Model H30 Service Manual
Contents
1. PG H30 51 LINE PULL VS OIL PRESSURE NOTE MAX ALLOWABLE LINE PULL WHEN LOWERING Bare drum 5 353 Ib 23 8 kN Full drum 1 414 lb 6 3 kN LINE PULL kN 0 22 44 67 89 11 2500 172 2000 138 5 ui 1500 103 gt 5 B 1000 Li a o dd 500 34 O 0 0 0 5000 10000 15000 20000 25000 LINE PULL Ib LINE SPEED VS OIL VOLUME HOISTING LINE SPEED LOWERING LINE SPEED LINE SPEED m min 0 154 308 462 615 769 125 473 2 E B 7 100 pp 379 c gt E L3 E 5 CE 75 284 gt 5 2 3 B 50 139 gt gt 25 95 O 0 0 0 500 1000 1500 2000 2500 LINE SPEED fpm Performance graphs are based on standard hydraulic motor gear ratio and 51 cable drum with 7 8 inch diameter wire rope PAGE 6 342 REV 020331 TYPICAL HYDRAULIC CIRCUIT 400 PSI 28 BAR PRESSURE REQUIRED FOR MODELS SUPPLIED WITH FREESPOOL OPTION CIRCULATION RETURN LINE MUST GO DIRECT TO RESERVOIR HC M30 H30 CIRCULATION SUPPLY LINE M30 5 US GPM 19 L MIN H30 7 US GPM 26 L MIN EXTERNAL CIRCULATION MODELS ONLY 800 PSI 55 BAR 2 US GPM 8 L MIN REQUIRED FOR MODELS SUPPLIED WITH EXTERNAL BRAKE2. 1 1HOd Yal 43138 3SIMA9OT9 Y S1HOd 539 9 SLYOd HOLON 56 2 ISAWIL TIV LV Q3NIV LNIVIN 38 LSANW 3dOH 3HIM JO SdVHM S AO WAWININ V 144 5 HOW 9 i YAHLVSYa S3HONI NI SNOISNAWIG 342 REV 051117 PAGE 28 APPENDIX A LINE PULL AT HOISTING LINE MAXIMUM OWERING LINE MAXIMUM SPEED AT ALLOWABLE SPEED AT LUB OIL we or E WIRE REUS PRESSURE MAXIMUM LINE PULL MAXIMUM VOLUME MILLIMETERS METERS HOISTING VOLUME LOWERING VOLUME REQUIRED POUNDS FEET MINUTE POUNDS FEET MINUTE U S KILONEWTONS METERS MINUTE KILONEWTONS METERS MINUTE GALLONS BARE FULL BARE FULL BARE FULL BARE FULL LITERS pe a Performance specifications are based on standard hydraulic motor with 7 8 inch diameter rope 342 REV 020331 PAGE 29 APPENDIX B ITEM 340 530 FINAL BEARING SUNGEAR FLANGE DRUM CODE PAGE 30 342 REV 020331 APPENDIX C BRAKE CODE PARTNUMBERS CIRCULATION 1 4 18 NPT 1 8 27 NPT PART DESCRIPTION 1 8 27 NPT PIPE N A 25622 25622 N A N A 25622 25622 N A ADAPTOR 1 8 NPT 3 8 18 NPT 3 8 18 NPT MOTOR 20504 22011 22012 20804 20505 21977 22013 20805 342 REV 020331 PAGE 31 BOLT TORQUE CHART BOLT DIAMETER TORQUE TORQUE Inches lb ft Nm NOTE Unless otherwise specified torque bolts per above chart PAGE 32 342 REV 020331
3. Pv MASTER THE LOGICAL CHOICE INSTRUCTION AND PARTS MANUAL MODEL H30 PLANETARY HYDRAULIC WINCH amp N POWER to Move the World TWG Canada LANTEC and Pullmaster Brands 19350 22nd Ave Surrey BC V3S 356 Voice 1 604 547 2100 e 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 342 120612 POVER MONA Effective 2011 10 01 A TOWER comen 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 therewith whic
4. 6 3 6 2 1 1 1 1 1 1 1 9 9 2 These parts vary according to drum code Refer to APPENDIX B Refer to PAGE 24 for winch seal kit and PAGE 21 for ASSEMBLY DRAWING PAGE 22 342 REV 110817 FINAL DRIVE GROUP G1190 A 127 130 320 129 323 321 311 105 502 500 603 311 T 513 VALLE 1 126 122 340 GES Fm 300 o 123 LZ I 100 551 553 550 555 553 556 Groups drawings may reference parts than are actually present a specific assembly Parts that referenced on the drawing but are not on the PARTS REFERENCE list should be ignored 342 REV 020331 PAGE 23 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 INTERNAL GEAR CIRCLIP ROTOR CLIP SH 300 THRUST WASHER TORRINGTON TRA 6881 THRUST BEARING TORRINGTON NTA 6881 SUNGEAR SUNGEAR STOPPER BEARING FLANGE OILSEAL CYLINDRICAL ROLLER BEARING NU 1026 BEARING RETAINER CAPSCREW HEX HEAD 1 2 13NC X 1 50 GRADE 5 O RING 269 8 3 4 ID 1 8 CS LOCKWASHER 1 2 BASE PLATE CAPSCREW HEXHEAD 5 8 11NC X 1 75 GRADE 5 LOCKWASH
5. 713 inspect for damage or wear Plates should be flat and smooth Plates should not show heat discoloration Paper material on friction plates 342 REV 020331 PAGE 15 SERVICE INSTRUCTIONS 7 8 should be intact and grooved If any damage is detected replace friction and divider plates as a set Remove brake spacer item 712 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 2 3 4 5 6 7 8 9 10 11 12 13 14 15 Remove four hex capscrews item 555 with lockwashers item 553 from each side of both tie bars item 556 and remove tie bars from the assembly Remove the access plug item 734 using a 1 2 13NC bolt motor adaptor bolt item 821 is suitable from inside brake housing and discard O ring item 735 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 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
