Pullmaster HL25 Technical reference manual

PMC 313 030619
INSTRUCTION AND PARTS MANUAL
MODEL HL25
PLANETARY HYDRAULIC WINCH
PML
THE LOGICAL CHOICE
PULLMASTER WINCH CORPORATION
8247-130th Street, Surrey, B.C. V3W 7X4, Canada
Telephone: [phone] Fax: [phone]
Website: www.pullmaster.com
E-mail: [email protected]
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.

PULLMASTER LIMITED WARRANTY
Effective 1/1/2002
SUPERSEDES ALL PRIOR WARRANTIES
Seller warrants that each article 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.
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 Seller’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, overloading, or employment for
other than normal and ordinary use and service.
This Warranty shall not apply to any articles or parts thereof furnished by Seller to Buyer’s specifications and/or
furnished by Buyer or acquired from others at 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.
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.
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.
PULLMASTER planetary winches/drives are not designed for operations involving lifting or moving
personnel. The PULLMASTER WINCH CORPORATION cannot be held liable or responsible
for any accident resulting from such use of PULLMASTER planetary winches/drives.
WARNING
Note: Specifications contained in this Instruction and Parts Manual are subject to change without notice.

PAGE 1313 REV.970901
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.
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.
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 three 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 87dBA 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.

PAGE 2
GENERAL DESCRIPTION:
The PULLMASTER Model HL25 is a planetary, hydraulic winch with two forward speeds and one reverse speed.
At low forward or hoisting speed this unit has a line pull capacity of 25,000 lb on the first layer of wire. In the "rapid
forward" mode the line pull capacity is reduced by a ratio of 4.67 and the line speed increases by the same ratio.
The change from low speed to rapid forward speed is actuated hydraulically and can be made while the drum
is rotating. The main components of this unit are:
✧Hydraulic motor
✧Multi-disc brake with static and dynamic function
✧High speed clutch
✧Primary planet reduction
✧Final planet reduction
✧Brake housing
✧Final drive housing
✧Cable drum
FUNCTION IN FORWARD ROTATION:
LOW FORWARD SPEED
During low forward speed the output torque and rpm of the hydraulic motor is transmitted by the motor drive shaft
to the primary sungear of the primary drive. The output torque and rpm of the primary drive is transmitted to the
final drive by the final sungear, which is splined to the primary planet hub. The output torque and rpm of the final
drive is transmitted to the cable drum by a spline, attaching the final planet hub to the cable drum.
The motor drive shaft is splined to a clutch hub which connects to a set of friction and divider plates. During low
speed operation, a pressure plate, which is "spring applied" and "pressure released", permits free rotation of the
friction plates.
The motor drive shaft is also attached to a connecting shaft by a sprag clutch which permits free rotation of the
motor drive shaft while the connecting shaft is stationary. The connecting shaft is held stationary by another sprag
clutch to a brake hub. During low forward speed operation, the automatic brake remains applied, hence, the brake
hub, the connecting shaft and the internal gear do not rotate.
RAPID FORWARD SPEED
When rapid forward speed is actuated, hydraulic pressure is channelled from the motor to the center bore of the
motor drive shaft to the clutch piston. The hydraulic pressure causes the clutch to engage against the clutch
springs. The clutch hub is splined to the motor drive shaft and the drive gear is splined to the connecting shaft,
the internal gear of the primary drive will rotate with the motor drive shaft. Thus, the planetary drive is eliminated.
The elimination of the primary drive results in a forward or hoisting line speed 4.67 times faster than low forward
speed. The line pull capacity during "rapid forward" operation must be decreased by a ratio of 4.67. When the
pressure is removed from the clutch, the clutch is disengaged by the clutch springs and the unit reverts to low
forward speed. Since the sprag clutch, which connects the connecting shaft to the brake hub, permits free
rotation, the automatic brake of the winch is not affected during rapid forward speed.
NOTE: The change over from low forward speed to rapid forward speed can be made while the drum is
rotating, providing the load on the wire rope does not exceed 5357 lb (23.8 kN) on the first layer
of wire rope. If this load is exceeded, winch will stall.
313 REV.980301
DESCRIPTION OF THE MODEL HL25

