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Bearcat BC-502/CRC, Instruction Manual

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Bearcat BC-502/CRC Instruction Manual Download Page 148

 

148

 

 

 

 

 
 

 

Figure 5 

VALVE BANK 

ID PART #

DESCRIPTION

QTY

1 200710

TERMINAL BLOCK SECT

6

2 201058

DEUTSCH 40 PIN PLUG

1

3 206356

FUSE BLOCK, 6 CIR

1

4 206357

FUSE, BLADE TYPE, 20 AMP

2

5 206359

FUSE, BLADE TYPE, 40 AMP

4

6 208005

PANEL, ENGRAVED, REAR CNT

1

7 4FP-4MJBH FITTING

2

8 ELC-24254 DIODE, 6A, 50V

2

9 ELC-24270 RELAY, 70A, 12V

3

10 ELC-24271 SWITCH, PUSH BUTTON

2

11 ELC-24274A SWITCH, 3 POS

6

12 ELC-24276A SWITCH, 3 POS

2

13 ELC-24420 CONNECTOR, 3/8"

1

14 ELC-24425 CONNECTOR, 1/2"

1

15 ELC-25172 SWITCH, PRESSURE

1

16 ELC-80705 SWITCH, PRESSURE

3

17 FIT-24221

PLUG, BUTTON

1

18 HSG-24246 BOX, REAR CONTROL

1

208092 REAR CONTROL PANEL

Figure 4 

REAR CONTROL PANEL 

ID PART #

DESCRIPTION

QTY

1 MSC-35032

DBL MODLR SUB BASE

5

2 MSC-35030

END PLATE KIT

1

3 204546

CANOPEN PC BOARD

1

4 205993

GASKET, RED PILOT VALVE

1

5 207501

GASKET, VALVE

1

6 ELC-35037

MANIFOLD FIELDBUS PCB

1

7 RNG-35042

GASKET, VALVE SECTION

1

8 ELC-35007

SOLENOID

1

9 ELC-35033

CONNECTOR KIT, CANOPEN

1

10 FAS-35043

GASKET, END PLATE

1

11 VLV-35005

VALVE, 4 WAY ASM W/COIL

1

211968 VALVE GROUP

Summary of Contents for BC-502/CRC

Page 1: ...INSTRUCTION MANUAL Model BC 502 CRC Asphalt Distributor ...

Page 2: ...Revision 8 19 Unit Serial Number FCAL GCAL Date of Service Customer Training Performed By I Have Received Hours Training Signature ...

Page 3: ...fully informed of such changes If you do not understand any part of this manual and need assistance please contact your BearCat dealer or BearCat directly BearCat Mfg 3650 Sabin Brown Road Wickenburg AZ 85390 Phone 928 684 7851 Fax 928 684 3241 service bearcatmfg com Manuals can be accessed via the BearCat website at the following address www bearcatmfg com Please help up to continually improve th...

Page 4: ...ersonal injury DANGER Immediate hazards which will result in death or serious injury WARNING Hazards or unsafe practices which could result in serious injury or death CAUTION Hazards or unsafe practices which could result in minor or moderate injury product or property damage All of these warnings are listed below and they also appear throughout the manual In addition to these you will find notes ...

Page 5: ...r abrasive atmosphere or materials 4 Has not been damaged through malice or ignorance 5 Has not been subject to flood lightning accidents misuse neglect or unauthorized modification repair or service Parts replaced under this warranty are warranted only through the remaining time of the original warranty BearCat warrants that at the time of delivery the product manufactured by BearCat and delivere...

Page 6: ...VEL TIME MILEAGE LABOR COSTS OR OTHER EXPENSES OF ANY DEFECTIVE PARTS REPLACED OR REPAIRED UNLESS THE USER HAS REACHED A PRIOR AGREEMENT WITH BEARCAT The user shall notify BearCat of any defect within this warranty no later than thirty 30 days after a defect is discovered No defective parts will be accepted for return or replacement without the written authorization of BearCat or verbal authorizat...

Page 7: ...BearCat shall not be responsible for any loss damage incidental or consequential damages of any kind whether based upon warranty contract or negligence arising concerning the sale use or repair of the product Components manufactured by any supplier other than BearCat shall bear only the warranty made by the manufacturer of that product ...

Page 8: ... THIS EQUIPMENT EMPLOYS HIGHLY COMBUSTIBLE OR EXPLOSIVE FUELS POTENTIALLY LIFE THREATENING HAZARDS MAY EXIST DURING EQUIPMENT OPERATION PERSONNEL MUST BE TRAINED AND FAMILIAR WITH SAFETY PRECAUTIONS BEFORE OPERATING BEARCAT EQUIPMENT WARNING POTENTIALLY LIFE THREATENING HAZARDS MAY EXIST DURING EQUIPMENT OPERATION ONLY QUALIFIED PERSONNEL SHOULD ATTEMPT TO OPERATE SERVICE OR MAKE ADJUSTMENTS TO TH...

Page 9: ... CW Clockwise FCAL Footage Calibration FPM Feet per Minute GCAL Gallons Calibration GPM Gallons per Minute KgSM Kilograms per Square Meter LPM Liters per Minute LSM Liters per Square Meter MPM Meters per Minute PSI Pounds per Square Inch PSY Pounds per Square Yard PTO Power Take Off RPM Revolutions per Minute Wet Asphalt Emulsified asphalt or containing water ...

Page 10: ...N 17 Hydraulics 18 Pump Drive Options 18 Hydraulic Reservoir and Filter 19 Hydrostatic Pump 19 Hydrostatic Motor 21 Asphalt Plumbing 22 Asphalt Pump 22 Spread Circulate Relief Valve 22 Auxiliary Hydraulic System 23 Spray Bar 24 Folding Wing Configurations 24 Circulation Control 25 Bar Movements 25 Wing Shear Pins 26 Controls 27 Cab Console 27 Side Control Panel 28 Rear Control Panel 28 Computerize...

Page 11: ...s 32 SAFETY PRECAUTIONS 36 Personnel Safety 36 Pumping Operations 38 Burner Operations 39 Clean the Equipment 41 Safety Decals and Plates 41 GENERAL OPERATION 44 CONTROLS 45 Operator s Panel In Cab 46 GSY switch 46 PTO 46 Heat 46 Pump 46 Manual 46 Bar Latch 46 Beacon 46 Tank 46 Power 46 Error 47 Left Wing Un Lock 47 Right Wing Un Lock 47 L Wing R Wing 47 Mirror 47 Spray Valve Switches 48 Left Wing...

Page 12: ...direction 51 Manual Increase Speed 51 Rear Control Panel 51 Hyd Bar Lock 51 Swing 51 Lift 51 LH RH Wing Locks 52 L Wing R Wing 52 R Burner 52 L Burner 53 Asphalt Valve Locations and Functions 54 Asphalt Tank Gauge 56 Asphalt Temperature Gauge 57 Preparation 57 Selection of Correct Spray Nozzles 57 Spray Nozzle Removal and Installation 58 Initial Checkout of the Equipment 58 Check Hydraulic Control...

Page 13: ...rm Asphalt 76 Cold Asphalt too stiff to circulate 77 Heating with Diesel Fired Burners 77 OPERATING INSTRUCTIONS 79 Spraying Operations with CRC Computerized Rate Control 79 Spraying Operations using the optional Front Suction 81 Setting Spread Rate Manually 82 Hand Spraying While Circulating Spray bar 83 Hand Spraying 84 Spray Bar Flushing 86 Stage 1 87 Stage 2 88 Stage 3 88 Empty Flush Tank 89 S...

