Etnyre Black-Topper Operation, Maintenance And Safety Manual
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Etnyre Black-Topper Operation, Maintenance And Safety Manual

Centennial series asphalt distributor with bt 1 controls
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  • Page 2 WARRANTY E. D. Etnyre & Co. warrants to the original Purchaser, its new product to be free from defects in material and workmanship for a period of twelve (12) months after date of delivery to original Purchaser. The obligation of the Company is limited to repairing or replacing any defective part returned to the Company and will not be responsible for consequential damages or any further loss by reason of such defect.
  • Page 3 © Copyright 2010 E.D. Etnyre & Co. All brand names, trademarks and registered trademarks are the property of their respective owners. Information contained within this document is subject to change without notice. All rights reserved.

  • Page 4: Table Of Contents

    Fire Burners ............61 Automatic Transmissions ......20 Replacing Speed Pickup ........61 Spraying Operations .........21 Servicing the Etnyre P-15 Pump ......62 Setting the Digital Memory Presets ....22 Vacuum Check ..........62 Adjusting the Spray Bar Nozzle Angle ....22 Pump Disassembly And Inspection ....62 Adjusting the Spray Bar Height ......22...
  • Page 5 Figure 29. Right Hand / Left Hand Electrodes ..........60 Figure 30. Electrode Setting................. 60 Figure 31. Hydraulic Motor................61 Figure 32. Etnyre Asphalt Pump..............62 Figure 33. Fluid Cleanliness Chart............... 65 Figure 34. Serial Number Plate Location............69...

  • Page 6: Warning And Instruction Plates

    Warning And Instruction Plates 24 25 17 18 For operator safety and possible liability protection, all Safety and Instruction Plates should remain in place and be legible Should a plate be removed, lost, or become illegible, reorder and replace immediately If plates become difficult to read because of material coating the surface, clean with solvent REF PART NO.
  • Page 7 It is believed the chemistry of the emulsion - specifically the residual fumes promote the corrosion • Etnyre Distributors are compatible with Cationic Emulsions provided that certain precautions are taken. • Prior to placing a distributor in to service with Cationic Emulsion, it should be loaded with an AC or MC type material to develop a protective coating.

  • Page 8: General Safety Instructions

    General Safety Instructions The operation of a bituminous distributor normally requires handling of liquid products at elevated temperature. Also, these liquids may be of a volatile nature. A heating system is supplied to raise or maintain the product temperature, and these systems use highly combustible fuels. As with any type of construction equipment, there are certain hazards associated with careless or improper operation.

  • Page 9: Warnings

    WARNINGS To prevent an explosion or fire hazard: WARNING • Do not operate the burners when the vehicle A fully charged dry chemical type fire is unattended, when the vehicle is in motion, extinguisher must be within easy reach or with the vehicle in a confined area. whenever the burners are operating or there •...
  • Page 10 WARNINGS WARNING To prevent possible burns from leaking To prevent possible personal injury: material: • Do not load the vehicle beyond the GAWR • Be sure all pipe, cap and hose connections or GVWR. The maximum load volume must are secure before opening valves, or be calculated based on material density.

  • Page 11: Foaming

    To prevent possible burns from foaming the operator should also receive instruction or violent eruption: by an authorized Etnyre dealer, or Etnyre • Do not load tank with material temperature representative. over 200ºF if water or condensation is...

  • Page 12: Introduction

    E. D. Etnyre & Co. This manual is provided as a tool to aid personnel in To contact NHTSA, you may either call the Auto...

  • Page 13: Component Location And Identification

    Component Location And Identification Rear and Side Components Manhole & Platform Tank Gauge Exhaust Stacks Exhaust Stack Dampers Ladder Sample Valve Hand Burners Spray Air Oiler Hydraulic Oil Filters (in right side tool box) Hydraulic Oil Tank Suction Valve Thermometer Well Strainer/Valve Box LPG Tank Asphalt Pump...

  • Page 14: Spray Bar Components

    Spray Bar Components Right Wing Section Breakaway with Spray Valves Swivel Joint Flip Lever Spray Valve Spray Bar Feed Tubes Nozzle 8' Center Section with Valves and Nozzles Left Wing Spray Valve Control Linkage Section and Air Cylinder Figure 4. Spray Bar Component Identification Hydraulic Tank Components 1.

