Integral Spray Paver User manual

08.20.2020 Rev G www.integraldx.com
Spray Paver
Operator’s Manual
Operation • Maintenance • Troubleshooting
©2020 Integral dx. All rights reserved.

3 |P a g e
Table of Contents
Introduction.........................................................................................7
Thank you!............................................................................................... 7
Limited warranty ..................................................................................... 8
Claim Administration Policy Procedures ............................................. 8
Indemnity........................................................................................... 10
Product Improvement Liability Disclaimer........................................ 10
Safety..................................................................................................... 11
Safety alerts....................................................................................... 11
Damage warning, notes and tips....................................................... 12
General safety rules........................................................................... 13
Safety decals...................................................................................... 15
General description............................................................................ 18
General specifications ........................................................................... 20
Components .......................................................................................... 21
Emulsion tank group.......................................................................... 22
Pump group ....................................................................................... 24
Emulsion spray group ........................................................................ 26
Hydraulic system ............................................................................... 41
Pneumatic system ............................................................................. 41
Emulsion tank heating system........................................................... 43
Control system................................................................................... 48
Installation......................................................................................... 58
System delivery and inspection............................................................. 58
Machine setup....................................................................................... 58
Operation .......................................................................................... 59
Pre-operating precautions .................................................................... 59
Operating precautions .......................................................................... 60
Fire and explosion precautions ............................................................. 61
Hydraulic system precautions ............................................................... 62
Using the display screen unit ................................................................ 63
Start screen........................................................................................ 60
Display navigation ............................................................................. 61

4 | P a g e
Sprayer selection screen ................................................................... 62
Pump function screen ....................................................................... 68
Spray bar vacuum screen .................................................................. 71
Totals screen...................................................................................... 72
Camera screens (1 and 2).................................................................. 70
Password screen................................................................................ 71
Service screen.................................................................................... 72
System Data Screen........................................................................... 73
Troubleshoot Sequence..................................................................... 74
Auto-Nozzle Option ........................................................................... 79
Alarms screen .................................................................................... 81
Spray paving steps................................................................................. 84
Loading emulsion in the tank(s) ........................................................ 88
Circulating the tank ........................................................................... 90
Circulating the spray bar ................................................................... 91
Spraying emulsion ............................................................................. 92
Vacuuming back emulsion................................................................. 94
Cleaning out and rinsing.................................................................... 95
Maintenance.................................................................................... 102
Recommended spare parts ................................................................. 102
Service interval.................................................................................... 103
Routine maintenance procedures....................................................... 100
Cleaning the spray wand ................................................................. 102
Cleaning the machine...................................................................... 102
Cleaning the strainer screen in the pumping station...................... 107
Checking the hydraulic oil level....................................................... 108
Inspecting hydraulic hoses and emulsion hoses ............................. 108
Checking the fluid level in the clean out tank................................. 108
Cleaning blockage from the emulsion tank overflow tubes ........... 108
Cleaning the hydraulic cylinder rods............................................... 109
Draining the air compressor tank and air filter............................... 109
Draining the emulsion tank sump ................................................... 110
Inspecting the packing gland on the emulsion pumps.................... 110
Inspecting the emulsion pump coupler........................................... 111

5 |P a g e
Lubricating the emulsion pump bearings........................................ 111
Inspecting the packing gland on the emulsion tank........................ 111
Checking the tightness of the tank tie-down hardware.................. 111
Checking spray nozzle alignment .................................................... 111
Checking the spray bar hardware.................................................... 111
Checking the condition of the hydraulic filter................................. 112
Removing debris in the emulsion tank sump.................................. 112
Checking oil in the compressed air oiler ......................................... 112
Changing the hydraulic oil and filter ............................................... 113
Changing the fluid in the clean out tank ......................................... 113
Replacing the engine air filter element........................................... 113
Calibrating the small asphalt pump................................................. 113
Storage ................................................................................................ 116
Startup after storage........................................................................... 117
Hydraulics system check.................................................................. 117
Cleaning agent check....................................................................... 117
Function check................................................................................. 118
Troubleshooting............................................................................... 121
Cleaning the emulsion tank................................................................. 125
Cleaning a stuck pump ........................................................................ 129
Setting the small emulsion pump bypass pressure............................. 132
Appendices ...................................................................................... 133
Appendix 1: Valve and emulsion pump configurations for the pump
functions.............................................................................................. 134
Appendix 2: Pump group flow paths................................................... 136
Tank load ......................................................................................... 136
Tank circulate .................................................................................. 137
Spray bar circulate........................................................................... 138
Spray auto........................................................................................ 139
Spray bar vacuum............................................................................ 140
Clean out.......................................................................................... 141
Bypass setting.................................................................................. 142
Appendix 2: Updating PLC and display software ................................ 143
Downloading and running the software ......................................... 143

6 | P a g e
Programming the display screen unit ............................................. 144
Programming the control unit......................................................... 147
Appendix 3: Maintenance record........................................................ 150
Appendix 4: Emulsion tank configuration........................................... 151

7 |P a g e
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 is designed and manufactured in the USA with quality
materials and workmanship. With proper use and care, it will provide you
many years of trouble-free service.
Keep this manual handy for frequent reference, and to pass onto new
operators or owners. Contact Integral dx if you need assistance, further
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.

