Model H50 Service Manual
Contents
1. 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 254 REV 110120 PARTS REFERENCE BRAKE GROUP RETAINING RING PLANET HUB PLANET PIN CIRCLIP ROTOR CLIP C 87 CIRCLIP ROTOR CLIP SH 87 PLANET GEAR THRUST WASHER TORRINGTON TRC 1423 LOOSE ROLLER 5 32 X 1 25 TOR 151 INTERNAL GEAR CIRCLIP ROTOR CLIP SH 300 THRUST WASHER TORRINGTON TRA 6681 THRUST BEARING TORRINGTON NTA 6681 SUNGEAR SUNGEAR STOPPER PLANET HUB SECONDARY HOUSING PLANET PIN CIRCLIP ROTOR CLIP C 100 CIRCLIP ROTOR CLIP SH 100 PLANET GEAR THRUST WASHER TORRINGTON TRC 1625 NEEDLE BEARING TORRINGTON BH 1620 RETAINING RING SUNGEAR PLANET HUB STOPPER OIL SEAL THRUST PLATE BEARING SPHERICAL ROLLER SKF 23032 CC RETAINING RING CAPSCREW HEX HEAD 1 2 13NC X 1 50 GRADE 5 O RING 277 11 1 2 ID 1 8 CS LOCKWASHER 1 2 CONNECTING SHAFT NEEDLE BEARING TORRINGTON B 3012 NEEDLE BEARING TORRINGTON NBH 4812 OIL SEAL THRUST WASHER INA AS 90120 THRUST BEARING INA AXK 90120 BRAKE HOUSING PLASTIC CAPLUG 1 NPT THR D O RING 278 12 ID 1 8 CS OIL SEAL BRAKE SPACER DIVIDER PLATE FRICTION PLATE CIRCLIP ROTOR CLIP SH 187 BRAKE HUB CIRCLIP ROTOR CLIP SH 387 SPRAG CLUTCH SP2. FEET MINUTE METERS MINUTE MAXIMUM ALLOWABLE LINE PULL LOWERING POUNDS KILONEWTONS LOWERING LINE SPEED AT MAXIMUM VOLUME FEET MINUTE METERS MINUTE LUBRICATING OIL VOLUME REQUIRED US GALLONS LITERS FLANGE LENGTH 1 1 4 inch 1 1 8 inch BARE FULL DRUM DRUM BARE FULL DRUM DRUM BARE FULL DRUM DRUM BARE FULL DRUM DRUM 50000 222 4 33889 150 7 69 102 21 31 10714 47 7 7514 33 4 324 99 478 146 7 0 26 39610 176 2 26522 118 0 88 131 27 40 8487 37 8 5854 26 0 409 125 611 186 12 7 48 50000 222 4 21942 97 6 69 158 21 48 10714 47 7 4704 20 9 324 99 739 225 12 0 45 Performance specifications are based on standard hydraulic motor with 1 1 4 inch diameter rope PAGE 30 254 REV 011203 APPENDIX B DRUM CODE PART NO DESCRIPTION PART NUMBER QUANTITY FINAL HOUSING pc scd 1 1 FINAL 21030 E n SUNGEAR 1 i 1 25299 25299 LOCKWASHER M 21007 dor 2 25682 25564 mme 21013 21049 TIE BAR s T 21038 21039 1 1 gt 5 m 700 BRAKE HOUSING 254 REV 981001 PAGE 31 APPENDIX C BRAKE CODE ITEM NO DESCRIPTION PART NUMBERS CIRCULATION 1 4 18 NPT 806 PIPE PLUG 25031 25031 25031 25031 1 8 27 NPT 1 8 2
3. vill MASTER THE LOGICAL CHOICE INSTRUCTION AND PARTS MANUAL MODEL H50 PLANETARY HYDRAULIC WINCH amp N POWER to Move the World TWG Canada LANTEC and Pullmaster Brands 19350 22nd Ave Surrey BC V3S 356 Voice 1 604 547 2100 e 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 ANDMAINTENANCE OF THIS PRODUCT PMC 254 120612 POVER e MONA Effective 2011 10 01 a DOVER comen SUPERSEDES ALL PRIOR WARRANTIES Pull MASTER LIMITED WARRANTY 50130 0 Seller warrants that each article whether Gear Drive Products Brake Products and or Winch Products all of which are covered hereunder sold under this order shall at the time of shipment i conform to applicable specifications and ii be free from defects in material and workmanship during normal and ordinary use and service the Warranty Buyer s exclusive remedy and Seller s sole obligation under this Warranty shall be at Seller s option to repair or replace any article or part thereof which has proven to be defective or to refund the purchase price of such article or part thereof Buyer acknowledges that Buyer is knowledgeable concerning the articles covered by this Warranty and sold in connection th
4. 5 Press remaining 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 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 PAGE 18 254 REV 981001 SERVICE INSTRUCTIONS conrmueo IMPORTANT Before operating the winch add lubricating oil up to the level of the end cover oil fill port Refer to INSTALLATION INSTRUCTIONS for location of fill port Refer to APPENDIX A for oil volume required To ensure proper reassembly run the winch in both directions without load LIFTING A LOAD WITH A NEWLY SERVICED WINCH 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
5. Bare drum 69 fpm 21 m min Full drum 102 fpm 31 m min LOWERING LINE SPEED AT MAXIMUM VOLUME Bare drum 322 fpm 98 m min Full drum 462 fpm 141 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 254 REV 011203 5 PERFORMANCE GRAPHS PG H50 LINE PULL VS OIL PRESSURE LINE PULL kN 0 22 44 67 89 111 133 156 178 200 222 2500 172 2000 138 E o E 5 F 3 1 _ lt _ 1 X Lu oc 1500 103 cc 2 7 ep 09 f 5 1000 69 A A _ 500 34 0 ATA 11 tg 0 5000 10000 15000 20000 25000 30000 35000 40000 45000 50000 LINE PULL Ib HOISTING LINE SPEED LINE SPEED VS OIL VOLUME a LOWERING LINE SPEED LINE SPEED m min 0 15 30 46 61 76 91 37 122 137 152 125 O TTT TTT Ty ryt yt rt 473 e _ SN ae E 100 379 o S c v D 2 2 J n 75 Y 2 ya J 284 Pd gt gt gt a 7 m 5 idi 5 50 Y 189 77 gt gt 2 7 _ 25 95 o a 0 50 100 150 200 250 300 350 400 450 500 LINE SPEED fpm Performance gra
