Crafco E-Z 50 User manual

Parts Manual - 26211
Revision C
Melter/Applicator

Rev.
Description
Date
C
Fixed Error on Page 8-5, Temp controller & control box part numbers
4/7/17
Fill in appropriate fields that apply to this machine
Machine S/N: ___________________________________
1st Hose S/N: ___________________________________
2nd Hose S/N:___________________________________
1st Pump S/N:___________________________________
2nd Pump S/N: __________________________________
Engine S/N: ____________________________________
Compressor S/N: ________________________________
Gear Box S/N (Patcher): __________________________
Blower S/N (Magnum):____________________________

E-Z 50 Melter Part Manual
Table of Contents
Contents
1.0 About This Manual................................................................................................................ 1-1
2.0 Safety Precautions................................................................................................................ 2-1
2.1 General Safety .............................................................................................................. 2-1
2.2 Personal Safety............................................................................................................. 2-1
2.3 Equipment or Operational Safety ................................................................................ 2-1
2.4 Safety Symbols and Notices........................................................................................ 2-2
3.0 Limited Warranty................................................................................................................... 3-1
3.1 Warranty Claim Instructions........................................................................................ 3-2
4.0 Machine Specifications ........................................................................................................ 4-1
5.0 Starting the Machine............................................................................................................. 5-1
5.1 Introduction................................................................................................................... 5-1
5.2 Preparing the Machine for Start Up............................................................................. 5-1
5.3 Starting the Burner....................................................................................................... 5-2
5.4 Dispensing the Material................................................................................................ 5-3
5.5 Loading Material into the Machine .............................................................................. 5-3
5.6 Shutting Down and Cleaning Out the Machine........................................................... 5-4
5.7 Storing the Machine ..................................................................................................... 5-4
6.0 Preventative Maintenance.................................................................................................... 6-1
6.1 Hydraulic System.......................................................................................................... 6-1
6.2 Heat Transfer Oil........................................................................................................... 6-1
6.3 Wheel Bearings............................................................................................................. 6-1
6.4 Lug Nuts........................................................................................................................6-1
6.5 Brakes ................................................................................... Error! Bookmark not defined.
6.6 Tongue Jack.................................................................................................................. 6-2
6.7 Temperature Control Calibration................................................................................. 6-2
6.8 Maintenance Chart........................................................................................................ 6-2
6.9 Service Instructions ..................................................................................................... 6-3
6.10 Recommended Fluids and Lubricants........................................................................ 6-3
6.11 Applicable Brands of Heat Transfer Oil ...................................................................... 6-4
6.12 Typical Heat Transfer Oil Specifications..................................................................... 6-4
7.0 Burner Troubleshooting....................................................................................................... 7-1
7.1.1 Symptom: Pilot Will Not Light............................................................................... 7-1

E-Z 50 Melter Part Manual
Table of Contents
7.1.2 Symptom: Burner Will Not Light...........................................................................7-1
7.2 Troubleshooting Sealant Flow.....................................................................................7-1
7.2.1 Symptom: Sealant Will Not Flow ..........................................................................7-1
7.2.2 Sealant Heating to Slow ........................................................................................7-2
7.3 Troubleshooting Agitator.............................................................................................7-2
7.3.1 Symptom: Agitator will Not Rotate.......................................................................7-2
8.0 About the Illustrated Parts List............................................................................................8-1
8.1 Ordering Crafco Parts ..................................................................................................8-1
8.2EZ50 Melter/Applicator.................................................................................................8-2
8.3 Tank Assembly .............................................................................................................8-4
8.4 Gas Control Box............................................................................................................8-5
8.5 Propane Burner Assembly...........................................................................................8-6
8.6 Hydraulic Schematic.....................................................................................................8-7
8.7 Propane Piping Schematic...........................................................................................8-8
8.8 L.P. Regulator Assembly..............................................................................................8-9
8.9 Propane Torch Assembly...........................................................................................8-10

E-Z 50 Melter Part Manual
IntroductionChapter 1
© Copyright 2014 by Crafco, Inc. All Rights Reserved…………………………………………………………….Introduction 1-1
1.0 About This Manual
This manual is supplied with each new Crafco E-Z Pour 50 Propane Melter. The manual assists
your machine operators in the proper use of the melter applicator and provides information about
the machine’s mechanical functions
Your Crafco E-Z Pour 50 Propane Melter is specially made to give excellent service and save
maintenance expense. However, as with all specially engineered equipment, you get best results at
minimum cost if you:
Operate your machine as instructed in this manual.
Maintain your machine regularly as stated in tis manual.
WARNING
California Proposition 65 Warning
Engine exhaust and some of its constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm. Always use care to avoid breathing
engine exhaust. Failure to comply could result in death or serious injury.

