Model M75 Service Manual
Contents
1. JL LE LLLI LLLI LLLI LLI 0 0 20 40 60 80 100 120 140 160 LINE SPEED Performance graphs are based on standard hydraulic motor gear ratio and cable drum with 1 1 8 inch diameter wire rope 354 REV 030819 PAGE 7 TYPICAL HYDRAULIC CIRCUIT HC H M75 STD EXTERNAL BRAKE RELEASE 800 PSI 55 BAR AT 1 L MIN at EE LA mi z z e CIRCULATION SUPPLY LINE H75 9 US GPM 34 L MIN M75 7 US GPM 26 L MIN CONTROL VALVE MOTOR SPOOL 4 WAY SPRING jc eed RETURN TO CENTER e cos 595 l PRESSURE 25 0 RELIEF VALVE 2 O gu 5 lt CS FILTER HYDRAULIC ROMP RESERVOIR PAGE 8 354 REV 030819 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 t2. il f 0 2 LIA 0 0 7500 15000 22500 30000 37500 45000 52500 60000 67500 75000 LINE PULL Ib LINE SPEED VS OIL VOLUME LINE SPEED m min 0 6 12 18 24 30 36 42 e er WE FD 125 473 100 379 2 i 75 284 5 1 gt gt 50 189 O O 25 95 0 20 40 60 80 100 120 140 LINE SPEED Performance graphs are based on standard hydraulic motor gear ratio and cable drum with 1 1 8 inch diameter wire rope 6 354 REV 030819 PERFORMANCE GRAPHS PG M75 4 MODEL NUMBER 75 191 4 LINE PULL VS OIL PRESSURE LINE PULL kN 0 33 66 100 133 166 200 233 266 200 333 366 400 3000 ITT Tir IIIT 207 _ 2500 B 172 _ U Fu gt LLI 2000 l 138 tc l Y 2 gt o 1500 108 U 2 0 LLI C 7 LLI oc B H a 1000 69 A i 7 4 O 500 34 O 0 LIII Lii 4 0 O 7500 15000 22500 30000 37500 45000 52500 60000 67500 75000 80000 85000 LINE PULL Ib LINE SPEED VS OIL VOLUME LINE SPEED m min 0 6 12 18 24 30 36 42 48 150 568 12 473 5 1 eo 4 2 100 379 wa 3 LU 75 284 gt 2 3 11 50 189 gt gt 3 z O 25 95 0
3. 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 Do not use the wire rope as a ground for welding 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 under tension on the cable drum at all times 27 Incase 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 Clean up any oil spillage immediately 29 Winches should be stored in inside facility 30 Do not store beyond a period of one year without operation because of limited shelf life of rings and oil seals 31 Wear proper clothing and personal protection equipment such as footwear safety goggles and a hard hat Read manual first 6090 354 REV 051117 PAGE 1 DESCRIPTION OF THE MODEL M75 GENERAL DESCRIPTION The PULLMASTER Model M75 is aplanetary hydraulic winch with reversing speeds 4 1 times faster than forward speed The main components of this unit are hydraulic gear motor mu
4. 399 24093 1 SUB ASSY PRIMARY PLANETARY DRIVE 400 24095 1 PLANET HUB HLV30 PRIMARY 410 24094 3 PLANET PIN PL4 FINAL M25 PRIMARY 413 26773 6 CIRCLIP ROTOR CLIP SH 84 420 24096 3 PLANET GEAR HLV30 PRIMARY 421 26772 6 THRUST WASHER TORRINGTON TRC 1427 423 25308 45 LOOSE ROLLER 7 32 DIA X 1 50 444 21809 1 STOPPER SUNGEAR SPEC 224 354 REV 060315 PAGE 19 SERVICE INSTRUCTIONS 6 DISASSEMBLY OF SECONDARY PLANETARY DRIVE item 299 6 1 Remove Circlip item 311 from Planet Pin item 310 and press Planet Pin out of Primary Planet Hub item 300 Remove Primary Planet Gear item 320 together with Loose Rollers item 323 and Thrust Washers item 321 6 2 Inspect Sungear Stopper item 344 for wear replace if thickness is less than 0 44 inch 299 23544 1 SECONDARY PLANETARY DRIVE SUB ASSEMBLY 300 23538 1 PLANET HUB FINAL 310 20406 3 PLANET PIN M25 FINAL 311 25199 6 CIRCLIP ROTOR CLIP SH 168 320 23536 3 PLANET GEAR HLV30 FINAL 321 25167 6 THRUST WASHER TORRINGTON TRB 2840 2 323 25297 7 LOOSE ROLLER TORRINGTON 024054 PAGE 20 354 REV 030819 SERVICE INSTRUCTIONS 7 DISASSEMBLY OF BRAKE HUB SUB ASSEMBLY item 718 71 Disassemble Brake Hub Assembly by removing Circlip item 719 from Motor Drive Shaft item 730 Remove Motor Drive Shaft from Brake Hub item 720 Remove Sprag Clutch Aligners item 722 and 724 and Sprag Clutch item 723 MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES TH
5. 9 3 Check thickness of Planet Hub Stopper item 126 and Sungear Stopper item 122 for excessive wear Replace Planet Hub Stopper if less than 0 25 inch thick and Sungear Stopper if less than 0 44 inch thick 9 4 Insert eye bolts in 3 4 10 UNC Puller holes and remove Final Planet Hub Assembly item 349 from Final Housing item 100 9 5 Pull Final Sungear item 340 out of Cable Drum item 500 1 8 UNC puller holes are provided on both ends of the shaft FOR WIDE DRUMS ONLY NOTE Tapered pin item 342 is installed on the end of Sungear item 340 with Setscrew item 343 to facilitate reassembly of the sungear if installation is from the Final Drive end 10 REMOVAL OF DRUM SEAL item 106 10 1 Remove 18 Capscrews item 551 along with Lockwashers item 553 and remove Final Housing item 100 with Cable Drum item 500 from Base item 550 10 2 To separate Final Housing item 100 and Cable Drum item 500 first remove Circlip item 513 and press the Cable Drum through the Spherical Roller Bearing item 103 Two 1 8 UNC holes inside the final housing are provided for installation of a strong back and hydraulic jack to facilitate this operation PAGE 22 354 REV 030819 SERVICE INSTRUCTIONS 11 DISASSEMBLY OF FINAL PLANETARY DRIVE item 349 If disassembly of Final Planetary Drive is required proceed as follows 11 1 11 2 11 3 11 4 Remove Circlip item 361 from Planet Pin item 360 Press Planet Pin item 3
