Operation & Instruction Manual Om 1270 50 FT

Series 1270 – 50
E llic o t t D r e d g e s , L L C "Dragon" Dredge
OPERATION AND INSTRUCTION MANUAL

FOR
Helport S.A.
Buenos Aires, Argentina
Ellicott Dredges, LLC

1425 Wicomico Street Baltimore, MD 21230
Ph 410-625-0808 Fax 410-752-3294
www.dredge.com
www.mudcat.com
Contract #401390 ©2013 Ellicott Dredges, LLC

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SERIES 1270 50’ D.D.
18 x 18 Assy. Dwg. 150900
Dredge Pump Assembly #151145 Rev. 2
OPERATION & INSTRUCTION MANUAL

TABLE OF CONTENTS
SECTION I INFORMATION AND SPECIFICATIONS
SECTION II SAFETY
SECTION III OPERATION AND SERVICE OF INDIVIDUAL SYSTEMS
SECTION IV DREDGE OPERATION
SECTION V LUBRICATION AND MAINTENANCE
SECTION VI FIELD ASSEMBLY
SECTION VII VENDOR SERVICE LITERATURE
SEPARATE COVER ELLICOTT PARTS (ASSEMBLY DRAWINGS)
THIS DOCUMENT, INCLUDING ALL DRAWINGS, CHARTS, TABLES, ETC. TOGETHER WITH THE
INFORMATION WHICH IT DISCLOSES, IS THE EXCLUSIVE PROPERTY OF ELLICOTT DREDGES, LLC.
IT IS PROVIDED TO THE PURCHASER UPON THE UNDERSTANDING AND AGREEMENT THAT IT

SHALL BE USED ONLY FOR PURPOSES OF MAINTENANCE, SERVICE, AND REPAIR OF THE PARTY
OF THE DREDGE OR MACHINE TO WHICH IT APPLIES, AND UPON THE UNDERSTANDING THAT IT
SHALL NOT BE LOANED, DISCLOSED, OR DUPLICATED IN WHOLE OR IN PART, AND SHALL NOT BE
USED FOR THE MANUFACTURE, RENEWAL, OR PROCUREMENT OF ANY DREDGE PART WITHOUT
THE WRITTEN PERMISSION OF ELLICOTT.
THE INFORMATION AND DESIGNS CONTAINED IN THIS MANUAL ARE SUBJECT TO CHANGE
WITHOUT NOTICE.
©2012 ELLICOTT DREDGES, LLC. THIS MANUAL REPLACES AND SUPERSEDES ALL PREVIOUS
VERSIONS OF SERIES 1270 (18 x 18) OPERATION AND INSTRUCTION MANUALS.
©2012 Ellicott Dredges, LLC

SECTION I: INFORMATION AND SPECIFICATIONS
TABLE OF CONTENTS
Page
A. INTRODUCTION .. 1
B. GENERAL ARRANGEMENT DRAWING . 2
C. GENERAL DESCRIPTION . 1-3
D. WARRANTY .. 3
E. FIELD SERVICE ... 3
F. CUSTOMER SERVICE ... 3
G. CONTACTING DREDGE SALES DEPARTMENT . 4
H. SERIES 1270 SPECIFICATIONS . . ........... 4-5
I. PERFORMANCE RATING 6-8
1. RANGE DIAGRAM .. 6-7
2. MAIN PUMP THEORETICAL PRODUCTION CURVE . 8
DREDGE ASSEMBLY (DWG# 150900) .. INSERT
TANK, CENTER ASSEMBLY (DWG# 151086) . INSERT

Section I Information and Specifications
A. INTRODUCTION
The information contained in this manual covers the operation, maintenance, replacement parts, repair
procedures, and safety hints as outlined in the main Table of Contents. This manual, and any
supplemental component manual(s), should be read and understood thoroughly by all personnel before
operating or working on the dredge. In addition to reading this manual, the operator and all other
personnel should know the location and proper function of all the dredge's safety devices, controls, and
instrumentation before beginning operation.
Throughout this manual three terms (NOTE, CAUTION, and WARNING) are used to alert you to items of
special consideration regarding your safety and that of your co-workers as well as the dredge's proper
operation and maintenance. These terms (as shown below) indicate information which must be
understood and followed:
Definitions for these terms are:
NOTE: Information which can affect operational procedures.
CAUTION: Deviation from outlined steps or procedures could result in damage to

equipment.
WARNING: Safety reminder advising that any deviation from recommended steps or
procedure could result in INJURY to personnel.
Recommended changes to this manual consisting of additions, deletions, or clarifications should be

addressed to the Literature Department of Ellicott Dredges at (410) 545-0253 or by FAX at (410) 752-3294.
B. GENERAL ARRANGEMENT DRAWING (See Page 2)

C. GENERAL DESCRIPTION
The Ellicott Series 1270 is a non-self-propelled, transportable, hydraulic pipeline, cutterhead dredge. Its
prime movers consist of a diesel driven centrifugal dredge pump and a diesel driven hydraulic system
which powers the cutter, ladder lifting cylinders, and swing and spud winches.
The 1270 hull consists of pontoon-type sections which are connected together. The center tank supports
the main dredging machinery while the side tanks provide floatation with compartments for fuel and water
ballast.
The entire dredging operation is controlled from a fully enclosed lever room on the forward deck. The lever
room has sliding windows on all sides to provide ventilation, lighting and a complete view of the dredging
operation. The operator's console in the lever room provides fingertip control of the prime mover and all
equipment, insuring an efficient dredging operation.
A steel dredge ladder of tubular construction is horizontally hinged at the forward center hull. This allows
the ladder to be raised and lowered by means of a ladder winch assembly.
Connected to the forward end of the ladder is a variable speed hydraulically driven cutter which excavates
the material to be transported. The excavated material is transported through suction piping to the pump
and through discharge piping away from the pump and the dredge.
©2012 Ellicott Dredges, LLC 1

Series 1270 HP Dredge (Dwg. # 150900)
2 ©2012 Ellicott Dredges, LLC

At the aft end of the ladder, mounted as a integral part, are two winches driven by hydraulic motors. These
winches swing the dredge via cables that are reeved through sheaves and connected to anchors placed at
opposite sides of the dredging area. A third hydraulic winch attached to the aft end of the ladder is used for
raising and lowering of the dredge ladder.
Installed at the aft end of the center tank are the tubular steel spuds. The starboard spud is for advancing
and the port spud is utilized when digging. Both spuds are raised and lowered by individual single-drum
winches with free-fall provision.
D. WARRANTY
Ellicott warrants your dredge in accordance with Paragraph 7 under the Terms and Conditions of Sale that
appear on the reverse side of Ellicott's Acknowledgement and Acceptance of Order.
Should any problems occur during the warranty period, the obligations of the dredge owner are to: (1)
identify the faulty component(s) by name and Ellicott part number; and (2) notify Ellicott immediately of the
need for repair or replacement using the original contract number and/or dredge name in all
correspondence.
E. FIELD SERVICE
Ellicott’s Field Service Team of highly qualified field engineers, with advance notification and scheduling,
can be available for the following:
1. Assembly of new dredges;

2. Installation of new dredge equipment;
3. Service supervision of dredge operations and maintenance procedures (especially helpful to new
crews);
4. Advice on efficient operation, etc.;
5. Troubleshooting and diagnostics;
6. Replacement part recommendations
Service rates are based on a per diem basis.
Contact Information:
For Technical Assistance Jerry Gladwell Email: jgladwell@dredge.com Ph. 410-545-0253

Field Service Manager Mark Heimberger Email: mheimberger@dredge.com Ph. 410-545-0212
F. CUSTOMER SERVICE & PARTS DEPARTMENT

This department was established to provide you with replacement parts for the equipment on your dredge.
When ordering parts, use the illustrated parts breakdown section to identify the part(s) by name and Ellicott
part number. In addition to the part number, it is also necessary to give the dredge name and/or original
contract number (stamped into the identification plate attached to the starboard side of the dredge slurry
pump speed reducer assembly). For more information on parts ordering, see the Parts Accessory Catalog.
Customer Service Fax no. 410-752-3294
Customer Service Manager Jack Fiddes Email: jfiddes@dredge.com Ph. 410-545-0256
Parts Sales Representative Brian D’ Angelo Email: bdangelo@dredge.com Ph. 410-545-0239
Parts Sales Representative Andrew Queral Email: aqueral@dredge.com Ph. 410-545-0223
OR call 1-888-4MUDCAT (1-888-468-3228) in the U.S.A.

G. CONTACTING DREDGE SALES DEPARTMENT

Address: Ellicott Dredges, 1425 Wicomico Street, Baltimore, MD 21230
Telephone: (410) 545-0232
Fax: (410) 545-0293
Email: rmanning@dredge.com
H. SERIES 1270 SPECIFICATIONS
Description Aspect English Metric
Hull Length 68 ft. 20.7 m
Width 26 ft. 7.9 m
Depth 4-1/2 ft. 1.4 m
Power Movers Dredge Pump Engine Continuous Rating (CAT C32) 1000 hp 746 kw
Auxiliary Engine Intermittent Rating (CAT C9) 350 hp 261 kw
Cutter Basket Type Shaft Horsepower Rating 155 shp 116 kw
Speed Range 29-45 rpm 29-45 rpm
Head Mean Diameter 43-1/4 in. 1,099 mm
Number of Blades 6 6
Shaft Diameter 4-7/16 in. 113 mm
Head Weight 1,400 lbs. 635 kg
Swing Winches (2) Shaft Horsepower 49 shp
Line Pull 15,000 lbs. 6804 kg.
Line Speed 0-103 ft/min 0-31.5 m/min
Wire Size 5/8 inch 15.9 mm
Drum Capacity 400 ft. 122 m
Ladder Hoist Shaft Horsepower 42 shp 31 kw
Line Pull 19,703 lbs 3,937 kg
Line Speed 0-61 ft/min 18.5 m/min
Wire Size ¾ inch 19 mm
Drum Capacity 400 ft. 122 m
Spud Winches (2) Shaft Horsepower 47 shp 35 shp
Line Speed 50 ft/min 15.2 m/min
Line Pull 26,738 12,138 kg
Wire Size 7/8 in. 22.2 mm
Weights Total Assembled Dry Weight (est.) 235,000 lbs. 106,594 kg
(Approximate) Ladder with Suction Pipe & Cutter Basket 32,614 lbs. 14,795 kg
Spuds (each) 10,456 lbs. 4,743 kg
Control Room 2,500 lbs. 1,130 kg
Dredge Pump Engine 7,200 lbs. 3,266 kg
Dredge Pump Casing 4,200 lbs. 1,190 kg
Dredge Pump Reduction Gear 6,100 lbs. 2,767 kg
Dredge Pump Assembly 15,997 lbs. 7,256 kg.
Center Tank Assembly 118,500 lbs. 53,750 kg.
-Starboard Side Tank w/Handrail & Start Kit 32,000 lbs. 14,514 kg.
-Port Side Tank w/Handrail & Discharge Pipe 38,000 lbs. 17,237 kg.
Capacities Fuel Tanks (Combined) 3800 gal (14,385 Litre) per tank 7,600 gal 28,770 liter
Hydraulic Oil:
Tank 180 gal. 681 liter
System 330 gal 1,249 liter
Dredge Pump Reducer 46 gal 174 liter
Hydraulic Pump Drive 3.3 quart 3.1 liter
Main Engine (CAT C32):
Lubrication 35.6 gal. 134.7 liter
Cooling 65 gal. 246 liter
Auxiliary Engine (CAT C9):
Lubrication 8 gal. 30 liter
Cooling (Including Radiator) 10.4 gal. 39.4 liter

H. SERIES 1170 SPECIFICATIONS (Continued)
General Mean Draft (Approximate) 3 ft. 91.3 cm
Digging Depth 50 ft. 15.2 m
Suction Pipe:
I.D. 18 in. 457 mm
O.D. 18 ¾ in. 476 mm
Discharge Pipe
I.D. 18 in. 457 mm
O.D. 18 ¾ in. 476 mm
Ladder Hoist Wire Size ¾ inch 19 mm
Ladder Length (Approximate) 59 ft. 18.2 m
NOTE: Refer to the Caterpillar operators manual supplied for more detailed information on fuel,
oil, and coolant requirements. See Section VII, Tabs 4 & 5.
HYDRAULIC OIL:
The following specifications are for use when the ambient temperature is 35° F. (2°C) to 110°F (43°C). The
normal operating temperature of the hydraulic system should be 110-120°F (43-49°C). The maximum hydraulic
system temperature should not exceed 140°F (60°C).
Viscosity: 275-315 SUS at 100°F (37.8°C), 50-55 SUS at 210°F. (99°C)

Viscosity Index: 95
Specific Gravity: .84-.90 @ 60°F (15.6°C)
Recommended Additives - Rust, oxidation and wear inhibitors, foam depressant.
The following brands of hydraulic oils or their equivalents may be used. Extreme ambient temperatures may
require a different oil viscosity.
Texaco – RANDO HD68 Optional: Biodegradable Hydraulic Oil (Do not mix with any other
HDC Humble - NUTO H54 or H68 type of oil) Citgo Clarion® Green R/W Oil 68
Mobil - DTE 26
Duralene AW68
Shell- TELLUS 33 or TELLUS 68
Chevron – EP68
Conoco – Hydraulic 68
Dredge Pump Speed Reducer Oil - ISO-220 AGMA 5 non-detergent with anti-foam and oxidation inhibitors.
Mobile Gear 630, Exxon Spartan 220, Shell OMALP 220.
Hyd. Pump Drive - SAE 90 EP (API-GL5) oil for ambient temperatures from -10°F. (-23°C.) to l00°F (37.8°C.).
Main and Auxiliary Engines - Lubrication: oil type is dependent on air temperature. Refer to the engine
manufacturers manual.
Cooling: See engine manufacturer’s manual for proper mix and type of coolant/conditioners.
Service Water Pump – NGLI#2 grease of sodium or lithium base (Mobilux EP2 or equivalent)
Grease Fittings – NLGI#2 consistency (Mobilux EP2 or equivalent)

I. PERFORMANCE RATING
To properly determine and achieve the dredge's optimum performance, various ratings have been devised
and set down in the manner of diagrams and charts. This information, which is based on calculations, tests
and data (both empirical and theoretical), is to help guide and inform operating personnel in the planning
and performing of projects.
1270 Range Diagram – 50 Ft. D.D.

(Ref. Dwg. #)

1270 Range Diagram – 50 Ft. D.D.



SECTION II: SAFETY
TABLE OF CONTENTS
Page
B. SAFETY RECOMMENDATIONS ... 1-2
C. REFERENCE MATERIAL .. . 3

Section II Safety
A. INTRODUCTION
Safety is everyone’s business and should be of primary concern to all equipment operators and service
personnel. However conformance to any safety recommendations, practice or regulation is the
responsibility of the user. For the user has the most control over a dredge’s application, operation,
inspection, and maintenance or the varying and numerous regulations governing safety requirements.
As stated in Section I, Information and Specifications, you will be alerted throughout this manual to items of
importance to personal safety and the dredge’s operational performance by the terms “NOTE”,
“CAUTION”, and “WARNING”, as they apply to the information at hand.
Because of the many and varied situations encountered in the field, it is impractical to point out all of the
safety requirements and recommendations covering them. However, it is reasonable to presume that by
knowing and following the guidelines given in the succeeding pages, you will provide a safer working
environment for yourself, those around you, and the dredge’s operation. If you have any questions about
safety or other issues, please don’t hesitate to ask Ellicott.
B. SAFETY RECOMMENDATIONS
1. DO NOT operate the dredge or its machinery unless authorized to do so.
2. READ and UNDERSTAND this manual and any component equipment instruction manual thoroughly
before attempting to operate or perform any maintenance or service procedures.
3. ALWAYS wear or utilize the proper safety equipment necessary for personal protection.
4. INSPECT the dredge and have any malfunction and broken or missing parts corrected before
operating.
5. MAKE SURE that any petroleum based substances or foreign materials are cleaned from the steps,
handrails and walkways to reduce the danger of slipping.
6. DO NOT carry unauthorized passengers.
7. MAKE SURE that the main engine’s clutch is disengaged and that all machinery guards are in place
before starting the engines.
8. ALWAYS use caution and be observant when working in close quarters or congested areas.
9. MAKE SURE that all persons, vessels and obstructions in your work area are cleared BEFORE
beginning operations.
10. LOOK in all directions before changing the dredge’s position.
11. NEVER leave the dredge running and unattended; shut it down instead.
12. DO NOT service or clean the dredge with the engine(s) running.
WARNING: If it becomes necessary to troubleshoot or service the dredge with the

engine(s) running, use extreme caution and all safety procedures necessary to insure the
safety or personnel.
13. DO NOT smoke or have an open flame near batteries or fueling operations.

Section II Safety
14. As all batteries are potentially hazardous, due to their emitting flammable gases, injury or damage
could result unless caution and the proper procedures are ALWAYS used to minimize arcing when
jump-starting. (refer to your engine operator’s manual)
15. NEVER remove the cooling system cap from a hot engine.
16. DO NOT alter the engines’ governor settings.
17. ALWAYS secure the dredge ladder with safety cables or straps BEFORE providing service or
maintenance to the dredge.
18. ALWAYS use the appropriate lifesaving and fire fighting equipment in accordance with regulatory laws
having jurisdiction in your working area.
19. ALWAYS use the proper contaminant free material handling and dispensing equipment when adding or
changing systems fluids.
20. NEVER operate or secure the dredge with both spuds down.
21. ALWAYS watch the spudding process (raising, lowering) to assure its proper operation.
22. ALWAYS wear the proper hand protection when handling wire rope.
23. ALWAYS use warning and signal lights and devices as required on the dredge and pipeline.
24. ALWAYS follow the procedures in the instruction manual for start-up, shut-down, maintenance and
service. WHEN IN DOUBT, CHECK.
25. NEVER exceed the maximum load limit of the pump handling or other crane.
26. PROVIDE life rings at appropriate places on the deck.
27. WEAR life jackets whenever working on the deck, ladder, or transporting to and from shore.
WARNING: Do not allow untrained or inexperienced personnel to launch, operate, or

perform maintenance on this equipment. A minimum crew of two qualified people, one
dredge operator and one dredge systems engineer or systems monitor should be on board
at all times during dredge operation. Maintenance crews should also consist of a
minimum of two people. A suitable personnel transport boat should be available for
immediate use at the dredge in the event of an emergency during operations or
maintenance. A reliable form of electronic communication for contact with emergency
personnel should be immediately available and accessable whenever any personnel are on
board.
WARNING: DO NOT undercut high banks. Cave-ins can cause injury to personnel and
damage or sink the dredge. Always bench cut the deposit to avoid bank heights in excess
of 8 feet.
WARNING: The Series 1270 dredge is intended for service ponds, rivers, and intracostal
waterways in calm water. Operators are cautioned to avoid operating or mooring the
dredge in agitated waters and waves or swells that exceed 1 ft (0.3 m) or in currents that
exceed 2 knots (3.4 fps).
Section II Safety
ALWAYS BE ALERT; CAREFUL OPERATIONS AND SERVICE PERSONNEL ARE THE BEST
INSURANCE AGAINST ACCIDENTS.
C. REFERENCE MATERIAL:
Many times procedures, requirements and regulations are not followed because they are not known. For
those who are interested in obtaining more information on safety, the following list of reference material
may prove helpful.
1. Accident Prevention in Construction:

The Associated General Contractors of America, Washington, D.C., U.S.A
2. Rules & Regulations for Cargo & Miscellaneous Vessels CG257:

Department of Transportation, U.S. Coast Guard (G-CMC/81) Washington, D.C. 20590
3. General Safety Requirements Manual EM 385-1-1:

Department of the Army Corps of Engineers, Washington, D.C. 20314 U.S.A
4. General Industry Safety & Health Standards OSHA 2206 (29-CFR 1910):
U.S. Department of Labor, Occupational Safety and Health Administration, Washington, D.C., U.S.A.
5. Safety and Health Regulations for Maritime Employment:

(Federal Register Volume 39, Number 119 Part II) U.S. Department of Labor, Occupational Safety and
Health Administration, Washington, D.C., U.S.A.
6. Safety Requirements for Dredging:

American National Standards Institute, Inc. 1430 Broadway, New York, New York 10018 U.S.A.

SECTION III: OPERATION & SERVICE OF
INDIVIDUAL SYSTEMS
TABLE OF CONTENTS
TAB 1 INSTRUMENTATION AND CONTROLS
TAB 2 MAIN ENGINE, DREDGE PUMP, AND DREDGE PUMP SPEED REDUCTION
DRIVE UNIT
TAB 3 LADDER AND CUTTER ASSEMBLY
TAB 4 LADDER HOIST AND SWING WINCHES
TAB 5 SPUD SYSTEM
TAB 6 HYDRAULIC SYSTEM
TAB 7 SUCTION AND DISCHARGE PIPING
TAB 8 FUEL SYSTEM
TAB 9 ELECTRICAL SYSTEM
TAB 10 SERVICE WATER SYSTEM

SECTION III-TAB 1:
INSTRUMENTATION AND CONTROLS
TABLE OF CONTENTS
Page
A. INTRODUCTION . 1
B. CONTROL STAND AND IDENTIFICATION CHART 1
(Includes SK05-21-12-01 Emergency Clutch Disengagement)
C. DESCRIPTION AND OPERATION (Dredge Operator’s Cabin) 2-3
D. DESCRIPTION AND OPERATION (Center Tank) . 4-5
E. LADDER DEPTH GAUGE . 5
MARINE POWER DISPLAY OPERATOR’S GUIDE Insert

Section III-Tab 1 Instrumentation and Controls
A. INTRODUCTION:
Before operating any equipment, an operator must know the location and function of the operating controls
& gauges. While many of these items are self-explanatory, their exact location and operation must be
known for safe, effective dredging. With the continued use of the controls the operator’s skills will increase.
B. CONTROL STAND IDENTIFICATION CHART:
Ref 148268

C. DESCRIPTION AND OPERATION (Dredge Operator’s Cabin)
1. Service Water Pressure Gauge
Indicates the pressure developed in the service water circuit at the dredge pump stuffing box. During
operation, the pressure reading must exceed the pressure reading on the dredge pump discharge
gauge. By maintaining this pressure difference, the dredge pump’s stuffing box packing will be
lubricated and the stuffing box sealed against the entrance of the slurry.
CAUTION: Do not operate the dredge pump without adequate service water pressure;
doing so may result in damage to the impeller shaft sleeve, water ring and stuffing box.
2. Cutter Motor Pressure Gauge
Measures the resistance to rotation encountered by the cutter. Low pressure readings will result when
excavating soft material and high readings when excavating harder materials.
3. Dredge Pump Discharge Pressure Gauge
This gauge indicates the relative resistance flow in the discharge pipe and varies with pipeline length,
pipeline elevation, slurry density and slurry velocity.
4. Oil Pressure and Water Temperature Gauges
These gauges allow for the remote monitoring at the dredge pump engine oil pressure and water
temperature. Both gauges should operate within their respective "normal" ranges. Refer to the
Caterpillar "Operation Guide" for more information.
5. Water Temperature Gauges
These gauges allow for the remote monitoring at the dredge pump engine oil pressure and water
temperature. Both gauges should operate within their respective "normal" ranges. Refer to the
Caterpillar "Operation Guide" for more information.
6. Main Engine Alarm Lights
These lights will illuminate to warn the operator of low oil pressure and/or high water temperature at the
dredge pump engine. Push to test the indicator lights daily to be sure they are operating properly, or
use the “Press to Test” function of the warning lights on a per shift basis.
7. Dredge Pump Suction Vacuum Gauge
Shows the level of vacuum in the suction pipe, which varies with pump speed, digging depth, slurry
density and slurry velocity.
8. Winch Motor Pressure Gauge
Measures the resistance to rotation encountered by the dredge swing winches.
9. Dredge Pump Engine Speed (Tachometer)
This gauge allows for the remote monitoring of the dredge pump engine speed. The engine speed will
vary depending on dredging conditions. The maximum dredge pump engine speed must not exceed
1800 RPM under a loaded condition.
10. Cutter Speed Control
This lever allows variable hydrostatic speed control of the cutter’s motor. During operation, the speed
can be adjusted as necessary to the material being excavated. “Slow” is toward the right (ccw); “Fast”
is toward the left (cw).
11. Cutter Direction Control
This switch controls the cutter forward (switch to the left), or reverse (switch to the right) rotation.
Reverse is normally used to clear obstructions. Allow the switch to set in the neutral or center position
for a few seconds when changing the direction of the cutter rotation.
12. PTO Clutch Assembly Engagement/Disengagement Switch (24 VDC)
This two position toggle type switch is powered by 24 VDC. Activation of this switch starts the oil pump
on the #151130 Hydraulic Power Pack. Hydraulic Oil Flow is supplied to the clutch engagement piston
housing assembly. Flow ceases when the piston housing is filled and a hydraulic pressure of
approximately 200 psi is applied to the clutch drive disc assemblies with the aid of relief and unloader
valving in the PTO Hydraulic Package. This engages the clutch assembly and transfers power from the
C32 engine to the slurry pump impeller shaft. Deactivation of the 24 VDC power switch stops the
hydraulic power pack pump and hydraulic flow pressure against the clutch friction discs is then
decreased which disengages the #151129 PTO assembly from the engine.
CAUTION/WARNING: Insure that the activation switch on the #151130 Hydraulic Power
Pack is in the “off” position prior to engine cranking or performing any maintenance on
the #151146 Dredge Pump Drive Assembly. Do not engage or disengage the PTO clutch
assembly with the C32 Engine RPMs above 750-800 engine RPMs. Doing so may cause
damage to the main pump or drive assemblies.
13. Port and Starboard Swing Brake Control
These two silver-handled valves remove slack from the swing winch cables through selective braking
by applying controlled hydraulic drag to the winches only when in the pay-out mode. Turning the
handle clockwise increases the drag, and turning it counterclockwise decreases the drag. When a
swing winch is in the haul-in (forward) mode, its swing brake is inactive. Refer to Tab 6 “Hydraulic
System” for more information.
14. Port and Starboard Swing Winch Control Switch
These two controls provide for the winch “Forward”, “Reverse”, and “Neutral” positions. Only one switch
is activated by the operator during the swing mode.
15. Spud Directional Control Switch
These two four-position controls provide three modes of spud movement: “Hoist”, “Reverse”
(controlled drop), and “Drop” (free-fall). Braking of the spuds is accomplished by returning the switch
lever to the neutral (center) position. Do not release the switch to neutral when the spuds are in the free
fall mode until the downward motion of the spud has stopped completely.
16. Ladder Directional Control Switch
The ladder is lowered and raised by winch assembly mounted at the aft end of the ladder. The ladder
is connected to this winch via a cable running over the bow gantry assembly sheaves and through a

ladder bale sheave assembly. By observing the ladder “Depth Gauge”, the operator can determine the
cutter’s depth. The switch has three operating positions, lower, neutral, and raise.
17. Dredge Pump Engine Speed Control Switch (Throttle)
This toggle switch provides remote operator control of the dredge pump engine speed. The speed of
the engine is dependent on the operating requirements and conditions. The speed can be controlled in
increments of approximately 50 RPM or continuously
18. Winch Speed Control
This lever allows variable speed control of the swing and ladder winches. During operation, the speed
can be adjusted as necessary. "Slow" is to the right (ccw); "Fast" is to the left (cw).
19. Dredge Pump Speed Reduction Unit Low Lube Oil Pressure Alarm.
The light will illuminate when the lube oil pressure in the dredge pump speed reduction unit is low. If
the lamp illuminates during pumping operations, or if it will not go out 5-10 seconds after pump drive
start up, the pump drive should be shut down as soon as safely practical. Activate the “Press to Test”
function of the warning light on a per shift basis.
D. CENTER TANK MOUNTED CONTROLS AND GAUGES (Not Illustrated)
1. Cutter Drive Hydraulic Circuit Pressure Relief Valve
This valve is located inside the dredge center tank on the port side wall. The proper relief setting is
2960 psi (210 kg/cm2) with the cutter in a relief (stall) condition. Adjustment is made by turning the
relief valve screw and securing with locknut. The pressure reading is made at the “Cutter Motor
Pressure gauge on the control stand.
2. Winch Brake Pilot Circuit Relief and Hydraulic Directional Valve Control Pilot Circuit Pressure Regulator
Circuit Gauges
Located inside the dredge center tank on the port side wall. These gauges register the spud winch
brake pilot circuit pressure which is normally about 800 psi (56 kg/cm2), and the Hydraulic Directional
Valve Control Pilot Circuit which is 400 psi.
3. Flow Indicator (Cutter Hydraulic Oil Return)
The “Flow Indicator” is located inside the dredge center tank on the port side wall and in the cutter’s
hydraulic motor case drain line. The indicator is a flap valve type with sight glass to view return flow.
During normal operation the flap valve is partially open. This opening continues to increase (indicating
heavier flow) as the cutter’s motor begins to wear allowing additional oil seepage into the cutter’s drive
shaft.
4. Dredge Pump Speed Reducer Drive Lube Oil Flow Gauge.
The dredge pump drive speed reduction unit has a lube oil flow indicator on the port side of the unit in
the lube oil piping. This indicator should be visually monitored by the dredge engineer systems monitor
periodically during pumping operations.
5. Dredge Pump Service Water Gauge

This gauge projects above the dredge pump reducer’s starboard side. Its operation and proper reading
is the same as the “Service Water Pressure” gauge in the Control Stand.
6. Spud Circuit Pressure Gauge
This gauge, located on the aft, upper starboard side of the engine room, measures this circuit’s
pressure. The maximum gauge reading is normally about 2346 psi (160 BAR).
7. Dredge Pump Speed Reducer Oil Level Gauge
The speed reducer’s oil level gauge is on the it’s starboard side. The oil level should be maintained at
a visible level in the gauge window. Add ISO 220 oil with anti-foam and oxidation inhibitors to maintain
level; do not overfill. Check the oil level with the speed reducer unit idle.
8. Hydraulic Reservoir Oil Level and Temperature Gauge
The hydraulic system oil level is visually monitored at a sight gauge on the forward end of the hydraulic
system head tank located in the upper aft portion of the dredge center tank (port side). The oil level
should be maintained as noted on the indicating arrow. Add hydraulic oil of the specification listed in
Section I of this manual; do not overfill. Operating temperature of the hydraulic system is visually
indicated by a thermometer on the forward end of the hydraulic reservoir. The reservoir is located
beneath the hydraulic system drive engine in the dredge center tank. The hydraulic oil temperature
should never exceed 140°F during dredge operations. Never mix biodegradable rated and standard
mineral based hydraulic fluids.
9. Hydraulic Pump Inlet Line Vacuum Indicators
There are three hydraulic oil vacuum indicators; each is located on the forward end of the hydraulic
reservoir on the three main suction lines. As the strainers within the reservoir clog, the indicators will
show red. When any of the indicators show red, the reservoir must be drained and the strainers
removed and cleaned. (See “caution” in Item #10)
10. Hydraulic System Return Line Filter Indicators
There are two return line filters used in this series; one located in the center tank aft port side; the other
in the center tank aft starboard side. An integral part of the filters is the pointer type indicator. This
indicator has three phases – OK (green), CHANGE (yellow), and BY-PASS (red) – depending on the
elements’ level of contamination.
CAUTION: The hydraulic system should never be operated with a filter assembly
indicator or a vacuum indicator in the red phase. Filter element should be changed as
soon as practical when the indicator is the yellow phase.
11. Service Water Valve and Service Water Strainer Assy.
The handle controlled water valve is located on the aft, lower starboard side of the engine room. When
the handle is paralleled to the service water line, the valve is open; when turned to 90°, it is closed.
Forward of the valve is the service water line strainer. This assembly contains a basket type strainer
which should be removed and cleaned periodically.

E. LADDER DEPTH GAUGE:
The ladder depth gauge board is mounted to the dredge ladder forward of the dredge operations and CAB
(Lever Room). The depth gauge assembly should be calibrated at "0" prior to dredging operations. This
assembly should be used only for reference. Exact cutting depths should be measured by a separate
sounding probe or other reliable means frequently during dredging operations.
NOTE: Set the indicator at “0” when the ladder’s center line is at water level.

REF. 150191 ENGINE
M A R I N E P O W E R D I S P L AY
Operator’s Guide
C AT E R P I L L A R M A R I N E P O W E R D I S P L AY Operator’s Guide
TABLE OF CONTENTS
INTRODUCTION
Hardware Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-5

Software Features (J1939 Data Link) . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Software Features (J1708 Data Link) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
MARINE POWER DISPLAY CONFIGURATION AND OPERATION
System Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Gauge Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Current Engine Totals Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Display Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Signal Loss to Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Marine Power Display Screen Builder Software . . . . . . . . . . . . . 8
Marine Power Display Parameters . . . . . . . . . . . . . . . . . . . . . . . 9-10
MARINE POWER DISPLAY SCREEN BUILDER SOFTWARE
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Screen Design . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Tool Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
Flash Download of Customized Files . . . . . . . . . . . . . . . . . . . . . . . 13
Method 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-17
Method 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
INTRODUCTION
The Marine Power Display is a monitoring system for all electronically
controlled Caterpillar® marine engines. The Marine Power Display provides
current engine and transmission operating data. The screens can be customized
to display different engine parameters using different sizes and types of
gauges. One Marine Power Display is required for each engine up to a maximum
of eight.
Hardware Features
Dimensions:
• 147.93 mm high x 228.68 mm wide x 47.65 mm deep (5.82 in. high
x 9.00 in. wide x 1.88 in. deep)
Screen:
• Positive image LCD, fully graphic, monochrome transflective, 320 by
240 pixels
• Double edgelit, red LED backlighting
Illumination:
• Stable over voltage range
• Adjustable by user, including off
Buttons:
• Marked with SAE Standard ICONS
• Red LED back lighting
Data Link:
• SAE J1939 CAN (Full Support)
• SAE J1708 Data Link (limited parameters)
4
Operating Range:
• Input system voltage of 12 or 24 VDC
• Full functionality from -20°C to +70°C (-4°F to 158°F)
• Sealed to 34.48 kPa (5 psi)
• Maximum viewing angle ± 35 degrees vertical, ± 50 degrees horizontal
Alarm:
• Piezo alarm is sealed in the interior of case
• External output for Relay Driver (100mA) – applicable to MPD hardware
part# 212-6187 and up
Mounting System:
• Panel mounting system for display module with side mounted brackets
and mounting screws
• Refer to the Marine Engine Electronic Displays Installation Guide
SENR5002-03 or higher revision level
• When used with Multi-Station Control System refer to MSCS Installation
Guide LEGM2735-00 or higher revision level
• Optional above dash mounting bracket
Application Code:
• Flash programmable
Service Tool Compatibility:
• Caterpillar ET field programming (3.1 or higher) with J1939 Data Link
connection and Communications Adapter II
Software Features (J1939 Data Link)
Engine parameter data can be displayed in analog, bar graph or digital gauges
in English or metric units:
Engine Speed, Percent Load, Boost Pressure, Coolant Temperature, Oil
Pressure, Oil Temperature*, Fuel Rate, Fuel Pressure, Fuel Temperature,
Inlet Manifold Temperature*, Transmission Temperature, Transmission
Pressure, Engine Hours, Battery Voltage, Vessel Speed, Latitude, Longitude,
Heading, Engine Trip Totals, Current Engine Totals
(* when applicable)
Software Features (J1708 Data Link)
Engine parameters can be displayed in analog, bar graph or digital gauges in
English or metric units. These engine parameters can be displayed for 3408C
and 3412C engines:
Engine Speed, Percent Load, Fuel Rate, Boost Pressure, Coolant
Temperature, Oil Pressure, Engine Location, Fuel Pressure
These engine parameters can be displayed for 3176B engines:
Engine Speed, Percent Load, Fuel Rate, Boost Pressure, Coolant
Temperature, Oil Pressure, Inlet Air Temperature
5
MARINE POWER DISPLAY CONFIGURATION AND OPERATION

The Marine Power Display can accommodate up to three users with five
screens for each. Three users can set up the Power Display screens to
their preferences.
The buttons have multiple functions dependent on which screen is displayed.
The button primary functions for the gauge screens are:
• Alarm acknowledgment for all displays on that specific Data Link,
silences audible alarm, and recalls active diagnostics
• Screen display
Normal (black letters with white background) Day Mode (bold) or
Reverse (white letters with black background) Night Mode
• Next screen
• Previous screen
System Information
On initial power up, scroll through the screens to the “System Information”
screen. This screen allows the following parameters to be configured: User
Name, Unit Location, Display Units, and Vessel Speed Units. A menu box is
located in the upper right corner of the screen. Press to display the
functions of the buttons
In the configuration mode the buttons have the following functions:
• Scroll through parameter choices
• Exit
• Move cursor up
• Move cursor down
Use or to move the cursor up or down to select the parameter. The
parameter name will appear in the box in the upper right corner of the screen.
Press to scroll through the choices:
• User Name
USER000001, USER000002, USER000003
• Unit Location
BRIDGE, PORT WING STATION, STBD WING STATION,
TOWER, ENGINE ROOM, AFT STATION, FLYBRIDGE,
BOW STATION
• Display Units
ENGLISH, METRIC
• Vessel Speed Units
6 KNOTS, MPH, KPH
The parameter choices will be highlighted on the screen with a black

background and white letters.
When all the correct parameters have been chosen, press to exit
the configuration mode and then press or to return to the
gauge screens.
Gauge Screens
The gauge screens can be configured with three different sizes of three types of
gauges. Analog, bar graph, and digital gauges can be arranged to each user’s
requirements for the available engine parameters. Refer to Marine Power
Display Screen Builder Software for gauge screen design options.
NOTE: If the engine software does not provide output for certain parameters, that particular gauge
will disappear from the display screen. The gauge will reappear if the software is upgraded to
support that parameter’s output, or if the display is used with a different engine.
Current Engine Totals Screen

Engine hours, fuel used, average load factor, and average fuel consumption for
a trip are available on the Current Engine Totals screen for engines with
ADEM™ II ECUs and appropriate engine software. To clear the trip
information and reset the trip parameters a toggle switch must be installed.
See engine installation guide.
In addition to these parameters, engines with ADEM A3 ECUs also display the
following parameters: trip values for idle hours and idle fuel; lifetime values for
engine hours, idle hours, fuel, idle fuel, average load factor, and average fuel
consumption. To clear the trip information and reset the trip parameters
press and simultaneously. When the Clear Trip? window appears
press and release to confirm clearing the trip information. Press and
release to return without clearing the information.
Diagnostics
All diagnostic messages from the engine’s ECU are supported by both a visual
indicator and an audible alarm. With no active diagnostic codes, no DIAGNOSTIC
indicator will be shown on the gauge screens. When an active fault is detected,
the DIAGNOSTIC indicator will appear in the upper left corner of the screen,
a diagnostic code description window will appear in the center of the screen,
and the audible alarm will sound. Press the alarm acknowledgment button
to silence the alarm. Press the alarm acknowledgment button again to
scroll through or remove the diagnostic code description window. The
DIAGNOSTIC code indicator will remain on the screen until the fault
is corrected.
7
Display Modes
• Day Mode - The normal display is a white background with black letters
and gauges. To increase or decrease the contrast, press and
hold to display the contrast slide bar. Use the arrow
keys to adjust the contrast.
• Night Mode - Press and release to change the display to the night
mode of a black background with white letters and gauges.
To increase or decrease the brightness, press and hold
to display the brightness slide bar. Use the arrow keys to
adjust the brightness. To increase or decrease the contrast
with the back light on, press and release again to
display the contrast slide bar. Use the arrow keys to adjust
the contrast. Press and release to exit the contrast bar.
Press and release to return to Day Mode.
Signal Loss to Display
The loss of a signal to the display will result in a DIAGNOSTIC with the
description of “NO DATA LINK SIGNAL.”
Marine Power Display Screen Builder Software
• Allows the Marine Power Display screens to be customized to the
requirements of the vessel operator or operators.
• Three sets of five screens can be downloaded and saved to the Marine
Power Display.
• Compatible with Windows 95/98/NT 4.0/2000/ME/XP
• User defined display screens
Parameters to display
Format to display parameters (gauge, digital, or bar graph)
Sizes limited to two or three for each type (gauge, digital, or bar graph)
Location on screen for parameter display
Addition/Deletion of screens (max 15 screens)
Multiple user configurations (max 3 different users)
User configuration file can be flashed
8
Marine Power Display Parameters

Engine operating and vessel control parameters available for display on MPD vary
by control system version (ADEM II, ADEM A3, etc.) and by engine model.
Available parameters will also differ between the primary ECU and backup ECU
on engines with two ECUs. The charts on pages 9 and 10 list engine operating
and vessel control parameters available for display by engine model.
3176C 3412E
C9 C12
Parameter 3126B 3196 C30
C7 C18
3406E C32
Engine Speed X X X X X
Battery Voltage X X X X X
Coolant Temperature X X X X X
Oil Pressure X X X X X
Fuel Rate X X X X X
Engine Load X X X X X
Boost Pressure X X X X X
Fuel Pressure X1 X X X X
Fuel Temperature X1 X X X X
Transmission Pressure X X X X X
Transmission Temperature X X X X X
Inlet Manifold Temperature X X X X
Oil Temperature X2 X X
Engine Hours X X X X X
Vessel Speed X X X X X
Latitude X X X X
Longitude X X X X
Heading X X X X
Coolant Level X X X
Total Engine Hours (Lifetime) X X X X
Total Fuel Used (Lifetime) X X X X
Total Idle Fuel (Lifetime) X X X X
Total Idle Hours (Lifetime) X X X X
Average Load Factor (Lifetime) X X X X
Average Fuel Consumption (Lifetime) X X X X
Trip Engine Hours X X X X X
Trip Idle Hours X X X X
Trip Fuel X X X X X
Trip Idle Fuel X X X X
Trip Average Load Factor X X X X
Trip Average Fuel Consumption X X X X X
Gear Position X X X X X
Troll Mode X X X X X
Slow Vessel Mode Status X X X X X
Sync Master Status X X X X X
Sync Cruise Status X X X X X
Shaft Speed X X X X X
Active Control Station X X X X X
Control Station Button/Lamp Status X X X X X
X1 Commercial Ratings Only X2 Optional 9
Marine Power Display Parameters
3500B 3500B 3500B 3500B

Primary Backup Series II Series II 3412C 3176B
Parameter Primary Backup 3408C
ECU ECU
ECU ECU
Engine Speed X X X X X X
Battery Voltage X X X X
Coolant Temperature X X X X
Oil Pressure X X X X
Fuel Rate X X X X
Engine Load X X X X
Boost Pressure X X X X
Fuel Pressure X X
Transmission Pressure X X
Transmission Temperature X X
Inlet Manifold Temperature X
Engine Hours X X
Vessel Speed X X
Latitude X
Longitude X
Heading X
Air Inlet Temperature X
Exhaust Temperature Right X X
Exhaust Temperature Left X X
Oil Filter Pressure X X
Fuel Filter Pressure X X
Coolant Level X
75% Overspeed Verify X X
Total Engine Hours (Lifetime) X
Total Fuel Used (Lifetime) X
Total Idle Fuel (Lifetime) X
Total Idle Hours (Lifetime) X
Average Load Factor (Lifetime) X
Average Fuel Consumption (Lifetime) X
Trip Engine Hours X
Trip Idle Hours X
Trip Fuel X
Trip Idle Fuel X
Trip Average Load Factor X
Trip Average Fuel Consumption X
Gear Position X
Troll Mode X
Slow Vessel Mode Status X
Sync Master Status X
Sync Cruise Status X
Shaft Speed X
Active Control Station X
Control Station Button/Lamp Status X
10
MARINE POWER DISPLAY SCREEN BUILDER SOFTWARE

Installation
Please refer to the MPD Builder (LERM0436-02), version 1.2 of the Marine
Power Display screen builder software. It is available through the Caterpillar
Media Logistics ordering system.
Screen Design
MPD Builder provides a layout grid to arrange the gauges and a gauge menu.
The left side of the screen has a miniature image of each of the five screens.
Tool Bar
The tool bar at the top of the MPD Builder screen has the following functions:
• New – opens a new file with five screens
• Open – opens a previously saved file
• Save – saves the current open file
• Cut – removes a highlighted gauge or gauges
• Copy – copies the highlighted gauge or gauges
11
• Paste – pastes the highlighted gauge or gauges to the same screen or to

another screen
• Zoom In – enlarges the layout grid
• Zoom Out – reduces the layout grid to the default size
• Print – prints the current open file
• Help – displays a window with the software version
Screen Selection
Each file contains five screens. When a new file is opened the layout grid for
screen one is displayed. To select another screen, click the left mouse button
on one of the miniature screens on the left side of the Builder screen.
Gauges Selection Menu
• On the gauge menu, click on the tabs for Analog, Bar Graph, and Digital
to display the available gauges for each type. These gauges are available in
the three types:
Battery Volts, Boost Pressure, Coolant Temperature, Engine Load, Engine
Speed, Fuel Pressure, Fuel Rate, Fuel Temperature, Manifold Temperature,
Oil Pressure, Oil Temperature, Vessel Speed, Transmission Pressure,
Transmission Temperature.
• The digital gauge menu also includes:
Engine Hours, Heading, Latitude, Longitude.
• Use the black arrow on the far right side of the gauge menu to scroll
through the remainder of the gauge selections.
Gauge Application
• To add a gauge to the screen, click the left mouse button and drag the
gauge to the layout grid, or click the left mouse button on the gauge and
click again on the layout grid. Click the white arrow on the left side of the
gauge menu to deselect the gauge.
• Once a gauge is on the layout grid it can be highlighted. A single gauge on
the layout grid can be highlighted by clicking the left mouse button.
Multiple gauges can be highlighted by holding the shift key and clicking
on each gauge.
• The gauge must be highlighted to perform the available functions. With
the gauge highlighted it can be moved to any part of the layout grid by
clicking the left mouse button and dragging. When the gauge is
highlighted, click the right mouse button to display a menu with Cut,
Copy, Paste, Type, Size, Scaling, and Align. These menu selections
12 perform the following functions on the highlighted gauge or gauges:
Cut – removes the gauge from the layout grid of the screen.
Copy – copies the gauge.
Paste – pastes the gauge to a different part of the same layout grid or to
another grid.
Type – changes the gauge to analog, graph, or digital.
Size – changes the gauge size to medium or large (the default size
is small).
Scaling – changes the scale on the Engine Speed, Fuel Rate, and Vessel
Speed analog and digital gauges. Engine Speed scale can be
changed from the default of 0-3000 to 0-3600 or 0-4000.
Fuel Rate scale can be changed from the default of 0-50 to
0-80. Vessel Speed can be changed from the default of 0-30
to 0-50 or 0-80.
Align – aligns the highlighted gauges by the left, right, top, or
bottom edges.
Flash Download of Customized Files

After the set of five screens has been constructed, select the intended
user for these screens. Select Options, User Bank, then select the number
of the appropriate user. Then save the file.
When the gauge screens for each user have been saved, the files can be
transferred to the Marine Power Display using the Caterpillar Electronic
Technician (ET) service tool, version 3.1 or higher, and Communication
Adapter II 1.1 software. Customer version of ET 2001B or higher will allow
the customer to program builder tool files to the Marine Power Display.
13
Method 1
This procedure applies to engines with the following serial number and below:
3412E s/n 9KS00800 and lower 3500B s/n All
3412E s/n 9PW00355 and lower 3412C s/n All
3406E s/n 9WR01560 and lower 3408C s/n All
3196 s/n 2XR03370 and lower 3176B s/n All
3176C s/n 6BW00493 and lower
A service tool field harness must be fabricated to connect the service tool to
the data link for transferring the screen files. This harness must also be
connected to the engine service tool connector.
Harness Fabrication
Parts required for the harness are:
Qty Part Number Description
1 165-0200 Cable Assembly
1 8T8735 Connector
1 8T8736 Connector
* 143-5018 Data Cable (twisted pair, 2 conductors)
* 16 AWG wire
(* fabricate to length)
14
The connector pin outs for the 8T8736 and the 8T8735 connectors are:
F CAN Negative
G CAN Positive
C CAN Shield
A + Battery (11-45 VDC)
B - Battery (ground)
D Cat Data Link Positive
E Cat Data Link Negative
J ATA Data Link Positive
H ATA Data Link Negative
1. Remove the 133-0969 Sockets from the 165-0200 Cable As. and replace
the sockets with 8T8729 Pins. This becomes the 165-0200 (modified)
cable.
2. Connect the wires as shown in the diagram and the pin out chart.
3. Use 143-5018 Data Cable for the Cat Data Link and the ATA Data Link
connections between the 8T8736 and the 8T8735 Connectors.
4. Use 16 AWG wire for the + Battery and - Battery connections between the
8T8736 and the 8T8735 Connectors.
File Download
1. Disconnect the vessel data link wiring from the 165-0200 Data Cable that
is connected to the 40 pin customer connector.
2. Connect the service tool field harness (8T8735 Connector) to the engine
service tool connector.
3. Connect the modified 165-0200 Cable As. of the service tool field harness
to the 133-0970 TEE Receptacle of the data link for the Power Display.
4. Connect the laptop to the Communication Adapter II with the 160-0141
Adapter Cable and the Communication Adapter II to the 8T8736
Connector of the service tool field harness with the 207-6845
Adapter Cable.
IMPORTANT: On some laptops running on battery power, the power saving features interfere
with the WinFlash program. If you experience difficulties with the download, connect your
laptop to AC power. When downloading to Marine Power Display, the ET window should be the
only one open. All other windows should be closed for the downloading process.
5. Start the WinFlash program by clicking on Start / Programs / Caterpillar
ET / WinFlash.
15
6. When the ECU Selector window comes up, select Marine Power Display
and click on OK.
7. Information on the Marine Power Display unit will appear. Click on

Select File to display the flash files. Be sure that the file type window has
all files selected. The customized screen files have a .mpd extension. The
Marine Power Display application files have a .fls extension.
16
8. Select the customized screen file and click on OK.

9. Click on Begin Flash. Observe the status bar until downloading is
100% complete.
As the file is downloading, the Marine Power Display will have the message
“Programming Receiving Data.”
10. When downloading is complete, the Cat® Electronic Technician window

will appear with the message “Flash completed successfully.” Select Exit
to shut down WinFlash.
17
Method 2
The ET service tool can be directly connected to the engine’s service tool
connector on the following engines:
3412E s/n 9KS00801 and up C30 s/n All
3412E s/n 9PW00356 and up C18 s/n All
3406E s/n 9WR01561 and up C12 s/n All
3196 s/n 2XR03371 and up C9 s/n All
3176C s/n 6BW00494 and up 3126B s/n All
File Download
Follow steps 4 through 10 beginning on page 15.
18
NOTES
19
O p e r a t o r ’s G u i d e
CAT, CATERPILLAR, ADEM, their respective logos and “Caterpillar Yellow,” as well as corporate and product identity used
herein, are trademarks of Caterpillar and may not be used without permission.
LEBM0189-04 ©2006 Caterpillar

SECTION III-TAB 2:
MAIN ENGINE, PTO, DREDGE PUMP, AND
DREDGE PUMP SPEED REDUCTION DRIVE UNIT
TABLE OF CONTENTS
Page
A. SYSTEM DESCRIPTION..""""""""""""""""""""""""""". 1
B. OPERATION""""""""""""""""""""""""""""""""". 1-3
1. Service Water Pressure""""""""""""""""""""""""""""".. 1

2. Clutch Operation"""""""""""""""""""""""""""""""".. 1
3. Pump Operation Basics""""""""""""""""""""""""""""".. 1-3
C. SERVICING""""""""""""""""""""""""""""""""".. 3-6
1. Main Engine"""""""""""""""""""""""""""""""""".. 3
2. Dredge Pump"""""""""""""""""""""""""""""""""" 3-6
D. TROUBLESHOOTING""""""""""""""""""""""""""""" 8
E. DREDGE PUMP ASSY. FEATURES"""""""""""""""""""""".. 9-13
DRIVE, DREDGE PUMP ASSEMBLY (DWG. #151146)"""""""""""""""" INSERT
PUMP, DREDGE ASSEMBLY (DWG. #151145)""""""""""""""""""". INSERT
REDUCER, DREDGE PUMP (DWG. #151128)""""""""""""""""""".. INSERT
MAIN PUMP DRIVE COUPLING INFORMATION (P/N 150431)"""""""""""". INSERT
COUPLING, FLEXIBLE (REF. DWG. #150431)""""""""""""""""""".. INSERT
CLUTCH, HYDRAULIC (P/N 151129)"""""""""""""""""""""""" INSERT
CLUTCH, HYDRAULIC POWER PACK (P/N 151130)""""""""""""""""" INSERT
NOTE: The gap between the impeller face and the forward liner in the #151145 pump assembly
is set at 1/8" on a new pump assembly. It is recommended that the dredge operator establish a
program to examine this gap as well as other areas of the pump to detect excess wear.
Periodic shimming of the impeller can help maintain maximum pump efficiency. Pump part
wear rates will vary with individual site and pumping conditions.

Section III-Tab 2 Main Engine and Dredge Pump
A. SYSTEM DESCRIPTION:
The centrifugal, single suction, volute-type dredge pump is driven by a Caterpillar diesel engine through
a close-coupled, enclosed reduction gear drive and an electrically actuated hydraulically engaged, multi-
plate clutch. The impeller shaft, an integral part of the reduction gear, is equipped with tapered roller
bearings to handle thrust and radial loads. A flexible coupling connects the engine to the input shaft of
the reduction gear.
NOTE: Actual engine power and RPM settings are set to Ellicott specifications and may
vary from the engine data tag.
A stuffing box and gland arrangement is provided at the impeller shaft opening in the pump. Water from
the service water system (from a service water pump also driven by the main engine) lubricates the
packing in the stuffing box and accomplishes the additional functions of sealing the shaft entrance area
of the pump against air leaks, and flushes the area between the engine side head and the impeller.
Service water also cools the dredge pump speed reduction drive unit lube oil. A replaceable sleeve is
fitted on the impeller shaft in the area where the shaft passes through the stuffing box. A quick release
collar is provided for easy removal of the dredge pump impeller.
Replaceable liners are provided to shield the heads of the pump from wear. A replaceable throat liner,
located at the suction entrance to the pump, shields the suction side head and protects the eye of the
impeller.
The pump interior is sealed against the entrance of air except through the suction pipe mouth which is
lowered beneath the surface of the water. A water jet priming exhauster, operated by service water
pressure, evacuates the air from inside the pump casing and suction line. The resulting partial vacuum
draws water in from the submerged suction line to fill the pump casing and suction pipe. When the
pump has sufficient flooding, the impeller’s rotation establishes a discharge flow; and the pump is now
“primed”. The exhauster can then be turned off and normal pumping carried on. See Section IV for
pump priming instructions.
B. OPERATION:
1. Service Water Pressure (Also see Tab 10 “Service Water System”)
Of prime importance in the operation of the dredge pump is the maintenance of adequate service water
flow and pressure in the stuffing box. The service water pressure must exceed the discharge pressure
of the dredge pump by 10-15 PSI when operating. This assures that the packing in the stuffing box, if
installed correctly, will be adequately lubricated and that the stuffing box will be sealed against the
entrance of slurry.
CAUTION: Do not operate the dredge pump without adequate service water pressure;
doing so may result in damage to the impeller shaft sleeve, stuffing box, and water ring.
2. Clutch Operation
An electrically actuated and hydraulically engaged, multiplate clutch is provided between the Caterpillar
C32 diesel engine and the main pump reduction gear. The clutch can only be engaged or disengaged
by the use of the toggle switch provided on the clutch power pack assembly.

The service life of the PTO/Clutch assembly depends on proper maintenance and adjustment. The
clutch pressure plate force adjustment must be checked frequently at time of equipment delivery and at
least once per 8 hour running shift thereafter. (Maximum hydraulic engagement force is 200 psi (13-79
BAR) and minimum hydraulic engagement force is 175 psi (12.06 BAR).
CAUTION: Never engage or disengage the clutch above 700-750 RPM or allow the
clutch to slip for more than two seconds during engagement.
3. Pump Operation Basics
A dredge pump operates by evacuating its casing and allowing barometric pressure to fill the void with
fluid.
As long as the available barometric pressure is sufficient to overcome the losses in the suction pipe, the
pump will operate in a smooth and satisfactory manner.
Whenever the suction pipe losses exceed the available barometric pressure, the pump will cavitate or
“break suction” and will generate noise, vibration and destructive forces that will damage the pump and
dredge if corrective action is not taken.
The dredge operator is faced with the responsibility of obtaining the highest solids output from the
dredge pump while remaining below the cavitation point of the system.
The most efficient pumping operation occurs when the system is pumping the highest possible density
slurry at the lowest possible velocity at a vacuum level that is just below the dredge pump cavitation
point.
To guide the operator in obtaining the best output, the dredge is equipped with dredge pump vacuum
and discharge pressure gauges in the dredge operator’s control stand.
The vacuum gauge displays the losses in the suction pipe and gives an indication of the slurry density
and velocity. Higher densities and velocities result in higher vacuum readings. If cavitation should
occur, the velocity will reduce and the vacuum gauge will show a low or erratic vacuum as the pump
noise and vibration increase. Also if the suction becomes plugged by oversize or excessive material,
the vacuum reading will increase until cavitation begins. Additionally, the vacuum reading will reduce if
the discharge pipe begins to plug which causes a slowdown of pipeline velocity.
The discharge gauge displays the resistance to flow in the pipeline to the disposal site. Its reading is an
indication of slurry density, velocity and the height of the disposal point above the water line. A sudden
rise in discharge pressure indicates an obstruction in the pipeline and requires immediate attention by
the dredge operator to reduce the viscosity of the slurry mixture in the pipeline.
When starting operation on a new project, the operator should obtain a preliminary clear water pump
velocity by lowering the ladder below water and increasing the pump rpm to obtain the optimum
pipeline flow velocity for the material being dredged. Without changing the clear water speed, the
ladder should be lowered to engage the material and the swing operation started. As the dredge begins
to transport slurry, the vacuum and discharge readings will increase and the readings should be
maintained as high as possible without causing cavitation. At this time, it may be necessary to adjust
the pump speed to suit the slurry transport.
Following is a list of observations that may be seen by the operator and the recommended action to be taken:

a. The vacuum gauge reading increases with a fall in discharge pressure.
The suction pipe is becoming plugged by a cave-in, excessive swing speed or excessive cutter
immersion. Slow the swing speed initially and if necessary, raise the ladder temporarily and pump
clear water.
b. The vacuum reading falls and the discharge gauge reading increases.
The discharge pipe is becoming plugged due to settling of the slurry. Reduce the swing speed
initially and if necessary, lift the ladder temporarily and pump clear water. When resuming
operation, consider increasing the pump speed if possible to provide a higher slurry velocity.
NOTE: A plugging discharge line requires immediate attention to avoid a costly pipe
cleaning operation.
c. The engine speed will not respond to an increase in throttle position.
The engine is operating in a ‘lugged’ condition due to overload which will reduce engine life. This
overload is sometimes characterized by black exhaust smoke. Reduce the engine speed sufficiently
to regain throttle response.
d. The vacuum and discharge gauge readings are low and the engine is lightly loaded.
Increase the swing speed and\ or ladder depth to obtain more solids and increase the slurry
density. Also increase the pump speed if possible. Consider a longer forward step on the next
spudding operation.
C. SERVICING:
1. Main Engine
Service information on the main engine is contained in Caterpillar’s ”Operation Guide” and other
supplemental literature supplied. (See Section VII Tab 4)
2. Dredge Pump (Reference Figure 4-2.1)
Since the dredge pump is the “heart” of the dredge, it is recommended that internal pump inspections
be made part of a routine maintenance program. Wear data collected will permit the scheduling of part
replacement so that new parts can be ordered and on hand when needed.
a. Piping
When bolting the suction and discharge piping to the pump, be careful that the pump is not pulled
out of alignment. The suction and discharge pipe must not be supported by the pump.
b. Repacking The Stuffing Box
NOTE: The dredge pump stuffing box requires regular inspection and periodic
repacking. indications that the stuffing box may require maintenance are: (1) excessive
water leaks; (2) the gland cannot be adjusted any further to correct leakage; (3) the
stuffing box runs hot; and (4) the pump is difficult to prime or loses prime.
When repacking a stuffing box, old packing must be removed and discarded. Only rings made from
new, unused packing should be used in the stuffing box.
1) Remove the four gland nuts from the studs; slide the gland assembly back along the shaft out of
the stuffing box. Remove the gland assembly bolts; separate and remove the halves.
2) Remove the five rings of old packing; discard. (A packing tool will facilitate packing removal).
3) Pull the water ring back along the shaft; separate and remove that water ring halves. Clean and
carefully inspect the water ring, If badly, worn, replace. (The water ring has tapped holes to
facilitate removal using threaded rods.
4) Remove all foreign matter from the stuffing box. Clean and inspect the impeller sleeve, If the
sleeve is scored, worn, or badly pitted, replace with a new sleeve (See “Impeller Shaft Sleeve
Replacement”).
5) Use the correct packing. Approximately 190 inches (483 cm) of ¾” (19 mm) square, graphite-
filled, braided, packing is required.
6) Cut five rings approximately 35” (89 cm) long. Dress each ring to the exact sleeve
circumference making certain that the ends form a straight butt radial joint (his helpful to make
the first ring a “master” ring pattern for cutting the rest.)
7) Place the two halves of the water ring about the shaft sleeve; slide the assembled ring into the
stuffing box. Check to make sure that the service water entrance hole lines up with the outer
grooves of the water ring.
8) When installing the packing rings, twist them sideways just enough to get them around the
shaft. Do not pull the rings straight apart at the ends.
NOTE: As each ring is placed about the shaft, slide it into the stuffing box and firmly
seat each ring. Make sure that the end joints of the rings are staggered from each other
by at least 90°.
9) Replace the gland assembly halves on the shaft, assemble the gland into the box.
10) Place the four hex head nuts over the studs and draw up evenly but not tight.
c. Stuffing Box Packing Adjustment
The stuffing box packing should be adjusted while the pump is running at normal rpm. There are
several points to remember when making these adjustments:
1) A properly adjusted stuffing box will permit a small amount of leakage to pass. This leakage is
necessary to lubricate the packing and maintain a cool stuffing box.
2) The packing must NEVER be drawn so tight as to cause the stuffing box to overheat.
3) Always draw up the gland nuts evenly and only while the pump is running. NEVER tighten or
loosen the gland nuts while the pump is stopped. This will usually result in excessive leakage
and ruined packing.
4) Draw up the gland nuts evenly and no more than a quarter-turn at a time. Allow time between
adjustments for the packing to “runin”. It will generally require some time and several
adjustments for the packing to become properly “run-in”. If the stuffing box heats up during the
run-in period, loosen the gland nuts and let the packing cool while the pump is running, If the
stuffing box will not cool, stop the pump until the stuffing box has cooled. Remember not to
loosen the gland nuts while the pump is stopped. It may require several starts before the stuffing
box runs cool and passes the proper water leakage
5) Always check and see that the service water pressure equals or exceeds the discharge
pressure.
WARNING: Beware of rotating parts when adjusting the stuffing box gland. Use a long
handled wrench to distance personnel from the machinery.
d. Impeller Removal and Replacement
CAUTION: The principal parts of the dredge pump, including the impeller, are cast from
extremely hard, abrasive-resistant alloy white iron, which is brittle and susceptible to
cracking or shattering if dropped. Particular care must be exercised when handling
these pump parts to assure that they are not struck, bumped, or dropped.
Removal:
1) Before removing the impeller, the suction cleanout, throat liner, and (suction side) head (with
liner intact) must be removed in order to gain access to the impeller.
2) An impeller is usually set very tight upon the impeller shaft threads, and it is often difficult to
break the impeller free. Remove the quick- release collar by removing its three screws and
splitting it with a chisel. The impeller shaft sleeve will be allowed to move back along the shaft,
away from the impeller, making the impeller easier to unseat.
WARNING: Do not heat the impeller hub to ease removal. Heating can result in a
dangerous explosion and cause serious injury or death.
3) The impeller shaft is held rigid by engaging a wrench on the forward, hexagonal end of the high-
speed pinion shaft located under the impeller shaft With one man holding the wrench, another
should turn the impeller to the right (the impeller shaft has left handed threads) to break the
seat. After this is done, the impeller should be supported by a hoist and impeller hook or a
chainfall, and the wrench turned to the right to unscrew the impeller.
Reassembly:
1) Replacing the impeller upon the shaft is essentially the reverse of the removal procedure.
Before reassembly, carefully inspect the threads on both the shaft and impeller hubs for
particles and metal chips.
2) Be certain that the metal gaskets between the impeller hub and the end of the impeller sleeve
are in place. These gaskets, normally five in number - each .020” (.5mm) thick - establish the
nominal 1/8 of an inch (3mm) gap which should be maintained between the impeller front
shroud and the face of the assembled pump front headliner. An increased gap dimension can
reduce pump performance.
3) Reassemble the quick-release collar on the impeller shaft.
4) Supply a coat of grease or “never seize” to both threads, and then screw the impeller fight upon
the shaft. The grease will make the joint easier to break loose on subsequent disassembles.

5) The impeller must be tightened or firmly engaged. This tightening will usually occur
automatically when are assembled pump first begins to pump material.
CAUTION: ALWAYS disengage the manual clutch between the main engine and the
reduction gear before stopping the dredge pump engine, If the impeller’s momentum
breaks it loose from a suddenly stopped shaft, the impeller will unscrew itself and
travel forward damaging the impeller, shaft bearing, throat piece, and front head liner.
e. Impeller Shaft Sleeve Replacement
The impeller shaft sleeve is secured to the impeller shaft by the clamping action of a split, quick-
release collar assembly. It should be replaced when the outside surface in the packing area
becomes worn, scored, or pitted.
The procedure for replacing the sleeve is as follows:
1) Remove the quick-release collar assembly.
2) Remove the stuffing box packing and gland assembly following the aforementioned procedure.
3) Remove the pump impeller following the procedure previously described.
4) Slide the sleeve off the end of the impeller shaft.
5) Reassemble the quick-release collar in place on the impeller shaft.
6) Grease the inside of the replacement sleeve; slide it onto the impeller shaft.
7) Reinstall the impeller following the previously described procedure.
8) Replace the stuffing box packing and gland assembly following the procedure described earlier.
WARNING: All components coming into contact with the dredged material are subject
to varying rates of wear based on but not limited to material abrasiveness and pipe line
velocity. The dredge operator is advised to perform scheduled inspections of the slurry
pumping system to determine remaining thickness or other pertinent material wear
data to make a decision on replacement interval requirements. Pump case “scuffing”
and recirculation wear on head liners cannot be detected by visual inspection through
the pump suction cleanout assy.
Excess wear on slurry pumping components can create explosion or rupture condition
that could result in equipment damage or injury to personnel.

