CIMLINE MAGMA 110 Owner's manual

2601 Niagara Lane · Plymouth, MN 55447 · [phone] · [phone] · Fax [phone]
Model 110/230/410 MelterApplicator
Owner / Operator Manual
Part#160921 Revised11/02
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 SystemAir 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
Setting Temperature Control ........................................................................................... 17
Cabinet Pre-Heating (Diesel Units) ................................................................................. 18
Cabinet Pre-Heating (Propane Units) ............................................................................. 19
Agitation Start-up ............................................................................................................. 20
Circulation and Pumping Procedure .............................................................................. 21
Sealing Procedure............................................................................................................ 22
Unplugging a Clogged Hose (Non-Heated Hose Models) ............................................ 23
Material System Cleanout ................................................................................................ 25
Material PumpAdjustment ............................................................................................... 28
Diesel Burner - Electric Eye and Fuse Inspection ......................................................... 29
Burner Motor Brush Inspection ...................................................................................... 30
Chamber Lining Inspection ............................................................................................. 31
Burner Nozzle Replacement ........................................................................................... 31
Adjusting Replacement Burner....................................................................................... 32
Adjusting Fuel Pump Pressure ....................................................................................... 33
Adjusting Burner Nozzle, Electrode and Head Position ............................................... 34
Remote Wand Option ....................................................................................................... 36
Lofa Shutdown System ................................................................................................... 38
Maintenance .....................................................................................................................39
Fluid and Components Specifications ........................................................................... 41
Heat Transfer Oil Specifications ...................................................................................... 42
Material Tank Capacity ..................................................................................................... 43

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Trouble Shooting Guide................................................................................................... 44
Hydraulic Schematic ........................................................................................................ 46
Wiring Diagrams ............................................................................................................... 47
Components..............................................................................................................................48
Trailer Wiring Diagram .............................................................................................................49
Engine and Burner Wiring Diagram........................................................................................50
Relay Panel ................................................................................................................................51
Temperature Control Wiring Diagram ....................................................................................52
Primary Control ........................................................................................................................53
Micro Panel/Generator .............................................................................................................54
Electrical Components Parts List ................................................................................... 55
Isuzu 3LB1 Diesel Engine and Pump Parts List ............................................................ 56
LP Engine and Pump Parts List ...................................................................................... 57
Plumbing System Parts List ............................................................................................ 58
Gear Pump Parts List ....................................................................................................... 60
Sealing Hose and Accessories (Standard Hose)........................................................... 61
Sealing Hose and Accessories (Heated Hose with Remote) ........................................ 62
Sealing Hose and Accessories (Heated Hose) .............................................................. 63
SealingAttachments ........................................................................................................ 64
Agitation System Parts List ............................................................................................. 65
LP Components ............................................................................................................... 66
Oil Burner Parts List ......................................................................................................... 68
Combustion Chamber Parts List..................................................................................... 69
Hydraulic Reservoir Components .................................................................................. 70
Fuel Tank Components (Diesel Engine) ......................................................................... 71
Hydraulic Manifold Parts List .......................................................................................... 72
Control Box....................................................................................................................... 73
Miscellaneous Parts ......................................................................................................... 74

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ApacketcontainingIMPORTANTINFORMATIONhasbeenenclosedwithyourMelter. This
packetcontains:
1) OperationInstructions
2) Parts List
3) WarrantyInformation
4) Manufacturer'sDocuments
a) Engine
b) MaterialPump
c) Burner(Dieselonly)
IMPORTANT: Thismanualcontainsthebasicinformationrequiredtooperate,maintainand
repairtheCIMLINEMelteryouhavepurchased. Theuseofthismanualinsuresaccurate
adjustments,operationandproperlubricationofyourequipment. Pleasekeepithandy.
AnypartsordersorserviceproblemsrelatingtoCIMLINEequipmentshouldbedirectedtothe
CIMLINEParts Departmentat either(763) 557-1982or [phone]. When ordering
parts,pleasehavethefollowinginformationavailable.
SerialNumber: ____________________________
ModelNumber: ____________________________
EngineModel(H.P.): ____________________________
EngineManufacturer: ____________________________
PumpNumber: ____________________________
ReplacementPartNumber(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) Weargloveswithwristlets.
2) Wearlongsleeveshirtwithsleevesrolleddownandcuffsbuttoned.
3) Wear a face shield.
4) LoadMelterfromgroundlevel.
5) Keepmaterialdoor closed at alltimes except whenadding material.
6) Neverstandonanypartofthemachine.
7) Donotpull,twist,stretchorkinkthematerialhose.
8) Donotoperatewithoutsafetycoveronhose.
9) Donottouchexhauststacksormufflers.
10) Wearheavyleatherbootsorshoes.
11) Wearlongpantswithnocuffs.
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 110 - 78 gallons, Model 230 - 168 gallons & Model 410 - 308 gal-
lons).
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.
SafetyNotes

