Ergon Crafco E-Z 1000 Series II User manual

Parts Manual - 26458
Revision Q

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 1000 Series II Melter Part Manual
Revisions
Rev. Description Date
G Converted to Microsoft Word from Adobe Pagemaker. Changed
manual layout. 5/27/2015
H Updated hose, wand, and trailer light part numbers. Fixed misc.
errors. 3/8/16
J Added pump maintenance section, corrected wand 41629 was
46129 8/17/16
K Changed start-up procedure and all pages associated to the 4LE2T
engine change; Air Comp Oil Changes Sec. 6.15; Air Comp Oil
Sec. 6.19; Temp Switch Sec. 9.18; Diagnostic Trouble Codes
Sec. 8.5; Hyd Valve Pressure Setting Sec.8.2.2
8/30/17
L Added jacketed pump information. Note: all EZ1000s now have
jacketed pump. Deleted frame solenoid from 4LE2 equipped
melters. Warranty changed to two years. 12/5/2017
M Updated warranty duration and start to invoice date in sections 3.0
and 3.1. Updated section 4.0, heat transfer oil volume to 36.5
gallons. Updated section 9.17, air compressor exploded view
and parts list to include safety air shut off valve. Updated Fig. 9-
22 parts list, item 6 to PN 45614N. Updated parts list of Fig. 9-36
items 9 and 12 part numbers. Updated section 9.16 image and
parts list items 2 and 4 part numbers. Updated Fig. 9-38 and
parts list item 3 and 4 part numbers. Updated Fig. 9-39.
Updated Fig. 9-40. Updated parts list item 3 and 4 for Fig 9-41.
Updated section 5.13 Overnight Heater Use by adding the
warning statement. Updated Fig 9-5 parts list conveyor assembly
part number.
7/1/2018
N Added section 2.4 for Prop 65 information. Edited Section 5.16.
Changed figure on pg. 5-7. Added Section 9.12 to show engine
air filter and safety filter. Changed Fig. 9-28 to newest wand.
Updated wand part numbers. Added a section to Table 6-2.
12/12/2018
P ENG-601: Updated DIN plug locations on figures 9-39, 9-40, 9-41,
9-42, 9-43, 9-44. Update Section 10.0 with newest tool names. 2/6/2019
Q Update hydraulic pressure relief valve setting for the agitator shown
in figure 8-8. Agitator pressure is 1500 psi; was 2000 psi. Add
image of 45433 hydraulic valve assembly and show hot oil relief
valve setting at 800 psi
4/22/2019

EZ1000 Series II Melter - Electric Hose
PN 47600EC100
EZ1000 Series II Melter - Electric Hose
PN 46200EB

EZ1000 Series II Melter - Standard Hose
PN 47600SC100
EZ1000 Series II Melter - Standard Hose
PN 46200SB
Picture Coming Soon

EZ 1000 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......................................................................................... 2-1
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 Machine Start Up for Electric Compressor........................................................................... 5-5
5.4 Altitude Compensation System (46200EB, 46200SB Only)................................................. 5-7
5.5 About the Heated Hose, Wand, Valve, and Tip Guard......................................................... 5-7
5.6 Electric Hose Care and Cautions......................................................................................... 5-8
5.7 Storing the Electric Hose for Transport................................................................................5-8
5.8 Machine Start Up for Standard Hose................................................................................... 5-9
5.9 Machine Start Up for Standard Compressor...................................................................... 5-10
5.10 Loading Material into the Sealant Tank ........................................................................... 5-12
Material Tank Depth Chart..................................................................................... 5-135.10.1
5.11 Dispensing the Material................................................................................................... 5-14
5.12 Shutting Down and Cleaning Out the Machine ................................................................ 5-15
5.13 Overnight Heater Use...................................................................................................... 5-18
5.14 Storing the Machine ........................................................................................................ 5-19
5.15 Air Compressor: PN 47600EC100, 47600SC100 ............................................................ 5-20
5.16 Mounting a Skid Machine ................................................................................................ 5-21
6.0 Maintenance Instructions........................................................................................................ 6-1
6.1 Engine................................................................................................................................. 6-1
6.2 Air Compressor ...................................................................................................................6-1

