Model M30 Service Manual
Contents
1. PAGE 30 336 REV 030528 APPENDIX A LINE PULL LINE SPEED AT MAXIMUM AT MAXIMUM tuBRICATING INCHES FEET REQUIRED MILLIMETERS METERS POUNDS FEET MINUTE U S GALLONS KILONEWTONS METERS MINUTE LITERS BARREL FLANGE LENGTH Performance specifications are based on standard hydraulic motor with 7 8 inch diameter rope 336 REV 030528 PAGE 31 APPENDIX B DRUM CODE PART DESCRIPTION PART NUMBER QUANTITY FINAL HOUSING FINAL SUNGEAR STANDARD RATIO FINAL SUNGEAR F RATIO CABLE DRUM BASE PLATE CAPSCREW LOCKWASHER 5 8 CAPSCREW TIE BAR BRAKE HOUSING PAGE 32 336 REV 030528 APPENDIX C BRAKE CODE ITEM PART NO DESCRIPTION an CIRCULATION 1 4 18 NPT 806 PIPE PLUG 1 8 27 NPT PIPE PLUG 25040 1 8 27 NPT PIPE ADAPTOR PART NUMBERS 20849 20849 20849 20849 25040 pe 25374 25085 25085 25085 2146 FIC va wa va 26276 26276 26276 26276 22011 22012 20804 20505 21977 22013 20805 1 8 NPT CAPLUG 3 8 18 NPT 3 8 NPT CAPLUG MOTOR SUB ASSY 20504 336 REV 030528 PAGE 33 APPENDIX D MODEL REDUCTION CODE PART DESCRIPTION M NA Mave wer O PART NUMBER FINAL PLANET PRIMARY PLANET GEAR 23588 20545 23245 PRIMARY INTERNAL GEAR 23541 20411 20411 PRIMARY SUN GEAR 23603 20547 23174 PAGE 34 336 REV 030528 BOLT TORQUE CHART BOLT DIAMET2. via 26 6 L S31OH ONILNNOW t S 2 r 68 9 Ge les t Usi 14 91 0 6 861 eT st 1HOd 2 1 1HOd NOILYTNOHIO W 81 27 SMAHOS ONDIOVP yy i o o 0 g 1 5 1891 i e v 1 3 A1NO 573 0 8 NOLLWINOHIO 1VNH31X3 14 1dN81 8 E1HOd m 1HOd 3SsVvaTaH 140d 33Vu8 IVNH3 IX3 HOLON 33S 19 3302 1 YATIIA WNOILdO 1 1708 7 AVS S1HOd HOLOW NOLLVLOH NOLLV LOY 3SIMM2O 19 ASIMMOOTOHALNNOOD 3ziunissdud 3719155999 SS LANGE SWNHG S HOS 5 HO 3SIMM2019 s1HOd S3ovo NOLLOQIHISNI NOLIVTIVISNI OL 43438 iS3INLL TIY LY HOLON HL LY A8 C3NIV LNIVIN 38 LSNW 3dOH SHIM G3HSIMEV LSA SI NOLLV LOH JO NOLLO3HIG SdVHM S Y AL34VS SH3 13ATTTIIN S3HONI NI SNOISN3WWIG PAGE 29 336 REV 051117 INSTALLATION DIMENSIONS 11102 2 Dimensions in inches Dimensions in millimeters HYDRAULIC MOTORS COMMERCIAL WM76 SERIES GEAR MOTOR PORT SIZE L WIDTH SAE SPLIT FLANGE 3 00 2 0 2 75 CODE 61 2 50 2 25 2 00 1 5 CODE 61 1 25 CODE 61 1 0 CODE 61
3. CIRCULATION SUPPLY LINE M30 5 US GPM 19 L MIN H30 7 US GPM 26 L MIN pom EXTERNAL CIRCULATION L MODELS ONLY CONTROL VALVE MOTOR SPOOL 4 WAY SPRING Z RETURN TO CENTER 4 PRESSURE RELIEF VALVE CIRCULATION RETURN LINE MUST GO DIRECT TO RESERVOIR E a HYDRAULIC RELIEF VALVE RESERVOIR 336 REV 030528 PAGE 7 RECOMMENDATIONS HYDRAULIC FLUID The hydraulic fluid selected for use with PULLMASTER planetary winches should be a high grade petroleum based fluid with rust oxidation and wear resistance Fluid cleanliness and operating viscosity are critical to winch reliability efficiency and service life For optimum performance the recommended viscosity range at operating temperature is 81 167 SUS 16 36 CS For extreme operating conditions of short duration the maximum viscosity range of 58 4635 SUS 10 1000 CS should not be exceeded For optimum performance the winch recommended hydraulic fluid temperature operating range is 80 150F 27 66 C For extreme operating conditions of short duration the maximum temperature range of 5 180F 21 82 C should not be exceeded LUBRICATION The winch gear train requires oil bath lubrication The winch is shipped from the factory without lubricating oil IMPORTANT ADD LUBRICATING OIL BEFORE RUNNING WINCH Refer to INSTALLATION DRAWING for loc
4. Pull MASTER THE LOGICAL CHOICE INSTRUCTION AND PARTS MANUAL MODEL M30 PLANETARY HYDRAULIC WINCH amp NM POWER to Move the World TWG Canada LANTEC and Pullmaster Brands 19350 22nd Ave Surrey BC V3S 356 Voice 1 604 547 2100 Fax 1 604 547 2147 www team twg com A COMPANY READ THIS MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS PRODUCT THIS MANUAL CONTAINS IMPORTANT INFORMATION MAKE THIS MANUAL AVAILABLE TO ALL PERSONS RESPONSIBLE FOR THE OPERATION INSTALLATION SERVICING AND MAINTENANCE OF THIS PRODUCT PMC 336 120612 POVER MONA Effective 2011 10 01 40888 compar SUPERSEDES ALL PRIOR WARRANTIES LANTEC ul MASTER LIMITED WARRANTY 50130 0 Seller warrants that each article whether Gear Drive Products Brake Products and or Winch Products all of which are covered hereunder sold under this order shall at the time of shipment i conform to applicable specifications and ii be free from defects in material and workmanship during normal and ordinary use and service the Warranty Buyer s exclusive remedy and Seller s sole obligation under this Warranty shall be at Seller s option to repair or replace any article or part thereof which has proven to be defective or to refund the purchase price of such article or part thereof Buyer acknowledges that Buyer is knowledgeable concerning the articles covered by this Warranty and sold in connection therewith
5. 336 REV 120330 PAGE 23 FINAL DRIVE GROUP G1190 A m 27 130 320 129 en 104 103 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 PAGE 24 336 REV 030528 PARTS REFERENCE BRAKE GROUP 20417 20369 25004 25091 25068 25308 25338 20452 21809 23175 26359 26464 20461 25081 25109 25014 20445 25341 25334 21086 25345 25347 25339 20451 25305 25304 25336 20446 20455 25303 20421 25335 20422 25344 20397 25343 20413 25342 1 1 3 3 3 3 6 5 1 1 1 1 1 1 1 1 1 6 1 6 1 1 1 1 1 1 1 1 1 6 5 1 1 1 1 1 1 1 1 1 1 4 1 23408 PLANET RETAINING RING PLANET PIN CIRCLIP ROTOR CLIP C 87 CIRCLIP ROTOR CLIP SH 87 PLANET GEAR THRUST WASHER TORRINGTON TRA 1423 LOOSE ROLLER 5 32 X 1 25 TOR E151 Q INTERNAL GEAR CIRCLIP ROTOR CLIP SH 300 SPACER SUNGEAR SUNGEAR STOPPER BEARING FLANGE OIL SEAL CYLINDRICAL ROLLER BEARING NU 1026 BEARING RETAINER CAPSCREW HEX HEAD 1 2 18NC X 1 50 GRADE 5 O RING 269 8 3 4 ID 1 8 CS LOCK WASHER 1 2 CONNECTING SHAFT