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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) Refertofuelsystemairbleedingbeforestarting. 12
2) Startengineperengineoperatinginstructions. 14
3) Settemperaturecontroller(s). 16
4) Makesuretankoutlet,sealinghose,andaircleanoutvalvesareclosed. 10-11
5) OpenThermalRegulatingGateifcabinetheatingisrequired. 18
6) Igniteburner. 16
7) Allowoiltemperaturetoreachapproximately250ºF.
8) Regulatecabinettemperature. 18
9) Startagitation. 20
10) Addmaterial,typically2-3 biscuits iftankisempty. 20
11) Allowforsufficientmelting. 21
12) Startmaterialpump. 21
13) CloseThermalRegulatingGate. 18
14) Attachsealingwandextensionandadjustflow. 21-22
15) Beginsealingprocedure. 21-22
16) 10-15minutesbeforetheendoftheworkday,returntemperature 25
controlknobstozero.
17) CleanoutMelter. 25-27

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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) Turnthetemperaturecontrolboxoffandshutoffengine. 14,16
19) Coilsealinghoseandplaceincabinetalong withwand (Non-heated
hosemodelsonly).
20) Lock hose boom in tow position.
21) Alwayssecuresealingwand,sealinghoseandhoseboom
beforetowingtheMelter.
Operating Sequence
Onelectrichoseoptiononly.

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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) HookupLPbottle(s). 13
2) Turnongasandadjustregulator. 13
3) Settemperaturecontroller(s). 16
4) Makesuretankoutlet,sealinghose,andaircleanoutvalvesareclosed. 10-11
5) OpenThermalRegulatingGateandclosestackdiverterifcabinet 18
heatingisrequired.
6) Igniteburner. 16
7) Allowoiltemperaturetoreachapproximately250ºF.
8) Startengineperengineoperatinginstructions. 15
9) Regulatecabinettemperature. 19
10) Startagitation. 20
11) Addmaterial,typically2-3 biscuits iftankisempty. 20
12) Allowforsufficientmelting. 21
13) Startmaterialpump. 21
14) CloseThermalRegulatingGateandopenstackdiverter. 19
15) Attachsealingwandextensionandadjustflow. 21-22
16) Beginsealingprocedure. 21-22
17) 10-15minutesbeforetheendoftheworkday,returntemperature 25
controlknobstozero
Operating Sequence

