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116

Scheduled Maintenance

5.4 Ultra High Pressure Pump

Scheduled Maintenance

The 40K UHP pump operates at very high pres-

sure and has specific lubrication and maintenance

requirements. Refer to the Maintenance Matrix

in this section and the pump manufacturer’s op-

erating and maintenance manual for lubrication

specifications and maintenance schedules.

Daily Inspection and Maintenance

•

Check the crankcase lubricating oil level.

NOTICE:

THE PROCEDuRE FOR CHECKING THE CRANKCASE OIL

LEvEL IS DIFFERENT FOR WHEN THE PuMP HAS NOT BEEN

OPERATING FOR 5 OR MORE HOuRS AND WHILE THE PuMP

IS IN OPERATION. REFER TO uHP PuMP CRANKCASE OIL

LEvEL CHECK PROCEDuRE IN THIS SECTION FOR THE

CORRECT PROCEDuRES FOR CHECKING THE CRANKCASE

OIL.

•

Check for obvious loose mounting nuts and

bolts.

• Inspect all hoses, fittings, valves and seals for

leaks and proper operation. Repair or replace

leaking or malfunctioning components before

operating the system.

• Make sure cooling water is flowing to the

plunger packing seals when the charge water

is activated. Constant water flow is essential

to lubricate and cool the seals. Adjust flow

with the metering valves or replace packing

if necessary.

•

Make sure the cooling water sump and drain

are clean for proper drainage.

•

Check for water dripping from the UHP Pump

manifold weep holes during the high pressure

test. Water dripping from the square holes

indicates the face seals are leaking. Water

leaking from round holes indicates the high

pressure seals are leaking. Find and correct

the problem before waterblasting.

•

Test the diverter (dump) valve for proper op-

eration daily. Never operate the system if the

dump valve is not working properly.

•

Test the manual bypass valve and make sure

it is operating properly.

UHP Pump & Packing Lube Metering Valves

UHP Pump Packing Lube Lines & Sump

Metering valves

UHP Pump Weep Holes

Face Seal Weep Holes

High Pressure Weep Holes

Содержание Stripe Hog SH8000

Страница 1: ...Operations Manual...

Страница 2: ...2...

Страница 3: ...10 Electrical System 59 2 11 Console Switch Panel 61 2 12 Joystick Console 63 2 13 Programmable Logic Controller 65 2 14 Skip Meter Skip Speed Remote Control Video System 67 2 15 Waterblasting Hydrau...

Страница 4: ...Oil Level Changing Crankcase Oil 118 5 6 High Pressure Pump UNI VALVE Service 121 5 7 High Pressure Pump Stuffing Box Packing Replacement 125 5 8 Ultra High Pressure Pump Assembly 128 5 9 Diverter Va...

Страница 5: ...176 Appendix 4 Nozzle Spray Bar Configuration Nozzle Configuration Chart 177 Spray Bar Configuration Charts 178 Nozzle Calculation Sheet 183 Appendix 5 Glossary of Terms Waterblasting Terms 185 Append...

Страница 6: ...6 NOTES...

Страница 7: ...s designed to be used by operators trained by Hog Technologies During the training experience your team will be given the basic knowledge and skills necessary to maintain operate troubleshoot and repa...

Страница 8: ...not be liable for damage abnormal wear or consequential damage to their sys tem components resulting from the use of replacement components that are not furnished by Hog Technologies Hog Technologies...

Страница 9: ...PRODUCT AND PROPERTY DAMAGE WARNING HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT IN SEVERE PERSONAL INJURY OR DEATH DANGER Indicates a hazardous situation which if not avoided will result in death o...

Страница 10: ...and maintenance of this equipment and provided with adequate supervision Before attempting to connect operate or repair this equipment thoroughly read these instructions and any safety warning or inst...

Страница 11: ...p to work in areas properly protected from traffic and other hazards Individuals being struck by vehicles or mobile equipment lead to many work zone fatali ties or injuries Work zones need traffic con...

Страница 12: ...is in questionable condition Use only components which are marked with the recommended operating pressure Never exceed the operating pressure of the weakest component in the system IMPORTANT NOTE You...

Страница 13: ...lanes of traffic etc Test System With the spray bar installed with proper high co hesive nozzles operate the pump at low pressure to check for nozzle accuracy and leaks in spray bars connections or n...

Страница 14: ...he seat area on nozzle to ensure a tight seal If it is damaged do not use Clogged Nozzles If a nozzle appears clogged immediately disen gage pump Remove any clogged nozzles and replace with new nozzle...

Страница 15: ...sed or stretched Check Dump Valve Water Hose Any hose used for returning dumped water back to the pump or vacuum line must have a large enough diameter and psi strength so that poten tially dangerous...

Страница 16: ...16 NOTES...

