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Teflon seals, gasket seals and ring seals in the hydraulic motor assembly are not part of the winch seal kit. The
seal kit for the hydraulic motor can be ordered from the factory under Part No. 23117. All parts of the hydraulic
motor, with the exception of the motor adaptor, item 800, and the port end cover, item 870, are standard parts
of the hydraulic motor, having a 3 inch gear section. All of these parts can be ordered from PULLMASTER or
authorized Distributors/Dealers in Canada, the United States and in most overseas areas.
REMOVAL OF HYDRAULIC MOTOR ASSEMBLY:
If disassembly of the hydraulic motor is not necessary, proceed as follows:
1) Remove 12 hex head capscrews, item 821, with lockwashers, item 823, from motor adaptor, item 800. (Since
the brake springs, item 752, apply pressure against the inside of the motor adaptor, it is recommended that
the hex capscrews are unscrewed, one turn at a time, until the spring pressure has been released.) The
complete motor assembly, including motor adaptor, can now be removed from brake housing assembly.
2) Remove and discard three O-rings, item 801, and O-ring, item 707. (O-rings, item 801, seal the pressure
transfer hole for the automatic brake release and are situated on the flange of the brake housing.)
f
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:
1) After motor assembly has been removed, all parts of brake assembly are accessible. Remove 14 brake
springs, item 752. 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 motor drive shaft, item 730, and complete brake hub assembly from brake housing.
3) Disassemble brake hub assembly by removing circlip, item 727, from motor drive shaft. Remove motor drive
shaft from brake hub, item 720. Remove sprag clutch aligners, items 722 and 724, and sprag clutch, item
723, from brake hub.
249 REV.000315
SERVICE INSTRUCTIONS CONTINUED
4) Thoroughly inspect motor drive shaft, item 730, and brake hub, item 720, particularly the surfaces where
sprag clutch, item 723, engages. If any indentation or surface damage is detected, replace brake hub, sprag
clutch and motor drive shaft as a set.
5) 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 item 753.
6) 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.
MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE
MOTOR DRIVE SHAFT AND BRAKE HUB, WILL RESULT IN BRAKE
FAILURE AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. THOROUGHLY INSPECT
THESE AREAS AND, IF NECESSARY, REPLACE MOTOR DRIVE
SHAFT, SPRAG CLUTCH AND BRAKE HUB AS A SET.
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.
DANGER
DANGER
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