Dover PullMaster PH136 Technical reference manual

070228
INSTRUCTION AND PARTS MANUAL
MODEL PH136
PLANETARY HYDRAULIC WINCH
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.
PMC 340
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
340 REV.991125
SAFETY RECOMMENDATIONS
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
DESCRIPTION OFTHE MODEL PH136
340 REV.991125
The PULLMASTER Planematic drive is a high performance, highly efficient, planetary hydraulic drive with
reversing speed 4.7 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:
Inforwardrotation thetorqueandrpm ofthehydraulicmotor aretransmittedtothe sungearoftheprimary planet
reduction. The sprag clutch which connects the motor drive shaft to the automatic brake assembly permits free
rotation in forward direction.
The output torque and rpm of the primary reduction are transmitted to the final reduction by the final sungear
which 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
maximumpermissible load isheld safelyby thedisc brake. Thepressure requiredto rotate theoutput shaftmay
vary from 50 to 250 psi (3 to 17 bar) without load, depending upon speed.
FUNCTION IN REVERSE ROTATION:
In reverse rotation, hydraulic pressure from the reversing side of the hydraulic motor is channelled to the brake
piston,causingthebrakepistontorelease themulti-discbrakeagainstthebrakesprings.Thesprag clutchlocks
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
4.7timesofforwarddirection.Basedonstandardmotor,pressurerequiredtorotatetheoutputshaft,withoutload
depending upon speed, may vary from 500 to 1100 psi (34 to 76 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,
suppliedoutofthehydraulicmotororfromanexternalsource.Formodelswithexternalcirculation,requiredflow
is approximately 7 (US) gpm (26 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.

PAGE 3
340 REV.991125
MODEL PH136
PHX - XX - XXX - XX X - X XXX
BASIC UNIT
P = Planematic drive
TYPE OF UNIT
H = High speed reverse
SIZE OF UNIT
136 = 135,937 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
*Automatic brake = spring applied, automatically released by the hydraulic
pressure of the motor
HYDRAULIC MOTOR
-86 WM76 hydraulic motor, 3 inch gear section, 12.3 cid
OUTPUT SHAFT
-1 splined output shaft, 34 teeth, 10/20 DP ( STANDARD)
-2 keyed output shaft, 3.50 diameter 7/8 inch square key
-3 splined output shaft with inboard flange adaptor
-4 splined output shaft with outboard flange adaptor
-5 splined output shaft, 31 teeth, 10/20 DP
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
136

PAGE 4 340 REV.991125
OPTIONS
REDUCTION RATIO:
The reduction ratio of the standard PULLMASTER Planematic drive is 40.8:1. 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 34 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 2500 psi (172 bar). For
hydraulicsystemsoperating withahigher rangeofhydraulic pressure,thedrivecan besuppliedwith ahydraulic
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
340 REV.991125
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: 135,937 lb-in 15,359 Nm
Reverse: 29,127 lb-in 3,291 Nm
MAXIMUM OUTPUT RPM:
Forward: 49 rpm
Reverse: 229 rpm
MAXIMUM OPERATING PRESSURE: 2,500 psi 172 bar
MAXIMUM OPERATING VOLUME: 115 (US) gpm 435 l/min
MINIMUM OPERATING VOLUME: 30 (US) gpm 114 l/min
REDUCTION RATIO:
Forward: 40.8 : 1
Reverse: 8.8 : 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 7 gpm 26 l/min

PAGE 6 340 REV.991125
OVERHUNG LOAD RATING
PG-136-OH
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 = -0.295
T = basic thrust load = 14,500
c = basic load constant = 136,000
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
T
y
L
L = = lbs
c x SF
(y + a) AF
Allowable thrust or tension load in lbs. = T x SF

PAGE 7
FORWARD
REVERSE
FORWARD
REVERSE
229200175150125100755025
379100
30380
22760
15140
7620
120
135.6
100
113.0
80
90.4
60
67.8
40
45.2
20
22.6
OUTPUT TORQUE - Nm (x 100)
2000
2500
1500
1000
500
0
120
0
1400
0 158.2 172
138
103
69
35
0
OUTPUT TORQUE - lb.in. (x 1000)
OIL PRESSURE - psi
OIL PRESSURE - bar
00
OUTPUT RPM
454
OIL VOLUME - (US)gpm
OIL VOLUME - l/min
340 REV.991125
PERFORMANCE GRAPHS
PG-PH136
OUTPUT TORQUE VS. OIL PRESSURE
OUTPUT RPM VS. OIL VOLUME
Performance graphs are based on standard hydraulic motor and gear ratio.

