HP6500

Parts Manual

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.............................................................................................................................. 7
MAIN FRAME AND AXLE ........................................................................................................................... 7
CONTROLS ................................................................................................................................................. 8
PLUS 1 CONTROL SCREEN SHOTS.............................................................................................................. 9
REMOTE CONTROL .............................................................................................................................. 13
LOADING INSTRUCTIONS ........................................................................................................................ 14
HYDRAULIC CONTROLS ........................................................................................................................... 15
Power Unit Features ........................................................................................................................... 15
FRONT HYDRAULIC CONTROLS ........................................................................................................... 16
FRONT CONTROL BANK....................................................................................................................... 17
REEL CARRYING RACKS (MANDREL RACKS) ........................................................................................ 18
POWERED IDLER WHEELS AND HYDRAULIC CONTROLS ..................................................................... 18
AUXILIARY POWER SHAFT ................................................................................................................... 18
POWER UNIT ....................................................................................................................................... 18
JACKSTANDS ........................................................................................................................................ 19
ADJUSTING ROLLERS FOR REEL DIAMETER ............................................................................................. 20
ROLLER HOUSING COMPONENTS ....................................................................................................... 20
STEER-GO OPERATION ........................................................................................................................ 21
MANUERVERING INSTRUCTIONS ............................................................................................................ 21
TO STEER AND MOVE .......................................................................................................................... 22
THE JOYSTICK ...................................................................................................................................... 22
ON BOARD AIR COMPRESSOR............................................................................................................. 23
BRAKE CONTROLLERS.......................................................................................................................... 23
TOOL CIRCUIT (OPTIONAL)...................................................................................................................... 24
LEVELWIND OPERATIONS ....................................................................................................................... 25
LEVELWIND COMPONENTS ................................................................................................................. 26

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PULLING PROCEDURES............................................................................................................................ 27
OVERHEAD WIRE ................................................................................................................................. 27
UNDERGROUND PULLING ................................................................................................................... 28
SERVICE ............................................................ 29
HP 6500 Lubrication ............................................................................................................................ 30
JACKSTAND INSTALLATION ................................................................................................................. 30
DRIVE ROLLER MAINTENANCE ............................................................................................................ 30
DRAWDAR INSPECTION ...................................................................................................................... 30
ACME ADJUSTING SCREW ................................................................................................................... 30
MANDREL RACK STABILIZER INSTALLATION ....................................................................................... 30

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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 DIESEL ENGINE SPECIFICATIONS

The Hogg & Davis, Inc HP 6500 Cable Reel Unit is 4TNV98-ZDSNA General
an advanced design cable pulling trailer that Specification
provides tremendous pulling forces in a compact 67.7 HP (50.5 kW) @ 2500 rated rpm*
vehicle. Its total design provides for easy
____________________________________________________________________________
__________________

Type• • • 4 Cylinder, 4-Cycle, Liquid Cooled

operations and affords great savings in set-up and
Diesel Engine
manpower. Full utilization of the HP 6500 will Bore • • • • • • • • • • • • • • • • • • • • • • 98 mm
greatly improve your cable installation and Stroke • • • • • • • • • • • • • • • • • • • • • 110 mm
Displacement • • • • • • • • • • • • • • • • • 3.319 L
removal operations.
Aspiration • • • • • • • • • • • • • Naturally
Aspirated
This manual is designed to make you familiar with Combustion System • • • • • • • • • • Direct
the machine and its operation. Injection
Rotation (from flywheel end) • • • • • •
Counterclockwise
Dry Weight • • • • • • • • • • • • • 518 lbs (234 kg)
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

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MAIN FRAME AND AXLE

TRAILER ORIENTATION The main frame and axle carry the entire weight of the
trailer and its payload. Constructed of heavy steel, the
The HP 6500 is made up of four (4) major
main frame will provide many years of durable service and
working components (see Fig.1) they are:
minimum maintenance. The fenders and tool
A. MAIN FRAME AND AXLE compartments are incorporated as part of the main frame
B. POWER UNIT structure.
C. POWER IDLER WHEEL AND CONTROLS
D. REEL CARRYING RACKS
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

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CONTROLS
The control panel has a variety of gauges and switches that control certain functions during the operation
of the HP 6500. Here is a description of these controls. (Figure 2)

A. Engine Control Center: This panel controls engine throttle, as well as displaying fuel level, RPM's,
coolant temperature, and oil pressure. Units equipped with a Remote Display Panel may have
more functions.
B. Hydrostatic Pressure Gauge: This gauge alerts the operator to the system pressure at all times
during operation. IT IS NOT A GUAGE TO ILLUSTRATE line pull.
C. Front / Rear Control: This switch isolates the front and rear controls of the unit during operation.
D. Ignition Switch
E. Switch Panel: This panel contains various switch 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, maker beacons, level wind, auxiliary air compressor, work lights, auxiliary
hydraulic tool circuit, etc.
F. 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

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PLUS 1 CONTROL SCREEN SHOTS

The following screenshots of the Plus 1 system installed on this unit will help you navigate and understand
the various screens that are displayed throughout the panel.

Main Menu

This screen displays the various panels that are displayed

throughout the Plus 1 system.

Using the [SELECT] buttons, move the arrow to the panel

you wish to display and press [OK]

Main Display (OPERATION)

This panel displays the following items

• Engine RPM, Fuel Level, Oil Pressure, Engine

Temp, Battery Voltage, Engine Load Percentage,
Parking Brake (PULLER not Trailer), HI / LOW
pulling speed, and a pulling percentage display
bar

The throttle is adjusted by using the UP and Down Arrow

buttons.

Hi / Low Speed is changed with the [SPEED] button. This

can be shifted "on the fly" during take up or pay-out
function

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Pressure Display

This panel displays the pressure for the Drive Holding

Brake, the PVG valve system (all functions other than
pulling or payout), and the overall Hydrostatic System
Pressure.

Faults Display

This panel displays information resulting from the

malfunction of the electronic sensors or functioning
components of the units system.

Engine Faults

This panel displays the current engine faults.

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Engine History (Engine Faults)

This panel displays the faults that may occur with

regard to the engine. Used for diagnostic
purposes, this panel will keep a history of faults.

Engine

This panel displays the current engine RPM,

percentage of load on the engine, and the
voltage into the engine ECU.

Background

This panel displays the screen contrast settings.

These settings can be configured by the operator
to adjust for various lighting conditions.

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Tool Flow

This panel displays the amount of flow through the

tool circuit. At 100%, the tool circuit is set at 10
GPM at 2000 psi.

Press the up and down arrow buttons to adjust

flow.

Level Wind Flow

This panel displays the Level Wind flow. By

adjusting the percentage from 0-100% you can
adjust the speed of the Level Wind.

Press the up and down arrow buttons to adjust

flow.

NOTE: The SAME valve operates both the Level Wind Circuit and the Tool Circuit flow. The
settings are different for both and the computer will only allow use for one at a time.

If operation of BOTH functions is needed at the same time, the unit must be equipped with a
second vale.

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REMOTE CONTROL
If this unit is equipped with a Remote Control unit that allows for the operation of the trailer using a
remote belly pack. This remote can be either tethered or wireless. (3 'D' Batteries)

DANGER - USING THE REMOTE ALLOWS AN OPERATOR TO PUT THEMSELVES IN HARMS WAY.
ALWAYS REMAIN FREE AND CLEAR OF THE TRAILER WHEN OPERATING WITH THE REMOTE. NEVER
OPERATE THE PULLING TAKE-UP FEATURE WHILE POSITIONED IN THE "BITE OF THE LINE"

It is designed to operate most of the functions as they are controlled on the trailer itself. All switches
are the same style in design, (i.e. spring return to neutral joystick and pay-out / take-up, momentary
and detent switches). The remote also features an EMERGENCY STOP, Engine start/stop, Operator
present / Override switch.

Operating with the remote disables all functions that are based on the trailer itself. This means
there is not a possibility of someone controlling the trailer from the front or rear controls at the
same time the remote is powered on.

To operate the HYDRA 985 with the Remote, you must do the following:

1. Turn the key switch located on the Main Control Panel to on.
2. Set the Remote Power switch to on. The "Power On" indicator light with illuminate.
3. Reset the EMERGENCY STOP switch.

All functions on the remote are now usable. Take a moment to familiarize yourself with the operation
of the HYDRA 985 while using the remote BEFORE you get on the job. Although all the functions are
the same, there is a slight difference in orientation of the operator with regards to where the trailer is.
Take special care when maneuvering the HYDRA 985 with the remote. As all controls on the trailer
operate something that moves in the same direction as the control (drawbar lever up = drawbar up),
orientation of the joystick for the Steer Go Idler Wheel can change as the operator moves about the
trailer.

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LOADING INSTRUCTIONS

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HYDRAULIC CONTROLS

Power Unit Features

• C - ACME ADJUSTING SCRW
• D - EXTENDED SHAFT GUARD COVER
• E - POWER UNTI DRIVE SHAFT 2 7/16"

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FRONT HYDRAULIC CONTROLS

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

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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

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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, and the Remote Pendant box (if equipped). 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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ADJUSTING ROLLERS FOR REEL

DIAMETER
1. Open housing to maximum position. Use
adjusting screw at top of housing.
2. Bring rollers to reel until center roller
barely touches reel
3. close housing down, using adjusting
screw, until all three roller barely touch
the reel flange
4. Use power unit control to bring all rollers
and power unit against reel

IF YOU FOLLOW THIS PROCEDURE, YOU SHOULD

HAVE EQUAL PRESSURE ON EACH ROLLER AND
PROVIDE MAXIMUM ROLLER LIFE.

ROLLER HOUSING COMPONENTS

A. Adjusting Mechanism
B. Driver Roller
C. Upper Housing
D. Lower Housing

IT IS IMPORTANT TO HAVE AN EQUAL VISIBLE

INDENTATION IN THE DRIVE ROLLER FRICTION
MATERIAL. FAILURE TO DO SO WILL RESULT IN
UNEVEN PRESSURE AND PREMATURE FAILURE OF
ONE OR ALL DRIVE ROLLERS.

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MANUERVERING INSTRUCTIONS
One of the main features of the HP 6500 is its ability to maneuver under its own power by use of the
Powered Idler Wheel and the Steer Go System.

The Power Steering Joystick is used to maneuver the unit into position

USE OF THE STICK WHICH CONTROLS THE IDLER 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 out 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 HP 6500 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.

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LEVELWIND COMPONENTS
The following are the main components in the LW Assembly

A. Hinge Pin
B. Lower Boom Assembly
C. Level wind cylinder
D. Turnbuckle
E. Hydraulic QD fittings
F. Carriage Assembly
G. Upper Boom Assembly
H. Lock pin for Boom Assemblies

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PULLING PROCEDURES
Although all jobs will vary, below is a basic description of how to operate the HP 6500. Please
consult your Employers rules and regulations and always consult and follow guidelines set for by the
IEEE.

OVERHEAD WIRE
The following is a basic description of how to set up and pull overhead wire.

1. Set up the dolly with the longest lead possible with the axis of the trailer in line with the
pull.
2. Lower the drawbar - set the jack stands - raise the drawbar to put pressure on the legs
3. Chock the wheels
4. Move the drive rollers against the flange of the reel until visible indentations are visible on
the drive roller friction material. Apply more pressure to reel flange if drive wheels slip.
5. Select the desired Hi-Lo speed setting
6. Increase engine RPM to 2000
7. Move control lever to take-up position and start pulling.
8. To stop the pull, return the control lever to neutral.

