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Contents
Safety Summary ...................................................................i
General ............................................................................. 1-1
Introduction ........................................................................ 1-1
Description ........................................................................ 1-1
Unit Identifi cation ........................................................ 1-2
Serial Number Codes ................................................. 1-3
Nameplate .................................................................. 1-3
Specifi cations .................................................................... 1-4
Drum Line Capacities ................................................. 1-4
Hydraulic Specifi cations ............................................. 1-4
Oil Specifi cations ........................................................ 1-4
Torque Specifi cations ................................................. 1-5
Gear Train ......................................................................... 1-6
FREESPOOL Operation ............................................. 1-7
Operation and Control ....................................................... 1-8
Hydraulic System ............................................................... 1-9
Planetary Reducer ..................................................... 1-9
Brake ........................................................................ 1-10
Motor ........................................................................ 1-11
Direction Control Manifold ........................................ 1-12
Logic Control Manifold .............................................. 1-12
BRAKE-OFF Manifold .............................................. 1-12
HI-SPEED Limit Switch ............................................ 1-12
Electronic Control Panel ........................................... 1-12
Sequence of Operation, Rescue Winch ........................... 1-13
BRAKE-ON ............................................................... 1-13
LINE-IN ..................................................................... 1-14
LINE-OUT ................................................................. 1-15
FREESPOOL ........................................................... 1-16
Sequence of Operation, High-Performance Winch .......... 1-17
BRAKE-ON ............................................................... 1-17
LINE-IN ..................................................................... 1-18
HI-SPEED LINE-IN ................................................... 1-20
LINE-OUT ................................................................. 1-22
HI-SPEED LINE-OUT .............................................. 1-24
BRAKE-OFF ............................................................. 1-26
FREESPOOL ........................................................... 1-28
Schematics ...................................................................... 1-33
Troubleshooting ............................................................... 2-1
General .............................................................................. 2-1
Step-By-Step Pump & Controller Troubleshooting ............. 2-2
Troubleshooting Analysis Check Chart .............................. 2-4
Service .............................................................................. 3-1
General ............................................................................. 3-1
Maintenance ...................................................................... 3-1
Maintenance Points .................................................... 3-1
Maintenance Schedule ............................................... 3-1
Checks Before Operation ........................................... 3-2
Checks During Operation ........................................... 3-2
FREESPOOL Drag Adjustment ......................................... 3-2
Hydraulic System Pressure Checks .................................. 3-2
Preparation ................................................................. 3-2
Pressure Gauges ....................................................... 3-2
Standby Pilot Supply Pressure Check ........................ 3-3
Maximum Pilot Supply Pressure Check ..................... 3-3
Counterbalance Valve Pressure Check ...................... 3-4
Motor Supply Pressure Check .................................... 3-4
Brake Pressure Check ................................................ 3-5
Brake Valve Pressure Check ...................................... 3-5
FREESPOOL Pressure Check ................................... 3-5
HI-SPEED Pressure Check ........................................ 3-5
BRAKE-OFF Pressure Check .................................... 3-6
LINE-IN Pressure Check ............................................ 3-6
LINE-OUT Pressure Check ........................................ 3-6
Valve Setting Procedures .................................................. 3-6
Load Sense Relief Valve ............................................ 3-6
Brake Release Valve .................................................. 3-6
Pilot Supply Reducing Valve ....................................... 3-7
Hydraulic System Pressure Tests Table ............................. 3-7
Repairs ............................................................................ 4-1
General ............................................................................. 4-1
Winch Removal.................................................................. 4-1
Winch Disassembly ........................................................... 4-1
Intermediate & FREESPOOOL Shaft Removal .......... 4-2
Drum Shaft & Drum Removal ..................................... 4-5
Hydraulic System Disassembly, Rescue Winch ......... 4-9
Hydraulic System Disassembly, High-Performance
Winch ....................................................................... 4-13
Motor Shaft Removal & Disassembly ....................... 4-18
Motor Disassembly ................................................... 4-21
Brake Disassembly ................................................... 4-24
Planetary Reducer Disassembly .............................. 4-26
Winch Assembly .............................................................. 4-28
Visual Inspection ...................................................... 4-28
Planetary Reducer Assembly ................................... 4-30
Brake Assembly ....................................................... 4-32
Motor Assembly ........................................................ 4-34
Motor Shaft Assembly & Installation ......................... 4-37
Hydraulic System Assembly, Rescue Winch ............ 4-40
Hydraulic System Assembly, High-Performance
Winch ....................................................................... 4-44
Drum & Drum Shaft Installation ................................ 4-49
Intermediate & FREESPOOL Shaft Installation ....... 4-54
Winch Installation ............................................................ 4-58
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