Etnyre Black-Topper Operation Maintenance Safety Download Page 5

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List of Illustrations

Figure 1 - Location of Warning and Instruction Plates.......5

Figure 2 - Flashing Low Level Indicator........................... 10

Figure 3 - Low Tank - Burners fault ................................. 10

Figure 4 - Rear and Side Component Identification

........ 12

Figure 5 - Rear Component Identification

........................ 12

Figure 6 - Spray Bar Component Identification

............... 13

Figure 7 - Hydraulic Tank Component Identificaiton

........ 13

Figure 8 - Cab Control Panel Components ..................... 14

Figure 9 - Rear Control Panel Components .................... 16

Figure 10 - Gear Icon ...................................................... 18

Figure 11 - Setup Button .................................................. 18

Figure 12 - Setup Login Button........................................ 18

Figure 13 - Page 1 of Setup Screen ................................ 19

Figure 14 - Pump Threshold Description ......................... 19

Figure 15 - Reset Defaults button.................................... 20

Figure 16 - Memory Window and Keyboard .................... 21

Figure 17 - Machine Calibrations button.......................... 21

Figure 18 - Machine Calibrations Window ....................... 22

Figure 19 - Left Bar Smart Cylinder START Calibrate Window .22

Figure 20 - Hydraulic Pump EDC Threshold Calibration . 23

Figure 21 - Pump Calibration Fault.................................. 23

Figure 22 - Ground Speed Radar Calibration .................. 24

Figure 23 - Radar Height and Angle ................................ 24

Figure 24 - Tank Level Sensor Calibration ...................... 25

Figure 25 - Calibrate Empty and Calibrate Full Buttons...25

Figure 26 - Page 2 of Setup Screen ................................ 26

Figure 27 - Metric units White Bar .................................. 26

Figure 28 - Page 3 of Setup Screen ................................ 27

Figure 29 - Faults Disabled Icon...................................... 27

Figure 30 - Display Screen .............................................. 28

Figure 31 - Front Display / Rear Display ......................... 29

Figure 32 - USB Icons ..................................................... 29

Figure 33 - Speaker Volume ............................................ 29

Figure 34 - Page 1 of Faults Screen................................ 30

Figure 35 - Page 2 of Faults Screen................................ 31

Figure 36 - Page 1 of Diagnostics Screen ....................... 33

Figure 37 - Page 2 of Diagnostics Screen ....................... 34

Figure 38 - Help Screen .................................................. 35

Figure 39 - Black-Topper Computator ............................. 35

Figure 40 - Information Screen ........................................ 36

Figure 41 - Pump Meter................................................... 36

Figure 42 - Lights Icon Button ......................................... 37

Figure 43 - Lights Screen ................................................ 37

Figure 44 - Lights Name Keyboard...................................37

Figure 45 - Home Screen, Page 1 ................................... 38

Figure 46 - Operation Mode ............................................ 38

Figure 47 - Pump Control ................................................ 39

Figure 48 - Motor Speed.................................................. 39

Figure 49 - Burner Control ............................................... 40

Figure 50 - Smart Clean Window .................................... 40

Figure 51 - Tank Valve ..................................................... 42

Figure 52 - Front Load Valve ........................................... 42

Figure 53 - Suck Back Bar Circ ....................................... 42

Figure 54 - Operation page 2 screen............................... 42

Figure 55 - Taper Switch .................................................. 43

Figure 56 - Marker Valves.................................................43

Figure 57 - Wash Pump ................................................... 43

Figure 58 - Operation page 3 screen............................... 44

Figure 59 - Log Spray Totals ........................................... 44

Figure 60 - Tank Level ..................................................... 45

Figure 61 - Valve Positions for Loading Through the Manhole ...46

Figure 62 - Using the Measuring Stick ............................ 47

Figure 63 - LOAD Operation Mode.................................. 48

Figure 64 - Increasing Pump Speed Slider...................... 48

Figure 65 - LED Tank Gauge Bar .................................... 48

Figure 66 - Valve Positions for Loading Through the Load Line

..... 49

Figure 67 - TANK CIRC Operation Mode ........................ 50

Figure 68 - Valve Positions for Circulating in the Tank .... 51

Figure 69 - BAR CIRC Operation Mode .......................... 52

Figure 70 - Valve Positions for Circulating in the Spray Bar ......