EZ 1000 Series II Melter Part Manual
Table of Contents
6.3 Hydraulic System.................................................................................................................6-1
6.4 Heat Transfer Oil.................................................................................................................6-1
6.5 Wheel Bearing.....................................................................................................................6-1
6.6 Material Sensor Tube ..........................................................................................................6-1
6.7 Pump Packing Adjustment and Replacement......................................................................6-2
6.8 Lug Nuts..............................................................................................................................6-2
6.9 Brakes.................................................................................................................................6-2
6.10 Tongue Jack......................................................................................................................6-2
6.11 Temperature Control Calibration........................................................................................6-3
6.12 Replacing Heat Transfer Oil...............................................................................................6-3
6.13 Cleaning Material Tank and Sensor Area ..........................................................................6-3
6.14 Cleaning the Melter ...........................................................................................................6-3
6.15 Maintenance Chart............................................................................................................6-4
6.16 Service Instructions ...........................................................................................................6-5
6.17 General Maintenance Parts...............................................................................................6-6
6.18 Recommended Spare Parts...............................................................................................6-7
6.19 Recommended Fluids and Lubricants................................................................................6-7
6.20 Applicable Brands of Heat Transfer Oil..............................................................................6-8
6.21 Typical Heat Transfer Oil Specifications ............................................................................6-8
6.22 Material Pump Replacement..............................................................................................6-9
6.23 Wand Repair Instructions ................................................................................................6-11
6.24 Cable Replacement.........................................................................................................6-11
6.25 Switch Replacement........................................................................................................6-11
6.26 Terminal Block Replacement...........................................................................................6-11
6.27 Wand Handle Replacement.............................................................................................6-12
6.28 Burner Fuel Filter Replacement.........................................................................................6-3
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......................................................................................................8-18
8.2 Agitator Troubleshooting....................................................................................................8-19
Symptom: Mixer Does Not Rotate..........................................................................8-198.2.1

EZ 1000 Series II Melter Part Manual
Table of Contents
Mixer Hydraulic Troubleshooting ........................................................................... 8-258.2.2
8.3 Hose Troubleshooting ....................................................................................................... 8-28
Symptom: Hose Does Not Heat............................................................................. 8-288.3.1
Symptom: Trigger is Not Working.......................................................................... 8-338.3.2
RTD Sensor Ohms vs. Temperature...................................................................... 8-348.3.3
8.4 Pump Troubleshooting ...................................................................................................... 8-36
Symptom: Material Does Not Dispense When the Pump is Activated.................... 8-368.4.1
Pump Hydraulic Troubleshooting........................................................................... 8-418.4.2
8.5 Engine Diagnostic Trouble Codes (DTC)........................................................................... 8-42
How to use the Diagnostic Trouble Code Table..................................................... 8-428.5.1
Engine DTC Table (47600EC100, 47600SC100)................................................... 8-428.5.2
9.0 About the Illustrated Parts List ................................................................................................9-1
9.1 Ordering Crafco Parts .........................................................................................................9-1
9.2 EZ1000 Series II EZ1000 Melters: 47600EC100 / 47600SB100 / 46200EB / 46200SB....... 9-2
9.3 EZ1000 Series II Melter Options.......................................................................................... 9-8
9.4 Tank Detail........................................................................................................................9-15
9.5 Plumbing...........................................................................................................................9-16
9.6 Control Box Assembly 47202 – 46200EB.......................................................................... 9-18
9.7 Control Box Assembly 47201 – 46200SB.......................................................................... 9-22
9.8 Control Box Assembly 47210 – 47600EC100.................................................................... 9-26
9.9 Control Box Assembly 47215 – 47600SC100.................................................................... 9-30
9.10 Engine Assembly – Non Compressor.............................................................................. 9-34
9.11 Engine Assembly – 47600SC100.................................................................................... 9-36
9.12 Engine Assembly 47600SC, 47600EC Air Filter Side...................................................... 9-38
9.13 Engine Assembly – 47600EC100.................................................................................... 9-40
9.14 Material Flow Control Assembly...................................................................................... 9-42
9.15 Hydraulic Compressor Valve Assembly........................................................................... 9-43
9.16 Diesel Burner Assembly.................................................................................................. 9-44
9.17 Material Pump Assembly................................................................................................. 9-46
9.18 Air Compressor Assembly............................................................................................... 9-48
9.19 High Output Air Lance Assembly..................................................................................... 9-50
9.20 Wand Assembly .............................................................................................................. 9-52
9.21 Diesel Fuel Line Schematic – Non-Compressor .............................................................. 9-54
9.22 Diesel Fuel Line Schematic – Compressors.................................................................... 9-56
9.23 Electrical Schematic – Electric Hose ............................................................................... 9-58