6. 870 are standard parts of the hydraulic motor having a3 inch gear section All ofthese 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 Removeanddiscardthree O rings item 801 and O ring item 707 O rings item 801 sealthe pressure transfer hole for the automatic brake release and are situated on the flange of the brake housing DISASSEMBLY OF BRAKE HOUSING ASSEMBLY 1 Afterthe motor assembly has been removed all parts ofthe 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 Pullthe 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 shoul
7. EN 418 PAGE 8 342 REV 021030 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 1 Make certain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted 2 Set the winch with 51 52 or 53 drum on the mounting platform and check Gap B C and D JACKING 511082 SCREW B JACKING SCREW D LIS GAP 2M ud FLANHE i H tu 1 9 7 a JACKING L gt gt GAP D GAP B SCREW A Bn HT DETAIL JACKING SCREW C zl MOUNTING BOLT 1 1 4 4 PLACES 3 If Gap A is within 007 to Gap B and Gap is within 007 to Gap D proceed to step 5 If Gaps are outside this limit proceed to step 4 Note Difference between
8. Remove and discard oil seal item 531 16 To separate the final drive housing item 100 and cable drum item 500 first remove external circlip item 513 off end of cable drum Insert two heel bars into slot between final housing and cable drum flange and pry cable drum out of ball bearing item 103 17 Remove internal circlip item 109 to remove ball bearing item 103 Remove and discard oil seal item 105 PAGE 16 342 REV 020331 SERVICE INSTRUCTIONS conrinueo DISASSEMBLY OF FINAL DRIVE Stand winch on cable drum flange with final end up and disassemble as follows 1 Remove eight hex capscrews item 127 and lockwashers item 129 Remove end cover item 120 2 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 3 Remove final planet hub assembly from final housing item 100 4 Inspectthree 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 5 Remove final sungear item 340 from cable drum The PULLMASTER Model H30 has now been completely disassembled REASSEMBLY Thoroughly clean all parts Use only new well greased O rings and oil
9. Remove retaining ring item 401 and remove primary planet hub assembly from inside the internal gear item 430 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 planetpin item 410 outof planethub item 400 Inspectloose rollers item 423 and two thrust washers item 421 and replace if damaged Remove primary sungear item 440 from center of connecting shaft item 600 Remove circlip item 431 and internal gear item 430 from connecting shaft spline Remove andinspecttwo thrust washers item 433 and thrust bearing item 435 Replace if cracked or otherwise damaged 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 Remove needle bearing item 603 inspect and replace if damaged Remove and discard oil seal item 607 from inside of connecting shaft Remove and discard oil seal item 711 from bore of brake housing Inspect two needle bearings item 605 and replace if necessary 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 Remove the internal retaining ring item 534 to remove the ball bearing item 533
10. 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 MERCHANT ABILITY 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 accelerated
11. 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 ambienttemperature 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 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 342 REV 051117 PAGE 11 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 fl
12. 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 anumber 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 the hydraulic motor are transmitted directly to the final plane
13. 3 inch flange diameter X 28 inch length STANDARD For 52 amp 53 drum sizes refer to APPENDIX A OPTIONS X X X XXXX F Hyaraulically 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 342 REV 020331 PAGE 3 OPTIONS COUNTERCLOCKWISE ROTATION The drum rotation of the standard PULLMASTER Model H30 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 H30 7 86 X requires 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 DANGER 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 H30 pl