6. IN H Mise RR RER H 1 fi l v ag 1 il ONILVOIHANT LAN ti v 19 02 1HOd DNILvOIH8N1 PE LHOd NOLLV INOHIO NOLLVLOH SUP 3S8IMA0010 H3LNNOJ 3ziHniss3ud 86 219 H N ANO 3SIMHOO1O 1304 S39VD LH04 3Zlunss3ud HOLOW LV A8 53 on d A SI NOILV LOH ASIMADOTO HALNNO9 HO ASIMA0019 5 TV LV GANIVLNIVW ONIGOO TAGOW JO NOILWNV1dX3 3909 OL H313H NOISN3 L 3dOH ONITINd HO ONILSIOH NOILV LOH 3HL 53 OL 3HIM 40 SdVHM S Y AL34VS 33 354 REV 051117 APPENDIX DRUM CODE PART DESCRIPTION PART NUMBER QUANTITY FINAL HOUSING FINAL SUNGEAR SUNGEAR EXTENSION TAPERED PIN SET SCREW CABLE DRUM BASE PLATE CAPSCREW LOCKWASHER 3 4 TIE BAR PAGE 34 354 REV 030819 APPENDIX BRAKE CODE PART DESCRIPTION PART NUMBER QUANTITY 90 TUBE ELBOW TUBE CONNECTOR SHUTTLE VALVE UNION CAPLUG SAE 6 ORB BRAKE HUB SUB ASSY 354 REV 030819 PAGE 35 BOLT TORQUE CHART BOLT DIAMETER TORQUE TORQUE Inches Lb ft Nm NOTE
7. OLOL PLE 292 2512 9101 6721 6101 229 61821 Le 596 952 912 822 v 1006161 866 006 678 OOP res 802 00989 96 ge vl 11105 029 282 281 1 008 996 zee 198 sez 928 9011 019 906 529 LS 6528 809 218 90 goz 02 zz loose 97 rer see see 229 Ove 992 972 871 Joos zej oz ze 9l 5 n 1 5 d d N W 1 M r H 9 d 2 suorsuswiq ui suoisuauiiq 211 1 SI 3ZIS 3HIM WAWIXVW 9NO1 9L v z NOHH ACISLNO 91 l Z 8 1 S3ZIS SATINYHAS LINS 01 13004 JINHH3H SHIM OML SVH IHL ANY PE 431139 HO 8 430VHD 51108 ONILNNOW w t ASN LHOd DNILVTNOHIO bl 2 L 1HOd 91 8 L 8 1HOd 9 sq 353 1 1 ONY E SM3HOS DNIADVT t gt lt Q lt lt U lt
8. TO APPENDIX B 354 REV 030819 PAGE 29 zj Z gt Ix A SN JE Qe m zk h HIS NET ES 555 20 299 A ASSEMBLY DRAWING RE ee Ge 00 REFER 21 850 16 722 7 27 2 LL 22222 22 22 A GG 8 777277272 r RZE 559 amp N GG moni THESE ITEMS ARE SUB ASSEMBLIES FOR PARTS BREAK DOWN REFER TO PAGE NUMBERS SHOWN THESE ITEMS ARE NOT REQUIRED FOR 1 DRUM CODE 31 EXPLODED VIEW 299 344 tere vo REFER TO PAGE20 P di 850 lt A sa mri REFER sad 21 REFER PAGE 19 THESE ITEMS ARE SUB ASSEMBLIES FOR PARTS L 7 BREAK DOWN REFER TO PAGE NUMBERS SHOWN THESE ITEMS ARE NOT REQUIRED FOR 1 DRUM CODE PAGE 32 354 REV 030819 679 698 81 96 6601 922
9. Unless otherwise specified torque bolts per above chart PAGE 36 354 REV 030819
10. brake primary drive and secondary drive from Secondary Housing item 456 Secondary Sun Gear item 490 may or may not stay with secondary drive 2 2 Remove Secondary Sun Gear item 490 Circlip item 491 and Planet Hub Stopper item 451 PAGE 16 354 REV 030819 SERVICE INSTRUCTIONS 3 DISASSEMBLY OF BRAKE HOUSING AND PRIMARY HOUSING 3 1 Remove 12 Capscrews item 537 and Lockwashers item 541 from Brake Housing item 700 from Primary Housing item 701 Brake Springs item 752 apply pressure against the Primary Housing item701 Itis recommended that Capscrews are unscrewed one turn at atime until spring pressure has been released 3 2 Remove Primary Housing item 701 along with Connecting Shaft item 600 Primary Drive item 399 and Internal Gear item 430 from Brake Housing item 700 3 3 Remove 20 Brake Springs item 752 Replace if springs measures less than 2 21 inches 3 4 Pull Brake Piston item 750 out of the Brake Housing using two 5 8 11UNC bolts screwed into two puller holes in piston and discard O rings item 751 and item 753 3 5 Friction Plates item 715 and 7 Divider Plates item 713 Inspect for damage or wear Plates should be flat and smooth Plates should not show heat discoloration Paper material on friction plates should be intact and grooved If any damage is detected replace friction and divider plates as set DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING CAPACITY AND ALL
11. 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 fumished 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 tensional 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 wear caused by machine or ambient vibration Further Buyer acknowledges and agrees
12. 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 a 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 to property or injury to persons resulting from faulty installation repair or mo
13. 0 8 9 Install Primary Housing item 701 together with Primary Sungear item 440 Primary Planetary Drive item 399 and Connection Shaft item 600 into Brake Housing item 700 8 10 Orientate Primary Housing and Brake Housing in the correct position and fasten with 12 Capscrews item 537 and Lockwashers item 541 Tighten one turn at a time evenly compress springs 8 11 Carefully position Motor Drive Shaft item 730 with Brake Hub Assembly item 718 into Connecting Shaft until it engages spline of Primary Sungear item 440 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 PERINSTRUCTIONS 354 REV 060315 PAGE 25 SERVICE INSTRUCTIONS 8 12 8 13 8 14 8 15 8 16 8 17 8 18 8 19 8 20 8 21 8 22 Starting and finishing with a Divider Plate alternately install 7 Divider Plates item 713 and a6 Friction Plates item 715 Install liberally greased O ring item 707 in groove Brake Housing item 700 Verify Brake Spacer item 712 is installed on Motor Adaptor item 800 and install Motor Adaptor item 800 on Brake Housing item 700 Orientate Motor Adaptor in the correct position and fasten with 12 Capscrews item 537 and Lockwashers item 541 Tighten one turn at a time to evenly compress the Brake Springs Install well greased O ring item 819 in groove of Motor Adaptor
