Model M18 Service Manual
Contents
1. 8715 LHOd LYVHO YOLOW 33S 39NV AVS NOILV 1 LAN 81 8 1HOd NOILVINOYIO _ NOILW LOY 3SINDI2O TO 3 X LHOd LdIHS HOLOIN 911 1 180 9 dN Z2 8 L LAN 81 v L SLHOd 35v9 M H 4 9338 g 65 TWNOILAO u NOILdO S31OH SNILNDON t YOLOW Q33dS tL 2 L LdN 2 8 1 LHOd 3Sv3r13H OML LHOd 1HOd 1VNH31X3 4 ONIY O AVS v WAWIXVIN LL A LHOd IDINIXVIN 1dIHS HOLOW se zz 6 i eee Se QI a eee Fl B ao N B 3 Vo V J L3390d HOHONVY 3 18vO NI HO NO 1 LAN 1 2 1 1HOd HATH 9 a8 LdN 1 2 L LHOd HATH NOILV LOH L 5 NOLLdO HOLOW Q33dS 2 1HOd 0 AVS INIR 3334 H3H1V3H8 i SHINLL TIY LV GANIVLNIVW 38 LSNIW 3dOH 3HIM SdVHM S dO WAWININ V ALSFAVS 240 REV 051117 PAGE 26 INSTALLATION DIMENSIONS Dimensions in inches Dimensions in millimeters 13 500 342 90 17 250 438 15 17 250 438 15 20 500 520 70 Dimensions in inches Dimensions in millimeters HYDRAULIC MOTORS COMMERCIAL M365 GEAR MOTORS COMMERCIAL2. vll MASTER THE LOGICAL CHOICE INSTRUCTION AND PARTS MANUAL MODEL M18 PLANETARY HYDRAULIC WINCH amp POWER to Move the World TWG Canada LANTEC and Pullmaster Brands 19350 22nd Ave Surrey BC V3S 356 Voice 1 604 547 2100 Fax 1 604 547 2147 www team twg com A COMPANY READ THIS MANUAL BEFORE INSTALLING OPERATING OR SERVICING THIS PRODUCT THIS MANUAL CONTAINS IMPORTANT INFORMATION MAKE THIS MANUAL AVAILABLE TO ALL PERSONS RESPONSIBLE FOR THE OPERATION INSTALLATION SERVICING AND MAINTENANCE OF THIS PRODUCT PMC 240 120612 POVER MONA Effective 2011 10 01 A TOWER 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 connection ther
3. WM TWO SPEED GEAR MOTORS MOTOR GEAR MOTOR PORT SIZE i MOTOR GEAR MOTOR PORT SIZE L PORT PORT CODE WIDTH SAE4BOLTFLANGE CODE WIDTH SAE4BOLTFLANGE x Rd 042 2 50 8 1 2 5 143 2 50 2 50 2 9 DRAIN LOW 63 5 205 64 63 5 63 5 74 SPEED 1 25 inch 2 25 7 8 2 5 148 2 50 2 50 Code 61 2 9 HIGH DRAIN 57 2 198 64 63 5 63 5 74 SPEED 2 00 7 6 2 5 50 8 192 64 1 50 inch 1 75 Code 61 7 3 2 5 44 5 186 64 1 00 6 6 2 5 25 4 167 64 1 25 6 9 2 5 31 2 173 64 1 50 7 1 2 5 38 1 180 64 240 REV 030505 PAGE 27 ASSEMBLY DRAWING G1017 amp G1043 A amp 61045 PAGE 28 240 REV 001122 APPENDIX A LINE PULL LINE SPEED MAXIMUM AT MAXIMUM uenire CABLE DRUM SIZES WIRE ROPE STORAGE pressure VOLUME ae FEET REQUIRED MILLIMETERS METERS U S POUNDS FEET MINUTE GALLONS KILONEWTONS METERS MINUTE LITERS BARE FULL BARE FULL Performance specifications are based on standard hydraulic motor with 3 4 inch diameter rope EE 240 REV 001 122 PAGE 29 APPENDIX B DRUM CODE DESCRIPTION NUMBER ET 25139 30 240 REV 980615 APPENDIX C BRAKE CODE PART DESCRIPTION CIRCULATION 1 4 18 NPT PIPE PLUG 1 8 27 NPT PIPE PLUG 25040 1 8 27 NPT PIPE ADAPTOR 1 8 NPT CAPLUG 3 8 NPT CAPLUG
4. 391 2185 060 SEAL END CHANNEL COMM 391 2885 070 SEAL SIDE CHANNEL COMM 391 2885 069 SEAL BACKUP COMM 391 2885 071 SUB ASSY MOTOR 101 COMM M365 2 25 CAPSCREW HEXHEAD 3 4 10NC X 6 0 GRADE 5 WASHER COMM 391 3782 114 PLASTIC CAPLUG 1 625 12 PIPE PLUG 1 4 18 NPT MOTOR SEAL KIT CONSISTS OF ITEMS 869 887 891 AND 897 NOTE ITEM 950 MOTOR SUB ASSY CONSISTS OF ITEMS 800 802 805 806 807 809 813 861 865 869 870 875 881 885 887 891 897 929 951 953 955 AND 959 These part numbers and descriptions vary according to brake code Referto APPENDIX C Refer to PAGE 22 for winch seal kit and PAGE 28 for ASSEMBLY DRAWING PAGE 24 240 REV 980615 MOTOR GROUP G1017 q Y 5 ZAN FT lt Group drawings may reference more parts than are actually presentin a specific assembly Parts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored 240 REV 951201 PAGE 25 o lt o lt LLI lt 2 lt lt o 11023 J 3dOt SHIM 8 5 HOA ATEVLINS SI HOHONV 318V9 GYVGNVLS
5. G1043 A SSS d 502 121 500 d 5 A 455 VEZ 477 pes 122 ZZ 2422 2 Z C Groups 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 NEN 240 REV 980615 PAGE 21 PARTS REFERENCE BRAKE GROUP PLANET HUB RETAINING RING PRIMARY PLANET PIN CIRCLIP ROTOR CLIP C 81 CIRCLIP ROTOR CLIP SH 81 PLANET GEAR THRUST WASHER TORRINGTON TRB 1423 LOOSE ROLLER 5 32 X 1 25 TOR 151 0 INTERNAL GEAR CIRCLIP ROTOR CLIP SH 255 SPACER PRIMARY SUNGEAR PRIMARY SUNGEAR STOPPER BEARING FLANGE OILSEAL BALL BEARING 6022 CIRCLIP ROTOR CLIP HO 662 CAPSCREW HEX HEAD 3 8 16NC X 1 25 GRADE 5 O RING 168 7 1 4 ID 3 32 CS LOCKWASHER3 8 CONNECTING SHAFT O RING 239 3 5 8 ID 1 8 CS NEEDLE BEARING TORRINGTON B2812 OILSEAL BRAKE HOUSING PLASTIC CAPLUG 1 11 5 NPT THR D O RING 271 9 1 4 ID 1 8 CS BRAKE SPACER DIVIDERPLATE BRAKEPLATE CIRCLIP ROTOR CLIP SH 187 BRAKEHUB SPRAG CLUTCH ALIGNER SPRAG CLUTCH BORG WARNER 140373 SPRAG CLUTCH ALIGNER CIRCLIP ROTOR CLIP SH 196 ACCESS PLUG O RING 117 13 16 ID 3 32 CS PISTON O RI
6. 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 M18 winch p j gt 2FlsN a au usss ps s a sa 6 x s la 3uxs gt ws a s r PAGE 12 240 REV 951201 SERVICE INSTRUCTIONS GENERAL Before attempting disassembly of the PULLMASTER Model M18 planetary winch the following instructions for disassembly and reassembly should be read and understood Itis suggested that all expendable parts suchas O rings and oil seals are not reused on reassembly Itis therefore important to have a seal kit Part No 23135 and providing the hydraulic motor has to be serviced a seal kit Part No 23139 on hand before the unit is taken apart NOTE Backup washers may be included with seal kit Install with oil seals as per instructions If not present in seal kit the oil seals supplied do not require backup washers A clean working area is of prime importance similar to conditions used for service work on any other hydraulic component All parts as they are
7. does 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 disc 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 due to plugged brake release orifice in the brake housing 240 REV 951201 PAGE 11 TROU B LE SHOOTI NG 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 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 pres
