black-topper centennial asphalt distributor1 m-114-10 black-topper centennial operation,...

E.D. ETNYRE & CO. – 1333 S. Daysville Road – Oregon, Illinois 61061Phone: 815-732-2116 or 800-995-2116 – Fax: 800-521-1107 – www.etnyre.com

Version 3.9.4

Black-Topper® CENTENNIAL

Asphalt DistributorWith BT 1 Controls

M-114-10Serial Number S3985 thru S5315

with BT1 Controls

For Units with Variable Width Spray Bar

1

M-114-10Black-Topper Centennial Operation, Maintenance, and Safety Manual

BLACK-TOPPER Distributor withVariable Width Spraybar and BT-1 Controls

Serial Number S3985 thru S5315

WARRANTYE. D. Etnyre & Co. warrants to the original Purchaser, it’s new product to be free from defects in material andworkmanship for a period of twelve (12) months after date of delivery to original Purchaser. The obligation of theCompany is limited to repairing or replacing any defective part returned to the Company and will not be responsible forconsequential damages or any further loss by reason of such defect.

The company excludes all implied warranties of merchantability and fitness for a particular purpose. There are nowarranties, express or implied, which extend beyond the description of the goods contained in this contract.

This warranty does not obligate the Company to bear the cost of machine transportation in connection with thereplacement or repair of defective parts, nor does it guarantee repair or replacement of any parts on which unauthorizedrepairs or alterations have been made or for components not manufactured by the Company except to the extent ofthe warranty given by the original Manufacturer.

This warranty does not apply to:

(1) Normal startup services, normal maintenance services or adjustments usually performed by the selling dealer,factory service representative or customer personnel.

(2) Any product manufactured by E. D. Etnyre & Co. purchased or subjected to rental use.

(3) Any product or part thereof which shows improper operation, improper maintenance, abuse, neglect, damage ormodification after shipment from factory.

(4) Any product or part thereof damaged or lost in shipment. Inspection for damage should be made before acceptanceor signing any delivery documents releasing responsibility of the delivering carrier.

This warranty and foregoing obligations are in lieu of all other obligations and liabilities including negligence and allwarranties of merchantability or otherwise, express or implied in fact or by law.

WARNING

Do not use this machine for any operation that isnot described in this manual.

If you have any questions about operation of thismachine, contact the Etnyre Service Departmentat 1-800-995-2116 or 1-815-732-2116.

Operations that are not approved could causeserious injury or death.

WARNING

Diesel engine exhaust and some of its constituentsare known to the State of California to causecancer, birth defects, and other reproductive harm.

Please note this warningand remember:

• Always start and operate the engine in a wellventilated area.

• If in an enclosed area, vent the exhaust to theoutside.

• Do not modify or tamper with the exhaust system.Can cause serious injury or death.

Version 3.9.4

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© Copyright 2008 E.D. Etnyre & Co.All brand names, trademarks and registeredtrademarks are the property of their respectiveowners. Information contained within thisdocument is subject to change without notice. Allrights reserved.

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Table of Contents

Safety InstructionsWarning And Instruction Plates ......................... 5General Safety Instructions .............................. 7Safety Precautions, Hazard Seriousness Level 7WARNINGS ...................................................... 8 Fluoroelastomer Handling .............................. 8Foaming .......................................................... 10Asphalt Institute .............................................. 10Introduction ................................................... 11Reporting Safety Defects ................................ 11Component Location And Identification .......... 12Rear and Side Components............................ 12Spray Bar Components ................................... 13Hydraulic Tank Components ........................... 13Cab Control Panel ........................................... 14Rear Control Panel ......................................... 17Preparing for Operation ............................... 19Setting Up the Computer ................................ 19First Screen ..................................................... 19Second Screen ............................................... 19Third Screen ................................................... 19Fourth Screen ................................................. 20Fifth Screen ..................................................... 20Sixth Screen .................................................... 20Seventh Screen .............................................. 20Eighth Screen ................................................. 20Engaging Pump on PTO Equipped Distributors .... 21Manual Transmissions .................................... 21Automatic Transmissions ................................ 21Spraying Operations ....................................... 22Setting the Digital Memory Presets ................ 23Adjusting the Spray Bar Nozzle Angle ............ 23Adjusting the Spray Bar Height ....................... 23Operation ....................................................... 25Tank Capacity ................................................. 25Operation Screens .......................................... 25First Operating Screen .................................... 25Second Operating Screen............................... 25Third Operating Screen................................... 26Information Messages..................................... 26Loading ........................................................... 28Loading Through the Manhole ........................ 28Loading Through the Load Line Connectionsand Preliminary Checks .................................. 29Check Strainers .............................................. 29Using the Measuring Stick .............................. 29Loading Through the Load Line ...................... 29Circulating in the Tank..................................... 31Circulating Product in the Bar ......................... 33

Spraying (Auto) ............................................... 35Hand Spraying ................................................ 36Bar Suck Back Override.................................. 37Spray Bar Suckback ....................................... 38Flushing Operations ........................................ 40Bar Flush (Auto) .............................................. 40Bar Flush (Manual) ......................................... 41Unload Operations with External Pump .......... 42Unload Operations with Distributor Pump....... 44Transfer Operations ........................................ 46Heating Product in Distributors .................. 48Heating with Liquid Propane Gas (LPG) Burners .. 48LPG Supply Tank Requirements ..................... 48Manual Control Burners .................................. 49Burner Operation ............................................ 49Burners With Outfire Controls ......................... 50Burners with Automatic Ignition and Temperature Limiting Control ........................ 53Burner Operation with Auto Ignition & Temperature Control ..................................... 53Electric Driven Burner Diesel Operation ......... 54Troubleshooting ............................................ 55Maintenance .................................................. 57Electrode Assembly Adjustments .................... 57Burner Air Band Settings................................. 57Check Ignition Transformer Spark .................. 58Fire Burners .................................................... 58Replacing Speed Pickup ................................. 58Servicing the Etnyre P-15 Pump..................... 59Vacuum Check ................................................ 59Impeller Installation And Pump ....................... 59General Fuel Data and Heating Terminology .. 60Fuel Data ........................................................ 60Approximate Burner Fuel Consumption .......... 60Heating Terminology ....................................... 60Hydraulic Fluid Requirements ......................... 61General Information ........................................ 61Hydraulic Fluid Requirements ......................... 61Viscosity & Temperature Requirements .......... 61Contamination Levels ..................................... 62Lubrication Chart ............................................. 64Etnyre Spraybar Nozzles ................................ 65Decimal Equivalent Chart ............................... 66

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List of Illustrations

Figure 1. Location of Warning and Instruction Plates. ................................... 5Figure 2. Rear and Side Component Identification. ..................................... 12Figure 3. Rear Component Identification. .................................................... 12Figure 5. Hydraulic Tank Component Identification. .................................... 13Figure 4. Spray Bar Component Identification. ............................................ 13Figure 6. Cab Control Panel Components. .................................................. 14Figure 7. Rear Control Panel Components. ................................................. 17Preparing for OperationFigure 8. Adjusting the Spray Bar Nozzles. ................................................. 23Figure 9. Adjusting the Spray Bar Height. .................................................... 23OperationFigure 11. Valve Positions for Loading Through the Manhole. .................... 28Figure 12. Using the Measuring Stick. ......................................................... 29Figure 13 Valve Positions for Loading Through the Load Line. ................... 30Figure 14. Valve Positions for Circulating in the Tank. ................................ 31Figure 15. Valve Positions for Circulating in the Bar. ................................... 33Figure 16. Valve Positions for Spraying Through the Bar. ........................... 35Figure 17. Valve Positions for Handspray. ................................................... 36Figure 18. Valve Positions for Spray Bar Suck Back. .................................. 38Figure 19. Valve Positions for Flushing. ...................................................... 40Figure 20. Valve Positions for Unload with External Pump. ........................ 42Figure 21. Valve Positions for Unload withDistributor Pump. ...................... 44Figure 22. Valve Positions for Transfer. ....................................................... 46Figure 23. Manual Control Burner System. ................................................. 49Figure 24. Outfire Controlled Burner System. ............................................. 51Figure 25. Burner System with Auto Ignition and Temperature Control. ..... 53Figure 26. Electric Burner System. .............................................................. 54MaintenanceFigure 27. Burner Electrode Adjustments. ................................................... 57Figure 28. Electrode Assembly Installation .................................................. 57Figure 29. Nozzle Adjustment. ..................................................................... 57Figure 30. Hydraulic Motor. .......................................................................... 58Figure 31. Etnyre Asphalt Pump. ................................................................. 59Figure 32. Fluid Cleanliness Chart. ............................................................. 62Figure 33. Serial Number Plate Location. .................................................... 66

5

20

1

2

45

5

5

67

8

910

11

12

13

14

15

16

17

18

18 19

202122

232425

26

27

2829

3031

3233

3435

1 6320807 1 Decal-Warn, Master Power2 6320808 1 Decal-Warn, Electrical Equipment4 3390696 2 Decal, Blacktopper Centennial5 6320797 3 Plate- Caution, Hot Surface6 3390645 1 Label-Measuring Stick, 1 Flue

3390656 1 Label-Measuring Stick, 2 Flues7 6320272 AR Placard System (Optional)8 6320794 2 Plate- Warning, Manhole9 6320790 1 Decal-Warning, GVWR

10 6320791 1 Decal-Handspray Operation11 3390562 1 Bracket- Mtg, Decal, Hot Surface12 6320800 1 Decal-Diesel Fuel Only13 6320809 1 Decal-Instr, Air Oiler14 6320784 1 Decal-Warning, Personal Protection15 6320802 1 Decal-Warning, Handspray Hose16 6320799 1 Plate- Warning, Burner, General17 6320787 AR Decal- Directions, LPG Burner18 6320785 2 Decal-Warn, 1” Handspray Hose

6320806 2 Decal-Warn, 3/4” Handspray Hose

Warning And Instruction Plates

For operator safety and possibleliability protection, all Safety andInstruction Plates should remainin place and be legible.

Should a plate be removed, lost,or become illegible, reorder andreplace immediately.

If plates become difficult to readbecause of material coating thesurface, clean with solvent.

19 6320804 1 Decal-Warning, No Riders20 6320803 1 Decal-Gate Valve21 6320801 1 Decal-Gate Valve Close22 6320795 1 Decal- Warning, Fill Line Cap23 6320789 1 Decal- Warning, Asphalt Grades24 3390636 1 Decal- Warning, Flues Covered25 6320796 2 Decal- Warning, Before Starting26 6320793 2 Plate- Warning, Manuals27 6320788 1 Decal-Lubrication Chart28 6320792 AR Decal- Directions, Fuel Oil Burners29 6320798 1 Decal- Warning, Safety, General30 6320805 1 Decal- All American31 3390655 1 Plate- Name, Distributor S/N, Brass32 2790530 1 Plate-Name, Spec, 178.34533 6320786 1 Plate-Instr, Hydraulic Oil34 6320796 1 Decal- Warning, Before Starting35 6320793 1 Decal- Warning, Manuals

AR = As required

Ref Part No. Qty Description Ref Part No. Qty Description

Figure 1. Location of Warning and Instruction Plates.

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NOTICE

The handling of Cationic Emulsions (CRS-2, CMS-2, CSS-1 and CSS) maycreate an environment within the Asphalt Distributor that can be corrosive tocarbon steel and cast iron.

• Cationic Emulsions are widely used within the industry.

• Cationic Emulsion is manufactured with asphalt, water, emulsifiers andhydrochloric acid. The chemistry of individual emulsions varies in asphaltcontent and Ph levels.

• Tanks and spray mechanisms used with Cationic emulsions may experiencecorrosion

• It is believed the chemistry of the emulsion - specifically the residual fumespromote the corrosion

• Etnyre Distributors are compatible with Cationic Emulsions provided thatcertain precautions are taken.

• Prior to placing a distributor in to service with Cationic Emulsion, it should beloaded with an AC or MC type material to develop a protective coating.

• Periodic inspection of the tank and spray system should be preformed in thenormal course of operation.

• It is recommended that distributors used in Cationic service be flushedperiodically and at the end of the season with an AC, MC or cutback toremove the corrosive materials and to provide a protective coating.

• Increasing the quantity of flushing material during daily suck back andcleanout operations will also help to minimize corrosion damage.

• Dilution is the solution.

• Additional information can be acquired from your Emulsion supplier as well asthe Asphalt Institute or the Asphalt Emulsion Manufactures Association.

WARNING

Take extra care and follow recommendedprocedures when alternating asphalt materialsespecially when loading hot product, over 212degrees Fahrenheit (100 degrees Celsius), onto a tank and system previously in Emulsionservice.

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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 producttemperature, and these systems use highly combustible fuels. As with any type of construction equipment,there are certain hazards associated with careless or improper operation.

Safety warnings have been provided to call attention to any potentially hazardous situation that may causeproperty damage, personal injury or death to the operator or bystanders. These safety warnings will beshown at various times throughout this manual, as they are applicable to the subject being presented.These safety warnings are identified by the following warning symbols:

Safety Precautions, Hazard Seriousness LevelYou will find safety information boxes throughout this manual. These boxes contain information alerting youto situations or actions to avoid.

Signal words (DANGER, WARNING, and CAUTION) are used to identify levels of hazard seriousness.Their selection is based on the likely consequence of human interaction with a hazard. Definitions of hazardlevels are as follows.

DANGER - Immediate hazards which will result in severe personal injury or death.

WARNING - Hazards or unsafe practices which could result in severe personal injury or death.

CAUTION - Hazards or unsafe practices which could result in minor personal injury or product orproperty damage.

All of these warnings are listed below and they also appear throughout the manual. In addition to these, youwill find notes throughout the manual.

NOTE - A note provides general information that the operator should be aware of when performing anoperation.

General Safety Instructions

DANGER

To avoid an extreme fire hazard or explosion,NEVER use gasoline as fuel in diesel or fueloil burners.

WARNING

A fully charged dry chemical type fireextinguisher must be within easy reachwhenever the burners are operating or thereis an open flame near the Distributor. Theminimum capacity of the fire extinguishershould be 10 pounds.

Please Note This Warningand Remember:

• Always start and operate the engine in awell ventilated area.• If in an enclosed area, vent the exhaust tothe outside.• Do not modify or tamper with the exhaustsystem.

