CIMLINE MATRIX 1500 Owner's manual

1
Melter Applicator
Owner/Operator Manual
2601 Niagara Lane – Plymouth, MN 55 7 – (800) 328-387 – Fax [phone]
PN 161251 Last Modified 1/12/12

2
Table of Contents
Shipping Papers and Information. 3
Safety Notes 4
Dimensions & Weights.... 5
Controls & Their unctions. 6
Operating Sequence.. 7
Starting the Engine. 8
Automatic Temperature Control Setting.. 9
Setting Temperature Controllers ...10
Material Loading Procedure 11
Sealing Procedure. 11
Material System Cleanout... 12
Electric Eye & use Inspection.. 13
Burner Motor Brush Inspection. 13
Burner Nozzle Replacement... 14
Chamber Lining Inspection. 14
Adjusting Replacement Burner.. 15
Adjusting uel Pump Pressure... 16
Adjusting Burner Nozzle, Electrode & Head Position. 17-18
Maintenance... 19-20
luid & Components Specifications.. 21
Heat Transfer Oil Specifications. 22
Material Tank Capacity.. 23
Trouble Shooting Guide.. 23-24
Hydraulic Schematics.. 25-26
Primary Control... 27
Wiring Diagrams.... 28-29
Electrical Components.. 30
Diesel Engine Components.. 31
Sealing Attachments.. 32
Sealing Hose Accessories 33
Plumbing System Parts List... 34-35
Oil Burner Parts List... 36
Combustion Chamber Parts List. 37
Hydraulic & uel Tank Components.. 38
Misc Parts.. 39
or compressor information see manual PN 161384

3
Shipping Papers and Information
Shipping Papers and InformationShipping Papers and Information
Shipping Papers and Information
A packet containing IMPORTANT INFORMATION has been enclosed with your
Melter. This packet contains:
) Operation Instructions
2) Parts List
3) Warranty Information
4) Manufacturer's Documents
a) Engine
b) Material Pump
c) Burner (Diesel only)
d) Parts/ Wiring Manual
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 (763) 557- 982 or (800) 328-
3874. 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):

4
Safety Notes
PLEASE READ AND UNDERSTAND ENTIRE OPERATORS MANUAL
BE ORE PROCEEDING
WARNING: Protective clothing must be worn. Refer to ANSI Regulations:
) 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.
0) Wear heavy leather boots or shoes.
) Wear long pants with no cuffs.
WARNING: Do not over fill the melting tank. or best results, add only as
much material as required for the job or a maximum of 75% of
tank capacity. (Model 1500-112 gallons.)
WARNING: On a new Melter applicator or a unit that has been idle for
some time, slowly raise the oil temperature to 250º and hold
there for approximately 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.

5
Dimensions & Weights
Model Number "A" in/cm "B" in/cm "C" in/cm Weight lbs/Kg (empty)
500 83.5/2 2 58/402 89.5/227 3925/ 780

6
Controls and Their Functions
Controls and Their FunctionsControls and Their Functions
Controls and Their Functions
N TE: This general outline will only familiarize you with the machine. Read
N TE: This general outline will only familiarize you with the machine. Read N TE: This general outline will only familiarize you with the machine. Read
N TE: This general outline will only familiarize you with the machine. Read
through the entire manual before putting this machine into operation.
through the entire manual before putting this machine into operation. through the entire manual before putting this machine into operation.
through the entire manual before putting this machine into operation.
1) Access Port: The sealing wand is placed in here when not in use. This
allows operator to continue circulating material through the hose to prevent
material from cooling and freezing up.
2) Loading Door Place the material on safety door to load the melting tank.
3) Oil Temperature Gauge: Monitors the heat transfer oil temperature.
4) Material Temperature Gauge: Monitors the heat of the material in the
tank.
5) 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 operations, this valve alone can be used
to regulate flow.
6) Agitation Drive Control Switch: Flip this toggle switch to the forward-off-
reverse function.
7) Pressure Gauge: This gauge measures the pressure required to turn the
agitator. By observing this gauge, the operator can tell if the agitator is ro-
tating.
8) Pump Drive Control Switch: Flip this toggle switch to the forward-off-
reverse function.
9) Temperature Control Box: This control allows the operator to set the de-
sired oil and material temperatures. The setting will be maintained auto-
matically.
10) Wand Holder: On models with the electrically heated hose, the wand is
placed into
this holder..
11) PSI Gauge: This gauge will tell you the amount of pressure in the hydrau-
lic system.
12) Ignition: This will allow you to start the engine. (This must be turned on
to allow the machine to start.
13) Pump Access Cover and Catch Tray: Open this door to access the
ump packings and the catch tray.
14)
14)14)
14) Temperature Gauge:
Temperature Gauge:Temperature Gauge:
Temperature Gauge: This allows you to view the temperature of the cabi
net. If this temp. gets above 400 deg. F open the pump door.