DANGER

NEVER allow the Power Unit to become disengaged from the reel during an overhead pull. This
will cause the reel to spin freely and may drop the rope or conductor. Doing so may cause the
pulling line and or wire to drop onto other energized conductors causing serious injury or death

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UNDERGROUND PULLING
1. Position the trailer over the manhole (vault opening, etc). The best position for maximum
pulling power is to position the reel DIRECTLY over the pull.
2. Lower trailer drawbar
3. Set Jack stands
4. Raise trailer drawbar to set pressure on the jack stands. It is not advised to remove the tires
from the ground when setting the jack stands. They are there to help stabilize the trailer
and spread the load over the entire frame, stub axles and front idler wheel.
5. Chock the tires
6. Set the brakes - Air ABS systems ONLY
7. Move the drive rollers against the flange of the reel until visible indentations are visible on
the drive roller friction material. Apply more pressure to reel flange if drive wheels slip.
8. Select the desired Hi-Lo speed setting
9. Set the engine RPM to IDLE. Increase engine RPM as needed.

NOTE: Most wreck out jobs can be broken loose with the RPM at idle. If slipping occurs during the
pull, gently increase the pressure of the Power Unit against the reel flange.

Level wind on the reel.

After the pull has begun, it may be necessary to keep the pulling rope or wire level on the reel. To
do so, stop the pull, lower the drawbar to release pressure on the jack stands, turn the Idler wheel
perpendicular to the axis of the trailer and slight change the rear angle of the unit. This slight
change with all for the rope to wind itself back towards the other flange. Set the pressure back to
the jack stands and continue take-up operation.

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SERVICE

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HP 6500 Lubrication HP6500
The following lubrication instructions are offered as "rule of thumb". Precise lubrication instructions
will vary with each usage of each unit. CHECK ALL LUBRICATIONS BEFORE EACH USE

ENGINE: Consult Engine Manual for precise instructions. Unit is delivered by Hogg & Davis, Inc. with
10W40 oil.

HYDRASTATIC DRIVE SYSTEM: This Drive System is practically maintenance- free, however the oil
should be changed every six months with ISO 46 wt. or its equivalent. There are three oil filters that
should be changed also at this time. (Refer to schematic) One of these filters is a high pressure filter
and has a restriction gauge on it, this gauge should be checked daily, if it reaches the red line, this
filter should be changed immediately.

WHEEL BEARINGS: Wheel bearings are of the oil bath style and should be inspected as part of the
Drivers Pre-Trip Inspection.

IDLER WHEEL: Lubricate every 30 days. Zerk fittings are provided for proper application of lube. Lube
all parts, including spindle housing, "A" frame supports, and hydraulic cylinder linkage.

LIFTING RACKS: Lubricate every 30 days.. Lube all parts, including rack and attached stabilizer bars.
NOTE: If racks do not lower properly, it may be necessary to lift rack entirely off cylinder, and with
solvent clean away caked grease and dirt build-up. Wipe thin coat of lube all around cylinder before
replacing rack. The holes on the racks are NOT designed for Zerk fittings. They allow air to escape
during the lowering process. It may be helpful to spray some light oil into the holes to aid with
raising and lowering.

DRIVER ROLLERS: Sealed bearings.

SPROCKET ASSEMBLIES: Lubricate once each week. Zerk fittings are provided for proper lube
application.

ROLLER CHAIN: Lubricate once each week. Use regular lube oil to oil all chain, including driver roller
chain, main drive chain (oil cup provided), and power idler wheel chain.

DRIVE SHAFT BEARINGS: Lubricate as required. It is recommended that the track be kept clean of
grease and dirt build up, and fresh lube be applied after each cleaning.

TOOL BOX DOORS: Lubricate as required. Hinges and locks should be lubricated with oil as needed
for easy operation.

NOTE: All lubrication should be performed consistently to Insure proper operation and extended life
of equipment.

CAUTION: OILS SHOULD NOT BE MIXED. IF BRAND OR TYPE IS

CHANGED, OLD OIL MUST BE DRAINED, ALL FILTERS CHANGED, AND
NEW OIL USED THROUGHOUT THE SYSTEM.

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JACKSTAND INSTALLATION
When installing any model Hogg and Davis
Jack stand, the following procedure should be
Used.
1. Determine If stand Is left or right. Hole in side of stand should line up with holding lug on trailer
when teeth of stand engage with spring loaded ratchet pawl.
2. Insert stand into sleeve.
3. Install pad with pad bolt. Screw bolt all the way in, leaving Just loose enough for pad to swivel.
4. Screw stud Into stand until it wedges against the pad bolt. Tighten stud HARD AGAINST pad bolt.
This LOCK bolt and eliminates loss of pad from bolt vibrating loose.

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DRIVE ROLLER MAINTENANCE

The "heart" of any friction drive cable pulling machine is the rollers that transfers the power to the
reel. This Is also usually the highest mortality Item on these units because they take the full brunt
of all the pulling torque. The current production drive roller consists of two (2) pieces; a core and a
ring.
The ring consists of a special composition neoprene rubber compound (or optional urethane)
molded to a steel ring. The core is made of steel, has bearing seats and a 24-tooth #60 sprocket
welded on one end. The core and the ring are machined for press fit tolerance. When repairing
roller due to "dead" or torn rubber, the core is pressed out of the old ring and new rings are
pressed on.
When replacing rollers, it is advised that they be replaced in horizontal pairs, i.e. both top rollers or
both bottom rollers. This is so equal thickness of rubber is applied to each flange of the reel. If
replaced in vertical pairs with new, thick rollers in one housing and old compressed rollers in the
other housing, the power unit will have the tendency to cock under pressure. This tendency forces
the rollers to be cut by the reel flange edges and can greatly reduce the expected life of the roller.

32
© COPYRIGHT 2013 HOGG & DAVIS, INC
 HP6500

ACME ADJUSTING SCREW

Ninety to ninety-five percent of all damage to the acme adjusting screws on the above machine Is in the
form of bending. Since it is nearly impossible to straighten them to work properly, it is necessary to
replace them.

This damage can be prevented by employing one or more of the following simple precautions.

1. Instruct all operators, that after they have adjusted the drive roller housing to its proper
position, by use of the screw, to back-off one-half turn. This relieves that binding pressure
between the acme nut and the drive roller housing, allowing the housing to "dolly" freely with
the shape of the reel flange.
2. Keep the acme screws and drive shaft well greased. This not only allows the drive roller housing
to move laterally and "dolly" properly, but will also protect the parts from corrosion and rust.
3. Wipe grease on housing where acme nut makes contact. This will also allow housing to "dolly"
easier without binding.
4. Be sure acme screw brackets are adjusted to maintain a level setting throughout the drive roller
housings

DRAWDAR INSPECTION
1. Regularly inspect the drawbar for wear and damage. If wear exceeds 1/8", replace the drawbar.
2. Check all drawbar mounting fasteners for proper torque.
3. Do not modify or add to the product.
4. Do not weld on this product without written permission from the factory.
5. Be sure the drawbar size is compatible with the coupling device on the tow vehicle.
6. Do not damage the coupling components. Be particularly careful during coupling and
uncoupling.
7. Inspect the coupling device on the tow vehicle for proper locking prior to use.
8. Consult OSHA and DOT regulations and AMERICAN TRUCKING ASSOCIATION GUIDELINES FOR
COMPLETE OPERATING PROCEDURES.

33
© COPYRIGHT 2013 HOGG & DAVIS, INC
 HP6500

MANDREL RACK STABILIZER INSTALLATION

The mandrel rack stabilizers are very critical to the proper operation of your trailer. One stabilizer Is
attached to each mandrel rack. This stabilizer keeps the racks rigid and takes all the strain put
against the racks when pressure Is applied by the power unit against the reel. Without the
stabilizers, the power unit could apply enough pressure to bend or break the lifting cylinders upon
which the mandrel racks ride. Therefore, it is Important that the stabilizers be properly installed
and maintained.

When It becomes necessary to replace a stabilizer due to damage or loss, the new stabilizer will be
sent with the stop nut loose on the male rod portion of the stabilizer (Fig. 1).

The stabilizer should be bolted in position between the mandrel rack and the anchor bracket on the
fender panel. The rack should then be raised to Its locked position and settled on the lock. The
stabilizer should now be at a right angle to the rack and parallel to the top of the fender panel. The
stop nut should be screwed on the male shaft until it sits against the female portion of the stabilizer.
(Fig.2).

Locktite® can be used to properly set the stop nut. Proper Installation will assure protection against
damage to lifting cylinders and stability for rack and reel mandrel.

34
© COPYRIGHT 2013 HOGG & DAVIS, INC
 JOHN DEERE NEW OFF-HIGHWAY ENGINE WARRANTY

Warranty Duration
Unless otherwise provided in writing, John Deere* makes the following warranty to the first retail purchaser and each
subsequent purchaser (if purchase is made prior to expiration of applicable warranty) of each John Deere new off-highway
engine marketed as part of a product manufactured by a company other than John Deere or its affiliates and on each John
Deere engine used in an off-highway repower application:
• 12 months, unlimited hours of use, or
• 24 months and prior to the accumulation of 2000 hours of use
Note: In the absence of a functional hour meter, hours of use will be determined on the basis of 12 hours of use per calendar
day.

Warranty Coverage
This warranty applies to the engine and to integral components and accessories sold by John Deere, and delivered to the first
retail purchaser on or after 1 May 2010.
All John Deere-warranted parts and components of John Deere engines which, as delivered to the purchaser, are defective in
materials and/or workmanship will be repaired or replaced, as John Deere elects, without charge for parts or engine repair
labor, including reasonable costs of labor to remove and reinstall non-engine parts or components of the equipment in which
the engine is installed, and, when required, reasonable costs of labor for engine removal and reinstallation, if such defect
appears within the warranty period as measured from the date of delivery to the first retail purchaser.

Emissions Warranty
Emissions warranties appear in the Operator’s Manual, that is furnished with the engine/machine.

Obtaining Warranty Service

Warranty service is to be performed by a local John Deere engine service outlet before the expiration of the warranty. An
authorized service outlet is a John Deere engine distributor, a John Deere engine service dealer, or a John Deere equipment
dealer selling and servicing equipment with an engine of the type covered by this warranty. Authorized service outlets will use
only new or remanufactured parts or components furnished or approved by John Deere.
Authorized service locations can be found by using the dealer locator on www.johndeere.com, or by calling 1-800-JDENGINE
(800-533-6446).
At the time of requesting warranty service, the purchaser must be prepared to present evidence of the engine’s delivery date.
John Deere reimburses authorized service outlets for limited travel expenses incurred in making warranty service repairs in
non-John Deere applications when travel is actually performed. Contact your local authorized service dealer for current travel
reimbursement limits. If distances and travel times are greater than reimbursed by John Deere, the service outlet will charge
the purchaser for the difference.

Purchaser's Responsibilities
The cost of normal maintenance and depreciation.
Periodic cleaning of the Diesel Exhaust Filter.
Consequences of negligence, misuse, or accident involving the engine, or improper application, installation, or storage of the
engine.
Consequences of service performed by someone other than a party authorized to perform warranty service, if such service, in
John Deere's judgment, has adversely affected the performance or reliability of the engine.
Consequences of any modification or alteration of the engine not approved by John Deere, including, but not limited to,
tampering with fuel and air delivery systems.
Consequences of fuels, lubricants or coolant that fails to meet the specifications and requirements listed in the Operator’s
Manual.

* ”John Deere” means John Deere Power Systems with respect to users in the United States, John Deere Limited with respect to users in Canada,
and Deere & Company or its subsidiary responsible for marketing John Deere equipment in other countries where the user is located.

