Model R5 Service Manual
Contents
1. AAWA AL34VS m Lee 100d NI HO T3HHV8 NO 1 207 LdN81 8 E 140d S3INLL LY GANIVLNIVIN ____ W SY TSCOW 38 LSNW 3dOH JO SHIM 91 6 OL 8 6 lOOdSddHd Sony ee GOOD 318VO 15 172 REV 051117 PARTS REFERENCE MANUAL FREESPOOL ITEM NO PART DESCRIPTION 1 1 1 1 2 1 1 1 1 1 1 4 1 4 1 1 1 1 1 1 2 2 3 2 1 1 2 1 1 1 1 3 3 3 3 6 3 1 1 1 2 1 FINAL HOUSING BALL BEARING 070 X 125 X 24 6214 OIL SEAL 80 X 100 X7 CIRCLIP ANDERTON N1300 0500 PIPE PLUG 1 2 NPT SOCKET HEAD O RING 273 9 3 4 ID 1 8 CS RETAINING RING PLANETHUB STOPPER BREATHERRELIEF FREESPOOL HOUSING SEALCARRIER CAPSCREW HEX HEAD 3 8 16NC X 1 00 GR 5 FREESPOOLHANDLE LOCKWASHER 3 8 FREESPOOL NUT DRIVE O RING 042 3 1 4 ID 1 16 CS SLOTTED SPRING PIN 5 32 X 1 LONG FREESPOOL FOLLOWER SLOTTED SPRING PIN 1 8 X 3 8 LONG CIRCLIP ANDERTON N1400 0078 INDEX PIN DETENT SPRING SLOTTED SPRING PIN 5 32 X 5 8 LONG SPRING SEAT CIRCLIP ANDERTON N1300 0231 BALL BEARING 020 X 042 X 12 6004 CIRCLIP ANDERTON 31300 0165 CAPSCREW HEX HEAD 5 16 18NC X 88 GR 5 LOCKWASHER 5 16 OIL SEAL 1 75 X 2 25 31 PLANETHUB PLANET PIN CIRCLIP ANDERTON N1400 0087 CIRCLIP ANDERTON N1400 00872. Pull MASTER THE LOGICAL CHOICE INSTRUCTION AND PARTS MANUAL MODEL R5 PLANETARY HYDRAULIC WINCH amp POWER to Move the World TWG Canada LANTEC and Pullmaster Brands 19350 22nd Ave Surrey BC V3S 356 Voice 1 604 547 2100 Fax 1 604 547 2147 www team twg com A COMPANY READTHIS MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS PRODUCT THIS MANUAL CONTAINSIMPORTANT INFORMATION MAKE THIS MANUAL AVAILABLE TO ALL PERSONS RESPONSIBLE FORTHE OPERATION INSTALLATION SERVICING AND MAINTENANCE OF THIS PRODUCT PMC 172 120612 POVER e MONA Effective 2011 10 01 A TOWER SUPERSEDES ALL PRIOR WARRANTIES 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 co
3. 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 APPENDIX A for quantity of oil required For normal operating temperatures use SAE 90 lubricating oil Consult lubricating oil supplier or factory fortemperature beyond normal operating range HYDRAULIC PUMP For maximum performance of the PULLMASTER planetary winch the hydraulic pump must supply the maximum flow of hydraulic fluid atthe hydraulic pressure stated in SPECIFICATIONS HYDRAULIC CONTROL VALVE The standard control valve used for operation of the PULLMASTER planetary winch must have a four way spring return to neutral feature which provides for open flow from the pressure ports of the winch to the reservoir in neutral position of the control motor spool It is importantto point out that good speed control especially when lowering a load depends on the metering characteristics of the control valve The better the oil flow is metered the better will be the speed control
4. 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 set atthe recommended maximum pressure HYDRAULIC RESERVOIR It is recommended that the hydraulic reservoir has sufficient capacity to provide good heat dissipation in orderto 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 andall return lines should enterthe reservoir below the fluid level The reservoir should be mounted close to and above the hydraulic pump in a location which providesforfree aircirculation aroundthe reservoir HYDRAULIC HOSES The following hydraulic hoses are recommended for maximum efficiency of the PULLMASTER Model R5 planetary winch Pressure lines Hydraulic freespool line Equivalent to SAE 100R12 12 Equivalent to SAE 100R3 3 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 fo
5. 19 4 N 8 9 SERVICE INSTRUCTIONS continuep Install brake hub assembly through thrust washers item 615 engage spline with freespool coupling item 260 and fasten with coupling fastener item 738 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 Install brake spacer item 712 into brake housing Starting and finishing with a divider plate alternately install 14 divider plates item 713 and 13 friction plates item 715 Liberally grease O ring item 751 and O ring item 753 and install on the brake piston item 750 Carefully insert the brake piston into the brake housing and turn the piston to line up the bore for the connecting tube item 830 with the bore in the motor item 850 Install the eight brake springs item 752 Install new well greased O ring item 707 on motor adaptor pilot item 800 10 Position motor adaptor with hydraulic motor mounting holes horizontal and the connecting tube holes of the piston aligned with motor adaptor Tighten six capscrews item 821 and lockwashers item 823 one turn ata time to evenly compress springs REPLACE HYDRAULIC MOTOR ASSEMBLY Install new O rings item 831 on each end of the connecting tube item 830 and apply grease liberally Insert the long end of the connecting tube into motor adaptor item 800
6. Remove and discard O ring item 811 3 Remove connecting tube item 830 Remove and discard two O rings item 831 4 Remove two check valves item 832 Remove and discard two O rings item 833 The standard motor of the Model R5 is a NICHOLS Series 110 IGR hydraulic motor with 12 9 cubic inch displacement If a problem is analysed to be in the hydraulic motor we recommend that a NICHOLS dealer be contacted for parts and service If the hydraulic motor is disassembled the original flange section of the motor must be re used in order to provide the required porting to operate the automatic brake and for the circulation flow DISASSEMBLY OF BRAKE HOUSING ASSEMBLY Disassemble brake housing assembly as follows 1 Remove motor adaptor item 800 by removing six capscrews item 821 and lockwashers item 823 Allow brake springs item 752 to expand safely by unscrewing capscrews one turn at a time 2 Remove and discard O ring item 707 3 Removeeightbrake springs item 752 Examine brake springs for damage and measure overall length Overall spring length should be 1 54 inch If any spring measures less than 1 48 inch replace all springs as a set 4 Pullthe 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 753 172 REV 030429 PAGE 15 SERVICE INSTRUCTIONS 5 Remove pipe plug item 755 and verify that circulation ho
