Pullmaster M25 Technical reference manual

PMC 261 051117
INSTRUCTION AND PARTS MANUAL
MODEL M25
FREE FALL
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 a 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 1261 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.
DANGER
SAFETY RECOMMENDATIONS
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 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.
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
GENERAL DESCRIPTION:
The PULLMASTER Model M25 with free fall is a planetary hydraulic winch having equal speed in both directions
and the ability to lower a load FAST. The free fall option comes in three variations: emergency free fall,
controlled free fall, or with both combined. The main components of this unit are:
jj ✛Hydraulic gear motor
✛Multi disc brake with static and dynamic function
✛Over-running clutch
✛Hydraulic gear motor
✛Primary planet reduction
✛Final planet reduction
✛Brake housing
✛Cable drum
✛Free fall housing
✛Free fall clutch assembly
✛Metering pump assembly (for controlled free fall)
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 of the primary reduction is transferred to the final sungear, which is splined to the
primary planet hub. The final planet assembly is locked in place by the free fall clutch and does not rotate, so the
rotation is transmitted to the cable drum by the final drive planet gears. In forward rotation, or when a load is lifted,
an over-running clutch, which connects the motor drive shaft to the automatic brake assembly, permits free
rotation of the sungear, 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, or when the winch is pressurized for lowering of a load, hydraulic pressure from the reverse
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, which are engaged into the brake
housing. If the load on the cable drum tends to effect the lowering speed, the resulting pressure drop in the brake
piston causes friction between the brake discs and the divider plates. In this way, a completely smooth pay out
speed can be achieved in a stepless operation by modulation of the winch control handle. When the control
handle is returned to neutral position, rotation stops and the disc brake applies automatically. A hydraulic counter-
balance valve or holding valve is not required for smooth and positive operation of the automatic brake.
During lowering operations of the winch, the friction created by the brake discs results in heat. This heat is
dissipated by the circulation of hydraulic fluid through the brake housing, supplied internally from the motor, or
externally, depending on the brake code of the winch. For efficient cooling of the automatic brake, models with
external circulation should be adjusted to supply 5 (US) gpm - 19 l/min. This flow must be returned directly to
the reservoir with a permissible back pressure of 30 psi (2 bar).
IMPORTANT: Under no circumstances must the 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.
DESCRIPTION OF THE MODEL M25 WITH FREE FALL
261 REV.040708
PRIOR TO OPERATION OF THIS UNIT ALWAYS ENSURE COMPLIANCE
WITH ANY NATIONAL OR LOCAL SAFETY CODES AND REGULATIONS
REGARDING THE USE OF FREE FALL WINCHES.
WARNING

PAGE 3
FUNCTION OF THE EMERGENCY FREE FALL:
When the Model M25 planetary winch is actuated for emergency free fall, hydraulic pressure is channelled to
the clutch piston, causing the clutch piston to press against a series of springs and release the multi-disc clutch.
This effectively disconnects the cable drum from the gear train of the winch and any suspended load will drop.
The minimum load required to establish the emergency free fall mode is 500 lb (227 kg).
CONTROLLED FREE FALL:
The controlled free fall offers positive down control of a load at selected speeds and can be stopped anywhere
on the way down. The controlled free fall is not designed, nor intended to lower the maximum load in a
controlled free fall. The permissible load is 30% of the maximum line pull capacity of the winch. Since the clutch
release pressure of the controlled free fall varies in accordance with the size of the load, a metering pump is
utilized to compensate for clutch release pressure variations.
FUNCTION OF CONTROLLED FREE FALL:
The controlled free fall has the same basic function as the emergency free fall with the addition of a metering
pump which regulates the different clutch pressure requirements during a controlled free fall. When the
controlled free fall is actuated, hydraulic pressure is channelled into the clutch piston, causing the clutch piston
to press against a series of springs and release the multi-disc clutch. When the clutch has been released, the
final planet assembly rotates with the cable drum, around a stationary sungear. A small hydraulic gear pump is
splined to the final planet hub. This hydraulic pump displaces hydraulic oil flow out of the free fall control circuit
to compensate for the difference in the clutch release pressure, which varies according to the actual lowering
speed. The faster the load is lowered with the free fall control, the faster the planet hub will cause the pump to
turn, increasing the displacement volume drawn out of the control circuit. When the free fall control is returned
to neutral, the hydraulic pressure in the clutch piston is vented and the free fall clutch is re-engaged by spring
pressure.
COMBINED EMERGENCY AND CONTROLLED FREE FALL:
The emergency and controlled free fall can be combined for installations where both of these options are
required. Two separate controls must be used for this option and the operating criteria for both functions must
be adhered to.
IMPORTANT: Under no circumstances must the pressure in the free fall housing be permitted to exceed 10
psi (.7 bar). Excessive pressure in the free fall housing will damage the oil seal separating the
free fall housing from the drum interior. Damage to this seal will cause the drum to fill up with
hydraulic fluid.
DESCRIPTION OF THE MODEL M25 WITH FREE FALL
261 REV.980701
CONTINUED
DANGER
RE-ENGAGING FREE FALL CLUTCH WHILE LOAD IS DROPPING
CAUSES SHOCK LOADS AND WILL LEAD TO CABLE FAILURE,
PROPERTY DAMAGE, SEVERE INJURY OR DEATH. INTERLOCK
HYDRAULIC CONTROL TO PREVENT RE-ENGAGING FREE FALL
CLUTCH WHILE LOAD IS DROPPING.
EMERGENCY FREE FALL:
The emergency free fall is used for a full release of a suspended load up to the maximum load capacity of the
Model M25 planetary winch. Upon acitivating the emergency free fall function the load will drop and must be
allowed to fall to its end travel without re-engagement.

