Dover Pull MASTER R5-12-70-1F, Instructions And Parts Manual

Page 1: ...THE LOGICAL CHOICE READTHISMANUALBEFOREINSTALLING OPERATINGORSERVICING THISPRODUCT THISMANUALCONTAINSIMPORTANTINFORMATION MAKE THIS MANUAL AVAILABLE TO ALL PERSONS RESPONSIBLE FORTHEOPERATION INSTALLA...

Page 2: ...er 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 damag...

Page 3: ...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...

Page 4: ...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 platesandslowsthedrum Inthisway acompletelysmo...

Page 5: ...Thefreespoolfunctioncannotbeengagedordisengagedunderloadorwhilethe cable drum is rotating MODEL R5 12 70 1F This model has a hydraulically actuated freespool feature The final sungear is pulled out o...

Page 6: ...low speed hydraulic motor 12 9 cubic inch displacement Otherdisplacementsareoptional DRUM SIZE 1 5 0 inch drum diameter X 11 3 8 inch flange diameter X 9 inch between flanges STANDARD For other drum s...

Page 7: ...ENDIX A for optional cable drum sizes and specifications OPTIONAL HYDRAULIC GEAR MOTOR TheperformanceofthestandardPULLMASTERModelR5planetarywinchisbasedonaNICHOLSSeries110IGR hydraulic motor with a di...

Page 8: ...in 732 ft 223 m 5 16 in 481 ft 147 m 3 8 in 337 ft 103 m 7 16 in 268 ft 82 m 1 2 in 209 ft 64 m 9 16 in 160 ft 49 m MAXIMUM OPERATING PRESSURE 2350 psi 162bar MAXIMUM OPERATING VOLUME 15 US gpm 57 l...

Page 9: ...1 2 inch diameter wirerope 2000 2500 1500 1000 500 0 15 12 9 6 3 0 11020 8816 6612 4408 2204 0 0 1000 2000 3000 4000 5000 176 141 105 70 35 0 LINE PULL lb kg OIL PRESSURE PSI OIL PRESSURE kg cm 2 16 0...

Page 10: ...PAGE 8 TYPICAL HYDRAULIC CIRCUIT R5 M HC R5 M C 172REV 030429 PRESSURE RELIEF VALVE CONTROL VALVE MOTOR SPOOL 4 WAY SPRING RETURN TO CENTER RESERVOIR HYDRAULIC PUMP FILTER...

Page 11: ...2REV 030429 TYPICAL HYDRAULIC CIRCUIT R5 F HC R5 F C PRESSURE RELIEF VALVE RESERVOIR HYDRAULIC PUMP FILTER 400 PSI 28 BAR PRESSURE REQUIRED FOR FREESPOOL CONTROL VALVE MOTOR SPOOL 4 WAY SPRING RETURN...

Page 12: ...the control valve The better the oil flow is metered the better will be the speed control HYDRAULIC PRESSURE RELIEF The hydraulic circuit for the PULLMASTER planetary winch requires a pressure relief...

Page 13: ...surface For mounting bolt size and grade see INSTALLATION DRAWING b Measurethespaceunderneaththefourthmountingpadwithafeelergaugeanduseshimstockofequivalent thickness in the space between the mounting...

Page 14: ...speed forward and reverse several times 5 Prevent corrosion damage to winch interior If not used regularly run winch up and down at least once every two weeks 6 To ensure proper winch installation an...

Page 15: ...the relief valve and the control valve Whencheckingoilpressureofoilvolumeanywhereinthehydraulicsystem makecertainthatthehydraulic pump is running at maximum operating rpm Installations using a belt dr...

Page 16: ...ed when a load is lowered b Brakeisrunningtoohot Thisiscausedbyacompletelack of or insufficient circulation flow To check circulation flow removesafetyvalvefrommotoradaptor Whenwinch isreversed oilflo...

Page 17: ...LY 1 Remove two capscrews item 815 and lockwashers item 817 Pull the hydraulic motor item 850 out of the winch assembly 2 Remove and discard O ring item 811 3 Remove connecting tube item 830 Remove an...

Page 18: ...g clutch and brake shaft as a set 11 Removethe14dividerplatesitem713 togetherwith13brakeplatesitem715 andinspectfordamageorwear Platesshouldnotshowheatdiscoloration Papermaterialonfrictionplatesshould...