7. WITH A NEWLY SERVICED WINCH WILL ENABLE AN INSTALLATION OR SERVICE PROBLEM TO GO UNDETECTED AND WILL ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH TO ENSURE PROPER REINSTALLATION REFER TO PROCEDURES AND TESTS DESCRIBED IN INSTALLATION AND OPERATING INSTRUCTIONS 172 REV 030429 PAGE 21 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 preventative maintenance service should be done every 12 months or 500 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 Inspect all parts for wear and replace if necessary 5 Clean all parts and inspect for wear and damage as per instructions Replace worn or damaged parts as required 6 Follow INSTALLATION and OPERATING INSTRUCTIONS when returning winch to its mounting When ordering parts for the PULLMASTER Model 5 planetary winch always quote the complete model and serial number of the unit MODEL NO SERIAL NO PULLMASTER WINCH CORPORATION reserves the righ
8. emery cloth 172 REV 030429 PAGE 17 SERVICE INSTRUCTIONS Inspect nylon planet hub stopper item 126 and replace if less than 0 14 inch thick Remove and discard O ring item 123 from outside of freespool housing To separate the final sungear item 340 from the freespool piston remove circlip item 269 Inspect the two splines on the end of the final sungear for wear and cracks Replace if necessary To separate the ball bearing item 291 from the freespool piston remove circlip item 267 MANUAL FREESPOOL 5 70 1 1 2 Remove hex head capscrew item 297 andlockwasher item 298 to allow removal of freespool handle item 254 from nut drive item 256 Remove four hex head capscrews item 253 and lockwashers item 255 from seal carrier item 252 For correct positioning of the seal carrier upon reassembly make a chalk mark on the seal carrier and freespool housing item 250 Pull the seal carrier out of the freespool housing discard O ring item 257 and oil seal item 299 Remove index pin item 272 detent spring item 276 and spring seat item 284 Check these parts for wear and replace if necessary Turn the nut drive item 256 to disconnect from the follower item 266 Inspect the three spring pins item 278 and replace if damaged or worn Remove circlip item 288 and pull the final sungear item 340 together with the follower and ball bearing item 291 out of the freespool housing Remove circlip it
9. hoisting direction is available as an option CABLE DRUM SIZES Refer to APPENDIX A for optional cable drum sizes and specifications OPTIONAL HYDRAULIC GEAR MOTOR The performance of the standard PULLMASTER Model R5 planetary winch is based NICHOLS Series 110 IGR hydraulic motor with a displacement of 12 9 cubic inches The performance of the winch can be changed by using motors with different displacements Contact the factory for performance information if using motors with different displacements The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements 172 REV 950101 PAGE 5 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 refer to APPENDIX A Performance specifications for winches supplied with optional motors are provided in attached supplement CABLE DRUM DIMENSIONS STANDARD DRUM Barrel diameter 5 00 in 127mm Flange diameter 11 38 289mm Barrellength 9 00 in 229mm CABLE STORAGE CAPACITY Size of wire rope 3 16 in 1394 ft 425m 1 4 in 732 223 5 16 481 147 3 8 337 ft 103m 7 16 in 268 ft 82m 1 2 in 209 ft 64 9 16 in 160 ft 49m MAXIMUM OPERATING PRESSURE 2350 psi 162 bar MAXIMUM OPERATING VOLUME 15 US 57 l min MINIMUM OPERATING VOLUME 5 US gpm 19 l min DRUM TORQUE AT MAXIMUM PRESSURE 30 30 3 424 Nm DRUM RPM AT MA
10. 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 When checking oil pressure of oil volume anywhere in the hydraulic system make certain that the hydraulic pumpis running at maximum operating rpm Installations using a belt drive for hydraulic pump must be checked for belt slippage Verify that hydraulic reservoir is filled to the top level Only if the hydraulic system has been checked and found tobe inorder use the following indications for probable causes of failure in the winch FAILURE PROBABLE CAUSE Winch will not produce line pull at maximum Winch is mounted to an uneven surface see pressure as listed in SPECIFICATIONS INSTALLATION INSTRUCTIONS Cable sheaves or block purchase operated with the winch are not turning freely Damage or wear in the hydraulic motor Excessive back pressure in the hydraulic system Relief valve may be set too low 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 b
