PNEUMATICS CONTENTS HST-TAMPER

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Christopher Fitzgerald
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1 CONTENTS Tamper Pneumatic Component Locations...2 Manually Releasing Air Brakes... 3 Releasing Air Pressure... 4 Removing Water from Air Tanks... 4 Adjusting Air Compressor Governor... 4 Check/Replace Air Dryer Desiccant... 5 Adjust Brake Shoes... 6 Transmission Shift Air Cylinders 6 5 Station Pneumatic Manifold 6 Trouble Shooting Guide

2 Tamper 2

3 Manually releasing parking brakes to allow for towing. There is a parking/service brake chamber (Figure 1) at each wheel. The parking brakes are spring actuated and air released by a push/pull button valve (Figure 2). Pulling knob out releases the parking brakes. The service brakes are actuated only with air pressure controlled by a hand lever (Figure 2). As the service brake control is pushed forward the brakes will apply. If there is an engine failure and air tanks are depressurized or there is a malfunction in the pneumatic system use one of two methods listed to release the spring applied parking brakes to allow for towing. To manually release the spring applied brakes if another source of air pressure is available. 1. With the machine on level track, chock ALL wheels to prevent movement. 2. Remove the drive shafts. 3. Use another machine s air compressor to pressurize the air tanks, pull the parking brake (black knob) located on the left arm console to pressurize the four brake chambers to release brakes shoes from wheels. 4. Remove release tool assembly (T head screw, washer, and ½ nut) from side pocket of the center brake valve chamber (figure 1). 5. Remove the tethered dust plug from the release tool key hole in the center of the spring brake chamber. 6. Insert release tool through key hole in chamber into the spring piston. 7. Turn release tool ¼ turn clockwise. 8. Pull on release tool to ensure stud cross pin is properly seated in the spring piston. 9. Assemble the release washer and nut on the release stud, finger tight only. 10. Turn release tool nut clockwise (CW) with a hand wrench until the brake shoes are off the wheel. 11. After the machine has been towed, return the T Head screws, washers, and nuts back to their storage location (Figure 1). 12. Reinstall the tethered dust plug back into the release tool key hole in the center of the spring brake chamber. DUST PLUG MUST BE INSTALLED! The plug prevents damage caused by moisture and contamination of brake chamber components. 14. Install drive shafts. Procedure for manually releasing the spring applied brakes if no air pressure is available. 1. With the machine on level track, chock ALL wheels to prevent movement. 2. Remove the drive shafts. 3. Remove release tool assembly (T head screw, washer, and ½ nut) from side pocket of the center brake valve chamber (figure 1). 4. Remove the tethered dust plug from the release tool key hole in the center of the spring brake chamber. 5. Insert release tool through key hole in chamber into the spring piston. 6. Turn release tool ¼ turn clockwise. 7. Pull on release tool to ensure stud cross pin is properly seated in the spring piston. 8. Assemble the release washer and nut on the release stud, finger tight only. 9. Turn release tool nut clockwise (CW) with a hand wrench until the brake shoes are off the wheel. NOTE: Do not over torque the release tool assembly. Over torquing release tool can cause spring piston damage. NOTE: Do not over torque the release tool assembly. Over torquing release tool can cause spring piston damage. 3

EXERCISE CAUTION WHEN TOWING MACHINERY & ALLOW EXTRA STOPPING DISTANCE WHEN TOWING THIS MACHINE. REDUCE SPEED ACCORDINGLY AS DICTATED BY WEATHER OR TRACK CONDITIONS.

After the machine has been towed, return the T Head screws, washers, and nuts back to their storage location (Figure 1). 11.

The plug prevents damage caused by moisture and contamination of brake chamber components. 12. Install drive shafts.

