Pullmaster M50 Technical reference manual

PMC 323 070228
INSTRUCTION AND PARTS MANUAL
MODEL M50
FREE FALL
PLANETARY HYDRAULIC WINCH
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. MAKETHISMANUALAVAILABLETOALLPERSONS
RESPONSIBLE FOR THE OPERATION, INSTALLATION, SERVICING
AND MAINTENANCE OF THIS PRODUCT.

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 1323 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 89dBA 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 2 323 REV.040708
GENERAL DESCRIPTION:
The PULLMASTER Model M50 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):
Inforwardrotation,theoutputtorqueandrpm ofthehydraulicmotoraretransmittedtothesungearoftheprimaryplanet
reduction.Theoutputoftheprimaryreductionistransferredtothe final sungear, which issplinedtotheprimaryplanet
hub.Thefinalplanetassemblyislockedinplacebythefreefallclutchanddoesnotrotate,sotherotationistransmitted
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
effectingthebrake.The pressurerequiredto rotatethedrumwithoutloadatfullspeed mayvaryup to350psi(24bar).
Whenthewinchrotationisstopped,theloadonthecabledrumcausestheover-runningclutchtolockandthemaximum
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
ofthehydraulicmotorischannelledtothebrakepiston,causingthebrakepistontoreleasethemulti-discbrakeagainst
a number of brake springs. The pressure required to rotate the drum at full speed may vary from 250 to 550 psi (17
to 38 bar) depending upon the load and without load from 500 to 1000 psi (34 to 69 bar). The over-running clutch,
connectingthemotordriveshafttothebrakeassembly,locks,causingthebrakediscstorotatebetweendividerplates,
whichareengagedintothebrakehousing. Iftheloadonthecabledrumtendstoeffecttheloweringspeed,theresulting
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.
jlk
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,
dependingonthebrakecodeofthewinch.Forefficientcoolingoftheautomaticbrake,modelswithexternalcirculation
shouldbeadjustedtosupply5(US)gpm-19l/min. Thisflowmustbereturneddirectlytothereservoirwithapermissible
back pressure of 30 psi (2 bar).
jlIMPORTANT: 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
housingfromthedruminterior. Damagetothissealwillcausethedrumtofillupwithhydraulicfluid.
DESCRIPTION OFTHE MODEL M50 FREE FALL
WARNING
PRIOR TO OPERATION OF THIS UNIT, VERIFY COMPLIANCE WITH
ALL NATIONAL AND LOCAL SAFETY CODES AND REGULATIONS
REGARDING THE USE OF FREE FALL WINCHES.

PAGE 3323 REV.030624
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 M50 planetary winch. Upon activating the emergency free fall function, the load will drop and it must be
allowed to fall to its end travel without re-engagement.
FUNCTION OF THE EMERGENCY FREE FALL:
When the Model M50 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.
Thiseffectivelydisconnectsthecabledrumfromthegeartrainofthewinchandthesuspendedloadwilldrop.The
minimum load required to establish emergency free fall mode is 1,000 lb (554 kg).
CONTROLLED FREE FALL:
Thecontrolled free fall offerspositive down controlofa loadat selectedspeedsand canbe stoppedanywhere
onthewaydown.Thecontrolledfreefallisnotdesigned,norintendedtolowerthemaximumloadinacontrolled
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 thesame basic function asthe emergency free fall with theaddition ofa metering
pump which regulates the different clutch pressure requirements during a controlled free fall. When the
controlledfreefallisactuated,hydraulicpressureischannelledintotheclutchpiston,causingtheclutchpiston
topressagainstaseriesofspringsandreleasethemulti-discclutch.Whentheclutchhasbeenreleased,thefinal
planetassemblyrotateswiththecabledrum,aroundastationarysungear.Asmallhydraulicgearpumpissplined
to the final planet hub. This hydraulic pump displaces hydraulic oil flow out of the free fall control circuit to
compensateforthedifferenceintheclutchreleasepressure,whichvariesaccordingtotheactualloweringspeed.
The faster the load is lowered with the free fall control, the faster the planet hub will cause the pump to turn,
increasingthedisplacementvolumedrawnoutofthecontrolcircuit.Whenthefreefallcontrolisreturnedtoneutral,
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.Twoseparatecontrolsmustbeusedforthisoptionandtheoperatingcriteriaforbothfunctionsmustbe
adhered to.
IMPORTANT: Under no circumstances must the pressure in the free fall housing be permitted to exceed 10
psi (.7 bar). Excessive pressure will damage the main drum seals. Damage to these oil seals
will cause oil to leak between drum flange of brake housing or free fall housing.
CONTINUED
DESCRIPTION OFTHE MODEL M50 FREE FALL
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.

