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Crafco EZ 500 Series II Manual

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Parts Manual - 26603
Revision K

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Summary of Contents for Crafco EZ 500 Series II

  • Page 1 Parts Manual - 26603 Revision K...
  • Page 2 Fill in appropriate fields that apply to this machine Machine S/N: _ _______________________________ Hose S/N: _______________________________ Hose S/N: _______________________________ Pump S/N: _______________________________ Pump S/N: ______________________________ Engine S/N: ________________________________ Compressor S/N: _____________________________ Gear Box S/N (Patcher): ______________________ Blower S/N (Magnum): ________________________...
  • Page 3 EZ 500 Series II Melter Part Manual Revisions Rev. Description Date Converted to Microsoft Word from Adobe Pagemaker. Changed 5/27/2015 manual layout. Updated hose and wand part numbers. Fixed misc. errors 3/8/16 Added pump maintenance section, corrected wand 41629 was 46129 8/17/16 Added EAC, CE logo;...
  • Page 4 EZ500 Series II Melter - Electric Hose PN 46100EB EZ500 Series II Melter - Standard Hose PN 46100SB...

  • Page 5: Table Of Contents

    2.4 California Proposition 65 ...................... 2-2 2.4.1 All Crafco, Inc. Equipment ..................2-2 2.4.2 All Crafco, Inc. Equipment using a diesel engine ............. 2-2 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 ......................
  • Page 6 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 ....................
  • Page 7 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 –...
  • Page 8 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.
  • Page 9 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.
  • Page 10 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 ................
  • Page 11 EZ 500 Series II Melter Part Manual List of Tables Table 8-9 Testing the DC Controller ....................8-8 Table 8-10 Burner Fuel Solenoid Testing ..................8-8 Table 8-11 Burner Ignition Coil Testing ..................8-9 Table 8-12 Bleeding the Burner ....................8-9 Table 8-13 Sealant is Heating Slowly ..................

  • Page 13: About This Manual

    Chapter 1 Introduction 1.0 About This Manual This manual is supplied with each new Crafco EZ Series II 500 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.

  • Page 15: Safety Precautions

    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.

  • Page 16: Equipment Or Operational Safety

    Tighten all bolts and screws every 100 hours of machine operation. 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: 2.4.1 All Crafco, Inc. Equipment ! WARNING: Cancer and Reproductive Harm - www.P65Warnings.ca.gov...

  • Page 17: Safety Symbols And Notices

    EZ 500 Series II Melter Part Manual Chapter 2 Safety 2.5 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.

  • Page 18: Table 2-2 Safety Symbols And Notices (Continued)

    EZ 500 Series II Melter Part Manual Chapter 2 Safety Table 2-2 Safety Symbols and Notices (continued) Symbol Item Remark Crush Hazard Keep feet and legs clear. Pinch Hazard Keep hands and feet clear. Exhaust Hazard Avoid breathing engine exhaust.

  • Page 19: Limited Warranty

    CAUTION Use of replacement parts other than genuine Crafco parts may impair the safety or reliability of your equipment and nullifies any warranty. ©2019 by Crafco, Inc. All Rights Reserved………………………………………………………….…Warranty Information 3-1...

  • Page 20: Warranty Claim Instructions

    RA number. The customer will be emailed or faxed an RA form with all instructions to return the item to Crafco, Inc. See example. If the part is found to be within the two year warranty period and has not been abused or modified, a credit will be issued to the customer’s account or credit card.

  • Page 21: Machine Specifications

    Full sweep mixer with 2 horizontal paddles, vertical risers Axle Capacity 5,200lbs. Tires ST225/75R15 Load Range D Ship Weight Approximately 4,500 lbs. Diesel tank Capacity 30 Gallons Hydraulic Tank Capacity 26 Gallons Air Compressor ©2019 by Crafco, Inc. All Rights Reserved……………………………………………………………Machine Specifications 4-1...

  • Page 23: Operating Instructions

    EZ 500 Series II Melter Part Manual Chapter 5 Operating Instructions 5.0 Operating Instructions The Crafco EZ 500 Series II 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.

  • Page 24: Fig. 5.1 Hydraulic Fluid Level And Temp. Gauge

    EZ 500 Series II Melter Part Manual Chapter 5 Operating Instructions Fig. 5.1 Hydraulic Fluid Level and Temp. Gauge Dipstick for Heat Transfer Oil Fig. 5.2 Heat Transfer Oil Dipstick ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-2...

