Model PL5 Service Manual
Contents
1. CONTROL VALVE STACK E WE D aL H H H d E p gt lt gt lt 6 gt VALVE CONTROL gt lt VALVE MOTOR SPOOL POWER BEYOND 2 TYPICAL HYDRAULIC CIRCUIT POWER BEYOND CONTROL VALVE Refer to above hydraulic circuit when the winch control valve is used in a circuit containing stacked valves controlling other functions as occurs on hydraulic cranes and loaders The winch control valve must have a motor spool and power beyond feature The winch valve is shown upstream of the stacked control valves If the winch control valve is located downstream of the stacked control valves the valve stack must have the power beyond feature A motor drain line is not required 365 REV 050718 PAGE 7 TYPICAL HYDRAULIC CIRCUITS conrinueo HC PL5 S1 B MOTOR DRAIN LINE MUST GO DIRECT TO RESERVOIR CONTROL VALVE STACK F4 kg RN E H H 9 M bd pa gt lt WINCH CONTROL H if VALVE a 1 CYLINDER SPOOL 3 TYPICAL HYDRAULIC CIRCUIT STACKED CONTROL VALVE Refer to above hydraulic circuit when the wi2. 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 Refer to PAGE 21 for ASSEMBLY DRAWING and PAGE 25 for winch seal kit 365 REV 050718 PAGE 23 BRAKE GROUP 752 754 753 707 801 FRICTION PLATE STACK UP 711 FOR PL5 WITH 213 MOTOR 704 865 882 N lt 871 ja cO VRG S Co f Ee 897 713 700 750 CE 888 Refer to PAGE 21 for ASSEMBLY DRAWING and PAGE 25 for winch seal kit DESIGN REVISION EFFECTIVE FROM SERIAL f 75036 G1283 802 807 809 Group drawings mav 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 PAGE 24 365 REV 050718 PARTS REFERENCE BRAKE GROUP ITEM NO PART NO DESCRIPTION m SUNGEAR BRAKE HOUSING PLANET HUB STOPPER O RING 047 4 1 2 ID 1 16 C
3. On wire rope installation care must be taken that the wire rope is wrapped completely around the cable anchor and properly pulled into the cable anchor slot in the cable drum The cable drum requires a minimum of 5 wraps of wire rope for safety The winch operation is controlled by a single control valve lever which has a forward a reverse and a neutral position Speed control in either direction is obtained by modulation of the control valve lever Maximum line speed in either direction is obtained when the control valve lever is moved as far as it can go The disc brake of the winch will come on automatically when the winch control lever is returned to neutral Always warm up equipment prior to operating winch particularly in low ambient temperature Circulate hydraulic oil through the winch control valve for several minutes to warm the hydraulic systems To prime the winch with warm oil operate the winch at slow speed forward and reverse several times To ensure proper winch installation and function raise and lower a full test load to a safe height before using winch for regular operation at the start of each shift Prevent corrosion damage to winch interior If not used regularly run winch up and down at least once every two weeks If after a new installation the winch does not function properly refer to the TROUBLE SHOOTING section of this manual 365 REV 051117 PAGE 11 TROUBLE SHOOTING GENERAL
4. 1200 83 cc 2 2 M 900 62 0 LU LU 600 41 300 21 0 0 0 750 1500 2250 3000 3750 4500 LINE PULL Ib LINE SPEED VS OIL VOLUME LINE SPEED m min 0 10 20 30 40 50 60 24 91 E 20 L zi S D l J e 2 l L 2 EE 2 2 m A all 8 30 gt J 4 15 e et jf p TNNT il S an 0 33 66 99 132 165 198 LINE SPEED fpm Performance graphs are based on standard hydraulic motor gear ratio and cable drum with 7 16 inch diameter rope PAGE 6 365 REV 050718 TYPICAL HYDRAULIC CIRCUITS HC PL5 S1 B PRESSURE 800 PSI 55 BAR RELIEF VALVE 2 5 US GPM 9 5 L MIN M REQUIRED MODELS SUPPLIED WITH EXTERNAL L J e gt BRAKE RELEASE OPTION m HYDRAULIC WINCH CONTROL EE PUMP RETER 7 VALVE L MI T MOTOR SPOOL 4 WAY SPRING RETURN CENTER IU RESERVOIR L d 1 TYPICAL HYDRAULIC CIRCUIT STANDARD CONTROL VALVE Refer to above hydraulic circuit for installations where the winch is controlled by an individual control valve Note that the valve must have a motor spool both winch ports open to tank in neutral position A motor drain line is not required
5. 5284 699 ve zek 0007 99 ul 29 3009 3809 5 HOLOW 5 4 d H 9 8 nua d s uali38 51108 4 3sn Y Uus 69 fet el via es a S31OH ONILNNOW b W 22 81 8 p 1HOd 3evanau aava 7 NOLLV LOH B IVNOILHO 3SIMHOOTO H31NNOD LN Pl 2 L 1HOd ssoa 3SIMMOO 10 3SINOIOO TOH31N0OO JYS 303 3ziunssaud 8ENN SIHOd HOLOW 9 SANA hades LdN 81 8 LHOd 7 0 05 2 1 ppe UNSIOU asimyoojo JO UIJSIOU JO SI 1 iS3INLL TIY LV GANIVLNIVW 38 LSNIW 3dOH 4HIM dO dVHM S dO WANINIW V ALI VS 365 REV 080512 PAGE 20 lt lt gt a LLI 0 0 lt G1153 8 61283 LIS JOVA uo JHVHA 0 19 91 JOJOW ELZ dn yoe s 104 3BLON gt PAGE 21 365 REV 050718 PARTS REFERENCE DRUM G
6. Do not install operate or service winch before reading and understanding manufacturer s instructions 18 Use only recommended hydraulic oil and gear lubricant 19 Keep hydraulic system clean and free from 2 The winch described herein is not designed for contamination at all times operations involving lifting or moving personnel 20 Maintain winch equipment in good operating 3 Do not lift or carry loads over people condition Perform scheduled maintenance regularly 4 Do not exceed recommended operating pressure 21 Keep hands clear when winding wire rope onto the psi and operating volume gpm winch drum 5 Donotjerkthe winch Always smoothly accelerate 22 Do not use the wire rope as a ground for welding and decelerate load i 23 Rig the winch carefully that the wire 6 Donotoperate a damaged noisy or malfunctioning is properly anchored to the correct cable anchor winch slot at the cable drum 7 Do not leave a load suspended for any extended 24 Do not lift a load with a twisted kinked or damaged period of time wire rope 8 Never leave a suspended load unattended 25 Consult wire rope manufacturer for size type and maintenance of wire rope 9 Winch should be maintained and operated by P qualified personnel 26 Maintain five wraps of wire rope on the cable drum at all times 10 Inspect winch rigging mounting bolts and hoses before each shift 27 In case of a power
