Dover TWG PULLMASTER M12 Technical reference manual

PMC 256
READ THIS MANUAL BEFORE INSTALLING, OPERATING OR
SERVICING THIS PRODUCT. THIS MANUAL CONTAINS IMPORTANT
INFORMATION. MAKE THIS MANUAL AVAILABLE TO ALL PERSONS
RESPONSIBLE FOR THE OPERATION, INSTALLATION, SERVICING
AND MAINTENANCE OF THIS PRODUCT.
INSTRUCTION AND PARTS MANUAL
THE LOGICAL CHOICE
MODEL M12
PLANETARY HYDRAULIC WINCH
FREESPOOL
07 2020
TWG Headquarters, 11135 S
James Ave Jenks, OK 74037 USA
[phone]
s[email protected]
TWG Canada, 19350 22nd Ave
Surrey, BC V3Z 3S6 CANADA
[phone]
[email protected]

Effective 2011/10/01
SUPERSEDES ALL PRIOR WARRANTIES
LIMITED WARRANTY 50130-0
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 itemsare
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 shallnot
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 torsional 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 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.

PAGE 1
256 REV.051117
The planetary hydraulic winches are made for hoisting and lowering loads and to be operated by trained and professional
personnel. They are not designed for operations involving lifting or moving personnel. The winches are powered by hydraulic
power. The ropes / cables for hoisting operations are not supplied by PULLMASTER. The winches are always assembled
in an application, they do not function as an independent machine and it is not allowed to use them as such.
The winches are to be used within the specifications as listed in the manual under “SPECIFICATIONS”. Other use as foreseen
in the functional description of the hydraulic winch is not allowed without written permission from PULLMASTER.
FAILURE TO COMPLY WITH THE FOLLOWING SAFETY
RECOMMENDATIONS AND LOCAL RULES AND
REGULATIONS WILL RESULT IN PROPERTY
DAMAGE, SEVERE INJURY OR DEATH.
Definition: Caution indicates a potentially
hazardous situation which, if not avoided may
result in minor or moderate injury.
Definition: Warning indicates a potentially
hazardous situation which, if not avoided could
result in death or serious injury.
Definition: Danger indicates a potentially
hazardous situation which, if not avoided will
result in death or serious injury.
18. Use only recommended hydraulic oil and gear
lubricant.
19. Keep hydraulic system clean and free from
contamination at all times.
20. Maintain winch and equipment in good operating
condition. Perform scheduled maintenance regularly.
21. Keep hands clear when winding wire rope onto
the winch drum.
22. Do not use the wire rope as a ground for welding.
23. Rig the winch carefully. Ensure that the wire rope
is properly anchored to the correct cable anchor slot at
the cable drum.
24. Do not lift a load with a twisted, kinked or
damaged wire rope.
25. Consult wire rope manufacturer for size, type and
maintenance of wire rope.elen
26. Maintain five wraps of wire rope on the cable
drum at all times.
27. 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 area where
the load is halted.
28. The noise level of the winch is 86 dBA measured
on a distance of 1.00 meter, 1.60 meters high. The
measuring equipment used was: Realistic #42-3019.
29. Clean up any oil spillage immediately.
30. Wear proper clothing and personal protection
equipment such as, footwear, safety goggles and a hard
hat. Read manual first.
DANGER
SAFETY RECOMMENDATIONS
1. Do not install, operate or service winch before
reading and understanding manufacturer's
instructions.
2. The winch 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 winch. Always smoothly
accelerate and decelerate load.
6. Do not operate a damaged, noisy or
malfunctioning winch.
7. Do not leave a load suspended for any extended
period of time.
8. Never leave a suspended load unattended.
9. Winch should be maintained and operated by
qualified personnel.
10. Inspect winch, rigging, mounting bolts and
hoses before each shift.
11. Warm-up equipment before operating winch,
particularly at low ambient temperatures.
12. Verify winch function by raising and lowering a
full test load to a safe height before each shift.
13. Do not weld any part of the winch.
14. Verify gear lubrication and brake circulation
supply and return before operating winch.
15. Be sure of equipment stability before operating
winch.
16. Wear proper clothing to avoid entanglement in
rotating machinery.
17. Always stand clear of the load.

