Dover Pull Master PH50 Technical reference manual

PMC 338 070228
READ THIS MANUAL BEFORE INSTALLING, OPERATING OR
SERVICING THIS PRODUCT. THIS MANUAL CONTAINS IMPORTANT
INFORMATION. MAKETHISMANUALAVAILABLETOALLPERSONS
RESPONSIBLE FOR THE OPERATION, INSTALLATION, SERVICING
AND MAINTENANCE OF THIS PRODUCT.
INSTRUCTION AND PARTS MANUAL
MODEL PH50
PLANEMATIC DRIVE
THE LOGICAL CHOICE

US.DIST.01.01.07 [PULLMASTER LOGO]
Pullmaster Limited Warranty Effective 8/1/2008
SUPERSEDES 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").
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.

PAGE 1
SAFETY RECOMMENDATIONS
338 REV.990801
FAILURE TO COMPLY WITH THE FOLLOWING SAFETY
RECOMMENDATIONS AND LOCAL RULES AND
REGULATIONS COULD RESULT IN PROPERTY
DAMAGE, SEVERE INJURY OR DEATH.
WARNING
1. Do not install, operate or service Planematic drive before reading and understanding manufacturer's
instructions.
2. The Planematic drive described herein is not designed for operations involving lifting or moving
personnel.
3. Do not lift or carry loads over people.
4. Do not exceed recommended operating pressure (psi) and operating volume (gpm).
5. Do not jerk the Planematic drive. Always smoothly accelerate and decelerate load.
6. Do not operate a damaged, noisy or malfunctioning Planematic drive.
7. Do not leave a load suspended for any extended period of time.
8. Never leave a suspended load unattended.
9. The Planematic drive should be maintained and operated by qualified personnel.
10. Inspect Planematic drive mounting bolts and hoses before each shift.
11. Warm up equipment before operating Planematic drive, particularly at low ambient temperatures.
12. Do not weld any part of the Planematic drive.
13. Verify circulation return before operating Planematic drive.
14. Ensure equipment stability before operating Planematic drive.
15. Wear proper clothing to avoid entanglement in rotating machinery.
16. Always stand clear of the load.
17. Use only recommended hydraulic oil.
18. Keep hydraulic system clean and free from contamination at all times.
19. MaintainPlanematicdriveandequipmentingoodoperatingcondition.Performscheduledmaintenance
regularly.
20. In case of a power failure or breakdown leading to an unexpected stop of the hydraulic power circuit,
stand clear of the area and the load being hoisted. Take the necessary precautions to prevent access
to the area where the load is halted.
21. The noise level of the Planematic drive is 86 dBA measured on a distance of 1.00 meter, 1.60 meters
high. The measuring equipment used was: Realistic #42-3019.
22. Clean up any oil spillage immediately.
23. Wear proper clothing and personal protection equipment such as footwear, safety goggles and a hard
hat. Read manual first.

PAGE 2 338 REV.031001
The PULLMASTER Planematic drive is a high performance, highly efficient, planetary hydraulic drive with
reversing speed 4.3 times faster than forward speed.
The main components of this unit are:
✛hydraulic motor
✛brake housing
✛hydraulicallyreleasedmulti-discbrakewithstaticanddynamicfunction
✛primary planetary reduction
✛final drive housing
✛final planetary reduction
✛output shaft
FUNCTION IN FORWARD ROTATION:
Inforwardrotationthetorqueandrpm of the hydraulic motor are transmitted tothe sungearof theprimary planet
reduction. The sprag clutch which connects the motor drive shaft to the automatic brake assembly permits free
rotation in forward direction* (brake is not effective in forward direction).
Theoutputtorqueandrpmoftheprimaryreductionaretransmittedtothefinalreductionbythefinalsungearwhich
is splined to the primary planet hub. The output shaft is splined to the final planet hub. When the rotation is
stopped, the suspended load or the tension in the reverse direction causes the sprag clutch to lock and the
maximum permissible load is held safely by the disc brake. The pressure required to rotate the output shaft may
vary up to 200 psi (14 bar) without load.
* With the exception of models supplied with brake effective in both directions, brake assembly permits free
rotation in forward direction.
FUNCTION IN REVERSE ROTATION:
In reverse rotation, hydraulic pressure from the reversing side of the hydraulic motor is channelled to the brake
piston,causingthebrake piston to release the multi-discbrakeagainstthebrakesprings.Thespragclutchlocks
motor drive shaft with the connecting shaft. Connecting shaft coupled with brake hub and primary internal gear
causes the primary reduction to rotate at the rpm of hydraulic motor, thus eliminating the primary reduction.
Eliminationofprimaryreductioninthismannerincreasestheoutputshaftspeedanddecreasestheoutputtorque
4.3timesofforwarddirection.Basedonstandardmotor,pressurerequiredtorotatetheoutputshaft,withoutload
depending upon speed, may vary from 450 to 750 psi (31 to 52 bar).
If the applied load drives the Planematic faster than desired, the motor consumes more oil than is supplied and
pressure at the reversing port decreases. The brake partially applies and slows the drive. In this manner, the motor
continuously regulates brake pressure to safely and smoothly control the load without counterbalance or holding
valves.
The partially applied brake results in temperature. This temperature is dissipated by an internal circulation flow,
suppliedoutofthehydraulic motororfromanexternalsource.Formodelswithexternal circulation,requiredflow
is approximately 4.5 (US) gpm (17 l/min). The circulation return line must go to the reservoir directly.
IMPORTANT: For proper drive function, system back pressure in the brake housing and at the motor return
port must never exceed the allowable limits listed in the SPECIFICATIONS section of this
manual.
DESCRIPTION OFTHE MODEL PH50

