Huchez PULLEY-MAN Operating instructions

© 2014 by Huchez Treuils S.A.S.
Portable mini-winches
Portable mini-winches
PULLEY-MAN 300 kg
Manual instruction ____________________ ENG
252-113-14

© 2014 by Huchez Treuils S.A.S.
Translation of the original instructions manual 2EN Reproduction prohibited
In an endeavour to improve its products,
HUCHEZ reserves the right to alter the equipment featured herein and supply it, in this case, different to the illustrations
or specifications of these instructions.
Reproduction prohibited
Contents
1 - Conditions of use.......................................................................................................... 2
2 –Safety instructions ....................................................................................................... 3
3 –Warranty .................................................................................................................... 4
4 –Reception of the equipment........................................................................................... 5
5 –Obligatory regulatory checks by the user ........................................................................ 5
6 –Presentation of the machines......................................................................................... 6
7 –Handling –Storage –Transport ..................................................................................... 8
8 –Assembly and start-up.................................................................................................. 9
9 –Servicing and maintenance ..........................................................................................15
10 –Decommissioning –Dismantling –Scrapping ................................................................22
11 –Example of the Declaration of Conformity.....................................................................22
12 –Operating faults ........................................................................................................23
13 –Annexes...................................................................................................................24
A. Optional equipment
B. Spare parts
C. Maintenance booklet
1 - Conditions of use
All users are asked to read the start-up instructions carefully before using the winch for the first
time. These instructions will help the user to become familiar with the winch and to use it to the
best of its capabilities. The start-up instructions contain important information on how to use the
winch in a safe and correct manner. Observing these instructions can help prevent risks, minimize
repair costs, reduce down time and increase the reliability and useful life of the winch. The
instruction manual must always be available at the winch operation location. In addition to the
start-up instructions and the regulations relating to accident prevention, it is important to
consider current rules in terms of industrial safety and professional standards in force in each
country.
This machine is covered by European regulations and, more specifically, machinery
directive 2006/42/CE.
These winches are designed to move loads using a suitable steel rope. They have been designed
to perform lifting and pulling operations within the defined load capacity limit.
The capacity indicated on the winch corresponds to the maximum capacity of use (MCU); in no
event should this capacity be exceeded..
This winch is intended for continuous operation for a period of 25 minutes at most.
THIS WINCH CAN UNDER NO CIRCUMSTANCES BE USED TO LIFT PEOPLE.
Do not begin moving the load until you have attached it correctly and checked that all
personnel are outside the danger zone.
Before use, the operator must always check that the machine, rope, hook, markings and
moorings are in good working order.
The operator must check that the load is attached in such a way that the winch, the rope and
the load place neither the operator nor any other person is in danger.
The winches can be used at ambient temperatures ranging from -10°C to +55°C. Please
consult the manufacturer in the event of extreme conditions of use.
Important: In the event of an ambient temperature below 0°C, the brake must be tested to
ensure that there are no operating faults resulting from the freezing conditions.
The data concerning the heat-resistance of the steel rope and its fastenings must be available
on request from the manufacturer and must be respected.
HUCHEZ cannot accept any liability for the consequences resulting from the use or installation
of equipment not provided for in the present instructions or for the consequences of removal,