6. 877 AND 887 These part numbers and descriptions vary according to brake code Refer to APPENDIX C ITEM 950 MOTOR SUB ASSY CONTAINS ITEMS 800 802 805 806 807 809 813 861 865 869 870 875 877 881 885 887 899 929 951 953 AND 955 Refer to PAGE 24 for winch seal kit and PAGE 21 for ASSEMBLY DRAWING PAGE 26 254 REV 981001 aq pinous 451 IDN3483338 1 uo jou Buimeip ay uo yey sueg Aiquesse e jueseud ase uey sued Aew sDBuiweJp G1002 D PAGE 27 948 488 A O am O N 698 188 LEZ 008 208 108 008 0 Z 254 REV 981001 Y Q Y 2 O lt 1 x H Y Q T 9 edoJ v L p JO ejqeins SI JoOYOUe ejqeo prepuelg e LAN bL b 8 1HOd 5 feri 1 9 S 911 1
7. 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 H50 planetary winch can be supplied with optional drums to accommodate large wire rope storage capacity DRUM GROOVING Cable drums for the PULLMASTER Model H50 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 ofthe standard PULLMASTER Model H50 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 H50 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 o
8. REINSTALLATION REFER TO PROCEDURES AND TESTS DESCRIBED IN INSTALLATION AND OPERATING INSTRUCTIONS E 254 REV 981001 PAGE 19 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 for the PULLMASTER Model H50 planetary winch always quote the complete model and serial number of the unit MODEL SERIAL PULLMASTER WINCH CORPORATION reserves the right to change specifications and the design of PULLMASTER planetary winches at any time without prior notice and without incurring any obligations PAGE 20 254 REV 981001 ASSEMBLY DRAWING
9. 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 inthe 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 CABLE ANCHOR SLOT m 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 AU 511013 50 On wire installation care must be taken that the wire 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 spe
10. cover 6 Attach end cover to end housing item 100 using 12 capscrews item 127 and lockwashers item 541 7 Temporarily remove breather relief item 130 from end cover Turn winch over with brake housing item 700 facing upward 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 254 REV 110214 PAGE 17 SERVICE INSTRUCTIONS conrnueo 2 Starting and finishing with a divider plate alternately install 13 divider plates item 713 and 12 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 sprag clutch item 723 and sprag clutch aligner item 724 into bore of connecting shaft item 600 6 Carefully slide motor drive shaft item 730 into connecting shaft until it engages spline of primary sungear item 440 and circlip item 727 is tight against sprag clutch aligner 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 fre
11. plates The over running clutch which connects the motor shaft with the brake assembly is damaged Air mixed with hydraulic oil foamy oil Oil leaks from the hydraulic motor flange and the motor adaptor are caused by damaged O ring seals Oilleaks 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 tank Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model H50 winch PAGE 12 254 REV 981001 SERVICE INSTRUCTIONS GENERAL Before attempting disassembly of the PULLMASTER Model H50 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 23148 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 ite
12. the multi disc brake against a number of brake springs The over running clutch which connects the motor drive shaft with the internal gear of the primary planet reduction locks causing the internal gear to rotate at the same rpm as the primary sungear Thus the primary reduction stage is eliminated and the output torque and rpm of the hydraulic motor are transmitted directly to the final planet reduction stage With the primary reduction stage eliminated the reduction is reduced to a ratio of 24 6 1 and the cable drum will rotate 4 67 times faster than in forward or hoisting speed If the load on the cable drum tends to effect the lowering speed the resulting pressure drop in the brake piston causes friction between the brake discs and divider plates In this way a completely smooth lowering speed can be achieved in a stepless operation by modulation of the winch control handle When the control handle is returned to neutral position rotation stops and the disc brake applies automatically During the lowering operation of the winch the friction created by the brake discs results in heat This heat 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 7 0 US gpm 26 l min This circulation flow must be returned directly to
13. 5 775 784 650 88 1100 393 7 841 609 60 762 152 a 14 0 36 0 36 0 9 5 36 5 36 5 46 0 40 768 58 4 18 50 39 1 30 000 36 0 6 0 356 914 914 241 927 927 1169 1035 49 1483 469 9 994 762 00 914 152 14 0 240 22 0 8 9 26 6 26 8 31 1 25 625 43 3 14 63 27 5 21 000 26 5 5 5 356 610 559 225 676 679 791 650 88 1100 371 5 699 533 40 673 140 14 0 30 0 22 0 8 9 30 5 27 6 31 1 25 625 43 3 15 50 33 1 24 000 30 0 6 0 356 762 559 225 775 702 791 650 88 1100 393 7 841 609 60 762 152 Dimensions in inches Dimensions in millimetres HYDRAULIC MOTORS COMMERCIAL WM76 SERIES COMMERCIAL M365 SERIES MOTOR GEAR MOTOR PORT SIZE GEAR MOTOR PORT SIZE 1 CODE WIDTH SAE4 BOLTFLANGE WIDTH SAE4 BOLTFLANGE 86 3 00 7 6 2 50 8 0 76 2 194 63 5 I 2 0 2 75 CODE 61 74 2 25 7 8 69 9 187 57 2 2 50 74 2 00 7 5 63 5 181 50 8 2 25 6 9 57 2 175 2 00 6 6 168 6 4 162 6 1 156 5 9 149 5 6 143 7 6 194 254 REV 110124 PAGE 29 APPENDIX A CABLE DRUM SIZES WIRE ROPE STORAGE INCHES LLIMETERS FEET METERS LINE PULL AT MAXIMUM PRESSURE HOISTING POUNDS KILONEWTONS LINE SPEED AT MAXIMUM VOLUME