8. manual under SPECIFICATIONS Other use as foreseen in the functional description of the hydraulic winch is not allowed without written permission from PULLMASTER 1 Do not install operate or service winch before reading and understanding manufacturer s instructions 2 The winch described herein is not designed for operations involving lifting or moving personnel 3 Do not lift or carry loads over people 4 Do not exceed recommended operating pressure psi and operating volume gpm 5 Do not jerk the winch Always smoothly accelerate and decelerate load 6 Do not operate a damaged noisy or malfunctioning winch 7 Do not leave a load suspended for any extended period of time 8 Never leave a suspended load unattended 9 Winch should be maintained and operated by qualified personnel 10 Inspect winch rigging mounting bolts and hoses before each shift 11 Warm up equipment before operating winch particularly at low ambient temperatures 12 Verify winch function by raising and lowering a full test load to a safe height before each shift 13 Do not weld any part of the winch 14 Verify gear lubrication and brake circulation supply and return before operating winch 15 Be sure of equipment stability before operating winch 16 Wear proper clothing to avoid entanglement in rotating machinery 17 Always stand clear of the load 18 Use only recommended hydraulic oil and gear lubricant 1
9. 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 Gee APPENDIX A for oil volume required Use recommended circuit components and hydraulic hoses The circulation return line of the winch should be plumbed in such a manner that the brake housing remains full of oil at all times Connect the return line directly to reservoir Do not connect to a common return line Before operating the winch with a load verify adequate circulation flow through the circulation return line as stated in TYPICAL HYDRAULIC CIRCUIT Verify that pressure measured at the circulation supply port does not exceed the permissible pressure stated in SPECIFICATIONS Winches equipped with the internal circulation option will supply circulation flow only when the winch is run in the lowering
10. 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 notuse solventto 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 M18 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 Ifthe 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 with the disassembly as follows 1 Remove the four hex capscrews item 951 together with the lockwashers item 953 from the motor assembly IMPORTANT Failure to exercise care when removing the motor port end cover or gear housing could permanently damage the machined surfaces of these motor components Take care not to damage machined surfaces of motor components at dis
11. third parties to property or injury to persons resulting from faulty installation repair or modification of the article and misuse or negligent operation or use of the article whether or not such damage to property or injury to persons may be caused by defective material workmanship or construction ADVISORY Winches and hoists are not approved for lifting or handling personnel or persons unless specifically approved in writing from Seller for the specific intended application Under no circumstances shall Seller be liable i for any damage or loss to any property other than the warranted article or part thereof or ii for any special indirect incidental or consequential damage or loss even though such expenses damages or losses may be foreseeable The foregoing limitations on Seller s liability in the event of breach of warranty shall also be the absolute limit of Seller s liability in the event of Seller s negligence in manufacture installation or otherwise with regard to the articles covered by this Warranty and at the expiration of the Warranty period as above stated all such liabilities shall terminate Buyer s purchase of any article s covered by this Warranty shall constitute acceptance of the terms and conditions hereof and shall be binding upon Buyer and Buyer s representatives heirs and assigns The laws of the Province of British Columbia shall govern Buyer s rights and responsibilities in regard to this Warranty and the tran
12. 3 8 18 NPT MOTOR SUB ASSY 22032 PARTNUMBERS 20849 20849 20849 20849 1 1 goca fmf alm 1 em m nm m n 806 ITEM NO 240 REV 980615 PAGE 31 BOLT TORQUE CHART BOLT DIAMETER TORQUE TORQUE Inches lb ft Nm NOTE Unless otherwise specified torque bolts per above chart PAGE 32 240 REV 951201
13. 9 Keep hydraulic system clean and free from contamination at all times 20 Maintain winch and equipment in good operating condition Perform scheduled maintenance regularly 21 Keep hands clear when winding wire rope onto the winch drum 22 not use the wire rope as a ground for welding 23 Rig the winch carefully Ensure that the wire rope is properly anchored to the correct cable anchor slot at the cable drum 24 Do not lift a load with a twisted kinked or damaged wire rope 25 Consult wire rope manufacturer for size type and maintenance of wire rope 26 Maintain five wraps of wire rope on the cable drum at all times 27 n 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 86 dBA measured on a distance of 1 00 meter 1 60 meters high The measuring equipment used was Realistic 42 3019 29 Clean up any oil spillage immediately 30 Wear proper clothing and personal protection equipment such as footwear safety goggles and a hard hat Read manual first 90000 240 REV 051117 PAGE 1 DESCRIPTION OF THE MODEL M18 GENERAL DESCRIPTION The PULLMASTER Model M18 is a planetary hydraulic winch having equal speed in both directions The main components of this unit are hydr