Figure 71 - Bar Latch Symbol .......................................... 54

Figure 72 - Valve Positions for Spraying Through the Spray Bar

... 55

Figure 73 - Suck Back Operation Mode .......................... 56

Figure 74 - Valve Positions for Spray Bar Suck Back ...... 57

Figure 75 - Open Nozzles Flashing Green ...................... 58

Figure 76 - Auto Spray Mode........................................... 58

Figure 77 - Manual Spray Mode ...................................... 58

Figure 78 - Handspray Operation Mode .......................... 60

Figure 79 - Valve Positions for Spraying With the Hand Spray

. 61

Figure 80 - Suck Back Override ...................................... 63

Figure 81 - Flush Operation Mode................................... 64

Figure 82. Valve Positions for Flushing ........................... 65

Figure 83 - Unload Operation AUTO Mode ..................... 66

Figure 84 - Valve Positions for Unload with External Pump 67

Figure 85 - Unload Operation MANUAL Mode ................ 68

Figure 86 - Valve Positions for Unload with Distributor Pump

.. 69

Figure 87 - Transfer Operation Mode .............................. 70

Figure 88 - Valve Positions for Transfer .......................... 71

Figure 89 - Ignition & Out Fire Control System................ 73

Figure 90 - Gun Assembly ............................................... 78

Figure 91 - Electrode Setting ........................................... 78

Figure 92 - Right Hand / Left Hand Electrodes ............... 78

Figure 93 - Hydraulic Motor ............................................. 79

Figure 94 - Etnyre Asphalt Pump..................................... 80

Figure 95 - Fluid Cleanliness Chart ................................. 82

Summary of Contents for Black-Topper

Page 1: ...116 Fax 800 521 1107 www etnyre com Parts Service 888 586 1899 CustomerService etnyre com Asphalt Distributor with Touch Screen Controls Operation Maintenance Safety Black Topper Starting with Serial Number S9000 Standard and Variable Width Spray Bar With Touch Screen Controls R R M 103 22 ...

Page 2: ...1 Starting with Serial Number S9000 Black Topper Operation Maintenance and Safety Manual BLACK TOPPER Distributor Standard Spraybar or Variable Width Bar with Touch Screen Controls M 103 22 ...

Page 3: ...2021 E D Etnyre Co All brand names trademarks and registered trademarks are the property of their respective owners Information contained within this document is subject to change without notice All rights reserved ...

Page 4: ...pray Bar 32 Right Variable Width Spray Bar 32 DIAGNOSTICS 33 Page 1 33 Spray Valves 33 Page 2 34 Page 3 34 HELP 35 View PDFs 35 INFORMATION 36 Pump Meter 36 LIGHTS 37 Maximum Current Draw Amps 37 OPERATION Main Controls 38 Operation Mode 38 Pump Control 38 Page 1 39 Two Speed Motor if equipped 39 Smart Clean if equipped 39 Burner Control 40 Ignition and Out Fire Control 41 Fuel Oil Burners 41 Tank...

Page 5: ...Page 1 38 Figure 46 Operation Mode 38 Figure 47 Pump Control 39 Figure 48 Motor Speed 39 Figure 49 Burner Control 40 Figure 50 Smart Clean Window 40 Figure 51 Tank Valve 42 Figure 52 Front Load Valve 42 Figure 53 Suck Back Bar Circ 42 Figure 54 Operation page 2 screen 42 Figure 55 Taper Switch 43 Figure 56 Marker Valves 43 Figure 57 Wash Pump 43 Figure 58 Operation page 3 screen 44 Figure 59 Log S...

Page 6: ...struction Plates should remain in place and be legible Should a plate be removed lost or become illegible reorder and replace immediately If plates become difficult to read because of material coating the surface clean with solvent 30 6705038 1 Gauge Tank LED Figure 1 Location of Warning and Instruction Plates ...

Page 7: ... loaded with an AC or MC type material to develop a protective coating Periodic inspection of the tank and spray system should be preformed in the normal course of operation It is recommended that distributors used in Cationic service be flushed periodically and at the end of the season with an AC MC or cutback to remove the corrosive materials and to provide a protective coating Increasing the qu...

Page 8: ...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 or property damage All of these warnings are listed below and they also appear throughout the manual In addition to these you will find notes throughout the manual NOTE A note p...

Page 9: ... the vehicle in a confined area When the burners go out shut off the fuel supply to both burners and allow the flues to ventilate for at least 3 minutes before re lighting the burners Do not heat the material beyond the manufacturer s recommended temperature Keep burning cigarettes or other sources of combustion away from manholes and overflow vents Keep area free of all sources of combustion when...

Page 10: ...9 GENERAL SAFETY INSTRUCTIONS WARNING WARNING If a flue is not covered by 6 of material the corre 00 100 Using the Measuring Stick ...

Page 11: ...s active and the burner ON button is pressed the fault Burners Low Level will become active on the faults page Figure 2 Flashing Low Level Indicator Figure 3 Low Tank Burners fault Foaming If the Distributor is to be filled with hot bitumen proceed very cautiously If there is any moisture in the tank or if an emulsion product was the last load foaming or eruption may occur Dow Corning DC 200 may b...

Page 12: ... this manual may not apply If you have any questions regarding this manual or your unit contact your Etnyre dealer or the E D Etnyre service department at 1 800 995 2116 To turn on the Etnyre Blacktopper distributor the power switch in the front control box must be turned on and the emergency stopped in the rear control box must be released The touchscreen display always begins in its Home page in...

Page 13: ... Nozzles Spray Valve Flip Lever Breakaway Swivel Joint Nozzle Hydraulic Oil Tank Hydraulic Oil Filters Location depends per unit LPG Tank may be on right or left side Fuel Oil Burner Fuel Tank on right side frame when applicable Thermometer Well Tool Box and Rear Control Panel Hose Trough Transfer Line Fill Line Fill Line Strainer Manhole Platform LED Tank Gauge Exhaust Stack Dampers Exhaust Stack...

Page 14: ...e Spray Valve Spray Valve Control Linkage and Air Cylinder Standard Spray Bar Components Hydraulic Tank Components 1 2 1 3 8 8 3 4 5 6 7 1 Hydraulic Filter 2 Thermo Switch 3 Mounting Bracket 4 Thermometer 5 Vented Breather Cap 6 Oil Eye Sight Plug 7 Hydraulic Tank Assembly 8 Vacuum Gauge Indicators Figure 6 Spray Bar Component Identification Figure 7 Hydraulic Tank Component Identification ...

