Hog Technologies PAINT HOG User manual

PAINT HOG
Operation Manual
WWW. STRIPEHOGSUPPORT.COM
SE Slater Street Stuart, FL 34997 1-877-HOG-ROAD (001) [phone]

3
WARNING
INCORRECTUSEOFEQUIPMENTMAYCAUSESERIOUSINJURYOREVENDEATH.
DO NOT USE THIS EQUIPMENT WITHOUT PROPER SUPERVISIONAND TRAINING.
INEXPERIENCED PERSONNEL ATTEMPTING TO USE THIS EQUIPMENT MAY
RESULT IN INJURYTO THEMSELVES,OTHER TEAM MEMBERS OR BYSTANDERS
AND DAMAGE TO COMPONENTS.
ALL OPERATING AND MAINTENANCE PERSONNEL MUST BE THOROUGHLY
TRAINED IN SAFE OPERATION BYAHOG TECHNOLOGIES CERTIFIED TRAINER,
IN THE INSTALLATIONAND MAINTENANCE OF THIS EQUIPMENT,AND PROVIDED
WITH ADEQUATE SUPERVISION.
BEFORE ATTEMPTING TO CONNECT, OPERATE, OR REPAIR THIS EQUIPMENT,
THOROUGHLY READ THESE INSTRUCTIONS AND ANY SAFETY WARNING OR
INSTRUCTION PAMPHLETS INCLUDED WITH YOUR SHIPMENT.
FOR ANY QUESTIONS CONCERNING SAFE OPERATIONS AND MAINTENANCE
PROCEDURES,CONTACTYOUR HOG TECHNOLOGIES REPRESENTATIVE PRIOR
TO USE.
[phone] OR [phone]
HOG TECHNOLOGIES
WWW.HOGTECHNOLOGIES.COM
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 [phone].
Copyright/General Warning

4
STOP
TOAVOID SERIOUS INJURY,MAKE SURE TO COMPLETELY READ THIS MANUALAND
FOLLOWALL SAFETYPRECAUTIONS LISTED IN THE MANUALAND ON COMPONENT
LABELS BEFORE OPERATING THIS EQUIPMENT.

5
Table of Contents
Copyright/General Warning.................................................................................................. 3
Table of Contents................................................................................................................ 5
Welcome ........................................................................................................................... 7
Hog Technologies Limited Warranty ...................................................................................... 8
Safety Warnings & Instructions............................................................................................. 9
Section 1:
Safety Information
1.1 General Safety............................................................................................................11
1.2 Hot Fluids & Components Hazard ..................................................................................12
1.3 Electrical System Hazards ............................................................................................13
1.4 Hydraulic System Hazard .............................................................................................13
1.5 Fire Hazard ................................................................................................................13
1.6 Fueling Fire Hazard .....................................................................................................14
1.7 Fall Hazard.................................................................................................................14
Section 2:
Paint Hog Systems
2.1 Paint Hog System Introduction......................................................................................15
2.2 Truck Chassis .............................................................................................................16
2.3 Paint Deck .................................................................................................................17
2.4 Auxiliary Engine/Air Compressor ...................................................................................18
2.5 Compressed Air Supply System ....................................................................................20
2.6 Hydraulic System........................................................................................................23
2.7 Paint Tanks & Delivery System......................................................................................25
2.8 Paint Tank Fill System..................................................................................................26
2.9 Pressurized Flush Water System....................................................................................27
2.10 Paint Heater System (Optional)...................................................................................28
2.11 Bead Tank & Delivery System......................................................................................30
2.12 Spray Gun Carriages..................................................................................................33
2.13 Rear Control Station ..................................................................................................34
2.14 12 Volt Electrical System............................................................................................36
2.15 Cab Control Switches & Panels ....................................................................................39
2.16 Cameras & Video System (Optional) ............................................................................41
2.17 Rear Control Station Switches and Panels ....................................................................43
2.18 Access Panels, Ladders & Tool Boxes............................................................................49

