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MN RCO Ce Model 6E niGearmatic... A DIVISION OF PRGOAR OF CANADA LTD. 7400:182ND STREET, SURREY, BC, CANADAVaT axa PHONE e08) 596.7511 TELEKO4 55721 ‘CABLE: GEARMATIC, NEW WESTMINSTER BC CANADA FACTORY WARRANTY FOR GEARMATIC PRODUCTS. Gearmatic Co., (Hereinatter "Gearmatic"), warrants its products to be tree 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 detective when Shipped, and such product was stored and maintained in factory condition until commencement of service, Gearmatic will repair or replace said part, .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 for a period of ninety (90) days after proper installation. Gearmatic’s liability under this warranty is limited to such repair or replace- ‘ment, 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 FITNESS FOR PURPOSE and shall not be liable for any conditions, guaranties or warranties, express or implied by law, except those specifically set forth herein. Gearmatic shall not in any event be held liable for any consequential or any other damages, loss, attorney's fees or expense resulting from any allegeddefectin 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 stampedon the manufacturer's name plate attached to the winch base.Index of contents: Description of the Gearmatic Hydraulic Winch Explanation of Winch Model Number Mounting Instructions Lubrication Hydraulic Oils Basic Components to be used with Winch Lowering Application Parts Lists and Drawings Foreword to Servicing Disassembly Instructions ‘Assembly Instructions Trouble Shooting Performance Graphs How to use this Manuat Numerical index Maintenance Procedure Model 6E Winch Speci ations STANDARD DRUM DIMENSION Barrel diameter s Flange diameter WK Barrel length between flanges 7” MAXIMUM LINE PULL on Bare Drum at Max. psi Model 6-"-S-" = 6,000 Ibs. + = 3,000 Ibs. 1630 Ibs. LINE SPEED on Bare Drum at Full Load and Max. gpm 64 fpm 128 tpm 608 fp Maximum rated pressure 1750 psi 1950 psi Maximum allowable oil supply Model 6-26-"-" = 17 US gpm Model 6-35-"-" = 23 US gpm Page 6-18 19 20 20 36-37 38 40Description 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 housing fastened to a winch base by dowel bolts which hold the housings concentric. The winch barrel is carried on anti \gs between the drive housings. riction bea The primary drive housing contains a hydraulic 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 centre of the winch barrel to the sun gear of a final planetary reduction in the final drive housing, The output from the final planetary redue- tion is uansmitted 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 dise type friction brake which is attached to the ‘output shaft of the hydraulic motor 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 connected 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 times until the winch is powered in reverse, ‘The brake hub forms the outer race of a cam- type over-running 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 motor shaft forms the inner race for the cam clutch and roller bearings. When the winch is powered in a forward direction of rotation, the over-running clutch permits the motor shaft to run free and the full power from the hydraulic motor is transmitted 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 sufficiently to permit the motor shaft and brake plate to rotate as a solid unit. This unit can be used to lower any load (up to the designed maximum load) with smooth acceleration 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 motor shaft. 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 sufficiently to allow it to slip. If the load on the barrel tries to drive the motor faster than the supply of oil will permit (ie. 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 de- pendent on the volume of oi! 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 motor shaft 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 rotation to release the brake, Due to the special design of this model, a noticeable drop in output torque will be experienced as the output speed is increased. This hydraulic winch is also available without the automatic brake for use in special applications.Explanation of Winch Model Number MODEL 6-3-5-4 ae ea ee 26 = Standard 35 = Optional FINAL DRIVE 'S = Standard Ratio 95 to 1 H = High Speed Ratio 478 to 1 DIRECTION OF DRUM ROTATION (viewed from final drive end) EC = Clockwise Forward Rotation (std) EA = Anticlockwise Forward Rotation EB = Brake Active in Both Rotations EN — No Brake EXAMPLE: MODEL 6-26-5-6C The above model number indicates: 6 = Basic model number indicating the size of the winch, 26 ~ Standard size motor cartridge, ye winch has a standard final ive planetary reduction EC— When viewed from the final drive end, the winch, drum rotates dlgck: wise "when “winehing in’. The Winch “drum rotates at the’ same Speed in both directions. The auto matic brake is ‘active in reverse rotation only. MOUNTING INSTRUCTIONS General Information Mount the winch on a rigid mounting base. Do not weld to any part of the winch, Check alignment of the winch when mounted, Use correct type of control valve. Use hose and control valve sizes recom: mended, Use oil recommended. Connect vent port ‘Q’ (Figure ‘A’) directly to the reservoir. ae 10. u 12, Do not exceed the maximum PST or GPM stated in the winch specifications. Keep the hydraulic system clean and free from dust and grit at all times. If the winch does not perform according to specifications, check the hydraulic system before dismantling the winch. Read the disassembly and assembly instructions for the winch before removing any part of the winc! Disassemble the winch and sub-assemblies in a work area that is clean and free from dust and grit. Primary Drive Final Drive Assembly giant br Motce Porte ® ae" NPT, FIGURE AMOUNTING 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 machined face the following mounting procedure should be used. Take a piece of flat MS plate of sufficient size to suit the mounting holes in the winch, This plate should have a minimum thick- hess of 34". Weld 1°" x 15" 44" thick pads at three corners of the top surface of this plate so that the mounting holes of the winch will be located over these pads. Drill mounting holes *%2" diameter, spaced according to the mounting holes in the winch. Also drill one 1%"xl%4"x%e" spacer using the same drill, Now weld the mounting plate in its required ovation so that it forms a Tigid 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, [asten the winch using “grade 5” eapscrews, nuts and lockwashers at the three corners which have the welded pads. Measure the clearance betwecn the mounting plate and winch at the fourth corner. Now grind the 1%4"x1 34x %ia" 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 winch as stated below fnd tack weld the ground spacer to the mounting plate so that it will not be lost if the winch is removed for servicing in the future. CHECK THE ALIGNMENT OF THE WINCH Measure clearance "Y’ with fecler gauges, at points 'V' and ‘W" as indicated on Figure ‘A’ Measure clearance ‘2’ at, points “V' and “W" also indicated on Figure ‘A’. For good alignment, clearance "Y’ should be equal when measured lat points ‘V" and ‘W" within .005". Clearance '2" should also be equal when measured at 'V’ and "W' within 005". Clearance "Y’ docs not require to be equal to clearance ‘2’. If the clearances measured at 'V" and ‘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 level 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 required location remove the cover according to the disassembly instructions for the final drive assembly and replace as required. Refill with SAE 90 transmission oil to the level of the filler plug, LOCATION OF MOTOR PORTS 'R’ AND VENT PORT 'G! (Ref. Figure ‘A? When the winch is 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. pits check that all oil has been drained from the primary housing by removing the '4” pipe plug ‘U' from the underside of the primary housing, also remove the top %" pipe plug allowing air to enter the housing, Remove the spring cover which contains port ‘Q' by slackening capscrews ‘T' 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 if can be withdrawn from the winch, In most cases there will be a spring in every second hole provided, but in certain applications a smaller or greater number of 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. 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 capscrews "T" so that port ‘Q" is'in the requited location Tighten the capscrews evenly by one half turn ata time, progressively as before. Care must be used to instre that the spring cover remains pi allel to the end of the primary housing as it is tightened into place. ‘Torque load capscrews ‘T’ to 35 Ibs. ft 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 ‘O' with the same oil as is used in the hydraulic system. The drum bearings at the primary drive end and the final drive end are pre-packed with bearing grease on assembly and do not requis further attention peeHYDRAULIC OILS General Application Any good QUALITY HYDRAULIC OIL may be used in the hydraulic system. The following is to express these oils in general terms, for areas where the minimum climatic temperature is above 32°F. a hydraulic oil having a weight equivalent to an SAE rating of 10W will be satisfactory. When the minimum’ climatic temperature is between 0°F. and 32°F. use a hydraulic oil having a weight equivalent to an SAE rating of 5W. For low temperature climates below 0°F, consuit the local oil company representative fora hydraulic oil having a maximum viscosity of 3,000 SSU’s at the minimum temperature encountered. Oils having 150 to 250 SSU viscosity at 100°F. and a viscosity index of 100 or greater will give good results under normal temperature conditions. The use of an oil having ahigh viscosity index will minimize cold-start trouble and reduce the ength of warm-up periods. A high viscosity index will minimize changes in viscosity with cor responding changes in temperature. Under continuous operating conditions the tem perature of the oil at any pointin the system must not be allowed to exceed 180°F, Definite operational advantages will be obtained by operating below 130°F. ing ond Lowering Application In an application where the winch is used to lower a load, Type ‘A’ Suffix ‘A’ Transmission Oil is recommended for use in the hydraulic system. Warm Up Procedure ‘A warm-up procedure is recommended at each startup and is essential at ambient temperatures below +40°F (4°C), The prime mover should be run at its lowest recommended RPM with the hydraulic winch control valve in neutral allowing sufficient time to warm up the system. The hydraulic winch should then be operated at low speeds, forward and reverse, several times to prime all lines with warm hydraulic oil. Failure to properly warm up the hydraulic winch, particularly under low ambient temperature conditions, can result in excessive pressure build-up in the primary housing, causing damage to the housing, cover and premature seal failure. BASIC COMPONENTS TO BE USED WITH THE WINCH Control Valve ‘The control valve used to operate this winch must be a foursway, spring return to neutral, ‘open centre valve, having a motor spool, that is, all ports must be open to the reservoir when the valve spool is in the neutral position. This control valve should have good metering characteristics in order to provide smooth winch control, and have a built.in relief valve suitable for the maximum operating pressure. The use of a long control valve handle will provide better control. The control valve must have port sizes suitable for the hoses recommended under the heading “Hose Sizes” (Page 6). When the winch control valve is to be installed between the pump and an existing control valve, it will be necessary to use a control valve for the winch which has a “high pressure carryover” or “Power Beyond” Port.Pump For maximum pump life it is important that the manufacturer's recommendations for maximum PST and RPM 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. Iter When these winches are installed with their own hydraulic system or when there is no filter in the existing system, a partial flow micro filter should be installed in the return line 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 systems without micro air breathers are not recommended. 