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Component Repair

6.4 Manual Bypass Valve Repair

(Bypass Valve Assy. Diagram)

1. Remove outlet adapter (11). Pull cartridge (3) out. If cartridge (3) is stuck together and not

releasing pull the pin and cartridge body apart to inspect the seats for cuts and other damage.

Replace the cartridge as necessary.

2. Check diffuser (4) for damage or wear from bypass water.

3. Check all O-rings, replace any that are damaged. Lubricate all O-rings with silicone lubricant.

4. Replace cartridge (3) and reassemble to the bypass valve body (2) making sure to anti-seize all

stainless steel threads.

Manual Bypass Valve

Содержание Stripe Hog SH5000

Страница 1: ...Operations Manual...

Страница 2: ...2...

Страница 3: ...N BEFORE ATTEMPTING TO CONNECT OPERATE OR REPAIR THIS EQUIPMENT THOROUGHLY READ THESE INSTRUCTIONS AND ANY SAFETY WARNING OR INSTRUCTION PAMPHLETS INCLUDED WITH YOUR SHIPMENT For any questions concern...

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Страница 5: ...ckly to keep your equipment operating and producing results for you Every team member is at your disposal at any moment throughout the year to resolve any and all issues that would hinder your machine...

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Страница 7: ...used throughout the manual IMPORTANT NOTE Your Waterblasting equipment uses internal combustion engines and flam mable fuel Every precaution has been taken by Hog Technologies to reduce the risks asso...

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Страница 9: ...Systems 26 2 5 Fluid Cooler Placement 27 2 6 Hood Ventilation System 28 2 7 Truck Mounted Hog Head 30 2 8 Waterblast System 35 2 9 Vacuum System 43 Section 3 Waterblasting Hog Tools 51 3 1 Hog Tools O...

Страница 10: ...r 95 6 4 Manual Bypass Valve Repair 97 Appendix A Drawings and Supplies 99 Fluid End Replacement Parts 99 Appendix B Troubleshooting Guide 101 Appendix C SH5500 Specifications 105 SH5500 Specification...

Страница 11: ...tractors engines pumps and drive units provide their own owner s manuals which have been included with your equipment You should read the information in this manual and the manuals of other suppliers...

Страница 12: ...of publication Hog Technologies reserves the right to make changes at anytime without notice in colors materials equipment specifications and models If you have questions about the equipment on your S...

Страница 13: ...0 gal 2 500 ltr CLEAN WATER TANK 600 gal 2 271 ltr BLOWER Dresser Roots U RAI 59u BLOWER CFM 718 cfm MAXIMUM SYSTEM VACUUM 15 INHGV UHP PUMP Jetstream 3600 UHP PUMP GPM 6 gpm 23 ltr MAXIMUM UHP Pressu...

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Страница 15: ...edures and that update may not be reflected here Work Area Safety Remember safety is first Only set up to work in areas properly protected from traffic and other hazards Outfit all operators with prop...

Страница 16: ...equip ment pressure rating and warning tags should be left intact Be Prepared If the equipment malfunctions or a malfunction is suspected immediately stop all blasting activ ity and relieve all pressu...

Страница 17: ...HE WORK AREA BEFORE THE PRESSURE PUMP IS ENGAGED NEVER PUT HANDS FEET OR ANY PART OF YOUR BODY IN OR NEAR THE HIGH PRESSURE STREAM TURN OFF UHP IF ANYONE GETS CLOSE TO THE HEAD Nozzle Flow Chart Check...

Страница 18: ...s Never use power tools to run the nozzles in or out Always turn the nozzles by finger as much as possible If the threads gall you should use a back and forth motion to slowly extract it from the Spra...

Страница 19: ...the system without bursting Inspect this line periodically to ensure it is in good condition Re place when it becomes compromised in any way chaffed cut dry rotted cracked or leaking 1 5 High Pressure...

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Страница 21: ...n and the chassis manufacturer All truck chassis are equipped with two heavy duty main circuit breakers located below the hood on the driver s side just forward of the battery The circuit breakers pro...