7. PAGE 4 365 REV 050718 SPECIFICATIONS Performance specifications are based on standard hydraulic motor gear ratio and cable drum with 7 16 inch diameter wire rope See APPENDIX A for performance of available options CABLE DRUM DIMENSIONS STANDARD DRUM Barrel Diameter 7 38 in 187 mm Flange Diameter 11 00 in 279 mm Barrel Length 6 56 in 167 mm CABLE STORAGE CAPACITV Size of wire rope 1 4 in 348 ft 106 m 5 16 in 218 ft 67 m 3 8 in 157 ft 48 7 16 in 110 ft 34 1 2 in 100 ft 31m MAXIMUM OPERATING PRESSURE 2100 psi 145 bar MAXIMUM OPERATING VOLUME 24 US gpm 91 l min MINIMUM OPERATING VOLUME 6 US gpm 23 l min DRUM TORQUE AT MAXIMUM PRESSURE 17 578 Ib in 1986 Nm DRUM RPM AT MAXIMUM VOLUME 66 rpm LINE PULL AT MAXIMUM PRESSURE Bare drum 4500 Ib 20 0 kN Full drum 3328 Ib 14 8 kN LINE SPEED AT MAXIMUM VOLUME Bare drum 135 fpm 41 m min Full drum 183 fpm 56 m min PERMISSIBLE SYSTEM BACK PRESSURE AT MOTOR RETURN PORT 65 psi 4 5 bar PERMISSIBLE PRESSURE AT BRAKE HOUSING SAFETY VALVE 100 psi 7 bar LUBRICATING OIL Volume required 1 2 drum 0 3 US gal 1 1 litre Volume required 6 drum 0 5 US gal 1 9 litre Refer to RECOMMENDATIONS for viscosity and instructions 365 REV 050718 PAGE 5 PERFORMANCE GRAPHS PG PL5 C LINE PULL VS OIL PRESSURE LINE PULL kN 0 3 3 6 7 10 0 13 3 16 7 20 0 2100 145 1800 124 B 1500 104 8
8. 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 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 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 p
9. The E stop has to be designed and placed in line with EN 60204 and EN 418 365 REV 050718 PAGE 9 INSTALLATION INSTRUCTIONS FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL RESULT IN PROPERTY DAMAGE SEVERE INJURY OR DEATH The initial installation or mounting of a PULLMASTER planetary winch is critically important for proper operation and performance If the winch is mounted to an uneven surface the centre line of the unit can be distorted to a point where the winch will not operate in either direction It is therefore very important that the following instructions are observed when a PULLMASTER planetary winch is installed 1 Make certain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted 2 Set the winch on the mounting platform and check for surface contact on all mounting pads of the winch 3 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 Only a
10. 24211 24211 MOTOR 212 24212 24212 MOTOR 213 24213 24213 365 REV 060714 PAGE 25 APPENDIX A PERFORMANCE DATA Model Number Hydraulic Requirement Drum Drum Bare Drum Full Drum Flow Pressure Torque RPM Line Pull Line Speed Line Pull Line Speed PL5 12 210 1 24 US gom 2100 psi 17 578 Ib in 66 4500 Ib 135 fpm 3328 Ib 183 fom 91 l min 145 bar 1986 Nm 20 0kN 41 m min 14 8 kN 56 m min PL5 12 210 2 24 US gpm 2100 psi 17 578 Ib in 66 450016 135fpm 294516 206 fpm 91 l min 145 bar 1986 Nm 20 0kN 41 m min 13 1 kN 63 m min PL5 12 211 1 11 US gpm 2250 psi 15 625 Ib in 35 4000 Ib 72 3098 Ib 92 fpm 42 l min 155 bar 1765 Nm 17 8kN 22 m min 13 8 kN 63 m min PL5 12 211 2 11 US gpm 2250 psi 15 625 Ib in 35 4000 Ib 72 269516 106 42 l min 155 bar 1765 Nm 17 8kN 22 m min 12 0 kN 32 m min PL5A 12 212 1 11 US gpm 2400 psi 19 532 Ib in 29 5 5000 Ib 60 fpm 3698 Ib 82 fpm 42 l min 165 bar 2207 Nm 22 2kN 18 m min 16 4 kN 25 m min PL5A 12 212 2 11 US 2400 psi 19 532 Ib in 29 5 5000 Ib 60 fpm 327216 92fpm 42 l min 165 bar 2207 Nm 22 2kN 18 m min 14 6 kN 28 m min PL5 12 213 1 11 US gpm 2250 psi 7 813 Ib in 69 200016 142fpm 14796 191 42 l min 155 bar 883 Nm 8 9 kN 43 m min 6 6 58 m min PL5 12 213 2 11 US gpm
11. Starting and finishing with a divider plate alternately install six divider plates item 713 and five friction plates item 716 3a Starting with two divider plates item 713 two friction plates item 716 repeat two divider plates two friction plates one divider plate one friction plate ending with one divider plate item 713 4 Install new well greased O rings items 751 and 753 into piston item 750 Carefully install brake piston in brake housing item 700 5 Install ten brake springs item 752 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 24227 for hydraulic motor 2 Install new well greased rubber channel seal item 887 and item 888 into thrust block item 885 so that protrusions in seal match recesses in block Install new backup seal item 897 over top of channel seal leaving flat side of backup seal flush with surface of thrust block Insert thrust block item 885 into the gear housing making sure seals are facing away from gear set 365 REV 050718 PAGE 17 SERVICE INSTRUCTIONS conrinueo 3 Install well greased section seal item 869 on gear housing item 860 Install gear housing together with seal section onto motor adaptor item 900 lined up on two dowel pins Tap on tight using a soft headed h
12. and conditions contained within this Warranty are void the remaining provisions thereof are and shall remain valid and enforceable SAFETY RECOMMENDATIONS Amen __ Definition Caution indicates a potentially hazardous situation which if not avoided mav minor or moderate injury FAILURE TO COMPLY WITH THE FOLLOWING SAFETY RECOMMENDATIONS ANDLOCAL RULES Definition Warning indicates a potentially A hazardous situation which if not avoided could AND REGULATIONS WILL RESULT IN PROPERTY result in death or serious injury DAMAGE SEVERE INJURY OR DEATH Definition Danger indicates a potentially hazardous situation which if not avoided will result in death or serious injury PULLMASTER planetary hydraulic winches are made for hoisting and lowering loads and are 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 WINCH CORPORATION 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 SPECIFICATIONS Other use as foreseen in the functional description of the hydraulic winch is not allowed without written permission from PULLMASTER WINCH CORPORATION Le
13. caused by a complete lack of or insufficient circulation flow Control valve for the winch operation has poor metering characteristics Damaged brake plates or divider plates Over running clutch is damaged or surface where over running clutch engages on motor drive shaft is worn or indented 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 housings 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 cable drum interior Oil leaks from the safety valve are caused by the excessive pressure in the brake housing or operation with incorrect hydraulic fluid during cold weather or incorrect spool in the control valve Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model PL5 winch 365 REV 050718 PAGE 13 SERVICE INSTRUCTIONS GENERAL Before disassembling the PULLMASTER Model PL5 planetary winch read and understand the following instructions Replace expendable parts such as O rings and oil seals when reassembling the winch Have a winch seal kit Part No 23025 on hand before the unit is disassembled If motor is to be serviced have on hand motor seal kit Part No 24227 NOTE Backup washers may be included with seal kit Install with oil
