Pullmaster HL25 Instructions And Parts Manual Download | Manualshive

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FINAL

SUNGEAR

CABLE

DRUM

BASE

APPENDIX B

313 REV.970317

500

550 / 552

ITEM

DRUM CODE

- 1

- 2

- 3

- 4

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Summary of Contents for HL25

Page 1: ...rey 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...

Page 2: ...rmal and ordinary use and service 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 Buye...

Page 3: ...ad suspended for any extended period of time 8 Never leave a suspended load unattended 9 Winch should be maintained and operated by qualified personnel 10 Inspect winch rigging mounting bolts and hose...

Page 4: ...attached to a connecting shaft by a sprag clutch which permits free rotation of the motor drive shaft while the connecting shaft is stationary The connecting shaft is held stationary by another sprag...

Page 5: ...e control is returned to neutral position rotation stops and the disc brake applies automatically The pressure in the brake piston is vented to the reservoir by the motor spool of the winch control va...

Page 6: ...Automatic brake counterclockwise drum rotation external circulation flow HYDRAULIC MOTOR 86 Standard hydraulic gear motor WM76 12 3 in3 displacement 129 Standard hydraulic piston motor VOLVO 110 cc 6...

Page 7: ...ch may be changed by using a different displacement motor Contact the factory for performance information HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS The operating pressure of the PULLMASTER...

Page 8: ...OPERATING VOLUME 115 US gpm 435 l min 61 US gpm 231 l min MINIMUM OPERATING VOLUME 30 US gpm 114 l min 14 US gpm 53 l min DRUM TORQUE AT MAXIMUM PRESSURE 135 937 lb in 15 359 Nm DRUM RPM AT MAXIMUM V...

Page 9: ...ry winch requires a pressure relief set at the operating pressure see SPECIFICATIONS Usually a pressure relief is part of the hydraulic control valve Where this is not the case a separate pressure rel...

Page 10: ...183 600 213 700 244 800 274 900 F U L L D R U M B A R E D R U M AND LOWERING HIGH SPEED HOISTING HOISTING LINE PULL kN LINE SPEED m min LINE PULL lb OIL PRESSURE psi OIL PRESSURE bar LINE SPEED fpm OI...

Page 11: ...R U M AND LOWERING HIGH SPEED HOISTING HOISTING LINE PULL kN LINE SPEED m min 3040 3800 2280 1520 760 61 0 262 209 157 105 52 LINE PULL lb OIL PRESSURE psi OIL PRESSURE bar 0 LINE SPEED fpm 231 OIL V...

Page 12: ...AR WITH FREESPOOL OPTION FOR MODELS SUPPLIED PRESSURE REQUIRED 400 PSI 28 BAR CONTROL VALVE FAST FORWARD FILTER HYDRAULIC PUMP RESERVOIR CONTROL VALVE MOTOR SPOOL 4 WAY SPRING RETURN TO CENTER PRESSUR...

Page 13: ...FACTORY PRESET 250 PSI 800 PSI 55 BAR 2 US GPM 8 L MIN REQUIRED FOR MODELS SUPPLIED WITH EXTERNAL BRAKE RELEASE OPTION CONTROL VALVE MOTOR SPOOL 4 WAY SPRING RETURN TO CENTER 400 PSI 28 BAR PRESSURE...

Page 14: ...hten all four bolts per BOLT TORQUE CHART 4 Fill the winch with lubricating oil See APPENDIX A for oil volume required 5 Use recommended circuit components and hydraulic hoses 6 The circulation return...

Page 15: ...s 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...

Page 16: ...relief valve and the control valve Only if the hydraulic system has been checked and found to be in order use the following indications for probable causes of failure in the winch 313 REV 970317 TROU...

Page 17: ...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 circu...

Page 18: ...y to all Model HL25s DISASSEMBLY For the majority of required service or repair work disassembly is required only in the brake housing or clutch housing of the PULLMASTER Model HL25 planetary winch Th...

Page 19: ...from flange of motor adaptor REMOVAL OF HYDRAULIC PISTON MOTOR If fitted with a piston motor proceed as follows 1 Remove brake tube assembly item 852 from motor and motor adaptor item 800 2 Remove fo...

Page 20: ...nto two puller holes in piston and discard O rings item 751 and 753 3 Thoroughly examine inner bores of brake housing and outer diameters of brake piston for scoring caused by hydraulic fluid contamin...

Page 21: ...m 410 out of planet hub item 400 Inspect loose rollers item 423 and two thrust washers item 421 and replace if damaged 7 Remove primary sungear item 440 from center of connecting shaft item 600 8 Remo...

Page 22: ...l planet hub spline is fully engaged with cable drum item 500 6 Install new well greased O ring item 123 into end cover item 120 Verify that planet hub stopper item 126 and sungear stopper item 122 ar...

Page 23: ...m 735 into access plug item 734 Install access plug into access hole inside brake housing 15 Attach base halves item 500 and 552 using 28 capscrews item 551 and lockwashers item 553 REASSEMBLY OF BRAK...

Page 24: ...th drive gear item 660 IMPORTANT For proper drive function verify that sprag clutch item 672 is installed correctly When viewed from motor end motor drive shaft of a clockwise hoisting winch must turn...

Page 25: ...953 to approximately 50 ft lb 70 Nm 7 Plumb winch assembly to a hydraulic supply and torque motor capscrews according to the following procedure Ensure that circulation supply flow is being supplied t...

