Hurco Spin Doctor User manual

OWNERS MANUAL
FOR
HYDRAULIC
VALVE EXERCISER
P.O. Box 70 •Harrisburg, SD 57032
Phone: [phone] •Fax #: [phone] •E-mail: [email protected]
SDG2OM-02-111405
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FORWARD
This manual contains information about the many features of the Hurco Spin Doctor and Power Pack.
It also contains operator safety precautions, maintenance instructions and operating techniques. This manual
will assist you in the proper break-in, daily care, and troubleshooting of your new Spin Doctor.
In addition to the design and configuration of equipment, hazard control and accident prevention are
dependent upon the awareness, concern, prudence, and proper training of personnel involved in the operation,
transport, maintenance, and storage of equipment. Read carefully this entire manual before operating the unit.
Spend time becoming acquainted with the units performance features, adjustments, and maintenance
schedules. In order to prevent injury and obtain a long and satisfactory life from this equipment the operator
must know how to properly operate and maintain the unit. Failure to do so will increase the cost of repairs.
Remember, even a Doctor needs care.
SD head serial number: _________________ _
G2 boom serial number:
Power pack serial number:
If at any time, you have a service problem with your Spin Doctor contact your authorized dealer for correct
service and parts needed.
HURCO DEALER: FOR:
Hurco Technologies Inc.
409 Enterprise St.
Harrisburg, SD 57032
Phone: [phone]

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CONTENTS
I. Safety precautions.
A. General Safety Rules……………………………………………………… 4
II. Operating Instructions……………………………………………………… 5 - 6
III. Trouble shooting section…………………………………...................……… 7
IV. Maintenance section......................................................................................... 8
V. Parts breakdown and listing
A. Boom mechanical assembly.………………………………………..…..… 9
B. Boom hydraulic assembly.................................................................... 10
C. Spin Doctor head assembly.……………………..……..……….….………. 11
D. Counter wiring diagram……………………………………….….………… 12
VI. Warranty……………………………………….…………..…………….……. 13 - 14

