Pullmaster M5 Technical reference manual

120612PMC 316
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.
INSTRUCTION AND PARTS MANUAL
MODEL M5
Design Revision 'B'
PLANETARY HYDRAULIC WINCH
THE LOGICAL CHOICE

PAGE 2
DESCRIPTION OF THE MODEL M5
316 REV.980601
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 3
EXPLANATION OF MODEL CODING
316 REV.081208
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
-230 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.
* Model M5 Design Revision 'B'
Instruction and Parts Manual # PMC 316 PUB.960901
Effective from Serial # 46161

PAGE 4 316 REV.980601
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 5
SPECIFICATIONS
316 REV.010406
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.

PAGE 6
PERFORMANCE GRAPHS
PG-M5-A
LINE PULL VS. OIL PRESSURE:
LINE SPEED VS. OIL VOLUME:
Performance graphs are based on standard hydraulic motor and cable drum with 1/2 inch diameter
wire rope.
316 REV.980601
100
30.5
80
24.4
60
18.3
40
12.2
20
6.1
BARE DRUM
FULL DRUM
LINE PULL - kN
LINE SPEED - m/min
FULL DRUM
BARE DRUM
1600
2000
1200
800
400
0
15
12
9
6
3
0
6000500040003000200010000
0 4.5 8.9 13.3 17.8 22.3 26.7
138
110
83
55
28
0
LINE PULL - lb
OIL PRESSURE - psi
OIL PRESSURE - bar
0
0
0
LINE SPEED - fpm
11
23
34
45
57
OIL VOLUME - (US)gpm
OIL VOLUME - l/min

PAGE 7
TYPICAL HYDRAULIC CIRCUITS
HC-M5-A
316 REV.030430
FILTER
HYDRAULIC
PUMP
RESERVOIR
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
PRESSURE
RELIEF VALVE
CIRCULATION RETURN LINE
DIRECT TO RESERVOIR

PAGE 8
RECOMMENDATIONS
316 REV.030430
HYDRAULIC FLUID:
The hydraulic fluid selected for use with PULLMASTER
planetary winches should be a high grade, petroleum
based fluid, with rust, oxidation and wear resistance.
Fluid cleanliness and operating viscosity are critical to
winch reliability, efficiency and service life.
For optimum performance, the recommended viscosity
range at operating temperature is 81 - 167 SUS (16 - 36
CS). For extreme operating conditions of short duration,
the maximum viscosity range of 58 - 4635 SUS (10 -
1000 CS) should not be exceeded.
For optimum performance, the winch recommended
hydraulic fluid temperature operating range is 80 - 150F
(27 - 66 C). For extreme operating conditions of short
duration, the maximum temperature range of -5 - 180F
(-21 - 82 C) should not be exceeded.
LUBRICATION:
The winch gear train requires oil bath lubrication. The
winch is shipped from the factory without lubricating oil.
IMPORTANT: ADD LUBRICATING OIL UP TO
THE LEVEL OF THE OIL FILL PORT
BEFORE RUNNING WINCH.
Refer to INSTALLATION DIMENSIONS for location of
lubricating oil fill port. Refer to APPENDIX A for quantity
of oil required. For normal operating temperature use
SAE 90 lubricating oil. For temperature beyond normal
operating range, consult lubricating oil supplier or factory.
HYDRAULIC PUMP:
For maximum performance of the PULLMASTER
planetary winch, the hydraulic pump must supply the
maximum flow of hydraulic fluid at the hydraulic pressure
stated in SPECIFICATIONS.
HYDRAULIC CONTROL VALVE:
The standard control valve used for operating the
PULLMASTER planetary winch must have a four-way,
spring return to neutral feature, which provides for open
flow from the pressure ports of the winch to the reservoir
in neutral position of the control (motor spool). It is
important to point out that good speed control, especially
when lowering a load, depends on the "metering"
characteristics of the control valve. The better the oil
flow is "metered" the better will be the speed control.
HYDRAULIC PRESSURE RELIEF:
The hydraulic circuit for the PULLMASTER planetary
winch requires a pressure relief set at the operating
pressure (see SPECIFICATIONS). Usually, a pressure
relief is part of the hydraulic control valve. Where this is
not the case, a separate pressure relief valve must be
installedandsetat therecommended maximumpressure.
HYDRAULIC RESERVOIR:
It is recommended that the hydraulic reservoir has
sufficient capacity to provide good heat dissipation in
order to prevent over-heating of the hydraulic fluid. The
hydraulic reservoir should be made from clean and
scale-free material to prevent contamination of the
hydraulic fluid. In order to prevent air from being mixed
with the hydraulic fluid, the reservoir should have an
over-flow baffle separating the return lines from the
suction line and all return lines should enter the reservoir
below the fluid level. The reservoir should be mounted
close to and above the hydraulic pump in a location
whichprovides for freeair circulation aroundthe reservoir.
HYDRAULIC HOSES:
The following hydraulic hoses are recommended for
maximum efficiency of the PULLMASTER Model M5
planetary winch:
Pressure lines: Equivalentto SAE100R12-12
Circulation return line: Equivalent to SAE 100R4-10
It is recommended that a larger size of hydraulic hose is
installed where the pressure lines or the circulation lines
are excessively long.
HYDRAULIC FILTER:
Consult hydraulic component manufacturer for
recommendation. Generally, 5 to 10 micron filters are
acceptable. In order to prevent accidental stoppage of
the return line flow, the filter should have a by-pass
feature.
USE OF AN E STOP:
(FOR EUROPEAN MACHINERY DIRECTIVE APPLICATIONS)
The use of an E stop (emergency) is mandatory in the
controls circuit. The E stop is to be placed in the
operator's control panel. The E stop must be designed
and placed in line with EN 60204 and EN 418.