6. may also be required 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 friction plates During reassembly lubricate all O rings and oils seals with grease before installation In the following service instructions reference to parts is made by numbers and shown on the applicable group drawings DISASSEMBLY For the majority of required service or repair work disassembly is required only on the brake housing of the PULLMASTER Model M30 planetary winch There are no special tools needed for the service or repair work and no adjustments or calibrations are necessary Proceed with the disassembly as follows DISASSEMBLY OF HYDRAULIC MOTOR ASSEMBLY If the analyzed service or repair work requires access to the interior of the brake housing the hydraulic 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 analyzed to be in the hydraulic motor proceed with the disassembl
7. C is within 007 to Gap D proceed to step 5 If Gaps are outside this limit proceed to step 4 Note Difference between Gaps A and B and Gaps C and D may not be equal 4 Gaps can be adjusted as required by adjusting Jacking Screw diagonally opposite to the Gap Reduce by turning Jacking Screw clockwise or increase a gap by turning Jack Screw counterclockwise a To adjust Gap A adjust Jacking Screw A b To adjust Gap B adjust Jacking Screw B C To adjust Gap adjust Jacking Screw d To adjust Gap D adjust Jacking Screw D 336 REV 030528 PAGE 9 INSTALLATION INSTRUCTIONS 5 Measure the space underneath the four mounting pads with a feeler gauge and use shim stock of equivalent thickness in the space between the mounting pad and the mounting surface Install mounting bolts for bolt size and grade refer to INSTALLATION DIMENSIONS Tighten mounting bolts per BOLT TORQUE CHART Fill the winch with lubricating oil Gee APPENDIX A for oil volume required Use recommended circuit components and hydraulic hoses The circulation return line of the winch should be plumbed in such a manner that the brake housing remains full of oil at all times Connect the return line directly to reservoir Do not connect to a common return line Before operating the winch with a load verify adequate circulation flow through the circulation return line as stated in TYPICAL HYDRAULIC CIRCUIT Verify that pressu
8. O RING 239 3 5 8 ID 1 8 CS NEEDLE BEARING TORRINGTON B2812 BACKUP WASHER OIL SEAL BRAKE HOUSING PLASTIC CAPLUG 1 NPT THR D O RING 278 12 ID 1 8 CS BRAKE SPACER DIVIDER PLATE FRICTION PLATE CIRCLIP ROTOR CLIP SH 187 BRAKE HUB SPRAG CLUTCH ALIGNER SPRAG CLUTCH BORG WARNER 140373 B SPRAG CLUTCH ALIGNER CIRCLIP ROTOR CLIP SH 196 PLUG O RING 123 1 3 16 ID 3 32 CS 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 WINCH SEAL KIT CONSISTS OF ITEMS 105 123 531 539 601 606 607 707 735 751 753 AND 801 This part varies according to drum code Refer to APPENDIX B These parts vary according to Reduction Ratio Refer to APPENDIX D Refer to PAGE 22 for ASSEMBLY DRAWING 336 REV 030528 PAGE 25 BRAKE GROUP G1189 B 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 PAGE 26 336 REV 030528 PARTS REFERENCE MOTOR GROUP ITEM NO DESCRIPTION CAPSCREW HEX HEAD 1 2 13NC X 1 5 GRADE 5 LOCKWASHER 1 2 MOTOR DRIVE SHAFT CIRCLIP ROTOR CLIP C 112 MOTOR ADAPTOR O RING 013 7 16 ID 1 16 CS PIPE PLUG 1 8 27 NPT PIPE PLUG 1 4 18 NPT GEAR HOUSING 086 DOWEL PIN GASKET SEAL PORT END COVER WITH PLUGS ROLLER BEARING RING SEAL GEAR SET THRUST PLATE TEFLO
9. Part No 23117 All parts of the hydraulic motor with the exception of the motor adaptor item 800 and the 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 MOTOR ASSEMBLY If disassembly of the hydraulic motor is not necessary proceed as follows 1 Remove 12 hex capscrews item 537 with lockwashers item 541 from motor adaptor item 800 Since the brake springs item 752 apply pressure against the inside of the motor adaptor it is recommended that the hex capscrews are unscrewed one turn at a time until the spring pressure has been released The complete motor assembly including motor adaptor can now be removed from brake housing assembly 2 Remove and discard three O rings item 801 and O ring item 707 O rings item 801 seal the pressure transfer hole for the automatic brake release and are situated on the flange of the brake housing DISASSEMBLY OF BRAKE HOUSING ASSEMBLY 1 After motor assembly has been removed all parts of brake assembly are accessible Remove 14 brake springs item 752 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 motor drive shaft item 730 and complete brak
10. and secure with circlip item 109 336 REV 030528 PAGE 17 7 SERVICE INSTRUCTIONS Press cable drum item 500 into ball bearing item 103 and secure with circlip item 513 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 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 item 122 are installed into end cover Gently insert end cover into final housing item 100 and fasten using 8 hex capscrew item 127 and 8 lockwashers item 129 REASSEMBLY OF PRIMARY DRIVE Turn winch over resting on end cover with cable drum opening facing up Reassemble primary drive as follows NOTE Care must be take when handling the assembly at this stage avoid separation of the bearing flange subassembly and brake housing 1 Press new well greased oil seal item 531 into bearing flange item 530 Press outer race complete with caged roller assembly of cylindrical roller bearing item 533 into bearing flange and secure with retaining ring item 534 Verify two NPT pipe plugs are ins
