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Welcome to BC Service School 2015

BC501/502

BearCat Spray System Operation & Start-up


March 4-5, 2015
Hydraulic System

Closed Loop Hydrostatic Pump


Hydraulic System

PPU
Closed Loop
Hydrostatic Motor
3.5 to 1 Gear Box
Hydraulic System

PPU
Closed Loop
Hydrostatic Motor
3.5 to 1 Gear Box
Hydrostatic System
Hydrostatic
System (Pump)
Hydrostatic
System (Motor)
Axial Piston Pump
 Hydrostatic pump:
http://www.youtube.com/watch?v=2mh902AP7Yw
 Pressure comp pump:

http://www.youtube.com/watch?v=_CnIP85oY3o
 Hydrostatic pump:
http://www.youtube.com/watch?v=D6FHU54qyRE
https://www.youtube.com/watch?v=qxZFSNITK-
c&index=13&list=PLB96E97514E04836E
 YouTube Library of Hyd. & Pneumatic Animations:
https://www.youtube.com/playlist?list=PLB96E97514E04836E
Hydraulic System 2013 -

Tank
TANK Vent
VENT
5PSI Cap
FILLER
CAP

SIGHT
GLASS

SE10 Suction Filter


BC501 Only

Type 46 Hyd. Fluid


Hydraulic System

Tank Vent
5PSI Cap
AE10 Case
Drain Filter

100 Mesh
Suction Strainer

SE10 Case
Drain Filter

Type 46 Hyd. Fluid


Asphalt Pump

Relief Valve

Hot Water Lines


Checking Pump
Clearance

The Asphalt Pump is a


positive Displacement
Pump Delivering 0.45
Gallons per/rev

NOTE: Each asphalt pump


received at Bearcat must
pass a flow & vacuum test.
CRC Closed Loop Control

CRC
Feedback GPM
Asphalt
PPU F.B.
Out

CRC Command
(23gpm) Hyd. Asphalt
Pump Pump
FPM x Width / 9 x
GSY = GPM
Test
Non-directio
testtest
LIGHT SHOT OR UNEVEN ACROSS THE SPRAY-BAR

Most BearCat Asphalt Distributors are computer controlled. The


computer will not give a light rate unless the calibration numbers
have been altered. Hopefully you have these numbers recorded.
Compare them with the numbers that the computer shows briefly
when it is turned on.

There are two basic reasons for a light shot.


1. The material is not getting to the bar.
2. The material is finding a way back into the tank.
LIGHT SHOT OR UNEVEN ACROSS THE SPRAY-BAR
Cont.

1. Plugged Screens
2. Spread/Circulation valve is leaking.
3. Is the ‘F’ valve closed?
4. Check pump clearance.
5. Plugged or restricted tank valve.
Calculating Spread Rate

Calculate Spread Rate


(FPM x Width / 9 = sq. yds. min.) x GSY = GPM
Distance (ft) x Width / 9 = Total sq. yds. Covered
Total sq. yds. x GSY = Total Gallons Used

Check your rate on large runs, minimum of 1000 gallons.


Example: you check 200 gallon run, can only read the gauge in 20
gallon accuracy, that’s a 10% possible error.
Calculating Area Covered
Calculate Gallons to use (US Standard)
Distance (ft) x Width / 9 = Total sq. yds. covered
4500 x 13 / 9 = 6500 yrds²
4500ft
1371.6

Total yds² x GSY = Total Gallons Used


M

Calculate Liters=to2340
6500 x 0.36 usegallons
(Metric)used
Distance M x Width M = Tot. sq. Meters covered
3.96 x 1372 = 5433 meters²
13ft
3.96M
Total meters² x LSM = Total Liters Used
5433 x 1.63 = 8856 liters used
Calculating Spread Rate
Nozzle #3 or #4 400FPM 0.3 GSY
Calculating Gallons Used

16ft 0.3 GSY

1000feet = 533.3 Gallons


Calculating Spread Rate
Calculating Pump GPM
Calculate Pump GPM (US Standard)
Speed FPM x Width / 9 = Sq. yds. per. min.
220 x 13 / 9 = 318 Yrds² min.
Yrds² Per min x GSY = GPM
318 x 0.36 = 115 GPM
Calculate Pump LPM (Metric)
Speed MPM x Width M = Sq. Meters per. min.
67 x 3.96 = 265 Meter² min.
Meters² per. min. x LSM = LPM
265 x 1.63 = 432
Calculating Pump RPM
Calculate Pump RPM (US Standard)
Req. GPM / Pump Disp. = Pump RPM
115 / 0.110 = 1045
115 / 0.170 = 676
115 / 0.300 = 383
115 / 0.450 = 255
115 / 0.600 = 192
115 / 0.960 = 120
Calculate Pump RPM (Metric)
Req. LPM / Pump Disp. = Pump RPM
435 / 0.416 = 1045
435 / 0.644 = 676
435 / 1.136 = 383
435 / 1.703 = 255
435 / 2.271 = 192
435 / 3.634 = 120
Asphalt Valve Selector & Manual Pump Control
Asphalt Valve Selector / BC502
When Spraying, Eq. Needs to be Open