Страница 17: ...the selected options Each truck chassis manufacturer provides owners information manuals with their product It is important that you read the manuals care fully and become familiar with the proper ca...

Страница 18: ...ough the interconnecting tank hoses and the flow capacity of tank air vent Overfilling the tank or tanks will cause excessive pressure and damage the tanks It is normal to pause the water flow several...

Страница 19: ...ight will illuminate to con firm the charge water pump is engaged A charge pressure gauge located on the Joystick console must be monitored closely when engaging the charge water pump Once engaged the...

Страница 20: ...number one reason for low charge water pressure Sensors in the charge water system will disengage the 40K clutch and the high pressure pump will shut down if charge water pressure drops below 30 psi...

Страница 21: ...high pressure pump is 40 000 psi 2 758 bar Pressure is monitored by the manual high pressure gauge on the Ultra high pressure pump manifold and a digital gauge on the joystick console in the cab of t...

Страница 22: ...ow pressure side of the manifold of the Ultra high pressure pump then through a set of 3 univalves into the 3 stuffing boxes The plungers then force the water back through the high pressure side of th...

Страница 23: ...Manual Bypass Valve is located on top of the ultra high pressure pump Manifold The operator can open or close the valve to increase or de crease water volume and pressure to the blasting heads while...

Страница 24: ...e same time which could damage components in the Ultra high pressure system The burst rating for each rupture disc is calculated based on 1 25 times the maximum operating pressure of the ultra high pr...

Страница 25: ...ering valve on each line controls the flow of water to the stuffing box The flow of water to the stuffing box should be checked at the beginning of each shift and periodically during operation This sh...

Страница 26: ...t is important to periodically remove the lid to inspect the switch and clean out accumulated debris that can restrict water flow to the pump Information and owner s manuals for the bilge drain system...

Страница 27: ...h 5 Axis Hog Arm The arm is a two stage design allowing the operator to move the entire arm side to side or only move the forward section using controls in the joystick control console The arm can als...

Страница 28: ...djustment during blasting opera tions and enabling the simultaneous removal of parallel markings in the side by side parallel configuration or rapid removal of single continu ous lines with the blasti...

Страница 29: ...blast on a vertical surface while carrying up to 2 36 91 4 cm spray bars The arm was forward engineered to support new products as they are developed well into the future 1 Primary Left and Right Arti...

Страница 30: ...available option that enables the operator to manually move the arm to either side of the truck or any place in between The Hog Arm is mounted to a special chassis plate that rides on heavy duty roll...

Страница 31: ...he spray bars from contacting the pavement A wear brush clamped to each blasting head shroud provides a partial seal between the blast ing head and pavement The wear brush regulates vacuum air flow in...

Страница 32: ...lasting head is also adjust able Special brackets with jam bolts and nuts secure the spray heads and other tubular head plate components in the desired position The blasting heads operate simultaneous...

Страница 33: ...ntation Addi tional adjustments can be made during operation by swiveling the blasting head chassis with the helac cylinder or by moving the arm left or right The tubular head plate is equipped with t...

Страница 34: ...ual for additional information on the operation and maintenance of the castor wheels and blasting head assemblies NOTICE FOR MAXIMUM PRODUCTION STANDOFF DISTANCE SHOULD NEVER BE MORE THAN ONE 1 INCH T...

Страница 35: ...sure it is tight and that the swivel seal is not leaking Any water drip ping from the weep holes just below the swivel nut while the system is pressurized indicates the seal is leaking and must be rep...

Страница 36: ...aint thermal or rubber The thickness of the material being removed The type of road surface Concrete or asphalt Profile requirements per job specifications Hog Technologies offers a variety of spray b...

Страница 37: ...ggressive or least aggressive It will leave the best profile of any of the bars When used in both blasting heads with the same configuration this spray bar will give you the best profile unless the ma...

Страница 38: ...t of each shift as part of the pre operation check or when the operator notices a loss in pres sure or a change in performance while blasting If visual inspection of the nozzle spray pattern indi cate...

Страница 39: ...y dirt or debris in the system can clog nozzle orifice s causing a spike in the high pressure system which will rupture the burst discs and could cause damage to components Notice NOZZLES MUST ALWAYS...

Страница 40: ...maged Nozzle is clogged Nozzle water spray is fanned out Nozzle s ability to hold pressure is suspect Nozzle s hex head is worn excessively from blasting Nozzle threads are damaged When replacing nozz...

Страница 41: ...ount of debris and water exiting the blasting head during waterblasting operations The wear brush is an important safety feature of the blast ing head system It must be adjusted as it wears and replac...

Страница 42: ...be inspected prior to the start of each shift as part of the pre start procedure and replaced if it becomes worn or damaged When installing a dirt shield it should be adjusted finger tight If it is s...

