Model H25 Service Manual
Contents
1. 251 REV 110817 PAGE 27 ASSEMBLY DRAWING G1000 amp G1002 amp G1004 PAGE 28 251 REV 980615 APPENDIX A LINE PULL HOISTING MAXIMUM LOWERING AT MAXIMUM LINE SPEED ALLOWABLE LINE SPEED LUBRICATING CABLE DRUM SIZES WIRE ROPE STORAGE PRESSURE ATMAXIMUM LINEPULL ATMAXIMUM e INCHES FEET HOISTING VOLUME LOWERING VOLUME REQUIRED MILLIMETERS METERS POUNDS FEET MINUTE POUNDS FEET MINUTE 0 5 KILONEWTONS METERS MINUTE KILONEWTONS METERS MINUTE TERS BARE FULL BARE FULL BARE FULL BARE FULL BARREL FLANGE ENGTH 3 4 inch DRUM DRUM DRUM DRUM DRUM DRUM DRUM Performance specifications are based on standard hydraulic motor with 7 8 inch diameter rope js sasa a s s s l 8sms a as s a a iai a o lt lt SMaTIC asaa z E 251 REV 991224 PAGE 29 APPENDIX B ITEM 340 530 550 552 FINAL BEARING DRUM CODE SUNGEAR FLANGE BASE PAGE 30 251 REV 950901 APPENDIX C BRAKE CODE fo PART NO DESCRIPTION E n 5 1 8 27 NPT PIPE PLUG 25040 25622 25622 25622 25622 ae ADAPTOR 3 8 18 NPT PART NUMBERS CIRCULATION 1 4 18 NPT 1 8 27 NPT PIPE 1 8 NPT CAPLUG 25374 25374 25374 25374 3 8 18 NPT MOTOR SUB ASSY 20504 22011 22012 20804 20505 21977 22013 20805 251 REV 9806152. vill MASTER THE LOGICAL CHOICE INSTRUCTION AND PARTS MANUAL MODEL H25 PLANETARY HYDRAULIC WINCH amp POWER to Move the World TWG Canada LANTEC and Pullmaster Brands 19350 22nd Ave Surrey BC V3S 356 Voice 1 604 547 2100 Fax 1 604 547 2147 www team twg com A COMPANY 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 251 120612 POVER MONA Effective 2011 10 01 A TOWER compar SUPERSEDES ALL PRIOR WARRANTIES LANTEC Pull MASTER LIMITED WARRANTY 50130 0 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 therewi
3. BOLT TORQUE CHART at back of manual REASSEMBLY OF FINAL DRIVE Reassemble final drive end of winch as follows 1 4 7 Press a new well greased oil seal item 105 into final housing item 100 Press ball bearing item 103 into final housing and secure with retaining ring item 104 Press cable drum item 500 into ball bearing item 103 and secure with circlip item 513 Reassemble final planet hub assembly Use grease to temporarily hold 24 loose rollers item 323 in the bore of the planet gear item 320 Position thrust washers item 321 on either side of planet gear and press planet pin item 310 into the final planet hub item 300 Retain with circlip item 311 Insert final planet hub assembly into final housing item 100 Ensure that final planet hub spline is fully engaged with cable drum item 500 Install a new well greased O ring item 123 into the end cover item 120 Verify that planet hub stopper item 126 and sungear stopper item 122 are installed into end cover Gently insert end cover into final housing item 100 and fasten with retaining ring item 124 REASSEMBLY OF PRIMARY DRIVE Turn winch over resting on end cover with cable drum opening facing up Reassemble primary drive as follows Press a new well greased oil seal item 531 into bearing flange item 530 Press ball bearing item 533 into bearing flange and secure with retaining ring item 534 Press bearing flange as
4. for damage or wear Plates should be flat and smooth Plates should not show heat discoloration Paper material on friction plates PAGE 14 251 REV 021126 SERVICE INSTRUCTIONS should be intact and grooved If any damage is detected replace friction and divider plates as a set 7 Remove brake spacer item 712 8 Remove the drain plug item 121 from the end cover item 120 and drain the lubricating oil from the final drive assembly and the cable drum interior To drain all of the oil out of the cable drum interior the winch should be tipped to an angle and the filler plug item 503 removed DISASSEMBLY OF PRIMARY DRIVE For ease of working on the rest of the unit set the winch upright on the final drive housing 1 Remove the two winch base halves item 550 and item 552 by removing the 28 hex capscrews item 551 and lockwashers item 553 2 Remove the access plug item 734 using a 1 2 13NC bolt motor adaptor bolt item 821 works nicely from inside brake housing and discard O ring item 735 3 Remove six hex capscrews item 537 with lockwashers item 541 from bearing flange item 530 by rotating brake housing until access hole is over top 4 Lift brake housing together with the bearing flange and primary planet hub assembly out of the cable drum item 500 and discard O ring item 539 5 Remove final sungear item 340 from cable drum 6 Remove retaining ring item 401 and remove primary p
5. item 440 and circlip item 727 is tight against the sprag clutch aligner IMPORTANT For proper brake function verify that the sprag clutch is installed correctly When viewed from the motor end the motor drive shaft of a clockwise hoisting winch must turn freely clockwise and lock in the counterclockwise direction 7 Install 18 brake springs item 752 in the brake piston The brake piston has 20 holes and the two empty holes should be opposite each other 8 Liberally grease three new O rings item 801 and install into the recesses on the motor adaptor item 800 Install new well greased O ring item 707 on the flange of the motor adaptor a 251 REV 970601 PAGE 17 SERVICE INSTRUCTIONS 9 Slide the hydraulic motor assembly on the splined end of the motor drive shaft item 730 and line up the pressure transfer holes of the brake housing and the motor adaptor Tighten 12 capscrews item 821 and lockwashers item 823 one turn at a time to evenly compress springs REASSEMBLY OF HYDRAULIC MOTOR If the hydraulic motor was disassembled the following procedure should be followed for reassembly 1 Clean all parts thoroughly before reassembly and apply grease liberally to all seals Use only new seals seal kit Part No 23117 for hydraulic motor 2 Install two new teflon seals item 887 on each thrust plate item 885 Press one of the thrust plates together with two teflon seals onto the bearings item 87
