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INSTRUCTION AND PARTS MANUAL
MODEL H12
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 246
070228
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Summary of Contents for Dover PULL MASTER H12
- Page 1 Click Here To Visit INSTRUCTION AND PARTS MANUAL MODEL H12 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
SAFETY RECOMMENDATIONS Definition: Caution indicates a potentially DANGER hazardous situation which, if not avoided may 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 H12 GENERAL DESCRIPTION: The PULLMASTER Model H12 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-disc 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 X - XX - XX - XX X - X XXXX BASIC UNIT SERIES H = 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 H12 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 disc 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 5/8 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 8: Performance Graphs
PERFORMANCE GRAPHS PG-H12-A LINE PULL VS. OIL PRESSURE LINE PULL - kN 17.8 26.7 35.6 44.5 53.4 2200 1760 1320 2000 4000 6000 8000 10000 12000 LINE PULL - lb LINE SPEED VS. OIL VOLUME HOISTING LOWERING LINE SPEED - m/min LINE SPEED - fpm Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with 5/8 inch diameter wire rope. -
Page 9: Typical Hydraulic Circuit
TYPICAL HYDRAULIC CIRCUIT HC-M12-E 400 PSI [28 BAR] PRESSURE REQUIRED FOR MODELS SUPPLIED 800 PSI [55 BAR] WITH FREESPOOL 2(US)GPM [8 L/MIN] CIRCULATION RETURN LINE OPTION REQUIRED FOR MODELS (MUST GO DIRECT SUPPLIED WITH EXTERNAL TO RESERVOIR) BRAKE RELEASE OPTION CIRCULATION SUPPLY LINE M12: 3.5 (US) GPM [13 LPM] H12: 4.5 (US) GPM [17 LPM]... - Page 10 RECOMMENDATIONS HYDRAULIC FLUID: HYDRAULIC PRESSURE RELIEF: The hydraulic fluid selected for use with PULLMASTER The hydraulic circuit for the PULLMASTER planetary 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 OPERATING 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 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 14 TROUBLE SHOOTING CONTINUED 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 H12 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. 23121. REMOVAL OF HYDRAULIC MOTOR ASSEMBLY: If disassembly of the hydraulic motor is not necessary proceed as follows: 1) Remove 12 hex capscrews, item 821, with lockwashers, item 823, from motor adaptor, item 800.
- Page 17 SERVICE INSTRUCTIONS CONTINUED 11) Thoroughly examine inner bores of brake housing and outer diameters of brake piston for scoring caused by hydraulic fluid contamination. Minor surface damage may be repaired by polishing with a fine emery cloth. DANGER DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
- Page 18 SERVICE INSTRUCTIONS CONTINUED 3) If primary planet assembly has to be taken apart, remove circlips, item 411, and push primary planet pins, item 410, out of planet hub, item 400. 4) Remove primary planet gears, item 420, together with needle bearings, item 423, and thrust washers, item 421.
- Page 19 SERVICE INSTRUCTIONS CONTINUED 7) Install primary sungear, item 440, into centre of three primary planet gears, item 420. Ensure gear teeth are fully engaged by rotating cable drum. 8) Carefully insert brake housing, item 700, into ball bearings, items 507 and 509. 9) Fasten base, item 550, onto housings using 12 capscrews, item 551, and lockwashers, item 553.
- Page 20 SERVICE INSTRUCTIONS CONTINUED REASSEMBLY OF HYDRAULIC MOTOR: If the hydraulic motor was disassembled, the following procedure should be followed for reassembly: NOTE: Thrust plates with six slots require pocket seals as indicated below. Thrust plates without slots do not require these seals. 1) Clean all parts thoroughly beofre reassembly and apply grease liberally to all seals.
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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 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 22 PARTS REFERENCE - FINAL DRIVE DESCRIPTION ITEM NO. QTY. PART NO. 20283 FINAL HOUSING 25095 BALL BEARING # 6020 25142 OIL SEAL 25093 CIRCLIP ROTOR CLIP HO-600 21813 END COVER 25032 PIPE PLUG 1/2 - 14 NPT 19036 SUNGEAR STOPPER 25088 O-RING -279 13"...
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Page 23: Final Drive Group
FINAL DRIVE GROUP G1031-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. PAGE 21 246 REV.941201... -
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 G1032-A 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 23 246 REV.000930... -
Page 26: Parts Reference - Motor Group
PARTS REFERENCE - MOTOR GROUP DESCRIPTION ITEM NO. QTY. PART NO. 21390 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 G1033-A 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 25 246 REV.000930... -
Page 28: Installation Dimensions
INSTALLATION DIMENSIONS I1017-1-E 246 REV.051117 PAGE 26... - Page 29 INSTALLATION DIMENSIONS I1017-2-D & I1017-3-D Dimensions in inches (Dimensions in millimeters) DRUM CODE 14.6 10.0 15.9 15.6 19.1 17.000 23.8 10.6 8.56 11.000 17.5 (194) (371) (254) (173) (404) (396) (486) (431.80) (604) (269) (217) (279.40) (445) 14.6 10.0 15.9 15.6 19.1 17.000...
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Page 30: Assembly Drawing
ASSEMBLY DRAWING G1031-A & G1032-A & G1033-A 246 REV.000930 PAGE 28... - Page 31 APPENDIX A LINE PULL HOISTING MAXIMUM LOWERING AT MAXIMUM LINE SPEED LINE SPEED ALLOWABLE LUBRICATING WIRE ROPE STORAGE CABLE DRUM SIZES PRESSURE AT MAXIMUM LINE PULL AT MAXIMUM VOLUME FEET INCHES DRUM - HOISTING* VOLUME* VOLUME* REQUIRED - LOWERING* (MILLIMETERS) (METERS) CODE POUNDS...
- Page 32 APPENDIX B ITEM DRUM FINAL SUNGEAR CABLE DRUM BASE CODE 20198 20201 20148 20198 20186 20148 20305 20299 20293 20198 20300 20148 20198 20302 20148 20305 20309 20293 - 11 20305 21122 21132 246 REV.960201 PAGE 30...
- 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 1200 1627 1500 2034 NOTE: Unless otherwise specified, torque bolts per above chart. Click Here To Visit 246 REV.960201 PAGE 32...
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