Flameless Patch Heater.doc

Specifications

Flameless Patch Heater

These minimum specifications describe a asphalt transport and delivery system unit truck mounted. Flameless pothole patcher with equipment including: 5.1 cu. yd. double steel encased material hopper with 2 inches of industrial insulation; 6x6 hydraulically driven, reversible auger with controls at operators work station; Full length, hydraulically driven, reversible agitator with control at operators work station; Discharge chute locks in multiple positions for mix distribution and transport; Double steel jacketed, hydraulically operated doors with 2 inches of industrial insulation, safety lock outs keep auger and agitator from operating while doors are open; Variable volume piston pump mounted on truck PTO producing 12 GPM at 3000psi, multi-spool control valve for all operating functions and hand tool auxiliary circuit; On board Hydraulically driven 230 volt AC electric generator with two 3.5kw electric heating elements for hopper heating, hopper thermostat displays set point and temperature and has a fail safe off mode to prevent overheating, all circuits protected by GFI breakers, onboard voltage and amperage meters; Self-Cleaning, air assisted tack coat system with dual purpose wand, 12 ft. hose, and stowage hooks, 80 gal. heated tack coat tank; .51 cu. yd. rear mounted and .47 cu.Yds. side mounted spoils bins; hydraulic jackhammer with asphalt chisel and 25 ft. hose mounted on a fully enclosed retractable hose reel; a vibratory plate compactor; Compactor and breaker are stored on a hydraulically raised and lowered platform; 12v DC amber beacon, electronic back up alarm. Unit must be guaranteed against faulty material and workmanship for a minimum period of one year. At delivery site, a minimum of one day of training for both operators and mechanics and all operating, service, and parts manuals shall be provided. Equipment must meet all applicable state and federal laws, rules, and regulations pertaining to the equipment specified

Item 1 Container:

1.1 Hopper shall be 50 degree steel sloped 3/16 thick inner side wall making up a triple wall construction

1.2 Inner wall construction shall consist of a 4 ½ inch air chamber, and a 3 inch insulated chamber. The air chamber shall be electrically heated and thermocouple temperature controlled.

1.3 Vertical end walls and side walls shall be double wall construction filled with 2 inch of insulation.

1.4 The operators platform shall be located at the front of the hopper and constructed of 3/16 diamond tread plate built in to the two, three inch x six inch hopper main frame rail tubes and is constructed with a four inch front channel cross member, four inch tall side flanges and heavy duty reinforcement below.

1.5 The large platform area shall measure 77 ½ inches (197cm) wide x 47 inches (119cm) front to back.

1.6 For easy of operation, the platform shall houses the emulsion tank, stacked hydraulic and air reservoir, water and cleaning fluid tanks, the 20 lb. propane tank, used for the heating torch, along with the main electrical control panel, still leaving room for the operator to move around freely.

1.7 An operator’s step constructed of 3/16 diamond tread plate shall be located next to the emulsion tank to help with access viewing and filling the hopper and emulsion tank.

1.8 Passenger side platform shall come with ladder with two rungs made of dimpled tread grip for easy access on to the platform with two climb assist handles.

1.9 Hopper doors shall be steel, double wall construction with a 2 inch insulated chamber

1.10 Hopper Doors shall have large hinge pins at each end and moisture drip flashing built into the edge of the two inner doors.

1.11 Hopper doors shall be hydraulically operate by two 1 ½ x 10 inch stroke cylinders from the ground on the passenger side for opening and closing.

1.12 Door opening shall be a minimum of 54 inches wide x 108 inches long.

1.13 Hopper shall have a full length lockable tool / storage box which shall be located on the drives side of the hopper.

1.14 Tool / Storage box size shall be a minimum of 22 inches (56cm) deep with a full length door opening 13 ½ inches (34cm) tall x 108 inches (274cm) long.

1.15 The door shall be constructed of heavy gauge steel with a full length hinge and two lockable hand latches.

1.16 The asphalt is discharged shall be from the rear of the hopper by means of an Auger, 6 inch diameter, 6 inch pitch, 3/8 inch thick flight, nested in the radius bottom of the hopper which runs the full length of the hopper.

1.17 The auger shall be powered by a high torque hydraulic motor which is reversible when the job is complete and ready to move.

1.18 Auger shall be reversible to move the asphalt at the discharge opening, back into the heated hopper so it stays warm.

1.19 Auger shall have a second hydraulic drive motor and manual selector valve.

1.20 Manual selector valve shall the capability to run both motors at the same time to double the torque on the auger.

1.21 When this torque is doubled the auger speed shall be reduced by half.

1.22 Manual selector valve shall have the capability of being shifted and the speed of the auger shall return back to normal.

