Etnyre Black-Topper CENTENNIAL S-2000 Series Service manual

Black-Topper®
CENTENNIAL Series,
S-2000 Series
Updates &
Service Material
M-131-07R
Supersedes M-131-07

1
Updates & Service Manual
Black-Topper Centennial Series, S-2000 Series
M-131-07R
Contents
Cationic Emulsion Notice ........................... 2
Warning - Fluoroelastomer Handling.......... 2
Etnyre Spraybar Nozzles ........................... 3
Adjusting the Spray Bar Nozzles................ 4
Flow Diagrams
Filling from Supply (Loading)............ 5
Circulate In Tank ............................... 6
Circulate In Bar................................. 7
Spraying............................................ 8
Suckback Spraybar........................... 9
Handspray ...................................... 10
Suckback Handspray...................... 11
Pump Off......................................... 12
Transfer .......................................... 13
Flushing .......................................... 14
Start Up Factor......................................... 15
DC2 Self Diagnostics ............................... 16
Checking: DC-2 Computer EDC Threshold .. 18
Speed Sensor Repair Kit.......................... 19
Tach Calibration ....................................... 20
Wiring - Radar and Pump Tach ................ 21
Dickey Johns Radar Wiring Diagram - Kit,
Radar Analog, 7510025 ........................... 22
12 Volt Power Supply ............................... 23
12 Volt Power Supply - Centennial with new
style wiring harness.................................. 24
12 Volt Relay in Rear Control Box without
Spray Delay Switch .................................. 25
Solenoid Valve Coils with built-in Diodes .... 26
Electronic Temperature Probe - DC-2 Com-
puter ......................................................... 27
Temperature Conversion - Resistance of
RTD Temperature Probe - Omega PR-14-2-
100-1/4-9-E 3370234 ............................ 28
Radio Frequency Interference Filter Installa-
tion ........................................................... 29
Wiring Schematic – Fuel Oil Burners with
Built-In Fuses ........................................... 30
Wiring Schematic – Fuel Oil Burners with
External Fuses ......................................... 31
Beckett Fuel Oil Burner Instruction Manual .... 32
4 Way Valve Rotary Actuator Modification 37
Installation of Actuators ............................ 38
4 Way Valve Modification ......................... 39
Asphalt Pump Shaft Seal Installation Tool
(3321447)................................................. 40
Instructions for installing (6445090) Shaft
Coupling between Asphalt Pump and Gear-
box on Centennial Distributors ................. 41
Ball Case Screw Tightening Procedure.... 42
Ball Joint Tightening and Locking............. 43
Heavy Duty Bar Raise.............................. 44

2
Cationic Emulsion Notice
Certain Cationic Emulsions are known to be corrosive to carbon steel, aluminum, and even some
grades of stainless steel. Hydrocloric acid is often used in cationic emulsions to produce the electronic
charge that makes the emulsion cationic. Cationic emulsions may be identified by the “C” at the beginning
of the product name or identification number, such as “CRS-2” or “CSS-1”. Cationic emulsions with low
amounts of residual asphalt, (below 60%) such as “CSS-1” have been found to cause corrosion to a
greater extent than those containing a higher percentage of asphalt.
Tanks used in cationic emulsion service may experience unexpected corrosion inside the tank,piping
and spray bar system. This corrosion may be worse if the tank is left loaded with a cationic emulsion
containing a low asphalt content, over extended periods of time, or in continuos use.The effects of this
corrosion activity may be lessend by alternating cationic emulsions with other products in the tank, such
as anionic emulsions, cut backs, or asphalt cements. Take necessary precautions whenever changing
types of asphalt to avoid boiling the water from emulsions when loading “HOT” asphalt cement.
Periodic inspection of tank should be performed in the normal course of operation. It becomes even
more important in the case of cationic emulsions. Visual inspection of the inside of the tank should be
performed regularly. Removal of the spray bar end caps will allow visual inspection of the spray bar. If any
corrosion is noted, the tank, piping, and spray bar should be flushed with a cut back asphalt, such as an
“MC” grade or with an asphalt cement.
Warning
Fluoroelastomer Handling
Some O-rings and seals used in this vehicle are made from fluoroelastomers, When used under design
conditions, fluoroelastomers do not require special handling. However, when fluoroelastomers are heated
to temperatures beyond their design temperature (around 600º Fahrenheit), decomposition may occur
with the formation of hydrofluoric acid. Hydrofluoric 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 hydrofluoric 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