14. 0819 PAGE 3 5 COUNTERCLOCKWISE ROTATION The drum rotation of the standard PULLMASTER Model M75 planetary winch is clockwise for pulling or hoisting when looking at the hydraulic motor of the winch Drum rotation for counterclockwise pulling or hoisting direction 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 the PULLMASTER Model M75 planetary winch may be supplied with optional drums to accommodate large wire rope storage capacity DRUM GROOVING Cable drums for the PULLMASTER Model M75 planetary winch may be grooved Where this optionis 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 M75 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 PULLM
15. 16 ID 1 8 CS LOCKWASHER 1 2 BASE PLATE CAPSCREW HEX HEAD 3 4 10NC X 2 50 GR 5 LOCKWASHER 3 4 TIE BAR CONNECTING SHAFT O RING 239 3 5 8 ID 1 8 CS NEEDLE BEARING TORRINGTON B 3012 354 REV 060315 PARTS REFERENCE BACK UP WASHER OIL SEAL DEAMAR 175225312 HP3 BRAKE HOUSING PRIMARY HOUSING PLASTIC CAPLUG SAE 20 ORB O RING 277 11 1 2 ID 1 8 CS O RING 278 12 ID 1 8 BRAKE SPACER DIVIDER PLATE FRICTIONPLATE SUB ASSEMBLY BRAKE HUB LOCKWASHER 7 8 CAPSCREW HEAD 7 8 X 1 LONG PISTON O RING 90 DURO 451 11 ID 1 4 CS BRAKE SPRING 4 5C 2 270 X 1 230 O RING 90 DURO 452 11 1 2 ID 1 4 CS MOTORADAPTOR PIPE PLUG 1 2 SOC STEEL AIRWAY 5409 8 CAPSCREW SOCKET HEAD 3 8 16 UNC X 1 00 GR 5 LOCKWASHER 3 8 HIGH COLLAR O RING 159 5 ID 3 32 CS MOTOR 191 3 GEAR HOSE ASSY 1 4 ID STRT 4JIC 90 15 LG TUBE 90 ELB 4 JIC X 46 ORB AIRWAY 6801 4 6 SANDWICH GAGE BLOCK 2 CODE 61 ORB 6 PLUG SAE 6 ORB SOC HEAD AIRWAY 6409 6 TUBE CONN 4 JIC X 6 ORB AIRWAY 6400 4 6 O RING 228 2 1 4 ID 1 8 CS SHUTTLE VALVE UNION 6 ORB X 6 ORB PLASTIC CAPLUG SAE 6 ORB PLASTIC CAPLUG SAE 12 ORB PLASTIC CAPLUG 2 0 DAEMAR 21 1 1 1 1 1 1 1 1 7 6 1 2 2 1 1 0 1 1 1 2 2 1 1 1 1 1 1 m THESE PARTS VARY ACCORDING TO DRUM CODE REFER THESE PARTS VARY ACCORDING TO BRAKE CODE REFER
16. 60 out of Planet Hub item 350 Remove Planet Gear item 370 out of Planet Hub item 350 Inspect Loose Rollers item 373 and two Thrust Washers item 371 Replace if necessary wre CG FINAL PLANETARY DRIVE SUB ASSEMBLY 349 23750 1 SUB ASSY FINAL DRIVE 350 23751 1 PLANET HUB H M75 FINAL 360 21027 4 PLANET PIN M50 FINAL 361 25678 8 CIRCLIP ROTOR CLIP SH 215 370 21010 4 PLANET GEAR M50 FINAL 371 25677 8 THRUST WASHER INA AS 5578 373 26630 120 LOOSE ROLLER 354 REV 030819 PAGE 23 SERVICE INSTRUCTIONS REASSEMBLY Thoroughly clean all parts Use only new well greased O rings and oil seals Unless otherwise specified torque fasteners per BOLT TORQUE CHART at back of manual 1 REASSEMBLY OF FINAL PLANETARY DRIVE ITEM 349 Refer to Page 23 for item numbers Use grease to temporarily hold 30 Loose Rollers item 373 in bore of Planet Gear item 370 Position Thrust Washers item 371 on either side of Planet Gear Press Planet Pin item 360 into Final Planet Hub item 300 and retain with Circlips item 361 2 REPLACEMENT OF OIL SEAL item 106 2 1 Press new Oil Seal item 105 into End Housing item 100 to inside edge of Circlip groove and install Circilp item 106 2 2 Verify Spherical Roller Bearing item 103 and Circlip item 104 are installed in Final Housing item 100 2 3 Stand Cable Drum upright on the Flange and lower End Housing item 100 carefully onto the Cable Drum while locating the Spherica
17. ASTER Model M75 planetary winch with 191 motoris limited to 3000 psi 270 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 coupling 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 4 354 REV 030819 SPECIFICATIONS Performance specifications are based on standard 191 hydraulic motor and gear ratio with 1 1 8 inch diameter wire rope For other cable drums reductions or motors refer to supplement inside back cover Performance specifications for winches supplied with optional motors are provided in attached supplement DRUM CODES CABLE DRUM DIMENSIONS Barrel diameter Flange diameter Barrellength 16 0 in 406 mm 32 0 in 813 mm 20 0 in 508 mm 14 0 in 356 mm 38 0 in 965 mm 36 0 in 914 mm CABLE STORAGE CAPACITY size of wire rope 1in 11 8 11 4 907 ft 276 m 727 ft 221 m 559 ft 170 m 2489 ft 759 m 2104 ft 641 m 1503 ft 458 m MAXIMUM OPERATING PRESSURE 3000
18. E MOTOR DRIVE SHAFT AND BRAKE HUB WILL RESULT IN BRAKE FAILURE AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH THROUGHLY INSPECT THESE AREAS AND IF NECESSARY REPLACE MOTOR DRIVE SHAFT SPRAG CLUTCH AND BRAKE HUB AS ASET BRAKE HUB SUB ASSEMBLY 718 lt 1 SUB ASSEMBLY BRAKE HUB 719 23536 1 CIRCLIP ROTOR CLIP SH 187 720 23865 1 BRAKE HUB 722 20455 1 SPRAG CLUTCH ALIGNER 723 25303 1 SPRAG CLUTCH 724 20421 1 SPRAG CLUTCH ALIGNER RIGHT 730 23810 1 MOTOR DRIVE SHAFT PART NO VARIES ACCORDING TO BRAKE CODE REFER TO APPENDIX 354 REV 030819 PAGE 21 SERVICE INSTRUCTIONS 8 REMOVAL OF DRUM SEAL item 531 8 1 Remove Circlip item 344 from Final Sungear item 340 or from Coupling item 341 if present 8 2 Remove 18 Capscrews item 551 along with Lockwashers item 553 from Secondary Housing item 456 to separate Base item 550 from Secondary Housing 8 3 Pull Secondary Housing item 456 out of Cable Drum item 500 along with Coupling item 341 if present 8 4 Check thicknees of Sungear Stopper item 122 for excessive wear Replace if less than 0 44 thick 8 5 Remove Retaining Ring item 532 and pull Oil Seal item 531 out of Cable Drum item 500 9 DISASSEMBLY OF FINAL DRIVE 9 1 Remove 12 Capscrews item 537 along with 12 Lockwashers item 541 from End Cover item 120 9 2 Remove End Cover item 120 from End Housing item 100 and discard O ring item 123