14. 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 system Relief valve may be settoolow 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 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 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 O ring seals onthe 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 PAGE 12 342 REV 020331 TROU B LE NG CONTINUED FAILURE PROBABLE CAUSE Brake will not hold Brake plates or divider plates have been damaged by contamination in the hydrauli
15. ER 5 8 CONNECTING SHAFT NEEDLE BEARING TORRINGTON B 3012 NEEDLE BEARING TORRINGTON NBH 4812 OILSEAL 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 OILSEAL BRAKE SPACER DIVIDERPLATE FRICTION PLATE BRAKE HUB CIRCLIP ROTOR CLIP SH 387 SPRAG CLUTCH BORG WARNER 140373 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 ID 1 4 CS BRAKE SPRING O RING 90 DURO 452 11 1 2 ID 1 4 CS S AAA AAA E AAN EME CA 601 00 00 4 4 gt e 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 21 for ASSEMBLY DRAWING PAGE 24 342 REV 020331 BRAKE GROUP G1195 401 423 413 435 534 605 711 617 712 751 750 753 707 421 752 411 721 410 723 420 3 724 400 E rer 444 440 N 431 2 BUS 433 615 430 720 710 715 531 734 533 703 539 530 541 537 700 553 551 550 735 Group drawings may reference more parts than are actually presentin a specific assembly Parts that are referenced on the drawing but are not on
16. Gaps A and B and Gaps C and D may not be equal 4 Gaps can be adjusted as required by adjusting Jacking Screw diagonally opposite to the Gap Reduce gap by turning Jacking Screw clockwise or increase a gap by turning Jack Screw counterclockwise a To adjust Gap A adjust Jacking Screw A b To adjust Gap B adjust Jacking Screw B C To adjust Gap C adjust Jacking Screw C d To adjust Gap D adjust Jacking Screw D 342 REV 020331 PAGE 9 INSTALLATION INSTRUCTIONS conrivueo 6 7 8 9 10 Measure the space underneath the four mounting pads with a feeler gauge and use shim stock of equivalent thickness in the space between the mounting pad and the mounting surface Install mounting bolts for bolt size and grade refer to INSTALLATION DIMENSIONS Tighten mounting bolts per BOLT TORQUE CHART Fill the winch with lubricating oil See 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
17. RELEASE OPTION Np mu PRESSURE RELIEF VALVE HYDRAULIC PUMP e EX lt gt 1 RESERVOIR CONTROL VALVE MOTOR SPOOL 4 WAY SPRING RETURN TO CENTER FILTER 342 REV 020331 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 from 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
18. 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 item 120 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 10 342 REV 020331 OPERATING INSTRUCTIONS FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL RESULT IN PROPERTY DAMAGE SEVERE INJURY OR DEATH Afterthe 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 1 Refer to manufacturers handling inspection and maintenance recommendations to avoid potential accidents For selection of ropes etc please check following product standards DIN 15020 prEN 818 1 9 prEN1492 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
19. 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 CABLE ANCHOR CABLE ANCHOR SLOT 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 SI1013 30 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 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
20. anetary winch can be supplied with optional drums to accommodate large wire rope storage capacity DRUM GROOVING Cable drums forthe PULLMASTER Model H30 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 H30 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 H30 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 forthe 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 4 342 REV 020331 SPECIFICATIONS Performance specifications are based on standard hydraulic motor gear ratio and 51 cable drum with 7 8 inc
21. c 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 automatic 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
22. d be 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 examinethe inner bores ofthe brake housing and the outer diameters ofthe brake piston for scoring caused by hydraulic fluid contamination Minor surface damage may be repaired by polishing with a fine emery cloth DANGER 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 Remove 12friction plates item 715 together with 13 divider plates item