1.23 Their shall be a spoils bin mounted at the rear of the Hopper. It shall be of heavy steel construction with a hinged fill door that can be lowered for easy access for filling.

1.24 The bin shall have a minimum capacity of 0.51 cu. yd. It shall be equipped with a side gravity dump door and shall have a lever arm handle.

1.25 Mounted on the passengers side of the Hopper shall be another spoils bin with a capacity of 0.47 cu. Yd. It shall be equipped with a side gravity dump door, operated with a lever arm handle.

Item 2 DISCHARGE CHUTE

2.1 Discharge Chute shall rotates left to right 105 degrees, 45 degrees to the left and 60 degrees to the right with a locking pin position every 15 degrees.

2.2 The Chute shall have the capability of being used without locking pin.

2.3 The Chute shall pivot from a down operational position of 45 degrees and shall have the capability of being locked in positions at 30 degrees, 15 degrees and horizontal. Transport locks vertically up at 45 degrees.

Item 3 AGITATOR

3.1 A material agitator shall be located in the hopper directly above the auger and shall run the full length of the hopper.

3.2 This agitator shall be hydraulic driven and controlled from the rear of the hopper at the operators control station.

3.3 The agitator shall only be required to rotate when bridging of the asphalt occurs causing the discharge to slow down or stop.

Item 4 HYDRAULICS

4.1 The Hydraulics shall be variable volume, pressure compensated, load sensing.

4.2 The reservoir shall have a minimum of a steel 25 Gal. fabricated constructed tank, equipped with an oil level sight glass and breather type filler cap.

4.3 In the lower side of the reservoir their shall be a outlet fitting with a 2 inch NPT 100 mesh strainer that filters the hydraulic oil before entering the pump.

4.4 The reservoir shall have a shutoff valve used for maintenance and shall be attached to the strainer at the reservoir for the pumps suction line to attach.

4.5 The hydraulic oil filter shall be mounted in the return line of the system and shall have a disposable spin on 10 micron element and sight gauge which indicated when element needs to be changed.

4.6 The main hydraulic pump shall be mounted to a Gear Box bolted to the truck’s transmission shall be a variable volume; pressure compensated / load sensing axial piston pump.

4.7 This pump shall be driven by the electric controlled PTO gear box which is turned on and off by a switch in the cab of the truck with an automatic transmission.

4.8 Trucks with a standard transmissions shall use a pull cable to turn the PTO driven pump on and off.

4.9 All hydraulic hoses shall be rated for a minimum of 3000 PSI working pressure.

4.10 Hydraulic control valve shall have a minimum of five spool valves located at the front of the hopper on the passenger’s side

4.11 Hydraulic valves shall operate but not limited to the loading doors, auger, agitator, auxiliary tools, and asphalt compactor platform all operate from the rear of the truck at the operator’s station.

4.12 Auxiliary hydraulic outlets and lever control shall be located at the rear, tools, auxiliary hydraulic outlets and lever control shall control tools such as Jack Hammer.

4.13 The hydraulic outlets shall be male and female quick disconnects at the ends of two 25 foot long hoses which are stored on the spring rewind dual hose reel located under the right side fender.

4.14 The Auger and Agitator shall be powered by their own hydraulic motors which shall provide a minimum of 13,209 inch pounds of torque and generate 13.6 HP.

Item 5 HEATING SYSTEM

5.1 The asphalt shall be kept hot by the use of two immersion heaters that shall run the full length of the hopper. Heaters shall heat the air cavity on both sides of the hopper side walls.

5.2 Heaters shall be 220 volt single phase 4 kw triple element heaters.

5.3 220 volt AC electrical power shall be generated by a hydraulic driven generator mounted on the hopper and capable of producing 60 Hz, 10 kVA or 42 amps.

5.4 When the truck is not in use and the asphalt is needed to be kept warm, a 25 foot power cord with a four prong male plug shall be supplied.

5.5 Power cord shall have the capacity to handle 220 volt single phase power through a minimum 40 amp outlet.

5.6 Outlet shall be attached to the bottom of the control panel on the hopper.

5.7 A 220 volt single phase control panel shall be mounted on the hopper.

5.8 Control panel shall house a 40 amp GFI main ground fault breaker for the system, the temperature controller, emulsion tank heater switch, amp meter, and voltage meter.

5.9 The temperature controller shall be used to regulate the hopper temperature.

5.10 The temperature shall be sensed with a thermal coupler mounted in the front of the hopper.

5.11 Emulsion tank shall be construction is an ASME approved tank wrapped with sheet metal, with two inches of insulation between.

5.12 A heater switch shall be used to turn the heating element on that is wrapped around the lower portion of the emulsion tank.