14. 534 to remove spherical roller bearing item 533 Remove and discard oil seal item 531 17 To separate final drive housing item 100 and cable drum item 500 first remove external circlip item 513 off end of cable drum then insert two heel bars into slot between final drive housing and cable drum and pry out of ball bearing item 103 18 Remove internal retaining ring item 104 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 PRIMARY DRIVE AND SECONDARY DRIVE 1 Press new well greased oil 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 Turn winch over resting on end housing with cable drum opening facing upward Reassemble primary drive as follows 4 Press new well greased oil seal item 531 into secondary planet housing item 456 Press spherical roller bearing item 533 into secondary housing and secure with retaining ring item 534 5 Press secondary housing assembly onto brake housing item 700 and install new well greased O ring item 539 6 Install new well greased oil seal item 607 with backup washer item 606 if i
15. 7 NPT PIPE ADAPTOR 25622 25622 25622 25622 1 8 NPT MOTOR 20504 22011 22012 20804 20505 21977 22013 20805 3 8 18 NPT PAGE 32 254 REV 981001 BOLT TORQUE CHART BOLT DIAMETER TORQUE TORQUE Inches Lb ft Nm NOTE Unless otherwise specified torque bolts per above chart 254 REV 981001 PAGE 33
16. ATIONS Winches equipped with the internal circulation option will supply circulation flow only when the winch is run in the lowering direction Verify that breather relief item 130 is in place on end cover above oil level Rotate end cover if breather relief is below oil level IMPORTANT Do not replace breather relief with a pipe plug The breather relief does not prevent oil seal failure but serves as an indicator or warning that the oil seals between brake housing and the cable drum interior have failed and must be replaced immediately If these oil seals are changed additional failure of the drum seal and potential damage to the end cover is prevented 254 REV 981001 PAGE 9 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 standards The cable drum of the PULLMASTER planetary winch has two cable anchor slots one for clockwise and one for
17. Brake will not hold Brake plates or divider plates have been damaged by contamination inthe hydraulic fluid or lack of circulation flow in the brake housing Brake piston is seized in the brake housing because of contamination in the hydraulic fluid Excessive back pressure in the return line causes the brake to be released Control valve has incorrect spool which traps hydraulic pressure in the brake piston when the control valve handle is returned to neutral position For proper function of the automatic brake both pressure ports of the winch must be open to the reservoir in neutral position of the control valve Wire rope is fastened to the incorrect cable anchor slot Sprag clutch is damaged or surfaces where sprag clutch engages on motor drive shaft or 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
18. G1002 amp G1070 amp G1067 254 REV 981001 PAGE 21 PARTS REFERENCE FINAL DRIVE 25669 21035 25670 21818 25237 20419 25681 21029 25158 20677 24554 21027 25678 25678 21010 24548 25297 ak 1 1 1 1 1 2 1 1 1 2 1 1 3 3 3 3 6 10 a 21005 25237 25679 25014 25564 xum 2NN O FINAL HOUSING BALL BEARING 6040 RETAINING RING OIL SEAL END COVER PIPE PLUG 3 4 14 NPT SUNGEAR STOPPER O RING 391 22 ID 3 16 CS PLANET HUB STOPPER CAPSCREW HEX HEAD 1 2 13 NC X 1 75 GRADE 5 BREATHER RELIEF ASSEMBLY PLANETHUB PLANET PIN CIRCLIP ROTOR CLIP SH 215 CIRCLIP ROTOR CLIP SH 215 PLANET GEAR THRUSTWASHER LOOSE ROLLER TORRINGTON G613 Q SUNGEAR CABLE DRUM CABLE ANCHOR PIPE PLUG 3 4 14 NPT CIRCLIP ROTOR CLIP SH 800 LOCKWASHER 1 2 CAPSCREW HEX HEAD 3 4 10NC X 2 00 GRADE 5 LOCKWASHER 3 4 BASE PLATE CAPSCREW HEX HEAD 3 4 10NC GRADE 5 TIE BAR LOCKWASHER 7 8 CAPSCREW HEX HEAD 7 8 9NC X 1 50 GRADE 5 These part numbers and quantities vary according to drum code Refer to APPENDIX B Refer to PAGE 24 for winch seal kit and PAGE 21 for ASSEMBLY DRAWING PAGE 22 254 REV 110817 FINAL DRIVE GROUP G1067 C Ec m es
19. Lo 1HOd NN 38 H LdN 81 t 1 y NOILLWINOYIO 9c 140d 38V3138 NOSE NOR VIO 100ds33u4 YNY31X3 LAN 81 8 S1708 DNILNNOW 8 ISN VNOLLAO gt 1HOd 5 96 91 2 1 O LAN _ je id SATOH ONILNNON v S1HOd 39nv5 8 v N 3 v 17 cel Dn i 3 o o E OV H E B A oro SER ppp HB In 3 10 i J 3 LdN 22 81 Ny la 1HOd 38V37138 1 3215 1HOd EN TvNH3LX3 1HVHO HOLON 33S TVNOILJO 3ONv14 1108 7 375 HO1ON HY39 MM 15 ONILSIOH LdN t1 b 1HOd 114 d NOLLVLOY es INVA ISIMA90719 43LNNOO NOLLV LOY 3ZIENSSIVA JSIAMOO TO 3219188994 LAN bL b 8 1HOd HATHA is w ye eq snw ado am sdelm jo ALJAVS HOS 254 REV 110124 PAGE 28 INSTALLATION DIMENSIONS Dimensions in inches 11029 2 Dimensions in millimeters A 5 2 14 0 23 8 14 0 8 9 26 5 26 8 22 9 17 625 35 3 14 63 27 5 21 000 26 5 5 5 356 603 356 225 673 681 581 447 68 897 371 5 699 533 40 673 140 a 18 0 30 0 22 0 8 9 30 5 30 5 30 9 25 625 43 3 15 50 33 1 24 000 30 0 6 0 457 762 559 225 77
