Model H8 Service Manual
Contents
1. nl 248 REV 971001 PAGE 13 SERVICE INSTRUCTIONS Pocket seals body seals and ring seals in the hydraulic motor assembly are not part of the winch seal kit The seal kit for the hydraulic motor can be ordered from the factory under Part No 23131 All parts of the hydraulic motor with the exception of the motor adaptor item 800 are standard parts ofthe COMMERCIAL WM31 hydraulic motor having a 2 inch gear section All of these parts can be ordered from PULLMASTER or COMMERCIAL INTERTECH 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 12 hex head capscrews item 821 with lockwashers item 823 from the motor adaptor item 800 Since the brake springs item 752 apply pressure against the inside of the motor adaptor it is recommended that the hex capscrews are unscrewed one turn at a time until the spring pressure has been released The complete motor assembly including the motor adaptor can now be removed from the brake housing assembly 2 Remove and2. o 43734 3SIMMOO19 IVNH3 LX3 TIVNOILLdO 3dOH VIG olF V L d 18V LInS SI HOHONV 3 18VO 15 248 REV 051117 PAGE 26 INSTALLATION DIMENSIONS 11025 2 CID RIS 7 0 11 5 8 0 4 8 12 6 12 6 15 0 13 500 19 6 8 7 6 88 8 000 12 9 mm 178 292 203 122 321 321 381 342 90 499 221 174 6 203 20 327 in 7 0 135 8 0 4 8 13 6 12 6 15 0 13 500 19 6 8 7 6 88 8 000 12 9 2 178 343 203 122 346 321 381 342 90 499 221 174 6 203 20 327 7 0 13 5 12 0 48 13 6 12 6 19 0 17 500 23 6 87 6 88 8 000 12 9 4 178 343 305 122 346 321 483 444 50 599 221 174 6 203 20 327 COMMERCIAL WM31 SERIES MOTOR GEAR MOTOR PORT SIZE I L CODE WIDTH SAE O RING 2 00 in 6 0 5 4 30 50 8 POR mm 152 137 1 75 5 8 5 4 31 44 5 146 137 1 50 5 5 5 4 32 38 1 danes ie mm 140 137 1 25 in 53 5 4 33 31 8 133 137 1 00 5 0 5 4 34 25 4 3 mm 127 137 248 REV 960101 PAGE 27 ASSEMBLY DRAWING G1050 B amp G1052 B amp G1086 PAGE 28 248 REV 000830 APPENDIX LINE PULL MAXIMUM HOISTING LOWERING AT MAXIMUM ALLOWABLE LINE SPEED LINE SPEED CABLE DRUM SIZES WIRE ROPE ST
3. EE EE 2522 EAE EN z 8 9 TE NI Group drawings may reference parts than are actually present in specific assembly Parts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored 248 REV 950715 PAGE 25 N Z 9 7 2 T A 2 9 lt a N Z 11025 1 C SH3 L3IATTTIIN SIHONI NI SNOISNINIA i SAWIL TIV LY GQ3NIV LNIVIN 38 LSNW 3dOH 3HIM SdVHM S WAWINIW V AL34VS vL c L LHOd NIVHG H3TII4 sve M S 981 9 reL m 83218 7 SM rese LYVHO HOLOW 33S 431139 HO S 99 5508 AVS S1709 ONILNNOW 8 S ISN S1HOd HOLON Zt SAITOH ONILNNOW 14 81 1 L 92 lev S1HOd 39nv5 l 08 0 99 1 pee 24 1 1 V NOI LV LOH 3SIMMOO T1O AZIYNSSAYd 1 81 8 8 AINO siaaon 1HOd 1X3 lAN 81 8 8 1HOd 1 AlddNS 9 9 1HOd NYNLSY 3SIMM2010 H3 1NnOO NOILVn2HIO H04 321905539494 0
4. vll MASTER THE LOGICAL CHOICE INSTRUCTION AND PARTS MANUAL MODEL H8 PLANETARY HYDRAULIC WINCH amp NM POWER to Move the World TWG Canada LANTEC and Pullmaster Brands 19350 22nd Ave Surrey BC V3S 356 Voice 1 604 547 2100 Fax 1 604 547 2147 www team twg com A COMPANY READ THIS MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS PRODUCT THIS MANUAL CONTAINS IMPORTANT INFORMATION MAKE THIS MANUAL AVAILABLE TO ALL PERSONS RESPONSIBLE FORTHE OPERATION INSTALLATION SERVICING AND MAINTENANCE OF THIS PRODUCT PMC 248 120612 POVER e Mav Soe MONA Effective 2011 10 01 A TOWER compar SUPERSEDES ALL PRIOR WARRANTIES LANTEC Pull MASTER LIMITED WARRANTY 50130 0 Seller warrants that each article whether Gear Drive Products Brake Products and or Winch Products all of which are covered hereunder sold under this order shall at the time of shipment i conform to applicable specifications and ii be free from defects in material and workmanship during normal and ordinary use and service the Warranty Buyer s exclusive remedy and Seller s sole obligation under this Warranty shall be at Seller s option to repair or replace any article or part thereof which has proven to be defective or to refund the purchase price of such article or part thereof Buyer acknowledges that Buyer is knowledgeable concerning the articles covered by this Warranty and sold in connection therewith
5. HEX HEAD 3 8 16 NC X 1 25 GRADE 5 LOCKWASHER 3 8 GEAR HOUSING 030 COMM 312 8220 327 DOWEL PIN COMM 391 2082 032 SEAL BODY COMM 391 2884 050 PORT END COVER ROLLER BEARING COMM 391 0381 906 SEAL RING COMM 391 2585 024 GEAR SET 030 COMM 312 2820 007 THRUST PLATE COMM 391 2185 059 SEAL STRIP COMM 391 2882 051 PIPE PLUG 1 4 18 NPT SUB ASSY MOTOR 030 COMM WM31 2 0 CAPSCREW HEX HEAD 5 8 X 5 25 COMM 391 1401 103 WASHER COMM 391 3784 028 PLASTIC CAPLUG 1 312 12 THR D MOTOR SEAL KIT CONSISTS OF ITEMS 869 877 AND 887 NOTE 950 MOTOR SUB ASSY CONSISTS OF ITEMS 800 802 803 804 805 807 809 861 865 869 870 875 877 881 885 887 899 929 951 953 AND 955 These part numbers and descriptions vary according to brake code Refer to APPENDIX C Refer to PAGE 22 for winch seal kit and PAGE 28 for ASSEMBLY DRAWING PAGE 24 248 REV 971001 MOTOR GROUP G1086 o 807 809 885 869 e P 7 803
6. O ring item 123 and inspect planet hub stopper item 126 and sungear stopper item 122 for excessive wear Replace if planet hub stopper is less than 14 inch or if sungear stopper is less than 37 inch thick 3 Remove final planet hub assembly from final housing item 100 Winches with optional B reduction ratio only 3A Inspect planet hub stopper item 128 and replace if necessary 4 Inspect three final planet gears item 320 for damage or wear If it is necessary to remove final planet gears remove circlip item 311 and press planet pin item 310 out of planet hub item 300 Inspect needle bearing item 323 and two thrust washers item 321 and replace if damaged 5 Remove final sungear item 340 from cable drum item 500 DISASSEMBLY OF PRIMARY DRIVE If primary drive requires service or repair proceed as follows 1 Turn winch over to sit flat on end of final housing item 100 2 Remove and discard oil seal item 515 3 Using a standard bearing puller remove ball bearings item 509 and bearing spacer item 508 4 Remove internal gear item 430 and primary planet hub assembly from cable drum item 500 248 REV 971001 PAGE 15 SERVICE INSTRUCTIONS If itis necessary to remove primary planet gears remove circlip item 411 and press planet pin item 410 out of planet hub item 400 Inspect needle bearing item 423 and two thrust washers item 421 and replace if damaged 6 Inspect i
