CIMLINE 105 Owner's manual

2601 Niagara Lane · Plymouth, MN 55447 · [phone] · [phone] · Fax [phone]
Model 105/225 Melter Applicator
Owner / Operator Manual
(For Diesel & LP Units
with Standard and Heated Hoses)
Part # 160718 Revised 11/00
Melter Applicator

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Table of Contents
Shipping Papers and Information ..................................................................................... 4
Safety Notes ....................................................................................................................... 5
Operating Sequence .......................................................................................................... 6
Diesel Units ..................................................................................................................................6
Propane Units ..............................................................................................................................8
Controls and Their Functions ......................................................................................... 10
Fuel System Air Bleeding ................................................................................................. 12
Bottle Hookup and Ignition (LP Units only).................................................................... 13
Starting the Engine........................................................................................................... 14
Diesel Engine: ........................................................................................................................... 14
Propane Engine: ....................................................................................................................... 15
Automatic Temperature Control Setting ......................................................................... 16
Cabinet Pre-Heating (Diesel Units) ................................................................................. 17
Cabinet Pre-Heating (Propane Units) ............................................................................. 18
Agitation Start-up ............................................................................................................. 19
Circulation and Pumping Procedure .............................................................................. 20
Sealing Procedure ............................................................................................................ 21
Unplugging a Clogged Hose (Non-Heated Hose Models) ............................................ 22
Material System Cleanout ................................................................................................ 24
Material Pump Adjustment ............................................................................................... 27
Burner Motor Brush Inspection ...................................................................................... 28
Chamber Lining Inspection ............................................................................................. 29
Burner Nozzle Replacement ........................................................................................... 30
Diesel Burner - Electric Eye and Fuse Inspection ......................................................... 31
Adjusting Burner Nozzle, Electrode and Head Position ............................................... 32
Adjusting Replacement Burner ....................................................................................... 34
Adjusting Fuel Pump Pressure ....................................................................................... 35
Fluid and Components Specifications ........................................................................... 38
Heat Transfer Oil Specifications ...................................................................................... 39
Material Tank Capacity ..................................................................................................... 40
Trouble Shooting Guide ................................................................................................... 41
Hydraulic Schematic ........................................................................................................ 43
Wiring Diagrams ............................................................................................................... 44
Trailer Wiring Diagram ............................................................................................................. 44
Battery Box Wiring Diagram with Heated Hose .....................................................................45
Temperature Control Wiring Diagram with Heated Hose ....................................................46
Complete Wiring Diagram with Heated Hose ........................................................................47
Temperature Control Wiring Diagram - No Heated Hose ..................................................... 48
Complete Wiring Diagram - No Heated Hose......................................................................... 49

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Isuzu 3LB1 Diesel Engine and Pump Parts List ............................................................ 50
LP Engine and Pump Parts List ...................................................................................... 51
Plumbing System Parts List ............................................................................................ 52
Gear Pump Parts List ....................................................................................................... 53
Sealing Hose and Accessories ....................................................................................... 54
Sealing Attachments ........................................................................................................ 56
Agitation System Parts List ............................................................................................. 57
LP Components ............................................................................................................... 58
Oil Burner Parts List ......................................................................................................... 60
Combustion Chamber Parts List..................................................................................... 61
Hydraulic Reservoir Components .................................................................................. 62
Fuel Tank Components (Diesel Engine) ......................................................................... 63
Hydraulic Manifold Parts List .......................................................................................... 64
Miscellaneous Parts ......................................................................................................... 66
Available Options .............................................................................................................. 69
Notes ................................................................................................................................. 70
Limited Warranty............................................................................................................... 71