19. EATH TO ENSURE PROPER REINSTALLATION REFER TO PROCEDURES AND TESTS DESCRIBED IN INSTALLATION AND OPERATING INSTRUCTIONS PAGE 26 354 REV 030819 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 Follow INSTALLATION and OPERATING INSTRUCTIONS when returning winch to its mounting Please record for future reference a complete model and serial number from the nameplate of the Pullmaster Model M75 planetary winch Quote complete model and serial number when ordering parts MODEL NUMBER SERIAL NUMBER PULLMASTER WINCH CORPORATION reserves the right to change specifications andthe design of PULLMASTER planetary winches at any time without prior notic
20. ERE INJURY OR DEATH Afterthe PULLMASTER planetary winch has beeninstalledin accordance with the INSTALLATIONINSTRUCTIONS 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 the manufacturer s handling inspection and maintenance recommendations to avoid potential accidents For selection of ropes etc please check the following product standards DIN 15020 prEN 818 1 9 prEN 1492 1 2 prEN 1677 1 3 and other relevant product standards 1 Thecable drum ofthe PULLMASTER planetary winch has two pockets for wire rope ferrules one for clockwise and one for counterclockwise hoisting Standard rotation for hoisting is clockwise when looking atthe hydraulic motor of the unit It is critical to select the ferrule pocket which will permit winding of the wire rope on the drum inthe correct direction of rotation If the wire 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 warning label onthe drum indicating the correct cable anchor ferrule pocket and direction of hoisting CABLE DRUM FLANGE WIRE ROPEINSTALLATION Clockwise hoisting winch shown FERRULE Use ferrule pocket on opposite side of drum for counterclockwise hoisting winch FERRULE POCKET CLOSEST TO MOTOR FOR CLOCKWISE ROTATION Attach ferrule to rope per manufact
21. INSTRUCTION AND PARTS MANUAL MODEL M75 PLANETARY HYDRAULIC WINCH Pulis MASTER A COMPANV THE LOGICAL CHOICE PULLMASTER WINCH CORPORATION 8247 130th Street Surrev V3W 7 4 Canada Telephone 604 594 4444 Fax 604 591 7332 Website www pullmaster com E mail sales pullmaster com 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 354 070228 Pullmaster Limited Warranty Effective 8 1 2008 SUPERSEDES ALL PRIOR WARRANTIES 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 which are being purchased that Buyer has reviewed this Warranty and that the remedi
22. 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 pressure 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
23. OTE FOR ALL DRUMS EXCEPT 1 MEASURE GAPS BETWEEN HOUSINGS AND DRUM FLANGES TIE BAR JACKING SCREW i jq l i DETAIL FOR 1 DRUM 9 14 mae JACKING SCREW D d i 6 d GAP D 1 JACKING SCREW je je L JACKING SCREW A 3 If Gap A is within 0 01 to Gap B and Gap C is within 0 01 to Gap D proceed to step 5 If Gaps are outside this limit proceed to step 4 Note Difference between Gaps A and B and Gaps C and D may not be equal PAGE 10 354 REV 030819 INSTALLATION INSTRUCTIONS Gaps can be adjusted as required by adjusting Jacking Screw diagonally opposite to the Gap Reduce a gap by turning Jacking Screw clockwise or increase a gap by turning Jack Screw counterclockwise To adjust Gap TURN Jacking Screw A To adjust Gap B TURN Jacking Screw To adjust Gap C TURN Jacking Screw To adjust Gap D TURN Jacking Screw 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 b
24. OW 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 3 6 Thoroughly examine bores of Brake Housing and outer diameters of Brake Piston for scoring caused by contamination By polishing with fine emery cloth minor surface damages of brake housing bore and or piston outer diameter may be repaired 3 7 Remove Brake Hub Sub assembly item 718 3 8 Remove Retaining Ring item 432 Primary Drive item 399 and Primary Sungear item 440 from Primary Internal Gear item 430 3 9 Remove Circlip item 431 and Primary Internal Gear item 430 along with Spacer item 434 from Connecting shaft item 600 3 10 Remove Connecting Shaftitem 600 from Primary Housing item 701 Remove and discard O ring item 601 3 11 Remove and discard Oil Seal item 607 and Backup Washer item 606 if present from bore of Connecting Shaft Inspect Needle Bearing item 603 and replace if necessary Brake Housing and all brake related components are now disassembled Inspect all parts before re assembling 354 REV 030819 PAGE 17 SERVICE INSTRUCTIONS 4 DISASSEMBLY OF BRAKE PLATES ONLY If removal of Brake Piston and Hydraulic Motor is not necessary proceed as follows 4 1 4 2 4 3 4 4 Disconnect Brake Hose item 852 Remove 12 Hex He