6
Table of Contents
Section 3:
Operation
3.1 Start Up/Shutdown Introduction....................................................................................51
3.2 Pre-Operation Inspection .............................................................................................52
3.3 Starting & Stopping the Air Compressor .........................................................................53
3.4 Filling The Water Tank..................................................................................................54
3.5 Filling Paint Tanks .......................................................................................................54
3.6 Filling Bead tank .........................................................................................................56
3.7 Changing Spray Gun Paint Color....................................................................................57
3.8 Starting & Shutting Down The Paint Heater.....................................................................57
3.9 Starting Paint Operations .............................................................................................58
3.10 Routine Paint System Shutdown..................................................................................59
3.11 Hand Spray Gun Operation .........................................................................................60
3.12 Emergency Shutdown ................................................................................................61
Section 4:
General Maintenance
4.1 Lubrication & General Maintenance Introduction..............................................................63
4.2 Lubrication Grease Fittings ...........................................................................................64
4.3 General Maintenance ..................................................................................................65
4.4 Paint Filter Maintenance...............................................................................................66
4.5 Clearing Paint Supply Lines...........................................................................................68
4.6 Clearing Bead Supply Line............................................................................................70
4.7 Water Heater & Burner Maintenance (Optional) ...............................................................72
4.8 Hydraulic System Maintenance......................................................................................74
4.9 Compressed Air System...............................................................................................76
4.10 Hand Gun, Reel & Hoses.............................................................................................78
4.11 Maintenance Matrix ...................................................................................................79
Appendix 1:
Pre-Operation Check List...............................................................................................81
Appendix 2:
Hog Technologies Support.............................................................................................83

7
Welcome
Congratulations on your recent purchase of the Paint Hog! The Paint Hog is the
world’s most advanced equipment for applying pavement markings. Your purchase
demonstrates your commitment to excellence and positions you as a world leader
in pavement marking.
Hog Technologies is excited to welcome you and your crew to the Paint Hog Operators’
Team. Together we embrace the challenge of constantly developing our equipment,
knowledge and skills so that our highways will be safer for all who rely on them and
our pavement marking will last longer for those who pay for them. The Paint Hog,
in the hands of a trained/certied/licensed operator with this work ethic, will be a
tting complement to our mutual commitment to excellence.
As you know, no machine is capable of outperforming its operator so we have de-
signed a training experience that will equip your operators with the tools needed to
maximize productivity and minimize operational expenses while building our mutual
reputation for high quality, ecient pavement markings. This manual is designed to
be used by operators trained by Hog Technologies. During the training experience
your team will be given the basic knowledge and skills necessary to maintain, oper-
ate, troubleshoot and repair your Paint Hog.
Please take the time to read this operation manual before attempting to operate your
system. This manual is an important aid in the operation and maintenance of your
new equipment. The information is intended as a guide and cannot cover every ques-
tion you may have about your Paint Hog or every operating situation. We encourage
you to contact Hog Technologies for any additional information you might need. We
provide support to our customers for all of the equipment we sell. We maintain an
experienced support team that is available 24 hours a day 7 days a week along with a
well-stocked inventory of parts and accessories for your convenience. Please contact
us for any and all of your support issues and questions toll free at [phone]
or online at www.hogtechnologies.com or www.stripehogsupport.com
From our family to yours we would like to take a moment to say thank you from all of
us at Hog Technologies! We look forward to many successful years working together
to provide maximum productivity at minimal operational cost.