Page 15: ...zles are off and will not spray 4 BLUE Position of the taper switch The noz zles are off and all nozzles outside taper switch position are off and colored YELLOW and or RED 2 MASTER SPRAY Switch Turning this switch to ON opens all activated spray valves when BAR CIRCULATE or SUCK BACK is selected The spray valves are allowed to open in SUCK BACK for troubleshooting 3 WING FOLD Switches Wing Module...

Page 16: ...pray bar left or right at four inch incre ments 8 Right Bar Variable Width Bar only For variable bar units the right bar thumb wheel will shift the right spray bar left or right at four inch increments 9 Left Taper If the Taper Switch paid option is activated the left thumbwheel will move the left taper position in either direction 10 Right Taper If the Taper Switch paid option is activated the ri...

Page 17: ...at will automatically activate The EMERGENCY STOP switch is turned Off by pushing in and turned On by rotating counter clockwise 3 Joystick The Joystick shifts the spray bar left and right and moves it up and down If the spray bar is latched the spray bar cannot shift left or right 4 Left Bar Variable Width Bar only For variable bar units the left bar thumbwheel will shift the left spray bar left ...

Page 18: ...17 PREPARING FOR OPERATION ...

Page 19: ...y Pages 28 29 3 Network 4 Factory 5 Faults Pages 30 32 6 Diagnostics Pages 33 34 7 Help Page 35 8 Information Page 36 To get in machine Setup touch the Setup button enter the Setup password and touch Login Setup Password 61061 Oregon Illinois ZIP code Figure 10 Gear Icon Figure 11 Setup Button Figure 12 Setup Login Button Be careful when entering the Setup pass word Three consecutive login attempt...

Page 20: ...Rexroth 15 milliamps Danfoss Minimum Flow o Minimum pump flow rate in Bar Circulate and Spray modes When all one foot switches are off this is not used and the flow rate goes to zero o Default 5 gallons per minute Spray Delay ON o Amount of time after turning the Master Spray Switch ON that the spray valves will open This allows time for the four way valve to turn before opening the spray bar o De...

Page 21: ...raulic motor speed sensor The correct setting is dependent on the speed sensor used on the asphalt motor Be cautious in changing this from factory default o Default 48 Rexroth 43 42 series Danfoss 46 90 series Danfoss Smart Clean Suck Back o Amount of time the asphalt pump and circulation system automatically runs in Smart Clean Suck Back mode only for units equipped with SmartClean option o Defau...

Page 22: ...The four 4 memory slots other than Factory can be renamed by holding the memory name for 1 second A keyboard will pop up displaying the current memory name Edit this how you wish and press the green ACCEPT button to save the name The Factory memory slot cannot be saved over given a new name nor reset with the Reset Defaults button Figure 16 Memory Window and Keyboard Calibrations All calibrations ...

Page 23: ...tracted feedback will read close to 500 mV Press the STOP button once fully retracted and the calibration will save The extend and retract parameters will flash to indicate new calibrations have been saved into mem ory The red reset button will default calibrations to their factory values of 4700 mV for extend and 300 mV for retract Setup Figure 18 Machine Calibrations Window Figure 19 Left Bar Sm...

Page 24: ...alibration fault will activate in the fault screen Each of the three calibrations should settle on a similar current within 1 milliamp Danfoss series or 10 milliamps Rexroth series If this does not happen the calibration may not be accurate and it it recommended to recalibrate If the fault remains active and you wish to continue hold the Reset button to clear the fault and manually set your EDC th...

Page 25: ...0 meters per minute 3 Tap the green START button when the radar hits the beginning of the course 4 When the radar hits the end of the course press the red STOP button The computer counts a certain number of radar pulses throughout the calibration The saved calibration value is given in pulses The default calibration is 3014 If outside an acceptable range a fault will activate on the fault screen T...

Page 26: ...this sensor is the voltage feedback from the sensor The feedback is given in millivolts mV These values are unique on every machine and is set at factory Holding the red reset button will set the calibra tions to their factory defaults Joysticks and Thumbwheels Select the device you wish to calibrate and hold START Move the device across its entire range up down left and right and hold at the maxi...

Page 27: ... is open to allow material to return to the tank During the spray mode the power return valve has 2 options 1 Power return on This will close the return valve and then re open it after 3 seconds every time the spray switch is activated This will help in initial pressure when the spray bar opens 2 power return off This will keep the return valve open during spray operations Tank Valve can be set AU...

Page 28: ...t active until it is halfway between its center and maximum position A smaller deadband means the device is active closer to its center and a larger deadband means the device is active closer to its maximum position The Reset Defaults button set these to their default values Joystick Deadband 50 Taper Deadband 75 VWSB Deadband 90 It is recommended to make the Taper and VWSB Deadband relatively hig...

Page 29: ...cross the control panels scale with their corresponding display s brightness Touch Point The transparent yellow circle that indicates a touch point throughout this manual can be shown or hidden on the display with the Touch Point control Its size can be adjusted up or down A size of 1000 is default Screen Saver Screen Saver Delay sets the time the display goes into its screen saver after not regis...

Page 30: ...e will be displayed here and an icon will be visible in the header To remove the flash drive you must touch Remove and wait until the folder reads not available or else the display is unable to read another flash drive until after a power cycle A flash drive can be used for computer or display application or firmware updates or as a place to move data logs from the display Reference 6 on page 14 i...