E-Z 50 Melter Part Manual
SafetyChapter 2
©2017 by Crafco, Inc. All Rights Reserved………………………………………………...……………………………...Safety 2-1
2.0 Safety Precautions
2.1 General Safety
•Crafco, Inc. assumes no liability for an accident or injury incurred through improper use of the
machine.
•Read this manual thoroughly before operating the machine.
•Obey all CAUTION and WARNING signs posted on the machine.
•Make sure an operator fully knows how to operate the machine before using the machine.
2.2 Personal Safety
•The high operating temperatures of this machine and the sealant it contains requires that
protective clothing, gloves, hard-soled shoes, and safety glasses or a face shield be worn at all
times by operators of the machine.
•Prevent water from going into any part of the machine. If there is indication of water in the heat
transfer oil system, warm heating oil to 250-300°F for 2 to 3 hours.
•Bodily contact with hot sealant or heat transfer oil can cause severe burns.
•If the mixer is not stopped before adding solid material, hot material can get on an operator’s
body and cause severe burns.
•Keep hands, feet, and clothing away from all moving parts.
2.3 Equipment or Operational Safety
•Do not operate the machine in buildings or work areas that do not have sufficient airflow.
•Shut-down the burner and the engine before refilling the gas tank.
•Stop the mixer before adding solid material to the sealant tank. Lift the lid, place the material on
the lid and close the lid. Restart the mixer.
•Always keep a correctly maintained fire extinguisher near the machine and know how to use it.
•DO NOT heat transfer oil to a temperature of more than 525°F.
•DO NOT put too much heat transfer oil in the reservoir. The expansion of oil while it heats up
can cause overflow. With the machine on level ground, check the oil each day before starting
the burner. Add oil to the top mark on the dipstick if required (at 70°F). Use only recommended
heat transfer oil. Change the oil after 500 hours of machine operation, or one year, whichever
comes first.
•Follow the operating instructions for starting and shutting down the burner. Instructions are
mounted on the control box on the machine.

E-Z 50 Melter Part Manual
SafetyChapter 2
©2017 by Crafco, Inc. All Rights Reserved………………………………………………...……………………………...Safety 2-2
2.3 Equipment or Operational Safety Continued
•Calibrate the temperature control operation after each 50 hours of machine operation. Refer to
Chapter 6, Maintenance Instructions.
•Replace any hoses which show signs of wear, fraying or splitting.
•Make sure all fittings and joints are tight and do not leak each time the machine is used.
•Do not leave the machine unattended while the burner is lit.
•Tighten all bolts and screws every 100 hours of machine operation.
2.4 Safety Symbols and Notices
Important safety symbols and notices are marked on the machine and in this manual. Failure to
comply could result in equipment damage, operational malfunction, serious injury, or death. Please
read and comply with all symbols and notices. The table below includes the most commonly used
symbols and notices.
Table 2-1 Safety Symbols and Notices
Symbol
Item
Remarks
WARNING
Warning
Refers to possible bodily injury or death.
CAUTION
Caution
Refers to possible equipment damage or operational
malfunction.
Severe Burn Hazard
Hot material can cause severe burns.
Protective Shoes
Wear hard-soled work shoes.
Protective Gloves
Wear heat resistant gloves.
Protective Face or Eye Wear
Wear face shield or safety glasses.
Body Crush Hazard
Do not stand between trailer and hitch when hooking
melter to truck.

E-Z 50 Melter Part Manual
SafetyChapter 2
©2017 by Crafco, Inc. All Rights Reserved………………………………………………...……………………………...Safety 2-3
Table 2-2 Safety Symbols and Notices Continued
Symbol
Item
Remarks
Crush Hazard
Keep feet and legs clear.
Pinch Hazard
Keep hands and feet clear.
Exhaust Hazard
Avoid breathing engine exhaust.
Read Manual
Read and understand operator and safety manuals
before operating machine

E-Z 50 Melter Part Manual
Warranty InformationChapter 3
©2017 by Crafco, Inc. All Rights Reserved…………………...……………………………………………………..…Warranty 3-1
3.0 Limited Warranty
Crafco, Inc., through Crafco or one of its affiliated distributor, will replace for the original purchaser
free of charge any parts found upon examination by the factory at Chandler, Arizona, to be
defective in material or workmanship. This warranty is for a period one year from in-service date,
but excludes engine or components, tires, and battery as these items are subject to warranties
issued by their manufactures.
Crafco, Inc. shall not be liable for parts that have been damaged by accident, alteration, abuse,
improper lubrication/maintenance, normal wear, or other cause beyond our control.
The warranty provided herein extends only to the repair and/or replacement of those components
on the equipment covered above and does not cover labor costs. The warranty does not extend to
incidental or consequential damages incurred as a result of any defect covered by this warranty.
All transportation and labor costs incurred by the purchaser in submitting or repairing covered
components must be borne by the purchaser. Crafco, Inc. specifically disavows any other
representation, warranty, or liability related to the condition or use of the product.
CAUTION
Use of replacement parts other than genuine Crafco parts may impair the safety or
reliability of your equipment and nullifies any warranty.