PAGE 8
TYPICAL HYDRAULIC CIRCUIT
340 REV.030925
HC-PMH136-A
FILTER
HYDRAULIC
PUMP
RESERVOIR
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
PRESSURE
RELIEF VALVE
CIRCULATION RETURN LINE
(MUST GO DIRECT TO RESERVOIR)
CIRCULATION SUPPLY LINE
PM136: 5 (US) GPM [19 L/MIN]
PH136: 7 (US) GPM [26 L/MIN]
(EXTERNAL CIRCULATION
MODELS ONLY)
800 PSI [55 BAR]
2(US)GPM [8 L/MIN]
REQUIRED FOR MODELS
SUPPLIED WITH EXTERNAL
BRAKE RELEASE OPTION

PAGE 9
RECOMMENDATIONS
340 REV.991125
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
short duration, the maximum temperature range of -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, circulationissupplied internallybythe
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
dependsonthe“metering”characteristicsofthecontrol
valve.The betterthe oil flowis “metered”the betterwill
be the speed control.
HYDRAULIC PRESSURE RELIEF:
ThehydrauliccircuitforthePULLMASTERPlanematic
drive requires a pressure relief set at the operating
pressure(seeSPECIFICATIONS).Usually,apressure
relief is part of the hydraulic control valve. Where this
isnot the case, aseparatepressure relief valve must
be installed and set at the recommended maximum
pressure.
HYDRAULIC RESERVOIR:
It is recommended that the hydraulic reservoir has
sufficient capacity to provide good heat dissipation in
ordertopreventover-heatingofthehydraulicfluid.The
hydraulic reservoir should be made from clean and
scale-free material to prevent contamination of the
hydraulicfluid. Inorder toprevent airfrom beingmixed
with the hydraulic fluid, the reservoir should have an
over-flow baffle separating the return lines from the
suctionlineandallreturnlinesshouldenterthereservoir
belowthefluidlevel. Thereservoir shouldbemounted
close to and above the hydraulic pump in a location
which provides for free air circulation around the
reservoir.
HYDRAULIC HOSES:
The following hydraulic hoses are recommended for
maximum efficiency of the PULLMASTER Planematic
drive:
Pressure lines: EquivalenttoSAE100R12-32
Circulation return line: Equivalent to SAE 100R4-16
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.

PAGE 10
INSTALLATION INSTRUCTIONS
340 REV.991125
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) Useeight 3/4inchdiameter mountingbolts (grade5 orbetter).Evenly tightenbolts perBOLTTORQUECHART.
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.
DANGER

PAGE 11
OPERATING INSTRUCTIONS
340 REV.991125
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS
WILL RESULT IN PROPERTY DAMAGE,
SEVERE INJURY OR DEATH.
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.
DANGER

PAGE 12
TROUBLE SHOOTING
340 REV.991125
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
doesnotproduce desired outputtorque, install pressure gaugesat both drivemotorgauge ports. Stallthe 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.
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) Insufficienthydraulicpressuretoreleasethebrake.Refer
toPERFORMANCE GRAPH.Gaugereleasepressureat
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.
Drive will not produce rated speed or rpm as
listed in SPECIFICATIONS.
Drive will not reverse (brake will not release).

PAGE 13
340 REV.991125
TROUBLE SHOOTING CONTINUED
FAILURE PROBABLE CAUSE
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.Refertoproceduredescribedin
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.
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Planematic drive.

PAGE 14 340 REV.030926
SERVICE INSTRUCTIONS
GENERAL:
Before attempting disassembly of the PULLMASTER Model PH136 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. 23141) and, if the hydraulic motor has to be serviced, a motor
seal kit (Part No. 23117) on hand before the unit is taken apart. If working on the hydraulic motor, two new roller
bearings item 875, (Part No. 25352) 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) Teflonsealsitem887,areincludedinthemotorsealkit.Teflonsealsarenotrequiredifthrust
plates item 885, are not grooved.
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 G1078 on page 27.
1) Remove eight 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) If thrust plate stayed on motor adaptor, carefully pry it off of bearings item 875, and discard teflon seals item
887.
7) Discard gasket 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.

