INSTRUCTION AND PARTS MANUAL

MODEL M5
Design Revision 'B'

PLANETARY HYDRAULIC WINCH

THE LOGICAL CHOICE

PULLMASTER WINCH CORPORATION

8247-130th Street, Surrey, B.C. V3W 7X4, Canada
Telephone: 604-594-4444 Fax: 604-591-7332
Website: www.pullmaster.com
E-mail: sales@pullmaster.com

READ THIS MANUAL BEFORE INSTALLING, OPERATING OR

SERVICING THIS PRODUCT. THIS MANUAL CONTAINS IMPORTANT
INFORMATION. MAKE THIS MANUAL AVAILABLE TO ALL PERSONS
RESPONSIBLE FOR THE OPERATION, INSTALLATION, SERVICING
AND MAINTENANCE OF THIS PRODUCT.

PMC 316 070228

Pullmaster Limited Warranty
Effective 8/1/2008
SUPERSEDES ALL PRIOR WARRANTIES

Seller warrants that each article (whether Gear Drive Products, Brake Products and/or Winch Products, all of which are covered hereunder)
sold under this order shall at the time of shipment (i) conform to applicable specifications, and (ii) be free from defects in material and
workmanship during normal and ordinary use and service (the "Warranty").

Buyer's exclusive remedy and Seller's sole obligation under this Warranty shall be, at Seller's option, to repair or replace any article or part
thereof which has proven to be defective, or to refund the purchase price of such article or part thereof. Buyer acknowledges that Buyer is
knowledgeable concerning the articles covered by this Warranty and sold in connection therewith which are being purchased, that Buyer has
reviewed this Warranty and that the remedies provided hereunder are adequate and acceptable to Buyer.

This Warranty shall expire one (1) year from the date the article is first shipped by Seller. Notice of claimed breach of this Warranty must be
given by Buyer to Seller within the applicable period. Such notice shall include an explanation of the claimed warranty defect and proof of
date of purchase of the article or part thereof for which warranty coverage is sought. No allowances shall be made by Seller for any
transportation, labor charges, parts, "in and out" costs, adjustments or repairs, or any other work, unless such items are authorized in writing
and in advance by Seller. Nor shall Seller have any obligation to repair or replace items which by their nature are expendable.

If an article is claimed to be defective in material or workmanship, or not to conform to the applicable specifications, Seller will either
examine the article at Buyer's site or issue shipping instructions for return to Seller. This Warranty shall not extend to any articles or parts
thereof which have been installed, used, or serviced otherwise than in conformity with Seller's applicable specifications, manuals, bulletins,
or instructions, or which shall have been subjected to improper installation, operation, or usage, misapplication, neglect, incorrect
installation, overloading, or employment for other than normal and ordinary use and service. This Warranty shall not apply to any article
which has been repaired, altered or disassembled, or assembled by personnel other than those of Seller. This Warranty shall not apply to
any article upon which repairs or alterations have been made (unless authorized in writing and in advance by Seller). This Warranty shall
not apply to any articles or parts thereof furnished by Seller to Buyer's specifications and/or furnished by Buyer or acquired from others at
Buyer's request.

SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND, OTHER THAN THE WARRANTY
EXPRESSLY SET FORTH ABOVE. SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND ACCEPTED IN LIEU OF ANY AND ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Buyer expressly agrees that Seller is not responsible to perform any work or investigation related in any way to tensional vibration issues
and is not responsible for the detection or remedy of Natural Frequency Vibration of the mechanical system in which the unit is installed.
Buyer acknowledges, understands and agrees that this Warranty does not cover failures of the unit which result in any manner from the
operation of the machine or unit at vibration frequencies at or near the natural frequency vibration of the machine in such a way that damage
may result. Buyer expressly agrees that Seller is not responsible for failure damage or accelerated wear caused by machine or ambient
vibration. Further, Buyer acknowledges and agrees that Buyer is always solely responsible for determination and final approval of the
“application factor”
which may be used in Seller’ s calculations, and this application factor is 1.0 unless otherwise stated in Seller’
s quotation
specifications.

The remedies for this Warranty shall be only those expressly set forth above, to the exclusion of any and all other remedies of whatsoever
kind. The limited remedies set forth above shall be deemed exclusive, even though they may fail their essential purpose. No agreement
varying or extending the foregoing Warranty, remedies, exclusions, or limitations shall be effective unless in a writing signed by an executive
officer of Seller and Buyer. This Warranty is non-transferable. If a party who had purchased articles from Buyer, or from persons in privity
with Buyer, brings any action or proceeding against Seller for remedies other than those set forth in this Warranty, Buyer agrees to defend
Seller against the claims asserted in such action or proceeding at Buyer’ s expense, including the payment of attorneys’ fees and costs, and
indemnify Seller and hold Seller harmless of, from and against all such claims, actions, proceedings or judgments therein. Buyer also
agrees to defend and indemnify Seller of, from and against any loss, cost, damage, claim, debt or expenses, including attorneys’ fees,
resulting from any claims by Buyer or third parties to property or injury to persons resulting from faulty installation, repair or modification of
the article and misuse or negligent operation or use of the article, whether or not such damage to property or injury to persons may be
caused by defective material, workmanship, or construction. ADVISORY: Winches and hoists are not approved for lifting or handling
personnel or persons unless specifically approved in writing from Seller for the specific intended application.

Under no circumstances shall Seller be liable (i) for any damage or loss to any property other than the warranted article or part thereof, or (ii)
for any special, indirect, incidental, or consequential damage or loss, even though such expenses, damages, or losses may be foreseeable.

The foregoing limitations on Seller's liability in the event of breach of warranty shall also be the absolute limit of Seller's liability in the event
of Seller's negligence in manufacture, installation, or otherwise, with regard to the articles covered by this Warranty, and at the expiration of
the Warranty period as above stated, all such liabilities shall terminate. Buyer’ s purchase of any article(s) covered by this Warranty shall
constitute acceptance of the terms and conditions hereof and shall be binding upon Buyer and Buyer’ s representatives, heirs and assigns.
The laws of the Province of British Columbia shall govern Buyer’ s rights and responsibilities in regard to this Warranty and the transaction(s)
subject thereto, and the Province of British Columbia shall be the exclusive forum and jurisdiction for any action or proceedings brought by
Buyer in connection herewith or any dispute hereunder. If any of the terms and conditions contained within this Warranty are void, the
remaining provisions thereof are and shall remain valid and enforceable.

