INSTRUCTION AND PARTS MANUAL
MODEL PH136
PLANETARY HYDRAULIC WINCH
THE LOGICAL CHOICE
PMC 340
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.
070228
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.
US.DIST.01.01.07 [PULLMASTER LOGO]
SAFETY RECOMMENDATIONS
WARNING
FAILURE TO COMPLY WITH THE FOLLOWING SAFETY
RECOMMENDATIONS AND LOCAL RULES AND
REGULATIONS COULD RESULT IN PROPERTY
DAMAGE, SEVERE INJURY OR DEATH.
1. Do not install, operate or service Planematic drive before reading and understanding manufacturer's
instructions.
2. The Planematic drive 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 Planematic drive. Always smoothly accelerate and decelerate load.
6. Do not operate a damaged, noisy or malfunctioning Planematic drive.
7. Do not leave a load suspended for any extended period of time.
8. Never leave a suspended load unattended.
9. The Planematic drive should be maintained and operated by qualified personnel.
10. Inspect Planematic drive mounting bolts and hoses before each shift.
11. Warm up equipment before operating Planematic drive, particularly at low ambient temperatures.
12. Do not weld any part of the Planematic drive.
13. Verify circulation return before operating Planematic drive.
14. Ensure equipment stability before operating Planematic drive.
15. Wear proper clothing to avoid entanglement in rotating machinery.
16. Always stand clear of the load.
17. Use only recommended hydraulic oil.
18. Keep hydraulic system clean and free from contamination at all times.
19. Maintain Planematic drive and equipment in good operating condition. Perform scheduled maintenance
regularly.
20. 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 the area where the load is halted.
21. The noise level of the Planematic drive is 86 dBA measured on a distance of 1.00 meter, 1.60 meters
high. The measuring equipment used was: Realistic #42-3019.
22. Clean up any oil spillage immediately.
23. Wear proper clothing and personal protection equipment such as footwear, safety goggles and a hard
hat. Read manual first.
340 REV.991125
PAGE 1
DESCRIPTION OF THE MODEL PH136
The PULLMASTER Planematic drive is a high performance, highly efficient, planetary hydraulic drive with
reversing speed 4.7 times faster than forward speed.
The main components of this unit are:
✛ hydraulic motor
✛ brake housing
✛ hydraulically released multi-disc brake with static and dynamic function
✛ primary planetary reduction
✛ final drive housing
✛ final planetary reduction
✛ output shaft
FUNCTION IN FORWARD ROTATION:
In forward rotation the torque and rpm of the hydraulic motor are transmitted to the sungear of the primary planet
reduction. The sprag clutch which connects the motor drive shaft to the automatic brake assembly permits free
rotation in forward direction.
The output torque and rpm of the primary reduction are transmitted to the final reduction by the final sungear
which is splined to the primary planet hub. The output shaft is splined to the final planet hub. When the rotation
is stopped, the suspended load or the tension in the reverse direction causes the sprag clutch to lock and the
maximum permissible load is held safely by the disc brake. The pressure required to rotate the output shaft may
vary from 50 to 250 psi (3 to 17 bar) without load, depending upon speed.
FUNCTION IN REVERSE ROTATION:
In reverse rotation, hydraulic pressure from the reversing side of the hydraulic motor is channelled to the brake
piston, causing the brake piston to release the multi-disc brake against the brake springs. The sprag clutch locks
motor drive shaft with the connecting shaft. Connecting shaft coupled with brake hub and primary internal gear
causes the primary reduction to rotate at the rpm of hydraulic motor, thus eliminating the primary reduction.
Elimination of primary reduction in this manner increases the output shaft speed and decreases the output torque
4.7 times of forward direction. Based on standard motor, pressure required to rotate the output shaft, without load
depending upon speed, may vary from 500 to 1100 psi (34 to 76 bar).
If the applied load drives the Planematic faster than desired, the motor consumes more oil than is supplied and
pressure at the reversing port decreases. The brake partially applies and slows the drive. In this manner, the motor
continuously regulates brake pressure to safely and smoothly control the load without counterbalance or holding
valves.
The partially applied brake results in temperature. This temperature is dissipated by an internal circulation flow,
supplied out of the hydraulic motor or from an external source. For models with external circulation, required flow
is approximately 7 (US) gpm (26 l/min). The circulation return line must go to the reservoir directly.
IMPORTANT: For proper drive function, system back pressure in the brake housing and at the motor return
port must never exceed the allowable limits listed in the SPECIFICATIONS section of this
manual.
PAGE 2
340 REV.991125
MODEL CODING FOR PLANEMATIC DRIVE
MODEL PH136
136
H
P
BASIC UNIT
P = Planematic drive
TYPE OF UNIT
H = High speed reverse
SIZE OF UNIT
136 = 135,937 lb-in output torque
REDUCTION RATIO
Used for non standard reduction ratios only
TYPE OF BRAKE
(Clockwise & counterclockwise rotation of shaft established by looking at the motor)
-3 Automatic brake*, clockwise shaft rotation, internal circulation flow
-4 Automatic brake*, clockwise shaft rotation, external brake release,
internal circulation flow
-5 Automatic brake*, counterclockwise shaft rotation,
external brake release, internal circulation flow
-6 Automatic brake*, counterclockwise shaft rotation,
internal circulation flow
-7
-8 Automatic brake*, clockwise shaft rotation, external brake release,
-9 Automatic brake*, counterclockwise shaft rotation,
-10 Automatic brake*, counterclockwise shaft rotation,
*Automatic brake = spring applied, automatically released by the hydraulic
HYDRAULIC MOTOR
-86
OUTPUT SHAFT
-1
-2 keyed output shaft, 3.50 diameter 7/8 inch square key
-3 splined output shaft with inboard flange adaptor
-4 splined output shaft with outboard flange adaptor
-5 splined output shaft,
OPTIONS
DESIGN REVISION
SPECIFICATION NUMBER
Automatic brake*, clockwise
external circulation flow
external brake release, external circulation flow
external circulation flow
pressure of the motor
WM76
hydraulic motor, 3 inch gear section, 12.3 cid
splined output shaft, 34 teeth, 10/20 DP (
31 teeth, 10/20 DP
Absence of a letter denotes no options supplied with the drive
This letter for factory use only
Describes features not identified by preceding codes
shaft
rotation, external circulation flow
STANDARD)
X - XX - XXX - XX X - X XXX
340 REV.991125
PAGE 3
OPTIONS
REDUCTION RATIO:
The reduction ratio of the standard PULLMASTER Planematic drive is 40.8:1. Drives with different reduction
ratios and altered output performances are optionally available.
TYPE OF BRAKE:
The standard PULLMASTER Planematic drive output shaft rotates forward in clockwise direction as viewed from
the motor end of the unit. Standard brake is effective only during reverse rotation and automatically functions
during operation.
