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LeeBoy Rosco Maximizer 4B Safety And Operation Manual

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Safety and Operations Manual
Maximizer 4B Distributor
Manual No. 1027819-SOP
REV A
This manual applies to
Serial Number 243966
and above.

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Summary of Contents for LeeBoy Rosco Maximizer 4B

  • Page 1 Safety and Operations Manual Maximizer 4B Distributor Manual No. 1027819-SOP REV A This manual applies to Serial Number 243966 and above.
  • Page 3 The LeeBoy family of companies is committed to total quality management with a strong focus on meeting customer needs. LeeBoy is also proud to be an accredited ANAB manufacturer, which is a certification process comprised of quality standards established by the American National Standards Institute (ANSI) and the American Society for Quality (ASQ).
  • Page 4 2023 LeeBoy 2023 LeeBoy LeeBoy reserves all copyright and other rights in this manual and its content. No part of this manual may be reproduced or used in any way without the written permission of LeeBoy, except as necessary to operate LeeBoy equipment.

  • Page 5: Table Of Contents

    Hydraulic Fittings ......2-7 Determining Proper Torque ..... 2-8 Rosco Maximizer 4B Distributor...
  • Page 6 Reverse Suction Screen ..... . . 4-13 Clean-Out Screen ......4-14 Rosco Maximizer 4B Distributor...
  • Page 7 Preparing to Spray ......4-47 Spray Bar ......4-47 Rosco Maximizer 4B Distributor...
  • Page 8 Outfire Burner Control ......4-76 Beacon Light ......4-77 viii Rosco Maximizer 4B Distributor...
  • Page 9 Automatic Valve System ..... . . 5-21 Hydraulic Valve Manifold ..... . . 5-22 Rosco Maximizer 4B Distributor...
  • Page 10 Spray Down Pump ......5-26 Troubleshooting Chart ......5-27 Rosco Maximizer 4B Distributor...

  • Page 11: Safety

    Safety Decal Locations ..... . . 1-10 Safety Decals Care ......1-12 Rosco Maximizer 4B Distributor...

  • Page 12: Safety

    Safety NOTES Rosco Maximizer 4B Distributor...
  • Page 13 ARE EXTREMELY IMPORTANT. READ AND UNDERSTAND THOROUGHLY. HEED THE you MUST read and understand this manual before operating the Rosco Maximizer 4B Distributor and WARNINGS AND FOLLOW THE INSTRUCTIONS. follow its instructions. Safety is everyone’s business and our top concern.

  • Page 14: Safety Precautions

    • Never block windows, vents or other means of machine parts. ventilation. • Always ensure that all connections are tightened to specifications after repair is made to the exhaust system. Rosco Maximizer 4B Distributor...
  • Page 15 Never modify the machine without the written consent of equipment is available. LeeBoy. Any modification can affect the safe operation of the machine and may cause personal injury or even • Keep a charged fire extinguisher within reach at all death.
  • Page 16 Section 2, Torque Tables) Loose parts can cause fuel spray, obtain prompt medical treatment. improper operation and damage to the machine. Only use replacement parts approved by LeeBoy. Other • Never check for a hydraulic fluid or fuel leak with your replacement parts may affect warranty coverage.

  • Page 17: Machine Precautions

    • Tighten fuel cap securely. Should the fuel cap be lost, replace it ONLY with original manufacturer’s cap. Pressurization of the tank may result from use of non- approved cap. Contact your authorized dealer for replacement. Rosco Maximizer 4B Distributor...

  • Page 18: Battery Precautions

    • When moving the machine, adjust speed and direction of travel for the terrain and ground conditions present. Always consider adjusting travel speed to match ground conditions. Rosco Maximizer 4B Distributor...

  • Page 19: Poor Visibility

    • DO NOT permit children to play on or around the condition. machine. • Make sure the unit is stored on a surface that is firm, level, and free from debris. • Store the machine inside a building or cover securely with a weather-proof tarpaulin. Rosco Maximizer 4B Distributor...

  • Page 20: Safety Decals

    (see following graphics). readable and located on the machine. Contact your authorized dealer immediately to order a replacement kit (Group Part #26422). Safety Decal Locations Safety Decal Locations Part #39167-04 Part #39167-02 Part #39166-01 Part #39166-08 1-10 Rosco Maximizer 4B Distributor...

  • Page 21: Safety Decal Locations

    Safety Safety Decal Locations Safety Decal Locations Part #39166-02 Part #36202 Part #983071 Part #39166-01 Part #39141-05 Part #39166-04 Rosco Maximizer 4B Distributor 1-11...

  • Page 22: Safety Decals Care

    5. Slowly remove remaining backing and carefully smooth into place. • Obtain replacement safety decals or signs from your authorized dealer. 6. Small air pockets can be pierced with a pin and smoothed using a piece of decal backing. 1-12 Rosco Maximizer 4B Distributor...

  • Page 23: Information And Specifications

    Section 2 Section 2 Information and Specifications Information and Specifications Page Information and Specifications ......2-1 Two Year Limited Warranty ......2-2 Contact Information .

  • Page 24: Two Year Limited Warranty

    Exclusion of Other Warranties/Limitation of Liability Exclusion of Other Warranties/Limitation of Liability OTHER THAN THE EXPRESS WARRANTY PROVIDED IN SECTION A. ABOVE, LEEBOY GIVES NO EXPRESS, STATUTORY, OR IMPLIED WARRANTY OR GUARANTEE AND HEREBY DISCLAIMS ALL SUCH WARRANTIES, INCLUDING WITHOUT LIMITATION ANY IMPLIED WARRANTY OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, SUITABILITY, DURABILITY, CONDITION, QUALITY, OR FREEDOM FROM CLAIMS OF ANY PERSON BY WAY OF INTERFERENCE, INFRINGEMENT, OR THE LIKE.