11. if present backup washer item 606 from inside of connecting shaft 13 Remove needle bearing item 603 Inspect and replace if damaged 14 Separate bearing flange item 530 and brake housing item 700 using a standard bearing puller or insert two heel bars in slot between bearing flange and brake housing Pry brake housing out of cylindrical bearing item 533 15 Remove internal retaining ring item 534 and remove the outer race and caged roller assembly of cylindrical roller bearing item 533 Two 14 NPT pipe plugs in bearing flange item 530 can be removed to facilitate bearing removal 16 Remove and discard oil seal item 531 17 Inspect the separate inner race of cylindrical roller bearing item 533 and if damaged remove from brake housing item 700 18 Separate cable drum from final housing by first removing circlip item 513 Insert two heel bars between flange of cable drum and final drive housing and gently pry cable drum out of ball baring item 103 19 Remove internal circlip item 109 to remove ball bearing item 103 Remove and discard oil seal item 105 REASSEMBLY Thoroughly clean all parts Use only new well greased O rings and oil seals Unless otherwise specified torque fasteners per BOLT TORQUE CHART at back of manual REASSEMBLY OF FINAL DRIVE Reassemble final drive end of winch as follows 1 Press new well greased oil seal item 105 into final housing item 100 2 Press ball bearing item 103 into final housing
12. subject thereto and the Province of British Columbia shall be the exclusive forum and jurisdiction for any action or proceedings brought by Buyer in connection herewith or any dispute hereunder If any of the terms and conditions contained within this Warranty are void the remaining provisions thereof are and shall remain valid and enforceable SAFETY RECOMMENDATIONS Definition Caution indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Definition Warning indicates a potentially FAILURE TO COMPLY WITH THE FOLLOWING SAFETY hazardous situation which if not avoided could RECOMMENDATIONS AND LOCAL RULES AND REGULATIONS WILL RESULT IN PROPERTY DAMAGE SEVERE INJURY OR DEATH result in death or serious injury Definition Danger indicates a potentially N hazardous situation which if not avoided will result in death or serious injury The planetary hydraulic winches are made for hoisting and lowering loads and to be operated by trained and professional personnel They are not designed for operations involving lifting or moving personnel The winches are powered by hydraulic power The ropes cables for hoisting operations are not supplied by PULLMASTER The winches are always assembled in an application they do not function as an independent machine and it is not allowed to use them as such The winches are to be used within the specifications as listed in the manual under SPECI
13. 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 or not to conform to the applicable specifications Seller will either examine the article at Buyer s site or issue shipping instructions for return to Seller This Warranty shall not extend to any articles or parts thereof which have been installed used or serviced otherwise than in conformity with Seller s applicable specifications manuals bulletins or instructions or which shall have been subjected to improper installation operation or usage misapplication neglect incorrect installation overloading or employment for other than normal and ordinary use and ser
14. ATION INSTRUCTIONS for location of fill port Refer to APPENDIX A for oil volume required To ensure proper reassembly run the winch in both directions without load LIFTING A LOAD WITH A NEWLY SERVICED WINCH COULD ENABLE AN INSTALLATION OR SERVICE PROBLEM TO GO UNDETECTED WHICH WILL ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH TO ENSURE PROPER REINSTALLATION REFER TO PROCEDURES AND TESTS DESCRIBED IN INSTALLATION AND OPERATING INSTRUCTIONS PAGE 20 336 REV 030528 RECOMMENDED MAINTENANCE Winch gear train lubricating oil should be changed after the initial six months or 50 hours of operation whichever comes first Lubricating oil should then be changed every 12 months or 500 operating hours whichever comes first Hydraulic system fluid should be changed at least once every 12 months For optimum performance over an extended period of time the following preventive maintenance service should be done every 12 months or 500 operating hours whichever comes first 1 Disconnect all hydraulic hoses and remove the winch from its mounting 2 Disassemble the winch as per instructions 3 Discard and replace all O rings and oil seals 4 Clean all parts and inspect for wear and damage as per instructions Replace worn or damaged parts as required 5 Reassemble the winch as per instructions 6 FollowINSTALLATION and OPERATING INSTRUCTIONS when returning winch to its mounting When ordering parts
15. EMBLY OF PRIMARY DRIVE AND CABLE DRUM ASSEMBLY For ease of working on remainder of unit set winch upright on final drive housing 1 2 Remove four hex capscrews item 555 with lockwashers item 553 from each side of both tie bars item 556 and take the tie bars from the assembly Remove access plug item 734 using a 2 18NC bolt motor adaptor bolt item 821 is suitable from inside brake housing and discard O ring item 735 PAGE 16 336 REV 030528 SERVICE INSTRUCTIONS NETS 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 Lift brake 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 final sungear item 340 from cable drum item 500 7 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 8 Remove primary sungear item 440 from center of connecting shaft item 600 9 Remove circlip item 431 and internal gear item 430 from connecting shaft spline 10 Remove spacer item 434 11 Pull connecting shaft item 600 out of brake housing Discard O ring item 601 12 Remove and discard oil seal item 607 and
16. ER TORQUE TORQUE Inches Lb ft Nm NOTE Unless otherwise specified torque bolts per above chart 336 REV 030528 PAGE 35
17. FICATIONS Other use as foreseen in the functional description of the hydraulic winch is not allowed without written permission from PULLMASTER 1 Do not install operate or service winch before reading and understanding manufacturer s instructions 2 The winch described herein is not designed for operations involving lifting or moving personnel 3 Do not lift or carry loads over people 4 Do not exceed recommended operating pressure psi and operating volume gpm 5 Do not jerk the winch Always smoothly accelerate and decelerate load 6 Do not operate a damaged noisy or malfunctioning winch 7 Do not leave a load suspended for any extended period of time 8 Never leave a suspended load unattended 9 Winch should be maintained and operated by qualified personnel 10 Inspect winch rigging mounting bolts and hoses before each shift 11 Warm up equipment before operating winch particularly at low ambient temperatures 12 Verify winch function by raising and lowering a full test load to a safe height before each shift 13 Do not weld any part of the winch 14 Verify gear lubrication and brake circulation supply and return before operating winch 15 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 lubricant 19 Keep hydraulic syst