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A packet containing IMPORTANT INFORMATION has been enclosed with your melter. This
packet contains:
1) Operation Instructions
2) Parts List
3) Warranty Information
4) Manufacturer's Documents
a) Engine
b) Material Pump
c) Burner (Diesel only)
IMPORTANT: This manual contains the basic information required to operate, maintain and
repair the CIMLINE melter you have purchased. The use of this manual insures accurate
adjustments, operation and proper lubrication of your equipment. Please keep it handy.
Any parts orders or service problems relating to CIMLINE equipment should be directed to the
CIMLINE Parts Department at either [phone] or [phone]. When ordering
parts, please have the following information available.
Serial Number: ____________________________
Model Number: ____________________________
Engine Model (H.P.): ____________________________
Engine Manufacturer: ____________________________
Pump Number: ____________________________
Replacement Part Number(s):
Shipping Papers and Information

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PLEASE READ AND UNDERSTAND ENTIRE OPERATORS MANUAL BEFORE
PROCEEDING
WARNING: Protective clothing must be worn. Refer to ANSI Regulations:
1) Wear gloves with wristlets.
2) Wear long sleeve shirt with sleeves rolled down and cuffs buttoned.
3) Wear a face shield.
4) Load melter from ground level.
5) Keep material door closed at all times except when adding material.
6) Never stand on any part of the machine.
7) Do not pull, twist, stretch or kink the material hose.
8) Do not operate without safety cover on hose.
9) Do not touch exhaust stacks or mufflers.
10) Wear heavy leather boots or shoes.
11) Wear long pants with no cuffs.
WARNING: Do not over fill the melting tank. For best results, add only as much
material as required for the job or a maximum of 75% of tank capacity.
(Model 105 - 78 gallons & Model 225 - 168 gallons).
WARNING: On a new melter applicator or a unit that has been idle for some time,
slowly raise the oil temperature to 250º F and hold there for approxi-
mately 20 to 30 minutes. This will help get rid of any condensation that
may be in the oil chamber.
WARNING: Never leave machine unattended while it is running.
Safety Notes

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Operating Sequence
Diesel Units
NOTE: This step by step procedure is only an outline. Refer to the page(s) indicated
for complete instructions.
PROCEDURE: PAGE
1) Refer to fuel system air bleeding before starting. 12
2) Start engine per engine operating instructions. 14
3) Set temperature controller(s). 16
4) Make sure tank outlet, sealing hose, and air cleanout valves are closed. 10-11
5) Open Thermal Regulating Gate if cabinet heating is required. 17
6) Ignite burner. 16
7) Allow oil temperature to reach approximately 250º F.
8) Regulate cabinet temperature. 17
9) Start agitation. 19
10) Add material, typically 2-3 biscuits if tank is empty. 19
11) Allow for sufficient melting. 20
12) Start material pump. 20
13) Close Thermal Regulating Gate. 17
14) Attach sealing wand extension and adjust flow. 20-21
15) Begin sealing procedure. 20-21
16) 10-15 minutes before the end of the work day, return temperature 24
control knobs to zero.
17) Clean out melter. 24-26

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NOTE: When leaving reheatable material in tank, allow the agitator to run until the oil
and material temperatures are the same.
PROCEDURE: PAGE
18) Turn the temperature control box off and shut off engine. 14,16
19) Coil sealing hose and place in cabinet along with wand (Non-heated
hose models only).
20) Lock hose boom in tow position.
21) Always secure sealing wand, sealing hose and hose boom
before towing the melter.
Operating Sequence
On electric hose option only.

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Propane Units
NOTE: This step by step procedure is only an outline. Refer to the page(s) indicated
for complete instructions.
PROCEDURE: PAGE
1) Hook up LP bottle(s). 13
2) Turn on gas and adjust regulator. 13
3) Set temperature controller(s). 16
4) Make sure tank outlet, sealing hose, and air cleanout valves are closed. 10-11
5) Open Thermal Regulating Gate and close stack diverter if cabinet 18
heating is required.
6) Ignite burner. 16
7) Allow oil temperature to reach approximately 250º F.
8) Start engine per engine operating instructions. 15
9) Regulate cabinet temperature. 18
10) Start agitation. 19
11) Add material, typically 2-3 biscuits if tank is empty. 19
12) Allow for sufficient melting. 20
13) Start material pump. 20
14) Close Thermal Regulating Gate and open stack diverter. 18
15) Attach sealing wand extension and adjust flow. 20-21
16) Begin sealing procedure. 20-21
17) 10-15 minutes before the end of the work day, return temperature 24
control knobs to zero
Operating Sequence