PAGE 4 323 REV.030624
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 14 inch drum diameter X 23.75 inch flange diameter X 14 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
50
M

PAGE 5323 REV.030624
OPTIONS
COUNTERCLOCKWISE ROTATION:
The drum rotation of the standard PULLMASTER Model M50 free fall planetary winch is clockwise for hoisting
whenlookingatthehydraulicmotorofthewinch.Drumrotationforcounterclockwisehoistingdirectionisavailable
as an option.
INTERNAL CIRCULATION:
The PULLMASTER Model M50 free fall has an external circulation flow supply line to cool the brake. Internal
circulation is available as an option.
EXTERNAL BRAKE RELEASE:
PULLMASTERplanetary winchescan besupplied withan external brake release which permitsreleaseof the
automatic disc brake from an external pressure source.
CABLE DRUM SIZES:
AsidefromthestandarddrumsizeslistedinAPPENDIXA, thePULLMASTERModelM50freefallplanetarywinch
can be supplied with optional drums to accommodate large wire rope storage capacity.
DRUM GROOVING:
Cable drums for the PULLMASTER Model M50 free fall 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:
Theperformanceof the PULLMASTERModelM50free fall planetarywinch canbe changedbyusinga different
displacement motor. (Contact the factory for performance information of different gear sections.)
HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS:
TheoperatingpressureofthePULLMASTERModelM50freefallplanetarywinchislimitedto2500psi(172bar).
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”.
DANGER

PAGE 6 323 REV.030624
SPECIFICATIONS
Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 1.25 inch
diameter wire rope. For other cable drums and reductions refer to APPENDIX A. For other motors, refer to
supplementinsidebackcover.Performancespecificationsforwinchessuppliedwithoptionalmotorsareprovided
in attached supplement.
CABLE DRUM DIMENSIONS (STANDARD DRUM):
Barrel diameter 14.00 in 356 mm
Flange diameter 23.75 in 603 mm
Barrel length 14.00 in 356 mm
CABLE STORAGE CAPACITY:
(Size of wire rope) 9/16 in 854 ft 260 m
5/8 in 691 ft 211 m
3/4 in 519 ft 158 m
7/8 in 375 ft 114 m
1 in 276 ft 84 m
1 1/8 in 195 ft 60 m
1 1/4 in 177 ft 54 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: 381,250 lb-in 43,075 Nm
DRUM RPM AT MAXIMUM VOLUME: Hoisting 17.4 rpm
HOISTING LINE PULL AT MAXIMUM PRESSURE:
Bare drum 50,000 lb 222.4 kN
Full drum 33,889 lb 150.7 kN
PERMISSIBLE CONTROLLED FREE FALL LOAD:
Bare drum 15,000 lb 66.7 kN
Full drum 10,520 lb 46.8 kN
HOISTING LINE SPEED AT MAXIMUM VOLUME:
Bare drum 69 fpm 21 m/min
Full drum 102 fpm 31 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 10 psi .7 bar
LUBRICATING OIL: Refer to RECOMMENDATIONS for instructions.

PAGE 7323 REV.030624
Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with 1.25 inch diameter
wire rope.
PERFORMANCE GRAPHS
LINE PULL VS. OIL PRESSURE
LINE SPEED VS. OIL VOLUME
PG-M50-A
MAXIMUM ALLOWABLE LINE PULL WHEN USING
CONTROLLED FREE FALL: jjlkjalkf
Bare drum 15,000 lb 66.7 kN
Full drum 10,520 lb 46.8 kN
90
27
80
24
70
21
60
18
50
15
40
12
30
9
20
6
10
3
45000
200
40000
178
35000
156
30000
133
25000
111
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
500000
0 222 172
138
103
69
34
0
LINE PULL - lb
OIL PRESSURE - psi
OIL PRESSURE - bar
0 99
0 30
0
LINE SPEED - fpm
95
189
284
379
473
OIL VOLUME - (US)gpm
OIL VOLUME - l/min