PAGE 4
X - XX - XX - XX X - X XXXX
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
- 86 Hydraulic motor, 3 inch gear section (12.3 cubic inch displacement)
(Other gear sections for this motor are optional)
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
- C Controlled free fall
- D Emergency free fall
- G Combined emergency and controlled free fall
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.
EXPLANATION OF MODEL CODING
25
M
261 REV.980701

PAGE 5
OPTIONS
COUNTERCLOCKWISE ROTATION:
The drum rotation of the standard PULLMASTER Model M25 planetary winch with free fall is clockwise for
hoisting when looking at the hydraulic motor of the winch. Drum rotation for counterclockwise hoisting direction
is available as an option.
INTERNAL CIRCULATION:
The PULLMASTER Model M25-7-86-X has an external circulation flow supply line to cool the brake. Internal
circulation 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 M25 planetary winch with
free fall can be supplied with optional drums to accommodate large wire rope storage capacity.
DRUM GROOVING:
Cable drums for the PULLMASTER Model M25 planetary winch with free fall 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 PULLMASTER Model M25 planetary winch with free fall can be changed by using a
different displacement motor. (Contact the factory for performance information of different gear sections.)
HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS:
The operating pressure of the PULLMASTER Model M25 planetary winch with free fall 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.)
The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements.
FAILURE TO PROPERLY VENT EXTERNAL BRAKE RELEASE
PORT WILL TRAP BRAKE PRESSURE AND ALLOW THE
LOAD TO DROP, CAUSING PROPERTY DAMAGE, SEVERE
INJURY OR DEATH. WINCHES SUPPLIED WITH EXTERNAL
RELEASE OPTION MUST BE CONNECTED ACCORDING
TO TYPICAL HYDRAULIC CIRCUIT.
261 REV.970701
DANGER

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 486 ft 148 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
MAXIMUM OPERATING PRESSURE: 2500 psi 172 bar
MAXIMUM OPERATING VOLUME: 115 (US) gpm 435 l/min
MINIMUM OPERATING VOLUME: 30 (US) gpm 114 l/min
DRUM TORQUE AT MAXIMUM PRESSURE: 135,937 lb-in 15,359 Nm
DRUM RPM AT MAXIMUM VOLUME: Hoisting 49 rpm
HOISTING LINE PULL AT MAXIMUM PRESSURE:
Bare drum 25,000 lb 111.2 kN
Full drum 16,860 lb 75.0 kN
MAXIMUM ALLOWABLE LINE PULL WHEN USING
CONTROLLED FREE FALL: Bare drum 7,500 lb 33.4 kN
Full drum 5,289 lb 23.5 kN
HOISTING LINE SPEED AT MAXIMUM VOLUME:
Bare drum 140 fpm 43 m/min
Full drum 207 fpm 63 m/min
PERMISSIBLE SYSTEM BACK PRESSURE
AT MOTOR RETURN PORT:
65 psi 4.5 bar
PERMISSIBLE PRESSURE
AT CIRCULATION SUPPLY PORT:
Brake housing 30 psi 2 bar
Free fall housing 30 psi 2 bar
LUBRICATING OIL: Refer to RECOMMENDATIONS for viscosity and instructions.
Refer to APPENDIX A for oil volume required.
261 REV.010611

