RUMBLE HOG RH7500 Operation Manual

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Summary of Contents for RUMBLE HOG RH7500

Page 1 RH7500 Operations Manual...
Page 3: Copyright/General Warning
Copyright/General Warning COPYRIGHT Hog Technologies maintains and holds all rights and privileges to the in- formation contained in the manual. The contents herein cannot be shared or reproduced in any way or by any method without prior express writ- ten consent by an authorized representative. Copies of this manual are available by calling (772) 223-7393.
Page 4 STOP TO AVOID SERIOUS INJURY AND DAMAGE TO EQUIPMENT, MAKE SURE TO COMPLETELY READ THIS MANUAL AND FOLLOW ALL SAFETY AND OTHER PRECAUTIONS LISTED IN THE MANUAL AND ON COMPONENT LABELS BEFORE OPERATING THIS EQUIPMENT.
Page 5 WARNING FOURTEEN COMMANDMENTS RH7500 FAILURE TO FOLLOW THESE GUIDELINES WILL RESULT IN PREMATURE FAILURE OF CRITICAL COMPONENTS AND COULD CAUSE INJURY TO PERSONNEL. • NEVER OPERATE WHEN HYDRAULIC FLUID IS LESS THAN 68O F (Follow the warm up procedure). • NEVER BACK UP WITH CUTTER HEAD ON THE GROUND.
Page 6 NOTES...
Page 7: Table Of Contents
1.3 Operation & Cutter Safety ...................15 1.4 Electrical System Hazards ....................16 1.5 Hydraulic System Hazard .....................17 1.6 Dumping Safety ......................19 Section 2: Rumble Hog Systems 2.1 Introduction .......................21 2.2 Hydraulic System ......................22 2.3 Hydrostatic Drive System .....................28 2.4 Fluid Coolers ......................29 2.5 Water System ......................30...
Page 8 4.13 Water System Pumps ....................129 4.14 Optional Debris Recovery W/O Continuous Off-Loading .............130 4.15 Optional Debris Recovery With Continuous Off-Loading ..........135 4.16 Checking & Changing Blower Gear Case Oil ..............142 4.17 Vacuum Hose Replacement & Rotation Procedure ............144 4.18 RH7500 Maintenance Matrix ..................145...
Page 9 Table of Contents appendix 1: System Status & Faults Troubleshooting System Status Screen ......................146 Digital Controller Faults Screen ..................146 Troubleshooting Wires & Cables ..................146 appendix 2: General Troubleshooting Lift Arm..........................148 Water System .........................148 Laser Guidance System ....................149 Video System ........................149 Cutting System .......................149 Vacuum System ......................150 appendix 3:...
Page 10 NoteS...
Page 11: Welcome
Hog Technologies is excited to welcome you and your crew to the Rumble Hog Opera- tors’ Team. We believe that by partnering with you we can create roads that are safer for travelers and answer the global call for technology that keeps cars from veering out of their lane unintentionally.
Page 12: Warranty
Warranty Hog Technologies Limited Warranty Hog Technologies warrants its components to be free from defects in material and workmanship while under normal use and service. Hog Technologies will, at its option, either repair or replace free of charge any such part that appears to us to be defective in material or workmanship during the warranty period.
Page 13: Safety Information
Section 1: Safety Information 1.1 Safety hazard & warning labels Pavement grinding equipment can cause serious injury or even death if it is not operated or main- tained properly. This manual has been written to include a number of safety instructions to assure the safe operation and maintenance of the equipment.
Page 14: General Safety
Rumble Hog is not operated properly and/or proper safety precautions are not followed. Most rumble stripping and grinding operations gen- erate noise levels above 90 dB.
Page 15: Operation & Cutter Safety
Perform all recommended checks and report If you have questions about the equipment on all vehicle defects. your Rumble Hog, please contact the Customer • Check the area around entire vehicle prior to Support Department at (877) HOG ROAD or (001) operation.
Page 16: Electrical System Hazards
Section 1 - Safety Information Be Prepared DANGER If the equipment malfunctions or a malfunction is suspected, immediately stop all operations A ROTATING CUTTING DRUM CAN CAUSE SEVERE INJURY and shutdown the vehicle until proper repairs OR DEATH IF HANDS, FEET OR LOOSE CLOTHING ARE are made.
Page 17: Hydraulic System Hazard
Section 1 - Safety Information • Disconnect the negative (-) battery cable first • Stretched or abused hose can fail prematurely and when reconnecting, connect the negative and unexpectedly, which could cause injury to (-) cable last. personnel. Hoses that have been exposed to excessive stretching, kinks or chaffing should •...
Page 18: Dumping Safety
Never THE DEBRIS TANK AND NEVER WEAR LOOSE CLOTHING OR attempt to dump on uneven or sloped ground. JEWELRY WHILE OPERATING RH7500. • Always drain all the liquid from the debris RAISING THE DEBRIS TANK WITH THE TRUCK ON GROUND...
Page 19 Section 1 - Safety Information...
Page 20 NOTES...
Page 21: Rumble Hog Systems
Section 2: Rumble Hog Systems RH7500 W/O Debris Recovery 2.1 Introduction The Rumble Hog RH7500 is a multi-purpose machine that can grind pavement markings, cut grooves for in-laid pavement markings and cut rumble strips. The cutting system is mounted on a commercially available truck chassis. It is...
Page 22: Hydraulic System
Proper operation and Maintenance procedures for Rumble Hog systems are essential to efficient and safe operation. Maintenance requirements and operating instructions are outlined in subsequent sections of this manual. Make sure you read this...
Page 23 Section 2 - Rumble Hog Systems Pump Block Diagrams Hydraulic Pumps Pump #1 Also know as Aux 1, is the implement pump. It is driven by the transmission auxiliary PTO. It provides power to the cutter arm lift cyl- inders, skip cylinders, water pump, debris tank hoist, arm lock, and arm slide motor.
Page 24 Section 2 - Rumble Hog Systems Electric Hydraulic Pump An electric hydraulic pump activated by a toggle switch on hydraulic manifold provides hydraulic power to raise or lower heavy components in the event of a hydraulic pump failure. This pump is capable of raising only one component at a time.