4 EXERCISE CAUTION WHEN TOWING MACHINERY & ALLOW EXTRA STOPPING DISTANCE WHEN TOWING THIS MACHINE. REDUCE SPEED ACCORDINGLY AS DICTATED BY WEATHER OR TRACK CONDITIONS. Parking Brake Push/Pull Valve Knob Service Brake Control Lever Tamper 10. After the machine has been towed, return the T Head screws, washers, and nuts back to their storage location (Figure 1). 11. Reinstall the tethered dust plug back into the release tool key hole in the center of the spring brake chamber. DUST PLUG MUST BE INSTALLED! The plug prevents damage caused by moisture and contamination of brake chamber components. 12. Install drive shafts. Pneumatic Instructions Figure 2 Figure 1 T Head Screw, Washer, & Nut Ensure that all air pressure is released from the air system before opening any fittings, hose connection, or component on the air horn / brake system. Air Parking/Service Brake Chamber Releasing Air Pressure To release air from the air system, turn off engine, and pull lanyard going to air tank (Figure 2) located on the right side (back) of machine. Figure 2 Air Release Lanyard 4

Adjusting Air Compressor Governor Air Compressor Air Compressor Governor Figure 3 When checking or adjusting the air compressor governor pressure setting use an accurate test gauge (0-200 psi) that

5 Removing Water From Air System To remove water from air system, turn off engine, and pull lanyard going to air tank (Figure 2). As air is released, observe for water and that it stops appearing in a mist before air tank is empty. Adjusting Air Compressor Governor Air Compressor Air Compressor Governor Figure 3 When checking or adjusting the air compressor governor pressure setting use an accurate test gauge (0-200 psi) that is registering accurately in 5 psi increments. System air pressure is set at 120 psi. If the air compressor governor pressure setting needs to be adjusted: Figure 4 1. Air compressor & governor are on the right side of the engine (Figure 3). 2. Remove the protective cap (Figure 4) 3. Loosen the adjusting screw lock nut (Figure 6). 4. If pressure setting is below 120 PSI, turn the adjusting screw counterclockwise ¼ of a turn and recheck pressure by releasing air at the air tank until pressure on gauges begins to rise back up, adjust further if needed. 5. If pressure setting is above 120 PSI, turn the adjusting screw clockwise ¼ of a turn and recheck pressure by releasing air at the air Be careful not to over adjust the air compressor governor pressure setting. Each ¼ turn of the adjusting screw raises or lowers the pressure setting approximately 4 psi. 6. When proper adjustment is obtained, tighten the adjustment screw locknut, and replace the protective cap. Note: The pressure range between cut-in and cut-out is not adjustable. Adjusting Screw / Lock Nut Check / Replace Air Dryer Desiccant The desiccant media in the air drier removes water from the compressed air. Normally the desiccant will last a year and should be changed then. If excessive water or oil is collecting in the air tank(s), the desiccant cartridge should be replaced. 1. Drain air system (Figure 2) 2. Using a strap wrench, turn the desiccant cartridge counterclockwise, remove and discard (Figure 5). 3. Remove and discard o-ring from the adapter stud. NOTE: If there is excessive oil in the check valve port, compressor may require servicing. 5

4. Clean top surface of adapter plate and treaded stud. 5. Install new o-ring on adapter stud. 6. Apply a coat of grease on the new desiccant cartridge gasket surface. 7.

Figure 6 Tamper Desiccant Cartridge Brake Adjustment Transmission Shift Pneumatic Cylinders & 5 Station Air Manifold (Figure 7) shows 2 air cylinders that are extended in their relaxed state (not