PAGE 7
180
54
160
48
140
42
120
36
100
30
80
24
60
18
40
12
20
6
20000
89
15000
67
10000
44
5000
22
BARE DRUM
FULL DRUM
LINE PULL - kN
LINE SPEED - m/min
BARE DRUM
FULL DRUM
2000
2500
1500
1000
500
0
125
100
75
50
25
0
250000
0 111
172
138
103
69
34
0
LINE PULL - lb
OIL PRESSURE - psi
OIL PRESSURE - bar
0207
063
0
LINE SPEED - fpm
95
189
284
379
473
OIL VOLUME - (US)gpm
OIL VOLUME - l/min
PG-M25-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 7/8 inch
diameter wire rope.
261 REV.010611
MAXIMUM ALLOWABLE LINE PULL WHEN USING
CONTROLLED FREE FALL: jjlkjalkf
Bare drum 7,500 lb 33.4 kN
Full drum 5,289 lb 23.5 kN
PERFORMANCE GRAPHS

PAGE 8
EMERGENCY FREE FALL: HC-M25-X-XX-XD-B
RE-ENGAGING FREE FALL CLUTCH WHILE LOAD IS DROPPING
CAUSES SHOCK LOADS AND WILL LEAD TO CABLE FAILURE,
PROPERTY DAMAGE, SEVER INJURY OR DEATH. INTERLOCK
HYDRAULIC CONTROL TO PREVENT RE-ENGAGING FREE FALL
CLUTCH WHILE LOAD IS DROPPING.
261 REV.970701
DANGER
TYPICAL HYDRAULIC CIRCUIT
0-1000 PSI
PRESSURE GAUGE
FREEFALL CLUTCH RELEASE
750 PSI (52 BAR)
FREEFALL
CIRCULATION
RETURN
BRAKE CIRCULATION
RETURN (DIRECT TO
RESERVOIR)
BRAKE
CIRCULATION
5 USGPM
(19 L/MIN)
EXTERNAL
CIRCULATION
MODELS ONLY
FREEFALL
CIRCULATION
2 USGPM
(8 L/MIN)
HYDRAULIC
PUMP
RESERVOIR
FILTER
PRESSURE
RELIEF VALVE
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER

PAGE 9
TYPICAL HYDRAULIC CIRCUIT
CONTROLLED FREE FALL: HC-M25-X-86-XC
261 REV.950501
FLOW DIVIDER
(PRESSURE &
TEMPERATURE
COMPENSATED)
CONTROL VALVE
WITH METERING
MOTORSPOOL;
SPRING RETURN
TO NEUTRAL;
PORT B PLUGGED
BA
P
T
RELIEF VALVE
750 PSI
(52 BAR)
0-1000 PSI
PRESSURE GAUGE
2.5 USGPM
(9 LPM)
FREEFALL
CIRCULATION
RETURN
BRAKE CIRCULATION
RETURN (DIRECT TO
RESERVOIR)
BRAKE
CIRCULATION
5 USGPM
(19 L/MIN)
EXTERNAL
CIRCULATION
MODELS ONLY
FREEFALL
CIRCULATION
9 USGPM
(34 LPM)
HYDRAULIC
PUMP
RESERVOIR
FILTER
RELIEF VALVE
2500 PSI
(172 BAR)
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO
CENTER

