THE INTRAVENT

PL2
PLANETARY HYDRAULIC WINCH
DESIGN REVISION EFFECTIVE FROM SERIAL # 76061

DESIGN REVISION ‘B’

INSTRUCTION
AND
PARTS
MANUAL

READ THIS MANUAL BEFORE INSTALLING, OPERATING OR

SERVICING THIS PRODUCT. THIS MANUAL CONTAINS IMPORTANT
INFORMATION. MAKE THIS MANUAL AVAILABLE TO ALL PERSONS
RESPONSIBLE FOR THE OPERATION, INSTALLATION, SERVICING
AND MAINTENANCE OF THIS PRODUCT.

THE LOGICAL
CHOICE
Pullmaster Limited Warranty
Effective 8/1/2008
SUPERSEDES ALL PRIOR WARRANTIES

Seller warrants that each article (whether Gear Drive Products, Brake Products and/or Winch Products, all of which are covered hereunder)
sold under this order shall at the time of shipment (i) conform to applicable specifications, and (ii) be free from defects in material and
workmanship during normal and ordinary use and service (the "Warranty").

Buyer's exclusive remedy and Seller's sole obligation under this Warranty shall be, at Seller's option, to repair or replace any article or part
thereof which has proven to be defective, or to refund the purchase price of such article or part thereof. Buyer acknowledges that Buyer is
knowledgeable concerning the articles covered by this Warranty and sold in connection therewith which are being purchased, that Buyer has
reviewed this Warranty and that the remedies provided hereunder are adequate and acceptable to Buyer.

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

If an article is claimed to be defective in material or workmanship, or not to conform to the applicable specifications, Seller will either
examine the article at Buyer's site or issue shipping instructions for return to Seller. This Warranty shall not extend to any articles or parts
thereof which have been installed, used, or serviced otherwise than in conformity with Seller's applicable specifications, manuals, bulletins,
or instructions, or which shall have been subjected to improper installation, operation, or usage, misapplication, neglect, incorrect
installation, overloading, or employment for other than normal and ordinary use and service. This Warranty shall not apply to any article
which has been repaired, altered or disassembled, or assembled by personnel other than those of Seller. This Warranty shall not apply to
any article upon which repairs or alterations have been made (unless authorized in writing and in advance by Seller). This Warranty shall
not apply to any articles or parts thereof furnished by Seller to Buyer's specifications and/or furnished by Buyer or acquired from others at
Buyer's request.

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

Buyer expressly agrees that Seller is not responsible to perform any work or investigation related in any way to tensional vibration issues
and is not responsible for the detection or remedy of Natural Frequency Vibration of the mechanical system in which the unit is installed.
Buyer acknowledges, understands and agrees that this Warranty does not cover failures of the unit which result in any manner from the
operation of the machine or unit at vibration frequencies at or near the natural frequency vibration of the machine in such a way that damage
may result. Buyer expressly agrees that Seller is not responsible for failure damage or accelerated wear caused by machine or ambient
vibration. Further, Buyer acknowledges and agrees that Buyer is always solely responsible for determination and final approval of the
“application factor”
which may be used in Seller’ s calculations, and this application factor is 1.0 unless otherwise stated in Seller’
s quotation
specifications.

The remedies for this Warranty shall be only those expressly set forth above, to the exclusion of any and all other remedies of whatsoever
kind. The limited remedies set forth above shall be deemed exclusive, even though they may fail their essential purpose. No agreement
varying or extending the foregoing Warranty, remedies, exclusions, or limitations shall be effective unless in a writing signed by an executive
officer of Seller and Buyer. This Warranty is non-transferable. If a party who had purchased articles from Buyer, or from persons in privity
with Buyer, brings any action or proceeding against Seller for remedies other than those set forth in this Warranty, Buyer agrees to defend
Seller against the claims asserted in such action or proceeding at Buyer’ s expense, including the payment of attorneys’ fees and costs, and
indemnify Seller and hold Seller harmless of, from and against all such claims, actions, proceedings or judgments therein. Buyer also
agrees to defend and indemnify Seller of, from and against any loss, cost, damage, claim, debt or expenses, including attorneys’ fees,
resulting from any claims by Buyer or third parties to property or injury to persons resulting from faulty installation, repair or modification of
the article and misuse or negligent operation or use of the article, whether or not such damage to property or injury to persons may be
caused by defective material, workmanship, or construction. ADVISORY: Winches and hoists are not approved for lifting or handling
personnel or persons unless specifically approved in writing from Seller for the specific intended application.

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

The foregoing limitations on Seller's liability in the event of breach of warranty shall also be the absolute limit of Seller's liability in the event
of Seller's negligence in manufacture, installation, or otherwise, with regard to the articles covered by this Warranty, and at the expiration of
the Warranty period as above stated, all such liabilities shall terminate. Buyer’ s purchase of any article(s) covered by this Warranty shall
constitute acceptance of the terms and conditions hereof and shall be binding upon Buyer and Buyer’ s representatives, heirs and assigns.
The laws of the Province of British Columbia shall govern Buyer’ s rights and responsibilities in regard to this Warranty and the transaction(s)
subject thereto, and the Province of British Columbia shall be the exclusive forum and jurisdiction for any action or proceedings brought by
Buyer in connection herewith or any dispute hereunder. If any of the terms and conditions contained within this Warranty are void, the
remaining provisions thereof are and shall remain valid and enforceable.

Note: Prices and specifications contained in this price book are subject to change without notice.

US.DIST.01.01.07
 SAFETY RECOMMENDATIONS
Definition: Caution indicates a potentially
DANGER hazardous situation which, if not avoided may
result in minor or moderate injury.
FAILURE TO COMPLY WITH THE FOLLOWING SAFETY Definition: Warning indicates a potentially
RECOMMENDATIONS AND LOCAL RULES AND hazardous situation which, if not avoided could
result in death or serious injury.
REGULATIONS WILL RESULT IN PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. Definition: Danger indicates a potentially
hazardous situation which, if not avoided will
result in death or serious injury.

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.