  • Page 25: Contact Information

    Sales Representative: Dealership Name: Dealership Address: Dealership Phone: Record of Ownership Please complete the following information for use if you need to contact LeeBoy for service, parts or literature. Machine Model #: Product Serial #: Date of Purchase: Nameplate Nameplate The nameplate contains the model and serial numbers used to identify the machine and its components for parts or service information.

  • Page 26: Specification Charts

    The specifications provided in this section apply only to Replace distributor original equipment the asphalt distributor components. Consult your truck only with Rosco LeeBoy approved components. model Operator Manual for chassis information. Torque values for both metric and standard inch fasteners are also included.
  • Page 27 (76 liters) hydraulic tank. Enviroflush system allows solvent circulation throughout asphalt pump, valves, distributing lines and spraybar, with clean-out material returned to Clean Out enviroflush tank for easy disposal. 25-gallon (95L) tank mounted onto side of truck. Rosco Maximizer 4B Distributor...

  • Page 28: Torque Specifications

    1520 1139 1817 1363 2464 1848 12 UNF 1241 1683 1261 2012 1509 2728 2046 1-1/2 6 UNC 1950 1462 2644 1982 3162 2371 4287 3215 12 UNF 2194 1645 2975 2230 3557 2668 4823 3617 Rosco Maximizer 4B Distributor...

  • Page 29: Metric Fasteners

    Place one wrench on the connector body and tighten the swivel nut with the second to the torque shown in the following table: NOTE: The torque values shown are based upon 1 1/4 lubricated connections. 1 3/8 Rosco Maximizer 4B Distributor...

  • Page 30: Determining Proper Torque

    TS = Torque setting indicated on wrench Equations Equations • Torque setting if the crowfoot is placed in line with respect to the wrench: TS = TD * L / LA TS = TD * L / (L+E) Rosco Maximizer 4B Distributor...
  • Page 31 2. The flats method is most accurate for the first assembly cycle. For multiple disassembly and assembly cycles, torque values are more reliable. 3. Tightening two (2) flats or more may damage seal faces. Rosco Maximizer 4B Distributor...
  • Page 32 2. Torque values apply to bolts that are plated or coated in light engine oil. 3. Before assembly, lubricate O-Ring with light oil (SAE 10W or 20W). Rosco Maximizer 4B Distributor 2-10...
  • Page 33 2. When using a male tapered pipe thread with a female straight or parallel pipe thread, maximum values are 50% of those listed in the table above. 3. If thread sealant is used, maximum values shown should be decreased by 25%. Rosco Maximizer 4B Distributor 2-11...
  • Page 34 Information and Specifications NOTES Rosco Maximizer 4B Distributor 2-12...
  • Page 35 Rear Fender Controls ......3-10 Burner System Controls ......3-12 Rosco Maximizer 4B Distributor...

  • Page 36: Components

    Components NOTES Rosco Maximizer 4B Distributor...

  • Page 37: Components

    This section describes the major components for the functions from the safety and comfort of the truck cab. It Rosco Maximizer 4B Asphalt Distributor. Become is important to drive the truck at the appropriate speed. familiar with these components and read the entire...

  • Page 38: Circulating System

    The burner’s flame is directed through flue tubes along the bottom of the tank. It is important that the tubes are covered by at least eight (8) inches (20 cm) of material. Rosco Maximizer 4B Distributor...

  • Page 39: Machine Overview- Left Side

    8- to 24-feet (2.4 to 7.3 m), fully circulating with in-cab controls. Diesel Tank Contains diesel fuel for diesel burner system option or for use as solvent. Burners Heats asphalt material in the tank. Rosco Maximizer 4B Distributor...

  • Page 40: Machine Overview- Right Side

    Holds and recycles EnviroFlush solvent for cleaning the spray bar. If equipped, the FLP system is a variable displacement pump providing power FLP (Front Live Power) to the hydraulic motor that turns the asphalt pump. Mounted on front of the [OPTION] truck. (Page 4-7) Rosco Maximizer 4B Distributor...

  • Page 41: Pumps, Valves And Lines

    ALWAYS WEAR GLOVE PROTECTION. Load Line Used to load material into the tank. Transfer/Unload Line Used to transfer/unload material from tank to another container. EnviroFlush Valve Valve opens and closes automatically during the Clean-Out mode. Rosco Maximizer 4B Distributor...

  • Page 42: Main Control Panel

    Pressing the switch DOWN again will turns the hot oil system OFF. NOTE: The burner will only operate when the distributor is traveling less than 5 mph (8 kph) and/or the burner temperature has not exceeded its high-temperature limit to prevent overheating the material. Rosco Maximizer 4B Distributor...
  • Page 43 Switch has been reached in either direction. When the switch is released, it returns to the center position and spray bar movement stops. Rosco Maximizer 4B Distributor...

  • Page 44: Rear Fender Controls

    When the button is released, it Left Spray Bar RETRACT returns to the center position and spray bar movement stops at the nearest 4-inch increment point. Depress and hold the button (}) to retract the left spray bar. 3-10 Rosco Maximizer 4B Distributor...
  • Page 45 NOTE: To transfer these work functions to the rear fender control box, you must select “Rear” on the DP700 Run screen in the cab. (See Section 4 Operations for detailed information.) Rosco Maximizer 4B Distributor 3-11...