Page 26: ...ts mounting 2 Disassemble the winch as per instructions 3 Discard and replace all O rings and oil seals 4 Clean all parts and inspect for wear and damage as per instructions Replace worn or damaged pa...

Page 27: ...PAGE 25 PISTON MOTOR ASSEMBLY DRAWING G1000 A G1003 B G1010 E 313 REV 010201...

Page 28: ...13 3 25199 CIRCLIP ROTOR CLIP SH 168 320 3 20405 PLANET GEAR 321 6 25167 THRUST WASHER TORRINGTON TRB 2840 323 72 25297 LOOSE ROLLER TORRINGTON G613 Q 340 1 SUNGEAR 343 1 25242 CIRCLIP ROTOR CLIP SH 2...

Page 29: ...present in a specific assembly Parts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored FINAL DRIVE GROUP 313 REV 970317 552 553 551 500 503 502 105 103 104 3...

Page 30: ...IL SEAL 615 2 25296 THRUST WASHER TORRINGTON TRB 6074 617 1 25690 THRUST BEARING TORRINGTON NTA 6074 650 1 21090 CLUTCH HOUSING 651 1 25339 O RING 278 12 ID 1 8 CS 660 1 21135 DRIVE GEAR 661 1 25696 C...

Page 31: ...he drawing but are not on the PARTS REFERENCE list should be ignored G1003 B BRAKE GROUP 313 REV 970317 763 703 734 724 700 712 722 723 607 713 603 683 682 651 707 753 750 751 660 672 606 617 711 605...

Page 32: ...ANSFER TUBE ASSY INCLUDES ITEM 867 845 1 25716 O RING 906 SAE ORB 06 846 1 21114 TRANSFER TUBE HOUSING 847 2 25298 LOCKWASHER 3 8 HIGH COLLAR 848 1 21115 TUBE LOCATOR 849 2 25772 CAPSCREW SOCKET HEAD...

Page 33: ...assembly Parts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored 849 847 654 827 841 846 931 541 951 953 955 827 950 813 843 845 899 870 112 877 113 848 859...

Page 34: ...16 CS 727 1 25335 CIRCLIP ROTOR CLIP SH 196 730 1 21570 MOTOR DRIVE SHAFT 735 1 25344 O RING 123 1 3 16 ID 3 32 CS 800 1 22116 MOTOR ADAPTOR 801 3 25127 O RING 90 DURO 013 7 16 ID 1 16 CS 803 1 25370...

Page 35: ...d on the drawing but are not on the PARTS REFERENCE list should be ignored 819 939 827 931 541 805 815 817 NOTE BRAKE TUBE IS SHOWN FOR CW HOISTING FOR CCW HOISTING CONNECT TO OPPOSITE MOTOR PORT 828...

Page 36: ...CKWISE ROTATION OPTIONAL EXTERNAL BRAKE RELEASE PORT 1 8 27 NPT 4 MOUNTING HOLES 1 9 32 DIA 32 5 USE 1 1 4 MOUNTING BOLT GRADE 5 OR BETTERS CIRCULATION RETURN PORT 1 11 1 2 NPT SAE 4 BOLT FLANGE SEE M...

Page 37: ...0 0 25 9 22 875 25 9 254 610 559 308 619 530 813 749 30 1088 1148 314 254 657 581 03 657 DRUM E F G D C A H J K M N P R B Dimensions in inches Dimensions in millimeters S MOTOR GEAR MOTOR PORT SIZE I...

Page 38: ...B 173 6 8 M FREE SPOOL MODELS K A MINIMUM OF 3 TO 4 WRAPS OF WIRE ROPE MUST BE MAINTAINED AT ALL TIMES FOR SAFETY OPTIONAL EXTERNAL BRAKE RELEASE PORT 1 8 27 NPT 4 MOUNTING HOLES 1 9 32 DIA 32 5 USE...

Page 39: ...OR INCLUDES SANDWICH GAGE BLOCK MODEL NO MOTOR PORT SIZE SAE 4 BOLT FLANGE SCREW THREAD DRAIN PORT DRUM CODE E F G H J D C A K M N P R B Dimensions in inches Dimensions in millimeters S 1 10 0 17 0 11...

Page 40: ...PAGE 38 G1000 A G1003 B G1007 B GEAR MOTOR ASSEMBLY DRAWING 313 REV 010201...

Page 41: ...11 2 52 3 43 90 23 8 11 2 198 422 8 7 3 10 0 17 0 796 615 408 25000 5357 651 3 0 254 23 8 11 2 198 4 10 0 22 0 1031 528 25000 5357 2519 651 1384 3 6 254 610 559 314 243 161 111 2 52 3 43 90 23 8 11 2...

Page 42: ...PAGE 40 20409 20395 20671 20409 20396 20444 20408 20393 20443 20407 20391 20403 340 FINAL SUNGEAR CABLE DRUM BASE APPENDIX B 313 REV 970317 500 550 552 ITEM DRUM CODE 1 2 3 4...

Page 43: ...A 22054 7 8 9 10 20849 N A 25622 26276 22055 20849 N A 25622 26276 22056 N A 25040 N A N A 22057 802 807 807 809 950 1 8 27 NPT PIPE PLUG 1 8 27 NPT PIPE ADAPTOR 1 8 NPT CAPLUG PART NUMBERS BRAKE CODE...

Page 44: ...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 BOLT DIAMETER Inches TORQUE lb ft TORQUE Nm NOTE Unless otherwise specified torque bolts per...

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