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ETC Hammerhead HG12, Operator And Maintenance Manual

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ETC Hammerhead HG12 Operator And Maintenance Manual Download Page 20

10-4     

Safety Messages

HG12 Winch

K

EEP

 S

PECTATORS

 A

WAY

 

FROM

 M

ACHINE

Keep all spectators and other workers away from the machine and work area while in 
operation.

C

ONFINED

 S

PACE

 R

EGULATIONS

Do not work in a confined space, such as a sewer, until requirements are met to ensure a 
hazard free environment. Specific requirements for confined space entry are available from 
federal and state O.S.H.A. offices.

W

IRE

 R

OPE

 F

AILURE

•

Wire rope may break or suddenly release while pulling. Serious injury or death will 
occur if struck. Stay away!

•

Inspect wire rope and hook for damage or wear before each pull.

•

Securely hook winch rope to attachment tool.

•

The last fire wraps of cable must be left on drum to hold the load.

S

AFE

 W

INCH

 O

PERATING

 P

RACTICES

•

Do not guide wire rope by hand while pulling with winch.

•

Do not exceed maximum line pull of 24,000 lb (10,886 kg).

•

Do not use winch to lift, support, or transport personnel.

•

Do not lift loads over personnel.

Summary of Contents for Hammerhead HG12

Page 1: ...HG12 Winch HG12_Winch_o1_03 Serial No 96095 and up Order No OM1001 TM Operator s and Maintenance Manual ...

Page 2: ...able at time of publication Your machine may have product improvements and features not yet contained in this manual Earth Tool Company LLC reserves the right to make changes at any time without notice or obligation Operation and maintenance instructions are included in the Operator s Manuals provided with the machine The tethered cabled manual must remain attached to the machine for ready referen...

Page 3: ...HG12 Winch 5 HAMMERHEAD MOLE and HAMMERHEAD are trademarks of Earth Tool Company LLC NOTE Right and left sides of the machine are determined by facing in the direction of forward travel ...

Page 4: ... 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 US 6 263 983 B1 US 6 269 889 B1 US 6 273 201 B1 US 6 283 229 B1 US 6 302 410 B1 US 6 299 382 B1 US 5 337 837 US 6 321 858 B1 US 6 390 207 B2 US 6 371 223 B2 US 6 390 087 B1 ...

Page 5: ...n No part shall be returned without prior written authorization from ETC and this warranty does not obligate ETC to bear any transportation charges in connection with the repair or replacement of defective parts earth Tool Company LLC will not accept any charges for labor and or parts incidental to the removal or remounting of parts repaired or replaced under this Warranty This Warranty shall not ...

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Page 7: ..._ 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 ___ Check the engine for proper operation Hydraulics ___ Check the level of the hydraulic fluid ___ Check all hydraulic components for leaks or damage Winch ___ Check the level of the oil in the gear boxes ...

Page 8: ...r 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 ___ Check the operation of the taillights ___ Check that the safety towing chains are installed ___ Check that break away brake switch is installed and functions ___ Check all phases of operation ___ Complete Dealer Customer Information page iii ___ Complete I...

Page 9: ...HG12 Winch Receiving and Delivery Report iii DEALER CUSTOMER INFORMATION dealer owner address address city city state province state province zip postal code zip postal code country country ...

Page 10: ...iv Receiving and Delivery Report HG12 Winch IDENTIFICATION NUMBERS RECORD Machine Identification Numbers Model Number Serial Number Engine Identification Numbers Model Number Serial Number ...

Page 11: ...HG12 Winch Receiving and Delivery Report v Winch Identification Numbers Model Number Serial Number Bull Wheel Identification Numbers Model Number Serial Number ...

Page 12: ...als ___ Ensure all requested options are installed ___ Review Winch operation refer to to the Controls section page 25 1 and to the Operating the Winch section page 50 1 Dealer Installed Options ___ Review all appropriate operation and adjustment information Review of Operation ___ Review and demonstrate with customer the various aspects of winch operation overall explanation of how the Winch work...

