model m12
Contents
1. ul N e o SHIM 8 6 8 6 QJ SI HOHONV 8 8 Z 5 QJ s 3avuo 81 v L 51108 DNILNNOW 8 4 ISN gt LAN PL v e ez 26 62 0 S310H ONILNNOW v LdN vL 2 L Ls 1HOd Nuni3u 4 wy 1HOd LLI 0 09 ez A EB a 1 2 M 9 2 i 4 OQ _ _ f x S NOILYLOH 3ziunssaud EM 3716 1HOd HOLON 33S lt S1HOd HOLOW 81 8 1HOd HATHA IMYA Ted QJ NOILV LOH ANO 9 aSIMA90 19 44 LNNO9 81 8 6 LHOd Z 1HOd Ygl G3NIV LNIVIN 38 ISAN SHIM 1HOd ANO JO SdVHM S JO WAWININY AT34VS LAN 12 lHOd 1OOdS33HH 245 REV 051117 PAGE 26 INSTALLATION DIMENSIONS Dimensions in inches Dimensions in millimeters 11017 2 D amp 11017 3 D prum ryjaca nj osj xk M nJj s E ee ee a 245 REV 110110 Dimensions in inches Dimensions in millimeters HYDRAULIC MOTORS2. 5 If itis necessary to remove primary planet gears 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 6 Inspectinternal gear stopper item 412 for excessive wear Replace if less than 10 inch protrudes out the end of planet pin item 410 7 Remove sungear stopper item 444 from primary planet hub and replace if less than 19 inch thick mE Pw 245 REV 950201 PAGE 15 SERVICE INSTRUCTIONS 8 Toseparate cable drum from final housing first remove circlip item 513 Inserttwo heel bars between the flange of the cable drum and the final drive housing and gently pry cable drum out of ball bearing item 103 9 Remove circlip item 109 and press ball bearing item 103 out of final housing item 100 Check ball bearing and replace if damaged 10 Remove and discard oil seal item 105 REASSEMBLY Thoroughly clean all parts Use only new well greased O rings and oil seals Unless otherwise specified torque fasteners per BOLT TORQUE CHART at back of manual REASSEMBLY OF FINAL DRIVE Reassemble final drive end of winch as follows 1 Pressa new well greased 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 P
3. EXPLANATION MODEL CODING M12 X XX XX XX X X XXXX BASIC UNIT SERIES Jr 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 circulation flow 4 Automatic brake external brake release clockwise drum rotation internal circulation flow 5 Automatic brake external brake release counterclockwise drum rotation internal circulation flow 6 Automatic brake counterclockwise drum rotation internal circulation flow 7 Automaticbrake clockwisedrum rotation externalcirculation 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 97 WM51 hydraulic motor 2 inch gear section Other gear sections for this motor are optional DRUM SIZE 1 756einchdrumdiameterX 145 einchflangediameterX 10inchlength STANDARD For other drum sizes refer to APPENDIX A OPTIONS F Hyaraulically actuated freespooling DESIGN REVISION SPECIFICATION NUMBER Describes features not identified by preceding codes NOTE Clockwise and counterclockwise drum rotation is the direction of rotation for pulling or hoisting e
4. vll MASTER THE LOGICAL CHOICE INSTRUCTION AND PARTS MANUAL MODEL M12 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 245 120612 POVER e 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 connecti
5. Fluid cleanliness and operating viscosity are critical to winch reliability efficiency and service life For optimum performance the recommended viscosity range at operating temperature is 81 167 SUS 16 36 CS For extreme operating conditions of short duration the maximum viscosity range of 58 4635 SUS 10 1000 CS should not be exceeded For optimum performance the winch recommended hydraulic fluid temperature operating range is 80 150F 27 66 C For extreme operating conditions of short duration the maximum temperature range of 5 180F 21 82 C should not be exceeded LUBRICATION The winch gear train requires oil bath lubrication The winch is shipped from the factory without lubricating oil IMPORTANT ADD LUBRICATING OIL BEFORE RUNNING WINCH Refer to INSTALLATION 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 Fortemperatures beyond normal operating range consultlubricating oil supplier orfactory HYDRAULIC PUMP For maximum performance of the PULLMASTER planetary winch the hydraulic pump must supply the maximum flow of hydraulic fluid at the 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 fro
6. observe the flow of oil from the circulation return line of the winch approx 3 5 US gpm 13 l min 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 Oil leaks from the hydraulic motor flange and the motor adaptor are caused by damaged O ring seals Oil leaks occurring between the cable drum flanges and housings are caused by excessive pressure in the brake housing Excessive pressure will damage the oil seal which separates the brake housing from the cable drum interior If the breather relief on the end cover leaks the seal between the drum interior and the brake housing is damaged and must be replaced This condition is caused by excessive pressure in the brake housing of the winch operation with the incorrect hydraulic fluid during cold weather or a restriction in the circulation return line leading back to tank Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model M12 winch p PAGE 12 245 REV 950201 SERVICE INSTRUCTIONS GENERAL Before attempting disassembly of the PULLMASTER Model M12 planetary winch the following instructions for disassembly and reassembly should be read and understood Itis sugg