Drives with counterclockwise forward rotation and drives with brake effective in both directions are optionally
available. Drives with porting to allow brake release from an external power source are optionally available.
DANGER
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. PLANEMATIC DRIVES SUPPLIED
WITH EXTERNAL RELEASE OPTION MUST BE CONNECTED
ACCORDING TO "TYPICAL HYDRAULIC CIRCUIT".
OUTPUT SHAFT:
The standard PULLMASTER Planematic drive has a 34 teeth, 10/20 DP splined output shaft. Drives with keyed
or splined output shafts or adaptor flanges are optionally available.
OPTIONAL GEAR SECTION FOR THE HYDRAULIC MOTOR:
The performance of the standard PULLMASTER Planematic drive can be changed by using different gear
sections. (Contact the factory for performance information.)
HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS:
The operating pressure of the standard PULLMASTER Planematic drive is limited to 2500 psi (172 bar). For
hydraulic systems operating with a higher range of hydraulic pressure, the drive can be supplied with a hydraulic
piston motor, which will provide for the same basic performance. (Contact the factory for this requirement.)
The PULLMASTER WINCH CORPORATION may consider other options for quantity requirements.
PAGE 4
340 REV.991125
SPECIFICATIONS
Performance specifications are based on standard hydraulic motor and gear ratio. Performance specifications
for Planematic drives supplied with optional motors and/or reductions are provided in attached supplement.
MAXIMUM OUTPUT TORQUE:
Forward: 135,937 lb-in 15,359 Nm
Reverse: 29,127 lb-in 3,291 Nm
MAXIMUM OUTPUT RPM:
Forward: 49 rpm
Reverse: 229 rpm
MAXIMUM OPERATING PRESSURE: 2,500 psi 172 bar
MAXIMUM OPERATING VOLUME: 115 (US) gpm 435 l/min
MINIMUM OPERATING VOLUME: 30 (US) gpm 114 l/min
REDUCTION RATIO:
Forward: 40.8 : 1
Reverse: 8.8 : 1
OUTPUT SHAFT: Axial or Radial load See OVERHUNG LOAD RATING
PERFORMANCE AT VARYING
PRESSURE OR VOLUME: See PERFORMANCE GRAPHS
PERMISSIBLE SYSTEM BACK PRESSURE
AT MOTOR RETURN PORT: 65 psi 4.5 bar
PERMISSIBLE PRESSURE
AT CIRCULATION SUPPLY PORT: 30 psi 2 bar
CIRCULATION OIL VOLUME:
Models with external circulation 7 gpm 26 l/min
340 REV.991125
PAGE 5
OVERHUNG LOAD RATING
The magnitude and location of a load is dependent on the following factors:
SF = service factor (Table A)
AF = application factor (Table B)
a = bearing geometry constant = -0.295
T = basic thrust load = 14,500
c = basic load constant = 136,000
L = allowable overhung load in lbs.
y = distance of load centre to mounting face in inches
L
y
PG-136-OH
T
c x SF
L = = lbs
(y + a) AF
Allowable thrust or tension load in lbs. = T x SF
TABLE A TABLE B
24 hr. day, continuous duty, full load 0.75
8 hr. day, continuous duty, full load
3 hr. day, intermittent duty, full load
Intermittent duty at variable loads,
up to full load occasionally
1.00
1.50
2.68
Chain drive
Gear
V-belt
Flat belt
1.00
1.25
1.50
2.50
PAGE 6
340 REV.991125
PERFORMANCE GRAPHS
OUTPUT TORQUE VS. OIL PRESSURE
OUTPUT TORQUE - Nm (x 100)
45.2
2500
0 158.2
22.6
67.8
90.4
113.0
PG-PH136
135.6
172
2000
REVERSE
1500
1000
OIL PRESSURE - psi
500
0
20
40
OUTPUT TORQUE - lb.in. (x 1000)
OUTPUT RPM VS. OIL VOLUME
120
60
FORWARD
80
100
120
138
103
69
35
0
1400
454
379100
OIL PRESSURE - bar
OIL VOLUME - (US)gpm
0
0
Performance graphs are based on standard hydraulic motor and gear ratio.
340 REV.991125
FORWARD
OUTPUT RPM
REVERSE
30380
22760
15140
OIL VOLUME - l/min
7620
0
229200175150125100755025
PAGE 7
TYPICAL HYDRAULIC CIRCUIT
CIRCULATION RETURN LINE
(MUST GO DIRECT TO RESERVOIR)
HC-PMH136-A
800 PSI [55 BAR]
2(US)GPM [8 L/MIN]
REQUIRED FOR MODELS
SUPPLIED WITH EXTERNAL
BRAKE RELEASE OPTION
CIRCULATION SUPPLY LINE
PM136: 5 (US) GPM [19 L/MIN]
PH136: 7 (US) GPM [26 L/MIN]
(EXTERNAL CIRCULATION
MODELS ONLY)
HYDRAULIC
PUMP
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
PRESSURE
RELIEF VALVE
FILTER
PAGE 8
RESERVOIR
340 REV.030925
RECOMMENDATIONS
HYDRAULIC FLUID:
The hydraulic fluid selected for use with PULLMASTER
Planematic drives should be a high grade, petroleum
based fluid, with rust, oxidation and wear resistance.
Fluid cleanliness and operating viscosity are critical to
drive 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 drive 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 Planematic drive mechanism requires an oil bath
lubrication of the internal components. Depending on
the model code, circulation is supplied internally by the
motor or externally (see TYPICAL HYDRAULIC
CIRCUIT). If the unit is internally circulated, fill the
Planematic with hydraulic oil through one of the filler /
drain ports before operating.
HYDRAULIC PUMP:
For maximum performance of the PULLMASTER
Planematic drive, the hydraulic pump must supply the
maximum flow of hydraulic fluid at the hydraulic pressure
stated in SPECIFICATIONS.
HYDRAULIC CONTROL VALVE:
The standard control valve used for operating the
PULLMASTER Planematic drive must have a fourway, spring return to neutral feature, which provides for
open flow from the pressure ports of the drive to the
reservoir in neutral position of the control
It is important to point out that good speed control
depends on the “metering” characteristics of the control
valve. The better the oil flow is “metered” the better will
be the speed control.
(motor spool).
HYDRAULIC PRESSURE RELIEF:
The hydraulic circuit for the PULLMASTER Planematic
drive 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 Planematic
drive:
Pressure lines: Equivalent to SAE 100R12-32
Circulation return line: Equivalent to SAE 100R4-16
Circulation supply line:*
* Only for models with external circulation.
It is recommended that a larger size of hydraulic hose
is installed where the pressure lines or the circulation
lines are excessively long.
