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Pullmaster M50 Instructions And Parts Manual

Free fall planetary winch
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PMC 323
INSTRUCTION AND PARTS MANUAL
MODEL M50
FREE FALL
PLANETARY HYDRAULIC WINCH
THE LOGICAL CHOICE
PULLMASTER WINCH CORPORATION
8247-130th Street, Surrey, B.C. V3W 7X4, Canada
Telephone: 604-594-4444
Website: www.pullmaster.com
E-mail: sales@pullmaster.com
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.
Fax: 604-591-7332
070228

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  • Page 1 INSTRUCTION AND PARTS MANUAL MODEL M50 FREE FALL 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 GENERAL DESCRIPTION: The PULLMASTER Model M50 free fall is a planetary hydraulic winch having equal speed in both directions and the ability to lower a load FAST. The free fall option comes in three variations: emergency free fall, controlled free fall, or with both combined.
  • Page 5 The emergency free fall is used for a full release of a suspended load up to the maximum load capacity of the Model M50 planetary winch. Upon activating the emergency free fall function, the load will drop and it must be allowed to fall to its end travel without re-engagement.

  • Page 6: Explanation Of Model Coding

    EXPLANATION OF MODEL CODING 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 Automatic brake, clockwise drum rotation, internal circulation flow Automatic brake, external brake release, clockwise drum rotation, internal circulation flow...
  • Page 7 DRUM GROOVING: Cable drums for the PULLMASTER Model M50 free fall 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 8: Specifications

    SPECIFICATIONS Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 1.25 inch diameter wire rope. For other cable drums and reductions refer to APPENDIX A. For other motors, refer to supplement inside back cover. Performance specifications for winches supplied with optional motors are provided in attached supplement.

  • Page 9: Performance Graphs

    PERFORMANCE GRAPHS PG-M50-A MAXIMUM ALLOWABLE LINE PULL WHEN USING LINE PULL VS. OIL PRESSURE CONTROLLED FREE FALL: jjlkjalkf Bare drum 15,000 lb 66.7 kN Full drum 10,520 lb 46.8 kN LINE PULL - kN 2500 2000 1500 1000 5000 10000...

  • Page 10: Typical Hydraulic Circuit

    TYPICAL HYDRAULIC CIRCUIT EMERGENCY FREE FALL: HC-M50-X-86-XD-B FREEFALL CIRCULATION RETURN BRAKE CIRCULATION SUPPLY 0-1000 PSI 5 USGPM PRESSURE GAUGE (19 L/MIN) EXTERNAL CIRCULATION MODELS ONLY FREEFALL CIRCULATION SUPPLY 2 USGPM (8 L/MIN) FREEFALL CLUTCH RELEASE 750 PSI (52 BAR) CONTROL VALVE...
  • Page 11 TYPICAL HYDRAULIC CIRCUIT CONTROLLED FREE FALL: HC-M50-X-86-XC-B FREEFALL CIRCULATION RETURN BRAKE 0-1000 PSI CIRCULATION PRESSURE GAUGE SUPPLY 5 USGPM (19 L/MIN) EXTERNAL CONTROL VALVE CIRCULATION WITH METERING MODELS ONLY MOTORSPOOL; SPRING RETURN TO NEUTRAL; PORT B PLUGGED FREEFALL CIRCULATION SUPPLY...
  • Page 12 TYPICAL HYDRAULIC CIRCUIT HC-M50-X-86-XG-B COMBINED EMERGENCY & CONTROLLED FREE FALL: FREEFALL CIRCULATION RETURN 0-1000 PSI PRESSURE GAUGE BRAKE CIRCULATION SUPPLY 5 USGPM (19 L/MIN) EXTERNAL CIRCULATION MODELS ONLY SHUTTLE VALVE CONTROL VALVE WITH METERING MOTORSPOOL; SPRING RETURN TO NEUTRAL; FREEFALL...
  • Page 13 HYDRAULIC PRESSURE RELIEF: HYDRAULIC FLUID: The hydraulic circuit for the PULLMASTER planetary The hydraulic fluid selected for use with PULLMASTER winch requires a pressure relief set at the operating planetary winches should be a high grade, petroleum pressure (see SPECIFICATIONS). Usually, a pressure based fluid, with rust, oxidation and wear resistance.
  • Page 14 RECOMMENDATIONS CONTINUED EMERGENCY FREE FALL PRESSURE GAUGE: CONTROL VALVE: To monitor free fall release port pressure install a 1000 psi (69 bar) pressure gauge between the free fall The emergency free fall requires a two position, three- control valve and the release port. way valve.

