ETC Hammerhead HG12 Operator And Maintenance Manual
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ETC Hammerhead HG12 Operator And Maintenance Manual

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TM
HG12 Winch
Operator's and Maintenance Manual
HG12_Winch_o1_03
Serial No. 96095 and up
Order No. OM1001

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Summary of Contents for ETC Hammerhead HG12

  • Page 1 HG12 Winch Operator’s and Maintenance Manual HG12_Winch_o1_03 Serial No. 96095 and up Order No. OM1001...
  • Page 2 NTRODUCTION This manual explains the proper operation of your machine. Study and understand these instructions thoroughly before operating or maintaining the machine. Failure to do so could result in personal injury or equipment damage. Consult your HammerHead dealer if you do not understand the instructions in this manual, or need additional information. The instructions, illustrations, and specifications in this manual are based on the latest information available at time of publication.
  • Page 3 NOTE: Right and left sides of the machine are determined by facing in the direction of forward travel. HAMMERHEAD MOLE®, and HAMMERHEAD™ are trademarks of Earth Tool Company, LLC. HG12 Winch...
  • Page 4 ATENTS This machine may be covered by one or more of the following patents: US 5,025,868 US 5,199,151 US 5,487,430 US 5,317,953 US 5,465,797 US 5,440,797 US 5,494,116 US 5,505,270 US 5,603,383 US 5,651,639 US 5,687,803 US 5,782,311 US 6,148,935 US 6,171,026 B1 US 6,260,634 B1 US 6,261,027 B1...
  • Page 5 Warranty. This Warranty shall not apply to any part or product which shall have been installed or operated in a manner not recommended by ETC nor to any part or product which shall have been neglected, or used in any way which, in ETC’s opinion, adversely affects its performance; nor negligence of proper maintenance or other negligence, fire or other accident;...
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  • Page 7: Engine

    Receiving and Delivery Report EALER Check or perform the following: ___ Check machine for shortage or damage in transit. Engine ___ Check the coolant level/anti-freeze mix. ___ Check the oil level of the engine. ___ Check the battery electrolyte level and charge. ___ Check the condition of the air cleaner.

  • Page 8: General

    General ___ Check the alternator/fan belt for proper tension. ___ Check all shields for installation and condition. ___ Check the machine for proper lubrication. ___ Check the wheel lug nuts for tightness, 90-95 ft-lb (122-130 Nm). ___ Check the tires for proper air pressure, 75 psi (5.1 bar) maximum. ___ Check the condition of all decals.

  • Page 9: Dealer/Customer Information

    EALER USTOMER NFORMATION dealer owner address address city city state / province state / province zip / postal code zip / postal code country country HG12 Winch Receiving and Delivery Report...

  • Page 10: Identification Numbers - Record

    DENTIFICATION UMBERS ECORD Machine Identification Numbers Model Number Serial Number Engine Identification Numbers Model Number Serial Number Receiving and Delivery Report HG12 Winch...

  • Page 11: Winch Identification Numbers

    Winch Identification Numbers Model Number Serial Number Bull Wheel Identification Numbers Model Number Serial Number HG12 Winch Receiving and Delivery Report...

  • Page 12: Delivery

    ELIVERY Check and perform the following with the customer: Winch ___ Review all sections of the Operator’s Manual. ___ Grease or oil all lubrication points; review lubrication, decal, and maintenance intervals. ___ Ensure all requested options are installed. ___ Review Winch operation (refer to to the section, and to the section,...

  • Page 13: Table Of Contents

    ABLE OF ONTENTS Receiving and Delivery Report......i Engine Controls........25-1 Dealer Prep .
  • Page 14 Wire Rope........45-1 Winch Gearbox Oil - Initial Change .
  • Page 15 Automatic Brake Controller with Manual Override (Optional) - Check ........85-3 Adjustment .
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  • Page 17: Safety Messages

    Safety Messages Section 10: General safety messages appear in this Safety Messages section. Specific safety messages are located in appropriate sections of the manual where a potential hazard may occur if the instructions or procedures are not followed. NDERSTAND AFETY LERT YMBOL This is the safety alert symbol.