Page 25 Section 2 - Rumble Hog Systems Hydraulic Motors and Actuators The water pumps, auger, eccentric, cutting drum and cutter arm slide mechanism are powered by hydraulic motors. Internal components of the motors are lubricated and cooled by the hydraulic fluid that powers the motor. All hydraulic motors have maximum pressure ratings and RPM settings that should never be exceeded.
Page 26 Section 2 - Rumble Hog Systems Hydraulic Accumulators Two accumulator tanks with gas charged pistons provide reserve hydraulic power and compensate for normal pressure variations in the cutter and skip cylinder hydraulic circuits. They are located near the high pressure filters below the deck access plate.
Page 27 Section 2 - Rumble Hog Systems Cutter Loop Charge Filter There is a charge filter located below the OMSI drive for the cutter circuit. It is a spin on type filter that should changed every 150 hours of op- eration or if there is a noticeable decline in cutter performance.
Page 28 Section 2 - Rumble Hog Systems Hydraulic Hoses Hydraulic Hoses WARNING The hydraulic system operates at pressures of up to 3,000 psi (207 BAR). Therefore, it is criti- cal that the operator and maintenance personnel INJURIES FROM HIGH PRESSURE HYDRAULIC SYSTEM...
Page 29: Hydrostatic Drive System
A pressure gauge near the filter alerts the operator when the filter is dirty and requires changing. 2.4 Fluid coolers The RH7500 is equipped with coolers for the en- gine, transmission, drivetrain components and hydraulic system. Engine And Drivetrain Coolers...
Page 30: Water System
Section 2 - Rumble Hog Systems Clean Water Tank Water Tank Water Tank Sight Gauge Debris Tank Water Pump Water Tank Fill Fitting & Valve 2.5 water System The water system that suppresses dust during operation consists of a water storage tank, de- livery pump, hoses and nozzles that spray water on the cutter during operation.
Page 31 Section 2 - Rumble Hog Systems Operators must always monitor the tank closely during filling operations as the flow of water from a hydrant will be greater than the flow capacity of tank air vent. Overfilling the tank will cause excessive pressure and damage the tank.
Page 32: Handheld Pressure Washer
Section 2 - Rumble Hog Systems is open prior to engaging the water pump. If the pump is engaged while this valve is closed or there is no water in the tank, the cutter will not be cooled properly and the pump impeller will likely be damaged.
Page 33: Lift Arm & Locking Mechanism
Section 2 - Rumble Hog Systems Cutter Lift Arm the cutter and truck to follow the contour of the 2.7 lift arm & locking mechanism pavement without causing damage to the cutter Lift Arm And Cylinders or pavement. The cutter lift arm assembly is mounted to a slide track on the rear of the chassis.
Page 34 Section 2 - Rumble Hog Systems Lift Arm Locking Mechanism Locking Arm Hydraulically Activated Latch Latch Hydraulic Cylinder & Ram Hinged Locking Plate The locking mechanism consists of a lock arm with a hydraulically activated latch that secures the lock arm to the lift arm.
Page 35 Section 2 - Rumble Hog Systems NOTICE: TO RELEASE THE LOCK, THE TRUCK PTO WILL HAVE TO BE ENGAGED AND THE LIFT ARM RAISED SLIGHTLY TO RELIEVE THE STRAIN ON THE LATCH. ADDITIONALLY, THE LOCKING ARM MUST BE MANUALLY RAISED FROM THE LIFT ARM AND THE HYDRAULIC LATCH CLOSED AND LOCKED BEFORE OPERATING THE LIFT ARM AND CUTTER.
Page 36: Cutter
Section 2 - Rumble Hog Systems pins by raising the cutter. Then rotate the cutter slightly until the pins can be inserted in the holes. 2.8 cutter Overview The cutter assembly and chassis is mounted on the lifting arm. It can be operated in two modes, rumble stripping or planing.
Page 37 Section 2 - Rumble Hog Systems forward of the cutting drum. Water cools the drum and reduces dust during operation. Always make sure the water system is activated and supplying water to the cutter when rumble stripping or plan- ing operations are underway.
Page 38 Section 2 - Rumble Hog Systems Cutter Skip Cylinders The hydraulic cylinders that lift the drum during rumble cutting or planing operations are separate from the cylinders that raise the lift arm and cutter chassis. The skip cylinders are located at the rear of the cutter chassis and powered by the implement hydraulic pump driven by the TRUCK PTO.
Page 39 Section 2 - Rumble Hog Systems Refer to the Lubrication & Maintenance section for instructions to adjust the rear gauge wheels and cutting depth. Planing Mode Wheels There are two trim wheels, two rear gauge wheels and four planing chassis wheels on the bottom of the cutter chassis.
Page 40: Drive Belts
Section 2 - Rumble Hog Systems 2.9 drive Belts The drive belts that connect the hydraulic motor to the cutting drum eccentric are carbon fiber industrial belts designed for high horsepower applications. The ribbed drive belts are matched to grooved pul- leys and have very little stretch.
Page 41: Debris Recovery System
2.10 debris recovery System Overview A debris recovery system is an available option on the Rumble Hog. Two systems are available, a vacuum system with a debris tank or a vacuum system with debris tank and continuous off-load- ing auger. A high lift dump system is an option on either system.
Page 42: Debris Recovery Without Continuous Off-Loading
Section 2 - Rumble Hog Systems Optional Debris Recovery System W/O Continuous Off-loading System Blower Filter Canister Drain Valve Debris Tank, Door & Chute Silencer & Flapper Clean Water Tank Vacuum Hose Filter Canister & Door Relief (Kunkle) Valve Cyclonic Separator shroud.
Page 43 Section 2 - Rumble Hog Systems Blower & Hydraulic Motor Blower Drive End & Grease Fitting Locations Blower airflow is expelled through a silencer con- nected to the outlet side of the blower. A flapper installed on the silencer keeps water and debris from entering the system damaging the blower when the unit is shutdown.