  • Page 25: Machine Start Up For Electric Hose

    ‘HEATED HOSE” will illuminate when the hose control is calling for heat. Adjust the temperature dial to the manufacturer’s recommended temperature. Note: The hose reaches operating temperature in approximately 30 minutes. ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-3...
  • Page 26 DO NOT remove the hose from the boom during operation or kinking will occur. Important: It is strongly recommended that the hose be stored in the boom (locked position) when not in use or when in transit. This will prevent twisting or kinking. ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-4...

  • Page 27: Altitude Compensation System

    THE DUCKBILL VALVE LOCKED UNLOCKED 50270 TRIGGER LOCK TIP GUARD IS HELD IN PLACE MAKE SURE TRIGGER LOCK IS WITH 2 BOLTS ENGAGED AT ALL TIMES EXCEPT WHEN APPLYING MATERIAL! 50278 ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-5...

  • Page 28: Electric Hose Care And Cautions

    Note: Do not twist or bend the hose over sharp edges such as the edge of the frame or tank. Crafco, Inc. recommends you do not work directly under the boom; this may cause damage to the hose. Follow all machine instructions in this manual.

  • Page 29: Machine Start Up For Standard Hose

    The oven must be at 300°F for 20 minutes before attempting to pump. The oven temperature can be regulated by opening the slide gate to increase temperature or close slide gate to decrease temperature. Slide gate is located on passenger side. ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-7...

  • Page 30: Loading Material Into The Sealant Tank

    When sealant placement volume is low, or the crew has stopped working for lunch hot oil and material temperatures can equalize. To lower material temperature add a few blocks of cold sealant. This may not be an option if the tank is full. ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-8...

  • Page 31: Material Tank Depth Chart

    354.50 37.21 140.86 99.09 375.10 32.02 121.21 104.53 395.69 26.84 101.60 109.97 416.28 21.65 81.95 115.41 436.87 16.47 62.35 120.85 457.47 11.28 42.70 126.29 478.06 6.09 23.05 25.19 132.71 502.36 0.00 ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-9...

  • Page 32: Dispensing The Material

    To get the oven hot enough to start pumping again, add several blocks of sealant to lower the material temperature enough to cause burner to ignite. This may not be an option if the tank is already full. ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-10...

  • Page 33: Shutting Down And Cleaning Out The Machine

    5.10 Shutting Down and Cleaning Out the Machine 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 allows enough material to start dispensing right away when the material becomes molten.

  • Page 34: Table 5-10 Shutting Down With An Electric Hose

    Stop the engine by pressing the “OFF” button once. This will throttle down the engine and shut it “OFF” NOTE: Ensure the hose is not touching the tank wall or plumbing. ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-12...

  • Page 35: Storing The Machine

    Failure to follow this procedure will cause the material to overflow the tank resulting in possible machine damage and/or personal injury. Store the machine for longer periods with the material tank empty. ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-13...

  • Page 36: Overnight Heaters

    Disconnect the heaters when using the machine’s burner system. CAUTION Do not use the heaters without heat transfer oil in the tank. Doing so will overheat and damage the heaters, and they will have to be replaced. ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-14...

  • Page 37: Mounting A Skid Machine

    The center of gravity of the loaded machine should be above or in front of the rear main axle. Contact Crafco for help in determining the location of the center of gravity of your machine before mounting.

  • Page 39: Maintenance Instructions

    DO NOT over tighten the packing. The gland nuts should then be backed off until finger tight. Follow adjusting pump packing at the beginning of this section. ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-1...

  • Page 40: Lug Nuts

    Check the control knob calibration weekly. Calibrate by turning the knob counterclockwise. If the marks do not align, loosen screw in knob and align the line on the control knob with the calibration mark on the scale plate. (See Fig. 6.2) ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-2...

  • Page 41: Replacing Heat Transfer Oil

    3. Start burner and heat the heat transfer oil until one drop of oil comes out of ball valve. 4. Close ball valve immediately. (CAUTION: HOT OIL WILL CAUSE SEVERE BURNS) NOTE: THIS PROCEDURE IS NOT REQUIRED FOR DAILY OPERATION. ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-3...

  • Page 42: Maintenance Chart

    Once a year or as needed the material tank Scrape out built up material Material Sensor Guard around guard For a list of parts required for maintenance see Table 6-3 General Maintenance Parts. ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-4...