Page 31: ...r after that time if it is still active in the computer Page 1 Under Application The hydraulic pump is at its maximum output and the asphalt pump is under the desired application rate The ground speed is too fast and or the engine speed is too slow Over Application The hydraulic pump is at its minimum output and the asphalt pump is over the desired application rate The ground speed is too slow and...

Page 32: ...omputer or it is not turned on Rear Display The rear display ethernet is disconnected from the computer or it is not turned on Front I O Module The I O module in the front control box is disconnected from the CAN bus or indicating a faulty input or output Left Air Output Module The left side output module bank is disconnected from the CAN bus or a fault code is present on at least one of the outpu...

Page 33: ...he outputs Other CAN Modules At least one of the other CAN devices on the control panel is disconnected from the CAN bus or indicating a faulty input or output signal Computer IOs At least one input feedback is out or range or output command is not functioning properly Left Variable Width Spray Bar The left bar smart cylinder has been calibrated incorrectly or is showing unacceptable feedback Righ...

Page 34: ...alve or function it is controlling whether it is commanded ON or OFF current supplied at the output in milliamps and PWM duty cycle percentage Each output can also be toggled on or off for testing purposes Please refer to Ap pendix A Page 93 Appendix B Page 94 to relate abbreviations to function names Spray Valves Spray Valves control can help the operator test the spray nozzle outputs Hold ON to ...

Page 35: ...r and needs to be replaced To replace switch unscrew 6 socket screws on switch panel face plate Remove face plate and gently pull the switch straight out Replace bar feet switch with new P N 6705048 Wing module switches are P N 6705049 Position and millivolt feedback of the joystick and thumbwheels are shown When the joystick button is pressed it will turn from white to orange If the thumbwheels o...

Page 36: ...or is now built in to the touchscreen display Access it by tapping the Computator button Adjust desired spray bar length application rate and ground speed The resulting pump speed to reach the application rate is shown in Auto Pump After selecting the spray nozzle number and which nozzles are spraying the minimum optimal and maximum driving speeds are also shown For a solid and con sistent fan out...

Page 37: ...Service representative A key of all paid for factory options is given in the bottom right Please refer to Appendix A Page 93 to relate abbreviations to options The bottom header shows the application versions of the computer and displays The Etnyre service depart ment phone number is also given Pump Meter The pump meter shows the amount of time the asphalt pump has been spun Figure 40 Information ...

Page 38: ...tputs for the operator to install their own lights Each light sig nal is 12 volts but has a maximum current draw NOTE Ensure your lights draw less current than what is available or they will not turn on The name of each of the two Beacon Strobe and Work lights can be changed Tap the yellow Title bar to bring up a keyboard and enter the desired name Press the green ACCEPT button to save the new nam...

Page 39: ...peration Mode control to show a pop up of the eight modes available in a Distributor 10 if equipped with the Smart CleanTM option To change the Operation Mode tap any of the pop up buttons The pop up is automatically hidden three seconds after no input or changing the mode Pump Control During AUTO pump control the computer continuously adjusts the hydraulic pump output to maintain a con stant appl...

Page 40: ... ON motor speed is set by the automatic pump control GPM flow rate When the flow rate goes above 30 GPM 115 LPM motor speed becomes HIGH When the flow rate goes below 25 GPM 95 LPM motor speed becomes LOW Between 25 and 30 GPM motor speed is unchanged It is recommend to set this to AUTO while spraying This setting is saved in computer memory and stored on a power cycle Smart Clean if equipped If e...

Page 41: ... on and will shut both burners OFF when finished The timer begins at 60 minutes or 15 minutes if there is poor feedback from the temperature sensor While less than five minutes remain on the timer all flame icons will flash as a reminder the burners will be shutting off soon To reset the timer and extend burn time hold the red Reset Timer button for 5 seconds Burners can only operate in the operat...

Page 42: ...rate for 15 min utes without further operator input The burner s will automatically shutdown if the built in timer is allowed to expire The timer can be reset by the operator at anytime through the Timer Reset switch During the last 5 minutes of the timer interval the message BURNER TIMER ENDING will be displayed on the screen The burner s will not turn back on without cycling the burner switch s ...

Page 43: ...can also be used to OPEN or CLOSE a front load valve This always begins CLOSED on a power cycle and is not saved to computer memory Suck Back Bar Circ if equipped The Suck Back Bar Circ control allows you to open the Suck Back valve while in Bar Circ This valve always starts CLOSED after a power cycle Page 2 In addition to the main controls Page 2 gives control for the Taper Switches Wash Pump if ...

Page 44: ... move the taper position one foot left on the spray bar Moving it right will shut off the nozzle at the taper position and move the taper position one foot right on the spray bar Likewise the right taper switch con trols the right spray bar taper position Moving this right will turn on the nozzle at the taper position and move the taper position one foot right on the spray bar Moving it left will ...

Page 45: ...rameters are tracked and stored to a file timestamp start and end of spray spray totals av erage ground speed average pump rate total spray time and minimum and maximum asphalt temperatures Tap ON to tell the touchscreen to begin logging spray totals parameters These are continuously saved while the Distributor is spraying Tapping DONE will write the parameters to a file and reset logging for the ...

Page 46: ...ace or expansion space above the tank full level This air space should not be used to carry product The tank full level is based on the vehicle s axle ratings and GVWR at a material density per gallon If a material of heavier density is used the resulting tank full is lower If you suspect there may be moisture or emulsions in the tank Dow Corning DC 200 additive Etnyre P N 7220056 can be used to r...