6. 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 In the following service instructions reference to parts is made by numbers and shown on the applicable group drawings DISASSEMBLY For the majority of required service or repair work disassembly is required only on the brake housing of the PULLMASTER Model H25 planetary winch There are no special tools needed for the service or repair work and no adjustments or calibrations are necessary Proceed with the disassembly as follows DISASSEMBLY OF HYDRAULIC MOTOR ASSEMBLY If the analysed service or repair work requires access to the interior of the brake housing the hydraulic motor should not be disassembled In this case the hydraulic motor should be removed together with the motor adaptor as a complete assembly If a problem has been analysed to be in the hydraulic motor proceed with the disassembly as follows 1 Removethe eighthex capscrews item 951 together with the lockwashers item 953 from the motor assembly IMPORTANT Failure to exercise care when removing the motor port end cover or gear housing could permanently damage the machined surfaces of these motor components Take care not to damage machined surfaces of motor components at disassembly 2 Remove pry loose if necessary port end cover item 870 together with bearin
7. the PULLMASTER Model H25 planetary winch always quote the complete model and serial number of the unit MODEL NO SERIAL NO 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 251 REV 980615 PAGE 19 PARTS REFERENCE FINAL DRIVE DESCRIPTION FINAL HOUSING BALL BEARING 6024 BEARING RETAINER OILSEAL END COVER PIPE PLUG 3 4 14 NPT SUNGEAR STOPPER O RING 281 15 ID 1 8 CS RETAINING RING PLANET HUB STOPPER BREATHER RELIEF ASSEMBLY PLANET HUB PLANET PIN CIRCLIP ROTOR CLIP SH 168 CIRCLIP ROTOR CLIP SH 168 PLANET GEAR THRUST WASHER TORRINGTON TRB 2840 LOOSE ROLLER TORRINGTON 6613 Q SUNGEAR CIRCLIP ROTOR CLIP SH 206 CABLE DRUM CABLE ANCHOR PIPE PLUG 1 2 14 NPT CIRCLIP ROTOR CLIP SH 475 BASE CAPSCREW HEXHEAD 5 8 11NC X 1 75 GRADE 5 BASE LOCKWASHER 5 8 N N 1 1 1 1 1 2 1 1 1 1 1 il 3 3 3 3 6 2 1 1 1 1 1 1 1 8 1 8 N These parts vary according to drum code Refer to APPENDIX B Refer to PAGE 22 for winch seal kit and PAGE 28 for ASSEMBLY DRAWING m V PAGE 20 251 REV 110817 FINAL DRIVE GROUP G1000 A 130 320 124 323 321 313 104 103 105 503 500 311 310 126 553 551 550 5
8. the hydraulic motor are transmitted directly to the final planet reduction stage With the primary reduction stage eliminated the reduction is reduced to a ratio of 8 75 1 and the cable drum will rotate 4 67 times faster than in forward or hoisting speed If the load on the cable drum tends to effect the lowering speed the resulting pressure drop in the brake piston causes friction between the brake discs and divider plates In this way a completely smooth lowering speed can be achieved in a stepless operation by modulation of the winch control 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 heat This heat is dissipated by the circulation of hydraulic fluid through the brake housing supplied internally from the motor or externally depending on the brake code of the winch For efficient cooling of the automatic brake models with external circulation should be adjusted to supply 7 0 US gpm 26 l min This circulation flow 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 d
9. 1 1 1 8 1 WINCH SEAL KIT CONSISTS OF ITEMS 105 123 531 539 607 707 711 735 751 753 AND 801 This part varies according to drum code Refer to APPENDIX B Refer to PAGE 28 for ASSEMBLY DRAWING PAGE 22 251 REV 110817 BRAKE GROUP G1004 A 423 413 435 534 605 711 617 712 607 713 751 750 753 530 541 537 700 Group drawings may reference more parts than are actually present in a specific assembly Parts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored 251 REV 950201 PAGE 23 PARTS REFERENCE MOTOR GROUP mk mk m 1 1 1 3 1 2 1 1 1 1 1 4 2 1 4 2 1 2 4 2 1 1 8 8 2 CAPSCREW HEX HEAD 1 2 13 NC X 1 5 GRADE 5 LOCKWASHER 1 2 MOTOR DRIVE SHAFT CIRCLIP ROTOR CLIP C 112 MOTOR ADAPTOR O RING 013 7 16 ID 1 16 CS PIPE PLUG 1 8 27 NPT PIPE PLUG 1 4 18 NPT GEAR HOUSING 086 DOWEL PIN GASKET SEAL PORT END COVER ROLLER BEARING RING SEAL GEAR SET THRUST PLATE TEFLON SEAL PIPE PLUG 1 4 18 NPT SUB ASSY MOTOR 086 CAPSCREW HEX HEAD 5 8 X 6 75 GRADE 5 WASHER PLASTIC CAPLUG 2 0 MOTOR SEAL KIT CONTAINS ITEMS 869 877 AND 887 These part numbers and descriptions vary according to brake code Refer to APPENDIX C TEM 950 MOTOR SUB ASSY CONSISTS OF ITEMS 800 802 803 804 805 807 809 861 865 869 870 875 877 881 885 887 899 929 951