14. failure or breakdown leading to 11 W f l an unexpected stop of the hydraulic power circuit SR ore operating winch stand clear of the area and the load being hoisted particularly at low ambient temperatures take the necessary precautions to prevent access 12 Verify winch function by raising and lowering a full to area where the load is halted test load to a safe height before each shift 28 The noise level of the winch is 90 dBA measured 13 Do not weld any part of the winch on a distance of 1 00 meter 1 60 meters high The measuring equipment used was Realistic 42 14 Verify gear lubrication and brake circulation supply 3019 and return before operating winch M 29 Clean any oil spillage immediately 15 Be sure of equipment stability before operating winch 30 Wear proper clothing and personal protection equipment such as footwear safety goggles and 16 Wear proper clothing to avoid entanglement in a hard hat Read manual first rotating machinery 17 Always stand clear of the load 365 REV 051117 PAGE 1 DESCRIPTION OF THE MODEL PL5 GENERAL DESCRIPTION The PULLMASTER Model PL5 is a planetary hydraulic winch having equal speed in both directions The main components of this unit are Hydraulic gear motor Multi disc brake with static and dynamic function Over running clutch Primary planet reduction Final planet reduction Brake housing End housing Cable drum a FUNCTIO
15. inside of motor adaptor therefore it is recommended that capscrews are unscrewed one turn at a time until spring pressure has been released The complete motor assembly including motor adaptor can now be removed from brake housing assembly 3 Remove and discard two O rings item 801 and item 707 O ring item 801 seals pressure transfer hole for automatic brake release and is situated on flange of brake housing DISASSEMBLY OF HYDRAULIC MOTOR ASSEMBLY If service or repair work requires access to interior of brake housing hvdraulic motor should not be disassembled If problem has been analvsed to be in hvdraulic motor proceed with disassembiv as follows 1 Remove four hex capscrews item 951 together with lockwashers item 953 from motor assembly IMPORTANT Failure to exercise care when removing motor port end cover or gear housing could permanentiv damage machined surfaces of motor components Take care not to damage machined surfaces of motor components at disassembiv 2 Remove port end cover item 871 from gear housing item 860 3 Remove gear set item 881 item 882 and thrust blocks item 885 4 Remove and discard channel seals item 887 item 888 and backup seals item 897 5 Carefullv prv gear housing item 860 off of motor adaptor item 900 Dowel pins item 865 mav stav in gear housing 6 Discard section seals item 869 Section seals channel seals and backup seals in hvdraulic motor assembly are not part of
16. winch seal kit Seal kit for hvdraulic motor can be ordered from factorv under Part No 24227 PAGE 14 365 REV 050718 SERVICE INSTRUCTIONS conrinueo DISASSEMBLV OF BRAKE HOUSING ASSEMBLV Disassemble brake housing assembiv as follows 1 Remove ten brake springs item 752 Examine springs for damage and measure overall length Overall spring length should be 1 25 inch Springs measuring less than 1 19 inch should be replaced 2 Pull brake piston item 750 out of brake housing item 700 3 Remove and discard O rings item 751 and 753 4 Thoroughiv inspect 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 5 Remove circlip item 727 from primary sungear item 440 Remove brake hub item 720 sprag clutch item 723 and sprag clutch aligners item 722 from primary sungear DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH SOLVENT MAY DAMAGE THE FRICTION PLATES DO NOT USE SOLVENT TO CLEAN THE FRICTION PLATES PERFORM THOROUGH INSPECTION AND IF NECESSARY REPLACE FRICTION AND DIVIDER PLATES AS ASET 6 Remove five friction plates item 716 and six divider plates item 713 and inspect for damage or wear Plates should be flat and smooth Plates should not show heat discoloration Paper material on frictio
17. 2250 psi 7 813 Ib in 69 2000 Ib 142 fpm 1309 Ib 216 fpm 42 l min 155 bar 883 Nm 8 9 kN 43 m min 5 8kN 66 m min CABLE STORAGE DRUM BARREL FLANGE LENGTH WIRE ROPE DIAMETER CODE DIAMETER DIAMETER 1 8 3 16 1 4 5 16 3 8 7 16 1 2 2 7 38 12 38 6 56 2146ft 975ft 510 ft 354 ft 234 ft 177 ft 130 ft 187 mm 314 mm 167 mm 654m 297 155 108 m 71m 54m 40m 6 7 38 11 00 10 00 2106ft 1022ft 531 ft 333ft 239ft 168ft 153 ft 187 mm 279 mm 254 mm 642 311m 162m 101 73 51 47 Performance specifications are based 7 16 inch diameter wire Performance data line pull and line speed for models with 6 drum is same as equivalent model with 1 drum PAGE 26 365 REV 050718 APPENDIX B WINCH PARTS DRUM 100 500 511 520 556 700 CODE END CABLE SET COUPLING TIE BRAKE HOUSING DRUM SCREW BAR HOUSING 1 23026 20361 5 23042 23033 2 23077 22299 3 23042 23075 6 23026 22123 25526 21745 23076 23033 MOTOR PARTS ITEM MOTOR 860 881 882 951 CODE GEAR GEAR GEAR CAPSCREW HOUSING DRIVEN DRIVE HEX HEAD 210 26793 26791 26792 26370 211 26797 26795 26796 26794 212 26798 26799 26800 26801 213 26802 26803 26804 26399 REDUCTION RATIO PART NUMBERS 400 410 420 440 PLANET PLANET PLANET HUB PIN GEAR SONGEAR STANDARD 23022 20776 23023 23028 A 20373 20080 20
