KETTLE -...

ROOFING EQUIPMENT CO., INC. P.O. Box 720 Helotes, Tx 78023-0720(210) 695-3567 Fax (210) 695-3554 e-mail: [email protected]: www.reevesequipment.com1-800-383-3063

KETTLEOPERATING INSTRUCTIONS with D.O.T. Information

09/10

IMPORTANT SAFETY & OPERATING INSTRUCTIONS

READ THE INSTRUCTIONSYou have purchased a quality piece of roofing equipment. Years of engineering experience have gone

into its manufacturing. This equipment must be used by knowledgeable professionals in the roofingindustry. All persons operating this unit must have full knowledge of proper operating and equipmentsafety procedures. If you are not familiar with the hazards associated with the application and removal ofbuilt up roofing, do not attempt to use this product. If you are a knowledgeable roofing professional,continue by reading all these Safety & Operation Instructions. Reeves has developed these OperatingInstructions to ensure you will enjoy years of trouble-free operation. It is full of valuable information on howto operate and maintain your piece of equipment properly and safely. After reading all of this informationcompletely and understanding it entirely, continue with the operation. If you have any doubts aboutunderstanding any portion, STOP, Do Not Continue. Call Reeves for further information. Safety should beyour number one consideration! Knowing the rules means "SAFETY IS NO ACCIDENT, THINK ABOUTIT”.

ATENCIONLas instrucciones y etiquetas proporcionadas con esta maquina, escritas en ingles, se deben leer y

entender completamente antes de usar por primera vez. Si no lee entende ingles, debe pedir que alguienle lee en espanol para que puede entender completamente los requerimientos de sequridad y operacionantes de que se utilice esta maquina.

WARRANTYReeves Roofing Equipment Co., Inc. “Reeves” warrants that all goods will be free from defects in

material and workmanship for a period of 90 days. Should any failure appear within 90 days from thedelivery date to the user, “Reeves”, shall upon notification that the goods have been stored, installed,maintained and operated in accordance with the manufacturer’s recommendations, correct such defect bysuitable repair or replacement. The warranties stated above are the sole warranties applicable to “Reeves”products.

“Reeves” shall not in any event be liable for any consequential damages, secondary charges,expenses for installing or disconnecting, or loss of time resulting from any alleged defect in the product.

Each “Reeves” product is designed for a specific use and purpose. Use this machine only as intendedand described in these safety and operating instructions, otherwise the warranty is void. Unauthorizedchanges or modifications will void the manufacturer's warranty. Changes or modification may result in thecreation of a new danger and/or the elimination of a feature which had some safety value.

“Reeves” may make changes and improvements at any time to its products, and “Reeves” shall beunder no obligation to incorporate the same in or substitute the same for any products previously sold.

This is the only warranty on any “REEVES” equipment written in these instructions. No other writing ordescription in this instruction shall be construed as a warranty.

ENGINESRead the instructions sent with each engine. Fill out the Warranty Sheet and place a copy in your file

for future reference. If you have questions or problems with your engine, contact your nearest AuthorizedService Center to help you. If the engine is sent to Reeves Roofing Equipment Co., Inc., whether underwarranty or not, we will take it to our local Authorized Service Center. You will be charged for the freight toand from Helotes, Texas, and for repairs (if not under warranty), plus a $25.00 charge for handling.

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REEVES ROOFING EQUIPMENT CO., INC.P.O. Box 720, Helotes, Texas 78023-0720

(210) 695-3567 Fax (210) 695-3554(800) 383-3063

Table of Contents

D.O.T. Information Page 4Safety Precautions Page 5Towing Pages 5-6Job Set-Up and Preparing Kettle Page 6Personal Protective Equipment Page 6Setting Up Hot Pipe Page 7Preparing Pump System Pages 8-9Preparing for LP Burner Operation Page 9Starting Empty Kettle using LP Gas Pages 9-10For kettles with Cold Bitumen Above the Flues Page 10Pumping “Hot” to the Roof Page 11Withdrawal of Hot Bitumen from Draincock Page 12Shutting Down Kettle for the Day Page 12Maintaining Hot Pipe Page 12Daily Maintenance of Roofing Kettles Page 12Periodical Checks Page 13How to Extinguish a Kettle Fire Page 13Prevent Hot Stuff Burns Page 13Hot Stuff Burns and Fumes Pages 13-14LP-Gas Cylinder Information Page 14Cleaning Kettles Page 14Trouble Shooting LP-Gas Burners and Pump Pages 15-17Parts list for Kettle Drawing Pages 18-19Drawing of Kettle Page 20Schematic Drawing of Single Burner LP Unit Page 21Schematic Drawing of Double Burner LP Unit Page 22Labels Page 23

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D.O.T. Compliance Information

Thank you for purchasing REEVES equipment. The D.O.T. compliance information and D.O.T. marking kitare provided with each kettle. Sample shipping papers are reproducible for your use to aid in complyingwith D.O.T. requirements. If you have any questions or suggestions, please call REEVES at 1-800-383-3063.