3
Ref. Part No. Description Application Application Flow
Gallons (Metric) Liters Per Gallons Per
Per Square Yard Square Meter Minute Per Foot
1 3353788 V Slot Tack Nozzle .05 – .20 .19 – .75 3.0 to 4.5
2 3351008 S36-4 V Slot .10 – .35 .38 – 1.30 4.0 to 7.5
33351009 S36-5 V Slot .18 – .45 7.0 to 10.0
43352368 Multi-Material V Slot .15 – .40 .57 – 1.50 6.0 to 9.0
53351015 3/32” Coin Slot .15 – .40 .57 – 1.50 6.0 to 9.0
63352204* Multi-Material V Slot .35 – .95 1.30 – 3.60 12.0 to 21.0
73352205* Multi-Material V Slot .20 – .55 .75 – 2.08 7.5 to 12.0
83352210 End Nozzle (3352205) .20 – .55 .75 – 2.08 7.5 to 12.0
93351014 3/16” Coin Slot .35 – .95 1.30 – 3.60 12.0 to 21.0
10 3351010 1/4” Coin Slot .40 – 1.10 1.50 – 4.16 15.0 to 24.0
* Recommended nozzles for seal and chip with emulsified asphalts.
Etnyre Spraybar Nozzles

4
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.
Spray bar nozzles have a limited flow range at
which optimal performance will be achieved. Flow
rates greater than this optimal range will cause
excessive fogging. Rates that are too low will
cause the fan to sag and cause heavy edges.
Refer to the nozzle selection chart in the
operator’s manual to select the nozzles appropri-
ate for your conditions.
Adjusting the Spray Bar Nozzle Angle
Adjust the nozzles to obtain an angle of
approximately 30 degrees with the spraybar
centerline. Every nozzle should be at the same
angle. A nozzle adjustment wrench is supplied
with each new unit.
30º
Adjusting the Spray Bar Nozzles
Figure 7. Adjusting the Spray Bar Height.
Figure 6. Adjusting the Spray Bar Nozzles

5
Filling from Supply (Loading)
Centennial Flow Diagram

6
Circulate In Tank
Centennial Flow Diagram

7
Circulate In Bar
Centennial Flow Diagram

8
Spraying
Centennial Flow Diagram

9
Suckback Spraybar
Centennial Flow Diagram

10
Handspray
Centennial Flow Diagram

11
Suckback Handspray
Centennial Flow Diagram

12
Pump Off
Centennial Flow Diagram

13
Transfer
Centennial Flow Diagram

14
Flushing
Centennial Flow Diagram

15
You can get to the start up factor screen by pushing the "change
display" button on the control panel and stepping through the
GPM/FPM screen, the feet and gallons traveled screen, and the
temperature screen. The next screen is the start up factor screen.
Change the start up factor by pushing the application rate switch
up to increase or down to decrease.
A higher number will make for a "harder", more aggressive start
when the spray bar is first turned on.
A lower number will make for a "softer", more gentle start when
the spray bar is first turned on.
You may need to change the start up factor by 25% to 30% to see
much change in the spray. That means if you want a harder start,
set the start up factor to 125%. If you want a softer start, set
the start up factor to 75% as a first try. You may then adjust
again up or down as you like.
The Start Up Factor screen looks like this:
Start Up Factor

16
DC2 Self Diagnostics
The DC2 is equipped with a self diagnostics
system that may display messages on the LCD.
Some of the more common messages are
described below.
Under Application
Indicates that the distributor is applying less
than the pre—selected application rate. This
could be caused by travelling too fast for the
application selected when the hydraulic pump is
operating at full stroke.
Over Application
Indicates that the distributor is applying more
than the pre—selected application rate. This
could be caused by travelling too slowly for the
application selected.
No Pump CK PR SW
Indicates that the rear pump override switch is
still in the rear position.
Pump Signal at Max
Indicates that the pump is at full stroke.
Pump Signal at Min
Indicates that the pump is not stroking.
Pump Sensor Error
Indicates that the pump sensor is not reading.
This could be due to sensor failure or the sensor
is positioned too far from the cog gear. Reset or
replace sensor.
Radar Speed Error
Indicates that the radar sensor is not working.
Replace the sensor.
Pump Control Short
Indicates that the pump stroke wire is loose or
shorted to ground. Inspect the cable for proper
installation. Replace if necessary.
DC2 Self Diagnostics
Low Battery Voltage
Indicates that the truck’s voltage has dropped
below 9 VDC. Inspect the truck power supply or
the voltage to the DC2 Controller. Make repairs
as necessary.
RAM Replace 6702191
Indicates the computer has failed. Consult a
factory dealer or the factory for information on
computer replacement.
ROM Replace 6702191
Indicates the computer has failed. Consult a
factory dealer or the factory for information on
computer replacement.
PROM Replace 6702191
Indicates the computer has failed. Consult a
factory dealer or the factory for information on
computer replacement.