  • Page 43: Service Instructions

    Note: Refer to the material manufacturer’s instructions for recommendations. Follow the recommended maintenance per Table 6-1 Maintenance Chart For service, find a list of authorized Distributors and service centers at Crafco.com/Distributors. 6.14 General Maintenance Parts Table 6-3 General Maintenance Parts...

  • Page 44: Recommended Spare Parts

    Shell AW Hydraulic 46 24 Gals. All Models Heat Transfer Oil Shell Turbo T 68 (Group II) 21.5 Gals. All Models Legend: PN 46100EB EZ500 Electric Base PN 4610SB EZ500 Standard Base ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-6...

  • Page 45: Typical Heat Transfer Oil Specifications

    Shell Turbo T 68 (Group II) CAUTION The heat transfer oil in this machine is a grade that has been tested and recommended by Crafco, Inc. Using a grade of oil not specifically recommended by Crafco, Inc., is cause for warranties to be voided.

  • Page 46: Material Pump Replacement

    Install hydraulic motor on material pump using (4) 3/8-16 x 1 1/4” bolts and lock washers. Tighten setscrew on pump/motor coupling. Tighten all bolts and nuts. Replace heat compartment using (12) 1/4-20 x 3/4” bolts, flat washers, and lock washers. ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-8...

  • Page 47: Fig. 6.3 Material Pump Replacement

    EZ 500 Series II Melter Part Manual Chapter 6 Maintenance Instructions Step 5 Step 3 Step 6 Step 7 Step 4 Fig. 6.3 Material Pump Replacement ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-9...

  • Page 48: Cleaning Material Tank And Sensor Area

    6.20 Cleaning the Melter We recommend using Orange-Sol industrial cleaner for cleaning the exterior of the machine. The cleaner can be found at the following website; https://www.orange-sol.com/industrial-formula/. ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-...

  • Page 49: How To Use A Multimeter

    Touch one probe to each screw or wire of the sensor. The meter will read X.XX if in the 2K range or XXX.X if in the 2000 range. ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…How to Use a Multimeter 7-1...

  • Page 50: Checking Amperage

    Use these ports. Do not DC Voltage use the fuse port, it is for • Everything amps. except Generator AC Voltage ~ • Generator Output Fig. 7.1 Standard Multimeter ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…How to Use a Multimeter 7-2...

  • Page 51: Fig. 7.2 Clamp-On Amp Meter/Multimeter

    • Sensors • Hyd. Coils AC Amps ~ • Burner Ignition Coil • Hose Current Audible Continuity • Hose, Wand, and wire connection Fig. 7.2 Clamp-On Amp Meter/Multimeter ©2019 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…How to Use a Multimeter 7-3...

  • Page 53: Burner Troubleshooting

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting 8.0 Burner Troubleshooting 8.0.1. Symptoms: Burner will Not Ignite Table 8-1 Basic Visual Burner Troubleshooting Step Possible Cause If . . . • Yes, go to Step 2. Is the engine running?

  • Page 54: Table 8-2 Basic Visual Burner Troubleshooting (Continued)

    Is your burner working properly, but it Table 8-13 Sealant is Heating seems to take a while to reach operating Slowly. temperature? • No, Call Crafco, Inc. and speak to a customer service technician. Note: Fig. 8.1 Diesel Burner Schematic while troubleshooting the burner electrical system.

  • Page 55: Table 8-4 Burner Electrical Troubleshooting (Continued)

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting Table 8-4 Burner Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, then there should be 12Vdc on the Is there 12Vdc between the positive and negative battery post? If this check is done battery side of the circuit breaker.

  • Page 56: Table 8-5 Burner Electrical Troubleshooting (Continued)

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting Table 8-5 Burner Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, replace PAKSTAT. Is there 12Vdc between terminal #3 orange wire and terminal #8 black wire of the •...

  • Page 57: Table 8-6 Burner Electrical Troubleshooting (Continued)

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting Table 8-6 Burner Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, replace circuit breaker. Is there 12Vdc between bottom terminal of • No, go to Step 13.

  • Page 58: Fig. 8.1 Diesel Burner Schematic

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting GRY-1 GRY-3 PNK-3 PNK-2 WHT/GRN-1 WHT/GRN-4 WHT/GRN-5 WHT/GRN-2 ORN-2 ORN-1 BLK-5 BLK-1 BLK GND BLK-4 WHT/GRN-1 HOSE MAT'L GRY-2 GRN BRNR WHT/GRN-2 HOT OIL 43391 GRY-2 BLK-5 RED-3 WHT/BLK WHT/BLK...