DF2369E (29July13) (continued on reverse)

 The effects of cooling system neglect as manifested in cylinder liner or block cavitation (“pitting”, “erosion”, “electrolysis”).
Any premium for overtime labor requested by the purchaser.
Costs of transporting the engine or the equipment in which it is installed to and from the location at which the warranty service
is performed, if such costs are in excess of the maximum amount payable to the service location were the warranty service
performed at the engine's location.
Costs incurred in gaining access to the engine; i.e., overcoming physical barriers such as walls, fences, floors, decks or
similar structures impeding access to the engine, rental of cranes or similar, or construction of ramps or lifts or protective
structures for engine removal and reinstallation.
Incidental travel costs including meals, lodging, and similar.
Service outlet costs incurred in solving or attempting to solve non-warrantable problems.
Services performed by a party other than an authorized John Deere engine service dealer, unless required by law.
Charges by dealers for initial engine start-up and inspection, deemed unnecessary by John Deere when operation and
maintenance instructions supplied with the engine are followed.
Costs of interpretation or translation services.
Periodic cleaning of the Diesel Exhaust Filter.
John Deere will not be responsible for the cost of Exhaust Filter or Diesel Particulate Filter (DPF) cleaning unless:
• The need for cleaning resulted from the failure of a part that is covered by the engine’s Standard Product Warranty
or Extended Warranty, or
• The engine is located in California and the need for cleaning was caused by a failure covered under applicable
CARB emissions regulations.

No Representations or Implied Warranty

Where permitted by law, neither John Deere nor any company affiliated with it makes any guaranties, warranties, conditions,
representations or promises, express or implied, oral or written, as to the nonoccurrence of any defect or the quality or
performance of its engines other than those set forth herein, and DOES NOT MAKE ANY IMPLIED WARRANTY OR
CONDITIONS OF MERCHANTABILITY OR FITNESS otherwise provided for in the Uniform Commercial Code or required by
any Sale of Goods Act or any other statute. This exclusion includes fundamental terms. In no event will a John Deere engine
distributor or engine service dealer, John Deere equipment dealer, John Deere or any company affiliated with John Deere be
liable for incidental or consequential damages or injuries including, but not limited to, loss of profits, loss of crops, rental of
substitute equipment or other commercial loss, damage to the equipment in which the engine is installed or for damage
suffered by purchaser as a result of fundamental breaches of contract or breach of fundamental terms, unless such damages
or injuries are caused by the gross negligence or intentional acts of the foregoing parties.

Remedy Limitation
The remedies set forth in this warranty are the purchaser’s exclusive remedies in connection with the performance of, or any
breach of guaranty, condition, or warranty in respect of new John Deere engines. In the event the above warranty fails to
correct purchaser’s performance problems caused by defects in workmanship and/or materials, purchaser’s exclusive remedy
shall be limited to payment by John Deere of actual damages in an amount not to exceed the cost of the engine.

No Seller's Warranty
No person or entity, other than John Deere, who sells the engine or product in which the engine has been installed makes any
guaranty or warranty of its own on any engine warranted by John Deere unless it delivers to the purchaser a separate written
guaranty certificate specifically guaranteeing the engine, in which case John Deere shall have no obligation to the purchaser.
Neither original equipment manufacturers, engine or equipment distributors, engine or equipment dealers, nor any other
person or entity, has any authority to make any representation or promise on behalf of John Deere or to modify the terms or
limitations of this warranty in any way.

Additional Information
For additional information concerning the John Deere New Off-Highway Engine Warranty, see the Operator’s Manual

DF2369E (29July13)
 Common SPN.FMI Codes
SPN FMI TEXT TRANSLATION
28 3 % Accelerator Position #3 (Throttle 2) Voltage Above Normal or Shorted to High Source H
28 4 Percent Accelerator Position #3 (Throttle 2) Voltage Below Normal or Shorted to Low Source
29 3 Percent Accelerator Position #2 (Throttle 1) Voltage Above Normal or Shorted to High Source
29 4 Percent Accelerator Position #2 (Throttle 1) Voltage Below Normal or Shorted to Low Source
91 3 Accelerator Pedal Position (Multi-State Throttle) Voltage Above Normal, or Shorted to High Source
91 4 Accelerator Pedal Position (Multi-State Throttle) Voltage Below Normal or Shorted to Low Source
91 9 Accelerator Pedal Position A valid throttle message is not being received or is late
91 14 Accelerator Pedal Position Throttle signal voltage is or has been out of range
94 1 Fuel Delivery Pressure Pressure Very low
94 3 Fuel Delivery Pressure Fuel Rail Pressure Voltage out of range high
94 4 Fuel Delivery Pressure Fuel Rail Pressure Voltage out of range low
94 10 Fuel Delivery Pressure Pressure dropping too fast
94 13 Fuel Delivery Pressure Out of calibration
94 16 Fuel Delivery Pressure High fuel pressure
94 17 Fuel Delivery Pressure No rail fuel pressure
94 18 Fuel Delivery Pressure Low fuel pressure
97 0 Water In Fuel Indicator Water In Fuel Detected
97 3 Water In Fuel Indicator Water In Fuel Voltage out of range high
97 4 Water In Fuel Indicator Water In Fuel Voltage out of range low
97 16 Water In Fuel Indicator Water In Fuel Detected
97 31 Water In Fuel Indicator Water In Fuel Detected
100 1 Engine Oil Pressure Low oil pressure
100 3 Engine Oil Pressure Voltage Above Normal or Shorted to High Source
100 4 Engine Oil Pressure Voltage Below Normal or Shorted to Low Source
100 16 Engine Oil Pressure Oil pressure reading incorrect
100 18 Engine Oil Pressure Low oil pressure
105 0 Intake Manifold 1 Temperature High manifold air temperature
105 3 Intake Manifold 1 Temperature Voltage Above Normal or Shorted to High Source
105 4 Intake Manifold 1 Temperature Voltage Below Normal or Shorted to Low Source
105 16 Intake Manifold 1 Temperature High manifold air temperature
107 0 Air Filter Differential Pressure Plugged air filter condition detected
107 31 Air Filter Differential Pressure Plugged air filter condition detected
110 0 Engine Coolant Temperature High coolant temperature
110 3 Engine Coolant Temperature Voltage Above Normal or Shorted to High Source
110 4 Engine Coolant Temperature Voltage Below Normal or Shorted to Low Source
110 15 Engine Coolant Temperature High coolant temperature
110 16 Engine Coolant Temperature High coolant temperature
111 1 Coolant Level Low coolant level
158 2 Keyswitch Intermittent
158 17 Keyswitch Circuit problem
174 0 Fuel Temperature High fuel temperature
174 3 Fuel Temperature Voltage Above Normal or Shorted to High Source
174 4 Fuel Temperature Voltage Below Normal or Shorted to Low Source
174 15 Fuel Temperature High fuel temperature
174 16 Fuel Temperature High fuel temperature
174 31 Fuel Temperature Voltage out of range
189 31 Rated Engine Speed Speed Derate Condition Exists due to fault
190 0 Engine Speed Engine overspeed
190 2 Engine Speed Data Erratic, Intermittent or Incorrect
190 3 Engine Speed Voltage Above Normal or Shorted to High Source
190 4 Engine Speed Voltage Below Normal or Shorted to Low Source
190 5 Engine Speed Circuit is open
190 16 Engine Speed Engine overspeed

SPN - Suspect Parameter Number

FMI - Failure Mode Identifier Page 1 of 3
 Common SPN.FMI Codes
SPN FMI TEXT TRANSLATION
611 3 Injector Wiring Shorted to battery
611 4 Injector Wiring Shorted to ground
620 3 Sensor Supply Voltage 1 (+5V DC) Voltage Above Normal or Shorted to High Source
620 4 Sensor Supply Voltage 1 (+5V DC) Voltage Below Normal or Shorted to Low Source
627 1 Power Supply Low voltage to injectors
627 4 Power Supply Power interruption
629 13 Reprogram Controller ECU problem
629 19 ECU to Pump Communications Error ECU not receiving messages from Pump
632 2 Fuel Shutoff Valve Fuel Shutoff Error Detected
632 5 Fuel Shutoff Valve Fuel Shutoff Non-Functional
632 11 Fuel Shutoff Valve Fuel Shutoff Solenoid circuit is open or shorted
636 2 Engine Position Sensor Timing signal error
636 8 Engine Position Sensor Timing signal error
636 10 Engine Position Sensor Timing signal error
637 2 Timing (Crank) Sensor Timing signal error
637 7 Timing (Crank) Sensor Timing signal error
637 8 Timing (Crank) Sensor Timing signal error
637 10 Timing (Crank) Sensor Timing signal error
639 13 CAN Bus The CAN bus failure
651 5 Injector Cylinder #1 The current to the injector is less than expected
651 6 Injector Cylinder #1 The current to the injector increases too rapidly
651 7 Injector Cylinder #1 The injector fuel flow is lower than expected
652 5 Injector Cylinder #2 The current to the injector is less than expected
652 6 Injector Cylinder #2 The current to the injector increases too rapidly
652 7 Injector Cylinder #2 The injector fuel flow is lower than expected
653 5 Injector Cylinder #3 The current to the injector is less than expected
653 6 Injector Cylinder #3 The current to the injector increases too rapidly
653 7 Injector Cylinder #3 The injector fuel flow is lower than expected
654 5 Injector Cylinder #4 The current to the injector is less than expected
654 6 Injector Cylinder #4 The current to the injector increases too rapidly
654 7 Injector Cylinder #4 The injector fuel flow is lower than expected
655 5 Injector Cylinder #5 The current to the injector is less than expected
655 6 Injector Cylinder #5 The current to the injector increases too rapidly
655 7 Injector Cylinder #5 The injector fuel flow is lower than expected
656 5 Injector Cylinder #6 The current to the injector is less than expected
656 6 Injector Cylinder #6 The current to the injector increases too rapidly
656 7 Injector Cylinder #6 The injector fuel flow is lower than expected
729 3 Inlet Air Heater Driver #1 Inlet air heater stuck on
729 5 Inlet Air Heater Driver #1 Inlet air heater will not turn on
833 2 Rack Position Sensor Error
833 3 Rack Position Sensor Rack Position Voltage above normal
833 4 Rack Position Sensor Rack Position Voltage below normal
834 2 Rack Actuator Rack Error
834 3 Rack Actuator Rack Actuator Circuit voltage above normal
834 5 Rack Actuator Rack Actuator Circuit open
834 6 Rack Actuator Rack Actuator Circuit grounded
834 7 Rack Actuator Rack Position Error
970 2 Auxiliary Engine Shutdown Switch External Engine Shutdown Switch intermittent
970 11 External Engine Protection Shutdown External Engine Protection Shutdown active
970 31 Auxiliary Engine Shutdown Switch External Engine Protection Shutdown active
971 31 Engine Derate Switch External Derate input has been activated
1041 2 Start Signal Indicator Start Signal Missing
1041 3 Start Signal Indicator Start Signal Always Active