EZ 1000 Series II Melter Part Manual
Table of Contents
9.24 Electrical Schematic – Standard Hose.............................................................................9-60
9.25 Optional Engine Cover for Compressor Models...............................................................9-62
9.26 Hot Air Lance...................................................................................................................9-64
9.27 Jacketed Pump System...................................................................................................9-66
9.28 Hydraulic Control Valve Assembly...................................................................................9-70
9.29 Hot Oil Pump and Motor ..................................................................................................9-72
9.30 Hydraulic System Diagram for Jacketed Pump Machines with the 23 HP engine (46200EB,
46200SB)................................................................................................................................9-74
9.31 Hydraulic System Diagram for Jacketed Pump Machines with the 42 HP engine
(47600EC100, 47600SC100, 47600ECPA, 47600SCPA)........................................................9-80
10.0 Tools and Accessories........................................................................................................10-1

EZ 1000 Series II Melter Part Manual
List of Figures
Fig. 5-1 Hydraulic Fluid Level and Temp. Gauge.......................................................................... 5-2
Fig. 5-2 Dipstick............................................................................................................................ 5-2
Fig. 5-3 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.......................................................................................... 6-10
Fig. 6-4 Switch Wire Location ..................................................................................................... 6-12
Fig. 6-5 Terminal Block Wiring.................................................................................................... 6-12
Fig. 6-6 Wire Routing..................................................................................................................6-12
Fig. 6-7 Actuator Spring Location..................................................................................................6-2
Fig. 6-8 Actuator / Trigger Assembly.............................................................................................6-2
Fig. 7-1 Standard Multimeter.........................................................................................................7-2
Fig. 7-2 Clamp – On Amp Meter/Multimeter..................................................................................7-3
Fig. 8-1 ECM ................................................................................................................................8-7
Fig. 8-2 Diesel Burner Schematic – 4LE2 Engine ......................................................................... 8-8
Fig. 8-3 Diesel Burner Schematic – 3C Engine........................................................................... 8-13
Fig. 8-4 Diesel Burner Electrode Adjustment .............................................................................. 8-17
Fig. 8-5 Diesel Burner Air Settings.............................................................................................. 8-17
Fig. 8-6 Checking Din Plug Voltage ............................................................................................ 8-23
Fig. 8-7 Mixer Circuit...................................................................................................................8-24
Fig. 8-8 Hydraulic Valve Pressure Setting................................................................................... 8-26
Fig. 8-9 Din Plug Layout ............................................................................................................. 8-27
Fig. 8-10 Junction Box Voltage Testing....................................................................................... 8-30
Fig. 8-11 Hose Circuit Schematic................................................................................................ 8-31
Fig. 8-12 Junction Box Wiring..................................................................................................... 8-32
Fig. 8-13 Pump Circuit Schematic............................................................................................... 8-40
Fig. 8-14 Engine Control Display DTC........................................................................................ 8-42
Fig. 9-1 EZ1000 Series II Melters: 47600EC100 / 47600SB100 (NOT SHOWN) .......................... 9-2
Fig. 9-2 EZ1000 Series II Melter: 47600EC100 / 47600SB100 (NOT SHOWN)........................... 9-4
Fig. 9-3 EZ1000 Series II Melter: 47600EC100 / 47600SB100 (NOT SHOWN)............................ 9-6
Fig. 9-4 EZ1000 Series II Melter Options...................................................................................... 9-8

