1. Remove the wire rope from the cable drum and
rotate the drum until the fill/drain plug is at the bot-
tom, six o'clock position. Remove the drain plug and
capture the gear oil in a suitable container. Recycle
or dispose of used oil in an environmentally respon-
sible manner. Install the drain plug.
2. Label the hydraulic hoses as they are removed from
the hoist motor. Install plugs in the open hoses and
motor ports to reduce entrainment of dirt in the open
port.
3. Remove the hoist mounting fasteners and lift the
hoist from the mount. Begin disassembly by placing
the hoist on a stable work surface with the motor
end facing up. Secure the hoist in this position to
prevent it from falling and causing injury.
4. Remove the hose that connects the brake valve to
the brake release port. Remove the fasteners secur-
ing the motor to the brake cylinder assembly. Lift the
motor straight up to disengage the motor shaft from
the brake clutch assembly.
5. Remove the brake clutch assembly from the brake
cylinder assembly. Refer to "Brake Clutch Service"
section for additional information.
6. Place an alignment mark on the brake cylinder and
the hoist end-bracket to ensure the correct position
of the brake cylinder on the end-bracket is main-
tained. Remove the eight capscrews that secure the
brake cylinder to the hoist end-bracket. Install two
½-13 in. eye-bolts into the motor mounting holes
and lift the brake cylinder out of the hoist end-brack-
et. Be careful to avoid damaging the seal surfaces
of the brake cylinder. Refer to "Brake Cylinder
Service" for additional information.
7. Remove the capscrews that secure the two tie-
plates to the hoist end-brackets and remove the tie-
plates and the motor end end-bracket.
8. Install two 3/8-16 in. eye-bolts into the drum closure
or use two heel-type pry bars placed between the
primary planet carrier and the drum closure, pry
upward to remove the drum closure. Remove the
seal and bearing from the drum closure as required.
9. Remove the primary sun gear and thrust washer
from the primary planet carrier. Remove the primary
planet carrier from the drum. The planet shafts are
tapped for ¼-20 in. lifting bolts for convenience.
Lifting hooks may also be fabricated from steel bar.
Refer to "Planet Carrier Service" for additional infor-
mation.
DISASSEMBLY OF WINCH
15
The H20R hoist weighs approximately 500 pounds
(227 kg). Use adequate lifting equipment.
CAUTION
All disassembly and assembly MUST be performed
with the motor end facing up. The thrust washer
located under the input sun gear may become dis-
lodged if components are removed while the hoist is
in the horizontal position. The dislodged thrust wash-
er may become trapped in the hoist gear train and
cause a catastrophic failure that may result in loss of
load control, property damage injury or death.