SPN - Suspect Parameter Number

FMI - Failure Mode Identifier Page 2 of 3
 Common SPN.FMI Codes
SPN FMI TEXT TRANSLATION
1076 0 Fuel Injection Pump Fuel Control Value Error
1076 1 Fuel Injection Pump Fuel Control Value Error
1076 2 Fuel Injection Pump Fuel Control Valve Error
1076 3 Fuel Injection Pump Fuel Control Valve Error
1076 5 Fuel Injection Pump Fuel Control Valve Error
1076 6 Fuel Injection Pump Fuel Control Valve Error
1076 7 Fuel Injection Pump Fuel Control Valve Error
1076 10 Fuel Injection Pump Fuel Control Valve Error
1076 13 Fuel Injection Pump Fuel Control Valve Error
1077 7 Fuel Injection Pump Controller
1077 11 Fuel Injection Pump Controller
1077 12 Fuel Injection Pump Controller
1077 19 Fuel Injection Pump Controller
1077 31 Fuel Injection Pump Controller Power derated
1078 7 Fuel Injection Pump Speed/Position Sensor Error
1078 11 Fuel Injection Pump Speed/Position Sensor Error
1078 31 Fuel Injection Pump Speed/Position Sensor VP44 Unable to Achieve Desired Timing
1079 3 Sensor Supply Voltage 1 (+5V DC) Voltage Above Normal or Shorted to High Source
1079 4 Sensor Supply Voltage 1 (+5V DC) Voltage Below Normal or Shorted to Low Source
1080 3 Sensor Supply Voltage 2 (+5V DC) Voltage Above Normal or Shorted to High Source
1080 4 Sensor Supply Voltage 2 (+5V DC) Voltage Below Normal or Shorted to Low Source
1109 31 Engine Protection System Approaching Shutdown Approaching Shutdown
1110 31 Engine Protection System Engine has been shutdown
1347 5 Fuel Pump Assembly #1 The circuit is open, shorted to ground, or overloaded
1347 7 Fuel Pump Assembly #1 Rail pressure control mismatch
1347 10 Fuel Pump Assembly #1 Low fuel flow
1348 5 Fuel Pump Assembly #2 The circuit is open, shorted to ground, or overloaded
1348 10 Fuel Pump Assembly #2 Low fuel flow
1485 2 ECU Main Relay Pump power relay fault
1569 31 Engine Protection Torque Derate Fuel derate limit condition exists
2000 6 Fuel Injection Pump Fuel Control Valve Error
2000 13 Security Violation The proper controller has not been installed

SPN - Suspect Parameter Number

FMI - Failure Mode Identifier Page 3 of 3
Appendix D
2G-ECO Governor Controller DTC Table Ver. 3.8.1 2007/5/18

DTC
J1939 Lamp Status

Remark
J1939 Format
Description
SPN SPN
FMI MIL RSL AWL PL
(Hex) （DEC）
4 Engine Fuel Rack Position Sensor : Shorted to low source X
X X
4BA 1210
3 Engine Fuel Rack Position Sensor : Shorted to high source (Engine (E-ECU
drive) start)
4 Accelerator Pedal Position Sensor "A" : Shorted to low source X
3 Accelerator Pedal Position Sensor "A" : Shorted to high source X
2 Accelerator Pedal Position Sensor "A" : Intermittent fault
Accelerator Pedal Position Sensor "A" : Below normal operational range
5B 91 1 X
（SAE J1843）
Accelerator Pedal Position Sensor "A" : Above normal operational range
0 X
（SAE J1843）
15 Accelerator Pedal Position Sensor "A" : Not available （SAE J1843） X
4 Accelerator Pedal Position Sensor "B" : Shorted to low source X
3 Accelerator Pedal Position Sensor "B" : Shorted to high source X
2 Accelerator Pedal Position Sensor "B" : Intermittent fault
Accelerator Pedal Position Sensor "B" : Below normal operational range
1 X
1D 29 （SAE J1843）
Accelerator Pedal Position Sensor "B" : Above normal operational range
0 X
（SAE J1843）
8 Accelerator Pedal Position Sensor "B" : Communication fault X
15 Accelerator Pedal Position Sensor "B" : Not available （SAE J1843） X
4 Barometric Pressure Sensor : Shorted to low source X
6C 108 3 Barometric Pressure Sensor : Shorted to high source X
2 Barometric Pressure Sensor : Intermittent fault
4 E-ECU Internal Temperature Sensor : Shorted to low source X
3 E-ECU Internal Temperature Sensor : Shorted to high source X
470 1136
2 E-ECU Internal Temperature Sensor : Intermittent fault
0 E-ECU Internal Temperature : Too High X
4 Engine Coolant Temperature Sensor : Shorted to low source X
3 Engine Coolant Temperature Sensor : Shorted to high source X
6E 110
2 Engine Coolant Temperature Sensor : Intermittent fault
0 Engine Coolant Temperature : Too High X
4 Sensor 5V : Shorted to low source X
437 1079 3 Sensor 5V : Shorted to high source (FUEL INJ PUMP SPEED SENSOR) X
2 Sensor 5V : Intermittent fault
1 System Voltage : Too Low X
9E 158
0 System Voltage : Too High X
436 1078 4 Engine Fuel Injection Pump Speed Sensor : Shorted to low source X X
(Both) (Ether)
* 7F8A2 522402 4 Auxiliary Speed Sensor : Shorted to low source
4 Engine Fuel Rack Actuator Relay : Circuit fault A X
3 Engine Fuel Rack Actuator Relay : Circuit fault B X
* 7F801 522241
7 (Reserved)
2 Engine Fuel Rack Actuator Relay : Intermittent fault
4 Air Heater Relay : Circuit fault A X
* 7F803 522243 3 Air Heater Relay : Circuit fault B X
2 Air Heater Relay : Intermittent fault
4 Cold Start Device : Circuit fault A X
* 7F802 522242 3 Cold Start Device : Circuit fault B X
2 Cold Start Device : Intermittent fault
4 EGR Stepping Motor "A" : Circuit fault A X
* 7F80B 522251
3 EGR Stepping Motor "A" : Circuit fault B X
4 EGR Stepping Motor "B" : Circuit fault A X
* 7F80C 522252
3 EGR Stepping Motor "B" : Circuit fault B X
4 EGR Stepping Motor "C" : Circuit fault A X
* 7F80D 522253
3 EGR Stepping Motor "C" : Circuit fault B X
4 EGR Stepping Motor "D" : Circuit fault A X
* 7F80E 522254
3 EGR Stepping Motor "D" : Circuit fault B X
4 Oil Pressure Switch : Shorted to low source X
64 100
1 Oil Pressure : Too Low X
4 Battery Charge Switch : Shorted to low source X
A7 167
1 Charge warning X
* 7F84A 522314 0 Engine Coolant Temperature : Abnormal temperature X
* 7F853 522323 0 Air Cleaner : Mechanical Malfunction X

* 7F859 522329 0 Oily Water Separator : Mechanical Malfunction X

BE 190 0 Engine speed : Over speed Condition X

4 Engine Fuel Rack Actuator : Shorted to low source X
3 Engine Fuel Rack Actuator : Shorted to high source X
27E 638
7 Engine Fuel Rack Actuator : Mechanical Malfunction X
2 Engine : Malfunction X
27F 639 12 High Speed CAN Communication : Communication fault X
2 E-ECU internal fault : EEPROM Check Sum Error (Data Set 2) X
276 630
12 E-ECU internal fault : EEPROM ReadWrite fault X
12 E-ECU internal fault : FlashROM Check Sum Error (Main Software) X
274 628 2 E-ECU internal fault : FlashROM Check Sum Error (Data Set 1) X
2 E-ECU internal fault : FlashROM Check Sum Error (Data Set 2) X
5CD 1485 4 E-ECU Main Relay : Shorted to low source X
12 E-ECU internal fault : Sub-CPU Error A X
* 7F9E7 522727 12 E-ECU internal fault : Sub-CPU Error B X
12 E-ECU internal fault : Sub-CPU Error C X
* 7F9E8 522728 12 E-ECU internal fault : Engine Map Data Version Error X
12 Immobilizer : CAN Communication fault X
* 7F9EA 522730
8 Immobilizer : Pulse Communication fault X
4B2 1202 2 Immobilizer : System fault X
Remark : Yanmar original DTC

YANMAR D-1
HP 6500
Parts Manual

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
www.hoggdavis.com

v 1.0
COPYRIGHT 2017 HOGG & DAVIS, INC
HP 6500

Table of Contents

Isometric View 1
Curbside View (Unit Dimensions) 2
Rear View 3
Powerunit 4
Engine/Pump Assembly 5
Staffa 6
Drive System Assembly 8
Drive Rollers 10
Steer-Go Assembly 11
Steer-GO Controls 13
Prince Valve Bank 14
Husco Valve Bank 15
Mandrel Rack Assembly 16
Air Brake Assembly 17
Air Compressor 19
Front Controls +1 20
Rear Controls +1 21
Controls 22
Front Controls Analog 23
Rear Controls 24
Hydraulic Capstan 25
Hydraulic Outriggers 26
Manual Jackstands 28
HPLW Post Levelwind 29
HPLW2 Screw Levelwind 31
Fuel/Hydraulic Tanks 33
Brake Manifold 35
Electrical Hood 36
Optional Hy-Vis Screen 37
Hoods & Doors 38
Quick Connectors 39
Outrigger Fender Lights 40
LED Trailer Lights 41
Standard Fender Lights 42
Trailer Wiring (Electric Brakes) 43
Trailer Wiring (Air Brakes) 44
Wheel Torque Requirements 45
Lubrication Instructions 47
Decals/ Decal Locations 49
Wiring Schematics 54

COPYRIGHT 2017 HOGG & DAVIS, INC

 1

2 3 4 5
6
7 8

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 Rear controls See Rear Controls Sheet 1
2 D05150 Toolbox Door 2
3 Power Unit See Power Unit Sheet 1
4 Valve Bank See Prince Valve Bank Sheet 1
5 HPPS2 See Steer-Go Controls Sheet 1
Page 1 6 HPPS1 See Steer-Go Assembly Sheet 1
7 HPEC7 See Electrical Hood Sheet 1
HP6500 8 E04017 Eye, Pintle 1
9 HPBA See Air Brake Assembly Sheet 1
 85.66
1
7'-1 2 "

193.92
16'-2"

Page 2

HP6500
 1

98.34
1
8'-2 2 "

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 Mandrel Racks See Mandrel Rack Sheet 1
2 Trailer Lighting See Lighting Sheets 1
Page 3
3 Quick connectors See Quick Connector Sheet 1
4 Manual jackstands See Jackstand Sheet 1
HP6500 5 f10010 Mud Flap 2
 If items look different than the parts breakdown please call for assistance. (541)354-1001

8
9

4
5
7

10

11
12

6
10
1
13

ITEM PART NUMBER DESCRIPTION QTY.

1 C41039 HP 6500 PU CHASSIS 1
2 Engine see Engine Page 1
3 Tanks see Tank Page 1
4 Staffa see Staffa Page 1
5 Drive Assembly see Drive Page 1
6 Front controls E see Controls page 1
7 Hood and doors see Sheetmetal page 1
W06005 8 HPBAC see HPBAC page 1
Wrench, Drive Roll Adjust 9 HPHVG see HPHVG page 1
Page 4 10 T19020-6500 6500 UHMW 2
11 S28048 Spring, Power Unit 1
Power Unit 12 F06005 Flange, PowerUnit Spring 1
13 Slide Assembly see Slide Page 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001

5 8
6
1 7

2 4

19 20

12
10 11
9 13

14
18
17
W06005-001 15
16
Wrench, Drive
Roll Adjusting

HP6500 Power Unit T4f

If items look different than the parts breakdown please call for assistance. (541)354-1001

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 Drive Assembly T4f See Drive Sheet 1
2 C29301 Cover, Air Compressor 6500T4f 1
3 HPBAC T4f Extreme Air Compressor 1
4 Staffa See Staffa Sheet 1
5 S08001 Screen, HP6500 Power Unit 1
6 C35010 Cooler, Oil 1
7 C29201 Cover, Radiator 1
8 Engine T4f See Engine Sheet 1
9 Tanks See Tank Sheet 1
10 Front Controls T4 See Controls Sheet 1
11 Slide Assembly See Slide Sheet 1
12 C32050 Cylinder, PowerUnit 1
13 L01020 Latch, Over center 1
14 C29083 Cover, Driveshaft Capstan 1
15 C29053 Cover, Control Panel Side 1
16 L08025 Lock, T-Handle 2
17 D05170 Door, Engine Cover Curbside 1
18 D05171 Door, Engine Cover Streetside 1
19 C29170 Cover, Exhaust 1
20 H05008 Hood, Power Unit 1

HP6500 Power Unit T4f

If items look different than the parts breakdown please call for assistance. (541)354-1001

16
15
17
1
13 9
14

11

18

6 23

4
21
3

2
19
25

12

10

24

20

22

ITEM PART NUMBER DESCRIPTION QTY.