Page 14: ... Circulate 98 Manual 98 Simulate FPM 99 Flush Time 100 Cal 1 100 Calibration Page 100 F Cal 100 G Cal 101 T Cal 103 Auto Shutdown 103 Hyd Elc Rub 103 Cab Exp Box 103 Pump 104 Std Metric 104 PTO 104 Speed Sensor 104 Heat 104 Ready Set Point 104 Spray Bar 105 Spray bar Settings 105 Tank 107 Defaults 107 Diagnostic Menu 107 Volts Snsr 108 Vlv Cmds 108 ...

Page 15: ...with a Torch 127 Clear Clogged Spray Nozzle 127 Clean Asphalt Intake Strainer 127 Clean Bar Screen 128 Replace Swing Joint Seal 128 Disassembly 128 Seal Replacement 129 Reassemble 129 Replace Asphalt Pump Seals 129 Replace Nozzle Valve Stem Seals 130 Adjust Actuators for Spray Nozzle Valves Mechanical Linkage 131 Adjust Remote Curbside Mirror 133 Lubrication 133 Preparation for Storage 133 Removal...

Page 16: ...BC 502 CRC 16 K Valve spread circulate or bypass valve 137 Troubleshooting 139 Bolt Torque Chart 144 Conversion Chart 145 Calculate Area 145 Check Spread Rate 145 PARTS 146 ...

Page 17: ...Cab Operated Computer Controlled Liquid Asphalt Distributor is pictured below The following description of the equipment should be read to familiarize yourself with the operating features and capabilities of the Model BC 502 CRC asphalt distributor ...

Page 18: ...that constantly operates once the PTO is engaged The transmission PTO is engaged by use of a switch on the Cab Console In general the PTO can be switched on when the truck arrives at the job site and left on continuously until the shift is finished for the day All configurations of the PTO can be operated at highway speed See your truck Operations Manual for details on the PTO operation for your s...

Page 19: ...ates the presence of sufficient fluid to operate the system The tank has an internal 100 mesh suction screen A 10 micron return filter is located immediately adjacent to the tank A pressure gauge mounted on the filter housing serves as an indication of the condition of the filter element When the element is clean and unobstructed the gauge will indicate pressure in the range 0 to 24 PSI Hydrostati...

Page 20: ...e selector is in the MANUAL position The pump control functions are described further in the Cab Console Controls section of this manual CAUTION INSUFFICIENT HYDRAULIC FLUID FLOW TO THE HYDROSTATIC PUMP WILL CAUSE CATASTROPHIC DAMAGE TO THE PUMP INSUFFICENT HYDRAULIC FLUID FLOW TYPICALLY INDICATES A CLOGGED FILTER BLOCKED HYDRAULIC LINE OR LOW FLUID LEVEL The hydrostatic pump receives power direct...

Page 21: ...uipped with an integral relief valve that opens if the maximum rated pressure is exceeded as may occur if the asphalt is frozen or the asphalt pump attempts to force asphalt against a closed valve The system is engineered to create a maximum asphalt pressure of 70 PSI The output shaft of the hydrostatic motor is coupled to the asphalt pump through a gearbox A hall effect sensor installed at the mo...

Page 22: ...to an appropriate amount to maintain the correct flow of asphalt through the spray nozzles The asphalt pump operates in either direction at any flow rate within its operating range as determined by either the CRC system or the manual pump controls See the Cab Console Controls section of this manual for additional information The asphalt flow rates or pump output is displayed in GPM on the digital ...

Page 23: ...An additional safety is provided by the hydrostatic transmission which is designed to hydraulically relieve at 150 PSI asphalt system pressure WARNING EXTREME CARE MUST BE USED DURING PUMPING OPERATIONS TO MAKE SURE SYSTEM COMPONENTS OPERATE AT THEIR RATED PRESSURES FAILURE TO CHECK THE CONDITION OF ALL HOSES AND CONNECTIONS WHEN PUMPING COULD RESULT IN SEVERE BURNS INJURY OR DEATH WARNING ALWAYS ...

Page 24: ...hin the Tri Valve Manifolds The spray valves are actuated when the operator actuates the corresponding switches on the Cab Console An optional mechanical linkage system is also available in lieu of the Tri Valve Manifolds Folding Wing Configurations The spray bar can be provided with single fold double fold or triple fold wings permitting maximum coverage as wide as 24 feet A double fold wing conf...

Page 25: ...ack to the tank Bar Movements The spray bar can be moved right and left to a maximum of 13 inches 33 cm in either direction allowing a total horizontal travel of 26 inches 66 cm The bar can be raised to approximately 20 inches above the ground and lowered to within 10 inches of the ground 51 and 15 cm respectively A hydraulic lockout valve holds the bar at any height within this range A mechanical...

Page 26: ...of the wings with the main bar The shear pins act as a safeguard in the event that the wing strikes an object while in motion On impact the shear pin will break thereby protecting the wing mechanism Spare shear pins are provided with Model BC 502 CRC use only soft cotter pins Wing Shear Pin ...

Page 27: ...Console The following functions are controlled with switches on the panel Cab Console Power on Open and close spray valves Open and close right and left marker valves Position spray bar raise lower side shift Raise and lower wings Engage PTO Adjust remote curb side mirror Control pump direction Adjust spread rate Beacon Light Bar and Wing Latch ...

Page 28: ...olling the speed and direction of the asphalt pump when the Cab Console Selector Switch is set to Load Outside The operator selects pump and spray options with the rotary selector switch that indicates an option and the necessary control valves to actuate The functions of the Rear Control Panel are further described in GENERAL OPERATION Rear Control Panel The Rear Control Panel is equipped with sw...

Page 29: ...ption This option provides one or two 8 inch diameter flues each containing an atomizing diesel oil burner or a propane burner Solid state igniters powered from the vehicle electrical system individually ignite the burners Switches located on the Rear Control Panel control the igniters The burner s will operate only when the truck parking brake is engaged for obvious safety reasons Asphalt tempera...

Page 30: ...y operated reel with a swivel Pattern Spray Capability As described previously the spray valves in the standard BearCat spray bar can be opened and closed in one foot increments utilizing the in cab control panel switches One foot consists of three individual valves or one Tri Valve group This design enables the operator to exercise a high degree of control in the application of liquid asphalt mat...

Page 31: ...lectric heating systems can be powered by external power sources or via an onboard hydraulically driven generator The belly heat option consists of a heating element that mounts to the exterior bottom surface of the tank This heating element is powered by external 240V power for overnight heating Electric heating element options are available The heating elements are mounted into heat tubes into t...

Page 32: ...ng Functions Load through spray bar Off load Transfer Circulate Heat Spray Flush BearCat Asphalt Pump Type Positive Displacement Internal Pressure Relief 70 PSI Standard Capacity 400 Gallons Per Minute Spray Bar Seals Standard High Temperature Shaft Packing Optional Teflon Shaft Seal Wing Swivel Seals Lip Seal Over all Length Standard 12ft 3 7m Options Up to 24ft 7 3m Pump Drive Type Hydrostatic T...