7. TYPICAL HYDRAULIC CIRCUIT Verify that pressure measured atthe circulation supply port does not exceed the permissible pressure stated in SPECIFICATIONS Winches equipped with the internal circulation option will supply circulation flow only when the winch is run in the lowering direction Verify that breather relief item 130 is in place on end cover above oil level Rotate end cover if breather relief is below oil level IMPORTANT Do not replace breather relief with a pipe plug The breather relief does not prevent oil seal failure but serves as an indicator or warning that the oil seals between brake housing and the cable drum interior have failed and 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 248 REV 971001 PAGE 9 OPERATING INSTRUCTIONS FAILURE TO FOLLOW INSTALLATION 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 Refer to manufacturer s handling inspection and maintenance recommendations to avoid potential accidents For selection of ropes etc please check following product standards DIN 15020 prEN818 1 9 prEN 1492 1 2 prEN 1677 1 3 and other re
8. brake housing 248 REV 950715 PAGE 11 TROUBLE SHOOTING FAILURE Brake will not hold Brake vibrates when lowering a load PROBABLE CAUSE 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 whichtraps hydraulic pressure in the brake piston when the control valve handleis returnedto neutral position For properfunction ofthe 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 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 approx 3 5 US gpm 13 l mi
9. breather relief see PARTS REFERENCE item 130 is installed on the end cover The breather relief bleeds to atmosphere and serves as a warning signal that the oil seal between the brake housing and drum has been damaged PAGE 2 248 REV 000830 EXPLANATION OF MODEL CODING Rapid reverse H 8 BASIC UNIT SERIES T 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 30 WM37 hydraulic motor 2 inch gear section Other gear sections for this motor are optional DRUM SIZE 1 7 inch drum diameter X 11 1 2 inch flange diameter X 8 inch length STANDARD For other drum sizes refer to APPENDIX A OPTIONS DESIGN REVISION SPECIFICATION NUMBER Describes features not
10. discard O ring item 801 and O ring item 707 O ring item 801 seals the pressure transfer hole for the automatic brake release and is 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 16 brake springs item 752 Thoroughly examine springs for damage and measure overall length Overall spring length should be 1 99 inch If any spring measures less than 1 93 inch replace all springs as a set 2 Pull the motor drive shaft item 730 out of the brake housing together with sprag clutch aligner item 724 support washer item 717 sprag clutch item 723 sprag clutch spacer item 726 and circlips items 727 and 731 3 Remove circlip item 727 from the motor drive shaft to take off sprag clutch item 723 sprag clutch spacer item 726 support washer item 717 and sprag clutch aligner item 724 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 Thoroughly inspect the surface of the motor drive shaft where the sprag clutch engages If any indentation or surface damage is detected replace motor drive shaft sprag clutch and connecting shaf
11. 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 248 REV 971001 PAGE 3 OPTIONS COUNTERCLOCKWISE ROTATION The drum rotation of the standard PULLMASTER Model H8 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 EXTERNAL BRAKE RELEASE PULLMASTER planetary winches can be supplied with an external brake release which permits release of the automatic disk 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 BRAKE 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 H8 planetary winch can be supplied with optional drums to accommodate large wire rope storage capacity DRUM GROOVING Cable drums forthe PULLMASTER Model H8 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 H8
12. parties to property or injury to persons resulting from faulty installation repair or modification of the article and misuse or negligent operation or use of the article whether or not such damage to property or injury to persons may be caused by defective material workmanship or construction ADVISORY Winches and hoists are not approved for lifting or handling personnel or persons unless specifically approved in writing from Seller for the specific intended application Under no circumstances shall Seller be liable i for any damage or loss to any property other than the warranted article or part thereof or ii for any special indirect incidental or consequential damage or loss even though such expenses damages or losses may be foreseeable The foregoing limitations on Seller s liability in the event of breach of warranty shall also be the absolute limit of Seller s liability in the event of Seller s negligence in manufacture installation or otherwise with regard to the articles covered by this Warranty and at the expiration of the Warranty period as above stated all such liabilities shall terminate Buyer s purchase of any article s covered by this Warranty shall constitute acceptance of the terms and conditions hereof and shall be binding upon Buyer and Buyer s representatives heirs and assigns The laws of the Province of British Columbia shall govern Buyer s rights and responsibilities in regard to this Warranty and the transactio
