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INSTRUCTION AND PARTS MANUAL
MODEL PH136
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 340
070228
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Table of Contents
Related Manuals for Dover PullMaster PH136
Summary of Contents for Dover PullMaster PH136
- Page 1 INSTRUCTION AND PARTS MANUAL MODEL PH136 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
SAFETY RECOMMENDATIONS WARNING FAILURE TO COMPLY WITH THE FOLLOWING SAFETY RECOMMENDATIONS AND LOCAL RULES AND REGULATIONS COULD RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH. Do not install, operate or service Planematic drive before reading and understanding manufacturer's instructions. The Planematic drive described herein is not designed for operations involving lifting or moving personnel. -
Page 4: Description Of The Model Ph136
DESCRIPTION OF THE MODEL PH136 The PULLMASTER Planematic drive is a high performance, highly efficient, planetary hydraulic drive with reversing speed 4.7 times faster than forward speed. The main components of this unit are: hydraulic motor brake housing hydraulically released multi-disc brake with static and dynamic function primary planetary reduction final drive housing final planetary reduction... - Page 5 MODEL CODING FOR PLANEMATIC DRIVE MODEL PH136 X - XX - XXX - XX X - X XXX BASIC UNIT P = Planematic drive TYPE OF UNIT H = High speed reverse SIZE OF UNIT 136 = 135,937 lb-in output torque REDUCTION RATIO Used for non standard reduction ratios only TYPE OF BRAKE...
- Page 6 OPTIONS REDUCTION RATIO: The reduction ratio of the standard PULLMASTER Planematic drive is 40.8:1. Drives with different reduction ratios and altered output performances are optionally available. TYPE OF BRAKE: The standard PULLMASTER Planematic drive output shaft rotates forward in clockwise direction as viewed from the motor end of the unit.
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Page 7: Specifications
SPECIFICATIONS Performance specifications are based on standard hydraulic motor and gear ratio. Performance specifications for Planematic drives supplied with optional motors and/or reductions are provided in attached supplement. MAXIMUM OUTPUT TORQUE: Forward: 135,937 lb-in 15,359 Nm Reverse: 29,127 lb-in 3,291 Nm MAXIMUM OUTPUT RPM: Forward: 49 rpm... -
Page 8: Overhung Load Rating
OVERHUNG LOAD RATING PG-136-OH The magnitude and location of a load is dependent on the following factors: SF = service factor (Table A) AF = application factor (Table B) a = bearing geometry constant = -0.295 T = basic thrust load = 14,500 c = basic load constant = 136,000 L = allowable overhung load in lbs. -
Page 9: Performance Graphs
PERFORMANCE GRAPHS PG-PH136 OUTPUT TORQUE VS. OIL PRESSURE OUTPUT TORQUE - Nm (x 100) 22.6 45.2 67.8 90.4 113.0 135.6 158.2 2500 2000 1500 1000 OUTPUT TORQUE - lb.in. (x 1000) OUTPUT RPM VS. OIL VOLUME OUTPUT RPM Performance graphs are based on standard hydraulic motor and gear ratio. PAGE 7 340 REV.991125... -
Page 10: Typical Hydraulic Circuit
TYPICAL HYDRAULIC CIRCUIT HC-PMH136-A 800 PSI [55 BAR] 2(US)GPM [8 L/MIN] CIRCULATION RETURN LINE REQUIRED FOR MODELS (MUST GO DIRECT TO RESERVOIR) SUPPLIED WITH EXTERNAL BRAKE RELEASE OPTION CIRCULATION SUPPLY LINE PM136: 5 (US) GPM [19 L/MIN] PH136: 7 (US) GPM [26 L/MIN] (EXTERNAL CIRCULATION MODELS ONLY) CONTROL VALVE... - Page 11 RECOMMENDATIONS HYDRAULIC FLUID: HYDRAULIC PRESSURE RELIEF: The hydraulic fluid selected for use with PULLMASTER The hydraulic circuit for the PULLMASTER Planematic Planematic drives should be a high grade, petroleum drive requires a pressure relief set at the operating based fluid, with rust, oxidation and wear resistance. pressure (see SPECIFICATIONS).
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Page 12: Installation Instructions
INSTALLATION INSTRUCTIONS DANGER FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH. To ensure satisfactory operation, the PULLMASTER Planematic drive must be properly installed. Observe the following installation instructions: 1) The Planematic drive mounting structure must be strong enough to withstand operating torques without excessive deflection. - Page 13 OPERATING INSTRUCTIONS DANGER FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH. Verify proper installation, acceptable system back pressure and adequate brake circulation flow before operating the Planematic drive. 1) The standard Planematic drive brake applies only in counterclockwise rotation as viewed from the motor end of the unit.
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Page 14: Troubleshooting
TROUBLE SHOOTING GENERAL: Typical Planematic drive operating problems are caused by a malfunctioning hydraulic system. Verify hydraulic pressure and flow at the drive motor are as specified before dismounting or disassembling Planematic. IMPORTANT: Ensure that the hydraulic system reservoir is full and that the system pump is running at full rpm before doing any system checks. - Page 15 TROUBLE SHOOTING CONTINUED PROBABLE CAUSE FAILURE Brake will not hold load. Hydraulic system back pressure not per SPECIFICATIONS. Refer to procedure described in TROUBLE SHOOTING - HYDRAULIC SYSTEM PRESSURE AND PLANEMATIC TORQUE to verify system back pressure at motor. Brake piston release oil being trapped by hydraulic system control valve.
- Page 16 SERVICE INSTRUCTIONS GENERAL: Before attempting disassembly of the PULLMASTER Model PH136 Planematic drive, the following instructions for disassembly and reassembly 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 Planematic seal kit (Part No.