WARNING!
READ ALL OPERATING MANUALS
BEFORE OPERATION OF EQUIPMENT
GENERAL SAFETY INFORMATION
• Always wear protective clothing and safety glasses when operating machinery.
• Do not operate at pressures greater than the maximum rated for the equipment.
• Never service or repair equipment while running. Bring to a complete stop and allow cooling.
• Whenever fueling power pac, shut off engine and do not smoke.
• Release all pressure within system before servicing any component.
• Check hoses for weak or worn condition before each use.
• Make sure all connections are tight and secure.
• Periodically inspect system components. Perform routine maintenance as required.
(See Maintenance section).
• Do not operate a gasoline engine in an enclosed area. Be sure the area is well ventilated.
• Always determine valve size, type, brand and torque specifications prior to operating unit. Do
not exceed manufacturers recommended specifications.
• Inspect the unit daily for such things as leaky hoses, loose bolts, kinked hydraulic hoses,
and worn or broken parts. Discovering these problems ahead of time can save down time
and prevent operator injury.
• Be alert to maintenance indicators such as the In-tank filter pressure gauge, hydraulic reservoir sight
gauge, etc. Take the required actions to correct any problems.
• Do not use hands to check for suspected leaks in the hydraulic hoses. Hydraulic fluid escaping under
pressure has sufficient force to penetrate skin and cause serious injury. If fluid is injected into skin, it
must be surgically removed within a few hours or gangrene may result. Use a small piece of wood or
cardboard, not hands, to search for pinhole leaks. Be sure all pressure is relieved whenever
disconnecting lines. Be sure all connections are tight and that hoses and lines are not damaged before
applying pressure.
• Relieve hydraulic pressure prior to doing any maintenance or repair..
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Operating Instructions
Situations may vary; it is impossible to list all Hazards. Stay alert. Be aware. YOU can help or
prevent accidents
• Before any operation of Spin Doctor, be familiar with the locations and functions of the unit’s
instruments and controls. Being familiar with the machine and its controls will increase efficiency and
reduce the possibility of personal injury or damage to the unit. The operator should work slowly and
carefully until he feels comfortable with the machine. Speed and skill will be attained much easier if
the necessary time is spent to familiarize the operator with the machine and its operations.
• Always check engine oil level and hydraulic oil level in reservoir prior to starting engine.
• Attach hydraulic boom hoses to the power pack, making sure they are correctly connected and coupler
is locked.
• Remove position lock pins from boom to allow boom to extend and swivel.
• Start power pac engine. (See engine owners manual for operating instructions)
• Insert extension key attaching to valve nut. (Valve manufacturers recommend the first and last turn be
done by hand).
• Insert hydraulic motor drive into valve extension wrench.
AMERICAN WATER WORKS RECOMMENDED VALVE MAINTENANCE PROCEDURES:
Operation and maintenance procedures for various types of valves are detailed in manufacturer’s operation
manuals and in the appropriate product standards. The following paragraphs provide the guidelines for most
situations.
A valve that has not been operated for a number of years needs to be closed by using a series of up and
down motions. Crews attempting to close a difficult valve should never use a T-handle and cheater bar to
force the valve closed. Exceeding manufacturers recommended torque values to obtain a positive shutoff can
cause damage to the valve. Torque-limiting devices are available. Crews should follow these guidelines to
close a valve properly:
1. Begin with a steady amount of torque in the direction necessary to close the valve,
moving through 5 to 10 rotations.
2. Reverse for two or three rotations.
3. Reverse again and rotate 5 to 10 more turns in the closing direction.
4. Repeat this procedure until full closure is attained.
5. Once the valve is fully closed, it should be opened a few turns so that high-velocity water
flowing under the gates can move the remainder of the sediment downstream with more
force and clear the bottom part of the valve body for seating.
6. Fully close the valve again.
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The reason for this cautious approach is that debris and sediment often build up on the gates, stem, and
slides. If this material is compacted while the valve is being closed, the torque required to close the valve
continues to build as the material is loaded. If the procedure described above is used, the stem and other
parts are “scrubbed” by the series of back-and-forth motions, and water in the system can flush the debris
that has broken loose away from the stem gate and slides or guides.
• Slowly operate valve lever to begin operation in the required direction to open or close valve.
• Utilizing the revolution counter, completely open (or close) the valve slowing at the required number
of revolutions. (Refer to valve chart for average number of revolutions required) DO NOT OVER-
TORQUE VALVE!
• Reverse valve direction to complete exercise stopping prior to the last complete turn.
• Remove hydraulic motor drive from key and complete the last turn of the operation by hand.
• Retract boom and insert locking pins for transport.
WARNING! NEVER MOVE UNIT WITHOUT FIRST INSERTING
LOCKING PINS SECURING THE BOOM!
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TROUBLE SHOOTING SECTION:
PROBLEM:
Power pac won’t start.
SOLUTION:
1. Spin Doctor hoses must be connected to power pac for the engine to start. Connect hoses from Spin
Doctor to power pac making sure connectors are locked together and start engine.
2. Check battery and connections.
3. Check engine oil.
4. Check fuel.
PROBLEM:
Excessive Hydraulic oil heat build up.
SOLUTION:
1. Check hydraulic oil level in the reservoir. Refill if necessary.
2. Check pressure gauge. Adjust to 2000 PSI if necessary.
PROBLEM:
Counter quit working.
SOLUTION:
1. Check wiring for loose wire.
2. Check gap between magnet (located on spindle adapter) and pickup sensor. Gap should be
between 1/16 and 1/8 inch. Adjust if necessary.
3. Replace counter if required.

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MAINTENANCE SECTION:
SPIN DOCTOR:
• Grease main boom at connection to swivel bracket using grease gun weekly or as needed.
• Visually inspect all connections and bolts daily. Physically check bolts and connections weekly.
• Grease SD head to pivot bracket using grease gun weekly or as needed.
• Grease all pivot points on ER using grease gun weekly or as needed.
• Counter is water resistant NOT waterproof. Do not operated in rain, pressure wash, and keep covered
when not in use.
POWER PAC:
• Check engine oil level daily. Refill as needed. Change according to engine manufacturer’s
recommendations.
• Visually check hydraulic tank sight glass level daily. Replenish if necessary.
• At the end of the first 50 hours of service replace the in-tank hydraulic fluid filter. Thereafter, replace
every 500 hours or yearly.
• Follow engine maintenance requirements as noted in manufacturer’s manual provided with new unit.
• Visually inspect all connections and bolts daily. Physically check bolts and connections weekly.
HYDRAULIC FLUID RECOMMENDATIONS
MANUFACTURER UNIVERSAL TRACTOR
FLUID
ARCO………………………………………….…………… .ARCO TRACTOR FLUID
AMOCO……………………………………………………………...………...1000 Fluid
CHEVRON……………………………………………………….Tractor Hydraulic Fluid
CITGO………………………………………………………………………….….AW/32
MOBIL…………………………………………………………………….Mobilfluid 423
SHELL……………………………………………………….………………....Donax TD
SUN……………………………………………………………….……………..TH Fluid
TEXACO………………………………………………………………………THD Fluid