  • Page 59: Table 8-7 Smoke Coming Out Of Exhaust Stack

    If it has been longer than 500 hours since the last time the burner nozzle was replaced, Crafco recommends replacing the burner nozzle at this time. Reassemble the burner, using the reverse order in Step 3.

  • Page 60: Table 8-9 Testing The Dc Controller

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting 8.0.4. Testing the DC Controller Table 8-9 Testing the DC Controller Step Bench Test DC Controller Remove all wire nuts attaching the DC Controller to the burner. Attach the black ground wire to the negative battery post.

  • Page 61: Table 8-11 Burner Ignition Coil Testing

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting 8.0.6. Burner Ignition Coil Testing Table 8-11 Burner Ignition Coil Testing Step Ignition Coil Test Make sure the burner is off. Open the ignition transformer (located above the blower) to expose the springs.

  • Page 62: Fig. 8.2 Diesel Burner Electrode Adjustment

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting 5/32 ELECTRODE R 1/4 NOZZLE 5/32 Fig. 8.2 Diesel Burner Electrode Adjustment Air Shutter = 7 Air Band = 0 Fuel Pressure = 140 PSI Adjustment Plate = 3 IGNITION COIL LOCKING TAB...

  • Page 63: Sealant Heating Slowly

    Check your records of the last service replacement of the heat transfer oil. If it has been longer than 500 hours, or one year, you need to change your oil. Many of Crafco, Inc. service centers can perform these service steps for you if you cannot. Call your local service center to find out if they can.

  • Page 64: Mixer Troubleshooting

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting 8.2 Mixer Troubleshooting 8.2.1 Symptom: Mixer Does Not Rotate Table 8-14 Basic Visual Mixer Troubleshooting Step Possible Cause If . . . • Yes, go to Step 2. Is the Material Temperature Display at or above 275°F?

  • Page 65: Table 8-15 Mixer Electrical Troubleshooting

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting Note: Fig. 8.5 Mixer Circuit while troubleshooting the mixer electrical system. Table 8-15 Mixer Electrical Troubleshooting Step Possible Cause If . . . • Yes, then the mixer should be working. If it Is the amber light "ON"...

  • Page 66: Table 8-16 Mixer Electrical Troubleshooting (Continued)

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting Table 8-16 Mixer Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, on both red wires check for loose Is there 12Vdc between the D.S. lid switch red wires and a nearby ground source? connections or broken wires between D.S.

  • Page 67: Table 8-17 Mixer Electrical Troubleshooting (Continued)

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting Table 8-17 Mixer Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, check for loose connections or broken Is there 12Vdc between top terminal of the power switch and a nearby ground (black...

  • Page 68: Fig. 8.4 Checking Din Plug Voltage

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting Fig. 8.4 Checking Din Plug Voltage ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-16...

  • Page 69: Fig. 8.5 Mixer Circuit

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting PNK-3 PNK-2 RED LID D.S. ORN-2 ORN-1 BLK-1 BLK-5 BLK GND BLK-4 HOSE MAT'L HOT OIL 43391 MOUNT SWITCH NOTCH DOWN RED-3 BRN-4 WHT/BLK RED-8 PNK-3 WHT/BLK HOSE BLK-5 MATERIAL...

  • Page 70: Mixer Hydraulic Troubleshooting

    Next turn "OFF" the Isuzu engine, remove the cap and pressure gauge, then re-attach the hose. • Yes, call Crafco, Inc. and speak to a Is the hydraulic flow 1.5 GPM from the hydraulic valve? If you do not have a flow...

  • Page 71: Fig. 8.6 Hydraulic Valve Pressure Setting

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting RVA - Agitator Pressure Relief Allen Screw Set @ 1500 PSI Jam Nut RVP - Pump Pressure Relief Set @ 1000 PSI RVHO - Hot Oil Pump Pressure Relief Set @ 800 PSI Agitation Direction = Counterclockwise Hydraulic Flow EB/SB= 10.8 GPM @ 2400 RPM...

  • Page 72: Fig. 8.7 Din Plug Layout

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting Mixer Reverse Mixer Forward Pump Forward Pump Reverse Mounting Tube Mounting Plate Fig. 8.7 Din Plug Layout ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-20...

  • Page 73: Hose Troubleshooting

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting 8.3 Hose Troubleshooting 8.3.1 Symptom: Hose Does Not Heat Table 8-19 Basic Visual Troubleshooting Step Possible Cause If . . . • Yes, go to Step 2. Is the Material Temperature Display at or above 275°F?