Note: Prices and specifications contained in this price book are subject to change without notice.

US.DIST.01.01.07 [PULLMASTER LOGO]

 SAFETY RECOMMENDATIONS
Definition: Caution indicates a potentially
hazardous situation which, if not avoided may
DANGER result in minor or moderate injury.

Definition: Warning indicates a potentially

FAILURE TO COMPLY WITH THE FOLLOWING SAFETY hazardous situation which, if not avoided could
result in death or serious injury.
RECOMMENDATIONS AND LOCAL RULES AND
REGULATIONS WILL RESULT IN PROPERTY Definition: Danger indicates a potentially
hazardous situation which, if not avoided will
DAMAGE, SEVERE INJURY OR DEATH. result in death or serious injury.
The planetary hydraulic winches are made for hoisting and lowering loads and to be operated by trained and professional
personnel. They are not designed for operations involving lifting or moving personnel. The winches are powered by hydraulic
power. The ropes / cables for hoisting operations are not supplied by PULLMASTER. The winches are always assembled
in an application, they do not function as an independent machine and it is not allowed to use them as such.

The winches are to be used within the specifications as listed in the manual under “SPECIFICATIONS”. Other use as foreseen
in the functional description of the hydraulic winch is not allowed without written permission from PULLMASTER.

1. Do not install, operate or service winch 18. Use only recommended hydraulic oil and gear
before reading and understanding manufacturer's lubricant.
instructions.
19. Keep hydraulic system clean and free from
2. The winch described herein is not designed contamination at all times.
for operations involving lifting or moving personnel.
20. Maintain winch and equipment in good operating
3. Do not lift or carry loads over people. condition. Perform scheduled maintenance regularly.
4. Do not exceed recommended operating 21. Keep hands clear when winding wire rope onto
pressure (psi) and operating volume (gpm). the winch drum.
5. Do not jerk the winch. Always smoothly 22. Do not use the wire rope as a ground for welding.
accelerate and decelerate load.
23. Rig the winch carefully. Ensure that the wire
6. Do not operate a damaged, noisy or rope is properly anchored to the correct cable anchor
malfunctioning winch. slot at the cable drum.
7. Do not leave a load suspended for any 24. Do not lift a load with a twisted, kinked or
extended period of time. damaged wire rope.
8. Never leave a suspended load unattended. 25. Consult wire rope manufacturer for size, type
and maintenance of wire rope.elen
9. Winch should be maintained and operated
by qualified personnel. 26. Maintain five wraps of wire rope on the cable
drum at all times.
10. Inspect winch, rigging, mounting bolts and
hoses before each shift. 27. In case of a power failure or breakdown leading
to an unexpected stop of the hydraulic power circuit,
11. Warm-up equipment before operating winch,
stand clear of the area and the load being hoisted, take
particularly at low ambient temperatures.
the necessary precautions to prevent access to area
12. Verify winch function by raising and lowering where the load is halted.
a full test load to a safe height before each shift.
28. The noise level of the winch is 86 dBA measured
13. Do not weld any part of the winch. on a distance of 1.00 meter, 1.60 meters high. The
14. Verify gear lubrication and brake circulation measuring equipment used was: Realistic #42-3019.
supply and return before operating winch. 29. Clean up any oil spillage immediately.
15. Be sure of equipment stability before 30. Wear proper clothing and personal protection
operating winch. equipment such as, footwear, safety goggles and a
16. Wear proper clothing to avoid entanglement hard hat. Read manual first.
in rotating machinery.
17. Always stand clear of the load.

316 REV.051117 PAGE 1

 DESCRIPTION OF THE MODEL M5
GENERAL DESCRIPTION:
The PULLMASTER Model M5 is a planetary, hydraulic winch having equal speed in both directions. The main
components of this unit are:

✛ hydraulic gear motor

✛ multi-disc brake with static and dynamic function
✛ primary planet reduction
✛ final planet reduction
✛ brake housing
✛ final drive housing
✛ cable drum

FUNCTION IN FORWARD ROTATION (HOISTING):

In forward rotation, the output torque and rpm of the hydraulic motor are transmitted to the sungear of the primary
planet reduction. The output torque and rpm of the primary reduction stage are transmitted to the final reduction
stage by the final sungear shaft, which is splined to the primary planet hub. Final output torque and rpm are then
transmitted to the cable drum, which is splined to the final drive planet hub. In forward rotation, or when a load is
raised, an over-running clutch, which connects the motor drive shaft to the automatic brake assembly, permits free
rotation of the sun gear without effecting the brake. When the winch rotation is stopped, the load on the cable drum
causes the over-running clutch to lock and the maximum load is held safely by the disc brake.

FUNCTION IN REVERSE ROTATION (LOWERING):

In reverse rotation, hydraulic pressure from the reversing side of the hydraulic motor is channelled to the brake
piston, causing the brake piston to release the multi disc brake against a number of brake springs. The over-running
clutch, connecting the motor drive shaft to the brake assembly, locks, causing the brake discs to rotate between
divider plates. Thus, a completely smooth lowering speed can be achieved in a stepless operation by modulation
of the winch control valve handle. When the control handle is returned to neutral position, rotation stops and the
disc brake applies automatically.

During the lowering operation of the winch, the friction created by the brake discs results in temperature. This
temperature is dissipated by an internal circulation flow, supplied out of the hydraulic motor. This circulation flow
of approximately 1 (US) gpm - 4 l/min, must be returned directly to the reservoir with a permissible back pressure
of 30 psi (2 bar).

IMPORTANT: Under no circumstances must the back pressure in the brake housing be permitted to exceed 30
psi (2 bar). Excessive pressure in the brake housing will damage the oil seal separating the brake
housing from the drum interior. Damage to this seal will cause the drum to fill up with hydraulic
fluid. In order to forewarn potential damage to the drum seals and the end cover of the winch, when
the cable drum fills up with hydraulic fluid, a breather relief (see PARTS REFERENCE, item 130)
is installed on the end cover. The breather relief bleeds to atmosphere and serves as a warning
signal that the oil seal between the brake housing and drum has been damaged.