PAGE 2
DESCRIPTION OF THE MODEL M12F
GENERAL DESCRIPTION:
The PULLMASTER Model M12 with freespool is a planetary, hydraulic winch having equal speed in both
directions. The main components of this unit are:
✛hydraulic gear motor
✛multi-disc brake with static and dynamic function
✛primary planet reduction
✛final planet reduction
✛brake housing
✛freespool mechanism
✛final drive housing
✛cable drum
FUNCTION IN FORWARD ROTATION (HOISTING):
In forward rotation, the output torque and rpm of the hydraulic motor are transmitted to the sungear of the primary
planet reduction. The output torque and rpm of the primary reduction stage are transmitted to the final reduction
stage by the final sungear shaft, which is splined to the primary planet hub. In forward rotation, or when a load
is raised, an over-running clutch, which connects the motor drive shaft to the automatic brake assembly, permits
free rotation of the sun gear without effecting the brake. When the winch rotation is stopped, the load on the cable
drum causes the over-running clutch to lock and the maximum load is held safely by the disc brake.
FUNCTION IN REVERSE ROTATION (LOWERING):
In reverse rotation, hydraulic pressure from the reversing side of the hydraulic motor is channelled to the brake
piston, causing the brake piston to release the multi disc brake against a number of brake springs. The over-
running clutch, connecting the motor drive shaft to the brake assembly, locks, causing the brake discs to rotate
between divider plates. Thus, a completely smooth lowering speed can be achieved in a stepless operation by
modulation of the winch control valve handle. When the control handle is returned to neutral position, rotation
stops and the disc brake applies automatically.
During the lowering operation of the winch, the friction created by the brake discs results in temperature. This
temperature is dissipated by an internal circulation flow, supplied out of the hydraulic motor, or from an external
source, for models with external circulation (approx. 3.5 (US) gpm - 13 l/min). This circulation flow must be
returned directly to the reservoir with a permissible back pressure of 30 psi (2 bar).
FUNCTION IN FREESPOOLING:
Freespooling may be used only when there is no load on the cable drum and the cable drum is not turning. Upon
pressurizing the freespool release port with 400 psi (28 bar), the freespool piston pushes the freespool shaft
against the freespool spring. Since the freespool coupling is held in place, the two splines which hold the shaft
and coupling together, disengage. This allows free rotation of the cable drum, as long as pressure is maintained
to the freespool release port.
IMPORTANT: Under no circumstances must the back pressure in the brake housing be permitted to exceed
30 psi (2 bar). Excessive pressure in the brake housing will damage the oil seal separating the
brake housing from the drum interior. Damage to this seal will cause the drum to fill up with
hydraulic fluid. In order to prevent potential damage to the drum seals and the end cover of the
winch, when the cable drum fills up with hydraulic fluid, a breather relief (see PARTS
REFERENCE, item 130) is installed on the end cover. The breather relief bleeds to atmosphere
and serves as a warning signal that the oil seal between the brake housing and drum has been
damaged.
256 REV.970801

PAGE 3
EXPLANATION OF MODEL CODING
X - XX - XX - XX X - X XXXX
12
BASIC UNIT SERIES
M = Equal speed in both directions
SIZE OF UNIT
REDUCTION RATIO
Only used for non standard reduction ratios
TYPE OF BRAKE
-3 Automatic brake, clockwise drum rotation, internal circulation flow
-4 Automatic brake, external brake release, clockwise drum rotation,
internal circulation flow
-5 Automatic brake, external brake release, counterclockwise drum
rotation, internal circulation flow
-6 Automatic brake, counterclockwise drum rotation, internal
circulation flow
-7
Automatic brake, clockwise drum rotation, external circulation flow
-8 Automatic brake, external brake release, clockwise drum rotation,
external circulation flow
-9 Automatic brake, external brake release, counterclockwise drum
rotation, external circulation flow
-10 Automatic brake, counterclockwise drum rotation, external
circulation flow
HYDRAULIC MOTOR
-97 Hydraulic motor, 2 inch gear section (5.1 cubic inch displacement)
(Other gear sections for this motor are optional)
DRUM SIZE
-1 7 5/8 inch drum diameter X 14 5/8 inch flange diameter X 10 inch length - STANDARD
(For other drum sizes refer to APPENDIX A)
OPTIONS
-F Hydraulically actuated freespooling
DESIGN REVISION
SPECIFICATION NUMBER
Describes features not identified by preceding codes
NOTE: Clockwise and counterclockwise drum rotation is the direction of rotation for pulling or hoisting,
established by looking at the hydraulic motor.
M
256 REV.980701

PAGE 4
OPTIONS
CABLE DRUM SIZES:
Aside from the standard drum sizes listed in APPENDIX A, the PULLMASTER Model M12 planetary winch can
be supplied with optional drums to accommodate large wire rope storage capacity.
DRUM GROOVING:
Cable drums for the PULLMASTER Model M12 planetary winch can be grooved. Where this option is a
requirement, it is necessary to state the size of wire rope which is to be used with the winch.
OPTIONAL GEAR SECTION FOR THE HYDRAULIC MOTOR:
The performance of the standard PULLMASTER Model M12 planetary winch may be changed by using a
different displacement motor. (Contact the factory for performance information.)
HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS:
The operating pressure of the PULLMASTER Model M12 planetary winch is limited to 2200 psi (152 bar). For
hydraulic systems operating with a higher range of hydraulic pressure, the winch can be supplied with a hydraulic
piston motor, which will provide for the same basic performance in terms of line pull and line speed capacity.
(Contact the factory for this requirement.)
FREESPOOLING:
This option permits wire rope being pulled off the cable drum by an operator. Freespooling should not be
confused with free fall. The freespool coupling cannot be disengaged or re-engaged with a load on the wire rope
or while the cable drum is turning.
CHAIN SPROCKET DRIVE:
With a chain sprocket in place of the cable drum, the PULLMASTER Model M12 planetary winch can be used
as a hydraulic drive motor with the facility of an automatic disc brake. For requirements of this type, the
specifications for the chain sprocket must be supplied to the factory.
The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements.
COUNTERCLOCKWISE ROTATION:
The drum rotation of the standard PULLMASTER Model M12 planetary winch is clockwise for hoisting when
looking at the hydraulic motor of the winch. Drum rotation for counterclockwise hoisting direction is available as
an option.
EXTERNAL BRAKE RELEASE:
PULLMASTER planetary winches can be supplied with an external brake release which permits release of the
automatic disc brake from an external pressure source.
FAILURE TO PROPERLY VENT EXTERNAL BRAKE RELEASE
PORT WILL TRAP BRAKE PRESSURE AND ALLOW THE
LOAD TO DROP, CAUSING PROPERTY DAMAGE, SEVERE
INJURY OR DEATH. WINCHES SUPPLIED WITH EXTERNAL
RELEASE OPTION MUST BE CONNECTED ACCORDING
TO "TYPICAL HYDRAULIC CIRCUIT".
256 REV.970801
DANGER