  • Page 74: Table 8-21 Electrical Troubleshooting (Continued)

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting Table 8-21 Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, go to Step 3a. Check for continuity in the hose from end to end. Disconnect the three heating element •...

  • Page 75: Fig. 8.8 Junction Box Voltage Testing

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting Table 8-22 Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, check for loose or broken wires Is there 12Vdc between the Hose Selector switch pink wire labeled “PNK-4 (bottom left between switch and upper terminal block.

  • Page 76: Fig. 8.9 Hose Circuit Schematic

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting PNK-3 PNK-2 ORN-2 ORN-1 BLK-1 BLK-5 BLK GND BLK-4 PNK-4 PNK-1 BLU-1&BLU-GEN BLU-2 HOSE MAT'L HOT OIL 43391 BLU-2 MOUNT SWITCH NOTCH DOWN BLK-5 RED-3 WHT-2 BLK-10 WHT/BLK WHT/BLK HOSE...

  • Page 77: Fig. 8.10 Junction Box Wiring

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting TRIGGER RED TRIGGER RED SENSOR BLACK SENSOR WHITE HEATER BLUE HEATER BLUE HEATER BLUE TRIGGER RED TRIGGER GREEN SENSOR BLACK SENSOR WHITE HEATER GREEN HEATER WHITE HEATER BLACK KETTLE END WAND END Fig.

  • Page 78: Symptom: Trigger Is Not Working

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting 8.3.2 Symptom: Trigger is not Working Table 8-23 Trigger is not Working Step Possible Cause If . . . • Yes, go to Check continuity between two red wires Table 8-26 Basic Visual Pump coming from the hose in junction box.

  • Page 79: Rtd Sensor Ohms Vs. Temperature

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting 8.3.3 RTD Sensor Ohms vs. Temperature Table 8-23 below shows what the ohm reading would be for a given temperature. The following are the instructions for using the table. Measure the resistance (ohms) of the sensor in question with an ohm meter (See 7.3 Checking...

  • Page 80: Table 8-25 Rtd Sensor Ohms Vs. Temperature (Continued)

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting Table 8-25 RTD Sensor Ohms vs. Temperature (continued) °F 1506.6 1508.7 1510.8 1512.8 1514.9 1517.0 1519.1 1521.2 1523.3 1525.3 1527.4 1529.5 1531.6 1533.7 1535.7 1537.8 1539.9 1542.0 1544.1 1546.1 1548.2 1550.3...

  • Page 81: Pump Troubleshooting

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting 8.4 Pump Troubleshooting 8.4.1 Symptom: Material Does Not Dispense When the Pump is Activated Table 8-26 Basic Visual Pump Troubleshooting Step Possible Cause If . . . • Yes, go to Step 2.

  • Page 82: Pump Hydraulic Troubleshooting

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting NOTE: Fig. 8.11 Pump Circuit Schematic while troubleshooting the pump electrical system. Table 8-27 Pump Electrical Troubleshooting Step Possible Cause If . . . • Yes, then the pump should be working. If it Is the amber light “ON”...

  • Page 83: Table 8-28 Pump Electrical Troubleshooting (Continued)

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting Table 8-28 Pump Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, check for loose or broken wire Is there 12Vdc between the blue wire on terminal #12 of pump relay and the black...

  • Page 84: Table 8-29 Pump Electrical Troubleshooting (Continued)

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting Table 8-29 Pump Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, replace terminal block. Is there 12Vdc between pink wire labeled PNK-2 upper terminal block and nearby •...

  • Page 85: Fig. 8.11 Pump Circuit Schematic

    EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting Table 8-30 Pump Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, check for loose or broken wire Is there 12Vdc between pink wire labeled “PNK-3 on the upper terminal block and a...

  • Page 86: Table 8-31 Pump Hydraulic Troubleshooting

    Next turn “OFF” the Isuzu engine, remove the cap, pressure gauge and reattach the hose. Is the hydraulic flow correct from the • Yes, call Crafco, Inc. and speak to a service hydraulic pump? technician. You should have been able to (Refer to Table 8-31 Pump Hydraulic find the problem.

  • Page 87: About The Illustrated Parts List

    9.1 Ordering Crafco Parts Crafco distributors and Crafco Pavement Preservation Supply Centers are strategically located throughout the United States. Parts can be ordered from your local Crafco distributor or directly from Crafco, Inc. if a distributor is not available in your area.