7. 1 16 27 NPT PIPE PLUG 1 8 27 NPT CAPSCREW HEX HEAD 3 8 16 NC X 1 25 GRADE 5 LOCKWASHER 3 8 GEAR HOUSING 097 DOWEL SEAL BODY PORT END COVER NEEDLE BEARING SEAL RING GEAR SET 097 THRUSTPLATE SEAL STRIP PIPE PLUG 1 4 18 NPT SUB ASSY MOTOR CAPSCREW HEX HEAD 5 8 X 5 25 COMM 391 1401 103 WASHER PLASTIC CAPLUG 1 625 12 THREADED 1 1 1 1 1 2 1 1 2 2 1 4 2 1 4 2 1 2 1 2 1 1 4 4 2 MOTOR SEAL KIT CONSISTS OF ITEMS 869 877 AND 887 NOTE 950 MOTOR SUB ASSY CONSISTS OF ITEMS 800 802 803 804 805 807 809 861 865 869 870 875 877 881 885 887 899 929 951 953 AND 955 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 24 245 REV 990710 MOTOR GROUP G1033 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 245 REV 950201 PAGE 25
8. 1 3 and other relevant product standards The cable drum of the PULLMASTER planetary winch has two cable anchor slots one for clockwise and one for counterclockwise hoisting Standard rotation for hoisting is clockwise when looking at the hydraulic motor of the unit It is critical to select the cable anchor slot which will permit winding of the wire rope on the drum in the correct direction of rotation If the wire rope is wound on the cable drum in the wrong direction of rotation the winch will have no braking capacity Each winch is shipped from the factory with a label on the drum indicating the correct cable anchor slot CABLE ANCHOR WIRE ROPE INSTALLATION Clockwise hoisting winch shown Use cable anchor slot on opposite side of drum for counterclockwise hoisting winch CABLE ANCHOR SLOT Feed the wire rope through the cable anchor slot Loop rope back into slot as shown Insert cable anchor into slot small end first and long side nearest the drum flange Pull rope tight to wedge rope in slot 511013 12 wire rope installation care must be taken that the wire rope is wrapped completely around the cable anchor and properly pulled into the cable anchor slot in the cable drum The cable drum requires 5 wraps of wire rope for safety The winch operation is contro
9. COMMERCIAL WM51 GEAR MOTORS MOTOR GEARMOTOR PORT SIZE L CODE WIDT SAE O RING 95 2 50 6 0 63 5 225 15 8 12 6 0 57 2 2 00 6 0 50 8 1 50 _ 6 0 38 1 1 5 16 12 1 00 6 0 25 4 1116 12 1 75 E 6 0 44 5 1 5 16 12 SAE CODE 61 3000 PSI FLANGE 2 00 50 8 1 1 4 1 75 44 5 1 00 25 4 PAGE 27 ASSEMBLY DRAWING G1031 A amp G1033 amp G1034 PAGE 28 245 REV 950201 APPENDIX LINE PULL LINE SPEED AT MAXIMUM AT MAXIMUM LUBRICATING CABLE DRUM SIZES WIRE ROPE STORAGE PRESSURE VOLUME INCHES FEET REQUIRED MILLIMETERS METERS POUNDS FEET MINUTE U S KILONEWTONS METERS MINUTE BARREL FLANGE 9 16 in Performance specifications are based on standard hydraulic motor with 5 8 inch diameter rope 245 990710 29 APPENDIX 340 500 DRUMCODE FINALSUNGEAR CABLE DRUM PAGE 30 245 REV 960215 APPENDIX C BRAKE CODE DESCRIPTION PARTNUMBERS 804 ORIFICE 21483 21483 21483 21483 N A N A N A PLUG 1 8 27 NPT 1 8 27 NPT PLUC 25040 E 1 8 27 25622 25622 25622 25622 ADAPTOR 1 8 NPT 3 8 NPT 3 8 18 NPT 950 SUB ASSY 21938 22014 22015 22016 22017 22018 22019 22020 245 REV 971001 PAGE 31 BOLT TORQUE CH
10. 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 direction Verify that breather relief item 130 is in place on end cover above oil level Rotate end cover if breather relief is below oil level IMPORTANT Do not replace breather relief with a pipe plug The breather relief does not prevent oil seal failure but serves as an indicator or warning that the oil seals between brake housing and the cable drum interior have failed and must be replaced immediately If these oil seals are changed additional failure of the drum seal and potential damage to the end cover is prevented 245 REV 971001 PAGE 9 OPERATING INSTRUCTIONS FAILURE TO FOLLOW OPERATING INSTRUCTIONS 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 ropes chains slings etc are not part of the winch and are not covered by this manual 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
11. into the primary planet hub item 400 Retain with circlip item 411 2 Install primary planet hub onto end of final sungear item 340 inside of cable drum item 500 3 Install internal gear item 430 over top of three primary planet gears item 420 Ensure gear teeth are fully engaged by rotating cable drum 4 Press ball bearings item 507 and item 509 into cable drum 5 Press new well greased oil seal item 515 into cable drum pu M L LLZLI L L L E ZZZZZELLLLILLLLLILII PAGE 16 245 REV 950201 SERVICE INSTRUCTIONS 6 Install primary sungear item 440 into center of three primary planet gears item 420 Ensure gear teeth are fully engaged by rotating cable drum REASSEMBLY OF BRAKE HOUSING ASSEMBLY Reassemble brake housing assembly by reversing the disassembly procedure 1 If needle bearing item 603 was removed from center of connecting shaft item 600 press back into place 2 Pressanew well greased oil seal item 607 into connecting shaft item 600 If a back up washer is included in your seal kit it should be installed together with and behind oil seal 3 Install new well greased O ring item 601 onto connecting shaft 4 Insert connecting shaft into brake housing item 700 Slightly rotate drum to allow spline of connecting shaft to fully engage with internal gear item 430 5 Install two s