18. G PROPERTY DAMAGE SEVERE INJURY OR DEATH REASSEMBLE PER INSTRUCTIONS 4 Starting and finishing with a divider plate alternately install six divider plates item 713 and five friction plates item 715 5 Liberally grease O ring item 751 and O ring item 753 and install on brake pistonitem 750 6 Slide brake piston item 750 into brake housing item 700 with holes for brake springs facing out of brake housing assembly 7 Install 14 brake springs item 752 in brake piston using hole pattern shown LOCATION OF BRAKE SPRINGS FOURTEEN SPRINGS TWENTY HOLES 336 REV 030528 PAGE 19 SERVICE INSTRUCTIONS 8 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 9 Slide hydraulic motor assembly onto splined end of motor drive shaft item 730 and line up pressure transfer holes of brake housing and motor adaptor Install 12 capscrews item 821 and lockwashers item 823 Tighten one turn at a time to evenly compress springs 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 23117 for hydraulic motor 2 Install two new teflon seals item 887 on each thrust plate item 885 Press one of the t
19. N SEAL SUB ASSY MOTOR 086 CAPSCREW HEX HEAD 5 8 X 6 75 GRADE 5 WASHER PLASTIC CAPLUG 2 0 1 1 3 1 2 1 1 1 1 1 4 2 1 4 2 1 2 4 1 1 8 8 2 MOTOR SEAL KIT CONSISTS OF ITEMS 869 877 AND 887 These part numbers and descriptions vary according to brake code Refer to APPENDIX C TEM 950 MOTOR SUB ASSY CONTAINS ITEMS 800 802 803 804 805 807 809 861 865 869 870 875 877 881 885 887 929 951 953 AND 955 Refer to PAGE 25 for winch seal kit and PAGE 22 for ASSEMBLY DRAWING 336 REV 030528 PAGE 27 MOTOR GROUP 181 G1002 D 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 mn PAGE 28 336 REV 030528 gt lt lt lt H o Y N e ualldguo83avuo S1709 ONILNNOW 1 ISN d
20. PAGE 5 PERFORMANCE GRAPHS PG M30 B LINE PULL VS OIL PRESSURE LINE PULL kN 0 2500 a 2000 5 ui ui oc 1500 D mi 2001 1000 L x A E 500 1 9 0 1 1 1 1 0 0 5000 10000 15000 20000 25000 LINE PULL Ib LINE SPEED VS OIL VOLUME LINE SPEED m min 0 6 12 18 24 30 36 42 48 54 63 125 4 SIT EEL 4 1751 lt 14 T 473 E 100 379 8 5 d i 5 E 23 50 189 if gt 5 25 J 95 0 Li jp Li Li LILI LI d 1 1 0 20 40 60 80 100 120 140 160 180 207 LINE SPEED fpm Performance graphs are based on standard hydraulic motor gear ratio and cable drum with 7 8 inch diameter wire rope pem PAGE 6 336 REV 030528 TYPICAL HYDRAULIC CIRCUIT HC M30 H30 400 PSI 28 BAR PRESSURE REQUIRED FOR MODELS SUPPLIED 800 PSI 55 BAR WITH FREESPOOL OPTION SPOOL OF TIO 2 US GPM 8 L MIN REQUIRED FOR MODEL SUPPLIED WITH EXTERNAL BRAKE RELEASE OPTION
21. SOLVENT TO CLEAN THE FRICTION PLATES PERFORM THOROUGH INSPECTION AND IF NECESSARY REPLACE FRICTION AND DIVIDER PLATES AS A SET 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 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 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 Remove eight hex capscrews item 127 and lockwashers item 129 and pull end cover item 120 from final drive housing item 100 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 0 30 inch thick and sungear stopper if less than 0 21 inch thick Remove final planet hub assembly from final housing item 100 Inspect three final planet gears item 320 for damage or wear If necessary to remove final planet gears 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 DISASS
22. ated 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 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 par
23. ates The over running clutch which connects the motor shaft with the brake assembly is damaged Air mixed with hydraulic oil foamy oil Oil leaks from the hydraulic motor flange and the motor adaptor are caused by damaged O ring seals Oilleaks occurring betweenthe 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 tank Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model M30 winch 336 REV 030528 PAGE 13 SERVICE INSTRUCTIONS GENERAL Before attempting disassembly of the PULLMASTER Model M30 planetary winch the following instructions for disassembly and reassembly should be read and understood It is suggested that all expendable parts such as O rings and oil seals are not reused on reassembly It is therefore important to have a seal kit Part No 23408 and providing the hydraulic motor has to be serviced a seal kit Part No 23117 on hand before the unit is taken apart Two new roller bearings item 875
24. ation of lubricating oil fill port Refer to APPENDIX A for quantity of oil required For normal operating temperatures use SAE 90 lubricating oil Consult lubricating oil supplier or factory fortemperature beyond normal operating range HYDRAULIC PUMP For maximum performance of the PULLMASTER planetary winch the hydraulic pump must supply the maximum flow of hydraulic fluid atthe hydraulic pressure stated in SPECIFICATIONS HYDRAULIC CONTROL VALVE The standard control valve used for operation of the PULLMASTER planetary winch must have a four way spring return to neutral feature which provides for open flow from the pressure ports of the winch to the reservoir in neutral position ofthe 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 beinstalled 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 hea