E-Z 50 Melter Part Manual
Warranty InformationChapter 3
©2017 by Crafco, Inc. All Rights Reserved…………………...……………………………………………………..…Warranty 3-2
3.1 Warranty Claim Instructions
Crafco, Inc. warrants parts and machinery purchased through Crafco or one of its affiliated
distributors for one year from purchased or in-service date**. If parts fail to function within the first
year of purchase, a return authorization number (RA) must be obtained. If the part was purchased
through Crafco, Inc., please contact Crafco returns department at [e-mail] for a RA
number or if purchased through a Crafco distributor please contact your distributor. Note: if the part
has a serial number associated with it, for example; a machine or electric hose or wand, this must
be furnished when requesting the RA number. The customer will be emailed or faxed a RA form
with all instructions to return the item to Crafco, Inc. See example. If the part is found to be within
the one year warranty period and has not been abused or modified, a credit will be issued to the
customer’s account or credit card. The customer may request the part be replaced instead of a
credit, if desired.
Wear items are not covered under Crafco, Inc. limited warranty. A wear item is defined as but not
limited to: material pumps, sealing tips, tires, etc.
Note: All engine warranties are covered through the engine manufacture. If you need information for
a distributor in your area please contact us and we will direct you to the closest engine distributor.
All parts returned are tested and evaluated. If the part has been modified in anyway without prior
consent from Crafco, Inc. representative, warranty is void.
Please follow the instructions stated below when calling in a Warranty Claim. Failure to follow these
procedures may be cause to void the warranty.
Call your local Crafco Distributor. If you do not know who your local distributor is, call a Crafco
Customer Service Representative, (Toll Free 1-800-528-8242) for name, location and telephone
number.
On contacting the distributor, be prepared to identify the serial number, model number, engine
number, engine manufacturer, and the date of purchase if available.
Should the cause of the malfunction be a defective part, the Distributor will advise you of the
procedure to follow foe a replacement.
The warranty is valid only for parts, which have been supplied or recommended by Crafco, Inc.
If you have any additional questions regarding warrant repairs and parts, please do not hesitate to
call toll free 1-800-528-8242.
For Warranty:
Crafco, Inc.
25527 South Arizona Avenue, Chandler, AZ
85248
Phone: [phone] or [phone]
Fax: [phone]
For all other inquires:
Crafco, Inc.
6165 W. Detroit St., Chandler, AZ 85226
Phone: [phone] or [phone]
Fax: [phone]
[email protected]
.

E-Z 50 Melter Part Manual
Machine SpecificationsChapter 4
©2017 by Crafco, Inc. All Rights Reserved………………………………………………………….…Machine Specifications 4-1
4.0 Machine Specifications
Table 4-1 Specifications
Specification
PN 40900
Vat capacity
50 gallons
Melt Capacity
400 lbs. per hour
Heat transfer oil required
18 gallons at 70°F
Tank construction
Double boiler type
Tank opening size
14 3/4” x 12 3/4”
Maximum heat input
Vapor Burner 185,000 BTUs
Burner and temperature
control
Automatic – Fail Safe
Engine Briggs & Stratton
Single cylinder 3 BHP @ 3600 RPM
Drive Mechanism
All hydraulic with infinite forward and reverse action
Mixer
Full sweep mixer with 2 blades
Axle
2250lbs. Capacity
Tires
ST 175/80 D13 (1,360lbs. Capacity each)
Dry Weight
Approximately 1500lbs.
Propane Bottle
100lbs.

