Etnyre Black-Topper User guide

1
M-103-12R1
Black-Topper Centennial Operation, Maintenance, and Safety Manual
BLACK-TOPPER Distributor with
Standard Spraybar and BT-1 Controls
Version 4.5 & up
WARRANTY
E. D. Etnyre & Co. warrants to the original Purchaser, its new product to be free from defects in material and workmanship
for a period of twelve (12) months after date of delivery to original Purchaser. The obligation of the Company is limited
to repairing or replacing any defective part returned to the Company and will not be responsible for consequential
damages or any further loss by reason of such defect.
The company excludes all implied warranties of merchantability and tness for a particular purpose. There are no
warranties, 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 the
replacement or repair of defective parts, nor does it guarantee repair or replacement of any parts on which unauthorized
repairs or alterations have been made or for components not manufactured by the Company except to the extent of
the 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 or
modication after shipment from factory.
(4) Any product or part thereof damaged or lost in shipment. Inspection for damage should be made before acceptance
or 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 all
warranties of merchantability or otherwise, express or implied in fact or by law.
WARNING
Do not use this machine for any operation that is
not described in this manual.
If you have any questions about operation of this
machine, contact the Etnyre Service Department at
1-800-995-2116 or 1-815-732-2116.
Operations that are not approved could cause
serious injury or death.
WARNING
Diesel engine exhaust and some of its constituents
are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
Please note this warning
and remember:
• Always start and operate the engine in a well
ventilated area.
• If in an enclosed area, vent the exhaust to the
outside.
• Do not modify or tamper with the exhaust system.
Can cause serious injury or death.
Serial Number S5613 and up
Updated June 23, 2014

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© Copyright 2010 E.D. Etnyre & Co.
All brand names, trademarks and registered
trademarks are the property of their respective
owners. Information contained within this
document is subject to change without notice. All
rights reserved.

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Table of Contents
Safety Instructions
Warning And Instruction Plates ..........................5
General Safety Instructions ................................7
Safety Precautions, Hazard Seriousness Level .7
WARNINGS........................................................8
Fluoroelastomer Handling ...............................8
Foaming............................................................10
Asphalt Institute................................................10
Introduction.....................................................11
Reporting Safety Defects..................................11
Component Location And Identication............12
Rear and Side Components .............................12
Spray Bar Components ....................................13
Hydraulic Tank Components.............................13
Cab Control Panel ............................................14
Rear Control Panel...........................................16
Preparing for Operation.................................19
Setting Up the Computer..................................19
First Screen ..................................................19
Second Screen.............................................19
Third Screen .................................................19
Fourth Screen...............................................20
Fifth Screen ..................................................20
Sixth Screen .................................................20
Engaging Pump on PTO Equipped Distributors .. 20
Manual Transmissions..................................20
Automatic Transmissions..............................20
Spraying Operations.........................................21
Setting the Digital Memory Presets ..................22
Adjusting the Spray Bar Nozzle Angle..............22
Adjusting the Spray Bar Height ........................22
Operation.........................................................23
Tank Capacity...................................................23
Operation Screens............................................23
First Operating Screen .....................................23
Second Operating Screen ................................23
Third Operating Screen ....................................24
Information Messages ......................................24
Loading.............................................................26
Loading Through the Manhole......................26
Loading Through the Load Line
Connections and Preliminary Checks...........27
Check Strainers............................................27
Using the Measuring Stick............................27
Loading Through the Load Line....................28
Circulating in the Tank ......................................30
Circulating Product in the Bar...........................32
Spraying Through the Bar ................................34
Hand Spraying..................................................35
Spray Bar Suckback.........................................36
Bar Suck Back Override ...................................38
Handspray Suckback........................................39
Flushing Operations .........................................40
Bar Flush (Auto) ...........................................40
Bar Flush (Manual).......................................41
Enviro-Flush System (OPTIONAL)..............42
Recycle Enviro-Flush................................... 43
Unload Operations with External Pump............44
Unload Operations with Distributor Pump ........46
Transfer Operations..........................................48
Heating Product in Distributors ....................50
Heating with Propane Burners .......................50
Propane Requirements................................50
Manual Ignition Control................................51
Ignition and Out Fire Control .......................52
Thermostatic Control ...................................54
Heating with Fuel Oil Burners ........................55
Ignition and Out Fire Control .......................56
Thermostatic Control ...................................57
Troubleshooting .............................................58
Maintenance....................................................60
Gun Assembly ..................................................60
Electrode Settings ............................................60
Check Ignition Transformer Spark....................61
Fire Burners......................................................61
Replacing Speed Pickup ..................................61
Servicing the Etnyre P-15 Pump ......................62
Vacuum Check .............................................62
Pump Disassembly And Inspection ..............62
Impeller Installation And Pump Assembly.....62
General Fuel Data and Heating Terminology ...63
Fuel Data......................................................63
Approximate Burner Fuel Consumption........63
Heating Terminology.....................................63
Hydraulic Fluid Requirements ..........................64
General Information......................................64
Hydraulic Fluid Requirements ......................64
Viscosity & Temperature Requirements .......64
Contamination Levels...................................65
Lubrication Chart ..............................................67
Etnyre Spraybar Nozzles..................................68
Serial Number Plate Location ..........................69
Decimal Equivalent Chart.................................69