PAGE 3
FUNCTION IN REVERSE ROTATION:
RAPID REVERSE
When the hydraulic motor is pressurized for rapid reverse, the rotation of the motor drive shaft causes the sprag
clutch to lock, resulting in a solid assembly between the motor drive shaft and the connecting shaft. Rotation of
the connecting shaft causes the sprag clutch between the connecting shaft and the brake hub to lock making
a solid assembly between these two components. Hydraulic pressure is automatically transmitted to the brake
piston, forcing the brake piston to release brake against a series of brake springs. The friction plates, which are
engaged in the brake hub, can now rotate between the divider plates. Since both sprag clutches are locked, the
friction plates, brake hub, connecting shaft, internal gear and primary sungear turn at the same revolution as the
motor drive shaft. Thus, the primary drive is eliminated, resulting in a reversing speed 4.67 times faster than low
forward speed.
If a load on the cable drum tends to affect the reversing speed, the resulting pressure drop in the brake piston
causes friction between the friction plates and the divider plates. Thus, a completely smooth reversing speed can
be controlled in a stepless operation by modulation of the winch control handle. When the control is returned to
neutral position, rotation stops and the disc brake applies automatically. The pressure in the brake piston is vented
to the reservoir by the motor spool of the winch control valve.
During reverse operation of the winch, or when a load is being lowered, the friction created by the brake disc
results in temperature. On the standard Model HL25 this temperature is dissipated by a circulation flow of
hydraulic fluid, supplied from an external source (see HYDRAULIC CIRCUIT). For efficient cooling of the
automatic brake, the external circulation flow should be adjusted to 7 (US) gpm (26 l/min). This circulation flow
must be returned directly to the reservoir with a permissible back pressure of 30 psi (2 bar) (see HYDRAULIC
CIRCUIT).
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 seals separating the
brake housing from the drum interior. Damage to this seal will cause the cable 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.
CONTINUED
DESCRIPTION OF THE MODEL HL25
313 REV.970901

PAGE 4
X - XX - XX - XX X - X XXXX
25
313 REV.970901
HL
EXPLANATION OF MODEL CODING
BASIC UNIT SERIES
HL = Rapid forward and reverse
SIZE OF UNIT
REDUCTION RATIO
Only used for non standard reduction ratios
TYPE OF BRAKE
-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
-86 Standard hydraulic gear motor - WM76 (12.3 in3 displacement)
-129 Standard hydraulic piston motor - VOLVO 110 cc (6.7 in3 displacement)
(For other motor options contact factory)
DRUM SIZE
-1 10 inch drum diameter X 17 inch flange diameter X 11 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.

PAGE 5
COUNTERCLOCKWISE ROTATION:
The drum rotation of the standard PULLMASTER Model HL25 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.
CABLE DRUM SIZES:
Aside from the standard drum sizes listed in APPENDIX A, the PULLMASTER Model HL25 planetary winch can
be supplied with optional drums to accommodate large wire rope storage capacity.
DRUM GROOVING:
Cable drums for the PULLMASTER Model HL25 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 HL25 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 HL25 planetary winch is limited to 2500 psi (172 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 clutch cannot be disengaged or re-engaged with a load on the wire rope
or while the cable drum is turning.
The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements.
OPTIONS
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.
DANGER
313 REV.970901

PAGE 6
SPECIFICATIONS
Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 7/8 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 10.00 in 254 mm
Flange diameter 17.00 in 432 mm
Barrel length 11.00 in 279 mm
CABLE STORAGE CAPACITY:
(Size of wire rope) 7/16 in 612 ft 186 m
1/2 in 413 ft 126 m
9/16 in 383 ft 117 m
5/8 in 297 ft 90 m
3/4 in 210 ft 64 m
7/8 in 140 ft 43 m
1 in 91 ft 28 m
-86 Gear Motor -129 Piston Motor
MAXIMUM OPERATING PRESSURE:
2500 psi (172 bar) 3800 psi (262 bar)
MAXIMUM OPERATING VOLUME: 115 (US) gpm (435 l/min) 61 (US)gpm (231 l/min)
MINIMUM OPERATING VOLUME: 30 (US) gpm (114 l/min) 14 (US) gpm (53 l/min)
DRUM TORQUE AT MAXIMUM PRESSURE: 135,937 lb-in 15,359 Nm
DRUM RPM AT MAXIMUM VOLUME: Hoisting 49 rpm
Lowering & High Speed Hoisting 229 rpm
LINE PULL AT MAXIMUM PRESSURE IN LOW FORWARD MODE:
Bare drum 25,000 lb 111.2 kN
Full drum 16,860 lb 75.0 kN
ALLOWABLE LINE PULL IN RAPID FORWARD OR RAPID REVERSE MODE:
Bare drum 5,357 lb 23.8 kN
Full drum 3,613 lb 16.1 kN
LINE SPEED AT MAXIMUM VOLUME IN LOW FORWARD MODE:
Bare drum 140 fpm 43 m/min
Full drum 207 fpm 63 m/min
LINE SPEED AT MAXIMUM VOLUME IN RAPID FORWARD OR RAPID REVERSE MODE:
Bare drum 651 fpm 198 m/min
Full drum 965 fpm 294 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.
313 REV.010201