- Page 17 SERVICE INSTRUCTIONS CONTINUED NOTE: Teflon seals, gasket seals, and ring seals in the hydraulic motor assembly are not part of the Planematic seal kit. The motor, with the exception of the motor adaptor item 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 Authorized Distributors/Dealers in Canada, the United States and in most overseas areas.
- Page 18 SERVICE INSTRUCTIONS CONTINUED 6) Remove connecting shaft item 600, and internal gear item 430, from brake housing. Remove circlip item 431, to separate internal gear from brake hub. Inspect needle bearing item 603. Replace if necessary. 7) Remove primary sungear item 440. 8) Pull primary planet hub assembly out of bushing item 774.
- Page 19 SERVICE INSTRUCTIONS CONTINUED REASSEMBLY Thoroughly clean all parts. Use only new, well-greased O-rings and oil seals. Unless otherwise specified, torque fasteners per BOLT TORQUE CHART. REASSEMBLY OF FINAL DRIVE AND OUTPUT SHAFT ASSEMBLY: Reassemble final drive and output shaft assembly by reversing disassembly procedure. 1) Press sungear stopper item 160, into end of output shaft item 150, and press output shaft into tapered roller bearings items 151 and 103.
- Page 20 SERVICE INSTRUCTIONS CONTINUED 9) Insert primary sungear item 440, in opening between three primary planet gears item 420. 10) Place thrust bearing item 617 (held between two thrust washers item 615), into bore of primary planet hub item 400. 11) Fasten internal gear item 430, onto connecting shaft item 600, using circlip item 431. 12) Verify placement of needle bearing item 603, in connecting shaft item 600.
- Page 21 SERVICE INSTRUCTIONS CONTINUED 7) Plumb Planematic assembly to hydraulic supply and torque motor capscrews according to following procedure: Ensure that circulation supply flow is being supplied to the brake housing. Run Planematic, with no load, in hoisting direction at reduced speed (approximately 30% of maximum hydraulic volume).
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Page 22: Recommended Maintenance
RECOMMENDED MAINTENANCE In order to maintain the PULLMASTER Planematic drive in peak operating condition at all times, it is recommended that the following preventive maintenance procedure is carried out every 12 months or 500 operating hours, whichever occurs first. Disconnect all hydraulic connections and remove the Planematic drive from its mounting. Disassemble the Planematic drive in accordance with the SERVICE INSTRUCTIONS. -
Page 23: Assembly Drawing
ASSEMBLY DRAWING G1015-B, G1016-A & G1078-B PAGE 21 340 REV.030926... -
Page 24: Parts Reference - Final Drive
PARTS REFERENCE - FINAL DRIVE ITEM NO. QTY. PART NO. DESCRIPTION 21855 FINAL HOUSING 25938 BEARING - TAPERED ROLLER 25340 O-RING -281 15"ID 1/8"CS 26007 WASHER KEYED TIMKEN K91522 OUTPUT SHAFT 25932 BEARING - TAPERED ROLLER SKF #32222 FLANGE CAPSCREW FLANGE CAP LOCKWASHER 21860... -
Page 25: Final Drive Group
FINAL DRIVE GROUP G1016-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 23 340 REV.030926... -
Page 26: Parts Reference - Brake Group
PARTS REFERENCE - BRAKE GROUP ITEM NO. QTY. PART NO. DESCRIPTION 25259 CAPSCREW -HEX HEAD 3/8 - 16NC X 1.50 GRADE 5 25037 LOCKWASHER 3/8" 21871 PRIMARY PLANET HUB 20369 PRIMARY PLANET PIN 25004 CIRCLIP ROTOR CLIP C-87 25091 CIRCLIP ROTOR CLIP SH-87 20370 PLANET GEAR 25068... - Page 27 PARTS REFERENCE - BRAKE GROUP G1015-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. PAGE 25 340 REV.991125...
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Page 28: Parts Reference - Motor Group
PARTS REFERENCE - MOTOR GROUP QTY. PART NO. DESCRIPTION ITEM NO. 25081 CAPSCREW - HEX HEAD 1/2 - 13NC X 1.50 GRADE 5 21875 MOTOR DRIVE SHAFT 22223 MOTOR DRIVE SHAFT SPACER 25942 NEEDLE BEARING TORRINGTON #F-3516 25014 LOCKWASHER 1/2" 20401 MOTOR ADAPTOR 25127... -
Page 29: Motor Group
MOTOR GROUP G1078-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. PAGE 27 340 REV.030926... -
Page 30: Installation Drawing
INSTALLATION DRAWING I1012-C 340 REV.030926 PAGE 28... - Page 31 APPENDIX A OUTPUT SHAFT CODE ITEM PART DESCRIPTION PART NUMBER OUTPUT SHAFT 22164 23018 22164 22164 22569 150A 23019 FLANGE 21856 21874 CAPSCREW 25139 25139 FLANGE CAP 21420 21420 LOCKWASHER 25359 25359 PAGE 29 340 REV.991125...
- Page 32 APPENDIX B BRAKE CODE - 10 ITEM PART DESCRIPTION PART NUMBERS SHUTTLE 20849 20849 20849 20849 CIRCULATION 20456 20456 20456 20456 VALVE 1/4-18 NPT PIPE PLUG 25031 25031 25031 25031 1/8-27 NPT 25040 25040 25040 25040 PIPE PLUG 1/8-27 NPT 25622 25622 25622...
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Page 33: Bolt Torque Chart
BOLT TORQUE CHART TORQUE TORQUE BOLT DIAMETER 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. 340 REV.991125 PAGE 31...
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