Страница 43: ...e swivel nut A swivel seal and brass backup ring are installed in the fitting at the swivel nut connection creat ing a Ultra High pressure seal while allowing the thru shaft to rotate freely The swive...

Страница 44: ...rom service if A Cover is damaged and reinforcing wires are exposed to rust and corrosion B End fitting shows evidence of damage or is leaking C Hose has been kinked crushed or stretched beyond its mi...

Страница 45: ...generally on location to apply new line markings immediately after existing markings have been removed The efficiency of the vacuum system in removing water and debris from the road sur face after bla...

Страница 46: ...y relief valves called Kunkle valves that open if there is insufficient airflow and consequently excess vacuum in the vacuum sys tem These valves are preset at the factory and equipped with a data tag...

Страница 47: ...eads reducing the efficiency of operation or causing operations to stop completely Debris buildup inside the hoses can be removed by pe riodically tapping the outside walls with a dead blow hammer whi...

Страница 48: ...of this manual for belt tension specifications and instructions for adjusting the drive belt The blower bearing housing is equipped with two grease fittings that must be lubricated daily to achieve ma...

Страница 49: ...vel filter canister Excessive water in the canister can pass through the vacuum filter and cause severe damage to the blower There is a manual drain valve connected to a hose at the bottom of the filt...

Страница 50: ...atable door seal and hydraulic cylinders that open and close the door Water is drained from the tank prior to dumping by two pneumatically activated drain valves in the bottom the tank near the door A...

Страница 51: ...alves open to draw air through the valves and clear debris from the valves and drain fittings The pressurized door seal is supplied compressed air by the truck brake system air supply A solenoid activ...

Страница 52: ...rolled by the dump switch remote control unit The remote dump switch control plugs into the grey junction box located near the waste tank control switch panel on the side of the truck chas sis The rem...

Страница 53: ...made of perforated metal As the water drains out the sides and bottom of the debris bag or through the filter panels it flows into the debris tank where it accumulates until it is drained The debris...

Страница 54: ...n the primary vacuum tube on top of the debris tank must also be cleaned before the tank is lowered to the full down position Also make sure all drain valves are closed before resuming waterblasting o...

Страница 55: ...r tank is provided to the pump by the charge water system Always make sure to close the hydraulic pressure and water ball valves whenever the pump is not being used Use the following procedures to act...

Страница 56: ...clockwise until it seats in the closed position to deactivate the hydraulic motor and pres sure pump 2 Slowly close the ball valve on the clean water supply then briefly pull the trigger on the spray...

Страница 57: ...Hydraulic Connection Hydraulic hoses with quick disconnect fittings are connected from the tool to the truck hydraulic system at the Tool Connection The hydraulic manifold on the truck controls the fl...

Страница 58: ...uring high pressure blasting Outfit the tool operator with proper safety apparel Hard hat safety shield or glasses gloves ear protection etc DANGER The single blasting head on the tractor or any other...

Страница 59: ...he operation of the truck electrical system 50 Amp 30 Amp Main Circuit Breakers The waterblasting electrical system is powered and protected by two heavy duty circuit breakers The breakers are connect...

Страница 60: ...AMP rating printed on the fuse The fuse body is translucent plastic with the fuse element clearly visible making it easy to identify a blown fuse When replacing fuses never replace the blown fuse with...

Страница 61: ...of the console switch functions and other console compo nents and indicator lights PTO Switch Energizes the circuits for other waterblasting function rocker switches on the console switch panel Activ...

Страница 62: ...ompo nents Strobe Light Activates the safety strobe lights during opera tions Debris Tank Drain Activates pneumatic powered drain valves located in the bottom of the debris tank that drain the waste w...

Страница 63: ...that position Joystick Rocker Switch A momentary switch that activates the spray head swivel control Squeeze the joystick trigger then simultaneously press and hold the rocker switch Move the joystick...

Страница 64: ...ch and the waterblasting system when a low charge water pressure low OMSI lubrication pump pressure low gearbox fluid or high fluid temperature condi tion is detected Once the reset button is pressed...

Страница 65: ...y to prevent the thru shaft motors from exceeding safe operating RPM PLC Control Modes The PLC has two control modes Screen Control Automatic Mode and Pot Control Potentiometer Control Manual Mode Scr...

Страница 66: ...ime an arrow button is pressed 3 Press the DOOR Exit button to return to the Main screen Once the maximum RPM has been set spray bar speed is controlled simultaneously using the control UP DOWN button...

Страница 67: ...converts the readings into linear feet or meters The data is recorded and saved until the operator deletes it There are two toggle switches on the front of the meter One toggle switch turns the meter...

Страница 68: ...p Vale ON OFF switch must be in the ON position before the Start button on the joystick control will activate the high pressure water supply to the blastheads When the blastheads reach the end of a pa...