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. Reservoir 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 ¥ of the pump capacity. That is, if the pump delivers 23 GP M, the minimum reservoir capacity will be 8 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 recommended 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 (%" NPT). The reservoir should be located close to and above the pump if possible, clear of other equipment 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 lines from table 1 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 when “winching in” a load (see paragraph 3 of Descrip- tion of Gearmatic Winch, page 2) The sizes shown in table 1 are to be used as a guide only. If trouble is experienced due to the use of long hoses, it will be necessary to use hoses which are one size larger. TABLE 1 LAINIMUM SIZE OF HYDRAULIC HOSE INSIDE DIAMETER Volume | High Pressure us orm ‘usesseat cxcuanersy wee am aca Wiicalter semen _psstcnon saa “even cur Gass seccene senate ieee owns | arcs = | ‘weruasiae| | vat eu qa eee ee ap ssune sara &—fit cca vas FIGURE 8 LOWERING APPLICATION ‘Type ‘A’ Suffix ‘A’ Transmission Oil is recommended for use in the hydraulic system when the winch is used to lower a load. 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 housing is completely filled with oil. Figure ‘B illustrates the basic hydraulic circuit for a lowering application. Oil is circulated through the primary housing so that it enters at port ‘P’ and leaves at port ‘Q’. The hose used. for the circulation lines to ports ‘P’ and ‘Q’ can be low pressure hose with “push on” fittings. Figure ‘B’ illustrates a partial flow micro oil filter being used to filter the oil and create a back pressure to cause circulation through the winch. The pressure in the primary housing due to the circulating oil must not exceed 15 P $1. The filter should be installed close to the reservoir and the circulating line to port ‘P' should be connected from a point close to the oil filter as shown. Port 'Q' should be connected directly to the reservoir as shown, Once the hydraulic circuit has been completed, bleed all air from the primary housing before running the winch. This is done by slackening the 4” pipe plug ‘U’ (Figure A) on top of the primary housing while oil is being circulated through the housing. In installations where the amount of heat ab- sorbed by the oil is greater than the cooling ‘capacity of the reservoir and the other compon ents, it is necessary to install a heat exchanger as shown by dotted lines on Figure ‘B’. All the oi leaving the control valve passes through the heat exchanger before returning to the reservoir. The hheat exchanger illustrated on Figure ‘B’ is a water cooled unit. The volume of water entering the heat exchanger is regulated by a thermostatic valve which is controlled by the temperature of the oil in the reservoir. When it is not practical to use a water cooled unit an air cooled heat exchanger may be used. The temperature of the oil at any point in the system must not be allowed to exceed 180°F. It is recommended that the pump inlet temperature be limited to 130°E. Definite operational advantages will be obtained by operating below 130°F,SECTIONAL DRAWING OF COMPLETE WINCH Model 6-26-S-EC ‘amsnjour gf 01 6 Safed uo saquinu japour youl 242 02 Sumpsoso¥ asqp sited ayy ynsuos ‘you Kue sy syd quauode}dos BuTLapIO Udy “suojsuaunp WNP Prepueis TPM YoU Jg-$-92-9 POW ay1 UF pasn sized [Te Jo UOMO] ay sarENSNIE Fue osoqe a4, ae o9xcies9 an@nasey INUO AewAueDRUM AND WINCH BASE ASSEMBLY Model 6-*-*-EC Item No. Part No. | Description 1 50101 Hex Nut 2 50100 Washer 30 | Abel Dowel Bolt “4 C5569 Winch Base 6 | 51279 Ball Bearing (51245 included) 7 38303 Drum ' 8 56019 Ball Bearing (51246 included) 9 50105 Hondu "to 42" cable 10 51246 Snap Ring ul 51065, Oil beal Sun Model 6-*- All parts in this model are the same as listed above except [tem 7 (drum); change to C 502A. ‘Item 4. Winch Base C5569 is used for a winch having a standard drum with dimensions as listed in the winch specifications on the inside of front cover. Winch base C5569 is also used for a winch having a larger than standard barrel diameter; up to 14” flange diameter and standard barrel length between flanges. When ordering a winch base to be used with a drum that has, up to 14” flange diameter and a barrel length between flanges that is greater than 7", state the barrel length between flanges after the basic part no. C5S72X as illustrated below. Part No, for NonStandard Winch Base ~ C5572X-t~ Insert barrel length measured between flanges (inches) DRUM ASSEMBLY | BARREL DIA [FLANGE DIA. | BARREL LENGTH. 58303 5 15 7 56595 [BaEEES: 4 a eRe 56596 5 4 13 **Item 12. Sun gear shaft B5505 is used in a winch having a drum with standard barrel length between flanges as listed in the winch specifications on the inside of the front cover. When ordering a sun gear shaft to be used with a drum that is longer than standard, state the barrel length between flanges after the basic part no. B5522 as illustrated below. Part No. for Non-Standard Sun Gear Shaft — B5522. Insert barrei length measured between flanges (inches). =~ WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NUMBER OF WINCHPRIMARY DRIVE ASSEMBLY Model 6-*-*-EC No. Weight Item No. Part No. Description Req'd Mos." Ors. Ass’y DS5513XEC26 | Primary Drive Ass’y for Model 6-26°-EC 1 1300 Ass'y DSS13XEC-35 | Primary Drive Ass’y for ‘Model 6:35-*-EC 1 1300 al 11029 Capscrew 10 = +2 50391 Seal Washer 10 a "3 C5504M =| Spring Cover 1 Pee 4 S515 Brake Spring 10 0 38 5 0342 ‘0’ Ring 1 os 6 BS5OL Snap Ring 1 0 48 7 | 50334 | 'O" Ring 1 a eg | C5561XEC-26 | Motor Ass'y for Model 6:26-"-EC 1 580 €5561XEC-35 Motor Ass'y for | Model 6:35-"-EC 1 580 9 50933, Brake Plate 1 14 10 31004 Snap Ring 2 ie u 1BSS32 Brake Ring 1 acto 2 | 50754 Pin 3 ae B 51668 Primary Planet Ass'y 1 od) 14 ‘A5S06 Bushing 1 0 25 1s 5542 Primary Housing 1 48 0 16 | 50585 Pipe Plug 1 - 7 51065 Oil Seal 1 01 18 51067 Snap Ring 1 en 19 51965 Pipe Plug 2 = * On Winches Serial Number 6-607 and down, item 1 — A5514, item 2 — 52381 and item, are used. These parts are not interchangeable individually with parts listed above. If C5504 is to be replaced, order C5504M + A11029 + 50391. ** On Winches Serial Number 61837 and down, the Motor Assembly part no. was C5512: replacing Motor Assemblies C5512X-*-*, order C5561X-* interchangeable with the old style. WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NUMBER OF WINCH 10 3 — ©5504 When ‘The new Motor ‘Assembly is completelyModel 6-*-*-EA. | | Ne Weight tom No. rt No. Description Req'd Ors. ‘Assy | DSSISXEA26| Primary Drive Ass'y for | Model 6-26".EA feast 1300 Assy |: DSSIAXEA.35_) Primary Drive Ass’y for | Model 6.35-*-EA. 1 1300 (This assembly includes all parts listed under DS513XEC-26 and DS513XEC-35, except item 8; changes 10 the part numbers listed below.) 8 C5561XEA.26 | Motor Ass'y for Model 626-"-EA 1 580 C5561XEA.35 | Motor Ass'y for Model 635°-EA 1 380 Model 6-*-*-EB N Weight Item No. | Part No. Description | Rea'a tbs. Os. Ass'y D5516X-EB-26| Primary Drive Ass'y for Model 6.26"-EB 1 1300 Ass'y DS5516X-EB.35| Primary Drive Ass'y for | Model 635-*-EB 1 1300 (This assembly includes all parts, listed, under DSS13XEC26 and D5513XEC-35, except item 8; changes to the part number listed below ani | items 20 and 21 are added.) 8 €5561XEBP-24 Motor Ass’y for | Model 626--EB } ot 378 (5561XEBP-35 Motor Ass'y for | Model 635-"-EB jo 78 20 A586 | Brake Hub 1 aces. 21 51007 ‘Snap Ring 1 oe WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NUMBER OF WINCHoe MOTOR a Model_6-*-*. T ‘Weight ltem_No. Part No. Description Lbs. Oz. 5 C5561XEC-26| Motor—Model 626*-EC 1 58 C5861XEC-35| Motor Model 6-35.°-EC 1 SetieeeO. 50428 Pipe Plug. 2 ee ©5560 Motor Housing 1 2 43520 Short Bushing 1 gee ‘AS510 Pin 1 an 5524 Sleeve 1 0 os S614 Cartridge—Model 626¢* | 1 Wcaees AS615 Cartridge—Model 635" | 1 4 8 ‘85529 Snap 1 Deiide 50300 Pin 5 an €5508 Brake Piston 1 40 30365 Backup Washer 1 ee 50332 ‘O" Ring 1 en 50336, ‘0’ Ring 1 = 30366, Backup Washer 1 a 50293, ‘0’ Ring 3 an 50361 Backup Washer 2 a 50935 ‘Snap Ring 1 a ‘45522 Hydraulic Tube 1 0 15 50292 ‘O' Ring 2 ee 52598 Shaft End Cover 1 is gece: | AS583, Spacer 1 085 | 52312 Capscrew 5 0 2 50289 ‘O" Ring i a ASOLXC Brake Hub Ass'y for Ei 1 3 0 24 Not Required i 25 No! Required in Model 6-*-*-E 6 S521 |" Long Bushing 1 coca! 27 Not Required in Model 6" EC Model_6-*-*-EA thom No. Part No. Description - ‘Ass (€5561XEA-26| Motor—Model 626 EA BOO Ass C5561XEA-35| Motor—Model 6.35-*-E: 1 50 (This assembly includes all parts listed under C5561XEC-*, except items 2, 19 & 23; changes to the part nu d below & items 24 & 28 ‘are added. Item 27 is not required.) 2 Motor Hous 1 ai eeol 19 5: Shalt End Cover 1 1300 B ASODIXA Brake Hub Ass'y for Model 6°“ EA 1 aad 24 50287 ‘O' Ring 2 ae 25 5540 Brake Tube i Ofaeet 2 WHEN ORDERING PART: BE SURE TO STATE THE SERIAL NUIModel 6-*-*-EB tem No. rt No. Description No. Read | ths the, Kssembly_| C5561XEB-26 Motor Assembly for Model 626°-EB 1 37 o Assembly | C5561XEB-35 Motor Assembly for Model 635-*-EB L 87 ° (This assembly includes all parts listed under C5561XEC-*, except items 2 and 19; change to the part numbers listed below. Items 24 and 25 are added; item 27 replaces item 23; items 28 10 33 on page 13 are added ‘and item 1 is not required.) 2 €5560B Motor Housing 1 a ° 19 52597 Shaft End Cover 1 3 0 24 50287 ‘0’ Rin, 2 as 25 ‘A5540 Brake Tube i o 07 7 B3534 Motor Shaft 1 1 8 8 50865 Elbow 2 0 1 30 51691 Tube 2 - 3 50533 Elbow 1 0 15 2 51690 Tube 1 - 33__| 51018 |__ Valve 1 = ‘On Winches Serial Number 63688 and down, Items 19 and 21 should change as shown below. MODEL 6.