Page 47: ...the previous load Do not heat material over 200 F if moisture or emulsion is present in tank Handspray Valve Position Return Valve Open Hand Spray Valve Closed 4 Way Valve Tank Valve Closed Master Handspray Valves Off Transfer Valve Closed Transfer Line Suck Back Valve Closed Flush Valve Closed Suck Back Valve Closed Transfer Line cap on and secured Load Line cap on and secured HOME Keyway in 12 o...

Page 48: ...prevent an explosion or fire hazard keep burning cigarettes or other sources of com bustion away from manholes and overflow vents To prevent burns always wear eye protection long sleeve shirt insulated gloves boots and long pants outside the boots when working around the Distributor WARNING Before removing the fill line cap make certain the asphalt pump is turning and the suction valve is closed U...

Page 49: ...ns will increase or decrease the pump speed by 10 Figure 63 LOAD Operation Mode 13 When the desired amount of product is in the Distributor tank close the supply tank a Tank fill volume is always visible in the touchscreen Header and rounded to the nearest 25 gallons b The rear LED bar has 15 segments that each represent 1 15 of the listed tank volume 14 At the supply tank carefully open the bleed...

Page 50: ...with experience Short periods of operation while the pump is cavitating will not damage the pump but you should not operate the pump in this condition for extended periods Higher pump speeds will not load thicker materials faster Lighter materials or heavy materials which are already at spraying temperature may be loaded at faster rates CAUTION OFF Handspray Valve Position Return Valve Open Hand S...

Page 51: ...ransfer line valve closed Flush valve closed Load and transfer line caps are in place and secured WARNING To prevent possible burns from material overflow allow sufficient space in the tank for expansion of the material when heating To prevent burns always wear insulated gloves when handling spray bar sections or hoses Figure 67 TANK CIRC Operation Mode 7 Set pump control to AUTO or MANUAL 8 Press...

Page 52: ...ot operate the burners when the vehicle is unattended when the vehicle is in motion or with the vehicle in a confined area To prevent possible burns from material overflow allow sufficient space in the tank for expansion of the material when heating OFF Handspray Valve Position Return Valve Open Hand Spray Valve Closed 4 Way Valve Tank Valve Open Master Handspray Valves Off Transfer Valve Closed T...

Page 53: ...alve closed Load and transfer line caps are in place and secured 9 Set pump control to AUTO You may also select MANUAL if desired If in AUTO set the desired application rate Figure 69 BAR CIRC Operation Mode 10 Press the green START PUMP button a If AUTO the asphalt pump will start spinning at the auto pump rate b If MANUAL adjust pump speed by increas ing the Pump Speed slider 11 If no other oper...

Page 54: ...er Line Suck Back Valve Closed Flush Valve Closed Suck Back Valve Closed Transfer Line cap on and secured Load Line cap on and secured BAR CIRC Keyway in 9 o clock position Figure 70a Valve Positions for Circulating in the Variable Width Spray Bar Figure 70b Valve Positions for Circulating in the Standard Spray Bar WARNING To prevent excessive pressure in the spray bar the asphalt pump speed shoul...

Page 55: ... the desired spray width using the One Foot switches and folding the spray bar wings If variable bar you may adjust spray bar width by extending or retracting either bar 6 If driving an automatic transmission truck select the transmission gear and rear axle speed that produces the most optimal engine and ground speed for spraying 7 Release the parking brake and start moving the truck 8 When the sp...

Page 56: ...ve Positions for Spraying Through the Standard Spray Bar Figure 72a Valve Positions for Spraying Through the Variable Width Spray Bar WARNING Do not run the pump above the rated capacity of 400 GPM Damage to equip ment may occur To prevent an explosion or fire hazard do not operate the burners while spraying OFF Handspray Valve Position Return Valve Closed Hand Spray Valve Closed 4 Way Valve Spray...

Page 57: ...ue to the nature of the condition of the wash down system this may take extra time With the wash down pump running open the flush valve for a period of time 20 to 30 seconds depending on material in the circulating system to allow release agent to migrate into the strainer box and over to the asphalt pump NOTE The pump can be stopped and the auto mat ic tank valve can be closed immediately at any ...

Page 58: ...Spray Bar Suck Back Figure 74a Valve Positions for Variable Width Spray Bar Suck Back WARNING To prevent possible burns from hot asphalt spray do not stand or allow anyone to stand where accidental opening of a valve may cause contact with hot asphalt When using rear pump control engine RPM changes will affect asphalt pump speed CAUTION OFF Handspray Valve Position Return Valve Open Hand Spray Val...

Page 59: ... bar width actual flow rate and target flow rate is also shown In Auto SPRAY mode the computer will continuously adjust the pump output to spray a steady amount of asphalt at the chosen application rate While spraying the spray icon will flash in the header The operator can press the HOME button to adjust any operator parameters and the distributor will still remain in SPRAY mode To get back on th...

Page 60: ... an optimal fan on to the ground If the nozzle flow is at or below the minimum the NRI bar will be red and all the way to the left in the UNDER range The operator should speed the truck up to spray closer to the optimal range If the nozzle flow is at or above the maximum the NRI bar will be red and all the way to the right in the OVER range The operator should slow the truck down to spray closer t...

Page 61: ...ng at the default rate of 100 GPM Press START The pump will start turning at the default rate of 100 GPM WARNING To prevent possible burns from hot asphalt spray do not stand or allow anyone to stand where accidental opening of a valve may cause contact with hot asphalt Figure 78 Handspray Operation Mode 79 ...