PAGE 15
340 REV.030926
SERVICE INSTRUCTIONS CONTINUED
MINOR SURFACE DEFECTS WHERE SPRAG CLUTCH ENGAGES MOTOR DRIVE
SHAFT AND CONNECTING SHAFT, WILL RESULT IN BRAKE FAILURE AND ALLOW
THE LOAD TO DROP, CAUSING PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
THOROUGHLY INSPECT THESE AREAS AND, IF NECESSARY, REPLACE MOTOR
DRIVE SHAFT, SPRAG CLUTCH AND CONNECTING SHAFT AS A SET.
DANGER
DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING CAPACITY
AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY DAMAGE, SEVERE
INJURY OR DEATH. SOLVENT MAY DAMAGE THE FRICTION PLATES.
DO NOT USE SOLVENT TO CLEAN THE FRICTION PLATES. PERFORM THOROUGH
INSPECTION AND, IF NECESSARY, REPLACE FRICTION AND DIVIDER PLATES AS A SET.
DANGER
NOTE: Teflon seals, gasket seals, and ring seals in the hydraulic motor assembly are not part of the
Planematic seal kit. The motor, with the exception of the motor adaptor item 800, and the port
end cover item 870, are standard parts of the hydraulic motor, having a 3 inch gear section.
All of these parts can be ordered from PULLMASTER or Authorized Distributors/Dealers in
Canada, the United States and in most overseas areas.
REMOVAL OF HYDRAULIC MOTOR ASSEMBLY:
If disassembly of the hydraulic motor is not necessary, proceed as follows:
1) Remove12hexcapscrewsitem537,togetherwithlockwashersitem773,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.)
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:
Refer to PARTS REFERENCE on page 24 and BRAKE GROUP drawing G1015 on page 25.
1) Remove brake spacer item 712, from brake housing item 700.
2) Pull motor drive shaft item 730, out of brake hub assembly. Surface of motor drive shaft that engages sprag
clutchitem723,shouldbeinspectedforwearorindentations.Ifmotordriveshaftshowsanysurfacedamage,
it should be replaced.
3) Spragclutchaligneritem724,andspragclutchitem723,cannowberemovedfromboreofbrakeconnecting
shaft item 600. Inspect both parts for wear or damage and replace if necessary.
4) Remove circlip item 721, and brake hub item 720, from connecting shaft item 600.
5) Remove12frictionplatesitem715,togetherwith13dividerplatesitem713,andinspectfordamageorwear.
Platesshould beflat andsmooth. Platesshould notshowheatdiscoloration.Fibermaterialon frictionplates
should be intact and grooved. Replace plates if damaged.

PAGE 16
SERVICE INSTRUCTIONS CONTINUED
340 REV.030926
6) Remove connecting shaft item 600, and internal gear item 430, from brake housing. Remove circlip item 431,
to separate internal gear from brake hub. Inspect needle bearing item 603. Replace if necessary.
7) Remove primary sungear item 440.
8) Pull primary planet hub assembly out of bushing item 774.
9) Remove thrust bearing item 617, and two thrust washers item 615, from primary planet hub item 400. Inspect
and replace if cracked or otherwise damaged.
10) Remove 16 capscrews item 111, and lockwashers item 113, to separate brake housing item 700, from final
housing item 100. Remove and discard O-ring item 107.
11) Remove eight capscrews item 771, and lockwashers item 773, one turn at a time, to relieve pressure being
exerted by brake springs item 752.
12) Inspect thrust washer item 776, and replace if less than 0.13 inch thick. Inspect bushing item 774, and replace
if inside bore is worn above 3.145 inch diameter.
13) Remove 18 brake springs item 752. Thoroughly examine springs for damage and measure overall length. Overall
spring length should be 2.27 inch. If any spring measures less than 2.21 inch replace all springs as a set.
14) Pull brake piston item 750, out of brake housing, using two 5/8 inch - 11 NC bolts screwed into two puller holes
in piston and discard O-rings item 751 and item 753.
15) 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.
DISASSEMBLY OF PRIMARY PLANET HUB ASSEMBLY:
Inspect three primary planet gears item 420, for damage or wear. If necessary, disassemble as follows:
1) R emove circlips item 411, and press planet pins item 410, out of primary planet hub item 400. Remove planet
gears item 420, and inspect loose rollers item 423, and two thrust washers item 421. Replace if damaged.
2) Presssungear stopperitem 444,out ofprimaryplanet huband measure thickness.If lessthan 0.21inch thick,
replace sungear stopper.
All parts have now been removed from brake housing and there is no need for further disassembly unless a failure
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 G1016 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) Pull out final planet hub assembly and inspect for wear or damage. If final planet hub gears item 320, require
removal,take offcirclip item311, fromplanet pinitem 310,and pressplanet pinout offinal planethub item300.
Remove final planet gear item 320, and inspect thrust washers item 321, and loose rollers item 323. Replace
if damaged.
3) If Planematic drive includes an inboard or outboard flange, remove capscrew item 153, lockwasher item 155,
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) Untab lockwasher item 161, from locknut item 159. Unscrew locknut and remove lockwasher and keyed washer
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.