20. RAG CLUTCH ALIGNER CIRCLIP ROTOR CLIP SH 196 PLASTIC CAPLUG 1 2 NPT 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 a k ik a 3 3 3 3 6 0 1 1 2 1 1 1 1 1 3 3 3 3 6 3 1 1 1 1 1 1 1 2 1 2 1 1 2 1 2 1 1 1 1 1 1 3 2 1 1 1 1 1 1 1 1 1 8 1 WINCH SEAL KIT CONTAINS ITEMS 105 123 531 539 607 707 711 751 753 AND 801 This part varies according to drum code Refer to APPENDIX B Refer to PAGE 21 for ASSEMBLY DRAWING PAGE 24 254 REV 120330 BRAKE GROUP G1070 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 254 REV 981001 PAGE 25 PARTS REFERENCE MOTOR GROUP 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 E PIPE PLUG 1 8 27 PIPE PLUG 1 4 18 NPT GEAR HOUSING 086 DOWEL PIN SEAL GASKET PORT END COVER BEARING ROLLER RING SEAL GEAR SET 086 THRUST PLATE TEFLON SEAL PIPE PLUG 1 4 18 NPT SUB ASSY MOTOR 086 CAPSCREW HEX HEAD 5 8 X 6 75 GRADE 5 WASHER PLASTIC CAPLUG 2 0 4 1 1 3 1 2 1 1 1 1 1 4 2 1 4 2 1 2 4 2 1 1 8 8 2 MOTOR SEAL KIT CONTAINS ITEMS 869
21. SSEMBLY OF PRIMARY DRIVE AND SECONDARY DRIVE For ease of working on the unit set winch upright on final drive housing 1 2 3 4 5 6 7 8 9 Remove five hex capscrews item 555 with lockwashers item 553 from each side of both tie bars item 556 and remove tie bars from assembly Remove 12 hex capscrews item 537 along with lockwashers item 541 from secondary housing item 456 by rotating brake housing until access hole is overtop of hex capscrews Brake housing together with primary and secondary planet hub assemblies can now be lifted out of cable drum item 500 Discard O ring item 539 To disassemble secondary drive assembly remove internal retaining ring item 481 Secondary planet hub assembly can now be pulled out of secondary planet housing item 456 Remove secondary sungear item 490 from between planet gears item 470 Inspect secondary planet hub stopper item 494 for wear Replace if less than 16 inch thick If secondary planet hub stopper needs to be replaced or if secondary planet gears item 470 must be removed start by removing circlips item 461 Secondary planet pins item 460 can now be pressed out of secondary planet hub item 450 Remove secondary planet gears item 470 along with thrust washers item 471 Inspect needle bearings item 473 and replace if damaged Primary assembly may now be slid out of internal gear and inspected for wear or damage If primary planet gears i
22. 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 by Buyer or t
23. actory under 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 an 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 head capscrews item 537 with lockwashers item 541 from motor adaptor item 800 Since brake springs item 752 apply pressure against the inside of motor adaptor it is recommended that hex capscrews are unscrewed one turn at a time until spring pressure has been released 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 pressure transfer hole for automatic brake release and are situated on flange of brake housing DISASSEMBLY OF BRAKE HOUSING ASSEMBLY 1 After motor assembly has been removed all parts of brake assembly are accessible Remove 18 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 out of brake hub assemb
24. 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 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
25. ange at operating temperature is 81 167 SUS 16 36 CS Forextreme 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 DIMENSIONS for location of lubricating oil fill port Referto APPENDIXA for quantity of oil required For normal operating temperature use SAE 90 lubricating oil Consult lubricating oil supplier or factory for temperatures beyond normal operating range HYDRAULIC PUMP For maximum performance of the PULLMASTER planetary winch the hydraulic pump must supply the maximum flow of hydraulic fluid atthe hydraulic pressure stated in SPECIFICATIONS HYDRAULIC CONTROL VALVE The 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 w
26. ction s subject thereto and the Province of British Columbia shall be the exclusive forum and jurisdiction for any action or proceedings brought by Buyer in connection herewith or any dispute hereunder If any of the terms and conditions contained within this Warranty are void the remaining provisions thereof are and shall remain valid and enforceable SAFETY RECOMMENDATIONS Definition Caution indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury 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 DANGER FAILURE TO COMPLY WITH THE FOLLOWING SAFETY RECOMMENDATIONS AND LOCAL RULES AND REGULATIONS WILL RESULT IN PROPERTY DAMAGE SEVERE INJURY OR DEATH N 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 u