11. soitstands on final housing end Press spherical roller bearing item 507 into cable drum item 500 5 Press new well greased oil seal item 515 into cable drum item 500 6 Install new well greased O ring item 293 on end of final sungear item 340 and slide final sungear through journal bearing item 286 7 Place brake housing item 700 into cable drum item 500 Use 16 capscrews item 971 and lockwashers item 973 to secure tie bars item 970 REASSEMBLY OF BRAKE HOUSING ASSEMBLY Reassemble brake housing assembly by reversing the disassembly procedure 1 Install new backup washer item 710 and new well greased oil seal item 711 inthe bore of the brake housing 2 Install bronze washer item 706 Place thrust bearing item 617 in between two thrust washers item 615 on top of bronze washer item 706 3 Install sprag clutch item 723 in bore of brake hub item 720 Insert sprag clutch aligner item 722 into one side ofthe brake hub Insert the other sprag clutch aligner item 724 into the other side of the brake hub Carefully slide the brake shaft item 730 through the sprag clutch aligner item 724 into the brake hub assembly and fasten into place by installing circlip item 727 IMPORTANT For proper brake function ensure that the brake hub rotation is correct When viewed from the motor end the brake shaft of a counterclockwise pulling winch must turn freely counterclockwise and lock in the clockwise direction 172 REV 030429 PAGE
12. 31 for ASSEMBLY DRAWINGS PAGE 28 172 REV 060714 m x lt oc m G1131 151 32N3H3H3H SLHYd uo 100 eui uo sued 9 Aen oL eje uey Aew cus 098 996 918 128 228 008 202 068 992 128 092 912 062 882 218 8 LL8 078 291 292 194 204 004 622 212 214 024 2022 219 A10 89950 0907 14 LSNYHL NOLONIHHOL osn 919 104 12285 191935 OL 29 172 950101 ASSEMBLY DRAWING R5 M G1131 amp G1137 PAGE 30 172 REV 950101 1131 amp 1136 R5 F PAGE 31 YE de p ei weil 24 S A 2 gt lt O gt TT 172 REV 950101 APPENDIX A CABLE DRUM SIZES WIRE ROPE STORAGE OIL INCHES FEET DRUM PART MILLIMETERS CODE NUMBER METERS LINE PULL LINE SPEED AT MAXIMUM AT MAXIMUM _ vusricatina PRESSURE VOLUME VOLUME REQUIRED POUNDS FEET MINUTE U S GALLONS KILONEWTONS METERS MINUTE LITERS B
13. 8 ID 1 16 CS SPHERICAL ROLLER BEARING OIL SEAL 3 375 X 4 000 X 500 THRUST WASHER TORRINGTON FTRA 4060 THRUST BEARING TORRINGTON FNT 4060 BRAKE HOUSING BRONZE WASHER O RING 163 6 ID 3 32 CS BACK UP WASHER OILSEAL BRAKE SPACER DIVIDERPLATE FRICTION PLATE BRAKEHUB SPRAG CLUTCH ALIGNER SPRAG CLUTCH BORG WARNER 140373 B SPRAG CLUTCH ALIGNER CIRCLIP ANDERTON N1400 0196 BRAKE SHAFT COUPLING FASTENER PISTON O RING 90 DURO 253 5 3 8 ID 1 8 CS BRAKE SPRING O RING 90 DURO 256 5 3 4 ID 1 8 CS PIPE PLUG 1 16NPT SOCKET HEAD MOTORADAPTOR O RING 100 MM ID x 2 CS CAPSCREW HEX HEAD 1 2 13NC X 1 25 GR 5 LOCKWASHER 1 2 CAPSCREW HEX HEAD 1 2 13NC X 1 25 GR 5 LOCKWASHER 1 2 CONNECTING TUBE O RING 010 1 4 ID 1 16 CS CHECKVALVE O RING 306 ID X 034 C S SAFETY VALVE MOTOR 070 HIGH TORQUE LOW SPEED 12 9 CID PLASTIC CAPLUG SAE 10 ORB TIEBAR CAPSCREW HEX HEAD 7 16 14NC X 1 25 GR 5 LOCKWASHER 7 16 1 1 1 1 1 2 1 1 1 1 1 1 1 4 3 1 1 1 1 1 1 1 1 1 8 1 1 1 1 2 2 6 6 1 2 2 2 1 1 2 2 6 6 WINCH SEAL KIT CONSISTS OF ITEMS 105 123 257 265 277 293 299 515 707 710 711 751 753 811 831 AND 834 MOTOR SEAL KIT These part numbers and descriptions vary according to brake code Refer to APPENDIX B gt Donot substitute Available from PULLMASTER or Authorized Dealer only Refer to PAGES 30 amp
14. ARE FULL BARE FULL DRUM DRUM DRUM DRUM Performance specifications are based on standard hydraulic motor with 1 2 inch diameter rope PAGE 32 172 REV 010215 APPENDIX 800 MOTORADAPTOR 172 REV 950101 PAGE 33 BOLT TORQUE CHART NOTE Unless otherwise specified torque bolts per above chart PAGE 34 172 REV 950101
15. EV 030429 PAGE 11 OPERATING INSTRUCTIONS FAILURE TO FOLLOW OPERATING INSTRUCTIONS COULD 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 relevant product standards The cable drum of the PULLMASTER planetary winch has two cable anchor slots one for clockwise and one for counterclockwise pulling Standard rotation for pulling is counterclockwise 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 SH013 R5 WIRE ROPE INSTALLATION Counterclockwise pulling winch shown Use cable anchor slot on opposite side of drum for clockwise pulling winch F
16. INSTALLATION DRAWING When the hydraulic pressure is removed the freespool coupling will re engage IMPORTANT The freespool coupling cannot be engaged or disengaged under load or while the cable drum is rotating 172 REV 950101 PAGE 3 EXPLANATION MODEL CODING 5 X XXXXX BASIC UNIT SERIES Jl R Recovery winch SIZE OF UNIT REDUCTION RATIO Only used for non standard reduction ratios TYPE OF BRAKE 12 Automatic brake counterclockwise drum rotation intravent 15 Automatic brake clockwise drum rotation intravent HYDRAULIC MOTOR 70 High torque low speed hydraulic motor 12 9 cubic inch displacement Other displacements are optional DRUM SIZE 1 5 0inch drum diameter X 11 3 8 inch flange diameter X 9 inch between flanges STANDARD For other drum sizes refer to APPENDIX A OPTIONS F Hydraulically actuated freespooling M Manually actuated freespooling DESIGN REVISION SPECIFICATION NUMBER Describes features not identified by preceding codes NOTE Clockwise and counterclockwise drum rotation is the direction of rotation for pulling or hoisting established by looking at the hydraulic motor PAGE 4 172 010215 5 CLOCKWISE ROTATION The drum rotation of the standard PULLMASTER Model R5 planetary winch is counterclockwise for pulling when looking at the hydraulic motor of the winch Drum rotation for clockwise