PAGE 5
Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 5/8 inch
diameter wire rope. For other cable drums refer to APPENDIX A. For other reductions or motors, refer to
supplement inside back cover. Performance specifications for winches supplied with optional motors are
provided in attached supplement.
CABLE DRUM DIMENSIONS (STANDARD DRUM):
Barrel diameter 7.63 in 194 mm
Flange diameter 14.63 in 371 mm
Barrel length 10.00 in 254 mm
CABLE STORAGE CAPACITY:
(Size of wire rope) 1/4 in 1280 ft 390 m
5/16 in 793 ft 242 m
3/8 in 569 ft 173 m
7/16 in 458 ft 140 m
1/2 in 307 ft 94 m
9/16 in 287 ft 87 m
5/8 in 222 ft 68 m
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
DRUM TORQUE AT MAXIMUM PRESSURE: 50,000 lb-in 5,649 Nm
DRUM RPM AT MAXIMUM PRESSURE: 48 rpm
LINE PULL AT MAXIMUM PRESSURE:
Bare drum 12,121 lb 53.9 kN
Full drum 7,143 lb 31.8 kN
LINE SPEED AT MAXIMUM VOLUME:
Bare drum 104 fpm 32 m/min
Full drum 176 fpm 54 m/min
PERMISSIBLE SYSTEM BACK PRESSURE AT
MOTOR RETURN PORT: 65 psi 4.5 bar
PERMISSIBLE PRESSURE AT CIRCULATION
SUPPLY PORT: 30 psi 2 bar
LUBRICATING OIL: Refer to RECOMMENDATIONS for viscosity and instructions.
Refer to APPENDIX A for oil volume required.
256 REV.030718
SPECIFICATIONS

PAGE 6
PG-M12-B
LINE PULL VS. OIL PRESSURE
LINE SPEED VS. OIL VOLUME
Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with
5/8 inch diameter wire rope.
256 REV.030718
PERFORMANCE GRAPHS
1382000
1101600
831200
55800
28400
FULL DRUM
BARE DRUM
LINE PULL - kN
LINE SPEED - m/min
FULL DRUM
BARE DRUM
2200
0
50
40
30
20
10
0
120001000080006000400020000
0 8.9 17.8 26.7 35.6 44.5 53.4
152
0
LINE PULL - lb
OIL PRESSURE - psi
OIL PRESSURE - bar
300 60 90 120 150 180
0 9 18 27 37 46 55
0
LINE SPEED - fpm
38
76
114
151
189
OIL VOLUME - (US)gpm
OIL VOLUME - l/min

PAGE 7
HC-M12-F
256 REV.030718
TYPICAL HYDRAULIC CIRCUIT
FILTER
RESERVOIR
PRESSURE
RELIEF VALVE
CIRCULATION RETURN LINE
(MUST GO DIRECT TO RESERVOIR)
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
HYDRAULIC
PUMP
800 PSI [55 BAR]
2(US)GPM [8 L/MIN]
REQUIRED FOR MODELS
SUPPLIED WITH EXTERNAL
BRAKE RELEASE OPTION
400 PSI [28 BAR]
PRESSURE REQUIRED
FOR MODELS SUPPLIED
WITH FREESPOOL
OPTION
CIRCULATION SUPPLY LINE
M12: 3.5 (US) GPM [13 LPM]
H12: 4.5 (US) GPM [17 LPM]
(EXTERNAL CIRCULATION
MODELS ONLY)

PAGE 8
RECOMMENDATIONS
HYDRAULIC FLUID:
The hydraulic fluid selected for use with PULLMASTER
planetary winches should be a high grade, petroleum
based fluid, with rust, oxidation and wear resistance.
Fluid cleanliness and operating viscosity are critical to
winch reliability, efficiency and service life.
For optimum performance, the recommended viscosity
range at operating temperature is 81 - 167 SUS (16 - 36
CS). For extreme operating conditions of short duration,
the maximum viscosity range of 58 - 4635 SUS (10 -
1000 CS) should not be exceeded.
For optimum performance, the winch 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 winch gear train requires oil bath lubrication. The
winch is shipped from the factory without lubricating oil.
IMPORTANT: ADD LUBRICATING OIL BEFORE
RUNNING WINCH.
Refer to INSTALLATION DRAWING for location of
lubricating oil fill port. Refer to APPENDIX A for quantity
of oil required. For normal operating temperature use
SAE 90 lubricating oil. Consult lubricating oil supplier or
factory for temperatures beyond normal operating
range.
HYDRAULIC PUMP:
For maximum performance of the PULLMASTER
planetary winch, the hydraulic pump must supply the
maximum flow of hydraulic fluid at the hydraulic pressure
stated in SPECIFICATIONS.
HYDRAULIC CONTROL VALVE:
The standard control valve used for operation of the
PULLMASTER planetary winch must have a four-way,
spring return to neutral feature, which provides for
open flow from the pressure ports of the winch to the
reservoir in neutral position of the control (motor spool).
It is important to point out that good speed control,
especially when lowering a load, depends on the
"metering" characteristics of the control valve. The
better the oil flow is "metered" the better will be the
speed control.
HYDRAULIC PRESSURE RELIEF:
The hydraulic circuit for the PULLMASTER planetary
winch requires a pressure relief set at the operating
pressure (see SPECIFICATIONS). Usually, a pressure
relief is part of the hydraulic control valve. Where this is
not the case, a separate pressure 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
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
suction line and all return lines should enter the reservoir
below the fluid level. The reservoir should be mounted
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 Model M12
planetary winch:
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:
Hydraulic filter recommendations for the hydraulic circuit
of the PULLMASTER planetary winch, 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.
USE OF AN E STOP:
(FOR EUROPEAN MACHINERY DIRECTIVE APPLICATIONS)
The use of an E stop (emergency) is mandatory in the
controls circuit. The E stop is to be placed in the
operator's control panel. The E stop must be designed
and placed in line with EN 60204 and EN 418.
256 REV.030718