10. 1 10 inch drum diameter X 17 inch flange diameter X 11 inch length STANDARD For other drum sizes refer to APPENDIX A OPTIONS F Hydraulically actuated freespooling 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 251 REV 980615 PAGE 3 OPTIONS COUNTERCLOCKWISE ROTATION The drum rotation of the standard PULLMASTER Model H25 planetary winch is clockwise for hoisting when looking at the hydraulic motor of the winch Drum rotation for counterclockwise hoisting direction is available as an option INTERNAL CIRCULATION The PULLMASTER Model H25 7 86 X has an external circulation flow supply line to cool the brake Internal circulation is available as an option EXTERNAL BRAKE RELEASE PULLMASTER planetary winches can be supplied with an external brake release which permits release of the automatic disc brake from an external pressure source FAILURE TO PROPERLY VENT EXTERNAL BRAKE RELEASE PORT WILL TRAP BRAKE PRESSURE AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH WINCHES SUPPLIED WITH EXTERNAL RELEASE OPTION MUST BE CONNECTED ACCORDING TO TYPICAL HYDRAULIC CIRCUIT CABLE DRUM SIZES Aside from the standard drum sizes listed in APPENDIX A the PULLMASTER Model H25 pla
11. 2 L 9 9 ee vL v A1NO STAGOW 9 1VNH31X3 ios pn 1HOd 81 8 LHOd 197 NOLLY InOHIO NOIISEIRSHIS Y31139 S 3avu9 S1708 v L 10 ISN 2 Stoa VS S z vid 26 6 S3 10H ONILNNOW eel m pode set 100dS 3344 N OF IN x Das 6 BN ge OF Le i 4 8 cue PA vid v 3ZIS 1HOd GED z 1HVHO HO1ON 33S N 1708 AVS 22 8 1 1HOd 3Sv313u TVNH31X3 VNOILdO g NO HO 13 904 HOHONV 18 NI NOILV LOH EDU calvo LAN 1 67 3SIM99019 H31NnOO AZINSSaud ASIMA9O19 1HOd NOILV LOH a 2 51 I d HOd AZIYNSSAWd i SAWIL TIV LV G3NIV LNIVIN 38 LSNW 3dOH 3HIM SdaVuM S dO V ALd4vS 251 REV 051117 PAGE 26 INSTALLATION DIMENSIONS 11001 2 A amp 11001 3 A Dimensions in inches Dimensions in millimeters Dimensions in inches Dimensions in millimeters HYDRAULIC MOTORS COMMERCIAL WM76 SERIES COMMERCIAL M365 SERIES GEAR MOTOR PORT SIZE WIDTH SAE SPLIT FLANGE CODE 61 MOTOR CODE GEAR MOTOR PORT SIZE WIDTH SAE SPLIT FLANGE CODE 61 3 00 76 2 42 2 50 63 5 101 2 25 57 2 2 00 50 8
12. 5 installed in the motor adaptor item 800 3 Install a new well greased gasket seal item 869 on each side of the gear housing item 861 Slide the gear housing together with the gasket seals onto the motor adaptor lined up on two dowel pins Tap on tight using a soft headed hammer 4 Install the gear set item 881 in the gear housing The longer gear with the internal spline goes into the top position 5 Pressthe otherthrust plate complete with two new teflon seals onto the bearings installed in the port end cover 6 Install the port end cover item 870 together with two bearings item 875 and a new ring seal item 877 onto the gear housing lined up on the two dowel pins item 865 Tap on tight using a soft headed hammer Install and lightly torque eight hex capscrews item 951 and lockwashers item 953 to approximately 50 ft lb 70 Nm 7 Plumb winch assembly to a hydraulic supply and torque motor capscrews according to the following procedure Ensure that circulation supply flow is being supplied to the brake housing Run the winch with no load in the hoisting direction at reduced speed approximately 3096 of maximum hydraulic volume With winch running evenly tighten eight capscrews item 951 to 200 ft Ib 270 Nm Test motor operation by running winch at full speed in both directions IMPORTANT Before operating the winch add lubricating oil up to the level of the end cover oil fill port Refer to INSTAL
13. 52 Groups drawings may reference more parts than are actually present in a specific assembly Parts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored 251 REV 950201 21 PARTS REFERENCE BRAKE GROUP PLANET HUB RETAINING RING PLANET PIN CIRCLIP ROTOR CLIP C 87 CIRCLIP ROTOR CLIP SH 87 PLANET GEAR THRUST WASHER TORRINGTON TRA 1423 LOOSE ROLLER 5 32 X 1 25 TORRINGTON E151 Q INTERNAL GEAR CIRCLIP ROTOR CLIP SH 300 THRUST WASHER TORRINGTON TRA 6681 THRUST BEARING TORRINGTON NTA 6681 SUNGEAR SUNGEAR STOPPER BEARING FLANGE OILSEAL BALL BEARING 6026 BEARING RETAINER CAPSCREW HEX HEAD 1 2 18NC X 1 50 GRADE 5 O RING 269 8 3 4 ID 1 8 CS LOCKWASHER 1 2 CONNECTING SHAFT NEEDLE BEARING TORRINGTON B 3012 NEEDLE BEARING TORRINGTON NBH 4812 OIL SEAL THRUST WASHER INA AS 90120 THRUST BEARING INA AXK 90120 BRAKE HOUSING PLASTIC CAPLUG 1 NPT THREADED O RING 278 12 ID 1 8 CS OIL SEAL BRAKE SPACER DIVIDER PLATE FRICTION PLATE BRAKE HUB CIRCLIP ROTOR CLIP SH 387 SPRAG CLUTCH BORG WARNER 140373 B SPRAG CLUTCH ALIGNER CIRCLIP ROTOR CLIP SH 196 ACCESS PLUG O RING 123 1 3 16 ID 3 32 CS PISTON O RING 90 DURO 451 11 ID1 4 CS BRAKE SPRING O RING 90 DURO 452 11 1 2 ID 1 4 CS mer 3 3 3 3 6 0 1 1 2 1 1 1 1 1 1 1 6 1 6 1 1 2 1 2 1 1 1 1 1 1 3 2 1 1 1 1 1 1
14. 9 Keep hydraulic system clean and free from contamination at all times 20 Maintain winch and equipment in good operating condition Perform scheduled maintenance regularly 21 Keep hands clear when winding wire rope onto the winch drum 22 23 Rig the winch carefully Ensure that the wire rope is properly anchored to the correct cable anchor slot at the cable drum 24 Do not lift a load with a twisted kinked or damaged wire rope 25 Consult wire rope manufacturer for size type and maintenance of wire rope 26 Maintain five wraps of wire rope on the cable drum at all times 27 In case of a power failure or breakdown leading to an unexpected stop of the hydraulic power circuit stand clear of the area and the load being hoisted take the necessary precautions to prevent access to area where the load is halted 28 The noise level of the winch is 87 dBA measured on a distance of 1 00 meter 1 60 meters high The measuring equipment used was Realistic 442 3019 29 30 Wear proper clothing and personal protection equipment such as footwear safety goggles and a hard hat Read manual first 9000 Do not use the wire rope as a ground for welding Clean up any oil spillage immediately 251 REV 051117 PAGE 1 DESCRIPTION OF THE MODEL H25 GENERAL DESCRIPTION The PULLMASTER Model 25 is a planetary hydraulic winch with reversing or lowering speed 4 67 times faster than forward or hoisting spee
