Crafco EZ 500 Series II User manual

Parts Manual - 26603
Revision K

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): ________________________

EZ 500 Series II Melter Part Manual
Revisions
Rev. Description Date
D Converted to Microsoft Word from Adobe Pagemaker. Changed
manual layout. 5/27/2015
E Updated hose and wand part numbers. Fixed misc. errors 3/8/16
F Added pump maintenance section, corrected wand 41629 was 46129 8/17/16
G Added EAC, CE logo; updated warranty; added overnight heater
extension cord info Table 5-12; added Section 5.15; 6.21; 6.22;
changed Fig. 9-15 and updated table to match; updated Fig. 5-2;
added item 5 in Fig.9.16 table; copyright date.
3/15/18
H
Removed information for machines no longer in production 46100EC63, and
46100SC63. Replaced diagrams for sections 9.2 and 9.3 with non-
compressor machines. Updated Prop. 65 warning, warranty information,
Added warning to Section 5.13, Section 9.5 used 42071 was 46020, Fig.
9.18 and list; 52202N was 52202, 52201RN was 52201, 52201LN was
52201L, 52203N was 52203. Changed wand figure on page 5-5. Added
parts 45443N, 47155N, 43612, 45748, 47150, 29399, 45444L, 45444U,
41872, 47138N to table 6-3. Changed section 5.15
11/29/18
J Move overnight heater to be easily accessible. Update section 9.3,
figure 9.3. Updated Section 10.0 with newest tool names. 2/11/2019
K
Update hydraulic pressure relief valve setting for the pump side shown
in figure 8.6. Pump pressure is 1000 psi; was 1500 psi 4/22/2019

EZ500 Series II Melter - Electric Hose
PN 46100EB
EZ500 Series II Melter - Standard Hose
PN 46100SB

EZ 500 Series II Melter Part Manual
Table of Contents
1.0 About This Manual..................................................................................................................1-1
1.1 How to use 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.........................................................................................2-2
2.4 California Proposition 65......................................................................................................2-2
All Crafco, Inc. Equipment........................................................................................2-22.4.1
All Crafco, Inc. Equipment using a diesel engine .....................................................2-22.4.2
2.5 Safety Symbols and Notices................................................................................................2-3
3.0 Limited Warranty.....................................................................................................................3-1
3.1 Warranty Claim Instructions.................................................................................................3-2
4.0 Machine Specifications ...........................................................................................................4-1
5.0 Operating Instructions.............................................................................................................5-1
5.1 Preparing the Machine for Start Up......................................................................................5-1
5.2 Machine Start Up for Electric Hose......................................................................................5-3
5.3 Altitude Compensation System............................................................................................5-5
5.4 About the Heated Hose, Wand, Valve, and Tip Guard.........................................................5-5
5.5 Electric Hose Care and Cautions.........................................................................................5-6
5.6 Storing the Electric Hose for Transport................................................................................5-6
5.7 Machine Start Up for Standard Hose...................................................................................5-7
5.8 Loading Material into the Sealant Tank................................................................................5-8
Material Tank Depth Chart.......................................................................................5-95.8.1
5.9 Dispensing the Material.....................................................................................................5-10
5.10 Shutting Down and Cleaning Out the Machine.................................................................5-11
5.11 Storing the Machine.........................................................................................................5-13
5.12 Overnight Heaters ...........................................................................................................5-14
5.13 Mounting a Skid Machine ................................................................................................5-15
6.0 Maintenance Instructions ........................................................................................................6-1
6.1 Engine.................................................................................................................................6-1
6.2 Hydraulic System.................................................................................................................6-1
6.3 Heat Transfer Oil.................................................................................................................6-1
6.4 Wheel Bearing.....................................................................................................................6-1

