Pullmaster Model pl8 Service Manual
Pullmaster Model pl8 Service Manual
Pullmaster Model pl8 Service Manual
MODEL PL8
PLANETARY HYDRAULIC WINCH
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").
Buyer's exclusive remedy and Seller's sole obligation under this Warranty shall be, at Seller's option, to repair or replace any article or part
thereof which has proven to be defective, or to refund the purchase price of such article or part thereof. Buyer acknowledges that Buyer is
knowledgeable concerning the articles covered by this Warranty and sold in connection therewith which are being purchased, that Buyer has
reviewed this Warranty and that the remedies provided hereunder are adequate and acceptable to Buyer.
This Warranty shall expire one (1) year from the date the article is first shipped by Seller. Notice of claimed breach of this Warranty must be
given by Buyer to Seller within the applicable period. Such notice shall include an explanation of the claimed warranty defect and proof of
date of purchase of the article or part thereof for which warranty coverage is sought. No allowances shall be made by Seller for any
transportation, labor charges, parts, "in and out" costs, adjustments or repairs, or any other work, unless such items are authorized in writing
and in advance by Seller. Nor shall Seller have any obligation to repair or replace items which by their nature are expendable.
If an article is claimed to be defective in material or workmanship, or not to conform to the applicable specifications, Seller will either
examine the article at Buyer's site or issue shipping instructions for return to Seller. This Warranty shall not extend to any articles or parts
thereof which have been installed, used, or serviced otherwise than in conformity with Seller's applicable specifications, manuals, bulletins,
or instructions, or which shall have been subjected to improper installation, operation, or usage, misapplication, neglect, incorrect
installation, overloading, or employment for other than normal and ordinary use and service. This Warranty shall not apply to any article
which has been repaired, altered or disassembled, or assembled by personnel other than those of Seller. This Warranty shall not apply to
any article upon which repairs or alterations have been made (unless authorized in writing and in advance by Seller). This Warranty shall
not apply to any articles or parts thereof furnished by Seller to Buyer's specifications and/or furnished by Buyer or acquired from others at
Buyer's request.
SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND, OTHER THAN THE WARRANTY
EXPRESSLY SET FORTH ABOVE. SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND ACCEPTED IN LIEU OF ANY AND ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
Buyer expressly agrees that Seller is not responsible to perform any work or investigation related in any way to tensional vibration issues
and is not responsible for the detection or remedy of Natural Frequency Vibration of the mechanical system in which the unit is installed.
Buyer acknowledges, understands and agrees that this Warranty does not cover failures of the unit which result in any manner from the
operation of the machine or unit at vibration frequencies at or near the natural frequency vibration of the machine in such a way that damage
may result. Buyer expressly agrees that Seller is not responsible for failure damage or accelerated wear caused by machine or ambient
vibration. Further, Buyer acknowledges and agrees that Buyer is always solely responsible for determination and final approval of the
“application factor”
which may be used in Seller’ s calculations, and this application factor is 1.0 unless otherwise stated in Seller’
s quotation
specifications.
The remedies for this Warranty shall be only those expressly set forth above, to the exclusion of any and all other remedies of whatsoever
kind. The limited remedies set forth above shall be deemed exclusive, even though they may fail their essential purpose. No agreement
varying or extending the foregoing Warranty, remedies, exclusions, or limitations shall be effective unless in a writing signed by an executive
officer of Seller and Buyer. This Warranty is non-transferable. If a party who had purchased articles from Buyer, or from persons in privity
with Buyer, brings any action or proceeding against Seller for remedies other than those set forth in this Warranty, Buyer agrees to defend
Seller against the claims asserted in such action or proceeding at Buyer’ s expense, including the payment of attorneys’ fees and costs, and
indemnify Seller and hold Seller harmless of, from and against all such claims, actions, proceedings or judgments therein. Buyer also
agrees to defend and indemnify Seller of, from and against any loss, cost, damage, claim, debt or expenses, including attorneys’ fees,
resulting from any claims by Buyer or third parties to property or injury to persons resulting from faulty installation, repair or modification of
the article and misuse or negligent operation or use of the article, whether or not such damage to property or injury to persons may be
caused by defective material, workmanship, or construction. ADVISORY: Winches and hoists are not approved for lifting or handling
personnel or persons unless specifically approved in writing from Seller for the specific intended application.
