oil from the primary housing (22) by removing one capscrew (1) with its Seal washer (2) fram, the lowest point, of the spring cover (3), Remove one pipe plug from the top of the housing (22) to allow air to enter the housing. 3. Remove the spring cover (3) using the fol. lowing procedure, Remove the remaining capscrews (1) with washers (2) by slacken- ing each capscrew (1) half a turn ata time, progressively around in a clockwise or counterclockwise direction, Care must be used to insure that the spring cover (3) is removed evenly as it carries the full spring Ioad for the brake. When all che spring load has been removed from the spring cover (3) it can be withdrawn from the winch, 4, Remove and discard ‘O' ring ( spring cover (3). 5. In most cases there will be a spring in every hole, but in certain. applications fewer springs are required and it is important that they be located symmetrically when they are replaced. Note and mark any hole that does not contain a spring and then remove all the springs. 6. Remove and discard the ‘O" ring (6) from the motor assembly (8). 7. Remove snap ring (7) and motor assembly (3). 8. The brake hub assembly (11) may have been removed with the motor assembly. (8) in step 7. If not, remove the brake hub as- sembly (11) from the bore of the primary planet assembly (14) 9, Remove the pressure plate (9) and brake plate (1) nary planet as- sembly (14) first remove the sun gear shaft (13), (page 12) by following the disassembly instructions for the final drive’ assembly on. page 23. 11, When the sun gear shaft has been removed, remove the primary planet assembly (14). 12, Remove the remaining parts in sequence as shown by the item numbers (15) 10 (24)Inspection of Parts for Primary Drive Assembly D22033XEC, D22033XEA D22054XEB or D22055XEN Model 23-*-EC, Model 23-*-EA 1. Discard all ‘O" rings and oil seais. 2. Place the brake hub assembly (11) and the primary planet assembly (14) to. one side and wash all other parts in a suitable sol- vent, Dry thoroughly with compressed air or clean cloths. Do not wash the primary lanet assembly or, brake hub assembly un- less it is faulty and requires to be replaced or disassembled, 3. Inspect the bore in the spring cover (3) for scores or bruises. If possible smooth out scores or bruises with a scraper and extra fine emery cloth in order that “O’ ring (6) will seal effectively. 4, Check snap ring (7) for flatness and that it forms a true circle, if bent or damaged, replace. 5. If the motor requires inspection see disas- sembly instructions for the motor assembly ‘on page 27. 6. Check that the sun gear in the brake hub assembly (11) will rotate freely and smooth; ly in one direction and that it will “lock up” in the opposite direction. If the sun gear will not lock instantly in the “lock up” direc- nor if there is the slighest slippage in t this direction, replace the assembly. If fur- ther inspection is necessary see disassembly instructions on page 27. 7. Check that the planet gears in the primary rotate freely an rections. planet, assembly will smoothly in bot 8. Inspect the gear teeth in the primary hous- ing (20) for wear. If wear is greater than .015” when compared to the unworn part eto teeth replace the primary housing 9. Inspect the friction surfaces of the brake plate (9), if wear has removed the grooves, replace the plate. 10. Remove and discard the oil seal (16) from the seal ring (17), discard the O-Ring (15). Model 23-*-EB or Model 23-*-EN I. Inspect the teeth of the sun gear (26) that engage with the primary planet gears for wear. If wear is greater than 015” when compared to the unworn part of the teeth, replace the sun gear. To Disassemble Bearings and Seals from Drum (Ref. Page 12) All Model 23 Winches 1, Remove bearing (1) from the drum (20) using special puller to grip in the groove provided in the .D. of the bearing. Support the puller screw on a plug located in the bore of the drum (20), Gearmatic tool No. C13115 an be supplied for removing this bearing. 2, Remove the small seal ring (3) which con- tains oil seal’ (4) and ‘O' ring (2). Remove and discard the ‘' ring and the oil seal 3. Remove the drum bushing (5) with a bear- ing puller only if it requires to be replaced. 4. To remove bearing (18) first remove the snap ring (17) from its O.D. Using the same puller as used in step I above, place a plug Foca the bore of the drum and pull the ating by gripping in the snap ring groove on the OD. of the bearing. 5. Remove the large seal ring (15) which con- tains oll Seal (14) and ‘O" ring (16). Remove and discard the ‘O' ring and the oil’ seal Inspection of Drum and Bearings, Etc. 1, Discard all ‘O' rings and oil seals. 