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PROCEDURE: PAGE
18) Clean out melter. 24-26
NOTE: When leaving reheatable material in tank, allow the agitator to run until the oil
and material temperatures are the same.
19) Turn the temperature control box off and shut off engine. 15
20) Turn LP bottle(s) off. 13
21) Coil sealing hose and place in cabinets along with wand (Non-heated
hose models only).
22) Lock hose boom in tow position.
23) Always secure sealing wand, sealing hose and hose boom
before towing the melter.
Operating Sequence (LP Units cont.)

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Controls and Their Functions
NOTE: This general outline will only familiarize you with the machine. Read through
the entire manual before putting this machine into operation.
1) Tank Outlet Valve: Allows melted material from the tank to flow into the pumping
system.
2) Access Port: The sealing wand is placed in here when not in use. This allows opera-
tor to continue circulating material through the hose to prevent material from cooling and
freezing up.
3) Loading Door (2 on Model 225): Place the material on safety door to load the melt-
ing tank.
4) Oil Temperature Gauge: Monitors the heat transfer oil temperature.
5) Material Temperature Gauge (optional): This gauge shows the temperature of
material inside the melting tank. This gauge is for reference before pumping starts.
Once pumping begins, gauge (6) will be an exact reading of material passing through
the system. (Not shown)
6) Material Temperature Gauge: Reads material temperature as it pumps through
plumbing system.
7) Pressure Valve: This valve controls the flow rate of the material being pumped to the
hose and sealing wand by changing the pressure setting. (Turning the valve clockwise
will increase the pressure which in turn will increase the flow). During sealing opera-
tions, this valve alone can be used to regulate flow.
8) Sealing Hose Valve: Opening this valve will allow the material being pumped to flow
through the hose and sealing wand. The valve should be in the full "on" position during
operation to prevent flow restriction.
9) Agitation Drive Control Knob: Rotate knob counterclockwise to start agitation.
Rotate knob clockwise to reverse agitation, which is useful for dislodging material.
Center position is neutral.
10) Pressure Gauge: This gauge measures the pressure required to turn the agitator. By
observing this gauge, the operator can tell if the agitator is rotating.
11) Pump Drive Control Knob: Rotate knob counterclockwise to start material pump for
sealing operation. Rotate the knob clockwise to reverse the material flow. Reverse
flow is used for system cleanout. Center position is neutral.

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Controls and Their Functions
12) Air Cleanout Valve (optional): Connect air line or solvent line to this connector to
flush out system. This valve should remain closed at all times other than cleanout.
13) Temperature Control Box: This control allows the operator to set the desired oil
temperature. The setting will be maintained automatically.
14) Engine Throttle: Refer to Engine Manual for start up and maintenance procedures.
15) Cabinet Temperature Gauge: Indicates the temperature inside the cabinet. Do not
exceed 320º F. If conditions permit exceeding this temperature, open cabinet door.
16) Thermal Regulating Gate: Lift lever (A) to open gate (B) which will direct hot air to
cabinet to heat pump and plumbing.
17) Battery Box: Battery and related electrical components are located inside.
18) Ignition Access Door: On Diesel models, lift this door for access to ignition key.
19) Wand Holder: On models with the electrically heated hose, the wand is placed into
this holder.
1
7
12
8
19
6
15
13 42
16
3
10
9
14
11
18
17