Page 44 Section 2 - Rumble Hog Systems Vacuum Hose - Debris Tank to Cutter Vacuum Tube - Debris Tank to Cyclonic Separator Vacuum Hoses & Tubes Some types of debris will buildup on the inside walls of the hoses to the point where it restricts...
Page 45 Section 2 - Rumble Hog Systems filter canister, prematurely filling the canister and clogging the filter. Therefore, the separator box must be drained and cleaned at the start of each shift and each time the debris tank is drained to reduce the amount of water and debris getting past the separator to the filter canister.
Page 46 Section 2 - Rumble Hog Systems NOTICE: THE CYCLONIC SEPARATOR AND FILTER CANISTER WILL NOT DRAIN IF THE VACUUM SYSTEM IS OPERATING. ALWAYS MAKE SURE THE SYSTEM IS COMPLETELY SHUTDOWN BY REDUCING ENGINE SPEED TO IDLE AND DISENGAGING THE BLOWER BEFORE DRAINING THE SEPARATOR BOX OR FILTER CANISTER.
Page 47: Debris Recovery With Continuous Off-Loading
Section 2 - Rumble Hog Systems Optional Debris Recovery System With Continuous Off-Loading System Cone Shaped Separator & Auger Hydraulic Hoses Cyclonic Separator Door Cone Shaped Separator Door Vacuum Hose 10. Cyclonic Separator Box Auger Hydraulic Motor Vacuum Tube 11. Turret & Lift Cylinder...
Page 48 Section 2 - Rumble Hog Systems Blower & Hydraulic Motor Blower Drive End & Grease Fitting Locations CAUTION THE BLOWER BEARINGS MUST BE LUBRICATED DAILY WITH THE GREASE SPECIFIED IN THE MAINTENANCE MATRIX AND BY THE BLOWER MANUFACTURER. FAILURE TO LUBRICATE...
Page 49 120 once each week. dump truck traveling with the Rumble Hog. After the debris dumps, the valve automatically closes Some types of debris will buildup on the inside...
Page 50 Section 2 - Rumble Hog Systems tor if it becomes clogged. The engine must be at idle with the blower and auger disengaged before attempting to open the separator door. Make sure the door seal is clean and the door is properly latched before reactivating the blower and auger.
Page 51 Section 2 - Rumble Hog Systems It is normal for some debris and water vapor to travel from the debris tank to the cyclonic sepa- rator box where it will accumulate. Excessive ac- cumulation of water and debris in the cyclonic...
Page 52 Section 2 - Rumble Hog Systems The vacuum filter is a pleated, reusable filter that is easily accessed through the door on the side of the canister. Once the filter has been removed you should de-grease with detergent and power wash at 2000 psi (138 BAR).
Page 53 Section 2 - Rumble Hog Systems Remote Control Switches Side Switch Panel & Grey Junction Box for Remote Control The chute and door rams are controlled by switch- es in the in the side and rear switch panels. The hydraulic tilt ram is controlled by switches in a remote control or the CUTE and DOOR switches on the side and rear switch panels.
Page 54: Debris Tank
Section 2 - Rumble Hog Systems Debris Tank Raised 2.14 optional debris tank high dump System The high dump debris tank is equipped with a scis- sor lift system that allows the tank to be raised up to 12 feet. Other than the lift system, the debris tank features and operation are the same as the standard debris tank.
Page 55 Section 2 - Rumble Hog Systems The scissor lift and debris tank are heavy and the truck could become unstable if lifted when the truck is not level or other precautions are not taken prior to lifting the tank. Operators should be aware of this and always follow proper procedures when lifting and dumping the debris tank.
Page 56: System Controls
Section 2 - Rumble Hog Systems Typical Rumble Hog Digital Controller - MAIN Screen Note: The controller display shown in this picture is for demonstration purposes only. The display and controls in the controller on your truck may be different.
Page 57 Section 2 - Rumble Hog Systems 1. Left Switch Panel • TRUCK PTO - Engages/disengages the truck transmission PTO that drives the implement hydraulic pump. • POWER - Toggles Main electrical power to all other switches ON or OFF. No cutter or work mode truck functions can be activated until the power switch is turned ON.
Page 58 Section 2 - Rumble Hog Systems 4. Joystick Trigger Switch The momentary trigger switch on the front of the joystick is a safety lockout feature that must be activated before any function controlled by the joystick with activate. 5. Joystick Control Buttons Six buttons on the joystick control handle that activate various cutter functions.
Page 59 Section 2 - Rumble Hog Systems Rear Control Switches Toggle switches that are used to select or control functions typically performed at the rear of the truck. The following is a description of the functions per- formed by the rear control switches.
Page 60 Section 2 - Rumble Hog Systems Remote Switch Control The remote switch control harness plugs into a receptacle on the driver side or rear of the chassis. The UP/DOWN switches in the control allow the operator to control debris tank dumping opera- tions a safe distance from the truck.
Page 61 Section 2 - Rumble Hog Systems All other buttons are not used. If your truck is equipped with an optional continuous off-loading debris recovery system, the wireless remote also controls the hydraulic cylinders and motors that raise and lower the auger or move it left or right.
Page 62: Video Systems
Section 2 - Rumble Hog Systems Camera Video Screens 2.16 Video Systems The video system includes 2 monitors and 4 cameras that provide a complete video guidance and monitoring system during cutting operations. Each monitor is mounted to a bracket on the dash that allows the monitors to be rotated down to im- prove visibility when the truck is in TRAVEL mode.
Page 63 Section 2 - Rumble Hog Systems aligned to the white line or a seam in the pavement to help set the cutter at the proper offset and make sure the cutter position setting is Maintained. The cutter video also assists the operator in making minor right/left cutter position adjustments dur- ing operation.
Page 64: Laser Guidance System
Section 2 - Rumble Hog Systems 2.17 laser Guidance System The optional laser guidance system uses an ultra high visibility green laser to establish visual line control for your truck. The system provides the operator with another alignment tool that can be...
Page 65: Electrical System
Section 2 - Rumble Hog Systems 2.18 electrical System Your truck is equipped with either a 12 volt or 24 volt DC electrical system depending on your location and the chassis manufacturer. The cutter electrical system is totally isolated from the truck electrical system.