  • Page 88: Ez500 Series Ii Melter

    EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 9.2 EZ500 Series II Melter 7 7a 7b 7c 14 16 Fig. 9.1 EZ500 Series II Melter ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-2...
  • Page 89 MATERIAL PUMP ASSEMBLY 45553 BEARING, BOOM 45420 HYDRAULIC CONTROL VALVE ASSEMBLY 44027 JUNCTION BOX ASSEMBLY 25057 GAUGE, HOSE COMPARTMENT 43465 SENSOR, RTD 56940 SENSOR, RTD – PUMPING TEMPERATURE 46580 DRIP PAN ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-3...

  • Page 90: Fig. 9.2 Ez500 Series Ii Melter

    EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 28 29 Fig. 9.2 EZ500 Series II Melter ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-4...
  • Page 91 23082 JACK ASSEMBLY, 7000# 52400 ELECTRIC HEATED HOSE ASSEMBLY, 15’ OPT. 27009 HOSE, 20’ SEALANT (NOT SHOWN) OPT. 46263 BOOM LOCK ASSEMBLY 45762 HYDRAULIC OIL COOLER 45542 TEMPERATURE SWITCH, COOLER ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-5...

  • Page 92: Series Ii Melter Options

    EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 9.3 Series II Melter Options Fig. 9.3 EZ500 Series II Melter Options ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-6...
  • Page 93 ††This item is recommended for standard hose connection in the heat compartment. †††Only one of these can be installed on the machine. Select the hitch extension length based on your tow vehicle requirements. ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-7...
  • Page 94 EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List This page left blank intentionally ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-8...

  • Page 95: Tank Detail

    MOTOR, HYDRAULIC – AGITATOR 46050 SHAFT ASSEMBLY – AGITATOR 46380 BURNER, 14 VOLT DIESEL 46058 BURNER BOX ASSEMBLY 43179 BURNER BOX INSULATION KIT 40029 MOUNTING PLATE – MOTOR 40030 SPACER. MOTOR ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-9...

  • Page 96: Plumbing

    EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 9.5 Plumbing Fig. 9.5 Plumbing ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-10...
  • Page 97 46509 EXTENSION, VALVE HANDLE 46065 FLEXHOSE ASSEMBLY, 2 1/2” X 8 1/4” LG. 29292 VALVE, 3” FLANGED GATE 46754 ELBOW, RECIRC LINE 46085 TEE, LOWER SUCTION 28273 CAP, 2” PIPE ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-11...

  • Page 98: Control Box Assembly - Electric Hose

    COVER WITH 1.5" OF 51532 YLW-1 BLK/RED-1 BLK-6 RED-5 BRN-3 RED/BLK-3 BLK/RED WHT-3 BLK-11 WHT-4 BLK-12 BLK-2 BRN-1 PNK-4 PNK-3 MOUNT SWITCH NOTCH DOWN Fig. 9.6 Control Box Assembly: 46100SB ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-12...
  • Page 99 CABLE ASSEMBLY, POWER 51836 CABLE ASSEMBLY, TRIGGER/SENSOR 51684 RIBBON CABLE, 36” (NOT SHOWN) 51670 SPACER, TEMPERATURE CONTRLLER 43984 CABLE ASSEMBLY, VALVE 51805 END BRACKET 44979 RELAY, STARTER 44980 TIMER RELAY ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-13...

  • Page 100: Fig. 9.7 Control Box Assembly: 46100Eb

    Chapter 9 Illustrated Parts List CUT BACK 1.5" & SOLDER DIODE WITH SILVER MARK TOWARDS TERMINAL BLOCK COVER WITH 1.5" OF 51532 MOUNT SWITCH NOTCH DOWN Fig. 9.7 Control Box Assembly: 46100EB ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-14...
  • Page 101 44975 GAUGE, WATER TEMPERATURE (Not Shown) OPT. 44976 GAUGE, OIL PRESSURE (Not Shown) OPT. 44977 GAUGE, VOLT METER (Not Shown) OPT. 44987 RESISTANCE CONTROL 44989 LIGHT, AMBER 44988 LIGHT, RED ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-15...

  • Page 102: Control Box Assembly - Standard Hose

    EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 9.7 Control Box Assembly – Standard Hose Fig. 9.8 Control Box Assembly: 46100SB ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-16...
  • Page 103 CABLE ASSEMBLY, TRIGGER/SENSOR 51684 RIBBON CABLE, 36” (NOT SHOWN) 51670 SPACER, TEMPERATURE CONTROLLER 44994 TERMINAL BLOCK 5-POLE 51805 END BRACKET 44979 RELAY, STARTER 44980 TIMER 51673 RELAY (NOT SHOWN) 24076 HOUR METER ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-17...