After October 1, 1993These instructions are for kettles greater than 118 gallons that will transport heated asphalt or coal tar(above 212°F). Per D.O.T., regulated kettles must be marked on two opposing sides, with all openingslocked to resist opening in an overturn. Reeves provides locking eyes for locks. REEVES’ DOT kitincludes 2 - white “square on point” placard like decals with the word “HOT” in black Gothic lettering andthe “UN” number “3257" displayed to denote elevated temperature material (ETM). Regulated kettles mustalso be accompanied with shipping papers that include the following information on this reproduciblesample below. Please be sure to have this form filled out correctly and included with other importantdocuments of the vehicle pulling the kettle.

Again, this is only required by D.O.T. if the kettle is greater than 118 gallons and transporting heatedasphalt or coal tar that is above 212°F. Reeves suggests not moving any kettle until the material hascooled and solidified.

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Cross the Safety Chains Fig. 1

Fig. 2

Fig. 3

WARNING: The kettle man must be present at all times to operate the kettle safely.

SAFETY PRECAUTIONS

1. Never operate a kettle that is damaged in any way. Do not modify the kettle. Look for bent framemembers, cracks, broken welds and other damaged components daily. A qualified mechanic shouldrepair or replace damaged components. As repairs are needed, use only original Reeves parts.

2. The operator and anyone near the kettle must wear proper protective equipment (see page 6).3. Do not take chances or shortcuts.4. Keep head and hands away from the exhaust stack and burner well while the kettle is in operation.5. Do not drink alcoholic beverages or use drugs that could impair judgement and ability. No fighting or

horse-play on the job.6. Keep the kettle in good condition by maintaining regularly.7. See that all warning decals are in place and legible. Write, call or email Reeves Roofing Equipment Co.

for replacement decals and instructions.

TOWING1. Make certain the towing vehicle and hitch are rated to tow the total weight of your kettle. Add 8 lbs. for

every gallon of bitumen in the kettle. The following bumper capacity should be considered when towing:140 Gallon to 380 Gallon Kettle 5,000 lb.450 Gallon to 750 Gallon Kettle 10,000 lb.1000 Gallon Kettle 20,000 lb.

2. Make sure your hitch is in safe operating condition. Repair or replace asnecessary.

3. Reeves provides a 1-1/32" hole in the tow tongue plate. You must use a 1"Grade 5 tow bolt to connect the kettle to the towing vehicle. The bolt shouldhave a safety pin hole with a safety pin to keep the nut from vibrating offduring transit.

4. The kettle must be level when towing to maintain the proper tongue weight.5. Make certain the hitch is secure and the safety chains are attached.

These double chains must be crossed under the tongue. This will preventthe tongue from dropping to the ground in the event the hitch, coupler orball fails (fig. 1). Attach safety chains to the frame of the towing vehicle.Loop the chain around the member and hook it back into itself. Chainsshould have only enough slack to allow the towed vehicle to turn easily,yet tight enough to prevent the tongue from dragging in the event thehitch becomes disconnected (fig. 2).

6. Check tire pressure for the load and adjust as necessary. Check lug nutson wheels for tightness.

7. Test the taillights to make sure they work. Reeves has provided theproper length of wire for your kettle and five wire connectors. This is forthe connection of lights to the main line wire. We provide wire clips inthe frame and wire conduit under the kettle for wire protection. See fig.3 for the proper color code to follow.

8. Check your local area for brake requirements. Also be aware of minimum stopping distance regulations where the kettle is being towed. Allow plenty of braking distance.

9. Remember the length of your vehicle when towing.10. Always raise the jacks out of the way for clearance before towing.11. All kettle openings must be closed and locked according to D.O.T.

transportation.(Continued next page)

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TOWING (Continued)

12. Burners must be off and bitumen cooled down and solidified before towing. 13. Bitumen level must be no higher than just above the flues. 14. The kettle is classified as a trailer and should be towed at speeds set by local laws accordingly.

IMPORTANT: Read and follow OSHA No. 1926.501 and 1926.502 Fall Protection Standard for theproper type of fall protection before working or allowing work to be done on the roof. Guard all roof openings.

JOB SET-UP and PREPARING KETTLE

1. Select an area where the ground is firm and level and the kettle will be stable.2. Set up the equipment where fumes and dust will not be drawn into fresh air intakes and windows of

nearby buildings.3. Locate away from flammable materials, fuel, open flames and electrical wires. 4. Locate the kettle as close as practical (for proper setup of the roof tubing), but be aware of the possible

hazards from locating too close, such as splashing of bitumen or the spread of fire. The kettle lid shouldopen away from the building and should fit tightly. Be careful to protect the building and property.

5. Locate the kettle close to the work area on the roof to reduce transport distance and reduce cooling ofbitumen before application.

6. Place felt paper or plywood underneath and around the kettle to protect the ground from spillage. 7. Keep unauthorized people away from the construction area by setting up a warning line system around

the setup area on the ground.8. Lower front jack, chock wheels and lower rear drop leg (single axle kettles) before disconnecting hitch.

Once front jack and rear drop leg jacks are lowered, push the pin through the leg and insert the hitch pin clip. For 140 and 200 gallon kettles, the front jack will lock into place once pushed to proper location.

9. Make sure you have the right fuel (LP-Gas or Kerosene) for the kettle you are operating. If usingkerosene, please read the “Supplemental Instructions for Operating with Kerosene” before continuing.