8 | P a g e
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
the obligation to install such changes on any previously delivered
products.
Claim Administration Policy Procedures
Integral dx must be contacted immediately for authorization to proceed
when a warranty problem is suspected. If parts need to be replaced,
please ask for a Return Goods Authorization (RGA) number at this time.
Hydraulic components (i.e. pumps, motors, planetary drives, and valves)
are not to be disassembled when performing possible warranty work.
Unauthorized disassembly of these components will void warranty.
A Returned Goods Authorization (RGA) number must be obtained and the
defective parts returned immediately with the RGA number marked on
the parts and the shipping containers before any warranty consideration
can be determined. Return these components prepaid via common
carrier or UPS ground to Integral dx for examination.

9 |P a g e
Warranty will not be allowed against failure due to the following:
Normal wear and tear
Abuse or accident
Modification of original equipment
Improper service or maintenance
Improper installation
Contamination
Labor will be credited at 75% of the authorized providers published labor
rate, travel time not included.
Travel to and from job sites will be covered at $0.50 per mile and not to
exceed a 100 mile round trip.
Before warranty claims will be paid, Integral dx will need to have on file
the In-Service Report.
Overnight or other special freight charges will not be covered under
warranty.
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.

10 | P a g e
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.

11 |P a g e
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 may
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 be sure 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.

12 | P a g e
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.
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.
0

13 |P a g e
General safety rules
The general safety rules are included in this section of the manual.
Specific safety rules will 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.
Warning: Wear safe work clothing, which includes rough-
soled work shoes, safety glasses and any other protective gear that is
warranted by the work environment. Do not wear clothing that is
loose fitting or in poor repair when working on machinery. Do not
wear rings, wristwatches, or other jewelry while working on
machinery. They can catch moving parts and pull you into the
machinery, causing serious injury or death.

14 | P a g e
Warning: Stop operation and investigate anything that does
not look or feel right.
Danger: Asphalt emulsion is a water-base product. As such it
will boil at 212°F (100°C), causing steam inside pipes, which can result
in an explosion.
Warning: When hot emulsion touches your skin, flush the
affected area immediately with cold water. Do not apply ice directly
to the affected area. Do not attempt to remove emulsion with
products containing solvents or ammonia. Natural separation will
occur in about 48 to 72 hours. Get medical attention as soon as
possible.

15 |P a g e
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.

16 | P a g e
Do not disconnect lines. Doing so
during spray paver operation will
cause death or serious injury.
Spray bars may be damaged by low
ground clearance. Always tilt and pin
the spray bar assembly up when not
spraying emulsion.
Safety decal location
Note the location of each of the safety decals on the Integral dx spray
paver (see Figure 1).
Note: Decal location will vary with machine configuration.
Safety decals must be present, in good condition, and in the specified
locations at all times.
If any decals are missing or damaged, replace them before
operating the spray paver.
When replacing parts that previously displayed a safety decal, be
sure to replace the decal as well.
Instructions for replacing worn or missing decals are provided
below.

17 |P a g e
Figure 1: Safety decal location (may vary depending upon model)

18 | P a g e
Safety decal replacement
Warning: Do not operate the spray paver until the safety
labels are in place.
Replace safety decals as follows:
1. Be sure that the installation area is clean and dry. Use hot soapy
water, then dry the application area thoroughly.
2. Decide on the exact decal position by taking measurements and
test fitting before you remove any of the backing paper.
3. Remove part of the adhesive backing.
4. Align the decal over the specified area, and carefully press the
exposed adhesive backing into place.
5. Slowly peel back the remaining adhesive backing, carefully
smoothing the remaining portion of the decal in place with a
cloth or sponge.
6. Check decal for air bubbles. If found, pierce small air pockets
with a pin, then carefully smooth them out.
7. When the decal is completely smoothed out, carefully remove
the top paper if present. Wipe the decal clean with a soft cloth
and warm soapy water.

19 |P a g e
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 independently:
The paver can pave with or without the spray paving system
operating.
The spray paver can operate with or without the paver operating.

20 | P a g e
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.
Avoid damage: Check with Integral dx before applying
anything other than emulsion products below 200° F.
Our spray paving system has an easy-to-use display screen unit. The
operator uses the display screen unit to set both application rate and
spray width. Using these inputs along with vehicle speed, the display
screen unit works with a control unit to automatically apply emulsion at
the set application rate.
Volumetric spraying is different from using a pressure system. With
volumetric spraying, each revolution of the emulsion pump achieves a
specified amount of flow in gallons; flow is directly related to the pump
RPM. By monitoring the pump RPM using a sensor in the hydraulic pump
drive motor, the control unit knows the exact amount of flow achieved. A
flow meter is not needed when using the volumetric emulsion pump(s).
The spray system is “ground oriented,” meaning it is linked to the paver
speed. The spray system monitors speed using the paver speed signal;
the control unit knows the exact paver speed during spraying.
As the paver speeds up or slows down, the pump also speeds up or slows
down to ensure the exact application rate, measured in gallons per
square yard (liters per square meter), is achieved.
The emulsion application maximum width depends upon the specific
model. Spray width can be adjusted incrementally.