  • Page 15: Cab Control Panel

    Cab Control Panel SPRAY 3361571 SHIFT LEFT BAR RIGHT BAR LIFT LATCH UNLATCH WING FOLD MESSAGE ON DISPLAY APPLICATION RATE MEMORIES SUCKBACK CLEAR POWER TANK VALVE START SELECT VALUE OVERRIDE FRONT REAR MESSAGE 6-10 3361570 Figure 6. Cab Control Panel Components Cab Control Panel Descriptions 2.
  • Page 16 6. SHIFT Switch 11. Message Light Moves the entire spray bar left or right. Holding Indicates that there is critical information to be the switch in either direction moves the spray bar viewed on the Display. continuously until the switch is released, or until full 12.

  • Page 17: Rear Control Panel

    CONTROL or turning ON the POWER switch in button is pressed. In MANUAL control, M flashes the cab or the EMERGENCY STOP switch in the until the START button is pressed. Use Etnyre rear panel. computator (p/n 3390408) when spraying in...
  • Page 18 3. START Button 8. Timer Reset Switch Starts the asphalt pump turning at the target pump When the optional burner controls are in- rate, and also for calibration operations in the setup stalled, selecting this switch when the burners screens. When the Function knob is turned to BAR are operating will extend the heating time.
  • Page 19 14. WASH PUMP Switch and Light 18. SELECT Switch (Included with optional Display) When the optional solvent pump and switch is installed turning the switch ON will allow use of Navigate through the display using the SELECT the solvent wash wand or application of solvent switch.

  • Page 20: Preparing For Operation

    Preparing for Operation Note: and bar control. VALUE increase from English to Always refer to the truck chassis owner’s get Metric. SELECT Switch to the right to enter manual for chassis and engine maintenance Bar Control. VALUE decrease from FOOT to get information.

  • Page 21: Fourth Screen

    Fourth Screen Sixth Screen This screen allows for setting the hydraulic pump This screen provides the ability to reset param- EDC threshold in milliamps. The threshold is the eters in the computer back to their default values. minimum required electrical current for the asphalt You should record all of your settings before pro- pump to turn.

  • Page 22: Spraying Operations

    excessive overspray. Rates that are too low will WARNING cause the fan to sag and cause heavy edges. Refer to the nozzle selection chart in the operator’s To prevent an explosion or fire hazard, do not manual to select the nozzles appropriate for your heat the material beyond the manufacturer’s conditions.

  • Page 23: Setting The Digital Memory Presets

    Adjusting the Spray Bar Nozzle WARNING Angle To prevent possible burns from material Adjust the nozzles to obtain an angle of ap- overflow, allow sufficient space in the tank for proximately 30 degrees with the spraybar center expansion of the material when heating. line.

  • Page 24: Operation

    Additional DC-200 additive may be obtained from accumulated values can be used for recording E. D. Etnyre & Co. or your Etnyre dealer. shots or the area and distance can be used for dry measuring. The accumulated values will exceed the displayed values after 999,999.

  • Page 25: Third Operating Screen

    Information Messages Third Operating Screen The following messages will be displayed in order once before they are displayed again. Mes- sages will be displayed only in the main operating screens and will alternate or flash between the The third operating screen allows for quick set message and the current operating screen.
  • Page 26 on the CAN bus. There are several reasons why the module might not be recognized on the CAN bus. It may be unplugged from the CAN bus or electrical power or may be damaged. Radar Calibration Hydraulic Pump This message flashes on the display after the This message flashes on the display after ground START switch has been selected in AUTO pump speed calibration when the radar is either not con-...

  • Page 27: Loading

    LOADING Loading Through the Manhole Refer to Figure 11 for the following procedures. To reduce the risk of accidental discharge of 1. Park the Distributor in the desired location for asphalt, the asphalt pump should not be running, loading overhead through the manhole. the 4 way valve should be in tank circulate, all tank 2.

  • Page 28: Loading Through The Load Line Connections And Preliminary Checks

    LOADING Loading Through the Load Line Using the Measuring Stick Connections and Preliminary Checks The measuring stick is only accurate when the WARNING tank is level. To prevent possible burns from leaking material, be sure all pipe, cap and hose connections are secure before opening valves or beginning any operation.

  • Page 29: Loading Through The Load Line

    LOADING Loading Through the Load Line (cont) At the rear of the distributor: Set or confirm the following: • Tank valve closed WARNING • Return valve open To prevent possible burns from foaming • Bar suck back valve(s) closed or violent eruption: Do not load tank with •...
  • Page 30 6. Connect the load line to the supply tank Depending on material viscosity, as the loading rate is increased, the asphalt pump may cavitate. through an asphalt hose. When this happens, the pump will make a distinc- 7. Open the tank valve on the supply tank. tive sound, easily recognized with experience.