10. Place the LP-Gas cylinders away from the kettle or any source of flame. Check local laws for the exactdistance. If LP bottle racks are installed, remove the LP-Gas cylinders before operating (they are fortransporting cylinders only). All LP-Gas cylinders must be upright and secured so they cannot tip over.

11. Inspect kettle thoroughly for worn or broken parts, cracks and loose parts. Make repairs before using withoriginal Reeves parts.

12. Place bitumen to be used for the day in a location convenient for loading the kettle. 13. See that there is no water or foreign matter in the kettle. 14. Have two ABC-rated dry chemical fire extinguishers within 20 feet of the kettle. Be prepared to use it.15. After doing the above, continue to next section.

PERSONAL PROTECTIVE EQUIPMENT1. Wear a hard hat with a full face shield attachment and goggles. 2. Wear a long-sleeved cotton shirt, buttoned at the cuff and within one button of the collar. 3. Wear long cotton pants without cuffs.4. Wear over the ankle boots with thick rubber or composite soles that fit snugly under the pants. 5. Wear thick cotton or leather gloves that fit snug at the cuffs and extend under shirt sleeves.6. Do not wear jewelry or earphones.

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Fig. 4

WARNING: Before starting the engine/pump system, make sure youhave either set up the roof tubing following instructions below or capped thepump discharge at the kettle with a 1-1/2" steel pipe cap (fig. 4-A). Failureto do this before starting the engine could result in serious injury or deathand/or property damage.WARNING: If the kettle’s pump and valve assembly is not thoroughlymelted, starting the engine could cause “hot” to go to the roof unexpectedly.This could result in serious injury or death and/or property damage.

SETTING UP HOT PIPE (Roof Tubing) Read and follow OSHA No. 1926.501and 1926.502 Fall Protection Standard for the proper type of fall protectionbefore working or allowing work to be done on the roof. Guard all roof openings.

WARNING: Check flex metal hose carefully before every usage andreplace after 30 days of usage or before if necessary.

1. Before assembling hot pipe, elbow and unions, check all of them for cracks,bends (especially near welds or threaded ends) or any type of damage. Do not use if there is damageto any part of this assembly. Once the job is set up, these fittings should be checked regularly. If anydamage is found, replace as needed with original Reeves parts.

2. Set up a Reeves Guard Rail at the receiving area on the roof where the hot pipe is going to be set up atthe roof edge. The Guard Rail must have a 90 degree rail at each end. (See fig. 5 on page 8)

3. Set up a Reeves Hot Pipe Stand inside of the Guard Rail. The Stand needs to be vertical and not leaningto one side. Secure the Stand to the Guard Rail (see fig. 6 on page 8)

4. Measure the distance from the outlet of the pumping system to the roof. Make sure the hot pipe willextend high enough above the roof so the flex hose will point downward and yet long enough to be in thecontainer when filling. (See Fig. 7 on page 8)

5. Assemble the amount of hot pipe needed on the ground, including a 120° elbow and a flex hose ratedfor tar & asphalt. Reeves' offers a 5' flex metal hose with a sleeve rated for tar and asphalt.WARNING: Use a pipe wrench only on the steel nipples that are welded to each end of the hot pipe.Do not use the wrench directly on the hot pipe.

6. Each piece of hot pipe comes with a loop on one end. Run a 3/16" safety wire cable through each looptwice and secure the ends of the cable to the hot pipe before it is lifted to the roof and put in place (Seefig. 8 on page 8). This safety cable will be secured differently after the hot pipe is lifted and in place.

7. Tie a lifting rope or cable underneath the union closest to the 120 degree elbow so the rope or cable willnot slide off. WARNING: Do not attach the rope or cable to the 120 degree elbow or the flex metal hose.

8. Lift the hot pipe up to the roof, being careful not to bend, break, or loosen any connections.9. Connect the pump end of the hot pipe to the pump system. 10. On the roof, put the hot pipe in the Hot Pipe Stand holder and tighten. Tie and brace the hot pipe between

the kettle and the roof if needed. The hot pipe should be as vertical as possible. The more horizontal thehot pipe is, the more bracing it needs. The hot pipe is not designed to be self-supporting.

11. Secure the lower end of the safety cable to the fitting at the pump system and to the Reeves Guard Railon the roof.WARNING: As the job changes, be sure to adjust the hot pipe accordingly for lower or highercontainers. Ensure all fittings are assembled tight so there are not leaks. This is very important and couldcause serious injury, death and/or property damage if not assembled properly.

12. If possible, it is a good idea to place a tarp on the side of the building next to the pipe to prevent leakagefrom hitting the building.

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Fig. 5

Fig. 6

Fig. 8

Fig. 7

PREPARING PUMP SYSTEM

WARNING: Before starting the pump system, make sure you have either set up the roof tubing (seeSetting Up Hot Pipe-Pg. 7) or capped the pump discharge at the kettle with a 1-1/2" steel pipe cap (fig.9-A on Page 9). Failure to do this before starting engine could result in serious injury or death and/orproperty damage. WARNING: If the kettle’s pump and valve assembly is not thoroughly melted, starting the enginecould cause “hot” to go to the roof unexpectedly.

