Pullmaster M5 Series - Page 198

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13) Insert secondary sungear, item 490, between three planet gears, item 470. Slide assembly into secondary
planet housing, item 456, engaging sungear spline with primary planet hub, item 400, and planet gears with
secondary planet housing. Insert retaining ring, item 481.
14) Lower brake housing assembly onto cable drum. Line up mounting holes of secondary housing, item 456,
with those in cable drum.
15) Rotate brake housing to line up access holes and fasten secondary housing using 12 capscrews, item 537,
and lockwashers, item 529.
16) Attach tie bars, item 556, using 20 capscrews, item 555, and lockwashers, item 553.
REASSEMBLY OF FINAL DRIVE:
Turn winch over to sit upright on brake housing, item 700, with end housing, item 100, facing upward.
1) Reassemble final planet hub assembly. Use grease to temporarily hold 30 loose rollers, item 323, in bore
of planet gear, item 320. Position thrust washers, item 321, on either side of planet gear. Press planet pin, item
310, into final planet hub, item 300, and retain with circlip, item 311.
2) Insert final planet hub assembly into final housing, item 100. Ensure that final planet hub spline is fully
engaged with cable drum, item 500.
3) Install final sungear, item 340, through centre of three final planet gears and into secondary planet hub, item
450.
4) Install new, well-greased O-ring, item 123, into end cover, item 120.
5) Verify planet hub stopper, item 126, is installed onto end cover.
6) Attach end cover to end housing, item 100, using 12 capscrews, item 127, and lockwashers, item 541.
7) Temporarily remove breather relief, item 130, from end cover. Turn winch over with brake housing, item 700,
facing upward.
REASSEMBLY OF BRAKE HOUSING ASSEMBLY:
Reassemble brake housing assembly as follows:
1) Install sprag clutch, item 723, into bore of brake hub, item 720. Position sprag clutch aligners, item 722 and
item 724, on either side of brake hub. Carefully slide motor drive shaft, item 730, into brake hub assembly
and secure with circlip, item 727. Verify that circlips, item 719 and item 731, are installed on motor drive shaft.
2) Carefully slide motor drive shaft, item 730, with brake hub assembly, into connecting shaft until it engages
spline of primary sungear, item 440.
IMPORTANT: For proper brake function, verify that sprag clutch is installed correctly. When viewed from
the motor end, the motor drive shaft of a clockwise hoisting winch must turn freely clockwise
and lock in the counterclockwise direction.
3) Install brake spacer, item 712, into brake housing.
SERVICE INSTRUCTIONS CONTINUED
253 REV.110214
INCORRECT ASSEMBLY OF THE FRICTION PLATE AND DIVIDER PLATE
STACK WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD
TO DROP, CAUSING PROPERTY DAMAGE, SEVERE INJURY OR
DEATH. REASSEMBLE PER INSTRUCTIONS.
DANGER