Pullmaster M5 Technical reference manual

070228
INSTRUCTION AND PARTS MANUAL
PMC 316
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.
THE LOGICAL CHOICE
MODEL M5
Design Revision 'B'
PLANETARY HYDRAULIC WINCH

US.DIST.01.01.07 [PULLMASTER LOGO]
Pullmaster Limited Warranty Effective 8/1/2008
SUPERSEDES ALL PRIOR WARRANTIES
Seller warrants that each article (whether Gear Drive Products, Brake Products and/or Winch Products, all of which are covered hereunder)
sold under this order shall at the time of shipment (i) conform to applicable specifications, and (ii) be free from defects in material and
workmanship during normal and ordinary use and service (the "Warranty").
Buyer's exclusive remedy and Seller's sole obligation under this Warranty shall be, at Seller's option, to repair or replace any article or part
thereof which has proven to be defective, or to refund the purchase price of such article or part thereof. Buyer acknowledges that Buyer is
knowledgeable concerning the articles covered by this Warranty and sold in connection therewith which are being purchased, that Buyer has
reviewed this Warranty and that the remedies provided hereunder are adequate and acceptable to Buyer.
This Warranty shall expire one (1) year from the date the article is first shipped by Seller. Notice of claimed breach of this Warranty must be
given by Buyer to Seller within the applicable period. Such notice shall include an explanation of the claimed warranty defect and proof of
date of purchase of the article or part thereof for which warranty coverage is sought. No allowances shall be made by Seller for any
transportation, labor charges, parts, "in and out" costs, adjustments or repairs, or any other work, unless such items are authorized in writing
and in advance by Seller. Nor shall Seller have any obligation to repair or replace items which by their nature are expendable.
If an article is claimed to be defective in material or workmanship, or not to conform to the applicable specifications, Seller will either
examine the article at Buyer's site or issue shipping instructions for return to Seller. This Warranty shall not extend to any articles or parts
thereof which have been installed, used, or serviced otherwise than in conformity with Seller's applicable specifications, manuals, bulletins,
or instructions, or which shall have been subjected to improper installation, operation, or usage, misapplication, neglect, incorrect
installation, overloading, or employment for other than normal and ordinary use and service. This Warranty shall not apply to any article
which has been repaired, altered or disassembled, or assembled by personnel other than those of Seller. This Warranty shall not apply to
any article upon which repairs or alterations have been made (unless authorized in writing and in advance by Seller). This Warranty shall
not apply to any articles or parts thereof furnished by Seller to Buyer's specifications and/or furnished by Buyer or acquired from others at
Buyer's request.
SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND, OTHER THAN THE WARRANTY
EXPRESSLY SET FORTH ABOVE. SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND ACCEPTED IN LIEU OF ANY AND ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT LIMITATION THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
Buyer expressly agrees that Seller is not responsible to perform any work or investigation related in any way to tensional vibration issues
and is not responsible for the detection or remedy of Natural Frequency Vibration of the mechanical system in which the unit is installed.
Buyer acknowledges, understands and agrees that this Warranty does not cover failures of the unit which result in any manner from the
operation of the machine or unit at vibration frequencies at or near the natural frequency vibration of the machine in such a way that damage
may result. Buyer expressly agrees that Seller is not responsible for failure damage or accelerated wear caused by machine or ambient
vibration. Further, Buyer acknowledges and agrees that Buyer is always solely responsible for determination and final approval of the
“application factor”which may be used in Seller’s calculations, and this application factor is 1.0 unless otherwise stated in Seller’s quotation
specifications.
The remedies for this Warranty shall be only those expressly set forth above, to the exclusion of any and all other remedies of whatsoever
kind. The limited remedies set forth above shall be deemed exclusive, even though they may fail their essential purpose. No agreement
varying or extending the foregoing Warranty, remedies, exclusions, or limitations shall be effective unless in a writing signed by an executive
officer of Seller and Buyer. This Warranty is non-transferable. If a party who had purchased articles from Buyer, or from persons in privity
with Buyer, brings any action or proceeding against Seller for remedies other than those set forth in this Warranty, Buyer agrees to defend
Seller against the claims asserted in such action or proceeding at Buyer’s expense, including the payment of attorneys’fees and costs, and
indemnify Seller and hold Seller harmless of, from and against all such claims, actions, proceedings or judgments therein. Buyer also
agrees to defend and indemnify Seller of, from and against any loss, cost, damage, claim, debt or expenses, including attorneys’fees,
resulting from any claims by Buyer or third parties to property or injury to persons resulting from faulty installation, repair or modification of
the article and misuse or negligent operation or use of the article, whether or not such damage to property or injury to persons may be
caused by defective material, workmanship, or construction. ADVISORY: Winches and hoists are not approved for lifting or handling
personnel or persons unless specifically approved in writing from Seller for the specific intended application.
Under no circumstances shall Seller be liable (i) for any damage or loss to any property other than the warranted article or part thereof, or (ii)
for any special, indirect, incidental, or consequential damage or loss, even though such expenses, damages, or losses may be foreseeable.
The foregoing limitations on Seller's liability in the event of breach of warranty shall also be the absolute limit of Seller's liability in the event
of Seller's negligence in manufacture, installation, or otherwise, with regard to the articles covered by this Warranty, and at the expiration of
the Warranty period as above stated, all such liabilities shall terminate. Buyer’s purchase of any article(s) covered by this Warranty shall
constitute acceptance of the terms and conditions hereof and shall be binding upon Buyer and Buyer’s representatives, heirs and assigns.
The laws of the Province of British Columbia shall govern Buyer’s rights and responsibilities in regard to this Warranty and the transaction(s)
subject thereto, and the Province of British Columbia shall be the exclusive forum and jurisdiction for any action or proceedings brought by
Buyer in connection herewith or any dispute hereunder. If any of the terms and conditions contained within this Warranty are void, the
remaining provisions thereof are and shall remain valid and enforceable.
Note: Prices and specifications contained in this price book are subject to change without notice.

