Model PL5 Free Fall Service Manual
Contents
1. seuin eq JSNW 9JIM Jo sdeim G JO AL1I4VS 090603 24 367 gt L oc gt a lt G1283 amp G1197 8Z JOVd uo JMYYg 01 19 91 LZ dn yoe s 104 3 LON 050906 PAGE 25 367 367 PARTS REFERENCE DRUM GROUP 1 1 1 1 1 1 9 8 1 6 1 1 1 1 1 1 1 22 1 1 1 3 6 3 6 60 1 1 1 1 1 3 6 3 6 3 1 1 2 2 2 1 2 1 1 1 1 1 6 1 6 8 8 2 PIPE PLUG 1 2 14 NPT PLASTIC CAPLUG 1 2 13NC THR D PLASTIC CAPLUG 1 8 NPT PLASTIC CAPLUG 1 4 NPT FREEFALLHOUSING CLUTCHSPACER DIVIDERPLATE FRICTIONPLATE PLASTIC CAPLUG 1 2 NPT CAPSCREW SOCKET HEAD 3 8 16NC X3 5 GRADE 8 O RING 271 9 1 4 ID 1 8 CS BALLBEARING CONNECTING SHAFT CLUTCHHUB CIRCLIP ROTOR CLIP SH 250 CLUTCHPISTON O RING 90DURO 371 8 1 2 ID 3 16 CS BRAKE SPRING O RING 90DURO 374 9 1 4 ID 3 16 CS FREEFALLEND HOUSING FINALPLANET HUB FINAL PLANET PIN CIRCLIP ROTOR CLIP SH 87 FINALPLANET GEAR THRUST WASHER TORRINGTON TRA 1423 LOOSE ROLLER 5 32 X 1 25 TOR E151 Q FINALSUNGEAR CIRCLIP ANDERTON A1000 137 SUNGEAR STOPPER PRIMARY PLANET HUB PLANET HUBSTOPPER PRIMARY PLANET PIN CIRCLIP ROTOR CLIP SH 62 PRIMARY PLANET GEAR THRUST WASHER TORRINGTON TRA 1018 NEEDLE BEARING TORRINGTON B10122. YOLOW 212 S1d dN MOWLS 31V ld NOILOIHJ 8219 EE PES ES PARTS REFERENCE BRAKE GROUP SUNGEAR RAKE HOUSING LANET HUB STOPPER RING 047 4 1 2 ID 1 16 CS UP WASHER FOR OIL SEAL 25278 LSEAL RAKE SPACER IVIDER PLATE ICTION PLATE OPTIONAL METALLIC PLATES 26362 RCLIP ROTOR CLIP SE 118 RAKE HUB PRAG CLUTCH ALIGNER PRAG CLUTCH CIRCLIP ROTOR CLIP SH 106 RUST WASHER INA AS 3047 RUST BEARING INA AXK 3047 PISTON O RING 90 DURO 245 4 3 8 ID 1 8 CS BRAKE SPRING O RING 90 DURO 246 4 1 2 ID 1 8 CS ORIFICE PLUG STEEL BALL 5 82 DIA O RING 009 7 32 ID 1 16 CS SHUTTLE PIPE PLUG 1 8 27 NPT 0 0 D QOUOTOCUOUO o CHECKVALVE SAFETY VALVE GEARHOUSING These parts vary DOWELPIN Refer to BRAKE CODE CHART below SECTIONSEAL Refer to APPENDIX B PORT END COVER PLUG ORB 4 GEAR DRIVEN GEAR DRIVE THRUST BLOCK CHANNEL SEAL CHANNEL SEAL BACKUP SEAL MOTOR ADAPTOR CAPSCREW LOCKWASHER 3 8 HIGH COLLAR MOTOR CAPSCREW HEX HEAD WASHER PLASTIC CAPLUG 1 0625 12 THREADED MARGOARANMARROBAA OI TINI WINCH SEAL KIT CONTAINS ITEMS 213 231 233 505 539 707 710 711 751 753 AND 801 MOTOR SEAL CONSISTING OF ITEMS 869 887 888 AND 897 ITEM 950 MOTOR SUB ASSY CONSISTS OF ITEMS 800 802 805 807 809 832 860 865 869 871 872 881 882 885 887 888 897 951 AND 953 BRAKE C
3. REPLACEMENT OF FREE FALL ASSEMBLY 1 Carefully rest free fall assembly on its side 2 Install pipe plug item 101 into free fall end housing item 240 3 Support cable drum item 500 and insert free fall assembly until spline of connecting shaft item 220 engages final planet hub item 300 4 Use four capscrews item 555 and lockwashers item 553 to secure free fall housing item 200 to tie bars item 556 5 Install pipe plug item 503 into cable drum item 500 IMPORTANT Before operating the winch add lubricating oil through cable drum oil fill port Refer to INSTALLATION INSTRUCTIONS for location of fill port Required volume of oil is 0 3 US gallon 1 1 litre for 1 drum 0 5 US gallon 1 9 litre for 6 drum Plumb winch assembly to a hydraulic supply and torque motor capscrews according to following procedure Ensure that circulation supply flow is being supplied to the free fall and brake housing Run the winch with no load in the hoisting direction at reduced speed approximately 30 of permissible hydraulic volume With winch running evenly tighten four capscrews item 951 to 45 ft lb 61 Nm Test motor operation by running winch at full speed in both directions To ensure proper reassembly run the winch in both directions without load LIFTING A LOAD WITH A NEWLY SERVICED WINCH WILL ENABLE AN INSTALLATION OR SERVICE PROBLEM TO GO UNDETECTED AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMA
4. L I i d HYDRAULIC PUME FILTER M FREEFALL PI 9 L CIRCULATION SUPPLY 2 US GPM 8L MIN RESERVOIR FREEFALL CIRCULATION RETURN DIRECT TO RESERVOIR 1 TYPICAL HYDRAULIC CIRCUIT STANDARD CONTROL VALVE Refer to above hydraulic circuit for installations where the winch is controlled by an individual control valve Note that the valve must have a motor spool both winch ports open to tank in neutral position A brake circulation return line is not required WINCH CONTROL VALVE CONTROL VALVE STACK MOTOR SPOOL amp POWER BEYOND 2 TYPICAL HYDRAULIC CIRCUIT POWER BEYOND CONTROL VALVE Refer to above hydraulic circuit when the winch control valve is used in a circuit containing stacked valves controlling other functions as occurs on hydraulic cranes and loaders The winch control valve must have a motor spool and power beyond feature The winch valve is shown upstream of the stacked control valves If the winch control valve is located downstream of the stacked control valves the valve stack must have the power beyond feature A brake circulation return line is not required 367 PAGE 8 050906 TYPICAL HYDRAULIC CIRCUITS HC PL5 D S1 A BRAKE CIRCULATION RETURN MUST GO DIRECT TO RESERVOIR WINCH CONTROL VALVE CYLINDER SPOOL CONTROL VALVE STACK CETUR L EJ 3 TYPICAL HYDRAULIC CIRCUIT STACKED CONTROL VALVE Refer to above hydraulic circuit wh
5. Pull MASTER THE LOGICAL CHOICE INSTRUCTION AND PARTS MANUAL PL5 FREE FALL PLANETARY HYDRAULIC WINCH TWG amp 5 N POWER to Move the World TWG Canada LANTEC and Pullmaster Brands 19350 22nd Ave Surrey V3S 356 Voice 1 604 547 2100 Fax 1 604 547 2147 www team twg com A COMPANY 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 367 120612 POWER to Move the World Effective 2011 10 01 nd SUPERSEDES ALL PRIOR WARRANTIES LANTEC Pull MASTER LIMITED WARRANTY 50130 0 Seller warrants that each article whether Gear Drive Products Brake Products and or Winch Products all of which are covered hereunder sold under this order shall at the time of shipment i conform to applicable specifications and ii be free from defects in material and workmanship during normal and ordinary use and service the Warranty Buyer s exclusive remedy and Seller s sole obligation under this Warranty shall be at Seller s option to repair or replace any article or part thereof which has proven to be defective or to refund the purchase price of such article or part thereof Buyer acknowledges that Buyer is knowledgeable concerning the articles covered by this Warranty and sold in co
6. INCORRECT ASSEMBLY OF THE FRICTION PLATE AND DIVIDER PLATE STACK WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH REASSEMBLE PER INSTRUCTIONS 2 Install brake spacer item 712 into brake housing item 700 NOTE For PL5 free fall with 213 motor Refer to 3a 3 Starting and finishing with a divider plate alternately install six divider plates item 713 and five friction plates item 716 3a Starting with two divider plates item 713 two friction plates item 716 repeat two divider plates two friction plates one divider plate one friction plate ending with one divider plate item 713 4 Install new well greased O rings items 751 and 753 into piston item 750 Carefully install brake piston in brake housing item 700 5 Install ten brake springs item 752 REASSEMBLY OF HYDRAULIC MOTOR If the hydraulic motor was disassembled the following procedure should be followed for reassembly 1 Clean all parts thoroughly before reassembly and apply grease liberally to all seals Use only new seals seal kit Part No 24227 for hydraulic motor 2 Install new well greased rubber channel seal item 887 and item 888 into thrust block item 885 so that protrusions in seal match recesses in block Install new backup seal item 897 over top of channel seal leaving flat side of backup seal flush with surface of thrust block Insert thrust block item 885 into the gear housing