Page 62: ... pants outside the boots when working around the Distributor Handspray Valve Position Return Valve Closed Hand Spray Valve Open 4 Way Valve HAND SPRAY Keyway in 12 o clock position Tank Valve Open Master Handspray Valves Handspray Transfer Valve Closed Transfer Line Suck Back Valve Closed Flush Valve Closed Suck Back Valve Closed Transfer Line cap on and secured Load Line cap on and secured OFF HA...

Page 63: ...g NOTE The pump can be stopped and the automatic tank valve can be closed immediately at any time during operation by turning the EMERGENCY STOP switch OFF Before turning the EMERGENCY STOP switch back ON turn the PUMP SPEED to zero to prevent the pump from turning WARNING To prevent possible burns from hot asphalt spray do not stand or allow anyone to stand where accidental opening of a valve may...

Page 64: ...ose and the pump will begin sucking back material in the spray bar at 200 GPM The following steps are performed in the cab while BAR CIRC Bar Circulate is selected on the rear panel Function keypad 1 Turn the SUCK BACK OVERRIDE switch ON 2 If complete bar suck back is desired follow the instructions for Bar Suck Back beginning with the opening of the left bleeder valve Otherwise con tinue to the n...

Page 65: ...he pump in AUTO control with the PUMP SPEED knob fully counter clockwise select MANUAL control NOTE The pump can be stopped and the automatic tank valve can be closed immediately at any time during operation by turning the EMERGENCY STOP switch OFF Before turning the EMERGENCY STOP switch back ON turn the PUMP SPEED to zero to prevent the pump from turning Bar Flush Manual Refer to Figure 82c for ...

Page 66: ... Valve Closed Transfer Line cap on and secured Load Line cap on and secured Tank Circ Keyway in 12 o clock position Figure 82b Standard Bar Valve Positions for Flushing Figure 82a Variable Width Bar Valve Positions for Flushing OFF Handspray Valve Position Return Valve Open Hand Spray Valve Closed 4 Way Valve Circulate In Bar Tank Valve Closed Master Handspray Valves Off Transfer Valve Closed Tran...

Page 67: ...AUTO 9 Press the UNLOAD button on the Function keypad If so equipped 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 at the desired pump speed 12 When finished unloading press the HOME but ton on the Function keypad If so equipped the optional manual tank valve should be closed 13...

Page 68: ...alt Operations WARNING To prevent burns always wear insulated gloves when handling spray bar sections or hoses TANK CIRC Keyway in 12 o clock position with Spray switch ON Figure 84 Valve Positions for Unload with External Pump ...

Page 69: ...g the flow between the Distributor and the storage tank is unobstructed decrease the PUMP SPEED to zero 10 Put the PUMP CONTROL to AUTO 11 Press START The pump will start turning at the default rate of 100 GPM 12 When finished unloading press the SUCK BACK button If so equipped the optional manual tank valve should be closed 13 Close the valve at the storage tank 14 Close the transfer valve 15 Ope...

Page 70: ...ATIONS Asphalt Operations Figure 86 Valve Positions for Unload with Distributor Pump UNLOAD Keyway in 12 o clock position WARNING To prevent burns always wear insulated gloves when handling spray bar sections or hoses ...

Page 71: ...nk carefully open the bleeder valve or break the hose connection until a strong vacuum is heard It may be necessary to reduce the pump speed in order to overcome the pump vacuum when breaking the hose connection El evating the hose above the load line connection will allow maximum drainage of the hose 17 Disconnect the hose from the load line 18 Replace the load line cap and secure 19 Put the PUMP...

Page 72: ...8 Valve Positions for Transfer WARNING To prevent burns always wear insulated gloves when handling spray bar sections or hoses Suckback of the storage tank line will put material into the tank and could cause an explosion if the tank has not been fully cleaned of emulsion material WARNING ...

Page 73: ...ivered will be dramatically reduced and the life of the burner will be shortened HEATING PRODUCT IN DISTRIBUTORS Liquid Propane Gas LPG Burners IMPORTANT Circulating the asphalt in the tank while heating is recommended for faster heating and reduced carbon formation on the flues Only when the asphalt pump is Frozen is it acceptable to operate the burners without circulating asphalt in the tank How...

Page 74: ...NDING will be displayed on the screen The burner s will also turn off if the temperature sender goes out of range during burner operation In all conditions the burner s will not turn back on without cycling the burner switch s Turn the switch or switches off then on The thermostatic control temperature is measured at the bottom of the tank The temperature in the bottom of the tank may be significa...

Page 75: ...rgency Stop switch is turned off during burner operation the burner s will turn off and will not turn back on with out cycling the burner switch s If the distributor is driven faster than 300 FPM or if Hand Spray Unload Transfer Spray Flush or Aux is selected during burner operation the burn er s will turn off and will not turn back on with out cycling the burner switch s Without the optional ther...

Page 76: ...anufac turers recommended temperature 8 Do not heat material over 200ºF 95ºC if moisture is present in tank 9 To prevent possible burns from material overflow allow sufficient space in tank for expansion of material when heating 10 Check overflow tube for restrictions 11 There must be at least 6 inches of material covering the entire length of the upper flue before the second burner can be lit 12 ...