5.13 A 230 volt, adjustable thermostatically controlled, 750 watt, band heater shall be use to heat the emulsion tank.

5.14 Emulsion tank heater shall have over temp Snap-Action temperature protection used.

5.15 Amp and voltage meters shall be located in the main control panel indicate the power required.

Item 6 Emulsion / Tack System

6.1 Emulsion / tack system shall be air supplied from the truck’s engine driven air compressor and shall fill a 20 gal. ASME certified reservoir mounted at the front of the hopper.

6.2 Regulated air pressure of approx. 30 PSI from the patchers reservoir shall fill an air cavity above the emulsion in the 80 gal. ASME certified reservoir

6.3 Emulsion / Tack tank shall be located at the front of the hopper.

6.4 The emulsion tank shall be insulated with 2 inches of R12 insulation and wrapped with a steel shell.

6.5 The top of the tank Shall have an easy to fill oval opening of 6 3/8 (162mm) x 8 (203mm) with a lid that seals under pressure.

6.6 The emulsion, while under pressure shall be transferred to the tack wand which shall be stored on the right side of the hopper and shall be used to spray a tack coat of emulsion around the inside of potholes.

6.7 Included with this same wand their shall be a minimum air supply of 100 PSI supplied from the truck’s air system.

6.8 The air supply at the wand shall be used to blow debris from the pot holes within 20 foot (6.1m) of the back of the hopper.

6.9 The tack wand shall have a minimum of a 20 foot delivery hose located at the rear of the hopper.

6.10 The air delivery system shall be valved in such a way as to use this air to clean emulsion out of the wand and hose by pushing it back to the emulsion tank.

6.11 Mounted on the driver’s side at the rear of the hopper shall be a cleaning fluid spray wand with enough hose to extend 24 foot.

6.12 Cleaning fluid shall be pumped by a 12 volt DC pump mounted under the Hopper front platform and shall be fed from a 15 gallon tank mounted on the hopper platform.

6.13 The cleaning fluid tank shall be equipped with a fluid level sight tube and a filter suction strainer mounted in the outlet port.

Item 7 Vibratory Plate Compactor Storage Platform

7.1 The storage platform shall be located at the rear of the hopper on the right hand side.

7.2 The platform shall raise and lower hydraulically with a 2 inch bore x 24 inch stroke cylinder controlled from the operator’s station at the rear of the hopper.

7.3 When raised with the packer in place it automatically locks the packer for transport.

7.4 Their shall be a warning light inside the cab of the truck that shall remain on when the platform is not totally raised and is unsafe to transport.

7.5 Their shall be an additional transport lock bar installed at the rear of the unit to eliminate bounce of the compactor while being transported.

7.6 The pavement breaker shall be stored on the side of the platform which can be lowered for easy loading and unloading.

7.7 The pavement breaker shall have a transport lock can be padlocked for security.

Item 8 Vibratory Plate Compactor

8.1 Vibratory Plate Compactor shall be equipment with a 5 hp (3.7 kW) Air cooled, 4 cycle single cylinder gas engine.

8.2 Vibratory Plate Compactor size shall be a minimum of 19.5 inches X 23 inches.

8.3 Vibratory Plate Compactor weight shall be a minimum of 190 lbs.

8.4 Vibratory Plate Compactor shall have an adjustable height operators handle.

8.5 Vibratory Plate Compactor shall have a minimum water tank capacity of 8 qt.

8.6 Vibratory Plate Compactor shall have a maximum centrifugal force is 3,375 lb.

Item 9 PAVEMENT BREAKER

9.1 Pavement breaker shall have a minimum weight of 67lb.

9.2 Hydraulic Breaker shall come with a 5 inch asphalt Cutter Blade, an 11 inch shank, An a tamper foot with detachable shank.

9.3 Hydraulic hoses shall be run from the control valve to a mid mounted spring rewind dual hose reel located under the passengers side fender.

9.4 A pair of ½ inch hydraulic hoses 25 feet in length shall coil around the hose reel and shall be quick coupled to the Breaker.

9.5 Hydraulic hoses shall have the capability of be pulled from the back of the hopper for easy access to the potholes.

9.6 The Breaker shall be stored and transported on the storage / platform mounted at the right rear of the hopper.

9.7 The platform shall be hydraulically operated up and down for easy removal and installation of the Breaker.

Item 10 SWING AUGER

10.1 Swing auger shall be mounted to the rear of the Pothole Patcher hopper.

10.2 The Swing Auger shall be powered by hydraulics supplied by the Pothole Patcher truck’s hydraulic system.

10.3 Swing auger shall be controlled by a valve, mounted on the side of the discharge box of the hopper.

10.4 The control shall be mounted on the operator’s station at the rear of the hopper where a single lever activates the hydraulic motor for the hopper feed auger nested in the radius bottom of the hopper and the motor on the Swing Auger.

