1. Mainframe
- a. Fuel Tank
- b. Hydraulic Oil Tanks
- c. Water Tanks
- b. Hydraulic Oil Tanks
2. Legs
3. Tracks
4. Conveyors
5. Primary Power Unit (Engine B)
6. Cutter
7. Cutter Power Unit (Engine A)
8. Consoles and Controls
9. Elevation Sensors
10. Optional Cross Slope Sensor
Mainframe
The mainframe is an all-welded, heavy plate assembly with box-type structural support beams. Decking is grid plate with grated inspection panels. The mainframe rides on three hydraulic cylinders which fit inside the legs and are used to adjust the elevation of the mainframe and the attached cutter.
Water Tanks
The four interconnected water tanks have a total capacity of about 1000 gallons. Water is drawn equally from all the tanks by the water spray system pump or by the optional high pressure pump that supplies the water for machine cleanup. An external 3-inch male, automatic check type, quick connect coupling on each side of the machine provides the capability of filling the tanks from ground level. The tanks can also be filled through uncapped top fill openings.
Fuel Tank
FUEL SHUTOFF VALVES
The 400 gallon fuel tank supplies fuel to both engines from its location just in front of the cutter engine (engine A). The tank fill pipe has a cap and an internal strainer to strain fuel being added. Three manual shutoff valves are located at the bottom of the tank, one valve in the supply line to each engine and one valve in the fuel return line from both engines. A sight gauge on the side of the tank provides a continuous indication of the fuel supply.
Hydraulic Oil Tanks
There are two tanks that hold hydraulic oil, a 44 gallon main tank and a 12 gallon replenishing tank. Oil for the hydraulic pumps is drawn from the main tank. If the main tank oil level gets low, oil is transferred to the main tank from the replenishing tank by using the hand operated pump mounted on the main tank. The oil passes through the 10 micron system filters before it enters the main tank.
The main hydraulic oil tank has a sight gauge so that the oil level can easily be checked. A 10 micron breather filter mounted on the tank filters any air drawn into the tank as the tank "breathes" because of atmospheric and/or system temperature changes. The breather filter has a valve in it that will allow the tank pressure to build up to a maximum of 5 PSI. This pressure should be relieved by opening the bleed valve before breaking any connection on the tank or in the systems.
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THIS IS A PRESSURIZED HYDRAULIC SYSTEM. RELIEVE THE PRESSURE BEFORE WORKING ON THE SYSTEM. |
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The replenishing tank has a screen in the fill pipe that should always be in place when adding hydraulic oil. Only ATF Type F hydraulic oil should be used. A breather in the top of the replenishing tank will prevent dust and other large particles from entering the tank as it "breathes".
Legs
The legs each consist of a leg yoke, a leg barrel, a leg cap and a hydraulic cylinder. The front leg assembly also has a steering plate and a drive sleeve to provide for steering of the front track. The upper portion of each leg barrel is an integral part of the mainframe. The lower portion is a separate piece that bolts to the upper portion.
On the rear legs, the leg yoke fits into the lower portion of the leg barrel and the elevation cylinder is installed inside the leg yoke and leg barrel. The cylinder is connected to the bottom of the leg yoke and to the leg cap. When the cylinder extends or retracts, it moves the leg barrel up or down the leg yoke, thus raising or lowering the mainframe.
The front leg yoke fits into the drive sleeve which rides in the lower portion of the leg barrel, and the steering plate bolts to the drive sleeve. When the steering cylinders move the steering plate, the plate turns the leg yoke and drive sleeve inside the lower leg barrel. When the elevation cylinder extends or retracts, it moves the leg barrel steering plate, and drive sleeve up or down the leg yoke, thus raising or lowering the mainframe.
Tracks
Each track has a variable positive displacement hydraulic motor that drives a 98:1 planetary gear reducer on which the motor is mounted. A drive sprocket bolted to the reducer turns with the reducer and meshes with the track chain on which the track pads (shoes) are mounted. The drive sprocket pulls the machine forward over the portion of the track chain on the ground. The weight of the machine is distributed over the portion of the track chain on the ground by the lower (track) rollers. The upper (carrier) rollers support the upper portion of the track.
The slack in the track chain is controlled by an adjustable tensioner that presses the idler sprocket forward against the track chain. The tensioner also acts as a relief to prevent damage whenever foreign material is caught between the track chain and a sprocket or roller.