17
The signal is sent from the pot to the EDC.
Measure the signal from the pots to the EDC with
an amp meter. Connect the amp meter leads to
the red and black wires at the pump stroker on
the EDC. The amp meter should register be-
tween 0 and 119 milliamps. The 119 milliamp
reading correlates to the pumps full stroke
operation.
The pump can be manually overridden by
selecting the rear pump controller pot or complet-
ing the electrical circuit with a 9 volt transistor
battery. Consult the factory before installing a 9
volt battery.
Other Electrical Controls
All other electrical controls and problems can
be troubleshot with the electrical schematic .
S-2000 With Digital Gauges
Hydrostatic Pump Controller
EDC with DC2 Controller
The DC2 controller sends electrical signals to
the hydraulic pump controller (EDC). The signal
can be checked by disconnecting the red wire
and connecting the digital amp meter in series.
The signal should read between 0 at neutral and
119 milliamps on full stroke.
Radar Sensor
If the LCD on the controller is not registering
the ground speed, check the power to the radar
sensor. The red wire is 1 2VDC and the black
wire is ground. If the power to the sensor checks
out, check the voltage on the green signal wire.
The signal should be 7 VAC while the unit is
moving. Replace the sensor if the signal wire
does not register 7 VAC.
Asphalt Pump Sensor
If the LCD is not registering the asphalt pump
speed, check the power across the red and black
wires to the sensor. The red wire is the hot wire
and the black wire is ground. The voltage should
measure 1 2 VDC across the red and black
wires. If the power to the sensor checks out,
check the voltage on the white signal wire. The
signal wire should register 7 VAC while the
asphalt pump is turning. Replace the sensor if
the signal wire does not register 7 VAC.
Electronic Controls
The DC2 is a blue, notebook sized, self-
contained electronic control module located
under or behind the operator’s seat. A green light
should be illuminated on the controller. Inspect
the three plugs into the controller if the light does
not illuminate. If the plugs are inserted tightly,
check the controller input voltage. The voltage
should measure 1 2 VDC across the red wire
labeled El on the 18 pin controller and ground.
A red light on the controller usually indicates a
non-serviceable condition. The DC2 will most
likely have to be replaced. Consult the dealership
or the factory for more information.
LCD Display Problems
Verify that 5 VDC is present at the inverter
attached to the LCD Driver Board.
SERVICE TIP: A row of dots across the LCD
(usually below the characters) is caused by a
short between the connector on the circuit board
and the board itself.
LCD Not Sharp
The LCD may not be dark and sharp when
viewed from an angle. The LCD can be adjusted
with a small phillips head screwdriver. First, use a
small, right angle screwdriver to loosen the driver
board from its standoff and lift slightly. Use the
phillips screwdriver to turn the adjustment screw
on the blue pot on the back of the LCD driver
board. Turn the screw clockwise to darken the
characters or counterclockwise to lighten the
characters.
LCD Does Not Work
Check for 5 VDC across the red/white wire on
the main circuit board 20 pin connector in the
main control panel. Also check for the presence
of 5 VDC to the inverter on the blue/white wire. If
voltage is present at the inverter but not the 20
pin connector, the display driver board is most
likely faulty If voltage is not present at the in-
verter, check the blue/red wire on the 30 pin
connector at the DC2 controller box. Replace the
controller if less than 5 VDC is present at the
controller output.

18
Checking: DC-2 Computer EDC Threshold
Threshold is determined by how many milliamps it takes to put the hydraulic pump
on stroke.
a) Disconnect red wire from center terminal post of front / rear asphalt pump control
switch (located in rear control panel).
b) Attach multi-meter leads (in series) to read DC milliamps.
c) Turn asphalt pump control switch to rear.
d) Adjust pump control pot (CW) until asphalt pump shaft just starts to turn. The
reading on the meter is what threshold should be set at.
Normally 16 to 19 milliamps.
e) Reconnect red wire to center terminal post of front / rear asphalt pump control
switch.
f) Check and adjust the EDC Threshold in computer set-up if needed.