EZ 500 Series II Melter Part Manual
Table of Contents
6.5 Material Sensor Tube..........................................................................................................6-1
6.6 Pump Packing Adjustment and Replacement...................................................................... 6-1
6.7 Lug Nuts..............................................................................................................................6-2
6.8 Brakes................................................................................................................................. 6-2
6.9 Tongue Jack........................................................................................................................6-2
6.10 Temperature Control Calibration ....................................................................................... 6-2
6.11 Replacing Heat Transfer Oil ..............................................................................................6-3
6.12 Maintenance Chart............................................................................................................6-4
6.13 Service Instructions...........................................................................................................6-5
6.14 General Maintenance Parts............................................................................................... 6-5
6.15 Recommended Spare Parts ..............................................................................................6-6
6.16 Recommended Fluids and Lubricants ............................................................................... 6-6
6.17 Typical Heat Transfer Oil Specifications............................................................................ 6-7
6.18 Material Pump Replacement .............................................................................................6-8
6.19 Cleaning Material Tank and Sensor Area........................................................................ 6-10
6.20 Cleaning the Melter ......................................................................................................... 6-10
7.0 How to Use a Multimeter.........................................................................................................7-1
7.1 Checking DC Voltage with a Multimeter ..............................................................................7-1
7.2 Checking AC Voltage with Multimeter..................................................................................7-1
7.3 Checking Resistance (Ohms)..............................................................................................7-1
7.4 Checking Amperage............................................................................................................ 7-2
8.0 Burner Troubleshooting ..........................................................................................................8-1
8.1 Sealant heating Slowly...................................................................................................... 8-11
8.2 Mixer Troubleshooting....................................................................................................... 8-12
Symptom: Mixer Does Not Rotate.......................................................................... 8-128.2.1
Mixer Hydraulic Troubleshooting ........................................................................... 8-188.2.2
8.3 Hose Troubleshooting ....................................................................................................... 8-21
Symptom: Hose Does Not Heat............................................................................. 8-218.3.1
Symptom: Trigger is not Working........................................................................... 8-268.3.2
RTD Sensor Ohms vs. Temperature...................................................................... 8-278.3.3
8.4 Pump Troubleshooting ...................................................................................................... 8-29
Symptom: Material Does Not Dispense When the Pump is Activated.................... 8-298.4.1
Pump Hydraulic Troubleshooting........................................................................... 8-348.4.2
9.0 About the Illustrated Parts List ................................................................................................9-1

EZ 500 Series II Melter Part Manual
Table of Contents
9.1 Ordering Crafco Parts..........................................................................................................9-1
9.2 EZ500 Series II Melter.........................................................................................................9-2
9.3 Series II Melter Options.......................................................................................................9-6
9.4 Tank Detail..........................................................................................................................9-9
9.5 Plumbing ...........................................................................................................................9-10
9.6 Control Box Assembly – Electric Hose...............................................................................9-12
9.7 Control Box Assembly – Standard Hose............................................................................9-16
9.8 Engine Assembly..............................................................................................................9-20
9.9 Hydraulic Control Valve Assembly.....................................................................................9-22
9.10 Material Flow Control Assembly ......................................................................................9-23
9.11 Compressor Hydraulic Valve Assembly...........................................................................9-24
9.12 Diesel Burner Assembly ..................................................................................................9-25
9.13 Material Pump Assembly.................................................................................................9-29
9.14 Wand Assembly...............................................................................................................9-30
9.15 Hydraulic Diagram...........................................................................................................9-32
9.16 Diesel Fuel Line Schematic .............................................................................................9-36
9.17 Electrical Schematic – Electric Hose................................................................................9-38
9.18 Electrical Schematic – Standard Hose.............................................................................9-40
9.19 Hot Air Lance...................................................................................................................9-42
10.0 Tools and Accessories........................................................................................................10-1

EZ 500 Series II Melter Part Manual
List of Figures
Fig. 5.1 Hydraulic Fluid Level and Temp. Gauge .......................................................................... 5-2
Fig. 5.2 Heat Transfer Oil Dipstick ................................................................................................5-2
Fig. 6.1 Lug Bolt Tightening Sequence......................................................................................... 6-2
Fig. 6.2 Temperature Control Calibration...................................................................................... 6-3
Fig. 6.3 Material Pump Replacement............................................................................................ 6-9
Fig. 7.1 Standard Multimeter.........................................................................................................7-2
Fig. 7.2 Clamp-On Amp Meter/Multimeter..................................................................................... 7-3
Fig. 8.1 Diesel Burner Schematic.................................................................................................. 8-6
Fig. 8.2 Diesel Burner Electrode Adjustment............................................................................... 8-10
Fig. 8.3 Diesel Burner Air Settings.............................................................................................. 8-10
Fig. 8.4 Checking Din Plug Voltage............................................................................................. 8-16
Fig. 8.5 Mixer Circuit................................................................................................................... 8-17
Fig. 8.6 Hydraulic Valve Pressure Setting................................................................................... 8-19
Fig. 8.7 Din Plug Layout..............................................................................................................8-20
Fig. 8.8 Junction Box Voltage Testing......................................................................................... 8-23
Fig. 8.9 Hose Circuit Schematic.................................................................................................. 8-24
Fig. 8.10 Junction Box Wiring ..................................................................................................... 8-25
Fig. 8.11 Pump Circuit Schematic............................................................................................... 8-33
Fig. 9.1 EZ500 Series II Melter ..................................................................................................... 9-2
Fig. 9.2 EZ500 Series II Melter ..................................................................................................... 9-4
Fig. 9.3 EZ500 Series II Melter Options ........................................................................................9-6
Fig. 9.4 Tank Detail....................................................................................................................... 9-9
Fig. 9.5 Plumbing........................................................................................................................9-10
Fig. 9.6 Control Box Assembly: 46100SB ................................................................................... 9-12
Fig. 9.7 Control Box Assembly: 46100EB ................................................................................... 9-14
Fig. 9.8 Control Box Assembly: 46100SB ................................................................................... 9-16
Fig. 9.9 Control Box Assembly – 46100SB ................................................................................. 9-18
Fig. 9.10 Compressor Valve Assembly ....................................................................................... 9-20
Fig. 9.11 Hydraulic Control Valve................................................................................................ 9-22
Fig. 9-12 Material Flow Control Assembly................................................................................... 9-23
Fig. 9.13 Compressor Valve Assembly ....................................................................................... 9-24