PAGE 2 316 REV.980601

 EXPLANATION OF MODEL CODING

M 5 X - XX - XX - XX X - B XXXX
BASIC UNIT SERIES
M = Equal speed in both directions
SIZE OF UNIT
REDUCTION RATIO
Only used for non standard reduction ratios
TYPE OF BRAKE
-3 Automatic brake, clockwise drum rotation, internal circulation flow
h
-6 Automatic brake, counterclockwise drum rotation,
internal circulation flow
HYDRAULIC MOTOR
- 10 Hydraulic gear motor, 1.20 cubic inch displacement
(Other motors are optional)
DRUM SIZE
-1 7 inch drum diameter X 11 1/2 inch flange diameter X 8 inch length - STANDARD
(For other drum sizes refer to Appendix A)
OPTIONS
DESIGN REVISION *
SPECIFICATION NUMBER
Describes features not identified by preceding codes

NOTE: Clockwise and counterclockwise drum rotation is the direction of rotation for pulling or hoisting,
established by looking at the hydraulic motor.

* ModelM5 Design Revision 'B'

Instruction and Parts Manual # PMC 316 PUB.960901
Effective from Serial # 46161

316 PAGE 3
 OPTIONS
COUNTERCLOCKWISE ROTATION:
The drum rotation of the standard PULLMASTER Model M5 planetary winch is clockwise for hoisting when looking
at the hydraulic motor of the winch. Drum rotation for counter clockwise hoisting direction is available as an option.

CABLE DRUM SIZES:

Aside from the standard drum sizes listed in APPENDIX A, the PULLMASTER Model M5 planetary winch can be
supplied with optional drums to accommodate large wire rope storage capacity.

OPTIONAL GEAR SECTION FOR THE HYDRAULIC MOTOR:

The performance of the standard PULLMASTER Model M5 planetary winch can be changed by using a different
displacement motor. (Contact the factory for performance information.)

The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements.

PAGE 4 316
 SPECIFICATIONS
Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 1/2 inch diameter
wire rope. For other cable drums and gear ratios, refer to APPENDIX A. Performance specifications for winches
supplied with optional motors are provided in attached supplement.

CABLE DRUM DIMENSIONS (STANDARD DRUM):

Barrel diameter 7.00 in 178 mm
Flange diameter 11.50 in 292 mm
Barrel length 8.00 in 203 mm

CABLE STORAGE CAPACITY:

(Size of wire rope) 1/8 in 2115 ft 645 m
3/16 in 959 ft 292 m
1/4 in 532 ft 162 m
5/16 in 359 ft 109 m
3/8 in 227 ft 69 m
7/16 in 166 ft 51 m
1/2 in 152 ft 46 m

MAXIMUM OPERATING PRESSURE: 2000 psi 138 bar

MAXIMUM OPERATING VOLUME: 14.5 (US) gpm 55 l/min

MINIMUM OPERATING VOLUME: 4 (US) gpm 15 l/min

DRUM TORQUE AT MAXIMUM PRESSURE: 22,500 lb-in 2,542 Nm

DRUM RPM AT MAXIMUM VOLUME: 35 rpm

HOISTING LINE PULL AT MAXIMUM PRESSURE:

Bare drum 6,000 lb 26.7 kN
Full drum 4,091 lb 18.2 kN
HOISTING LINE SPEED AT MAXIMUM VOLUME:
Bare drum 69 ft/min 21 m/min
Full drum 101 ft/min 31 m/min

PERMISSIBLE SYSTEM BACK PRESSURE AT

MOTOR RETURN PORT: 65 psi 4.5 bar

PERMISSIBLE PRESSURE AT
CIRCULATION RETURN PORT: 30 psi 2 bar

LUBRICATING OIL: Refer to RECOMMENDATIONS for viscosity and instructions.

Refer to APPENDIX A for oil volume required.

316 REV.010406 PAGE 5

 PERFORMANCE GRAPHS
PG-M5-A
LINE PULL VS. OIL PRESSURE:

LINE PULL - kN
0 4.5 8.9 13.3 17.8 22.3 26.7
2000 138

OIL PRESSURE - bar

OIL PRESSURE - psi

1600 110

UM UM
DR
DR RE
LL BA
1200 FU 83

800 55

400 28

0 0
0 1000 2000 3000 4000 5000 6000
LINE PULL - lb

LINE SPEED VS. OIL VOLUME:

LINE SPEED - m/min

0 6.1 12.2 18.3 24.4 30.5
15 57
OIL VOLUME - (US)gpm

OIL VOLUME - l/min

12 UM 45
DR
RE M
BA RU
L LD
FU
9 34

6 23

3 11

0 0
0 20 40 60 80 100
LINE SPEED - fpm

Performance graphs are based on standard hydraulic motor and cable drum with 1/2 inch diameter
wire rope.