Page 13: ...ecals 15 1 Safety Decal Maintenance 15 1 How the HG12 Winch Works 20 1 Controls 25 1 Engine Controls 25 1 Engine Monitors 25 3 Winch Control 25 4 Hydraulic Pressure Gauge 25 6 Auxiliary Electrical Connector 25 7 Circuit Breakers 25 8 Starting Procedure 30 1 Starting the Engine 30 1 Approximate Preheating Times Cold Engine 30 1 Cold Weather Starting 30 2 Jump Starting 30 3 Jump Starting Procedure 3...

Page 14: ... Level 60 2 Fuel Tank Fill 60 2 Fairlead Rollers Grease 60 3 Winch Gearbox Oil Initial Change 60 4 Wire Rope Inspect 60 4 Normal Wear 60 4 Damage 60 4 Maintenance 50 Service Hours or Weekly 65 1 Kubota Engine Maintenance 65 1 Wire Rope Lubricate 65 1 Winch Gearbox Oil Change 65 2 Maintenance 100 Service Hours 70 1 Kubota Engine Maintenance 70 1 Hydraulic System Check 70 1 Tires and Rims Check 70 2...

Page 15: ...0 Service Hours or Yearly 90 1 Cooling System Drain and Clean 90 1 Hydraulic Fluid Change 90 2 Wheel Bearings Check 90 3 Maintenance As Required 95 1 Engine System Check 95 1 Replace Battery 95 1 Hydraulic Fluid Filter Change 95 2 Grease Points 95 3 Service Specifications 100 1 Fuel and Lubricants 100 1 Machine Specifications 100 2 ...

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Page 17: ...d is used to alert you to the potential for bodily injury or death UNDERSTAND SIGNAL WORDS A signal word DANGER WARNING or CAUTION is used with the safety alert symbol Safety signs with signal word DANGER WARNING or CAUTION are located near specific hazards DANGER Imminent hazards which if not avoided will result in serious personal injury or death WARNING Potential hazards or unsafe practices whi...

Page 18: ...s injury or death Keep all safety decals and instruction decals in good condition Replace any missing or damaged decals KEEP MACHINE IN GOOD CONDITION Be sure the machine is in good operating condition and that all safety devices are installed and functioning properly Visually inspect the machine daily before starting the machine Make no modifications to your equipment unless specifically recommen...

Page 19: ...hington D C 20590 You can also obtain other information about motor vehicle safety from the Hot line PERSONAL PROTECTIVE EQUIPMENT Operating this machine will require you to wear personal protective equipment Wear close fitting clothing and confine long hair Avoid wearing jewelry such as rings wrist watches necklaces or bracelets Always wear safety glasses work shoes hard hat leather gloves when h...

Page 20: ...federal and state O S H A offices WIRE ROPE FAILURE Wire rope may break or suddenly release while pulling Serious injury or death will occur if struck Stay away Inspect wire rope and hook for damage or wear before each pull Securely hook winch rope to attachment tool The last fire wraps of cable must be left on drum to hold the load SAFE WINCH OPERATING PRACTICES Do not guide wire rope by hand whi...

Page 21: ...o the outside HANDLE FUEL SAFELY Fuel and fumes can catch fire or explode and cause serious injury from burns Shut off engine before refueling No smoking No flame AVOID HIGH PRESSURE LEAKS Pressurized fluid can penetrate body tissue and result in serious injury or death Leaks can be invisible Relieve pressure before working on system When searching for a leak use an object like cardboard not your ...

Page 22: ...flammable and can explode Keep all burning materials away from battery Do not smoke Tools and cable clamps can make sparks Shield eyes and face from battery AVOID BATTERY BURNS Battery contains sulfuric acid which can cause severe burns Avoid contact with eyes skin and clothing In case of acid contact External Flush with plenty of water If eyes have been exposed flush with water for 15 minutes and...

Page 23: ...ms Do not weld or heat wheel assembly Heating will increase tire pressure USE SHUTDOWN PROCEDURE For your safety and the safety of others the Starting Procedure page 30 1 must be followed before servicing cleaning repairing inspecting lubricating fueling or transporting the machine WARNING Failure to follow any of the preceding safety instructions or those that follow within this manual could resu...