(Continued next page)

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Fig. 9

Fig. 10

Fig. 11

PREPARING PUMP SYSTEM (Continued)

1. Read manufacturer’s instructions for engine (Honda) and pump (Vican) included in the instruction tube. 2. Kettle engines are shipped without oil. Add oil and service the engine before starting.3. Check fuel supply. Fill with fresh, clean gasoline (preferably unleaded). Do not

use mixed gasoline or gasohol. Clean up any spills completely. NEVER addgasoline to the engine while it is running. Shut off the engine and allow to coolfive minutes before refueling. Gasoline is highly flammable and must behandled with care. Do not smoke or allow flames or sparks where engine isrefueled or where gasoline is stored.

4. Grease the pump on a new kettle before starting. Use high temperature greaseonly in the pump.

5. Attach valve control rope to the ring on the valve linkage rod (fig. 9-A). Feedthe rope through the guide ring and up to the roof (fig. 9-B). Untie any knots inthe line that could cause binding or hangup.

6. Continue to “LP Burner Operation” below, or read “Supplemental Instructionsfor Operating with Kerosene” on separate instructions.

PREPARING FOR LPG BURNER OPERATION

WARNING: To avoid flash fire or damaged flues, never operateburner(s) forcefully until "hot" is well above tube system.

NOTE: Reeves LPG burners are designed for liquid or vapor propane. Donot use a torch with a disposable lighter or matches to light thelighter rod. Use a spark lighter.

1. Install regulator assembly (fig. 10 #4) to one end of 25' LP hose andvalve assembly(s) (fig. 10 #3 & #1) to the other end. Connect the valveassembly(s) to the burner(s), then the regulator assembly to the LP-Gas cylinder (fig. 11). Make sure connections are tight. Never operateburner without regulator and gauge. The factory sets the regulator at 30P.S.I. DO NOT EXCEED.

2. Move the LP-Gas cylinder away from the kettle or source of flame.Check local laws for distance.

3. Make a visible inspection of LP-Gas cylinder and components for damage ordefects. If damage or defects are found, replace or repair before continuing.

4. Check all LP-Gas fittings to ensure they are tight.5. Make sure the burner valve is off. 6. Turn on the LP-Gas cylinder valve approximately one-half turn.7. Use a soap solution to check for leaks. Do not use a flame . If a leak is

detected, turn off the cylinder valve. Repair all leaks and continue only if thereare no leaks.

8. If you have a Reeves Afterburner, read the “Afterburner and Loader Instructions”, before continuing. Ifyou do not, go to “Starting Kettle using LP-Gas” next.

WARNING: There must not be any condensation (moisture, water, etc.) in the kettle or on thematerial (or inside the material package if the wrapper can be melted) as it is being loaded into the kettle.This will cause the bitumen to react violently and cause serious injury.

STARTING an EMPTY KETTLE using LP Gas

1. Check carton for optimum operating temperature and flash point temperature. DO NOT EXCEEDMAXIMUM RECOMMENDED TEMPERATURE. (Continued next page)

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STARTING EMPTY KETTLE using LP Gas (Continued)

2. Place a keg of bitumen in the preparation area and remove wrapping. Make sure there is notcondensation (moisture or water, etc.) on the material. Dispose of flammable wrapping materials.Maintain good housekeeping.

3. Chop bitumen into small pieces. Small chunks (6 to 8") are ideal and will melt more quickly. For initialmelt, load material evenly into the kettle until the vat is full. Never fire the kettle until it is full of choppedmaterial (or bitumen covers flues on used kettle).

4. Open the exhaust stack covers and firebox cover. They must be open while operating for proper draft.5. Open the main LP-Gas cylinder valve slowly all the way.6. Light the lighter rod (fig. 10 #2) and adjust to a small pilot flame with the ball valve (fig. 10 #3). Place the

lighter rod in the burner well, and hold the flame next to the burner jet. 7. Keep hands and head away from the burner well and exhaust stacks. Light the burner(s) one at a time

by partially opening each burner valve slowly (fig. 10 #1).8. Keep burner(s) at an extremely low flame. As initial material melts, add more material. You must allow

plenty of time when heating from a cold start and be extremely careful. 9. Pay close attention to the bitumen, because the thermometer is not yet registering. It will not register until

the melted bitumen has reached the stem of the thermometer. Once the “heated bitumen” gets to thethermometer, the reading will increase quickly.

10. If at any time the smoke becomes thicker, turn burners off completely until bitumen has cooled down.Thick smoke means material is overheated and can result in a fire immediately. Once material hascooled, resume with low flame until flues are covered with at least three to four inches of melted bitumen.

NOTE: Read “How to Extinguish a Kettle Fire” on page 13 and be prepared in case of fire.11. As you continue to put larger (10-12") chunks of bitumen into the hot vat, you can adjust the burners to

achieve desired temperature. Never heat material higher than the material manufacturer'srecommendation. Never throw or drop the material into the vat. The kettle is considered full when liquidmaterial is approximately one to two inches below the splash guard.

12. If a Safety Loader is installed on the kettle, you can close the kettle lid and load through the SafetyLoader Door (read “Afterburner & Safety Loader Instructions”). Load with smaller pieces of bitumen soit will move out from under the door as pump circulates.