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WARNING

A fully charged dry chemical type fireextinguisher must be within easy reachwhenever the burners are operating or thereis an open flame near the Distributor. Theminimum capacity of the fire extinguishershould be 10 pounds.

Fluoroelastomer HandlingSome O-rings and seals used in this vehicleare made from fluoroelastomers, When usedunder design conditions, fluoroelastomers donot require special handling. However, whenfluoroelastomers are heated to temperaturesbeyond their design temperature (around600º Fahrenheit), decomposition may occurwith the formation of hydrofluoric acid.Hydrofluoric acid can be extremely corrosiveto human tissue if not handled properly.

A degraded seal may appear as a charred orblack sticky mass, Do not touch either theseal or the surrounding equipment withoutwearing neoprene or PVC gloves ifdegradation is suspected. Wash parts andequipment with 10% lime water (calciumhydroxide solution) to neutralize anyhydrofluoric acid.

If contact with the skin occurs, wash theaffected areas immediately with water. Thenrub a 2.5 calcium gluconate gel into the skinuntil there is no further irritation, whileseeking prompt medical attention.

Note to Physicians: For advice or treatmentof HF burns, call the DuPont MedicalEmergency number, 1-800-441-3637.

To prevent an explosion or fire hazard:• Position the unit broadside to the wind to

prevent volatile fumes from drifting towardthe burners.

• Do not operate the burners if the tank isdamaged or leaking.

• Ensure that the burners are extinguishedbefore removing any material from the tankin any manner. Liquid petroleum (LP)burners can support a flame for severalminutes after the fuel supply is turned off.

To prevent an explosion or fire hazard:• Do not operate the burners when the vehicle

is unattended, when the vehicle is inmotion, or with the vehicle in a confinedarea.

• When the burners go out, shut off the fuelsupply to both burners and allow the flues toventilate for at least 3 minutes before re-lighting the burners.

• Do not heat the material beyond themanufacturer’s recommended temperature.

• Keep burning cigarettes or other sources ofcombustion away from manholes andoverflow vents.

• Keep area free of all sources of combustionwhen spraying.

• Check the tank vent to insure that it is freefrom obstruction before lighting the burners.

• Eliminate sparks from engine exhaust.

• Do not operate the burners with themanhole open or open the manhole whilethe burners are in operation.

• Flues must be covered by a minimum 6inches of material (bitumen) when burnersare in operation.

To prevent possible hand or facial burns:• Always light the inside burner first. Do not

reach across a lit burner to light or re-light theinside burner. Shut off the outside burnerbefore lighting the inside burner.

To prevent possible burns:• Always use a torch to light the burners.

Never attempt to light the burners using amatch or pocket lighter.

• Always wear insulated gloves whenhandling spray bar sections or hoses.

• Always wear eye protection, face shield,long sleeve shirt, insulated gloves, boots,and long pants outside the boots whenworking around the Distributor.

• Use extreme caution when using a torch toheat the pump. Asphalt accumulated aroundthe pump may ignite when heating thepump with a torch.

WARNINGS

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WARNINGS

To prevent possible burns from leakingmaterial:• Be sure all pipe, cap and hose connections

are secure before opening valves, orbeginning any operation.

To prevent possible burns from hotasphalt spray:• Do not stand, or allow anyone to stand,

where accidental opening of a valve maycause contact with hot asphalt.

To prevent possible burns from foamingor violent eruption:• Do not load tank with material temperature

over 200ºF if water or condensation ispresent in tank, or if emulsion was used inthe previous load.

• Do not heat material over 200 ºF if moistureor emulsified material is present in tank.

To prevent burns from hot asphalt whenhand spraying:• Hold the handspray gun in proper positionand watch for other people.

To prevent possible burns to operators orbystanders, or possible equipmentdamage:• Do not start any operation if any control

settings are unknown.

To prevent severe injury from becomingentangled in machinery:• Stand clear of rotating drives.

To prevent possible injury:• Always open the manhole cover slowly.

Pressure build up in the tank may causethe cover to burst open.

To prevent possible fire hazards, burns orfalls:• Keep the unit clean for safe operation.

To prevent possible burns from materialoverflow:• Allow sufficient space in the tank for

expansion of the material when heating

• Before removing the fill line cap, makecertain that the asphalt pump is turning andthe tank valve is closed.

WARNING

To prevent possible personal injury:

• Do not load the vehicle beyond the GAWRor GVWR. The maximum load volume mustbe calculated based on material density.

Allowing the burners to operate for a long periodof time without circulating can damage the productand create explosive fumes. If product cannot becirculated after fifteen minutes of heating withoutcirculation, the burners should be extinguished for20 - 30 minutes before re-lighting the burners.

Use the measuring stick as shown in Figure 9 inthe Using the Measuring Stick section to determinethe amount of product in the tank before lightingburners. The minimum amounts shown on thewarning placard only apply if the tank is level.

Remember that the measuring stick is accurateonly when the tank is level. If the tank is not level,reposition the Distributor to place the tank in a levelposition before taking final measurement. You musthave at least the amounts shown, with the tanklevel, in order to safely light the lower burner andupper burner respectively. Failure to have theappropriate amount, accurately measured canresult in an explosion causing death or seriousinjury.

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Foaming

WARNING

To prevent possible burns from foamingor violent eruption:• Do not load tank with material temperature

over 200 ºF if water or condensation ispresent in tank, or if emulsion was used inthe previous load.

• Do not heat material over 200 ºF if moistureor emulsified material is present in tank.

If the Distributor is to be filled with hot bitumen,proceed very cautiously. If there is any moisture inthe tank, or if an emulsion product was the lastload, foaming or eruption may occur.

Dow-Corning DC-200 may be used to preventfoaming in Distributors, Transports, andMaintenance Units.

Mix the contents of one can (16 oz.) with one (1)gallon of diesel fuel or kerosene. Add one (1) oz.of this diluted mixture to each 1000 gallons ofasphalt. The correct amount may be pouredthrough the manhole. This will assist in reducingfoaming, particularly if moisture is present or if anemulsified asphalt was used in a previous load.

If foaming does not occur at the start of the loadingoperation, but you suspect that there may bemoisture in the spray bar or circulating system, theloading operation should be stopped when the tankis no more than 25% full. The product should thenbe circulated through the spray bar at a rate of 80to 100 GPM before continuing the loadingoperation.

If foaming does occur, continue circulating until thefoaming stops, and then suck back the product inthe spray bar back into the tank before filling thetank the rest of the way.

Asphalt InstituteTo further increase awareness of the hazardsassociated with the operation of a bituminousdistributor, and before beginning initial operation,the operator should also receive instruction by anauthorized Etnyre dealer, or Etnyre representative.

The Centennial Distributor is designed to handlea number of different products, such as ACs,cutbacks & emulsions.

Knowledge of these liquid asphalts is required forsafe operation of the Distributor. It is critical to knowwhich product can be loaded after the previousproduct, and which products react with each other.

The Asphalt Institute is a source of asphalt handlingsafety information.

Asphalt InstituteResearch Park DrivePO Box 140052Lexington, KY 40512-4052606-288-4960

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Your Etnyre Blacktopper Centennial Distributor isdesigned to give you many years of accurate,dependable, and economic service. The followinginstructions will enable you to receive the maximumperformance from your Blacktopper CentennialDistributor.

The Blacktopper Centennial Distributor’s controlsare designed for simple operation. They require aminimum of training for proficient usage. Theexclusive Etnyre circulating system is designedand built for handling all grades of bituminousmaterials efficiently.

This manual is provided as a tool to aid personnel inthe operation of the Etnyre Blacktopper CentennialDistributor in a safe and efficient manner. As withany type of construction equipment, there arecertain hazards associated with improper orcareless operation. The ability to read andunderstand the instructions in this manual shouldbe a required qualification to become an operator.There are also functions that require a certainamount of physical strength to accomplish.Persons lacking the required strength may not onlyplace themselves in jeopardy, but also others inthe vicinity.

This manual covers standard features and optionsfor truck mounted units with computerizedcontrollers only. If your unit is equipped with BasicControls, please refer to Operation manual numberM-102-99 or later. If your unit incorporates customfeatures, some of the information contained in thismanual may not apply. If you have any questionsregarding this manual or your unit, contact yourEtnyre dealer or the E. D. Etnyre ServiceDepartment at 1-800-995-2116.

CAUTION

Unusually strong electromagneticinterference could cause the electroniccontrols on this equipment to temporarilymalfunction. Test the effect of two way radiosand similar equipment while operating in asafe area.

Introduction

Reporting Safety DefectsIf you believe that your vehicle has a defect whichcould cause a crash, or could cause injury or death,you should immediately inform the NationalHighway Traffic Safety Administration (NHTSA) inaddition to notifying E. D. Etnyre & Co.

If NHTSA receives similar complaints, it may openan investigation; and, if it finds that a safety defectexists in a group of vehicles, it may order a recalland remedy campaign. However, NHTSA cannotbecome involved in individual problems betweenyou, your dealer, or E. D. Etnyre & Co.

To contact NHTSA, you may either call the AutoSafety Hotline toll free at 1-800-424-9393 (or 336-0123 in the Washington, D.C. area) or write toNHTSA, U.S. Department of Transportation,Washington, DC, 20696. You can also obtain otherinformation about motor vehicle safety from thehotline.

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Component Location And IdentificationRear and Side Components

Figure 2. Rear and Side Component Identification.

Figure 3. Rear Component Identification.

20

Hand Spray Gun

Hydraulic Oil Tank

Hydraulic Oil Filters

LPG Tank (may be on right or left side)Fuel Oil Burner Fuel Tank on right side frame when applicable

Hose Trough

Thermometer Well

Tool Box and Rear Control Panel

Manhole & Platform

Tank Gauge

Exhaust Stacks

Ladder

Burners

Sample Valve

Air Oiler (in right sidetool box)

Suction Valve

Strainer/Valve Box

Asphalt Pump

Transfer Line

Fill Line

Fill Line Strainer

Spray Bar Lift Cylinder

8’ Telescopic barwith Valves and Nozzles

Exhaust Stack Dampers

4 Way ValveRotary Actuator

Suction Screen

Optional Front Tank Valve(not shown)

Rear Tank Valve

Asphalt PumpDrive Motor

Left Spray BarFeed Tube

Right Spray BarFeed Tube

Asphalt Pump Gearbox

Asphalt Pump

Hand Spray Gun

Suck Back Valve

Strainer Box

Master Handspray Valve

Transfer Valve

Transfer Line

Transfer LineSuck Back Valve

ReturnValve

Fill Line

Fill Line Strainer

Flush Valve

Hand Spray Valve

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Spray Bar Components

Hydraulic Tank Components

Figure 4. Spray Bar Component Identification.

Figure 5. Hydraulic Tank Component Identification.

4

1

15

6

7

8

8

9

2

310

4

1. Hydraulic Filter2. Mounting Bracket3. Hydraulic Tank Assembly4. Thermometer5. Fill Cap6. Breather7. Hydraulic Oil Specifications Instruction Plate8. Pipe Plug9. Oil Eye Sight Plug10. Thermo Switch

LeftFolding Wing

RightFolding Wing

Left 8 Ft Section

Right 8 Ft Section

Left Bar Shift Cylinder

Right Bar Shift Cylinder

BreakawaySwivel Joint

BreakawaySwivel Joint

Nozzle

Spray Bar Hanger

Left Wing Tilt Switch

Spray Valve

Air Valves

Right Bar Feed Connection

Left Bar Feed Connection

Wing Fold CylinderWing Fold Cylinder

Lift Cylinder

Lift Cylinder

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Figure 6. Cab Control Panel Components.

Cab Control Panel Descriptions

1. One Foot SwitchesThese switches activate a corresponding foot of

spray bar valves, there are three spray valves perfoot of spray bar. Switch and spray valve number-ing starts from the center of the Distributor and goesoutward in each direction. One Foot switches thatare on a wing, which is raised, do not add to thedisplayed spray width even if they are turned ON.

The activated, switch ON, foot of spray bar willcome on when the SPRAY switch is turned ON.The computer will automatically change the pump-ing rate as spray valves are turned on or off whilespraying to compensate for the number of feetbeing sprayed.

On variable width spray bars the spray valvesassociated with switch 1 are only in the center ofthe Distributor when the spray bar is fully extended.From the fully retracted position, spray valves as-sociated with switch 4 are the first to be turned ON,with switch 4 ON, as the spray bar is extended.One Foot switches that are in the retracted portionof a variable width spray bar do not add to the dis-played spray width even if they are turned ON.

2. MASTER SPRAY SwitchTurning this switch to ON when the Function knob

(rear panel) is turned to BAR CIRCULATE or BARSUCK BACK, opens all activated spray valves. Thespray valves are allowed to open in BAR SUCKBACK for troubleshooting. Turning the SPRAYswitch ON the LOAD/TRANSFER or TANK CIRCU-LATE positions of the Function knob allows the ac-cumulated values to increment for measuring.

3. TANK VALVE SwitchSelects between the standard REAR tank valve

and the optional FRONT tank valve. FRONT shouldalways be selected prior to spraying to eliminate airin the load line. FRONT can then be selected atanytime while spraying.

4. LEFT MARKER VALVE Switch (Optional)

Activates the left side marker valve.

5. RIGHT MARKER VALVE Switch (Optional)

Activates the right side marker valve.

Cab Control Panel

1 2 34 56 7 8

1413121110

17

9

1615

11918

15

6. SHIFT SwitchMoves the entire spray bar left or right. Holding

the switch in either direction moves the spray barcontinuously until the switch is released, or untilfull right or left is obtained.

7. LIFT SwitchThe bar latching position is when the spray bar

is completely centered and raised. Unlatch thespray bar before lowering it. The spray bar mayneed to be raised to allow the bar latching mecha-nism to move. The spray bar cannot be loweredbeyond the height adjuster setting, which is set fora spray height of 12 inches at the factory. Theheight adjusters may be adjusted higher or lowerfor individual preference. Also see the AdjustingSpray Bar Height section.

8. BAR Latch Switch (Optional) The bar latching mechanism will remain in the

desired position even though the switch does not.The spray bar should be latched prior to transportand unlatched prior to lowering for spraying.