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PROCEDURE: PAGE
18) CleanoutMelter. 25-27
NOTE: When leaving reheatable material in tank, allow the agitator to run until the oil
and material temperatures are the same.
19) Turnthetemperaturecontrolboxoffandshutoffengine. 15
20) TurnLPbottle(s)off. 13
21) Coilsealinghoseandplaceincabinetsalong withwand (Non-heated
hosemodelsonly).
22) Lock hose boom in tow position.
23) Alwayssecuresealingwand,sealinghoseandhoseboom
beforetowingtheMelter.
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. (Refer to Dia-
gram 1 on page 11)
1) Tank Outlet Valve: Allowsmeltedmaterial fromthetank to flowintothe pumping
system.
2) Access Port: The sealingwand isplaced in herewhen notin use. This allowsopera-
tortocontinuecirculatingmaterialthroughthehosetopreventmaterialfromcoolingand
freezingup.
3) Loading Door (2 on Model 230 & 410): Place the material on safety door to load the
meltingtank.
4) OilTemperature Gauge: Monitorstheheattransferoiltemperature.
5) Material Temperature Gauge (optional): This gauge showsthetemperature of
materialinsidethemeltingtank. Thisgaugeisfor referencebeforepumpingstarts.
Oncepumpingbegins,gauge(6)willbe an exactreadingofmaterialpassingthrough
thesystem. (Notshown)
6) Material Temperature Gauge: Readsmaterialtemperature asitpumps through
plumbingsystem.
7) Pressure Valve: This valvecontrolsthe flowrateof thematerialbeingpumped tothe
hoseandsealingwandbychangingthepressuresetting. (Turningthevalveclockwise
willincreasethepressurewhichinturnwillincreasetheflow). Duringsealingopera-
tions,thisvalvealonecanbeusedtoregulateflow.
8) Sealing Hose Valve: Openingthis valvewill allowthe materialbeing pumpedto flow
throughthehoseandsealingwand. Thevalveshouldbeinthefull"on"positionduring
operationtopreventflowrestriction.
9) Agitation Drive Control Knob: Rotate knobcounterclockwise to startagitation.
Rotateknobclockwisetoreverseagitation,whichisusefulfordislodgingmaterial.
Centerpositionisneutral.
10) Pressure Gauge: This gaugemeasures thepressure requiredto turn the agitator. By
observingthisgauge,theoperatorcantellif the agitatorisrotating.
11) Pump Drive Control Knob: Rotate knob counterclockwise to start material pump for
sealingoperation. Rotatetheknobclockwisetoreversethematerialflow. Reverse
flowisusedforsystemcleanout. Centerpositionisneutral.

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Controls and Their Functions
12) Air Cleanout Valve (optional): Connectair lineorsolvent lineto thisconnector to
flushoutsystem. Thisvalveshouldremainclosedatalltimesotherthancleanout.
13) Temperature Control Box: This control allows the operator to set the desired oil and
materialtemperatures. Thesettingwillbemaintainedautomatically.
14) Wand Holder: Onmodels with theelectrically heatedhose, thewandis placedinto
thisholder.
15) Cabinet Temperature Gauge: Indicates the temperature inside the cabinet. Do not
exceed320ºF. Ifconditionspermit exceedingthistemperature,opencabinetdoor.
16) Thermal Regulating Gate: Lift lever to open gate which will direct hot air to cabinet
toheatpumpandplumbing.
17) PSIGauge:Thisgaugewilltellyoutheamount ofpressureinthehydraulicsystem.
18) Ignition Access Door: On Diesel models, lift this door for access to ignition key.
Diagram 1

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Fuel System Air Bleeding
BleedingScrew
This section only pertains to Diesel engines. The engine and burner are pretested and
bledduringfactoryrunin. Ifthefueltankispermittedtorundryorwhenchangingfilters,bleed-
ingmaybenecessarytorestarttheburner.
Yourfueltankisequippedwitha visualfuellevelgauge(diagram3).Avoidlettingthefuellevel
dropbelowthelowestvisiblelevel.Thereissomereservebelowthislevel,butyourburnermay
drawairduetosplashingoffuelwhiletransportingtheunit.Onceairgetsintothefuelsupply
line,theburnerwillrunerraticallyornotatall.
Tobleed thediesel burner(Diagram 2):
1) Attacha1/4"ID hose tothebleederscrew.Runthe otherendofthehoseinto a clean
collectioncanorbottle.
2) Starttheengine.
3) Turnthetemperaturecontrolsystemonsothattheburnerwilltrytoignite.
4) Loosenthebleederscrewandallowthefueltoflowthroughthehoseintothecollection
can.Oncetherearenomorebubblesinthefuelstream,tightenthescrewimmediately.
5) Turnoffthetemperaturecontrolsystem.Whenyourestartthetemperaturecontrol,the
burnershouldignite.
FuelLevel
Gauge
FuelTank
CollectionCan
Hose
Diagram 2 Diagram 3