  • Page 18: Reporting Safety Defects

    NDERSTAND OLLOW NSTRUCTIONS Read, understand, and follow all safety instructions and safety messages included in this manual and on decals attached to the machine. These instructions and safety messages contain important information. Allow only responsible, properly instructed individuals to operate and service the machine.
  • Page 19 If NHTSA receives similar complaints, it may open an investigation, and if it finds that a safety defect exists in a group of vehicles, it may order a recall and remedy campaign. However, NHTSA cannot become involved in individual problems between you, your dealer or Earth Tool Co.
  • Page 20 PECTATORS WAY FROM ACHINE Keep all spectators and other workers away from the machine and work area while in operation. ONFINED PACE EGULATIONS Do not work in a confined space, such as a sewer, until requirements are met to ensure a hazard free environment.
  • Page 21 • Use the winch for pipe bursting only. • Do not disengage drum under load. Keep winch trailer access doors closed while pulling. • ORK IN ENTILATED Exhaust fumes can be fatal. If operating the machine in an enclosed area, remove the exhaust fumes with an exhaust pipe extension to the outside.
  • Page 22 LEAN LAMMABLE ATERIALS FROM ACHINE Prevent fires by keeping engine compartment, battery, hydraulic lines, fuel tank and operator’s station clean of accumulated trash, grease, and debris. VOID OOLANT URNS Hot fluid under pressure can erupt and scald if opened. Allow to cool before opening. VOID ATTERY XPLOSION...
  • Page 23 VOID XPLOSION Tire explosion can result if the following procedures are not followed: • Maintain correct tire pressure. Do not inflate tire above recommended pressure. Low tire pressure can cause internal tire damage. Inflate to recommended pressure. • • Replace any tire with cuts or bubbles. Replace any damaged rims. •...
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  • Page 25: Safety Decals

    Safety Decals Section 15: AFETY ECAL AINTENANCE Safety decals located on your machine contain important and useful information that will help you operate your equipment safely. To assure that all decals remain in place and in good condition, follow these instructions: •Keep decals clean.
  • Page 26 15-2 Safety Decals HG12 Winch...
  • Page 27 HG12 Winch Safety Decals 15-3...
  • Page 28 15-4 Safety Decals HG12 Winch...

  • Page 29: How The Hg12 Winch Works

    How the HG12 Winch Works Section 20: The HammerHead HG12 HydroGuide Power Winch has a dual capstan design coupled with a large take-up reel with a capacity of 2000 ft (610 m) of 5/8″ (15.8 mm) wire rope. The HG12 provides up to 12 Tons of constant tension for pipe bursting, pipe splitting, slip lining, and cable pulling. Speed is infinitely variable up to a maximum no-load speed of 48 ft/min (14.6 m/min).
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  • Page 31: Controls

    Controls Section 25: NGINE ONTROLS Key Switch Center position..........ignition system OFF Fully Counterclockwise ......turns on preheat system 1st position clockwise ......turns on electrical system 1st position clockwise ..........engine run 2nd position clockwise ........starts the engine Emergency Shutdown Switch Push in.............Shuts down all systems NOTE: Engine does have an electronic fuel shut off.
  • Page 32 Throttle Push center button to push in or pull out: Push knob ..........does not stop engine Pull knob............. increase speed Push knob ............decrease speed Turn knob to make fine adjustments: Clockwise ..............decrease Counterclockwise ............increase Turn base ring to lock setting: Clockwise ................lock Counterclockwise ..............unlock 25-2...