**-EC. Ttem No.[ Part N Description. No, Reqd Tssembly | C3361 KEC- 25, Motor Assembly T Assembly | C5561XEC-35 Motor Assembly 19 €5559C Shaft End Cover 1 21 50934 Capserew, 5 On motors C5S6IXEC™, when replacing Shaft end cover C5559C, order kit 52610 which consists of 1- 52598 and 5 -52312, MODEL 6-"-*-EA Tem No.| Part No. ‘Description No. Reqd Tesembly | C5561XEA-26 | Motor Assembly ‘Assembly | C5561XEA35 | Motor Assembly 19 55590 Shaft End Cover 1 21 50934 Capscrew | 5 On motors CSS6IXEA*, when Feplacing Shaft end cover C3559A, order kit 52608 which consists of 152596 and 5-52312, MODEL 6-*-*-EB Ttem No.| Part No. Description No. Req'd Assembly | C5561XEB-26 Motor Assembly Assembly | C5561XEB-35 Motor Assembly 19 ¢5559B Shaft End Cover | 21 50934, Capserew 5 On motors C5561XEB-*, when replacing Shaft end cover C5559B, 152597 and 5- 52312. WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NUMBER OF THE WINCH ‘order kit 52609 which consists of142 3 45 MOTOR CARTRIDGE ASSEMBLY Model 6-26-*-* Description Motor Cartridge for | Model 6-26- 1 Spring 4 Port Plate 2 Vane 20 Cam Ring for, I Model 626-4." steerer Pin 4 Port Plate Assy ‘consists of half the gty. of items 1 thru 6 and 8 thru 10, Sequence Valve Assy consists of half the qty. of] items 3, 4, 5,6 Model 6-35-¥-* Weight tem No. Part No. Req Assy S615 | ( Model 635-7-* 1 (This assembly includes all parts listed above except item 13; changes (o the part number listed below.) 13 ASSe4 Cam Ring for I Model 635°." 1 @® Winches Serial Number 6-1083 and down were assembled with Bronze Port Plates A 5558 and A 6559. When Port Plates A5562 require to be replaced, order 2 of Kit 53709. “ WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NUMBER OF WINCHPRIMARY PLANET ASSEMBLY All Models | No. Weight Hem No. Part No. Description Req'd tbs, Ons. Ass’y | 51668 Primary Planet Ass’y 1 GaiHG) 1 BS531 Primary Planet Hub 1 0 2 51203 Pin 3 3 A551 Planet Gear 3 o 7 4 51306 Bearing 3 o 47 5 5582 Planet Pin 3 0 22 6 A5525 Thrust Plug 1 oo4 7 5584 Bushing 1 0 32 8 51090 Drive Screw 2 WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NUMBER OF WINCH SHERORDERING PARTS. BE SURE TO STATE THE SERIAL NUMBER OF WINCHINAL DRIVE ASSEMBLY Model 6- i No. ‘Weight tem No. Part No. Description Red Us." Ons. Assy 5517xS | Final Drive Ass'y 1 6 (0 1 50513 Pipe Plug 1 - 2 5501 Snap Ring 1 0 45 3 50341 ‘O' Ring a} a 4 B5500 End Cover 1 8 oO 5 A350 Thrust Plate il 1 0 6 C5500XS__| Final Planet Assy (Std) 1 2% 0 7 C5501 Final Housing, 1 30 oo Qo 56020 ‘O' Ring, 1 i © 0 50428 Pipe Plug 1 = Model 6-*-H-* Ne. Item Ne. Part No, Description Req'd . Ass’y C5517XH_ | Final Drive Ass’y 1 (This assembly includes all parts listed above under, CS517XS except item 6 is replaced by item 8. 8 BSS04K Final Planet Reduction (High Speed) 1 23 0 added on winches serial number 6-3008 and up. added on winches serial number 6-9060 and up. WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NUMBER OF WINCH iFINAL PLANET ASSEMBLY Model 6-*-S-* ] | no. | Weight I | _ Description (Read | lbs. Oxs, 7 C5500XS_—| Final Planet Ass’y ( ieee ar) | css00s' Final Planet Hub IRB 40 | 50873 Pin 3 | it ‘A5502 | Final, Planet Gear Biea 4.8 50602 Needle Bearing 3 0 3 | 50835 Final Planet Pin 3 0.8 Model_6-*-H-* No. Part No. Description Req'd BS504X Final Planet Reduction i (High Speed) (tems 640 I2inclusive)| 1 23 0 s ASS19 Retainer Ring 1 7 | Assis ) Sun Gear 1 14 Sub-Ass'y | C5500XH Final Planet Ass'y 5 Clery 8 to 12 inclusive) | 1 ar) 8 C5500H | Final Planet Hu 1 4 0 8 50573, Pin yar ta ~ 10 ASSI7 aj tc 0 a + $0602 3 0 3 2 150535 3 | 08 WHEN ORDERING PARTS, BE SURE TO STATE THE SERIAL NUMBER OF WINCH SEERLORDERING PARTS. GE SURE TO STATE THE SERIAL NUMBER OF WINCH 18FOREWORD TO SERVICING ‘The following service instructions have been arranged to provide the best methods for assembly and disassembly of the Gearmatic Model 6E 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, backup washers, ‘O' rings, and Seal Washers should never be reused even though inspection may show these items 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 been 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’ rings and oil seals with grease before installation. 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 C5517XS, C5517XH 4. For primary housings with tapped puller holes in the flange, use two 4" N.F. x 2° cap- (Ref. Page 9) All Model 6E Winches I drive assembly according to the instructions on page 20. 2. Remove the five nuts (1) and washers (2) from the final drive end of the winch. 3. If the primary drive assembly has already been removed from the winch base, and if the drum (7) has standard flange diameter as listed in the winch specifications, remove the drum (7). 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 4, If the primary drive assembly has not been removed or if the drum has a flange diameter that is larger than the standard flange, remove the final housing (7), (page 17) from the winch base and drum as follows. 5. For final housings with tapped puller holes in the flange, use two ¥4” NP. x 2” caperews as jacks and pull the housing off the dowel bolts (3). For final housings with cast slots under the edge of the flange, use two heel bars and remove the housing from the dowel bolts (3). To Remove the Primary Assembly D5513XEC-*, D5514XEA-* or D5516XEB-* (Ref. Page 9) All Model 6E Winches 1. The primary drive assembly can be removed from the winch as a complete unit by using steps 3 and 4 below. This assembly can also be disassembled according to the instructions on page 21 while the primary housing is still attached to the winch. If the primary drive assembly is disassembled at this stage, remove the housing using the following instructions, 2. If the final drive assembly has already been removed from the winch base and if the drum (7) has standard flange diameter as listed in the winch specifications, remove the drum (7). 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 housin; 3. If the final drive assembly has not been removed or if the drum has a flange diameter that is larger than the standard flange, remove the five nuts (1) and washers (2) from the primary drive end of the winch. screws as jacks and pull the housing off the dowel bolis (3). For primary housings with cast slots under the edge of the flange, use two heel bars and remove the housings from the dowel bolts (3). jal To Disassemble the Final Drive Assembly C5517XS, C5517XH, (Ref. Page 9 and 17) Model 6-*-S* ASSEMBLY C5517XS 1. Remove snap ring (2) 2. Remove the end cover (4) using a heel bar under the lug provided below the filler plug boss. Remove and discard ‘O” ring (3) from the end cover (4) 3. Remove the thrust plate (5) from the final planet assembly (6). 4. Remove the final planet assembly (6). Using, two pinch bars under the rim of the planet hub and against the end of the final housing (7) pull the final planet assembly (6) off the splined end of the drum. Care must be taken not to damage the pilot bore in the final housing (7) that carried the end cover (4), (Figure’D). Remove and discard the’O’ ring (9) from the pilot bore. 5. Remove the sun gear shaft (12). Model 6-*-H-* ASSEMBLY C5517XH 1. Remove the snap ring (2) 2. Remove the end cover (4) using a heel bar under the lug provided below the filler plug, boss. Remove and discard 'O’ ring (3) from the end cover (4)3. Remove the thrust plate (5) from the final lanet assembly (80) 4, Remove the sun gear shaft (12). The sun gear (8a) and retainer ring (8b) will be removed with the sun gear shaft (12) as an assembly. 5. Remove the final planet assembly (80) Using two pinch bars under the rim of the planet hu! and against the end of the final housing (7), pull the final planet assembly housing (80) off the splined end of the drum (figure D). Care must be taken not to damage the pilot bore in the final housing (7) that carried the end cover (4), Remove and discard “0 ring (9) from the pilot bore, Inspection of Parts for Final Drive Assembly C5517XS, C5517XH 1. Discard ‘O’ ring (3) and ‘O’ ring (9). 2. Wash all parts in a suitable solvent and dry thoroughly with compressed air or clean cloths. WARNING: Do not dry the final planet assembly (6) or (8c) with compressed air as this may drive particles of dirt into the needle bearings which carry the planet gears 3. Check snap ring (2) for flatness and that it forms a true circle, if it is bent or damaged replace with a new part 4. Check for wearat the centre of the thrust plate (8). The original thickness at the centre of the thrust plate was 625”, if the wear is greater than 116" replace the thrust plate (5) Check that the planet gears run freely in the final planet assembly (6) or (9c). For disassembly instructions and inspection of parts in. the final planet assembly (6) or (8c) see page 2 and 25, 6. Inspect the gear teeth in the final housing (7). If wear is greater than 015” when compared to the unworn part of the teeth, replace the final housing (7). Check the large pilot bore at the end of the final housing (7) used to carry the end cover (4). Remove all roughness and scores carefully using a scraper and extra fine emery cloth so that’ ring (3) will seal on this diameter. 7. Inspectthe sun gear shaft (12). Check the gear teeth for wear by comparing the tooth thickness at the worn area of the teeth with the tooth thickness at the unworn end. Ifthe wear is greater than 012” replace the sun gear shaft (12), 8. Inspect the seal diameters of the sun gear shaft (12), if the seal diameters have any roughness or scratches, replace with a new sun gear shaft (12). NOTE: If any one of the gears in this assembly requires to be replaced because of tooth wear, all gears in the assembly should be replaced, To Disassemble the Primary Drive Assembly D5513XEC. D5514XEA-* or D5516XEB-* (Ref. Page 10) All Model 6E 1. Clean all dust and dirt away from the motor ports and vent port and disconnect the hy draulic hoses. Mark the location of the spring cover (3) with respect to the housing (15. 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 (15) by removing one capscrew (1) with its seal washer (2) from. the lowest point of the spring cover (3). Remove one pipe plug (16) from the top of the housing (15) to allow air to enter the housing. 3. Remove the spring cover (3) using the following. procedures Remove the. remaiaing capscrews (1) with washers (2) by slacken. ing each capscrew (1) 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 (3) is removed evenly as it carries the full sprin load for the brake. When all the spring loac has been removed fr the spring cover (3) it can be withdrawn from the winch. 4. Remove all washers (2) from eapserews (1) and remove! "sing (8) from the sping cover (3) and discard. 5. In most cases there will be a spring in every second hole, but in certain applications & smaller or greater number of springs are required and it is important that they be located symmetrically when they are_re- placed, Note and mark any hole that does not contain a spring and then remove all the springs. 