1 E02021 4TNV98-ZDSNA 1
2 C28002 Coupler, Pump Adaptor 1
3 P09001 Pump mount plate 1
4 P20005 75cc Series 90 Pump 1
5 O01111 O-ring Small Gear Pump 1
6 P20103 Pump, 10gpm 1
7 M09005 Mount, Engine Front 2
8 M09004 Mount, Engine Right Rear 1
9 M09006 Mount, Engine Left Rear 1
10 I04000 Isolator, Engine 4
11 M09035 Mount, ECU 1
12 M09018 Mount, Fuel Pump 1
13 B15115 Bracket, Air Cleaner 1
14 E02021-2 Air Cleaner Assembly 1
15 E02021-4 Inner Air Filter 1
16 E02021-5 Outter Air Filter 1
17 E02021-1 Exhaust 1
18 P07402 6500 4TNV Exhaust 1
Page 5 19 E02021-3 Radiator 1
20 R16020 Radiator Shroud 1
21 C35010 Cooler, Oil 1
22 E02021-8 Lower Radiator Hose 1
23 E02021-9 Upper Radiator Hose 1
Engine/Pumps 24 E02021-6 Oil Filter 1
25 E02021-7 Fuel Filter 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001

11

10
9 1 8 2
3
4 5
6

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 E02037 Yanmar 4TNV98C-NYEM 1
2 C28002 Coupler, Pump Adaptor 1
3 P09001 Pump mount plate 1
4 P20005 75cc Series 90 Pump 1
5 O01111 O-ring Small Gear Pump 1
6 P20103 Pump, 10gpm 1
7 M09004 Mount, Engine Right Rear 1
8 M09006 Mount, Engine Left Rear 1
9 M09005 Mount, Engine Front 2
10 I04000 Isolator, Engine 4
Engine Assembly T4f
11 S16021 Shroud, Fan 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001

NOTE: Brake Pads (P01013) purchased as a set of 2

2 sets per unit
(Mounting Screws Included)
D02020: min. thickness - 1.125"

21
19
20
5
6
8
7 2
11

13 3 1
11 14 15
9
10 13 23 24

22

4
12 25 26
16 26

17
Page 6

Staffa Motor Assembly

 If items look different than the parts breakdown please call for assistance. (541)354-1001

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 F09001 Frame, Staffa mount 1
2 M08001 Motor, Drive Staffa 1
3 B11490 Bolt, Hx Head 3/4"-16 x 3" Z8 5
4 N04586 Nut, Hx Nylock® 3/4"-16 10
5 S43003 Shaft, Drive 6500 1
6 D02020 Disc, Vented Brake 1
7 B11363 Bolt, Hx Head 1/2"-13 x 1-1/4" 4
8 W01565 Washer, Split Lock 1/2"zinc 4
9 S29006 Sprocket D100B14 1
10 K01010 Key, 1/2 x 1/2 x 2-1/2 2
11 S04261 Screw, Set 1/2"-13 x 1/2" CP 3
12 B07275 Bearing, 2-7/16 Pillow Block 1
13 B11007 Bolt, Hx Head 3/4"-16 x 6" Z8 5
14 W01285 Washer, Flat SAE 3/4"zinc 2
15 C04024 Caliper, Fail Safe 2
16 P01013 Pad, Brake 4
17 F05183 Fitting, -4 JIC to 1/8 NPT 4
18 B18000 Bleader, 1/8 NPT 4
19 M04050 Manifold, Distribution 1
20 F05377 Bleader, 1/8 NPT 1
21 F05042 Fitting, 4-4 Str SAE 5
22 T14090-6500 Tube, Brake 6500 Fail-Safe 4
23 F05113 Fitting, Sleeve -4 8
24 F05300 Fitting, -4 nut 8
25 S45005 Valve, Shuttle 1
26 F05754 Fitting, 4-6 Str SAE 3
Page 7

Staffa Motor Assembly

 If items look different than the parts breakdown please call for assistance. (541)354-1001

11 10

16 3
12
5
8
14 7
6
4
13
15 9 40 40

28 25
3
8
26
39 33
41

17 2
19
21 42
25 37 20
31
18
24
18 25
42 1

20 25

34
37
30
29
35
Page 8 32 Chain Slack Range:
37 Drive Chain: 1/4"-3/4"
6500 Drive System Parts 38
Drive Roller Chain: 1/4"-1/2"
If items look different than the parts breakdown please call for assistance. (541)354-1001

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 P06103 Pin, Capstan drive HYDRA 1
2 S04476 Screw, Set 1/2"-13 x 1-1/2" 1
3 B07198 Bearing, SC Pilot Flange 2-7/16" 2
4 S24106 Spacer, 1-3/4" 1
5 S24105 Spacer, 3/4" 1
6 S29004 Sprocket D100B16 1
7 K01010 Key, 1/2 x 1/2 x 2-1/2 2
8 S04032 Screw, Set 1/2"-13 x 1/2" 3
9 B03063 Bar, Short Drive Roller Adjusting 2
10 F05785 Fitting, Zerk 1/4-28 90° 4
11 R18133 Ring, Snap 8
12 R19010 Rod, Adjusting Drive Rollers 2
13 N04586 Nut, Hx Nylock® 3/4"-16 2
14 P06187 Pin, Roll 1/8" x 1-1/4" 2
15 W01285 Washer, Flat SAE 3/4"zinc 2
16 B06045 Bar, Long Drive Roller Adjusting 2
17 H08038 Housing, Drive Roller Upper 2
18 B15968 Bracket, Drive Roller Adjusting 8
19 B11381 Bolt, Hx Head 5/8"-11 x 2-1/2" 4
20 N04474 Nut, Hx Jam 5/8"-11 8
21 Drive roller Drive Roller Assembly 2
22 Drive roller Drive Roller Assembly 2
23 A07055 Axle, Drive Roller Assembly 2
24 A07055 Axle, Drive Roller Assembly 2
25 B07030 Bearing, SCM Pilot Flange 2-7/16 4
26 Center drive roller Center Drive Roller Assembly 1
27 Center drive roller Center Drive Roller Assembly 1
28 K01020 Key, 1/2 x 1/2 x 7-3/4 2
29 H08048 Housing, Drive Roller Lower 2
30 B11376 Bolt, Hx Head 5/8"-11 x 2" 4
31 W01294 Washer, Flat SAE 1"zinc 4
32 S04153 Screw, Acme Long 2
33 B15980 Bracket, Acme Screw Adjust 1
34 B15043 Bracket, Acme Screw Adjust Long 1
35 N04098 Nut, Acme Screw 4
36 B11150 Bolt, Carriage 1/2"-13 x 1-1/2" 2
37 B11153 Bolt, Carriage 1/2"-13 x 1-3/4" 6
38 N04555 Nut, Hx Nylock® 1/2"-13 24
39 B11120 Bolt, FHSHCS 1/2"-13 x 2-1/4" 16
40 B07198 Bearing, SC Pilot Flange 2-7/16" 2
41 S43128 Shaft, 2-7/16 Keyed Chrome 1
42 R18034 Plate 1/2 A36 4

6500 Drive System BOM Page 9

 If items look different than the parts breakdown please call for assistance. (541)354-1001
2 3

4 5 4

ITEM PART NUMBER DESCRIPTION QTY.

1 C27005 Core, Drive Roller Standard 1
2 R18024 Roller, Drive Urethane 1
3 R18025 Roller, Drive Rubber 1
4 B07135 Bearing, 1" I.D. 2
5 S24010 Spacer, Drive Roller 1 Drive Rollers

2 3
1

ITEM PART NUMBER DESCRIPTION QTY.

Page 10
1 R20050 Roller, Center Drive 1
2 R18024 Roller, Drive Urethane 1
3 R18025 Roller, Drive Rubber 1 Center Drive Rollers
 If items look different than the parts breakdown please call for assistance. (541)354-1001

6
11 8
10
9 18

13 17
14
19 21

12
6
20 1

22
13
15

4
39
38 34 23

37 33 2
32
35 6
24
31 3
25

6
36 29
32
33
28 26

27
30
31

Page 11

Steer-Go Assembly
If items look different than the parts breakdown please call for assistance. (541)354-1001

ITEM PART NUMBER DESCRIPTION QTY.

1 F09020 Frame, Lower A-arm 1
2 S24070 Spacer, Torsion Spring 2
3 S43099 Shaft, Lower A-arm Pivot 1
4 S28101 Spring, 985 torsion, LH 1
5 S28102 Spring, 985 Torsion, RH 1
6 W01294 Washer, Flat SAE 1"zinc 7
7 F09005 Frame, Upper A-arm 1
8 B07365 Bearing, I-Glide 3/4x1x5/8 2
9 B11460 Bolt, Hx Head 3/4"-16 x 2-1/4" Z8 2
10 W01285 Washer, Flat SAE 3/4"zinc 2
11 N04587 Nut, Hx Jam Nylock® 3/4"-16 4
12 A08015 Plate 3/4" A36 1
13 P06070 Pin, 1x2-1/2 2
14 M09010 Mount, Actuator plate 1
15 B11449 Bolt, Hx Head 3/4"-16 x 5" Z8 2
16 F05630 Zerk, Grease 1/4"-28 2
17 C32030 Cylinder, Drawbar 1
18 P06073 Pin, 1x2-3/4 1
19 A01050 Actuator, Rotary 1
20 B11482 Bolt, Hx Head 1"-8 x 4" Z8 4
21 N11482 Nut, Hx Toplock 1"-8 Z8 4
22 S24009 Spacer, Actuator 1
23 F08912A Fork, Hydra Idler Wheel 1
24 B11605-S Bolt, Hx Head 1/2"-13 x 3" special 1
25 B11370 Bolt, Hx Head 5/8"-11 x 1-1/2" 1
26 W03907A Wheel and Tire assy 18x7 1
27 S29905 Sprocket and Hub 1
28 N04040 Nut, Lug 1/2"-20 Z 1
29 A07015 Axle, Drive Wheel 1
30 S24053 Spacer, Hub and Sprocket 1
31 B07135 Bearing, 1" I.D. 2
32 W01090 Washer, Internal Lock 1" 2
33 N04095 Nut, Hx Jam 1"-14 2
34 M08050 Motor, Hydraulic Drive 1
35 S29005 Sprocket, Drive 1
36 C10060-26 Chain, #60 39"L 1
37 B11343 Bolt, Hx Head 3/8"-16 x 1-1/4" 1
38 W01545 Washer, Split Lock 3/8"zinc 1
39 W01002 Washer, Flat SAE 3/8"zinc 1

Page 12

Steer-Go Assembly
 If items look different than the parts breakdown please call for assistance. (541)354-1001

2
1
7
4

5
3 8
6

10 3 6 11 12 13 14

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 B15093 Bracket, Steer-Go Box 1
2 B13930 Box Steer-Go 1
3 F05324 Fitting, 6-6 90° STC 2
4 F05326 Fitting, 8-8 90° STC 1
5 F05322 Fitting, 8-8 STR STC 1
6 F05754 Fitting, 4-6 Str SAE 2
7 L03055 Lever, Steer-Go Joystick 1
8 K02500 Kit, Linkage 2
9 V02401 Valve, Priority Flow 1
Page 13 10 V02185 Vavle, Check 2
11 M04015 Manifold Steer-Go 1
HP 6500 12 V02186 Valve, Relief 1
STEER-GO CONTROLS 13 V02021 Valve, Directional 2
14 C29120 Cover, Steer-Go 1
 If items look different from the parts breakdown please call for assistance. (541)354-1001

