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Pullmaster HL25 Instructions And Parts Manual

Planetary hydraulic winch
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INSTRUCTION AND PARTS MANUAL
MODEL HL25
PLANETARY HYDRAULIC WINCH
PML
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. MAKE THIS MANUAL AVAILABLE TO ALL PERSONS
RESPONSIBLE FOR THE OPERATION, INSTALLATION, SERVICING
AND MAINTENANCE OF THIS PRODUCT.
PMC 313
030619

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  • Page 1 INSTRUCTION AND PARTS MANUAL MODEL HL25 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

    GENERAL DESCRIPTION: The PULLMASTER Model HL25 is a planetary, hydraulic winch with two forward speeds and one reverse speed. At low forward or hoisting speed this unit has a line pull capacity of 25,000 lb on the first layer of wire. In the "rapid forward"...
  • Page 5 During reverse operation of the winch, or when a load is being lowered, the friction created by the brake disc results in temperature. On the standard Model HL25 this temperature is dissipated by a circulation flow of hydraulic fluid, supplied from an external source (see HYDRAULIC CIRCUIT). For efficient cooling of the automatic brake, the external circulation flow should be adjusted to 7 (US) gpm (26 l/min).

  • Page 6: Explanation Of Model Coding

    EXPLANATION OF MODEL CODING X - XX - XX - XX X - X XXXX BASIC UNIT SERIES HL = Rapid forward and reverse SIZE OF UNIT REDUCTION RATIO Only used for non standard reduction ratios TYPE OF BRAKE Automatic brake, clockwise drum rotation, external circulation flow Automatic brake, external brake release, clockwise drum rotation, external circulation flow Automatic brake, external brake release, counterclockwise drum...
  • Page 7 HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS: The operating pressure of the PULLMASTER Model HL25 planetary winch 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 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 10: Performance Graphs

    PERFORMANCE GRAPHS FOR STANDARD GEAR MOTOR PG-HL25-86-A LINE PULL VS. OIL PRESSURE LINE PULL - kN 2500 2000 1500 1000 5000 10000 15000 20000 25000 LINE PULL - lb HOISTING LINE SPEED VS. OIL VOLUME HIGH SPEED HOISTING AND LOWERING...
  • Page 11 PERFORMANCE GRAPHS FOR STANDARD PISTON MOTOR PG-HL25-129-A LINE PULL VS. OIL PRESSURE LINE PULL - kN 3800 3040 2280 1520 5000 10000 15000 20000 25000 LINE PULL - lb HOISTING LINE SPEED VS. OIL VOLUME HIGH SPEED HOISTING AND LOWERING...

  • Page 12: Typical Hydraulic Circuit

    TYPICAL HYDRAULIC CIRCUIT GEAR MOTOR HC-HL25-D PRESSURE REDUCING VALVE - FACTORY PRESET 250 PSI [17 BAR] FAST FORWARD CONTROL VALVE 400 PSI [28 BAR] PRESSURE REQUIRED FOR MODELS SUPPLIED WITH FREESPOOL OPTION 800 PSI [55 BAR] 2(US)GPM [8 L/MIN] REQUIRED FOR MODELS...
  • Page 13 TYPICAL HYDRAULIC CIRCUIT PISTON MOTOR HC-HL25-129-C PRESSURE REDUCING VALVE - FACTORY PRESET 250 PSI [17 bar] FAST FORWARD CONTROL VALVE 3.5 TO 4(US) gpm [13 TO 15 l/min] 400 PSI [28 BAR] PRESSURE REQUIRED FOR MODELS SUPPLIED 800 PSI [55 BAR]...