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Page 25: ...ndition follow these instructions Keep decals clean Use soap and water not mineral spirits abrasive cleaners or other similar cleaners that will damage the decal Replace any damaged or missing decals When attaching decals surface temperature of the metal must be at least 40 F 5 C The metal must be clean and dry When replacing a machine component with a decal attached replace the decal also Replace...

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: ...fed through the existing line to be burst into the entrance pit where it is attached to the HammerHead Mole The tool and burst head assembly are then winched into the entrance pit and lined up with the existing service The tool is then started and the winch assists the tools forward progress through the old service while simultaneously pulling in the new service The purpose of the HG12 Winch is to...

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Page 31: ...clockwise turns on preheat system 1st position clockwise turns on electrical system 1st position clockwise engine run 2nd position clockwise starts the engine 2 Emergency Shutdown Switch Push in Shuts down all systems 1 2 NOTE Engine does have an electronic fuel shut off Pushing the throttle in will not shut down the engine ...

Page 32: ... 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 3 ...

Page 33: ...1 Control Panel Remote Selector Up position Remote down position Panel 2 Neutral Start Indicator Winch Control Knob Center position neutral Center position engine can be started 3 Auxilary Light Selector Up position On Down position Off 1 2 3 ...

Page 34: ...g 6 Voltage indicator On alternator is not changing 7 Glow Plug Indicator On glow plug is hot 8 High Hydraulic Oil Temperature Indicator On hydraulic oil hot 9 Hydraulic Oil Filter Condition Indicator On hydraulic filter flow restricted 10 Hourmeter Hours total number of hours machine has been in operation 4 5 6 7 8 9 10 ...

Page 35: ...eft position pay out cable Centered neutral Right position pay in cable NOTE Cable will pay in or out at any engine speed 2 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 1 2 ...

Page 36: ...25 6 Controls HG12 Winch 3 Pressure Control Knob Clockwise more pressure pulling power Counterclockwise less pressure pulling power 3 ...

Page 37: ...HG12 Winch Controls 25 7 HYDRAULIC PRESSURE GAUGE 1 Hydraulic Pressure Gauge Winch in neutral approximately 0 300 psi 20 bar in use operational pressure up to approximately 3000 psi 207 bar 1 ...

Page 38: ...s HG12 Winch AUXILIARY ELECTRICAL CONNECTOR 1 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 1 ...

Page 39: ...HG12 Winch Controls 25 9 DOWNRIGGER CONTROL 1 Downrigger direction selector Up Raises downrigger Down Lowers downrigger 1 ...

Page 40: ...25 10 Controls HG12 Winch ...

Page 41: ...regulator control 4 completely out and back in two full turns to set setup pressure Step 5 On a cold engine turn key 5 fully counterclockwise to turn on the preheat system and hold see time duration below Step 6 Start the engine and warm it up at medium speed IMPORTANT Never run the starter for more than 10 seconds at a time Wait 30 seconds between attempts Approximate Preheating Times Cold Engine...

Page 42: ...ove slower until the oil is warmed In cold weather a longer warm up period will become necessary Let the engine run for a minimum of five minutes at a fast idle before starting any operating functions Before starting the engine refer to the Engine Operation Manual section on cold weather starting for correct procedures Also refer to Starting the Engine procedures located in this section IMPORTANT ...

Page 43: ...sion 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 Batteries produce and explosive gas when being charged Keep flames and sparks away from the battery area ...

Page 44: ...ischarged battery POSITIVE 2 Red to boost battery POSITIVE 3 Black to boost battery NEGATIVE 4 Black to discharged machine frame away from battery fuel lines and moving parts Do not attach to negative terminal of discharged bat tery Step 3 While at the controls start engine Remove cables in REVERSE order RED BLACK 4 1 2 3 DISCHARGE BATTERY BOOST BATTERY ...