PAGE 9
INSTALLATION INSTRUCTIONS
The initial installation or mounting of a PULLMASTER planetary winch is critically important for proper operation
and performance. If the winch is mounted to an uneven surface, the centre line of the unit can be distorted to a
point where the winch will not operate in either direction. It is therefore very important that the following
instructions are observed when a PULLMASTER planetary winch is installed:
1) Make certain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted.
2) Set the winch on the mounting platform and check for surface contact on all mounting pads of the winch.
3) If there is a space between the mounting surface and one of the mounting pads, the mounting surface is not
even and the space below the mounting pad must be shimmed. If this condition exists, proceed as follows:
a) Install mounting bolts snug tight on the three mounting pads which are in contact with the mounting
surface. (For mounting bolt size and grade see INSTALLATION DRAWING.)
b) Measure the space underneath the fourth mounting pad with a feeler gauge and use shim stock of
equivalent thickness in the space between the mounting pad and the mounting surface.
c) Only after this procedure should the fourth mounting bolt be installed. Tighten all four bolts per BOLT
TORQUE CHART.
4) Fill the winch with lubricating oil. (See APPENDIX A for oil volume required.)
5) Use recommended circuit components and hydraulic hoses.
6) The circulation return line of the winch should be plumbed in such a manner that the brake housing remains
full of oil at all times. Connect the return line directly to reservoir. Do not connect to a common return line.
7) Before operating the winch with a load, verify adequate circulation flow through the circulation return line as
stated in TYPICAL HYDRAULIC CIRCUIT. Verify that pressure measured at the circulation supply port does
not exceed the permissible pressure stated in SPECIFICATIONS. Winches equipped with the internal
circulation option will supply circulation flow only when the winch is run in the lowering direction.
8) Verify that breather relief, item 130, is in place on end cover above oil level. Rotate end cover if breather relief
is below oil level.
IMPORTANT:
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
Do not replace breather relief with a pipe plug. The breather relief does not prevent
oil seal failure but serves as an indicator or warning that the oil seals between brake
housing and the cable drum interior have failed and must be replaced immediately.
If these oil seals are changed, additional failure of the drum seal and potential
damage to the end cover is prevented.
256 REV.030718
DANGER

PAGE 10 256 REV.051117
OPERATING INSTRUCTIONS
After the PULLMASTER planetary winch has been installed in accordance with the INSTALLATION
INSTRUCTIONS, the wire rope can be fastened to the cable drum.
IMPORTANT: The ropes, chains, slings, etc. are not part of the winch and are not covered by this manual.
Refer to manufacturer’s handling, inspection and maintenance recommendations to avoid
potential accidents. For selection of ropes, etc. please check following product standards:
DIN 15020, prEN818-1/9, prEN 1492-1/2, prEN 1677-1/3 and other relevant product standards.
1) The cable drum of the PULLMASTER planetary winch has two cable anchor slots, one for clockwise and one
for counterclockwise hoisting. Standard rotation for hoisting is clockwise when looking at the hydraulic motor
of the unit. It is critical to select the cable anchor slot which will permit winding of the wire rope on the drum
in the correct direction of rotation. If the wire rope is wound on the cable drum in the wrong direction of rotation,
the winch will have no braking capacity. Each winch is shipped from the factory with a label on the drum
indicating the correct cable anchor slot.
FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
DANGER
2) On wire rope installation, care must be taken that the wire rope is wrapped completely around the cable
anchor and properly pulled into the cable anchor slot in the cable drum. The cable drum requires 5 wraps
of wire rope for safety.
3) The winch operation is controlled by a single control valve lever which has a forward, a reverse and a neutral
position. Speed control in either direction is obtained by modulation of the control valve lever. Maximum line
speed in either direction is obtained when the control valve lever is moved as far as it can go. The disc brake
of the winch will come on automatically when the winch control lever is returned to neutral.
4) Always warm up equipment prior to operating winch, particularly in low ambient temperature. Circulate
hydraulic oil through the winch control valve for several minutes to warm the hydraulic system. To prime the
winch with warm oil, operate the winch at slow speed, forward and reverse, several times.
5) Prevent corrosion damage to winch interior. If not used regularly, run winch up and down at least once every
two weeks.
6) To ensure proper winch installation and function, raise and lower a full test load to a safe height before using
winch for regular operation at the start of each shift.
7) Do not engage or disengage freespool coupling if there is a load on the drum or if the drum is turning.
IMPORTANT: Freespooling must not be disengaged or re-engaged while the cable drum is turning or the
wire rope is under tension.
If, after a new installation, the winch does not function properly, refer to the TROUBLESHOOTING section
of this manual.
WIRE ROPE INSTALLATION
Clockwise hoisting winch shown.
(Use cable anchor slot on opposite side of
drum for counterclockwise hoisting winch.)
Feed the wire rope through the cable
anchor slot. Loop rope back into slot
as shown. Insert cable anchor into
slot, small end first and long side
nearest the drum flange. Pull rope
tight to wedge rope in slot. SI1013
CABLE ANCHOR
CABLE ANCHOR SLOT

