Pullmaster HL25 Instructions And Parts Manual

INSTRUCTION AND PARTS MANUAL

MODEL HL25

PLANETARY HYDRAULIC WINCH

PML

THE LOGICAL CHOICE

PULLMASTER WINCH CORPORATION

8247-130th Street, Surrey, B.C. V3W 7X4, Canada

Telephone: [phone] Fax: [phone]

Website: www.pullmaster.com

E-mail: [e-mail]

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.

PMC 313 030619

PULLMASTER LIMITED WARRANTY

Effective 1/1/2002

SUPERSEDES ALL PRIOR WARRANTIES

Seller warrants that each article sold under this order shall at the time of shipment (i) conform to applicable
specifications, and (ii) be free from defects in material and workmanship during normal and ordinary use and
service (the “

Buyer’s exclusive remedy and Seller’s sole obligation under this Warranty shall be, at Seller’s option, to repair or
replace any article or part thereof which has proven to be defective, or to refund the purchase price of such article
or part thereof.

This Warranty shall expire one (1) year from the date the article is first shipped by Seller. Notice of claimed breach
of this Warranty must be given by Buyer to Seller within the applicable period. Such notice shall include an
explanation of the claimed warranty defect and proof of date of purchase of the article or part thereof for which
warranty coverage is sought. No allowances shall be made by Seller for any transportation, labor charges, parts,
“in and out” costs, adjustments or repairs, or any other work, unless such items are authorized in writing and in
advance by Seller. Nor shall Seller have any obligation to repair or replace items which by their nature are
expendable.

If an article is claimed to be defective in material or workmanship, or not to conform to the applicable specifications,
Seller will either examine the article at Seller’s site or issue shipping instructions for return to Seller. This Warranty
shall not extend to any articles or parts thereof which have been installed, used, or serviced otherwise than in
conformity with Seller’s applicable specifications, manuals, bulletins, or instructions, or which shall have been
subjected to improper installation, operation, or usage, misapplication, neglect, overloading, or employment for
other than normal and ordinary use and service.

Warranty”).

This Warranty shall not apply to any articles or parts thereof furnished by Seller to Buyer’s specifications and/or
furnished by Buyer or acquired from others at Buyer’s request.

SELLER MAKES NO EXPRESS WARRANTIES AND NO IMPLIED WARRANTIES OF ANY KIND, OTHER THAN
THE WARRANTY EXPRESSLY SET FORTH ABOVE. SUCH WARRANTY IS EXCLUSIVE AND IS MADE AND
ACCEPTED IN LIEU OF ANY AND ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING WITHOUT
LIMITATION THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR
PURPOSE.

The remedies for this Warranty shall be only those expressly set forth above, to the exclusion of any and all other
remedies of whatsoever kind. The limited remedies set forth above shall be deemed exclusive, even though they
may fail their essential purpose. No agreement varying or extending the foregoing Warranty, remedies, exclusions,
or limitations shall be effective unless in writing signed by an executive officer of Seller and Buyer. This Warranty
is non-transferable.

Under no circumstances shall Seller be liable (i) for any damage or loss to any property other than the warranted
article or part thereof, or (ii) for any special, indirect, incidental, or consequential damage or loss, even though
such expenses, damages, or losses may be foreseeable.

The foregoing limitations on Seller’s liability in the event of breach of warranty shall also be the absolute limit of
Seller’s liability in the event of Seller’s negligence in manufacture, installation, or otherwise, with regard to the
articles covered by this Warranty, and at the expiration of the Warranty period as above stated, all such liabilities
shall terminate.

WARNING

PULLMASTER planetary winches/drives are not designed for operations involving lifting or moving

personnel. The PULLMASTER WINCH CORPORATION cannot be held liable or responsible

for any accident resulting from such use of PULLMASTER planetary winches/drives.

Note: Specifications contained in this Instruction and Parts Manual are subject to change without notice.

SAFETY RECOMMENDATIONS

Definition: Caution indicates a potentially

DANGER

FAILURE TO COMPLY WITH THE FOLLOWING SAFETY

RECOMMENDATIONS AND LOCAL RULES AND

REGULATIONS WILL RESULT IN PROPERTY

DAMAGE, SEVERE INJURY OR DEATH.

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.

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.

1. Do not install, operate or service winch before
reading and understanding manufacturer's
instructions.

2. The winch described herein is not designed for
operations involving lifting or moving personnel.

3. Do not lift or carry loads over people.

4. Do not exceed recommended operating pressure
(psi) and operating volume (gpm).

5. Do not jerk the winch. Always smoothly
accelerate and decelerate load.

6. Do not operate a damaged, noisy or
malfunctioning winch.

7. Do not leave a load suspended for any extended
period of time.

8. Never leave a suspended load unattended.

9. Winch should be maintained and operated by
qualified personnel.

10. Inspect winch, rigging, mounting bolts and
hoses before each shift.

11. Warm-up equipment before operating winch,
particularly at low ambient temperatures.

12. Verify winch function by raising and lowering a
full test load to a safe height before each shift.

13. Do not weld any part of the winch.

14. Verify gear lubrication and brake circulation
supply and return before operating winch.

15. Be sure of equipment stability before operating
winch.

16. Wear proper clothing to avoid entanglement in
rotating machinery.

17. Always stand clear of the load.

18. Use only recommended hydraulic oil and gear
lubricant.

19. Keep hydraulic system clean and free from
contamination at all times.

20. Maintain winch and equipment in good operating
condition. Perform scheduled maintenance regularly.

21. Keep hands clear when winding wire rope onto
the winch drum.

22. Do not use the wire rope as a ground for welding.

23. Rig the winch carefully. Ensure that the wire rope
is properly anchored to the correct cable anchor slot at
the cable drum.

24. Do not lift a load with a twisted, kinked or
damaged wire rope.

25. Consult wire rope manufacturer for size, type and
maintenance of wire rope.

26. Maintain three wraps of wire rope on the cable
drum at all times.

27. In case of a power failure or breakdown leading to
an unexpected stop of the hydraulic power circuit, stand
clear of the area and the load being hoisted, take the
necessary precautions to prevent access to area where
the load is halted.

28. The noise level of the winch is 87dBA measured
on a distance of 1.00 meter, 1.60 meters high. The
measuring equipment used was: Realistic #42-3019.

29. Clean up any oil spillage immediately.

30. Wear proper clothing and personal protection
equipment such as, footwear, safety goggles and a hard
hat. Read manual first.

elen

PAGE 1313 REV.970901

DESCRIPTION OF THE MODEL HL25

GENERAL DESCRIPTION:

The PULLMASTER Model HL25 is a planetary, hydraulic winch with two forward speeds and one reverse speed.
At low forward or hoisting speed this unit has a line pull capacity of 25,000 lb on the first layer of wire. In the "rapid
forward" mode the line pull capacity is reduced by a ratio of 4.67 and the line speed increases by the same ratio.
The change from low speed to rapid forward speed is actuated hydraulically and can be made while the drum
is rotating. The main components of this unit are:

✧ Hydraulic motor
✧ Multi-disc brake with static and dynamic function
✧ High speed clutch
✧ Primary planet reduction
✧ Final planet reduction
✧ Brake housing
✧ Final drive housing
✧ Cable drum

FUNCTION IN FORWARD ROTATION:

LOW FORWARD SPEED

During low forward speed the output torque and rpm of the hydraulic motor is transmitted by the motor drive shaft
to the primary sungear of the primary drive. The output torque and rpm of the primary drive is transmitted to the
final drive by the final sungear, which is splined to the primary planet hub. The output torque and rpm of the final
drive is transmitted to the cable drum by a spline, attaching the final planet hub to the cable drum.

The motor drive shaft is splined to a clutch hub which connects to a set of friction and divider plates. During low
speed operation, a pressure plate, which is "spring applied" and "pressure released", permits free rotation of the
friction plates.

The motor drive shaft is also attached to a connecting shaft by a sprag clutch which permits free rotation of the
motor drive shaft while the connecting shaft is stationary. The connecting shaft is held stationary by another sprag
clutch to a brake hub. During low forward speed operation, the automatic brake remains applied, hence, the brake
hub, the connecting shaft and the internal gear do not rotate.

RAPID FORWARD SPEED

When rapid forward speed is actuated, hydraulic pressure is channelled from the motor to the center bore of the
motor drive shaft to the clutch piston. The hydraulic pressure causes the clutch to engage against the clutch
springs. The clutch hub is splined to the motor drive shaft and the drive gear is splined to the connecting shaft,
the internal gear of the primary drive will rotate with the motor drive shaft. Thus, the planetary drive is eliminated.
The elimination of the primary drive results in a forward or hoisting line speed 4.67 times faster than low forward
speed. The line pull capacity during "rapid forward" operation must be decreased by a ratio of 4.67. When the
pressure is removed from the clutch, the clutch is disengaged by the clutch springs and the unit reverts to low
forward speed. Since the sprag clutch, which connects the connecting shaft to the brake hub, permits free
rotation, the automatic brake of the winch is not affected during rapid forward speed.

NOTE: The change over from low forward speed to rapid forward speed can be made while the drum is

rotating, providing the load on the wire rope does not exceed 5357 lb (23.8 kN) on the first layer
of wire rope. If this load is exceeded, winch will stall.

PAGE 2

313 REV.980301

DESCRIPTION OF THE MODEL HL25

CONTINUED

FUNCTION IN REVERSE ROTATION:

RAPID REVERSE

When the hydraulic motor is pressurized for rapid reverse, the rotation of the motor drive shaft causes the sprag
clutch to lock, resulting in a solid assembly between the motor drive shaft and the connecting shaft. Rotation of
the connecting shaft causes the sprag clutch between the connecting shaft and the brake hub to lock making
a solid assembly between these two components. Hydraulic pressure is automatically transmitted to the brake
piston, forcing the brake piston to release brake against a series of brake springs. The friction plates, which are
engaged in the brake hub, can now rotate between the divider plates. Since both sprag clutches are locked, the
friction plates, brake hub, connecting shaft, internal gear and primary sungear turn at the same revolution as the
motor drive shaft. Thus, the primary drive is eliminated, resulting in a reversing speed 4.67 times faster than low
forward speed.

If a load on the cable drum tends to affect the reversing speed, the resulting pressure drop in the brake piston
causes friction between the friction plates and the divider plates. Thus, a completely smooth reversing speed can
be controlled in a stepless operation by modulation of the winch control handle. When the control is returned to
neutral position, rotation stops and the disc brake applies automatically. The pressure in the brake piston is vented
to the reservoir by the motor spool of the winch control valve.

