Remove And Install Asphalt Spray System Hydraulic Pump
1. Close the shutoff cock (1) beside the filters located on right side of machine near the rotor drive axle.
2. Mark all the hydraulic lines for identification at installation. Disconnect the four hydraulic lines from the spray system hydraulic pump (2) and immediately plug or cap the openings.
3. Loosen the locknut for belt tightener bolt (3), unscrew the bolt to lower pump mounting bracket (4), and remove drive belts (5) from pump sheave (6).
4. Remove the two setscrews (7) from sheave bushing (8).
5. Apply oil to the threads and point of one of the setscrews, and install the setscrew into the hole (9) that was previously vacant (hole that has threads in the bushing only).
6. Tighten the setscrew until sheave (6) is loosened from bushing (8), and remove the bushing, setscrew, sheave and key (10) from the pump shaft (11).
7. Remove the two pump mounting bolts and remove the hydraulic pump (2) from pump mounting bracket.
NOTE: The following steps are for installation of the spray system hydraulic pump.
8. Put hydraulic pump (2) into position on the mounting bracket (4) and install the two mounting bolts.
9. Insert the bushing (8) into the hub of sheave (6), matching the two unthreaded holes of the bushing with the two threaded holes in the sheave hub.
10. Insert the key (10) in the shaft keyway and slide the sheave (6) and bushing (8) onto the pump shaft (11) over the key.
11. Put oil on the threads and points of both setscrews (7) and install them into the threaded holes (12) of the sheave hub.
12. Tighten the setscrews only enough to hold the sheave on the shaft.
13. Install the three drive belts (5) and align the two sheaves. Tighten the setscrews (7) to lock the sheave (6) and the bushing (8) to the pump shaft.
14. Turn the belt tightener bolt (3) to adjust the belt tension, and tighten the locknut.
15. Fill the pump with clean ATF Type F hydraulic oil through the case drain port at top of pump and install and tighten case drain line (16).
16. Remove the caps or plugs, connect the other hydraulic lines back to the pump, but only tighten the pressure compensator line at the bottom of the pump pressure compensator (14).
17. Check the oil level in the hydraulic tank and, if necessary, fill to the proper level with the recommended oil.
18. Open the hydraulic oil shutoff cock at the filters and, when oil appears at pump inlet connection (15), tighten the inlet connection.
19. Start the engine, set the engine speed at low idle and position rotor transmission lever in Neutral. Activate the spray cylinder to shut the spray nozzles off.
20. With the pump outlet line (13) still loose, partially engage (feather) the rotor clutch lever just enough to rotate the hydraulic pump until air free oil appears at the loosened output line connection.
21. Stop the engine and tighten pump outlet connection (13).
22. Start the engine again and, with the rotor transmission still in the Neutral position, engage the rotor clutch fully.
23. Increase the engine speed to full throttle and allow the asphalt spray hydraulic pump and motor (with the asphalt inlet control valve at the off position) to operate for approximately 2 minutes to purge any air from the system.
24. Disengage the rotor clutch, stop the engine and check the oil level in the hydraulic tank.
Remove And Install Asphalt Spay Pump Assembly
1. Mark the hydraulic lines (1) for identification at installation, disconnect the lines from the asphalt spray system hydraulic motor (2) and immediately plug or cap the openings.
2. Loosen hose clamps (3) and remove the flexible asphalt return line (4) from the pipe nipple.
3. Remove the U-bolt (5) from the support bracket.
4. Remove the flange bolts (6), remove the valves (7) and piping as a unit from the front of the asphalt spray pump assembly (8), and remove the flange gasket.
5. Disconnect the flow meter wiring (9).
6. Remove the flange bolts (10) and the return line support bracket (11) at flexible joint (12).
7. Remove flange bolts (13) and remove pump outlet line (14) and both flange gaskets.
8. Attach a lifting device to the asphalt spray pump assembly (8), remove the mounting bolts and remove the complete pump assembly from the machine.
NOTE: The following steps are for installation of the asphalt spray pump assembly.
9. Attach a lifting device to the asphalt spray pump assembly (8), position the pump assembly on the machine and install the mounting bolts.
