INSTRUCTION AND PARTS MANUAL
MODEL R7
PLANETARY HYDRAULIC WINCH
THE LOGICAL CHOICE
PMC 257
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
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 be
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 the
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 pers
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.
onnel other than those of Seller. This Warranty shall not apply to
ir nature are expendable.
ing purchased, that Buyer has
Effective 8/1/2008
SELLER MAKES NO EXPRESS WARRANTI
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
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 calcu
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 extendin
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
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
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
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 Co
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.
g the foregoing Warranty, remedies, exclusions, or limitations shall be effective unless in a writing signed by an executive
ES AND NO IMPLIED WARRANTIES OF ANY KIND, OTHER THAN THE WARRANTY
the natural frequency vibration of the machine in such a way that damage
lations, and this application factor is 1.0 unless otherwise stated in Seller’s quotation
defend
attorneys’ fees,
approved for lifting or handling
lumbia shall be the exclusive forum and jurisdiction for any action or proceedings brought by
Note: Prices and specifications contained in this price book are subject to change without notice.
US.DIST.01.01.07 [PULLMASTER LOGO]
SAFETY RECOMMENDATIONS
Definition: Caution indicates a potentially
hazardous situation which, if not avoided may
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.
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.elen
26. Maintain five wraps of wire rope on the cable
drum at all times.
27. In case of a power failure or breakdown leading
to an unexpected stop of the hydraulic power circuit,
stand clear of the area and the load being hoisted,
take the necessary precautions to prevent access to
area where the load is halted.
28. The noise level of the winch is 83 dBA measured
on a distance of 1.00 meter, 1.60 meters high. The
measuring equipment used was: Realistic #42-3019.
29. Clean up any oil spillage immediately.
30. Wear proper clothing and personal protection
equipment such as, footwear, safety goggles and a
hard hat. Read manual first.
257 REV.051117
PAGE 1
DESCRIPTION OF THE MODEL R7
GENERAL DESCRIPTION:
The PULLMASTER Model R7 is a planetary, hydraulic winch primarily intended for mobile or recovery adaptations.
The winch has equal speed in both directions and a freespool feature which can be operated manually or
hydraulically, depending on the option. The main components of this unit are:
✛ hydraulic gear motor
✛ multi-disc brake with static and dynamic function
✛ primary planet reduction
✛ secondary planet reduction
✛ final planet reduction
✛ brake housing
✛ cable drum
✛ final drive housing
✛ freespool mechanism
FUNCTION IN FORWARD ROTATION (PULLING):
In forward rotation, or when the winch is pressurized for pulling, the output torque and rpm of the hydraulic motor
are transmitted through the brake shaft and freespool coupling to the final sungear. The planet gears are driven by
the final sungear and cause the planet hub to drive the cable drum at a reduction of 9.25:1. When a load is pulled,
an over-running clutch which connects the motor drive shaft to the automatic brake assembly, permits free rotation
of the sungear, without effecting the brake. When the winch rotation is stopped, the load on the cable drum causes
the over-running clutch to lock and the load is held safely by the disc brake.
FUNCTION IN REVERSE ROTATION (PAYING OUT):
In reverse rotation, or paying out of a load, hydraulic pressure from the reverse side of the hydraulic motor is
channelled to the brake piston, causing the brake piston to release the multi-disc brake. The pressure required to
release the brake is 400 - 600 psi (28 - 42 bar). The over-running clutch, connecting the motor drive shaft to the brake
assembly, locks, causing the brake discs to rotate between stationary divider plates. If the load on the cable drum
increases the pay out speed, the resulting pressure drop in the brake piston increases friction between the friction
plates and slows the drum. In this way, a completely smooth pay out speed can be achieved in a stepless operation
by modulation of the winch control valve. When the control valve is returned to neutral position, rotation stops and
the disc brake applies automatically.
During pay out operations of the winch, the friction created by the brake discs results in heat. This heat is dissipated
by the circulation of hydraulic fluid from the brake housing, supplied internally through the hydraulic motor. This
circulation flow is internally vented to the return line through a check valve arrangement inside the specially modified
motor. The circulation flow is supplied only when the wire rope is payed out. A separate vent line connecting the
PULLMASTER Model R7 with the hydraulic reservoir is not required (see TYPICAL HYDRAULIC CIRCUIT).
IMPORTANT: SAFETY VALVE
The PULLMASTER Model R7 winch does not require a drain line up to 100 psi permissible back
pressure in the brake housing. To indicate excessive pressure and potential damage to the
hydraulic motor or to the oil seal in the brake housing, a safety valve is installed on the motor
adaptor.
PAGE 2
257 REV.021217
DESCRIPTION OF THE MODEL R7 CONTINUED
BREATHER RELIEF VALVE
Excessive pressure in the brake housing will damage the oil seal separating the brake housing from
the drum interior. Damage to this seal will cause the drum to fill up with hydraulic fluid. To prevent
damage to the drum seal and end cover of the final drive if the cable drum fills up with hydraulic
fluid, a breather relief (PARTS REFERENCE item 130) is installed on the end cover. The breather
relief does not prevent oil seal failure but serves as an indicator or warning that the seals between
brake housing and the cable drum interior have failed and must be replaced immediately.
FUNCTION OF THE FREESPOOL MECHANISM:
MODEL R7-15-135-1M
This model has a manually actuated freespool function. The freespool feature is enabled by turning the freespool
handle 180 degrees in a counterclockwise direction. This will disengage the final sungear from the secondary planet
hub and provide for a free turning drum. To re-engage the drum, turn the handle 180 degrees in a clockwise direction.
IMPORTANT: The freespool function cannot be engaged or disengaged under load or while the
cable drum is rotating.
MODEL R7-15-135-1F
This model has a hydraulically actuated freespool feature. The final sungear is pulled out of engagement with the
secondary planet hub, by the freespool piston, which is spring applied and pressure released. To disengage the
sungear, hydraulic pressure of 400 psi (28 bar) must be supplied to the freespool release port (see INSTALLATION
DRAWING). When the hydraulic pressure is removed, the sungear will re-engage.