2. Wash all parts in a suitable solvent and dry thoroughly using compressed air or clean cloths. WARNING: Do not dry or spin the bearings with compressed air. Allow the bearings to air dry after they are properly cleaned. 3. Check the seal diameters at each end of the drum (20) for rust or roughness. Clean and polish the seal diameters using extra fine emery cloth. Check the bearing hub diam- eters for scores and wear. If there is any wear, possibly caused by, a seized bearing, the drum will require to be replaced. 4, Inspect the ‘O' ring seal face in the bore of the dram (20) at the splined end. ‘This face must have a smooth finish and be free from scratches, etc. If this surface is damaged the drum will require to be replaced. 5. Inspect the drum bushing (5) for bruises, scores and wear. Remove all high spots from bruises or scores using a scraper. The orig- inal inside diameter of this bushing was 2.190", if wear is greater than .010" in diam- cer remove the bushing and replace it with a new part. 6. Inspect all ball bearings (1) and (18) for wear and pitting at the balls and. ball grooves, Replace bearings if worn or pitted. 25To Disassemble Final Planet Assembly €22006XS, C22006XM or B22009X (Ref. Page 21) Model 23-S-* or Model 23-M-* ASSEMBLY C22006XS and C22006XM 1. Using a 4” diameter pin punch, drive pin (5) completely into the final planet pin (1). 2, Remove the final planet pin (1) by tapping it out of the planet hub (6) so that it is, removed from the splined bore side of the planet hub. Remove pin (5) from the planet in (1) jow remove the planet gear (4). Drive the ball bearings (2) out of the planet gear (4) using a drift. Remove the snap Tings (3) only if they are to be replaced because of damage. Model 23-H-* ASSEMBLY B22009X (includes C22006XH) 1. Using a 4" diameter pin punch, drive pin (11) completely into the final planet pin (7). 2. Remove the final planet pin (7) by tapping it out of the planet hub (12) so that it is removed from the splined bore side of the plant hub. Remove pin (11) from the planet in Now remove the planet gear (10) 4. Drive the ball bearings (8) out of the planet gear (10) using a drift. Remove the snap Tings (9) only if they are to be replaced because of damage. 5. The sun gear (14) and retainer ring (13) will have been removed from the winch with the sun gear shaft (13) on page 12 during the dis- assembly of the final drive assembly. Remove the sun gear (14) from the sun gear shaft by pressing the sun gear shaft out of the sun gear (14) only if the sun gear shaft (14) is to be replaced or if the tapered seal ring (12), (page 12) has to be removed. The re- tainer ring (13) will remain in the splined bore of the sun gear (14) and can be removed separately. Inspection of Parts for Planet Assembly €22006XS_€22006XM or B22009X ASSEMBLY C€22006XS, C22006XM and B22009X (including C22006XH) 1. Wash all parts in a suitable solvent and dry thoroughly using compressed air or clean cloths, WARNING: Do not dry the ball bearings with compressed air, allow them to air dry after they are properly cleaned. 2. Inspect the planet pin bores in the planct hub (6) or (12) for scores or bruises which Be may have been caused in removing the planet pins. Remove the high spots of any Scores or bruises carefully with a scraper, sufficiently 10 allow a planet pin to be pressed into each bore by hand. 3, Inspect the planet pin (1) or (7) for exces sive wear at the bearing area, If wear ex. ceeds .001" on the diameter the pins should be replaced. 4 Check the planet gears (4) or (10), for weat and damage on the gear teeth. If wear is excessive or if the sun gear (14) of B22009X tems (13), (page 12) and (1), (page 20) are being replaced because ol gear tooth wear, replace the planct gears (4) or (10) 5. Inspect the ball bearings (2) or (8) for wear and pitting at the balls and ball, grooves, Replace bearings if worn or pitted, ASSEMBLY B22009X In addition to thi above inspection steps make the following inspections which apply to assembly B22000X only, 1. Inspect the gear teeth on the sun gear (14) for wear, If wear is excessive replace the sun tainer ring (13) for damage. If \S notches on the inside diameter replace the retainer ring (13). To Disassemble the Primary Planet Assembly C22059X (Ref. Page 16) 1. Remove bushing (6). 