PAGE 6 316 REV.980601

 TYPICAL HYDRAULIC CIRCUITS
HC-M5-A
CIRCULATION RETURN LINE
DIRECT TO RESERVOIR

CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER

PRESSURE
RELIEF VALVE

FILTER

HYDRAULIC
PUMP

RESERVOIR

316REV.030430 PAGE 7
 RECOMMENDATIONS
HYDRAULIC FLUID: HYDRAULIC PRESSURE RELIEF:
The hydraulic fluid selected for use with PULLMASTER The hydraulic circuit for the PULLMASTER planetary
planetary winches should be a high grade, petroleum winch requires a pressure relief set at the operating
based fluid, with rust, oxidation and wear resistance. pressure (see SPECIFICATIONS). Usually, a pressure
Fluid cleanliness and operating viscosity are critical to relief is part of the hydraulic control valve. Where this is
winch reliability, efficiency and service life. not the case, a separate pressure relief valve must be
installed and set at the recommended maximum pressure.
For optimum performance, the recommended viscosity
range at operating temperature is 81 - 167 SUS (16 - 36 HYDRAULIC RESERVOIR:
CS). For extreme operating conditions of short duration, It is recommended that the hydraulic reservoir has
the maximum viscosity range of 58 - 4635 SUS (10 - sufficient capacity to provide good heat dissipation in
1000 CS) should not be exceeded. order to prevent over-heating of the hydraulic fluid. The
hydraulic reservoir should be made from clean and
For optimum performance, the winch recommended scale-free material to prevent contamination of the
hydraulic fluid temperature operating range is 80 - 150F hydraulic fluid. In order to prevent air from being mixed
(27 - 66 C). For extreme operating conditions of short with the hydraulic fluid, the reservoir should have an
duration, the maximum temperature range of -5 - 180F over-flow baffle separating the return lines from the
(-21 - 82 C) should not be exceeded. suction line and all return lines should enter the reservoir
below the fluid level. The reservoir should be mounted
LUBRICATION: close to and above the hydraulic pump in a location
The winch gear train requires oil bath lubrication. The which provides for free air circulation around the reservoir.
winch is shipped from the factory without lubricating oil.
HYDRAULIC HOSES:
IMPORTANT: ADD LUBRICATING OIL UP TO The following hydraulic hoses are recommended for
THE LEVEL OF THE OIL FILL PORT maximum efficiency of the PULLMASTER Model M5
BEFORE RUNNING WINCH. planetary winch:
Refer to INSTALLATION DIMENSIONS for location of Pressure lines: Equivalent to SAE 100R12-12
lubricating oil fill port. Refer to APPENDIX A for quantity
Circulation return line: Equivalent to SAE 100R4-10
of oil required. For normal operating temperature use
SAE 90 lubricating oil. For temperature beyond normal
It is recommended that a larger size of hydraulic hose is
operating range, consult lubricating oil supplier or factory.
installed where the pressure lines or the circulation lines
are excessively long.
HYDRAULIC PUMP:
For maximum performance of the PULLMASTER
HYDRAULIC FILTER:
planetary winch, the hydraulic pump must supply the
Consult hydraulic component manufacturer for
maximum flow of hydraulic fluid at the hydraulic pressure
recommendation. Generally, 5 to 10 micron filters are
stated in SPECIFICATIONS.
acceptable. In order to prevent accidental stoppage of
the return line flow, the filter should have a by-pass
HYDRAULIC CONTROL VALVE: feature.
The standard control valve used for operating the
PULLMASTER planetary winch must have a four-way,
USE OF AN E STOP:
spring return to neutral feature, which provides for open
(FOR EUROPEAN MACHINERY DIRECTIVE APPLICATIONS)
flow from the pressure ports of the winch to the reservoir
in neutral position of the control (motor spool). It is The use of an E stop (emergency) is mandatory in the
important to point out that good speed control, especially controls circuit. The E stop is to be placed in the
when lowering a load, depends on the "metering" operator's control panel. The E stop must be designed
characteristics of the control valve. The better the oil and placed in line with EN 60204 and EN 418.
flow is "metered" the better will be the speed control.

PAGE 8 316 REV.030430

 INSTALLATION INSTRUCTIONS

DANGER
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.

The initial installation or mounting of a PULLMASTER planetary winch is critically important for proper operation
and performance. If the winch is mounted to an uneven surface, the centre line of the unit can be distorted to a point
where the winch will not operate in either direction. It is therefore very important that the following instructions are
observed when a PULLMASTER planetary winch is installed:

1) Make certain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted.

2) Set the winch on the mounting platform and check for surface contact on all mounting pads of the winch.

3) If there is a space between the mounting surface and one of the mounting pads, the mounting surface is not
even and the space below the mounting pad must be shimmed. If this condition exists, proceed as follows:

a) Install mounting bolts snug tight on the three mounting pads which are in contact with the mounting surface.
(For mounting bolt size and grade see INSTALLATION DIMENSIONS.)

b) Measure the space underneath the fourth mounting pad with a feeler gauge and use shim stock of equivalent
thickness in the space between the mounting pad and the mounting surface.

c) Only after this procedure should the fourth mounting bolt be installed. Tighten all four bolts per BOLT
TORQUE CHART.

4) Fill the winch with lubricating oil. See APPENDIX A for oil volume required.

5) Use recommended circuit components and hydraulic hoses.

6) The circulation return line of the winch should be plumbed in such a manner that the brake housing remains full
of oil at all times. Connect the circulation return line directly to reservoir. Do not connect to a common return line.

7) Before operating the winch with a load, verify adequate circulation flow through the circulation return line as
stated in TYPICAL HYDRAULIC CIRCUIT. Verify that pressure measured at the circulation supply port does
not exceed the permissible pressure stated in SPECIFICATIONS. Winches equipped with the internal
circulation option will supply circulation flow only when the winch is run in the lowering direction.

8) Verify that breather relief, item 130, is in place on end cover above oil level. Rotate end cover if breather relief
is below oil level.

IMPORTANT:
Do not replace breather relief with a pipe plug. The breather relief does not prevent oil
seal failure but serves as an indicator or warning that the oil seals between brake
housing and the cable drum interior have failed and must be replaced immediately. If
these oil seals are changed, additional failure of the drum seal and potential damage
to the end cover is prevented.

316 REV.980601 PAGE 9

 OPERATING INSTRUCTIONS
DANGER
FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.

After the PULLMASTER planetary winch has been installed in accordance with the INSTALLATION INSTRUCTIONS,
the wire rope can be fastened to the cable drum.
IMPORTANT: The ropes, chains, slings, etc. are not part of the winch and are not covered by this manual.
Refer to manufacturer’s handling, inspection and maintenance recommendations to avoid
potential accidents. For selection of ropes, etc. please check following product standards: DIN
15020, prEN818-1/9, prEN 1492-1/2, prEN 1677-1/3 and other relevant product standards.
1) The cable drum of the PULLMASTER planetary winch has two cable anchor slots, one for clockwise and one
for counterclockwise hoisting. Standard rotation for hoisting is clockwise when looking at the hydraulic motor
of the unit. It is critical to select the cable anchor slot which will permit winding of the wire rope on the drum
in the correct direction of rotation. If the wire rope is wound on the cable drum in the wrong direction of rotation,
the winch will have no braking capacity. Each winch is shipped from the factory with a label on the drum
indicating the correct cable anchor slot.
CABLE ANCHOR SI1013 - M5
WIRE ROPE INSTALLATION CABLE ANCHOR SLOT
Clockwise hoisting winch shown.
(Use cable anchor slot on opposite side
of drum for counterclockwise hoisting winch.)
Feed the wire rope through the cable
anchor slot. Loop rope back into slot
as shown. Insert cable anchor into
slot, small end first and long side
nearest the drum flange. Pull rope
tight to wedge rope in slot.
2) On wire rope installation, care must be taken that the wire rope is wrapped completely around the cable anchor
and properly pulled into the cable anchor slot in the cable drum. The cable drum requires 5 wraps of wire rope
for safety.