PAGE 7
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 DIMENSIONS 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. For temperatures beyond normal
operating range, consult lubricating oil supplier or
factory.
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"
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 HL25
planetary winch:
Pressure lines: Equivalent to SAE 100R12-32
Circulation return line: Equivalent to SAE 100R4-16
Circulation supply line: Equivalent to SAE 100R6-6
High speed shifting line: Equivalent to SAE 100R1-4
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.
313 REV.021028
RECOMMENDATIONS

PAGE 8
100 378
80 302
60 227
40 151
20 76
435
0
0
115
20000
89
15000
67
10000
44
5000
22
BARE DRUM
FULL DRUM
2000
2500
1500
1000
500
0
250000
0 111
172
138
103
69
34
0
294
965
FULL DRUM
BARE DRUM
BARE DRUM
FULL DRUM
0
030
100
61
200
91
300
122
400
152
500
183
600
213
700
244
800
274
900
FULL DRUM
BARE DRUM
AND LOWERING
HIGH SPEED HOISTING
HOISTING
LINE PULL - kN
LINE SPEED - m/min
LINE PULL - lb
OIL PRESSURE - psi
OIL PRESSURE - bar
LINE SPEED - fpm
OIL VOLUME - (US)gpm
OIL VOLUME - l/min
Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with
7/8 inch diameter wire rope.
313 REV.970901
PERFORMANCE GRAPHS
FOR STANDARD GEAR MOTOR
PG-HL25-86-A
LINE SPEED VS. OIL VOLUME
LINE PULL VS. OIL PRESSURE

PAGE 9
965
294
189
50
151
40
113
30
76
20
38
10
900
274
800
244
700
213
600
183
500
152
400
122
300
91
200
61
100
30
20000
89
15000
67
10000
44
5000
22
BARE DRUM
FULL DRUM
0
250000
0 111
0
0
0
FULL DRUM
BARE DRUM
BARE DRUM
FULL DRUM
FULL DRUM
BARE DRUM
AND LOWERING
HIGH SPEED HOISTING
HOISTING
LINE PULL - kN
LINE SPEED - m/min
3040
3800
2280
1520
760
61
0
262
209
157
105
52
LINE PULL - lb
OIL PRESSURE - psi
OIL PRESSURE - bar
0
LINE SPEED - fpm
231
OIL VOLUME - (US)gpm
OIL VOLUME - l/min
PERFORMANCE GRAPHS
FOR STANDARD PISTON MOTOR
PG-HL25-129-A
LINE SPEED VS. OIL VOLUME
LINE PULL VS. OIL PRESSURE
Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with
7/8 inch diameter wire rope.
313 REV.970901

PAGE 10
HC-HL25-D
313 REV.010201
GEAR MOTOR
TYPICAL HYDRAULIC CIRCUIT
BRAKE RELEASE OPTION
SUPPLIED WITH EXTERNAL
REQUIRED FOR MODELS
2(US)GPM [8 L/MIN]
800 PSI [55 BAR]
WITH FREESPOOL OPTION
FOR MODELS SUPPLIED
PRESSURE REQUIRED
400 PSI [28 BAR]
CONTROL VALVE
FAST FORWARD
FILTER
HYDRAULIC
PUMP
RESERVOIR
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
PRESSURE
RELIEF VALVE
CIRCULATION RETURN LINE
(MUST GO DIRECT
TO RESERVOIR)
CIRCULATION SUPPLY
LINE 7 (US) GPM
[26 L/MIN]
[17 BAR]
PRESET 250 PSI
VALVE - FACTORY
PRESSURE REDUCING