10. Align the bottom flange of outlet line (14) with pump flange, position a new gasket between the flanges, and install the flange bolts (13).
11. Align the flange of flexible joint (12) with top flange of outlet line (14), position a new gasket between the flanges and install and hand tighten the two flange bolts (10) closest to the engine.
12. Position return line support bracket (11) to the flange, install the other two flange bolts (10) and tighten all the bolts.
13. Position the piping and valves (7) and a new gasket at the front of pump assembly (8), and install the flange bolts (6).
14. Install the U-bolt (5) to the support bracket for the valves (7).
15. Install the flexible return line (4) back onto the pipe nipple and tighten the hose clamps (3).
16. Connect the wiring back to the flow meter.
17. Remove the caps or plugs and connect the hydraulic lines (1) back to the spray system hydraulic motor (2).
Remove And Install Asphalt Spray Bar Assembly
1. Remove mounting bolt (1) at head end of spray bar cylinder (2).
2. Remove mounting bolt (3) that holds rod end of cylinder (2) and valve shutoff rod (4) to the nozzle valve actuator bar (5), remove cylinder and lay it out of the way on top of rotor hood.
3. Disconnect other end of shutoff rod (4) at the valve lever, and remove the rod.
4. Remove the bolts for the spray bar flexible return line flange (6) on the right side of the machine, and the bolts for the spray bar flexible inlet line flange on the left side of the machine.
5. Fasten a lifting device to each side of the asphalt spray bar assembly (7) and remove the mounting bolts at each end of the spray bar.
6. Carefully lift the spray bar until the nozzles (8) are out of the slots in the rotor hood, then remove the spray bar from the machine.
NOTE: The following steps are for installation of the asphalt spray bar assembly.
7. Carefully position the spray bar assembly (7) over the rotor hood until the nozzles (8) are in the slots in the rotor hood, then install the mounting bolts at each end of the spray bar.
8. Install a new gasket and the bolts for the flexible spray bar inlet line flange (9) on the left side of the machine, and a new gasket and the bolts for the flexible spray bar return line flange (6) on the right side of the machine.
9. Position end of shutoff rod (4) back to spray bar return line valve lever (10), and install the pin.
10. Position spray bar cylinder (2) and install mounting bolt (1) at head end of the cylinder.
11. Position rod end of cylinder (2) over the nozzle valve actuator bar (5), align valve shutoff rod (4) and install mounting bolt (3).
Disassemble And Assemble Asphalt Spray Bar Assembly
Start By:
a. remove asphalt spray bar assembly
1. Unscrew the flexible lines (1) at each end of the asphalt spray bar.
2. Remove the asphalt spray return valve (2).
3. Loosen the two capscrews (3) in each nozzle valve lever (4) and remove the valve levers.
4. Remove the two bolts (5) and remove retainer bar (6).
5. Remove the nozzle valve actuator bar (7) from the spray bar (8).
6. Remove the nozzles from the nozzles valves (9).
7. Remove the nozzle valves (9) from the spray bar.
NOTE: The following steps are for assembly of the asphalt spray bar assembly.
8. Install the nozzle valves (9) in the spray bar (8).
9. Install the nozzles in the nozzles valves (9).
10. Put the nozzle valve actuator bar (7) into position on the spray bar, and install retainer bar (6).
NOTE: The slack adjuster bolts may have to be adjusted to maintain the correct play between actuator bar and the guides on the spray bar.
11. To adjust actuator bar (7), loosen the locknuts of slack adjuster bolts (10) and turn the bolts until actuator bar can be moved back and forth without any binding between the actuator bar and guides (11), then tighten the locknuts.
12. Position each nozzle valve lever (4) with one end on nozzle valve (9) and the slot of the other end over pin (12) of actuator bar (7), and tighten the two capscrews (3).
13. Install the asphalt spray return valve (2) into the return end of asphalt spray bar.
14. Screw the return flexible spray line (1) into spray return valve (2) and the inlet flexible spray line into other end of the asphalt spray bar.
End By:
a. install asphalt spray bar assembly