7
perating Sequence
perating Sequenceperating Sequence
perating Sequence
N TE: This step by step procedure is only an outline.
N TE: This step by step procedure is only an outline. N TE: This step by step procedure is only an outline.
N TE: This step by step procedure is only an outline.
Refer to the page(s) indicated for complete instructions.
Refer to the page(s) indicated for complete instructions.Refer to the page(s) indicated for complete instructions.
Refer to the page(s) indicated for complete instructions.
PROCEDURE:
PAGE
) Place wand in return port 6
2) Switch pump and agitator toggle switch to the forward position. 9
3) Start engine per engine operating instructions. 8
4) Add material, typically 2-3 biscuits if tank is empty.
5) Adjust flow to sealing wand.
6) Remove Wand and start sealing.
Once the oil temperature reaches 325deg F, the agitator will start rotating.
Once the Material temperature reaches 350 Deg F, the material pump
will start.
At the end of the Day
) Return Wand to Access Port and pin trigger 6
2) Switch the material toggle switch to the reverse operation and allow
to run 2 min.
3) Turn engine off and remove key.
4) Lock hose boom in tow position.
5) Always secure sealing wand, sealing hose and hose boom
before towing the Melter.
N TE: When leaving reheatable material in tank, allow the agitator to
N TE: When leaving reheatable material in tank, allow the agitator to N TE: When leaving reheatable material in tank, allow the agitator to
N TE: When leaving reheatable material in tank, allow the agitator to
run until the oil and material temperatures are the same.
run until the oil and material temperatures are the same.run until the oil and material temperatures are the same.
run until the oil and material temperatures are the same.

8
Starting the Engine
Starting the Engine Starting the Engine
Starting the Engine
N TE: Read the engine instruction manual before starting.
N TE: Read the engine instruction manual before starting.N TE: Read the engine instruction manual before starting.
N TE: Read the engine instruction manual before starting.
Engine RPM is factory set and fixed at 3000 RPM.
Engine RPM is factory set and fixed at 3000 RPM.Engine RPM is factory set and fixed at 3000 RPM.
Engine RPM is factory set and fixed at 3000 RPM.
Diesel Engine:
Diesel Engine:Diesel Engine:
Diesel Engine:
Your Isuzu Diesel Powered Melter is equipped with an electronic shut-
down system . If the system detects excessive water temperature, low
alternator output, or low oil pressure, the engine will automatically shut
down. The indicator light that remains on indicates the malfunction. An
integral digital hour meter records engine run time,
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.
Automatic Temperature Control Setting
Automatic Temperature Control SettingAutomatic Temperature Control Setting
Automatic Temperature Control Setting
N TE: n diesel units, the engine must be running before activating temperature
N TE: n diesel units, the engine must be running before activating temperature N TE: n diesel units, the engine must be running before activating temperature
N TE: n diesel units, the engine must be running before activating temperature
control. The automatic temperature control system monitors the heat trans-
control. The automatic temperature control system monitors the heat trans-control. The automatic temperature control system monitors the heat trans-
control. The automatic temperature control system monitors the heat trans-
fer oil temperature and material temperature.
fer oil temperature and material temperature.fer oil temperature and material temperature.
fer oil temperature and material temperature.
) Set the oil controller (A) to 550º F(288º C) (See Setting Temperature Control-
lers, pg. 0)
2) Set the material controller (B) to the recommended material working tempera-
ture which is typically listed on the material container.
3) Turn switch (H) on to activate the heated hose.
(Continued on page 9)

9
4) Set the heated hose controller (C) to350º. Light (J) will be on when the control-
ler is calling the generator to activate.
5) Turn rocker switches (D) and (K) to the forward position.
When lights (G) and (F) are on, the burner has been activated.
Light (E) will only be on when the material temperature is above 350º. (this signals the
material pump to come on.
Light (I) will only be on when the oil temperature is above 325º. (this signals the agita-
tor to come on).