PAGE 11
FAILURE PROBABLE CAUSE
Winch will not produce line pull at maximum
pressure as listed in SPECIFICATIONS.
Winch does not produce line speed at maximum
volume as listed in SPECIFICATIONS.
Winch will not reverse.
a) Winch is mounted to an uneven surface (see
INSTALLATION INSTRUCTIONS).
b) Cable sheaves or block purchase operated with the
winch are not turning freely.
c) Damage or wear in the hydraulic motor.
d) The relief valve pressure may be set too low.
e) Excessive back pressure in the hydraulic circuit might
cause the automatic brake to release momentarily.
a) Winch is mounted to an uneven surface (see
INSTALLATION INSTRUCTIONS).
b) Cable sheaves or block purchase operated with the
winch are not turning freely.
c) Damage or wear in the hydraulic motor.
d) Excessive back pressure in the hydraulic circuit.
a) Leakage out of the brake piston prevents the disc brake
from being released against the brake springs. This is
caused by damaged O-ring seals on the brake piston or
connecting tube.
b) The O-ring seals, on the brake release channel between
the motor adaptor and the brake housing is damaged.
If this failure occurs there will be substantial leakage
from between the motor adaptor and brake housing.
c) Insufficient hydraulic pressure (see SPECIFICATIONS
for minimum operating pressure).
d) Winch is mounted to an uneven surface (see
INSTALLATION INSTRUCTIONS).
GENERAL:
In most cases, when the hydraulic winch does not perform satisfactorily, the cause of malfunction is found
somewhere in the hydraulic circuit. Before the winch is removed from its mounting and disassembled, all of the
hydraulic circuit components should be checked for proper function.
IMPORTANT:
The hydraulic oil volume relates to the line speed or rpm of the winch.
Therefore, if the winch does not produce the specified maximum rated line speed or drum rpm, a loss of
hydraulic flow somewhere in the hydraulic circuit can be analysed. If this condition exists, install a flow meter
into the hydraulic circuit to check the volume of oil supplied to the pressure port of the hydraulic winch motor
when the winch control is completely opened. The flow meter should indicate the maximum operating volume.
If this test indicates a loss of hydraulic flow, check the hydraulic pump, the relief valve and the control valve.
If the pump is driven by V-belts, check for belt slippage.
The hydraulic pressure relates to the line pull or lifting capacity of the winch.
If the winch will not produce the specified maximum line pull, install a pressure gauge in the pressure line leading
to the hoisting port on the hydraulic winch motor. Stall the winch to prevent rotation of the drum and then open
the control valve. Check the hydraulic pressure reading of the installed pressure gauge. If the pressure reads
below the specified maximum operating pressure, look for trouble in the hydraulic pump, the relief valve and
the control valve. If the hydraulic pump is driven by V-belts, check for belt slippage. When checking oil pressure
and volume in the hydraulic circuit, verify that the hydraulic reservoir is filled to the top level and the hydraulic
pump is running at maximum operating rpm.
Only if the hydraulic system has been checked and found to be in order, use the following indications for
probable causes of failure in the winch:
TROUBLE SHOOTING
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PAGE 12
TROUBLE SHOOTING CONTINUED
PROBABLE CAUSE
FAILURE
a) Brake plates or divider plates have been damaged by
contamination in the hydraulic fluid, or lack of circulation
flow in the brake housing.
b) Brake piston is seized in the brake housing because of
contamination in the hydraulic fluid.
c) Excessive back pressure in the return line causes the
brake to be released.
d)
Control valve has incorrect spool, which traps hydraulic
pressure in the brake piston when the control valve handle
is returned to neutral position. For proper function of the
automatic brake, both pressure ports of the winch must be
open to the reservoir in neutral position of the control valve.
e) Wire rope is fastened to the incorrect cable anchor slot.
f) Sprag clutch is damaged or surfaces where sprag
clutch engages on motor drive shaft or brake hub are
worn or indented.
g) Winch supplied with external brake release option is
not plumbed per HYDRAULIC CIRCUIT. Failure to
vent external brake release port to reservoir may trap
pressure and cause winch brake to slip.
ljlkjl
a) Pump is too slow. Pump rpm must be maintained at
normal operating speed when a load is lowered.
b) Brake is running too hot. This is caused by a complete
lack of, or insufficient circulation flow. To check the
circulation, observe the flow of oil from the circulation
return line of the winch (approx. 3.5 (US) gpm - 13 l/min)
when the winch is reversed.
c) Control valve has poor metering characteristics.
d) Damaged brake plates or divider plates.
e) The over-running clutch, which connects the motor
shaft with the brake assembly, is damaged.
f) Air mixed with hydraulic oil (foamy oil).
ljlkjl
a) Insufficient hydraulic pressure (see HYDRAULIC
CIRCUIT for minimum pressure required for freespooling).
b) If pressure is lost at freespool release port, freespool
piston O-ring, item 265, is damaged.
c) Freespool piston may be seized due to contamination
in hydraulic fluid.
d) Drum is turning or holding load. Drum must be stopped
with no load on wire rope while freespool option is used.
ljlkjl
a) Oil leaks from the hydraulic motor flange and the motor
adaptor are caused by damaged O-ring seals.
b) Oil leaks occurring between the cable drum flanges and
housings are caused by excessive pressure in the brake
housing. Excessive pressure will damage the oil seal which
separates the brake housing from the cable drum interior.
c) If the breather relief on the end cover leaks, the seal
between the drum interior and the brake housing is
damaged and must be replaced. This condition is
caused by excessive pressure in the brake housing of
the winch, operation with the incorrect hydraulic fluid
during cold weather, or a restriction in the circulation
return line leading back to tank.
l
Brake will not hold.
Brake vibrates when lowering a load.
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model M12 winch with freespool.
Cable drum will not freespool.
Oil leaks.
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PAGE 13
GENERAL:
Before attempting disassembly of the PULLMASTER Model M12 planetary winch with freespooling, the following
instructions for disassembly and reassembly should be read and understood:
It is suggested that all expendable parts, such as O-rings and oil seals, are not reused on reassembly. It is
therefore important to have a seal kit (Part No. 23123) and, providing the hydraulic motor has to be serviced,
a seal kit (Part No. 23121) on hand before the unit is taken apart. Two new needle bearings item 875, may also
be required (Part No. 25723).
NOTE: Back up 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 back up washers.
A clean working area is of prime importance, similar to conditions used for service work on any other hydraulic
component. All parts, as they are removed from the winch assembly, should be inspected for wear and damage.
Worn or damaged parts must be replaced. Thoroughly clean parts before reassembly. Do not use solvent to clean
the brake friction plates.
During reassembly, lubricate all O-rings and oil seals with grease before installation.
In the following service instructions, reference to parts is made by numbers 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
PULLMASTER Model M12 planetary winch with freespooling. There are no special tools needed for the service
or repair work and no adjustments or calibrations are necessary. Proceed with the disassembly as follows:
DISASSEMBLY OF HYDRAULIC MOTOR ASSEMBLY:
If the analysed service or repair work requires access to the interior of the brake housing, the hydraulic motor
should not be disassembled. In this case, the hydraulic motor should be removed together with the motor adaptor
as a complete assembly. If a problem has been analysed to be in the hydraulic motor, proceed with the
disassembly as follows:
1) Remove four hex capscrews item 951, together with lockwashers item 953, from motor assembly.
IMPORTANT: Failure to exercise care when removing the motor port end cover or gear housing could
permanently 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) If thrust plate comes off with end cover, carefully pry it off of bearings item 875, and discard pocket seals item
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 stays on motor adaptor, carefully pry it off of bearings item 875, and discard pocket seals item 887.
7) Discard body seals item 869. It is also advisable to replace ring seals item 877, at this time. Bearings item
875, must be removed to allow access to ring seals.
Pocket seals, body seals, and ring seals in the hydraulic motor assembly are not part of the winch seal kit. The
seal kit for the hydraulic motor can be ordered from the factory under Part No. 23121. All parts of the hydraulic motor,
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SERVICE INSTRUCTIONS