2. Using a %c” diameter pin punch drive pin (1) into the planet pin (2) until it can be removed with the planet pin (2) 3. Remove the primary planet pin (2) by tap. ping it out of the planet hud (9) so that it Is removed from the side of the planet h that carried the bushing (6) 4, Remove the planct gear (4) with the needle bearing (3) from the planet hub. 5. After all the planet gears have been re- moved, the thrust pad (7) and ‘O" ring (8) can be removed from the planet hub. Remove and discard the 'O' ring (8) Inspection of Parts for P Planet Assembly C22059X 1. Discard ‘0’ ring (8). 2, Wash all parts in 2 thoroughly us cloths WARNING: Do not dty the necdle bearings with compressed air, allow them to air dry after they are properly cleaned, 3. Check the planet hub (9). Inspect the seal diameter for scores or roughness. Try re- moving roughness with extra fine emery cloth, TE roughness can not be removed com. pletely in this way replace she planet hub 9). ary ‘table solvent and dry ig compressed air or clean4. Inspect the planet pin bores for scores and bruises which may have been caused in re- moving the planet pins (2). Remove the high spots of any scores or bruises carefully with a scraper, sufficiently to allow a planet pin (2) to be pressed info each bore by hand. 5. Inspect the pins (1) for damage. If they are bent or distorted discard them. 6. Inspect the planet pins (2) for excessive wear at the bearing area. If the wear at the bearing area is greater than 001” on the diameter when compared with the unworn areas, the planet pins (2) should be replaced. 7. Check the planet gears (4) for wear and damage on the gear tecth. If wear is exces- sive, replace the planet, gears (4). 8. Inspect the needle bearings (3) for freeness of rollers. Check for pits, broken rollers oF excessive wear on the bronze bearing cage or flange, and replace the bearings (3) if any oes conditions exist, : heck thrust plug (5) for wear on, flange end. If flange has worn down to "2" thick the, thrust plugs (5) will require to be replace 10. Check thrust pad (7) for wear on slotted face, if wear exceeds %" replace. Original thickness of thrust pad (7) was 500" 11, Check bushing (6) for wear on bore and flange. If flange has worn to M»" thick, replace the bushing (6) NOTE: If planet pins (2), or needle bearings (3) require replacement ail these parts must be replaced at the same time. To Disassemble the Brake Hub Assembly (Ref. Page 16) A22073XC or A22073XA Model 23-*-EC or Model 23-*-EA. It is recommended that if this assembly does not function properly or is worn, it should be traded in complete for a new assembly. If the assembly is to be disassembled, do so only if clean-dust-free work bench is available. 1, Remove the snap ring (8) from the primary sun gear (1). 2. Remove the spacer (7) and rollers (2) from the gear end of the sun gear. Do not drop the brake hub off the “sum gear during 3. Slide the sun gear (1) out of the brake hub, assembly and_at the same time remove the remaining rollers (2). 4. Remove the spacer (7) from the sun gear 5. Remove the garter springs (5) and the cam. locks (4) from the brake hub (6) and place them on a perfectly clean surface. 6. Remove one snap ring (3) NOTE: Do not remove both snap rings (3) unless they are to be replaced Inspection of Parts for Brake Hub Assembly A22073XC or A22073XA 1, Wash all parts in a suitable solvent and dry thoroughly using compressed air or clean cloths. 2. Inspect the primary sun gear (1) for exces- sive wear at the bearing and camlock areas ris greater than 001” on the diameter n compared with the unworn areas, the primary sun gear (1) should be replaced. 3. Inspect the bore of the brake hub (6) for ridges in the centre area of the bore and for wear at the centre and ends of the bore. Tf there are definite ridges at the centre of the bore or wear at any point in the bore greater than 001" in diameter the brake hub will require to be replaced. The original bore was 2.8014", 4. Check the rollers (2) for pits, cracks or excessive wear and replace if any of these conditions exist 5. Check the camlocks (4) for wear at the points where they contact the primary sun gear (1) and brake hub (6). If flats are worn on the camlocks at these points they will require to be replaced. 6. Inspect the snap rings (3) to see if they are bent or distorted. Replace if these conditions exist, NOTE: If the sun gear (1), brake hub (6), rollers (2), or camlocks (4) require replace: ment, all these parts must be replaced at the same’ time. Th w To Disassemble the Motor Assembly D22093XC, D22093XA, D22093XBP or D22093XN All Models (Ref. Page 17 and 18) It is RECOMMENDED that if this assembly is found to be faulty, that it he traded in for new or reconditioned unit Before disassembling this unit, be sure to have new ‘O' rings and backup washers on hand. It is important to install new ‘O" rings once the old parts have been disturbed. This assembly should be disassembled only if trouble has been traced to the motor, and only if a clean, dust free work bench is available. The motor assembly must be removed from the primary drive assembly according to the instructions on page 24 before disassembly of the motor is started. 