Under no circumstances shall Seller be liable (i) for any damage or loss to any property other than the warranted article or part thereof, or (ii)
for any special, indirect, incidental, or consequential damage or loss, even though such expenses, damages, or losses may be foreseeable.
The foregoing limitations on Seller's liability in the event of breach of warranty shall also be the absolute limit of Seller's liability in the event
of Seller's negligence in manufacture, installation, or otherwise, with regard to the articles covered by this Warranty, and at the expiration of
the Warranty period as above stated, all such liabilities shall terminate. Buyer’ s purchase of any article(s) covered by this Warranty shall
constitute acceptance of the terms and conditions hereof and shall be binding upon Buyer and Buyer’ s representatives, heirs and assigns.
The laws of the Province of British Columbia shall govern Buyer’ s rights and responsibilities in regard to this Warranty and the transaction(s)
subject thereto, and the Province of British Columbia shall be the exclusive forum and jurisdiction for any action or proceedings brought by
Buyer in connection herewith or any dispute hereunder. If any of the terms and conditions contained within this Warranty are void, the
remaining provisions thereof are and shall remain valid and enforceable.
Note: Prices and specifications contained in this price book are subject to change without notice.
US.DIST.01.01.07
SAFETY RECOMMENDATIONS
Definition: Caution indicates a potentially
hazardous situation which, if not avoided may
DANGER result in minor or moderate injury.
The winches are to be used within the specifications as listed in the manual under “SPECIFICATIONS”. Other use as foreseen
in the functional description of the hydraulic winch is not allowed without written permission from PULLMASTER.
1. Do not install, operate or service winch before 18. Use only recommended hydraulic oil and gear
reading and understanding manufacturer’s lubricant.
instructions.
19. Keep hydraulic system clean and free from
2. The winch described herein is not designed for contamination at all times.
operations involving lifting or moving personnel.
20. Maintain winch and equipment in good operating
3. Do not lift or carry loads over people. condition. Perform scheduled maintenance regularly.
4. Do not exceed recommended operating pressure 21. Keep hands clear when winding wire rope onto
(psi) and operating volume (gpm). the winch drum.
5. Do not jerk the winch. Always smoothly 22. Do not use the wire rope as a ground for welding.
accelerate and decelerate load.
23. Rig the winch carefully. Ensure that the wire rope
6. Do not operate a damaged, noisy or is properly anchored to the correct cable anchor slot at
malfunctioning winch. the cable drum.
7. Do not leave a load suspended for any extended 24. Do not lift a load with a twisted, kinked or
period of time. damaged wire rope.
8. Never leave a suspended load unattended. 25. Consult wire rope manufacturer for size, type and
maintenance of wire rope.
9. Winch should be maintained and operated by
qualified personnel. 26. Maintain five wraps of wire rope on the cable
drum at all times.
10. Inspect winch, rigging, mounting bolts and hoses
before each shift. 27. In case of a power failure or breakdown leading
to an unexpected stop of the hydraulic power circuit,
11. Warm-up equipment before operating winch,
stand clear of the area and the load being hoisted,
particularly at low ambient temperatures.
take the necessary precautions to prevent access to
12. Verify winch function by raising and lowering a area where the load is halted.
full test load to a safe height before each shift.
28. The noise level of the winch is 89 dBA measured
13. Do not weld any part of the winch. on a distance of 1.00 meter, 1.60 meters high. The
14. Verify gear lubrication and brake circulation measuring equipment used was: Realistic #42-3019.
supply and return before operating winch. 29. Clean up any oil spillage immediately.
15. Be sure of equipment stability before operating 30. Wear proper clothing and personal protection
winch. equipment such as, footwear, safety goggles and a
16. Wear proper clothing to avoid entanglement in hard hat. Read manual first.
rotating machinery.
17. Always stand clear of the load.
During the lowering operation of the winch, the friction created by the brake discs results in temperature. This
temperature is dissipated by an internal circulation flow, supplied out of the hydraulic motor or from an external
source. For models with external circulation, supply winch with approximately 2.5 (US) gpm - 9.5 l/min circulation
flow. This circulation flow must be returned directly to the reservoir with a permissible back pressure of 30 psi (2
bar).