18. 371 23078 365 REV 050718 PAGE 27 BOLT TORQUE CHART BOLT DIAMETER TORQUE TORQUE Inches Lb Ft Nm NOTE Unless otherwise specified torque bolts per above chart PAGE 28 365 REV 050718 RAPID REVERSE H and HL Series For winch operations where a load has to be lowered at high speed and with complete control the PULLMASTER planetary winches in the H series offer reversing speeds approximately 4 5 times faster than forward speed Modelsinthe series are available in line pull capacities from 8 500 Ib 3 856 kp to 50 000 Ib 22 680 kp RECOVERY R Series The R Series PULLMASTER recovery winches are ofthe same design conceptas PULLMASTER hoisting winches Freespooling is a standard fea ture of this model and is offered with a manually actuated clutch or is suitable for hydraulic remote control The Three Basic Types of PULLMASTER Planetary Winches EQUAL SPEED IN BOTH DIRECTIONS PL and M Series Seven basic models provide for line pull capacities from 1 102 Ib 500 kp to 50 000 Ib 22 680 kp With the available options PULLMASTER planetary winches can be adapted a b forawiderange of applications and for special operational requirements Pull MASTER A COMPANY Service for PULLMASTER planetary winches can be obtained through a world wide network of PULLMASTER distributors For the distributor nearest to you contact the factory Use o
19. N 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 of the primary reduction is transferred to the final sungear which is splined to the primary planet hub The final planet assembly does not rotate so the rotation is transmitted to the cable drum by the final drive planet gears In forward rotation or when a load is lifted 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 Pressure required to rotate the drum at full speed without load mav varv up to 400 psi 28 bar 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 safelv bv the disc brake FUNCTION IN REVERSE ROTATION LOWERING In reverse rotation or when the winch is pressurized for lowering a load hvdraulic pressure from the reverse side of the hvdraulic motor is channelled to the brake piston causing the brake piston to release the multi disc brake against a number of brake springs The pressure required to rotate the drum at full speed depending upon load mav varv 250 psi to 500 psi 17 bar to 34 bar and without load from 500 psi to 1000 psi 34 bar to 69 bar The over running clutch connecting the motor drive shaft to the brake assembiv locks causing the brake discs to
20. OF MODEL CODING PL 5 X XX X XX XX X XXXX BASIC UNIT SERIES SIZE OF UNIT REDUCTIONRATIO Only used for non standard reduction ratios For A ratio refer to appendix B TYPE OF BRAKE 12 Automatic brake counterclockwise hoisting intravent 13 Automatic brake external brake release counterclockwise hoisting intravent 14 Automatic brake external brake release clockwise hoisting intravent 15 Automatic brake clockwise hoisting intravent Denotes metallic brake plates HYDRAULIC MOTOR 210 Gear motor 33 cc displacement For optional motors refer to APPENDIX A DRUM SIZE 1 7 38 inch drum diameter x 11 00 inch flange diameter x 6 56 inch length STANDARD For optional drum sizes refer to APPENDIX A OPTIONS SPECIFICATIONNUMBER 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 365 REV 050718 PAGE 3 OPTIONS CLOCKWISE ROTATION The drum rotation of the standard PULLMASTER Model PL5 planetary winch is counterclockwise for hoisting when looking at the hydraulic motor of the winch Drum rotation for clockwise hoisting direction is available as an option EXTERNAL BRAKE RELEASE PULLMASTER planetary winches can be supplied with an external brake release which permits release of the automatic disc brake from an
21. PLS THE INTRAVENT PLANETARY HYDRAULIC WINCH INSTRUCTION AND PARTS MANUAL READ THIS MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS PRODUCT THIS MANUAL CONTAINS IMPORTANT INFORMATION MAKE THIS MANUAL AVAILABLE TO ALL PERSONS RESPONSIBLE FOR THE OPERATION INSTALLATION SERVICING AND MAINTENANCE OF THIS PRODUCT POWER to Move the World Effective 2011 10 01 emmen SUPERSEDES 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 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 S
22. RAULIC RESERVOIR It is recommended that the hydraulic reservoir has sufficient capacity to provide good heat dissipation in order to prevent over heating of the hydraulic fluid The hydraulic reservoir should be made from clean and scale free material to prevent contamination of the hydraulic fluid In order to prevent air from being mixed with the hydraulic fluid the reservoir should have an over flow baffle separating the return lines from the suction line and all return lines should enter the reservoir below the fluid level The reservoir should be mounted close to and above the hydraulic pump in a location which provides for free air circulation around the reservoir HYDRAULIC FILTER Consult hydraulic component manufacturer for recommendation Generally 5 to 10 micron filters are acceptable In order to prevent accidental stoppage of the return line flow the filter should have a by pass feature HYDRAULIC HOSES The following hydraulic hose with suitable fittings is recommended for the PULLMASTER Model PL5 planetary winch Pressure lines SAE 100R2 14 or better Motor drain line when required SAE 100R6 6 or better It is recommended that larger hydraulic hose be installed where drain line or pressure lines are excessively long USE OF ANE 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
23. ROUP DESCRIPTION END HOUSING 25237 PIPE PLUG 3 4 14 20367 LANET HUB 20369 25091 ROTOR CLIP SH 87 25091 ROTOR CLIP SH 87 20370 25068 WASHER TORRINGTON TRA 1423 25270 ROLLER5 32X 1 25 TOR E151 Q 20366 R 25273 P ANDERTON A1000 137 UNGEAR STOPPER LANET HUB LANET STOPPER LANETPIN RCLIP ROTORCLIP SH 62 LANET GEAR HRUST WASHER TORRINGTON TRA 1018 NEEDLE BEARING TORRINGTON t B1012 CABLE DRUM CABLE ANCHOR PIPE PLUG 3 8 18 NPT OILSEAL BALLBEARING 6014 SET SCREW 5 16 18NC X 7 16 CIRCLIP ROTOR CLIP HO 433 COUPLING BEARINGFLANGE OILSEAL BALLBEARING 6014 CIRCLIP ROTOR CLIP HO 433 CAPSCREW HEX HEAD 5 16 18 NC X 7 8 GRADE 5 O RING 164 6 1 4 ID 3 32 CS LOCKWASHER 5 16 LOCKWASHER 7 16 CAPSCREW HEX HEAD 7 16 14 NC X 1 25 GRADE 5 TIEBAR AHuouuuooo 1 1 1 3 3 3 3 6 60 1 1 1 1 1 3 6 3 6 3 1 These parts vary Referto APPENDIX B These parts vary Referto APPENDIX B Before Serial 79792 item 101 was part 25032 PAGE 22 365 REV 060714 DRUM GROUP N N SS 77 IV Xs Za a ieee A lt CSS EA t 212 152 7 gt mem DESIGN REVISION EFFECTIVE FROM SERIAL 75036 G1153 LLII ZT AWZ 27 AS ISS A gt RAPS