Page 33: ... Center Spacing 4in 10cm Actuation Solenoid Pneumatic Cylinder Line Markers Number 2 Right Left Actuation Solenoid Pneumatic Cylinder Asphalt Piping Standard Intake Diameter 4in 10cm Discharge Diameter 3in 8cm Asphalt Valves Type Gate Butterfly Control Console Switches Actuation Solenoid Pneumatic Cylinder Manual Flexible Hoses feed to spray bar Diameter 2 5in 6 4cm Standard 250 F Rubber Optional ...

Page 34: ...uction Cylindrical External Wash down Flush Tank 8 Gallons Pressurized Withdrawal Truck Compressed Air Tank Capacity 15 Gallons 57 L or as Specified Hose Diameter in 6 4mm Hose Length 25ft 7 6m Asphalt Tank As Specified Capacity 1000 4800 Gallons 3785 18 169L Shell Standard 10 Gauge HSLA Shell Optional 12 Gauge HSLA Heads Standard 3 16 Plate HSLA Heads Optional 10 Gauge HSLA Insulation Material Mi...

Page 35: ...2V Electrically driven Pump 12 V Integral Fuel Pump and Filters Fuel Source Truck Tank Burner Flue Liner Stainless Steel Exhaust Flue Stainless Steel with Rain Cap Heating Capacity BTU Up to 770 000 per flue Propane Fired Burner Air Blower 12V Electrically driven Fuel Source Onboard 60 Gallon Tank Burner Flue Liner Stainless Steel Exhaust Flue Stainless Steel with Rain Cap Heating Capacity BTU Up ...

Page 36: ...N THE BURNERS WHICH HEAT THESE MATERIALS IS HIGHLY FLAMMABLE EXTREME CARE MUST BE EXERCISED AT ALL TIMES TO ASSURE THE SAFETY OF PERSONNEL WORKING IN PROXIMITY TO THESE POTENTIALLY HAZARDOUS CONDITIONS Read each safety rule and make them a part of the daily work routine General Protection WARNING EXHAUST SPARKS FROM AN ENGINE CAN IGNITE VOLATILE GASES ALWAYS KEEP A DRY CHEMICAL FIRE EXTINGUISHER F...

Page 37: ...LLOWING LIST OF SAFETY RULES COULD RESULT IN A FIRE OR EXPLOSION THAT COULD CAUSE SEVERE BURNS INJURY OR DEATH DO NOT ALLOW LIGHTED CIGARETTES OR ANY BURNING MATERIAL NEAR OPEN MANHOLES OR OVERFLOW VENTS DO NOT USE GASOLINE IN A BURNER THE BURNERS OPERATE ON DIESEL FUEL ONLY DO NOT HEAT MATERIAL BEYOND THE MAXIMUM TEMPERATURE RECOMMENDED BY THE SUPPLIER DO NOT OFF LOAD MATERIAL WITHIN 20 MINUTES O...

Page 38: ...ns ALWAYS check to make sure that all pipe and hose connections are secure before opening a valve ALWAYS start the asphalt pump VERY SLOWLY and make sure that all hoses and valves work properly ALWAYS open the manhole cover SLOWLY to relieve pressure in the tank If it is necessary to stop the flow of material while filling the tank close the suction valve or pump intake NEVER pump against a closed...

Page 39: ...ake sure flues are covered by at least 6 inches 152 mm of material before heating Burners should NEVER be operated under the following conditions 1 During unloading or loadingoperations 2 While the vehicle is unattended 3 While the vehicle is in motion 4 When the vehicle is parked in a confined area 5 When the content of the tank is unknown NEVER remove materials from the tank while the burners ar...

Page 40: ...ventilate for a least two 2 minutes before re igniting a burner that has gone out ALWAYS allow sufficient space in the tank for the material to expand when heating ALWAYS keep material that contains volatile cutbacks solvents away from open flames or sources of sparks during spray operations ALWAYS make sure to keep a hand spray wand pointed AWAY from personnel NEVER spray off material below the f...

Page 41: ...es All safety decals and plates must be clean legible and in good condition Always clean any safety decal or plate that becomes dirty Always check the condition of safety decals and plates before each use Always replace any safety decal that is illegible through wear and tear or is peeling off the equipment Never operate the equipment with a safety decal orplate that is hard to read or is missing ...

Page 42: ...BC 502 CRC 42 ...

Page 43: ...43 ...

Page 44: ...ough improper use of thisequipment This Section contains information with which the operator must be familiar in order to prepare the Model BC 502 CRC distributor for spraying operations Five essential areas are covered Operating controls gages and indicators The operator should thoroughly understand the functions of all controls before attempting to use the equipment Operation of the Computerized...

Page 45: ...iarity with these areas of activity will prepare the operator for efficient safe operation of the equipment To understand how the equipment at the rear of the BearCat equipment works the operator should first operate the rear control panel functions before operating from the front control panel Controls ...

Page 46: ...p rotation functions before cycling this switch This switch must be recycled each time the Power switch is turned on Manual Select Manual pump speed control or CRC Computerized Rate Control Bar Latch Optional hydraulic bar latch for travel Beacon Turns the beacon light on and off Tank Optional remote tank valve control option for rear or front suction When Spread Heat or Circulate Heat is selected...

Page 47: ...d Inner wings automatically lock in the full upright position L Wing R Wing WARNING MAKE SURE ALL PERSONNEL ARE CLEAR OF THE REAR AREA OF THE TRUCK WHEN THE WINGS OR THE SPRAY BAR ARE MOVED FAILURE TO KEEP A SAFE DISTANCE COULD RESULT IN SERIOUS INJURY OR DEATH 1 This raises and lowers the wing section next to the main spray bar 2 On a Double Fold raises and lowers the 2nd wing section out from th...

Page 48: ...One switch per section Right Wing Dedicated spray valve control sections on right wing One switch per section NOTE The standard section or cut is 3 nozzles 1 foot Optional 2 foot sections or cuts have been produced controlling 6 nozzles L Marker R Marker MAST turns on single spray nozzle at extreme end of spray bar with the spray bar Master switch ON Momentary turns on single spray nozzle at extre...

Page 49: ...edicated bar switches with Master on or off Both Taper Cut selection and dedicated bar switch must be on to operate nozzle Valve Selector Dial Controls the asphalt plumbing valves based on selection OFF All asphalt valves closed and pump stopped Spread Heat General spreading with spray bar and full circulation Opens valves C E and K and enables pump Load Outside Disables Cab Console and enables Si...

Page 50: ...disabled and the Side Control panel is active The Side control panel is disabled when the Cab Console selector switch is set to anything but Load Outside Valve Selector Dial Selections for loading and off loading material The panel description describes the procedure which valve to connect the load hose pump direction and the lettered valves in operation When making a selection the Pump Valves red...

Page 51: ... the speed slowly while observing the pump and hoses Always leave the pump direction control in neutral and manual increase speed at zero or to the left WARNING EXTREME CARE MUST BE USED DURING PUMPING OPERATIONS TO MAKE SURE THAT SYSTEM COMPONENTS OPERATE AT THEIR RATED PRESSURES FAILURE TO CHECK THE CONDITION OF ALL HOSES AND CONNECTIONS WHEN PUMPING COULD RESULT IN SEVERE BURNS INJURY OR DEATH ...

Page 52: ... ON WHEN LOWERING A WING THE WING WILL TURN ON SPRAY THIS COULD RESULT IN INJURY SEVERE BURN OR DEATH TO PERSONNEL CLOSE TO THE WING AREA R Burner Right or Lower Burner On Runs and ignites burner Off Stops burner Cool Down After burner is stopped run in cool down for at least two minutes to cool burner liner If you fail to cool down the burner it will melt the pump coupling and the ignition module...