1. Do not install, operate or service winch before 18. Use only recommended hydraulic oil and gear
reading and understanding manufacturer's lubricant.
instructions.
19. Keep hydraulic system clean and free from
2. The winch described herein is not designed for contamination at all times.
operations involving lifting or moving personnel.
20. Maintain winch and equipment in good operating
3. Do not lift or carry loads over people. condition. Perform scheduled maintenance regularly.
4. Do not exceed recommended operating 21. Keep hands clear when winding wire rope onto
pressure (psi) and operating volume (gpm). the winch drum.
5. Do not jerk the winch. Always smoothly 22. Do not use the wire rope as a ground for welding.
accelerate and decelerate load.
23. Rig the winch carefully. Ensure that the wire
6. Do not operate a damaged, noisy or rope is properly anchored to the correct cable anchor
malfunctioning winch. slot at the cable drum.
7. Do not leave a load suspended for any 24. Do not lift a load with a twisted, kinked or
extended period of time. damaged wire rope.
8. Never leave a suspended load unattended. 25. Consult wire rope manufacturer for size, type and
maintenance of wire rope.
9. Winch should be maintained and operated by
qualified personnel. 26. Maintain five wraps of wire rope on the cable
drum at all times.
10. Inspect winch, rigging, mounting bolts and
hoses before each shift. 27. In case of a power failure or breakdown leading
to an unexpected stop of the hydraulic power circuit,
11. Warm-up equipment before operating winch, stand clear of the area and the load being hoisted,
particularly at low ambient temperatures. take the necessary precautions to prevent access to
12. Verify winch function by raising and lowering a area where the load is halted.
full test load to a safe height before each shift. 28. The noise level of the winch is 90 dBA measured
13. Do not weld any part of the winch. on a distance of 1.00 meter, 1.60 meters high. The
measuring equipment used was: Realistic #42-3019.
14. Verify gear lubrication and brake circulation
supply and return before operating winch. 29. Clean up any oil spillage immediately.

15. Be sure of equipment stability before operating 30. Wear proper clothing and personal protection
winch. equipment such as, footwear, safety goggles and a
hard hat. Read manual first.
16. Wear proper clothing to avoid entanglement in
rotating machinery.
17. Always stand clear of the load.

315 REV.051117 PAGE 1

 DESCRIPTION OF THE MODEL PL2
GENERAL DESCRIPTION:
The PULLMASTER Model PL2 is a planetary hydraulic winch having equal speed in both directions.
The main components of this unit are:

✛ Hydraulic gear motor

✛ Multi disc brake with static and dynamic function
✛ Over-running clutch
✛ Primary planet reduction
✛ Final planet reduction
✛ Brake housing
✛ End housing
✛ Cable drum

FUNCTION IN FORWARD ROTATION (HOISTING):

In forward rotation, the output torque and rpm of the hydraulic motor are transmitted to the sungear
of the primary planet reduction. The output of the primary reduction is transferred to the final sungear,
which is splined to the primary planet hub. The final planet assembly does not rotate, so the rotation
is transmitted to the cable drum by the final drive planet gears. In forward rotation, or when a load
is lifted, an over-running clutch, which connects the motor drive shaft to the automatic brake assembly,
permits free rotation of the sungear, without effecting the brake. Pressure required to rotate the drum
at full speed without load may vary up to 450 psi (31 bar). When the winch rotation is stopped, the
load on the cable drum causes the over-running clutch to lock and the maximum load is held safely
by the disc brake.

FUNCTION IN REVERSE ROTATION (LOWERING):

In reverse rotation, or when the winch is pressurized for lowering 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 against a number of brake springs. The pressure required to rotate the
drum at full speed may vary from 200 - 500 psi (14 - 34 bar) depending upon load and from 550 -
1075 psi (38 - 74 bar) without load. The over-running clutch, connecting the motor drive shaft to the
brake assembly, locks, causing the brake discs to rotate between divider plates, which are engaged
into the brake housing. If the load on the cable drum tends to effect the lowering speed, the resulting
pressure drop in the brake piston causes friction between the brake discs and the divider plates. In
this way, a completely smooth paying out speed can be achieved in a stepless operation by
modulation of the winch control handle. When the control handle is returned to neutral position,
rotation stops and the disc brake applies automatically. A hydraulic counter-balance valve or holding
valve is not required for smooth and positive operation of the automatic brake.

During the lowering operation of the winch, the friction created by the brake discs results in heat. This
heat is dissipated by the circulation of hydraulic fluid through the brake housing, supplied internally
through the hydraulic motor. This circulation flow is internally vented to the return line flow through
a check valve arrangement inside the hydraulic motor. The circulation flow is supplied only when a
load is lowered. A separate vent line connecting the PULLMASTER Model PL2 with the hydraulic
reservoir is not normally required.
(See TYPICAL HYDRAULIC CIRCUITS.)

IMPORTANT: Pressure in the brake housing must never exceed 100 psi (7 bar). Excessive brake
housing pressure will cause the safety valve located on top of the motor to leak.
Brake housing pressure can be gauged at the safety valve port.

PAGE 2 315 REV.990607

 EXPLANATION OF MODEL CODING
PL 2 X - XX - XX - XX X - B XXXX

BASIC UNIT SERIES

SIZE OF UNIT

REDUCTION RATIO
Only used for non-standard reduction ratios

TYPE OF BRAKE
-12 Automatic brake, counterclockwise hoisting, intravent
-13 Automatic brake, external brake release, counterclockwise hoisting,
intravent
-14 Automatic brake, external brake release, clockwise hoisting, intravent

-15 Automatic brake, clockwise hoisting, intravent

-16 Automatic brake, counterclockwise hoisting, intravent,
external brake release
-17 Automatic brake, effective in both directions, external brake release,
external circulation, external drain port
-18 Automatic brake, effective in both directions, intravent
-19 Automatic brake, external brake release, zero leakage,
counterclockwise hoisting, intravent
-20 Automatic brake, external brake release, zero leakage,
clockwise hoisting, intravent

HYDRAULIC MOTOR
-221 Gear motor (.81 cubic inch displacement)
(Other motors are optional)

DRUM SIZE
-1 6.13 inch drum diameter x 9.00 inch flange diameter x 5.25 inch length - STANDARD
(For other drum sizes refer to APPENDIX A)

OPTIONS

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.

DESIGN REVISION EFFECTIVE FROM SERIAL # 76061

315 REV.050722 PAGE 3

 OPTIONS
CLOCKWISE ROTATION:
The drum rotation of the standard PULLMASTER Model PL2 planetary winch is counterclockwise for hoisting, when
looking at the hydraulic motor of the winch. Drum rotation for clockwise 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 BRAKE 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 PL2 planetary
winch can be supplied with optional drums to accommodate large wire rope storage capacity.

DRUM GROOVING:
Cable drums for the PULLMASTER Model PL2 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 PL2 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 PL2 planetary winch is limited to 2200 psi (152
bar). For hydraulic systems operating with higher hydraulic pressure, the winch can be supplied with
a hydraulic piston motor, which will provide for the same basic performance in terms of line pull and line
speed capacity.
(Contact the factory for this requirement.)

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

PAGE 4 315 REV.990607

 SPECIFICATIONS
Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with
5/16 inch diameter wire rope. For other cable drums and gear ratios refer to APPENDIX A. Performance
specifications for winches supplied with optional motors are provided in attached supplement.