7. CABLE DRUM CABLE ANCHOR PIPE PLUG 3 8 18 NPT OIL SEAL BALL BEARING 6014 SET SCREW 5 16 18NC X 7 16 CIRCLIP ROTOR CLIP HO 433 COUPLING BEARING FLANGE OIL SEAL BALL BEARING 6014 CIRCLIP ROTOR CLIP HO 433 CAPSCREW HEX HEAD 5 16 18NC X 7 8 GRADE 5 O RING 164 6 1 4 ID 3 32 CS LOCKWASHER 5 16 LOCKWASHER 7 16 CAPSCREW HEX HEAD 7 16 14NC X 1 25 GRADE 5 TIEBAR These parts vary Refer to APPENDIX B PAGE 26 050906 2 A9Vd 15 JOVd L9E 19 1895 10 3OVd peasy ATEWASSV 10 Sc JDVA 01 JejeH ozs w pe1ouf pinoys 151 JONIHA4IH S1HVd 99 uo jou eje umep uo P ase yey sued Ajquiesse UI jueseijd jjenjoe Si uey sued Aew unap 9 AjUO LLG 26119 9060S0 8z JOVd 495 eq 15 JONIHAHIH WY E S YOUIM 10 62 JOVd PUB ATEWASSV 10 Sc JOVd 0119 94 S LHVd y uo jou au uo jeu sueg ouioeds B ul jueseud jjenjoe uey syed 9JOW Aew dnog 288 998
8. 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 as per BOLT TORQUE CHART at back of manual Fill the drum with lubricating oil Refer to RECOMMENDATIONS page 10 for oil volume required Refer to INSTALLATION DIMENSIONS for location of fill port Use recommended circuit components and hydraulic hoses The circulation return line of the free fall housing should be plumbed in such a manner that the free fall housing remains full of oil at all time Connect the return line directly to reservoir Do not connect to a common return line When required the winch drain line must be connected directly to the reservoir Do not connect to a common return line IMPORTANT Excessive pressure at brake housing will damage the winch motor o
9. is a planetary hydraulic winch having equal speed in both directions and the ability to lower a load FAST The main components of this unit are hydraulic gear motor multi disc brake with static and dynamic function over running clutch primary planet reduction final planet reduction brake housing cable drum free fall end housing free fall clutch assembly FUNCTION IN FORWARD ROTATION HOISTING In forward rotation the output torque and rpm of the hydraulic motor are transmitted to the sungear of the primary planet reduction The output of the primary reduction is transferred to the final sungear which is splined to the primary planet hub The final planet assembly is locked in place by the free fall clutch and does not rotate so the rotation is transmitted to the cable drum by the final drive planet gears In forward rotation or when a load is lifted an over running clutch which connects the motor drive shaft to the automatic brake assembly permits free rotation of the sungear without effecting the brake Pressure required to rotate the drum at full speed without load may vary up to 300 psi 21 bar When the winch rotation is stopped the load on the cable drum causes the over running clutch to lock and the maximum load is held safely by the disc brake FUNCTION IN REVERSE ROTATION LOWERING In reverse rotation or when the winch is pressurized for lowering a load pressure from the hydraulic motor is channelled t
10. making sure seals are facing away from gear set 3 Install well greased section seal item 869 on gear housing item 860 Install gear housing together with seal section onto motor adaptor item 900 lined up on two dowel pins Tap on tight using a soft headed hammer 4 Install gear set item 881 and item 882 in gear housing External spline end of gear goes into bore of motor adaptor 5 Insert other thrust block complete with backup and channel seals making sure seals are facing away from gear set Install a well greased seal section item 869 on gear housing 6 Install port end cover item 870 onto gear housing and lightly torque four hex capscrews item 951 and lockwashers item 953 to approximately 10 ft lb 14 Nm REPLACE HYDRAULIC MOTOR ASSEMBLY 1 Install new O ring item 707 onto motor adaptor pilot Use grease to temporarily hold two O rings item 801 into recesses on flange of motor adaptor item 900 2 Position motor assembly with brake release pressure transfer holes of motor adaptor and brake housing aligned as per drawing SI1043 on page 22 Tighten four capscrews item 931 and lockwashers item 933 one turn at a time to evenly compress springs 367 PAGE 21 050906 SERVICE INSTRUCTIONS conrinueo HOISTING 12 13 cw HOIS TING 14 11043 AI PIPE ADAPTOR AND SHUTTLE r ARE USED ON THIS SIDE FOR EXTERNAL BRAKE RELEASE
11. models with 6 drum is same as equivalent model with 1 drum 367 PAGE 30 050906 APPENDIX B ITEMNUMBERS 400 410 420 440 500 511 520 556 PART DESCRIPTION PLANET PLANET PLANET SUNGEAR CABLE SET COUPLING TIEBAR HUB PIN GEAR DRUM SCREW DRUM STANDARD REDUCTIONRATIO CODE PART NUMBERS 4 23022 20776 23023 23028 20361 23042 6 23022 20776 23023 23028 22123 25526 21745 23076 DRUM A REDUCTION RATIO CODE PART NUMBERS 1 20373 20080 20371 23078 20361 23042 6 20373 20080 20371 23078 22123 25526 21745 23076 MOTORPARTS ITEM 860 881 882 951 MOTOR GEAR GEAR GEAR CAPSCREW CODE HOUSING DRIVEN DRIVE HEXHEAD 210 26793 26791 26792 26370 211 26797 26795 26796 26794 212 26798 26799 26800 26801 213 26802 26803 26804 26399 367 PAGE 31 050906 BOLT TORQUE CHART BOLT DIAMETER TORQUE TORQUE Inches lb ft Nm NOTE Unless otherwise specified torque bolts per above chart 367 PAGE 32 050906 The Three Basic Types of PULLMASTER Planetary Winches EQUAL SPEED IN BOTH DIRECTIONS PL and M Series Seven basic models provide for line pull capacities from 1 100 Ib 4 9 kN to 50 000 Ib 222 4 kN With the available options PULLMASTER planetary winches can be adapted for a wide range of applications and for special operational requirements RAPID
12. psi generally there is no need for a brake circulation return line See TYPICAL HYDRAULIC CIRCUITS IMPORTANT Pressure in the brake housing must never exceed 100 psi 7 bar Excessive brake housing pressure will cause the safety valve located on top of the motor to leak Brake housing pressure can be gauged at the safety valve port 367 PAGE 2 050906 DESCRIPTION OF THE MODEL PL5 WITH FREE FALL ALWAYS ENSURE COMPLIANCE WITH ANY NATIONAL OR LOCAL SAFETY CODES AND REGULATIONS REGARDING THE USE OF FREE FALL WINCHES PRIOR TO OPERATION OF THIS UNIT EMERGENCY FREE FALL The emergency free fall is used for a full release of a suspended load up to the maximum load capacity of the PULLMASTER Model PL5 planetary winch with free fall Upon activating the emergency free fall function the load will drop and must be allowed to fall to its end travel without re engagement RE ENGAGING FREE FALL CLUTCH WHILE LOAD IS DROPPING CAUSES SHOCK LOADS AND WILL LEAD TO CABLE FAILURE PROPERTY DAMAGE SEVERE INJURY OR DEATH INTERLOCK HYDRAULIC CONTROL TO PREVENT RE ENGAGING FREE FALL CLUTCH WHILE LOAD IS DROPPING FUNCTION OF THE EMERGENCY FREE FALL When the PULLMASTER Model PL5 planetary winch with free fall is actuated for emergency free fall hydraulic pressure is supplied to the clutch piston compressing a series of springs to release the multi disc clutch This effectively disconnects the cable drum from the gear train of the winch to drop t
