Dover Pull MASTER R5-12-70-1M Instructions And Parts Manual
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Dover Pull MASTER R5-12-70-1M Instructions And Parts Manual

Dover Pull MASTER R5-12-70-1M Instructions And Parts Manual

Planetary hydraulic winch
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INSTRUCTION AND PARTS MANUAL
MODEL R5
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 172
070228

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Summary of Contents for Dover Pull MASTER R5-12-70-1M

  • Page 1 Click Here To Visit INSTRUCTION AND PARTS MANUAL MODEL R5 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").

  • Page 3: Safety Recommendations

    SAFETY RECOMMENDATIONS Definition: Caution indicates a potentially hazardous situation which, if not avoided may DANGER result in minor or moderate injury Definition: Warning indicates a potentially FAILURE TO COMPLY WITH THE FOLLOWING SAFETY hazardous situation which, if not avoided could result in death or serious injury.
  • Page 4 DESCRIPTION OF THE MODEL R5 GENERAL DESCRIPTION: The PULLMASTER Model R5 is a planetary, hydraulic winch primarily intended for mobile or recovery adaptations. The winch has equal speed in both directions and a freespool feature which can be operated manually or hydraulically, depending on the option.
  • Page 5 DESCRIPTION OF THE MODEL R5 CONTINUED FUNCTION OF THE FREESPOOL MECHANISM: MODEL R5-12-70-1M This model has a manually actuated freespool function. The freespool feature is enabled by turning the freespool handle 180 degrees in a counterclockwise direction. This will disengage the final sungear from the freespool coupling and provide for a free turning drum.

  • Page 6: Explanation Of Model Coding

    EXPLANATION OF MODEL CODING R 5 X - XX - XX - X X - X XXXX BASIC UNIT SERIES R = Recovery winch SIZE OF UNIT REDUCTION RATIO Only used for non-standard reduction ratios TYPE OF BRAKE Automatic brake, counterclockwise drum rotation, intravent Automatic brake, clockwise drum rotation, intravent HYDRAULIC MOTOR High torque, low speed hydraulic motor, 12.9 cubic inch displacement...
  • Page 7 OPTIONS CLOCKWISE ROTATION: The drum rotation of the standard PULLMASTER Model R5 planetary winch is counterclockwise for pulling when looking at the hydraulic motor of the winch. Drum rotation for clockwise hoisting direction is available as an option. CABLE DRUM SIZES: Refer to APPENDIX A for optional cable drum sizes and specifications.

  • Page 8: 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 refer to APPENDIX A. Performance specifications for winches supplied with optional motors are provided in attached supplement. CABLE DRUM DIMENSIONS (STANDARD DRUM): Barrel diameter 5.00 in...

  • Page 9: Performance Graphs

    PERFORMANCE GRAPHS PG-R5 LINE PULL VS. OIL PRESSURE: 2500 2000 1500 1000 2204 4408 6612 8816 11020 1000 2000 3000 4000 5000 LINE PULL LINE SPEED VS. OIL VOLUME: m/min LINE SPEED Performance graphs are based on standard hydraulic motor and cable drum with 1/2 inch diameter wire rope.
  • Page 10 TYPICAL HYDRAULIC CIRCUIT R5-M HC-R5-M-C CONTROL VALVE (MOTOR SPOOL) 4-WAY SPRING RETURN TO CENTER PRESSURE RELIEF VALVE FILTER HYDRAULIC PUMP RESERVOIR 172 REV.030429 PAGE 8...
  • Page 11 TYPICAL HYDRAULIC CIRCUIT R5-F HC-R5-F-C 400 PSI (28 BAR) PRESSURE REQUIRED FOR FREESPOOL CONTROL VALVE (MOTOR SPOOL) 4-WAY SPRING RETURN TO CENTER PRESSURE RELIEF VALVE FILTER HYDRAULIC PUMP RESERVOIR 172 REV.030429 PAGE 9...
  • Page 12 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. pressure (see SPECIFICATIONS).

  • Page 13: Installation Instructions

    INSTALLATION INSTRUCTIONS DANGER FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS COULD 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 OPERATING INSTRUCTIONS DANGER FAILURE TO FOLLOW OPERATING INSTRUCTIONS COULD RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH. After the PULLMASTER planetary winch has been installed in accordance with the INSTALLATION INSTRUCTIONS, the wire rope can be fastened to the cable drum. The ropes, chains, slings, etc.