Page 53: ...b Open exhaust stack lid c Turn on right or lower burner d Turn on left or upper burner if necessary or so equipped e Circulate pump at 150 GPM f To stop heating switch burners to cool down position for 2 minutes then to off g Close exhaust stack lid After heating allow 20 minutes for tube cool down prior to off loading Off loading with a hot tube can cause an explosion ...

Page 54: ...urce with pump in FORWARD Gravity unload B Pump Isolation optional C Main Tank Valve rear D External Discharge with pump in FORWARD Intake from external source with pump in REVERSE E Spray bar Isolation F Tank Circulation to front of tank G Front Suction optional H Flush Intake I Flush Air Vent ...

Page 55: ...Load Optional M Hand Wand Supply Study the layout of the valve locations This plumbing diagram will be used throughout the manual to reference different circulation paths Notice the difference between the closed valves previous page and the open valves in the circuit ...

Page 56: ...t of material in the tank is shown on a flotation gauge mounted on the driver s side of the tank The gauge is marked in 50 gallon increments NOTE The vehicle must be stationary and level to obtain an accurate reading from the asphalt tank gauge ...

Page 57: ...e not of a suitable size change them according to the instructions given below Refer to the side of the Calculator that represents your measurement system English or metric On top in the first window align the required SPREADING RATE with TRUCK SPEED Then in the 3rd window Spray Bar Pressure choose the Nozzle that fits most closely in the range of 6 to 12 PSI The acceptable range is actually 5 to ...

Page 58: ... at an angle of 30 to the long axis of the spray bar for application of asphalt at the specified rate DO NOT attempt to estimate this angle ALWAYS use the wrench The skill level or reputation of an operator or truck can quickly deteriorate when nozzles are misaligned or poorly maintained and plugged The skill level of an operator may be overlooked if the truck shoots a beautiful spray pattern Init...

Page 59: ...t while watching the spray bar in the mirror Bar should move approximately 10 inches to the left and then 10 inches to the right from center f Return the bar to the center position CAUTION IF ANY SPRAY BAR VALVE FAILS TO CLOSE DURING THE WING SAFETY SWITCH TEST NOTIFY A QUALIFIED MAINTENANCE TECHNICIAN IF A WING VALVE INADVERTENTLY OPENS WHILE IN THE VERTICAL POSITION A POTENTIAL HAZARD EXISTS FOR...

Page 60: ...RNS INJURY OR DEATH WARNING IF ANY MOISTURE IS PRESENT IN THE TANK OR IF THE DISTRIBUTOR WAS PREVIOUSLY USED WITH EMULSIFIED OR WATER BASED MATERIAL DO NOT LOAD WITH NEW MATERIAL AT ANY TEMPERATURE ABOVE 200 F 93 C BEFORE MACHINE CAN BE LOADED WITH HOT MATERIAL IT MUST BE FLUSHED USING THE TANK FLUSHING PROCEDURE Anytime an asphalt distributor has been used with emulsified asphalt or a water based...

Page 61: ...with a Cut Back asphalt This method is the safest but does not flush 100 of the water out This is a good first step to flushing the tank prior to loading hot asphalt Shooting emulsion over a long period of time can form pockets or areas where wet emulsion is trapped under broken or dried emulsion Cut Back may not be hot enough to soften and dissolve these pockets Whenever you use the Asphalt Pump ...

Page 62: ...oiling hissing and popping stops the water has boiled out j Off load the cut back k Load Hot Asphalt through the Spray Bar l On the Side Control Panel select and perform On Load Thru Spray bar Hose A Load the tank slowly 40 GPM with enough material to cover the heat tubes m On the Cab Console select Spread Heat and circulate the spray bar for 10 30 minutes With optional Front Suction select and ci...

Page 63: ...E CARE MUST BE USED DURING PUMPING OPERATIONS TO MAKE SURE THAT SYSTEM COMPONENTS OPERATE AT THEIR RATED PRESSURES AND TEMPERATURES FAILURE TO CHECK THE CONDITION OF ALL HOSES AND CONNECTIONS WHEN PUMPING COULD RESULT IN SEVERE BURNS SERIOUS INJURY OR DEATH a Connect transfer hose inspect condition from supply vessel to Valve A ...

Page 64: ...turn or approximately 40 60 GPM While observing all connections and the transfer hose open the A valve Now open supply tank valve If all is well speed pump up to desired transfer GPM approximately 250gpm when using a 3 transfer hose Asphalt will be pulled through Valve A and through valve F to the bottom of tank d When the desired amount of asphalt has been pumped shut off the supply ...

Page 65: ...ugh the hose to help clean it f Close Valve A g On Side Control Panel push Pump Valves red button h Zero Manual Increase dial i Neutral pump direction Loading Through Optional Valve L Valve L Trough mounted load valve and swivel has the same function as valve A It is located at the end of the hose trough on the driver s side Because of its location and swivel the hose can remain attached to the va...

Page 66: ... as may occur when handling paving grade asphalt in cool weather It is slower than Method A being limited to approximately 150 gallons per minute a Connect feed hose between Valve A and the supply tank valve b On the Side Control Panel select On Load Thru Spray bar Hose A c Pull on the Pump Valves red button to actuate the E K valves d Select Forward pump direction e Turn Manual Increase Speed clo...

Page 67: ...s been pumped close supply valve j Loosen the hose connection at the supply valve so it will draw in air to suck the hose clear Do this for three minutes and then remove the hose from the supply vessel elevating it to help clean it If you wish draw some diesel through the hose to help clean it k Close Valve A l On the Side Control Panel Push the Pump Valves red button to close the E K valves m Swi...

Page 68: ...c Monitor the filling procedure closely Do not overfill Allow space in the tank for expansion when material is heated d Observe material in tank for signs of boiling which would indicate moisture If boiling exists stop filling at tank or just cover heat tubes and proceed to step e If no boiling exists fill to desired level and proceed to step h e On the Cab Console select Spread Heat and circulate...

Page 69: ...69 ...

Page 70: ...Pump Valves red button to actuate C valve c Open Valve D d Open Supply Valve e With pump in Forward slowly turn the Manual Increase dial clockwise to turn or approximately 40 60 GPM While observing all connections and the transfer hose If all is well speed pump up to desired transfer GPM approximately 250gpm when using a 3 transfer hose Asphalt will be pulled through Valve C and pushed through val...

Page 71: ...clear Do this for three minutes and then remove the hose from the supply vessel elevating it to help clean it If you wish draw some diesel through the hose to help clean it l Close Valve D m On Side Control Panel push Pump Valves red button n Zero Manual Increase dial o Put pump in Neutral ...

Page 72: ... the supply tank valve b Connect feed hose between Valve D and the Transfer tank valve c Open vales A D d Open Transfer and Supply valves e On the Side Control Panel select Thru Pump Transfer f Pull on the Pump Valves red button to actuate pump g Select Forward pump direction h Turn Manual Increase Speed clockwise turn or about 40 60 GPM while observing the hose and the connections ...

Page 73: ...n Switch the pump direction to neutral o Zero the Manual Increase Speed dial p Close the Transfer Valve q On the Side Control Panel Select OFF Load Hose D r Pull on the Pump Valves red button to actuate C valve and pump s Select Reverse pump direction t Turn Manual Increase Speed clockwise turn or about 40 60 GPM while observing the hose and the connections u Loosen the hose connection at the Tran...