PAGE 8 323 REV.030624
EMERGENCY FREE FALL: HC-M50-X-86-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.
DANGER
TYPICAL HYDRAULIC CIRCUIT
PRESSURE GAUGE
0-1000 PSI
FREEFALL
CIRCULATION
RETURN
FREEFALL CLUTCH RELEASE
750 PSI (52 BAR)
BRAKE CIRCULATION
RETURN (DIRECT TO
RESERVOIR)
BRAKE
CIRCULATION
SUPPLY
5 USGPM
(19 L/MIN)
EXTERNAL
CIRCULATION
MODELS ONLY
FREEFALL
CIRCULATION
SUPPLY
2 USGPM
(8 L/MIN)
HYDRAULIC
PUMP
RESERVOIR
FILTER
PRESSURE
RELIEF VALVE
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER

PAGE 9323 REV.030624
HC-M50-X-86-XC-B
TYPICAL HYDRAULIC CIRCUIT
CONTROLLED FREE FALL:
SUPPLY
SUPPLY
FLOW DIVIDER
(PRESSURE &
TEMPERATURE
COMPENSATED)
PORT B PLUGGED
TO NEUTRAL;
SPRING RETURN
MOTORSPOOL;
WITH METERING
CONTROL VALVE
BA
P
T
(52 BAR)
750 PSI
RELIEF VALVE
PRESSURE GAUGE
0-1000 PSI
(9 LPM)
2.5 USGPM
RETURN
CIRCULATION
FREEFALL
BRAKE CIRCULATION
RETURN (DIRECT TO
RESERVOIR)
MODELS ONLY
CIRCULATION
EXTERNAL
(19 L/MIN)
5 USGPM
CIRCULATION
BRAKE
(34 LPM)
9 USGPM
CIRCULATION
FREEFALL
RESERVOIR
FILTER
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
PRESSURE
RELIEF VALVE
HYDRAULIC
PUMP

PAGE 10 323 REV.030624
TYPICAL HYDRAULIC CIRCUIT
COMBINED EMERGENCY & CONTROLLED FREE FALL: HC-M50-X-86-XG-B
SHUTTLE
VALVE
FLOW DIVIDER
(PRESSURE &
TEMPERATURE
COMPENSATED)
CONTROL VALVE
WITH METERING
MOTORSPOOL;
SPRING RETURN
TO NEUTRAL;
PORT B PLUGGED
BA
PT
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
SUPPLY
5 USGPM
(19 L/MIN)
EXTERNAL
CIRCULATION
MODELS ONLY
FREEFALL
CIRCULATION
SUPPLY
9 USGPM
(34 LPM)
HYDRAULIC
PUMP
RESERVOIR
FILTER
PRESSURE
RELIEF VALVE
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER

PAGE 11323 REV.030624
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 -
1000 CS) should not be exceeded.
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 is lubricated by hydraulic oil
circulated through the free fall end cover.
IMPORTANT: VERIFY FREE FALL CIRCULATION
SUPPLY FLOW BEFORE RUNNING
WINCH.
RefertoINSTALLATIONDRAWINGforlocationoffree
fall circulation supply and return ports.
HYDRAULIC PUMP:
For maximum performance of the PULLMASTER
planetary winch, the hydraulic pump must supply the
maximumflowofhydraulicfluidatthehydraulicpressure
stated in SPECIFICATIONS.
HYDRAULIC WINCH CONTROL VALVE:
The standard control valve used for operation of the
PULLMASTERplanetarywinchmusthaveafour-way,
springreturntoneutralfeature,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.
RECOMMENDATIONS
HYDRAULIC PRESSURE RELIEF:
The hydraulic circuit for the PULLMASTER planetary
winch requires a pressure relief set at the operating
pressure(seeSPECIFICATIONS).Usually,apressure
relief is part of the hydraulic control valve. Where this
isnot thecase, aseparatepressure relief valvemust
be installed and set at the recommended maximum
pressure.
HYDRAULIC RESERVOIR:
It is recommended that the hydraulic reservoir has
sufficient capacity to provide good heat dissipation in
ordertopreventover-heatingofthehydraulicfluid.The
hydraulic reservoir should be made from clean and
scale-free material to prevent contamination of the
hydraulicfluid.Inordertopreventairfrombeingmixed
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
which provides for free air circulation around the
reservoir.
HYDRAULIC HOSES:
The following hydraulic hoses are recommended for
maximum efficiency of the PULLMASTER Model M50
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:
Hydraulicfilterrecommendationsforthehydrauliccircuit
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.

