The logical choice planetary hydraulic winch (251 pages)
Summary of Contents for Pullmaster HL25
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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.
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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.
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.
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"...
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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).
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...
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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.
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.
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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.
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...
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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...
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.
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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.
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.
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Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model HL25 winch. 313 REV.970317 PAGE 15...
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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.
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.
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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.
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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.
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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.
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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.
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.
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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.
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.
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...
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...
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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"...
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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...
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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...
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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...
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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)
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