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

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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 

 

   

40 

 

 

 

 

    

41