Page 74: ...transfer hose inspect condition from supply vessel to Valve A b On Side Control Panel Select Gravity OFF Load and pull Pump Valves red button to actuate C valve c Start External Transfer Pump d Open the A valve e When the desired amount of asphalt has been pumped push the red Pump Valves button to close valve C f Close Valve A ...

Page 75: ...rough the hose to help clean it Heating Asphalt NOTE Before starting the heaters position the vehicle broadsideto the wind to allow the wind to carry emitted vapors away from the hot exhaust stacks of the heater and the truck engine air intake WARNING POTENTIAL FIRE OR EXPLOSION HAZARDS EXIST WHEN OPERATING THE BURNERS FAILURE TO FOLLOW THE BURN OPERATION SAFETY PROCEDURES COULD RESULT IN SEVERE B...

Page 76: ...ve materials from the tank while the burners are operating or the automatic burner controls are set to operate NEVER remove materials from the tank within 20 minutes of heating Hot heat tubes can ignite vapors when exposed to oxygen Tank Circulation While Heating Warm Asphalt a On Cab Console select Circulate Heat b Select Pump FOR forward c Select Manual d Use the GSY switch INC to set pump speed...

Page 77: ...rst As much as 20 of the heat developed in the asphalt can be dissipated due to heat losses in the spray bar Heating with Diesel Fired Burners WARNING POTENTIAL FIRE OR EXPLOSION HAZARDS EXIST WHEN OPERATING THE BURNERS FAILURE TO FOLLOW THE BURN OPERATION SAFETY PROCEDURES COULD RESULT IN SEVERE BURNS INJURY OR DEATH WARNING IF A BURNER GOES OUT DO NOT ATTEMPT TO RE LIGHT IT FOR AT LEAST TWO 2 MI...

Page 78: ...witch to increase pump speed to 150 GSY Check Equalizers If an equalizer valve is open a plug of asphalt can form in the spray bar and prevent material from circulating a Visually verify that all three equalizer valves are closed The actuating rods on the pneumatic cylinders that drive the valves must be fully extended b Turn CRC unit ON and set CRC manual switch to manual c Run pump in FORWARD an...

Page 79: ...ned on the display will show a Warning Read and comply with the instructions given Press OK to continue b Switch Master OFF Selector Switch OFF Pump OFF c Engage the PTO d With Selector Switch select Spread Heat Listen for and check that valves C and E have opened e Switch CRC f Switch Pump Forward Circulation should start and GPM should indicate Idle speed g Once Spray bar is warmed up unlatch Sp...

Page 80: ...to not over speed the pump s capability this will affect your application rate p As you get to the end of the shot have your finger ready on the Master Switch and roll past the stop line turning OFF the Master Switch as the Spray bar passes over the stop line Starting or stopping the spray while stopped or not moving will result in zero GPM and cause the spray pattern to drizzle or streak you must...

Page 81: ...Suction With the optional Front Suction or G valve you can spread while spraying down a steep incline The G valve draws from the bottom front of the tank With this option there is a switch on the Cab Console labeled Front Suction choose Front or Rear ...

Page 82: ...he calculator align TRUCK SPEED 400 feet per minute with SPREADING RATE 0 4 gallon per square yard e On the BAR LENGTH scale locate 12 feet the desired spreading width and immediately above it read the PUMP OUTPUT in gallons per minute In this example it is 215 GPM f On Side 2 of the Calculator set the SPREADING RATE 0 4 gallon per square yard at the BAR LENGTH 12 feet Read the OIL REQUIRED in gal...

Page 83: ...ng OFF the Master Switch as the Spray bar passes over the stop line Hand Spraying While Circulating Spray bar During the course of normal CRC spreading on occasion there is a need for quick patch work You have just finished a normal shot in CRC and need a little hand spraying a On the Cab Console switch to Manual b Switch Pump to FOR c With the GSY Switch select 50 GPM d Remove the Hand Wand e Ope...

Page 84: ...se Valve M m On Cab Console return Pump to FOR n Switch to CRC Hand Spraying a On the Cab Console select Load Outside b Remove Hand Wand and uncoil needed amount of hose c On the Side Control Panel select OFF Load Hose D ...

Page 85: ...ase dial to desired pressure Use only enough pressure as necessary j When finished on Side Control Panel switch Pump to Reverse k Open Hand Wand Handle Valve to suck back material l With the Hand Wand Handle Valve open use the wash down hose to spray diesel into the nozzle of the Hand Wand while sucking back m Close Hand Wand Handle Valve and replace Hand Wand n Close Valve M o On Side Control Pan...

Page 86: ...witch Pump to Neutral Spray Bar Flushing 1 Check Flush Tank fluid level 2 With spray bar warm and circulating a Check Master Switch OFF b Switch Pump OFF c Select Auto Flush d Switch Pump FWD Display should indicate GPM ...

Page 87: ...87 Stage 1 ...

Page 88: ... high speed to evacuate the system After 5 minutes of purging the system switches to stage 2 Stage 2 Actuates valves H E J circulating flush fluid from the Flush Tank at 40 GPM through hthe Spray Bar and back to the Flush Tank After 5 minutes of circulating the system with flush fluid switches to Stage 3 The circulation time is adjustable Stage 3 ...

Page 89: ...onsuming problems that develop when residual asphalt is allowed to solidify in the spray bar A quick flush takes less time and is not nearly so tedious as having to free all of the valves in a frozen spray bar Empty Flush Tank When the fuel in the FLUSH FUEL tank b Showecomes too thick with asphalt to flush effectively check with dip stick on tank cap you can empty the tank as follows a On the Cab...

Page 90: ... 90 d Switch Pump Forward e Turn Manual Increase Speed dial to turn about 100 GPM f Cycle about 5 Minutes and push red button to stop g Zero Manual Increase Speed dial h Switch Pump to Neutral i Refill Flush Tank ...

Page 91: ...atches to lock it in place d Raise the wings fully upright and latch the safety chains e Lock the reel that holds the hand spray hose and make sure other hoses are secured in place f Disengage PTO g Oil on the tail lights will quickly pick up enough dust to impair the effectiveness of the lights h Wipe the tail lights clean of oil film i Ensure valves A B D M L and the Hand Wand Handle Valve are c...

Page 92: ...few seconds a warning will display It is important to read and understand the condition of your truck If your truck is wet or the spray bar and tank contain moisture left over from shooting emulsion and you are about to circulate or load hot asphalt 200 degrees a serious danger to you and people near the truck exists If your tank is loaded with hot asphalt and ...

Page 93: ...t To continue press the button below OK The Display has four buttons at the base that control different functions based on the current page or activity The Control Button window disappears to show temperature but can be reactivated any time by pressing any of the 4 buttons Some functions that require an increase or decrease of a integer can be changed with the appropriate button or the GSY Inc Dec...

Page 94: ...llons per Square Yard GSY is the controlled application rate The rate can be changed when the window is selected yellow Use the button below the select icon to select the GSY window then use the INC DEC switch to set the desired rate The four buttons at the bottom correspond to the windows above Another method to change the rate is GSY window selected to push the button below the Edit icon to ente...