CABLE DRUM DIMENSIONS (STANDARD DRUM):

Barrel diameter 6.13 in 156 mm
Flange diameter 9.00 in 229 mm
Barrel length 5.25 in 133 mm

CABLE STORAGE CAPACITY:

Size of wire rope 1/4 in 172 ft 52 m
5/16 in 122 ft 37 m
3/8 in 84 ft 25 m

MAXIMUM OPERATING PRESSURE: 2200 psi 152 bar

MAXIMUM OPERATING VOLUME: 7.7 (US) gpm 29 l/min

MINIMUM OPERATING VOLUME: 2.5 (US) gpm 9 l/min

DRUM TORQUE AT MAXIMUM PRESSURE: 7095 lb-in 802 Nm

DRUM RPM AT MAXIMUM VOLUME: 49 rpm

LINE PULL AT MAXIMUM PRESSURE:

Bare drum 2204 lb 9.8 kN
Full drum 1633 lb 7.3 kN

LINE SPEED AT MAXIMUM VOLUME:

Bare drum 83 fpm 25 m/min
Full drum 111 fpm 34 m/min

PERMISSIBLE SYSTEM BACK PRESSURE AT

MOTOR RETURN PORT: 65 psi 4.5 bar

PERMISSIBLE PRESSURE AT
BRAKE HOUSING SAFETY VALVE: 100 psi 7 bar

LUBRICATING OIL: Refer to RECOMMENDATIONS for viscosity and instructions.

Refer to APPENDIX A for oil volume required.

315 REV.050722 PAGE 5

 PERFORMANCE GRAPHS
PG-PL2-B
LINE PULL VS. OIL PRESSURE

LINE PULL - kN
0 1.8 3.6 5.3 7.1 8.9 10.7
2200 152
2000 138

OIL PRESSURE - bar

OIL PRESSURE - psi

M
UM DRU
1500 DR RE
103
L
L BA
FU

1000 69

500 35

0 0
0 400 800 1200 1600 2000 2400
LINE PULL - lb

LINE SPEED VS. OIL VOLUME

LINE SPEED - m/min

0 3 6 9 12 15 18 21 24 27 31 34
7.7 29
7.0 26
M M
RU RU
OIL VOLUME - (US)gpm

OIL VOLUME - l/min

6.0 D D 23
RE LL
FU
BA
5.0 19

4.0 15

3.0 11

2.0 8

1.0 4

0 0
0 10 20 30 40 50 60 70 80 90 100 110
LINE SPEED - fpm

Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with 1/4
inch diameter rope.

PAGE 6 315 REV.990607

 TYPICAL HYDRAULIC CIRCUITS
HC-PL2-S1

PRESSURE 800 PSI [55 BAR]

RELIEF VALVE 2(US)GPM [8 L/MIN]
REQUIRED FOR MODELS
SUPPLIED WITH EXTERNAL
BRAKE RELEASE OPTION

HYDRAULIC WINCH CONTROL

FILTER
PUMP VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO
CENTER
RESERVOIR

1. TYPICAL HYDRAULIC CIRCUIT - STANDARD CONTROL VALVE

Refer to above hydraulic circuit for installations where the winch is controlled by an individual control
valve. Note that the valve must have a “motor spool” (both winch ports open to tank in neutral
position). A motor drain line is not required.

CONTROL VALVE STACK

WINCH CONTROL
VALVE
(MOTOR SPOOL +
POWER BEYOND)

2. TYPICAL HYDRAULIC CIRCUIT - POWER BEYOND CONTROL VALVE

Refer to above hydraulic circuit when the winch control valve is used in a circuit containing stacked
valves controlling other functions, as occurs on hydraulic cranes and loaders. The winch control
valve must have a “motor spool” and “power beyond” feature. The winch valve is shown upstream
of the stacked control valves. If the winch control valve is located downstream of the stacked control
valves, the valve stack must have the “power beyond” feature. A motor drain line is not required.

315 REV.020730 PAGE 7

 TYPICAL HYDRAULIC CIRCUITS CONTINUED

HC-PL2-S1

MOTOR DRAIN LINE

(MUST GO DIRECT
TO RESERVOIR)
CONTROL VALVE STACK

WINCH CONTROL
VALVE
(CYLINDER SPOOL)

3. TYPICAL HYDRAULIC CIRCUIT - STACKED CONTROL VALVE

Refer to above hydraulic circuit when the winch control valve is one of several stacked control
valves and has a “cylinder spool” (winch ports blocked in neutral position). In this configuration,
the safety valve must be replaced with a drain line plumbed directly to the reservoir. The drain
line cannot be connected to a common return line.

IMPORTANT: For proper function of the winch in any circuit, the return line back pressure measured
at the motor return port and the brake housing pressure measured at the safety valve
must not exceed pressures per SPECIFICATIONS.

PAGE 8 315 REV.990607

 RECOMMENDATIONS
HYDRAULIC FLUID: HYDRAULIC PRESSURE RELIEF:
The hydraulic fluid selected for use with The hydraulic circuit for the PULLMASTER
PULLMASTER planetary winches should be a planetary winch requires a pressure relief set at the
high grade, petroleum based fluid with rust, oxidation operating pressure (see SPECIFICATIONS).
and wear resistance. Fluid cleanliness and Usually, a pressure relief is part of the hydraulic
operating viscosity are critical to winch reliability, control valve. Where this is not the case, a separate
efficiency and service life. pressure relief valve must be installed and set at
the recommended maximum pressure.
For optimum performance, the recommended
viscosity range at operating temperature is 81 - 167 HYDRAULIC RESERVOIR:
SUS (16 - 36 CS). For extreme operating conditions It is recommended that the hydraulic reservoir has
of short duration, the maximum viscosity range of sufficient capacity to provide good heat dissipation
58 - 4635 SUS (10 - 1000 CS) should not be in order to prevent over-heating of the hydraulic
exceeded. fluid. The hydraulic reservoir should be made from
clean and scale-free material to prevent
The winch recommended hydraulic fluid contamination of the hydraulic fluid. In order to
temperature operating range is 80 - 150F (27 - prevent air from being mixed with the hydraulic
66C). For extreme operating conditions of short fluid, the reservoir should have an over-flow baffle
duration, the maximum temperature range of -5 - separating the return lines from the suction line and
180F (-21 - 82C) should not be exceeded. all return lines should enter the reservoir below the
fluid level. The reservoir should be mounted close
LUBRICATION: to and above the hydraulic pump in a location
The winch gear train requires oil bath lubrication. which provides for free air circulation around the
The winch is shipped from the factory without reservoir.
lubricating oil.

