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Miscellaneous Components and Parts

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Содержание P1

Страница 1: ...elopment some of the details shown in this manual may differ from your equipment We reserve the right to change the contents of the manual without notification CIMLINE COM 2601 Niagara Lane Plymouth MN 55447 763 557 1982 800 328 3874 Fax 763 557 1971 Part 305 000 000 6 8 2021 Rev B ...

Страница 2: ...2 ...

Страница 3: ...machine can expose you to dust containing crystalline silica and engine exhaust which contains chemicals that are known to the State of California to cause cancer birth defects or other reproductive harm For more information go to www P65Warnings ca gov ...

Страница 4: ...Controls Overview 23 Operating the P1 24 28 Before starting out 24 Engine startup procedures 25 Pump startup procedures 26 Making a patch 26 27 Cleanup 27 Prepping for next day operation 28 Short Term Storage 28 Summer Hot Weather 28 Winter Cold Weather 28 Long Term Storage 29 End of season 29 Removal from storage 29 Emulsion Tank Cleanout Procedure 30 General Maintenance General Maintenance Safet...

Страница 5: ...t design 50 Trailer Wiring for Brakes and Lights 51 Parts Section Engine Parts 53 55 Top Level Assembly 305 015 004 53 Sub Assembly 305 028 004 54 55 Engine Service Parts 55 Pump Assembly 56 Axle Assembly 57 Aggregate Plumbing Assembly 58 59 Boom Arm Assembly 60 Wand Assembly 61 Rock Gate Actuator Assembly 62 Miscellaneous Components and Parts 63 65 Replacement Safety Labels free replacement 66 Re...

Страница 6: ...r serious injury This manual contains the basic information required to operate maintain and repair the CIMLINE P1 Patcher you have purchased The use of this manual insures accurate adjustments operation and proper lubrication of your equipment Please keep it handy NOTICE Also read and understand the Kohler Command Pro CH752 Engine Owners Manual Machine Specific Information P1 Serial Number Engine...

Страница 7: ... looking for answers to your questions CIMLINE Local Dealer Name CIMLINE Local Dealer Phone Number ________________________________ _________________________________ CIMLINE Sales Toll Free 877 841 0848 Telephone 763 694 2665 Fax 866 557 1971 Corporate Headquarters 2601 Niagara Lane N Plymouth Minnesota 55447 www cimline com Any parts orders or service problems relating to CIMLINE equipment should...

Страница 8: ...rself and those around you Lack of attention to safety can result in accidents personal injury reduction in efficiency and worst of all loss of life Watch for safety hazards and correct them promptly Understanding the proper operation of this equipment is critical to its safe operation In addition to following these safety guidelines the operator s should follow any company specific guidelines and...

Страница 9: ...des the safety cover on emulsion hose 7 Never leave machine unattended while it is running 8 Do not touch exhaust stacks or mufflers 9 Keep tank access closed at all times except when adding material 10 Do not use the patcher without first providing proper traffic control measures to prevent collisions with the DuraPatcher or its workers 11 Never extend the discharge boom into unprotected or uncon...

Страница 10: ...oximity to the nozzle must always wear PPE The continuous noise from the P1 engine and blower can lead to hearing loss The operator and anyone working in close proximity to running equipment must use hearing protection ALL PPE must be well maintained and in proper working order Required PPE includes Gloves with wristlets Heavy leather boots or shoes Face Shield Long sleeve shirt with sleeves rolle...

Страница 11: ... has been misplaced most manufacturers provide free downloadable copies on their website Towing with an undersized tow vehicle can cause the trailer to tow improperly potentially causing loss of control Overloading can also cause unintended failures to tow vehicle The weight of your trailer listed in this manual is for the base model without any additional accessories or the weight of the sealant ...

Страница 12: ...Failure to use correct rim contour may cause dramatic separation of tire and wheel and could cause serious injury or death Attempting to modify or repair a wheel can cause unsafe conditions that may result in an explosion Air pressure on a weakened or cracked rim can cause serious injury or death Torque Requirements It is extremely important to apply and maintain proper wheel mounting torque on yo...