Page 95: ...hen change nozzles Nozzles only affect spread Rate when you spread to fast and the increased bar pressure causes bypass For instance if you are using 2 nozzles and while spraying the Nozzle Size indicator reads 3 or 4 you are going to fast Either slow down or change nozzles Going too slow only affects the nozzles ability to fan properly resulting in streaking If streaking is a problem reduce nozzl...

Page 96: ... the Spray Valve switches are OFF The Spray Valve switches are their own indicators for on and off while the display only indicates the Taper Cut position Gallons When the master switch is ON gallons used is indicated in the left window This number will reset every time the Master Switch is turned ON Total Gallons While spreading the computer accumulates the total volume spread Spread Rate X Width...

Page 97: ...hold Reset to zero the counter Both Total Feet and Sq Yards reset at the same time Temp At the bottom of the home page on the left and right after the Edit button window disappears is the Set Temp and actual Temp The Set Temp is the high limit for the burner and will shut it off or prohibit it from turning on if material temperature is hotter than the setting The lower right is the actual temperat...

Page 98: ...ster switch OFF the spray system and plumbing is valved to circulate When circulating in CRC the pump is turning at Idle or Circulate speed By highlighting Circulate and pressing Edit you can use the Up and Down buttons to change to the desired speed Press OK after changing speed to save your settings and exit edit mode Manual ManPump on the settings page is for setting the pump speed in manual op...

Page 99: ...rrassing when you return to work and your spreading the wrong application rate because you left it switched to Manual Don t forget the Pump direction as well Simulate FPM Simulate FPM is a Diagnostic tool for testing components that are FPM driven like GPM in CRC mode By selecting Simulate FPM and pressing Edit you can change the speed To actuate this feature select Simulate FPM OFF and toggle On ...

Page 100: ...p or down by selecting FlushTM pressing Edit and raising or lowering the time with the Up or Down buttons Press OK to save and exit edit mode If you are spraying paving grade asphalt you may want to increase the circulate time for better or more thorough flushing Cal 1 On the Settings menu Press the Select button to highlight Cal 1 A preview of the available settings is shown Press OK to enter the...

Page 101: ... all Spray Valve Switches or turn the Valve Selector Dial Off 4 Turn ON the Master Switch and drive the pre measured distance Speed is not a factor so drive slow and strait Upon approaching the finish line slow down and turn Off the Master Switch when your reference point lines up with the finish line At this point the Feet Spread should read 1000 ft or the pre measured distance 5 If the Feet Spre...

Page 102: ... is an even worse idea to make G Cal adjustments on short shots 1000 gallons or less Start compensating by increasing or decreasing the spread rate GSY Inc Dec If a change in spread has no effect then screens are plugged or you are over speeding the pump driving too fast If an increase or decrease in spread rate solves the problem your G Cal needs adjustment You have increased or decreased your sp...

Page 103: ...er right part of the Home page receives a signal from a temperature sensor in the asphalt tank If the displayed temperature reading is different than the pencil thermometer a calibration adjustment may be required Press Edit and use the Up Down buttons to change the Actual Temp window to match the thermometer on tank then press OK Auto Shutdown If left idle no switches are actuated or the FPM and ...

Page 104: ...e ring gear for which you would toggle Axle For some skid mounted and special custom equipment a radar my be used to obtain an FPM or speed signal for which you would toggle Radar Heat A factory setting for burner controls Toggle Off for no burner or heat system Toggle On for diesel propane or 48v electric Toggle ElcGen for hydraulic driven 230v AC generator Ready Set Point The Ready position on t...

Page 105: ...rly to match your spray bar In order to activate functions on this page the controls and hardware must be physical mounted to your machine From the Settings Menu Select Spray Bar and OK Width Press select to highlight width and use the Up Down buttons to set the overall spray bar width Line Markers are added separately Press OK to save and exit Line Markers Select Line markers and use the On Off b...

Page 106: ... the Up Down buttons to enter the length of the extension in feet 3 nozzles per foot If the Extension Tee s into a Line Marker cylinder Select and Edit the appropriate side of Ext On Line Marker Wing Sections Set the wing increments as the number of controlled feet in between wing folds The diagram above the wing windows shows the layout of the wings in accordance to the windows It is important to...

Page 107: ... reset ALL settings YOU WILL LOSE ALL THE SETUP PARAMETERS This is used as a factory initial build tool and will not fix anything Only reset these parameters if instructed to do so by the factory Again if you reset the defaults you WILL lose all of the setup parameters and you will need to reconfigure ALL the Setup Pages Diagnostic Menu From the Home Page press the Back button to access the Diagno...

Page 108: ... Vlv Cmds Valve Commands displays in bar graph form the computers command output to a function like the product pump The first line displays the output command The second line is the feedback response If the computer is asking output command the pump to run at 150 GPM the Feedback response should be equal If there was a mechanical problem like a frozen pump or cold material was prohibiting the pum...

Page 109: ... only switch signal voltage to the node or computer If there is a problem and the switch is working on the diagnostic page then the problem is not the switch Side Ctrl Like the Switches diagnostic page the Side Control panel has a diagnostic page Select and OK to enter the page The switch on the screen or display should act just like the mechanical switch on the Side Control Panel If you turn a sw...

Page 110: ... Safety Lockout Condition If all the lights are green the computer will allow the burner to fire Safety lockouts prevent the burner from running if the following conditions are true 1 FPM movement 2 Actual Temp is higher than Set Temp 3 30 minutes of zero GPM no circulation 4 Master Switch is On 5 Temp Sensor failure after 30 minutes If Safety Lockout shuts down the burner while burning it will ru...

Page 111: ...Bar width Pump does not circulate with Master Off a Connect asphalt hoses from there source to the A D valves and open pertaining valves b Select Pump T 1 and press OK c Select Spread heat and Pump Forward d Operate as if spreading Use the Master switch to start the metering Pump T 2 Spray Valve Actuation allows the testing and actuation of all the spray valve cylinders on the spray bar with all t...

Page 112: ...M if moving Spread Rate and Bar width Pump circulates thru F with Master Off a Connect asphalt hose from the external spray bar to the D valve and open pertaining valves b Select Pump T 4 and press OK c Select Spread heat and Pump Forward d Operate as if spreading Use the Master switch to start the metering ...

Page 113: ...e undertaken until the next one is known The following examples of pattern spray operations show typical ways in which the equipment can be employed Many other approaches are possible However no operation should be commenced until both of the conditions listed above have been satisfied Parking Lot Plan of a parking area with restricted entrance and exit routes Concrete curbing bound perimeter The ...

Page 114: ...ral clear area the truck is first driven diagonally across the parking area in two passes first with both marker valves open and again with only the left hand marker valve open The result is a defined area of twice the width of the spray bar ...

Page 115: ...nd the left hand portion of the curbed perimeter with only the left wing spray valves open The spaces at the entrance and exit are left unsprayed NOTE More satisfactory lines with the line markers may be obtained by turning the pump off ...

Page 116: ...rallel to the left hand curb at the entrance area As the vehicle is moved forward spray valve switches are turned on to produce the pattern shown When the farther section of the area is reached the switches are turned off in the appropriate sequence ...

Page 117: ...ong the central clear area with one wing projecting over the edge of the area sprayed on in Step 5 The wing spray valves are switched on and off as needed to produce the pattern shown The result is a straight edge along the clear area ...

Page 118: ...BC 502 CRC 118 Step 5 Steps 2 through 4 are repeated on the right hand side of the area to produce the pattern shown ...