IMPORTANT: The freespool function cannot be engaged or disengaged under load or while
the cable drum is rotating.
257 REV.021217
PAGE 3
EXPLANATION OF MODEL CODING
All variations of the PULLMASTER Model R7 planetary winch are identified by the following code:
7
R
BASIC UNIT SERIES
R = Recovery winch
SIZE OF UNIT
OPTIONAL REDUCTION RATIO
TYPE OF BRAKE
-12 Automatic brake, counterclockwise drum rotation, intravent
-13 External brake release, automatic brake, counterclockwise
drum rotation, intravent
-14 External brake release, automatic brake, clockwise drum rotation, intravent
-15 Automatic brake, clockwise drum rotation, intravent
HYDRAULIC MOTOR
-135 Commercial M315 hydraulic motor, 1-1/2" gear section. (Other gear sections
for this motor are optional)
X - XX - XX - XX - X
DRUM SIZE
-1 STANDARD DRUM
6-3/8 drum diam. X 12-5/8 flange diam. X 8" between flanges.
OPTIONS
- F Hydraulically actuated freespooling
- M Manually actuated freespooling
NOTE:
Options for drum grooving are identified by a spec. number.
Clockwise and counterclockwise drum rotation is the direction of rotation for pulling, established by looking at
the hydraulic motor.
PAGE 4
257 REV.021217
OPTIONS
CLOCKWISE ROTATION:
The drum rotation of the standard PULLMASTER Model R7 planetary winch is clockwise for pulling when looking
at the hydraulic motor of the winch. Drum rotation for counter clockwise hoisting direction is available as an option.
OPTIONAL HYDRAULIC GEAR MOTOR:
The performance of the standard PULLMASTER Model R7 planetary winch is based on a
hydraulic motor with a displacement of 1.9 cubic inches. The performance of the winch can be changed by using
motors with different displacements.
(Contact the factory for performance information if using motors with different displacements.)
Commercial model M315
The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements.
257 REV.010401
PAGE 5
SPECIFICATIONS
Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 5/8 inch diameter
wire rope. Performance specifications for winches supplied with optional motors are provided in attached
supplement.
CABLE DRUM DIMENSIONS (STANDARD DRUM):
Barrel diameter 6.38 in 162 mm
Flange diameter 12.63 in 321 mm
Barrel length 8.00 in 203 mm
CABLE STORAGE CAPACITY:
(Size of wire rope) 7/16 in 278 ft 85 m
1/2 in 217 ft 66 m
9/16 in 167 ft 51 m
5/8 in 124 ft 38 m
MAXIMUM OPERATING PRESSURE: 2100 psi 145 bar
MAXIMUM OPERATING VOLUME: 18 (US) gpm 68 l/min
MINIMUM OPERATING VOLUME: 6 (US) gpm 23 l/min
DRUM TORQUE AT MAXIMUM PRESSURE: 54,000 lb-in 6,101 Nm
DRUM RPM AT MAXIMUM VOLUME: 15.5 rpm
LINE PULL AT MAXIMUM PRESSURE:
Bare drum 15,429 lb 68.6 kN
Full drum 9,000 lb 40.0 kN
LINE SPEED AT MAXIMUM VOLUME:
Bare drum 28 fpm 8.7 m/min
Full drum 49 fpm 15 m/min
PERMISSIBLE SYSTEM BACK PRESSURE
AT MOTOR RETURN PORT:
100 psi 6.9 bar
LUBRICATING OIL: Volume: 0.8 (US) gal 3 liters
Refer to RECOMMENDATIONS for viscosity and instructions.
PAGE 6
257 REV.021217
FULL DRUM
15.0
49
FULL DRUM
57
15
45
12
34
9
23
6
11
3
40
12.2
35
10.7
30
9.1
25
7.6
20
6.1
15
4.6
10
3.0
5
1.5
12,000
53.4
9,000
40.0
6,000
26.7
3,000
13.3
1800 124
1500 104
1200 83
900 62
600 41
300 21
45
13.7
BARE DRUM
LINE PULL - kN
LINE SPEED - m/min
BARE DRUM
2100
0
18
0
15,4290
0 68.6
145
0
LINE PULL - lb
OIL PRESSURE - psi
OIL PRESSURE - bar
0
0
0
LINE SPEED - fpm
68
OIL VOLUME - (US)gpm
OIL VOLUME - l/min
PERFORMANCE GRAPHS
LINE PULL VS. OIL PRESSURE:
PG-R7-A
LINE SPEED VS. OIL VOLUME:
Performance graphs are based on standard hydraulic motor and cable drum with 5/8 inch diameter
wire rope.
257 REV.021217
PAGE 7
TYPICAL HYDRAULIC CIRCUIT (R7-M)
HC-R7-M-A
800 PSI [55 BAR]
2(US)GPM [8 L/MIN]
REQUIRED FOR MODELS
SUPPLIED WITH EXTERNAL
BRAKE RELEASE OPTION
PAGE 8
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
PRESSURE
RELIEF VALVE
FILTER
HYDRAULIC
PUMP
RESERVOIR
257 REV.021217
TYPICAL HYDRAULIC CIRCUIT (R7-F)
HC-R7-F-A
800 PSI [55 BAR]
2(US)GPM [8 L/MIN]
REQUIRED FOR MODELS
SUPPLIED WITH EXTERNAL
BRAKE RELEASE OPTION
400 PSI [28 BAR]
PRESSURE REQUIRED
FOR FREESPOOL
HYDRAULIC
PUMP
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
PRESSURE
RELIEF VALVE
FILTER
257 REV.021217
RESERVOIR
PAGE 9
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 SPECIFICATIONS for
quantity of oil required. For normal operating temperatures
use SAE 90 lubricating oil. Consult lubricating oil
supplier or factory for temperature beyond normal
operating range.
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 R7
planetary winch:
Pressure lines: Equivalent to SAE 100R12-12
Hydraulic freespool line: Equivalent to SAE 100R3-3
It is recommended that a larger size of hydraulic hose is
installed where the pressure lines or the circulation lines
are excessively long.
