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

- 2 -
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

- 3 -
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

- 4 -
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

- 5 -
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

- 6 -
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

- 7 -
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.

- 8 -
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

- 9 -
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.)

- 10 -
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.