Equivalent to SAE 100R6-6
HYDRAULIC FILTER:
Hydraulic filter recommendations for the hydraulic circuit
of the PULLMASTER Planematic drive, based on a
return line filter, are given as follows:
Average Atmosphere: 10 microns
Dusty Atmosphere: 5 microns
340 REV.991125
In order to prevent accidental stoppage of the return
line flow, the oil filter should have a by-pass feature.
PAGE 9
INSTALLATION INSTRUCTIONS
DANGER
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS
WILL RESULT IN PROPERTY DAMAGE,
SEVERE INJURY OR DEATH.
To ensure satisfactory operation, the PULLMASTER Planematic drive must be properly installed. Observe the
following installation instructions:
1) The Planematic drive mounting structure must be strong enough to withstand operating torques without
excessive deflection.
2) The Planematic drive mounting surface and pilot bore must be machined.
3) Position the Planematic drive using a lifting eyebolt in the tapped hole provided.
4)
Use eight 3/4 inch diameter mounting bolts (grade 5 or better). Evenly tighten bolts per BOLT TORQUE CHART.
5) Use only recommended circuit components and hydraulic hoses.
6) Plumb a separate circulation return line directly to tank. Keep the return line above the drive to maintain
housing oil level at all times.
7) Fill Planematic drive housing with oil through filler/drain port before operating. Units ported for external
circulation can be filled through circulation supply line.
IMPORTANT: System brake housing back pressure must never exceed the limit allowed in the
SPECIFICATIONS section of this manual.
Before loading the Planematic drive, verify adequate brake circulation flow by checking at the
circulation return line port while driving in reverse direction.
PAGE 10
340 REV.991125
OPERATING INSTRUCTIONS
DANGER
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS
WILL RESULT IN PROPERTY DAMAGE,
SEVERE INJURY OR DEATH.
Verify proper installation, acceptable system back pressure and adequate brake circulation flow before operating
the Planematic drive.
1) The standard Planematic drive brake applies only in counterclockwise rotation as viewed from the motor end
of the unit. The drive has no brake during clockwise rotation. Ensure brake option is appropriate for particular
application.
2) The Planematic drive hydraulic motor is supplied through a single lever control valve with reverse, neutral
and forward positions. Drive speed is regulated by metering the control valve lever. Standard brake
automatically releases when driving in reverse direction and sets when control valve lever is returned to
neutral position.
Refer to OPTIONS section of this manual for explanation of optional brake configurations.
3) Verify installation and connection by slowly driving a full test load through a safe distance, forward and
reverse. Complete functional test by driving test load at full speed, forward and reverse, several times.
If Planematic drive does not function properly after following above procedure, refer to TROUBLESHOOTING
section of this manual.
340 REV.991125
PAGE 11
TROUBLE SHOOTING
GENERAL:
Typical Planematic drive operating problems are caused by a malfunctioning hydraulic system. Verify hydraulic
pressure and flow at the drive motor are as specified before dismounting or disassembling Planematic.
IMPORTANT: Ensure that the hydraulic system reservoir is full and that the system pump is running at
full rpm before doing any system checks.
HYDRAULIC SYSTEM VOLUME AND PLANEMATIC SPEED:
The Planematic output speed depends on the hydraulic flow supplied to the drive motor. Maximum output speed
and required hydraulic volume appear in the SPECIFICATIONS section of this manual. If the Planematic does
not rotate at desired output speed, install a flow meter at the drive motor forward port. Fully open control valve
and measure hydraulic flow. Verify hydraulic operating volume as specified.
HYDRAULIC SYSTEM PRESSURE AND PLANEMATIC TORQUE:
The Planematic output torque depends on the hydraulic pressure supplied to the drive motor. Maximum output
torque and required hydraulic pressure appear in the SPECIFICATIONS section of this manual. If the Planematic
does not produce desired output torque, install pressure gauges at both drive motor gauge ports. Stall the drive,
fully open control valve and measure hydraulic pressure at motor ports. Verify hydraulic operating pressure and
maximum allowable motor return port back pressure as specified.
Sources of potential hydraulic flow and/or pressure loss include the hydraulic pump, relief control valves and
slipping belts on a v-belt driven pump.
If the hydraulic volume and pressure are per specification, refer to the following TROUBLESHOOTING chart to
identify failure probable causes.
FAILURE
Drive will not produce maximum rated torque as
listed in SPECIFICATIONS.
Drive will not produce rated speed or rpm as
listed in SPECIFICATIONS.
Drive will not reverse (brake will not release).
PROBABLE CAUSE
a) Hydraulic system supply pressure or back pressure not
per SPECIFICATIONS. Refer to procedure described in
TROUBLE SHOOTING - HYDRAULIC SYSTEM
PRESSURE AND PLANEMATIC TORQUE to verify
system pressures.
b) Damaged or worn hydraulic motor.
a) Hydraulic system supply volume, supply pressure or back
pressure not per SPECIFICATIONS. Refer to procedures
described in TROUBLE SHOOTING - HYDRAULIC
SYSTEM VOLUME AND PLANEMATIC SPEED and
HYDRAULIC SYSTEM PRESSURE AND PLANEMATIC
TORQUE to verify system pressures and volumes.
b) Damaged or worn hydraulic motor.
a) Leaking brake piston O-ring. Both piston O-rings must
seal to develop hydraulic brake release pressure.
b)
Leaking brake release pressure port O-ring. O-ring is located
on the motor adaptor and seals release oil pressure at the
brake housing. Failure of this O-ring results in significant
leakage between the motor adaptor and brake housing.
c) Insufficient hydraulic pressure to release the brake. Refer
to PERFORMANCE GRAPH. Gauge release pressure at
external brake release port on motor adaptor.
d) Plugged brake release pressure port. Hydraulic passages
in the motor adaptor and brake housing must be clear to
allow oil passage to reach brake piston.
PAGE 12
340 REV.991125
TROUBLE SHOOTING CONTINUED
FAILURE
Brake will not hold load.
Brake vibrates or chatters when lowering load.
PROBABLE CAUSE
a) Hydraulic system back pressure not per SPECIFICATIONS.