19
Speed Sensor Repair Kit
Part # 7050221
Instructions to change speed
sensor from 12V to 5V controlled
voltage for all distributors
1. Turn off power.
2. Disconnect 30 pin connector from
computer.
3. The Red and Black wires will be
added to the connector by first in-
serting the wires into the proper
pin location and pulling the wires
throughthe connectoruntil thepin
is properly seated in the connec-
tor. Insert the Black wire in “H3”
and the Red wire in “H1”.
4. Reconnect the 30 pin connector.
5. Pull the Red and Black wires up
into the cab control box.
6. Replace the portion of the +12V
power wire that is before the pull
up resistor (usually found at the
first white terminal strip). For the
speed sensor with the new Red
wire (remove the old Black wire).
7. Connect the Black wire to the
speed sensor ground (this wire
may be connected to the ground
stud if the speed sensor ground is
connectedthere, ifso usering ter-
minal - part number 6700146).
+12
RED
BLK
100
6702033 1
6701911
SELECTOR
SWITCH
6701976
AT REAR
(BROWN,BLACK.
BROWN, GOLD)
2
31
27 27
DB
CA
PUMP STROKER
CABLE TO REAR BOX
RED/BLK
BLK/WHT
GRN/BLK
TERMINAL STRIP
IN CAB
RADAR
CABLE
ASPHALT PUMP
MAG PICK-UP
CABLE
GRN
RED
BLK
BLK
RED
WHT WHT/RED
+12V
5K
ORA
BLU
GRN/WHT
GRN
BLU/WHT
RED/WHT
BLK
RED
WHT/BLK
WHT
LIGHT BLU
LIGHT ORA
12
11
10
9
8
7
6
5
4
3
2
1
+12 RED
BLK
PRINTER
3
7
2
PINK
6 PIN
MILITARY
CONNECTOR
6702209
"P3"ON DC-2
COMPUTER
A
B
WHITE
BLACK
22-3 SHIELDED CABLE
6702195
INVERTER
BLK
BLK
6700255
BACKLITE
SWITCH
BLU/RED
+5VDC
ORA/RED GRD
RED
BLACK
GREEN
ORANGE
BLUE
F1
F1
E1
C2
F3
D2
18 PIN
PACKARD
CONNECTOR "P2"
6702206
PIN #6702207
ON DC-2 COMPUTER
19 CONDUCTOR
18 GA
RED/BLK
GRN/BLK
BLK/WHT
WHT/RED
BLU/WHT
WHT/BLK
RED/WHT
GRN/WHT
BLU/RED
ORA/RED
J1
J2
J3
K2
A1
A2
A3
F3
B1
B3
30 PIN
PACKARD
CONNECTOR "P1"
6702208
PIN #6702207
ON DC-2
COMPUTER
POT
V
PUMP
STROKER
ASPH TEMP
PRINTER
MASTER
POWER
12 PIN
PHOENIX
CONNECTOR
6702216
ON CIRCUIT
BOARD
6701863
6701048
WIRING
HARNESS
3370756
Before
+12
RED
BLK
100
6702033 1
6701911
SELECTOR
SWITCH
6701976
AT REAR
(BROWN,BLACK.
BROWN, GOLD)
2
31
27 27
DB
CA
PUMP STROKER
CABLE TO REAR BOX
RED/BLK
BLK/WHT
GRN/BLK
TERMINAL STRIP
IN CAB
RADAR
CABLE
ASPHALT PUMP
MAG PICK-UP
CABLE
GRN
RED
BLK
BLK
RED
WHT
RED
BLACK
WHT/RED
+12V
5K
ORA
BLU
GRN/WHT
GRN
BLU/WHT
RED/WHT
BLK
RED
WHT/BLK
WHT
LIGHT BLU
LIGHT ORA
12
11
10
9
8
7
6
5
4
3
2
1
+12 RED
BLK
PRINTER
3
7
2
PINK
6 PIN
MILITARY
CONNECTOR
6702209
"P3"ON DC-2
COMPUTER
A
B
WHITE
BLACK
22-3 SHIELDED CABLE
6702195
INVERTER
BLK
BLK
6700255
BACKLITE
SWITCH
BLU/RED
+5VDC
ORA/RED GRD
RED
BLACK
GREEN
ORANGE
BLUE
F1
F1
E1
C2
F3
D2
18 PIN
PACKARD
CONNECTOR "P2"
6702206
PIN #6702207
ON DC-2 COMPUTER
19 CONDUCTOR
18 GA
RED/BLK
GRN/BLK
BLK/WHT
WHT/RED
BLU/WHT
WHT/BLK
RED/WHT
GRN/WHT
BLU/RED
ORA/RED
J1
H3
H1
J2
J3
K2
A1
A2
A3
F3
B1
B3
30 PIN
PACKARD
CONNECTOR "P1"
6702208
PIN #6702207
ON DC-2
COMPUTER
POT
V
PUMP
STROKER
ASPH TEMP
PRINTER
MASTER
POWER
12 PIN
PHOENIX
CONNECTOR
6702216
ON CIRCUIT
BOARD
6701863
6701048
WIRING
HARNESS
3370756
After