13. 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 H8 planetary winch is limited to 2000 psi 138 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 The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements PAGE 4 248 REV 971001 SPECIFICATIONS Performance specifications are based on standard hydraulic motor gear ratio and cable drum with 1 2 inch diameter wire rope For other cable drums and gear ratios refer to APPENDIX A Performance specifications for winches supplied with optional motors are provided in attached supplement CABLE DRUM DIMENSIONS STANDARD DRUM Barrel diameter 7 00 in 178 mm Flange diameter 11 50 in 292 mm Barrel length 8 00 in 203 mm CABLE STORAGE CAPACITY Size of wire rope 1 8 in 2115 ft 645 m 3 16 in 959 ft 292m 1 4 in 532 ft 162m 5 16 in 359 ft 109 m 3 8 in 227 ft 69 m 7 16 in 166 ft 51m 1 2 in 152 ft 46m MAXIMUM OPERATING PRESSURE 2000 psi 138 bar MAXIMUM OPERATING VOLUME 37 US gpm 140 l min MINIMUM OPERATING VOLUME 11 US gpm 42 l min DRUM TORQUE AT MAXIMUM PRESSURE
14. the control motor spool It is important to point out that good speed control especially during lowering of a load depends on the metering characteristics of the control valve The better an 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 a separate pressure relief valve must be installed and setatthe 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 forfree air circulation around the reservoir HYDRAULIC HOSES The following hydraulic hoses are recommended for maximum efficiency of the PULLMASTER Model H8 planetary winch Pressure lines Equivalent to SAE 10
15. which are being purchased that Buyer has reviewed this Warranty and that the remedies provided hereunder are adequate and acceptable to Buyer This Warranty shall expire one 1 year from the date the article is first shipped by Seller Notice of claimed breach of this Warranty must be given by Buyer to Seller within the applicable period Such notice shall include an explanation of the claimed warranty defect and proof of date of purchase of the article or part thereof for which warranty coverage is sought No allowances shall be made by Seller for any transportation labor charges parts in and out costs adjustments or repairs or any other work unless such items are authorized in writing and in advance by Seller Nor shall Seller have any obligation to repair or replace items which by their nature are expendable 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 ser
16. 0 into the centre bore of the brake housing until its splined end engages with the spline of the primary internal gear item 430 6 Install thrust bearing item 617 and thrust washers item 615 onto brake hub item 720 7 Slide the brake hub item 720 onto the spline of the connecting shaft item 600 ensuring that thrust washer item 615 does not fall off and secure with circlip item 513 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 8 Install brake spacer item 712 into brake housing Starting and finishing with a divider plate alternately install nine divider plates item 714 and eight friction plates item 715 9 Liberally grease O ring item 751 and O ring item 753 and install on the brake piston item 750 10 Slide the brake piston into the brake housing with the holes for the brake springs facing out of the brake housing assembly 11 Install sprag clutch item 723 sprag clutch spacer item 726 sprag clutch aligner item 724 and support washer item 717 on the motor drive shaft item 730 Secure this assembly in position with circlip item 727 NOTE The sprag clutch spacer item 726 must be located between the sprag clutch item 723 and the sprag clutch aligner item 724 as shown in the brake group drawing 12 Carefully slide the motor drive shaft item 730 in
17. 012 16 Circulation return line Equivalent to SAE 100R4 12 Circulation supply line Equivalent to SAE 100R6 6 Only for models with external circulation It is recommended that a larger size of hydraulic hose is installed where the pressure lines or the circulation lines are excessively long HYDRAULIC FILTER Hydraulic filter recommendations for the hydraulic circuit of the PULLMASTER planetary winch based on a return line filter are given as follows 10 microns 5 microns Average Atmosphere Dusty Atmosphere In order to prevent accidental stoppage of the return line flow the oil 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 PAGE 8 248 REV 011105 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 planet
18. 1 o _ 24 e 92 2 1 4 a gt 8 o L LI LL Li i I L LI L LI Li if 0 100 200 300 400 500 600 700 800 LINE SPEED fpm 151 121 91 60 30 OIL VOLUME l min Performance graphs are based on standard hydraulic motor gear ratio and cable drum with 1 2 inch diameter wire rope PAGE 6 248 REV 950715 TYPICAL HYDRAULIC CIRCUIT 8 CIRCULATION RETURN LINE DIRECT TO RESERVOIR H D S i pV 9 mno o5 3 Y 1 800 PSI 55 BAR CIRCULATION SUPPLY LINE 2 US GPM 8 L MIN 3 US GPM 11 LPM REQUIRED FOR MODELS H8 4 US GPM 15 LPM SUPPLIED WITH EXTERNAL EXTERNAL CIRCULATION BRAKE RELEASE OPTION CONTROL VALVE MOTOR SPOOL 4 WAY SPRING RETURN TO CENTER x PRESSURE RELIEF VALVE FILTER HYDRAULIC PUMP RESERVOIR 248 REV 000830 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 win
19. 23125 and providing the hydraulic motor has to be serviced a seal kit Part No 23131 on hand before the unit is taken apart Two new needle bearings item 875 may also be required Part No 25322 NOTE Back up washers may be included with seal kit Install with oil seals as per instructions If not present in seal kit the oil seals supplied do not require back up 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 must be replaced Thoroughly clean parts before reassembly Do not use solvent to clean the brake friction plates During reassembly lubricate all O rings and oil seals with grease before installation Inthe following service instructions reference to parts is made by numbers and shown on the applicable group drawings DISASSEMBLY For the majority of required service or repair work disassembly is required only on the brake housing of the PULLMASTER Model H8 planetary winch There are no special tools needed for the service or repair work and no adjustments or calibrations are necessary Proceed with the disassembly as follows DISASSEMBLY OF HYDRAULIC MOTOR ASSEMBLY If the analysed service or repair work requires access to the interior of the brake housing the hydraulic motor should not be disassembled In this case the h