IMPORTANT: Under no circumstances must the back pressure in the brake housing be permitted to exceed 30
psi (2 bar). Excessive pressure in the brake housing will damage the oil seal separating the brake
housing from the drum interior. Damage to this seal will cause the drum to fill up with hydraulic
fluid.
PL 8 - XX - XX - XX - X - XXXX
BASIC UNIT SERIES
SIZE OF UNIT
TYPE OF BRAKE
DESIGN REVISION
SPECIFICATION NUMBER
Describes features not identified by preceding codes
NOTE: Clockwise and counterclockwise drum rotation is the direction of rotation for pulling or hoisting,
established by looking at the hydraulic motor.
DANGER
FAILURE TO PROPERLY VENT EXTERNAL BRAKE RELEASE PORT
WILL TRAP BRAKE PRESSURE AND ALLOW THE LOAD TO DROP,
CAUSING PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
WINCHES SUPPLIED WITH EXTERNAL RELEASE OPTION
MUST BE CONNECTED ACCORDING TO TYPICAL HYDRAULIC CIRCUIT.
DRUM GROOVING:
Cable drums for the PULLMASTER Model PL8 planetary winch can be grooved. Where this option is a requirement,
it is necessary to state the size of wire rope which is to be used with the winch.
The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements.
PERMISSIBLE PRESSURE
AT CIRCULATION RETURN PORT: 30 psi 2 bar
M
DRU
1720 119
LL
FU
UM
DR
RE
BA
1290 89
860 60
430 30
0 0
0 1200 2400 3600 4800 6000 7200
LINE PULL - lb
32 121
OIL VOLUME - (US)gpm
16 60
8 30
0 0
0 27 54 81 108 135 162
Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with 1/2 inch diameter
wire rope.
CIRCULATION
RETURN LINE
(MUST GO
DIRECT TO
RESERVOIR)
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
PRESSURE
RELIEF VALVE
FILTER
HYDRAULIC
PUMP
RESERVOIR
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. It is therefore very important that the following instructions are
observed when a PULLMASTER planetary winch is installed:
1) Make certain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted.
2) Set the winch on the mounting platform and check for surface contact on all mounting pads of the winch.
3) If there is a space between the mounting surface and one of the mounting pads, the mounting surface is not
even and the space below the mounting pad must be shimmed. If this condition exists, proceed as follows:
a) Install mounting bolts snug tight on the three mounting pads which are in contact with the mounting
surface. For mounting bolt size and grade see INSTALLATION DIMENSIONS.
b) Measure the space underneath the fourth mounting pad with a feeler gauge and use shim stock of
equivalent thickness in the space between the mounting pad and the mounting surface.
c) Only after this procedure, should the fourth mounting bolt be installed. Tighten all four bolts as per BOLT
TORQUE CHART.
4) Fill the winch with lubricating oil. (See APPENDIX A for oil volume required).
6) The circulation return line of the winch should be plumbed in such a manner that the brake housing remains full
of oil at all times. Connect the return line directly to reservoir. Do not connect to a common return line.
7) Before operating the winch with a load, verify adequate circulation flow through the circulation return line as
stated in TYPICAL HYDRAULIC CIRCUIT. Verify that pressure measured at the circulation supply port does
not exceed the permissible pressure stated in SPECIFICATIONS. Winches equipped with the internal
circulation option will supply circulation flow only when the winch is run in the lowering direction.
8) If, after new installation, the winch does not function properly, refer to the TROUBLESHOOTING section of
this manual.
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. are not part of the winch and are not covered by this manual.
Refer to manufacturer’s handling, inspection and maintenance recommendations to avoid
potential accidents. For selection of ropes, etc. please check following product standards: 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 counterclockwise when looking at the hydraulic
motor of the unit. It is critical to select the cable anchor slot which will permit winding of the wire rope on the
drum in the correct direction of rotation. If the wire rope is wound on the cable drum in the wrong direction of
rotation, the winch will have no braking capacity. Each winch is shipped from the factory with a label on the drum,
indicating the correct cable anchor slot.
2) On wire rope installation, care must be taken that the wire rope is wrapped completely around the cable anchor
and properly pulled into the cable anchor slot in the cable drum. The cable drum requires 5 wraps of wire rope
for safety.