15. 953 AND 955 Refer to PAGE 22 for winch seal kit and PAGE 28 for ASSEMBLY DRAWING PAGE 24 251 REV 980615 MOTOR GROUP TT 7 Suq Z Za 22 wp 7 o 10 o I Wy QUU 8 lt E G1002 D Get eo a u WM HB N N Te 5 NH RA 2 M m 777 6 5 5 d 5 9 Te Group drawings may reference parts than are actually present in a specific assembly Parts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored 251 REV 970601 PAGE 25 o lt o lt LLI lt lt d lt H o Q as 1 o Y HOLOWI STAGOW 10046 3344 z VIG 01 NO 3dOH SHIM VIG 1 330 161 W Z 91 4 HOS 318V LInS n SI HOHONV 3 18VO QHVONVIS 16 96 9 9 9 ldN
16. ATIONS INSTALLATION INSTRUCTIONS Cable sheaves or block purchase operated with the winch are not turning freely Damage or wear in the hydraulic motor Excessive back pressure in the hydraulic circuit Winch will not reverse Leakage out of the brake piston prevents the brake from being released against the brake springs This is caused by damaged O ring seals on the brake piston The O ring seals on the brake release channel between the motor adaptor and the brake housing is damaged If this failure occurs there will be substantial leakage from between the motor adaptor and brake housing Insufficient hydraulic pressure See SPECIFICATIONS for minimum operating pressure Winch is mounted to an uneven surface see INSTALLATION INSTRUCTIONS Hydraulic pressure is not reaching the brake piston plugged brake release orifice in the brake housing 251 REV 950201 PAGE 11 TROU BLE SHOOTING CONTINUED FAILURE PROBABLE CAUSE Brake will not hold Brake plates or divider plates have been damaged by contamination in the hydraulic fluid or lack of circulation flow in the brake housing Brake piston is seized in the brake housing because of contamination in the hydraulic fluid Excessive back pressure in the return line causes the brake to be released 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 automati
17. E INSTALLATION Clockwise hoisting winch shown J Use cable anchor slot on opposite side of drum for counterclockwise hoisting winch d Feed the wire rope through the cable Fea anchor slot Loop rope back into slot as oo shown Insert cable anchor into slot small end first and long side nearest the drum flange Pull rope tight to wedge rope in slot i 511013 On wire installation care must be taken that the wire 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 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 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 time
18. LATION 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 COULD ENABLE AN INSTALLATION OR SERVICE PROBLEM TO GO UNDETECTED AND WILL 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 18 251 REV 970601 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 FollowINSTALLATION and OPERATING INSTRUCTIONS when returning winch to its mounting When ordering parts for
19. OL OPTION 800 BAR 2 US GPM 8 L MIN CIRCULATION RETURN LINE REQUIRED FOR MODELS MUST GO DIRECT TO RESERVOIR SUPPLIED WITH EXTERNAL 2 BRAKE RELEASE OPTION CIRCULATION SUPPLY LINE M25 5 US GPM 19 L MIN H25 7 US GPM 26 L MIN EXTERNAL CIRCULATION MODELS ONLY Wi E CONTROL VALVE MOTOR SPOOL 4 WAY SPRING RETURN TO CENTER PRESSURE RELIEF VALVE FILTER HYDRAULIC PUMP RESERVOIR 251 REV 980615 PAGE 7 RECOMMENDATIONS 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 f
20. PAGE 31 BOLT TORQUE CHART BOLT DIAMETER TORQUE TORQUE Inches lb ft Nm NOTE Unless otherwise specified torque bolts per above chart PAGE 32 251 REV 950201
21. S SSS 251 REV 010406 PAGE 5 PERFORMANCE GRAPHS PG H25 C LINE PULL VS OIL PRESSURE NOTE MAX ALLOWABLE LINE PULL WHEN LOWERING Bare drum 5 357 16 23 8 kN Full drum 3 778 Ib 16 8 kN LINE PULL kN 2500 172 _ 2000 138 _ S LLI C 1500 103 2 5 1000 69 A 500 34 0 L L L Ll i LL L1 L Ll j 0 0 5000 10000 15000 20000 25000 LINE PULL Ib LINE SPEED VS OIL VOLUME HOISTING LINE SPEED I LOWERING LINE SPEED LINE SPEED m min 0 30 61 91 122 152 183 213 244 274 125 7 3 a 7 nll 100 27 377 379 E 4 o 7 ge 2 E 7 71 1 75 m ea 284 T T 2 27 _ a 50 z 189 4 gt gt 7 25 95 o J o 0 100 200 300 400 500 600 700 800 900 LINE SPEED fpm Performance graphs are based on standard hydraulic motor gear ratio and cable drum with 7 8 inch diameter wire rope jE FF PAGE 6 251 REV 991224 TYPICAL HYDRAULIC CIRCUIT HC M25 C c TIED Fe sj nt r M E N loo oo P OO Oo i N du 400 PSI 28 BAR PRESSURE REQUIRED FOR MODELS SUPPLIED WITH FREESPO
22. TION 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 Fill the winch with lubricating oil Gee APPENDIX A for oil volume required Use recommended circuit components and hydraulic hoses 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 return line directly to reservoir Do not connect to a common return line 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 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 mu