Refer to procedure described in TROUBLE SHOOTING HYDRAULIC SYSTEM PRESSURE AND PLANEMATIC
TORQUE to verify system back pressure at motor.
b) Brake piston release oil being trapped by hydraulic system
control valve. Control valve spool must open motor ports to
reservoir when in the neutral position. Refer to
RECOMMENDATIONS - HYDRAULIC CONTROL VALVE.
c)
Worn brake and/or divider plates. Inspect brake plates and
divider plates for wear as described in SERVICE
INSTRUCTIONS - DISASSEMBLY OF BRAKE ASSEMBLY.
d)
Damaged brake and/or divider plates. Plate discolouration
and distortion will occur if plates overheat due to insufficient
circulation flow. Required brake circulation flow is listed in
SPECIFICATIONS. Plate abrasion damage will occur if
contamination is present in hydraulic fluid.
e) Damaged over-running clutch. Inspect sprag clutch,
connecting shaft and motor drive shaft as described in
SERVICE INSTRUCTIONS - DISASSEMBLY OF BRAKE
ASSEMBLY.
f)
Damaged brake springs. Measure brake springs as
described in SERVICE INSTRUCTIONS - DISASSEMBLY
OF BRAKE ASSEMBLY. Verify springs are straight and
length is as indicated.
g)
Seized brake piston. Brake piston could be seized by
hydraulic fluid contamination, scored brake housing bore or
damaged piston O-rings.
a) Inadequate hydraulic flow. Refer to procedure described in
TROUBLE SHOOTING - HYDRAULIC SYSTEM VOLUME
AND PLANEMATIC SPEED to verify supply.
b) Inadequate hydraulic control. System control valve must
have good metering characteristics.
c) Foamy hydraulic fluid. Foam will occur if air is mixed with
hydraulic oil.
d)
Worn brake and/or divider plates. Inspect brake plates and
divider plates for wear as described in SERVICE
INSTRUCTIONS - DISASSEMBLY OF BRAKE ASSEMBLY.
e) Damaged brake plates and/or divider plates. Plate
discolouration and distortion will occur if plates overheat
due to insufficient circulation flow. Required brake circulation
flow is listed in SPECIFICATIONS. Plate abrasion damage
will occur if contamination is present in hydraulic fluid.
f)
Damaged over-running clutch. Inspect sprag clutch, connecting
shaft and motor drive shaft as described in SERVICE
INSTRUCTIONS - DISASSEMBLY OF BRAKE ASSEMBLY.
Oil leaks.
a) Damaged O-ring. Static O-rings seal between the end
cover and final housing, final housing and brake housing ,
brake housing and motor adaptor. Another O-ring seals
brake release pressure between the motor adaptor and
brake housing. A failed O-ring will result in oil leakage at
that particular area.
b)
Worn or damaged output shaft seal. Excessive circulation
return line back pressure can damage this seal. Refer to
procedure described in TROUBLE SHOOTING - HYDRAULIC
SYSTEM PRESSURE AND PLANEMATIC TORQUE to
measure back pressure. Back pressure must never exceed
the allowable circulation return line back pressure listed in
SPECIFICATIONS. Back pressure will be higher at start-up
and during cold weather when oil viscosity is greater.
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Planematic drive.
340 REV.991125
PAGE 13
SERVICE INSTRUCTIONS
GENERAL:
Before attempting disassembly of the PULLMASTER Model PH136 Planematic drive, the following instructions
for disassembly and reassembly should be read and understood.
It is suggested that all expendable parts, such as O-rings and oil seals, are not reused on reassembly. It is therefore
important to have a Planematic seal kit (Part No. 23141) and, if the hydraulic motor has to be serviced, a motor
seal kit (Part No. 23117) on hand before the unit is taken apart. If working on the hydraulic motor, two new roller
bearings item 875, (Part No. 25352) are also required.
NOTES: 1) Backup washers may be included with seal kit. Install with oil seals as per instructions. If not
present in seal kit, the oil seals supplied do not require backup washers.
2) Teflon seals item 887, are included in the motor seal kit. Teflon seals are not required if thrust
plates item 885, are not grooved.
A clean working area is of prime importance, similar to conditions used for service work on any other hydraulic
component. All parts, as they are removed from the Planematic assembly, should be carefully inspected for wear
and damage. Thoroughly clean parts before reassembly. Do not use solvent to clean the brake friction plates.
During reassembly, lubricate all O-rings and oil seals before installation.
In the following service instructions, reference to parts is made by number and shown on the applicable group
drawings.
DISASSEMBLY
For the majority of required service or repair work, disassembly is required only on the brake housing of the
PULLMASTER Planematic drive. There are no special tools needed for service or repair work and no adjustments
or calibrations are necessary. Proceed with the disassembly as follows:
DISASSEMBLY OF HYDRAULIC MOTOR ASSEMBLY:
If the analysed service or repair work requires access to the interior of the brake housing, the hydraulic motor
should not be disassembled. In this case, the hydraulic motor should be removed together with the motor adaptor
as a complete assembly. If a problem has been analysed to be in the hydraulic motor, proceed with the
disassembly as follows:
Refer to PARTS REFERENCE on page 26 and MOTOR GROUP drawing G1078 on page 27.
1) Remove eight hex capscrews item 951, together with lockwashers item 953, from motor assembly.
NOTE: Failure to exercise care when removing the motor port end cover or gear housing could permanently
damage the machined surfaces of these motor components. Take care not to damage machined
surfaces of motor components at disassembly.
2) Remove (pry loose if necessary) port end cover item 870, together with bearings item 875, and ring seal
item 877. Thrust plate item 885, and dowel pins item 865, may stay in gear housing.
3) If thrust plate comes off with end cover, carefully pry it off of bearings item 875, and discard pocket seals item
887.
4) Remove gear set item 881, which consists of two gears which are a matched set.
5) Carefully pry gear housing item 861, off of motor adaptor item 800. Thrust plate item 885, and dowel pins
item 865, may stay in gear housing.
6) If thrust plate stayed on motor adaptor, carefully pry it off of bearings item 875, and discard teflon seals item
887.
7) Discard gasket seals item 869. It is also advisable to replace ring seals item 877, at this time. Bearings
item 875, have to be removed to allow access to ring seals.
PAGE 14
340 REV.030926
SERVICE INSTRUCTIONS CONTINUED
NOTE:
Teflon seals, gasket seals, and ring seals in the hydraulic motor assembly are not part of the
Planematic seal kit. The motor, with the exception of the motor adaptor item 800, and the port
end cover item 870, are standard parts of the hydraulic motor, having a 3 inch gear section.
All of these parts can be ordered from PULLMASTER or Authorized Distributors/Dealers in
Canada, the United States and in most overseas areas.
REMOVAL OF HYDRAULIC MOTOR ASSEMBLY:
If disassembly of the hydraulic motor is not necessary, proceed as follows:
1) Remove 12 hex capscrews item 537, together with lockwashers item 773, from motor adaptor item 800. Since
brake springs item 752, apply pressure against inside of motor adaptor, it is recommended that hex
capscrews are unscrewed, one turn at a time, until spring pressure has been released. Complete motor
assembly, including motor adaptor, can now be removed from brake housing
2) For models with internal circulation, ensure that hole in orifice plug item 804, is clear. For models with external
brake release option, verify that shuttle item 802, moves freely.
3) Remove and discard O-ring item 801, and O-ring item 707. (O-ring item 801, seals pressure transfer hole
for automatic brake release and is situated on flange of brake housing.)