PAGE 11
HC-HL25-129-C
313 REV.010201
PISTON MOTOR
TYPICAL HYDRAULIC CIRCUIT
TO
FORWARD
PORT
TO
REVERSE
PORT
[17 bar]
CONTROL VALVE
FAST FORWARD
FILTER
HYDRAULIC
PUMP
RESERVOIR
PRESSURE REDUCING
VALVE - FACTORY
PRESET 250 PSI
800 PSI [55 BAR]
2(US)GPM [8 L/MIN]
REQUIRED FOR MODELS
SUPPLIED WITH EXTERNAL
BRAKE RELEASE OPTION
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
400 PSI [28 BAR]
PRESSURE REQUIRED
FOR MODELS SUPPLIED
WITH FREESPOOL OPTION
CIRCULATION RETURN LINE
(MUST GO DIRECT
TO RESERVOIR)
CIRCULATION
SUPPLY LINE
7 (US) gpm
26 l/min
PRESSURE
RELIEF VALVE
3.5 TO 4(US) gpm
[13 TO 15 l/min]

PAGE 12
The initial installation or mounting of a PULLMASTER planetary winch is critically important for proper operation
and performance. If the winch is mounted to an uneven surface, the centre line of the unit can be distorted to a
point where the winch will not operate in either direction. It is therefore very important that the following
instructions are observed when a PULLMASTER planetary winch is installed:
1) Make certain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted.
2) Set the winch on the mounting platform and check for surface contact on all mounting pads of the winch.
3) If there is a space between the mounting surface and one of the mounting pads, the mounting surface is not
even and the space below the mounting pad must be shimmed. If this condition exists, proceed as follows:
a) Install mounting bolts snug tight on the three mounting pads which are in contact with the mounting
surface. (For mounting bolt size and grade see INSTALLATION DIMENSIONS.)
b) Measure the space underneath the fourth mounting pad with a feeler gauge and use shim stock of
equivalent thickness in the space between the mounting pad and the mounting surface.
c) Only after this procedure should the fourth mounting bolt be installed. Tighten all four bolts 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. Ensure there is no back pressure at
pressure reducing valve tank port.
8) Verify that breather relief, item 130, is above oil level on end cover, item 120. Rotate end cover if breather
relief is below oil level.
IMPORTANT: 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.
9) Ensure brake housing and clutch housing are full of oil at all times.
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
313 REV.970901
INSTALLATION INSTRUCTIONS
DANGER

PAGE 13
FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
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.
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 3-4 wraps
of wire rope for safety.
3) The winch operation is controlled by a single control valve lever which has a forward, a reverse and a neutral
position. Speed control in either direction is obtained by modulation of the control valve lever. Maximum line
speed in either direction is obtained when the control valve lever is moved as far as it can go. The disc brake
of the winch will come on automatically when the winch control lever is returned to neutral.
4) Always warm up equipment prior to operating winch, particularly in low ambient temperature. Circulate
hydraulic oil through the winch control valve for several minutes to warm the hydraulic system. To prime the
winch with warm oil, operate the winch at slow speed, forward and reverse, several times.
5) Prevent corrosion damage to winch interior. If not used regularly, run winch up and down at least once every
two weeks.
6) To ensure proper winch installation and function, raise and lower a full test load to a safe height before using
winch for regular operation at the start of each shift.
If, after a new installation, the winch does not function properly, refer to the TROUBLESHOOTING section
of this manual.
OPERATING INSTRUCTIONS
313 REV.970901
SI1013 - HL25
DANGER
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.
CABLE ANCHOR SLOT
CABLE ANCHOR

PAGE 14
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
hydraulic circuit components should be checked for proper function. Make certain hydraulic reservoir is filled to
top level. If the pump is drive by v-belts, check for belt slippage.
IMPORTANT:
The hydraulic operating 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, install a flow
meter into the hydraulic circuit to check the volume 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.
The hydraulic operating pressure relates to the line pull or lifting capacity of the winch.
If the winch will not lift the specified maximum line pull, install a pressure gauge into 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.
Only if the hydraulic system has been checked and found to be in order, use the following indications for
probable causes of failure in the winch:
313 REV.970317
TROUBLE SHOOTING
FAILURE PROBABLE CAUSE
Winch will not produce line pull at maximum
pressure as listed in SPECIFICATIONS.
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 system.
e) Relief valve may be set too low. (See SPECIFICATIONS
for maximum operating pressure.)
f) Winch is in high speed mode.
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 brake
from being released against the brake springs. This is
caused by damaged O-ring seals on the brake piston.
b) The O-ring seals, on the brake release channel between
the motor adaptor, clutch housing or brake housing is
damaged. If this failure occurs there will be leakage either
from the motor adaptor, clutch housing or brake housing.
c) Insufficient hydraulic pressure. (See SPECIFICATIONS
for minimum operating pressure.)
d) Winch is mounted to an uneven surface.
(See INSTALLATION INSTRUCTIONS.)
e) Hydraulic pressure is not reaching the brake piston
(plugged brake release passage in the brake housing).
Winch will not produce line speed at maximum
volume as listed in SPECIFICATIONS.
Winch will not reverse.