12. 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
13. or accelerated wear caused by machine or ambient vibration Further Buyer acknowledges and agrees that Buyer is always solely responsible for determination and final approval of the application factor which may be used in Seller s calculations and this application factor is 1 0 unless otherwise stated in Seller s quotation specifications The remedies for this Warranty shall be only those expressly set forth above to the exclusion of any and all other remedies of whatsoever kind The limited remedies set forth above shall be deemed exclusive even though they may fail their essential purpose No agreement varying or extending the foregoing Warranty remedies exclusions or limitations shall be effective unless in writing signed by an executive officer of Seller and Buyer This Warranty is non transferable If party who had purchased articles from Buyer or from persons in privity with Buyer brings any action or proceeding against Seller for remedies other than those set forth in this Warranty Buyer agrees to defend Seller against the claims asserted in such action or proceeding at Buyer s expense including the payment of attorneys fees and costs and indemnify Seller and hold Seller harmless of from and against all such claims actions proceedings or judgments therein Buyer also agrees to defend and indemnify Seller of from and against any loss cost damage claim debt or expenses including attorneys fees resulting from any claims by
14. use and service This Warranty shall not apply to any article which has been repaired altered or disassembled or assembled by personnel other than those of Seller This Warranty shall not apply to any article upon which repairs or alterations have been made unless authorized in writing and in advance by Seller This Warranty shall not apply to any articles or parts thereof furnished by Seller to Buyer s specifications and or furnished by Buyer or acquired from others at Buyer s request SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND OTHER THAN THE WARRANTY EXPRESSLY SET FORTH ABOVE SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE Buyer expressly agrees that Seller is not responsible to perform any work or investigation related in any way to torsional vibration issues and is not responsible for the detection or remedy of Natural Frequency Vibration of the mechanical system in which the unit is installed Buyer acknowledges understands and agrees that this Warranty does not cover failures of the unit which result in any manner from the operation of the machine or unit at vibration frequencies at or near the natural frequency vibration of the machine in such a way that damage may result Buyer expressly agrees that Seller is not responsible for failure damage
15. 19 Keep hydraulic system clean and free from contamination at all times 20 Maintain winch and equipment in good operating condition Perform scheduled maintenance regularly 21 Keep hands clear when winding wire rope onto the winch drum 22 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 equipmentused 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 245 REV 051117 PAGE 1 DESCRIPTION OF THE MODEL M12 GENERAL DESCRIPTION The PULLMASTER Model M12 is a planetary hydraulic winch having equal speed in both directions The main components of this unit are hyd
16. 2 into brake piston item 750 The brake piston has 18 holes andthe two empty holes should be opposite each other 11 Use grease to temporarily hold a new O ring item 801 into recess on flange of motor adaptor 800 Install anew well greased O ring item 707 onto motor adaptor pilot 12 Positionmotoradaptor withbrakereleasepressuretransferholesofmotoradaptorandbrakehousingaligned Tighten 12capscrews item821 andlockwashers item823 onetumatatimeto evenly compress springs 13 Attach base item 550 to winch using 12 capscrews item 551 and 12 lockwashers item 553 14 Lower winch to horizontal position on base and re install breather relief valve item 130 245 REV 990710 PAGE 17 SERVICE INSTRUCTIONS 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 23121 for hydraulic motor 2 Install six new pocket seals item 887 on each thrust plate item 885 The seal kit includes a single strip of rubber Using a sharp knife cut lengths to fit the openings in thrust plates Press one of the thrust plates together with six pocket seals onto bearings item 875 installed in motor adaptor item 800 so that pocket seals are against motor adaptor 3 Installa well greased body seal item 869 on each sid
17. 9 18 27 37 46 55 50 189 E 40 151 c D 1 30 114 gt 5 a 20 76 gt 10 38 0 0 30 60 90 120 LINE SPEED fpm 150 180 Performance graphs are based on standard hydraulic motor gear ratio and cable drum with 5 8 inch diameter wire rope SSS SSS PAGE 6 245 REV 990710 TYPICAL HYDRAULIC CIRCUIT HC M12 E f CED z LAW 1 u S e p I 1 4 400 PSI 28 BAR PRESSURE REQUIRED FOR MODELS SUPPLIED 800 PSI 55 BAR dE CIRCULATION RETURN LINE SEGUE MEETS SUPPLIED WITH EXTERNAL BRAKE RELEASE OPTION CIRCULATION SUPPLY LINE M12 3 5 US GPM 13 LPM H12 4 5 US GPM 17 LPM EXTERNAL CIRCULATION MODELS ONLY s CONTROL VALVE MOTOR SPOOL 4 WAY SPRING RETURN TO CENTER PRESSURE RELIEF VALVE lt gt FILTER HYDRAULIC PUMP RESERVOIR 245 REV 990710 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