PAGE 1
316REV.051117
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.
The planetary hydraulic winches are made for hoisting and lowering loads and to be operated by trained and professional
personnel.Theyare notdesignedfor operationsinvolvingliftingor movingpersonnel. Thewinches arepowered byhydraulic
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.
Thewinchesaretobeusedwithinthespecificationsaslistedinthemanualunder“SPECIFICATIONS”.Otheruseasforeseen
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 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.

PAGE 2
DESCRIPTION OFTHE MODEL M5
316REV.980601
GENERAL DESCRIPTION:
The PULLMASTER Model M5 is a planetary, hydraulic winch having equal speed in both directions. The main
components of this unit are:
✛✛
✛✛
✛hydraulicgearmotor
✛✛
✛✛
✛multi-disc brake with static and dynamic function
✛✛
✛✛
✛primaryplanetreduction
✛✛
✛✛
✛finalplanetreduction
✛✛
✛✛
✛brakehousing
✛✛
✛✛
✛finaldrivehousing
✛✛
✛✛
✛cabledrum
FUNCTION IN FORWARD ROTATION (HOISTING):
Inforwardrotation,theoutputtorqueandrpmofthehydraulicmotoraretransmittedtothesungearoftheprimary
planetreduction. The output torque andrpm of the primaryreduction stage are transmittedtothe final reduction
stage by the final sungear shaft, which is splined to the primary planet hub. Final output torque and rpm are then
transmitted to the cable drum, which is splined to the final drive planet hub. In forward rotation, or when a load is
raised,anover-runningclutch,whichconnectsthemotordriveshafttotheautomaticbrakeassembly,permitsfree
rotationofthesungearwithouteffectingthebrake. Whenthewinchrotationisstopped,theloadonthecabledrum
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,causingthebrakepistontoreleasethemultidiscbrakeagainstanumberofbrakesprings.Theover-running
clutch, connecting the motor drive shaft to the brake assembly, locks, causing the brake discs to rotate between
dividerplates.Thus,acompletelysmoothloweringspeedcanbeachievedinasteplessoperationbymodulation
ofthe winch control valve handle. Whenthe control handleis returned toneutral position, rotation stops andthe
disc brake applies automatically.
During the lowering operation of the winch, the friction created by the brake discs results in temperature. This
temperatureis dissipated by aninternal circulation flow, suppliedout of the hydraulicmotor.This circulation flow
of approximately1 (US) gpm- 4 l/min,mustbe returned directly tothe reservoir withapermissible back pressure
of 30 psi (2 bar).
IMPORTANT: Undernocircumstancesmustthebackpressureinthebrakehousingbepermittedtoexceed30
psi(2bar).Excessivepressureinthebrakehousingwilldamagetheoilsealseparatingthebrake
housing from the drum interior. Damage to this seal will cause the drum to fill up with hydraulic
fluid.Inordertoforewarnpotentialdamagetothedrumsealsandtheendcoverofthewinch,when
thecabledrumfillsupwithhydraulicfluid,abreatherrelief(seePARTSREFERENCE, item130)
isinstalled on the end cover.The breather reliefbleeds to atmosphereand serves as a warning
signal that the oil seal between the brake housing and drum has been damaged.

PAGE 3
EXPLANATION OF MODEL CODING
316
M 5 X - XX - XX - XX X - B XXXX
BASIC UNIT SERIES
M = Equal speed in both directions
SIZE OF UNIT
REDUCTION RATIO
Onlyused for non standardreductionratios
TYPE OF BRAKE
-3 Automatic brake, clockwise drum rotation, internal circulation flow
h-6 Automaticbrake,counterclockwisedrumrotation,
internalcirculationflow
HYDRAULIC MOTOR
- 10 Hydraulic gear motor, 1.20 cubic inch displacement
(Othermotorsareoptional)
DRUM SIZE
-1 7inchdrumdiameterX111/2inchflangediameterX8inchlength -STANDARD
(For other drum sizes refer to Appendix A)
OPTIONS
DESIGN REVISION *
SPECIFICATIONNUMBER
Describesfeatures not identified bypreceding codes
NOTE: Clockwise and counterclockwise drum rotation is the direction of rotation for pulling or hoisting,
established by looking at the hydraulic motor.
*Model M5 Design Revision 'B'
Instruction and Parts Manual # PMC 316 PUB.960901
Effective from Serial # 46161