14. A for oil volume required LIFTING A LOAD WITH A NEWLY SERVICED WINCH WILL ENABLE AN INSTALLATION OR SERVICE PROBLEM TO GO UNDETECTED AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH TO ENSURE PROPER REINSTALLATION REFER TO PROCEDURES AND TESTS DESCRIBED IN INSTALLATION AND OPERATINGINSTRUCTIONS PAGE 18 240 REV 980615 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 partsforthe PULLMASTER Model M18 planetary winch always quote the complete model and serial number of the unit MODEL NO SERIAL NO PULLMASTERWI
15. AKE HUB WILL RESULT IN BRAKE FAILURE AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH THOROUGHLY INSPECT THESE AREAS AND IF NECESSARY REPLACE MOTOR DRIVESHAFT SPRAG CLUTCH AND BRAKE HUB AS A SET 4 Thoroughly inspect motor drive shaft item 730 and brake hub item 720 particularly the surfaces where the sprag clutch item 723 engages If any indentation or surface damage is detected replace brake hub sprag clutch and motor drive shaft as a set 5 Pull the brake piston item 750 out of the brake housing using two 5 8 11NC bolts screwed into the two puller holes in the piston and discard O rings item 751 and item 753 6 Thoroughly examine the inner bores of the brake housing and the outer diameters of the brake piston for scoring caused by hydraulic fluid contamination Minor surface damage may be repaired by polishing with a fine emery cloth DANGER 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 7 Removesix friction plates item 715 and seven divider plates item 713 andinspect 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
16. EV 980615 TYPICAL HYDRAULIC CIRCUIT HC M18 E E nh 5 9 s E O 1 400 PSI 28 BAR PRESSURE REQUIRED 800 PSI 55 BAR FOR MODELS SUPPLIED 2 US GPM 8 L MIN WITH FREESPOOL OPTION REQUIRED FOR MODELS SUPPLIED WITH EXTERNAL BRAKE RELEASE OPTION CIRCULATION SUPPLY LINE wr M18 5 US GPM 19 L MIN H18 7 US GPM 26 L MIN A EXTERNAL CIRCULATION MODELS NEY CONTROL VALVE N MOTOR SPOOL 4 WAY SPRING RETURN TO CENTER Ll PRESSURE RELIEF VALVE i LA FILTER CIRCULATION RETURN LINE MUST GO DIRECT TO RESERVOIR HYDRAULIC PUMP RESERVOIR 240 REV 030505 PAGE 7 RECOMMENDATIONS HYDRAULIC FLUID The hydraulic fluid selected for use with PULLMASTER planetary winches should be a high grade petroleum based fluid with rust oxidation and wear resistance Fluid cleanliness and operating viscosity are critical to winch reliability efficiency and service life For optimum performance the recommended viscosity range at operating temperature is 81 167 SUS 16 36 CS For extreme operating conditions of short duration the maximum viscosity r
17. IMUM VOLUME Bare drum 122 fom 37 m min Full drum 195 fom 59 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 SSS SSS 240 REV 001122 PAGE 5 PERFORMANCE GRAPHS PG M18 B LINE PULL VS OIL PRESSURE LINE PULL kN 0 13 3 26 7 40 0 53 4 66 7 80 1 2500 T TT I TT TT 1 TT T TT T 172 2000 138 5 CC 1500 103 T 2 2 2 1000 69 500 34 0 l l SA a n L LI 0 0 8000 6000 9000 12000 15000 18000 LINE PULL Ib LINE SPEED VS OIL VOLUME LINE SPEED m min 0 6 12 18 24 30 37 43 49 55 58 80 TT salts T TT T TIT TI T 303 70 265 NS gt 60 E 227 50 E J 189 E 40 E 1 152 5 4 21 30 114 4 gt gt 20 E 76 E 4 O O 10 E J 0 E J 1 LI J 1 1 4 0 60 80 100 120 140 160 180 191 LINE SPEED fpm B Performance graphs are based standard hydraulic motor gear ratio cable drum with 3 4 inch diameter wire rope PAGE 6 240 R
18. NCH CORPORATION reservesthe rightto change specifications andthe design of PULLMASTER planetary winches at any time without prior notice and without incurring any obligations 240 REV 980615 PAGE 19 PARTS REFERENCE FINAL DRIVE FINAL HOUSING 25150 BALL BEARING 6022 26359 OIL SEAL 25153 CIRCLIP ROTOR CLIP HO 662 21968 END COVER 25032 PIPE PLUG 1 2 14 NPT 19036 SUNGEAR STOPPER 25488 O RING 280 14 ID 1 8 CS 21923 RETAINING RING INT 5 32 X 1 4 X 15 5 OD 21180 PLANET HUB STOPPER 20458 BREATHER RELIEF ASSEMBLY 1 2 NPT 7 5 PSI 21925 FINAL PLANET HUB 21940 FINAL PLANET PIN 25960 CIRCLIP ROTOR CLIP SH 131 25960 CIRCLIP ROTOR CLIP SH 131 21937 PLANET GEAR 25965 THRUST WASHER TORRINGTON TRD 2233 25308 LOOSE ROLLER 7 32 DIA X 1 50 FINAL SUNGEAR 25963 CIRCLIP ROTOR CLIP SH 181 T CABLE DRUM 21960 CABLE ANCHOR 25489 CIRCLIP ROTOR CLIP SH 425 25139 CAPSCREW HEX HEAD 5 8 11NC X 1 50 GRADE 5 LOCKWASHER 5 8 BASE PLATE CAPSCREW HEX HEAD 5 8 11NC GRADE 5 TIE BAR 1 1 1 1 1 3 1 1 1 1 1 1 3 3 3 3 6 6 1 1 1 1 1 These parts and quantities vary according to drum code Referto APPENDIX B Refer to PAGE 22 for winch seal kit and PAGE 28 for ASSEMBLY DRAWING PAGE 20 240 REV 110817 FINAL DRIVE GROUP
19. NG 90 DURO 372 8 3 4 ID 3 16 CS BRAKE SPRING O RING 90 DURO 373 9 ID 3 16 CS o 1 1 1 1 1 1 1 1 1 8 1 8 1 1 1 1 1 1 1 1 7 6 1 1 1 1 1 1 1 1 1 1 0 1 WINCH KIT CONTAINS ITEMS 105 123 531 539 601 607 707 735 751 753 AND 801 These parts vary according to drum code Refer to APPENDIX B Refer to PAGE 28 for ASSEMBLY DRAWING PAGE 22 240 REV 110817 BRAKE GROUP G1045 c 413 600 535 539 541 601 712 603 607 722 421 411 734 606 715 703 700 750 720 723 724 719 752 707 753 751 713 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 240 REV 951201 PAGE 23 PARTS REFERENCE MOTOR GROUP 1 1 1 3 1 3 1 1 1 1 8 8 1 4 2 1 4 1 2 4 4 2 1 1 4 4 2 2 MOTOR DRIVE SHAFT CIRCLIP ROTOR CLIP C 112 MOTORADAPTOR O RING 013 7 16 ID 1 16 CS PIPE PLUG 1 8 27 NPT PIPE PLUG 1 4 18 NPT CAPSCREW HEX HEAD 1 2 13NC X 1 50 GRADE 5 LOCKWASHER 1 2 GEAR HOUSING 101 COMM 322 8222 100 DOWEL PIN HOLLOW COMMERCIAL 391 2082 069 SEAL GASKET COMMERCIAL 391 2884 023 PORT END COVER M365 INCLUDES 2 EACH OF ITEMS 875 955 amp 959 BUSHING COMM 391 0482 307 GEAR SET 101 COMM 322 2822 000 THRUST PLATE COMM