Страница 69: ...he truck chassis It provides high pressure fluid to the hydrau lic powered waterblasting accessory systems Some return fluid is routed through the cooler mounted on the forward side of the clean water...

Страница 70: ...inates and increase the life of the fluid and hydraulic components Low Pressure filters The low pressure filter is a cartridge type filter on the top of the reservoir tank All return fluid passes thro...

Страница 71: ...lic motors have maximum pressure ratings and RPM settings that should never be exceeded Most hydraulic motors are designed to rotate in one direction If a motor needs to be removed for any reason alwa...

Страница 72: ...2 16 Hydrostatic Drive Pump Motor The Hydrostatic Drive pump is bolted to the OMSI gearbox It is activated whenever the truck is in Operation Mode A swash plate controlled by the Forward Reverse swit...

Страница 73: ...on section of this manual Manual Transmissions On trucks with manual transmissions the operator must manually select the proper gear for Oper ate Mode with the shift lever The correct gear is chassis...

Страница 74: ...n automatic transmission there will be a Mode switch in the console switch panel next to the PTO switch When the Mode Switch is ON it sends a signal to the transmission that tells it to select the pro...

Страница 75: ...ion WARNING The truck could surge forward or backward unexpectedly WHEN Operate Mode IS SELECTED IF THE Forward Reverse SWITCH IS IN FORWARD OR REVERSE POSITION AND THE SPEED CONTROL DIAL IS NOT SET T...

Страница 76: ...econds and the low oil high fluid temperature or low fluid pressure condition must be corrected before operations can resume The following conditions will activate the warning lights and disengage the...

Страница 77: ...belt has a different tension specification Addition ally new belts have a different tension specifica tion than used belts drive belts with 20 hours or more Instructions for adjusting the primary dri...

Страница 78: ...orm is folded Always make sure the access plate is open when the platform and ladder are folded and closed when the platform and ladder are down Return the ladder and platform to the stored position w...

Страница 79: ...e waterblasting components is located below the service platform Compressed air is supplied to the fitting by the truck compressed air system The switch is supplied electrical power whenever the truck...

Страница 80: ...80 NOTES...

Страница 81: ...ll waterblasting system components for obvi ous signs of leaks wear and deterioration The inspection should be conducted in an orderly and consistent fashion to ensure all critical points are inspecte...

Страница 82: ...UHP pump drive belt tension and alignment 9 Inspect clean water tanks hoses and fittings for leaks and damage Repair if necessary 10 Check clean water tank level and fill if neces sary 11 Drain debris...

Страница 83: ...ocedure to engage Operate Mode on trucks with an automatic transmis sion 1 Make sure all switches and speed dials are in the OFF position or set at 0 2 Be sure the truck transmission is in N NEU TRAL...

Страница 84: ...hold the clutch pedal and brake pedals Then release the park brake 5 Verify the green Drive Mode LED light is lit 6 Make sure the truck is not moving then turn the console PTO switch ON and listen fo...

Страница 85: ...panel to close the diverter valve and activate high pressure at the spray bars Notice The Dump Valve toggle switch on the skip speed remote control must be ON before the START button will close the di...

Страница 86: ...ow volume 007 011 nozzles are less aggressive and will provide somewhat slower results but provide less potential for damage and a smoother profile Low volume nozzles are well suited for weak pavement...

Страница 87: ...aste water reduce the power of other nozzles and slow production Avoid running the blast head wheels on rumble strips Always adjust the Hog Arm and the castor wheel support arms on the blast heads to...

Страница 88: ...e STOP button on the joystick console to open the diverter valve and stop high pressure water flow to the blast heads Remember never supply high pres sure water to the blast heads when the truck is st...

Страница 89: ...dial This sets the speed the truck will accelerate to when the control is activated Skip Speed The Dump Valve ON OFF switch is always in the ON position unless it is re quired to be turned OFF to shu...

Страница 90: ...es 4 Plug the hand remote control in to the grey receptacle next to the debris tank control switch panel 5 Move the Door Seal switch on the debris tank control panel to the DEFLATE position to complet...

Страница 91: ...mote to open the door to the full open position 9 Move the Door switch to the OFF position to deactivate DOOR CONTROL MODE and acti vate DEBRIS TANK TILT MODE on the remote control Note that DEBRIS T...

Страница 92: ...20 25 psi 1 4 1 7 BAR 20 Inspect the vacuum system filter and drain water from the vacuum canister Clean or replace the filter if necessary 21 Make sure all the drain valves are closed then activate...

Страница 93: ...Water switches OFF 3 Allow the vacuum blower to operate for a couple of minutes after shutting down the high pres sure and charge water pumps to clear waste water from hoses and dry out blower system...

Страница 94: ...BLASTING COMPONENTS TO HELP MINIMIZE EQUIPMENT DAMAGE WHEN AN EMERGENCY SHUTDOWN IS ACTIVATED To stop all operations immediately use one of the following methods 1 Turn off the chassis ignition Turn a...