During reverse operation of the winch, or when a load is being lowered, the friction created by the brake disc
results in temperature. On the standard Model HL25 this temperature is dissipated by a circulation flow of
hydraulic fluid, supplied from an external source (see HYDRAULIC CIRCUIT). For efficient cooling of the
automatic brake, the external circulation flow should be adjusted to 7 (US) gpm (26 l/min). This circulation flow
must be returned directly to the reservoir with a permissible back pressure of 30 psi (2 bar) (see HYDRAULIC
CIRCUIT).

IMPORTANT: Under no circumstances must the back pressure in the brake housing be permitted to exceed

30 psi (2 bar). Excessive pressure in the brake housing will damage the oil seals separating the
brake housing from the drum interior. Damage to this seal will cause the cable drum to fill up with
hydraulic fluid. In order to prevent potential damage to the drum seals and the end cover of the
winch, when the cable drum fills up with hydraulic fluid, a breather relief (see PARTS
REFERENCE, item 130) is installed on the end cover. The breather relief bleeds to atmosphere
and serves as a warning signal that the oil seal between the brake housing and drum has been
damaged.

313 REV.970901

PAGE 3

EXPLANATION OF MODEL CODING

25

HL

BASIC UNIT SERIES

HL = Rapid forward and reverse

SIZE OF UNIT

REDUCTION RATIO

Only used for non standard reduction ratios

TYPE OF BRAKE

-7 Automatic brake, clockwise drum rotation, external circulation flow

-8 Automatic brake, external brake release, clockwise drum rotation,
external circulation flow

-9 Automatic brake, external brake release, counterclockwise drum
rotation, external circulation flow

-10 Automatic brake, counterclockwise drum rotation, external
circulation flow

HYDRAULIC MOTOR

X - XX - XX - XX X - X XXXX

-86 Standard hydraulic gear motor -

-129 Standard hydraulic piston motor -
(For other motor options contact factory)

DRUM SIZE

-1 10 inch drum diameter X 17 inch flange diameter X 11 inch length -

(For other drum sizes refer to APPENDIX A)

OPTIONS

-F Hydraulically actuated freespooling

DESIGN REVISION

SPECIFICATION NUMBER

Describes features not identified by preceding codes

NOTE: Clockwise and counterclockwise drum rotation is the direction of rotation for pulling or hoisting,

established by looking at the hydraulic motor.

WM76

(12.3 in3 displacement)

VOLVO 110 cc

(6.7 in3 displacement)

STANDARD

PAGE 4

313 REV.970901

OPTIONS

COUNTERCLOCKWISE ROTATION:

The drum rotation of the standard PULLMASTER Model HL25 planetary winch is clockwise for hoisting when
looking at the hydraulic motor of the winch. Drum rotation for counterclockwise hoisting direction is available as
an option.

EXTERNAL BRAKE RELEASE:

PULLMASTER planetary winches can be supplied with an external brake release which permits release of the
automatic disc brake from an external pressure source.

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. WINCHES SUPPLIED WITH EXTERNAL

RELEASE OPTION MUST BE CONNECTED ACCORDING

TO TYPICAL HYDRAULIC CIRCUIT.

CABLE DRUM SIZES:

Aside from the standard drum sizes listed in APPENDIX A, the PULLMASTER Model HL25 planetary winch can
be supplied with optional drums to accommodate large wire rope storage capacity.

DRUM GROOVING:

Cable drums for the PULLMASTER Model HL25 planetary winch can be grooved. Where this option is a
requirement, it is necessary to state the size of wire rope which is to be used with the winch.

OPTIONAL GEAR SECTION FOR THE HYDRAULIC MOTOR:

The performance of the standard PULLMASTER Model HL25 planetary winch may be changed by using a
different displacement motor. (Contact the factory for performance information.)

HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS:

The operating pressure of the PULLMASTER Model HL25 planetary winch is limited to 2500 psi (172 bar). For
hydraulic systems operating with a higher range of hydraulic pressure, the winch can be supplied with a hydraulic
piston motor, which will provide for the same basic performance in terms of line pull and line speed capacity.
(Contact the factory for this requirement.)

FREESPOOLING:

This option permits wire rope being pulled off the cable drum by an operator. Freespooling should not be
confused with free fall. The freespool clutch cannot be disengaged or re-engaged with a load on the wire rope
or while the cable drum is turning.

The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements.

313 REV.970901

PAGE 5

SPECIFICATIONS

Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 7/8 inch
diameter wire rope. For other cable drums refer to APPENDIX A. For other reductions or motors, refer to
supplement inside back cover. Performance specifications for winches supplied with optional motors are
provided in attached supplement.

CABLE DRUM DIMENSIONS (STANDARD DRUM):

Barrel diameter 10.00 in 254 mm
Flange diameter 17.00 in 432 mm
Barrel length 11.00 in 279 mm

CABLE STORAGE CAPACITY:

(Size of wire rope) 7/16 in 612 ft 186 m

1/2 in 413 ft 126 m

9/16 in 383 ft 117 m

5/8 in 297 ft 90 m
3/4 in 210 ft 64 m
7/8 in 140 ft 43 m

1 in 91 ft 28 m

-86 Gear Motor -129 Piston Motor

MAXIMUM OPERATING PRESSURE:

MAXIMUM OPERATING VOLUME:

MINIMUM OPERATING VOLUME:

2500 psi (172 bar) 3800 psi (262 bar)

115 (US) gpm (435 l/min) 61 (US)gpm (231 l/min)

30 (US) gpm (114 l/min) 14 (US) gpm (53 l/min)

DRUM TORQUE AT MAXIMUM PRESSURE: 135,937 lb-in 15,359 Nm

DRUM RPM AT MAXIMUM VOLUME: Hoisting 49 rpm

Lowering & High Speed Hoisting 229 rpm

LINE PULL AT MAXIMUM PRESSURE IN LOW FORWARD MODE:

Bare drum 25,000 lb 111.2 kN

Full drum 16,860 lb 75.0 kN

ALLOWABLE LINE PULL IN RAPID FORWARD OR RAPID REVERSE MODE:

Bare drum 5,357 lb 23.8 kN

Full drum 3,613 lb 16.1 kN

LINE SPEED AT MAXIMUM VOLUME IN LOW FORWARD MODE:

Bare drum 140 fpm 43 m/min
Full drum 207 fpm 63 m/min

LINE SPEED AT MAXIMUM VOLUME IN RAPID FORWARD OR RAPID REVERSE MODE:

Bare drum 651 fpm 198 m/min
Full drum 965 fpm 294 m/min

PERMISSIBLE SYSTEM BACK PRESSURE AT MOTOR RETURN PORT: 65 psi 4.5 bar

PERMISSIBLE PRESSURE AT CIRCULATION SUPPLY PORT: 30 psi 2 bar

LUBRICATING OIL: Refer to RECOMMENDATIONS for viscosity and instructions.

Refer to APPENDIX A for oil volume required.

PAGE 6

313 REV.010201

RECOMMENDATIONS

HYDRAULIC FLUID:

The hydraulic fluid selected for use with PULLMASTER
planetary winches should be a high grade, petroleum
based fluid, with rust, oxidation and wear resistance.
Fluid cleanliness and operating viscosity are critical to
winch reliability, efficiency and service life.

For optimum performance, the recommended viscosity
range at operating temperature is 81 - 167 SUS (16 - 36
CS). For extreme operating conditions of short duration,
the maximum viscosity range of 58 - 4635 SUS (10 -
1000 CS) should not be exceeded.

For optimum performance, the winch recommended
hydraulic fluid temperature operating range is 80 -
150F (27 - 66 C). For extreme operating conditions of
short duration, the maximum temperature range of -5

- 180F (-21 - 82 C) should not be exceeded.

LUBRICATION:

The winch gear train requires oil bath lubrication. The
winch is shipped from the factory without lubricating oil.

IMPORTANT: ADD LUBRICATING OIL BEFORE
RUNNING WINCH.

Refer to INSTALLATION DIMENSIONS for location of
lubricating oil fill port. Refer to APPENDIX A for quantity
of oil required. For normal operating temperature use
SAE 90 lubricating oil. For temperatures beyond normal
operating range, consult lubricating oil supplier or
factory.

HYDRAULIC PUMP:

For maximum performance of the PULLMASTER
planetary winch, the hydraulic pump must supply the
maximum flow of hydraulic fluid at the hydraulic pressure
stated in SPECIFICATIONS.

HYDRAULIC CONTROL VALVE:

The standard control valve used for operation of the
PULLMASTER planetary winch must have a four-way,
spring return to neutral feature, which provides for
open flow from the pressure ports of the winch to the
reservoir in neutral position of the control (motor spool).
It is important to point out that good speed control,
especially when lowering a load, depends on the
"metering"

HYDRAULIC PRESSURE RELIEF:

The hydraulic circuit for the PULLMASTER planetary
winch requires a pressure relief set at the operating
pressure (see SPECIFICATIONS). Usually, a pressure
relief is part of the hydraulic control valve. Where this is
not the case, a separate pressure relief valve must be
installed and set at the recommended maximum pressure.

HYDRAULIC RESERVOIR:

It is recommended that the hydraulic reservoir has
sufficient capacity to provide good heat dissipation in
order to prevent over-heating of the hydraulic fluid. The
hydraulic reservoir should be made from clean and
scale-free material to prevent contamination of the
hydraulic fluid. In order to prevent air from being mixed
with the hydraulic fluid, the reservoir should have an
over-flow baffle separating the return lines from the
suction line and all return lines should enter the reservoir
below the fluid level. The reservoir should be mounted
close to and above the hydraulic pump in a location
which provides for free air circulation around the reservoir.

HYDRAULIC HOSES:

The following hydraulic hoses are recommended for
maximum efficiency of the PULLMASTER Model HL25
planetary winch:

Pressure lines: Equivalent to SAE 100R12-32
Circulation return line: Equivalent to SAE 100R4-16
Circulation supply line: Equivalent to SAE 100R6-6
High speed shifting line: Equivalent to SAE 100R1-4

It is recommended that a larger size of hydraulic hose
is installed where the pressure lines or the circulation
lines are excessively long.

HYDRAULIC FILTER:

Hydraulic filter recommendations for the hydraulic circuit
of the PULLMASTER planetary winch, based on a
return line filter, are given as follows:

Average Atmosphere: 10 microns
Dusty Atmosphere: 5 microns

In order to prevent accidental stoppage of the return
line flow, the oil filter should have a by-pass feature.

USE OF AN E STOP:

(FOR EUROPEAN MACHINERY DIRECTIVE APPLICATIONS)

The use of an E stop (emergency) is mandatory in the
controls circuit. The E stop is to be placed in the
operator's control panel. The E stop must be designed
and placed in line with EN 60204 and EN 418.