PAGE 3
338 REV.990801
MODEL PH50
PH50 X - XX - XXX - XX X - X XXX
BASIC UNIT
P = Planematic drive
TYPE OF UNIT
H = High speed reverse
SIZE OF UNIT
50 = 50,000 lb-in output torque
REDUCTION RATIO
Used for non standard reduction ratios only
TYPE OF BRAKE
(Clockwise & counterclockwise rotation of shaft established by looking at the motor)
-3 Automatic brake*, clockwise shaft rotation, internal circulation flow
-4 Automatic brake*, clockwise shaft rotation, external brake release,
internal circulation flow
-5 Automatic brake*, counterclockwise shaft rotation,
external brake release, internal circulation flow
-6 Automatic brake*, counterclockwise shaft rotation,
internal circulation flow
-7 Automatic brake*, clockwise shaft rotation, external circulation flow
-8 Automatic brake*, clockwise shaft rotation, external brake release,
external circulation flow
-9 Automatic brake*, counterclockwise shaft rotation,
external brake release, external circulation flow
-10 Automatic brake*, counterclockwise shaft rotation,
external circulation flow
-11 Brake effective in both directions, external circulation flow
-17 Brake effective in both directions, external circulation flow,
external brake release
*Automatic brake = spring applied, automatically released by the hydraulic
pressure of the motor
HYDRAULIC MOTOR
-97 WM51 hydraulic motor, 2 inch gear section, 5.1 cid
OUTPUT SHAFT
-1 splined output shaft, 29 teeth, 10/20 DP ( STANDARD)
-2 keyed output shaft, 3.00 diameter 3/4 inch square key
-3 splined output shaft with inboard flange adaptor
-4 splined output shaft with outboard flange adaptor
-5 splined output shaft, 22 teeth, 10/20 DP
-6 splined output shaft, 23 teeth, 2 x 1/2NC
OPTIONS
Absence of a letter denotes no options supplied with the drive
DESIGN REVISION
This letter for factory use only
SPECIFICATION NUMBER
Describes features not identified by preceding codes
MODEL CODING FOR PLANEMATIC DRIVE

PAGE 4
OPTIONS
338 REV.990801
REDUCTION RATIO:
The reduction ratio of the standard PULLMASTER Planematic drive is 41.2:1. Drives with different reduction
ratios and altered output performances are optionally available.
TYPE OF BRAKE:
ThestandardPULLMASTERPlanematicdriveoutputshaftrotatesforwardinclockwisedirectionasviewedfrom
the motor end of the unit. Standard brake is effective only during reverse rotation and automatically functions
during operation.
Drives with counterclockwise forward rotation and drives with brake effective in both directions are optionally
available. Drives with porting to allow brake release from an external power source are optionally available.
OUTPUT SHAFT:
The standard PULLMASTER Planematic drive has a 29 teeth, 10/20 DP splined output shaft. Drives with keyed
or splined output shafts or adaptor flanges are optionally available.
OPTIONAL GEAR SECTION FOR THE HYDRAULIC MOTOR:
The performance of the standard PULLMASTER Planematic drive can be changed by using different gear
sections. (Contact the factory for performance information.)
HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS:
The operating pressure of the standard PULLMASTER Planematic drive is limited to 2200 psi (152 bar). For
hydraulicsystemsoperatingwithahigherrange of hydraulic pressure, the drive can besupplied witha hydraulic
piston motor, which will provide for the same basic performance. (Contact the factory for this requirement.)
The PULLMASTER WINCH CORPORATION may consider other options for quantity requirements.
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. PLANEMATIC DRIVES SUPPLIED
WITH EXTERNAL RELEASE OPTION MUST BE CONNECTED
ACCORDING TO "TYPICAL HYDRAULIC CIRCUIT".
DANGER

PAGE 5
338 REV.990801
SPECIFICATIONS
Performance specifications are based on standard hydraulic motor and gear ratio. Performance specifications
for Planematic drives supplied with optional motors and/or reductions are provided in attached supplement.
MAXIMUM OUTPUT TORQUE:
Forward: 50,000 lb-in 5649 Nm
Reverse: 11,630 lb-in 1314 Nm
MAXIMUM OUTPUT RPM:
Forward: 48 rpm
Reverse: 208 rpm
MAXIMUM OPERATING PRESSURE: 2200 psi 152 bar
MAXIMUM OPERATING VOLUME: 50 (US) gpm 189 l/min
MINIMUM OPERATING VOLUME: 17 (US) gpm 64 l/min
REDUCTION RATIO:
Forward: 41.2 : 1
Reverse: 9.5 : 1
OUTPUT SHAFT: Axial or Radial load See OVERHUNG LOAD RATING
PERFORMANCE AT VARYING
PRESSURE OR VOLUME: See PERFORMANCE GRAPHS
PERMISSIBLE SYSTEM BACK PRESSURE
AT MOTOR RETURN PORT: 65 psi 4.5 bar
PERMISSIBLE PRESSURE
AT CIRCULATION SUPPLY PORT: 30 psi 2 bar
CIRCULATION OIL VOLUME:
Models with external circulation 4.5 gpm 17 l/min