20. Remove final sungear item 340 from cable drum item 500 DISASSEMBLY OF PRIMARY DRIVE If primary drive requires service or repair proceed as follows 9 Turn winch over to sit flat on end of final housing item 100 Remove four hex capscrews item 555 with lockwashers item 553 from each side of both tie bars item 556 and take the tie bars from the assembly Using a 1 2 inch capscrew item 821 pull out access plug item 734 out of the brake housing item 700 and discard O ring item 735 Remove eight hex capscrews item 537 along with lockwashers item 541 from bearing flange item 530 by rotating brake housing until access hole is over top of them The brake housing together with the primary planet hub assembly can now be lifted out of the cable drum item 500 Remove internal retaining ring item 401 from inside of internal gear item 430 The primary planet hub assembly may now be slid out of the internal gear and inspected for wear or damage If the primary planet gears item 420 need to be removed take off circlip item 411 from planet pin item 410 and press the planet pin out of the primary planet hub item 400 Remove the primary planet gear item 420 together with loose rollers item 423 and thrust washers item 421 On reassembly these thrust washers must be installed Remove primary sungear item 440 from center of connecting shaft item 600 Take circlip item 431 off the end of the connecting shaft and
21. Retain with circlip item 411 2 Press new well greased oil seal item 531 into bearing flange item 530 Press ball bearing item 533 into bearing flange and secure with retaining ring item 534 3 Press bearing flange assembly onto brake housing item 700 and install new well greased O ring item 539 4 Press new well greased oil seal item 607 into bore in connecting shaft item 600 If a backup washer item 606 is included in seal kit install it behind oil seal 5 Install new well greased O ring item 601 onto connecting shaft and insert through bore of brake housing item 700 Place spacer item 434 onto shoulder of internal gear item 430 and slide internal gear onto spline of connecting shaft Fasten with circlip item 431 16 240 REV 951201 SERVICE INSTRUCTIONS continuep 6 Insert primary sungear item 440 between three primary planet gears item 420 and insert sungear shaft into connecting shaft engaging planet gears with internal gear Fasten with retaining ring item 401 7 Insert final sungear item 340 into cable drum and engage three planet gears item 320 8 Lowerbrake housing assembly onto cable drum while engaging spline of final sungear with primary planet hub item 400 Line up mounting holes of bearing flange item 530 with those in the cable drum 9 Rotate brake housing to line up access hole to fasten bearing flange to cable drum using six capscrews it
22. ange 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 Refer to APPENDIX A for quantity of oil required For normal operating temperature use SAE 90 lubricating oil For temperatures beyond normal operating range consult lubricating oil supplier or factory HYDRAULIC PUMP For maximum performance of the PULLMASTER planetary winch the hydraulic pump must supply the maximum flow of hydraulic fluid atthe hydraulic pressure stated in SPECIFICATIONS HYDRAULIC CONTROL VALVE The standard control valve used for operation of the PULLMASTER planetary winch must have a four way spring return to neutral feature which provides for open flow from the pressure ports of the winch to the reservoir in neutral position of the control motor spool It is importantto 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 bett
23. assembly 2 Remove pry loose if necessary port end cover item 870 together with two bushings item 875 Two dowel pins item 865 which are hollow for the capscrews to go through will stay in either the port end cover or in the gear housing item 861 3 Remove gear set item 881 which consists of two gears which are a matched set 4 Asthe gears are removed so is a thrust plate item 885 two end seals item 887 two side seals item 891 and a backup seal item 897 Discard end side and backup seals 5 Remove gear housing item 861 together with gasket seals item 869 and the remaining thrust plate with its end side and backup seals Discard the gasket end side and backup seals End side backup and gasket seals in the hydraulic motor assembly are not part of the winch seal kit The seal kit for the hydraulic motor can be ordered from the factory under Part No 23139 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 COMMERCIAL M365 hydraulic motor having a 2 25 inch gear section All of these parts can be ordered from COMMERCIAL INTERTECH dealers in Canada the United States and in most overseas areas If there is no COMMERCIAL INTERTECH representation all parts for the hydraulic motor can be ordered from the factory 240 REV 980615 PAGE 13 SERVICE INSTRUCTIONS REMOVAL OF HYDRAULIC MOTOR ASSEMBLY If disass
24. aulic gear motor multi disc brake with static and dynamic function primary planet reduction final planet reduction brake housing final drive housing cable drum 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 torque and rpm of the primary reduction stage are transmitted to the final reduction stage by the final sungear shaft which is splined to the primary planet hub In forward rotation or when a load is raised an over running clutch which connects the motor drive shaft to the automatic brake assembly permits free rotation of the sungear without effecting the brake When the winch rotation is stopped the load on the cable drum causes the over running clutch to lock and the maximum load is held safely by the disc brake FUNCTION IN REVERSE ROTATION LOWERING In reverse rotation hydraulic pressure from the reversing side of the hydraulic motor is channelled to the brake piston causing the brake piston to release the multi disc brake against anumber of brake springs The over running clutch connecting the motor drive shaft to the brake assembly locks causing the brake discs to rotate between divider plates Thus a completely smooth lowering speed can be achieved in stepless operation by modulation of the winch control valve handle When the control handle is returned to neutral posi