The front track has an emergency and parking brake between the motor and the planetary gear reducer. The brake is engaged by springs inside the brake case and disengaged by control system (auxiliary) hydraulic pressure. The brake will automatically engage anytime the control system pressure falls below 180 PSI.
Reclaiming System (Conveyors)
The reclaiming system consists of two separate belt conveyors; a lower or collecting conveyor and an upper or loading conveyor. Material loosened from the roadway by the cutter is funneled onto the lower conveyor which carries the material back under the machine and empties it onto the upper conveyor. The upper conveyor then carries the material up and dumps it. The discharge end of the upper conveyor can be positioned anywhere within an arc of 90°, 45° each side of center. The discharge height of the upper conveyor is 12 1/2 feet at a 30 degree angle of incline. This provides a clearance under the head pulley of approximately 12 feet.
The conveyors are powered by the dual-section conveyor pump that is driven by the primary engine (engine B) through the pump drive gearbox. The front section of the pump powers the two hydraulic motors that turn the upper conveyor head pulley. The rear section powers a single hydraulic motor that turns the lower conveyor head pulley.
The upper conveyor is mounted on a pivot frame that rides in two self aligning bearings on the mainframe. One hydraulic cylinder rotates the pivot frame and the attached conveyor in the bearings to swing the discharge end of the conveyor. A second hydraulic cylinder is mounted between the pivot frame and a spreader frame connected to the conveyor. This cylinder raises or lowers the discharge end of the conveyor.
The lower conveyor is suspended from two turnbuckles at the rear, and from a support assembly at the front. A hydraulic cylinder mounted between the support assembly and mainframe will raise the front of the conveyor to disengage the mounting hooks on the conveyor from the moldboard. This makes removal of the cutter easier.
Primary Power Unit (Engine B)
A turbocharged AVSpare 3208 diesel engine supplies the power for machine propulsion (track drive), to drive the conveyors (reclaiming system) and for the machine controls. A pump drive gearbox mounted on the rear of the engine transmits the power from the engine to four hydraulic pumps tandem mounted on the gearbox:
- 1. A track drive pump which supplies the pressurized hydraulic oil to drive the three track motors.
- 2. A control system (auxiliary) pump mounted on the rear of the track drive pump.
- 3. A dual-section pump that provides the hydraulic oil to drive the conveyor motors.
- 2. A control system (auxiliary) pump mounted on the rear of the track drive pump.
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NEVER START ENGINE A (AVSpare 3412) WITH THE CUTTER CLUTCH ENGAGED. ALWAYS START ENGINE B (AVSpare 3208) BEFORE STARTING ENGINE A (AVSpare 3412) AND ALWAYS CHECK THAT THE AIR BOX COVER IS CLOSED BEFORE STARTING ENGINE B. COOLING AIR WILL NOT FLOW THROUGH THE RADIATORS UNLESS ENGINE B IS RUNNING AND THE AIR BOX COVER IS CLOSED. THE HYDRAULIC MACHINE CONTROLS WILL NOT OPERATE UNLESS ENGINE B IS RUNNING. |
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ALWAYS SHUT ENGINE A DOWN BEFORE SHUTTING ENGINE B DOWN.
The 60-inch fan that provides the flow of cooling air through the hydraulic oil cooler and both engine radiators is belt driven by the primary engine.
The primary engine also drives an air compressor that provides the compressed air for operation of the air hammer used to change cutter bits, and for operation of the cutter clutch in the power take-off (see page 2-35).
The engine is protected against dust and other foreign material by a dry type induction air cleaner that has a centrifugal pre-cleaner, a main filter element and a safety filter element. As the induction air passes through the pre-cleaner fins, it is given a cyclonic twist that separates most of the dust from the air and sends it into the dust cup where it is collected. Any particles not removed by the pre-cleaner are trapped by the main filter element. The safety filter element protects the engine if the main element is damaged, and a service indicator shows when the main element requires service.
Cutter
The cutter assembly includes the cutter, the housing and the moldboard.
The cutter is a cylinder (drum) with 264 replaceable tungsten carbide bits (teeth) mounted in holders welded to the cutter flighting. The auger-type cutter flighting is welded to the drum. The bits break the material loose and the flighting channels the loose material onto the lower conveyor. The cutter drum is filled 3/4 full with a 50% solution of water and ethylene glycol antifreeze that cools the planetary gear reducers.
