HOGG & DAVIS HYDRA 985 User manual

HYDRA 985
The information, specifications, and illustrations in this manual are on the basis of
information available at the time it was written. The specifications, torque values,
pressures of operation, measurements, adjustments, illustrations, and other
items can change at any time. These changes can affect the service of the given
product.
For the complete and most current information, contact:
Hogg & Davis, Inc
P.O. Box 405 / 3800 Eagle Loop
Odell, OR 97044-0405
541-354-1001
541-354-1080 Fax
For most recent manual
version please visit:
www.hoggdavis.com

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Contents
PRODUCT WARNINGS ........................................4
OPERATIONS ......................................................5
DIESEL ENGINE SPECIFICATIONS ............................................................................................................... 6
INTRODUCTION......................................................................................................................................... 6
GENERAL SPECIFICATIONS. ....................................................................................................................... 6
TRAILER ORIENTATION.............................................................................................................................. 8
MAIN FRAME AND AXLE ........................................................................................................................... 8
CONTROLS................................................................................................................................................. 9
LOADING INSTRUCTIONS ........................................................................................................................10
HYDRAULIC CONTROLS ...........................................................................................................................11
Power Unit Features ...........................................................................................................................11
FRONT HYDRAULIC CONTROLS ...........................................................................................................12
FRONT CONTROL BANK....................................................................................................................... 13
REEL CARRYING RACKS (MANDREL RACKS) ........................................................................................ 14
POWERED IDLER WHEELS AND HYDRAULIC CONTROLS.....................................................................14
AUXILIARY POWER SHAFT...................................................................................................................14
POWER UNIT .......................................................................................................................................14
JACKSTANDS........................................................................................................................................ 15
STEER-GO OPERATION ........................................................................................................................ 16
MANUERVERING INSTRUCTIONS............................................................................................................ 16
TO STEER AND MOVE.......................................................................................................................... 17
THE JOYSTICK ...................................................................................................................................... 17
ON BOARD AIR COMPRESSOR............................................................................................................. 18
BRAKE CONTROLLERS.......................................................................................................................... 18
TOOL CIRCUIT (OPTIONAL)......................................................................................................................19
LEVELWIND OPERATIONS ....................................................................................................................... 20
LEVELWIND COMPONENTS................................................................................................................. 21
PULLING PROCEDURES............................................................................................................................22
OVERHEAD WIRE................................................................................................................................. 22

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UNDERGROUND PULLING...................................................................................................................23
SERVICE ............................................................24
HYDRA 985 Lubrication .......................................................................................................................25
JACKSTAND INSTALLATION ................................................................................................................. 26
DRIVE ROLLER MAINTENANCE............................................................................................................27
DRAWDAR INSPECTION ...................................................................................................................... 28
ACME ADJUSTING SCREW................................................................................................................... 28
MANDREL RACK STABILIZER INSTALLATION ....................................................................................... 29

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PRODUCT WARNINGS
These warning labels and others like it are placed in critical areas of the machine. The warnings
are to be read and fully understood prior to operation of the unit.

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OPERATIONS

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INTRODUCTION
The Hogg & Davis, Inc HYDRA 985 Cable Reel Unit
is an advanced design cable pulling trailer that
provides tremendous pulling forces in a compact
vehicle. Its total design provides for easy
operations and affords great savings in set-up and
manpower. Full utilization of the HYDRA 985 will
greatly improve your cable installation and
removal operations.
This manual is designed to make you familiar with
the machine and its operation.
READ THIS MANUAL THOUROUGHLY BEFORE
OPERATING THE MACHINE
GENERAL SPECIFICATIONS.
 REEL CAPACITY: 108” dia X 56” wide
 HYDRAULIC REEL LIFITING CYLINDERS
 HYDRAULIC POWERED IDLER WHEEL
 HYDRASTATIC TRANMISSION POWER
UNIT
 CADMIUM PLATED, QUICK RELEASE
JACKSTANDS
 20,000 STUB STPINDLE AXLE
 AIR BRAKES w/ABS
 2.5” REEL MANDREL WITH TAPERED
CENTERING CONES, LOCKING
COLLARS, AND NYLATRON BEARINGS
DIESEL ENGINE SPECIFICATIONS
3TNV88-BDSA General
Specification
36.0 HP (26.9 kW) @ 3000 rated rpm*
____________________________________________________________________________
__________________
Type• • • 3 Cylinder, 4-Cycle, Liquid Cooled
Diesel Engine
Bore • • • • • • • • • • • • • • • • • • • • • • 88 mm
Stroke • • • • • • • • • • • • • • • • • • • • • 90 mm
Displacement • • • • • • • • • • • • • • • • • 1.642 L
Aspiration • • • • • • • • • • • • • Naturally
Aspirated
Combustion System • • • • • • • • • • Direct
Injection
Rotation (from flywheel end) • • • • • •
Counterclockwise
Dry Weight • • • • • • • • • • • • • 341 lbs (154 kg)

