Pullmaster M12 Series - Page 100

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7) Remove six friction plates, item 715, together with seven divider plates, item 714, 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.
8) Remove brake spacer, item 712.
9) Remove thrust bearing, item 617, and two thrust washers, item 615.
All parts have now been removed from brake housing and there is no need for further disassembly unless a failure has been analyzed
in the remaining winch assembly. If continuing, remove pipe plug, item 121, from end cover, item 120, and tip winch to drain lubricating
oil from inside of final drive housing and cable drum.
10) Remove 12 capscrews, item 551, 12 lockwashers, item 553, and base, item 550.
11) Slide brake housing, item 700, out of cable drum ball bearings, item 507 and item 509. Connecting shaft, item
600, can now be removed from center of brake housing. Remove and discard O-ring, item 601.
12) Remove and discard oil seal, item 607, and if present, backup washer, item 606.
13) Inspect needle bearing, item 603, inside connecting shaft, and replace if damaged.
14) Remove primary sungear, item 440, from center of primary planet hub, item 400.
DISASSEMBLY OF FINAL DRIVE:
Stand winch on cable drum flange with final end up and disassemble as follows:
1) Remove retaining ring, item 124, and pull end cover, item 120, out of final housing, item 100.
2) Discard O-ring, item 123, and inspect planet hub stopper, item 126, and sungear stopper, item 122, for
excessive wear. Replace if less than .21 inch thick.
3) Remove final planet hub assembly from final housing, item 100.
4) Inspect three final planet gears, item 320, for damage or wear. If it is necessary to remove final planet gears,
remove circlip, item 313, and press planet pin, item 310, out of planet hub, item 300. Inspect needle bearing,
item 323, and two thrust washers, item 321, and replace if damaged.
5) Remove final sungear, item 340, from cable drum, item 500.
DISASSEMBLY OF PRIMARY DRIVE:
If primary drive requires service or repair, proceed as follows:
1) Turn winch over to sit flat on end of final housing, item 100.
2) Remove and discard oil seal, item 515.
3) Using a standard bearing puller, remove ball bearings, item 509 and item 507.
4) Remove internal gear, item 430, and primary planet hub assembly from cable drum, item 500.
5) If it is necessary to remove primary planet gears, remove circlip, item 411, and press planet pin, item 410, out
of planet hub, item 400. Inspect needle bearing, item 423, and two thrust washers, item 421, and replace if
damaged.
6) Inspect internal gear stopper, item 412, for excessive wear. Replace if less than .10 inch protrudes out the end
of planet pin, item 410.
7) Remove sungear stopper, item 444, from primary planet hub, and replace if less than .19 inch thick.
245 REV.950201
SERVICE INSTRUCTIONS CONTINUED