  • Page 15: 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 16 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 clockwise when looking at the hydraulic motor of the unit.
  • Page 17 The controlled free fall is not designed nor intended to lower the maximum load in a controlled free fall. The permissible load of the PULLMASTER Model M50 controlled free fall operation is 30% of the maximum line pull capacity of the winch.

  • Page 18: Troubleshooting

    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.
  • Page 19 Insufficient load on the wire rope. A minimum of 1000 lb (454 kg) on a standard -1 drum is required to drop a load in free fall. Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model M50 free fall winch. 323 REV.030624 PAGE 17...
  • Page 20 TROUBLESHOOTING CONTINUED PROBABLE CAUSE FAILURE a) Emergency free fall is non-controllable. Free fall cannot be controlled. b) Piping circuit or control valve is incorrect. Check hydraulic circuit. c) Control valve used has poor metering characteristics. The control valve should have a flow capacity of 3 - 6 gpm maximum.
  • Page 21 For the majority of required service or repair work, disassembly is required only on the brake housing of the PULLMASTER Model M50 free fall 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 22 SERVICE INSTRUCTIONS CONTINUED REMOVAL OF HYDRAULIC MOTOR ASSEMBLY: If disassembly of the hydraulic motor is not necessary, proceed as follows: 1) Remove 12 hex head capscrews item 537, with lockwashers item 541, from motor adaptor item 800. (Since brake springs item 752, apply pressure against the inside of motor adaptor, it is recommended that hex capscrews are unscrewed, one turn at a time, until spring pressure has been released.) Complete motor assembly, including motor adaptor, can now be removed from brake housing assembly.
  • Page 23 SERVICE INSTRUCTIONS CONTINUED DISASSEMBLY OF FREE FALL ASSEMBLY: NOTE: All instructions which refer to controlled free fall also apply to combined free fall. If a failure occurs in free fall section of the winch, proceed as follows: 1) Remove drain plug item 503, from end cover item 240, and drain lubricating oil from free fall housing and end cover.
  • Page 24 SERVICE INSTRUCTIONS CONTINUED remove circlip item 311, and press planet pin item 310, out of planet hub item 300. Inspect loose rollers item 323, bearing spacers item 322, and two thrust washers item 321, and replace if necessary. 8) Pull final sungear item 340, out of cable drum item 500. 9) Remove 8 socket head capscrews item 207, along with lockwashers item 217, from spring retainer item 212.
  • Page 25 SERVICE INSTRUCTIONS CONTINUED out of primary planet hub item 400. Remove primary planet gear item 420, together with loose rollers item 423, and thrust washers item 421. 7) Remove primary sungear item 440, from centre of connecting shaft item 600. 8) Remove circlip item 431, from end of connecting shaft and slide internal gear item 430, along with bearing stopper item 532, off of connecting shaft spline.
  • Page 26 SERVICE INSTRUCTIONS CONTINUED lockwashers item 217. Fasten capscrews, one turn at a time, to compress 99 springs. 12) Reassemble final planet hub assembly. Use grease to temporarily hold 30 loose rollers item 323, in bore of planet gear item 320. Position bearing spacers item 322, and thrust washers item 321, on either side of planet gear.
  • Page 27 SERVICE INSTRUCTIONS CONTINUED 13) Attach tie bars item 556, using 20 capscrews item 555, and lockwashers item 553. Stand winch horizontally on feet. REASSEMBLY OF FREE FALL METERING PUMP: If metering pump was disassembled, the following procedure should be followed for reassembly: 1) Clean all parts thoroughly before reassembly and apply grease to all seals.
  • Page 28 6) Slide brake piston into brake housing with hoes for brake springs facing out of brake housing assembly. 7) Install 14 brake springs item 752, in brake piston using hole pattern shown. HOLE PATTERN FOR BRAKE SPRING INSTALLATION: SI1007 - M50 Location of brake springs (14 springs, 20 holes) 8) Liberally grease three new O-rings item 801, and install in to recesses on motor adaptor item 800.

  • Page 29: 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 M50 free fall planetary winch, always quote the complete model and serial number of the unit.

  • Page 30: Parts Reference - Free Fall

    PARTS REFERENCE - FREE FALL ITEM NO. QTY. PART NO. DESCRIPTION 25669 BALL BEARING #6040 21035 RETAINING RING 25670 OIL SEAL PLANET HUB STOPPER 25331 PLASTIC CAPLUG 3/4 NPT STOPPER 26278 PLASTIC CAPLUG 1/4 NPT 25370 PIPE PLUG 1/16 NPT 23298 PORT END COVER 26372...

  • Page 31: Free Fall Group

    FREE FALL GROUP G1185-B 232 231 177 217 207 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. 323 REV.030624 PAGE 29...