6. Remove and discard the 'O' ring (7) from the motor assembly (8) 7. Remove snap ring (6) and motor assembly (8). Gearmatic tool No. B13083 can be used to remove the motor assembly (8). 8. Remove the remaining parts in sequence as shown by the item numbers 9 to 12 from the motor assembly and 13 to 19 from the housing. Remove and discard cil seal (17) chesInspection of Parts for Primary Drive Assembly D5513XEC-*, D5S14XEA-* or D5516XEB-* Discard all ‘O' rings and oil seals. 2. Place the primary planet assembly (13) to one side and wash all other parts in a suit able solvent. Dry thoroughly with compressed air or clean cloths. Do not wash the Primary planet assembly unless 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 (7) will seal effectively, 4. Check snap ring (6) for flatness and that it forms a true circle, if bent or damaged replace. 5. If the motor or brake hub assembly requires inspection see "TO DISASSEMBLE ‘THE MOTOR ASSEMBLY” (page 24) and “TO DISASSEMBLE THE BRAKE HUB AS: SEMBLY" (page 26) 6. Check that the planet gears in the primary planet assembly (13) will rotate freely and smoothly. 7. Inspect the gear teeth in the primary housing (15) for wear. If wear is greater than (OIS” when compared to the unworn part af. the teeth replace the primary housing 1 8. Inspect the friction surfaces of the brake plate (9), if wear has removed the grooves, replace the plate, Does not apply to EN models. To Disassemble Bearings and Seals from Drum (Ref. Page 9) All Model 6E Winches 1, Remove the bearing (6) from the drum (7). using a puller in the bearing bore. 2. Remove and discard oil seal (11). 3. To remove bearing (8) first remove the snay ring (10) from its OD. Using special pulller, place a plug located in the bore of the drum to support the puller screw and pull the bearing by gripping in the snap ring groove on the O.D. of the bearing. Gearmatic tool No. 13116 can be supplied for removing this bearing, Inspection of Drum and Bearings, etc. 1, Discard oil seal (11). 2. Wash alll 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 {0 air dry after they are properly cleaned. 3. Check the bearing hub diameter at the splined end of the drum and the bearing bore at the opposite end 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 ball bearings (6) and (8) for wear and pitting at the balls and ball grooves, Replace bearings if worn or pitted. a ec lenenaneiec To Disassemble Final Planet Assembly C5500XS, B5504X or B5530X (Ref. Page 18) Model 6-*-S-* ASSEMBLY C5500XS 1. Using a %e" diameter pin punch, drive (2) completely into the final planet pin (5), 2. Remove the final planet pin (5) by tapping it ‘out of the planet hub (1) so that it is removed from the splined bore side of the planet hub. Remove pin (2) from the planet pin () 3. Now remove the planet gear (3). 4, Press the needle bearing (4) out of the planet gear (3) using an arbour that is ls" diameter. Model 6-*-H-* ASSEMBLY B5504X (includes C5500XH) 1. Using a *s” diameter pin punch, drive pin (9) completely into the final planet pin (12) 2. Remove the final planet pin (12) by tapping it out of the planet hub (8) so that it is removed from the splined bore side of the lanet hub. Remove pin (9) from the planet (12). 3, Now remove the planet gear (10). 4, Press the needle bearing (11) out of the planet, gear (10) using an arbour that is Ie" diameter. 5. The sun gear (7) and retainer ring (6) will have been removed From ihe winch with the sun gear shaft a luring the disassembly of the final drive assembly: Remove Dithe sun gear (7) from the sun gear shaft by pressing the sun gear shaft out of the sun gear (7), only if the sun gear (7) is to be replaced. The retainer ring (6) will remain in the splined bore of the sun gear (7) and can be removed separately. Inspection of Parts for Final Planet Assembly C5500XS, B5504X or B5530X ASSEMBLY C550OXS and B5504X (including €5500XH) 1. Wash all parts in a suitable solvent and dry thoroughly using compressed air or clean cloths. WARNING: Do not dry the needle bearings with compressed air, allow them to air dry after they are properly cleaned. 2. Inspect the planet pin bores in the planet hub (1) or (8) for scores or bruises which may have been caused in removing the planet pins. Remove the high spots of any scores or bruises carefully with a scraper, sufficiently to allow a planet pin to be pressed into each bore by hand, 3. Inspect the planet pin (5) or (12) for excessive wear at the bearing area. If wear ex ceeds 001" on the diameter the pins should be replaced. 4. Check the planet gears (3) or (10) for wear and damage on the gear tecth. If wear is excessive or if the sun gear (7) of BS504X or Stems (7) and (8), tpage 17) are. being replaced because of gear tooth wear, replace the planet gears (3) or (10). 5. Inspect the needle bearings (4) or (11) for freeness of rollers. Check for pits, broken rollers or excessive wear, and replace if any of these conditions exist. NOTE: If either the planet pins (5) or (12) or needle bearings (4) or (I1) are replaced secause of wear, both the pins and the beat ngs should be replaced. Replacement of one part and not the other will cause premature ‘wear on the new part. ASSEMBLY B5504X In addition to the above inspection steps make the following inspections which apply to assembly B5504X only. 1. Inspect the gear teeth on the sun gear (7) for wear. If wear is excessive replace the sun gear. 2, Inspect the retainer ring (6) for damage. If it is bent or has notches on the inside diameter replace the retainer ring (6). ASSEMBLY B5S30X 1. Check the thrust pad (14) for wear. The I thickness of the thrust pad was 500", if the wear is greater than Me" replace the thrust pad. To Disassemble the Primary Planet Assembly 51668 (Ref. Page 16) 1, Remove bushing (7). 2. Using a 4" diameter pin. punch drive pin (2) into the planet pin (5) until it can‘ be removed with the planet pin (5). 3. Remove the primary planet pin (5) by tapping it out of the planet hub (1) so. that it is removed from the side of the planet hub that carried the bushing (7) 4. Remove the planet gear (3) with the needle bearing (4) from the planet hub. After all the planet gears have been removed, the thrust pad (6) can be removed from the planet hub. ——— Inspection of Parts for Primary Planet Assembly 51668 1, Wash all parts in a suitable solvent and dry thoroughly using compressed air or clean cloths. WARNING: Do not dry the needle bearings with compressed air, allow them to air dry alter they are properly cleaned 2. Cheek the planet hub (1). Inspect the small hub for scores or roughness. Try removin, roughness with extra fine emery cloth. I oughness can not be removed completely in this way replace the hub (1). Inspect the planet pin bores for scores and’ bruises sh may have been caused in removing the planet pins (5). Remove the high spots of any scores or bruises carefully with a scraper, sufficiently to allow a planet pin (5) to be pressed into each bore by hand, 233. Inspect the pins (2) for damage. If they are bent or distorted discard them, 4, Inspect the planet pins (5) for excessive wear at the bearing area. If the wear at the bearing arca is greater than 001” on the diameter when compared with the unworn, areas, the planet pins (5) should be replaced. 5. Check the planet gears (3) for wear and damage on the gear teeth. If wear is ex cessive, replace the planet gears (3). 6. Inspect the needle bearings (4) for free: ness of rollers. Check for pits, broken rollers, or excessive wear, and replace the bearings (4) if any of thest conditions exist. 7. Check thrust pad (6) for wear on slotted face, if wear exceeds .032", replace. Original thickness of thrust pad (6) was 187”. 8. Check bushing (7) for wear on bore and flange. If flange has worn more than \é" or if bore has worn more than .010", replace the bushing (7). Original bore was 2.127”, original flange thickness was .268 NOTE: If planet pins (5), or needle bearings (4) require replacement, all these parts must be replaced at the same time. To Disassemble the Motor Assembly C5561XEC-*, C5561XEA-* or C5561 XEB.* (Ref. Page 12 and 13) It is recommended that if this assembly is found to be faulty that it be traded in for a new ‘or reconditioned unit. Before disassembling this unit be sure to have new ‘0’ rings and back up washers on hand. It is important to install new ‘O” rings when the ‘old parts have been disturbed. This assembly should be disassembled only if trouble has been traced to the motor and brake hub assembly 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 21 before disassembly of the motor is started. 1. Remove the five capscrews (21) from the shaft end cover (19). Separate the shaft end cover and the motor housing (2). 2. Remove the bushing (3) from the motor housing (2) only if replacement is required because of damage or wear. 4 3. Remove the hydraulic tube (17). Remove and discard ‘O’ rings (18) Model 6-*-*-BA and Model 6.*-*-EB only; remove. the brake tube (25), remove and discard ‘0 rings (24). 4. Using a %” pin punch, drive the pin (4 ut of the inétor Shaft em 23, Agere Se, Remove the sleeve (5) and ‘O" ring (22) from the motor shaft. Discard ‘O” ring (22). FIGURE E 5. Slide the motor cartridge (6) off the motor shaft. Lay the motor cartridge (6) to one side for later disassembly under section “TO DISASSEMBLE THE MOTOR CART- RIDGE,” page 25. 6. Remove the brake hub assembly (23) from the shaft end cover (19). Push the long bushing (26) out of the shaft end cover (19). Remove the snap ring (16), ‘O" rings (14) and backup washers (15). Discard ‘O" rings (14) and backup washers (15). NOTE: When the brake hub assembly has been removed be careful that the brake hub does not drop off the motor shaft. See “TO DISASSEMBLE THE BRAKE HUB AS- SEMBLY" (page 26). 7. Remove the snap ring (7) from the shaft end cover (19). Does not apply to EN models 8. Remove the brake piston (9). Remove and discard ‘O’ rings (11) and (12), and back washers (10) and (13) from the shaft, enc cover (19). Remove the five pins (8) frot the brake piston (9) only if replacement is required because of damage or wear.MODEL 6-*.*-EB Brake hub assemblies AS60IXC and AS6OIXA are not used in this model and are replaced by items 20 and 21 (page 10). Inspection of Parts for Motor Assembly C5561XEC-*, C5561XEA-* or C5561XEB-* 1, Discard all ‘O' rings and backup washers. 2. Wash all parts thoroughly in a suitable solvent. Dry thoroughly with compressed air or clean cloths, Do not wash the motor cartridge (6) unless it is to be disassembled or traded in complete for a new assembly. 3. Inspect the bores of the motor housing (2) and the shaft end cover (19) for scoring or roughness. If possible remove roughness and scoring with a fine hone. 4, Inspect the bushings (3) and (26) for wear in the bores; if wear is in excess of .003” replace the bushing. A new bushing bore measures .7505". 5. Inspect the shaft end cover (19) and brake piston (9) for scoring and roughness on the cylinder diameters. If scoring and roughness is excessive replace (9) and (19) with new parts. 