Страница 22: ...traveled while in Work Mode When the meter is activated an inductive sensor records the revolutions of the truck drive shaft and converts the readings into linear feet or meters The data is recorded...

Страница 23: ...to Work Mode when the PTO switches are activated An electric air compressor located on the passen ger side of the chassis below the clean water tank provides the compressed air for the pneumatic cont...

Страница 24: ...to select forward or reverse The TRUCK SPEED dial controls the truck speed in forward or reverse 0 7 mph Engine RPM is controlled by the speed dial on the Remote Engine Control panel on the truck dash...

Страница 25: ...the Hog Head Hog Arm and other waterblasting hydraulic systems It is con trolled by the PTO switch in the truck dashboard An indicator light in the switch panel illuminates when the PTO is engaged Ref...

Страница 26: ...System Reservoir and Fluid Level Temperature Gauge Level Site Glass Temperature the various components The hydraulic oil level and temperature is monitored by a site gauge and thermometer on the side...

Страница 27: ...rd diesel engine the Ford manual transmission the OMSI Gearbox and the Hydraulic Pumps This incredibly efficient package maintains the respective components at their optimum temperatures to ensure the...

Страница 28: ...which dramatically improves air flow around the engine radiator and engine compartment oil coolers while in work mode It is extremely important for the hood to be raised to provide proper cooling when...

Страница 29: ...ion WARNING Never operate the truck in drive mode at speeds exceeding 15 mph with the hood raised to the ventilation position The hood is not designed to be operated at highway speeds in this position...

Страница 30: ...pressure water and DC power for Waterblasting accessories or Hog Tools that can be powered by the SH5500 systems Hog Head Hydraulic System The hydraulic system is powered by the truck en gine The truc...

Страница 31: ...may be installed by Hog Technologies Individual fuses in a fuse panel located inside the control panel protect the circuits activated by the switches There is no power available to the control panel u...

Страница 32: ...al to 0 will stop the truck motion setting the Head Rotation dial to 0 will stop the rotation of the spray bar Hog Head The Hog Head is attached to the end of the Hog Arm There is one blasting head su...

Страница 33: ...mples of available spray bar configurations are included in the Appendix section of the this manual You can also contact Hog Technologies Customer Service for assistance in selecting the right spray b...

Страница 34: ...ads must be corrected before beginning high pressure operations or the spray bar and or thru shaft will be ruined Should any repairs or adjustments be necessary disengage the pump to relieve all press...

Страница 35: ...IS CLEAR OF PEOPLE HANDS FEET ETC BEFORE ENGAGING THE 40K CLUTCH HIGH PRESSURE SWITCH FOR THE STRIPE HOG Clean Water Tank The clean water tank is mounted to the chassis just forward of the debris tank...

Страница 36: ...roughly cleaned if the tank was filled from a contaminated water source or if the source was not properly flushed prior to filling A ladder on the rear of the debris tank provides access to the top an...

Страница 37: ...ing turn off the charge pump and disengage the OMSI Drive PTO immediately when low water or low charge pres sure is observed Water supply problems to the charge pump can also be indicated by the sound...

Страница 38: ...and the area around the tank fill valve clean Never use water drawn from retention ponds canals or other non potable sources Packing Lube Water and Bilge Pump Lube and cooling water for the plunger p...

Страница 39: ...and components Maximum operating pressure for the UHP pump of 40 000 PSI 2 758 Bar 8 5 gallons 32 Liters per minute is achieved at maximum engine RPM typically 2300 RPM The water pressure is moni tor...

Страница 40: ...ESSURE IN THE HIGH PRESSURE BLASTING SYSTEM CAN CAUSE EXTENSIVE DAMAGE TO EQUIPMENT AND SEVERE INJURY OR EVEN DEATH TO PERSONNEL IF A RUPTURE DISC BURSTS IT USUALLY INDICATES A PROBLEM THAT NEEDS TO B...

Страница 41: ...NANCE OR REPAIRS ON THE HIGH PRESSURE SYSTEM Take care of Your Hoses Protect the hoses from contact with sharp objects abrasive surfaces and foot or wheel traffic Add additional anti chaffing material...