13. For troubleshooting information on LP Burners, see page 15.14. Continue to “Pumping Hot to the Roof” on pages 11-12.NOTE: If the kettle burners go out while the kettle is in operation, they will not relight themselves. Close theLP valve(s) at the burner(s) and wait five minutes to purge the kettle of LP-Gas. (Exhaust stack covers andfirebox cover must be open). Repeat steps 6 and 7. Continue with operation.

WARNING: If the kettle’s pump and valve assembly is not thoroughly melted, starting the enginecould cause “hot” to go to the roof unexpectedly.

For Kettles with Cold Bitumen Above the Flues

1. Follow steps 1-7 of the above section. Adjust the valve to have a low flame. 2. The immersion tubes (flues) are imbedded in solid bitumen. The kettle must gradually thaw the material

surrounding the flues to allow the flues to expand without undue stress. If the kettle is heated too quickly,the flues can be damaged and you will probably flash the kettle. To keep this from happening, you needto run the burner(s) at a low flame for a minimum of fifteen minutes and possibly up to thirty minutes.

3. Pay close attention to the bitumen (the thermometer is not yet registering) and watch for hot liquidbitumen to break through around the edges of the cold top layer. The thermometer will not register untilthe melted bitumen has reached the stem portion of the thermometer. Once the “heated bitumen” getsto the thermometer, the reading will increase quickly.

4. Follow Numbers 10-14 plus the note in the above section.

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Fig. 12 Fig. 13

PUMPING “HOT” TO THE ROOF

WARNING: The kettle man must be present at all times to operate the kettle safely. 1. Make sure the engine has oil and gasoline before starting. Read p. 8-9 “Preparing Pump System”.2. Never start the pump engine until material is melted and has reached proper temperature. Make sure the

pump is thawed out before starting engine. NOTE: Disconnect spark plug wire on engine beforechecking pump. You can test the pump by pulling the starter rope on the engine slowly to make certainthe pump is turning free.

3. The roof control valve must be in the open position (rope released) before starting engine (fig. 12). Pullingon the valve control rope closes the valve and sends hot stuff to the roof (fig. 13). Releasing the ropeopens the valve and stops the flow of material to the roof. Do not tie the rope so that the pump will keeppumping by itself. The roofer on the roof must always have the rope in his hand for full control of hotbitumen coming to the roof. Always make sure the valve is operating freely, with nothing obstructing itbefore starting pump system.

4. Once the pump is running, it will circulate material in the vat through the roof control valve (in openposition). This will even out the temperature in the vat. Heat bitumen according to the materialmanufacturers recommendation.

5. When material is required at the roof, pull the rope hard to close the roof control valve completely untilthe required amount of bitumen is delivered to the roof and then release the rope. It is very important tomake sure the rope does not slip and partially bypass material into the kettle. If this happens, it willeventually clog tubing lines (see Maintaining Hot Pipe-p. 13). NEVER allow anyone to stand under thetubing line.

WARNING: Do not allow the level of bitumen to drop below the top of any portion of the flues. Thiscould result in flash fire and cause serious injury or death. If you must pump below the flues, burnersshould be shut off at least ten minutes before lowering the level.

6. Grease the pump twice a day: once at noon when the entire system is hot and once at the end of the day.Use hi-temp grease only.

7. It is highly recommended that engine oil be changed daily. The oil breaks down quicker because of theheat involved with this application. Frequent oil changes will significantly prolong the life of the engine.See Honda operating instructions for recommended oil. Use unleaded gasoline to increase valve life.

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Fig. 14

WITHDRAWAL OF HOT BITUMEN FROM DRAINCOCK

1. Make certain material is hot enough for proper application and that the draincock isthawed, but do not overheat the material.

2. Place the container under the draincock and open the valve slowly. Never attempt to pryor hit draincock handle to open if it is stuck. Do not overfill containers.

WARNING: Do not allow bitumen to drop below the top of the flues. This willresult in flash fire causing serious injury or death.

3. Draincocks with threads in the mouth are available for outlet extensions when filling lowcontainers. See figure 14.

SHUTTING DOWN KETTLE FOR THE DAY

1. Allow pump to circulate for a few minutes (with valve rope released) so the tubing line and flex metal hosecan drain. Failure to drain tubing line and flex hose completely will result in a freeze up later.

2. Stop engine using the on-off switch. If your engine is fueled by LP-Gas, turn off the main LP-Gas cylindervalve at the tank first (if different from the burner supply tank) and let the engine stop.

3. If using LP-Gas to fuel burners, do the following: a. Turn off tanks supplying burners, waiting for burners to extinguish on their own (this may take a

minute or two if using liquid LP-Gas). b. Turn off burner valves and disconnect hose from tank to burners.

4. Close exhaust stack covers and burner well cover.5. Lock up engine cover, burner well cover, lid and draincock.6. Take down tubing line to roof and disconnect line from kettle. (See next section for details)7. Move equipment to middle of the roof and chock wheels.8. Lock and secure trucks and hoisting equipment.9. Remove and secure the ladder to prevent access to the roof.10. Remove and secure chemicals, adhesives, solvents, and flammables.11. Store mops away from combustible materials at night.