18. ALLATION INSTRUCTIONS Hydraulic pressure is not reaching the brake piston due to plugged brake release passage 245 REV 971001 PAGE 11 TROU B LE 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 pressure in the brake piston when the control valve handle is returned to neutral position For proper function of the automatic brake both pressure ports of the winch must be open to the reservoir in neutral position of the control valve Wire rope is fastened to the incorrect cable anchor slot Sprag clutch is damaged or surfaces where sprag clutch engages on motor drive shaft or brake hub are worn or indented Winch supplied with external brake release option is not plumbed per HYDRAULIC CIRCUIT Failure to vent external brake release port to reservoir may trap pressure and cause winch brake to slip Brake vibrates when lowering a load Pump is too slow Pump rpm must be maintained at normal operating speed when a load is lowered Brake is running too hot This is caused by a complete lack of or insufficient circulation flow To check the circulation
19. ART BOLT DIAMETER TORQUE TORQUE Inches lb ft Nm NOTE Unless otherwise specified torque bolts per above chart PAGE 32 245 REV 950201
20. ASTER Model M12 planetary winch Pressure lines Circulation return line Circulation supply line Equivalent to SAE 100R12 20 Equivalent to SAE 100R4 12 Equivalent to SAE 100R6 6 Only for models with external circulation Itis recommended that a larger size of hydraulic hose is installed where the pressure lines orthe 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 8 245 REV 021030 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 impor
21. Buyer or third parties to property or injury to persons resulting from faulty installation repair or modification of the article and misuse or negligent operation or use of the article whether or not such damage to property or injury to persons may be caused by defective material workmanship or construction ADVISORY Winches and hoists are not approved for lifting or handling personnel or persons unless specifically approved in writing from Seller for the specific intended application Under no circumstances shall Seller be liable i for any damage or loss to any property other than the warranted article or part thereof or ii for any special indirect incidental or consequential damage or loss even though such expenses damages or losses may be foreseeable The foregoing limitations on Seller s liability in the event of breach of warranty shall also be the absolute limit of Seller s liability in the event of Seller s negligence in manufacture installation or otherwise with regard to the articles covered by this Warranty and at the expiration of the Warranty period as above stated all such liabilities shall terminate Buyer s purchase of any article s covered by this Warranty shall constitute acceptance of the terms and conditions hereof and shall be binding upon Buyer and Buyer s representatives heirs and assigns The laws of the Province of British Columbia shall govern Buyer s rights and responsibilities in regard to this Warranty and
22. D DRUM Barrel diameter 7 63 in 194mm Flange diameter 14 63 in 371mm Barrellength 10 00in 254mm CABLE STORAGE CAPACITY Size of wire rope 1 4 in 1280 ft 390m 5 16 793 ft 242 3 8 in 569 ft 173m 7 16 in 458 ft 140m 1 2 in 307 ft 94m 9 16 in 287 ft 87m 5 8 in 222 ft 68m MAXIMUM OPERATING PRESSURE 2200 psi 152bar MAXIMUM OPERATING VOLUME 50 US gpm 189 l min MINIMUM OPERATING VOLUME 17 US gpm 64 l min DRUM TORQUE AT MAXIMUM PRESSURE 50 0001 5 649 Nm DRUM RPM AT MAXIMUM PRESSURE 48 rpm LINE PULL AT MAXIMUM PRESSURE Bare drum 12 121 Ib 53 9 kN Full drum 7 1431 31 8 LINE SPEED AT MAXIMUM VOLUME Bare drum 104 fpm 32 m min Full drum 176 fpm 54 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 2 lt gt lt lt lt 7 7 lt 5 lt 245 021030 5 PERFORMANCE GRAPHS PG M12 B LINE PULL VS OIL PRESSURE LINE PULL kN 0 8 9 17 8 26 7 35 6 44 5 53 4 2200 152 2000 138 1600 110 S ui ui 1200 83 5 D D LN 800 55 c d d 400 28 L i L i L i 0 0 2000 4000 6000 8000 10000 12000 LINE PULL Ib LINE SPEED VS OIL VOLUME LINE SPEED m min 0
23. ERIAL NO PULLMASTERWINCH CORPORATION reservesthe rightto change specifications andthe design of PULLMASTER planetary winches at any time without prior notice and without incurring any obligations 245 REV 990710 PAGE 19 PARTS REFERENCE FINAL DRIVE DESCRIPTION FINALHOUSING BALL BEARING 6020 OIL CIRCLIP ROTOR CLIP HO 600 END COVER PIPE PLUG 1 2 14 NPT SUNGEAR STOPPER O RING 279 13 ID 1 8 CS RETAINING RING INT PLANET HUB STOPPER BREATHERRELIEF ASSEMBLY PLANET HUB PLANET PIN CIRCLIP ROTOR CLIP SH 100 CIRCLIP ROTOR CLIP C 100 PLANET GEAR THRUST WASHER TORRINGTON TRA 1625 NEEDLE BEARING TORRINGTON BH1620 SUNGEAR CIRCLIP ROTOR CLIP SH 137 CABLE DRUM CABLE ANCHOR PIPE PLUG 3 8 18 NPT CIRCLIP ROTOR CLIP SH 393 BASE CAPSCREW HEX HEAD 5 8 11NC X 1 50 GRADE 5 LOCKWASHER 5 8 HI COLLAR 1 1 1 1 1 2 1 1 1 1 1 1 3 3 3 3 6 3 1 1 1 1 1 1 1 2 2 These parts vary according to drum code Refer to APPENDIX B Refer to PAGE 22 for winch seal kit and PAGE 28 for ASSEMBLY DRAWING PAGE 20 245 REV 081208 FINAL DRIVE GROUP G1031 A 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 245 REV 950201 PAGE 21 PARTS REFERENCE BRAKE GROUP DESCRIPTION BALL BEARING 6020 PLANETHUB PLANET PIN CIRCLI
