INTEGRAL DX Spray Paver User manual

09.16.2016RevF www.integraldx.com

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SprayPaver

Operator’sManual

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Operation•Maintenance•Troubleshooting

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TableofContents

Introduction...........................................................................................7

Thankyou!...............................................................................................7

Limitedwarranty.....................................................................................7

ClaimAdministrationPolicyProcedures.............................................8

Indemnity.............................................................................................9

ProductImprovementLiabilityDisclaimer..........................................9

Safety.....................................................................................................10

Safetyalerts.......................................................................................10

Damagewarning,notesandtips.......................................................11

Generalsafetyrules...........................................................................11

Safetydecals......................................................................................13

Generaldescription.............................................................................17

Generalspecifications...........................................................................19

Components..........................................................................................20

Emulsiontankgroup..........................................................................20

Pumpgroup.......................................................................................23

Emulsionspraygroup........................................................................24

Hydraulicsystem...............................................................................36

Pneumaticsystem.............................................................................39

Emulsiontankheatingsystem...........................................................42

Controlsystem...................................................................................47

Installation...........................................................................................54

Systemdeliveryandinspection.............................................................54

Machinesetup.......................................................................................54

Operation............................................................................................55

Pre‐operatingprecautions....................................................................55

Operatingprecautions..........................................................................56

Fireandexplosionprecautions.............................................................56

Hydraulicsystemprecautions...............................................................57

Usingthedisplayscreenunit................................................................58

Startscreen........................................................................................58

Displaynavigation.............................................................................59

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Sprayerselectionscreen...................................................................60

Pumpfunctionscreen.......................................................................64

Spraybarvacuumscreen..................................................................67

Totalsscreen......................................................................................68

Camerascreens(1and2)..................................................................69

Passwordscreen................................................................................70

Servicescreen....................................................................................71

Alarmsscreen....................................................................................72

Spraypavingsteps.................................................................................74

Loadingemulsioninthetank(s)........................................................74

Circulatingthetank...........................................................................80

Circulatingthespraybar...................................................................81

Sprayingemulsion.............................................................................82

Vacuumingbackemulsion.................................................................84

Cleaningoutandrinsing....................................................................85

Maintenance........................................................................................87

Recommendedspareparts...................................................................87

Serviceinterval......................................................................................88

Routinemaintenanceprocedures.........................................................90

Cleaningthespraywand...................................................................92

Cleaningthemachine........................................................................92

Cleaningthestrainerscreeninthepumpingstation........................93

Checkingthehydraulicoillevel.........................................................93

Inspectinghydraulichosesandemulsionhoses...............................93

Checkingthefluidlevelinthecleanouttank...................................94

Cleaningblockagefromtheemulsiontankoverflowtubes.............94

Cleaningthehydrauliccylinderrods.................................................94

Checkingtheoilintheaircompressor..............................................94

Drainingtheaircompressortankandairfilter.................................95

Inspectingthepackingglandontheemulsionpumps......................95

Inspectingtheemulsionpumpcoupler.............................................96

Lubricatingtheemulsionpumpbearings..........................................97

Inspectingthepackingglandontheemulsiontank..........................97

Checkingthetightnessofthetanktie‐downhardware....................97

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Checkingspraynozzlealignment......................................................97

Checkingthespraybarhardware......................................................97

Checkingtheconditionofthehydraulicfilter...................................97

Removingdebrisintheemulsiontanksump....................................98

Changingthehydraulicoilandfilter.................................................98

Changingthefluidinthecleanouttank...........................................98

Calibratingthesmallasphaltpump...................................................98

Storage................................................................................................101

Startupafterstorage...........................................................................102

Hydraulicssystemcheck..................................................................102

Cleaningagentcheck.......................................................................102

Functioncheck.................................................................................103

Troubleshooting................................................................................106

Cleaningtheemulsiontank.................................................................112

Cleaningastuckpump........................................................................116

Settingthesmallemulsionpumpbypasspressure.............................119

Appendices........................................................................................120