27. ed in either direction is obtained when the control valve lever is moved as far as it can go The disc brake of the winch will come on automatically when the winch control lever is returned to neutral Always warm up equipment prior to operating winch particularly in low ambient temperature Circulate hydraulic oil through the winch control valve for several minutes to warm the hydraulic 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 PAGE 10 254 REV 051117 TROUBLE SHOOTING GENERAL In most cases when the hydraulic winch does not perform satisfactorily the cause of malfunction is found somewhere in the hydraulic circuit Before the winch is removed from its mounting and disassembled all of the hydraulic circuit components should be checked for proper function IMPORTANT The hydraulic oil volume relates to the line speed or rpm of the winch Therefore if the winch does not produce the specified maximum rated line speed or drum rpm a loss of hydraulic flow somewhere
28. ely clockwise and lock in the counterclockwise direction 7 Install 18 brake springs item 752 in brake piston Brake piston has 20 holes and two empty holes should be opposite each other 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 537 and lockwashers item 541 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 thrust plate 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 into gear housing The longer gear with the internal spline goes into the top position
29. ent to SAE 100R6 6 Only for models with external circulation It is recommended that a larger size of hydraulic hose is installed where the pressure lines or the circulation lines are excessively long HYDRAULIC FILTER Hydraulic filter recommendations for the hydraulic circuit of the PULLMASTER planetary winch based on a return line filter are given as follows 10 microns 5 microns Average Atmosphere Dusty Atmosphere In order to prevent accidental stoppage of the return line flow the oil filter should have a by pass feature USE OF AN E STOP FOR EUROPEAN MACHINERY DIRECTIVE APPLICATIONS The use of an E stop emergency is mandatory in the controls circuit The E stop is to be placed in the operator s control panel The E stop must be designed and placed in line with EN 60204 and EN 418 PAGE 8 254 REV 011105 INSTALLATION INSTRUCTIONS FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL RESULT IN PROPERTY DAMAGE SEVERE INJURY OR DEATH The initial installation or mounting of a PULLMASTER planetary winch is critically important for proper operation and performance If the winch is mounted to an uneven surface the centre line of the unit can be distorted to a point where the winch will not operate in either direction It is therefore very important that the following instructions are observed when a PULLMASTER planetary winch is installed Make certain that the mounting platform is sufficiently strong i
30. erewith 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
31. hen lowering a load depends on the metering characteristics of the control valve The better the oil flow is metered the better will be the speed control HYDRAULIC PRESSURE RELIEF The hydraulic circuit for the PULLMASTER planetary winch requires a pressure relief set at the operating pressure see SPECIFICATIONS Usually a pressure relief is part of the hydraulic control valve Where this is not the case a separate pressure relief valve must be installed and setatthe recommended maximum pressure HYDRAULIC RESERVOIR It is recommended that the hydraulic reservoir has sufficient capacity to provide good heat dissipation in order to prevent over heating of the hydraulic fluid The hydraulic reservoir should be made from clean and scale free material to prevent contamination of the hydraulic fluid In order to prevent air from being mixed with the hydraulic fluid the reservoir should have an over flow baffle separating the return lines from the suction line and all return lines should enter the reservoir below the fluid level The reservoir should be mounted close to and above the hydraulic pump in a location which provides forfree air circulation around the reservoir HYDRAULIC HOSES The following hydraulic hoses are recommended for maximum efficiency of the PULLMASTER Model H50 planetary winch Pressure lines Circulation return line Circulation supply line Equivalent to SAE 100R12 32 Equivalent to SAE 100R4 16 Equival