24. IC SYSTEMS The operating pressure of the PULLMASTER Model M12 planetary winch is limited to 2200 psi 152 bar For hydraulic systems operating with a higher range of hydraulic pressure the winch can be supplied with a hydraulic piston motor which will provide for the same basic performance in terms of line pull and line speed capacity Contact the factory for this requirement FREESPOOLING This option permits wire rope being pulled off the cable drum by an operator Freespooling should not be confused with free fall The freespool clutch cannot be disengaged or re engaged with a load on the wire rope or while the cable drum is turning CHAIN SPROCKET DRIVE With a chain sprocket in place of the cable drum the PULLMASTER Model M12 planetary winch can be used as a hydraulic drive motor with the facility of an automatic disc brake For requirements of this type the specifications for the chain sprocket must be supplied to the factory The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements PAGE 4 245 REV 971001 SPECIFICATIONS Performance specifications are based on standard hydraulic motor gear ratio and cable drum with 5 8 inch diameter wire rope For other cable drums refer to APPENDIX A For other reductions or motors refer to supplement inside back cover Performance specifications for winches supplied with optional motors are provided in attached supplement CABLE DRUM DIMENSIONS STANDAR
25. O ring item 601 12 Remove and discard oil seal item 607 and if present backup washer item 606 13 Inspect needle bearing item 603 inside connecting shaft and replace if damaged 14 Remove primary sungear item 440 from center of primary planet hub item 400 DISASSEMBLY OF FINAL DRIVE Stand winch on cable drum flange with final end up and disassemble as follows 1 Remove retaining ring item 124 and pull end cover item 120 out of final housing item 100 2 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 3 Remove final planet hub assembly from final housing item 100 4 Inspectthree final planet gears item 320 for damage or wear If it is necessary to remove final planet gears remove circlip item 313 and press planet pin item 310 out of planet hub item 300 Inspect needle bearing item 323 and two thrust washers item 321 and replace if damaged 5 Remove final sungear item 340 from cable drum item 500 DISASSEMBLY OF PRIMARY DRIVE If primary drive requires service or repair proceed as follows 1 Turn winch over to sit flat on end of final housing item 100 N Remove and discard oil seal item 515 gt Q Usinga standard bearing puller remove ball bearings item 509 and item 507 Remove internal gear item 430 and primary planet hub assembly from cable drum item 500
26. P ROTOR CLIP C 62 INTERNAL GEAR STOPPER CIRCLIP ROTOR CLIP SH 62 PLANET GEAR THRUST WASHER TORRINGTON TRA 1018 NEEDLE BEARING TORRINGTON BH1016 INTERNAL GEAR SUNGEAR SUNGEAR STOPPER BALL BEARING 6022 OILSEAL CONNECTING SHAFT O RING 234 3 ID 1 8 CS RETAINING RING NEEDLE BEARING TORRINGTON B2012 OILSEAL THRUST WASHER TORRINGTON TRB 2031 THRUST BEARING TORRINGTON NTA 2031 BRAKE HOUSING PLASTIC CAPLUG 3 4 NPT THREADED O RING 173 8 1 2 ID 3 32 CS BRAKE SPACER DIVIDER PLATE FRICTION PLATE SUPPORT WASHER ANDERTON R 28 40 2 0 CIRCLIP ROTOR CLIP SH 125 BRAKE HUB SPRAG CLUTCH ALIGNER SPRAG CLUTCH SPRAG CLUTCH ALIGNER CIRCLIP ROTOR CLIP SH 106 MOTOR DRIVE SHAFT CIRCLIP ROTOR CLIP C 93 PISTON O RING 90 DURO 171 8 ID 3 32 CS BRAKE SPRING O RING 90 DURO 267 8 1 4 ID 1 8 CS 1 3 3 3 3 3 6 3 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 7 6 2 1 1 1 2 1 1 1 1 1 1 6 1 WINCH SEAL KIT CONSISTS OF ITEMS 105 123 515 601 607 707 751 753 AND 801 Refer to PAGE 28 for ASSEMBLY DRAWING PAGE 22 245 REV 110110 BRAKE GROUP G1034 A 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 245 REV 971001 PAGE 23 PARTS REFERENCE MOTOR GROUP DESCRIPTION MOTOR ADAPTOR O RING 012 3 8 ID 1 16 CS PIPE PLUG
27. ave to be removed to allow access to ring seals Pocket seals body seals and ring seals in the hydraulic motor assembly are not part of the winch seal kit The 245 REV 971001 PAGE 13 SERVICE INSTRUCTIONS seal kit for the hydraulic motor can be ordered from the factory under Part No 23121 All parts of the hydraulic motor with the exception of the motor adaptor item 800 are standard parts of the WM51 hydraulic motor having a2inch gear section All ofthese parts can be ordered from PULLMASTER or Authorized Distributors Dealers in Canada the United States and in most overseas areas REMOVAL OF HYDRAULIC MOTOR ASSEMBLY If disassembly of the hydraulic motor is not necessary proceed as follows 1 Remove 12 hex head capscrews item 821 with lockwashers item 823 from motor adaptor item 800 Since brake springs item 752 apply pressure againstthe inside of the motor adaptor itis recommended that the hex capscrews are unscrewed one turn 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 Removeanddiscard O ring item 801 and O ring item 707 O ring item 801 sealsthe pressuretransferhole for the automatic brake release and is situated on the flange of the brake housing DISASSEMBLY OF BRAKE HOUSING ASSEMBLY 1 Afterthe motorassembly has been removed all parts ofthe brake assembly are accessi
