Model HL25 Service Manual
Contents
1. Groups drawings reference more parts than are actually present specific assembly Parts that referenced on the drawing but are not on the PARTS REFERENCE list should be ignored 313 REV 970317 PAGE 27 PARTS REFERENCE BRAKE GROUP PLANET HUB RETAINING RING PLANET PIN CIRCLIP ROTOR CLIP C 87 CIRCLIP ROTOR CLIP SH 87 PLANET GEAR THRUST WASHER TRA 1423 LOOSE ROLLER 5 32 X 1 25 TORRINGTON E151 Q INTERNAL GEAR CIRCLIP ROTOR CLIP SH 300 THRUST WASHER TORRINGTON TRA 6681 THRUST BEARING TORRINGTON NTA 6681 SUNGEAR SUNGEAR STOPPER BEARING FLANGE OILSEAL BALL BEARING 6026 BEARING RETAINER CAPSCREW HEX HEAD 1 2 13NC X 1 50 GRADE 5 O RING 269 8 3 4 ID 1 8 CS LOCKWASHER 1 2 CONNECTING SHAFT NEEDLE BEARING TORRINGTON B 3012 NEEDLE BEARING TORRINGTON NBH 4812 OIL SEAL THRUST WASHER TORRINGTON TRB 6074 THRUST BEARING TORRINGTON NTA 6074 CLUTCH HOUSING O RING 278 12 ID 1 8 CS DRIVE GEAR CIRCLIP ROTOR CLIP SH 375 SPRAG CLUTCH BORG WARNER 140373 B SPRAG CLUTCH ALIGNER CAPSCREW SOC HEAD 1 2 13NC X 4 1 4 LONG GRADE 8 LOCKWASHER 1 2 COLLAR BRAKE HOUSING PLASTIC CAPLUG 1 NPT THREADED O RING 278 12 ID 1 8 CS OIL SEAL BRAKE SPACER DIVIDER PLATE FRICTION PLATE BRAKE HUB SPRAG CLUTCH ALIGNER SPRAG CLUTCH SPRAG CLUTCH ALIGNER ACCESS PLUG O RING 123 1 3 16 ID 3 32 CS2. WNYd VIC 0L NO 3dOH VIG 18 2 94 2 ATAVLINS SI HOHONV 3 1H VO GHVGNVLS STAGOW 100445 3344 M STAGOW 15 1 5 89 9 ONIWO AVS tan eu Et H 28 LdN 1 ANN 81 91 6 14 81 8 LHOd 1HOd 1HOd 1HOd 5 NOILWINSHID S431139 HOS JYS 1108 NILNNON v L L ISN iig 8L v L ANN 81 91 6 LHOd sze VIG 26 6 S310H ONILNNOW 527 HOLM10 Q33dS H9IH I 100465 3344 Tn u Y asap ii ig N 8 Y Y H 3 8 B i 1 9 6 i 22 8 1 140d 3SV43 T3H 3ZIS 1HOd IVNH3LX3 8L v L HOLOW 33S NO HO 13 00 TWNOILdO S1HOd 35v5 FONV14 L108 v AVS HOHONV 318 0 NI 1 001 RR 14 3SIMMOO19 H31Nn0OO 3SINo2019 190 HATHA aziunssaud NOILV LOH 1 1 3SIMM2012 LYOd H3TII i SAWIL TIV LV d 3ziunss3ud Q3NIV LNIVIN 38 LSNW 3dOH 3HIM SdVHM S A 1348 HOS 3ATVA 33r138 H3H1V3H8 313 REV 051117 PAGE 34 INSTALLATION DIMENSIONS GEAR MOTOR
3. 1 L LJ 0 0 100 200 300 400 500 600 700 800 900 965 LINE SPEED fpm Performance graphs are based on standard hydraulic motor gear ratio and cable drum with 7 8 inch diameter wire rope a w a m aa ssaBpzyj 8j al j s b c PAGE 8 313 REV 970901 PERFORMANCE GRAPHS FOR STANDARD PISTON MOTOR PG HL25 129 A LINE PULL VS OIL PRESSURE LINE PULL kN 0 22 44 67 89 111 3800 262 3040 209 i 2 LLI LLI 2280 157 tc 2 2 2 2 1520 105 A A 760 52 0 0 0 5000 10000 15000 20000 25000 LINE PULL Ib HOISTING LINE SPEED VS OIL VOLUME SQA R R R SQ A HIGH SPEED HOISTING AND LOWERING LINE SPEED m min 0 91 122 152 183 213 244 274 294 61 Paty el wu epe T 231 L 271 4 E ae 1 iter jJ D 40 be D 151 Pd 2 7 1 i gt 2 2 2 _ LLI 27 E 0 2 113 5 C 3 2 1 20 76 gt gt C J 10 E 4 38 0 1 1 d LF L 1 L T 1 Lo 0 A 400 500 600 700 800 900 965 LINE SPEED fpm Performance graphs are based on standard hydraulic motor gear ratio and cable drum with 7 8 inch diameter wire rope u sayw a s sTs ss
4. PRIOR TO SERIAL 52015 129 Motor was Model F11 110 with 11 4 4 bolt flange ports with M14 x 2 screw threads Drain ports were 3 4 BSP 313 REV 010201 PAGE 37 ASSEM BLY DRAWI NG G1000 A amp G1003 B amp G1007 B PAGE 38 313 REV 010201 LOW SPEED HOISTING HIGH SPEED HOISTING amp LOWERING LINE PULL LINE SPEED MAXIMUM LINE SPEED AT MAXIMUM AT MAXIMUM ALLOWABLE AT MAXIMUM __ Lusricatine CABLE DRUM SIZES WIRE ROPE STORAGE PRESSURE VOLUME LINE PULL VOLUME ETA INCHES FEET REQUIRED POUNDS FEET MINUTE POUNDS FEET MINUTE Us KILONEWTONS METERS MINUTE KILONEWTONS METERS MINUTE TERS BARE FULL BARE FULL BARE FULL BARE FULL BARREL FLANGE LENGTH 3 4 inch DRUM DRUM DRUM DRUM DRUM DRUM DRUM DRUM MILLIMETERS METERS Performance specifications are based on standard hydraulic motor with 7 8 inch diameter rope 313 REV 010201 PAGE 39 340 550 552 FINAL BASE DRUM CODE SUNGEAR PAGE 40 313 REV 970317 APPENDIX C BRAKE CODE NO DESCRIPTION PART NUMBERS 1 8 27 NPT 807 PIPE PLUG 25040 N A N A 25040 1 8 27 NPT PIPE 25622 25622 ADAPTOR 1 8 NPT MOTOR 22054 22055 22056 22057 313 REV 970901 PAGE 41 BOLT TORQUE CHART BOLT DIAMETER TORQUE TORQUE Inches lb ft Nm NOTE Unless otherwise specified torque bolts per above chart
5. d CONTROL VALVE T 3 5 4 US 13 15 I min I Le IA ME 400 PSI 28 BAR PRESSURE REQUIRED FOR MODELS SUPPLIED 7 US WITH FREESPOOL OPTION a gpm Sus ONINI REQUIRED FOR MODELS SUPPLIED WITH EXTERNAL CIRCULATION RETURN LINE BRAKE RELEASE OPTION MUST GO DIRECT zs TO RESERVOIR FORWARD REVERSE PORT PORT A CIRCULATION SUPPLY LINE AA i M CONTROL VALVE MOTOR SPOOL E 4 WAY SPRING RETURN TO CENTER pu PRESSURE RELIEF VALVE lt gt FILTER jT HYDRAULIC PUMP RESERVOIR 313 REV 010201 PAGE 11 INSTALLATION INSTRUCTIONS FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL RESULT IN PROPERTY SEVERE INJURY OR DEATH The initial installation or mounting 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 winchon 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
6. 4635 SUS 10 1000 CS should not be exceeded For optimum performance the winch recommended hydraulic fluid temperature operating range is 80 150F 27 66 C For extreme operating conditions of short duration the maximum temperature range of 5 180F 21 82 C should not be exceeded LUBRICATION The winch gear train requires oil bath lubrication The winch is shipped from the factory without lubricating oil IMPORTANT ADD LUBRICATING OIL BEFORE RUNNING WINCH Refer to INSTALLATION DIMENSIONS for location of lubricating oil fill port Refer to APPENDIX A for quantity of oil required For normal operating temperature use SAE 90 lubricating oil For temperatures beyond normal operating range consult lubricating oil supplier or factory 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 important to point out that good speed control especially when lowering a load depends on the metering HYDRAULIC PRESSURE RELIEF The hydraulic circuit for the PULLMASTER planetary winch requ
7. Avi MASTER THE LOGICAL CHOICE INSTRUCTION AND PARTS MANUAL MODEL HL25 PLANETARY HYDRAULIC WINCH amp to Move the World TWG Canada LANTEC and Pullmaster Brands 19350 22nd Ave Surrey BC V3S 356 Voice 1 604 547 2100 Fax 1 604 547 2147 www team twg com A COMPANY READ THIS MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS PRODUCT THIS MANUAL CONTAINS IMPORTANT INFORMATION MAKE THIS MANUAL AVAILABLE TO ALL PERSONS RESPONSIBLE FOR THE OPERATION INSTALLATION SERVICING AND MAINTENANCE OF THIS PRODUCT PMC 313 120612 POVER e Effective 2011 10 01 A TOWER compar SUPERSEDES ALL PRIOR WARRANTIES LANTEC Pull MASTER LIMITED WARRANTY 50130 0 Seller warrants that each article whether Gear Drive Products Brake Products and or Winch Products all of which are covered hereunder sold under this order shall at the time of shipment i conform to applicable specifications and ii be free from defects in material and workmanship during normal and ordinary use and service the Warranty Buyer s exclusive remedy and Seller s sole obligation under this Warranty shall be at Seller s option to repair or replace any article or part thereof which has proven to be defective or to refund the purchase price of such article or part thereof Buyer acknowledges that Buyer is knowledgeable concerning the articles covered by this Warranty and sold in connecti
8. PAGE 42 313 REV 970317