10
Setting Temperature Controllers
Setting Temperature ControllersSetting Temperature Controllers
Setting Temperature Controllers
To change temperature of the material, oil or heated hose, use the (A) button. To
change the temperature on when the material pump or agitator engages, use the (C)
button.
) Press and hold set button (A) for 5 sec. Light (B) will turn on while in the set-
ting mode.
2) Press "UP" or "DOWN" button until desired temp is shown.
3) Press set button (A) , light (B) will turn off and the readout will display actual
temperature.
4) Indicator light (B) will remain on anytime the burner is running.
NOTE: Press set button (A) at anytime to display the setpoint temperature.
For safety, the high limit settings are locked in at the factory to prevent overheating.
The settings are:
Oil Controller- 550º F (288º C)
Material Controller- 450º F (232º C)
Heated Hose Controller- 400º F (2 8º C)
These settings can be field adjusted
for specific applications.
Consult the factory for instruc-
tions.
"P o" indicates broken or absent probe.
"P c" indicates short circuited probe.

11
Material Loading Procedure
Material Loading ProcedureMaterial Loading Procedure
Material Loading Procedure
Loading Empty Tank
) All material must be clean. Keep all foreign matter out of melting tank.
2) Open the material door ( ) and place slab or biscuit (2) on the open door
against the holder (3).
3) Push door to the closed position.
DO NOT DROP MATERIAL INTO
THE MELTER WITH DOOR
OPEN.
1
2
3
Sealing Procedure
Sealing ProcedureSealing Procedure
Sealing Procedure
) Turn flow control valve (A) counter clockwise until valve bottoms out.
2) With wand in access port (B) and the trigger pinned, open loading (C) door
and increase flow valve (A) until the desired flow has been achieved.
3) Close loading door (C) and unpin wand trigger.
4) Pull wand from access port and proceed to joint or crack to be filled.
5) Place the sealing tip into the joint, press trigger and begin sealing by drag-
ging tip through the joint.
6) If the flow rate is incorrect, repeat steps through 5.
7) As you approach the end of the joint, depress the trigger to avoid access
spillage.
8) To avoid material freezing in the hose, always return the wand to the access
port and pin the trigger to allow material to circulate through the hose.

12
Material System Cleanout
Material System CleanoutMaterial System Cleanout
Material System Cleanout
NOTE: The material loading doors and wand access port must be closed at all
times.
REVERSE LOW CLEANOUT METHOD (Diagram 13)
) To clean out the machine at the end of the day, return the wand to the access
port (B) and pin trigger. Go to the Run the pump in reverse for 2 - 3 minutes.
2) Go to the control box and flip the pump toggle switch to the reverse mode (see
page 9). Run the pump in reverse for 2 - 3 minutes.
3) Turn off engine (see page 8).
4) Return pump toggle to the forward operation.
5) Unpin and remove wand from access port and place in wand holder.
LUSHING NON-REHEATABLE MATERIALS
(must have optional draincock)
) Pump the material tank as low as possible and open draincock to empty tank.
2) Add 5 to 0 gallons of recommended flushing solvent to tank through the ac-
cess port.
3) Place the wand into access port and open wand valve.
4) Circulate the solvent approximately 5 to 0 minutes.
5) Pump the solvent through the wand into a container and dispose of it accord-
ing to EPA
guidelines.
6) Add another 5 to 0 gallons of material and circulate for 5 minutes.
7) Pump this 5 to 0 gallons into empty containers and reuse it for the first purge
next time the unit is used.

13
A
B
C D
Electric Eye and Fuse Inspection
Electric Eye and Fuse InspectionElectric Eye and Fuse Inspection
Electric Eye and Fuse Inspection
Diesel Burner - Electric Eye Inspection
The diesel burner is equipped with an electronic eye which detects the pres-
ence of a flame. If the eye does not detect a flame after ignition, it will shut
down the burner.
Periodically this eye will get covered
with soot or dirt from the burner. If your
burner lights and then shuts down im-
mediately, you can normally expect the
problem to be a dirty electric eye. To
clean the eye, simply loosen the two
retaining clip screws (A) and rotate the
clips which hold the hinged spark box
(B) to the burner. Gently wipe the eye
(C) with a soft cloth and reattach the
spark box.
After cleaning the eye, if the burner will not stay ignited after initial firing,
check fuse located inside the primary control box. You can open the box by
loosening the two screws (D) and removing the box.
Burner Motor Brush Inspection
Due to the high current draw of the burner motor, it is advised to inspect the
brushes for excessive wear every 00 hours of operation. If the brushes are
worn out completely it will stop the motor and typically damage or destroy the
ignition transformer assembly.
The brushes can be inspected and installed in a matter of minutes as follows:
) Remove the brush caps (A) with a standard straight slot screw driver.
2) Remove the brushes (B) and inspect. If there is less than /8" of brush
remaining, replace it imme-
diately. If not, reinstall exist-
ing brush.
3) Be sure the radius (C) of the
brush follows the curvature
of the motor as shown be-
low.
4) When the brushes are worn
close to /8", check fre-
quently to avoid failure.
A
B
C