  • Page 31: Circulating In The Tank

    CIRCULATING Circulating in the Tank 3. The engine must be running and the optional transmission PTO must be engaged. 4. On the cab control panel, turn the POWER switch WARNING To prevent possible burns from material At the rear of the distributor: overflow, allow sufficient space in the tank for Set or confirm the following: expansion of the material when heating.
  • Page 32 4. Press START. The pump will start turning at the WARNING desired circulation rate. To prevent possible burns, use extreme 5. If no other operation will be performed, go to the caution when using a torch to heat the pump. next step.

  • Page 33: Circulating Product In The Bar

    CIRCULATING At the rear of the distributor: Set or confirm the following: Circulating Product in the Bar • Return valve open • Bar suck back valve(s) closed Refer to Figure 15 for the following procedures. • Master hand spray valve closed 1.
  • Page 34 NOTE: The pump can be stopped and the auto- WARNING matic tank valve can be closed immediately at any time during operation by turning the EMERGENCY To prevent an explosion or fire hazard, STOP switch OFF. Before turning the EMERGEN- ensure that the burners are extinguished CY STOP switch back ON, turn the PUMP SPEED before removing any material from the tank...

  • Page 35: Spraying Through The Bar

    SPRAYING Spraying Through the Bar 7. When the spray bar reaches the beginning of the shot, turn the SPRAY switch ON. Refer to Figure 16 for valve positions. 8. When the spray bar reaches the end of the shot 1. Complete the procedure for circulating in the Circulating Product in the Bar turn the SPRAY switch OFF.

  • Page 36: Hand Spraying

    SPRAYING Hand Spraying • Transfer line valve closed Refer to Figure 17 for the following procedure. • Flush valve closed • Load and transfer line caps are in place and secured. WARNING At the rear control panel: To prevent burns from hot asphalt when 1.

  • Page 37: Spray Bar Suckback

    SUCKBACK At the rear control panel: Spray Bar Suckback 1. Turn the Function knob to SUCK BACK. (Op- Refer to Figure 18 for the following procedures. tional manual tank valve should be closed and 1. Park the Distributor and set the truck parking the optional manual bar suck back valve(s) brake.
  • Page 38 NOTE: The pump can be stopped and the auto- For asphalts like AC it is recommended that this matic tank valve can be closed immediately at any procedure be repeated a second time, after which time during operation by turning the EMERGENCY adding solvent such as diesel fuel through each STOP switch OFF.

  • Page 39: Bar Suck Back Override

    SUCKBACK Suck Back Override Note: The pump can be stopped and the automatic tank valve can be closed immediately at any time This optional feature is designed for quick in-cab during operation by turning the EMERGENCY switching between bar circulate and bar suck back STOP switch OFF.

  • Page 40: Handspray Suckback

    SUCKBACK NOTE: Handspray Suckback The pump can be stopped and the auto- matic tank valve can be closed immediately at any time during operation by turning the EMERGENCY WARNING STOP switch OFF. Before turning the EMERGEN- CY STOP switch back ON, turn the PUMP SPEED To prevent burns from hot asphalt when to zero to prevent the pump from turning.

  • Page 41: Flushing Operations

    FLUSHING OPERATIONS Bar Flush (Auto) Normally the suckback procedure will remove sufficient material from the circulating system to Refer to Figure 19 for the following procedures. negate the need for draining the circulating system 1. Park the Distributor and set the truck parking and spray bar before proceeding with the wash brake.

  • Page 42: Bar Flush (Manual)

    Bar Flush (Manual) At the rear control panel: Refer to Figure 14 for the following procedures. 1. Turn the Function knob to FLUSH. 1. Park the Distributor and set the truck parking 2. Turn the EMERGENCY STOP switch ON. brake. 3.

  • Page 43: Enviro-Flush System (Optional)

    FLUSHING OPERATIONS Enviro Flush System (OPTIONAL) The Enviro-Flush system is a closed system which pulls flushing solvent from the Flush Tank, pumps it through the circulating system and spray bar and returns the solvent to the Flush Tank (Refer to Figure 20). Figure 20.

  • Page 44: Recycle Enviro-Flush

    FLUSHING OPERATIONS 8. Refill Enviro-Flush Tank with new solvent. Complete the appropriate suckback Recycle Enviro Flush procedure(s) found earlier in this manual. WARNING NOTE: This procedure will transfer material from the Enviro-Flush tank to the Asphalt Tank. To prevent possible burns from foaming or Normally the suckback procedure will remove violent eruption: sufficient material from the circulating system...