Page 77: ...nged in 5 degree increments is reset to 95 F 35 C when the system power is turned on The timer will allow 15 minute heating intervals if temperature sender is out of range 999 is dis played in place of the actual temperature or 60 minute intervals otherwise The timer can be reset by the operator at anytime through the Timer Reset switch During the last 5 minutes of the timer interval the burner ic...

Page 78: ...system pressure low Raise pressure Low oil in hydraulic reservoir Add hydraulic oil to correct level Defective Hyd motor Check for excessive case drain in motor Material in tank or pump below pumping temperature Heat material to proper pump temperature Air leak in suction line from reservoir to filter to inlet of charge pump Locate and repair leak Low oil in hydraulic reservoir Add hydraulic oil t...

Page 79: ...p area free of sparks or open flames when testing burners Gun Assembly NOTE Before installing gun assembly check that blower wheel turns freely and that all set screws are tightened securely Figure 90 Gun Assembly Figure 92 Right Hand Left Hand Electrodes Maintenance Electrode Settings WARNING ...

Page 80: ...ion transformer and secure to burner housing Fire Burners 1 Ensure that fuel oil pressure is 150 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 flues must be covered by minimum 6 inches of material when burners are in operation When testing burners do not run burners for more than 15 seconds if t...

Page 81: ... measure the bore of the case at its widest point horizontally side to side This measurement must not exceed 9 910 inches 6 Next measure the case bore vertically at a point 2 8 inches from each side The vertical measure ment must not exceed 5 660 inches If any bore measurements exceed these limits the entire pump must be replaced 7 If inspection indicates the pump case is accept able measure the o...

Page 82: ...Service Department for recommendations for these fluids Avoiding the use of Dexron II transmission fluids which do not meet Allison C 3 specification is recommended Viscosity Temperature Requirements The fluid must have sufficient viscosity to maintain an oil film at the bearing surfaces This depends on fluid selection and on operating temperature Recommended viscosity for best life and efficiency...

Page 83: ...t up for the system loop should be equal to or better than Curve D The machine may be exercised to 500 psi but should not be worked pressure over 500 psi until the oil cleanliness meets or exceeds Curve C The machine should clean up during a relatively short period of normal operation to meet the oil cleanliness level of Curve A or Curve B A system that meets Curve A will provide the user with a l...

Page 84: ...ght Per BTU Content Gallon 2 Fuel Oil 7 49 lbs 144 300 per gallon Propane 4 20 lbs 91 500 per gallon Approximate Burner Fuel Consumption Fuel Oil 350 000 BTU 2 50 GPH per burner 140 000 BTU per gallon Propane 1 600 000 BTU 25 PSI 7 25 GPH per burner 82 800 BTU per gallon Heating Terminology Flash Point Open Cup The temperature at which a flammable liquid in an open container emits vapor that will ...

Page 85: ... Y X R Y BK 6705043 PADDLE ROCKER SWITCH NOTE RED WIRE TO FACE UP W L TAPER LEFT RIGHT Y R TAPER LEFT RIGHT 1 2 3 3 2 1 1 2 6 3 4 5 1 2 6 3 4 5 OR 5V OR 5V OR 5V BK BK BK 1 2 3 3 2 1 X R BK Y X R Y BK 6705043 PADDLE ROCKER SWITCH NOTE RED WIRE TO FACE UP 6705043 PADDLE ROCKER SWITCH NOTE RED WIRE TO FACE UP TO CONNECT LINES 6704594 5 POSITION BUSS 6705286 2 POSITION BUSS TYP W L VWSB FRONT SIGNAL ...

Page 86: ... MOD BK WING MOD R WING MOD BK WING MOD 12 TOUCHSCREEN 3371090 6704978 NON PROGRAMMED 1 R SCREEN 14 GA BK SCREEN 14 GA 2 R SCREEN 14 GA BK SCREEN 14 GA 3371146 TOUCHSCREEN HARNESS R INPUT MOD BK INPUT MOD R INPUT MOD BK INPUT MOD R REVERSE SIGNAL 1 2 BK NIGHTLIGHT BL NIGHTLIGHT 1 2 W BK NIGHTLIGHT 6703972 PLUG 6703787 WEDGE 6703788 PIN SOCKETS 6703789 6705044 SPEAKER 3371026 CAB HARNESS 6705016 IN...

Page 87: ...CKER SWITCH NOTE RED WIRE TO FACE UP OR VWSB 5V OR VWSB 5V BK W L BAR L R Y R BAR L R VWSB OPTION SWITCH ADDITION 1 2 BK NIGHTLIGHT BK NIGHTLIGHT 20 BL NIGHTLIGHT 1 2 W BK NIGHTLIGHT 6703972 PLUG 6703787 WEDGE 6703788 PIN SOCKETS 6703789 6705010 JOYSTICK NOTE NOTCH ON BODY TO FACE UP 6 BL EDC 45 W HYD TEMP 46 W RTD 18 BL AUGER R RADAR OR TANK LEVEL R HYD TEMP R RADAR R HYD TEMP BK RADAR BK WASH PU...

Page 88: ... BK 12V BATTERY 14 GA R BK 12V BATTERY 14 GA R E STOP R R MASTER R GN RELAY R GN RELAY C B A R 10 GA BK 10 GA TO CONTROLLER TO CONTROLLER R BK 12V BATTERY 14 GA TRUCK BATTERY POWER IF NEEDED R MASTER R BK 12V BATTERY R BK 12V BATTERY 14 GA R MASTER HED 14 GA HED 14 GA R 12V SWITCHED R 12V SWITCHED BN CAB SENSOR BK CAB GROUND BK CAB GROUND UND 14 GA UND 14 GA 3371030 HARNESS BK POWER RELAY R 10 GA ...