28. ble Remove 16 brake springs item 752 Thoroughly examine springs for damage and measure overall length Overall spring length should be 1 99 inch If any spring measures less than 1 93 inch replace all springs as a set 2 Pull motor drive shaft item 730 and complete brake hub assembly from brake housing 3 Disassemble brake hub assembly by removing circlip item 727 from motor drive shaft Remove motor drive shaftfrom brake hub item 720 Remove sprag clutch aligners items 722 and 724 support washers item 717 and two sprag clutches item 723 from brake hub MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE MOTOR DRIVE SHAFT AND BRAKE HUB WILL RESULT IN BRAKE FAILURE AND ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH THOROUGHLY INSPECT THESE AREAS AND IF NECESSARY REPLACE MOTOR DRIVE SHAFT SPRAG CLUTCH AND BRAKE HUB AS A SET 4 Thoroughly inspect motor drive shaft item 730 and brake hub item 720 particularly the surfaces where two sprag clutches item 723 engage If any indentation or surface damage is detected replace brake hub sprag clutch and motor drive shaft as a set 5 Pullbrake piston item 750 outof brake housing using two 1 2 13NC bolts screwed into two puller holes in piston and discard O rings item 751 and item 753 6 Thoroughly examine the inner bores ofthe brake housing and the outer diameters of the brake piston for scoring caused by hydraulic fluid contamination Minor
29. e of gear housing item 861 Slide gear housing together with body seals onto motor adaptor lined up on two dowel pins Tap on tight using a soft headed hammer 4 Install gear set item 881 in gear housing The longer gear with the internal spline goes into the top position 5 Pressthe other thrust plate complete with six new pocket seals onto bearings installed in port end cover so pocket seals are facing port end cover 6 Install port end cover item 870 together with two bearings item 875 and a new ring seal item 877 onto gear housing lined up on two dowel pins item 865 Tap ontightusing a softheaded 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 a hydraulic supply and torque motor capscrews according to the following procedure Ensure that circulation supply flow is being supplied to the brake housing Run the winch with no load in the hoisting direction at reduced speed approximately 3096 of maximum hydraulic volume With winch running evenly tighten four capscrews item 951 to 200 ft Ib 270 Nm Test motor operation by running winch at full speed in both directions IMPORTANT Before operating the winch add lubricating oil up to the level of the end cover oil fill port Refer to INSTALLATION INSTRUCTIONS for location of fill port Refer to APPENDIX A for oil volume required To ensure proper reassembl
30. e 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 four hex capscrews item 951 together with lockwashers item 953 from motor assembly IMPORTANT Failure to exercise care when removing the motor port end cover or gear housing could permanently damage the machined surfaces of these motor components Take care not to damage machined surfaces of motor components at disassembly 2 Remove pry loose if necessary port end cover item 870 together with bearings item 875 and ring seal item 877 Thrust plate item 885 and dowel pins item 865 may stay in gear housing 3 If the thrust plate comes off with the end cover carefully pry it off of bearings item 875 and discard pocket seals item 887 4 Remove gear set item 881 which consists of two gears which are a matched set 5 Carefully pry gear housing item 861 off of motor adaptor item 800 Thrust plate item 885 and dowel pins item 865 may stay in gear housing 6 Ifthrustplatestaysonmotoradaptor carefully pryitoffofbearings item 875 and discard pocketseals item 887 7 Discard body seals item 869 It is also advisable to replace ring seals 877 at this time Bearings item 875 h
31. ested that all expendable parts such as O rings and oil seals are not reused on reassembly Itistherefore important to have a seal kit Part No 23123 and providing the hydraulic motor has to be serviced a seal kit Part No 23121 on hand before the unit is taken apart Two new needle bearings item 875 may also be required Part No 25723 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 workingareais of prime importance similar to conditions used for service work on any otherhydraulic component All parts as they are removed from the winch assembly should be inspected for wear and damage Worn or damaged parts must be replaced Thoroughly clean parts before reassembly Do notuse solvent to clean the brake friction plates During reassembly lubricate all O rings and oil seals with grease before installation Inthe following service instructions reference to parts is made by numbers and shownonthe 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 M12 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 servic
