r 15 hydraulic pummpp hoist - beeman equipment sales · 2019. 4. 18. · achine exam ccupational s...
TRANSCRIPT
R
R1P5
PUM
Inst
Hun
HYMP
tructi
nke Man
Sny
YDP H
ion M
nufactur
yder, NE
RAOIS
Manu
ring LL
E
AULST
ual
LC
LIC
C
1
CONTENTS
Introduction .................................................................................... 2 Safety Information ......................................................................... 2 Inspection & Maintenance ............................................................. 5 Lubrication ..................................................................................... 6 Operation Instructions .................................................................... 9 Load Capacity ................................................................................ 10 Cable Reeving Mainline ................................................................ 14 Cable Reeving Sandline ................................................................. 15 Repair Procedures .......................................................................... 16 Brake Repair .................................................................................. 17 Hydraulic Diagrams ....................................................................... 19 Pump Flow & Spline Grease.......................................................... 24 Pump Seal Replacement ................................................................ 25 Oil Cooler & Filter Parts ................................................................ 26 OPTIONAL FEATURES INSTRUCTIONS AND SAFETY WARNINGS Wire Rope Information & Other Documentation
Fill in the following cable information for reference:
Mast Length:
Main Cable: Socket:
Sandline Cable: _______ Socket: Tailout Cable: Socket:
The materpump hoibe inform If a part mdistributothe ownerbenefit frofailure to We wish y
This manthroughopump hoiare availa
Thimportanor death. The manuwarn agaiprotect yo
WOperatorsnear overh Overheadinsulatedcharged pimperativaccording TDepartme
HU
rial covered inst and to redu
med of correct
malfunctions wr from whomr/operator. Thom the manufprovide reaso
you the best o
nual containsout the manuist. This maable at no co
his symbol isnce. Failure t
ufacturer canninst. You, theourself and th
WARNING! s, crew membhead power li
d power lines pd against elecpower line, thee that the ope
gly. The National Ient of Health a
UNKE R
n this manualuce the risk ofand safe proc
within the wam the machine
he malfunctiofacturer’s waronable and ne
of success and
HU610 W. 4
PHON
SA
s important iual. All operanual should st.
used througto follow all
not possibly ime owner, operose around yo
bers, and bystaines.
present a greatrical conduce charge will erator of the m
Institute for Oand Human S
R15 HYD
INTRO
l is intended tf pump, well ocedures when
arranty periodwas purchase
oning part murranty. The wecessary main
d satisfaction
UNKE MA4TH St. P.O. NE: 402-568-2
E-mail: salWebsite: w
AFETY I
information tators must rebe kept with
ghout the maof the inform
magine all therator or membou from injur
anders may b
at hazard to thctivity. If ancarry to all p
machine exam
Occupational SServices, in its
2
DRAULIC
ODUCTIO
to aid in the oor equipment
n operating th
d contact Hunked. Hunke M
ust be returnedwarranty doesntenance while
with our pro
ANUFACTBox 128 Sn
2221 FAX: les@hunkem
www.hunkem
NFORM
that can saveead the entir
h the pump h
anual to indicmation contai
e different pober of the worry or death.
e electrocuted
he well servicy part of the Harts of the ma
mines the work
Safety and Hes May 1995 A
C PUMP
ON
operation and t damage. It ie Hunke pum
ke ManufactuManufacturing
d to Hunke Ms not apply to e in the posse
duct.
TURINGnyder, NE 68 402-568-222
mfg.com mfg.com
MATION
e a life. Safere manual behoist truck at
cate safety inined in this m
ossibilities andrk crew, must
d when the pu
ce worker. ThHunke machiachine and to k area for pow
ealth (NIOSHAlert recomm
HOIST
maintenanceis important t
mp hoist.
uring. Do notg will send theManufacturing
unreasonableession of the p
8664 23
ty warnings efore operatint all times. A
nformation omanual could
d situations tht use every sa
ump hoist is b
he Hunke pumine comes in canything tou
wer lines and
H), a division mends that emp
e of the R15 Hthat all operat
t contact the e part directlyg in order to e use, includinpurchaser.
are includedng the Hunk
Additional cop
f especially hd result in in
hat can occur afety precautio
being operate
mp hoist is nocontact with a
uching it. It isprepares
of the U.S. ployers take t
Hunke tors
y to
ng
d ke pies
high njury
to on to
ed
ot a s
the
followingenergized
“CTenan Ean DUlinmAki10 Wpelim Dfo Ncotrboanmpren CP
W The only and the righave to mappears frtake the ri Hunke puvisual andobstructio
g measures to d overhead po
Comply with These regulationergized untilnd they have
Employers shand its load by
De-energize anUse insulated b
nes are not demaintained as At least 10 fee
ilovolt above 0 feet)
Where it is diferson to obsemits of safe c
Do not use cagor de-energizi
NIOSH also reontrol the hazrained in safe oom guards, ind to recogniz
maintaining saroper techniqnergy.”