PAGE 10
TYPICAL HYDRAULIC CIRCUIT
COMBINED EMERGENCY & CONTROLLED FREE FALL: HC-M25-X-86-XG
261 REV.950501
CONTROL VALVE
WITH PUSH
BUTTON AND
TWO DETENTS
BA
PT
2.5 USGPM
(9 LPM)
SHUTTLE
VALVE
0-1000 PSI
PRESSURE GAUGE
CONTROL VALVE
WITH METERING
MOTORSPOOL;
SPRING RETURN
TO NEUTRAL;
PORT B PLUGGED
FLOW DIVIDER
(PRESSURE &
TEMPERATURE
COMPENSATED)
RELIEF
VALVE
750 PSI
(52 BAR)
FREEFALL
CIRCULATION
RETURN
BRAKE CIRCULATION
RETURN (DIRECT TO
RESERVOIR)
BRAKE
CIRCULATION
5 USGPM
(19 L/MIN)
EXTERNAL
CIRCULATION
MODELS ONLY
FREEFALL
CIRCULATION
9 USGPM
(34 LPM)
HYDRAULIC
PUMP
RESERVOIR
FILTER
RELIEF VALVE
2500 PSI
(172 BAR)
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER

PAGE 11
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. Consult lubricating oil supplier or
factory for temperatures beyond normal operating
range.
The final drive of the winch is lubricated by the hydraulic
oil which is circulated through the free fall housing.
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 WINCH 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 M25
planetary winch with free fall:
Pressure lines: Equivalent to SAE 100R 12-32
Circulation return line: Equivalent to SAE 100R 4-16
Circulation supply line: Equivalent to SAE 100R 6-6
Free fall release line: Equivalent to SAE 100R 3-4
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.
RECOMMENDATIONS
261 REV.021029

PAGE 12
EMERGENCY FREE FALL
CONTROL VALVE:
The emergency free fall requires a two position,
three-way valve. The pressure port must be open to
the reservoir when the emergency free fall is not
actuated and must pressurize the free fall release port
on the winch when the free fall control button is
pressed. A selector valve with two detent positions is
best suited. If the emergency free fall is combined
with controlled free fall, a standard two position, four-
way selector valve with two detents should be used.
(Refer to TYPICAL HYDRAULIC CIRCUIT.)
CONTROLLED FREE FALL
CONTROL VALVE:
For positive speed control, the valve used for the
controlled free fall must be a “spring return”, two
position selector valve, which has good metering
characteristics and on which the pressure port is open
to the reservoir when the controlled free fall is not
operating.
PRESSURE GAUGE:
To monitor free fall release port pressure install a 1000
psi (69 bar) pressure gauge between the free fall
control valve and the release port.
IMPORTANT:
The circulation return lines must go direct to reservoir.
Pressure in the free fall housing must not be permitted
to exceed 10 psi (.7 bar).
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.
RECOMMENDATIONS CONTINUED
261 REV.980701

PAGE 13
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 and free
fall housing remain full of oil at all times. Connect the return lines directly to reservoir. Do not connect to a
common return line.
7) Bleed the air out of the free fall control circuit by loosening the connection at the free fall release port on the
winch. With no load on the cable drum, operate the free fall control valve, letting all air escape, then re-tighten
the connection at the release port.
8) 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.
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
INSTALLATION INSTRUCTIONS
DANGER
261 REV.970701

PAGE 14
OPERATING INSTRUCTIONS
261 REV.051117
FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
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.
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. 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 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.
SI1013 - M25FF
CABLE ANCHOR SLOT
CABLE ANCHOR

PAGE 15
EMERGENCY FREE FALL:
To actuate the emergency free fall, push the emergency free fall control to disconnect the cable drum from the
gear train of the winch. The load (minimum 500 lb - 227 kg) will drop. The speed of the free fall will depend on
the size of the load on the wire rope.
RE-ENGAGING FREE FALL CLUTCH WHILE LOAD IS DROPPING
CAUSES SHOCK LOADS AND WILL LEAD TO CABLE FAILURE,
PROPERTY DAMAGE, SEVER INJURY OR DEATH. INTERLOCK
HYDRAULIC CONTROL TO PREVENT RE-ENGAGING FREE FALL
CLUTCH WHILE LOAD IS DROPPING.
CONTROLLED FREE FALL:
To operate the controlled free fall, open the free fall control lever gradually to obtain smooth acceleration of the
lowering speed of the winch. The lowering speed is in direct proportion with the movement of the free fall control
lever. To decelerate or slow down the load, slowly return the control lever back to it’s neutral position. Sudden
stops of an accelerating load and erratic operation of the free fall control lever should be avoided. For better
modulation of the free fall control, a long handle should be used on the free fall control valve.
IMPORTANT: The controlled free fall is not designed nor intended to lower the maximum load in a controlled
freefall. The permissible load of the PULLMASTER Model M25 controlled free fall operation
is 30% of the maximum line pull capacity of the winch.
If, after a new installation, the winch does not function properly, refer to the TROUBLESHOOTING section of this
manual.
DANGER
261 REV.010611
OPERATING INSTRUCTIONS CONTINUED

