PAVEMASTER ASPHALT SCREEDS Vibrator System Caterpillar

Remove And Install Vibrator Motor

1. Thoroughly clean around the hydraulic hose connections on vibrator motor (1). Mark the hoses for identification and the motor for orientation at reinstallation.

2. Disconnect the hoses from the motor and cap or plug all openings immediately.

3. Loosen the three bolts (2) that hold bushing (3) to the motor sheave (4).

4. Loosen the bolts from motor mount (5), slide the motor toward vibrator shaft far enough to remove the drive belts (6), and remove the bushing, sheave and key from the motor shaft.

5. Remove bolts (7) and remove the motor from the motor mount (5).

NOTE: The following steps are for installation of the vibrator motor.

6. Position vibrator motor (1) with the marks aligned for correct orientation to motor mount (5) and install bolts (7).

7. Position the bushing (3) inside sheave (4), and install the key in the motor shaft keyway. Align the keyways and install the sheave and bushing onto the motor shaft.

NOTE: Be sure that the sheave of the motor is in alignment with the sheave of vibrator shaft before bushing bolts (2) are tightened.

8. Install drive belts (6) on both sheaves, align the sheaves and tighten the three bushing bolts (2) that hold sheave in position on the motor shaft.

9. Slide the motor and motor mount forward until the drive belts are at the correct tension, and tighten the bolts of motor mount (5).

10. Remove all the caps or plugs and install the hydraulic hoses back to the vibrator motor.

Disassemble Vibrator Motor

Start By:

a. remove vibrator motor.

1. Clean outside of unit thoroughly.

2. Remove snap ring (1) from inside the housing assembly (10).

3. Clamp end of shaft in a protected jaw vise with back plate (23) end pointed upward.

4. Remove the six bolts (24) from back plate (23).

5. Use a plastic mallet and tap the back plate (23) to loosen it, then pull the back plate straight out.

6. Remove O-ring (22) from the back plate.

7. Remove the complete piston block assembly.

8. Remove piston assemblies (12), spider (13), and pivot (14) from the piston block assembly.

9. The piston block assembly does not need to be disassembled unless the spring (19) or the internal pins (17) are damaged.

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Do not remove internal snap ring (20) from the piston block unless the procedure that follows is used, or personal injury could result. Spring (19) is highly compressed against snap ring (20), and must be compressed more with bolt and washer arrangement to relieve the force against the snap ring.

The following parts will be needed to disassemble the piston block:

2 flatwashers, 7.94 mm (.312 in) I.D. × 23.81 mm (.938 in) O.D.1 bolt, 5/16-18 NC THD, 73 mm (2.88 in) long1 nut, 5/16-18 NC THD

10. Place one of the flatwashers over the bolt and insert the bolt through the center of the piston block.

11. Place the other flatwasher over the bolt and let it rest on the three pins (17). Install the nut on the bolt by hand.

12. Make sure the first washer does not touch the snap ring, but is centered inside the snap ring on spring (19). Install and tighten the nut on the bolt to compress the spring inside the piston block.

13. When the spring is clear of the snap ring, use a pair of snap ring pliers and remove the internal snap ring (20).

14. Unscrew the nut to release the spring compression, and remove the bolt and two washers. Remove spring (19), washer (18), pin keeper (16), and the three pins (17) from inside the piston block.

15. Remove thrust race (11) from housing.

16. Remove shaft seal (2) from housing.

17. Remove spacer (3) and drive shaft (8) from housing.

18. Remove the two snap rings (4), thrust washers (5), and thrust bearing (6) from drive shaft.

19. Wash all parts thoroughly in a suitable solvent.

20. Examine needle bearings (9) and (21) in the housing (10) and back plate (23). If the needles are free of excessive play and remain in the bearing cage, there is no need to replace the bearing.

21. Inspect both thrust washers (5) and thrust bearing (6). All surfaces should be free of any signs of wear or fretting.

22. Inspect spider (13) and the pivot (14). The conical surfaces should be free of wear and score marks.

23. Inspect pistons (12), making sure the surface of the outside diameter is smooth and free from scoring. The shoes should fit snugly to the pistons. The face of each shoe should be flat and free of scoring and flaking. Do not lap the piston shoes.

24. Inspect the piston block (15) to see that bores are free of scoring. The surface that contacts the back plate should be smooth and free of grooves or metal build-up.