© 2014 by Huchez Treuils S.A.S.
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modification or replacement of original parts or components with parts or components from
other sources without the written agreement of HUCHEZ.
The use of winches requires strict compliance with the accident prevention and safety
measures in force in the country where they are used.
YOU MUST ALSO RESPECT THE REGULATIONS APPLICABLE IN YOUR COUNTRY.
2 –Safety instructions
Before using the equipment, check that there are no causes of overloading such as: adhesion to
the ground, suction, jamming, etc. of the load.
As the operator of the winch, you are responsible for your own safety and the safety of your
colleagues in the work zone of the machine.
The operator must respect all the following safety information, without exception, concerning the
handling and operation of the winch as well as the references to other sections of this instruction
manual. Failure to comply with these instructions increases the level of risk.
Only the people designated by the company are authorised to operate the winch
Before using the winch for the first time, familiarise yourself with its conditions of use. To this
end, read the present instruction manual carefully and in its entirety and perform all the
operations described herein one after the other.
Inform your departmental manager or the safety officer of any malfunction so that the fault
can be repaired immediately.
Respect the directives of the industrial accident prevention organisations such as, in France,
the Caisse Régionale d’Assurance Retraite et de la Santé au Travail (C.A.R.S.A.T.) and the
Health and Safety Committee (HSC) of your company, if one exists.
Scrupulously respect all information in the sections concerning the CONDITIONS OF USE
(section §1) and the WORK ROPE (section §8.1).
The operator(s) must have an unimpeded view of the load.
Please ensure that the operator is qualified to operate the machine in the conditions provided
for in this manual. This will ensure the safety of both people and the environment.
Do not lift or transport loads when there are personnel inside the danger zone.
Do not authorise the personnel to walk under a suspended load.
Do not leave a load suspended or with the rope taut unsupervised.
Do not overload the winch.
Do not remain immediately below the suspended load or the PULLEY-MAN.
Make sure there is no-one and nothing in front of or behind a moving load.
Remain at least 60 cm from the load, when using with drill as power source
Keep the working area tidy and maintain lighting of at least 300 Lux.
Install the PULLEY-MAN at least 1–1.5 m from any wall or obstacle.
Fix or attach the load or the PULLEY-MAN so it is stable. Take the necessary measures, as
appropriate.
Do not keep or place your hands under the load when lifting.
Do not use the winch near dangerous gas (such as an acid or alkali) or in flammable
environments.
Do not use the winch near an unprotected flame, excessive heat or sparks.
Do not use it in damp or wet places or on rainy days (except for manual use), as this could
cause an electric shock. If the PULLEY-MAN is used outside or in damp places, take precautions
that follow the IP54 instructions.
If a hand drill is used as a power source, use only the voltage and frequency specified on the
labels.
In addition to the above instructions, we must warn you against all incorrect use or handling
listed below. It is dangerous and prohibited to:
pull at an angle.
swing the load.
use ropes of a different diameter and texture to those specified in this instruction
manual.
use damaged ropes or ropes with splices.

© 2014 by Huchez Treuils S.A.S.
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grab or touch a moving rope.
use hooks without a latch, which do not correspond to the loads indicated on the
winch or which are in poor condition.
insert objects into moving parts.
work on loaded winches or when the rope is taut.
use the winch rope as a towing chain.
place hands or clothes, etc. in contact with moving parts, in particular the areas
where the rope is wound in/out.
repair, clean, supervise and check the winch when the power supply is not turned
off.
use parts not supplied or certified by the manufacturer.
3 –Warranty
Our PULLEY-MAN portable mini-winches are guaranteed for 1 year from the date of shipment (ex-
works).
The seller undertakes to repair any operating fault resulting from a fault in the design, execution,
components or materials themselves.
The warranty does not cover wear and tear or damage resulting from a lack of regular or periodic
maintenance. It does not cover damage resulting from a lack of supervision, incorrect handling or
an incorrect use of the machines, in particular overloading, pulling at an angle, under or
overvoltage or incorrect connection.
The warranty also does not cover damage occurring to a load worth more than 10,000 euros.
The warranty does not apply to any disassembly, modification or replacement of mechanical or
electrical parts undertaken without our agreement or by a non-approved operator. The warranty
only applies to the manufacturer's original spare parts. During the warranty period, the seller
must replace or repair any parts recognised as faulty after inspection by the qualified and
approved department, all free of charge.
The warranty excludes all other services or compensation.
Repairs undertaken within the scope of the warranty are, in principle, performed in the seller's
workshops or the workshop of a representative approved by the manufacturer. When work is
carried out on the equipment outside of their workshops, the seller must cover the labour costs
related to the disassembly or reassembly of these parts if these operations are performed
exclusively by their personnel or a representative approved by the manufacturer. The parts
replaced become the property of the seller and must be returned to them at their own expense.
In the case of components with a particular relative importance not manufactured by the seller
themselves and which bear the brand of a specialist manufacturer, the warranty, which may vary
according to the manufacturer, is the same as that agreed by this manufacturer.
4 –Reception of the equipment
Make a visual inspection of the packaging to ensure that it is in good condition.
In the event of a problem, issue the usual reserves.
Check that the winch corresponds to your order.
5 –Obligatory regulatory checks by the user
The users are required to comply with the standards in force in their country.
With regard to France:

© 2014 by Huchez Treuils S.A.S.
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Order of 1st March 2004 relating to the verification of lifting machines and accessories:
The modifications to the regulation relating to the use and verification of lifting machines and
accessories, which came into effect on 1st April 2005, impose new obligations on all users:
The suitability inspection that involves checking that the lifting machine is suitable for the work
that the user intends to carry out, as well as for the risks to which workers are exposed, and
that the intended operations are compatible with the conditions of use for the machine defined
by the manufacturer.
The assembly and installation inspection that involves ensuring that the lifting machine is
assembled and installed safely in accordance with the manufacturer's instruction manual,
The general periodic visits that involve an inspection of the state of preservation and the
operating tests.
The commissioning or recommissioning inspections in the event of a change in the place of
use, the configuration or the conditions of use on the same site; following the disassembly and
subsequent reassembly of the lifting machine; after any major replacement, repair or
transformation concerning the essential components of the lifting machine; or following any
accident caused by the failure of an essential component of the lifting machine.
The maintenance booklet (order of 2nd March 2004 applicable from 1st April 2005) which must
be used to record the maintenance operations carried out in accordance with the
recommendations of the manufacturer of the machine as well as any other inspection,
maintenance operation, repair, replacement or modification carried out on the machine. For
each operation, it is essential to record the date of the work, the names of the people and,
where appropriate, the companies which carried out the work, the nature of the operation and,
if it is a periodic operation, the frequency. If the operations involve the replacement of certain
components of the machine, the references of these components are indicated. The English
version of the maintenance booklet for our lifting winches can be downloaded from our website
www.huchez.com under the heading "After sales services”. A copy is however proposed in the
annexes of this manual.
The inspections must be carried out in accordance with a protocol and are intended to ensure
preventive maintenance aimed at detecting any damage or defect liable to cause a hazard.

© 2014 by Huchez Treuils S.A.S.
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6 –Introduction to the machines
PULLEY-MAN portable winches are lifting and pulling equipment manufactured in accordance with
the standards and regulations in force.
They are used to lift and transport loads.
6.1 –Description
The PULLEY-MAN basically consists of reduction gear, a frame and a pulley.
Automatic load handling system (reduction gear with patented self-locking brake mechanism).
Power supply: The PULLEY-MAN can be used with all cordless and conventional
screwdriver/drills.
Rope length:
-unlimited when pulling
-limited to 50 m when lifting (beyond 12 m, loss of 10% of lifting strength per 10 m
length).
Delivered as standard with 12 m of rope (Ø 4.76 mm galvanised steel rope).
Possible options: cf. Appendices - §A –Optional equipment.
6.3 –Dimensions
Dimensions in mm

