Pullmaster M6 Series - Primary Drive and Cable Drum Assembly Disassembly

PAGE 15
SERVICE INSTRUCTIONS CONTINUED
316 REV.980601
DISASSEMBLY OF PRIMARY DRIVE:
If the primary drive requires service or repair, disassemble as follows:
1) Remove pipe plug, item 503, from cable drum, item 500, and pipe plug, item 121, from end cover, item 120,
to drain lubricating oil from winch interior. Remove breather relief, item 130.
NOTE: Breather relief, item 130, is not user serviceable. Must be replaced if not functioning properly.
2) Stand winch upright on end cover, item 120. Remove 12 capscrews, item 911, and lockwashers, item 931.
Remove base, item 550.
3) Remove circlip, item 535, and, with two heel bars, pry end housing, item 698, away from cable drum flange.
Remove and discard O-ring, item 539.
4) Press ball bearing, item 103, out of end housing, item 698.
5) Remove seal carrier, item 538, from end housing and discard Parker seal, item 543, and O-ring, item 545.
6) Remove six socket head capscrews, item 537, and bearing flange, item 530, from cable drum. Remove circlip,
item 517, from inside bearing flange. Press oil seal, item 531, against journal bearing, item 706, to remove.
Discard oil seal, item 531, and O-ring, item 539.
7) Remove primary planet hub assembly, and final sungear, item 340, from cable drum, item 500.
8) If necessary to remove primary planet gears, remove circlip, item 411, from chamfered side of planet pin, item
410, and press pin out of planet hub, item 400. Inspect needle bearing, item 423, and two thrust washers, item
421, and replace if damaged.
9) Remove circlip, item 343, from end of final sungear, item 340, and extract from planet hub.
10) Inspect sungear stopper, item 344, for excessive wear. Replace if less than .03 inch protrudes out of final
sungear, item 340.
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 planet hub stopper is less than .14 inch or if sungear stopper is less than .37 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) To separate cable drum from final housing, first remove circlip, item 513. Insert two heel bars between flange
of cable drum and final drive housing and gently pry cable drum out of ball bearing, item 103.
6) Remove circlip, item 104, and press ball bearing, item 103, out of final housing, item 100. Check ball bearing
and replace if damaged.
7) Remove and discard oil seal, item 105.