Page 45: ...tep 3 Turn ignition key counterclockwise to off position Step 4 Remove the key For your safety and the safety of others use this shutdown procedure before servicing cleaning inspecting or transporting the winch A variation of the above procedure may be used if so instructed within this manual or if an emergency requires it NOTE The Emergency Shutdown Switch will immediately shutdown all the HG12 W...

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Page 47: ...nch PREPARE FOR TRANSPORT 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 1 2 3 4 ...

Page 48: ...ne level during transport Step 1 To adjust the hitch Step 2 Remove four hitch bolts 3 Step 3 Raise or lower hitch to match towing vehicle height Step 4 Replace the four hitch bolts and tighten Torque to 145 ft lbs 197 Nm NOTE There is only the Pintle type hitch available from the factory for the HG12 Winch ATTACHING TO TOWING VEHICLE NOTE It is recommended that towing vehicle be equipped with mud ...

Page 49: ...usted so the breakaway system applies the brakes only after both the hitch and the safety towing chains have disconnected The breakaway system is not to be used as a parking brake Attach the electrical connector 3 to the towing vehicle Check that the highway lights and electric brakes are functioning properly IMPORTANT The towing vehicle must be equipped with a brake controller that automatically ...

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Page 51: ...rking near traffic wear high visibility clothing WIRE ROPE Specification 5 8 inch x 2080 feet with swaged on closed eye 6 x 25 IWRC Extra Improved Plow Steel all purpose flexible rope The wire rope has a breaking strength of 40 600 pounds 18 454 kg It must be maintained in good condition for use with the winch which is rated at 24 000 pounds 10 909 kg line pull Damage Damaged wire rope must be rep...

Page 52: ...nder 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 When it breaks wire rope will whip or lash because of the sudden release of tension on the wire rope The wire rope can also whip or lash if it is suddenly pulled loose from its load Be sure the wire rope is securely attached to its loa...

Page 53: ... 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 Illustration 3 shows signs of reverse bending Routing the wire cable over one sheave and under another caused fatigue breaks in the wires Keep wire rope lubricated Lack of lubrication causes strands to lock and break prematurely 4 4 3...

Page 54: ... 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 Keep wire rope from corroding Exposure to elements combined with wear and loss of lubrication causes corrosion and pitting 7 6 7 5 ...

Page 55: ...nds ruining the wire rope To prevent kinks remove loops in the wire rope before tightening it or it will kink as shown 1 To keep the wire rope from bending sharply do not route it around sharp corners and do not wrap it around the load Do not overstress wire rope Snapping the wire rope by adding or removing releasing 2 the load quickly will shorten its life and lead to failure Only use the wire ro...

Page 56: ... 4 Insert the end of the cable over the top bull wheel 1 Feed the cable down and around the bottom bull wheel and back up over the top Step 5 Continue this procedure until all of the slots on the bull wheels have been used Step 6 Thread the end of the cable through the level wind system and secure it to the take up drum using the cable clamp supplied 2 IMPORTANT Do not operate winch with less than...

Page 57: ...Step 1 Position winch bumper 1 approximately 4 to 6 in 100 150 mm inside the edge of excavation or manhole Step 2 Lower front jack and disconnect from towing vehicle NOTE Outriggers 2 can be positioned to extend to either the side or back of the trailer to clear obstructions or for locating over secure footings To position the outrigger A Remove pin 3 and rotate the outrigger toward the back of th...

Page 58: ...de with ground Final adjustment will be made after downrigger assembly is installed NOTE The outriggers are stabilizers although they are capable of supporting the full weight of the HG12 it is not recommended Downrigger Setup NOTE Make sure the cable eye is securely fastened to the mast with the clevises as shown in the photo Failure to attach the cable will prevent the mast from being extended o...

Page 59: ...tarting the Engine page 30 1 for detailed instructions Step 2 Release Mast Latch 6 and push mast 7 away from latch Step 3 Move Cylinder Winch Mode Switch 8 to cylinder position The warning beeper will sound to alert personnel that the downrigger mast hydraulic circuit is engaged 6 7 8 ...