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List of Illustrations
Figure 1. Location of Warning and Instruction Plates..................................... 5
Figure 2. Rear and Side Component Identication....................................... 12
Figure 3. Rear Component Identication...................................................... 12
Figure 4 Spray Bar Component Identication.............................................. 13
Figure 5. Hydraulic Tank Component Identication. ..................................... 13
Figure 6. Cab Control Panel Components.................................................... 14
Figure 7. Rear Control Panel Components. ................................................. 16
Preparing for Operation
Figure 8. Adjusting the Spray Bar Nozzles. .................................................. 22
Figure 9. Adjusting the Spray Bar Height. .................................................... 22
Operation
Figure 11. Valve Positions for Loading Through the Manhole. ..................... 26
Figure 12. Using the Measuring Stick........................................................... 27
Figure 13. Valve Positions for Loading Through the Load Line.................... 28
Figure 14. Valve Positions for Circulating in the Tank. ................................. 30
Figure 15. Valve Positions for Circulating in the Bar..................................... 32
Figure 16. Valve Positions for Spraying Through the Bar............................. 34
Figure 17. Valve Positions for Handspray..................................................... 35
Figure 18. Valve Positions for Spray Bar Suck Back.................................... 36
Figure 19. Valve Postions for Flushing. ........................................................ 40
Figure 20. Enviro-Flush Flow Diagram........................................................ 42
Figure 21. Recirculating Flushing System Operation................................... 43
Figure 22. Valve Positions for Unload with External Pump. ......................... 44
Figure 23. Valve Positions for Unload with Distributor Pump. ...................... 46
Figure 24. Valve Positions for Transfer......................................................... 48
Figure 25. Manual Ignition Control. .............................................................. 51
Figure 26. Ignition and Out Fire Control. ...................................................... 52
Figure 27. Fuel Oil Burner System. .............................................................. 56
Maintenance
Figure 28. Gun Assembly. ............................................................................ 60
Figure 29. Right Hand / Left Hand Electrodes.............................................. 60
Figure 30. Electrode Setting......................................................................... 60
Figure 31. Hydraulic Motor. .......................................................................... 61
Figure 32. Etnyre Asphalt Pump................................................................... 62
Figure 33. Fluid Cleanliness Chart. .............................................................. 65
Figure 34. Serial Number Plate Location...................................................... 69