1 Remove the brake hub assembly (11), (page 14), 3 has remained on the motor shaft 2. Remove the eight capscrews (18).Lift off the shaft end cover (17). Ttems (3) to (18) inclusive, will be removed with the shaft end cover’ (17). For disassembly of these parts, see step 6, Remove and discard ‘0’ rings (13) and (16). Remove the motor cartridge (2) from the motor housing (1) and set it to one side for disassembly later, Gearmatic Too! TBLAIL3 can be supplied for this purpose.) move the ‘O’ ring (13), (page 19), from the bore in the port end’ cover. For’ disas- sembly instructions on the motor cartridge, see “To Disassemble the Motor Cartridge”, on page Remove the pilot ring (10) and ‘O' ring (11). Remove the snap ring (3) from the shafi_end cover (17), Remove the brake piston (6). Remove and discard 'O' rings (5) and (7) and backup washers (4) and (8). Remove the motor shaft (9), ball bearin (15), and snap rings (14) from the shaft enc cover (17). Remove one snap ring (14) and pull the bearing (15) off of themotor shaft (9) only in the bearing (15) is being re- placed. On Model 23-*-EC, remove the bush- ing (10), (page 14) only’ if the bushing is joing to be replaced. Remove the snap ring (S)"and then the brake piston (6) Mode! 23-*-EN This assembly does not use the brake pis- ton (9), ‘0’ rings (8) and (10), backup washers (7) and (11), snap ring (6) and pin 1 Inspection of Parts for Motor Assembly D22093XC, D22093XA. D22093XB or D22093XN All. Models 1 2 6. 28 Discard all ‘O’ rings and backup washers. Wash all parts thoroughly ina suitable sol- vent. Dry thoroughly with compressed air or clean cloths. Do not wash the motor cart. ridge (2) unless it is to be disassembled or traded in complete for a new assembly. WARNING: Do not dry bearing (15) with compressed air. Allow it to air dry after it fs properly cleaned. Inspect the bearing (15) for freeness of balls or excessive wear. Replace if either of these conditions exist Inspect the bore and face of the motor hous- ing (1) and face of the shaft end cover (17) for scores or roughness. If possible, remove roughness and scoring with a fine hone. Inspect the shaft end cover (17) and brake piston (6) for scoring and roughness on the cylinder diameters. If scoring and roughness is ean replace the shalt end cover (17) and brake piston (6) with new parts. Rewash ail’parts that have been’ honed and dry thoroughly. To Disassemble the Motor Cartridge B22088X (Ref. Page 19) 1 2. 3. Remove and discard all ‘O’ rings and backup petnee (4) from th r femove capscrews (4) from the port plate (5), then remove port plates. i Remove pin (1) from the port plate (5) only if replacement is required because of damage or wear. Remove bushing (6) from the port plate (5) only if replacement is required because of damage or wear. Remove the pins (10) from the cam ring (7), then separate the cam ring (7) and the port plates (5) and (12). Carefully position the rotor (11) and vanes (8) halfway out of the cam ring (11) and install a standard four inch ring compressor (see Figure E). Compress the vanes (8) into the rotor (11) and remove this assembly from the cam ring (7). Release the ring com: pressor and disassemble the vanes (8), springs (9), and rotor (11). FIGURE E Inspection of Parts for Motor Cartridge Assembly Wash all parts thoroughly in a suitable sol- vent. Dry thoroughly with compressed air or clean cloths. Inspect the cam ring (7) for scoring and roughness. If either of these conditions exist, replace the cam ring (7) Inspect ‘the wear faces of the port plates (5) and (12) for wear. Remove any light scoring by lapping. If wear is greater than 005", these components need to be replaced Inspect, the bushing (6) for wear in the bore. If wear is in excess of 003", replace the bushing. A new bushing measures 1,0405" Inspect the vanes (8), springs (9), and rotor (11) for excessive wear in the stots or burrs, If these conditions exist, replace them with new parts, NOTE: If the cam ring (7), rotor (11), vanes (8), or springs (9) are t6 be replaced, be cause of excessive wear, it is good practice to replace all of the abéve components, Re- placement of one part and not the others, will