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:
Refer to PARTS REFERENCE on page 24 and BRAKE GROUP drawing G1015 on page 25.
1) Remove brake spacer item 712, from brake housing item 700.
2) Pull motor drive shaft item 730, out of brake hub assembly. Surface of motor drive shaft that engages sprag
clutch item 723, should be inspected for wear or indentations. If motor drive shaft shows any surface damage,
it should be replaced.
3) Sprag clutch aligner item 724, and sprag clutch item 723, can now be removed from bore of brake connecting
shaft item 600. Inspect both parts for wear or damage and replace if necessary.
DANGER
MINOR SURFACE DEFECTS WHERE SPRAG CLUTCH ENGAGES MOTOR DRIVE
SHAFT AND CONNECTING SHAFT, WILL RESULT IN BRAKE FAILURE AND ALLOW
THE LOAD TO DROP, CAUSING PROPERTY DAMAGE, SEVERE INJURY OR DEATH.
THOROUGHLY INSPECT THESE AREAS AND, IF NECESSARY, REPLACE MOTOR
DRIVE SHAFT, SPRAG CLUTCH AND CONNECTING SHAFT AS A SET.
4) Remove circlip item 721, and brake hub item 720, from connecting shaft item 600.
DANGER
DAMAGED FRICTION OR DIVIDER PLATES WILL REDUCE BRAKING CAPACITY
AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY DAMAGE, SEVERE
INJURY OR DEATH. SOLVENT MAY DAMAGE THE FRICTION PLATES.
DO NOT USE SOLVENT TO CLEAN THE FRICTION PLATES. PERFORM THOROUGH
INSPECTION AND, IF NECESSARY, REPLACE FRICTION AND DIVIDER PLATES AS A SET.
5) Remove 12 friction plates item 715, together with 13 divider plates item 713, and inspect for damage or wear.
Plates should be flat and smooth. Plates should not show heat discoloration. Fiber material on friction plates
should be intact and grooved. Replace plates if damaged.
340 REV.030926
PAGE 15
SERVICE INSTRUCTIONS CONTINUED
6) Remove connecting shaft item 600, and internal gear item 430, from brake housing. Remove circlip item 431,
to separate internal gear from brake hub. Inspect needle bearing item 603. Replace if necessary.
7) Remove primary sungear item 440.
8) Pull primary planet hub assembly out of bushing item 774.
9) Remove thrust bearing item 617, and two thrust washers item 615, from primary planet hub item 400. Inspect
and replace if cracked or otherwise damaged.
10) Remove 16 capscrews item 111, and lockwashers item 113, to separate brake housing item 700, from final
housing item 100. Remove and discard O-ring item 107.
11) Remove eight capscrews item 771, and lockwashers item 773, one turn at a time, to relieve pressure being
exerted by brake springs item 752.
12) Inspect thrust washer item 776, and replace if less than 0.13 inch thick. Inspect bushing item 774, and replace
if inside bore is worn above 3.145 inch diameter.
13)
Remove 18 brake springs item 752. Thoroughly examine springs for damage and measure overall length. Overall
spring length should be 2.27 inch. If any spring measures less than 2.21 inch replace all springs as a set.
14) Pull brake piston item 750, out of brake housing, using two 5/8 inch - 11 NC bolts screwed into two puller holes
in piston and discard O-rings item 751 and item 753.
15) Thoroughly examine inner bores of brake housing and outer diameters of brake piston for scoring caused by
hydraulic fluid contamination. Minor surface damage may be repaired by polishing with a fine emery cloth.
DISASSEMBLY OF PRIMARY PLANET HUB ASSEMBLY:
Inspect three primary planet gears item 420, for damage or wear. If necessary, disassemble as follows:
1) R
emove circlips item 411, and press planet pins item 410, out of primary planet hub item 400. Remove planet
gears item 420, and inspect loose rollers item 423, and two thrust washers item 421. Replace if damaged.
2) Press sungear stopper item 444, out of primary planet hub and measure thickness. If less than 0.21 inch thick,
replace sungear stopper.
All parts have now been removed from brake housing and there is no need for further disassembly unless a failure
has been analysed in the remaining drive assembly.
DISASSEMBLY OF FINAL DRIVE AND OUTPUT SHAFT ASSEMBLY:
Refer to PARTS REFERENCE on page 22 and FINAL DRIVE GROUP drawing G1016 on page 23.
If final drive or output shaft assembly requires service or repair, disassemble as follows:
1) Remove final sungear item 340, from center of three final planet gears item 320.
2) Pull out final planet hub assembly and inspect for wear or damage. If final planet hub gears item 320, require
removal, take off circlip item 311, from planet pin item 310, and press planet pin out of final planet hub item 300.
Remove final planet gear item 320, and inspect thrust washers item 321, and loose rollers item 323. Replace
if damaged.
3) If Planematic drive includes an inboard or outboard flange, remove capscrew item 153, lockwasher item 155,
and flange cap item 154, to slide off flange item 152.
4) Remove six hex capscrews item 163, and lockwashers item 165. Pull off end cover item 156, and discard Oring item 167, and oil seal item 157.
5)
Untab lockwasher item 161, from locknut item 159. Unscrew locknut and remove lockwasher and keyed washer
item 149. Output shaft item 150, can now be pressed out of tapered roller bearings items 151 and 103.
6) Check sungear stopper item 160, for wear and replace if less than 0.21 inch thick.
The Pullmaster Planematic drive has now been completely disassembled.
PAGE 16
340 REV.030926
SERVICE INSTRUCTIONS CONTINUED
REASSEMBLY
Thoroughly clean all parts. Use only new, well-greased O-rings and oil seals. Unless otherwise specified, torque
fasteners per BOLT TORQUE CHART.
REASSEMBLY OF FINAL DRIVE AND OUTPUT SHAFT ASSEMBLY:
Reassemble final drive and output shaft assembly by reversing disassembly procedure.
1) Press sungear stopper item 160, into end of output shaft item 150, and press output shaft into tapered roller
bearings items 151 and 103.
2) Slide keyed washer item 149, and lockwasher item 161, onto output shaft against tapered roller bearing item
151. Screw locknut item 159, onto output shaft against lockwasher. Tighten locknut to a point where 10 to
15 pounds of pull is required to rotate output shaft item 150, freely. Bend tabs of lockwasher into openings
on locknut to lock output shaft into position.
3) Press new, well-greased oil seal item 157, into end cover item 156, and place new, well-greased O-ring item
167, onto flange.
4) Fasten end cover to final housing item 100, using six capscrews item 163, and lockwashers item 165.