Страница 95: ...er pump and allow the hoses and pump to completely drain With the valve still open activate the pump briefly to pump out any remaining water about a cupful Then close the valve 7 Pour 2 gallons of ant...

Страница 96: ...the op erator allows the clean water tank to run dry air will be introduced into the charge water system that must be purged before the system will prime and supply clean water to the ultra high press...

Страница 97: ...cedures for these items are described in this section of the manual The frequency for maintaining general maintenance items will vary depending on the quality of the clean water supply the overall con...

Страница 98: ...ints 8 Blast Head Chassis Wheels Casters 3 Vacuum Door Hinges Latches 9 All Blast Head Chassis Hog Arm Safety Pins 4 Ladder Service Platform Hinges Safety Pins 10 Debris Tank Tilt Cylinder Bearings 5...

Страница 99: ...Debris Tank Door Latch 5 Right Side Hydraulic Debris Tank Door Latch 2 Debris Tank Door Hydraulic Open Close Cylinders 6 Vacuum Tube Seal 3 Drain Valve 7 Drive Belt Access Door Hinges Latches 4 Debris...

Страница 100: ...o clear obstacles permanently attached in the pavement such as runway lights or road markers It is the operator s responsibility to evalu ate the pavement surface and permanently attached obstacles th...

Страница 101: ...level the blast heads 8 Before starting operations confirm proper clearance by moving the blast heads slowly over a typical obstacle in the pavement on the current job while monitoring the clearance M...

Страница 102: ...waterblasting system is shut down and the truck is in the service posi tion 2 Close the clean water supply valve and bleed pressure from the charge water system 3 Remove filter canister lid and retai...

Страница 103: ...anister to remove debris and con taminants with clean fresh water 5 Apply a thin coat of anti sieze to the filter retainer bolt threads 6 Insert the new filter and retainer bolt into the filter canist...

Страница 104: ...truck engine must be at idle 2 Open the clean water supply valve and turn ON the charge water pump 3 While the charge pump is running open the discharge valve on the charge water pump for 2 or 3 seco...

Страница 105: ...onto a level surface 2 Turn on the float switch to be sure the heads are flat with the surface 3 Shutdown the waterblasting system and place the truck in service position 4 Note the gap between the bo...

Страница 106: ...eal on the dirt shield and apply a light coating of anti sieze to the thru shaft threads 9 Hold the thru shaft with the 3 4 19 mm wrench install the new dirt shield and hand tighten NOTICE ONLY HAND T...

Страница 107: ...ange in performance while blasting If visual inspection of the nozzle spray pattern indi cates that the pattern is not in the 1 4 quality range as indicated on the Nozzle Quality Guide the nozzle must...

Страница 108: ...truck and the waterblasting system by following the steps in the Start Up Procedure 12 Set the Head Rotation speed dial to 0 then turn the 40K Clutch switch ON to activate the ultra high pressure wate...

Страница 109: ...sc cap as sembly from the base 2 Remove the hold down ring from the base Item 4 in drawing below and set it in a clean safe location 3 Remove the blown rupture disc 4 Insert a new rupture disc into th...

Страница 110: ...ing system is shut down and the truck is in the service position 2 Loosen the swivel nut on the top of the thru shaft motor Be sure to pull the hose and adapter straight up so you don t bend the swive...

Страница 111: ...provides lubrication for the seal and swivel tit at startup when the swivel seal connection and thru shaft are dry 9 Install the brass back up ring onto the swivel tit with the beveled seat facing up...

Страница 112: ...d cleaned before each shift Use the following procedure to drain the can ister and remove and clean the vacuum filter 1 Make sure the waterblasting system is shut down and the truck is in the service...

Страница 113: ...in this section are considered typical for units used in normal operating conditions Units used in extremely dirty conditions high temperatures or other severe duty applications will require more freq...

Страница 114: ...nd proper operation Find and correct the cause of unusual noises or erratic operation Bilge Pump And Automatic Switch Weekly 50 Hours Supply water to the high pressure pump stuff ing box sump and moni...

Страница 115: ...e making sure it is not in contact with sharp edges or near a source of heat that could damage the hose Install anti chaffing or heat deflectors to pro tect the hose if necessary 7 Remove the caps and...

Страница 116: ...eration Repair or replace leaking or malfunctioning components before operating the system Make sure cooling water is flowing to the plunger packing seals when the charge water is activated Constant w...

Страница 117: ...case drain valve when oil draining is com plete The safety plug prevents crankcase oil from draining if the valve is accidentally opened 200 Hour Maintenance Perform all daily and 100 hour maintenanc...

Страница 118: ...there is a significant difference in the oil level while the pump is operating and when it is shutdown It takes 5 to 8 hours for oil in the Crankcase Oil Level Pump Running Crankcase Oil Level Pump Sh...