23. ect 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 Definition Caution indicates a potentially DAN DAGER 0 E R hazardous situation which if not avoided may result in minor or moderate injury Definition Warning indicates a potentially FAILURE TO COMPLY WITH THE FOLLOWING SAFETY 2 hazardous situation which if not avoided could RECOMMENDATIONS AND LOCAL RULES AND result in death or serious injury REGULATIONS WILL RESULT IN PROPERTY Definition Danger indicates a potentially DAMAGE SEVERE INJURY OR DEATH 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 manual unde
24. etween 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 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 Install both tie bars item 556 using 16 hex capscrews item 555 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
25. f wire rope on the cable 10 Inspect winch rigging mounting bolts and drum at all times hoses before each shift 27 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 12 Verify winch function by raising and lowering a the load is halted full test load to a safe height before each shift 11 Warm up equipment before operating winch particularly at low ambient temperatures 28 The noise level of the winch is 87 dBA measured 13 Do not weld any part of the winch on a distance of 1 00 meter 1 60 meters high The 14 Verify gear lubrication and brake circulation measuring equipment used was Realistic 442 3019 supply and return before operating winch 29 Clean up any oil spillage immediately 15 Be sure of equipment stability before operating 30 Wear proper clothing and personal protection winch equipment such as footwear safety goggles and a hard 16 Wear proper clothing to avoid entanglement in hat Read manual first rotating machinery 17 Always stand clear of the load O 342REV 051117 PAGE 1 DESCRIPTION OF THE MODEL H30 GENERAL DESCRIPTION The PULLMASTER Model H30 is a planetary hydraulic winch with reversing or lowering speed 4 67 times faster than forward or hoisting speed The main components of this unit are hydraulic gear
26. h 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 51 DRUM Barrel diameter 10in 254mm Flange diameter 42 3 in 1073mm Barrel length 28 in 711 mm CABLE STORAGE CAPACITY Size of wire rope 5 8 in 6 914 ft 2 107 3 4 in 4 830 ft 1 472m 7 8 in 3 598 ft 1 097 m 1in 2 706 ft 825m MAXIMUM OPERATING PRESSURE 2500 psi 172 bar MAXIMUM OPERATING VOLUME 115 US 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 6 601 Ib 29 4 kN MAXIMUM ALLOWABLE LINE PULL WHEN LOWERING Bare drum 5 353 Ib 23 8 kN Full drum 1 4141 6 3 KN HOISTING LINE SPEED AT MAXIMUM VOLUME Bare drum 140 fom 43 m min Full drum 528 fpm 162 m min LOWERING LINE SPEED AT MAXIMUM VOLUME Bare drum 651 fpm 198 m min Full drum 2 467 fom 759 m min PERMISSIBLE SYSTEM BACK PRESSURE AT MOTOR RETURN PORT 65psi 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 EA 342 REV 021030 PAGE 5 PERFORMANCE GRAPHS
27. h 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 service
28. 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 Carefully slide motor drive shaft item 730 into the connecting shaft until it engages the spline of the primary sungear 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 A A PAGE 18 342 REV 020331 SERVICE INSTRUCTIONS conrmueo 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 al
29. 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 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 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 H30 winch 342 REV 020331 PAGE 13 SERVICE INSTRUCTIONS GENERAL Before attempting disassembly of the PULLMASTER Model H30 planetary winch the following instructions for disassembly and reassembly should be read and understood Itis suggested that all expendable parts such as O rings and oil seals are not reused on reassembly Itis 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 inc
30. l 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 AE PAGE 2 342 REV 040708 EXPLANATION OF MODEL CODING H 30 X XX XX BASIC UNIT SERIES E H 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 51 10inch drum diameter X 42
31. l 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 875 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 Presstheotherthrustplate 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 Ib 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 maxi