PAGE 4 316
OPTIONS
COUNTERCLOCKWISE ROTATION:
ThedrumrotationofthestandardPULLMASTERModelM5planetarywinchisclockwiseforhoistingwhenlooking
atthehydraulicmotorofthewinch.Drumrotationforcounterclockwisehoistingdirectionisavailableasanoption.
CABLE DRUM SIZES:
AsidefromthestandarddrumsizeslistedinAPPENDIXA, thePULLMASTERModelM5planetarywinchcanbe
suppliedwithoptional drums to accommodatelargewireropestorage capacity.
OPTIONAL GEAR SECTION FOR THE HYDRAULIC MOTOR:
TheperformanceofthestandardPULLMASTERModelM5planetarywinchcanbechangedbyusingadifferent
displacementmotor.(Contactthe factoryforperformanceinformation.)
ThePULLMASTERWINCHCORPORATIONwillconsiderotheroptionsforquantityrequirements.

PAGE 5
SPECIFICATIONS
316REV.010406
Performancespecificationsarebasedonstandardhydraulicmotor,gearratioandcabledrumwith1/2inchdiameter
wirerope. For othercable drums andgear ratios, referto APPENDIX A.Performance specifications forwinches
suppliedwithoptionalmotorsareprovidedin attached supplement.
CABLE DRUM DIMENSIONS (STANDARD DRUM):
Barreldiameter 7.00 in 178mm
Flangediameter 11.50in 292mm
Barrellength 8.00in 203mm
CABLE STORAGE CAPACITY:
(Size of wire rope) 1/8 in 2115 ft 645 m
3/16in 959 ft 292m
1/4 in 532 ft 162m
5/16in 359 ft 109m
3/8 in 227 ft 69 m
7/16in 166 ft 51 m
1/2 in 152 ft 46 m
MAXIMUM OPERATING PRESSURE: 2000psi 138bar
MAXIMUM OPERATING VOLUME: 14.5(US)gpm 55 l/min
MINIMUM OPERATING VOLUME: 4(US)gpm 15 l/min
DRUM TORQUE AT MAXIMUM PRESSURE: 22,500lb-in 2,542Nm
DRUM RPM AT MAXIMUM VOLUME: 35 rpm
HOISTING LINE PULL AT MAXIMUM PRESSURE:
Bare drum 6,000 lb 26.7kN
Fulldrum 4,091lb 18.2kN
HOISTING LINE SPEED AT MAXIMUM VOLUME:
Bare drum 69 ft/min 21 m/min
Fulldrum 101 ft/min 31 m/min
PERMISSIBLE SYSTEM BACK PRESSURE AT
MOTOR RETURN PORT: 65 psi 4.5 bar
PERMISSIBLE PRESSURE AT
CIRCULATION RETURN PORT: 30 psi 2 bar
LUBRICATING OIL: Refer to RECOMMENDATIONS for viscosity and instructions.
Refer to APPENDIX A for oil volume required.

PAGE 6
PERFORMANCE GRAPHS
PG-M5-A
LINE PULL VS. OIL PRESSURE:
LINE SPEED VS. OIL VOLUME:
Performancegraphsarebasedonstandardhydraulicmotorandcabledrumwith1/2inchdiameter
wirerope.
316REV.980601
100
30.5
80
24.4
60
18.3
40
12.2
20
6.1
BARE DRUM
FULL DRUM
LINE PULL - kN
LINE SPEED - m/min
FULL DRUM
BARE DRUM
1600
2000
1200
800
400
0
15
12
9
6
3
0
6000500040003000200010000
0 4.5 8.9 13.3 17.8 22.3 26.7 138
110
83
55
28
0
LINE PULL - lb
OIL PRESSURE - psi
OIL PRESSURE - bar
0
0
0
LINE SPEED - fpm
11
23
34
45
57
OIL VOLUME - (US)gpm
OIL VOLUME - l/min

PAGE 7
TYPICAL HYDRAULIC CIRCUITS
HC-M5-A
316REV.030430
FILTER
HYDRAULIC
PUMP
RESERVOIR
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
PRESSURE
RELIEF VALVE
CIRCULATION RETURN LINE
DIRECT TO RESERVOIR