PAGE 6 338 REV.990801
OVERHUNG LOAD RATING
PG-50-OH
T
y
L
L = c x SF
(y + a) AF
Allowable thrust or tension load in lbs. = T x SF
= lbs
The magnitude and location of a load is dependent on the following factors:
SF = service factor (Table A)
AF = application factor (Table B)
a = bearing geometry constant = -3.10
T = basic thrust or tension load = 25,300
c = basic load constant = 51,000
L = allowable overhung load in lbs.
y = distance of load centre to mounting face in inches
up to full load occasionally
Intermittent duty at variable loads,
3 hr. day, intermittent duty, full load
8 hr. day, continuous duty, full load
24 hr. day, continuous duty, full load 0.75
1.00
1.50
2.68
1.00
1.25
1.50
2.50
Chain drive
Gear
V-belt
Flat belt
TABLE A TABLE B

PAGE 7
PG-PH50
338 REV.990801
PERFORMANCE GRAPHS
OUTPUT TORQUE VS. OIL PRESSURE
OUTPUT RPM VS. OIL VOLUME
Performance graphs are based on standard hydraulic motor and gear ratio.
FORWARD
REVERSE
FORWARD
REVERSE
210180150120906030
4519
40,000
3390
30,000
2260
20,000
1130
10,000
1382000
1101600
831200
55800
28400
OUTPUT TORQUE - Nm
2200
0
50
40
30
20
10
0
50,0000
0 5649152
0
OUTPUT TORQUE - lb.in.
OIL PRESSURE - psi
OIL PRESSURE - bar
0
0
OUTPUT RPM
38
76
114
151
189
OIL VOLUME - (US)gpm
OIL VOLUME - l/min

PAGE 8
HC-PMH50-A
338 REV.031001
TYPICAL HYDRAULIC CIRCUIT
BRAKE RELEASE OPTION
SUPPLIED WITH EXTERNAL
REQUIRED FOR MODELS
2(US)GPM [8 L/MIN]
800 PSI [55 BAR]
FILTER
PUMP
HYDRAULIC
RESERVOIR
RETURN TO CENTER
4-WAY SPRING
(MOTOR SPOOL)
CONTROL VALVE
RELIEF VALVE
PRESSURE
TO RESERVOIR)
(MUST GO DIRECT
CIRCULATION RETURN LINE
MODELS ONLY
EXTERNAL CIRCULATION
PH50: 4.5 (US) GPM [17 LPM][
PM50: 3.5 (US) GPM [13 LPM]
CIRCULATION SUPPLY LINE

PAGE 9
338 REV.990801
RECOMMENDATIONS
HYDRAULIC PRESSURE RELIEF:
The hydraulic circuit for the PULLMASTER Planematic
drive 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 relief valve must be
installedandsetattherecommendedmaximumpressure.
HYDRAULIC RESERVOIR:
It is recommended that the hydraulic reservoir has
sufficient capacity to provide good heat dissipation in
order to prevent over-heating of the hydraulic fluid. The
hydraulic reservoir should be made from clean and
scale-free material to prevent contamination of the
hydraulic fluid. In order to prevent air from being mixed
with the hydraulic fluid, the reservoir should have an
over-flow baffle separating the return lines from the
suctionlineandallreturnlinesshouldenterthereservoir
below the fluid level. The reservoir should be mounted
close to and above the hydraulic pump in a location
whichprovidesforfreeaircirculationaroundthereservoir.
HYDRAULIC HOSES:
The following hydraulic hoses are recommended for
maximum efficiency of the PULLMASTER Planematic
drive:
Pressure lines: Equivalent to SAE 100R12-20
Circulation return line: Equivalent to SAE 100R4-12
Circulation supply line:* Equivalent to SAE 100R6-6
* Only for models with external circulation.
It is recommended that a larger size of hydraulic hose
is installed where the pressure lines or the circulation
lines are excessively long.
HYDRAULIC FILTER:
Hydraulicfilterrecommendationsforthehydrauliccircuit
of the PULLMASTER Planematic drive, based on a
return line filter, are given as follows:
Average Atmosphere: 10 microns
Dusty Atmosphere: 5 microns
In order to prevent accidental stoppage of the return
line flow, the oil filter should have a by-pass feature.
HYDRAULIC FLUID:
ThehydraulicfluidselectedforusewithPULLMASTER
Planematic drives should be a high grade, petroleum
based fluid, with rust, oxidation and wear resistance.
Fluid cleanliness and operating viscosity are critical to
drive reliability, efficiency and service life.
Foroptimumperformance,therecommendedviscosity
rangeatoperatingtemperatureis81-167SUS(16-36
CS).Forextremeoperatingconditionsofshortduration,
the maximum viscosity range of 58 - 4635 SUS (10 -
1000 CS) should not be exceeded.
For optimum performance, the drive recommended
hydraulic fluid temperature operating range is 80 -
150F (27 - 66 C). For extreme operating conditions of
shortduration,themaximumtemperaturerangeof-5 -
180F (-21 - 82 C) should not be exceeded.
LUBRICATION:
The Planematic drive mechanism requires an oil bath
lubrication of the internal components. Depending on
themodelcode,circulation is supplied internally by the
motor or externally (see TYPICAL HYDRAULIC
CIRCUIT). If the unit is internally circulated, fill the
Planematic with hydraulic oil through one of the filler /
drain ports before operating.
HYDRAULIC PUMP:
For maximum performance of the PULLMASTER
Planematic drive, the hydraulic pump must supply the
maximumflowofhydraulicfluidatthehydraulicpressure
stated in SPECIFICATIONS.
HYDRAULIC CONTROL VALVE:
The standard control valve used for operating the
PULLMASTER Planematic drive must have a four-
way,spring returntoneutralfeature,whichprovidesfor
open flow from the pressure ports of the drive to the
reservoir in neutral position of the control (motor
spool). It is important to point out that good speed
control depends on the "metering" characteristics of
thecontrolvalve.Thebettertheoilflowis"metered"the
better will be the speed control.