Page 119: ...119 Step 6 The right half of the central clear area is sprayed in one pass from the exit end Recall that the clear area was made twice the full width of the spray bar ...

Page 120: ...BC 502 CRC 120 Step 7 Finally the remaining half of the central area is sprayed in a single pass from the entrance to the exit The entire area can now be spread with chips ...

Page 121: ...he line where it joins the primary The chip spreader is instructed to stop at the dashed line and hold there until the intersection has been sprayed Step 1 To define the work area the truck is driven from A to B with a marker valve open then from C to D and from E to F to produce the guidelines shown ...

Page 122: ... driven through the arcs spray valve switches are turned on and off as needed to produce the patterns shown Step 3 The irregular edges along the lines BC and FA are sprayed The truck is driven along the primary road with only as many wing spray valves open as are needed to make a smooth edge ...

Page 123: ...marks the termination of the previous work If any hand spraying along the line DC is required it should be completed first Step 5 Last the right hand section of the road is sprayed after any necessary hand spraying At the conclusion of the spray run the truck is located as shown The entire intersection can now be spread with chips ...

Page 124: ...location of the spray nozzles relative to the surface and help to avoid overlaps and gaps Shooting a Straight Line The following techniques will be helpful in controlling the vehicle so the sprayed area follows a straight line with minimum need for weaving jogging and random corrections When following an existing continuous line such as a curb or guide string use the side shift as little as possib...

Page 125: ...ar in the center of its travel SWING Drive to a point far enough away from the connection so that you have adequate space to back straight toward the connection For approximately the final 50 feet of the backing run grip the steering wheel firmly with your left hand and place your left arm solidly on the window frame The object is to prevent the steering wheel from moving In this way you can make ...

Page 126: ...ee them Procedure for flushing Spray bar as described in Chapter 4 Spray bar Flushing Clear Spray Bar Clogged with Frozen Asphalt Preferred Method Clearing with Live Steam CAUTION IF A WRENCH IS NECESSARY TO OPEN THE SPRAY VALVE APPLY AS GENTLE A FORCE AS POSSIBLE TO AVOID DAMAGE TO THE VALVE LINKAGE a Manually open the first set of spray valves at either end of the bar Use a wrench if necessary b...

Page 127: ...ating that the bar has been cleared of all material Clear Clogged Spray Nozzle If asphalt does not flow from a single nozzle the blockage is in the nozzle Remove it with a wrench and clear the obstruction by pushing a wire through the nozzle If asphalt continues to flow when the valve is commanded to close the blockage is in the valve seat area Run the pump in REVERSE to remove material from the v...

Page 128: ...e the four nuts that hold the cover plate c Take off the plate and remove the internal gasket d Pull out the cylindrical screen and remove the material collected on it e When reinserting the screen be sure it is properly seated in the locater ring inside the Y chamber You may need to rotate the screen until it fully enters the chamber and seats in the locater ring f Replace the cover plate Tighten...

Page 129: ...d of the oval into the seat Then move your fingertips around the seal a little at a time until it is seated BE CAREFUL at all times not to force the seal or bend it excessively If a kink develops the seal will no longer be usable Reassemble a Wipe the shank of the wing clean and apply a thin coating of grease b Replace the wing assembly Maneuver it into the swing joint sleeve until it is fully sea...

Page 130: ... inner seal j Replace the shaft key drive shaft and companion flange Tighten the bolts securely Replace Nozzle Valve Stem Seals The spray nozzle valves are equipped with seals and O rings that require replacement if leaks develop a Close Valve E and drain the spray bar b Use a wrench to remove the seat bushing of the leaking valve The bushing is located on the underside of the spray bar c Remove t...

Page 131: ...he seat bushing and washer and o ring Coat the threads with No 1 Permatex gasket cement q Reinstall the seat bushing Tighten it to 15 ft lbs Of torque Avoid distorting the seat NOTE Do not guess at the proper torque Use a torque wrench Adjust Actuators for Spray Nozzle Valves Mechanical Linkage This adjustment is for the optional mechanical linkage and does not apply to the Tri Valves This adjustm...

Page 132: ...ed e When the center valve has been properly positioned check the two remaining valves of the set If adjustment is necessary to achieve 1 16 travel twist the shaft as required f When all three valves have been properly positioned measure the clearance between the edge of the square tube and the flat of the nut that secures the valve stem It must be at least 1 16 or the valve may become cocked ...

Page 133: ... listed below at the intervals specified a Asphalt pump certain models only If the pump contains a fitting lubricate weekly with chassis grease b Heating system air blower Follow manufacturer s instructions included in this Operations Manual c Vehicle engine drive train running gear etc Follow maintenance instructions provided by vehicle manufacturer Preparation for Storage To prepare the asphalt ...

Page 134: ...the spin on filters adjacent to the hydraulic tank and discard them properly c Install new filters Hand tighten only Use the filters in our parts list d Close the drain valve and refill the reservoir with 22 gallons of Type 46 Hydraulic Fluid e Condensation that may build up in the hydraulic system is capable of clogging the filter This condition can lead to insufficient hydraulic fluid at the pum...

Page 135: ...ottom The cargo pump operates on the positive displacement principal That is when the gears mesh a partial vacuum is produced Atmospheric pressure can then force the bituminous material into the pump where it is carried between the gear teeth and the casing to the other port The messing of the gears then forces the material through the outlet port Note the maximum acceptable clearance between gear...

Page 136: ...ect until the desired G Cal or F Cal box illuminates yellow d Press edit e Press up or down to change the setting f Press OK FCAL footage calibration A setting of 1 raises the measured footage by 1 part in 1000 A setting of 2 lowers the measured footage by 2 parts in 1000 etc GCAL Pump calibration Gallons Calibration raises or lowers measured pump rate by a factor of GCAL 1000 like FCAL Equalizer ...

Page 137: ...ick to the seat of the disk This can cause bypass or leakage through the K valve resulting in light spread rate or the loss of an entire tank of flush fluid The disk can be checked and cleaned without the removal of the K valve a Product pump in neutral remove 6 bolts on top of K valve Be careful with gasket Lift the top of the assembly out of the valve housing Notice the slots in the top outside ...

Page 138: ...inspect the valve seat inside for similar problems Some emulsions and corrosive products can cause pitting which will result in valve replacement d Inspect the O ring that seats on the top of the disk e Reassemble the valve by inserting the disk back into the valve housing seat facing down f Replace gasket and check to see that O ring stays in place while ...

Page 139: ...tion Repair or replace as needed 4 Inspect pump and replace parts as needed 5 Clean tank to remove obstruction 6 Be sure it is closed tight Replace as needed 7 Clean seat Check air pressure which should be 40 60 psi with the master switch on Hydrostatic pump develops excessive noise 1 Hydraulic fluid level excessively low 2 Hydraulic filters dirty or plugged 3 Intake screen inside tank dirty or cl...

Page 140: ... turns but burner does not ignite 1 No smoke from stack 2 No oil flow at nozzle 3 System appears to be air bound 4 Blows white smoke 1 Check flue level Check coupling in burner replace if necessary 2 Clean clogged screen in the nozzle or replace nozzle 3 Check for and insert bypass plug in return port on fuel pump 4 Check for proper voltage at coil Replace if necessary Check condition of electrode...