32. luded 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 on 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 mustbe replaced Thoroughly clean parts before reassembly Do notuse solventto clean the brake friction plates During reassembly lubricate all O rings and oil seals with grease before installation Inthefollowingservice instructions referenceto parts is made by numbers and shownonthe 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 H30 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 Ifthe 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 Remove the eight hex capscrews item 951 together
33. luid 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 H30 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 Itis 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 ofthe PULLMASTER planetary winch basedonareturn 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 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
34. mum 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 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 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 342 REV 020331 PAGE 19 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 2 3 4 5 6 Disconnect all hydraulic hoses and remove the winch from its mounting Disassemble the winch as per in
35. ng flange and secure with retaining ring item 534 2 Press bearing flange assembly onto brake housing item 700 and install new well greased O ring item 539 3 Pressa new well greased oil seal item 711 into bore of brake housing item 700 4 Pressanew well greased oil seal item 607 into bore of connecting shaft item 600 followed by needle bearing item 603 5 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 H 342 REV 020331 PAGE 17 SERVICE INSTRUCTIONS 6 Place thrust bearing item 435 held between two thrust washers item 433 onto internal gear item 430 and fasten internal gear onto connecting shaft using circlip item 431 7 Reassemble primary planet hub assembly Use grease to temporarily hold 15 loose rollers item 423 inthe 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 b
36. oil Fortemperatures beyond normal operating range consult lubricating oil supplier orfactory 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 importantto 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 aseparate pressure relief valve must be installed andsetatthe recommended maximum pressure 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 f
37. ow 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 pressure relates to the line pull or lifting capacity of the winch If the winch will notliftthe 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 openthe control valve Checkthe hydraulic pressure reading ofthe installed pressure gauge Ifthe 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 reservoir is 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 SPECIFIC
38. r 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 18 Use only recommended hydraulic oil and gear reading and understanding manufacturer s lubricant Instructions 19 Keep hydraulic system clean and free from 2 The winch described herein is not designed for contamination at all times operations involving lifting or moving personnel 20 Maintain winch and equipment in good operating 3 Do not lift or carry loads over people condition Perform scheduled maintenance regularly 4 Do not exceed recommended operating pressure 21 Keep hands clear when winding wire rope onto psi and operating volume gpm the winch drum 5 Do not jerk the winch Always smoothly 22 not use the wire rope as a ground for welding accelerate and decelerate load 23 Rig the winch carefully Ensure that the wire rope 6 Do not operate a damaged noisy or is properly anchored to the correct cable anchor slot at malfunctioning winch the cable drum Do not leave a load suspended for any extended 24 not lift a load with a twisted kinked or period of time damaged wire rope 8 Never leave a suspended load unattended 25 Consult wire rope manufacturer for size type and 9 Winch should be maintained and operated by maintenance of wire rope qualified personnel 26 Maintain five wraps o