IMPORTANT: ADD LUBRICATING OIL UP TO THE

HYDRAULIC FILTER:
LEVEL OF THE END HOUSING OIL Consult hydraulic component manufacturer for
FILL PORT BEFORE RUNNING recommendation. Generally, 5 to 10 micron filters
WINCH. are acceptable. In order to prevent accidental
stoppage of the return line flow, the filter should
Refer to INSTALATION DIMENSIONS for location have a by-pass feature.
of lubricating oil fill port. Refer to APPENDIX A for
quantity of oil required. SAE 90 lubricating oil is HYDRAULIC HOSES:
recommended. Consult lubricating oil supplier or The following hydraulic hose with suitable fittings
factory for temperature beyond normal operating is recommended for the PULLMASTER Model PL2
range. planetary winch.

HYDRAULIC PUMP: Pressure lines: SAE 100R2-8 or better

For maximum performance of the PULLMASTER Motor drain line
planetary winch the hydraulic pump must supply (when required): SAE 100R6-4 or better
the maximum flow of hydraulic fluid at the hydraulic
pressure stated in SPECIFICATIONS. It is recommended that larger hydraulic hose be
installed where pressure lines are excessively
HYDRAULIC CONTROL VALVE: long.
The standard control valve used for operating
PULLMASTER planetary winches must have a USE OF AN E STOP:
four-way, spring return to neutral feature, which (FOR EUROPEAN MACHINERY DIRECTIVE
provides for open flow from the pressure ports of APPLICATIONS)
the winch to the reservoir in neutral position of the The use of an E stop (emergency) is mandatory in
control (motor spool). It is important to point out that the controls circuit. The E stop is to be placed in the
good speed control, especially when lowering a operator’s control panel. The E stop must be
load, depends on the “metering” characteristics of designed and placed in line with EN 60204 and EN
the control valve. The better the oil flow is “metered”, 418.
the better will be the speed control.

315 REV.030106 PAGE 9

 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
as per torque chart at back of manual.

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

5) Use recommended circuit components and hydraulic hoses.

6) When required, the winch motor drain line must be connected directly to the reservoir. Do not
connect to a common return line.

IMPORTANT: Excessive pressure at brake housing will damage the winch motor or oil seals. Never
plug safety valve port. Higher pressure inside the brake housing requires higher brake
release pressure to rotate the drum in the lowering direction.

7) Before operating the winch with a load, verify that hydraulic fluid is circulating through the brake
assembly by removing the safety valve and checking flow when the winch is run in the lowering
direction. Flow should measure 3/4 - 1 gpm (3 - 4 l/min).

NOTE: Pressure required to rotate the drum in forward direction at full speed without load may
vary up to 450 psi (31 bar).

Pressure required to rotate the drum in reverse direction at full speed may vary from
200 - 500 psi (14 - 34 bar) depending upon load and from 550 - 1075 psi (38 - 74 bar)
without load.

PAGE 10 315 REV.990607

 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 counterclockwise 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 SI1013 - PL2

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

Feed the wire rope through the cable anchor

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

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 minimum 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
systems. To prime the winch with warm oil, operate the winch at slow speed, forward and reverse,
several times.

5) 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.

315 REV.051117 PAGE 11

 TROUBLE SHOOTING
GENERAL:
In most cases, when the hydraulic winch does not perform satisfactorily, the cause for malfunction is
found somewhere in the hydraulic circuit. Before the winch is removed from its mounting and
disassembled, all of the hydraulic circuit components should be checked for proper function.

IMPORTANT:
The hydraulic oil volume relates to the line speed or rpm of the winch.
Therefore, if the winch does not produce the specified maximum rated line speed or drum rpm, a loss
of hydraulic flow somewhere in the hydraulic circuit can be analysed. If this condition exists, install
a flow meter into the hydraulic circuit to check the volume of oil supplied to the pressure port of the
hydraulic winch motor when the 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. If the pump is driven by V-belts, check for belt slippage.
The hydraulic pressure relates to the pulling capacity of the winch.
If the winch will not produce the specified maximum line pull, install a pressure gauge in 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. If the hydraulic pump is driven
by V-belts, check for belt slippage. When checking oil pressure and volume in the hydraulic circuit,
verify that the hydraulic reservoir is filled to the top level and the hydraulic pump is running at maximum
operating rpm.

Only after 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 PROBABLE CAUSE

Winch will not produce line pull at maximum a) Winch is mounted to an uneven surface.
pressure as listed in SPECIFICATIONS. (See INSTALLATION INSTRUCTIONS.)
b) Cable sheaves or block purchase operated with the
winch are not turning freely.
c) Damage or wear in the hydraulic motor.
d) The relief valve pressure may be set too low.
(See SPECIFICATIONS for maximum operating pressure.)
e) Excessive back pressure in the hydraulic circuit

Winch will not produce line speed at maximum a) Winch is mounted to an uneven surface.
volume as listed in SPECIFICATIONS. (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.

Winch will not reverse. a) Leakage out of the brake piston prevents the disc
brake from being released against the brake springs.
This is caused by damage to the O-rings on the brake
piston or connecting tube.
b) Insufficient hydraulic pressure.
(See SPECIFICATIONS for minimum operating pressure.)
c) Winch is mounted to an uneven surface.
(See INSTALLATION INSTRUCTIONS.)
d) Hydraulic pressure is not reaching the brake piston
due to plugged connecting tube.

PAGE 12 315 REV.990607

 TROUBLE SHOOTING CONTINUED

FAILURE PROBABLE CAUSE

Brake will not hold. 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 of the
hydraulic circuit 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) Over-running clutch is damaged or surface where over-
running clutch engages on motor drive shaft is worn or
indented.
g) Winch supplied with external brake release option is not
plumbed per TYPICAL HYDRAULIC CIRCUITS. Failure
to vent external brake release port to reservoir may trap
pressure and cause winch brake to slip.

Brake vibrates when lowering a load. a) Pump does not supply sufficient flow. Pump rpm must
be maintained at normal operating speed when a load
is lowered.
b) Brake is running too hot. This is caused by a complete
lack of, or insufficient, circulation flow.
c) Control valve for the winch operation has poor metering
characteristics.
d) Damaged brake plates or divider plates.
e) Over-running clutch is damaged or surface where over-
running clutch engages on motor drive shaft is worn or
indented.
f) Air has mixed with hydraulic oil resulting in foamy oil.

Oil leaks. a) Oil leaks from the motor flange are caused by a
damaged O-ring seal on the motor flange.
b) Oil leaks occurring between the cable drum flanges and
housings are caused by excessive pressure in the
brake housing. Excessive pressure in the brake
housing will damage the oil seal between the brake
housing and cable drum interior.

Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model PL2 winch.

315 REV.990607 PAGE 13

 SERVICE INSTRUCTIONS
GENERAL:
Before disassembling the PULLMASTER Model PL2 planetary winch, read and understand the following instructions.

Replace expendable parts such as O-rings and oil seals when reassembling the winch. Have a seal kit (Part No.
23111) on hand before the unit is disassembled.

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.

Disconnect all hydraulic hoses, remove the winch from its mounting and relocate to a clean working area, similar
to one used for service work on any other hydraulic component. Special tools are not required to service the winch.
Adjustments and calibrations are not required.

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

The following SERVICE INSTRUCTIONS refer to part descriptions and item numbers which appear in the group drawings.

DISASSEMBLY
REMOVAL OF HYDRAULIC MOTOR ASSEMBLY:
The motor is not user serviceable and must be replaced if not functioning properly. Contact your nearest
PULLMASTER WINCH CORPORATION distributor for a replacement. Remove the motor assembly as follows:

1) Remove two capscrews, item 935, and lockwashers, item 937. Pull the hydraulic motor, item 950, out of the
winch assembly.

2) Remove and discard O-ring, item 811.

3) Connecting tube, item 830, will either be in motor or in motor adaptor. Note and mark which brake release
port this part is from (required for reassembly) then remove. Remove motor plug, item 888, from other brake
release port. These parts must be reinstalled properly for winch brake to function correctly. Remove and discard
three O-rings, item 831.

DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:

The majority of service and repair work is done on the brake housing assembly which is accessed by removing
the hydraulic motor assembly. Disassemble brake housing assembly as follows:

1) Remove motor adaptor, item 800, by removing four capscrews, item 931, and lockwashers, item 933. Allow
brake springs, item 752, to expand safely by unscrewing capscrews one turn at a time.

2) Remove and discard O-ring, item 707.

3) Remove six brake springs, item 752. Examine springs for damage and measure overall length. Overall spring
length should be 1.25 inch. Springs measuring less then 1.19 inch should be replaced.

4) Pull the brake piston, item 750, out of the brake housing, item 700. Remove pipe plug, item 757. Verify hole
in orifice plug, item 754, is clear and unobstructed.

5) Remove and discard O-rings, items 751 and 753.

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

Winches with standard reduction ratio only:

7) Pull the primary sungear, item 440, with brake hub, item 720, sprag clutch, item 723, and clutch aligners,
items 722 and 724, from the brake housing. Proceed to step 8.

Winches with optional 'A' reduction ratio only:

7A) Design of the 'A' reduction primary sungear, item 440, prevents its removal from the motor side of the
brake housing. Disassemble brake inside the brake housing by following steps 8 through 12.

PAGE 14 315 REV.990607

 SERVICE INSTRUCTIONS CONTINUED

8) Remove circlip, item 727 and clutch aligner, item 724.

9) Remove brake hub, item 720, and sprag clutch, item 723.
10) Remove clutch aligner, item 722. Inspect both clutch aligners and replace if damaged.

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.

11) Remove three friction plates, item 716, and four divider plates, item 713, and inspect for damage
or wear. Plates should be flat and smooth. Plates should not show heat discolouration. Paper
material on friction plates should be intact and grooved. If any damage is detected, replace friction
and divider plates as a set.
12) Remove brake spacer, item 712.
Winches with standard reduction ratio only:
13) Remove thrust bearing, item 739, two thrust washers, item 737, and thrust washer, item 736.
Inspect bearing and washers and replace if damaged or worn.

14) Remove and discard oil seal, item 711, and backup washer, item 710.

DANGER
MINOR SURFACE DEFECTS WHERE THE OVER-RUNNING CLUTCH
ENGAGES THE SUNGEAR WILL RESULT IN BRAKE FAILURE AND
ALLOW THE LOAD TO DROP, CAUSING PROPERTY DAMAGE,
SEVERE INJURY OR DEATH. THOROUGHLY INSPECT
THIS AREA AND IF NECESSARY, REPLACE SUNGEAR
AND BRAKE HUB ASSEMBLY AS A SET.

15) Thoroughly inspect sungear, item 440, particularly surface where over-running clutch, item
723, engages. If any indentation or surface damage is detected, replace sungear, brake
hub and sprag clutch as a set. Proceed to DISASSEMBLY OF PRIMARY DRIVE.
Winches with optional 'A' reduction ratio only:
13A) Remove circlip, item 719. Remove thrust bearing, item 739, two thrust washers, item 737,
and thrust washer, item 736. Inspect bearing and washers and replace if damaged or worn.
To remove primary sungear, item 440. Proceed to DISASSEMBLY OF PRIMARY DRIVE.

DISASSEMBLY OF PRIMARY DRIVE:

If the primary drive requires service or repair, disassemble as follows:
1) Remove pipe plug, item 503, from cable drum, item 500, to drain lubricating oil from the winch
interior.
2) Remove eight capscrews, item 555, and lockwashers, item 553. Remove two tie bars, item 556.
Stand the winch upright on its end housing.
3) Lift the brake housing with loose needle rollers, item 701, and needle retainer, item 702, out of
the cable drum, item 500.

315 REV.990607 PAGE 15

 SERVICE INSTRUCTIONS CONTINUED

Winches with standard reduction ratio only:

4) The standard reduction primary sungear, item 440, was removed from the motor side of the brake housing.
Proceed to step 5.

Winches with optional 'A' reduction ratio only:

4A) Remove primary sungear, item 440, from the drum side of the brake housing. Refer to the warning
preceding step 15 of DISASSEMBLY OF BRAKE HOUSING ASSEMBLY and thoroughly inspect the
sungear, particularly where the over-running clutch, item 723, engages. If any indentation or surface
damage is detected, replace sungear, brake hub and sprag clutch as a set.

4B) Remove and discard oil seal, item 711, and backup washer, item 710. Proceed to step 5.

5) Remove the primary planet hub assembly from the cable drum.

6) Inspect planet hub stopper, item 402, for damage or wear and replace if less than .09 inch thick.

7) Inspect three primary planet gears, item 420, for damage or wear. If it is necessary to remove planet gears,
remove circlip, item 411, and press planet pin, item 410, out of the planet hub, item 400. Inspect needle bearing,
item 423, and two thrust washers, item 421, and replace if damaged or worn.

8) Remove final sungear, item 340, with circlip, item 341, and sungear stopper, item 344. Inspect stopper for
damage or wear. If stopper is worn to within .06 inch of the sungear face, stopper should be replaced.

