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INSTRUCTION AND PARTS MANUAL
MODEL R7
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.
PMC 257
070228
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Table of Contents
Related Manuals for Pullmaster R7 Series
Summary of Contents for Pullmaster R7 Series
- Page 1 INSTRUCTION AND PARTS MANUAL MODEL R7 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.
- 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").
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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 R7
IMPORTANT: SAFETY VALVE The PULLMASTER Model R7 winch does not require a drain line up to 100 psi permissible back pressure in the brake housing. To indicate excessive pressure and potential damage to the hydraulic motor or to the oil seal in the brake housing, a safety valve is installed on the motor adaptor. - Page 5 DESCRIPTION OF THE MODEL R7 CONTINUED BREATHER RELIEF VALVE 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. To prevent damage to the drum seal and end cover of the final drive if the cable drum fills up with hydraulic fluid, a breather relief (PARTS REFERENCE item 130) is installed on the end cover.
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Page 6: Explanation Of Model Coding
EXPLANATION OF MODEL CODING All variations of the PULLMASTER Model R7 planetary winch are identified by the following code: R 7 X - XX - XX - XX - X BASIC UNIT SERIES R = Recovery winch SIZE OF UNIT... - Page 7 OPTIONS CLOCKWISE ROTATION: The drum rotation of the standard PULLMASTER Model R7 planetary winch is clockwise for pulling when looking at the hydraulic motor of the winch. Drum rotation for counter clockwise hoisting direction is available as an option. OPTIONAL HYDRAULIC GEAR MOTOR: The performance of the standard PULLMASTER Model R7 planetary winch is based on a Commercial model M315 hydraulic motor with a displacement of 1.9 cubic inches.
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Page 8: Specifications
SPECIFICATIONS Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 5/8 inch diameter wire rope. Performance specifications for winches supplied with optional motors are provided in attached supplement. CABLE DRUM DIMENSIONS (STANDARD DRUM): Barrel diameter 6.38 in 162 mm Flange diameter... -
Page 9: Performance Graphs
PERFORMANCE GRAPHS PG-R7-A LINE PULL VS. OIL PRESSURE: LINE PULL - kN 13.3 26.7 40.0 53.4 68.6 2100 1800 1500 1200 3,000 6,000 9,000 12,000 15,429 LINE PULL - lb LINE SPEED VS. OIL VOLUME: LINE SPEED - m/min 13.7 15.0 10.7 12.2... -
Page 10: Typical Hydraulic Circuit (R7-M)
TYPICAL HYDRAULIC CIRCUIT (R7-M) HC-R7-M-A 800 PSI [55 BAR] 2(US)GPM [8 L/MIN] REQUIRED FOR MODELS SUPPLIED WITH EXTERNAL BRAKE RELEASE OPTION CONTROL VALVE (MOTOR SPOOL) 4-WAY SPRING RETURN TO CENTER PRESSURE RELIEF VALVE FILTER HYDRAULIC PUMP RESERVOIR 257 REV.021217 PAGE 8... -
Page 11: Typical Hydraulic Circuit (R7-F)
TYPICAL HYDRAULIC CIRCUIT (R7-F) HC-R7-F-A 800 PSI [55 BAR] 2(US)GPM [8 L/MIN] REQUIRED FOR MODELS SUPPLIED WITH EXTERNAL BRAKE RELEASE OPTION 400 PSI [28 BAR] PRESSURE REQUIRED FOR FREESPOOL CONTROL VALVE (MOTOR SPOOL) 4-WAY SPRING RETURN TO CENTER PRESSURE RELIEF VALVE FILTER HYDRAULIC PUMP... - Page 12 For maximum performance of the PULLMASTER Hydraulic filter recommendations for the hydraulic circuit planetary winch, the hydraulic pump must supply the of the PULLMASTER planetary winch, based on a return maximum flow of hydraulic fluid at the hydraulic pressure line filter, are given as follows: stated in SPECIFICATIONS.
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Page 13: 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 14 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 pulling. Standard rotation for pulling is clockwise when looking at the hydraulic motor of the unit.
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Page 15: 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 16 TROUBLE SHOOTING 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.
- Page 17 SERVICE INSTRUCTIONS GENERAL: Before attempting disassembly of the PULLMASTER Model R7 planetary winch with freespool, the following instructions should be read and understood. It is suggested that all expendable parts such as o-rings and oil seals are not reused on reassembly. It is therefore important to have a seal kit, part no.
- Page 18 SERVICE INSTRUCTIONS CONTINUED sides of the brake hub, item 720, and inspect for wear. Carefully remove the sprag clutch, item 723, and inspect for damage. Inspect the surfaces of the motor drive shaft and the brake hub, where the sprag clutch engages.