  • Page 33: Engine Monitors

    NGINE ONITORS Control Panel/Remote Selector Up position ..............Remote down position ..............Panel Neutral Start Indicator Winch Control Knob Center position ..............neutral Center position ......... engine can be started Auxilary Light Selector Up position................On Down position................ Off HG12 Winch Controls 25-3...
  • Page 34 Oil Pressure Indicator On ..............oil pressure is low Temperature Indicator On ............. engine is overheating Voltage indicator On ............alternator is not changing Glow Plug Indicator On ..............glow plug is hot High Hydraulic Oil Temperature Indicator On.................hydraulic oil hot Hydraulic Oil Filter Condition Indicator On.............hydraulic filter flow restricted (10)

  • Page 35: Winch Control

    INCH ONTROL Winch Control Knob With Control Panel/Remote Selector switch left: Left position ............pay out cable Centered................neutral Right position............pay in cable NOTE: Cable will pay in or out at any engine speed. Remote Control Remote can be plugged into panel for remote operation. With Control Panel/Remote Selector switch right: Press lower button..........pay out cable Press upper button ...........pay in cable...
  • Page 36 Pressure Control Knob Clockwise ........more pressure/pulling power Counterclockwise ......less pressure/pulling power 25-6 Controls HG12 Winch...

  • Page 37: Hydraulic Pressure Gauge

    YDRAULIC RESSURE AUGE Hydraulic Pressure Gauge Winch: in neutral........approximately 0-300 psi (20 bar) in use: operational pressure..up to approximately 3000 psi (207 bar) HG12 Winch Controls 25-7...

  • Page 38: Auxiliary Electrical Connector

    UXILIARY LECTRICAL ONNECTOR Connector Use connector to operate a 12 volt electrical accessory. The circuit is on when the ignition switch is in the run position and is protected by a 15 amp fuse. 25-8 Controls HG12 Winch...
  • Page 39 OWNRIGGER ONTROL Downrigger direction selector Up ..............Raises downrigger. Down..............Lowers downrigger HG12 Winch Controls 25-9...
  • Page 40 25-10 Controls HG12 Winch...

  • Page 41: Starting Procedure

    Starting Procedure Section 30: TARTING THE NGINE Step 1: Check to make sure the area is clear of personnel. Step 2: Place Cylinder/Winch Switch (1) and Cable Direction Switch (2) in center (neutral) position. Set throttle (3) at 1/8 to 1/4 throttle. Step 3: Turn pressure regulator control (4) completely out and back in two full Step 4:...

  • Page 42: Cold Weather Starting

    EATHER TARTING When operating in cold weather it is important to use the recommended engine oil viscosity and fuel to reduce starting problems. In cold weather, the hydraulic oil will become thicker causing hydraulic functions to move slower until the oil is warmed.

  • Page 43: Jump Starting

    TARTING Do not jump start or charge a battery that is frozen or low on electrolyte. Avoid explosion hazard. Battery caps must be in place and tight on all batteries. IMPORTANT: Use only a 12 volt system for jump starting. Do not allow vehicles to touch. WARNING: Wear protective clothing and face shield when working around batteries.

  • Page 44: Jump Starting Procedure

    Jump Starting Procedure Step 1: Turn ignition key OFF. Make jumper cable connections in following order: Step 2: Red to discharged battery POSITIVE (+). DISCHARGE Red to boost battery POSITIVE (+). BATTERY Black to boost battery NEGATIVE (-). BLACK Black to discharged machine frame (away from battery, fuel lines, and moving parts).

  • Page 45: Shutdown Procedure

    Shutdown Procedure Section 35: TOPPING THE NGINE When stopping the machine, use the following shutdown procedure: Step 1: Return the winch control switches to neutral. Step 2: Reduce engine speed to idle. Step 3: Turn ignition key counterclockwise to off position. Remove the key.
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  • Page 47: Transporting The Winch

    Transporting the Winch Section 40: REPARE FOR RANSPORT Store downrigger (1) in horizontal position and make sure latch (2) is engaged. Fully raise the jacks (3) and rotate the outriggers to the side toward the fenders. Rotate them completely and insert lock pin (4) and secure the pin with the linchpin. HG12 Winch Transporting the Winch 40-1...