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Bottle Hookup and Ignition (LP Units only)
NOTE: Liquid withdrawal requires optional hose adapters and engine vaporizer
(Diagram4).
1) Place100 lb.propane bottle(s)inrack andsecure inplace with chainbinder(s).
2) Connecthoses(A)tobottle(s).
NOTE: POL fittings are left hand thread. All connections must be air tight.
3) Closehandtorchsupplyvalve(B).(optional)
4) Onmodelswithoptional twobottles,openthevalve(C)fromonebottleortheother.
5) Openvalve onLP bottleand setregulator(D) at13 to14 PSI.
WARNING: DO NOT exceed 14 PSI.
6) Set the oil controller (E) to 550º F (Diagram 5). DO NOT exceed 550º F. Set the
materialcontroller(F)totherecommendedmaterialworkingtemperature(typically
listedoncanorbox).(optional)
7) Turntherockerswitch(G)on. Thelightintheswitchwillindicatethatthecontrolsystem
ison.
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) Ifignitiondoesnotoccur,checkthefuseandgassupply.
B
AC
D
C
A
E
F
G
Diagram 4 Diagram 5

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Starting the Engine
NOTE: Read the engine instruction manual before starting.
Engine RPM is factory set and fixed at 2200 RPM.
Diesel Engine:
YourIsuzuDieselPoweredMelterisequippedwithanelectronicshutdownsystem(seepage
38). Ifthesystemdetectsexcessivewatertemperature,lowalternatoroutput,orlowoilpres-
sure,theenginewillautomaticallyshutdown. Theindicatorlightthatremainsonindicatesthe
malfunction. Anintegraldigitalhourmeterrecordsengineruntime,
Theenginemustberunningbeforeignitingtheburner. Theburnerwillonlyoperateifthe
ignitionkeyisturnedon. DONOTturnonburnerwithoutenginerunning. Tostartengine:
1) Placethepumpdrive(A)andagitationcontrolknobs(B)intheneutral(centerdetent)
position (Diagram 6).
2) Open the ignition access door (Diagram 7(C)).
3) Rotate the key to position #1 (Diagram 8).
4) Waitforsystem"on"lighttofinishflashing(about10
seconds). Thisistheglowplugheatingcycle.***
(Diagram 8)
5) RotatetheKeytothe#2positionuntiltheenginestarts
(Diagram 8).
6) Iftheenginedoesnotstartwithin6-7seconds,
repeatglowplugcycle.
***Glowplugcycleusenotrequiredonwarmengines. B
A
C
EngineEnclosure
Digital
Hourmeter
System"On"
Light
Charging
System
Oil
System
Water
Temperature
Glow
Plug
Circuit
Diagram 7
Diagram 6
Diagram 8

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Starting the Engine
NOTE: Read the Kohler engine instruction manual before starting.
The Engine RPM is factory set and fixed.
Propane Engine:
NOTE: Allow oil thermometer (mounted on tank) to reach 250º F. before starting this
procedure.
1) Placethepumpdrive(A)andagitationcontrol(B)leversintheneutral(centerdetent)
position (Diagram 9).
2) Starttheengine(RefertoKohlerEngineManualforstartupprocedure,maintenance
andtroubleshooting).
3) TheprimebuttonontheL.P.regulatorwillallowfueltoenterthecarburetorwhilede-
pressed. Thismay berequired forcold startup.
BA
Choke
Keyswitch
Throttle
Diagram 9
Diagram 10

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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 (Refer to diagram 11).
1) Settheoil controller (A)to550ºF (See SettingTemperatureControllers,pg. 17)
2) Setthematerialcontroller(B)totherecommendedmaterialworkingtemperaturewhich
istypicallylistedonthematerialcontainer.
3) Onunitswithheatedhose,setthehosecontroller(C)tothepourtemperature.
4) Turnrockerswitch(D)on. Theswitchwilllightuptoindicatethatthecontrolsystemis
activated. Theoilcontrolindicator(F)willlightalso. Thematerialcontrollight(G)will
beononlywhenburnerisrunning. Lights(D,FandG)shouldlightduringacoldstart
up.
5) Turnswitch(H)ontoactivatetheheatedhose(ifequipped). Theswitchwilllightupto
indicate power is on.
6) Hoseindicatorlight(J)willlightonlywhenhoseisbeingheated.
7) Switch(E)isusedto activate remotecontrolsealingwandvalve(ifequipped).
8) Switch(I)isusedtoactivateanyoptionalaccessories.
A
B
C
F
D
H
I
G
J
E
Diagram 11