© 2014 by Huchez Treuils S.A.S.
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6.4 –Technical specifications
References
PULLEY-MAN
Load lifting capacity on one fall (kg)
300
Load lifting capacity on two falls (kg)
600
Pulling/hauling capacity on one fall for a load on wheels
depending on gradient (6°/12°/16°/27°/35°) (kg)
1,500/975/825/585/450
Pulling/hauling capacity on two falls for a load on wheels
depending on gradient (kg)
3,000/1,950/1,650/1,170/900
Rope length
-unlimited when pulling/hauling
-limited to 50 m when lifting (beyond
12 m, loss of 10% of lifting strength
per 10 m length).
Rope
Ø 4.76 mm (7 x 19) galvanised steel
rope.
12 m with hook, sleeving and end stop.
Linear speed (empty/fully loaded) on one fall m/mn
10.3/3.73
Linear speed (empty/fully loaded) on two falls m/mn
5.1/1.85
Weight (with 12 m of rope and hook) kg
7.5
6.5 - Accessories (optional)
PULLEY-MAN portable mini-winches are delivered as standard with 12 m of rope and a hook. They
can also be delivered in complete kit form (case, winch, drill –cordless drill 18 V 4 A, 1,700
revs/min. max., reversible, charger, sling and shackles), with a wall bracket or even a pulley
block.
6.6 –Operation
The PULLEY-MAN can be used as a winch or a hoist:
PULLEY-MAN can operate as a winch or hoist, moving the load horizontally or with an
angle of inclination.
PULLEY-MAN can be used in all positions, even 360°.
The pulling capacity varies with the weight of the load and the inclination of the rope:
Important!
Leave 10% to 50% tolerance with respect to the maximum capacities.
Use on 1 fall
Use on 2 falls
Maximum load capacity for
haulage on wheels on a flat
surface, depending on the
gradient
6°
1,500 kg
3,000 kg
12°
975 kg
1,950 kg
16°
825 kg
1,650 kg
27°
585 kg
1,170 kg
35°
450 kg
900 kg

© 2014 by Huchez Treuils S.A.S.
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The figures can change depending on the working conditions, the environment or the friction
coefficient of the load.
The methods for fixing the PULLEY-MAN are the same both for lifting and pulling a load: it
is a good idea to choose the method best suited to the working conditions.
7 –Handling –Storage –Transport
The PULLEY-MAN portable mini-winch is easy to store and transport.
Separate the power source (e.g. drill) from the main body before storage.
Separate the rope from the main body and roll it up properly.
If it is not going to be used for a long time, clean well and lubricate.
When the main body is damaged, repair before storage. If spare parts are needed, use those
supplied or recommended by the manufacturer.
Keep the PULLEY-MAN protected from damp and dust. As with any machine including electrical
equipment, these winches must be stored protected from weather conditions and at a
temperature between 0°C and + 55°C.
When transporting the equipment, secure the hook firmly to the main body. Protective gloves
should be worn.

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8 –Assembly, set-up and use
Important!
Assembly and dismantling must be carried out by qualified personnel. The PULLEY-MAN basically
consists of reduction gear, a frame and a pulley, and is assembled/dismantled in accordance with
the following procedure.
8.1. Rope assembly
8.1.1. Procedure
The rope must be separated from the main body while it is not assembled on the PULLEY-MAN.
The procedure below should be followed in order to fit the rope to the main body:
1) Remove the cotter pin and pull the input-side locking pin ring.
2) Remove the cotter pins and pull the locking pins of the pressure roller
housing.
3) Use with one fall:
Remove the hook from the main body.
Remove the locknut and nut and take out the hex bolt.
Use with two falls:
Remove the hook fixing.
Remove the locknut and nut and take out the hex bolt.
4) Insert the rope in the pulley groove.
Important! The direction of insertion is from the input-side locking pin
towards the pressure roller housing.
Pull out enough length of rope for use before fitting it in the pulley
groove.
5) Put in the input-side locking pin and the housing-side flange pin.
Insert the cotter pin.
6) Use with one fall:
Remove the hook from the main body.
Tighten the hex bolt and the locknut and introduce the locking pin.
Use with two falls:
Reassemble the hook fixing.
Tighten the hex bolt and the locknut and insert the locking pin.