  • Page 46: Burner System Controls

    Controls pilot light operation for the upper LPG burner. Turn valve Pilot Light Valve (Upper LPG clockwise to close the valve when lighting the pilot light. Turn coun- Burner) terclockwise to open the valve after the pilot light is lit. 3-12 Rosco Maximizer 4B Distributor...

  • Page 47: Operation

    Flow Distance Calibration Screen ....4-15 Bar Offset ......4-16 Rosco Maximizer 4B Distributor...
  • Page 48 Set Spray Bar Width and Height ....4-50 Distributor Calibration ......4-52 Rosco Maximizer 4B Distributor...
  • Page 49 Beacon Light ......4-77 LED Work Light Package ..... . . 4-77 Rosco Maximizer 4B Distributor...
  • Page 50 Operation NOTES Rosco Maximizer 4B Distributor...

  • Page 51: General Information

    ALWAYS remove locking pins before spraying. If equipped with this option, • Refer to your truck model operator’s manual for check oil level and refill if Oil Heat Tank (OPTION) additional instructions. needed. Use only Citgo Hytherm 46 oil. Rosco Maximizer 4B Distributor...

  • Page 52: Initial Operation

    ENGAGED and other people are clear of the distrib- While there are no restrictions for operating the utor before operating to prevent possible injury. Maximizer 4B for the first time, LeeBoy recommends fol- Always check the following items before operating: lowing these “break-in” procedures: •...

  • Page 53: Spray Bar Wing Locking Pins

    The PTO must be engaged before operating the distributor by turning the control button ON. (Figure 4-3) Figure 4-3. Power Take-Off (PTO) On-Off Button Rosco Maximizer 4B Distributor...

  • Page 54: Distributor Controls

    • The ON/OFF/OIL ONLY switch for the distributor and hot oil (if equipped) heating systems is located in the upper right corner. (Figure 4-5) Master Switch Burner/Hot Oil Switch Manual Pump Speed Dial Figure 4-5. DP700 and Switches Rosco Maximizer 4B Distributor...

  • Page 55: Rear Fender Controls

    Figure 4-7. Rear Fender Controls The Manual Pump Speed dial on the rear fender controls can only be used when operating in the manual mode with control set to rear fender. NOTE: Buttons not labeled are non functioning. Rosco Maximizer 4B Distributor...

  • Page 56: Dp700 Digital Display

    Always heed burner activation, and other settings as feedback for the any warning icon and resolve the problem to prevent operator. damage to system components. 4-10 Rosco Maximizer 4B Distributor...

  • Page 57: Memory Screen

    If the truck is traveling too slow, circles to the left of the center circle illuminate yellow to red to alert the operator to speed up. Rosco Maximizer 4B Distributor 4-11...

  • Page 58: Mode Selection Screen

    (and others that follow) that change accord- ALWAYS circulate the material in the ingly, described in more detail beginning on Page 5-21. tank before use. Figure 4-15. Hand Spray Tank Circulate Screen 4-12 Rosco Maximizer 4B Distributor...

  • Page 59: Load Screen

    (Figure 4-17) Reverse Suction mode before the Clean-Out mode. The distributor can be used as a pumping station between two external storage tanks. Figure 4-19. Reverse Suction Screen Figure 4-17. Transfer Screen Rosco Maximizer 4B Distributor 4-13...

  • Page 60: Clean-Out Screen

    2 - Flow Distance Calibration 3 - Bar Offset 4 - Bar Delay 5 - Machine Set-Up 6 - Temperature Set Point 7 - Bar and Speed Control Calibration 8 - Bar Circulate Flow Rate 4-14 Rosco Maximizer 4B Distributor...

  • Page 61: Totals Screen

    “print” icon. (Page 4-76) The printer will print the machine serial number, total feet, total square yards, total gallons, date and time. Figure 4-23. Flow Distance Calibration Screen Rosco Maximizer 4B Distributor 4-15...

  • Page 62: Bar Offset

    Figure 4-24. Bar Offset Screen • If the spray pattern on the road surface is too far rearward compared to the right side, increase the bar delay time. 4-16 Rosco Maximizer 4B Distributor...

  • Page 63: Calibration Screen

    • Repeat calibration process on the right spray bar. Pump Pump Figure 4-27. Temperature Set Point Calibrate Calibrate (Cab) (Rear) Left Right Spray Bar Spray Bar Figure 4-26. Calibration Screen Rosco Maximizer 4B Distributor 4-17...

  • Page 64: Hydraulic System Check

    3. Release the height adjustment chains from the slots on both sides of the spray bar frame. (Figure 4-30) SLOT DO NOT raise or lower the spraybar while secured by support chains. Figure 4-28. Bar Circulate Screen Figure 4-30. Height Adjustment Chains 4-18 Rosco Maximizer 4B Distributor...

  • Page 65: Hydrostatic System Check

    Then push the switch up and hold until the left spray bar is fully raised. 13. Perform the same procedure in Step 12 using the right spray bar wing switch. Rosco Maximizer 4B Distributor 4-19...

  • Page 66: Automatic Valve System Check

    Selection screen and select Spray Bar Circulate. (Page 4-12) 3. From the rear of the distributor, your assistant can now check each valve directional indicator for proper movement using the figures shown Pages 4-21 and 4-22 as a guide. 4-20 Rosco Maximizer 4B Distributor...
  • Page 67 Table 4-2. 2-Way Valve Indicator Positions DOWN 2-Way Valve Indicator Position MODE OPEN Closed Spray / Bar Circulate Reverse Suction Figure 4-34. Tank Valve Directional Indicator Fitting CLOSED Transfer Clean-Out Load Tank Circulate Hand Spray/ Fitting Unload Rosco Maximizer 4B Distributor 4-21...
  • Page 68 Circulate Transfer Fitting Unload POSITION 3 Indicator Load Tank Circulate Fitting Figure 4-36. 3-Way Valve Directional Indicator Complete material flow and valve status in the various operational modes are included on the fol- lowing pages. 4-22 Rosco Maximizer 4B Distributor...