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19 3390645 1 Label-Measuring Stick, 1 Flue
3390656 1 Label-Measuring Stick, 2 Flues
20 6320794 2 Plate- Warning, Manhole
21 6320790 1 Decal-Warning, GVWR
22 3390880 1 Decal-Handspray Operation
23 3390562 1 Bracket- Mtg, Decal, Hot Surface
24 6320800 1 Decal-Diesel Fuel Only
25 6320809 1 Decal-Instr, Air Oiler
26 6320785 2 Decal-Warn, 1" Handspray Hose
6320806 2 Decal-Warn, 3/4" Handspray Hose
27 6320802 1 Decal-Warning, Handspray Hose
28 6320784 1 Decal-Warning, Personal Protection
29 6320799 1 Plate- Warning, Burner, General
30 6320787 AR Decal- Directions, LPG Burner
31 6320804 1 Decal-Warning, No Riders
32 6320792 AR Decal- Directions, Fuel Oil Burners
*Included in 6320782 Decal Kit
•Included in 6320956 Decal Kit
starting with Serial# S5724
Warning And Instruction Plates
Figure 1. Location of Warning and Instruction Plates
For operator safety and possible liability protection, all Safety and Instruction Plates should
remain in place and be legible
Should a plate be removed, lost, or become illegible, reorder and replace immediately
If plates become difcult to read because of material coating the surface, clean with solvent
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1
23
4
4
57
8
9
10
11
32
16 17 18
12
15
13
14
8
8
19
20 21
22
23
24 25
28
27
30
29
26
31
26
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AR = As required
REF PART NO. QTY DESCRIPTION REF PART NO. QTY DESCRIPTION
1 6320808 1 Decal-Warn, Electrical Equipment
2 6320807 1 Decal-Warn, Master Power
3 6320796 1 Decal- Warning, Before Starting
4 6320793 2 Decal- Warning, Manuals
5 3390597 1 Plate-Name, Spec, VIN
6 3390696 2 Decal, Blacktopper Centennial
7 6320786 1 Plate-Instr, Hydraulic Oil
8 6320797 3 Plate-Caution, Hot Surface
9 3390655 1 Plate-Name, Distributor S/N, Brass
10 6320798 1 Decal-Warning, Safety, General
11 6320953 1 Decal-LP Burners
or
6320954 1 Decal-LP Burners w/ Outre
or
6320966 1 Decal-Fuel Oil Burners
12 6320272 AR Placard System (Optional)
13 6320789 1 Decal- Warning, Asphalt Grades
14 6320795 1 Decal- Warning, Fill Line Cap
15 6320788 1 Decal-Lubrication Chart
16 6320796 1 Decal- Warning, Before Starting
17 3390636 1 Decal- Warning, Flues Covered
18 9320955 1 Decal-Spray Valve Lubrication (VWSB)
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NOTICE
The handling of Cationic Emulsions (CRS-2, CMS-2, CSS-1 and CSS) may
create an environment within the Asphalt Distributor that can be corrosive to
carbon steel and cast iron.
• Cationic Emulsions are widely used within the industry.
• Cationic Emulsion is manufactured with asphalt, water, emulsiers and
hydrochloric acid. The chemistry of individual emulsions varies in asphalt
content and Ph levels.
• Tanks and spray mechanisms used with Cationic emulsions may experience
corrosion
• It is believed the chemistry of the emulsion - specically the residual fumes
promote the corrosion
• Etnyre Distributors are compatible with Cationic Emulsions provided that
certain precautions are taken.
• Prior to placing a distributor in to service with Cationic Emulsion, it should be
loaded with an AC or MC type material to develop a protective coating.
• 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 ushed
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 quantity of ushing material during daily suck back and
cleanout operations will also help to minimize corrosion damage.
• Dilution is the solution.
• Additional information can be acquired from your Emulsion supplier as well as
the Asphalt Institute or the Asphalt Emulsion Manufactures Association.
WARNING
Take extra care and follow recommended
procedures when alternating asphalt materials
especially when loading hot product, over 212
degrees Fahrenheit (100 degrees Celsius), on
to a tank and system previously in Emulsion
service.

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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 product
temperature, and these systems use highly combustible fuels. As with any type of construction equipment,
there are certain hazards associated with careless or improper operation.
Safety warnings have been provided to call attention to any potentially hazardous situation that may cause
property damage, personal injury or death to the operator or bystanders. These safety warnings will be shown
at various times throughout this manual, as they are applicable to the subject being presented. These safety
warnings are identied by the following warning symbols:
Safety Precautions, Hazard Seriousness Level
You will nd safety information boxes throughout this manual. These boxes contain information alerting you
to 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. Denitions of hazard levels
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 or
property damage.
All of these warnings are listed below and they also appear throughout the manual. In addition to these, you
will nd notes throughout the manual.
NOTE - A note provides general information that the operator should be aware of when performing an
operation.
General Safety Instructions
DANGER
To avoid an extreme re hazard or explosion,
NEVER use gasoline as fuel in diesel or fuel
oil burners.
WARNING
A fully charged dry chemical type re
extinguisher must be within easy reach
whenever the burners are operating or there
is an open ame near the Distributor. The
minimum capacity of the re extinguisher
should be 10 pounds.
Please Note This Warning
and Remember:
• Always start and operate the engine in a
well ventilated area.
• If in an enclosed area, vent the exhaust to
the outside.
• Do not modify or tamper with the exhaust
system.