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 paying-ing out a load, depends on the “metering”
characteristics of the control valve. The better the oil
flow is “metered” the better will be the speed control.
PAGE 10
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:
The use of an E stop (emergency) is mandatory in the
controls circuit, the E stop is to be placed in the
operators control panel. The E stop has to be designed
and placed in line with EN 60204 and EN 418.
257 REV.021217
INSTALLATION INSTRUCTIONS
DANGER
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS COULD
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 SPECIFICATIONS for oil volume required.)
5) Use recommended circuit components and hydraulic hoses.
6) Verify that breather relief, item 130, is in place on end cover above oil level. End cover may need to be rotated
if winch is not installed upright.
IMPORTANT:
Do not replace breather relief or safety valve 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. The safety valve acts as a warning that excessive pressure is present
in the brake housing and must be rectified immediately.
7) The circulation return line of the winch should be plumbed in such a manner that the brake housing remains
filled with oil at all times. Connect the return line directly to reservoir. Do not connect to a common return line.
257 REV.021217
PAGE 11
OPERATING INSTRUCTIONS
D ANGER
FAILURE TO FOLLOW OPERATING INSTRUCTIONS COULD
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 pulling. Standard rotation for pulling 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
CABLE ANCHOR
SI1013-R7
Clockwise pulling winch shown. (Use
cable anchor slot on opposite side of
drum for counterclockwise pulling
winch.)
Feed the wire rope through the cable
anchor slot. Loop rope back into slot as
shown. Insert cable anchor into slot,
small end first 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 5 wraps of wire rope
for safety.
3) The winch operation is controlled by a single control valve lever which has a forward, a reverse and a neutral
position. Speed control in either direction is obtained by modulation of the control valve lever. Maximum line
speed in either direction is obtained when the control valve lever is moved as far as it can go. The disc brake
of the winch will come on automatically when the winch control lever is returned to neutral.
4) Always warm up equipment prior to operating winch, particularly in low ambient temperature. Circulate hydraulic
oil through the winch control valve for several minutes to warm the hydraulic system. To prime the winch with
warm oil, operate the winch at slow speed, forward and reverse, several times.
5) Prevent corrosion damage to winch interior. If not used regularly, run winch up and down at least once every
two weeks.
CABLE ANCHOR SLOT
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.
PAGE 12
257 REV.051117
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 of the
hydraulic circuit components should be checked for proper function.
IMPORTANT:
The hydraulic oil volume relates to the line speed or rpm of the winch.
Therefore, if the winch does not produce the maximum rated line speed, a loss of hydraulic flow somewhere in
the hydraulic circuit system can be analysed. If this condition exists, install a flow meter into the hydraulic circuit
to check the volume supplied to the motor ports when the winch control is completely opened. The flow meter
should indicate the maximum operating volume. If the test described indicates a loss of hydraulic flow, check
the hydraulic pump, the relief valve and the control valve.
The hydraulic pressure relates to the line pull or lifting capacity of the winch.
If the winch will not pull the maximum rated load, install a pressure gauge into the pressure line leading to the
pulling port on the hydraulic winch motor. Stall the winch to prevent rotation of the drum and then open the control
valve and 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. When checking oil pressure of oil volume anywhere in the hydraulic system, make certain that the hydraulic
pump is running at maximum operating rpm. Installations using a belt drive for hydraulic pump must be checked
for belt slippage. Verify that hydraulic reservoir is filled to the top level.
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.
a) Winch is mounted to an uneven surface (see
INSTALLATION INSTRUCTIONS).
b) Cable sheaves or block purchase operated with the
winch are not turning freely.
c) Damage or wear in the hydraulic motor
d) Excessive back pressure in the hydraulic circuit.
a) Leakage out of the brake piston prevents the brake
from being released against the brake springs. This is
caused by damaged O-ring seals on the brake piston.
b) The O-ring seals, on the brake release channel between
the motor adaptor and the brake housing is damaged.
If this failure occurs there will be substantial leakage
from between the motor adaptor and brake housing.
c) Insufficient hydraulic pressure (see SPECIFICATIONS
for minimum operating pressure).
d) Winch is mounted to an uneven surface (see
INSTALLATION INSTRUCTIONS).
e) Hydraulic pressure is not reaching the brake piston
(plugged brake release orifice in the brake housing).
257 REV.010401
PAGE 13
TROUBLE SHOOTING
FAILURE PROBABLE CAUSE
Brake will not hold
Brake vibrates when lowering a load
a) Brake plates or divider plates have been damaged by
contamination in the hydraulic fluid, or lack of circulation flow in
the brake housing.
b) Brake piston is seized in the brake housing because of
contamination in the hydraulic fluid.
c) Excessive back pressure in the return line causes the brake to be
released. Back pressure in the circuit return line should be held
below 100 psi (7 bar).
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) The over-running clutch, which connects the motor shaft with the
brake assembly, is damaged.
g) Winch supplied with external brake release is not plumbed per
HYDRAULIC CIRCUIT. Failure to vent external brake release
port to reservoir may trap pressure and cause winch brake to slip.
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 (approx. 3.5
(US) gpm - 13 l/min when the winch is reversed.
c) Control valve has poor metering characteristics.
d) Damaged brake plates or divider plates.
e) Air mixed with hydraulic oil (foamy oil).
Cable drum will not freespool
Oil leaks
a) Insufficient pressure to disengage freespool shaft. Check with a
pressure gauge to verify that 400 psi (28 bar) is being supplied
to the freespool release port.
b) If pressure is being lost at the freespool release port, then the o-
ring that seals the freespool piston, item 265, has been damaged.
c) The freespool piston may have become seized, due to foreign
material in the hydraulic fluid.
d) There is a load on the drum, or the drum is turning. The drum must
be stopped and there can be no load on the wire rope, while the
freespool option is used.
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 tank.
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model R7 winch.