Copies of the NPublication No
WARNING! T
safe power ling may shift, d
make contact wrom ground leisk. If power
ump hoists havd audible warnons that could
protect workewer lines:
OSHA Reguons require wl the owner ofbeen visibly g
all ensure thaty implementin
nd visibly grobarriers that ae-energized, ofollows: t for lines rate50 kilovolts;
fficult for the rve the cleara
clearance.
ge-type booming and groun
ecommends thzards of boomoperating proinsulated linkze that these d
afe clearance. ques when res
NIOSH Alert o. 95-108
This rig and
ne is a de-enedecreasing thewith the poweevel to be suflines are in th
ve a buzzer anning to check
d create a safe
ers and opera
ulations. Trainworkers and em
f the lines or grounded.
t overhead pong one or mor
ound electricaare not a part operate rigs in
ed 50 kilovol or maintain t
operator to mance and to gi
m guards, insulnding lines or
hat employersm contact withocedures and ks, ground roddevices are no Workers shocuing cowork
can be obtain
its componen
ergized powere distance beter line in ordefficient clearanhe work area,
nd a red lightk the work areety hazard.
3
ators of cranes
n workers to cmployers to cthe electric ut
ower lines are re of the follo
al distributionof the rig to pn the area ON
lts or below. twice the leng
maintain safe cive immediate
lating links, or maintaining
s develop safeh overhead potrained to und
ds, nonconducot substitutes ould also be trkers or recove
ned by calling
nts are not in
r line. Be awtween the power to deliver a nce may actu, contact the p
t that are activea again for o
s and other bo
comply with consider all ovutility indicate
de-energizedowing:
n and transmisprevent conta
NLY if a safe
At least 10 fegth of the line
clearance by ve warning wh
or proximity wsafe clearanc
fety programs ower lines. Wderstand the lctive links, an for de-energrained to recoering equipme
g 1-800-356-4
nsulated aga
ware that windwer line and tdeadly charg
ually be muchpower compa
vated when thoverhead pow
oomed vehicl
current OSHAverhead powees that they ar
d or separated
ssion lines at act with the linminimum cle
eet plus 0.4 ine insulator. (b
visual means,hen the boom
warning devicce.
to help workWorkers shoullimitations ofnd proximity izing and groognize the hazent in contact
4674 and requ
ainst electrica
d can cause pothe boom. Thge of electricith closer than pany for assista
he boom is raiwer lines, trees
les from conta
A regulationser lines to be re not energiz
d from the boo
the point of wnes. If the poearance is
nches for eachbut never less
, designate a approaches t
ces as a subst
kers recognizeld be specificaf such deviceswarning devi
ounding lines zards and uset with electric
uesting
al shock.
ower lines to he boom doesty. Also, wha
perceived. Doance.
ised. This is s and other
acting
s.
zed,
om
work. ower
h than
the
titute
e and ally s as ices; or
e cal
sway not at on’t
a
SAWARNINobject raisnear the w WARNINobstructiocause serithe vehicl
Your Hundecals, as cost from
AFETY WARNG! Do not ssed overhead
work area.
NG! Never mons in the pathious injury or le.
Diesel eCalif
nke pump hoishown belowHunke Manu
RNINGS! set the boom ucan fall and p
move the pumh of the boomdeath. Alwa
Cengine exhausfornia to caus
Ple Always start If in an e Do not
st is equippedw. If any of thufacturing.
up into trees present a dan
mp hoist with tm and there is ays put the bo
California Prst and some ose cancer, birt
ease note this t and operate enclosed areat modify or ta
d with a load hese items are
4
or any other oger to those in
the boom raisdanger that thom in the hor
roposition 65 of its constitueth defects, and
warning and the engine in, vent the exh
amper with th
rating plate, oe missing or a
overhead obsn the work ar
sed! There mhe truck can trizontal, road
Warning ents are knowd other reprod
remember –n a well-ventilhaust to the ouhe exhaust sys
operational deare not readab
tructions. Berea. Always
may be power tip over. Eith
d ready positio
wn to the Stateductive harm
lated area. utside. stem.
ecals and safeble they can b
e aware that awear a hard h
lines or otherher situation con before mov
e of m.
ety warning be replaced at
any hat
r can ving
t no
The followoperating
The follow
1. Tansy
2. A
wco
3. C
su
SAinside tow
4. A
5. Tofhoav
SAfunctionin
6. Tw
SA The follow
1. Tbepius
SAto drop.