6. If the brake hub assembly requires inspection see “INSPECTION OF PARTS FOR BRAKE HUB" page 26, 7. Rewash all parts that have been honed and dry thoroughly. To Disassemble the Motor Cartridge Assembly Model 6-26-*-* or Model 6-35-*-* (Ref. Page 14) It is recommended that if this assembly found to be faulty that it be traded in for a new or reconditioned unit. 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. 1. Remove screws (1) and springs (2) from the port plates (8), remove sequence plates (4). 2. Remove the screws (6), nuts (3) and sequence springs (5) from the sequence plates (4). 3. Remove screws (7) to separate the port plates (8) from the cam ring (13). 4. Remove one port plate (8) at a time, taking care not to drop the rotor (12) and vanes (11) which are held in the cam ring (13) by the port plates (8) 5. Remove the snap ring (10) and the differential plates (9) from the port plates (8). 6. Remove the rotor (12) and vanes (11) from the cam ring (13). Inspection of Parts for Motor Cartridge Assembly Model 6-26-*-* or Model 6-35-*.* 1. Wash all parts thoroughly in a suitable solvent, Dry thoroughly with compressed air or clean cloths. 2. Inspect the cam ring (13) for scoring and roughness. If scoring and roughness exist, replace the cam ring (13). 3. Inspect the wear faces of the port plates (8) for wear. If wear is greater than 005” the components require to be replaced. 4. Inspect snap ring (10), and sequence springs (5) for damage. If they are bent or distorted, replace with new parts, NOTE: If the cam ring (13), rotor (12) or vanes (11) are replaced because of excessive wear, it is good practice to replace all of the above components. Replacement of one part and not the others will cause premature wear of the new part because of its attempt to conform to the wear pattern of the old parts, 25To Disassemble the Brake Hub Assembly (Ref. Page 15) A5601XC or A5601XA 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 a clean, dust free work bench is available. 1. Remove the motor shaft from the brake hub: assembly with care so that the roller bearings (1) do not drop off the brake hub during removal 2. Remove the roller bearings (1), garter spring (2), the cam locks (3) and (4), and place them on a perfectly clean surface. 3. Remove the snap ring (5) from the bore of the brake hub closest to the plain end. NOTE: Do not remove both snap rings unless they are to be replaced. 4. Remove the gear spacer (7) and ‘O' ring (8) from the motor shaft (9) Inspection of Parts for Brake Hub Assembly A5601XC or A5601XA 1, Wash all parts in a suitable solvent and dry thoroughly using compressed air or clean cloths WARNING: Do not dry the roller bearings with compressed air, allow them to air dry after they are properly cleaned. 2. Inspect the motor shaft (9) for excessive wear at the bearing and cam lock areas. If wear is greater than 001" on the diameter when compared with the unworn areas, the motor shaft (9) 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. If 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 replacement. The original bore diameter was 1.7852. 4, Inspect the roller bearings (1) for freeness of rollers. Check for pits, broken rollers or excessive wear, also damage or excessive wear on the bronze bearing cage or flange and replace if any of these conditions exist 5. Check the cam locks (3) and (4) for wear at the points where they contact the motor shaft (9) and brake hub (6). If flats are worn on the cam locks at these points they will require to be replaced. 6. Inspect the snap rings (5) to see if they are bent or distorted. Replace if these conditions exist. NOTE: If the motor shaft (9), brake hub (6), bearings (1) or cam locks (3) and (4) require replacement, all these parts must be replaced at the same time. ASSEMBLY INSTRUCTIONS To Assemble Bearings and Seals to Drum (Ref. Page 9) All Model 6E Winches 1. Install the bearing, (6) in the large bore of the drum (7) so that the snap ring (5) is away from the drum. Using a drift or suitable assembly mandrel drive the beating in until the snap ring is firmly seated against the drum (7) 2 Install bearing (8) on the. splined end of the drum so that the snap ring (10), on the outside of the bearing, is towards the drum. 3. Install oil seal (11) in the bore at the splined end of the drum (7) so that the lip of the al is facing away from the drum. Coat the inside of the seal with grease. 4. Install the hondu (9) in the slot in the drum, so that the small end of the hondu enters the wide end of the slot. NOTE: Bearings (6) and (8) are prepacked with grease at the time of manufacture and require no further lubrication To Assemble the Winch Completely from Sub-Assemblies All Model 6E Winches 1. Place the winch base (4), (page 9) 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 (7), (page 17) to the winch base using five dowel Bolts (3), washers (2) and nuts (1), (page 9). 3. Turn this assembly over so that iy ests on the end of the final housing (7), (page 17) Now take the drum (). (gage by which has previously been assembled with the seals and bearings according to the instructions‘on page 26 and pilot the bearing on, the splined end of the drum into the bore of the final housing. Tap the drum assembly down until the snap ring on the bearing at the splined end of the drum is properly seated ‘on the end of the final housing bore. There wall be approximately Ye clearance between the final housing and the end of the drum flange when the bearing snap ring is seated. . If the drum (7), (page 9) has a, flange diameter that is larger than standard, steps 2 and 3 can not be used. In this case it will be necessary to proceed from step 1 as fel ome te te ace le age 9) in the winch base, (4), (page 9) Place the "winch base on. blocks 30" 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 of the winch is facing up. Take the drum, assembled according to the instructions on’ page 26 and nest it into the winch base so that the splined end of the drum is up. Now place the final housing (7), (page 17) 30 that the bearing bore in the housing pilots over the bearing on the splined. end of the drum and the dowel bolts (3), (page 9), locate in the flange of the final housing. Tap the housing into place and secure it to the winch base using five washers (2) and nuts (1) on the dowel bolts (3), (page 9). Turn the assembly over so that it rests on the end of the final housing. and tap the dram down until the snap ring on the bearing at the splined end of the drum is properly seated. If the primary drive assembly is already assembled it can be installed as a complete unit according to step 7. ”. Take the primary drive assembly, assembled according to the instructions on page 27, and pilot the primary housing into the bear: ing in the plain end of the drum. Tf the sun gear shaft (12), (page 9) is already installed in the final drive assembly, pilot the splined bore of the primary, planet bub (1), (page 16) in the primary drive assembly. ‘Tap the primary drive assembly on until it contacts the winch base and secure it to the winch base using the five nuts (1) and (2) and dowel bolts (3), (page 9). If the primary drive assembly is not already assembled, proceed according to step 9. Take the primary housing (15), (page 10) and install the oil seal (17), (page 10) so that the lip of the oil seal faces in towards the large open end of the housing. Install the snap ring (18), (page 10) in the groove next to the oil seal and make sure that it is, properly seated all the way around the groove. Coat the inside lip of the oil seal With grease. Now pilot the primary housing 10. ul 12 13, 4, into the bearing in the plain end of the drum so that the dowel bolts (3), (page 9) will locate in the flange of the primary. housing. Tap the primary housing on until its flange contacts the winch base and secure it to the winch base using the five ‘outs, (1) and pashers (2) on the dowel bolts (3), (page Torque load nuts (1) (page 9) to 50 Ibs. ft, Assemble the primary drive assembly according to the assembly instructions on pages 27 and 28. Assemble the final drive assembly according to the assembly instructions on pages 28 and 29. When the assembly of the winch has been completed and secured to its mounting base, check the alignment of the winch according to the instructions on page 4. Connect, the hydraulic hoses to the motor ports ‘R’ and vent 'Q' on figure ‘A’, page 3. To Assemble the Primary Drive Assembly (Ref. Page 10) All Model 6E Winches 1 It is recommended that this assembly be made as a complete unit before the primary housing (15) is fastened to the winch base. Take, the primary housing (15) and install the oil seal (17) so that the lip of the oil seal faces in towards the large open end of the primary housing (15). Install the snap rinj (18) int the groove next to the oil seal (17 and make sure that it is properly seated all the way around the groove. If the primary housing (15) is already fastened to the winch base, check that the oil seal (17) and the snap ring (18) are in place in. the primary housing (13). Also if the ary housing, (15) is fastened tothe fh base, set the partly completed winch on end so ‘that it rests on the end of the final housing (7), (page 17) Install the bushing (14) in the small bore of the primary housing (15) so that the bushing shoulder faces the large open end of the primary housing (15) Install the primary planet assembly (13) so that the projecting boss locates in the bush- ig (14), When, this assembly is in_place rotate it by hand to make sure that it is free to turn. Check that the bushing (7), (page 15) is in place in the primary planet assembly (13). Take the motor assembly (8) and place it fon the work bench with the motor shaft end up, Check that the brake piston (9) (page 12) is located "s” away’ from. the au 28 motor housing {2), (page 12) as illustrated on figure 'F'. If necessary, tap brake piston down with a soft hammer, or pry it up by until two heel bars as shown in figure ‘F’ the 4" gap is obtained. ¢ brake hub so that it pilots over on the motor shaft, Install the pring in its groove. Install one snap ring (10) in the groove on the O.D. of the brake hub (6), (page 15) closest fo the motor. Place the brake plate on ‘the face of the brake pisten on the motor assembly. Assemble the brake ring (11) so that it pilots over the spline on the OD, of the brake hub and into the teeth of the brake plate. Check that the pins (12) are in place to retain the brake plate and install the sccond snap ring (10) on the OD. of the brake hub. This does not apply to Model 6-°--EN Install the motor assembly (8) in the primary housing (15) by holding it square with the end of the primary housing as it enters the housing. The gear at the end of the motor shalt will cngage with the planet gears in the primary planet assembly and the motor will pilot into the planet hub bushing (7), (page 15). It may be necessary to rotate the motor assembly (8) slightly so that the gear at the end of the motor shaft will engage with the primary planet assembly. The motor assembly will assemble into the primary housing easily by tapping the outside of the motor assembly lightly ‘with fa copper drift until the snap ring (6) can be installed. Do not use force to install the motor assembly (8). If there is interference remove the motor assembly and investigate Once the motor assembly (8) is in place install snap ring (6) and make sure that it is properly seated in the bottom of the snap ting groove all the way around the housing (15), When snap ring (6) has been alled, rotate the motor assembly in the ing to locate the motor ports ed angle for the particular installation, Lubricate ‘O' ring (7) with grease and install it in its groove on the motor assembly (8). After the ‘O' ring is installed lubricate it again with grease. 