13. too hot This is caused by a complete lack of or insufficient circulation flow Control valve for the winch operation has poor metering characteristics Damaged brake plates or divider plates Over running clutch is damaged or surface where over running clutch engages on motor drive shaft is worn or indented Air has mixed with hydraulic oil resulting in foamy oil Free fall clutch cannot be disengaged Insufficient pressure or flow supplied to free fall port Check TYPICAL HYDRAULIC CIRCUITS for pressure and volume requirements O ring seals in clutch piston are damaged Insufficient load on the wire rope A minimum of 100 Ib 45 kg is required to drop a load in free fall Oil leaks from the motor adaptor are caused by a damaged O ring seal on the motor adaptor Oil leaks occurring between the cable drum flange and free fall housing is caused by excessive pressure in the free fall housing or brake housing Oil leak occurring between the cable drum flange and brake housing is caused by excessive pressure in the brake housing Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model PL5 winch with free fall 367 PAGE 15 050906 SERVICE INSTRUCTIONS GENERAL Before disassembling the PULLMASTER Model PL5 planetary winch with free fall read and understand the following instructions Replace expendable parts such as O rings and oil seals when reassembling the winch Have a winch seal kit Par
14. winch sitting flat on its mounting pads remove four capscrews item 555 and lockwashers item 553 which connect free fall housing item 200 to tie bars item 556 3 Support cable drum item 500 and withdraw free fall end housing item 240 until spline of connecting shaft item 220 is clear of cable drum 4 Remove pipe plug item 101 from free fall end housing item 240 to drain oil from free fall assembly interior 5 Stand free fall assembly on its end with connecting shaft item 220 vertical 6 Proceed to DISASSEMBLY OF FREE FALL ASSEMBLY REMOVAL OF HYDRAULIC MOTOR ASSEMBLY 1 Before removing hydraulic motor refer to page 22 drawing SI1043 and tick mark the position of the hydraulic motor to facilitate reassembly 2 Remove fourcapscrews item 931 and lockwashers item 933 from the motor adaptor item 900 Brake springs item 752 apply pressure against inside of motor adaptor therefore it is recommended that capscrews are unscrewed one turn atatime until spring pressure has been released The complete motor assembly including motor adaptor can now be removed from brake housing assembly 3 Remove and discard two O rings item 801 and item 707 O ring item 801 seals pressure transfer hole for automatic brake release and is situated on flange of brake housing DISASSEMBLY OF HYDRAULIC MOTOR ASSEMBLY If service or repair work requires access to interior of brake housing hydraulic motor should not be disasse
15. 3a Replace coupling item 520 on connecting shaft spline 4 Reassemblefinal planet hub assembly Use grease to temporarily hold 20 loose rollers item 323 in bore of planet gear item 320 Position thrust washers item 321 on either side of planet gear and press planet pin item 310 into final planet hub item 300 Retain with circlip item 311 5 Insert final planet hub assembly into cable drum Ensure that planet hub spline is fully engaged REASSEMBLY OF PRIMARY DRIVE Reassemble primary drive by reversing the disassembly procedure 1 Pressnew well greased oil seal item 531 into bearing flange item 530 Press ball bearing item 533 into bearing flange and secure with circlip item 535 Press bearing flange assembly onto brake housing hub 2 Verify planet hub stopper item 704 is installed on brake housing hub 3 Verify sungear stopper item 344 and circlip item 341 are installed on final sungear item 340 4 Install final sungear into primary planet hub item 400 5 Reassemble primary planet hub assembly Press needle bearing item 423 into planet gear item 420 Position thrust washer item 421 on either side of planet gear and press planet pin item 410 into primary planet hub item 400 Retain with circlip item 411 6 Verify planet hub stopper item 402 is installed on planet hub 7 Insert primary planet hub assembly into cable drum Ensure that final sungear item 340 is fully engaged with final plan
16. G section of this manual 367 PAGE 13 050906 TROUBLE SHOOTING GENERAL In most cases when the hydraulic winch does not perform satisfactorily the cause for malfunction is found somewhere in the hydraulic circuit Before the winch is removed from its mounting and disassembled all of the hydraulic circuit components should be checked for proper function IMPORTANT The hydraulic oil volume relates to the line speed or rpm of the winch Therefore if the winch does not produce the specified maximum rated line speed or drum rpm a loss of hydraulic flow somewhere in the hydraulic circuit can be analysed If this condition exists install a flow meter into the hydraulic circuit to check the volume of oil supplied to the pressure port of the hydraulic winch motor when the winch control is completely opened The flow meter should indicate the maximum operating volume If this test indicates a loss of hydraulic flow check the hydraulic pump the relief valve and the control valve If the pump is driven by V belts check for belt slippage The hydraulic pressure relates to the pulling capacity of the winch If the winch will not produce the specified maximum line pull install a pressure gauge in the pressure line leading to the hoisting port on the hydraulic winch motor Stall the winch to prevent rotation of the drum and then open the control valve Check the hydraulic pressure reading of the installed pressure gauge If the pressure read
17. GE SEVERE INJURY OR DEATH TO ENSURE PROPER REINSTALLATION REFER TO PROCEDURES AND TESTS DESCRIBED IN INSTALLATION AND OPERATING INSTRUCTIONS 367 PAGE 22 050906 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 Follow INSTALLATION and OPERATING INSTRUCTIONS when returning winch to its mounting When ordering parts for the PULLMASTER Model PL5 planetary winch with free fall 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 obligat
18. ODE CHART BRAKE CODE 13 14 PART DESCRIPTION PART NUMBERS SHUTTLE 20849 20849 PIPE PLUG 1 8 27 NPT N A N A PIPE ADAPTOR 1 8 27 NPT 25622 25622 CAPLUG 1 8 NPT 25374 25374 MOTOR 210 24210 24210 MOTOR 211 24211 24211 MOTOR 212 24212 24212 MOTOR 213 24213 24213 367 PAGE 29 050906 APPENDIX A PERFORMANCE DATA Model Number Hydraulic Requirement Drum Drum Bare Drum Full Drum Flow Pressure Torque RPM LinePull LineSpeed LinePull Line Speed PL5 XX 210 1D 24 US gpm 2100psi 17 578 66 450016 135fpm 33286 183fpm 91 l min 145bar 1986Nm 20 0kN 41 m min 14 8kN 56m min PL5 XX 211 1D 11 US gpm 2250psi 15 625Ib in 35 400016 72fpm 309816 92fpm 421 min 155bar 1765Nm 17 8 22m min 13 8kN 28m min PL5A XX 212 1D 11 US gpm 2400psi 19 532 Ib in 295 50006 60fpm 3698 Ib 82fpm 421 min 165bar 2207Nm 22 2kN 18m min 16 4kN 25m min PL5 XX 213 1D 11 US gpm 2250psi 7 813Ib in 69 200016 141 fpm 147916 191 fpm 421 min 155bar 883Nm 8 9kN 43 m min 6 6kN 58 m min CABLE STORAGE CABLE BARREL FLANGE LENGTH WIRE ROPE DIAMETER STORAGE DIAMETER DIAMETER 1 4 5 16 3 8 7 16 1 2 6 7 38 11 00 10 00 531 ft 333ft 2391 1681 1531 187mm 279mm 254mm 162m 101m 73m 51m 47m Performance specifications are based on 7 16 inch diameter wire rope Performance data line pull and line speed for