313 REV.021028

PAGE 7

PERFORMANCE GRAPHS

FOR STANDARD GEAR MOTOR

LINE PULL VS. OIL PRESSURE

0 111

2500

22

LINE PULL - kN

44

PG-HL25-86-A

67

89

172

2000

FULL DRUM

BARE DRUM

1500

1000

OIL PRESSURE - psi

500

0

5000

LINE SPEED VS. OIL VOLUME

030

115

100

61

FULL DRUM

10000

BARE DRUM

LINE PULL - lb

LINE SPEED - m/min

91

122

152

15000

183

213

20000

244

138

103

69

34

0

250000

HOISTING

HIGH SPEED HOISTING
AND LOWERING

274

294

435

378

OIL PRESSURE - bar

80

60

40

20

OIL VOLUME - (US)gpm

0

0

Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with
7/8 inch diameter wire rope.

PAGE 8

FULL DRUM

BARE DRUM

100

200

300

BARE DRUM

400

500

FULL DRUM

600

LINE SPEED - fpm

700

800

302

227

151

76

0

965

900

313 REV.970901

OIL VOLUME - l/min

PERFORMANCE GRAPHS

FOR STANDARD PISTON MOTOR

LINE PULL VS. OIL PRESSURE

0 111

3800

22

LINE PULL - kN

44

67

PG-HL25-129-A

89

262

3040

FULL DRUM

BARE DRUM

2280

1520

OIL PRESSURE - psi

760

0

5000

LINE SPEED VS. OIL VOLUME

61

61

0

30

FULL DRUM

10000

BARE DRUM

LINE PULL - lb

LINE SPEED - m/min

91

122

152

15000

183

20000

213

244

209

157

105

52

0

250000

HOISTING

HIGH SPEED HOISTING
AND LOWERING

274

294

231

OIL PRESSURE - bar

50

40

30

20

OIL VOLUME - (US)gpm

10

0

0

FULL DRUM

BARE DRUM

100

200

300

400

BARE DRUM

500

FULL DRUM

600

700

800

LINE SPEED - fpm

Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with
7/8 inch diameter wire rope.

313 REV.970901

900

189

151

113

76

OIL VOLUME - l/min

38

0

965

PAGE 9

TYPICAL HYDRAULIC CIRCUIT

400 PSI [28 BAR]
PRESSURE REQUIRED
FOR MODELS SUPPLIED
WITH FREESPOOL OPTION

CIRCULATION RETURN LINE
(MUST GO DIRECT
TO RESERVOIR)

GEAR MOTOR

HC-HL25-D

PRESSURE REDUCING
VALVE - FACTORY
PRESET 250 PSI
[17 BAR]

FAST FORWARD
CONTROL VALVE

800 PSI [55 BAR]
2(US)GPM [8 L/MIN]
REQUIRED FOR MODELS
SUPPLIED WITH EXTERNAL
BRAKE RELEASE OPTION

CIRCULATION SUPPLY
LINE 7 (US) GPM
[26 L/MIN]

PRESSURE
RELIEF VALVE

HYDRAULIC

PUMP

RESERVOIR

CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER

FILTER

PAGE 10

313 REV.010201

TYPICAL HYDRAULIC CIRCUIT

400 PSI [28 BAR]
PRESSURE REQUIRED
FOR MODELS SUPPLIED
WITH FREESPOOL OPTION

CIRCULATION RETURN LINE
(MUST GO DIRECT
TO RESERVOIR)

PISTON MOTOR

7 (US) gpm
26 l/min

3.5 TO 4(US) gpm
[13 TO 15 l/min]

PRESSURE REDUCING
VALVE - FACTORY
PRESET 250 PSI
[17 bar]

800 PSI [55 BAR]
2(US)GPM [8 L/MIN]
REQUIRED FOR MODELS
SUPPLIED WITH EXTERNAL
BRAKE RELEASE OPTION

TO

FORWARD

PORT

TO

REVERSE

PORT

HC-HL25-129-C

FAST FORWARD
CONTROL VALVE

CIRCULATION
SUPPLY LINE

PRESSURE
RELIEF VALVE

HYDRAULIC

PUMP

RESERVOIR

CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER

FILTER

313 REV.010201

PAGE 11

INSTALLATION INSTRUCTIONS

DANGER

FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL

RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.

The initial installation or mounting of a PULLMASTER planetary winch is critically important for proper operation
and performance. If the winch is mounted to an uneven surface, the centre line of the unit can be distorted to a
point where the winch will not operate in either direction. It is therefore very important that the following
instructions are observed when a PULLMASTER planetary winch is installed:

1) Make certain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted.

2) Set the winch on the mounting platform and check for surface contact on all mounting pads of the winch.

3) If there is a space between the mounting surface and one of the mounting pads, the mounting surface is not
even and the space below the mounting pad must be shimmed. If this condition exists, proceed as follows:

a) Install mounting bolts snug tight on the three mounting pads which are in contact with the mounting

surface. (For mounting bolt size and grade see INSTALLATION DIMENSIONS.)

b) Measure the space underneath the fourth mounting pad with a feeler gauge and use shim stock of

equivalent thickness in the space between the mounting pad and the mounting surface.

c) Only after this procedure should the fourth mounting bolt be installed. Tighten all four bolts per BOLT

TORQUE CHART.

4) Fill the winch with lubricating oil. (See APPENDIX A for oil volume required.)

5) Use recommended circuit components and hydraulic hoses.

6) The circulation return line of the winch should be plumbed in such a manner that the brake housing remains
full of oil at all times. Connect the return line directly to reservoir. Do not connect to a common return line.

7) Before operating the winch with a load, verify adequate circulation flow through the circulation return line as
stated in TYPICAL HYDRAULIC CIRCUIT. Verify that pressure measured at the circulation supply port does
not exceed the permissible pressure stated in SPECIFICATIONS. Ensure there is no back pressure at
pressure reducing valve tank port.

8) Verify that breather relief, item 130, is above oil level on end cover, item 120. Rotate end cover if breather
relief is below oil level.

IMPORTANT: Do not replace breather relief with a pipe plug. The breather relief does not prevent oil seal

failure but serves as an indicator or warning that the oil seals between brake housing and the
cable drum interior have failed and must be replaced immediately. If these oil seals are
changed, additional failure of the drum seal and potential damage to the end cover is
prevented.

9) Ensure brake housing and clutch housing are full of oil at all times.

PAGE 12

313 REV.970901

OPERATING INSTRUCTIONS

DANGER

FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL

RESULT IN PROPERTY DAMAGE, SEVERE INJURY OR DEATH.

After the PULLMASTER planetary winch has been installed in accordance with the INSTALLATION
INSTRUCTIONS, the wire rope can be fastened to the cable drum.

IMPORTANT: The ropes, chains, slings, etc. are not part of the winch and are not covered by this manual.

Refer to manufacturer’s handling, inspection and maintenance recommendations to avoid
potential accidents. For selection of ropes, etc. please check following product standards:
DIN 15020, prEN818-1/9, prEN 1492-1/2, prEN 1677-1/3 and other relevant product standards.

1) The cable drum of the PULLMASTER planetary winch has two cable anchor slots, one for clockwise and one
for counterclockwise hoisting. Standard rotation for hoisting is clockwise when looking at the hydraulic motor
of the unit. It is critical to select the cable anchor slot which will permit winding of the wire rope on the drum
in the correct direction of rotation. If the wire rope is wound on the cable drum in the wrong direction of rotation,
the winch will have no braking capacity. Each winch is shipped from the factory with a label on the drum
indicating the correct cable anchor slot.

WIRE ROPE INSTALLATION

Clockwise hoisting winch shown.
(Use cable anchor slot on opposite side of
drum for counterclockwise hoisting winch.)

CABLE ANCHOR

CABLE ANCHOR SLOT

SI1013 - HL25

Feed the wire rope through the cable
anchor slot. Loop rope back into slot
as shown. Insert cable anchor into
slot, small end first and long side
nearest the drum flange. Pull rope
tight to wedge rope in slot.

2) On wire rope installation, care must be taken that the wire rope is wrapped completely around the cable
anchor and properly pulled into the cable anchor slot in the cable drum. The cable drum requires 3-4 wraps
of wire rope for safety.

3) The winch operation is controlled by a single control valve lever which has a forward, a reverse and a neutral
position. Speed control in either direction is obtained by modulation of the control valve lever. Maximum line
speed in either direction is obtained when the control valve lever is moved as far as it can go. The disc brake
of the winch will come on automatically when the winch control lever is returned to neutral.

4) Always warm up equipment prior to operating winch, particularly in low ambient temperature. Circulate
hydraulic oil through the winch control valve for several minutes to warm the hydraulic system. To prime the
winch with warm oil, operate the winch at slow speed, forward and reverse, several times.

5) Prevent corrosion damage to winch interior. If not used regularly, run winch up and down at least once every
two weeks.

6) To ensure proper winch installation and function, raise and lower a full test load to a safe height before using
winch for regular operation at the start of each shift.

If, after a new installation, the winch does not function properly, refer to the TROUBLESHOOTING section
of this manual.

313 REV.970901

PAGE 13

TROUBLE SHOOTING

GENERAL:

In most cases, when the hydraulic winch does not perform satisfactorily, the cause of malfunction is found
somewhere in the hydraulic circuit. Before the winch is removed from its mounting and disassembled, all
hydraulic circuit components should be checked for proper function. Make certain hydraulic reservoir is filled to
top level. If the pump is drive by v-belts, check for belt slippage.

IMPORTANT:

The hydraulic operating volume relates to the line speed or rpm of the winch.

Therefore, if the winch does not produce the specified maximum rated line speed or drum rpm, install a flow
meter into the hydraulic circuit to check the volume supplied to the pressure port of the hydraulic winch motor
when the winch control is completely opened. The flow meter should indicate the maximum operating volume.
If this test indicates a loss of hydraulic flow, check the hydraulic pump, the relief valve and the control valve.

The hydraulic operating pressure relates to the line pull or lifting capacity of the winch.

If the winch will not lift the specified maximum line pull, install a pressure gauge into the pressure line leading
to the hoisting port on the hydraulic winch motor. Stall the winch to prevent rotation of the drum and then open
the control valve. Check the hydraulic pressure reading of the installed pressure gauge. If the pressure reads
below the specified maximum operating pressure, look for trouble in the hydraulic pump, the relief valve and
the control valve.

Only if the hydraulic system has been checked and found to be in order, use the following indications for
probable causes of failure in the winch:

FAILURE

Winch will not produce line pull at maximum
pressure as listed in SPECIFICATIONS.

Winch will not produce line speed at maximum
volume as listed in SPECIFICATIONS.

Winch will not reverse.

PROBABLE CAUSE

a) Winch is mounted to an uneven surface.

(See INSTALLATION INSTRUCTIONS.)

b) Cable sheaves or block purchase operated with the

winch are not turning freely.
c) Damage or wear in the hydraulic motor.
d) Excessive back pressure in the hydraulic system.
e) Relief valve may be set too low. (See SPECIFICATIONS

for maximum operating pressure.)
f) Winch is in high speed mode.

a) Winch is mounted to an uneven surface.

