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INSTRUCTION AND PARTS MANUAL
MODEL M5
Design Revision 'B'
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 316
070228
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Table of Contents
Related Manuals for Pullmaster M5
Summary of Contents for Pullmaster M5
- Page 1 INSTRUCTION AND PARTS MANUAL MODEL M5 Design Revision 'B' 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 M5
DESCRIPTION OF THE MODEL M5 GENERAL DESCRIPTION: The PULLMASTER Model M5 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 primary planet reduction... -
Page 5: Explanation Of Model Coding
NOTE: Clockwise and counterclockwise drum rotation is the direction of rotation for pulling or hoisting, established by looking at the hydraulic motor. Model M5 Design Revision 'B' Instruction and Parts Manual # PMC 316 PUB.960901 Effective from Serial # 46161... - Page 6 Drum rotation for counter clockwise hoisting direction is available as an option. CABLE DRUM SIZES: Aside from the standard drum sizes listed in APPENDIX A, the PULLMASTER Model M5 planetary winch can be supplied with optional drums to accommodate large wire rope storage capacity.
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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 and gear ratios, refer to APPENDIX A. Performance specifications for winches supplied with optional motors are provided in attached supplement. CABLE DRUM DIMENSIONS (STANDARD DRUM): Barrel diameter 7.00 in... -
Page 8: Performance Graphs
PERFORMANCE GRAPHS PG-M5-A LINE PULL VS. OIL PRESSURE: LINE PULL - kN 13.3 17.8 22.3 26.7 2000 1600 1200 1000 2000 3000 4000 5000 6000 LINE PULL - lb LINE SPEED VS. OIL VOLUME: LINE SPEED - m/min 12.2 18.3 24.4... -
Page 9: Typical Hydraulic Circuits
TYPICAL HYDRAULIC CIRCUITS HC-M5-A CIRCULATION RETURN LINE DIRECT TO RESERVOIR CONTROL VALVE (MOTOR SPOOL) 4-WAY SPRING RETURN TO CENTER PRESSURE RELIEF VALVE FILTER HYDRAULIC PUMP RESERVOIR 316REV.030430 PAGE 7... - 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.
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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 clockwise when looking at the hydraulic motor of the unit.
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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 Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model M5 winch. PAGE 12 316 REV.980601...
- Page 15 SERVICE INSTRUCTIONS GENERAL: Before disassembling the PULLMASTER Model M5 planetary winch, read and understand the following instructions. Replace expendable parts such as O-rings and oil seals when reassembling the winch. Have a winch seal kit (Part No. 23099) on hand before the unit is disassembled.
- Page 16 SERVICE INSTRUCTIONS CONTINUED 7) Pull primary sungear, item 440, with brake hub assembly, item 720, and clutch aligners, items 722 and 724, from brake housing. 8) Disassemble brake hub assembly by removing circlip, item 727, from primary sungear, item 440. Remove primary sungear from brake hub, item 720.
- Page 17 SERVICE INSTRUCTIONS CONTINUED DISASSEMBLY OF PRIMARY DRIVE: If the primary drive requires service or repair, disassemble as follows: 1) Remove pipe plug, item 503, from cable drum, item 500, and pipe plug, item 121, from end cover, item 120, to drain lubricating oil from winch interior. Remove breather relief, item 130. NOTE: Breather relief, item 130, is not user serviceable.
- Page 18 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 as back of manual. REASSEMBLY OF FINAL DRIVE: Reassemble final drive end of winch as follows: 1) Press new, well-greased oil seal, item 105, into final housing, item 100.
- Page 19 SERVICE INSTRUCTIONS CONTINUED REASSEMBLY OF BRAKE HOUSING ASSEMBLY: Reassemble brake housing assembly by reversing the disassembly procedure: 1) Place brake spacer, item 712, in end housing with flat side facing up. 2) Install new, well-greased O-ring, item 695, onto mounting flange of brake housing, item 700. Fasten brake housing to end housing using two flat head capscrews, item 693.
- Page 20 SERVICE INSTRUCTIONS CONTINUED REPLACEMENT OF HYDRAULIC MOTOR ASSEMBLY: Replace the hydraulic motor assembly by reversing the removal procedure. IMPORTANT: Before installing motor, determine brake code of winch. Install motor plug as indicated below. SI-1029 MOTOR PLUG WITH 0-RING NOTE: INSERT MOTOR PLUG, O-RING END FIRST, INTO PORT A OR B AS INDICATED IN CHART BELOW.
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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 M5 planetary winch, always quote the complete model and serial numbers of the unit. -
Page 22: Assembly Drawing
ASSEMBLY DRAWING G1144-A PAGE 20... -
Page 23: Parts Reference
PARTS REFERENCE ITEM NO. QTY. PART NO. DESCRIPTION 20072 FINAL HOUSING 25007 BALL BEARING 070 X 110 X 20 #6014 25006 CIRCLIP ROTOR CLIP HO-433 25008 OIL SEAL 3.000 X 4.003 X .375 20071 END COVER 25032 PIPE PLUG 1/2 NPT SOC HD 20063 SUNGEAR STOPPER 25069... - Page 24 PARTS REFERENCE - CONTINUED ITEM NO. QTY. PART NO. DESCRIPTION 20183 SPRAG CLUTCH ALIGNER 25187 SPRAG CLUTCH 25492 CIRCLIP ROTOR CLIP SH-106 25483 THRUST WASHER INA # AS 3047 25537 THRUST BEARING INA # AXK 3047 21597 PISTON SUBASSEMBLY 25258 O-RING -90 DURO -247 4-5/8"...
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Page 25: Installation Dimensions
INSTALLATION DIMENSIONS 1041-B PAGE 23... - Page 26 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 1/2 inch 7/16 inch 3/8 inch DRUM...
- Page 27 APPENDIX B ITEM NUMBERS PART DESCRIPTION BEARING FINAL SUNGEAR CABLE DRUM BASE FLANGE STANDARD REDUCTION RATIO DRUM PART NUMBERS CODE 20078 20067 20068 20074 20078 20297 20068 20074 21008 21019 21018 20325 PAGE 25...
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Page 28: 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. PAGE 26...
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