9. Two new roller bearings item 875 may also be required Part No 25352 For models with a piston motor use seal kit Part No 23140 NOTE Backup washers may be included with seal kit Install with oil seals as per instructions If not present in seal kit the oil seals supplied do not require backup washers A clean working area is of prime importance similar to conditions used for service work on any other hydraulic component All parts as they are removed from the winch assembly should be inspected for wear and damage Worn or damaged parts must be replaced Thoroughly clean parts before reassembly Do not use solvent to clean the brake or clutch friction plates During reassembly lubricate all O rings and oil seals with grease before installation In the following service instructions reference to parts is made by numbers and shown on the applicable group drawings The service instructions cover assembly and disassembly of Model HL25 with either hydraulic gear or piston motors Refer to appropriate instructions and group drawing for each motor The remaining instructions apply to all Model HL25s DISASSEMBLY For the majority of required service or repair work disassembly is required only in the brake housing or clutch housing of the PULLMASTER Model HL25 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 D
10. 11006 2 amp 11006 3 A Dimensions in inches Dimensions in millimeters Dimensions in inches Dimensions in millimeters HYDRAULIC GEAR MOTORS COMMERCIAL WM76 SERIES COMMERCIAL M365 SERIES MOTOR GEAR MOTOR PORT SIZE L MOTOR GEAR MOTOR PORT SIZE I CODE WIDTH SAE 4 BOLT FLANGE CODE WIDTH SAE 4 BOLT FLANGE CODE 61 CODE 61 86 3 00 5 42 2 50 9 3 76 2 63 5 236 87 2 75 101 2 25 9 0 69 9 57 2 229 88 2 50 102 2 00 8 8 63 5 50 8 223 89 2 25 57 2 90 2 00 50 8 91 175 44 5 92 1 50 38 1 93 1 25 31 8 94 1 00 25 4 313 REV 970317 PAGE 35 11007 1 STAGOW 10046 3344 3dOH VIG a 8 2 9L HO3 318V1InS S13qON 15 QJ SI HOHONV d 18VO QHVONVIS a 5 eet LAN 1HOd Z L NOILV LOW 1HOd 3 H _ feel ASIMMOOTOHALNNOOD QJ 3ZltinSS3tid 1HOd S 70095 4344 81108 v 1 L
11. 4 2 1 9 1 8 8 2 O RING 022 1 ID 1 16 CS O RING 015 9 16 ID 1 16 CS CAPSCREW HEX HEAD 1 2 13NC X 4 3 4 LONG GRADE 5 PRESSURE PLATE O RING 126 1 3 8 ID 3 32 CS CLUTCH PLATE GLAND O RING 153 3 1 2 ID 3 32 CS RETAINING RING CLUTCH HUB CIRCLIP ROTOR CLIP SH 387 FRICTION PLATE DIVIDER PLATE CLUTCH SPRING CIRCLIP ROTOR CLIP SHR 125 CIRCLIP ROTOR CLIP SH 196 MOTOR DRIVE SHAFT CIRCLIP ROTOR CLIP C 112 O RING 123 1 3 16 ID 3 32 CS MOTOR ADAPTOR O RING 90 DUPO 013 7 16 ID 1 16 CS PIPE PLUG 1 8 PIPE PLUG 1 4 NPT SOCKET HEAD LEVL SEAL UNBRAKO PLASTIC CAPLUG 3 8 NPT PRESSURE REDUCING VALVE PIPE ADAPTOR 6 SAE X 1 4 NPT AIRWAY 6401 6 4 TRANSFER TUBE ASSY INCLUDES ITEM 867 O RING 906 SAE ORB 06 TRANSFER TUBE HOUSING LOCKWASHER 3 8 HIGH COLLAR TUBE LOCATOR CAPSCREW SOCKET HEAD 3 8 16NC X 1 00 GRADE 5 SLOTTED SPRING PIN 1 16 DIA X 1 4 LONG GEAR HOUSING DOWEL PIN LOOSE ROLLER 2 5 MM DIA X 15 8 MM GASKET SEAL PORT END COVER ROLLER BEARING RING SEAL O RING 010 1 4 ID 1 16 CS GEAR SET THRUST PLATE TEFLON SEAL PIPE PLUG 1 4 NPT SOCKET HEAD LEVL SEAL UNBRAKO PIPE PLUG 1 4 NPT LOCKWASHER 1 2 SUB ASSY MOTOR CAPSCREW HEX HEAD 5 8 X 6 75 GRADE 5 WASHER PLASTIC CAPLUG 2 0 DAEMAR T 21 MOTOR SEAL KIT FOR GEAR MOTOR CONTAINS ITEMS 869 877 AND 887 These part numbers and descriptions vary according to brake code Refer to APPENDIX C ITEM 950
12. If this load is exceeded winch will stall PAGE 2 313 REV 980301 DESCRIPTION OF THE MODEL HL25 CONTINUED FUNCTION IN REVERSE ROTATION RAPID REVERSE When the hydraulic motor is pressurized for rapid reverse the rotation of the motor drive shaft causes the sprag clutch to lock resulting in a solid assembly between the motor drive shaft and the connecting shaft Rotation of the connecting shaft causes the sprag clutch between the connecting shaft and the brake hub to lock making a solid assembly between these two components Hydraulic pressure is automatically transmitted to the brake piston forcing the brake piston to release brake against a series of brake springs The friction plates which are engaged in the brake hub can now rotate between the divider plates Since both sprag clutches are locked the friction plates brake hub connecting shaft internal gear and primary sungear turn at the same revolution as the motor drive shaft Thus the primary drive is eliminated resulting in a reversing speed 4 67 times faster than low forward speed If load on the cable drum tends to affect the reversing speed the resulting pressure drop in the brake piston causes friction between the friction plates and the divider plates Thus a completely smooth reversing speed can be controlled in a stepless operation by modulation of the winch control handle When the control is returned to neutral position rotation stops and the disc brake applies
13. PISTON O RING 90 DURO 451 11 ID 1 4 CS BRAKE SPRING O RING 90 DURO 452 11 1 2 ID 1 4 CS O RING 90 DURO 013 7 16 ID 1 16 CS k 3 3 3 3 6 0 1 1 2 1 1 1 1 1 1 1 6 1 6 1 1 2 1 2 1 1 1 1 1 1 1 3 3 1 1 1 1 1 7 1 1 1 1 1 1 1 1 8 1 3 Refer to PAGE 26 for winch seal kit and PAGE 25 for ASSEMBLY DRAWING PISTON MOTOR or PAGE 38 for ASSEMBLY DRAWING GEAR MOTOR PAGE 28 313 120330 GROUP G1003 B N O 606 715 600 751 750 753 N N N ME aN DDE N N DG N k O N g G 39 530 541 537 734 735 700 712 615 722 723 703 713 607 720 7 Group drawings reference more parts than actually present specific assembly Parts that referenced on the drawing but are not on the PARTS REFERENCE list should be ignored 313 REV 970317 PAGE 29 REFERENCE GEAR MOTOR GROUP 1 1 9 1 1 1 1 1 1 1 1 8 7 3 1 1 1 1 1 1 3 1 2 1 1 2 3 1 1 1 1 1 2 1 2 2 1 4 1 2 1 4 2 1 1 2
14. Remove five friction plates item 715 together with 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 friction plates should be intact and grooved If any damage is detected replace friction and divider plates as a set 5 Remove brake spacer item 712 DISASSEMBLY OF FINAL DRIVE 1 Remove drain plug item 121 from end cover item 120 and drain lubricating oil from final drive assembly and the cable drum interior To drain all oil out of cable drum interior winch should be tipped to an angle and filler plug item 503 removed 2 Remove internal retaining ring item 124 and pull end cover item 120 out of final drive housing item 100 3 Discard O ring item 123 and inspect planet hub stopper item 126 and sungear stopper item 122 for excessive wear Replace planet hub stopper if less than 30 inch and sungear stopper if less than 21 inch thick 4 Remove final planet hub assembly from final housing item 100 m f PAGE 18 313 REV 970901 SERVICE INSTRUCTIONS 5 Inspect three final planet gears item 320 for damage or wear If necessary to remove final planet gears
15. any spring measures less than 1 19 inch all three springs should be replaced as a set 6 Inspect eight friction plates item 673 for damage or excessive wear Plates should be flat and smooth Plates should not show heat discoloration Paper material on friction plates should be intact and grooved If any damage is detected replace friction plates and divider plates as a set 7 Remove circlip item 661 and slide drive gear item 660 off of connecting shaft item 600 DISASSEMBLY OF BRAKE HOUSING ASSEMBLY 1 Remove 18 brake springs item 752 from brake piston item 750 Thoroughly examine springs for damage and measure overall length Overall spring length should be 2 27 inch If any spring measures less than 2 21 inch replace all springs as a set 2 Pull brake piston item 750 out of brake housing using two 5 8 11NC bolts screwed into two puller holes in piston and discard O rings item 751 and 753 3 Thoroughly examine inner bores of brake housing and outer diameters of brake piston for scoring caused by hydraulic fluid contamination Minor surface damage may be repaired by polishing with a fine emery cloth DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH SOLVENT MAY DAMAGE THE FRICTION PLATES DO NOT USE SOLVENT TO CLEAN THE FRICTION PLATES PERFORM THOROUGH INSPECTION AND IF NECESSARY REPLACE FRICTION AND DIVIDER PLATES AS A SET 4