INSPE
wing inspectiefficiently an
wing items m
The hydraulicnd return hoseystem or sharp
All operation with proper opomponents an
Check the masufficient tensi
AFETY WARwer will drop
All safety dev
The hoist hookf 15% or morook must alwvailable from
AFETY WARng.
The operator swear or damag
AFETY WAR
wing items m
The main drue replaced whinion gear. Tsed. The gea
AFETY WAR
ECTION
on and maintnd trouble fre
INS
must be inspe
c system shoues do not intep objects on t
control mechperation. The nd contaminat
st extension lion to comple
RNING! If thresulting in p
ices should b
ks should be re, or more th
ways have a prm Hunke Manu
RNING! Do
hould be consge. The clamp
RNING! Do
must be inspe
m gears shouhen any narro
The rate of wers will wear c
RNING! Fail
N, MAINT
tenance procee.
SPECTIO
ected daily:
uld be inspecterfere with thethe deck or tru
hanisms shoucontrol mech
tion by lubric
latch for weaetely engage l
he latch is allopossible pump
e inspected fo
inspected for an 10 degreesroperly operatufacturing. De
not operate th
stantly awareps and socket
not operate th
ected monthl
uld be inspectowing of the teear on the geaconsiderably f
lure of the pin
5
TENANC
edures should
ON PROCE
ted for deterioe drive line oruck frame.
uld be inspecthanisms also ncants or other
ar or damage. latch.
owed to becomp damage and
or any malfun
cracks or defs twist from thting safety latesignate hook
he machine w
e of the conditts also need to
he machine if
ly:
ted for wear, eeth is percep
ars is relative tfaster in areas
nion gear caus
CE & OP
be followed
EDURES
oration or leakr come into co
ted for misadjneed to be insforeign matte
The latching
me unhookedd/or operator i
nction.
formation (anthe plane of thtch. Replacemk size when o
with a hook sa
tion of all wiro be inspected
f the cable is d
cracked or chptible. The wto the conditis where blow
sed by sheare
PERATIO
to keep your
kage. Be sureontact with th
djustment whispected for exer.
g spring shou
d when hoistininjury.
n increase in the unbent hooment safety la
ordering.
afety latch tha
re rope, lookd for wear or
damaged in a
hipped teeth. wear will normions in which
wing sand and
ed teeth will c
ON
Hunke pump
e that the preshe truck exhau
ich would intexcessive wear
uld provide
ng a load, the
the throat opeok). The hoisatches are
at is not prope
king for any sidamage.
any way.
The gears shmally show onh the hoist is b
dust are com
cause hoisted
p hoist
ssure ust
erfere r of
e
ening st
erly
ign of
hould n the being
mmon.
load
6
2. The pivot pins at the base of the mast and at both ends of the hydraulic cylinders should be inspected for excessive wear or cracks.
The holes at these points should be reamed if they become oblong from excessive wear. If reaming the holes is necessary, the pins must be replaced with larger diameter pins. Material for replacement pins must be cold drawn C1020 steel, or stronger. Standard size replacement pins and bushings are available from Hunke Manufacturing. Oversized pins to fit reamed holes are also available. When ordering special pins the exact size and identification must to be specified.
3. The complete pump hoist must be inspected for structural failure which includes weld failures, metal stress and rust deterioration.
If problems have occurred, contact Hunke Manufacturing for proper repair procedures. HYDRAULIC SYSTEM MAINTENANCE The hydraulic oil will normally last four to five years if the oil filter is changed regularly. The oil level in the reservoir should be kept within 4” from the top of the reservoir. The oil level should be checked with the mast and the downriggers in road ready position. The oil filter should be replaced every 12 months and when the hydraulic oil is changed. 10W-20 universal custom tractor hydraulic oil is recommended in the hydraulic system. Hydraulic motors and pumps are built to extremely close tolerances. Foreign matter in the hydraulic oil will damage these parts. Therefore, extreme care should be used in changing or adding hydraulic oil.
Replacement oil filter element numbers: Large filter: Gresen #K23013 or Napa #1506. Small filter: Gresen #K22001 or Napa #1551.