24. S BACK UP WASHER FOR OIL SEAL 25278 OIL SEAL BRAKE SPACER DIVIDER PLATE FRICTION PLATE OPTIONAL METALLIC PLATES 26362 CIRCLIP ROTOR CLIP SE 118 BRAKE HUB SPRAG CLUTCH ALIGNER SPRAG CLUTCH CIRCLIP ROTOR CLIP SH 106 THRUST WASHER INA AS 3047 THRUST BEARING INA AXK 3047 PISTON O RING 245 4 3 8 ID 1 8 CS 90 DUROMETER BRAKE SPRING O RING 246 4 1 2 ID 1 8 CS 90 DUROMETER ORIFICE PLUG O RING 009 7 32 ID 1 16 CS SHUTTLE PIPE PLUG 1 8 27 NPT CHECK VALVE SAFETY VALVE GEAR HOUSING DOWEL PIN SECTION SEAL PORT END COVER PLUG ORB 4 cere These parts vary THRUST BLOCK Refer to BRAKE CODE CHART below CHANNEL SEAL Refer to APPENDIX B Motor Parts CHANNEL SEAL Refer to APPENDIX B Reduction Ratio BACKUP SEAL MOTOR ADAPTOR CAPSCREW LOCKWASHER 3 8 HIGH COLLAR MOTOR PSCREW HEX HEAD WASHER PLASTIC CAPLUG 1 0625 12 THREADED WINCH SEAL CONSISTING ITEMS 505 531 539 707 710 711 751 753 AND 801 MOTOR SEAL KIT CONSISTING OF ITEMS 869 887 888 AND 897 ITEM 950 MOTOR SUB ASSY CONSISTS OF ITEMS 900 802 805 807 809 832 860 865 869 871 872 881 885 887 888 897 951 AND 953 BRAKE CODE CHART BRAKE CODE 13 14 PART DESCRIPTION PART NUMBERS SHUTTLE 20849 20849 PIPE PLUG 1 8 27 NPT N A N A PIPE ADAPTOR 1 8 27 NPT 25622 25622 CAPLUG 1 8 NPT 25374 25374 MOTOR 210 24210 24210 MOTOR 211
25. S 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 6 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 ofthe PULLMASTER planetary winch has two cable anchor slots one for clockwise and one for counterclockwise hoisting Standard rotation for hoisting 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 capacitv Each winch is shipped from the factorv with a label on the drum indicating the correct cable anchor slot WIRE ROPE INSTALLATION Counterclockwise hoisting winch shown Use cable anchor slot on opposite side of drum for clockwise hoisting winch s 51013 PL5 Feed the wire 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 CABLE ANCHOR SLOT rope in slot ee CABLE ANCHOR
26. Winch is mounted to an uneven surface See INSTALLATION INSTRUCTIONS Hydraulic pressure is not reaching the brake piston due to plugged passage PAGE 12 365 REV 050718 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 of the hydraulic system causes the brake to release Control valve has incorrect spool which traps hydraulic pressure in the brake piston when the control valve handle is returned to neutral position For proper function of the automatic brake both pressure ports of the winch must be open to the reservoir in neutral position of the control valve Wire rope is fastened to the incorrect cable anchor slot Over running clutch is damaged or surface where over running clutch engages on motor drive shaft is worn or indented Winch supplied with external brake release option is not plumbed per TYPICAL HYDRAULIC CIRCUITS Failure to vent external brake release port to reservoir may trap pressure and cause winch brake to slip Pump does not supply sufficient flow Pump rpm must be maintained at normal operating speed when a load is lowered Brake is running too hot This is
27. ammer 4 Install gear set item 881 and item 882 in gear housing External spline end of gear goes into bore of motor adaptor 5 Insert other thrust block complete with backup and channel seals making sure seals are facing away from gear set Install a well greased seal section item 869 on gear housing 6 Install port end cover item 870 onto gear housing and lightly torque four hex capscrews item 951 and lockwashers item 953 to approximately 10 ft lb 14 Nm REPLACE HYDRAULIC MOTOR ASSEMBLY 1 Install new O ring item 707 onto motor adaptor pilot Use grease to temporarily hold two O rings item 801 into recesses on flange of motor adaptor item 900 2 Position motor assembly with brake release pressure transfer holes of motor adaptor and brake housing aligned as per drawing SI1043 below Tighten four capscrews item 931 and lockwashers item 933 one turn at a time to evenly compress springs CCW HOISTING 12 13 CW HOISTING 14 15 11043 ET PIPEADAPTORAND SHUTTLE ARE USED ON THIS SIDE FOR EXTERNAL BRAKE RELEASE 3 Plumb winch assembly to a hydraulic supply and torque motor capscrews according to following procedure Ensure that circulation supply flow is being supplied to the brake housing Run the winch with no load in the hoisting direction at reduced speed approximately 3096 of maximum hydraulic volume With winch running evenly tighten four capscrews
28. calculations and this application factor is 1 0 unless otherwise stated in Seller s quotation specifications The remedies for this Warranty shall be only those expressly set forth above to the exclusion of any and all other remedies of whatsoever kind The limited remedies set forth above shall be deemed exclusive even though they may fail their essential purpose No agreement varying or extending the foregoing Warranty remedies exclusions or limitations shall be effective unless in writing signed by an executive officer of Seller and Buyer This Warranty is non transferable If a party who had purchased articles from Buyer or from persons in privity with Buyer brings any action or proceeding against Seller for remedies other than those set forth in this Warranty Buyer agrees to defend Seller against the claims asserted in such action or proceeding at Buyer s expense including the payment of attorneys fees and costs and indemnify Seller and hold Seller harmless of from and against all such claims actions proceedings or judgments therein Buyer also agrees to defend and indemnify Seller of from and against any loss cost damage claim debt or expenses including attorneys fees resulting from any claims by Buyer or third parties 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 pers
29. eller Notice of claimed breach of this Warranty must be given by Buyer to Seller within the applicable period Such notice shall include an explanation of the claimed warranty defect and proof of date of purchase of the article or part thereof for which warranty coverage is sought No allowances shall be made by Seller for any transportation labor charges parts in and out costs adjustments or repairs or any other work unless such items are authorized in writing and in advance by Seller Nor shall Seller have any obligation to repair or replace items which by their nature are expendable If an article is claimed to be defective in material or workmanship or not to conform to the applicable specifications Seller will either examine the article at Buyer s site or issue shipping instructions for return to Seller This Warranty shall not extend to any articles or parts thereof which have been installed used or serviced otherwise than in conformity with Seller s applicable specifications manuals bulletins or instructions or which shall have been subjected to improper installation operation or usage misapplication neglect incorrect installation overloading or employment for other than normal and ordinary use and service This Warranty shall not apply to any article which has been repaired altered or disassembled or assembled by personnel other than those of Seller This Warranty shall not apply to any article upon which repairs or alterations