5) Reassemble final planet hub assembly. Use grease to temporarily hold 24 loose rollers item 323, in bore of
planet gear item 320. Position thrust washers item 321, on either side of planet gear and press planet pin
item 310, into final planet hub item 300. Retain with circlip item 311.
6) Insert final planet hub assembly into final housing. Ensure that planet hub spline is fully engaged.
7) Install final sungear item 340. Verify circlip item 343, is installed on sungear.
REASSEMBLY OF PRIMARY DRIVE:
If primary planet hub assembly was disassembled, reassemble by reversing disassembly procedure.
1) Reassemble primary planet hub assembly. Use grease to temporarily hold 20 loose rollers item 423, in bore
of planet gear item 420. Verify placement of sungear stopper item 444. 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.
REASSEMBLY OF BRAKE HOUSING ASSEMBLY:
Refer to PARTS REFERENCE on page 24 and BRAKE GROUP drawing G1015 on page 25.
Reassemble brake housing assembly by reversing disassembly procedure.
1) Liberally grease O-ring item 751, and O-ring item 753, and install on brake piston item 750.
2) Slide brake piston into brake housing with holes for brake springs facing out of brake housing assembly.
3) Install 18 brake springs item 752, in brake piston. Piston has 20 holes and two holes which have no brake
springs installed should be located opposite to each other.
4) Verify thrust washer item 776, and bushing item 774, are in place on spring stopper item 770.
5) Install spring stopper item 770, onto brake housing item 700, and fasten with eight capscrews item 771, and
lockwashers item 773. Tighten capscrews, one turn at a time, to evenly compress brake springs item 752.
6) Install new, well-greased O-ring item 107, onto brake housing.
7) Install brake housing item 700, onto final housing item 100, and fasten with 16 capscrews item 111 and
lockwashers item 113.
8) Install primary planet hub assembly so that hub slides into bushing item 774.
340 REV.030926
PAGE 17
SERVICE INSTRUCTIONS CONTINUED
9) Insert primary sungear item 440, in opening between three primary planet gears item 420.
10) Place thrust bearing item 617 (held between two thrust washers item 615), into bore of primary planet hub
item 400.
11) Fasten internal gear item 430, onto connecting shaft item 600, using circlip item 431.
12) Verify placement of needle bearing item 603, in connecting shaft item 600. Install sprag clutch item 723, and
sprag clutch aligner item 724, into connecting shaft.
13)
Install internal gear item 430, through center of piston item 750, and interlock gear teeth with three planet gears
item 420. Ensure that end of connecting shaft item 600, is through center of thrust washers item 615.
14) Install motor drive shaft item 730, into connecting shaft item 600, so that circlip item 727, comes into contact
with sprag clutch aligner item 724.
15) Slide brake hub item 720, onto connecting shaft spline and secure with circlip item 721.
DANGER
INCORRECT ASSEMBLY OF THE FRICTION PLATE AND DIVIDER PLATE
STACK WILL REDUCE BRAKING CAPACITY AND ALLOW THE LOAD
TO DROP, CAUSING PROPERTY DAMAGE, SEVERE INJURY
OR DEATH. REASSEMBLY PER INSTRUCTIONS.
16) Starting and finishing with a divider plate, alternately install 13 divider plates item 713, and 12 friction plates
item 715. Install brake spacer item 712, into brake housing.
17) Install motor drive shaft spacer item 732, onto motor drive shaft item 730.
18) Liberally grease three new O-rings item 801, and install into recesses on motor adaptor item 800. Install new
well-greased O-ring item 707, on flange of motor adaptor.
19) Slide hydraulic motor assembly onto splined end of motor drive shaft item 730, and line up pressure transfer
holes of brake housing and motor adaptor. Install 12 capscrews item 537, and lockwashers item 773. Tighten
one turn at a time to evenly compress springs.
REASSEMBLY OF HYDRAULIC MOTOR:
Refer to PARTS REFERENCE on page 26 and MOTOR GROUP drawing G1078 on page 27.
If hydraulic motor was disassembled, proceed with reassembly as follows:
1) Clean all parts thoroughly before reassembly and apply grease liberally to all seals. Use only new seals (seal
kit Part No. 23117) for hydraulic motor.
2) Install two new teflon seals item 887, on each thrust plate item 885. Press one thrust plate, together with two
teflon seals, onto bearings item 875, installed in motor adaptor item 800.
3) Install new, well-greased gasket seal item 869, on each side of gear housing item 861. Slide gear housing
together with gasket seals, onto motor adaptor, lined up on two dowel pins. Tap on tight using soft-headed
hammer.
4) Install gear set item 881, in gear housing (longer gear with internal spline goes into top position).
5)
Press other thrust plate, complete with two new teflon seals item 887, onto bearings installed in port end cover.
6) Install port end cover item 870, together with two bearings item 875, and new ring seal item 877, onto gear
housing, lined up on two dowel pins item 865. Tap on tight using a soft-headed hammer. Install and lightly
torque eight hex capscrews item 951, and lockwashers item 953, to approximately 50 ft-lb (70 Nm).
PAGE 18
340 REV.030926
SERVICE INSTRUCTIONS CONTINUED
7)
Plumb Planematic assembly to hydraulic supply and torque motor capscrews according to following procedure:
- Ensure that circulation supply flow is being supplied to the brake housing.
- Run Planematic, with no load, in hoisting direction at reduced speed (approximately
30% of maximum hydraulic volume).
- With Planematic running, evenly tighten eight capscrews item 951, to 200 ft-lb (271 Nm).
- Test motor operation by running Planematic drive at full speed in both directions.
IMPORTANT: After performing any service or repair work, reinstall Planematic according to INSTALLATION
INSTRUCTIONS. Before operating Planematic, ensure that circulation oil is being supplied
to brake housing. If an internal circulation model, fill with hydraulic oil through the uppermost
drain port before running. To ensure proper reassembly, run Planematic in both directions
without load. To ensure proper reinstallation, refer to test procedures described in
INSTALLATION and OPERATING INSTRUCTIONS.
DANGER
LIFTING A LOAD WITH A NEWLY SERVICED PLANEMATIC WILL ENABLE AN
INSTALLATION OR SERVICE PROBLEM TO GO UNDETECTED AND
ALLOW THE LOAD TO DROP CAUSING PROPERTY DAMAGE,
SEVERE INJURY OR DEATH. TO ENSURE PROPER
REINSTALLATION, REFER TO PROCEDURES AND
TESTS DESCRIBED IN "INSTALLATION" AND
"OPERATING INSTRUCTIONS".
340 REV.030926
PAGE 19
RECOMMENDED MAINTENANCE
In order to maintain the PULLMASTER Planematic drive in peak operating condition at all times, it is
recommended that the following preventive maintenance procedure is carried out every 12 months or 500
operating hours, whichever occurs first.
1) Disconnect all hydraulic connections and remove the Planematic drive from its mounting.