19. PLATES WILL REDUCE CLUTCHING 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 12 Remove nine divider plates item 204 and eight friction plates item 206 and inspect for damage or wear Plates should be flat and smooth Plates should not show heat discolouration Paper material on friction plates should be intact and grooved If any damage is detected replace friction and divider plates as a set 13 Remove clutch spacer item 202 14 Pull ball bearing item 215 out of free fall end housing Inspect and replace if damaged REASSEMBLY Thoroughly clean all parts Use only new well greased O rings and oil seals Unless otherwise specified torque fasteners per BOLT TORQUE CHART REASSEMBLY OF FREE FALL ASSEMBLY Reassemble free fall assembly by reversing the disassembly procedure 1 Press ball bearing item 215 into free fall end housing item 240 2 Install clutch hub item 226 into free fall end housing INCORRECT ASSEMBLY OF THE FRICTION PLATE AND DIVIDER PLATE STACK WILL REDUCE CLUTCHING CAPACITY AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH REASSEMBLE PER INSTRUCTIONS wo Install clutch spacer item 202 into free fall end housing Starting and finishing with a divider plate
20. REVERSE HL and HL Series For winch operations where aload has to be lowered at high speed and with complete control the PULLMASTER planetary winches in the H series offer reversing speeds approximately 4 5 times faster than forward speed Models in the series are available in line pull capacities from 8 500 Ib 37 8 kN to 50 000 Ib 222 4kN RECOVERY R Series The R Series PULLMASTER recovery winches are of the same design concept as PULLMASTER hoisting winches Free Spooling is a standard feature of this model and is offered with a manually actuated clutch or is suitable for hydraulic remote control Service for PULLMASTER planetary winches can be obtained through a worldwide network of PULLMASTER Distributors For the Distributor nearest to you contact the factory Use only authentic PULLMASTER replacement parts in the repair of a PULLMASTER planetary winch Purchased items such as bearings seals O rings etc can be supplied from the factory However a cross reference list for such parts is shown in the PARTS REFERENCE of this manual When in doubt about proper function installation or repair of a PULLMASTER planetary winch please contact your nearest PULLMASTER Distributor or the factory Pull MASTER THE LOGICAL cover Pee CHOICE
21. Remove six capscrews item 537 and lockwashers item 541 through access opening in brake housing Lift brake housing with bearing flange out of cable drum item 500 bearing flange may stay in the cable drum Remove and discard O ring item 539 Remove circlip item 719 from primary sungear item 440 5 Remove primary sungear item 440 from brake housing item 700 367 PAGE 17 050906 SERVICE INSTRUCTIONS continuep MINOR SURFACE DEFECTS WHERE THE OVER RUNNING CLUTCH ENGAGES THE MOTOR DRIVE SHAFT WILL RESULT IN BRAKE FAILURE AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH THOROUGHLY INSPECT THIS AREA AND IF NECESSARY REPLACE PRIMARY SUNGEAR SPRAG CLUTCH AND BRAKE HUB ASSEMBLY AS ASET 6 Thoroughly inspect primary sungear item 440 and brake hub item 720 particularly surfaces where sprag clutch item 723 engages 7 Manvindentation or surface damage is detected replace brake hub sprag clutch and primary sungear as a set 8 Remove two thrust washers item 737 and thrust bearing item 739 Inspect parts and replace if damaged 9 Remove and discard oil seal item 711 and backup washer item 710 10 Remove primary planet hub assembly with final sungear item 340 from cable drum 11 Inspect planet hub stopper item 402 for damage or wear and replace if less than 09 inch thick 12 Inspect three primary planet gears item 420 for damage or wear If it is necessary to remove planet gea
22. ailure damage or accelerated wear caused by machine or ambient vibration Further Buyer acknowledges and agrees that Buyer is always solely responsible for determination and final approval of the application factor which may be used in Seller s calculations and this application factor is 1 0 unless otherwise stated in Seller s quotation specifications The remedies for this Warranty shall be only those expressly set forth above to the exclusion of any and all other remedies of whatsoever kind The limited remedies set forth above shall be deemed exclusive even though they may fail their essential purpose No agreement varying or extending the foregoing Warranty remedies exclusions or limitations shall be effective unless in writing signed by an executive officer of Seller and Buyer This Warranty is non transferable If 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 fro
23. ain requires oil bath lubrication The winch is shipped from the factory without lubricating oil IMPORTANT ADDLUBRICATING OIL THROUGH THE CABLE DRUM FILL PORT BEFORE RUNNING WINCH Refer to INSTALLATION DIMENSIONS for location of lubricating oil fill port For normal operating temperature use SAE 90 lubricating oil in the cable drum 0 3 gallon 1 2 liters for 1 drum and 0 5 gallon 2 liters for 6 drum Consult lubricating oil supplier or factory for temperatures beyond normal operating range HYDRAULIC PUMP Formaximum performance of the PULLMASTER planetary winch the hydraulic pump must supply the maximum flow of hydraulic fluid at the hydraulic pressure stated in SPECIFICATIONS EMERGENCY FREE FALL CONTROL VALVE A two position three way detented valve is required to actuate emergency free fall Emergency free fall is used to fully release a load up to the maximum capacity of the winch The valve is not required to meter oil supply In neutral position the free fall clutch release port must be vented to reservoir RE ENGAGING FREE FALL CLUTCH WHILE LOAD IS DROPPING CAUSES SHOCK LOADS AND WILL LEAD TO CABLE FAILURE PROPERTY DAMAGE SEVERE INJURY OR DEATH INTERLOCK HYDRAULIC CONTROL TO PREVENT RE ENGAGING FREE FALL CLUTCH WHILE LOAD IS DROPPING HYDRAULIC CONTROL VALVE Astandard control valve used for operating PULLMASTER planetary winches must have a four way spring return to neutral feature which provides for ope
24. alternately install nine divider plates item 204 and eight friction plates item 206 4 Install new well greased O rings items 231 and 233 into clutch piston glands item 230 Carefully install clutch piston into free fall end housing Install 22 free fall springs item 232 Press new well greased oil seal item 505 into free fall housing item 200 Press ball bearing item 507 into free fall housing and secure with circlip item 513 aN Oo Push connecting shaft item 220 through free fall housing bearing Install circlip item 228 367 PAGE 19 050906 SERVICE INSTRUCTIONS conrinueo 9 Install new well greased O ring item 213 into free fall housing groove 10 Position free fall housing item 200 over free fall end housing item 240 Tighten six capscrews item 209 with lockwashers item 211 one turn at a time to evenly compress springs 11 If a specific malfunction at the free fall end has been serviced and the rest of the winch is intact proceed to REPLACEMENT OF FREE FALL ASSEMBLY If the winch has been disassembled proceed to REASSEMBLY OF FINAL DRIVE REASSEMBLY OF FINAL DRIVE Reassemble final drive by reversing the disassembly procedure 1 Press new well greased oil seal item 505 into cable drum item 500 2 Press ball bearing item 507 into cable drum and secure with circlip item 513 3 Install cable drum item 500 onto connecting shaft item 220 Winches with optional 6 drum only