PAGE 14
with the exception of the motor adaptor item 800, are standard parts of the hydraulic motor, having a 2 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) Remove 12 hex head capscrews item 821, with lockwashers item 823, from motor adaptor item 800. 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. The complete motor
assembly, including motor adaptor, can now be removed from brake housing assembly.
2) 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:
1) After motor assembly has been removed, all parts of brake assembly are accessible. Remove 16 brake
springs item 752. Thoroughly examine springs for damage and measure overall length. Overall spring length
should be 1.99 inch. If any spring measures less than 1.93 inch, replace all springs as a set.
2) Pull motor drive shaft item 730, and complete brake hub assembly from brake housing.
3) Disassemble brake hub assembly by removing circlip item 727, from motor drive shaft. Remove motor drive
shaft from brake hub item 720. Remove sprag clutch aligners items 722 and 724, support washers item 717,
and two sprag clutches item 723, from brake hub.
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.
MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE
MOTOR DRIVE SHAFT AND BRAKE HUB, WILL RESULT IN BRAKE
FAILURE AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. THOROUGHLY INSPECT
THESE AREAS AND, IF NECESSARY, REPLACE MOTOR
DRIVESHAFT, SPRAG CLUTCH AND BRAKE HUB AS A SET.
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4) Thoroughly inspect motor drive shaft item 730, and brake hub item 720, particularly surfaces where two sprag
clutches item 723, engage. If any indentation or surface damage is detected, replace brake hub, sprag clutch
and motor drive shaft as a set.
5) Pull brake piston item 750, out of brake housing using two 1/2-13NC bolts screwed into two puller holes in
piston and discard O-rings item 751 and item 753.
6) 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.
SERVICE INSTRUCTIONS CONTINUED