MAINTAINING HOT PIPE

WARNING: Moisture can get trapped inside the tubing running from the kettle to the roof,causing hot bitumen to react violently.

1. To keep hot pipe clean, at the end of the day run hot material up and down the supply line a few times.Once it has drained and cooled off, dismantle your tubing line. This will allow the moisture to run out ofthe tubing lines at night. Even small amounts of moisture will react violently with hot bitumen.

2. If hot pipe line gets clogged, you must dismantle the line before trying to thaw it. Once dismantled andon the ground, heat up either end of the tubing with a burner, moving up the tubing as the bitumen meltsto free clog. NEVER start heating up the tubing in the middle. This will cause the pipe to explode.

DAILY MAINTENANCE OF ROOFING KETTLES

1. Fill engine with fresh, clean gasoline (preferably unleaded). Do not use mixed gasoline or gasohol. Cleanup any spills completely. NEVER add gasoline to the engine while it is running. Shut off the engine andallow to cool (five) minutes before refueling. Gasoline is highly flammable and must be handled with care. Do not smoke or allow flames or sparks where engine is refueled or where gasoline is stored.

2. It is highly recommended that engine oil be changed daily. The oil breaks down quicker because of theheat involved with this application. Frequent oil changes will significantly prolong the life of the engine. SeeHonda operating instructions for manufacturers' recommended oil.

3. Clean air filter often. (See Honda maintenance instructions)4. Grease the pump twice daily with hi-temperature grease. Refer to Vican Pump instructions for further

maintenance and adjustments. For troubleshooting pump information, see pages 15-16.5. Clean draincock after each use and make certain it is in proper working condition.

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PERIODICAL CHECKS

1. Grease chassis and bearings every 10,000 miles or as needed.2. Check tires for pressure (look on side of tire for proper air pressure) and wear. Replace as necessary.3. Oil chain on motor coupling. Check bushings for tightness and make sure keys are in place.4. Check pump for proper end clearance. (Refer to fig. 16 Troubleshooting/Rotary Pump #2 on p. 17)5. Inspect tow hitch for cracks or excessive wear. If any are found, repair or replace immediately.

HOW TO EXTINGUISH A KETTLE FIRE

1. If flash fire occurs from overheated bitumen, close the lid and turn off the burners at fuel supply. Neverthrow water into the vat, as this makes bitumen boil over. Make certain area is clear of flammables. Useof a ABC-rated, dry chemical fire extinguisher is highly recommended for control of kettle fires. As a lastresort, cover the fire with some sort of powdered cement, sand or dirt. If fire threatens to spread, call thefire department.

2. Check the kettle lid daily to make sure that it fits tightly.

PREVENT HOT STUFF BURNS

1. Hot stuff can splash if containers are overfilled.2. Do not jerk on a bucket stuck to the roof if it is full of hot material.3. Open valves and draincock slowly.4. Do not walk in hot stuff.

HOT STUFF BURNS & FUMES

1. Avoid breathing fumes. Fumes will cause eye and respiratory track irritation and may cause nausea anddizziness. If inhaled, remove individual to fresh air. If irritation persists, administer oxygen and seekmedical aid.

2. Have an adequate supply of water on the job while working with hot stuff. 3. If splashed with bitumen, cool the burned area with water or ice. Do not attempt to remove bitumen,

seek medical attention.4. Do not put ointment or salve on second or third degree burns. Seek medical attention .5. Only cool the area until hot stuff has hardened. Seek medical attention .6. Do not remove hot stuff or clothing from the burned area. Seek medical attention .7. Keep burned area elevated higher than the heart. Make sure burned area remains open to air.

LP-GAS CYLINDER INFORMATION

1. All LP Gas cylinders should be handled by the rules set forth by the Railroad Commission.2. You must also follow all local regulations regarding the use of LP-Gas Cylinders.

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CLEANING KETTLES

1. A clean kettle heats better and lasts longer. Frequency of cleaning depends on usage, materials andcircumstances. It is recommended that inside the kettle be cleaned completely at least once a year. Sometrouble signs to watch for are: a. Excessive carbon buildup on the tube unit, and under the flue cover and back cover. The accumulation

of oil soaked carbon can cause a fire that is difficult to put out. Carbon buildup can also significantlyreduce the usable capacity of bitumen in your kettle.

b. Excess carbon around the roof control valve can effect proper performance of the valve. A cokebuildup around the roof control valve could cause a gradual creep of bitumen to climb tubing line andeventually clog the line. If this happens, DO NOT use until cleaned .

c. Accumulation of carbon on suction screen can reduce flow and hinder pump performance.d. Heat performance can be seriously affected by carbon buildup on the flues. Carbon buildup insulates

the heat and restricts the transfer of heat to the bitumen. This buildup also reduces life of the flue. e. On kettles with semi-automatic controls, carbon accumulation on the sensing tube can cause kettle

to vary from too hot to too cold, due to delayed transfer of temperature changes through the carbon.f. Flashing may occur frequently on the kettle that needs cleaning.g. Material on the outside of the kettle that is not cleaned off makes kettle fires more difficult to contain

and increases the chances of a fire spreading elsewhere.2. Cleaning procedure is as follows:

a. Tilt kettle back slightly while still hot and drain as completely as possible through the draincock.b. Tube unit removal: Remove the following in order listed below:

1) Bolts on flue cover and back cover. Lid chains from the flue cover and back cover. If cleaning a draw kettle, skip to No. 8 listed below. If a pump kettle, remove the following.:

2) Remove sensing element if Hi-Lo Controls are installed. 3) 1-1/2" or 2" lift line pipe.4) Bolt that attaches roof control valve to linkage rod. Unscrew linkage rod.5) Hook strainer or strainer pipe with heavy rod and pull up, leaving as much clearance as possible

under strainer for flue to clear.6) Remove tube unit (flues) using chain hoist. Hook chain(s) to lifting eye provided on return flues.

Lift slowly, watching for the end of the flue to clear pump and strainer pipe. There is another liftingeye available on the junction box if needed.

c. With covers and flues removed, shovel out trash or residue remaining in vat. Carbonized materialsmust be chipped off, taking care not to damage inside of the vat. Burn, scrape or sandblast the fluesuntil clean. Inspect and fill with water to check for leaks. If leaks are found, repair as necessary.

3. Reinstall the tube unit as follows: Inspect and replace if necessary, the fiberglass rope around the edgeof the vat (where flue cover and back cover sit). Lower flue with junction box end tilting down, making iteasier to slide under suction pipe and pump. Install bolts in flue cover. Install back cover with bolts. Reinstall lid chains. Close the lid and inspect for perfect fit. Adjust flue cover or back cover if necessary.

4. Clean outside of kettle. Clean draincock and make certain it is in proper working condition.

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TROUBLE SHOOTING CHART

TROUBLE

LP GAS BURNERS (Vapor)1. No gas to burner

2. Small flame(Burner not producing sufficient heat.)

PROBABLE CAUSE

a) Plugged jet or fuel lineb) Tank valve or burner valve not open atall or not open all the way.

c) Tank valve (on supply tank) openedtoo quickly (LPG tank equipped w/excessflow valve)

d) Kinked hosee) Regulator not set

f) Tank(s) empty

a) Pressure too low and/or will notproduce continuous forceful flame.b) In colder climates, small bottles frostup quickly and freeze.

REMEDY

a) Clean jet or fuel lineb) Main valve on tank should be fullyopen. Burner valve should be used foradjusting flame.c) Close tank, bleed gas in system.Reopen valve slowly to prevent flowvalve from automatically shutting due tohigh velocity.d) Repair or replacee) Turn in on regulator until pressureshows 20-30 lbs. on gauge.f) Refill tank(s)

a) See causes above

b) Use several bottles manifold togetheror use single large supply tank (in colderclimates, liquid should be used ifpossible.

LP GAS BURNERS (Liquid)

1. No gas to burner

2. Burner flare up

3. Small flame

4. Flame goes out

a)

a) Pressure too high

b) Liquid not yet vaporized

a) Burner jet blockedb) Low Pressurec) Tank Running Low

a) Empty tankb) Condensation (water) in supply tankc) Condensation and/or water in hosesor burner

a) See chart on LP (Vapor A-F)

a) Set pressure at regulator to max. 30psib) Burn the burner at a lower flame afew minutes to preheat the burner.Liquid will then vaporize.

a) Remove and cleanb) See 2a abovec) Fill tank

a) Fill tankb) Change tankc) Clean and dry lines and burner.

15

Fig. 15

ROTARY GEAR SUBMERGED PUMP (Refer to fig. 15)

1. Will not Pump(Not circulating in kettle)

(Continue next page)

a) Bitumen too low to reach strainer(Pump does not have to be submergedto pump)b) Leak in suction line fittings frompump to strainer (#13&14)c) Strainer (14) clogged with debris.

d) If strainer (14) is missing, inlet pipemay be clogged with asphalt or debris.

e) Motor coupling needs repair (keysmissing, bolts in bushings broken ormissing).

a) Bring bitumen level above strainer

b) Tighten fittings. Even a small leakwill prevent pump from pumping.c) Clean debris from outside of strainer.To prevent debris from collecting onstrainer, use a skimmer to collectfloating debris.d) Bring asphalt level down belowsuction pipe. Remove pipe and fittingsand clean. Reinstall piping with strainer.e) Repair or replace as needed.

16

Fig. 16

ROTARY GEAR SUBMERGED PUMP (Continued)

2. If back plate bas been replaced, andpump fails to pump or circulate in kettle

3. Material circulating in kettle, but will not pump to roof.

4. Pump will not stop pumping to roof.

5. Engine stalls out when adjusting rodhandle is pulled to pump bitumen toroof.

6. Engine will not start

a) Gasket not sealing properly (leakingair)b) Back plate installed in wrongposition.

c) Pump needs to have end plateadjusted. (refer to fig. 16 whenadjusting)

a) See fig. 15, the lift line and numbers1-4 may be clogged.

b) Lift line tubing clogged.c) Roof control valve (8) not shuttingproperly or is worn out.

d) Pump will not build pressure to pumpto roof.

e) Engine running to slow.f) Discharge pipe (4) has comeunscrewed from the tee (10).