Страница 42: ...SSURE WATER CAN TEAR OFF SKIN AND INJECT WATER DIRECTLY INTO THE BLOOD STREAM WHICH CAN BE FATAL ALWAYS DEACTIVATE THE HIGH PRESSURE SYSTEM BEFORE RAISING THE HOG HEAD AND MAKE SURE THE AREA IS CLEAR...

Страница 43: ...ion and maintenance of the blower The vacuum is monitored by a digital gauge in the control panel or an optional gauge on the debris tank It is adjusted by increasing or decreasing the engine RPM Thus...

Страница 44: ...m hoses to be added or for servicing Hog Head vacuum hoses and components Other quick connectors provide access to other components of the vacuum system Consistent and proper vacuum is important to th...

Страница 45: ...lows for quick drain ing and easy disposal of filtered waste water while retaining the solids enabling the operator to regain tank capacity A site tube on the side of the debris tank indi cates the re...

Страница 46: ...to select either NORMAL or DISCHARGE modes When Normal mode is selected an automatic float switch controls the water level in the debris tank by activating the pump and moving water from the debris t...

Страница 47: ...e Water Divert switch is turned ON with the Debris Pump switch set to Normal to activate the pump and float switch when automatic water level control in the debris tank is desired Always turn the Wate...

Страница 48: ...a hose to clean the tank liner thoroughly with fresh water Make sure to the clean the automatic float switch for the pump out system and the cutoff ball valve When the tank is clean install a new fil...

Страница 49: ...AR THE DUMPING AREA 9 9 HAVE ALL PERSONNEL STAND WELL CLEAR OF THE UNIT AND DEBRIS TANK DOOR THE OPERATOR SHOULD USE THE REMOTE CONTROL AND BE WELL CLEAR 9 9 LIFT THE TANK SLOWLY AND MONITOR HOSES AND...

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Страница 51: ...safety precautions before operating the tool Section 3 WARNING Injuries from Ultra High Pressure waterblasting can be very serious and result in fatal injuries Proper operation of high pressure waterb...

Страница 52: ...sting head on the tool When the system is activated it operates much like the truck mounted high pressure water sys tem The tools must be moving before the high pressure is activated and all waterblas...

Страница 53: ...to the proper operation the Stripe Hog This manual and the associated manufacturers information is provided to enhance your knowl edge of the Stripe Hog Make sure you have read them carefully and ful...

Страница 54: ...s and parts 5 Inspect the Hog Head for loose components and damage 6 Check vacuum canister for water and the vacuum filter Drain water or clean filter as required 7 Check the vacuum blower and UHP pum...

Страница 55: ...asting operations WARNING ANY CONTACT WITH HIGH PRESSURE WATER IS VERY DANGEROUS AND CAN BE FATAL USE EXTREME CAUTION RAISING OR MOVING HOG HEAD ARM ASSEMBLY IF HIGH PRESSURE IS ENGAGED CAUTION ENGAGI...

Страница 56: ...ement is weak and will require lighter aggression spray bars Brittle pavement is a challenge and will require lighter aggression spray bars and reduced pressure Consider spray bar width Choose a spray...

Страница 57: ...refer to pump manufacturer s procedures for maintaining equipment in freezing climates 5 Open the drain valve at the charge water pump and allow the hoses and pump to completely drain With the valve...

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Страница 59: ...iodically lubricate all hinges and latch as semblies with a light oil Periodically clean and coat gasket materials with silicone to help keep them pliable Adjust latches as necessary Hydraulic Cylinde...

Страница 60: ...ck fluid level in the OMSI Drive and inspect for signs of leakage The fluid level is checked by removing the plug on the drivers side rear of the OMSI Drive The fluid level should be maintained within...

Страница 61: ...e tension and alignment Periodic Maintenance Check drive belt tension pulleys and belt align ment monthly Adjust or replace as required Check and grease pillow drive pulley pillow block bearings Check...

Страница 62: ...ower mount is used for adjusting the blower drive belt Two adjusting bolts on the pulley end of the UHP pump mounting frame are used to adjust the UHP drive belt Typical Gates Sonic Tension Meter Driv...