25. and 753 4 Thoroughly inspect brake piston outer diameters and brake housing inner bores for scoring caused by hydraulic fluid contamination Minor surface damage may be repaired by polishing with a fine emery cloth 5 Remove circlip item 727 from primary sungear item 440 Remove brake hub item 720 sprag clutch item 723 and sprag clutch aligners item 722 from primary sungear DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH SOLVENT MAY DAMAGE THE FRICTION PLATES DO NOT USE SOLVENT TO CLEAN THE FRICTION PLATES PERFORM THOROUGH INSPECTION AND IF NECESSARY REPLACE FRICTION AND DIVIDER PLATES AS ASET 6 Remove five friction plates item 716 and six divider plates item 713 and inspect for damage or wear Plates should be flat and smooth Plates should not show heat discoloration Paper material on friction plates should be intact and grooved If any damage is detected replace friction and divider plates as a set winches may contain optional metallic friction plates 7 Remove brake spacer item 712 DISASSEMBLY OF PRIMARY DRIVE If the primary drive requires service or repair disassemble as follows 1 Remove pipe plug item 503 from cable drum item 500 to drain lubricating oil from the winch interior 2 Remove four remaining capscrews item 555 and lockwashers item 553 Remove two tie bars item 556 Stand winch upright 3
26. aulic pressure the winch can be supplied with a hydraulic piston motor which will provide for the same basic performance in terms of line pull and line speed capacity Contact the factory for this requirement The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements 367 PAGE 5 050906 SPECIFICATIONS Performance specifications are based on standard hydraulic motor gear ratio and cable drum with 7 16 inch diameter wire rope See APPENDIX A for performance of available options CABLE DRUM DIMENSIONS STANDARD DRUM Barrel Diameter 7 38 in 187 mm Flange Diameter 11 00 in 279 mm Barrel Length 6 56 in 167 mm CABLE STORAGE CAPACITY Size of wire rope 1 4 in 348 ft 106 m 5 16 in 218 ft 67m 3 8 in 157 ft 48m 7 16 in 110 ft 34m 1 2 in 100 ft 31m MAXIMUM OPERATING PRESSURE 2100 psi 145 bar MAXIMUM OPERATING VOLUME 24 US gpm 91 l min MINIMUM OPERATING VOLUME 6 US gpm 23 l min DRUM TORQUE AT MAXIMUM PRESSURE 17 578 Ib in 1986 Nm DRUM RPM AT MAXIMUM VOLUME 66 rpm LINE PULL AT MAXIMUM PRESSURE Bare drum 4500 Ib 20 0 kN Full drum 3328 Ib 14 8 kN LINE SPEED AT MAXIMUM VOLUME Bare drum 135 fpm 41 m min Full drum 183 fpm 56 m min PERMISSIBLE SVSTEM BACK PRESSURE AT MOTOR RETURN PORT 65 psi 4 5 bar PERMISSIBLE PRESSURE IN BRAKE HOUSING GAUGED AT SAFETV VALVE PORT 100 psi 7 bar PERMISSIBLE PRESSURE AT FREE FALL CIRCULATION SUPPLY PORT 10 psi 0 7 bar LUBRICATING OIL Volume required 1
27. ays stand clear of the load 18 Useonly recommended hydraulic oil and gear lubricant 19 Keep hydraulic system clean and free from contamination at all times 20 Maintain winch and equipment in good operating condition Perform scheduled maintenance regularly 21 Keephands clear when winding wire rope onto the winch drum 22 23 Rigthe winch carefully Ensure that the wire rope is properly anchored to the correct cable anchor slot at the cable drum 24 Do notlift 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 Incase 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 90 dBA measured on a distance of 1 00 meter 1 60 meters high The measuring equipment used was Realistic 442 3019 29 30 Wear proper clothing and personal protection equipment such as footwear safety goggles and a hard hat Read manual first 9600 Do not use the wire rope as a ground for welding Clean up any oil spillage immediately 367 PAGE 1 051117 DESCRIPTION OF THE MODEL PL5 WITH FREE FALL GENERAL DESCRIPTION The PULLMASTER Model PL5 with free fall
28. d to this Warranty and the transaction s subject thereto and the Province of British Columbia shall be the exclusive forum and jurisdiction for any action or proceedings brought by Buyer in connection herewith or any dispute hereunder If any of the terms and conditions contained within this Warranty are void the remaining provisions thereof are and shall remain valid and enforceable SAFETY RECOMMENDATIONS amm JO FAILURE TO COMPLY WITH THE FOLLOWING SAFETY RECOMMENDATIONS AND LOCAL RULES AND REGULATIONS WILL RESULT IN PROPERTY DAMAGE SEVERE INJURY OR DEATH Definition Caution indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Definition Warning indicates a potentially hazardous situation which if not avoided could result in death or serious injury Definition Danger indicates a potentially hazardous situation which if not avoided will result in death or serious injury PULLMASTER planetary hydraulic winches are made for hoisting and lowering loads and are to be operated by trained and professional personnel They are not designed for operations involving lifting or moving personnel The winches are powered by hydraulic power The ropes cables for hoisting operations are not supplied by PULLMASTER WINCH CORPORATION The winches are always assembled in an application they do not function as an independent machine and it is not allowed to use them as such The w
29. drum 0 3 US gal 1 1 litre Volume required 6 drum 0 5 US gal 1 9 litre Refer to RECOMMENDATIONS for viscosity and instructions 367 PAGE 6 050906 PERFORMANCE GRAPHS LINE PULL VS OIL PRESSURE Fes LINE PULL kN 0 3 3 6 7 10 0 13 3 16 7 20 0 2100 145 1800 124 8 1500 104 5 1200 83 25 900 62 8 cc ra G 600 41 za 300 21 0 0 0 750 1500 2250 3000 3750 4500 LINE PULL Ib LINE SPEED VS OIL VOLUME LINE SPEED m min 0 10 20 30 40 50 60 24 T 91 20 al 76 E l 4 S L ki 16 61 2 ort 1 m C E 4 zu O B i i gt s 9 L 2 45 o C L I L I L I L I L I 0 0 33 66 99 132 165 198 LINE SPEED fpm Performance graphs are based on standard hydraulic motor gear ratio and cable drum with 7 16 inch diameter rope 367 PAGE 7 050906 TYPICAL HYDRAULIC CIRCUITS HC PL5 D S1 A 800 PSI 55 BAR JURE uy WINCH CONTROL PRESSURE VALVE SUPPLIED WITH EXTERNAL 0 Shee PAD BOER VALVE MOTOR SPOOL BRAKE RELEASE OPTION gt 4 WAY SPRING PL RETURN TO CENTER EJ L in il xs lt
30. en the winch control valve is one of several stacked control valves and has a cylinder spool winch ports blocked in neutral position In this configuration the safety valve must be replaced with a circulation return line plumbed directly to the reservoir The brake circulation return line cannot be connected to a common return line IMPORTANT For proper function of the winch in any circuit the return line back pressure measured at the motor return port the brake housing pressure measured at the safety valve and the free fall end housing pressure measured at the circulation inlet port must not exceed pressures per SPECIFICATIONS 367 PAGE 9 050906 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 The recommended hydraulic fluid temperature operating range is 80 150F 27 66C For extreme operating conditions of short duration the maximum temperature range of 5 180F 21 82C should not be exceeded LUBRICATION The winch gear tr