25. 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 way a completely smooth lowering speed can be achieved in a stepless operation by modulation of the winch control handle When the control handle is returned to neutral position rotation stops and the disc brake applies automatically During lowering operations of the winch the friction created by the brake discs results in temperature This temperature is dissipated by the circulation of hydraulic fluid through the brake housing supplied internally from the motor or externally depending on the brake code of the winch For efficient cooling of the automatic brake models with external circulation should be adjusted to supply 5 US gpm 19 l min This flow must be returned directly to the reservoir with a permissible back pressure of 30 psi 2 bar IMPORTANT Under no circumstances must the pressure in the brake housing be permitted to exceed 30 psi 2 bar Excessive pressure in the brake housing will damage the oil seal separating the brake housing from the drum interior Damage to this seal will cause the drum to fill up with hydraulic fluid In order to prevent damage to the drum seal and end cover of the final drive housing 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 atmos
26. e hub assembly from brake housing 3 Disassemble brake hub assembly by removing circlips 727 and 719 from motor drive shaft Remove motor drive shaft from brake hub item 720 Remove sprag clutch aligners items 722 and 724 and sprag clutch item 723 from brake hub MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE MOTOR DRIVE SHAFT AND BRAKE HUB WILL RESULT IN BRAKE FAILURE AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH THOROUGHLY INSPECT THESE AREAS AND IF NECESSARY REPLACE MOTOR DRIVE SHAFT SPRAG CLUTCH AND CONNECTING SHAFT AS A SET 336 REV 030528 PAGE 15 SERVICE INSTRUCTIONS 8 Thoroughly inspect motor drive shaft item 730 and brake hub item 720 particularly the surfaces where sprag clutch item 723 engages If any indentation or surface damage is detected replace brake hub sprag clutch and motor drive shaft as a set 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 item 753 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
27. em clean and free from contamination at all times 20 Maintain winch and equipment in good operating condition Perform scheduled maintenance regularly 21 Keep hands clear when winding wire rope onto the winch drum 22 not use the wire rope as a ground for welding 23 Rigthe winch carefully Ensure that the wire rope is properly anchored to the correct cable anchor slot at the cable drum 24 Do not lift a load with a twisted kinked or damaged wire rope 25 Consult wire rope manufacturer for size type and maintenance of wire rope 26 Maintain five wraps of wire rope on the cable drum at all times 27 In case of a power failure or breakdown leading to an unexpected stop of the hydraulic power circuit stand clear of the area and the load being hoisted take the necessary precautions to prevent access to area where the load is halted 28 The noise level of the winch is 89 dBA measured on a distance of 1 00 meter 1 60 meters high The measuring equipment used was Realistic 42 3019 29 Clean up any oil spillage immediately 30 Wear proper clothing and personal protection equipment such as footwear safety goggles and a hard hat Read manual first 90000 336 REV 051117 PAGE 1 DESCRIPTION OF THE MODEL M30 GENERAL DESCRIPTION The PULLMASTER Model M30 is a planetary hydraulic winch having equal speed in both directions The main components of this unit are hydraulic gear motor mu
28. for the PULLMASTER Model M30 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 336 REV 030528 PAGE 21 ASSEMBLY DRAWING AS M30 PAGE 22 336 REV 030528 PARTS REFERENCE FINAL DRIVE 1 1 1 1 1 2 1 1 1 8 8 1 1 3 6 3 6 2 1 1 1 1 1 1 m 25333 26467 26359 23623 25237 19036 25340 20418 25118 25037 20677 20406 25199 25167 25297 25700 20423 25032 25514 25346 FINAL HOUSING BALL BEARING 6026 CIRCLIP ROTOR DHO 200 OIL SEAL END COVER PIPE PLUG 3 4 14 NPT SUNGEAR STOPPER O RING 281 15 ID 1 8 CS PLANET HUB STOPPER CAPSCREW HEX HEAD 3 8 16 NC X 1 25 GRADE 5 LOCK WASHER 3 8 BREATHER RELIEF ASSEMBLY PLANET HUB PLANET PIN CIRCLIP ROTOR CLIP SH 168 PLANET GEAR THRUST WASHER TORRINGTON TRB 2840 LOOSE ROLLER TORRINGTON 024054 SUNGEAR CIRCLIP ROTOR CLIP SH 206 CABLE DRUM CABLE ANCHOR PIPE PLUG 1 2 14 NPT CIRCLIP ROTOR CLIP SH 500 CAPSCREW HEX HEAD 5 8 11 NC GRADE 5 LOCKWASHER 5 8 BASE PLATE CAPSCREW HEX HEAD 5 8 11 NC GRADE 5 TIE BAR These part numbers vary according to drum code Refer to APPENDIX B These parts vary according to Reduction Ration Refer to APPENDIX C
29. g holes of bearing flange item 530 with those in cable drum PAGE 18 336 REV 030528 SERVICE INSTRUCTIONS 11 Rotate brake housing to line up access holes and fasten bearing flange using six capscrews item 537 and lockwashers item 541 12 Install new well greased O ring item 735 into access plug item 734 Install access plug into access hole inside brake housing 13 Fasten two tie bars item 556 using 16 capscrews item 555 and lockwashers item 553 REASSEMBLY OF BRAKE HOUSING ASSEMBLY Reassemble brake housing assembly as follows 1 Install sprag clutch item 723 into bore of brake hub item 720 Position sprag clutch aligners items 722 and 724 on either side of brake hub Carefully slide motor drive shaft item 730 into brake hub assembly and secure with circlip item 727 Verify that circlips items 719 and 731 are installed on motor drive shaft 2 Carefully slide motor drive shaft item 730 with brake hub assembly into connecting shaft until it engages spline of primary sungear item 440 IMPORTANT For proper brake function verify that sprag clutch is installed correctly When viewed from the motor end the motor drive shaft of a clockwise hoisting winch must turn freely clockwise and lock in the counterclockwise direction 3 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 CAUSIN