Страница 13: ...ire pressure should always be what is recommended by the manufacturer for the load Always check pressure cold before operation DO NOT bleed air from tires when they are hot Check inflation pressure weekly during use to insure maximum tire and tread life The following tire wear diagnostic chart will help you pinpoint the causes and solutions of tire wear problems NOTE Tire wear should be checked fr...

Страница 14: ...ll covers closed and guards in place AVOID contact with any live terminals or connectors ALWAYS use proper lockout tag out procedures to prevent accidental startup when access to these areas is required see sheet 32 ONLY trained professionals should preform live voltage testing DANGER POISONOUS GAS Using the gas powered P1 indoors WILL KILL YOU IN MINUTES The engine exhaust contains carbon monoxid...

Страница 15: ...RD Exposed moving parts can cause serious injury DO NOT operate with guards removed ALWAYS follow lockout procedures before servicing see page 32 BURN HAZARD Contact with the hot surfaces of the engine muffler blower and alternator can result in burns NEVER reach inside the engine enclosure during or immediately after operation NEVER service the engine or change the blower oil when hot Allow the u...

Страница 16: ...EVER fuel a running or hot engine ALWAYS fill gas tank outdoors DO NOT overfill tank Fill gas tank to bottom of filler neck only Make sure fuel cap is on tight after filling Clean up fuel spills immediately Keep sources of sparks and flames away ALWAYS keep a Class ABC Fire Extinguisher nearby and know its proper use WARNING ...

Страница 17: ...ator as well as the engine exhaust are ignition sources Keep a Class ABC fire extinguisher nearby and know its proper use Keep running patcher at least 5 feet from buildings other equipment or stored flammables DO NOT store or transport flammable materials on the Patcher This includes spare gasoline or solvent Remove any rags or other combustible materials from the inside and around the engine hou...

Страница 18: ...it without options Weight listed DOES NOT include material 88 92 195 HEIGHT 92 INCHES 2 34 m WIDTH 88 INCHES 2 24 m LENGTH 195 INCHES 4 95 m BASE WEIGHT 4800 Lbs 2177 kg Emulsion Tank Size is 300 Gallons Maximum Safe Operational Emulsion Tank Capacity is 270 Gallons ...

Страница 19: ...we measure the tanks empty volume and subtract that from the tanks total volume The total volume of the emulsion tank is 300 gallons Every inch below the top if the tank is about 10 gallons used The best way to measure the empty space is to take a 4 foot stick and make a mark 28 from one end Open the hatch and dip the stick into the tank until the mark aligns with the bottom of the access port thi...

Страница 20: ...Replace cover Plug the power cord into a standard 120 volt 20 amp outlet and the thermostat will maintain the emulsion at the selected temperature for overnight heating DO NOT plug the tank heating blanket into a 15 amp circuit overnight The amperage load is high enough to potentially trip the circuit breaker which may leave you with cold material in the morning Estimated Tank Heating Times Note T...

Страница 21: ...h Emulsion flow control knob and Throttle control knob Engine Ignition and Choke Controls for starting the engine Control Panel Contains the ON OFF switch for main power pump reverse switch and traffic control lights ON OFF switch along with the gauges for monitoring engine RPM hours and AC Voltage Controllers for the heated hose and pump motor are mounted inside along with electrical fuses breake...

Страница 22: ...not function if set to OFF Pump Reverse Switch Hold switch to ON to temporarily reverse pump Switch toggles to OFF automatically when released Traffic Safety Light Switch This switch controls the amber and strobe lights on the rear on the patcher This switch does not require the Controls Power Switch to be on in order to operate Inlet Filter Filters the panel cooling air NOTICE keep clean and DO N...

Страница 23: ...utting this machine into operation Engine Controls Choke Applies choke to aid in starting the engine Ignition key Removable key for starting the engine Wand Controls Throttle Controls engine and blower speed Emulsion Flow Rate Knob Allows the user to control the amount of emulsion sprayed Emulsion Switch Turns the pump ON and OFF Rock Switch Opens and closes the rock gate Horn Press to honk horn ...