PAGE 14
257 REV.021217
SER VICE INSTRUCTIONS
GENERAL:
Before attempting disassembly of the PULLMASTER Model R7 planetary winch with freespool, the following
instructions 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 seal kit, part no. 26035, on hand before the unit is taken apart.
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 carefully inspected for wear and
damage and be thoroughly cleaned before installation.
During reassembly, lubricate all o-rings and oil seals with grease before installation.
In the following service instructions, reference to parts is made by part desciption and reference number, which
you will find in one of the three parts lists and associated group drawings.
DISASSEMBLY
FOR THE MAJORITY OF REQUIRED SERVICE OR REPAIR WORK, DISASSEMBLY IS REQUIRED ONLY ON
THE BRAKE HOUSING ASSEMBLY OF THE PULLMASTER MODEL R7 PLANETERY WINCH. There are no
special tools needed for the service and repair work and no adjustments or calibrations are necessary. Proceed
with the disassembly as follows:
REMOVE HYDRAULIC MOTOR ASSEMBLY:
1) Remove two capscrews, item 815, together with lockwashers, item 817, which attach the motor to the motor
adapter, item 800. The hydraulic motor, item 850, can now be pulled out of the winch assembly.
2) Remove and discard o-ring, item 811.
3) Remove the connecting tube, item 830, and discard o-rings, item 831, from both ends of the connecting tube.
4) The standard motor of the Model R7 is a Commercial M315 hydraulic gear motor with a 1-1/2" gear section.
If a problem is analysed to be in the hydraulic motor, we recommend that a COMMERCIAL INTERTECH dealer
be contacted for parts and service. Normally, a problem in the hydraulic motor occurs in the gear section.
If the hydraulic motor is disassembled, the original flange section of the motor must be re-used in order to provide
the required porting for the operation of the automatic brake, and for the circulation flow.
REMOVE BRAKE ASSEMBLY:
1) Remove the four capscrews, item 821, and lockwashers, item 823, from the motor adaptor, item 800. The
motor adaptor can now be taken from the brake housing assembly, and o-ring, item 707, discarded.
NOTE: Since the brake springs, item 752, apply pressure against the inside of the motor adaptor, it is
recommended that the hex capscrews are unscrewed one turn at a time until the spring pressure has been
released.
2) After the hydraulic motor assembly has been removed, all parts of the brake assembly are accesible. Remove
the 6 brake springs, item 752.
3) Pull the brake piston, item 750, out of the brake housing. Discard o-rings, item 751 and item 753. Remove
pipe plug, item 757, and make certain that the hole of the orifice plug, item 754, is clear and unobstructed by
debris and contamination. Re-install pipe plug, item 757.
Check the brake piston outside diameters and the inside diameters of the brake housing for surface scratches
due to particles in the hydraulic fluid (contamination). If there is any evidence of surface damage, polish with
fine emery cloth.
4) Pull the motor drive shaft, item 730, out of the brake housing together with hub assembly. Remove the brake hub
assembly by taking off circlip, item 727. Remove the 2 sprag clutch aligners, items 722 and 724, from both
257 REV.021217
PAGE 15
SERVICE INSTRUCTIONS CONTINUED
sides of the brake hub, item 720, and inspect for wear. Carefully remove the sprag clutch, item 723, and
inspect for damage. Inspect the surfaces of the motor drive shaft and the brake hub, where the sprag clutch
engages. If these surfaces show any deep indentations or surface damage, they should be replaced.
5) Remove the 7 divider plates, item 713, and the 6 brake plates, item 716. Inspect these parts for wear or
damage and replace if necessary.
6) Remove brake spacer, item 712, two thrust washers, item 737, and thrust bearing, item 739.
7) The oil seal, item 711, along with backup washer, item 710, which seals the brake housing from the cable
drum interior, can now be removed and discarded
All parts have now been removed from the brake housing, and there is no need for further disassembly, unless
a failure has been analysed in the remaining winch assembly.
REASSEMBLY OF BRAKE HOUSING ASSEMBLY:
Unless otherwise specified, use torque chart at back of manual.
1) Clean all parts thoroughly before reassembly and apply grease liberally to all o-rings and oil seals. Use only
new o-rings and oil seals (Seal kit for winch assembly, part no. 26035).
2) Install new backup washer, item 710, and new well lubricated oil seal, item 711, in the bore of the brake
housing.
3) Install thrust bearing, item 739, with a thrust washer, item 737, on each side, into the brake hub.
4) Install the sprag clutch, item 723, in the bore of the brake hub, item 720. Insert the sprag clutch aligner, item
722, into one side of the brake hub. Insert the other sprag clutch aligner, item 724, into the other side of the
brake hub. Carefully slide the motor drive shaft, item 730, through the sprag clutch aligner, item 724, into the
brake hub assembly and fasten into place by installing circlip, item 727.
IMPORTANT: For the -14 and -15 brake configurations the sprag clutch must be installed in such a manner that
the motor end of the motor drive shaft turns free in clockwise rotation and locks up in counter clockwise rotation.
For the -12 and -13 brake configurations, the rotation is opposite to the above procedure.
5) Insert the externally splined end of the motor drive shaft, together with the brake hub assembly, into the brake
housing and rotate it until it engages into the spline of the primary sungear, item 440.
6) Insert brake spacer, item 712, so that the flat side face out towards you, and install a divider plate, item 713,
against it. Then, starting with a brake plate, item 716, alternate the 6 brake plates with the remaining 6 divider
plates. The brake stack must finish with a divider plate.
7) Install well greased o-rings, item 751 and 753, onto the brake piston, item 750. Carefully insert the brake piston
into the brake housing and turn the piston to line up the bore for the connecting tube, item 830, with the bore
in the motor adapter, item 800. Install the six brake springs, item 752.
8) Check the safety valve, item 840, on the motor adaptor for proper sealing. Install new, well greased o-ring,
item 707, on the flange of the motor adaptor, and fasten this part to the brake housing by using four hex head
capscrews, item 821, and lockwashers, item 823. These screws should be tightened evenly, one turn at a
time, against the pressure exerted by the brake springs.