16. item 537 and lockwashers item 541 14 Install new well greased O ring item 735 into access plug item 734 Install access plug into access hole inside brake housing 15 Attach base halves item 500 and 552 using 28 capscrews item 551 and lockwashers item 553 REASSEMBLY OF BRAKE HOUSING ASSEMBLY Reassemble brake housing assembly as follows 1 Install brake spacer item 712 into brake housing INCORRECT ASSEMBLY OF THE FRICTION PLATE AND DIVIDER PLATE STACK WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH REASSEMBLE PER INSTRUCTIONS 2 Starting and finishing with a divider plate alternately install seven divider plates item 713 and six friction plates item 715 3 Liberally grease O ring item 751 and O ring item 753 and install on brake piston item 750 4 Slide brake piston into brake housing with holes for brake springs facing out of brake housing assembly 5 Install 18 brake springs item 752 in brake piston Brake piston has 20 holes and two empty holes should be opposite each other 6 Liberally grease three new O rings item 763 and install into recesses on clutch housing item 650 Install new well greased O ring item 707 on flange of clutch housing 7 Usingthree socket head capscrews item 682 and high collar lockwashers item 683 fasten clutch housing item 650 to brake housing item 700 Ensure brake release passage way is to right
17. remove circlip item 311 and press planet pin item 310 out of planet hub item 300 Inspect loose rollers item 323 and two thrust washers item 321 and replace if damaged DISASSEMBLY OF PRIMARY DRIVE AND CABLE DRUM ASSEMBLY For ease of working on remainder of unit set winch upright on final drive housing 1 Remove the two winch base halves item 550 and 552 by removing the 28 hex capscrews item 551 and lockwashers item 553 2 Remove access plug item 734 using a 1 2 13NC bolt motor adaptor bolt item 821 is suitable from inside brake housing and discard O ring item 735 3 Remove six hex capscrews item 537 with lockwashers item 541 from bearing flange item 530 by rotating brake housing until access hole is over top 4 Liftbrake housing together with the bearing flange and primary planet hub assembly out of cable drum item 500 and discard O ring item 539 5 Remove retaining ring item 401 and remove primary planet hub assembly from inside internal gear item 430 6 Inspect three primary planet gears item 420 for damage or wear If necessary to remove primary planet gears remove circlip item 411 and press planet pin item 410 out of planet hub item 400 Inspect loose rollers item 423 and two thrust washers item 421 and replace if damaged 7 Remove primary sungear item 440 from center of connecting shaft item 600 8 Remove circlip item 431 and internal gear item 430 from connecting shaft
18. Hoisting 229 rpm LINE PULL AT MAXIMUM PRESSURE IN LOW FORWARD MODE Bare drum 25 000 Ib 111 2 kN Full drum 16 860 Ib 75 0 kN ALLOWABLE LINE PULL IN RAPID FORWARD OR RAPID REVERSE MODE Bare drum 5 357 Ib 23 8 kN Full drum 3 613 Ib 16 1 kN LINE SPEED AT MAXIMUM VOLUME IN LOW FORWARD MODE Bare drum 140 fpm 43 m min Full drum 207 fpm 63 m min LINE SPEED AT MAXIMUM VOLUME IN RAPID FORWARD OR RAPID REVERSE MODE Bare drum 651 fpm 198 m min Full drum 965 fpm 294 m min PERMISSIBLE SYSTEM BACK PRESSURE AT MOTOR RETURN PORT 65 psi 4 5 bar PERMISSIBLE PRESSURE AT CIRCULATION SUPPLY PORT 30 psi 2 bar LUBRICATING OIL Refer to RECOMMENDATIONS for viscosity and instructions Refer to APPENDIX A for oil volume required t PAGE 6 313 REV 010201 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
19. Press one of thrust plates together with two teflon seals onto bearings item 875 installed in motor adaptor item 800 3 Install new well greased gasket seal item 869 on each side of gear housing item 861 Slide gear housing together with gasket seals onto motor adaptor lined up on two dowel pins Tap on tight using soft headed hammer 4 Install gear set item 881 in gear housing Longer gear with internal spline goes into top position 5 Press other thrust plate complete with two new teflon seals onto bearings installed in port end cover 6 Install port end cover item 870 together with two bearings item 875 and new ring seal item 877 onto gear housing lined up two dowel pins item 865 Tap on tight using soft headed hammer Install and lightly torque eight hex capscrews item 951 and lockwashers item 953 to approximately 50 ft Ib 70 Nm 7 Plumb winch assembly to a hydraulic supply and torque motor capscrews according to the following procedure Ensure that circulation supply flow is being supplied to the brake housing Run the winch with no load in the hoisting direction at reduced speed approximately 3096 of maximum hydraulic volume With winch running evenly tighten eight capscrews item 951 to 200 ft Ib 270 Nm Test motor operation by running winch at full speed in both directions IMPORTANT Before operating the winch add lubricating oil up to the level of the end cover oil fill port Refe
20. SHR 125 LOCKWASHER 1 2 COLLAR CAPSCREW SOCKET HEAD 1 2 13NC X 1 50 GRADE 5 O RING 022 1 ID 1 16 CS CIRCLIP ROTOR CLIP SH 196 MOTOR DRIVE SHAFT O RING 123 1 3 16 ID 3 32 CS MOTOR ADAPTOR O RING 90 DURO 013 7 16 ID 1 16 CS PIPE PLUG 1 16 NPT PIPE PLUG 1 8 PIPE PLUG 1 8 CAPSCREW HEX HEAD 3 4 10NC X 2 00 GRADE 5 LOCKWASHER 3 4 O RING 163 6 ID 3 32 CS PIPE NIPPLE 1 4 NPT AIRWAY 5405 4 4 PLASTIC CAPLUG 3 8 NPT PIPE COUPLING 1 4 NPT AIRWAY 5000 4 4 PRESSURE REDUCING VALVE PIPE ADAPTOR 6 SAE X 1 4 NPT AIRWAY 6401 6 4 O RING 906 SAE ORB 06 MOTOR 129 VOLVO F12 110 TUBE ASSEMBLY 1 4 OD 1 8 NPT X 1 8 NPT 90L CAPSCREW HEX HEAD 1 2 13NC X 4 3 4 LONG PIPE PLUG 1 8 NPT Refer to PAGE 26 for winch seal kit and PAGE 25 for ASSEMBLY DRAWING PAGE 32 313 REV 980301 PISTON MOTOR GROUP G1010 E BRAKE TUBE IS SHOWN FOR CW HOISTING FOR CCW HOISTING CONNECT TO OPPOSITE MOTOR PORT NOTE 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 E nHnrmmsra s 313 REV 970901 PAGE 33 9 lt N Z 9 D Z a 2 9 lt l l lt 7 lt 11006 1 D
21. automatically The pressure in the brake piston is vented to the reservoir by the motor spool of the winch control valve During reverse operation of the winch or when a load is being lowered the friction created by the brake disc results in temperature On the standard Model HL25 this temperature is dissipated by a circulation flow of hydraulic fluid supplied from an external source see HYDRAULIC CIRCUIT For efficient cooling of the automatic brake the external circulation flow should be adjusted to 7 US gpm 26 This circulation flow must be returned directly to the reservoir with a permissible back pressure of 30 psi 2 bar see HYDRAULIC CIRCUIT IMPORTANT Under no circumstances must the back pressure in the brake housing be permitted to exceed 30 psi 2 bar Excessive pressure in the brake housing will damage the oil seals separating the brake housing from the drum interior Damage to this seal will cause the cable drum to fill up with hydraulic fluid In order to prevent potential damage to the drum seals and the end cover of the winch when the cable drum fills up with hydraulic fluid a breather relief see PARTS REFERENCE item 130 is installed on the end cover The breather relief bleeds to atmosphere and serves as a warning signal that the oil seal between the brake housing and drum has been damaged 313 REV 970901 PAGE 3 EXPLANATION OF MODEL CODING HL Rapid forward and reverse SIZE OF UNIT REDUCTION
22. hydraulic circuit to check the volume supplied to the pressure port of the hydraulic winch motor when the winch control is completely opened The flow meter should indicate the maximum operating volume If this test indicates a loss of hydraulic flow check the hydraulic pump the relief valve and the control valve The hydraulic operating pressure relates to the line pull or lifting capacity of the winch If the winch will not lift the specified maximum line pull install a pressure gauge into the pressure line leading to the hoisting port on the hydraulic winch motor Stall the winch to prevent rotation of the drum and then open the control valve Check the hydraulic pressure reading of the installed pressure gauge If the pressure reads below the specified maximum operating pressure look for trouble in the hydraulic pump the relief valve and the control valve Only if the hydraulic system has been checked and found to be in order use the following indications for probable causes of failure in the winch FAILURE PROBABLE CAUSE Winch will not produce line pull at maximum Winch is mounted to an uneven surface pressure as listed in SPECIFICATIONS See INSTALLATION INSTRUCTIONS Cable sheaves or block purchase operated with the winch are not turning freely Damage or wear in the hydraulic motor Excessive back pressure in the hydraulic system Relief valve may be settoolow See SPECIFICATIONS for maximum operating pressure Winch is in high s