32. hird parties to property or injury to persons resulting from faulty installation repair or modification of the article and misuse or negligent operation or use of the article whether or not such damage to property or injury to persons may be caused by defective material workmanship or construction ADVISORY Winches and hoists are not approved for lifting or handling personnel or persons unless specifically approved in writing from Seller for the specific intended application Under no circumstances shall Seller be liable i for any damage or loss to any property other than the warranted article or part thereof or ii for any special indirect incidental or consequential damage or loss even though such expenses damages or losses may be foreseeable The foregoing limitations on Seller s liability in the event of breach of warranty shall also be the absolute limit of Seller s liability in the event of Seller s negligence in manufacture installation or otherwise with regard to the articles covered by this Warranty and at the expiration of the Warranty period as above stated all such liabilities shall terminate Buyer s purchase of any article s covered by this Warranty shall constitute acceptance of the terms and conditions hereof and shall be binding upon Buyer and Buyer s representatives heirs and assigns The laws of the Province of British Columbia shall govern Buyer s rights and responsibilities in regard to this Warranty and the transa
33. in the hydraulic circuit system can be analysed If this condition exists install a flow meter into the hydraulic circuit to check the volume supplied to the 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 li
34. lic 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 Do 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 Donotlift 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 under tension 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 254 051117 PAGE 1 DESCRIPTION THE MODEL 50 GENERAL DESCRIPTION The PULLMASTER Model H50 is a planetary hydraulic winch with reversing speeds 4 67 times faster than forward speed The main component
35. ly Surface of motor drive shaft which engages sprag clutch item 723 should be inspected for wear or indentations If motor drive shaft shows any surface damage it should be replaced 3 Spragclutch aligner item 724 and sprag clutch item 723 can now be removed from bore of brake connecting shaft item 600 Inspect both parts for wear or damage and replace if necessary MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE MOTOR DRIVE SHAFT AND CONNECTING SHAFT WILL RESULT IN BRAKE FAILURE AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH THOROUGHLY INSPECT THESE AREAS AND IF NECESSARY REPLACE MOTOR DRIVE SHAFT SPRAG CLUTCH AND CONNECTING SHAFT AS A SET 4 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 5 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 PAGE 14 254 REV 981001 6 7 SERVICE INSTRUCTIONS co
36. m 875 may also be required Part No 25352 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 Aclean working area is of prime importance similar to conditions used for service work on any other hydraulic component All parts as they are removed from the winch assembly should be inspected for wear and damage Worn or damaged parts must be replaced Thoroughly clean parts before reassembly Do not use solvent to clean the brake friction plates During reassembly lubricate all O rings and oil seals with grease before installation 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 H50 planetary winch There are no special tools needed for the service or repair work and no adjustments or calibrations are necessary Proceed with the disassembly as follows DISASSEMBLY OF HYDRAULIC MOTOR ASSEMBLY If the analysed service or repair work requires access to the interior of the brake housing the hydraulic motor should not be disassembled In this case the 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 wi
37. n order to avoid deflection when a load is lifted Set the winch on the mounting platform and check for surface contact on all mounting pads of the winch If there is a space between the mounting surface and one of the mounting pads the mounting surface is not even and the space below the mounting pad must be shimmed If this condition exists proceed as follows a Install mounting bolts snug tight on the three mounting pads which are in contact with the mounting surface For mounting bolt size and grade see INSTALLATION DIMENSIONS b Measure the space underneath the fourth mounting pad with a feeler gauge and use shim stock of equivalent thickness in the space between the mounting pad and the mounting surface c Only after this procedure should the fourth mounting bolt be installed Tighten all four bolts per BOLT TORQUE CHART Fill the winch with lubricating oil See APPENDIX A for oil volume required Use recommended circuit components and hydraulic hoses The circulation return line of the winch should be plumbed in such a manner that the brake housing remains full of oil at all 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 pressure measured atthe circulation supply port does not exceed the permissible pressure stated in SPECIFIC