PAGE 16
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) Clutch release valve may be in release position.
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 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.)
e) Hydraulic pressure is not reaching the brake piston
(plugged brake release orifice in the brake housing).
Winch will not produce line speed at maximum
volume as listed in SPECIFICATIONS.
Winch will not reverse.
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 system can be analysed. If this condition exists, 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.
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 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. If the pump is driven by V-belts, check for belt slippage. When checking oil pressure and
volume in the hydraulic circuit, make certain 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:
261 REV.950501
TROUBLE SHOOTING

PAGE 17261 REV.950501
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model M25 winch with free fall.
TROUBLESHOOTING CONTINUED
FAILURE PROBABLE CAUSE
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) Hydraulic pressure is trapped in the clutch piston, preventing
total engagement. This is caused by using an incorrect
control valve. The free fall control valve must leave the free
fall release port open to reservoir when not activated.
f) Wire rope is fastened to the incorrect cable anchor slot.
g) Sprag clutch is damaged or surfaces where sprag clutch
engages on motor drive shaft or brake hub are worn or
indented.
h) Winch supplied with external brake release option is not
plumbed per TYPICAL HYDRAULIC CIRCUIT. Failure to
vent external brake release port to reservoir may trap
pressure and cause winch brake to slip.
a) Pump does not supply sufficient flow. Pump rpm must be
maintained at normal operating speed when a load is
lowered.
b) Brake is running too hot. This is caused by insufficient
circulation flow. To check the circulation, observe the flow of
oil from the circulation return line of the winch (approx. 5
(US) gpm - 19 l/min when the winch is reversed).
c) Control valve for the winch operation 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).
a) Insufficient pressure or flow supplied to free fall release port
(refer to TYPICAL HYDRAULIC CIRCUIT).
b) O-ring seals in clutch piston are damaged.
c)
Insufficient load on the wire rope. A minimum of 500 lb (227 kg)
on a standard -1 drum is required to drop a load in free fall.
Brake will not hold.
Brake vibrates when powering down a load.
Free fall clutch cannot be disengaged.

PAGE 18 261 REV.950501
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model M25 winch with free fall.
TROUBLESHOOTING CONTINUED
FAILURE PROBABLE CAUSE
Free fall cannot be controlled. a) Emergency free fall is non-controllable.
b) Piping circuit or control valve is incorrect. Check hydraulic
circuit.
c) Control valve used has poor metering characteristics. The
control valve should have a flow capacity of 3-6 gpm
maximum. If a large volume control valve is used, it may
not provide good metering of the hydraulic oil, resulting in
poor speed control.
d) Hydraulic metering pump, installed in the end housing, is
damaged.
a) Oil leaks from the motor flange are caused by a damaged
O-ring seal on the motor flange.
b) Oil leaks occurring between the cable drum flange and
brake housing are caused by excessive pressure in the
brake housing or free fall housing. Excessive pressure in
the brake housing will damage oil seal, item 607, which
separates the brake housing from the drum interior.
Excessive pressure in the free fall housing will damage oil
seal, item 505, which separates the free fall housing from
the drum interior. In this condition hydraulic fluid will leak
into the drum interior, then damage oil seal, item 531.
c) Oil leaks occurring between the cable drum flange and
free fall housing are caused by excessive pressure in the
free fall housing. Excessive pressure in the free fall
housing will damage oil seal, item 105. Maximum allowable
back pressure in the free fall housing is 10 psi (0.7 bar).
Check for restrictions in circulation return line (must go
directly to reservoir).
d) Oil leaking out of the free fall housing on either side of the
spring retainer is caused by a damaged O-ring seal, item
213.
e) Oil leaking out of the end cap indicates a damaged O-ring,
item 241.
Oil leaks.