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SERVICE INSTRUCTIONS
GENERAL:
Before disassembling the PULLMASTER Model M5 planetary winch, read and understand the following instructions.
Replace expendable parts such as O-rings and oil seals when reassembling the winch. Have a winch seal kit (Part
No. 23099) on hand before the unit is disassembled.
helen
NOTE: Backup washers may be included with seal kit. Install with oil seals as per instructions. If not present
in seal kit, the oil seals supplied do not require backup washers.
Disconnect all hydraulic hoses, remove the winch from its mounting and relocate to a clean working area, similar
to one used for service work on any other hydraulic component. Special tools are not required to service the winch.
Adjustments and calibrations are not required.
All parts, as they are removed from the winch assembly, should be inspected for wear and damage. Worn or
damaged parts must be replaced. Thoroughly clean parts before reassembly. Do not use solvent to clean the brake
friction plates.
During reassembly, lubricate all O-rings and oil seals with grease before installation.
The following SERVICE INSTRUCTIONS refer to part descriptions and item numbers which appear in ASSEMBLY
DRAWING on page 20.
DISASSEMBLY
REMOVAL OF HYDRAULIC MOTOR ASSEMBLY:
The motor is not user serviceable and must be replaced if not functioning properly. Contact your nearest
PULLMASTER WINCH CORPORATION Distributor for a replacement. Remove the motor assembly as follows:
1) Remove two capscrews, item 935, and lockwashers, item 937. Pull hydraulic motor, item 950, out of winch
assembly.
2) Remove and discard O-ring, item 811.
3) Connecting tube, item 830, will either be in motor or motor adaptor. Note and mark which brake release port
part is from (required for reassembly) then remove. Remove motor plug, item 888, from other brake release port.
These parts must be reinstalled properly for winch brake to function correctly. Remove and discard three O-
rings, item 831.
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:
The majority of service and repair work is done on the brake housing assembly which is accessed by removing the
hydraulic motor assembly. Disassemble brake housing assembly as follows:
1) Remove motor adaptor, item 800, by removing eight capscrews, item 931, and lockwashers, item 933. Allow
brake springs, item 752, to expand safely by unscrewing capscrews one turn at a time.
2) Remove and discard O-ring, item 539.
3) Remove six brake springs, item 752. Examine springs for damage and measure overall length. Overall spring
length should be 1.25 inch. Springs measuring less then 1.19 inch should be replaced.
4) Pull brake piston, item 750, out of brake housing, item 700. Verify free movement of by-pass valves. If valves
are seized, replace piston assembly.
5) Remove and discard O-rings, items 751 and 753.
6) Thoroughly inspect brake piston outer diameters and brake housing inner bores for scoring caused by hydraulic
fluid contamination. Minor surface damage may be repaired by polishing with a fine emery cloth.
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