3) The winch operation is controlled by a single control valve lever which has a forward, a reverse and a neutral
position. Speed control in either direction is obtained by modulation of the control valve lever. Maximum line
speed in either direction is obtained when the control valve lever is moved as far as it can go. The disc brake
of the winch will come on automatically when the winch control lever is returned to neutral.

4) Always warm up equipment prior to operating winch, particularly in low ambient temperature. Circulate hydraulic
oil through the winch control valve for several minutes to warm the hydraulic system. To prime the winch with
warm oil, operate the winch at slow speed, forward and reverse, several times.

5) Prevent corrosion damage to winch interior. If not used regularly, run winch up and down at least once every
two weeks.

6) To ensure proper winch installation and function, raise and lower a full test load to a safe height before using
winch for regular operation at the start of each shift.

If, after a new installation, the winch does not function properly, refer to the TROUBLESHOOTING section of
this manual.

PAGE 10 316 REV.051117

 TROUBLE SHOOTING
GENERAL:
In most cases, when the hydraulic winch does not perform satisfactorily, the cause for malfunction is found
somewhere in the hydraulic circuit. Before the winch is removed from its mounting and disassembled, all of the
hydraulic circuit components should be checked for proper function.
IMPORTANT:
The hydraulic oil volume relates to the line speed or rpm of the winch.
Therefore, if the winch does not produce the specified maximum rated line speed or drum rpm, a loss of hydraulic
flow somewhere in the hydraulic circuit can be analysed. If this condition exists, install a flow meter into the
hydraulic circuit to check the volume of oil supplied to the pressure port of the hydraulic winch motor when the
winch control is completely opened. The flow meter should indicate the maximum operating volume. If this test
indicates a loss of hydraulic flow, check the hydraulic pump, the relief valve and the control valve. If the pump
is driven by V-belts, check for belt slippage.
The hydraulic pressure relates to the pulling capacity of the winch.
If the winch will not produce the specified maximum line pull, install a pressure gauge in the pressure line leading
to the hoisting port on the hydraulic winch motor. Stall the winch to prevent rotation of the drum and then open
the control valve. Check the hydraulic pressure reading of the installed pressure gauge. If the pressure reads
below the specified maximum operating pressure, look for trouble in the hydraulic pump, the relief valve and the
control valve. If the hydraulic pump is driven by V-belts, check for belt slippage. When checking oil pressure and
volume in the hydraulic circuit, make sure that the hydraulic reservoir is filled to the top level and the hydraulic
pump is running at maximum operating rpm.

Only after the hydraulic system has been checked and found to be in order, use the following indications for probable
causes of failure in the winch:
FAILURE PROBABLE CAUSE
Winch will not produce line pull at maximum a) Winch is mounted to an uneven surface.
pressure as listed in SPECIFICATIONS. (See INSTALLATION INSTRUCTIONS.)
b) Cable sheaves or block purchase operated with the
winch are not turning freely.
c) Damage or wear in the hydraulic motor.
d) The relief valve pressure may be set too low.
(See SPECIFICATIONS for maximum operating pressure.)
e) Excessive back pressure in the hydraulic circuit might
cause the automatic brake to release momentarily.

Winch will not produce line speed at maximum a) Winch is mounted to an uneven surface.
volume as listed in SPECIFICATIONS. (See INSTALLATION INSTRUCTIONS.)
b) Cable sheaves or block purchase operated with the
winch are not turning freely.
c) Damage or wear in the hydraulic motor.
d) Excessive back pressure in the hydraulic circuit.

Winch will not reverse. a) Leakage out of the brake piston prevents the disc brake
from being released against the brake springs. This is
caused by damaged O-ring seals on the brake piston or
connecting tube.
b) Insufficient hydraulic pressure. (See SPECIFICATIONS
for minimum operating pressure.)
c) Winch is mounted to an uneven surface.
(See INSTALLATION INSTRUCTIONS.)
d) Hydraulic pressure is not reaching the brake piston due
to plugged connecting tube.

316 PAGE 11
 TROUBLE SHOOTING

FAILURE PROBABLE CAUSE

Brake will not hold. a) Brake plates or divider plates have been damaged by
contamination in the hydraulic fluid or lack of circulation
flow in the brake housing.
b) Brake piston is seized in the brake housing because
of contamination in the hydraulic fluid.
c) Excessive back pressure in the return line of the
hydraulic circuit causes the brake to release.
d) Control valve has incorrect spool which traps hydraulic
pressure in the brake piston when the control valve
handle is returned to neutral position. For proper
function of the automatic brake, both pressure ports of
the winch must be open to the reservoir in neutral
position of the control valve.
e) Wire rope is fastened to the incorrect cable anchor slot.
f) Sprag clutch is damaged or surfaces where sprag
clutch engages on primary sungear or brake hub are
worn or indented.

Brake vibrates when lowering a load. a) Pump is too slow. Pump rpm must be maintained at
normal operating speed when a load is lowered.
b) Brake is running too hot. This is caused by insufficient
circulation flow. To check the circulation, observe the
flow of oil from the circulation return line of the winch
(approx. 1 (US) gpm - 4 l/min) when the winch is
reversed.
c) Control valve for the winch operation has poor metering
characteristics.
d) Damaged brake plates or divider plates.
e) Over-running clutch, which connects the primary
sungear with the brake assembly, is damaged.
f) Air has mixed with hydraulic oil resulting in foamy oil.

Oil leaks. a) Oil leaks from the motor flange are caused by a
damaged O-ring seal on the motor flange.
b) Oil leaks occurring between the cable drum flanges
and housing are caused by excessive pressure in the
brake housing. Excessive pressure in the brake housing
will damage the oil seal between the brake housing
and cable drum interior.
c) If the breather relief on the end cover leaks, the seal
between the drum interior and the brake housing is
damaged and must be replaced. This condition is
caused by excessive pressure in the brake housing of
the winch, or operation with the incorrect hydraulic
fluid during cold weather, or a restriction in the circulation
return line leading back to tank.

Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model M5 winch.

PAGE 12 316 REV.980601

 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.

316 REV.980601 PAGE 13

 SERVICE INSTRUCTIONS CONTINUED
7) Pull primary sungear, item 440, with brake hub assembly, item 720, and clutch aligners, items 722 and 724,
from brake housing.
8) Disassemble brake hub assembly by removing circlip, item 727, from primary sungear, item 440. Remove
primary sungear from brake hub, item 720. Remove sprag clutch aligners, items 722 and 724, and sprag clutch,
item 723, from brake hub.

DANGER
MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE
BRAKE 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 BRAKE SHAFT,
SPRAG CLUTCH AND BRAKE HUB AS A SET.

9) Thoroughly inspect primary sungear, item 440, and brake hub, item 720, particularly surfaces where sprag
clutch, item 723, engages.
10) If any indentation or surface damage is detected, replace brake hub, sprag clutch and primary sungear as a
set.

DANGER
DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING
CAPACITY AND ALLOW THE LOAD TO DROP CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. DO NOT USE SOLVENT TO
CLEAN THE FRICTION PLATES. PERFORM THOROUGH
INSPECTION AND, IF NECESSARY, REPLACE FRICTION
AND DIVIDER PLATES AS A SET.

11) Remove four friction plates, item 715, and five divider plates, item 713, and inspect for damage or wear. Plates
should be flat and smooth. Plates should not show heat discoloration. Paper material on friction plates should
be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
12) Remove thrust bearing, item 739, and thrust washers, item 737. Inspect bearing and washers and replace if
damaged or worn.
13) Remove two flat head capscrews, item 693, and brake housing, item 700. Remove brake spacer, item 712, and
discard O-ring, item 695.

PAGE 14 316 REV.980601

 SERVICE INSTRUCTIONS CONTINUED
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.

316 PAGE 15
 SERVICE INSTRUCTIONS CONTINUED

REASSEMBLY
Thoroughly clean all parts. Use only new, well-greased O-rings and oil seals. Unless otherwise specified, torque
fasteners per BOLT TORQUE CHART as back of manual.

REASSEMBLY OF FINAL DRIVE:

Reassemble final drive end of winch as follows:
1) Press new, well-greased oil seal, item 105, into final housing, item 100.
2) Press ball bearing, item 103, into final housing and secure with circlip, item 104.
3) Press cable drum, item 500, into ball bearing, item 103, and secure with circlip, item 513.
4) Reassemble final planet hub assembly. Press needle bearing, item 323, into final planet gear, item 320. Position
thrust washers, item 321, on either side of planet gear and press planet pin, item 310, into final planet hub, item
300. Retain with circlip, item 313.
5) Insert final planet hub assembly into final housing, item 100. Ensure that planet hub spline is fully engaged with
cable drum, item 500.
6) 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.
7) Gently insert end cover into final housing, item 100, and fasten with retaining ring, item 124.
8) Turn winch up on end with cable drum opening upwards.

REASSEMBLY OF PRIMARY DRIVE:

Reassemble primary drive as follows:
1) Reassemble primary planet hub assembly. Press sungear stopper, item 344, into end of final sungear, item
340. Insert final sungear into planet hub, item 400, and fasten with circlip, item 343. Press needle bearing, item
423, into primary planet gear, item 420. Position thrust washers, item 421, on either side of planet gear and
press planet pin, item 410, into primary planet hub, item 400. Retain with circlip, item 411.
2) Insert final sungear and primary planet hub assembly into cable drum. Rotate drum by hand until sungear
engages final planet gears and primary planet gears engage cable drum.
3) Press new, well-greased oil seal, item 531, into bearing flange, item 530, followed by journal bearing, item 706.
Install circlip, item 517, and new, well-greased O-ring, item 539, into bearing flange.
4) Fasten bearing flange, item 530, to cable drum, item 500, using six socket head capscrews, item 537.
5) Install new, well-greased O-ring, item 545, and Parker seal, item 543, into seal carrier, item 538. Install seal
carrier into opening of end housing, item 698, and press ball bearing, item 103, tight against seal carrier. Press
end housing, with seals and ball bearing, onto bearing flange. Fasten with circlip, item 535.

PAGE 16 316
 SERVICE INSTRUCTIONS CONTINUED

REASSEMBLY OF BRAKE HOUSING ASSEMBLY:

Reassemble brake housing assembly by reversing the disassembly procedure:
1) Place brake spacer, item 712, in end housing with flat side facing up.
2) Install new, well-greased O-ring, item 695, onto mounting flange of brake housing, item 700. Fasten brake
housing to end housing using two flat head capscrews, item 693.
3) Install thrust bearing, item 739, with thrust washer, item 737, on either side, into bearing flange, item 530.
4) Install sprag clutch, item 723, into bore of brake hub, item 720. Position sprag clutch aligners, item 722 and
724, on either side of brake hub. Carefully slide primary sungear, item 440, into brake hub assembly and secure
with circlip, item 727.
IMPORTANT: For proper brake function, verify that brake hub rotation is correct. When viewed
from motor end, primary sungear of a clockwise hoisting winch must turn freely
clockwise and lock in the counterclockwise direction.
5) Install primary sungear assembly, carefully twisting shoulder of sungear through oil seal, item 531. Ensure oil
seal is not damaged as sungear is installed.

DANGER
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.

6) Starting and finishing with divider plate, alternately install five divider plates, item 713, and four friction plates,
item 715.
7) Install new, well-greased O-ring, item 751, into brake housing and new, well-greased O-ring, item 753, into
piston gland. Carefully install brake piston in brake housing. Rotate piston to align connecting tube hole with
corresponding hole in motor.
8) Install six brake springs, item 752.
9) Install new, well-greased O-ring item 539, onto motor adaptor flange, item 800.
10) Position motor adaptor with hydraulic motor mounting holes horizontal and connecting tube holes of piston and
motor adaptor aligned. Tighten eight capscrews, item 931, and lockwashers, item 933, one turn at a time to
evenly compress springs.