3) The winch operation is controlled by a single control valve lever which has a forward, a reverse and a neutral
position. Speed control in either direction is obtained by modulation of the control valve lever. Maximum line
speed in either direction is obtained when the control valve lever is moved as far as it can go. The disc brake
of the winch will come on automatically when the winch control lever is returned to neutral.
4) Always warm up equipment prior to operating winch, particularly in low ambient temperature. Circulate
hydraulic oil through the winch control valve for several minutes to warm the hydraulic system. To prime the
winch with warm oil, operate the winch at slow speed, forward and reverse, several times.
5) Prevent corrosion damage to winch interior. If not used regularly, run winch up and down at least once every
two weeks.
6) To ensure proper winch installation and function, raise and lower a full test load to a safe height before using
winch for regular operation at the start of each shift.
If, after a new installation, the winch does not function properly, refer to the TROUBLESHOOTING section
of this manual.
IMPORTANT:
The hydraulic oil volume relates to the line speed or rpm of the winch.
Therefore, if the winch does not produce the specified maximum rated line speed or drum rpm, a loss of hydraulic
flow somewhere in the hydraulic circuit can be analysed. If this condition exists, install a flow meter into the
hydraulic circuit to check the volume of oil supplied to the pressure port of the hydraulic winch motor when the
winch control is completely opened. The flow meter should indicate the maximum operating volume. If this test
indicates a loss of hydraulic flow, check the hydraulic pump, the relief valve and the control valve. If the pump
is driven by V-belts, check for belt slippage.
The hydraulic pressure relates to the pulling capacity of the winch.
If the winch will not produce the specified maximum line pull, install a pressure gauge in the pressure line leading
to the hoisting port on the hydraulic winch motor. Stall the winch to prevent rotation of the drum and then open
the control valve. Check the hydraulic pressure reading of the installed pressure gauge. If the pressure reads
below the specified maximum operating pressure, look for trouble in the hydraulic pump, the relief valve and
the control valve. If the hydraulic pump is driven by V-belts, check for belt slippage. When checking oil pressure
and volume in the hydraulic circuit, make sure that the hydraulic reservoir is filled to the top level and the
hydraulic pump is running at maximum operating rpm.
Only after the hydraulic system has been checked and found to be in order, use the following indications for
probable causes of failure in the winch:
Winch will not produce line speed at maximum a) Winch is mounted to an uneven surface.
volume as listed in SPECIFICATIONS. (See INSTALLATION INSTRUCTIONS.)
b) Cable sheaves or block purchase operated with the
winch are not turning freely.
c) Damage or wear in the hydraulic motor.
d) Excessive back pressure in the hydraulic circuit.
Winch will not reverse. a) Leakage out of the brake piston prevents the disc brake
from being released against the brake springs. This is
caused by damaged O-ring seals on the brake piston.
b) Insufficient hydraulic pressure. (See SPECIFICATIONS
for minimum operating pressure.)
c) Winch is mounted to an uneven surface.
(See INSTALLATION INSTRUCTIONS.)
d) Hydraulic pressure is not reaching the brake piston due
to plugged passages.
Brake vibrates when lowering a load. a) Pump is too slow. Pump rpm must be maintained at
normal operating speed when a load is lowered.
b) Brake is running too hot. This is caused by a complete
lack of, or insufficient circulation flow. To check the
circulation, observe the flow of oil from the circulation
return line of the winch (approx. 2-3 (US) gpm (8-11 l/
min) when the winch is reversed.
c) Control valve for the winch operation has poor metering
characteristics.
d) Damaged brake plates or divider plates.
e) The over-running clutch, which connects the motor
shaft with the brake assembly, is damaged.
f) Air has mixed with hydraulic oil resulting in foamy oil.
Oil leaks. a) Oil leaks from the motor flange are caused by a
damaged O-ring seal on the motor flange.
b) Oil leaks occurring between the cable drum flanges
and housing are caused by excessive pressure in the
brake housing. Excessive pressure in the brake housing
will damage the oil seal between the brake housing and
cable drum interior.
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model PL8 winch.