EZ 1000 Series II Melter Part Manual
List of Figures
Fig. 9-5 EZ1000 Series II Melter Options ....................................................................................9-10
Fig. 9-6 EZ1000 Series II Melter Options ....................................................................................9-12
Fig. 9-7 EZ1000 Series II Melter Options ....................................................................................9-14
Fig. 9-8 Tank Detail.....................................................................................................................9-15
Fig. 9-9 Plumbing........................................................................................................................9-16
Fig. 9-10 Control Box Assembly 47202 - 46200EB .....................................................................9-18
Fig. 9-11 Control Box Assembly 47202 - 46200EB .....................................................................9-20
Fig. 9-12 Control Box Assembly 47201 - 46200SB .....................................................................9-22
Fig. 9-13 Control Box Assembly 47201 - 46200SB .....................................................................9-24
Fig. 9-14 Control Box Assembly 47210 – 47600EC100...............................................................9-26
Fig. 9-15 Control Box Assembly 47210 – 47600EC100...............................................................9-28
Fig. 9-16 Control Box Assembly 47215 – 47600SC100...............................................................9-30
Fig. 9-17 Control Box Assembly 47215 – 47600SC100...............................................................9-32
Fig. 9-18 Engine Assembly - 46200EB, 46200SB.......................................................................9-34
Fig. 9-19 Engine Assembly – 47600SC100.................................................................................9-36
Fig. 9-20 Engine Assembly – 47600SC, 47600EC Air Filter Side................................................9-38
Fig. 9-21 Engine Assembly – 47600EC100.................................................................................9-40
Fig. 9-22 Material Flow Control Assembly...................................................................................9-42
Fig. 9-23 Compressor Valve Assembly .......................................................................................9-43
Fig. 9-24 Diesel Burner...............................................................................................................9-44
Fig. 9-25 Material Pump Assembly..............................................................................................9-46
Fig. 9-26 Compressor Assembly.................................................................................................9-48
Fig. 9-27 High Output Air Lance Assembly..................................................................................9-50
Fig. 9-28 Wand Assembly...........................................................................................................9-52
Fig. 9-29 Diesel Fuel Line Schematic – Non-Compressor...........................................................9-54
Fig. 9-30 Diesel Fuel Line Schematic - Compressors..................................................................9-56
Fig. 9-31 Electrical Schematic – 47600EC100 ............................................................................9-58
Fig. 9-32 Electrical Schematic – 47600SC100 ............................................................................9-60
Fig. 9-33 Optional Engine Cover for Compressor Models ...........................................................9-62
Fig. 9-34 Hot Air Lance (Option) .................................................................................................9-64
Fig. 9-35 Jacketed Pump System................................................................................................9-66

EZ 1000 Series II Melter Part Manual
List of Figures
Fig. 9-36 Jacketed Pump System ............................................................................................... 9-68
Fig. 9-37 Hydraulic Valve Assembly PN 45433........................................................................... 9-70
Fig. 9-38 Pump and Motor Assy, Hot Oil..................................................................................... 9-72
Fig. 9-39 Hydraulic System Diagram – non compressor ............................................................. 9-74
Fig. 9-40 Hydraulic System Diagram – non compressor ............................................................. 9-76
Fig. 9-41 Hydraulic System Diagram – non compressor ............................................................. 9-78
Fig. 9-42 Hydraulic System Diagram - compressor..................................................................... 9-80
Fig. 9-43 Hydraulic System Diagram - compressor..................................................................... 9-82
Fig. 9-44 Hydraulic System Diagram - compressor..................................................................... 9-84