31. et gears item 320 8 Press new well greased oil seal item 711 and backup washer item 710 into brake housing bore item 700 9 Install thrust bearing item 739 with thrust washer item 737 on either side against oil seal item 711 10 Insert primary sungear item 440 through brake housing bore item 700 and fasten with circlip item 719 Install new well greased O ring item 539 onto bearing flange item 530 Insert bearing flange into cable drum opening and fasten with six capscrews item 537 and lockwashers item 541 Slide brake housing item 700 into bearing flange turning primary sungear item 440 to engage primary planet gears item 420 12 Use eight capscrews item 555 and lockwashers item 553 to secure tie bars item 556 13 Install pipe plug item 503 into cable drum REASSEMBLY OF BRAKE HOUSING ASSEMBLY Reassemble brake housing assembly by reversing the disassembly procedure 1 Install sprag clutch item 723 into bore of brake hub item 720 and position sprag clutch aligners item 722 on either side of brake hub Carefully slide brake hub assembly onto primary sungear item 440 Secure with circlip item 727 367 PAGE 20 050906 SERVICE INSTRUCTIONS conrinueo IMPORTANT For proper brake function verify that brake hub rotation is correct When viewed from the motor end the primary sungear of a counterclockwise hoisting winch must turn freely clockwise and lock in the counterclockwise direction
32. ged 5 Remove and discard oil seal item 505 6 Inspect cable drum gear teeth for damage or wear DISASSEMBLY OF FREE FALL ASSEMBLY If service or repair is required on free fall assembly disassemble as follows 1 Allow free fall springs item 232 to expand safely by unscrewing capscrews item 209 one turn at a time 2 Remove free fall housing item 200 together with connecting shaft item 220 3 Remove circlip item 228 and pull connecting shaft item 220 out of free fall housing bearing item 507 4 Remove and discard O ring item 213 5 Remove circlip item 513 Push ball bearing item 507 out of free fall housing Inspect and replace if damaged 367 PAGE 18 050906 SERVICE INSTRUCTIONS continuep 6 Remove and discard oil seal item 505 7 Remove 22 free fall springs item 232 Examine springs for damage and measure overall length Overall spring length should be 1 79 inch Springs measuring less than 1 73 inch should be replaced 8 Pull free fall clutch piston item 230 from free fall end housing item 240 using two 3 8 NC threaded puller holes 9 Remove and discard O ring item 231 and 233 10 Thoroughly inspect free fall clutch piston outer diameters and free fall end housing inner bores for scoring caused by hydraulic fluid contamination Minor surface damage may be repaired by polishing with a fine emery cloth 11 Pull clutch hub item 226 out of free fall end housing DAMAGED FRICTION OR DIVIDER
33. he suspended load Minimum load 100 Ibs 45 kg is required to overcome the resistance in free fall mode IMPORTANT Pressure in the free fall end housing must never exceed 10 psi 7 bar Free fall end housing pressure can be gauged at the circulation inlet port 367 PAGE 3 050906 EXPLANATION OF MODEL CODING PL 5 X XX XX XX D XXXX BASIC UNIT SERIES SIZE OF UNIT REDUCTION RATIO Only used for non standard reduction ratios TYPE OF BRAKE 12 Automatic brake counterclockwise hoisting intravent 13 Automatic brake external brake release counterclockwise hoisting intravent 14 Automatic brake external brake release clockwise hoisting intravent 15 Automatic brake clockwise hoisting intravent HYDRAULICMOTOR 210 Gear motor 2 0 cubic inch displacement For optional motors refer to APPENDIX A DRUMSIZE 1 7 38 inch drum diameter x 11 00 inch flange diameter x 6 56 inch length STANDARD For optional drum sizes refer to APPENDIX A OPTIONS D Emergency free fall SPECIFICATIONNUMBER Describes features not identified by preceding codes NOTE Clockwise and counterclockwise drum rotation is the direction of rotation for pulling or hoisting established by looking at the hydraulic motor 367 PAGE 4 050906 OPTIONS CLOCKWISE ROTATION The drum rotation of the standard PULLMASTER Model PL5 planetary winch with free fall is counterclockwise for hoisting when looking at the hydrau
34. inches are to be used within the specifications as listed in the manual under SPECIFICATIONS Other use as foreseen in the functional description of the hydraulic winch is not allowed without written permission from PULLMASTER WINCH CORPORATION 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 Donotexceed 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 14 Verify gear lubrication and brake circulation supply and return before operating winch 15 Be sure of equipment stability before operating winch 16 Wear proper clothing to avoid entanglement in rotating machinery 17 Do not weld any part of the winch Alw
35. ings on the brake piston or connecting tube 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 due to plugged brake release passage 367 PAGE 14 050906 TROU B LE SHOOTING CONTINUED FAILURE PROBABLE CAUSE Brake 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 or clutch piston seize because of contamination in the hydraulic fluid Excessive back pressure in the return line of the hydraulic system causes the brake to release Control valve has incorrect spool which traps hydraulic pressure in the brake piston when the control valve handle is returned to neutral position For proper function of the automatic brake both pressure ports of the winch must be open to the reservoir in neutral position of the control valve Wire rope is fastened to the incorrect cable anchor slot Over running clutch is damaged or surface where over running clutch engages on motor drive shaft is worn or indented Failure to vent free fall clutch or optional external brake release may cause winch load to slip Brake vibrates when lowering a load Pump does not supply sufficient flow Pump rpm mustbe maintained at normal operating speed when a load is lowered Brake is running
36. ions 367 PAGE 23 050906 DIMENSIONS je gt a lt 11124 A Og Z L ppe Bunsiou SSIM J0JO UJIM 104 UNSIOU SSIM OOJJ49JUNOD YIM 10 SI 5141 816 Ivsel oor 9v tl ELZ ww ges vo soz vsz ul Ger Ol 0 OL 9 ls dr ost 08 1 491 SEL es 15 ul 1721 0007 9 9 Sp zs ge orz n H 22 3aoo uu r u r LNAWJOVIASIG HOLOW 315 H3H 1O 1dN 1 2 1 1HOd NHNL34 NOILVINOYIO TIv4 3383 7 LAN 81 v L LHOd AlddNS NOLLVINOUIO Tiv4 3384 1 H H3144 HO 8 sz 51108 HALAWVIG Z L Up asn S EL via es zu 22 8 1 1HOd 3SV3 13H IVHA TIVNHILXA NOLLVLOH i M 3SIMHOOTO 32191585999 JSIMMOOTOHALNAQI teg sz S31OH lov led 156 F p 67 IVA p ca 622 Let v10 NOLLV1OH JSIMHOOTO H3INNOD HOS f IZIHNSSIHA ia IMA AL3 VS 5 LAN 81 8 1HOd TE o HOLMIO 3384 5808 avs 2 J L S1HOd HOLOW
37. lic motor of the winch Drum rotation for clockwise hoisting direction is available as an option EXTERNAL BRAKE RELEASE PULLMASTER planetary winches can be supplied with an external brake release which permits release of the automatic disc brake from an external pressure source FAILURE TO PROPERLY VENT EXTERNAL BRAKE RELEASE PORT WILL TRAP BRAKE PRESSURE AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH WINCHES SUPPLIED WITH EXTERNAL BRAKE RELEASE OPTION MUST BE CONNECTED ACCORDING TO TYPICAL HYDRAULIC CIRCUITS CABLE DRUM SIZES Aside from the standard drum sizes listed in APPENDIX A the PULLMASTER Model PL5 planetary winch with free fall can be supplied with optional drums to accommodate large wire rope storage capacity DRUM GROOVING Cable drums for the PULLMASTER Model PL5 planetary winch with free fall can be grooved Where this option is a requirement it is necessary to state the size of wire rope which is to be used with the winch OPTIONAL GEAR SECTION FOR THE HYDRAULIC MOTOR The performance of the standard PULLMASTER Model PL5 planetary winch with free fall may be changed by using a different displacement motor See APPENDIX A for performance information HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS The operating pressure of the PULLMASTER Model PL5 planetary winch with free fall and standard gear motor is limited to 2100 psi 145 bar For hydraulic systems operating with higher hydr