Page 66 Section 2 - Rumble Hog Systems Outside Terminal Box The OTB is located behind the cab on the driver’s side of the truck. The logic controllers for the digital controller and joystick, relays that activate accessories and a fuse panel are located in this box.
Page 67 Section 2 - Rumble Hog Systems OTB Fuse Panel The following circuits are protected by fuses in the OTB Fuse Panel. 1. Protects and supplies power to logic controller 1 in the OTB. 2. Protects and supplies power to logic controller 2 in the OTB.
Page 68: Engine & Transmission
Section 2 - Rumble Hog Systems 2.19 engine & transmission Overview Power is transferred from the engine to the drive- train and cutting system through the chassis transmission and the OMSI gearbox. The OMSI gearbox provides two modes of opera- tion that can be selected by the operator;...
Page 69: Access Panels, Ladders & Tool Boxes
Section 2 - Rumble Hog Systems Both conditions are programmed into the engine ECM and are automatically selected with MODE switch on the joystick panel. When the MODE switch is on, it sends a signal to the transmis- sion that tells it to select the pre-programmed conditions when the operator puts it into drive.
Page 70 Section 2 - Rumble Hog Systems Tool Boxes Heavy duty, lockable tool boxes are located on each side of the truck chassis and behind the cab on both sides. The tool boxes are used for stor- ing hoses, fittings, extra parts and tools. Always make sure the tool box doors are closed, latched and locked before operating the truck.
Page 71: Rumble Hog Operation
Hog edge of the Rumble Hog. Make sure you have read Technologies includes a quick reference placard them carefully and fully understand the truck and...
Page 72: Pre-Operation Inspection
Section 3 - operation 3.2 pre-operation Inspection The pre-operation Inspection in this section and the Pre-Op Check List in Appendix 4 is provided as a guideline. Additional items should be added to the checklist as determined by company policy, your operating environment and other factors unique to your situation.
Page 73 Section 3 - operation 17. Make sure the Mobile Spare Parts and Tool Systems are complete and onboard. 18. Conduct a final walk around and visually check all components. Look for obvious problems that may have been overlooked. Optional vacuum debris recovery system w/o Debris Recovery System Without continuous off-loading: Optional Continuous Off-Loading System...
Page 74: Filling The Clean Water Tank
Section 3 - operation Rear Clean Water Tank Man-Way & Wastewater Bladder Clean Water Fill Fitting & Valve 3.3 Filling the clean water tank The clean water fill connection on the driver side of the tank is a quick connect fitting that accommo- dates large hoses that are typically connected to a metered source like a fire hydrant to expedite the filling of the tank.
Page 75: Cutter Drum Setup
Section 3 - operation 4. Open the water tank fill valve and connect the hose to the quick connect fill fitting. Secure the hose to the fitting with the cam-lock levers. 5. Slowly open the source valve to begin filling the tank.
Page 76 Section 3 - operation Configuring Cutter for Rumble Strips 1. Raise the cutter and secure it with the lock- ing arm. 2. Secure the front of the cutter chassis with safety stands. 3. Shutdown the truck and place it in the service position.
Page 77 Section 3 - operation Configuring Cutter for Milling (Planing) 1. Raise the cutter and secure it with the lock- ing arm. 2. Secure the front of the cutter chassis with safety stands. 3. Shutdown the truck and place it in the service position.
Page 78: Mounting Monitors & Cameras
Section 3 - operation Typical Monitor Mounted to Windshield Front Camera Mounted 4. Remove the monitor and clean the suction cup 3.5 mounting monitors & cameras and window if the red line becomes exposed The video system includes 2 monitors and 4 frequently.
Page 79 Section 3 - operation Upper Rear Cameras Two rear facing cameras mounted on the upper rear of the debris tank provide an overhead view of the pavement on each side of the cutter in sepa- rate windows on the rear camera monitor. These cameras provide the operator with the location of the cutter and monitor cutting operations.
Page 80: Laser Guidance System
Section 3 - operation Laser Laser Spot Alignment Indicator On Reference Line 3.6 laser Guidance System The laser guidance system uses an ultra high vis- ibility green laser to establish visual line control for your truck. The system provides the operator with another alignment tool that can be used with the forward video camera monitor or instead of the forward monitor, depending the operator’s...
Page 81: Auto Guidance Camera
Section 3 - operation 4. When the green light goes out use the Laser ON/OFF/MODE Switch to turn on the laser and select the mode. (Laser spot mode, steady on or blinking. 5. Use the Laser Spot Controls to move the laser spot UP/DOWN or RIGHT/LEFT.
Page 82: Hydraulic System Cold Weather Warm Up Procedure
Section 3 - operation 3.8 hydraulic System cold weather warm up procedure Starting the RH7500 improperly in cold weather (below 68 F [20 C] will cause significant and po- tentially catastrophic damage to the hydraulic system. Always perform this warm up process before any operational functions if the time lapse since the last cutter system operation is more than 30 minutes and outside temperature is below 68 degrees F.
Page 83: System Startup Procedure
Section 3 - operation 3.9 System Startup procedure Once the truck is at the job site it must be shifted to work mode. The startup procedure to shift the truck from TRAVEL mode to WORK mode and acti- vate the cutting system is outlined in the following instructions.
Page 84 Section 3 - operation 12. Select Drive (D) with the transmission shift lever 13. Transmission will shift into 4th gear (4.4) and you will hear a change in engine rpm 14. Release the brake pedal 15. Using the truck cruise control accelerate but- ton, raise engine speed to 1800 RPM.
Page 85: Aligning The Truck & Positioning The Head
Section 3 - operation Front Camera 3.10 aligning the truck & positioning the head The truck must be properly positioned prior to set- ting the head on the ground. The head must also be in proper alignment prior to setting it on the ground.
Page 86 Section 3 - operation Forward Camera Video Monitor With Rear Video Monitor Alignment Indicator On Reference Line 8. Now stop and align front camera with a refer- ence line, so the line is visible in the center of the front camera monitor. The truck is now aligned, and you are ready to cut.