20. 31 875 Ib in 3 601 Nm DRUM RPM AT MAXIMUM VOLUME HOISTING 59 rpm LOWERING 256 rpm HOISTING LINE PULL AT MAXIMUM PRESSURE Bare drum 8 500 Ib 37 8 kN Full drum 5 795 Ib 25 8 kN MAXIMUM ALLOWABLE LINE PULL WHEN LOWERING Bare drum 1 962 Ib 8 7 kN Full drum 1 342 Ib 6 0 kN HOISTING LINE SPEED AT MAXIMUM VOLUME Bare drum 116 ft min 35 m min Full drum 170 ft min 52 m min LOWERING LINE SPEED AT MAXIMUM VOLUME Bare drum 502 ft min 153 m min Full drum 736 ft min 224 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 248 REV 011105 PAGE 5 HOISTING LINE PULL VS OIL PRESSURE MAXIMUM ALLOWABLE LINE PULL WHEN LOWERING BARE DRUM 1962 Ib FULLDRUM 134216 LINE PULL kN 0 6 7 13 3 20 0 26 7 33 4 40 0 2000 1600 1200 800 OIL PRESSURE psi 400 0 1500 3000 4500 6000 7500 9000 LINE PULL Ib LINE SPEED VS OIL VOLUME 138 110 83 55 28 PG H8 A 8 7 kN 6 0 kN OIL PRESSURE bar HOISTING LINE SPEED LOWERING LINE SPEED LINE SPEED m min 0 30 61 91 122 152 183 213 244 oe paroi d TT TT TT 32 E 7
21. 5 30 248 960101 APPENDIX C BRAKE CODE NO DESCRIPTION PART NUMBERS ORIFICE 1 8 27 NPT 1 8 27 NPT 25040 1 8 27 25622 25622 25622 25622 PLASTIC CAPLUG 11 25374 25374 25374 25374 3 8 18 PLASTIC CAPLUG 26276 26276 26276 26276 3 8 NPT MOTOR SUB ASSY 22026 22027 22028 22029 22303 22083 22084 22304 248 REV 971001 PAGE 31 BOLT TORQUE CHART NOTE Unless otherwise specified torque bolts per above chart PAGE 32 248 REV 950715
22. ASHER FOR OIL SEAL 25195 OIL SEAL BRAKE SPACER DIVIDER PLATE FRICTION PLATE SUPPORT WASHER ANDERTON R 28 40 2 0 BRAKE HUB SPRAG CLUTCH BORG WARNER X138769 SPRAG CLUTCH ALIGNER SPRAG CLUTCH SPACER CIRCLIP ROTOR CLIP SH 106 MOTOR DRIVE SHAFT CIRCLIP ROTOR CLIP SH 75 PISTON O RING 90 DURO 266 8 ID 1 8 CS BRAKE SPRING O RING 90 DURO 267 8 1 4 ID 1 8 CS 1 3 3 3 3 3 6 3 1 1 1 1 2 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 9 8 1 1 1 1 1 1 1 1 1 1 16 1 WINCH SEAL KIT CONSISTS OF ITEMS 105 123 515 623 625 707 710 711 751 753 AND 801 Refer to PAGE 28 for ASSEMBLY DRAWING PAGE 22 248 REV 000830 BRAKE GROUP PRIOR TO SERIAL NO 37799 G1052 B Item 723 Was Part No 25071 Borg Warner sprag clutch 13143 Qty 2 Item 726 Was not required PRIOR TO SERIAL NO 56185 Item 727 Was Part No 25411 Item 730 Was Part No 21457 20 412 413 430 600 508 750 752 720 5 4 Group drawings may reference more parts than are actually present in a specific assembly Parts that referenced on the drawing but are not on the PARTS REFERENCE list should be ignored 248 REV 990325 PAGE 23 PARTS REFERENCE MOTOR GROUP 1 1 1 1 1 2 1 1 2 2 1 4 2 1 4 2 1 2 1 2 1 1 4 4 2 MOTOR ADAPTOR O RING 90 DURO 012 3 8 ID 1 16 CS PIPE PLUG 1 16 27 NPT PIPE PLUG 1 8 27 NPT CAPSCREW
23. CIFICATIONS Other use as foreseen in the functional description of the hydraulic winch is not allowed without written permission from PULLMASTER 1 Do not install operate or service winch before reading and understanding manufacturer s instructions 2 The winch described herein is not designed for operations involving lifting or moving personnel 3 Do not lift or carry loads over people 4 Do not exceed recommended operating pressure psi and operating volume gpm 5 Do not jerk the winch Always smoothly accelerate and decelerate load 6 Do not operate a damaged noisy or malfunctioning winch 7 Do not leave a load suspended for extended period of time 8 Never leave a suspended load unattended 9 Winch should be maintained and operated by qualified personnel 10 Inspect winch rigging mounting bolts and hoses before each shift 11 Warm up equipment before operating winch particularly at low ambient temperatures 12 Verify winch function by raising and lowering a full test load to a safe height before each shift 13 14 Verify gear lubrication and brake circulation supply and return before operating winch Do not weld any part of the winch 15 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 K
24. ORAGE PRESSURE LINE PULL AT MAXIMUM AT MAXIMUM OIL INCHES FEET HOISTING LOWERING VOLUME VOLUME VOLUME MILLIMETERS METERS REQUIRED POUNDS POUNDS FEET MINUTE FEET MINUTE us KILONEWTONS KILONEWTONS METERS MINUTE METERS MINUTE cairows BARE FULL BARE FULL BARE FULL BARE FULL LITERS BARREL FLANGE LENGTH 1 2 inch 7 16 inch 3 8 inch DRUM DRUM DRUM DRUM DRUM DRUM STANDARD REDUCTION RATIO A REDUCTION RATIO 343 305 178 343 Performance specifications are based on standard hydraulic motor with 1 2 inch diameter ie nS SEEEEEREUELLLLLLLLLLLLLLLLLLLLLIZZLLLLLLLZLZZZZZLZLZLLLLLLLUUULULULULULLLLLLLLLLLLLLLLLLLLLLLLLOCLLILLLLLLLLLLLLLLLLLLLLLLLLLLLLLULLLLULULUULLLLULULULLLLLLLLLLLLLLLLLLLLLILILIO MZM D A U UUZYJ 248 REV 000830 PAGE 29 ITEM NUMBERS PART DESCRIPTION PLANET HUB FINAL FINAL FINAL STOPPER PLANETHUB PLANETGEAR SUNGEAR C PLEDRUM BASE DRUM STANDARD REDUCTION RATIO CODE PART NUMBERS 20143 20113 20142 20174 20074 20143 20113 20142 20298 20074 DRUM A REDUCTION RATIO CODE PART NUMBERS N A 20109 20102 20104 20174 20074 N A 20109 20102 20104 20298 20074 20109 20102 20351 20324 20325 DRUM B REDUCTION RATIO CODE PART NUMBERS 1 20314 20353 20355 22174 20174 20074 2 20314 20353 20355 22174 20298 20074 4 20314 20353 20355 22094 20324 2032