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Setting Temperature Controllers
1) Presssetbutton(A). Light(B)willflashwhileinthesettingmode.
2) Press"UP" or"DOWN" buttonuntil desiredtemp isshown.
3) Afterafewseconds,light(B)willquitflashingandthereadoutwilldisplayactual
temperature.
4) Indicatorlight(B)willremainonanytimetheburnerisrunning.
A
B
Increase(UP)
Decrease(DOWN)
NOTE: Press set button (A) at anytime to display the setpoint temperature.
Forsafety,thehighlimitsettingsarelockedinatthefactorytopreventoverheating. The
settingsare:
OilController- 575DegreesFahrenheit
MaterialController-450DegreesFahrenheit
HeatedHoseController-425DegreesFahrenheit
Thesesettings canbe field adjustedfor specificapplications.
Consultthefactoryforinstructions.
Settingyourcontrollershigherthanthehighlimitwillcauseanerrorcodeasshownbelow.
TroubleshootingCodes
"EEE"indicates thermocouplebreak,no sensor,
oroverrangeofsystem.
"---"indicatesshortedthermocouple.

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Cabinet Pre-Heating
WARNING: Always wear gloves when adjusting the damper.
TheburnerexhaustisequippedwithanadjustableThermalRegulatingGate(A)tohelpregu-
latetheamountofheatdivertedtothecabinetforhose,wandandplumbingpreheating. Atthe
endofeachdayaftercleaningoutthesystem, the hoseshouldbecoiledandplacedinthe
cabinet. Thewandmayremainattachedas itwillfitinthecabinet.
NOTE: On units equipped with a heated hose, the hose and wand must remain out-
side the cabinet.
COLD START-UP
1) Openthegate,usingthegatelever(B),tothefullposition. Thiswillforcehotairintothe
cabinet.Thetemperaturegaugeinstalledinthesideofthecabinetwillmeasureactual
temperature. Never allowcabinet temperature toexceed 320ºF. Open the door
partiallyifnecessary. Adjustgateorclosecompletelytokeeptemperature
below320º F.
2) Oncethematerialintankhasstartedmeltingandiscirculatingthroughtheplumbing
system,closethegate. Thiswillpreventexcessivecabinettemperaturesandwilldivert
theheataroundtheoilformoreefficientheating.
A
B

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Cabinet Pre-Heating (Propane Units)
WARNING: Always wear gloves when adjusting the damper.
TheburnerexhaustisequippedwithanadjustableThermalRegulatingGate(A)andadamper
(B)tohelpregulatetheamountofheatdivertedtothecabinetforhose,wandandplumbing
preheating. Attheendofeachdayaftercleaningoutthesystem,thehoseshouldbecoiled
andplacedin thecabinet. Thewand mayremainattachedas itwillfit inthecabinet.
NOTE: On units equipped with a heated hose, the hose and wand must remain out-
side the cabinet.
COLD START-UP
1) Closethedamperuntilitcoverstheexhauststack. Openthegatebyliftinglever(C)to
thefull openposition. Thiswill forcehotair intothecabinet. Thetemperature gauge
installedinthesideofthecabinetwillmeasureactualtemperature. Never allow
cabinettemperaturetoexceed320ºF. Openthedoor partially ifnecessary. Adjust
gateorclose completelytokeep thetemperaturebelow 320ºF.
2) Oncethematerialinthetankhasstartedmeltingandiscirculatingthroughtheplumbing
system,openthedamperandclosethegate. Thiswillpreventexcessivecabinet
temperaturesandwilldiverttheheataroundtheoilformoreefficientheating.
A
C
B

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AgitationStart-up
Loading Empty Tank
1) Startagitationbyrotatingknob(A)counterclockwise.
2) Tankoutletvalvemustbeinthe"off"position.
3) Allmaterialmustbeclean. Keepallforeignmatteroutofmeltingtank.
4) Openthematerial door (1) andplace slab orbiscuit (2) onthe open door againstthe
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) Whenoilreaches250ºF.,rotateknob(A)counterclockwiseandobservepressure
gauge(B). Ifthegaugejumpsto1000-1200psiandremainstherewithnofluctuation,
theagitatorisnot turning. Theoilisgoing overthereliefvalve setting. Place knobinto
neutralpositionandwaituntilsufficientmeltingoccurs. (OnModel230and410,gauge
willvarybetween750-850PSI).