23. ULIC 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 which provides for free air circulation around the reservoir HYDRAULIC HOSES The following hydraulic hoses are recommended for maximum efficiency of the PULLMASTER Model H25 planetary winch Pressure lines Circulation return line Circulation supply line Equivalent to SAE 100R12 32 Equivalent to SAE 100R4 16 Equivalent to SAE 100R6 6 Only for models with external circulation 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 Hydraulic filter recommendations for the hydraulic circuit of the PULLMASTER planetary winch based on a return line filter are given as follows 10 microns 5 microns Average Atmosphere Dusty Atmosphere In order to prevent accidental stoppage of the return line flow the oil fil
24. al 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 before reading and understanding manufacturer s instructions 2 The winch described herein is not designed for operations involving lifting or moving personnel 3 Do not lift or carry loads over people 4 Do not exceed recommended operating pressure psi and operating volume gpm Do not jerk the winch Always smoothly accelerate and decelerate load 6 Do not operate a damaged noisy or malfunctioning winch 7 Do not leave a load suspended for any extended period of time 8 Never leave a suspended load unattended 9 Winch should be maintained and operated by qualified personnel 10 Inspect winch rigging mounting bolts and hoses before each shift 11 Warm up equipment before operating winch particularly at low ambient temperatures 12 Verify winch function by raising and lowering a full test load to a safe height before each shift 13 14 Verify gear lubrication and brake circulation supply and return before operating winch Do not weld any part of the winch 15 Besure of equipment stability before operating winch 16 Wear proper clothing to avoid entanglement in rotating machinery 17 Always stand clear of the load 18 Use only recommended hydraulic oil and gear lubricant 1
25. c brake both pressure ports of the winch must be open to the reservoir in neutral position of the control valve Wire rope is fastened to the incorrect cable anchor slot Sprag clutch is damaged or surfaces where sprag clutch engages on motor drive shaft or connecting shaft are worn or indented Winch supplied with external brake release option is not plumbed per HYDRAULIC CIRCUIT Failure to vent external brake release port to reservoir may trap pressure and cause winch brake to slip Brake vibrates when lowering a load Pump is too slow Pump rpm must be maintained at normal operating speed when a load is lowered Brake is running too hot This is caused by a complete lack of or insufficient circulation flow To check the circulation observe the flow of oil from the circulation return line of the winch see TYPICAL HYDRAULIC CIRCUIT when the winch is reversed Control valve has poor metering characteristics Damaged brake plates or divider plates The over running clutch which connects the motor shaft with the brake assembly is damaged Air mixed with hydraulic oil foamy oil Oil leaks Oil leaks from the hydraulic motor flange and the motor adaptor are caused by damaged O ring seals Oil leaks occurring between the cable drum flanges and housings are caused by excessive pressure in the brake housing Excessive pressure will damage the oil seal which separates the brake housing from the cable drum interior If the breather reli
26. d 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 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 with the internal gear of the primary planet reduction locks causing the internal gear to rotate at the same rpm as the primary sungear Thus the primary reduction stage is eliminated and the output torque and rpm of
27. diameter wire rope For other cable drums refer to APPENDIX A For other reductions or motors refer to supplement inside back cover Performance specifications for winches supplied with optional motors are provided in attached supplement CABLE DRUM DIMENSIONS STANDARD DRUM Barrel diameter 10 00 in 254 mm Flange diameter 17 00 in 432 mm Barrel length 11 00 in 279 mm CABLE STORAGE CAPACITY Size of wire rope 7 16 in 612 ft 186 1 2 413 ft 126 9 16 383 ft 117m 5 8 in 297 ft 90 3 4 210 ft 64m 7 8 in 140 ft 43m 1in 91 ft 28m MAXIMUM OPERATING PRESSURE 2500 psi 172 bar MAXIMUM OPERATING VOLUME 115 US gpm 435 l min MINIMUM OPERATING VOLUME 30 US gpm 114 l min DRUM TORQUE AT MAXIMUM PRESSURE 135 937 Ib in 15 359 Nm DRUM RPM AT MAXIMUM VOLUME Hoisting 49 rpm Lowering 229 rpm HOISTING LINE PULL AT MAXIMUM PRESSURE Bare drum 25 000 Ib 111 2 kN Full drum 16 860 Ib 75 0 kN MAXIMUM ALLOWABLE LINE PULL WHEN LOWERING Bare drum 5 357 Ib 23 8 kN Full drum 3 778 Ib 16 8 kN HOISTING LINE SPEED AT MAXIMUM VOLUME Bare drum 140 fpm 43 m min Full drum 207 fpm 63 m min LOWERING LINE SPEED AT MAXIMUM VOLUME Bare drum 651 fpm 198 m min Full drum 965 fpm 294 m min PERMISSIBLE SYSTEM BACK PRESSURE AT MOTOR RETURN PORT 65 psi 4 5 bar PERMISSIBLE PRESSURE AT CIRCULATION SUPPLY PORT 30 psi 2 bar LUBRICATING OIL Refer to RECOMMENDATIONS for viscosity and instructions Refer to APPENDIX A for oil volume required SSS SS