  • Page 69: Valve Status And Material Flow

    Solvent Valve Valve Load Pump Line Manifold Handspray Circulate Valve Transfer Valve Line EnviroFlush Valve Asphalt Pump Left Spray Bar Right Spray Bar Right Spray Left Spray Figure 4-37. Valve Overview Graphic Bar Wing Bar Wing Rosco Maximizer 4B Distributor 4-23...

  • Page 70: Valve Status Symbols

    Reverse Suction Reverse Forward or Hand Spray/Unload Reverse Transfer Forward Load Forward Forward or Tank Circulate Reverse Spray / Bar Circulate Forward (OFF) Spray / Bar Circulate Forward (Bar CLCT) Spray / Bar Circulate Forward (Spray) 4-24 Rosco Maximizer 4B Distributor...

  • Page 71: Valve Status In Spray / Bar Circulate (Bar Clct) Mode

    Asphalt Pump Material Circulates Throughout Spray Left Spray Bar Right Spray Bar Bar and Wings Right Spray Left Spray Bar Wing Bar Wing Figure 4-39. Valve Status and Material Flow in Spray / Bar Circulate Mode Rosco Maximizer 4B Distributor 4-25...

  • Page 72: Valve Status In Spray / Bar Circulate (Off) Mode

    Load Line Hand Spray Transfer Line Asphalt Pump Left Spray Bar Right Spray Bar Right Spray Left Spray Bar Wing Bar Wing Figure 4-40. Valve Status and Material Flow in Spray Bar Circulate (OFF) Mode 4-26 Rosco Maximizer 4B Distributor...

  • Page 73: Valve Status In Spray / Tank Circulate Mode

    Material Circulates Throughout Spray Left Spray Bar Right Spray Bar Bar and Wings Right Spray Left Spray Bar Wing Bar Wing Figure 4-41. Valve Status and Material Flow in Spray Bar / Tank Circulate Mode Rosco Maximizer 4B Distributor 4-27...

  • Page 74: Valve Status In Tank Circulate Mode

    Solvent Load Valve Line Hand Spray Transfer Line Asphalt Pump Left Spray Bar Right Spray Bar Right Spray Left Spray Bar Wing Bar Wing Figure 4-42. Valve Status and Material Flow in Tank Circulate Mode 4-28 Rosco Maximizer 4B Distributor...

  • Page 75: Valve Status In Hand Spray / Bar Circulate Mode

    3-Way Valve Solvent Valve Load Line Hand Spray Valve Transfer Line Asphalt Pump Right Spray Left Spray Bar Wing Bar Wing Figure 4-43. Valve Status and Material Flow in Hand Spray / Bar Circulate Mode Rosco Maximizer 4B Distributor 4-29...

  • Page 76: Valve Status In Load Mode

    Solvent Valve Load Line Hand Spray Transfer Line Asphalt Pump Left Spray Bar Right Spray Bar Left Spray Right Spray Bar Wing Bar Wing Figure 4-44. Valve Status and Material Flow in the Load Mode 4-30 Rosco Maximizer 4B Distributor...

  • Page 77: Valve Status In Transfer Mode

    Un lled means the valve is open. Tank Valve Transfer Valve 2-Way Vent Valve Valve 3-Way (Behind Solvent Valve) Valve Solvent Valve Load Line Hand Spray Transfer Line Asphalt Pump Figure 4-45. Valve Status and Material Flow in Transfer Mode Rosco Maximizer 4B Distributor 4-31...

  • Page 78: Valve Status In Hand Spray / Unload Mode

    3-Way 2-Way Valve Valve Solvent Valve Load Line Hand Spray Transfer Line Asphalt Pump Right Spray Left Spray Bar Wing Bar Wing Figure 4-46. Valve Status and Material Flow in Hand Spray / Unload Mode 4-32 Rosco Maximizer 4B Distributor...

  • Page 79: Valve Status In Reverse Suction Mode

    Valve Asphalt Pump Material Circulates Throughout Spray Left Spray Bar Right Spray Bar Bar and Wings Right Spray Left Spray Bar Wing Bar Wing Figure 4-47. Valve Status and Material Flow in Reverse Suction Mode Rosco Maximizer 4B Distributor 4-33...

  • Page 80: Valve Status In Clean-Out Mode

    EnviroFlush Valve Asphalt Pump Material Circulates Throughout Spray Left Spray Bar Right Spray Bar Bar and Wings Right Spray Left Spray Bar Wing Bar Wing Figure 4-48. Valve Status and Material Flow in Clean-Out Mode 4-34 Rosco Maximizer 4B Distributor...

  • Page 81: Material Considerations

    Cutback asphalts are typically used above their flash materials can corrode the pump valves and contami- points, which can cause serious burns. nate the tank material. Rosco Maximizer 4B Distributor 4-35...
  • Page 82 For more information about selecting, storing and handling liquid asphalt, see the “MS-19 Basic Asphalt Emulsion Manual” available from the Asphalt Institute at www.asphaltinstitute.org. 4-36 Rosco Maximizer 4B Distributor...