9. WING FOLD SwitchesSpray bars have fixed center sections and fold-

ing wings on both sides. Spray bars that have thecorresponding One Foot switches turned ON willincrease the spray width when the wing is loweredand decrease the spray width when raised beyondthe wing tilt switch setting. It is always a good prac-tice to turn OFF the corresponding One Footswitches before raising the wing while spraying.

10. DisplayAll information critical for Distributor operation

is displayed on this two-line LCD. When the sys-tem is turned ON, the installed software version isdisplayed for a few seconds, after which the firstof the operating screens is displayed. Additionalscreens are used for setting up the computer. In-formation messages flash over the entire displayto communicate critical information.

Refer to the Setting up the Computer and Op-eration Screens sections in this manual for moreinformation.

11. WARNING LightIndicates that there is critical information to be

viewed on the Display.

12. MEMORY SwitchesStore and recall up to ten preset application rates

for quick selection. To store the desired applica-tion rate, make the application rate the selectedvalue on the display then press and hold the de-sired Memory button while selecting the desiredapplication rate with the VALUE switch. Each but-ton has a factory preset between 0.050 and 0.500G/SQYD, or the Metric equivalent. Memories 1-5are available when the Memory expander switchis set to 1-5 and similarly, memories 6-10 are avail-able when the Memory expander switch is set to6-10.

13. SELECT SwitchNavigate through the display using the SELECT

switch. The selected position on the screen is iden-tified by the black box. The display reads like abook, right moves right and down while left movesleft and up.

14. VALUE SwitchThe selected value, identified by the black box,

can be changed using this switch. Most values canbe increased or decreased by holding the switchin the desired direction for large changes. The ac-cumulated values on the second operating screencan be reset to zero by first selecting the desiredvalue and then selecting VALUE decrease. Lengthand area reset together when area is selected priorto selecting VALUE decrease.

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15. START ButtonStarts the asphalt pump turning at the target

pump rate, used also for calibration operations inthe setup screens. When the Function knob (rearpanel) is turned to BAR CIRCULATE, the displayedspray width must be greater than zero for the pumpto start turning when the START button is pressed.

16. Power SwitchBoth POWER switches, front and rear, must be

ON for the system to be ON. The entire systemcan be shut down by turning either POWER switchto OFF. Before turning either POWER switch toON be sure you know what will automatically acti-vate.

17. SUCK BACK OVERRIDE SwitchWhen ON, this switch overrides the current set-

ting of the Function knob in the rear panel to theSUCK BACK selection. The SUCK BACK OVER-RIDE must be OFF for the Function knob and thePUMP CONTROL switch to work correctly.

18. LEFT BAR SwitchExtends or retracts the left variable width spray

bar. Holding the switch in either direction moves

the spray bar continuously until the switch is re-leased or until the spray bar is fully extended orretracted. A single press of the switch in either di-rection moves the spray bar 4 inches until it is fullyextend or retracted. If the spray bar, due to shift-ing, does not fully extend or retract, holding theswitch in the desired direction for 5 seconds forcesthe spray bar into position.

19. RIGHT BAR SwitchExtends or retracts the right variable width spray

bar. Holding the switch in either direction movesthe spray bar continuously until the switch is re-leased or until the spray bar is fully extended orretracted. A single press of the switch in either di-rection moves the spray bar 4 inches until it is fullyextend or retracted. If the spray bar, due to shift-ing, does not fully extend or retract, holding theswitch in the desired direction for 5 seconds forcesthe spray bar into position.

Components Not ShownThe following components are not on the Cab

Control Panel but may be mounted below the panelor on the vehicle’s dash. Such as hour meter, mirrorswitch(s), beacon, strobe, PTO light.

17

Rear Control Panel Descriptions

1. PUMP SPEED Control KnobWhen MANUAL PUMP CONTROL is selected,

turning this knob to the right (clockwise) increasesthe asphalt pump speed. It is possible to over-speedthe asphalt pump in MANUAL control since the as-phalt pump speed is also dependent on the enginespeed. Always turn the knob back to the left(counter-clockwise) before selecting AUTO PUMPCONTROL or turning ON either POWER switches(front or rear).

2. PUMP CONTROL SwitchWith the switch turned to AUTO, the asphalt pump

speed is controlled at the desired rate through thecomputer which limits the maximum pump speedto 450 GPM. When the Function knob is set to BARCIRCULATE, the pump speed is limited to a maxi-mum of 120 GPM. With the switch turned toMANUAL, the asphalt pump speed is controlled withthe PUMP SPEED control knob.

In AUTO control, A flashes until the START but-ton is pressed. In MANUAL control, M flashes untilthe START button is pressed. Use Etnyrecomputator (p/n 3390408) when spraying inMANUAL control.

NOTE: Some early units were not wired so thatthe START button must be pressed before the pumpcan turn in MANUAL pump control.

3. START ButtonStarts the asphalt pump turning at the target

Rear Control Panel

Figure 7. Rear Control Panel Components.

pump rate, and also for calibration operations inthe setup screens. When the Function knob isturned to BAR CIRCULATE, the displayed spraywidth must be greater than zero for the pump tostart turning when the START button is pressed.

4. ENGINE HIGH IDLE SwitchWhen this option is available and installed, turn-

ing ON this switch makes the engine run at a higherRPM. Turning OFF the switch resumes the enginespeed to idle. The high idle setting varies but canbe programmed to your preference through yourtruck dealer. This switch is not disabled throughthe POWER switch.

5. Wing Fold SwitchesSpray bars have fixed center sections and folding

wings on both right and left sides. Spray bars thathave the corresponding One Foot switches turnedON will increase the spray width when the wing islowered and decrease the spray width when raisedbeyond the wing tilt switch setting. It is always a goodpractice to turn OFF the corresponding One Footswitches before raising the wing while spraying.

6. LOWER BURNER SwitchWhen an optional fuel oil burner is installed, this

switch directly controls the lower burner unless anoptional thermostatic control or brake interlockswitch is also installed. Then it is possible for theswitch to be ON when the burner is off. Beforeoperating the burner, refer to the Burner Opera-tion section in this manual.

ON

OFF

LATCH

UNLATCH

1 2 3 4 5 6 7

8 14131211 1516 17 18

18

7. UPPER BURNER SwitchWhen an optional fuel oil burner is installed, this

switch directly controls the upper burner unless anoptional thermostatic control or brake interlockswitch is also installed. Then it is possible for theswitch to be ON when the burner is off. Before op-erating the burner, refer to the Burner Operationsection in this manual.

8. FUNCTION knobWhen the desired operation is selected through

this knob, all automatic valves (tank valve, 4-wayvalve, bar suck back valves, and balance valves)are set for the desired operation, and the asphaltpump stops and when the PUMP CONTROL is inAUTO the stored asphalt pump rate target presetfor the desired operation is recalled. Changing theselection after the pump is turning will stop the as-phalt pump in AUTO or MANUAL control. WhenBAR CIRCULATE is selected, the asphalt pumprate target is calculated based on the displayedspray width, application rate, and the setting of the%CIRC factor. For all positions of this switch, ex-cept BAR CIRCULATE, the asphalt pump rate pre-set can be set to operator preference by first se-lecting AUTO PUMP CONTROL. Then beforepressing the START button, change the pump ratetarget to the desired rate and then press the STARTbutton to save the desired rate and start the pumpturning.

The factory pump rate target presets are (WithMetric equivalents also):

• LOAD/TRANSFER 100 GPM• TANK CIRCULATE 150 GPM• BAR SUCK BACK 200 GPM• BAR FLUSH 100 GPM• UNLOAD 100 GPM• HAND SPRAY 50 GPM

NOTE: Some early units were not wired for theasphalt pump to automatically stop turning whenthe FUNCTION knob selection is changed inMANUAL pump control.

11. SHIFT SwitchMoves the entire spray bar left or right. Holding

the switch in either direction moves the spray barcontinuously until the switch is released, or untilfull right or left is obtained.

12. LIFT SwitchThe bar latching position is when the spray bar

is completely centered and raised. Unlatch thespray bar before lowering it. The spray bar mayneed to be raised to allow the bar latching mecha-

nism to move. The spray bar cannot be loweredbeyond the height adjuster setting, which is set fora spray height of 12 inches at the factory. The heightadjusters may be adjusted higher or lower for indi-vidual preference. Also see the Adjusting Spray BarHeight section.

13. BAR Latch Switch (Optional)The bar latching mechanism will remain in the

desired position even though the switch does not.The spray bar should be latched prior to transportand unlatched prior to lowering for spraying.

14. WASH PUMP Switch and LightWhen the optional solvent pump and switch is in-

stalled turning the switch ON will allow use of thesolvent wash wand or application of solvent to thetop of the asphalt pump without the pump turning. Thelight is a reminder that the switch and pump are ON.

15. POWER SwitchBoth POWER switches, front and rear, must be

ON for the system to be ON. The entire system canbe shut down by turning either POWER switch toOFF. Before turning either POWER switch to ON besure you know what will automatically activate.

16. FRONT LOAD Switch (Optional)When the optional front load switch is installed,

selecting Open when in the Load or Transfer posi-tions of the Function knob will open the front loadvalve. The Closed position allows the use of thestandard load line.

17. LEFT BAR SwitchExtends or retracts the left variable width spray


18. RIGHT BAR SwitchExtends or retracts the right variable width spray


19

Note: Always refer to the truck chassis owner’smanual for chassis and engine maintenance in-formation.

The following procedures apply to new or rebuiltunits.

1. Inspect the unit for damage that may have oc-curred during transporting.

2. Check and tighten all fasteners, body tie-downbolts, pipe and circulating line connections, etc.that may have loosened in transit.

3. Check the fluid level in the hydraulic reservoir. Thefluid must always be visible in the sight glass.

WARNING

To prevent possible personal injury, do notload the vehicle beyond the GAWR orGVWR. The maximum load volume must becalculated based on material density.

Setting Up the ComputerBefore the Distributor is used, the control com-

puter has to to be set for each particular Distributor.The setup screens are used to set parameters andperform calibrations for the Distributor that the con-trol computer is installed in. Setup is performed forthe customer at the factory and should not need tobe changed except for when major service or repairis performed on the Distributor.

To enter the set up screens hold Memory 6 and10 buttons down while turning the POWER switch toON. Then release the buttons. To exit the setup, turnthe power OFF. Any changes that are made while inthe setup screens are automatically saved.

The SELECT switch is used to navigate throughthe Setup screens, while the VALUE switch is usedto change the value that is selected. The STARTswitch is used to initiate calibration procedures in theSetup screens. Abbreviated instructions for the cali-bration procedures are displayed for quick recall.

First Screen

This screen allows you to set the display unitsand bar control. VALUE increase from English to

get Metric. VALUE increase from FOOT to getGANG or decrease from FOOT to get VW (vari-able width). Additional setup screens, for the cali-bration of VW spray bars, will become present ifVW is selected for bar control.

Second Screen

This screen allows the setting of the Spray De-lay On and Off times. The Spray Delay On is theamount of time, in seconds, after the Master Sprayswitch is turned on that the spray bar valves willbe turned on. The Spray Delay Off is the amountof time, in seconds, after the Master Spray switchis turned off that the spray bar valves will be turnedoff. These delays allow time for the 4-way valve toturn before open and closing the spray bar. Physi-cal delays within the mechanical controls of thesevalves may have significantly changed and shouldbe addresed before making significant deviationsfrom 0.20 seconds.

Third Screen

This screen allows for selection of the hydraulicmotor speed sensor pulses per revolution. Thecorrect setting is dependent upon displacement.Holding the VALUE switch will not continuously in-crement or decrement the value. Two values arecurrently valid for the motor: 43 for 1.53 cubicinches per revolution (CIR) motor, and 46 for both2.1 and 2.69 CIR motors.

This screen is used to set the flow factor. Theflow factor is the calibration factor for the asphaltpump. Changing the value from 1000 (100%) doesnot change the pump flow but does change thedisplayed pump rate. Values greater than 1000 in-crease the displayed pump rate while values lessthan 1000 decrease the displayed pump rate. Theflow factor increments or decrements by 0.1% andshould only be changed when you are absolutelysure that such a correction needs to be made.

Preparing for Operation

20

Fourth Screen

This screen allows for setting the hydraulic pumpEDC threshold in milliamps. The threshold is theminimum required electrical current for the asphaltpump to turn. The threshold is optimally determinedat a hydraulic pump speed of 1200 RPM. Thresh-old settings lower than actual produce instability inthe pump control while settings higher than actualdo not allow the asphalt pump to be controlled atthe lowest speed possible.

This screen also allows the setting of the StartUp Factor (SUF) Time, in seconds. The SUF Timeis the amount of time that the %SUF parameter, inthe operating screens, adjusts the pump speedimmediately after the SPRAY switch is turned ON.

Fifth Screen

This screen allows for ground speed calibration.The ground speed is calibrated at the factorythrough the proper angle and height settings of theradar. Ground speeds that are displayed when theDistributor is parked are most likely due to enginevibrations through the truck frame or reflections offsurfaces, such as water. Standing water presentwhile spraying may give incorrect ground speeds.The instructions for calibration are abbreviated onthe display.

First mark out a smooth, dry, flat, straight 300foot path. While driving the Distributor at a con-stant speed of approximately 300 FPM pressSTART when a fixed point on the truck crosses thefirst line. Then press the START button again whenthe same fixed point on the truck crosses the sec-ond line. Once the START button is pressed thefirst time, BEGIN on the screen changes to ENDand will change back to BEGIN when pressed thesecond time.

Sixth Screen

This screen provides the ability to reset param-eters in the computer back to their default values.You should record all of your settings before pro-ceeding. Resetting the parameters will clear allchanges to the setup and operating parametersand including all calibrations.

Seventh Screen

This screen allows for calibration of the left VWspray bar. The instructions for calibration are ab-breviated on the display. Press START, extend theleft spray bar completely, and retract the left spraybar completely. The feedback number on the dis-play should increase as the spray bar extends anddecreases as the spray bar retracts. When fullyextended the feedback value should be 99 or 100,after which the fully retracted value should be 0.Recalibration from the factory calibration shouldnot be required except when the smart cylinder orwiring to the smart cylinder has been replaced.