  • Page 48: Adjust Hitch Height

    Adjust Hitch Height Before attaching the machine to the towing vehicle, check the height of the hitch on the towing vehicle to the hitch on the machine. The height of the machine hitch and towing vehicle hitch need to be approximately the same to keep the machine level during transport.

  • Page 49: Pintle Hitch

    Pintle Hitch • Cross the safety chains (1) under the tongue and attach them to the towing vehicle. Keep the chains as short as possible, but leave enough slack to turn corners. • Attach the breakaway cable (2) to the towing vehicle bumper or frame. IMPORTANT: The breakaway cable length should be adjusted so the breakaway system applies the brakes only after both the hitch and the safety towing chains have disconnected.
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  • Page 51: Preparing The Winch And Work Area

    Preparing the Winch and Work Area Section 45: ERSONAL ROTECTIVE QUIPMENT Operating the machine will require you to wear protective equipment. You should always wear a hard hat, work shoes, and eye protection. Wear leather gloves when handling the wire rope. If working near traffic, wear high visibility clothing. Specification 5/8 inch x 2080 feet with swaged on closed eye;...

  • Page 52: Wire Rope Failure

    Wire Rope Failure Wire rope will break if abused or misused. Failure is usually cumulative. A wire rope that almost fails under a heavy load can fail under a lighter load on the next pull. DANGER: Wire rope whip lash can be fatal. Be sure the wire rope is in good condition and that it is securely attached to the load.

  • Page 53: Maintaining Wire Rope

    Maintaining Wire Rope For maximum wire rope life: Install wire rope properly • The top illustration shows what can happen when wire rope is loosely wound on the drum (1). When tightened, it was pulled between underlying wraps and crushed out of shape. Spot abrasion ("dog leg") is caused by improper handling and/or installation (2).
  • Page 54 Don't use over-sized wire rope. The strands will be pinched and the • wire will fail in the valley between the strands as shown (5). • Protect the wire rope from damage. Poor work procedures can lead to unnecessary damage. The illustration shows how electrical arcing can damage a wire rope (6).
  • Page 55 The following conditions increase corrosion: acid and alkaline solutions, gases, fumes, brine and salt air, sulphurous compounds, high humidity, and temperature. Lubricants are available to reduce the damage caused by these conditions. Keep wire rope from kinking or bending sharply. Kinks and sharp •...

  • Page 56: Installing Wire Rope

    NSTALLING Step 1: To prevent kinking, roll the shipping reel along the ground to unwind the wire rope. Step 2: To prevent fraying, securely wrap the end of the wire rope. IMPORTANT: Note drum rotation for winding the wire rope. If wire rope is not installed correctly, the brake will not hold the load.

  • Page 57: Outrigger Initial Setup

    When setting up at an excavated hole, make sure the ground is stable and proper shoring is used. If entry into a confined space is necessary, follow all OSHA requirements for working in confined spaces. Outrigger Initial Setup Position winch bumper (1) approximately 4 to 6 in (100 - 150 mm) Step 1: inside the edge of excavation or manhole.

  • Page 58: Downrigger Setup

    Pull jack extension pin (4) and push extension (5) to the ground. Install Step 3: pin in nearest available hole. NOTE: The outrigger extension is spring loaded and must be manually pushed down. Use caution when retracting the extension as it will spring up when the pin is pulled.
  • Page 59 Start the engine. Refer to “Starting the Engine”, for detailed Step 1: page 30-1 instructions. Release Mast Latch (6) and push mast (7) away from latch. Step 2: Move Cylinder/Winch Mode Switch (8) to cylinder position. The warning Step 3: beeper will sound to alert personnel that the downrigger mast hydraulic circuit is engaged.
  • Page 60 Step 4: Move Cylinder Control Switch (9) up to raise mast into the vertical position over the manhole or exit pit. NOTE: Cylinder lift will not function with pressure control set at the minimum pressure. Step 5: Pull pin (10) on Mast Latch (11). Leaving the cylinder/winch switch in the cylinder mode, use the cable direction switch to jog mast up or down to free the latch.
  • Page 61 Once the desired depth is reached, remove pin in latch and lock latch Step 8: into the mast. Reinstall the pin to lock the mast in place. NOTE: For deeper installation lower the bottom telescopic section first, lock in place, then proceed to the middle section and so on. Each section of the telescopic mast has stops on it to prevent the sections from coming completely apart during setup.
  • Page 62 Remove pin (13) to extend leg to face of wall and reinsert pin to lock leg into Step 11: extended position. Step 12: Fine adjustment of the leg can be made by turning adjustment screw (14) on foot of each leg in or out with a pipe wrench or 1-5/8” flat wrench. Step 13: Once the lower unit and mast is secure and in place, disconnect the cable eye from the clevis securing it to the mast.

