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INSTRUCTION AND PARTS MANUAL
MODEL H8
PLANETARY HYDRAULIC WINCH
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 248
070228
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Summary of Contents for Dover Pull MASTER H8
- Page 1 Click Here To Visit INSTRUCTION AND PARTS MANUAL MODEL H8 PLANETARY HYDRAULIC WINCH 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 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 H8 GENERAL DESCRIPTION: The PULLMASTER Model H8 is a planetary, hydraulic winch with reversing or lowering speed 4.3 times faster than forward or hoisting speed. The main components of this unit are: hydraulic gear motor multi-disk brake with static and dynamic function primary planet reduction final planet reduction brake housing...
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Page 5: Explanation Of Model Coding
EXPLANATION OF MODEL CODING H 8 X - XX - XX - XX X - X XXXX BASIC UNIT SERIES = Rapid reverse SIZE OF UNIT REDUCTION RATIO Only used for non standard reduction ratios TYPE OF BRAKE Automatic brake, clockwise drum rotation, internal circulation flow Automatic brake, external brake release, clockwise drum rotation, internal circulation flow Automatic brake, external brake release, counterclockwise drum... - Page 6 OPTIONS COUNTERCLOCKWISE ROTATION: The drum rotation of the standard PULLMASTER Model H8 planetary winch is clockwise for hoisting when looking at the hydraulic motor of the winch. Drum rotation for counterclockwise hoisting direction is available as an option. EXTERNAL BRAKE RELEASE: PULLMASTER planetary winches can be supplied with an external brake release which permits release of the automatic disk brake from an external pressure source.
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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-H8-A HOISTING LINE PULL VS. OIL PRESSURE MAXIMUM ALLOWABLE LINE PULL WHEN LOWERING: BARE DRUM 1962 lb 8.7 kN FULL DRUM 1342 lb 6.0 kN LINE PULL - kN 13.3 20.0 26.7 33.4 40.0 2000 1600 1200 1500 3000 4500 6000... -
Page 9: Typical Hydraulic Circuit
TYPICAL HYDRAULIC CIRCUIT HC-M8-C CIRCULATION RETURN LINE DIRECT TO RESERVOIR 800 PSI [55 BAR] 2(US)GPM [8 L/MIN] CIRCULATION SUPPLY LINE REQUIRED FOR MODELS M8: 3 (US) GPM [11 LPM] SUPPLIED WITH EXTERNAL H8: 4 (US) GPM [15 LPM] BRAKE RELEASE OPTION (EXTERNAL CIRCULATION MODELS ONLY) CONTROL VALVE... - Page 10 RECOMMENDATIONS HYDRAULIC PRESSURE RELIEF: HYDRAULIC FLUID: The hydraulic circuit for the PULLMASTER planetary The hydraulic fluid selected for use with PULLMASTER winch requires a pressure relief set at the operating planetary winches should be a high grade, petroleum pressure (see SPECIFICATIONS). Usually, a pressure based fluid with rust, oxidation and wear resistance.
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Page 11: Installation Instructions
INSTALLATION INSTRUCTIONS DANGER FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL 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 OPERATING INSTRUCTIONS DANGER FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL 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. IMPORTANT: The ropes, chains, slings, etc.
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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 TROUBLE SHOOTING FAILURE PROBABLE CAUSE Brake 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. Brake piston is seized in the brake housing because of contamination in the hydraulic fluid.
- Page 15 SERVICE INSTRUCTIONS GENERAL: Before attempting disassembly of the PULLMASTER Model H8 planetary winch, 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 seal kit (Part No.
- Page 16 SERVICE INSTRUCTIONS CONTINUED Pocket seals, body seals and ring seals in the hydraulic motor assembly are not part of the winch seal kit. The seal kit for the hydraulic motor can be ordered from the factory under Part No. 23131. All parts of the hydraulic motor, with the exception of the motor adaptor, item 800, are standard parts of the COMMERCIAL WM31 hydraulic motor, having a 2 inch gear section.
- Page 17 SERVICE INSTRUCTIONS CONTINUED DANGER DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY DAMAGE, SEVERE INJURY OR DEATH. SOLVENT MAY DAMAGE THE FRICTION PLATES. DO NOT USE SOLVENT TO CLEAN THE FRICTION PLATES. PERFORM THOROUGH INSPECTION AND, IF NECESSARY, REPLACE FRICTION AND DIVIDER PLATES AS A SET.
- Page 18 SERVICE INSTRUCTIONS CONTINUED 5) If it is necessary to remove primary planet gears, remove circlip, item 411, and press planet pin, item 410, out of planet hub, item 400. Inspect needle bearing, item 423, and two thrust washers, item 421, and replace if damaged. 6) Inspect internal gear stopper, item 412, for excessive wear.
- Page 19 SERVICE INSTRUCTIONS CONTINUED engaged by rotating cable drum. 4) Press ball bearing, item 509, into cable drum. Install bearing spacer, item 508, then press second ball bearing, item 509, into cable drum. 5) Press new, well-greased oil seal, item 515, into cable drum. 6) Install primary sungear, item 440, into center of three primary planet gears, item 420.