Eighth Screen

This screen allows for calibration of the right VWspray bar on. The instructions for calibration areabbreviated on the display. Press START, extendthe right spray bar completely, and retract the rightspray bar completely. The feedback number on thedisplay should increase as the spray bar extendsand decreases as the spray bar retracts. When fullyextended the feedback value should be 99 or 100,after which the fully retracted value should be 0.Recalibration from the factory calibration shouldnot be required except when the smart cylinder orwiring to the smart cylinder has been replaced.

21

Engaging Pump on PTOEquipped Distributors

Start the truck engine. Then, follow one of theprocedures below.

Ensure that the truck parking brake is engagedbefore leaving the cab.

Manual TransmissionsDepress the clutch and pull outward or upward

on the PTO control knob. Slowly let the clutch up.If the PTO fails to engage, depress the clutch pedaland pull up on the PTO handle until engagementoccurs. Or, depress the electric air shift PTO switchif your vehicle is so equipped. Increase the enginerpm to a fast idle.

Automatic TransmissionsPush down on the foot brake pedal, move the

gear selector to any forward gear and do one ofthe following.

• Pull upward or outward on the PTO control knob.

• Press the switch activated PTO switch.

• Press the electric air shift PTO switch if your ve-hicle is so equipped. When the PTO engages,move the gear selector to neutral. If the PTOfails to engage, release the brake pedal slightlywhile pressing the PTO switch, allowing the truckto inch forward until the PTO engages. Thenmove the gear selector back to neutral.

WARNING

To prevent an explosion or fire hazard, do not

heat the material beyond the manufacturer’s

recommended temperature.

WARNING

To prevent possible burns to operators orbystanders, or possible equipment damage,do not start any operation if any controlsettings are unknown.

WARNING

To prevent severe injury from becomingentangled in machinery, stand clear ofrotating drives.

CAUTION

To prevent possible damage to equipmentfrom material setting up in hose orDistributor, ensure that bitumen in supplytank is heated sufficiently.

22

WARNING

To prevent an explosion or fire hazard, do notheat the material beyond the manufacturer’srecommended temperature.

WARNING

To prevent an explosion or fire hazard, keepburning cigarettes or other sources ofcombustion away from manholes andoverflow vents.

WARNING

To prevent possible hand or facial burns,always light the inside burner first. Do notreach across a lit burner to light or re-lightthe inside burner. Shut off the outside burnerbefore lighting the inside burner.

WARNING

To prevent possible burns from materialoverflow, allow sufficient space in the tank forexpansion of the material when heating.

WARNING


WARNING

To prevent possible burns from leakingmaterial, be sure all pipe, cap and hoseconnections are secure before openingvalves.

WARNING

To prevent possible burns from hot asphaltspray, do not stand, or allow anyone tostand, where accidental opening of a valvemay cause contact with hot asphalt.

Spraying OperationsA correct spray pattern cannot be obtained unlessthe product is heated to its proper sprayingtemperature. Cold product will not provide sharpspray edges, and will cause streaking. If heatingof the product is required, refer to the section ofthis manual on Heating Product in Distributors forinstruction on operation of your particular type ofburners.

The computer automatically adjusts the asphalt pumpspeed to deliver the correct amount of asphalt for theapplication rate, spray width and vehicle speed. Thecirculation rate in the bar when not spraying shouldbe set to 50% of the pump speed while spraying.This circulation rate will allow the asphalt pump toreach the desired speed quickly when spraying isstarted. Circulation rates higher than 50% will resultin a heavier start while rates below 50% will producea lighter start.

Spray bar nozzles have a limited flow range atwhich optimal performance will be achieved. Flowrates greater than this optimal range will causeexcessive overspray. Rates that are too low willcause the fan to sag and cause heavy edges. Referto the nozzle selection chart in the operator’smanual to select the nozzles appropriate for yourconditions.

WARNING

To prevent an explosion or fire hazard,ensure that the burners are extinguishedbefore removing any material from the tank inany manner. Liquid petroleum (LP) burnerscan support a flame for several minutes afterthe fuel supply is turned off.

WARNING

To prevent an explosion, do not operate theburners when the vehicle is unattended,when the vehicle is in motion, or with thevehicle in a confined area.

WARNING

To prevent an explosion or fire hazard, whenthe burners go out, shut off the fuel supply toboth burners and allow the flues to ventilatefor at least 3 minutes before re-lighting theburners.

23

Setting the Digital Memory PresetsSetting the digital memory presets is not required

to spray. The memory buttons offer the operator aconvenient way to store different preset applica-tion rates. These settings are saved in the memoryeven after the power switch has been shut off.

To store an application rate in a memory loca-tion, select GAL/SQ YD in the digital display usingthe SELECT switch.

To set a memory, push that preset button in andhold it. While holding it in, set the application rateto the desired value using the VALUE switch. Toraise the application rate hold the VALUE switchup and to lower the application rate, hold theVALUE switch down. When you have the applica-tion rate set to the desired value, release thememory button. The displayed application rate willbe stored in that memory location until it is over-written with a new application rate using the sameprocedure.

Adjusting the Spray Bar NozzleAngle

Adjust the nozzles to obtain an angle of approxi-mately 30 degrees with the spraybar center line.Every nozzle should be at the same angle. A nozzleadjustment wrench is supplied with each new unit.

Figure 8. Adjusting the Spray Bar Nozzles.

Figure 9. Adjusting the Spray Bar Height.

Adjusting the Spray Bar HeightLower the spraybar and adjust the height ad-

justers so that the nozzles are approximately 12inches above the road, on the main bar with bothwings folded, when the tank is empty. At this height,the spray fans from the nozzles will overlap to pro-vide triple lap coverage of material on the ground.This is the normal spraying height. Lower the wingsand adjust them with the cylinder nuts to follow thecrown of the road.

Spraying through the BarA tack coat selector valve on the air oiler as-

sembly allows you to select between truck pres-sure and 20 psi. The lower regulator should be setto 20 psi. When Tack Coat is selected, the top sideof every other spray valve has truck pressure ap-plied, which overcomes the truck pressure appliedto the underside of the spray valve because of thedifference in areas and the additional spring on thetop side. In Normal Spray, all spray valves have20 psi on the top side. Be sure that this valve isselected correctly before continuing.

Figure 10. Selector Valve set to Normal Spraying.

If you are stopped and shut the spray bar off,the computer will shut the spray bar off within afew seconds so that asphalt doesn’t puddle, butyou will not get a straight line.

24

Section Notes

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25

Tank CapacityThe Centennial Distributor is designed to pump

and spray a variety of asphalt products in an effi-cient and user friendly manner with great accuracy.The Centennial Distributor utilizes a computer tosense the vehicle’s ground speed and control thehydrostatically driven asphalt pump to maintain theset application rate, regardless of variations in ve-hicle speed or spray bar width in use.

For a complete description of each of the con-trols and how to set up the machine, refer to thePreparing for Operation section of this manual.

WARNING

To prevent possible personal injury, do notload the vehicle beyond the GAWR orGVWR. The maximum load volume must becalculated based on material density.

The Centennial Distributor tank has a built-in airspace, or expansion space, above the Tank Fulllevel. This air space is designed to minimize thechance that the tank will overflow if the material inthe tank expands due to heating or foaming. Thisair space should not be used to carry product. TheTank Full level is based on the vehicle’s axle rat-ings, and, GVWR at a material density of 7.7 lbs/gallon. A lower tank full must be calculated if a prod-uct with a density greater than 7.7 lbs/gallon is tobe loaded. The lower tank full is calculated bymultiplying the original tank full by 7.7 and dividingthe result by the new heavier product density.

If you suspect there may be moisture or emul-sion in the tank, Dow-Corning¨ DC-200 additive canbe used to reduce foaming if a product beingpumped is at a temperature in excess of 200 ºF.Additional DC-200 additive may be obtained fromE. D. Etnyre & Co. or your Etnyre dealer.

Operation ScreensThe following screens on the Cab Control Panel

are used during normal operation. Use the SELECTswitch to scroll through the values and screens andthe VALUE switch to increase or decrease the se-lected value, when appropriate.

When the system is turned ON the installed soft-ware version is displayed for a few seconds, afterwhich the first operating screen is displayed.

First Operating Screen

The first operating screen displays ground speed,spray width, asphalt pump speed, and applicationrate. The application rate is automatically the firstselected value and is identified as the selected valuewith the black box. A or M will also flash in front ofthe pump rate. When PUMP CONTROL is in AUTO,A will stop flashing after pushing the START but-ton. When PUMP CONTROL is in MANUAL, M willstop flashing after pushing the START button. Spraywidth is only selectable in gang bar control. Groundspeed is never selectable and the pump speed isnot selectable in manual pump control, bar circu-late, or when spraying.

Second Operating Screen

The second operating screen displays thesquare yards, gallons sprayed and distance in feettraveled as well as the asphalt tank temperature.The accumulated values can be used for record-ing shots or the area and distance can be used fordry measuring. The accumulated values will ex-ceed the displayed values after 999,999. The tem-perature is displayed as 999 when the RTD is notconnected to the computer.

Operation

26

Third Operating Screen

The third operating screen allows for quick setup of the start-up factor, bar circulation rate factor,and minimum pump speed. This screen is not view-able when the PUMP CONTROL is in MANUAL.The start up factor changes the pump speed forthe first half-second of spraying. 100 %SUF makesno change. Higher start-up factors increase thepump speed while lower start up factors decreasethe pump speed. In BAR CIRCULATE, the asphaltpump rate target is calculated based on the dis-played spray width, application rate, and the set-ting of the %CIRC factor. A setting of 50% is rec-ommended and is equivalent to half the pumpspeed required when traveling at a speed of 150FPM while spraying. The minimum pump speed isused in bar circulate and spray. In either opera-tion, when all of the One Foot switches are turnedOFF, the minimum pump speed is not used andthe pump speed goes to zero.

Information MessagesMessages will be displayed only in the main

operating screens and will alternate or flash be-tween the message and the current operatingscreen. If more than one message is active, eachof the active messages will be sent to the displaybefore an individual message is repeated to thedisplay.

Additional messages will become present if VWis selected for bar control in the setup screens. VWbar control should not be selected for units withFOOT bar control.

Application Pump

These messages will only appear in the spray-ing operation. The over application message indi-cates that the ground speed is too slow and/or pos-sibly the engine speed is too fast, while the underapplication message indicates that the groundspeed is too fast and/or possibly the engine speedis too slow.

Hot Hydraulics

This message flashes on the display when thehydraulic reservoir temperature reaches or ex-ceeds 200 ºF.

WARNING

Stop immediately and determine the cause ofthe high temperature. Failure to do so willresult in damage to hydraulic components.

27

Switch Module

This message flashes on the display when theinput module in the cab control box is not presenton the CAN bus. There are several reasons whythe module might not be recognized on the CANbus. It may be unplugged from the CAN bus orelectrical power or may be damaged.

Hydraulic Pump

This message flashes on the display after theSTART switch has been selected in AUTO pumpcontrol if the EDC is disconnected from the com-puter or is electrically shorted.

Motor Feedback

This message flashes on the display after theSTART switch has been selected in AUTO pumpcontrol if the asphalt pump speed remains or be-comes zero for too long. This may mean that thespeed sensor is not set correctly, faulty, damagedor is disconnected from the computer.

Low Level

This message flashes on the display when inbar circulate or spray and the asphalt tank mate-rial level reaches the low level.

Radar Calibration

This message flashes on the display after groundspeed calibration when the radar is either not con-nected to the computer or produces a signal thatis out of the acceptable range.

Left Module

This message flashes on the display when VWcontrol is selected and the left module by the rearcontrol box is not present on the CAN bus. Thereare several reasons why the module might not berecognized on the CAN bus. It may be unpluggedfrom the CAN bus or electrical power or may bedamaged.

Right Module

This message flashes on the display when VWcontrol is selected and the right module by the rearcontrol box is not present on the CAN bus. Thereare several reasons why the module might not berecognized on the CAN bus. It may be unpluggedfrom the CAN bus or electrical power or may bedamaged.

Left Smart Cylinder

This message flashes on the display when VWcontrol is selected and the feedback from the leftsmart cylinder is out of the acceptable range orhas been calibrated incorrectly. There are severalreasons why the feedback may be out of the ac-ceptable range. It may be unplugged from the com-puter or electrical power or may be damaged.

Right Smart Cylinder

This message flashes on the display when VWcontrol is selected and the feedback from the rightsmart cylinder is out of the acceptable range orhas been calibrated incorrectly. There are severalreasons why the feedback may be out of the ac-ceptable range. It may be unplugged from the com-puter or electrical power or may be damaged.

28

Loading

Loading Through the ManholeTo reduce the risk of accidental discharge of as-

phalt, the asphalt pump should not be running, the4 way valve should be in tank circulate, all tankvalves should be closed, and both the load andtransfer line caps should be on and secured. whenloading through the manhole.

WARNING

To prevent possible injury, always open themanhole cover slowly. Pressure build up inthe tank may cause the cover to burst open.

Figure 11. Valve Positions for Loading Through the Manhole.

Refer to Figure 11 for the following procedures.

1. Park the Distributor in the desired location forloading overhead through the manhole.

2. Set the truck parking brake and turn off engine.

3. Before exiting the cab, turn the POWER switchOFF.

4. When the desired amount of product is in thetank and the supply tank valve is closed, closethe manhole lid and properly secure before mov-ing the Distributor

WARNING

To prevent possible burns from foaming orviolent eruption: Do not load tank with materialtemperature over 200 ºF if water or condensationis present in tank, or if emulsion was used in theprevious load. Do not heat material over 200 ºF ifmoisture or emulsion is present in tank.

Return Valve Open

SUCK BACK

OFF

HAND SPRAY

Hand Spray Valve Positions

Hand Spray ValveClosed

4 Way ValveCirculate In Tank

Tank ValveClosed

MasterHandspray ValveOff

Transfer ValveClosed

Transfer Line Suck Back Valve Closed

Flush ValveClosed

Suck Back Valve Closed

Transfer Line cap on and secured

Load Line cap on and secured

29

Loading Through the Load LineConnections and PreliminaryChecks

WARNING

To prevent possible burns from leakingmaterial, be sure all pipe, cap and hoseconnections are secure before openingvalves or beginning any operation.