17. Install new well greased O ring item 811 on flange of the hydraulic motor and two new well greased O rings item 834 on check valves item 832 Insert check valves in face of motor and fasten motor to motor adaptor using two capscrews item 815 and lockwashers item 817 REASSEMBLY OF FINAL DRIVE ASSEMBLY Reassemble final drive assembly by reversing the disassembly procedure Return winch to a horizontal position standing on its mounting feet Reassemble final planet hub assembly Press pre greased needle bearing item 323 midway 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 Insert final planet hub assembly into final housing so that spline interlocks with cable drum Install freespool housing item 250 in final housing item 100 being sure to align spring pin item 259 with notch in final housing Install retaining ring item 124 and pipe plugs item 121 3 20 172 030429 SERVICE INSTRUCTIONS continuep IMPORTANT Before operating the winch add lubricating oil up to the oil level fill port on the freespool housing 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 PULLING A LOAD
18. PLANET GEAR THRUST WASHER TORRINGTON TRA 1423 NEEDLE BEARING TORRINGTON B1416 FINAL SUNGEAR CABLE DRUM CABLE ANCHOR PIPE PLUG 3 8 NPT SOCKET HEAD CIRCLIP ANDERTON N1400 0262 These parts vary according to drum code Referto APPENDIX A Refer to PAGE 28 for winch seal kit and PAGE 30 for ASSEMBLY DRAWING PAGE 24 172 REV 010215 FREESPOOL GROUP HYDRAULIC RELEASE G1137 130 311 321 259 100 310 313 109 513 105 500 340 N N N Groups drawings reference more parts than are actually present a specific assembly Parts that referenced on the drawing but are not on the PARTS REFERENCE list should be ignored 172 REV 950101 PAGE 25 PARTS REFERENCE HYDRAULIC FREESPOOL 1 1 1 1 2 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 1 1 3 3 3 3 6 3 1 1 1 2 1 FINAL HOUSING BALL BEARING 070 X 125 X 24 6214 OIL SEAL 80 X 100 X7 CIRCLIP ANDERTON N1300 0500 PIPE PLUG 1 2 NPT SOCKET HEAD O RING 273 9 3 4 ID 1 8 CS RETAINING RING PLANET HUB STOPPER BREATHERRELIEF FREESPOOL HOUSING PLASTIC CAPLUG 1 8 NPT FREESPOOL COVER CAPSCREW HE
19. X HEAD 3 8 16NC X 1 25 GR5 LOCKWASHER3 8 O RING 042 3 1 4 ID 1 16 CS SLOTTED SPRING PIN 5 32 X 1 LONG FREESPOOL PISTON O RING 235 3 1 8 ID 1 8 CS CIRCLIP ANDERTON N1300 0165 CIRCLIP ANDERTON N1400 0078 O RING 236 3 1 4 0 1 8 CS FREESPOOL SPRING BALL BEARING 020 X 042 X 12 6004 PLANET HUB PLANET PIN CIRCLIP ANDERTON N1400 0087 CIRCLIP ANDERTON N1400 0087 PLANET GEAR THRUST WASHER TORRINGTON TRA 1423 NEEDLE BEARING TORRINGTON 81416 FINAL SUNGEAR CABLE DRUM CABLE ANCHOR PIPE PLUG 3 8 NPT SOCKET HEAD CIRCLIP ANDERTON N1400 0262 These parts vary according to drum code Referto APPENDIXA Refer to PAGE 28 for winch seal kit and PAGE 31 for ASSEMBLY DRAWING PAGE 26 172 REV 010215 FREESPOOL GROUP HYDRAULIC RELEASE G1136 69 64 5 69 69 69 69 9 9 9 98 320 1 277 253 K 252 2 iN B 280 AS NX 257 NS 255 269 ae 265 291 251 250 121 o S 502 Groups drawings may reference parts than are actually present a specific assembly Parts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored 172 REV 950101 PAGE 27 PARTS REFERENCE BRAKE GROUP FREESPOOL COUPLING JOURNAL BEARING O RING 016 5
20. XIMUM VOLUME 26 rpm LINE PULL AT MAXIMUM PRESSURE Bare drum 11 020 Ib 49 0 kN Full drum 5 573 b 24 8 kN LINE SPEED AT MAXIMUM VOLUME Bare drum 37 fom 11 m min Full drum 74 fom 23 m min PERMISSIBLE SYSTEM BACK PRESSURE AT MOTOR RETURN PORT 100 psi 6 9 bar LUBRICATING OIL Refer to RECOMMENDATIONS for viscosity and instructions Refer to APPENDIX A for oil volume required ers eer PAGE 6 172 REV 030429 PERFORMANCE GRAPHS LINE PULL VS OIL PRESSURE 2500 2000 1500 1000 OIL PRESSURE PSI 500 Lo L d d 0 PG R5 110 NIW SH3 LIT 3IACYTIOA 0 2204 4408 6612 8816 11020 Ib 0 1000 2000 3000 4000 5000 kg LINE PULL LINE SPEED VS OIL VOLUME 15 57 S 55 12 45 gt A 9 34 LLI B 2 6 23 J 9 9 P 11 3 L IL 11 Li rin 20 0 16 49 66 82 fpm 0 5 10 15 20 25 m min LINE SPEED Performance graphs are based on standard hydraulic motor and cable drum with 1 2 inch diameter wire rope 172REV 950101 PAGE 7 TYPICAL HYDRAULIC CIRCUIT R5 M L4 rnmmnmmn
21. al roller bearing item 507 and replace if damaged 7 Turn winch over to stand upright on the drum flange Remove circlip item 513 from splined hub of cable drum item 500 8 Inserttwo heel bars between the drum flange and the final housing and carefully pry the cable drum out of ball bearing item 103 9 Remove and discard oil seal item 105 If removal of ball bearing item 103 is necessary first remove circlip item 109 DISASSEMBLY OF FREESPOOL ASSEMBLY If a problem in the freespool assembly is analysed follow instructions 1 and 2 from the section titled DISASSEMBLY OF FINAL DRIVE ASSEMBLY then proceed to the appropriate sub heading of HYDRAULIC or MANUAL FREESPOOL HYDRAULIC FREESPOOL R5 X 70 1F 1 Remove four hex capscrews item 253 and lockwashers item 255 from the end of the freespool assembly Since the freespool spring item 280 applies pressure against the inside of the freespool cover it is recommended that the hex capscrews are unscrewed one turn ata time evenly until the spring pressure has beenreleased 2 Discard O ring item 257 and remove freespool spring item 280 3 Remove the freespool piston item 264 along with the final sungear item 340 from the freespool cover and discard O rings item 265 and item 277 Inspect the outside diameter of the piston and the internal diameter of the housing for any scoring caused by hydraulic fluid contamination Minor surface damage may be repaired by polishing with a fine
22. ations as listed in the manual under SPECIFICATIONS Other use as foreseen in the functional description of the hydraulic winch is not allowed without written permission from PULLMASTER 1 Do not install operate or service winch before reading and understanding manufacturer s instructions 2 The winch described herein is not designed for operations involving lifting or moving personnel 3 Do not lift or carry loads over people 4 Do not exceed recommended operating pressure psi and operating volume gpm 5 Do not jerk the winch Always smoothly accelerate and decelerate load 6 Do not operate a damaged noisy or malfunctioning winch Ta Do not leave a load suspended for any extended period of time 8 Never leave a suspended load unattended 9 Winch should be maintained and operated by qualified personnel 10 Inspect winch rigging mounting bolts and hoses before each shift 11 Warm up equipment before operating winch particularly at low ambient temperatures 12 Verify winch function by raising and lowering 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 hydrauli