  • Page 83: Handling Liquid Asphalt

    145° + 350° 177° 450° 232° PEN 85-100 280° + 140° + 350° 177° 450° 232° PEN 120-150 270° + 130° + 350° 177° 425° 219° PEN 200-300 270° + 130° + 335° 168° 350° 177° Rosco Maximizer 4B Distributor 4-37...
  • Page 84 160° 71° 150° 66° SC-250 165° + 75° + 195° 91° 175° 79° SC-800 200° + 95° + 210° 99° 200° 93° SC-3000 230° + 110° + 210° 99° 225° 107° (Courtesy the Asphalt Institute) 4-38 Rosco Maximizer 4B Distributor...

  • Page 85: Loading The Tank

    Empty Tank Empty Tank OK to Load Crude Petroleum or Empty Tank Empty Tank Empty Tank Empty Tank Residual Duel Oils Products Not Listed Empty Tank Empty Tank Empty Tank Empty Tank (Courtesy the Asphalt Institute) Rosco Maximizer 4B Distributor 4-39...

  • Page 86: Top Tank Loading

    Mode procedure on Page 4-68) Fumes from hot asphalt material can cause serious burns. ALWAYS wear protective gear. Ensure the coupling from the asphalt material hose and the distributor load line coupling fits properly BEFORE filling the asphalt tank. 4-40 Rosco Maximizer 4B Distributor...
  • Page 87 Figure 4-54. Load Screen 4. Navigate to the Mode Selection screen and select LOAD. (Figure 4-54) 5. Return to the Run screen by pressing the “X” button on the lower left of the DP700 controller. Rosco Maximizer 4B Distributor 4-41...
  • Page 88 (or lower if DO NOT continue this procedure. Contact your needed to comply with federal and state authorized Rosco LeeBoy dealer immediately “Bridge Law” weight regulations). for assistance. 14. When asphalt material level is reached, turn the...

  • Page 89: Heating The Material

    NOT drive distributor while heating asphalt material. death as fuel/fumes can ignite. Upper Burner (Flue) Lower Burner (Flue) Figure 4-59. Burner Flues Inside Asphalt Tank Rosco Maximizer 4B Distributor 4-43...
  • Page 90 LOWER BURNER (1 FLUE) UPPER BURNER (2 FLUES) Gallons Liters Gallons Liters Gallons Liters 1900 7382 2839 1150 4353 3000 11,356 1000 3785 1600 6057 3500 13,249 1000 3785 1600 6057 4000 15,142 1150 4353 1800 6814 4-44 Rosco Maximizer 4B Distributor...

  • Page 91: Diesel Burners

    Fire or an explosion can occur and result in serious injury. If equipped with the optional LPG Burner Figure 4-61. Burner Switch system, refer to Pages 4-70 to 4-71. Rosco Maximizer 4B Distributor 4-45...

  • Page 92: Tank Circulate

    2. Allow the blower(s) to operate at least one (1) minute to cool the burner flues and purge any fumes or unburned fuel from the system. 3. Turn off the blower(s). 4. Wait at least five minutes before relighting. 4-46 Rosco Maximizer 4B Distributor...

  • Page 93: Preparing To Spray

    Figure 4-63 on the following page shows the switches with corresponding spray width incre- ments, along with switches to extend or retract each spray bar, and raise/lower the entire spray bar. Rosco Maximizer 4B Distributor 4-47...
  • Page 94 Master Switch 4-Foot 4-Foot Raise/Lower Spray Bar Side Shift Spray Bar Spray Extend/Retract Spray Extend/Retract Activation** Activation ** Automatically activated in 4-inch increments. Figure 4-63. Spray Bar Control Switches / Corresponding Spray Nozzles (Left Spray Bar) 4-48 Rosco Maximizer 4B Distributor...

  • Page 95: Spray Nozzle Selection

    Use ONLY the nozzle alignment wrench included with your distributor as it is designed for the correct 20-degree angle alignment. If wrench is lost, contact your authorized dealer for a replacement. Rosco Maximizer 4B Distributor 4-49...

  • Page 96: Set Spray Bar Width And Height

    4-inch point) or the bar has reached its limit of travel. • Raise or lower the spray bar wings using the raise/ lower switch on the main control panel (and rear control buttons). Ensure transport pins have been removed before lowering wings. 4-50 Rosco Maximizer 4B Distributor...
  • Page 97 DO NOT forget to remove the support chains before using the spray bar Figure 4-67. Securing the Spray Bar Height raise/lower switch to adjust the height. Rosco Maximizer 4B Distributor 4-51...

  • Page 98: Distributor Calibration

    Continue pressing the left arrow button to decrease application rate level. • The application rate is shown in the lower right corner on the digital display window. Figure 4-68. Radar Horn Application Rate Decrease Increase Figure 4-69. Run Screen 4-52 Rosco Maximizer 4B Distributor...
  • Page 99 Steps 2 - 4. 15. Repeat Steps 7 and 8 to “zero out” the Totals, then press “X” to return to the Run screen. Figure 4-71. Totals Screen Rosco Maximizer 4B Distributor 4-53...
  • Page 100 DO NOT change the target volume previously set. Ensure the measuring stick is clean 25. Press “X” to return to the Run Screen. Calibration before inserting into the tank. is now complete. 4-54 Rosco Maximizer 4B Distributor...
  • Page 101 2. Read the cubic yards required opposite road length 2. Read the truck speed opposite your chosen pump on the slide rule. GPMs. NOTE: DO NOT exceed a 400 GPM pump rate. Figure 4-76. Asphalt Application Slide Rule (US Standard Side) Rosco Maximizer 4B Distributor 4-55...

  • Page 102: Spraying The Material

    LED working light package. Use reflective tape on all sides of the unit and erect impact barriers to protect workers from traffic hazards. Be sure all personnel also wear reflective vests. 4-56 Rosco Maximizer 4B Distributor...