30. ess planet pin item 310 into final planet hub item 300 Retain with circlip item 311 5 Insert final planet hub assembly into cable drum Ensure that planet hub spline is fully engaged REASSEMBLY OF PRIMARY DRIVE Reassemble primary drive by reversing the disassembly procedure 1 Press new well greased oil seal item 531 into bearing flange item 530 Press ball bearing item 533 into bearing flange and secure with circlip item 535 2 Verify planet hub stopper item 704 is installed on brake housing hub 3 Verify sungear stopper item 344 and circlip item 341 are installed on final sungear item 340 PAGE 16 365 REV 050718 SERVICE INSTRUCTIONS conrinueo 4 Install final sungear into primary planet hub item 400 5 Reassemble primary planet hub assembly Press needle bearing item 423 into planet gear item 420 Position thrust washer item 421 on either side of planet gear and press planet pin item 410 into primary planet hub item 400 Retain with circlip item 411 6 Verify planet hub stopper item 402 is installed on planet hub 7 Insert primary planet hub assembly into cable drum Ensure that final sungear item 340 is fully engaged with final planet gears item 320 8 Press new well greased oil seal item 711 and backup washer item 710 into brake housing bore item 700 9 Install thrust bearing item 739 with thrust washer item 737 on either side against oil seal item 711 10 Insert prima
31. 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 PL5 planetary winch can be supplied with optional drums to accommodate large wire rope storage capacity DRUM GROOVING Cable drums for the PULLMASTER Model PL5 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 PL5 planetary winch may be changed by using a different displacement motor See APPENDIX A for performance information HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS The operating pressure of the PULLMASTER Model PL5 planetary winch with standard hydraulic motor is limited to 2100 psi 145 bar For hydraulic systems operating with higher 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
32. fter this procedure should the fourth mounting bolt be installed Tighten all four bolts as per BOLT TORQUE CHART at back of manual 4 Fill the winch with lubricating oil Required volume is 0 3 US gallon 1 1 litre Refer to SPECIFICATIONS for 2 and 6 drums Refer to INSTALLATION DIMENSIONS for location of filler port 5 Use recommended circuit components and hydraulic hoses 6 When required the winch motor drain line must be connected directly to the reservoir Do not connect to a common return line IMPORTANT Excessive pressure at brake housing will damage the winch motor or oil seals Never plug safety valve port 7 Before operating the winch with a load verify that hydraulic fluid is circulating through the brake assembly by removing the safety valve and checking flow when the winch is run in the lowering direction Flow should measure 1 5 gpm 6 I min NOTE The hydraulic pressure to rotate the drum at full speed in reverse direction may vary 250 psi to 500 psi 17 bar to 34 bar depending on the load and from 500 psi to 1000 psi 34 bar to 69 bar without load To rotate the drum at full speed in forward direction pressure required may be up to 400 psi 28 bar PAGE 10 365 REV 050718 OPERATING INSTRUCTIONS FAILURE TO FOLLOW OPERATING INSTRUCTIONS COULD RESULT IN PROPERTY DAMAGE SEVERE INJURY OR DEATH After the PULLMASTER planetary winch has been installed in accordance with the INSTALLATION INSTRUCTION
33. gs and oil seals 4 Clean all parts and inspect for wear and damage as per instructions Replace worn or damaged parts as required 5 Reassemble the winch as per instructions 6 Follow INSTALLATION and OPERATING INSTRUCTIONS when returning winch to its mounting When ordering parts for the PULLMASTER Model PL5 planetary winch always quote the complete model number serial number and specification spec number if applicable of the unit MODEL SERIAL SPEC 11030 PL5 Spec Serial 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 365 REV 050718 PAGE 19 2 2 LLI a z lt lt E 0 11120 GY vl ELZ 00 00c 815 081 cov 70 992 6 8 9 ul 0 0L 9181 699 A 9 94 Ser OL 0 0L 621 FS glg E 975 01262 292 291 16 958 08771 61 291 vLE z GEL 12 LLZ ul gel 00911 BEL 85 9 84 cel 0007 92 9 9 vel N 00 00c 815 vvl 081 955 08 1 291 6 2 l EL 18 ee ole ur oor
34. 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 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
35. item 951 to 45 ft Ib 61 Nm Test motor operation by running winch at full speed in both directions IMPORTANT Before operating the winch add lubricating oil up to the level of the end housing oil fill port Refer to INSTALLATION INSTRUCTIONS for location of fill port Required volume of oil is 0 3 US gallon 1 1 litre for 1 and 2 drum 0 5 US gallon 1 9 litre for 6 drum 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 PROBLEMTO GOUNDETECTED AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH TO ENSURE PROPERREINSTALLATION REFER TO PROCEDURES AND TESTS DESCRIBEDIN INSTALLATION AND OPERATING INSTRUCTIONS PAGE 18 365 REV 050718 RECOMMENDED MAINTENANCE Winch gear train lubricating oil should be changed after the initial six months or 50 hours of operation whichever comes first Lubricating oil should then be changed every 12 months or 500 operating hours whichever comes first Hydraulic system fluid should be changed at least once every 12 months For optimum performance over an extended period of time the following preventive maintenance service should be done every 12 months or 500 operating hours whichever comes first 1 Disconnect all hydraulic hoses and remove the winch from its mounting 2 Disassemble the winch as per instructions 3 Discard and replace all O rin