Dredge Pump Assembly (Figure 4-2.1)

D. Troubleshooting
Effect Possible Cause(s) Remedy

Dredge Pump Engine Runs Jacket water cooler fouled Rod out (clean tubes)
Hot Insufficient jacket coolant 1. Fill
Insufficient cooling water 2. Refer to Caterpillar Instruction Manual
Material binding impeller 1. Reset head clearances
2. Replace impeller
Engine speed too high for pipeline 1. Reduce engine rpm
length (pump may also cavitate) 2. Increase line length
No lube oil pressure See Caterpillar Instruction Manual
Incorrect engine rack setting or timing Inspection by Caterpillar representative required
Dredge Pump Will Not Prime Suction inlet above or too close to Lower ladder/Ballast dredge if required
or Loses Prime water surface.
Air leaks 1. Check gaskets
2. Tighten bolts
3. Check stuffing box packing
4. Check suction pipe for holes
Low service water pressure 1. Check service water system pump for wear
or slipping belts.
2. Check slurry pump packing and sleeve.
Exhauster not pulling vacuum. 1. Exhauster valve closed; manually open air
exhauster valve.
2. Exhauster clogged or damaged; clean or
repair.
Excessive Stuffing Box Packing requires adjustment or See procedure previously discussed in this tab.
Leaks repacking.
Pump Vibrates Impeller out of balance (no noise or Remove debris from impeller through suction
crackling, rumbling) cleanout. Check impeller for damage.
Rebalance/replace impeller
Excessive impeller shaft run-out (no 1. Replace worn bearings, adjust end play
noise or crackling, rumbling) clearance.
2. Replace impeller shaft if bearing fits are worn.
Pump cavitating (loud noises and 1. Reduce engine rpm or increase length of
cracking, rumbling) discharge line
2. Reduce material concentration (S.G.)
digging depth or swing speed
3. Clear obstruction fouling suction pipe
4. Investigate system imbalance
Impeller Shaft Bearing 1. No service water 1. Check service water system
Housing Hot 2. Fouled cooler tubes 2. Clear
3. Oil pump failure or loss of prime 3. Replace pump/re-prime system
4. Oil strainer clogged 4. Clean
5. Lack of oil 5. Refill
Loud Rumbling from Main 1. Improperly set bearing end play
Pump Bearing Housing or bearing wear 1. Reset
2. Loss of oil to bearing 2. Check/replace bearing
3. Oil contamination 3. Drain housing. Add new oil
High Dredge Pump Vacuum, Obstruction in suction pipe or dredge 1. Raise ladder off bottom; try quick variation
Low Discharge Pressure pump entrance in pump speed to pull obstruction
2. Remove obstruction from suction pipe and
suction clean-out.
High Discharge Pressure, Obstruction in discharge pipeline 1. Raise ladder off bottom; pump water
Low Vacuum 2. Strike pipe in vicinity of obstruction while
pumping
3. Disassemble pipe and remove obstruction






ITEM NO. PART NO. DESCRIPTION QTY.
6X
1 151028 ENGINE, DIESEL C32 MARINE 1
5.16 45 1 22 33 2 151145 PUMP SLURRY ASSY 18 IN 1270 1
3 151129 CLUTCH, ENCLOSED 18 IN HYD. 1
CLUTCH 4 151130 CLUTCH, HYDRAULIC POWER PACK 1
ENGINE
DRIVE RING 5 150431 COUPLING, VULKAN 1
TORQUE TO
FLYWHEEL
6 150204 SUPPORT, ENGINE PORT 1
G
57-63 LB-FT TORQUE TO 9 7 150205 SUPPORT, ENGINE STBD 1
145-155 LB-FT
4
8 151144 SUPPORT, CLUTCH 1
9 151016 BRACKET, MTG CLUTCH PWR PACK 1
1 46
10 150255 LINER, EQUIPMENT FDN, KIT 1
11 124570 PLATE, CLUTCH BOLTG 4
12 125174 PLATE, JACKING ASSY 12
REF
CLUTCH SHAFT 13 227406 BUSHING, PVC DAMPING 4
FLUSH WITH FACE 1 14 150217 PLATE, ENGINE BOLTING 4
OF COUPLING HUB 15 13 28 31 24
15 200003 BOLT, HEX HD SS 0.25 X 1.00 4
1 47 16 200137 BOLT, HEX HD 0.62 X 2.25 4
4X 1
17 200135 BOLT, HEX HD 0.62 D X 1.75 14
CLUTCH HOUSING 18 200183 BOLT, HEX HD 0.75 D X 4.50 4
F
19 200252 BOLT, HEX HD 1.00 D X 4.50 18
11 REF
33 16 44 20 200291 BOLT, HEX HD 1.25 D X 5.00 4
1
DETAIL E 21 223690 BOLT, HEX HD GR-8 0.50 X 1.50 16
TORQUE TO 4X
1 DETAIL D
145-155 LB-FT SCALE 1 : 8 22 221400 BOLT, HEX HD GR-8 0.62 D X 1.50 6
TORQUE TO 1/D6 23 221422 BOLT, HEX HD GR-8 0.62 D X 1.75 6
275-300 LB-FT
24 225015 NUT, HEX SS REG UNC 0.25 4
25 200421 NUT, HVY HEX .75 UNC 4
26 200423 NUT, HEX HVY 1.00 UNC 18
27 200425 NUT, HEX 1.25 UNC 4
6.23 28 200468 WASHER, PLATE SS .25 4
1
29 200477 WASHER, PLATE 1.0 8
ITEM 5
1/A8 B A 1/C10 E
SCALE 1:4
C 1/A10 30 200479 WASHER, PLATE 1.25 4
2 31 200493 WASHER, LOCK SS .25 4
1/E6
SEE DETAIL 32 200497 WASHER, LOCK .50 16
1/E10 33 200499 WASHER, LOCK .62 32
TORQUE TO
TORQUE TO 159 LB-FT (LUB) 34 200501 WASHER, LOCK .75 4
5
80 LB-FT (LUB) REF 35 200505 WASHER, LOCK 1.0 18
33 23
32 21 1 36 200509 WASHER, LOCK 1.25 4
3 REF 6X
37 202545 SETSCREW, SQ HD OVAL PT 1.0 X 3.00 4
16X
38 201310 NIPPLE, 1.00 DIA X 1.50 SCH 40 1
D 1/ F7 CL 39 217487 VALVE, BALL 1.00 WORCH 4211B 1
3 40 209378 PLUG, SQ HD, #3000 FST 1.00 IN 1
41 150356 KIT, SHIM 1
42 900111 BAR, FLAT F11F 1.50 X 1.50 X 4.00 2
D
43 227419 GREASE, LONG TERM NLGI GRADE 1 1
44 152109 BRACKET 1
4X 45 152264 HOSE ASSY, 100R1, .50 X 31.00 1
42
48 20 30 36 27 46 217176 U-BOLT GRINNELL 137 4.00 1
1
1 2X 47 221808 ELBOW, PKR 8-C5OX-S 1
48 223339 BOLT HEX HD TAP 0.50 X 3.00 2
10 47.50 49 222817 BOLT, HEX HD GR-5 0.62 X 1.50 2
10
REF
SECTION A-A NOTES:
1/E6
C
ML 1. JACKING PLATE ASSEMBLIES TO BE LOCATED WHERE NECESSARY
C B A 26 35 19 10 37 12
TO MAINTAIN PROPER POSITION OF MAIN ENGINE AND GEAR BOX AND
4X MUST BE WELDED TO PRIMARY STRUCTURAL MEMBERS ONLY.
REF 4X 8X
10 7 19 29 26 35 14 40 39 38 FR.18 25 34 11 18 8 10X FR. 24
2. CLUTCH OUTPUT SHAFT (ITEM 3 ) DEFLECTION SHOULD BE .005"
REF 8X (6.23)
R.F.O.B. 5.60 4X 29.00 MAX. USE SHIMS (ITEM 41 ) AS REQUIRED.
CPLG GAP
40.61 59.76 3. CLUTCH OUTPUT SHAFT AND PUMP SHAFT TO HAVE AN AXIAL
REF 4X TOLERANCE OF .020 RADIAL OF .012 T.I.R. AND ANGULAR OF
106.60
1 .010 T.I.R. USE SHIM KIT AS REQUIRED.
17 33
4. ALL UNUSED SHIMS FROM ITEM 41 AND INSERTION TOOL TO BE
REF
REF
STBD ENGINE 1 44
SHIPPED WITH UNIT. B
7
SUPPORT (SHOWN) REF 5. AFTER FINAL ALIGNMENT OF MACHINERY HAS BEEN COMPLETED
6 OPPOSITE 1 1 1
9 AND ALL FOUNDATION BOLTS HAVE BEEN DRAWN UP, INSTALL ENGINE
4X 2X
CHOCKS (ITEM 42 ) FRONT AND REAR OF ENGINE MOUNTING BASE.
33 17
49 33
SEE NOTE 1 12 6. HARDWARE TO BE SECURED WITH LOCTITE 242 AT FINAL ASSEMBLY.
17 33
2X PORT SIDE 7. GEAR COUPLING (ITEM 5 ) TO BE LUBRICATED WITH LONG TERM
REF 2X
1/4 BEARING GREASE (ITEM 43 )AT FINAL ASSEMBLY.
7
6 STBD SIDE
10 DO NOT SCALE - ALL DIMENSIONS SHOWN WITHOUT DIMENSION LINES REFER TO DATUM LINE MARKED "0" SH 1 OF 1
10
SECTION C-C 6 SERIES DIMENSIONAL TOLERANCES UNLESS
ELLICOTT
THIS DRAWING INCLUDES PROPRIETARY DATA
SCALE 1 : 8 WHICH IS THE EXCLUSIVE PROPERTY OF 5
OTHERWISE NOTED
1270
COMM. STOCK SIZES EXCLUDED A
PORT SIDE SIMILAR 1 SECTION B-B ELLICOTT DREDGES, LLC. NO DISCLOSURE
4
BALTIMORE, MARYLAND, U.S.A.
SCALE 1 : 8 1 - PLACE DECIMAL ± .060

1/E8 OR REPRODUCTION ALLOWED WITHOUT THE DR. Admin
1/E7 WRITTEN CONSENT OF ELLICOTT DREDGES, 3 MADE FROM 2 - PLACE DECIMAL ± .030
CHK. PHJ DRIVE, DREDGE PUMP
LLC. ELLICOTT AND MUDCAT ARE REGISTERED 2 3 - PLACE DECIMAL ± .015
SCALE: 1:12
EST.
APPR. & NOTED WEIGHT:25970 Lbs. DATE: 5/19/11
TRADEMARKS. FIELD
BOM 1 5604 5/31/13 LAV JWK/SIM
CAD ANGULAR MACHINED SURFACES ± 30' APPR. ES FIRST USED SHT.SIZE REV.
C ELLICOTT DREDGES LLC 2011 ZONE NO

CHG.
NO. DATE BY CK. DO NOT EDIT
MACHINED SURFACE TEXTURE 250 MFG. 401270 4 151146 1
11 10 9 8 7 6 5 4 3 SECT. 11 2 1 REQ'D. 1
LUBE OIL COOLER
2/B5 C C
PARTIAL PLAN VIEW
2X
A
20 35 16 2/A9 23 27
B
E
2
22 18X FRONT &

22 BACK HEAD
34 32 26
1 8X
28 18 SEE NOTE 4 26 34 19
4X 16X FRONT & D
BACK HEAD
17 33 30 24
B
SECTION B-B
C
29
3X FRONT &
BACK HEAD
DO NOT SCALE - ALL DIMENSIONS SHOWN WITHOUT DIMENSION LINES REFER TO DATUM LINE MARKED "0" SH 1 OF 2
6 SERIES DIMENSIONAL TOLERANCES UNLESS
WHICH IS THE EXCLUSIVE PROPERTY OF 5 1270
OTHERWISE NOTED
COMM. STOCK SIZES EXCLUDED
ELLICOTT A
ELLICOTT DREDGES, LLC. NO DISCLOSURE
4 1 - PLACE DECIMAL ± .060
OR REPRODUCTION ALLOWED WITHOUT THE DR. PWD
WRITTEN CONSENT OF ELLICOTT DREDGES, SHT 2 3 5055 12/30/11 LAV KFF MADE FROM 2 - PLACE DECIMAL ± .030
CHK. SJC PUMP, DREDGE ASSY 1270
LLC. ELLICOTT AND MUDCAT ARE REGISTERED SHT 2 2 4931 10/28/11 PWD IFS
4-148256 3 - PLACE DECIMAL ± .015 EST.
APPR. SCALE: 1:8 WEIGHT:15967 Lbs. DATE: 5/9/11
TRADEMARKS. FIELD
1 4869 9/21/11 PHJ SIM CAD ANGULAR MACHINED SURFACES ± 30' APPR. ES FIRST USED SHT.SIZE REV.

CHG.
MACHINED SURFACE TEXTURE 250 MFG. 401270 4 REF-151145 3
11 10 9 8 7 6 5 4 3 SECT. 11 2 1 REQ'D. 1
1 151128 REDUCER, DREDGE PUMP 1
27 23 2 151088 CASE, PUMP FINISH 1
1
3 121045 IMPELLER, 3 BLADE WARPED 1
4 121726 HEAD, FRONT 1
16 5 121047 HEAD, BACK 1
6 121046 LINER, FRONT HEAD 1
G
2 7 121049 LINER, BACK HEAD 1
8 117357 COLLAR, QUICK REL. ASSY. 1
9 117047 SLEEVE, IMPELLER 1
10 100342 PACKING, .75 SQ. GARLOC 8913 190.00
11 100344 GLAND, 10.49 BORE ASSY 1
12 100345 RING, WATER 1
13 114371 GASKET, COPPER 5
22 22 14 102757 GASKET, .275 DIA 90 DURO BUNA-N 250.00
15 120433 CAP, SHAFT END 1
16 118023 BAR, PUMP CASE 1
17 200655 GROMMET, CANDLEWICK .75 32
25 25
18 123569 NAMEPLATE, DREDGE PUMP DR. 2
F
19 200270 BOLT, HEX HD 1.12 X 4.00 8
20 200339 BOLT, HEX HD 1.50 X 4.50 2
4 21 118696 CAPSCREW, DRILLED HEAD 4
22 217754 EYEBOLT, 1.00 DIA X 2.50 2
23 218803 EYEBOLT, 1.50 DIA X 3.50 1
14 FRONT & BACK HEAD 24 200421 NUT, HVY HEX .75 UNC 36
25 200423 NUT, HVY HEX 1.00 UNC 2
26 200424 NUT, HEX HVY 1.12 UNC 44
5X
27 200427 NUT, HEX HVY 1.50 UNC 1
13 28 219167 SCREW, DR PKU #6 X .50 4
29 219855 STESCREW, SQ HD OVAL PT .75 X 3.50 UNF 6
30 108039 STUD, .750 DIA X 3.25 32
E
3
31 103009 STUD, .750 DIA X 4.38 4
39 40 32 121818 STUD, 1.12 DIA X 4.38 36
REF 10 33 200475 WASHER, PLATE .75 32
34 200507 WASHER, LOCK 1.12 44
1 8
9 35 200513 WASHER, LOCK 1.50 2
36 102832 WIRE, NO.14 AMER GA STL. 10.00
37 219514 WRENCH, BOX 1
38 148579 PIPING, L.O. & S.W. ASSY 1
2
39 206197 CAPSCREW, HEX SOC .62DX1.50 1
3 40 200499 WASHER, LOCK .62 1
L (FALK COUPLING)
PUMP PINION SHAFT
4X TORQUE TO 21
170 FT./LBS.-WET
C
36
24 31 11 6
4X
12 15
CL
INION SHAFT
3
B
SECTION C-C
SCALE 1 : 2
7 1/F10
4
OTHERWISE NOTED
ELLICOTT A
OR REPRODUCTION ALLOWED WITHOUT THE BOM DR. PWD
WRITTEN CONSENT OF ELLICOTT DREDGES, A3,E8 3 5055 12/30/11 LAV KFF MADE FROM 2 - PLACE DECIMAL ± .030
CHK. SJC PUMP, DREDGE ASSY 1270
LLC. ELLICOTT AND MUDCAT ARE REGISTERED
BOM
2 4931 10/28/11 PWD IFS
4-148256 3 - PLACE DECIMAL ± .015 1:4 EST.
SECTION A-A TRADEMARKS. BOM
APPR. SCALE: & NOTED WEIGHT:15967 Lbs. DATE: 5/9/11
1 4869 9/21/11 PHJ SIM CAD ANGULAR MACHINED SURFACES ± 30' APPR. ES FIRST USED SHT.SIZE REV.
4 REF-151145 3
1/E4
CHG.
MACHINED SURFACE TEXTURE 250 MFG. 401270
11 10 9 8 7 6 5 4 3 SECT. 11 2 1 REQ'D. 1
REF. DWG. #150431
MAIN PUMP DRIVE COUPLING
SECTION III-TAB 3:
LADDER AND CUTTER
TABLE OF CONTENTS
Page
A. GENERAL DESCRIPTION 1
B. OPERATION 2
1. Ladder Wedge . 2
2. Ladder Mounted Machinery .. 2
C. MAINTENANCE ............................................................................................ 2-4
1. Rigging the Ladder .. 2

2. Cutter Removal and Reassembly . 2
3. Cutter Shaft Removal . 2
4. Cutter Shaft Reassembly .. 4
DUOCONE SEAL ASSEMBLY AND INSTALLATION, 3 PAGES . INSERT
LADDER, DREDGE ASSY. (DWG# 151066) .. INSERT
LADDER SECTION #1 ASSEMBLY (DWG# 151078) INSERT
LADDER SECTION #3 ASSEMBLY (DWG# 151077) INSERT
MOTOR/REDUCER ASSY. (DWG# 149940) .. INSERT
MOTOR PARTS ILLUSTRATION (REF. P/N 147320) ... INSERT
SPEED REDUCTION UNIT PARTS ILLUSTRATION (REF. P/N 149939) . INSERT
BALE, LADDER ASSY. (DWG# 125342) . INSERT
GAUGE, DEPTH INST. (DWG# 129786) . INSERT
CUTTER, 6 BLADE PLAIN EDGE (DWG# 147511) . INSERT
CUTTER, 6 BLADE PIN TOOTH (DWG# 127860) . INSERT

Section III-Tab 3 Ladder and Cutter
A. GENERAL DESCRIPTION:
The dredge ladder is the excavating tool of the dredge. The forward portion of the ladder is constructed
from large diameter structural steel pipe. The aft portion of the ladder is fabricated from heavy steel
plates. The combined effect of these two types of ladder construction produces the strength and stability
necessary to permit the exertion of full cutter force on the material being dredged.
The ladder is supported on a pair of trunnion bearings, supported by a gantry, and is raised and lowered
by a winch mounted on its aft end. During maintenance or shut down the ladder can be secured on
safety cables. The ladder winch has its own built-in brake which only releases with hydraulic pressure.
This provides a safety feature to prevent loss of ladder downward motion control.
Warning: Always install the ladder safety cables during maintenance or dredge shut down.
Heavy-duty swing sheaves with anti-friction bearings are mounted just aft of the cutterhead to insure that
the maximum pulling force is exerted on the cutter. These sheaves are designed to minimize wear and
jamming of the swing wires.
Two swing winches, driven by two independent motors, are mounted on top of the ladder aft section.
The swing wire is reeved through a moveable guide sheave, which provides a direct fairlead to the drum.
Normal or Deep Digging Arrangement (Figure 3-3.1)
Shallow Digging Depth Arrangement (Figure 3-3.2)
NOTE: Suction Pipe Wedge is not used for shallow digging.

B. OPERATION
1. Ladder Wedge
The ladder is equipped with a reversible, wedge-shaped section which, by the manner of its
installation, places the ladder in either a shallow or deep digging mode. When arranged for deep
digging, the normal arrangement, the ladder appears as shown in Figure 3-3.1. In the shallow digging
configuration, the ladder wedge is turned 180° (bottom up) which tilts the forward section of the ladder
down as shown in Figure 3-3.2. Note that the wedge-shaped piece of suction piping is not used when
rigged for shallow dredging.
The shallow digging arrangement places the cutter at an angle such that the dredge pump suction
piping and the ladder structure are clear of the bottom during the swing of the cutter through the cut.
This is an important feature because a ladder dragging in material imposes severe strain of the swing
wires, drains a good portion of the power available to swing the dredge, and causes unnecessary
wear to the suction piping.
2. Ladder-Mounted Machinery
The cutter is driven by a heavy duty, oil-tight, radial piston type hydraulic motor and planetary
reduction gear spline-coupled to the cutter shaft. Support for the cutter shaft is supplied by two
tapered roller bearings mounted inside an oil-tight tube within the forward ladder section. The spline
coupling and both bearings are totally immersed in hydraulic oil drained from the cutter motor. These
components, along with the cutter motor itself, are protected from the entrance of water by
maintenance of a positive oil pressure within the irrespective housing.
The cutter drive is an integral part of the forward ladder section, giving maximum power efficiency anti
minimum mechanical losses. A unique feature of the cutter drive design is the ability to maintain
constant torque through all cutter speed ranges. All operating speeds and directions of rotation are
fully controlled at the control console.
Two swing winches mounted on the aft end of the ladder swing the dredge through use of wire ropes.
Details of the winch construction and operation appear in Tab 4.
C. MAINTENANCE
Little maintenance is required to keep the ladder and its equipment in good operating order. The cutter
shaft bearings are lubricated by hydraulic oil draining from the motor. The only maintenance that need be
scheduled is the lubrication of the swing sheaves, guide sheaves; and trunnion pins with an NGLI #2
grease (Mobilux 2 or equivalent).
1. Rigging the Ladder (For Deep or Shallow Digging)
The forward sections of the suction pipe are removed. The forward ladder section is disconnected
from the ladder. The wedge is turned bottom up and is then refitted to the aft ladder sections. A
wedge shaped piece of suction pipe is added to the suction piping to rig for deep digging, or removed
to rig in the shallow digging configuration. The forward ladder section is then reattached to the ladder
wedge and the forward sections of suction piping reinstalled.

NOTE: When rigging the ladder, take the dredge to shore and place ladder on bank or
rest ladder section in immediately aft of wedge on pontoon barge. The hydraulic lines
do not have to be disconnected when rotating the wedge as long as the ladder and
cutter are properly supported.
CAUTION: Be sure to use the correct high strength bolts and nuts when reassembling
the ladder. The torque should be at 480 ft-lbs (wet). Structural failure may occur,
especially at the flange, if bolts are loosened during operation. These bolts should be
checked periodically during operations.
2. Cutter Removal and Reassembly
WARNING: When performing any maintenance, appropriate “Lockout-Tagout”

procedures should be implemented on the dredge machinery.
a. Bring the dredge to shore and rest ladder on bank or on pontoon barge.
b. Remove cutter shaft nut with a special wrench (optional) after putting the locking bar out of the nut.
NOTE: The cutter shaft nut is removed clockwise facing aft. (Left hand thread)
c. Pull the cutter off the shaft.
d. The reinstallation is a reverse procedure of those steps used for disassembly. Always pack the
cutter shaft keyway and threads with heavy grease before reassembly.
3. Cutter Shaft Removal (Reference Figure 4-3.3)
a. Remove the cutter.
b. Open drain connections at the cutter shaft bearing housing. With the hydraulic system shut down,
there should be little, if any, flow from the drain hose.
c. Lift the ladder so that the cutter end is slightly higher than aft end and secure in this position.
d. Remove seal housing (8) after removing the locking screws (14); there are two screws for each
tapped hole.
e. Slip the Duo-cone seal (12) off of shaft. (4). Prevent dam age to seal or exposure to abrasives.
f. Remove the seal and bearing retainer (7) with its cap screws (13), and remove from shaft with
shim (15) and O-ring (10).
WARNING: The cutter shaft can easily slide out of the cutter drive once the seal and
bearing retainer have been unfastened. Make absolutely sure that the cutter end of the
ladder is raised sufficiently to prevent the shaft from sliding forward due to gravity.
Severe personal injury may result and equipment may be damaged if this precaution is
not taken.
g. Reinstall the cutter shaft nut to protect the shaft threads (9).
h. Pull cutter shaft (4) forward for complete removal from the cutter drive.
i. The splined coupling and both roller bearings can now be pressed off the shaft.

4. Cutter Shaft Reassembly (Ref. Figures 4-3.3 and 4-3.4)
a. Cleanliness of parts is a prerequisite for assembly. Thoroughly clean all dirt or rust accumulations
where bearings, seals, or O-rings (10 and 11) are to be installed. Coat all bearing and seal faces
with hydraulic oil to assure initial lubrication.
b. Insert cutter shaft with both roller bearings and coupling in place into forward end of cutter drive
bearing housing. Slide shaft as far as possible into housing. It may be necessary to jack-up cutter
shaft (accessible through large coupling on bottom of shaft housing to assure proper engagement
with motor spline).
c. Install seal (16) and bearing retainer (7) without shim (15).
d. Draw up retainer until it contacts forward bearing outer race.
e. Measure gap at shim location (15) between retainer and bearing housing. Add .005” to .008” (.127
to .203 mm) to the measured gap and add the correct shim with thickness equal to the total sum
recorded.
f. Reinstall the retainer with shim as specified above and O-ring. This way .005” minimum clearance
to .008” maximum clearance will be obtained between the forward bearing outer race and the
retainer.
g. Install the Duo-cone seal (12) which consists of rubber sealing rings and two metal sealing rings.
CAUTION: Do not attempt to reinstall a used duo cone seal assembly. Always replace
with a new unit.
NOTE: A simple seal installer is available (optional) in order to permit uniform
pressure to be exerted directly on the toric to get it into the seal and to provide
protection of the sealing surface.
h. Place a new O-ring (11) in place on cutter shaft along with the seal housing (8). Set gap between
the seal housing and the retainer to .100” (2.54 millimeter).
i. Reconnect hydraulic drain hoses on each side.
j. Fill the shaft bearing housing with hydraulic oil through the opening on top. Always insure that the
cutter drive motor case drain is prefilled with clean hydraulic oil prior to start up.
k. Reinstall cutter, shaft nut and nut locking bar.



Place the rubber torics on the metal seal ring at the
Seal Assembly and bottom of the seal ring ramp and against the
Installation Guidelines for retaining lip.
Duo-Cone Seals
Duo-Cone Seal Assembly Contents:
- (2) Metal Seal Rings
- (2) Elastomeric Toric Rings
Terminology
Make sure the rubber toric is straight on the seal
ring and not twisted. Be careful not to nick or cut the
torics during the assembly, as this can cause leaks.
Put the installation tool onto the metal seal ring and
rubber toric. Lightly dampen the lower half of the
rubber toric with the appropriate assembly lubricant.
Techniques to dampen the toric include wiping with
a lint-free towel, lubricating using a clean foam
brush, or dipping in a container lined with towels
saturated in the assembly lubricant (as shown).
1. Seal Ring 5. Seal Ring Housing

2. Rubber Toric 6. Seal Ring Face
3. Housing Retainer Lip 7. Seal Ring Ramp
4. Housing Ramp 8. Seal Ring Retaining Lip
9. Installation Tool
Housing Preparation
The housing components that contact the rubber
toric rings (3 and 4) must be free from foreign
material (oil, grease, dirt, metal chips, dust or lint Seal groups with silicone torics can be assembled
particles, etc) before installing the seal. This should using a freezer to slightly contract the toric rings.
be done using a lint-free wipe and a non-petroleum Seal groups should be placed in a freezer for 5
based solvent. Dry with a clean wipe. minutes at -40o to -18oC prior to installation.
Contraction will be sufficient to allow installation.
Remove any foreign material from the rubber torics Groups should warm to room temperature prior to
(2), the ramps (7) and the lips (8) of both seal rings. further assembly.
This should also be done with a lint-free wipe and a
non-petroleum based solvent. Dry with a clean Approved Assembly Lubricants
wipe. - Isopropyl Alcohol *
- Houghto-Grind 60 CT
- QuakerR Solvo Clean 68-RAH
(*) All applicable safety and disposal guidelines for

flammable liquids must be followed.
Note: Do not use Stanosol or any other liquid that

leaves an oil film does not evaporate quickly.
11
Installation Process
With the lower half of the rubber toric still wet, use
the installation tool to position the seal ring and the
rubber toric squarely against the application housing
(as shown).
The rubber torics must never slip on the ramps of

either the seal ring or the housing. To prevent
slippage, allow adequate evaporation time for the
lubricant before proceeding with further assembly.
Once correctly in place, the rubber toric must roll on
the ramp only. The following shows incorrect
installations resulting in cocked seals.
For smaller diameter seals, use sudden and even

pressure to push the rubber toric under the retaining
lip of the housing. For larger diameter seals, which
will not press in with sudden and even pressure, it is
acceptable to work the toric past the retaining lip by
starting one side and tapping the opposite side of
the installation tool with a rubber mallet until it is
engaged past the retaining lip of the housing.
Check the assembled height variation (A) in a least

four places, 90o apart, use a caliper, toolmakers'
ruler or any other calibrated measuring device.
Wipe the face of each seal ring using a lint-free

wipe. No particles of any kind are permissible on the
sealing surfaces. (Even a hair can hold the seal
faces apart and cause a leak.)
The difference in height around the ring must not be

more than 1.0mm. If small adjustments are
necessary, do not push or pull directly on the seal
ring. Use the installation tool to push down and your
fingers to pull up uniformly on the rubber toric and
seal ring.
The rubber toric can twist if it is not wet all around

during installation or if there are burrs or fins on the Apply a thin film of oil on the entire seal face of one
retaining lip of the housing. Twists, misalignment, or both seals using a lint-free applicator. Oil must
and bulges of the toric (as shown) will result in seal not contact surfaces other than the sealing face.
failure. If correct installation is not obvious, remove
the seal from the housing and repeat process.
12
Final Assembly
While completing the final assembly of the unit,
make sure that both housings are in correct
alignment and are concentric. Slowly bring the two
housings together. High impact can scratch or break
the seal components.
If the rubber toric slips at any location, it will twist,

causing the seal rings to cock. Any wobbling motion
of the seal is an indication of cocked seals and can
cause dirt to enter by pumping mud past the torics.
The following examples show the effects of a
cocked seal group.
The above depicts how the torics have slipped

instead of rolling on the left hand side of the seal.
The following shows the same seal after the bottom
o
half is rotated 180 .
13
1 151078 LADDER, SECTION 1 ASSY 1
NOTES: 2 151093 LADDER, SECTION 2 ASSY 1
15 3 151077 LADDER, SECTION 3 ASSY 1
X. TORQUE BOLTS TO 480 FT/LBS (WET) 4 128996 WEDGE, LADDER ASSY 1
9 5 125342 BALE, LADDER ASSY 1
6 151092 PIPE, SUCTION LADDER ASSY 1
G
7 220295 GRIP, STRUT 81512 1
8 109200 BLOCK, SWING 2
16
9 119649 KEEPER 1
10 125335 PIN, SHEAVE 1
11 213756 BOLT, HEX HD A449 1.00 D X 3.50 48
12 215319 BOLT, HEX HD A449 1.00 D X 6.50 24
13 218272 NUT, LOCK MACLEAN-FOGG 1.00-8 72
14 123694 BOLT, HEX HD DR .62 D X 2.0 2
15 218165 WIRE, LOCK TYPE-316 14GA 1
10
16 900039 BAR, F03 .50 X 2.0 X 6.0 1
17 109702 SHACKLE, CHAIN SAFETY 2
18 147329 PIPING, LADDER SECTION 1 ASSY 1
F
8 18 19 148269 PIPING, HYD LADDER EXT ASSY 1
20 128827 PIPING, HYD LADDER EXT ASSY 1
14 40X
21 200096 BOLT, HEX HD 0.50 D X 1.50 SS 40
2X 7 22 21 10 22 200418 NUT, HEX .50 UNC-SS 40
DETAIL A
SCALE 1 : 4
8 18
D
48X
5
X 11 13
24X
2 1
3 X13 12
A
20 19
4 18 C
CL
CL
B
716.50
ELLICOTT
OTHERWISE NOTED
A
4 - 1 - PLACE DECIMAL ± -
OR REPRODUCTION ALLOWED WITHOUT THE DR. OMM
WRITTEN CONSENT OF ELLICOTT DREDGES, 3 MADE FROM
148260
2 - PLACE DECIMAL ± -
CHK. RPC LADDER, DREDGE ASSY
LLC. ELLICOTT AND MUDCAT ARE REGISTERED 2 3 - PLACE DECIMAL ± - EST.
APPR. ES WEIGHT: 31174 DATE: 5/16/2011
TRADEMARKS. 1 CAD ANGULAR MACHINED SURFACES ± 30' APPR. - FIRST USED SHT.SIZE REV.

CHG.
MACHINED SURFACE TEXTURE 250 MFG. - 401270 4 REF-151066 -
11 10 9 8 7 6 5 4 3 SECT. 25 2 1 REQ'D. 1 1
1 151119 LADDER, SECTION 1 STRUCTURE ASSY 1
2 149940 MOTOR, REDUCER ASSY 1
3 109193 SHAFT, CUTTER 1
4 109159 BEARING, TAPERED ROLLER 1
5 109160 BEARING, TAPERED ROLLER 1
"OUT" CL 6 109156 RETAINER, BEARING 1
G
7 109192 SEAL, DUO CONE 1
8 109155 HOUSING, SEAL 1
9 217714 O-RING, PRECISION 426 1
"IN" CL 10 109536 SHIM, BRASS 1
11 217715 O-RING, PRECISION 374 1
12 100235 NUT, CUTTER SHAFT 1
13 116000 WRENCH, CUTTER SHAFT NUT 1
14 107508 GASKET 1
15 226634 CAPSCREW, HEX SOC M20 X 2.5 X 180 MM GR 8.8 32
16 206188 CAPSCREW, HEX SOC 0.50 D X 4.50 8
17 216874 SETSCREW, HEX SOC CUP PT 0.50 8
18 900121 BAR, FLAT F19AF 1.00 X 1.00 X 7.3125 1
F
19 900087 BAR, F11 R .25 X 3.50 1
20 900121 BAR, FLAT F19AF 1.00 X 1.00 X 5.3125 1
VIEW A
SCALE 1:8
1/B-8
DO NOT DAMAGE
SEAL ATASSEMBLY
MOTOR MUST BE ORIENTED AS SHOWN IN VIEW A.
14
6
8
E
A
18
7 12 13
D
DETAIL D CL
SCALE 1 : 1
19
1/D-11 8X
6
D 16 20 3 4
7
15 C
32X
5 A
17 2 PER TAPPED HOLE TORQUE BOLTS TO
1/E-10 230 FT/LBS (LUBE)
18
B
5 APPLY A THIN COAT OF NON-HARDENING PERMATEX
6 SEALANT TO THE MATING SURFACES BETWEEN THE 1/A-10
REDUCER DRIVE AND CUTTER DRIVE HOUSING.
3
9 11
8
10 DO NOT SCALE - ALL DIMENSIONS SHOWN WITHOUT DIMENSION LINES REFER TO DATUM LINE MARKED "0" SH 1 OF 1
11
C THIS DRAWING INCLUDES PROPRIETARY DATA 6 SERIES DIMENSIONAL TOLERANCES UNLESS

OTHERWISE NOTED
ELLICOTT A
1/A-7 BALTIMORE, MARYLAND, U.S.A.
DETAIL C ELLICOTT DREDGES, LLC. NO DISCLOSURE
4 -
DETAIL B SCALE 1 : 1 OR REPRODUCTION ALLOWED WITHOUT THE
1 - PLACE DECIMAL ± -
DR. OMM
SCALE 1 : 4 WRITTEN CONSENT OF ELLICOTT DREDGES, 3 MADE FROM 2 - PLACE DECIMAL ± -
CHK. RPC LADDER, SECTION 1 ASSY
LLC. ELLICOTT AND MUDCAT ARE REGISTERED 2 147510 3 - PLACE DECIMAL ± - 1:6 EST.
1/B-1 1/A-11 APPR. ES SCALE: & NOTED WEIGHT: 5022 DATE: 5/17/2011
TRADEMARKS. 1 CAD ANGULAR MACHINED SURFACES ± 30' APPR. - FIRST USED SHT.SIZE REV.

CHG.
MACHINED SURFACE TEXTURE 250 MFG. - 401270 4 REF-151078 -
11 10 9 8 7 6 5 4 3 SECT. 25 2 1 REQ'D. 1
Code Description QTY
101 Motor Case 1
102 Valve Housing ▲ 1
103 Front Cover 1
104 Valve End Cap ▲ 1
105 Cylinder Head 5
201 Crankshaft 1
202 Piston ■ 5
203 Connecting Rod ■ 5
204 Piston Retaining Half Ring ■ 10
205 Con Rod Retaining Ring 2
206 Restrictor Screw ■ 5
301 Valve Spool ▲ 1
303 Oldham Coupling 1
305 Shim Kit 1
-Kit Includes:
Two .010” Plastic, Two .005” Plastic
Four .002” Plastic, Two .020” Steel
Steel Shim Kit 1
-Kit Includes:
One .032” Steel, One .020” Steel
401 Rear Bearing 1
402 Front Bearing 1
404 Piston Seal Ring ● 5
405 Valve Seal Ring ●▲ 12
408 Circlip ■ 5
410 “O” Ring (Front Cover) ● 1
413 “O” Ring (Valve End Cap) ●▲ 1
414 “O” Ring (Cylinder Head) ● 5
415 “O” Ring (Internal Ports) ●▲ 5
417 Shaft Seal ● 1
418 Socket Head Cap Screw 5
419 Socket Head Cap Screw (Front 10
Cover)
420 Socket Head Cap Screw (Cylinder 50
Head)
422 Socket Head Cap Screw (Valve ▲ 5
End Cap)
426 Bonded Seal, Drain ● 2
435 Drain Plug 2
476 Back-Up Ring (Cylinder Head) ● 5
479 Steel Plug (Valve Housing) ▲ 2
482 “O” Ring (Valve Housing Surround) ●▲ 1
483 Piston Seal Backing Ring ● 5
●■▲ Complete Seal Kits, Piston and Valve Assemblies at end of parts list
REF. 149939
# Description # Description # Description # Description
1 Magnetic Plug 12 Spring Pin 23 Spacer 35 Output Shaft
2 Screw 13 Output Support 24 Ring, Retaining 36 Retaining Ring
3 Oil Seal Support 14 O-Ring 25 Planet Wheel 37 Coupling
4 Plug With Or 15 Planetary Ring 26 Planet Wheel Pin 38 Retaining Ring
5 O-Ring 16 O-Ring 27 Ring, Retaining 39 Flange
6 Oil Seal 17 Spacer 28 Pinion 40 Washer Lock
7 Bearing 18 Ring, Retaining 29 Bearing 41 Screw
8 Spacer 19 Spacer 30 Plug With Or 42 Spring Pin
9 Magnetic Plug With Or 20 Planetary Carrier 32 Input Support 43 O-Ring
10 Plug With Or 21 Washer 33 Plug With Or
11 Screw 22 Roller 34 O-Ring
‫ﺭﻗﻢ ﺍﻟﺮﺳﻢ‬
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‫ﻣﺴﺎﻣﻴﺮ ﺗﻮﺻﻴﻞ ﺑﺼﻮﺍﻣﻴﻞ ﻣﺴﺎﻛﺔ‬
‫ﺑﺮﺍﻏﻲ ﻣﺮﺑﻂ ﺑﺼﻮﺍﻣﻴﻞ ﻣﺴﺎﻛﺔ‬
‫ﻏﻄﺎء ﻋﻠﺒﺔ )ﻳﻤﻴﻦ(‬
‫ﻏﻄﺎء ﻋﻠﺒﺔ )ﻳﺴﺎﺭ(‬
‫ﺑﺮﺍﻏﻲ ﺗﻮﺻﻴﻞ ﺑﺼﻮﺍﻣﻴﻞ ﻣﺴﺎﻛﺔ‬
‫ﻋﻴﻦ ﻭﻣﻘﺮﻥ ﻣﺴﺎﻣﻴﺮ ﺗﺤﻤﻴﻞ ﺍﻟﻮﺻﻠﺔ ﺍﻟﻤﺘﺮﺍﻭﺣﺔ‬
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‫ﻋﻴﻦ ﻭﻣﻘﺮﻥ ﺧﻄﺎﻑ ﺗﺤﻤﻴﻞ ﺍﻟﻮﺻﻠﺔ ﺍﻟﻤﺘﺮﺍﻭﺣﺔ‬
‫ﻻ ﻳﺘﻌﻴﻦ ﻗﻴﺎﺱ ﺟﻤﻴﻊ ﺍﻷﺑﻌﺎﺩ ﺍﻟﻤﻮﺿﺤﺔ ﺩﻭﻥ ﺍﻟﺮﺟﻮﻉ ﺇﻟﻰ ﺧﻄﻮﻁ ﺍﻷﺑﻌﺎﺩ ﺍﻟﻤﺴﺒﻮﻗﺔ ﺑﻌﻼﻣﺔ "‪"0‬‬ ‫ﺻﻔﺤﺔ ‪1-1‬‬
‫ﻳﺘﻀﻤﻦ ﻫﺬﺍ ﺍﻟﺮﺳﻢ ﺑﻴﺎﻧﺎﺕ ﻣﻤﻠﻮﻛﺔ ﺣﺼﺮﻳًﺎ ﻟﺸﺮﻛﺔ ﺑﻠﺘﻴﻤﻮﺭ‬
‫ﻟﻠﺠﺮﺍﻓﺎﺕ – ﺷﺮﻛﺔ ﺫﺍﺕ ﻣﺴﺆﻭﻟﻴﺔ ﻣﺤﺪﻭﺩﺓ‪ .‬ﻭﻣﻦ ﺛﻢ ﻻ ﻳﺤﻖ‬
‫ﺍﻟﻤﺠﻤﻮﻋﺔ‬
‫ﺯﻭﺍﻳﺎ ﺗﺴﺎﻣﺢ ﺛﻼﺛﻴﺔ ﻣﺎ ﻟﻢ ﻳﻼﺣﻆ‬
‫‪ COMM‬ﺃﺣﺠﺎﻡ ﺍﻟﻤﺨﺰﻭﻥ ﻣﺴﺘﺒﻌﺪﺓ‬ ‫ﺷﺮﻛﺔ ﺍﻟﻴﻜﻮﺕ‬
‫‪1170 x 33‬‬ ‫ﻭﻻﻳﺔ ﻣﺎﺭﻳﻼﻧﺪ ‪ -‬ﺍﻟﻮﻻﻳﺎﺕ ﺍﻟﻤﺘﺤﺪﺓ ﺍﻷﻣﺮﻳﻜﻴﺔ‬
‫ﺍﻟﺤﺼﻮﻝ ﻋﻠﻰ ﺃﻳﺔ ﻣﻌﻠﻮﻣﺎﺕ ﺃﻭ ﺍﻟﺴﻌﻲ ﻟﻄﺒﺎﻋﺘﻬﺎ ﺩﻭﻥ ﺍﻟﺤﺼﻮﻝ‬ ‫‪.060‬‬ ‫ﻣﻜــﺎﻥ ﻋﺸـﺮﻱ‬
‫ﻋﻠﻰ ﻣﻮﺍﻓﻘﺔ ﺧﻄﻴﺔ ﻣﻦ ﺍﻟﺸﺮﻛﺔ‪ ،‬ﻋﻠﻤًﺎ ﺑﺄﻥ ﻛﻼ ﻣﻦ‬
‫‪ ELLICOTT‬ﻭ‪ MUDCAT‬ﺗﻌﺪﺍﻥ ﻣﻦ ﺍﻟﻌﻼﻣﺎﺕ‬
‫ﻣﺼﻨﻊ ﻣﻦ‬ ‫‪.030‬‬ ‫ﻣﻜــﺎﻥ ﻋﺸـﺮﻱ‬
‫ﺍﻟﻔﺤﺺ‬
‫ﻣﺠﻤﻊ ﺍﻟﺒﻜﺮﺓ ﺍﻟﻤﺤﺰﻭﺯﺓ ﺍﻟﻤﺘﺄﺭﺟﺤﺔ‬
‫‪.015‬‬ ‫ﻣﻜــﺎﻥ ﻋﺸـﺮﻱ‬
‫ﺍﻟﺘﺠﺎﺭﻳﺔ ﺍﻟﻤﺴﺠﻠﺔ‬ ‫ﺍﻟﺘﻘﺮﻳﺐ‬ ‫ﺍﻟﻤﻘﻴﺎﺱ‬ ‫ﺍﻟﺘﺎﺭﻳﺦ‬
‫ﻻ ﻳﻤﻜﻦ ﺗﻌﺪﻳﻞ ﺍﻟﻬﻴﻜﻞ‬ ‫‪ 30‬ﺩﺭﺟﺔ‬ ‫ﺃﺳﻄﺢ ﺯﻭﺍﻳﺎ ﺗﺪﺍﺭ ﺁﻟﻴﺎ ﺑﺰﺍﻭﻳﺔ‬ ‫ﺍﻟﺘﻘﺮﻳﺐ‬ ‫ﺍﻻﺳﺘﺨﺪﺍﻡ ﺍﻷﻭﻝ‬
‫ﺍﻟﻤﻨﻄﻘﺔ‬ ‫ﺭﻗﻢ ﺍﻟﺘﻐﻴﻴﺮ ﺍﻟﺮﻗﻢ‬ ‫ﻣﻦ ﺧﻼﻝ ﺍﻟﺘﺎﺭﻳﺦ‬ ‫ﺍﻟﻔﺤﺺ‬
‫ﺍﻟﻤﺼﻤﻢ ﺑﻤﺴﺎﻋﺪﺓ ﺍﻟﺤﺎﺳﺐ‬ ‫ﻗﻮﺍﻡ ﺃﺳﻄﺢ ﻳﺪﺍﺭ ﺁﻟﻴًﺎ‪.‬‬ ‫ﺍﻟﺮﻗﻢ‬
‫ﻃﻠﺐ‬ ‫ﺍﻟﻘﺴﻢ‬
REF-
REF-
SECTION III-TAB 4:
LADDER HOIST, GANTRY AND SWING WINCHES
TABLE OF CONTENTS
Page
A. OPERATION .. 1
1. Ladder Hoist .. . 1
2. Swing Winches .. 1
B. SERVICING.. . 1-2
1. Ladder Hoist*. 1
2. Swing Winches .. 1-2
3. Swing Winch Wires ... 2
C. SWING WINCH ASSEMBLY ILLUSTRATION . 3
LADDER SECTION #3 ASSY. (DWG# 151077) INSERT
WINCH, PORT AND STARBOARD SWING ASSY (DWG# 128619) INSERT
MOTOR, SWING WINCH-PARTS ILLUSTRATION (REF. P/N 118835) .. INSERT
WINCH, LADDER-LUBE OIL FILL ILLUSTRATION (REF. P/N 148948) .. INSERT
GANTRY, BOW ASSEMBLY (REF. DWG. #123755) .. INSERT
*SEE SECTION VII TAB 2 FOR MORE INFORMATION ON P/N 148948 LADDER WINCH

Section III-Tab 4 Ladder Hoist Winch and Swing Winches
A. OPERATION
1. Ladder Hoist
The ladder hoist is supported on a pair of trunnion bearings and by a gantry structure, It is raised and
lowered by a winch mounted on its aft end. Raising and lowering is controlled by the dredge operator
utilizing the 3 position switch in the operator’s control stand. The ladder winch has its own built-in brake
which only releases with hydraulic pressure. This provides a safety feature to prevent loss of ladder
downward motion control in the event of hydraulic system failure.
Warning: Whenever maintenance is performed or the dredge is shut down, secure the
ladder with the safety straps provided.
2. Swing Winches
The dredge swings by means of 5/8 in. (15 mm) wire rope that is wound onto the 400 ft. (122 m)
capacity winch drums (which are individually driven by hydraulic motors) and then reeved through the
ladder guide sheaves, swing sheaves and attached to the swing anchors. The swing line travel speed
may be varied form 0-98 ft/mm (0-30 m/min) with speed and direction of movement hydraulically
controlled by knobs and levers on the dredge operator’s control stand. Each winch has a maximum line
pull of 15,000 lbs (6804 kg) to swing the dredge through its cut by “pulling in” and “paying out” the
swing wire.
Swing wire tensioning force is hydraulically applied by the adjustable swing winch brake valves on the
control stand. (Pay-out mode only)
The swing wires may be secured for anchoring when the dredge is not in operation or is unattended by
using the hand-operated pawl locking device at each swing winch assembly mounted on ladder section
# 3. The Pawl assembly consists of items 12, 13, and 14 shown in the illustration 3.4.1.
B. SERVICING
1. Ladder Hoist
The ladder hoist winch requires no external lubrication other than initially filling with the proper
lubrication as called for in the vendor’s manual. The primary drive side is lubricated from the hydraulic
oil in the system.
2. Swing Winches
a. Maintenance - Every 250 hours, greasing with an NGLI#2 grease is required at the swing winch
grease fittings.
b. Swing Winch Motor Removal (Refer to the Assembly Chart on page 2)
1) Secure the winch drum with the pawl (12, 13, 14).
2) Stop the auxiliary engine.
3) Properly mark the motor’s ports and corresponding hydraulic lines for identification at
reassembly.
4) Remove the piping, and cover the exposed openings to prevent system contamination.

5) Support the motor and remove its five assembly fasteners (16 & 17).
6) Slide the motor out of the winch assembly. Internal repairs and inspection of the hydraulic
motor should be done by an authorized OEM service center.
c. Swing Winch Drum Bearing Removal and Reassembly (Refer to the Assembly Chart on page 2)
Removal:
1) Remove swing wire from the drum.
2) Stop the auxiliary engine and secure the controls to prevent accidental restarting of the
hydraulic system.
3) Remove the bearing cover and two retaining rings (7 & 10).
4) Support the winch drum and remove the winch retaining plate (2F).
5) Remove the inner bearing from the retaining plate (5).
6) Slide the drum (2A) out of the outer winch structure; outer bearing (4), seal (8), and retaining
rings (9) will come off with the drum.
7) Remove the retaining rings (9) and seal (8); slide or pull the bearing of the drum shaft.
Reassembly
1) Install a new bearing by tapping the inner race lightly and uniformly until it is in position.
2) Reverse steps 1-7 above.
3) Grease the swing winch after reassembly (NGLI #2).
3. Swing Winch Wires
Inspect grease or as required.
Warning: Wear appropriate personal protective equipment when handling wire rope
cables. Relieve cable tension before attempting any service on a cabling system.
Always shut down the dredge hydraulic system completely prior to loosening or
moving any hydraulic line fitting. The hydraulic system may have static pressure built
up in the lines which must be released slowly.

C. SWING WINCH ASSEMBLY ILLUSTRATION (Ref. Ladder Assy. Dwg. #150574, ladder winch not shown)
(DWG. 151077 Ladder Section #3, and 128619 Winch Assy, Port & Starboard)

SECTION III-TAB 5:
SPUD SYSTEM
TABLE OF CONTENTS
Page
A. SYSTEMS DESCRIPTION.!!!!!!!!!!!!!!!!!!!!!!!!!!!. 1
B. SERVICING.!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!.. 1-2
1. Spuds!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!.. 1-2
2. Spud Winches*!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! 2
SPUDWELL, WINCH INSTALLATION (DWG# 148236)!!!!!!!!!!!!!!!!.. INSERT
WINCH, SPUD (REF. 148149)!!!!.!!!!!!!!!!!!!!!!!!!!!!!. INSERT
* See Section VII Tab 1 for more information on P/N 148149 Spud Winches.

Section III-Tab 5 Spud System
A. SYSTEM DESCRIPTION
The spuds are hydraulically operated through controls located on the operator’s console in the lever room
(these controls are covered in Tab 1 “controls and Instruments”). Both the “Digging” spud and “Walking”
spud are powered by individual winches. Their ”Hoist”, ‘Reverse” (controlled drop), “Drop” (free-fall) and
“Braking” actions are governed by individual controls, one for each spud, in the lever room.
NOTE: Discussion of the spudding operation during the dredging process is contained in
Section IV, “Dredge Operation”. Spud installation is discussed in Section VI, Field Assembly.
B. SERVICING
1. Spuds (Ref. Dwg. 148236 Spudwell Inst. 151086 Center Tank Assy., 150900 Dredge Assy.).
a. Pinning (Figure 4-5.1)
Figure 4-5.1
WARNING: Reeving or wrapping of the sling around the spud must be done from a suitable work
boat. Wear appropriate protective equipment when handling wire rope cables. Before
attempting cable service, connect or disconnect, always relieve the tension on a spud cable and
secure the system hydraulic drive to prevent accidental system startup or activation.
b. Retrieval
Should the spud hoisting cable break, the following steps should be taken for retrieval:
STEP 1: Make sure enough cable remains on the winch drum.

Section III-Tab 5 Spud System
STEP 2: Let out enough cable to reach the lowest accessible point of the spud.
STEP 3: Reeve the cable around the spud so that it engages one of the notches on the aft side of
the spud. Make a loose sling using rope wire clips.
STEP 4: Hoist the spud up until the spud keeper pin can be installed. If it is necessary to repeat
Step 4, place a bar though the notch to hold the spud in place then drop the wire rope sling out of
this notch and into a lower one.
STEP 5: After the spud has been pinned, fasten the cable to the spud hoisting bracket.
c. Applying Wire Rope Clips (Figures 3-5.1 thru 3-5.3)
As shown in Figure 3-5.1, the correct way to attach U-bolt type clips is to have the base of the clips
bear against the live end of the rope while the “U” presses against the dead end. The clips are
spaced about 6 rope diameters apart for adequate holding power and are tightened as follows:
1. Tighten the nuts before placing the rope under tension.
2. Tighten the nuts again with a load on the rope.
Figures 3-5.2 and 3-5.3 illustrate improper methods of attaching the rope clips. Note that these
instructions apply to the use of wire rope clips in any circumstances.
Figure 3-5.1
Figure 3-5.2 Figure 3-5.3
Applying Wire Rope Clips
2. Spud Winches
The spud winches primary drives are lubricated internally by the hydraulic oil circulating within. Some
winch models may require filling with gear lubricant through the winch drum or through another
designated port for secondary drive lubrication. Servicing and troubleshooting of these units are found
in the manufacturer’s literature.

REF-
SECTION III-TAB 6:
HYDRAULIC SYSTEM
TABLE OF CONTENTS
Page
A. DESCRIPTION .. 1-3
1. General 1
2. System and Components . 1-3
B. OPERATION. . 3-4
1. Oil Filling Procedures. .. 3

2. Filtering. .. 3-4
3. System Operation .. 4
C. SERVICING .. 4-5
1. Hydraulic Oil . .. 4
2. Valves... .. 4
3. Piping .. 4-5
D. FIELD ADJUSTMENT PROCEDURE .. . 5
1. Filters and Strainers . . 5

2. Spud Winch Circuit ... 5
3. Pilot Choke/Throttle Valves . 5
4. Hydraulic System Heat Exchanger Oil Flow . 5
HYDRAULIC SCHEMATIC (Dwg. # 148252).. Insert
DRIVE, HYDRAULIC PUMP ASSY. (DWG# 150189).. Insert
DRIVE, HYDRAULIC PUMP (DWG# 151177).. . Insert

Section III-Tab 6 Hydraulic System
A. SYSTEM DESCRIPTION (Ref. Hydraulic Schematic # 148252)

1. General (Figure 3-6.1)
Three gear type pumps, driven by a Caterpillar C9 engine (5) through a direct coupled gear box (1),
supply hydraulic oil to the open circuits of the hydraulic system. A two section tandem-gear pump (4)
supplies oil to the cutter circuit; another (3) supplies oil to the spud winches. The third pump (2), which
is a two section tandem-gear pump, supplies oil to two circuits, one for the swing winches and ladder
winch and the other for the pilot circuit to activate various directional valves and spud free-fall. The
pumps get oil from a 180 U.S. gallon (681 liter) reservoir under the auxiliary engine (5). To insure the
proper cooling and cleanliness of the hydraulic oil, the entire system is passed through a water-cooled
heat exchanger (6), strainers and filters (see hydraulic schematic insert). A center tank mounted head
tank is filled with oil to keep a positive oil pressure at the inlet of the hydraulic pump. (See Section VII
Tab 3 for Hydraulic Drive Engine information).
NOTE: Head tank and reservoir not shown.
CAUTION: The hyudraulic drive unit is equipped with

manually operated shut off valves at the entrance of each
hydraulic pump at their suction inlet. These must always be
in their fully opened position when the hydraulic drive is
cranked or running.
2. Systems and Components
a. Reservoir, Strainers, Filters, and Heat Exchanger
The reservoir, mounted below the auxiliary engine, incorporates the following features:
1) A head tank mounted overhead in the deck house;
2) A 12-inch vertical baffle plate which prevents excessive oil turbulence;
3) A filler cap with built-in micro air breather on head tank;
4) A large manhole for clean-out;
5) An oil level sight glass on head tank;
6) A reservoir;
7) A low oil level alarm switch; and
8) A drain plug.
A 100 mesh cleanable strainer is provided on the intake line of each circuit while two filter
assemblies, with cleanable elements, are installed on the return lines.

The water-cooled heat exchanger is on the port side of the reservoir. All oil except case drain oil
returns to the reservoir through the heat exchanger. Case drain or motor leakage oil returns directly
to the reservoir without passing through the heat exchanger or filters.
b. Cutter Circuit
The cutter circuit is a separate, open-loop circuit with a four-way valve to direct oil to the motor. Oil
is supplied from a gear pump to the directional valve and then returns to the reservoir through the
filter and heat exchanger. A relief valve is installed in this circuit to prevent pressure above that
necessary for full motor torque.
The cutter’s directional valve is externally controlled from the pilot circuit and internally drained to
the reservoir. It has an open centered spool which connects all ports together in the center position
until the electric solenoid is energized allowing the pilot oil to shift the spool in either the forward or
reverse direction.
The manually operated variable flow control valve, installed on the control console and connected
across the cutter directional valve, allows the operator to control the cutter’s speed, from
approximately 29-45 rpm.
Installed in the port block of the cutter’s motor is a relief valve that is set at a pressure higher than
the normal system pressure. This valve prevents high pressure spikes from damaging the hydraulic
system when the cutter assembly strikes firm material or an underwater obstruction.
Bypass or slippage oil from the cutter’s motor/reducer assy. drains into the cutter bearing housing,
then back to the reservoir through a flow indicator located on the forward port side of the center
tank; this enables the dredge engineer/systems monitor to periodically check the drain flow from the
motor.
The cutter motor pressure is displayed at the gauge located on the dredge operator’s control console.
c. Swing Winch and Ladder Hoist Circuit
The swing winch and ladder hoist open- loop circuit oil is supplied by a section of the tandem gear-
pump. The flow is directed through float-centered, pilot-operated directional valves and returns
through the filter and heat exchanger to the reservoir. All directional valves in this circuit are
activated by hydraulic pressure from the solenoid controlled four-way pilot valve. Manifold
assemblies, the pilot valve/manifold assemblies have manually adjustable throttle and chokes to
control the system engagement or disengagement response time. Manually operated variable flow
control valve for swing speed is located on the control console.
1) Swing Winches
Each of the two swing winches is directly driven by an individual low speed high-torque
hydraulic motor. A counterbalance valve in the swing winch system allows for unrestricted flow
during forward (pay in) rotation while its cartridge relief setting provides adjustment for wire rope
transition in the payout mode (braking).
Wire rope payout tensioning is controlled hydraulically by hand- operated brake valves located
on the dredge operator’s control stand. Braking of the swing winch is provided by controlling the
return oil flow through the vent in the counterbalance valve while the winch directional valve is
in the neutral position.
The swing winch motor circuit pressure is indicated by a gauge located on the control console.
2) Ladder Winch
In parallel with the swing winch directional valve, is the ladder system’s four-way valve that
directs the oil flow to the ladder winch, which raises and lowers the ladder. The winch stops by
means of an internal brake whenever the dredge operator’s ladder directional control switch
returned to neutral.
d. Spud Circuit
A normally open two-way valve associated with a compound relief valve is provided to unload the
circuit whenever the spud four-way valves are in the neutral position. The two-way valve is in the
closed position as soon as the spud control lever is activated. The compound relief valve is used to
provide protection against circuit overloading.
Two, four-way valves direct the 800 psi pilot pressure to release the spud winch brake (at its final
drive) allowing the spud to free-fall.
A relief valve is located in the main pilot circuit while the spud free-fall has two additional relief
valves which serve as tensioning devices and provide light drag on the spud wire preventing free-
spooling of the drum when the spud hits bottom.
e. Pilot Circuit
Pilot pressure to the four-way valves in the cutter, swing winch, ladder, and spud free-fall circuits is
provided by a section of the tandem gear-pump. A relief valve, set at 800 psi, is located in the main
pilot circuit for spud winch brake release. A pressure regulator valve set at 400 psi is located in the
pilot circuit for four way valve directional control.
B. OPERATION
1. Oil Filling Procedures
CAUTION: Verify the type of oil in the hydraulic system! (Petroleum based vs.
biodegradable). These two types of oil must never be mixed.
Before operating, the hydraulic system must be filled with a proper grade of clean hydraulic oil to give
proper lubrication of parts. The oil specification are given in Section I page 2.
Fill the hydraulic system by adding oil to the head tank; the housings of the three pumps, three
winches, four motors, and the cutter reducer should be filled with hydraulic oil. Allow the oil to pass into
the filter lines; loosen connections and open the vent valve on the filters to allow air to escape during filling.
NOTE: Do not fill the reservoir above the full mark on the head tank sight glass.
2. Filtering
Before filtering the system as required before initial start-up, bypass the hydraulic motors four cylinders
in the system to prevent contaminants from causing damage. Circulate the oil by running the hydraulic
pumps for 30 minutes; check the oil for contamination. If water is present due to condensation during
storage or shipment, emulsion will occur. The oil should be drained and discarded in this event.
CAUTION: Never use dirty or contaminated oil in the hydraulic system. Do not mix
different brands of oil in the system.

Air can cause considerable damage to the pumps, motors, and valves. It causes cavitation at the pump
and is usually accompanied by unusual hissing noise, excessive vibrations, and heat.
3. System Operation
The system pilot valves are actuated by the 24-volt DC electric control circuit. As the operator actuates
a control lever, this energizes an electric solenoid on the corresponding pilot valve. Pilot pressure shifts
the corresponding directional valve spool. Oil then flows through a directional valve driving the selected
hydraulic activator.
The pilot circuit directional valves have manual overrides which allow the dredge engineer/systems
monitor to manually actuate a valve if the solenoid is not functioning. This is an aid when trouble
shooting a particular hydraulic circuit. This feature is not meant to be utilized for normal operations.
C. SERVICING
1. Hydraulic Drive Engine
Service the hydraulic drive engine per the manufacturer’s operation and maintenance manual. (Refer to
Section VII Tab 3).
2. Hydraulic Oil
Drain the hydraulic reservoir periodically to remove any collected sediment or other contaminants. A
drain valve is provided in the front of the hydraulic reservoir. The reservoir’s front-mounted, bolt-on
access cover must then be removed to access and clean the four wire mesh suction strainers.
NOTE: Always drain oil into a suitable container to avoid spillage.

Although the frequency of changing the hydraulic oil depends on the oil and operating conditions, it
should be changed at least once a year. When draining the oil for changing, the system should be
normal operating temperature to suspend any suspected impurities. After draining, remove the
reservoir’s access cover and clean out the inside.
Periodic sampling and laboratory analysis of the oil is recommended to help detect wear in the system’s
components before a major break-down, and to determine when oil should be changed.
3. Valves
Hydraulic valves are located for ease in servicing. Solenoids or coils can be replaced by removing only
the retaining ring, without any loss of oil.
Though the pressure of each relief valve is set during Ellicott’s initial testing, the settings are fully adjustable.
CAUTION: Do not set a circuit pressure higher than that shown on the schematic drawing.
If proper pressure cannot be obtained or maintained, the relief valve may be stuck in the open position.
In this event, dismantle, clean, reinstall the valve and operate the system again.
WARNING: When working on the hydraulic lines, care must be taken to ensure that
pressure is relieved before a line is disconnected. Never use your hands when
checking for leaks. Fluid under pressure can be injected into the skin or body tissues
causing serious injury or death.
4. Piping
It is very important that all threaded connections be kept tight at all times. Any pipe thread connections
taken apart should be sealed at the threads with Loctite hydraulic thread sealant. Ellicott does not
recommend the use of pipe dope or teflon tape on threaded joints in the hydraulic system. Do not use
sealant on SAE type hydraulic connections.
Only hydraulic tubing or cold-drawn seamless pipe are used in Ellicott hydraulic systems. Any
replacement pipe sections or hoses should match the original piece in quality and pressure rating.
CAUTION: When piping sections are replaced, the circuit should be cleaned as
described earlier.
WARNING: Only qualified persons should attempt to adjust the hydraulic system.
D. FIELD ADJUSTMENT PROCEDURES
1. Filters and Strainers
a. Filters (Reference items #23 and #44 on the Hydraulic Schematic #148252)
Check the filters on the return lines to see that they have a replaceable elements. These should be
replaced whenever the mechanical dirt-alarm indicator shows that they are dirty. With the pointer in
the yellow area the filter is getting dirty and should be changed at the next shutdown.
CAUTION: When the pointer reaches the red area, the filter is on bypass
and should be replaced immediately as damage to the hydraulic system
could result from the lack of filtration.
b. Strainers (Reference Items #31, #32, and #33 on the Hydraulic Schematic #148252)
These are strainers inside the reservoir for the suction lines to each pump. The vacuum indicators
in these lines will give an indication on the condition of the strainers. When the indicators show all
red during normal operating temperatures, the reservoir should be drained and the strainers
removed and cleaned. Cold oil will give a false indicator reading.
2. Spud Winch Circuit
a. Spud Free-fall (Drop)
Each spud has four modes, hoist, reverse (controlled drop), drop (free-fall), and brake. When
dropping, an adjustment is required to control the drag on the cable to prevent spooling off the
drum. This drag is made by adjusting the small relief valve located in the upper aft section of the
engine compartment. (Reference Item #18 on Hydraulic Schematic 148252) Adjustment
counterclockwise adjustment increases the drag at free-fall.
3. Pilot Choke/Throttle Valves (Reference Item #24 on Hydraulic Schematic #148252)
The triple valve manifold controlling the pilot pressure direction to the ladder and swing winch
directional valve (Item #7, part number 148257) has adjustable throttle valves to allow some control of
the force shifting the selected directional valve spool.
4. Hydraulic System Heat Exchanger Oil Flow Throttle Valve (Reference Item #43 on Hyd. Sch. 148252)
This valve is located on the port side of the hydraulic reservoir and is used to adjust the rate of oil flow
through the hydraulic system’s heat exchanger. Moving the throttle valve towards the closed position
increases the amount of dwell time the oil has in the cooler, thus increasing the cooling effect of the
heat exchanger. It should not be normal practice to run with the throttle valve fully closed. Ideal
hydraulic oil operating temperature should be approximately 110°F (43°C) with a maximum
temperature of 140°F (60°C).

Hydraulic Drawing Symbols
Actuators & Controls
Spring Manual Lever Solenoid (Single Winding) Detent Push Button

Valves
Typical Flow Paths for Center Condition of Three-Position Valves Three Position
Pressure Control Valves
Pressure Relief Unloading Counter Balance Sequence Pressure Reducing
See Hydraulic Schematic Drawing # 148252

Reference # 121954 Two Element Assembly

Reference # 124979 Three Element Assembly

REF-
SECTION III-TAB 7:
SUCTION AND DISCHARGE PIPING
TABLE OF CONTENTS
Page
A. OPERATION . . 1
1. Suction and Discharge Pipe..... .. 1

2. Suction Line Vacuum Gauge Piping .. 1
3. Discharge Line Pressure Gauge Piping.. .. 1
B. SERVICING .. 1-2
1. Suction and Discharge Piping.. .. 1

2. Floating Discharge Line. .. 1
3. Ball Joints .. . 1
4. Suction Cleanout ... 1
5. Flap Valve .. 2
6. Suction Line Vacuum Gauge Piping .. 2
7. Discharge Line Pressure Gauge Piping 2
PIPE, SUCTION-LADDER (DWG# 151092) .. INSERT
PIPE, SUCTION IN HULL (DWG# 151149) INSERT
PIPE, DISCHARGE ON HULL ASSY. (DWG# 151238) .. INSERT
CLEANOUT, SUCTION ASSY. (DWG# 126037) .. INSERT
VALVE, FLAP ASSY. (DWG.# 127433) .. INSERT
HOSE, DISCHARGE (DWG.# 145359) ........................... INSERT

Section III-Tab 7 Suction and Discharge Piping
A. Operation
1. Suction and Discharge Pipe
As material is excavated it mixes with water creating a mixture called slurry. The slurry is drawn through
the suction pipe by the dredge pump and discharged through a deck-mounted discharge line. This
discharge line is connected to any variety of floating or pontoon supported "pipeline" through which the
slurry passes to the point of fill (deposit).
The slurry travels from the suction entrance, through the suction pipe on the ladder and the on board
suction line, to the dredge pump.
The slurry is pressurized at the pump and is forced out through the discharge line which consists of the
on board-discharge line with flap valve; and the floating line.
Like the floating line, the shore line pipe can consist of various types and combinations of pipe. At or
near the discharge end, a Y-valve can be added to provide for fast switching to different selected
“discharge” areas.
The dredge operator/user is responsible for proper connection, anchoring placement, and
marking of all discharge line components.
2. Suction Line Vacuum Gauge Piping

Sensing of the suction vacuum is taken at an access pipe mounted to the suction line just forward of
the suction cleanout. The vacuum reading is made at the gauge marked “Dredge Pump Suction” on
control console (Refer to Tab 1 “Controls and Gauges” for more information).
3. Discharge Line Pressure Gauge Piping
Sensing of the discharge pressure is taken at an access pipe mounted to the discharge line just aft of
the flap valve. The pressure reading is made at the gauge marked “Dredge Pump Discharge” on
control console (refer to Tab 1 “Controls and Gauges” for more information).
B. Servicing
1. Suction and Discharge Piping
To compensate for irregular wear, rotate the applicable pipeline section at suitable intervals.
2. Floating Discharge Line
Assure that adequate flexibility is provided to allow proper dredge movement.
WARNING: Never walk a pipeline to shore, always obtain suitable boat for
transportation to shore.
3. Ball Joints
Lubricate at regular intervals to reduce wear. Use NLGI#2 or equivalent grease.
4. Suction Cleanout
When necessary, use the cleanout to remove debris causing obstruction in the suction line. Shut down
the dredge pump engine and raise the ladder above the water line before opening the cleanout.
WARNING: Insure that all back flushing action has ceased and use caution to relieve
pipeline static pressure before removing the suction cleanout cover.
Section III-Tab 7 Suction and Discharge Piping
5. Flap Valve
When the dredge pump is shutdown, this valve is closed by a counterweight. This prevents the
backward flow of slurry, and facilitates the next priming operation. Check the valve at regular intervals
to assure that it is operating properly.
WARNING: Insure that all personnel are clear of the flap valve arm and counter weight
radius of rotation before starting or shutting down the dredge pump.
6. Suction Line Vacuum Gauge Piping
Because of its operating principle, the vacuum gauge line is subject to blockage by contaminants.
Such blockage would be indicated by no reading or only slight fluctuation on the vacuum gauge in the
lever room. To clear the line: With the dredge pump in operation, open the petcock (protruding from
under the center of the control stand), which will draw air from the control room through the line and into
the suction pipe; check for proper gauge operation then close the petcock.
7. Discharge Line Pressure Gauge Piping
Unlike the suction line, the discharge line's operating principle makes it less subject to blockage.
However, should the line become blocked no reading or only a slight fluctuation will be registered at
the discharge pressure gauge in the lever room. Most blockages occur within the access pipe aft of the
pump room.
To clear the access pipe:
a. Prior to pump start up, remove the 1” plug from the top of the tee which is mounted on the access
pipe and couple a suitable length hose to a point overboard.
b. Start the dredge pump and pump only water. Use caution as the water and/or contaminants will be
forced out under pressure. Insure that the hose is secure so it cannot “whip” or blow water towards
personnel or equipment.
c. Suction the pump and replace the plug, open the ball valve and check the pressure reading in the
lever room.
If the reading still is not normal, the pressure line itself may be clogged.
To clear the line:
a. Remove the access panel on the front of the lever room to underside of the control console.
b. With the dredge pump running – pumping water only – disconnect the line from the pressure gauge.
Use caution as this will exhaust the water and/or contaminants into the lever room unless plans are
made beforehand for a container to be used.
c. Reconnect the line to the gauge, check the gauge for proper operation and replace the access
panel.
NOTE: Should the suction or discharge gauges not function properly after the
above procedures, their respective lines may need to be cleaned out with a steel
cable or the gauges replaced.
WARNING: As with any piping system static or residual pressure can be present.
Use care to safely release or loosen fittings and insure any pressure is released
prior to disconnecting lines. Wear safety glasses or other personal protective
equipment as required.

1 150557 PIPE, SUCT. LADDER 18" 1
2 151094 PIPE, SUCT LADDER 18" ANGLED FLG 1
3 150568 HOSE, SUCTION 18 I.D ASSY. 1
4 151095 PIPE, WEDGE ASSY 1
5 151097 PIPE, SUCTION 18" ASSY 1
6 151102 HOOD, SUCTION 1
G
7 141991 U-BOLT, 18.75 OD PIPE 8
8 900208 GASKET, .125 X 27.50 X 27.50 1
9 900208 GASKET, .125 X 25.50 X 25.50 2
LADDER SECTION 1
10 200252 BOLT, HEX HD 1.00 D X 4.50 16
11 200254 BOLT, HEX HD 1.00 D X 5.50 16
12 200251 BOLT, HEX 1.00 D X 4.00 32
13 200423 NUT, HEX 1.0 UNC 70
14 200478 WASHER, PLATE 1.12 16
15 200424 NUT, HEX HVY 1.12 UNC 32
16 211221 BOLT, CSK HD 1.00 D X 6.00 6
17 900966 ANGLE, 5.00 X 3.00 X .375 X 4.00 16
F
13 16 TACKWELD NUTS TO BAR

AFTER BOLTS ARE IN PLACE.
14 15
6X
32X
16X E
17
16X
SECTION B-B
SCALE 1 : 8
1/B-1
7
8X
D
SECTION A-A
SCALE 1 : 8
1/A-7
A
C
CL
CL
6
B
4
A
5 B
3 2
11 13 1/D-5
10 13 8
1
16X 16X
TRIM PIPE TO 12 13 9
SUIT FIT UP.
32X 2X
CL TRUNNION
ELLICOTT
OTHERWISE NOTED
A
OR REPRODUCTION ALLOWED WITHOUT THE DR. OMM
WRITTEN CONSENT OF ELLICOTT DREDGES, 3 MADE FROM 2 - PLACE DECIMAL ± .030
CHK. RPC PIPE, SUCTION LADDER ASSY
LLC. ELLICOTT AND MUDCAT ARE REGISTERED 2 150538 3 - PLACE DECIMAL ± -
SCALE: 1:24
EST.
APPR. ES & NOTED WEIGHT: 5638 DATE: 5/16/2011
TRADEMARKS. 1 CAD ANGULAR MACHINED SURFACES ± 30' APPR. SHT.SIZE REV.
4 REF-151092 -
- FIRST USED
MACHINED SURFACE TEXTURE 250
401270
CHG.
C ELLICOTT DREDGES LLC 2011 ZONE NO NO. DATE BY CK. DO NOT EDIT MFG. -
11 10 9 8 7 6 5 4 3 SECT. 25 2 1 REQ'D. 1 1
REF-
REF-
REF-
REF
SECTION III-TAB 8:
FUEL SYSTEM
TABLE OF CONTENTS
Page
A. INTRODUCTION . . . 1
B. OPERATION . . 1
C. SERVICING. . . 1-2
1. Fuel Oil ..... .. 1

2. Fuel/Water Separator . .. 2
3. Fuel Filter .. . 2
D. FUEL OIL SCHEMATIC (Dwg. #150219).. Insert
PIPING, FUEL OIL ASSY. (DWG. #150711) . Insert

Section III-Tab 8 Fuel System
A. INTRODUCTION
As stated in the Specifications, the Series 1170 dredge has a total fuel capacity of 3,300 U.S. gallons
(12,490 liters) – 1,650 U.S. gallons (6,245 liters) per fuel tank. The fuel tanks are connected by valve
equipped piping that allows for balancing or "trimming" the dredge. This also allows the dredge engine to
draw fuel from either tank as determined by the manually operated ball valves which can be switched
during operation. Leave approximately 6” of air space in the top of each tank to allow for heat expansion
of the fuel.
B. OPERATION
The vented fuel tanks are filled through the 3” filler plug located on each side tank. Each tank has two
valves (located just outside the pump room on the port and starboard aft corners) which control the engine
fuel "supply" and "return". With reference to the Fuel Oil Schematic, the V-1 and V-3 valves are for supply,
while the V-2 and V-4 valves are for return of excess fuel from the engine's fuel pump. The four valves
mentioned can be used in the following manner.
1. Valves V-1 and V-2 OPEN and V-3 and V-4 CLOSED - fuel drawn and returned to starboard tank.
2. Valves V-1 and V-2 CLOSED and V-3 and V-4 OPEN - fuel drawn and returned to port tank.
WARNING: Never smoke or allow spark/flame producing devices in the vicinity of fuel
vents, or during refueling operations. Turn off all cellular equipment.
CAUTION: Use the supply and return lines only in pairs as described in this section.
To keep the fuel use balanced, it is recommended that the combinations listed be
alternated with each shift.
As the schematic shows, both the main and auxiliary engines draw and return fuel through a common
line which allows for the two variations in valve settings. Each engine’s fuel supply passes through
individual fuel/water separators.
C. SERVICING
1. Fuel Oil
Fuel oil contaminated with water and sediment shortens an engine's life and decreases its operating
efficiency. To help remedy this problem, the fuel tank should be filled frequently to keep condensation
to a minimum. In addition, periodic draining of accumulated water and sediment as well as an
established sampling program can help alleviate potential engine problems. Refer to the engine
manuals located in Section VII Tabs 4 & 5 for recommended fuels.
Draining and sampling of the fuel can be made at the valve located in the forward bulkhead of each
side tank. This valve is accessible by going through the manhole cover into the forward bulkhead.
WARNING: Follow all safety precautions necessary for entering closed or confined
spaces.
If it is necessary to remove a large quantity of fuel, attach the proper size hose and a fuel rated pump to
the valve. Open the valve and start the pump running until the required amount of fuel is removed.
When finished, stop the pump and close tile valve. Fuel may also be drawn out through the individual
tank’s fill plug.

