Pullmaster PL8 Instructions And Parts Manual

Planetary hydraulic winch

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PULLMASTER WINCH CORPORATION

8247-130th Street, Surrey, B.C. V3W 7X4, Canada

Telephone: 604-594-4444 Fax: 604-591-7332

Website: www.pullmaster.com

E-mail: sales@pullmaster.com

PMC 271

INSTRUCTION AND PARTS MANUAL

MODEL PL8

PLANETARY HYDRAULIC WINCH

THE LOGICAL CHOICE

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.

070228

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Page 1 INSTRUCTION AND PARTS MANUAL MODEL PL8 PLANETARY HYDRAULIC WINCH THE LOGICAL CHOICE PULLMASTER WINCH CORPORATION 8247-130th Street, Surrey, B.C. V3W 7X4, Canada Telephone: 604-594-4444 Fax: 604-591-7332 Website: www.pullmaster.com E-mail: sales@pullmaster.com READ THIS MANUAL BEFORE INSTALLING, OPERATING OR SERVICING THIS PRODUCT. THIS MANUAL CONTAINS IMPORTANT INFORMATION.
Page 2 Pullmaster Limited Warranty Effective 8/1/2008 UPERSEDES ALL PRIOR WARRANTIES 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").
Page 3: Safety Recommendations
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.
Page 4: Description Of The Model Pl8
DESCRIPTION OF THE MODEL PL8 GENERAL DESCRIPTION: The PULLMASTER Model PL8 is a planetary, hydraulic winch having equal speed in both directions. The main components of this unit are: Hydraulic gear motor Multi-disc brake with static and dynamic function Over-running clutch...
Page 5: Explanation Of Model Coding
EXPLANATION OF MODEL CODING PL 8 - XX - XX - XX - X - XXXX BASIC UNIT SERIES SIZE OF UNIT TYPE OF BRAKE Automatic brake, counterclockwise drum rotation, internal circulation flow Automatic brake, external brake release, counterclockwise drum rotation, internal circulation flow Automatic brake, external brake release, clockwise drum rotation, internal circulation flow Automatic brake, clockwise drum rotation,...
Page 6 DRUM GROOVING: Cable drums for the PULLMASTER Model PL8 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.
Page 7: Specifications
SPECIFICATIONS Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 1/2 inch diameter wire rope. For other cable drums refer to APPENDIX A. Performance specifications for winches supplied with optional motors are provided in attached supplement. CABLE DRUM DIMENSIONS (STANDARD DRUM): Barrel diameter 9.63 in...
Page 8: Performance Graphs
PERFORMANCE GRAPHS PG-PL8 LINE PULL VS. OIL PRESSURE LINE PULL - kN 10.7 16.0 21.4 26.7 32.0 2150 1720 1290 1200 2400 3600 4800 6000 7200 LINE PULL - lb LINE SPEED VS. OIL VOLUME LINE SPEED - m/min LINE SPEED - fpm Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with 1/2 inch diameter wire rope.
Page 9: Typical Hydraulic Circuit
TYPICAL HYDRAULIC CIRCUIT HC-PL8 CIRCULATION RETURN LINE (MUST GO DIRECT TO RESERVOIR) 800 PSI [55 BAR] 1/2(US)GPM [2 L/MIN] REQUIRED FOR MODELS SUPPLIED WITH EXTERNAL BRAKE RELEASE OPTION CIRCULATION SUPPLY LINE 2.5 (US) gpm [9.5 l/min] EXTERNAL CIRCULATION MODELS ONLY...
Page 10 RECOMMENDATIONS HYDRAULIC FLUID: HYDRAULIC PRESSURE RELIEF: The hydraulic fluid selected for use with PULLMASTER The hydraulic circuit for the PULLMASTER planetary planetary winches should be a high grade, petroleum winch requires a pressure relief set at the operating based fluid, with rust, oxidation and wear resistance.
Page 11: Installation Instructions
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.
Page 12 15020, prEN818-1/9, prEN 1492-1/2, prEN 1677-1/3 and other relevant product standards. 1) The cable drum of the PULLMASTER planetary winch has two cable anchor slots, one for clockwise and one for counterclockwise hoisting. Standard rotation for hoisting is counterclockwise when looking at the hydraulic motor of the unit.
Page 13: Troubleshooting
TROUBLE SHOOTING GENERAL: In most cases, when the hydraulic winch does not perform satisfactorily, the cause for malfunction is found somewhere in the hydraulic circuit. Before the winch is removed from its mounting and disassembled, all of the hydraulic circuit components should be checked for proper function. IMPORTANT: The hydraulic oil volume relates to the line speed or rpm of the winch.