12, 13, 15, Install the brake springs (4) in the same symmetrical pattern as they were in before disassembly. In most cases there will be a spring for every second hole but in some installations a smaller or greater number of springs are used and it is important that the springs be installed in a symmetrical pattern for an even load on the brake. Lubricate ‘O" ring (5) with grease and install it in its groove in the spring cover (3). Once the 0” ring is installed lubricate it again. Install the spring cover (3) over the motor assembly so that the vent port is located in the correct position for the particular installation. Install capscrews (1) with washers (2). Sctew in all the capscrews to be finger tight and then tighten them evenly by one half turn at a time progressively around ina clockwise or counter clockwise direction. Care must be used to insure that the spriny cover (3) remains parallel to the end ol the primary housing (15) as it is tightened into place. Torque load the capscrews to 25 pounds feet. To Assemble the Final Drive Assembly C5517XS, C5517XH (Ref. Page 9 and 17) Before starting this ass mbly the drum must be mounted between the final and primary housings, secured to the winch base according to the instructions TO ASSEMBLE THE WINCH COM. PLETELY FROM SUB.ASSEMBLIES on page 26 up to and including step 9. Model 6-*-S-* ASSEMBLY C5517xS 1 4. Lubricate’O’ ring (9) with grease and install in it's groove located in the pilot bore of the final drive housing (7). 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 (12) in Sint contacts the end of the primary planet hub. Install the final planet assembly (6) so that the lanet gears engage in the internal teeth ofthe ‘inal housing (7), the teeth of the sun gear shaft (12) and the splined bore of the planet hub locates over the splined end of the drum Tap the planet assembly (6) into place until it contacts the bearing that carries the drum in the final housing (7), Install the thrust plate (5) in the end of the final planet assembly (6)5. Lubricate‘O’ ring (3) with grease and install in its groove in the end cover (4). Give the ‘O’ ring an additional coat of grease and install the ‘end cover in the final housing (8) so that the filler boss will be located at the bottom of the final housing when the winch is mounted Make sure that the end cover is properly seated against the end of the gear teeth in the final housing 6. Install the snap ring (2) and make sure that itis properly seated in the bottom of the snap ring groove all the way around the housing (7). 7. Fill the final housing (7) with SAE 90 transmission oil to the level of the filler hole and install the filler plug (1) Model 6*-H-* ASSEMBLY C5517XH 1. Lubricate’O’ ring (9) with grease and install in it's groove located in the pilot bore of the final drive housing (7). 2. Install the final planet assembly (80) so that the planet gears engage in the internal teeth of, the final housing (7) and the splined bore of, the planet hub locates over the splined end of the drum Tap the planet assembly (80) into place until it contacts the bearing that carried the drum in the final housing (7). 3. Fit the retainer ring (8b) to the groove in the bore of the sun gear (8a). Press the sun gear (8a) over the gear teeth of the sun gear shaft (12) until the retainer ring snaps into the groove provided in the gear teeth of the sun gear shaft 4, Install the sun gear shaft in the winch so that it engages in the splined bore of the primary planet hub, Slide the gun gear shaft (12) in until it contacts the end of the primary planet hub. 5. Install the thrust plate (5) in the end of the final planet assembly (80) 6. Lubricate’O’ ring (3) with grease and install in its groove in the end cover (4). Give the” ring an additional coat of grease and install the end cover in the final housing (7) so that the filler boss will be located at the bottom of the final housing when the winch is mounted Make sure that the end cover is properly seated against the end of the gear teeth in the final housing, 7. Install the snap ring (2) and make sure that itis properly seated in the bottom of the snap ring, groove all the way around the housing (7). I the final housing (7) with SAE 90 trans: ion oil to the level of the filler hole and install the filler plug (1) To Assemble the Final Planet Assembly C5500XS, B5504X or B5530X (Ref. Page 18) Model 6-*-S-* ASSEMBLY C550OXS Press the needle bearing (4) into the final planet gear (3) so that the ends of the bearing are Hush or slightly below the side of the ‘gear at cach end. Place the final planet gear (3) into the final planet hub (1) so that the bore of the bearing lines up with a planet pin hole. Install a final planet pin (5) in the final planet hub (1) so that it passes through the needle 29bearing (4) in the planet gear and the drilled hole in the final planet pin lines up with the hole in the rim of the final planet hub. 4. Install pin (2) and using 4ie" diameter pin punch, drive the pin in until the outer end Of the pin is %e” below the outside diameter of the final planet hub (1). 5. Repeat the above for the remaining two final planet gears (3) and check that all the gears run freely. Model 6-*-H-* ASSEMBLY B5504X (includes C5S00XH) 1. Press the needle bearing (11) into the final planet gear (10) so that the ends of the bear: Ing are flush or slightly below the side of the gear at each end 2. Place the final planet gear (10) into the final planet hub (8), so that the bore of the bear- Ing lines up with a planet pin hole. 3. Install a final planet pin (12) in the final planet hub (8) so that it passes through the heedle bearing (11) in the planct gear and the drilled hole in the final planet pin lines up with the hole in the rim of the final planet hub, 4, Install pin (9), drive the pin in until the outer end of the pin is “is” below the outside diameter of the final planet hub (8). 5. Repeat the above for the remaining two final planet gears (10) and check that all the gears run freely. 6. Fit the sun gear (7) and the retainer ring (6) to the sun gear shaft (12) (page 9) by following the Assembly instructions for ASSEMBLY C3SI7XH, sicp 2 on page 29. Leone To Assemble the Primary Planet Assembly 51668 (Ref. Page 16) 1. Install the thrust pad (6) in its recess in the inside wall of ‘the primary_planet hub (1), so that the slotied face of the thrust pad is outwards. Fasten thrust pad (6) to Planet hub (1) securely with screws (8). 2. Press the needle bearing (4) into the prim. ary planet gears (3) so that the ends of the ‘bearings are flush or slightly below the side of the gear at each end, 3. Place the primary planet gear (3) into the primary planet hub (1) so that the bore of the bearing lines up with a planet pin hole. Tap the primary planet pin (5) through the planet hub (1) until the drilled hole in the end of the primary planet pin (5) lines up with the hole in the rim of the planet hub (1). 4. Install pin (2) and using a %+" diameter pin punch, drive the pin in until the outer end of the’pin is #s” below the outside diameter of the primary planet hub (1), 5. Repeat the above steps, from step 2, for all three primary planet gears (3) and when they are installed check that all the gears rotate freely. To Assemble the Motor Assembly C5561XEC-*, C5561XEA-* or C5561 XEB-* (Ref. Page 12 and 13) Before starting this assembly make sure that all parts are perfectly clean and free from dust and that a dust froe work bench is availal 1, Install the snap ring (16) in the middle groove of the long bushing (26), Install jackup washer (15) in the groove closest to the end of bushing (26). Lubricate two ‘0° rings (14) with grease and install one ‘O" ring between the backup washer (15) and the end of the bushing (26); install the other 'O' ring (14) in the groove closest to the center of the bushing’ (26). Give both “O' rings (14) an additional coat of grease. 2. Place the shaft end cover (19) on the work bench with the cartridge bore facing up. Install the long bushing (26) assembled as in step 1 into the bore of the shaft end cover (19) so that the long diameter enters the bore, taking care not to damage the ‘O" ring (14) as it enters the shaft end cover (19) (Figure ‘G’). FIGURE G10, After the bushing (26) has, been, positioned correctly, assemble the brake hub assembly according to the instructions "TO ASSEM- BLE THE BRAKE HUB ASSEMBLY” page Turn the shaft end cover (19) up on edge and install the brake hub assembly (23) in the bushing (26) from the opposite side of the shaft end cover (19). Place the shaft end gover (19) on parallel’ bars on the work beach, with the cartridge bore up, so that it does not rest on the motor shaft (23), or (27), Assemble the motor cartridge (6) accordin, to the instructions “TO ASSEMBLE TH) MOTOR CARTRIDGE”, page 31. Install the motor cartridge (6) so that the spline of the motor shaft engages in the splined bore of the rotor in the motor cartridge (6) and the outside diameter of the motor cartridge (6) pilots into the shaft end cover (19). The motor cartridge (6) may be installed with either end entered first. Lubricate ‘O' ring (22) with grease and install in the groove of the motor shaft. Give ‘0 ring (32) an additional. coat of grease then slide the sleeve (5) over the Shaft and ‘O" ring so that the slotted end of sleeve (5) aligns with the drilled hole in the end of the motor shaft. Now drive pi (4) into the hole in the motor shaft so that it projects the same amount from each side of the motor shaft. With the shaft end cover (19) sitting on parallel bars as outlined in step 4, install the backup washer (13) in the large diameter groove of the shaft end cover (19). Lubricate ‘O" ring (12) and install in the groove with the backup washer so that it sits on top of the ‘O’ ring (11). If the backup. washers (10) and (13) appear to be too large in diameter, warm them in a low temperature oven or on a hot-plate. This will reduce their moisture content and make the assembly easier. Install five pins (8) in the holes provided in the brake piston (9). Give ‘O" rings (11) and (12) on the shaft end cover (19) an additional coat of grease and assemble the brake piston (9) over the shaft end cover (19) until the snap ring (7) can be installed in its groove. Care should be used not to pinch the ‘O” rings and backup washers. In- stall snap ring (7) and be sure that it bot- toms in its groove all around the diameter. Lubricate ‘O” rings (18) with grease and in: stall the hydraulic tube (17) in the counter bore of the shaft end cover (19) For Model €-*-1-EA, and 6.