  • Page 45: Unload Operations With External Pump

    UNLOAD OPERATIONS • Bar suck back valve(s) closed • Master hand spray valve closed with External Pump • Transfer line suck back valve closed Refer to Figure 22 for the following procedures. • Transfer line valve closed 1. Park the Distributor in the desired location for •...
  • Page 46 NOTE: 9. Turn the Function knob to UNLOAD The pump can be stopped and the auto- matic tank valve can be closed immediately (the optional manual tank valve should be open). at any time during operation by turning the 10. Open any valves on the storage tank between EMERGENCY STOP switch OFF.

  • Page 47: Unload Operations With Distributor Pump

    UNLOAD OPERATIONS At the rear of the distributor: Set or confirm the following: with Distributor Pump • Tank valve closed Refer to Figure 23 for the following procedures. • Bar suck back valve(s) closed 1. Park the Distributor in the desired location for •...
  • Page 48 5. Turn the Function knob to UNLOAD 16. Press START. (the optional manual tank valve should be open). 17. At the storage tank, carefully open the bleeder valve or break the hose connection until a 6. Turn the POWER switch ON. strong vacuum is heard.

  • Page 49: Transfer Operations

    TRANSFER OPERATIONS At the rear control panel: 1. Turn the Function knob to TRANSFER (the Refer to Figure 24 for the following procedures. tional manual tank valve should be 1. Park the Distributor for transferring. closed). 2. Set the truck parking brake. 2.
  • Page 50 16. At the supply tank, carefully open the bleeder 28. Close the transfer line suck back valve. valve or break the hose connection until a 29. It may be necessary to flush the pump before strong vacuum is heard. It may be necessary doing the next step.

  • Page 51: Heating Product In Distributors

    9. Do not heat material over 200ºF (95ºC) vapor type burners. the propane burners on your if moisture is present in tank. Etnyre Distributor require a supply tank for liquid type burners. Liquid type burners will operate from 10. To prevent possible burns from material...

  • Page 52: Manual Ignition Control

    PROPANE BURNER OPERATION The burners are vaporizing burners which means Manual Ignition Control that they convert liquid propane to vapor in The main shutoff valve and bleeder valves are the coils of the burner. When the burners are closed by turning their knobs clockwise. The operating correctly the system will frost over bleeder valves are equipped with a bypass orifice from the regulator to the first coil of the burner.

  • Page 53: Ignition And Out Fire Control

    PROPANE BURNER OPERATION Ignition and Out Fire Control Manual Ignition Control (cont) 1. Ensure that there is at least 6 inches The safety valve located in the supply line (152mm) of material covering the flue that between the tank and the regulator should be will be used for heating before proceeding.
  • Page 54 1. Ensure that there is at least 6 inches (152mm) This condition must be corrected immediately of material covering the flue that will be used to prevent damage to the burners. If frost does for heating before proceeding. form but then the flame diminishes and the frost 2.

  • Page 55: Thermostatic Control

    PROPANE BURNER OPERATION Thermostatic Control After setting the target temperature in the display The timer can be reset by the operator at any the burners can be operated following the time through the Timer Reset switch. During the instructions and precautions for Operation last 5 minutes of the timer interval the message, with Ignition and Out Fire Control.

  • Page 56: Heating With Fuel Oil Burners

    Heating Product in Distributors Heating Asphalt w/ Fuel Oil Burners WARNING IMPORTANT 1. Position unit broadside to wind whenever Circulating the asphalt in the tank while possible to prevent volatile fumes from heating is recommended for faster heating drifting toward burners and reduced carbon formation on the flues.

  • Page 57: Ignition And Out Fire Control

    FUEL OIL BURNER OPERATION During the last 5 minutes of the timer interval the message, BURNER TIMER ENDING, will be Ignition and Out Fire Control displayed on the screen. The burner(s) will not turn back on without cycling the burner switch(s). The air inlet screen on the burner needs to be kept clean and free of debris in order for efficient operation.

  • Page 58: Thermostatic Control

    FUEL OIL BURNER OPERATION Thermostatic Control Controller LED Fault After setting the target temperature in the display the burners can be operated following the instructions and precautions for Operation with Ignition and Out Fire Control. The target temperature, which can be changed in 5 degree increments, is reset to 95 F or 35 C when...

