Pullmaster HL25 - DISASSEMBLY OF FINAL DRIVE

PAGE 18
Clamp clutch hub, item 670, to pressure plate, item 652, and remove circlip, item 679. Remove clutch hub, three
clutch springs, item 676, pressure plate, item 652, and gland, item 656, from motor drive shaft. Remove and
discard O-rings, item 653, 657 and 735.
Models with piston motors only: Discard two O-rings, item 689.
4) The surface of motor drive shaft which engages sprag clutch, item 672, should be inspected for wear or
indentations. If motor drive shaft shows any surface damage, it should be replaced.
5) Inspect three clutch springs for damage and measure overall length. Overall spring length should be 1.25
inch. If any spring measures less than 1.19 inch, all three springs should be replaced as a set.
6) Inspect eight friction plates, item 673, for damage or excessive wear. Plates should be flat and smooth. Plates
should not show heat discoloration. Paper material on friction plates should be intact and grooved. If any
damage is detected, replace friction plates and divider plates as a set.
7) Remove circlip, item 661, and slide drive gear, item 660, off of connecting shaft, item 600.
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:
1) Remove 18 brake springs, item 752, from brake piston, item 750. Thoroughly examine springs for damage
and measure overall length. Overall spring length should be 2.27 inch. If any spring measures less than 2.21
inch, replace all springs as a set.
2) Pull brake piston, item 750, out of brake housing using two 5/8-11NC bolts screwed into two puller holes in
piston and discard O-rings, item 751 and 753.
3) Thoroughly examine inner bores of brake housing and outer diameters of brake piston for scoring caused by
hydraulic fluid contamination. Minor surface damage may be repaired by polishing with a fine emery cloth.
DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING
CAPACITY AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. SOLVENT MAY DAMAGE THE
FRICTION PLATES. DO NOT USE SOLVENT TO CLEAN THE FRICTION
PLATES. PERFORM THOROUGH INSPECTION AND, IF NECESSARY,
REPLACE FRICTION AND DIVIDER PLATES AS A SET.
4) Remove five friction plates, item 715, together with six divider plates, item 713, and inspect for damage or
wear. Plates should be flat and smooth. Plates should not show heat discoloration. Paper material on friction
plates should be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
5) Remove brake spacer, item 712.
DISASSEMBLY OF FINAL DRIVE:
1) Remove drain plug, item 121, from end cover, item 120, and drain lubricating oil from final drive assembly
and the cable drum interior. (To drain all oil out of cable drum interior, winch should be tipped to an angle and
filler plug, item 503, removed.)
2)
Remove internal retaining ring, item 124, and pull end cover, item 120, out of final drive housing, item 100.
3) Discard O-ring, item 123, and inspect planet hub stopper, item 126, and sungear stopper, item 122, for
excessive wear. Replace planet hub stopper if less than .30 inch and sungear stopper if less than .21 inch thick.
4) Remove final planet hub assembly from final housing, item 100.
313 REV.970901
SERVICE INSTRUCTIONS CONTINUED
DANGER