2) Disassemble the Planematic drive in accordance with the SERVICE INSTRUCTIONS.
3) Discard and replace all O-rings and oil seals.
4) Inspect all parts for wear and replace if necessary.
5) Clean all parts thoroughly with solvent before reassembly.
6) Follow INSTALLATION and OPERATING INSTRUCTIONS when returning Planematic
drive to its mounting.
When ordering parts for the PULLMASTER Planematic drive, always quote the complete model and serial
numbers of the unit.
MODEL NO. _____________________
SERIAL NO. _____________________
PULLMASTER WINCH CORPORATION reserves the right to change specifications and the design of
PULLMASTER Planematic drives at any time without prior notice and without incurring any obligations.
PAGE 20
340 REV.991125
ASSEMBLY DRAWING
G1015-B, G1016-A & G1078-B
340 REV.030926
PAGE 21
PARTS REFERENCE - FINAL DRIVE
ITEM NO.
100 1 21855 FINAL HOUSING
103 1 25938 BEARING - TAPERED ROLLER
107 1 25340 O-RING -281 15"ID 1/8"CS
149 1 26007 WASHER KEYED TIMKEN K91522
150 1 * OUTPUT SHAFT
151 1 25932 BEARING - TAPERED ROLLER SKF #32222
152 1 * FLANGE
153 1 * CAPSCREW
154 1 * FLANGE CAP
155 1 * LOCKWASHER
156 1 21860 END COVER
157 1 25937 OIL SEAL
159 1 25939 LOCKNUT TIMKEN #TAN22
160 1 20450 SUNGEAR STOPPER
161 1 25940 LOCKWASHER TIMKEN #WH22
163 6 25034 CAPSCREW - HEX HEAD 5/16 - 18 NC X 1.00 GRADE 5
165 6 25025 LOCKWASHER 5/16"
167 1 25190 O-RING -90 DURO 171 8"ID 3/32"CS
300 1 21857 FINAL PLANET HUB
310 3 20406 FINAL PLANET PIN
311 3 25199 CIRCLIP ROTOR CLIP SH-168
313 3 25199 CIRCLIP ROTOR CLIP SH-168
320 3 20405 FINAL PLANET GEAR
321 6 25167 THRUST WASHER TORRINGTON #TRB 2840
323 72 25297 LOOSE ROLLER TORRINGTON #G613 - Q
340 1 21876 FINAL SUNGEAR
343 1 25242 CIRCLIP ROTOR CLIP SH-206
QTY.
PART NO.
DESCRIPTION
* These parts vary according to Output Shaft Code. Refer to APPENDIX A.
Refer to PAGE 26 for Planematic drive seal kit and PAGE 21 for ASSEMBLY DRAWING.
PAGE 22
340 REV.991125
FINAL DRIVE GROUP
G1016-A
159
152
155
153
103165163
321311 323 320 310
313
160
340
343
154
300
107150
161 149156157
Group drawings may reference more parts than are actually present in a specific assembly. Parts that are
referenced on the drawing but are not on the PARTS REFERENCE list should be ignored.
340 REV.030926
167 151 100
PAGE 23
PARTS REFERENCE - BRAKE GROUP
ITEM NO.
111 16 25259 CAPSCREW -HEX HEAD 3/8 - 16NC X 1.50 GRADE 5
113 16 25037 LOCKWASHER 3/8"
400 1 21871 PRIMARY PLANET HUB
410 3 20369 PRIMARY PLANET PIN
411 3 25004 CIRCLIP ROTOR CLIP C-87
413 3 25091 CIRCLIP ROTOR CLIP SH-87
420 3 20370 PLANET GEAR
421 6 25068 THRUST WASHER TORRINGTON #TRA 1423
423 60 25270 LOOSE ROLLER 5/32 X 1.25 TORRINGTON #E151-Q
430 1 20411 INTERNAL GEAR
431 1 25338 CIRCLIP ROTOR CLIP SH-300
440 1 21877 PRIMARY SUNGEAR
444 1 20419 SUNGEAR STOPPER
600 1 21880 CONNECTING SHAFT
603 1 25361 NEEDLE BEARING TORRINGTON #B-3012
615 2 25755 THRUST WASHER TORRINGTON #TRA 3648
617 1 25756 THRUST BEARING TORRINGTON #NTA 3648
700 1 21862 BRAKE HOUSING
703 1 25347 PLASTIC CAPLUG 1 NPT
707 1 25339 O-RING -278 12"ID 1/8"CS
712 1 21885 BRAKE SPACER
713 13 25305 DIVIDER PLATE
715 12 25304 FRICTION PLATE
720 1 21879 BRAKE HUB
721 1 25369 CIRCLIP ROTOR CLIP SH-387
723 1 25303 SPRAG CLUTCH
724 1 20421 SPRAG CLUTCH ALIGNER
727 1 25335 CIRCLIP ROTOR CLIP SH-196
743 1 25481 PIPE PLUG 1 NPT SOC HD
750 1 21884 PISTON
751 1 25343 O-RING -90 DURO -451 11"ID 1/4"CS
752 18 20413 BRAKE SPRING
753 1 25342 O-RING -90 DURO -452 11-1/2"ID 1/4"CS
770 1 21869 SPRING STOPPER
771 8 25158 CAPSCREW - HEX HEAD 1/2 - 13NC X 1.75 GRADE 5
773 8 25014 LOCKWASHER 1/2"
774 1 25873 BUSHING
776 1 21801 THRUST WASHER
QTY.
PART NO.
DESCRIPTION
PAGE 24
23141 PLANEMATIC DRIVE SEAL KIT, CONSISTS OF ITEMS:
107, 157, 167, 707, 751, 753, AND 801.
Refer to PAGE 21 for ASSEMBLY DRAWING.
340 REV.050516
PARTS REFERENCE - BRAKE GROUP
G1015-B
423
411
776
774
410
413
773771 753752420
421 743 751 750 700 707
712
715
720
721
723
727
444
440
400615
Group drawings may reference more parts than are actually present in a specific assembly. Parts that are
referenced on the drawing but are not on the PARTS REFERENCE list should be ignored.
340 REV.991125
430 603431713703111113770617
724
600
PAGE 25
PARTS REFERENCE - MOTOR GROUP
ITEM NO.