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7) Compress the rope with the pressure roller housing.
Lift the pressure roller housing to an angle of about 90° and pass the
rope between the output roller and the pulley rim.
Pull the rope in the direction of the sleeve end so it is at the bottom
of the pulley groove.
Close the pressure roller housing in the direction of the flange to
compress the rope.
Important! Check that the pressure rollers are compressing the
rope.
8) Insert the pressure roller housing locking pin.
When the locking pin holes on the flanges and the pressure roller
housing are aligned, insert the locking pins from the reduction-gear
side and insert the cotter pins.
End of the procedure if using one fall.
9) Separate the hook from the hook support.
Remove the locknut, the bolt and the hook support nut that connects
the rope hook to the end of the rope.
10)Install the rope on the pulley and reassemble the hook.
Insert the rope between the pulley and the pulley cover. Before
reassembling the hook, check whether the rope is correctly placed in
the centre of the pulley groove.
Tighten the bolt and the nut and insert the locknut.
Reassemble the hook and the hook support.
11)Reattach the hook support to the hook fixing.
Assemble the hook support on the hook fixing.
Tighten the nut and introduce the locknut.
End of the procedure if using two falls.
Follow the procedure in reverse to take the rope out of the main body.
8.1.2. –Rope end
8.1.2.a. Sleeving:
Use cold-pressed steel.

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IMPORTANT!
When using a rope longer than the one supplied by the manufacturer (12 m), use a rope
recommended by the manufacturer, fix the end of the rope using one of the methods
illustrated above and attach it to the hook support (the rope supplied by the manufacturer
is sleeved).
When fixing the end of the rope, the safety factor must be at least five times the load and
a safety test must be carried out before use.
Contact the manufacturer if a rope longer than 12 m is used.
8.1.2.b. Fixing the stop sleeve end:
Fix the other end of the rope to the steel cube with
sleeving. The thickness of the steel must be
greater than 10 mm after sleeving.
Remove excess rope from the stop sleeve end by
grinding.
8.2. –Power supply
Important! If the PULLEY-MAN is used as a hoist, it should be earthed to protect it from
lightning.
8.2.1. Hand drill:
Important! Product not supplied by the manufacturer, so check the following:
-Specifications: 110/220 V single phase, min. 550 W, 3,000 rev./min., reversible
-Precautions:
oInstall anti-leakage insulation to the main power supply and earth.
oUse the main power supply voltage specified on the label.
oIf used as a power supply, make sure the chuck is properly fixed to the hexagonal
end of the input shaft.
oDo not touch the rotating chuck.
8.2.2. Cordless drill:
Important! For products not supplied by the manufacturer (others supplied optionally with the
model), check the following:
-Specifications: 3/8" (10 mm), 18 V DC max., max. torque 230 inches/pound or more,
reversible.
-Precautions:
oUse fully charged.
oIf used as a power supply, make sure the chuck is properly fixed to the hexagonal
end of the input shaft.
oDo not touch the rotating chuck.
Stop sleeve

© 2014 by Huchez Treuils S.A.S.
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8.3. Installing the PULLEY-MAN
Several fixing methods are possible:
Fixed PULLEY-MAN
Fix the main body to an I-beam, round beam
or another stable, raised structure and attach
the load to be vertically moved to the rope.
IMPORTANT! Conditions to be followed for
fixing the PULLEY-MAN:
. The raised structure must be solid enough to
bear the load weights.
. When fixing the PULLEY-MAN to shackles at
the end of an extension arm, the length of the
extension arm must not be too long.
Conditions affecting the raised structures (Reach: 2 metres):
PULLEY-MAN
I-beam
H-beam
Round beam
300 kg
100 x 75 x 5 x 8 mm
100 x 100 x 6 x 8 mm
Ø 80 mm
600 kg
125 x 75 x 9,5 x 9 mm
150 x 75 x 5 x 7 mm
Ø 80 mm
Fixed rope hook
Fix the rope hook to an I-beam, round beam or
another stable, raised structure and attach the
load to the hook on the main body to move the
load vertically.
IMPORTANT! Conditions to be followed for
fixing the PULLEY-MAN:
. The raised structure must be solid enough to
bear the load weights.
. When fixing the rope hook to shackles at the
end of an extension arm, the length of the
extension arm must not be too long.
Conditions affecting the raised structures (Reach: 2 metres):
PULLEY-MAN
I-beam
H-beam
Round beam
300 kg
100 x 75 x 5 x 8 mm
100 x 100 x 6 x 8 mm
Ø 80 mm
600 kg
125 x 75 x 9,5 x 9 mm
150 x 75 x 5 x 7 mm
Ø 80 mm