Page 87 Section 3 - operation Locking Arm Released From Lift Arm Remote Switch Control With Latch Closed For Operation Unlock the Lift Arm 1. Activate the Hydrostatic Drive 2. Attach the remote control to the receptacle on the driver’s side of the truck 3.
Page 88 Section 3 - operation Aligning the Cutting Head 1. Make sure the monitors and all guidance sys- tems are activated. 1. Align the forward video and/or laser guidance indicators on the reference line, pavement seam or edge of the pavement. 2.
Page 89: Programing Controller
Section 3 - operation 3.11 programing controller Once you have completed the Pre-Op Inspection and you have set up the drum for the proper cut style and width it’s time to program the PLC system. NOTICE: THE CONTROLLER DISPLAY SCREENS SHOWN IN THIS SECTION ARE FOR DEMONSTRATION PURPOSES ONLY.
Page 90 Section 3 - operation Skip Pattern The skip pattern controls set the cut/stop cut pat- tern for the cutter. This setting causes cutter to lower and cut for a specified distance, then raise and stop cutting for a specified distance, then re- peat the sequence throughout cutting operations.
Page 91: Wireless Remote Control
Section 3 - operation 3.12 wireless remote control Trucks W/O Optional Continuous Off-Loading The top two buttons on the wireless remote are programmed to raise or lower the skip cylinders. The control allows an assistant located within 25 feet (7.5 meters) of the truck to momentarily raise cutting drum from the pavement to cause a manual skip, then lower the drum to resume cutting operations.
Page 92 Section 3 - operation Use the following procedure to active the skip function with the wireless remote. 1. Skip Function • Press and hold either button 1 or 2 to acti- vate the skip cylinders and raise the cutting drum off the pavement and stop cutting. •...
Page 93: Vacuum System Operation
Section 3 - operation Debris Recovery System Without Optional Continuous Off-Loading System 3.13 Vacuum System operation The vacuum recovery system is an available option. If your truck is equipped with a debris recovery system, use the following procedure to activate the vacuum system.
Page 94 Section 3 - operation Debris Recovery System With Optional Continuous Off-Loading System 3. Use remote control’s primary up/down function to raise the auger tube up. 4. Use a remote control to move an auger tube left or right. 5. Press auger button located on the left side of the joystick, then use the auger speed control dial to increase auger speed to at least 50%.
Page 95: Rumble Strip Cutting Operations
Section 3 - operation 3.15 rumble Strip cutting operations NOTICE: THE CONTROLLER DISPLAY SCREENS SHOWN IN THIS SECTION ARE FOR DEMONSTRATION PURPOSES ONLY. THE DISPLAY AND CONTROLS IN THE CONTROLLER ON YOUR TRUCK MAY BE DIFFERENT. REFER TO THE SUNSOURCE HOG TECHNOLOGIES USER GUIDE FOR A DESCRIPTION OF THE CONTROLS AND FEATURES.
Page 96 Section 3 - operation 14. Adjust water pressure using buttons 3(+) and • Check cutter depth before starting each shift. 4(-). Percentage of PSI depends on type of the Remember that cutter diameter decreases as material and whether the vacuum system is in teeth wear.
Page 97: Milling (Planing) Operations
Don’ts Use the following procedure to begin planing • Do not allow untrained personnel to operate operations. Rumble Hog equipment. Starting Planing Operations • Do not aim the laser guidance beam at any 1. Perform all steps Pre-Operation Inspection and person, vehicle or airplane.
Page 98: Routine Shutdown
Section 3 - operation Controller MAIN Screen & Control Buttons Controller MAIN Screen & Control Buttons Indicating Work Mode Indicating Travel Mode 3.17 routine Shutdown The routine shutdown procedure should be fol- lowed each time the cutting system is deactivated and the truck is shifted from WORK mode to TRAVEL mode.
Page 99 Section 3 - operation Notice: If an emergency situation involving the po- tential for personal injury and/or equipment damage occurs, press the E-Stop Button (C). Change the cutter configuration and truck from WORK mode to TRAVEL mode: 1. With the engine still running at idle speed, use the joystick to move the cutter right or left to the center of the chassis.
Page 100: Dumping Debris Tank
Section 3 - operation Debris Tank & Door 5. Press button #5 on the controller Main Screen 3.18 dumping debris tank to turn the water pump off. The debris tank must be emptied when it is near full. A hydraulic actuator below the tank lifts the 6.
Page 101 Section 3 - operation 11. While you and all other personnel stand well clear of the debris tank, press the white UP button to raise the tank and dump the debris. 12. If all debris does not slide out, use a rod or shovel to break up the debris until it is all removed.
Page 102: Convert Continuous Off-Loading To Debris Recovery
Section 3 - operation Cone Shaped Cyclonic Separator Hoses 3.19 Convert Continuous Off- loading to debris recovery The optional continuous off-loading system oper- ates in two modes, continuous discharge or debris tank recovery. In Continuous discharge mode, the system creates vacuum in the cyclonic separators that continuously move debris from the cutter to the cone shaped separator on the top of auger.
Page 103 Section 3 - operation 3. Connect the separator end of the shroud 6. Make sure all hose connections are secure, vacuum hose to the intake elbow hose fitting then activate the vacuum system and test for on the top of the debris tank. proper vacuum pressure.
Page 104: Emergency Shutdown
Section 3 - operation WARNING IF AN EMERGENCY SITUATION INVOLVING THE POTENTIAL FOR PERSONAL INJURY AND/OR EQUIPMENT DAMAGE OCCURS, THE OPERATOR SHOULD ALWAYS SELECT THE EMERGENCY SHUTDOWN PROCEDURE. THIS PROVIDES IMMEDIATE SHUTDOWN OF THE TRUCK AND ALL WATER BLASTING SYSTEMS TO REDUCE THE POSSIBILITY OF INJURY AND DAMAGE TO EQUIPMENT.
Page 105: Pressure Washer Operation
Section 3 - operation Pressure Washer Pump & Water Supply Valve Clean Water Pressure Pump & Supply Valves Pressure Washer Water Supply Valve Water System Pressure Pump Wand Pressure Gauge Pressure Pump Supply Valve Manual Bypass Valve Cutter Nozzle Water Supply Valve Use the following procedures to activate or shut- 3.21 pressure washer operation down the pressure washer.