9) Inspect planet hub stopper, item 704, for damage or wear and replace if less than .09 inch thick.

10) Inspect loose rollers, item 701, and needle retainer, item 702, and replace if damaged or worn.

11) Remove and discard oil seal, 515.

DISASSEMBLY OF FINAL DRIVE:

If final drive requires service or repair, disassemble as follows:

1) Remove final planet hub assembly from the cable drum.

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

Winches with optional -5 drum only:

2A) Remove coupling, item 520, from end housing spline. Proceed to step 3.

3) Remove circlip, item 109. Pull end housing, item 100, out of the cable drum ball bearing, item 507.

4) Remove circlip, item 513. Push ball bearing, item 507, out of the cable drum. Inspect and replace if damaged.

5) Remove and discard oil seal, item 505.

6) Inspect cable drum gear teeth for damage or wear.

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 by reversing the disassembly procedure.
1) Press a new, well-greased oil seal, item 505, into cable drum, item 500.
2) Press ball bearing, item 507, into cable drum and secure with circlip, item 513.
3) Press end housing, item 100, into the cable drum ball bearing, item 507. Secure with circlip, item 109.
Winches with optional -5 drum only:
3A) Replace coupling, item 520, on end housing spline. Proceed to step 4.

PAGE 16 315 REV.990607

 SERVICE INSTRUCTIONS CONTINUED

4) Reassemble final planet hub assembly. Press needle bearing, item 323, in the bore of the planet gear, item
320. Position thrust washers, item 321, on either side of the planet gear and press planet pin, item 310, into
the final planet hub, item 300. Retain with circlip, item 311.
5) Insert final planet hub assembly into the cable drum. Ensure that the planet hub spline is fully engaged.

REASSEMBLY OF PRIMARY DRIVE:

Reassemble primary drive by reversing the disassembly procedure.
1) Press a new, well-greased oil seal, item 515, into the cable drum, item 500.
2) Verify planet hub stopper, item 704, is installed on brake housing hub.
3) Verify sungear stopper, item 344, and circlip, item 341, are installed on final sungear, item 340.
4) Install final sungear into primary planet hub, item 400.
5) Reassemble primary planet hub assembly. Press needle bearing, item 423, into planet gear, item 420. Position
thrust washer, item 421, on either side of planet gear and press planet pin, item 410, into the primary planet
hub, item 400. Retain with circlip, item 411.
6) Verify planet hub stopper, item 402, is installed on planet hub.
7) Insert primary planet hub assembly into the cable drum. Ensure that the final sungear, item 340, is fully engaged
with the final planet gears, item 320.
8) Press a new, well-greased oil seal, item 711, and backup washer, item 710, into brake housing bore, item
700.
Winches with standard reduction ratio only:
9) Lower the brake housing, item 700, into the cable drum. Proceed to step 10.
Winches with optional 'A' reduction ratio only:
9A) The design of the 'A' reduction primary sungear dictates that it be installed from the drum side of the
brake housing. Carefully twist the shoulder of the sungear through the oil seal, item 711. Ensure that
the oil seal is not damaged as the sungear is installed.
9B) Install thrust bearing, item 739, with a thrust washer, item 737, on either side. Install thrust washer,
item 736, with circlip, item 719.
9C) Lower the brake housing, item 700, into the cable drum. Proceed to step 10.
10) Use eight capscrews, item 555, and lockwashers, item 553, to secure tie bars, item 556.
11) Install pipe plug, item 503, into the cable drum.

REASSEMBLY OF BRAKE HOUSING ASSEMBLY:

Reassemble brake housing assembly by reversing the disassembly procedure.
1) Verify circlip, item 719, is in place.
2) Position sprag clutch aligners, items 722 and 724, on either side of the sprag clutch, item 723, inside the
brake hub, item 720. Carefully install brake hub and sprag clutch aligners on the primary sungear, item 440.
Secure with circlip, item 727.

IMPORTANT: For proper brake function, verify that brake hub rotation is correct. When viewed from the
motor end, the primary sungear of a counterclockwise hoisting winch must turn freely
clockwise and lock in the counterclockwise direction.
Winches with standard reduction ratio only:
3) Install thrust bearing, item 739, with a thrust washer, item 737, on either side.
4) Install the primary sungear assembly, carefully twisting the shoulder of the sungear through the oil seal,
item 711. Ensure that the oil seal is not damaged as the sungear is installed. Proceed to step 5.
Winches with optional 'A' reduction ratio only:
3A) Verify that the primary sungear assembly is properly installed and retained in the brake housing. Proceed
to step 5.

315 REV.990607 PAGE 17

 SERVICE INSTRUCTIONS CONTINUED

5) Install brake spacer, item 712, into brake housing, item 700.

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.
6) Starting and finishing with divider plate, alternately install four divider plates, item 713, and three friction plates,
item 716.
7) Install pipe plug, item 757, in brake piston, item 750. Install new, well-greased O-rings, items 751 and 753,
into piston glands. Carefully install brake piston in brake housing. Rotate piston to align connecting tube hole
with corresponding hole in motor adaptor.
8) Install six brake springs, item 752.
9) Install new, well-greased O-ring, item 707, onto motor adaptor pilot, item 800.
10) Position motor adaptor with hydraulic motor mounting holes horizontal and connecting tube holes of piston
and adaptor aligned. Tighten four capscrews, item 931, and lockwashers, item 933, one turn at a time to evenly
compress springs.

REPLACEMENT OF HYDRAULIC MOTOR ASSEMBLY:

Replace the hydraulic motor assembly by reversing the removal procedure.

IMPORTANT: Before installing motor, determine brake code of winch. Install motor plug as indicated below.
(May not be exactly as illustrated) SI-1029
MOTOR PLUG
WITH O-RING

888 831

NOTE: Insert motor plug, O-ring end,

into Port A or B as per BRAKE RELEASE BRAKE RELEASE
Brake Code chart below.
PORT ’A’ PORT ’B’
BRAKE CODE PLUG PORT
-12 or -13 B 950
-14 or -15 A
SHAFT SIDE OF MOTOR

1) Install three new, well-greased O-rings, item 831; two onto connecting tube, item 830, and one onto motor
plug, item 888. Install connecting tube and motor plug into motor, item 950. Verify that holes are same as
parts were removed from.
2) Install new, well-greased O-ring, item 811, onto motor pilot, item 950.
3) Fasten motor to motor adaptor using two capscrews, item 935, and lockwashers, item 937.

IMPORTANT: Before operating the winch, add lubricating oil up to the level of the end housing oil fill port.
(Refer to INSTALLATION INSTRUCTIONS for location of fill port. Refer to APPENDIX A for
oil volume required.) To ensure proper reassembly, run the winch in both directions without load.