25. USING 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 12 Remove eight friction plates item 715 together with nine divider plates item 714 and inspect for damage or wear Plates should be flat and smooth Plates should not show heat discoloration Paper material on friction 13 Remove brake spacer item 712 14 Remove oil seal item 711 and backup washer item 710 and discard All parts have now been removed from brake housing and there is no need for further disassembly unless a failure has been analyzed in the remaining winch assembly If continuing remove pipe plug item 121 fromthe end cover item 120 and tip winch to drain lubricating oil from inside the final drive housing and cable drum 15 Remove 12 capscrews item 551 12 lockwashers item 553 and base item 550 16 Slide brake housing item 700 out of cable drum ball bearings item 509 Thoroughly inspect needle bearings item 605 and replace if necessary 17 Remove and discard oil seal item 515 18 Remove primary sungear item 440 from center of primary planet hub item 400 DISASSEMBLY OF FINAL DRIVE Stand winch on cable drum flange with final end up and disassemble as follows 1 Remove retaining ring item 124 and pull end cover item 120 out of final housing item 100 2 Discard
26. X B Refer to PAGE 22 for winch seal kit and PAGE 28 for ASSEMBLY DRAWING PAGE 20 248 REV 000830 FINAL DRIVE GROUP G1050 B 553 2 126 B REDUCTION ONLY Group drawings may reference more parts than are actually present in a specific assembly Parts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored 248 REV 960101 PAGE 21 PARTS REFERENCE BRAKE GROUP mewNo DESCRIPTION O PLANET HUB PLANET PIN CIRCLIP ROTOR CLIP C 62 INTERNAL GEAR STOPPER CIRCLIP ROTOR CLIP SH 62 PLANET GEAR THRUST WASHER TORRINGTON TRA 1018 NEEDLE BEARING TORRINGTON BH1016 INTERNAL GEAR SUNGEAR SUNGEAR STOPPER BEARING SPACER BALL BEARING 6020 CIRCLIP ROTOR CLIP SH 262 OIL SEAL CONNECTING SHAFT RETAINING RING NEEDLE BEARING TORRINGTON B4216 THRUST WASHER TORRINGTON TRD 5266 THRUST BEARING TORRINGTON NTA 5266 BEARING SLEEVE CIRCLIP ROTOR CLIP HO 175 OIL SEAL O RING 030 1 5 8 ID 1 16 CS NEEDLE BEARING TORRINGTON B2012 BRAKE HOUSING PLASTIC CAPLUG 3 4 NPT THR D O RING 173 8 1 2 ID 3 32 CS BACK UP W
27. ary winch is installed 1 2 3 4 5 6 7 8 Make certain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted Set the winch on the mounting platform and check for surface contact on all mounting pads of the winch If there is a space between the mounting surface and one of the mounting pads the mounting surface is not even and the space below the mounting pad must be shimmed If this condition exists proceed as follows a Install mounting bolts snug tight on the three mounting pads which are in contact with the mounting surface For mounting bolt size and grade see INSTALLATION DIMENSIONS b Measure the space underneath the fourth mounting pad with a feeler gauge and use shim stock of equivalent thickness in the space between the mounting pad and the mounting surface c Only after this procedure should the fourth mounting bolt be installed Tighten all four bolts as per torque chart at back of manual 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 time 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
28. ch 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 66C For extreme operating conditions of short duration the maximum temperature range of 5 180F 21 82C 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 oil Consult lubricating oil supplier or factory for temperatures beyond normal operating range HYDRAULIC PUMP For maximum performance of the PULLMASTER planetary winch the hydraulic pump must supply the maximum flow of hydraulic fluid atthe hydraulic pressure stated in SPECIFICATIONS HYDRAULIC CONTROL VALVE The control valve used for the 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
29. does not produce the specified maximum rated line speed or drum rpm a loss of hydraulic flow somewhere in the hydraulic circuit can be analysed If this condition exists install a flow meter into the hydraulic circuit to check the volume of oil 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 pulling capacity of the winch If the winch will not produce the specified maximum line pull install a pressure gauge in the pressure line leading to the hoisting port on the hydraulic winch motor Stall the winch to prevent rotation of the drum and then open the control valve Check the hydraulic pressure reading of the installed pressure gauge If the pressure reads below the specified maximum operating pressure look for trouble in the hydraulic pump the relief valve and the control valve If the hydraulic pump is driven by V belts check for belt slippage When checking oil pressure and volume in the hydraulic circuit make sure that the hydraulic reservoir is filled to the top level and the hydraulic pump is running at maximum operating rpm Only after the hydraulic system has been checked and found to be in order use the following indicati
30. eep hydraulic system clean and free from contamination at all times 20 Maintain winch and equipment in good operating condition Perform scheduled maintenance regularly 21 Keep hands clear when winding wire rope onto the winch drum 22 not use the wire rope as a ground for welding 23 Rigthe winch carefully Ensure that the wire rope is properly anchored to the correct cable anchor slot at the cable drum 24 Do not lift a load with a twisted kinked or damaged wire rope 25 Consult wire rope manufacturer for size type and maintenance of wire rope 26 Maintain five wraps of wire rope on the cable drum at all times 27 In case of a power failure or breakdown leading to an unexpected stop of the hydraulic power circuit stand clear of the area and the load being hoisted take the necessary precautions to prevent access to area where the load is halted 28 The noise level of the winch is 89 dBA measured on a distance of 1 00 meter 1 60 meters high The measuring equipment used was Realistic 442 3019 29 Clean up any oil spillage immediately 30 Wear proper clothing and personal protection equipment such as footwear safety goggles and a hard hat Read manual first 248 051117 1 DESCRIPTION OF THE MODEL H8 GENERAL DESCRIPTION PULLMASTER Model H8 is a planetary hydraulic winch with reversing or lowering speed 4 3 times faster than forward or hoisting s