Страница 119: ...y on the sight gauge When the breather port at the top of sump is used oil is added to the upper sump and it can take up to several hours before the oil will drain to the main sump and the correct oil...

Страница 120: ...he back plate fill port be used to fill the crankcase whenever possible The oil will be added directly to the main oil sump and the level will register immediately on the sight gauge When the breather...

Страница 121: ...E HIGH PRESSURE valve SEALS ARE LEAKING Removing UNI VALVES 1 Make sure the waterblasting system is shut down with the truck in the service position 2 Remove the valves using a 2 lb hammer and 7 8 All...

Страница 122: ...cedure Lapping a valve to the seat creates a unique suc tion valve to UNI VALVE cartridge seat seal If the valve is moved to another cartridge it must be lapped to that seat for a proper seal Disassem...

Страница 123: ...kwise on the valve cartridge seat A 7 Each 180 degree clockwise 180 degree coun terclockwise movement is considered one rotation Complete 5 rotations 8 Rotate valve cartridge A 90 degrees coun tercloc...

Страница 124: ...s perfectly smooth with a consistent color 14 Alternate grit sizes every 3 or 4 cycles until lapping is complete The final cycle should always be completed with 600 grit compound 15 Follow the same pr...

Страница 125: ...haft end of the pump This will provide the clearance required to remove the gland nut and plunger 1 Plunger Coupling Bolts 4 Stuffing Boxes 2 Pony Rods 5 Power Frame 3 Glandnuts 2 1 4 3 1 1 2 3 3 4 4...

Страница 126: ...against the guide bushing 13 Carefully install the plunger packing and gland nut assembly into the stuffing box 14 Hand tighten the gland nut Then insert the Jetstream Tool into the gland nut and hit...

Страница 127: ...stuffing box suddenly by charge water pressure which will be activated in the next step 4 Make sure both water supply valves are open and all personnel are clear of all waterblasting components Activa...

Страница 128: ...Guide Bushing 7 K54117 6 Packing K54118 7 Packing K54119 8 Packing 8 K54097 6 Sleeve K54098 7 Sleeve 5 8 Ultra High Pressure Pump Assembly ITEM PART NUMBER DESCRIPTION 1 K26488 Deflector 2 K51737 Plu...

Страница 129: ...ng 14b K53577 Base 14c K27485 Disc 50 000 psi burst pressure K27486 Disc 56 000 psi burst pressure 14d K53579 Hold down Ring 14e K53580 Cap 15 K27489 Gauge 0 60 000 psi 16 K28091 Anti vibration Gland...

Страница 130: ...d lubricated every 200 hours to keep it operating properly Replace components as required Diverter dump Valve Repair Hydraulically operated 1 Remove diffuser tube 2 with cartridge 3 Remove cartridge 3...

Страница 131: ...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...

Страница 132: ...filter surface Inspect the filter for holes or thin areas that could allow vacuumed water or debris to get into the vacuum blower or silencer Clean secure filtration is necessary to keep your vacuum...

Страница 133: ...e breather and overflow plugs before they are removed This will reduce the possibility of dirt and debris from enter ing the gear case when the fill plugs are removed Checking The Gear Case Oil Level...

Страница 134: ...ten the plug to specifications Refilling the gear case 1 Clean the area around the breather plug on the top of the gear case and remove the plug 2 Make sure the drain valve is closed and the safety pl...

Страница 135: ...a surement into the actual static tension in the belt Begin by entering the belt unit weight belt width and the span length To measure the span vibra tion press the measure button on the meter tap the...

Страница 136: ...the center of the pulleys If it is riding hard on either side of the pulleys the blower will have to be aligned slightly using the mounting plate adjusting bolts Repeat alignment and tension steps un...

Страница 137: ...e the 40K clutch at idle speed for 30 seconds 6 Deactivate the 40K clutch disengage the PTO and shutdown the engine 7 Check that the belt is riding on the center of the pulleys If it is riding hard on...

Страница 138: ...ruck cab The life of the hoses in these areas can be ex tended by rotating the hoses 1200 every 200 hours Vacuum hoses should be inspected daily and replaced as needed Make sure the waterblasting syst...

Страница 139: ...in the service position 3 Remove the vacuum hose from the shroud 4 Remove the spray bar protector 5 Hold the thru shaft with a 3 4 19 mm wrench inserted in the slot at the base of the thru shaft motor...

Страница 140: ...d NOTICE ONLY HAND TIGHTEN THE DIRT SHIELD NEVER USE TOOLS TO TIGHTEN THE DIRT SHIELD If the dirt shield IS TIGHTENED more than hand tight it WILL cause the spray bar to rotate SLOWLY OR not ROTATE AT...