8
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. The warranty evaluation by Hog Technologies as to the cause of the defect shall be conclusive.
For approved warranty shipments, Hog Technologies will provide no charge Fed-ex ground or Fed-Ex
Economy shipping. If customer requests expedited shipping, the dierence in the shipping costs will
be invoiced to the customer.
Hog Technologies reserves the right to request the component(s) to be returned, freight pre-paid, for
analysis before proceeding with any warranty claim. The customer shall be responsible for payment
of any replacement components requested. If the warranty claim is approved by Hog Technologies,
credit will be issued for the components under warranty.
No warranty is made, either expressed or implied, for defects, failures or malfunctions resulting from
corrosion, misapplication, over-pressurization, insucient or lack of maintenance and any modica-
tions to the component as supplied by Hog Technologies.
Any components replaced during the period of warranty will be warranted only during the period of
the initial warranty, and no extensions shall be made, unless in writing by Hog Technologies in addi-
tion to the provision of the terms of the original warranty.
Hog Technologies will not be liable for damage, abnormal wear or consequential damage to their sys-
tem components resulting from the use of replacement components that are not furnished by Hog
Technologies.
Hog Technologies will not be liable for charges incidental to the removal of damaged or defective com-
ponents, lost time and prots, or any consequential damages resulting from failure of the component.
Hog Technologies reserves the right to make improvements to future models without the need to retrot
or upgrade prior models. Hog Technologies shall not be obligated to perform retrots and/or modi-
cations to components manufactured prior to the incorporation of the new design and specications.
Components that are not originally manufactured by Hog Technologies, including but not limited to,
the truck chassis, Jetstream Pump, OMSI (Gear Box), Dresser Roots Blower, are warranted only to
the extent of the original manufacturer’s warranty and are subject to their allowance to us if found
defective by them. Copies of other manufacturers warranty statements are supplied at the time of
sale. Hog Technologies will assist with warranty claims on components not originally manufactured
by Hog Technologies.
*For approved warranty claims that include labor: If such labor is provided at customer location and
not at Hog Technologies headquarters, Hog Technologies reserves the right to invoice customer for
reimbursement of travel-related expenses.
Hog Technologies Warranty Schedule
Warranty starts from the date of acceptance by the purchaser. Date of acceptance shall
be dened as the time that the Stripe Hog is received by the purchaser. Acceptance of
the Stripe Hog shall imply agreement to the terms and conditions of this warranty.
• 1 - 365 Days: 100% Parts and 100% Labor *

9
Safety Warnings & Instructions
NOTICE:
INDICATES A SITUATION WHICH CAN CAUSE DAMAGE
TO THE MACHINE, PERSONAL PROPERTY, AND/OR THE
ENVIRONMENT OR CAUSE THE EQUIPMENT TO OPERATE
IMPROPERLY.
CAUTION
HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT
INMINORPERSONAL INJURYOR PRODUCTAND PROPERTY
DAMAGE.
WARNING
HAZARDS OR UNSAFE PRACTICES WHICH COULD RESULT
IN SEVERE PERSONAL INJURY OR DEATH.
DANGER
INDICATES A HAZARDOUS SITUATION WHICH, IF NOT
AVOIDED, WILL RESULT IN DEATH OR SERIOUS INJURY.
This manual has been written to include a number of safety instructions to assure the safe operation
and maintenance of the equipment. These instructions are in the form of a General Safety Section as
well as individual NOTICE, CAUTION, WARNING and DANGER statements. There are also WARNING
AND DANGER LABELS located on some components. You should read these warnings carefully and
make sure you understand the nature of the hazard as well as the precautions and recommended
procedures required to ensure your safety. The following denitions apply:
Every precaution has been taken by Hog Technologies to reduce the risks associated with possible
injury and damage from electrical faults, high temperature antifreeze, paint or components, hydraulic
components or mechanical failure. However, your own precaution and good maintenance procedures
are necessary in order to maintain a safe working environment.
All instructions given in this book are as seen from the rear looking forward. Common industry ter-
minology is used throughout the manual.