- Page 20 SERVICE INSTRUCTIONS CONTINUED 13) Install 16 brake springs, item 752, in the brake piston. 14) Liberally grease new O-ring, item 801, and install on the transfer hole for the brake release pressure on the flange of the motor adaptor, item 800. Install new, well-greased O-ring, item 707, on the flange of the motor adaptor. 15) Slide the hydraulic motor assembly onto the splined end of the motor drive shaft, item 730, and line up the pressure transfer holes of the brake housing and the motor adaptor.
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Page 21: 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 preventive maintenance service should be done every 12 months or 500 operating hours (whichever comes first): 1) Disconnect all hydraulic hoses and remove the winch from its mounting. - Page 22 PARTS REFERENCE - FINAL DRIVE DESCRIPTION ITEM NO. QTY. PART NO. 21376 FINAL HOUSING 25087 BALL BEARING #6214 25008 OIL SEAL 25086 CIRCLIP ROTOR CLIP HO-500 21811 END COVER 25032 PIPE PLUG 1/2 - 14 NPT 20063 SUNGEAR STOPPER 25069 O-RING -274 10"...
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Page 23: Final Drive Group
FINAL DRIVE GROUP G1050-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 21 248 REV.960101... -
Page 24: Parts Reference - Brake Group
PARTS REFERENCE - BRAKE GROUP DESCRIPTION ITEM NO. QTY. PART NO. 20095 PLANET HUB 21169 PLANET PIN 25060 CIRCLIP ROTOR CLIP C-62 21176 INTERNAL GEAR STOPPER 25119 CIRCLIP ROTOR CLIP SH-62 20101 PLANET GEAR 25064 THRUST WASHER TORRINGTON # TRA 1018 25269 NEEDLE BEARING TORRINGTON # BH1016 21174... -
Page 25: Brake Group
BRAKE GROUP G1052-B PRIOR TO SERIAL NO. 37799 Item 723 - Was Part No. 25071 (Borg Warner sprag clutch #X13143 - Qty. 2) Item 726 - Was not required PRIOR TO SERIAL NO. 56185 Item 727 - Was Part No. 25411 Item 730 - Was Part No. -
Page 26: Parts Reference - Motor Group
PARTS REFERENCE - MOTOR GROUP DESCRIPTION ITEM NO. QTY. PART NO. 21973 MOTOR ADAPTOR 25310 O-RING 90 DURO -012 3/8" ID 1/16" CS 25370 PIPE PLUG 1/16 - 27 NPT 25040 PIPE PLUG 1/8 - 27 NPT 25118 CAPSCREW - HEX HEAD 3/8 - 16 NC X 1.25, GRADE 5 25037 LOCKWASHER 3/8"... -
Page 27: Motor Group
MOTOR GROUP G1086 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 25 248 REV.950715... -
Page 28: Installation Dimensions
INSTALLATION DIMENSIONS I1025-1-C PAGE 26 248 REV.051117... - Page 29 INSTALLATION DIMENSIONS I1025-2 DRUM CODE 11.5 12.6 12.6 15.0 13.500 19.6 6.88 8.000 12.9 342.90 499 174.6 203.20 13.5 13.6 12.6 15.0 13.500 19.6 6.88 8.000 12.9 342.90 499 174.6 203.20 13.5 12.0 13.6 12.6 19.0 17.500 23.6 6.88 8.000 12.9 444.50 599 174.6 203.20...
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Page 30: Assembly Drawing
ASSEMBLY DRAWING G1050-B & G1052-B & G1086 PAGE 28 248 REV.000830... - Page 31 APPENDIX A LINE PULL LOWERING MAXIMUM HOISTING AT MAXIMUM LINE SPEED ALLOWABLE LINE SPEED LUBRICATING PRESSURE AT MAXIMUM WIRE ROPE STORAGE LINE PULL AT MAXIMUM CABLE DRUM SIZES - HOISTING * VOLUME* FEET INCHES - LOWERING * VOLUME* VOLUME DRUM REQUIRED (METERS) (MILLIMETERS)
- Page 32 APPENDIX B ITEM NUMBERS PART DESCRIPTION FINAL FINAL FINAL PLANET HUB CABLE DRUM BASE PLANET HUB PLANET GEAR SUNGEAR STOPPER STANDARD REDUCTION RATIO DRUM CODE PART NUMBERS 20143 20113 20142 20174 20074 20143 20113 20142 20298 20074 20143 20113 20352 20324 20325 'A' REDUCTION RATIO...
- Page 33 APPENDIX C BRAKE CODE - 10 ITEM PART DESCRIPTION PART NUMBERS SHUTTLE 20849 20849 20849 20849 ORIFICE 21483 21483 21483 21483 PLUG 1/8-27 NPT 25040 25040 25040 25040 PIPE PLUG 1/8-27 NPT 25040 25040 25040 25040 PIPE PLUG 1/8-27 NPT PIPE 25622 25622...
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Page 34: Bolt Torque Chart
BOLT TORQUE CHART BOLT DIAMETER TORQUE TORQUE Inches lb-ft 5/16 7/16 9/16 1085 1000 1356 NOTE: Unless otherwise specified, torque bolts per above chart. Click Here To Visit PAGE 32 248 REV.950715...
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