cause premature wear of the new parts because of their attempt to conform to the wear pattern of the old parts.ASSEMBLY INSTRUCTIONS To Assemble Bearings and Seals Etc. to Drum (Ref. Page 12 and 13) All Model 23E Winches 1. Install oil seal (4) in the small seal ring (3), so that the lip of the oil seal is. at’ the end of the seal ring farthest from the ‘O’ ring groove. Lubricate ‘O" ring (2) with grease and install it in the groove on the outside diameter of the seal ring. Lubricate the oil seal, give the 'O" ring an additional coat of grease, and install this seal assembly on the nonsplined end of the drum (20) so that the lip of the oil seal is towards the drum. Be careful not to damage the lip of the oil seal as it is pressed over the taper on the seal diameter of the drum. Pack the seal with grease around the seal diameter of the drum. 2. Install oil seal (14) in the large seal ring (15) so that the lip of the seal is at the end of the seal ring which has the projecting diam: eter at the bore. Lubricate ‘O’ ring (16) with grease and install it in the groove on the Outside of the seal ring. Lubricate the oil seal, give the ‘O' ring an additional coat of grease and install this assembly on the splined end of the drum (20) so that the lip of the oil seal is towards the drum. Be care- ful not to damage the lip of the oil seal as it is pressed over the taper on the seal diameter of the drum. Pack the seal with grease around the seal diameter of the drum, 3. Install bearing (1) on the non-splined end of the drum (20) so that the groove on the outside diameter of the bearing ts installed towards the drum. Pack the bearing thor- oughly with good quality ball bearing grease. 4. Install bearing (18) on the splined end of the drum (20) so that the snap ring on the ouside diameter of the bearing is installed towards the drum. 5. Install the hondu (9) in its slot in the drum (20) so that the small end of the hondu enters the wide end of the slot, 6. Press bushing (5) into the drum (20) using a sizing mandrel that is 2.1885" diameter. Install the bushing so that the end of thg bushing is flush with the end of the drum. Gearmatic tool No. B1397 can be used to install this bushing. To Assemble the Winch Completely from Sub-Assemb! All Model 23E Winches 1. Place the winch base (19), (page 12) on the work bench so that the side which is to be the final drive end of the winch is facing up. 2. Attach the final housing (1), (page 20) to the winch base using seven dowel bolts (6), washers (7) and nuts (8), (page 12) 3 10. Turn this assembly over so that it rests on the end of the final housing (I), (page 20) Now take the drum (20), (page 12) which has previously been assembled with the seals and bearings according to the instructions on page 29 and pilot the bearing on the splined end of the drum into the bore of the inal housing. Tap the drum assembly down until the wap, ring on the bearing at the splined end of the drum is properly seated on the end of the fina] housing bore. There will be approximately Mis" clearance between the final housing and the end of the drum flange when the bearing snap ring is seated. If the drum (20), (page 12) has a flange diameter that is larger than standard, steps 2 and 3 above can not be used. In this case it will be necessary to proceed from step 1 as follows: Total he fouricen dowel bois . (page 12) in the winch base (19), (page 12). Place the winch base on blocks so that the ends of the dowel bolts are Clear of the work bench and the side of the winch base which is to be the final drive end of the winch is facing up. Take the drum, assembled according to the instructions (page 29), and nest it into the winch base so that the splined end of the Gram is up. Now place the final housing (1). (page 20)" s0 that the bearing bore 1h the housing pilots over the bearing on the splined end of the drum and the dowel bolts (6), (page 12) locate in the flange of the final using. a the housing into place and secure tt to the winch base using seven wash- ers (7) and nuts (8) on the dowel bolts (6), (page 12), Turn the assembly over so that it Fests-on the end of the final housing and tap the drum down until the snap ring on the bearing at the splined end of the drum is properly seated. Take the primary housing (20), (page 14) and install snap ting (18). (page 1a) un the snap ring groove that 1s Closest to the large open end of the housing, Now pilot the pet mary housing over the bearing, on the plain end of the drum (nom-splined end) so that the dowel bolts (6), (page 12) will locate in the flange of the primary