*-*EB only. Lubricate ‘O” rings (24) with grease and install them on the brake tube (25). Give the ‘O' rings (24) an additional coat of grease and install the brake tube (25) in the coun- terbore of the shaft end cover (19) ML. 12, Lubricate the ‘O’ ring (14) and install it in the groove in the bushing (3). Install backup washer (15) in the same groove. Install bush ing (3) in the bore of the motor housing (2). Assemble the motor housing (2) over the motor cartridge (6) taking care that the sleeve (5) and the hydraulic tube (17), also the brake tube (24) if used, enter ‘their respective bores in the motor housing (2), see figure "H’. Be sure also that the pins (8) enter their respective holes in the motor housing (2) and that the large counter bore ‘of the motor housing (2) passes over the ‘outside diameter of the snap ring (7). At this stage the motor housing (2) will be tight against the side of the motor cartri (6). DO NOT FORCE THIS ASSEMBLY, there is interference remove the motor housing (2) and investigate. FIGURE H Install the five capscrews (21). Tighten them evenly in stages to torque of 30 to 40 pounds eet. CAUTION: After tightening the capscrews to their specified torque be sure that the motor shalt can be rotated by hand. ee To Assemble the Motor Cartridge Assembly (Ref. Page 14) Model 6-26-*-* or Model 6-35-*-* Before starting this assembly make sure that all parts are perfectly clean and free from dust and that a dust free work bench is available. Install a differential plate (9) in the bore of the port plate (8) from the rotor side of the port plate. Install a snap ring (10) in each port plate (8)32 Place a port plate (8) on the work bench with the rotor wear face up. Position the cam ring (13) on top of the port plate (8) and fine up the holes for the screws (7) Place the rotor (12) in the bore of the cam ring (12) and insert two vanes (11) in cach slot of the rotor. The vanes (11) are to be installed so that the faces having the cham- fered ends are in contact as illustrated in Figure ‘J! and installed in the rotor (12) as illustrated in Figure 'K’. CHAMEER ON ENDS OF CONTACT FACES FIGURE J Check that the two center holes in the rim of the cam ring (13) line up with the two tapped holes in the port plates (8). Install a port plate (8) on top of the cam ring (13) with the rotor wear face towards the cam ring. Line up the holes in the port plate (8) with the two center holes in the rim of the cam ring (13) and install the screws (7) Line up the outside diameters of the port plates (8) with the outside diameter of the cam ring (13) so that the outside surfaces are flush and tighten the screws (7) securely Assemble the sequence springs (5) to the sequence plates (4) with the screws (6) and nuts (3). Tighten the screws (6) securely. FIGURE K 5. Place the sequence plates (4) on the port plates (8) with the heads of the screws (6) towards the port plates (8); fasten the sequence plates (4) to the port plates (8) using the springs (2) on the screws (1) with the small end of the spring (2) towards the head of the screw (1), Be sure that the shoulders of the screws (1) enter the holes jin the sequence plates (4). Tighten the serews (1) securely, To Assemble the Brake Hub Assembly A5601XC or AS60IXA (Ref, Page 15) 1. Place the motor shaft (9), gear end down, on a clean work surface. Install the ‘O” rin, (8) and gear spacer (7) over the motor shaft (9) so that the slotted face is up away from gear teeth. Place a roller bearing (1), flange down, over the motor shaft (9) so ‘that it rests ‘against the slotted face of the gear spacer ( 2. Check to see that there is a snap ring (5) in the bore of the brake hub closest to the spigot end. Then place the brake hub (6) over the motor shaft (9) and roller bearing (1) 30 that it resis end up on the roller bearing flange. 3, Take sixteen cam locks (3) and one cam Jock (4) (copper coloured) and assemble them so that they stand on end between the motor shaft (9) and the bore of the brake hub (6) as illustrated in figure ‘L’ Figure 'L’ shows the correct location of the cams, assembled to permit free rotation of the brake hub in the clockwise direction of rotation, When all seventeen cams have been assembled install one garter spring (2) so that it engages under ‘the projecting ends the cam locks (3) and (4) to force them into engagement with the motor shaft (9) and the bore of the brake hub (6). 4. Install the reinaining snap ting (3) in the groove of the bore of the brake hub next to the cam lock ends. Now install a roller bearing (1) over the end of the motor shaft (9) so that it enters the bore of the brake hub and rests with its flange on the end of the brake hub. 5. Pick up the complete assembly and turn it over, Remove the motor shaft (9) with a twisting motion in the direction of free rotation, Remove the roller bearing that was sembled next to the gear spacer (7) and install a garter spring (2) under the projecting ends of the cam locks as before. Now replace the roller bearing (1) and the motor ghaft with the same twisting motion usedLONG FACE OF FIGURE L CAM tock 6. To chock that the brake hub (6), assembled according to steps | to 5 rotates freely in the correct direction of rotation. proceed as follows. Hold the gear end of the motor shaft with one hand and view the end of the assembly while the gear teeth are away from you. With the other hand try to rotate the brake hub in both directions. If the cam Jocks have been assembled correctly accord: ing to steps 1 10S above, the brake hub will rotate freely in a clockwise ditcetion nd “lock up" in the opposite direction. This assembly is cornet. for assembly__No ‘AS601XC for use in a model 6-*-*-EC winch. 7. In order to change the direction of rotation of the brake hub (6) for assembly No. AS60IXA for use in a model 6-*-*-EA winch ie necessary to weniowe and reassemble the cam locks (3) and (4) to the opposite hand. a TORQUE LOADING FOR FASTENERS Part No. | Torque Load sor | SO Ibs. fe. 11029 35 Ibs. 3212 «(| «30 t0 40 Ibs. ft ae FREE ROTATION FIGURE M MODEL 6-*-*.EC ASSEMBLY AS6OIXC RonoNiatee oat. seat Ne i FIGURE N MODEL 6*-*-6A ASSEMBLY AS6OIXA BRAKE HUB ROTATION The rotation stated below for the brake hub is determined by looking on the brake hub assembly from the splined end of the motor shaft (See figures ‘M’ and ‘N’.) MODEL 6-".".8C AS60IXC — in this assembly the brake hub must rotate freely in a clockwise direction and “lockup” in an anti-clockwise direction MODEL 6-*."-EA A560IXA — in this assembly the brake hub must rotate freely in an anticlockwise direction and “lock-up” se direction, SEAL KIT CHART MODEL 6 SEAL KITS Seal Complete Winch Assembly A5604X Complete Primary Drive Assembly AS606X AS6OSBX, Primary Drive Less Motor Assembly A5607X AS607BX Motor Assembly AS608X AS6O8BX Final Drive Assembly 56023 = *Butyl Seals are for use with Phosphate Ester Fluids only. 33TROUBLE SHOOTING PRESSURE GAUGE LOCATION 1 MODEL 6-*-*-EC MODEL 6°-"EA Install a prossure gauge PRESSURE GAUGE LOCATION 2 MODEL 6.*-*-EC : Install a pressure gauge MODEL 6-°-"EA gauge port ‘B Install a pressure gauge in gauge port ‘C’ gauge port ‘C’. {nstall pressure gauge in gauge port ‘B'. cura Gauge ports 'B’ and ‘C’ are not provided in the first few hundred winches produced. To check the pressure at either motor port on these winches instal a tee fitting the tee fitting. GENERAL the motor port and install a pressure gauge in When checking the oil pressure at any point in the hydraulic system, run the pump at maximum operating R.P.M. so that the maximum gallons per ute will be delivered by the pump. Trouble Probable Cause Remedy A 1 Winch will not pull maximum load Relief valve may be set too low. 2. If this trouble occurs suddenly after work- ing at maximum pall, a particle of dirt may be lodged under the relief valve, holding it partially open, If this is the cause a con. Siderable loss in Tine speed may be noticed as the load on the cable is increased, 3. Mf the pump is belt driven the belts may be slipping. 4. The oll level in the reservoir may be too low. The suction line may be restricted or have an air leak causing cavitation at the inlet pump. This will catise the pump to make a Whining, noise, 5, Alter all the causes listed above have been sd and it is found that the winch will. stall at maximum pressure without developing the maximum pull on the bare drum, the trouble may be in the winch, Install a pressure gauge in location 1 and apply a stall pull on the winch. If pressure is Tow, imerease relief valve setting until recom: mended pressure Is obtained. Remove relief valve, disassemble and clean parts thoroughly in a suitable solvent. Reas- Semble and install relief valve. Reset pressure according to remedy under trouble ‘A’ cause 1 Check belts when pump is at full PST (Stall pull on winch). Tighten belts if they are found to be slipping. Check oil level in the reservoir, Check the suction line for damage, externally and intern. ally, Replace suction line if necessary. Install a pressure gauge in Iocation 1 and apply a stall pull on the winch. If the pressure is up to maximum and the bare drum line pull is less than the specified line pull, the trouble will be in the winch. Disassemble winch according to disassembly instructions and inspect. Check that all gears turn freely for "winehing in” rotation. If gears are found to be satisfactory, inspect the hy: draulic motor, according to the service instruc. tions for the hydraulic motor. 34Trouble Probable Cause Remedy B. Considerable redue- tion in line speed. © Reverse speed is 1. Same as cause 2 of trouble A. ‘Same as cause 4 of trouble A. 4. If this trouble has increased gradually, the pump or winch motor may be worn, 1. Control valve may be restricted in its travel. 2. Same as cause 1 of trouble A. 3. Oil may be too thick causing a high resist ance to rotation at the brake plates and causing the relief valve to by-pass. 4. Oil may be escaping past a damaged ‘O' ring im the brake cylinder. ‘Same as for cause 2 of trouble A. Same as for cause 4 of trouble A. Remove and Inspect pump. IF satisfactory, consult the disassembly instructions for the winch and remove and inspect the motor according to the service instructions for the hydraulic motor, Check the travel of the control valve spoot. The spool travel should be the same in both directions. Same as for cause 1 of trouble A. Change to a lighter weight oll fn the hydraulic system and primary hosing, Check the flow of oil from the vent line of the winch (port Q fig. A) while the winch is ran at full speed reverse for 2 or 3 minutes with port 'P” plugged. If the flow continues, remove the motor as per disassembly instructions. Dis- assemble and inspect the 'O" rings in the brake cylinder according to the service instructions (or the hydraulic motor. slower than for ward speed. D. Brake will not hold when control valve is returned to neut ral after pulling or lifting a load, L. Control valve is not correct type. The correct control valve must have all ports open to tank when the spool is returned to neutral See “Control Valve” page 5. 