36. lubricating oil IMPORTANT ADDLUBRICATINGOIL UP TO THE LEVEL OF THE END HOUSING OIL FILL PORT BEFORE RUNNING WINCH Refer to INSTALLATION DIMENSIONS for location of lubricating oil fill port Refer to SPECIFICATIONS for quantity of oil required SAE 90 lubricating oil is recommended Consult lubricating oil supplier or factory for temperature beyond normal operating range HYDRAULIC PUMP For maximum performance of the PULLMASTER planetary winch the hydraulic pump must supply the maximum flow of hydraulic fluid at the hydraulic pressure stated in SPECIFICATIONS HYDRAULIC CONTROL VALVE The standard control valve used for operating PULLMASTER planetary winches must have a four way spring return to neutral feature which provides for open flow from the pressure ports of the winch to the reservoir in neutral position of the control motor spool It is important to point out that good speed control especially when lowering a load depends on the metering characteristics of the control valve The better the oil flow is metered the better will be the speed control HYDRAULIC PRESSURE RELIEF The hydraulic circuit for the PULLMASTER planetary winch requires a pressure relief set at the operating pressure see SPECIFICATIONS Usually a pressure relief is part of the hydraulic control valve Where this is not the case a separate pressure relief valve must be installed and set at the recommended maximum pressure HYD
37. n plates should be intact and grooved If any damage is detected replace friction and divider plates as a set winches may contain optional metallic friction plates 7 Remove brake spacer item 712 DISASSEMBLY OF PRIMARY DRIVE If the primary drive requires service or repair disassemble as follows 1 Remove pipe plug item 503 from cable drum item 500 to drain lubricating oil from the winch interior 2 Remove eight capscrews item 555 and lockwashers item 553 Remove two tie bars item 556 Stand winch upright on its end housing 3 Remove six capscrews item 537 and lockwashers item 541 through access opening in brake housing Lift brake housing with bearing flange out of cable drum item 500 bearing flange may stay in the cable drum Remove and discard O ring item 539 4 Remove circlip item 719 from primary sungear item 440 5 Remove primary sungear item 440 from brake housing item 700 MINOR SURFACE DEFECTS WHERE THE OVER RUNNING CLUTCH ENGAGES THE MOTOR DRIVE SHAFT WILL RESULTIN BRAKE FAILURE AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH THOROUGHLY INSPECT THIS AREA AND IF NECESSARY REPLACE PRIMARY SUNGEAR SPRAG CLUTCH AND BRAKE HUB ASSEMBLY AS 6 Thoroughly inspect primary sungear item 440 and brake hub item 720 particularly surfaces where sprag clutch item 723 engages 7 If any indentation or surface damage is detected replace brake hub sprag clutch and primar
38. nch control valve is one of several stacked control valves and has cylinder spool winch ports blocked in neutral position In this configuration the safety valve must be replaced with a drain line plumbed directly to the reservoir The drain line cannot be connected to a common return line IMPORTANT For proper function of the winch in any circuit the return line back pressure measured at the motor return port and the brake housing pressure measured at the safety valve must not exceed pressures per SPECIFICATIONS PAGE 8 365 REV 050718 RECOMMENDATIONS HYDRAULIC FLUID The hvdraulic 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 viscositv are critical to winch reliabilitv efficiencv and service life For optimum performance the recommended viscositv 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 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
39. nly authentic PULLMASTER replacement parts in the repair of a PULLMASTER Planetary winch Purchased items such as bearings seals O rings etc can be supplied from the factory However a cross reference list for such parts is shown in the PARTS REFERENCE of this manual When in doubt about proper function installation or repair of a PULLMASTER planetary winch please contact your nearest PULLMASTER Distributor or the factory POW ER to Move the World TWG Canada LANTEC and Pullmaster Brands 19350 22nd Ave Surrey V3S 356 Voice 1 604 547 2100 Fax 1 604 547 2147 www team twg com A COMPANY PMC365 REV 120612
40. ons 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 the event of Seller s negligence in manufacture installation or otherwise with regard to the articles covered by this Warranty and at the expiration of the Warranty period as above stated all such liabilities shall terminate Buyer s purchase of any article s covered by this Warranty shall constitute acceptance of the terms and conditions hereof and shall be binding upon Buyer and Buyer s representatives heirs and assigns The laws of the Province of British Columbia shall govern Buyer s rights and responsibilities in regard to this Warranty and the transaction s subject thereto and the Province of British Columbia shall be the exclusive forum and jurisdiction for any action or proceedings brought by Buyer in connection herewith or any dispute hereunder If any of the terms
41. rotate between divider plates which are engaged into the brake housing If the load on the cable drum tends to effect the lowering speed the resulting pressure drop in the brake piston causes friction between the brake discs and the divider plates In this wav a completelv smooth paving out speed can be achieved in a stepless operation bv modulation of the winch control handle When the control handle is returned to neutral position rotation stops and the disc brake applies automaticallv A hvdraulic counter balance valve or holding valve is not required for smooth and positive operation of the automatic brake During the lowering operation of the winch the friction created bv the brake discs results in heat This heat is dissipated bv the circulation of hvdraulic fluid through the brake housing supplied internallv through the hvdraulic motor This circulation flow is internallv vented to the return line flow through a check valve arrangement inside the hvdraulic motor The circulation flow is supplied only when a load is lowered A separate vent line connecting the PULLMASTER Model PL5 with the hvdraulic reservoir is not normallv required See TYPICAL HYDRAULIC CIRCUITS IMPORTANT Pressure in the brake housing must never exceed 100 psi 7 bar Excessive brake housing pressure will cause the safety valve located on top of the motor to leak Brake housing pressure can be gauged at the safety valve port PAGE 2 365 REV 050718 EXPLANATION