  • Page 14: 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 15 DIN 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 16: 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 hydraulic circuit components should be checked for proper function. Make certain hydraulic reservoir is filled to top level.
  • Page 17 Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model HL25 winch. 313 REV.970317 PAGE 15...
  • Page 18 It is suggested that all expendable parts, such as O-rings and oil seals, are not reused on reassembly. Because the following service instructions cover the HL25 planetary winch with either a gear motor or a piston motor, verify the proper seal kits are on hand before disassembly. For models with a gear motor, use seal kit (Part No. 23120) and, providing the hydraulic motor has to be serviced, seal kit (Part No.

  • Page 19: Gear Motor Assembly

    800, and 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 20 SERVICE INSTRUCTIONS CONTINUED Clamp clutch hub, item 670, to pressure plate, item 652, and remove circlip, item 679. Remove clutch hub, three clutch springs, item 676, pressure plate, item 652, and gland, item 656, from motor drive shaft. Remove and discard O-rings, item 653, 657 and 735.
  • Page 21 SERVICE INSTRUCTIONS CONTINUED 5) Inspect three final planet gears, item 320, for damage or wear. If necessary to remove final planet gears, remove circlip, item 311, and press planet pin, item 310, out of planet hub, item 300. Inspect loose rollers, item 323, and two thrust washers, item 321, and replace if damaged.
  • Page 22 SERVICE INSTRUCTIONS CONTINUED 15) Remove and discard oil seal, item 711, and if present, backup washer, item 710, from bore of brake housing. Inspect two needle bearings, item 605, and replace if necessary. 16) To separate bearing flange, item 530, and brake housing, item 700, use a standard bearing puller or insert two heel bars in slot between bearing flange and brake housing and pry brake housing out of ball bearing, item 533.
  • Page 23 SERVICE INSTRUCTIONS CONTINUED 7) Place thrust bearing, item 617 (held between two thrust washers, item 615), onto sprag clutch aligner, and against brake hub, item 720. 8) Install connecting shaft, item 600, with brake hub assembly, into bore of brake housing, item 700, and through oil seal, item 711.

  • Page 24: Testing Procedure

    SERVICE INSTRUCTIONS CONTINUED REASSEMBLY OF CLUTCH ASSEMBLY: Reassemble clutch assembly as follows: 1) Install drive gear, item 660, onto connecting shaft, item 600, and fasten with circlip, item 661. 2) Install new, well-greased O-ring, item 735, into motor drive shaft, item 730. 3) Install new, well-greased O-ring, item 657, into gland, item 656, and install gland onto motor drive shaft.
  • Page 25 SERVICE INSTRUCTIONS CONTINUED REPLACEMENT OF HYDRAULIC GEAR MOTOR ASSEMBLY: 1) Liberally grease three new O-rings, item 801, and install into recesses on motor adaptor, item 800. Install new, well-greased O-ring, item 707, on flange of motor adaptor. 2) Slide hydraulic motor assembly on splined end of motor drive shaft, item 730, and line up pressure transfer holes of clutch housing and motor adaptor.

  • Page 26: 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 HL25 planetary winch, always quote the complete model and serial number of the unit.

  • Page 27: Assembly Drawing

    ASSEMBLY DRAWING PISTON MOTOR G1000-A & G1003-B & G1010-E 313 REV.010201 PAGE 25...
  • Page 28 PARTS REFERENCE - FINAL DRIVE DESCRIPTION ITEM NO. QTY. PART NO. 20399 FINAL HOUSING 25332 BALL BEARING # 6024 20460 BEARING RETAINER 25148 OIL SEAL 21816 END COVER 25237 PIPE PLUG 3/4 - 14 NPT 19036 SUNGEAR STOPPER 25340 O-RING -281 15" ID 1/8" CS 20416 RETAINING RING 20418...

  • Page 29: Final Drive Group

    FINAL DRIVE GROUP G1000-A 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. 313 REV.970317 PAGE 27...

  • Page 30: Parts Reference - Brake Group

    PARTS REFERENCE - BRAKE GROUP DESCRIPTION ITEM NO. QTY. PART NO. 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 TORRINGTON # E151 - Q 20411...