316 REV.980601 PAGE 17

 SERVICE INSTRUCTIONS CONTINUED

REPLACEMENT OF HYDRAULIC MOTOR ASSEMBLY:

Replace the hydraulic motor assembly by reversing the removal procedure.
IMPORTANT: Before installing motor, determine brake code of winch. Install motor plug as indicated below.
SI-1029
MOTOR PLUG
WITH 0-RING

888 831

NOTE:
INSERT MOTOR PLUG, O-RING END
FIRST, INTO PORT A OR B AS
INDICATED IN CHART BELOW.

BRAKE RELEASE BRAKE RELEASE

PORT ’A’
PORT ’B’

950
BRAKE CODE PLUG PORT
-3 B SHAFT SIDE OF MOTOR
-6 A (MAY NOT BE EXACTLY AS ILLUSTRATED)

1) Install three new, well-greased O-rings, item 831; two onto connecting tube, item 830, and one onto motor plug,
item 888. Install connecting tube and motor plug into motor, item 950. Verify that holes are same as parts were
removed from.
2) Install new, well-greased O-ring, item 811, onto motor pilot, item 950.
3) Fasten motor to motor adaptor using two capscrews, item 935, and lockwashers, item 937.

IMPORTANT: Before operating the winch, add lubricating oil up to the level of the end housing oil fill port.
(Refer to INSTALLATION INSTRUCTIONS for location of fill port. Refer to APPENDIX A for
oil volume required.)
To ensure proper reassembly, run the winch in both directions without load.

DANGER
LIFTING A LOAD WITH A NEWLY SERVICED WINCH WILL ENABLE
AN INSTALLATION OR SERVICE PROBLEM TO GO UNDETECTED AND
ALLOW THE LOAD TO DROP, CAUSING PROPERTY DAMAGE, SEVERE
INJURY OR DEATH. TO ENSURE PROPER REINSTALLATION, REFER
TO PROCEDURES AND TESTS DESCRIBED IN "INSTALLATION" AND
"OPERATING INSTRUCTIONS".

PAGE 18 316 REV.980601

 RECOMMENDED MAINTENANCE
Winch gear train lubricating oil should be changed after the initial six months or 50 hours of operation, whichever
comes first. Lubricating oil should then be changed every 12 months or 500 operating hours, whichever comes first.

Hydraulic system fluid should be changed at least once every 12 months.

For optimum performance over an extended period of time, the following preventive maintenance service should
be done every 12 months or 500 operating hours, whichever comes first:

1) Disconnect all hydraulic hoses and remove the winch from its mounting.

2) Disassemble the winch as per instructions.

3) Discard and replace all O-rings and oil seals.

4) Clean all parts and inspect for wear and damage as per instructions. Replace worn or damaged
parts as required.

5) Reassemble the winch as per instructions.

6) Follow INSTALLATION and OPERATING INSTRUCTIONS when returning winch to its mounting.

When ordering parts for the PULLMASTER Model M5 planetary winch, always quote the complete model and serial
numbers of the unit.

MODEL # __________________

SERIAL # __________________

PULLMASTER WINCH CORPORATION reserves the right to change specifications and the design of PULLMASTER
planetary winches at any time without prior notice and without incurring any obligations.

316REV.030430 PAGE 19
 Design Revision 'B' - Effective from Serial # 46161

PAGE 20
323 123 320 313 104 103 105 500 502 503 343 411 421 410 423 420 537 698 545 538 535 713 720 723 722 831

321

130 830

310 955

311 913

126 727

122 935

340 911

120 937

513 933

300 831

121 873

124 888

100 931

344 950
ASSEMBLY DRAWING

440 550 400 706 531 737 517 739 543 719 530 539 103 712 715 695 700 693 539 751 703 750 800 753 752 811
G1144-A

316
 PARTS REFERENCE
ITEM NO. QTY. PART NO. DESCRIPTION

100 1 20072 FINAL HOUSING

103 2 25007 BALL BEARING 070 X 110 X 20 #6014
104 1 25006 CIRCLIP ROTOR CLIP HO-433
105 1 25008 OIL SEAL 3.000 X 4.003 X .375
120 1 20071 END COVER
121 1 25032 PIPE PLUG 1/2 NPT SOC HD
122 1 20063 SUNGEAR STOPPER
123 1 25069 O-RING -274 10" ID 1/8" CS
124 1 20898 RETAINING RING
126 1 20092 PLANET HUB STOPPER *These parts vary according to drum code.
130 1 20458 BREATHER RELIEF Refer to APPENDIX B.
300 1 20073 PLANET HUB
310 3 20079 PLANET PIN
311 3 25091 CIRCLIP ROTOR CLIP SH-87
313 3 25004 CIRCLIP ROTOR CLIP C-87
320 3 20076 PLANET GEAR
321 6 25068 THRUST WASHER TORRINGTON #TRA 1423
323 3 25005 NEEDLE BEARING TORRINGTON #B1416
340 1 * FINAL SUNGEAR
343 2 25239 CIRCLIP ANDERTON #A1000 - 0150
344 1 20082 SUNGEAR STOPPER
400 1 20069 PLANET HUB
410 3 20080 PLANET PIN
411 6 25119 CIRCLIP ROTOR CLIP SH-62
420 3 20075 PLANET GEAR
421 6 25064 THRUST WASHER TORRINGTON #TRA 1018
423 3 25063 NEEDLE BEARING TORRINGTON #B1012
440 1 22882 PRIMARY SUNGEAR
500 1 * CABLE DRUM
502 1 20085 CABLE ANCHOR
503 1 25085 PIPE PLUG 3/8 NPT SOC HD
513 1 25055 CIRCLIP ROTOR CLIP SH-262
517 1 26280 CIRCLIP ROTOR CLIP HO-187
530 1 * BEARING FLANGE
531 1 25062 OIL SEAL
535 1 25012 CIRCLIP ROTOR CLIP SH-275
537 6 25001 CAPSCREW - SOC HD 5/16 - 18NC X .62 GRADE 5
538 1 20377 SEAL CARRIER
539 2 25061 O-RING -163 6" ID 3/32" CS
543 1 25281 SEAL - PARKER 3" ID #1870 - 3000
545 1 25280 O-RING -90 DURO -154 3-3/4" ID 3/32" CS
550 1 * BASE
693 2 25271 CAPSCREW - FLAT HD 5/16 - 18NC X .75
695 1 25026 O-RING -248 4-3/4" ID 1/8" CS
698 1 20379 END HOUSING
700 1 20334 BRAKE HOUSING
703 1 25388 PLASTIC CAPLUG 1/2 NPT
706 1 20086 JOURNAL BEARING
712 1 20024 BRAKE SPACER
713 5 25024 DIVIDER PLATE
715 4 20034 FRICTION PLATE
719 1 25539 CIRCLIP ROTOR CLIP SE-118
720 1 22881 BRAKE HUB