5 7
5
4 8
9
3 10

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 C29121 Cover, Electic Steergo 1
2 C34039 Manifold HYPS-E 1
3 C34101 Controler, 24 Pin 1
4 B13935 Box, Steergo Electric 1
5 F05438 Fitting, Air 90° 6-4 2
6 V02008 Valve, Cab control 1
7 F05413 Fitting Brass Str 68NTA-6-4 3
8 C34037 JS1000 Joystick Steer-Go 1
9 B15093 Bracket, Steer-Go Box 1
HPPS-E Electric Steer-Go
10 V02018 Valve, Trolley Air 1
 If items look different from the parts breakdown please call for assistance. (541)354-1001

9
7 8
6
6

10
11

3
2

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 C34039 Manifold Steer-Go Electronic 1
2 B13935 Box, Steergo Electric 1
3 R13006 Remote, Control Box 1
4 B15093 Bracket, Steer-Go Box 1
5 F05413 Fitting Brass Str 68NTA-6-4 3
6 F05438 Fitting, Air 90° 6-4 2
7 V02008 Valve, Cab control 1
8 C34037 JS1000 Joystick Steer-Go 1
9 V02018 Valve, Trolley Air 1
HPPS-ER
Electric Steer-Go w/ Remote 10 C34101 Controler, 24 Pin 1
11 R13005 Remote, Reciever Kit 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001

6
1

B15947A
Bracket, Straight Prince Lever

3
5
4

S22067
B15948A
S22068 Bracket, 90° Prince Lever

Parts available for replacement:

S22067 - Coil only for V02103
S22068 - Cartridge only for V02103
K02073 - Seal kit for S22068
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 V02100 Valve Inlet w/relief Prince 1
2 V02101 Valve 4 Way Manual Prince 2
3 V02102 Valve 3 Way Manual Prince 2
Page 14
4 V02103 Valve 4 Way Solenoid Prince 2
Prince Valve Bank 5 V02104 Valve Sec Outlet w/PB Prince 1
6 K02319 Kit, Rod 6-Bank Prince 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001

6
5 5 5

4
3
2 2 3

BOM Table
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 V02138 Inlet w/o Relief 1
2 V02130 Double Acting 2
3 V02135 Single Acting 2
4 V02065 Outlet w/PB 1
5 B15910A Handle, Straight 3
6 B15912A 90° lever assembly 1
Page 15
V02120 7 F05150 Fitting, Street Elbow 4-4 1
Valve Bank 4-Section 8 G02055 3K bottom mount 1
9 V02150 relief valve 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001

14 15 16 17

9 11
18
10 12 19

13 11
7 3
8
20 ITEM NO. PART NUMBER DESCRIPTION QTY.
9
1 C32040 Mandrel Cylinder LH D3188 1
2 C32025 Mandrel Cylinder RH D3189 1
6
3 R01925 Rack, Mandrel LH 1
4 R01945 Rack, Mandrel RH 1
5 21 8 4 5 L08015A Lock Assy, Mandrel Rack LH 1
6 H02045A Handle, Mandrel Lock LH 1
22
1 7 S30021 Stabilizer, Outside 2
8 B15130 Bracket, Mandrel Lock Handle 2
9 B07365 Bearing, I-Glide 3/4x1x5/8 8
10 S30005 Stabilizer, Inner 2
2
11 S28030 Spring, Mandrel Return 2
12 P06035 Pin, Mandrel Locking 2
13 B22045 Block, Mandrel Bearing 2
14 S43115 Shaft, 2-1/2" Mandrel 1
15 C25020 4" Aluminum Cone 2
16 C20015 Collar, 2-1/2" w/ studs 2
17 B07075 Bearing, Nylatron Mandrel 2
18 P04020 Pawl, Mandrel Locking Pin 2
19 P06095 Pin, 1/2 x 2 2
Page 16
20 G07010 Handle, Rubber Flapper lock 2

Mandrel Rack Assembly 21 H02050A Handle, Mandrel Lock RH 1

22 L08020A Lock Assy, Mandrel Rack RH 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001

21
23
26
LOCATED ON TONGUE OF TRAILER
4
29
28
25
1
14

3
8 5

7
30
6
9 17

22

24

11 15 27
12
16
16 29
35
13 36
37
10 31
32
2 33
28 34
18
30 19
20

Page 17

AIR BRAKE ASSEMBLY

If items look different than the parts breakdown please call for assistance. (541)354-1001

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 S26945 Spindle, Air LH 1
2 S26953 Spindle Air RH 1
3 T01041 Tank, Air large 1
4 C32095 Can, Air 30/30 w/Long Rod 1
5 C32095 Can, Air 30/30 w/Long Rod 1
6 B12210 Bracket, Gladhand 1
7 V02008 Valve, Cab control 1
8 V02018 Valve, hand control 1
9 V02038 Valve, check 2-way 1
10 B15096 Bracket, S-Cam Bushing RH 1
11 B15097 Bracket, S-Cam Bushing LH 1
12 B15902 Bushing,S-Cam RH 1
13 B15903 Bushing S-Cam LH 1
14 C44015 Cam, Air brake LH 1
15 C44020 Cam, Air brake RH 1
16 A11030 Adjuster, Auto Slack 10 spline 2
17 Y01043 Yoke Midland Straight 2
18 G01010 Gasket, Hub acp 16-1/2x5 2
19 C06071 Cap, Hub 16-1/2 x 5 2
20 D08000 Drum Only, Air Brake 16-1/2x5 2
21 H09974 Hub Only, Air Brake LH 1
22 H09975 Hub Only, Air Brake RH 1
23 S37083 Stud, Air Brake 1-1/8-16 LH 10
24 S37082 Stud, Air Brake 1-1/8-16 RH 10
25 W01290 Washer, Thick Drum Assembly 20
26 N04058 Nut, Lug 1-1/8-16 LH 10
27 N04059 Nut, Lug 1-1/8-16 RH 10
28 P04002-1 Pin, Air Brake Large 4
29 P04002-2 Pin, Air Brake Small 4
30 S15030 Shoe, Air Brake 16-1/2x5 4
31 N04201 Nut, Hub Inner 2
32 W01202 Washer, Locking Air Brake 2
33 W01201 Washer, Lock Spindle Tab 2
34 N04202 Nut, Hub Outer 2
35 S05130 Seal, Grease Hub 2
36 B07140 Bearing, Inner 2
37 B07085 Bearing, Outter 2

Page 18

AIR BRAKE ASSEMBLY

 If items look different than the parts breakdown please call for assistance. (541)354-1001

3 2

ITEM PART NUMBER DESCRIPTION QTY.

1 C21020 Compressor, Air 1
2 B36003 50amp Circuit Breaker 1
3 S22050 Cole Hersee HD Solenoid 1
4 F05150 Fitting, Street Elbow 4-4 1
5 V02220 Valve, check one way 1
6 F05728 Fitting, Street Tee 4-4-4 1
Page 19 7 S40120 Extreme Air pressure switch 1
8 F05438 Fitting, Air 90° 6-4 1
HP6500 Air Compressor
9 C29300 Cover, Air Compressor 1
If items look different than the parts breakdown please call for assistance. (541)354-1001

6 1
4
3

5
2

9 8
Located Inside
Control Panel

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 C21023 Compressor, Air 1
2 V02220 Valve, check one way 1
3 F05059 Fitting, Pipe Cross 4-4-S 1
4 F05150 Fitting, Street Elbow 4-4 1
5 S40120 Extreme Air pressure switch 1
6 V02012 Valve, pop-off 140psi 1
7 F05438 Fitting, Air 90° 6-4 1
8 B36003 50amp Circuit Breaker 1
Air Compressor Tier IV
9 S22050 Cole Hersee HD Solenoid 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001

3
2

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 C34035 Controller, Joystick JS1000 Front 1
2 S40070 Switch, Key Cole Hersee 1
Page 20 3 S40035 Switch, SP/ST Toggle 5
4 D09021 Display, DP250 +1 1
Front Controls +1 5 P03022 Panel, Control +1 1
6 S40100 Switch, SP/DT Momentary 1
7 Plus 1 Decal Decal +1 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001

4 1

ITEM PART NUMBER DESCRIPTION QTY.

NO.
1 B13962 Box, Rear Control 6500 +1 1
2 C34036 Controller, Joystick JS1000 1
Page 21
3 S40190 Switch, Multiplex +1 1
Rear Controls+1 4 S40100 Switch, SP/DT Momentary 2
5 P03019 Panel, Rear Control 6500 +1 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001

14
3
13

12
4
11
10
9

5 ITEM NO. PART NUMBER DESCRIPTION QTY.

7
1 D09030 Display, Controls Inc. 1
2 G02075 5000 PSI GAUGE back mount 1
3 S40035 Switch, SP/ST Toggle 5
8 4 P03021 Panel, HP6500 Electronic Engine 1
5 B36003 50amp Circuit Breaker 1
6 B22075 10 Pole Terminal Strip 1
6
7 S40016 Bosch Relay 1
8 H10060 Tray, battery 1
9 B06012 Battery MTP-24 1
10 R19025 Battery hold down 1
Page 22 11 C34030 Controller, Joystick MCH 1
12 S40100 Switch, SP/DT Momentary 1
13 S40070 Switch, Key Cole Hersee 1
Controls
14 S40008 Switch, SP/DT Maintained 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001
ITEM PART NUMBER DESCRIPTION QTY.
1 S41100 Switch Ignition JDD 1
2 C34030 Controller, Joystick MCH 1
3 S41001 JD Pre-Heat Timer 1
4 S40035 Switch, SP/ST Toggle 5
4 7 4 4 4 5 S40150 Switch, DP/DT Momentary 1
6 L04025 Light, Pilot 1
7 S40100 Switch, SP/DT Momentary 1
8 G02033 Gauge, Livorsi 4 in 1 1
6 9 P03020 Control Panel (Analog) 1
10 G02022 Livorsi Tachometer 1
5 11 G02003 Gauge, 4 Gauge Cluster 1
12 G02002 Gauge, Tachometer VDO 1
4

11
8

10
12

Page 23

Front Controls Analog

If items look different than the parts breakdown please call for assistance. (541)354-1001

9
4 5 4

5
2

3
8

7
6

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 P03023 Panel, Control 1
2 D09022 Display, Yanmar T4 Final 1
3 S40070 Switch, Key Cole Hersee 1
4 S40035 Switch, SP/ST Toggle 6
5 S40100 Switch, SP/DT Momentary 2
6 C34030 Controller, Joystick MCH 1
7 D30150 Decal, Control Panel T4f 1
8 G02005 Gauge, Fuel Level 1
Control Panel T4f
9 G02075 5000 PSI GAUGE back mount 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001

3
If the unit has both level wind and tool circuit,
5 the rear control will have the level wind switch
the tool circuit will be controlled by the front control
Optional Level Wind ITEM PART
NO. NUMBER DESCRIPTION QTY.
Optional Tool Circuit
3 1 B13960 Rear Control Panel 1
Page 24 2 C34030 Controller, Joystick MCH 1
3 S40035 Switch, SP/ST Toggle 2
4 S40150 Switch, DP/DT Momentary 1
Rear Controls
5 S40100 Switch, SP/DT Momentary 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001

9
6

4 2

3
8
1

ITEM PART NUMBER DESCRIPTION QTY.