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TRAILER ORIENTATION
The HYDRA 985 is made up of four (4) major
working components (see Fig.1) they are:
A. MAIN FRAME AND AXLE
B. POWER UNIT
C. POWER IDLER WHEEL AND CONTROLS
D. REEL CARRYING RACKS
MAIN FRAME AND AXLE
The main frame and axle carry the entire weight of the
trailer and its payload. Constructed of heavy steel, the
main frame will provide many years of durable service and
minimum maintenance. The fenders and tool
compartments are incorporated as part of the main frame
structure.
The axle is of the 20,000 lb capacity stub type. Heavy duty
brakes, hubs and bearings provide many years of service
over all highway types.
LUBRICATION SCHEDULE SHOULD
BE FOLLOWED
D
B
A
C

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CONTROLS
The control panel has a variety of gauges and switches that control certain functions during the operation
of the HYDRA 985. Here is a description of these controls. (Figure 2)
A. Hydrastatic Pressure Gauge: This gauge alerts the operator to the system pressure at all times
during operation. IT IS NOT A GAUGE TO ILLUSTRATE line pull.
B. Front / Rear Control: This switch isolates the front and rear controls of the unit during operation.
C. Ignition Switch
D. Switch Panel: This panel contains various switches to control functions of the unit. Depending on
options installed the location of the switches may vary. They Include: Two speed on the fly shift
to Hi or Low speed, marker beacons, level wind, auxiliary air compressor, work lights, auxiliary
hydraulic tool circuit, etc.
E. Joystick: Spring return to Neutral control joystick for operating the Pay out or Take up feature of
the puller. Proportional control allows for infinite speeds and pulling force during operation. An
"OPERATOR PRESENT" switch may be installed on certain units. This provides security against
payout under power. Unit will not pay out until the switch has been pressed and the joystick
moved out of the neutral position
A
E
D
C
B

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LOADING INSTRUCTIONS

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HYDRAULIC CONTROLS
Power Unit Features
 A- ACME ADJUSTING SCRW
 B - EXTENDED SHAFT GUARD COVER
 C- POWER UNTI DRIVE SHAFT 2 7/16"
A
B
C

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FRONT HYDRAULIC CONTROLS
 A - STEER GO SYSTEM
 B - FRONT HYDRAULIC CONTROLS (DRAWBAR, POWER UNIT, LEFT AND RIGHT
MANDREL RACKS
A
B

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FRONT CONTROL BANK
 A - DRAWBAR RAISE AND LOWER
 B - POWER UNIT FORWARD AND BACK
 C,D - RIGHT AND LEFT AND RIGHT MANDREL RACK RAISE AND LOWER
A
B
C
D