  • Page 103: Spray Bar Circulate

    This also cold. Truck Tires Pick Up prevents material from setting up in the spray bar, Asphalt Material Spray temperature too low. asphalt pump and plumbing. Dusty substrate pavement. Rosco Maximizer 4B Distributor 4-57...

  • Page 104: Basic Material Spraying

    4. Heat and circulate material in the asphalt tank. Switch (Pages 4-45 to 4-46) 5. On the DP700 digital controller Run Screen, select Figure 4-78. Spray Bar Master Switch AUTO operational mode and the pump control pri- ority to FRONT. (Page 4-10) 4-58 Rosco Maximizer 4B Distributor...

  • Page 105: Hand Spray

    Be extra careful spraying components hot. Refer to Reverse Suction hot asphalt in this mode and maintain a very firm grip for cleaning the system when finished. on the spray wand to prevent serious burns. Rosco Maximizer 4B Distributor 4-59...
  • Page 106 It may be necessary Left to Open) to draw some clean-out material into the hand spray hose to remove oil in the hose and spray nozzle. Figure 4-81. Hand Spray Valve (Closed Position) 4-60 Rosco Maximizer 4B Distributor...

  • Page 107: Cleaning The System

    12. Turn the Manual Pump Speed dial back to “0.” procedure,material removed from the spray bar by suction will gravity-feed back into the spray bar and material build-up will occur. Rosco Maximizer 4B Distributor 4-61...

  • Page 108: Clean-Out Mode

    DO NOT operate the burner system while cleaning! Figure 4-84. Clean-Out Screen 4-62 Rosco Maximizer 4B Distributor...

  • Page 109: Enviroflush Clean-Out

    The asphalt pump stops. 4. If the hand spray wand was used, follow the steps described in the previous section for cleaning it. Enviro ush Release Agent Clean-Out Clean-Out Figure 4-85. Rear Fender Clean-Out Controls Rosco Maximizer 4B Distributor 4-63...

  • Page 110: Unload Or Transfer Asphalt Material

    FORWARD direc- tion and the vent valve is OPEN. Hot asphalt in the load line is under pressure and could spray the oper- ator and/or bystanders, resulting in severe burns. Figure 4-88. Vent Valve 4-64 Rosco Maximizer 4B Distributor...
  • Page 111 9. After checking that the loading hose is secure on both sides, open the valve on the external storage tank. 10. Open the Transfer Valve on the distributor by turning it counterclockwise. NOTE: The transfer valve must be manually opened and closed. (Figure 4-87) Rosco Maximizer 4B Distributor 4-65...

  • Page 112: Transfer Mode

    FORWARD direction and the vent valve is OPEN. Hot asphalt in the load line is under pressure and could spray the operator and/or bystanders, resulting in severe burns. 4-66 Rosco Maximizer 4B Distributor...

  • Page 113: Transport

    Operation TRANSPORT Loading Loading To prevent damage to the machine LeeBoy recommends transporting the distributor on a undercarriage, frame and components, reduce flat-bed trailer rather than towing. speed before wheels come into contact with loading Remember the following guidelines: ramps or any abrupt change in the surface. The drive system or other components can be damaged by •...

  • Page 114: Unloading

    11. Cover the exhaust pipe with heavy-gauge plastic. a customer-supplied truck chassis, depending upon Don’t forget to remove before starting the engine! specifications. Other customized options may also be possible. See your Rosco/LeeBoy authorized dealer or sales representative to discuss your customized needs. Unloading Unloading Place chocks at front and back of wheels to prevent machine movement.
  • Page 115 The oil heat tank provides a place for the heat transfer oil to expand into when heated, and to draw oil from to keep the system full when cooled. Keep an eye on the level in your expansion tank daily--and only fill about Rosco Maximizer 4B Distributor 4-69...

  • Page 116: Lpg Burners

    ON/OFF 14. Once the burner lights, open the pilot valve com- Switch pletely by turning counterclockwise. (Figure 4-100) 15. Open the lower shut-off valve completely by turning counterclockwise. Figure 4-96. Left Rear Fender Burner Switch 4-70 Rosco Maximizer 4B Distributor...
  • Page 117 3. Turn OFF the burner switch in the rear left fender control box. (Figure 4-96) DO NOT relight the burner for at least five (5) minutes to ensure any fumes in the flue have dissipated. Rosco Maximizer 4B Distributor 4-71...

  • Page 118: Overnight Electric Heater

    OFF. When using solvents and release agents, consider the environment and DO NOT allow cleaning solvent to run onto the ground. Only spray down the machine in a designated area where solvent can be contained. 4-72 Rosco Maximizer 4B Distributor...

  • Page 119: E-Max

    3. Turn ON the overnight heat box by turning the switch clockwise. (Figure 4-103) Figure 4-100. Generator Cable in STORED position. Figure 4-103. Overnight Heat Box ON/OFF Switch Figure 4-101. Generator Cable in LOAD position. Rosco Maximizer 4B Distributor 4-73...

  • Page 120: Tank Hand Railing

    6. Use the UP and DOWN arrows on the digital display to set the temperature and press enter. Set the high temperature limit to at least 50°F HIGHER than the desired spray temperature on the limit control dial. 4-74 Rosco Maximizer 4B Distributor...

  • Page 121: Remote Printer

    LCD color monitor integrated into a rearview mirror that integrates four ultrasonic sensors with the camera image. The system provides both audible and visual obstacle warning. The high-resolution monitor and flush-mount camera system delivers excellent picture quality. Figure 4-106. Set-Up Screen Rosco Maximizer 4B Distributor 4-75...