32. f the hydraulic system has been checked and found tobe inorder 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 Excessive back pressure in the hydraulic circuit might cause the automatic brake to release momentarily Winch 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 or connecting tube The O ring seals on the brake release channel between the motor adaptor and the brake housing is damaged If this failure occurs there will be substantial leakage from between the motor adaptor and brake housing Insufficient hydraulic pressure See SPECIFICATIONS forminimum operating pressure Winch is mounted to an uneven surface See INST
33. lled 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 system To prime the winch with warm oil operate the winch at slow speed forward and reverse several times Prevent corrosion damage to winch interior If not used regularly run winch up and down at least once every two weeks To ensure proper winch installation and function raise and lower a full test load to a safe height before using winch for regular operation at the start of each shift If after a new installation the winch does not function properly refer to the TROUBLESHOOTING section of this manual PAGE 10 245 REV 051117 TROUBLE SHOOTING GENERAL In most cases when the hydraulic winch does not perform satisfactorily the cause of malfunction is found somewhere in the hydraulic circuit Before the winch is removed from its mounting and disassembled all of the hydraulic circuit components should be checked for proper function IMPORTANT The hyd
34. m 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 aseparate pressure relief valve must be installed and set atthe recommended maximum pressure HYDRAULIC RESERVOIR It is recommended that the hydraulic reservoir has sufficient capacity to provide good heat dissipation in order to prevent over heating of the hydraulic fluid The hydraulic reservoir should be made from clean and scale free material to prevent contamination of the hydraulic fluid In order to prevent air from being mixed with the hydraulic fluid the reservoir should have an over flow baffle separating the return lines from the suction line and all return lines should enter the reservoir below the fluid level The reservoir should be mounted close to and above the hydraulic pump in a location which provides for free air circulation around the reservoir HYDRAULIC HOSES The following hydraulic hoses are recommended for maximum efficiency of the PULLM
35. on therewith which are being purchased that Buyer has reviewed this Warranty and that the remedies provided hereunder are adequate and acceptable to Buyer This Warranty shall expire one 1 year from the date the article is first shipped by Seller Notice of claimed breach of this Warranty must be given by Buyer to Seller within the applicable period Such notice shall include an explanation of the claimed warranty defect and proof of date of purchase of the article or part thereof for which warranty coverage is sought No allowances shall be made by Seller for any transportation labor charges parts in and out costs adjustments or repairs or any other work unless such items are authorized in writing and in advance by Seller Nor shall Seller have any obligation to repair or replace items which by their nature are expendable 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
36. prag clutches item 723 into bore of brake hub item 720 Position sprag clutch aligners item 722 anditem 724 and support washers item 717 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 IMPORTANT For proper brake function verify that the 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 6 Installthrustbearing item617 betweentwothrustwashers item615 and placeonconnectingshaft item600 7 Install motor drive shaft assembly through thrust washer item 615 Carefully twist motor drive shaft through oil seal item 607 and engage spline with primary sungear item 440 INCORRECT ASSEMBLY OF THE FRICTION PLATE AND DIVIDER PLATE STACK WILL REDUCE BRAKING CAPACITY AND ALLOW THELOAD TO DROP CAUSING PROPERTY DAMAGE SEVERE INJURY OR DEATH REASSEMBLE INSTRUCTIONS 8 Install brake spacer item 712 into brake housing item 700 Starting and finishing with a divider plate alternately install seven divider plates item 714 and six friction plates item 715 9 Install new well greased O rings item 751 and item 753 into glands of piston item 750 Carefully install brake piston in brake housing 10 Install 16 brake springs item 75
37. raulic 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 shaftto the automatic brake assembly permits free rotation ofthe sun gear without effecting the brake The pressure requiredto rotate the drum atfull speed may vary up to 250 psi 17 bar without load 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 a number of brake springs The pressure requiredto rotate the drum atfull speed may vary from 250to 500 psi 17 to 34 bar depending upon load and without load from 500 to 800 psi 34 to 55 bar The over running clutch connecting the motor drive shaft to
38. raulic 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 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 i