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”.

PAGE 18 315 REV.990607

 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 PL2 planetary winch, always quote the complete
model number, serial number and specification (spec) number (if applicable) of the unit.

MODEL # ________________________

SERIAL # ________________________

SPEC # ________________________

SI1030

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.

315 REV.990607 PAGE 19

 FOR SAFETY: OPTIONAL
A MINIMUM OF 5 WRAPS OF
EXTERNAL BRAKE
WIRE ROPE MUST BE MAINTAINED
RELEASE PORT
AT ALL TIMES !

PAGE 20
1/8-27 NPT PRESSURIZE COUNTER CLOCKWISE
4.604 PRESSURIZE
C FOR COUNTER FOR CLOCKWISE
[117] CLOCKWISE ROTATION
FILL + DRAIN ROTATION 10.5
PORT 3/8-18 NPT
[267]

FILL + DRAIN SAFETY VALVE

PORT 1/2-14 NPT

9.2
[233]
9.0 6.1
[229] [156]

4.7 L
[119]

4 MOUNTING HOLES
1.2 .41 [10.3] DIA 2.1
[32] USE 3/8 BOLTS [54] .38
GRADE 5 OR BETTER [9.5]
.9 7.560 c/c
H c/c
[24] [192.0]
J I
9.3
STANDARD CABLE ANCHOR IS [235]
SUITABLE FOR 1/4 - 3/8" OUTLET PORT
DIA WIRE ROPE 1 1/16-12UN-2B THD.
SAE O-RING BOSS
INSTALLATION DIMENSIONS

315
MOTOR DRUM
C H I J L UNITS MOTOR MODEL
CODE CODE
5.3 6.688 6.1 11.3 6.1 in.
-218 -1 -218 PARKER 33CC
133 169.88 155 286 155 mm
5.3 6.688 5.2 11.3 6.2 in.
-1 133 169.88 131 286 157 mm REXROTH
-221 10.8 12.250 5.2 16.8 6.2 in. 9 511 290 041
-5 275 311.15 131 427 157 mm

REV.061026
I1121-C
 ASSEMBLY DRAWING
G1285 & G1146

315 REV.050722 PAGE 21

 PARTS REFERENCE - DRUM GROUP
ITEM NO. QTY. PART NO.** DESCRIPTION

100 1 20701 END HOUSING

101 1 25032 PIPE PLUG 1/2 - 14 NPT
109 1 25012 CIRCLIP ROTOR CLIP SH-275
300 1 20703 PLANET HUB
310 3 20080 PLANET PIN
311 3 25060 CIRCLIP ROTOR CLIP C-62
313 3 25119 CIRCLIP ROTOR CLIP SH-62
320 3 20708 PLANET GEAR
321 6 25064 THRUST WASHER TORRINGTON # TRA 1018
323 3 25269 NEEDLE BEARING TORRINGTON #BH1016
340 1 20709 SUNGEAR
341 1 25527 CIRCLIP ANDERTON # A1000 - 0125
344 1 20713 SUNGEAR STOPPER
400 1 * PLANET HUB
402 1 20712 PLANET HUB STOPPER
410 3 20710 PLANET PIN
411 3 25525 CIRCLIP ROTOR CLIP SH-50
413 3 25525 CIRCLIP ROTOR CLIP SH-50
420 3 * PLANET GEAR
421 6 25524 THRUST WASHER TORRINGTON # TRA 815
423 3 25523 NEEDLE BEARING TORRINGTON # B88
500 1 * CABLE DRUM
502 1 * CABLE ANCHOR
503 1 25085 PIPE PLUG 3/8 - 18 NPT * These parts vary.
505 1 25008 OIL SEAL Refer to APPENDIX B.
507 1 25007 BALL BEARING # 6014 * * Effective Serial # 46684.
511 2 * SET SCREW 5/16 - 18 NC X .43
513 1 25006 CIRCLIP ROTOR CLIP HO-433
515 1 25151 OIL SEAL
520 1 * COUPLING
553 8 25037 LOCKWASHER 3/8"
555 8 25264 CAPSCREW HEX HEAD 3/8 - 16NC X 1.00 GRADE 5
556 2 * TIE BAR

PAGE 22 315 REV.990607

 DRUM GROUP
G1146
Design Revision 'B' - Effective from Serial # 46684

502 513 321 323 320 310 503 313 411 511
NOTE: Items 511 and 520 used only
in winches with - 5 drum.

507 421

505 413 520

311 410

101 423

100 420

555 344

553 515
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 LIST should be ignored.
556 109 300 340 402 341 500 400
Refer to PAGE 21 for ASSEMBLY DRAWING and PAGE 25 for
winch seal kit.

315 PAGE 23
 BRAKE GROUP
G1285
Design Revision Effective from Serial # 76061

724 712 716 759 754 757 708 709 831 830 840

702

720 931

722 933

737 950

704 937

935
710
955
719

440

711

739

736

723

727

700 701 713 750 751 752 753 707 800 811 888 831 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.
Refer to PAGE 21 for ASSEMBLY DRAWING and PAGE 25 for winch seal kit.

PAGE 24 315 REV.050722

 PARTS REFERENCE - BRAKE GROUP
ITEM NO. QTY. PART NO. ** DESCRIPTION
440 1 **** SUNGEAR
700 1 * BRAKE HOUSING (INCLUDES ITEMS 701 AND 702)
701 106 25270 LOOSE ROLLER 5/32 X 1.25 TOR. #E151-Q (INCLUDED IN ITEM 700)
702 1 20717 NEEDLE RETAINER (INCLUDED IN ITEM 700)
704 1 20712 PLANET HUB STOPPER
707 1 25275 O-RING -048 4 3/4" ID 1/16" CS
708 1 * CHECK VALVE
709 1 * PLASTIC CAPLUG 1/8 NPT
710 1 20714 BACK UP WASHER FOR OIL SEAL #25278
711 1 25278 *** OIL SEAL
712 1 20107 BRAKE SPACER
* These parts vary.
713 4 25024 DIVIDER PLATE
Refer to BRAKE CODE CHART.
716 3 20034 FRICTION PLATE ** Effective Serial # 46684.
719 1 25492 CIRCLIP ROTOR CLIP SH-106 *** Do not substitute.
720 1 22881 BRAKE HUB Available from PULLMASTER
722 1 20183 SPRAG CLUTCH ALIGNER or Authorized Dealer only.
723 1 25187 SPRAG CLUTCH **** Refer to APPENDIX B.
724 1 20183 SPRAG CLUTCH ALIGNER
727 1 25492 CIRCLIP ROTOR CLIP SH-106
736 1 26310 THRUST WASHER TORRINGTON # TRA 1828
737 2 25483 THRUST WASHER INA # AS 3047
739 1 25537 THRUST BEARING INA # AXK 3047
750 1 * PISTON ASSEMBLY (INCLUDES ITEMS: 754, 757 AND 759)
751 1 25528 O-RING -245 4 3/8" ID 1/8" CS, 90 DURO
752 6 20340 BRAKE SPRING
753 1 25261 O-RING -246 4 1/2" ID 1/8" CS, 90 DURO
754 1 20732 ORIFICE PLUG
757 1 25040 PIPE PLUG 1/8 - 27 NPT
759 1 * STEEL BALL 5/32 DIA
800 1 21079 MOTOR ADAPTOR
811 1 25016 O-RING -042 3 1/4" ID 1/16" CS
830 1 20519 CONNECTING TUBE
831 3 25018 O-RING -010 1/4" ID 1/16" CS
840 1 20870 SAFETY VALVE
888 1 22962 MOTOR PLUG
931 4 25264 CAPSCREW - HEX HEAD 3/8 - 16 NC X 1.00 GRADE 5
933 4 25037 LOCKWASHER 3/8"
935 2 25264 CAPSCREW - HEX HEAD 3/8 - 16 NC X 1.00 GRADE 5
937 2 25037 LOCKWASHER 3/8"
950 1 26829 *** MOTOR
955 2 25536 PLASTIC CAPLUG 1.0625" -12 THREADED