23. becomes necessary to disassemble the Model 5 winch 14 172 REV 950101 SERVICE INSTRUCTIONS GENERAL Before attempting disassembly of the PULLMASTER Model R5 planetary winch with freespool the following instructions should be read and understood It is suggested that all expendable parts such as O rings and oil seals are not reused on reassembly Itis therefore important to have a winch seal kit Part No 25829 and providing the hydraulic motor has to be serviced a motor seal kit Part No 25688 on hand A clean working area is of prime importance similar to conditions used for service work on any other hydraulic components All parts as they are removed from the winch assembly should be inspected for wear and damage Thoroughly clean parts before reassembly however do not use solvent to clean friction plates During reassembly lubricate all O rings and oil seals with grease In the following service instructions reference to parts is made by numbers and shown on the applicable group drawings DISASSEMBLY The majority of service or repair work is accomplished by disassembling the brake housing of the PULLMASTER Model 5 planetary winch There are no special tools adjustments or calibrations necessary to service or repair the winch REMOVE HYDRAULIC MOTOR ASSEMBLY 1 Remove two capscrews item 815 and lockwashers item 817 Pull the hydraulic motor item 850 out of the winch assembly 2
24. 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 12 172 REV 051117 TROUBLE SHOOTING GENERAL In most cases when the hydraulic winch does not perform satisfactorily the cause of malfunction is found somewhere in the hydraulic circuit Before the winch is removed from its mounting and disassembled all of the hydraulic circuit components should be checked for proper function IMPORTANT The hydraulic oil volume relates to the line speed or rpm of the winch Therefore if the winch does not produce the maximum rated line speed 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 motor ports when the winch control is completely opened The flow meter should indicate the maximum operating volume If the test described indicates a loss of hydraulic flow check the hydraulic pump the relief valve and the control valve The hydraulic pressure relates to the line pull or lifting capacity of the winch If the winch will not pull the maximum rated load install a pressure gauge into the pressure line leading to the pulling port onthe hydraulic winch motor Stallthe winch to prevent rotation ofthe drum and then open the control valve and check the hydraulic pressure
25. c oil and gear lubricant 19 Keep hydraulic system clean and free from contamination at all times 20 Maintain winch and equipment in good operating condition Perform scheduled maintenance regularly 21 Keep hands clear when winding wire rope onto the winch drum 22 23 Rig the winch carefully Ensure that the wire rope is properly anchored to the correct cable anchor slot at the cable drum 24 Do not lift a load with a twisted kinked or damaged wire rope 25 Consult wire rope manufacturer for size type and maintenance of wire rope 26 Maintain five wraps of wire rope on the cable drum at all times 27 n 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 83 dBA measured on a distance of 1 00 meter 1 60 meters high The measuring equipment used was Realistic 442 3019 29 30 Wear proper clothing and personal protection equipment such as footwear safety goggles and a hard hat Read manual first 06600 Do not use the wire rope as a ground for welding Clean up any oil spillage immediately 172 REV 051117 PAGE 1 DESCRIPTION OF THE MODEL R5 GENERAL DESCRIPTION The PULLMASTER Model 5 planetary hydraulic winch primarily intended for mobile or recovery adaptat
26. d per HYDRAULIC CIRCUIT Failure to vent external brake release port to reservoir may trap pressure and cause winch brake to slip Brake vibrates when lowering a load Pump is too slow Pump rpm must be maintained at normal operating speed when a load is lowered Brake is running too hot This is caused by a complete lack of or insufficient circulation flow To check circulation flow remove safety valve from motor adaptor When winch is reversed oil flow should be approximately 2 5 US gom 9 liter min 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 brake housing from the cable drum interior If the breather relief on the end cover leaks the seal betweenthe drum interior andthe brake housing is damaged mustbe 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 the circulation return line leading backto tank Refer to the SERVICE INSTRUCTIONS if it
27. damage or accelerated 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 clai
28. dinary use and service 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