Appendix1:Valveandemulsionpumpconfigurationsforthepump

functions..............................................................................................121

Appendix2:Pumpgroupflowpaths...................................................123

Tankload.........................................................................................123

Tankcirculate..................................................................................124

Spraybarcirculate...........................................................................125

Sprayauto........................................................................................126

Spraybarvacuum............................................................................127

Cleanout..........................................................................................128

Bypasssetting..................................................................................129

Appendix2:UpdatingPLCanddisplaysoftware................................131

Downloadingandrunningthesoftware.........................................131

Programmingthedisplayscreenunit.............................................132

Programmingthecontrolunit.........................................................135

Appendix3:Maintenancerecord........................................................138

Appendix4:Emulsiontankconfiguration...........................................140

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Introduction

Thankyou!

ThankyouforchoosingtheIntegraldxspraypaver.

Thespraypaverisanaccessoryforanasphaltpavingmachinethat

appliesemulsifiedasphalts(emulsion)tosurfacesbeforepaving.Thespray

paverspraysemulsionuniformly,atspecifiedapplicationrates,andwithout

thepaverwheelsortracksrunningovertheappliedemulsion.

ThespraypaverwasdesignedandmanufacturedintheUSAwithquality

materialsandworkmanship.Withproperuseandcare,itwillprovide

manyyearsoftrouble‐freeservice.

Keepthismanualhandyforfrequentreferenceandtopassontonew

operatorsorowners.ContactIntegraldxifyouneedassistance,

informationoradditionalcopiesofthemanuals.

Theinformationinthisoperator’smanualisineffectattimeofprinting.

Itissubjecttochangewithoutnotice.Configurationsofspecificmodels

mayvary.

Limitedwarranty

Integraldxwarrantsproductsofitsmanufacture,whenusedcorrectly

undernormaloperatingconditions,tobefreeofdefectsinmaterialsand

workmanship.Integraldxmakesnootherwarrantyexpressedorimplied.

Thiswarrantyshallbeforaperiodof6monthsfromthedatetheproduct

isputintoservice,providedIntegraldxissuppliedwiththein‐service

date.Thewarrantyshallnotapplytoanyproductsthathavebeen

altered,changed,orrepairedinanymannerwhatsoever,exceptbyan

authorizedIntegraldxrepairfacility;nortoanyproductwhichhasbeen

subjecttomisuse,negligence,oraccident.Theexclusiveandsoleremedy

forbreachofcontractshallbelimitedtorepair,modification,or

replacementatthesolediscretionofIntegraldx.Integraldxshallnotin

anyeventbeliableforthecostofanyspecial,directorconsequential

damages.Integraldxreservestherighttomakechangesor

improvementsinthedesignorconstructionofanypartwithoutincurring

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Allclaimsmustbesubmittedwithin30daysofserviceonanIntegraldx

claimformwiththeauthorizedprovidersworkorderattached.

Allrepairpartorderswillrequireapurchaseorderandwillbebilledata

normalrate.Creditwillbeissuedwhenwarrantyisapproved.

OriginalEquipmentManufacturer(OEM)partswillbewarranted

accordingtotheOEMwarrantyuponshipmentdateofproduct.

Indemnity

BuyeragreestoindemnifyandholdIntegraldxharmlessforallloss,cost

includingbutnotlimitedtolegalandothercostofproceedings,and

damagessufferedbyBuyerorclaimedbythirdpartiesbyorrelatedto

Buyer’suseofIntegraldxproducts.

ProductImprovementLiabilityDisclaimer

Integraldxreservestherighttomakeanychangesinorimprovementsto

itsproductswithoutincurringanyliabilityorobligationwhatsoeverand

withoutbeingrequiredtomakeanycorrespondingchangesor

improvementstoproductspreviouslymanufacturedorsold.