PAGE 8
RECOMMENDATIONS
316REV.030430
HYDRAULIC FLUID:
ThehydraulicfluidselectedforusewithPULLMASTER
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.
Foroptimumperformance,therecommendedviscosity
rangeatoperatingtemperatureis81-167SUS(16-36
CS).Forextremeoperatingconditionsofshortduration,
the maximum viscosity range of 58 - 4635 SUS (10 -
1000CS)shouldnotbeexceeded.
For optimum performance, the winch recommended
hydraulicfluidtemperatureoperatingrangeis80-150F
(27 - 66 C). For extreme operating conditions of short
duration,themaximumtemperaturerangeof-5 -180F
(-21 - 82 C) should not be exceeded.
LUBRICATION:
The winch gear train requires oil bath lubrication. The
winchisshippedfromthefactorywithoutlubricatingoil.
IMPORTANT: ADD LUBRICATING OIL UP TO
THELEVEL OF THEOIL FILL PORT
BEFORE RUNNING WINCH.
Refer to INSTALLATION DIMENSIONS for location of
lubricatingoilfillport.RefertoAPPENDIXAforquantity
of oil required. For normal operating temperature use
SAE90lubricatingoil. Fortemperaturebeyondnormal
operatingrange,consultlubricatingoilsupplierorfactory.
HYDRAULIC PUMP:
For maximum performance of the PULLMASTER
planetary winch, the hydraulic pump must supply the
maximumflowofhydraulicfluidatthehydraulicpressure
stated in SPECIFICATIONS.
HYDRAULIC CONTROL VALVE:
The standard control valve used for operating the
PULLMASTERplanetarywinchmusthaveafour-way,
spring returntoneutralfeature,whichprovidesforopen
flowfromthepressureportsofthewinchtothereservoir
in neutral position of the control (motor spool). It is
importanttopointoutthatgoodspeedcontrol,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(seeSPECIFICATIONS).Usually,apressure
reliefispartofthehydrauliccontrolvalve. Wherethisis
not thecase, aseparatepressure relief valvemustbe
installedandsetattherecommendedmaximumpressure.
HYDRAULIC RESERVOIR:
It is recommended that the hydraulic reservoir has
sufficient capacity to provide good heat dissipation in
ordertopreventover-heatingofthehydraulicfluid.The
hydraulic reservoir should be made from clean and
scale-free material to prevent contamination of the
hydraulicfluid.Inorder to prevent air frombeingmixed
with the hydraulic fluid, the reservoir should have an
over-flow baffle separating the return lines from the
suctionlineandallreturnlinesshouldenterthereservoir
belowthefluidlevel. Thereservoirshouldbemounted
close to and above the hydraulic pump in a location
whichprovidesforfreeaircirculationaroundthereservoir.
HYDRAULIC HOSES:
The following hydraulic hoses are recommended for
maximum efficiency of the PULLMASTER Model M5
planetarywinch:
Pressurelines: EquivalenttoSAE100R12-12
Circulationreturnline: EquivalenttoSAE100R4-10
Itisrecommendedthatalargersizeofhydraulichoseis
installedwherethepressurelinesorthecirculationlines
are excessively long.
HYDRAULIC FILTER:
Consult hydraulic component manufacturer for
recommendation. Generally, 5 to 10 micron filters are
acceptable. In order to prevent accidental stoppage of
the return line flow, the 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.

PAGE 9
INSTALLATION INSTRUCTIONS
FAILURETOFOLLOWINSTALLATIONINSTRUCTIONSWILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
316REV.980601
DANGER
Theinitial installation ormounting of aPULLMASTER planetary winch iscritically important forproper operation
andperformance.Ifthewinchismountedtoanunevensurface,thecentrelineoftheunitcanbedistortedtoapoint
wherethewinchwillnotoperateineitherdirection.Itisthereforeveryimportantthatthefollowinginstructionsare
observedwhena PULLMASTER planetary winchisinstalled:
1) Makecertainthatthemounting platformissufficientlystronginordertoavoiddeflectionwhenaloadis 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) Installmountingboltssnugtightonthethreemountingpadswhichareincontactwiththemountingsurface.
(FormountingboltsizeandgradeseeINSTALLATIONDIMENSIONS.)
b) Measurethespaceunderneaththefourthmountingpadwithafeelergaugeanduseshimstockofequivalent
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
TORQUECHART.
4) Fill the winch with lubricating oil. See APPENDIX A for oil volume required.
5) Userecommendedcircuitcomponentsandhydraulichoses.
6) The circulationreturn line of the winchshould be plumbedin such amanner that thebrake housing remains full
ofoilatalltimes.Connectthecirculationreturnlinedirectlytoreservoir.Donotconnecttoacommonreturnline.
7) Before operating the winch with a load, verify adequate circulation flow through the circulation return line as
statedinTYPICALHYDRAULICCIRCUIT.Verifythatpressuremeasuredatthecirculationsupplyportdoes
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) Verifythatbreatherrelief,item130,isinplaceonendcoveraboveoillevel.Rotateendcoverifbreatherrelief
is below oil level.
IMPORTANT: Donotreplacebreatherreliefwithapipeplug.Thebreatherreliefdoesnotpreventoil
seal failure but serves as an indicator or warning that the oil seals between brake
housingandthecabledruminteriorhavefailedandmustbereplacedimmediately.If
theseoilsealsare changed,additionalfailureofthedrumsealandpotentialdamage
to the end cover is prevented.