PAGE 10
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS
WILL RESULT IN PROPERTY DAMAGE,
SEVERE INJURY OR DEATH.
To ensure satisfactory operation, the PULLMASTER Planematic drive must be properly installed. Observe the
following installation instructions:
1) The Planematic drive mounting structure must be strong enough to withstand operating torques without
excessive deflection.
2) The Planematic drive mounting surface and pilot bore must be machined.
3) Position the Planematic drive using a lifting eyebolt in the tapped hole provided.
4) Useeight3/4inchdiametermountingbolts (grade 5 or better). Evenly tighten boltsper BOLTTORQUE CHART.
5) Use only recommended circuit components and hydraulic hoses.
6) Plumb a separate circulation return line directly to tank. Keep the return line above the drive to maintain
housing oil level at all times.
7) Fill Planematic drive housing with oil through filler/drain port before operating. Units ported for external
circulation can be filled through circulation supply line.
IMPORTANT: System brake housing back pressure must never exceed the limit allowed in the
SPECIFICATIONS section of this manual.
BeforeloadingthePlanematicdrive,verifyadequatebrakecirculationflowbycheckingatthe
circulation return line port while driving in reverse direction.
338 REV.990801
INSTALLATION INSTRUCTIONS
DANGER

PAGE 11
OPERATING INSTRUCTIONS
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS
WILL RESULT IN PROPERTY DAMAGE,
SEVERE INJURY OR DEATH.
DANGER
Verifyproperinstallation,acceptablesystembackpressureandadequatebrakecirculationflowbeforeoperating
the Planematic drive.
1) ThestandardPlanematicdrivebrakeappliesonlyincounterclockwiserotationasviewedfromthemotorend
oftheunit.Thedrivehasnobrakeduringclockwiserotation.Ensurebrakeoptionisappropriateforparticular
application.
2) The Planematic drive hydraulic motor is supplied through a single lever control valve with reverse, neutral
and forward positions. Drive speed is regulated by metering the control valve lever. Standard brake
automatically releases when driving in reverse direction and sets when control valve lever is returned to
neutral position.
Refer to OPTIONS section of this manual for explanation of optional brake configurations.
3) Verify installation and connection by slowly driving a full test load through a safe distance, forward and
reverse. Complete functional test by driving test load at full speed, forward and reverse, several times.
If Planematic drive does not function properly after following above procedure, refer to TROUBLESHOOTING
section of this manual.
338 REV.990801

PAGE 12
PROBABLE CAUSE
FAILURE
GENERAL:
Typical Planematic drive operating problems are caused by a malfunctioning hydraulic system. Verify hydraulic
pressure and flow at the drive motor are as specified before dismounting or disassembling Planematic.
IMPORTANT: Ensure that the hydraulic system reservoir is full and that the system pump is running at
full rpm before doing any system checks.
HYDRAULIC SYSTEM VOLUME AND PLANEMATIC SPEED:
ThePlanematicoutputspeeddependsonthehydraulicflowsuppliedtothedrivemotor.Maximumoutputspeed
and required hydraulic volume appear in the SPECIFICATIONS section of this manual. If the Planematic does
not rotate at desired output speed, install a flow meter at the drive motor forward port. Fully open control valve
and measure hydraulic flow. Verify hydraulic operating volume as specified.
HYDRAULIC SYSTEM PRESSURE AND PLANEMATIC TORQUE:
The Planematic output torque depends on the hydraulic pressure supplied to the drive motor. Maximum output
torqueandrequiredhydraulicpressureappearintheSPECIFICATIONSsectionofthismanual.IfthePlanematic
does not produce desired output torque, install pressure gauges at both drive motor gauge ports. Stall the drive,
fully open control valve and measure hydraulic pressure at motor ports. Verify hydraulic operating pressure and
maximum allowable motor return port back pressure as specified.
Sources of potential hydraulic flow and/or pressure loss include the hydraulic pump, relief control valves and
slipping belts on a v-belt driven pump.
If the hydraulic volume and pressure are per specification, refer to the following TROUBLESHOOTING chart to
identify failure probable causes.
TROUBLE SHOOTING
Drivewillnotproducemaximumratedtorqueas
listed in SPECIFICATIONS.
a) Hydraulic system supply pressure or back pressure not
per SPECIFICATIONS. Refer to procedure described in
TROUBLE SHOOTING - HYDRAULIC SYSTEM
PRESSURE AND PLANEMATIC TORQUE to verify
system pressures.
b) Damaged or worn hydraulic motor.
a) Hydraulicsystemsupplyvolume,supplypressureorback
pressurenotperSPECIFICATIONS.Refertoprocedures
described in TROUBLE SHOOTING - HYDRAULIC
SYSTEM VOLUME AND PLANEMATIC SPEED and
HYDRAULICSYSTEMPRESSUREANDPLANEMATIC
TORQUE to verify system pressures and volumes.
b) Damaged or worn hydraulic motor.
a) Leaking brake piston O-ring. Both piston O-rings must
seal to develop hydraulic brake release pressure.
b) LeakingbrakereleasepressureportO-ring.O-ringislocated
on the motor adaptor and seals release oil pressure at the
brake housing. Failure of this O-ring results in significant
leakage between the motor adaptor and brake housing.
c) Hydraulic brake release pressure not per
SPECIFICATIONS. Gauge release pressure at external
brake release port on motor adaptor.
d) Pluggedbrakereleasepressureport.Hydraulicpassages
in the motor adaptor and brake housing must be clear to
allow oil passage to reach brake piston.
338 REV.990801
Drive will not produce rated speed or rpm as
listed in SPECIFICATIONS.
Drive will not reverse (brake will not release).