23111 WINCH SEAL KIT, CONSISTS OF ITEMS:

505, 515, 707, 710, 711, 751, 753, 811 AND 831.

BRAKE CODE CHART BRAKE CODE

-12 -13 -14 -15
ITEM
NO. PART DESCRIPTION
PART NUMBERS
708 CHECK VALVE N/A 21530 21530 N/A
709 1/8 NPT CAPLUG N/A 25374 25374 N/A
750 PISTON ASSEMBLY 21571 21531 21531 21571
759 5/32 DIA STEEL BALL N/A 25533 25533 N/A

REDUCTION RATIO
700 BRAKE HOUSING STANDARD 22464 22467 22467 22464
700 BRAKE HOUSING 'A' 22469 22470 22470 22469

315 REV.050722 PAGE 25

 APPENDIX A

LINE PULL LINE SPEED

LUBRICATING
CABLE DRUM SIZES WIRE ROPE STORAGE AT MAXIMUM AT MAXIMUM OIL
INCHES FEET PRESSURE* VOLUME* VOLUME
DRUM REQUIRED
(MILLIMETERS) (METERS) POUNDS FEET/MINUTE
CODE U.S.
(KILONEWTONS) (METERS/MINUTE)
GALLONS
(LITERS)
BARE FULL BARE FULL
BARREL FLANGE LENGTH 3/8 INCH 5/16 INCH 1/4 INCH DRUM DRUM DRUM DRUM

STANDARD REDUCTION RATIO

-1 6.13 9.0 5.25 84 122 172 2204 1633 83 111 .13
(156) (229) (133) (25) (37) (52) (9.8) (7.3) (25) (34) (.5)
-5 6.13 9.0 10.81 172 251 354 2204 1633 83 111 .27
(156) (229) (275) (53) (76) (108) (9.8) (7.3) (25) (34) (1.0)

'A' REDUCTION RATIO

-1 6.13 9.0 5.25 84 122 172 1285 952 142 189 .13
(156) (229) (133) (25) (37) (52) (5.7) (4.2) (43) (58) (.5)
-5 6.13 9.0 10.81 172 251 354 1285 952 142 189 .27
(156) (229) (275) (53) (76) (108) (5.7) (4.2) (43) (58) (1.0)

* Performance specifications are based on standard hydraulic motor with 1/4 inch diameter wire rope.

PAGE 26 315 REV.061026

 APPENDIX B

ITEM NUMBERS

400 420 440 500 502 511 520 556

PART DESCRIPTION
PRIMARY
CABLE CABLE SET COUPLING
PLANET PLANET SUNGEAR TIE BAR
HUB GEAR DRUM ANCHOR SCREW

DRUM STANDARD REDUCTION RATIO

CODE
PART NUMBERS

-1 20705 20707 22896 21830 21882 - - 20706

-5 20705 20707 22896 22227 - 25526 21620 21621

DRUM 'A' REDUCTION RATIO

CODE
PART NUMBERS

-1 20912 20911 22912 21830 21882 - - 20706

-5 20912 20911 22912 22227 - 25526 21620 21621

315 REV.990607 PAGE 27

 BOLT TORQUE CHART

BOLT DIAMETER TORQUE TORQUE

Inches Lb-Ft Nm

1/4 9 12
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
1 640 868
1 1/8 800 1085
1 1/4 1000 1356

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

PAGE 28 315 REV.990607

 The Three Basic
Types of
PULLMASTER
Planetary
Winches
EQUAL SPEED IN
BOTH DIRECTIONS
PL and M Series
Seven basic models provide for line
RAPID pull capacities from 1,102 lb (500 kp)
to 50,000 lb (22,680 kp). With the
REVERSE available options PULLMASTER
H and HL Series planetary winches can be adapted
For winch operations where a for a wide range of applications
load has to be lowered at high and for special operational
speed and with complete control requirements.
the PULLMASTER planetary
winches in the 'H' series offer
reversing speeds approximately
4.5 times faster than forward
speed. Models in the series are available in line pull
capacities from 8,500 lb (3,856 kp) to 50,000 lb
(22,680 kp).

RECOVERY
R Series
The 'R' Series PULLMASTER recovery winches
are of the same design concept as PULLMASTER
hoisting winches. Freespooling is a standard fea-
ture of this model and is offered with a manually
actuated clutch or is suitable for
hydraulic remote control.

Service for PULLMASTER planetary winches can be obtained through a world wide network of
PULLMASTER distributors. For the distributor nearest to you contact the factory.
Use only authentic PULLMASTER replacement parts in the repair of a PULLMASTER Planetary winch.
Purchased items such as bearings, seals, O-rings, etc., can be supplied from the factory.
However, a cross reference list for such parts is shown in the PARTS REFERENCE of this manual.
When in doubt about proper function, installation or repair of a PULLMASTER planetary winch please
contact your nearest PULLMASTER Distributor or the factory.

PULLMASTER WINCH CORPORATION

8247 - 130TH STREET, SURREY, B.C. CANADA V3W 7X4
TELEPHONE: 604-594-4444 FAX: 604-591-7332
E-MAIL: [email protected] WEBSITE: www.pullmaster.com
PMC 315 REV.070228
PRINTED IN CANADA