Section III-Tab 8 Fuel System
2. Fuel/Water Separator
Drain the fuel/water separators daily before starting the engines.
3. Primary Fuel Filter
An additional device in the dredge engine fuel supply system which helps prevent contaminants from
entering the engine is the primary fuel filter. This filter is mounted on the port side of the engine next to
the fuel/water separator on the main engine fuel supply line. The fuel filters are located on the starboard
side of the auxiliary engine. It should be cleaned quarterly or as needed. Refer to the engine
manufacturer's Operating Guide and Parts Book for more information on this filter.
D. FUEL OIL SCHEMATIC
See insert Fuel Oil Schematic Drawing #150219

SECTION III-TAB 9:
ELECTRICAL SYSTEM
TABLE OF CONTENTS
Page
A. INTRODUCTION . . . 1
B. OPERATION . . 1
1. Lighting Circuit ..... .. 1

2. Control Circuit (Dwg. 150260).. . .. 1
3. Safety Shut-Off Circuit Aux. Engine (Dwg. 150261) .. .. 1
C. SERVICING. . . 1-2
1. Control and Lighting Circuits..... .. 1-2

2. Batteries .. . .. 2
D. One Line DC Wiring Schematic (DWG # 150258).. . Insert

Kit, Start-Main Engine (Dwg. 121260) ... Insert
Kit, Start-Aux Engine (Dwg. 121378) . Insert
Wiring, GA-Tach Main Engine Assy (DWG# 150262) . Insert
Wiring, Control-Tach-GA Assy (DWG# 150260) .. Insert
Wiring, Control Stand (DWG# 150259) .. Insert
Wiring, Aux. Engine Shutdown (DWG# 150261) .. Insert
Panel, Lighting Assy (DWG# 121488) Insert
Wiring, Power Assy (DWG# 121376) . Insert
Wiring, Lights Assy (DWG# 121377) .. Insert
CAUTION: Welding operations can cause damage to dredge component bearings and
electrical equipment. Always disconnect engine starting batteries and isolate sensitive
electrical equipment prior to welding. Keep the welder ground lead as close as practical to the
positive lead when welding. Do not weld on any engine without consulting the engine
manufacturer. Engine ECM’s or other engine components may be specifically susceptible to
stray current damage. Consult the individual engine manufacturer prior to beginning any
welding operation on the dredge or connected equipment.

Section III-Tab 9 Electrical System
A. INTRODUCTION (Ref. Dwg. #150258 Wiring, One Line DC)

Power for the dredge electrical system is provided by the main and auxiliary engine starting systems.
Each system consists of two 12-volt 205-amp hour batteries connected in series for delivering 24-volt DC
current output. Battery racks are installed on the starboard side tank deck, one for the main engine and
one for the auxiliary engine.
The electrical system is designed to provide 24-volt DC cranking power for the engines, battery recharging
system (alternator) dredge pump and auxiliary engine gauges, auxiliary engine safety shutdown, console
dial illumination, solenoid control valves, and the internal and external 24V DC lighting systems.
The electrical control power and lighting circuit may be disconnected by turning off the battery disconnect
switch furnished with each engine starting kit or removing the circuits’ fuses. The lighting fuse box
contains two 60-amp 250-volt time-delay cartridge-type fuse including two spares while the control fuse
box installed forward has two 10-amp 250-volt time-delay cartridge-type fuses with two additional spares.
The lighting and control fuse boxes are located in the dredge center tank on the starboard side wall
adjacent to the auxiliary engine.
B. OPERATION
1. Lighting Circuit (Ref. Dwg. 121377)
There are four lighting circuits, each controlled by a 15-amp breaker and mounted in a distribution
panel located on the starboard side of the lever room. Each circuit has an “ON-OFF” switch, indicating
light (shows when a circuit is on) and a nameplate describing the circuit it controls. The lighting panel
is located on the aft interior wall of the dredge operator’s control cab.
2. Control Circuit (Ref. Dwg. 150260)
The control stand circuit is fed from 10-amp fuses and wired to the auxiliary engine fuel oil pressure
switch which will automatically disconnect the control and console lighting circuits when the auxiliary
engine is shutdown. The feed cables to the control stand are connected under the floor of the
operator’s control stand, terminal box 2TB is located in the lower left hand side of the operator’s
control cab.
When troubleshooting the control system, the hydraulic schematic should be referred to in conjunction
with the one line wiring diagram.
3. Safety Shut-Off Circuit-Auxiliary Engine (Ref. Dwg. 150261)
The auxiliary engine is equipped with a safety shut-off device which consists of a solenoid activated by
a low engine oil pressure, high water temperature, or low hydraulic oil level in the reservoir. When any
sensor activates, it closes a leg of the circuit, the solenoid is energized to move the fuel rack to the fuel
shut-off position and automatically shuts down the engine.
CAUTION: Whenever the automatic shut-off is actuated, the cause of the shutdown
must be determined and corrected before the engine is restarted.
4. Battery Cut Off Switches.
Battery power to the main and auxiliary engines can be shut off by a twist type switch for each engine
located in the center tank on the starboard wall adjacent to the corresponding engine

Section III-Tab 9 Electrical System
C. SERVICING
1. Control and Lighting Circuit
The control and lighting circuits are designed to permit simultaneous and continuous operation of all
equipment. The addition of circuits and more load on any panel should be preceded by due
consideration of power availability. Consult Ellicott before making any additions to these circuits. Any
addition or modification to the circuit is made at the owner’s risk.
CAUTION: ALWAYS find the cause of a blown fuse or tripped circuit breaker before
replacing or resetting it and returning to operation. NEVER wire around a fuse block or
substitute a fuse other than that recommended for the circuit.
2. Batteries (Ref. 121260 Kit, Main Engine Start and 121378 Kit, Aux. Engine Start)
Periodically clean the battery area with a mixture of baking soda and water, paint it, and cover the
terminals with heavy grease to prevent corrosion build-up. Check battery terminal fastener tightness
periodically as loose thermal clamps can cause sparking and battery terminal damage.
Battery electrolyte is 47% sulfuric acid and 53% distilled water which can cause chemical burns and
violent reaction when combined with many ordinary materials. Battery electrolyte may be neutralized
with a solution of ammonia or baking soda with water.
Established standard safety instructions and local regulations must be enforced when servicing the
electrical system.
Always insure that polarity of battery cables is correct before making connections to
the batteries.
WARNING: DO NOT breathe battery acid fumes. ALWAYS wear safety glasses when
handling battery acid or batteries. If acid spills especially on the skin or eyes,
neutralize immediately with large amounts of water and seek medical attention.
Neutralize clothes with baking soda and water solution.
WARNING: A battery on charge can produce an explosive mixture of hydrogen and
oxygen gases. ALWAYS charge batteries in an open, well ventilated area. NEVER
smoke in the vicinity of batteries on charge.
CAUTION: NEVER add battery acid to the batteries. Distilled water is recommended
for servicing batteries.
CAUTION: Always verify correct battery cable and terminal polarity before making
connections on battery terminals. Serious damage can occur to the engine gauges,
charging system and diner portions of the dredge electrical system if batteries are
incorrectly connected. (See Dwgs. 121378 and 121260 engine starting kits in this
manual tab).
D. One Line DC Wiring Schematic (Ref. DWG. 150258)

SECTION III-TAB 10:
SERVICE WATER SYSTEM
TABLE OF CONTENTS
Page
A. SYSTEM DESCRIPTION..!!.!!!!!!!!!!!!!!!!!!!!!!!!!. 1
B. SERVICE WATER SCHEMATIC (DWG # 150268)!!!!!!!!!!!!!!!!!. Insert
C. OPERATION!!!!!!!!.!!!!!!!!!!!!!!!!!!!!!!!!!. 1
1. Starting the Water Pump..!.....!!!!!!!!!!!!!!!!!!!!!!!!!!!.. 1

2. Priming the Dredge Pump!!!!.!!!!!!!!!!!!!!!!!!!!!!!!!.. 1
3. Operating Pressure!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!... 1
4. Jacket Water!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!.. 1
D. MAINTENANCE!!!!!!!.!!!!!!!!!!!!!!!!!!!!!!!!! 2
E. TROUBLESHOOTING!!!....!!!!!!!!!!!!!!!!!!!!!!!!! 2
Illustration: 125185 Service Water Strainer!!!!!!!!!!!!!!!!!!!!!! Insert
Parts List, 146257 Service Water Pump!!!!!!!!!!!!!!!!!!!!!!!. Insert

Section III-Tab 10 Service Water System
A. SYSTEM DESCRIPTION (Reference Schematic #150223)
Water entering the sea chest through a recessed well located below the water line on the aft end of the
starboard side tank is drawn through a strainer and into a service water pump. This centrifugal pump (belt
driven by main engine) supplies water for cooling the hydraulic oil, the main engine jacket water, and
charge air cooler, the dredge pump reducer lubricating oil, lubricating and sealing the dredge pump
stuffing box, the auxiliary engine anter. cooler, and dredge pump priming.
NOTE: The jacket water system of the main and auxiliary engines is described in the
Caterpillar Operation Guide.
B. SERVICE WATER SCHEMATIC
Refer to insert at end of this tab.
C. OPERATION
1. Starting the Service Water Pump (Refer to the Service Water System Schematic # 150223)
The service water pump is located below the water line of the dredge and usually requires no priming.
However, before the initial start-up or after opening the pump or its suction line for any reason, make
sure that water has returned to fill the pump by loosening the upper plug in the pump casing.
CAUTION: Do not run the water pump dry as it uses the pumped liquid for lubrication.
The service water system begins operation when the dredge pump engine is started. Before starting
the main engine at any time, be sure that the valve V-3 is closed to the exhauster, while V4 is also
closed as shown on the schematic in the normal configuration.
WARNING: Always close the sea chest valve V-1 when the dredge is unattended as
leaks in the piping system or water pumps could fill the hull with water.
CAUTION: The water system must be thoroughly drained before a prolonged
shutdown and during cold weather.
2. Priming the Dredge Pump
A priming system is supplied. Refer to Section IV – Paragraph E – “Priming the Dredge Pump” in this
manual.
3. Operating Pressure
The pressure developed in the service water circuit at the dredge pump stuffing box MUST EQUAL or
EXCEED the discharge pressure (pressure developed by the dredge pump itself) while dredging. This
pressure prevents the entrance of slurry to the stuffing box and flushes the area between the impeller
and the engine side head liner to minimize wear. This pressure can be regulated by adjusting valve V-5
until adequate service water pressure is restored.
4. Jacket Water
There are two closed jacket water systems on the dredge. The auxiliary engine has a radiator with an
engine-driven fan cooling system while the main engine is of the heat exchanger cooling type. Detailed
operating information is contained in Caterpillar’s “Operation Guide” supplied.
D. MAINTENANCE (Ref. Dwg. # 150223 Drive, SW Inst.)
Information on the engine-mounted jacket water pumps is included in Caterpillar’s literature. Inspection
and servicing instructions for the heat exchanger can be found in the American Standard literature (See
insert included in this tab.) Cleaning information on the #125185 inlet strainer is supplied on an insert in this
tab.
Tension on the service water pump V-belts is adjusted by the sliding base at the pump foundation. The
belt has a take-up allowance of 3.00 inches. Adjustment of the belt drive is necessary whenever there is
an insufficient service water flow resulting from excessive belt slip. New belt tension should be lbs of force
with a deflection of 9/16”.
The service water strainer basket and sea chest inlet screen must be cleaned periodically. The sea chest
inlet screen is located at water level on the outboard face of the starboard side floatation tank. It is
contained in a slide frame and attached to the tank deck by a chain.
CAUTION: Do not over tighten the belt, to do so can damage the engines or pump drive
shafts. Always replace belts as a set for even wear and load distribution.
WARNING: Always close the sea chest valve when the dredge is unattended since leaks
in the piping system or service pump could fill the hull with water.
CAUTION: Before a prolonged shutdown and during cold weather, the system must be
drained completely.
D. TROUBLESHOOTING
EFFECT POSSIBLE CAUSE(S) REMEDY

System valves set incorrectly. Set valves as directed on schematic.
Sea chest or strainer clogged. Clean clogged unit.
Low Service Water Pressure/
Insufficient Flow Service pump not operating
Refer to manufacturer's manual.
properly.
(Service water pump housing Loose service water pump belts. Tighten belts to proper tension.
is hot.)
Service water pump impeller or
main pump stuffing box inlet Check for and remove obstruction.
clogged.
Possible air leak at service water pump
Improper installation of packing.
Low Service Water Pressure packing or suction inlet. Check for and correct
(This condition can also restrict
at Dredge Pump leakage. Pack units per instructions in Section
service water flow.)
III, Tab 2.
Water pump not operating properly. Check faulty unit per manufacturer's manuals.
Hot Lube Oil, Hydraulic Oil,
Cooler tubes clogged or tubes
and Jacket Water Clean or replace.
coated with foreign matter.
Temperature
Refer to the comments above concerning low
Insufficient water flow.
service water pressure and insufficient flow.



P/N 146257
Operation/Start up (Ref. 125185 Strainer)
Slowly introduce fluid to be strained by opening the inlet Basket Cleaning
valve. When to Clean
Note: Check and clean the dredge sea chest inlet
Caution: Start system GRADUALLY. This eliminates screen every 8 running hours more frequently if floating
sudden shock to the strainer and other equipment in the debris are present around the dredge. Check/clean the
line. strainer basket every 8 running hours.
Shut-Down Caution: To prevent damage to basket, DO NOT permit
After main engine shutdown, tightly close the inlet strainer pressure differential between inlet and outlet
butterfly valve. connections to exceed 20 psi.
Caution: DO NOT loosen cover while there is liquid or How to Clean
air flow from the vent. Invert basket and wash out debris by directing a stream
of air or water against the basket exterior. Use solvent if
Basket Removal strained fluid is fuel or a chemical. Follow
Follow shut-down procedure. manufacturer’s instruction when using a solvent to clean
When pressure is relieved, loosen T-bolt. Drain fluid the basket.
through bottom drain to a level below the basket seat. Note: Do not allow basket contents to dry as this will
Item #9 on parts illustration. make cleaning most difficult.
Swing yoke clear of cover and remove cover and dirty Inspect basket at each cleaning for holes and tears and
basket. replace as required.
Basket Replacement Shut-Down Periods
Place new or clean basket squarely on the basket seat.
Be sure basket handle is sufficiently high to be Always turn off the strainer inlet butterfly valve during
compressed by strainer cover. dredge shutdown. Drain the strainer in freezing
temperatures.
Inspect O-ring and seal surface: Clean seat or replace
cover O-ring as necessary. Always keep spare O-rings Recommended Spare Parts
in stock. 1 Replacement Basket
1 Replacement O-Ring
Replace cover, swing the yoke over the cover and make
full contact with the yoke stud. Tighten the center T-bolt. When ordering spare parts specify all nameplate data as
If strainer is on suction service, fill basket chamber from well as the description and quantity of parts.
outside source before installing cover. Follow start-up
procedure.
REF-
SECTION IV:
BASIC DREDGE OPERATION
TABLE OF CONTENTS
Page
A. PRE-OPERATION CHECKLIST""""""""""""""""""""""""". 1
B. INITIAL STARTING PROCEDURES""""""""""""""""""""""". 1-2
C. INITIAL DREDGE POSITIONING."""""""""""""""""""""""". 2
D. CHECKING SWING ANCHOR LOCATION"""""""""""""""""""".. 2
E. PRIMING THE DREDGE PUMP""""""""""""""""""""""""" 3
F. DREDGING"""""""""""""""""""""""""""""""""" 3-4
1. Swinging the Dredge"""""""""""""""""""""""""""""""" 3

2. Finding the Material""""""".""""""""""""""""""""""""". 3-4
G. ADVANCING THE DREDGE.".""""""""""""""""""""""""" 4
H. RESETTING THE SWING ANCHORS METHOD OF ADVANCING THE DREDGE.."".. 5
I. STOPPING PROCEDURES""""""""""""""""""""""""""". 5
J. OPERATING SITUATIONS""""""""""""""""""""""""""". 5-7
1. Dredging at Ground Level".....""""""""""""""""""""""""""".. 5

2. Dredging Gaseous Materials""".""""""""""""""""""""""""".. 6
3. Pumping Through Long Lines and/or High Terminal Elevations"""""""""""""... 6
4. Excavating/Pumping of Abrasive Material""""""""""""""""""""""". 6
5. Anchors Fail to Hold"""""""""""""""""""""""""""""""". 6

CAUTION: Insure that the service water strainer inlet valve is in it’s full open position
before cranking or running the main pump drive engine. (Ref. Dwg.# 150268)
CAUTION: Insure that the manually controlled shut off valves located on the inlet side
of the hydraulic drive pumps are fully open prior to cranking or running the auxiliary
(hydraulic) drive engine. (Ref. Dwg. #150213, Items 63 & 64).
NOTE: The Hydraulic pump suction indicators located in the hydraulic pump suction
lines will not function unless the #217483, ¼” NPT ball valves are in the fully opened
position. (Ref. Dwg. #150213, Item 17-3 plcs)
CAUTION: When shutting down the dredge in freezing temperatures, care must be
taken to drain the service water system and protect the main pump housing from freeze
damage. Insure that all dredge engine coolant systems have the proper anti-
freeze/coolant mixtures for your operating ambient temperatures.
NOTE: It is the dredge operator’s responsibility to develop, implement, and maintain a

safety, operation, and maintenance plan. Site conditions and local/regional regulations
may vary. Dredge discharge pipe layout, placement, and spoils area design is the
responsibility of the dredge operator.
NOTE: A minimum of 3 suction pipe diameters ladder depth should be maintained

whenever the slurry pump is in operation to avoid creating a vortex at the suction pipe
entrance which will result in pump cavitation or loss of pump prime.
CAUTION: A minimum of 2’ (.6m) of clear water depth must be maintained below the
service water sea chest inlet screen to avoid ingesting bottom sediment into the service
water system.
CAUTION: Operation of this equipment in navigable waters requires USCG or other

agency approved navigation and marker lighting. It is the dredge operator’s
responsibility to comply with any vessel, pipeline oil other ancillary equipment lighting
and marker requirements.

Section IV Basic Dredge Operation
A. Pre-Operation Checklist
WARNING: Do not service the engine while it is running.
1. Read and follow the safety recommendations outlined in Section II, “Safety.”
2. Inspect all equipment for damage. Insure that all tank access covers and hatches are installed and
properly secured.
3. Check fuel level. If required, add diesel fuel per Caterpillar’s specification.
4. Check the water level of the starting batteries. Add clean distilled water if needed.
5. Assure that all fluid lines and connections are tight and do not leak.
6. Assure that engine cooling systems are filled per Caterpillar’s Operation Guide (Main, Auxiliary and
Genset if so equipped).
WARNING: Do not smoke or allow flame/spark-producing devices in the vicinity of a fuel

tanks or open lines, or the engine cranking batteries. Turn off all cellular phone
equipment.
WARNING: Do not remove a radiator cap or expansion tank cap until an engine’s cooling
system is at or near ambient temperature.
7. Check that all lubrication and/or adjustments have been performed to those areas requiring it. Use the
Lubrication and Maintenance Chart in Section VI of this manual and the supplied component manuals
as guides.
8. Check that all obstructions have been removed from the equipment and on-board work area. Clean up
any spilled hydraulic fluid, lubricants, or other fluids.
9. Assure that both port and starboard swing brakes are “ON” and that the swing winch speed control is in
the “SLOW” position. Check that the swing winch directional controls are in the off or neutral position.
10. Assure that the cutter directional control is in the “OFF” position, and the speed control is in the slow
position.
11. Check that all other controls governing the hydraulics of the unit are in the “NEUTRAL” position.
12. Make sure the main pump engine’s clutch is disengaged.
13. Open the sea chest valve for service water operations.
WARNING: Insure that all personnel and equipment are clear of the discharge pipe flap
valve counterweight arm swing radius during startup and shutdown operations.
B. INITIAL STARTING PROCEDURES
1. Read and follow the Pre-Operation Checklist at the start of this section.
2. Start the engines per Caterpillar’s instructions in the Operation Guide supplied.
a. Observe the engine oil pressure gauge. Shut down the engine immediately if no oil pressure
registers within 5 seconds.

b. Move the governor controls to the low engine speed and allow the engine to idle 5 to 10 minutes to
reach operating temperature.
3. Gradually increase the dredge engine’s speed. Maximum main engine speed is 1600 RPM (pumping
conditions permitting). Maximum Hydraulic Drive Engine Speed is 1800 RPM (3406/C15)
CAUTION: The minimum engine operating speed is approximately 1200 RPM for proper
hydraulic function. Recommend the engine speed be set and kept at 1800RPM to achieve
the designed hydraulic performance.
4. Check the hydraulic system.
a. Note the pilot winch brake pressure gauge which should read 500-800 psi within 30-45 seconds
after starting. If no or low pressure is observed, shut-down the auxiliary engine and determine the
cause. The directional valve shifting pilot circuit should read 400 psi.
b. Check for normal flow at the indicators on hydraulic oil filters. Assure that the reservoir oil level
remains steady. Check for excessive noise, vibration or heat at components. Should any problems
occur shutdown the auxiliary engine and determine the cause.
c. During operation, continually check the above procedures. Also note that the hydraulic oil
temperature which should not exceed 140°F. (60°C.). Should the oil begin to exceed this
recommendation, make sure that the valves in the service water, hydraulic oil return line and jacket
water system are adjusted properly otherwise, shutdown the auxiliary engine and determine the
cause of overheating.
5. Check the service water system.
a. Insure proper packing adjustment and leakage at the S.W. and main pump stuffing box.
b. Observe S.W. pump belts for proper tensioning.
c. Check for S.W. gauge function on main pump and in the dredge operator’s control stand.
6. Check the electrical system.
a. Observe engine gauges in the center tank and control stand for operation.
b. Observe that all flood lamps, control stand illumination lamps, center tank interior lamps, and any
required exterior lighting or markers are functioning.
c. Check electrically operated hydraulic controls for response.
C. INITIAL DREDGE POSITIONING

1. Position the dredge on the centerline of the “cut.”
2. Disconnect the ladder safety straps and remove spud stowage pins.
3. Lower the ladder until the cutter rests on the bottom.
CAUTION: Insure that spud stowage pins have been removed and water depth is known
prior to spud lowering or freefall.
4. Freefall the digging (port) spud so that it is secure in the bottom.

5. Raise the ladder and place the swing anchors.
D. CHECKING SWING ANCHOR LOCATION

CAUTION: Never swing the dredge with both spuds down. Insure that equipment and
personnel are out of the dredge swing path.
Swing the dredge to port and starboard with the ladder up. The angle between the cutter and swing cables
should be such to prevent the cables from being cut of fouled by the cutter when dredging.
When at the end of each swing, note the angle between the buoys or stakes that mark the sides of the cut
and a point on the bow of the dredge. By returning to this point during each of the progressively lower cuts,
the edges should be uniform. Note that as the dredge advances, this point will have to be relocated.
E. PRIMING THE DREDGE PUMP
1. Start the main engine following procedures listed in paragraph B (Initial Starting Procedures) of this
Section.
2. Prime the pump as follows, refer to Figure 4-1 for valve references:
a. Lower the ladder until the suction inlet is 3’ to 6’ (one to two meters) below the water’s surface.
b. Make sure the discharge piping flap valve is closed.
WARNING: Insure that personnel and equipment are clear of this discharge pipe outfall
area. Use a discharge pipe tap and valve to take material samples, never attempt to hold a
container in the discharge stream.
c. Engage the dredge pump clutch at a minimum of 700-750 RPM and gradually increase the engine
rpm to 2/3 speed (approx. 1200 RPM).
d. Open valves V-3 and V-4
e. Close valve V-5 (overboard discharge) and partially close valve V-2.
f. Observe the vacuum gauge and discharge pressure gauge in the lever room. Gauge readings may
fluctuate as the pump picks up prime. When the pump is primed, the vacuum gauge reading will be
steady and the discharge pressure gauge will have risen to a constant measure.
NOTE: As the pump picks up prime, the engine

speed should be reduced to about ½ maximum
RPM until the discharge pipe is full and water is
flowing from its end.
g. Close valves V-3 and V-4; open valves V-2 and V-5.
CAUTION: Make sure the service water pressure

reading exceeds the discharge pressure reading
by 10-20 PSI. If necessary, adjust the service
Figure 4.1
water valve V-2 to reach the proper reading.

F. DREDGING
1. Swing the Dredge
This dredge cuts best when swinging from port to starboard; this is due to the direction of rotation by
the cutter. If the material is compacted and an attempt is made to dredge from starboard to port, the
cutter will tend to “walk” across the top of the embankment. When this occurs, the port swing drum
cannot spool-in its cable fast enough and the cutter may foul in the swing line. It is possible to dredge
from starboard to port if the material is soft. When this is done, the starboard swing drum brake should
be applied slightly to retard the swing of the dredge and prevent the possibility of a slack port swing
cable.
The speed and direction of the dredge’s swing is controlled by the levers of the swing winches, swing
winch brakes and winch speed control. The swing speed is highly dependent on the material being
excavated as well as the operator’s skills.
CAUTION: Never attempt to swing the dredge with both spuds down. Do not pivot the
dredge on the starboard side spud while digging at this will put excess strain on the
discharge line connections at the aft end of the dredge.
2. Finding the Material
Lower the ladder until a noticeable increase in the vacuum gauge or cutter pressure occurs to indicate
material contact.
NOTE: Be careful not to lower the ladder too far into the material after contact is made as
this puts a strain on the swing cables.
G. ADVANCING THE DREDGE
Once the required depth is reached, it becomes necessary to advance the dredge. Swing the dredge until
the cutter is on the port side of the centerline. The operator should note the alignment of some object of the
dredge with the centerline stake or buoy. After stopping the swing of the dredge, raise the ladder above the
material; then drop the starboard spud and raise the port spud. Swing the dredge to a point on the star-
board side of the centerline (equal to the distance to port that the dredge was previously swung). Stop the
swing of the dredge. Lower the port spud and then raise the starboard one. The dredge has now advanced
and the dredging operation can again proceed. This procedure is illustrated on the following page.
The amount of advance depends on the material to be dredged; usually the cutter’s length in soft material
and half-length in more compact material. The character of the material and the vacuum reading
encountered during the starboard swing of the advance will determine how far the swing can be made or
the dredge advanced. Light mud, silt, and certain types of sand allow larger advances as they will slide
down to the cutter as it agitates the foot of the bank. Other types of material, such as sticky mud, fine sand,
and combinations, will not slide and must be agitated to be removed. This type of material will choke of the
suction pipe if the excavator is forced too far into the bank.
CAUTION: Never drop a spud while the dredge is still swinging. Always raise the
advancing (starboard) spud sufficient distance to allow for clearance of an uneven bottom.

Figure 4.2 Method of Advancing the Dredge (Spud-equipped Dredges)
H. RESETTING THE SWING ANCHORS
As the dredge advances, the swing anchors will eventually be in a position where they are too far aft of the
cutter as illustrated in Figure 4-3. When this situation develops, the anchors or “dead-men” must be moved
forward.
The anchors are advanced to prevent the pulling of the dredge from the face of the cut by the swing lines,
which may occur if the spud is imbedded in soft material, or if it has only slightly penetrated the bottom.
Conversely, if the spud is deeply seated in compact material, the breaking or bending of a spud by the
excessive backward pull of the swing cables becomes possible.
I. STOPPING PROCEDURES
1. Raise the cutter out of the material being excavated and pump clear water long enough to clear the
pipeline.
2. Gradually lower the main engine speed to 700-750 RPM; disengage the clutch; allow the engine to idle
for several minutes to cool; shut it down.
3. Apply the swing winch mooring brakes.
4. Raise and secure the ladder with its safety cables and pins.
5. Secure the swing winches by the pawl at each winch drum.

WARNING: Stopping the main engine without disengaging the clutch is a safety hazard,
as the pump impeller could unscrew from its shaft and damage the pump.
6. In calm areas, and tidal areas, anchor the dredge securely (in addition to the swing anchors). Set stern
winch cable (if applicable). In rough water or high currents, the dredge must be secured by outside
means such as mooring to a pier or barge in calm waters.
7. Close the sea chest valve.
8. Lower the auxiliary engine speed allowing it to idle for several minutes to cool; shut it down.
9. Use safety lights and markers as required in the work area and on the dredge, swing anchor lines and
pipeline.
J. OPERATING SITUATIONS
1. Dredging at Ground Level
When dredging new waterways, the cutter can be used to cut down the bank ahead of the dredge or, if
the bank is too high for the cutter, other methods (i.e. bulldozer) should be used.
Roots, grass, and other vegetation covering the ground to be dredged should be cut or removed before
dredging. Sometimes it is possible to dredge away the material under the vegetation first, allowing the
vegetation to float away or slide down the face of the cut to the channel bottom.
WARNING: DO NOT undercut high banks. Cave-ins can cause injury to personnel and
damage or sink the dredge. Always bench cut the deposit to avoid bank heights in
excess of six (8) feet.
2. Dredging Gaseous Materials
Decayed vegetation deposited at the bottom of a body of water is occasionally covered by sand or mud
deposits. The gas caused by the decomposition of this organic material is trapped in pockets overlying
deposits. When disturbed by the cutter, the gas is indicated by bubbles on the surface over the cutter,
wide fluctuations in the vacuum gauge, or by cracking noises in the dredge pump. The gas is
sometimes present in such quantities that the pump will lose its prime. In this event, it may be
necessary to make one light pass over the material with the cutter running and the pump stopped. In
addition, the rate of advance and swing as well as depth of cut may have to be reduced to decrease the
percentage of gas being drawn into the dredge pump.
3. Pumping Through Long Lines and/or High Terminal Elevations
Dredge output will be reduced as the pipeline length and elevations increase. This reduction is due to
the velocity of the water in the pipeline being reduced through the increased head loss associated with
longer lines and high terminal elevations, and the water carrying less material in suspension. When
pumping through short pipelines, the water velocity is higher, and greater percentages of material can
be carried in suspension.
Continued heavy digging on long lines may cause the material to settle out in the pipeline, causing it to
plug. The time and labor necessary to clean a plugged line and the danger associated with the
accompanied high pressure make this a very undesirable situation. To alleviate the problem, the
operator must constantly be alert. The danger point will be signaled by an increasing discharge
pressure reading and a falling vacuum reading. The ladder must be raised immediately to allow water

to pass through the line. A substantial decrease in the discharge pressure indicates that the line is
again reasonably clean of excess material.
A discharge line check or flap valve is recommended on lines with a positive terminal elevation.
4. Excavating/Pumping Abrasive Material
Prior to project start up, the dredging operator must anticipate the amount of wear that may be
encountered on components that come in contact with the dredged material. Hard surface welding may
be applied to the cutter basket sheave and blade leading edges for prolonged service life. In most
cases, the replaceable cutter teeth are already hardened and welding could make them brittle.
Hardened pump cases, impellers and liners must never be welded on. Keeping the impeller to front
liner gap properly adjusted, in the slurry pump will assist in providing maximum service life. If abrasive
materials are anticipated, it is good practice to have a spare cutter basket assembly on hand so one
may be serviced while the other unit is in operation.
It is often advantageous to apply thin beads of hard surfacing weld to the entrance area of the dredge
suction pipe hood.
Pipe sections and section hoses with symmetrical flange ends should be rotated periodically
approximately 120 degrees.
The discharge pipe elbows will normally wear faster along the outer or longer curve radius and these
areas should be monitored periodically to facilitate scheduled repair or replacement.
5. Anchors Fail to Hold
a. Raise the anchor and check for fouling of the cable or flukes. Reset the anchor.
b. The ladder structure may be dragging the bottom. Consider the use of the shallow digging wedge.
c. The material may be too soft or hold the anchors and an additional or heavier anchor may be
needed.
d. The anchors may be positioned too close to the dredge cut. Move the anchors farther away.

CAUTION: Use the starboard or walking spud only for dredge advancement. Pivoting
continuously on the walking spud may cause undue wear to the discharge line flex hose
and connections at the aft end of the dredge.

Page 1/2
Dredge Daily Log

Contract No.: Report No. Date
Project Shift From To
Location Foreman
Weather
Crew Name Rate Straight Overtime Hours

Time Hours Operating Repairs
Foreman
Operator
Shoreman
Fuel taken on Gals/Liters

Lube taken on Qrts/Liters
Dredging Time
Start Stop Description
Lost Time
Start Stop Explanation
Other Equipment
Start Stop Description Fuel Lube
Misc. Comments
Approved
Owner’s Representative Superintendent
Page 2/2
Dredge Daily Log

Maintenance Checks
Fluid Levels
Main Engine Oil Main Engine Coolant
Aux. Engine Oil Aux. Engine Coolant
Genset Engine Oil Genset Engine Coolant
Hydraulic Pump Drive Other
Main Pump Drive
Hyd. Reservoir/Head Tank
Winches-Spud/Ladder
Fuel Port
Fuel Starboard
Fuel Genset
Scheduled Visual Slurry Pump Inspection:
Impeller face to suction side liner clearance (Recommended 1/8”-3mm) Actual:
Notes:
General Dredge Condition: Loose Fasteners/Damaged Equipment/Leaks/Missing Equipment
Scheduled Lubrication:
Swing Sheaves Main Pump Seals
Fleeting Sheaves PTO Bearings
Gantry Sheaves SW/RW, JW, Pump Bearings
Ladder Trunnions Spud Cylinder Sheave Assy.
Other Other
Other Other
Scheduled Adjustments:
PTO Clutch engagement Engine Fan Belt Tension
SW/RW/JW Pump Packing Other
Pump Belt Drive Tension Other
Genset Voltage Other
Wire Rope Inspection:
Spud Lifts Other
Swing Sheaves/Winches Other
Ladder Lift/Gantry Other
SECTION V:
LUBRICATION AND MAINTENANCE
TABLE OF CONTENTS
Page
A. INTRODUCTION .. . 1
B. PREVENTIVE MAINTENANCE AND LUBRICATION CHART .. 1-2
During Operation................................................................................................................................ 1
Daily 1-2
Weekly 2
Monthly .. 2
Quarterly ...................... 2
6 Months 2
Yearly . 2
As Required .. 2
C. STORING LUBRICANTS . 3
D. WINTERIZATION/COLD WEATHER OPERATION 4
NOTICE: Every effort has been made to insure proper installation of all components on your Ellicott
Dredge. It is the dredge operator’s responsibility to develop, practice, and document their own routine and
scheduled maintenance programs including but not limited to fluid changes, lubrication, inspection for
work/damaged equipment, and periodic checking of fasteners tightness/torque. Ellicott Dredges, LLC
assumes no equipment warranty or personnel injury liabilities arising from insufficient/improper
maintenance or improper operation of this equipment.
WARNING: Winch manufacturers specify periodic tear down inspections in addition to other
maintenance. Lubricating oil requirements may change with ambient temperature extremes for proper
operation of the winch. Refer to Section VII Tabs 1 & 2 of this manual for further information.
WARNING: All components coming into contact with the dredged material are subject to varying rates of
wear based on but not limited to material abrasiveness and pipe line velocity. The dredge operator is
advised to perform scheduled inspections of the slurry pumping system to determine remaining thickness
or other pertinent material wear data to make a decision on replacement interval requirements. Pump
case “scuffing” and recirculation wear on head liners cannot be detected by visual inspection through the
pump suction cleanout assembly.
Excess wear on slurry pumping components can create explosion or rupture condition that could result in
equipment damage on injury to personnel.

Section V Lubrication and Maintenance
A. Introduction
This section covers the basic maintenance and lubrication of the dredge and its components. It should be
noted that any information on a component manufacturer’s part is only supplemental to that manufacturer’s
literature. When preparing a maintenance schedule, be sure to read this supplied material carefully.
To reduce the quantity of recommended lubricants on hand, the number has been held to a minimum. Any
product names listed are to serve only as a guide for obtaining satisfactory lubricants and not as a product
endorsement. If a particular lubricant is not available, check with a lubricant distributor for a like product
meeting the necessary specifications.
The Maintenance and Lubrication Chart is provided to give brief and basic description of the part requiring
maintenance and its general location.
NOTE: Use the lubrication chart’s hourly intervals when working a 2 to 3 shift operation. Use the
other intervals when working a single shift operation. The lubrication chart is a guide to be used
with the additional information given in your Ellicott manual and the supplier manufacturer’s
literature. Some modifications of the intervals may be necessary depending on local operating
conditions. All lubricant capacities are approximate.
B. PREVENTIVE MAINTENANCE AND LUBRICATION CHART
ITEM PROCEDURE REQUIREMENTS
FREQUENCY: DURING OPERATION
Engine Room and General Dredge:
Engine Oil Pressure Note any change from normal range.
Fuel Oil Pressure Determine cause for change and make
Engine Coolant Temperature necessary repairs.
Ammeter Reading
Hydraulic Oil Temperature and Level
Engine Coolant Level (Sight Gauge Only)
Hydraulic Oil Filter Status Indicators
Main Pump Reduction Gear Unit
Temperature and Lube Oil Flow
Engine Air Filter Status Indicators
Main Pump Packing Temperature/Leakage Adjust service water flow or packing as
required.
Hydraulic Pump Inlet Line Vacuum Follow procedure for cleaning strainers.
Indicators
Visually check accessible components for Clean/Repair as necessary.
oil or fluid leakage
Hydraulic Pump Gear Drive Temperature Check lubricant or trouble shoot as
required.
Service Water Pump Packing Adjust packing gland as required.
Temperature/Leakage
Control Console/Dredge Operator: Observe gauges which monitor these
Hydraulic Swing Pressure variables continuously. Inaccurate or
Service Water Pressure inoperable gauges/readouts must be
Winch Hydraulic Pressure replaced.
Dredge Pump Vacuum
Dredge Pump Pressure
Engine RPM
FREQUENCY: DAILY, OR EVERY 8 HOURS OF OPERATION
Main Pump PTO/Assembly Clutch Check engagement force. Lubricate clutch Adjust the maximum or minimum
as required. engagement force as required..
Crankcase Lube Oil, All Engines Check engine oil level See Engine Manufacturer’s manual for oil
requirements. See Section VII tabs 4 & 5.
Hydraulic Pump Gear Drive Check oil level EP 90 (-10 to 100F)
Dredge Assembly Walk around inspection for damaged,
loose or missing equipment.

Fuel Tanks Check level and fill as required See engine manufacturer’s manual for
fuel specifications.
Swing Sheaves and Guide Sheaves Grease NLGI #2
Ladder Trunnions Grease Pins NLGI #2
FREQUENCY: EVERY 40 HOURS OR WEEKLY
Flap Valve Grease shaft fittings NLGI #2
Gantry Sheaves and Ladder Bale Assembly Grease cross shafts (4 Places) NLGI #2
Fuel/Water Separator Drain Accumulated water or sediment
Batteries Check fluid level Add distilled or potable water as required
Spud Winches/Ladder Winches Check drive lubricant levels Add lubricant as required.
Swing Winch and Spud Wires Lubricate Mobiltac D
Sea Chest Strainer & Seachest Screen Clean
FREQUENCY: EVERY 100 HOURS
PTO Assembly Lubricate shaft bearing? NLGI#2. Remove lower plug during
lubrication.
Spud Winches (P/N 148149) Initial Oil Change SAE 90 Drum/ISO 68 final drive
Ladder Winch Initial Oil Change-500 hours thereafter SAE 90
FREQUENCY: EVERY 250 HOURS OR MONTHLY
Engine Alternator Belts Check for excess wear & proper tension. See engine manufacturer’s manual
Service Water Pump Belts Check for excess wear & proper tension. Tighten when necessary
Caterpillar C9 Engine Crank case Lube Oil Change Oil. Clean Breather. Change See engine manufacturer’s manual for oil
System Filter Element. requirements
Caterpillar C32 Engine Crankcase Lube Oil Change Oil. Clean Breather. Change See engine manufacturer’s manual for oil
System Filter Element(s). requirements
Swing Winch Drum Support Bearings Grease NLGI#2
FREQUENCY: EVERY 500 HOURS OR 3 MONTHS
Hydraulic Pump Drive Initial oil change EP 90 (-10 to 100F)
Main Pump Reduction Gear Unit Initial oil change, clean strainer AGMA5/ISO220
NLGI#2 (for seals)
Ladder Winch Change oil in drum/final drive SAE 90
Spud Winches (P/N 148149) Change oil in drum and final drive SAE 90 drum/ISO 68 final drive
Hydraulic Pump Drive Change lube oil EP 90 (-10 to 100F)
FREQUENCY: EVERY 2000 HOURS OR YEARLY
All Engines Major inspection and maintenance See engine manufacturer’s manual.
Hydraulic System Flush entire system. Change oil. Drain Mobile DTE 26 (Ambient Temperature
and clean reservoir, clean suction Dependent)
strainers.
Winches Disassemble Replace seals, gaskets, O-rings, worn
parts
Engine PTO-Slurry Pump Drive Coupling Remove and inspect coupler element. Realign shafts if required, see Section III
Check shaft parallel/axial alignment. Tab 2 150431 Coupler
FREQUENCY: AS REQUIRED
Hull Clean and repaint. General overhaul
Fuel Tanks Clean
Winch Wire Replace
Battery Compartments Clean and repaint
Windows All windows made of plexiglass. Caution Use a soft cloth, mild soap and water
must be used when cleaning. Do not use only to clean plexiglass windows.
oil, fuel solvent, or paint thinner to clean.
Heat Exchangers Inspect and clean thoroughly when
necessary
Hydraulic Lines, Piping, and Fittings Replace, repair or reconnect Seal threaded areas with Loctite
hydraulic sealant only. (Not on SAE type
fittings).
Main Pump Head O-Ring Seals Replace if pump heads are removed. When manufacturing seals, join seal
ends with Loctite 484 Quick-Set
adhesive.

Maintenance Fluid Information
ITEM LUBRICANT CAPACITY/NOTES
Spud Winch Primary Drive ISO 68 Initial fill
Spud Winch Drum Assembly SAE 90# Fill as required
Spud Winch Secondary Drive ISO 68 Fill as required
Slurry Pump Bearing Housing ISO 220 46 Gallons (174.1 Liters) Plus lines and
heat exchanger
Slurry Pump Drive Shaft Seals NLGI #2 2-3 Strokes or as required
Service Water Pump Shaft Bearings NLGI #2 2-3 Strokes or as required
Slurry Pump Drive PTO Power Pack ISO 32 3 Quarts (2.8L)
Slurry Pump Drive PTO Shaft Bearings NLGI #2 2-3 Strokes or as required
Ladder Trunnions NLGI #2 2-3 Strokes or as required
Ladder Gantry and Ladder Bale Sheaves NLGI #2 2-3 Strokes or as required
Ladder Swing Sheaves NLGI #2 2-3 Strokes or as required
Main Engine Crank Case Oil See engine operation/Maintenance 35.6 Gallon (134.8 Liter) plus filters if
manual required
Hydraulic Drive (Auxiliary) Engine Oil See engine operation/Maintenance 8 Gallons (30.2 Liters) plus filters if
manual required
Hydraulic Pump Drive Lube Oil EP 90# 3.3 Quarts (3.2 Liters)
Hydraulic Drive (Auxiliary) Engine Fan Drive NLGI #2 2-3 Strokes or as required
Bearings
Ladder Winch Drum Assembly and Final SAE 90# Fill as required
Drive
Ladder Winch Primary Drive ISO 68 Fill as required
Swing Winches, Inner and Outer Bearings NLGI #2 2-3 Strokes or as required
Swing Winch Pawl Shafts NLGI #2 2-3 Strokes or as required
Discharge Line Flap Valve Assy. NLGI #2 2-3 Strokes or as required
Wire Rope Lubricant Mobiltac A or equal As required
Cutter Drive Assembly ISO 68 Initial fill of housing, planetary, and motor
NOTE: Consult Lube Oil Supplier for lubricant recommendations when operating in extreme temperature ranges (Below 25F or above
120F ambient temperature)
NOTE: The gap between the impeller face and the forward liner in the #151145 pump assembly
is set at 1/8" on a new pump assembly. It is recommended that the dredge operator establish a
program to examine this gap as well as other areas of the pump to detect excess wear.
Periodic shimming of the impeller can help maintain maximum pump efficiency. Pump part
wear rates will vary with individual site and pumping conditions.

C. STORING LUBRICANTS
Lubricants should be stored and dispensed efficiently, purchased in bulk whenever possible, and safe-
guarded against contamination.
The money spent on quality lubricants can be wasted and the dredging equipment jeopardized if lubricants
are allowed to become contaminated during storage. If lubricant drums cannot be stored under cover, they
should at least be placed in racks in a horizontal or tilted position so that water and dirt cannot settle on
their covers.
Appropriate containment safeguards must be taken in the event that any barrel leakage should occur.
It should be noted that hydraulic oil may require further filtering prior to it’s installation into an existing
system. Never mix used oil or drained oil with new oil.
DO NOT STORE DRUMS UNCOVERED

D. WINTERIZATION/COLD WEATHER OPERATION
If the body of water that the dredge is in is subject to freezing, it is recommended that a water circulation or
air bubbler system be installed around the dredge. Ideally for storage, the dredge should be removed from
the water and stored on land.
When operating in freezing temperatures, there are certain precautions that must be taken to prevent
damage to the dredge systems and engines. This includes, but is not limited to:
Engines:
1) Insure that the coolant/antifreeze mixture is checked and provides protection for the locally anticipated
temperatures.
2) Refer to the engine manufacturer’s manuals to be sure that the correct viscosity of crankcase oil is
being utilized. If a reliable shore power source or genset is available, the operator may elect to use an
approved on-board space heater system or engine block heaters. Consult the engine manufacturer for
special storage instructions if the engines are expected to be out of service for more than a month.
Main Pump:
If an approved space heater system is not utilized, it may be necessary to evacuate the pump casing of
water or introduce antifreeze solution into the pump through the suction clean out assembly when the
dredge is shut down for any significant period of time. (Environmental regulations may prohibit the
discharge of an antifreeze solution, check with appropriate regulatory agency prior to using antifreeze).
Service Water System:
Upon dredge shut down, the service water inlet gate valve should be closed and the drain plug removed
from the service water inlet strainer assembly. The strainer assembly lid and basket may also be removed
to remove any remaining water then reinstalled. Leave out the drain plug and insure that water is not
bypassing the gate valve assembly. The lower drain plug in the face of the service water pump should be
removed to allow the service water system to drain. Additionally, a drain plug should be removed from the
hydraulic, main engine, and main pump speed reducer heat exchangers to release any static water in
them.
Hydraulic and Lubricating Oils:
When ambient temperatures approach the freezing range (32F/0C), the operator should consider using a
lighter grade oil in the hydraulic system, the main pump gear reduction drive, and the hydraulic power unit
pump drive. When ambient temperatures approach 0F/-18C, further medication in oil grade is required.
Colder, more viscous oil can have an adverse effect on a hydraulic pumps ability to obtain oil as well as
interfere with the main pump gear reduction lube oil pump’s ability to prime and circulate oil. Hydraulic
controls as well as the braking control on winches may be adversely affected creating an unsafe operating
condition.
Fuel System:
If the dredge is to be operated in freezing temperatures, then frequent draining or sampling of the fuel cells
should be accomplished to prevent water build up. The operator should consult with the dredge engine
manufacturer and the local fuel distributor regarding any change in fuel (i.e. #1 Diesel vs. #2 diesel) or any
recommended fuel additives. The fuel water separators on the engines should have a small amount of fuel
drained from them daily or at the beginning of every shift.
If the dredge is going to be stored for an extended period of time, the fuel tanks should be drained, inerted,
and coated with a light oil or other diesel duel compatible rust preservative and inspected periodically for
rust build up. The fuel lines and filters should also be drained to avoid fuel congealing and plugging the
lines.
General:
1) Decks, walkways, handrails, and stairs can become covered with a thin layer of ice from precipitation or
wave mist during freezing weather so extra caution is to be taken while moving about the dredge to
avoid slips and falls.
2) Engine cranking batteries should be removed during dredge storage and placed in a suitably ventilated
on a trickle charge or otherwise maintained in a serviceable condition.
3) Removable pins (i.e. ladder locking straps, spud gate pins) should receive a coat of grease or rust
preventative in preparation for storage to allow easy removal at start up.
4) Ladder, spud winch and swing winch cables should receive a coat of wire rope lubricant or other
suitable rust preventative during storage.
5) Empty tank areas or ballast tanks should be inspected for water build up and drained for storage. A
light film of grease on the man hole cover access lid o-rings will aid in post-storage removal of the lids
and assist in preventing the o-rings from drying out.
6) When extended storage is expected, it would be advantageous to drain the lubricating oil from the main
pump drive speed reducer and the hydraulic pump drive and replacing it with Shell VSI Circulating Oil
or equivalent. The air vents on these components should be sealed to contain the rust preventing
vapors of the oil. The circulating oil must be drained and replaced by the recommended lube oil prior to
operational start up and the seals removed from the component vents. If circulating oil is not used, the
main pump drive should be manually rotated on a monthly basis to assist with recoating the internal
parts. Consult the engine manufacturer before attempting to “bar” an engine over to rotate the hydraulic
pump drive.
7) Ether or other similar starting aids are highly flammable and produce hazardous vapors. Care should
be taken with their use and the operator must consult with the engine manufacturer prior to utilizing a
starting aid as some types of engines may incur damage from their use or over-use. Use of a starting
aid in an enclosed space may create an explosive hazard.

SECTION VI: FIELD ASSEMBLY
TABLE OF CONTENTS
Page
B. FACILITIES AND EQUIPMENT REQUIRED .. 1-2
C. PREPARATION OF LAUNCHING SITE .. 2-4
D. PRELAUNCH ASSEMBLY . 5-7
E. PREPARATION FOR LAUNCHING .. 7
F. LAUNCHING THE DREDGE .. 7
G. INSTALLING THE SPUDS . 7-8
H. START UP PREPARATION .. 8
I. INITIAL ENGINE START-UP ..... 8-11
J. REEVING THE SWING LINES . 11
K. DISCHARGE PIPE ON HULL CONNECTION INFORMATION .. Insert
WARNING: The 1170/1270 Series Dredges must be launched with all flotation tanks
connected. The center tank will not float without both side tanks attached. Post launch
installation of the ladder or gantry assemblies is not recommended.

Section VI Field Assembly
A. INTRODUCTION:
It is recommended that this dredge be launched stern first from ways into the water; if this is not possible
due to the site condition, Ellicott’s Field Engineering Department should be consulted for other means.
These assembly instructions are intended to illustrate only basic standard procedures. Additional
precautions may be necessary for safe assembly and launching. Conformance with safety codes, rules,
and regulations at the assembly site is the responsibility of the customer.
NOTE: The preparation of the launching site and supplying equipment for assembly is the
customer’s responsibility.
Before beginning assembly, thoroughly check the packing list for component identification, weights and
dimensions.
NOTE: When required, the following conversions can be used:
TO CONVERT INTO MULTIPLY BY

Feet (ft or ‘) Centimeters (cm) 30.48
Feet (ft or ‘) Meters (m) 0.3048
Inches (in. or “) Centimeters (cm) 2.540
Inches (in. or “) Millimeters (mm) 25.40
B. FACILITIES AND EQUIPMENT RECOMMENDED:
1. Facilities
The minimum launching requirements are as follows:
a. A suitably level area capable of taking the load of the dredge and the servicing cranes during
assembly;
b. Adequate machine shop service with drill, grinder, air compressor, vises, and bench;
c. Supply of heavy timber logs or mats, wedges, crow bar, hydraulic jack, come-along, various “c”
clamps, and shackles.
2. Suggested Number of Personnel:
a. Two riggers
b. One mechanic
c. One electrician
d. One welder
e. Four Laborers
3. Equipment and Tools
NOTE: Selection of crane capacity is the responsibility of the customer and crane contractor.
a. Two mobile cranes (required only for placing the center tank and side tanks on ways);

b. One mobile crane to complete the assembly;
c. Miscellaneous wire rope slings and shackles, spreader bars and fittings;
d. Standard hand tools including a heavy duty portable hand drill with attachment for grinding and
paint mixing;
e. One cutting torch.
f. Paint sprayer.
g. One 250-ampere arc welding machine.
h. Ellicott tool kit, part number 122230 and torque wrench for machinery installation.
i. Torque wrench and sockets for side tank bolt installation.
j. Dial indicator and base for engine/pump coupler alignment.
C. PREPARATION OF THE LAUNCHING SITE

Ellicott’s Series 1170 dredge is designed to be launched from ways. If this is impossible due to the lack of
a suitable launching site, the Field Engineering Department at Ellicott should be consulted.
1. Preliminary Considerations
The dredge will draw approximately 3 ft (91.4 cm) of water when fully assembled. There should be,
however, a minimum of 8 ft (2.4 m) of water at the launching site.
A slope of one inch to one foot (2.54 centimeters to 30.48 centimeters) is ideal for launching. If the
bank is solid enough to support the weight of the equipment, place the launching ways directly on the
bank; if not, cross ties or similar material must be placed under the ways for additional bearing surface.
Material available at the site will determine of what the ways will be constructed. Ten 10” x 10” timbers
(25.4 cm x 25.4 cm), steel “H” beams, or railway rail can be used as shown in Figure 3 of page 7.
Regardless of the base structure, it is good practice to use timber (sliding ways) at the point of contact
with the hull bottom in order to avoid scoring or otherwise damaging the hull.
NOTE: It is best to have the supporting timbers (sliding ways) travel with the hull when
launching. The length of the ground cleared will depend on the layout of the launching
site. However, the minimum length permissible is 60 ft (18.3 m for 33 ft DD) and 120 ft
(36.6 m for 50 ft DD).
2. Preparing the Bank
The Ellicott Series 1170 dredge is normally launched stern first with the ladder installed as shown in
Figure 1. Before launching, clearance must be obtained for those portions of the side tanks that extend
forward of the bow of the center tank and also for the cutter. An area slightly larger than these
overhanging portions should be dug out of the bank to provide this necessary clearance as shown in
Figure 2.
3. Preparing the Ways

Regardless of the materials used, the ways must be placed apart at a distance of 7 ft (2.13 m) from
center to center and must extend into the water until the top of the ways are at least 6 in. (15.24 cm)
below water level.
A heavy grease is then applied about 1/8 inch (3.18 mm) deep to the top side of the ground ways. The
construction of the ways from the various materials is shown on the following page.
If the side hull tanks for this dredge were fabricated by the customer, instructions would have been
given to refrain from welding the lower locking devices to the side tanks before the arrival of the center
tank. If this is the case, block up the center section of the ways approximately 2 ft (61 cm). When the
center tank is placed on the ways, the side tanks can be connected to it and the lower locking devices
positioned and welded to the side tanks.
Bank Preparation and Dredge Launching
Figure 1 (Reference Illustration)
Clearance or Cut Out Area
Figure 2 (Reference Illustration)

Figure 6.1
Figure 6.2

D. PRELAUNCH ASSEMBLY (Local site conditions may require change in method or order
of assembly)
1. Lifting the Center Tank
The center hull section is lifted using one crane at each end.
The forward end of the dredge is lifted by the ladder trunnions. Place the bits of both slings on the hook
of one crane. Put the loop of one sling in each trunnion, insert the trunnion pins and secure them in
place. The pins should then be protected to prevent their being damaged when the lift is made.
The aft end of the dredge is lifted by the lifting lugs (See figure 6.3). Use appropriate shackles on each
lifting lug.
Fasten tag lines to the hull for control. Take care to prevent shock loads during the lift cycle. Both
cranes must raise, lower and work together as smoothly as possible during this operation.
Once located on the ways, the center tank should be secured to the deadman by means of cable.
Sight conditions permitting, the placing of the center tank on the ways is the only operation that requires
the use of two cranes. For the remainder of the assembly one crane should be sufficient.
2. Ladder Installation (33. Ft. Digging Depth and Under)
The ladder installation should be made before installing the side tanks to insure working room.
However, if the dredge doesn’t have its connecting blocks welded on, the side tanks will have to be
temporarily aligned and marked for mounting before the ladder is installed.
a. Install the two ladder lifting cylinders and four ladder safety straps (if not already installed).
b. Bolt the rubber suction hose to the center tank.
c. Lift the ladder into position and install both the trunnion pins and the pin locking bars.
d. Connect the suction hose to the ladder; raise and lower the ladder as necessary to align the hose.
e. Connect the four ladder safety straps to the ladder. These straps will securely hold the ladder.
f. Tighten the various connecting bolts on the ladder and suction pipe to the required torque.
3. Lifting and connecting the Side Tanks
a. Side Tank Without Connecting Block Welded On
Using four equal lengths of sling, lift each side tank and move it along side of the center tank. Align
the hull plating and seal chest opening. If some irregularities in hull plating occur, use temporary
lugstack welded on the hull and “C” clamps to force the side plating into contact. From inside the
center tank, mark each side tank bolting pad (from the holes in the center tank) with spray paint or a
center punch. Be sure that the pads are centered over the holes so there is enough room for a
socket to fit the bolting nut. These holes are to be burned out once the tanks are removed.
At the bottom of each side tank, locate the connecting hooks (item 12-6) so that the sloped surface
is in tight contact with mating surface on the center tank connecting block. While holding the hook
in position, apply several tack welds to secure the location of the hook to the side tank frame.
Then, move the side tank away from the center tank and complete the welding of the hooks to the
bottom of the side hull tanks. Use ½ inch fillet welds on the three sides of each hook and a ¾ inch
build-up of weld on the inboard side of each hook as shown using an AWSE-6010 welding
electrode.
WARNING: Proper welding is required to insure the integrity of the dredge hull. Do
not accept poor welds in this critical area. Follow the above instructions carefully
and insure that the welding is performed by qualified personnel. Disconnect dredge
engine cranking batteries and isolate sensitive electronic components prior to any
welding operations.
After welding, wire brush and repaint the burned area.
b. Side Tank with Connecting Block Installed
Lifting the side tank in a manner similar to that shown on Figure 6.3, use two shackles on each
lifting lug on the outboard side of the tank while using one on each of the inboard lugs. By lifting the
tanks in this manner, it is easier to engage the bottom hull connection.
Once the bottom hull connections have been engaged, boom out to bring the tops of the tanks in
contact with each other. The tanks should then be bolted together as shown on Figure 6.4.
NOTE: On 50 ft DD versions, the ladder gantry would be installed after installation of the ladder and
side tanks. Lift the ladder with a crane and secure it with the ladder stowage safety cables. The
ladder winch cable may be reeved after launching.
Figure 6.3 (Reference only, actual design may vary)

4. Installing the Lever Room
Bolt the lever room in place after installing the rubber gasket between the base of the lever room and
the hull foundation. The gaskets should also be installed between the deckhouse and the rear of the
lever room and between the hatch way cover and the deckhouse roof. All of these gaskets should be
installed very carefully to prevent leaks. A bead of RTV sealant will assist with sealing at the mating
surfaces.
5. Remaining Equipment
Install all additional equipment except for the spuds which will be installed after launching. Connect the
various hydraulic lines and recheck all connecting bolts for proper torque and tightness.
E. PREPARATION FOR LAUNCHING
The dredge must be secured to bollards or deadmen by cables. Be sure that the waterfront at the
launching area is free from underwater obstructions and the water depth in the launching area is at least 8’.
F. LAUNCHING THE DREDGE
Launching is the most critical step in the assembly of the dredge. Extreme care should be taken to see
that the safety of all personnel involved in the launching is insured.
To launch the dredge:
1. Make sure the spudwell gates are open inboard for later spud installation.
2. Attach lines to the deck cleats to control the dredge after launching.
3. Make sure that the sea chest gate valve is closed and that the dredge pump and the portion of the
suction pipe within the center tank are fully assembled and water-tight. Check that all side and center
tank covers are installed properly.
4. Release the cables to the deadmen. In most cases, the dredge will need a push from a crane or dozer
to begin sliding.
CAUTION: Use timber at the point of contact between the dredge and the crane or
bulldozer.
5. After launching, pull the dredge to shore or to a dock and make fast. If the dredge is in tidal water, be
sure that the securing lines will not restrict the floating of the dredge at high tide or “land” the dredge in
low tide.
6. Inspect all compartments for leaks and again tighten the bolts that connect the side tanks to the center
tank.
G. INSTALLING THE SPUDS (Figure 7)
1. Open the four spudwell gates (if not open) by removing the outboard gate pins and hinging the wells
inboard.
2. Wrap the crane’s lifting sling around the upper portion of the spud in a chocker hitch.

3. Lift the spuds and guide it into the spud well insuring that the spud lifting plate (located approximately
80 inches from the point end/bottom) of the spud is facing forward. Check for bottom clearance under
the spud tip prior to releasing the crane or pinning the spud.
4. Install the spud keeper pin in its hole, the second one from the bottom of the spud.
5. Close the spud well gates and lock with the pins provided.
CAUTION: Insure that the spud keeper pin is above the upper spud well before closing
the wells.
6. Lower the spuds until the spud keeper pin engages its recessed stop on the upper spud well.
NOTE: After start-up of the auxiliary engine, the individual spud/ladder winches can be
operated and the spud lifting cable connected to the spud lifting plate. The spud can
then be raised and the spud keeper pin removed when required.
H. START-UP PREPARATIONS
Most diesel engine warranties are void if some one other than an authorized manufacturer’s representative
makes the initial start-up. Be sure to contact your local manufacturer’s representative and arrange to have
a service person on hand at start-up. The cost of this pre-start and initial start-up service may be included
in the purchase price of the engine.
Connect the fuel lines. Prior to filling, have someone thoroughly clean the fuel tanks with a wire brush to
remove any scale formed during shipment. The tanks should then be filled immediately to minimize the
change of scale again forming.
Filling the ballast tanks. Some operators like to clean these tanks and then fill them with water. A ready
supply of clean water is then available for filling the jacket water systems of the engine and other uses.
Check all equipment against the lubrication charts. Make sure all items are lubricated as directed.
Align the dredge pump drive coupling post-launch and install the stuffing box with its lantern ring. Fill and
vent all hydraulic components. Fill each battery with electrolyte in preparation for start up.
WARNING: Only an experienced battery person should handle the electrolyte.
Follow all safety procedures when working with the batteries. Do not smoke or have an open flame near
the batteries. Wear protective clothing and glasses to avoid being burned by spilled or splashed battery
electrolyte.
I. INITIAL ENGINE START-UP
An authorized Ellicott or engine manufacturer representative should start the main and auxiliary engine. All
controls should be set to neutral so that “no load” is placed on the engine at this time. When the engine
representative is satisfied with the operation of the auxiliary engine with “no load”, run the cutter and winch
motors in the high idle position. A close watch should then be placed upon the hydraulic oil filter. When,
and if, the color indicator on the filter gets close to the red area, stop, and replace the filter elements.
Repeat this process until you can get approximately two hours of running time with a clean filter.
The dredge owner is responsible for warranty registration of engines.

The next step is to remove the ladder safety straps and raise and lower the ladder. Adjustment of the
ladder travel speed can be done with the swing winch flow control valve on the operator’s left side of the
control stand.
Figure 6.4 (Reference only, actual design may vary)

Figure 6.5 (Reference Illustration)

Lower and raise the spuds utilizing the joy stick control located in the center portion of the control stand.
Make another check of the hydraulic oil filters and clean them if necessary.
Have the engine service representative then start the dredge pump engine (main).
CAUTION: The dredge pump clutch must be disengaged and the sea chest valve
opened before starting.
After start-up, check the service water pump for proper operation. Prime the dredge pump following the
instructions contained in the Instruction Manual. Check for flow to the dredge pump reducer oil cooler,
prime the reducer’s lube oil pump prior to the initial start-up, if necessary.
J. REEVING THE SWING LINES
WARNING: The winch reeving operation requires that personnel work in close
proximity to rotating equipment. Do not wear loose clothing or equipment that may be
caught in a rotating winch. Insure that there is a clear means of communication
between the cable handlers and the winch operator. Wear appropriate protective
equipment when handling cable (gloves and glasses, etc.).
NOTE: The ladder winch cable and ladder bale may also be installed at this time.
The procedure for reeving the swing lines is as follows:
1. Set a drum of cable on the forward end of each side tank.
2. Support each drum on a piece of pipe positioned across two wood blocks high enough for each drum to
turn.
3. Lead the line down the ladder, through the swing sheave, across the top of the guide sheave on the aft
end of the ladder, and across the top of the winch drum.
4. Make a loop around the drum, put the line through the opening in the drum flange, and secure it with the
wedge socket provided.
5. Reeve in the cable. Have a person with a hammer tap the cable over so that it winds on the drum
evenly.
6. Form an eye in the outer end of the line into which a shackle can be inserted and the anchor connected.
It is advisable to attach the anchor buoys to the swing line at the same time as attaching the anchors.
7. Connect the anchors.
8. Wrap the swing cable around the deck cleat on the outboard hull tank, tie the cable to the cleat with a
piece of rope, and rest the anchor on deck until needed.