29. e brake housing from the drum interior Damage to this seal will cause the drum to fill up with hydraulic fluid To prevent damage to the drum seal and end cover of the final drive if the cable drum fills up with hydraulic fluid a breather relief PARTS REFERENCE item 130 is installed on the end cover The breather relief does not prevent oil seal failure but serves as an indicator or warning that the seals between brake housing and the cable drum interior have failed and must be replaced immediately PAGE 2 172 REV 950101 DESCRIPTION OF THE MODEL R5 FUNCTION OF THE FREESPOOL MECHANISM MODEL 5 12 70 1 This model has a manually actuated freespool function The freespool feature is enabled by turning the freespool handle 180 degrees in a counterclockwise direction This will disengage the final sungear from the freespool coupling and provide fora free turning drum re engage the freespool coupling turn the handle 180 degrees a clockwise direction IMPORTANT The freespool function cannot be engaged or disengaged under load or while the cable drum is rotating MODEL R5 12 70 1F This model has a hydraulically actuated freespool feature The final sungear is pulled out of engagement with the freespool coupling by the freespool piston which is spring applied and pressure released To disengage the freespool coupling hydraulic pressure of 400 psi 28 bar must be supplied to the freespool release port see
30. eed the wire rope through the cable anchor slot Loop rope back into slot as shown Insert cable anchor into EM slot small end first and long side nearest the drum flange Pull rope tight to wedge rope in slot CABLE ANCHOR SLOT 7 CABLE ANCHOR wire rope installation care must be taken that the wire rope is wrapped completely around the cable anchor and properly pulled into the cable anchor slot in the cable drum The cable drum requires 5 wraps of wire rope for safety The winch operation is controlled by a single control valve lever which has a forward a reverse and a neutral position Speed control in either direction is obtained by modulation of the control valve lever Maximum line speed in either direction is obtained when the control valve lever is moved as far as it can go The disc brake of the winch will come on automatically when the winch control lever is returned to neutral Always warm up equipment prior to operating winch particularly in low ambienttemperature Circulate hydraulic oil through the winch control valve for several minutes to warm the hydraulic system To prime the winch with warm oil operate the winch at slow speed forward and reverse several times Prevent corrosion damage to winch interior If not used regularly run winch up and down at least once every two weeks To ensure proper winch installation and function raise and lower a full test load to a safe height
31. em 295 from the inside of the follower and pull the ball bearing together with the final sungear out of the follower To remove ball bearing item 291 from the final sungear remove circlip item 269 The PULLMASTER Model 5 winch has now been completely disassembled REASSEMBLY Thoroughly clean and lubricate 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 FREESPOOL ASSEMBLY MANUAL FREESPOOL R5 X 70 1M Press ball bearing item 291 onto final sungear item 340 and secure with circlip item 269 Slide freespool follower item 266 over ball bearing item 291 and fasten between two circlips item 295 Insert follower into bore of freespool housing item 250 and secure with circlip item 288 Engage nutdrive item 256 with freespool follower item 266 by twisting three spring pins item 278 into grooves of follower Place two spring seats item 284 together with detent springs item 276 and indexes item 272 into holes in end of nut drive item 256 Press new well greased oil seal item 299 into seal carrier item 252 Install new well greased O ring item 257 onto seal carrier and fasten onto freespool housing item 250 using four capscrews item 253 and lockwashers item 255 Check chalk marks for proper positioning before tightening PAGE 18 172 REV 030429 SERVICE INSTRUCTIONS continuep 8 Attach freespool hand
32. etected replace friction and divider plates as aset Check oil for contamination if plates are in poor condition DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH 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 brake spacer item 712 two thrust washers item 615 and thrust bearing item 617 13 Remove bronze washer item 706 Remove and discard oil seal item 711 and backup washer item 710 All parts have now been removed from the brake housing and there is no need for further disassembly unless a failure has been analysed in the final drive or freespool mechanism of the Model R5 DISASSEMBLY OF FINAL DRIVE ASSEMBLY If a failure occurs in the mechanism located inside the final drive housing or the winch has to be disassembled beyond the point described in the preceding chapter proceed as follows 1 Remove the drain plug 121 from the freespool housing item 250 and drain the lubricating oil from the final drive assembly and the cable drum interior In order to drain all of the oil out of the cable drum interior the winch should be tipped to an angle and the filler plug item 503 removed PAGE 16 172 REV 030429 SERVICE INSTRUCTIONS 2 After draining all lubricating oil from the final drive housing item 100 rem