  • Page 104: Fig. 9.9 Control Box Assembly - 46100Sb

    EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List Fig. 9.9 Control Box Assembly – 46100SB ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-18...
  • Page 105 RIBBON CABLE, 5” 44976 GAUGE, OIL PRESSURE OPT. 44977 GAUGE, VOLT METER OPT. 43984 CABLE ASSEMBLY, VALVE 44987 RESISTANCE CONTROL 44989 LIGHT, AMBER 44988 LIGHT, RED 51678 SWITCH, DPDT 32522 SWITCH, PUMP ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-19...

  • Page 106: Engine Assembly

    EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 9.8 Engine Assembly Fig. 9.10 Engine Assembly – 46100EB/SB ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-20...
  • Page 107 BELT, DRIVE – GEN. (46100EB ONLY) 41867 FUEL FILTER 45389 OIL FILTER 29399 ISOMOUNTS 45439 HYDRAULIC PUMP 45391 AIR FILTER ELEMENT 47155N RADIATOR OVERFLOW BOTTLE KIT(NOT SHOWN) 47150 WATER SEPARATOR (NOT SHOWN) ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-21...

  • Page 108: Hydraulic Control Valve Assembly

    TEE, MALE #8 ORB X #8 JIC RUN 45413 CAP, DUST 45414 FITTING, TEST POINT 45416 FLOW CONTROL, PRIORITY FITTING, #6 ORB X #6 JIC LONG STRAIGHT FITTING, #6 ORB X #8 JIC STRAIGHT ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-22...

  • Page 109: Material Flow Control Assembly

    Fig. 9-12 Material Flow Control Assembly FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-12 29896 3/8” TUBE X 1/2” O-RING ELBOW 46077 KNOB ONLY 46060 HYDRAULIC FLOW CONTROL (NO FITTINGS) ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-23...

  • Page 110: Compressor Hydraulic Valve Assembly

    COIL, SOLENOID VALVE 45424 VALVE, SOLENOID FITTING, #12 ORB X #10 JIC STRAIGHT 45436 FLOW CONTROL, PRESSURE COMP. 45414 FITTING, TEST POINT 45413 CAP, DUST TEE, #12 ORB X #12 JIC RUN ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-24...
  • Page 111 EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List This page left blank intentionally ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-25...

  • Page 112: Diesel Burner Assembly

    EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 9.12 Diesel Burner Assembly BACK VIEW SIDE VIEW Fig. 9.14 Diesel Burner ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-26...
  • Page 113 NOZZLE, 1.5X80B 41953N STD HEAD, F22 BURNER 41964N GASKET, AIR TUBE TO HOUSING 46381N AIR TUBE W/ HEAD & ELECTRODE MOUNT 41993 ELECTRODE ASSY (COMES WITH 2) 41966N AIR GUIDE, BURNER ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-27...
  • Page 114 EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List This page left blank intentionally ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-28...

  • Page 115: Material Pump Assembly

    MOTOR, HYDRAULIC 42071 PUMP ASSEMBLY, NON-JACKETED 29990S PACKING RING (SET OF 7) 43129 MOUNTING PLATE ASSEMBLY 22029 FITTING, #10 ORB X #6 JIC STRAIGHT 42073N PUMP REBUILD KIT (SEE NOTE) ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-29...

  • Page 116: Wand Assembly

    EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 9.14 Wand Assembly Fig. 9.16 Wand Assembly ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-30...
  • Page 117 HANDLE, WAND – RIGHT (W/INSERTS) GEN2 52201LN HANDLE, WAND – LEFT (NOT SHOWN) GEN2 52208 SWITCH, WAND 52202N ACTUATOR, TRIGGER, GEN2 52207 SPRING, ACTUATOR 52209 PIN, ACTUATOR 52203N LOCK, TRIGGER, GEN2 51656 TERMINAL STRIP ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-31...

  • Page 118: Hydraulic Diagram

    EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 9.15 Hydraulic Diagram Fig. 9.17 Hydraulic Diagram 46100EB, 46100SB ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-32...
  • Page 119 HYDRAULIC VALVE “PA” TO FLOW CONTROL #1 PORT 40308 FITTING, #6 ORB X #6 JIC LONG 6M3K 6G-6FJX90S 6G-8FJX 17 HYDRAULIC HOSE 29896 FITTING, #8 ORB X #8 JIC 90° ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-33...