25. ad Capscrews item 537 and Lock Washers item 541 from Motor Adaptor item 800 Itis recommened thatthe capscrews be unscrewed one turn until spring pressure has beenreleased Carefully withdraw Motor Adaptor item 800 complete with Brake Spacer item 712 and Motor item 850 from Brake Housing item 712 Remove 12 Friction Plates item 715 and 13 Divider Plates item 713 Inspect for damage or wear Plates should be flat and smooth Plates should not show heat discoloration Paper material on friction plates should be intact and grooved If any damage is detected replace friction and divider plates as a set 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 PAGE 18 354 REV 030819 SERVICE INSTRUCTIONS 5 DISASSEMBLY OF PRIMARY PLANETARY DRIVE item 399 If primary Planet Gears item 420 must be removed proceed as follows 5 1 Remove Circlip item 413 from Planet Pin 410 and press Planet Pin out of Primary Planet Hub item 400 Remove Primary Planet Gear item 420 together with Loose Rollers item 423 and Thrust Washers item 421 5 2 Inspect Primary Sungear Stopper item 444 for wear replace if thickness is less than 0 21 inch
26. assembly of the PULLMASTER model M75 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 15 therefore important to have a seal kit Part No 23839 on hand before the unit is taken apart NOTE Oil seal must be installed with backup washer if included with the seal kit absence of backup washer in a seal kit indicates no back up washer required for oil seals 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 must be 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 In the following service instructions reference to parts is made by numbers and shown on the applicable drawing and or on the assembly drawing DISASSEMBLY For the majority of required service or repair work disassembly may be required only on the brake housing of the PULLMASTER Model M75 planetary winch Since the parts are heavy appropriate care should be taken during disassembly and reassembly Puller holes are provided on the parts for safety use of proper eye bolts or any other safe m
27. dification 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 subject thereto and the Province of British Columbia shall be the exclusive forum and ju
28. e and without incurring any obligations 354 REV 030819 PAGE 27 28 26631 26634 25511 23841 23846 25237 23817 26638 23805 25158 20677 5 1 1 1 1 1 1 6 2 1 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 0 1 2 2 2 1 1 1 FINALHOUSING BEARING SPHER ROLLER 23948 OR EQ CIRCLIP ROTOR CLIP DHO 320 OIL SEAL 10 000 X 11 250 X 625 RETAINING RING INT 5 32 X 1 4 X 11 5 OD END COVER PIPE PLUG 3 4 NPT SOC STEEL AIRWAY 5409 12 SUNGEAR STOPPER O RING 392 23 ID 3 16 CS PLANET HUB STOPPER FINAL CAPSCREW HEX HEAD 1 2 13NC X 1 75 GR 5 BREATHER RELIEF ASSEMBLY SUB ASSEMBLY SECONDARY PLANETARY DRIVE SUNGEAR H M75 FINAL SUNGEAR EXTENSION TAPERED PIN SET SCREW 1 8 UNC X 2 LG CIRCLIP ROTOR CLIP SH 500 SUB ASSY FINAL PLANETARY DRIVE SUB ASSY PRIMARY PLANETARY DRIVE INTERNAL GEAR H M30 PRIMARY CIRCLIP ROTOR CLIP SH 300 RETAINING RING INTERNAL SPACER SUNGEAR PRIMARY PLANET HUB STOPPER SECONDARY SECONDARY HOUSING PIPE PLUG 3 8 SOC STEEL AIRWAY 5409 6 SUNGEAR SECONDARY CIRCLIP ROTOR CLIP SH 237 CABLE DRUM RETAINER CAPSCREW SOCKET HEAD 3 8 16UNC X 1 0 GR 5 LOCKWASHERS 3 8 CIRCLIP ROTOR CLIP SH 950 OIL SEAL 8 500 X 10 000 X 562 RETAINING RING INT 5 82 X 1 4 X 10 88 OD BEARING SPHER ROLLER SKF 23936 CC OR EQ CAPSCREW HEX HEAD 1 2 13NC X 1 50 GR 5 O RING 282
29. e 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 onthe end cover The breather relief bleeds to atmosphere and serves as a warning signal that the oil seal between brake housing and drum has been damaged PAGE 2 354 REV 030819 EXPLANATION OF MODEL CODING BASIC UNIT SERIES Equal Speed SIZE OF UNIT REDUCTION RATIO Only used for non standard reduction ratios TYPE OF BRAKE 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 191 Hydraulic motor 3 inch gear section 12 3 cubic inch displacement Other gear sections for this motor are optional DRUM SIZE 1 16 inch drum diameter X 32 inch flange diameter X 20 inch length 4 14inch drum diameter X 35 inch flange diameter X 36 inch length OPTIONS DESIGN REVISION SPECIFICATION NUMBER Describes features not identified by preceding codes NOTE Clockwise and counterclockwise drum rotation is the direction of rotation for pulling or hoisting established by looking at the hydraulic motor 354 REV 03
30. eans must be used for handling parts during assembly and disassembly of the winch DRAIN OIL FROM THE WINCH To drain hydraulic oil from the Brake Housing item 700 remove Pipe Plug item 801 To drain gear lube oil from the Primary Housing item 701 and Secondary Housing item 456 remove Pipe Plugs item 121 and 457 To drain gear lube oil from the Final Housing item 100 and Cable Drum item 500 remove Pipe Plug item 121 from End Cover item 120 and Cable Drum item 500 Proceed with the disassembly after draining the oil from the winch as described below 354 REV 030819 PAGE 15 SERVICE INSTRUCTIONS conrnueo 1 REMOVAL OF HYDRAULIC MOTOR Refer to Parts Reference APPENDIX B for item numbers 1 1 Disconnect Brake Hose item 852 from Motor item 850 1 2 Remove 4 Capscrews item 127 along with Lockwashers item 541 and carefully remove motor from Motor Adaptor item 800 Motor Drive Shaft item 730 may stay on motor shaft 1 3 Discard O Ring item 819 These parts and description vary according to brake code Refer to APPENDIX B Install these parts as shown for clockwise hoisting Install on opposite motor port for counter clockwise hoisting HYDRAULIC MOTOR 2 REMOVAL OF BRAKE PRIMARY AND SECONDARY DRIVE SUB ASSEMBLIES Refer to Assembly drawing for item numbers 2 1 Remove 12 Capscrews item 537 along with 12 Lockwashers item 541 connecting Secondary Housing item 456 and Primary Housing item 701 Pull Brake Group