  • Page 59: Troubleshooting

    Ball joint O-ring is loose. Replace ball joint O-ring. Tube Ball Joints Leak Quantity of material in tank not being Use Etnyre measuring stick for accurate readings. Application Rate measured accurately. Be sure tank is level when measuring. Varies Suction strainer plugged.
  • Page 60 Troubleshooting Switch Input Module in Cab Control Box Problem Cause RED (32V Fault) When Short or Overcurrent Occurs, Cycle Power RED (Can Transmitting) Flashing = Transmitting Off = No Activity RED (Can Receiving) Currently Not Used GREEN (Change of State) Flashes When The Voltage Changes On Any Of the 56 Inputs BLUE (Ready) Flashes When Unit Is Ready...

  • Page 61: Maintenance

    Maintenance Gun Assembly Electrode Settings NOTE: Before installing gun assembly, check that blower wheel turns freely and that all set screws are tightened securely. Figure 30. Electrode Setting Figure 28. Gun Assembly WARNING To prevent an explosion or fire hazard, keep area free of sparks or open flames when testing burners.

  • Page 62: Check Ignition Transformer Spark

    Check Ignition Transformer Spark Replacing Speed Pickup 1. Turn on power switch in rear control box. 1. Loosen locknut and remove old speed pickup. 2. Turn the BURNER switches on. 2. Turn in the new speed pickup clockwise by hand until the bottom end gently touches the internal 3.

  • Page 63: Servicing The Etnyre P-15 Pump

    Servicing the Etnyre P-15 Pump 6. Next, measure the case bore vertically at a point 2.8 inches from each side. The vertical measure- ment must not exceed 5.660 inches. If any bore Vacuum Check measurements exceed these limits, the entire 1.

  • Page 64: General Fuel Data And Heating Terminology

    General Fuel Data and Heating Closed Flash Point The temperature at which a flammable liquid in a Terminology closed container emits a vapor that will flash when exposed to a direct flame. This temperature is lower Fuel Data than required for the liquid mass to ignite. The closed flash point is generally 30ºF lower than the open Fuel Weight Per...

  • Page 65: Hydraulic Fluid Requirements

    Petroleum Based Fluids which it is used. Etnyre field service experience indicates that most Maximum Continuous SUS (cSt) 500 (110) transmission failures result from a breakdown Optimum Viscosity SUS (cSt) 70 (13) of fluid quality.

  • Page 66: Contamination Levels

    Fluid contaminant profile requirements for Etnyre hydraulic units have been determined empirically based on measuring fluid quality in successful application, and in laboratory tests designed to evaluate hydraulic unit contaminant sensitivity.
  • Page 67 the generation of contaminants in the system, the As a rough guide, a capacity in grams equal to required fluid cleanliness, and the desired main- twice the charge flow in GPM has been found to tenance interval. Filters are selected to meet the be satisfactory for our systems.

  • Page 68: Lubrication Chart

    Lubrication Chart (in right side tool box) INTERVAL POINT IDENTIFICATION LUBRICANT QUANTITY DAILY Strainers (Fill Line, Manhole, Strainer Box) Clean — WEEKLY Air Oiler Fill Bar Latches Sparingly Swivels Sparingly MONTHLY Transfer Line Cap Sparingly Load Line Cap Sparingly Manhole Lid Sparingly Exposed Hydraulic and Air Cylinder Rods Sparingly...

  • Page 69: Etnyre Spraybar Nozzles

    Etnyre Spraybar Nozzles Ref. Part No. Description Application Application US Flow Gallons Per (Metric) Liters Per Gallons Per Square Yard Square Meter Minute Per Foot 3353788 V Slot Tack Nozzle .05 - .20 .23 - .91 3.0 to 4.5 3351008 S36-4 V Slot .10 - .35...

  • Page 70: Serial Number Plate Location

    Tank Capacity 2000 U. S. Gallons Manufactured under one or more of the following U.S. patents 2,505,390; 2,571,850; 2,599,704; 3,198,548. E. D. ETNYRE & CO., Oregon, Ill., U.S.A. Figure 34. Serial Number Plate Location Decimal Equivalent Chart Fraction Decimal Fraction...
  • Page 71 If you find inaccurate or confusing information in this manual, or just have a suggestion for improvement, please let us know. Mail or FAX this form to us at: E. D. ETNYRE & CO. 1333 S. Daysville Rd. Oregon, Illinois 61061 • Fax: 800-521-1107 • www.etnyre.com...

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