Страница 63: ...d alignment Readjust as necessary to achieve correct belt tension and or alignment 5 Start the engine and engage the OMSI Drive PTO at idle speed for 30 seconds 6 Disengage the PTO and shutdown the en...

Страница 64: ...and recheck the belt tension and alignment Readjust as necessary to achieve correct belt tension and or alignment 4 Tighten the bolts in the slotted holes Then tighten the pivot bolts 5 Start the engi...

Страница 65: ...er is flowing to the plunger packing seals when the charge water is activated Constant water flow is essential to lubricate and cool the seals Make sure the cooling water sump and drain are clean to p...

Страница 66: ...p pressure is lower than 30 PSI 2 Bar replace both of the filters between the charge pump and the high pressure pump To change the filters make sure the system is not engaged and the switches for the...

Страница 67: ...onal operation and service data Inspection and Routine Maintenance Daily Inspect the cooling water sump in the UHP pump daily and clean any debris that may restrict drainage to the bilge pump system I...

Страница 68: ...s or replace questionable components before wa terblasting Check hydraulic connections for leaks tighten if necessary Test and inspect the nozzles and spray bar for proper operation and leaks Correct...

Страница 69: ...he manufacturer s specifications Refer to the Lubrication Chart in this section and the pump manufacturer s op erating and information manual for information on the hydraulic system and oil specificat...

Страница 70: ...Inspection and Routine Maintenance Daily Check for obvious loose mounting nuts and bolts Grease blower drive end and idler pulley bear ings with the lube specified by the blower manufacturer Check the...

Страница 71: ...ccidentally opened Check pulley clearances and drive belt tension at least once each month Check and tighten all mounting bolts and hardware Lubricate filter canister inspection door hinges regularly...

Страница 72: ...to ensure good vacuum sealing and clean if necessary Grease debris tank door hinges and clamp threads regularly Inspect and lubricate ball valves periodically Inspect the cutoff ball valve and automa...

Страница 73: ...necessary Grease the hydraulic lift hinge pins and fit tings weekly Inspect safety strut Make sure the hinge pins are tight and lubricate pins weekly Lubricate the debris door gas spring pivot hinge...

Страница 74: ...at least daily or when the flow of dirty water becomes restricted Cleaning the Debris Pump Strainer 1 Turn the divert switch in the cab control panel OFF 2 Deactivate the vacuum and waterblasting sys...

Страница 75: ...er level in the debris tank is at least 10 25 cm above the bottom of the tank 2 Deactivate the vacuum and waterblasting systems 3 Open the back flush valve on the bottom of the pump strainer 4 Allow t...

Страница 76: ...tream Pump Grease Points Weekly Mobil PolyRex EM Grease Jetstream Pump Crankcase Oil After 1 st 100 hours Then Every 500 Hours High Grade 80w90 Gear Oil NEVERRUNBLOWERORJETSTEAMPUMPUNDERLOADIFCRANKCAS...

Страница 77: ...n in and will provide trouble free operation there are situations where the bearing preload will need to be reset after the truck has been operating in the field for a period of time Setting the bear...

Страница 78: ...d in your Truck Tool Kit 1 6 mm Allen Wrench Supplies Anti Seize Grease Gun and Multi Purpose Grease Rags or Paper Towels 9396K21 O ring Supplied in Spare Parts Kit Note Use anti seize compound on bol...

Страница 79: ...gh Pressure Hose Remove the high pressure hose from the top of the thru shaft motor by tuning the hand nut at the base of the hose counterclockwise If the hand nut is too tight to turn by hand use the...

Страница 80: ...thrust housing until it is free Figure 5 Note that the O ring seal in the thrust housing cap will provide some resistance until it is clear of the thrust housing The cap will tend to pop slightly whe...

Страница 81: ...ivel tit assembly gland nut by turning it counterclockwise Inspect the swivel tit assembly and set it in a safe clean location Figure 7 and 8 Figure 7 Swivel Tit assembly gland nut to be removed by tu...