LUBRICATION Proper lubrication is the most beneficial preventive maintenance procedure. The following lubrication guidelines are specified for normal operating conditions. In areas where the pump hoist is operated in dusty or sandy environments the servicing interval should be shortened to accommodate such conditions. GREASE POINTS Every 10 Hours of Operation: Apply 3 pumps from a standard grease gun to the two main winch bushings and to all the sheaves using good quality grease. Apply grease to the main winch drive gears. Every 15 Hours of Operation: If the main hydraulic pump is driven by a drive shaft, grease the universal joints on the pump drive shaft. Apply grease to u-joints slowly to prevent seal damage. Allow grease to squeeze out of the seals which will clear the road grit from the bearings. Apply grease to the slip joint on the pump drive shaft until grease comes out the end. Every 30 Hours of Operation: Grease all pivot points with a standard grease gun. Every 12 Months: Apply 2 to 3 pumps from a standard grease gun to all ball bearings while shafts are being rotated. Apply grease slowly to avoid pushing out the seal. IMPORTANT! If the hydraulic pump is direct mount to the PTO, remove the pump and grease the splined pump shaft with spline grease.
7
8
Single linLoad capaLoad capaLoad capa The followare to be u
SA M
so W
it fr
D T
Tm
T SpecificatOccupatio80% of thto be lifteThereforereaction o Your Hunyour rig. damaged,Manufactu WARNINSerious in All Hunkestandard hstandard lheight. Fcontact Hto allow fowner/ope It is recomshould beinformatio
ne load capaciacity at 0 – 5 acity at 5 – 9 acity at 9 – 12
wing drawingused as a guid
AFETY WARMast cylinder po that mast cy
When the pumis required th
rom skidding Do not exceed This machine iThe machine ismoment of theThe pump hois
tions for crawonal Safety anhe tipping loadd is seldom k
e, it is advisedof the front ax
nke pump hoiThe load rati lost or no lonuring at no ch
NG! Never honjury or death
e pump hoistsheight mast. length. The ror specific inunke Manufa
for wind load erator.
mmended that performed won on the prop
OPE
ty is 14,000 pfeet is 55,000feet is 22,000
2 feet is 11,00
g illustrates thde to indicate
RNINGS! pressure mus
ylinder pressump hoist is opehat the rear doout under heathe rated loa
is designed tos not designed
e truck and incst should neve
wler, locomotind Health Admd of the crane
known. This md that the operxle springs of
st is equippedng plate shounger readableharge.
oist a load thah may occur.
s are designedOn occasion, ated load capformation on
acturing. All and other fac
t the pump howith caution an
per testing pr
ERATING
pounds. Max0 pounds. 0 pounds. 00 pounds.
he load capaciapproximate
t not exceed 2ure does not eerated with inownriggers beavy load. d.
o only pull load to pull loadcreases the riser hoist a load
ive and truck ministration (
e (Register Vomakes it hardrator be awarethe truck.
d with a load uld be kept sece, it should be
at will apply a
d, equipped anHunke pump
pacity for thesrated load cabooms that ex
ctors that coul
oist be tested tnd only by qurocedure.
9
G PROC
ximum load ca
ities for the Rlifting capac
2,500 PSI. Ifxceed this lim
ndependent gue anchored to
ads that are ceds from either sk and dangerd that causes
cranes publis(OSHA) stateolume 39, RE
d to calculate te of approach
rating plate wcurely fastene replaced. Lo
a force to the
nd tested to op hoists are dese machines dapacities for mxtend higher ld cause tippin
to its rated caualified perso
CEDURE
apacity is 55,
R15 pump hoicity of the pum
f guy cables amit when the luy cables and o the well casi
entered betweside. A side
r of tipping. the front whe
shed by the De that the hoisE: 1910, 180).the exact tipp
hing the tippin
which displayed and be visioad rating pla
hook in exce
operate at the esigned and b
decreases relatmachines withthan 40 feet sng. All guy l
apacity weeklonnel. Contac
ES
000 pounds.
ist. The load mp host.
are used they load is applie
d a layback of ing to prevent
een the two re load greatly j
eels to be lifte
Department ofsted load shou. The exact wping load for tng load by ob
ys the rated loaible to the opates are availa
ss of the hook
rated load cabuilt with mastive to the inch additional mshould be guylines are to be
ly. The testinct Hunke Man
capacities sho
must be adjused. f more than 8 t the machine
ear downriggjeopardizes th
ed off the grou
f Labor uld never exceweight of the lthe pump hoi
bserving the
ad capacities perator. If it isable from Hun
k load rating.
apacity with asts that are nocreased mast mast length, pyed on both sie supplied by
ng procedure nufacturing fo
own
sted
feet, e
ers. he tilt
und.
eed load st.
for s nke
a ot
please ides the
or
10
SAoverhead ENGAGINAll of the pump.