28. e internal retaining ring item 534 to remove the ball bearing item 533 Remove and discard oil seal item 531 DISASSEMBLY OF FINAL DRIVE Stand winch on cable drum flange with final end up and disassemble as follows 1 Remove the internal retaining ring item 124 and pull the end cover item 120 out of final drive housing item 100 SS 251 REV 970601 PAGE 15 6 SERVICE INSTRUCTIONS continuen Discard O ring item 123 and inspect planet hub stopper item 126 and sungear stopper item 122 for excessive wear Replace planet hub stopper if less than 30 inch and sungear stopper if less than 21 inch thick Remove final planet hub assembly from final housing item 100 Inspect three final planet gears item 320 for damage or wear If it is necessary to remove final planet gears remove circlip item 311 and press planet pin item 310 out of planet hub item 300 Inspect loose rollers item 323 and two thrust washers item 321 and replace if damaged To separate cable drum from final housing first remove circlip item 513 Insert two heel bars between the flange of the cable drum and final drive housing and gently pry cable drum out of ball bearing item 103 Remove the internal retaining ring item 104 to remove ball bearing item 103 Remove and discard oil seal item 105 REASSEMBLY Thoroughly clean all parts Use only new well greased O rings and oil seals Unless otherwise specified torque fasteners per
29. e relates to the line pull or lifting capacity of the winch If the winch will not lift the specified maximum line pull install a pressure gauge into 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 pump is driven by V belts check for belt slippage When checking oil pressure and volume in the hydraulic circuit make certain that the hydraulic reservoiris filled to the top level and the hydraulic pump is running at maximum operating rpm Only if 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 Winch is mounted to an uneven surface see pressure as listed in SPECIFICATIONS INSTALLATION INSTRUCTIONS Cable sheaves or block purchase operated with the winch are not turning freely Damage or wear in the hydraulic motor Excessive back pressure in the hydraulic system Relief valve may be settoo low See SPECIFICATIONS for maximum operating pressure Winch will not produce line speed at maximum Winch is mounted to an uneven surface see volume as listed in SPECIFIC
30. ef 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 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 H25 winch jg PAGE 12 251 REV 970601 SERVICE INSTRUCTIONS GENERAL Before attempting disassembly of the PULLMASTER Model H25 planetary winch the following instructions for disassembly and reassembly 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 seal kit Part No 23126 and providing the hydraulic motor has to be serviced a seal kit Part No 23117 on hand before the unit is taken apart Two new roller bearings item 875 may also be required Part No 25352 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 A clean working area is of prime importance similar to conditions used for service work any other hydraulic component All parts as they are removed from the winch assembly should be inspected for wear and damage Worn or damaged parts
31. ervice 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 torsional 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 accele
32. gs item 875 and ring seal item 877 Thrust plate item 885 and dowel pins item 865 may stay in the gear housing 3 Ifthe thrust plate comes off with the end cover carefully pry it off of the bearings item 875 and discard teflon seals item 887 4 Remove gear set item 881 which consists of two gears which are a matched set 5 Carefully pry the gear housing item 861 off ofthe motor adaptor item 800 Thrust plate item 885 and dowel pins item 865 may stay in the gear housing 6 Ifthe thrust plate stays on the motor adaptor carefully pry it off of the bearings item 875 and discard teflon seals item 887 7 Discard gasket seals item 869 It is also advisable to replace ring seals item 877 atthis time Bearings item 875 have to be removed to allow access to the ring seals Teflon seals gasket seals and ring seals in the hydraulic motor assembly are not part of the winch seal kit The seal kit for the hydraulic motor can be ordered from the factory under Part No 23117 All parts of the hydraulic EM 251 REV 991224 PAGE 13 SERVICE INSTRUCTIONS continuen motor with the exception of the motor adaptor item 800 and the port end cover item 870 are sta
33. inspected for wear or indentations If the motor drive shaft shows any surface damage it should be replaced 3 The sprag clutch aligner item 724 and the sprag clutch item 723 can now be removed from the bore of the brake connecting shaft item 600 Inspect both parts for wear or damage and replace if necessary MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE MOTOR DRIVE SHAFT AND CONNECTING SHAFT 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 MOTOR DRIVE SHAFT SPRAG CLUTCH AND CONNECTING SHAFT AS A SET 4 Pullthe brake piston item 750 out of the brake housing using two 5 8 11NC bolts screwed into the two puller holes in the piston and discard O rings item 751 and item 753 5 Thoroughly examine the inner bores of the brake housing and the outer diameters of the brake piston for scoring caused by hydraulic fluid contamination Minor surface damage may be repaired by polishing with a fine emery cloth DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH SOLVENT MAY DAMAGE THE FRICTION PLATES DO NOT USE SOLVENT TO CLEAN THE FRICTION PLATES PERFORM THOROUGH INSPECTION AND IF NECESSARY REPLACE FRICTION AND DIVIDER PLATES AS A SET 6 Remove 12friction plates item 715 together with 13 divider plates item 713 and inspect