  • Page 120: Fig. 9.18 Hydraulic Diagram 46100Eb, 46100Sb

    EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List Fig. 9.18 Hydraulic Diagram 46100EB, 46100SB ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-34...
  • Page 121 FITTING, #16 ORB X #16 JIC STR. HYDRAULIC OIL COOLER TO HYDRAULIC TANK 29824 FITTING, #16 ORB X #16 JIC 90° 16G4H 16G-16FJX 16G-16FJX 32 HYDRAULIC HOSE 29818 FITTING, #20 ORB X #16 JIC STR. ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-35...

  • Page 122: Diesel Fuel Line Schematic

    EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 9.16 Diesel Fuel Line Schematic Fig. 9.19 Diesel Fuel Line Schematic ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-36...
  • Page 123 3. ENGINE RETURN LINE TO DIESEL FUEL TANK 29591 HOSE, 5/16 FUEL LINE 26767 FITTING, #5 HOSE PUSH-ON 26782 FITTING, 1/4 MPT X 5/16 JIC ELBOW 26080 CLAMP, #4 GEAR ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-37...

  • Page 124: Electrical Schematic - Electric Hose

    SENSOR WHITE HEATER BLUE HEATER BLUE HEATER BLUE TRIGGER RED TRIGGER GRN SENSOR BLACK SENSOR WHITE HEATER GREEN HEATER WHITE HEATER BLACK JUNCTION BOX WIRING Fig. 9.20 Electrical Schematic 46100EB ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-38...
  • Page 125 SENSOR, RTD – PUMPING TEMPERATURE 43947 CABLE ASSEMBLY, HOSE 45569 WIRING HARNESS, COOLER 45542 SWITCH, TEMPERATURE – OIL COOLER 45349 SWITCH, TEMPERATURE – COMPRESSOR 43886 CABLE ASSEMBLY, COMPRESSOR VALVE 39602 SOLENOID, FRAME ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-39...

  • Page 126: Electrical Schematic - Standard Hose

    WHITE WIRE TO TEMPERATURE SWITCH TO ENG. OIL PRESS SWITCH 24000 BATTERY SENSOR WHITE WHITE BURNER PLUG PUMPING TEMP SENSOR BLK SENSOR 45762 HYDRAULIC OIL COOLER Fig. 9.21 Electrical Schematic 46100SB ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-40...
  • Page 127 CABLE ASSEMBLY, VALVE 56940 SENSOR, RTD – PUMPING TEMPERATURE 45569 WIRING HARNESS, COOLER 45542 SWITCH, TEMPERATURE – OIL COOLER 45349 SWITCH, TEMPERATURE – COMPRESSOR 43886 CABLE ASSEMBLY, COMPRESSOR VALVE 39602 SOLENOID, FRAME ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-41...

  • Page 128: Hot Air Lance

    EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 9.19 Hot Air Lance Fig. 9.22 Hot Air Lance (Option) ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-42...
  • Page 129 BUSHING, 3/8” NPT X 1/4” NPT REDUCER 45659 VALVE, NEEDLE 45675 HOSE ASSEMBLY, PROPANE 45679 COUPLING, 1/4” FPT X M 45681 COUPLING, 1/4” NPT X FM 45664 FITTING, 1/4” NPT X 3/8 JIC FERRULE LOCK ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-43...

  • Page 131: Tools And Accessories

    Crafco Round Sealing Tip 27170 – 3/8” Sealing Tip 27171 – 1/2” Sealing Tip Crafco Sealing Foot/Flush 27154 – 1/4” Flush 27155 – 3/8” Flush Crafco Cold Air Lance - 42648 ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..………………..Tools and Accessories 10-1...
  • Page 132 Use with 50270 Duckbill 27114 – Tip Adapter 27115 – Shroud, Tip Adapter Crafco Hand Held Pour Pot - 40201 Crafco Duckbill - 50270 Crafco High Velocity Heat Lance - 45650 ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..………………..Tools and Accessories 10-2...
  • Page 133 Chapter 10 Tools and Accessories Crafco Low Velocity Heat Lance - 32259 Crafco Hand Torch W/ 20ft. Hose – 25012 W/ 12ft. Hose – 25016 W/ 50ft. Hose – 25021 ©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..………………..Tools and Accessories 10-3...
  • Page 136 ©2019 Crafco, Inc.

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