WARNING


WARNING

To prevent an explosion or fire hazard, keepburning cigarettes or other sources of combustionaway from manholes and overflow vents.

WARNING

To prevent burns, always wear eyeprotection, long sleeve shirt, insulatedgloves, boots, and long pants outside theboots when working around the Distributor.

Check StrainersBefore removing the load line cap or strainer

access cover perform the suck back operation toensure that there is not material in the strainer box.Finally ensure that the tank valve(s) are closed andthe POWER switches are OFF before removingthe load line cap and stainer access cover.

Ensure that both the fill line and the suctionstrainers are clean and properly installed.

Ensure that all connections on the Distributorare tight to prevent asphalt leaks. Do not pressur-ize the fill line with an external pump.

WARNING

Before removing the fill line cap, makecertain that the asphalt pump is turning andthe suction valve is closed.

Using the Measuring Stick

The measuring stick is only accurate when thetank is level.

Figure 12. Using the Measuring Stick.

Loading Through the Load Line

WARNING

To prevent possible burns from foaming orviolent eruption: Do not load tank with materialtemperature over 200 ºF if water or condensationis present in tank, or if emulsion was used in theprevious load. Do not heat material over 200 ºF ifmoisture or emulsion is present in tank.


1. Park the Distributor in the desired location forloading through the fill line.

2. Set the truck parking brake.

3. The engine must be running and the optionaltransmission PTO must be engaged.

4. Before continuing further, the PUMP SPEEDknob, at the rear panel, must be turned to zero(full counter clockwise) so that the pump doesnot start turning when the POWER switch isturned ON.

5. On the cab control panel, turn the POWERswitch ON.

00

100

30

At the rear of the distributor:Set or confirm the following: • Tank valve closed • Return valve open • Bar suck back valve(s) closed • Master hand spray valve closed • Transfer line suck back valve closed • Transfer line valve closed • Flush valve closed • Load and transfer line caps are in place and se-

cured.

At the rear of control panel:1. Turn the Function knob to the LOAD/ TRANS-

FER position.

2. Turn the POWER switch ON. Both the front andrear power switches must be ON to operate.

3. Turn the PUMP CONTROL switch to MANUAL.

4. Press START. Turn the PUMP SPEED knob sothe asphalt pump turns slowly.

5. Remove the load line cap.6. Connect the load line to the supply tank through

an asphalt hose.7. Open the tank valve on the supply tank.8. Decrease the PUMP SPEED to zero.9. Turn the PUMP CONTROL switch to AUTO.10. Press START. The pump will start turning at

the desired loading rate.

Figure 13 Valve Positions for Loading Through the Load Line.

11. When the desired amount of product is in theDistributor tank, close the supply tank valve.

12. At the supply tank, carefully open the bleedervalve or break the hose connection until astrong vacuum is heard. It may be necessaryto reduce the pump speed in order to overcomepump vacuum when breaking the hose con-nection. Elevating the hose above the load lineconnection will allow maximum drainage of thehose.

13. Disconnect the hose from the load line.

14. Replace the load line cap and secure.

15. If no other operation will be performed, it maybe necessary to flush the pump before stop-ping the pump in the next step. Otherwise goto the instructions for the desired operation.

16. To stop the pump in MANUAL control selectAUTO control. To stop the pump in AUTO con-trol, with the PUMP SPEED knob fully counterclockwise select MANUAL control.

NOTE: The pump can be stopped and the auto-matic tank valve can be closed immediately at anytime during operation by turning the POWER switchOFF. Before turning the POWER switch back ON,turn the PUMP SPEED knob to zero to prevent thepump from turning.

A pump rate of 100 GPM is recommended tobegin the loading operation. The pump rate canbe increased at any time after loading has begun.

Suck Back

OffHand Spray


Hand Spray Valve

Closed

Tank ValveClosed


Flush ValveClosed

Suck Back ValveClosed


Return Valve Open




Do not remove Load Line cap iffront or rear tank valve is open

31

Depending on material viscosity, as the loadingrate is increased, the asphalt pump may cavitate.When this happens, the pump will make a distinc-tive sound, easily recognized with experience.Short periods of operation while the pump is cavi-tating will not damage the pump but you shouldnot operate the pump in this condition for extendedperiods.

Higher pump speeds will not load thicker mate-rials faster. Lighter materials, or heavy materialswhich are already at spraying temperature, maybe loaded at faster rates.

WARNING


WARNING

To prevent an explosion or fire hazard, keepburning cigarettes or other sources ofcombustion away from manholes andoverflow vents.

WARNING

To prevent burns, always wear insulatedgloves when handling spray bar sections orhoses.

Circulating in the TankIf the product is too cold to be circulated, someheating with the burners will be needed to increasethe temperature enough to be able to start circulat-ing. Refer to the portion of this operating manual forinstructions on your particular type of burner.


1. If heating, park the Distributor broadside to the wind.





At the rear of the distributor:Set or confirm the following:

• Return valve open• Bar suck back valve(s) closed• Master hand spray valve closed• Transfer line suck back valve closed• Transfer line valve closed• Flush valve closed• Load and transfer line caps are in place and secured.

Figure 14. Valve Positions for Circulating in the Tank.




Suck Back

Off

Hand Spray


4 Way ValveCirculate in Tank

TankValveOpen



Flush ValveClosed

Hand Spray Valve

Closed


Return Valve Open

32

At the rear control panel:1. Turn the Function knob to TANK CIRCULATE.

(Optional manual tank valve should be opened.)

2. Turn the POWER switch ON.

3. Put the PUMP CONTROL to AUTO.

4. Press START. The pump will start turning at thedesired circulation rate.

5. If no other operation will be performed, go tothe next step. Otherwise go to the instructionsfor the desired operation.

6. The optional manual tank valve should be closedat this time before stopping the pump.

7. To stop the pump in MANUAL control selectAUTO control. To stop the pump in AUTO con-trol, with the PUMP SPEED knob fully counterclockwise select MANUAL control.

8. Flush the pump if necessary before quitting.

NOTE: The pump can be stopped and the au-tomatic tank valve can be closed immediately atany time during operation by turning the POWERswitch OFF. Before turning the POWER switchback ON, turn the PUMP SPEED to zero to pre-vent the pump from turning.

WARNING

To prevent possible burns, use extremecaution when using a torch to heat the pump.Asphalt accumulated around the pump mayignite when heating the pump with a torch.

WARNING

To prevent an explosion or fire hazard, whenthe burners go out, shut off the fuel supply toboth burners and allow the flues to ventilatefor at least 3 minutes before re-lighting theburners.

WARNING

To prevent an explosion, do not operate theburners when the vehicle is unattended,when the vehicle is in motion, or with thevehicle in a confined area.

WARNING


33

Circulating Product in the BarRefer to Figure 15 for the following procedures.

1. If heating, park the Distributor broadside to thewind.




5. Turn the SPRAY switch OFF.

6. Set the application rate with a MEMORY switchor by using the SELECT and VALUE switches.

7. Set the desired spray width with the One Footswitches. The spray bar should always bewarmed before moving it in order obtain the de-sired spray width. Lowering the wings allow forincreased spray width selections.

8. Turn the POWER switch ON in the cab panel.

Figure 15. Valve Positions for Circulating in the Bar.


• Return valve open

• Bar suck back valve(s) closed

• Master hand spray valve closed

• Transfer line suck back valve closed

• Transfer line valve closed

• Flush valve closed

• Load and transfer line caps are in place andsecured.

At the rear control panel:1. Turn the Function knob to BAR CIRCULATE.

(Optional manual tank valve should be opened.)




5. If no other operation will be performed, go to thenext step. Otherwise go to the instructions forthe desired operation.

Suck Back

OffHand Spray


Flush Valve Closed

4 Way ValveCirculate in Bar

Return Valve Open

Tank ValveOpen




Hand Spray Valve Closed




34

WARNING

To prevent an explosion or fire hazard,ensure that the burners are extinguishedbefore removing any material from the tank inany manner. Liquid petroleum (LP) burnerscan support a flame for several minutes afterthe fuel supply is turned off.

CAUTION

To prevent excessive pressure in the spraybar, the asphalt pump speed should noexceed 160 GPM while circulating in thespray bar.

NOTE: The pump can be stopped and the auto-matic tank valve can be closed immediately at anytime during operation by turning the POWER switchOFF. Before turning the POWER switch back ON,turn the PUMP SPEED to zero to prevent the pumpfrom turning.

Circulate product long enough to ensure removalof all air from the bar and to heat the spray barvalves sufficiently. For better material circulation,in the bar ends, the wings should be lowered. Be-fore moving the bar, circulate some hot materialthrough the bar. This allows the bar to warm up andalso extends the life of the bar seals and o-rings.

35

Spraying (Auto)Refer to Figure 16 for valve positions.

1. Complete the procedure for circulating in thespray bar. See the Circulating Product in the Barsection of this manual.

2. Unlatch the spray bar.

3. Lower the spray bar to the desired spray height.

4. Set the desired spray width using the One Footswitches and configuring the spray bar to thedesired width with the wings. Extend or retractthe right and left spray bars as needed.

5. Select the transmission gear and rear axle speedthat produces the desired engine and groundspeed for spraying.

6. Release the parking brake and start the Dis-tributor moving.

7. When the spray bar reaches the beginning ofthe shot, turn the SPRAY switch ON.

Figure 16. Valve Positions for Spraying Through the Bar.

8. When the spray bar reaches the end of the shotturn the SPRAY switch OFF.

9. Continue spraying by turning ON and OFF theSPRAY switch as desired. When finished, fol-low the instructions for bar suck back. See theSpray Bar Suck Back section.

WARNING

Do not run the pump above rated capacity of400 GPM. Damage to equipment may occur.

WARNING

To prevent an explosion or fire hazard, do notoperate the burners while spraying.

Suck Back

OffHand Spray


4 Way ValveSpray

Tank ValveOpen




Flush ValveClosed


Return ValveOpen




36

Hand SprayingRefer to Figure 17 for the following procedure.

WARNING

To prevent burns from hot asphalt when

handspraying, hold the handspray gun inproper position and watch for other people.

WARNING

To prevent burns, always wear eyeprotection, long sleeve shirt, insulatedgloves, boots, and long pants outside theboots when working around the Distributor.




4. On the cab control panel, turn the POWER switchON.

Figure 17. Valve Positions for Handspray.








• Load and transfer line caps are in place and se-cured.

At the rear control panel:1. Turn the Function knob to HAND SPRAY. (Op-

tional manual tank valve should be open)



4. Press START. The pump will start turning at thedesired rate.

5. Move the master hand spray valve into the handspray position.

6. Open the hand spray valve on the hand spraywand.

7. Gradually turn the return valve handle clockwiseto increase hand spray pressure. The usefulrange for hand spraying is typically between an

Suck Back

Off Hand Spray


Tank ValveOpen


MasterHandspray ValveHandspray


Flush ValveClosed

4 Way ValveCirculate in TankReturn Valve

Partially Open

Adjust pressure by open/close Return Valve. Do not close completely. If more pressure is desired increase GPM before Return Valve is completely closed.

Hand Spray ValveOpen




37

inch and a half inch of exposed valve stem (areabetween stem extension coupling and valvebody). When the desired application cannot beobtained with the minimum exposed valve stem,repeat the adjustment after first opening the re-turn valve and then increasing the pump speed.

8. Continue hand spraying by opening and closingthe hand spray valve on the wand as needed.

9. When finished, with the hand spray valve on thewand closed, open the return valve.

10.Turn the Function knob to BAR SUCK BACK.(Optional manual tank valve should be closed)

11.Press START. The pump will start turning atthe desired rate, 200 GPM is recommended.

12. Move the master hand spray valve into the suckback position.

13.Open the hand spray valve on the hand spraywand until a strong vacuum is heard and thenclose the valve.

14. If no other operation will be performed, go tothe next step. Otherwise go to the instructionsfor the desired operation.

15.To stop the pump in MANUAL control selectAUTO control. To stop the pump in AUTO con-trol with the PUMP SPEED knob fully counterclockwise select MANUAL control.

16.Flush the pump if necessary before quitting.


WARNING


For asphalts like AC it is recommended that thisprocedure be repeated a second time, after whichadding solvent such as diesel fuel through thenozzles of the hand spray wand will quickly flushthe hand spray wand and hose.

If not equipped with the electric pump, it is help-ful to pour some diesel fuel down the fill line afterall operations are completed. The diesel fuel will

Bar Suck Back Override

This optional feature is designed for quick in-cabswitching between bar circulate and bar suck backfor units equipped with automatic tank and bar suckback valves. When the BAR SUCK BACKOVERRIDE switch is ON, all automaticallycontrolled valves are set to their correct positionsfor BAR SUCK BACK. This overrides any settingsof the Function knob and can also stop the asphaltpump.

The following steps performed in the cab while theFunction knob is turned to BAR CIRCULATE.

1. Turn the BAR SUCK BACK OVERRIDE switchON.

2. Press START. The pump will start turning at thedesired rate. 200 GPM is recommended.

3. If complete bar suck back is desired, follow theinstructions for bar suck back, beginning withthe opening of the left bleeder valve. Otherwisecontinue to the next step.

4. Turn the BAR SUCK BACK OVERRIDE switchOFF.


Note: The pump can be stopped and the automatictank valve can be closed immediately at any timeduring operation by turning the POWER switchOFF. Before turning the POWER switch back ON,turn the PUMP SPEED to zero to prevent the pumpfrom turning.

remain in the pump overnight to keep the pumpfree for the next morning’s operation.

Ensure that the self flush valve is closed at theend of this function, or before loading or circulat-ing asphalt to eliminate chances of inducing as-phalt into the self flush fuel tank.

CAUTION

When using rear pump control, engine RPMchanges will affect asphalt pump speed.

38

Spray Bar SuckbackRefer to Figure 18 for the following procedures.

1. Park the Distributor and set the truck parking brake.


3. Before continuing further, the PUMP SPEED knob,at the rear pabel, must be turned to zero (full counterclockwise) so that the pump does not start turningwhen the POWER switch is turned ON.



• Tank valve closed







At the rear control panel:1. Turn the Function knob to BAR SUCK BACK.

(Optional manual tank valve should be closedand the optional manual bar suck back valve(s)should be open.)