23. instructed in step 1 3 under DISASSEMBLY OF HYDRAULIC GEAR MOTOR ASSEMBLY 2 Remove nine hex head capscrews item 931 with lockwashers item 541 and remove motor adaptor item 800 from clutch housing item 650 3 Remove and discard three O rings item 801 from flange of motor adaptor REMOVAL OF HYDRAULIC PISTON MOTOR If fitted with a piston motor proceed as follows 1 Remove brake tube assembly item 852 from motor and motor adaptor item 800 2 Remove four hex head capscrews item 815 and lockwashers item 817 from motor item 850 Pull motor out of motor adaptor item 800 and discard O ring item 819 3 Remove nine hex head capscrews item 931 with lockwashers item 933 Remove motor adaptor item 800 and discard three O rings item 801 4 Unscrew six socket head capscrews item 687 with lockwashers item 685 and remove bearing carrier item 664 from motor adaptor Discard O ring item 667 Remove two seal rings item 666 5 Remove clutch connector item 668 from bearing carrier item 664 and check that oil passages are clear 6 Inspect ball bearing item 665 for damage If replacement is required press out of bearing carrier item 664 7 Inspect needle bearing item 669 in motor adaptor If damaged press out of motor adaptor and replace DISASSEMBLY OF CLUTCH ASSEMBLY 1 Remove three socket head capscrews item 682 and lockwashers item 683 from clutch housing item 650 Since brake springs item
24. rm amr uzzzzz rss 313 REV 970901 PAGE 9 TYPICAL HYDRAULIC CIRCUIT GEAR MOTOR HC HL25 D CED PRESSURE REDUCING H VALVE FACTORY 0 PRESET 250 PSI Fo 17 BAR d m 99 FAST FORWARD CONTROL VALVE I 2 DP Iw 400 PSI 28 BAR PRESSURE REQUIRED FOR MODELS SUPPLIED 11 WITH FREESPOOL 800 PSI 55 BAR 2 US GPM 8 L MIN REQUIRED FOR MODELS SUPPLIED WITH EXTERNAL CIRCULATION RETURN LINE MUST GO DIRECT BRAKE RELEASE OPTION TO RESERVOIR CIRCULATION SUPPLY AA A LINE 7 US GPM 26 L MIN _ CONTROL VALVE MOTOR SPOOL 4 WAY SPRING LL Y PRESSURE VALVE Z FILTER HYDRAULIC PUMP Y RESERVOIR PAGE 10 313 REV 010201 TYPICAL HYDRAULIC CIRCUIT PISTON MOTOR OO OO HC HL25 129 C PRESSURE REDUCING VALVE FACTORY PRESET 250 PSI 17 bar FAST FORWARD
25. side below center and capscrews are at 2 o clock 6 o clock and 10 o clock positions Tighten one turn at a time to compress brake springs item 752 8 Install sprag clutch item 672 and sprag clutch aligner item 677 into bore of connecting shaft item 600 313 REV 970901 PAGE 21 SERVICE INSTRUCTIONS REASSEMBLY OF CLUTCH ASSEMBLY Reassemble clutch assembly as follows 1 Install drive gear item 660 onto connecting shaft item 600 and fasten with circlip item 661 2 Install new well greased O ring item 735 into motor drive shaft item 730 3 Install new well greased O ring item 657 into gland item 656 and install gland onto motor drive shaft 4 Install new well greased O ring item 653 into pressure plate item 652 and install pressure plate onto motor drive shaft and gland 5 Install three clutch springs item 676 into holes in clutch piston item 670 and install clutch piston onto motor drive shaft item 730 While holding clutch springs compressed install circlip item 679 which fastens clutch hub onto motor drive shaft 6 Starting and finishing with a friction plate alternately install eight friction plates item 673 and seven divider plates item 675 onto clutch hub item 670 Install external retaining ring item 658 into clutch hub Install clutch plate item 654 and fasten with circlip item 671 TESTING PROCEDURE Before clutch assembly is installed into winch it shou
26. spline 9 Remove and inspect two thrust washers item 433 and thrust bearing item 435 Replace if cracked or otherwise damaged 10 Connecting shaft item 600 can now be pulled out of brake housing Remove and inspect two thrust washers item 615 and thrust bearing item 617 Replace if cracked or otherwise damaged 11 Remove sprag clutch aligner item 677 and sprag clutch item 672 from connecting shaft item 600 12 Remove needle bearing item 603 inspect and replace if damaged 2 13 Remove and discard oil seal item 607 andif present backup washer item 606 from inside of connecting shaft 14 Remove sprag clutch aligner item 722 from outside of connecting shaft Remove brake hub item 720 sprag clutch item 723 and sprag clutch aligner item 724 Thoroughly inspect surfaces where sprag clutches ride on and in connecting shaft If damaged or indented connecting shaft must be replaced MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE CONNECTING 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 HUB SPRAG CLUTCH AND CONNECTING SHAFT AS A SET 313 REV 970901 PAGE 19 SERVICE INSTRUCTIONS continuen 15 Remove and discard oil seal item 711 and if present backup washer item 710 from bore of brake housing Inspect two needle bearings item 605 and replace if ne
27. 752 apply pressure against inside of clutch housing it is recommended that these three capscrews are unscrewed one turn at a time until spring pressure has been released Remove and discard O ring item 707 and O ring item 651 Remove and discard three O rings item 763 2 Pull motor drive shaft item 730 and complete clutch assembly from brake housing 3 Disassemble clutch assembly by removing circlip item 671 from clutch hub item 670 Remove clutch plate item 654 external retaining ring item 658 eight friction plates item 673 and seven divider plates item 675 rr 313 REV 010201 PAGE 17 SERVICE INSTRUCTIONS continuen Clamp clutch hub item 670 to pressure plate item 652 and remove circlip item 679 Remove clutch hub three clutch springs item 676 pressure plate item 652 and gland item 656 from motor drive shaft Remove and discard O rings item 653 657 and 735 Models with piston motors only Discard two O rings item 689 4 The surface of motor drive shaft which engages sprag clutch item 672 should be inspected for wear or indentations If motor drive shaft shows any surface damage it should be replaced 5 Inspect three clutch springs for damage and measure overall length Overall spring length should be 1 25 inch
28. E 20 313 REV 970317 SERVICE INSTRUCTIONS 7 Place thrust bearing item 617 held between two thrust washers item 615 onto sprag clutch aligner and against brake hub item 720 8 Install connecting shaft item 600 with brake hub assembly into bore of brake housing item 700 and through oil seal item 711 Place thrust bearing item 435 held between two thrust washers item 433 onto internal gear item 430 Install internal gear onto spline of connecting shaft item 600 and fasten with circlip item 431 9 Reassemble primary planet hub assembly Use grease to temporarily hold 20 loose rollers item 423 in bore of planet gear item 420 Verify placement of sungear stopper item 444 Position thrust washers item 421 on either side of planet gear and press planet pin item 410 into final planet hub item 400 Retain with circlip item 411 10 Insert primary sungear item 440 between three planet gears and insert sungear shaft into connecting shaft engaging planet gears with internal gear Fasten with retaining ring item 401 11 Insert final sungear item 340 into cable drum and engage three planet gears item 320 12 Lower brake housing assembly onto cable drum while engaging spline of final sungear with primary planet hub item 400 Line up mounting holes of bearing flange item 530 with those in cable drum 13 Rotate brake housing to line up access holes and fasten bearing flange using six capscrews