Page 19: ...spect journal bearing item 286 for excessive wear and replace if necessary 5 Remove and discard oil seal item 515 6 Inspect spherical roller bearing item 507 and replace if damaged 7 Turn winch over t...

Page 20: ...88 and pull the final sungear item 340 together with the follower and ball bearing item 291 out of the freespool housing 6 Removecirclipitem295 fromtheinsideofthefollowerandpulltheballbearing together...

Page 21: ...r side of final drive housing 3 Press final housing item 100 onto hub of cable drum item 500 and fasten with circlip item 513 4 Turn winch over so it stands on final housing end Press spherical roller...

Page 22: ...item 821 and lockwashers item 823 one turn at a time to evenly compress springs REPLACE HYDRAULIC MOTOR ASSEMBLY 1 Install new O rings item 831 on each end of the connecting tube item 830 and apply g...

Page 23: ...Refer to APPENDIX A for oil volume required To ensure proper reassembly run the winch in both directions without load PULLING A LOAD WITH A NEWLY SERVICED WINCH WILL ENABLE AN INSTALLATION OR SERVICE...

Page 24: ...remove the winch from its mounting 2 Disassemble the winch as per instructions 3 Discard and replace all O rings and oil seals 4 Inspect all parts for wear and replace if necessary 5 Clean all parts a...

Page 25: ...8 14 SAE O RING BOSS 57 2 3 16 6 175 6 9 250 8 9 875 337 13 3 9 3 211 298 46 11 750 c c 5 8 148 R5 F 6 3 159 R5 M 4 MOUNTING HOLES 78 20 DIA USE 3 4 BOLTS GRADE 5 OR BETTER PRESSURIZE FOR COUNTER CLOC...

Page 26: ...CIRCLIP ANDERTON N1400 0078 272 2 20968 INDEXPIN 276 2 20488 DETENTSPRING 278 3 25383 SLOTTED SPRING PIN 5 32 X 5 8 LONG 284 2 21075 SPRINGSEAT 288 1 25378 CIRCLIP ANDERTON N1300 0231 291 1 25172 BALL...

Page 27: ...assembly Parts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored FREESPOOL GROUP HYDRAULIC RELEASE 503 255 252 257 299 295 502 103 300 291 268 250 123 124 12...

Page 28: ...25379 SLOTTED SPRING PIN 5 32 X 1 LONG 264 1 20894 FREESPOOLPISTON 265 1 25628 O RING 235 3 1 8 ID 1 8 CS 267 1 25179 CIRCLIP ANDERTON N1300 0165 269 1 25175 CIRCLIP ANDERTON N1400 0078 277 1 25477 O...

Page 29: ...in a specific assembly Parts that are referenced on the drawing but are not on the PARTS REFERENCE list should be ignored FREESPOOL GROUP HYDRAULIC RELEASE 503 502 513 300 100 267 264 126 124 121 250...

Page 30: ...629 O RING 90 DURO 253 5 3 8 ID 1 8 CS 752 8 20859 BRAKESPRING 753 1 25630 O RING 90 DURO 256 5 3 4 ID 1 8 CS 755 1 25370 PIPEPLUG1 16NPTSOCKETHEAD 800 1 MOTORADAPTOR 811 1 26624 O RING 100 MM ID x 2...

Page 31: ...nced on the drawing but are not on the PARTS REFERENCE list should be ignored NOTE PRIOR TO SERIAL 38771 For Item No 615 use TORRINGTON THRUST WASHER FTA 4060 PART NO 25668 QTY 2 715 970 973 850 955 8...

Page 32: ...PAGE 30 172REV 950101 ASSEMBLY DRAWING R5 M G1131 G1137...

Page 33: ...PAGE 31 172REV 950101 ASSEMBLY DRAWING R5 F G1131 G1136...

Page 34: ...NUTE LINE PULL AT MAXIMUM PRESSURE BARE FULL BARE FULL 5 8 in 9 16 in 1 2 in BARREL FLANGE LENGTH 5 0 11 4 9 0 119 160 209 11020 5573 37 74 5 127 289 229 36 49 63 49 0 24 8 11 23 1 9 7 5 11 4 9 0 86 9...

Page 35: ...PAGE 33 172REV 950101 APPENDIX B IITEM 800 850 BRAKE CODE MOTORADAPTOR MOTOR 12 20876 20906 15 21403 21508...

Page 36: ...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 1 3 8 1200 1627 1 1 2 1500 2034 BOLT DIAMETER Inches TORQUE lb ft TORQUE Nm NOTE Unless...