Integral Spray Paver Manuale utente

08.20.2020 Rev G www.integraldx.com

Spray Paver

Operator’s Manual

Operation • Maintenance • Troubleshooting

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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 

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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 

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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 

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Programming the display screen unit ............................................. 144

Programming the control unit......................................................... 147

Appendix 3: Maintenance record........................................................ 150

Appendix 4: Emulsion tank configuration........................................... 151

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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 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.

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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.

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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.

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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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