38. n the wire rope or while the cable drum is turning The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements BE PAGE 4 254 REV 981001 SPECIFICATIONS Performance specifications are based on standard hydraulic motor gear ratio and cable drum with 1 25 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 14 00 in 356 mm Flange diameter 23 75 in 603 mm Barrel length 14 00 in 356 mm CABLE STORAGE CAPACITY Size of wire rope 9 16 in 854 ft 260 m 5 8 in 691 ft 211m 3 4 in 519 ft 158 m 7 8 in 375 ft 114m 1in 276 ft 84m 1 1 8 in 195 ft 60 m 1 1 4 in 177 ft 54m 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 381 250 Ib in 43 075 Nm DRUM RPM AT MAXIMUM VOLUME Hoisting 17 4 rpm Lowering 81 2 rpm HOISTING LINE PULL AT MAXIMUM PRESSURE Bare drum 50 000 Ib 222 4 kN Full drum 33 889 Ib 150 7 kN MAXIMUM ALLOWABLE LINE PULL WHEN LOWERING Bare drum 10 714 Ib 47 7 kN Full drum 7 514 Ib 33 4 kN HOISTING LINE SPEED AT MAXIMUM VOLUME
39. ncluded with seal kit into connecting shaft item 600 7 Press needle bearing item 603 into connecting shaft 8 Slide brake hub item 720 onto connecting shaft and secure with circlip item 721 Place thrust bearing item 617 held between two thrust washers item 615 against brake hub and slide connecting shaft into brake housing 9 Place thrust bearing item 435 held between two thrust washers item 433 onto internal gear item 430 Install thrust plate item 532 onto internal gear and slide internal gear onto connecting shaft item 600 and fasten with circlip item 431 10 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 PAGE 16 254 REV 981001 SERVICE INSTRUCTIONS conrinueo side of planet gear and press planet pin item 410 into final planet hub item 400 Retain with circlip item 411 11 Insert primary sungear item 440 between three planet gears and insert sungear shaft into connecting shaft engaging planet gears with internal gear 12 Reassemble secondary planet hub assembly If removed press needle bearing item 473 into planet gear item 470 Verify placement of planet hub stopper item 494 Position thrust washers item 471 on either side of planet gear and press planet pin item 460 into secondary planet hub item 450 Retain with circli
40. nder SPECIFICATIONS Other use as foreseen in the functional description of the hydraulic winch is not allowed without written permission from PULLMASTER Use only recommended hydraulic oil and gear 1 Do nat install operate or service winch before 18 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 Donotleave aload suspendedfor any extended period of time 8 Never leave a suspended load unattended 9 Winch should be maintained and operated by qualified personnel 10 Inspectwinch 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 Besureof equipment stability before operating winch 16 Wear proper clothing to avoid entanglement in rotating machinery 17 Always stand clear of the load lubricant 19 Keep hydrau
41. ne 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 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 onthe brake release channel between the motor adaptor and the brake housing is damaged If this failure occurs there will be substantial leakage from between the motor adaptor and brake housing Insufficient hydraulic pressure See SPECIFICATIONS for minimum operating pressure Winch is mounted to an uneven surface See INSTALLATION INSTRUCTIONS Hydraulic pressure is not reaching the brake piston plugged brake release orifice in the brake housing 254 REV 981001 PAGE 11 TROU B LE NG CONTINUED FAILURE PROBABLE CAUSE
42. nrinueo 12 friction plates item 715 together with 13 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 2 3 4 5 6 7 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 of the oil out of cable drum interior winch should be tipped to an angle and filler plug item 121 removed Remove 12 capscrews item 127 and 12 lockwashers item 541 Remove end cover item 120 from end housing item 100 and discard O ring item 123 Check thickness of planet hub stopper item 126 and sungear stopper item 122 for excessive wear Replace planet hub stopper if less than 25 inch thick and sungear stopper if less than 21 inch thick Remove final planet hub assembly from hub of cable drum item 500 Inspect three planet gears item 320 for damage or wear If it is necessary to remove final planet gears extract 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 necessary Pull final sungear item 340 out of cable drum assembly DISA
43. p item 461 13 Insert secondary sungear item 490 between three planet gears item 470 Slide assembly into secondary planet housing item 456 engaging sungear spline with primary planet hub item 400 and planet gears with secondary planet housing Insert retaining ring item 481 14 Lower brake housing assembly onto cable drum Line up mounting holes of secondary housing item 456 with those in cable drum 15 Rotate brake housing to line up access holes and fasten secondary housing using 12 capscrews item 537 and lockwashers item 541 16 Attach tie bars item 556 using 20 capscrews item 555 and lockwashers item 553 REASSEMBLY OF FINAL DRIVE Turn winch over to sit upright on brake housing item 700 with end housing item 100 facing upward 1 Reassemble final planet hub assembly Use grease to temporarily hold 30 loose rollers item 323 in bore of planet gear item 320 Position thrust washers item 321 on either side of planet gear Press planet pin item 310 into final planet hub item 300 and retain with circlip item 311 2 Insert final planet hub assembly into final housing item 100 Ensure that final planet hub spline is fully engaged with cable drum item 500 3 Install final sungear item 340 through centre of three final planet gears and into secondary planet hub item 450 4 Install new well greased O ring item 123 into end cover item 120 5 Verify planet hub stopper item 126 is installed onto end