29. ISASSEMBLY OF HYDRAULIC GEAR MOTOR ASSEMBLY If the analysed service or repair work requires access to the interior of the brake housing or clutch housing the hydraulic gear motor should not be disassembled In this case the hydraulic motor should be removed together with the motor adaptor as a complete assembly If a problem has been analysed to be in the hydraulic motor proceed with the disassembly as follows 1 Remove two socket head capscrews item 849 and lockwashers item 847 from transfer tube housing item 846 Remove transfer tube housing from end cover item 870 Remove and discard O ring item 112 If pressure reducing valve item 841 is faulty replace at this time 2 Press slotted spring pins item 848 partially out of transfer tube housing item 846 to release tube locator item 848 Remove and discard O ring item 113 3 Remove transfer tube assembly item 844 from center of motor drive gear which is part of gear set item 881 Remove and discard O ring item 879 4 Remove eight 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 permanently damage machined surfaces of these motor components Take care not to damage machined surfaces of motor components at disassembly 5 Remove pry loose if necessary port end cover item 870 together with bearings item 875 and ring seal item 877 Thrust pl
30. ISN VIG 26 6 SATOH ONILNNOW 3718 1HOd HOS Seb HOLOW 33S 3 NV14 11O8 r 3VS m N pe 5 5 2 1 3 Zaz N O i 4 E E ZZ 8 L 1HOd JSV3THH 1 1 340439 3SVO HOLOW 73437 AINT TvNti31X3 AO138 HIOAH3S3H NO lt SAW HOHONV 318VO NI e 4 1 207 3SIMMOO TO YNYL 01 193 1 1SOWH3ddn gna 3ZIS LHOd HOLOW 336 c QJ NIVHG 3S VO HOLOW q lt ONIY 0 AVS 3ATVA ANN 81 96 S1LHOd 81 8 LHOd AlddNs NOILVINOYID SS SS da SAWIL TI LY GANIVLNIVW 38 LSNW 3dOH SHIM JO SdYHYM v OLE 4O WNANWININY AL34vS 313 REV 010201 PAGE 36 INSTALLATION DIMENSIONS PISTON MOTOR 11007 2 E amp 11007 3 E Dimensions in inches Dimensions in millimeters DRUM Dimensions in inches Dimensions in millimeters HYDRAULIC PISTON MOTOR VOLVO F SERIES MODEL MOTOR PORT SIZE SCREW DRAIN NO 5 4 BOLT FLANGE THREAD PORT F11 112 M16x2 3 4 150 CODE 62 BSP F12 114 12 13 1 e 12 110 62 SAEORB F11 114 78 CODE 62 1 7 16 14 7 8 14 62 SAEORB INCLUDES SANDWICH GAGE BLOCK
31. LING This option permits wire rope being pulled off the cable drum by an operator Freespooling should not be confused with free fall The freespool clutch cannot be disengaged or re engaged with a load on the wire or while the cable drum is turning The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements 313 REV 970901 PAGE 5 SPECIFICATIONS Performance specifications are based on standard hydraulic motor gear ratio and cable drum with 7 8 inch diameter wire rope For other cable drums refer to APPENDIX A For other reductions or motors refer to supplement inside back cover Performance specifications for winches supplied with optional motors are provided in attached supplement CABLE DRUM DIMENSIONS STANDARD DRUM Barrel diameter 10 00 in 254 mm Flange diameter 17 00 in 432 mm Barrel length 11 00 in 279 mm CABLE STORAGE CAPACITY Size of wire rope 7 16 in 612 ft 186 1 2 4138 126 9 16 383 ft 117 5 8 297 ft 90 3 4 210 ft 64 7 8 140 ft 43 1 91 ft 28 86 Gear Motor 129 Piston Motor MAXIMUM OPERATING PRESSURE 2500 psi 172 bar 3800 psi 262 bar MAXIMUM OPERATING VOLUME 115 US gpm 435 I min 61 US gpm 231 I min MINIMUM OPERATING VOLUME 30 US 114 l min 14 US gpm 53 l min DRUM TORQUE AT MAXIMUM PRESSURE 135 937 Ib in 15 359 Nm DRUM RPM AT MAXIMUM VOLUME Hoisting 49 rpm Lowering amp High Speed
32. MOTOR SUB ASSY CONSISTS OF ITEMS 800 802 803 804 805 807 809 846 848 849 859 861 865 869 870 875 877 881 885 887 899 929 951 953 AND 955 Refer to PAGE 26 for winch seal kit and PAGE 38 for ASSEMBLY DRAWING PAGE 30 313 REV 980301 GEAR MOTOR GROUP G1007 B 2 212 4 L 881 861 899 112 841 845 827 843 931 541 827 950 658 671 805 813 885 654 731 802 800 801 807 809 727 656 657 670 652 679 675 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 313 REV 970901 PAGE 31 PARTS REFERENCE PISTON MOTOR GROUP 9 1 1 4 1 1 1 1 1 2 1 1 1 1 1 8 7 3 1 6 6 2 1 1 1 1 3 1 2 1 4 4 1 1 3 1 1 1 1 1 1 9 1 LOCKWASHER 1 2 PRESSURE PLATE O RING 126 1 3 8 ID 3 32 CS CLUTCH PLATE GLAND O RING 153 3 1 2 ID 3 32 CS RETAINING RING BEARING CARRIER BALL BEARING 065 X 100 X 18 6013 SEAL RING O RING 237 3 3 8 ID 1 8 CS CLUTCH CONNECTOR NEEDLE BEARING TORRINGTON NB4012 CLUTCH HUB CIRCLIP ROTOR CLIP SH 387 FRICTION PLATE DIVIDER PLATE CLUTCH SPRING CIRCLIP ROTOR CLIP
33. P ROTOR CLIP SH 168 CIRCLIP ROTOR CLIP SH 168 PLANET GEAR THRUST WASHER TORRINGTON TRB 2840 LOOSE ROLLER TORRINGTON G613 Q SUNGEAR CIRCLIP ROTOR CLIP SH 206 CABLE DRUM CABLE ANCHOR PIPE PLUG 1 2 14 NPT CIRCLIP ROTOR CLIP SH 475 BASE CAPSCREW HEXHEAD 5 8 11NC X 1 75 GRADE 5 BASE LOCKWASHER 5 8 N 1 1 1 1 1 2 1 1 1 1 1 1 3 3 3 3 6 2 1 1 1 1 1 1 1 8 1 8 WINCH SEAL FOR MODELS WITH GEAR MOTORS CONSISTS OF ITEMS 105 123 531 539 607 651 653 657 659 707 711 735 751 753 763 801 837 839 845 AND 879 WINCH SEAL KIT FOR MODELS WITH PISTON MOTORS CONSISTS OF ITEMS 105 123 531 539 607 651 653 657 659 667 689 707 711 735 751 753 763 801 819 AND 845 These parts vary according to drum code Refer to APPENDIX Refer to PAGE 25 for ASSEMBLY DRAWING PISTON MOTOR and PAGE 38 for ASSEMBLY DRAWING GEAR MOTOR PAGE 26 313 REV 110817 FINAL DRIVE GROUP G1000 A 130 320 124 323 321 313 104 103 105 502 503 343 ORD Z SASS 2 PEN M Z c lt lt O N Nu N O A O m
34. RATIO Only used for non standard reduction ratios TYPE OF BRAKE 7 Automatic brake clockwise drum rotation external circulation flow BASIC UNIT SERIES 8 Automatic brake external brake release clockwise drum rotation external circulation flow 9 Automatic brake external brake release counterclockwise drum rotation external circulation flow 10 Automatic brake counterclockwise drum rotation external circulation flow HYDRAULIC MOTOR 86 Standard hydraulic gear motor WM76 12 3 in displacement 129 Standard hydraulic piston motor VOLVO 110 cc 6 7 in displacement For other motor options contact factory DRUM SIZE 1 10 inch drum diameter X 17 inch flange diameter X 11 inch length STANDARD For other drum sizes refer to APPENDIX A OPTIONS F Hyadraulically 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 4 313 REV 970901 OPTIONS COUNTERCLOCKWISE ROTATION The drum rotation of the standard PULLMASTER Model HL25 planetary winch is clockwise for hoisting when looking at the hydraulic motor of the winch Drum rotation for counterclockwise hoisting direction is available as an option EXTERNAL BRAKE RELEASE PULLMASTER planetary win
35. ate item 885 and dowel pins item 865 may stay in gear housing PAGE 16 313 REV 970901 SERVICE INSTRUCTIONS 6 If thrust plate comes off with end cover carefully pry it off of bearings item 875 and discard teflon seals item 887 7 Remove gear set item 881 which consists of two gears which are a matched set 8 Carefully pry gear housing item 861 off of motor adaptor item 800 Thrust plate item 885 and dowel pins item 865 may stay in gear housing 9 Ifthrust plate stays on motor adaptor carefully pry it off of bearings item 875 and discard teflon seals item 887 10 Discard gasket seals item 869 It is also advisable to replace ring seals item 877 at this time Bearings item 875 have to be removed to allow access to ring seals Teflon seals gasket seals and ring seals in the hydraulic motor assembly are not part of winch seal kit Seal kit for hydraulic motor can be ordered from factory under Part No 23117 All parts of the hydraulic motor with exception of motor adaptor item 800 and port end cover item 870 are standard parts of the hydraulic motor having a 3 inch gear section All of these parts can be ordered from PULLMASTER or Authorized Distributors Dealers in Canada the United States and in most overseas areas REMOVAL OF HYDRAULIC GEAR MOTOR ASSEMBLY If disassembly of the hydraulic gear motor is not necessary proceed as follows 1 Remove transfertube assembly item 844 as