Sh S D E E
If the temhydraulic procedure
SAdesigned tjeopardize SETTING The downshould beground is control ofto correct the groun ERECTIN Release ththe crownmast is be
SA A L T
sh Pull back The mast extension
OPE
AFETY WARd obstruction
NG THE PTOpump hoist f
hift transmisset parking bra
Disengage clutEngage PTO. Engage the clu
mperature is beoil to circula
e.
AFETY WARto pull only loes the tilt mom
G THE DOWN
nriggers are lo lowered untisoft, shoring
f the downriggextremes in ld must be lev
NG THE MA
he mainline cn detach the heing raised. A
AFETY WARAllow sufficienLook Up! AvoThe mast extenhould be raise
on the mast eextension haslatch is enga
ERATIO
RNING! Insps. If the site
O functions are h
sion to neutraake. tch.
utch.
elow 20 F, ruate. Raising a
RNING! A sooads that are ment of the tr
NRIGGERS
owered using il approximateor planking s
gers can be uleveling. If th
veled.
ST
able and detaook from the
Allow sufficie
RNINGS! nt slack in alloid overhead nsion must beed and lowere
erection levers latching not
aged in the no
ON AND S
pect workingis clear of all
hydraulically
al.
un the pump aand lowering t
olid base is recentered betw
ruck and creat
the independely 50% of thshould be usesed to bring the pump hois
ach the hook froad position
ent slack for e
l the cables wpower lines a
e completely red very slowly
r and raise thetches for diffetch required,
11
SET UP
g site for oveobstructions,
y operated. En
at low speed fthe hydraulic
equired for doween the two tes the risk an
dently controlhe truck weighed to provide athe truck to a t is extremely
from the roadn as well. Theerecting the m
when erecting and other obstretracted befoy to avoid sud
e boom to a verent mast heireverse the d
INSTRU
rhead power, prepare to se
ngaging the P
for a short pedownriggers
ownrigger starear downrig
nd danger of t
led downrigght is carried badequate loadlevel position
y out of level,
d position. If tese cables mu
mast.
or lowering ttructions. ore raising or dden jolts.
ertical positioights. Power
drawworks an
UCTION
r lines, trees et up the pum
PTO powers t
eriod of time ts will expedite
abilization. Tgers. A side tipping.
ger valves. Thby the downrid distributionn. Do not use, the truck mu
the sand reel ust be gradual
the mast.
lowering the
on. r the tailout wnd lower the li
NS
or any othermp hoist.
the hydraulic
to allow the e the warm up
his machine iload greatly
he downriggeiggers. If the . Independen
e the downrigust be relocate
cable is riggelly let out as t
mast. The m
winch up until ine.
r
p
is
ers
nt ggers ed or
ed on the
mast
the
SAlatch is nodamage, btailout win NOTE: Rlatching a Center theThe Hunk
SAposition. cylinders
MAST R
B A
di P
to Pu
do L A R D
IMPORTroad posit
SAlowered. SAND R The sand The Sand motor faildown poslet go of thold the lo
AFETY WARot fully engagbodily injury nch.
Regularly cheability. If the
e hook over thke pump hoist
AFETY WARThe mast mudo not allow
RETRACTI
Bring the mastAttach the wei
istance to the ower the tailo
o allow the latull and hold town.
Lower the masAttach hooks tRaise the downDisengage the
TANT: Whention the mast
AFETY WAR
REEL OPER
reel consists
reel is drivenls, the sand reition the drum
the control levoad.
RNING! Visuged, it may coor death. All
eck the conditspring is wea
he pump usint is now ready
RNING! At nust be positionfor any addit
TEARION
t forward so thight to the hootop.
out winch up tch to be releathe latch relea
st to the horizto loops provinriggers. PTO.
n lowering thecylinders mu
RNING! Mak
RATION
of a cable spo
n by two hydreel will not opm will free-faver allowing t
ually inspect ome unhookedl the load mus
tion of the latak or deforme
ng the mast coy for work.
no time shoulned with the btional load ind
R-DOWN
hat it is positiok and winch
until the hookased. ase cable. Re
zontal, road reided, draw cab
e mast to the rust be in a neu
ke sure that en
ool, hydraulic
raulic motors perate hydraull to the bottothe valve to c
12
the latch to bd and drop thest be carried o
tch spring to ied, replace the
ontrol.
ld the pump hboom cylindeduced pressur
N INSTR
ioned slightlyh the cable we
k dead ends o
everse the tailo
eady position.bles taut.
road position,utral position w
nough slack e
c motors and a
connected in lically and if
om of the wellenter which w
be sure that it e inside toweon the latch an
insure sufficiee spring.
hoist be operaers partially exre bought on b
RUCTION
y rear of vertieight up appro
on the crown.
out winch un
.