30. he hydraulic circuit system can be analysed If this condition exists install a flow meter into the hydraulic circuit to check the volume supplied to the pressure port of the hydraulic winch motor when the winch control is completely opened The flow meter should indicate the maximum operating volume If this test indicates a loss of hydraulic flow check the hydraulic pump the relief valve and the control valve If the pump is driven by V belts check for belt slippage The hydraulic pressure relates to the line pull or lifting capacity of the winch If the winch will not lift the specified maximum line pull install a pressure gauge into the pressure line leading to the hoisting port on the hydraulic winch motor Stall the winch to prevent rotation of the drum and then open the control valve Check the hydraulic pressure reading of the installed pressure gauge If the pressure reads below the specified maximum operating pressure look for trouble in the hydraulic pump the relief valve and the control valve If the pump is driven by V belts check for belt slippage When checking oil pressure and volume in the hydraulic circuit make certain that the hydraulic reservoiris filled to the top level and the hydraulic pump is running at maximum operating rpm Only if the hydraulic system has been checked and found to be in order use the following indications for probable causes of failure in the winch FAILURE PROBABLE CAUSE Winch will not produce line p
31. hrust 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 a soft headed hammer 4 Install gear set item 881 into 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 on 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 Runthe 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 Refer to INSTALL
32. ke will not hold Brake plates or divider plates have been damaged by contamination in the hydraulic fluid or lack of circulation flow in the brake housing Brake piston is seized in the brake housing because of contamination in the hydraulic fluid Excessive back pressure in the return line causes the brake to be released Control valve has incorrect spool which traps hydraulic pressure in the brake piston when the control valve handle is returned to neutral position For proper function of the automatic brake both pressure ports of the winch must be 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 pl
33. ll consider other options for quantity requirements PAGE 4 336 REV 030528 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 m 1 2 in 413 ft 126m 9 16 in 383 ft 117m 5 8 in 297 ft 90m 3 4 in 210 ft 64 m 7 8 in 140 ft 43 m 1in 91 ft 28m MAXIMUM OPERATING PRESSURE 2500 psi 172 bar MAXIMUM OPERATING VOLUME 115 US gpm 435 l min MINIMUM OPERATING VOLUME 30 US gpm 114 l min DRUM TORQUE AT MAXIMUM PRESSURE 135 937 Ib in 15 359 Nm DRUM RPM AT MAXIMUM VOLUME 49 rpm MAXIMUM LINE PULL AT MAXIMUM PRESSURE Bare drum 25 000 Ib 111 2 kN Full drum 16 860 Ib 75 0 kN MAXIMUM LINE SPEED AT MAXIMUM VOLUME Bare drum 140 fpm 43 m min Full drum 207 fpm 63 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 TE 336 REV 030528
34. lti disc brake with static and dynamic function primary planet reduction secondary planet reduction final planet reduction brake housing cable drum final drive housing FUNCTION IN FORWARD ROTATION HOISTING In forward rotation or when the winch is pressurized for hoisting the output torque and rpm of the hydraulic motor are transmitted to the sungear of the primary planet reduction The output torque and rpm of the primary reduction stage are transmitted to the secondary reduction stage by the secondary sungear which is splined to the primary planet hub In forward rotation or when a load is raised an over running clutch which connects the motor drive shaft to the automatic brake assembly permits free rotation of the sungear without effecting the brake When the winch rotation is stopped the load on the cable drum causes the over running clutch to lock and the maximum load is held safely by the disc brake FUNCTION IN REVERSE ROTATION LOWERING In reverse rotation or when the winch is pressurized for lowering of a load hydraulic pressure from the reverse side of the hydraulic motor is channelled to the brake piston causing the brake piston to release the multi disc brake against a number of brake springs The over running clutch connecting the motor drive shaft to the brake assembly locks causing the brake disks to rotate between divider plates which are engaged into the brake housing Ifthe load on the cable
35. meter X 17 0 inch flange diameter X 11 0 inch length STANDARD For other drum sizes refer to APPENDIX A OPTIONS DESIGN REVISION SPECIFICATION NUMBER Describes features not identified by preceding codes NOTE Clockwise and counterclockwise drum rotation is the direction of rotation for pulling or hoisting established by looking at the hydraulic motor 336 REV 030528 PAGE 3 OPTIONS COUNTERCLOCKWISE ROTATION The drum rotation of the standard PULLMASTER Model M30 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 INTERNAL CIRCULATION The PULLMASTER Model M30 planetary winch has an external circulation flow supply line to cool the brake Internal circulation is available as an option EXTERNAL BRAKE RELEASE PULLMASTER planetary winches can be supplied with an external brake release which permits release of the automatic disc brake from an external pressure source FAILURE TO PROPERLY VENT EXTERNAL BRAKE RELEASE PORT WILL TRAP BRAKE PRESSURE AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH WINCHES SUPPLIED WITH EXTERNAL RELEASE OPTION MUST BE CONNECTED ACCORDING TO TYPICAL HYDRAULIC CIRCUIT CABLE DRUM SIZES Aside from the standard drum sizes listed in APPENDIX A the PULLMASTER Model M30 planetary winch can be supplied with optional drums