36. bricant 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 In case of a power failure or breakdown leading to an unexpected stop of the hydraulic power circuit stand clear of the area and the load being hoisted take the necessary precautions to prevent access to area where the load is halted 28 The noise level of the winch is 87dBA 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 0600 Do not use the wire rope as a ground for welding Clean up any oil spillage immediately 313 REV 051117 PAGE 1 DESCRIPTION OF THE MODEL HL25 GENERAL DESCRIPTION The PULLMASTER Model HL25 is a planetary hydraulic winch with two forward speeds and one reverse speed At low forward or h
37. cessary 16 To separate bearing flange item 530 and brake housing item 700 use a standard bearing puller or insert two heel bars in slot between bearing flange and brake housing and pry brake housing out of ball bearing item 533 17 Remove internal retaining ring item 534 to remove ball bearing item 533 Remove and discard oil seal item 531 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 end of winch as follows Press new well greased seal item 105 into final housing item 100 2 Press ball bearing item 103 into final housing and secure with retaining ring item 104 3 Press cable drum item 500 into ball bearing item 103 and secure with circlip item 513 4 Reassemble final planet hub assembly Use grease to temporarily hold 24 loose rollers item 323 in bore of planet gear item 320 Position thrust washers item 321 on either side of planet gear and press planet pin item 310 into final planet hub item 300 Retain with circlip item 311 5 Insert final planet hub assembly into final housing item 100 Ensure that final planet hub spline is fully engaged with cable drum item 500 Install new well greased O ring item 123 into end cover item 120 Verify that planet hub stopper item 126 and sungear stopper it
38. ches can be supplied with an external brake release which permits release of the automatic disc brake from an external pressure source FAILURE TO PROPERLY VENT EXTERNAL BRAKE RELEASE PORT WILL TRAP BRAKE PRESSURE AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH WINCHES SUPPLIED WITH EXTERNAL RELEASE OPTION MUST BE CONNECTED ACCORDING TO TYPICAL HYDRAULIC CIRCUIT CABLE DRUM SIZES Aside from the standard drum sizes listedin APPENDIX A the PULLMASTER Model HL25 planetary winch can be supplied with optional drums to accommodate large wire rope storage capacity DRUM GROOVING Cable drums for the PULLMASTER Model HL25 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 HL25 planetary winch may be changed by using a different displacement motor Contact the factory for performance information HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS The operating pressure of the PULLMASTER Model HL25 planetary winch is limited to 2500 psi 172 bar For hydraulic systems operating with a higher range of hydraulic pressure the winch can be supplied with a hydraulic piston motor which will provide for the same basic performance in terms of line pull and line speed capacity Contact the factory for this requirement FREESPOO
39. d 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 FAILURE TO COMPLY WITH THE FOLLOWING SAFETY RECOMMENDATIONS AND LOCAL RULES AND REGULATIONS WILL RESULT IN PROPERTY DAMAGE SEVERE INJURY OR DEATH Definition Caution indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Definition Warning indicates a potentially hazardous situation which if not avoided could result in death or serious injury Definition Danger indicates a potentially hazardous situation which if not avoided will result in death or serious injury The planetary hydraulic winches are made for hoisting and lowering loads and to be operated by trained and professional personnel They are not designed for operations involving lifting or moving personnel The winches are powered by hydraulic power The ropes cables for hoisting operations are not supplied by PULLMASTER The winches are always assembled in an application they do not function as an independent machine and it is not allowed to use them as such The winches are to be used within the specifications as listed in the man
40. ecting shaft is stationary The connecting shaft is held stationary by another sprag clutch to a brake hub During low forward speed operation the automatic brake remains applied hence the brake hub the connecting shaft and the internal gear do not rotate RAPID FORWARD SPEED When rapid forward speed is actuated hydraulic pressure is channelled from the motor to the center bore of the motor drive shaft to the clutch piston The hydraulic pressure causes the clutch to engage against the clutch springs The clutch hub is splined to the motor drive shaft and the drive gear is splined to the connecting shaft the internal gear of the primary drive will rotate with the motor drive shaft Thus the planetary drive is eliminated The elimination of the primary drive results in a forward or hoisting line speed 4 67 times faster than low forward speed The line pull capacity during rapid forward operation must be decreased by a ratio of 4 67 When the pressure is removed from the clutch the clutch is disengaged by the clutch springs and the unit reverts to low forward speed Since the sprag clutch which connects the connecting shaft to the brake hub permits free rotation the automatic brake of the winch is not affected during rapid forward speed NOTE The change over from low forward speed to rapid forward speed can be made while the drum is rotating providing the load on the wire rope does not exceed 5357 Ib 23 8 on the first layer of wire rope
41. em 122 are installed into end cover 7 Gently insert end cover into final housing item 100 and fasten with retaining ring item 124 REASSEMBLY OF PRIMARY DRIVE Turn winch over resting on end cover with cable drum opening facing up Reassemble primary drive as follows 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 retaining ring item 534 2 Press bearing flange assembly onto brake housing item 700 and install new well greased O ring item 539 3 Install new well greased oil seal item 607 with backup washer if included in seal kit item 606 into connecting shaft item 600 4 Press needle bearing item 603 into connecting shaft item 600 5 Ifremoved replace two needle bearings item 605 by pressing into brake housing item 700 Install new well greased oil seal item 711 with backup washer if included in seal kit item 710 into brake housing 6 Slide sprag clutch aligner item 724 onto connecting shaft item 600 followed by sprag clutch item 723 and sprag clutch aligner item 722 Twist connecting shaft assembly through center of brake hub item 720 as shown in BRAKE GROUP drawing IMPORTANT For proper brake function verify that sprag clutch is installed correctly When viewed from motor end connecting shaft of clockwise hoisting winch must run freely clockwise and lock in counterclockwise direction PAG
42. ge 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 claims b
43. hever comes first Hydraulic system fluid should be changed at least once every 12 months For optimum performance over an extended period of time the following preventive maintenance service should be done every 12 months or 500 operating hours whichever comes first 1 Disconnect all hydraulic hoses and remove the winch from its mounting 2 Disassemble the winch as per instructions 3 Discard and replace all O rings and oil seals 4 Clean all parts and inspect for wear and damage as per instructions Replace worn or damaged parts as required 5 Reassemble the winch as per instructions 6 Follow INSTALLATION and OPERATING INSTRUCTIONS when returning winch to its mounting When ordering parts for the PULLMASTER Model HL25 planetary winch always quote the complete model and serial number of the unit MODEL NO SERIAL NO PULLMASTER WINCH CORPORATION reserves the right to change specifications and the design of PULLMASTER planetary winches at any time without prior notice and without incurring any obligations ay PAGE 24 313 REV 980301 ASSEM BLY DRAWI NG G1000 A amp G1003 B amp G1010 E 313 REV 010201 PAGE 25 REFERENCE FINAL DRIVE FINAL HOUSING BALL BEARING 6024 BEARING RETAINER OILSEAL END COVER PIPE PLUG 3 4 14 SUNGEAR STOPPER O RING 281 15 ID 1 8 CS RETAINING RING PLANET HUB STOPPER BREATHER RELIEF ASSEMBLY PLANET HUB PLANET PIN CIRCLI