Страница 82: ...en the seal nut 2 full turns Hold the thru shaft firmly with the 3 4 19mm open end wrench and use the spanner socket to hand tighten the seal nut until it is snug Do not over tighten Figure 8 and 10 T...

Страница 83: ...he spanner socket and remove it from the housing Now it is safe to move the thru shaft When loosening the spanner socket and seal nut one bolt hole to set the bearing preload or when tightening the ja...

Страница 84: ...e to be completely disassembled and rebuilt While holding the thru shaft with the 3 4 19mm open end wrench install the swivel tit assembly gland nut and hand tighten Then use a 15 16 24mm deep well so...

Страница 85: ...hem in a crisscross pattern to snug using a 6mm Allen wrench Step 9 Install the High Pressure Water Hose and Grease the Thru Shaft Bearings Apply anti seize to the threads on the top of the thrust hou...

Страница 86: ...re all personnel are well clear of the spray head and apply full water pressure Run the thru shaft motor for another 15 minutes Figure 20 When testing is complete and with the unit still running at ma...

Страница 87: ...T69 5154T69 SEAL 25 X 52 X 8MM MCMASTER 18 1 52052 001 MP2253 SEAL SWIVEL 19 1 52100 001 MP2752 RING BACKUP BRASS SMU 20 1 52102 001 MP1008 SEAL BRASS BUTTON VARIOUS 21 1 70153 001 CS1000 TSN4 FABRICA...

Страница 88: ...L GREASE THRU SHAFT HOG HEAD MP MANUFACTURING 17 1 5154T69 5154T69 SEAL 25 X 52 X 8MM MCMASTER 18 1 52052 001 MP2253 SEAL SWIVEL 19 1 52100 001 MP2752 RING BACKUP BRASS SMU 20 1 52102 001 MP1008 SEAL...

Страница 89: ...IRE 8MM DIA SS NOTES 1 VENDOR MCMASTER 2 VENDOR PART NUMBER 2250K14 3 DESCRIPTION FITTING ZERK GREASE M8 X 1 MALE 14 9MM METRIC SS NOTES 1 VENDOR CASAPPA 2 VENDOR PART NUMBER PRC04999 3 DESCRIPTION MO...

Страница 90: ...NG BACKUP BRASS SMU 20 1 52102 001 MP1008 SEAL BRASS BUTTON VARIOUS 21 1 70153 001 CS1000 TSN4 FABRICATION WASHER COUNTER THRU SHAFT HOG HEAD WEST GATE SHEET METAL 22 1 70837 70837 NUT JAM 3 4 16 SS F...

Страница 91: ...TON SEAL EVERY TIME A SPRAYBAR IS REPLACE D C B A A B C D 1 2 3 4 5 6 7 8 8 7 6 5 4 2 1 THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO WATERBLASTING TECHNOLOGIES NO PART MAY BE REPRODUCED USED IN A...

Страница 92: ...92 Component Repair THIS PAGE WAS LEFT BLANK INTENTIONALLY...

Страница 93: ...1 Grease wheels and caster bearings daily 2 If necessary remove bearing seal to clean bearings in casters Use degreaser or brake cleaner to remove dirt and paint debris 3 Replace worn wheels as wear...

Страница 94: ...94 Component Repair...

Страница 95: ...e 2 Remove cartridge 2 from slotted end and replace with a new cartridge 2 Replace diffuser tube 1 into valve body 3 2 Periodic maintenance of air actuator is necessary Remove cap screws 8 to disassem...

Страница 96: ...96 Component Repair...

Страница 97: ...cartridge body apart to inspect the seats for cuts and other damage Replace the cartridge as necessary 2 Check diffuser 4 for damage or wear from bypass water 3 Check all O rings replace any that are...

Страница 98: ...98 Component Repair...

Страница 99: ...99 Fluid End Replacement Parts Appendix A Drawings and Supplies...

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Страница 101: ...e and not convex repair or replace shroud Flow control is shut off turn on flow ball valve Electric connection is unplugged or no voltage to coil check that LED light on coil is lit and repair circuit...