PAGE 13
FAILURE PROBABLE CAUSE
TROUBLE SHOOTING CONTINUED
Brake will not hold load.
Brake vibrates or chatters when lowering load.
a) HydraulicsystembackpressurenotperSPECIFICATIONS.
Refer to procedure described in TROUBLE SHOOTING -
HYDRAULIC SYSTEM PRESSURE AND PLANEMATIC
TORQUE to verify system back pressure at motor.
b) Brakepistonreleaseoilbeingtrappedbyhydraulicsystem
controlvalve.Controlvalvespoolmustopenmotorportsto
reservoir when in the neutral position. Refer to
RECOMMENDATIONS-HYDRAULICCONTROLVALVE.
c) Worn brake and/or divider plates. Inspect brake plates and
divider plates for wear as described in SERVICE
INSTRUCTIONS-DISASSEMBLYOFBRAKEASSEMBLY.
d) Damaged brake and/or divider plates. Plate discolouration
and distortion will occur if plates overheat due to insufficient
circulation flow. Required brake circulation flow is listed in
SPECIFICATIONS. Plate abrasion damage will occur if
contamination is present in hydraulic fluid.
e) Damaged over-running clutch. Inspect sprag clutch,
connecting shaft and motor drive shaft as described in
SERVICEINSTRUCTIONS-DISASSEMBLYOFBRAKE
ASSEMBLY.
f) Damaged brake springs. Measure brake springs as
describedinSERVICEINSTRUCTIONS-DISASSEMBLY
OF BRAKE ASSEMBLY. Verify springs are straight and
length is as indicated.
g) Seized brake piston. Brake piston could be seized by
hydraulicfluidcontamination,scoredbrakehousingboreor
damaged piston O-rings.
a) Inadequatehydraulicflow.Refer toprocedure describedin
TROUBLESHOOTING-HYDRAULICSYSTEMVOLUME
AND PLANEMATIC SPEED to verify supply.
b) Inadequate hydraulic control. System control valve must
have good metering characteristics.
c) Foamy hydraulic fluid. Foam will occur if air is mixed with
hydraulic oil.
d) Worn brake and/or divider plates. Inspect brake plates and
divider plates for wear as described in SERVICE
INSTRUCTIONS-DISASSEMBLYOFBRAKEASSEMBLY.
e) Damaged brake plates and/or divider plates. Plate
discolouration and distortion will occur if plates overheat
duetoinsufficientcirculationflow.Requiredbrakecirculation
flowislistedinSPECIFICATIONS.Plateabrasiondamage
will occur if contamination is present in hydraulic fluid.
f) Damagedover-runningclutch.Inspectspragclutch,connecting
shaft and motor drive shaft as described in SERVICE
INSTRUCTIONS-DISASSEMBLYOFBRAKEASSEMBLY.
a) Damaged O-ring. Static O-rings seal between the end
cover and final housing, final housing and brake housing ,
brake housing and motor adaptor. Another O-ring seals
brake release pressure between the motor adaptor and
brake housing. A failed O-ring will result in oil leakage at
that particular area.
b) Worn or damaged output shaft seal. Excessive circulation
return line back pressure can damage this seal. Refer to
proceduredescribedinTROUBLESHOOTING-HYDRAULIC
SYSTEM PRESSURE AND PLANEMATIC TORQUE to
measure back pressure. Back pressure must never exceed
the allowable circulation return line back pressure listed in
SPECIFICATIONS. Back pressure will be higher at start-up
and during cold weather when oil viscosity is greater.
Oil leaks.
338 REV.990801
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Planematic drive.