, be sure that with no tensi
exists in the c
automatic bra
n a series or pathe control vl. If the sandwill automatic
is completelyr causing posnd none what
ent tension to
ated in the maxtended. Fullyby the load b
NS
cal. oximately thre
Extend the m
ntil the extensi
the engine ison up or dow
cables while t
akes.
arallel circuitvalve is held ind reel suddenlycally engage
y engaged. Ifssible pump tsoever on the
o allow full
aximum laybay retracted eing hoisted.
ee quarters of
mast a few in
ion is all the w
at an idle. Inwn.
the mast is
t. If one hydrn either the upy fails to operthe brakes an
f the
e
ack
f the
ches
way
n the
raulic p or rate,
nd
The sand speed is 2540 feet p CAUTIOreel with e IMPORTthe sand r
SAlifting can SAND R The sandlstop befordirection prematurehydraulic direct-coudirection wcause losswell.
SA
reel can be sw270 feet per mper minute lin
ON! In the serextreme cauti
TANT! If thereel be shifted
AFETY WARn cause a com
REEL OPER
line is used inre changing sof travel while failure may motors. This
upled motors. without stopps of control of
AFETY WAR
witched betweminute at 5,000ne speed with
ies circuit, thion.
e sand reel is rd to series unl
RNING! Lowmplete loss of
RATION TO
n power-up, pand reel direcle the sand reeoccur. The ra force on the The sand ree
ping, severe inf the sand ree
RNING! Alw
een a series a0 pounds lifti2,500 pounds
e line speed i
required to beless the sand b
wering a load icontrol and m
O AVOID I
ower-down oction. The sanel is in motioapid change inmotors is a re
el travels at sunternal damag
el, which will
ways stop the s
13
and parallel ciing capacity os lifting capac
s extremely f
e in the parallbucket has be
in the series cmay cause inju
INJURY AN
operation. Bend reel contron. If the hydrn direction caesult of the spuch a high ratge to the hydrthen drop the
sand reel befo
ircuit. While on a bare spoocity.
fast so the ope
lel position toeen emptied.
circuit that requry or death.
ND SAND R
e sure that the ol valve must raulic sandlin
auses large forpool and cablte of speed tharaulic motors e swab or san
ore changing
in the paralleol. In the seri
erator needs t
o lift the load,
quired the par
REEL DAM
sand reel comnot be shifted
ne is used in trces to be exee rotating at hat if the sand may result. T
nd bucket to th
sand reel dire
el circuit the lies circuit it h
to operate the
, at no time sh
rallel circuit f
MAGE
mes to a compd to change ththis way, erted on the high speed wireel is shifted
This damage che bottom of t
ection.
line has
sand
hould
for
plete he
ith d can the
14
15
16
REPAIR PROCEDURES Hunke Manufacturing does not recommend the repair or replacement of parts on the “built in” structure to be done by anyone other than Hunke Manufacturing. If work of this nature must be performed by personnel other than Hunke, it is important to require first grade material and workmanship. All hydraulic components such as motors, pumps, valves and hoses are available from Hunke Manufacturing. Replacement parts can be ordered using the parts diagrams appearing in this manual. After repairs, Hunke Manufacturing recommends that the rig be tested to no more than 110% of its rated capacity. Contact Hunke Manufacturing for information on the proper testing procedure. POWER TAKE OFF (PTO) The PTO supplies power from the truck transmission to the hydraulic pump. The PTO number corresponds with the truck transmission number. PTO failure is rare, however if this occurs, a new PTO assembly should be installed. HYDRAULIC PUMP The hydraulic gear pump supplies oil under pressure to hydraulic motors and cylinders. Oil is returned to the reservoir via a low pressure manifold. Pump failure can result in loss of power and reduced line speed. If this occurs, first check to make sure that the PTO is functioning properly. Also, make sure that the oil lines are free of kinks and that the shaft keys are intact. A gear pump will, under some conditions, pump pressure, but if the pump is badly worn, the pump will not pump the required gallons per minute, resulting in a slow line speed. If this is apparent, a replacement pump is required. Contact the Hunke factory for more information regarding hydraulic pump testing and repair. Hydraulic pumps should be repaired only by qualified hydraulic system service personnel. HYDRAULIC MOTORS Hydraulic motors normally have a long, trouble free service life. Hydraulic motors are built to extremely close tolerances. Any foreign matter in the hydraulic oil could cause scoring of the internal parts and result in oil leaks and/or loss of power. Failure of the motor to rotate in either direction indicates motor seizure. In the event of motor seizure the motor will have to be replaced. If there appears to be a problem with a motor, be sure to check for keys that may be sheared in the motor or spool shafts. Motor shaft seals can be field installed. Replacement shaft seals, complete seal kits and replacement motors are available from Hunke Manufacturing. When ordering a seal kit, provide the complete motor model number that is attached to the motor. Hydraulic motors should be repaired only by qualified hydraulic system service personnel. HYDRAULIC VALVES All valves within the main valve bank require the same repair parts. Oil leaks at either end of the valve spool can be fixed by replacing the seals. Malfunctions other than leaking seals require a valve replacement. HYDRAULIC CYLINDERS Cylinder drift when the cylinders are loaded indicates faulty internal seals. Replacement seals are available from Hunke Manufacturing.