Страница 141: ...is critical in maintaining acceptable oil temperatures in the hydraulic system and must be kept clean to maintain efficiency 600 Hour Inspection and Maintenance Drain hydraulic fluid and flush hydraul...

Страница 142: ...en 5 18 Replacing Hydraulic Filters Before performing any maintenance procedure make sure the waterblasting system is shutdown with the truck in the service position Low Pressure Filter The low pressu...

Страница 143: ...Monitor the hydraulic pressure gauge to verify 0 pressure in the system Changing the high pressure filter element 1 Verify 0 pressure in the system then use a socket wrench to loosen the bolt at the...

Страница 144: ...signs of leakage There are three site glasses the main gearbox oil level on the passenger side near the frame the hydrostatic drive oil level on the passenger side at the hydrostatic planetary and on...

Страница 145: ...wn and winterize the vacuum system 1 Allow the vacuum blower to operate for a couple of minutes after shutting down the high pressure and charge water pumps to clear waste water from hoses and dry out...

Страница 146: ...cold climates Circulating anti freeze through the system is preferred by many operators for trucks operating daily during freezing weather because startup and shutdown procedures are quicker GLYCOL ba...

Страница 147: ...13 Connect an air pressure hose to the drain valve fitting at the charge pump and blow clean air through the open system at low pressure Open and close valves as necessary to increase airflow to spec...

Страница 148: ...gh the system to protect components from freezing This procedure requires 15 to 20 US gallons 58 to 76 liters of antifreeze to properly winterize the waterblasting system Make sure you have enough ant...

Страница 149: ...y bars NOTICE If you are intending to reuse the recovered ANTIFREEZE make sure to test it and make sure the anitfreeze mixture has not become deluted to the point where it will not protect the water s...

Страница 150: ...rform properly This is accomplished using what we call a spanner nut The spanner nut threads onto the thru shaft and rests on top of the thrust bearing By turn ing the spanner nut clockwise we can rai...

Страница 151: ...1 Feeler Gauge 015 1 Small Hammer Supplies Anti Seize Grease Gun and Mobile Poly Rex EM Grease Rags or Paper Towels Brake Cleaner Notice Use anti seize compound on bolt and thru shaft threads and thr...

Страница 152: ...nut at the base of the hose counterclockwise If the hand nut is too tight to turn by hand use the channel lock pliers to free it then continue loosening it by hand Figure 1 and 2 Slot for 3 4 End Wre...

Страница 153: ...he 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 w...

Страница 154: ...wivel tit gland nut by turning it counterclockwise Inspect the swivel tit assembly and set it in a safe clean location Figure 7 and 8 Swivel Tit Assembly Gland Nut Figure 7 Swivel Tit gland nut to be...

Страница 155: ...the slot in the motor base use a 1 1 8 deep well socket to loosen the jam nut two full turns Fig ure 11 While holding the Thru Shaft Remove the Cap Bolts and tighten the Spanner tool as far as possibl...

Страница 156: ...er 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 jam nut it...

Страница 157: ...ell socket and a torque wrench to tighten swivel tit assembly gland nut to 50 ft lbs Figure 14 Step 7 Set The Rpm Sensor To Counter Washer Gap Set the gap between the rpm sensor and the counter washer...

Страница 158: ...d Figure 15 Set the thrust housing cap on top of the thrust housing and carefully press it into the housing Align the bolt holes in the cap to the threaded holes in the thrust housing Apply Anti seize...

Страница 159: ...hand nut on the pressure hose Use a grease gun and apply grease to the thru shaft bearing until grease comes out of the relief hole on the side of the thrust housing Pressure Water Hose Hand Nut Greas...

Страница 160: ...re 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 maximum pressure che...

Страница 161: ...DOUBLE SEAL LOWER HOUSING 30 1 60952 RING INTERNAL RETAINING STEEL 31 4 67048 HELICAL INSERT 3 8 16 SS 32 1 68290 PROXIMITY SWITCH METALIC 33 1 70153 001 FABRICATION WASHER COUNTER THRU SHAFT 34 1 708...

Страница 162: ...SEAL 31 X 52 X 7MM 26 1 60161 SEAL 25 X 52 X 8MM 27 1 60266 001 WASHER BRASS COMPRESSION SWIVEL TIT 375in ID x 625in OD x 025in Thick Rockwell B77 28 1 60950 BEARING ANGULAR CONTACT BALL 20x52x15 MED...

Страница 163: ...62 5 65 2 13 7 00 D C B A A B C D 1 2 3 4 5 6 7 8 8 7 6 5 4 2 1 SIZE B ENGINEERING PART NUMBER REV 20025 001C H DRAWN DG DG CHECKED DG ENG APPR WGT 20 42 LBS SCALE 1 3 SHEET 3 OF 4 DESCRIPTION ASSEMBL...