PAGE 14
SERVICE INSTRUCTIONS
338 REV.031001
GENERAL:
Before attempting disassembly of the PULLMASTER Model PH50 Planematic drive, the following instructions
for disassembly and reassembly should be read and understood.
Itissuggestedthatallexpendableparts,suchasO-ringsandoilseals,arenotreusedonreassembly.Itistherefore
important to have a Planematic seal kit (Part No. 23134) and, if the hydraulic motor has to be serviced, a motor
seal kit (Part No. 23121) on hand before the unit is taken apart. If working on the hydraulic motor, two new needle
bearings item 875, (Part No. 25723) are also required.
NOTES: 1) Backup washers may be included with seal kit. Install with oil seals as per instructions. If not
present in seal kit, the oil seals supplied do not require backup washers.
2) Pocketsealstripisincludedinthemotorsealkit.Pocketsealsarenotrequiredifthrustplates
are not slotted.
A clean working area is of prime importance, similar to conditions used for service work on any other hydraulic
component. Allparts,astheyareremovedfromthePlanematic assembly,shouldbecarefullyinspectedforwear
and damage. Thoroughly clean parts before reassembly. Do not use solvent to clean the brake friction plates.
During reassembly, lubricate all O-rings and oil seals before installation.
In the following service instructions, reference to parts is made by number and shown on the applicable group
drawings.
DISASSEMBLY
For the majority of required service or repair work, disassembly is required only on the brake housing of the
PULLMASTERPlanematicdrive.Therearenospecialtoolsneededforserviceorrepairworkandnoadjustments
or calibrations are necessary. Proceed with the disassembly as follows:
DISASSEMBLY OF HYDRAULIC MOTOR ASSEMBLY:
If the analysed service or repair work requires access to the interior of the brake housing, the hydraulic motor
shouldnotbedisassembled.Inthiscase,thehydraulicmotorshouldberemovedtogetherwiththemotoradaptor
as a complete assembly. If a problem has been analysed to be in the hydraulic motor, proceed with the
disassembly as follows:
Refer to PARTS REFERENCE on page 26 and MOTOR GROUP drawing G1033 on page 27.
1) Remove four hex capscrews item 951, together with lockwashers item 953, from motor assembly.
NOTE: Failuretoexercisecarewhenremovingthemotorportendcoverorgearhousingcouldpermanently
damage the machined surfaces of these motor components. Take care not to damage machined
surfaces of motor components at disassembly.
2) Remove (pry loose if necessary) port end cover item 870, together with bearings item 875, and ring seal
item 877. Thrust plate item 885, and dowel pins item 865, may stay in gear housing.
3) Ifthrustplatecomesoffwithendcover,carefullypryitoffofbearingsitem875,anddiscardpocketsealsitem
887.
4) Remove gear set item 881, which consists of two gears which are a matched set.
5) Carefully pry gear housing item 861, off of motor adaptor item 800. Thrust plate item 885, and dowel pins
item 865, may stay in gear housing.
6) Ifthrustplate stayedonmotoradaptor, carefullypryitoffofbearingsitem875,anddiscardpocket sealsitem
887.
7) Discard body seals item 869. It is also advisable to replace ring seals item 877, at this time. Bearings item
875, have to be removed to allow access to ring seals.

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SERVICE INSTRUCTIONS CONTINUED
338 REV.031001
NOTE: Pocket seals, body seals, and ring seals in the hydraulic motor assembly are not part of the PULLMASTER
Planematic drive 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) Remove12hexcapscrewsitem821,togetherwithlockwashersitem823,frommotoradaptoritem800.Since
brake springs item 752, apply pressure against inside of motor adaptor, it is recommended that hex
capscrews are unscrewed, one turn at a time, until spring pressure has been released. Complete motor
assembly, including motor adaptor, can now be removed from brake housing
2) Formodelswithinternalcirculation,ensurethatholeinorificeplugitem804,isclear.Formodelswithexternal
brake release option, verify that shuttle item 802, moves freely.
3) Remove and discard O-ring item 801, and O-ring item 707. (O-ring item 801, seals pressure transfer hole
for automatic brake release and is situated on flange of brake housing.)
4) Remove bearing carrier item 610, with ball bearing item 609. Inspect ball bearing item 609, and replace if
necessary.
5) Proceed to applicable DISASSEMBLY OF BRAKE ASSEMBLY.
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:
Refer to BRAKE GROUP drawing G1038 on page 25.
1) Pull motor drive shaft item 730, along with sprag clutches item 723, out of connecting shaft item 600.
2) Disassemble sprag clutch assembly by removing circlip item 727, from motor drive shaft item 730. Remove
spragclutch aligneritem724,supportwasheritem717,andspragclutchesitem 723,frommotordrive shaft.
Inspectboreof connecting shaftandouterdiameterofmotor drive shaftwherebothpartsengagewithsprag
clutches. If parts show any deep indentations or surface damage, they must be replaced.
3) Remove connecting shaft item 600, together with brake hub item 720.
4) Removeretainingringitem602,todisassemblebrakehubfromconnectingshaftandinspectneedlebearing
item 603. If needle bearing is damaged, press out of connecting shaft and replace.
5) Remove 13 divider plates item 714, and 12 friction plates item 715, and inspect for damage or wear. Plates
shouldbeflatandsmooth.Platesshouldnotshowheatdiscolouration.Fibrematerialonfrictionplatesshould
be intact and grooved. Replace plates if damaged.
6) Remove internal gear item 430, two thrust washers item 615, and thrust bearing item 617.
7) Remove primary sungear item 440, from center of primary planet hub item 400.
8) Pull primary planet hub assembly out of ball bearing item 777, and oil seal item 775.
9) Remove 16 capscrews item 111, and lockwashers item 113, to separate brake housing item 700, from final
housing item 100.
10) Remove and discard O-ring item 107.
11) Remove six capscrews item 771, and lockwashers item 773, one turn at a time, to relieve pressure being
exerted by brake springs item 752.
12) Remove spring stopper item 770, and discard O-ring item 779.
13) Check planet hub stopper item 304, on spring stopper item 770, for wear and replace if less than 0.21 inch thick.
14) Press ball bearing item 777, out of spring stopper item 770. Remove and discard oil seal item 775.