PAGE 17
340 REV.030926
SERVICE INSTRUCTIONS CONTINUED
REASSEMBLY
Thoroughlyclean allparts. Useonly new,well-greased O-ringsand oilseals. Unlessotherwise specified,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.
2) Slidekeyedwasher item149,andlockwasheritem161, ontooutputshaftagainsttaperedroller bearingitem
151. Screw locknut item 159, onto output shaft against lockwasher. Tighten locknut to a point where 10 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-greasedoil sealitem 157,intoend coveritem 156,and placenew,well-greased O-ringitem
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. Use grease to temporarily hold 24 loose rollers item 323, in bore of
planet gear item 320. Position thrust washers item 321, on either side of planet gear and press planet pin
item 310, into final planet hub item 300. Retain with circlip item 311.
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 343, is installed on sungear.
REASSEMBLY OF PRIMARY DRIVE:
If primary planet hub assembly was disassembled, reassemble by reversing disassembly procedure.
1) Reassemble primaryplanet hub assembly.Use grease totemporarily hold 20loose rollers item423,in bore
ofplanet gear item420. Verify placementof sungear stopperitem444. Positionthrustwashers item421,on
either side of planet gear and press planet pin item 410, into primary planet hub item 400. Retain with circlip
item 411.
REASSEMBLY OF BRAKE HOUSING ASSEMBLY:
Refer to PARTS REFERENCE on page 24 and BRAKE GROUP drawing G1015 on page 25.
Reassemble brake housing assembly by reversing disassembly procedure.
1) Liberally grease O-ring item 751, and O-ring item 753, and install on brake piston item 750.
2) Slide brake piston into brake housing with holes for brake springs facing out of brake housing assembly.
3) Install 18 brake springs item 752, in brake piston. Piston has 20 holes and two holes which have no brake
springs installed should be located opposite to each other.
4) Verify thrust washer item 776, and bushing item 774, are in place on spring stopper item 770.
5) Install spring stopper item 770, onto brake housing item 700, and fasten with eight capscrews item 771, and
lockwashers item 773. Tighten capscrews, one turn at a time, to evenly compress brake springs item 752.
6) Install new, well-greased O-ring item 107, onto brake housing.
7) Install brake housing item 700, onto final housing item 100, and fasten with 16 capscrews item 111 and
lockwashers item 113.
8) Install primary planet hub assembly so that hub slides into bushing item 774.

PAGE 18
SERVICE INSTRUCTIONSCONTINUED
340 REV.030926
9) Insert primary sungear item 440, in opening between three primary planet gears item 420.
10) Place thrust bearing item 617 (held between two thrust washers item 615), into bore of primary planet hub
item 400.
11) Fasten internal gear item 430, onto connecting shaft item 600, using circlip item 431.
12) Verifyplacement ofneedle bearingitem603, inconnecting shaftitem 600.Install spragclutchitem723,and
sprag clutch aligner item 724, into connecting shaft.
13) Installinternalgearitem430,throughcenterofpiston item750,andinterlockgearteethwiththreeplanetgears
item 420. Ensure that end of connecting shaft item 600, is through center of thrust washers item 615.
14) Installmotor drive shaftitem 730, intoconnecting shaft item600,so thatcirclipitem 727,comesinto contact
with sprag clutch aligner item 724.
15) Slide brake hub item 720, onto connecting shaft spline and secure with circlip item 721.
16) Starting and finishing with a divider plate, alternately install 13 divider plates item 713, and 12 friction plates
item 715. Install brake spacer item 712, into brake housing.
17) Install motor drive shaft spacer item 732, onto motor drive shaft item 730.
18) Liberallygreasethreenew O-ringsitem801,and installintorecessesonmotor adaptoritem800.Install new
well-greased O-ring item 707, on flange of motor adaptor.
19) Slidehydraulic motor assemblyonto splinedend ofmotor drive shaftitem 730,and line uppressure transfer
holesofbrakehousingandmotoradaptor.Install12capscrewsitem537,andlockwashersitem773.Tighten
one turn at a time to evenly compress springs.
REASSEMBLY OF HYDRAULIC MOTOR:
Refer to PARTS REFERENCE on page 26 and MOTOR GROUP drawing G1078 on page 27.
If hydraulic motor was disassembled, proceed with reassembly as follows:
1) Cleanallpartsthoroughlybeforereassemblyandapplygreaseliberallytoallseals.Useonlynewseals(seal
kit Part No. 23117) for hydraulic motor.
2) Install twonew teflonseals item887, oneach thrustplate item885. Pressonethrust plate,together withtwo
teflon seals, onto bearings item 875, installed in motor adaptor item 800.
3) Install new, well-greased gasket seal item 869, on each side of gear housing item 861. Slide gear housing
together with gasket 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) Pressotherthrustplate,complete withtwonew teflonsealsitem 887,ontobearingsinstalledin portendcover.
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 eight hex capscrews item 951, and lockwashers item 953, to approximately 50 ft-lb (70 Nm).
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. REASSEMBLY PER INSTRUCTIONS.
DANGER