housing. Tap the primary housing on until its flange contacts the winch base and securite it to the winch base using seven washers (7) and nuts (8) on the dowel bolts (6), (page 12). Torque load nuts (8), (page 12) to 475 fi. Ibs. Assemble the primary “drive assembly ac. cording to the assembly instructions (pages 27 and 28). Assemble the final drive assembly according to the assembly instructions on (pages 31 and 32). When the assembly of the winch has been completed and secured to its mounting base, cheek the alignment of the winch according to the instructions on page 7.Te 12, Connect, the hydraulic hoses to the motor ports ‘R’ and vent ‘Q' on Figure ‘A’, page 6, Run the winch in the reverse rotation. This will centralize the brake plate (9), (page 14). To Assemble the Primary Drive Assembly D22033XEC, D22033XEA, D22054XEB' or D22055XEN (Ref. Page 14 and 15) Model 23-*-EC, Model 23-*-EA, Model 23.*-EB’ or Model 23-*-EN Before starting this, assembly the drum must be mounted between the final and primary hous. igs, secured to the winch base according to the instructions TO ASSEMBLE THE WINCH COM. PLETELY FROM SUB-ASSEMBLIES on page 29 up to and including step 6. 1, Whenever possible set the partly completed 30 winch on end so that it rests on the end of the final housing (1), (page 20). Check that the drum bearing which is carried in the primary housing has been thoroughly packed with grease. Lubricate 'O" ring (15) with grease and stall it in its groove in the seal ring (17 Install the oil seal (16) in the seal ring (17) so that the back of the oil seal contacts the shoulder in the seal ring bore. Give the ‘O° ring and oil seal an additional coat of grease and install the seal ring (17) in the bore of the primary housing so that the lip of the oil seal is out towards the open end of the housing (20) (Figure 'F'). Tap the seal ring (17) into place with a soft hammer so that it locates against the snap ring (18) which was previously installed. Install the primary planet assembly (14) so that the projecting boss locates in the bush dng (5); (page 12) at the end of the drum When this assembly is in place rotate it by hand to make sure that it is free to turn. Check that the bushing (6), (page 16) is in place in the primary planet assembly (16) Assemble the brake ring (15) and snap rin, (14) on the brake hub assembly (13). Install the brake hub assembly (13) so that the sun gear (1) on page 16 engages with gears in the primary planet assembly (14). If this assembly is being made with the winch in a horizontal position place four spots of grease (about the size of a, pea) equally spaced on the brake face on the side wall of the primary housing (20). Install the brake plate (9) so that it engages over the teeth of the brake ring (13) and against the brake face in the primary housing which hhas just been grease: FIGURE F If the winch has been removed from its mounting, and the assembly is being made with the winch placed vertically, do not grease the surface of the brake plate and primary housing as explained “above. The grease is only required in order to hold the rake plate in place while the motor assem- biy (8) 18 being installed as explained: tn step 6 ‘Take tie motor assembly (8) and place it on the work bench with the motor shaft end up. Install spacer (10) on the motor so that the counter bored and slotted end is up, Gheck ‘that the brake piston o) page 17) is located %" away from the motor housing (1), (page 17) as illustrated on Figure ‘G’. If necessary, tap the brake piston down with a soft hammer, or pry it up by using two heel bars as shown in Figure ‘G' until the He gap fs obtained Install the motor assembly (8) in the pri- mary housing (20) by holding it square with FigueG YY 2 the end of the primary housing as it enters the housing. The spline at the end of the motor shaft (9), (page 17) will engage with the Brake hub assembly (11) and the motor will pilot into the primary housing (20). It may ‘be necessary to rotate the motor as: sembly (8) slightly so that the spline at the end of the motor shaft will engage with the brake hub assembly (11). When the motor is installed, install the snap ring (7)When the winch is removed from its mount- ing base and assembled in a vertical position the brake plate cannot drop behind the ring gear. Do not use force to install the motor assembly (8). If there is interference remove the motor assembly and investigate. 