  • Page 122: Magnetic Cup Holder

    Figure 4-110. Outfire Control your machine (and the rest of your fleet). (Figure 4-110) See your authorized dealer for details. Ask for Part Number 1020521. Figure 4-109. Magnetic Cup Holder 4-76 Rosco Maximizer 4B Distributor...

  • Page 123: Beacon Light

    Work lights at the front and rear of the paver provide illumination when paving at night or other dark condi- tions. The work light package includes four LED lights for superior illumination. (Figure 4-112) Figure 4-112. LED Work Light Package Rosco Maximizer 4B Distributor 4-77...
  • Page 124 Operation NOTES 4-78 Rosco Maximizer 4B Distributor...

  • Page 125: Maintenance

    Discharge Screen ......5-13 Load Line Screen ......5-14 Rosco Maximizer 4B Distributor...
  • Page 126 Spray Down Pump ......5-26 Troubleshooting Chart ......5-27 Rosco Maximizer 4B Distributor...

  • Page 127: Maintenance

    Refill if needed. Inspect nozzles and hardware. Adjust nozzle alignment and tighten hardware if needed. Replace spray bar extension, pivot point Spray Bar gaskets and washers. Clean hydraulic cylinders. Change hydraulic oil. Hydraulic System Change hydraulic filter. Rosco Maximizer 4B Distributor...

  • Page 128: Routine Maintenance

    4. Inspect nozzles and hardware. Adjust nozzle damage or possible injury. alignment and tighten hardware if needed. Always wear heat-resistant gloves 5. Perform previous routine maintenance and any when handing hot components. other preventive maintenance described in your truck manuals. Rosco Maximizer 4B Distributor...

  • Page 129: Every 100 Hours Or Monthly Routine Maintenance

    3. Flush fuel and solvent. (See your authorized dealer environmental regulations. for service.) 4. Replace spray bar extension, pivot point gaskets and washers. (See your authorized dealer for service.) 5. Perform previous routine maintenance and any other preventive maintenance described in your truck manuals. Rosco Maximizer 4B Distributor...

  • Page 130: Lubrication Points

    Chain Coupling Multi-Purpose Grease Monthly Oil Heat OPTION Multi-Purpose Grease Every 6 Months * Lubricate these grease points at least twice daily (every three hours) and at the end of every work day to prevent seizing. Rosco Maximizer 4B Distributor...

  • Page 131: Asphalt Tank Components

    6. Fit the new gasket by lining up with the fastener holes. Reinstall the gasket fasteners. 8. To provide a good seal, retighten the four (4) crossbar adjustment bolts for uniform pressure on the gasket. Rosco Maximizer 4B Distributor...

  • Page 132: Contents Gauge Packing Gland

    Turn clockwise if repacking the front contents gauge. • Turn counterclockwise if repacking the rear contents gauge. When the shaft is released, the float ball should move freely up and down. 8. Reinstall the pointer into its previous position. Rosco Maximizer 4B Distributor...

  • Page 133: Asphalt Pump System

    Clean-Out mode. See your authorized dealer to purchase packing material. Discharge Suction Suction Discharge Drive Drive Shaft Shaft (Clockwise) FORWARD REVERSE (Counterclockwise) Figure 5-7. Forward and Reverse Pump Rotation Rosco Maximizer 4B Distributor...

  • Page 134: Asphalt Pump Packing Gland

    3. Use a small screwdriver to remove the old packing material from the cavity. 4. Repack cavity with new packing material. 5. Reinstall the packing nuts and turn until it contacts the packing material. 6. Reinstall the chain coupler cover. 5-10 Rosco Maximizer 4B Distributor...

  • Page 135: Hydraulic Pump/Motor Installation Start-Up Procedure

    The port plugs should only be removed from the motor when the system connections are ready to be made. Rosco Maximizer 4B Distributor 5-11...

  • Page 136: Relief Valve

    CRCLT on the DP700 controller. to the strainer box and proceed to Step 7. (Figure 3. Operate the pump FORWARD at 300 GPM (1135 5-12) LPM) for five minutes. 4. Check the pressure. It should read 70 PSI. 5-12 Rosco Maximizer 4B Distributor...

  • Page 137: Discharge Screen

    3. Align and install new cover gasket, tighten the contact your authorized dealer for proper mounting bolts, and torque to 28 ft lbs. adjustment of the relief valve. 6. Affix new gaskets and reattach relief valve to the pump housing. Rosco Maximizer 4B Distributor 5-13...

  • Page 138: Load Line Screen

    Load Line Screen Load Line Screen A conical screen at the load line cap also prevents The Rosco Maximizer 4B Asphalt Distributor is debris and large contaminants from entering the equipped with diesel burners or the optional LPG distributor system. (Figure 5-15) burners.

  • Page 139: Lpg Burners (Option)

    • Tighten fittings that are leaking and replace any damaged parts. • Use a wrench to tighten the burner mounting hardware before lighting the burners. • Contact your authorized dealer to check (or replace if needed) the flue liner and tubes annually. Rosco Maximizer 4B Distributor 5-15...

  • Page 140: Spray Bar System

    Leaks can result in hot asphalt spilling onto the when the hot asphalt flows through the system machine or the operator, causing serious injury and/ in the SPRAY/BAR CIRCULATE mode. or damage to components. 5-16 Rosco Maximizer 4B Distributor...

  • Page 141: Hydraulic System

    • Unusual noise in the hydraulic pump or motor. indicator of the need for service. (See your authorized If you suspect a suction leak, verify that all hydraulic Rosco LeeBoy dealer if these components need tank connectors and fittings are properly tightened. If servicing.) the problem persists, replace the defective hose(s) or fitting(s).