(See INSTALLATION INSTRUCTIONS.)
b) Cable sheaves or block purchase operated with the

winch are not turning freely.
c) Damage or wear in the hydraulic motor
d) Excessive back pressure in the hydraulic circuit.

a) Leakage out of the brake piston prevents the brake

from being released against the brake springs. This is

caused by damaged O-ring seals on the brake piston.
b)

The O-ring seals, on the brake release channel between

the motor adaptor, clutch housing or brake housing is

damaged. If this failure occurs there will be leakage either

from the motor adaptor, clutch housing or brake housing.
c) Insufficient hydraulic pressure. (See SPECIFICATIONS

for minimum operating pressure.)
d) Winch is mounted to an uneven surface.

(See INSTALLATION INSTRUCTIONS.)
e) Hydraulic pressure is not reaching the brake piston

(plugged brake release passage in the brake housing).

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313 REV.970317

TROUBLE SHOOTING CONTINUED

FAILURE

Clutch will not engage (will not shift into rapid
forward speed).

Brake will not hold.

PROBABLE CAUSE

a) Loss of clutch release pressure. Check pressure

reducing valve and O-rings.

b)

Seized clutch piston caused by contamination in oil supply.

c) Incorrect hydraulic connections. Refer to TYPICAL

HYDRAULIC CIRCUITS.

a) Brake plates or divider plates have been damaged by

contamination in the hydraulic fluid, or lack of circulation
flow in the brake housing.

b) Brake piston is seized in the brake housing because of

contamination in the hydraulic fluid.

c) Excessive back pressure in the return line causes the

brake to release.

d)

Control valve has incorrect spool, which traps hydraulic
pressure in the brake piston when the control valve handle
is returned to neutral position. For proper function of the
automatic brake, both pressure ports of the winch must be

open to the reservoir in neutral position of the control valve.
e) Wire rope is fastened to the incorrect cable anchor slot.
f) Sprag clutch is damaged or surfaces where sprag

clutch engages on motor drive shaft or brake hub are

worn or indented.
g) Winch supplied with external brake release option is

not plumbed per HYDRAULIC CIRCUIT. Failure to

vent external brake release port to reservoir may trap

pressure and cause winch brake to slip.

Brake vibrates when lowering a load.

Oil leaks.

a) Pump is too slow. Pump rpm must be maintained at

normal operating speed when a load is lowered.
b) Brake is running too hot. This is caused by a complete

lack of, or insufficient circulation flow. To check the

circulation, observe the flow of oil from the circulation

return line of the winch. (See TYPICAL HYDRAULIC

CIRCUIT when the winch is reversed.)
c) Control valve has poor metering characteristics.
d) Damaged brake plates or divider plates.
e) The sprag clutch, which connects the motor shaft with

the brake assembly, is damaged.
f) Air mixed with hydraulic oil (foamy oil).

a) Oil leaks from the hydraulic motor flange and the motor

adaptor are caused by damaged O-ring seals.
b)

Oil leaks occurring between the cable drum flanges and

housings are caused by excessive pressure in the brake

housing. Excessive pressure will damage the oil seal which

separates the brake housing from the cable drum interior.
c) If the breather relief on the end cover leaks, the seal

between the drum interior and the brake housing is

damaged and must be replaced. This condition is

caused by excessive pressure in the brake housing of

the winch, operation with the incorrect hydraulic fluid

during cold weather, or a restriction in the circulation

return line leading back to reservoir.

Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model HL25 winch.

313 REV.970317

PAGE 15

SERVICE INSTRUCTIONS

GENERAL:

Before attempting disassembly of the PULLMASTER Model HL25 planetary winch, the following instructions for
disassembly and reassembly should be read and understood:

It is suggested that all expendable parts, such as O-rings and oil seals, are not reused on reassembly. Because
the following service instructions cover the HL25 planetary winch with either a gear motor or a piston motor, verify
the proper seal kits are on hand before disassembly. For models with a gear motor, use seal kit (Part No. 23120)
and, providing the hydraulic motor has to be serviced, seal kit (Part No. 23117). Two new roller bearings, item
875, may also be required (Part No. 25352). For models with a piston motor, use seal kit (Part No. 23140).

NOTE: Backup washers may be included with seal kit. Install with oil seals as per instructions. If not present

in seal kit, the oil seals supplied do not require backup washers.

A clean working area is of prime importance, similar to conditions used for service work on any other hydraulic
component.

All parts, as they are removed from the winch assembly, should be inspected for wear and damage. Worn or
damaged parts must be replaced. Thoroughly clean parts before reassembly. Do not use solvent to clean the
brake or clutch friction plates.

During reassembly, lubricate all O-rings and oil seals with grease before installation.

In the following service instructions, reference to parts is made by numbers and shown on the applicable group
drawings. The service instructions cover assembly and disassembly of Model HL25 with either hydraulic gear
or piston motors. Refer to appropriate instructions and group drawing for each motor. The remaining instructions
apply to all Model HL25s.

DISASSEMBLY

For the majority of required service or repair work, disassembly is required only in the brake housing or clutch
housing of the PULLMASTER Model HL25 planetary winch. There are no special tools needed for the service

or repair work and no adjustments or calibrations are necessary. Proceed with the disassembly as follows:

DISASSEMBLY OF HYDRAULIC GEAR MOTOR ASSEMBLY:

If the analysed service or repair work requires access to the interior of the brake housing or clutch housing, the
hydraulic gear motor should not be disassembled. In this case, the hydraulic motor should be removed together
with the motor adaptor as a complete assembly. If a problem has been analysed to be in the hydraulic motor,
proceed with the disassembly as follows:

1) Remove two socket head capscrews, item 849, and lockwashers, item 847, from transfer tube housing, item

846. Remove transfer tube housing from end cover, item 870. Remove and discard O-ring, item 112. If
pressure reducing valve, item 841, is faulty, replace at this time.

2) Press slotted spring pins, item 848, partially out of transfer tube housing, item 846, to release tube locator,
item 848. Remove and discard O-ring, item 113.

3) Remove transfer tube assembly, item 844, from center of motor drive gear, which is part of gear set, item

881. Remove and discard O-ring, item 879.

4) Remove eight hex capscrews, item 951, together with lockwashers, item 953, from motor assembly.

IMPORTANT: Failure to exercise care when removing motor port end cover or gear housing could

permanently damage machined surfaces of these motor components. Take care not
to damage machined surfaces of motor components at disassembly.

5) Remove (pry loose if necessary) port end cover, item 870, together with bearings, item 875, and ring seal,
item 877. Thrust plate, item 885, and dowel pins, item 865, may stay in gear housing.

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313 REV.970901

SERVICE INSTRUCTIONS CONTINUED

6) If thrust plate comes off with end cover, carefully pry it off of bearings, item 875, and discard teflon seals,
item 887.

7) Remove gear set, item 881, which consists of two gears which are a matched set.

8) Carefully pry gear housing, item 861, off of motor adaptor, item 800. Thrust plate, item 885, and dowel pins,
item 865, may stay in gear housing.

9) If thrust plate stays on motor adaptor, carefully pry it off of bearings, item 875, and discard teflon seals, item 887.

10) Discard gasket seals, item 869. It is also advisable to replace ring seals, item 877, at this time. Bearings, item
875, have to be removed to allow access to ring seals.

Teflon seals, gasket seals and ring seals in the hydraulic motor assembly are not part of winch seal kit. Seal kit
for hydraulic motor can be ordered from factory under Part No. 23117. All parts of the hydraulic motor, with
exception of motor adaptor, item 800, and port end cover, item 870, are standard parts of the hydraulic motor,
having a 3 inch gear section. All of these parts can be ordered from PULLMASTER or Authorized Distributors/
Dealers in Canada, the United States and in most overseas areas.

REMOVAL OF HYDRAULIC GEAR MOTOR ASSEMBLY:

If disassembly of the hydraulic gear motor is not necessary, proceed as follows:

1) Remove transfer tube assembly, item 844, as instructed in step 1 - 3 under DISASSEMBLY OF HYDRAULIC
GEAR MOTOR ASSEMBLY.

2) Remove nine hex head capscrews, item 931, with lockwashers, item 541, and remove motor adaptor, item
800, from clutch housing, item 650.

3) Remove and discard three O-rings, item 801, from flange of motor adaptor.

REMOVAL OF HYDRAULIC PISTON MOTOR:

If fitted with a piston motor, proceed as follows:

1) Remove brake tube assembly, item 852, from motor and motor adaptor, item 800.

2) Remove four hex head capscrews, item 815, and lockwashers, item 817, from motor, item 850. Pull motor
out of motor adaptor, item 800, and discard O-ring, item 819.

3) Remove nine hex head capscrews, item 931, with lockwashers, item 933. Remove motor adaptor, item 800,
and discard three O-rings, item 801.

4) Unscrew six socket head capscrews, item 687, with lockwashers, item 685, and remove bearing carrier, item
664, from motor adaptor. Discard, O-ring, item 667. Remove two seal rings, item 666.

5) Remove clutch connector, item 668, from bearing carrier, item 664, and check that oil passages are clear.

6) Inspect ball bearing, item 665, for damage. If replacement is required, press out of bearing carrier, item 664.

7) Inspect needle bearing, item 669, in motor adaptor. If damaged, press out of motor adaptor and replace.

DISASSEMBLY OF CLUTCH ASSEMBLY:

1) Remove three socket head capscrews, item 682, and lockwashers, item 683, from clutch housing, item 650.
Since brake springs, item 752, apply pressure against inside of clutch housing, it is recommended that these
three capscrews are unscrewed, one turn at a time, until spring pressure has been released. Remove and
discard O-ring, item 707, and O-ring, item 651. Remove and discard three O-rings, item 763.

2) Pull motor drive shaft, item 730, and complete clutch assembly, from brake housing.

3) Disassemble clutch assembly by removing circlip, item 671, from clutch hub, item 670. Remove clutch plate,
item 654, external retaining ring, item 658, eight friction plates, item 673, and seven divider plates, item 675.

313 REV.010201

PAGE 17

SERVICE INSTRUCTIONS CONTINUED

Clamp clutch hub, item 670, to pressure plate, item 652, and remove circlip, item 679. Remove clutch hub, three
clutch springs, item 676, pressure plate, item 652, and gland, item 656, from motor drive shaft. Remove and
discard O-rings, item 653, 657 and 735.

Models with piston motors only: Discard two O-rings, item 689.

4) The surface of motor drive shaft which engages sprag clutch, item 672, should be inspected for wear or
indentations. If motor drive shaft shows any surface damage, it should be replaced.

5) Inspect three clutch springs for damage and measure overall length. Overall spring length should be 1.25
inch. If any spring measures less than 1.19 inch, all three springs should be replaced as a set.