33. ions The winch has equal speed in both directions and a freespool feature which can be operated manually or hydraulically depending on the option The main components of this unit are high torque low speed hydraulic motor multi disc brake with over running clutch planetary reduction brake housing cable drum final drive housing freespool mechanism FUNCTION FORWARD ROTATION PULLING In forward rotation or when the winch is pressurized for pulling the output torque and rpm of the hydraulic motor are transmitted through the brake shaft and freespool coupling to the final sungear The planet gears are driven by the final sungear and cause the planet hub to drive the cable drum at a reduction of 9 25 1 When a load is pulled 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 load is held safely by the disc brake FUNCTION IN REVERSE ROTATION PAYING OUT In reverse rotation or paying out 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 The pressure required to release the brake is 400 600 psi 28 42 bar The over running clutch connecting the motor drive shaft to the brake assemb
34. le in piston is clear and unobstructed Re install pipe plug item 755 6 Thoroughly inspect the brake piston outer diameters and brake housing inner bores for scoring caused by hydraulic fluid contamination Minor surface damage may be repaired by polishing with a fine emery cloth 7 Remove coupling fastener item 738 from center of brake shaft item 730 8 the brake shaft item 730 and complete brake hub assembly from the brake housing 9 Disassemble brake hub assembly by removing circlip item 727 from brake shaft item 730 Remove brake shaft from brake hub assembly Remove sprag clutch aligners item 722 and item 724 and sprag clutch item 723 from brake hub MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE MOTOR DRIVE SHAFT AND BRAKE HUB 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 BRAKE SHAFT SPRAG CLUTCH AND BRAKE HUB AS A SET 10 Thoroughly inspect brake shaft item 730 and brake hub item 720 particularly the surfaces where the sprag clutch item 723 engages If any indentation or surface damage is detected replace brake hub sprag clutch and brake shaft as a set 11 Remove the 14 divider plates item 7 13 together with 13 brake plates item 715 andinspect for damage or wear Plates should not show heat discoloration Paper material on friction plates should be intact and smooth If any damage is d
35. le item 254 to nut drive item 256 with capscrew item 297 and lockwasher item 298 Verify handle is in PULLING position when sungear is fully extended 9 Install new well greased O ring item 123 into freespool housing item 250 Verify that planet hub stopper item 126 is in place HYDRAULIC FREESPOOL R5 X 70 1F 1 Press ball bearing item 291 onto final sungear item 340 and secure with circlip item 269 2 Slide freespool piston item 264 over ball bearing item 291 and retain with circlip item 267 3 Install a new well greased O ring item 277 into O ring groove inside freespool housing Install new well greased O ring item 265 onto freespool piston item 264 4 Insertfinal sungear item 340 through opening of freespool housing 5 Install freespool spring in freespool piston item 264 6 Install new well greased O ring item 257 on freespool cover item 252 7 Fastenfreespoolcoveritem 252 using four capscrews item 253 and lockwashers item 255 Tighten capscrews one turn at a time to compress freespool spring REASSEMBLY OF CABLE DRUM ASSEMBLY Reassemble cable drum assembly by reversing the disassembly procedure 1 Press ball bearing item 103 into final housing item 100 and fasten with circlip item 109 2 Press new well greased oil seal item 105 into other side of final drive housing BOO Press final housing item 100 onto hub of cable drum item 500 and fasten with circlip item 513 Turn winch over
36. ly locks causing the brake discs to rotate between stationary divider plates If the load on the cable drum increases the pay out speed the resulting pressure drop in the brake piston increases friction between the friction plates and slows the drum In this way a completely smooth pay out speed can be achieved in a stepless operation by modulation of the winch control valve When the control valve is returned to neutral position rotation stops and the disc brake applies automatically During pay out operations of the winch the friction created by the brake discs results in heat This heatis dissipated by the circulation of hydraulic fluid from the brake housing supplied internally through the hydraulic motor This circulation flow is internally vented to the return line through a check valve arrangementinside the specially modified motor The circulation flow is supplied only when the wire rope is payed out A separate vent line connecting the PULLMASTER Model 5 with the hydraulic reservoir is not required see TYPICAL HYDRAULIC CIRCUIT IMPORTANT SAFETY VALVE The PULLMASTER Model R5 winch does not require a drain line up to 100 psi permissible back pressure in the brake housing To indicate excessive pressure and potential damage to the hydraulic motor or to the oil seal in the brake housing a safety valve is installed on the motor adaptor BREATHER RELIEF VALVE Excessive pressure in the brake housing will damage the oil seal separating th
37. mm 75060017 HC R5 M C CONTROL VALVE MOTOR SPOOL 4 WAY SPRING RETURN TO CENTER PRESSURE Ld RELIEF VALVE HYDRAULIC PUMP RESERVOIR PAGE 8 172 REV 030429 TYPICAL HYDRAULIC CIRCUIT R5 F qmm ems oou EL E LL E 400 PSI 28 BAR PRESSURE REQUIRED FOR FREESPOOL CONTROL VALVE MOTOR SPOOL 4 WAY SPRING RETURN TO CENTER PRESSURE ANE RELIEF VALVE Q FILTER HYDRAULIC PUMP T RESERVOIR 172 REV 030429 PAGE 9 RECOMMENDATIONS HYDRAULIC FLUID The hydraulic fluid selected for use with PULLMASTER planetary winches should be a high grade petroleum based fluid with rust oxidation and wear resistance Fluid cleanliness and operating viscosity are critical to winch reliability efficiency and service life For optimum performance the recommended viscosity range at operating temperature is 81 167 SUS 16 36 CS For extreme operating conditions of short duration the maximum viscosity range of 58 4635 SUS 10