Equalizer Valve Open

Equalizer Valve Closed


When Spraying, Eq. Needs to be Open

Equalizer Valve Closed


Asphalt Valve Selector Operates the Air
Operated Slide valves
Spray Bar
Circulate
w/Front
Suction
Off-load
Tank by
Gravity or
External
Pump
Clean
Hand
Wand
Option #8 Flush Spray Bar Step-1 / BC501
Option #9 Flush Spray Bar Step-2 / BC501
Option #10 Flush Spray Bar Step-3 / BC501
Option #11 Flush Spray Bar Step-4 / BC501
Cylinder Mount (old style)
Cylinder Mount (old style)
Foot Mount (new style can be retro fitted)
Foot Mount
(new style can be retro fitted)
Foot Mount
(new style can be retro fitted)
Tri-Valve ISO
Tri-Valve Cutaway
Tri-Valve Cutaway
Line-Marker Cutaway
Tri-valve interference on older BC501’s
New Wing Switch
New Wing Switch
New Wing Switch Solid-state Relay
New Wing Switch Solid-state Relay KIT-29508
Rubber Trucks
Rubber Trucks
Hot Oil in the Exhaust
Rubber
Nurse
Trailer
Operating Controls
Operating Controls

Start-up Question Idle Display

Typical Display Spray Bar ON


Operating Controls

Hold Reset On Power-up to get


into Adjustments Use up/dn to Change Value
Information Icons

X
Burner Trouble Shooting
Burner does not fire
1. Is there enough fuel in the truck’s fuel tank? Any valves closed? If
the truck is on level ground, fuel may begin to drip from the tube. This
would indicate that the problem is likely electrical and not a fuel pumping
problem.

2. Does the motor turn?


a. check for voltage at the burner. Minimum12.5V+
b. check for current at the switch and across the switch when it is operated.
c. check the burner relay for proper operation
d. check for ground from the burner safety switch
e. check the wire for the heated gun assembly, 12V+
Burner Trouble Shooting
Burner does not fire
1. If it is turning do you see smoke from the stack?
a. If there is no smoke check the fuel pump coupler located between the
motor and the fuel pump.
b. check the fuel solenoid.
c. check the fuel pump pressure with a gauge dead headed in the nozzle line.
150psi
Do not attempt adjusting the pressure without a gauge
Burner Trouble Shooting
Burner runs but blows white smoke
1. Check for spark across the springs on the bottom of the coil.
2. Check the electrode settings and the condition of the electrodes.
Burner Trouble Shooting
Burner runs but blows heavy black smoke
1. Check the air intake vents for proper setting
2. check for obstruction to air flow from debris
3. check the voltage at the motor, minimum of 12.5V+
4. check the nozzle for proper spray and size
5. check for fuel leaks inside the burner housing
6. check the motor speed with a Photo-tach. Speed is 3,400 RPM

7. Check fuel pressure as described above.


Burner Trouble Shooting
Burner runs but blows heavy black smoke
1. Pull the burner and check for soot build up just ahead of the heat tube
liner check the condition of the heat tube line. Replace it if is collapsing or
showing signs of deterioration. This inspection should be made annually.
Burner Trouble Shooting
CAUTION:
NEVER ATTEMPT TO FIRE THE BURNERS BELOW THE FIRE
LINE MARKED ON THE FLOAT GAUGE!!!

1. If there are dual burners the lower one must be turned on for the upper
to operate.
2. Any time the lid (ignition coil) of the burner is open while the burner is
running, make sure the springs are connected with a jumper to prevent
damage to the ignition coil.
BC502 Control

3/9/2010
Can you upgrade?

 For your older Chip Spreader that has a Skipline, master/slave. We


have a new BC-Chipper Retro-kit.
All upgrades are now Plus1?

 New operator display.


 New wire harness.
 New MC088 Plus1 Control (valvebox)
2012-13 Spreader Truck Control
2012-13 Spreader Truck Control

• Skipline CRC started in 1985 thru 1996.


• There were 3 generations of this unit.
• Skipline Serial System started in 1997 thru mid 2012
• Mid 2012 to current is the Plus1
2012-13 Spreader Truck Control
2012-13 Spreader Truck Control
2012-13 Spreader Truck Control
2012-13 Spreader Truck Control
2012-13 Spreader Truck Control Diagnostics
2012-13 Spreader Truck Control Diagnostics
2012-13 Spreader Truck Control Diagnostics
2012-13 Spreader Truck Control Diagnostics
2014 Spreader Truck Control
Wiring practices
BearCat Mfg. Color Standards:
1. Red = 12vdc (Battery)
2. Red-Wht. = 12v acc. (on w/ignition)
3. Black = Ground (Battery)
4. Yellow = 5v (sensor power)
5. Blue = Sensor ground
6. Blu-Red = CAN (+)
7. Blu-Wht = CAN (-)

Note: with power off you should have 60ohms across the CAN network
(Blu-Red to Blu-Wht). There are two 120ohm resistors across the CAN
Network usually one at each end of the network.
Wiring practices
Sensor leads.
1. Red = Supply (12vdc)
2. White = Signal
3. Black = Ground
4. Green = 2nd signal

At the sensors if equipped with European standard colors.


1. Brown = Supply (12vdc)
2. Black or White = Signal
3. Blue = Ground
Typical Wiring in the Control Box
Typical Wiring in the Control Box
Typical Wiring in the Control Box
Deutsch Connectors
Repair of Wiring
Repair of Wiring
Repair of Wiring
How does CAN network

 At BearCat we use the Sauer-Danfoss


 Plus1 Guide computer system.
 CAN (computer area network)
DIN Connectors
w/LEDs
Up-grade to new control system
Up-grade to new control system
Norgren CAN
Network Valves
Norgren CAN Network Valves
Up-grade to new control system
Up-grade to new control system
Using The Plus1 Service Tool
Using The Plus1 Service Tool
Remote WS403 Hardware
Wiring Schematics

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