Page 89: ... BK 1 LW2 12V BK 2 LW2 GRND Y GN LW3 SIGNAL BK 1 LW3 12V BK 2 LW3 GRND Y GN RW2 SIGNAL BK 1 RW2 12V BK 2 RW2 GRND Y GN RW3 SIGNAL BK 1 RW3 12V BK 2 RW3 GRND Y GN RW2 SIGNAL BK 1 RW2 12V BK 2 RW2 GRND Y GN RW3 SIGNAL BK 1 RW3 12V BK 2 RW3 GRND 6 3 1 6 3 1 6 3 1 6 3 1 6705018 TILT SWITCH L W2 6705018 TILT SWITCH L W3 6705018 TILT SWITCH R W2 6705018 TILT SWITCH R W3 3371037 HARNESS BI FOLD 3371139 H...

Page 90: ...S 7 12 GREEN OUTPUTS 1 6 BROWN 6705015 OUTPUT DRIVER T BALANCE Y R10 W R11 V R12 W R R MARK BK BK BK BK BK BK BK BK BK BK BK PR R4 R R5 GN W R6 BL W R7 LTBL R8 LTGN R9 BK BK BK BK BK BK BL R VALVE BR BAR LATCH GN BAR CIRC GR R1 OR R2 PK R3 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 ONE PLUG FOR EVERY VALVE ON THE MANIFOLD 6605101 THAT IS USED IF THERE IS A BAR SECTION OR F...

Page 91: ... 9 4 5 11 R 14 GA R 14 GA BK 14 GA BK 14 GA R CAN HI GOLD BK CAN LO GOLD 3371076 HARNESS 3371033 HARNESS OUTSIDE OF UNIT V 3371073 HARNESS 1 2 W L VWSB FRONT SIGNAL Y R VWSB FRONT SIGNAL MAIN HARNESS MAIN HARNESS NOTE THIS CONNECTION ONLY NEEDS TO BE MADE IF UNIT HAS A VWSB 4 1 2 3 5 6 7 R GOLD BK GOLD SHIELD GOLD R 14 GA R 14 GA BK 14 GA BK 14 GA 4 1 2 3 5 6 7 3371033 HARNESS R GOLD BK GOLD SHIEL...

Page 92: ...R LWL GN W LWR BL W RWL LTBL RWR LTGN S LOCK BK BK BL DUMP PK LOWER 1 2 1 2 1 2 1 2 1 2 1 2 1 2 1 2 3371076 HARNESS SS 3371094 HARNESS 3371094 HARNESS BLACK 3371093 HARNESS GREY 3371093 HARNESS ONE PLUG FOR EVERY VALVE ON THE HYDRAULIC MANIFOLD THAT IS USED IF THERE IS A FUNCTION NOT CALLED FOR ON THE UNIT ZIP TIE UNUSED PLUGS OF UNIT VWSB 8 10 3 9 4 6 5 11 12 BK BK BK BK BR BAR LATCH GN BAR CIRC ...

Page 93: ...aringly 14 Pump Shaft Coupling AS Sparingly SERVICE 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 F AS 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 ro...

Page 94: ...Wing 3 Lower 15 R3R Right Wing 3 Raise 16 SL Bar Shift Left 17 SR Bar Shift Right 18 MS Motor Speed 19 unused 20 unused APPENDIX A Right Side Air 1 RT Rear Tank 2 BL Bar Latch 3 BC Bar Circulate 4 R1 Right Foot 1 inner 5 R2 Right Foot 2 6 R3 Right Foot 3 7 R4 Right Foot 4 8 R5 Right Foot 5 9 R6 Right Foot 6 10 R7 Right Foot 7 11 R8 Right Foot 8 12 R9 Right Foot 9 13 R10 Right Foot 10 14 R11 Right ...

Page 95: ...unused 10 unused 11 unused 12 unused 13 unused 14 unused 15 unused 16 unused 17 unused 18 unused 19 unused 20 unused Left Side Air 1 1 1 Left 1 1 inner 2 1 2 Left 1 2 3 1 3 Left 1 3 4 2 1 Left 2 1 5 2 2 Left 2 2 6 2 3 Left 2 3 7 3 1 Left 3 1 8 3 2 Left 3 2 9 3 3 Left 3 3 10 4 1 Left 4 1 11 4 2 Left 4 2 12 4 3 Left 4 3 13 5 Left 5 14 6 Left 6 15 7 Left 7 16 8 Left 8 17 9 Left 9 18 10 Left 10 19 11 ...

Page 96: ...5 Wait until completion and cycle power The display should start with the new program For computer program updates 1 Navigate to the Computer Updates screen by touching the Computer Updates button in Setup Page 3 a If the touchscreen program version does not match the computer program version the touchscreen will not boot past its Splash Screen after turning on The Computer Updates screen can be a...

Page 97: ...6 APPENDIX D Default GPM LPM Chart APPENDIX D Operation Default Default Mode GPM LPM Tank Circ 150 567 81 Hand Spray 50 189 27 Suck Back 200 757 08 Flush 100 378 54 Unload 100 378 54 Transfer 100 378 54 ...

Page 98: ...97 Etnyre Spraybar Nozzles Application Application US Flow ...

Page 99: ...98 Fraction 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 Decimal Equivalent Chart ...

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