Page 141: ...e correctly contact BearCat s Service Department 928 684 7851 For additional assistance in troubleshooting or repairing your BearCat equipment please contact us BearCat Mfg 3650 Sabin Brown Road Wickenburg AZ 85390 Phone 928 684 7851 Fax 928 684 3241 service bearcatmfg com Links to various troubleshooting and operational videos can be found on our website at the following link www bearcatmfg com ...

Page 142: ...r leaks 7 Drain the air tanks 8 Inspect for correct operation of wing limit switches 9 Test the burner safety switch Burner should not work if brakes are not set 10 Clean the bar and suction screens or as needed 11 Clean the spray bar with an approved cleaning agent at the end of the day 12 As needed during the day spray the shafts of the hydraulic cylinders and the air cylinders with PAM or equiv...

Page 143: ...sing recommended oil ISO 46 2 Change the hydraulic filters Older trucks may only have one 3 Inspect the heat flue liner 4 Inspect the tank vent for build up and remove any that is found 5 Check the bar for level and height setting Storage 1 It is best to leave diesel in the bar 2 During winter be sure the bar and tank valve have been drained of emulsions Water will freeze and crack the bar and val...

Page 144: ... 13 35 55 80 95 1 2 20 40 65 90 105 9 16 12 50 80 110 140 9 16 18 55 90 130 150 5 8 11 70 110 170 185 5 8 18 80 130 180 205 3 4 10 120 200 280 290 3 4 16 140 220 320 355 7 8 9 140 300 460 505 7 8 14 155 320 500 585 1 8 160 440 680 775 1 14 170 480 740 900 1 1 8 7 220 600 960 1150 1 1 8 12 260 660 1080 1325 1 1 4 7 320 840 1360 1600 1 1 4 12 360 920 1500 1750 1 3 8 6 420 1100 1780 2345 1 3 8 12 460...

Page 145: ...SM 1 GSY 3 16 LSM 1 LSM 316 GSY Emulsion 140 F approximately 1 ton 240 gal 908 4 liter 1 tone 264 gal 1001 liters Asphalt 325 F approximately 1 Ton 245 gal 927 4 liter 1 tone 270 gal 1022 liters GPM LPM 1 gal min 3 785 liter min 1 liter min 264 gal min PSI Bar 1 psi 069 bar 1 bar 14 504 psi Horse Power Kilowatt 1 hp 746 kw 1 kw 1 34 hp BTU hr Kilowatt hr 1 btu hr 0002931 kw hr 1 kw hr 3412 2 btu h...

Page 146: ...2 Rear Control Assembly 150 Figure 13 Inner Wing Assembly 151 Figure 14 Hydraulic System 151 Figure 15 Rear Panel Assembly 152 Figure 16 Product Tank 153 Figure 17 Plumbing and Valve Assembly 154 Figure 18 Bar Mount and Actuator Assembly 155 Figure 19 Pump Drive Assembly 156 Figure 20 Product Pump 157 Figure 21 Side Control Box Schematic 158 Figure 22 Cab Console Schematic 159 Figure 23 Valve Box ...

Page 147: ...GED 1 14 207041 DECAL CONTROL BOX 1 15 207055 NODE 111 PROGRAMMED 1 16 207056 NODE 112 PROGRAMMED 1 17 205738 DEUTSCH 9 PIN RECPT 1 18 200710 TERMINAL BLOCK SECT 7 207045 CONTROL PANEL ID PART DESCRIPTION QTY 1 101308 NODE 5 PROGRAMMED 1 2 202823 SWITCH ROTARY 1 3 202834 KNOB ROTARY SWITCH 1 4 205738 DEUTSCH 8 PIN RECPT 1 5 207622 PANEL ENGRAVED 1 6 ELC 24272A SWITCH 3 POS MOMENTARY 1 7 ELC 61122 ...

Page 148: ...C 24420 CONNECTOR 3 8 1 14 ELC 24425 CONNECTOR 1 2 1 15 ELC 25172 SWITCH PRESSURE 1 16 ELC 80705 SWITCH PRESSURE 3 17 FIT 24221 PLUG BUTTON 1 18 HSG 24246 BOX REAR CONTROL 1 208092 REAR CONTROL PANEL Figure 4 REAR CONTROL PANEL ID PART DESCRIPTION QTY 1 MSC 35032 DBL MODLR SUB BASE 5 2 MSC 35030 END PLATE KIT 1 3 204546 CANOPEN PC BOARD 1 4 205993 GASKET RED PILOT VALVE 1 5 207501 GASKET VALVE 1 6...

Page 149: ...149 Figure 6 BURNER Figure 7 FLUSH TANK Figure 9 REAR ASSEMBLY Figure 8 MECHANICAL LINKAGE ASSEMBLY ...

Page 150: ...150 Figure 11 TRI VALVE INNER WING ASSEMBLY Figure 10 SPRAYBAR ASSEMBLY Figure 12 REAR CONTROL ASSEMBLY ...

Page 151: ...151 Figure 13 INNER WING ASSEMBLY Figure 14 HYDRAULIC SYSTEM ...

Page 152: ...152 Figure 15 REAR PANEL ASSEMBLY ...

Page 153: ...GE TANK VALVE 1 11 FIT 29160 FLANGE 1 12 GRD 23223 FENDER 2 13 GRD 50009 STEP ASM 2 14 GRD 50477 CAT WALK ASM 1 15 HSG 25253 LINER ASM 2 16 HSG 91106 EXAUST STACK DOUBLE 1 17 RNG 29085 GASKET 5 FLANGE 1 18 TNK 21480 TANK FLUSH 11 1 19 VLV 27256 VALVE TANK 4 1 19 VLV 27257 VALVE TANK 5 1 20 FIT 29157 FLANGE 3 2 21 MTR 21266 FLOAT ARMASM 1 22 HSG 21236 MANHOLE LID 1 23 MSC 26634 TANK PAD RUBBER 8 24...

Page 154: ...154 Figure 17 PUMBING AND VALVE ASSEMBLY ...

Page 155: ...300 CYLINDER WING 1 28 BRK 52011 RAIL HANGER RH 2 29 204965 SUPT LH WING 1 30 209062 VALVE BOX STAND 1 BAR MOUNT AND ACTUATION ASM 31 GRD 52054 CAMLOCK BAR LATCH ASM 2 32 204964 SUPPORT RH WING 1 33 206266 LIGHT BACK UP LED 4 1 34 206277 LIGHT S T T LED 4 1 35 BRK 52061 ANGLE BRACKET 4 36 BRK 26443 LIFTING BAIL EYE 2 37 BRK 27475 CARGO PUMP BRACKET PLT 1 38 BRK 52062 HOSE REEL BRACKET 2 39 BRK 520...

Page 156: ...156 Figure 19 PUMP DRIVE ASSEMBLY ...

Page 157: ...157 Figure 20 PRODUCT PUMP ...

Page 158: ...158 Figure 21 SIDE CONTROL BOX SCHEMATIC ...

Page 159: ...159 Figure 22 CAB CONSOLE SCHEMATIC ...

Page 160: ...160 Figure 23 VALVE BOX SCHEMATIC ...

Page 161: ...161 Figure 24 REAR CONTROL BOX SCHEMATIC ...

Page 162: ...162 Figure 25 REAR CONTROL BOX PROPANE SCHEMATIC ...

Page 163: ...163 Figure 26 HYDRAULIC LAYOUT ...

Page 164: ...164 Figure 27 HYDRAULIC SCHEMATIC ...

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