10
NOTES

11
1.1 General Safety
Use Professional Training
Operating painting equipment requires profes-
sional training, including safe work practices and
procedures. Only professionally trained personnel
should be allowed to setup, operate, or maintain
this equipment. If you have not completed the Hog
Technologies training course you will be a danger
to yourself and others.
Always Read Instructions
Read this manual and all other equipment opera-
tion manuals and instructions prior to using any
Hog Technologies product. Contact Hog Technolo-
gies (877-HOG ROAD) should any questions arise.
Major Component Operation Manuals
The suppliers of some major components such
as the truck chassis, air compressor, pumps, and
heater, provide their own operation manuals which
have been included with your equipment. Before
operating this equipment, you should read the in-
formation in this manual and the manuals of other
manufacturers completely and have a thorough
understanding of all component systems and their
proper operation.
REMEMBER - IT IS YOUR RESPONSIBILITY
TO ENSURE THAT YOUR EQUIPMENT IS SAFE
FOR YOU AND YOUR CREW. ALWAYS EXER-
CISE GOOD JUDGMENT WHEN INSTALLING
OR REPAIRING EQUIPMENT AND WHILE OP-
ERATING PAVEMENT MARKING EQUIPMENT.
Work Area Safety
Remember, safety is rst! Only set up to work in
areas properly protected from trac and other
hazards. Individuals being struck by vehicles or
mobile equipment lead to many work zone fatali-
ties or injuries. Work zones need trac controls
identied by signs, cones, barrels and barriers.
You should always wear high visibility clothing
with a uorescent background and made of retro-
reective material to be more visible to motorists
and reduce the possibility of an accident. Work
stations should always be illuminated.
Outt all operators with proper safety apparel.
Always use eye protection to shield from projected
debris and ear protection to protect from noise. It
is very important to wear boots that provide good
traction on slippery surfaces.
Never wear loose clothing. Loose clothing can get
caught on moving or rotating parts causing serious
injury or even death.
Pavement marking application operations gener-
ate noise levels above 90 dB. Hearing protection
is required in accordance with OSHA standards.
OSHA’s Permissible Noise Exposure
90 dB 8.0 hours
92 dB 6.0 hours
95 dB 4.0 hours
97 dB 3.0 hours
100 dB 2.0 hours
102 dB 1.5 hours
105 dB 1.0 hours
110 dB 30 minutes
115 dB 15 minutes
WARNING
ALL PERSONNEL EXPOSED TO 90 DB OR GREATER
NOISE LEVELS SHOULD RECEIVE INSTRUCTION IN THE
CORRECT USE OFEAR PROTECTION SO THAT THEIR NOISE
EXPOSURE LIES WITHIN THE LIMITS SPECIFIED BY OSHA.
NEVER ALLOW ANYONE NEAR THE WORK AREA WITHOUT
PROPER EAR PROTECTION.
ALWAYS BE SURE YOUR WORK AREA IS CLEAR OF
PEOPLE WHENEVER PAVEMENT MARKING EQUIPMENT IS
ACTIVATED.
Section 1:
Safety Information

12
Section 1 - Safety Information
Product changes
Hog Technologies is committed to the continuous
improvement of our products. As a result, some
of the equipment described in this manual or
pictured in the catalog may change or no longer
be available.
All information, illustrations, and specications
contained in this manual are based on the lat-
est product information available at the time of
publication. Hog Technologies reserves the right
to make changes at any time, without notice, in
colors, materials, equipment, specications, and
models.
If you have questions about the equipment on
your Paint Hog, please contact the Customer sup-
port Department at (877) HOG ROAD or (001)
772-223-7393.
Never Alter a Hog Technologies Product
Do not alter any product without written consent
from the manufacturer. Any alterations could have
serious consequences including bodily harm or
death. Alterations without manufacturer consent
will void the warranty.
Inspect Equipment
Inspect the condition of all components prior to
use. Do not use any item that is in questionable
condition.
IMPORTANT NOTE:
YOUR EQUIPMENTUSESINTERNALCOMBUSTIONENGINES
AND FLAMMABLE FUEL. EVERY PRECAUTION HAS BEEN
TAKEN BY HOG TECHNOLOGIES TO REDUCE THE RISKS
ASSOCIATED WITH POSSIBLE INJURYAND DAMAGE FROM
FIRE OR EXPLOSION, BUT YOUR OWN PRECAUTION AND
GOOD MAINTENANCE PROCEDURES ARE NECESSARY TO
ENSURE THE SAFE OPERATION OF YOUR EQUIPMENT.
Store Components Properly
Protect all components from damage when not in
use. Secure for travel.
1.2 Hot Fluids & Components Hazard
The optional paint heating system heat exchang-
ers, tanks, pumps, and other components are
heated by circulating hot antifreeze. The antifreeze
is heated by a diesel fuel red heater to high
temperatures. Consequently, the heater, tanks,
valves, pipes hoses and other components of the
system are very hot during operation.
Always use extreme caution when working around
heated components. Contacting hot components
or antifreeze leaking from a damaged hose, pipe
or tting can cause severe burns.
The following precautions apply whenever
a vehicle equipped with an optional paint
heating system is operating:
• Make sure all team members are properly
trained and aware of hot components and the
associated burn hazard.
• Always wear heavy gloves while working near
hot components and never touch any hot com-
ponent with bare hands.
• Make sure hoses are protected from contact
with sharp objects or chang. Repair leaks in
hot uid hoses and ttings immediately. Never
operate heating equipment with leaking hoses
or ttings.
• Only use the specied antifreeze in the paint
heating system. The use of any other uid can
damage equipment.
• Always allow room for expansion in antifreeze
expansion tank. Never over ll the tank.
• Inspect heater fuel supply lines frequently.
Never operate the system if fuel lines or t-
tings are leaking.
• Ensure all fuel soaked rags are stored in an
appropriate reproof container.
• Maintain at least 1 fully charged re extin-
guisher on the vehicle at all times. If an ex-
tinguisher is used, have it serviced.