14
Chamber Lining Inspection
After each 200 hours of operation, the chamber lining should be inspected.
Remove (8) burner mount securing bolts (A) and pull out burner and mount.
Inspect lining (B) for excessive cracking. Also check the condition of retainer
(C). Lining cracks are acceptable as long as they are not large enough to al-
low flame to contact the combustion chamber walls.
C
B
A
Burner Nozzle Replacement
During operation, oil is forced through the burner nozzle at 40 PSI to permit the fuel
to be atomized for easy ignition. The nozzle orifice has normal wear due to this high
pressure. Due to the high wear, it is recommended that the nozzle be replaced at
least once per operating season. To replace the nozzle, remove the burner from
chamber. Remove the two screws which secure the burner head (A) to the air tube
(B). Carefully insert a 5/8" deep well socket over the nozzle (C) and turn it counter-
clockwise to remove. Be very careful not to bend the electrodes (D) while performing
this task. When installing the new nozzle, do not touch the filter portion (E) of the
nozzle. The filter is so fine that oil from your skin can clog the filter.
A B D
C
E

15
Adjusting Replacement Burner
Adjusting Replacement BurnerAdjusting Replacement Burner
Adjusting Replacement Burner
The excess air adjustments on the Beckett ADC burner are essential to prevent the
potential damage to the burner and the burner combustion chamber. Excess air is
required to insure that the carbon and hydrogen are supplied with enough oxygen to
burn completely.
If there is not enough excess air, the unit will smoke inside the combustion chamber
and eventually lead to unburned fuel residue left in the chamber. The function of the
combustion chamber is to reflect and retain heat to insure that all the atomized oil is
burned.
Even a slight amount of soot can decrease the effectiveness of the chamber. It is es-
timated that /8" of soot is equivalent to approximately a " thick fiberglass sheet.
With too little excess air, eventually the unburned fuel accumulates into the lining ma-
terial. Eventually it will burn even when the burner is turned off. The heat generated
by this flame will vent out through the burner and can cause internal damage to the
burner. Typically it will damage the plastic coupling which operates the fuel pump
and it can also damage the primary control unit. Other common problems include
blackening and even distorting the optic eye.
The burner is factory set with the air band (B) at the wide open position and the air
shutter (D) adjusted typically between the 8 and 10 setting. Decreasing the excess air
settings can lead to the chamber fires as outlined above.
To adjust excess air flow into the burner: (Diagram 4, Page 6)
) Loosen screw (A) and rotate air band (B) to the wide open position, then
tighten screws.
2) Loosen 2 screws (C) and rotate the air shutter (D) until the pointer arrow (E)
points to the number 8 setting.
3) Start the burner and allow it to run for about 0 minutes.
4) Loosen the view port retaining bolt (F) and swing cover (G) out of the way as
shown.
5) While observing the flame through the view port , decrease the air shutter (D)
by rotating it until the flame tip appears slightly smoky, then increase the air
until the flame clears up. The arrow (E) should be in the vicinity of 7 - 0.
Tighten two screws (C).
6) Close and secure view port.