SECTION VII: VENDOR/REFERENCE LITERATURE
TABLE OF CONTENTS
Part Number
TAB 1 PULL MASTER MODEL M25 (Spuds)...................................................................... 148149
TAB 2 WINCH, PULL MASTER MODEL H25 ..................................................................... 148948
TAB 3 CATERPILLAR WARRANTY REGISTRATION AND RECOMMENDED FLUIDS... INSERT
TAB 4 ENGINE, HYDRAULIC DRIVE (C9) ......................................................................... 150161
TAB 5 ENGINE, MAIN PUMP DRIVE ................................................................................. 151028
TAB 6 PUMP, PORTABLE BILGE (OPTIONAL) ................................................................ 102054
TAB 7 HOIST, FORWARD JIB CRANE (OPTIONAL, REF. DWG #122824) ..................... 112991
TAB 8 HEAT EXCHANGER GENERAL INFORMATION.................................................... INSERT
TAB 9 BELT DRIVE MAINTENANCE.................................................................................. INSERT
TAB 10 REFERENCE MATERIAL......................................................................................... INSERT

148149 SPUD WINCH
INSTRUCTION AND PARTS MANUAL
MODEL M25
FREE FALL
PLANETARY HYDRAULIC WINCH
THE LOGICAL CHOICE
PULLMASTER WINCH CORPORATION

8247-130th Street, Surrey, B.C. V3W 7X4, Canada
Telephone: 604-594-4444 Fax: 604-591-7332
Website: www.pullmaster.com
E-mail: sales@pullmaster.com
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.
PMC 261 070228

PULLMASTER LIMITED WARRANTY
Effective 1/1/2002
SUPERSEDES ALL PRIOR WARRANTIES
Seller warrants that each article 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.
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 Seller’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, overloading, or employment for other than
normal and ordinary use and service.
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.
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.
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.
WARNING
PULLMASTER planetary winches/drives are not designed for operations involving lifting or moving
personnel. The PULLMASTER WINCH CORPORATION cannot be held liable or responsible
for any accident resulting from such use of PULLMASTER planetary winches/drives.
Note: Specifications contained in this Instruction and Parts Manual are subject to change without notice.
SAFETY RECOMMENDATIONS
Definition: Caution indicates a potentially
hazardous situation which, if not avoided may
DANGER result in minor or moderate injury.
Definition: Warning indicates a potentially

FAILURE TO COMPLY WITH THE FOLLOWING SAFETY hazardous situation which, if not avoided could
result in death or serious injury.
RECOMMENDATIONS AND LOCAL RULES AND
REGULATIONS WILL RESULT IN PROPERTY Definition: Danger indicates a potentially
hazardous situation which, if not avoided will
DAMAGE, SEVERE INJURY OR DEATH. 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 pressure 21. Keep hands clear when winding wire rope onto the
(psi) and operating volume (gpm). 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 rope
6. Do not operate a damaged, noisy or is properly anchored to the correct cable anchor slot at
malfunctioning winch. the cable drum.
7. Do not leave a load suspended for any extended 24. Do not lift a load with a twisted, kinked or
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.elen
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, stand
11. Warm-up equipment before operating winch,
clear of the area and the load being hoisted, take the
particularly at low ambient temperatures.
necessary precautions to prevent access to area where
12. Verify winch function by raising and lowering a the load is halted.
full test load to a safe height before each shift.
28. The noise level of the winch is 87dBA measured
13. Do not weld any part of the winch. on a distance of 1.00 meter, 1.60 meters high. The
14. Verify gear lubrication and brake circulation measuring equipment used was: Realistic #42-3019.
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
16. Wear proper clothing to avoid entanglement in hat. Read manual first.
rotating machinery.
17. Always stand clear of the load.
261 REV.051117 PAGE 1

DESCRIPTION OF THE MODEL M25 WITH FREE FALL
GENERAL DESCRIPTION:
The PULLMASTER Model M25 with free fall is a planetary hydraulic winch having equal speed in both directions
and the ability to lower a load FAST. The free fall option comes in three variations: emergency free fall,
controlled free fall, or with both combined. The main components of this unit are:
jj ✛ Hydraulic gear motor
✛ Multi disc brake with static and dynamic function
✛ Over-running clutch
✛ Hydraulic gear motor
✛ Primary planet reduction
✛ Final planet reduction
✛ Brake housing
✛ Cable drum
✛ Free fall housing
✛ Free fall clutch assembly
✛ Metering pump assembly (for controlled free fall)
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 is locked in place by the free fall clutch and 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. 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 of a load, hydraulic pressure from the reverse
side of the hydraulic motor is channelled to the brake piston, causing the brake piston to release the multi-disc
brake against a number of brake springs. 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 pay 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 lowering operations 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 from the motor, or
externally, depending on the brake code of the winch. For efficient cooling of the automatic brake, models with
external circulation should be adjusted to supply 5 (US) gpm - 19 l/min. This flow must be returned directly to
the reservoir with a permissible back pressure of 30 psi (2 bar).
IMPORTANT: Under no circumstances must the pressure in the brake housing be permitted to exceed 30 psi (2
bar). Excessive pressure in the brake housing will damage the oil seal separating the brake housing
from the drum interior. Damage to this seal will cause the drum to fill up with hydraulic fluid.
WARNING
PRIOR TO OPERATION OF THIS UNIT ALWAYS ENSURE COMPLIANCE
WITH ANY NATIONAL OR LOCAL SAFETY CODES AND REGULATIONS
REGARDING THE USE OF FREE FALL WINCHES.
PAGE 2 261 REV.040708

DESCRIPTION OF THE MODEL M25 WITH FREE FALL
CONTINUED
EMERGENCY FREE FALL:

The emergency free fall is used for a full release of a suspended load up to the maximum load capacity of the
Model M25 planetary winch. Upon acitivating the emergency free fall function the load will drop and must be
allowed to fall to its end travel without re-engagement.
DANGER
RE-ENGAGING FREE FALL CLUTCH WHILE LOAD IS DROPPING
CAUSES SHOCK LOADS AND WILL LEAD TO CABLE FAILURE,
PROPERTY DAMAGE, SEVERE INJURY OR DEATH. INTERLOCK
HYDRAULIC CONTROL TO PREVENT RE-ENGAGING FREE FALL
CLUTCH WHILE LOAD IS DROPPING.
FUNCTION OF THE EMERGENCY FREE FALL:

When the Model M25 planetary winch is actuated for emergency free fall, hydraulic pressure is channelled to
the clutch piston, causing the clutch piston to press against a series of springs and release the multi-disc clutch.
This effectively disconnects the cable drum from the gear train of the winch and any suspended load will drop.
The minimum load required to establish the emergency free fall mode is 500 lb (227 kg).
CONTROLLED FREE FALL:

The controlled free fall offers positive down control of a load at selected speeds and can be stopped anywhere
on the way down. The controlled free fall is not designed, nor intended to lower the maximum load in a
controlled free fall. The permissible load is 30% of the maximum line pull capacity of the winch. Since the clutch
release pressure of the controlled free fall varies in accordance with the size of the load, a metering pump is
utilized to compensate for clutch release pressure variations.
FUNCTION OF CONTROLLED FREE FALL:

The controlled free fall has the same basic function as the emergency free fall with the addition of a metering
pump which regulates the different clutch pressure requirements during a controlled free fall. When the
controlled free fall is actuated, hydraulic pressure is channelled into the clutch piston, causing the clutch piston
to press against a series of springs and release the multi-disc clutch. When the clutch has been released, the
final planet assembly rotates with the cable drum, around a stationary sungear. A small hydraulic gear pump is
splined to the final planet hub. This hydraulic pump displaces hydraulic oil flow out of the free fall control circuit
to compensate for the difference in the clutch release pressure, which varies according to the actual lowering
speed. The faster the load is lowered with the free fall control, the faster the planet hub will cause the pump to
turn, increasing the displacement volume drawn out of the control circuit. When the free fall control is returned
to neutral, the hydraulic pressure in the clutch piston is vented and the free fall clutch is re-engaged by spring
pressure.
COMBINED EMERGENCY AND CONTROLLED FREE FALL:

The emergency and controlled free fall can be combined for installations where both of these options are
required. Two separate controls must be used for this option and the operating criteria for both functions must
be adhered to.
IMPORTANT: Under no circumstances must the pressure in the free fall housing be permitted to exceed 10
psi (.7 bar). Excessive pressure in the free fall housing will damage the oil seal separating the
free fall housing from the drum interior. Damage to this seal will cause the drum to fill up with
hydraulic fluid.
261 REV.980701 PAGE 3

EXPLANATION OF MODEL CODING
M 25 X - XX - XX - XX X - X XXXX
BASIC UNIT SERIES
M = Equal speed in both directions
SIZE OF UNIT
REDUCTION RATIO
Only used for non standard reduction ratios
TYPE OF BRAKE
-3 Automatic brake, clockwise drum rotation, internal circulation flow
-4 Automatic brake, external brake release, clockwise drum rotation,

internal circulation flow
-5 Automatic brake, external brake release, counterclockwise drum

rotation, internal circulation flow
-6 Automatic brake, counterclockwise drum rotation, internal

circulation flow
-7 Automatic brake, clockwise drum rotation, external circulation flow

external circulation flow

rotation, external circulation flow
-10 Automatic brake, counterclockwise drum rotation, external

circulation flow
HYDRAULIC MOTOR
- 86 Hydraulic motor, 3 inch gear section (12.3 cubic inch displacement)
(Other gear sections for this motor are optional)
DRUM SIZE
-1 10 inch drum diameter X 17 inch flange diameter X 11 inch length - STANDARD
(For other drum sizes refer to APPENDIX A)
OPTIONS
- C Controlled free fall
- D Emergency free fall
- G Combined emergency and controlled free fall
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.
PAGE 4 261 REV.980701

OPTIONS
COUNTERCLOCKWISE ROTATION:
The drum rotation of the standard PULLMASTER Model M25 planetary winch with free fall is clockwise for
hoisting when looking at the hydraulic motor of the winch. Drum rotation for counterclockwise hoisting direction
is available as an option.
INTERNAL CIRCULATION:
The PULLMASTER Model M25-7-86-X has an external circulation flow supply line to cool the brake. Internal
circulation 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
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 M25 planetary winch with
free fall can be supplied with optional drums to accommodate large wire rope storage capacity.
DRUM GROOVING:
Cable drums for the PULLMASTER Model M25 planetary winch with free fall 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 PULLMASTER Model M25 planetary winch with free fall can be changed by using a
different displacement motor. (Contact the factory for performance information of different gear sections.)
HYDRAULIC MOTORS FOR HIGH PRESSURE HYDRAULIC SYSTEMS:

The operating pressure of the PULLMASTER Model M25 planetary winch with free fall is limited to 2500 psi (172
bar). For hydraulic systems operating with a higher range of 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.
261 REV.970701 PAGE 5

SPECIFICATIONS
Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 7/8 inch
diameter wire rope. For other cable drums refer to APPENDIX A. For other reductions or motors, refer to
supplement inside back cover. Performance specifications for winches supplied with optional motors are
provided in attached supplement.
CABLE DRUM DIMENSIONS (STANDARD DRUM):

Barrel diameter 10.00 in 254 mm
Flange diameter 17.00 in 432 mm
Barrel length 11.00 in 279 mm
CABLE STORAGE CAPACITY:

(Size of wire rope) 7/16 in 612 ft 186 m
1/2 in 486 ft 148 m
9/16 in 383 ft 117 m
5/8 in 297 ft 90 m
3/4 in 210 ft 64 m
7/8 in 140 ft 43 m
1 in 91 ft 28 m
MAXIMUM OPERATING PRESSURE: 2500 psi 172 bar
MAXIMUM OPERATING VOLUME: 115 (US) gpm 435 l/min
MINIMUM OPERATING VOLUME: 30 (US) gpm 114 l/min
DRUM TORQUE AT MAXIMUM PRESSURE: 135,937 lb-in 15,359 Nm
DRUM RPM AT MAXIMUM VOLUME: Hoisting 49 rpm
HOISTING LINE PULL AT MAXIMUM PRESSURE:

Bare drum 25,000 lb 111.2 kN
Full drum 16,860 lb 75.0 kN
MAXIMUM ALLOWABLE LINE PULL WHEN USING

CONTROLLED FREE FALL: Bare drum 7,500 lb 33.4 kN
HOISTING LINE SPEED AT MAXIMUM VOLUME:

Bare drum 140 fpm 43 m/min
Full drum 207 fpm 63 m/min
PERMISSIBLE SYSTEM BACK PRESSURE

AT MOTOR RETURN PORT:
65 psi 4.5 bar
PERMISSIBLE PRESSURE
AT CIRCULATION SUPPLY PORT:
Brake housing 30 psi 2 bar
Free fall housing 30 psi 2 bar
LUBRICATING OIL: Refer to RECOMMENDATIONS for viscosity and instructions.

Refer to APPENDIX A for oil volume required.
PAGE 6 261 REV.010611

PERFORMANCE GRAPHS
PG-M25-B
MAXIMUM ALLOWABLE LINE PULL WHEN USING
LINE PULL VS. OIL PRESSURE CONTROLLED FREE FALL: jjlkjalkf

LINE PULL - kN
0 22 44 67 89 111
2500 172
OIL PRESSURE - bar

OIL PRESSURE - psi
2000 138
M
D RU
LL M
FU RU
1500 RED 103
BA
1000 69
500 34
0 0
0 5000 10000 15000 20000 25000
LINE PULL - lb
LINE SPEED VS. OIL VOLUME
LINE SPEED - m/min

0 6 12 18 24 30 36 42 48 54 63
125 473
OIL VOLUME - (US)gpm
379
OIL VOLUME - l/min

100
UM UM
DR DR
LL
E FU
75 B AR 284
50 189
25 95
0 0
0 20 40 60 80 100 120 140 160 180 207
LINE SPEED - fpm
Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with 7/8 inch
diameter wire rope.
261 REV.010611 PAGE 7

TYPICAL HYDRAULIC CIRCUIT
EMERGENCY FREE FALL: HC-M25-X-XX-XD-B
FREEFALL
CIRCULATION
RETURN
BRAKE
CIRCULATION
5 USGPM
0-1000 PSI (19 L/MIN)
PRESSURE GAUGE EXTERNAL
CIRCULATION
MODELS ONLY
FREEFALL
CIRCULATION
2 USGPM
(8 L/MIN)
FREEFALL CLUTCH RELEASE

750 PSI (52 BAR)
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
PRESSURE
RELIEF VALVE
BRAKE CIRCULATION FILTER

RETURN (DIRECT TO
RESERVOIR)
HYDRAULIC
PUMP
RESERVOIR
DANGER
PROPERTY DAMAGE, SEVER INJURY OR DEATH. INTERLOCK
PAGE 8 261 REV.970701

CONTROLLED FREE FALL: HC-M25-X-86-XC
FREEFALL
CIRCULATION
RETURN
0-1000 PSI
PRESSURE GAUGE
CONTROL VALVE
WITH METERING BRAKE
MOTORSPOOL; B A
SPRING RETURN CIRCULATION
TO NEUTRAL; 5 USGPM
PORT B PLUGGED (19 L/MIN)
FREEFALL EXTERNAL
CIRCULATION CIRCULATION
T P 9 USGPM
CONTROL VALVE MODELS ONLY
(34 LPM)
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO
2.5 USGPM CENTER
(9 LPM)
RELIEF VALVE
750 PSI
(52 BAR)
RELIEF VALVE
2500 PSI
(172 BAR)
FLOW DIVIDER
(PRESSURE & BRAKE CIRCULATION FILTER
TEMPERATURE RETURN (DIRECT TO
COMPENSATED) RESERVOIR)
HYDRAULIC
PUMP
RESERVOIR
261 REV.950501 PAGE 9

COMBINED EMERGENCY & CONTROLLED FREE FALL: HC-M25-X-86-XG
CAUTION: The 148149 Spud Winch does not utilize a recirculation line in the final drive/
freefall brake assembly. the lubricant level must be separately filled and periodically checked.
FREEFALL
CIRCULATION
RETURN
0-1000 PSI
PRESSURE GAUGE
BRAKE
CIRCULATION
CONTROL VALVE SHUTTLE 5 USGPM
WITH METERING B A VALVE
MOTORSPOOL;
(19 L/MIN)
SPRING RETURN FREEFALL EXTERNAL
TO NEUTRAL; CIRCULATION
9 USGPM
CIRCULATION
PORT B PLUGGED
(34 LPM) CONTROL VALVE MODELS ONLY
T P
(MOTOR SPOOL)
4-WAY SPRING
CONTROL VALVE RETURN TO CENTER
WITH PUSH
BUTTON AND
TWO DETENTS
2.5 USGPM
(9 LPM)
RELIEF
VALVE
750 PSI
(52 BAR)
RELIEF VALVE
2500 PSI
(172 BAR)
FLOW DIVIDER
(PRESSURE & BRAKE CIRCULATION FILTER
TEMPERATURE RETURN (DIRECT TO
COMPENSATED) RESERVOIR)
HYDRAULIC
PUMP
RESERVOIR
PAGE 10 261 REV.950501

RECOMMENDATIONS
HYDRAULIC FLUID: HYDRAULIC PRESSURE RELIEF:
The hydraulic fluid selected for use with PULLMASTER The hydraulic circuit for the PULLMASTER planetary
planetary winches should be a high grade, petroleum winch requires a pressure relief set at the operating
based fluid, with rust, oxidation and wear resistance. pressure (see SPECIFICATIONS). Usually, a pressure
Fluid cleanliness and operating viscosity are critical to relief is part of the hydraulic control valve. Where this
winch reliability, efficiency and service life. is not the case, a separate pressure relief valve must
be installed and set at the recommended maximum
For optimum performance, the recommended viscosity pressure.
range at operating temperature is 81 - 167 SUS (16 - 36
CS). For extreme operating conditions of short duration, HYDRAULIC RESERVOIR:
the maximum viscosity range of 58 - 4635 SUS (10 -
It is recommended that the hydraulic reservoir has
1000 CS) should not be exceeded.
sufficient capacity to provide good heat dissipation in
order to prevent over-heating of the hydraulic fluid. The
For optimum performance, the winch recommended
hydraulic reservoir should be made from clean and
hydraulic fluid temperature operating range is 80 -
scale-free material to prevent contamination of the
150F (27 - 66 C). For extreme operating conditions of
hydraulic fluid. In order to prevent air from being mixed
short duration, the maximum temperature range of -5
with the hydraulic fluid, the reservoir should have an
- 180F (-21 - 82 C) should not be exceeded.
over-flow baffle separating the return lines from the
suction line and all return lines should enter the reservoir
LUBRICATION: below the fluid level. The reservoir should be mounted
The winch gear train requires oil bath lubrication. The close to and above the hydraulic pump in a location
winch is shipped from the factory without lubricating oil. which provides for free air circulation around the
reservoir.
IMPORTANT: ADD LUBRICATING OIL BEFORE
RUNNING WINCH. HYDRAULIC HOSES:
Refer to INSTALLATION DIMENSIONS for location of The following hydraulic hoses are recommended for
lubricating oil fill port. Refer to APPENDIX A for quantity maximum efficiency of the PULLMASTER Model M25
of oil required. For normal operating temperature use planetary winch with free fall:
SAE 90 lubricating oil. Consult lubricating oil supplier or
factory for temperatures beyond normal operating Pressure lines: Equivalent to SAE 100R 12-32
range. Circulation return line: Equivalent to SAE 100R 4-16
The final drive of the winch is lubricated by the hydraulic Circulation supply line: Equivalent to SAE 100R 6-6
oil which is circulated through the free fall housing. Free fall release line: Equivalent to SAE 100R 3-4
It is recommended that a larger size of hydraulic hose

HYDRAULIC PUMP: is installed where the pressure lines or the circulation
For maximum performance of the PULLMASTER
lines are excessively long.
planetary winch, the hydraulic pump must supply the
maximum flow of hydraulic fluid at the hydraulic pressure
stated in SPECIFICATIONS.
HYDRAULIC FILTER:
Hydraulic filter recommendations for the hydraulic
circuit of the PULLMASTER planetary winch, based on
HYDRAULIC WINCH CONTROL VALVE: a return line filter, are given as follows:
The standard control valve used for operation of the
PULLMASTER planetary winch must have a four-way,
Average Atmosphere: 10 microns
spring return to neutral feature, which provides for open
Dusty Atmosphere: 5 microns
flow from the pressure ports of the winch to the reservoir
in neutral position of the control (motor spool). It is
In order to prevent accidental stoppage of the return
important to point out that good speed control, especially
line flow, the oil filter should have a by-pass feature.
when lowering a load, depends on the “metering”
characteristics of the control valve. The better the oil flow
is "metered" the better will be the speed control.
261 REV.021029 PAGE 11

RECOMMENDATIONS CONTINUED
EMERGENCY FREE FALL PRESSURE GAUGE:

CONTROL VALVE: To monitor free fall release port pressure install a 1000
The emergency free fall requires a two position, psi (69 bar) pressure gauge between the free fall
three-way valve. The pressure port must be open to control valve and the release port.
the reservoir when the emergency free fall is not
actuated and must pressurize the free fall release port IMPORTANT:
on the winch when the free fall control button is The circulation return lines must go direct to reservoir.
pressed. A selector valve with two detent positions is Pressure in the free fall housing must not be permitted
best suited. If the emergency free fall is combined to exceed 10 psi (.7 bar).
with controlled free fall, a standard two position, four-
way selector valve with two detents should be used. USE OF AN E STOP:
(Refer to TYPICAL HYDRAULIC CIRCUIT.) (FOR EUROPEAN MACHINERY DIRECTIVE APPLICATIONS)
The use of an E stop (emergency) is mandatory in the

CONTROLLED FREE FALL controls circuit. The E stop is to be placed in the
CONTROL VALVE: operator’s control panel. The E stop must be designed
For positive speed control, the valve used for the and placed in line with EN 60204 and EN 418.
controlled free fall must be a “spring return”, two
position selector valve, which has good metering
characteristics and on which the pressure port is open
to the reservoir when the controlled free fall is not
operating.
PAGE 12 261 REV.980701

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 per BOLT
TORQUE CHART.
4) Fill the winch with lubricating oil. (See APPENDIX A for oil volume required.)
5) Use recommended circuit components and hydraulic hoses.
6) The circulation return line of the winch should be plumbed in such a manner that the brake housing and free
fall housing remain full of oil at all times. Connect the return lines directly to reservoir. Do not connect to a
common return line.
7) Bleed the air out of the free fall control circuit by loosening the connection at the free fall release port on the
winch. With no load on the cable drum, operate the free fall control valve, letting all air escape, then re-tighten
the connection at the release port.
8) Before operating the winch with a load, verify adequate circulation flow through the circulation return line as
stated in TYPICAL HYDRAULIC CIRCUIT. Verify that pressure measured at the circulation supply port does
not exceed the permissible pressure stated in SPECIFICATIONS. Winches equipped with the internal
circulation option will supply circulation flow only when the winch is run in the lowering direction.
261 REV.970701 PAGE 13

OPERATING INSTRUCTIONS
DANGER
FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL
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 clockwise when looking at the hydraulic motor
of the unit. It is critical to select the cable anchor slot which will permit winding of the wire rope on the drum
in the correct direction of rotation. If the wire rope is wound on the cable drum in the wrong direction of rotation,
the winch will have no braking capacity. Each winch is shipped from the factory with a label on the drum
indicating the correct cable anchor slot.
CABLE ANCHOR
WIRE ROPE INSTALLATION CABLE ANCHOR SLOT

Clockwise hoisting winch shown.
(Use cable anchor slot on opposite side of
drum for counterclockwise 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. Pull rope
tight to wedge rope in slot. SI1013 - M25FF
2) On wire rope installation, care must be taken that the wire rope is wrapped completely around the cable
anchor and properly pulled into the cable anchor slot in the cable drum. The cable drum requires 5 wraps
of wire rope for safety.
3) The winch operation is controlled by a single control valve lever which has a forward, a reverse and a neutral
position. Speed control in either direction is obtained by modulation of the control valve lever. Maximum line
speed in either direction is obtained when the control valve lever is moved as far as it can go. The disc brake
of the winch will come on automatically when the winch control lever is returned to neutral.
4) Always warm up equipment prior to operating winch, particularly in low ambient temperature. Circulate
hydraulic oil through the winch control valve for several minutes to warm the hydraulic system. To prime the
winch with warm oil, operate the winch at slow speed, forward and reverse, several times.
5) Prevent corrosion damage to winch interior. If not used regularly, run winch up and down at least once every
two weeks.
6) To ensure proper winch installation and function, raise and lower a full test load to a safe height before using
winch for regular operation at the start of each shift.
PAGE 14 261 REV.051117

OPERATING INSTRUCTIONS CONTINUED
EMERGENCY FREE FALL:

To actuate the emergency free fall, push the emergency free fall control to disconnect the cable drum from the
gear train of the winch. The load (minimum 500 lb - 227 kg) will drop. The speed of the free fall will depend on
the size of the load on the wire rope.
DANGER
PROPERTY DAMAGE, SEVER INJURY OR DEATH. INTERLOCK
CONTROLLED FREE FALL:

To operate the controlled free fall, open the free fall control lever gradually to obtain smooth acceleration of the
lowering speed of the winch. The lowering speed is in direct proportion with the movement of the free fall control
lever. To decelerate or slow down the load, slowly return the control lever back to it’s neutral position. Sudden
stops of an accelerating load and erratic operation of the free fall control lever should be avoided. For better
modulation of the free fall control, a long handle should be used on the free fall control valve.
IMPORTANT: The controlled free fall is not designed nor intended to lower the maximum load in a controlled
freefall. The permissible load of the PULLMASTER Model M25 controlled free fall operation
is 30% of the maximum line pull capacity of the winch.
If, after a new installation, the winch does not function properly, refer to the TROUBLESHOOTING section of this
manual.
261 REV.010611 PAGE 15

TROUBLE SHOOTING
GENERAL:
In most cases, when the hydraulic winch does not perform satisfactorily, the cause of malfunction is found
somewhere in the hydraulic circuit. Before the winch is removed from its mounting and disassembled, all of the
hydraulic circuit components should be checked for proper function.
IMPORTANT:
The hydraulic oil volume relates to the line speed or rpm of the winch.
Therefore, if the winch does not produce the specified maximum rated line speed or drum rpm, a loss of
hydraulic flow somewhere in the hydraulic circuit system can be analysed. If this condition exists, install a flow
meter into the hydraulic circuit to check the volume supplied to the 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 line pull or lifting capacity of the winch.
If the winch will not lift the specified maximum line pull, install a pressure gauge into 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 pump is driven by V-belts, check for belt slippage. When checking oil pressure and
volume in the hydraulic circuit, make certain that the hydraulic reservoir is filled to the top level and the hydraulic
pump is running at maximum operating rpm.
Only if the hydraulic system has been checked and found to be in order, use the following indications for
probable causes of failure in the winch:
FAILURE 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) Excessive back pressure in the hydraulic system.
e) Relief valve may be set too low. (See SPECIFICATIONS
for maximum operating pressure.)
f) Clutch release valve may be in release position.
Winch will not produce line speed at maximum a) Winch is mounted to an uneven surface.
volume as listed in SPECIFICATIONS. (See INSTALLATION INSTRUCTIONS.)
d) Excessive back pressure in the hydraulic circuit.
Winch will not reverse. a) Leakage out of the brake piston prevents the brake
from being released against the brake springs. This is
caused by damaged O-ring seals on the brake piston.
b) The O-ring seals, on the brake release channel between
the motor adaptor and the brake housing is damaged.
If this failure occurs there will be substantial leakage
from between the motor adaptor and brake housing.
c) Insufficient hydraulic pressure. (See SPECIFICATIONS
for minimum operating pressure.)
d) Winch is mounted to an uneven surface.
(See INSTALLATION INSTRUCTIONS.)
e) Hydraulic pressure is not reaching the brake piston
(plugged brake release orifice in the brake housing).
PAGE 16 261 REV.950501

TROUBLESHOOTING CONTINUED

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 causes the brake
to be released.
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) Hydraulic pressure is trapped in the clutch piston, preventing
total engagement. This is caused by using an incorrect
control valve. The free fall control valve must leave the free
fall release port open to reservoir when not activated.
f) Wire rope is fastened to the incorrect cable anchor slot.
g) Sprag clutch is damaged or surfaces where sprag clutch
engages on motor drive shaft or brake hub are worn or
indented.
h) Winch supplied with external brake release option is not
plumbed per TYPICAL HYDRAULIC CIRCUIT. Failure to
vent external brake release port to reservoir may trap
pressure and cause winch brake to slip.
Brake vibrates when powering down 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 insufficient
circulation flow. To check the circulation, observe the flow of
oil from the circulation return line of the winch (approx. 5
(US) gpm - 19 l/min when the winch is reversed).
c) Control valve for the winch operation has poor ‘metering’
characteristics.
d) Damaged brake plates or divider plates.
e) The over-running clutch, which connects the motor shaft
with the brake assembly, is damaged.
f) Air mixed with hydraulic oil (foamy oil).
Free fall clutch cannot be disengaged. a) Insufficient pressure or flow supplied to free fall release port
(refer to TYPICAL HYDRAULIC CIRCUIT).
b) O-ring seals in clutch piston are damaged.
c) Insufficient load on the wire rope. A minimum of 500 lb (227 kg)
on a standard -1 drum is required to drop a load in free fall.
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model M25 winch with free fall.
261 REV.950501 PAGE 17

TROUBLESHOOTING CONTINUED

Free fall cannot be controlled. a) Emergency free fall is non-controllable.
b) Piping circuit or control valve is incorrect. Check hydraulic
circuit.
c) Control valve used has poor metering characteristics. The
control valve should have a flow capacity of 3-6 gpm
maximum. If a large volume control valve is used, it may
not provide good metering of the hydraulic oil, resulting in
poor speed control.
d) Hydraulic metering pump, installed in the end housing, is
damaged.
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 flange and
brake housing are caused by excessive pressure in the
brake housing or free fall housing. Excessive pressure in
the brake housing will damage oil seal, item 607, which
separates the brake housing from the drum interior.
Excessive pressure in the free fall housing will damage oil
seal, item 505, which separates the free fall housing from
the drum interior. In this condition hydraulic fluid will leak
into the drum interior, then damage oil seal, item 531.
c) Oil leaks occurring between the cable drum flange and
free fall housing are caused by excessive pressure in the
free fall housing. Excessive pressure in the free fall
housing will damage oil seal, item 105. Maximum allowable
back pressure in the free fall housing is 10 psi (0.7 bar).
Check for restrictions in circulation return line (must go
directly to reservoir).
d) Oil leaking out of the free fall housing on either side of the
spring retainer is caused by a damaged O-ring seal, item
213.
e) Oil leaking out of the end cap indicates a damaged O-ring,
item 241.
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model M25 winch with free fall.
PAGE 18 261 REV.950501

SERVICE INSTRUCTIONS
GENERAL:
Before attempting disassembly of the PULLMASTER Model M25 planetary winch with free fall, the following
instructions for disassembly and reassembly should be read and understood:
It is suggested that all expendable parts, such as O-rings and oil seals, are not reused on reassembly. It is
therefore important to have a seal kit (Part No. 23115) and, providing the hydraulic motor has to be serviced,
a seal kit (Part No. 23117) on hand before the unit is taken apart. Two new needle bearings, item 875, may also
be required (Part No. 25352).
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.
A clean working area is of prime importance, similar to conditions used for service work on any other hydraulic
component.
All parts, as they are removed from the winch assembly, should be 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.
In the following service instructions, reference to parts is made by numbers and shown on the applicable group
drawings.
DISASSEMBLY
For the majority of required service or repair work, disassembly is required only on the brake housing of the
PULLMASTER Model M25 planetary winch with free fall. There are no special tools needed for the service or
repair work and no adjustments or calibrations are necessary. Proceed with the disassembly as follows:
DISASSEMBLY OF HYDRAULIC MOTOR ASSEMBLY:

If the analysed service or repair work requires access to the interior of the brake housing, the hydraulic motor
should not be disassembled. In this case, the hydraulic motor should be removed together with the motor adaptor
as a complete assembly. If a problem has been analysed to be in the hydraulic motor, proceed with the
disassembly as follows:
1) Remove eight hex capscrews, item 951, together with lockwashers, item 953, from motor assembly.
IMPORTANT: Failure to exercise care when removing the motor port end cover or gear housing could
permanently damage the machined surfaces of these motor components. Take care not
to damage machined surfaces of motor components at disassembly.
2) Remove (pry loose if necessary) port end cover, item 870, together with bearings, item 875, and ring seal,
item 877. Thrust plate, item 885, and dowel pins, item 865, may stay in gear housing.
3) If thrust plate comes off with end cover, carefully pry it off of bearings, item 875, and discard pocket seals, item 887.
4) Remove gear set, item 881, which consists of two gears which are a matched set.
5) Carefully pry gear housing, item 861, off of motor adaptor, item 800. Thrust plate, item 885, and dowel pins,
item 865, may stay in gear housing.
6) If thrust plate stays on motor adaptor, carefully pry it off of bearings, item 875, and discard teflon seals, item 887.
7) Discard gasket seals, item 869. It is also advisable to replace ring seals, item 877, at this time. Bearings, item
875, must be removed to allow access to ring seals.
Teflon seals, gasket seals and ring seals in the hydraulic motor assembly are not part of the winch seal kit. The
261 REV.010611 PAGE 19

SERVICE INSTRUCTIONS CONTINUED
seal kit for the hydraulic motor can be ordered from the factory under Part No. 23117. All parts of the hydraulic
motor, with the exception of the motor adaptor, item 800, and the port end cover, item 870, are standard parts of
the hydraulic motor, having a 3 inch gear section. All of these parts can be ordered from PULLMASTER or an
Authorized Distributor / Dealer in Canada, the United States and in most overseas areas.
REMOVE HYDRAULIC MOTOR ASSEMBLY:

If disassembly of hydraulic motor is not necessary, proceed as follows:
1) Remove 12 hex head capscrews, item 537, with lockwashers, item 541, from motor adaptor, item 800. Since
brake springs, item 752, apply pressure against inside motor adaptor, it is recommended that hex capscrews
are unscrewed, one turn at a time, until spring pressure has been released. The complete motor assembly,
including motor adaptor, can now be removed from brake housing assembly.
2) Remove and discard three O-rings, item 801, and O-ring, item 707. (O-rings, item 801, seal pressure transfer
hole for automatic brake release and are situated on flange of brake housing.)
DISASSEMBLE BRAKE HOUSING ASSEMBLY:

1) After motor assembly has been removed, all parts of brake assembly are accessible. Remove 14 brake
springs, item 752. Thoroughly examine springs for damage and measure overall length. Overall spring
length should be 2.27 inches. If any spring measures less than 2.21 inches, replace all springs as a set.
2) Pull motor drive shaft, item 730, and complete brake hub assembly from brake housing.
3) Disassemble brake hub assembly by removing circlip, item 719, from motor drive shaft. Remove motor drive
shaft from brake hub, item 720. Remove sprag clutch aligners, items 722 and 724, and sprag clutch, item
723, from brake hub.
DANGER
MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE
MOTOR DRIVE SHAFT AND BRAKE HUB, WILL RESULT IN BRAKE
FAILURE AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. THOROUGHLY INSPECT
THESE AREAS AND, IF NECESSARY, REPLACE MOTOR
DRIVESHAFT, SPRAG CLUTCH AND BRAKE HUB AS A SET.
4) Thoroughly inspect motor drive shaft, item 730, and brake hub, item 720, particularly surfaces where sprag
clutch, item 723, engages. If any indentation or surface damage is detected, replace brake hub, sprag clutch
and motor drive shaft as a set.
5) Pull brake piston, item 750, out of brake housing using two 5/8-11NC bolts screwed into two puller holes in
piston. Discard O-rings, item 751 and item 753.
6) Thoroughly examine inner bores of brake housing and outer diameters of brake piston for scoring caused
by hydraulic fluid contamination. Minor surface damage may be repaired by polishing with a fine emery cloth.
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.
PAGE 20 261 REV.980701

7) Remove five friction plates, item 715, together with six divider plates, item 713, and inspect for damage or
wear. Plates should be flat and smooth. Plates should not show heat discoloration. Paper material on friction
plates should be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
8) Remove brake spacer, item 712.
9) Oil seal, item 607, and backup washer, item 606, which seals brake housing from cable drum interior, can
now be removed and discarded.
All parts have now been removed from the brake housing and there is no need for further disassembly, unless
a failure has been analysed in the remaining winch assembly.
DISASSEMBLY OF FREE FALL ASSEMBLY:

If a failure occurs in free fall section of the winch, proceed as follows:
1) Remove drain plug, item 121, from end cover, item 240, and drain lubricating oil from free fall housing and
end cover. The oil will drain quicker if the filler plug, item 121, is removed.
2) If a failure has occurred in metering pump, the pump can be removed without disassembling the rest of the
free fall assembly. To remove metering pump, remove six capscrews, item 197, six lockwashers, item 199,
and remove and discard O-ring, item 241. If winch is a controlled free fall model, tube assembly, item 216,
need to be removed also. The metering pump is not user serviceable, and must be replaced.
3) Remove 16 hex head capscrews, item 537, with lockwashers, item 541, and separate end cover, item 240,
from free fall housing, item 200. Remove and discard O-ring, item 213, from flange of spring retainer, item
212.
4) Inspect planet hub stopper, item 126, and sungear stopper, item 344, for excessive wear. Replace if planet
hub stopper is less than .21 inch thick and replace sungear stopper if less than .22 inch thick.
5) Pull final planet assembly out of final internal gear, item 330, and inspect for wear or damage. (Mounting
capscrews, item 551, can be screwed into two tapped pulling holes in planet hub to assist with removal of
final planet hub assembly.)
6) Inspect three final planet gears, item 320, for damage or wear. If it is necessary to remove final planet gears,
remove circlip, item 311, and press planet pin, item 310, out of planet hub, item 300. Inspect loose rollers,
item 323, and two thrust washers, item 321, and replace if damaged.
7) Pull final sungear, item 340, out of free fall assembly.
8) Remove circlip, item 331, from clutch connecting shaft, item 220, and pull off final internal gear, item 330.
9) Remove 16 socket head capscrews, item 207, along with lockwashers, item 217, from spring retainer, item 212.
CAUTION: Since 88 springs apply pressure behind spring retainer, socket head capscrews should be
loosened one turn at a time, until spring pressure has been relieved.
10) Pull spring retainer, item 212, out of free fall housing, item 200. Remove and discard O-ring, item 213, from
spring retainer.
11) Remove 88 springs, item 232, from clutch piston, item 230.
12) Pull clutch piston, item 230, out of free fall housing, item 200. (Use two long 5/8-11NC capscrews screwed
into piston to assist removal. Alternatively, compressed air may be carefully applied to free fall release port
to assist removal of clutch piston.)
261 REV.021029 PAGE 21

13) Remove and discard O-rings, items 231 from clutch piston, and 233 from free fall housing.
14) Check clutch piston outside diameters and inside diameters of free fall housing for surface scratches due
to contamination resulting from particles in the hydraulic fluid. If there is any evidence of surface damage,
polish with fine emery cloth.
15) Pull clutch connecting shaft, item 220, out of free fall housing, along with two bearings, item 215.
DANGER
PLATES. PERFORM THROUGH INSPECTION AND, IF NECESSARY,
REPLACED FRICTION AND DIVIDER PLATES AS A SET.
16) Remove 9 friction plates, item 206, together with 10 divider plates, item 204, and inspect for damage or wear.
Plates should be flat and smooth. Plates should not show heat discoloration. Paper material on friction plates
should be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
17) Remove clutch spacer, item 202.
18) Pull drum coupling, item 302, off splined end of cable drum, item 500.
19) Pry bearing holder, item 222, along with spring pin, item 223, out of free fall housing, item 200.
20) Remove journal bearing, item 510, from bore in cable drum and inspect for damage or excessive wear.
21) Remove and discard oil seal, item 505, and back-up washer, item 506.
All parts have now been removed from inside the free fall assembly. If further disassembly is required, proceed
as follows:
1) For ease of working on the rest of the unit, set winch upright on free fall housing. Remove pipe nipple, item
181, along with pipe coupling, item 179, from hole in base, item 550. Remove two winch base halves, item
550 and 552, by removing the 28 hex capscrews, item 551, and lockwashers, item 553, which attach winch
base to winch assembly.
2) Remove access plug, item 734, using a 1/2-13 NC bolt (motor adaptor bolt, item 537, works nicely), from
inside brake housing, item 700, and discard O-ring, item 735. Remove six hex head capscrews, item 537,
along with lockwashers, item 541, from bearing flange, item 530, by rotating brake housing until access hole
is over top of them. Brake housing, together with bearing flange and primary planet hub assembly, can now
be lifted out of cable drum, item 500. Discard O-ring, item 539.
3) Remove free fall coupling, item 210, from inside cable drum.
4) Remove retaining ring, item 401, from inside of internal gear, item 430. Primary planet hub assembly may
now be slid out of internal gear and inspected for wear or damage. If primary planet gears, item 420, have
to be removed, take off circlip, item 411, from planet pin, item 410, and press planet pin out of primary planet
hub, item 400. Remove primary planet gear, item 420, together with loose rollers, item 423, and thrust
washers, item 421.
5) Remove primary sungear, item 440, from center of connecting shaft, item 600.
6) Take circlip, item 431, off end of connecting shaft and slide internal gear, item 430, along with internal gear
spacer, item 434, off of connecting shaft spline.
PAGE 22 261 REV.021029

7) Connecting shaft, item 600, may now be pulled out of brake housing, and O-ring, item 601, discarded. Inspect
needle bearing, item 603, and remove and replace if necessary.
8) To separate bearing flange, item 530, and brake housing, item 700, use a standard bearing puller or insert
two heel bars in the slot between bearing flange and brake housing and pry brake housing out of ball bearing,
item 533.
9) Remove internal retaining ring, item 534, to remove ball bearing, item 533. Remove and discard oil seal, item
531.
10) To separate free fall housing, item 200, and cable drum, item 500, first remove external circlip, item 513, off
end of cable drum, then insert two heel bars in slot between final drive housing and cable drum and pry cable
drum out of ball bearing, item 103.
11) Remove internal retaining ring, item 104, to remove ball bearing, item 103. Remove and discard oil seal, item
105 (this seal separates interior of free fall housing and interior of cable drum).
The PULLMASTER Model M25 with free fall has now been completely disassembled.
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. If the entire winch was disassembled, start by
reassembling the free fall end (without the metering pump) first. Turn the cable drum up on end, so that the splined
end is up.
REASSEMBLY OF FINAL DRIVE:

Reassemble final drive end of winch as follows:
1) Insert new back-up washer, item 506, and new oil seal, item 505, together into bore in cable drum, until back-
up washer stops against edge in bore (the second edge).
2) Carefully press journal bearing, item 510, into bore of cable drum until it comes into contact with the first edge.
3) If free fall housing was removed, press in new oil seal, item 105, and bearing, item 103, if removed. Re-install
circlip, item 104.
4) Press free fall housing, item 200, onto splined end of cable drum, and install circlip, item 513.
5) Press bearing holder, item 222, along with spring pin, item 223, into free fall housing, item 200, turned so that
pin lines up with slot in the top of bore.
6) Slide drum coupling, item 302, onto spline of cable drum.
7) Gently tap clutch connecting shaft, item 220, with two bearings, item 215, into place over bearing holder, item
222.
8) Set clutch spacer, item 202, into free fall housing, and place a divider plate, item 204, against it, lining up teeth
with those inside of free fall housing.
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.
261 REV.970701 PAGE 23

9) Place brake plate, item 206, against divider plate, lining up teeth onto teeth of clutch connecting shaft, item
220. Alternate remaining divider and brake plates, finishing stack with a divider plate.
10) Install new, well-greased O-ring, item 233, into O-ring groove in free fall housing, item 200. Install new, well-
greased O-ring, item 231, onto clutch piston, item 230.
11) Carefully press clutch piston, item 230, into free fall housing, item 200. If a hoist is available, piston can be
supported using two 5/8 -11NC eyebolts.
12) Place 88 springs, item 232, into holes in clutch piston.
13) Install new, well-greased O-ring, item 213, into groove on end of spring retainer, item 212. Slide spring
retainer, complete with bearing retainer, item 214, onto bearing, item 215.
14) Fasten spring retainer to free fall housing using 16 socket head capscrews, item 207, along with 16 high collar
lockwashers, item 217. Fasten capscrews, one turn at a time, to compress 88 springs.
15) Slide final internal gear, item 330, onto spline of clutch connecting shaft, item 220, and fasten with circlip, item 331.
16) Install final sungear, item 340, through journal bearing, item 510, and twist to engage spline with free fall
coupling, item 210.
17) Install final planet assembly into clutch connecting shaft, item 220, and engage spline of drum coupling, item
302, as well as gears of final internal gear, item 330, and final sungear, item 340. (Using two 5/8 -11NC
eyebolts screwed into final planet hub, item 300, to suspend planet assembly, greatly assists in this operation.)
18) Install new, well-greased O-ring, item 213, on end of spring retainer, item 212, and place end cover, item 240,
over top. Fasten in place with 16 hex head capscrews, item 537, and lockwashers, item 541. Turn winch over
with open end of cable drum facing up. (To keep winch secure and to help prevent it from falling over, we
recommend sitting end cover, item 240, upon a piece of steel tube of approximately 12 inch ID and 6 inch deep.)
REASSEMBLY OF PRIMARY DRIVE:

Reassemble primary drive as follows:
1) Insert free fall coupling, item 210, with circlip, item 343, into cable drum, item 500, and engage spline with
final sungear, item 340.
2) Press bearing, item 533, into bearing flange, item 530, and secure with bearing retainer, item 534. Carefully
press new, well greased oil seal, item 531, into other side of bearing flange, and press assembly onto hub
of brake housing, item 700.
3) Press new, well-greased oil seal, item 607, into connecting shaft, item 600. If a backup washer is included
in your seal kit, it should be installed together with and behind the oil seal.
4) Install new, well greased O-ring, item 601, onto connecting shaft, item 600, and insert through bore in brake
housing. Slide internal gear, item 430, along with spacer, item 434, onto spline of connecting shaft and fasten
with circlip, item 431.
5) Reassemble primary planet hub assembly. Use grease to temporarily hold 20 loose rollers, item 423, in bore
of planet gear, item 420. Verify placement of sungear stopper, item 444. Position thrust washers, item 421,
on either side of planet gear and press planet pin, item 410, into final planet hub, item 400. Retain with circlip,
item 411.
6) Insert primary sungear, item 440, between three planet gears and insert sungear shaft into connecting shaft,
engaging planet gears with internal gear. Fasten with retaining ring, item 401.
7) Insert sungear, item 440, into center of three planet gears, item 420. Place planet assembly into internal gear,
item 430. Insert retaining ring, item 401, into internal gear, item 430.
PAGE 24 261 REV.970701

8) Place new, well-greased O-ring, item 539, onto bearing flange, item 530. Brake housing with primary
reduction attached may now be lowered into cable drum, item 500.
9) Rotate brake housing to line up access holes and fasten bearing flange using six capscrews, item 537, and
lockwashers, item 541.
10) Install new, well-greased O-ring, item 735, into access plug, item 734. Install access plug into access hole
inside brake housing.
11) Attach two base halves, items 550 and 552, using 28 capscrews, item 551, and lockwashers, item 553.
12) Insert pipe nipple, item 181, with pipe coupling, item 179, attached, through hole in base and screw tightly
into free fall housing.
REASSEMBLY OF BRAKE HOUSING ASSEMBLY:

Reassemble brake housing assembly as follows:
1) Install sprag clutch, item 723, into bore of brake hub, item 720. Position sprag clutch aligners, item 722 and
item 724, on either side of brake hub. Carefully slide motor drive shaft, item 730, into brake hub assembly and
secure with circlip, item 719. Verify that circlips, item 727 and item 731, are installed on motor drive shaft.
IMPORTANT: For proper brake function, verify that the sprag clutch is installed correctly. When
viewed from the motor end, the motor drive shaft of a clockwise hoisting winch
must turn freely clockwise and lock in the counter clockwise direction.
2) Install motor drive shaft assembly into brake housing and carefully twist shoulder of shaft through oil seal,
item 607. Twist slightly more to engage spline with primary sungear, item 440.
DANGER
3) Install brake spacer, item 712, into brake housing, item 700. Starting and finishing with a divider plate,
alternately install seven divider plates, item 714, and six friction plates, item 715.
4) Install new, well-greased O-rings, item 751 and item 753, into glands of piston, item 750. Carefully install
brake piston in brake housing.
5) Install 14 brake springs, item 752, in brake piston using hole pattern shown below.
HOLE PATTERN FOR BRAKE SPRING INSTALLATION:

LOCATION OF
BRAKE SPRINGS
(FOURTEEN SPRINGS,
TWENTY HOLES)
SI1007 - M25/50
261 REV.970701 PAGE 25

6) Liberally grease three new O-rings, item 801, and install in to recesses on motor adaptor, item 800. Install
new, well-greased O-ring, item 707, on flange of motor.
7) Slide hydraulic motor assembly on splined end of motor drive shaft, item 730, and line up pressure transfer
holes of brake housing and motor adaptor. Tighten 12 capscrews, item 537, and lockwashers, item 541, one
turn at a time to evenly compress springs.
REASSEMBLY OF HYDRAULIC MOTOR:

If hydraulic motor was disassembled, the following procedure should be followed for reassembly:
1) Clean all parts thoroughly before reassembly and apply grease liberally to all seals. Use only new seals (seal
kit Part No. 23117) for hydraulic motor.
2) Install two new teflon seals, item 887, on each thrust plate, item 885. Press one of the thrust plates, together
with two teflon seals, onto bearings, item 875, installed in motor adaptor, item 800.
3) Install new, well-greased gasket seal, item 869, on each side of gear housing, item 861. Slide gear housing
together with gasket seals, onto motor adaptor, lined up on two dowel pins. Tap on tight using a soft-headed
hammer.
4) Install gear set, item 881, in gear housing (the longer gear with the internal spline goes into the top position).
5) Press other thrust plate, complete with two new teflon seals, onto bearings installed in port end cover.
6) Install port end cover, item 870, together with two bearings, item 875, and new ring seal, item 877, onto gear
housing, lined up on two dowel pins, item 865. Tap on tight using a soft-headed hammer. Install and lightly
torque eight hex capscrews, item 951, and lockwashers, item 953, to approximately 50 ft-lb (70 Nm).
7) Plumb winch assembly to a hydraulic supply and torque motor capscrews according to the following
procedure:
- Ensure that circulation supply flow is being supplied to the brake housing.
- Run the winch , with no load, in the hoisting direction at reduced speed
(approximately 30% of maximum hydraulic volume).
- With winch running, evenly tighten eight capscrews, item 951, to 200 ft-lb (270 Nm).
- Test motor operation by running winch at full speed in both directions.
IMPORTANT: Before operating the winch, add lubricating oil through the cable drum 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 26 261 REV.970701

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 M25 planetary winch with free fall, always quote the complete
model and serial number of the unit.
MODEL NO. _______________
SERIAL NO. _______________
PULLMASTER WINCH CORPORATION reserves the right to change specifications and the design of
PULLMASTER planetary winches at any time without prior notice and without incurring any obligations.
261 REV.980701 PAGE 27

PARTS REFERENCE - FINAL DRIVE
ITEM NO. QTY. PART NO. DESCRIPTION
103 1 25332 BALL BEARING 120 x 180 x 28 # 6024
104 1 20460 BEARING RETAINER
105 1 25148 OIL SEAL
121 2 25237 PIPE PLUG 3/4 - 14 NPT
126 1 20756 PLANET HUB STOPPER
171 1 ** **
179 1 25641 PIPE COUPLING 3/8 NPT
181 1 21789 PIPE NIPPLE 3/8 NPT X 7" L
183 1 ** **
183A 1 25031 PIPE PLUG 1/4 - 18 NPT
185 1 ** **
197 6 25265 CAPSCREW - HEX HEAD 7/16 - 14NC X 1.25 GRADE 5
199 6 25328 LOCKWASHER 7/16"
200 1 20939 FREE FALL HOUSING
201 1 25481 PIPE PLUG 1 - 11 1/2 NPT
202 1 20766 CLUTCH SPACER
203 6 25085 PIPE PLUG 3/8 - 18 NPT
204 10 20760 DIVIDER PLATE
206 9 20759 FRICTION PLATE
207 16 25517 CAPSCREW - SOCKET HEAD 5/8 - 11NC X 2.25 GRADE 5
210 1 * FREE FALL COUPLING
212 1 20758 SPRING RETAINER
213 2 25592 O-RING -387 18"ID 3/16"CS
215 2 25575 BALL BEARING 160 X 200 X 20 #61832
216 1 ** **
217 16 25099 LOCKWASHER 5/8" HI-COLLAR
220 1 20762 CLUTCH CONNECTING SHAFT
222 1 20768 BEARING HOLDER
223 1 25599 SLOTTED SPRING PIN 3/16" DIA X 3/4" L
230 1 20749 CLUTCH PISTON
231 1 25594 O-RING -90 DURO -465 18"ID 1/4"CS
232 88 20761 CLUTCH SPRING
233 1 25593 O-RING -90 DURO -463 17"ID 1/4"CS
236 1 26088 SLOTTED SPRING PIN 3/32" DIA X 3/4" L
240 1 20763 END COVER
241 1 25136 O-RING -159 5"ID 3/32"CS
242 1 ** **
248 1 22380 METERING PUMP CONNECTOR * These parts vary with drum code.
249 1 25379 SLOTTED SPRING PIN 5/32" X 1" L Refer to APPENDIX B.
290 1 22379 STOPPER
300 1 20748 FINAL PLANET HUB * * These parts vary with free fall option.
302 1 20767 DRUM COUPLING Refer to APPENDIX C.
310 3 20406 FINAL PLANET PIN
311 3 25199 CIRCLIP ROTOR CLIP SH-168
320 3 20405 FINAL PLANET GEAR
321 6 25167 THRUST WASHER TORRINGTON # TRB 2840
323 72 25297 LOOSE ROLLER TORRINGTON #G613 - Q
330 1 20755 FINAL INTERNAL GEAR
340 1 20765 FINAL SUNGEAR
344 1 20450 SUNGEAR STOPPER
500 1 * CABLE DRUM
502 1 20423 CABLE ANCHOR
503 1 25032 PIPE PLUG 1/2 - 14 NPT
505 1 25597 OIL SEAL
506 1 20824 BACK-UP WASHER FOR OIL SEAL #25597
510 1 20825 JOURNAL BEARING
541 16 25014 LOCKWASHER 1/2"
550 1 * BASE
552 1 * BASE
553 28 25359 LOCKWASHER 5/8"
703 1 25347 PLASTIC CAPLUG 1 -11.5 NPT
Refer to PAGE 30 for winch seal kit and PAGE 36 for ASSEMBLY DRAWING.
PAGE 28 261 REV.970701

FINAL DRIVE GROUP
G1008-F
502 503 210 343
220 212 537 541 302 510 185 230 171 183 203 215 506 703 222 553 203 179 181 550 551 513 500 552
323 320 330 313 214 215 213 232 207 217 213 231 233 505 206 204 201 223 202 200 104 103 105
121
340
121
300
310
126
240
311
242
331
241
236
249
344
216
321
248
290
197
199
Metering pump connection is shown for clockwise hoisting winch. For counterclockwise hoisting, connect
metering tube to alternate port on metering pump and use metering tube, item 216A. Refer to Appendix E.
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 PART REFERENCE list should be ignored.
261 REV.970701 PAGE 29

PARTS REFERENCE - BRAKE GROUP
400 1 20404 PLANET HUB
401 1 20417 RETAINING RING
410 3 20369 PLANET PIN
411 3 25004 CIRCLIP ROTOR CLIP C-87
420 3 20370 PLANET GEAR
421 6 25068 THRUST WASHER TORRINGTON # TRA 1423
423 60 25270 LOOSE ROLLER 5/32 X 1.25 TOR. #E151 - Q
430 1 20411 INTERNAL GEAR
434 1 20452 SPACER
440 1 20414 SUNGEAR
530 1 * BEARING FLANGE
531 1 25148 OIL SEAL
533 1 25333 BALL BEARING #6026
539 1 25109 O-RING -269 8-3/4" ID 1/8" CS
541 6 25014 LOCKWASHER 1/2"
600 1 20445 CONNECTING SHAFT
601 1 25341 O-RING -239 3-5/8" ID 1/8" CS
603 1 25334 NEEDLE BEARING TORRINGTON #B2812
606 1 21086 BACKUP WASHER
607 1 25345 OIL SEAL
700 1 20447 BRAKE HOUSING
703 1 25347 PLASTIC CAPLUG 1 NPT
707 1 25339 O-RING -278 12" ID 1/8" CS
712 1 20451 BRAKE SPACER
720 1 20446 BRAKE HUB
722 1 20455 SPRAG CLUTCH ALIGNER
723 1 25303 SPRAG CLUTCH BORG WARNER #140373 B
734 1 20422 PLUG
735 1 25344 O-RING -123 1-3/16" ID 3/32" CS
750 1 20397 PISTON
751 1 25343 O-RING -90 DURO -451 11" ID 1/4" CS
752 14 20413 BRAKE SPRING
753 1 25342 O-RING -90 DURO -452 11-1/2" ID 1/4" CS
23115 WINCH SEAL KIT, CONSISTS OF ITEMS:

105, 213, 231, 233, 241, 505, 506, 531, 539,
601, 606, 607, 707, 735, 751, 753, AND 801
* This part varies with drum code.

Refer to APPENDIX B.
Refer to PAGE 36 for ASSEMBLY DRAWING.
PAGE 30 261 REV.980701

BRAKE GROUP
G1001-B
411 421 423 420 413 434 600 601 712 603 606 750 720
410 719
400 723
440 724
444 727
431 607
531 722
401 752
430
534
533
539
530 541 537 734 735 715 713 751 703 700 753 707
261 REV.970701 PAGE 31

PARTS REFERENCE - MOTOR GROUP
537 12 25081 CAPSCREW - HEX HEAD 1/2 - 13 NC X 1.5 GRADE 5
541 12 25014 LOCKWASHER 1/2"
730 1 20415 MOTOR DRIVE SHAFT
800 1 20401 MOTOR ADAPTOR
801 3 25127 O-RING -90 DURO -013 7/16" ID 1/16" CS
802 1 * *
805 2 25040 PIPE PLUG 1/8 - 27 NPT
806 1 * *
807 1 * *
809 1 * *
813 1 25031 PIPE PLUG 1/4 - 18 NPT
861 1 25350 GEAR HOUSING
865 4 25356 DOWEL PIN
869 2 25348 SEAL - GASKET
870 1 21761 PORT END COVER
875 4 25352 BEARING - ROLLER
877 2 25646 SEAL - RING
881 1 25645 GEAR SET
885 2 25644 THRUST PLATE
887 4 25647 SEAL - TEFLON
899 2 25031 PIPE PLUG 1/4 - 18 NPT
929 1 * *
950 x 1 * SUB - ASSY MOTOR
951 8 25357 CAPSCREW - HEX HEAD 5/8 X 6.75 GRADE 5
953 8 25325 WASHER
955 2 25559 PLASTIC CAPLUG 2.0"
23117 MOTOR SEAL KIT, CONTAINS ITEMS:

869, 877, AND 887
* These part numbers and descriptions vary according to brake code.

Refer to APPENDIX D.
x
ITEM 950, MOTOR SUB-ASSY, CONSISTS OF ITEMS:
800, 802, 805, 806, 807, 809, 813, 861, 865, 869, 870,
875, 877, 881, 885, 887, 899, 929, 951, 953 AND 955
PAGE 32 261 REV.980701

MOTOR GROUP
G1002-D
950
953
955
951
870
929
877
899
869
875
881
887
731
861
802
885
807
865
809
537
801
541
800
806
730
805
813
261 REV.970701 PAGE 33

PAGE 34
PRESSURIZE FOR
CLOCKWISE
FOR SAFETY: A MINIMUM OF 5 WRAPS OF ROTATION
WIRE ROPE MUST BE MAINTAINED
SAFETY VALVE FREE FALL
AT ALL TIMES !
P
PORT CIRCULATION C D
3/4-14 NPT RETURN PORT
FILLER PORT PRESSURIZE FOR
1-11 1/2 NPT
1/2-14 NPT CLOCKWISE COUNTER-CLOCKWISE
(LOCATED EITHER
SAE SPLIT FLANGE ROTATION
IN CABLE ANCHOR
POCKET OR ON SEE MOTOR CHART
BARREL) FOR PORT SIZE
OPTIONAL
EXTERNAL BRAKE
B DIA RELEASE PORT
1/8-27 NPT
F A DIA
M
N
1.25
[31.8] 5 4 1/16
DRAIN PORT BRAKE GAUGE PORTS
3/4-14 NPT CLUTCH RELEASE CIRCULATION 1/4-18 NPT
4 MOUNTING HOLES
PORT 1/4-18 NPT 1 9/32" DIA [32.5] RETURN PORT
USE 1.1/4" MOUNTING 1-11 1/2 NPT BRAKE CIRCULATION SUPPLY
BOLTS GRADE 5 OR BETTER PORT 3/8-18 NPT (EXTERNAL
CIRCULATION MODELS ONLY)
1.3
H c/c R c/c
[32]
3.6 I S
G [91] [MOTOR]
FREE FALL
CIRCULATION SUPPLY
PORT 3/8-18 NPT STANDARD CABLE ANCHOR IS
SUITABLE FOR 7/16 - 7/8"
J DIA WIRE ROPE ON 10" DIA
INSTALLATION DIMENSIONS
DRUM BARREL
261 REV.051117
I1004-1-E
Dimensions in inches
(Dimensions in millimeters)
DRUM
CODE A B C D E F G H J M N P R S
-1 10.0 17.0 11.0 8.6 19.9 21.9 21.0 18.500 39.9 11.38 8.9 20.8 17.750 20.8
(254) (432) (279) (218) (505) (556) (533) (469.90) (1014) (289) (225) (527) (450.85) (527)
-2 10.0 24.0 11.0 8.6 24.4 22.9 21.0 18.500 39.9 12.38 10.0 25.9 22.875 25.9
(254) (610) (279) (218) (619) (581) (533) (469.90) (1014) (314) (254) (657) (581.03) (657)
-3 10.0 24.0 17.0 8.6 24.4 22.9 27.0 24.500 45.9 12.38 10.0 25.9 22.875 25.9
(254) (610) (432) (218) (619) (581) (686) (622.30) (1167) (314) (254) (657) (581.03) (657)
-4 10.0 24.0 22.0 8.6 24.4 22.9 32.0 29.500 50.9 12.38 10.0 25.9 22.875 25.9
(254) (610) (559) (218) (619) (581) (813) (749.30) (1294) (314) (254) (657) (581.03) (657)
-5 10.0 34.0 29.0 9.1 34.4 27.9 40.0 37.500 58.9 17.38 13.6 35.6 28.500 31.5
(254) (864) (737) (230) (875) (708) (1016) (952.50) (1497) (441) (345) (905) (723.90) (800)
- 10 10.0 17.0 29.0 9.1 19.9 21.9 40.0 37.500 58.9 11.38 8.9 20.8 17.750 20.8
(254) (432) (737) (230) (505) (556) (1016) (952.50) (1497) (289) (225) (527) (450.85) (527)
- 14 14.5 24.0 17.0 8.6 24.4 22.9 27.0 24.500 45.9 12.38 10.0 25.9 22.875 25.9
(368) (610) (432) (218) (619) (581) (686) (622.30) (1167) (314) (254) (657) (581.03) (657)
- 17 14.4 24.0 11.0 8.6 24.4 22.9 21.0 18.500 39.9 12.38 10.0 25.9 22.875 25.9
(368) (610) (279) (218) (619) (581) (533) (469.90) (1014) (314) (254) (657) (581.03) (657)
- 31 13.0 24.0 17.0 8.6 24.4 22.9 27.0 24.500 45.9 12.38 10.0 25.9 22.875 25.9
(330) (610) (432) (218) (619) (581) (686) (622.30) (1167) (314) (254) (657) (581.03) (657)
HYDRAULIC MOTORS
COMMERCIAL WM76 SERIES COMMERCIAL M365 SERIES
MOTOR GEAR MOTOR PORT SIZE I L MOTOR GEAR MOTOR PORT SIZE I L
CODE WIDTH SAE SPLIT FLANGE CODE WIDTH SAE SPLIT FLANGE
- 86 3.00 7.6 2.7 - 42 2.50 8.0 2.5

(76.2) (194) (68) (63.5) (203) (64)
2.0
- 87 2.75 7.4 2.7 - 101 2.25 1.5 7.8 2.5
(69.9) (187) (68) (57.2) (197) (64)
- 88 2.50 7.1 2.7 - 102 2.00 7.5 2.5

(63.5) (181) (68) (50.8) (191) (64)
- 89 2.25 1.5 6.9 2.7

(57.2) (175) (68)
- 90 2.00 6.6 2.7

(50.8) (168) (68)
- 91 1.75 6.4 2.7

(44.5) (162) (68)
- 92 1.50 1.25 6.1 2.7

(38.1) (156) (68)
- 93 1.25 5.9 2.7

(31.8) (149) (68)
- 94 1.00 1.00 5.6 2.7

(25.4) (143) (68)
261 REV.960215 PAGE 35

ASSEMBLY DRAWING
G1001-B & G1002-D & G1008-F
PAGE 36 261 REV.970701

APPENDIX A
LINE PULL HOISTING MAXIMUM

ALLOWABLE LUBRICAT-
AT MAXIMUM LINE SPEED ING
WIRE ROPE STORAGE LOAD FOR
CABLE DRUM SIZES PRESSURE AT MAXIMUM OIL
CONTROLLED VOLUME
DRUM INCHES FEET - HOISTING* VOLUME*
(METERS) OR REQUIRED
CODE (MILLIMETERS)
POUNDS FEET/MINUTE COMBINED
U.S.
(KILONEWTONS) (METERS/MINUTE) FREE FALL GALLONS
BARE FULL BARE FULL POUNDS (LITERS)
BARREL FLANGE LENGTH 3/4 inch 7/8 inch 1 inch DRUM DRUM DRUM DRUM (KILONEWTONS)
-1 10.0 17.0 11.0 210 140 91 25000 17629 140 198 7500 1.3
(254) (432) (279) (64) (43) (28) (111.2) (78.4) (43) (60) (33.4) (4.9)
-2 10.0 24.0 11.0 515 398 264 25000 11821 140 295 7500 1.3
(254) (610) (279) (157) (121) (80) (111.2) (52.6) (43) (90) (33.4) (4.9)
-3 10.0 24.0 17.0 796 615 408 25000 11821 140 295 7500 2.0
(254) (610) (432) (243) (187) (124) (111.2) (52.6) (43) (90) (33.4) (7.6)
-4 10.0 24.0 22.0 1031 796 528 25000 11821 140 295 7500 2.6
(254) (610) (559) (314) (243) (161) (111.2) (52.6) (43) (90) (33.4) (9.8)
-5 10.0 34.0 29.0 3189 2204 1689 25000 8427 140 412 7500 3.4
(254) (864) (737) (972) (672) (515) (111.2) (37.7) (43) (126) (33.4) (12.8)
- 10 10.0 17.0 29.0 555 370 241 25000 17629 140 198 7500 3.4
(254) (432) (737) (169) (113) (73) (111.2) (78.4) (43) (60) (33.4) (12.8)
- 14 14.5 24.0 17.0 647 468 344 17629 11845 197 294 5305 4.7
(368) (610) (432) (197) (143) (105) (78.4) (52.7) (60) (90) (23.6) (17.8)
- 17 14.5 24.0 11.0 419 303 223 17629 11845 197 294 5305 3.1
(368) (610) (279) (128) (92) (68) (78.4) (52.7) (60) (90) (23.6) (11.7)
- 31 13.0 24.0 17.0 705 523 397 19595 11837 178 295 5878 3.4
(330) (610) (432) (215) (159) (121) (87.2) (52.7) (54) (90) (26.1) (12.8)
* Performance specifications are based on standard hydraulic motor with 7/8 inch diameter rope.
261 REV.021029 PAGE 37

APPENDIX B
ITEM 210 500 530 550/552
FREE FALL BEARING

DRUM CODE CABLE DRUM BASE
COUPLING FLANGE
-1 20751 20395 20402 20671
-2 20751 20396 20402 20444
-3 20752 20393 20402 20443
-4 20753 20391 20402 20403
-5 20754 20688 21841 20690
- 10 20754 20935 20402 20937
- 14 20752 20990 20402 20443
- 17 20751 21550 20402 20444
- 31 20752 21641 20402 20443
PAGE 38 261 REV.980715

APPENDIX C
TYPE OF FREE FALL

ITEM DESCRIPTION
NO.
CONTROLLED (C) EMERGENCY (D)
171 PLASTIC CAPLUG 1/4NPT 25395 N/A
183 PIPE ELBOW 1/4 NPT 25538 N/A
183 PLASTIC CAPLUG 1/4 NPT N/A 25395
185 PIPE TEE 1/4 NPT 25552 N/A
216 METERING TUBE SEE APPENDIX D N/A
242 METERING PUMP SEE APPENDIX D N/A

SUB-ASSEMBLY
242 END CAP N/A 22381
261 REV.970701 PAGE 39

APPENDIX D
PART NUMBERS
ITEM BRAKE CODE

PART DESCRIPTION
NO.
-3 -4 -5 -6 -7 -8 -9 -10
216 METERING TUBE 22612 22612 N/A N/A 22612 22612 N/A N/A
ASSEMBLY
216A METERING TUBE N/A N/A 22611 22611 N/A N/A 22611 22611
ASSEMBLY
242 METERING PUMP 22382 22382 22383 22383 22382 22382 22383 22383
SUB-ASSEMBLY
802 SHUTTLE N/A 20849 20849 N/A N/A 20849 20849 N/A
806 CIRCULATION VALVE 20456 20456 20456 20456 N/A N/A N/A N/A
806 1/4-18 NPT PIPE PLUG N/A N/A N/A N/A 25031 25031 25031 25031
807 1/8-27 NPT PIPE PLUG 25040 N/A N/A 25040 25040 N/A N/A 25040
807 1/8 NPT PIPE ADAPTOR N/A 25622 25622 N/A N/A 25622 25622 N/A
809 1/8 NPT CAPLUG N/A 25374 25374 N/A N/A 25374 25374 N/A
929 3/8 NPT CAPLUG N/A N/A N/A N/A 26276 26276 26276 26276
929 3/8-18 NPT PIPE PLUG 25085 25085 25085 25085 N/A N/A N/A N/A
950 MOTOR (-86) 20504 22011 22012 20804 20505 21977 22013 20805
PAGE 40 261 REV.970701

APPENDIX E
SI 1046
CONNECT METERING TUBE, ITEM 216A,

TO THIS PORT FOR CCW HOISTING
END VIEW OF METERING PUMP, ITEM 242
261 REV.970701 PAGE 41

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
1 3/8 1200 1627
1 1/2 1500 2034
NOTE: Unless otherwise specified, torque bolts per above chart.
PAGE 42 261 REV.970701

148948
INSTRUCTION AND PARTS MANUAL
MODEL H25
PLANETARY HYDRAULIC WINCH
THE LOGICAL CHOICE
PULLMASTER WINCH CORPORATION

8247-130th Street, Surrey, B.C. V3W 7X4, Canada
Telephone: 604-594-4444 Fax: 604-591-7332
Website: www.pullmaster.com
E-mail: sales@pullmaster.com
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.
PMC 251 070228

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 [PULLMASTER LOGO]

SAFETY RECOMMENDATIONS
Definition: Caution indicates a potentially
hazardous situation which, if not avoided may
DANGER result in minor or moderate injury.
Definition: Warning indicates a potentially

FAILURE TO COMPLY WITH THE FOLLOWING SAFETY hazardous situation which, if not avoided could
result in death or serious injury.
RECOMMENDATIONS AND LOCAL RULES AND
REGULATIONS WILL RESULT IN PROPERTY Definition: Danger indicates a potentially
hazardous situation which, if not avoided will
DAMAGE, SEVERE INJURY OR DEATH. 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 pressure 21. Keep hands clear when winding wire rope onto
(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 rope
6. Do not operate a damaged, noisy or is properly anchored to the correct cable anchor slot at
malfunctioning winch. the cable drum.
7. Do not leave a load suspended for any extended 24. Do not lift a load with a twisted, kinked or
period of time. damaged wire rope.
h
8. Never leave a suspended load unattended. 25. Consult wire rope manufacturer for size, type and
maintenance of wire rope.elen
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, stand
11. Warm-up equipment before operating winch,
clear of the area and the load being hoisted, take the
particularly at low ambient temperatures.
necessary precautions to prevent access to area where
12. Verify winch function by raising and lowering a the load is halted.
full test load to a safe height before each shift.
28. The noise level of the winch is 87 dBA measured
13. Do not weld any part of the winch. on a distance of 1.00 meter, 1.60 meters high. The
14. Verify gear lubrication and brake circulation measuring equipment used was: Realistic #42-3019.
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
16. Wear proper clothing to avoid entanglement in hat. Read manual first.
rotating machinery.
17. Always stand clear of the load.
251 REV.051117 PAGE 1

DESCRIPTION OF THE MODEL H25
GENERAL DESCRIPTION:
The PULLMASTER Model H25 is a planetary, hydraulic winch with reversing or lowering speed 4.67 times faster
than forward or hoisting speed. The main components of this unit are:
★ hydraulic gear motor

★ multi-disc brake with static and dynamic function
★ primary planet reduction
★ final planet reduction
★ brake housing
★ final drive 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 torque and rpm of the primary reduction stage are transmitted to the final reduction
stage by the final sungear shaft, which is splined to the primary planet hub. In forward rotation, or when a load
is raised, an over-running clutch, which connects the motor drive shaft to the automatic brake assembly, permits
free rotation of the sun gear without effecting the brake. When the winch rotation is stopped, the load on the cable
drum causes the over-running clutch to lock and the maximum load is held safely by the disc brake.
FUNCTION IN REVERSE ROTATION (LOWERING):

In reverse rotation, hydraulic pressure from the reversing 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 over-
running clutch, connecting the motor drive shaft with the internal gear of the primary planet reduction locks,
causing the internal gear to rotate at the same rpm as the primary sungear. Thus, the primary reduction stage
is eliminated and the output torque and rpm of the hydraulic motor are transmitted directly to the final planet
reduction stage. With the primary reduction stage eliminated, the reduction is reduced to a ratio of 8.75:1 and
the cable drum will rotate 4.67 times faster than in forward or hoisting speed.
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 divider plates. In this way a completely smooth lowering 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.
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 from the motor, or
externally, depending on the brake code of the winch. For efficient cooling of the automatic brake, models with
external circulation should be adjusted to supply 7.0 (US) gpm - 26 l/min. This circulation flow must be returned
directly to the reservoir with a permissible back pressure of 30 psi (2 bar).
IMPORTANT: Under no circumstances must the back pressure in the brake housing be permitted to exceed
30 psi (2 bar). Excessive pressure in the brake housing will damage the oil seal separating the
brake housing from the drum interior. Damage to this seal will cause the drum to fill up with
hydraulic fluid. In order to prevent potential damage to the drum seals and the end cover of the
winch, when the cable drum fills up with hydraulic fluid, a breather relief (see PARTS
REFERENCE, item 130) is installed on the end cover. The breather relief bleeds to atmosphere
and serves as a warning signal that the oil seal between the brake housing and drum has been
damaged.
PAGE 2 251 REV.040708

EXPLANATION OF MODEL CODING
H 25 X - XX - XX - XX X - X XXXX
BASIC UNIT SERIES
H = Rapid reverse
SIZE OF UNIT
REDUCTION RATIO
Only used for non standard reduction ratios
TYPE OF BRAKE
-3 Automatic brake, clockwise drum rotation, internal circulation flow

internal circulation flow

rotation, internal circulation flow
-6 Automatic brake, counterclockwise drum rotation, internal

circulation flow
-7 Automatic brake, clockwise drum rotation, external circulation flow

external circulation flow

rotation, external circulation flow
-10 Automatic brake, counterclockwise drum rotation, external

circulation flow
HYDRAULIC MOTOR
-86 Hydraulic motor, 3 inch gear section (12.3 cubic inch displacement)
(Other gear sections for this motor are optional)
DRUM SIZE
-1 10 inch drum diameter X 17 inch flange diameter X 11 inch length - STANDARD
(For other drum sizes refer to APPENDIX A)
OPTIONS
-F Hydraulically actuated freespooling
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.
251 REV.980615 PAGE 3

