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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©2016Integraldx.Allrightsreserved.

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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.


Movingpartscouldpinchahand,
foot,etc.Takecaretonotgetbody
partstrappedbetweentheparts.


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.


Ensurecoversareinplaceforsafe
operationofthespraypaver.



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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


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Figure1:Safetydecallocation(mayvarydependinguponmodel)

x2x2
X2

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Generaldescription
TheIntegraldxspraypaver(Figure2)appliesemulsionvolumetricallyto
theroadsurfacethroughasystemofspraybarswithnozzles.


Figure2:Spraypavermajorcomponents
Thespraypavingsystemismountedonthepavingmachineandoperates
independently:
 Thepavercanpavewithorwithoutthespraypavingsystem
operating.
 Thespraypavercanoperatewithorwithoutthepaveroperating.
Thespraypaver’semulsionpump(s)arecapableofhandlingproducts
rangingfromlightapplicationsofemulsifiedasphalttoheavyasphalt
cementsheatedtosprayingviscosity.
Emulsiontanks
(p.20)
Frontspraybar
housing(p.24)
Aircompressor
(p.39)
Rearspraybar
(p.24)
Swingarm(p.24)
Telescoping
spraybar(p.24)
Pumpingstation
(p.23)
Displayscreen
unit(p.47)
Maincontrol
box(p.47)
Heatingsystem
enclosure(p.42)

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Components
Thespraypaverismadeupofthreegroupsandfoursystems:
Groups:
 Emulsiontank
 Pump
 Emulsionspray
Systems:
 Hydraulic
 Pneumatic
 Heating
 Control
Emulsiontankgroup
Theemulsiontankgroupincludestheemulsiontank(s)andassociated
equipment:
Avoiddamage:Ifthepaverisconfiguredwithemulsiontanks
mountedintheasphalthopper,donottiltthehopper.Attemptingto
tiltthehopperwilldamagethetanksand/orpaver.
Emulsiontank(s)
Theemulsiontankisaninsulatedvesselthatholdsthehotemulsionfor
spraying.
Onetankcanbemountedonthepaverdeck(Figure3),and/ortwotanks
canbemountedintheasphalthopper(Figure4).
Note:Ifemulsiontanksaretoberemoved,firstdrainthem.
Usealltheliftingeyeswhenliftingtodistributetheirweightas
evenlyaspossible.
Eachtankhasadipstickandalargelevelindicatoronthesidefor
checkingemulsionlevel.

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Pumpgroup
Thepumpgroup’sfunctionistocontroltheflowdirectionandrateofthe
emulsionandcleaningagent.Itconsistsofemulsionpump(s),thestrainer
housing,pneumaticballvalves,alllocatedwithinthepumpingstation
(Figure5).

Figure5:Emulsionpumpingstation(right‐sideview)
Thepumpgroupcontrolsthesixbasicpumpfunctions:
 Tankload
 Tankcirculate
 Spraybarcirculate
 Sprayauto
 Spraybarvacuum
 Spraybarcleanout
Valveandpumpconfigurationsforthepumpfunctionsareshownin
Appendix1:Valveandemulsionpumpconfigurationsforthepump
functions,page121.

Strainer
housing
Emulsion
pump
Pneumatic
ballvalve

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Frontspraybarhousing:Thefrontspraybarhousing(Figure6)contains
therightandlefttelescopingspraybarsandthecenterspraybar.The
frontspraybarhousingismountedinfrontofthepaverhopperand
replacesthepaver’soriginalpushbar.
Tip:Coverthefrontspraybarhousingwithathinrubber
mattohelpwithspillagecleanupandpreventdamagetothe
spraybarhoses,cylinders,andvalves.

Figure6:Frontspraybarhousing,telescopingspraybarsretracted
Avoiddamage:Whenthepaverisusedtopushadump
truck,thefrontspraybarhousingmustbedownandpinnedin
place.


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Rightandlefttelescopingspraybars:Therightandlefttelescopingspray
bars(Figure7)aremountedinthefrontspraybarhousing.Retracted,
theyarebehindthecenterspraybar.

Figure7:Telescopingspraybar(left)extendedandswingarm
Swingarmsareattachedtothesideofthepaverandsupportthe
telescopingspraybars.
Thetelescopingspraybarseachextendhydraulicallyupto48inches.To
modifyspraywidth,nozzlesonthetelescopingspraybarscanbeturned
onoroff.
 Theouterthreespraynozzlesareturnedonoroffindividually.
 Theinnernozzlesareturnedonoroffwithothernozzlesonthe
telescopingspraybarin“gangs.”
Avoiddamage:Ifthetelescopingspraybarsareallowedto
strikeanobject,theycancauseseveredamagetopropertyorthe
spraypaver.Releaseofhotemulsionmayalsooccur,whichcould
injurethosenearthemachine.Beawareofobstaclesduringspray
paving.
Centerspraybar:Thecenterspraybarismountedinthefrontspraybar
housing.Itspanstheinsidedistancebetweenthepavertracksorwheels.
Allofthecenterspraybarnozzlesareturnedonoroffasasinglegang.
Swingarm
Telescoping
spraybar

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Nozzlealignment:Toachieveanevensurfacecoverage,turnthelong
accessofthenozzlesataslightangle(~10)fromthehorizontalaccessof
thespraybars(seeFigure10).Thispreventsinterferenceofthespray
pattern.