PAGE 16
SERVICE INSTRUCTIONS CONTINUED
338 REV.031001
15) Remove16brakespringsitem752.Examinespringsfordamageandmeasureoveralllength.Overallspring
length should be 1.99 inch. Springs measuring less than 1.93 inch should be replaced.
16) Pull brake piston item 750, out of brake housing, using two tapped holes in brake piston and two 1/2 inch -
13NC capscrews.(Two capscrews item771, from springstopper item770, can be used.Alternatively, turn
brake housing over and gently tap uppermost surface of brake piston with soft-headed hammer until it falls
out onto workbench.)
17) Remove and discard O-ring item 751, and O-ring item 753.
18) Check brake piston outside diameters and inside diameters of brake housing for surface scratches due to
particlesinhydraulicfluid(contamination).Ifthereisanyevidenceofsurfacedamage,polishwithfineemerycloth.
DISASSEMBLY OF PRIMARY PLANET HUB ASSEMBLY:
Inspect three primary planet gears item 420, for damage or wear. If necessary, disassemble as follows:
1) R emovecirclipsitem411, and press planet pins item410,outofprimaryplanethubitem400.Removeplanet
gears item 420, and inspect needle bearings item 423, and two thrust washers item 421. Replace if damaged.
2) Press sungear stopper item 444, out of primary planet hub and measure thickness. If less than 0.21 inch
thick, replace sungear stopper.
Allpartshavenowbeenremovedfrombrakehousingandthereisnoneedforfurtherdisassemblyunlessafailure
has been analysed in the remaining drive assembly.
DISASSEMBLY OF FINAL DRIVE AND OUTPUT SHAFT ASSEMBLY:
Refer to PARTS REFERENCE on page 22 and FINAL DRIVE GROUP drawing G1037A on page 23.
If final drive or output shaft assembly requires service or repair, disassemble as follows:
1) Remove final sungear item 340, from center of three final planet gears item 320.
2) Pulloutfinalplanethubassemblyandinspectforwearordamage.Iffinalplanethubgearsitem320,require
removal, take off circlip item 311, from planet pin item 310, and press planet pin out of final planet hub item
300. Remove final planet gear item 320, and inspect thrust washers item 321, and needle bearing item 323.
Replace if damaged.
3) IfPlanematicdriveincludesaninboardoroutboardflange,removecapscrewitem153,lockwasheritem155,
and flange cap item 154, to slide off flange item 152.
4) Remove six hex capscrews item 163, and lockwashers, item 165. Pull off end cover item 156, and discard
O-ring item 167, and oil seal item 157.
5) Untablockwasheritem161,fromlocknutitem159.Unscrewlocknutandremovelockwasherandkeyedwasher
item 149. Output shaft item 150, can now be pressed out of tapered roller bearings items 151 and 103.
6) Check sungear stopper item 160, for wear and replace if less than 0.21 inch thick.
The Pullmaster Planematic drive has now been completely disassembled.
REASSEMBLY
Thoroughlycleanallparts.Use only new, well-greased O-rings andoilseals.Unlessotherwisespecified,torque
fasteners per BOLT TORQUE CHART.
REASSEMBLY OF FINAL DRIVE AND OUTPUT SHAFT ASSEMBLY:
Reassemble final drive and output shaft assembly by reversing disassembly procedure.
1) Press sungear stopper item 160, into end of output shaft item 150, and press output shaft into tapered roller
bearings items 151 and 103.