36. n 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 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 336 REV 051117 PAGE 11 TROUBLE SHOOTING GENERAL In most cases when the hydraulic winch does not perform satisfactorily the cause of malfunction is found somewhere in the hydraulic circuit Before the winch is removed from its mounting and disassembled all of the hydraulic circuit components should be checked for proper function IMPORTANT The hydraulic oil volume relates to the line speed or rpm of the winch Therefore if the winch does not produce the specified maximum rated line speed or drum rpm a loss of hydraulic flow somewhere in t
37. phere and serves as a warning that the seal between brake housing and drum has been damaged PAGE 2 336 REV 040708 EXPLANATION OF MODEL CODING 30 X XX XX XX X X XXXX BASIC UNIT SERIES T M Equal speed in both directions SIZE OF UNIT REDUCTION RATIO Only used for non standard reduction ratios For other ratios refer to appendix TYPE OF BRAKE 0 Winch without brake 3 Automatic brake clockwise drum rotation internal circulation flow 4 Automatic brake external brake release clockwise drum rotation internal circulation flow 5 Automatic brake external brake release counterclockwise drum rotation internal circulation flow 6 Automatic brake counterclockwise drum rotation internal circulation flow 7 Automatic brake clockwise drum rotation external circulation flow 8 Automatic brake external brake release clockwise drum rotation external circulation flow 9 Automatic brake external brake release counterclockwise drum rotation external circulation flow 10 Automatic brake counterclockwise drum rotation external circulation flow 11 Brake effective in both directions external circulation flow 17 Brake effective in both directions external circulation flow external drain external brake release HYDRAULIC MOTOR 86 Hydraulic motor 3 inch gear section 12 3 cubic inch displacement Other gear sections for this motor are optional DRUM SIZE 1 10 0 inch drum dia
38. re measured at the circulation supply port does not exceed the permissible pressure stated in SPECIFICATIONS Winches equipped with the internal circulation option will supply circulation flow only when the winch is run in the lowering direction 10 Verify that breather relief item 130 is in place on end cover item 120 above oil level Rotate end cover if breather relief is below oil level IMPORTANT Do not replace breather relief with a pipe plug The breather relief does not prevent oil seal failure but serves as an indicator or warning that the oil seals between brake housing and the cable drum interior have failed and must be replaced immediately If these oil seals are changed additional failure of the drum seal and potential damage to the end cover is prevented PAGE 10 336 REV 030528 OPERATING INSTRUCTIONS FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL RESULT IN PROPERTY DAMAGE 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 Refer to manufacturer s handling inspection and maintenance recommendations to avoid potential accidents For selection of ropes etc please check the following product standards DIN 15020 prEN 818 1 9 prEN 1492 1 2 prEN 1677 1 3 and other relevant product
39. standards The cable drum of the PULLMASTER planetary winch has two cable anchor slots one for clockwise and one for counterclockwise hoisting Standard rotation for hoisting is clockwise when looking at the hydraulic motor of the unit It is critical to select the cable anchor slot which will permit winding of the wire rope on the drum in the correct direction of rotation If the wire rope is wound on the cable drum in the wrong direction of rotation the winch will have no braking capacity Each winch is shipped from the factory with a label on the drum indicating the correct cable anchor slot CABLE ANCHOR WIRE ROPE INSTALLATION Clockwise hoisting winch shown Use cable anchor slot on opposite side of drum for counterclockwise hoisting winch Feed the wire rope through the cable anchor slot Loop rope back into slot as shown Insert cable anchor and pull rope tight to wedge rope in slot 511013 30 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 5 wraps of wire rope under tension 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 i
40. talled in bearing flange item 530 Install bearing flange assembly onto brake housing and then press the inner race of cylindrical roller bearing item 533 onto brake housing item 700 and install new well greased O ring item 539 Press needle bearing item 603 into connecting shaft item 600 Install new well greased oil seal item 607 into connecting shaft Install new well greased O ring item 601 onto connecting shaft item 600 and insert connecting shaft into brake housing item 700 Slide internal gear item 430 along with spacer item 434 onto end of connecting shaft and fasten in place with circlip item 431 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 primary planet hub item 400 Retain with circlip item 411 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 Insert final sungear item 340 into cable drum and engage three planet gears item 320 If final sungear is installed verify that circlip item 343 is in place on final sungear 10 Lower brake housing assembly onto cable drum while engaging spline of final sungear with primary planet hub item 400 Line up mountin
41. ties to property or injury to persons resulting from faulty installation repair or modification of the article and misuse or negligent operation or use of the article whether or not such damage to property or injury to persons may be caused by defective material workmanship or construction ADVISORY Winches and hoists are not approved for lifting or handling personnel or persons unless specifically approved in writing from Seller for the specific intended application Under no circumstances shall Seller be liable i for any damage or loss to any property other than the warranted article or part thereof or ii for any special indirect incidental or consequential damage or loss even though such expenses damages or losses may be foreseeable The foregoing limitations on Seller s liability in the event of breach of warranty shall also be the absolute limit of Seller s liability in the event of Seller s negligence in manufacture installation or otherwise with regard to the articles covered by this Warranty and at the expiration of the Warranty period as above stated all such liabilities shall terminate Buyer s purchase of any article s covered by this Warranty shall constitute acceptance of the terms and conditions hereof and shall be binding upon Buyer and Buyer s representatives heirs and assigns The laws of the Province of British Columbia shall govern Buyer s rights and responsibilities in regard to this Warranty and the transaction s