Page 106 Section 3 - operation 7. Make sure someone is holding the wand and the tip is point away from all people and the machine. 8. Open the ON/OFF hydraulic pressure valve and slowly turn the knob on the hydraulic flow control valve counterclockwise until the bot- tom edge of the knob is even with the desired reference ring to activate the hydraulic motor...
Page 107: Operating In Freezing Conditions
There are no special startup procedures with a cupful. Then close the valve. operation the Rumble Hog in freezing conditions 5. Pour 15 gallons of 50/50 antifreeze mixture other than to follow the cold weather warm up into the clean water tank.
Page 108 NOTES...
Page 109: Lubrication & Maintenance
Some of the components used in assembling your teeth. RH7500 were manufactured by other companies. Their operations manuals have been supplied Scheduled Maintenance refers to procedures that along with the delivery of your unit. If you do...
Page 110 Section 4 - lubrication & maintenance Service Position 4. Shutdown the engine and disable the truck electrical system at the main circuit breakers. Properly shutting down and securing the machine for service is critical to the safety of the operator 5.
Page 111: Lubrication & Grease Point Locations
Section 4 - lubrication & maintenance 4.2 lubrication & Grease point locations Rumble Hog Lubrication Chart 1 ITEM# COMPONENT DESCRIPTION ITEM# COMPONENT DESCRIPTION Skip Cylinders Gauge Wheel Bearings (Auto Lube) Main Bearing Gauge Wheel Bearings (Auto Lube) Motor Mount Bearing Trim Wheel Bearings 9”...
Page 112 Section 4 - lubrication & maintenance Rumble Hog Lubrication Chart 2 ITEM# COMPONENT DESCRIPTION ITEM# COMPONENT DESCRIPTION Trim Wheel Bearings Driveshaft Universal Joints & Spline Shafts Skip Wheel Bearings (Auto Lube) Water Tank Fill Valve Gauge Wheel Bearings Debris Tank Door Hinges Tool Box &...
Page 113 Section 4 - lubrication & maintenance Rumble Hog Lubrication Chart 3 ITEM# COMPONENT DESCRIPTION ITEM# COMPONENT DESCRIPTION Ladder Hinges & Locking Pin Debris Tank Inspection Hatch Hinges & Latch Drain Valves Articulation Hinge (Optional) Latches & Hinges Lift Arm Hinge Pin Grease Fittings...
Page 114 Section 4 - lubrication & maintenance Rumble Hog Lubrication Chart 4 ITEM# COMPONENT DESCRIPTION ITEM# COMPONENT DESCRIPTION Grease Pump Reservoir Fill Fitting Auger Pivot Gear Grease Fittings (3) NOTICE: SOME LUBRICATION POINTS SHOWN IN THIS SECTION ARE FOR OPTIONAL EQUIPMENT THAT MAY NOT BE ON YOUR MACHINE.
Page 115: Periodic Maintenance Items
Section 4 - lubrication & maintenance Ball Valves 4.3 periodic maintenance Items Monthly/200 Hours: The primary components in the cutting system • Open and close ball valves at least once each have specific stated service intervals. Other com- month to keep them free and operating prop- ponents of the chassis and cutting system require erly.
Page 116: Truck Maintenance
Engine and Chassis Proper engine and chassis maintenance is es- sential to the proper performance and reliability of the Rumble Hog truck. You should perform all recommended maintenance according to the man- ufacturers’ specifications. Maintenance schedules and procedures are outlined in the truck owner’s manual.
Page 117: Cutting Depth Adjustment Procedure
Section 4 - lubrication & maintenance 4.5 cutting depth adjustment procedure Depth adjustment refers to the depth the cutting teeth will cut into the pavement. Depth is set by turning the adjustment bolts on each gauge wheel mount. Depth directly affects cutter performance and should be checked before each shift.
Page 118: Replace Cutting Teeth
Section 4 - lubrication & maintenance Cutting Drum With Teeth Installed 4.6 replace cutting teeth Cutting teeth gradually wear during operations and will need to be replaced when they are worn out. Service life for the teeth will vary, depending on the type of pavement and pavement condition.
Page 119 Section 4 - lubrication & maintenance Remove Wedge & Tooth With A Slide Hammer Tooth, Wedge & Bolt In Socket 4. Thread the slide hammer extraction tool into the wedge and remove the wedge and tooth. 5. Thoroughly clean the tooth socket. NOTICE: IF THE TOOTH SOCKET IS NOT CLEANED THOROUGHLY AND MATERIAL REMAINS IN THE SOCKET, THE NEW TOOTH WILL...
Page 120: Cutter Eccentric Drive Belts
Section 4 - lubrication & maintenance 4.7 cutter eccentric drive Belts The drive belts that connect the hydraulic drive motor to the eccentric are carbon fiber industrial belts that are designed for high horsepower appli- cations. They are matched to grooved pulleys and have very little stretch.
Page 121 Section 4 - lubrication & maintenance WARNING DRIVE BELT DEFLECTION EXCESSIVE IMPACTED MATERIAL AROUND BELTS AND PULLEYS IS A COMMON CAUSE OF CUTTER ECCENTRIC BELT AND PULLEY SYSTEM FAILURE. MAKE SURE TO INSPECT ECCENTRIC BELT AND PULLEYS FREQUENTLY AND CLEAN AS REQUIRED. Checking Belt Tension With Force Deflection The proper way to check belt tension is to use a...
Page 122 Section 4 - lubrication & maintenance Eccentric Drive Belt Guards, Hydraulic Motor, Pulleys & Belts Eccentric Hydraulic Motor Drive Axle Pillow Block Bearings Hydraulic Motor To Eccentric Drive Axle Belt Eccentric Drive Belt Guard Eccentric Drive Axle Eccentric Drive Belt Drive Belt Adjustment And Timing Step 1 - Adjust Eccentric Drive Timing: Make sure the left and right eccentric pulleys...