13
Section 1 - Safety Information
1.3 Electrical System Hazards
The electrical system on your vehicle is powered
by a high amperage 12 volt DC electrical system.
To avoid short circuits and circuit overloads that
can damage the electrical system or cause a re,
the following precautions apply:
• Turn o the 12 volt master disconnect switch
and circuit breakers when the vehicle is unat-
tended or before servicing components.
• All circuit breakers and fuses for overload
protection in electrical circuits must be kept
in good condition.
• Disconnect the negative (-) battery cable rst
and when reconnecting, connect the negative
(-) cable last.
• Do not grind, weld or have open ame near
batteries. Sparks can cause explosion.
• Do not weld on truck without turning o the 12
volt master switch and disconnecting batteries.
• Do not short across battery terminals. Sparks
can cause an explosion.
1.4 Hydraulic System Hazard
The hydraulic system that powers mixer motors
and cylinders operates at extremely high pressure
(up to 3000 PSI). Always use extreme caution
when working around hydraulic systems. A high
pressure uid leak from a damaged hose or tting
can cause severe lacerations to a person’s skin or
inject hydraulic uid into the blood stream, which
can be fatal.
The following precautions apply whenever
the vehicle is operating:
• Hydraulic hoses and connections must be
inspected frequently to ensure they are in
good condition and that there are no signs of
chang or deterioration.
• Make sure hoses are protected from contact
with sharp objects or chang.
• Stretched or abused hose can fail prematurely
and unexpectedly, which could cause injury to
personnel. Hoses that have been exposed to
excessive stretching, kinks or chang should
be replaced.
• Always make sure all personnel maintain a
safe distance from all hydraulic components
and hoses whenever the unit is in operation.
• Always depressurize the hydraulic system
before removing any hydraulic components,
hoses or ttings. Failure to do so could result
in serious injury or death.
WARNING
INJURIES FROM HIGH PRESSURE HYDRAULIC SYSTEM
COMPONENT FAILURES ARE VERY SERIOUS AND CAN
RESULT IN SEVERE INJURY OR A FATALITY. ALWAYS
MAKE SURE ALL PERSONNEL ARE A SAFE DISTANCE
FROM HYDRAULIC SYSTEM COMPONENTS AND HOSES
WHENEVER THE VEHICLE IS OPERATING.
1.5 Fire Hazard
Fire is a potential hazard with all fuel powered
equipment. Your machine is equipped with a re
extinguisher that must be inspected and serviced
at intervals recommended by the re extinguisher
manufacturer.
Fire Suppression Equipment
Manual and automatic re suppression equipment
operate dierently. Operators should be properly
trained in the use of all re suppression equipment
installed on your truck and be prepared to react
quickly if a re occurs.
Fire suppression equipment requires regular
inspections to ensure that:
• Seals & tamper indicators are not broken or
missing.
• Pressure gauges or indicators read in the op-
erable range.
• The suppression equipment is properly
charged and ready for activation if needed.
• There is no obvious physical damage, corro-
sion, leakage or clogged nozzles.
Heater Exhaust System (Optional)
The heater exhaust system is designed to be
open to the atmosphere and requires unrestricted
exhaust ow for proper operation. Never add ex-
haust pipe caps or automatic apper valves to the
heater exhaust pipe. These will restrict the ow
of exhaust gases which will result in incomplete
combustion and excessive temperatures in certain
components.