316 REV.980601 PAGE 21

 PARTS REFERENCE - CONTINUED

ITEM NO. QTY. PART NO. DESCRIPTION

722 2 20183 SPRAG CLUTCH ALIGNER

723 1 25187 SPRAG CLUTCH
727 1 25492 CIRCLIP ROTOR CLIP SH-106
737 2 25483 THRUST WASHER INA # AS 3047
739 1 25537 THRUST BEARING INA # AXK 3047
750 1 21597 PISTON SUBASSEMBLY
751 1 25258 O-RING -90 DURO -247 4-5/8" ID 1/8" CS
752 6 20340 BRAKE SPRING
753 1 25261 O-RING -90 DURO -246 4-1/2" ID 1/8" CS
800 1 21401 MOTOR ADAPTOR
811 1 25016 O-RING -042 3-1/4" ID 1/16" CS
830 1 20337 CONNECTING TUBE
831 3 25018 O-RING -90 DURO -010 1/4" ID 1/16" CS
873 1 25031 PIPE PLUG 1/4 NPT SOC HD
888 1 22962 MOTOR PLUG
911 12 25013 CAPSCREW - HEX HD 1/2 - 13NC X 1.25 GRADE 5
913 12 25014 LOCKWASHER 1/2"
931 8 25027 CAPSCREW - HEX HD 5/16 - 18NC X 1.25 GRADE 5
933 8 25025 LOCKWASHER 5/16"
935 2 25264 CAPSCREW - HEX HEAD 3/8 - 16NC X 1.00 GRADE 5
937 2 25037 LOCKWASHER 3/8"
950 1 20741 MOTOR -010 REXROTH MC15-10
955 2 25536 PLASTIC CAPLUG SAE #12 ORB

23099 WINCH SEAL KIT, CONSISTS OF ITEMS:

105, 123, 531, 539, 543, 545, 695, 751, 753,
811 AND 831.

* These parts vary according to drum code. Refer to APPENDIX B.

Refer to PAGE 20 for ASSEMBLY DRAWING.

PAGE 22 316 REV.980601

 FILLER HOLE-

316
3/8-18NPT PRESSURIZE FOR
CLOCKWISE
ROTATION PRESSURIZE FOR
COUNTER-CLOCKWISE
9.5 ROTATION
BREATHER RELIEF C
VALVE [242] CLOCKWISE
FILLER PORT CIRCULATION
1/2-14 NPT RETURN PORT
1/2-14 NPT

12.6
[321] 7.0
[178] 6.88
[175]
8.5
[215]
3.5
[89]

4 MOUNTING HOLES
.56 21/32 DIA [16.6]
USE 5/8 MOUNTING BOLTS
[14] 8.000
GRADE 8
[203.2]
H
MOTOR PORTS 12.9
DRAIN PORT 1-1/16-12 UN
1/2-14 NPT [327]
SAE O RING BOSS

J
FOR SAFETY:
STANDARD CABLE ANCHOR IS A MINIMUM OF 5 WRAPS OF
SUITABLE FOR 1/4 - 1/2" WIRE ROPE MUST BE MAINTAINED
DIA WIRE ROPE AT ALL TIMES !

DRUM CODE B C E H J UNITS

INSTALLATION DIMENSIONS

-1 11.5 8.0 12.6 13.500 24.3 in

292 203 321 342.90 617 mm
-2 13.5 8.0 13.6 13.500 24.3 in
343 203 346 342.90 617 mm
-4 13.5 12.0 13.6 17.500 28.3 in
343 305 346 444.50 719 mm

PAGE 23
I1041-B
 APPENDIX A

LINE PULL LINE SPEED

LUBRICATING
AT MAXIMUM AT MAXIMUM OIL
CABLE DRUM SIZES WIRE ROPE STORAGE
PRESSURE* VOLUME* VOLUME
DRUM INCHES FEET REQUIRED

CODE (MILLIMETERS) (METERS)

U.S.
POUNDS FEET/MINUTE GALLONS
(KILONEWTONS) (METERS/MINUTE) (LITERS)
BARE FULL BARE FULL
BARREL FLANGE LENGTH 1/2 inch 7/16 inch 3/8 inch DRUM DRUM DRUM DRUM

STANDARD REDUCTION RATIO

-1 7.0 11.5 8.0 152 166 227 6000 4091 69 101 0.8
(178) (292) (203) (46) (51) (69) (26.7) (18.2) (21) (31) (3.0)

-2 7.0 13.5 8.0 231 297 375 6000 3462 69 119 0.8
(178) (343) (203) (71) (90) (114) (26.7) (15.4) (21) (36) (3.0)

-4 7.0 13.5 12.0 347 445 562 6000 3462 69 119 1.0
(178) (343) (305) (106) (136) (171) (26.7) (15.4) (21) (36) (3.8)

* Performance specifications are based on standard hydraulic motor with 1/2 inch diameter wire rope.

PAGE 24 316 REV.000315

 APPENDIX B

ITEM NUMBERS
340 500 530 550

PART DESCRIPTION
FINAL SUNGEAR CABLE DRUM BEARING
BASE
FLANGE

DRUM STANDARD REDUCTION RATIO

CODE PART NUMBERS

-1 20078 20067 20068 20074

-2 20078 20297 20068 20074

-4 21008 21019 21018 20325

316 PAGE 25
 BOLT TORQUE CHART

BOLT DIAMETER TORQUE TORQUE

Inches lb-ft Nm

1/4 9 12
5/16 18 24
3/8 32 43
7/16 50 68
1/2 75 102
9/16 110 149
5/8 150 203
3/4 265 359
7/8 420 569
1 640 868
1 1/8 800 1085
1 1/4 1000 1356
1 3/8 1200 1627
1 1/2 1500 2034

NOTE: Unless otherwise specified, torque bolts per above chart.

PAGE 26 316