2. There is excessive back pressure acting on the reverse port of the winch motor. This back pressure is usually caused by the use of a control valve and hoses that are too sinall, Tt can also be caused by a restriction in the return line from the contral valve to the reservoir. Remove hose lines from control valve and with the spool in neutral blow air Uhrough the cylinder or motor ports. The air should escape through the return port on the valve. If the motor ports in the valve are blocked by the spool when the spool is in neutral, remove the valve and replace with correct valve, Install @ pressure gauge in location 2 Run the pump st its maximum RPM. and with the control valve in the neutral position read the pressure gauge. IT the pressure is greater than 95 PST itis too high. Consult the winch man- wal for the recommended hose and control valve size and install the correct size if neces sary. If the hose and control valve are as recommended, check for restrictions in the re turn line from the control valve to the reservoir. E. Brake will not con- 1 Same ay cause f or 2 of trouble D, Winch is being over loaded. 3. Alter the causes listed above have been in: vestigated and found 16 be satisfactory the trouble may be in the winch, Same as for cause | oF 2 of trouble D, Install a pressure gauge in location 1 and apply a stall pull on the winch, If the pressure is higher than the maximum specified PST reduce the pressure Disassemble the primary drive assembly ac cording to the disassembly instructions. Inspect the brake springs, brake plates and brake hub assembly. Check dat the brake hub assembly will “lock up" in the required direction. of rotation, trol or stop. the Toad when lowering. F. Brake vibrates violently. when lowering a load, 1. Ts type ‘A sullix “A” transmission off being used in primary drive assembly and in the hydraulic system? 2. Is oil being circulated through the primary housing of the winch? 3. Does the control valve have good metering characteristies? Replace oil if necessary. Sce lowering application page 7 and figure ‘B’ for required circulating lines. See control valve page 5, 35OW surely us opm ‘ue omessune 951 PERFORMANCE GRAPHS Model 6-26-*-* FOR A WINCH HAVING STANDARD DRUM DIMENSIONS UNE SPEED FFM — OlLSUPHLY US GPM AT FULL OAD Ss FOR LINE SPEED AT NO LOAD ‘ADD 18% 40 50 6070 89010010120 Mod.6-26-5-" 400 120 140,160,180 200220240 Mod. 6-26-H-* LINE SPEED FPM {FORWARD} 3s ss LINE PULL LBS. — OIL PRESSURE P $1 ° 500 1000 1500 2000 2500 3000 Mod.6.26-H.* 9 1000 2000 3000 4000 5000 6000 Mod.6.26. LINE PULL Lf 36PERFORMANCE GRAPHS Model 6-35-*-* FOR A WINCH HAVING STANDARD DRUM DIMENSIONS LINE SPEED FP-M — OIL SUPPLY US GPM_AT FULL LOAD 234 MAX. 29) ‘WL surmty us cpm FOR LINE SPEED AT NO LOAD ‘ADD 18% 50 607080 120M 0100120140180 180200220240 Mod 6-35-H-* LINE SPEED FP-M (FORWARD! LINE PULL LBS. — OIL PRESSURE PSI 0 500 To00 7500 7000 7500 3000 Med 6351." oO 1000 2000 +3000 4000, 5000 6000 = Mod 6-35-5-* LINE PULL LBS. a738 HOW TO USE THIS MANUAL Read and understand the Explanation of Winch Model Number on page 3. The example shown of Model 6-26-S-EC is the model normally supplied unless otherwise requested. The first code number following the basic model number refers to the motor cartridge size. ‘The first code letter following the second code number refers to the Final Drive Reduction only, 'S’ for, standard ratio, 'H’ for high speed ratio, and 'D’ for direct drive. The second code letter EC or EA refers to the direction of rotation of the drum when “winch: ing in”, viewed from the final drive end of the winch, "EC’ for clockwise rotation and ‘EA’ for anti-clockwise rotation. The winch has the same speed in both dircctions and the automatic brake is active in. reverse rotation only. To convert a winch from clockwise rotation to anticlockwise the Motor Assembly and the Brake Hub Assembly require to be changed. To Determine the Correct Part Number Determine the model number of the winch as marked on manufacturer's name plate. Turn to the required assembly drawing, pages 9 to 18 inclusive, and read the part number from the parts list under the appropriate model number wading. Service Instructions Disassembly and Assembly instructions are dealt with as assemblies and sub-assemblies under the appropriate model number headings. The model number headings in these instructions show only the letter code that applies to the assembly or sub-assembly being described.NUMERICAL INDEX OF PARTS. Part Page Part Page Part Page Part Page No. No, No. No. No. No. No. No. 50100 51258 8 68608 12 055608 13 50101 51279 9 A8510 12 S661 14 50105, 51306 16 C5512x 10 05561x- 10 50287 51446 14 D5513XEC-26. 10 CS861XEA26 11, 12.13 50289 51447 14 D8513XEC-36. 10 C5S61XEASS...11, 12, 13 50292 51668. 10.16 -AB514 10 C5561XEB-26.......11, 13 50293 51690 13 DBS14XEA-26. 1 C5561XEBS5. 11.13 50203 51631 13 D51aXEASS. 11 C5861 XEC* 12.13, 50332 51985 10 AS5I5 10 C5961XEG-26, 10, 12.13 50334 52912 12,1833 _D5616XEB-26 11 G5561XEC-35... 10. 12. 13 50336 52381 10 DSS16XEB-36. 11 05561 XEBP-26 " 50341 52596. 12.13 ASBI7 18 C5861 XEBP-35, 4 50342 52597 13 C8517xH 17 85862 12 50361 52598. 12,13 CS517XS 17 85663 14 50365 52608 435518 18 A564 14 50366 52609 13 A5519 18 C5969. 8 50391 52610 138520 12 C9872-" 9 50428, 53698 14 A552 3.12 A56B1 16 50513 53699 14 ass22 12 A5582 16 50533 53708 14 B5522-* 9 ASS83 2 50535, 53709 14 as824 12 A8684 16 50573 54271 148525 16 5586 n 50585 56019 98529 42 ABBO1XA 12,18 50602 56020 1785531 16 A5601XC 12.18 50754 86203 3385532 10 AS604x 93 50800 58303 9 85533 15 ASBO4BX 33 50865 ‘98500 17 BS534 13. AS608x 33 50933 85500 17 8640 9.13 ASBOBBX 33 50934 ‘C5500H 18 5541 9 AS607x 33 50935 ¢35008 18 C8542 10 A5607Bx 33 51003 ‘C5500xH 1B 5553 14 _A5608x 33 51004 C5800xS, 1.18 AS654 14 AS80BBX 33 51007 5501 10.17 5555 14 AS614 12 51018 05501 1788857 14 A8B15 12.14 51065. 85502 18 A555 14 an1029 10.33 51067 658024 9 ASSES 14 A11033. 18 51090 85504 17.18 055594 13811039. 18 1144 5504 10 55598 13 Attoas. 15 51203, c5604M 10 C5580C 13811051 16 51245 05504 9 AS56O 14811076. 15 51246 985505 2 ¢5560 12 AN1077 15 51253 148606 10 C5S60A. 12 A22009, 16MAINTENANCE PROCEDURE FOR GEARMATIC HYDRAULIC WINCHES ‘The following service recommendations are to be carried out where- ever the safety of personnel is involved and are made with a view to providing long trouble free service from your Gearmatic Hydraulic Winch Steps 1, 2 and 3 are to be carried out every 12 months or after 500 hours of actual winch operation, whichever comes first. The hours referred to are 500 hours of actual drum rotation which will be a percentage of actual man hours, depending on the application. Before any part is removed from the winch, all the steps for disassembly and assembly in the parts and instruction manual should be read and understood. 1. Drain the oil from the final drive assembly by removing the pipe plug from the end cover. Remove the planet hub assembly by following the disassembly instructions for the final drive assembly. Check all parts according to the inspection instructions for this assembly. Reassemble and fill the final housing with SAE 90 transmission 2. Drain the oil from the primary drive housing and disassemble the primary drive assembly by following the disassembly instructions. Check all parts according to the inspection instructions for this assembly. 3. (a) Disassemble the motor assembly and remove the brake hub assembly from the motor shaft and, without removing the snap rings, garter springs and cam locks from the inside diameter of the brake hub, inspect the cam locks for flats at the points where they contact the motor shaft, If flats exist on the cam locks, replace them with new parts. (b) Inspect the shaft diameter for excessive wear at the bearing and cam lock arcas. If the wear at these points is greater than “001 on the diameter when compared with the unworn areas, replace the brake hub, cam locks, bearing and motor shaft. (c} Clean out the inside of the primary housing, reassemble the primary drive assembly and refill the primary housing with the same oil as is used in the hydraulic system.LLL TT TE EE TT TT I TTT 3 ‘nan anon ‘cAUFORNA cometnest unos uS.. pisTrieuToRS of Gearmatic, ‘atvation Ine. PO. Box 58067 Homewood Ala, 25209 Nobels 38607 a Eamon In ‘S01 ey Woy Seatie ach 8107 ‘x rates Co, 0. Boe si68 Phoen Aona 85051 ‘eras Ca Stade 8 Ae. ‘ese, Aeon 65713 Jock Tipe Egon 6112 eran Are tite Rok 72209 faker Prose 260 Foye See Barbark Ca 81504 fer Poe 1788 Osowt Set Gelder Ee 4021 Tre Wisco 15 oll Stet ‘ee, 80299 Slewat-het e Aas Ae ysis 1200 Aare te Catons Ditibutng Co ‘edad Pare Spokane, Washington 98215 Moat "EN Faves Co 519 w. Lire ‘Schaumburg tt 60172 Southern "Bo Products PO, Box 506 Hazelwood Missousi 63042 Rock Ita, 61201, onaco ine, 20 Kansas Avene ansas Cay, Kansas. 65119 ‘Seat Equipment Co. 272 Lao Steet Dayton, Ono 45401 Houston Systems mig. co 749 Veta, PO. Box 778 Haney, La 70088 ‘Stewart Hut Ine 8 Gare cece ington, Mass. 01803 sar ew HAMPSHIRE aunnesera massissen, wissount mowraua ew sense ew mexico ew roa (coun yor CAROLINA oar ‘oaroTs Doss Hycrauies Co. 8860 Kelso Dive Batimore, M2121 Stewart Hunt Ine 8 Garin Ciel Burington, Mass. 01800, ub ng 251 Minesota vere “oy, Miengen 48084 4. Fawer Nortwest Hid Power Di. 1476 Marin Dive, ten Pra, Minn $5343 Activation in ‘3 Carton Mat Road Suite 31 eckson, Ms 39211 Eastern Fb Padus 0. Bac 505 Hazeiwond, Missouri 63042 {eta Pover Syste re ON Alan ansas Cty, Missou 64116 atey Contos In. PO, Box 7496 Mssaua, Montara 58807 Conmaco Ine. 1820 Kansas Avenoe Kansas City, Kansas. 66119 Fucker Pocus 7728 Oakport Set Oaléand Ca. 94621 Norte "Arojel Co 43 Newark Way Maplewood, Nl 07040, Souther Fuld Power ne 584 Townsh Lie Road Ble Get, Pa 13422, Ai Drauies Co Po. Bax 6500 23117 Claremont Ave, SE Auquerie NM 87107 ‘iol Co, 43 Newark Way Maplewood, Ni 07040, Sharp Controls Co 2180 Gateway Bia Chavo, WC” 28266, Contos Co, 7330 Chap! Hl Boas Faiagh NC. 27607 AN Fawer eriest Fuid Power On. 14770 Marin Deve Een Praia, Mion $5343 Norte Hebi ne 251 Minesota Averve Troy, Menigan 48084 Soutern 00 seat Busser Deyn Oe 45401 Aber Dytanis Step it sare whee isa Onanone 74145, Peso “ ‘CAROLINA ‘suru panaTA tes may veawont sea ‘wisconsin west sence nena aclu HYDRAULIC WINCHES & ROTO-VERSAL HYDRAULIC DRIVES den Pai, Minn 55343 Easter ‘Aatvation ic. 199 Spance Lane enn. 37210 Activation In. 205 Ean Orne Roosvil Tenn 37919 a eaeace, pees Teas 740 The was 15 Wen 2060 St Sat Lae iy, ah 4115 Stewart. 5 Goma Grae Burge, as. 01808 Dees Hyer Co of Va 751 Woon Aetna a 4 Westen {501 ay Way Seat Weng 98107 tase Ens Dstog fais Fa Sore Wash. 56215 ib Fane Labs er 24 Brettla Wears 2005 Dayton, ona 45401 Western “The Wid Co, 125 West 2980 sour, Salt Lake City, Utah 84115, astern “he Wik Co 4875 Jolt Steet Dewey, Cotrado” 80280 scape Ine. 40 Fine Ove ‘edison ils 60101 GearMatle co. soveoucemnem orcwecauo so ssa eRe smn 86. ansoave na

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