PAGE 10
OPERATING INSTRUCTIONS
316REV.051117
FAILURETOFOLLOWOPERATINGINSTRUCTIONSWILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
DANGER
SI1013 - M5
2) Onwireropeinstallation,caremustbetakenthatthewireropeiswrappedcompletelyaroundthecableanchor
andproperlypulledintothecableanchorslotinthecabledrum. Thecabledrumrequires5wrapsofwirerope
for safety.
3) Thewinchoperationiscontrolledbyasinglecontrolvalveleverwhichhasaforward,areverseandaneutral
position.Speed control ineither direction isobtained by modulationof the controlvalve lever. Maximumline
speedineither direction is obtainedwhenthe control valve leverismovedas far as itcango. The disc brake
of the winch will come on automatically when the winch control lever is returned to neutral.
4) Alwayswarmupequipmentpriortooperatingwinch,particularlyinlowambienttemperature.Circulatehydraulic
oilthroughthewinchcontrolvalveforseveralminutestowarmthehydraulicsystem.Toprimethewinchwith
warm oil, operate the winch at slow speed, forward and reverse, several times.
5) Preventcorrosiondamagetowinchinterior.Ifnotusedregularly,runwinchupanddownatleastonceevery
twoweeks.
6) Toensureproperwinchinstallationandfunction,raise and lower a full test load to a safe height before using
winch for regular operation at the start of each shift.
If,afteranewinstallation,thewinchdoesnotfunctionproperly,refertotheTROUBLESHOOTINGsectionof
this manual.
AfterthePULLMASTERplanetarywinchhasbeeninstalledinaccordancewiththeINSTALLATIONINSTRUCTIONS,
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
potentialaccidents.Forselectionofropes,etc.pleasecheckfollowingproductstandards:DIN
15020,prEN818-1/9,prEN1492-1/2,prEN1677-1/3andotherrelevantproductstandards.
1) ThecabledrumofthePULLMASTERplanetarywinchhastwocableanchorslots,oneforclockwiseandone
forcounterclockwisehoisting.Standardrotationforhoistingisclockwisewhenlookingatthehydraulicmotor
of the unit. It is critical to select the cable anchor slot which will permit winding of the wire rope on the drum
inthecorrectdirectionofrotation.Ifthewireropeiswoundonthecabledruminthewrongdirectionofrotation,
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.
WIREROPEINSTALLATION
Clockwisehoistingwinchshown.
(Use cable anchor slot on opposite side
of drum for counterclockwise hoisting winch.)
Feedthewirerope throughthecable
anchor slot. Loop rope back into slot
as shown. Insert cable anchor into
slot, small end first and long side
nearestthedrum flange. Pull rope
tight to wedge rope in slot.
CABLE ANCHOR SLOT
CABLE ANCHOR

PAGE 11
316
TROUBLE SHOOTING
GENERAL:
In most cases, when the hydraulic winch does not perform satisfactorily, the cause for 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,ifthewinchdoesnotproducethespecifiedmaximumratedlinespeedordrumrpm,alossofhydraulic
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
winchcontroliscompletelyopened.The flowmetershouldindicatethemaximumoperatingvolume.If thistest
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 pulling capacity of the winch.
Ifthewinchwillnotproducethespecifiedmaximumlinepull,installapressuregaugein thepressurelineleading
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
belowthespecifiedmaximumoperatingpressure,lookfortroubleinthehydraulicpump,thereliefvalveandthe
controlvalve.IfthehydraulicpumpisdrivenbyV-belts,checkforbeltslippage.Whencheckingoilpressureand
volume in the hydraulic circuit, make sure that the hydraulic reservoir is filled to the top level and the hydraulic
pumpisrunning at maximum operatingrpm.
Onlyafterthehydraulicsystemhasbeencheckedandfoundtobeinorder,usethefollowingindicationsforprobable
causes of failure in the winch:
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.
(SeeSPECIFICATIONSformaximumoperating pressure.)
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) Insufficient hydraulic pressure. (See SPECIFICATIONS
for minimum operating pressure.)
c) Winch is mounted to an uneven surface.
(See INSTALLATION INSTRUCTIONS.)
d) Hydraulic pressure is not reaching the brake piston due
to plugged connecting tube.
Winch will not produce line pull at maximum
pressure as listed in SPECIFICATIONS.
Winch will not produce line speed at maximum
volume as listed in SPECIFICATIONS.
Winch will not reverse.
FAILURE PROBABLE CAUSE

PAGE 12
FAILURE PROBABLE CAUSE
TROUBLE SHOOTING
Brake will not hold.
Brake vibrates when lowering a load.
Oil leaks.
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model M5 winch.
316REV.980601
a) Brake plates or divider plates have been damaged by
contaminationinthehydraulicfluidor lackofcirculation
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 of the
hydraulic circuit causes the brake to release.
d) Controlvalvehasincorrect spoolwhichtrapshydraulic
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) Wireropeisfastenedtotheincorrectcableanchorslot.
f) Sprag clutch is damaged or surfaces where sprag
clutch engages on primary sungear or brake hub are
worn or indented.
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 insufficient
circulation flow. To check the circulation, observe the
flow of oil from the circulation return line of the winch
(approx. 1 (US) gpm - 4 l/min) when the winch is
reversed.
c) Controlvalveforthewinchoperationhaspoormetering
characteristics.
d) Damaged brake plates or divider plates.
e) Over-running clutch, which connects the primary
sungear with the brake assembly, is damaged.
f) Air has mixed with hydraulic oil resulting in foamy oil.
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 flanges
and housing are caused by excessive pressure in the
brakehousing. Excessivepressureinthebrakehousing
will damage the oil seal between the brake housing
and 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, or operation with the incorrect hydraulic
fluidduringcoldweather,orarestrictioninthecirculation
return line leading back to tank.