DISASSEMBLY:
For the majority of required service or repair work, disassembly is required only on the brake housing of the
PULLMASTER Model PL8 planetary winch. There are no special tools needed for the service or repair work and
no adjustments or calibrations are necessary. Proceed with the disassembly as follows:
DANGER
MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES
THE MOTOR DRIVE SHAFT AND BRAKE HUB, WILL RESULT IN
BRAKE FAILURE AND ALLOW THE LOAD TO DROP, CAUSING
PROPERTY DAMAGE, SEVERE INJURY OR DEATH. THOROUGHLY
INSPECT THESE AREAS AND REPLACE MOTOR DRIVESHAFT,
SPRAG CLUTCH AND BRAKE HUB AS A SET.
4) Thoroughly inspect motor drive shaft, item 730, and brake hub, item 720, particularly surfaces where sprag
clutch, item 723, engages. If any indentation or surface damage is detected, replace brake hub, sprag clutch
and motor drive shaft as a set.
5) Pull the brake piston, item 750, out of brake housing using two 7/16-14NC bolts screwed into two puller holes
in piston and discard O-rings, item 751 and item 753.
6) Thoroughly examine inner bores of the brake housing and outer diameters of the 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. SOLVENT MAY
DAMAGE THE FRICTION PLATES. DO NOT USE SOLVENT TO CLEAN
THE FRICTION PLATES. PERFORM THOROUGH INSPECTION AND
REPLACE FRICTION AND DIVIDER PLATES AS A SET.
7) Remove four friction plates, item 715, together with five divider plates, item 714, and inspect for damage or wear.
Plates should be flat and smooth. Plates should not show heat discoloration. Paper material on friction plates
should be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
9) Remove oil seal, item 711, and backup washer, item 710, and discard.
All parts have now been removed from brake housing and there is no need for further disassembly unless a failure
has been analyzed in the remaining winch assembly.
1) Remove pipe plug, item 503, from cable drum, item 500, to drain lubricating oil from winch interior.
2) Remove eight capscrews, item 971, and lockwashers, item 973. Remove two tie bars, item 970. Stand winch
upright on its end housing.
3) Remove six capscrews, item 537, and lockwashers, item 541, through access opening in brake housing. Lift
brake housing with bearing flange assembly out of cable drum, item 500. Remove and discard O-ring, item 539.
4) Pull bearing flange, item 530, and ball bearing, item 533, off of brake housing, item 700.
5) Remove circlip, item 535. Push ball bearing, item 533, out of bearing flange. Inspect and replace if damged.
7) Inspect planet hub stopper, item 704, for damge or wear and replace if less than 0.13 inch thick.
10) Inspect planet hub stopper, item 402, for damage or wear and replace if less than 0.13 inch thick.
11) Inspect three primary planet gears, item 420, for damage or wear. If it is necessary to remove 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 or worn.
12) Remove final sungear, item 340, with circlip, item 341, and sungear stopper, item 344. Inspect stopper for
damage or wear. If stopper protrudes less than .03 inch from sungear, stopper should be replaced.
2) Inspect three final planet gears, item 320, for damage or wear. If it is necessary to remove planet gears, remove
circlip, item 311, and press planet pin, item 310, out of the final planet hub, item 300. Inspect seventeen loose
rollers, item 323, and two thrust washers, item 321, and replace if damaged.
3) Pull the end housing, item 100, out of the cable drum ball bearing, item 507.
4) Remove circlip, item 513. Push ball bearing, item 507, out of the cable drum. Inspect and replace if damaged.
REASSEMBLY:
Thoroughly clean all parts. Use only new, well-greased O-rings and oil seals. Unless otherwise specified, torque
fasteners per BOLT TORQUE CHART at back of manual.
1) Press a new, well-greased oil seal, item 505, into cable drum, item 500.
2) Press ball bearing, item 507, into cable drum and secure with circlip, item 513.
3) Press end housing, item 100, into the cable drum ball bearing, item 507.
4) Reassemble final planet hub assembly. Use grease to temporarily hold 17 loose rollers, item 323, in the bore
of the planet gear, item 320. Position thrust washers, item 321, on either side of the planet gear and press planet
pin, item 310, into the final planet hub, item 300. Retain with circlip, item 311.
5) Insert final planet hub assembly into the cable drum. Ensure that the planet hub spline is fully engaged.
1) Press a new, well-greased oil seal, item 531, into the bearing flange, item 530. Press ball bearing, item 533,
into bearing flange and install circlip, item 535. Press bearing flange assembly onto brake housing hub.