44. phs are based on standard hydraulic motor gear ratio and cable drum with 1 25 inch diameter wire rope E PAGE 6 254 REV 981001 TYPICAL HYDRAULIC CIRCUIT HC M50 C g gg B 8 i E IDC SAA IIS i p E f 400 PSI 28 BAR PRESSURE REQUIRED FOR MODELS SUPPLIED WITH FREESPOOL OPTION REQUIRED FOR MODELS SUPPLIED WITH EXTERNAL CIRCULATION RETURN LINE BRAKE RELEASE OPTION MUST GO DIRECT TO RESERVOIR CIRCULATION SUPPLY LINE M50 5 US GPM 19 L MIN H50 7 US GPM 26 L MIN AM EXTERNAL CIRCULATION MODELS ONLY Y 7 CONTROL VALVE i T MOTOR SPOOL 4 WAY SPRING RETURN TO CENTER PRESSURE RELIEF VALVE gt FILTER 1 O 1 HYDRAULIC PUMP RESERVOIR 254 REV 981001 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 r
45. s of this unit are hydraulic gear motor multi disc brake with static and dynamic function primary planet reduction secondary planet reduction final planet reduction brake housing final drive housing cable drum 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 The final sungear is splined to the secondary planet hub and transmits the output torque and rpm of the secondary reduction stage to the final planet reduction stage The final planet hub is splined onto the cable drum 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
46. tem 420 must be removed remove circlip item 411 from planet pin item 410 and press planet pin out of primary planet hub item 400 Remove primary planet gear item 420 together with loose rollers item 423 and thrust washers item 421 Remove primary sungear item 440 from centre of connecting shaft item 600 Remove circlip item 431 and internal gear item 430 from connecting shaft spline Remove and inspect two thrust washers item 433 and thrust bearing item 435 Replace if cracked or otherwise damaged 254 REV 981001 PAGE 15 SERVICE INSTRUCTIONS conrinueo 10 Remove thrust plate item 532 11 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 12 Remove needle bearing item 603 inspect and replace if damaged 13 Remove and discard oil seal item 607 and if present backup washer item 606 from inside of connecting shaft 14 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 necessary 15 To separate secondary housing item 456 and brake housing item 700 use a standard bearing puller or insert two heel bars into slot between secondary housing and brake housing and pry brake housing out of spherical roller bearing item 533 16 Remove internal retaining ring item
47. th the disassembly as follows 1 Remove eight hex capscrews item 951 together with lockwashers item 953 from 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 Ifthrust plate comes off with end cover carefully pry it off of the bearings item 875 and discard teflon seals item 887 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 motor adaptor item 800 Thrust plate item 885 and dowel pins item 865 may stay in gear housing 6 Ifthrust 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 atthis 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 254 REV 011203 PAGE 13 SERVICE INSTRUCTIONS conrinueo seal kit for the hydraulic motor can be ordered from the f
48. 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 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 brake housing and drum has been damaged PAGE 2 254 REV 040708 EXPLANATION OF MODEL CODING H BASIC UNIT SERIES H Rapid reverse SIZE OF UNIT REDUCTION RATIO Only used for non standard reduction ratios TYPE OF BRAKE 3 Automatic brake clockwise drum rotation internal circulation flow 4 Automatic brake external brake release clockwise drum rotation internal circulation flow 5 Automatic brake external brake release counterclockwise drum rotation internal circulation flow 6 Automatic brake counterclockwise drum rotation internal circulation flow 7 Automatic brake clockwise drum rotation external circulation flow 8 Automatic brake external brake release clockwise drum rotation external circulation flow 9 Au
49. tomatic brake external brake release counterclockwise drum rotation external circulation flow 10 Automatic brake counterclockwise drum rotation external circulation flow 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 14 inch drum diameter X 23 75 inch flange diameter X 14 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 254 REV 981001 PAGE 3 OPTIONS COUNTERCLOCKWISE ROTATION The drum rotation of the standard PULLMASTER Model H50 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 H50 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
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