Страница 102: ...place with new button seal Air lock in fluid end remove rupture disc assembly or side port fitting engage pump and run up to high RPM to remove air from the manifold Low inlet water pressure change di...

Страница 103: ...ean seal Seal is damaged replace damaged seal Debris tank 4 dump valve open clear valve of any debris and close tightly if valve still leaks it may be necessary to replace worn valve Relief valve stuc...

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Страница 105: ...TANK 600 gal 2 271 ltr BLOWER Dresser Roots U RAI 59u BLOWER CFM 718 cfm MAXIMUM SYSTEM VACUUM 15 INHGV UHP PUMP Jetstream 3600 UHP PUMP GPM 6 gpm 23 ltr MAXIMUM UHP Pressure 40 000 PSI 2 722 bar BLO...

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Страница 107: ...clean filter as required 7 Check the vacuum blower and UHP pump drive belt tension and alignment 8 Check clean water tank level and fill if necessary 9 Drain debris tank water and check debris level E...

Страница 108: ...and Charge Pump switches to OFF 8 Turn all other switches and dials on the control panels to OFF or 0 9 Make sure the Hog Arm locking lever is engaged and secure it with a safety strap to ensure the l...

Страница 109: ...maining water about a cupful Then close the valve 6 Remove the debris pump strainer and run the pump briefly to drain the pump hoses Then clean and reinstall the strainer 7 Pour 2 gallons of anti free...

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Страница 111: ...ess Agressive set up 4 27 GPM 36K psi 5 0 GPM 40K psi 2 8 8 Nozzle Medium Agressive set up 4 73 GPM 36K psi 5 0 GPM 40K psi 1 8 8 Nozzle Most Agressive set up 5 39 GPM 36K psi 5 69 GPM 40K psi Spray B...

Страница 112: ...112 Spray Bar Configuration 5 8 8 Nozzle Concrete Prep Curing Compound Removal 25 000 35 000psi 5 48 GPM 40K psi 4 8 8 Nozzle Least Agressive set up 3 71 GPM 36K psi 3 93 GPM 40K psi Nozzle Flow Chart...

Страница 113: ...8 8 10 16 Nozzle Most Aggressive set up 5 4 GPM 36K psi 5 72 40K psi 7 6 14 Nozzle Spray Bar 4 lines Less Aggressive 4 48 GPM 36K psi 4 74 GPM 40K psi 6 6 14 Nozzle Spray Bar 4 lines Argessive 5 72 G...

Страница 114: ...n 11 8 10 16 Nozzle Concrete Prep Curing Compound removal set up 25 000 35 000 psi 10 8 10 16 Nozzle Less Aggressive Set up 4 82 GPM 36K psi 5 1 GPM 40K psi 9 8 10 16 Nozzle Less Aggressive set up 5 4...

Страница 115: ...r Configuration 14 14 Less Aggressive set up 5 46 GPM 36K psi 5 78 GPM 40K psi 13 14 Most Aggressive set up 5 66 GPM 36K psi 5 98 GPM 40K psi 12 14 Most Aggressive set up 5 83 GPM 36K psi will not ach...

Страница 116: ...116 Spray Bar Configuration 14 Rubber Removal 30 000K psi 16 14 Concrete PRep Curing Compound Removal Will not achieve 40K psi 15 14 Least Aggressive set up 4 81 GPM 36K psi 5 09 GPM 40K psi...

Страница 117: ...al Accumulative GPM Size GPM Quantity Total GPM Total Accumulative GPM Remember to multiply the total by two if you have a two head system The total should not exceed 11 8 gpm If it does you will not...

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Страница 119: ...e Department stands ready to answer your questions and provide technical assistance 24 hours a day 7 days a week h h Customer Service can also assist you with part orders h h Always contact Hog Techno...

Страница 120: ...lease login or register 001 772 223 7393 This number that will find an available customer support representative 24 7 We are excited to take your call any hour of the day Please don t hesitate to call...

Страница 121: ......

Страница 122: ...Print Date 02 21 2019 Rev 4 3170 SE Slater Street Stuart Florida 34992 001 772 214 1714 P 001 772 223 5461 F www hogtechnologies com...

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