4. Press START. The pump will start turning at thedesired rate. 200 GPM is recommended.

5. Open the bleeder valve on the left wing until astrong vacuum is heard and then close valve.

6. Open the bleeder valve on the right wing untilstrong vacuum is heard and then close valve.


8. Close the optional manual bar suck back valve.

9. To stop the pump in MANUAL control selectAUTO control. To stop the pump in AUTO con-trol with the PUMP SPEED knob fully counterclockwise select MANUAL control.


Figure 18. Valve Positions for Spray Bar Suck Back.

Suck Back

OffHand Spray


Tank ValveClosed

Suck Back ValveOpen

MasterHandspray Valve Off

Transfer Valve Closed


Flush ValveClosed


Return ValveOpen

BleederValve


Transfer line cap on and secured

Load line cap on and secured

39


WARNING


For asphalts like AC it is recommended that thisprocedure be repeated a second time, after whichadding solvent such as diesel fuel through eachbleeder will quickly flush the spray bar.

If not equipped with the electric pump, it is help-ful to pour some diesel fuel down the fill line afterall operations are completed. The diesel fuel willremain in the pump overnight to keep the pumpfree for the next morning’s operation.

Ensure that the self flush valve is closed at theend of this function, or before loading or circulat-ing asphalt to eliminate chances of inducing as-phalt into the self flush fuel tank.

40

Flushing OperationsNormally the suckback procedure will remove

sufficient material from the circulating system tonegate the need for draining the circulating sys-tem and spray bar before proceeding with the washout operation. The flushing operation requires onlythree quarts of flushing solvent. This small amountis not sufficient to fill the lines to the tank, thus pre-venting solvent from being forced into the tank.

A common practice following completion of theflushing procedure and subsequent shutdown isto pour one to two quarts of solvent into the fill line.This softens or dissolves the residual asphalt inthe pump. Allow these solvents to remain in thesystem until the next use.

Figure 19. Valve Positions for Flushing.

Bar Flush (Auto)Refer to Figure 19 for the following procedures.

1. Park the Distributor and set the truck parkingbrake.




At the rear of the distributor:Set or confirm the following:• Tank valve closed• Bar suck back valve(s) closed• Return valve open• Master hand spray valve closed• Transfer line suck back valve closed• Transfer line valve closed• Load and transfer line caps are in place and secured.

Suck Back

OffHandSpray


Tank ValveClosed


Master Handspray ValveOff



Flush ValveOpen

4 Way ValveCirculate in Bar

Return ValveOpen


Transfer line cap on and secured

Load line cap on and secured

41

At the rear control panel:1. Turn the Function knob to BAR FLUSH.2. Turn the POWER switch ON.3. Put the PUMP CONTROL to AUTO.4. Press START. The pump will start turning at the

desired circulation rate.5. Open the flush valve for 2 minutes.6. Close the flush valve.7. If no other operation will be performed, go to the

next step. Otherwise go to the instructions forthe desired operation.


NOTE: The pump can be stopped and theautomatic tank valve can be closed immediatelyat any time during operation by turning the POWERswitch OFF. Before turning the POWER switchback ON, turn the PUMP SPEED to zero to preventthe pump from turning.

Bar Flush (Manual)Refer to Figure 14 for the following procedures.1. Park the Distributor and set the truck parking

brake.2. The engine must be running and the optional

transmission PTO must be engaged.3. Before continuing further, the PUMP SPEED

knob, at the rear panel, must be turned to zero(full counter clockwise) so that the pump doesnot start turning when the POWER switch isturned ON.


At the rear of the distributor:Set or confirm the following:• Tank valve closed• Return valve open• Master hand spray valve closed• Transfer line suck back valve closed• Transfer line valve closed• Flush valve closed• Load and transfer line caps are in place and secured.

At the rear control panel:1. Turn the Function knob to BAR SUCK BACK.2. Turn the POWER switch ON.3. Put the PUMP CONTROL to AUTO.4. Press START. The pump will start turning at the

desired rate. 200 GPM is recommended.5. Open the bleeder valve on the left wing. After a

strong a vacuum is heard, add 1 quart of solventthrough the valve and then close the valve.

6. Open the bleeder valve on the right wing. After astrong a vacuum is heard, add 1 quart of solventthrough the valve and then close the valve.




NOTE: The pump can be stopped and the automatictank valve closed immediately at any time duringoperation by turning the POWER switch OFF. Beforeturning the POWER switch back ON, turn the PUMPSPEED to zero to prevent the pump from turning.

42

Figure 20. Valve Positions for Unload with External Pump.

Unload Operationswith External PumpRefer to Figure 20 for the following procedures.1. Park the Distributor in the desired location for

unloading through the load line.2. Set the truck parking brake.3. The engine must be running and the optional

transmission PTO must be engaged.4. Before continuing further, the PUMP SPEED

knob, at the rear panel, must be turned to zero(full counter clockwise) so that the pump doesnot start turning when the POWER switch isturned ON.


WARNING

To prevent burns, always wear insulated gloveswhen handling spray bar sections or hoses.

At the rear of the distributor:Set or confirm the following:• Tank valve closed• Return valve open• Bar suck back valve(s) closed• Master hand spray valve closed• Transfer line suck back valve closed• Transfer line valve closed• Flush valve closed• Load and transfer line caps are in place and secured.

At the rear control panel:1. Turn the Function knob to LOAD/TRANSFER.

(Optional manual tank valve should be closed.)2. Turn the POWER switch ON.3. Put the PUMP CONTROL to MANUAL.4. Press START. Increase the PUMP SPEED knob

so that the asphalt pump turns slowly.5. Remove the load line cap.

Suck Back

OffHandSpray

Hand Spray Valve Positions Suck Back Valve

Closed

Hand Spray Valve

Closed


Tank ValveOpen



Transfer Line Suck BackValve Closed

Flush ValveClosed

Return Valve Open



43


16. Flush the pump before quitting.

NOTE: The pump can be stopped and the auto-matic tank valve can be closed immediately atany time during operation by turning the POWERswitch OFF. Before turning the POWER switchback ON, turn the PUMP SPEED to zero to pre-vent the pump from turning.

WARNING


6. Connect the load line to the storage tank throughan asphalt hose.

7. Decrease the PUMP SPEED to zero.8. Put the PUMP CONTROL to AUTO9. Turn the Function knob to UNLOAD (the optional

manual tank valve should be open).10. Open any valves on the storage tank between

the asphalt hose and the tank.

11. Run the asphalt pump on the storage tank atthe desired pump speed.

12. When finished unloading, turn the Functionknob to LOAD/TRANSFER (the optionalmanual tank valve should be closed).

13. As the load line on the Distributor is being un-loaded, carefully open the bleeder valve orbreak the hose connection until a strongvacuum is heard. It may be necessary to re-duce the pump speed in order to overcomepump vacuum when breaking the hose con-nection. Elevating the hose above the storagetank connection will allow maximum drainageof the hose.


44

Unload Operationswith Distributor Pump


1. Park the Distributor in the desired location forunloading through the load line.





WARNING

To prevent burns, always wear insulatedgloves when handling spray bar sections orhoses.PeRATiON

At the rear of the distributor:Set or confirm the following:• Tank valve closed






• Load, and unload and transfer line caps are inplace and secured.

At the rear control panel:

1. Remove the transfer line cap.

2. Connect the transfer line to the storage tankwith an asphalt hose.

3. Open the transfer valve.

4. Close the return valve.

5. Open any valves on the storage tank betweenthe asphalt hose and the tank.

6. Turn the Function knob to UNLOAD (the optionalmanual tank valve should be open).

Figure 21. Valve Positions for Unload withDistributor Pump.

Suck Back

OffHandSpray


Closed

Hand Spray Valve

Closed


Tank ValveOpen


Transfer ValveOpen


Flush ValveClosed

Return Valve Open


Do not remove Transfer Line cap iffront or rear tank valve is open or ifasphalt pump is turning

45


8. Put the PUMP CONTROL to MANUAL.

9. Press START. Increase the PUMP SPEED knobso that the asphalt pump turns slowly.

10. After ensuring the flow between the Distributorand the storage tank is unobstructed, decreasethe PUMP SPEED to zero.


12. Press START. The pump will start turning atthe desired rate.

13. When finished unloading, turn the Functionknob to LOAD/TRANSFER (the optional manualtank valve should be closed).

14. Open the return valve.

15. Close the valve at the storage tank.

16. Close the transfer valve.

17. Open the transfer suck back valve.

18. Press START.

19. At the storage tank, carefully open the bleedervalve or break the hose connection until a strongvacuum is heard. It may be necessary to reducethe pump speed in order to overcome pumpvacuum when breaking the hose connection.Elevating the hose above the storage tank con-nection will allow maximum drainage of the hose.

20. Disconnect the hose from the transfer line.

21. Replace the transfer line cap and secure.

22. Close the transfer suck back valve.

23. Flush the pump before quitting.


46

Transfer OperationsRefer to Figure 22 for the following procedures.

1. Park the Distributor for transferring.






• Tank valve closed







Figure 22. Valve Positions for Transfer.

At the rear control panel:1. Turn the Function knob to LOAD/TRANSFER

(the optional manual tank valve should beclosed).

2. Turn the POWER ON.3. Remove the transfer line cap.4. Connect the transfer line to the storage tank

through an asphalt hose.5. Open the transfer valve.6. Put the PUMP CONTROL switch in MANUAL.7. Press START. Increase the PUMP SPEED so that

the asphalt pump turns slowly.8. Remove the load line cap.9. Connect the load line to the supply tank with an

asphalt hose.10. Open any valves on the storage tank between

the asphalt hose and the tank.11. Close the return valve.12. Open the tank valve on the supply tank.13. Decrease the PUMP SPEED to zero.14. Put the PUMP CONTROL to AUTO.15. Press START. The pump will start turning at

the desired rate.16. Close the tank valve on the supply tank when

the desired amount of product is in the storagetank.

Suck Back

OffHand Spray


Closed


Tank ValveClosed


Transfer ValveOpen

Flush ValveClosed

Hand Spray Valve

Closed


Return Valve Closed

Do not remove Transfer Line cap iffront or rear tank valve is open or ifasphalt pump is turning


47

17. At the supply tank, carefully open the bleedervalve or break the hose connection until astrong vacuum is heard. It may be necessaryto reduce the pump speed in order to overcomethe pump vacuum when breaking the hoseconnection. Elevating the hose above the loadline connection will allow maximum drainageof the hose.



20. Put the PUMP CONTROL to MANUAL to stopthe pump and then put it back to AUTO.

21. Close the valve at the storage tank.

22. Close the transfer valve.

23. Open the return valve.

24. Open the transfer suck back valve.

25. Press START.

26. At the storage tank, carefully open the bleedervalve or break the hose connection until astrong vacuum is heard. It may be necessaryto reduce the pump speed in order to overcomethe pump vacuum when breaking the hoseconnection. Elevating the hose above the loadline connection will allow maximum drainageof the hose.

27. Disconnect the hose from the transfer line.

28. Replace transfer line cap and secure.

29. Close the transfer line suck back valve.

30. It may be necessary to flush the pump beforedoing the next step.


NOTE: The pump can be stopped and theautomatic tank valve can be closed immediatelyat any time during operation by turning the POWERswitch OFF. Before turning the POWER switchback ON, turn the PUMP SPEED to zero to preventthe pump from turning.

WARNING


WARNING

Suckback of the storage tank line will putmaterial into the tank and could cause anexplosion if the tank has not been fullycleaned of emulsion material.

48

Heating Product in Distributors

Heating Asphalt with LiquidPropane Gas (LPG) Burners

IMPORTANT

Circulating the asphalt in the tank whileheating is recommended for faster heatingand reduced carbon formation on the flues.Only when the asphalt pump is Frozen is itacceptable to operate the burners withoutcirculating asphalt in the tank. However, if theasphalt pump is frozen, carefully apply heatto the pump and start circulating the materialas soon as possible.

WARNING

Residual fuel in LPG burners will support aflame for several minutes after the fuel flowhas been shut off. After using LPG burners,confirm that all flame has been extinguishedbefore attempting any operation that couldrelease flammable vapors.

Failure to ensure that the flame is completelyextinguished could result in an explosion orfire that can cause injury or death.

WARNING

To prevent an explosion or fire hazard:Position unit broadside to wind wheneverpossible to prevent volatile fumes fromdrifting toward burners

Flues MUST be covered by a minimum of 6inches of material when the burners are inoperation.

Do not remove material from tank in anymanner when the burners are in operation.

Do not drive unit when burners are operating.

Do not operate burners if tank is damaged or

leaking.

When burners go out, allow flues to ventilatefor several minutes before relighting burners.

Do not heat material beyond themanufacturers recommended temperature.

WARNING

To prevent an explosion or fire hazard: Toprevent foaming or violent eruption, do notheat material over 200 ºF if moisture ispresent in tank.

WARNING

To prevent possible burns from materialoverflow, allow sufficient space in tank forexpansion of material when heating.

LPG Supply Tank RequirementsUse only liquid withdrawal type supply tanks for

your LPG burners.

Two types of LPG supply tanks are available:tanks for liquid type burners and tanks for vaportype burners. The LPG burners on your Etnyre Dis-tributor require a supply tank for liquid type burn-ers. Liquid type burners will operate from a vaporwithdrawal tank, however the amount of heat de-livered will be dramatically reduced, and the life ofthe burner will be shortened.

There are three different types of LPG burners:manual control burners, burners with outfire con-trol, and burners with automatic ignition and tem-perature limiting control.

49

Manual Control BurnersFour valves are associated with the operation

of the manual control burners: one at the supplytank and three in the burner piping.

The two smaller valves (one at each burner) arebleeder type valves with a small hole in the valvecase. Propane liquid is supplied to the bleeder valvedirectly from the supply tank shutoff valve. Becauseof the bleeder hole in this valve, it is NOT possibleto shut off all of the fuel to the lower burner byshutting the main valve at the burners. The mainburner valve will only shut off the upper burner.The lower burner must be shut off using the sup-ply tank valve.

WARNING

Always shut off burners using the mainshutoff valve on the supply tank.

The large valve located in the fuel line to theoutside or upper burner is a positive cut offvalve that allows all fuel to be cut off to thebleeder valve on the upper burner only.