Страница 24: ...is securely latched 8 Make sure all guards are secured and covers are closed on the patcher 9 Perform a DOT pre trip inspection including but not limited to a Verifying that the hitch chains break away switch and lights are properly connected to the tow vehicle Refer to the vehicle manual safe towing guide b Confirm the trailer brakes are properly adjusted and in good repair c Make sure all lights...

Страница 25: ...ging of the aggregate pipe or unintentional spraying of material 5 Apply choke by pulling knob out as needed 6 Turn engine key to start a Do not engage starter for more than 10 seconds b If engine fails to start make sure to allow 10 seconds for starter to cool down before retrying 7 After engine starts a If choke was used slowly push it back in b Turn throttle down to 1800 rpm At RPM s below 1800...

Страница 26: ...med b Refer to the pump diagnostic matrix pages 76 77 if the pump does not start or material does not flow 7 Flip emulsion switch to OFF 8 Switch pump valve to emulsion 9 Turn emulsion switch back clearing the line of solvent If the material does not flow refer to the pump diagnostic matrix page 76 77 Making a patch 1 Verify traffic is routed away from your work area 2 Fill the aggregate hopper wi...

Страница 27: ...ch to OFF This stops the flow of emulsion so the machine is only distributing clean aggregate at this point Cover the repair with a light coat of clean aggregate to prevent traffic from tracking any emulsion from the patch while curing After the desired coating of dry aggregate is achieved flip the Rock toggle to the OFF position The aggregate will continue to flow until the blower airstream empti...

Страница 28: ...ents moisture from escaping and drying out the emulsion b The breather valve is to prevent a vacuum and over pressurization of the tank during the days temperature swings 3 Once a week open the access port and gently stir the emulsion using a clean board or pole This will help prevent a skin from forming on top of the emulsion Winter Cold Weather DO NOT allow the emulsion to freeze If the emulsion...

Страница 29: ...the guard when the cleaning is finished 12 Remove the pump guard and check the pump for leaking seals and inspect the coupling Clean out the coupling box as needed Replace the guard 13 Empty the drip catch tank 14 Thoroughly clean the unit Make sure to remove all 15 Cover or shrink wrap the engine housing control panel and the electric pump motor 16 Zip tie or lock the emulsion tank cover Removal ...

Страница 30: ...material to the back of the tank where the drain is located Proper PPE must be worn when accessing the tank and drain valve Operator should take care to avoid contact with hot emulsion 5 With a catch basin set under the tank drain slowly remove the cap and drain the material from the tank NOTICE Optional drain valve is available DO NOT use a torch on the drain plug or optional drain valve Any open...

Страница 31: ...31 General Maintenance Section ...

Страница 32: ...s power switch to off c Disconnect battery d Disconnect trailer plug from tow vehicle 5 If access to thermostat or tank blanket is required a Unplug the heating blanket b Use plug lock to secure plug 6 When finished with maintenance a Clean up any spills debris and all tools from the machine b Replace all guards 7 Reconnect the battery cables plug in the heating blanket and return the key to the i...

Страница 33: ...33 General Maintenance Chart ...

Страница 34: ...d for use by Kohler Also DO NOT use gasoline older than 30 days or gas that is mixed with oil Old stale or contaminated fuel will adversely affect your engine Engine Oil The engine requires 1 7 to 1 9 quarts of oil We recommend use of high quality detergent oils including synthetic of API American Petroleum Institute service class SJ or higher are acceptable Select viscosity based on air temperatu...

Страница 35: ...ater at wiring harness or any electrical components General Maintenance of Material Pump If you pump came with mechanical seals AM No maintenance required If your P1 came with a pump with packing AP Examine the packing for leakage Slight leakage with the valve on solvent 1 drip per minute is a necessary and normal condition for packing and allows for expansion and proper seating If leakage is exce...

