Hurco HH500 User manual

Read these instructions thoroughly before using the HH500. For more in-
formation, call Hurco at 800-888-1436 or email [email protected]. This
product is sold with the understanding that the purchaser agrees to
thoroughly train all operators and maintenance personnel in the correct and
safe assembly, operation, and maintenance of the product and to provide
adequate supervision of personnel at all times. Retain these instructions for
future reference. If this product is resold or otherwise conveyed, purchaser
must pass on the instructions to the new user.
REFERENCE MANUAL
The HH500 Kit Includes:
•HH500
•Batteries (2)
•Charger
•Socket
•Wrench
•Grease Zerk
•Product Instructions
•Tool Bag or Crate

2
Table of Contents
Section 1: Safety 3
Section 2: Product Specifications 4
Section 3: Components 5
Section 4: HH500 Controls 6
Section 5: Operation 7
Opening Hydrant Valves 8
Closing Hydrant Valves 9
Section 6: Other Attachments 10
Attachment Options 10
Gate Valve Key 11
Section 7: Maintenance 14
Greasing the Output Drive 14
Greasing the Output Drive Housing 15
Section 8: Reference Tables 16
Gate Valve Tables 16
Section 9: Troubleshooting 18

3
Section 1: Safety
The HH500 is designed to produce an intense amount of torque.
PLEASE USE EXTREME CAUTION AT ALL TIMES.
This tool has been designed to help operators open and close
valves. The tool can create in excess of 450 lb-ft of torque.
DANGER
The incorrect use of HH500 equipment may cause
serious injury. Read these instructions in their
entirety before using any HH500 products.
WARNING
Use caution when operating any power tool. Read
and follow the operating and safety instructions in
the product manual. Always wear safety goggles
and other appropriate safety items for protection.
CAUTION
Never apply manual torque to open or close a valve! ONLY
USE MOTOR POWER TO ACTUATE THE VALVE,
OTHERWISE, DAMAGE TO THE MOTOR MAY OCCUR.
WARNING
MAKE SURE THE REACTION HANDLE IS PULLING
AWAY FROM THE OPERATOR DURING USE. Misuse
could lead to loss of operator balance and potential fall
injury.

4
Section 2: Product Specifications
Model Name HH500
Model Type Cordless
Width (in) 6.5”
Length (in) 26”
Height (in) 12” from output drive to top motor handle
Weight 22.5 lbs with socket and battery
Battery Capacity Up to 20 hydrants / 10 gate valves
Battery Charge Time 65 minutes
Variable Speed Up to 30 rpms
Torque Up to 400 lb-ft
NOTE: This is lower then Section 1 states because
this is the torque the tool starts out with. Over time,
the tool will have less friction and more torque.

5
Section 3: Components
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CHARGER
WRENCH
GREASE
ZERK
BATTERIES (2)
PRODUCT
INSTRUCTIONS
HH500
5-POINT
ADJUSTABLE
SOCKET
1.5 "
WRENCH
ADAPTER

6
Section 4: HH500 Controls
ROTATION FORCE AWAY FROM OPERATOR
Threaded
Fastener
Set Screw
Battery
Reaction
Handle
Socket
Directional Switch
Trigger
Digital Counter
Handle
Lock

7
Section 5: Operation
WARNING
MAKE SURE THE REACTION HANDLE IS PULLING AWAY FROM
THE OPERATOR DURING USE. Misuse could lead to loss of
operator balance and potential fall injury.
CAUTION
Never apply manual torque to open or close a valve! ONLY USE
MOTOR POWER TO ACTUATE THE VALVE, OTHERWISE, DAMAGE
TO THE MOTOR MAY OCCUR.
Follow all HH500 procedures outlined in these Product
Instructions. Failure to follow product usage instructions,
including manually turning the valve, will invalidate the product
warranty.

8
Opening Hydrant Valves
1. Insert the socket onto the HH500 3/4” square drive shaft.
2. Tighten the set screw to secure the socket.
3. Place the HH500 with the socket onto the hydrant with the reaction
handle facing away from the operator.
4. Adjust socket size by turning threaded fastener.
5. Zero out the digital rotation counter.
6. Move the directional switch to the left for counter clockwise
rotation or to the right for clockwise rotation.
7. Operate the HH500 to open the hydrant valve, slowing down as
it nears the fully open position. See the hydrant manufacturer’s
specifications to determine the approximate number of valve
rotations.

