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Pullmaster M25 Instructions And Parts Manual

Free fall planetary hydraulic winch
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PML
PMC 261
INSTRUCTION AND PARTS MANUAL
MODEL M25
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
051117

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  • Page 1 INSTRUCTION AND PARTS MANUAL MODEL M25 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 Warranty, and at the expiration of the Warranty period as above stated, all such liabilities shall terminate. WARNING PULLMASTER planetary winches/drives are not designed for operations involving lifting or moving personnel. The PULLMASTER WINCH CORPORATION cannot be held liable or responsible for any accident resulting from such use of PULLMASTER planetary winches/drives.

  • 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

    DESCRIPTION OF THE MODEL M25 WITH FREE FALL GENERAL DESCRIPTION: The PULLMASTER Model M25 with 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 M25 planetary winch. Upon acitivating the emergency free fall function the load will drop and 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 HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS: The operating pressure of the PULLMASTER Model M25 planetary winch with free fall is limited to 2500 psi (172 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.

  • Page 8: Specifications

    SPECIFICATIONS Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 7/8 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.

  • Page 9: Performance Graphs

    PERFORMANCE GRAPHS PG-M25-B MAXIMUM ALLOWABLE LINE PULL WHEN USING LINE PULL VS. OIL PRESSURE CONTROLLED FREE FALL: jjlkjalkf Bare drum 7,500 lb 33.4 kN Full drum 5,289 lb 23.5 kN LINE PULL - kN 2500 2000 1500 1000 5000 10000...

  • Page 10: Typical Hydraulic Circuit

    TYPICAL HYDRAULIC CIRCUIT EMERGENCY FREE FALL: HC-M25-X-XX-XD-B FREEFALL CIRCULATION RETURN BRAKE CIRCULATION 5 USGPM 0-1000 PSI (19 L/MIN) PRESSURE GAUGE EXTERNAL CIRCULATION MODELS ONLY FREEFALL CIRCULATION 2 USGPM (8 L/MIN) FREEFALL CLUTCH RELEASE 750 PSI (52 BAR) CONTROL VALVE (MOTOR SPOOL)
  • Page 11 TYPICAL HYDRAULIC CIRCUIT HC-M25-X-86-XC CONTROLLED FREE FALL: FREEFALL CIRCULATION RETURN 0-1000 PSI PRESSURE GAUGE CONTROL VALVE WITH METERING BRAKE MOTORSPOOL; CIRCULATION SPRING RETURN 5 USGPM TO NEUTRAL; PORT B PLUGGED (19 L/MIN) FREEFALL EXTERNAL CIRCULATION CIRCULATION 9 USGPM MODELS ONLY...
  • Page 12 TYPICAL HYDRAULIC CIRCUIT COMBINED EMERGENCY & CONTROLLED FREE FALL: HC-M25-X-86-XG FREEFALL CIRCULATION RETURN 0-1000 PSI PRESSURE GAUGE BRAKE CIRCULATION 5 USGPM SHUTTLE CONTROL VALVE VALVE WITH METERING (19 L/MIN) MOTORSPOOL; EXTERNAL FREEFALL SPRING RETURN CIRCULATION TO NEUTRAL; CIRCULATION 9 USGPM...
  • Page 13 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 14: Pressure Gauge

    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, control valve and the release port. three-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 freefall. The permissible load of the PULLMASTER Model M25 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 500 lb (227 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 M25 winch with free fall. 261 REV.950501...
  • Page 20 O-ring seal, item 213. e) Oil leaking out of the end cap indicates a damaged O-ring, item 241. Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model M25 winch with free fall. PAGE 18 261 REV.950501...
  • Page 21 For the majority of required service or repair work, disassembly is required only on the brake housing of the PULLMASTER Model M25 planetary winch with free fall. 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 22 800, and the port end cover, item 870, are standard parts of the hydraulic motor, having a 3 inch gear section. All of these parts can be ordered from PULLMASTER or an Authorized Distributor / Dealer in Canada, the United States and in most overseas areas.
  • Page 23 SERVICE INSTRUCTIONS CONTINUED 7) Remove five friction plates, item 715, together with six divider plates, item 713, and inspect for damage or wear. Plates should be flat and smooth. Plates should not show heat discoloration. Paper material on friction plates should be intact and grooved. If any damage is detected, replace friction and divider plates as a set. 8) Remove brake spacer, item 712.
  • Page 24 SERVICE INSTRUCTIONS CONTINUED 13) Remove and discard O-rings, items 231 from clutch piston, and 233 from free fall housing. 14) Check clutch piston outside diameters and inside diameters of free fall housing for surface scratches due to contamination resulting from particles in the hydraulic fluid. If there is any evidence of surface damage, polish with fine emery cloth.
  • Page 25 11) Remove internal retaining ring, item 104, to remove ball bearing, item 103. Remove and discard oil seal, item 105 (this seal separates interior of free fall housing and interior of cable drum). The PULLMASTER Model M25 with free fall has now been completely disassembled. REASSEMBLY Thoroughly clean all parts.
  • Page 26 SERVICE INSTRUCTIONS CONTINUED 9) Place brake plate, item 206, against divider plate, lining up teeth onto teeth of clutch connecting shaft, item 220. Alternate remaining divider and brake plates, finishing stack with a divider plate. 10) Install new, well-greased O-ring, item 233, into O-ring groove in free fall housing, item 200. Install new, well- greased O-ring, item 231, onto clutch piston, item 230.
  • Page 27 5) Install 14 brake springs, item 752, in brake piston using hole pattern shown below. HOLE PATTERN FOR BRAKE SPRING INSTALLATION: LOCATION OF BRAKE SPRINGS (FOURTEEN SPRINGS, TWENTY HOLES) SI1007 - M25/50 261 REV.970701 PAGE 25...
  • Page 28 SERVICE INSTRUCTIONS CONTINUED 6) Liberally grease three new O-rings, item 801, and install in to recesses on motor adaptor, item 800. Install new, well-greased O-ring, item 707, on flange of motor. 7) Slide hydraulic motor assembly on splined end of motor drive shaft, item 730, and line up pressure transfer holes of brake housing and motor adaptor.