34. ird 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 transac
35. lanet hub assembly from inside the internal gear item 430 7 Inspect three primary planet gears item 420 for damage or wear If itis necessary to remove primary planet gears remove circlip item 411 and press planet pin item 410 out of planet hub item 400 Inspect loose rollers item 423 and two thrust washers item 421 and replace if damaged 8 Remove primary sungear item 440 from center of connecting shaft item 600 9 Remove circlip item 431 and internal gear item 430 from connecting shaft spline 10 Remove and inspect two thrust washers item 433 and thrust bearing item 435 Replace if cracked or otherwise damaged 11 The connecting shaft item 600 can now be pulled out of the brake housing Remove and inspect two thrust washers item 615 and thrust bearing item 617 Replace if cracked or otherwise damaged 12 Remove needle bearing item 603 inspect and replace if damaged 13 Remove and discard oil seal item 607 and if present backup washer item 606 from inside of connecting shaft 14 Remove and discard oil seal item 711 and if present backup washer item 710 from bore of brake housing Inspect two needle bearings item 605 and replace if necessary 15 To separate bearing flange item 530 and brake housing item 700 use a standard bearing puller or insert two heel bars in the slot between the bearing flange and the brake housing and pry brake housing out of ball bearing item 533 16 Remove th
36. ndard parts of the hydraulic motor having a 3 inch gear section All of these parts can be ordered from PULLMASTER or Authorized Distributors Dealers in Canada the United States and in most overseas areas REMOVAL OF HYDRAULIC MOTOR ASSEMBLY If disassembly of the hydraulic motor is not necessary proceed as follows 1 Remove the 12 hex head capscrews item 537 with lockwashers item 541 from the motor adaptor item 800 Since the brake springs item 752 apply pressure against the inside of the motor adaptor it is recommended that the hex capscrews are unscrewed one turn at a time until the spring pressure has been released The complete motor assembly including the motor adaptor can now be removed from the brake housing assembly 2 Remove and discard three O rings item 801 and O ring item 707 O rings item 801 seal the pressure transfer hole for the automatic brake release and are situated on the flange of the brake housing DISASSEMBLY OF BRAKE HOUSING ASSEMBLY 1 After the motor assembly has been removed all parts of the brake assembly are accessible Remove 18 brake springs item 752 Thoroughly examine springs for damage and measure overall length Overall spring length should be 2 27 inch If any spring measures less than 2 21 inch replace all springs as a set 2 Pull the motor drive shaft item 730 out of the brake hub assembly The surface of the motor drive shaft which engages the sprag clutch item 723 should be
37. netary winch can be supplied with optional drums to accommodate large wire rope storage capacity DRUM GROOVING Cable drums for the PULLMASTER Model H25 planetary winch can be grooved Where this option is a requirement it is necessary to state the size of wire rope which is to be used with the winch OPTIONAL GEAR SECTION FOR THE HYDRAULIC MOTOR The performance of the standard PULLMASTER Model H25 planetary winch may be changed by using a different displacement motor Contact the factory for performance information HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS The operating pressure of the PULLMASTER Model H25 planetary winch is limited to 2500 psi 172 bar For hydraulic systems operating with a higher range of hydraulic pressure the winch can be supplied with a hydraulic piston motor which will provide for the same basic performance in terms of line pull and line speed capacity Contact the factory for this requirement FREESPOOLING This option permits wire rope being pulled off the cable drum by an operator Freespooling should not be confused with free fall The freespool clutch cannot be disengaged or re engaged with a load on the wire rope or while the cable drum is turning The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements PAGE 4 251 REV 970601 SPECIFICATIONS Performance specifications are based on standard hydraulic motor gear ratio and cable drum with 7 8 inch
38. rated 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 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 th
39. rom the factory without lubricating oil IMPORTANT ADD LUBRICATING OIL 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 Consult lubricating oil supplier or factory for temperatures beyond normal operating range HYDRAULIC PUMP For maximum performance of the PULLMASTER planetary winch the hydraulic pump must supply the maximum flow of hydraulic fluid atthe hydraulic pressure stated in SPECIFICATIONS HYDRAULIC CONTROL VALVE The standard control valve used for operation of 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 isnot the case aseparate pressure relief valve must be installed and set at the recommended maximum pressure HYDRA