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Fuel System Air Bleeding
BleedingScrew
This section only pertains to Diesel engines. The engine and burner are pretested and
bled during factory run in. If the fuel tank is permitted to run dry or when changing filters, bleed-
ing may be necessary to restart the burner.
Your fuel tank is equipped with a visual fuel level gauge. Avoid letting the fuel level drop below
the lowest visible level. There is some reserve below this level, but your burner may draw air
due to splashing of fuel while transporting the unit. Once air gets into the fuel supply line, the
burner will run erratically or not at all.
To bleed the diesel burner:
1) Attach a 1/4" ID hose to the bleeder screw. Run the other end of the hose into a clean
collection can or bottle.
2) Start the engine.
3) Turn the temperature control system on so that the burner will try to ignite.
4) Loosen the bleeder screw and allow the fuel to flow through the hose into the collection
can. Once there are no more bubbles in the fuel stream, tighten the screw immediately.
5) Turn off the temperature control system. When you restart the temperature control, the
burner should ignite.
FuelLevel
Gauge FuelTank
CollectionCan
Hose

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Bottle Hookup and Ignition (LP Units only)
NOTE: Liquid withdrawal requires optional hose adapters and engine vaporizer.
1) Place 100 lb. propane bottle(s) in rack and secure in place with chain binder(s). Model
225 melter uses (2) bottles, Model 105 holds (1).
2) Connect hoses (A) to bottle(s).
NOTE: POL fittings are left hand thread. All connections must be air tight.
3) Close hand torch supply valve (B). (optional)
4) On models with two bottles, open the valve (C) from one bottle or the other.
5) Open valve on LP bottle and set regulator (D) at 13 to 14 PSI.
WARNING: DO NOT exceed 14 PSI.
6) Set the oil controller (E) to 550º F. DO NOT exceed 550º F. Set the material controller
(F) to the recommended material working temperature (typically listed on can or box).
(optional)
7) Ignite the burner by turning the toggle switch (G) "on".
NOTE: If the burner does not ignite within 8-10 seconds, the unit will require reset-
ting. Turn switch "off", allow time for the unburned fuel to exit the chamber
and repeat procedure.
8) If ignition does not occur, check the fuse and gas supply.
B
AC
D
C
AE
F
G

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Starting the Engine
NOTE: Read the engine instruction manual before starting.
Diesel Engine:
The engine must be running before igniting the burner. The burner will only operate if the
ignition key is turned on. DO NOT turn on burner without engine running. To start engine:
1) Place the pump drive (A) and agitation control knobs (B) in the neutral (center detent)
position.
2) Open the ignition access door (C).
3) Refer to engine operation section of Engine Manual for preheating and starting.
4) The maximum engine RPM stop is factory set at 2500 RPM. The engine should be run
at 2200 to 2500 RPM during use. It will have adequate power to perform all functions at
this setting. Increasing engine speeds will create hydraulic failure and shorten engine
life.
NOTE: On heated hose models, the engine RPM is set and fixed at the factory.
5) To stop engine, turn ignition key off.
A
B
C
BatteryBox

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Starting the Engine
NOTE: Read the engine instruction manual before starting.
Propane Engine:
NOTE: Allow oil thermometer (mounted on tank) to reach 250º F. before starting this
procedure.
1) Place the pump drive (A) and agitation control (B) levers in the neutral (center detent)
position.
2) Start the engine (Refer to Kohler Engine Manual for start up procedure, maintenance
and trouble shooting).
3) The prime button (C) on the L.P. regulator will allow fuel to enter the carburetor while de-
pressed. This may be required for cold start up.
4) The maximum engine RPM stop is factory set at 2500 RPM. The engine should be run
at 2200 to 2500 RPM during use. It will have adequate power to perform all functions at
this setting. Increasing engine speeds will create hydraulic failure and shorten engine
life.
B
C
A
Vaporizer (optional for
liquid withdrawal applications)