Страница 36: ...10 lubricating oil drain thoroughly Reinstall the grease and grease relief fittings Then lubricate the bearings per step 1 Blower Oil 1 It is recommended that the blowers oil is to be changed after the initial 100 hours of operation and every 1500 hours after that a For average outdoor temps between 32 F and 90 F use 1 to 1 5 quarts of Roots or similar brand of ISO 220 synthetic bower oil b If the...

Страница 37: ...e right machine front b To loosen the belt slide the plate to the left machine rear 3 Using a gauge confirm the belt is the proper tension sliding the mounting plate as required 4 Retighten the four 4 bolts for the mounting plate corners Retest the belt tension and torque the mounting plate bolts each to 40 ft lbs Generator Belt 1 Loosen the Alternator top bolt and pivot bolt but DO NOT remove the...

Страница 38: ...g Modifying the heated hose controller settings The Hose Temperature Control on your P1 Patcher has been factory set to run the most common types of emulsions at a temperature of 150 F 65 C As you adjust your emulsion tank thermostat for different emulsions you may require a change to the hose temperature controller to better match the emulsion tank temperature To achieve this open the control box...

Страница 39: ... or equipment This can damage the equipment and may cause a electrical fire VFD pump motor controller The VFD will display the letters rdy when the enough voltage is present to run the pump motor When the pump motor is turned on the display will show numbers from 0 60 These numbers indicate how many Hertz are being sent to the motor The higher the number the faster the motor is turning and the mor...

Страница 40: ...enter will save your changes and exit you to the original parameter Pressing enter on bFr and enter on 60 will save the change and return you to bFr 2 Pressing the ESC button 4 returns you the previous parameter Pressing ESC button from Fun brings you back to FULL 3 Rotate the center dial 7 clockwise or counter clockwise to change the parameters or values After pressing enter on rdy scroll through...

Страница 41: ...rom the original factory settings The end column indicates the proper values for the controls and electric pump motor This flow chart does not contain sub menus we do not access or variables that are unedited Please refer to the Schneider Electric Altivar 12 User Manual if you have questions on any variable not listed NOTICE ...

Страница 42: ...42 Control Panel Wiring and Parts Diagram Motor Control Harness Generator Harness ...

Страница 43: ...31042 VFD 1HP 220 VAC INPUT 1 I 131025 CORD GRIP 2 J 131024 ENDCAP DIN RAIL FUSE TERMINAL 1 K 131023 ENDCAP SINGLE DIN TERMINAL 2 L 131022 END CLAMP DIN RAIL 2 ITEM LETTER PART DESCRIPTION QTY M 131021 TERMINAL BLOCK SINGLE DIN MOUNT 6 N 131020 FUSE TERMINAL DIN MOUNT 1 O 131019 POWER RELAY 200V SPST NO 1 P 131018 BREAKER 5 AMP DIN MOUNT 1 Q 131017 BREAKER 10AMP DIN MOUNT 1 R 131016 RAIL DIN 35 MM...

Страница 44: ...44 Control Panel Motor Harness Diagram HEATED HOSE CONNECTION PUMP MOTOR REFER TO PAGE 43 FOR WIRE NUMBER DETAILS HEATED HOSE THERMOSTAT CONNECTION WAND CONTROLS WIRES SEE PAGE 46 ...

Страница 45: ...STROBE LIGHT WIRE SEE PAGE 44 BRAKES WIRE SEE PAGE 44 ENGINE GROUND STARTER GENERATOR REFER TO PAGE 43 FOR WIRE NUMBER DETAILS BATTERY NEGATIVE TO ENGINE GROUND POSITIVE TO STARTER IGNITION WIRING P N 111217 IGNITION SWITCH P N 111068 REGULATOR ...

Страница 46: ...5 163 000 See page 47 for wire information 29 30 31 25 28 24 23 Where routes to Horn Ground Retraction Limit Switch Actuator Black Wire Extension Limit Switch Horn Positive Optional Nozzle Heater Connect the optional nozzle heater wires to the terminals on the Open Closed switch where wires 24 25 are connected ...