  • Page 32: Parts Reference - Brake Group

    PARTS REFERENCE - BRAKE GROUP DESCRIPTION ITEM NO. QTY. PART NO. 20172 RETAINING RING PLANET HUB 20369 PLANET PIN 25004 CIRCLIP ROTOR CLIP C-87 25091 CIRCLIP ROTOR CLIP SH-87 PLANET GEAR 25068 THRUST WASHER #TRA 1423 25270 LOOSE ROLLER 5/32 X 1.25 TOR. #E151 - Q 25338 CIRCLIP ROTOR CLIP SH-300 SUNGEAR...

  • Page 33: Brake Group

    BRAKE GROUP G1065-B Group drawings may reference more parts than are actually present in a specific assembly. Parts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored. 323 REV.030624 PAGE 31...

  • Page 34: Parts Reference - Motor Group

    PARTS REFERENCE - MOTOR GROUP ITEM NO. QTY. PART NO. DESCRIPTION 25081 CAPSCREW - HEX HEAD 1/2-13NC X 1.5 GRADE 5 25014 LOCKWASHER 1/2" 20415 MOTOR DRIVE SHAFT 25288 CIRCLIP ROTOR CLIP C-112 20401 MOTOR ADAPTOR 25127 O-RING -013 7/16" ID 1/16" CS 25040 PIPE PLUG 1/8 - 27 NPT 25031...

  • Page 35: Motor Group

    MOTOR GROUP G1002-D 323 REV.030624 PAGE 33...

  • Page 36: Installation Drawing

    INSTALLATION DRAWING 1077-1-B 323 REV.051117 PAGE 34...

  • Page 37: Installation Dimensions

    INSTALLATION DIMENSIONS 1077-2 Dimensions in inch (Dimensions in millimeters) DRUM CODE 14.0 23.8 14.0 26.8 28.2 17.625 46.3 14.63 27.5 21.000 26.5 (356) (603) (356) (225) (681) (715) (447.68) (1176) (371.5) (699) (533.40) (673) 18.0 30.0 22.0 30.5 30.9 25.625 54.3 15.50 33.1...

  • Page 38: Assembly Drawing

    ASSEMBLY DRAWING G1002 & G1065 & G1185 323 REV.030624 PAGE 36...
  • Page 39 BARE FULL BARE FULL BARREL FLANGE LENGTH 1 inch 1 inch 1 inch DRUM DRUM DRUM DRUM 14.0 23.8 14.0 50000 33889 M50-1 (356) (605) (356) (54) (60) (84) (222) (150) (21) (31) 18.0 30.0 22.0 39610 26522 M50-2 (457)
  • Page 40 APPENDIX B DRUM CODE - 13 ITEM PART DESCRIPTION PART NUMBER (QUANTITY) 23565 23053 23053 FREE FALL ( 1 ) ( 1 ) ( 1 ) HOUSING FINAL 21030 21031 22134 SUNGEAR ( 1 ) ( 1 ) ( 1 ) Standard Reduction FINAL 23351...
  • Page 41 APPENDIX C MODEL REDUCTION CODE PART ITEM DESCRIPTION M50A M50C M50D PART NO. FINAL 21010 21010 22239 21010 PLANET GEAR PRIMARY 20404 20546 20404 20404 PLANET HUB PRIMARY 20370 20545 20370 20370 PLANET GEAR PRIMARY 21061 21061 21061 21061 INTERNAL GEAR PRIMARY 21036 21380...
  • Page 42 APPENDIX D TYPE OF FREE FALL ITEM PART DESCRIPTION CONTROLLED (C) EMERGENCY (D) PLANET HUB STOPPER 23314 STOPPER 23316 METERING PUMP SHAFT 23311 PIPE PLUG 1/4 NPT 25031 x 2 25031 x 3 PIPE PLUG 1 NPT 25481 x 1 25481 x 2 SOC HEAD CAPSCREW 26495...
  • Page 43 APPENDIX E BRAKE CODE ITEM PART DESCRIPTION PART NO. METERING PUMP 23357 23304 23357 23357 23304 23357 23304 23304 SUB-ASSEMBLY SHUTTLE 20849 20849 20849 20849 CIRCULATION VALVE 20456 20456 20456 20456 1/4-18 NPT PIPE PLUG 25031 25031 25031 25031 1/8-27 NPT PIPE PLUG 25040 25040 25040...

  • Page 44: Bolt Torque Chart

    BOLT TORQUE CHART BOLT DIAMETER TORQUE TORQUE Inches Lb-ft 5/16 7/16 9/16 1085 1000 1356 1200 1627 1500 2034 NOTE: Unless otherwise specified, torque bolts per above chart. 323 REV.030624 PAGE 42...

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