1 B15998 Bracket, Capstan Mount 1
2 M08050 Motor, Hydraulic Drive 1
3 S40153 Switch, SP/DT Maintained w/center 1
4 G09021 Guard, Toggle Switch 1
5 C38905A Cathead, Capstan 1
6 P09170 Plate, Sub 1
Page 25
7 V02145 Valve Capstan/Levelwind 1
8 F05170 Fitting, -6 JIC bulkhead 2
Hydraulic Capstan
9 F05762 Fitting, 6-10 Str SAE 2
 If items look different than the parts breakdown please call for assistance. (541)354-1001

9
5

3
11 10 5 9

4
3 1
17
4 18

12 10 16

3
16 2

14 3 20

19

19 7 6
13
6
20

6
7 6

8 7
15

8
Page 26

Hydraulic Outriggers #11 + #12 are for Units with a Levelwind, Otherwise use (2) #10's
 If items look different than the parts breakdown please call for assistance. (541)354-1001

ITEM PART NUMBER DESCRIPTION QTY.

1 J04005 Jack, Hydraulic Outriggers 2
2 C32015 Cylinder Outrigger 2
3 F05565 Fitting, 6-4 Elbow 4
4 P06200 Pin, Outrigger Cylinder Upper 2
5 C20040 Spacer, Outrigger Cylinder 4
6 P06165 Pin, Lower Outrigger 4
7 S04261 Screw, Set 1/2-13x1/2 CP 4
8 P01035 Pad, Hydraulic Outrigger 2
9 C29013 Cover, Outrigger Top 2
10 C29055 Cover, Outrigger Hoses 2
11 C29058 Cover, Outrigger Hoses RH 1
12 C29056 Cover, Outrigger Hoses LH 1
13 G09015 Guard, Fender Wiring 1
14 G09020 Guard, Fender Wiring 1
15 A03005 Alarm, motion 1
16 F05170 Fitting, -6 JIC bulkhead 4
17 G09021 Guard, Toggle Switch 1
18 S40150 Switch, DP/DT Momentary 2
19 V02075 Valve, Loadlock 2
20 F05755 Fitting, 6-6 Str SAE 8

Page 27

Hydraulic Outriggers
 If items look different than the parts breakdown please call for assistance. (541)354-1001

7
8
7 9
6

10
11
12
13
14
15
5

ITEM PART DESCRIPTION QTY.

4 NO. NUMBER
16 1 B11060 Bolt Hx head 7/8-9x3 Z8 2
2 P01020 Pad, Jackstand Large 2
3 3 S37010 5/8"-11 X 2" STUD 2
4 J01010 Jackstand, 985/6500 2
5 S17930 Sleeve, Jackstand bolt on LH 1
2 6 P06105 Pin, Clevis 1/2 x 2-1/2 2
7 W01005 Washer, Flat SAE 1/2" 4
8 P06933 Pin, Cotter 1/8x1 Z 2
1 9 H02015 Handle, Jackstand 2
10 S17935 Sleeve, Jackstand bolt on RH 1
11 W01585 Washer Split Lock 3/4 8
12 S04245 Screw SHCS 3/4-16x1-3/4 8
Page 28 13 P06925 Pin, Cotter 1/8x2 Z 2
14 S28075 Spring, Jackstand / E.P.O. 2
Manual Jackstands 15 P04005 Pawl, Jackstand 985/6500 2
16 P06104 Pin, Clevis 3/4 x 2-1/2 2
 If items look different than the parts breakdown please call for assistance. (541)354-1001

28 24
23 26
34 29
27
25
22
23
31
24 9
26 27

30 14 11 11
21 6
20

10
19
12
33
13

6 17
16

17 32
2
7
18

1
3

Page 29

HYLW
If items look different than the parts breakdown please call for assistance. (541)354-1001

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 B15943 Bracket, Levelwind Std Fenders 1
2 B15230 Bracket, levelwind Lower 1
3 B15996 Levelwind Arm Standard 1
4 B15995 Levelwind Arm X/wide 1
5 B15997 Levelwind Short Arm 1
6 P06029 Pin, Levelwind Pivot 2
7 P06042 Pin, Levelwind 1
8 P06830 Pin Lower Pivot 1
9 T15905A Turnbuckle Assembly 1
10 P06095 Pin, 1/2 x 2 2
11 W01005 Washer, Flat SAE 1/2" 4
12 C32020 Cylinder, Levelwind 1
13 P06073 Pin, 1x2-3/4 2
14 F05360 Fitting, 6-8 90° NPT 2
15 S17000 Sleeve, Levelwind 1
16 P06156 Pin, Levelwind Pivot 1
17 N04097 Nut Hex Jam 1-1/4-12 2
18 F05630 Fitting, 1/4-28 Zerk 1
19 P06027 Pin, 5/8 x 6 w/Handle 1
20 C17020 Clip, Hitch #20 1
21 A08089 Arm, Levelwind 1
22 R20044 Roller, Painted Steel 4
23 B07110 Bearing, Roller 8
24 C06041 Cap, End 5
25 S43129 Shaft, Roller 2
26 B11342 Bolt Hx head 3/8-16x1 5
27 W01545 Washer, Split Lock 3/8" 5
28 B15897 Bracket, Swing-away Fairlead 1
29 P06193 Pin, Roll 1/4 x 2-1/2 2
30 P09170 Plate, Sub 1
31 V02145 Valve Capstan/Levelwind 1
32 V02075 Valve, Loadlock 1
33 F05755 Fitting, 6-6 Str SAE 4
34 S04475 Screw, Set Sq Head 1/2 x 1 2
35 C17015 Clip, Hitch Pin 5" 1

Page 30

HYLW
 If items look different than the parts breakdown please call for assistance. (541)354-1001

10
11
9
5 27
6 32
2 33
31
7 41
9 29 42
11
28
10
4 10
11
9
28
29 27 30
25

5
29

8 24 14 16 15
3
8
39
23 13 11
38 17 22
26 10
38
8 12
37
18
40
3 21

9
34 11
36 39
10
38
38 34 17
Page 31 35 4
37 7 19 20
HPLW2 Screw Levelwind
If items look different than the parts breakdown please call for assistance. (541)354-1001

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 F09060 Frame L/W Acme Screw 1
2 P09080 Plate L/W End 1
3 B11155 Bolt Carriage 1/2-13x2-1/4 12
4 N04555 Nut, Hex Nylock® 1/2"-13 36
5 P06155 Pin, Level Wind 7" 2
6 C17015 Clip, Hitch Pin 5" 1
7 B07130 Bearing 2
8 B11364 Bolt Hx head 1/2-13x1-3/4 16
9 C06041 Cap, End 7
10 B11342 Bolt Hx head 3/8-16x1 11
11 W01545 Washer, Split Lock 3/8" 11
12 P09078 Plate L/W end w/Motor 1
13 P06925 Pin, Cotter 1/8x2 Z 1
14 M08050 Motor, Hydraulic Drive 1
15 F05015 Fitting, 8 JIC to -8 SAE 90° 1
16 F05315 Fitting,8-8 Str SAE 1
17 W01002 Washer Flat SAE 3/8 10
18 S29080 Sprocket, 14 tooth #60 1
19 S29075 Sprocket, 16 tooth #60 1
20 K01028 Key, Drive LW2 1
21 C10155 Chain, Drive LW2 1
22 G09045 Guard, Chain HYLW2 1
23 S04115 Bar, Round 1-1/2 CD 1018 1
24 N04905 Nut, Hex 1-1/2-6 2
25 C37905A Carrier, HYLW2 1
26 B11446 Bolt Hx head 1/2-13x2 Z8 8
27 S43129 Shaft, Roller 2
28 R20044 Roller, Painted Steel 2
29 B07110 Bearing, Roller 8
30 R20005 Roller, Vertical HYLW2 2
31 P06193 Pin, Roll 1/4 x 2-1/2 2
32 B15897 Bracket, Swing-away Fairlead 1
33 S04475 Screw, Set Sq Head 1/2 x 1 2
34 G09000 Guard, HYLW2 1
35 N04545 Nut, Hex Nylock® 3/8"-16 6
36 T15905A Turnbuckle Assembly 1
37 P06095 Pin, 1/2 x 2 2
38 W01005 Washer, Flat SAE 1/2" 4
39 P06933 Pin, Cotter 1/8x1 Z 2
40 P06830 Pin Lower Pivot 1
41 P09170 Plate, Sub 1
42 V02145 Valve Capstan/Levelwind 1

Page 32
 If items look different than the parts breakdown please call for assistance. (541)354-1001

3 19
18

8 10
11
18
13

14 12
15
12
5 20

5
1 7

16
16
4
9

21

17 2
Page 33

Tank Assembly
 If items look different than the parts breakdown please call for assistance. (541)354-1001

ITEM PART NUMBER DESCRIPTION QTY.

1 T01002 Tank, Hydraulic 6500 1
2 T01001 Tank, Fuel 6500 1
3 C06155A Cap, Hydraulic 1
4 C06205 Cap, Fuel 1
5 F04021 Filter Head 2
6 G02046 Gauge, Hyd oil level 1
7 Brake Manifold Brake Manifold Assembly 1
8 N06200 Neck, Hydraulic Fill 1
9 S46015 Sender, Fuel Level 1
10 B15004 Bracket, Accumulator Mount 1
11 A12001 Accumulator, 1 gallon 1
12 N02001 Nipple, 1-1/4" x 3"LG 3
13 E01002 Elbow, 1-1/4" FNPT 90° 1
14 N02002 Nipple, 1-1/4" x 6"LG 1
15 V02001 Valve, Ball 1-1/4" NPT 1
16 F04020 Filter 10 micron 2
17 P09171 Plate, Sub shift 1
18 G01165 Gasket, Neck Fill 2
19 C29203 Cover, Tank Access 1
20 F04040 Filter, Suction Strainer 1
21 S40002 Switch, Hi-Low Shift 1

Page 34
 If items look different than the parts breakdown please call for assistance. (541)354-1001

4
6

5
9

3
2

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 M04001 Manifold, Brake 1
2 V02066 Valve, 2Way Solenoid Cartridge 1
3 V02069 Valve, 3Way Solenoid Cartridge 1
4 S40001 PDI Switch 1
5 F05706 Fitting, 4-4 FNPT-SAE 1
6 F05018 -4 FNPT to -4 NPT 45° 1
Page 35 7 G02035 0-5k psi bottom mount 1
8 V02067 Valve, check 1
Brake Manifold
9 V02068 Valve, relief 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001

ITEM PART NUMBER DESCRIPTION QTY.

Page 36 1 H05070 Hood, Electrical 7 wire 1
2 S21035 Socket 7-wire Pollak 1
3 P10025 Plug, 7-Wire w/Spring 2
Electrical Hood
4 C02038-1 Cable 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001

5
6

3 4

ITEM PART NUMBER DESCRIPTION QTY.