Burner Operation1. Be sure that the main supply valve and the main

burner valves are fully closed, and the bleedervalves are turned fully clockwise before starting.

2. Open the dampers in the flue exhaust stacks.

3. Open the valve at the supply tank and immedi-ately light the inside burner. As soon as theburner lights, open the bleeder valve. No pre-heating is necessary.

IMPORTANT

It is recommended that two persons beinvolved in lighting the first burner. When themain fuel valve is opened at the tank, there isan immediate trickle of gas passing throughthe inside burner valve. The longer the gas isallowed to collect in the flue, the more likelythere will be a flashback when the burner isignited. Having one person light the burnerwhile the other opens the main supply valvewill reduce the likelihood of a flashback.

When the main fuel valve is opened at thebottle or tank, there is an immediate trickle ofgas passing through the inside burnerbleeder valve. Light the burner immediately.

WARNING

To prevent possible burns, always use atorch to light the burners. Never attempt tolight the burners with a match or pocketlighter.

Figure 23. Manual Control Burner System.

50

WARNING

A fully charged dry chemical type fireextinguisher must be within easy reachwhenever the burners are operating or there isan open flame near the Distributor. Minimumdry chemical capacity of the fire extinguishershould be 10 pounds.

4. Check the fuel pressure at the pressure regula-tor. Too much pressure for a small asphalt tankwill waste fuel. Too little pressure will increaseheating time. Some experimentation with thepressure will allow you to determine the mostefficient fuel pressure to use. The following is agood rule of thumb.

• 1000-1250 gallon tank- 15 psi• 1500-1750 gallon tank- 20 psi• 2000-2250 gallon tank- 25 psi• 2250-2500 gallon tank- 30 psi• 2750 gallon and larger- 40 psi

5. If necessary, adjust the flame with the bleedervalve at the burner. When the LPG burners areoperating, the outside of the fuel line up to thefirst coil of the burner should frost over. If nofrost forms it is an indication that the burnersare operating on vapor instead of liquid. Thiscondition must be corrected immediately to pre-vent damage to the burners. If after the linesfrost over, the flame starts to die down and thefrost melts off the fuel line, it is likely that thereis moisture in the fuel supply tank. Moisture inthe fuel can form ice crystals that stop the fuelflow. Your local LPG supplier can add an anti-icing agent to prevent burner icing.

IMPORTANT

There must be at least 6 inches of materialcovering the entire length of the upper fluebefore the second burner can be lit.

6. To ignite the second burner ensure that thebleeder valve on the burner is turned fully clock-wise. Position a lit torch at the burner nozzleand open up the positive shutoff valve in the lineto the burner. As soon as the low fire is estab-lished, the bleeder valve can be opened. Neverleave operating burners unattended.

WARNING

To prevent possible burns, always use atorch to light the burners. Never attempt tolight the burners with a match or pocketlighter.

WARNING

When heating, temperatures within the tankcan vary. Shut the burners off when thethermometer reaches a reading 10 ºF lowerthan the desired temperature. Continue tocirculate & monitor temperature untiltemperature stabilizes. Add remaining heatby operating burners for short periods,monitoring stabilized temperature after eachperiod.

IMPORTANT

Calibration of thermometers should beverified to be within + 2% of full scale readingannually.

Certification can be accomplished by aqualified laboratory or by comparingstabilized dial readings to the pencilthermometer reading. Replace anythermometer that does not meet the +2%accuracy requirement.

7. When the desired temperature is reached, closethe main fuel supply valve, at the LPG tank, first.Allow the burners to operate at full capacity untilthe fuel in the line from the tank burns out, thenclose both bleeder valves and the positive shutoffvalve for the outside burner.

8. Close the exhaust stack dampers to prevent heatloss.

Burners With Outfire Controls

Equipment DesignThe burner and the burner control valves areidentical to the manual operated burner system.

However, burners with outfire controls areequipped with an outfire control box. The outfirecontrols consist of two thermocouples, a push startbutton, an electric fuel solenoid valve, a pressureregulator and a pressure gage.

51

The heat sensing thermocouples are positionedin each burner. If either burner loses its flame, thethermocouple senses the drop in temperature, anddeactivates the fuel solenoid, and the fuel to bothburners is shut off.

The only operational differences between themanual burners and burners with the optionaloutfire controls is the start up and shut down pro-cedures. Unlike the manual burners, when theburners are equipped with outfire controls, no fuelflows to the burners when the main solenoid shutoffvalve is closed.

Burner Operation with Outfire Controls1. Turn the POWER switches ON.

2. Open the dampers in the exhaust stacks.

3. Ensure that the main burner control valve isclosed and that the bleeder valves for bothburners are turned fully clockwise.

IMPORTANT

It is recommended that two people be involvedin lighting the burners. One person should holdthe torch while the other person opens thevalves and holds the push button in.

4. Open the main fuel supply valve at the tank. Nofuel will be flowing at this point.

5. You must hold the bush button in while lightingthe burners.

6. As soon as the low fire is established at the in-ner burner, open the positive shutoff valve to theoutside burner and light the outside burner onlow fire.

7. After 30 to 40 seconds, release the push buttonand observe the pressure gage. If the pressurestarts to drop rapidly, depress the push buttonand hold it in for another 30 seconds. It mayrequire a slight increase in fuel to the outsideburner to adequately heat the thermocouple.Once both of the thermocouples are heated thepush button can be released.

IMPORTANT

In order to activate the thermocouples, bothburners must be lit on low flame even if onlyone burner will be used for heating. Place theignition torch at the inside burner nozzle anddepress the push button in the outfire controlbox. Continue to hold the push button in untilboth burners are lit.

Figure 24. Outfire Controlled Burner System.

52

8. If both burners are to be used for heating, youcan now open both bleeder valves. If only theinside burner is to be used for heating, open thebleeder valve on the inside burner and allow theoutside burner to remain burning on low flameso the thermocouple will be heated. Remember,if either burner flame goes out, the outfire con-trol will shut the solenoid valve cutting the fueloff to both burners.

WARNING

A fully charged dry chemical type fireextinguisher must be within easy reachwhenever the burners are operating or thereis an open flame near the Distributor.Minimum dry chemical capacity of the fireextinguisher should be 10 pounds.

WARNING

When heating, temperatures within the tankcan vary. Shut the burners off when thethermometer reaches a reading 10 ºF lowerthan the desired temperature. Continue tocirculate & monitor temperature until thetemperature stabilizes. Add remaining heatby operating burners for short periods,monitoring stabilized temperature after eachperiod.

IMPORTANT

Calibration of thermometers should beverified to be within + 2% of full scale readingannually.

Certification can be accomplished by aqualified laboratory or by comparingstabilized dial readings to the pencilthermometer reading. Replace anythermometer that does not meet the +2%accuracy requirement.

When the desired product temperature isreached:1. Close the main fuel supply valve at the tank.

2. After all the fuel is burned and there is no flameat either burner, turn both bleeder valves fullyclockwise and close the positive cut off valve atthe burners.

3. Close the exhaust stack dampers to prevent heatloss.

53

Burners with Automatic Ignitionand Temperature LimitingControl

Equipment DescriptionThe temperature limiting control box contains the

temperature limiting control components as well asthe automatic ignition circuitry.

The automatic ignition circuit consists of two 12Vcoils, two spark plugs, a pair of thermocouples, (oneat each burner), and a momentary push buttonswitch. The 12V coils send high voltage to the sparkplugs that causes sparks to arc intermittently ateach pilot burner whenever there is fuel pressurein the line from the main supply tank. The thermo-couples provide a signal that indicates when thereis a flame at the pilot burners. The momentary pushbutton switch on the control box is used to fire themain burners once the pilot burners have ignitedand the thermocouples have been heated suffi-ciently.

The temperature limiting control circuit consistsof a temperature probe in the Distributor tank thatsenses the asphalt temperature, a thermostaticswitch in the control box and a temperature adjust-ment dial on the face of the control box. When thetemperature of the asphalt in the Distributor isheated to the temperature selected with the tem-perature adjustment dial, the thermostatic switchshuts down the burners.

Figure 25. Burner System with Auto Ignition and Temperature Control.

Burner Operation with Auto Ignition& Temperature Control1. Open the dampers on the exhaust stacks. En-

sure that all burner valves are closed. With thistype of control, the inside or lower burner maybe operated without opening the positive shutoff valve to the outside burner. If both burnersare to be used, the positive shutoff valve shouldbe opened.

2. Open the main fuel valve at the supply tank.The spark plugs will begin to arc and will ignitethe pilot burners.

3. Set the thermostat to the desired temperature.

4. Allow the pilot burners to heat the thermocoupleprobes for at least 2 minutes. When the pilotburners have heated the thermocouples suffi-ciently the sparker will stop. Press the cycle but-ton to fire the main burners. The bleeder valvesmay then be opened. (Spark ignition will runwhile the burner is in operation.)

5. On new or rebuilt units, monitor the product ther-mometer to make certain that the burners shutdown when the desired temperature is reached(as set on the temperature adjustment dial). Ifthe burners do not shut down at the correct tem-perature, calibrate the thermostat.

6. Once the burner shuts off automatically, it willnot restart until the cycle button is again de-pressed.

54

7. To shut the system down, close the main fuelsupply valve at the tank.

8. Increase the thermostat setting 50 to 75 ºF higherand push the start button. This will bring on themain burners and quickly burn off all of the fuelin the line between the tank and the control box.The pilot burners may continue to burn for a shorttime after the main burners cut off. Do not drawmaterial from the tank as longas there is a flamepresent.

9. Close the exhaust stack dampers.

Electric Driven Burner DieselOperation1. Open the dampers in the exhaust stacks.

2. To light the burner, turn on the LOWER BURNERswitch.

3. If upper burner operation is desired, turn on theUPPER BURNER switch.

4. Do not heat the material higher than the spray-ing temperature recommended by the asphaltsupplier.

5. To shut down the burners, turn off the burnerpower switches.

WARNING

Flues MUST be covered by a minimum of 6inches of material when burners are inoperation.

Figure 26. Electric Burner System.

55

TroubleshootingProblem Cause Remedy

Pump speed too fast for size of nozzle. Lower pump speed or change nozzles.

Pump speed too slow. Increase pump speed.

Nozzles not at proper angle. Adjust angle of nozzles.

Spray bar at improper height above ground. Adjust spray bar height.

Material temperature too low. Heat material to correct temperature.

Pump speed too slow. Adjust pump speed.

One or more control valves in Check position of all control valves. Be sureincorrect position, not fully opened all valves are fully opened or closed.or closed, or leaking. Repair leaking valves as necessary.

Suction strainer plugged. Clean suction strainer.

Contaminate stuck in spray valve(s). Disassemble spray valve and clean.

Spray valve o-rings damaged or worn. Replace spray valve o-rings.

Tack Coat pressure too high. Verify Tack Coat pressure relief is set to 20 PSI.

Material in tank or pump belowpumping temperature. Heat material to proper pump temperature.

Air leak in suction line from reservoirto filter to inlet of charge pump. Locate and repair leak.

Hydraulic system pressure low. Raise pressure.

Low oil in hydraulic reservoir. Add hydraulic oil to correct level.

Spray bar valves set improperly. Correct spray bar valve settings.

Defective Hyd. motor. Check for excessive case drain in motor.

Material in tank or pump belowpumping temperature. Heat material to proper pump temperature.

Air leak in suction line from reservoirto filter to inlet of charge pump. Locate and repair leak.

Low oil in hydraulic reservoir. Add hydraulic oil to correct level.

Spray bar valves set improperly. Correct spray bar valve settings.

Swivel joint O-ring is loose. Replace swivel joint O-ring.

Quantity of material in tank not being Use Etnyre measuring stick for accurate readings.measured accurately. Be sure tank is level when measuring.

Suction strainer plugged. Clean suction strainer regularly.

Hydrostatic controls not firmly positioned. Ensure that all controls are firmly locked in place.

Suck back valves not fully closed. Ensure valve is closed.

Spray Fogs

Spray Streaks

Spray LacksPressure

All Nozzles Do Not

Cut Off Spray

Pump Will Not Turn

Or Turns Slowly

Hydraulic OilOverheats

Spray Bar SupplyTube Swivel JointsLeak

Application Rate

Varies

56

Section Notes

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57

Electrode AssemblyAdjustments1. Adjust electrode assembly per Figure 27.

NOTE: Before installing electrode assembly, checkthat blower wheel turns freely and that all setscrews are tightened securely.

Figure 27. Burner Electrode Adjustments.

2. Install electrode assembly into air tube unit. Useescutcheon plate for mounting.

Figure 28. Electrode Assembly Installation

Maintenance

Figure 29. Nozzle Adjustment.

Burner Air Band Settings1. Close bulk air bank (outside diameter band).

2. Set end air band between 3.5 - 4.0 on scale(see Figure 29).

3. Open covers or dampers on exhaust stacks.

WARNING

To prevent an explosion or fire hazard, keeparea free of sparks or open flames whentesting burners.Hole For Fuel Line

Mounting Screw - slide plate againstmounting screw. This will positionnozzle in air tube.

Electrode

Nozzle3/16" to 1/8"

5/16" to 1/4"

3/16" to 5/32"

3"+ 1/16"-

58

Check Ignition Transformer Spark1. Turn on power switch in rear control box.2. Turn the BURNER switches on.3. Hold an insulated screwdriver touching one of the

springs and approximately 3/4 inches above theother spring on the transformer. It should be pos-sible to jump a spark across the 3/4 inch gap be-tween the spring and the screwdriver. If unable togenerate a blue spark across this gap, check thevoltage at terminal spades of the 12 volt ignitioncontrol box. Voltage must be 12 VDC minimum. Ifvoltage is incorrect or not present, check groundwiring.

4. Reposition ignition transformer and secure toburner housing.

Fire Burners1. Ensure that fuel oil pressure is 125 PSIG.2. Turn the burner switch on.3. Run the burner for 15 seconds maximum after

lighting, then shut down.

WARNING

To prevent an explosion or fire hazard, fluesmust be covered by minimum 6 inches ofmaterial when burners are in operation.When testing burners, do not run burners formore than 15 seconds if tank is empty.

Replacing Speed Pickup1. Loosen locknut and remove old speed pickup.2. Turn in the new speed pickup clockwise by hand

until the bottom end gently touches the internalspeed ring.