EZ 1000 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 Starting the Burner for Electric Hose (continued)...........................................................5-4
Table 5-4 Starting the Burner for Electric Compressor..................................................................5-5
Table 5-5 Starting the Burner for Electric Compressor (continued)................................................5-6
Table 5-6 Electric Hose Care.......................................................................................................5-8
Table 5-7 Hose for Transport Instructions....................................................................................5-8
Table 5-8 Starting Burner for Standard Hose................................................................................5-9
Table 5-9 Starting Burner for Standard Hose (continued)............................................................5-10
Table 5-10 Starting the Burner for Standard Compressor ..........................................................5-10
Table 5-11 Starting Burner for Standard Compressor (continued)...............................................5-11
Table 5-12 Loading Material into the Sealant Tank.....................................................................5-12
Table 5-13 Material Tank Depth Chart........................................................................................5-13
Table 5-14 Dispensing the Material – Electric Hose...................................................................5-14
Table 5-15 Dispensing the Material – Standard Hose .................................................................5-15
Table 5-16 Shutting Down 46200EB..........................................................................................5-16
Table 5-17 Shutting Down 47600EC100.....................................................................................5-16
Table 5-18 Shutting Down 46200SB..........................................................................................5-17
Table 5-19 Shutting Down 47600SC100.....................................................................................5-17
Table 5-20 Overnight Heater Use................................................................................................5-18
Table 5-21 Mounting a Skid Machine..........................................................................................5-21
Table 6-1 Air Compressor Maintenance Chart ..............................................................................6-1
Table 6-2 Maintenance Chart........................................................................................................6-4
Table 6-3 Service Instructions.......................................................................................................6-5
Table 6-4 General Maintenance Parts...........................................................................................6-6
Table 6-5 Recommended Spare Parts..........................................................................................6-7
Table 6-6 Recommended Fluids and Lubricants...........................................................................6-7
Table 6-7 Applicable Brand of Heat Transfer Oil...........................................................................6-8

EZ 1000 Series II Melter Part Manual
List of Tables
Table 6-8 Material Pump Replacement.........................................................................................6-9
Table 6-9 Burner Fuel Filter Replacement ....................................................................................6-3
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 -4LE2 Engine........................................................... 8-2
Table 8-4 Burner Electrical Troubleshooting – 4LE2 Engine (continued) ...................................... 8-3
Table 8-5 Burner Electrical Troubleshooting - 4LE2 Engine (continued) ....................................... 8-4
Table 8-6 Burner Electrical Troubleshooting – 4LE2 (continued) .................................................. 8-5
Table 8-7 Electrical Troubleshooting – 4LE2 Engine (continued).................................................. 8-6
Table 8-8 Burner Electrical Troubleshooting – 4LE2 Engine (continued) ...................................... 8-7
Table 8-9 Burner Electrical Troubleshooting – 3C Engine............................................................. 8-9
Table 8-10 Burner Electrical Troubleshooting – 3C Engine (continued)...................................... 8-10
Table 8-11 Burner Electrical Troubleshooting – 3C Engine (continued)...................................... 8-11
Table 8-12 Burner Electrical Troubleshooting – 3C Engine (continued)...................................... 8-12
Table 8-13 Smoke Coming Out of Exhaust Stack....................................................................... 8-14
Table 8-14 Burner Lights but Shuts Down After 15 Seconds....................................................... 8-14
Table 8-15 Testing the DC controller .......................................................................................... 8-15
Table 8-16 Burner Fuel Solenoid Testing.................................................................................... 8-15
Table 8-17 Burner Ignition Coil Test............................................................................................ 8-16
Table 8-18 Bleeding the Burner – Non-Compressor Only........................................................... 8-16
Table 8-19 Sealant is Heating Slowly.......................................................................................... 8-18
Table 8-20 Basic Visual Mixer Troubleshooting .......................................................................... 8-19
Table 8-21 Mixer Electrical Troubleshooting............................................................................... 8-20
Table 8-22 Mixer Electrical Troubleshooting (continued)............................................................. 8-21
Table 8-23 Mixer Electrical Troubleshooting (continued)............................................................. 8-22
Table 8-24 Mixer Hydraulic Troubleshooting............................................................................... 8-25
Table 8-25 Basic Visual Troubleshooting.................................................................................... 8-28
Table 8-26 Electrical Troubleshooting......................................................................................... 8-28
Table 8-27 Electrical Troubleshooting (continued)...................................................................... 8-29
Table 8-28 Electrical Troubleshooting (continued)...................................................................... 8-30
Table 8-29 Trigger is not Working............................................................................................... 8-33