PAGE 12 323 REV.030624
EMERGENCY FREE FALL
CONTROL VALVE:
Theemergencyfreefallrequiresatwoposition,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.
Iftheemergencyfreefalliscombinedwithcontrolled
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.
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'scontrol panel.TheE stopmust be designed
and placed in line with EN 60204 and EN 418.
PRESSURE GAUGE:
Tomonitorfreefallreleaseportpressureinstalla1000
psi (69 bar) pressure gauge between the free fall
control valve and the release port.
IMPORTANT:
Thecirculationreturnlinesmustgodirecttoreservoir.
Pressureinthefreefallhousingmustnotbepermitted
to exceed 10 psi (0.7 bar).
RECOMMENDATIONS CONTINUED

PAGE 13323 REV.030624
Theinitialinstallation ormounting ofa PULLMASTERplanetarywinchis criticallyimportant forproper operation
and performance. If the winch is mounted to an uneven surface, the centre line of the unit can be distorted to a
pointwherethewinchwillnotoperateineitherdirection.Itisthereforeveryimportantthatthefollowinginstructions
are observed when a PULLMASTER planetary winch is installed:
1) Makecertainthatthemountingplatformissufficientlystronginordertoavoiddeflectionwhenaloadislifted.
2) Set the winch on the mounting platform and check for surface contact on all mounting pads of the winch.
3) Ifthere isa space betweenthe mountingsurfaceand oneof themountingpads, themounting surfaceisnot
even and the space below the mounting pad must be shimmed. If this condition exists, proceed as follows:
a) Install mounting bolts snug tight on the three mounting pads which are in contact with the mounting
surface. (For mounting bolt size and grade see INSTALLATION DRAWING.)
b) Measure the space underneath the fourth mounting pad with a feeler gauge and use shim stock of
equivalent thickness in the space between the mounting pad and the mounting surface.
c) Only after this procedure should the fourth mounting bolt be installed. Tighten all four bolts per BOLT
TORQUE CHART.
4) Use recommended circuit components and hydraulic hoses.
5) Thecirculationreturn line ofthe winchshould beplumbed insuch a mannerthat thebrake housing andfree
fall housing remain full of oil at all times. Connect the return lines directly to reservoir. Do not connect to a
common return line.
6) Bleed the air out of the free fall control circuit by loosening the connection at the free fall release port on the
winch.Withnoloadonthecabledrum,operatethefreefallcontrolvalve,lettingallairescape,thenre-tighten
the connection at the release port.
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.
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
DANGER
INSTALLATION INSTRUCTIONS

PAGE 14 323 REV.051117
OPERATING INSTRUCTIONS
FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL
RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
2) Onwireropeinstallation,caremustbetakenthatthewireropeiswrappedcompletelyaroundthecableanchor
and properly pulled into the cable anchor slot in the cable drum. The cable drum requires 5 wraps of wire
rope for safety.
3) Thewinchoperationiscontrolledbyasinglecontrolvalveleverwhichhasaforward,areverseandaneutral
position.Speed control ineitherdirection isobtainedby modulationof thecontrolvalve lever.Maximumline
speedineither direction isobtainedwhenthe control valvelever ismoved asfarasit can go.The discbrake
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
hydraulicoil throughthe winchcontrol valvefor severalminutes towarm the hydraulicsystem. Toprime the
winch with warm oil, operate the winch at slow speed, forward and reverse, several times.
5) Preventcorrosiondamagetowinchinterior.Ifnotusedregularly,runwinchupanddownatleastonceevery
two weeks.
6) Toensureproperwinchinstallationandfunction, raise and lowerafull test load toasafe height before using
winch for regular operation at the start of each shift.
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
potentialaccidents.Forselectionofropes,etc.pleasecheckfollowingproductstandards:DIN
15020, prEN818-1/9, prEN 1492-1/2, prEN 1677-1/3 and other relevant product standards.
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.
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. SI1013 - M50FF
CABLE ANCHOR
CABLE ANCHOR SLOT