31. fully Bl M M M M l M M Mr PAGE 16 248 REV 960101 SERVICE INSTRUCTIONS engaged by rotating cable drum 4 Press ball bearing item 509 into cable drum Install bearing spacer item 508 then press second ball bearing item 509 into cable drum 5 Press new well greased oil seal item 515 into cable drum 6 Install primary sungear item 440 into center of three primary planet gears item 420 Ensure gear teeth are fully engaged by rotating cable drum REASSEMBLY OF BRAKE HOUSING ASSEMBLY Reassemble brake housing assembly by reversing the disassembly procedure NOTE Oil seal backup washer not required unless included in the seal kit supplied by PULLMASTER 1 Cleanall parts thoroughly before reassembly and apply grease liberally to all O rings and oil seals Use only new O rings and oil seals seal kit for winch assembly Part No 23125 seal kit for hydraulic motor Part No 23131 2 Install new backup washer item 710 if included and new oil seal item 711 in the centre bore of the brake housing item 700 3 Installthe bearing sleeve item 620 with needle bearing item 627 new O ring item 625 backup washer item 622 if included and new oil seal item 623 in the bore of the connecting shaft 4 Install circlip item 621 5 Carefully insert the connecting shaft item 60
32. hydraulic motor are transmitted directly to the final planet reduction stage With the primary reduction stage eliminated the reduction is reduced to a ratio of 7 8 1 and the cable drum will rotate 4 3 times faster than in forward or hoisting speed If the load on the cable drum tends to effect the lowering speed the resulting pressure drop in the brake piston causes friction between the brake disks 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 disk brake applies automatically During the lowering operation of the winch the friction created by the brake disks results in temperature This temperature is dissipated by an internal circulation flow supplied out of the hydraulic motor approx 4 US 15 l min This circulation flow must be returned directly to the reservoir with a permissible back pressure of 30 psi 2 bar IMPORTANT Under 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 order to prevent potential damage to the drum seals and the end cover of the winch when the cable drum fills up with hydraulic fluid a
33. inch 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 disk brake of the winch will come on automatically when the winch control lever is returned to neutral 5 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 6 Toensure 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 TROUBLE SHOOTING section of this manual PAGE 10 248 REV 251117 TROUBLE SHOOTING GENERAL In most cases when the hydraulic winch does not perform satisfactorily the cause for 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
34. levant product standards 1 Thecable drum of the PULLMASTER planetary winch has two cable anchor slots one for clockwise and one for counterclockwise hoisting Standard rotation for hoisting is clockwise when looking at the hydraulic motor of the unit It is critical to select the cable anchor slot which will permit winding of the wire rope on the drum in the correct direction of rotation If the wire rope is wound on the cable drum in the wrong direction of rotation the winch will have no braking capacity Each winch is shipped from the factory with a label on the drum indicating the correct cable anchor slot 511013 8 5 CABLE ANCHOR SLOT WIRE ROPE INSTALLATION Clockwise hoisting winch shown Use cable anchor slot on opposite side of drum for counterclockwise hoisting winch 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 2 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 require 5 wraps of wire rope for safety 3 Rapid reverse winches have more line speed and less allowable line pull when lowering Refer to SPECIFICATIONS for hoisting and lowering values 4 Thew
35. n when the winch is reversed Control valve for the winch operation 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 has mixed with hydraulic oil resulting in foamy oil Oil leaks from the motor flange are caused by a damaged O ring seal on the motor flange Oil leaks occurring between the cable drum flanges and housing are caused by excessive pressure in the brake housing Excessive pressure in the brake housing will damage the oil seal between the brake housing and 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 or 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 H8 winch PAGE 12 248 REV 950715 SERVICE INSTRUCTIONS GENERAL Before attempting disassembly of the PULLMASTER Model H8 planetary winch the following instructions for disassembly and reassembly should be read and understood It is suggested that all expendable parts such as O rings and oil seals are not reused on reassembly It is therefore important to have a seal kit Part No
36. n s subject thereto and the Province of British Columbia shall be the exclusive forum and jurisdiction for any action or proceedings brought by Buyer in connection herewith or any dispute hereunder If any of the terms and conditions contained within this Warranty are void the remaining provisions thereof are and shall remain valid and enforceable SAFETY RECOMMENDATIONS FAILURE TO COMPLY WITH THE FOLLOWING SAFETY RECOMMENDATIONS AND LOCAL RULES AND REGULATIONS WILL RESULT IN PROPERTY DAMAGE SEVERE INJURY OR DEATH Definition Caution indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Definition Warning indicates a potentially hazardous situation which if not avoided could result in death or serious injury Definition Danger indicates a potentially hazardous situation which if not avoided will result in death or serious injury The planetary hydraulic winches are made for hoisting and lowering loads and to be operated by trained and professional personnel They are not designed for operations involving lifting or moving personnel The winches are powered by hydraulic power The ropes cables for hoisting operations are not supplied by PULLMASTER The winches are always assembled in an application they do not function as an independent machine and it is not allowed to use them as such The winches are to be used within the specifications as listed in the manual under SPE