42. ry sungear item 440 through brake housing bore item 700 and fasten with circlip item 719 11 Install new well greased O ring item 539 onto bearing flange item 530 Insert bearing flange into cable drum opening and fasten with six capscrews item 537 and lockwashers item 541 Slide brake housing item 700 into bearing flange turning primary sungear item 440 to engage primary planet gears item 420 12 Use eight capscrews item 555 and lockwashers item 553 to secure tie bars item 556 13 Install pipe plug item 503 into cable drum REASSEMBLY OF BRAKE HOUSING ASSEMBLY Reassemble brake housing assembly by reversing the disassembly procedure 1 Install sprag clutch item 723 into bore of brake hub item 720 and position sprag clutch aligners item 722 on either side of brake hub Carefully slide brake hub assembly onto primary sungear item 440 Secure with circlip item 727 IMPORTANT For proper brake function verify that brake hub rotation is correct When viewed from the motor end the primary sungear of a counterclockwise hoisting winch must turn freely clockwise and lock in the counterclockwise direction INCORRECT ASSEMBLY OF THE FRICTION PLATE AND DIVIDER PLATE STACK WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH REASSEMBLE PER INSTRUCTIONS 2 Install brake spacer item 712 into brake housing item 700 NOTE For PL5 with 213 motor Refer to 3a 3
43. seals as per instructions If not present in seal kit the oil seals supplied do not require backup washers Disconnect all hydraulic hoses remove the winch from its mounting and relocate to a clean working area similar to one used for service work on any other hydraulic component Special tools are not required to service the winch Adjustments and calibrations are not required 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 The following SERVICE INSTRUCTIONS refer to part descriptions and item numbers which appear in the group drawings DISASSEMBLY For the majority of required service or repair work disassembly is required only on the brake housing of the PULLMASTER Model PL5 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 REMOVAL OF HYDRAULIC MOTOR ASSEMBLY 1 Before removing hydraulic motor refer to page 18 drawing 511043 and tick mark the position of the hydraulic motor to facilitate reassembly 2 Remove four capscrews item 931 and lockwashers item 933 from the motor adaptor item 900 Brake springs item 752 apply pressure against
44. um 2 Inspect three final planet gears item 320 for damage or wear If it is necessary to remove planet gears remove circlip item 311 and press planet pin item 310 out of final planet hub item 300 Inspect 20 loose rollers item 323 and two thrust washers item 321 and replace if damaged Winches with optional 6 drum only 2a Remove coupling item 520 from end housing spline 3 Remove end housing item 100 out of cable drum ball bearing item 507 4 Remove circlip item 513 Push ball bearing item 507 out of cable drum Inspect and replace if damaged 5 Remove and discard oil seal item 505 6 Inspect cable drum gear teeth for damage or wear 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 Reassemble final drive by reversing the disassembly procedure 1 Press new well greased oil seal item 505 into cable drum item 500 2 Press ball bearing item 507 into cable drum and secure with circlip item 513 3 Insert end housing item 100 into cable drum ball bearing item 507 Winches with optional 6 drum only 3a Engage coupling item 520 onto end housing 4 Reassemble final planet hub assembly Use grease to temporarily hold 20 loose rollers item 323 in bore of planet gear item 320 Position thrust washers item 321 on either side of planet gear and pr
45. ump 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 verify 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 indications for probable causes of failure in the winch FAILURE PROBABLE CAUSE Winch will not produce line pull at maximum a Winch is mounted to an uneven surface pressure aslistedin SPECIFICATIONS See INSTALLATION INSTRUCTIONS b 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 system Winch will not produce line speed at maximum Winch is mounted to an uneven surface volumeaslistedin SPECIFICATIONS See INSTALLATION INSTRUCTIONS Cable sheaves or block purchase operated with the winch are not turning freely Damage or wear in the hydraulic motor Excessive back pressure in the hydraulic system Winch will not reverse Leakage out of the brake piston prevents the disc brake from being released against the brake springs This is caused by damage to the O rings on the brake piston or connecting tube Insufficient hydraulic pressure See SPECIFICATIONS for minimum operating pressure
46. y sungear as a set 8 Remove two thrust washers item 737 and thrust bearing item 739 Inspect parts and replace if damaged 9 Remove and discard oil seal item 711 and backup washer item 710 10 Remove primary planet hub assembly with final sungear item 340 from cable drum 365 REV 050718 PAGE 15 SERVICE INSTRUCTIONS 11 Inspect planet hub stopper item 402 for damage or wear and replace if less than 09 inch thick 12 Inspect three primary planet gears item 420 for damage or wear If it is necessary to remove 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 or worn 13 Remove final sungear item 340 with circlip item 341 and sungear stopper item 344 Inspect stopper for damage or wear If stopper is worn more than 03 inch below face of sungear stopper should be replaced 14 Inspect planet hub stopper item 704 for damage or wear and replace if less than 09 inch thick 15 Pull bearing flange item 530 and ball bearing item 533 off of brake housing 16 Remove circlip item 535 Push ball bearing item 533 out of bearing flange Inspect and replace if damaged 17 Remove and discard oil seal item 531 DISASSEMBLY OF FINAL DRIVE If final drive requires service or repair disassemble as follows 1 Remove final planet hub assembly from cable dr
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