6 4. Clean top surface of adapter plate and treaded stud. 5. Install new o-ring on adapter stud. 6. Apply a coat of grease on the new desiccant cartridge gasket surface. 7. Thread new cartridge onto adapter stud and turn clockwise. When gasket contacts adapter plate, tighten cartridge ½ turn. 8. DO NOT OVERTIGHTEN! Figure 6 Tamper Desiccant Cartridge Brake Adjustment Transmission Shift Pneumatic Cylinders & 5 Station Air Manifold (Figure 7) shows 2 air cylinders that are extended in their relaxed state (not pressurized) and their rod clevis are attached to transmission shift levers. Figure 5 Cylinder # 1 is normally extended 2 Transmission Shift Levers Adjusting Brake Shoes As brake shoes wear, the brake cylinder stroke increases and requires more air volume. In high temperature / humidity / elevation applications, the air compressor may not provide adequate air volume with frequent brake use. To adjust worn brake shoes on both parking/service and service brakes: 1. Block wheels 2. Start engine and charge air tanks to operating pressure 3. Release Parking Brake 4. Loosen the 2 jam nuts on brake apply arm adjuster (Figure 8). 5. Loosen both nuts. 6. From brake chamber output screw, turn the both nuts counterclockwise (CCW) to decrease clearance between shoe and wheel. 7. Adjust turn buckle so that the retracted brake shoes will clear (1/4 to 3/8 ) and do not drag on the wheel. 8. Tighten outside nut to lock in place and test brakes for proper function. (Figure 8) Shows the 2 air cylinders that are retracted in their relaxed state (not pressurized) and their rod clevis are attached to fixed mounts.. Cylinder # 2 is normally extended Figure 8 Figure 7 Cylinder # 3 is normally retracted Cylinder # 4 is normally retracted Valve # 1 (Figure 9) is energized by the Work/Travel Switch in WORK position (Figure 10) that sends air to cylinder # 1 (retracts) Figure 13. 6

Valve # 1 Work/Travel Switch in WORK position allows air to flow to cylinder # 1 Valve # 2 Gear Select Switch in 1 st or 2 nd position allows air to flow to cylinder # 3 Figure 9 Figure 12 Figure 13

7 Valve # 1 Work/Travel Switch in WORK position allows air to flow to cylinder # 1 Valve # 2 Gear Select Switch in 1 st or 2 nd position allows air to flow to cylinder # 3 Figure 9 Figure 12 Figure 13 Work/Travel Switch Gear Select Switch Cylinder # 3 EXTENDS when Gear Select Switch is in either 1 st or 2nd Valve # 3 (Figure 14) is energized by (a) Work/Travel Switch in the WORK position or (b) Gear Select Switch in the 1 st position (Figure 10) that sends air to cylinder # 2 (retracts) Figure 15. Figure 10 Cylinder # 1 RETRACTS when Work/Travel Switch is in Work position Valve # 3 Work/Travel Switch in the WORK position or (b) Gear Select Switch in the 1 st position that sends air to cylinder #2 Figure 11 Valve # 2 (Figure 12) is energized by the Gear Select Switch when in either 1 st or 2 nd position (Figure 10) that sends air to cylinder # 3 (extends) Figure 13. Figure 14 7

Tamper Cylinder # 2 Retracts Work/Travel Switch in the WORK position or Gear Select Switch in the 1 st Valve # 5 Work Head Lock Switch in the ON iti Figure 15 Valve # 4

Valve # 4 Gear Select Switch in 2 nd position this allows Figure 18 Figure 19 Figure 16 Work Head Lock Switch Cylinder # 4 Extends when Gear Select Switch in 2 nd position

8 Tamper Cylinder # 2 Retracts Work/Travel Switch in the WORK position or Gear Select Switch in the 1 st Valve # 5 Work Head Lock Switch in the ON iti Figure 15 Valve # 4 (Figure 16) is energized by the Gear Select Switch in the 2 nd position (Figure 10) that sends air to cylinder # 4 (extends) figure 17. Valve # 4 Gear Select Switch in 2 nd position this allows Figure 18 Figure 19 Figure 16 Work Head Lock Switch Cylinder # 4 Extends when Gear Select Switch in 2 nd position Left Work Head Lock Up Cylinder Figure 17 Figure 20 Valve # 5 (Figure 18) is energized by the Work Head Lock Up Switch in the ON position (Figure 19) that s sends air to the 2 work head lock up cylinders (Figure 20). 8