37. nd 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 for the PULLMASTER Model H8 planetary winch always quote the complete model and serial numbers of the unit MODEL NO SERIAL NO PULLMASTER WINCH CORPORATION reserves the right to change specifications and the design of PULLMASTER planetary winches at any time without prior notice and without incurring any obligations 248 REV 990325 PAGE 19 PARTS REFERENCE FINAL DRIVE FINAL HOUSING BALL BEARING 6214 OIL SEAL CIRCLIP ROTOR CLIP HO 500 END COVER PIPE PLUG 1 2 14 NPT SUNGEAR STOPPER O RING 274 10 ID 1 8 CS RETAINING RING PLANET HUB STOPPER PLANET HUB STOPPER BREATHER RELIEF ASSEMBLY FINAL PLANET HUB FINAL PLANET PIN CIRCLIP ROTOR CLIP SH 87 CIRCLIP ROTOR CLIP C 87 FINAL PLANET GEAR THRUST WASHER TORRINGTON TRA 1423 NEEDLE BEARING TORRINGTON B1418 FINAL SUNGEAR CIRCLIP ANDERTON A1000 0137 CABLE DRUM CABLE ANCHOR PIPE PLUG 3 8 NPT CIRCLIP ROTOR CLIP SH 262 BASE CAPSCREW HEX HEAD 1 2 13 1 25 GRADE 5 LOCKWASHER 1 2 1 1 1 1 1 2 1 1 1 1 1 1 1 3 3 3 3 6 3 1 1 1 1 1 1 1 2 2 1 1 These parts vary according to reduction Refer to APPENDIX B These parts vary according to drum code Refer to APPENDI
38. nternal gear stopper item 412 for excessive wear Replace if less than 10 inch protrudes out the end of planet pin item 410 7 Remove sungear stopper item 444 from primary planet hub and replace if less than 19 inch thick 8 To separate cable drum from final housing first remove circlip item 513 Insert two heel bars between the flange of the cable drum and the final drive housing and gently pry cable drum out of ball bearing item 103 9 Remove circlip item 109 and press ball bearing item 103 out of final housing item 100 Check ball bearing and replace if damaged 10 Remove and discard oil seal item 105 REASSEMBLY Thoroughly clean all parts Use only new well greased O rings and oil seals Unless otherwise specified torque fasteners per BOLT TORQUE CHART at back of manual REASSEMBLY OF FINAL DRIVE Reassembly final drive end of winch as follows 1 Press a new well greased oil seal item 105 into final housing item 100 2 Press ball bearing item 103 into final housing and secure with circlip item 109 3 Press cable drum item 500 into ball bearing item 103 and secure with circlip item 513 4 Reassemble final planet hub assembly Press needle bearing item 323 into final 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 Insert final planet hub assembly in
39. ons 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 INSTALLATION INSTRUCTIONS pressures lated IN ePEgIIGATIONS Cable sheaves or block purchase operated with the winch are not turning freely Damage or wear in the hydraulic motor The relief valve pressure may be set too low Excessive back pressure in the hydraulic circuit might cause the automatic brake to release momentarily 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 The O ring seals on the brake release channel between the motor adaptor and the brake housing is damaged If this failure occurs there will be substantial leakage from between the motor adaptor and brake housing Insufficient hydraulic pressure see SPECIFICATIONS for minimum operating pressure Winch is mounted to an uneven surface see INSTALLATION INSTRUCTIONS Hydraulic pressure is not reaching the brake piston plugged brake release orifice in the
40. peed The main components of this unit are hydraulic gear motor multi disk 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 disk 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 disk brake against a number of brake springs The over running clutch connecting the motor drive shaft with the internal gear of the primary planet reduction locks causing the internal gear to rotate at the same rpm as the primary sungear Thus the primary reduction stage is eliminated and the output torque and rpm of the
41. rp knife cut lengths to fit the openings in the thrust plates Press one of the thrust plates together with six pocket seals onto the bearings item 875 installed in the motor adaptor item 800 so that the pocket seals are against the motor adaptor 3 Install a well greased body seal item 869 on each side of the gear housing item 861 Slide the gear housing together with the body seals onto the motor adaptor lined up on two dowel pins Tap on tight using a soft headed hammer 4 Installthe gearset item 881 inthe gear housing the longer gear with the internal spline goes into the top position 5 Press the other thrust plate complete with six new pocket seals onto the bearings installed in the port end cover so the pocket seals are facing 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 four 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 in the hoisting direction with no load at reduced speed approximately 3096 of maximum hydraulic volume With winch running evenly tighten fo
42. t as a set 5 Pullthe connecting shaft item 600 out of the center bore of the brake housing together with brake hub item 720 Thoroughly inspect the bore of the connecting shaft where the sprag clutch engages If any indentation or surface damage is detected replace connecting shaft sprag clutch and motor drive shaft as a set 6 Remove the thrust bearing item 617 and two thrust washers item 615 7 To separate the brake hub item 720 from the connecting shaft item 600 remove circlip item 513 8 Remove circlip item 621 from bore of connecting shaft item 600 9 Pushthe bearing sleeve item 620 outthe bore of the connecting shaft Discard O ring item 625 and oil seal item 623 Check needle bearing item 627 for wear or damage and replace if necessary 10 Pull the brake piston item 750 out of the brake housing using two 1 2 13NC bolts screwed into the two puller holes in the piston and discard O rings item 751 and item 753 11 Thoroughly examine the inner bores of the brake housing and the outer diameters of the brake piston for scoring caused by hydraulic fluid contamination Minor surface damage may be repaired by polishing with a fine emery cloth L A Ma PAGE 14 248 REV 971001 SERVICE INSTRUCTIONS DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP CA