25. Inspect thrust race (11). The surface opposite the chamfered side should not show any signs of scoring.

26. Inspect the flat surface of back plate (23). It must not have excessive scoring or metal build-up.

27. Inspect the drive shaft (8) for fretting in the bearing areas. Check spline area for twisted or broken teeth. If keyed shaft, check for cracked or chipped keyway.

Assemble Vibrator Motor

1. Lubricate all the critical moving parts with clean oil before assembly.

2. Install one snap ring (4) in rear groove of drive shaft (8). Install one thrust washer (5), thrust bearing (6), and second thrust washer (5) on drive shaft (8). Install second snap ring (4) in the front groove on drive shaft.

3. If necessary, replace the needle bearing (9) in housing (10).

4. Install the shaft in the housing assembly (10).

5. Install washer (3) and shaft seal (2), then retain with snap ring (1).

6. Compress pin keeper (16) and install it in the spline I.D. of the piston block (15).

7. Install the three pins (17), washer (18), and spring (19) in piston block. Use the two 7.94 mm (.312 in) I.D. washers and the 5/16 -18 NC THD, 73 mm (2.88 in) long bolt to compress the spring. Retain the spring with snap ring (20) and remove the bolt and the two washers.

8. Install the pivot (14), spider (13), and piston assemblies (12) in the piston block assembly.

9. Lubricate the thrust race (11), and install it in housing assembly (10) with the chamfered edge of race against housing surface.

10. Install the piston block assembly in the housing assembly. The piston shoes must make contact against thrust race (11). Be sure all parts are in their proper position.

11. If necessary, install new needle bearing (21) in back plate (23).

12. Install a new O-ring (22) on the back plate.

13. Position the back plate over the shaft and onto the housing, and install the six bolts (24).

14. Tighten the bolts to a torque of 11 to 13 Nm (15 to 18 lb ft).

15. Fill the motor case with hydraulic oil to prevent dry startup.

NOTE: When any rebuilt motor is placed back into operation, it is important to follow this break-in procedure to prevent damaging the motor.

16. If at all possible, run the motor at operating RPM for 10 minutes with the motor disconnected from the machine. If the motor cannot be run without being connected to the machine, make all the necessary connections and run the motor at its operating RPM for 10 minutes with minimal load.

17. Increase the load on the motor, and then run motor for 3 minutes at operating RPM.

18. Now place the full load on the motor, and run for 3 minutes at operating RPM.

NOTE: If dual rotation motor is used, run motor in both directions during break-in procedure.

19. Slow the engine to an idle, and check for any external system leaks. Inspect all connections to be sure that they are tight. The motor is now ready to be placed back into service.

End By:

a. install vibrator motor.

Remove And Install Single Vibrator Shaft Bearing (Drive Belt End)

Start By:

a. remove universal joint.

1. Loosen the bolts that hold motor mount (1) to the screed, slide the motor and motor mount toward the vibrator shaft, and remove drive belts (2).

2. Loosen the three bolts (3) in the sheave bushing (4) and remove the bushing, sheave (5) and the key from the shaft.

3. Bend the lock plates (6) away and remove the mounting bolts (7) from the bearing assembly.

4. Loosen bearing collar setscrew (8) and slide the bearing assembly off the vibrator shaft (9).

NOTE: The following steps are for installation of the individual vibrator shaft bearing.

5. Slide the new bearing assembly onto the vibrator shaft, install new lock plates (6) and bolt the bearing assembly to the screed frame.

6. Bend the lock plates against the flats of the bearing mounting bolts, and tighten the bearing collar setscrew (8) against the vibrator shaft.

7. Position the bushing (4) inside sheave (5), and install the key in the vibrator shaft keyway. Align the keyways and install the sheave and bushing onto the vibrator shaft.

NOTE: Be sure that the sheave of the vibrator shaft is in alignment with the sheave of motor shaft before bushing bolts (3) are tightened.

8. Install the drive belts on both sheaves, align the sheaves and tighten the three bushing bolts (3) that hold sheave in position on the vibrator shaft.

9. Slide the motor and motor mount forward until the drive belts (2) are at the correct tension, and tighten the bolts to motor mount (1).

End By:

a. install universal joint.

Remove Vibrator Shaft And Bearings

Start By:

a. remove universal joint.

1. Loosen the bolts of motor mount (1), slide the motor and motor mount toward the vibrator shaft, and remove the drive belts (2).