31. es 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 This Warranty shall not apply to any article which has been repaired altered or
32. he 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 DRAWING for location of lubricating oil fill port Refer to SPECIFICATIONS 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 at the 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 f
33. inner race of Spherical Roller Bearing item 532 Note For 4 and wide drums install Coupling item 341 onto Final Sungear item 340 before installing Secondary Housing item 456 4 7 Install Circlip item 344 in groove of Final Sungear item 340 or Coupling item 341 if present 4 8 Mount Secondary Housing item 456 to Base item 550 and fasten with 18 Capscrews item 551 and lockwashers item 553 Attach Tie Bars item 566 using 10 Capscrews item 551 and Lockwashers item 553 Note 12 capscrews are required for 4 and other wide drums 5 REASSEMBLY OF SECONDARY PLANETARY DRIVE ITEM 299 Refer to Page 20 for item numbers 5 1 Use grease to temporarily hold 24 Loose Rollers item 323 in bore of Planet Gear item 320 Position thrust washers item 321 on either side of Planet Gear Press Planet Pin item 310 into Planet Hub item 300 and retain with Circlip item 311 PAGE 24 354 REV 030819 SERVICE INSTRUCTIONS 6 REASSEMBLY OF PRIMARY PLANETARY DRIVE ITEM 399 Refer to Page 19 for item numbers 6 1 If removed install Primary Sungear Stopper 444 into Planet Hub item 400 6 2 Use grease to temporarily hold 15 Loose Rollers item 423 in bore of Planet Gear item 420 Position Thrust Washers item 421 on either spline side of Planet Gear Press Planet Pin item 410 into Planet Hub item 300 and retain with Circlips item 413 7 REASSEMBLY OF BRAKE HUB SUB ASSEMBLY ITEM 718 Refer to Page 21 for item numbe
34. item 800 and an Install Motor item 850 with 4 Capscrews item 127 and Lockwashers item 541 Install Secondary Planetary Drive item 299 in Secondary Housing item 456 while engaging spline end of Final Sungear item 340 or spline end of coupling item 341 if present Coupling item 341 is required for 4 and other wide drums Verify Sungear Stopper item 122 is in place and install Secondary Sungear item 490 through center of Planet Gears item 320 complete with Planet Hub Stopper item 451 and Circlip item 491 Install well greased O ring item 539 in Secondary Housing item 456 Lower Primary Housing item 701 and Brake Group Brake Primary Drive along with motor onto Secondary Housing item 456 while engaging spline end of Secondary Sungear item 490 Orientate Housing in the correct position and fasten with 12 Capscrews item 537 and Lockwasher item 541 Return winch to horizontal position and reinstall Brake Hose item 852 and Breather Relief item 130 in End Cover item 120 IMPORTANT Before operating the winch add lubrication oil up to the level of the end cover oil fill port Refer to INSTALLATION DRAWING for location of fill port Refer to SPECIFICATIONS for oil volume required To ensure proper reassembly run the winch in both directions without load LIFTING A LOAD WITH A NEWLY SERVICED WINCH WILL ENABLE AN INSTALLATION OR SERVICE PROBLEM TO GO UNDETECTED AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR D
35. l Roller Bearing item 103 squarely on the Drum Hub and press the Cable Drum item 500 into Spherical Roller Bearing item 103 and secure with Circlip item 513 2 4 If Base item 550 and Final Housing item 100 have been separated assemble both parts using 18 Capscrews item 551 and Lockwashers item 553 3 REASSEMBLY OF FINAL DRIVE 3 1 Insert Final Planetary Drive item 349 into Final Housing item 100 Ensure that Final Planet Hub spline is fully engaged with Cable Drum item 500 3 2 Install new well greased O ring item 123 on End Cover item 120 3 3 Verify Planet Hub Stopper item 126 and Sungear Stopper item 122 are installed onto end cover 3 4 Attach end cover item 120 to End Housing item 100 using 12 Capscrews item 537 and Lockwashers item 541 4 REPLACEMENT OF OIL SEAL ITEM 531 Turn winch over resting upright on End Cover item 120 Press new Spherical Roller Bearing item 533 into Cable Drum item 500 if being replaced Press new Oil Seal item 531 into Cable Drum item 500 to inside edge of retaining ring groove 4 3 Install Retaining Ring item 532 Insert Final Sungear item 340 through Cable Drum with eye boltinstalledin 1 8 UNC hole in end shaft while engaging the four Planet Gears item 370 4 5 For 4 and wide drums install Tapered Pin item 342 and Setscrews item 343 in Final Sungear item 340 4 6 Lower Secondary Housing item 456 into Cable Drum item 500 until shoulder on housing is firmly seated against