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POWER UNIT
The Power Unit consists of the engine, Hydrostatic Transmission Drive Unit, Drive Rollers, Engine
Controls, hydraulic reservoir and auxiliary power shaft. The power unit supplies power for all hydraulic
functions and turns the reels to provide cable pulling. Pulling controls are located at the power unit,
the rear curb side of the trailer. Electronic controls at the rear of the trailer control the direction of pull
for cable take-up or pay-out and control the throttle, level wind, hydraulic tool circuit, and hi and low
shift. All primary engine controls are located at the front of the power unit.
AUXILIARY POWER SHAFT
This shaft is located on the side of the power unit and is used for light duty winding operations.
Attachments can be added to the shaft. The rotation of the shaft is controlled with the Joystick that
controls the take up and pay out functions. When not in use, the shaft should be covered with the
cover provided.
POWERED IDLER WHEELS AND HYDRAULIC CONTROLS
The powered idler wheel is located towards the front of the trailer. This wheel is hydraulically raised or
lowered and hydraulically powered to provide maneuverability of the trailer when disconnected from
the towing vehicle. The wheel is steered by means of a power steering control unit (figure 3). The
joystick controls forward and reverses movement as well as left and right direction of the trailer. Refer
to the Steer-Go Power Steering section. The hydraulic controls are located between the power unit and
the idler wheel at the main drawbar cross member.
The four valves control the following functions:
 Drawbar Height: raise and lower
 Power Unit direction: fore and aft
 Right Mandrel Rack: raise and lower
 Left Mandrel Rack: raise and lower
REEL CARRYING RACKS (MANDREL RACKS)
The reel carrying racks (mandrel racks) are located in the reel carrying area at the rear of the trailer (fig
5A and 5B). These racks have several pockets to allow a variety of reel diameters to be picked from the
ground. Follow the LOADING INSTRUCTIONS when loading the reel. The mandrel rack locks are
indicated in Fig 5C. Also, Fig 5D shows the rear controls for the power unit and the Jack stands (FIg 5E
and 5F)

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JACKSTANDS
JACKSTANDS ARE STABILIZING LEGS LOCATED AT THE REAR OF THE TRAILER. THE JACKSTANDS
SHOULD BE USED DURING ALL PULLING OPERATIONS
In Fig 5, the jack stand at the left is shown in the stowed or carried position. The jack stand at the
right is shown in the down or pulling position. Each jack stand is positioned by the use of a ratchet
locking in the notches. To release the jack stands from the carrying position, lift and rotate out of the
carrier. To raise, rotate stand one quarter turn to release the ratchet from the notch and raise the
stand to lock into the carrier.

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NOTE: Visual inspection of the drive chain and sprockets is required prior to
every use, check chain for wear, slack and damage.
MANUERVERING INSTRUCTIONS
One of the main features of the HYDRA 985 is its ability to maneuver under its own power by use of
the Powered Idler Wheel and the Steer Go System.
The main intent of the Idler wheel system is to provide for easy maneuverability of the unit around the
jobsite, to load and unload the reels, and to aid in the attachment and removal from the tow vehicle.
It is NOT designed to move the trailer long distances (example –vault to vault) without the aid of the
tow vehicle. It is NOT designed to be used for movement or transportation up or down an incline
greater than 2%. Using the Steer Go system in this manner can create extreme stress on the system
and could possibly create a failure that could lead to a trailer that can NOT be steered, controlled or
stopped.
Any operator MUST be familiar with the control of the trailer when it is being moved with the Idler
Wheel System. Familiarize the use of the joystick, engine speed, and the brake controls prior to
operating the trailer.
USE OF THE STICK WHICH CONTROLS THE IDELR WHEEL MOTOR AS A BRAKE SHOULD BE AVOIDED
STEER-GO OPERATION
There are two (2) main components in the
system.
A. The Steer-Go Control Box mounted to
the right hand (curb) side of the trailer
drawbar.
B. The Rotary Actuator Assembly attached
to the Idler Wheel Fork Assembly
Working together, these components allow the
operator to easily steer and maneuver the trailer
by merely moving the joystick control as desired.
The actuator can move the wheel through a 180
degree arc, 90 degrees either side of center.
In the instructions that follow we will often refer
to "steering" and "motion” For our purposes,
"Steering" will always refer to the action of
turning right or left. The word "motion" will
always refer to forward or reverse direction of
the idler wheel

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THE JOYSTICK
The joystick is a two-axis control that controls both steering and motion of the idler wheel functions.
The joystick is either mechanically linked or electronically controlled (depending on options) to
hydraulic control valves. Mechanical valves are spring return to neutral. Electronic joysticks are also
spring return to neutral. Releasing the joystick will cause all movement to stop.
The linkage system, in the mechanical system, provides quick positive response to the operators
action. Because the response is quick, steering right or left is usually accomplished by a series of
short, momentary movements of the joystick in the desired left or right direction.
NOTE: Refer to the directional decal (Fig. 7) on the top of the control box prior to operating. Become
familiar with the feel of the joystick with the engine running. Note the short movement required to
move through the full range of direction
TO STEER AND MOVE
CAUTION: Note the direction the idler wheel is pointing
before actuating the joystick. The trailer will move in the
direction the wheel is pointing
Start the Engine. With the engine running at IDLE SPEED,
move the joystick to the right or left. (NOTE: Steering
speed is NOT affected by engine RPM)
Move the joystick to the FWD position. The trailer now
travels forward. By holding the joystick in the forward
position and moving it to the RIGHT, the trailer will turn
RIGHT. Release the turning motion when the wheel has
reached the angle of turn you desire. Trailer will
continue to turn until you steer LEFT to straighten out the
wheel.
To back the trailer, move the joystick to the REV position.
When you turn to face the rear of the trailer as you are
backing, the steering directions are reversed.
NOTE: Idler wheel speed is a function of engine RPM. Idle
is enough to provide easy, smooth operation. The higher
the RPM the faster the unit will move
Figure 7