Page 60: ...he latch is free replace the pin in the hole in the latch to prevent the latch from locking the mast until the desired depth Step 7 Lower the mast by keeping the cylinder winch switch in the cylinder position and using the cable direction switch to pay out cable This will extend the telescopic sections to the desired depth NOTE The mast will be in Float mode or be movable whenever the Cylinder Win...

Page 61: ... the telescopic mast has stops on it to prevent the sections from coming completely apart during setup Step 9 Use the outriggers if necessary to fine tune the bottom of the sheave of the lower unit up or down to the centerline of the existing utility WARNING Do not disconnect the cable eye from the mast until all sections of the mast have been locked and secured in place Step 10 Remove the pin 12 ...

Page 62: ...uring it to the mast Step 14 Place the cylinder winch switch into the winch position NOTE The HG12 winch payout speed is 48 14 6 m per minute at full throttle Attempting to pull the cable out faster than this is not possible Step 15 Place the cable direction switch into the payout position and pull the cable through the existing utility to the entrance pit When paying out cable or pulling it throu...

Page 63: ... OUT WIRE ROPE Powered Pay Out Start engine and use control panel or remote control to rotate drum refer to the Controls section page 25 1 When paying out cable or pulling it through the existing service it is not necessary to stop the winch when the cable is not being pulled As soon as the cable is relaxed the cable will stop feeding out even though the capstans continue to turn NOTE Although the...

Page 64: ...he burst head tool and pipe assembly into the entrance pit aligning the burst head with the mouth of the existing pipe Step 6 While winching the new pipe into the entrance pit inspect the legs feet and position of the lower unit Step 7 When the tool and burst head assembly is in the old line still keeping tension on the winch cable start the tool Step 8 Once the tool is started pressure can be inc...

Page 65: ...nd equipment If a problem is encountered that is not understood or cannot be solved contact your authorized independent HammerHead dealer To provide a better view some photographs or illustrations in the maintenance sections may show the machine shields removed Never operate the machine with the shields removed keep all shields in place If removing a shield is necessary return it to its operating ...

Page 66: ...r 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: ...ure has cooled before removing the pressure cap Failure to do so can result in personal injury from heated coolant spray or steam Remove the filler cap slowly to relieve coolant system pressure Fill to within 1 2 13 mm of the bottom of the fill pipe with a low silicate ethylene glycol antifreeze and clean water mixture NOTE Never add pure antifreeze to a cooling system We recommend using a 50 50 m...

Page 68: ...ntaminants 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 1 Fill Cap 2 Site Glass NOTE The hydraulic fluid must be free of bubbles Bubbles indicate trapped air in the hydraulic system 1 2 ...

Page 69: ...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 3 Fill Cap FAIRLEAD ROLLERS GREASE 1 Fairlead Roller Bearings Grease one fitting per side two shots 2 Screw Ball Reverse Shaft Grease coat with grease 3 1 2 ...

Page 70: ...5 1 WIRE ROPE INSPECT Normal Wear Check the wire rope for abrasions cuts frayed spots and worn spots caused by normal wear If it has any broken strands replace it NOTE Due to vibration and whipping wire rope will fatigue more quickly at the end that connects to the load Damage Check the wire rope for permanent bends flattened spots rust and corrosion and other damage Refer to the Preparing the Win...

Page 71: ...1 Section 65 Maintenance 50 Service Hours or Weekly KUBOTA ENGINE MAINTENANCE Change engine oil Clean air filter dust cap Check fuel lines Refer to Engine Operation Manual supplied with machine for instructions WIRE ROPE LUBRICATE 1 Coat with light oil 1 ...

Page 72: ...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 1 Drain Plug 2 Check Plug 3 Fill GREASE POINTS GREASE 1 Mast Pivots Grease one fitting per side two shots 3 2 1 1 ...

Page 73: ...enance 50 Service Hours or Weekly 65 3 2 Level Wind Reverse Shaft Grease coat with grease 3 Lower Unit Sheave Bearings Grease two shots NOTE Access to grease fitting may be easier through slot milled in lower unit 3 2 ...