25. d service This Warranty shall not apply to any article which has been repaired altered or disassembled or assembled by personnel other than those of Seller This Warranty shall not apply to any article upon which repairs or alterations have been made unless authorized in writing and in advance by Seller This Warranty shall not apply to any articles or parts thereof furnished by Seller to Buyer s specifications and or furnished by Buyer or acquired from others at Buyer s request SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND OTHER THAN THE WARRANTY EXPRESSLY SET FORTH ABOVE SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Buyer expressly agrees that Seller is not responsible to perform any work or investigation related in any way to torsional vibration issues and is not responsible for the detection or remedy of Natural Frequency Vibration of the mechanical system in which the unit is installed Buyer acknowledges understands and agrees that this Warranty does not cover failures of the unit which result in any manner from the operation of the machine or unit at vibration frequencies at or near the natural frequency vibration of the machine in such a way that damage may result Buyer expressly agrees that Seller is not responsible for failure damage or acc
26. direction Verify that breather relief item 130 is above oil level on end cover item 120 Rotate end cover if breather relief is below oil level IMPORTANT Do not 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 240 REV 980615 PAGE 9 OPERATING INSTRUCTIONS FAILURE TO FOLLOW OPERATINGINSTRUCTIONS WILL RESULT IN PROPERTY DAMAGE SEVERE INJURY OR DEATH Afterthe PULLMASTER planetary winch has been installed in accordance with the INSTALLATION INSTRUCTIONS the wire rope can be fastened to the cable drum IMPORTANT The wire rope is not part of the winch and is not covered by this manual Refer to the wire rope manufacturer s handling inspection and maintenance recommendations to avoid potential accidents The cable drum of the PULLMASTER planetary winch has two cable anchor slots one for clockwise and one for counterclockwise hoisting Standard rotation for hoisting is clockwise when looking at the hydraulic motor of the unit It is critical to select the cable anchor slot which will permit winding of the wire rope on the drum in the correct direction of rotation If the wire rope is wound on the cable drum in the wro
27. elerated wear caused by machine or ambient vibration Further Buyer acknowledges and agrees that Buyer is always solely responsible for determination and final approval of the application factor which may be used in Seller s calculations and this application factor is 1 0 unless otherwise stated in Seller s quotation specifications The remedies for this Warranty shall be only those expressly set forth above to the exclusion of any and all other remedies of whatsoever kind The limited remedies set forth above shall be deemed exclusive even though they may fail their essential purpose No agreement varying or extending the foregoing Warranty remedies exclusions or limitations shall be effective unless in writing signed by an executive officer of Seller and Buyer This Warranty is non transferable If a party who had purchased articles from Buyer or from persons in privity with Buyer brings any action or proceeding against Seller for remedies other than those set forth in this Warranty Buyer agrees to defend Seller against the claims asserted in such action or proceeding at Buyer s expense including the payment of attorneys fees and costs and indemnify Seller and hold Seller harmless of from and against all such claims actions proceedings or judgments therein Buyer also agrees to defend and indemnify Seller of from and against any loss cost damage claim debt or expenses including attorneys fees resulting from any claims by Buyer or
28. em 537 and lockwashers item 541 10 Install new well greased O ring item 735 into access plug item 734 Install access plug into access hole inside brake housing 11 Fasten two tie bars item 556 using 16 capscrews item 555 and lockwashers item 553 REASSEMBLY OF BRAKE HOUSING ASSEMBLY Reassemble brake housing assembly as follows 1 Install sprag clutch item 723 into bore of brake hub item 720 Position sprag clutch aligners item 722 and item 724 on either side of brake hub Carefully slide motor drive shaft item 730 into brake hub assembly and secure with circlip item 727 Verify that circlips item 719 and item 731 are installed on motor drive shaft 2 Carefully slide motor drive shaft item 730 with brake hub assembly into connecting shaft until it engages spline of primary sungear item 440 IMPORTANT For proper brake function verify that sprag clutch is installed correctly When viewed from the motor end the motor drive shaft of a clockwise hoisting winch must turn freely clockwise and lock in the counterclockwise direction 3 Install brake spacer item 712 into brake housing INCORRECT ASSEMBLY OF THE FRICTION PLATE AND DIVIDER PLATE STACK WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH REASSEMBLE PER INSTRUCTIONS 4 Starting and finishing with a divider plate alternately install seven divider plates item 713 and six friction plat
29. embly of the hydraulic motor is not necessary proceed as follows 1 Remove the eight hex head capscrews item 821 with lockwashers item 823 from the motor adaptor item 800 Since the brake springs item 752 apply pressure against the inside of the motor adaptor it is recommended that the hex capscrews are unscrewed one turn at a time until the spring pressure has been released The complete motor assembly including the motor adaptor can now be removed from the brake housing assembly 2 Remove and discard three O rings item 801 and O ring item 707 O rings item 801 seal the pressure transfer hole for the automatic brake release and are situated on the flange of the brake housing DISASSEMBLY OF BRAKE HOUSING ASSEMBLY 1 Afterthe motor assembly has been removed all parts of the brake assembly are accessible Remove 10 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 the motor drive shaft item 730 and complete brake hub assembly from the brake housing 3 Disassemble brake hub assembly by removing circlip item 719 from motor drive shaft Remove motor drive shaft from brake hub item 720 Remove sprag clutch aligners items 722 and 724 and sprag clutch item 723 from brake hub MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE MOTOR DRIVE SHAFT AND BR
