CraigD. When the tolerances were defined for the Pinto Rig, the plan was to keep the sheave as close to the side plate as possible because we wanted to limit the probability of a throw line getting caught in that space. In reality, I think we were a little too adventurous, and the rubbing that you, and some other people, are seeing is because the tolerance, on occasion, is too tight. This issue only applies to the first two batches made, and has already been addressed on the subsequent production runs.
DMM test for clear rotation at WLL during production, and all has been fine, but there are tolerances, and obviously some Pinto Rigs are not functioning as anticipated. For info, all returned pulleys have been analyzed and tested. All have exceeded the quoted MBS by some considerable margin, and the bearings were intact and fully functional.
I would suggest returning your pulley to the retailer where you purchased it, and they will handle the procedure from there. DMM will analyse the issue with your pulley and then either issue a replacement or rebuild the pulley with the narrower sheave.
The bearings in the Pinto Rig are somewhat over specified, so I doubt that there has been a bearing failure, although it is possible. But of course without seeing your Pinto, I can not make a judgement.
Sincere apologies for the inconvenience you are experiencing. I know that DMM have already acted to sort this tolerance issue.
Chris