2. Loosen the three bolts (3) in the sheave bushing (4) and remove the bushing, sheave (5) and the key from the vibrator shaft.

3. Bend the lock plates (6) away and remove the mounting bolts from each pillow block bearing assembly (7).

4. Remove vibrator shaft (8) and the two bearings as a unit.

5. Remove the setscrew (9) from each bearing assembly collar and slide the assemblies off the vibrator shaft.

NOTE: If bearings need replacement, the complete pillow block bearing assembly will have to be replaced.

Install Vibrator Shaft And Bearings

1. Slide the bearing assemblies (1) into position on each end of the vibrator shaft (2), and tighten bearing collar setscrews (3) just enough to hold assemblies in place while the shaft is positioned on the screed.

2. Position the shaft and bearings on the screed, install new plate locks (4), and install the bearing mounting bolts. Tighten the bolts and bend the plate locks against the flat of the mounting bolts.

3. Position the bushing (5) inside sheave (6), and install the key in the vibrator shaft keyway. Align the keyways and install the sheave and bushing onto the vibrator shaft.

NOTE: Be sure that the sheave (6) on the vibrator shaft is in alignment with the sheave of motor shaft before bolts of bushing (5) are tightened. Bearing collar setscrews (3) may have to be loosened and vibrator shaft repositioned to get proper alignment.

4. Install the drive belts on both sheaves, align the sheaves and tighten the three bolts that hold bushing (5) and sheave (6) in position on the vibrator shaft. Tighten the bearing collar setscrews (3).

5. Slide the motor and motor mount (7) forward until the drive belts are at the correct tension, then tighten the motor mount bolts (8).

End By:

a. install universal joint.

Remove And Install Universal Joint

Start By:

a. remove handrail assembly.

1. Remove the screed covers.

2. Loosen setscrew (1) that holds the key to one of the vibrator shafts (3), and slide U-joint (4 or 5) off of the vibrator shaft [U-joints slide together on drive shaft (6)]. Remove the key from the shaft.

3. Slide the U-joints apart, and move the U-joint to a workbench.

4. If necessary to remove the drive shaft (6) from U-joint (5), drive the roll pin (7) out and pull the drive shaft out of the U-joint.

NOTE: The following steps are for installation of the universal joint.

5. If drive shaft (6) was removed, align the holes of the drive shaft and U-joint (5), and install the roll pin through the U-joint and shaft.

6. Move the U-joint into position on the installed U-joint at the screed.

7. Rotate the shafts as necessary to get alignment of keyways, install the key (2) and slide the U-joint onto the vibrator shaft (3).

8. Tighten the setscrews (1) against the keys and install the screed covers.

End By:

a. install handrail assembly.

Disassemble Universal Joint (U-Joint)

Start By:

a. remove universal joint.

1. Remove the snap ring at the inside of each end of one of the yokes.

2. Carefully press the bearings out of the yoke and remove this yoke from the journal cross.

3. Repeat this procedure for the other yoke and remove the cross from the yoke.

4. Use a suitable cleaning fluid and allow the parts to remain in the cleaner for some time to loosen up any particles of grease or foreign matter. Remove any burrs or rough spots from machined surfaces.

5. Do not disassemble the needle bearings, but clean with a short stiff brush and blow out with compressed air. Work a small quantity of lubricant (SAE 140 Oil) into each bearing cap and turn the needle bearing on the trunnion (1) to check wear. If worn, replacement is necessary.

6. Never use worn needle bearings with a new journal cross (2), or new needle bearings with a worn journal cross. The new parts will wear more rapidly making another replacement necessary in a short time. Always replace journal cross and the four needle bearing caps as a unit. For the replacement of journals and bearings, a Journal and Bearing Kit is available. The use of the Kit insures having the correct individual parts when required, and saves valuable time.

Assemble Universal Joint (U-Joint)

1. If unnecessary to install a new kit, make sure that four new seals (1) are installed in the journal retainers.

2. Install the cross member inside the yoke holes of one of the yokes.

3. Insert bearings from the outside of yoke and press into place carefully with an arbor press. Make sure the needles remain in their place within the bearing cup until the cross is started into the bearing cavity.

4. Press bearings in only far enough to enable snap rings to be installed in bearing cap groove at the inside of the yoke. Install the snap rings.

5. Install the other two bearings using the same procedure.

6. Lubricate with grease at fitting (2) until grease is visible at all four seals.

End By:

a. install universal joint.