30. er 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 aseparate pressure relief valve must be installed andsetatthe recommended maximum pressure HYDRAULIC RESERVOIR It is recommended that the hydraulic reservoir has sufficient capacity to provide good heat dissipation in order to prevent over heating of the hydraulic fluid The hydraulic reservoir should be made from clean and scale free material to prevent contamination of the hydraulic fluid In order to prevent air from being mixed with the hydraulic fluid the reservoir should have an over flow baffle separating the return lines from the suction line and all return lines should enter the reservoir below the fluid level The reservoir should be mounted close to and above the hydraulic pump in a location which provides for free air circulation around the reservoir HYDRAULIC HOSES The following hydraulic hoses are recommended for maximum efficiency of the PULLMASTER Model M18 planetary winch Pressure lines Circulation return line Circulation supply line Equivalent to SAE 100R10 24 Equivalent to SAE 100R4 12 Equivalent to SAE 100R6 6 Only for models with external circulation It is recommended that a larger size of hydraulic hose is insta
31. es item 715 5 Liberally grease O ring item 751 and O ring item 753 and install on brake piston item 750 6 Slide brake piston into the brake housing with holes for brake springs facing out of brake housing assembly 7 Install 14 brake springs item 752 in brake piston using hole pattern shown LOCATION OF M18 BRAKE SPRINGS TEN SPRINGS SIXTEEN HOLES 511007 18 240 REV 980615 PAGE 17 SERVICE INSTRUCTIONS conmnueo 8 Liberally grease three new O rings item 801 and install into the 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 eight capscrews item 821 and lockwashers item 823 Tighten one turn at a time to evenly compress springs REASSEMBLY OF HYDRAULIC MOTOR If the hydraulic motor was disassembled the following procedure should be followed for reassembly 1 Clean all parts thoroughly before reassembly and apply grease liberally to all seals Use only new seals seal kit Part No 23139 for hydraulic motor 2 Install two new end seals item 887 and two new side seals item 891 into openings in thrust plate item 885 Install new backup seal item 897 over top of side and end seals with tabs facing towards thrust plate Place thrust plate assembly onto motor adaptor item 800
32. ewith 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 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 an
33. grooved If any damage is detected replace friction and divider plates as a set ws rrr rr r rrrrrrrrrrrrrrrr r rr cr qp PAGE 14 240 REV 980615 SERVICE INSTRUCTIONS Remove brake spacer item 712 The oil seal item 607 which seals the brake housing from the cable drum interior can now be removed and discarded Remove and discard backup washer item 606 if used in winch Replacement backup washer not required unless included in seal kit All parts have now been removed from brake housing and there is no need for further disassembly unless a failure has been analyzed in the remaining winch assembly If continuing remove pipe plug item 121 from the end cover item 120 and tip winch to drain lubricating oil from inside of the final drive housing and cable drum DISASSEMBLY OF FINAL DRIVE Remove retaining ring item 124 and pull end cover item 120 out of final housing item 100 Discard O ring item 123 and inspect planet hub stopper item 126 and sungear stopper item 122 for excessive wear Replace if less than 21 inch thick Remove final planet hub assembly from final housing item 100 Inspect three final planet gears item 320 for damage or wear If it is necessary to remove final planet gears remove circlip item 311 and press planet pin item 310 out of planet hub item 300 Inspect loose rollers item 323 and two thrust washers item 321 and replace if damaged
34. lled where the pressure lines or the circulation lines are excessively long HYDRAULIC FILTER Hydraulic filter recommendations for the hydraulic circuit ofthe PULLMASTER planetary winch based on a return line filter are given as follows 10 microns 5 microns Average Atmosphere Dusty Atmosphere In orderto 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 8 240 REV 030505 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 in order to avoid deflection when a load is lifted Set the winch on the mounting platform and check for surface contact on all mounting
35. m 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 240REV 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 ifthe winch does not produce the specified maximum rated line speed or drum rpm aloss 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
36. ng 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 WIREROPEINSTALLATION Clockwise hoisting winch shown Use cable anchor slot on opposite side of drum for counterclockwise hoisting winch Sm CABLE ANCHOR 27 Feed the wire rope through the cable anchor slot Loop rope back into slot as shown Insert cable anchor into slot and pull rope tight to wedge rope in slot 511013 18 On wire rope installation care must be taken that the wire rope is wrapped completely around the cable anchor and properly pulled into the cable anchor slotin the cable drum The cable drum requires 5 wraps of wire rope for safety The winch operation is controlled by a single control valve lever which has a forward a reverse and a neutral position Speed control in either direction is obtained by modulation of the control valve lever Maximum line speed in either direction is obtained when the control valve lever is moved as far as it can go The disc brake 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 ambienttemperature Circulate hydraulic oil through the winch control valve for several minutes to warm the hydraulic syste