- Page 19 SERVICE INSTRUCTIONS CONTINUED The Pullmaster Winch is now reassembled and ready for installation. DISASSEMBLY OF FINAL DRIVE ASSEMBLY: If a failure occurs in the mechanism located inside the final drive housing, or the winch has to be disassembled beyond the point described in the preceding chapter, proceed as follows: 1) Remove the drain plug, item 121, from the freespool cover, item 250, and drain the lubricating oil from the final drive assembly and the cable drum interior.
- Page 20 7) To separate the ball bearing, item 291, from the final sungear, remove circlip, item 269. The PULLMASTER Model R7 with freespool has now been completely disassembled. REASSEMBLY: Reassemble the winch following reverse procedure of disassembly. All parts should be thoroughly cleaned and only new, well greased o-rings and oil seals should be used.
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Page 21: Recommended Maintenance
It is recommended that the lubrication oil in the final drive housing and the drum interior is replaced after the initial 50 hours of operation. In order to maintain your PULLMASTER Model R7 planetery winch in peak operating condition at all times and over a long period, it is recommended that the following preventative maintenance procedure is carried out at least once a year or after 500 hours of actual operation, whichever occurs first: 1) Disconnect all hydraulic hoses and remove the winch from its mounting. -
Page 22: Parts Reference - Final Drive (R7-M)
PARTS REFERENCE - FINAL DRIVE (R7-M) ITEM NO. QTY. PART NO. DESCRIPTION 22360 FINAL HOUSING 25150 BALL BEARING 110 X 170 X 28 #6022 20664 BEARING RETAINER #6022 26049 OIL SEAL 4.750 X 5.500 X .375 25032 PIPE PLUG 1/2 - 14 NPT 25484 O-RING -276 11"ID 1/8"... -
Page 23: Final Drive Group
FINAL DRIVE GROUP G1080-C Groups drawings may reference more parts than are actually present in a specific assembly. Parts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored. 257 REV.021217 PAGE 21... -
Page 24: Parts Reference - Final Drive (R7-F)
PARTS REFERENCE - FINAL DRIVE (R7-F) ITEM NO. QTY. PART NO. DESCRIPTION 22360 FINAL HOUSING 25150 BALL BEARING 110 X 170 X 28 #6022 20664 BEARING RETAINER #6022 26049 OIL SEAL 4.750 X 5.500 X .375 25032 PIPE PLUG 1/2 - 14 NPT 25484 O-RING -276 11"ID 1/8"... - Page 25 FINAL DRIVE GROUP G1081-C Groups drawings may reference more parts than are actually present in a specific assembly. Parts that are referenced on the drawing but are not on the PARTS REFERENCE should be ignored. 257 REV.021217 PAGE 23...
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Page 26: Parts Reference - Brake Group
PARTS REFERENCE - BRAKE GROUP DESCRIPTION ITEM NO. QTY. PART NO. 20660 PLANET HUB 20372 SPACER 20080 PLANET PIN 25060 CIRCLIP ANDERTON # N1800 - 0062 25060 CIRCLIP ANDERTON # N1800 - 0062 20101 PLANET GEAR 25064 THRUST WASHER TORRINGTON # TRA 1018 25269 NEEDLE BEARING TORRINGTON # BH1016 20670... -
Page 27: Brake Group
BRAKE GROUP G-1077-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 PARTS REFERENCE SHOULD BE IGNORED. 257 REV.021217 PAGE 25... -
Page 28: Installation Dimensions (R7-M)
INSTALLATION DIMENSIONS (R7-M) I1030-C 257 REV.051117 PAGE 26... -
Page 29: Installation Dimensions (R7-F)
INSTALLATION DIMENSIONS (R7-F) I1031-D 257 REV.051117 PAGE 27... -
Page 30: Assembly Drawing (R7-M)
ASSEMBLY DRAWING (R7-M) G1077-E & G1080-C 257 REV.010401 PAGE 28... -
Page 31: Assembly Drawing (R7-F)
ASSEMBLY DRAWING (R7-F) G1077-E & G1081-C 257 REV.010401 PAGE 29... - Page 32 APPENDIX A PART NUMBERS ITEM PART BRAKE CODE DESCRIPTION - 12 - 13 - 14 - 15 BRAKE HOUSING 22213 22372 22372 22213 CHECK VALVE 21530 21530 PLASTIC CAPLUG 25374 25374 BRAKE PISTON 20727 20735 20735 20727 STEEL BALL 25533 25533 MOTOR ADAPTER 21079...
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Page 33: 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. 257 REV.010401 PAGE 31...
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