42. ting 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 M30 planetary winch Pressure lines Circulation return line Circulation supply line Equivalent to SAE 100R12 32 Equivalent to SAE 100R4 16 Equivalent to SAE 100R6 6 Only for models with external circulation It is recommended that a larger size of hydraulic hose is installed where the pressure lines or the circulation lines are excessively long HYDRAULIC FILTER Hydraulic filter recommendations for the hydraulic circuit of the PULLMASTER planetary winch based on a return line filter are given as follows 10 microns 5 microns Average Atmosphere Dusty Atmosphere In order to prevent accidental stoppage of the return line flow the oil filter should have a by pass feature USE OF AN E STOP FOR EUROPEAN MACHINERY DIRECTIVE APPLICATIONS The use of an E stop emergency is manda
43. to accommodate large wire rope storage capacity DRUM GROOVING Cable drums for the PULLMASTER Model M30 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 M30 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 M30 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 FREESPOOLING This option permits wire rope being pulled off the cable drum by an operator Freespooling should not be confused with free fall The freespool coupling cannot be disengaged or re engaged with a load on the wire rope or while the cable drum is turning FREE FALL This option is available in an emergency or controlled free fall version The emergency free fall allows a full release of the maximum load The controlled free fall allows up to 30 of the maximum load to be lowered fast and stopped safely The PULLMASTER WINCH CORPORATION wi
44. tory in the controls circuit The E stop is to be placed in the operator s control panel The E stop must be designed and placed in line with EN 60204 and EN 418 PAGE 8 336 REV 030528 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 the mounting platform and check Gap A B C and D JACKING 511082 SCREW B T JACKING SCREW D Le jes DRUM IN SAP e FLANGE 5 1 8 6 2 0 JACKING IET GAP D GAP B SCREW A Bn nt DETAIL JACKING SCREW MOUNTING BOLT 1 1 4 4 PLACES TYP 3 If Gap A is within 007 to Gap B and Gap
45. ull 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 will not produce line speed at maximum Winch is mounted to an uneven surface volume as listed in SPECIFICATIONS See INSTALLATION INSTRUCTIONS Cable sheaves or block purchase operated with the winch are not turning freely Damage or wear in the hydraulic motor Excessive back pressure in the hydraulic circuit Winch will not reverse Leakage out of the brake piston prevents the brake from being released against the brake springs This is caused by damaged O ring seals on the brake piston The O ring seals on the brake release channel between the motor adaptor and the brake housing is damaged If this failure occurs there will be substantial leakage from between the motor adaptor and brake housing Insufficient hydraulic pressure See SPECIFICATIONS for minimum operating pressure Winch is mounted to an uneven surface See INSTALLATION INSTRUCTIONS Hydraulic pressure is not reaching the brake piston plugged brake release orifice in the brake housing PAGE 12 336 REV 030528 TROU B LE NG CONTINUED FAILURE PROBABLE CAUSE Bra
46. vice This Warranty shall not apply to any article which has been repaired altered or disassembled or assembled by personnel other than those of Seller This Warranty shall not apply to any article upon which repairs or alterations have been made unless authorized in writing and in advance by Seller This Warranty shall not apply to any articles or parts thereof furnished by Seller to Buyer s specifications and or furnished by Buyer or acquired from others at Buyer s request SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND OTHER THAN THE WARRANTY EXPRESSLY SET FORTH ABOVE SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANT ABILITY 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 acceler
47. y as follows 1 Removethe eight hex capscrews item 951 together with the lockwashers item 953 from the motor assembly IMPORTANT Failure to exercise care when removing the motor port end cover or gear housing could permanently damage the machined surfaces of these motor components Take care not to damage machined surfaces of motor components at disassembly 2 Remove pry loose if necessary port end cover item 870 together with bearings item 875 and ring seal item 877 Thrust plate item 885 and dowel pins item 865 may stay in gear housing 3 If thrust plate comes off with end cover carefully pry it off of bearings item 875 and discard pocket seals item 887 PAGE 14 336 REV 030528 SERVICE INSTRUCTIONS 4 Remove gear set item 881 which consists of two gears which are a matched set 5 Carefully pry gear housing item 861 off of the motor adaptor item 800 Thrust plate item 885 and dowel pins item 865 may stay in the gear housing 6 Ifthethrust plate stays on the motor adaptor carefully pry it off of bearings item 875 and discard teflon seals item 887 7 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 the winch seal kit The seal kit for the hydraulic motor can be ordered from the factory under
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