a) Roof control valve (8) partially orcompletely closed.b) Cholesterol build in discharge sideof pump (8,9,10), not allowing asphaltback in kettle when circulating. Thispiping is inside kettle.

a) Clogged line to roof.

a) Bitumen in kettle not hot enoughb) Normal engine problems

a) Completely clean surface of pump.Replace with new gasket. b) Refer to fig. 15. The large hex nut atend of pump should be in about the7:30 position. Only correct position willpump.c) Loosen both set bolts (1&2). Loosenrear adjusting collar (3) two-three turns.Tighten front adjusting collar (4) untilpump shaft no longer turns. Back offfront collar (4) one-quarter turn. Setfront (1) set bolt. Tighten rear set collar(3) until there is no movement. Set rear(2) set bolt. All the above adjustmentsmust be done with pump hot andrunning or complete clean.

a) Remove lift line tubing. Remove no.1-4 and make a visual inspection forclogs. Clean as necessary.b) Remove and cleanc) Adjust roof control valve (8) byturning linkage rod (7). Replace valve ifworn out.d) Adjust rotor and back plateclearance. Go to 2-c above forinstructions. If this doesn’t work,replace back plate and idler. Pump mayneed to be replaced.e) Run engine 3/4's to full speed.f) Rethread pipe (4) into tee (10) orreplace the pipe if necessary.

a) Adjust valve or replace valve if wornout or damaged.b) Clean piping (8,9.10) on dischargeside of pump.

a) Check and clean lift line tubing andnumbers 1-4.

a) Bring bitumen to operatingtemperature.b) See mfr’s “Engine Guide”.

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DETAILED PARTS LISTING WITH LOCATOR FOR ALL KETTLES

ITEM # DESCRIPTION

#1 Handle Assembly Lid

#2 Lid Assembly Complete

#3 Lid Only

#4 Firebox Lid

#5 Return Flue Cover

#6 Tube Unit

#7 Flue Cover Complete

#8 Firebox

#9 Center Tube

#10 Junction Box

#11 Vat Complete

#12 Rain Cover

#13 Fender with Braces

#14 Insulation Sr 26

#15 Eye Lid for Thermometer

#16 Thermometer

#17 Engine mount Complete

w/braces

#18 Pumps and Their Parts

#19 Bushing, H 1-1/8" 265-1500

#20 Motor Coupling Halves

#21 Bushing, H 1" 265-1500

#22 Mtr Coupling Master Link

#23 Mtr Coupling Chain W/Link

#24 Motor Coupling Complete

#25 & #26 Motor Coupling Shield

W/Rc Latch

#27 Engine

#28 Key 1/4x1"

#29 Pump Parts (See #18)

#30 & #31 Safety Chains W/Hooks (2)

#32 Frame and Running Gear

#33 Jacks

#34 Caster Only

#35 Axles

#36 U Bolts (In Kits)

#37 Hub Parts-Grease Seal

#38 Hub Parts-Inner Bearing

#39 Hub Only

#40 Hub Parts-Outer Bearing

#41 Hub Parts-Wheel Nut

#42 Spindle Washer

#43 Spindle Nut

#44 Stud for Hub

#45 Cotter Pin 1/8x2"

#46 Hub Parts-Dust Cap

#47 Hub Complete (Pair)

#48 Equalizer Bar

#49 U-Bolt Plate

#50 Spring

#51 Hangers (In Kits)

#52 Rear Drop Leg Jack

#53 Reflector Cup

#54 Reflector 3" Red

#55 Draincock 2-1/2"

#56 Nut Square Blk. 5/8"

#57 Splash Guard

#58 Rope Packing, Z Tex 3/4"

#59 & #60 Suction Pipe W/Strainer

#61 Street Ell

#62 Pump Parts (See #18)

#63 Close Nipple

#64 Reducing Tee

#65 Street Ell

#66 Drop Leg Bracket

W/Pin & Clip

#67 Roof Control Valve

#68 Adjustment Rod for

Roof Control Valve

#69 Roof Valve Return

Spring #8 Gate

#70 Adj Rod Lever W/Rings

#71 & #72 Adjustable Valve Stop w/nut

#73 Rope Guide Complete

#74 Cover Bolt 5/8x1-1/4"

#75 Lid Hinge (2 Req.)

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#76 Nipple for Valve

& Pump System

#77 Elbow

#78 Nipple 1-1/2x4" Tbe

#79 Street Ell 1-1/2"

#80 Shackle Bolt & Nut

#81 Fender Brace

#82 Tires

#83 Wheels

#84 Back Cover

#85 Lock Washer 5/8"

#86 Strut Spacer

#87 Strut Bolt 5/8x2"

#88 Lid Chain

#89 Vent Cap Lid

#90 U Bolt Nut (In Kits) See #36

#91 Shackle Nuts (In Kits)

#92, 93 & 94 Pump Parts See #18

#95 Pump Cover

#96 Trailer Coupler

#97 Double Seal

#98 Hitch Pin Clip

#99 Engine Spacer

#100 Standard Tongues

#101 Return Flue

Reinforcement

#102 Lifting Lug

#103 Junction Box Tie

#104 Insert for Hangers

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