6) Inspect eight friction plates, item 673, for damage or excessive wear. Plates should be flat and smooth. Plates
should not show heat discoloration. Paper material on friction plates should be intact and grooved. If any
damage is detected, replace friction plates and divider plates as a set.

7) Remove circlip, item 661, and slide drive gear, item 660, off of connecting shaft, item 600.

DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:

1) Remove 18 brake springs, item 752, from brake piston, item 750. Thoroughly examine springs for damage
and measure overall length. Overall spring length should be 2.27 inch. If any spring measures less than 2.21
inch, replace all springs as a set.

2) Pull brake piston, item 750, out of brake housing using two 5/8-11NC bolts screwed into two puller holes in
piston and discard O-rings, item 751 and 753.

3)

Thoroughly examine inner bores of brake housing and outer diameters of brake piston for scoring caused by
hydraulic fluid contamination. Minor surface damage may be repaired by polishing with a fine emery cloth.

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.

4) Remove five friction plates, item 715, together with six divider plates, item 713, and inspect for damage or
wear. Plates should be flat and smooth. Plates should not show heat discoloration. Paper material on friction
plates should be intact and grooved. If any damage is detected, replace friction and divider plates as a set.

5) Remove brake spacer, item 712.

DISASSEMBLY OF FINAL DRIVE:

1) Remove drain plug, item 121, from end cover, item 120, and drain lubricating oil from final drive assembly
and the cable drum interior. (To drain all oil out of cable drum interior, winch should be tipped to an angle and
filler plug, item 503, removed.)

Remove internal retaining ring, item 124, and pull end cover, item 120, out of final drive housing, item 100.

2)

3)

Discard O-ring, item 123, and inspect planet hub stopper, item 126, and sungear stopper, item 122, for
excessive wear. Replace planet hub stopper if less than .30 inch and sungear stopper if less than .21 inch thick.

4) Remove final planet hub assembly from final housing, item 100.

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313 REV.970901

SERVICE INSTRUCTIONS CONTINUED

5) Inspect three final planet gears, item 320, for damage or wear. If necessary to remove final planet gears,
remove circlip, item 311, and press planet pin, item 310, out of planet hub, item 300. Inspect loose rollers,
item 323, and two thrust washers, item 321, and replace if damaged.

DISASSEMBLY OF PRIMARY DRIVE AND CABLE DRUM ASSEMBLY:

For ease of working on remainder of unit, set winch upright on final drive housing.

1) Remove the two winch base halves, item 550 and 552, by removing the 28 hex capscrews, item 551, and
lockwashers, item 553.

2) Remove access plug, item 734, using a 1/2-13NC bolt (motor adaptor bolt, item 821, is suitable), from inside
brake housing and discard O-ring, item 735.

3) Remove six hex capscrews, item 537, with lockwashers, item 541, from bearing flange, item 530, by rotating
brake housing until access hole is over top.

4) Lift brake housing, together with the bearing flange and primary planet hub assembly, out of cable drum, item
500, and discard O-ring, item 539.

5)

Remove retaining ring, item 401, and remove primary planet hub assembly from inside internal gear, item 430.

6) Inspect three primary planet gears, item 420, for damage or wear. If necessary to remove primary planet
gears, remove circlip, item 411, and press planet pin, item 410, out of planet hub, item 400. Inspect loose
rollers, item 423, and two thrust washers, item 421, and replace if damaged.

7) Remove primary sungear, item 440, from center of connecting shaft, item 600.

8) Remove circlip, item 431, and internal gear, item 430, from connecting shaft spline.

9) Remove and inspect two thrust washers, item 433, and thrust bearing, item 435. Replace if cracked or
otherwise damaged.

10) Connecting shaft, item 600, can now be pulled out of brake housing. Remove and inspect two thrust washers,
item 615, and thrust bearing, item 617. Replace if cracked or otherwise damaged.

11) Remove sprag clutch aligner, item 677, and sprag clutch, item 672, from connecting shaft, item 600.

12) Remove needle bearing, item 603, inspect and replace if damaged.

13)

Remove and discard oil seal, item 607, and if present, backup washer, item 606, from inside of connecting shaft.

14) Remove sprag clutch aligner, item 722, from outside of connecting shaft. Remove brake hub, item 720, sprag
clutch, item 723, and sprag clutch aligner, item 724. Thoroughly inspect surfaces where sprag clutches ride
on and in connecting shaft. If damaged or indented, connecting shaft must be replaced.

DANGER

MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE

CONNECTING SHAFT AND BRAKE HUB, WILL RESULT IN BRAKE

FAILURE AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY

DAMAGE, SEVERE INJURY OR DEATH. THOROUGHLY INSPECT

THESE AREAS AND, IF NECESSARY, REPLACE BRAKE HUB,

SPRAG CLUTCH AND CONNECTING SHAFT AS A SET.

313 REV.970901

PAGE 19

SERVICE INSTRUCTIONS CONTINUED

15) Remove and discard oil seal, item 711, and if present, backup washer, item 710, from bore of brake housing.
Inspect two needle bearings, item 605, and replace if necessary.

16) To separate bearing flange, item 530, and brake housing, item 700, use a standard bearing puller or insert
two heel bars in slot between bearing flange and brake housing and pry brake housing out of ball bearing,
item 533.

17)

Remove internal retaining ring, item 534, to remove ball bearing, item 533. Remove and discard oil seal, item 531.

REASSEMBLY

Thoroughly clean all parts. Use only new, well-greased O-rings and oil seals. Unless otherwise specified, torque
fasteners per BOLT TORQUE CHART at back of manual.

REASSEMBLY OF FINAL DRIVE:

Reassemble final drive end of winch as follows:

1) Press new, well-greased oil seal, item 105, into final housing, item 100.

2) Press ball bearing, item 103, into final housing and secure with retaining ring, item 104.

3) Press cable drum, item 500, into ball bearing, item 103, and secure with circlip, item 513.

4) 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.

5) Insert final planet hub assembly into final housing, item 100. Ensure that final planet hub spline is fully
engaged with cable drum, item 500.

6) Install new, well-greased O-ring, item 123, into end cover, item 120. Verify that planet hub stopper, item 126,
and sungear stopper, item 122, are installed into end cover.

7) Gently insert end cover into final housing, item 100, and fasten with retaining ring, item 124.

REASSEMBLY OF PRIMARY DRIVE:

Turn winch over, resting on end cover with cable drum opening facing up. Reassemble primary drive as follows:

1) Press new, well-greased oil seal, item 531, into bearing flange, item 530. Press ball bearing, item 533, into
bearing flange and secure with retaining ring, item 534.

2) Press bearing flange assembly onto brake housing, item 700, and install new, well-greased O-ring, item 539.

3) Install new, well-greased oil seal, item 607, with backup washer (if included in seal kit), item 606, into
connecting shaft, item 600.

4) Press needle bearing, item 603, into connecting shaft, item 600.

5) If removed, replace two needle bearings, item 605, by pressing into brake housing, item 700. Install new, well-
greased oil seal, item 711, with backup washer (if included in seal kit), item 710, into brake housing.

6) Slide sprag clutch aligner, item 724, onto connecting shaft, item 600, followed by sprag clutch, item 723, and
sprag clutch aligner, item 722. Twist connecting shaft assembly through center of brake hub, item 720, as
shown in BRAKE GROUP drawing.

IMPORTANT: For proper brake function, verify that sprag clutch is installed correctly. When viewed from

motor end, connecting shaft of clockwise hoisting winch must run freely clockwise and lock
in counterclockwise direction.

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313 REV.970317

SERVICE INSTRUCTIONS CONTINUED

7) Place thrust bearing, item 617 (held between two thrust washers, item 615), onto sprag clutch aligner, and
against brake hub, item 720.

8)

Install connecting shaft, item 600, with brake hub assembly, into bore of brake housing, item 700, and through
oil seal, item 711. Place thrust bearing, item 435 (held between two thrust washers, item 433), onto internal
gear, item 430. Install internal gear onto spline of connecting shaft, item 600, and fasten with circlip, item 431.

9)

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 final planet hub, item 400. Retain with circlip, item 411.

10) Insert primary sungear, item 440, between three planet gears and insert sungear shaft into connecting shaft,
engaging planet gears with internal gear. Fasten with retaining ring, item 401.

11) Insert final sungear, item 340, into cable drum and engage three planet gears, item 320.

12) Lower brake housing assembly onto cable drum, while engaging spline of final sungear with primary planet
hub, item 400. Line up mounting holes of bearing flange, item 530, with those in cable drum.

13) Rotate brake housing to line up access holes and fasten bearing flange, using six capscrews, item 537, and
lockwashers, item 541.

14) Install new, well-greased O-ring, item 735, into access plug, item 734. Install access plug into access hole
inside brake housing.

15) Attach base halves, item 500 and 552, using 28 capscrews, item 551, and lockwashers, item 553.

REASSEMBLY OF BRAKE HOUSING ASSEMBLY:

Reassemble brake housing assembly as follows:

1) Install brake spacer, item 712, into brake housing.

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. REASSEMBLE PER INSTRUCTIONS.

2) Starting and finishing with a divider plate, alternately install seven divider plates, item 713, and six friction
plates, item 715.

3) Liberally grease O-ring, item 751, and O-ring, item 753, and install on brake piston, item 750.

4) Slide brake piston into brake housing with holes for brake springs facing out of brake housing assembly.

5) Install 18 brake springs, item 752, in brake piston. (Brake piston has 20 holes and two empty holes should
be opposite each other.)

6) Liberally grease three new O-rings, item 763, and install into recesses on clutch housing, item 650. Install
new, well-greased O-ring, item 707, on flange of clutch housing.

7) Using three socket head capscrews, item 682, and high collar lockwashers, item 683, fasten clutch housing,
item 650, to brake housing, item 700. Ensure brake release passage way is to right side below center and
capscrews are at 2 o'clock, 6 o'clock and 10 o'clock positions. Tighten one turn at a time to compress brake
springs, item 752.

8) Install sprag clutch, item 672, and sprag clutch aligner, item 677, into bore of connecting shaft, item 600.

313 REV.970901

PAGE 21

SERVICE INSTRUCTIONS CONTINUED

REASSEMBLY OF CLUTCH ASSEMBLY:

Reassemble clutch assembly as follows:

1) Install drive gear, item 660, onto connecting shaft, item 600, and fasten with circlip, item 661.

2) Install new, well-greased O-ring, item 735, into motor drive shaft, item 730.

3) Install new, well-greased O-ring, item 657, into gland, item 656, and install gland onto motor drive shaft.

4) Install new, well-greased O-ring, item 653, into pressure plate, item 652, and install pressure plate onto motor
drive shaft and gland.