10.5 Swing auger shall also have a secondary hydraulic valve mounted on the side of the discharge box of the hopper, that can be activated in order to stop the flow of asphalt from the hopper feed auger and allow only the Swing Auger to run.

10.6 The swing auger shall have an expanded metal guard and cover mounted on the top of the auger trough so the operator is able to see the amount of asphalt in the auger and spray cleaning fluid through while the auger is running.

10.7 Swing auger shall have a three angle position chute located at the discharge end of the Swing Auger, which gives the operator his choice of height and angle for the placement of the asphalt.

10.8 Located at the inlet of the Swing Auger their shall be a funnel that directs the asphalt into the auger so it can be fed to the discharge end.

10.9 When the Swing Auger is in its operating position, shall have the capability to swing a total of 110 degrees, from the center to the curb side 70 degrees and 40 degrees to the centerline side.

10.10 Swing auger shall have the capability of covering a minimum width of 99 inches.

10.11 The Swing Auger shall be stored in a sideways transport position at the rear of the hopper with the inlet end tucked under the sloped side of the rear spoils bin and extending to the right, but not exceeding the width of the truck.

10.12 Swing auger shall have a lock pin installed in the swing arm below the inlet end of the auger preventing the auger from moving to the right.

10.13 The Swing Auger Chute shall have the capacity of being flipped up and over and placed on top of the auger’s cover.

10.14 The auger’s outlet end and mounted to the compactor platform lift shall come equipped with a transport lock.

10.15 With the platform lowered, and the auger moved into its transport position, the platform shall be raised hydraulically, which shall bring the lock up and the auger and platform lift is locked for transport.

10.16 In order to position the Swing Auger for operation, the platform lift lock must be released and the platform hydraulically lowered to the ground.

10.17 With the Swing Auger located to the right side, the platform lift shall have the capability of being raised and locked.

10.18 Swing auger dimensions.

10.18.1 Auger trough length shall be a minimum of 60 inches.

10.18.2 Auger size shall be a minimum of 6 inch Dia. X 6 inch Pitch X 3/8 inch thick.

10.18.3 Auger speed shall be a minimum of 98 RPM 40% faster then hopper auger.

10.18.4 Auger torque 86 shall be a minimum of 74 in. lbs.

10.18.5 Max overall length with chute and hydraulic motor 75 shall be a minimum of inches

10.18.6 Trough to ground shall be a minimum of 24 inches

10.18.7 Chute to ground shall be a minimum of 10 inches

10.18.8 From center of hopper to chute in right side position shall be a minimum of 62 inches

10.18.9 From center of hopper to chute in left side position shall be a minimum of 42 inches

10.18.10 Distance to chute behind unit (back of spoils bin) shall be a minimum of 38 inches

10.18.11 Auger swing radius with chute shall be a minimum of 60 inches

Item 11Warranty

11.1 Manufacture’s standard warranty will apply.

11.2 Terms and conditions of warranty must be provided with bid proposal.

11.3 Manufacture’s warranty will start with the in-service date Item 12 Truck Requirements

12.1 Unit shall be designed to fit a vehicle with the following requirements.

12.2 Front Axle capacity of 12,000 Lbs.

12.3 Rear axle capacity of 23,000 Lbs.

12.4 Gross Vehicle Weight of 35,000 Lbs

12.5 Air Brakes

12.6 12 Volt electrical system

12.7 Vertical exhaust system

12.8 Cab to rear axle clearance of 126 inches.

Item 13 GENREAL 13.1 Unit shall be designed to fit on a 35,000 GVWR Chassis.

13.2 Unit shall come with two operators, parts, and service manuals.

13.3 All pinch points shall be clearly marked.

13.4 Be it known that these specifications are a minimum and that bids will be evaluated based on price, warranty, manufacturers performance data, delivery schedule, parts availability and other items deemed appropriate.

13.5 Bidders are required to provide sufficient information with their bid such as manufacturer’s brochures, etc. and to certify that they have service facilities in Maine, staffed with trained service technicians and stocked with repair parts for the equipment which is bid. Failure to provide this information may cause the bid to be rejected. The MaineDOT reserves the right to reject any and all bids.

13.6 Bidders shall supply a specification sheet with their bid proposals.

13.7 Exceptions to specifications shall be listed on a separate paper and noted as exceptions and submitted with bid proposal. If exceptions are not listed as such it shall be considered that the vendor will comply with all specifications as listed.

13.8 All bid prices to include shipping and delivery to MaineDOT Fleet Service, 105 Capitol St. Augusta Me. 04330 Rev. 2/10

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