14
Section 1 - Safety Information
DANGER
RESTRICTED HEATER EXHAUST PIPES WILL CAUSE
EXCESSIVE BURNERAND EXHAUST TEMPERATURES THAT
COULD DAMAGE COMPONENTS OR RESULT IN A FIRE OR
EXPLOSIONAND INJURY TO PERSONNEL. NEVER INSTALL
CAPS OR AUTOMATIC EXHAUST VALVES ON THE HEATER
EXHAUST PIPE.
1.6 Fueling Fire Hazard
The oil heater burner produces an open ame that
can ignite fuel fumes in high concentrations near
the burners causing a re or explosion. This is
particularly dangerous while fueling. It is essential
that the burner be turned o before entering a
fuel station and while fueling the truck.
DANGER
LEAVING THE BURNERS ACTIVATED WHILE FUELING CAN
CAUSEAFIREOR EXPLOSIONRESULTING INSEVER INJURY
OR DEATH. ALWAYS TURN OFF THE BURNERS BEFORE
ENTERING A FUEL STATION. THIS PROCEDURE SHOULD
NEVER BE OVERLOOKED.
1.7 Fall Hazard
The deck and rear platform are high o the ground
and personnel can be severely injured if they fall
from deck or platform. To reduce the possibility
for a fall, the following precautions apply:
• Always face the truck and use three points of
contact when climbing a ladder.
• When working on the deck, always pay atten-
tion to your position and avoid standing near
the edge.
• When working on the rear platform, avoid lean-
ing out past the rail.
• Spilled paint creates a slip and fall hazard. If
paint is spilled on the deck, mark the area of
the spill and notify all personnel. Clean up spilled
paint as soon as possible and before operating
the truck.

15
2.1 Paint Hog System Introduction
The pavement marking system is mounted to the
truck chassis. It is powered by the air compressor
auxiliary engine mounted front of the deck.
The system includes a 12 volt DC electrical sys-
tem, hydraulic system, paint tanks, glass bead
tank, rear control deck and 2 spray gun carriages.
It could also be equipped with an optional paint
heating system and/or dual controls.
Most components are controlled by switches in
the cab and rear control panels. A communication
system allows the driver in the cab to communi-
cate with the spray gun operator (switchman) at
the rear control station.
The operation and maintenance requirements for
the engine, drive train and chassis components
are unique to the manufacturer and the selected
options. Each truck chassis manufacturer provides
owners information manuals with their product.
It is important that you read the manuals care-
fully and become familiar with the proper care
and operation of engine, drive system, chassis,
safety equipment and all components of your
truck chassis.
Paint Hog
Section 2:
Paint Hog Systems

1616
Section 2 - Paint Hog Systems
2.2 Truck Chassis
The paint system components are mounted on a
heavy duty truck chassis. Other than the truck
batteries supplying DC electrical power to 12 volt
system, the system is completely isolated from
truck.
Dual Truck Controls (Optional)
Trucks can be equipped with dual steering and
controls. A rocker switch in the dash is typically
used to select either right or left side controls.
Refer to the truck operation manual for informa-
tion on the dual control system.
Truck Engine Fuel Tank
The truck fuel system supplies fuel to the truck
engine and the auxiliary engine that powers the air
compressor and hydraulic pump. It also provides
fuel to the diesel red heater for the paint heating
system if your truck is equipped with this option.
Consequently, fuel consumption will increase when
these systems are operating. The driver should
be aware of this and monitor fuel consumption
closely during striping operations.
Pointer Arm
A pointer arm/guide wheel assembly mounted to
the front of the chassis assists the driver in main-
taining truck position while spray operations are
underway. It can be moved to either side of the
truck if desired. When not being used, the pointer
arm assembly is folded against the front bumper
and secured with safety pins.
Once deployed, the arm and guide wheel is raised
or lowered by a hydraulic cylinder controlled by
the POINTER switch in the cab control panel. The
pointer arm is designed to be used only for spray
operations and must be folded against the bumper
and secured with the safety pins before driving
the truck on the road.
Refer to the Cab Control Switches & Panels and
Operation sections for additional information and
operating instructions for the pointer arm.
Pointer Arm Folded Against Front Bumper
& Secured With Safety Pins