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Automatic Temperature Control Setting
NOTE: On diesel units, the engine must be running before activating temperature
control. The automatic temperature control system monitors the heat transfer
oil temperature and material temperature.
1) Set the oil controller (A) to 550º F.
2) Set the material controller (B) to the recommended material working temperature which
is typically listed on the material container.
3) Turn on toggle switch (C). The oil controller indicator light (D) will indicate that the
temperature control system is activated. The burner indicator light (E) will light when the
material controller is calling for heat (burner is operating).
NOTE: At cold start-up with all control knobs set at zero, all indicator lights should
come on momentarily to indicate that the system is functional.
4) If the unit does not ignite within 15 seconds, turn switch off and wait 30 seconds before
attempting again.
NOTE: On units with oil control only, you must adjust the oil controller (A) down as
the material temperature reaches pouring temperature.
5) On units equipped with an electrically heated hose, turn controller (F) to the material
pouring temperature. The indicator light (G) will only light when the hose is drawing
current.
A
B
F
GC
D
E

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Cabinet Pre-Heating (Diesel Units)
WARNING: Always wear gloves when adjusting the damper.
The burner exhaust is equipped with an adjustable Thermal Regulating Gate (A) to help regu-
late the amount of heat diverted to the cabinet for hose, wand and plumbing preheating. At the
end of each day after cleaning out the system, the hose should be coiled and placed in the
cabinet. The wand may remain attached as it will fit in the cabinet.
NOTE: On units equipped with a heated hose, the hose and wand must remain out-
side the cabinet.
COLD START-UP
1) Open the gate, using the gate lever (B), to the full position. This will force hot air into the
cabinet. The temperature gauge installed in the side of the cabinet will measure actual
temperature. Never allow cabinet temperature to exceed 320º F. Open the door
partially if necessary. Adjust gate or close completely to keep temperature
below 320º F.
2) Once the material in tank has started melting and is circulating through the plumbing
system, close the gate. This will prevent excessive cabinet temperatures and will divert
the heat around the oil for more efficient heating.
A
B

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Cabinet Pre-Heating (Propane Units)
WARNING: Always wear gloves when adjusting the damper.
The burner exhaust is equipped with an adjustable Thermal Regulating Gate (A) and a damper
(B) to help regulate the amount of heat diverted to the cabinet for hose, wand and plumbing
preheating. At the end of each day after cleaning out the system, the hose should be coiled
and placed in the cabinet. The wand may remain attached as it will fit in the cabinet.
NOTE: On units equipped with a heated hose, the hose and wand must remain out-
side the cabinet.
COLD START-UP
1) Close the damper until it covers the exhaust stack. Open the gate by lifting lever (C) to
the full open position. This will force hot air into the cabinet. The temperature gauge
installed in the side of the cabinet will measure actual temperature. Never allow
cabinet temperature to exceed 320º F. Open the door partially if necessary. Adjust
gate or close completely to keep the temperature below 320º F.
2) Once the material in the tank has started melting and is circulating through the plumbing
system, open the damper and close the gate. This will prevent excessive cabinet
temperatures and will divert the heat around the oil for more efficient heating.
A
C
B

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Agitation Start-up
Loading Empty Tank
1) Start agitation by rotating knob (A) counterclockwise.
2) Tank outlet valve must be in the "off" position.
3) All material must be clean. Keep all foreign matter out of melting tank.
4) Open the material door (1) and place slab or biscuit (2) on the open door against the
holder (3).
5) Push door to the closed position. DO NOT DROP MATERIAL INTO THE MELTER
WITH DOOR OPEN.
3
1
2
A
B
Material Left in Tank
1) When oil reaches 250º F., rotate knob (A) counterclockwise and observe pressure
gauge (B). If the gauge jumps to 1000-1200 psi and remains there with no fluctuation,
the agitator is not turning. The oil is going over the relief valve setting. Place knob into
neutral position and wait until sufficient melting occurs. (On Model 225, gauge will vary
between 750 - 850 PSI).