  • Page 63: Operating The Winch

    Operating the Winch Section 50: NTENDED The HG12 is for installing or refurbishing underground utilities. The machine is specifically designed to assist a pneumatic piercing tool to burst existing underground pipe while installing replacement HDPE pipe. To use 100% of its cable pulling force, the machine must be used with the downrigger, lower unit and outrigger jacks. Careful inspection of the job site should be made to ensure adequate support for the winch and the lower unit feet.
  • Page 64 Set Cylinder/Winch Selector Switch to the winch position. Step 3: Pay in a small amount of cable and check cable wrap on drum. The take up reel supplies approximately 1500 lb. (608 kg) Step 4: of pull. It is not critical if the cable does not wind absolutely perfect. Step 5: Set the pressure using the control knob to approximately 1000 psi.

  • Page 65: Maintenance

    Maintenance Section 55: WARNING: Before performing any maintenance on the machine, follow the Shutdown Procedure, page 35-1, unless instructed differently in the maintenance manual. • The maintenance sections of this Operator’s Manual contains general maintenance guidelines for the machine. Do not attempt any maintenance procedure that is not fully understood, or that cannot be safely and accurately performed with the available tools and equipment.

  • Page 66: Greasing The Machine

    REASING THE ACHINE As a general rule, grease the machine after it is shut down for the day. This protects the metal under the seals from corrosion caused by condensation as the temperature drops. Make sure all fittings and the nozzle of the grease applicator are clean before applying the grease. If any grease fittings are missing, replace them immediately.

  • Page 67: Maintenance - 10 Service Hours Or Daily

    Maintenance - 10 Service Hours or Daily Section 60: LUID EVELS HECK Check fluid levels daily before operating the machine. Also inspect the machine and make any necessary adjustments and repairs before starting the engine. Engine Coolant Level WARNING: Do not remove radiator cap from a hot engine. Wait until the temperature has cooled before removing the pressure cap.

  • Page 68: Hydraulic Fluid Level

    Hydraulic Fluid Level Clean hydraulic fluid is very important so do not spill dirt or other contaminants into the reservoir. Filter all hydraulic fluid through a 10 micron filter before adding it to the reservoir. Fluid level must be showing in the site glass (2). Refer to Fuel and Lubricants Section for correct fluid.

  • Page 69: Fuel Tank - Fill

    Fuel Tank - Fill WARNING: Never refuel machine while smoking or with engine running. Fill fuel tank outdoors. Clean up spilled fuel. Do not allow any hot or burning material near the machine. Fill the fuel tank at the end of each day to prevent condensation. Do not fill tank to the very top, leave room for expansion.

  • Page 70: Winch Gearbox Oil - Initial Change

    Lower Unit Sheave Bearings grease ................... two shots INCH EARBOX NITIAL HANGE Change the oil: • after the first 10 service hours • every 50 service hours or yearly Refer to the Maintenance - 50 Service Hours or Weekly section, page 65-1.

  • Page 71: Maintenance - 50 Service Hours Or Weekly

    Maintenance - 50 Service Hours or Weekly Section 65: UBOTA NGINE AINTENANCE • Change engine oil. • Clean air filter dust cap. • Check fuel lines. Refer to Engine Operation Manual supplied with machine for instructions. UBRICATE Coat with light oil. HG12 Winch Maintenance - 50 Service Hours or Weekly 65-1...