Страница 47: ...47 Actuator Wiring Diagram Part Number 305 163 000 Limit Switch Assembly Extension Limit Switch Retraction Limit Switch Wand Control Actuator Horn ...

Страница 48: ...he life of the actuator Rock Gate Inspection 1 With an empty hopper and the guard in place close the gate a Check if the opening to the venturi is full blocked b Check the surface to see if it is wearing through in any spots c Listen for repeated clicking 2 Open the gate a Check for over or under travel b Check the thickness and straightness of the closing edge c Listen for repeated clicking NOTIC...

Страница 49: ...rm pivot b Using a screw driver rotate the center post until you hear feel a click This is the activation point of the switch c Rotate the actuator arm until its wheel is against the vertical plate on the sliding gate d Tighten the set screw on the actuator arm pivot 4 Close the rock gate and repeat steps 3a 3d for that limit switch 5 Open and close the gate a couple of times to determine if more ...

Страница 50: ...uator for extension closes gate b Apply negative 12 VDC to red wire on actuator for retraction opens gate c Clutched to prevent damage if jammed Open Close Switch a Double pole double throw DPDT switch to flip flop actuation direction b On On function only no center off position c Gate either opens 100 or closes 100 Limit Switches a Normally On turn actuator Off to prevent clutching at end of actu...

Страница 51: ...51 Trailer Wiring for Brakes and Lights ORANGE 14 AWG BLUE WHITE 14 AWG ...

Страница 52: ...52 Parts Section ...

Страница 53: ...53 Engine Parts Top Level 305 015 004 ...

Страница 54: ...54 Engine Parts continued Sub Assembly 305 028 004 ...

Страница 55: ...55 Engine Service Parts Engine Parts continued Sub Assembly 305 028 004 ...

Страница 56: ...56 Pump Assembly 305 018 004 ...

Страница 57: ...57 Axle Assembly ...

Страница 58: ...58 Aggregate Plumbing Assembly 1 3 2 4 5 4 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 ...

Страница 59: ...ION 1 8 305 025 000 HEATED EMULSION HOSE 1 9 101261 U BOLT 4 ID GALVANIZED 2 10 405609 AGREGATE TRANSFER PIPE 1 11 120865 EXHAUST CLAMP 1 12 407846 VENTURI ACCESS COVER 1 13 405608 VENTURI WELDMENT 1 14 120861 90 ELBOW 1 15 120963 90 ELBOW LARGE RADIOUS 1 16 172377 HOSE BLOWER PIPE TO VENTURI 24 1 17 172683 ELBOW 12MJ 12FJX 90 1 18 155314 SILENCER 1 19 172681 HOSE BLOWER TO SILENCER 28 1 20 172379...

Страница 60: ...IRD SECTION 1 5 155446 ROLLER YOKE 1 6 172079 SEAL 3 3 8 OD X 2 01 ID 2 7 154433 2 RACE 4 8 111511 ROLLER BEARING 1 75 ID 4 9 423444 WASHER 2 10 100971 CASTLE NUT 1 50 2 11 140576 BEARING CAP 3 875 2 12 172078 BOOM SEAL 1 13 154434 1 RACE 2 14 111512 ROLLER BEARING 1 00 ID 2 15 100347D WASHER 1 16 100972 CASTLE NUT 1 1 17 140577 BEARING CAP 2 1 Boom Arm Assembly ...

Страница 61: ... SWITCH 1 4 155309 GRIP HANDLE 2 5 131012 CORD GRIP 90 ELBOW 2 6 131011 THROTTLE CABLE SOLID CORE 1 7 131010 POTENTIOMETER 10K 1 8 131009 ROCK SWITCH 1 9 130561 HORN SWITCH 1 10 131014 EMULSION SWITCH 1 11 100169 NUT PLASTIC LOCK 38 1 12 100126 WASHER FLAT 38 2 13 100017 HHCS 38 X 1 25 1 14 100017 P1 WAND CONTROLS LABEL 1 15 161861 CLAMPS 2 2 ...

