PAGE 18
SERVICE INSTRUCTIONS
CONTINUED
172 REV.030429
4)
Inspect nylon planet hub stopper item 126, and replace if less than 0.14 inch thick. Remove and discard O-
ring item 123, from outside of freespool housing.
5)
To separate the final sungear item 340, from the freespool piston, remove circlip item 269. Inspect the two
splines on the end of the final sungear for wear and cracks. Replace if necessary.
6)
To separate the ball bearing item 291, from the freespool piston, remove circlip item 267.
MANUAL FREESPOOL (R5-X-70-1M):
1)
Remove hex head capscrew item 297, and lockwasher item 298, to allow removal of freespool handle item 254,
from nut drive item 256.
2)
Remove four hex head capscrews item 253, and lockwashers item 255, from seal carrier item 252. For correct
positioning of the seal carrier upon reassembly, make a chalk mark on the seal carrier and freespool housing item
250. Pull the seal carrier out of the freespool housing, discard O-ring item 257, and oil seal item 299.
3)
Remove index pin item 272, detent spring item 276, and spring seat item 284. Check these parts for wear and
replace if necessary.
4)
Turn the nut drive item 256, to disconnect from the follower item 266. Inspect the three spring pins item 278,
and replace if damaged or worn.
5)
Remove circlip item 288, and pull the final sungear item 340, together with the follower and ball bearing item
291, out of the freespool housing.
6)
Remove circlip item 295, from the inside of the follower and pull the ball bearing, together with the final sungear,
out of the follower.
7)
To remove ball bearing item 291, from the final sungear, remove circlip item 269.
The PULLMASTER Model R5 winch has now been completely disassembled.
REASSEMBLY
Thoroughly clean and lubricate all parts. Use only new, well-greased O-rings and oil seals. Unless otherwise
specified, torque fasteners per BOLT TORQUE chart at back of manual.
REASSEMBLY OF FREESPOOL ASSEMBLY:
MANUAL FREESPOOL (R5-X-70-1M):
1)
Press ball bearing item 291, onto final sungear item 340, and secure with circlip item 269.
2)
Slide freespool follower item 266, over ball bearing item 291, and fasten between two circlips item 295.
3)
Insert follower into bore of freespool housing item 250, and secure with circlip item 288.
4)
Engage nut drive item 256, with freespool follower item 266, by twisting three spring pins item 278, into grooves
of follower.
5)
Place two spring seats item 284, together with detent springs item 276, and indexes item 272, into holes in end
of nut drive item 256.
6)
Press new, well-greased oil seal item 299, into seal carrier item 252.
7)
Install new, well-greased O-ring item 257, onto seal carrier, and fasten onto freespool housing item 250, using
four capscrews item 253, and lockwashers item 255. Check chalk marks for proper positioning before
tightening.