EZ 1000 Series II Melter Part Manual
List of Tables
Table 8-30 RTD Sensor Ohms vs. Temperature.........................................................................8-34
Table 8-31 RTD Sensor Ohms vs. Temperature (continued).......................................................8-35
Table 8-32 Basic Visual Pump Troubleshooting..........................................................................8-36
Table 8-33 Pump Electrical Troubleshooting...............................................................................8-37
Table 8-34 Pump Electrical Troubleshooting (continued) ............................................................8-38
Table 8-35 Pump Electrical Troubleshooting (continued) ............................................................8-39
Table 8-36 Pump Electrical Troubleshooting (continued) ............................................................8-40
Table 8-37 Pump Hydraulic Troubleshooting ..............................................................................8-41
Table 8-38 Engine DTC Table PN 47600EC100, 47600SC100...................................................8-42
Table 8-39 Engine DTC Table PN 47600EC100, 47600SC100 (Continued)...............................8-43
Table 8-40 Engine DTC Table PN 47600EC100, 47600SC100 (Continued)...............................8-44

EZ 1000 Series II Melter Part Manual
Chapter 1 Introduction
©2019 by Crafco, Inc. All Rights Reserved …….. Introduction 1-1
1.0 About This Manual
This manual is supplied with each new Crafco EZ Series II 1000 Diesel 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 EZ Series II 1000 Diesel 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 this manual.
1.1 How to use this manual:
This manual is formatted to start each new chapter on the right page. There may be a blank page
on the left page if the previous chapter ends on the right page.
If you are viewing this in a digital format (PDF) the following features are available:
1. The Table of Contents, List of Tables, and List of Figures are all hyperlinks, when mouse is left
clicked on section, table, or figure you will be sent to that page.
2. The blue highlighted text throughout the manual is a hyperlink, when mouse is left clicked you
will be sent to that page, table, or figure.
3. The panel to the left in the PDF is a bookmarks panel, if you left mouse click on any
section/heading in the bookmarks panel you will be sent to that page.

EZ 1000 Series II Melter Part Manual
Chapter 2 Safety
©2019 by Crafco, Inc. All Rights Reserved………………………………………..…………………………………Safety 2-1
2.0 Safety Precautions
For more in-depth safety information, please see Safety Manual (PN 26221) which comes with the
machine. Or contact your nearest authorized Crafco Distributor at crafco.com/Distributors.
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 fuel tank.
•Make sure mixer stops before adding solid material to the sealant tank. Lift the lid, place the
material on the lid and close the lid. The mixer should restart automatically.
•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.
•Calibrate the temperature control operation after each 50 hours of machine operation. Refer
to section 6.11 Temperature Control Calibration.
•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.

EZ 1000 Series II Melter Part Manual
Chapter 2 Safety
©2019 by Crafco, Inc. All Rights Reserved………………………………………..…………………………………Safety 2-2
2.4 California Proposition 65
The state of California currently maintains a list of chemicals that can cause cancer, birth defects or
other reproductive harm. Your Crafco, Inc. equipment comes with the following warnings:
All Crafco, Inc. Equipment2.4.1
All Crafco, Inc. Equipment Using a Diesel Engine2.4.2
! WARNING:
Cancer and Reproductive Harm- www.P65Warnings.ca.gov
26471N
! WARNING: Breathing diesel engine exhaust exposes you to chemicals
known to the State of California to cause cancer and birth defects or other
reproductive harm.
• Always start and operate the engine in a well-ventilated area.
• If in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel. 26307