1717
Section 2 - Paint Hog Systems
Paint Deck
2.3 Paint Deck
The paint deck is located between the cab and rear
control station. The deck accommodates the paint
tanks, bead tank, water tank, the auxiliary engine/
air compressor and the paint heating system, if
the truck is equipped with this option. Ladders on
each side provide access to the deck.
Paint system and auxiliary engine main circuit
breakers, diaphragm paint transfer pumps, paint
lters, compressed air lters and other compo-
nents are mounted to the chassis below the deck.
The rear control station and canopy is mounted
on the rear of the deck.
WARNING
FALLING FROM THE DECK CAN RESULT IN SEVERE INJURY
OR DEATH. PERSONNEL WORKING ON THE DECK SHOULD
ALWAYS BE AWARE OF THEIR POSITION AND AVOID
STANDING NEAR THE EDGE. MAKE SURE TO FACE THE
DECK AND MAINTAIN THREE POINTS OF CONTACT WHEN
USING THE LADDERS.
WARNING
ANYONE ON THE DECK WHILE THE TRUCK IS MOVING
CAN BE THROWN FROM THE DECK BY AN UNEXPECTED
MANOEUVRE OR ROAD HAZARD. THIS COULD RESULT IN
SEVERE INJURY OR DEATH.
NEVER ALLOW ANYONE ON THE DECK WHILE THE TRUCK
IS MOVING. THE TRUCK DRIVER SHOULD ALWAYS CHECK
WITH THE SWITCHMAN TO VERIFY THAT ALL PERSONNEL
ARE OFF THE DECK AND SEATED IN THE CAB OR REAR
CONTROL STATION WITH SEAT BELTS FASTENED BEFORE
MOVING THE TRUCK.
WARNING
PAINT SPILLED ON THE DECK CREATES A SLIP AND
FALL HAZARD THAT CAN RESULT IN SEVERE INJURY TO
PERSONNEL. IF PAINT IS SPILLED ON THE DECK, ALERT
ALLPERSONNELAND MARK OFFTHEAREA. CLEAN UPTHE
SPILLED PAINT BEFORE OPERATING THE TRUCK.

1818
Section 2 - Paint Hog Systems
2.4 Auxiliary Engine/Air Compressor
General
The following is an overview of the features and
operation of the auxiliary engine/air compressor
for general information purposes. The manufac-
turer of the unit supplies an operation and main-
tenance manual. You should read this manual
completely before operating the engine and air
compressor.
The air compressor is powered by an onboard aux-
iliary diesel engine. A hydraulic pump connected to
the engine provides hydraulic uid pressure for the
hydraulic system. An engine control panel on the
side of the sound shield provides complete con-
trol of the engine. It also monitors critical engine
systems and provides warnings and/or automatic
shutdown to prevent costly engine repairs in the
event a critical engine or compressor function fails.
The chassis fuel tank supplies fuel to the auxiliary
engine. Consequently the driver should be aware
the fuel consumption will increase when the aux-
iliary engine is running and monitor the fuel level
closely during operations.
The auxiliary engine DC electrical system is pow-
ered by an onboard battery that is completely
isolated from the truck electrical system. It is
equipped with circuit protection and a charging
system that recharges and maintains the battery.
The air compressor is directly driven by the auxil-
iary engine. A exible coupler between the engine
and compressor reduces vibration and reduces the
possibility of engine damage from a catastrophic
pump failure.
The engine should be started only when the truck
is on the job site and ready to go to work or when
compressed air is required for paint and bead tank
lling operations.
Access to the engine is provided by removable
panels in the sound shield. Always check uid
levels and all systems before starting the engine.
Auxiliary Engine/Air Compressor