1 2 34 56782 1091211 151413 16 17 18
34 33 19 432 31 30
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37
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36
39
27
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19 4
20
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12
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37
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Spin Doctor Generation 2
Boom - Mechanical
p
arts
ITEM QTY DESCRIPTION PART NO. ITEM QTY DESCRIPTION PART NO.
1 1 PIVOT BRACKET 2201-011 22 1 R-clip 1/8" 990-320
2 3 NYLOCK NUT 5/16" NC 902-001 23 1 HITCH ASSEMBLY 2101-001
3 2 FLAT WASHER 1/2" 905-020 24 1 SD HITCH PIN 2105-013
4 8 NYLOCK NUT 1/2" NC 905-001 25 1 SWIVEL PIN ASSEMBLY 2101-150
5 1 HANDLE NUT 1/2" NC 990-150 26 1 NYLOCK NUT 1/4" NC 901-001
6 1 PLASTIC SLIDE BLOCK 2201-003-21 27 3 CAPSCREW 1/2 X 2 1/2 NC 905-109
7 1 CYLINDER ANCHOR ANGLE 2201-003-22 28 1 CAPSCREW 1/4 X 1 3/4 NC 901-106
8 2 NYLOCK NUT 1/4" NC 901-001 29 2 CARRIAGE BOLT 1/4 X 1 1/2 NC 915-105
9 1 LOCK LATCH HANDLE 2201-003-17 30 2 SET SCREWS 5/16 X 3/8 990-101
10 1 GAS CYLINDER 225# 2201-222 31 2 SLIDE ROD 2201-003-20
11 1 PRIMARY LATCH ARM 2201-015 32 1 PRIMARY LINKAGE ARM 2201-012
12 2 SPRING PIN 3/16 X 1 1/2 990-100 33 2 DOG LEG 2201-014
13 1 CAPSCREW 1/2 X 2 NC 905-107 34 3 CAPSCREW 1/2 X 2 3/4 NC 905-110
14 10 CYLINDER BALL STUD 2201-203 35 1 SECONDARY LINKAGE ARM 2201-013
15 10 CYLINDER SOCKET 2201-201 36 2 GAS CYLINDER 175# 2201-220
16 10 SOCKET LOCK CLIP 2201-202 37 2 CAPSCREW 5/16 X 1 1/2 NC 902-105
17 2 GAS CYLINDER 200# 2201-221 38 2 CARRIAGE BOLT 1/2 X 2 NC 915-507
18 1 BOOM - SWIVEL PIN 2101-111 39 1 SPRING 2101-126
19 2 1/2" LYNCH PIN 2101-149 40 1 SLIDE SPACER 2201-013-12
20 1 SWIVEL 2201-002 41 2 SLIDE LINK 2201-013-13
21 1 GREASE ZERK 1/4-28 990-301
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987 65 4 3 21
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Boom - Hydraulics parts
Spin Doctor Generation 2
ITEM QTY DESCRIPTION PART NO.
1 1 MALE FLAT FACE CONNECTOR 2101-120
2 1 FEMALE FLAT FACE CONNECTOR 2101-121
3 2 HOSE 3/8'' X 74'' 2101-74
4 16 CAPSCREW 1/4 X 1 1/2 NC 901-105
5 8 CLAMP COVER PLATE 2101-123
6 8 TUBE CLAMP BODY 2101-122
7 4 TUBE 2101-118
8 1 HOSE 3/8" X 23" 2102-116
9 1 HOSE 3/8" X 21" 2101-115
10 1 FITTING 2201-101
11 2 HOSE 3/8" X 31.5" SLEEVED 2101-114
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