Power from the cutter drive engine is transferred to the cutter by means of drive shafts and belt drives (see page 2-14) that turn the input shafts of two 24.96 to 1 planetary gear reducers. One planetary gear reducer fits inside each end of the cutter drum and bolts to the cutter drum. When the planetary gear reducers rotate, the cutter rotates.
The cutter housing, which is pin-connected to the mainframe, supports the cutter and encloses the cutter. Nozzles, in the top of the door, spray water into the housing to control the dust created by the cutting operation. A moldboard at the rear of the housing prevents material loosened by the cutter from moving back under the machine. Two hydraulic cylinders connect the moldboard to the housing and provide the moldboard with 3 inches of vertical "float". Hydraulic pressure in both sides of the cylinders is vented to the hydraulic oil tank when the moldboard control is at "Float", so the weight of the moldboard keeps the moldboard in contact with the freshly cut surface at all times. As the replaceable moldboard blade wears, mechanical stops must be adjusted to allow the moldboard to move further downward.
A hydraulically operated full width door on the front of the cutter housing provides easy access to the cutter for inspection and/or replacement of cutter bits. A hydraulic motor can be used to slowly turn the cutter so that the bits can be reached. Control system pressure is used for the hydraulic motor so the cutter engine (engine A) need not be running.
An air operated hammer and a punch are supplied with each machine to facilitate changing the bits when they are worn or broken. The bits should be replaced as a group so that all bits are approximately the same length. A single bit longer than the surrounding bits may break the bit holder when the bit hits the concrete. Uneven bits may also cause a surging in the machine travel.
A manually operated bit puller is also supplied with each machine so the bits can be changed without air pressure if necessary.
Cutter Power Unit (Engine A)
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ALWAYS START ENGINE B (AVSpare 3208) BEFORE STARTING ENGINE A (AVSpare 3412) AND ALWAYS CHECK THAT THE AIR BOX COVER IS CLOSED BEFORE STARTING ENGINE B. COOLING AIR WILL NOT FLOW THROUGH THE RADIATORS UNLESS ENGINE B IS RUNNING AND THE AIR BOX COVER IS CLOSED. THE HYDRAULIC MACHINE CONTROLS WILL NOT OPERATE UNLESS ENGINE B IS RUNNING. |
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The cutter is powered by a AVSpare 3412 diesel engine that has a power take-off unit mounted on the rear (right side). The power take-off includes an air operated clutch to engage or disengage the cutter. The output shaft of the power take-off turns two drive shafts through a belt drive arrangement. Each drive shaft turns a planetary gear reducer, one reducer inside each end of the cutter drum, by means of another belt drive.
When the cutter control valve on the front control panel is moved to "In", air from the compressed air system is sent to a hose connected to the power take-off output shaft. The compressed air travels through an axial chamber in the output shaft to three radial chambers, through the radial chambers and three short connected hoses to an actuating member in the clutch. The air pressure inside the actuating member, which is a full-circle neoprene tube, causes the actuating member to expand and apply pressure to the friction faces of the clutch. This engages the clutch.
When the cutter control valve is moved to "Out", it stops the air from the compressed air system and vents the clutch actuating member to the atmosphere. This relieves the pressure applied to the clutch friction faces by the actuating member which allows releasing springs to disengage the clutch. The releasing springs will disengage the clutch anytime air pressure is lost in the actuating member.
The engine is protected against dust and other foreign material by two dry type induction air cleaners which each have a pre-cleaner, a main filter element and a safety filter element. As the induction air passes through the pre-cleaner, most of the dust is separated out of the air and falls to the bottom of the pre-cleaner. Any particles not removed by the pre-cleaner are trapped by the main filter element. The safety element protects the engine if the main element is damaged. A service indicator on each air cleaner shows when the main element requires service.
NOTE: NEVER OPERATE THE ENGINE WITHOUT BOTH ELEMENTS IN PLACE IN BOTH AIR CLEANERS.
Consoles And Controls
The ER-1000B has three consoles grouped around the operator's seat; a forward console in front of the seat and a console on each side of the seat. These three consoles contain all the controls and gauges necessary for operation of the machine. Other controls used for servicing the machine are located where they are convenient when the specific service is being performed. See Section 3, Controls and Instruments, for a description of the function of each control and instrument.