38. lly 5 to 10 micron filters are acceptable In order to prevent accidental stoppage of the return line flow the filter should have a by pass feature HYDRAULIC HOSES The following hydraulic hose with suitable fittings is recommended forthe PULLMASTER Model PL5 planetary winch with free fall SAE 100R2 14 or better SAE 100R6 8 or better SAE 100R6 4 or better SAE 100R2 4 or better Pressure lines Circulation return line Circulation supply line Free fall release line 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 operators control panel The E stop has to be designed and placed in line with EN 60204 and EN 418 367 PAGE 10 050906 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 2 7 Make certain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted
39. m any claims by Buyer or third parties to property or injury to persons resulting from faulty installation repair or modification of the article and misuse or negligent operation or use of the article whether or not such damage to property or injury to 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 regar
40. mbled If problem has been analysed to be in hydraulic motor proceed with disassembly as follows 1 Remove four hex capscrews item 951 together with lockwashers item 953 from motor assembly 367 PAGE 16 050906 SERVICE INSTRUCTIONS continuep IMPORTANT Failure to exercise care when removing motor port end cover or gear housing could permanently damage machined surfaces of motor components Take care not to damage machined surfaces of motor components at disassembly Remove port end cover item 871 from gear housing item 860 Remove gear set item 881 and item 882 and thrust blocks item 885 Remove and discard channel seals item 887 and item 888 and backup seals item 897 Carefully pry gear housing item 860 off of motor adaptor item 900 Dowel pins item 865 may stay in gear housing 6 Discard section seals item 869 Section seals channel seals and backup seals in hydraulic motor assembly are not part of winch seal kit Seal kit for hydraulic motor can be ordered from factory under Part No 24227 DISASSEMBLY OF BRAKE HOUSING ASSEMBLY Disassemble brake housing assembly as follows 1 Remove ten brake springs item 752 Examine springs for damage and measure overall length Overall spring length should be 1 25 inch Springs measuring less than 1 19 inch should be replaced 2 Pull brake piston item 750 out of brake housing item 700 3 Remove and discard O rings item 751
41. n flow from the pressure ports of the winch to the reservoir in neutral position of the control motor spool It is important to point out that good speed control especially when lowering a load depends on the metering characteristics of the control valve The better the oil flow is metered the better will be the speed control HYDRAULIC PRESSURE RELIEF The hydraulic circuit for the PULLMASTER planetary winch requires a pressure relief set at the operating pressure see SPECIFICATIONS Usually a pressure relief is part of the hydraulic control valve Where this is not the case a separate pressure relief valve must be installed and set atthe recommended maximum pressure HYDRAULIC RESERVOIR It is recommended that the hydraulic reservoir has sufficient capacity to provide good heat dissipation in order to prevent over heating of the hydraulic fluid The hydraulic reservoir should be made from clean and scale free material to prevent contamination of the hydraulic fluid In order to prevent air from being mixed with the hydraulic fluid the reservoir should have an over flow baffle separating the return lines from the suction line and all return lines should enter the reservoir below the fluid level The reservoir should be mounted close to and above the hydraulic pump in a location which provides for free air circulation around the reservoir HYDRAULIC FILTER Consult hydraulic component manufacturer for recommendation Genera
42. nnection therewith which are being purchased that Buyer has reviewed this Warranty and that the remedies provided hereunder are adequate and acceptable to Buyer This Warranty shall expire one 1 year from the date the article is first shipped by Seller Notice of claimed breach of this Warranty must be given by Buyer to Seller within the applicable period Such notice shall include an explanation of the claimed warranty defect and proof of date of purchase of the article or part thereof for which warranty coverage is sought No allowances shall be made by Seller for any transportation labor charges parts in and out costs adjustments or repairs or any other work unless such items are authorized in writing and in advance by Seller Nor shall Seller have any obligation to repair or replace items which by their nature are expendable 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 o
43. o the brake piston causing the brake piston to release the multi disc brake against a number of brake springs The pressure required to release the brake is 300 500 psi 21 34 bar depending upon load The over running clutch connecting the motor drive shaft to the brake assembly locks causing the brake discs to rotate between divider plates which are engaged into the brake housing If the load on the cable drum tends to effect the lowering speed the resulting pressure drop in the brake piston causes friction between the brake discs and the divider plates In this way a completely smooth paying out speed can be achieved in a stepless operation by modulation of the winch control valve handle When the control valve handle is returned to neutral position pressure drops and the disc brake applies automatically A hydraulic counter balance valve or holding valve is not required for smooth and positive operation of the automatic brake During the lowering operation of the winch the friction created by the brake discs results in heat This heat is dissipated by the circulation of hydraulic fluid through the brake housing supplied internally through the hydraulic motor This circulation flow is internally drained to the return line flow through a check valve arrangement inside the hydraulic motor The circulation flow is supplied automatically by the hydraulic motor when a load is lowered If the pressure inside the brake housing is kept at or below 100
44. r oil seals Never 8 plug safety valve port Before operating the winch with a load verify that approximately 1 5 US gpm 6 I min hydraulic fluid is circulating through the brake assembly by removing the safety valve and checking flow when the winch is run in the lowering direction Verify that hydraulic fluid is circulating though the free fall clutch assembly by checking the flow at the circulation return line Bleed the air out of the free fall control circuit by loosening the connection at the free fall release port on the winch With no load on the cable drum operate the free fall control valve letting all air escape then re tighten the connection at the release port 367 PAGE 11 050906 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 Refer to manufacturer s handling inspection and maintenance recommendations to avoid potential accidents For selection of ropes etc please check following product standards DIN 15020 prEN818 1 9 prEN 1492 1 2 prEN 1677 1 3 and other relevant product standards 1 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 counterclock