5) Install three clutch springs, item 676, into holes in clutch piston, item 670, and install clutch piston onto motor
drive shaft, item 730. While holding clutch springs compressed, install circlip, item 679, which fastens clutch
hub onto motor drive shaft.

6) Starting and finishing with a friction plate, alternately install eight friction plates, item 673, and seven divider
plates, item 675, onto clutch hub, item 670. Install external retaining ring, item 658, into clutch hub. Install
clutch plate, item 654, and fasten with circlip, item 671.

TESTING PROCEDURE: Before clutch assembly is installed into winch, it should be tested for proper

operation. Apply pressure to motor drive shaft and verify friction and divider
plates close tight. Release pressure and verify that plates are loose and run free.

7) Verify circlip, item 727, is on motor drive shaft. Insert end of motor drive shaft into sprag clutch aligner, item

677. Twist motor drive shaft to allow each divider plate to engage with drive gear, item 660.

IMPORTANT: For proper drive function, verify that sprag clutch, item 672, is installed correctly. When

viewed from motor end, motor drive shaft of a clockwise hoisting winch must turn freely
clockwise and lock in counterclockwise direction.

RE-INSTALLATION OF HYDRAULIC PISTON MOTOR:

For models with hydraulic piston motors, proceed as follows:

1) Install two new, well-greased O-rings, item 689, into exposed grooves of motor drive shaft, item 730. Verify
pipe plug, item 663, is installed tightly into end of motor drive shaft.

2) If removed, press ball bearing, item 665, into bearing carrier, item 664.

3) Install clutch connector, item 668, into ball bearing, item 665. Tap tight with a soft-headed hammer if
necessary.

4) Install two seal rings, item 666, onto clutch connector. Notched sides must face each other. Install new, well-
greased O-ring, item 667, into bearing carrier, item 664, and install assembly onto motor adaptor, item 800.
Fasten with six socket head capscrews, item 687, and lockwashers, item 685.

5) 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, onto flange of motor adaptor.

6) Install motor adaptor assembly onto clutch housing, item 650. Engage clutch connector, item 666, with clutch
hub, item 670, and fasten with nine hex head capscrews, item 931, and lockwashers, item 541.

7) Install new, well-greased O-ring, item 819, onto hydraulic piston motor, item 850, and install motor into motor
adaptor, item 800. Fasten with four hex head capscrews, item 815, and lockwashers, item 817.

8) Install brake tube assembly, item 852.

PAGE 22

313 REV.970901

SERVICE INSTRUCTIONS CONTINUED

REPLACEMENT OF HYDRAULIC GEAR MOTOR ASSEMBLY:

1) 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.

2) Slide hydraulic motor assembly on splined end of motor drive shaft, item 730, and line up pressure transfer
holes of clutch housing and motor adaptor. Tighten nine capscrews, item 931, and lockwashers, item 541.

REASSEMBLY OF HYDRAULIC GEAR MOTOR:

If the hydraulic gear motor was disassembled, the following procedure should be followed for reassembly:

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 of thrust plates, together with
two teflon seals, onto bearings, item 875, installed in motor adaptor, item 800.

Install new, well-greased gasket seal, item 869, on each side of gear housing, item 861. Slide gear housing together

3)
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, 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 soft headed hammer. Install and lightly torque
eight hex capscrews, item 951, and lockwashers, item 953, to approximately 50 ft-lb (70 Nm).

7)

Plumb winch assembly to a hydraulic supply and torque motor capscrews according to the following procedure:

- Ensure that circulation supply flow is being supplied to the brake housing.

- Run the winch , with no load, in the hoisting direction at reduced speed
(approximately 30% of maximum hydraulic volume).

- With winch running, evenly tighten eight capscrews, item 951, to 200 ft-lb (270 Nm).

- Test motor operation by running winch at full speed in both directions.

IMPORTANT: Before operating the winch, add lubricating oil up to the level of the end cover oil fill port.

(Refer to INSTALLATION INSTRUCTIONS for location of fill port. Refer to APPENDIX A
for oil volume required.)

To ensure proper reassembly, run the winch in both directions without load.

8) Install new, well-greased O-ring, item 879, into transfer tube assembly, item 844. Install transfer tube
assembly through port end cover, item 870, and engage motor drive shaft, item 730.

9) Install new, well-greased O-ring, item 113, into tube locator, item 848, and install tube locator into transfer tube
housing, item 846. Press two slotted spring pins, item 859, which stop tube locator from spinning, into place.

10) Install new, well-greased O-ring, item 112, onto transfer tube housing, item 846. Install transfer tube housing,
with pressure reducing valve, item 841, attached, onto port end cover, item 870. Fasten with two socket head
capscrews, item 849, and high collar lockwashers, item 847.

DANGER

LIFTING A LOAD WITH A NEWLY SERVICED WINCH 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”.

313 REV.970901

PAGE 23

RECOMMENDED MAINTENANCE

Winch gear train lubricating oil should be changed after the initial six months or 50 hours of operation, whichever
comes first. Lubricating oil should then be changed every 12 months or 500 operating hours, whichever
comes first.

Hydraulic system fluid should be changed at least once every 12 months.

For optimum performance over an extended period of time, the following preventive maintenance service should
be done every 12 months or 500 operating hours (whichever comes first):

1) Disconnect all hydraulic hoses and remove the winch from its mounting.

2) Disassemble the winch as per instructions.

3) Discard and replace all O-rings and oil seals.

4) Clean all parts and inspect for wear and damage as per instructions. Replace worn or damaged
parts as required.

5) Reassemble the winch as per instructions.

6) Follow INSTALLATION and OPERATING INSTRUCTIONS when returning winch to its mounting.

When ordering parts for the PULLMASTER Model HL25 planetary winch, always quote the complete model and
serial number of the unit.

MODEL NO. _______________

SERIAL NO. _______________

PULLMASTER WINCH CORPORATION reserves the right to change specifications and the design of
PULLMASTER planetary winches at any time without prior notice and without incurring any obligations.

PAGE 24

313 REV.980301

ASSEMBLY DRAWING

PISTON MOTOR

G1000-A & G1003-B & G1010-E

313 REV.010201

PAGE 25

PARTS REFERENCE - FINAL DRIVE

ITEM NO.

100 1 20399 FINAL HOUSING
103 1 25332 BALL BEARING # 6024
104 1 20460 BEARING RETAINER
105 1 25148 OIL SEAL
120 1 21816 END COVER
121 2 25237 PIPE PLUG 3/4 - 14 NPT
122 1 19036 SUNGEAR STOPPER
123 1 25340 O-RING -281 15" ID 1/8" CS
124 1 20416 RETAINING RING
126 1 20418 PLANET HUB STOPPER
130 1 20677 BREATHER RELIEF ASSEMBLY
300 1 20398 PLANET HUB
310 3 20406 PLANET PIN
311 3 25199 CIRCLIP ROTOR CLIP SH-168
313 3 25199 CIRCLIP ROTOR CLIP SH-168
320 3 20405 PLANET GEAR
321 6 25167 THRUST WASHER TORRINGTON # TRB 2840
323 72 25297 LOOSE ROLLER TORRINGTON # G613 - Q
340 1 * SUNGEAR
343 1 25242 CIRCLIP ROTOR CLIP SH-206
500 1 * CABLE DRUM
502 1 20423 CABLE ANCHOR
503 1 25032 PIPE PLUG 1/2 - 14 NPT
513 1 25337 CIRCLIP ROTOR CLIP SH-475
550 1 * BASE
551 28 25346 CAPSCREW - HEXHEAD 5/8 - 11NC X 1.75 GRADE 5
552 1 * BASE
553 28 25359 LOCKWASHER 5/8"

QTY.

PART NO.

DESCRIPTION

23120 WINCH SEAL KIT FOR MODELS WITH GEAR MOTORS,

CONSISTS OF ITEMS:
105, 123, 531, 539, 607, 651, 653, 657, 659, 707, 711,
735, 751, 753, 763, 801, 837, 839, 845 AND 879

23140 WINCH SEAL KIT FOR MODELS WITH PISTON MOTORS,

CONSISTS OF ITEMS:
105, 123, 531, 539, 607, 651, 653, 657, 659, 667, 689,
707, 711, 735, 751, 753, 763, 801, 819 AND 845

* These parts vary according to drum code. Refer to APPENDIX B.

Refer to PAGE 25 for ASSEMBLY DRAWING - PISTON MOTOR and

PAGE 38 for ASSEMBLY DRAWING - GEAR MOTOR.

PAGE 26 313 REV.970901

FINAL DRIVE GROUP

G1000-A

311

310

126

340

122

513

120

321323124320130

500503502105103104313

343

300

121

123

100

550

Groups 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.

313 REV.970317

552553 551

PAGE 27

PARTS REFERENCE - BRAKE GROUP

ITEM NO.

400 1 20404 PLANET HUB
401 1 20417 RETAINING RING
410 3 20369 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
433 2 25363 THRUST WASHER TORRINGTON #TRA 6881
435 1 25362 THRUST BEARING TORRINGTON #NTA 6881
440 1 21036 SUNGEAR
444 1 20419 SUNGEAR STOPPER
530 1 20402 BEARING FLANGE
531 1 25148 OIL SEAL
533 1 25333 BALL BEARING #6026
534 1 20461 BEARING RETAINER
537 6 25081 CAPSCREW - HEX HEAD 1/2 - 13NC X 1.50 GRADE 5
539 1 25109 O-RING - 269 8-3/4 ID 1/8" CS
541 6 25014 LOCKWASHER 1/2"
600 1 21088 CONNECTING SHAFT
603 1 25361 NEEDLE BEARING TORRINGTON #B-3012
605 2 25366 NEEDLE BEARING TORRINGTON #NBH 4812
607 1 26009 OIL SEAL
615 2 25296 THRUST WASHER TORRINGTON #TRB 6074
617 1 25690 THRUST BEARING TORRINGTON #NTA 6074
650 1 21090 CLUTCH HOUSING
651 1 25339 O-RING -278 12" ID 1/8" CS
660 1 21135 DRIVE GEAR
661 1 25696 CIRCLIP ROTOR CLIP SH-375
672 1 25303 SPRAG CLUTCH BORG WARNER # 140373 "B"
677 1 21095 SPRAG CLUTCH ALIGNER
682 3 21140 CAPSCREW - SOC HEAD 1/2 - 13NC X 4-1/4 LONG GRADE 8
683 3 25161 LOCKWASHER 1/2" HI COLLAR
700 1 20390 BRAKE HOUSING
703 1 25347 PLASTIC CAPLUG 1 NPT THREADED
707 1 25339 O-RING -278 12" ID 1/8" CS
711 1 25933 OIL SEAL
712 1 21125 BRAKE SPACER
713 7 25305 DIVIDER PLATE
715 6 25304 FRICTION PLATE
720 1 21087 BRAKE HUB
722 1 21118 SPRAG CLUTCH ALIGNER
723 1 25663 SPRAG CLUTCH
724 1 21097 SPRAG CLUTCH ALIGNER
734 1 20422 ACCESS PLUG
735 1 25344 O-RING - 123 1-3/16" ID 3/32" CS
750 1 20397 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
763 3 25127 O-RING -90 DURO -013 7/16" ID 1/16" CS

QTY.