37. saction 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 DANGER ER hazardous situation which if not avoided may result in minor or moderate injury FAILURE TO COMPLY WITH THE FOLLOWING SAFETY RECOMMENDATIONS AND LOCAL RULES AND REGULATIONS WILL RESULT IN PROPERTY DAMAGE SEVERE INJURY OR DEATH Definition Warning indicates a potentially hazardous situation which if not avoided could result in death or serious injury Definition Danger indicates a potentially 5 hazardous situation which if not avoided will result in death or serious injury The planetary hydraulic winches are made for hoisting and lowering loads and to be operated by trained and professional personnel They are not designed for operations involving lifting or moving personnel The winches are powered by hydraulic power The ropes cables for hoisting operations are not supplied by PULLMASTER The winches are always assembled in an application they do not function as an independent machine and it is not allowed to use them as such The winches are to be used within the specifications as listed in the
38. sed oil seal item 105 into final housing item 100 2 Press ball bearing item 103 into final housing and secure with circlip item 109 3 Press cable drum item 500 into ball bearing item 103 and secure with circlip item 513 4 Reassemble final planet hub assembly Use grease to temporarily hold 22 loose rollers item 323 in the bore of the planet gear item 320 Position thrust washers item 321 on either side of planet gear and press planet pin item 310 into the final planet hub item 300 Retain with circlip item 311 5 Insertfinal planet hub assembly into final housing item 100 Ensure that planet hub spline is fully engaged with cable drum item 500 6 Install new well greased O ring item 123 into end cover item 120 Verify that planet hub stopper item 126 and sungear stopper item 122 are installed into end cover 7 Gently insert end cover into final housing item 100 and fasten with retaining ring item 124 8 Temporarily remove breather relief valve item 130 from end cover Turn winch up on end with cable drum opening upwards REASSEMBLY OF PRIMARY DRIVE Reassemble primary drive as follows 1 Reassemble primary planethub assembly Use grease to temporarily hold 20 loose rollers item 423 inthe bore of planet gear item 420 Verify placement of sungear stopper item 444 Position thrust washers item 421 on either side of planet gear and press planet pin item 410 into final planet hub item 400
39. slide the internal gear item 430 along with spacer item 434 off of the connecting shaft spline The connecting shaft item 600 may now be pulled out of the brake housing and O ring item 601 discarded Inspect needle bearing item 603 and remove and replace if necessary To separate the bearing flange item 530 and brake housing item 700 use a standard bearing puller or insert two heel bars in the slot between the bearing flange and the brake housing and pry the brake housing out of the ball bearing item 533 Remove the internal circlip item 535 to remove ball bearing item 533 Remove and discard oil seal item 531 240 REV 951201 PAGE 15 SERVICE INSTRUCTIONS 10 To separate the final drive housing item 100 and cable drum item 500 first remove the external circlip item 513 off the end of the cable drum then insert two heel bars in the slot between the final drive housing and the cable drum and pry the cable drum out of the ball bearing item 103 11 Remove the internal circlip item 109 to remove ball bearing item 103 Remove and discard oil seal item 105 The PULLMASTER Model M18 has now been completely disassembled REASSEMBLY Thoroughly clean all parts Use only new well greased O rings and oil seals Unless otherwise specified torque fasteners per BOLT TORQUE CHART at back of manual REASSEMBLY OF FINAL DRIVE Reassemble final drive end of winch as follows 1 Press new well grea
40. sure 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 plates The over running clutch which connects the motor shaft with the brake assembly is damaged Air mixed with hydraulic oil foamy oil Oilleaks from the hydraulic motor flange and the motor adaptor are caused by damaged O ring seals Oil leaks occurring between the cable drum flanges and housings are caused by excessive pressure in the brake housing Excessive pressure will
41. 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 Ifthe winch will not produce the specified maximum line pull install a pressure gauge inthe 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 Ifthe hydraulic pump is driven by V belts check for belt slippage When checking oil pressure and volume in the hydraulic circuit verify that the hydraulic reservoir is filled to the top level and the hydraulic pump is running at maximum operating rpm Only if the hydraulic system has been checked and found tobe inorder use the following indications for probable causes of failure in the winch FAILURE CAUSE Winch will not produce line pull at maximum Winch is mounted to an uneven surface pressure as listed in SPECIFICATIONS See INSTALLATION INSTRUCTIONS Cable sheaves or block purchase operated with the winch are not turning freely Damage or wear in the hydraulic motor Excessive back pressure in the hydraulic system Relief valve may be settoo low See SPECIFICATIONS for maximum operating pressure Winch