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BRAKE CONTROLLERS
Brake controllers on the HYDRA 985 are what is commonly used in an air brake trailer. Figure 6 shows us
the location of the following:
C: The hand control located on the apex of the trailer
D: The Push-Pull Switch located at the apex of the trailer
ON BOARD AIR COMPRESSOR
Each air brake unit that is equipped with an engine has an air compressor installed to charge the system
while away from a tow vehicle. This compressor is located in the power unit and can be controlled by a
switch on the main control panel. It is recommended that the unit engine be started with the switch in the
OFF position to allow for maximum battery power for starting. After the engine is running, turn the
compressor on to charge the system. Although the compressor has an automatic shut off when it reaches
the pre determined pressure in the system, for extended life and better starting power, it is recommended
that the compressor be switched OFF after the system pressure has been reached.

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TOOL CIRCUIT (OPTIONAL)
Some trailers may be equipped with an optional hydraulic tool circuit. The circuit is designed for tools
which are used intermittently or for short duration such as a pump or hydraulic cutters. It is NOT
designed for uses of long or continuous duration such as hydraulic blowers or generators.
The tool circuit outlets are located in the rear curbside (Fig. 8) fender panels. Two quick disconnect
fittings are provided. The tool circuit is actuated by an electric switch located on the main control
panel, and the rear fender panel. This system is designed to provide 10 GPM at 2000 psi.
WARNING: WHEN NOT IN USE, THE SWITCH MUST BE IN THE OFF POSITION. IF THE SWITCH IS LEFT
ON, WHEN TOOLS ARE DISCONNECTED, SEVERE BACKPRESSURE WILL OCCUR THAT COULD DAMAGE
THE HYDRAULIC SYSTEM.

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LEVELWIND OPERATIONS
Some units are equipped with a Level wind System. This system is hydraulically actuated boom style
level wind located at the rear of the trailer (Fig. 9)
There are two switch locations to operate the level wind. They are at the main control panel and the
rear control panel located at the curbside fender. Each switch is directional in relation with the
travel of the level wind boom. That is, if you push the switch to the right, the boom travels right as
you view the level wind. If you push the switch left, the boom travels left. The switches are
momentary and as you release them, it comes to a neutral position and the boom stops.
The level wind does not operate automatically. The operator must activate the switch each time the
rope or wire is to be moved on the reel. The top roller of the boom carriage is made with a swing
away mounting to allow for insertion or removal of the line. By removing the pin located in the
boom, the upper boom section can be extended or retracted as needed. DO NOT OPERATE THE
LEVELWIND WITHOUT THE PIN INSTALLED IN THE BOOM SECTIONS. THIS MAY CAUSE THE BOOM
TO COME OUT OF THE LOWER SECTION DURING OPERATION.
The level wind is most suitable for overhead pulls. Its use for underground is greatly restricted due
to manhole size and amount of pull required. Do not use the level wind as a "breaker bar" for
underground pulls.
To load with the level wind installed, pull the left hinge pin and swing the assembly out of the hinge
and to the right. After the reel is loaded, swing assembly back into hinge and insert the lock pin.
The lower turnbuckle support is provided to allow for easy movement of the level wind arm during
loading and unloading of reels. It may be necessary to adjust this turnbuckle if the unit becomes
difficult to swing in and out of the hinge.
The unit can be easily removed from the trailer by disconnecting the hoses and pulling the hinge
pins.
BE SURE TO USE A FORKLIFT OR OVERHEAD CRANE WHEN REMOVING AND INSTALLING THE
LEVELWIND ASSEMBLY.