PAGE 15
FAILURE PROBABLE CAUSE
a) Loss of clutch release pressure. Check pressure
reducing valve and O-rings.
b) Seized clutch piston caused by contamination in oil supply.
c) Incorrect hydraulic connections. Refer to TYPICAL
HYDRAULIC CIRCUITS.
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 release.
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.
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. (See TYPICAL HYDRAULIC
CIRCUIT when the winch is reversed.)
c) Control valve has poor metering characteristics.
d) Damaged brake plates or divider plates.
e) The sprag clutch, which connects the motor shaft with
the brake assembly, is damaged.
f) Air mixed with hydraulic oil (foamy oil).
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 reservoir.
Clutch will not engage (will not shift into rapid
forward speed).
TROUBLE SHOOTING CONTINUED
313 REV.970317
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model HL25 winch.
Brake will not hold.
Brake vibrates when lowering a load.
Oil leaks.

PAGE 16
GENERAL:
Before attempting disassembly of the PULLMASTER Model HL25 planetary winch, 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. Because
the following service instructions cover the HL25 planetary winch with either a gear motor or a piston motor, verify
the proper seal kits are on hand before disassembly. For models with a gear motor, use seal kit (Part No. 23120)
and, providing the hydraulic motor has to be serviced, seal kit (Part No. 23117). Two new roller bearings, item
875, may also be required (Part No. 25352). For models with a piston motor, use seal kit (Part No. 23140).
NOTE: 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.
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 or clutch 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. The service instructions cover assembly and disassembly of Model HL25 with either hydraulic gear
or piston motors. Refer to appropriate instructions and group drawing for each motor. The remaining instructions
apply to all Model HL25s.
DISASSEMBLY
For the majority of required service or repair work, disassembly is required only in the brake housing or clutch
housing of the PULLMASTER Model HL25 planetary winch. 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 GEAR MOTOR ASSEMBLY:
If the analysed service or repair work requires access to the interior of the brake housing or clutch housing, the
hydraulic gear 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 two socket head capscrews, item 849, and lockwashers, item 847, from transfer tube housing, item
846. Remove transfer tube housing from end cover, item 870. Remove and discard O-ring, item 112. If
pressure reducing valve, item 841, is faulty, replace at this time.
2) Press slotted spring pins, item 848, partially out of transfer tube housing, item 846, to release tube locator,
item 848. Remove and discard O-ring, item 113.
3) Remove transfer tube assembly, item 844, from center of motor drive gear, which is part of gear set, item
881. Remove and discard O-ring, item 879.
4) Remove eight hex capscrews, item 951, together with lockwashers, item 953, from motor assembly.
IMPORTANT: Failure to exercise care when removing motor port end cover or gear housing could
permanently damage machined surfaces of these motor components. Take care not
to damage machined surfaces of motor components at disassembly.
5) 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.
SERVICE INSTRUCTIONS
313 REV.970901