IMPORTANT: For the -14 and -15 brake configurations, the motor adaptor must be reassembled with the mounting
holes for the hydraulic motor in a parallel position to the mounting surface of the winch, and the bore for the
connecting tube on the right side. For the -12 and -13 brake configurations, the bore for the connecting tube is
located on the left hand side.
9) Install new o-rings, item 831, on each end of the connecting tube, item 830, and apply grease liberally. Insert
the long end of the connecting tube into the motor adaptor.
10 ) Install new, well greased o-ring, item 811, on the flange of the hydraulic motor and fasten the motor by using
two hex head capscrews, item 815, and lockwashers, item 817.
PAGE 16
257 REV.010401
SERVICE INSTRUCTIONS CONTINUED
The Pullmaster Winch is now reassembled and ready for installation.
DISASSEMBLY OF FINAL DRIVE ASSEMBLY:
If a failure occurs in the mechanism located inside the final drive housing, or the winch has to be disassembled
beyond the point described in the preceding chapter, proceed as follows:
1) Remove the drain plug, item 121, from the freespool cover, item 250, and drain the lubricating oil from the
final drive assembly and the cable drum interior. In order to drain all of the oil out of the cable drum interior,
the winch should be tipped to an angle, and the filler plug, item 503 removed.
2) After draining all lubricating oil from the final drive housing, item 100, remove internal retaining ring, item 124,
and knock spring pin, item 259, up into the hole in the final drive housing, for clearance. The freespool
assembly along with the final sungear can now be pulled out of the final drive housing and put aside. If a
problem exists in the freespool assembly, skip ahead to the section titled DISASSEMBLY OF FREESPOOL
ASSEMBLY.
3) Pull out the final planet hub assembly and inspect for wear or damage. If the final planet hub gears, item 320,
have to be removed, take off circlip, item 311, from planet pin, item 310, and press the planet pin out of the
final planet hub, item 300. Remove the final planet gear, item 320, together with loose rollers, item 323, and
thrust washers, item 321. NOTE: On reassembly these thrust washers must be installed.
All parts have now been removed from the final drive assembly. If further disassembly is required, proceed as
follows:
DISASSEMBLY OF CABLE DRUM ASSEMBLY:
If a problem is analysed to be in the primary or secondary reductions, the cable drum assembly must be
disassembled. After draining lubrication oil, proceed as follows:
1) Remove 16 hex head capscrews, item 555, along with lockwashers, item 553, from the final housing, item
100, and the brake housing, item 700, and remove the two tie bars, item 556 and 558.
2) The brake housing, item 700, can now be pulled out of the cable drum, item 500. The cylindrical roller bearing,
item 509, comes apart with the outer race remaining in the cable drum, and the rest stays on the hub of the
brake housing. Remove and discard oil seal, item 515, and inspect nylon spacer, item 704, for wear. Replace
spacer if less than 7/32” thick.
3) Pull the primary planet hub assembly out of the cable drum. Check nylon spacer, item 402, for wear and
replace if less that 7/32” thick.
4) If the primary planet gears, item 420, have to be removed, first remove primary sungear, item 440, and sungear
stopper, item 494, from the primary planet hub assembly. Take off circlip, item 411, from planet pin, item 410,
and press the planet pin out of the primary planet hub, item 400. Remove the primary planet gear, item 420,
together with needle bearings, item 423, and thrust washers, item 421.
NOTE: On reassembly these thrust washers must be re-installed. Also, ensure that the secondary sungear, item
490, with circlip, item 491, are in place before planet gears are re-installed.
5) The secondary planet hub assembly can now be pulled out of the cable drum. Inspect the planet hub stopper,
item 453, for wear and replace if less than 5/16” thick.
6) Inspect the internal splines of the secondary planet hub for excessive wear or broken teeth, and replace if
necessary. If the secondary planet gears, item 470, have to be removed, take off circlip, item 461, from planet
pin, item 460, and press the planet pin out of the primary planet hub, item 450. Remove the primary planet
gear, item 470, together with loose rollers, item 473, and thrust washers, item 471. NOTE: On reassembly,
these thrust washers must be re-installed.
7) To separate final housing, item 100, from brake housing, item 700, first remove circlip, item 513, from the
hub of the cable drum. Insert two heel bars between the drum flange and the final housing and carefully pry
the cable drum out of ball bearing, item 103. Remove the internal retaining ring, item 104, to remove ball
bearing, item 103, from inside the final housing. Remove and discard oil seal, item 105.
257 REV.010401
PAGE 17
SERVICE INSTRUCTIONS CONTINUED
DISASSEMBLY OF FREESPOOL ASSEMBLY:
If a problem is occuring in the freespool assembly, follow instructions 1 and 2 from the section DISASSEMBLY
OF FINAL DRIVE ASSEMBLY, then depending on whether you are working on a hydraulic or manually actuated
model, proceed form here.
HYDRAULIC FREESPOOL (R7-X-135-1F):
1) Remove four hex capscrews, item 253, and lockwashers, item 255, from the end of the freespool assembly.
Since the freespool spring, item 280, applies pressure against the inside of the freespool cover, it is
recommended that the hex capscrews are unscrewed one turn at a time until the spring pressure has been
released.
2) Discard o-ring, item 257, and remove the freespool spring.
3) Remove the freespool piston, item 264, along with the final sungear, item 340, from the freespool cover and
discard o-rings, item 265 and 277. Inspect the outside diameter of the piston and the internal diameter of the
housing for any surface scratches due to particles in the hydraulic fluid (contamination). If there is any
evidence of surface damage, polish with fine emery cloth.
4) Inspect nylon planet hub stopper, item 126, and replace if less than 1/8” thick. Remove and discard o-ring,
item 123, from outside of freespool housing.
5) In order to separate the final sungear, item 340, from the freespool piston, remove circlip, item 269. Inspect
the two splines on the end of the final sungear for wear and cracks, and replace if necessary.
6) To separate the ball bearing, item 291, from the final sungear, remove circlip, item 269.