44. ic 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 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 opento the reservoir in neutral position of the control valve Wire rope is fastened to the incorrect cable anchor slot Sprag clutch is damaged or surfaces where sprag clutch engages on motor drive shaft or brake hub are worn or indented Winch supplied with external brake release option is not plumbed per HYDRAULIC CIRCUIT Failure to vent external brake release port to reservoir may trap pressure and cause winch brake to slip Brake vibrates when lowering a load Pump is too slow Pump rpm must be maintained at normal operating speed when a load is lowered Brake is running too hot This is caused by a complete lack of or insufficient circulation flow To check the circulation observe the flow of oil from the circulation return line of the winch See TYPICAL HYDRAULIC CIRCUIT when the winch is reversed Control valve has poor metering characteristics Damaged brake plates or divider plates The sprag clutch which connects the motor shaft with the brake assembly is damaged Air m
45. ires 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 order to prevent over heating of the hydraulic fluid The hydraulic reservoir should be made from clean and scale free material to prevent contamination of the hydraulic fluid In order to prevent air from being mixed with the hydraulic fluid the reservoir should have an over flow baffle separating the return lines from the suction line and all return lines should enter the reservoir below the fluid level The reservoir should be mounted close to and above the hydraulic pump in a location which provides for free air circulation around the reservoir HYDRAULIC HOSES The following hydraulic hoses are recommended for maximum efficiency of the PULLMASTER Model HL25 planetary winch Pressure lines Circulation return line Circulation supply line High speed shifting line Equivalent to SAE 100R12 32 Equivalent to SAE 100R4 16 Equivalent to SAE 100R6 6 Equivalent to SAE 100R1 4 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 fi
46. is not even and the space below the mounting pad must be shimmed If this condition exists proceed as follows a Install mounting bolts snug tight on the three mounting pads which are in contact with the mounting surface For mounting bolt size and grade see INSTALLATION DIMENSIONS b Measure the space underneath the fourth mounting pad with a feeler gauge and use shim stock of equivalent thickness in the space between the mounting pad and the mounting surface c Only after this procedure should the fourth mounting bolt be installed Tighten all four bolts per BOLT TORQUE CHART 4 Fill the winch with lubricating oil See APPENDIX A for oil volume required 5 Use recommended circuit components and hydraulic hoses 6 Thecirculation 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 Before operating the winch with a load verify adequate circulation flow through the circulation return line as stated in TYPICAL HYDRAULIC CIRCUIT Verify that pressure measured atthe circulation supply port does not exceed the permissible pressure stated in SPECIFICATIONS Ensure there is no back pressure at pressure reducing valve tank port 8 Verify that breather relief item 130 is above oil level on end cover item 120 Rotate end cover if breather relief is below oil level IMPORTANT Do not re
47. ixed 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 between the drum interior and the brake housing is damaged and must be replaced This condition is caused by excessive pressure in the brake housing of the winch operation with the incorrect hydraulic fluid during cold weather or a restriction in the circulation return line leading back to reservoir Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model HL25 winch 313 REV 970317 PAGE 15 SERVICE INSTRUCTIONS GENERAL Before attempting disassembly of the PULLMASTER Model HL25 planetary winch the following instructions for disassembly and reassembly should be read and understood It is suggested that all expendable parts such as O rings and oil seals are not reused on reassembly Because the following service instructions cover the HL25 planetary winch with either a gear motor or a piston motor verify the proper seal kits are on hand before disassembly For models with a gear motor use seal kit Part No 23120 and providing the hydraulic motor has to be serviced seal kit Part No 23117
48. ld be tested for proper operation Apply pressure to motor drive shaft and verify friction and divider plates close tight Release pressure and verify that plates are loose and run free 7 Verify circlip item 727 is on motor drive shaft Insert end of motor drive shaft into sprag clutch aligner item 677 Twist motor drive shaft to allow each divider plate to engage with drive gear item 660 IMPORTANT For proper drive function verify that sprag clutch item 672 is installed correctly When viewed from motor end motor drive shaft of a clockwise hoisting winch must turn freely clockwise and lock in counterclockwise direction RE INSTALLATION OF HYDRAULIC PISTON MOTOR For models with hydraulic piston motors proceed as follows 1 Install two new well greased O rings item 689 into exposed grooves of motor drive shaft item 730 Verify pipe plug item 663 is installed tightly into end of motor drive shaft 2 If removed press ball bearing item 665 into bearing carrier item 664 3 Install clutch connector item 668 into ball bearing item 665 Tap tight with a soft headed hammer if necessary 4 Install two seal rings item 666 onto clutch connector Notched sides must face each other Install new well greased O ring item 667 into bearing carrier item 664 and install assembly onto motor adaptor item 800 Fasten with six socket head capscrews item 687 and lockwashers item 685 5 Liberally grease three new O rings i
49. lter recommendations for the hydraulic circuit of the PULLMASTER planetary winch based on a return line filter are given as follows 10 microns 5 microns Average Atmosphere Dusty Atmosphere In order to prevent accidental stoppage of the return line flow the oil filter should have a by pass feature USE OF AN E STOP FOR EUROPEAN MACHINERY DIRECTIVE APPLICATIONS The use of an E stop emergency is mandatory in the controls circuit The E stop is to be placed in the operator s control panel The E stop must be designed and placed in line with EN 60204 and EN 418 313 REV 021028 PAGE 7 FOR STANDARD GEAR MOTOR PG HL25 86 A LINE PULL VS OIL PRESSURE LINE PULL kN 0 22 44 67 89 111 2500 172 2000 138 o e 1500 103 oc D D 9 1000 69 A 500 34 0 0 0 5000 10000 15000 20000 25000 LINE PULL Ib HOISTING HIGH SPEED HOISTING AND LOWERING LINE SPEED m min 0 30 61 91 122 152 183 213 244 274 294 115 TT TT 435 7 2 100 2 2 378 2 2 E 5 2 5 80 AM T 302 E 4 2 1 60 227 LLI 2 3 40 151 gt gt 1 20 76 O _ 0 LL LI LL i 111 j
50. mit winding of the wire rope on the drum in the correct direction of rotation If the wire rope is wound on the cable drum 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 11013 HL25 WIRE ROPE INSTALLATION Clockwise hoisting winch shown Use cable anchor slot on opposite side of drum for counterclockwise hoisting winch 7 CABLE ANCHOR CABLE ANCHOR SLOT Feed the wire rope through the cable anchor slot Loop rope back into slot as shown Insert cable anchor into slot small end first and long side nearest the drum flange Pull rope tight to wedge rope in slot res Sr OO B I On wire 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