537 12 25081 CAPSCREW - HEX HEAD 1/2 - 13NC X 1.50 GRADE 5
730 1 21875 MOTOR DRIVE SHAFT
732 1 22223 MOTOR DRIVE SHAFT SPACER
733 1 25942 NEEDLE BEARING TORRINGTON #F-3516
773 12 25014 LOCKWASHER 1/2"
800 1 20401 MOTOR ADAPTOR
801 3 25127 O-RING -90 DURO -013 7/16"ID 1/16"CS
802 1 * *
805 2 25040 PIPE PLUG 1/8 NPT
806 1 * *
807 1 * *
809 1 * *
813 1 25031 PIPE PLUG 1/4 NPT SOC HD
861 1 25350 GEAR HOUSING
865 4 25356 DOWEL PIN
869 2 25348 SEAL - GASKET
870 1 26443 PORT END COVER WITH PLUGS (ITEM 899)
875 4 25352 BEARING - ROLLER
877 2 25646 SEAL - RING
881 1 25645 GEAR SET -086
885 2 25644 THRUST PLATE
887 4 25647 SEAL - TEFLON
899 2 25031 PIPE PLUG 1/4 NPT SOC HD
929 1 * *
950 1 ** MOTOR SUB-ASSY
951 8 25357 CAPSCREW - HEX HEAD 5/8 - 11NC X 6.75 GRADE 5
953 8 25325 WASHER
955 2 25559 PLASTIC CAPLUG 2.0"
QTY.
PART NO.
DESCRIPTION
23117 MOTOR SEAL KIT, CONSISTS OF ITEMS:
869, 877 AND 887.
* These parts and descriptions vary according to Brake Code.
Refer to APPENDIX B.
** ITEM 950, MOTOR SUB-ASSY, CONTAINS ITEMS:
733, 800, 802, 805, 806, 807, 809, 813, 861, 865, 869,
870, 875, 877, 881, 885, 887, 899, 929, 951, 953, AND 955.
Refer to PAGE 24 for Planematic drive seal kit and PAGE 21 for ASSEMBLY DRAWING.
PAGE 26
340 REV.991125
MOTOR GROUP
G1078-B
870877869881802800 801 809 807 955
929 951 953
899875887861885537773 865805813
806
733 950730 732
Group drawings may reference more parts than are actually present in a specific assembly. Parts that are
referenced on the drawing but are not on the PARTS REFERENCE list should be ignored.
340 REV.030926
PAGE 27
INSTALLATION DRAWING
PRESSURIZE
FOR COUNTER-
CLOCKWISE
ROTATION
OPTIONAL EXTERNAL
BRAKE RELEASE
PORT 1/8-27 NPT
8 MOUNTING HOLES
25/32 DIA {20} ON
18.625 {473.1} B.C.DIA
GAUGE PORTS
*
CLOCKWISE
PRESSURIZE FOR
ROTATION
CLOCKWISE
SAE SPLIT FLANGE
SEE MOTOR CHART
FOR PORT SIZE
20.38
[517.5]
5.2
2.7
[68]
[132]
1/4-18 NPT
CIRCULATION PORT
3/8-18 NPT
IN MM
MOTOR LENGTH (I)
SAE SPLIT FLANGE
MOTOR PORT SIZE
COMMERCIAL WM76 SERIES
HYDRAULIC MOTORS
WIDTH
I
GEAR
CODE
MOTOR
(EXTERNAL
CIRCULATION
MODELS ONLY)
181.1
187.5
193.8
7.13
7.38
7.63
2
2.50
2.75
3.00
-88
-87
-86
2 PULLER AND LIFTING
HOLES 3/4-10NC
143.0
149.4
155.7
162.1
168.4
174.8
5.63
5.88
6.13
6.38
6.63
6.88
1
1 1/4
1 1/2
1.00
1.25
1.50
1.75
2.00
2.25
-94
-93
-92
-91
-90
-89
I1012-C
PAGE 28
SHAFT10.38
[263.5]
7.31
[185.7]
.81
[20.6]
.63
[15.9]
OPTIONAL INBOARD FLANGE
6 HOLES .750 DIA [19]
16.997
17.000
[431.80]
3.63
[92.1]
4.50
7.749
[114]
7.747
9.4
[238]
[196.85]
.63
[15.9]
6.250 B.C.
[158.75]
12.69
[322.3]
DRAIN PORTS (2)
1-11 1/2 NPT
.75
[19.1]
24.08
[611.6]
6.94
[176.2]
10.44
[265.1]
34
10/20303.500
FLAT ROOT SIDE FIT
EXT SPLINE DATA
DIAMETR. PITCH
PRESSURE ANGLE
NUMBER OF TEETH
OPTIONAL OUTBOARD FLANGE
6 HOLES .750 DIA [19]
NOTE: Clockwise and counterclockwise output shaft rotation is established by looking at the hydraulic motor.
MAJOR DIAMETER
340 REV.030926
ITEM PART
NO. DESCRIPTION
APPENDIX A
OUTPUT SHAFT CODE
- 1 - 2 - 3 - 4 - 5
PART NUMBER
150 22164 23018 22164 22164 22569
150A N/A 23019 N/A N/A N/A
152 N/A N/A 21856 21874 N/A
153 N/A N/A 25139 25139 N/A
154 N/A N/A 21420 21420 N/A
155 N/A N/A 25359 25359 N/A
OUTPUT SHAFT
KEY
FLANGE
CAPSCREW
FLANGE CAP
LOCKWASHER
340 REV.991125
PAGE 29
APPENDIX B
BRAKE CODE
- 3- 4- 5- 6- 7- 8- 9- 10
ITEM
NO.
802
806
806
807
807
809
929
PART
DESCRIPTION
SHUTTLE
CIRCULATION
VALVE
1/4-18 NPT
PIPE PLUG
1/8-27 NPT
PIPE PLUG
1/8-27 NPT
PIPE ADAPTOR
1/8 NPT
CAPLUG
3/8 NPT
CAPLUG
PART NUMBERS
N/A 20849 20849 N/A
20456 20456 20456 20456 N/A N/A N/A N/A
N/A N/A N/A N/A 25031 25031 25031 25031
25040 N/A N/A 25040 25040 N/A N/A 25040
N/A 25622 25622 N/A N/A 25622 25622 N/A
N/A 25374 25374 N/A N/A 25374 25374 N/A
N/A N/A N/A N/A 26276 26276 26276 26276
N/A
20849 20849 N/A
PAGE 30
929
950
3/8-18 NPT
PIPE PLUG
MOTOR
SUB-ASSY
25085 25085 25085 25085 N/A N/A N/A N/A
22041 22404 22405 22042 22043 22406 22407 22044
340 REV.991125
BOL T TORQUE CHART
BOLT DIAMETER
Inches
1/4 912
5/16 18 24
3/8 32 43
7/16 50 68
1/2 75 102
9/16 110 149
5/8 150 203
3/4 265 359
7/8 420 569
TORQUE
Lb-ft
1 640 868
1 1/8 800 1085
1 1/4 1000 1356
1 3/8 1200 1627
1 1/2 1500 2034
TORQUE
Nm
340 REV.991125
NOTE: Unless otherwise specified, torque bolts per above chart.
PAGE 31
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