Page 74: ...65 4 Maintenance 50 Service Hours or Weekly HG12 Winch 4 Mast Cable Sheave Grease two shots NOTE See the Grease Points section page 65 2 for additional grease point locations if necessary 4 ...

Page 75: ...hine for instructions HYDRAULIC SYSTEM CHECK WARNING Pressurized fluid can penetrate body tissue and result in serious injury or death Leaks can be invisible Relieve pressure before working on system When searching for a leak use an object like cardboard not your hand Fluid injected under the skin must be removed immediately by a surgeon familiar with this type of injury Check hydraulic system for...

Page 76: ...ly to the machine Replace or repair any shields or guards that are damaged or have missing parts Decals Check the machine for any worn or missing safety and operating decals Refer to the Safety Decals section page 15 1 and the Controls section page 25 1 sections Hardware Check the machine for loose worn or missing parts and hardware Tighten any loose parts and replace any worn or missing parts ref...

Page 77: ... instructions COOLING SYSTEM ADDITIVE ADD 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 Remove the filler cap slowly to relieve coolant system pressure Add 0 8 ounces 24 cc Fleetguard DCA4 to cooling system to restore corrosion inhibitors ...

Page 78: ... 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 1 2 ...

Page 79: ...aintenance 400 Service Hours 80 1 Section 80 Maintenance 400 Service Hours KUBOTA ENGINE MAINTENANCE Change fuel filters Clean cooling system Refer to Engine Operation Manual supplied with machine for instructions ...

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Page 81: ...ell ventilated area Avoid breathing fumes from battery Avoid contact with skin eyes or clothing Keep flames and sparks away and do not smoke Keep out of reach of children Do not short across battery terminals or allow tools to short from battery terminals to frame Do not jump start or charge a battery with frozen electrolyte In case of acid contact EXTERNAL Flush with plenty of water If eyes have ...

Page 82: ... to allow water and electrolyte to mix Step 5 Install the positive cable 2 then the negative cable 1 ELECTRIC BRAKES TEST Electrical current from the tow vehicle controls the brakes To function properly the brakes must be correctly adjusted and the electrical components must be reliable Engage the brakes while coasting at 20 30 miles per hour 30 50 kph in a traffic free area The braking force shou...

Page 83: ...at steps 1 5 for the other brake AUTOMATIC BRAKE CONTROLLER WITH MANUAL OVERRIDE OPTIONAL CHECK The instructions given below are for the Warner Electric 12 Volt Automatic Brake Controller with Manual Override No 1100 40 If your towing vehicle is already equipped with an electric brake controller it must be capable of automatic and manual brake application Some automatic controllers accomplish this...

Page 84: ...is adjustment does not affect maximum braking capacity of the trailer brakes Because of the wide variety of towing vehicles encountered balancing towing vehicle brakes and trailer brakes is necessary for smooth synchronized stops To achieve this the controller adjustment should be set to provide a slight lead in trailer braking over towing vehicle braking Setting the adjustment in the MORE brake d...

Page 85: ...or signs of rust and add a cooling system cleaner to the water if necessary Step 3 Run the engine long enough to be sure thermostat has opened allowing the engine and radiator to receive fresh water Allow the system to cool then drain the water Add a 50 50 mixture of low silicate ethylene glycol antifreeze and clean water to the radiator Do not fill completely Run the engine until mixture has circ...

Page 86: ...ill cap 1 and drain plug 2 Drain fluid into a suitable container Clean inspect and install drain plug Change the hydraulic filters refer to Maintenance 500 Service Hours section Inspect the hydraulic strainer refer to Inspect Hydraulic Fluid Strainers Refer to Fuel and Lubricants section for approved oils and fill hydraulic fluid reservoir Operate the hydraulic system Follow shutdown procedure and...

Page 87: ... 4 and hub 5 Step 3 Remove outer bearing 6 seal 7 and inner bearing 8 To Inspect Bearing Step 1 Use a suitable solvent to wash all grease and oil from bearings Dry them with a clean lint free cloth and inspect each roller If there is any pitting or corrosion replace bearing and cup 9 Step 2 Wash the inside of the hub with solvent and wipe clean To Pack Bearings with Grease Work grease EP lithium c...