Страница 62: ...62 Rock Gate Actuator Assembly 1 2 3 7 5 6 6 7 Gate Guard 305 159 004 not shown for clarity purposes ...

Страница 63: ...63 Miscellaneous Components and Parts 1 2 3 4 5 7 8 9 10 11 6 14 13 12 15 ...

Страница 64: ... 5 120971 2 PIPE PLUG 1 6 130592 THERMOMETER WITH 5 FACE 1 7 131001 FLAT MOUNT AMBER LED STROBE LIGHT 3 FLAT MOUNT WHITE LED STROBE LIGHT 2 8 305 021 004 TANK OUTLET 1 9 120861 90 DEGREE ELBOW 1 10 120983 PIPE PLUG 1 11 305 119 000 HEATING BLANKET 1 12 131000 LED SIDE MARKER LIGHT ASSEMBLY 2 13 130595 THERMOSTAT W BOX 1 14 130607 THERMOSTAT POWER CORD 1 130608 15A MALE S O PLUG 1 15 CRUSH HAZARD D...

Страница 65: ...65 Miscellaneous Components and Parts 1 5 4 3 2 6 7 8 9 10 11 12 13 ...

Страница 66: ... 180 000 Operators Protection Decal 305 170 000 Dangerous Hazard Decal 305 171 000 Replacement Safety Labels Inspect your labels and replace any damaged Safety labels replaced free of charge Contact your dealer to order replacement labels ...

Страница 67: ...67 Replacement Labels Inspect your labels and replace any damaged Contact your dealer to order replacement labels Wand Control Label 161861 P1 Decal 161860 ...

Страница 68: ...s 305 179 000 Control Panel Decals 305 170 000 Pump Valve Decal 305 178 000 Engine Controls Decal 305 178 000 Replacement Labels Inspect your labels and replace any damaged Contact your dealer to order replacement labels ...

Страница 69: ...69 Tailgate Discharge Box Assembly ...

Страница 70: ...70 Tailgate Mounting Instructions ...

Страница 71: ...71 Tailgate Hose Length and Alignment ...

Страница 72: ...72 Optional Arrow Board Assembly ...

Страница 73: ...73 Trouble Shooting Section ...

Страница 74: ...74 Trouble Shooting the Engine ...

Страница 75: ... be an intermittent problem as a switch wears out 1 With control panel power on use a DC voltage tester and measure the voltage in both the open and closed toggle positions see page 46 a Green and Orange wires b Blue and Orange wires c Red and Black wires 2 If no voltage is present when measuring red and black wires see solution for No Movement 3 Replace switch if Blue Orange or Green Orange wires...

Страница 76: ...ey from the ignition Then manually attempt to rotate the pump in both directions to confirm the that the pump is not seized Pump motor turns slightly then stops Blockage in pump To free the pump 1 Set pump valve to Solution 2 Allow emulsion hose to heat up to the material application temperature 3 Jog the pump motor forward and reverse a Turn emulsion flow rate to max b Turn on the emulsion switch...

Страница 77: ...lity of the pump needs to be tested Please contact customer service for assistance Pump only operates when set to solvent Blocked restricted flow through the inlet hose 1 Confirm emulsion tank is a Full enough for the days work b Warm enough for the material freely flow c Material is not cooked or otherwise solidified 2 Turn the pump valve to solvent and fill emulsion hose with solvent 3 Heat the ...

Страница 78: ...78 ...

Страница 79: ...harge hose and nozzle which is one 1 year c Blower 3 The following items have a three 3 year limited warranty from the orginal purchase date a Kohler 27hp engine 4 This Warranty does not apply to any part of the goods which has been subject to improper or abnormal use negligence alteration accident or damage due to lack of maintenance 5 Cimline will replace for the purchaser any part or parts foun...

Страница 80: ...80 2601 Niagara Lane Plymouth MN 55447 763 557 1982 800 328 3874 Fax 763 557 1971 ...

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