9 PNEUMATIC TROUBLESHOOTING GUIDE PROBLEM POSSIBLE CAUSE SOLUTION Air Compressor does not develop pressure in air tanks (120 PSI) 1. Leak in Air System a. Loose fitting at component b. Broken or disconnected hose 2. Engine to air Compressor drive gear Damaged 3. Drain valve on air tank stuck open 4. Air compressor governor faulty or not adjusted properly 5. Air tank relief valve (safety valve) stuck open 1. Tighten fittings Repair or replace Hose 2. Inspect, repair or replace 3. Remove debris from valve orifice, repair or replace 4. Repair or replace 5. Remove debris from valve orifice, repair or replace 6. Air dryer (option) leaking air at exhaust port 6. Inspect unloader valve in air dryer, repair or replace Air pressure too high in air tanks 1. Air compressor governor faulty or not adjusted properly Repair or replace Water in air system Note: Drain air tanks at the end of a workday, more often in high humidity or after rain 1. Air dryer (option) element dirty 2. Air tanks not regularly drained 1. Replace air filter element 2. Drain air tanks Oil in Air system 1. Air dryer element dirty 2. Air tanks not regularly drained 3. Air compressor leaking oil internally 1. Replace 2. Drain air tanks daily 3. Inspect, repair or replace 9

10 Tamper PROBLEM POSSIBLE CAUSE SOLUTION Travel brakes sluggish on application or release Check brake shoe clearance Oil on shoes Check chamber return spring Adjust linkage replace shoes Clean shoes or replace Replace brake chamber assembly A parking brake chamber drags or wont release Improper Adjustment of linkage Restriction or broken air line to brake chamber Air pressure to low Broken return spring/ broken power spring in brake chamber Adjust linkage Inspect, repair or replace. Check air pressure Replace chamber Travel brakes not engaging Quick release valve not shifting Air apply valve not working Check to see if parking brake is disengaged Check parking brake switch Check brake shuttle valve (sends air to release parking brakes or to apply service brakes) Check linkage adjustment Inspect, repair, or replace valve Inspect, repair, or replace valve Inspect, repair, or replace Inspect for stuck shuttle and or leakage, repair, or replace. Adjust linkage Work Head Up/Down Air Lock Cylinder not Working Work Head Up/Down Lock air valve not shifting: a. Check electrical power at valve b. Check for system air pressure c. Install a gage in hose to 4 section pneumatic valve and check for system air pressure. d. Broom / Plow air valve spool stuck a. Inspect, repair, or replace wire or switch b. Make sure Air compressor / air system is ok (120 PSI). c. Look for problem in hose or connection d. Inspect valve, repair or replace. 10

11 PROBLEM POSSIBLE CAUSE SOLUTION Work Head Up/Down Air Lock Cylinder not Working (Continued) Broom / Plow speed air cylinder does not shift linkage: a. Check for air pressure at hose fitting from air lock valve b. Cylinder leaking internally c. Cylinder rod/piston locked in a position d. Check for broken attachment to lock pin a. If none, see above air valve problems b. Take apart cylinder, inspect, repair, or replace c. Take apart cylinder, inspect, repair, or replace. d. Replace/repair Transmission shift cylinder not Working Note: There are two dual acting air cylinders used to shift the transmission. Check for debris or other obstruction at shift cylinder on top of transmission Transmission air valve not shifting: a. Check electrical power at valve b. Check for system air pressure c. Install a gage in hose to 4 section pneumatic valve and check for system air pressure. d. Transmission air valve spool stuck Remove debris / lube linkage a. Inspect, repair, or replace wire or switch b. Make sure Air compressor / air system is ok (110 PSI). c. Look for problem in hose or connection d. Inspect valve, repair or replace. Safety Valve pop s off excessively Check system pressure Safety valve set to 150 psi. If leaking at system pressure (110 psi) and below Popping off at or below system pressure because of debris in valve Inspect, repair, or replace valve Inspect, repair, or replace safety valve 11

PRESSURE CABINETS PROBLEM CAUSE SOLUTION

PRESSURE CABINETS PROBLEM CAUSE SOLUTION BLAST CABINET TROUBLESHOOTING Page 1 PRESSURE CABINETS 1. Poor Visibility. Motor rotating backwards. The motor should rotate as indicated by the arrow on the housing. If it does not rotate in the proper