  • Page 72: Winch Gearbox Oil - Change

    INCH EARBOX HANGE Refer to the Service Specifications section, page 100-1 for required oil. Clean both magnetic plugs and fill to check plug level. Right side is shown. Change oil on both sides of winch. Drain Plug Check Plug Fill REASE OINTS REASE...
  • Page 73 Level Wind Reverse Shaft Grease ................coat with grease Lower Unit Sheave Bearings Grease ..................two shots NOTE: Access to grease fitting may be easier through slot milled in lower unit. HG12 Winch Maintenance - 50 Service Hours or Weekly 65-3...
  • Page 74 Mast Cable Sheave Grease ..................... two shots NOTE: See the Grease Points section page 65-2 for additional grease point locations if necessary. 65-4 Maintenance - 50 Service Hours or Weekly HG12 Winch...

  • Page 75: Maintenance - 100 Service Hours

    Maintenance - 100 Service Hours Section 70: UBOTA NGINE AINTENANCE • Change alternator/fan belt adjustment. • Change engine oil. • Clean/replace air cleaner element. • Clean fuel filter. Refer to Engine Operation Manual supplied with machine for instructions. YDRAULIC YSTEM HECK WARNING: Pressurized fluid can penetrate body tissue and result in serious injury or death.

  • Page 76: Tires And Rims - Check

    IRES AND HECK • Check tires for correct pressure. Inflate to 75 psi (5.1 bar). • Check tires and rims for damage. • Check lug nuts for tightness. Torque to 90 ft-lb (122 Nm). VERALL ACHINE HECK Shields and Guards - Check that all shields and guards are installed and are fastened securely to the machine. Replace or repair any shields or guards that are damaged or have missing parts.

  • Page 77: Maintenance - 200 Service Hours

    Maintenance - 200 Service Hours Section 75: UBOTA NGINE AINTENANCE Change engine oil filter. Refer to Engine Operation Manual supplied with machine for instructions. OOLING YSTEM DDITIVE WARNING: Do not remove radiator cap from a hot engine. Wait until the temperature has cooled before removing the pressure cap.

  • Page 78: Hydraulic Fluid Filter - Change

    YDRAULIC LUID ILTER HANGE Replace filter (1) when plugged filter gauge indicator (2) is illuminated with hydraulic oil at operating temperature. If the indicator does not indicate filter maintenance is required, replace it: at 200 service hours • • every 500 service hours whenever hydraulic fluid is changed •...

  • Page 79: Maintenance - 400 Service Hours

    Maintenance - 400 Service Hours Section 80: UBOTA NGINE AINTENANCE • Change fuel filters. • Clean cooling system. Refer to Engine Operation Manual supplied with machine for instructions. HG12 Winch Maintenance - 400 Service Hours 80-1...
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  • Page 81: Maintenance - 500 Service Hours

    Maintenance - 500 Service Hours Section 85: ATTERY LECTROLYTE EVEL AND ERMINALS HECK LEAN WARNING: Battery contains highly explosive hydrogen gas. Battery contains sulfuric acid which can cause severe burns. Remember safety rules when working with a battery: • Wear safety glasses and face shield and rubber gloves. •...

  • Page 82: Electric Brakes - Test

    To clean terminals and check electrolyte level: Step 1: Remove negative (-) cable (1), then positive (+) cable (2). Step 2: Clean terminals and clamps with a stiff wire brush. Step 3: Apply a light coating of petroleum jelly around the base of each terminal. Remove cell caps (3);...

  • Page 83: Brakes - Adjust

    Brakes - Adjust Jack up one wheel until it is off the ground. Block the machine. Step 1: Step 2: Remove the dirt plug (A) in backing plate. Step 3: While spinning the wheel, turn the adjuster screw (B) clockwise until the wheel has a heavy drag.