PAGE 15
7) Remove six friction plates item 715, together with seven divider plates item 714, and inspect for damage or wear.
Plates should be flat and smooth. Plates should not show heat discoloration. Paper material on friction plates
should be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
8) Remove brake spacer item 712.
9) Remove thrust bearing item 617, and two thrust washers item 615.
All parts have now been removed from brake housing and there is no need for further disassembly unless a
failure has been analyzed in the remaining winch assembly. If continuing, remove pipe plug item 121, from end
cover item 120, and tip winch to drain lubricating oil from inside final drive housing and cable drum.
10) Remove 12 capscrews item 551, 12 lockwashers item 553, and base item 550.
11) Slide brake housing item 700, out of cable drum ball bearings item 507 and item 509. Connecting shaft, item
600, can now be removed from center of brake housing. Remove and discard O-ring item 601.
12) Remove and discard oil seal item 607, and if present, backup washer item 606.
13) Inspect needle bearing item 603, inside connecting shaft, and replace if damaged.
14) Remove primary sungear item 440, from center of primary planet hub item 400.fffffffff
DISASSEMBLY OF FINAL DRIVE AND FREESPOOL:
Stand winch on cable drum flange with final end up and disassemble as follows:
1) Remove retaining ring item 124, and pull end cover item 120, out of final housing item 100.
2) Remove freespool piston item 264, from end cover item 120, and discard O-rings item 123 and item 265.
Inspect planet hub stopper item 126, for excessive wear and replace if less than 0.21 inch thick.
3) Remove and inspect two thrust washers item 261, and thrust bearing item 263. Replace if cracked or
otherwise damaged.
4) Lift final planet hub assembly out of final housing item 100. Inspect three final planet gears item 320, for
damage or wear. If it is necessary to remove final planet gears, remove circlip item 313, and press planet
pin item 310, out of planet hub item 300. Inspect needle bearing item 323, and two thrust washers, item 321,
and replace if damaged.
5) Remove freespool sungear item 340, and inspect for damage or wear. Replace if necessary.
6) Remove freespool spring item 280, from bore in cable drum, item 500.
7) Remove and inspect two thrust washers item 279, and thrust bearing item 281. Replace if cracked or
otherwise damaged.
DISASSEMBLY OF PRIMARY DRIVE:
If primary drive requires service or repair, proceed as follows:
1) Turn winch over to sit flat on end of final housing item 100.
2) Remove and discard oil seal item 515.
3) Using a standard bearing puller, remove ball bearings item 509 and item 103.
4) Remove internal gear item 430, and primary planet hub assembly from cable drum item 500.
5) If it is necessary to remove primary planet gears, remove circlip item 411, and press planet pin item 410, out of
planet hub item 400. Inspect needle bearing item 423, and two thrust washers item 421, and replace if damaged.
6) Inspect internal gear stopper item 412, for excessive wear. Replace if less than 0.10 inch protrudes out the
end of planet pin item 410.
7) Remove sungear stopper item 444, from primary planet hub, and replace if less than 0.19 inch thick.
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SERVICE INSTRUCTIONS CONTINUED