PAGE 17
SERVICE INSTRUCTIONS CONTINUED
338 REV.031001
2) Slidekeyedwasher item149,andlockwasher item161,ontooutputshaftagainsttaperedrollerbearingitem
151. Screw locknut item 159, onto output shaft against lockwasher. Tighten locknut to a point where 5 to 15
pounds of pull is required to rotate output shaft item 150, freely. Bend tabs of lockwasher into openings on
locknut to lock output shaft into position.
3) Pressnew,well-greased oil seal item 157, into end cover item 156, and place new,well-greased O-ring item
167, onto flange.
4) Fasten end cover to final housing item 100, using six capscrews item 163, and lockwashers item 165.
5) Reassemble final planet hub assembly. Press needle bearing item 323, into planet gear item 320. Position
thrust washers item 321, on either side of planet gear and press planet pin item 310, into planet hub. Retain
with circlip item 411.
6) Insert final planet hub assembly into final housing. Ensure that planet hub spline is fully engaged.
7) Install final sungear item 340. Verify circlip item 341, is installed on sungear.
REASSEMBLY OF PRIMARY DRIVE:
If primary plant hub assembly was disassembled, reassemble by reversing disassembly procedure.
1) Press sungear stopper item 444, into primary planet hub item 400.
2) Press needle bearing item 423, into planet gear item 420.
3) Position thrust washersitem421, on either sideof planet gear andpressplanet pin item 410,intoplanethub.
4) Retain with circlip item 411.
REASSEMBLY OF BRAKE HOUSING ASSEMBLY:
Reassemble brake housing assembly by reversing disassembly procedure.
1) Install new, well-greased O-rings item 751 and 753, into glands of brake piston item 750.
2) Slide brake piston into brake housing with holes for brake springs facing out of brake housing (see BRAKE
GROUP drawing).
3) Install 16 brake springs item 752, in brake piston. Piston has 18 holes and two holes which have no brake
springs installed should be located opposite to each other.
4) Installnew,well-greased oilsealitem775, intospringstopperitem770,andpressballbearingitem777, into
place.
5) Press planet hub stopper item 304, onto spring stopper item 770, and install new, well-greased O-ring item 779.
6) Installspringstopperitem770,ontobrakehousingitem700,usingsixcapscrewsitem771,andlockwashers
item 773. Tighten capscrews, one turn at a time, to evenly compress brake springs item 752.
7) Install new, well-greasedO-ringitem 107, intoouter flange O-ring groovein brake housing andfasten brake
housing to final housing item 100, with 16 capscrews item 111, and lockwashers item 113.
8) Installprimaryplanethubassemblythroughball bearing item 777,andoilsealitem775,engagingteeth with
final sungear item 340.
9) Install primary sungear item 440.
10) Install two thrust washers item 615, (with thrust bearing item 617, between) on top of planet hub item 400.
11) Install internal gear item 430, on top of thrust washer, engaging teeth of three planet gears item 420.
12) If needle bearing item 603, was replaced, press into connecting shaft item 600. Slide brake hub item 720,
onto connecting shaft and fasten with retaining ring item 602. Install connecting shaft assembly into internal
gear item 430.

PAGE 18
SERVICE INSTRUCTIONS CONTINUED
338 REV.031001
13) Starting and finishing with divider plate, alternately install 13 divider plates item 714, and 12 friction plates
item 715.
14) Install two sprag clutches item 723, onto motor drive shaft item 730. Slide sprag clutch aligner, and support
washer item 717, onto motor drive shaft and fasten with circlip item 727.
IMPORTANT: For proper brake function, verify that sprag clutches are installed correctly. Motor drive shaft
shouldturnfreelyinclockwiserotation and lock up in counterclockwise rotation (for standard
rotation).
15) Carefully install motor drive shaft assembly into center bore of connecting shaft item 600, engaging spline
in primary sungear item 440, until flange of sprag clutch aligner comes into contact with connecting shaft.
16) Slide ball bearing item 609, with bearing carrier item 610, onto connecting shaft item 600.
17) Use grease to temporarily hold new O-ring item 801, into recess on flange of motor adaptor item 800. Install
new, well-greased O-ring item 707, onto motor adaptor pilot.
18) Position motor adaptor item 800, at brake housing, aligning brake release pressure transfer holes of motor
adaptor and brake housing. Tighten 12 capscrews item 821, with lockwashers item 823, one turn at a time,
to evenly compress springs.
REASSEMBLY OF HYDRAULIC MOTOR:
If hydraulic motor was disassembled, proceed with reassembly as follows:
1) Cleanallpartsthoroughlybeforereassemblyandapplygreaseliberallytoallseals.Useonlynewseals(seal
kit Part No. 23121) for hydraulic motor.
2) Install six newpocketseals item 887,on each thrust plateitem 885. Seal kitincludes a singlestripof rubber.
Usingasharpknife,cutlengthstofitopeningsinthrustplates.Pressonethrustplate,togetherwithsixpocket
seals,ontobearingsitem875,installedinmotoradaptoritem800,sopocketsealsareagainstmotoradaptor.
3) Install new, well-greased body seal item 869, on each side of gear housing item 861. Slide gear housing
together with body seals, onto motor adaptor, lined up on two dowel pins. Tap on tight using soft-headed
hammer.
4) Install gear set item 881, in gear housing (longer gear with internal spline goes into top position).
5) Pressotherthrustplateitem885,completewithsixnewpocketsealsitem887,ontobearingsinstalledinport
end cover item 870, so pocket seals are facing port end cover.
6) Install port end cover item 870, together with two bearings item 875, and new ring seal item 877, onto gear
housing, lined up on two dowel pins item 865. Tap on tight using a soft-headed hammer. Install and lightly
torque four hex capscrews item 951, and lockwashers item 953, to approximately 50 ft-lb (70 Nm).
7) PlumbPlanematicassemblytohydraulicsupplyandtorquemotorcapscrewsaccordingtofollowingprocedure:
- Ensure that circulation supply flow is being supplied to and vented from brake housing. If an
internal circulation model, fill with hydraulic oil through one of three filler / drain ports
before running.
- Run Planematic drive in hoisting direction, with no load, at reduced speed (approximately
30% of maximum hydraulic volume).
- WithPlanematicdriverunning,evenlytightenfourcapscrewsitem951,to200ft-lb(271Nm)
- Test motor operation by running Planematic drive at full speed in both directions.