51. 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 system To prime the winch with warm oil operate the winch at slow speed forward and reverse several times Prevent corrosion damage to winch interior If not used regularly run winch up and down at least once every two weeks To ensure proper winch installation and function raise and lower a full test load to a safe height before using winch for regular operation at the start of each shift If after a new installation the winch does not function properly refer to the TROUBLESHOOTING section of this manual 313 REV 051117 PAGE 13 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 hydraulic circuit components should be checked for proper function Make certain hydraulic reservoir is filled to top level If the pump is drive by v belts check for belt slippage IMPORTANT The hydraulic operating 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 install a flow meter into the
52. oisting speed this unit has a line pull capacity of 25 000 Ib on the first layer of wire In the rapid forward mode the line pull capacity is reduced by a ratio of 4 67 and the line speed increases by the same ratio The change from low speed to rapid forward speed is actuated hydraulically and can be made while the drum is rotating The main components of this unit are Hydraulic motor Multi disc brake with static and dynamic function High speed clutch Primary planet reduction Final planet reduction Brake housing Final drive housing Cable drum FUNCTION FORWARD LOW FORWARD SPEED During low forward speed the outputtorque and rpm of the hydraulic motor is transmitted by the motor drive shaft to the primary sungear of the primary drive The output torque and rpm of the primary drive is transmitted to the final drive by the final sungear which is splined to the primary planet hub The output torque and rpm of the final drive is transmitted to the cable drum by a spline attaching the final planet hub to the cable drum The motor drive shaft is splined to a clutch hub which connects to a set of friction and divider plates During low speed operation a pressure plate which is spring applied and pressure released permits free rotation of the friction plates The motor drive shaft is also attached to a connecting shaft by a sprag clutch which permits free rotation of the motor drive shaft while the conn
53. on 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 If an article is claimed to be defective in material or workmanship 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 ordina
54. peed mode Winch will not produce line speed at maximum Winch is mounted to an uneven surface volume as listed in SPECIFICATIONS See INSTALLATION INSTRUCTIONS Cable sheaves or block purchase operated with the winch are not turning freely Damage or wear in the hydraulic motor Excessive back pressure in the hydraulic circuit Winch will not reverse Leakage out of the brake piston prevents the brake from being released against the brake springs This is caused by damaged O ring seals on the brake piston The O ring seals on the brake release channel between the motor adaptor clutch housing or brake housing is damaged If this failure occurs there will be leakage either from the motor adaptor clutch housing or 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 passage in the brake housing PAGE 14 313 REV 970317 TROU B LE SHOOTI NG CONTINUED FAILURE PROBABLE CAUSE Clutch will not engage will not shift into rapid Loss of clutch release pressure Check pressure forward speed reducing valve and O rings Seizedclutch piston caused by contamination in oil supply Incorrect hydraulic connections Refer to TYPICAL HYDRAULIC CIRCUITS Brake will not hold Brake plates or divider plates have been damaged by contamination in the hydraul
55. place breather relief with a pipe plug The breather relief does not prevent oil seal failure but serves as an indicator or warning that the oil seals between brake housing and the cable drum interior have failed and must be replaced immediately If these oil seals are changed additional failure of the drum seal and potential damage to the end cover is prevented 9 Ensure brake housing and clutch housing are full of oil at all times js s PAGE 12 313 REV 970901 OPERATING INSTRUCTIONS FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL RESULT IN PROPERTY SEVERE INJURY OR DEATH After the PULLMASTER planetary winch has been installed in accordance with the INSTALLATION INSTRUCTIONS the wire rope can be fastened to the cable drum IMPORTANT The ropes chains slings etc are not part of the winch and are not covered by this manual 1 to manufacturer s handling inspection 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 clockwise when looking at the hydraulic motor of the unit It is critical to select the cable anchor slot which will per
56. r 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 8 Install new well greased O ring item 879 into transfer tube assembly item 844 Install transfer tube assembly through port end cover item 870 and engage motor drive shaft item 730 9 Install new well greased O ring item 113 into tube locator item 848 and install tube locator into transfer tube housing item 846 Press two slotted spring pins item 859 which stop tube locator from spinning into place 10 Install new well greased O ring item 112 onto transfer tube housing item 846 Install transfer tube housing with pressure reducing valve item 841 attached onto port end cover item 870 Fasten with two socket head capscrews item 849 and high collar lockwashers item 847 LIFTING A LOAD WITH A NEWLY SERVICED WINCH WILL ENABLE AN INSTALLATION OR SERVICE PROBLEM TO GO UNDETECTED AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH TO ENSURE PROPER REINSTALLATION REFER TO PROCEDURES AND TESTS DESCRIBED IN INSTALLATION AND INSTRUCTIONS 313 REV 970901 PAGE 23 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 whic
57. ry 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 dama
58. tem 801 and install into recesses on motor adaptor item 800 Install new well greased O ring item 707 onto flange of motor adaptor 6 Install motor adaptor assembly onto clutch housing item 650 Engage clutch connector item 666 with clutch hub item 670 and fasten with nine hex head capscrews item 931 and lockwashers item 541 7 Install new well greased O ring item 819 onto hydraulic piston motor item 850 and install motor into motor adaptor item 800 Fasten with four hex head capscrews item 815 and lockwashers item 817 8 Install brake tube assembly item 852 PAGE 22 313 REV 970901 SERVICE INSTRUCTIONS REPLACEMENT OF HYDRAULIC GEAR MOTOR ASSEMBLY 1 Liberally grease three new O rings item 801 and install into recesses on motor adaptor item 800 Install new well greased O ring item 707 on flange of motor adaptor 2 Slide hydraulic motor assembly on splined end of motor drive shaft item 730 and line up pressure transfer holes of clutch housing and motor adaptor Tighten nine capscrews item 931 and lockwashers item 541 REASSEMBLY OF HYDRAULIC GEAR MOTOR If the hydraulic gear 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 23117 for hydraulic motor 2 Install two new teflon seals item 887 on each thrust plate item 885
59. ual 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 7 Do leave load suspended for extended period of time 8 Never leave a suspended load unattended 9 Winch should be maintained and operated by qualified personnel 10 Inspect winch rigging mounting bolts and hoses before each shift 11 Warm up equipment before operating winch particularly at low ambient temperatures 12 Verify winch function by raising and lowering a full test load to a safe height before each shift 13 14 Verify gear lubrication and brake circulation supply and return before operating winch Do not weld any part of the winch 15 Besure of equipment stability before operating winch 16 Wear proper clothing to avoid entanglement in rotating machinery 17 Always stand clear of the load 18 Use only recommended hydraulic oil and gear lu
60. y 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 Warranty an
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