43. ted 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 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
44. to final housing item 100 Ensure that planet hub spline is fully engaged with cable drum item 500 6 Verifycirclip item 343 is installed on splined end of final sungear item 340 Insertfinal sungearthrough center of three final planet gears item 320 and into cable drum Engage gear end with the three final planet gears Winches with optional B reduction ratio only 6A Insert planet hub stopper item 128 into planet hub item 300 7 Installanew well greased O ring item 123 into end cover item 120 Verify that planet hub stopper item 126 and sungear stopper item 122 are installed into end cover 8 Gently insert end cover into final housing item 100 and fasten with retaining ring item 124 9 Temporarily remove breather relief valve item 130 from end cover Turn winch up on end with cable drum opening upwards REASSEMBLY OF PRIMARY DRIVE Reassemble primary drive as follows 1 Reassemble primary planet hub assembly Press sungear stopper item 444 into primary planet hub item 400 Press needle bearing item 423 into primary planet gear item 420 Position thrust washers item 421 on either side of planet gear and press planet pin item 410 into the primary planet hub item 400 Retain with circlip item 411 2 Install primary planet hub onto end of final sungear item 340 inside of cable drum item 500 3 Install internal gear item 430 over top of three primary planet gears item 420 Ensure gear teeth are
45. to the connecting shaft item 600 until it engages the spline of the primary sungear item 440 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 248 REV 971001 PAGE 17 SERVICE INSTRUCTIONS 13 Install 16 brake springs item 752 in the brake piston 14 Liberally grease new O ring item 801 and install on the transfer hole for the brake release pressure on the flange ofthe motor adaptor item 800 Install new well greased O ring item 707 onthe flange of the motor adaptor 15 Slide the hydraulic motor assembly onto 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 Fasten motor assembly to brake housing using 12 hex capscrews item 821 with lockwashers item 823 These screws should be tightened evenly one turn at a time REASSEMBLY OF HYDRAULIC MOTOR If the hydraulic motor was disassembled the following procedure should be followed for reassembly 1 Clean all parts thoroughly before reassembly and apply grease liberally to all seals Use only new seals seal kit Part No 23131 for hydraulic motor 2 Install six new pocket seals item 887 on each thrust plate item 885 The seal kit includes a single strip of rubber Using a sha
46. ur 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 oil level fill port on the end cover 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 WILL ENABLE AN INSTALLATION OR SERVICE PROBLEM TO GO UNDETECTED AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH TO ENSURE PROPER REINSTALLATION REFER TO PROCEDURES AND TESTS DESCRIBED IN INSTALLATION AND OPERATING INSTRUCTIONS PAGE 18 248 REV 971001 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 k 5 6 Disconnect all hydraulic hoses and remove the winch from its mounting Disassemble the winch as per instructions Discard and replace all O rings and oil seals Clean all parts a
47. vice This Warranty shall not apply to any article which has been repaired altered or disassembled or assembled by personnel other than those of Seller This Warranty shall not apply to any article upon which repairs or alterations have been made unless authorized in writing and in advance by Seller This Warranty shall not apply to any articles or parts thereof furnished by Seller to Buyer s specifications and or furnished by Buyer or acquired from others at Buyer s request SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND OTHER THAN THE WARRANTY EXPRESSLY SET FORTH ABOVE SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Buyer expressly agrees that Seller is not responsible to perform any work or investigation related in any way to torsional vibration issues and is not responsible for the detection or remedy of Natural Frequency Vibration of the mechanical system in which the unit is installed Buyer acknowledges understands and agrees that this Warranty does not cover failures of the unit which result in any manner from the operation of the machine or unit at vibration frequencies at or near the natural frequency vibration of the machine in such a way that damage may result Buyer expressly agrees that Seller is not responsible for failure damage or accelera
48. ydraulic motor should be removed together with the motor adaptor as a complete assembly If a problem has been analysed to be in the hydraulic motor proceed with the disassembly as follows 1 Removethe four hex capscrews item 951 together with the lockwashers item 953 from the motor assembly IMPORTANT Failure to exercise care when removing the motor port end cover or gear housing could permanently damage the machined surfaces of these motor components Take care not to damage machined surfaces of motor components at disassembly 2 Remove pry loose if necessary port end cover item 870 together with bearings item 875 and ring seal item 877 Thrust plate item 885 and dowel pins item 865 may stay in the gear housing 3 Ifthethrustplate comes off with the end cover carefully pry it off ofthe bearings item 875 and discard pocket 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 6 Ifthe thrust plate stays on the motor adaptor carefully pry it off of the bearings item 875 and discard pocket seals item 887 7 Discard body 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 n
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