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WARNING
A fully charged dry chemical type re
extinguisher must be within easy reach
whenever the burners are operating or there
is an open ame near the Distributor. The
minimum capacity of the re extinguisher
should be 10 pounds.
Fluoroelastomer Handling
Some O-rings and seals used in this vehicle
are made from uoroelastomers, When used
under design conditions, uoroelastomers do
not require special handling. However, when
uoroelastomers are heated to temperatures
beyond their design temperature (around
600º Fahrenheit), decomposition may occur
with the formation of hydrouoric acid.
Hydrouoric acid can be extremely corrosive
to human tissue if not handled properly.
A degraded seal may appear as a charred
or black sticky mass, Do not touch either
the seal or the surrounding equipment
without wearing neoprene or PVC gloves if
degradation is suspected. Wash parts and
equipment with 10% lime water (calcium
hydroxide solution) to neutralize any
hydrouoric acid.
If contact with the skin occurs, wash the
affected areas immediately with water. Then
rub a 2.5 calcium gluconate gel into the skin
until there is no further irritation, while seeking
prompt medical attention.
Note to Physicians: For advice or treatment
of HF burns, call the DuPont Medical
Emergency number, 1-800-441-3637.
To prevent an explosion or re hazard:
• Position the unit broadside to the wind to
prevent volatile fumes from drifting toward
the burners.
• Do not operate the burners if the tank is
damaged or leaking.
• Ensure that the burners are extinguished
before removing any material from the
tank in any manner. Liquid petroleum (LP)
burners can support a ame for several
minutes after the fuel supply is turned off.
To prevent an explosion or re hazard:
• Do not operate the burners when the vehicle
is unattended, when the vehicle is in motion,
or with the vehicle in a conned area.
• When the burners go out, shut off the fuel
supply to both burners and allow the ues 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
overow vents.
• Keep area free of all sources of combustion
when spraying.
• Check the tank vent to insure that it is free
from obstruction before lighting the burners.
• Eliminate sparks from engine exhaust.
• Do not operate the burners with the manhole
open or open the manhole while the burners
are in operation.
• Flues must be covered by a minimum 6
inches of material (bitumen) when burners
are in operation.
To prevent possible hand or facial burns:
• Always light the inside burner rst. Do not
reach across a lit burner to light or re-light
the inside burner. Shut off the outside burner
before lighting the inside burner.
To prevent possible burns:
• Always use a torch to light the burners.
Never attempt to light the burners using a
match or pocket lighter.
• Always wear insulated gloves when handling
spray bar sections or hoses.
• Always wear eye protection, face shield,
long sleeve shirt, insulated gloves, boots,
and long pants outside the boots when
working around the Distributor.
• Use extreme caution when using a torch to
heat the pump. Asphalt accumulated around
the pump may ignite when heating the pump
with a torch.
WARNINGS

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WARNINGS
To prevent possible burns from leaking
material:
• Be sure all pipe, cap and hose connections
are secure before opening valves, or
beginning any operation.
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.
To prevent possible burns from foaming
or violent eruption:
• Do not load tank with material temperature
over 200º F if water or condensation is
present in tank, or if emulsion was used in
the previous load.
• Do not heat material over 200º F if moisture
or emulsied material is present in tank.
To prevent burns from hot asphalt when
hand spraying:
• Hold the handspray gun in proper position
and watch for other people.
To prevent possible burns to operators
or bystanders, or possible equipment
damage:
• Do not start any operation if any control
settings are unknown.
To prevent severe injury from becoming
entangled in machinery:
• Stand clear of rotating drives.
To prevent possible injury:
• Always open the manhole cover slowly.
Pressure build up in the tank may cause
the cover to burst open.
To prevent possible re hazards, burns or
falls:
• Keep the unit clean for safe operation.
To prevent possible burns from material
overow:
• Allow sufcient space in the tank for
expansion of the material when heating
• Before removing the ll line cap, make
certain that the asphalt pump is turning and
the tank valve is closed.
WARNING
To prevent possible personal injury:
• Do not load the vehicle beyond the GAWR
or GVWR. The maximum load volume must
be calculated based on material density.
Allowing the burners to operate for a long period
of time without circulating can damage the product
and create explosive fumes. If product cannot be
circulated after fteen minutes of heating without
circulation, the burners should be extinguished for
20 - 30 minutes before re-lighting the burners.
Use the measuring stick as shown in Figure 12
in the Using the Measuring Stick section to determine
the amount of product in the tank before lighting
burners. The minimum amounts shown on the
warning placard only apply if the tank is level.
Remember that the measuring stick is accurate
only when the tank is level. If the tank is not
level, reposition the Distributor to place the tank in
a level position before taking nal measurement.
You must have at least the amounts shown, with the
tank level, in order to safely light the lower burner
and upper burner respectively. Failure to have
the appropriate amount, accurately measured
can result in an explosion causing death or
serious injury.