  • 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 a) Friction plates or divider plates have been damaged by Brake will not hold. contamination in the hydraulic fluid, or lack of circulation flow in the brake housing. b) 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 R5 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 winch seal kit (Part No.
  • Page 18 SERVICE INSTRUCTIONS CONTINUED 5) Remove pipe plug item 755, and verify that circulation hole in piston is clear and unobstructed. Re-install pipe plug item 755. 6) Thoroughly inspect the brake piston outer diameters and brake housing inner bores for scoring caused by hydraulic fluid contamination.
  • Page 19 SERVICE INSTRUCTIONS CONTINUED 2) After draining all lubricating oil from the final drive housing item 100, remove internal retaining ring item 124. The freespool assembly, along with the final sungear, can now be pulled out of the final drive housing and put aside.
  • Page 20 SERVICE INSTRUCTIONS CONTINUED 4) Inspect nylon planet hub stopper item 126, and replace if less than 0.14 inch thick. Remove and discard O- ring item 123, from outside of freespool housing. 5) To separate the final sungear item 340, from the freespool piston, remove circlip item 269. Inspect the two splines on the end of the final sungear for wear and cracks.
  • Page 21 SERVICE INSTRUCTIONS CONTINUED 8) Attach freespool handle item 254, to nut drive item 256, with capscrew item 297, and lockwasher item 298. Verify handle is in PULLING position when sungear is fully extended. 9) Install new, well-greased O-ring item 123, into freespool housing item 250. Verify that planet hub stopper item 126, is in place.
  • Page 22 SERVICE INSTRUCTIONS CONTINUED 4) Install brake hub assembly through thrust washers item 615, engage spline with freespool coupling item 260, and fasten with coupling fastener item 738. DANGER INCORRECT ASSEMBLY OF THE FRICTION PLATE AND DIVIDER PLATE STACK WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
  • Page 23 SERVICE INSTRUCTIONS CONTINUED IMPORTANT: Before operating the winch, add lubricating oil up to the oil level fill port on the freespool housing. Refer to INSTALLATION INSTRUCTIONS for location of fill port. Refer to APPENDIX A for oil volume required. To ensure proper reassembly, run the winch in both directions without load. DANGER PULLING A LOAD WITH A NEWLY SERVICED WINCH WILL ENABLE AN INSTALLATION OR SERVICE PROBLEM TO GO UNDETECTED AND WILL ALLOW...

  • Page 24: Recommended Maintenance

    RECOMMENDED MAINTENANCE Winch gear train lubricating oil should be changed after the initial six months or 50 hours of operation, whichever comes first. Lubricating oil should then be changed every 12 months or 500 operating hours, whichever comes first. Hydraulic system fluid should be changed at least once every 12 months. For optimum performance over an extended period of time, the following preventative maintenance service should be done every 12 months or 500 hours, whichever comes first: 1) Disconnect all hydraulic hoses and remove the winch from its mounting.

  • Page 25: Installation Drawing

    INSTALLATION DRAWING I1061-C 172 REV.051117 PAGE 23...
  • Page 26 PARTS REFERENCE - MANUAL FREESPOOL ITEM NO. QTY. PART NO. DESCRIPTION 20868 FINAL HOUSING 25087 BALL BEARING 070 X 125 X 24 # 6214 25933 OIL SEAL 80 X 100 X 7 25086 CIRCLIP ANDERTON # N1300 - 0500 25032 PIPE PLUG 1/2 NPT SOCKET HEAD 25104 O-RING -273 9-3/4"ID 1/8"...
  • Page 27 FREESPOOL GROUP - HYDRAULIC RELEASE G1137 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. 172 REV.950101 PAGE 25...
  • Page 28 PARTS REFERENCE - HYDRAULIC FREESPOOL ITEM NO. QTY. PART NO. DESCRIPTION 20868 FINAL HOUSING 25087 BALL BEARING 070 X 125 X 24 # 6214 25933 OIL SEAL 80 X 100 X 7 25086 CIRCLIP ANDERTON # N1300 - 0500 25032 PIPE PLUG 1/2 NPT SOCKET HEAD 25104 O-RING -273 9-3/4"ID 1/8"...
  • Page 29 FREESPOOL GROUP - HYDRAULIC RELEASE G1136 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. 172 REV.950101 PAGE 27...

  • Page 30: Parts Reference - Brake Group

    PARTS REFERENCE - BRAKE GROUP ITEM NO. QTY. PART NO. DESCRIPTION 21015 FREESPOOL COUPLING 20901 JOURNAL BEARING 25584 O-RING - 016 5/8 "ID 1/16" CS 25664 SPHERICAL ROLLER BEARING 25665 OIL SEAL 3.375 X 4.000 X .500 26229 THRUST WASHER TORRINGTON # FTRA 4060 25667 THRUST BEARING TORRINGTON # FNT 4060 20869...

  • Page 31: Brake Group

    BRAKE GROUP G1131 172 REV.950101 PAGE 29...
  • Page 32 ASSEMBLY DRAWING R5 - M G1131 & G1137 172 REV.950101 PAGE 30...
  • Page 33 ASSEMBLY DRAWING R5 - F G1131 & G1136 172 REV.950101 PAGE 31...
  • Page 34 APPENDIX A LINE PULL LINE SPEED AT MAXIMUM AT MAXIMUM LUBRICATING CABLE DRUM SIZES WIRE ROPE STORAGE PRESSURE* VOLUME* INCHES VOLUME FEET DRUM PART REQUIRED (MILLIMETERS) (METERS) CODE NUMBER POUNDS FEET/MINUTE U.S. GALLONS (KILONEWTONS) (METERS/MINUTE) (LITERS) BARE FULL BARE FULL 5/8 in 9/16 in 1/2 in...
  • Page 35 APPENDIX B ITEM BRAKE CODE MOTOR ADAPTOR MOTOR 20876 20906 21403 21508 172 REV.950101 PAGE 33...

  • Page 36: 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. Click Here To Visit 172 REV.950101 PAGE 34...

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