MANUAL FREESPOOL (R7-X-135-1M):
1) Remove hex head capscrew, item 297, and lockwasher, item 298, to allow removal of freespool handle, item
254, form nut drive, item 256.
2) Remove four hex head capscrews, item 253, and lockwashers, item 255, from seal carrier, item 252. For
correct positioning of the seal carrier upon reassembly, make a chalk mark on the outside top flange of the
seal carrier and the freespool housing, item 250. Pull the seal carrier out of the freespool housing and discard
o-ring, item 257, and oil seal, item 299.
3) Remove index, item 272, detent spring, item 276, and spring seat, item 284. Check these parts for wear and
replace if necessary.
4) Turn the nut drive, item 256, to disconnect from the follower, item 266. Inspect the three spring pins, item
278, and replace if damaged or worn.
5) Remove circlip, item 288, and pull the final sungear, item 340, together with the follower and ball bearing, item
291, out of the freespool housing.
6) Remove circlip, item 295, from the inside of the follower and pull the ball bearing, together with the final
sungear, out of the follower.
7) To separate the ball bearing, item 291, from the final sungear, remove circlip, item 269.
The PULLMASTER Model R7 with freespool has now been completely disassembled.
REASSEMBLY:
Reassemble the winch following reverse procedure of disassembly. All parts should be thoroughly cleaned and
only new, well greased o-rings and oil seals should be used.
IMPORTANT:
Before operation of the winch, refill lubricating oil (SAE 90) through the oil level hole in the end cover, and through
the oil filler hole in the cable drum. The proper quantity is indicated on the winch SPECIFICATION sheet. To ensure
proper reassembly, run the winch in both directions without load, prior to regular operation.
PAGE 18
257 REV.010401
RECOMMENDED MAINTENANCE
It is recommended that the lubrication oil in the final drive housing and the drum interior is replaced after the initial
50 hours of operation. In order to maintain your PULLMASTER Model R7 planetery winch in peak operating condition
at all times and over a long period, it is recommended that the following preventative maintenance procedure is
carried out at least once a year or after 500 hours of actual operation, whichever occurs first:
1) Disconnect all hydraulic hoses and remove the winch from its mounting.
2) Disassemble the winch in accordance with the instructions given.
3) Discard and replace all O-rings and oil seals.
4) Inspect all parts for wear and replace if necessary.
5) Clean all parts with solvent before reassembly.
6) Reassemble the winch and re-fill lubricating oil (SAE 90) through the oil filler hole in the freespool
housing and through the oil filler hole in the cable drum.
Note:
Although the wire rope is not part of the winch, a regular inspection will help to prevent potential accidents.
WHEN ORDERING REPAIR PARTS FOR THE PULLMASTER MODEL R7 PLANETARY WINCH, ALWAYS
QUOTE THE 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.
257 REV.010401
PAGE 19
PARTS REFERENCE - FINAL DRIVE (R7-M)
ITEM NO.
100 1 22360 FINAL HOUSING
103 1 25150 BALL BEARING 110 X 170 X 28 #6022
104 1 20664 BEARING RETAINER #6022
105 1 26049 OIL SEAL 4.750 X 5.500 X .375
121 2 25032 PIPE PLUG 1/2 - 14 NPT
123 1 25484 O-RING -276 11"ID 1/8" CS
124 1 20663 COVER RETAINER
126 1 20662 PLANET HUB STOPPER
130 1 20458 BREATHER RELIEF ASSEMBLY
250 1 22248 FREESPOOL HOUSING
252 1 20966 SEAL CARRIER
253 4 25017 CAPSCREW - HEX HEAD 3/8 - 16NC X 1.0
254 1 20486 FREESPOOL HANDLE
255 4 25037 LOCKWASHER 3/8"
256 1 20477 FREESPOOL NUT DRIVE
257 1 25016 O-RING - 042 3-1/4"ID 1/16"CS
259 1 25379 SLOTTED SPRING PIN 5/32" X 1" L
266 1 20476 FREESPOOL FOLLOWER
268 1 25387 SLOTTED SPRING PIN 1/8"DIA X 3/8" L
269 1 25175 CIRCLIP ANDERTON # N1400 - 0078
272 2 20968 INDEX
276 2 20488 DETENT SPRING
278 3 25383 SLOTTED SPRING PIN 5/32 DIA 5/8"L
284 2 21075 SPRING SEAT
288 1 25378 CIRCLIP ANDERTON #N1300-0231
291 1 25172 BALL BEARING 020 X 042 X 12 #6004
295 2 25179 CIRCLIP ANDERTON # N1300 - 0165
297 1 25171 CAPSCREW - HEX HEAD 5/16 - 18NC x 7/8"L
298 1 25025 LOCKWASHER 5/16"
299 1 26009 OIL SEAL DAEMAR 175225312 1.750 X 2.250 X .31
300 1 20624 PLANET HUB
310 3 20659 PLANET PIN
311 3 25482 CIRCLIP ANDERTON # N1400 - 0018
313 3 25490 CIRCLIP ANDERTON # N1400 - 0125
320 3 22246 PLANET GEAR
321 6 25483 THRUST WASHER INA # AS 3047
323 60 25308 LOOSE ROLLER 7/32 DIA. X 1.50
340 1 22247 SUNGEAR
450 1 20653 PLANET HUB
453 1 20665 PLANET HUB STOPPER
460 3 20658 PLANET PIN
461 3 25060 CIRCLIP ANDERTON #N1800-0062
463 3 25119 CIRCLIP ANDERTON #N1400-0062
470 3 20657 PLANET GEAR
471 6 25486 THRUST WASHER TORRINGTON #FTA 1730
473 48 25270 LOOSE ROLLER 5/32 X 1.25 TOR. #E151-Q
500 1 22361 CABLE DRUM
502 1 20171 CABLE ANCHOR
503 1 25085 PIPE PLUG 3/8 - 18 NPT
513 1 25489 CIRCLIP ANDERTON # N1400 - 0425
553 16 25328 LOCKWASHER 7/16"
555 16 25265 CAPSCREW - HEX HEAD 7/16" - 14NC X 1.25
556 2 22374 TIE BAR
QTY.