16
Adjusting uel Pump Pressure
The fuel pressure is factory set @ 40 PSI. As the pump wears, it may require ad-
justment as follows:
) If your unit is not already equipped with a fuel pressure gauge, remove plug
(H) and insert a 0-200 psi gauge.
2) With the pump running, loosen jam nut (J) and turn screw (K) clockwise to in-
crease the pressure, CCW to decrease pressure.
3) Hold the screw (K) with a screwdriver while tightening jam nut (J).
Diagram 14
Diagram 14Diagram 14
Diagram 14

17
Adjusting Burner Nozzle, Electrode & Head Position
Adjusting Burner Nozzle, Electrode & Head PositionAdjusting Burner Nozzle, Electrode & Head Position
Adjusting Burner Nozzle, Electrode & Head Position
Your CIMLINE 500 Matrix is equipped with a model ADC burner. Each unit comes
with a nozzle, electrode and head position gauge. For optimum performance, the
steps below should be performed periodically. The burner must be removed from the
combustion chamber.
Step 1: Setting the Electrode Gap
Check electrodes to see if the gap is aligned with the lines on the gauge. The gap
should be
from /8" to 5/32" as shown below. Bend the electrodes slightly if required. If the
electrodes are way out of line, you may have to remove the head and realign as de-
scribed in Step 3.
Step 2: Inspecting Nozzle Concentricity
The nozzle should be approximately centered within the head. Insert the
gauge as shown. The center of the nozzle should be aligned with the cen-
ter line. Rotate the gauge and check alignment from several locations.
BE CAREFUL NOT TO SCRATCH THE SURFACE. If it is not concentric,
you may have to replace or straighten center bracket.

18
Adjusting Burner Nozzle, Electrode and Head Position
Step 3: Setting Electrode Position
Insert gauge as shown below. The electrode tip should be in line with the intersec-
tion of the cross hairs labeled "DC". If not, you must remove the head, then loosen
the electrode retaining screw just enough to allow you to slide the electrodes into the
proper location. Tighten the screws and replace the head.
Step 4: Setting Nozzle Position
Insert the gauge against the head. The end of the gauge should now touch the noz-
zle. If not, slightly loosen the knurled nut and the screw on the escutcheon plate until
the entire nozzle assembly can be moved forward or backward. Adjust accordingly
and tighten the knurled nut and screw.

19
Maintenance
Engine: The operation and life of the engine depends on you and your operator. Do
not start engine until the engine precheck is complete. The engine precheck consists
of checking the oil, the fuel level, the hydraulic oil level and the air filter. Basic engine
maintenance is shown in Table on page 34. For more detailed information please
refer to the Engine Operator Maintenance Manual and Warranty provided with your
Melter applicator.
NOTE: When breaking in a new Melter, we recommend running the engine for
one hour with no load prior to actual use on the job.
Air cleaner: Due to the dusty conditions that can be created by road work, it is es-
sential to check the engine air cleaner element daily. Remove element and shake
out the accumulated dust and dirt. Wipe out dirt from inside cover and from housing.
Check engine manual for washing instructions. We recommend stocking replace-
ment filters.
Lubrication: The Melter should be greased according to table on page 20 of this
manual.
Diesel Units: Use of high quality detergent oil of API (American Petroleum Institute)
service class CC or CD grade. Select the viscosity based on the air tempera-
ture at the time of operation. Check your engine manual for other recommen-
dations.
Burner: There are several items that need to be inspected periodically on the burn-
ers. These items include the burner motor brushes, the nozzle, electrode and head
position, chamber lining and the 4 electric eye. Inspect according to table on page
20. There is a section on how to perform each of these operations in this manual,
check the index on pages 2 & 3 to locate the appropriate section.

20
Maintenance
MaintenanceMaintenance
Maintenance
Maintenance Operation Daily 25 Hrs 100 Hrs 200 Hrs Yearly
Check fuel level (add if low)

Check engine and heat transfer oil (add if low)

Check hydraulic oil (add if low)

Check engine air cleaner

Inspect pre-cleaner (clean if dirty)

Cleanout material system

Inspect sealing hose and cover

Inspect sealing hose connections

Blow oil cooler on the air compressor option

Inspect and clean cooling system (Diesel units only)

Inspect material pump packing (adjust if leaking is
excessive)

Change engine oil and oil filter Diesel
Service air cleaner element

Inspect burner motor brushes (replace if worn out)

Inspect burner nozzle, electrode & head pos. (adjust
if nec.)

Grease agitator bearing block (load adapter)

Inspect fuel filter (replace if dirty)

Inspect Diesel burner electric eye (clean if dirty)

Grease wheel bearings

Inspect chamber lining (replace if excessive
cracking)

Inspect starting motor

Replace hydraulic oil

Replace hydraulic return filter

Replace hydraulic suction strainer
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Replace burner nozzle
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Change heat transfer oil
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Change Diesel fuel filter
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Flush radiator and replace fluid (Diesel units only)
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