40. rum to fill up with hydraulic fluid In order to prevent 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 2 251 REV 040708 EXPLANATION OF MODEL CODING BASIC UNIT SERIES Rapid reverse SIZE OF UNIT REDUCTION RATIO Only used for non standard reduction ratios TYPE OF BRAKE 3 Automatic brake clockwise drum rotation internal circulation flow 4 Automatic brake external brake release clockwise drum rotation internal circulation flow 5 Automatic brake external brake release counterclockwise drum rotation internal circulation flow 6 Automatic brake counterclockwise drum rotation internal circulation flow 7 Automatic brake clockwise drum rotation external circulation flow 8 Automatic brake external brake release clockwise drum rotation external circulation flow 9 Automatic brake external brake release counterclockwise drum rotation external circulation flow 10 Automatic brake counterclockwise drum rotation external circulation flow HYDRAULIC MOTOR 86 Hydraulic motor 3 inch gear section 12 3 cubic inch displacement Other gear sections for this motor are optional DRUM SIZE
41. s Prevent corrosion damage to winch interior If not used regularly run winch up and down at least once every two weeks 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 10 251 REV 051117 TROUBLE SHOOTING GENERAL In most cases when the hydraulic winch does not perform satisfactorily the cause of 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 system can be analysed If this condition exists install a flow meter into the hydraulic circuit to check the volume 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 pressur
42. sembly onto brake housing item 700 and install new well greased O ring item 539 Press a new well greased oil seal item 711 into bore of brake housing item 700 Press a new well greased oil seal item 607 into bore of connecting shaft item 600 followed by needle bearing item 603 Slide brake hub item 720 onto connecting shaft and secure with circlip item 721 Place thrust bearing item 617 held between two thrust washers item 615 against brake hub and slide connecting shaft into brake housing Place thrust bearing item 435 held between two thrust washers item 433 onto internal gear item 430 and PAGE 16 251 REV 970601 SERVICE INSTRUCTIONS continuep fasten internal gear onto connecting shaft using circlip item 431 7 Reassemble primary planet hub assembly Use grease to temporarily hold 20 loose rollers item 423 in the bore of the planet gear item 420 Verify placement of sungear stopper item 444 Position thrust washers item 421 on either side of the planet gear and press planet pin item 410 into the final planet hub item 400 Retain with circlip item 411 8 Insert primary sungear item 440 between three planet gears and insert sungear shaft into connecting shaft engaging planet gears with internal gear Fasten with retaining ring item 401 9 Insert final sungear item 340 into cable drum and engage three planet gears item 320 10 Lower brake housing assembly onto cable drum while engaging
43. spline of final sungear with primary planet hub item 400 Line up mounting holes of bearing flange item 530 with those in the cable drum 11 Rotate brake housing to line up access holes and fasten bearing flange using six capscrews item 537 and lockwashers item 541 12 Install new well greased O ring item 735 into access plug item 734 Install access plug into access hole inside brake housing 13 Attach base halves item 550 and item 552 using 28 capscrews item 551 and lockwashers item 553 REASSEMBLY OF BRAKE HOUSING ASSEMBLY Reassemble brake housing assembly as follows 1 Install brake spacer item 712 into brake housing 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 2 Starting and finishing with a divider plate alternately install 13 divider plates item 713 and 12 friction plates item 715 3 Liberally grease O ring item 751 and O ring item 753 and install on the brake piston item 750 4 Slide the brake piston into the brake housing with the holes for the brake springs facing out of the brake housing assembly 5 Install sprag clutch item 723 and sprag clutch aligner item 724 into the bore of connecting shaft item 600 6 Carefully slide motor drive shaft item 730 into the connecting shaft until it engages the spline of the primary sungear
44. st be replaced immediately If these oil seals are changed additional failure of the drum seal and potential damage to the end cover is prevented 251 REV 980615 PAGE 9 OPERATING INSTRUCTIONS 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 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 CABLE ANCHOR SLOT WIRE ROP
45. ter 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 8 251 REV 021028 INSTALLATION INSTRUCTIONS 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 Make certain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted Set the winch on the mounting platform and check for surface contact on all mounting pads of the winch 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 INSTALLA
46. th 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 s
47. tion 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 SAFETY RECOMMENDATIONS wm 19 FAILURE TO COMPLY WITH THE FOLLOWING SAFETY RECOMMENDATIONS AND LOCAL RULES AND REGULATIONS WILL RESULT IN PROPERTY DAMAGE SEVERE INJURY OR DEATH Definition Caution indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Definition Warning indicates a potentially hazardous situation which if not avoided could result in death or serious injury Definition Danger indicates a potentially hazardous situation which if not avoided will 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 manu
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