PART NO.
DESCRIPTION
REFER TO PAGE 26 FOR WINCH SEAL KIT AND PAGE 28 FOR ASSEMBLY DRAWING.
PAGE 20
257 REV.021217
FINAL DRIVE GROUP
256
254
298
297
299
252
257
253
255
272
276
284
266 278 269
295 288
121 124 123 126 268
130 259 250
291
100 320 323 321 313 310 104 103
105
300 513
502
503
311
461
471
460
500
450
463
340
453556553555
473
470
G1080-C
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.
257 REV.021217
PAGE 21
PARTS REFERENCE - FINAL DRIVE (R7-F)
ITEM NO.
100 1 22360 FINAL HOUSING
103 1 25150 BALL BEARING 110 X 170 X 28 #6022
104 1 20664 BEARING RETAINER #6022
105 1 26049 OIL SEAL 4.750 X 5.500 X .375
121 2 25032 PIPE PLUG 1/2 - 14 NPT
123 1 25484 O-RING -276 11"ID 1/8" CS
124 1 20663 COVER RETAINER
126 1 20662 PLANET HUB STOPPER
130 1 20458 BREATHER RELIEF ASSEMBLY
250 1 22254 FREESPOOL HOUSING
251 1 25374 PLASTIC CAPLUG 1/8 NPT
252 1 22279 FREESPOOL COVER
253 4 25264 CAPSCREW - HEX HEAD 3/8 - 16NC X 1.0
255 4 25037 LOCKWASHER 3/8"
257 1 25016 O-RING - 042 3-1/4"ID 1/16"CS
259 1 25379 SLOTTED SPRING PIN 5/32" X 1" L
264 1 20894 FREESPOOL PISTON
265 1 25628 O-RING -235 3-1/8"ID 1/8"CS
269 1 25175 CIRCLIP ANDERTON # N1400 - 0078
277 1 25477 O-RING -236 3-1/4"ID 1/8"CS
280 1 20159 FREESPOOL SPRING
291 1 25172 BALL BEARING 020 X 042 X 12 #6004
295 1 25179 CIRCLIP ANDERTON # N1300 - 0165
300 1 20624 PLANET HUB
310 3 20659 PLANET PIN
311 3 25482 CIRCLIP ANDERTON # N1400 - 0018
313 3 25490 CIRCLIP ANDERTON # N1400 - 0125
320 3 22246 PLANET GEAR
321 6 25483 THRUST WASHER INA # AS 3047
323 60 25308 LOOSE ROLLER 7/32 DIA. X 1.50
340 1 22247 SUNGEAR
450 1 20653 PLANET HUB
453 1 20665 PLANET HUB STOPPER
460 3 20658 PLANET PIN
461 3 25060 CIRCLIP ANDERTON #N1800-0062
463 3 25119 CIRCLIP ANDERTON #N1400-0062
470 3 20657 PLANET GEAR
471 6 25486 THRUST WASHER TORRINGTON #FTA 1730
473 48 25270 LOOSE ROLLER 5/32 X 1.25 TOR. #E151-Q
500 1 22361 CABLE DRUM
502 1 20085 CABLE ANCHOR
503 1 20171 PIPE PLUG 3/8 - 18 NPT
513 1 25489 CIRCLIP ANDERTON # N1400 - 0425
553 16 25328 LOCKWASHER 7/16"
555 16 25265 CAPSCREW - HEX HEAD 7/16" - 14NC X 1.25
556 2 22374 TIE BAR
QTY.
PART NO.
DESCRIPTION
REFER TO PAGE 26 FOR WINCH SEAL KIT AND PAGE 29 FOR ASSEMBLY DRAWING.
PAGE 22
257 REV.021217
FINAL DRIVE GROUP
310
255
121251277
265
269
291
253
252
280
257
264
461 470311
295
250 321
124 123 126
259
130
323 320 100 313
473
460
471
463
500
104 103 105
300 513
502 503
450
340453556553555
G1081-C
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 should be ignored.
257 REV.021217
PAGE 23
PARTS REFERENCE - BRAKE GR OUP
ITEM NO.
400 1 20660 PLANET HUB
402 1 20372 SPACER
410 3 20080 PLANET PIN
411 3 25060 CIRCLIP ANDERTON # N1800 - 0062
413 3 25060 CIRCLIP ANDERTON # N1800 - 0062
420 3 20101 PLANET GEAR
421 6 25064 THRUST WASHER TORRINGTON # TRA 1018
423 3 25269 NEEDLE BEARING TORRINGTON # BH1016
440 1 20670 SUNGEAR
490 1 20669 SUNGEAR
491 1 25377 CIRCLIP ANDERTON # A1000 - 0162
494 1 20450 SUNGEAR STOPPER
509 1 25480 CYCLINDRICAL ROLLER BRG. SKF #N217 (85X150X28)
515 1 25148 OIL SEAL 5.500 X 6.250 X .500
700 1 * BRAKE HOUSING
704 1 20372 SPACER
707 1 25275 O-RING -048 4-3/4"ID 1/16"CS
708 1 * CHECK VALVE SUB-ASSY
70 9 1 * PLASTIC CAPLUG 1/8 NPT
710 1 20714 BACK-UP WASHER FOR OIL SEAL #25278
711 1 25278 OIL SEAL GACO DPSM 30407
712 1 20107 BRAKE SPACER
713 7 25024 DIVIDER PLATE HI-LINE #19205
716 6 20034 FRICTION PLATE
719 1 25539 CIRCLIP ANDERTON # N1500 - X118
720 1 20640 BRAKE HUB
722 1 20183 SPRAG CLUTCH ALIGNER
723 1 25187 SPRAG CLUTCH BORG WARNER #X138769
724 1 20183 SPRAG CLUTCH ALIGNER
727 1 25492 CIRCLIP ANDERTON # N1400 - 0106
730 1 22214 MOTOR DRIVE SHAFT
731 1 25500 CIRCLIP ANDERTON # N1800 - 0093
737 2 25483 THRUST WASHER INA #AS 3047
739 1 25537 THRUST WASHER INA #AXK 3047
750 1 20727 PISTON
751 1 25528 O-RING -245 4-3/8"ID 1/8"CS
752 6 20340 BRAKE SPRING
753 1 25261 O-RING -246 4-1/2"ID 1/8"CS
754 1 20732 ORIFICE PLUG
757 1 25040 PIPE PLUG 1/8 - 27 NPT
759 1 * STEEL BALL
80 0 1 * MOTOR ADAPTOR
811 1 25016 O-RING - 042 3-1/4" ID 1/16"CS
815 2 25264 CAPSCREW - HEX HEAD 3/8 - 16NC X 1.00
817 2 25037 LOCKWASHER 3/8"
821 4 25264 CAPSCREW - HEX HEAD 3/8 - 16NC X 1.00
823 4 25037 LOCKWASHER 3/8"
830 1 20519 CONNECTING TUBE
831 2 25018 O-RING -010 1/4" ID 1/16"CS
840 1 20870 SAFETY VALVE
85 0 1 * MOTOR -135 COMM. M315 - 1.5 GS
QTY.