38. ms by Buyer or third 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 Warrant
39. nnection therewith 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 or
40. ove internal retaining ring item 124 The freespool assembly along with the final sungear can now be pulled out of the final drive housing and put aside If a problem exists in the freespool assembly skip ahead to the section titled DISASSEMBLY OF FREESPOOL ASSEMBLY 3 Remove final planet hub assembly from final housing item 100 4 Inspectthree final planet gears item 320 for damage or wear If itis necessary to remove planet gears remove circlip item 311 and press planet pin item 310 out of the final planet hub item 300 Inspect needle bearing item 323 and two thrust washers item 321 and replace if damaged All parts have now been removed from the final drive assembly If further disassembly is required proceed as follows DISASSEMBLY OF CABLE DRUM ASSEMBLY To separate brake housing item 700 and final housing item 100 from cable drum item 500 proceed as follows 1 Remove 16 capscrews item 971 and lockwashers item 973 Remove two tie bars item 970 Stand the winch upright on its end housing 2 Inserttwoheelbars between the flange of the cable drum item 500 and the brake housing item 700 and gently pry the brake housing out of spherical roller bearing item 507 3 Remove freespool coupling item 260 from brake housing Remove O ring item 293 from freespool coupling and discard 4 Inspect journal bearing 286 for excessive wear and replace if necessary 5 Remove and discard oil seal item 515 6 Inspect spheric
41. r the hydraulic circuit ofthe PULLMASTER planetary winch based on a return line filter are given as follows 10 microns 5 microns Average atmosphere Dusty atmosphere In orderto prevent accidental stoppage of the return line flow the oil filter should have a by pass feature USE OF AN E STOP The use of an E stop emergency is mandatory in the controls circuit the E stop is to be placed in the operators control panel The E stop has to be designed and placed in line with EN 60204 and EN 418 PAGE 10 172 REV 030429 INSTALLATION INSTRUCTIONS FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS COULD 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 PULLMASTER planetary winch is installed 1 Make certain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted 2 Set the winch on the mounting platform and check for surface contact on all mounting pads of the winch 3 Ifthere 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 mus
42. t be shimmed If this condition exists proceed as follows a Install mounting bolts snugtightonthe three mounting pads which are in contact with the mounting surface For mounting bolt size and grade see INSTALLATION DRAWING b Measurethe space underneath the fourth mounting pad with a feeler gauge and use shim stock of equivalent thickness in the space between the mounting pad and the mounting surface c Only after this procedure should the fourth mounting bolt be installed Tighten all four bolts per BOLT TORQUE CHART 4 Fill the winch with lubricating oil APPENDIX A for oil volume required 5 Use recommended circuit components and hydraulic hoses 6 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 7 Verify that breather relief item 130 is in place on end cover above oil level End cover may need to be rotated if winch is not installed upright IMPORTANT Do not replace breather relief or safety valve 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 The safety valve acts as a warning that excessive pressure is present in the brake housing and must be rectified immediately 172 R
43. t to change specifications and the design of PULLMASTER planetary winches at any time without prior notice and without incurring any obligations PAGE 22 172 REV 030429 23 Q TT 682 16 vu 4 5 W 22 871 I 1HOd 3sv33u 7100959995 Or TOvHOAH 5 8 V gt 4 94 zv 262 y NOLLVLOH W SH 294 962 8508 ONIH O JYS 3ziunssaud 71 8 2 S1HOd 692 19862 LL cSu eriles 201 09711 69119 0 14 _ lt LAN ae ezz nee 1908 8 082 3ziunssaud 28 loz e S310H ONLLNNOW Usi a e F 65 9 9 6 d 6 4 441 4 d Hr t 9 ud AN nS 52 O NIN H 802 23 1 1 EN 6 3AWA B c TN d L Ivez 622 LAN danau ASIM 9070 9 06
44. y and the transaction 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 Definition Caution indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury 16 FAILURE TO COMPLY WITH THE FOLLOWING SAFETY A RECOMMENDATIONS AND LOCAL RULES AND REGULATIONS WILL RESULT INPROPERTY 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 specific
45. y damaged O ring seals on the brake piston The O ring seals onthe brake release channel between the motor adaptor and the brake housing is damaged If this failure occurs there will be substantial leakage from between the motor adaptor and brake housing Insufficient hydraulic pressure see SPECIFICATIONS for minimum operating pressure Winch is mounted to an uneven surface see INSTALLATION INSTRUCTIONS Hydraulic pressure is not reaching the brake piston plugged brake release orifice in the brake housing 172 REV 950101 PAGE 13 TROUBLE SHOOTING FAILURE PROBABLE CAUSE Brake will not hold Friction 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 tothe 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 brake hub are worn or indented Winch supplied with external brake release option is not plumbe
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