HYDRAULeaking c NOTE: Tand possib Damaged hoses by i BULL GEThe bull aresulting iexcessive
SAdrop. SAND REIf a sand r Disconnechose placethe hoses If it does normally,motor tha SHEAVEProper lubroller bear AUTOMAThe brakehas an intWhen the If the brakavailable There shodrift, follo Check to the winchinternal spinstruction If the brakworn, coaclean, the Remove tand tighte
ULIC HOSEconnections ca
Teflon tape onbly cause crac
hoses shouldinside diamet
EAR AND Pand pinion gein chipped or wear occurs.
AFETY WAR
EEL reel motor fai
ct both hoses ement before are capped, hfunction norm reconnect th
at was disconn
ES brication willrings or bush
ATIC BRAKe assembly coernal spring t control valve
ke cylinder fufrom Hunke M
ould not be anow the proced
see if there ish is operated ipring is brokens.
ke cylinder shated with oil o
brake will hathe lock nut oen the lock nu
ES an usually be
n threaded fitcked fittings.
d be replaced.ter and length
PINION GEAar may be dambroken teeth
RNING! Fail
ils use the foll
on one of theyou disconne
hook the sandmally, the motat motor and nected is bad.
result in longings. Sheave
KE onsists of a brto activate thee is activated
unctions propeManufacturin
ny brake drift dure below.
s movement on the down pen and the cyl
haft moves whor the brake nave to be readn the cylinder
ut so the adjus
repaired by s
ttings reduces
Replacemenh.
AR maged when . The gears s
lure of the gea
lowing proce
e motors and ect them so th
dline cable to tor that is disdisconnect th
ger service lifpins should b
rake drum, brae brake when the cylinder d
erly but leaksng.
when the win
on the brake cosition. If thelinder must be
hen activated needs readjustdjusted. To rr shaft. Withstment stays s
17
simply tighten
s friction mak
nt hoses are av
an object accshould be insp
ars caused by
dure to find o
cap the hoseshey can be recan anchor andconnected is
he other moto
fe for the sheabe replaced w
ake band and the correspondepresses the
s oil, the cylin
nch or sandlin
ylinder shaft.ere is little ore replaced. S
but the braketing. If the brreadjust the Bh a torque wresecure.
ning the fittin
king it possibl
available from
cidentally getspected for we
y sheared teeth
out which mo
s with 1" pipeconnected to d see if the sathe bad moto
or. If it then o
aves. The facwhen replacing
d a hydraulic cnding control
e spring and re
nder will have
ne is in the ne
. The cylinder no movemenSee the brake
e does not holrake lining is
Brake: The truench tighten th
ng.
le to draw the
m Hunke Man
s caught betwear monthly an
h will cause h
otor has failed
e caps. Be certhe correct m
and reel will for. If it doesnoperates norm
ce of the sheag bearings, bu
cylinder. Thel valve is in theleases the br
e to be reseale
eutral position
er shaft shouldnt of the cylincylinder repla
ld, the brake not worn exc
uck engine muhe brake to 13
e fitting too tig
nufacturing. O
ween the two gnd replaced if
hoisted load t
d.
rtain to mark motor port. Affunction norm
n't function mally, the seco
ave may outlaushings or she
e brake cylindhe neutral posrake.
ed. Seal kits
n. If there is b
d move 1” whnder shaft, theacement
lining is posscessively and ust be shut off3 ft.-lbs. Rein
ght
Order
gears f
o
the fter
mally.
ond
ast the eaves.