PAGE 13316REV.980601
SERVICE INSTRUCTIONS
GENERAL:
BeforedisassemblingthePULLMASTERModelM5planetarywinch,readandunderstandthefollowinginstructions.
ReplaceexpendablepartssuchasO-ringsandoilsealswhenreassemblingthewinch.Haveawinchsealkit(Part
No. 23099) on hand before the unit is disassembled.helen
NOTE: Backupwashersmaybeincludedwithsealkit.Installwithoilsealsasperinstructions.Ifnotpresent
in seal kit, the oil seals supplied do not require backup washers.
Disconnectallhydraulichoses,removethewinchfromitsmountingandrelocate to a clean working area, similar
tooneusedforserviceworkonanyotherhydrauliccomponent.Specialtoolsarenotrequiredtoservicethewinch.
Adjustmentsandcalibrationsarenotrequired.
All parts, as they are removed from the winch assembly, should be inspected for wear and damage. Worn or
damagedpartsmustbereplaced.Thoroughlycleanpartsbeforereassembly.Donotusesolventtocleanthebrake
friction plates.
Duringreassembly, lubricate all O-rings andoil seals withgrease before installation.
ThefollowingSERVICEINSTRUCTIONSrefertopartdescriptionsanditemnumberswhichappearinASSEMBLY
DRAWINGonpage20.
DISASSEMBLY
REMOVAL OF HYDRAULIC MOTOR ASSEMBLY:
The motor is not user serviceable and must be replaced if not functioning properly. Contact your nearest
PULLMASTERWINCHCORPORATIONDistributorforareplacement.Removethemotorassemblyasfollows:
1) Remove two capscrews, item 935, and lockwashers, item 937. Pull hydraulic motor, item 950, out of winch
assembly.
2) RemoveanddiscardO-ring,item811.
3) Connecting tube, item830, will eitherbe in motor or motoradaptor. Note andmark which brakerelease port
partisfrom(requiredforreassembly)thenremove.Removemotorplug,item888,fromotherbrakereleaseport.
Theseparts must bereinstalled properly forwinch brake tofunction correctly. Removeand discard threeO-
rings, item 831.
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:
Themajorityofserviceandrepairworkisdoneonthebrakehousingassemblywhichisaccessedbyremovingthe
hydraulic motor assembly. Disassemble brake housing assembly as follows:
1) Removemotoradaptor,item800,byremovingeightcapscrews,item931,andlockwashers,item933.Allow
brake springs, item 752, to expand safely by unscrewing capscrews one turn at a time.
2) RemoveanddiscardO-ring,item539.
3) Removesixbrakesprings,item752.Examinespringsfordamageandmeasureoveralllength.Overallspring
length should be 1.25 inch. Springs measuring less then 1.19 inch should be replaced.
4) Pullbrakepiston,item750,outofbrakehousing,item700.Verifyfreemovementofby-passvalves.Ifvalves
are seized, replace piston assembly.
5) Remove and discard O-rings,items 751 and753.
6) Thoroughlyinspectbrakepistonouterdiametersandbrakehousinginnerboresforscoringcausedbyhydraulic
fluid contamination. Minor surface damage may be repaired by polishing with a fine emery cloth.

PAGE 14
MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE
BRAKE 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 BRAKE SHAFT,
SPRAG CLUTCH AND BRAKE HUB AS A SET.
DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING
CAPACITY AND ALLOW THE LOAD TO DROP CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. DO NOT USE SOLVENT TO
CLEAN THE FRICTION PLATES. PERFORM THOROUGH
INSPECTION AND, IF NECESSARY, REPLACE FRICTION
AND DIVIDER PLATES AS A SET.
316REV.980601
DANGER
DANGER
SERVICE INSTRUCTIONS CONTINUED
7) Pull primary sungear, item 440, with brake hub assembly, item 720, and clutch aligners, items 722 and 724,
frombrakehousing.
8) Disassemble brake hub assembly by removing circlip, item 727, from primary sungear, item 440. Remove
primarysungearfrombrakehub,item720.Removespragclutchaligners,items722and724,andspragclutch,
item 723, from brake hub.
9) Thoroughly inspect primary sungear, item 440, and brake hub, item 720, particularly surfaces where sprag
clutch, item 723, engages.
10) If any indentation or surface damage is detected, replace brake hub, sprag clutch and primary sungear as a
set.
11) Removefourfrictionplates,item715,andfivedividerplates,item713,andinspectfordamageorwear.Plates
shouldbeflatandsmooth.Platesshouldnotshowheatdiscoloration.Papermaterialonfrictionplatesshould
be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
12) Removethrust bearing, item739, and thrustwashers, item 737.Inspect bearing andwashers and replaceif
damagedorworn.
13) Removetwoflatheadcapscrews,item693,andbrakehousing,item700.Removebrakespacer,item712,and
discardO-ring,item695.