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PULLEY-MAN fixed to the ground
Fix the main body to a stable anchorage on the
ground.
Pass the rope through a pulley fixed to an I-
beam, round beam or another stable, raised
structure and attach the load with the rope for
vertical movement.
8.4. Installing the load
When the installation of the PULLEY-MAN is complete, you need to make the following checks
before attaching the load:
-Eliminate all potentially hazardous factors and obstacles from around the working area.
-Check the main body, the hook and whether the rope is tangled or twisted.
-Check whether the rope moves up and down correctly with no load.
You can then attach the load to the rope or the shackles in complete safety, in accordance with
the instructions in this manual.
Important! Do not overload the winch.
8.5. Using the PULLEY-MAN
When the installation of the PULLEY-MAN is complete, begin use in accordance with the
instructions in this manual.
Important! Do no overload the winch.
8.5.1. Before using the PULLEY-MAN
It is a good idea to:
check that the PULLEY-MAN’s connections are properly tightened.
check the rope for wear or deterioration.
check the rope is inserted in the right direction.
check that the rope is properly installed in the pulley groove and that the pressure rollers are
compressing the rope properly.
check that the nuts are properly locked and that the locknuts are in place.
check that the rope hook safety latch is working properly.
check that the hazard labels and signs are properly fixed.
your head must be protected with a hard hat that meets safety regulations.
wear safety shoes to protect your feet.
use safety gloves.
check that work clothing does not include loose items like ties or floppy sleeves.

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8.5.2. While using the PULLEY-MAN
Never detach the drill (or screwdriver) from the PULLEY-MAN during use: risk of a
sudden fall or movement of the load.
It is a good idea to take the following precautions:
Continuous operating time: 25 minutes.
For lifting operations:
-To prevent the top of the load knocking into the bottom of the main body of the
PULLEY-MAN, maintain at least 30 cm between the bottom of the main body and the
rope hook.
-Do not fix to a moving load.
-Do not change the direction of the power supply abruptly.
-Do not remain immediately below a suspended load or the PULLEY-MAN and keep out of
the way of the vertical line of a suspended load.
-Make sure the loose rope does not get tangled up with the power cable.
-Keep the loose rope away from the lifted load.
-Do not walk on the loose rope.
-Follow all other safety laws and regulations.
For pulling/haulage operations:
-Check the rope is aligned in the pulley groove.
-Do not leave any obstacle between the pulley and the load that puts the rope at an
angle. (This can wear or break the rope).
-Check that no-one and nothing is in front of or behind the moving load.
-Do not change the direction of the power supply abruptly.
-Do not walk on the loose rope during use.
-Make sure the loose rope does not get tangled with the power cable.
-Keep the loose rope that has passed through the pulley away from the load to be
moved.
-When the surface on which the load is being pulled is irregular or has hollows or holes,
use a plate to keep the route level.
Example: Where there is a gap, stairs or rising ground or when it is a load on a
mechanical tractor, etc.
-When pulling a load on an inclined surface and when the load is unbalanced, take safety
measures to prevent the load slipping.
-Do not halt operation when pulling a load on an inclined surface without taking control
or safety measures.
-Do not fix to a moving load.
-Follow all other applicable safety laws and regulations.
8.5.3. After using the PULLEY-MAN
You must make sure you:
Turn off the power supply.
Do not halt operation with a suspended load.
After use outside, tidy up everything in the area and put the PULLEY-MAN away in accordance
with the instructions in this manual.
Attention !