EZ 500 Series II Melter Part Manual
List of Figures
Fig. 9.14 Diesel Burner ...............................................................................................................9-26
Fig. 9.15 Material Pump Assembly..............................................................................................9-29
Fig. 9.16 Wand Assembly ...........................................................................................................9-30
Fig. 9.17 Hydraulic Diagram 46100EB, 46100SB........................................................................9-32
Fig. 9.18 Hydraulic Diagram 46100EB, 46100SB........................................................................9-34
Fig. 9.19 Diesel Fuel Line Schematic..........................................................................................9-36
Fig. 9.20 Electrical Schematic 46100EB......................................................................................9-38
Fig. 9.21 Electrical Schematic 46100SB......................................................................................9-40
Fig. 9.22 Hot Air Lance (Option)..................................................................................................9-42

EZ 500 Series II Melter Part Manual
List of Tables
Table 2-1 Safety Symbols and Notices.........................................................................................2-3
Table 2-2 Safety Symbols and Notices (continued)....................................................................... 2-4
Table 4-1 Machine Specifications................................................................................................. 4-1
Table 5-1 Preparing the Machine for Start Up...............................................................................5-1
Table 5-2 Starting the Burner for Electric Hose.............................................................................5-3
Table 5-3 Electric Hose Care....................................................................................................... 5-6
Table 5-4 Hose for Transport Instructions.................................................................................... 5-6
Table 5-5 Starting the Burner for Standard Hose......................................................................... 5-7
Table 5-6 Loading Material into the Sealant Tank......................................................................... 5-8
Table 5-7 Material Tank Depth Chart............................................................................................5-9
Table 5-8 Dispensing the Material – Electric Hose...................................................................... 5-10
Table 5-9 Dispensing the Material – Standard Hose................................................................... 5-11
Table 5-10 Shutting Down with an Electric Hose........................................................................ 5-12
Table 5-11 Shutting Down with a Standard Hose....................................................................... 5-12
Table 5-12 Overnight Heaters..................................................................................................... 5-14
Table 5-13 Mounting a Skid Machine.......................................................................................... 5-15
Table 6-1 Maintenance Chart........................................................................................................6-4
Table 6-2 Service Instructions.......................................................................................................6-5
Table 6-3 General Maintenance Parts ..........................................................................................6-5
Table 6-4 Recommended Spare Parts.......................................................................................... 6-6
Table 6-5 Recommended Fluids and Lubricants........................................................................... 6-6
Table 6-6 Applicable Brand of Heat Transfer Oil........................................................................... 6-7
Table 6-7 Material Pump Replacement.........................................................................................6-8
Table 8-1 Basic Visual Burner Troubleshooting ............................................................................ 8-1
Table 8-2 Basic Visual Burner Troubleshooting (continued).......................................................... 8-2
Table 8-3 Burner Electrical Troubleshooting................................................................................. 8-2
Table 8-4 Burner Electrical Troubleshooting (continued)............................................................... 8-3
Table 8-5 Burner Electrical Troubleshooting (continued)............................................................... 8-4
Table 8-6 Burner Electrical Troubleshooting (continued)............................................................... 8-5
Table 8-7 Smoke Coming Out of Exhaust Stack........................................................................... 8-7
Table 8-8 Burner Lights But Shuts Down After 15 Seconds.......................................................... 8-7