PAGE 16
8)
Withdraw freespool extender item 262, and freespool coupling item 260, from inside of cable drum item 500.
9) Remove and inspect two thrust washers item 285, and thrust bearing item 287. Replace if cracked or
otherwise damaged.
10) To separate cable drum from final housing, first remove circlip item 513. Insert two heel bars between flange
of cable drum and final drive housing and gently pry cable drum out of ball bearing item 103.
11) Remove circlip item 109, and press ball bearing item 103, out of final housing item 100. Check ball bearing
and replace if damaged.
12) Remove and discard oil seal item 105.
REASSEMBLY
Thoroughly clean all parts. Use only new, well-greased O-rings and oil seals. Unless otherwise specified, torque
fasteners per BOLT TORQUE CHART at back of manual.
REASSEMBLY OF FINAL DRIVE:
Reassemble final drive end of winch as follows
1) Press new, well-greased oil seal item 105, into final housing item 100.
2) Press ball bearing item 103, into final housing and secure with circlip item 109.
3) Press cable drum item 500, into ball bearing item 103, and secure with circlip item 513.
4) With winch sitting flat on cable drum flange, install thrust bearing item 281, sandwiched between two thrust
washers item 279, into bore of cable drum item 500.
5) Install freespool spring item 280, and freespool sungear item 340, into cable drum bore.
6) Reassemble final planet hub assembly. Press needle bearing item 323, into final 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 313.
7) Insert final planet hub assembly into final housing item 100. Ensure that planet hub spline is fully engaged
with cable drum item 500.
8) Install thrust bearing item 263, sandwiched between two thrust washers item 261, onto end of freespool
sungear item 340.
9) Install new, well-greased O-ring item 265, into bore of end cover, item 120. Insert freespool piston item 264,
into cavity. Install new, well-greased O-ring item 123, into flange of end cover and verify that planet hub
stopper item 126, is installed onto end cover.
10) Carefully insert end cover item 120, with freespool piston item 264, into final housing item 100, and fasten
with retaining ring item 124.
11) Temporarily remove breather relief valve item 130, from end cover. Turn winch up on end with cable drum
opening upwards.
REASSEMBLY OF PRIMARY DRIVE:
Reassemble primary drive as follows:
1) Install thrust bearing item 281, sandwiched between two thrust washers item 279, into cable drum item 500.
2) Install freespool coupling, item 260, into cable drum. Engage with splines of freespool sungear item 340, so
that end of freespool coupling goes through thrust washers item 279.
3) Install freespool extender item 262, into end of freespool coupling item 260, engaging end of freespool
sungear item 340, with freespool bushing item 270.
SERVICE INSTRUCTIONS CONTINUED
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PAGE 17
4) Reassemble primary planet hub assembly. Press sungear stopper item 444, into primary planet hub item 400.
Press needle bearing item 423, into primary planet gear item 420. Position thrust washers item 421, on either
side of planet gear and press planet pin item 410, into primary planet hub item 400. Retain with circlip item 411.
5) Install primary planet hub onto end of final sungear item 340, inside of cable drum item 500.
6) Install internal gear item 430, over top of three primary planet gears item 420. Ensure gear teeth are fully
engaged by rotating cable drum.
7) Press ball bearings item 103 and item 509, into cable drum.
8) Press new, well-greased oil seal item 515, into cable drum.
9) Install primary sungear item 440, into center of three primary planet gears item 420. Ensure gear teeth are
fully engaged by rotating cable drum.
REASSEMBLY OF BRAKE HOUSING ASSEMBLY:
Reassemble brake housing assembly by reversing the disassembly procedure:
1) If needle bearing item 603, was removed from center of connecting shaft item 600, press back into place.
2) Press new, well-greased oil seal item 607, into connecting shaft item 600. If back-up washer is included in
your seal kit, it should be installed together with and behind the oil seal.
3) Install new, well-greased O-ring item 601, onto connecting shaft.
4) Insert connecting shaft into brake housing item 700. Slightly rotate drum to allow spline of connecting shaft
to fully engage with internal gear item 430.
5) Install two sprag clutches item 723, into bore of brake hub item 720. Position sprag clutch aligners, item 722
and item 724, and support washers item 717, on either side of brake hub. Carefully slide motor drive shaft
item 730, into brake hub assembly and secure with circlip item 727. Verify that circlips item 719 and item 731,
are installed on motor drive shaft.
IMPORTANT: For proper brake function, verify that sprag clutch is installed correctly. When viewed from
motor end, motor drive shaft of a clockwise hoisting winch must turn freely clockwise and lock
in counterclockwise direction.
6) Install thrust bearing item 617, sandwiched between two thrust washers item 615, into brake housing item
700, and centered upon connecting shaft item 600.
7) Install motor drive shaft assembly through thrust washer item 615, and carefully twist shoulder of shaft
through oil seal item 607. Twist slightly more to engage spline with primary sungear item 440.
INCORRECT ASSEMBLY OF THE FRICTION PLATE AND DIVIDER PLATE
STACK WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD
TO DROP, CAUSING PROPERTY DAMAGE, SEVERE INJURY OR
DEATH. REASSEMBLE PER INSTRUCTIONS.
8) Install brake spacer item 712, into brake housing item 700. Starting and finishing with divider plate, alternately
install seven divider plates item 714, and six friction plates item 715.
9) Install new, well-greased O-rings item 751 and item 753, into glands of piston item 750. Carefully install brake
piston in brake housing.
10) Install 16 brake springs item 752, into brake piston item 750. The brake piston has 18 holes and the two empty
holes should be opposite each other.
11) Use grease to temporarily hold new O-ring item 801, into recess on flange of motor adaptor item 800.
SERVICE INSTRUCTIONS CONTINUED
256 REV.030718
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PAGE 18
Install new, well-greased O-ring item 707, onto motor adaptor pilot.
12) Position motor adaptor, with brake release pressure transfer holes of motor adaptor and brake housing aligned.
Tighten 12 capscrews item 821, and lockwashers item 823, one turn at a time to evenly compress springs.
13) Attach base item 550, to winch using 12 capscrews item 551, and 12 lockwashers item 553.
14) Lower winch to horizontal position, on base, and re-install breather relief valve item 130.
REASSEMBLY OF HYDRAULIC MOTOR:
If the hydraulic motor was disassembled, the following procedure should be followed for reassembly:
1) Clean all parts thoroughly before reassembly and apply grease liberally to all seals. Use only new seals (seal
kit Part No. 23121) for hydraulic motor.
2) Install six new pocket seals item 887, on each thrust plate item 885. Seal kit includes a single strip of rubber.
Using a sharp knife, cut lengths to fit openings in thrust plates. Press one of thrust plates, together with six
pocket seals, onto bearings item 875, installed in motor adaptor item 800, so that pocket seals are against
motor adaptor.
3) Install 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 a soft-headed hammer.
4) Install gear set item 881, in gear housing. (Longer gear with internal spline goes into top position.)
5) Press other thrust plate, complete with six new pocket seals, onto bearings installed in port end cover 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) Plumb winch assembly to a hydraulic supply and torque motor capscrews according to the following procedure:
- Ensure that circulation supply flow is being supplied to the brake housing.
- Run the winch , with no load, in the hoisting direction at reduced speed
(approximately 30% of maximum hydraulic volume).
- With winch running, evenly tighten four capscrews item 951, to 200 ft-lb (270 Nm).
- Test motor operation by running winch at full speed in both directions.
IMPORTANT: Before operating the winch, add lubricating oil up to the level of the end cover oil fill port.
(Refer to INSTALLATION DRAWING for location of fill port. Refer to APPENDIX A
for oil volume required.)
To ensure proper reassembly, run the winch in both directions without load.
LIFTING A LOAD WITH A NEWLY SERVICED WINCH WILL ENABLE AN
INSTALLATION OR SERVICE PROBLEM TO GO UNDETECTED AND
ALLOW THE LOAD TO DROP, CAUSING PROPERTY DAMAGE,
SEVERE INJURY OR DEATH. TO ENSURE PROPER
REINSTALLATION, REFER TO PROCEDURES AND
TESTS DESCRIBED IN "INSTALLATION" AND
"OPERATING INSTRUCTIONS".
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