2) Verify planet hub stopper, item 704, is installed on brake housing hub.
3) Verify sungear stopper, item 344, and circlip, item 341, are installd on final sungear, item 340.
5) Reassemble primary planet hub assembly. Press needle bearing, item 423, into planet gear, item 420. Position
thrust washers, item 421, on either side of planet gear and press planet pin, item 410, into the primary planet
hub, item 400. Retain with circlip, item 411.
7) Insert primary planet hub assembly into cable drum. Ensure that the final sungear, item 340, is fully engaged
with final planet gears, item 320.
9) Install new, well-greased O-ring, item 539, onto bearing flange, item 530. Lower brake housing, item 700,
complete with bearing flange assembly, into cable drum. To fasten bearing flange to cable drum, align holes
in the bearing flange with threaded holes in the cable drum. Install six capscrews, item 537, and lockwashers,
item 541, through access opening in brake housing.
10) Use eight capscrews, item 971, and lockwashers, item 973, to secure tie bars, item 970.
2) Press new, well-greased oil seal, item 711, and back-up washer, item 710, into brake housing bore.
3) Install sprag clutch, item 723, and sprag clutch spacer, item 726, into bore of brake hub, item 720. Position sprag
clutch aligners, item 722 and 724, and support washer, item 717, on either side of brake hub. Carefully slide
motor drive shaft, item 730, into brake hub assembly and secure with circlip, item 727.
IMPORTANT: For proper brake function, verify that the brake hub rotation is correct. When
viewed from the motor end, the motor drive shaft of a counterclockwise hoisting winch
must turn freely clockwise and lock in the counterclockwise direction.
4) Install motor drive shaft assembly, carefully twisting shoulder of shaft through oil seal, item 711. Ensure that
oil seal is not damaged as motor drive shaft is installed.
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. REASSEMBLE PER INSTRUCTIONS
5) Install brake spacer, item 712, into brake housing, item 700. Starting and finishing with divider plate, alternately
install five divider plates, item 714, and four friction plates, item 715.
6) Install new, well-greased O-rings, item 751 and 753, into piston glands, item 750. Carefully install brake piston
in brake housing.
7) Install 10 brake springs, item 752, into the 12 holes of brake piston, leaving two holes vacant opposite each
other.
8) Use grease to temporarily hold a new O-ring, item 801, into recess on the flange of motor adapter, item 800.
Install new, well-greased O-ring item 707, onto motor adapter pilot.
9) Position motor adapter, with brake release pressure transfer holes of motor adapter and brake housing aligned.
Tighten 12 capscrews, item 821, and lockwashers, item 823, one turn at a time to evenly compress springs.
IMPORTANT: Before operating the winch, add lubricating oil up to the level of the end housing oil fill port.
(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
LIFTING A LOAD WITH A NEWLY SERVICED WINCH WILL
ENABLE AN INSTALLATION OR SERVICE PROBLEM TO GO
UNDETECTED AND ALLOW THE LOAD TO DROP CAUSING
PROPERTY DAMAGE, SEVERE INJURY OR DEATH. TO ENSURE
PROPER REINSTALLATION, REFER TO PROCEDURES AND
TESTS DESCRIBED IN “INSTALLATION” AND
“OPERATING INSTRUCTIONS”.
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.
4) Clean all parts and inspect for wear and damage as per instructions. Replace worn or damaged
parts as required.
6) Follow INSTALLATION and OPERATING INSTRUCTIONS when returning winch to its mounting.
When ordering parts for the PULLMASTER Model PL8 planetary winch, always quote the complete model and serial
numbers of the unit.
PULLMASTER WINCH CORPORATION reserves the right to change specifications and the design of
PULLMASTER planetary winches at any time without prior notice and without incurring any obligations.
Refer to PAGE 22 for motor seal kit and PAGE 26 for ASSEMBLY DRAWING.
310 321 323 313 411 410 421 423 420 413
502
503
402
311
320
340
101
100
505
507
513
520
344
300 500 341 440 704 400 535 533 531 530 539 541 537
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.
Refer to PAGE 20 for winch seal kit and PAGE 26 for ASSEMBLY DRAWING.