Figure10:Spraypatternwith100%overlapandataslightangle
Nozzleheightadjustment:Settheheightofthespraybarstoachievea
100%(double)overlap;thefanreachesthecenteroftheadjacentfan(s)
(seeFigure10).
Note:Emulsionviscosityvarieswithtemperatureandtype.
Heavieremulsionsrequireahighernozzleheightthanlightermaterial
toachieveadoubleoverlap.
1. Adjusttheheightofthecenterandtelescopingspraybarsusing
method1and/ormethod2.

Method1:Addorremovespacers
a. Supportthespraybarhousingusingtheliftingeyes.
b. Removethethreefastenersoneachofthefourmounting
hinges(seeFigure11).
c. Addorremoveoneormorespacers(maximumfour)
beloweachmountinghinge.
d. Adjusttheswingarmheighttomatchbyremovingthepin
thatattachestheswingarmtothetelescopingspraybars
and/orlooseningthetop/bottomnutontheadjustment
bolt,whichislocatedattherearoftheswingarms(see
Figure12).

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Figure16:Spraywandconnectionandhose
Emulsionlines
Emulsionlinesconnecttheemulsiontank(s)tothepumpingstationand
thepumpingthestationtothespraybars.
Warning:Onlyusefactory‐suppliedemulsionlines,
emulsionlineconnectionsandhoseclamps.Otherhosesmay
ruptureduetoheatandcauseseriousinjury.Inmostcases,a
specifictypeofhosebarbfittingisusedtopreventthehosefrom
disconnectingfromthefitting.Donotuseastandardworm‐gear
hoseclamp,whichwillnotmeetrequirements.


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Asphalthopperextensions(option)
Forconventionalpaving,whereadumptruckispushedalongbythe
paver'spushbar,thespraygroupincludesanasphalthopperextension
(seeFigure17).
Thehopperextensionsmaintainproperinterfacewithasphalttrucks.
Sincethecenterspraybarrunsbetweenthehopperandtherollersthat
pushtheasphalttruck,theasphalthopperextensionallowsforcorrect
depthofdumpingintothepaver,minimizingspillage.

Figure17:Asphalthopperextensions
Hydraulicsystem
Thehydraulicsystemispressurizedbyapistonpump.Thepumpprovides
fluidpowertothehydraulicmotorsandhydrauliccylinders.Ahydraulic
reservoirsupplieshydraulicfluidtothesystem.Valvescontrolmotorand
cylinderfunction.
Pistonpump
Thepistonpump(Figure18)isdedicatedtothespraypavinghydraulic
system.ThepumpistypicallypoweredbyanunusedPTOlocatedonthe
paverengine.Itispressurecompensatedto2500psi.


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Figure18:Hydraulicpistonpump
Hydraulicreservoir
The25‐gallonhydraulicreservoirwithanintegralcooler(Figure19)
supplieshydraulicoiltothepumpaswellascoolsandfiltersthe
hydraulicoil.
Warning:Theoilcoolerfanisthermostaticallycontrolled.It
maystartupatanytime,evenifthepaverisnotrunning.Toprevent
injuryordamage,keepfingersandobjectsawayfromthefan.

Figure19:Hydraulicreservoir

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Needlevalves
Needlevalvesinthepumpingstationadjustthehydraulicflowtothe
cylinders.
Therearefour:oneforeachtelescopingspraybarextension/retraction
cylinder,oneforbothcylindersthatlockthefrontspraybarhousing,and
oneforthecylindersthattiltthefrontspraybarhousing.
Note:Theneedlevalvesaresetatthefactoryandlikelywillnot
needadjustment.
Pneumaticsystem
Thepneumaticsystemincludesanaircompressor(Figure20),whichis
poweredbyahydraulicmotor.Thissystemalsoincludesthesolenoid
valves,whichcontrolthevariousvalves.
Somemodelshaveanauxiliaryconnectionatthecompressorfora
compressedairsupply.
Aircompressor
Theaircompressorislocatedonthepaverorscreeddeck.Itprovides
compressedairtothesolenoidvalvesandultimatelytothepneumatic
valvesthatcontrolmanyofthespraypaverfunctions.
Whenthereislowpressure,aswitchontheaircompressortriggersa
relaytoopenthehydraulicvalvefortheaircompressor'shydraulic
motor.Thelowpressureswitchalsosendsasignaltothecontrolunitand
inturntothedisplayscreenunitasawarning(delayed45secondson
startup).
Anotherpressureswitchtriggerstherelaytoclosethevalvewhenthe
highpressureisreached.Thecompressorcyclesbetween85psiand125
psi.