7. Once the motor assembly (8) is in place in- stall the snap ring (7) and make sure that it is properly seated in the bottom of the snap ting groove all the way around the housin (20). When snap ring (7) has been installed, rotate the motor assembly in the primary housing, to locate the motor ports. at the required angle for the particular instalation 8. Lubricate ‘O" ring (6) with grease and in stall the snap ring (7) and make sure that it is properly seated in the bottom of the snap Ting groove all the way around the housinj (20). When snap ring (7) has been installed. rotate the motor assembly in the primary housing to locate the motor ports. atthe required angle for the particular installation Lubricate ‘O° ring (6) with grease and ji stall it in its groove on the motor assembly (8). After the 'O’ ring is installed lubricate it again with grease 9. Install the brake ‘springs (5) in the, same symmetrical pattern as they were in before sembly. In most cases there will be a spring for every hole but in some installa- tions fewer springs are used and it is im- portant that the springs be installed in a jymmetrical pattern for an even load on the 10. Lubricate ‘O" ring (4) with grease and install itin its groove in the spring cover (3). Once the ‘O' ring is installed lubricate jt again. 11, Install the spring cover (3) over the motor assembly so that the vent port is located in the correct position for the particular instal lation 12, Install capscrews (1) with washers (2). Screw in alf the capserews to be linger tight and then tighten them evenly by one half turn at a time progressively around in a clockwise or counter clockwise direction. Care must be used to insure that the spring cover (3) remains parallel to the end of the primary housing (20) as it is tightened into place. Torque load the capscrews to 50 Ibs. ft. To Assemble the Final Drive Assembly €22029XS, C22029XH_ or €22216X (Ref. Page 20 and 12) Model 23-S-* or Model 23 -‘M’-* Before starting this assembly the drum must be mounted between the final and primary hous- ings, secured to the winch base according to the instructions TO ASSEMBLE THE WINCH COM- PLETELY FROM SUB-ASSEMBLIES on page 28 up to and including step 7. Model 23-S.* or Model 23-M-* ASSEMBLY C22029XS and C22216X 1 Lubricate ‘O' ring (11) with grease and stall it over the taper seal ring (12) which is installed on the sun gear shaft (13). Check that the snap ring (10) is in place on the sun gear shaft (13) and install the sun ar shaft in the winch so that it engages in the splined bore of the primary planet hub. Slide the sun gear shaft (13) in until the snap Fing (10) contacts the end of the prima planet hub, at the same time ‘O' ring (iD will contact the seal face on the end of the drum and be pushed up the tapered diameter of the tapered seal ring (17) Install the final planet assembly (2) so that the planet pears engage in the internal teeth of the final housing (1) and the splined bore of the planct hub locates over the splined end of the drum. Tap the planct assembly (2) into place until it contacts the bearing that carties the drum in the final housing (1). Install the thrust plate (3) in the end of the final planet assembly (2). Lubricate ‘O" ring (5) with grease and install in its groove in the end cover (4). Give the ‘0’ ring an additional coat of grease and install the end cover in the final housing (1) ¢0 that the filler boss will be located at the bottom of the final housing when the Winch is mounted. Make sute that the end cover is properly seated against the en the gear teeth in the final housing. Install the snap ring (6) and make sure that it is properly seated in the bottom of the snap ring groove all the way around the housing (1). Fill the final housing (1) with SAE, 90 transmission oil to the level of the filler hole and install the filler plug (7) Model 23-H-* ASSEMBLY C22029XH Install the final planet assembly (8) so that the planet gears engage in the internal teeth of the final housing (1) and. the splined end of the drum. Tap the planet as- sembly (8c) into place until it contacts the bearing that carries the drum in the final jousing (1). Fit the retainer ring (8b) to the groove in the bore of sun gear (8a). Press the sun gear (8a) over the gear teeth of the sun gear shaft (13) until the retainer ring snaps into the groove provided in the gear teeth of the sun gear’ shaft Lubricate ‘O" ring (11) with grease and in- stall it over the taper seal ring (12) which is installed on the sun gear shaft (13). Check that the snap ring (10) is in place on the sun gear shaft (13) and install the sun gear shaft in the winch so that it engages in the splined bore of the primary planet hub. Slide the sun gear shaft (13) in until the snap a”