  • Page 84: Adjustment

    Adjustment After the entire controller system is installed and operating, the controller must be adjusted to synchronize the towing vehicle and trailer braking systems. Proper adjustment of your controller/braking system is important for safe automatic operation. NOTE: During the initial use of the controller, a slight electrical odor or smoking may be apparent which is normal during the break-in period.

  • Page 85: Maintenance - 1000 Service Hours Or Yearly

    Maintenance - 1000 Service Hours or Yearly Section 90: OOLING YSTEM RAIN AND LEAN WARNING: Do not remove radiator cap from a hot engine. Wait until the temperature has cooled before removing the pressure cap. Failure to do so can result in personal injury from heated coolant spray or steam.

  • Page 86: Hydraulic Fluid - Change

    YDRAULIC LUID HANGE NOTE: If the fluid smells burned, contains air bubbles, or appears contaminated, consult HammerHead dealer immediately. • When oil is warm, remove fill cap (1) and drain plug (2). Drain fluid into a suitable container. • Clean, inspect, and install drain plug. •...

  • Page 87: Wheel Bearings - Check

    HEEL EARINGS HECK To Remove Hub: Step 1: Block the machine so it cannot move; jack up one side until the wheel is off the ground; and, block the machine so it cannot fall. Step 2: Remove tire, dust cap (1), cotter pin (2), castellated nut (3), spindle washer (4), and hub (5).
  • Page 88 To Install Hub: Step 1: Install inner bearing (8); apply a sealant to the outside of a new seal (7); and, install it. Step 2: Install outer bearing (6) and hold in place while sliding hub (5) onto spindle. Step 3: Install spindle washer (4) and the castellated nut (3).

  • Page 89: Maintenance - As Required

    Maintenance - As Required Section 95: NGINE YSTEM HECK An Engine Operation manual is supplied with each machine. Refer to the manual for service requirements. Replace Battery Replacement batteries must meet standard battery specifications provided in the Service Specifications Section. To Replace Battery: Step 1: Remove the negative (-) cable (1) first.

  • Page 90: Hydraulic Fluid Filter - Change

    YDRAULIC LUID ILTER HANGE Replace filter (1) when plugged filter gauge indicator (2)is illuminated with hydraulic oil at operating temperature. If the gauge does not indicate filter maintenance is required, replace it: at 200 service hours • • every 500 service hours whenever hydraulic fluid is changed •...

  • Page 91: Grease Points

    REASE OINTS NOTE: The Capstans or Bull wheels contain approximately 5 gal of grease each and should only need re-greasing when the bearings are replaced. The following photo’s identify several of the grease point located throughout the machine. The bottom left photo shows the grease point locations for the capstans.
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  • Page 93 Torque Values Section 97: YDRAULIC ITTINGS Pipe Thread Fittings • Ensure all threads are free from nicks, burrs, and dirt. • Use a thread sealant such as Loctite Vibra-Seal, instead of pipe dope or Teflon tape, to seal the threads. Teflon tape can plug filters and drain orifices, and can cause hydraulic system failures. •...
  • Page 94 O-Ring Fittings • Ensure the threads and sealing surfaces are free from nicks, burrs, scratches, or any foreign material. Lubricate the O-ring with a light coat of oil. • • To tighten adjustable O-ring fittings, hold the fitting and tighten the nut. •...
  • Page 95 JIC Fittings • Ensure the threads and sealing surfaces are free from nicks, burrs, scratches, or any foreign material. To tighten, turn the fitting until finger tight. Then turn the fitting an additional number of flats as • indicated on the chart below. One flat equals 1/6 of a turn. IMPORTANT: Do not overtighten the fitting.
  • Page 96 ASTENERS For SAE Grade 2, Grade 5, and Grade 8 Cap Screws and Bolts NOTE: Torque values specified in text take precedence over values shown below. These values do not apply when used with lock nuts. Grade 2 Grade 5 Grade 8 Bolt Size Ft-Lb...
  • Page 97 Grade 5 Grade 2 Grade 8 5/8″ -18 NF 3/4″ -10 NC 3/4″ -16 NF 7/8″ -9 NC 7/8″ -14 NF 1″ -8 NC 1085 1″ -14 NF 1250 1 1/8″ -7 NC 1180 1600 1 1/8″ - 2 NF 1060 1340 1815...
  • Page 98 For Metric Grade 5.8, 6.9, 8.8, 10.9, & 12.9 Cap Screws and Bolts Grade 5.8 Grade 6.9 Grade 8.8 Grade 12.9 Grade 10.9 Bolt Size Ft-Lb Ft-Lb Ft-Lb Ft-Lb Ft-Lb 13.5 12.7 13.5 112.5 108.5 230.5 1077 1351 1205 1634 1105 1311 1357...
  • Page 99 For Grade B, C, F, and G Lock Nuts Grade F Grade G Grade C Grade B (Grade 5 Flange) (Grade 8 Flange) (Grade 8) (Grade 5) Nut Size Ft-Lb Ft-Lb Ft-Lb Ft-Lb 1/4″ -20 NC 7.5 - 10 10 - 13 10 - 14 14 - 19 8 - 10...
  • Page 100 Grade F Grade G Grade C Grade B (Grade 5 Flange) (Grade 8) (Grade 8 Flange) (Grade 5) 3/4″ -16 NF 155 - 200 210 - 271 200 - 255 271 - 346 163 - 227 221 - 308 215 - 315 291.5-427 7/8″...