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9 –Servicing and maintenance
The PULLEY-MAN portable mini-winch has been designed to keep maintenance strictly to a
minimum.
Although PULLEY-MAN is easy to install and use, it must be used and maintained properly so that
it operates and remains at maximum capacity.
Only people designated by the company are authorised to use, check and maintain the winch.
Warning labels are fixed on the PULLEY-MAN for complete safe use and maintenance. Make sure
they stay there so you can refer to them.
Incorrect maintenance can lead to the risk of death or serious injury.
Warning of electrical hazard:
Physical contact during operation can lead to immediate injury. Parts
bearing this symbol must be handled only by qualified technicians. The
power supply must be turned off when these parts are being handled.
Suspended load warning:
Operation under a suspended load can lead to serious accidents. Do not
walk under a suspended load.
Warning when handling during installation:
This symbol in the manual indicates a warning. Ignoring it can lead to
damage to the PULLEY-MAN or the load.
IMPORTANT! Respect the following points before and during maintenance or repair:
1) Turn off the power supply.
2) Place a label on the wall socket specifying “Out of service”.
3) Never start maintenance work while a load is suspended.
4) Maintenance must be carried out by maintenance personnel.
5) When maintenance work is carried out with a PULLEY-MAN installed in fixed PULLEY-MAN
mode, use a ladder or mobile platform for safety.
Attention !

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9.1 –Dismantling
Check whether there are signs of abrasion or deterioration of sprocket
wheels, rings, bearings, shafts or pulley grooves.
To do this, follow the dismantling procedure given below:
1. Unscrew the two M6 screws and remove the input-side flange cover.
2. Remove the input-side cotter pins and those of the pressure roller
housing.
3. Remove the hook and the locknut and unscrew the hex bolt.
4. Remove the hex bolt (M8) and the nut and then the pressure roller
housing from between the flanges.
5. Remove the M8 bolt, making a space between the flanges.
6. Remove the retaining ring from the input-side flange.
7. Remove the input-side flange from the output shaft.
8. Remove the flange spacer.

© 2014 by Huchez Treuils S.A.S.
Translation of the original instructions manual17EN Reproduction prohibited
9. Remove the pulley retaining ring on the output shaft.
10. Remove the pulley from the output shaft.
11. Remove the output-side flange retaining ring on the output shaft.
12. Unscrew the four (Allen) bolts fixing the reduction gear to the flange.
13. Remove the output-side flange from the output shaft.
14. Remove the output shaft from the gear housing.
15. Remove the input shaft assembly (planetary and
solar gear) from the gear housing.
Important! Do not dismantle the input shaft assembly. Once dismantled, it cannot be
reassembled. When the sprocket wheels are used or damaged for external reasons, they must be
changed.
Once the PULLEY-MAN has been dismantled, proceed with the following checks:
-Signs of wear and deterioration:
-Wear to sprocket wheels, rings, shafts and pulley grooves.
-Deformation of the flange.
-Wear and rotation of the hook and swivel mechanism.

