Pullmaster M8 Series - Page 42

PAGE 16
SERVICE INSTRUCTIONS CONTINUED
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.
REASSEMBLY OF FINAL DRIVE ASSEMBLY:
Reassemble final drive assembly by reversing the disassembly procedure.
1) Return winch to a horizontal position, standing on its mounting feet.
2) Install new, well-greased O-ring, item 293, on end of final sungear, item 340, and slide sungear through opening
in cable drum, item 500.
3) Reassemble final planet hub assembly. Press pre-greased needle bearing, item 323, midway into planet gear,
item 320. Position thrust washers, item 321, on either side of planet gear and press planet pin, item 310, into
the planet hub, item 300. Retain with circlip, item 311.
4) Insert final planet hub assembly into final housing, so that spline interlocks with cable drum, and planet gears
mesh with final sungear.
5) Install new, well-greased O-ring, item 123, into end cover, item 120. Verify that planet hub stopper, item 126,
and sungear stopper, item 122, are installed into end cover.
6) Gently insert end cover into final housing, item 100, and fasten with retaining ring, item 124.
7) Temporarily remove breather relief valve, item 130, from end cover. Turn winch up on end with cable drum
opening upwards.
8) Install new backup washer, item 710, and new, well-greased oil seal, item 711, in the bore of the brake housing.
9) Place brake housing, item 700, into cable drum, item 500, guiding it over final sungear, item 340. Use 16
capscrews, item 971, and lockwashers, item 973, to secure tie bars, item 970.
REASSEMBLY OF BRAKE HOUSING ASSEMBLY:
Reassemble brake housing assembly by reversing the disassembly procedure.
1) Install bronze washer, item 706. Place thrust bearing, item 617, in between two thrust washers, item 615, on
top of bronze washer, item 706.
2) Install sprag clutch, item 723, in bore of brake hub, item 720. Insert sprag clutch aligner, item 722, into one side
of the brake hub. Insert the other sprag clutch aligner, item 724, into the other side of the brake hub. Carefully
slide the brake shaft, item 730, through the sprag clutch aligner, item 724, into the brake hub assembly and
fasten into place by installing circlip, item 727.
IMPORTANT: For proper brake function, ensure that the brake hub rotation is correct. When
viewed from the motor end, the brake shaft of a counterclockwise hoisting winch
must turn freely counterclockwise and lock in the clockwise direction.
3) Install brake hub assembly through thrust washers, item 615, and engage spline with final sungear, item 340.
4) Install brake spacer, item 712, into brake housing. Starting and finishing with a divider plate, alternately install
14 divider plates, item 713, and 13 friction plates, item 715.
5) Liberally grease O-ring, item 751, and O-ring, item 753, and install on the brake piston, item 750.
184 REV.970901
DANGER