PAGE 17
6) If thrust plate comes off with end cover, carefully pry it off of bearings, item 875, and discard teflon seals,
item 887.
7) Remove gear set, item 881, which consists of two gears which are a matched set.
8) 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.
9) If thrust plate stays on motor adaptor, carefully pry it off of bearings, item 875, and discard teflon seals, item 887.
10) 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.
Teflon seals, gasket seals and ring seals in the hydraulic motor assembly are not part of winch seal kit. Seal kit
for hydraulic motor can be ordered from factory under Part No. 23117. All parts of the hydraulic motor, with
exception of motor adaptor, item 800, and 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 GEAR MOTOR ASSEMBLY:
If disassembly of the hydraulic gear motor is not necessary, proceed as follows:
1) Remove transfer tube assembly, item 844, as instructed in step 1 - 3 under DISASSEMBLY OF HYDRAULIC
GEAR MOTOR ASSEMBLY.
2) Remove nine hex head capscrews, item 931, with lockwashers, item 541, and remove motor adaptor, item
800, from clutch housing, item 650.
3) Remove and discard three O-rings, item 801, from flange of motor adaptor.
REMOVAL OF HYDRAULIC PISTON MOTOR:
If fitted with a piston motor, proceed as follows:
1) Remove brake tube assembly, item 852, from motor and motor adaptor, item 800.
2) Remove four hex head capscrews, item 815, and lockwashers, item 817, from motor, item 850. Pull motor
out of motor adaptor, item 800, and discard O-ring, item 819.
3) Remove nine hex head capscrews, item 931, with lockwashers, item 933. Remove motor adaptor, item 800,
and discard three O-rings, item 801.
4) Unscrew six socket head capscrews, item 687, with lockwashers, item 685, and remove bearing carrier, item
664, from motor adaptor. Discard, O-ring, item 667. Remove two seal rings, item 666.
5) Remove clutch connector, item 668, from bearing carrier, item 664, and check that oil passages are clear.
6) Inspect ball bearing, item 665, for damage. If replacement is required, press out of bearing carrier, item 664.
7) Inspect needle bearing, item 669, in motor adaptor. If damaged, press out of motor adaptor and replace.
DISASSEMBLY OF CLUTCH ASSEMBLY:
1) Remove three socket head capscrews, item 682, and lockwashers, item 683, from clutch housing, item 650.
Since brake springs, item 752, apply pressure against inside of clutch housing, it is recommended that these
three capscrews are unscrewed, one turn at a time, until spring pressure has been released. Remove and
discard O-ring, item 707, and O-ring, item 651. Remove and discard three O-rings, item 763.
2) Pull motor drive shaft, item 730, and complete clutch assembly, from brake housing.
3) Disassemble clutch assembly by removing circlip, item 671, from clutch hub, item 670. Remove clutch plate,
item 654, external retaining ring, item 658, eight friction plates, item 673, and seven divider plates, item 675.
SERVICE INSTRUCTIONS CONTINUED
313 REV.010201

PAGE 18
Clamp clutch hub, item 670, to pressure plate, item 652, and remove circlip, item 679. Remove clutch hub, three
clutch springs, item 676, pressure plate, item 652, and gland, item 656, from motor drive shaft. Remove and
discard O-rings, item 653, 657 and 735.
Models with piston motors only: Discard two O-rings, item 689.
4) The surface of motor drive shaft which engages sprag clutch, item 672, should be inspected for wear or
indentations. If motor drive shaft shows any surface damage, it should be replaced.
5) Inspect three clutch springs for damage and measure overall length. Overall spring length should be 1.25
inch. If any spring measures less than 1.19 inch, all three springs should be replaced as a set.
6) Inspect eight friction plates, item 673, for damage or excessive 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 plates and divider plates as a set.
7) Remove circlip, item 661, and slide drive gear, item 660, off of connecting shaft, item 600.
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:
1) Remove 18 brake springs, item 752, from brake piston, item 750. 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.
2) Pull brake piston, item 750, out of brake housing using two 5/8-11NC bolts screwed into two puller holes in
piston and discard O-rings, item 751 and 753.
3) Thoroughly examine inner bores of brake housing and outer diameters of brake piston for scoring caused by
hydraulic fluid contamination. Minor surface damage may be repaired by polishing with a fine emery cloth.
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.
4) Remove five friction plates, item 715, together with six divider plates, item 713, 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.
5) Remove brake spacer, item 712.
DISASSEMBLY OF FINAL DRIVE:
1) Remove drain plug, item 121, from end cover, item 120, and drain lubricating oil from final drive assembly
and the cable drum interior. (To drain all oil out of cable drum interior, winch should be tipped to an angle and
filler plug, item 503, removed.)
2)
Remove internal retaining ring, item 124, and pull end cover, item 120, out of final drive housing, item 100.
3) Discard O-ring, item 123, and inspect planet hub stopper, item 126, and sungear stopper, item 122, for
excessive wear. Replace planet hub stopper if less than .30 inch and sungear stopper if less than .21 inch thick.
4) Remove final planet hub assembly from final housing, item 100.
313 REV.970901
SERVICE INSTRUCTIONS CONTINUED
DANGER