PART NO.
DESCRIPTION
26035 WINCH SEAL KIT, CONSISTS OF:
ITEMS: 105, 123, 257, 265, 277, 299, 515, 707, 710, 711, 751, 753,
811, AND 831
* These part numbers vary according to brake code.
Refer to Appendix A.
REFER TO PAGES 28 & 29 FOR ASSEMBLY DRAWINGS.
PAGE 24
257 REV.021217
BRAKE GROUP
850815
895
750
831
888
811
G-1077-E
840757759
707
713716712739737
830
831
817
752
800
821
709 751 753 823727724720723 515509
708
700
711413 722
420 754 730
423
421
411
410
494
490
400
402
491
440
731
719710704
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 SHOULD BE IGNORED.
257 REV.021217
PAGE 25
INSTALLATION DIMENSIONS (R7-M)
6.50
[165.1]
.77
[19.6]
OPTIONAL EXT.
BRAKE PORT
14.6
[371]
1/8-27 NPT
CLOCKWISE
PRESSURIZE FOR
COUNTER CLOCKWISE
ROTATION
8.1
4.8
.75
[19.1]
[206]
[121]
PRESSURIZE
13.5
10.1
[257]
FOR CLOCKWISE
ROTATION
[343]
I1030-C
5.9
29.4
[748]
[151]
5.5
[141]
8.0
[203]
.9
[23]
FILLER PORT
3/8 - 18 NPT
SAFETY
VALVE
CONFORMS TO SAE J706a STANDARD
6.2
FREE SPOOL
HANDLE
[156]
FILLER PORT
1/2 - 14 NPT
BREATHER RELIEF
VALVE
6.4
12.6
[162]
[321]
MOTOR PORTS
SAE O RING BOSS
1.062 - 12
4 MOUNTING HOLES
53/64 (21 MM) DIA
DRAIN PORT
1/2 - 14 NPT
1.6
11.1
1.6
[41]
[283]
[41]
FOR 1/2 TO 5/8 DIA. CABLE
CABLE ANCHOR SUITABLE
MAINTAINED AT ALL TIMES
OF WIRE ROPE MUST BE
A MINIMUM OF 5 WRAPS
FOR SAFETY:
PAGE 26
12.8
[325]
257 REV.051117
INSTALLATION DIMENSIONS (R7-F)
6.50
[165.1]
.77
[19.6]
OPTIONAL EXT.
BRAKE PORT
14.6
[371]
1/8-27 NPT
CLOCKWISE
8.1
4.8
.75
[19.1]
[121]
[206]
10.1
[257]
13.5
PRESSURIZE FOR
COUNTER CLOCKWISE
ROTATION
[343]
I1031-D
5.9
29.0
[737]
5.5
8.0
6.2
[151]
[141]
[203]
[156]
SAFETY
VALVE
.9
[23]
FILLER PORT
3/8 - 18 NPT
FILLER PORT
1/2 - 14 NPT
BREATHER RELIEF
VALVE
CONFORMS TO SAE J706a STANDARD
6.4
12.6
[162]
[321]
PRESSURIZE
FOR CLOCKWISE
ROTATION
1.6
[41]
MOTOR PORTS
SAE O RING BOSS
1.062 - 12
11.1
[283]
4 MOUNTING HOLES
53/64 (21 MM) DIA
USE 3/4 BOLTS
GRADE 5 OR BETTER
1.6
[41]
DRAIN PORT
1/2 - 14 NPT
CABLE ANCHOR SUITABLE
FOR 1/2 TO 5/8 DIA. CABLE
A MINIMUM OF 5 WRAPS
OF WIRE ROPE MUST BE
MAINTAINED AT ALL TIMES
257 REV.051117
12.8
[325]
FREESPOOL RELEASE
PORT 1/8-27 NPT
FOR SAFETY:
PAGE 27
ASSEMBLY DRAWING (R7-M)
G1077-E & G1080-C
PAGE 28
257 REV.010401
ASSEMBLY DRAWING (R7-F)
G1077-E & G1081-C
257 REV.010401
PAGE 29
APPENDIX A
PART NUMBERS
ITEM
NO.
700 BRAKE HOUSING 22213 22372 22372 22213
708 CHECK VALVE N/A 21530 21530 N/A
709 PLASTIC CAPLUG N/A 25374 25374 N/A
750 BRAKE PISTON 20727 20735 20735 20727
759 STEEL BALL N/A 25533 25533 N/A
PART
DESCRIPTION
BRAKE CODE
- 12 - 13 - 14 - 15
800 MOTOR ADAPTER 21079 21079 20716 20716
950 MOTOR 22255 22255 22331 22331
PAGE 30
257 REV.010401
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
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
257 REV.010401
NOTE: Unless otherwise specified, torque bolts per above chart.
PAGE 31
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