  • 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 M25 planetary winch with free fall, always quote the complete model and serial number of the unit.
  • Page 30 PARTS REFERENCE - FINAL DRIVE PART NO. DESCRIPTION ITEM NO. QTY. 25332 BALL BEARING 120 x 180 x 28 # 6024 20460 BEARING RETAINER 25148 OIL SEAL 25237 PIPE PLUG 3/4 - 14 NPT 20756 PLANET HUB STOPPER 25641 PIPE COUPLING 3/8 NPT 21789 PIPE NIPPLE 3/8 NPT X 7"...

  • Page 31: Final Drive Group

    FINAL DRIVE GROUP G1008-F Metering pump connection is shown for clockwise hoisting winch. For counterclockwise hoisting, connect metering tube to alternate port on metering pump and use metering tube, item 216A. Refer to Appendix E. 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 PART REFERENCE list should be ignored.

  • Page 32: Parts Reference - Brake Group

    PARTS REFERENCE - BRAKE GROUP QTY. PART NO. ITEM NO. DESCRIPTION 20404 PLANET HUB 20417 RETAINING RING 20369 PLANET PIN 25004 CIRCLIP ROTOR CLIP C-87 25091 CIRCLIP ROTOR CLIP SH-87 20370 PLANET GEAR 25068 THRUST WASHER TORRINGTON # TRA 1423 25270 LOOSE ROLLER 5/32 X 1.25 TOR.

  • Page 33: Brake Group

    BRAKE GROUP G1001-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 PART REFERENCE list should be ignored. 261 REV.970701 PAGE 31...

  • Page 34: Parts Reference - Motor Group

    PARTS REFERENCE - MOTOR GROUP DESCRIPTION ITEM NO. QTY. PART NO. 25081 CAPSCREW - HEX HEAD 1/2 - 13 NC 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 -90 DURO -013 7/16"...

  • Page 35: Motor Group

    MOTOR GROUP G1002-D 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 PART REFERENCE list should be ignored. 261 REV.970701 PAGE 33...

  • Page 36: Installation Dimensions

    INSTALLATION DIMENSIONS I1004-1-E 261 REV.051117 PAGE 34...

  • Page 37: Hydraulic Motors

    INSTALLATION DIMENSIONS Dimensions in inches (Dimensions in millimeters) DRUM CODE 10.0 17.0 11.0 19.9 21.9 21.0 18.500 39.9 11.38 20.8 17.750 20.8 (254) (432) (279) (218) (505) (556) (533) (469.90) (1014) (289) (225) (527) (450.85) (527) 10.0 24.0 11.0 24.4 22.9 21.0 18.500...

  • Page 38: Assembly Drawing

    ASSEMBLY DRAWING G1001-B & G1002-D & G1008-F 261 REV.970701 PAGE 36...
  • Page 39 APPENDIX A MAXIMUM LINE PULL HOISTING LUBRICAT- ALLOWABLE AT MAXIMUM LINE SPEED LOAD FOR WIRE ROPE STORAGE CABLE DRUM SIZES PRESSURE AT MAXIMUM CONTROLLED VOLUME FEET VOLUME* DRUM - HOISTING* INCHES REQUIRED (METERS) (MILLIMETERS) CODE COMBINED FEET/MINUTE POUNDS U.S. FREE FALL (METERS/MINUTE) (KILONEWTONS) GALLONS...
  • Page 40 APPENDIX B ITEM 550/552 FREE FALL BEARING DRUM CODE BASE CABLE DRUM COUPLING FLANGE 20751 20395 20402 20671 20751 20396 20402 20444 20752 20393 20402 20443 20753 20391 20402 20403 20754 20688 21841 20690 - 10 20754 20935 20402 20937 - 14 20752 20990...
  • Page 41 APPENDIX C TYPE OF FREE FALL ITEM DESCRIPTION CONTROLLED (C) EMERGENCY (D) PLASTIC CAPLUG 1/4NPT 25395 PIPE ELBOW 1/4 NPT 25538 PLASTIC CAPLUG 1/4 NPT 25395 PIPE TEE 1/4 NPT 25552 METERING TUBE SEE APPENDIX D METERING PUMP SEE APPENDIX D SUB-ASSEMBLY END CAP 22381...

  • Page 42: Part Numbers

    APPENDIX D PART NUMBERS BRAKE CODE ITEM PART DESCRIPTION METERING TUBE 22612 22612 22612 22612 ASSEMBLY METERING TUBE 216A 22611 22611 22611 22611 ASSEMBLY METERING PUMP 22382 22382 22383 22382 22382 22383 22383 22383 SUB-ASSEMBLY SHUTTLE 20849 20849 20849 20849 CIRCULATION VALVE 20456 20456...
  • Page 43 APPENDIX E SI 1046 CONNECT METERING TUBE, ITEM 216A, TO THIS PORT FOR CCW HOISTING END VIEW OF METERING PUMP, ITEM 242 261 REV.970701 PAGE 41...

  • 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. 261 REV.970701 PAGE 42...

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