  • Page 31: Brake Group

    BRAKE GROUP G1003-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. 313 REV.970317 PAGE 29...
  • Page 32 PARTS REFERENCE - GEAR MOTOR GROUP DESCRIPTION ITEM NO. QTY. PART NO. 25694 O-RING -022 1" ID 1/16" CS 25695 O-RING -015 9/16" ID 1/16" CS 21139 CAPSCREW - HEX HEAD 1/2 - 13NC X 4-3/4 LONG GRADE 5 21134 PRESSURE PLATE 25588 O-RING -126 1-3/8"...
  • Page 33 GEAR MOTOR GROUP G1007-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. 313 REV.970901 PAGE 31...
  • Page 34 PARTS REFERENCE - PISTON MOTOR GROUP DESCRIPTION ITEM NO. QTY. PART NO. 25014 LOCKWASHER 1/2" 21635 PRESSURE PLATE 25588 O-RING -126 1-3/8" ID 3/32" CS 21136 CLUTCH PLATE 21137 GLAND 25703 O-RING -153 3-1/2" ID 3/32" CS 20172 RETAINING RING 21568 BEARING CARRIER 25810...
  • Page 35 PISTON MOTOR GROUP G1010-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 list should be ignored. 313 REV.970901 PAGE 33...

  • Page 36: Installation Dimensions

    INSTALLATION DIMENSIONS GEAR MOTOR I1006-1-D PAGE 34 313 REV.010201...
  • Page 37 INSTALLATION DIMENSIONS GEAR MOTOR I1006-2 & I1006-3-A Dimensions in inches (Dimensions in millimeters) DRUM 10.0 17.0 11.0 11.8 19.9 19.9 21.0 18.500 31.8 34.2 11.38 20.8 17.750 20.8 (254) (432) (279) (300) (505) (505) (533) (469.90) (808) (869) (289) (225) (527) (450.85) (527) 10.0...
  • Page 38 INSTALLATION DIMENSIONS PISTON MOTOR I1007-1-E PAGE 36 313 REV.010201...
  • Page 39 INSTALLATION DIMENSIONS PISTON MOTOR I1007-2-E & I1007-3-E Dimensions in inches (Dimensions in millimeters) DRUM CODE 10.0 17.0 11.0 11.8 19.9 19.9 21.0 18.500 31.8 34.2 11.38 20.8 17.750 20.8 (254) (432) (279) (300) (505) (505) (533) (469.90) (808) (869) (289) (225) (527) (450.85)
  • Page 40 ASSEMBLY DRAWING GEAR MOTOR G1000-A & G1003-B & G1007-B PAGE 38 313 REV.010201...
  • Page 41 APPENDIX A LOW SPEED HOISTING HIGH SPEED HOISTING & LOWERING LINE PULL LINE SPEED LINE SPEED MAXIMUM AT MAXIMUM AT MAXIMUM ALLOWABLE AT MAXIMUM LUBRICATING WIRE ROPE STORAGE CABLE DRUM SIZES PRESSURE* VOLUME* VOLUME* LINE PULL* VOLUME FEET INCHES DRUM REQUIRED (MILLIMETERS) (METERS)
  • Page 42 APPENDIX B ITEM 550 / 552 CABLE FINAL BASE DRUM CODE DRUM SUNGEAR 20409 20395 20671 20409 20396 20444 20408 20393 20443 20407 20391 20403 PAGE 40 313 REV.970317...

  • Page 43: Part Description

    APPENDIX C BRAKE CODE - 10 ITEM PART DESCRIPTION PART NUMBERS 20849 20849 SHUTTLE 1/8-27 NPT 25040 25040 PIPE PLUG 1/8-27 NPT PIPE 25622 25622 ADAPTOR 1/8 NPT 26276 26276 CAPLUG MOTOR 22054 22055 22056 22057 SUB-ASSY 313 REV.970901 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. PAGE 42 313 REV.970317...

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