36. l description of the hydraulic winch is not allowed without written permission from PULLMASTER 1 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 not lift or carry loads over people 4 not exceed recommended operating pressure psi and operating volume gpm 5 Donotjerkthe winch Always smoothly accelerate and decelerate load 6 Donotoperate a damaged noisy or malfunctioning winch 7 notleave 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 Do not weld any part of the winch 14 Verify gear lubrication and brake circulation supply and return before operating winch 15 Be sure 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 19 Keep hydraulic system clean and free from contamination at all times
37. low 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 and set at the 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 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 M75 planetary winch Pressure lines Circulation return line Circulation supply line Equivalent to SAE 100R12 32 Equivalent to SAE 100R4 20 Equivalent to SAE 100R6 12 recommended that a larger size of hydraulic hose is installed where the pre
38. lti disc brake with static and dynamic function primary planet reduction secondary planet reduction final planet reduction brake housing final drive housing cable drum FUNCTION IN FORWARD ROTATION HOISTING In forward rotation or when the winch is pressurized for hoisting 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 secondary reduction stage by the secondary sungear which is splined to the primary planet hub The final sungear is splined to the secondary planet hub and transmits the output torque and rpm of the secondary reduction stage to the final planet reduction stage The final planet hub is splined onto the cable drum 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 sungear 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 Inreverse rotation orwhen the winch is pressurized for lowering of a load hydraulic pressure from the reverse 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 spring
39. olts for bolt size and grade refer to INSTALLATION DRAWING Tighten mounting bolts per BOLT TORQUE CHART Fill the winch with lubricating oil up to Oil Level Plug on End Cover or see SPECIFICATIONS 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 inside the brake housing measured at the Circulation Supply Port does not exceed the permissible pressure stated in SPECIFICATIONS 10 Verify that Breather Relief item 130 isin place on End Cover item 120 above oil level Rotate End Cover if Breather Relief is below oil level IMPORTANT Donotreplace 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 354 REV 030819 PAGE 11 OPERATING INSTRUCTIONS FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL RESULT IN PROPERTY DAMAGE SEV
40. psi 207 bar 3000 psi 207 bar MAXIMUM OPERATING VOLUME 142 us gpm 538 l min 142 us gpm 538 l min MINIMUM OPERATING VOLUME 30 us gpm 114 l min 30 us gpm 114 l min DRUM TORQUE AT MAXIMUM PRESSURE 642 183 Ib in 72 556 Nm 642 183 Ib in 72 556 Nm DRUM RPM AT MAXIMUM VOLUME 16rpm 16rpm HOISTING LINE FULL AT MAXIMUM PRESSURE Bare drum Full drum 75 000 Ib 330 kN 41 748 Ib 185 8 kN 85 000 Ib 374 kN 35 166 Ib 154 7 kN HOISTING LINE SPEED AT rece MAXIMUM VOLUME Full drum 72 21 9 m min 129 fpm 39 3 m min 64 19 5 m min 154 47 m min PERMISSIBLE SYSTEM BACK PRESSURE AT MOTOR RETURN PORT 65 psi 4 5 bar 65 psi 4 5 bar PERMISSIBLE PRESSURE AT CIRULATION SUPPLY PORT 30 psi 2 bar 30 psi 2 bar LUBRICATING OIL VOLUME Refer to RECOMMENDATIONS for viscosity and instructions 354 REV 040901 13 US Gallons 49 Liters 15 US Gallons 57 Liters PAGE 5 PERFORMANCE GRAPHS MODEL NUMBER M75 X 191 1 LINE PULL VS OIL PRESSURE PG M75 LINE PULL kN 0 33 66 100 133 166 200 233 266 300 333 3000 2500 a S 2000 1 LLI LLI oc oc m 2 1500 op D D oc oc 1000 A O O 500 0 3 fff qr
41. 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 pressure as listed in SPECIFICATIONS See INSTALLATION INSTRUCTIONS Cable sheaves 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 volume as listed in SPECIFICATIONS See 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
42. risdiction 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 Note Prices and specifications contained in this price book are subject to change without notice US DIST 01 01 07 PULLMASTER LOGO TABLE OF CONTENTS SAFETY nennen 1 DECRIPTION OF THE MODEL 79 aras cnini nau rk ua san 2 EXPLANATION OF THE MODEL CODING eene 3 4 x zeige ge i M 5 PERFORMANCE GRAPHS 2200509 ain ub ons nsa sarta and nra en da Rn Adan 6 7 TYPICAL HYDRAULIC CIRCUIT iii iii OGG ion 8 RECOMMENDATIONS 9 INSTALATION INSTRUCTIONS 10 11 OPERATING INSTRUCTIONS ono 12 TROUBLE SHOOTING a 13 14 SERVICE INSTRUCTIONS cris enata van cit i a dax uda na 15 26 RECOMMENDED MAINTENANCE eene 27 PARTS REFERENCE and ich 28 29 ASSEMBLY DRAWING AND EXPLODED 30 31 INSTALLATION DRAWINQ iiccis cesa evan cua nd na kg xis