Page 14 Excessive pressure in the brake housing will damage the oil seal between the brake housing and cable drum interior. Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model PL8 winch. 271 REV.950401 PAGE 12...
Page 15 For the majority of required service or repair work, disassembly is required only on the brake housing of the PULLMASTER Model PL8 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:...
Page 16 800, are standard parts of the COMMERCIAL WM31 hydraulic motor, having a 2 inch gear section. All of these parts can be ordered from PULLMASTER or COMMERCIAL INTERTECH dealers in Canada, the United States and in most overseas areas.
Page 17 SERVICE INSTRUCTIONS CONTINUED 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 REPLACE FRICTION AND DIVIDER PLATES AS A SET.
Page 18 SERVICE INSTRUCTIONS CONTINUED DISASSEMBLY OF FINAL DRIVE If final drive requires service or repair, disassemble as follows: 1) Remove final planet hub assembly from the cable drum. 2) Inspect three final planet gears, item 320, for damage or wear. If it is necessary to remove planet gears, remove circlip, item 311, and press planet pin, item 310, out of the final planet hub, item 300.
Page 19 SERVICE INSTRUCTIONS CONTINUED 6) Verify planet hub stopper, item 402, is installed on planet hub. 7) Insert primary planet hub assembly into cable drum. Ensure that the final sungear, item 340, is fully engaged with final planet gears, item 320. 8) Install primary sungear, item 440.
Page 20 SERVICE INSTRUCTIONS CONTINUED 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.
Page 21: Recommended Maintenance
5) Reassemble the winch as per instructions. 6) Follow INSTALLATION and OPERATING INSTRUCTIONS when returning winch to its mounting. When ordering parts for the PULLMASTER Model PL8 planetary winch, always quote the complete model and serial numbers of the unit.
Page 22: Parts Reference - Drum Group
PARTS REFERENCE - DRUM GROUP ITEM NO. QTY. PART NO. DESCRIPTION 22137 END HOUSING 25237 PIPE PLUG 3/4 - 14 NPT 20433 PLANET HUB FINAL 20438 PLANET PIN FINAL 25122 CIRCLIP ROTOR CLIP C-100 25411 CIRCLIP ROTOR CLIP SH-100 20437 PLANET GEAR FINAL 25098 THRUST WASHER TORRINGTON #TRA 1625...
Page 23: Drum Group
DRUM GROUP G1085-A Group drawings may reference more parts than are actually present in a specific assembly. Parts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored. PAGE 21 271 REV.950401...
Page 24: Parts Reference - Brake Group
PARTS REFERENCE - BRAKE GROUP ITEM NO. QTY. PART NO. DESCRIPTION 22136 BRAKE HOUSING 25331 PLASTIC CAPLUG 3/4 NPT THR'D 25192 O-RING -174 8-3/4" ID 3/32" CS 20714 BACKUP WASHER FOR 25278 25278 OIL SEAL 21377 BRAKE SPACER 21252 DIVIDER PLATE 25194 FRICTION PLATE 25729...
Page 25: Brake Group
BRAKE GROUP G1084-B PAGE 23 271 REV.950401...
Page 26: Installation Dimensions
INSTALLATION DIMENSIONS I1024-1-C 271 REV.051117 PAGE 24...
Page 27 INSTALLATION DIMENSIONS 1024-2 DRUM CODE 14.1 14.3 14.3 13.3 10.557 16.5 7.25 11.750 16.0 268.15 184.2 298.45 14.1 10.0 14.3 14.3 15.3 12.557 18.5 7.25 11.750 16.0 318.95 184.2 298.45 HYDRAULIC MOTORS COMMERCIAL WM31 SERIES MOTOR GEAR MOTOR PORT SIZE CODE WIDTH SAE O-RING...
Page 28: Assembly Drawing
ASSEMBLY DRAWING G1085-A & G1084-B-A 271 REV.950401 PAGE 26...
Page 29 APPENDIX A LINE PULL LINE SPEED AT MAXIMUM LUBRICATING AT MAXIMUM WIRE ROPE STORAGE CABLE DRUM SIZES PRESSURE* VOLUME* VOLUME FEET INCHES DRUM REQUIRED (MILLIMETERS) (METERS) CODE U.S. POUNDS FEET/MINUTE GALLONS (METERS/MINUTE) (KILONEWTONS) (LITERS) BARE FULL BARE FULL BARREL FLANGE LENGTH 9/16 in 1/2 in 7/16 in DRUM...
Page 30 APPENDIX B ITEM DRUM CODE CABLE DRUM COUPLING TIE BAR 20430 20436 20820 20826 20819 271 REV.960215 PAGE 28...
Page 31 APPENDIX C BRAKE CODE - 10 ITEM PART DESCRIPTION PART NUMBERS SHUTTLE 20849 20849 20849 20849 ORIFICE 21720 21720 21720 21720 PLUG 1/8-27 NPT 25040 25040 25040 25040 PIPE PLUG 1/8-27 NPT 25040 25040 25040 25040 PIPE PLUG 1/8-27 NPT PIPE 25622 25622...
Page 32: Bolt Torque Chart
BOLT TORQUE CHART TORQUE BOLT DIAMETER TORQUE lb-ft Inches 5/16 7/16 9/16 1085 1000 1356 1200 1627 1500 2034 NOTE: Unless otherwise specified, torque bolts per above chart. 271 REV.950401 PAGE 30...

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