der sition.
are
brake
hen e
sibly it is
ff. nstall
18
19
20
21
22
23
24
25
26
Shouldthshallapp
1. Amcl
2. T3. T4. T
o5. A
For orderspurchaserfrom the dladder accthe factorymounted lserious injand intactclimbing For ordersdeck to boup to the bequipmenproviding WARNINpump hoiserious inj
SAoutlineda
Warning!
lowering t
position t
mast may
aware of t
Never mo
500 lbs. o
hepump‐hoislyandbestr
AcertifiedfulmustbethetylimbingoforheladderisheindividuaheclimbingnepersonocAtnotimesha
s placed contar the option ofdeck to the bocess ladder. Oy shall supplyladder. Shoul
njury or death t before occupof the ladder
s placed with oom ladder acboom mounte
nt to allow a fag proper traini
NG! Do not ast unit while a
njury or possib
AFETYWARaboveofthis
If equipped
the mast into
o avoid any o
y cause swing
the swing arm
ove the swing
n pump hoist
Ladder
stincludetherictlyadhered
l‐bodysafetyypethatallowrdescentdowtobeclimbealshallutilizeladderhasaccupancy.allthepump
aining the optf placing the ooom mounted
Orders placed y a specificallld any segmenmay result. It
pying the laddassembly.
Hunke Manuccess ladder, ted ladder is asfail-safe passaing to applica
attempt to climattempting toble death!
RNING!Fullusmanualisre
with a power
o the road pos
obstacles. Fai
arm collision
m position an
arm until the
t models 3T –
Mounted
eoptionalladto:
yharnessshawsfortheocwntheladdedonlywhenethethree‐pmaximumra
‐hoistbeope
tional boom morder with Hu
d ladder or plawhere the fac
ly designed acnt of the laddet is imperativder. Proper re
ufacturing thathe responsibssumed by theage to and fromable personnel
mb onto the pu access the bo
understandinequired.Fail
Power T
r tong swing a
sition. The sw
ilure to place
n and damage
d keep all pe
e mast is fully
– 12T and 1,50
27
On The sid
dderassemb
allbeutilizedccupanttobeer.theboomispointclimbinatedcapacity
eratedwhen
mounted laddunke Manufacacing the ordectory is to insccess ladder ter assembly b
ve that the inteepair or corre
at contain a bobility to offer e purchaser. Tm the factoryl.
ump hoist fraoom mounted
ngandcompluretodoso
Tong swing
arm, the swin
wing arm may
the swing ar
e to the pump
rsonnel clear
y raised. Load
00 lbs. on pum
de of The M
blyonthesid
dbytheoccuesecurelyatt
raisedinthegtechniqueyof300lbs.
theladderis
der, Hunke Macturing with aer without a fastall the deck that provides be damaged oegrity of the lection is requi
oom mountedsafe passage The purchasey supplied boo
ame, shields od ladder. Failu
plianceofthemayresulti
g Arm
ng arm must b
y also need to
rm in the road
p hoist or oth
r of the pump
d capacity for
mp hoist mod
Mast
deofthemas
upant.Thesatachedatall
everticalposatalltimes.perrungand
soccupied.
anufacturing a factory supp
factory supplieto boom laddsafe passage
or compromisladder assembired to any fla
d climbing ladfrom both the
er shall supplyom mounted l
or any other sure to comply
etermsandcnseriousinj
be in the road
o be in the sh
d position pri
her equipmen
p hoist while l
r the power to
dels R12 – 50
stthefollowi
afetyharnesstimesduring
sition
damaximum
allows the plied access led deck to bo
der access ladto the boom ed in any manbly be inspectaws for safe
dder but not the ground or dy the necessarladder as wel
egment of they may result in
conditionsuryordeath
d position bef
hortest arm le
or to lowerin
nt. Always be
owering the
ong swing arm
0T
ing
sgthe
mof
adder oom dder,
nner, ted
he deck ry l as
e n
h.
fore
ength
g the
mast.
m is
Sa
power ton
move the
if these in
afety Warning
ng that is with
truck with th
nstructions ar
g! The power
hin the weigh
he swing arm
e not adhere
tong swing a
ht limits of the
not in the ro
d to.
28
arm shall be u
e swing arm.
ad position.
used only for
Do not exce
Serious dama
operation an
ed the rated
age, injury or
d lifting of a
load. Do not
r death may r
t
esult
29
30
NOTEwarr
E: Hunkranty on
31 ke Manun all cab
ufacturbles or
ring excwire rop
cludes opes.
32
33
34
35
36
37
38
39
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