PAGE 15
SERVICE INSTRUCTIONS CONTINUED
316
DISASSEMBLY OF PRIMARY DRIVE:
If the primary drive requires service or repair, disassemble as follows:
1) Remove pipe plug, item 503, from cable drum, item 500, and pipe plug, item 121, from end cover, item 120,
todrain lubricating oilfrom winch interior.Remove breather relief,item 130.
NOTE: Breather relief, item 130, is not user serviceable. Must be replaced if not functioning properly.
2) Stand winch upright on end cover, item 120. Remove 12 capscrews, item 911, and lockwashers, item 931.
Remove base, item 550.
3) Remove circlip, item 535, and, with two heel bars, pry end housing, item 698, away from cable drum flange.
RemoveanddiscardO-ring,item539.
4) Press ball bearing, item 103, out of end housing, item 698.
5) Remove seal carrier, item 538, from end housing and discard Parker seal, item 543, and O-ring, item 545.
6) Removesixsocketheadcapscrews,item537,andbearingflange,item530,fromcabledrum.Removecirclip,
item 517, from inside bearing flange. Press oil seal, item 531, against journal bearing, item 706, to remove.
Discard oil seal, item 531, and O-ring, item 539.
7) Remove primary planet hub assembly, and final sungear, item 340, from cable drum, item 500.
8) Ifnecessarytoremoveprimaryplanetgears,removecirclip,item411,fromchamferedsideofplanetpin,item
410,andpresspinoutofplanethub,item400.Inspectneedlebearing,item423,andtwothrustwashers,item
421,andreplaceifdamaged.
9) Remove circlip, item 343, from end of final sungear, item 340, and extract from planet hub.
10) Inspect sungear stopper, item 344, for excessive wear. Replace if less than .03 inch protrudes out of final
sungear,item340.
DISASSEMBLY OF FINAL DRIVE:
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) DiscardO-ring,item123,andinspectplanethubstopper,item126,andsungearstopper,item122,forexcessive
wear. Replace if planet hub stopper is less than .14 inch or if sungear stopper is less than .37 inch thick.
3) Remove final planet hub assembly from final housing, item 100.
4) Inspectthreefinalplanetgears,item320,fordamageorwear.Ifitisnecessarytoremovefinalplanetgears,
removecirclip,item313,andpressplanetpin,item310,outofplanethub,item300.Inspectneedlebearing,
item 323, and two thrust washers, item 321, and replace if damaged.
5) Toseparatecabledrumfromfinalhousing,firstremovecirclip,item513.Inserttwoheelbarsbetweenflange
of cable drum and final drive housing and gently pry cable drum out of ball bearing, item 103.
6) Removecirclip,item104,andpressballbearing,item103, out of finalhousing,item100.Checkballbearing
andreplaceifdamaged.
7) Remove and discard oil seal, item 105.

PAGE 16
SERVICE INSTRUCTIONS CONTINUED
316
REASSEMBLY
Thoroughlycleanallparts.Useonlynew,well-greasedO-ringsandoilseals. Unless otherwise specified, torque
fasteners per BOLT TORQUE CHART as 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 104.
3) Press cable drum, item 500, into ball bearing, item 103, and secure with circlip, item 513.
4) Reassemblefinalplanethubassembly.Pressneedlebearing,item323,intofinalplanetgear,item320.Position
thrustwashers,item321,oneithersideofplanetgearandpressplanetpin,item310,intofinalplanethub,item
300. Retain with circlip, item 313.
5) Insertfinalplanethubassemblyintofinalhousing,item100.Ensurethatplanethubsplineisfullyengagedwith
cable drum, item 500.
6) Installnew,well-greasedO-ring,item123,intoendcover,item120.Verifythatplanethubstopper,item126,
and sungear stopper, item 122, are installed into end cover.
7) Gently insert end cover into final housing, item 100, and fasten with retaining ring, item 124.
8) Turnwinchuponendwithcable drumopeningupwards.
REASSEMBLY OF PRIMARY DRIVE:
Reassembleprimary drive asfollows:
1) Reassemble primary planet hub assembly. Press sungear stopper, item 344, into end of final sungear, item
340.Insertfinalsungearintoplanethub,item400,andfastenwithcirclip,item343.Pressneedlebearing,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.
2) Insert final sungear and primary planet hub assembly into cable drum. Rotate drum by hand until sungear
engagesfinalplanetgearsandprimaryplanetgearsengagecabledrum.
3) Pressnew,well-greasedoilseal,item531,intobearingflange,item530,followedbyjournalbearing,item706.
Install circlip, item 517, and new, well-greased O-ring, item 539, into bearing flange.
4) Fasten bearing flange, item 530, to cable drum, item 500, using six socket head capscrews, item 537.
5) Install new, well-greased O-ring, item 545, and Parker seal, item 543, into seal carrier, item 538. Install seal
carrierintoopeningofendhousing,item698,andpressballbearing,item103,tightagainstsealcarrier.Press
end housing, with seals and ball bearing, onto bearing flange. Fasten with circlip, item 535.