PAGE 15
323 REV.030624
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 1000 lb - 454 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:
Tooperatethecontrolled free fall, open the free fall control levergraduallytoobtainsmoothaccelerationofthe
loweringspeed ofthe winch. Thelowering speedisin directproportion withthemovement ofthe freefallcontrol
lever.Todecelerateorslowdowntheload,slowlyreturnthecontrolleverbacktoitsneutralposition.Suddenstops
ofanacceleratingloadanderraticoperationofthefreefallcontrollevershouldbeavoided.Forbettermodulation
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
controlledfreefall.ThepermissibleloadofthePULLMASTERModelM50controlledfreefall
operation is 30% of the maximum line pull capacity of the winch.
If,afteranewinstallation,thewinchdoesnotfunctionproperly,refertotheTROUBLESHOOTINGsectionofthis
manual.
DANGER
OPERATING INSTRUCTIONS CONTINUED

PAGE 16 323 REV.030624
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
SPECIFICATIONSformaximumoperatingpressure.)
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
frombeingreleased againstthe brakesprings. Thisis
causedbydamaged O-ringseals onthe brakepiston.
b) TheO-ringseals,onthebrakereleasechannelbetween
themotoradaptorandthe brakehousingisdamaged.
If this failure occurs there will be substantial leakage
from between the motor adaptor and brake housing.
c) Insufficient hydraulic pressure. (See
SPECIFICATIONSforminimumoperatingpressure.)
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,ifthewinchdoesnotproducethespecifiedmaximumratedlinespeedordrumrpm,alossofhydraulic
flowsomewhereinthehydrauliccircuitsystemcanbeanalysed.Ifthisconditionexists,installaflowmeterinto
the hydraulic circuit to check the volume supplied to the pressure port of the hydraulic winch motor when the
winchcontroliscompletelyopened.Theflowmetershouldindicatethemaximumoperatingvolume.Ifthistest
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
tothe hoistingport onthe hydraulicwinchmotor. Stallthe winchto preventrotation of thedrum andthen open
thecontrol valve.Check thehydraulic pressurereading ofthe installedpressure gauge. If thepressure 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
volumeinthehydrauliccircuit,makecertainthatthehydraulicreservoirisfilledtothetoplevelandthehydraulic
pump is running at maximum operating rpm.
Only if thehydraulicsystemhasbeen checked and found tobe inorder,usethefollowingindicationsforprobable
causes of failure in the winch:
TROUBLE SHOOTING

PAGE 17323 REV.030624
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
pressureinthebrakepistonwhenthecontrolvalvehandle
is returned to neutral position. For proper function of the
automaticbrake,both pressureportsof thewinchmustbe
opentothereservoirinneutralpositionofthecontrolvalve.
e) Hydraulic pressure is trapped in the clutch piston,
preventing totalengagement.Thisiscausedbyusingan
incorrect control valve. The free fall control valve must
leavethefreefallreleaseportopentoreservoirwhennot
activated.
f) Wire rope is fastened to the incorrect cable anchor slot.
g) Spragclutchis 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 1000 lb
(454 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.
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model M50 free fall winch.
TROUBLESHOOTING CONTINUED

PAGE 18 323 REV.030624
FAILURE PROBABLE CAUSE
Free fall cannot be controlled. a) Emergency free fall is non-controllable.
b) Pipingcircuit orcontrol valve isincorrect. Check hydraulic
circuit.
c) Controlvalveusedhaspoormeteringcharacteristics.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 cable drum flanges and
housings are caused by excessive pressure in free fall
housing or brake housing. If pressure in free fall end
exceeds 10 psi (0.7 bar) check for restrictions in free fall
circulationreturnline.Ifpressureinbrakehousingexceeds
30 psi (2 bar) check for damage to oil seal, item 607, and
restrictionsinbrakecirculationreturnline.Bothcirculation
return lines must go directly back to reservoir.
c) Oil leaking out of the free fall housing on either side of the
springretaineriscausedbyadamagedO-ringseal,item213.
TROUBLESHOOTING CONTINUED
Oil leaks.