39. ress cable drum item 500 into ball bearing item 103 and secure with circlip item 513 4 Reassemblefinal planet hub assembly Press needle bearing item 323 into final 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 313 5 Insertfinal planet hub assembly into final housing item 100 Ensure that planet hub spline is fully engaged with cable drum item 500 6 Verifycirclip item 343 is installed on splined end offinal sungear item 340 Insertfinal sungearthrough center of three final planet gears item 320 and into cable drum Engage gear end with the three final planet gears 7 Installanew 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 8 Gently insert end cover into final housing item 100 and fasten with retaining ring item 124 9 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 planet hub assembly Press sungear stopper item 444 into primary planet hub item 400 Press needle bearing item 423 into primary planet gear item 420 Position thrust washers item 421 on either side of planet gear and press planet pin item 410
40. stablished by looking at the hydraulic motor 245 REV 971001 PAGE 3 OPTIONS COUNTERCLOCKWISE ROTATION The drum rotation of the standard PULLMASTER Model M12 planetary winch is clockwise for hoisting when looking at the hydraulic motor of the winch Drum rotation for counterclockwise hoisting direction is available as an option EXTERNAL BRAKE RELEASE PULLMASTER planetary 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 M12 planetary winch can be supplied with optional drums to accommodate large wire rope storage capacity DRUM GROOVING Cable drums forthe PULLMASTER Model M12 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 M12 planetary winch may be changed by using a different displacement motor Contact the factory for performance information HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAUL
41. 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 PAGE 14 245 REV 990710 SERVICE INSTRUCTIONS 7 Remove six friction plates item 715 together with seven divider plates item 714 and inspect for damage 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 8 Remove brake spacer item 712 9 Remove thrust bearing item 617 and two thrust washers item 615 Allpartshavenowbeenremovedfrombrakehousingandthereisnoneedforfurtherdisassembly unlessafailurehasbeenanalyzed intheremainingwinchassembly Ifcontinuing remove pipe plug item 121 fromendcover item 120 andtipwinchtodrain lubricating oilfrominside offinal drive housing andcabledrum 10 Remove 12 capscrews item 551 12 lockwashers item 553 and base item 550 11 Slide brake housing item 700 out of cable drum ball bearings item 507 and item 509 Connecting shaft item 600 can now be removed from center of brake housing Remove and discard
42. tant 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 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 snugtightonthe three mounting pads which are in contact with the mounting surface For mounting bolt size and grade see INSTALLATION DIMENSIONS b Measurethe 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
43. the brake assembly locks causing the brake discs to rotate between divider plates Thus a completely smooth lowering speed can be achieved in a stepless operation by modulation of the winch control valve handle When the control handle is returned to neutral position rotation stops and the disc brake applies automatically During the lowering operation of the winch the friction created by the brake discs results in 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 the required flow is approximately 3 5 US gpm 13 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 order to prevent potential damage to the drum seals and the end cover of the winch when the cable drum fills up with hydraulic fluid a breather relief see PARTS REFERENCE item 130 is installed on the end cover The breather relief bleeds to atmosphere and serves as a warning signal that the oil seal between the brake housing and drum has been damaged 2 245 990710
44. 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 Definition Caution indicates a potentially 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 N hazardous situation which if not avoided will result in death or serious injury The planetary hydraulic winches are made for hoisting and lowering loads and to be operated by trained and professional personnel They are not designed for operations involving lifting or moving personnel The winches are powered by hydraulic power The ropes cables for hoisting operations are not supplied by PULLMASTER The winches are always assembled in an application they do not function as an independent machine and it is not allowed to use them as such The winches are to be used within the specifications as listed in the
45. y 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 DAMAGE SEVERE INJURY OR DEATH TO ENSURE PROPER REINSTALLATION REFER TO PROCEDURES AND TESTS DESCRIBED IN INSTALLATION AND OPERATING INSTRUCTIONS SSS PAGE 18 245 REV 971001 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 M12 planetary winch always quote the complete model and serial number of the unit MODEL NO S
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