PAGE 17
SERVICE INSTRUCTIONS CONTINUED
316REV.980601
DANGER
REASSEMBLY OF BRAKE HOUSING ASSEMBLY:
Reassemblebrakehousingassemblybyreversingthedisassemblyprocedure:
1) Place brake spacer, item 712, in end housing with flat side facing up.
2) Install new, well-greased O-ring, item 695, onto mounting flange of brake housing, item 700. Fasten brake
housing to end housing using two flat head capscrews, item 693.
3) Install thrust bearing, item 739, with thrust washer, item 737, on either side, into bearing flange, item 530.
4) Install sprag clutch, item 723, into bore of brake hub, item 720. Position sprag clutch aligners, item 722 and
724,oneithersideofbrakehub.Carefullyslideprimarysungear,item440,intobrakehubassemblyandsecure
with circlip, item 727.
IMPORTANT: For proper brake function, verify that brake hub rotation is correct. When viewed
from motor end, primary sungear of a clockwise hoisting winch must turn freely
clockwise and lock in the counterclockwise direction.
5) Installprimarysungearassembly,carefullytwistingshoulderofsungearthroughoilseal,item531.Ensureoil
seal is not damaged as sungear is installed.
INCORRECTASSEMBLYOFTHEFRICTION PLATE AND DIVIDERPLATE
STACKWILLREDUCEBRAKINGCAPACITYANDALLOWTHELOAD
TODROP,CAUSINGPROPERTY DAMAGE, SEVEREINJURYOR
DEATH.REASSEMBLEPERINSTRUCTIONS.
6) Startingandfinishingwithdividerplate,alternatelyinstallfivedividerplates,item713,andfourfrictionplates,
item 715.
7) Install new, well-greased O-ring, item 751, into brake housing and new, well-greased O-ring, item 753, into
pistongland. Carefully installbrakepiston in brakehousing. Rotate piston toalign connecting tubeholewith
correspondingholeinmotor.
8) Install six brake springs, item 752.
9) Installnew,well-greased O-ring item 539,ontomotoradaptorflange,item 800.
10) Positionmotoradaptorwithhydraulicmotormountingholeshorizontalandconnectingtubeholesofpistonand
motor adaptor aligned. Tighten eight capscrews, item 931, and lockwashers, item 933, one turn at a time to
evenly compress springs.

PAGE 18 316REV.980601
SERVICE INSTRUCTIONS CONTINUED
SI-1029
REPLACEMENT OF HYDRAULIC MOTOR ASSEMBLY:
Replacethehydraulicmotorassembly by reversing the removal procedure.
IMPORTANT: Beforeinstallingmotor,determinebrakecodeofwinch.Installmotorplugasindicatedbelow.
1) Installthreenew,well-greasedO-rings,item831;twoontoconnectingtube,item830,andoneontomotorplug,
item888.Installconnectingtubeandmotorplugintomotor,item950.Verifythatholesaresameaspartswere
removedfrom.
2) Install new, well-greased O-ring, item 811, onto motor pilot, item 950.
3) Fasten motor to motor adaptor using two capscrews, item 935, and lockwashers, item 937.
IMPORTANT: Before operating the winch, add lubricating oil up to the level of the end housing oil fill port.
(Refer to INSTALLATION INSTRUCTIONS for location of fill port. Refer to APPENDIX A for
oilvolumerequired.)
Toensure proper reassembly, run thewinch in bothdirections without load.
LIFTING A LOAD WITH A NEWLY SERVICED WINCH WILL ENABLE
ANINSTALLATION ORSERVICEPROBLEMTOGOUNDETECTEDAND
ALLOWTHELOADTO DROP, CAUSINGPROPERTYDAMAGE,SEVERE
INJURYORDEATH. TO ENSUREPROPERREINSTALLATION,REFER
TOPROCEDURESANDTESTSDESCRIBEDIN"INSTALLATION"AND
"OPERATINGINSTRUCTIONS".
DANGER
950
888 831
-6 A
B
-3
PLUG PORT
BRAKE CODE
NOTE:
INSERT MOTOR PLUG, O-RING END
FIRST, INTO PORT A OR B AS
INDICATED IN CHART BELOW.
MOTOR PLUG
WITH 0-RING
(MAY NOT BE EXACTLY AS ILLUSTRATED)
SHAFT SIDE OF MOTOR
BRAKE RELEASE
PORT ’B’
BRAKE RELEASE
PORT ’A’