OPTIONS
COUNTERCLOCKWISE ROTATION:
The drum rotation of the standard PULLMASTER Model H25 planetary winch is clockwise for hoisting when
looking at the hydraulic motor of the winch. Drum rotation for counterclockwise hoisting direction is available as
an option.
INTERNAL CIRCULATION:
The PULLMASTER Model H25-7-86-X has an external circulation flow supply line to cool the brake. Internal
circulation 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
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 H25 planetary winch can
be supplied with optional drums to accommodate large wire rope storage capacity.
DRUM GROOVING:
Cable drums for the PULLMASTER Model H25 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 H25 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 H25 planetary winch is limited to 2500 psi (172 bar). For
hydraulic systems operating with a higher range of 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.)
FREESPOOLING:
This option permits wire rope being pulled off the cable drum by an operator. Freespooling should not be
confused with free fall. The freespool clutch cannot be disengaged or re-engaged with a load on the wire rope
or while the cable drum is turning.
The PULLMASTER WINCH CORPORATION will consider other options for quantity requirements.
PAGE 4 251 REV.970601

SPECIFICATIONS
Performance specifications are based on standard hydraulic motor, gear ratio and cable drum with 7/8 inch
diameter wire rope. For other cable drums refer to APPENDIX A. For other reductions or motors, refer to
supplement inside back cover. Performance specifications for winches supplied with optional motors are
provided in attached supplement.
CABLE DRUM DIMENSIONS (STANDARD DRUM):

Barrel diameter 10.00 in 254 mm
Flange diameter 17.00 in 432 mm
Barrel length 11.00 in 279 mm
CABLE STORAGE CAPACITY:

(Size of wire rope) 7/16 in 612 ft 186 m
1/2 in 413 ft 126 m
9/16 in 383 ft 117 m
5/8 in 297 ft 90 m
3/4 in 210 ft 64 m
7/8 in 140 ft 43 m
1 in 91 ft 28 m
MAXIMUM OPERATING PRESSURE: 2500 psi 172 bar
MAXIMUM OPERATING VOLUME: 115 (US) gpm 435 l/min
MINIMUM OPERATING VOLUME: 30 (US) gpm 114 l/min
DRUM TORQUE AT MAXIMUM PRESSURE: 135,937 lb-in 15,359 Nm
DRUM RPM AT MAXIMUM VOLUME: Hoisting 49 rpm

Lowering 229 rpm
HOISTING LINE PULL AT MAXIMUM PRESSURE:

MAXIMUM ALLOWABLE LINE PULL WHEN LOWERING:

HOISTING LINE SPEED AT MAXIMUM VOLUME:

LOWERING LINE SPEED AT MAXIMUM VOLUME:

PERMISSIBLE SYSTEM BACK PRESSURE AT MOTOR RETURN PORT: 65 psi 4.5 bar
PERMISSIBLE PRESSURE AT CIRCULATION SUPPLY PORT: 30 psi 2 bar

L
LUBRICATING OIL: Refer to RECOMMENDATIONS for viscosity and instructions.
Refer to APPENDIX A for oil volume required.
251 REV.010406 PAGE 5

PERFORMANCE GRAPHS
PG-H25-C
LINE PULL VS. OIL PRESSURE NOTE: MAX. ALLOWABLE LINE PULL WHEN LOWERING:
jjlkjalkf

LINE PULL - kN
0 22 44 67 89 111
2500 172
2000 138
OIL PRESSURE - bar

OIL PRESSURE - psi
UM
DR RU
M
1500 LL ED 103
FU BA
R
1000 69
500 34
0 0
0 5000 10000 15000 20000 25000
LINE PULL - lb
LINE SPEED VS. OIL VOLUME HOISTING LINE SPEED
LOWERING LINE SPEED
LINE SPEED - m/min

0 30 61 91 122 152 183 213 244 274
125 473
RUM
UM
OIL VOLUME - (US)gpm
100 379
DR
ED
OIL VOLUME - l/min

LL
UM
BAR
FU
DR UM
E DR
AR LL
75 B FU 284
50 189
25 95
0 0
0 100 200 300 400 500 600 700 800 900
LINE SPEED - fpm
Performance graphs are based on standard hydraulic motor, gear ratio and cable drum with
7/8 inch diameter wire rope.
PAGE 6 251 REV.991224

HC-M25-C
400 PSI [28 BAR]

PRESSURE REQUIRED
FOR MODELS SUPPLIED
800 PSI [55 BAR]
WITH FREESPOOL OPTION
2(US)GPM [8 L/MIN]
CIRCULATION RETURN LINE REQUIRED FOR MODELS
(MUST GO DIRECT TO RESERVOIR) SUPPLIED WITH EXTERNAL
BRAKE RELEASE OPTION
CIRCULATION SUPPLY LINE

M25: 5 (US) GPM [19 L/MIN]
H25: 7 (US) GPM [26 L/MIN]
(EXTERNAL CIRCULATION
MODELS ONLY)
CONTROL VALVE
(MOTOR SPOOL)
4-WAY SPRING
RETURN TO CENTER
PRESSURE
RELIEF VALVE
FILTER
HYDRAULIC
PUMP
RESERVOIR
251 REV.980615 PAGE 7

RECOMMENDATIONS
HYDRAULIC FLUID: pressure (see SPECIFICATIONS). Usually, a pressure
The hydraulic fluid selected for use with PULLMASTER relief is part of the hydraulic control valve. Where this
planetary winches should be a high grade, petroleum is not the case, a separate pressure relief valve must
based fluid, with rust, oxidation and wear resistance. be installed and set at the recommended maximum
Fluid cleanliness and operating viscosity are critical to pressure.
winch reliability, efficiency and service life.
HYDRAULIC RESERVOIR:
For optimum performance, the recommended viscosity It is recommended that the hydraulic reservoir has
range at operating temperature is 81 - 167 SUS (16 - 36 sufficient capacity to provide good heat dissipation in
CS). For extreme operating conditions of short duration, order to prevent over-heating of the hydraulic fluid. The
the maximum viscosity range of 58 - 4635 SUS (10 - hydraulic reservoir should be made from clean and
1000 CS) should not be exceeded. scale-free material to prevent contamination of the
hydraulic fluid. In order to prevent air from being mixed
For optimum performance, the winch recommended with the hydraulic fluid, the reservoir should have an
hydraulic fluid temperature operating range is 80 - over-flow baffle separating the return lines from the
150F (27 - 66 C). For extreme operating conditions of suction line and all return lines should enter the reservoir
short duration, the maximum temperature range of -5 below the fluid level. The reservoir should be mounted
- 180F (-21 - 82 C) should not be exceeded. close to and above the hydraulic pump in a location
which provides for free air circulation around the reservoir.
LUBRICATION:
The winch gear train requires oil bath lubrication. The HYDRAULIC HOSES:
winch is shipped from the factory without lubricating oil. The following hydraulic hoses are recommended for
IMPORTANT: ADD LUBRICATING OIL BEFORE maximum efficiency of the PULLMASTER Model H25
RUNNING WINCH. planetary winch:
Pressure lines: Equivalent to SAE 100R12-32

Refer to INSTALLATION DIMENSIONS for location of
Circulation return line: Equivalent to SAE 100R4-16
lubricating oil fill port. Refer to APPENDIX A for quantity Circulation supply line: Equivalent to SAE 100R6-6*
of oil required. For normal operating temperature use
SAE 90 lubricating oil. Consult lubricating oil supplier or * Only for models with external circulation
factory for temperatures beyond normal operating range.
It is recommended that a larger size of hydraulic hose
is installed where the pressure lines or the circulation
HYDRAULIC PUMP:
lines are excessively long.
For maximum performance of the PULLMASTER
planetary winch, the hydraulic pump must supply the
maximum flow of hydraulic fluid at the hydraulic pressure HYDRAULIC FILTER:
stated in SPECIFICATIONS. Hydraulic filter recommendations for the hydraulic circuit
of the PULLMASTER planetary winch, based on a
return line filter, are given as follows:
HYDRAULIC CONTROL VALVE:
The standard control valve used for operation of the Average Atmosphere: 10 microns
PULLMASTER planetary winch must have a four-way, Dusty Atmosphere: 5 microns
spring return to neutral feature, which provides for open
flow from the pressure ports of the winch to the reservoir In order to prevent accidental stoppage of the return
in neutral position of the control (motor spool). It is line flow, the oil filter should have a by-pass feature.
important to point out that good speed control, especially
when lowering a load, depends on the “metering” USE OF AN E STOP:
characteristics of the control valve. The better the oil flow (FOR EUROPEAN MACHINERY DIRECTIVE APPLICATIONS)
is “metered” the better will be the speed control.
The use of an E stop (emergency) is mandatory in the
controls circuit. The E stop is to be placed in the
HYDRAULIC PRESSURE RELIEF: operator's control panel. The E stop must be designed
The hydraulic circuit for the PULLMASTER planetary and placed in line with EN 60204 and EN 418.
winch requires a pressure relief set at the operating
PAGE 8 251 REV.021028

INSTALLATION INSTRUCTIONS
DANGER
FAILURE TO FOLLOW INSTALLATION INSTRUCTIONS WILL
The initial installation or mounting of a PULLMASTER planetary winch is critically important for proper operation
and performance. If the winch is mounted to an uneven surface, the centre line of the unit can be distorted to a
point where the winch will not operate in either direction. It is therefore very important that the following
instructions are observed when a PULLMASTER planetary winch is installed:
1) Make certain that the mounting platform is sufficiently strong in order to avoid deflection when a load is lifted.
2) Set the winch on the mounting platform and check for surface contact on all mounting pads of the winch.
3) If there is a space between the mounting surface and one of the mounting pads, the mounting surface is not
even and the space below the mounting pad must be shimmed. If this condition exists, proceed as follows:
a) Install mounting bolts snug tight on the three mounting pads which are in contact with the mounting
surface. (For mounting bolt size and grade see INSTALLATION DIMENSIONS.)
b) Measure the space underneath the fourth mounting pad with a feeler gauge and use shim stock of
equivalent thickness in the space between the mounting pad and the mounting surface.
c) Only after this procedure should the fourth mounting bolt be installed. Tighten all four bolts per BOLT
TORQUE CHART.
4) Fill the winch with lubricating oil. (See APPENDIX A for oil volume required.)
5) Use recommended circuit components and hydraulic hoses.
6) The circulation return line of the winch should be plumbed in such a manner that the brake housing remains
full of oil at all times. Connect the return line directly to reservoir. Do not connect to a common return line.
7) Before operating the winch with a load, verify adequate circulation flow through the circulation return line as
stated in TYPICAL HYDRAULIC CIRCUIT. Verify that pressure measured at the circulation supply port does
not exceed the permissible pressure stated in SPECIFICATIONS. Winches equipped with the internal
circulation option will supply circulation flow only when the winch is run in the lowering direction.
8) Verify that breather relief, item 130, is in place on end cover above oil level. Rotate end cover if breather relief
is below oil level.
IMPORTANT: Do not replace breather relief with a pipe plug. The breather relief does not prevent
oil seal failure but serves as an indicator or warning that the oil seals between brake
housing and the cable drum interior have failed and must be replaced immediately.
If these oil seals are changed, additional failure of the drum seal and potential
damage to the end cover is prevented.
251 REV.980615 PAGE 9

DANGER
FAILURE TO FOLLOW OPERATING INSTRUCTIONS WILL
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 clockwise when looking at the hydraulic motor
of the unit. It is critical to select the cable anchor slot which will permit winding of the wire rope on the drum
in the correct direction of rotation. If the wire rope is wound on the cable drum in the wrong direction of rotation,
the winch will have no braking capacity. Each winch is shipped from the factory with a label on the drum
indicating the correct cable anchor slot.
CABLE ANCHOR
WIRE ROPE INSTALLATION
CABLE ANCHOR SLOT
Clockwise hoisting winch shown.
(Use cable anchor slot on opposite side of
drum for counterclockwise 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 rope tight to wedge rope in slot.
SI1013
2) On wire rope installation, care must be taken that the wire rope is wrapped completely around the cable
anchor and properly pulled into the cable anchor slot in the cable drum. The cable drum requires 5 wraps
of wire rope for safety.
3) The winch operation is controlled by a single control valve lever which has a forward, a reverse and a neutral
position. Speed control in either direction is obtained by modulation of the control valve lever. Maximum line
speed in either direction is obtained when the control valve lever is moved as far as it can go. The disc brake
of the winch will come on automatically when the winch control lever is returned to neutral.
4) Always warm up equipment prior to operating winch, particularly in low ambient temperature. Circulate
hydraulic oil through the winch control valve for several minutes to warm the hydraulic system. To prime the
winch with warm oil, operate the winch at slow speed, forward and reverse, several times.
5) Prevent corrosion damage to winch interior. If not used regularly, run winch up and down at least once every
two weeks.
6) To ensure proper winch installation and function, raise and lower a full test load to a safe height before using
winch for regular operation at the start of each shift.
If, after a new installation, the winch does not function properly, refer to the TROUBLESHOOTING section
of this manual.
PAGE 10 251 REV.051117

TROUBLE SHOOTING
GENERAL:
In most cases, when the hydraulic winch does not perform satisfactorily, the cause of malfunction is found
somewhere in the hydraulic circuit. Before the winch is removed from its mounting and disassembled, all of the
hydraulic circuit components should be checked for proper function.
IMPORTANT:
The hydraulic oil volume relates to the line speed or rpm of the winch.
Therefore, if the winch does not produce the specified maximum rated line speed or drum rpm, a loss of
hydraulic flow somewhere in the hydraulic circuit system can be analysed. If this condition exists, install a flow
meter into the hydraulic circuit to check the volume supplied to the 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 line pull or lifting capacity of the winch.
If the winch will not lift the specified maximum line pull, install a pressure gauge into 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 pump is driven by V-belts, check for belt slippage. When checking oil pressure and
volume in the hydraulic circuit, make certain that the hydraulic reservoir is filled to the top level and the hydraulic
pump is running at maximum operating rpm.
Only if the hydraulic system has been checked and found to be in order, use the following indications for
probable causes of failure in the winch:

Winch will not produce line pull at maximum a) Winch is mounted to an uneven surface (see
pressure as listed in SPECIFICATIONS. INSTALLATION INSTRUCTIONS).
d) Excessive back pressure in the hydraulic system.
e) Relief valve may be set too low. (See SPECIFICATIONS
for maximum operating pressure.)
Winch will not produce line speed at maximum a) Winch is mounted to an uneven surface (see
volume as listed in SPECIFICATIONS. INSTALLATION INSTRUCTIONS).
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 brake
from being released against the brake springs. This is
caused by damaged O-ring seals on the brake piston.
b) The O-ring seals, on the brake release channel between
the motor adaptor and the brake housing is damaged.
If this failure occurs there will be substantial leakage
from between the motor adaptor and brake housing.
c) Insufficient hydraulic pressure. (See SPECIFICATIONS
for minimum operating pressure.)
d) Winch is mounted to an uneven surface (see
INSTALLATION INSTRUCTIONS).
e) Hydraulic pressure is not reaching the brake piston
(plugged brake release orifice in the brake housing).
251 REV.950201 PAGE 11

TROUBLE SHOOTING CONTINUED

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 causes the
brake to be released.
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) Sprag clutch is damaged or surfaces where sprag
clutch engages on motor drive shaft or connecting
shaft are worn or indented.
g) Winch supplied with external brake release option is
not plumbed per HYDRAULIC CIRCUIT. 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 is too slow. Pump rpm must be maintained at
normal operating speed when a load is lowered.
b) Brake is running too hot. This is caused by a complete
lack of, or insufficient circulation flow. To check the
circulation, observe the flow of oil from the circulation
return line of the winch (see TYPICAL HYDRAULIC
CIRCUIT) when the winch is reversed.
c) Control valve has poor metering characteristics.
d) Damaged brake plates or divider plates.
e) The over-running clutch, which connects the motor
shaft with the brake assembly, is damaged.
f) Air mixed with hydraulic oil (foamy oil).
Oil leaks. a) Oil leaks from the hydraulic motor flange and the motor
adaptor are caused by damaged O-ring seals.
b) Oil leaks occurring between the cable drum flanges
and housings are caused by excessive pressure in the
brake housing. Excessive pressure will damage the
oil seal which separates the brake housing from the
cable drum interior.
c) If the breather relief on the end cover leaks, the seal
between the drum interior and the brake housing is
damaged and must be replaced. This condition is
caused by excessive pressure in the brake housing of
the winch, operation with the incorrect hydraulic fluid
during cold weather, or a restriction in the circulation
return line leading back to tank.
Refer to the SERVICE INSTRUCTIONS if it becomes necessary to disassemble the Model H25 winch.
PAGE 12 251 REV.970601

SERVICE INSTRUCTIONS
GENERAL:
Before attempting disassembly of the PULLMASTER Model H25 planetary winch, the following instructions for
disassembly and reassembly should be read and understood:
It is suggested that all expendable parts, such as O-rings and oil seals, are not reused on reassembly. It is
therefore important to have a seal kit (Part No. 23126) and, providing the hydraulic motor has to be serviced,
a seal kit (Part No. 23117) on hand before the unit is taken apart. Two new roller bearings, item 875, may also
be required (Part No. 25352).
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.
A clean working area is of prime importance, similar to conditions used for service work on any other hydraulic
component. All parts, as they are removed from the winch assembly, should be 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.
In the following service instructions, reference to parts is made by numbers and shown on the applicable group drawings.
DISASSEMBLY
For the majority of required service or repair work, disassembly is required only on the brake housing of the
PULLMASTER Model H25 planetary winch. There are no special tools needed for the service or repair work
and no adjustments or calibrations are necessary. Proceed with the disassembly as follows:
DISASSEMBLY OF HYDRAULIC MOTOR ASSEMBLY:

If the analysed service or repair work requires access to the interior of the brake housing, the hydraulic motor
should not be disassembled. In this case, the hydraulic motor should be removed together with the motor adaptor
as a complete assembly. If a problem has been analysed to be in the hydraulic motor, proceed with the
disassembly as follows:
1) Remove the eight hex capscrews, item 951, together with the lockwashers, item 953, from the motor assembly.
IMPORTANT: Failure to exercise care when removing the motor port end cover or gear housing could
permanently damage the machined surfaces of these motor components. Take care not
to damage machined surfaces of motor components at disassembly.
2) Remove (pry loose if necessary) port end cover, item 870, together with bearings, item 875, and ring seal,
item 877. Thrust plate, item 885, and dowel pins, item 865, may stay in the gear housing.
3) If the thrust plate comes off with the end cover, carefully pry it off of the bearings, item 875, and discard teflon
seals, item 887.
4) Remove gear set, item 881, which consists of two gears which are a matched set.
5) Carefully pry the gear housing, item 861, off of the motor adaptor, item 800. Thrust plate, item 885, and dowel
pins, item 865, may stay in the gear housing.
6) If the thrust plate stays on the motor adaptor, carefully pry it off of the bearings, item 875, and discard teflon
seals, item 887.
7) Discard gasket seals, item 869. It is also advisable to replace ring seals, item 877, at this time. Bearings, item
875, have to be removed to allow access to the ring seals.
Teflon seals, gasket seals and ring seals in the hydraulic motor assembly are not part of the winch seal kit. The
seal kit for the hydraulic motor can be ordered from the factory under Part No. 23117. All parts of the hydraulic
251 REV.991224 PAGE 13

motor, with the exception of the motor adaptor, item 800, and the port end cover, item 870, are standard parts of
the hydraulic motor, having a 3 inch gear section. All of these parts can be ordered from PULLMASTER or
Authorized Distributors/Dealers in Canada, the United States and in most overseas areas.
REMOVAL OF HYDRAULIC MOTOR ASSEMBLY:

If disassembly of the hydraulic motor is not necessary, proceed as follows:
1) Remove the 12 hex head capscrews, item 537, with lockwashers, item 541, from the motor adaptor, item 800.
Since the brake springs, item 752, apply pressure against the inside of the motor adaptor, it is recommended
that the hex capscrews are unscrewed, one turn at a time, until the spring pressure has been released. The
complete motor assembly, including the motor adaptor, can now be removed from the brake housing assembly.
2) Remove and discard three O-rings, item 801, and O-ring, item 707. (O-rings, item 801, seal the pressure
transfer hole for the automatic brake release and are situated on the flange of the brake housing.)
DISASSEMBLY OF BRAKE HOUSING ASSEMBLY:

1) After the motor assembly has been removed, all parts of the brake assembly are accessible. Remove 18
brake springs, item 752. Thoroughly examine springs for damage and measure overall length. Overall spring
length should be 2.27 inch. If any spring measures less than 2.21 inch, replace all springs as a set.
2) Pull the motor drive shaft, item 730, out of the brake hub assembly. The surface of the motor drive shaft which
engages the sprag clutch, item 723, should be inspected for wear or indentations. If the motor drive shaft
shows any surface damage, it should be replaced.
3) The sprag clutch aligner, item 724, and the sprag clutch, item 723, can now be removed from the bore of the
brake connecting shaft, item 600. Inspect both parts for wear or damage and replace if necessary.
DANGER
MINOR SURFACE DEFECTS WHERE THE SPRAG CLUTCH ENGAGES THE
MOTOR DRIVE SHAFT AND CONNECTING SHAFT, WILL RESULT IN BRAKE
FAILURE AND ALLOW THE LOAD TO DROP, CAUSING PROPERTY
DAMAGE, SEVERE INJURY OR DEATH. THOROUGHLY INSPECT
THESE AREAS AND, IF NECESSARY, REPLACE MOTOR DRIVE
SHAFT, SPRAG CLUTCH AND CONNECTING SHAFT AS A SET.
4) Pull the brake piston, item 750, out of the brake housing using two 5/8-11NC bolts screwed into the two puller
holes in the piston and discard O-rings, item 751 and item 753.
5) Thoroughly examine the inner bores of the brake housing and the outer diameters of the brake piston for
scoring caused by hydraulic fluid contamination. Minor surface damage may be repaired by polishing with
a fine emery cloth.
DANGER
PLATES. PERFORM THOROUGH INSPECTION AND, IF NECESSARY,
REPLACE FRICTION AND DIVIDER PLATES AS A SET.
6) Remove 12 friction plates, item 715, together with 13 divider plates, item 713, and inspect for damage or wear.
Plates should be flat and smooth. Plates should not show heat discoloration. Paper material on friction plates
PAGE 14 251 REV.021126

should be intact and grooved. If any damage is detected, replace friction and divider plates as a set.
7) Remove brake spacer, item 712.
8) Remove the drain plug, item 121, from the end cover, item 120, and drain the lubricating oil from the final drive
assembly and the cable drum interior. To drain all of the oil out of the cable drum interior, the winch should
be tipped to an angle, and the filler plug, item 503, removed.
DISASSEMBLY OF PRIMARY DRIVE:

For ease of working on the rest of the unit, set the winch upright on the final drive housing.
1) Remove the two winch base halves, item 550 and item 552, by removing the 28 hex capscrews, item 551,
and lockwashers, item 553.
2) Remove the access plug, item 734, using a 1/2-13NC bolt (motor adaptor bolt, item 821, works nicely), from
inside brake housing and discard O-ring, item 735.
3) Remove six hex capscrews, item 537, with lockwashers, item 541, from bearing flange, item 530, by rotating
brake housing until access hole is over top.
4) Lift brake housing, together with the bearing flange and primary planet hub assembly, out of the cable drum,
item 500, and discard O-ring, item 539.
5) Remove final sungear, item 340, from cable drum.
6) Remove retaining ring, item 401, and remove primary planet hub assembly from inside the internal gear, item 430.
7) Inspect three primary planet gears, item 420, for damage or wear. If it is necessary to remove primary planet
gears, remove circlip, item 411, and press planet pin, item 410, out of planet hub, item 400. Inspect loose
rollers, item 423, and two thrust washers, item 421, and replace if damaged.
8) Remove primary sungear, item 440, from center of connecting shaft, item 600.
9) Remove circlip, item 431, and internal gear, item 430, from connecting shaft spline.
10) Remove and inspect two thrust washers, item 433, and thrust bearing, item 435. Replace if cracked or
otherwise damaged.
11) The connecting shaft, item 600, can now be pulled out of the brake housing. Remove and inspect two thrust
washers, item 615, and thrust bearing, item 617. Replace if cracked or otherwise damaged.
12) Remove needle bearing, item 603, inspect and replace if damaged.
13) Remove and discard oil seal, item 607, and if present, backup washer, item 606, from inside of connecting
shaft.
14) Remove and discard oil seal, item 711, and if present, backup washer, item 710, from bore of brake housing.
Inspect two needle bearings, item 605, and replace if necessary.
15) To separate bearing flange, item 530, and brake housing, item 700, use a standard bearing puller or insert
two heel bars in the slot between the bearing flange and the brake housing and pry brake housing out of ball
bearing, item 533.
16) Remove the internal retaining ring, item 534, to remove the ball bearing, item 533. Remove and discard oil
seal, item 531.
DISASSEMBLY OF FINAL DRIVE:
Stand winch on cable drum flange with final end up and disassemble as follows:
1) Remove the internal retaining ring, item 124, and pull the end cover, item 120, out of final drive housing, item 100.
251 REV.970601 PAGE 15

2) Discard O-ring, item 123, and inspect planet hub stopper, item 126, and sungear stopper, item 122, for
excessive wear. Replace planet hub stopper if less than .30 inch and sungear stopper if less than .21 inch
thick.
3) Remove final planet hub assembly from final housing, item 100.
4) Inspect three final planet gears, item 320, for damage or wear. If it is necessary to remove final planet gears,
remove circlip, item 311, and press planet pin, item 310, out of planet hub, item 300. Inspect loose rollers,
item 323, and two thrust washers, item 321, and replace if damaged.
5) To separate cable drum from final housing, first remove circlip, item 513. Insert two heel bars between the
flange of the cable drum and final drive housing and gently pry cable drum out of ball bearing, item 103.
6) Remove the internal retaining ring, item 104, to remove ball bearing, item 103. Remove and discard oil seal,
item 105.
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 end of winch as follows:
1) Press a new, well-greased oil seal, item 105, into final housing, item 100.
2) Press ball bearing, item 103, into final housing and secure with retaining ring, item 104.
3) Press cable drum, item 500, into ball bearing, item 103, and secure with circlip, item 513.
4) Reassemble final planet hub assembly. Use grease to temporarily hold 24 loose rollers, item 323, in the bore
of the planet gear, item 320. Position thrust washers, item 321, on either side of 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 final housing, item 100. Ensure that final planet hub spline is fully
engaged with cable drum, item 500.
6) Install a new, well-greased O-ring, item 123, into the end cover, item 120. Verify that planet hub stopper, item
126, and sungear stopper, item 122, are installed into end cover.
7) Gently insert end cover into final housing, item 100, and fasten with retaining ring, item 124.
REASSEMBLY OF PRIMARY DRIVE:

Turn winch over, resting on end cover with cable drum opening facing up. Reassemble primary drive as follows:
1) Press a new, well-greased oil seal, item 531, into bearing flange, item 530. Press ball bearing, item 533, into
bearing flange and secure with retaining ring, item 534.
2) Press bearing flange assembly onto brake housing, item 700, and install new, well-greased O-ring, item 539.
3) Press a new, well-greased oil seal, item 711, into bore of brake housing, item 700.
4) Press a new, well-greased oil seal, item 607, into bore of connecting shaft, item 600, followed by needle
bearing, item 603.
5) Slide brake hub, item 720, onto connecting shaft and secure with circlip, item 721. Place thrust bearing, item 617
(held between two thrust washers, item 615), against brake hub and slide connecting shaft into brake housing.
6) Place thrust bearing, item 435 (held between two thrust washers, item 433), onto internal gear, item 430, and
PAGE 16 251 REV.970601

fasten internal gear onto connecting shaft using circlip, item 431.
7) Reassemble primary planet hub assembly. Use grease to temporarily hold 20 loose rollers, item 423, in the
bore of the planet gear, item 420. Verify placement of sungear stopper, item 444. Position thrust washers,
item 421, on either side of the planet gear and press planet pin, item 410, into the final planet hub, item 400.
Retain with circlip, item 411.
8) Insert primary sungear, item 440, between three planet gears and insert sungear shaft into connecting shaft,
engaging planet gears with internal gear. Fasten with retaining ring, item 401.
9) Insert final sungear, item 340, into cable drum and engage three planet gears, item 320.
10) Lower brake housing assembly onto cable drum, while engaging spline of final sungear with primary planet
hub, item 400. Line up mounting holes of bearing flange, item 530, with those in the cable drum.
11) Rotate brake housing to line up access holes and fasten bearing flange using six capscrews, item 537, and
lockwashers, item 541.
12) Install new, well-greased O-ring, item 735, into access plug, item 734. Install access plug into access hole
inside brake housing.
13) Attach base halves, item 550 and item 552, using 28 capscrews, item 551, and lockwashers, item 553.
REASSEMBLY OF BRAKE HOUSING ASSEMBLY:

Reassemble brake housing assembly as follows:
1) Install brake spacer, item 712, into brake housing.
DANGER
2) Starting and finishing with a divider plate, alternately install 13 divider plates, item 713, and 12 friction plates,
item 715.
3) Liberally grease O-ring, item 751, and O-ring, item 753, and install on the brake piston, item 750.
4) Slide the brake piston into the brake housing with the holes for the brake springs facing out of the brake
housing assembly.
5) Install sprag clutch, item 723, and sprag clutch aligner, item 724, into the bore of connecting shaft, item 600.
6) Carefully slide motor drive shaft, item 730, into the connecting shaft until it engages the spline of the primary
sungear, item 440, and circlip, item 727, is tight against the sprag clutch aligner.
IMPORTANT: For proper brake function, verify that the sprag clutch is installed correctly. When
viewed from the motor end, the motor drive shaft of a clockwise hoisting winch
must turn freely clockwise and lock in the counterclockwise direction.
7) Install 18 brake springs, item 752, in the brake piston. The brake piston has 20 holes and the two empty holes
should be opposite each other.
8) Liberally grease three new O-rings, item 801, and install into the recesses on the motor adaptor, item 800.
Install new, well-greased O-ring, item 707, on the flange of the motor adaptor.
251 REV.970601 PAGE 17

9) Slide the hydraulic motor assembly on the splined end of the motor drive shaft, item 730, and line up the
pressure transfer holes of the brake housing and the motor adaptor. Tighten 12 capscrews, item 821, and
lockwashers, item 823, one turn at a time to evenly compress springs.
REASSEMBLY OF HYDRAULIC MOTOR:

If the hydraulic motor was disassembled, the following procedure should be followed for reassembly:
1) Clean all parts thoroughly before reassembly and apply grease liberally to all seals. Use only new seals (seal
kit Part No. 23117) for hydraulic motor.
2) Install two new teflon seals, item 887, on each thrust plate, item 885. Press one of the thrust plates, together
with two teflon seals, onto the bearings, item 875, installed in the motor adaptor, item 800.
3) Install a new, well-greased gasket seal, item 869, on each side of the gear housing, item 861. Slide the gear
housing together with the gasket seals, onto the motor adaptor, lined up on two dowel pins. Tap on tight using
a soft headed hammer.
4) Install the gear set, item 881, in the gear housing. (The longer gear with the internal spline goes into the top
position.)
5) Press the other thrust plate, complete with two new teflon seals, onto the bearings installed in the port end cover.
6) Install the port end cover, item 870, together with two bearings, item 875, and a new ring seal, item 877, onto
the gear housing, lined up on the two dowel pins, item 865. Tap on tight using a soft headed hammer. Install
and lightly torque eight hex capscrews, item 951, and lockwashers, item 953, to approximately 50 ft-lb (70 Nm).
7) Plumb winch assembly to a hydraulic supply and torque motor capscrews according to the following
procedure:
- Ensure that circulation supply flow is being supplied to the brake housing.
- Run the winch , with no load, in the hoisting direction at reduced speed
(approximately 30% of maximum hydraulic volume).
- With winch running, evenly tighten eight capscrews, item 951, to 200 ft-lb (270 Nm).
- Test motor operation by running winch at full speed in both directions.
IMPORTANT: Before operating the winch, add lubricating oil up to the level of the end cover 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 COULD ENABLE AN
INSTALLATION OR SERVICE PROBLEM TO GO UNDETECTED AND
WILL 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 18 251 REV.970601

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 H25 planetary winch, always quote the complete model and
serial number of the unit.
MODEL NO. _______________
SERIAL NO. _______________
PULLMASTER WINCH CORPORATION reserves the right to change specifications and the design of
PULLMASTER planetary winches at any time without prior notice and without incurring any obligations.
251 REV.980615 PAGE 19

PARTS REFERENCE - FINAL DRIVE
100 1 20399 FINAL HOUSING
103 1 25332 BALL BEARING # 6024
105 1 25148 OIL SEAL
120 1 20400 END COVER
121 2 25237 PIPE PLUG 3/4 - 14 NPT
123 1 25340 O-RING -281 15" ID 1/8" CS
126 1 20418 PLANET HUB STOPPER
130 1 20677 BREATHER RELIEF ASSEMBLY
321 6 25167 THRUST WASHER TORRINGTON # TRB 2840
323 72 25297 LOOSE ROLLER TORRINGTON # G613 - Q
340 1 * SUNGEAR
500 1 * CABLE DRUM
502 1 20423 CABLE ANCHOR
503 1 25032 PIPE PLUG 1/2 - 14 NPT
550 1 * BASE
551 28 25346 CAPSCREW - HEXHEAD 5/8 - 11NC X 1.75 GRADE 5
552 1 * BASE
553 28 25359 LOCKWASHER 5/8"
* These parts vary according to drum code. Refer to APPENDIX B.
PAGE 20 251 REV.970601

FINAL DRIVE GROUP
G1000-A
130 320 124 323 321 313 104 103 105 502 503 500 343
311
310
126
340
122
513
120
300
121
123
100
553 551 550 552
Groups drawings may reference more parts than are actually present in a specific assembly. Parts that are
referenced on the drawing but are not on the PARTS REFERENCE list should be ignored.
251 REV.950201 PAGE 21

PARTS REFERENCE - BRAKE GROUP
421 6 25068 THRUST WASHER TORRINGTON # TRA 1423
423 60 25270 LOOSE ROLLER 5/32 X 1.25 TORRINGTON # E151 - Q
430 1 20411 INTERNAL GEAR
433 2 25363 THRUST WASHER TORRINGTON #TRA 6881
435 1 25362 THRUST BEARING TORRINGTON #NTA 6881
440 1 20414 SUNGEAR
530 1 * BEARING FLANGE
531 1 25148 OIL SEAL
533 1 25333 BALL BEARING #6026
539 1 25109 O-RING - 269 8-3/4 ID 1/8" CS
541 6 25014 LOCKWASHER 1/2"
600 1 20412 CONNECTING SHAFT
603 1 25361 NEEDLE BEARING TORRINGTON #B-3012
605 2 25366 NEEDLE BEARING TORRINGTON #NBH 4812
607 1 26009 OIL SEAL
615 2 25365 THRUST WASHER INA #AS 90120
617 1 25364 THRUST BEARING INA #AXK 90120
700 1 20390 BRAKE HOUSING
703 1 25347 PLASTIC CAPLUG 1 NPT THREADED
707 1 25339 O-RING -278 12" ID 1/8" CS
711 1 25933 OIL SEAL
712 1 20420 BRAKE SPACER
720 1 20410 BRAKE HUB
723 1 25303 SPRAG CLUTCH BORG WARNER #140373 B
734 1 20422 ACCESS PLUG
735 1 25344 O-RING - 123 1-3/16" ID 3/32" CS
750 1 20397 PISTON
751 1 25343 O-RING -90 DURO -451 11" ID1/4" CS
752 18 20413 BRAKE SPRING
753 1 25342 O-RING -90 DURO -452 11-1/2" ID 1/4" CS
23126 WINCH SEAL KIT, CONSISTS OF ITEMS:

105, 123, 531, 539, 607, 707, 711, 735, 751, 753 AND 801
* This part varies according to drum code. Refer to APPENDIX B.
Refer to PAGE 28 for ASSEMBLY DRAWING.
PAGE 22 251 REV.980615

BRAKE GROUP
G1004-A
401 423 413 435 534 605 711 617 712 607 713 751 750 753 707
421 752
411 721
410 723
420 724
400 727
444 603
440 600
431 606
433 615
430 720
710 715
531 734
533 703
539 530 541 537 700 735
251 REV.950201 PAGE 23

PARTS REFERENCE - MOTOR GROUP
537 12 25081 CAPSCREW - HEX HEAD 1/2 - 13 NC X 1.5 GRADE 5
541 12 25014 LOCKWASHER 1/2"
730 1 20415 MOTOR DRIVE SHAFT
800 1 20401 MOTOR ADAPTOR
801 3 25127 O-RING -013 7/16" ID 1/16" CS
802 1 * *
805 2 25040 PIPE PLUG 1/8 - 27 NPT
806 1 * *
807 1 * *
809 1 * *
813 1 25031 PIPE PLUG 1/4 - 18 NPT
861 1 25350 GEAR HOUSING -086
865 4 25356 DOWEL PIN
869 2 25348 GASKET SEAL
870 1 21761 PORT END COVER
875 4 25352 ROLLER BEARING
877 2 25646 RING SEAL
881 1 25645 GEAR SET
885 2 25644 THRUST PLATE
887 4 25647 TEFLON SEAL
899 2 25031 PIPE PLUG 1/4 - 18 NPT
929 1 * *
950** 1 * SUB - ASSY MOTOR -086
951 8 25357 CAPSCREW - HEX HEAD 5/8 X 6.75 GRADE 5
953 8 25325 WASHER
955 2 25559 PLASTIC CAPLUG 2.0"
23117 MOTOR SEAL KIT, CONTAINS ITEMS:

869, 877 AND 887
* These part numbers and descriptions vary according to brake code.

Refer to APPENDIX C.
** ITEM 950 MOTOR SUB-ASSY, CONSISTS OF ITEMS:

800, 802, 803, 804, 805, 807, 809, 861, 865, 869, 870,
875, 877, 881, 885, 887, 899, 929, 951, 953 AND 955
PAGE 24 251 REV.980615

MOTOR GROUP
G1002-D
950
953
955
951
870
929
877
899
869
875
881
887
731
861
802
885
807
865
809
537
801
541
800
806
730
805
813
251 REV.970601 PAGE 25

PAGE 26
FOR SAFETY: A MINIMUM OF 5 WRAPS OF
WIRE ROPE MUST BE MAINTAINED
AT ALL TIMES ! PRESSURIZE FOR P
BREATHER RELIEF VALVE CLOCKWISE
C D ROTATION
FILLER PORT PRESSURIZE FOR
FILLER PORT CLOCKWISE COUNTER-CLOCKWISE
1/2-14 NPT
3/4-14 NPT (LOCATED EITHER ROTATION
IN CABLE ANCHOR
POCKET OR ON
BARREL)
B DIA OPTIONAL
EXTERNAL BRAKE
RELEASE PORT
1/8-27 NPT
SAE 4-BOLT FLANGE
SEE MOTOR CHART
FOR PORT SIZE
A DIA
E L
F
M
N
FREE SPOOL
1.25
PORT [31.8] GAUGE PORTS
1/4-18 NPT 4 MOUNTING HOLES 1 9/32 DIA [32.5]
1/4-18 NPT
USE O
/ 1-1/4 BOLTS GRADE 5 OR BETTER
CIRCULATION
CIRCULATION INLET PORT 3/8-18 NPT
DRAIN PORT RETURN PORT
1.3 (EXTERNAL CIRCULATION MODELS ONLY)
3/4-14 NPT H c/c 1-11 1/2 NPT
[32]
R c/c
3.6
G {91} S
STANDARD CABLE ANCHOR IS

J
SUITABLE FOR 7/16 - 7/8"
[STANDARD MODELS] DIA WIRE ROPE ON 10" DIA
K I DRUM BARREL
[FREE SPOOL MODELS] [MOTOR]
I1001-1-D
251 REV.051117
I1001-2-A & I1001-3-A
DRUM
CODE A B C D E F G H J K M N P R S
-1 10.0 17.0 11.0 8.6 19.9 19.9 21.0 18.500 28.6 31.0 11.38 8.9 20.8 17.750 20.8
(254) (432) (279) (218) (505) (505) (533) (469.90) (726) (787) (289) (225) (527) (450.85) (527)
-2 10.0 24.0 11.0 8.6 24.4 20.9 21.0 18.500 28.6 31.0 12.38 10.0 25.9 22.875 25.9
(254) (610) (279) (218) (619) (530) (533) (469.90) (726) (787) (314) (254) (657) (581.03) (657)
-3 10.0 24.0 17.0 8.6 24.4 20.9 27.0 24.500 34.6 37.0 12.38 10.0 25.9 22.875 25.9
(254) (610) (432) (218) (619) (530) (686) (622.30) (879) (940) (314) (254) (657) (581.03) (657)
-4 10.0 24.0 22.0 8.6 24.4 20.9 32.0 29.500 39.6 42.0 12.38 10.0 25.9 22.875 25.9
(254) (610) (559) (218) (619) (530) (813) (749.30) (1006) (1067) (314) (254) (657) (581.03) (657)
-5 10.0 34.0 29.0 9.1 34.4 25.9 40.0 37.500 47.6 50.0 17.38 13.6 35.6 28.500 31.5
(254) (864) (737) (230) (875) (658) (1016) (952.50) (1209) (1270) (441) (345) (905) (723.90) (800)
- 10 10.0 17.0 29.0 9.1 19.9 19.9 40.0 37.500 47.6 50.0 11.38 8.9 20.8 17.750 20.8
(254) (432) (737) (230) (505) (505) (1016) (952.50) (1209) (1270) (289) (225) (527) (450.85) (527)
- 14 14.5 24.0 17.0 8.6 24.4 20.9 27.0 24.500 34.6 37.0 12.38 10.0 25.9 22.875 25.9
(368) (610) (432) (218) (619) (530) (686) (622.30) (879) (940) (314) (254) (657) (581.03) (657)
- 31 13.0 24.0 17.0 8.6 24.4 20.9 27.0 24.500 34.6 37.0 12.38 10.0 25.9 22.875 25.9
(330) (610) (432) (218) (619) (530) (686) (622.30) (879) (940) (314) (254) (657) (581.03) (657)
HYDRAULIC MOTORS
COMMERCIAL WM76 SERIES COMMERCIAL M365 SERIES
MOTOR GEAR MOTOR PORT SIZE I L MOTOR GEAR MOTOR PORT SIZE I L
CODE WIDTH SAE SPLIT FLANGE CODE WIDTH SAE SPLIT FLANGE
CODE 61 CODE 61
- 86 3.00 7.6 2.7 - 42 2.50 8.0 2.5

(76.2) (194) (68) (63.5) (203) (64)
2.0
- 87 2.75 7.4 2.7 - 101 2.25 1.5 7.8 2.5
(69.9) (187) (68) (57.2) (197) (64)
- 88 2.50 7.1 2.7 - 102 2.00 7.5 2.5

(63.5) (181) (68) (50.8) (191) (64)
- 89 2.25 1.5 6.9 2.7

(57.2) (175) (68)
- 90 2.00 6.6 2.7

(50.8) (168) (68)
- 91 1.75 6.4 2.7

(44.5) (162) (68)
- 92 1.50 1.25 6.1 2.7

(38.1) (156) (68)
- 93 1.25 5.9 2.7

(31.8) (149) (68)
- 94 1.00 1.00 5.6 2.7

(25.4) (143) (68)
251 REV.950901 PAGE 27

ASSEMBLY DRAWING
G1000 & G1002 & G1004
PAGE 28 251 REV.980615

APPENDIX A
LINE PULL HOISTING MAXIMUM LOWERING

AT MAXIMUM LINE SPEED ALLOWABLE LINE SPEED LUBRICATING
CABLE DRUM SIZES WIRE ROPE STORAGE PRESSURE AT MAXIMUM LINE PULL AT MAXIMUM
OIL
VOLUME
DRUM INCHES FEET - HOISTING* VOLUME* - LOWERING* VOLUME* REQUIRED
CODE (MILLIMETERS) (METERS) FEET/MINUTE POUNDS
POUNDS FEET/MINUTE U.S.
GALLONS
(KILONEWTONS) (METERS/MINUTE) (KILONEWTONS) (METERS/MINUTE) (LITERS)
BARREL FLANGE LENGTH 3/4 inch 7/8 inch 1 inch BARE FULL BARE FULL BARE FULL BARE FULL
DRUM DRUM DRUM DRUM DRUM DRUM DRUM DRUM
-1 10.0 17.0 11.0 210 140 91 25000 16860 140 207 5357 3778 651 965 2.3
(254) (432) (279) (64) (43) (28) (111.2) (75.0) (43) (63) (23.8) (16.8) (198) (294) (8.7)
-2 10.0 24.0 11.0 515 398 264 25000 11757 140 297 5357 2533 651 1384 2.3
(254) (610) (279) (157) (121) (80) (111.2) (52.3) (43) (90) (23.8) (11.3) (198) (422) (8.7)
-3 10.0 24.0 17.0 796 615 408 25000 11757 140 297 5357 2533 651 1384 3.0
(254) (610) (432) (243) (187) (124) (111.2) (52.3) (43) (90) (23.8) (11.3) (198) (422) (11.3)
-4 10.0 24.0 22.0 1031 796 528 25000 11757 140 297 5357 2533 651 1384 3.6
(254) (610) (559) (314) (243) (161) (111.2) (52.3) (43) (90) (23.8) (11.3) (198) (422) (13.6)
-5 10.0 34.0 29.0 3189 2204 1689 25000 8208 140 425 5357 1815 651 1983 4.4
(254) (864) (737) (972) (672) (515) (111.2) (36.5) (43) (130) (23.8) (8.1) (198) (604) (16.6)
- 10 10.0 17.0 29.0 555 370 241 25000 16860 140 207 5357 3778 651 965 4.4
(254) (432) (737) (169) (113) (73) (111.2) (75.0) (43) (63) (23.8) (16.8) (198) (294) (16.6)
- 14 14.5 24.0 17.0 647 468 344 17683 11757 197 297 3789 2538 920 1384 5.7
(368) (610) (432) (197) (143) (105) (78.7) (52.3) (60) (90) (16.9) (11.3) (281) (422) (21.5)
- 31 13.0 24.0 17.0 705 523 397 19595 11757 178 297 4199 2536 831 1384 4.4
(330) (610) (432) (215) (159) (121) (87.2) (52.3) (54) (90) (18.7) (11.3) (253) (422) (16.6)
* Performance specifications are based on standard hydraulic motor with 7/8 inch diameter rope.
251 REV.991224 PAGE 29

APPENDIX B
ITEM 340 500 530 550 / 552
FINAL CABLE BEARING

DRUM CODE BASE
SUNGEAR DRUM FLANGE
-1 20409 20395 20402 20671
-2 20409 20396 20402 20444
-3 20408 20393 20402 20443
-4 20407 20391 20402 20403
-5 20687 20688 21841 20690
- 10 20687 20935 20402 20937
- 14 20408 20990 20402 20443
- 31 20408 21641 20402 20443
PAGE 30 251 REV.950901

APPENDIX C
BRAKE CODE
-3 -4 -5 -6 -7 -8 -9 - 10
ITEM PART
NO. DESCRIPTION
PART NUMBERS
802 SHUTTLE N/A 20849 20849 N/A N/A 20849 20849 N/A
CIRCULATION
806 VALVE 20456 20456 20456 20456 N/A N/A N/A N/A
1/4-18 NPT
806 PIPE PLUG N/A N/A N/A N/A 25031 25031 25031 25031
1/8-27 NPT
807 PIPE PLUG 25040 N/A N/A 25040 25040 N/A N/A 25040
1/8-27 NPT
807 PIPE N/A 25622 25622 N/A N/A 25622 25622 N/A
ADAPTOR
1/8 NPT
809 CAPLUG N/A 25374 25374 N/A N/A 25374 25374 N/A
3/8-18 NPT
929 PIPE PLUG 25085 25085 25085 25085 N/A N/A N/A N/A
3/8 - 18 NPT
929 CAPLUG N/A N/A N/A N/A 26276 26276 26276 26276
950 MOTOR 20504 22011 22012 20804 20505 21977 22013 20805
SUB-ASSY
251 REV.980615 PAGE 31

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
1 3/8 1200 1627
1 1/2 1500 2034
NOTE: Unless otherwise specified, torque bolts per above chart.
PAGE 32 251 REV.950201

102050
(Revision 5)
OPERATING,
P/N 112991
Ref. 122824
MAINTENANCE & Crane Assy.
PARTS MANUAL
HAND OPERATED
CHAIN HOIST
Yale
®
LH2 HAND HOIST

AND LOW HEADROOM
TROLLEY HOIST
Rated Loads:
Hand Hoists ⁄ through 10 tons.
Low Headroom Trolley Hoists fi through 6 tons.
Follow all instructions and warnings for

inspecting, maintaining and operating this
hoist.
The use of any hoist presents some risk of per-

sonal injury or property damage. That risk is
greatly increased if proper instructions and 414 WEST BROADWAY AVE.
warnings are not followed. Before using this MUSKEGON, MICHIGAN 49443
hoist, each operator should become thoroughly
familiar with all warnings, instructions and Before installing hoist, fill in the information below.
recommendations in this manual. Retain this
manual for future reference and use. Rated Load
Forward this manual to operator.
Serial no.
Failure to operate equipment as directed in
manual may cause injury.
Purchase date
46221 Manual No. Y646

YALE HOIST PARTS AND SERVICES ARE AVAILABLE IN THE UNITED STATES.
As a Yale Hoist and Trolley user, you are assured of reliable repair and parts services through a network of Authorized
Parts Depots that are strategically located in the United States. These facilities have been selected on the basis of their
demonstrated ability to handle all parts and repair requirements promptly and efficiently. To quickly obtain the name
of the Authorized Parts Depot or Repair Station located nearest you, call (866) 805-2962, Fax (800) 742-9270.
NOTES
i
SAFETY PRECAUTIONS
Each Yale Hand Hoist and Low Headroom Trolley Hoist is built in accordance with the specifications contained herein and at
the time of manufacture complies with our interpretation of applicable sections of the American Society of Mechanical
Engineers Code B30.16 “Overhead Hoist” and the Occupational Safety and Health Act.
The safety laws for elevators and for dumbwaiters may specify construction details that are not necessarily
incorporated in Yale industrial hoist. We recommend the use of equipment that meets state and national safe-
ty codes. Yale cannot be responsible for applications other than those for which Yale equipment is recom-
THIS SYMBOL POINTS OUT IMPORTANT SAFETY INSTRUCTIONS WHICH IF NOT FOLLOWED
COULD ENDANGER THE PERSONAL SAFETY AND/OR PROPERTY OF YOURSELF AND OTHERS.
! READ AND FOLLOW ALL INSTRUCTIONS IN THIS MANUAL AND ANY PROVIDED WITH THE
EQUIPMENT BEFORE ATTEMPTING TO OPERATE YOUR YALE HOIST. !
Consult Yale for any usage of Yale Hoists that do not involve raising of the load on the lower hook, or usage of Yale Hoists in the inverted position.
Using hoists, without special precautions, in such applications may cause an accident that could result in injury and/or property damage.
! WARNING ! CAUTION
Improper operation of a hoist can create a potentially Improper operation of a hoist can create a potentially
hazardous situation which, if not avoided, could result hazardous situation which, if not avoided, could result
in death or serious injury. To avoid such a potentially in minor or moderate injury. to avoid such a potentially
hazardous situation, the operator shall: hazardous situation, the operator shall:
1. Maintain a firm footing or be otherwise secured when

1. NOT operate a malfunctioning or unusually performing operating the hoist.
hoist.
2. Check brake function by tensioning the hoist prior to
2. NOT operate the hoist until you have thoroughly read and
each lift or pulling operation.
understand this manufacturer’s Operating, Maintenance and
Parts Manual.
3. Use hook latches. Latches are to retain slings, chains, etc.
3. NOT operate a hoist which has been modified without the under slack conditions only.
manufacturer’s approval or certification to be in conformity 4. Make sure the hook latches are closed and not supporting
with applicable OSHA regs. any parts of the load.
4. NOT lift or pull more than rated load for the hoist. 5. Make sure the load is free to move and will clear all
5. NOT use damaged hoist or hoist that is Not working properly. obstructions.
6. NOT use hoist with twisted, kinked, damaged, or worn load 6. Avoid swinging the load or hook.
chain. 7. Inspect the hoist regularly, replace damaged or worn
7. NOT use the hoist to lift, support, or transport people. parts, and keep appropriate records of maintenance.
8. NOT lift loads over people and make sure all personnel remain 8. Use the hoist manufacturer’s recommended parts when
clear of the supported load. repairing the unit.
9. NOT attempt to lengthen the load chain or repair damaged load 9. Lubricate load chain per hoist manufacturer’s recommen-
chain. dations.
10. Protect the hoist’s load chain from weld splatter or other damaging 10. NOT use the hoist load limiting or warning device to
contaminants.
measure load.
11. NOT use load chain as a sling or wrap load chain around load.
11. NOT operate except with manual power.
12. NOT apply the load to the tip of the hook or to the hook latch.
13. NOT apply load unless load chain is properly seated in the chain
12. NOT permit more than one operator to pull on a single
wheel(s) or sprocket(s). hand chain at the same time. More than one operator is
14. NOT apply load if bearing prevents equal loading on all load likely to cause hoist overload.
supporting chains. 13. NOT allow your attention to be diverted from operating
15. NOT operate beyond the limits of the load chain travel. the hoist.
16. NOT leave load supported by the hoist unattended unless specific 14. NOT allow the hoist to be subjected to sharp contact with
precautions have been taken. other hoists, structures, or objects through misuse.
17. NOT allow the chain or hook to be used as an electrical or welding 15. NOT adjust or repair the hoist unless qualified to perform
ground. such adjustments or repairs.
18. NOT allow the chain or hook to be touched by a live welding
electrode.
19. NOT remove or obscure the warnings on the hoist.
20. NOT operate a hoist which has Not been securely attached to a
suitable support.
21. NOT operate a hoist unless load slings or other approved single
attachments are properly sized and seated in the hook saddle.
22. NOT operate a hoist when it is restricted from forming a straight
line from hook to hook in the direction of loading.
23. NOT lift loads that are Not balanced and that the holding action is
Not secure, taking up slack carefully.
24. NOT operate a hoist unless all persons are and remain clear of the
supported load.
25. Report malfunctions or unusual performances of a hoist, after it
has been shut down until repaired.
26. NOT operate a hoist on which the safety placards or decals are
missing or illegible.
27. Be familiar with operating controls, procedures, and warnings.
ii
iii
GENERAL INFORMATION
SPECIFICATIONS
Yale LH2 Hand Hoists Yale Low Headroom Trolley Hoists
The Yale LH2 Hand Hoist is a highly versatile The Yale Low Headroom Trolley Hoists (Figure 2, page 2)
tool that can be used to lift loads. The hoist has are a combination of the Yale Hand Hoist built
aluminum frame, handwheel, handwheel cover integral with a rugged trolley to provide better head-
and gear cover to provide dependable strength room than that obtained with the standard hoist and
at minimum weight. The internal gears are made trolley. The basic hoist is similar to the Yale LH2 Hand
of high grade, heat treated steel. Shielded ball Hoist except the frame, aluminum on the 1/2 through
bearings are used at each rotating point in the 3 ton units and cast iron on the 4 through 6 ton units,
mechanism. Latch type, heat treated, forged steel which is designed to provide low headroom and
upper and lower hooks are standard. The load chain attachment to the trolley. The trolley has a rugged
is strong and durable Hoistaloy®. A pawl and ratchet, frame, cast iron on the 1/2 through 1 ton units, and
dry-operating, Weston-type friction brake supplies steel plates on the 1-1/2 through 6 ton units. Crowned
very positive load control and will suspend the load tread, flanged trackwheels are provided to minimize
at any point. A Load Limiter is provided on every unit. rolling friction. Hardened, pressed steel ball bearing
As a result, the application of an excessive overload wheels are used on the 1/2 and 1 ton units. Hardened,
disengages the driving handwheel and prevents cast iron wheels with Timken bearings are used on the
hoisting. Note that the Load Limiter is not intended 1-1/2 through 6 ton units. Trolleys are adjustable for
for use as a scaling device. Removal of the excess operation on various American standard beams and
load automatically restores normal hoisting action the 1-1/2 through 6 ton units are available in a geared
(see Figure 1 for specifications of available models). type trolley.
1/4 to 2 Ton 3 & 4 Ton 5 & 6 Ton 8 Ton 10 Ton
Maximum
Capacity (Tons) 1/4 1/2 1 1-1/2 2 3 4 5 6 8 10
Code 924- 924- 924- 924- 924- 924- 924- 924- 924- 924- 924-
02100 03100 05100 06100 07100 09100 11100 13100 14100 16100 17100
Standard Lift (Ft.) 8 8 8 8 8 8 8 8 8 8 8
Net Weight (Lbs.) 33 33 36 59 60 84 91 122 127 207 219
Shipping Weight
(Lbs.) 35 35 38 63 64 91 98 129 134 237 244
Shortest Distance
Between Hooks (In.) 12-7/8 12-7/8 14 17-5/16 17-5/16 21-1/2 21-1/2 24-1/4 25-1/4 35-1/2 35-1/2
Chain Overhauled to
Lift Load 1 Foot (Ft.) 22-1/2 22-1/2 30 40-1/2 52 81 104 156 156 208 260
Chain Pull to
Lift Full Load (Lbs.) 23 46 69 80 83 85 88 75 90 89 95
Figure 1. Yale Hand Hoist, Available Models
1
HOOKS
With Plain Trolley Type of hooks supplied on the Yale Hoists are shown
in Figure 3.
YALE REPAIR/REPLACEMENT POLICY

All Yale LH2 Hand Hoists and Low Headroom Trolley
Hoists are thoroughly inspected and performance
tested prior to shipment. If any properly maintained
Yale Hoist develops a performance problem due to a
material or workmanship defect, as verified by Yale or
With Geared Trolley an authorized service station, repair or replacement
of the unit will be made to the original purchaser
without charge. This repair/replacement policy applies
only to Yale Hoists installed, maintained and operated
as outlined in this manual, and specifically excludes
parts subject to normal wear, abuse, improper instal-
lation, improper or inadequate maintenance, hostile
environmental effects, and unauthorized repairs/
modifications.
We reserve the right to change materials or design if
in our opinion, such changes will improve our product.
Abuse, repair by an unauthorized person, or use of
non-Yale replacement parts voids the guarantee and
could lead to dangerous operation. For full Terms of
Sale, see Sales Order Acknowledgement. Also, refer to
the back cover for Limitations of Warranties, Remedies
and Damages and, Indemnification and Safe Operation.
Figure 2.
Yale Low Headroom Trolley Hoists
OPERATION AND INSTALLATION

UNPACKING INFORMATION
After removing the hoist from the carton, check to To Lower Hook To Raise Hook
be sure there has been no damage in shipment. Pull on This Pull on This
Before cutting the cord ties on multiple-reeved Part of Part of
units, be sure that all strands of chain are straight Hand Chain Hand Chain
with no twist (due to a capsized hook block). If
length of lift is to be modified, follow disassembly
and assembly instructions for correct procedure.
After mounting and before placing in service,
check the hoist for proper operation. On multi-
reeved units, be sure that all strands of chain are
straight with no twist (due to a capsized hook
block).
The Yale Hand Hoist must always be rigged to lift
in a straight line from hook to hook (see Figure 4).
The hoist must always be free to swivel on the
upper hook. Under no condition should the hoist
be allowed to bear on any support when in use as
this would cause bending of the hook or frame Figure 4. Raising and Lowering Hook
and damage the unit.
2
TROLLEY INSTALLATION
! WARNING ! WARNING
Operating the trolley hoist on a beam that has no rail If washer spacing recommendations are not followed,
stops may allow the trolley hoist to fall off the end of trolley hoist may fall from beam.
the beam. To Avoid Injury:
To Avoid Injury: Measure the actual beam flange on which the trolley
Install rail stops at each end of the beam on which hoist is to operate and use figure 5 to determine the
the trolley hoist is to operate. arrangement of the spacer washers for that flange
width.
The railstops must be positioned so as to not exert
impact force on the hoist portion of the unit or the Immediately after installation, operate trolley with a
trolley wheels. They must contact the ends of the capacity load over the entire length of runway or
trolley side frames. monorail system to be sure that all adjustments and
operations are satisfactory.
Due to the variations in beam flange widths, it is sug-
gested that the beam flange width be measured to When applying a load, it should be directly under
determine the exact distribution of spacer washers. the trolley. Avoid off center loading of any kind.
The distance between trackwheel flanges (dimension Side loading may spread trolley side frames.
“X”) should be 1/8 to 3/16 inch greater than the
On systems with curves, the edges of the rail at the
beam flange width for straight runway beams, and
curved sections should be lightly lubricated with
3/16 to 1/4 inch greater than the beam flange width grease.
if runway system includes sharp curves. Also, the use
of other than Yale supplied washers may result in
trackwheel to beam flange variations and thus Figure
! WARNING
5 will not apply. An excessively worn beam flange may fail and
Assemble the trolley on the beam by sliding one side allow the trolley hoist to fall from the beam.
out far enough to allow the wheels to clear the To Avoid Injury:
beam flange. Draw side frames together and tighten Periodically inspect the beam flange for wear.
nuts securely (do not over tighten) and then install Replace beam if flange is worn.
the cotter pins.
S-Beam Number of Spacers

Size Flange 1/2-1 Ton 1 1/2-2 Ton 3 Ton 4-5-6 Ton
A B C D A B C D A B C D A B C D
4”x 7.7 2-5/8 4 0 0 4
4”x 9.5 2-3/4 4 0 1 3
5”x 10.0 3 2 2 2 2
5”x 14.7 3-1/4 0 4 3 1
6”x 12.5 3-3/8 10 0 0 10 13 0 0 13
6”x 17.2 3-5/8 9 1 2 8 12 1 1 12
7”x 15.3 3-5/8 8 2 2 8 11 0 0 11 11 0 0 11
7”x 20.0 3-7/8 7 3 3 7 10 1 1 10 10 1 1 10
8”x 18.4 4 6 4 4 6 9 2 2 9 9 2 2 9 18 0 0 18
8”x 23.0 4-1/8 5 5 5 5 8 3 3 8 8 3 3 8 17 1 1 17
10”x 25.4 4-5/8 2 8 8 2 5 6 6 5 5 6 6 5 14 4 4 14
10”x 35.0 5 0 10 10 0 3 8 8 3 3 8 8 3 12 6 6 12
12”x 31.8 5 0 10 10 0 3 8 8 3 3 8 8 3 12 6 6 12
12”x 35.0 5-1/8 3 8 9 2 3 8 9 2 12 6 7 11
12”x 40.8 5-1/4 2 9 10 1 2 9 10 1 11 7 8 10
12”x 50.0 5-1/2 0 11 11 0 0 11 11 0 9 9 9 9
15”x 42.9 5-1/2 0 11 11 0 0 11 11 0 9 9 9 9
15”x 50.0 5-5/8 8 10 10 8
18”x 54.7 6 6 12 12 6
18”x 70.0 6-1/4 4 14 13 5
20”x 65.4 6-1/4 4 14 13 5
20”x 75.0 6-3/8 3 15 14 4
24”x 79.9 7 0 18 18 0
FIGURE 5. Low Headroom Trolley Spacer Arrangement
3
Do not use this or any other overhead materials
OPERATING AND SAFETY PROCEDURES handling equipment for lifting persons.
Stand clear of all loads and avoid moving a load over
For safety precautions and a list of do’s and do not’s
the heads of any people. Warn any people of your
for safe operation of hoists, refer to page ii.
intention to move a load in their area.
The Yale LH2 Hand Hoist (see Figure 6) must always
Do not leave the load suspended in the air unattended.
be rigged to lift in a straight line from hook to
hook. The hoist must always be free to swivel on Do not lower the hook to a point where the chain
the upper hook. Under no condition should the becomes taut between the liftwheel and loose end
hoist frame or hanger be allowed to bear on any screw. (See Troubleshooting, Item 5C).
support when in use as this would cause bending of
The Yale LH2 Hand Hoist and Yale Low Headroom
the hook or frame and damage the unit.
Trolley Hoist have been designed for manual
When preparing to lift or move a load, be sure that operation only.
the attachments to both hooks are firmly seated in
the saddles of the hooks. Avoid off center loading
of any kind especially loading on the point of the ! WARNING
hook. Power operation may result in structural damage or
premature wear that may cause a part to break and
When lifting, raise the load only enough to clear allow the load to fall.
the floor or support, and check to be sure brake will To Avoid Injury:
hold load and that attachments to the load are Operate Yale LH2 Hand and Trolley Hoists using
firmly seated. Continue the lift only after you are hand power only.
assured the load is free of all obstructions.
Do not load beyond the rated capacity of the hoist.
Overloading can cause immediate failure of some INSPECTION
load carrying part or result in damage causing fail- To maintain continuous and satisfactory operation, a
ure at less than rated capacity. When in doubt, use regular inspection procedure must be initiated to
the next larger capacity of Yale LH2 Hoist. replace worn or damaged parts before they become
Do not wrap load chain around the load or bring unsafe. Inspection intervals must be determined by
the load in contact with the hoist. Doing this will the individual application and are based on the type
result in the loss of the swivel effect of the hook of service to which your hoist will be subjected and
which could cause twisted chain and a jammed lift- the degree of exposure to wear, deterioration or
wheel. The chain could be damaged at the hook. malfunction of the critical components.
Rail stops must be installed for all trolleys operating The type of service to which the hoist is subjected
on open end beams. These stops must be positioned can be classified as “Normal”, “Heavy” and “Severe”.
to exert impact force on the trolley side frames only. Normal Service: involves operation with randomly
distributed loads within the rated load limit, or
uniform loads less than 65% of rated load for not
more then 25% of the time.
Heavy Service: involves operating the hoist within
rated load limit which exceeds normal service.
Severe Service: is normal or heavy service with
abnormal operating conditions.
Following are the recommended, minimum intervals
of inspection. When the unit is subjected to extra
heavy usage or dusty, gritty, moist, or other adverse
atmospheric conditions, shorter time intervals must
be assigned. During the Periodic Inspection, inspection
must be made of all parts for unusual wear, corrosion
effect or damage in addition to those specifically
mentioned.
Before working on the hoist, review the disassembly
and assembly information on pages 8 through 13.
FIGURE 6. Yale LH2 Hand

4
Minimum Inspection Schedule
Frequent Inspections: These inspections are be kept to provide the basis for continuing evalua-
visual examinations by the operator or other des- tion of the condition of the hoist.
ignated personnel. Records of such inspections are
Periodic inspections are to be performed yearly for
not required. The frequent inspections are to be
normal service, semi-annually for heavy service and
performed monthly for normal service, weekly to
quarterly for severe service and they are to include
monthly for heavy service, and daily to weekly for
those items listed in Table 2.
severe service and they should include those items
listed in Table 1. Any parts that are deemed unserviceable are to be
replaced with new parts before the unit is returned
Periodic Inspections: These inspections are visu-
to service. It is very important that the unserviceable
al inspections of external conditions by an appoint-
parts be destroyed and properly disposed of to
ed person. Records of periodic inspections are to
prevent their possible future use as a repair item.
Table 1 Minimum Frequency Inspections
TYPE OF SERVICE ITEM
Normal Heavy Severe
a) Brake for evidence of slippage.
to Weekly
b) Hooks for damage, cracks or excessive throat opening, latch
Monthly
Monthly
Weekly
engagement and latch operation - see page 6.