PART NO.

DESCRIPTION

Refer to PAGE 26 for winch seal kit and PAGE 25 for ASSEMBLY DRAWING - PISTON MOTOR

or PAGE 38 for ASSEMBLY DRAWING - GEAR MOTOR.

PAGE 28

313 REV.010201

BRAKE GROUP

G1003-B

421

411

410

420

400

444

440

431

606617711605534435413423401

600715

753750751

763

707

650

752

661

677

672

660

651

433

430

710

531

533

539

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.

313 REV.970317

530

541 537

735

700 712 722 723 607713

615

703734

682

683

603

724

752

720

PAGE 29

PARTS REFERENCE - GEAR MOTOR GROUP

ITEM NO.

112 1 25694 O-RING -022 1" ID 1/16" CS
113 1 25695 O-RING -015 9/16" ID 1/16" CS
541 9 21139 CAPSCREW - HEX HEAD 1/2 - 13NC X 4-3/4 LONG GRADE 5
652 1 21134 PRESSURE PLATE
653 1 25588 O-RING -126 1-3/8" ID 3/32" CS
654 1 21136 CLUTCH PLATE
656 1 21137 GLAND
657 1 25703 O-RING -153 3-1/2" ID 3/32" CS
658 1 20172 RETAINING RING
670 1 21133 CLUTCH HUB
671 1 25369 CIRCLIP ROTOR CLIP SH-387
673 8 25623 FRICTION PLATE
675 7 25624 DIVIDER PLATE
676 3 20340 CLUTCH SPRING
679 1 25710 CIRCLIP ROTOR CLIP SHR-125
727 1 25335 CIRCLIP ROTOR CLIP SH-196
730 1 21131 MOTOR DRIVE SHAFT
731 1 25288 CIRCLIP ROTOR CLIP C-112
735 1 25344 O-RING -123 1-3/16" ID 3/32" CS
800 1 21112 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
807 1 * *
809 1 * *
813 2 25993 PIPE PLUG 1/4 NPT SOCKET HEAD 'LEVL-SEAL' UNBRAKO
827 3 26276 PLASTIC CAPLUG 3/8 NPT
841 1 25714 PRESSURE REDUCING VALVE
843 1 25715 PIPE ADAPTOR #6 SAE X 1/4 NPT AIRWAY 6401-6-4
844 1 21113 TRANSFER TUBE ASSY (INCLUDES ITEM 867)
845 1 25716 O-RING -906 SAE ORB #06
846 1 21114 TRANSFER TUBE HOUSING
847 2 25298 LOCKWASHER 3/8" HIGH COLLAR
848 1 21115 TUBE LOCATOR
849 2 25772 CAPSCREW - SOCKET HEAD 3/8 - 16NC X 1.00 GRADE 5
859 2 25717 SLOTTED SPRING PIN 1/16" DIA X 1/4 LONG
861 1 25350 GEAR HOUSING
865 4 25356 DOWEL PIN
867 1 25608 LOOSE ROLLER 2.5 MM DIA X 15.8 MM
869 2 25348 GASKET SEAL
870 1 21117 PORT END COVER
875 4 25352 ROLLER BEARING
877 2 25646 RING SEAL
879 1 25018 O-RING -010 1/4" ID 1/16" CS
881 1 25645 GEAR SET
885 2 25644 THRUST PLATE
887 4 25647 TEFLON SEAL
899 2 25993 PIPE PLUG 1/4 NPT SOCKET HEAD "LEVL-SEAL" UNBRAKO
927 1 25031 PIPE PLUG 1/4 NPT
933 9 25014 LOCKWASHER 1/2"
950** 1 * SUB - ASSY MOTOR
951 8 25357 CAPSCREW - HEX HEAD 5/8 X 6.75 GRADE 5
953 8 25325 WASHER
955 2 25559 PLASTIC CAPLUG 2.0" DAEMAR T-21

QTY.

PART NO.

DESCRIPTION

LK;

LK;

PAGE 30

23117 MOTOR SEAL KIT FOR GEAR MOTOR, CONTAINS ITEMS: 869, 877 AND 887.

* These part numbers and descriptions vary according to brake code.

Refer to APPENDIX C.

** ITEM 950 MOTOR SUB-ASSY, CONSISTS OF ITEMS:

800, 802, 803, 804, 805, 807, 809, 846, 848, 849, 859, 861, 865,
869, 870, 875, 877, 881, 885, 887, 899, 929, 951, 953 AND 955.

Refer to PAGE 26 for winch seal kit and PAGE 38 for ASSEMBLY DRAWING.

313 REV.980301

927

GEAR MOTOR GROUP

G1007-B

951953955

846

849847654

113848859844 875869867879809807801800802

827 950813 843845899870 112877

931 541

827841

865861 887881885805671658

731

673

676

653

735

730

727

656

657

670

652

679

675

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.

313 REV.970901

PAGE 31

PARTS REFERENCE - PISTON MOTOR GROUP

ITEM NO.

541 9 25014 LOCKWASHER 1/2"
652 1 21635 PRESSURE PLATE
653 1 25588 O-RING -126 1-3/8" ID 3/32" CS
654 1 21136 CLUTCH PLATE
656 1 21137 GLAND
657 1 25703 O-RING -153 3-1/2" ID 3/32" CS
658 1 20172 RETAINING RING
664 1 21568 BEARING CARRIER
665 1 25810 BALL BEARING 065 X 100 X 18 # 6013
666 2 21634 SEAL RING
667 1 25858 O-RING -237 3-3/8 ID 1/8 CS
668 1 21623 CLUTCH CONNECTOR
669 1 25856 NEEDLE BEARING TORRINGTON # NB4012
670 1 21549 CLUTCH HUB
671 1 25369 CIRCLIP ROTOR CLIP SH-387
673 8 25623 FRICTION PLATE
675 7 25624 DIVIDER PLATE
676 3 20340 CLUTCH SPRING
679 1 25710 CIRCLIP ROTOR CLIP SHR-125
685 6 25161 LOCKWASHER 1/2" HI COLLAR
687 6 25424 CAPSCREW - SOCKET HEAD 1/2 - 13NC X 1.50 GRADE 5
689 2 25694 O-RING -022 1" ID 1/16" CS
727 1 25335 CIRCLIP ROTOR CLIP SH-196
730 1 21570 MOTOR DRIVE SHAFT
735 1 25344 O-RING -123 1-3/16" ID 3/32" CS
800 1 22116 MOTOR ADAPTOR
801 3 25127 O-RING -90 DURO -013 7/16" ID 1/16" CS
803 1 25370 PIPE PLUG 1/16 NPT
805 2 25040 PIPE PLUG 1/8
807 1 25040 PIPE PLUG 1/8
815 4 25564 CAPSCREW - HEX HEAD 3/4 - 10NC X 2.00 GRADE 5
817 4 25299 LOCKWASHER 3/4"
819 1 25061 O-RING -163 6" ID 3/32" CS
826 1 25491 PIPE NIPPLE 1/4 NPT AIRWAY 5405-4-4
827 3 26276 PLASTIC CAPLUG 3/8 NPT
828 1 26048 PIPE COUPLING 1/4 NPT AIRWAY 5000-4-4
841 1 25714 PRESSURE REDUCING VALVE
843 1 25715 PIPE ADAPTOR #6 SAE X 1/4 NPT AIRWAY 6401-6-4
845 1 25716 O-RING -906 SAE ORB #06
850 1 23223 MOTOR -129 VOLVO F12-110
852 1 22715 TUBE ASSEMBLY 1/4" OD 1/8 NPT X 1/8 NPT -90L
931 9 21139 CAPSCREW - HEX HEAD 1/2 - 13NC X 4-3/4 LONG
939 1 25040 PIPE PLUG 1/8 NPT

QTY.

PART NO.

DESCRIPTION

PAGE 32

Refer to PAGE 26 for winch seal kit and PAGE 25 for ASSEMBLY DRAWING.

313 REV.980301

PISTON MOTOR GROUP

G1010-E

939827

815817

805 850

NOTE:

BRAKE TUBE IS SHOWN FOR

CW HOISTING. FOR CCW

HOISTING, CONNECT TO

OPPOSITE MOTOR PORT.

931541805

819

828 843 845 827 841826800

803 658658 671671 687 685 801 809 807 802 853 852

675

652

676

653

730

656

657

670

679

689

673

654

665 664 668 666 667 669

727

735

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.

313 REV.970901

PAGE 33

INSTALLATION DIMENSIONS

GEAR MOTOR

OPTIONAL

EXTERNAL BRAKE

RELEASE PORT

1/8-27 NPT

PRESSURIZE FOR

COUNTER-CLOCKWISE

ROTATION

DRAIN PORT

9/16"-18 UNF

SAE O-RING

I1006-1-D

P

CLOCKWISE

GAGE PORTS

PRESSURIZE FOR

CLOCKWISE

ROTATION

SAE 4-BOLT FLANGE

1/4-18 NPT

SEE MOTOR CHART

FOR PORT SIZE

S

R c/c

HIGH SPEED CLUTCH

PORT 9/16"-18 UNF

SAE O-RING

CIRCULATION SUPPLY

PORT 3/8-18 NPT

L

M

STANDARD CABLE ANCHOR IS

SUITABLE FOR 7/16" - 7/8"

DIA WIRE ROPE ON 10" DIA

DRUM BARREL

CIRCULATION

RETURN PORT

1-11 1/2 NPT

6.8

I

[173]

PAGE 34

A MINIMUM OF 3 TO 4 WRAPS OF

WIRE ROPE MUST BE MAINTAINED

AT ALL TIMES !