Page 123 Section 4 - lubrication & maintenance 3. Turn the bolt behind the pillow block until proper tension is achieved. 4. Use a spring scale tester to achieve proper tension for each belt. Then tighten the pillow block bearing bolts. Important: Tighten the pillow block bolts in the slotted holes and recheck the belt tension and align- ment.
Page 124: Auto Lube Electric Grease Pump
Section 4 - lubrication & maintenance 4.8 auto lube electric Grease pump Overview A Continuous duty, electric grease pump located on the center deck is an available option. It provides automatic lubrication for cutter grease fittings. The pump consists of a pump housing, electric gear motor, timer and a plastic reservoir with stirring pad- dle.
Page 125 Section 4 - lubrication & maintenance Grease Fittings And Faults Grease from the auto lube system serves two purposes, lubricate components & purge bear- ings of dirt and grit that will shorten bearing life. Consequently, it is important to monitor the auto lube system and all cutter bearings and compo- nents greased by the system every one to two hours during a shift.
Page 126: Hydraulic System Maintenance
Section 4 - lubrication & maintenance 4.9 hydraulic System maintenance Hydraulic System The hydraulic pumps operate at very high pressure and have specific maintenance requirements. You should perform all recommended maintenance ac- cording to the pump manufacturers’ specifications. Hydraulic fluid should be changed and the tank flushed on a regular schedule in accordance with Hog Technologies and the hydraulic component manufacture’s recommendations.
Page 127 Section 4 - lubrication & maintenance Weekly • Check accumulator charge pressure. • Trim accumulator= 150 psi (10.34 BAR) • Cutter drum accumulator= 1500 psi (103.4 BAR) • Eccentric accumulator = 350 psi (24.1 BAR) WARNING ACCUMULATORS ARE PRE-CHARGED AT EXTREMELY HIGH PRESSURE THAT CAN CAUSE SERIOUS INJURY OR DEATH IF SERVICED IMPROPERLY.
Page 128: Changing Hydraulic Fluid & Flushing Tank
Section 4 - lubrication & maintenance 4.10 changing hydraulic Fluid & Flushing tank The reservoir tank is equipped with a removable clean out/inspection plate on the top of the tank. When the fluid is changed, the clean out plate should be removed to inspect the tank and remove any sludge or debris accumulated on the bottom.
Page 129: Replacing Hydraulic Filters
Section 4 - lubrication & maintenance Low Pressure Return Filters & Gauges High Pressure Filters On Hydraulic Reservoir Below Deck Access Plate High Pressure Filters 4.11 replacing hydraulic Filters The filters are the spin on type filters located below Before performing any maintenance procedure, the center deck access plate.
Page 130 Section 4 - lubrication & maintenance Donaldson Filter Near OMSI Drive Zinga Suction Filter Below Hydraulic Reservoir Donaldson Cutter Pump Charge Filter Zinga Hydrostatic Drive/Eccentric Pump Suction Filter A horizontal, spin on type filter located below the chassis near the OMSI Drive. A spin on, screen mesh type suction filter located below the hydraulic system reservoir.
Page 131: Accumulator Tank Pressure & Charging
Section 4 - lubrication & maintenance 4.12 accumulator tank pressure & charging Two accumulator tanks with gas charged pistons that provide reserve hydraulic power and compensate for normal pressure variations in the cutter and skip cylinder hydraulic circuits are located near the high pressure filters below the center deck access plate.
Page 132: Water System Pumps
Section 4 - lubrication & maintenance 4.13 water System pumps All pumps in the water system are powered by hydraulic motors. The pump that supplies pres- surized water to the cutter nozzles also sup- plies charge water to the high pressure pump. It requires little maintenance other than routine inspections.
Page 133: Optional Debris Recovery W/O Continuous Off-Loading
Section 4 - lubrication & maintenance Optional Debris Recovery W/O Continuous Off-Loading 4.14 optional debris recovery W/O Continuous Off-Loading Vacuum Canister and Filter The canister houses the vacuum filter that protects the blower from debris and should be checked at the beginning of each shift.
Page 134 Section 4 - lubrication & maintenance Weekly/50 Hour Maintenance: • Inspect and lubricate door hinges and latches. Use the following procedure to drain the can- ister and remove and clean the vacuum filter: 1. Make sure the vacuum system is shutdown and the truck is in the service position.
Page 135 Section 4 - lubrication & maintenance Weekly/50 Hour Maintenance: • Grease the hydraulic lift hinge pins and fittings. • Inspect safety strut. Make sure the hinge pins are tight and lubricate pins. • Lubricate the debris door gas spring pivot hinge pins.
Page 136 Section 4 - lubrication & maintenance 200 Hour Maintenance Be sure the vacuum filter is always in good operat- ing condition with the plug inserted and secured in Perform all daily maintenance along with the items the service port so it fully protects the blower from outlined in this section.
Page 137 Section 4 - lubrication & maintenance Daily Shutdown Sequence: CAUTION MOISTURE ALWAYS PRESENT IN VACUUM AIR FLOW WILL CAUSE CORROSION IN INTERNAL BLOWER COMPONENTS WHICH WILL CAUSE THE BLOWER TO SEIZE WHEN IT IS SHUTDOWN. IT IS IMPORTANT THAT LIGHT PROTECTIVE OIL IS INJECTED INTO THE SERVICE PORT WITH THE BLOWER OPERATING ANYTIME THE VACUUM SYSTEM IS SHUTDOWN, EVEN JUST FOR A COUPLE OF HOURS.
Page 138: Optional Debris Recovery With Continuous Off-Loading
Separated debris flows down the funnel shaped sides to the auger where it is off-loaded to the shoulder or dump vehicle traveling with the Rumble Hog. Daily Maintenance: Perform the following procedures every two hours of operation with the vacuum and off-loading systems shutdown.
Page 139 Section 4 - lubrication & maintenance Secondary Cyclonic Separator The secondary separator is mounted on the pas- senger side of the center deck, between the cone shaped separator and the vacuum filter canister. It is designed to separate debris that gets past the primary cone shaped separator.