39. rts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored 342 REV 020331 PAGE 27 o lt Y 2 O lt Q lt d lt o E 11092 B 876 BLE 00672 081 vob 09 ES 3dOH 34 IM 3 EPA G 9 8 2 OL 91 2 ATEVLINS PA Lee SI d 18VO QHVONVIS Str ey LS 3009 9 v 28015 HO NOILONULSNI NOILVTIVLSNI OL 43438 XX YOLOW AHL LV 9ND4OO GAHSINEVLSS SI NOILVLOY JO NOLLO38IO S1709 ONILNNOW zg v L 1 ISN ldNrL v LHOd 4311398 HO AGVYD 1dNZ3 8 1 1HOd 38431384 IVNy3 1X3 TWNOILdO NOILVLOW ASIMMOOTOYALNNOOD AZIYNSSAYd ONv E SMAYOS t 97 ret 9 6r SNOISNAWIG NOLLWTIVLSNI 26 6 SITOH DNILNMON 0921 1HOd La Y gt g NOLLWINDHIO 5 ico 8 3 057256 982 09 ey Crez 221 D el ee NINO STICOMN NOLLWINIOHIO TVNH31X3 1dN81 8 L4Od 89 NOLLV LOH 3SIMA9019 AZIYNSSAYd 193009 0 JONVIS 1108 JYS AdN t L 2 L 1HOd Ygl
40. seals Unless otherwise specified torque fasteners per BOLT TORQUE CHART at back of manual REASSEMBLY OF FINAL DRIVE Reassemble final drive end of winch as follows 1 Pressa new well greased oil seal item 105 into final housing item 100 2 Press ball bearing item 103 into final housing and secure with retaining ring 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 Use grease to temporarily hold 24 loose rollers item 323 in the bore ofthe 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 5 Insertfinal planet hub assembly into final housing item 100 Ensure thatfinal planet hub spline is fully engaged with cable drum item 500 6 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 7 Install end cover item 120 into final housing item 100 and fasten with eight hex capscrews item 127 and lockwashers item 129 REASSEMBLY OF PRIMARY DRIVE Turn winch over resting on end cover with cable drum opening facing up Reassemble primary drive as follows 1 Pressa new well greased oil seal item 531 into bearing flange item 530 Press ball bearing item 533 into beari
41. structions Discard and replace all O rings and oil seals Clean all parts and inspect for wear and damage as per instructions Replace worn or damaged parts as required Reassemble the winch as per instructions Follow INSTALLATION and OPERATING INSTRUCTIONS when returning winch to its mounting When ordering parts forthe PULLMASTER Model H30 planetary winch always quote the complete model and serial number of the unit MODEL NO SERIAL NO PULLMASTERWINCH 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 20 342 REV 020331 ASSEMBLY DRAWING G1190 A amp G1195 amp G1002 342 REV 080608 PAGE 21 PARTS REFERENCE FINAL DRIVE DESCRIPTION FINAL HOUSING BALL BEARING 6026 BEARING RETAINER OILSEAL ENDCOVER PIPE PLUG 3 4 14 NPT SUNGEAR STOPPER O RING 281 15 ID 1 8 CS PLANET HUB STOPPER CAPSCREW HEXHEAD 3 8 16NC X 1 25 GRADE 5 LOCKWASHER 3 8 BREATHERRELIEF ASSEMBLY PLANETHUB PLANET PIN CIRCLIP ROTOR CLIP SH 168 PLANET GEAR THRUST WASHER TORRINGTON TRB 2840 LOOSE ROLLER TORRINGTON G613 SUNGEAR CIRCLIP ANDERTON A1000 0237 CABLE DRUM CABLE ANCHOR PIPE PLUG 1 2 14 NPT CIRCLIP ROTOR CLIP SH 500 BASE PLATE CAPSCREW HEXHEAD 5 8 11NC X 1 75 GRADE 5 LOCKWASHER 5 8 TIEBAR N m 1 1 1 1 1 2 1 1 1 8 8 1 1 3
42. t 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 Ifthe 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 drum to fill up with hydraulic fluid In orderto prevent potentia
43. the PARTS REFERENCE list should be ignored 342 REV 020331 PAGE 25 PARTS REFERENCE MOTOR GROUP m 1 1 1 3 1 2 1 1 1 1 1 4 2 1 4 2 1 2 4 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 MOTORADAPTOR O RING 013 7 16 ID 1 16 CS PIPE PLUG 1 8 27 NPT PIPE PLUG 1 4 18 NPT GEAR HOUSING 086 DOWELPIN GASKET SEAL PORT END COVER WITH PIPE PLUGS ROLLER BEARING RING SEAL GEAR SET THRUST PLATE TEFLON SEAL SUB ASSY MOTOR 086 CAPSCREW HEX HEAD 5 8 11NC 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 800 802 803 804 805 807 809 861 865 869 870 875 877 881 885 887 929 951 953 AND 955 Refer to PAGE 24 for winch seal kit and PAGE 21 for ASSEMBLY DRAWING PAGE 26 342 REV 020331 MOTOR GROUP mm G1002 D Or PS 2666 806 805 813 Group drawings may reference more parts than are actually presentin a specific assembly Pa
44. 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 transaction s subj
45. 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 third parties
46. 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 bearings 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 of the motor adaptor item 800 Thrust plate item 885 and dowel pins item 865 may stay in the gear housing 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 at this 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 Seo NI PAGE 14 342 REV 020331 SERVICE INSTRUCTIONS continuep motor with the exception of the motor adaptor item 800 and the port end cover item
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