Страница 164: ...OXIMITY SWITCH METALIC OBJECT W MALE PLUG 3 WIRE 8MM DIA SS 1 5MM Range 33 1 70153 001 FABRICATION WASHER COUNTER THRU SHAFT HOG HEAD 34 1 70837 NUT JAM 3 4 16 SS 35 1 71155 001 WRENCH 3 4 SIZE THRU S...

Страница 165: ...y 1 000 hours or yearly ISO VG 320 Roots Oil High Temp Synthetic changed Dresser Roots Blower Pulley End Bearings Grease Fittings Daily 2 pumps Each Fitting Shell GADUS S2 U1000 2 Grease Howden Roots...

Страница 166: ...166 NOTES...

Страница 167: ...ns slowly Hydraulics not engaged Make sure PTO is engaged to activate hydraulic system Debris packed around thru shaft or spray bar Clean thru shaft or spray bar Hog Head shroud is concave and not con...

Страница 168: ...w or no inlet water pressure Fill tank with water Empty Water Tank Fill tank with water Clogged impeller on pump Disassemble pump face and clean impeller or replace with a new impeller Cracked water l...

Страница 169: ...pect shaft and replace if damaged or cracked on nipple end Vacuum System Vacuum loss or failure Engine and or blower not running Make sure engine is running and vacuum system is activated Vacuum blowe...

Страница 170: ...es open and whistling Relief valve on top of debris tank open Indicates a blockage in vacuum hose between the tank and the Hog Head Locate and remove blockage Relief valve on vacuum filter canister op...

Страница 171: ...171 Troubleshooting UHP POWER FRAME...

Страница 172: ...172 Troubleshooting...

Страница 173: ...173 Appendix 2 Tools Spare Parts...

Страница 174: ...174 Tools Spare Parts...

Страница 175: ...175 Appendix 3 Daily Report Pre Op Checklist 1 877 HOG ROAD WWW STRIPEHOGSUPPORT COM...

Страница 176: ...176 Daily Report Pre Op Checklist 1 877 HOG ROAD WWW STRIPEHOGSUPPORT COM 61...

Страница 177: ...177 Nozzle Configuration Chart Appendix 4 Nozzle Spray Bar Configuration 1 877 HOG ROAD WWW STRIPEHOGSUPPORT COM Hog Technologies SPRAY BAR NOZZLE CONFIGURATION CHARTS FOR ALL STRIPE HOG MODELS...

Страница 178: ...178 Spray Bar Nozzle Configuration 1 877 HOG ROAD WWW STRIPEHOGSUPPORT COM 63 Spray Bar Configuration Charts...

Страница 179: ...179 Spray Bar Nozzle Configuration 1 877 HOG ROAD WWW STRIPEHOGSUPPORT COM 64...

Страница 180: ...180 Spray Bar Nozzle Configuration 1 877 HOG ROAD WWW STRIPEHOGSUPPORT COM 65...

Страница 181: ...181 Spray Bar Nozzle Configuration 1 877 HOG ROAD WWW STRIPEHOGSUPPORT COM 66...

Страница 182: ...182 Spray Bar Nozzle Configuration 1 877 HOG ROAD WWW STRIPEHOGSUPPORT COM 67 Hog Technologies SPRAY BAR NOZZLE CONFIGURATION CHARTS FOR ALL STRIPE HOG MODELS...

Страница 183: ...183 Spray Bar Nozzle Configuration 1 877 HOG ROAD WWW STRIPEHOGSUPPORT COM 68 Nozzle Calculation Sheet...

Страница 184: ...184 NOTES...

Страница 185: ...PSI at which a component will rupture Manual Bypass Valve Located on the ultra high pressure pump and used to manually adjust pressure Cam Lock Connector Installed at the end of each vacuum hose fitt...

Страница 186: ...y the ultra high pressure pump Head Rotation Speed Dial Controls the speed of the blast heads when operating in manual mode Hg Symbol that indicates inches mercury Used to measure vacuum air flow Maxi...

Страница 187: ...ce to protect equipment from over pressurization Shroud The stainless steel circular component that protects the spray head from debris Shutoff Cartridge Component of the diverter valve that shuts off...

Страница 188: ...Ultra High Pressure Pump UHP Pump Piston type positive displacement pump that supplies ultra high water pressure to the spray bars UNI VALVE Separates the high and low pressure water in the ultra high...

Страница 189: ...e Department stands ready to answer your questions and provide technical assistance 24 hours a day 7 days a week Customer Service can also assist you with part orders Always contact Hog Technologies C...

Страница 190: ...pe Hog please 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...

Страница 191: ......

Страница 192: ...Print Date 02 22 2019 Rev 5 3170 SE Slater Street Stuart Florida 34992 001 772 214 1714 P 001 772 223 5461 F www hogtechnologies com...

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