3. Back it out counter clockwise 1/2 to 3/4 turn.4. Using a 1/2 inch wrench to hold the speed pickup,

torque the locknut to 10 lb-ft (13 Nm) with an 11/16 inch wrench.

Figure 30. Hydraulic Motor.

59

Servicing the Etnyre P-15 Pump

Vacuum Check1. Flush pump with 3 quarts of diesel fuel through

fill line.

2. Set controls for loading operation.

3. Install vacuum gauge in fill line cap.

4. Operate pump at 140 GPM on pump tachometer. Avacuum reading of less than 5 inches Hg. (inchesof mercury) after 2 minutes of operation indicatesa vacuum leak or a worn pump.

Pump Disassembly AndInspection1. Remove 20 capscrews from perimeter of pump

end plate (see Figure 31).

2. Install two capscrews in the threaded holed nearthe outer edge of the end plate at approximatelythe 5 o’clock and 11 o’clock positions. Tightenthe capscrews evenly to force the endplate awayfrom the pump body.

3. Remove the endplate, impeller shafts and im-pellers (gears) as an assembly.

4. Clean the interior of the pump case. Slide yourfingers across the interior surfaces of the case.If a narrow raised area can be felt midway be-tween the front and the rear of the case, theentire pump should be replaced.

5. If there is no raised area, measure the bore ofthe case at its widest point horizontally (side-to-side). This measurement must not exceed 9.910inches.

6. Next, measure the case bore vertically at a point2.8 inches from each side. The vertical measure-ment must not exceed 5.660 inches. If any boremeasurements exceed these limits, the entirepump must be replaced.

7. If inspection indicates the pump case is accept-able, measure the outside diameter of the im-peller gears. Measure the impeller gears fromtooth point to tooth point on teeth directly oppo-site each other. The minimum outside diameterof the gears should be 5.635 inches. The mini-mum length of the gears should be 3.628 inches.

8. If any impeller gear is undersize, the entire four-gear set must be replaced.

9. End plate gasket thickness should be 0.014 to0.016 inches.

10. Divider plate thickness should be 0.127 to 0.128inches.

Impeller Installation And PumpAssemblyEach impeller gear set uses a series of dots onthe gear faces to indicate position of the gearswithin the pump. Refer to Figure 33 for properpositioning of the gears. The dots must face awayfrom the divider plate (towards the ends of thepump). Install the impellers in numerical order.

Figure 31. Etnyre Asphalt Pump.

60

General Fuel Data and HeatingTerminology

Fuel DataFuel Weight Per BTU Content

Gallon#2 Fuel Oil 7.49 lbs 144,300 per gallon

Kerosene 6.97 lbs. 134,500 per gallon

Propane 4.20 lbs. 91,500 per gallon

Approximate Burner FuelConsumptionLow Pressure Fuel Oil

935,000 BTU @ PSI

6.5 GPH per burner

(144,000 BTU per gallon)

Kerosene Generating575,000 BTU @ 40 PSI

4.25 GPH per burner

(135,000 BTU per gallon)

Heating Terminology

Flash Point (Open Cup)The temperature at which a flammable liquid in anopen container emits vapor that will flash whenexposed to a direct flame. This temperature islower than required for the liquid mass to ignite.

Closed Flash PointThe temperature at which a flammable liquid in aclosed container emits a vapor that will flash whenexposed to a direct flame. This temperature islower than required for the liquid mass to ignite.The closed flash point is generally 30ºF lower thanthe open cup flash point.

Fire PointThe temperature at which a flammable liquid emitsa vapor at a rate that will continue to burn after ithas flashed.

Ignition Temperature (KindlingTemperature)The lowest temperature at which a combustiblematerial will continue to burn once ignited.

ConvectionHeat transfer by a flow of a liquid or gas over asolid material. Example: Flues in asphalt tank areheated from hot gases passing through them, or,heat transfer coils in tank are heated from steamor hot oil passing through them.

ConductionHeat transfer through a solid mass by directmolecular contact. Example: Heat applied only toone end of a metal rod will be transferredthroughout the entire body by molecular transfer.

61

Hydraulic Fluid Requirements

General InformationThe ability of a hydrostatic transmission to maintaindesired performance for the expected life dependson the quality of fluid being circulated in the units.Fluid quality can be measured in threegeneralcategories: lubricity, contaminants, andtemperature. Obtaining satisfactory values in thesethree areas depends on the fluid and the circuit inwhich it is used.

Etnyre field service experience indicates that mosttransmission failures result from a breakdown offluid quality. Primary causes are solid particlecontamination and overheating. Water or oil in thefluids are also significant contributors. Theseproblems are usually the result of poormaintenance. Sometimes fluid selection can lessenthe impact of unusual environmental factors.

Hydraulic Fluid RequirementsThe catalog ratings and performance data arebased on operating with good quality petroleumbased fluids. Premium hydraulic fluids containinghigh quality rust, oxidation and foam inhibitors arerequired. These include premium turbine oils, APICD engine oils per SAE J183, M2C33F or Gautomatic transmission fluid (Type F), power shifttransmission fluids meeting Allison© C-3 orCaterpillar© TO-2, and certain specialty agriculturaltractor fluids.

Although fluids containing anti-wear additives arenot necessary for satisfactory performance, whenused, the fluids must possess good thermal andhydrolytic stability to prevent wear, erosion andcorrosion of the internal components.

Where water contamination is likely due tocondensation, operation in a damp environmentor frequent splashing, a fluid with outstandinghydrolytic stability is recommended. Consult theEtnyre Service Department for recommendationsfor these fluids. Avoiding the use of Dexron© IItransmission fluids which do not meet Allison C-3specification is recommended.

Viscosity & TemperatureRequirementsThe fluid must have sufficient viscosity to maintainan oil film at the bearing surfaces. This dependson fluid selection and on operating temperature.Recommended viscosity for best life and efficiency,and minimum for intermittent and continuousoperation is listed below.

Fluid Viscosity Limits ForPetroleum Based Fluids

Maximum Continuous SUS (cSt) 500 (110)

Optimum Viscosity SUS (cSt) 70 (13)

Minimum Continuous SUS (cSt) 55 (9.0)

Minimum Intermittent SUS (cSt) 47 (6.4)

Viscosity index improved (multi-viscosity) fluidsmay noticeably shear down in service when usedin hydrostatic transmissions. This will lower theoperating viscosity below the originally specifiedvalue. The lowest expected viscosity must be usedwhen selecting fluids. Consult your fluid supplierfor details on viscosity sheardown.

Fluid temperature affects the viscosity of the fluidand resulting lubricity and film thickness. Hightemperatures can also limit seal life, as mostnonmetallic seals are adversely affected by use atelevated temperatures. Also, fluids may breakdown or oxidize at high temperatures, reducingtheir lubricity and the resulting life of the unit.Cavitation is more likely at high temperature.Recommended limits for operating temperaturesare tabulated below.

Fluid Temperature Limits ForPetroleum Based Fluids

Continuous Limit 180ºF

Intermittent Limit 220ºF

These temperature limits apply at the hottest pointin the transmission, which is normally the motorcase drain.

Heat problems sometimes occur because ofproblems with one of the circuit components. Apartially stuck relief valve will heat up the oil rapidly.Circuit components that have developed highinternal leakage rates will contribute to heatgeneration.

62

Contamination LevelsClean fluid implies the absence of impurities suchas solid particles, water and air. Contaminationcontrol includes proper design, installation, andmaintenance of hydraulic components.

The reservoir is designed to limit entry ofcontamination during servicing and operation. A

sealed reservoir with a low pressure relief valvereduces the introduction of contaminants whilemaintaining inlet and case drain pressures belowthe maximum recommended.

The purpose of the filter in a system is to clean theoil at initial start up and to maintain acceptablelevels of particle contaminants as they are ingestedor generated during operation of the system.Filtration is a matter of controlling the particle sizesand their respective quantities to appropriate levelsso as to avoid degradation of the systemcomponents and thereby assure the desired life.

Fluid contaminant profile requirements for Etnyrehydraulic units have been determined empiricallybased on measuring fluid quality in successfulapplication, and in laboratory tests designed toevaluate hydraulic unit contaminant sensitivity.General contaminant levels have been developedbased on this experience and are shown in Figure32.

Acceptable contamination levels at machine startup for the system loop should be equal to or betterthan Curve D. The machine may be exercised to500 psi but should not be worked (pressure over500 psi) until the oil cleanliness meets or exceedsCurve C.

The machine should clean up during a relativelyshort period of normal operation to meet the oilcleanliness level of Curve A or Curve B. A systemthat meets Curve A will provide the user with alonger trouble-free operating life than one thatmeets Curve B. The Curve A cleanliness levelshould be met in systems exceeding thecontinuous pressure limit for 1000 hours/yearsmachine use.

Some control valves may require bettercontamination limits than specified in Figure 32.Controls with small area screens or low force levelvalues may be susceptible to malfunction fromcontamination.

The contamination sensitivity of componentsgenerally increases with higher pressure,temperature or speed. A better fluid contaminantprofile may be required for systems which operatenear the extremes of their ratings. Short life orinfrequent operation requirements may increaseallowable contaminants.

Figure 32. Fluid Cleanliness Chart.

Curve A Curve CDesired limit for longer Limit at machine shiplife (3500 PSI continuous and new fluid added tosystem pressure) transmission

Curve B Curve DContinuous operating Limit at machine start uplimit (2000 PSI continuouspressure) system

63

The selection of a filter depends on a number offactors including the contaminant ingression rate,the generation of contaminants in the system, therequired fluid cleanliness, and the desired mainte-nance interval. Filters are selected to meet theabove requirements using rating parameters ofefficiency and capacity.

Filter efficiency may be measured with a Betaratio. For simple closed circuit transmissions withcontrolled reservoir ingression, a filter with a Betaratio of 1.5 to 2 has been found to be satisfactory.For some open circuit systems, and closed sys-tems with cylinders being supplied from the samereservoir, a considerably higher filter efficiency isrecommended. This applies to systems with gearsor clutches using a common reservoir. For thesesystems, Beta ratios of 10 or 20 are typically re-quired.

The filter capacity required depends on theamount of contaminants ingressed and retained inthe filter and the desired maintenance interval. Asa rough guide, a capacity in grams equal to twicethe charge flow in GPM has been found to be sat-isfactory for our systems.

Since each system is unique, the filtration re-quirements for that system will be unique and mustbe determined by test in each case. It is essentialthat monitoring be the final criteria for judging theadequacy of the filtration system.

64

INTERVAL POINT IDENTIFICATION LUBRICANT QUANTITY

DAILY 1 Strainers (Fill Line, Manhole,Strainer Box) Clean —

WEEKLY 2 Air Oiler EO Fill

3 Bar Latches EO Sparingly4 Swivels MPG Sparingly5 Bar Carry Mechanism EO Sparingly6 Bar Shoe Slide Plates AS Sparingly

MONTHLY 7 Transfer Line Cap AS Sparingly8 Load Line Cap AS Sparingly9 Manhole Lid AS Sparingly

10 Exposed Hydraulic and Air Cylinder Rods EO Sparingly11 Thermometer Cap AS Sparingly12 Sample Valve Cap AS Sparingly13 Tool Box Hinge and Latch EO Sparingly

14 Pump Shaft Coupling AS SparinglySERVICE 15 Hydraulic Reservoir HTF Fill to Top of Sight Glass

16 Hydraulic Oil Filter — Replace when gauge is red

MPG: Multi Purpose Grease MIL-G-18458B-SH EO: (Engine Oil) 10W MIL-L-2104-FAS: Anti-Seize MIL-T-5544 HTF: Hydraulic Transmission Fluid - Type F

NOTE: Fill line oiler, located on outlet side of air reservoir, with light oil as needed. Also wipe cylinder rods cleanand lightly oil. Drain water from air reservoir daily.

NOTE: Fill Hydraulic Tank completely for winter storage. This will prevent condensation in the reservoir. Drain downto thermometer hole prior to use.

Lubrication Chart

20

91

3

12

1513

11

16

2

13

1

18

7

63

(in right sidetool box)

4

4

1010

10

14

5

65

Etnyre Spraybar Nozzles

Ref. Part No. Description Application Application US FlowGallons Per (Metric) Liters Per Gallons PerSquare Yard Square Meter Minute Per Foot

1 3353788 V Slot Tack Nozzle .05 - .20 .23 - .91 3.0 to 4.5

2 3351008 S36-4 V Slot .10 - .35 .45 - 1.58 4.0 to 7.5

3 3351009 S36-5 V Slot .18 - .45 .81 - 2.04 7.0 to 10.0

4 3352368 Multi-Material V Slot .15 - .40 .68 - 1.81 6.0 to 9.0

5 3351015 3/32" Coin Slot .15 - .40 .68 - 1.81 6.0 to 9.0

6 3352204* Multi-Material V Slot .35 - .95 1.58 - 4.30 12.0 to 21.0

7 3352205* Multi-Material V Slot .20 - .55 .91 - 2.49 7.5 to 12.0

8 3352210 End Nozzle (3352205) .20 - .55 .91 - 2.49 7.5 to 12.0

9 3351014 3/16" Coin Slot .35 - .95 1.58 - 4.30 12.0 to 21.0

10 3351010 1/4" Coin Slot .40 - 1.10 1.81 - 4.98 15.0 to 24.0

* Recommended nozzles for seal and chip with emulsified asphalts.

66

Figure 33. Serial Number Plate Location.

Serial Number Plate Location

Serial Number Plate Location The Serial Number Plate is a brass plate located on the left side of the vehicle toolbox. Generally, the serial number has a letter prefix followed by four numbers.

The unit serial number is also stamped on the left front tank mounting leg.

Decimal Equivalent ChartFraction Decimal Fraction Decimal

1/16 .06 9/16 .56

1/8 .12 5/8 .62

3/16 .19 11/16 .69

1/4 .25 3/4 .75

5/16 .31 13/16 .81

3/8 .38 7/8 .88

7/16 .44 15/16 .94

1/2 .50 1 1.00

Something Wrong with this manual?

If you find inaccurate or confusing information in this manual, orjust 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.comAttn: Service Manager

Recommended changes from: ___________________________________

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black-topper centennial asphalt distributor1 m-114-10 black-topper centennial operation,...

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