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SERVICE INSTRUCTIONS
172 REV.030429
GENERAL:
Before attempting disassembly of the PULLMASTER Model R5 planetary winch with freespool, the following
instructions should be read and understood.
It is suggested that all expendable parts, such as O-rings and oil seals are not reused on reassembly. It is therefore
important to have a winch seal kit (Part No. 25829), and providing the hydraulic motor has to be serviced, a motor
seal kit (Part No. 25688) on hand.
A clean working area is of prime importance, similar to conditions used for service work on any other hydraulic
components.
All parts, as they are removed from the winch assembly, should be inspected for wear and damage. Thoroughly
clean parts before reassembly, however, do not use solvent to clean friction plates.
During reassembly, lubricate all O-rings and oil seals with grease.
In the following service instructions, reference to parts is made by numbers and shown on the applicable group
drawings.
DISASSEMBLY
The majority of service or repair work is accomplished by disassembling the brake housing of the PULLMASTER
Model R5 planetary winch. There are no special tools, adjustments or calibrations necessary to service or repair
the winch.
REMOVE HYDRAULIC MOTOR ASSEMBLY:
1)
Remove two capscrews item 815, and lockwashers item 817. Pull the hydraulic motor item 850, out of the
winch assembly.
2)
Remove and discard O-ring item 811.
3)
Remove connecting tube item 830. Remove and discard two O-rings item 831.
4)
Remove two check valves item 832. Remove and discard two O-rings item 833.
The standard motor of the Model R5 is a
NICHOLS Series 110 IGR hydraulic motor with 12.9 cubic inch
displacement. If a problem is analysed to be in the hydraulic motor, we recommend that a NICHOLS dealer be
contacted for parts and service.
If the hydraulic motor is disassembled, the original flange section of the motor must be re-used in order to provide
the required porting to operate the automatic brake and for the circulation flow.
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:
Disassemble brake housing assembly as follows:
1)
Remove motor adaptor item 800, by removing six capscrews item 821, and lockwashers item 823. Allow brake
springs item 752, to expand safely by unscrewing capscrews one turn at a time.
2)
Remove and discard O-ring item 707.
3)
Remove eight brake springs item 752. Examine brake springs for damage and measure overall length. Overall
spring length should be 1.54 inch. If any spring measures less than 1.48 inch, replace all springs as a set.
4)
Pull the brake piston item 750, out of the brake housing using two 1/2 - 13NC bolts screwed into the two puller
holes in the piston and discard O-rings item 751 and item 753.