Daily
c) Inspect load chain for adequate lubrication, signs of wear,

to
damaged links or foreign matter - see page 6.

d) Inspect reeving of the load chain to make sure it is proper -
see page 6.
Table 2 Minimum Periodic Inspections
TYPE OF SERVICE ITEM

Normal Heavy Severe
a) Frequent inspections per Table 1.
b) External evidence of loose bolts or nuts.
c) External evidence of worn, corroded, cracked or distorted hook
blocks, suspension bolts, gears, pins, bearings, hand chain wheel,
frames, hoist hanger, load chain guide, hook block pin on 1/4
thru 2 ton units, dead end pin on 3, 4, 8 and 10 ton units, and
dead end screw on 5 and 6 ton units.
Every 3 Months
d) External evidence of damage to hooks, hook nuts or collars and

hook nut or collar pins.
Twice a Year
e) External evidence of damage or excessive wear of the pockets of

Yearly
the liftwheel, handwheel, hook block sheaves and hanger sheaves.

f) External evidence of worn, glazed or oil contaminated friction
discs, scoring of handwheel hub, ratchet, and friction hub.
g) External evidence of worn pawl and ratchet teeth; corroded,
stretched or broken pawl spring.
h) Supporting structure and trolley, if used, for continued ability to
support the imposed loads.
i) Inspect trolley wheels for external wear on the tread and flange,
and for wear on the internal bearing as evidenced by looseness
on the stud.
j) Warning label and tube for absence or illegibility.
k) Check for proper connections at dead end and loose end of load
chain.
l) Load Limiter components for corrosion.
! WARNING PREVENTIVE MAINTENANCE

In addition to the above inspection procedure, a preventive
Any deficiencies are to be corrected before returning the
hoist to service. Operating a hoist with worn or damaged maintenance program should be established to prolong
parts or a malfunctioning hoist may result in serious the useful life of the hoist and maintain its reliability and
personal injury to the operator, nearby personnel and/or
property damage. continued safe use. The program should include the
Also, the external conditions may show the need for dis- periodic inspections with particular attention being paid
assembly to permit a more detailed inspection which, in to the lubrication of various components using the
turn, may require the use of nondestructive type testing. recommended lubricants.
5
HOOK INSPECTION LOAD CHAIN
Hooks damaged from chemicals, deformation or Cleaning and Inspection
cracks, or that have more than a 10 degree twist First clean the load chain with a non-acid or non-caustic
from the plane of the unbent hook or excessive type solvent, then slack the chain and make a link-by-link
opening or seat wear must be replaced. inspection for nicks, gouges, twisted links and excessive
Also, on latch type hooks, hooks that are opened wear or stretching. Worn chain should be gaged through-
and allow the latch to disengage the tip, must be out its entire length and replaced if beyond serviceable
replaced. limits. Also, these chains are specially heat treated and
Any hook that is twisted or has excessive throat hardened and should never be repaired.
opening indicates abuse or overloading of the unit.
Other load sustaining components of the hoist
should be inspected for damage.
! WARNING
Check to assure latch is not damaged or bent and
that it operates properly with sufficient spring Using other than a Yale supplied load chain may
pressure to keep the latch tightly against the tip of cause the chain to jam and this, in turn may break
the hook and allow the latch to spring back to the the chain and allow the load to drop.
tip when released. If the latch does not operate To Avoid Injury:
properly, it should be replaced. Use only Hoistaloy® load chain in the Yale LH2 Hand
The charts below (Figures 7 and 8) should be used and Low Headroom Trolley Hoists.
to determine when the hook must be replaced.
Gaging Load Chain Wear
To determine if the load chain should be continued in
service, check gage lengths as indicated in Figure 9.
Chain worn beyond length indicated, nicked, gouged
or twisted should be replaced before returning the
hoist to service. Chain should be clean, free of twists
and pulled taut before measuring. To aid in checking
gage length, Yale can provide a chain gage. This can
be obtained by ordering chain gage part number 3191.
! WARNING
Worn load chain may break suddenly without visual
deformation.
To Avoid Injury:
Never use load chain for any other purposes such as
slings or tow chains. Cut worn chain into short
lengths to eliminate use after disposal.
FIGURE 7. Latch Hook Opening
FIGURE 9. Gaging Load Chain Wear

FIGURE 8. Latchlok Hook Opening 6
Note that worn chain can be an indication of HAND CHAIN
worn hoist components. For this reason, the Hand chain should be cleaned, inspected and gaged in
hoists chain guide, hook blocks and liftwheel the same manner as load chain. It is not hardened and
should be examined for wear and replaced as can be cut with a hacksaw.
necessary when replacing worn chain.
The hoist hand chain contains one unwelded connecting
The proper installation of the load chain is link. This link can be placed in a vise and twisted open
covered in the section on reeving, (see Pages to facilitate changing chain length. Additional connecting
10 through 13. links can be made by cutting the weld side of a standard
link.
Care must be taken to assure that there is no twist in
the hand chain loop.
MAINTENANCE
LUBRICATION
Load Limiter. Place a small amount of stay-put lubri-

! WARNING cant such as Moly-Duolube Style 69 (Hercules Packing
Co.) on load limiter handwheel threads. Do not allow
The lubricants used in and recommended for the lubricant to contact brake surfaces or friction surfaces
Yale LH2 Hand and Trolley Hoists may contain haz- of load limiter.
ardous materials that mandate specific handling and
disposal procedures. Gears. Lubricate the gears with Texaco Novatex #2 or
To Avoid Contact and Contamination: equal, 3 ounces for the 1/4-1 ton units and 4 ounces for
Handle and dispose of lubricants only as directed the 1-1/2-10 ton units. Spread some grease on gear
in applicable material safety data sheets and in teeth, place the balance in gear housing in contact
accordance with applicable local, state and federal with the gears.
regulations.
NOTE: To assure extra long life and top per- Geared Trolleys. Upon installation and once a month
formance, be sure to lubricate the various lubricate trackwheel gears and pinion with Texaco
parts of the Yale Hoist using the lubricants Novatex #2 or an equivalent heavy cup grease or
specified below. If desired, these lubricants graphite grease.
may be purchased from Yale. Refer to page 18
for information on ordering the lubricants. Brake. The brake parts should be thoroughly cleaned
LOAD CHAIN (by wiping with a cloth - not by washing with a
Lubricate chain with a light coat of Lubriplate®, Bar solvent) and inspected for wear or scoring. The friction
and Chain Oil (Fiske Bros. Refining Co.) or equal surfaces of the handwheel, ratchet and friction hub
lubricant. Be sure the lubricant reaches the bearing must be smooth and free from any score marks. When
surface between the links. Remove excess oil from friction washers are visibly worn to a thickness of 0.100
the chain. inches or less, scored excessively, or coated with foreign
matter, replace with new washers. Keep washers and
brake surfaces clean and dry.
! WARNING
RECOMMENDED SPARE PARTS. Refer to page 19 for
Used motor oils contain known carcinogenic materials. the list of recommended spare parts.
To Avoid Health Problems:
Never use used motor oils as a chain lubricant. EXTERIOR FINISH
Only use Lubriplate® Bar and Chain Oil 10-R as a
lubricant for the load chain. The exterior surfaces of the hoist and trolleys have a
durable, scratch resistant baked powder coating.
Normally, the exterior surfaces can be cleaned by
The hoist normally requires no additional lubri-
wiping with a cloth. However, if the finish is damaged,
cation except when a unit has been disassem-
compatible touch-up paint can be purchased from Yale.
bled for cleaning or repairs (see page 8).
Refer to page 18 for information on ordering
the paint.
NOTE: The brake is designed to operate dry.
Do not use any grease or lubricant on the
braking surfaces. On reassembly when
lubricating parts adjacent to the brake, do
not use an excessive amount of lubricant
which could seep onto the brake surfaces.
7
DISASSEMBLY Brake. Assemble the brake components per Figure 10.
Care must be exercised in disassembly of the Check the ratchet to be sure the bushing is flush with
hoist to assure proper assembly. The following or below the surface on both sides. When installed, the
pins have tapered splines and can only be teeth must face as shown in Figure 10 and engage the
removed by tapping on the end opposite the pawl. Do not lubricate. The brake operates dry.
splined grooves.
Lower Hook Block, Upper Hook Collar

and Dead End Pins
When removing or installing the Lower Hook

Block Pins (646-29J or 646-129J) on the 1/4 thru
2 ton units, the Upper Collar Pins (646-1E or 646-
101E) on the 1/4 thru 2 ton units and the Dead
End Pins (646-259) on the 3, 4, 8 and 10 ton units,
care must be taken so as to prevent damaging
the pin and/or the part into which the pin is driven.
These pins are tapered groove pins and as a
result, they can only be removed and installed in
one direction. To remove the pin, a drift and FIGURE 10. Brake Assembly
hammer (or slow acting press) are required. For
the lower hook block pins, a V-block will also be Load Limiter. Place a small amount of stay-put lubri-
necessary. The drift should be the same diameter cant such as Moly-Duolube Style 69 (Hercules Packing
as the pin (5/16” diameter for the 1/4 thru 1 ton Co.) on Load Limiter handwheel threads to lubricate
units and 7/16” diameter for the 1-1/2, 2, 3, 4, 8 the friction hub at assembly. Do not allow lubricant to
and 10 ton units) and it should be placed on the contact brake surfaces or friction surfaces of Load
small end of the pin. The small end of the pin is Limiter.
the end opposite the end on which the 3 grooves The handwheel shaft nut and washer must tighten
are visible. Place the drift on the small end of against the friction hub, not the Load Limiter (see
the pin and drive the pin out using a hammer or Figure 11). the Load Limiter must be free to revolve
slow acting press. When removing the pin from slightly on the friction hub. If the Load Limiter is
the lower hook block, the hook block should be disassembled, it must be recalibrated before being
placed in a V-block. placed in service.
To re-install the pin, the parts must be arranged
the same as they were when the pin was
removed. To do this, use the small end of the pin
as a gauge. After it is determined which end of
the hole is the largest, arrange the parts so that
the large holes are aligned and insert the small
end of the pin into the hole. Push the pin in by
hand until it stops and then use a hammer or
slow acting press to drive the pin into position
so that the end of the pin is flush with the
outside surface of the hook block body, upper
hook collar or hoist hanger.
! WARNING
Using other than the Yale supplied, high
strength pins may cause the pin to break and
allow the hoist and/or load to fall.
To Avoid Injury:
Use only the special high strength pin as
supplied by Yale.
ASSEMBLY
Consideration must be given to the following
when assembling the hoist: FIGURE 11. Load Limiter Assembly
8
Components must be assembled in the order Bearing Retainer Screws. Whenever the bearing
shown with the friction washers seated on the retainer screws have been removed and replaced,
handwheel projections. Handwheel, spring wash- they must be locked in place by prick punching the
er, lockwasher and nut must face as shown. head (see Figure 13). Always use new spots for locking.
Tighten the adjuster nut hand tight, then turn
clockwise one notch. A NOTCH is turning the nut
sufficient to bring a slot in the nut and a tang of
the lockwasher in line. The next notch brings a
different slot and tang in line.
Do not bend the lockwasher tang at this time.
The Load Limiter
must be calibrated
after assembly.
Calibration. Install
the Load Limiter
(see Figure 11) and
hand chain but not
the handwheel
cover. Mount the
hoist where a load
greater than that
shown in Table 3
can be applied.
Connect a straight
spring scale to the
hand chain so that
a pull can be
applied in the
hoisting direction.
FIGURE 12. Load Limiter Calibration FIGURE 13. Bearing Retainer Screw
Table 3 Minimum Hoist Loads & Pull Hoist Hanger. The Hoist Hanger and Hoist are not
Hoist Minimum Average Pull bolted together to form a rigid unit but can move
Capacity Load To Slip Load Limiter relative to each other.
(Tons) (Pounds) (Pounds) When installing a new hoist hanger screw (646-234A),
1/4 650 33 tighten the screw firmly and back off one flat (1/6
1/2 1,300 67 turn). Then:
1 2,600 100 3 and 4 ton hoists: Install hoist hanger set screw
1-1/2 3,900 113 (646-233B).
2 5,200 117
3 7,800 118
5 to 10 ton hoists: Using the hole in the end of the
hoist hanger as a guide, drill a 0.250 to 0.256 inch
4 10,400 121
diameter hole through the hoist hanger screw and the
5 13,000 106 other side of the hoist hanger. Complete the assembly
6 15,600 127 by driving the hoist hanger screw pin (646-234D) into
8 20,800 133 hole so that the end of the pin is flush with the end of
10 26,000 139 the hoist hanger (see Figure 14).
With the load chain taut, apply a steady pull to
the scale to slip the handwheel one revolution
(approx. 2 ft. of hand chain travel - see Figure
12). Record several pull values and obtain the
average. Disregard the initial “break free” pull -
use only values obtained after the handwheel has
started to slip. When properly adjusted, the
average pull should be as indicated in Table 3.
If the average pull is low, turn the adjuster nut
one notch clockwise and repeat the pull opera-
tion. Do this until the correct value is obtained,
then bend the lockwasher tang into the locknut
notch. Load Limiter is now ready for service.
If the handwheel does not slip or the pull is too
high, back off the adjuster nut and start over.
After the proper calibration is obtained, install
the handwheel cover. 9 FIGURE 14. Hoist Hanger
Hooks. Both upper and lower hooks must be free
to swivel. Those that are held by nuts must be
adjusted to provide 1/32” clearance as shown in
Figure 15 before the hook nut pin is inserted.
FIGURE 15. Hook Mounting

Lower Hook Thrust Bearings. The 1/4 thru 6
ton lower hook thrust bearings are mounted with
the outer shell down (see Figure 15).
Hand Chain. Hand chain must have an odd
number of links.
Join the ends with the “hand chain connecting
link”(646-45) so that there is no twist in the
completed chain loop. The connecting link must
be completely closed so that it will seat in the
handwheel the same as the welded links.
REEVING
! WARNING FIGURE 16. Reeving ⁄-fi-1 Ton Hoists

Mount hoist in a vertical position and check that the
Improper installation (reeving) of the load
lower hook is on the same side of the liftwheel as the
chain can result in a dropped load.
upper hook and in line with it.
To Avoid Injury:
Reeve and attach the ends of the load in 1-1/2-2 Ton Hoists
accordance with the following instructions.
Attach approximately 20 inches of wire to the loose
end of the load chain. Feed the wire around the lift-
1/4-1/2-1 Ton Hoists wheel as shown in Figure 17 until the first link starts
over it. The first link must lay flat on the liftwheel.
Attach approximately 20 inches of wire to the The second link must stand on edge with the weld
loose end of the load chain. Feed the wire around away from the liftwheel. After the chain has been
the liftwheel as shown in Figure 16 until the first started, pull the hand chain or turn the handwheel in
link starts over it. The first and third links must the hoisting direction until about 2 feet of load chain
stand on edge with the weld away from the lift- has passed over the liftwheel.
wheel. After the chain has been started, pull the
hand chain or turn the handwheel in the hoisting If it become difficult to pull the hand chain in the
direction until about 2 feet of load chain has hoisting direction, pull it in the lowering direction to
passed over the liftwheel. release the load chain. Start over. This will prevent the
load chain from being jammed between the liftwheel
If it becomes difficult to pull the hand chain in and frame.
the hoisting direction, pull it in the lowering
direction to release the load chain. Start over. This Remove the wire and attach the loose end of chain to
will prevent the load chain from being jammed the hoist using the loose end screw, washer and lock-
between the liftwheel and frame. washer (see Figure 17). The chain must not be twisted
between the liftwheel and loose end screw.
Remove the wire and attach the loose end of
chain to the hoist using the loose end screw and Mount hoist in a vertical position and check that the
washer (see Figure 16). The chain must not be lower hook is on the same side of the liftwheel as the
twisted between the liftwheel and loose end screw. upper hook and in line with it.
10
Loose End of Chain
Dead End Pin
Hand Chain omitted

for clarity
FIGURE 17. Reeving 1fi-10 Ton Hoists

3-4 Ton Hoists
FIGURE 18. Reeving 3-4 Ton Hoists
Load chain must have an even number of links.
Check at each stage of assembly to be sure chain 5-6 Ton Hoists
has no twist. Load chain must have an even number of links. Check
Attach approximately 20 inches of wire to one end at each stage of assembly to be sure chain has no twist.
of the load chain. Feed the wire around the lift- Attach approximately 20 inches of wire to one end of
wheel as shown in Figure 17 until the first link starts the load chain. Feed the wire around the liftwheel as
over it. The first link must lay flat on the liftwheel. shown in Figure 17 until the first link starts over it. The
The second link must stand on edge with the weld first link must lay flat on the liftwheel. The second link
end away from the liftwheel. After the chain has must stand on edge with the weld away from the lift-
been started, pull the hand chain or turn the handwheel. After the chain has been started, pull the hand
wheel in the hoisting direction until about 2 feet of chain or turn the handwheel in the hoisting direction
load chain has passed over the liftwheel. until about 2 feet of load chain has passed over the
If it becomes difficult to pull the hand chain in liftwheel.
the hoisting direction, pull it in the lowering If it becomes difficult to pull the hand chain in the
direction to release the load chain. Start over. hoisting direction, pull it in the lowering direction to
This will prevent the load chain from being release the load chain. Start over. This will prevent the
jammed between the liftwheel and frame. load chain from being jammed between the liftwheel
Remove the wire and attach the loose end of and frame.
chain to the hoist using the loose end screw,
washer and lockwasher (see Figure 17). Remove the wire and attach the loose end of chain
to the hoist using the loose end screw, washer and
Mount hoist in a vertical position. Operate in lockwasher (see Figure 17).
the hoisting direction until the remaining load
end of chain is approximately 5 feet long. Reeve Mount hoist in a vertical position. Operate in the
load end of chain as shown in Figure 18 in the hoisting direction until the remaining load end of chain
following sequence. is approximately 10 feet long. Reeve load end of chain
as shown in Figure 19 in the following sequence.
1. Down around the lower hook block sheave.
2. Up the the hoist hanger. 1. Down around the lower hook block sheave.
Secure chain end to hoist hanger with dead end 2. Up around the hoist hanger sheave.
pin. The first link around the hook block sheave
3. Down the lower hook block.
must stand on edge (be upstanding).
11
Place end of chain in slot in top of hook block Reeve load end of chain as shown in Figure 20 in the
and secure in place with hook block screw, lock- following sequence.
washer and nut. The first link around the hook
1. Down around the lower hook block sheave.
block and hanger sheaves must stand on edge
(be upstanding). 2. Up around the hoist hanger sheave.
3. Down around the second hook block sheave.
4. Up the the hoist hanger.
Secure end of chain to the chain anchor with the dead
end pin. The first link around the hook block sheaves
must stand on edge and the first link around the hoist
Loose End of Chain hanger sheave must lay flat.
Dead End Pin in

Chain Anchor Loose End of Chain
Hand Chain omitted

for clarity
FIGURE 19. Reeving 5-6 Ton Hoists

8 Ton Hoists
Hand Chain omitted
Load chain must have an even number of links. for clarity
Check at each stage of assembly to be sure chain
has no twist.
Attach approximately 20 inches of wire to one FIGURE 20. Reeving 8 Ton Hoists
end of the load chain. Feed the wire around the 10 Ton Hoists
liftwheel as shown in Figure 17 until the first link
starts over it. The first link must lay flat on the Load chain must have an odd number of links. Check at
liftwheel. The second link must stand on edge each stage of assembly to be sure chain has no twist.
with the weld away from the liftwheel. After the Attach approximately 20 inches of wire to one end of
chain has been started, pull the hand chain or the load chain. Feed the wire around the liftwheel as
turn the handwheel in the hoisting direction shown in Figure 17 until the first link starts over it. The
until about 2 feet of load chain has passed over first link must lay flat on the liftwheel. The second link
the liftwheel. must stand on edge with the weld away from the lift-
wheel. After the chain has been started, pull the hand
If it becomes difficult to pull the hand chain in chain or turn the handwheel in the hoisting direction
the hoisting direction, pull it in the lowering until about 2 feet of load chain has passed over the lift-
direction to release the load chain. Start over. wheel.
This will prevent the load chain from being If it becomes difficult to pull the hand chain in the hoist-
jammed between the liftwheel and frame. ing direction, pull it in the lowering direction to release
the load chain. Start over. This will prevent the load
Remove the wire and attach the loose end of
chain from being jammed between the liftwheel and
chain to the hoist using the loose end screw, frame.
washer and lockwasher (see Figure 17).
Remove the wire and attach the loose end of chain to
Mount hoist in a vertical position. Operate in the the hoist using the loose end screw, washer and lock-
hoisting direction until the remaining load end washer (see Figure 17).
of chain is approximately 15 feet long. 12
(1) Use a grinder and nick the link on both sides
(see Figure 22), then secure the link in a vise
and break off with a hammer.
(2) Use a 7 inch minimum diameter by 1/8 thick

abrasive wheel (of type recommended by wheel
supplier) that will clear adjacent links.
Yale
(3) Chain may also be cut using a bolt cutter (see
Figure 23) similar to the H.K. Porter No. 0590MTC
with special cutter jaws for cutting hardened
chain (1 inch long cutting edge).
FIGURE 23. Cutting Chain with a Bolt Cutter
FIGURE 21. Reeving 10 Ton Hoists

Mount hoist in a vertical position. Operate in the
hoisting direction until the remaining load end ! WARNING
of chain is approximately 20 feet long. Reeve
Cutting chain can produce flying particle.
load end of chain as shown in Figure 21 in the
following sequence. To Avoid Injury:
• Wear eye protection.
1. Down around the lower hook block sheave. • Provide a shield, such as a heavy rag, over the chain
2. Up around the hoist hanger sheave. to prevent flying particles.
3. Down around the second hook block sheave.
4. Up around the second hoist hanger sheave.
TESTING
5. Down to the lower hook block.
Prior to initial use, all altered or repaired hoists or used
Secure end of chain to the hook block with the
hoists that have not been operated for the previous 12
dead end pin. The first link around the hook block
sheaves must lay flat and the first link around the months shall be tested by the user for proper opera-
hoist hanger sheaves must stand on edge. tion.
Cutting Chains Test the unit first in the unloaded state and then with
a light load of 50 pounds times the number load sup-
Hoistaloy load chain is hardened for wear
®
resistance and is difficult to cut. However, the porting parts of load chain to be sure it operates prop-
following methods are recommended when erly and the brake holds the load when the hand chain
cutting a length of new chain from stock or cutting is released; then test with a load of *125% of rated
off a length of worn chain. capacity by or under the direction of an appointed per-
son and a written report prepared for record purposes.
After this test, the function of the Load Limiter is to be

tested (see Table 3, page 9).
*
If load limiter prevents lifting of a load of 125% of rated capacity, reduce load
to rated capacity.
NOTE: For additional information on inspection

and testing, refer to the current issue of ASME
B30.16 “Overhead Hoists” obtainable from ASME
Order Department, 22 Law Drive, Box 2300,
Fairfield, NJ 07007-2300, U.S.A.
FIGURE 22. Cutting Chain by Nicking
13
TROUBLESHOOTING
For disassembly and assembly follow instructions on pages 8 through 13. Always test the Yale LH2 Hoists under
load after reassembly of any parts to be sure it operates properly and holds the load when the hand chain is
released.
PROBLEM CAUSE MAY BE REMEDY
1 Hoist is hard to A) Load chain worn long to gage, thus A) Check gage of chain (see Page 6). Replace
operate in either binding between liftwheel and chain guide. if worn excessively.
direction. B) Load chain rusty, corroded or clogged up B) Clean by tumble polishing or using a non-
with foreign matter such as cement or acid or non-caustic type solvent. Lubricate
mud. with Lubriplate® Bar and Chain Oil 10-R
(Fiske Bros. Refining Co.) or equal lubricant.
C) Load chain damaged. C) Check chain for gouges, nicks, bent or
twisted links. Replace if damaged.
D) Liftwheel clogged with foreign matter or D) Clean out pockets. Replace if worn
worn excessively, causing binding between excessively.
the liftwheel and chain guide.
E) Hand chain worn long to gage, thus E) Check gage of chain (see Page 6).
binding between handwheel and cover.
F) Handwheel clogged with foreign mater or worn. F) Clean out pockets. Replace if worn excessively.
G) Liftwheel or gear teeth deformed. G) Excessive overload has been applied.
Replace damaged parts.
2. Hoist is hard to A) Brake parts corroded or coated with A) Disassemble brake and clean thoroughly.
operate in the foreign matter. (By wiping with a cloth - not by washing
lowering direction. in a solvent). Replace washers if gummy,
visibly worn or coated with a foreign
matter. Keep washers and brake surfaces
clean and dry.
B) Chain binding. B) See Items 1A, 1B and 1C.
3. Hoist is hard to A) Chain binding. A) See Items 1A, 1B and 1C.
operate in the hoisting
direction. B) Chain twisted. (3 ton capacity or larger). B) Rereeve chain on 3 and 4 ton unit, if both
chains are twisted, capsize hook block
through loop in chain until twists are
removed. Caution - do not operate unit in
hoisting direction with twisted chain or
serious damage will result.
C) Overload. C) Reduce load or use correct capacity hoist.
4) Hoist will not operate A) Liftwheel gear key or friction hub key A) Install or replace key.
in either direction. missing or sheared.
B) Gears jammed. B) Inspect for foreign matter in gear teeth.
5) Hoist will not operate in A) Locked brake due to a suddenly applied A) With hoist under load keep chain taut,
the lowering direction. load, shock load, or load removed by pull sharply on hand chain in the lowering
means other than by operating unit in direction to loosen brake.
the lowering direction.
B) Chain binding. B) See Items 1A, 1B and 1C.
C) Lower hook all the way out. Load chain C) Chain taut between the liftwheel and loose end
fully extended. screw. Operate unit in hoisting direction only.
6. Hoist will not operate A) Chain binding. A) See Items 1A, 1B and 1C.
in the hoisting direction.
7. Hoist will not hold load A) Lower hook or load side of chain on A) Lower hook must be on same side of lifwheel
in suspension. wrong side of liftwheel. as upper hook.
B) Ratchet assembled in reverse. B) Ratchet must be assembled as shown in Figure 10.
C) Pawl not engaging with ratchet. C) Pawl spring missing or broken. Pawl binding on
pawl stud. Replace spring and clean so pawl
operates freely and engages properly with
ratchet. Do not oil.
D) Ratchet teeth or pawl worn or broken. D) Replace pawl and/or ratchet.
E) Worn brake parts. E) Replace brake parts which are worn.
F) Oily, dirty or corroded brake friction surfaces.
14
PARTS LIST
ORDERING INFORMATION For parts orders also specify:
The following information must accompany all 1) Quantity desired.
correspondence or repair parts orders. 2) Key number of part.
1) Hoist capacity. 3) Part name.
4) Part number.
2) Serial Number - this is stamped on the hoist
frames as shown below. When ordering replacement parts, consideration
should be given to the need to replace other items:
bearings, fasteners, gaskets, etc. Items that may be
damaged or lost during disassembly or just unfit for
future use because of deterioration from age or service.
! WARNING
Using “Commercial” or other manufacturer’s parts to
repair the Yale LH2 Hand and Low Headroom Trolley
Hoists may cause load loss.
To Avoid Injury:
I.D. Label
Order all replacement parts from Yale. Parts may
646-276
look alike but often Yale parts are made of specific
materials or processed to achieve specific properties.
Parts should be ordered from Yale’s Authorized Parts

Depots conveniently located throughout the United
States. Refer to page i of this manual to locate the
parts depot nearest you.
I.D. Label
646-276
15
YALE LH2 HAND HOIST PARTS LIST
Capacity - Ton
Key No. 1/4 & 1/2 1 1-1/2 & 2 3&4 5&6 8 & 10
No. Req’d Part Name Part Number
646-1 1 Frame with Upper Hook (includes Items 646-1A
thru 646-1F and 646-15) - Not Shown C701Y C702Y --
646-1A 1 Frame 45612Y --
646-1B 1 Upper Hook (Includes Latch) - Latch Type 45601Y 45602Y --
646-1B 1 Upper Hook - Latchlok Type 1020 1022 --
646-1C 2 Upper Hook Washer 45930 --
646-1D 1 Upper Hook Collar 41350 27359 --
646-1E 1 Upper Hook Collar Pin 45940 45941 --
646-1F 1 Upper Hook Sleeve 45390 -- --
646-2A 1 Load Chain Guide 45047 45048 --
646-2B 2 Load Chain Guide Screw 945807 --
646-2C 2 Load Chain Guide Screw L.W. 945851 --
646-3A 1 Stripper 45043 --
646-3B 3 Stripper Screw 983745 --
646-3C 1 Stripper Screw L.W. 940830 --
646-4 1 Handwheel Shaft and Pinion with Bearings (Items
1 646-4A thru 646-4D - Not Shown) C703 C704 --
646-4A 1 Handwheel Shaft and Pinion 45353 45354 --
646-4B 1 Pinion Shaft Bearing (Handwheel End) 88437 --
646-4C 1 Pinion Shaft Bearing (Gear End) 88444 --
646-4D 1 Handwheel Shaft Snap Ring 45873 --
646-5 1 Pawl 45038
646-5A 1 Pawl Bushing 45735
646-6 1 Pawl Retaining Washer 45910
646-7 1 Pawl Stud Snap Ring 45767
646-8 1 Pawl Spring 45730
646-9 1 Brake Assembly (Items 646-9A, 646-9B and 646-
9CD) - Not Shown C705
646-9A 1 Friction Hub 45007
646-9B 2 Friction Washer 45741 For Units With Load Limiter, 45831 For Units Without Load Limiter
646-9CD 1 Ratchet with Bushing 45614
646-9D 1 Ratchet Bushing 45718
646-10 1 Non-Load Limiter Handwheel 46699
646-11 1 Handwheel Shaft Nut Washer 45915
646-12 1 Handwheel Shaft Nut 931717
646-13 1 Friction Hub Key 45770
646-14 1 Handwheel Cover 46236
646-14A 1 Cover Label 46200
646-15 1 Operating Instruction Label (See Page 16) - Not Shown 946900
646-15A 3 Handwheel Cover Screw 982698
646-16 1 Liftwheel with Bearings (Items 646-16A thru 646-16D)
1 - Not Shown C706 C707 --
646-16A 1 Liftwheel 45364 45365 --
646-16B 1 Liftwheel Bearing (Handwheel End) 88489 --
646-16C 1 Liftwheel Bearing (Gear End) 88429 --
646-16D 1 Liftwheel Snap Ring 45871 --
646-17A 1 Frame Bearing Retainer 45750 --
646-17B 2 Frame Bearing Retainer Screw 987716 --
646-18 1 Liftwheel Gear 45061 45060 --
646-19 1 Liftwheel Gear Key 989101 --
646-20 1 Liftwheel Gear Snap Ring 68703 --
646-24 1 Gear Cover with Capacity Insert C708Y for 1/4 Ton, C721Y for 1/2 Ton and C722Y for 1 Ton
46705 (1/4 Ton) --
646-24A 1 Capacity Insert 46706 (1/2 Ton) --
46707 (1 Ton) --
646-24B 2 Capacity Insert Pin 988271
646-24C 3 Gear Cover Screw 987322 --
646-24D 1 Gear Cover Gasket 45747 --
646-25A 1 Loose End Screw 946801 --
646-25B 1 Loose End Screw Washer 954807 --
646-29 1 Lower Hook and Block Assembly-Latch Type Hook 28683 45668 --
646-29A 1 Lower Hook with Latch-Latch Type Hook 28686 35611
646-29A 1 Lower Hook-Latchlok Type Hook 1051 --
646-29B 1 Hook Block Body 45401 --
646-29D 1 Lower Hook Washer 945921 --
646-29E 1 Lower Hook Thrust Bearing 88485 --
646-29F 1 Lower Hook Nut 982526
646-29G 1 Lower Hook Nut Pin 983772 --
646-29H 1 Lower Hook Chain Block 28007 45016 --
646-29J 1 Hook Block Pin 45943 --
646-30 1 Load Chain (Specify Lift or Length Req’d) 85839 85841 --
646-31 1 Hand Chain (Specify Lift or Length Req’d) 85808
646-32 1 Warning Tube 946735
646-38 2 Latch Kit 45661 45662 --
646-45 1 Hand Chain Connecting Link 945490
646-101 1 Frame with Upper Hook (Includes Items 646-101A
thru 646-101E and 646-15) - Not Shown -- C730Y --
646-101A 1 Frame -- 45613Y
16
Capacity - Ton
Key No. 1/4 & 1/2 1 1-1/2 & 2 3&4 5&6 8 & 10
646-101B 1 Upper Hook (Includes Latch) Latch Type -- 45604Y --
646-101B 1 Upper Hook-Latchlok Type -- 1023 --
646-101C 2 Upper Hook Washer -- 45918 --
646-101D 1 Upper Hook Collar -- 35478 --
646-101E 1 Upper Hook Collar Pin -- 45946 --
646-102A 1 Load Chain Guide -- 45049
646-102B 3 Load Chain Guide Screw -- 945815
646-102C 3 Load Chain Guide Screw L.W. -- 45852
646-103A 1 Stripper -- 45420
646-103B 2 Stripper Screw -- 982709
646-104 1 Handwheel Shaft and Pinion with Bearings (Items -- C710 For 1-1/2 & 3 Ton, C711
646-104A, 646-104B and 646-104C) - Not Shown -- For 2, 4, 5, 6, 8 & 10 Ton
646-104A 1 Handwheel Shaft and Pinion -- 45355 for 1-1/2 & 3 Ton, 45356 for 2, 4, 5, 6, 8 & 10 Ton
646-104B 1 Handwheel Shaft Bearing (Handwheel End) -- 88437
646-104C 1 Handwheel Shaft Bearing (Pinion End) -- 83671
646-116 1 Liftwheel with Bearings (Items 646-116A thru --
646-116E) - Not Shown C712
646-116A 1 Liftwheel -- 45057
646-116B 1 Liftwheel Bearing (Handwheel End) -- 88445
646-116C 1 Liftwheel Bearing (Gear End) -- 83669
646-116D 1 Liftwheel Snap Ring -- 45766
646-116E 1 Liftwheel Bearing Retaining Ring (Gear End) -- 46800
646-118 1 Liftwheel Gear -- 45008
646-119 2 Liftwheel Dowel Pin -- 45771
646-121 1 Intermediate Gear and Pinion with Bearings (Items C713 for 1-1/2 & 3 Ton, C714 for 2, 4, 5, 6, 8 & 10 Ton
646-121A, 646-121B and 646-121C) - Not Shown
646-121A 1 Intermediate Gear & Pinion -- 45014 for 1-1/2 & 3 Ton (7 & 45 Teeth)
-- 45015 for 2, 4, 5, 6, 8 & 10 Ton (7 & 47 Teeth)
646-121B 1 Intermediate Gear Bearing (Pinion End) -- 83682
646-121C 1 Intermediate Gear Bearing (Cover End) -- 88437
646-122 2 Gear Cover Dowel -- 46730
646-124 1 Gear Cover with Capacity Insert C715Y for 1-1/2 Ton, C723Y for 2 Ton, C724Y for 3 Ton, C725Y for 4 Ton,
C726Y for 5 Ton, C727Y for 6 Ton, C728Y for 8 Ton & C729Y for 10 Ton
46708 (1-1/2 Ton), 46709 (2 Ton), 46710 (3 Ton)
646-124A 1 Capacity Insert 46711 (4 Ton), 46712 (5 Ton), 46713 (6 Ton),
46714 (8 Ton), 46715 (10 Ton)
646-124B 2 Capacity Insert Pin -- 988271
646-124C 3 Gear Cover Screw -- 983732
646-124D 1 Gear Cover Gasket -- 46704
646-125A 1 Loose End Screw -- 945815
646-125B 1 Loose End Screw L.W. -- 945852
646-125C 1 Loose End Screw Washer -- 954806
646-129 1 Lower Hook and Block Assembly-Latch Type Hook -- 45669 --
646-129A 1 Lower Hook with Latch-Latch Type Hook -- 45603 --
646-129A 1 Lower Hook-Latchlok Type Hook -- 1024 --
646-129B 1 Hook Block Body -- 45399 --
646-129E 1 Lower Hook Thrust Bearing -- 88505
646-129F 1 Lower Hook Nut -- 45382
646-129G 1 Lower Hook Nut Pin -- 983779
646-129H 1 Lower Hook Chain Block -- 45017
646-129J 1 Hook Block Pin -- 45948
646-130 1 Load Chain (Specify Lift or Length Req’d) 85839 85864
646-131 1 Hand Chain (Specify Lift or Length Req’d) 85808
646-132 1 Load Limiter Complete 44602 for 1/4 Ton, 44601 for 1/2 Ton, 44600 for 1 thru 10 Ton
646-133 1 Handwheel Sub-Assembly 45675
646-134 1 Load Limiter Hub 45012
646-135 2 Friction Washer 45886
646-136 1 Steel Washer 45032
646-137 1 Spring Washer 45888
646-138 1 Lockwasher 45033
646-139 1 Nut 45737
646-144 2 Latch Kit -- 45663 --
646-201B 1 Upper Hook (Includes Latch)-Latch Type -- 45607Y 45606Y (5T.) 45609Y
40607Y (6T.)
646-201B 1 Upper Hook-Latchlok Type -- 1025 1027 1028
646-201C 2 Upper Hook Washer -- 40736 988005
646-201E 1 Upper Hook Nut Pin -- 983787 983788
646-201F 1 Upper Hook Nut -- 940834 945836
646-206 2 Latch Kit -- 45664 45664 (5T.) 45697
45665 (6T.)
46230 for 3 Ton, 46231 for 4 Ton.
646-229 1 Lower Hook Block Assembly - Not Shown 46232 for 5 Ton, 46233 for 6 Ton
46234 for 8 & 10Ton
646-229A 1 Lower Hook (Includes Latch)-Latch Type -- 45605 45606 (5T.) 45609
40607 (6T.)
646-229A 1 Lower Hook-Latchlok Type -- 1026 1027 1028
17
Capacity - Ton
Key No. 1/4 & 1/2 1 1-1/2 & 2 3&4 5&6 8 & 10
646-229B 1 Lower Hook Sleeve -- 45394 45393 45410
646-229G 1 Lower Hook Pin -- 983787 983788
646-229K 1 Lower Hook Nut -- 940834 945836
646-229L 1 Lower Hook Thrust Bearing -- 88507 88511
646-233A 1 Hoist Hanger (Also order 646-234A and 646-234B
or 646-234D as applicable) -- 45090Y 45091Y 45094Y
646-233B 1 Hoist Hanger Set Screw -- 986304 --
646-234A 1 Hoist Hanger Screw (Also order 646-234B or
646-234D as applicable) -- 987223 987179
646-234C 1 Hoist Hanger Screw Washer -- 945916 --
646-234D 1 Hoist Hanger Screw Pin -- 983789
646-235 1 Hoist Hanger Screw Sleeve -- 45391 --
646-236 1 Hoist Hanger Sheave Cap (Tapped) -- 45123Y
646-237 1 Hoist Hanger Sheave Cap (Drilled) -- 45124Y
646-238 1 Hoist Hanger Chain Anchor -- 45134Y (8T.)
646-239 1 or 2 Hoist Hanger Sheave -- 45085 45106
646-241 1 or 2 Hoist Hanger Bearing -- 88542
646-242 2 Hoist Hanger Sheave Bearing -- 83670 --
646-243 1 Hoist Hanger Snap Ring -- 45765 --
646-244 2 Hoist Hanger Bearing Retainer -- 45151 --
646-245 2 Hoist Hanger Sheave Shaft -- 45425
646-246A 1 Hoist Hanger Sheave Shaft Bolt -- 89411
646-246B 1 Hoist Hanger Sheave Shaft Bolt L.W. -- 987919
646-247 2 Lower Hook Block (Also order Capacity Insert 45107Y (3T.)
646-275 for 5 & 6 Ton Units) -- 45096Y (4T.) 45101Y --
646-248 1 Lower Hook Block Body (Also order Capacity
Insert 646-275) -- 45104Y
646-249A 3 Lower Hook Block Screw -- 945796 45812 --
646-249B 3 Hook Block Screw Nut -- 945820 945822 --
646-249C 3 Hook Block Screw L.W. -- 945851 945853 --
646-250 1 or 2 Hook Block Sheave -- 45086 45106
646-252 1 or 2 Hook Block Sheave Bearing -- 88542
646-253 2 Hook Block Sheave Bearing -- 83670 --
646-254 1 or 2 Hook Block Sheave Shaft -- 45425
646-256A 1 Hook Block Sheave Shaft Bolt -- 89411
646-256B 1 Hook Block Sheave Shaft Bolt L.W. -- 987919
646-257 1 Hook Block Sheave Cap (Tapped) -- 45123Y
646-258 1 Hook Block Sheave Cap (Drilled) -- 45124Y
646-259 1 Dead End Pin -- 45945 -- 45944
646-260 2 Reeving Caution Plate -- 45757 --
646-275 1 Capacity Insert 46712 for 5 Ton, 46713 for 6 Ton, 45837 for 8 Ton & 45838 for 10 Ton
646-276 1 I.D. Label 46211 46210
Part Numbers for packaged lubricants used in

Yale LH2 Hand and Low Headroom Trolley Hoists
Lubricant Type of Part Numbers
Usage Lubricant and Packaged
*These are not furnished by Yale in Packaged Quantities.
Quantities of
When ordering lubricants, specify the type of lubricant, part number and
Lubricants
packaged quantity required.
Gears Grease 28610 (1#can)
Touch-up Paints for Yale LH2 Hand and Low Headroom Trolley Hoists:
28632 (4#can)
1. Hoist. Order *(1) case (12-12 oz. Aerosol Cans) of Yellow Touch-up paint
Part Number 40215.
Handwheel Spray 46698 (16 oz.)
2. Trolley. Order *(1) case (12-12 oz. Aerosol Cans) of Black Touch-up paint
Threads
Part Number 84189.
*Touch-up paints are only available in case quantities.
Chain Oil 28608 (1 pt. can)
28619 (1 gal. can)
NOTE: When painting hoists or trolleys, also order warning labels,
identification labels, etc. that may be coated during painting.
Trackwheel Grease 28610 (1#can)
Bearings 28632 (4#can)
Trackwheel *Heavy Cup --

Gears Grease
Handwheel *Light Machine --

Shaft Oil
18
RECOMMENDED SPARE PARTS
To insure continued service of the Yale LH2 Hand and Low Headroom Trolley Hoist, the following is a
list of the parts that are recommended to be kept on hand at all times to replace parts that are worn.
Key No. Part Name Qty. for each Hoist in service

646-5 Pawl 1
646-5A Pawl Bushing 1
646-6 Pawl Retaining Washer 1
646-7 Pawl Stud Snap Ring 1
646-8 Pawl Spring 1
646-9B Friction Washer 2
646-24D Gear Cover Gasket (1/4, 1/2 & 1 T.) 1
646-124D Gear Cover Gasket (1-1/2 - 10T.) 1
648-124C Gear Cover Gasket (Trolley Hoist) 1
Refer to page 15 for ordering instructions and parts lists for part numbers.
NOTES
19
20
Yale
21
22
23
24
YALE LOW HEADROOM TROLLEY HOIST PARTS LIST
Capacity - Ton
Key No. 1/2 & 1 1-1/2, 2 & 3 4, 5 & 6
No. Req’d. Part Name Part Number
648-1 1 Main Frame 48001Y --
648-2A 1 Load Chain Guide 45047 (1/2 T.) --
45048 (1T.)
648-2B 2 Load Chain Guide Screw 982368 --
648-2C 2 Load Chain Guide Screw L.W. 945851 --
648-3A 1 Stripper 45043 --
648-3B 2 Stripper Screw-Long 982709 --
648-3C 3 Stripper Screw L.W. Order 648-3B & 648-3D --
648-3D 1 Stripper Screw-Short 987315 --
648-4A 1 Handwheel Shaft & Pinion 45357 (1/2 T.) --
45358 (1 T.)
648-4B 1 Handwheel Shaft Bearing (Handwheel End) 88437 --
648-4C 1 Handwheel Shaft Bearing (Gear End) 88444 --
648-4D 1 Handwheel Shaft Snap Ring 45873 --
648-14B 1 Cover Label 46216
648-15A 3 Handwheel Cover Screw 982698 --
648-16A 1 Liftwheel 48362 (1/2 T.) --
48368 (1 T.)
648-16B 1 Liftwheel Bearing (Handwheel End) 88429 --
648-16C 1 Liftwheel Bearing (Gear End) 83674 --
648-16D 2 Liftwheel Snap Ring 48704 --
648-17A 1 Frame Bearing Retainer 48702 --
648-17B 2 Frame Bearing Retainer Screws 987716 --
648-20 1 Liftwheel Shaft Nut 945841 --
648-24B 3 Gear Cover Screw 987322 --
648-30 1 Load Chain (Specify Lift or Length Req’d.) 85839 (1/2 T.) --
85841 (1 T.)
648-31 1 Hand Chain (Specify Lift or Length Req’d.) 85808 --
648-32 1 Warning Tube 946735
648-33 1 I.D. Plate 46219
648-34 2 Drive Screw 988271
648-45 1 Hand Chain Connecting Link 945490 --
648-60 1 Front Frame with Pawl Stud and Pawl Spring Pin 48611Y --
648-60B 1 Pawl Spring Pin 983531 --
648-60C 1 Pawl Stud Pin 983494 --
648-60D 1 Pawl Stud 48376 --
648-61A 4 Front Frame Screw 987019 --
648-61B 4 Front Frame Screw L.W. 945851 --
648-62 2 Trolley Frame *48005 --
648-63A 2 Suspension Bolt *48371 --
648-63B 4 Suspension Bolt Nut 948803 --
648-63C 4 Suspension Bolt Cotter Pin 988343 --
648-64 - Spacer Washer (Specify Quantity) 948700 --
648-65 4 Trackwheel *50762 --
648-66A 4 Trackwheel Stud *48300 --
648-66B 4 Trackwheel Stud Nut *948804 --
648-66C 4 Trackwheel Stud Nut L.W. *987924 --
648-101 1 Main Frame -- **48010Y for 1-1/2 & 2 Ton, 48010Y for 3 Ton,
48013Y for 4, 5 & 6 Ton
648-102A 1 Load Chain Guide -- 45049
648-102B 3 Load Chain Guide Screw -- 948805
648-102C 3 Load Chain Guide Screw L.W. -- 45852
648-103A 1 Stripper -- 48043
648-103B 1 Stripper Screw -- 87055
648-103C 1 Stripper Screw L.W. -- 987919
45360 (10 Teeth, 18-7/64 Long) for
648-104A 1 Handwheel Shaft and Pinion -- 1-1/2 & 3 Ton, 45359 (8 Teeth, 18-7/64
Long) for 2 Ton and 45361 (8 Teeth,
20-47/64 Long) for 4, 5 & 6 Ton.
648-104B 1 Handwheel Shaft Bearing (Handwheel End) -- 88437
648-104C 1 Handwheel Shaft Bearing (Gear End) -- 83671
648-112 2 Handwheel Shaft Nut -- 931717
648-115A 3 Handwheel Cover Screw -- 982698
648-116A 1 Liftwheel -- 48369 48370
648-116B 1 Liftwheel Bearing (Handwheel End) -- 83678
648-116C 1 Liftwheel Bearing (Gear End) -- 83669
648-116D 1 Liftwheel Snap Ring -- 45766
648-117A 1 Frame Bearing Retainer -- 45751
648-117B 2 Frame Bearing Retainer Screw -- 987716
648-121D 1 Intermediate Gear and Pinion Nut -- 931717
648-122A 1 Spider -- 45035
648-122B 2 Spider Dowel -- 45430
648-122C 3 Spider Attaching Screw -- 982689
648-122D 3 Spider Attaching Screw L.W. -- 940830
*Part numbers listed are for trolleys that operate on 6” thru 12” S-beams. If trolley operates on 4” or 5” S-beam, part numbers are as follows: 48006 for
648-62 trolley frame, 48373 for 648-63A suspension bolt, 54732 for 648-65 trackwheel, 54731 for 648-66A trackwheel stud, 982521 for 648-66B trackwheel
stud nut and 987921 for 648-66C trackwheel stud nut lockwasher.
**Part number listed is for trolley that operates on 7” thru 15” S-beams. If trolley operates on 6” S-beam, part number is 48032Y (1-1/2 & 2 Ton).
25
YALE LOW HEADROOM TROLLEY HOIST PARTS LIST
Capacity - Tons
Key No. 1/2 & 1 1-1/2, 2 & 3 4, 5 & 6
No. Req’d. Part Name Part Number
648-123A 1 Spider Bearing Retainer -- 45752
648-123B 2 Spider Bearing Retainer Screw -- 987716
648-124A 1 Gear Cover -- 45717Y
648-124B 3 Gear Cover Screw -- 983732
648-124C 1 Gear Cover Gasket -- 45746
648-130 1 Load Chain (Specify Lift or Length Req’d.) -- 85864
648-131 1 Hoist Hand Chain (Specify Lift or Length Req’d.) -- 85808
648-145 1 Hand Chain Connecting Link -- 945490
648-160 1 Front Frame with Pawl Stud and Pawl Spring Pin -- 48612Y
648-160B 1 Pawl Spring Pin -- 983531
648-160C 1 Pawl Stud Pin -- 983535
648-160D 1 Pawl Stud -- 48376
648-161A 4 Front Frame Screw -- 987020
648-161B 5 Front Frame Screw L.W. -- 945851
648-161C 1 Front Frame and Stripper Screw -- 948807 987034
648-162A 1 Trolley Frame (Specify if for Plain or Geared) -- 48668 48670
48667 for 1-1/2, 2 & 3 Ton Plain Trolley
648-162B 1 Trolley Frame (Specify if for Plain or Geared) 46664 for 1-1/2, 2 & 3 Ton Geared Trolley
-- 48669 for 4, 5 & 6 Ton Plain Trolley
46665 for 4, 5 & 6 Ton Geared Trolley
58503 (1” Dia. x 12-1/4” Long) for
648-163A 2 Suspension Bolt -- 1-1/2, 2 and 3 Ton. 48372 (1-1/4 Dia.
x 15”Long) for 4, 5 & 6 Ton
648-163B 4 Suspension Bolt Nut -- 958818 945835
648-163C 4 Suspension Bolt Cotter Pin -- 988368 988381
648-164 -- Spacer Washer (Specify Quantity) -- 958726 948701
648-165A 4 Trackwheel -- 58162 58163
648-165B 8 Trackwheel Bearing Cup -- 88521 88556
648-165C 8 Trackwheel Bearing Cone -- 88525 88545
648-165D 8 Trackwheel Bearing Seal Washer -- 68918 68917
648-166A 4 Trackwheel Stud -- 58459 58540
648-166B 4 Trackwheel Stud Nut -- 982613 988192
648-166C 4 Trackwheel Stud Collar -- 58484 58492
648-167 1 Gear Housing -- 48015Y
648-168A 5 Gear Housing Screw -- 948806 948807
648-168B 5 Gear Housing Screw L.W. -- 945851
648-169A 2 Trackwheel Gear -- 58548 58549
648-169B 4 Trackwheel Gear Pin -- 983503
648-170 1 Trackwheel Pinion -- 46385
648-171 1 Trackwheel Pinion Key -- 85446
648-172 1 Trolley Handwheel -- 33143
648-173 1 Trolley Handwheel Key -- 59967
648-174A 1 Handwheel Bracket with Bushings -- 59616
648-174B 2 Handwheel Bracket Bushing -- 58727
648-175A 3 Handwheel Bracket Screw -- 987061
648-175B 3 Handwheel Bracket Screw L.W. -- 945853
648-176 1 Trolley Hand Chain Guide -- 58152
648-177A 1 Trolley Hand Chain Guide Screw -- 987065
648-177B 1 Trolley Hand Chain Guide Screw Nut -- 945822
648-177C 1 Trolley Hand Chain Guide Screw L.W. -- 945853
648-177D 1 Trolley Hand Chain Guide Screw Washer -- 986224
648-178A 1 Trolley Handwheel Shaft -- 58504
648-178B 2 Trolley Handwheel Shaft Nut -- 988095
648-178C 2 Trolley Handwheel Shaft L.W. -- 986270
648-179 1 Trolley Hand Chain (Specify Lift or Length Req’d) -- 85808
648-180 1 Hand Chain Connecting Link -- 945490
648-230 1 Hanger Chain Anchor Pin (4 Ton) -- -- 45425
648-231 2 Hanger Chain Anchor Pin Retainer (4 Ton) -- -- 48024
648-232 2 Hanger Chain Anchor Pin Block (4 Ton) -- -- 48393
648-239 1 Upper Sheave (5 & 6 Ton) -- -- 45085
648-242 2 Upper Sheave Bearing (5 & 6 Ton) -- -- 83670
648-243 1 Hanger Snap Ring (4 Ton) -- -- 45765
648-243 1 Upper Sheave Bearing Snap Ring (5 & 6 Ton) -- -- 45765
648-244 2 Upper Sheave Bearing Retainer (5 & 6 Ton) -- -- 45151
648-260 1 Hanger Chain Anchor -- 48019Y 48021Y
(3 Ton) (4 Ton)
648-261 1 Dead End Pin (3 & 4 Ton) -- 45945 45944
(3 Ton) (4 Ton)
648-262 1 Liftwheel Gear -- 45062
648-263 1 Intermediate Gear and Pinion -- 45080 for 1-1/2 & 3 Ton, 45081 for 2, 4, 5 & 6 Ton
26
Note: When ordering parts, always furnish hoist model and serial number,
motor horsepower, voltage, phase, frequency and rated capacity of hoist on
which the parts are to be used.
For the location of the nearest Authorized Repair Station, Contact Yale, (see
inside front cover).
LIMITATION OF WARRANTIES, REMEDIES AND DAMAGES
THE WARRANTY STATED BELOW IS GIVEN IN PLACE OF Seller shall not be liable for any damage, injury or loss arising out
ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, OF MER- of the use of the goods if, prior to such damage, injury or loss,
CHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, OR such goods are (1) damaged or misused following Seller’s delivery
OTHERWISE, NO PROMISE OR AFFIRMATION OF FACT to carrier; (2) not maintained, inspected, or used in compliance
MADE BY ANY AGENT OR REPRESENTATIVE OF SELLER with applicable law and Seller’s written instructions and recommen-
SHALL CONSTITUTE A WARRANTY BY SELLER OR GIVE dations; or (3) installed, repaired, altered or modified without com-
RISE TO ANY LIABILITY OR OBLIGATION. pliance with such law, instructions or recommendations.
Seller warrants that on the date of delivery to carrier the goods UNDER NO CIRCUMSTANCES SHALL SELLER BE LIABLE FOR
are free from defects in workmanship and materials. INCIDENTAL OR CONSEQUENTIAL DAMAGES AS THOSE
TERMS ARE DEFINED IN SECTION 2-715 OF THE UNIFORM
SELLER’S SOLE OBLIGATION IN THE EVENT OF BREACH COMMERCIAL CODE.
OF WARRANTY OR CONTRACT OR FOR NEGLIGENCE OR
OTHERWISE WITH RESPECT TO GOODS SOLD SHALL BE INDEMNIFICATION AND SAFE OPERATION
EXCLUSIVELY LIMITED TO REPAIR OR REPLACEMENT, Buyer shall comply with and require its employees to comply with
F.O.B. SELLER’S POINT OF SHIPMENT, OF ANY PARTS directions set forth in instructions and manuals furnished by Seller
WHICH SELLER DETERMINES TO HAVE BEEN DEFECTIVE and shall use and require its employees to follow such instructions
or if Seller determines that such repair or replacement is not fea- and manuals and to use reasonable care in the use and mainte-
sible, to a refund of the purchase price upon return of the goods nance of the goods. Buyer shall not remove or permit anyone to
to Seller. remove any warning or instruction signs on the goods. In the event
of personal injury or damage to property or business arising from
Any action against Seller for breach of warranty, negligence or the use of the goods, Buyer shall within 48 hours thereafter give
otherwise, must be commenced within one year after such Seller written notice of such injury or damage. Buyer shall cooper-
cause of action occurs. ate with Seller in investigating any such injury or damage and in
the defense of any claims arising therefrom.
NO CLAIM AGAINST SELLER FOR ANY DEFECT IN THE
GOODS SHALL BE VALID OR ENFORCEABLE UNLESS If Buyer fails to comply with this section or if any injury or damage
BUYER’S WRITTEN NOTICE THEREOF IS RECEIVED BY is caused, in whole or in part, by Buyer’s failure to comply with
SELLER WITHIN ONE YEAR FROM THE DATE OF SHIPMENT. applicable federal or state safety requirements, Buyer shall indem-
nify and hold Seller harmless against any claims, loss or expense
for injury or damage arising from the use of the goods.
! WARNING
Alterations or modifications of equipment and use of non-
factory repair parts can lead to dangerous operation and
injury.
TO AVOID INJURY:
• Do not alter or modify equipment.
• Do use only factory provided replacement parts.
414 WEST BROADWAY AVENUE

MUSKEGON, MICHIGAN 49443-0769
1-866-805-2962 • Fax: 1-800-742-9270
2001 Yale Hoist 5-17-01 Printed in USA

Heat Exchangers
Storage,
Installation,
Operation
and
Maintenance
Standard
ITT Fluid Technology Corporation
This bulletin has been prepared as an aid Successful performance of heat transfer equip- Failure to perform properly may be due to one or
and guide to maintenance personnel. Read it ment, length of service and freedom from oper- more of the following:
thoroughly prior to installation of any ITT ating difficulties are largely dependent upon: 1. Exchanger being dirty.
Standard heat exchanger in order to ensure 1. Proper thermal design. 2. Failure to remove preservation materials
correct installation and best performance. 2. Proper physical design. after storage.
3. Storage practice prior to installation. 3. Operating conditions being different than
NOTE: Before placing this equipment design conditions.
4. Manner of installation, including design of
in operation, environment and service foundation and piping. 4. Air or gas binding.
conditions should be checked for compat- 5. The method of operation. 5. Incorrect piping connections.
ibility with materials of construction. 6. The thoroughness and frequency of cleaning. 6. Excessive clearances between internal
Contact your nearest ITT Standard repre- 7. The materials, workmanship, and tools used parts due to corrosion.
sentative if you are not sure what the in maintenance and making repairs 7. Improper application.
actual materials of construction are. and replacements.
Storage
ITT Standard heat exchangers are protected sibility of rust formation. Upon receipt, fill swings may cause condensation and
against the elements during shipment. If they these exchangers with appropriate oil or “sweating” of steel parts). Cover win-
cannot be installed and put into operation coat them with a corrosion prevention dows to prevent temperature variations
immediately upon receipt at the jobsite, certain compound for storage. These heat caused by sunlight. Provide thermome-
precautions are necessary to prevent deteriora- exchangers have a large warning decal, ters and humidity indicators at several
tion during storage. Responsibility for integrity of indicating that they should be protected points, and maintain atmosphere at
the heat exchangers must be assumed by the with oil. 40% relative humidity or lower.
user. ITT Standard will not be responsible for
damage, corrosion or other deterioration of heat
exchanger equipment during transit and storage. 4
The choice of preservation of interior
surfaces during storage for other service
applications depends upon your system
7 In tropical climates, it may be necessary
to use trays of renewable dessicant (such
as silica gel), or portable dehumidifiers,
Good storage practices are important, considering requirements and economics. Only to remove moisture from the air in the
the high costs of repair or replacement, and the when included in the original purchase storage enclosure. Thermostatically con-
possible delays for items which require long lead order specifications will specific preser- trolled portable heaters (vented to out-
times for manufacture. The following suggested vation be incorporated prior to shipment doors) may be required to maintain even
practices are provided solely as a convenience to from the factory. air temperatures inside the enclosure.
the user, who shall make his own decision on
whether to use all or any of them.
5 Remove any accumulations of dirt,
water, ice or snow and wipe dry before 8 Inspect heat exchangers and acces-
sories frequently while they are in stor-
1 On receipt of the heat exchanger, inspect

for shipping damage to all protective
covers. If damage is evident, inspect for
moving exchangers into indoor storage.
If unit was not filled with oil or other
preservative, open drain plugs to
age. Start a log to record results of
inspections and maintenance performed
while units are in storage. A typical log
possible contamination and replace pro- remove any accumulated moisture, then entry should include, for each compo-
tective covers as required. If damage is reseal. Accumulation of moisture usual- nent, at least the following:
extensive, notify the carrier immediately. ly indicates rusting has already started
and remedial action should be taken. a. Date
2 If the heat exchanger is not to be placed

in immediate service, take precautions
to prevent rusting or contamination. 6 Store under cover in a heated area, if
possible. The ideal storage environment
b.
c.
d.
Inspector’s name
Identification of unit or item
Location
for heat exchangers and accessories e. Condition of paint or coating
3 Heat exchangers for oil service, made of

ferrous materials, may be pressure-tested
with oil at the factory. However, the resid-
is indoors, above grade, in a dry, low-
humidity atmosphere which is sealed to
prevent entry of blowing dust, rain or
f.
g.
h.
Condition of interior
Is free moisture present?
Has dirt accumulated?
ual oil coating on the inside surfaces of snow. Maintain temperatures between i. Corrective steps taken
the exchanger does not preclude the pos- 70°F and 105°F (wide temperature
2
9 If paint deterioration begins, as evi-
denced by discoloration or light rusting,
consider touch-up or repainting. If the
10 If the internal preservation (Items 3 and 4 )
appears inadequate during storage, con-
sider additional corrosion prevention mea-
unit is painted with our standard shop sures and more frequent inspections.
enamel, areas of light rust may be wire Interiors coated with rust preventive
brushed and touched-up with any good should be restored to good condition and
quality air-drying synthetic enamel. Units re-coated promptly if signs of rust occur.
painted with special paints (when speci-
fied on customers’ orders) may require
special techniques for touch-up or repair. CAUTION:
Obtain specific information from the Provide fire extinguishers,
paint manufacturer. Painted steel units fire alarms or telephone to
should never be permitted to rust or dete- protect building and equip-
riorate to a point where their strength ment against fire damage.
will be impaired. But a light surface rust- Be sure that the building
ing, on steel units which will be re-paint- and storage practices meet
ed after installation, will not generally all local, state, and federal
cause any harm. (See Items 3 and 4 for fire and safety codes!
internal surface preservation.)
Installation Planning
1 On removable bundle heat exchangers,
provide sufficient clearance at the sta-
tionary end to permit the removal of the
7 Provide adequate supports for mounting
the heat exchanger so that it will not set-
tle and cause piping strains. Foundation
tube bundle from the shell. On the float- bolts should be set accurately. In con-
ing head end, provide space to permit crete footings, pipe sleeves at least one
removal of the shell cover and floating pipe size larger than the bolt diameter
head cover. slipped over the bolt and cast in place
are best for this purpose as they allow
2 On fixed bundle heat exchangers, provide

sufficient clearance at one end to permit
removal and replacement of tubes and at
the bolt centers to be adjusted after the
foundation has set.
the other end provide sufficient clearance

to permit tube rolling. 8 Install proper liquid level controls and
relief valves and liquid level and tem-
perature alarms, etc.
3 Provide valves and bypasses in the piping

system so that both the shell side and
tube side may be bypassed to permit iso- 9 Install gauge glasses or liquid level
alarms in all vapor or gas spaces to
lation of the heat exchanger for inspec- indicate any failure occurring in the
tion, cleaning and repairs. condensate drain system and to prevent
flooding of the heat exchanger.
Provide convenient means for frequent
4 cleaning as suggested under maintenance.
10 Install a surge drum upstream from the
heat exchanger to guard against pulsation
5 Provide thermometer wells and pressure

gauge pipe taps in all piping to and from
the heat exchanger, located as close to
of fluids caused by pumps, compressors
or other equipment.
the heat exchanger as possible.
Provide necessary air vent valves for the

11 Do not pipe drain connections to a com-
mon closed manifold; it makes it more
difficult to determine that the exchanger
6 heat exchanger so that it can be purged to
prevent or relieve vapor or gas binding on
has been thoroughly drained.
both the tube side and shell side.

3
Installation at Jobsite
special preservations were applied, you to freezing and/or corrosion.
should consult the preservative manu-
CAUTION:
1
If you have maintained the heat exchang-
er in storage,
Dress properly for thethoroughly
job. Youinspect
need any number of special itemsis—thoroughly
installation. Make sure it
may it prior to facturer’s product information data for
removal instructions. 5 After piping is complete, if support cra-
dles or feet are fixed to the heat exchang-
cleanedshoes,
safety hat, safety to remove all preservation
goggles, heavy mate- er, loosen foundation bolts at one end of
gloves, earrials unless stored
protective
used
soluble inand
items are required
in
devices,
the
the wear
fulletc.,
system,
lubricating
them.
of the
your own protection. Find out whatcoating is
being or
for same oil
the
system oil.
2 If the heat exchanger is not being stored,
inspect for shipping damage to all protec-
tive covers upon receipt at the jobsite.
the exchanger to allow free movement.
Oversized holes in support cradles or feet
are provided for this purpose.
If damage is evident, inspect for possible
contamination and replace protective If heat exchanger shell is equipped with
If the
covers as required. If damage is exten-
sive, notify the carrier immediately.
6 a bellows-type expansion joint, remove
shipping supports per instructions.
3 When installing, set heat exchanger level

and square so that pipe connections can
be made without forcing.
4 Before piping up, inspect all openings in

the heat exchanger for foreign material.
Remove all wooden plugs, bags of dessi-
cant and shipping covers immediately
CAUTION:
exchanger was oil-tested by ITT prior to installing. Do not expose internal
Standardisand
A heat exchanger your purchase
a pressure vesselorder did passages of the heat exchanger to the
not specify otherwise,
designed for operation at certain spe-the oil used was atmosphere since moisture or harmful
cific limitsTectyl 754, a light-bodied
of pressure and tempera- oil which is contaminants may enter the unit and
ture. The soluble
coolinginormost lubricating
process oils. Where
system, cause severe damage to the system due
which includes the heat exchanger,
must be safeguarded with safety
valves and controls so that these heat
exchanger design conditions are not
exceeded. All operating personnel
Operation
should be made aware
entireofsystem
these specif-
1 Be sure
ic design pressures and
is clean before
temperatures.
starting operation to prevent plugging of
tubes or shell side passages with refuse.
5 Re-tighten bolting on all gasketed or
packed joints after the heat exchanger
has reached operating temperatures to
9 In all installations there should be no pul-
sation of fluids, since this causes vibration
and will result in reduced operating life.
CAUTION: The use of strainers or settling tanks in prevent leaks and gasket failures.
Many heatpipelines leadingcirculate
exchangers
ids which recommended.
to the heatflu-
are irritating or dangerous
to the human system. These fluids
exchanger is Standard published torque values do not
apply to packed end joints. 10 Under no circumstances is the heat
exchanger to be operated at a flowrate
greater than that shown on the design
2
could cause Openproblems
vent connections beforeor
if bolted
threaded joints are not maintained in a
leak-tight condition at operating pres-
starting up.
6 Do not operate the heat exchanger
under pressure and temperature con-
ditions in excess of those specified on
specifications. Excessive flows can cause
vibration and severely damage the heat
exchanger tube bundle.
3 Start operating gradually.

sures, temperatures
suggested
ambient conditions.
and no-flow,
start-up and
See Table 1 for
shut-down proce-
the nameplate.
11 Heat exchangers that are out of service

dures for most applications. If in doubt,
If fluids areconsult the nearest
not irritating
sentative for
ITT Standard repre-
or dangerous,
specific instructions.
a leak will at least cause a slippery sit-
7 To guard against water hammer, drain
condensate from steam heat exchangers
and similar apparatus both when starting
for extended periods of time should be
protected against corrosion as described
in the storage requirements for new heat
uation on the floor below. up and shutting down. exchangers.
4
Because one
After the system is completely filled with
the fluid
operating
vented,
in thefluids
close all
heatand all air has been
exchang-
manual vent
er is at higher temperatures, any leaks connections. 8 Drain all fluids when shutting down to
eliminate possible freezing and corroding.
Heat exchangers that are out of service
for short periods and use water as the
might cause burns. flowing medium should be thoroughly
drained and blown dry with warm air, if
4
possible. If this is not practical, the
water should be circulated through the
heat exchanger on a daily basis to pre-
vent stagnant water conditions that can
ultimately precipitate corrosion.
RECOMMENDED START-UP AND SHUT-DOWN PROCEDURES

CAUTION: Every effort should be made to avoid subjecting the unit to thermal shock, overpressure, and/or hydraulic hammer, since these conditions
may impose stresses that exceed the mechanical strength of the unit or the system in which it is installed which may result in leaks and/or other dam-
age to the unit and/or system.
TABLE 1
Fluid Location & Relative Temp.
Heat Exchanger
Shell Side Tube Side Start-Up Shut-Down
Type of Procedure Procedure
Construction Type of Rel. Type of Rel.
Fluid Temp. Fluid Temp.
Liquid Hot Liquid Cold Start both fluids gradually Shut down both fluids gradually
at the same time. at the same time.
Condensing Liquid Start hot fluid first, then slowly Shut down cold fluid first, then
Gas Hot or Cold start cold fluid. Avoid temperature hot fluid.
Fixed Tubesheet (e.g., steam) Gas shock. (1)
(Non-Removable
Bundle) Gas Hot Liquid Cold Start cold fluid first, then hot fluid. Shut down cold fluid gradually,
then hot fluid.
Liquid Cold Liquid Hot Start both flows gradually at the Shut down both fluids gradually
same time. at the same time.
Liquid Cold Gas Hot Start cold fluid first, then hot fluid. Shut down hot fluid first, then
cold fluid.
Liquid Hot Liquid Cold Start cold fluid first, then start Shut down hot fluid first, then
U-Tube hot fluid gradually. cold fluid.
Packed Floating
Condensing Liquid
Head Start cold fluid first, then start Shut down cold fluid first, then
Gas Hot or Cold hot fluid gradually. shut down hot fluid gradually.
Packed Floating (e.g., steam) Gas
Tubesheet
Start cold fluid first, then start Shut down hot fluid first, then
Internal Floating Gas Hot Liquid Cold hot fluid gradually. cold fluid.
Head
Start cold fluid first, then start Shut down hot fluid first, then
Liquid Cold Liquid Hot hot fluid gradually. cold fluid.
(All these types
have Removable Start cold fluid first, then start Shut down hot fluid first, then
Bundles) Liquid Cold Gas Hot
hot fluid gradually. cold fluid.
General Comments:
1.) In all start-up and shut-down operations, fluid flows should be regu- 3.) Extreme caution should be taken on insulated units where fluid
lated so as to avoid thermal shocking the unit regardless of whether flows are terminated and then restarted. Since the metal parts
the unit is of either a removable or non-removable type construction. could remain at high temperatures for an extended period, severe
thermal shock could occur.
2.) For fixed tubesheet (non-removable bundle) type units where the tube
side fluid cannot be shut down, it is recommended that: a) A bypass
arrangement be incorporated in the system; and, b) the tube side
fluid be bypassed before the shell side fluid is shut down.
5
Maintenance
1 Clean exchangers subject to fouling
(scale, sludge deposits, etc.) periodically,
depending on specific conditions. A light
•Rods should be threaded at both ends,
provided with nuts, and should pass
through a steel bearing plate at each
10 Some suggested methods of cleaning
either the shell side or tube side are listed
below:
sludge or scale coating on either side of end of the bundle.
•Circulating hot wash oil or light distil-
the tube greatly reduces its effective-
•Insert a soft wood filler board between late through tube side or shell side will
ness. A marked increase in pressure
the bearing plate and tubesheet face to usually effectively remove sludge or
drop and/or reduction in performance
prevent damage to the tube ends. similar soft deposits.
usually indicates cleaning is necessary.
Since the difficulty of cleaning increases •Soft salt deposits may be washed out
•Screw forged steel eyebolts into both by circulating hot fresh water.
rapidly as the scale thickens or deposits
bearing plates for pulling and lifting.
increase, the intervals between clean- •Some commercial cleaning compounds
ings should not be excessive. •As an alternate to the rods, thread a such as “Oakite” or “Dowell” may be
steel cable through one tube and return effective in removing more stubborn
2 Neglecting to keep tubes clean may

result in random tube plugging. Con-
sequent overheating or cooling of the
through another tube.
•A hardwood spreader block must be

deposits. Use in accordance with the
manufacturer’s instructions.
plugged tubes, as compared to sur- inserted between the cable and each
rounding tubes, will cause physical
damage and leaking tubes due to differ-
tubesheet to prevent damage to the
tube ends.
11 Some tubes have inserts or longitudinal
fins and can be damaged by cleaning
when mechanical means are employed.
ential thermal expansion of the metals. Clean these types of tubes chemically or
3 To clean or inspect the inside of the tubes,

remove only the necessary tube side
7 If the heat exchanger has been in service
for a considerable length of time without
being removed, it may be necessary to
consult the nearest ITT Standard repre-
sentative for the recommended method of
cleaning.
channel covers or bonnets, depending on use a jack on the floating tubesheet to
type of exchanger construction. break the bundle free. •If the scale is hard and the above met-
hods are not effective, use a mechanical
4 If the heat exchanger is equipped with

sacrificial anodes or plates, replace these
as required.
•Use a good-sized steel bearing plate
with a filler board between the
tubesheet face and bearing plate to
means. Neither the inside nor the out-
side of the tube should be hammered
with a metallic tool. If it is necessary to
protect the tube ends. use scrapers, they should not be sharp
5 To clean or inspect the outside of the

tubes, it may be necessary to remove
the tube bundle. (Fixed tubesheet 8 Lift tube bundles horizontally by means of
a cradle formed by bending a light-gauge
enough to cut the metal of the tubes.
Take extra care when employing scra-
pers to prevent tube damage.
exchanger bundles are non-removable). plate or plates into a U-shape. Make
attachments in the legs of the U for lifting. Do not attempt to clean tubes by blowing
6 When removing tube bundles from heat

exchangers for inspection or cleaning,
exercise care to see that they are not 9 Do not drag bundles, since baffles or sup-
port plates may become easily bent.
steam through individual tubes. This over-
heats the individual tube and results in
severe expansion strains and leaking
damaged by improper handling. Avoid any damage to baffles so that the tube-to-tubesheet joints.
heat exchanger will function properly.
•The weight of the tube bundle should
not be supported on individual tubes
but should be carried by the tube-
12 Table 2 shows safe loads for steel rods
and eyebolts.
sheets, support or baffle plates or on

blocks contoured to the periphery of STEEL RODS STEEL EYEBOLTS
the tube bundles.
Tube Rod Safe Load Size Safe Load
Size Size Per Rod
•Do not handle tube bundles with hooks or
other tools which might damage tubes.
5/8” 3/8” 1,000 lbs. 3/4” 4,000 lbs.
Move tube bundles on cradles or skids.
3/4” 1/2” 2,000 lbs. 1” 6,000 lbs.
•To withdraw tube bundles, pass rods 1” or 1-1/4” 10,000 lbs.
through two or more of the tubes and larger 5/8” 3,000 lbs. 1-1/2” 15,000 lbs.
take the load on the floating tubesheet.
6 TABLE 2
13 To locate ruptured or corroded tubes or
leaking joints between tubes and
tubesheets, the following procedure is
CAUTION:
Do not remove channel covers, shell
covers, floating head covers or bon-
recommended: nets until all pressure in the heat
exchanger has been relieved and
•Remove tube side channel covers
both shell side and tube side are com-
or bonnets.
pletely drained.
•Pressurize the shell side of the exchang-
er with a cold fluid, preferably water. CAUTION:
Since many of the removable compo-
•Observe tube joints and tube ends for
nents of the heat exchanger, particu-
indication of test fluid leakage.
larly in the larger sizes, are too heavy
for people to handle, care must be
14 With certain styles of exchangers, it will

be necessary to buy or make a test ring to
seal off the space between the floating
used to take this weight with proper
rigging to avoid injury. Wear hard
hats and safety shoes as required.
tubesheet and inside shell diameter to
apply the test in paragraph 13. Consult
your nearest ITT Standard sales represen-
CAUTION:
Do not thread rods or cables through
tative for reference drawings showing
tubes of a heat exchanger equipped
installation of a test ring in your heat
with ITT Standard Amatran® tubes,
exchanger.
or any with internal fins.
15 To tighten a leaking tube joint, use a suit-

able parallel roller tube expander.
CAUTION:
When the heat exchanger is cleaned,
•Do not roll tubes beyond the back face it is important that full characteristics
of the tubesheet. Maximum rolling of the fouling material and the clean-
depth should be tubesheet thickness ing agent be known and care exer-
minus 1/8”. cised in handling them according to
instructions. Use eye protection to
•Do not re-roll tubes that are not leaking
prevent damage to your eyes. Wear
since this needlessly thins the tube wall.
a respirator when required.
16 It is recommended that when a heat

exchanger is dismantled, new gaskets be
used in reassembly.
CAUTION:
Do not blow out heat exchangers
with air when the normal process flu-
•Composition gaskets become brittle ids or the cleaning fluids being han-
and dried out in service and do not pro- dled are inflammable.
vide an effective seal when reused.
•Metal or metal jacketed gaskets in ini-
tial compression match the contact
surfaces and tend to work-harden and
cannot be recompressed on reuse.
17 Use of new bolting in conformance with

dimension and ASTM specifications of the
original design is recommended where
frequent dismantling is encountered.
7
Warranty
WARRANTY OF SELLER’S PRODUCTS under any circumstances for any damage beyond the price
Except where a different express warranty has been of the goods sold. Any freight allowance in connection
issued with respect to a particular product, no warranty of with a replacement will be on the same terms as were
any kind, express or implied, is extended by the seller to applicable to the original sale, except that a replacement
any person or persons other than its direct Buyers. To for a product or part or portion thereof which is proved to
direct Buyers, the Seller warrants only that it will furnish the Seller’s satisfaction to be defective in material or work-
by freight a replacement for, or at its option repair, any manship as provided herein above, will in any event be fur-
product of its manufacture or part or portion thereof, nished with freight (but not local cartage) allowed, within
proved to its satisfaction to be defective in material or the country of origin, to the first destination. Any
workmanship under normal use and service (i) within a substitution of parts not of Seller’s manufacture or not
period of six (6) months from date of shipment as to those authorized by Seller, or any modification, tampering, or
parts which contain perishable elastomers or (ii) within manipulation of Seller’s product, shall void the warranty.
one year from the date all other equipment or part thereof
is first placed in use, or two years from the date of ship- Other Warranties — The foregoing warranty is in lieu
ment, whichever shall be less. of all other warranties of any kind, express or implied, and
of all other obligations or liabilities, on the part of the
The Seller shall have no responsibility for the performance Seller. The Seller neither assumes, nor does it authorize
of any product sold by it under conditions varying materi- any other person to assume on its behalf, any other liabil-
ally from those under which such product is usually tested ity in connection with the sale of its products.
under existing industry standards, nor for any damage to
the product from abrasion, erosion, corrosion, deteriora- Seller expressly disclaims the implied warranties of mer-
tion or the like due to abnormal temperatures or corrosive chantability and fitness for a particular purpose.
fluids or the influence of foreign matter or energy, or flow
induced vibration caused by associated equipment or Goods of Other Manufacturers — Goods of other
external influences; nor for the design or operation of any manufacturers sold by the Seller are not warranted
system of which any such product may be made a part or except by express warranties which may be issued in
for the suitability of any such product for any particular writing from time to time with respect to a particular
application. The Seller shall not be liable for any cost or product or a particular sale; but the Seller will endeavor
expense, including, without limitation, labor expense, in to secure for its direct Buyers the benefits of warranties
connection with the removal or replacement of alleged extended by the manufacturers of such goods sold but not
defective equipment or any part or portion thereof nor for manufactured by the Seller.
incidental or consequential damages of any kind, nor
Represented by:
Standard
ITT Fluid Technology Corporation
P.O. Box 1102 In Canada:
175 Standard Parkway ITT Standard
C E R T I F I E D 1 9 9 2
Buffalo, NY 14240 225 Watline Avenue Suite 103
ISO 9001
800/447-7700 Mississauga, Ontario L4Z 1P3
R E G . N O . Q A 4 3 5
In New York State: 716/897-2800 905/890-6155

Lit #104-17 Fax: 716/897-1777 Fax: 905/890-6163
©1995 ITT Standard Printed on recycled paper 9256.10M.195.DI Formerly HEAT TRANSFER DIVISION AMERICAN-STANDARD
BELT DRIVE
PREVENTIVE MAINTENANCE
& SAFETY MANUAL
Table of Contents
The Driving Force in Power Transmission®

TABLE OF CONTENTS
Click any page number to go directly to that page.
Foreword
Why Have a Preventive Maintenance Program? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Maintaining a Safe Working Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Drive Shutdown & Thorough Inspection
Simple Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Preventive Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Preventive Maintenance Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Measuring Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Installation
How to Install Belts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
How to Install Taper-Lock® and QD® Bushed Sheaves and Sprockets . . . . . . . . . . . . . . . . . . . .14
Belt Storage and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Belt Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Belt Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Belt Styles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Belt Drive Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Sprocket Corrosion Prevention . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
Problem/Solution Summary Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Troubleshooting Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Technical Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Gates Publications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Drive Survey Worksheet
High Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Low Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Design IQ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Sources of Drive Problems
Copyright 2004
Gates Corporation
Denver, Colorado 80217-5887 Printed in U.S. of America
FOREWORD
Why have a preventive maintenance program?