Page 88: ...ub 5 onto spindle Step 3 Install spindle washer 4 and the castellated nut 3 To Tighten Hub Step 1 Tighten nut to approximately 50 ft lb 70 Nm then loosen it without rotating the hub Step 2 Hand tighten nut until snug then back it off just enough to install cotter pin 2 Step 3 Secure cotter pin and install dust cap 1 Step 4 Install tire remove blocks and lower jack Step 5 Repeat procedure for the o...

Page 89: ...lacement batteries must meet standard battery specifications provided in the Service Specifications Section To Replace Battery Step 1 Remove the negative cable 1 first Then remove the positive cable 2 Step 2 Remove battery Step 3 Install new battery Step 4 Apply a light coating of petroleum jelly around base of each terminal Step 5 Install the positive cable 2 first Then install the negative cable...

Page 90: ...ange Fluid Filter Step 1 Use a filter wrench to turn the filter counterclockwise to remove Step 2 Clean the filter head surface Step 3 Apply a thin film of oil to gasket of new filter Step 4 Install filter by hand clockwise onto the filter head until it contacts filter head surface Step 5 Tighten with filter wrench Step 6 Start engine and cycle control levers to pressurize system Step 7 Stop the e...

Page 91: ...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 3 1 4 5 2 Shield Removed for clarity ...

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Page 93: ... 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 To tighten turn the fitting approximately three turns past finger tight ...

Page 94: ...ring fittings hold the fitting and tighten the nut To tighten non adjustable O ring fittings tighten the fitting Size Thread Torque 2 5 16 24 7 8 ft lb 10 11 Nm 3 3 8 24 14 16 ft lb 19 21 Nm 4 7 16 20 16 18 ft lb 21 24 Nm 5 1 2 20 22 24 ft lb 29 32 Nm 6 9 16 18 24 26 ft lb 33 35 Nm 8 3 4 16 40 43 ft lb 54 59 Nm 10 7 8 14 68 70 ft lb 93 95 Nm 12 1 1 16 12 98 102 ft lb 133 138 Nm 16 1 5 16 12 146 15...

Page 95: ...t equals 1 6 of a turn IMPORTANT Do not overtighten the fitting If overtightened the female side of the fitting may deform or break causing the oil flow to become restricted or a leak to form Flats from Finger Tight Size New Fittings Loose Fittings 4 1 4 2 to 2 1 2 3 4 to 1 6 3 8 2 to 2 1 4 1 8 1 2 1 1 2 to 1 3 4 1 10 5 8 1 1 2 to 1 3 4 3 4 12 3 4 1 1 2 3 4 14 7 8 2 1 1 4 16 1 1 1 4 to 1 1 2 3 4 t...

Page 96: ... Grade 5 Grade 8 Bolt Size Ft Lb Nm Ft Lb Nm Ft Lb Nm 1 4 20 NC 4 5 6 8 5 10 13 1 4 28 NF 5 6 8 11 11 15 5 16 18 NC 9 12 13 18 20 27 5 16 24 NF 10 13 15 20 5 22 29 5 3 8 16 NC 16 22 25 35 35 47 3 8 24 NF 18 24 30 40 40 55 7 16 14 NC 25 35 40 55 55 75 7 16 20 NF 30 40 45 60 65 88 1 2 13 NC 40 55 60 80 90 120 1 2 20 NF 45 60 70 95 95 130 9 16 12 NC 55 75 90 120 120 165 9 16 8 NF 60 80 95 130 135 185...