Page 140 Section 4 - lubrication & maintenance Daily Maintenance: • Inspect and clean filter. • Drain water from canister as required. • Clean out accumulated debris in canister • Check canister door seal to ensure good seal- ing. Clean if necessary. Weekly/50 Hour Maintenance: •...
Page 141 Section 4 - lubrication & maintenance Debris Recovery Tank Daily Maintenance: (When used) • Check the water level sight tube for cracks or damage and clean or replace as necessary. • Check debris tank door seal to ensure good sealing. Clean if necessary. •...
Page 142 Section 4 - lubrication & maintenance Vacuum Blower Maintenance Overview The vacuum blower operates at an extremely high RPM and has specific lubrication and maintenance requirements. It is also very susceptible to dam- age from debris because of the tight tolerances in the blower impellers.
Page 143 Section 4 - lubrication & maintenance • Tap vacuum hose walls with a dead blow ham- mer while the system is operating at maximum vacuum to flex the hose walls and cause built up debris to break off and be sucked into the debris tank.
Page 144 Section 4 - lubrication & maintenance Continuous Off-Loading Auger Continuous Discharge Auger Daily Maintenance: • Inspect the auger housing at the base of the separator for a excessive material. Clean as required. • Check auger and pivot base for loose bolts. Tighten as necessary.
Page 145: Checking & Changing Blower Gear Case Oil
Section 4 - lubrication & maintenance Typical Vacuum Blower Gear Case Drain, Oil Level & Oil Fill Plugs A. Drain Valve & Safety Plug B. Overflow Plug C. Breather/Oil Fill Plug 2. Remove the overflow plug on the side of the 4.16 checking &...
Page 146 Section 4 - lubrication & maintenance 3. Attach a drain hose to the ball valve fitting and route the hose to a suitable waste oil container capable of handling at least 2 quarts (2.9 Liters) of oil. 4. Open the drain valve and drain the oil. 5.
Page 147: Vacuum Hose Replacement & Rotation Procedure
Section 4 - lubrication & maintenance Vacuum Hoses 4.17 Vacuum hose replacement & rotation procedure NOTICE: DAMAGED VACUUM HOSES CAN BE REPAIRED USING DUCT Debris buildup, kinks, clogs or leaks in the system TAPE AS A TEMPORARY SOLUTION TO EXTEND THE LIFE will cause a reduction in airflow at the blasting OF THE VACUUM HOSE.
Page 148: Rh7500 Maintenance Matrix
Section 4 - lubrication & maintenance 4.18 rh7500 maintenance matrix EQUIPMENT COMPONENT INTERVALS LUBRICANT SPECIFICATIONS Truck Engine Oil and Filter Refer To Truck Operating Manual Refer To Truck Operating Manual Truck Transmission Oil and Filter Refer To Truck Operating Manual...
Page 149: System Status & Faults Troubleshooting
appendix 1: System Status & Faults Troubleshooting System Status Screen The STATUS screen displays the current status of primary cutter systems on one screen. This screen provides the operator with a snapshot of real time pressure, temperature or HTZ of all cut- ter systems.
Page 150 NoteS...
Page 151: General Troubleshooting
appendix 2: General Troubleshooting PROBLEM CAUSE AND SOLUTION lift arm Lift arm won’t raise. • Hydraulics not engaged. Engage transmission PTO to activate hydraulic system. • POWER switch on joystick panel is not on. Turn on POWER switch. • Hydraulic fluid low. Add fluid to the hydraulic fluid reservoir.
Page 152: Laser Guidance System
appendix 2 - General troubleshooting PROBLEM CAUSE AND SOLUTION laser Guidance System Laser guidance is not activating • POWER switch on joystick panel is not on. Turn on POWER switch. • Laser power switch is not on. Turn power switch on laser panel on.
Page 153: Vacuum System
appendix 2 - General troubleshooting PROBLEM CAUSE AND SOLUTION cutting System Cutting drum doesn’t rotate when activated. • Lift arm and cutter are down. The last action of the lift arm must be up before the cutting drum will rotate. •...
Page 154 appendix 2 - General troubleshooting PROBLEM CAUSE AND SOLUTION Low vacuum pressure. • Truck engine speed is too low and PTO is not turning the vacuum blower at proper RPM. Raise engine speed to operating RPM. • Vacuum filter canister or cyclonic door seal leaking.
Page 155: Tools & Spare Parts
appendix 3: Tools & Spare Parts...
Page 156 appendix 3 -tools & Spare parts...
Page 157: Pre-Op Checklist
appendix 4: Pre-Op Checklist pre-op checKlISt Tires Grease Points F Tire Pressure - Front F Cutter & Eccentric Bearings F Tire Pressure - Rear F Lift Arm & Skip Cylinders F Gauge Wheel Bearings Lighting Systems F Brake Lights Tank System F Turn Signals F Water Tank Full &...
Page 158 NoteS...
Page 159: Glossary Of Terms
Display - Any instrument that shows information from a sensor to the driver / operator for evaluation. Drum - The rotating part of the Rumble Hog holding the teeth that do the cutting work. Drum chassis - The assembly that holds the drum and supporting mechanisms Eccentric - A hydraulic cylinder that rotates on an out of center axis.
Page 160 appendix 5 - Glossary of terms PLC – Programmable logic controller located in the cab of the truck and displays digital information on the water blasting system. Plunge - The action of pushing the drum into the pavement. Potable Water – Clean water that is suitable for drinking. PSI –...
Page 161: Customer Support & Support Web Site
appendix 6: Customer Support & Support Web Site customer Support 24 / 7 CUSTOMER SERVICE Hog Technologies Customer Service 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 Customer Service Department for assis- tance and cross reference specifications for parts you intend to purchase locally.
Page 162 5 - customer Support rumble hog Support web Site Stripe Hog Customer Support Center Home Training Ambassador Club Marketing Stripe Hog Store Contacts You are here Home Mike Logout Typical Registration & Log On Window Welcome to the Stripe Hog Support...
Page 164 3170 SE Slater Street Stuart, Florida 34992 (001) (772) 214-1714 P (001) 772-223-5461 F www.hogtechnologies.com Print Date 12/05/2019 Rev 1.A...