1919
Section 2 - Paint Hog Systems
Engine/Compressor Controls
The engine controls in the panel include the fol-
lowing:
1. Unloader Valve - Used to remove compressor
from the engine during startup and shutdown.
2. Bypass Switch - A momentary button that
activates the engine preheat system during
startup. Always press and hold this switch for
several seconds before starting the engine.
Continue holding the switch after the engine
starts until the oil pressure stabilizes, then
release the switch.
3. OFF-ON-RUN Switch - A three position
switch that starts and stops the engine.
4. Emergency Stop switch - Shuts down
the auxiliary engine and compressor in an
emergency. This switch only shuts down the
auxiliary engine and should never be used for
routine shutdown.
CAUTION
NEVERUSETHE EMERGENCYSTOPSWITCHTOSHUTDOWN
THE AIR COMPRESSOR ENGINE.
THE SWITCH GROUNDS THE CIRCUIT TO INTENTIONALLY
BLOW THE FUSE. THAT FUSE MUST BE REPLACED IN
ORDER TO RESTART THE AUXILIARY ENGINE.
CONTINUOUS USE OF THE EMERGENCY SWITCH WILL
CAUSE PERMANENT DAMAGE TO THE AIR COMPRESSOR.
Refer to the operation section in this manual and
the engine manufacturer’s operation and main-
tenance manual for additional information on the
operation of the engine and controls.
Air Compressor
The engine driven air compressor provides com-
pressed air to the paint and bead delivery systems
when the auxiliary engine is running. Maximum
system pressure is set by a pressure relief valve
on the compressor.
Auxiliary Engine/Compressor Control Panel
1. Unloader Valve 4. Emergency Stop Switch
2. Bypass Switch 5. Hydraulic Pressure
3. OFF-ON-Run Switch
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Section 2 - Paint Hog Systems
Gauges in the panel and on the sound shield moni-
tor critical engine systems, compressed air system
pressure and hours of operation. Refer to the en-
gine and compressor operation and maintenance
manual for additional information on gauges and
operating parameters for the compressor.
The compressor is an oil ooded, rotary screw
type compressor. During operation, compressed
air mixed with oil ows through a cooler, then to
the compressed air tank/oil reservoir.
Compressed Air Tank/Oil Reservoir
Compressor oil separates from the air and settles
to the bottom of the compressed air tank. Com-
pressed air is stored in the upper section of the
tank and delivered to the paint system on demand.
The bottom section of the compressed air tank
serves as a reservoir for the oil that lubricates the
compressor. There is a ll tting and sight gauge
on the lower rear side of the tank and sound shield.
The oil level should be maintained in the middle of
the sight glass. Always make sure to shutdown the
compressor and release tank air pressure before
opening the ll cap to add oil.
An in-line lter cleans the oil as it is returned to
the compressor. This lter should be changed at
regular intervals as recommended by the com-
pressor manufacturer.
The air compressor manufacturer operation man-
ual provides operation and maintenance informa-
tion for the air compressor. Refer to the Routine
Maintenance chapter for more information on the
pneumatic system.
2.5 Compressed Air Supply System
Overview
Compressed air is routed from the compressor
tank to a control manifold where it is separated
into ltered and unltered air circuits. Pressure
gauges on the main supply line, at each regula-
tor valve in the rear control console and on each
tank are used to monitor and control supply and
component pressures.
Solenoid activated pneumatic valves controlled
by switches on the gun control panels activate
spray gun nozzles, broom nozzles, atomization
nozzles, bead nozzles and the cylinders that raise
Compressor Oil Sight Gauge & Fill Fitting
Primary Moisture Separating Air Filters
and lower the carriages. The valves are located in
a box mounted on the carriages.
Compressed Air Circuits
There are two compressed air circuits. Unltered
cooled and dried high volume air and ltered
cooled and dried air that is treated by moisture
separating lters.