© 2014 by Huchez Treuils S.A.S.
Translation of the original instructions manual18EN Reproduction prohibited
-Lubrication
-The PULLEY-MAN reduction gear is ready greased.
Lubrication used: MoS².
-Applying the lubrication:
-Apply grease to the sprocket wheels, rings and shafts.
-Apply grease or oil to the hook swivel connection.
-Apply grease to the pressure roller housing tensioners.
-Dismantle the pulley and apply grease to its shaft.
-Depending on the frequency of use, re-grease at least once a year as part of the
maintenance programme.
9.2 –Reassembly
For reassembly, follow the dismantling procedure in reverse order and respect the following
points:
-Do not apply excessive force to the sprocket wheel or shaft.
In general, do not use excessive force or blows that could affect the life of the PULLEY-
MAN and damage its parts and components.
-Make sure the rings do not deteriorate.
-Before fixing the sprocket wheel to the flange, first apply a fixing product to the four
(Allen) bolts.
Once the PULLEY-MAN is reassembled, proceed as follows:
-Use the PULLEY-MAN without a load to see that it is properly assembled.
-Check that it is not making excessive noise.
-When no problems are detected, insert the rope.
9.3 Replacing parts and components
Important! Through daily and periodic checks, replace parts or components whose useful life has
been reached or exceeded with new parts, in accordance with maintenance instructions.
9.3.1. Rope
Conditions and limits of rope use:
-Less than 10% of the elementary strands are broken following twisting
(1 step).
-The diameter of the rope must be reduced by less than 7%.
-There must be no bends (folded or twisted rope) or corrosion.
-When the rope is replaced, fix the end with a stop sleeve.
-The stop sleeve (fixed to one end of the rope to prevent the rope and load slipping off
the pulley due to an excessive load) must be complete, without damage, and there
must be no risk of the rope escaping or becoming separated from it.
Attention !

© 2014 by Huchez Treuils S.A.S.
Translation of the original instructions manual19EN Reproduction prohibited
9.3.2. Hook
The hook must have a latch to prevent the rope slipping out of it. The areas most subject to wear
are the opening and the centre of the hook bearing the weight.
Hook limit values:
Item
Normal value
Limit value
Opening A (mm)
18.3
20.5
Hook centre T (mm)
13.15
11.8
9.3.3. Pulley
Wear in the pulley groove is caused by the rope, so the rope must also be checked.
Methods for recognising the limit values for the pulley groove with the naked eye:
-After production and heat treatment, the surface of the pulley groove is coated with
black zinc.
-When holding the load, the black zinc coating becomes worn away to the point when
the rope no longer moves at the bottom of the groove.
-When the equipment is used continuously, the score line moves to the bottom of the
groove.
There are two reasons for this:
-the rope diameter is reduced: the rope is worn and must be replaced,
-the pulley groove is worn: if a new rope touches the bottom of the groove, it is
time to replace the pulley.
Worn rope touching the bottom
of the pulley groove.
New rope touching the bottom
of the pulley groove.
1. Replace the rope
1. Replace the pulley
2. Mark the groove with an indelible marker.

© 2014 by Huchez Treuils S.A.S.
Translation of the original instructions manual20EN Reproduction prohibited
9.3.4. Sprocket wheels
When the wear value reaches 0.15 t, it is time to replace the sprocket wheel.
9.4 –Daily and periodic maintenance
It is essential to check the condition of the PULLEY-MAN with regular maintenance to maintain its
useful life and ensure user safety.
Always keep the maintenance programme within reach.
A PULLEY-MAN user or maintenance personnel must have a thorough knowledge of the daily and
periodic check points and safety rules in this manual.
Proper maintenance training must also be ensured.
When problems arise, take measures in accordance with the repair instructions in this manual (cf.
§ 12 –Operating faults). Consult the distributor or manufacturer for any other problems.
9.4.1. Daily checks
For safety reasons, carry out the following checks before beginning:
- Check that connections have not worked loose.
- Check that the rope is not damaged or worn.
- Check that the rope is inserted in the right direction.
- Check that the rope is properly inserted: towards the pulley and properly compressed by
the pressure rollers.
- Check that the nuts are properly locked and the locknuts properly fixed.
- Check that the hook has a safety latch and that it is working properly.
- Check that the hazard labels are properly in place.
9.4.2. Periodic checks
Personnel in charge of the care and maintenance of the PULLEY-MAN must record any damage,
wear, deformation, malfunctions, etc. in the maintenance log.
Largeur (t)
Abrasion (a)