1 S08001 Screen, HP6500 Power Unit 1
2 L04060 Light Bar, 3 light 1
3 L04105 Light, Amber Strobe 2
Page 37 4 G09019 Guard, strobe 2
5 S40035 Switch, SP/ST Toggle 1

Optional Hi-Vis Group 6 H10002 Holder, Fuse 2

7 F01002 Fuse, 30amp 2
 If items look different than the parts breakdown please call for assistance. (541)354-1001
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 L01020 Latch, Over center 4
2 C14045 Catch, Over Center 4
3 C29083 Cover, Driveshaft Capstan 1 10 11
4 C29011 Cover 6500 Control Panel 1
5 C29016 Cover, Control 6500 1 9
6 G09002 Guard, Center Drive Chain 1
7 H05001 Hood, 6500 Power Unit 1
8 N06102 Neck 3" Air Cleaner 1 8
9 E02021-10 Rain Cap 1
10 C29207 Cover, Driveshaft Access 1
11 C29201 Cover, Oil Cooler 6500 1 7
12 D05160 Door, Power Unit 6500 LH 1
13 L08025 Lock, T-Handle 2
14 B15901 Bracket, Center Hood 6500 1
15 D05161 Door, Power Unit 6500 RH 1

6
12
5

13

14

13
15
Page 38 2
1
1
2 Hoods & Doors
 If items look different than the parts breakdown please call for assistance. (541)354-1001

2
1

2
1

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 F05215 Fitting, 8-8 90° NPT 2
Page 39
2 F05393 Fitting 1/2 NPT Jam nut 2
3 C28062 Coupler, M quick 1/2 NPT 1
Quick Connectors
4 C28061 Coupler, F quick 1/2 NPT 1
 If items look different than the parts breakdown please call for assistance. (541)354-1001
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 B22050 Block, 4 Pole Terminal Strip 2
2 G08010 Grommet, 4" Tail/Stop/Turn 4
3 G08005 Grommet 2" Light 6
4 L04055 Light, License plate 1
5 L04030 Light, 4" Tail Stop Turn 4
6 L04070 Light, 2" Red 4
7 L04035 Light, 2" Amber 2

Standard Lights
7

3
2
2
5 7

4 5
3

1
3
6 3
6 1

6 3
3 6

LED Lights
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 B22050 Block, 4 Pole Terminal Strip 2
2 G08010 Grommet, 4" Tail/Stop/Turn 4
Page 40 3 G08005 Grommet 2" Light 6
4 L04055 Light, License plate 1
5 L04305 Light, 4" Tail Stop Turn LED 4
Outrigger Fender Lights 6 L04037 Light, 2" Red LED 4
7 L04036 Light, 2" Amber LED 2
 If items look different than the parts breakdown please call for assistance. (541)354-1001
ITEM NO. PART NUMBER DESCRIPTION QTY.
1 B13048 Box, light Vertical 2
2 B22050 Block, 4 Pole Terminal Strip 2
8 3 G08010 Grommet, 4" Tail/Stop/Turn 4
4 4 G08005 Grommet 2" Light 4
5 L04080 Light, License 1
9 6 L04305 Light, 4" Tail Stop Turn LED 4
4 7 L04037 Light, 2" Red LED 2
8 L04036 Light, 2" Amber LED 2
7 9 P10175 Plug, Plastic Button 1-1/4" 3
10 10 C26165 Liquidtite 90 2
11 C24005-1 Conduit, liquidtite 1/2" x 22" 1
12 C24005-2 Conduit, liquidtite 1/2" x 22" 1

12

4
9
6 2

1
1
5 2 8
3

10

6 11

Page 41
9
LED Light Package 3
 If items look different than the parts breakdown please call for assistance. (541)354-1001
ITEM PART NUMBER DESCRIPTION QTY.
NO.
1 B13048 Box, light Vertical 2
2 B22050 Block, 4 Pole Terminal Strip 2
7 3 G08010 Grommet, 4" Tail/Stop/Turn 4
4 G08005 Grommet 2" Light 4
5 L04030 Light, 4" Tail Stop Turn 4
6 L04070 Light, 2" Red 2
2 4 7 L04035 Light, 2" Amber 2
8 L04080 Light, License 1
9 9 P10175 Plug, Plastic Button 1-1/4" 3
4 10 C26165 Liquidtite 90 2
11 C24005-1 Conduit, liquidtite 1/2" x 22" 1
6 10 12 C24005-2 Conduit, liquidtite 1/2" x 22" 1

12 4
7

2
9
1
10

1
8 11
3 3

Page 42
Std. Light
5 9 4
Package
 C C C
E
A

6 B
-

GREEN 5 1 - YELLOW - LEFT TURN

+ 2 - RED - STOP
BLUE
3 - BROW - CLEARANCE, TAIL, MARKERS
BATTERY 4 - BLUE - ELECTRIC BRAKES
4 5 - GREEN - RIGHT TURN
6 - BLACK - HOT LEAD FOR BRAKE SWITCHES
PLUG A - TURN SIGNALS
B - STOP, TAIL COMBINATION
C - CLEARANCE, MARKER LAMPS
3 D - LICENSE LAMP
E -ELECTRIC BRAKES
BROWN C
RED
2 C
YELLOW
C D
WHITE
1 B

E
C C C
Page 43
HP6500 Trailer Wiring
With Electric Brakes
 C C C

WHITE 6 B
WHITE/YELLOW

GREEN
5 1 - YELLOW - LEFT TURN
BLUE 2 - RED - STOP
3 - BROW - CLEARANCE, TAIL, MARKERS
4 - BLUE - ABS
4 C 5 - GREEN - RIGHT TURN
6 - WHITE/YELLOW -
PLUG C A - TURN SIGNALS
B - STOP, TAIL COMBINATION
C C - CLEARANCE, MARKER LAMPS
3 D - LICENSE LAMP
E - ABS LIGHT
BROWN
RED
2 ABS
YELLOW ECU
WHITE HARNESS D
1 B

C E C C
Page 44

HP6500 Trailer Wiring (Air Brakes)

Page 45
Page 46
HP6500 Lubrication Instructions 2014

The following lubrication instructions are offered as a “rule of thumb”. Precise lubrication instructions
will vary with each usage of each unit. CHECK ALL LUBRICATION POINTS BEFORE EACH USE.

ENGINE: Consult engine manual for precise instructions. Units are delivered by Hogg & Davis, inc. with
10W-40 oil.

HYDRASTATIC DRIVE SYSTEM: This drive system is practically maintenance free, however the oil
should be changed every six months with ISO 46 or its equivalent. There are two oil filters that should
be changed at this time. (Refer to schematic) One is a high pressure filter and has a restriction gauge
on it. (Located inside control panel) This gauge should be checked daily, if it reaches the red line the
filter should be changed immediately.

DO NOT USE ANY LUBRICANT HEAVIER THAN RECOMMENDED

WHEEL BEARINGS: Should be checked and adjusted after FIRST 30 DAYS OF USE. Bearings should be
repacked yearly or as per company specifications.

IDLER WHEEL: Lubricate every 30 days. Zerk fittings are provided for proper application of grease.
Lubricate all parts, including spindle housing, “A” frame supports and hydraulic cylinder linkage.
Spindle bearings are packed at the factory and need not to be checked for 5 years.

DRIVE ROLLERS: Sealed bearings

SPROCKET ASSEMBLIES: Lubricate once a week. Zerk fittings are provided for proper grease
application.

ROLLER CHAIN: Lubricate roller chains weekly. Use regular lube oil to oil all chains. Including drive
roller chains, main drive chain (Oil cup provided) and power idler wheel chain.

DRIVE SHAFT BEARINGS: Lubricate as required. It is recommended that the track be kept clean of
grease and dirt buildup, and fresh lube be applied after each cleaning.

TOOL BOX DOORS: Lubricate as required. Hinges and locks should be lubricated with oil as needed for
easy operation.

CAUTION: OILS SHOULD NOT BE MIXED. IF BRAND OR TYPE IS CHANGED, OLD OIL
MUST BE DRAINED AND ALL FILTERS MUST BE CHANGED AND NEW OIL REPLACED
THROUGHOUT THE SYSTEM.
HYDRAULIC OIL: Machine is delivered with ISO 46 oil.

DO NOT USE AIRCRAFT TYPE HYDRAULIC FLUID.

Page 47

COPYRIGHT 2014 HOGG & DAVIS, INC

HP6500 Lubrication Instructions 2014

ITEM CHECK LUBE TYPE PERIOD

A ENGINE DIPSTICK 10W-40 DAILY

B HYD. SIGHT GAUGE ISO 46 DAILY

RESERVOIR
1 MANDREL ZERKS (3) MULTI-PURPOSE WEEKLY
STABILIZER GREASE
2 DOORS, HINGES OPEN LUBE OIL AS NEEDED

3 REEL DRIVE ZERKS (7) MULTI-PURPOSE WEEKLY

GREASE
4 SLIDE RAILS OPEN (2) MULTI-PURPOSE AS NEEDED
GREASE
5 IDLER WHEEL ZERKS (6) MULTI-PURPOSE WEEKLY
GREASE
6 DRIVE CHAIN OIL CUP LUBE OIL CHECK DAILY

2
2
A

3
1

2 2 6

Page 48

COPYRIGHT 2014 HOGG & DAVIS, INC

 Tier 4

D30009 D30027 D30010 D30015 D30032

(1) (1) (1) (1) D30023 (1)
D30001 (2)
(1)

D30018 D30034
(1) (2)
D30053
(2)

D30026 D30028 D30036

D30022 D30021 (2) (5) (3)
(1) (1)

D30069
D30037 D30042 (1) R09043 R09044
(1) (8) (4) (2)

Page 49

HP6500 Decals
 D30020
(1)

D30024
(1)
D30111
D30002 (1) Tier 4
(1)

D30030 D30151
(1) (1)

Tier 4

D30029
(1) D30128
(1)
D30025
(1)

D01013
(1) D30057 D30150
(1) (1)
Page 50

HP6500 Decals
 1
2

4
1
3

5
1
17 15
16

7 8 10 11
9 12 13
14 ITEM NO. PART NUMBER DESCRIPTION QTY.
1 D30042 Decal, Keep Hands Clear 8
2 D30002 Decal, Loading Instructions 1
3 D30028 Decal, Danger Twisty Man 5
4 D30026 Decal, Danger Stand Clear 2
5 D30111 Decal, Rear Control 1
6 R09043 Reflector, Red 2x3-1/2 4
7 D30023 Decal, Caution Extended Shaft 1
8 T19001 Red/White Reflective tape 10
9 R09044 Reflector, Amber 2x3-1/2 2
10 D30034 Decal, Grounding Lug 2
11 D30025 Decal, Steer-Go Directions 1
12 D30128 Established 1947 1
13 D30001 HD Logo 6x9 1

Page 51 14 D30018 Decal, HD 1/2" x 9" 1

15 D30037 Decal, Important - Idler Wheel 1

Decal Locations 16 D30053 Decal, Hydra 985 Tongue 2

17 D01013 Decal, 4 Bank Valve 1
 3 4 5
6

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 D30150 Decal, Control Panel T4f 1
2 D30151 Decal, Control Panel Hydrostatic 1
3 D30036 Decal, Electrocution Hazard 3
4 D30028 Decal, Danger Twisty Man 5
5 D30022 Decal, Danger Fluid Pressure 1
Page 52 6 D30021 Decal, Untrained Operator 1
7 D30010 Decal, Hydraulic Fluid Only 1
Decal Locations 8 D30032 Decal, Check Oil Daily 1
 6 6

6
6

2
4
3
4
5
6
8

ITEM NO. PART NUMBER DESCRIPTION QTY.

1 D30053 Decal, Hydra 985 Tongue 2
2 D30015 Decal, Hot Surface 1
3 D30036 Decal, Electrocution Hazard 3
4 D30028 Decal, Danger Twisty Man 5
5 R09044 Reflector, Amber 2x3-1/2 2
Page 53 6 D30042 Decal, Keep Hands Clear 8
7 R09043 Reflector, Red 2x3-1/2 4
Decal Locations
8 D30026 Decal, Danger Stand Clear 2
Page 54
 JOHN DEERE keyswitch pinout

to preheat timer Start signal

50 is active only when key is in

start position

17 and 19 only active when key is

in preheat postion 50
19

Key Switch

17 AC
30

AC is active when key is in ON

and Start position

to preheat relay 12V (+) from battery Keyed (+)