  • Page 142: Hydraulic Oil

    DO NOT remove the hydraulic tank fill cap from the reservoir when it is hot as this can cause serious injury. Allow hydraulic oil to cool down to a warm temperature. 5-18 Rosco Maximizer 4B Distributor...

  • Page 143: Change Hydraulic Oil And Filter

    2. Allow the hydraulic oil to cool until it is at a warm temperature. 3. Slowly loosen and remove the hydraulic tank fill strainer cap. (Figure 5-19) 4. Put a clean, lint-free cloth over the tank fill tube opening and secure in place with tape. Rosco Maximizer 4B Distributor 5-19...

  • Page 144: Change The Fill Cap Filter And Clean Hydraulic Tank Strainer

    NOTE: If the strainer is worn or damaged, it should be 14. Reinstall the fill strainer cap and tighten securely. replaced. (Figure 5-19 on Page 5-18) 15. Start the engine and operate hydraulic controls several times. 16. Check the hydraulic system for any leaks. 5-20 Rosco Maximizer 4B Distributor...

  • Page 145: Automatic Valve System

    Clean-Out Valves 3-Way Valve Bottom Solvent Right Outside Exhaust Right Inside 4-Foot Control Supply Automatic Valves Spray Bar Valves Left Inside 4-Foot Control Supply Left Outside Exhaust Figure 5-24. Electric Solenoid Circuit and Hydraulic Valve Manifold Rosco Maximizer 4B Distributor 5-21...

  • Page 146: Hydraulic Valve Manifold

    You should hear the valve or air actuator respond. system provides a cleaner, leak-free solution for 4. Reset to normal and valve should return to its machine component control. original position. 5. Repeat Steps 3 and 4 on each solenoid 5-22 Rosco Maximizer 4B Distributor...

  • Page 147: Mounting Hardware

    (The spring coils should have a visible gap between them.) 4. If mounting bolts can no longer be adjusted for the Figure 5-28. Spring-Loaded Bolts proper spring compression, contact your authorized dealer to replace the wooden planks. Rosco Maximizer 4B Distributor 5-23...

  • Page 148: Weldment

    Electrical current can ignite fire or cause an explosion, therefore it is critical to turn off power to the machine. It is also important to grind off the paint to ensure proper ground on the area being welded. 5-24 Rosco Maximizer 4B Distributor...

  • Page 149: Winterizing For Storage

    If you do not run the engine for six months or months. If storing any longer, drain the DEF fluid into longer, apply engine oil to the valve guide and stem an approved container. seal before starting. Rosco Maximizer 4B Distributor 5-25...

  • Page 150: Troubleshooting

    • Retighten the bleeder valve. slightly to expel air and facilitate priming. As soon as the pump is operating, close the bleeder valve. 5-26 Rosco Maximizer 4B Distributor...

  • Page 151: Troubleshooting Chart

    The troubleshooting charts below identify the most common symptoms and remedies. This information applies ONLY to the distributor components (some truck functions may be causing the problem). Refer to your truck Operator’s Manual as appropriate. If the problem persists, contact your authorized Rosco LeeBoy dealer. Table 5-2. Troubleshooting Chart...
  • Page 152 Asphalt pump leaks material at Lubricate pump rotor shaft. shaft. rotor shaft gland. Replace pump shaft. Check for causes of shaft Pump shaft grooved, bent or worn. damage: Misalignment, loose mounts, packing gland too tight. 5-28 Rosco Maximizer 4B Distributor...
  • Page 153 Asphalt pump isn’t turning in a “forward” speed dial is rotated clockwise. Contact your rotation. authorized Rosco Leeboy dealer for assistance if needed. Check that the corresponding air solenoids are Circulating system valves aren’t set activated and that the valves are in the correct correctly for the operating mode.
  • Page 154 Burners flutter and/or blow back. Low fuel pressure. Fuel pressure should read at least 100 PSI. Replace nozzle. Contact your Rosco LeeBoy Faulty fuel nozzle. dealer for the factory-recommended nozzle. Air in the fuel system. Check/tighten fuel connections and filters.
  • Page 155 A section of the spray bar is needed. not functioning. Air hose is plugged, collapsed, damaged Clean or replace hose(s). or broken. Asphalt feed hoses to that section are Clean or replace hose(s). plugged, collapsed, damaged or broken. Rosco Maximizer 4B Distributor 5-31...
  • Page 156 Check air actuators. Defective solenoid valve(s). Replace solenoid valve(s). No air pressure on lift side (bottom) of Check for kinked or blocked air hoses. Check Tank valves are stuck closed. spray valve air cylinder. solenoid valve(s) operation. 5-32 Rosco Maximizer 4B Distributor...
  • Page 157 Maintenance SYMPTOM CAUSE REMEDY GENERAL ITEMS Contact your authorized Rosco LeeBoy dealer for No GPM rate showing on Sensor not properly adjusted. assistance. DP700 digital display, or readout is inconsistent. Faulty wiring or sensor. Repair or replace if needed. Check fuses, circuit breakers and wiring. Repair, No power to GPS or radar horn.
  • Page 158 Maintenance NOTES 5-34 Rosco Maximizer 4B Distributor...
  • Page 160 ST Engineering LeeBoy, Inc., dba LeeBoy 500 Lincoln County Parkway Ext. Lincolnton, North Carolina 28092 Phone: (704) 966-3300 - Fax Sales: (704) 483-5802 www.LeeBoy.com Printed in the U.S.A.

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