42. tion rotation stops and the disc brake applies automatically During the lowering operation of the winch the friction created by the brake discs results in temperature This temperature is dissipated by an internal circulation flow supplied out of the hydraulic motor or from an external source for models with external circulation approximately 5 US gpm 19 l min This circulation flow must be returned directly to the reservoir with a permissible back pressure of 30 psi 2 bar IMPORTANT Under no circumstances must the back pressure in the brake housing be permitted to exceed 30 psi 2 bar Excessive pressure in the brake housing will damage the oil seal separating the brake housing from the drum interior Damage to this seal will cause the drum to fill up with hydraulic fluid In orderto prevent potential damage to the drum seals andthe end cover of the winch when the cable drum fills up with hydraulic fluid a breather relief see PARTS REFERENCE item 130 is installed on the end cover The breather relief bleeds to atmosphere and serves as a warning signal that the oil seal between the brake housing and drum has been damaged PAGE 2 240 REV 980615 EXPLANATION OF MODEL CODING M18 X XX XX XX X X XXXX BASIC UNIT SERIES M Equal speed in both directions SIZE OF UNIT REDUCTION RATIO Only used for non standard reduction ratios TYPE OF BRAKE 3 Automatic brake clockwise drum rotation internal circ
43. tion is available as an option EXTERNAL BRAKE RELEASE PULLMASTER planetary winches can be supplied with an external brake release which permits release of the automatic disc brake from an external pressure source FAILURE TO PROPERLY VENT EXTERNAL BRAKE RELEASE PORT WILL TRAP BRAKE PRESSURE AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH WINCHES SUPPLIED WITH EXTERNAL RELEASE OPTION MUST BE CONNECTED ACCORDING TO TYPICAL HYDRAULIC CIRCUIT CABLE DRUM SIZES Aside from the standard drum sizes listed in APPENDIX A the PULLMASTER Model M18 planetary winch can be supplied with optional drums to accommodate large wire rope storage capacity DRUM GROOVING Cable drums forthe PULLMASTER Model M18 planetary winch can be grooved Where this option is a requirement it is necessary to state the size of wire rope which is to be used with the winch OPTIONAL GEAR SECTION FOR THE HYDRAULIC MOTOR The performance of the standard PULLMASTER Model M18 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 M18 planetary winch is limited to 2300 psi 159 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 forthe same basic performance in terms of line p
44. ulation flow 4 Automatic brake external brake release clockwise drum rotation internal circulation flow 5 Automatic brake external brake release counterclockwise drum rotation internal circulation flow 6 Automatic brake counterclockwise drum rotation internal circulation flow 7 Automatic brake clockwise drum rotation external circulation flow 8 Automatic brake external brake release clockwise drum rotation external circulation flow 9 Automatic brake external brake release counterclockwise drum rotation external circulation flow 10 Automatic brake counterclockwise drum rotation external circulation flow HYDRAULIC MOTOR 101 COMMERCIAL M365 hydraulic motor 2 25 inch gear section Other gear sections for this motor are optional DRUM SIZE 1 81 2inch drum diameter X 15 1 2 inch flange diameter X 10 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 240 REV 980615 PAGE 3 OPTIONS COUNTERCLOCKWISE ROTATION The drum rotation of the standard PULLMASTER Model M18 planetary winch is clockwise for hoisting when looking at the hydraulic motor of the winch Drum rotation for counterclockwise hoisting direc
45. ull 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 notbe confused with free fall The freespool clutch cannot be disengaged or re engaged with a load on the wire rope or while the cable drum is turning The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements PAGE 4 240 REV 980615 SPECIFICATIONS Performance specifications are based on standard hydraulic motor gear ratio and cable drum with 3 4 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 8 50 in 216mm Flange diameter 15 50 in 394mm Barrellength 10 00 in 254mm CABLE STORAGE CAPACITY Size of wire rope 3 8 in 615 ft 187m 7 16 in 494 ft 151m 1 2 in 332 ft 101m 9 16 in 310 ft 94m 5 8 in 239 ft 73m 3 4 in 170 ft 52m 7 8 in 113 ft 34m MAXIMUM OPERATING PRESSURE 2300 psi 159bar MAXIMUM OPERATING VOLUME 76 US gpm 288 l min MINIMUM OPERATING VOLUME 20 US gpm 76 l min DRUM TORQUE AT MAXIMUM PRESSURE 83 250lb in 9 406 Nm DRUM RPM AT MAXIMUM PRESSURE 50 5 rpm LINE PULL AT MAXIMUM PRESSURE Bare drum 18 000 Ib 80 1 kN Full drum 11 288 Ib 50 2 kN LINE SPEED AT MAX
46. with backup seal against motor adaptor 3 Install gear set item 881 into bushings item 875 Gear with internal splines engages with motor drive shaft item 730 4 Install well greased gasket seal item 869 on each side of gear housing item 861 Slide gear housing together with gasket seals onto motor adaptor item 800 lined up on two dowel pins item 865 Tap on tight using a soft headed hammer 5 Install other thrust plate complete with seals on top of gear set with backup seal facing upwards 6 Install port end cover item 870 together with two bushings item 875 onto the gear housing lined up on two dowel pins item 865 Tap on tight using a soft headed hammer Install and lightly torque four hex capscrews item 951 and lockwashers item 953 to approximately 50 ft Ib 70 Nm 7 Plumb winch assembly to 8 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 four capscrews item 951 to 450 ft Ib 610 Nm Test motor operation by running winch at full speed in both directions IMPORTANT Before operating the winch add lubricating oil up to the level of the end cover oil fill port Refer to INSTALLATION INSTRUCTIONS for location of fill port Refer to APPENDIX
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