Item 723 - Was Part No. 25071 (Borg Warner sprag clutch # X13143 - Qty. 2)
Item 726 - Omitted
271 REV.950401
717 723 724 712 715 714 752 751 804 801 805 809 807 800 802 803 950
710 953
929
869
951
955
970
971
973
877
899
BRAKE GROUP
870
875
887
730 885
733 711 722 720 726 727 700 750 703 753 707 823 821 865 731 861 881
Group drawings may reference more parts than are actually present in a specific assembly. Parts that are referenced
G1084-B
PAGE 23
on the drawing but are not on the PARTS REFERENCE list should be ignored.
OPTIONAL EXTERNAL
BRAKE RELEASE
PAGE 24
PORT 1/8-27 NPT
C D
CIRCULATION PORT 3/8NPT COUNTER-CLOCKWISE
(EXTERNAL CIRCULATION
MODELS ONLY)
PRESSURIZE FOR
FILLER PORT FILLER PORT PRESSURIZE FOR CLOCKWISE
3/4 - 14 NPT 1/2 - 14 NPT COUNTER-CLOCKWISE ROTATION
ROTATION
MOTOR PORTS
SAE O RING BOSS
SEE MOTOR CHART
FOR SIZES
F
ø A L
E
ø B
K
M
.63
4 MOUNTING HOLES DRAIN PORT [16]
21/32 DIA [16.6]
3/4-14 NPT GAUGE PORTS
USE ø 5/8 BOLTS
1/4-18 NPT
GRADE 5 OR BETTER
1.3 R c/c
H c/c
[34]
3.2
G
[81] S
J I
INSTALLATION DIMENSIONS
Standard cable anchor is suitable for 3/8 - 9/16 inch diameter rope.
271 REV.051117
I1024-1-C
INSTALLATION DIMENSIONS
I1024-2
DRUM
CODE A B C D E F G H J K M R S
in 9.6 14.1 8.0 5.9 14.3 14.3 13.3 10.557 16.5 9.1 7.25 11.750 16.0
-1
mm 244 359 203 150 364 364 337 268.15 420 230 184.2 298.45 406
in 9.6 14.1 10.0 5.9 14.3 14.3 15.3 12.557 18.5 9.1 7.25 11.750 16.0
-2
mm 244 359 254 150 364 364 388 318.95 471 230 184.2 298.45 406
HYDRAULIC MOTORS
COMMERCIAL WM31 SERIES
-1 9.6 14.1 8.0 140 196 215 7000 5202 122 164 .5
(244) (359) (203) (43) (160) (66) (31.1) (23.1) (37) (50) (1.9)
-2 9.6 14.1 10.0 175 245 269 7000 5202 122 164 .8
(244) (359) (254) (53) (75) (82) (31.1) (23.1) (37) (50) (3.0)
* Performance specifications are based on standard hydraulic motor with 1/2 inch diameter wire rope.
ITEM
-1 20430 - 20436
-3 -4 -5 -6 -7 -8 -9 - 10
ITEM PART
NO. DESCRIPTION
PART NUMBERS
802 SHUTTLE N/A 20849 20849 N/A N/A 20849 20849 N/A
ORIFICE
804 PLUG 21720 21720 21720 21720 N/A N/A N/A N/A
1/8-27 NPT
804 PIPE PLUG N/A N/A N/A N/A 25040 25040 25040 25040
1/8-27 NPT
807 PIPE PLUG 25040 N/A N/A 25040 25040 N/A N/A 25040
1/8-27 NPT
807 PIPE N/A 25622 25622 N/A N/A 25622 25622 N/A
ADAPTOR
809 1/8 NPT N/A 25374 25374 N/A N/A 25374 25374 N/A
CAPLUG
3/8 NPT
929 CAPLUG N/A N/A N/A N/A 25393 25393 25393 25393
3/8-18 NPT
929 PIPE PLUG 25085 25085 25085 25085 N/A N/A N/A N/A
MOTOR
950 SUB-ASSY 22026 22027 22028 22029 22303 22083 22084 22304
1/4 9 12
5/16 18 24
3/8 32 43
7/16 50 68
1/2 75 102
9/16 110 149
5/8 150 203
3/4 265 359
7/8 420 569
1 640 868
1 1/8 800 1085
1 1/4 1000 1356
1 3/8 1200 1627
1 1/2 1500 2034