When compared to the constant lubrication problems
associated with chain drives, or the mechanical problems
and high costs associated with gear drives, belts are the
most cost-effective, reliable means of power transmission.
However, optimum belt drive performance requires proper
maintenance. The potential for long service life is built
into every Gates belt. When coupled with a regularly
scheduled maintenance program, belt drives will run rela-
tively trouble-free for a long time.
Belt drive should have adequate guard
Carefully inspect all belts

Power should be shut off and controls locked * Note - If belt looks bad, it probably is
before inspecting
Important to your business
An effective preventive maintenance program saves time
and money. Inspecting and replacing belts and faulty drive
components before they fail will reduce costly downtime
and production delays.
What is a good belt maintenance program?
A comprehensive, effective program of preventive mainte-
nance consists of several elements:
• Maintaining a safe working
environment.
• Regularly scheduled belt drive inspections.
• Proper belt installation
procedures.
• Belt drive performance
evaluations.
• Belt product knowledge.
• Belt storage and handling.
• Troubleshooting.
1
FOREWORD
Maintaining A Safe Working Environment Maintain Safe Access to Drives

It is common sense to establish a safe working environ- Always maintain a safe access to the belt drives. Keep
ment in and around belt drives. The following precautions area around drives free of clutter, debris and other
will make belt drive inspection and maintenance easier obstructions. Floors should be clean and free of oil and
and safer. debris to insure good footing and balance while working
on machinery.
Power should be shut off and controls locked

before inspecting Don’t clutter area around belt drive
Wear Proper Clothing Drive Guards

Never wear loose or bulky clothes, such as neckties, Always keep drives properly guarded. Every belt drive
exposed shirttails, loose sleeves or loose lab coats around must be guarded when in operation. Guard must be
belt drives. Wear gloves while inspecting sheaves or designed and installed according to OSHA standards.
sprockets to avoid being cut by nicks, burrs or sharply
worn pulley edges. Wear safety glasses to avoid eye
injuries. Don’t be foolish! Wear proper clothing.
This technician is not wearing safety glasses, and his bulky
lab coat and neck tie are hazards near moving components.
A properly guarded belt drive
A Properly Guarded Belt Drive

A properly designed guard has the following features:
No loose or bulky clothing • Completely encloses drive.
• Grills or vents for good ventilation.
• Accessible inspection door or panels.
• Can easily be removed and replaced if damaged.
• Where necessary, should protect the drive from weather,
debris and damage.
Follow these precautions to make your preventive main-

tenance easier.
2
DRIVE SHUTDOWN & THOROUGH INSPECTION
Simple Drive Inspection How Often To Inspect

Begin preventive maintenance with a periodic drive The following factors influence how often to inspect a
inspection as a normal part of your maintenance rounds. drive.
Look and listen for any unusual vibration or sound while
observing the guarded drive in operation. A well designed • Critical nature of equipment
and maintained drive will operate smoothly and quietly. • Drive operating cycle
• Accessibility of equipment
Inspect guard for looseness or damage. Keep it free of
debris or dust and grime buildup on either the inside or • Drive operating speed
the outside of the guard. Any accumulation of material • Environmental factors
on the guard acts as insulation, and could cause drives to • Temperature extremes in environment
run hotter.
Experience with specific equipment is the best guide to
The effect of temperature on belt life is important. For how often to inspect belt drives. Drives operating at high
example, an internal temperature increase of 18°F (or speeds, heavy loads, frequent stop/start conditions and at
approximately 36°F rise in ambient drive temperature) temperature extremes or operating on critical equipment
may cut belt life in half. require frequent inspection.
Also look for oil or grease dripping from guard. This may
indicate over-lubricated bearings. If this material gets on When To Perform Preventive Maintenance
rubber belts, they may swell and become distorted, lead- To help establish a preventive maintenance schedule, keep
ing to early belt failure. the following in mind.
It’s a good idea to check motor mounts for proper tight-
Critical Drives
ness. Check take-up slots or rails to see that they are
clean and lightly lubricated. A quick visual and noise inspection may be needed every
one to two weeks.
Normal Drives
With most drives, a quick visual and noise inspection can
be performed once a month.
Complete Inspection
A drive shutdown for a thorough inspection of belts,
sheaves or sprockets and other drive components may be
required every three to six months.
Remember, a well-designed industrial belt drive is capable
of operating for several years when properly maintained
and used under normal conditions.
Follow the Preventive Maintenance Procedure on the fol-
lowing page when performing detailed maintenance dur-
ing equipment shutdowns.
3
Preventive Maintenance Check List
By following these steps, belt drives can be maintained

efficiently and safely.
1. Always turn off the power to the drive. Lock the con-
trol box and tag it with a warning sign “Down For
Maintenance. Do Not Turn Power On.”
Make sure the power is turned off for the
correct drive.
2. Test to make sure correct circuit has been turned off.
3. Place all machine components in a safe (neutral)
position. Make sure that moving components are
locked down or are in a safe position. Make sure Turn off power, lock controls and tag
that fans cannot unexpectedly freewheel.
4. Remove guard and inspect for damage. Check for
signs of wear or rubbing against drive components. 7. Inspect other drive components such as bearings,
Clean and realign guard to prevent rubbing if neces- shafts, motor mounts and take-up rails.
sary.
8. Inspect static conductive grounding system (if used)
5. Inspect belt for wear or damage. Replace as needed. and replace components as needed.
6. Inspect sheaves or sprockets for wear and misalign- 9. Check belt tension and adjust as needed.
ment. Replace if worn.
10. Recheck sheave or sprocket alignment.
11. Reinstall belt guard.
12. Turn power back on and restart drive. Look and listen
for anything unusual.
4
Preventive Maintenance Procedure

Once the power is off, locked and tagged, and the
machine components are in safe positions, remove the
Using a straight edge to
guard and begin the inspection. check alignment
How to Inspect a Belt

Observing signs of unusual belt wear or damage will help
troubleshoot possible drive problems.
Mark or note a point on the belt, or on one of the belts
in a multiple V-belt drive. Wearing gloves, work around
the belt(s), checking for cracks, frayed spots, cuts, or Using a string to check
unusual wear patterns. alignment
Using EZ Align™ laser

alignment tool on both
ends
Begin by inspecting the belt

Using EZ Align™ laser
Check the belt for exposure to excessive heat. Excessive alignment tool, showing
reflected laser on emitter
heat can come from a hot environment or from belt slip
that generates heat. The maximum environmental tem-
perature for a properly maintained V-belt is 140˚F. The
maximum environmental temperature for a properly main-
tained synchronous belt is 185˚F.
Rubber belts that are running hot, or running in a hot
environment will harden and develop cracks from the bot- Using EZ Align™ laser
alignment tool showing
tom of the belt upwards.
laser line on target
Refer to the PROBLEM/SOLUTION SUMMARY TABLE for
other symptoms.
Belts should be replaced if there are obvious signs of
cracking, fraying, unusual wear or loss of teeth.
If using a straight edge (or string), line the straight edge
along the outside face of both sheaves or sprockets as
How to Check Alignment
shown in the photo. If the drive is properly aligned, the
While the drive is shut down, it is a good idea to check straight edge or string will contact each sheave or sprock-
the sheaves or sprockets for proper alignment. et evenly. The straight edge or string (pulled tight) should
To check alignment, use a straight edge, string, or Gates touch the two outer edges of each sheave or pulley for a
EZ Align™ laser alignment tool. total of four points of contact. Misalignment of sprockets
and shafts will show up as a gap between the outside
face of the sheave or sprocket and the straight edge.
Check for tilting or shaft misalignment by using a bubble
level. For proper alignment, the bubble should be in the
same position as measured on each shaft.
5
If using the Gates EZ Align™ laser alignment tool, follow Misalignment on V-belt drives should be less than 1/2˚ or
the detailed instructions included with the tool. The EZ 1/10” per foot of center distance. Misalignment for syn-
Align laser alignment tool makes it very quick and easy to chronous, Polyflex®, or Micro-V® belts should be less than
check alignment of shafts, sheaves and sprockets. 1/4˚ or 1/16” per foot of center distance.
When a synchronous belt drive has been aligned (follow-
ing the procedure discussed above in the “How to Check
Alignment” section), do not continue to adjust alignment
in an attempt to make the synchronous belt ride in the
center of the sprocket’s face width. Synchronous belts,
while neutral tracking, will tend to ride in contact with a
flange on one side of the sprockets. Synchronous belts
on drives that are properly aligned will lightly contact the
flanges. Synchronous belts on misaligned drives will ride
hard against the flanges and generate additional noise.
Attempting to adjust a synchronous belt drive’s alignment
to force the belt to ride in the center of the sprocket’s
face width will typically result in misalignment.
Guard Inspection
Check the guard for wear or possible damage. Don’t
overlook wear on the inside of the guard. Check for any
areas that may be contacting the belt. Clean the guard
to prevent it from becoming blocked and closed to venti-
lation. Clean off any grease or oil that may have spilled
onto the guard from over-lubricated bearings.
Check Other Drive Components

It is always a good idea to examine bearings for proper
lubrication. Check the motor base bolts and adjustment
screws to make sure they are not loose. If loose, tighten
to the recommended torque value. Make sure that
There are three possible causes and solutions of sheave or adjustment screws are free of debris, dirt, or rust.
sprocket misalignment:
1. Angular Misalignment: The motor shafts and Check Belt Tension
driven machine shafts are not parallel. Following the drive component inspection, the final step
is to check belt tension. Rotate the drive two or three
a. Correct alignment by adjusting the motor
revolutions by hand and check the belt tension. If neces-
shaft into alignment with the driveN shaft.
sary, retension the belt and make a final alignment check.
2. Parallel Misalignment: Sheaves or sprockets are
If V-belts are undertensioned, they can slip. Slippage gen-
not properly located on the shafts.
erates heat and will result in cracking and belt failure.
a. Loosen and reposition one or both sheaves
If synchronous belts are undertensioned, they can jump
or sprockets until properly aligned.
teeth or ratchet. Ratcheting will damage the belt and
3. Sheaves or sprockets are tilted on the shaft due result in premature belt failure.
to incorrect bushing installation.
If belts are overtensioned, belt and bearing life can be
reduced.
a. Rotate drive by hand and look for excessive The proper way to check belt tension is to use a tension
wobble. If wobble is observed, remove and tester. Gates has a variety of tension testers, ranging
reinstall sheave or sprocket. Follow the bush- from the simple spring scale type tester to the sophisticat-
ing installation procedures explained in the ed Sonic Tension Meter.
INSTALLATION section. Further check align-
ment by using one of the previously men-
tioned methods.
6
Measuring Belt Tension 1. Measure span length (t). Span length is the distance
The spring scale type tester measures how much force is from where the belt exits one pulley to where it enters
required to deflect the belt a specified distance at the the next pulley.
center of its span. This is the force deflection method of
tensioning belts.
The Sonic Tension Meter measures the vibration of the
belt span and instantly converts the vibration frequency
into belt static tension. This is the span vibration method
of tensioning belts.
2. Position the lower of the two O-Rings using either of

these methods:
a. On the scale reading “Deflection Inches”, set the
O-Ring to show a deflection equal to 1/64” per
inch of span length (t).
b. On the scale reading “Inches of Span Length”,
set O-Ring to show a deflection equal to the inch-
es of measured span length (t).
3. At the center of the span (t), apply force using the
appropriately sized Gates tension testers. Apply the
force perpendicular to the span. If the belt is a wide
synchronous belt or a PowerBand belt, place a piece of
steel or angle iron across the belt width and deflect the
entire width of the belt evenly. Deflect the belt until
the bottom edge of the lower O-Ring is at the correct
deflection distance. If multiple individual V-belts are
used on the drive, the deflection distance can be meas-
ured against an adjacent belt. For drives with only one
belt, use a straightedge or string pulled tight across the
sheaves, sprockets, or top of the belt to establish a ref-
For more information, refer to the Troubleshooting Tools erence line. When the belt is deflected to measure ten-
section. sion, measure the deflection distance by measuring from
the belt to the straight edge or string reference line.
Force Deflection Tension Method
The force deflection tension method does not directly
measure belt span tension or static tension. The deflec-
tion force is a calculated value that is based on the
amount of static tension required in the belt. Static ten-
sion is the tension force that is actually in the belt, while
deflection force is simply a measurement to check how
much static tension is in the belt. The tension testers
used for the force deflection tension method are available
in one, two, or five barrel configurations. The one barrel
tension tester can measure up to 30 lb. of force; the two
barrel tension tester can measure up to 66 lb. of force;
and the five barrel tension tester can measure up to 165
lb. of force. Add the force readings off each barrel to
determine the total force being measured.
7
4. Find the amount of deflection force on the upper scale

of the tension tester. The sliding rubber
O-Ring slides up the scale as the tool compresses and
stays up for a reading of the deflection force. Read at
the bottom edge of the ring. Remember to slide the
O-Ring down before using again.
5. Installation tension forces should ideally be calculated
for each specific drive. The tension calculations are
included in all Gates drive design manuals.
Additionally, the Gates drive design and selection com-
puter program, Design Flex® II can be used to quickly
calculate the proper installation tensions. Design Flex®
II is available for download at www.gates.com.
If installation tension values for a specific V-belt
drive are not available, the tables shown can be used
to determine generic tension values based on the V-
belt cross section. As synchronous belt drives are more
sensitive to proper belt tensioning, there are no similar
quick reference tension tables for them. Span Vibration Method
Compare the deflection force with the range of forces The Gates Sonic Tension Meter can be used with all Gates
recommended. If less than the minimum recommended belts. The Sonic Tension Meter measures the vibration in
deflection force, the belts are too loose and should be the belt span, and converts that measurement into a read-
tightened. If more than the maximum recommended ing of the actual static tension in the belt. To use the
deflection force, the belts are too tight and should be Sonic Tension Meter, you will need to enter the belt unit
loosened. weight, belt width for synchronous belts or number of
ribs or strands for V-belts, and the span length. To meas-
ure the span vibration, press the “Measure” key on the
meter, tap the belt span to vibrate the belt, and hold the
microphone approximately 3/8” to 1/2” away from the
back of the belt. The Sonic Tension Meter will display the
static tension, and can also display the vibration frequen-
cy.
Since the span vibration method is intended to be a very
accurate method of measuring actual tension in a belt, it
is important that the proper recommended tension is cal-
culated for the specific belt drive. Procedures for calculat-
ing belt tension are included in each of the appropriate
Gates drive design manuals. To determine the belt ten-
sion recommended for specific drive applications, refer to
the appropriate belt drive design manual or download the
Gates belt drive selection program, DesignFlex® II, at
www.gates.com. Alternatively, Gates Power Transmission
Product Application engineers can be contacted at (303)
744-5800.
8
The adjusted belt weights for use with the Gates Sonic Tension Meter are shown in the following table.
Belt Belt Belt Adjusted Belt Weight

Product Cross Type (grams/meter)
Family Section
3VX Single 61
5VX Single 158
3V Single 72
5V Single 200
8V Single 510
Super HC® V-belts
3VX PowerBand® 70
5VX PowerBand ®
185
3V PowerBand® 96
5V PowerBand ®
241
8V PowerBand ®
579
3VP PowerBand® 89
5VP PowerBand ®
217
Predator® Belts 8VP PowerBand® 528
BP PowerBand ®
212
CP PowerBand ®
332
AX Single 85
Tri-Power V-belts
®
BX Single 144
CX Single 232
A Single 96
B Single 168
C Single 276
D Single 554
Hi Power® II V-belts E Single 799
A PowerBand ®
151
B PowerBand ®
200
C PowerBand® 342
D PowerBand ®
663
AA Single 125
BB Single 194
Hi Power® II Dubl V-belts
CC Single 354
DD Single 750
A Single 108
Power Cable® Belts B Single 172
C Single 302
H Single 5
J Single 7
Micro-V Belts
®
K Single 18
L Single 29
M Single 109
9

Family Section
Metric Power™ V-belts 10X-Notched Single 44
13X-Notched Single 86
17X-Notched Single 139
For belt lengths over 3000mm 13X Single 100
For belt lengths over 3000mm 17X Single 171
XPZ Single 51
XPA Single 87
XPB Single 156
XPC Single 249
For belt lengths over 3000mm SPZ Single 72
For belt lengths over 3000mm SPA Single 115
For belt lengths over 3000mm SPB Single 186
For belt lengths over 3000mm SPC Single 337
2L Single 22
3L Single 44
Truflex® Belts
4L Single 77
5L Single 125
3L Single 52
PoweRated Belts
®
4L Single 83
5L Single 138
3M Single 4
5M Single 10
7M Single 24
11M Single 49
Polyflex® Belts
3M JB® 5
5M JB ®
11
7M JB ®
30
11M JB® 64
10

Family Section
MXL Synchronous 1.3
XL Synchronous 2.4
L Synchronous 3.2
PowerGrip® Timing Belts
H Synchronous 3.9
XH Synchronous 11.3
XXH Synchronous 14.9
XL Synchronous 1.9
PowerGrip® Timing Twin Power® Belts L Synchronous 3.2
H Synchronous 4.6
3M Synchronous 2.4
5M Synchronous 3.9
PowerGrip HTD Belts

® ®
8M Synchronous 6.2
14M Synchronous 9.9
20M Synchronous 12.8
3M Synchronous 2.7
5M Synchronous 4.6
PowerGrip® HTD® Twin Power® Belts
8M Synchronous 7.2
8M Synchronous 5.8
PowerGrip® GT® Belts
14M Synchronous 9.7
2M Synchronous 1.4
3M Synchronous 2.8
5M Synchronous 4.1
PowerGrip® GT® 2 Belts
8M Synchronous 5.5
14M Synchronous 9.6
8M Synchronous 6.93
PowerGrip® GT® 2 Twin Power® Belts
5M Synchronous 3
Poly Chain® GT® 2 Belts
and 8M Synchronous 4.7
Poly Chain® GT® Belts
14M Synchronous 7.9
11
INSTALLATION
How to Install Belts Inspection

When a belt is being installed, the same basic steps must 6. Inspect the old belt for any unusual wear. Excessive
be followed, regardless of whether the belt is a or unusual wear may indicate problems with the
V-belt or a synchronous belt. drive design or past maintenance procedures. Refer
to the Problem/Solution Summary Table in the Belt
Preparation Performance and Troubleshooting section for guide-
1. Confirm that the power is off, locked, and tagged. lines in matching belt appearance to possible prob-
Never work on a belt drive until this important step is lem causes.
completed. Wear proper safety equipment (hardhat, 7. Inspect the sheaves or sprockets for unusual or
gloves, safety glasses, steel toe shoes). excessive wear. Belt life will be reduced if the
2. Remove belt guard and place away from drive so sheaves or sprockets are worn. Wear gloves for pro-
that it does not interfere with working on the drive. tection from nicks or sharp surfaces.
For V-belt sheaves: Inspect grooves for wear and
Removal nicks. Use Gates sheave gauges to determine if the
3. Loosen motor mounting bolts or adjusting screws. grooves are worn. Place the proper sheave gauge
into the sheave groove and check for wear. If more
than 1/32” of wear can be seen between the gauge
and groove side wall, the sheaves are worn and
should be replaced. A light source such as a flash-
light may be used to backlight the gauge.
4. Move the motor in until the belt is slack and can be

removed easily without prying. Never pry off a belt,
as the sheave or sprocket can be damaged. Prying
off belts also adds the risk of injury.
Do not be misled by “shiny” grooves. Grooves that

are “shiny” are often polished because of heavy
wear.
Inspect the sheave grooves for rust or pitting. If rust-
ed or pitted surfaces are found, the sheave should be
replaced.
For Synchronous sprockets: Inspect sprocket grooves
for unusual or excessive wear. Check for excessive
wear by both visually inspecting the grooves and by
running your finger along the sprocket grooves. If
5. Remove old belt you can feel or see noticeable wear, the sprockets are
worn and should be replaced.
12
INSTALLATION
Do not be misled by “shiny” grooves. Grooves that Catenary effect is a curve made by a cord of uniform
are “shiny” are often polished because of heavy weight suspended between two points.
wear.
Follow the recommended run-in and retensioning
Inspect the sprocket grooves for rust or pitting. If
procedure to minimize the visible difference in belt
rusted or pitted surfaces are found, the sprocket
sag.
should be replaced.
14. Rotate the belt drive by hand for a few revolutions.
Check the sprocket flanges and make sure that they
Re-check the belt tension and adjust as necessary.
are not loose or bent. Bent flanges can interfere
with the belt and cause premature belt wear and fail- 15. Re-check the drive alignment and adjust as necessary.
ure.
Completion
8. If necessary, clean sheave and sprocket grooves by
wiping the surface with a rag slightly dampened with 16. Secure motor mounting bolts to the correct torque.
a light, non-volatile solvent. Do not sand or scrape 17. Re-check the belt tension and adjust as necessary.
the grooves to remove debris. Tightening the motor mounting bolts may have
changed the belt tension.
Installation
18. Replace the belt guard.
9. If necessary, install new sheaves or sprockets. Refer
to page 14 for detailed instructions for installing QD 19. Start the drive, looking and listening for any unusual
or Taper-Lock® bushings. noise or vibration. If possible, shut down the drive
and check the bearings and motor for unusual heat.
10. Check the sheave or sprocket alignment. In order to
If the motor or bearings are hot, the belt tension
achieve optimum belt life, it is important that the
may be too high, or bearings may not be properly
drive’s sheaves or sprockets be aligned properly. Use
lubricated. Temperatures can be checked with an
a straightedge or Gates EZ Align® laser alignment
infrared pyrometer.
tool. Adjust the sheave or sprocket position as nec-
essary.
V-belt Run-In Procedure
11. Install the new belt or set of belts. 20. A run-in procedure is recommended for all V-belt
Replace all belts on multiple V-belt drives. Never drives so that the optimum belt life can be achieved.
replace a single belt or a portion of a multiple belt A run-in consists of starting the drive and letting it
drive. Always use belts from the same manufacturer run under full load for up to 24 hours. If a 24 hour
on a multiple belt drive. If a new belt is used with run-in is not possible, let the belt drive run overnight,
old belts, the load will not be shared evenly between to the next shift, or at least a few hours. After the
the belts on a multiple V-belt drive. Mixing new and belts have run-in, stop the belt drive and check the
old belts very possibly could lead to premature belt belt tension. Running the belts under full load for an
failure and uneven sheave wear. extended period of time will seat the V-belts into the
sheave grooves.
When installing the belt, make sure that there is V-belt tension will drop after the initial run-in and
clearance to slip the belt over the sheave or sprocket. seating process. This is normal. Adjust the belt ten-
Do not pry or use force to install the belt. Do not sion as necessary.
roll the belt onto the drive.
Since tension in V-belts will drop after the initial run-
12. Adjust the motor base adjustment screws to take up in and seating process, failure to check and retension
the center distance on the belt drive until the belts the belt will result in low belt tension and belt slip-
are tight. page. This slippage will result in premature belt fail-
13. Check belt tension, using a tension gauge or Sonic ure.
Tension Meter. Adjust the belt drive’s center distance
until the correct tension is measured.
On multiple belt drives, some belts may appear to
hang unevenly when installed. It is normal for belts
within RMA length and matching tolerances to have
noticeable differences in the distance the belt span
sags. This is called the “catenary effect”.
13
INSTALLATION
How to Install Taper-Lock® and QD® Bushed Sheaves 5. Alternately torque the bolts until the sprocket and
and Sprockets bushing tapers are completely seated together (at
It is important that new or replacement sheaves or sprock- approximately half of the recommended torque; see
ets be properly installed. Most sheaves or sprockets are table below).
attached to a shaft with a tapered bushing that fits a
mating tapered bore in the sheave or sprocket. Bushings Note: Do not use worn hex key wrenches. Doing
come in several different bore size diameters. This allows so may result in a loose assembly or may damage
for a reduction in the parts inventory required in your bolts.
plant because one bushing size with multiple bore sizes 6. Check the alignment and sprocket runout (wobble),
can be used with a number of different sizes of sheaves and correct as necessary.
or sprockets.
7. Continue alternate tightening of the bolts to the rec-
There are two styles of bushings: Taper-Lock® and QD®. ommended torque values specified in the table
Installation and removal instructions for each style are below.
noted below.
Taper-Lock® Bushings
Taper-Lock® Type Sprocket Installation and
Removal Bushing Bolts Torque Wrench
Style Qty. Size lb-ft lb-in
1008 2 1/4-20 x 1/2 4.6 55
1108 2 1/4-20 x 1/2 4.6 55
1210 2 3/8-16 x 5/8 14.6 175
1610 2 3/8-16 x 5/8 14.6 175
2012 2 7/16-14 x 7/8 23.3 280
2517 2 1/2-13 x 1 35.8 430
3020 2 5/8-11 x 1 1/4 66.7 800
3525 3 1/2-13 x 1 1/2 83.3 1000
4030 3 5/8-11 x 1 3/4 141.7 1700
4535 3 3/4-10 x 2 204.2 2450
To Install TAPER-LOCK® Type Bushings 5040 3 7/8-9 x 2 1/4 258.3 3100
6050 3 1 1/4-7 x 3 1/2 651.7 7820
1. Clean the shaft, bore of bushing, outside of bushing 7060 4 1 1/4-7 x 3 1/2 651.7 7820
and the sprocket hub bore of all oil, paint and dirt.
File away any burrs.
Caution: Excessive bolt torque can cause sprocket
Note: The use of lubricants can cause sprocket and/or bushing breakage.
breakage. DO NOT USE LUBRICANTS IN THIS
INSTALLATION. Note: To insure proper bushing/sprocket performance,
full bushing contact on the shaft is recommended.
2. Insert the bushing into the sprocket hub. Match the
hole pattern, not threaded holes (each complete hole 8. To increase the bushing gripping force, firmly tap the
will be threaded on one side only). face of the bushing using a drift or sleeve (Do not hit
the bushing directly with the hammer).
3. “LIGHTLY” oil the bolts and thread them into those
half-threaded holes indicated by “O” on the diagram 9. Re-torque the bushing bolts after Step 8.
above. 10. Recheck all bolt torque values after the initial drive
run-in, and periodically thereafter. Repeat steps 5
Note: Do not lubricate the bushing taper, hub taper, through 9 if loose.
bushing bore, or the shaft. Doing so could result in
sprocket breakage. To Remove TAPER-LOCK® Type Bushings
4. With the key in the shaft keyway, position the assem- 1. Loosen and remove all mounting bolts.
bly onto the shaft allowing for small axial movement
2. Insert bolts into all jack screw holes indicated by “●”
of the sprocket which will occur during the tighten-
ing process. (see figure above).
3. Loosen the bushing by alternately tightening the
Note: When mounting sprockets on a vertical shaft, bolts in small but equal increments until the tapered
precautions must be taken to positively prevent the sprocket and bushing surfaces disengage.
sprocket and/or bushing from falling during installation.
14
INSTALLATION
QD® Type Sprocket Installation and Removal 6. Continue alternate tightening of the bolts to the rec-
ommended torque values specified in the table below.
Note: Excessive bolt torque can cause sprocket

and/or bushing breakage. When properly mounted,
there must be a gap between bushing flange and
sprocket after the bolts are tightened.
Bushing Bolts Torque Wrench

Position One Position Two Style Qty. Size lb-ft lb-in
H 2 1/4 x 3/4 7.9 95
JA 3 10-24 x 1 4.5 54
®
To Install QD Type Bushings SH & SDS 3 1/4-20 x 1 3/8 9.0 108
SD 3 1/4-20 x 1 7/8 9.0 108
1. Clean the shaft, bore of bushing, outside of bushing SK 3 5/16-18 x 2 15.0 180
and the sprocket hub bore of all oil, paint and dirt. SF 3 3/8-16 x 2 30.0 360
File away any burrs. E 3 1/2-13 x 2 3/4 60.0 720
F 3 9/16-12 x 3 5/8 75.0 900
J 3 5/8-11 x 4 1/2 135.0 1620
Note: The use of lubricants can cause sprocket M 4 3/4-10 x 6 3/4 225.0 2700
breakage. DO NOT USE LUBRICANTS IN THIS N 4 7/8-9 x 8 300.0 3600
INSTALLATION. W 4 1 1/8-7 x 11 1/2 600.0 7200
S 5 1 1/4-7 x 15 1/2 750.0 9000
2. For “Position One” or “Position Two” (whichever P 4 1-8 x 9 1/2 450.0 5400
applies), line up the unthreaded bushing holes “C”
with the threaded sprocket hub holes “T”. Lightly oil QD® Bushings
the bolts and thread them (with lock washers) into Caution: Excessive bolt torque can cause sprocket and/or
the sprocket hub engaging only 2 or 3 threads. Bolt bushing breakage.
heads should be mounted outside to allow for disas-
sembly. When mounting sprockets on ‘M’ through Note: To insure proper bushing/sprocket performance,
‘W’ bushing sizes, position the threaded jack screw full bushing contact on the shaft is recommended.
hole (J) as far from the bushing saw slot as possible 7. Tighten the set screw, when available, to hold the
to reduce the possibility of bushing breakage during key securely during operation.
disassembly.
To Remove QD® Type Bushings
Note: Do not lubricate the bushing taper, hub taper,
bushing bore, or the shaft. Doing so could result in 1. Loosen and remove all mounting bolts.
sprocket breakage. 2. Insert bolts into all threaded jack screw holes.
3. With the key in the shaft keyway, position the assem- 3. Loosen the bushing by first tightening the bolt fur-
bly onto the shaft allowing for small axial movement thest from the bushing saw slot, then alternately
of the sprocket which will occur during the tighten- tighten remaining bolts. Keep tightening the bolts in
ing process. When installing large or heavy parts in small but equal increments until the tapered sprocket
“Position One” (see figure above), it may be easier to and bushing surfaces disengage.
mount the key and bushing onto the shaft first, then
place the sprocket on the bushing and align the holes. Note: Excessive or unequal pressure on the bolts
can break the bushing flange, making removal nearly
Note: When mounting sprockets on a vertical shaft, impossible without destroying the sprocket.
precautions must be taken to positively prevent the
sprocket and/or bushing from falling during installation.
4. Alternately tighten the bolts until the sprocket and
bushing tapers are completely seated together (at
approximately half the recommended torque).
5. Check the alignment and sprocket runout (wobble),
and correct as necessary.
15
BELT STORAGE AND HANDLING
Storage Recommendations Do not crimp belts during handling or while stored.

Proper preventive maintenance should not be limited to Belts are crimped by bending them to a diameter smaller
the actual belt drive operating on equipment, but should than the minimum recommended diameter sheave or
also include following proper storage procedures. In sprocket for that cross section. Do not use ties or tape to
order to retain their serviceability and dimensions, proper pull belt spans tightly together near the “end” of the
storage procedures must be followed for all belt types. belt. This will crimp the belt and cause premature belt
Quite often premature belt failures can be traced to failure. Do not hang on a small diameter pin that sus-
improper belt storage procedures that damaged the belt pends all of the belt weight and bends the belt to a diam-
before it was installed on the drive. By following a few eter smaller than the minimum recommended sheave or
common sense steps, these types of belt failures can be sprocket diameter. Improper storage will damage the
avoided. tensile cord and the belt will fail prematurely. Handle
belts carefully when removing from storage and going to
General Guidelines the application. Do not inadvertently crimp or damage
Recommended the belts by careless handling.
Belts should be stored in a cool and dry environment with Storage Methods
no direct sunlight. Ideally, less than 85˚ F and 70% rela-
tive humidity. V-belts
Store on shelves or in boxes or containers. If the belt is V-belts can be coiled in loops for storage purposes. Each
packaged in a box, like Poly Chain® GT®2, store the belt in coil results in a number of loops. One coil results in three
its individual box. loops, two coils results in five loops, etc. The maximum
number of coils that can be used depends on the belt
V-belts may be stored by hanging on a wall rack if they length. If coiling a belt for storage, consult the table on
are hung on a saddle or diameter at least as large as the the next page and follow the limits shown.
minimum diameter sheave recommended for the belt
cross section.
When the belts are stored, they must not be bent to
diameters smaller than the minimum recommended
sheave or sprocket diameter for that cross section. (see
Technical Information section) Belts should not be stored
with back bends that are less than 1.3 times the minimum
recommended sheave or sprocket diameter for that cross
section.
If stored in containers, make sure that the belt is not dis-
torted when in the container. Limit the contents in a con-
tainer so that the belts at the bottom of the container are
not damaged by the weight of the rest of the belts in the
container.
Not Recommended
Belts should not be stored near windows, which may
expose the belts to direct sunlight or moisture.
Belts should not be stored near heaters, radiators, or in
the direct airflow of heating devices.
Belts should not be stored near any devices that generate
ozone. Ozone generating devices include transformers
and electric motors.
Belts should not be stored where they are exposed to sol-
vents or chemicals in the atmosphere.
Do not store belts on the floor unless they are in a protec-
tive container. Floor locations are exposed to traffic that
may damage the belts.
16
BELT STORAGE AND HANDLING
Belt Cross Section Belt Length (in) Belt Length (mm) Number of Coils Number of Loops
3L, 4L, 5L, A, AX, Under 60 Under 1500 0 1

AA, B, BX, 3V, 60 up to 120 1500 up to 3000 1 3
3VX, 9R, 13R, 13C, 120 up to 180 3000 up to 4600 2 5
13CX, 13D, 16R, 180 and over 4600 and over 3 7
16C, 16CX, 9N
BB, C, CX, 5V, Under 75 Under 1900 0 1
5VX, 16D, 22C, 75 up to 144 1900 up to 3700 1 3
22CX, 15N 144 up to 240 3700 up to 6000 2 5
240 and over 6000 and over 3 7
CC, D, 22D, 32C Under 120 Under 3000 0 1
120 up to 240 3000 up to 6100 1 3
240 up to 330 6100 up to 8400 2 5
330 up to 420 8400 up to 10,600 3 7
420 and over 10,600 and over 4 9
8V, 25N Under 180 Under 4600 0 1
80 up to 270 4600 up to 6900 1 3
270 up to 390 6900 up to 9900 2 5
390 up to 480 9900 up to 12,200 3 7
Over 480 12,200 and over 4 9
PowerBand® V-belts, Synchronous Belts, Micro-V ® Belts Variable Speed Belts

Poly Chain® GT®2 is shipped in individual boxes. Poly Variable speed belts have a thicker cross section and are
Chain® GT®2 should be stored in the box in which it was more sensitive to distortion than other V-belts. Do not
shipped. hang variable speed belts from pins, racks, or saddles.
Store variable speed belts on their edge on shelves.
These belts may be stored by hanging on a wall rack if
Variable speed belts that are in sleeves may be stacked,
they are hung on a saddle or diameter at least as large as
taking care to avoid distorting the belts at the bottom of
the minimum diameter sheave or sprocket recommended
the stack.
for the belt cross section, and the belts are not distorted.
PowerBand® V-belts, Synchronous belts, and Micro-V® Storage Effects
belts up to 120 inches (3000 mm) may be stored in a Belts may be stored up to six years if properly stored at
nested configuration. Nests are formed by laying a belt temperatures less than 85˚F and relative humidity less
on its side on a flat surface and placing as many belts than 70%.
inside the first belt as possible without undue force.
When nests are formed, do not bend the belts to a diam- If the storage temperature is higher than 85˚ F, the stor-
eter that is smaller than the minimum recommended age limit for normal service performance is reduced by
sheave or sprocket diameter. Nests may be stacked with- one half for each 15˚F increase in temperature. Belts
out damaging the belts if they are tight and stacked with should never be stored at temperatures above 115˚F.
each nest rotated 180˚ from the nest below. At relative humidity levels above 70%, fungus or mildew
PowerBand® V-belts and Micro-V® belts over 120 inches may form on stored belts. This has minimal affect on belt
(3000 mm) may be rolled up and tied for shipment. performance, but should be avoided.
These individual rolls may be stacked for easy storage. When equipment is stored for prolonged periods of time
When the belts are rolled, they must not be bent to a (over six months), the belt tension should be relaxed so
diameter that is smaller than the minimum diameter rec- that the belt does not take a set, and the storage environ-
ommended for the cross section. ment should meet the 85˚F and 70% or less relative
humidity condition. If this is not possible, belts should be
removed and stored separately in a proper environment.
17
BELT IDENTIFICATION
When preventive maintenance inspections indicate that The information on the following pages will help identify
belts need replacing, it is important to install the correct the belt types used in industry. Gates makes a belt to fit
belts. nearly any application.
Consequently, it is important to identify the various types
and sizes of belts available, and then quickly be able to
specify the correct replacement.
V-belts
Super HC® V-belts
Hi-Power® II V-belts
Tri-Power® V-belts PowerBand® – Hi-Power® II and

Super HC®
Metric Power™ V-belts
SPZ/XPZ SPA/XPA SPB/XPB SPC/XPC
18
BELT IDENTIFICATION
Multi-Speed Belts
Top Width-Sheave Angle
Example: Belt No. 2326V310 designates:

23 26 V 310
Top Width in 16ths of Sheave Angle in Multi-Speed Pitch Circumference to the
an Inch: 23/16" = 1-7/16" Degrees (26) Nearest 10th Inch: 31.0"
Truflex® (Light Duty) V-belts
PoweRated® V-belts Dubl V-belts
AA BB CC DD
Micro-V® Belts
Standard Polyflex® Belts Polyflex® JB® Belts
19
BELT IDENTIFICATION
Synchronous Belts
All synchronous belts are identified in a similar manner, in 2. Pitch Length: Total length (circumference) in inches or
either English or metric units. Belts are measured by: millimeters as measured along the pitch line. It is equal
to the pitch multiplied by the number of teeth in the belt.
1. Pitch: Distance in inches or millimeters between
two adjacent tooth centers as measured on the 3. Width: Denoted in inches or millimeters.
belt pitch line.
Poly Chain® GT®2 Belts PowerGrip® HTD® Belts
PowerGrip® GT®2 Belts PowerGrip® Timing Belts
Pitch Pitch
20
BELT IDENTIFICATION
Twin Power® Timing Belts
XL
.200” Pitch
L
.375” Pitch
H
.500” Pitch
Pitch
Twin Power® PowerGrip® GT®2 Belts
3M
3mm Pitch
5M
5mm Pitch
8M
8mm Pitch
14M
14mm Pitch
Pitch
21
BELT IDENTIFICATION
Synchro-Power® Polyurethane Belts
MXL
.080” Pitch
XL
.200” Pitch
L
.375” Pitch
H
.500” Pitch
Pitch
T2.5
2.5mm Pitch
T5
5mm Pitch
T10
10mm Pitch
T20
20mm Pitch
Pitch
22
BELT IDENTIFICATION
AT5
5mm Pitch
AT10
10mm Pitch
AT20
20mm Pitch
Pitch
5M HTD
5mm Pitch
8M HTD
8mm Pitch
14M
14mm Pitch
HTD
Pitch
23
BELT IDENTIFICATION
DT5
5mm Pitch
DT10
10mm Pitch
Pitch
24
BELT TYPES
Narrow Section V-Belts

These high capacity belts are used to substantially reduce
drive costs and decrease space requirements. This V-belt
handles the complete range of drive horsepower recom-
mended with three narrow cross sections instead of the
five regular cross sections needed for classical heavy-duty
belts. Specified by 3V, 5V or 8V cross sections. Specify
Gates Super HC® V-Belts.
Classical Section V-Belts

These are the original belts used in heavy duty applica-
tions. They are specified by cross section and standard
length. The size is designated as A, B, C, D or E. The easi-
est way to select a replacement is by finding the belt
number on the worn belt. If not legible, measure the belts
outside circumference with a flexible tape, preferably
while it is still on the drive.
Then, order the Gates Hi-Power® ll V-belt which has the next
shorter standard length. For example: For an “A” section
belt with a 28.0” O.C., order an A26 replacement belt.
Banded and Bandless Belts

Banded belts, also called wrapped or covered belts, have
a fabric cover. Un-notched and generally with concave
sidewalls, banded belts have rounded bottom corners and
arched tops.
Bandless belts have no fabric cover They have straight,
cut-edge sidewalls and special molded notches.
The notches reduce bending stress which allows belts to
run on smaller diameter sheaves than comparable non-
notched banded belts.
Gates offers these two types in both the classical and nar-
row sections. In the classical section, Gates
Tri-Power® molded notch is available in AX, BX and CX
cross sections. Its length is specified by the same standard Note: The revolutionary Gates Vextra® construction is
belt number as other classical section belts. used in the notched belts.
Gates also offers Super HC® Molded Notch V-belts in

3VX and 5VX sizes.
In both cases, an “X” is used in the belt number to desig-
nate a molded notch construction. For example: An AX26
is a bandless, molded notch classical section belt. A
5VX1400 is a narrow section, bandless, molded notch belt
with a 140” O.C.
25
BELT TYPES
Light Duty Belts

These are used on light duty fractional horsepower drives
and are designed for use with backside idlers. Gates
Truflex® and PoweRated® V-belts are offered in this cate-
gory and are specified by cross section and outside cir-
cumference. Truflex® is recommended for the lower
lighter duty range. PoweRated®, a special belt designed
for clutching, heavier shock-load and backside idler drives,
is recognized by its green color. Reinforced with an
aramid fiber tensile (pound for pound stronger than steel).
PoweRated® can interchange with Truflex®, but Truflex®
cannot interchange with PoweRated®.
Synchronous Belts
These belts are also known as timing or positive drive
belts and are used where driveN shaft speeds must be
synchronized to the rotation of the driveR shafts. They can
also be used to eliminate noise and maintenance prob-
lems caused by chain drives.
Synchronous belts, such as Gates Poly Chain® GT®2, can
be used in high horsepower drives, drives where space is
severely limited and where there is limited take up.
Synchronous drives are extremely efficient... as much as
98% with properly maintained Poly Chain® GT®2 or
PowerGrip® GT®2 systems. By contrast, chain drives are
in the 91-98% efficiency range, while V-belts average in Number of Sprocket Grooves
the 93-98% range.
Width - Face width.
Distinctive tooth profiles (shapes) identify synchronous
belts. Various sizes and constructions are available to meet Note: The sprocket’s pitch diameter is always greater than
a wide range of applications. The three important dimen- its outside diameter.
sions of a synchronous belt are pitch, width and pitch Note: PowerGrip® GT®2 belts must be used with
length. Tooth profiles must also be identified. PowerGrip® GT®2 sprockets for new designs.
Belt Pitch - Distance in inches or millimeters between Note: 8 and 14 mm pitch PowerGrip® GT®2 belts can be
two adjacent tooth centers as measured on the belt’s used as replacement belts at the next smaller width for
pitch line. the following: HTD, RPP®, RPP Plus®, HTB, HPT, HT100,
Belt Pitch Length - Circumference in inches or millime- HT150, HT200, ETH, HPR, HPPD, EHT or HTT.
ters as measured along the pitch line. Example: 14mm-170mm width – substitute a PowerGrip®
Width - Top width in inches or millimeters. GT®2-14mm-115 without any performance loss. Refer to
page 32 for crossover information.
Tooth Profile - See the Belt Identification section for the
easiest way to identify tooth profile.
Synchronous belts run on sprockets, which are specified
by the following:
Pitch - Distance between groove centers, measured on
the sprocket pitch circle. The pitch circle coincides with
the pitch line of the mating belt.
26
BELT TYPES
BELT TYPES
Polyflex® JB® Belts
Polyflex® is a unique belt with a distinctive 60° belt angle
and ribbed top specifically designed for long life in small
diameter sheave drives. Polyflex® JB® is ideal for compact
drives, drives with high speed ratios, and drives requiring
especially smooth operation.
The “JB” refers to the belt’s configuration: two, three or five
belts joined together to provide extra stability and improved
performance. This joined belt style should be used instead of
matched single belts whenever possible.
Polyflex® JB® belts are ideal for these applications:
• Milling, grinding or drilling machines
• Lathes
• Machine spindle drives
• Centrifuges
• Blowers
• High speed compressors
Polyflex® JB® belts are specified by Top Width and
Effective Length
Multi-Speed Belts
(Variable Speed Drives)
Multi-Speed belts have a distinct shape. Multi-Speed belt
top widths are usually greater than their thicknesses. This
permits a greater range of speed ratios than standard
belts. Usually cogged or notched on the underside, Multi-
Speed belts are specified for equipment which require
changes in driveN speed during operation.
Multi-Speed belts are specified by Top Width, Outside
Circumference, and the required Groove Angle. The
groove angle can be measured from the drive pulleys.
Micro-V® or V-Ribbed Belts

Gates Micro-V® belts outperform other V-ribbed belts
because the tips of the “V” are truncated (shorter). This
shorter profile gives the new Micro-V belts increased flexi-
bility, reduced heat buildup and allows them to operate at
extra high speeds on smaller diameter sheaves.
Additional advantages of the truncated tips are: (1) the belt
does not bottom in the sheave, therefore providing a higher
degree of wedging and (2) the belt can better tolerate debris
in the sheave groove. They are extremely smooth running and
highly resistant to oil, heat and other adverse conditions.
Three cross sections are available for industrial applications: J,
L and M.
27
BELT STYLES
Spliced Belting
Used on drives with little or no take-up, or as an emer-
gency belt replacement.
Belting is sold on reels in standard V-belt cross sections.
Ends are spliced with fasteners that require special assem-
bly tools. Always use the correct fasteners with the correct
belt type and cross section.
Nu-T-Link*, a high performance, spliced belt, is also avail-
able for use as emergency belting, and for drives where
conditions are detrimental to rubber belts.
*Nu-T-Link® is a Registered Trademark of Fenner-Manheim.
PowerBand® Belts
PowerBand belts were developed by Gates for drives sub- Predator® V-belts primary features:
jected to pulsating loads, shock loads or extreme vibrations
where single belts could flip over on the pulleys. A high- • Aramid tensile cords for extraordinary strength, durabili-
strength tie band permanently joins two or more belts to ty and virtually zero stretch.
provide lateral rigidity. This keeps the belts running in a • Chloroprene rubber compounds for superb oil and heat
straight line in the pulley grooves. PowerBand® construction resistance.
is offered with Gates • Specially-treated extra tough cover withstands slip and
Hi-Power® II, Super HC® and Super HC® Molded shear forces at peak loads without generating excessive
Notch Belts. heat. It also fends off penetration by foreign materials.
The Gates • Gates curves that compensate for effects that occur
Predator® V-belt is when belts bend around a sheave for uniform loading
a multi layered and maximum life.
PowerBand® construc- • Matched by request to maximize power absorption and
tion that adds strength, belt life.
durability, shear and tear resistance and
lateral rigidity to handle the toughest shock-loaded appli-
cations. It is available in Super HC® and
Hi- Power® II profiles.
28
BELT STYLES
Dubl-V Belts
A special version of Gates Hi-Power® II for serpentine
drives where power is transmitted by both the top and
bottom of the belt. Dubl-V belts are specified by A, B, or
C cross sections, and by Effective Length.
Round Endless Belts

Recommended for replacing leather belting on serpentine
or quarter-turn drives. They are specified by Diameter
and Inside Length.
If your current drive has leather or round endless belting,
you should consider a new drive design. V-belt drives
offer many advantages in performance, even on serpen-
tine or quarter-turn drives.
PowerBack™ Belts
PowerBack™ belts are “B” section V-belts with a flat back
surface. The flat back surface makes PowerBack™ belts
ideal for driving roll-to-roll conveyor applications.
Power Curve® Belts

Power Curve® belts are “B” section V-belts offering
increased flexibility for demanding power turn conveyor
applications. The belts “bend” around corners and drive
the rollers in most conveyor applications.
29
BELT STYLES
Power Cable® Belts

Recommended for the toughest shock load applications,
especially on drives that can’t be shut down for retension-
ing after initial belt run-in. Reinforced with an aramid
fiber tensile (pound for pound stronger than steel), Power
Cable® belts last longer and cost less than steel cable belts.
Flat Belts
Gates Speed- Flex® Belts, are designed for high speed
applications such as drill presses, lathes, grinders and
other woodworking equipment. Gates Powercord® Belts
are designed for general purpose, lower speed applica-
tions. Flat belts are specified by belt Width and required
Inside Diameter.
Static Conductive Belts

Static discharge can pose a hazard on belt drives that V-belts are generally manufactured to be static conductive
operate in potentially explosive environments. Static dis- in accordance with the RMA IP 3-3 bulletin, but it is
charge can also interfere with radios, electronic instru- important to confirm with the belt manufacturer that a
ments, or controls used in a facility. While uncommon, specific belt product or product line is static conductive.
static discharge can also cause bearing pitting if the dis-
Gates Hi-Power® II, Tri-Power®, Super HC®, Super HC®
charge occurs through the bearing. Static conductivity is
Molded Notch, Metric Power™, Micro-V®, and Truflex® V-
a required belt characteristic in these cases in order to
belts are all static conductive when new as defined by
prevent static discharge.
RMA Bulletin IP 3-3. Belts that have been in operation
The Rubber Manufacturer’s Association (RMA) has can be checked for static conductivity by using an ohm-
published Bulletin IP 3-3 for static conductivity. Static meter and following the inspection recommendations
conductivity testing involves using an ohmmeter to pass given in the RMA IP 3-3 bulletin.
an electrical current with a nominal open circuit 500 volt
PowerGrip®Timing, PowerGrip® GT®2, Poly Chain® GT®,
potential through a belt. The test should be performed
Poly Chain® GT®2, Polyflex®, Polyflex® JB®, Power Cable®,
with the belt off of the belt drive. The belt’s resistance is
PoweRated®, and Predator™ belts do not meet the static
measured by placing electrodes 8.5 inches apart on the
conductivity requirements specified in RMA Bulletin IP 3-3
clean driving surface of the belt. A resistance reading of
and are not considered to be static conductive.
six (6) megohms or more constitutes a test failure. Belts
that measure a resistance of 6 megohms or more are con- PowerGrip® GT®2 and PowerGrip® Timing belts can be
sidered to be non-conductive. Belts that measure a resist- manufactured in a static conductive construction on a
ance of less than 6 megohms are considered to be static made-to-order basis.
conductive. A static conductive belt with a resistance of
When a belt is used in a hazardous environment, addi-
6 megohms or less has sufficient conductivity to prevent
tional protection must be employed to assure that there
measurable static voltage buildup, thus preventing a static
are no accidental static spark discharges. The portion of
discharge.
the belt that contacts the sheave or sprocket must be
30
BELT STYLES
conductive to ensure that static charge is conducted into belt’s physical condition and its static conductivity characteris-
the drive hardware. V-belts must have a static conductive tics, replace the belt.
sidewall in contact with a conductive sheave groove.
Any belt drive system, whether it uses a synchronous belt
Synchronous belts must have a static conductive tooth
or V-belt, that operates in a potentially hazardous environ-
surface in contact with conductive sprocket grooves.
ment must be properly grounded. A continuous conduc-
Unusual or excessive debris or contaminant on the belt tive path to ground is necessary to bleed off the static
contact surface or sheave or sprocket grooves should be charge. This path includes a static conductive belt, a con-
cleaned and removed. Banded V-belts (V-belts with a fab- ductive sheave or sprocket, a conductive bushing, a con-
ric bandply on the driving surface) should be inspected for ductive shaft, conductive bearings, and the ground. As
bandply wear. If the fabric bandply on the belt sidewall an additional measure of protection, a static-conduc-
has worn away, the belts should be replaced immediately. tive brush or similar device should be employed to
Bandless V-belts do not have to be replaced if wear is evi- bleed off any residual static buildup that might remain
dent on the belt sidewall. If there is any question about the around the belt.
BELT DRIVE PERFORMANCE

To provide proper maintenance, you must understand the Gates Corporation is the recognized industry leader in
nature of the belt drives in your plant. You know the product innovation and belt drive technology. New prod-
expected belt service life on each drive, and you are aware ucts and applications are continually made available to
of the capabilities and limitations of this equipment. Gates customers. Here are examples of advanced Gates
belt innovations.
On occasion, however, it is necessary to give some
thought to belt service life, especially when belt service
Advanced Gates Belt Drive Products & Solutions
life is below the expected performance level and the situ-
ation must be improved. • Poly Chain® GT®2 positive drive (synchronous) belts
• PowerGrip® GT®2
Upgrade Drive Performance • Polyflex® JB® belts
A belt drive can sometimes be upgraded to improve per- • Power Cable® belts
formance. The first step is to see if simple improvements • PoweRated® light-duty V-belts
can be made at minimal costs. This involves checking the
• Nu-T-Link®* spliced belting
drive design for adequate capacity using the appropriate
drive design manual or Gates Design Flex® II drive design • Super HC® Molded Notch V-belts
software. • Predator® Powerband belts
• Vextra® technology
If further improvement is needed, the next step is to
upgrade the drive to a higher performance belt system. • Power Curve™ V-belts
• PowerBack™ V-belts
Here are examples of minor changes that could improve
• Stainless steel sprockets & bushings (stock)
performance.
• Polyflex® Sheaves (stock)
• Increase sheave or sprocket diameters
• Gates DesignFlex® II Software
• Increase the number of belts, or use wider belt
• Add vibration dampening to system • Gates DesignView® Software
*Registered Trademark of Fenner-Manheim.
• Improve guard ventilation to reduce operating
temperature Your local Gates distributor or representative can work
• Use at least the correct, minimum recommended pul- with you to upgrade your existing drives and reduce your
ley diameters on inside and backside idlers maintenance and down time costs.
• Use premium belts rather than general purpose types
Or, you may have a problem or excessive maintenance
• Replace sheaves or sprockets when they are worn
costs with a non-belt drive, such as gear or chain. Again,
• Keep sheaves or sprockets properly aligned your local Gates distributor or representative can offer you
• Place idler on span with lowest tension excellent advice as to whether or not a belt drive could
• Re-tension newly installed belts after a 4 to 24 hour solve the problem and reduce your maintenance costs.
run-in period
• Review proper belt installation and maintenance pro-
cedures
31
BELT DRIVE PERFORMANCE
In most cases, synchonous belt drives that are using non-Gates curvilinear belts can be changed to a Gates PowerGrip®
GT®2 belt to reduce width. Use the table below to identify product types that can be converted, and what widths are
recommended.
For example, a competitor’s belt in 14mm pitch, 85mm wide, can be replaced with a narrower 55mm Gates PowerGrip®
GT®2 belt.
Reference www.gates.com for electronic interchange information.
32
NOISE
V-belt, synchronous belt, roller chain, and gear drives will For comparison, some typical noise levels and their
all generate noise while transmitting power. Each type of sources are listed below.
system has its own characteristic sound. V-belt drives
tend to be the quietest belt drives, and synchronous belt
drives are much quieter than roller chain drives. When Normal Speech 60 dBA
noise is an issue, there are several design and mainte-
Busy Office 80 dBA
nance tips that should be followed to achieve the quietest
possible belt drive. Textile Weaving Plant 90 dBA
Canning Plant 100 dBA
Noise: Decibel and Frequency
Noise is an unwanted or unpleasant sound that can be Heavy City Traffic 100 dBA
described with two criteria – frequency and decibel (dBA) Punch Press 110 dBA
levels. Frequency is measured in Hertz.
The human ear is capable of distinguishing frequencies Air Raid Siren 130 dBA
typically from 20 to 20,000 Hertz. The human ear Jet Engine 160 dBA
generally does not perceive frequencies higher than
20,000 Hertz. Reducing Noise
The noise level or intensity of noise is measured in terms Following proper installation and maintenance proce-
of decibels (dBA). The decibel has become the basic unit dures, as well as some simple design alternatives can
of measure since it is an objective measurement that reduce belt drive noise.
approximately corresponds to the subjective measurement
Belt Drive Tension and Alignment
made by the human ear. Since sound is composed of sev-
eral distinct and measurable parts and the human ear Properly tensioning and aligning a belt drive will allow the
doesn’t differentiate between these parts, measuring belt drive to perform at its quietest level.
scales that approximate the human ear’s reaction have
Improperly tensioned V-belt drives can slip and squeal.
been adopted. Three scales – A, B, and C are used to
Improper tension in synchronous belt drives can affect
duplicate the ear’s response over the scale’s ranges. The
how the belt fits in the sprocket grooves. Proper tension
A scale is most commonly used in industry because of its
minimizes tooth to groove interference, and thereby
adoption as the standard in OSHA regulations.
reduces belt noise. Check to make sure that the drive is
Noise described in decibels (dBA) is generally perceived as properly tensioned by using Gates tension measurement
the loudness or intensity of the noise. gauges.
While the human ear can distinguish frequencies from 20 Misaligned V-belt drives will be noisier than properly
to 20,000 Hertz, the ear is most sensitive in the range of aligned drives since interference is created at the belt’s
normal speech – 500 to 2000 Hertz. As a consequence, entry point into the sheave. Misaligned synchronous belt
this range is the most common concern for noise control. drives tend to be much noisier than properly aligned
Frequency is most closely related to what the ear hears as drives due to the even greater amount of interference
pitch. High frequency sounds are perceived as whining or that is created between the belt teeth and the sprocket
piercing, while low frequency sounds are perceived as grooves. Misaligned synchronous belt drives may cause
rumbling. belt tracking that forces the edge of the belt to ride hard
against a sprocket flange. Misalignment causing belt con-
The combination of decibel and frequency describes the
tact with a flange will generate noise that is easily detect-
overall level of loudness to the human ear. One without
ed. Follow the guidelines discussed in the installation
the other does not adequately describe the loudness
section of this manual for checking and correcting alignment.
potential of the noise. For example, an 85 dBA noise at
3000 Hertz is going to be perceived as much louder than
an 85 dBA noise at 500 Hertz.
33
NOISE
Noise Barriers and Absorbers
Sometimes, even properly aligned and tensioned belt
drives may be too noisy for a work environment. When
this occurs, steps can be taken to modify the drive guard
to reduce the noise level.
Noise barriers are used to block and reflect noise. Noise

barriers do not absorb or deaden the noise; they block
the noise and generally reflect most of the noise back
towards its point of origin. Good noise barriers are
dense, and should not vibrate. A sheet metal belt guard
is a noise barrier. The more complete the enclosure is, the
more effective it is as a noise barrier. Noise barrier belt
guards can be as sophisticated as a completely enclosed
case, or as simple as sheet metal covering the front of the
guard to prevent direct sound transmission.
Noise absorbers are used to reduce noise reflections and

to dissipate noise energy. Noise absorbers should be used
in combination with a noise barrier. Noise absorbers are
commonly referred to as acoustic insulation. Acoustic
insulation (the noise absorber) is used inside of belt
guards (the noise barrier) where necessary. A large variety
of acoustic insulation manufacturers are available to pro-
vide different products for the appropriate situation.
A combination of noise barrier (solid belt guard) and noise

absorber (acoustic insulation) will provide the largest
reduction in belt drive noise. While the noise reduction
cannot be predicted, field experience has shown that
noise levels have been reduced by 10 to 20 dBA when
using complete belt guards with acoustic insulation.
34
SPROCKET CORROSION PREVENTION
Poly Chain® GT®2 belt drives are excellent replacements
for roller chain drives. Poly Chain® GT®2 belt drives offer
significant maintenance savings and performance advan-
tages over roller chain drives on applications that operate
in corrosive environments. Synchronous belt drives also
provide energy savings compared to V-belt drives. Some
of these applications may also operate in corrosive envi-
ronments.
Corrosive Environments
Many applications in the food and beverage industry are
located in areas that require periodic wash down. Unless
a drive is completely shielded and protected from wash
down, rust and corrosion will be rapidly apparent in these
types of environments.
Applications that are located in environments that have
high humidity or moisture content will also develop
sprocket and bushing corrosion. Examples of these types
of environments are pulp processing applications and
cooling tower applications that pass moist air over the
belt drive.
Effects of Corrosion
Corrosion will attack the sprocket grooves, building up
rust deposits. The corrosion will increase over time, build-
ing up in the sprocket grooves and non-driving surfaces
(flanges, sprocket faces, bushing face).
Sprockets with corrosion in the grooves will rapidly wear

the belt’s teeth. Sprockets with corroded grooves will
wear through the abrasion resistant tooth fabric, resulting
in tooth shear and premature belt failure.
35
SPROCKET CORROSION PREVENTION
Preventing Corrosion
Sprocket corrosion can be prevented by using Gates stain-
less steel Poly Chain® GT®2 sprockets and bushings.
Sprockets can also be electroless nickel plated. Both solu-
tions will eliminate corrosion as a cause of failure on belt
drives located in these damaging environments.
The sprocket shown below has been electroless nickel
plated. Compare the grooves to the unprotected corrod-
ed sprocket shown on page 35.
The photo below illustrates the difference in wear

between belts running on properly plated sprockets and
those running on corroded sprockets. The wear on the
belt running on corroded sprockets is severe and will
result in a greatly shortened belt life.
Belt ran on properly plated or stainless steel sprockets
Belt ran on corroded sprockets
36
TROUBLESHOOTING GUIDE
When troubleshooting a drive problem, the goal is to Step 1

identify the cause(s), then take appropriate corrective Describe the problem
action. The following stops should be followed to help
with this process. • What is wrong?
1. Describe the drive problem as accurately as possible. • When did it happen?
Use Step 1 as a guide. Use this step as a guide in the • How often does it happen?
troubleshooting process.
• What is the drive application?
2. Go through the list of “Drive Symptoms”. Check
those symptoms that are observed and record them, • Have the machine operations or output changed?
as well as observations of anything unusual about • What kind of belt(s) are being used?
the drive.
• What are the expectations for belt performance in this
3. Go through the “Problem/Solution Summary Table”. application?
List the probable cause(s) and corrective action. Also,
review the list of observations.
4. After identifying probable causes and corrective Step 2
action, review and implement.
Identify symptoms and record
What to Do When All Else Fails observations of anything unusual.
If the problem still exists after all troubleshooting efforts
have been exhausted, contact the local Gates distributor.
If the local distributor cannot solve the problem, a quali- V-belt Drive Symptoms
fied Gates representative can be contacted. Check List
(Check those that are observed)
Gates Power Transmission Product Application engineers
are also available at (303) 744-5800 to answer additional
drive design and troubleshooting questions. • Premature Belt Failure
■ Broken belt(s)
■ Belt(s) fail to carry load (slip). No visible reason
■ Edge cord failure
■ Belt delamination or undercord separation
• Severe or Abnormal Belt Wear

■ Wear on belt top surface
■ Wear on top corners of belt
■ Wear on belt sidewall
■ Wear on belt bottom corners
■ Wear on bottom surface of belt
■ Undercord cracking
■ Burn or hardening on bottom or sidewall
■ Belt surface flaking, sticky or swollen
■ Belt stretch
■ Extensive hardening of belt exterior
37
V-belt Drive Symptoms Checklist–cont. Synchronous Drive Symptoms Checklist
• Problems with PowerBand Belts ®
• Belt Problems
■ Tie-band separation ■ Unusual noise
■ Top of tie-band frayed, worn or damaged ■ Tension loss
■ Band comes off drive ■ Excessive belt edge wear
■ One or more ribs run outside of pulley ■ Tensile break
■ Cracking
• V-belt Turns Over or Jumps ■ Premature tooth wear
off Sheave
■ Tooth shear
■ Single belt
■ Belt ratcheting
■ One or more belts in a set
■ Land area worn
■ Joined or banded belts
• Sprocket Problems
• Problems with Belt Take-Up
■ Flange failure
■ Single belt
■ Unusual wear
■ Multiple belts stretch unequally
■ Rusted or corroded
■ All belts stretch equally
■ Belts do not match
• Performance Problems
■ Incorrect driveN speeds
• V-belt Noise
■ Belt tracking problems
■ Squeal or “chirp”
■ Excessive temperature: bearings, housings,
■ Slapping noise shafts, etc.
■ Rubbing sound ■ Shafts out of sync
■ Grinding ■ Vibration
■ Unusually loud drive
• Unusual Vibration
■ Belts flopping
■ Excessive vibration in drive system
• Problem With Sheaves

■ Broken or damaged
■ Severe, rapid groove wear
• Problems With Drive

Components
■ Bent or broken shafts
■ Hot bearings
38
PROBLEM/SOLUTION SUMMARY TABLE
V-belt Drive Symptoms
Premature Belt Failure
Symptoms Probable Cause Corrective Action
Broken belt(s) 1. Under-designed drive 1. Redesign, using Gates manual.
2. Belt rolled or pried onto sheave 2. Use drive take-up when installing.
3. Provide adequate guard or drive
3. Object falling into drive protection.
4. Redesign to accommodate shock
4. Severe shock load load.
Belts fail to carry load, no 1. Underdesigned drive 1. Redesign, using Gates manual.
visible reason 2. Damaged tensile member 2. Follow correct installation proce-
dure.
3. Worn sheave grooves 3. Check for groove wear; replace as
needed.
4. Center distance movement 4. Check drive for center distance
movement during operation.
Edge cord failure 1. Pulley misalignment 1. Check alignment and correct.

2. Damaged tensile member 2. Follow correct installation
procedure.
Belt de-lamination or undercord 1. Too small sheaves 1. Check drive design, replace with
separation larger sheaves.
2. Use of too small backside idler 2. Increase backside idler to accept-
able diameter.
39
Severe or Abnormal V-belt Wear
Wear on top surface of belt 1. Rubbing against guard 1. Replace or repair guard.
2. Idler malfunction 2. Replace idler.
Wear on top corner of belt 1. Belt-to-sheave fit incorrect (belt 1. Use correct belt-to-sheave
too small for groove) combination.
1. Belt slip 1. Retention until slipping stops.