Page 97: ...1 8 NC 180 245 480 650 800 1085 1 14 NF 200 270 560 760 920 1250 1 1 8 7 NC 240 325 700 950 1180 1600 1 1 8 2 NF 275 375 780 1060 1340 1815 1 1 4 7 NC 340 460 1020 1385 1720 2330 1 1 4 2 NF 370 500 1140 1545 1900 2575 1 3 8 6 NC 460 625 1360 1845 2280 3090 1 3 8 12 NF 540 730 1580 2140 2620 3550 1 1 2 6 NC 640 870 1840 2495 3060 4150 1 1 2 12 NF 740 1000 2100 2850 3460 4690 Grade 2 Grade 5 Grade 8...

Page 98: ...5 M7 6 5 8 8 9 4 12 7 11 15 16 22 20 27 M8 10 13 5 14 19 18 24 25 34 29 39 M10 20 27 29 39 32 43 47 64 58 79 M12 34 46 50 68 58 79 83 112 5 100 136 M14 54 73 79 107 94 127 133 180 159 216 M16 80 108 5 122 165 144 195 196 266 235 319 M18 114 155 170 230 5 190 258 269 365 323 438 M20 162 220 220 298 260 353 366 496 440 597 M22 202 274 318 431 368 499 520 705 628 852 M24 245 332 410 556 470 637 664 9...

Page 99: ...24 NF 27 5 38 37 51 5 22 5 31 30 5 42 23 5 31 5 32 43 31 42 42 57 7 16 14 NC 31 40 42 54 39 53 53 72 36 50 49 68 45 62 61 84 7 16 20 NF 39 51 53 69 41 56 56 76 38 53 51 5 72 51 71 69 96 1 2 13 NC 49 5 62 5 67 85 62 79 5 84 108 50 5 69 5 68 5 94 72 102 98 132 1 2 20 NF 50 65 68 88 67 87 91 118 56 5 78 5 77 106 67 106 91 144 9 16 12 NC 67 87 91 118 95 120 129 163 72 102 98 132 105 145 142 197 9 16 1...

Page 100: ...227 221 308 215 315 291 5 427 7 8 9 NC 235 300 319 407 295 382 5 400 519 7 8 14 NF 250 320 339 434 295 382 5 400 519 1 8 NC 345 445 468 603 450 512 5 610 695 1 14 NF 370 470 502 637 452 5 590 617 800 Grade B Grade 5 Grade C Grade 8 Grade F Grade 5 Flange Grade G Grade 8 Flange ...

Page 101: ...on II Transmission Fluid or Equivalent Grease As required EP Grease LF Ultra or equivalent To minimize condensation in bearings grease machine after it is shut down for the day Fittings and grease applicator nozzle must be clean before applying grease Replace all missing fittings General Lubricating Oil As required SAE 30 882 Heavy Moly Lube or equivalent Winch Gearbox Oil Approx 1 2 full 10 F 120...

Page 102: ... 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 24 000 lb 10 886 Kg Cable Tensile Rating 40 000 lb 18 143 Kg ...

Page 103: ... Clean 90 1 Cooling System Additive Add 75 1 Crankcase Oil Level 60 1 D Damage 45 1 Damage 60 4 Downrigger Setup 45 8 E Electric Brakes Test 85 2 Engine Controls 25 1 Engine Coolant Level 60 1 Engine Monitors 25 3 Engine System Check 95 1 F Fairlead Rollers Grease 60 3 Fluid Levels Check 60 1 Fuel and Lubricants 100 1 Fuel Tank Fill 60 2 G Grease Points 95 3 Greasing the Machine 55 2 H How the HG1...

Page 104: ...0 Service Hours or Weekly 65 1 Maintenance 500 Service Hours 85 1 Maintenance As Required 95 1 Maintenance Intervals 55 1 Maintenance 55 1 N Normal Wear 60 4 O Operating the Winch 50 1 Outrigger Final Setup 45 15 Outrigger Initial Setup 45 7 Overall Machine Check 70 2 P Paying Out Wire Rope 50 1 Personal Protective Equipment 45 1 Pintle Hitch 40 4 Prepare for Transport 40 1 Preparing the Winch and...

Page 105: ... Check 70 2 Transporting the Winch 40 1 U V W 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: ...HG12 Winch Revision History 7 Revision History Revision Date Page s Description o1_03 01 03 All 1st edition manual released ...

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