DIAB

C D

FILLER PORT

1/2-14 NPT

(LOCATED EITHER

IN CABLE ANCHOR

POCKET OR ON

BARREL)

FOR SAFETY:

FILLER PORT

3/4-14 NPT

BREATHER RELIEF VALVE

J

A DIA

G

H c/c

N

4 MOUNTING HOLES 1 9/32 DIA [32.5]

USE 1-1/4" MOUNTING BOLT

GRADE 5 OR BETTERS

1.3

1.25

[31.8]

[32]

K

[STANDARD MODELS]

[FREE SPOOL MODELS]

F

E

PORT

1/4-18 NPT

DRAIN PORT

FREE SPOOL

3/4-14 NPT

313 REV.010201

INSTALLATION DIMENSIONS

GEAR MOTOR

I1006-2 & I1006-3-A

Dimensions in inches

(Dimensions in millimeters)

DRUM

-1 10.0 17.0 11.0 11.8 19.9 19.9 21.0 18.500 31.8 34.2 11.38 8.9 20.8 17.750 20.8
(254) (432) (279) (300) (505) (505) (533) (469.90) (808) (869) (289) (225) (527) (450.85) (527)

- 2 10.0 24.0 11.0 11.8 24.4 20.9 21.0 18.500 31.8 34.2 12.38 10.0 25.9 22.875 25.9
(254) (610) (279) (300) (619) (530) (533) (469.90) (808) (869) (314) (254) (657) (581.03) (657)

- 3 10.0 24.0 17.0 11.8 24.4 20.9 27.0 24.500 37.8 40.2 12.38 10.0 25.9 22.875 25.9
(254) (610) (432) (300) (619) (530) (686) (622.30) (961) (1021) (314) (254) (657) (581.03) (657)

- 4 10.0 24.0 22.0 11.8 24.4 20.9 32.0 29.500 42.8 45.2 12.38 10.0 25.9 22.875 25.9
(254) (610) (559) (308) (619) (530) (813) (749.30) (1088) (1148) (314) (254) (657) (581.03) (657)

B

E

FGDCA

HJKM

Dimensions in inches

(Dimensions in millimeters)

NPR

S

HYDRAULIC GEAR MOTORS

COMMERCIAL WM76 SERIES COMMERCIAL M365 SERIES

MOTOR GEAR MOTOR PORT SIZE I L MOTOR GEAR MOTOR PORT SIZE I L

CODE WIDTH

- 86 3.00 8.9 2.7 - 42 2.50 9.3 2.5

- 87 2.75 8.6 2.7 - 101 2.25 1.5 9.0 2.5

- 88 2.50 8.4 2.7 - 102 2.00 8.8 2.5

- 89 2.25 1.5 8.1 2.7

- 90 2.00 7.9 2.7

- 91 1.75 7.6 2.7

- 92 1.50 1.25 7.4 2.7

- 93 1.25 7.1 2.7

- 94 1.00 1.00 6.9 2.7

SAE 4-BOLT FLANGE

CODE 61 CODE 61

(76.2) (225) (68) (63.5) (236) (64)

(69.9) (219) (68) (57.2) (229) (64)

(63.5) (212) (68) (50.8) (223) (64)

(57.2) (206) (68)

(50.8) (200) (68)

(44.5) (193) (68)

(38.1) (187) (68)

(31.8) (181) (68)

(25.4) (174) (68)

2.0

CODE WIDTH

SAE 4-BOLT FLANGE

PAGE 35313 REV.970317

INSTALLATION DIMENSIONS

PISTON MOTOR

M

OPTIONAL

EXTERNAL BRAKE

RELEASE PORT

1/8-27 NPT

PRESSURIZE FOR

COUNTERCLOCKWISE

ROTATION

P

CLOCKWISE

PRESSURIZE FOR

CLOCKWISE ROTATION

R c/c

S

I1007-1-E

CIRCULATION SUPPLY

PORT 3/8-18 NPT

MOTOR CASE DRAIN

(SEE MOTOR CHART FOR DRAIN

PORT SIZE) PLUMB UPPERMOST

DRAIN PORT DIRECT TO TANK.

DRAIN LINE MUST ENTER

RESERVOIR BELOW MINIMUM

FLUID LEVEL. FILL MOTOR

CASE BEFORE START-UP.

HIGH-SPEED CLUTCH

PRESSURE AND DRAIN

PORTS 9/16-18 UNF

SAE 0-RING

C D

BARREL)

POCKET OR ON

IN CABLE ANCHOR

(LOCATED EITHER

1/2-14 NPT

A MINIMUM OF 3 TO 4 WRAPS OF

WIRE ROPE MUST BE MAINTAINED

AT ALL TIMES !

FILLER PORT

L

T

STANDARD CABLE ANCHOR IS

SUITABLE FOR 7/16" - 7/8"

DIA WIRE ROPE

SAE 4-BOLT FLANGE

SEE MOTOR CHART

FOR PORT SIZE

I

CIRCULATION

RETURN PORT

1-11 1/2 NPT

6.8
[173]

DIAB

G

J

DIAA

N

4 MOUNTING HOLES 1-9/32 DIA [32.5]

USE 1-1/4" MOUNTING BOLTS

H c/c

GRADE 5 OR BETTER

K

[STANDARD MODELS]

[FREE SPOOL MODELS]

PAGE 36

FOR SAFETY:

BREATHER RELIEF VALVE

FILLER PORT

3/4-14 NPT

1.3

1.25

[31.8]

[32]

F

E

FREE SPOOL

PORT

1/4-18 NPT

DRAIN PORT

3/4-14 NPT

313 REV.010201

INSTALLATION DIMENSIONS

MOTOR

CODE

I

LT*

-68 F11 1

1

/2

" M16 x 2

3

/4

" 15.6 4.6 7.8

150 CODE 62

BSP

(396) (118) (197)

-129 F12 1

1

/4

"

1

/2

"-13

1

1

/16

"-12

12.0 3.3 6.7

110 CODE 62

SAE ORB

(305) (85) (170)

-130 F11 1

1

/4

" M14 x 2

3

/4

" 12.9 3.7 6.5

78 CODE 62

BSP

(327) (95) (165)

-166 F12 1"

7

/16

"-14

7

/8

"-14 11.1 3.1 6.3

80 CODE 62

SAE ORB

(282) (78) (160)

Dimensions in inches

(Dimensions in millimeters)

VOLVO F SERIES

HYDRAULIC PISTON MOTOR

*

* INCLUDES SANDWICH GAGE BLOCK

MODEL

NO.

MOTOR PORT SIZE

SAE 4-BOLT FLANGE

SCREW

THREAD

DRAIN

PORT

DRUM
CODE

E

FG H JDCA

KM

NPR

B

Dimensions in inches

(Dimensions in millimeters)

S

-1 10.0 17.0 11.0 11.8 19.9 19.9 21.0 18.500 31.8 34.2 11.38 8.9 20.8 17.750 20.8
(254) (432) (279) (300) (505) (505) (533) (469.90) (808) (869) (289) (225) (527) (450.85) (527)

- 2 10.0 24.0 11.0 11.8 24.4 20.9 21.0 18.500 31.8 34.2 12.38 10.0 25.9 22.875 25.9
(254) (610) (279) (300) (619) (530) (533) (469.90) (808) (869) (314) (254) (657) (581.03) (657)

- 3 10.0 24.0 17.0 11.8 24.4 20.9 27.0 24.500 37.8 40.2 12.38 10.0 25.9 22.875 25.9
(254) (610) (432) (300) (619) (530) ( 686) (622.30) (961) (1021) (314) (254) (657) (581.03) (657)

- 4 10.0 24.0 22.0 11.8 24.4 20.9 32.0 29.500 42.8 45.2 12.38 10.0 25.9 22.875 25.9
(254) (610) (559) (308) (619) (530) (813) (749.30) (1088) (1148) (314) (254) (657) (581.03) (657)

PISTON MOTOR

I1007-2-E & I1007-3-E

* PRIOR TO SERIAL # 52015: -129 Motor was Model F11-110 with 1

313 REV.010201

1

/4" 4 bolt flange ports with

M14 x 2 screw threads. Drain ports were 3/4" BSP.

PAGE 37

ASSEMBLY DRAWING

GEAR MOTOR

G1000-A & G1003-B & G1007-B

PAGE 38

313 REV.010201

APPENDIX A

POUNDS

(KILONEWTONS)

DRUM
CODE

CABLE DRUM SIZES

INCHES

(MILLIMETERS)

WIRE ROPE STORAGE

FEET

(METERS)

FEET/MINUTE

(METERS/MINUTE)

LINE PULL

AT MAXIMUM

PRESSURE*

BARREL

10.0 17.0 11.0 210 140 91 25000 16860 140 207 5357 3613 651 965 2.3

(254) (432) (279) (64) (43) (28) (111.2) (75.0) (43) (63) (23.8) (16.1) (198) (294) (8.7)

-2 10.0 24.0 11.0 515 398 264 25000 11757 140 297 5357 651 1384 2.3
(254) (111.2) (52.3) (43) (90) (23.8) (11.2) (198) (422) (8.7)

-3 10.0 17.0 796 615 408 25000 5357 651 3.0

(254) (23.8) (11.2) (198)

-4 10.0 22.0 1031 528 25000 5357 2519 651 1384 3.6

(254) (610) (559) (314) (243) (161) (111.2) (52.3) (43) (90) (23.8) (11.2) (198) (422) (13.6)

LUBRICATING

OIL

VOLUME

REQUIRED

U.S.
GALLON
(LITERS)

DRUM DRUM DRUM DRUM DRUM DRUM DRUM DRUM

LINE SPEED

AT MAXIMUM

VOLUME*

LINE SPEED

AT MAXIMUM

VOLUME*

MAXIMUM

ALLOWABLE

LINE PULL*

POUNDS

(KILONEWTONS)

FEET/MINUTE

(METERS/MINUTE)

BARE FULL BARE FULL BARE FULL BARE FULL

HIGH SPEED HOISTING & LOWERING

LOW SPEED HOISTING

-1

24.0

FLANGE LENGTH 3/4 inch 7/8 inch 1 inch

796

(610) (279) (157) (121) (80)

24.0

(610) (432) (243) (187) (124) (111.2) (52.3) (43) (90)

11757 140 297

1384

(422) (11.3)

11757 140 297 2519

2519

313 REV.010201

* Performance specifications are based on standard hydraulic motor with 7/8 inch diameter rope.

PAGE 39

APPENDIX B

DRUM CODE

- 1

- 2

- 3

- 4

340

FINAL

SUNGEAR

20409 20395 20671

20409 20396 20444

20408 20393 20443

20407 20391 20403

500 550 / 552ITEM

CABLE

DRUM

BASE

PAGE 40

313 REV.970317

APPENDIX C

BRAKE CODE

- 7 - 8 - 9 - 10

ITEM

NO.

802

807

807

809

950

PART

DESCRIPTION

SHUTTLE

1/8-27 NPT

PIPE PLUG

1/8-27 NPT

PIPE

ADAPTOR

1/8 NPT

CAPLUG

MOTOR

SUB-ASSY

N/A

25040

N/A

N/A

22054

PART NUMBERS

20849

N/A

25622

26276

22055

20849

N/A

25622

26276

22056

N/A

25040

N/A

N/A

22057

313 REV.970901

PAGE 41

BOLT 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

TORQUE

Nm

1 640 868
1 1/8 800 1085
1 1/4 1000 1356
1 3/8 1200 1627
1 1/2 1500 2034

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PAGE 42

NOTE: Unless otherwise specified, torque bolts per above chart.

313 REV.970317