E-Z 50 Melter Part Manual
Operating InstructionsChapter 5
©2017 by Crafco, Inc. All Rights Reserved…………………..…………………………………………Operating Instructions 5-1
5.0 Starting the Machine
5.1 Introduction
The Crafco E-Z Pour 50 Propane Melter was developed to melt Crafco sealants. However, it works
well with most road asphalt and federal specification crack or joint sealants.
Note: DO NOT attempt to operate the machine without using these and all other instructions.
5.2 Preparing the Machine for Start Up
Table 5-1 Preparing the Machine for Start Up
Step
Action
1
Fill the engine fuel tank with non-leaded gasoline.
2
Fill propane storage tank
3
Check the oil level in the engine crankcase. (Refer to the manufacturer’s
instruction for the engine.)
4
Check the hydraulic fluid level while at a temperature of 70°F. Add fluid if
necessary. Oil level should be 1”-2” from top of tank. See Figure 5.3
5
With the machine on level surface, check the heat transfer oil level. Add oil to
the top mark on the dipstick if required (at 70°F). DO NOT overfill or spillage
may occur when the oil is heated and expands. See Figure 5.2
5
Ensure that pour spout is in the closed position. See Figure 5.1
Warning
The safe operation of this machine is the operator’s responsibility.
Use extreme care when operating this machine; safety is the result of being
careful and paying attention to details. Remember the propane flame is
approximately 2,200°F. Some exposed parts of the machine reach 500°F, the
sealant 400°F, and the hydraulic fluid 200°F.
Always put on protective clothing, gloves, hard-soled shoes, and safety
glasses or a face shield. Be sure that all joints and fittings are tight and leak
proof. Immediately replace any hose, which shows any signs of wear, fraying,
or splitting. Tighten all bolts, nuts, and screws every 100 hours.
Figure 5.1
Figure 5.2
Figure 5.3

E-Z 50 Melter Part Manual
Operating InstructionsChapter 5
©2017 by Crafco, Inc. All Rights Reserved…………………..…………………………………………Operating Instructions 5-2
5.3 Starting the Burner
Table 5-2 Starting the Burner
Step
Action
1
Open LPG tank valve. See Figure 5.6
2
Open in-line ball valve. See Figure 5.6
3
Open propane burner access door. See Figure 5.5
4
Open burner control box
5
Turn temperature control “OFF”
6
Turn pilot control to pilot. See Figure 5.4
7
Push pilot control in and light pilot light using supplied torch. Pilot light is
located inside propane burner access door. Hold pilot control until pilot
remains lit when control knob is released. After pilot is burning, turn pilot
control knob to “ON”. See Figure 5.7
8
Turn temperature dial to desired setting. Burner should ignite.
9
Close access door
Important: The solid material in the tank melts first around the walls and
bottom of the tank. The material temperature sensor is located by the wall,
therefore, it is possible that at the beginning of the melt process the indicated
temperature reaches operating value, but the material closer to the center of
the tank is still solid. This is normal.
10
Allow the heat transfer oil to continue to heat.
11
When the sealant material reaches 275°F, engage the mixer. If the mixer
does not move, allow the material to heat longer.
12 Caution
Jamming the mixer can cause the hydraulic oil to overheat and damage the
machine
Figure 5.6
Figure 5.5
Figure 5.4
Figure 5.7

E-Z 50 Melter Part Manual
Operating InstructionsChapter 5
©2017 by Crafco, Inc. All Rights Reserved…………………..…………………………………………Operating Instructions 5-3
5.4 Dispensing the Material
Table 5-3 Dispensing the Material
Step
Action
Warning
Put on protective clothing, gloves, hard-soled shoes, and face shield or safety
glasses when operating or filling this machine. Read the entire manual before
operating the machine.
Hot materials can cause severe burns.
1
Allow the material to reach 380°F or proper operating temperatures.
2
Place pour pot under pour spout
3
Open ball valve slowly
5.5 Loading Material into the Machine
Table 5-4 Loading Material into Sealant Tank
Step
Action
Warning
Following this procedure prevents hot material from getting on operators and causing
severe burns
1
To load material into the sealant tank first open the lid
2
Place the solid material on the lid then close the lid
3
Continue adding solid blocks at intervals to allow the mixer to rotate without jamming.
Note: If blocks of solid material are added too quickly, jamming results and slows
down the melting process.

E-Z 50 Melter Part Manual
Operating InstructionsChapter 5
©2017 by Crafco, Inc. All Rights Reserved…………………..…………………………………………Operating Instructions 5-4
5.6 Shutting Down and Cleaning Out the Machine
Table 5-5 Shutting Down and Cleaning Out the Machine
Step
Action
Caution
When shutting down the machine for the day, Crafco recommends leaving the melter
about half full with material. This will give a fairly rapid heat up rate in the morning,
but allow enough material to start dispensing right away when the material becomes
molten.
1
Turn mixer “OFF”
2
Turn pilot control knob to “OFF”
3
Stop engine by turning the key to the “OFF” position.
5.7 Storing the Machine
Store the machine in an area where moisture cannot enter the heating system sach as hot oil,
controls, etc. Extended down time can cause moisture build up in the heating oil tank.
If there is any evidence that moisture has collected in the heat transfer oil, warm the heat transfer
oil to 300°F for two to three hours to evaporate the moisture.