THISWARRANTYISINLIEUOFALLOTHERWARRANTIESEXPRESSEDOR

IMPLIED INCLUDINGANYIMPLIEDWARRANTIESOFMERCHANTABILITY

ORFITNESSFORA PARTICULARPURPOSE,WHICHAREHEREBY

DISCLAIMEDANDOFANYOTHEROBLIGATION ORLIABILITYOFINTEGRAL

DX.THEREMEDYSETFORTHABOVEISBUYER’SEXCLUSIVE REMEDYFOR

ABREACHOFTHEWARRANTY.

UNDERNOCIRCUMSTANCESWILLINTEGRAL DXBERESPONSIBLEFOR

INCIDENTAL,CONSEQUENTIAL,SPECIALOROTHERINDIRECT DAMAGE.

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Safety

Howyouoperateandmaintainyourequipmentdirectlyaffectsyour

safetyandthesafetyofothers.Therefore,readandunderstandthis

manualandanyothersafetyinformationprovided,includingsafety

decalsontheequipment.

Integraldxcannotanticipateeverypossiblecircumstancethatmight

involveapotentialhazard.Thesafetyalertsinthismanualaretherefore

notallinclusive.Ifyouuseanoperatingprocedure,installationorwork

methodnotspecificallyrecommended,youmustsatisfyyourselfthatitis

safeforyouandforotherpersons.Youmustalsoensurethattheproduct

willnotbedamagedormadeunsafebytheprocedurethatyouuse.

Safetyalerts

Safetyalertsymbolsinthismanualoronthemachineindicateimportant

messagesregardingsafety.Whenyouseethesafetyalertsymbolandthe

signalwordafter,carefullyreadthemessagethatfollowsandunderstand

thereisapossibilityofinjuryordeathifyoudonotadheretothe

requirementsofthesafetymessage.

Danger:Indicatesahazardoussituationthat,ifnotavoided,

willlikelyresultindeathorseriousinjury.

Warning:Indicatesahazardoussituationthat,ifnotavoided,

couldresultindeathorseriousinjury.

Caution:Indicatesahazardoussituationthat,ifnotfollowed,

couldresultinminorormoderateinjury.

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Damagewarning,notesandtips

Avoiddamage:Indicatesasituationthatcouldcausedamage

tothespraypaverorpropertydamage.

Note:Anotecontainsinformationthatisimportantfor

operatingormaintainingthespraypaver.

Tip:Atipcontainsusefulinformationthatcanimproveor

optimizeuseofthespraypaver.

Generalsafetyrules

Thegeneralsafetyrulesareincludedinthissectionofthemanual.

Specificsafetyrulesappearthroughoutthemanual.

Danger:Beforeoperatingorservicingthisequipment,

completepropertraining.Alsoreadandfullyunderstandthe

operator'smanualandthesafetylabelsonthemachine.

Danger:Donotsmokearoundthemachine.Fuel,emulsion,

andfumescanexplodewhenexposedtoflamesorheatfrom

smokingorothersources.

Warning:Haveafirst‐aidkitavailableandknowhowtouseit.

Warning:Keepachargedfireextinguisherwithinreach

wheneveryouworkinanareawherefiremayoccur.

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Safetydecals

TheIntegraldxSprayPaverisequippedwithanumberofsafetydecals

indicatinghazardstobeavoidedwhenoperatingthespraypaver.

Understandthedecalsbeforeusingthespraypaver:

Hotmaterialispresent.Takecareto

avoidcontactwithitduringspray

paveroperations.

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Movingpartscouldpinchahand,

foot,etc.Takecaretonotgetbody

partstrappedbetweentheparts.

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Anelectricalhazardexiststhatcould

potentiallyprovideaseriousshock.

Avoidthehazardduringoperation.



Hotpipesarepresentthatcould

provideseriousburnstoexposed

skin.Avoidcontactwiththem.

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Ensurecoversareinplaceforsafe

operationofthespraypaver.

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Theoperatorcannotseethispartof

themachine.Stayawayduring

operation.



Donotdisconnectlines.Doingso

duringspraypaveroperationwill

causedeathorseriousinjury.

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Figure1:Safetydecallocation(mayvarydependinguponmodel)



x2x2

X2

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