43. rs Install Sprag Clutch item 723 into bore of Brake Hub item 720 Position Sprag Clutch Aligners item 722 and item 724 on either side of Brake Hub Carefully slide Motor Drive Shaft item 730 into Brake Hub Assembly and secure with Circlip item 719 IMPORTANT Forproper brake function verify that 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 counter clockwise direction 8 REASSEMBLY OF BRAKE PRIMARY AND SECONDARY DRIVE SUB ASSEMBLIES 8 1 Press Needle Bearing item 603 into Connection Shaft item 600 8 2 Press Backup Washer item 606 and Oil Seal item 607 into bore of Connecting Shaft item 600 8 3 Install new well greased O ring item 601 into groove of Connecting Shaft item 600 and install Connecting Shaft item 600 in splined bore of Primary Housing item 701 8 4 Install Primary Internal Gear item 430 together with Spacer item 434 onto Connection Shaft item 600 and secure with Circlip item 431 8 5 Slide Primary Planetary Drive item 399 together with Primary Sungear item 440 into internal Gear item 430 and secure with Retaining Ring item 432 8 6 Liberally grease O ring item 751 and 753 and install on Brake Piston item 750 8 7 Slide Brake Piston item 750 into Brake Housing item 700 8 8 Install 20 Brake Springs item 752 in Piston item 750 and well greased O ring item 708 in Brake Housing item 70
44. s The pressure required to release the brake is 400 800 psi 28 55 bar The over running clutch connecting the motor drive shaft to the brake assembly locks causing the brake disks to rotate between divider plages which are engaged into the brake housing If the load on the cable drum tends to affect the lowering speed the resulting pressure drop in the brake piston causes friction between the brake discs and the 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 externally 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 pressure in the brake housing be permitted to exceed 30 psi 2 bar Excessive pressure in the brake housing will damage the oil seal separating the brake housing from the drum interior Damage to this seal will cause the drum to fill up with hydraulic fluid In order to prevent potential damag
45. ssure lines or the circulation lines are excessively long HYDRAULIC FILTER Hydraulic filter recommendations for the hydraulic circuit ofthe PULLMASTER planetary winch based on areturn line filter are given as follows 10 microns 5 microns Average Atmosphere Dusty Atmosphere Inorderto 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 EN 418 354 REV 030819 PAGE 9 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 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 Makecertain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted 2 Setthe winch on the mounting platform and check Gap B C and D SI1094 2 N
46. taba Ea kw Ret akk ac 32 APPENDIX DRUM CODES kesa imdawrin ian 33 APPENDIX B BRAKE CODES 2 ina dwana rara auos 34 BOLT TORQUE CHART 35 354 REV 030819 SAFETY RECOMMENDATIONS Definition Caution indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury A wen JA FAILURE TO COMPLY WITH THE FOLLOWING SAFETY RECOMMENDATIONS AND LOCAL RULES AND REGULATIONS WILL RESULT IN PROPERTY DAMAGE SEVERE INJURY OR DEATH 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 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 winches are to be used within the specifications as listed in the manual under SPECIFICATIONS Other use as foreseen in the functiona
47. 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 354 REV 030819 PAGE 13 TROU B LE SHOOTI NG 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 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 pocket Sprag clutch is damaged or surfaces where sprag clutch engages on motor drive shaft or brake hub 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 lo
48. urers instructions and install ferrule into drum pocket Pull rope tight and install retainer plate item No 501 Retainer plate is suitable for ferrule lengths from 2 3 4 to 3 3 16 SI1013 75 2 For safety the cable drum requires 5 wraps of wire rope 3 The winch operation is controlled by a single control valve lever which has a forward a reverse and a neutral position Speed control in either direction is obtained by modulation of the control valve lever Maximum line speed in either direction is obtained when the control valve lever is moved as far as it can go The disc brake of the winch will come on automatically when the winch control lever is returned to neutral 4 Always warm up equipment prior to operating winch particularly in low ambient temperature Circulate hydraulic oil through the winch control valve for several minutes to warm the hydraulic system To prime the winch with warm oil operate the winch at slow speed forward and reverse several times 5 Preventcorrosion damage to winch interior If not used regularly run winch up and down at least once every two weeks 6 To ensure proper winch installation and function raise and lower a full test load to a safe height before using winch for regular operation at the start of each shift If after a new installation the winch does not function properly refer to the TROUBLESHOOTING section of this manual PAGE 12 354 REV 051117 TROUBLE SHOOTING GENERAL
49. wering 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 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 secondary housing from the cable drum interior If the breather relief on the end cover leaks the seal between the drum interior and the secondary 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 M75 winch PAGE 14 354 REV 030819 SERVICE INSTRUCTIONS GENERAL Before attempting dis
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