Wear on belt sidewalls
2. Misalignment 2. Realign sheaves.
3. Worn sheaves 3. Replace sheaves.
4. Incorrect belt 4. Replace with correct belt size.
Wear on bottom corner of belt 1. Belt-to-sheave fit incorrect 1. Use correct belt-to-sheave combi-
nation.
Wear on bottom surface of belt 1. Belt bottoming on sheave groove 1. Use correct belt/sheave match.
3. Debris in sheaves 3. Clean sheaves.
Undercord cracking 1. Sheave diameter too small 1. Use larger diameter sheaves.
2. Belt slip 2. Retention.
3. Backside idler too small 3. Use larger diameter backside idler.
4. Improper storage 4. Don’t coil belt too tightly, kink or

bend. Avoid heat and direct sun-
light.
40
Severe or Abnormal V-belt Wear–cont.
Undercord or sidewall burn or 1. Belt slipping 1. Retension until slipping stops.
hardening 2. Worn sheaves 2. Replace sheaves.
3. Underdesigned drive 3. Refer to Gates drive manual.
4. Shaft movement 4. Check for center distance
changes.
Belt surface hard or stiff 1. Hot drive environment 1. Improve ventilation to drive.
Belt surface flaking, sticky or 1. Oil or chemical contamination 1. Do not use belt dressing. Eliminate
swollen sources of oil, grease or chemical
contamination.
Problems With PowerBand® Belts

Tie band separation 1. Worn sheaves 1. Replace sheaves.
2. Improper groove spacing 2. Use standard groove sheaves.
Top of tie band frayed or worn 1. Interference with guard 1. Check guard.
2. Backside idler malfunction or dam- 2. Replace or repair backside idler
aged
PowerBand® belt comes off 1. Debris in sheaves 1. Clean grooves. Use single belts to
drive repeatedly prevent debris from being trapped
in grooves.
2. Misalignment 2. Realign drive.
41
Problems With PowerBand® Belts–cont.
One or more “ribs” runs out of 1. Misalignment 1. Realign drive.
pulley 2. Undertensioned 2. Retension.
V-belts Turn Over or Come Off Drive

Involves single or multiple belts 1. Shock loading or vibration 1. Check drive design. Use Gates
PowerBand® belts or Power Cable®
belts.
2. Foreign material in grooves 2. Shield grooves and drive.
3. Misaligned sheaves 3. Realign the sheaves.
4. Worn sheave grooves 4. Replace sheaves.
5. Damaged tensile member 5. Use correct installation and belt
storage procedure.
6. Incorrectly placed flat idler 6. Carefully align flat idler on slack
side of drive as close as possible to
driveR sheaves.
7. Mismatched belt set 7. Replace with Gates matched belts.
Do not mix old and new belts.
8. Poor drive design 8. Check for center distance stability

and vibration dampening.
Problems with V-belt Take-Up

Multiple belts stretch unequally 1. Misaligned drive 1. Realign and retension drive.
2. Debris in sheaves 2. Clean sheaves.
3. Broken tensile member or cord 3. Replace all belts, install properly.
damaged
4. Mismatched belt set 4. Install Gates matched belt set.
Single belt, or where all belts 1. Insufficient take-up allowance 1. Check take-up. Use allowance
stretch evenly specified in Gates design manuals.
2. Grossly overloaded or under 2. Redesign drive.
designed drive
3. Broken tensile members 3. Replace belt, install properly.
Belts do not match 1. Not all belts are from the same 1. Use Gates belts
manufacturer
42
V-belt Noise
Belt squeals or chirps 1. Belt slip 1. Retension.
2. Contamination 2. Clean belts and sheaves.
Slapping Sound 1. Loose belts 1. Retension.
2. Mismatched set 2. Install matched belt set.
3. Misalignment 3. Realign pulleys so all belts share
load equally.
Rubbing sound 1. Guard interference 1. Repair, replace or redesign guard.
Grinding sound 1. Damaged bearings 1. Replace, align & lubricate.
Unusually loud drive 1. Incorrect belt 1. Use correct belt size. Use correct
belt tooth profile for sprockets on
synchronous drive.
2. Incorrect Tension 2. Check tension and adjust
3. Worn sheaves 3. Replace sheaves
4. Debris in sheaves 4. Clean sheaves, improve shielding,
remove rust, paint, or remove dirt
from grooves.
Unusual Vibration
Belts flopping 1. Loose belts (under tensioned) 1. Retension.
2. Mismatched belts 2. Install Gates matched belts.
3. Pulley misalignment 3. Align pulley
Unusual or excessive vibration 1. Incorrect belt 1. Use correct belt cross section in
pulley. Use correct tooth profile
and pitch in sprocket.
2. Poor machine or equipment 2. Check structure and brackets for
design adequate strength.
3. Pulley out of round 3. Replace with non-defective pulley.
4. Loose drive components 4. Check machine components and
guards, motor mounts, motor
pads, bushings, brackets and
framework for stability, adequate
design strength, proper mainte-
nance and proper installation.
Problems With Sheaves

Broken or damaged sheave 1. Incorrect sheave installation 1. Do not tighten bushing bolts beyond
recommended torque values.
2. Foreign objects falling into drive 2. Use adequate drive guard.
3. Excessive rim speeds 3. Keep pulley rim speeds below
maximum recommended value.
4. Incorrect belt installation 4. Do not pry belts onto pulleys.
Severe Groove Wear 1. Excessive belt tension 1. Retension, check drive design.
2. Sand, debris or contamination 2. Clean and shield drive as well as
possible.
3. Wrong belt 3. Make sure belt and sheave combi-
nation is correct.
43
Problem With Other Drive Components
Bent or broken shaft 1. Extreme belt overtension 1. Retension
2. Overdesigned drive* 2. Check drive design, may need to
use smaller or fewer belts.
3. Accidental damage 3. Redesign drive guard.
4. Machine design error 4. Check machine design.
5. Accidental damage to guard or 5. Repair, redesign for durability.
poor guard design
6. Pulley mounted too far away from 6. Move pulley closer to bearing.
outboard bearing
Hot Bearings 1. Worn grooves - belts bottoming 1. Replace sheaves. Tension drive
and won’t transmit power until properly.
overtensioned*
2. Improper tension 2. Retension.
3. Motor manufacturer’s sheave 3. Redesign using drive design manual.
diameter recommendation not fol-
lowed
4. Bearing underdesigned 4. Check bearing design.
5. Bearing not properly maintained 5. Align and lubricate bearing.
6. Sheaves too far out on shaft 6. Place sheaves as close as possible to
bearings. Remove obstructions
7. Belt Slippage 7. Retension.
* Using too many belts, or belts that are too large, can severely stress motor or driveN shafts. This can happen when load requirements are reduced on
a drive, but the belts are not redesigned accordingly. This can also happen when a drive is greatly overdesigned. Forces created from belt tensioning
are too great for the shafts.
Synchronous Drive Symptoms

Synchronous Belt Problems
Unusual noise 1. Misaligned drive 1. Correct alignment.
2. Too low or high tension 2. Adjust to recommended value
3. Backside idler 3. Use inside idler.
4. Worn sprocket 4. Replace.
5. Bent guide flange 5. Replace.
6. Belt speed too high 6. Redesign drive.
7. Incorrect belt profile for sprocket 7. Use proper belt/sprocket combina-
(i.e. HTD®, GT®, etc.) tion.
8. Subminimal diameter 8. Redesign drive using larger diame-
ters.
9. Excessive load 9. Redesign drive for increased
capacity.
44
Synchronous Belt Problems–cont.
Tension Loss 1. Weak support structure 1. Reinforce structure.
2. Excessive sprocket wear 2. Use alternate sprocket material.
3. Fixed (non-adjustable) centers 3. Use inside idler for belt adjust-
ment.
4. Excessive debris 4. Remove debris, check guard.
capacity.
ters.
7. Belt, sprocket or shafts running 7. Check for conductive heat transfer
too hot from prime mover.
8. Unusual belt degradation 8. Reduce ambient drive temperature
to 185°F maximum.
Excessive Belt Edge Wear 1. Damage due to handling 1. Follow proper handling instructions.
2. Flange damage 2. Repair flange or replace sprocket.
3. Belt too wide 3. Use proper width sprocket.
4. Belt tension too low 4. Adjust tension to recommended
value.
5. Rough flange surface finish 5. Replace or repair flange (to elimi-
nate abrasive surface).
6. Improper tracking 6. Correct alignment.
7. Belt hitting drive guard or 7. Remove obstruction or use inside
bracketry idler.
8. Misalignment 8. Realign drive
Tensile Break 1. Excessive shock load 1. Redesign drive for increased
capacity.
ters.
3. Improper belt handling and storage 3. Follow proper storage and han-
prior to installation (crimping) dling procedures.
4. Debris or foreign object in drive 4. Remove objects and check guard.
5. Replace sprocket.
5. Extreme sprocket run-out
Belt Cracking 1. Subminimal diameter 1. Redesign drive using larger diame-

ter.
2. Backside idler 2. Use inside idler or increase diame-
ter of backside idler.
3. Extreme low temperature at start-up. 3. Pre-heat drive environment.
4. Extended exposure to harsh chem- 4. Protect drive.
icals
5. Cocked bushing/sprocket assembly 5. Install bushing per instructions.
Premature Tooth Wear 1. Too low or high belt tension 1. Adjust to recommended value.
2. Belt running partly off unflanged 2. Correct alignment.
sprocket
3. Misaligned drive 3. Correct alignment.
4. Incorrect belt profile for sprocket 4. Use proper belt/sprocket combina-
(i.e. HTD, GT®, etc) tion.
6. Rough sprocket teeth 6. Replace sprocket.
45
Synchronous Belt Problems–cont.
Premature Tooth Wear–cont. 7. Damaged sprocket 7. Replace.
8. Sprocket not to dimensional 8. Replace.
specification
9. Belt hitting drive bracketry or 9. Remove obstruction or use idler
other structure
capacity
11. Insufficient hardness of sprocket 11. Use a more wear-resistant
material sprocket
13. Cocked bushing/sprocket 13. Install bushing per instructions.
assembly
Tooth Shear 1. Excessive shock loads 1. Redesign drive for increased
capacity.
2. Less than 6 teeth-in-mesh 2. Redesign drive.
3. Extreme sprocket run-out 3. Replace sprocket.
5. Backside idler 5. Use inside idler
6. Incorrect belt profile for the 6. Use proper belt/sprocket combina-
sprocket (i.e. HTD®, GT®, etc.) tion.
7. Misaligned drive 7. Realign.
8. Belt undertensioned 8. Adjust tension to recommended
value.
Belt Ratcheting 1. Drive is undertensioned 1. Adjust tension to recommended
value.
2. Excessive shock loads 2. Redesign drive for increased
capacity.
3. Drive framework not rigid 3. Reinforce system.
Land Area Worn 1. Excessive tension 1. Adjust tension to recommended

value.
2. Excessive sprocket wear 2. Check sprocket condition. Replace
if necessary.
Synchronous Sprocket Problems

Flange Failure 1. Belt forcing flange off 1. Correct alignment or properly
secure flange to sprocket.
Unusual Sprocket Wear 1. Sprocket has too little wear resist- 1. Use alternate sprocket material.
ance (i.e. plastic, aluminum, soft
metals)
2. Misaligned drive 2. Correct alignment.
capacity.
5. Belt tension too low or high 5. Adjust tension to recommended
value.
6. Incorrect belt profile (i.e. HTD®, 6. Use proper belt/sprocket combina-
GT®, etc.) tion.
46
Synchronous Sprocket Problems–cont.
Rust and Corrosion 1. Rust caused by high moisture 1. Replace cast iron sprockets and
conditions in the production area, bushings with stainless steel com-
or by the use of water-based ponents.
cleaning solutions. 2. Replace cast iron sprockets with
nickel plated sprockets.
Performance Problems
Incorrect driveN speed 1. Design error 1. Use correct driveR/driveN sprocket
size for desired speed ratio.
Belt Tracking 1. Belt running partly off unflanged 1. Correct alignment.
sprocket
2. Centers exceed 8 times small 2. Correct parallel alignment to set
sprocket diameter belt to track on both sprockets.
Flange both sprockets.
3. Excessive belt edge wear 3. Correct alignment.
Excessive Temperature (Belt, 1. Misaligned drive 1. Correct alignment.
Bearing, Housing, Shafts, etc.) 2. Too low or high belt tension 2. Adjust tension to recommended
value.
3. Incorrect belt profile (i.e. HTD®, 3. Use proper belt/sprocket combina-
GT®, etc.) tion.
Shafts Out of Sync 1. Design error 1. Use correct sprocket sizes.
2. Incorrect belt 2. Use correct belt with correct tooth
profile for grooves.
Vibration 1. Incorrect belt profile for the 1. Use proper belt/sprocket combina-
sprocket (i.e. HTD®, GT®, etc.) tion.
2. Too low or high belt tension 2. Adjust tension to recommended
value.
3. Bushing or key loose 3. Check and reinstall per instructions.
47
TROUBLESHOOTING TOOLS
The tools available to help troubleshoot drive problems Belt & Sheave Groove Gauges
range from the surprisingly simple to complicated.
Following is a list of tools that can be used to effectively If a belt-to-sheave groove mismatch is suspected, English
diagnose a problem. While Gates does not sell all of the and metric belt and sheave groove gauges can be used to
items discussed in this section, the items are readily avail- check dimensions. These also are handy for identifying a
able from industrial instrumentation outlets throughout belt cross sec-
the United States. tion for replace-
ments and for
Eyes, Ears & Nose checking sheave
When troubleshooting a belt drive problem, stand back grooves for
and observe the drive while it is in operation and at rest. wear.
Is there a warm rubber smell? Is there anything unusual
about the way the belt travels around the drive? Is the These gauges
drive frame flexing under load? Are there chirping, are available
squealing or grinding noises? Is there an accumulation of from the local
dust or debris beneath the drive which might interfere Gates
with the belts? distributor.
English Gauge:
Squirt Bottle With Soapy Water
Product No.
When a belt drive is excessively noisy, the belt is often 7401-0014
incorrectly blamed. It is easy to eliminate the belt as the Metric Gauge:
problem by spraying it with soapy water while it is run- Product No.
ning. If the noise goes away, or decreases, then the belt is 7401-0013
part of the problem. If the same noise is still present, the
problem is likely due to other drive components. Long Straight
Edge
String
While V-belts can be somewhat forgiving of misalign-
Variation in drive center distance, often caused by weak
ment, this condition can still affect V-belt performance.
supporting structure, can cause problems from vibration
Even slight misalignment can cause major problems on a
to short belt life. To determine if center distance variation
synchronous drive. Use a long straight edge, made of
exists, turn off the drive and tightly tie a piece of string
wood, metal or any rigid material, to quickly check drive
from the driveR to the driveN shaft. Start up the drive and
alignment. Simply lay the straight edge across the pulley
note if the string stretches almost to the point of break-
faces and note the points of contact (or lack of contact).
ing, or goes slack. If either is the case, the problem could
be center distance variation. Design Flex® II and Design View® Software
It is particularly important to observe the string right at
drive start up when the loads are highest. String can also Gates design suite of engineering programs include inter-
be used to check pulley alignment. active support software and a user friendly interface for
rapid data retrieval and smooth design work.
Both programs are available at www.gates.com.
NOTE: In some cases redesign of the drive is

necessary. Gates Design Flex® II drive design software
provides a quick, accurate and flexible method of cor-
rectly redesigning problem drives.
48
A B C D E F
Belt Tension Testers D. Krikit Gauge Accessories:

Improper belt tension, either too (Product No. 7401-0071) F. Flexible Sensor
high or too low, can cause belt drive For use with Automotive V-belts (Product No. 7420-0204)
problems. An “experienced” thumb G. Optional Inductive Sensor
E. Sonic Tension Meter
may be okay for ordinary drives, but Model 505C (Product No. 7420-0212)
for critical drives, (Product No. 7420-0201)*
Gates recommends using a
For extremely accurate belt tension
tension gauge. Proper tension and
measuring, the Gates Sonic Tension
installation can extend belt life and
Meter is an electronic device that
reduce costly downtime.
measures the natural frequency of a
Several types of tension gauges are free stationary belt span and instantly
available. computes the static belt tension
based upon the belt span length,
A. Tension Tester belt width and belt type.
(Product No. 7401-0076)
Maximum deflection force: 30 lbs. Features:
For use with all small V-belt and • Can be used for synchronous and
Synchronous drives, including V-belts.
PowerBand® and Poly Chain®
• Uses sound waves instead of
GT®2 belt drives.
force/deflection.
B. Double Barrel • Results are repeatable with any
Tension Tester operator.
(Product No. 7401-0075) • Portable, lightweight and easy to use.
Maximum deflection force: 66 lbs.
• Fast. Calculates tension in seconds.
For use with all multiple
V-belt and large Synchronous • Can be used in almost any environ-
drives, including PowerBand® and ment.
Poly Chain® GT® 2 belt drives. • Model 505C runs on two AAA bat-
teries.
C. 5-Barrel Tension Tester
(Product No. 7401-0079) * Available until stock is depleted.
Maximum deflection force: 165 New model available January, 2005.
lbs. for use with multiple V-belt Sonic Tension Meter
Model 507C
and large Synchronous drives. (Product No. 7420-0507)
49
Dial Indicator Noise Meter EZ Align™ Laser Alignment Tool
Improperly mounted sheaves or out- Use a noise meter to measure envi- (Product No. 7420-1000)
of-round pulleys are sometimes the ronmental and belt drive noise. • Compact design
root of vibration or more severe prob-
• Laser projects a line
lems. This device can be used to meas-
• Mirror reflects laser line, making it
ure side-to-side sheave wobble or
easy to align shafts
diameter variation by holding it up to
• Laser line is very easy to read on
the sheave sidewall or top of the belt
targets
inside the pulley groove, respectively.
• Includes a hard foam filled plastic
IMPORTANT: Always turn off the
carrying case
machine before using the dial indica-
tor. Rotate the drive by hand to make
your measurements.
Strobe Tachometer
It is not always possible to see what
is happening to a drive while it is in
operation. This instrument visually
stops the action to get a better idea
of the dynamic forces affecting the
drive. The strobe tachometer is best
used after initial diagnosis of the
problem because it helps pinpoint
the cause. It will help identify such
things as single or dual mode belt
span vibration and frame flexure.
Infrared Pyrometer
The pyrometer accurately measures
external belt temperatures and envi-
ronmental temperatures.
50
TECHNICAL INFORMATION
Table No. 1 Table No. 2

Belt Section, Sheave Diameters and Standard Maximum Allowable Outside Diameters
Groove Angles* For Cast Iron Pulleys
Table No. 3
Depth hk
Shaft Diameter (Inches) Width wk +0.015-0.000
(inches)* (Inches)
Up Through 7/16 (0.44) 3/32 (0.094) 3/64 (0.047)
Over 7/16 ( 0.44) To and Incl. 9/16 ( 0.56) 1/8 (0.125) 1/16 (0.062)
Over 9/16 ( 0.56) To and Incl. 7/8 ( 0.88) 3/16 (0.188) 3/32 (0.094)
Over 7/8 ( 0.88) To and Incl. 1 1/4 ( 1.25) 1/4 (0.250) 1/8 (0.125)
Over 1 1/4 ( 1.25) To and Incl. 1 3/8 ( 1.38) 5/16 (0.312) 5/32 (0.156)
Over 1 3/8 ( 1.38) To and Incl. 1 3/4 ( 1.75) 3/8 (0.375) 3/16 (0.188)
Over 1 3/4 ( 1.75) To and Incl. 2 1/4 ( 2.25) 1/2 (0.500) 1/4 (0.250)
Over 2 1/4 ( 2.25) To and Incl. 2 3/4 ( 2.75) 5/8 (0.625) 5/16 (0.312)
Over 2 3/4 ( 2.75) To and Incl. 3 1/4 ( 3.25) 3/4 (0.750) 3/8 (0.375)
Over 3 1/4 ( 3.25) To and Incl. 3 3/4 ( 3.75) 7/8 (0.875) 7/16 (0.438)
Over 3 3/4 ( 3.75) To and Incl. 4 1/2 ( 4.50) 1 (1.000) 1/2 (0.500)
Over 4 1/2 ( 4.50) To and Incl. 5 1/2 ( 5.50) 1 1/4 (1.250) 5/8 (0.625)
Over 5 1/2 ( 5.50) To and Incl. 6 1/2 ( 6.50) 1 1/2 (1.500) 3/4 (0.750)
Over 6 1/2 ( 6.50) To and Incl. 7 1/2 ( 7.50) 1 3/4 (1.750) 3/4 (0.750)
Over 7 1/2 ( 7.50) To and Incl. 9 ( 9.00) 2 (2.000) 3/4 (0.750)
Over 9 ( 9.00) To and Incl. 11 ( 11.00) 2 1/2 (2.500) 7/8 (0.875)
Over 11 (11.00) To and Incl. 13 ( 13.00) 3 (3.000) 1 (1.000)
*Tolerance on Width, wk for widths up through 1/2'' (0.500) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.002-0.000

For widths over 1/2'' (0.500) through 1'' (1.000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.003-0.000
For widths over 1'' (1.000) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +0.400-0.000
51
Electric Motor Frames

and Minimum Sheave and Sprocket Diameters
Table No. 4
The National Electric Manufacturers Horsepower at Synchronous Speed (rpm) Synchronous
Association (NEMA) publishes recom- Belts
Motor Shaft 3600 1800 1200 900 Min.
mendations for the minimum diame- Frame Dia. (3450) (1750) (1160) (870) Pitch
ter of sheaves to be used on General Code (in) Dia. (in)
Purpose electric motors. Purpose of 143T 0.875 1-1/2 1 3/4 1/2 2.0
the recommendations is to prevent 145T 0.875 2—3 1-1/2 — 2 1 3/4 2.2
the use of too small sheaves, which 182T 1.125 3 3 1-1/2 1 2.2
can result in shaft or bearing dam- 182T 1.125 5 — — — 2.4
age because belt pull goes up as 184T 1.125 — — 2 1-1/2 2.2
sheave diameter goes down. 184T 1.125 5 — — — 2.2
The NEMA Standard MG-1-14.42, 184T 1.125 7-1/2 5 — — 2.7
November 1978 shows minimum 213T 1.375 7-1/2—10 7-1/2 3 2 2.7
recommended sheave diameters as a 215T 1.375 10 — 5 3 2.7
function of frame number. The table 215T 1.375 15 10 — — 3.4
below lists the NEMA frame assign- 254T 1.625 15 — 7-1/2 5 3.4
ments and minimum diameter rec- 254T 1.625 20 15 — — 4.0
ommendations according to the 256T 1.625 20-25 — 10 7-1/2 4.0
1964 rerating program. 256T 1.625 — 20 — — 4.0

284T 1.875 — — 15 10 4.0
284T 1.875 — 25 — — 4.0
286T 1.875 — 30 20 15 4.7
324T 2.125 — 40 25 20 5.4
236T 2.125 — 50 30 25 6.1
364T 2.375 — — 40 30 6.1
364T 2.375 — 60 — — 6.7
365T 2.375 — — 50 40 7.4
365T 2.375 — 75 — — 7.7
404T 2.875 — — 60 — 7.2
404T 2.875 — — — 50 7.6
404T 2.875 — 100 — — 7.7
405T 2.875 — — 75 60 9.0
405T 2.875 — 100 — — 7.7
405T 2.875 — 125 — — 9.5
444T 3.375 — — 100 — 9.0
444T 3.375 — — — 75 8.6
444T 3.375 — 125 — — 9.5
444T 3.375 — 150 — — 9.5
445T 3.375 — — 125 — 10.8
445T 3.375 — — — 100 10.8
445T 3.375 — 150 — — 10.8
445T 3.375 — 200 — — 11.9
For other than the General Purpose AC motors (for example, DC motors,
Definite Purpose motors, motors with special bearings or motors that are larger
than those covered by the NEMA standard), consult the motor manufacturer for
minimum sheave diameter recommendations. It is helpful to the manufacturer
to include details of the application with your inquiry.
52
Minimum Recommended Sprocket Outside Diameters

for General Purpose Electric Motors
Data in the white area are from NEMA Standard MG-1-14-42, June NOTE: For a given horsepower and speed, the total belt pull is relat-
1972. Figures in black area are from MG-1-43, January 1968. The ed to the motor sprocket size. As the size decreases, the total belt
gray area is a composite of electric motor manufacturer data. They pull increases. Therefore, to limit the resultant load on motor and
are generally conservative and specific motors and bearings may per- shaft bearings, NEMA lists minimum sprocket sizes for the various
mit the use of a smaller motor sprocket. Consult the motor manu- motors. The sprocket on the motor (DriveR sprocket) should be at
facturer. least this large.
NEMA Minumum Spocket Diameters
Table No. 5
*These RPM are for 50 cycle electric motors. # Use 8.6 for Frame Number 444 T only.
NEMA Minumum V-belt Sheave Diameters

Minimum Recommended Sheave Outside Diameters for Minimum Recommended Sheave Datum Diameters for
General Purpose Electric Motors General Purpose Electric Motors
Super HC ® V-belts, Super HC PowerBand ® Belts, Hi-Power ® II V-belts, Hi-Power II PowerBand Belts
Polyflex ® JB® Belts. or Tri-Power® Molded Notch V-belts.
Motor Motor RPM (60 cycle and 50 cycle Electric Motors) Motor Motor Motor RPM (60 cycle and 50 cycle Electric Motors) Motor
Horse- 575 690 870 1160 1750 3450 Horse- Horse- 575 690 870 1160 1750 3450 Horse-
power 485* 575* 725* 950* 1425* 2850 power power 485* 575* 725* 950* 1425* 2850 power
1/2 — — 2.2 — — — 1/2 1/2 2.5 2.5 2.2 — — — 1/2
3/4 — — 2.4 2.2 — — 3/4 3/4 3.0 2.5 2.4 2.2 — — 3/4
1 3.0 2.5 2.4 2.4 2.2 — 1 1 3.0 2.5 2.4 2.4 2.2 — 1
1 1/2 3.0 3.0 2.4 2.4 2.4 2.2 1 1/2 1 1/2 3.0 3.0 2.4 2.4 2.4 2.2 1 1/2
2 3.8 3.0 3.0 2.4 2.4 2.4 2 2 3.8 3.0 3.0 2.4 2.4 2.4 2
3 4.5 3.8 3.0 3.0 2.4 2.4 3 3 4.5 3.8 3.0 3.0 2.4 2.4 3
5 4.5 4.5 3.8 3.0 3.0 2.4 5 5 4.5 4.5 3.8 3.0 3.0 2.6 5
7 1/2 5.2 4.5 4.4 3.8 3.0 3.0 7 1/2 7 1/2 5.2 4.5 4.4 3.8 3.0 3.0 7 1/2
10 6.0 5.2 4.4 4.4 3.8 3.0 10 10 6.0 5.2 4.6 4.4 3.8 3.0 10
15 6.8 6.0 5.2 4.4 4.4 3.8 15 15 6.8 6.0 5.4 4.6 4.4 3.8 15
20 8.2 6.8 6.0 5.2 4.4 4.4 20 20 8.2 6.8 6.0 5.4 4.6 4.4 20
25 9.0 8.2 6.8 6.0 4.4 4.4 25 25 9.0 8.2 6.8 6.0 5.0 4.4 25
30 10.0 9.0 6.8 6.8 5.2 — 30 30 10.0 9.0 6.8 6.8 5.2 — 30
40 10.0 10.0 8.2 6.8 6.0 — 40 40 10.0 10.0 8.2 6.8 6.0 — 40
50 11.0 10.0 8.4 8.2 6.8 — 50 50 11.0 10.0 9.0 8.2 6.8 — 50
60 12.0 11.0 10.0 8.0 7.4 — 60 60 12.0 11.0 10.0 9.0 7.4 — 60
75 14.0 13.0 9.5 10.0 8.6 — 75 75 14.0 13.0 10.5 10.0 9.0 — 75
100 18.0 15.0 12.0 10.0 8.6 — 100 100 18.0 15.0 12.5 11.0 10.0 — 100
125 20.0 18.0 15.0 12.0 10.5# — 125 125 20.0 18.0 15.0 12.5 11.5† — 125
150 22.0 20.0 18.0 13.0 10.5 — 150 150 22.0 20.0 18.0 13.0 — — 150
200 22.0 22.0 22.0 — 13.2 — 200 200 22.0 22.0 22.0 — — — 200
250 22.0 22.0 — — — — 250 250 22.0 22.0 — — — — 250
300 27.0 27.0 — — — — 300 300 27.0 27.0 — — — — 300
*These RPM are for 50 cycle electric motors. # 9.5 for Frame Number 444T. *These RPM are for 50 cycle electric motors. † 11.0 for Frame Number 444T.
Data in the white area of Table No. 6 are from NEMA Standard MG-1-14.42, November 1978. Data in the gray Data in the white area of Table No. 7 are from NEMA Standard MG-1-14.42, November 1978. Data in the gray
area are from MG-1-14.43, January 1968. Data in the ?? area are a composite of electic motor manufacturers area are from MG-1-14.43, January 1968. Data in the ?? area are a composite of electic motor manufacturers
data. They are generally conservative, and specific motors and bearings may permit the use of a smaller motor data. They are generally conservative, and specific motors and bearings may permit the use of a smaller motor
sheave. Consult the motor manufacturer. See Page ??. sheave. Consult the motor manufacturer. See Page ??.
53
TECHNICAL
TROUBLESHOOTING
INFORMATION
TOOLS
Minimum Recommended Minimum Recommended
Sheave Diameter By Belt Sprocket Sizes
Cross Section

Min Recommended Min Recommended Sprocket Size
Belt Datum Diameter Belt Pitch (No. of Teeth)
Cross (Standard Groove)
Section (in) PowerGrip® Timing
Classical V-belts MXL 12
AX 2.20 XL 12
A 3.00 L 12
BX 4.00 H 14
B 5.40 XH 18
CX 6.80 XXH 18
C 9.00 PowerGrip® HTD®
D 13.00 3M 12
E 21.00 5M 14
Min Recommended PowerGrip® GT®2
Belt Outside Diameter
Cross (Standard Groove)
2M 12
Section (in) 3M 16
Narrow V-belts 5M 18
3VX 2.20 8M 22
3V 2.65 14M 28
5VX 4.40 20M 34
5V 7.10 Poly Chain® GT®2
8V 12.50 8M 22
Light Duty V-belts 14M 28
2L 0.8 Synchro-Power® Polyurethane
3L 1.5 MXL 10
4L 2.5 XL 10
5L 3.5 L 10
Micro-V® Belts H 14
J 0.8 T2.5 12
L 3.00 T5 10
M 7.00 T10 16
Polyflex® JB® Belts T20 15
3M 0.67 AT5 12
5M 1.04 AT10 18
7M 1.67 AT20 18
11M 2.64 5mm HTD 10
8mm HTD 16
14mm HTD 28
54
TROUBLESHOOTING
TOOLS
Minimum Recommended Idler
Diameters
Table No. 10
Min. O.D. Min. O.D.
Grooved Min. O.D. Flat
Inside Flat Inside Backside
Belt Cross Section Idler (in) Idler (in) Idler (in)
A, AA, AX 2.75 2.25 4.25
B, BB, BX 4.00 3.75 6.00
C, CC, CS 6.75 5.75 8.50
D 9.00 7.50 13.50
3V, 3VX 2.65 4.25
5V, 5VX 7.10 10.00
8V 12.50 17.50
Minimum Min. O.D.

Grooved Min. O.D. Flat
Inside Flat Inside Backside
Belt Cross Section (grooves) Idler (in) Idler (in)
MXL PowerGrip Timing 12 1.00 0.50
XL PowerGrip Timing 12 2.50 1.00
L PowerGrip Timing 10 4.75 1.60
H PowerGrip Timing 14 6.38 2.88
XH PowerGrip Timing 18 11.00 6.38
XXH PowerGrip Timing 18 15.75 9.25
3M PowerGrip HTD 12 1.50 0.75
5M PowerGrip HTD 14 2.50 1.25
2M PowerGrip GT2 12 1.00 0.50
20M PowerGrip GT2 34 10.00 11.00
5M Poly Chain GT 16 2.50 1.88
8M Poly Chain GT2 25 4.00 3.00
14M Poly Chain GT2 28 7.00 6.50
Minimum Center Distance Allowances

for Belt Installation and Takeup
Table No. 11
55
Minimum Center Distance
Allowances for Belt
Installation and Takeup
Table No. 12
Table No. 13
56
Poly Chain® GT®2 Installation & Table No. 14
Tensioning Allowances
Center Distance Allowance For
Installation and Tensioning
Table No. 15
Additional Center Distance
Allowance For Installation Over
Flanged Sprocket*
(Add to Installation Allowance in
Above Table)
57
Table No. 16
Power Grip GT2® Center Distance
Allowance For Installation and
Tensioning
Table No. 17

allowance For Installation Over
Flanged Sprockets*
Above Table)
58
Table No. 18
Power Grip® Timing Belts Center
Distance Allowance for
Installation and Tensioning
Table No. 19
Allowance for Installation Over
Flanged Pulleys*
Above Table)
Table No. 20
Estimating Belt Length from

Drive Dimensions
(2 Pulleys)
59
NOTES
66
FRACTIONS – DECIMALS - MILLIMETERS
Conversion Equivalency
To Convert To Multiply By 1 Cubic Meter = 1.307951 Cubic Yards 1 Cubic Meter = 264.1721 Gallons
Inches Millimeters 25.4 1 Cubic Yard = 0.7645549 Cubic Meters 1 Liter = 0.2641721 Gallons
Millimeters Inches .03937 1 U.S. Gallon = 3.785412 Liters 1 Gallon = 3.785412 Liter
Inches Centimeters 2.54 1 Liter = 0.2641721 Gallon 1 Gallon per Minute = 3.78 Liters Per Minute
Centimeters Inches .3937 1 Foot Per Second = 0.3048 Meter Per Second 1 Liter Per Minute = 0.264172 Gallons Per Minute
Inches Meters .0254 1 Meter Per Second = 3.28084 Feet Per Second 1 Milliliter = 0.03381402 Ounce
Meters Inches 39.3701 1 Bar = 14.50377 PSI 1 Ounce = 29.57353 Milliliter
Feet Meters .3048 1 PSI = 0.06894757 Bar 1 Liter = 33.81402 Ounce
Meters Feet 3.2808 1 Kilopascal = 0.1450377 PSI 1 Quart = 946.3529 Milliliter
Kilometers Miles .621414 1 PSI = 6.894757 Kilopascal 1 Acre = 0.4046862 Hectare
Miles Kilometers 1.60932 1 HP = 0.7456994 KW 1 Hectare = 2.471044 Acre
1 KW = 1.341022 HP 1 Acre Foot = 325,800 Gallons
1 Newton Meter (N.M.) = 0.737561 LB. FT. 1 Acre Foot = 12,331,531 Liter
1 Newton Meter (N.M.) = 8.85075 LB. IN. Pipe GPM = 2.448 x D2 x Velocity
1 LB. FT. = 1.35582 N.M. Pipe Velocity = GPM/2.448 x D2
1 LB. IN. = 0.1129848 N.M. Area of Pipe = GPM x .3208/Velocity
1 Gallon = 231 Cubic Inches PSI = Head (Ft.)/2.31
1 Cubic Yard = 201.974 Gallons
STANDARD HAND SIGNALS FOR CONTROLLING CRANE OPERATIONS
HOIST. With forearm vertical, LOWER. With arm extended USE MAIN HOIST. Tap fist on head; USE WHIPLINE (Auxiliary Hoist).
forefinger pointing up, move hand in downward, forefinger pointing down, then use regular signals. Tap elbow with one hand; then use
small horizontal circle. move hand in small horizontal circle. regular signals.
RAISE BOOM. Arm extended, fingers LOWER BOOM. Arm extended, fingers SWING. Arm extended, point with STOP. Arm extended, palm down,
closed, thumb pointing upward. closed, thumb pointing downward. finger in direction of swing of boom. move arm back and forth
horizontally.
LOWER THE BOOM AND RAISE THE MOVE SLOWLY. Use one hand to RAISE THE BOOM AND LOWER THE EMERGENCY STOP. Both arms
LOAD. With arm extended, thumb give any motion signal and place other LOAD. With arm extended, thumb extended, palms down, move arms
pointing down; flex fingers in and out as hand motionless in front of the hand pointing up; flex fingers in and out as back and forth horizontally.
long as the load movement is desired. giving the motion signal. (Hoist slowly long as load movement is desired.
shown as example).
TRAVEL. Arm extended forward, hand DOG EVERYTHING. Clasp hands in TRAVEL. (Both Tracks). Use both fists TRAVEL. (One Track) Lock the track on
open and slightly raised, make pushing front of body. in front of body, making a circular side indicated by raised fist. Travel
motion in direction of travel. motion about each other, indicating opposite track in direction indicated by
direction of travel, forward or circular motion of other fist, rotated
backward. (For land cranes only.) vertically in front of body. (For land
cranes only.)
EXTEND BOOM (Telescoping RETRACT BOOM (Telescoping EXTEND BOOM (Telescoping Boom). RETRACT BOOM (Telescoping
Booms). Both fists in front of body with Booms). Both fists in front of body with One Hand Signal. One fist in front of Boom). One Hand Signal. One first in
thumbs pointing outward. thumbs pointing toward each other. chest with thumb tapping chest. front of chest, thumb pointing outward
and heel of fist tapping chest.
NOTE: Other regulations may apply. Consult local governing authorities.
Appendix
Wire Rope
1.0 General
Data included in this appendix and the section on “Slings, Chains, and Accessories” include general
information and specific requirements about the design and construction characteristics of commonly used
wire rope and accessories.
1.1 General. Wire rope design and construction characteristics shown in this appendix are for reference only.
Manufacturer’s specification data may differ from these and must be used in determining safe working
loads and proper application.
1.2 Materials. Wire rope may be manufactured from many grades and types of steel and alloys. They may be
constructed from nonferrous materials or coated wires. Some of the more common grades with the differing
designations are as follows:
a. Improved plow steel monitor steel - purple grade - Level 3 steel 11
b. Extra improved plow steel - monitor AA grade - purple plus - Level 4 steel1, 2
1.3 Terminology. Cross section AA. General view.
1.3.1 Wire Rope. Figure D-1 shows the general terminology, structure, and cross- sectional views of wire
rope.
1.3.2 Cores for Wire Rope. The core is the central member about which the main strands are laid. The
principal function of the core is to provide a bearing for the strand. This foundation maintains the
proper lateral position of the strands and permits their relative longitudinal motion in adjusting the
distribution of stress. Figure D-2 shows the three common types of cores used in wire rope.
1.3.3 Wire Rope Lays. The lay direction of a wire rope is the direction in which the strands rotate around
the rope, as seen receding from the observer and viewed from above. The lay direction of outer wires
of a single strand is determined in the same manner. Figure D-3 shows the various lay combinations.
1
These two major grade classifications and corresponding rope breaking strengths may vary with different manufacturers and date of manufacturing.
2
Application of these high strengths should be under the direction of manufacturer or a professional engineer.
The lay as a unit of measure is the length a single strand extends in making one complete turn around the
rope. Lay length is measured in a straight line parallel to the centerline of the rope; not by following the path of
the strand.
1.3.4 Rope Diameter. Figure D-4 shows the right and wrong way to measure rope diameter.
1.3.5 Rope Class. Wire rope is designed by class: 6x7 (6 strands, 7 wires); 6x19 (6 strands, 19 main wires
per strand); 6x37 (6 strands, nominally 37 wires per strand). When “nominally” is used, the number of
wires per strand may vary significantly (i.e., 6x19 nominal may have from 9 to 26 wires per strand).
2.0 Wire Rope End Connectors (fittings, end attachments, terminals)
2.1 General. Choosing proper end connectors (fittings) to be used with wire rope is second in importance only
to selecting the rope itself. Connectors are subjected to the same loads as the wire rope used and must be
properly designed and built to withstand the stresses imposed on them.
2.2 Wire Rope Clip Connectors. Wire rope clip connectors may use the U-bolt type or the twin base clip (“First”
grip, double saddle) type. Use only new clips in making wire rope clip connectors.
Figure D-2. –Three common types of cores used in wire rope.
Figure D-3. – Various combinations of wire rope lays
2.2.1 U-bolt Type Clip. U-bolt clips shall be constructed of drop-forged steel bases protected by an
application of a galvanized zinc coating (see figure D-5). Approximate dimensions and construction
details are shown in table D-1.
There is only one correct way to attach U- bolt clips to wire rope ends. The base of the clip bears on
the live end of the rope; the HUH of the bolt bears on the dead end with a thimble installed in the
eye (see figure D-6).
The approximate number of clips and their spacing distance is shown in table D2 and figure D-7.
Consult the clip manufacturer for exact number of clips required and spacing dimensions.
2.2.2 Twin Base Clips. Twin base clips must be constructed of drop forged steel bases protected by an
application of zinc coating (galvanized). Approximate dimension and construction details are shown in
table D-3. Number of clips and their spacings are the same as shown for U-bolt clips.
Twin-base clips are installed as shown in figure U-S. Because of their special design, there is no top
or bottom, and they cannot be installed incorrectly.
Additional information on installation of wire rope clips is in the Rigging Manual
2.2.3 Joining Wire Ropes. Figure D-9 shows an acceptable method for joining wire ropes using a
combination of clips and thimbles.
Measure the larger dimension, between the outer limits of the strands. Do not measure the smaller dimensions across the “flats” of the strands.
Figure D-4. Correct and Incorrect way to measure rope diameter
Figure D-7. – Spacing dimensions for clips.
Nuts are heavy hexagon.
Figure D-8. – Twin-base clip installation.
Figure D-9. – Wire ropes joined with clips and thimbles.
2.3 Wedge Socket. The construction industry uses wedge sockets extensively because they attach easily to a wire
rope. In applying the socket, the live rope should lead out of the socket in a straight line. Figure D- 10 shows a
wedge socket. Figure D- 11 shows two recommended methods of attaching the socket to the wire rope.
Regularly inspect the integrity of the wire rope at the

point of exit at the dead-end side. High-velocity spin of
wire rope when loading and unloading causes the
rope to flip-flop, fatigue, and finally break off. When
the wire rope has delivered each one-fifth of service
life, remove the portion through the wedge and move
the wedge up the rope to a new location.
2.4 Handmade Spliced Eyes. Spliced eyes are frequently used as wire rope end attachments (see figure D-
12). They must incorporate rope thimbles to maintain rope strength and reduce wear. Because of the many
forms of eye splices and the varying efficiencies, do not use these types of attachments in slings or hoisting
operations.
Method using a Small Piece clipped to the Dead End The Extended Wedge Method
A small piece of rope is cut and clipped to the dead end. This method is In the extended wedge method, the wedge has an extension that
good for regular rope and approved by ASME B30.5. Distance “S” should accommodates a clip. Once the nuts are torqued, loading of the socket
be approximately 3X rope diameter or 3 inches, whichever is less. automatically result sin proper seating.
Figure D-11. – Two recommended methods of attaching the socket to the wire rope.
Figure D-12. – Example of a handmade spliced eye.
2.5 Manufactured Eye Splices. Manufactured eye splices, such as flemish eye, flemish eye plus serving, and
flemish eye plus pressed metal sleeve are the most efficient attachments and should be considered for all
hoisting operations. The zinc and swagged sockets are an excellent attachment for use in permanent
nonmovable-type installation such as pendant lines and guy wires. They, like the manufactured eyes, must
be constructed by well-trained, qualified personnel to ensure reliability.
2.6 Average Efficiency of Well-Made End Connectors on Terminals
a. Standard open and closed sockets. Attached with pure molten zinc: 100 percent
b. Flemish eye and pressed metal sleeve or swaged sockets on IWRC rope: 100 percent
c. Mechanically spliced eyes: 90 percent
d. Handmade eye splices: 80-90 percent
e. U-bolt clips (drop forged, new): 70-80 percent
f. Cast steel wedge sockets: 70 percent
Note: Percentages relate to rope breaking strength (i.e, a swaged socket has the same strength (100 percent) of the wire rope.
3.0 Common Safety Factors and Maximum (Safe) Working Loads
3.1 Safety Factors. The total stress in a wire rope, in service, is composed of several separate elements.
These are reduced to a single tensile load value. When this value exceeds the breaking strength of the
wire rope, a failure occurs.
The factor to provide a margin of safety between the applied tensile forces and the breaking strength of the
rope is defined as the factor of safety.
Minimum safety factors for wire rope used in different types of service are contained in national standards
(i.e., ANSI 17.1 safety code for elevators and escalators, ANSI/ASME B30.5 Mobile and Locomotive
Cranes).
Table D3 shows a partial compilation of approximate design safety factors. Refer to appropriate standards
for precise requirements.
3.2 Maximum (Safe) Working Load. Calculate the maximum safe working load of wire rope, dividing the
manufacturers’ supplied breaking strength by the safety factor.
Example: Calculate the maximum safe working load of a single-leg sling made from a 1/2-inch-diameter,
6X19 class wire rope constructed of improved plow steel (purple grade) material with poured zinc fittings
and an independent wire rope core (IWRC).
(1) Obtain the breaking strength of the wire rope from the 6X19 class table shown under paragraph 2.4.1 of
this appendix (11.5 tons or 23,000 pounds).
(2) Find the appropriate safety factor (5) for slings from table D3 or from subsection 17.4 of the text.
(3) Divide the breaking strength (23,000 pounds) by the safety factor (5) to obtain the maximum (safe)
working load (4,600 pounds).
Max (safe) working load = 23,000 pounds/5 = 4,600 pounds (1)
Conversely, to determine the actual safety factor under any condition of loading, multiply the rope breaking
strength by the number of parts of line under load and divide this product by the actual working load.
Example: Using a 1/2-inch-diameter, 6X19 class wire rope with the breaking strength shown, in a two-part
line hoisting operation with a maximum load including weight of blocks, hooks, etc., of 9,200 pounds,
calculate the actual safety factor.
23,000 pounds X 2 46,000 pounds
= = 5 safety factor
9,200 pounds 9,200 pounds
Note: Consult the table of required safety factors or specify safety factor requirements contained in national standards to determine what type of service
this specific hoisting system can be used for. In any service requiring a safety factor of 5 or less, the system would be satisfactory. In any system
requiring a safety factor greater than 5, the system would be unsatisfactory.
Exercise caution in using this simplified method of calculation as some dynamic forces may need to be
included in the maximum loading figure. Also, other factors such as sheave diameters, friction losses, hot
environments, etc., may require higher safety factors.
4.0 Inspection and Retirement of Wire Rope
Eventually, all wire ropes deteriorate to the point that they are no longer safe for use. The frequency of
inspections, the extent of the inspection, and the criteria for condemning wire ropes vary greatly for each
type of service, Inspection frequencies and rope retirement criteria are usually found in specific national
standards. If no standards exist for the type of service anticipated, the rope or equipment manufacturer or a
professional engineer must develop the criteria. In no ease shall the rope retirement criteria allow rope to
be continued in any hoisting or load carrying service when one or more of the following deficiencies exist:
(a) Ropes are not of proper size, grade, or construction for the particular performance or function.
(b) In running ropes, six randomly distributed broken wires in one rope lay, or three broken wires in one
strand in one rope lay. (A rope lay is the length along the rope in which one strand makes a complete
revolution around the rope.)
(c) In pendants or standing ropes, evidence of more than one broken wire in one lay.
(d) Abrasion, scrubbing, or peening causing loss of more than one-third of the original diameter of the
outside wires.
(e) Evidence of severe corrosion.
(f) Severe kinking, crushing, or other damage resulting in distortion of the rope structure.
(g) Evidence of any heat damage from a torch or arc caused by contact with electrical wires.
(h) Reduction from nominal rope diameter of more than 3/64 inch for diameters up to and including 3/4
inch; 1/16 inch for diameters 7/8 to 1-1/8 inches; and 3/32 inch for diameters 1-1/4 inch to 1-1/2 inches.
Marked reduction in diameter indicates deterioration of the core, resulting in lack of proper support for
the load carrying strands. Excessive rope stretch or elongation may also indicate internal deterioration,
(i) Evidence of “bird caging” or other distortion resulting in some members of the rope structure carrying
more load than others.
(j) Noticeable rusting or development of broken wires in the vicinity of attachments.
Wedge Sockets are among the simplest devices for anchoring a wire rope for any purpose. They are intended
for on the job attachment and for quick rope replacement. Principal advantages are simplicity ease and
speed of applying and detaching. They are also used where conditions are such that spliced eyes could not
be reeved and would have to be made after the rope was in place.
The efficiency of a wedge socket is row, however; only 80% of the strength of the rope. Care must be taken
that moving loads do not force the wedges out and accidental slackening of the cable does not release the
socket. To prevent this they should be positive locked. Also the dead or short end of the cable should either
have a clip attached to it, or be looped back and secured to itself by a clip. The loop thus formed must not
be allowed to enter the wedge. Do not attach the dead end of the cable to the live side of the line with the
clip as this will seriously weaken the attachment. The clip will ultimately take the load and could deform and
break the cable.
Wedge socket anchorages should not be used on rotation resistant ropes, because of the small radius of
wedge sockets and the possibility of severe core slippage, unless extreme care is used in their installation
Before the rope is pulled tightly into its final position in the wedge, the seizings should be removed to allow
for the inevitable relative movement of the strands in the different layers. Once seated, the seizings can be
re-applied.
When using wedge sockets it is good practice to start out with a longer rope than is required so that the socket
can be renewed periodically without having to splice the rope. The wedge can be punched out of the
socket the bad wire cut off and re-fitted in the socket. The rope end should always protrude at feast 6 to 9
inches beyond the socket.
It is very important to ensure that the loaded part of the rope is not kinked where it leaves the wedge. The
sockets must be installed so that the load line is in a straight line pull with the eye of the socket.
High Molecular Weight Poly Pipe
Pipe Data and Pressure Ratings
For reference only. Actual pipe condition, plumbing conditions, temperature and other factor’s will affect pipe pressure ratings.
Pressure 250 psi 200 psi 160 psi 130 psi 110 psi 100 psi 80 psi 65 psi 50 psi
Rating SDR 7.3 SDR 9 SDR 11 SDR 13.5 SDR 15.5 SDR 17 SDR 21 SDR 26 SDR 32.5
IPS* O.D. Min. Weight Min. Weight Min. Weight Min. Weight Min. Weight Min. Weight Min. Weight Min. Weight Min. Weight
Pipe Size Size Wall LB./FT. Wall LB./FT. Wall LB./FT. Wall LB./FT. Wall LB./FT. Wall LB./FT. Wall LB./FT. Wall LB./FT. Wall LB./FT.
(Inches)
2 2.375 0.325 0.90 0.264 0.75 0.216 0.63 0.176 0.52 0.153 0.46 0.140 0.42 -- -- -- -- -- --
3 3.500 0.479 1.96 0.389 1.64 0.318 1.37 0.259 1.14 0.226 1.00 0.206 0.92 -- -- -- -- -- --
4 4.500 0.616 3.24 0.500 2.71 0.409 2.26 0.333 1.88 0.290 1.65 0.265 1.52 0.214 1.24 -- -- -- --
5 5.375 -- -- -- -- -- -- -- -- -- -- -- -- 0.256 1.77 0.207 1.45 0.165 1.17
5 5.563 0.762 4.95 0.618 4.13 0.506 3.46 0.412 2.87 0.359 2.53 0.327 2.32 0.265 1.90 0.214 1.55 0.171 1.25
6 6.625 0.908 7.02 0.736 5.86 0.602 4.91 0.491 4.07 0.427 3.58 0.390 3.29 0.315 2.69 0.255 2.20 0.204 1.77
7 7.125 -- -- -- -- -- -- -- -- -- -- -- -- 0.339 3.11 0.274 2.54 0.219 2.05
8 8.625 1.182 11.90 0.958 9.94 0.784 8.32 0.639 6.90 0.556 6.07 0.507 5.57 0.411 4.56 0.332 3.72 0.265 3.00
10 10.750 1.473 18.48 1.194 15.44 0.977 12.92 0.796 10.72 0.694 9.43 0.632 8.65 0.512 7.09 0.413 5.78 0.331 4.66
12 12.750 1.747 26.00 1.417 21.72 1.159 18.17 0.944 15.08 0.823 13.27 .0750 12.17 0.607 9.97 0.490 8.13 0.392 6.56
13 13.380 -- -- -- -- -- -- -- -- -- -- -- -- 0.637 10.98 0.515 8.96 0.412 7.22
14 14.000 1.918 31.34 1.556 26.19 1.273 21.91 1.037 18.18 0.903 16.00 0.824 14.68 0.667 12.02 0.538 9.81 0.431 7.91
16 16.000 2.192 40.94 1.778 34.20 1.455 28.62 1.185 23.75 1.032 20.90 0.941 19.17 0.762 15.71 0.615 12.81 0.492 10.33
18 18.000 -- -- 2.000 43.29 1.636 36.22 1.333 30.06 1.161 26.45 1.059 24.26 0.857 19.88 0.692 16.21 0.554 13.07
20 20.000 -- -- 2.222 53.44 1.818 44.72 1.481 37.11 1.290 32.66 1.176 29.96 0.952 24.54 0.769 20.01 0.615 16.14
22 22.000 -- -- -- -- 2.000 54.11 1.630 44.91 1.419 39.51 1.294 36.25 1.048 29.69 0.846 24.21 0.677 19.52
24 24.000 -- -- -- -- 2.182 64.39 1.778 53.44 1.548 47.02 1.412 43.14 1.143 35.34 0.923 28.81 0.738 23.24
28 28.000 -- -- -- -- -- -- 2.074 72.74 1.806 64.01 1.647 58.71 1.333 48.10 1.077 39.22 0.862 31.63
30 30.000 -- -- -- -- -- -- -- -- 1.935 73.48 1.765 67.40 1.429 55.21 1.154 45.02 0.923 36.31
32 32.000 -- -- -- -- -- -- -- -- 2.065 83.60 1.882 76.69 1.524 62.82 1.231 51.23 0.985 41.31
36 36.000 -- -- -- -- -- -- -- -- -- -- 2.118 97.06 1.714 79.51 1.385 64.83 1.108 52.28
42 42.000 -- -- -- -- -- -- -- -- -- -- -- -- -- -- 1.615 88.25 1.292 71.16
48 48.000 -- -- -- -- -- -- -- -- -- -- -- -- -- -- 1.846 115.26 1.477 92.95
Pipe Sizes and Dimensions – For Reference Only
Pipe Dimensions Imperial/Metric Pipe Chart
Nominal Nominal OD OD Schedule Wall Wall Lbs/Ft Kg/M
Pipe Size Pipe Inches mm Designations Thickness Thickness
Inches Size mm ANSI/ASME Inches mm
1/8 6 0.405 10.30 10/10S 0.049 1.24 0.1863 0.28
1/8 6 0.405 10.30 STD/40/40S 0.068 1.73 0.2447 0.36
1/8 6 0.405 10.30 XS/80/80S 0.095 2.41 0.3145 0.47
1/4 8 0.540 13.70 10/10S 0.065 1.65 0.3297 0.49
1/4 8 0.540 13.70 STD/40/40S 0.088 2.24 0.4248 0.63
1/4 8 0.540 13.70 XS/80/80S 0.119 3.02 0.5351 0.80
3/8 10 0.675 17.10 10/10S 0.065 1.65 0.4235 0.63
3/8 10 0.675 17.10 STD 40/40S 0.091 2.31 0.5676 0.84
3/8 10 0.675 17.10 XS 80/80S 0.126 3.20 0.7388 1.10
1/2 15 0.840 21.30 5/5S 0.065 1.65 0.5383 0.80
1/2 15 0.840 21.30 10/10S 0.083 2.11 0.671 1.00
1/2 15 0.840 21.30 STD 40/40S 0.109 2.77 0.851 1.27
1/2 15 0.840 21.30 XS 80/80S 0.147 3.73 1.088 1.62
1/2 15 0.840 21.30 160 0.188 4.78 1.309 1.95
1/2 15 0.840 21.30 XX 0.294 7.47 1.714 2.55
3/4 20 1.050 26.7 5/5S 0.065 1.65 0.6838 1.02
3/4 20 1.050 26.7 10/10S 0.083 2.11 0.8572 1.28
3/4 20 1.050 26.7 STD/40/40S 0.113 2.87 1.131 1.68
3/4 20 1.050 26.7 XS/80/80S 0.154 3.91 1.474 2.19
3/4 20 1.050 26.7 160 0.219 5.56 1.944 2.89
3/4 20 1.050 26.7 XX 0.308 7.82 2.441 3.63
1 25 1.315 33.4 5/5S 0.065 1.65 0.8678 1.29
1 25 1.315 33.4 10/10S 0.109 2.77 1.404 2.09
1 25 1.315 33.4 STD/40/40S 0.133 3.38 1.679 2.50
1 25 1.315 33.4 XS/80/80S 0.179 4.55 2.172 3.23
1 25 1.315 33.4 160 0.25 6.35 2.844 4.23
1 25 1.315 33.4 XX 0.358 9.09 3.659 5.45
1-1/4 32 1.6600 42.2 5/5S 0.065 1.65 1.107 1.65
1-1/4 32 1.660 42.2 10/10S 0.109 2.77 1.806 2.69
1-1/4 32 1.660 42.2 STD/40/40S 0.140 3.56 2.273 3.38
1-1/4 32 1.6600 42.2 XS/80/80S 0.191 4.85 2.997 4.46
1-1/4 32 1.660 42.2 160 0.250 6.35 3.765 5.60
1-1/4 32 1.660 42.2 XX 0.382 9.70 5.214 7.76
1-1/2 40 1.900 48.3 5/5S 0.065 1.65 1.274 1.90
1-1/2 40 1.900 48.3 10/10S 0.109 2.77 2.085 3.10
1-1/2 40 1.900 48.3 STD/40/40S 0.145 3.68 2.718 4.05
1-1/2 40 1.900 48.3 XS/80/80S 0.200 5.08 3.631 5.40
1-1/2 40 1.900 48.3 160 0.281 7.14 4.859 7.23
1-1/2 40 1.900 48.3 XX 0.400 10.16 6.408 9.54
2 50 2.375 60.3 5/5S 0.065 1.65 1.604 2.39
2 50 2.375 60.3 10/10S 0.109 2.77 2.638 3.93
2 50 2.375 60.3 STD/40/40S 0.154 3.91 3.653 5.44
2 50 2.375 60.3 XS/80/80S 0.218 5.54 5.022 7.47
2 50 2.375 60.3 160 0.344 8.74 7.462 11.11
2 50 2.375 60.3 XX 0.436 11.07 9.029 13.44
2-1/2 65 2.875 73 5/5S 0.083 2.11 2.475 3.68
2-1/2 65 2.875 73 10/10S 0.120 3.05 3.531 5.26
2-1/2 65 2.875 73 STD/40/40S 0.203 5.16 5.793 8.62
2-1/2 65 2.875 73 XS/80/80S 0.276 7.01 7.661 11.4
2-1/2 65 2.875 73 160 0.375 9.53 10.01 14.9
2-1/2 65 2.875 73 XX 0.552 14.02 13.69 20.37
3 80 3.500 88.9 5/5S 0.083 2.11 3.029 4.51
3 80 3.500 88.9 10/10S 0.120 3.05 4.332 6.45
3 80 3.500 88.9 STD/40/40S 0.216 5.49 7.576 11.27
3 80 3.500 88.9 XS/80/80S 0.300 7.62 10.25 15.25
3 80 3.500 88.9 160 0.438 11.13 14.32 21.31
3 80 3.500 88.9 XX 0.600 15.24 18.58 27.65
3-1/2 90 4.000 101.6 5/5S 0.083 2.11 3.472 5.17
3-1/2 90 4.000 101.6 10/10S 0.120 3.05 4.973 7.40
3-1/2 90 4.000 101.6 STD 40/40S 0.226 5.74 9.109 13.56
3-1/2 90 4.000 101.6 XS 80/80S 0.318 8.08 12.500 18.6
3-1/2 90 4.000 101.6 XX 0.636 16.15 22.850 34.01
4 100 4.500 114.3 5/5S 0.083 2.11 3.915 5.83
4 100 4.500 114.3 10/10S 0.120 3.05 5.613 8.35
4 100 4.500 114.3 STD 40/40S 0.237 6.02 10.790 16.06
4 100 4.500 114.3 XS 80/80S 0.337 8.56 14.980 22.29
4 100 4.500 114.3 120 0.438 11.13 19.000 28.28
4 100 4.500 114.3 160 0.531 13.49 22.510 33.50
4 100 4.500 114.3 XX 0.674 17.12 27.540 40.99
5 125 5.563 141.3 5/5S 0.109 2.77 6.349 9.45
5 125 5.563 141.3 10/10S 0.134 3.40 7.770 11.56
5 125 5.563 141.3 STD 40/40S 0.258 6.55 14.620 21.76
5 125 5.563 141.3 XS 80/80S 0.375 9.53 20.780 30.93
5 125 5.563 141.3 120 0.500 12.70 27.040 40.24
5 125 5.563 141.3 160 0.625 15.88 32.960 49.05
5 125 5.563 141.3 XX 0.750 19.05 38.550 57.37
6 150 6.625 168.3 5/5S 0.109 2.77 7.585 11.29
6 150 6.625 168.3 10/10S 0.134 3.40 9.289 13.82
6 150 6.625 168.3 STD 40/40S 0.280 7.11 18.970 28.23
6 150 6.625 168.3 XS 80/80S 0.432 10.97 28.570 42.52
6 150 6.625 168.3 120 0.562 14.27 36.390 54.16
6 150 6.625 168.3 160 0.719 18.26 45.350 67.49
6 150 6.625 168.3 XX 0.864 21.95 53.160 79.12
8 200 8.625 219.1 5S 0.109 2.77 9.914 14.75
8 200 8.625 219.1 10/10S 0.148 3.76 13.600 19.94
8 200 8.625 219.1 20 0.250 6.35 22.360 33.28
8 200 8.625 219.1 30 0.277 7.04 24.700 36.76
8 200 8.625 219.1 STD/40/40S 0.322 8.18 28.550 42.49
8 200 8.625 219.1 60 0.406 10.31 35.640 53.04
8 200 8.625 219.1 XS/80/80S 0.500 12.70 43.390 64.58
8 200 8.625 219.1 100 0.594 15.09 50.950 75.83
8 200 8.625 219.1 120 0.719 18.26 60.710 90.35
8 200 8.625 219.1 140 0.812 20.62 67.760 100.84
8 200 8.625 219.1 XX 0.875 22.23 72.420 107.78
8 200 8.625 219.1 160 0.906 23.01 74.690 111.16
10 250 10.75 273.1 5S 0.134 3.40 15.19 22.61
10 250 10.75 273.1 10S 0.165 4.19 18.700 27.83
10 250 10.75 273.1 20 0.250 6.35 28.040 41.73
10 250 10.75 273.1 30 0.307 7.80 34.240 50.96
10 250 10.75 273.1 STD/40/40S 0.365 9.27 40.480 60.24
10 250 10.75 273.1 XS/60/80S 0.500 12.70 54.740 81.47
10 250 10.75 273.1 80 0.594 15.09 64.430 95.89
10 250 10.75 273.1 100 0.719 18.26 77.030 114.64
10 250 10.75 273.1 120 0.844 21.44 89.290 132.89
10 250 10.75 273.1 140/XX 1.000 25.40 104.130 154.97
10 250 10.75 273.1 160 1.125 28.58 115.640 172.10
12 300 12.75 323.9 5S 0.156 3.96 20.980 31.22
12 300 12.75 323.9 10S 0.180 4.57 24.200 36.02
12 300 12.75 323.9 20 0.250 6.35 33.380 49.68
21 300 12.75 323.9 30 0.330 8.38 43.770 65.14
12 300 12.75 323.9 STD/40S 0.375 9.53 49.560 73.76
12 300 12.75 323.9 40 0.406 10.31 53.520 79.65
12 300 12.75 323.9 XS/80S 0.500 12.70 65.420 97.36
12 300 12.75 323.9 60 0.562 14.27 73.150 108.87
12 300 12.75 323.9 80 0.688 17.48 88.630 131.90
12 300 12.75 323.9 100 0.844 21.44 107.320 159.72
12 300 12.75 323.9 120/XX 1.000 25.40 125.490 186.76
12 300 12.75 323.9 140 1.125 28.58 139.670 207.86
12 300 12.75 323.9 160 1.312 33.32 160.270 238.52
14 350 14 355.6 10S 0.188 4.78 27.73 41.27
14 350 14 355.6 10 0.250 6.35 36.71 54.63
14 350 14 355.6 20 0.312 7.92 45.61 67.88
14 350 14 355.6 STD/30/40S 0.375 9.53 54.57 81.21
14 350 14 355.6 40 0.438 11.13 63.44 94.41
14 350 14 355.6 XS/80S 0.500 12.70 72.09 107.29
14 350 14 355.6 60 0.594 15.09 85.05 126.58
14 350 14 355.6 80 0.750 19.05 106.13 157.95
14 350 14 355.6 100 0.938 23.83 130.85 194.74
14 350 14 355.6 120 1.094 27.79 150.90 224.58
14 350 14 355.6 140 1.250 31.75 170.21 253.32
14 350 14 355.6 160 1.406 35.71 189.10 281.43
16 400 16 406.4 10S 0.188 4.78 31.75 47.25
16 400 16 406.4 10 0.250 6.35 42.05 62.58
16 400 16 406.4 20 .0312 7.92 52.27 77.79
16 400 16 406.4 STD/30/40S 0.375 9.53 62.58 93.13
16 400 16 406.4 XS/40/80S 0.500 12.70 82.77 123.18
16 400 16 406.4 60 0.656 16.66 107.50 159.99
16 400 16 406.4 80 0.844 21.44 136.61 203.31
16 400 16 406.4 100 1.031 26.20 164.82 245.29
16 400 16 406.4 120 1.219 30.96 192.43 286.38
16 400 16 406.4 140 1.438 36.53 223.64 332.83
16 400 16 406.4 160 1.594 40.49 245.25 364.99
18 450 18 457.2 10S 0.188 4.78 35.76 53.22
18 450 18 457.2 10 0.250 6.35 47.39 70.53
18 450 18 457.2 20 0.312 7.92 58.94 87.72
18 450 18 457.2 STD/40S 0.375 9.53 70.59 105.06
18 450 18 457.2 30 0.438 11.13 82.15 122.26
18 450 18 457.2 XS/80S 0.500 12.70 93.45 139.08
18 450 18 457.2 40 0.562 14.27 104.67 155.78
18 450 18 457.2 60 0.750 19.05 138.17 205.63
18 450 18 457.2 80 0.938 23.83 170.92 254.37
18 450 18 457.2 100 1.156 29.36 207.96 309.50
18 450 18 457.2 120 1.375 34.93 244.14 363.34
18 450 18 457.2 140 1.562 39.67 274.22 408.11
18 450 18 457.2 160 1.781 45.24 308.5 459.13
20 500 20 508 10S 0.218 5.54 46.06 68.55
20 500 20 508 10 0.250 6.35 52.73 78.48
20 500 20 508 STD/20/40S 0.375 9.53 78.60 116.98
20 500 20 508 XS/30/80S 0.500 12.70 104.13 154.97
20 500 20 508 40 0.594 15.09 123.11 183.22
20 500 20 508 60 0.812 20.62 166.40 247.65
20 500 20 508 80 1.031 26.19 208.87 310.85
20 500 20 508 100 1.281 32.54 256.10 381.14
20 500 20 508 120 1.500 38.10 296.37 441.07
20 500 20 508 140 1.750 44.45 341.09 507.63
20 500 20 508 160 1.969 50.01 379.17 564.30
24 600 24 609.6 10/10S 0.250 6.35 63.41 94.37
24 600 24 609.6 STD/20/40S 0.375 9.53 94.62 140.82
24 600 24 609.6 XS/80S 0.500 12.70 125.49 186.76
24 600 24 609.6 30 0.562 14.27 140.68 209.37
24 600 24 609.6 40 0.688 17.48 171.29 254.92
24 600 24 609.6 60 0.969 24.61 238.35 354.72
24 600 24 609.6 80 1.219 30.96 296.58 441.39
24 600 24 609.6 100 1.531 38.89 367.39 546.77
24 600 24 609.6 120 1.812 46.02 429.39 639.04
24 600 24 609.6 140 2.062 52.37 483.10 718.97
24 600 24 609.6 160 2.344 59.54 542.13 806.83
30 750 30 762 10 0.312 7.92 98.93 147.23
30 750 30 762 STD/40S 0.375 9.53 118.65 176.58
30 750 30 762 XS/20/80S 0.500 12.70 157.53 234.44
30 750 30 762 30 0.625 15.88 196.08 291.82
36 900 36 914.4 10 0.312 7.92 118.92 176.98
36 900 36 914.4 STD/40S 0.375 9.53 142.68 212.34
36
0
900 36 914.4 XS/80S 0.500 12.70 189.57 282.13

Operation & Instruction Manual Om 1270 50 FT

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Series 1270 – 50

E llic o t t D r e d g e s , L L C "Dragon" Dredge

OPERATION AND INSTRUCTION MANUAL

Ellicott Dredges, LLC

Contract #401390 ©2013 Ellicott Dredges, LLC

OPERATION & INSTRUCTION MANUAL

SECTION III OPERATION AND SERVICE OF INDIVIDUAL SYSTEMS

SECTION IV DREDGE OPERATION

SECTION V LUBRICATION AND MAINTENANCE

SECTION VI FIELD ASSEMBLY

SECTION VII VENDOR SERVICE LITERATURE

SEPARATE COVER ELLICOTT PARTS (ASSEMBLY DRAWINGS)

IT IS PROVIDED TO THE PURCHASER UPON THE UNDERSTANDING AND AGREEMENT THAT IT

©2012 Ellicott Dredges, LLC

B. GENERAL ARRANGEMENT DRAWING . 2

C. GENERAL DESCRIPTION . 1-3

E. FIELD SERVICE ... 3

F. CUSTOMER SERVICE ... 3

G. CONTACTING DREDGE SALES DEPARTMENT . 4

H. SERIES 1270 SPECIFICATIONS . . ........... 4-5

I. PERFORMANCE RATING 6-8

1. RANGE DIAGRAM .. 6-7

2. MAIN PUMP THEORETICAL PRODUCTION CURVE . 8

DREDGE ASSEMBLY (DWG# 150900) .. INSERT

TANK, CENTER ASSEMBLY (DWG# 151086) . INSERT

©2012 Ellicott Dredges, LLC

Definitions for these terms are:

NOTE: Information which can affect operational procedures.

CAUTION: Deviation from outlined steps or procedures could result in damage to

Recommended changes to this manual consisting of additions, deletions, or clarifications should be

B. GENERAL ARRANGEMENT DRAWING (See Page 2)

©2012 Ellicott Dredges, LLC 1

2 ©2012 Ellicott Dredges, LLC

1. Assembly of new dredges;

Service rates are based on a per diem basis.

For Technical Assistance Jerry Gladwell Email: jgladwell@dredge.com Ph. 410-545-0253

F. CUSTOMER SERVICE & PARTS DEPARTMENT

©2012 Ellicott Dredges, LLC 3

G. CONTACTING DREDGE SALES DEPARTMENT

4 ©2012 Ellicott Dredges, LLC

Viscosity: 275-315 SUS at 100°F (37.8°C), 50-55 SUS at 210°F. (99°C)

Grease Fittings – NLGI#2 consistency (Mobilux EP2 or equivalent)

©2012 Ellicott Dredges, LLC 5

1270 Range Diagram – 50 Ft. D.D.

6 ©2012 Ellicott Dredges, LLC

©2012 Ellicott Dredges, LLC 7

8 ©2012 Ellicott Dredges, LLC

©2012 Ellicott Dredges, LLC 9

B. SAFETY RECOMMENDATIONS ... 1-2

©2012 Ellicott Dredges, LLC

6. DO NOT carry unauthorized passengers.

10. LOOK in all directions before changing the dredge’s position.

WARNING: If it becomes necessary to troubleshoot or service the dredge with the

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16. DO NOT alter the engines’ governor settings.

26. PROVIDE life rings at appropriate places on the deck.

WARNING: Do not allow untrained or inexperienced personnel to launch, operate, or

1. Accident Prevention in Construction:

2. Rules & Regulations for Cargo & Miscellaneous Vessels CG257:

3. General Safety Requirements Manual EM 385-1-1:

5. Safety and Health Regulations for Maritime Employment:

6. Safety Requirements for Dredging:

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