  • Page 101: Service Specifications

    Service Specifications Section 100: UEL AND UBRICANTS Lubricant Capacity Specification / Notes Recommended 11gal (47 L) Fuel Note: Use of any other hydraulic oil without written factory approval will jeopardize Hydraulic Fluid 18 gal (68 L) warranty. Dextron II Transmission Fluid or Equivalent EP Grease: LF Ultra, or equivalent.

  • Page 102: Machine Specifications

    ACHINE PECIFICATIONS Specifications General Length: 171″ (434 cm) Width: 70″ (178 cm) Height: 71-3/4″ (182 cm) Total Weight: 6970 lb (3161 kg) Drawbar Weight:: 700 lb (317 kg) Tires Size: P235 75R 15 Pressure: 75 psi (5.2 bar) Lug Nut Torque: 90-95 ft-lb (122-130 Nm) Winch Maximum Pull Capacity:...
  • Page 103 NDEX Adjust Hitch Height, 40-2 Electric Brakes - Test, 85-2 Adjustment, 85-4 Engine Controls, 25-1 Approximate Preheating Times (Cold Engine), 30-1 Engine Coolant Level, 60-1 Attaching to Towing Vehicle, 40-3 Engine Monitors, 25-3 Automatic Brake Controller with Manual Override (Optional) - Engine System - Check, 95-1 Check, 85-3 Auxiliary Electrical Connector, 25-7...
  • Page 104 Intended Use, 50-1 Operating the Winch, 50-1 Outrigger Final Setup, 45-15 Jump Starting Procedure, 30-4 Outrigger Initial Setup, 45-7 Jump Starting, 30-3 Overall Machine - Check, 70-2 Kubota Engine Maintenance, 65-1 Paying Out Wire Rope, 50-1 Kubota Engine Maintenance, 70-1 Personal Protective Equipment, 45-1 Kubota Engine Maintenance, 75-1 Pintle Hitch, 40-4...
  • Page 105 Threading Wire Rope, 45-15 Tires and Rims - Check, 70-2 Transporting the Winch, 40-1 Wheel Bearings - Check, 90-3 Winch Control, 25-4 Winch Gearbox Oil - Change, 65-2 Winch Gearbox Oil - Initial Change, 60-4 Winch Setup, 45-6 Wire Rope - Inspect, 60-4 Wire Rope - Lubricate, 65-1 Wire Rope Failure, 45-2 Wire Rope, 45-1...
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  • Page 107 Revision History Revision Date Page(s) Description o1_03 01/03 1st edition manual released. HG12 Winch Revision History...

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