45. rdinary use and service This Warranty shall not apply to any article which has been repaired altered or disassembled or assembled by personnel other than those of Seller This Warranty shall not apply to any article upon which repairs or alterations have been made unless authorized in writing and in advance by Seller This Warranty shall not apply to any articles or parts thereof furnished by Seller to Buyer s specifications and or furnished by Buyer or acquired from others at Buyer s request SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND OTHER THAN THE WARRANTY EXPRESSLY SET FORTH ABOVE SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Buyer expressly agrees that Seller is not responsible to perform any work or investigation related in any way to torsional vibration issues and is not responsible for the detection or remedy of Natural Frequency Vibration of the mechanical system in which the unit is installed Buyer acknowledges understands and agrees that this Warranty does not cover failures of the unit which result in any manner from the operation of the machine or unit at vibration frequencies at or near the natural frequency vibration of the machine in such a way that damage may result Buyer expressly agrees that Seller is not responsible for f
46. rol 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 4 Always warm up equipment prior to operating winch particularly in low ambient temperature Circulate hydraulic oil through the winch control valve for several minutes to warm the hydraulic systems To prime the winch with warm oil operate the winch at slow speed forward and reverse several times 5 Prevent corrosion damage to winch interior If not used regularly run winch up and down at least once every two weeks 6 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 shaft 367 PAGE 12 051117 OPERATING INSTRUCTIONS 7 Shift the emergency free fall control valve to pressurize the free fall clutch release port effectively disconnecting the cable drum from the gear train and dropping the load Free fall speed depends on size of the load The minimum load that will overcome the resistance in free fall mode is approximately 100 Ib 45 kg RE ENGAGING FREE FALL CLUTCH WHILE LOAD IS DROPPING CAUSES SHOCK LOADS AND WILL LEAD TO CABLE FAILURE PROPERTY DAMAGE SEVERE INJURY OR DEATH INTERLOCK HYDRAULIC CONTROL TO PREVENT RE ENGAGING FREE FALL CLUTCH WHILE LOAD IS DROPPING If after a new installation the winch does not function properly refer to the TROUBLESHOOTIN
47. rs remove circlip item 411 and press planet pin item 410 out of planet hub item 400 Inspect needle bearing item 423 and two thrust washers item 421 and replace if damaged or worn 13 Removefinalsungear item 340 with circlip item 341 and sungear stopper item 344 Inspect stopper for damage or wear If stopper is worn more than 03 inch below face of sungear stopper should be replaced 14 Inspect planet hub stopper item 704 for damage or wear and replace if less than 09 inch thick 15 Pull bearing flange item 530 and ball bearing item 533 off of brake housing 16 Remove circlip item 535 Push ball bearing item 533 out of bearing flange Inspect and replace if damaged 17 Remove and discard oil seal item 531 DISASSEMBLY OF FINAL DRIVE If final drive requires service or repair disassemble as follows 1 Remove final planet hub assembly from cable drum 2 Inspectthree final planet gears item 320 for damage or wear If itis necessary to remove planet gears remove circlip item 311 and press planet pin item 310 out of final planet hub item 300 Inspect 20 loose rollers item 323 and two thrust washers item 321 and replace if damaged Winches with optional 6 drum only 2a Remove coupling item 520 from connecting shaft spline item 220 3 Remove cable drum item 500 from connecting shaft item 220 4 Remove circlip item 513 Push ball bearing item 507 out of cable drum Inspect and replace if dama
48. s below the specified maximum operating pressure look for trouble in the hydraulic pump the relief valve and the control valve If the hydraulic pump is driven by V belts check for belt slippage When checking oil pressure and volume in the hydraulic circuit make sure that the hydraulic reservoir is filled to the top level and the hydraulic pump is running at maximum operating rpm Only after the hydraulic system has been checked and found to be in order use the following indications for probable causes of failure in the winch FAILURE PROBABLE CAUSE Winch will not produce line pull at maximum 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 The relief valve pressure may be set too low See SPECIFICATIONS for maximum operating pressure Excessive back pressure in the hydraulic system 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 system Winch will not reverse Leakage out of the brake piston prevents the disc brake from being released against the brake springs This is caused by damage to the O r
49. t No 23418 on hand before the unit is disassembled If motor is to be serviced have on a hand motor seal kit Part No 24227 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 Disconnect all hydraulic hoses remove the winch from its mounting and relocate to a clean working area similar to one used for service work on any other hydraulic component Special tools are not required to service the winch Adjustments and calibrations are not required Allparts as they are removed from the winch assembly should be inspected for wear and damage Worn or damaged parts must be replaced Thoroughly clean parts before reassembly Do not use solvent to clean the brake friction plates During reassembly lubricate all O rings and oil seals with grease before installation The following SERVICE INSTRUCTIONS refer to part descriptions and item numbers which appear in the group drawings DISASSEMBLY REMOVAL OF FREE FALL ASSEMBLY If the brake primary or final drives require service or if a general inspection overhaul is required proceed to REMOVAL OF HYDRAULIC MOTOR ASSEMBLY If specific service is required to correct a malfunction at the free fall end remove the free fall assembly as follows 1 Remove pipe plug item 101 from free fall end housing item 240 to drain lubricating oil from free fall end housing 2 With
50. wise 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 m 511013 WIRE ROPE INSTALLATION Counterclockwise hoisting winch shown Use cable anchor slot on opposite side of drum for clockwise hoisting winch Feed the wire rope through the cable anchor slot Loop rope back into slot as shown Insert cable anchor into slot small end first and long side nearest the drum flange Pull rope tight to wedge in slot x HE CABLE ANCHOR SLOT 7 CABLE ANCHOR T 2 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 minimum of 5 wraps of wire rope for safety 3 The winch operation is controlled by a single control valve lever which has a forward a reverse and a neutral position Speed control in either direction is obtained by modulation of the control valve lever Maximum line speed in either direction is obtained when the cont
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