9
8. After the valve has been opened completely, note the rotation count
on the digital display.
9. Zero out the digital rotation counter.
Closing Hydrant Valves
1. Move the handle lock to the “unlocked” position and swing the reac-
tion handle to the opposite side of the HH500.
Handle
Lock
UNLOCKED
LOCKED
2. Now, move the handle lock to the “locked” position. This sets the
handle facing away from the operator.
3. Move the directional switch in the opposite direction used for
open-ing.
4. Operate the tool carefully to close the hydrant valve, slowing
down as it nears the fully closed position.
5. Stop the HH500 when the digital counter reaches the previously
noted counter value.
NOTE: Be aware the torque will increase if you go over the previ-
ously noted counter value because now the hydrant valve is
being over-tightened and could potentially break or bind the
valve.
6. Remove the HH500 from the hydrant valve.

10
Section 6: Other Attachments
Attachment Options
ROTATION FORCE AWAY FROM OPERATOR
ADD WRENCHES

11
Gate Valve Key (Wrenches W1-8)
The gate valve key can be purchased separately. It fits onto the
HH500 and opens gate valves.

12
Exercising Gate Valves - Part I
1. Place the gate valve key onto the operating nut.
2. Adjust the length of the key to ensure the top of the key is at a
com-fortable height for the operator.
3. Ensure the HH500 tool is fully seated on the gate valve key with
the reaction handle facing away from the operator.
4. Zero out the digital rotation counter.
5. Move the directional switch to the left for counter clockwise
rotation or to the right for clockwise rotation.
6. Operate the HH500 to begin exercising the gate valve, slow-ing
down as it nears the fully open or closed position. See “Section
8: Reference Tables” on page 16 to determine the approximate
number of valve rotations.
7. After the valve has been open or closed completely, note the
rotation count on the digital display.
8. Zero out the digital rotation counter.

13
Exercising Gate Valves - Part II
1. Move the handle lock to the “unlocked” position and swing the reac-
tion handle to the opposite side of the HH500.
Handle
Lock
UNLOCKED
LOCKED
2. Now, move the handle lock to the “locked” position. This sets
the handle facing away from the operator.
3. Move the directional switch in the opposite direction used in Part
I.
4. Operate the tool carefully to open or close the gate valve.
5. Stop the HH500 when the digital counter reaches the previously
noted counter value, slowing down as it nears the fully open/
closed position.
NOTE: Be aware the torque will increase if you go over the
previously noted counter value because now the gate valve is
being over-torqued and could potentially break or bind the
valve.
6. Remove the HH500 from the gate valve.

14
Section 7: Maintenance
Greasing the Output Drive & Output Drive Housing
For proper operation the HH500 should be greased in two locations
every 12 months.
Greasing the Output Drive
1. Using Hex Key, remove the threaded plug from output drive.
2. Insert the grease zerk into the output drive threaded hole.
3. Attach a grease pump containing ThrmaPlex Hi-load - Item #70414.

15
4. Pump 1 oz. of grease.
5. Disconnect the grease pump.
6. Rotate the output drive by slowly operating the HH500 motor.
7. Repeat steps 3-6 four more times.
8. Remove the grease zerk.
9. Insert the threaded plug back into the output drive threaded hole and
tighten with the hex key.
10. Wipe off the excess grease from the exterior of the gearbox.
Greasing the Output Drive Housing
1. Attach a grease pump to the zerk fitting already installed on the
output drive housing.
2. Pump 1 oz. of grease into the output drive.
3. Disconnect the grease pump.
4. Wipe off the excess grease from the exterior of the output drive hous-
ing.

16
Section 8: Reference Tables
Gate Valve Tables
NOTE: The following tables are for reference only. For more accurate
information, see the specific hydrant manufacturer to determine the
number of valve rotations.
Most Double Disk Valves Used in Water Systems
Valve Size Number of Turns
3” 7-1/2
4” 14-1/2
6” 20-1/2
8” 27
10” 33-1/2
12” 38-1/2
14” 46
16” 53
18” 59
20” 65

17
Most Metal-Seated Sewage Valves
Valve Size Number of Turns
3” 11
4” 14
6” 20
8” 27
10” 33
12” 38
14” 46
16” 53
18” 57
20” 65

18
Section 9: Troubleshooting
Problem Remedy
Motor is loose and
rotates freely
Tighten the lock handle nut slightly so when open
it can be moved, but when closed the handle is
tight.
Counter not counting Ensure the magnet is properly located on the
socket so the counter can catch each rotation.
Please call Hurco at 800-888-1436 at any time with questions. We
are available and eager to answer your questions about the proper
use of the HH500, as well as, solve any problems you may have
with the tool.

NOTES

For the latest in Hurco Technologies product news & insights,
visit our website at www.HurcoTech.com. For more
information, call Hurco at 800-888-1436 or email
[email protected].
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