PAGE 9
INSTALLATION INSTRUCTIONS
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
316 REV.980601
DANGER
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.

PAGE 10
OPERATING INSTRUCTIONS
316 REV.051117
FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
DANGER
SI1013 - M5
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.
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.
WIRE ROPE INSTALLATION
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.
CABLE ANCHOR SLOT
CABLE ANCHOR

PAGE 11
316 REV.980601
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:
a) Winch is mounted to an uneven surface.
(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.
a) Winch is mounted to an uneven surface.
(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.
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.
Winch will not produce line pull at maximum
pressure as listed in SPECIFICATIONS.
Winch will not produce line speed at maximum
volume as listed in SPECIFICATIONS.
Winch will not reverse.
FAILURE PROBABLE CAUSE

PAGE 12
FAILURE PROBABLE CAUSE
TROUBLE SHOOTING
Brake will not hold.
Brake vibrates when lowering a load.
Oil leaks.
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model M5 winch.
316 REV.980601
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.
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.
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.

PAGE 13316 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.

PAGE 14
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.
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.
316 REV.980601
DANGER
DANGER
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.
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.
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 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.

PAGE 16
SERVICE INSTRUCTIONS CONTINUED
316 REV.980601
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 17
SERVICE INSTRUCTIONS CONTINUED
316 REV.980601
DANGER
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.
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.

PAGE 18 316 REV.980601
SERVICE INSTRUCTIONS CONTINUED
SI-1029
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.
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.
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".
DANGER
950
888 831
-6 A
B
-3
PLUG PORT
BRAKE CODE
NOTE:
INSERT MOTOR PLUG, O-RING END
FIRST, INTO PORT A OR B AS
INDICATED IN CHART BELOW.
MOTOR PLUG
WITH 0-RING
(MAY NOT BE EXACTLY AS ILLUSTRATED)
SHAFT SIDE OF MOTOR
BRAKE RELEASE
PORT ’B’
BRAKE RELEASE
PORT ’A’

PAGE 19
RECOMMENDED MAINTENANCE
316REV.030430
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.

PAGE 20 316 REV.080130
ASSEMBLY DRAWING
G1287
Design Revision 'B' - Effective from Serial # 46161
935
937
831
888
911
830
831
913
739737 517 719 750
727
723 722
950
503
130 321 323 310 311 126
123 320 313 104 103 105 500 502
122 340 120 513 300 121 124 100 440 344
400 706 531 543 530 539
343 411 421 410 423 420 537 698 545 538
103 712 695 700 539693 751715 752703 753800
535 713 720
811
955
550
933
931