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Table of Contents
Troubleshooting
Related Manuals for SealMaster CRACK PRO 60
Summary of Contents for SealMaster CRACK PRO 60
- Page 2 CRACK PRO GRAVITY FLOW Owner’s Manual Version 2.0 Issue Date: June 2019 Effective Date: April 2019 Version Date Changes Approval Original Issue 6/19 New Format and Updates S:\Engineering\13-Operator Manuals\Current\CRACKPRO_GRAVITY_V2.0_JUNE2019.docx...
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Page 3: Table Of Contents
Table of Contents CORRESPONDENCE ....................3 SealMaster® LIMITED WARRANTY ................ 4 SAFETY PRECAUTIONS AND CAUTIONS ..............5 PRECAUTIONS ..................... 5 CAUTIONS ......................5 FIRST AID ......................6 MANUAL COVERAGE ..................... 7 CRACK PRO® GRAVITY FLOW ................7 CRACK PRO® DIRECT FIRE MELTER ..............7 OPERATING INSTRUCTIONS - DIESEL FUEL BURNER .......... - Page 4 MACHINE MAINTENANCE ................... 21 MAINTENANCE SCHEDULE .................21 TROUBLESHOOTING DIESEL FUEL BURNER ............22 TROUBLESHOOTING LP GAS BURNER ..............23 HYDRAULIC OIL SHEET ..................24 SAFETY DATA SHEET .................... 26 WIRING DIAGRAMS ..................... 32 TEMPERATURE CONTROL BOX ................32 WIRING DIAGRAMS ..................... 33 ELECTRIC BRAKES AND RUNNING LIGHTS ............33 MACHINE PICTURES AND PARTS LIST ..............
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Page 6: Sealmaster® Limited Warranty
(30) days from the date failure occurs, and in all cases prior to the expiration of the warranty period of one (1) year. It is the intent of this paragraph to limit SealMaster’s liability solely to the cost of replacement parts, F.O.B. factory, or at the option of SealMaster to repair of the defective part or parts. -
Page 7: Safety Precautions And Cautions
SAFETY PRECAUTIONS AND CAUTIONS PRECAUTIONS • Always wear eye and ear protection, long sleeve shirt, face shield and gloves. • Be aware of all CAUTION, WARNING, DANGER signs on the unit. • Read all Owners Manuals that come with this unit. •... -
Page 8: First Aid
SAFETY PRECAUTIONS AND CAUTIONS FIRST AID... -
Page 9: Manual Coverage
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNER & LP GAS BURNER MANUAL COVERAGE CRACK PRO® GRAVITY FLOW This manual covers the oil jacketed CRACK PRO® model sizes 60,125 and 260 gals. CRACK PRO® DIRECT FIRE MELTER This manual also covers the non-oil jacketed CRACK PRO®... -
Page 10: Operating Instructions - Diesel Fuel Burner
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNERS OPERATING INSTRUCTIONS - DIESEL FUEL BURNER STARTUP CHECKLIST • Check engine oil level. Follow manufacturers guidelines as to type and frequency of changes. • Check hydraulic oil level. Use grade AW68 hydraulic oil. •... -
Page 11: Starting The Engine
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNERS OPERATING INSTRUCTIONS - DIESEL FUEL BURNER STARTUP ENGINE SWITCH THROTTLE CHOKE FUEL STARTING THE ENGINE • Set the fuel shutoff and choke levers to the position. •... -
Page 12: Starting Temperature Control
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNERS OPERATING INSTRUCTIONS - DIESEL FUEL BURNER STARTUP TOP SCALE ARROW SETTINGS BOTTOM SCALE STARTING TEMPERATURE CONTROL • The top scale is the ambient temperature of the heat transfer oil or material temperature for SM-125. - Page 13 CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNERS OPERATING INSTRUCTIONS - DIESEL FUEL BURNER MATERIAL OIL DIP STICK THERMOMETER THERMOMETER ENGINE MATERIAL DISCHARGE VALVE AGITATOR CONTROL VALVE...
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Page 14: Adding Material
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNERS OPERATING INSTRUCTIONS - DIESEL FUEL BURNER ADDING MATERIAL 1. Open the material tank lid and place three boxes of material inside. Close the lid. MATERIAL TEMPERATURE 2. -
Page 15: Pouring Material
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNERS OPERATING INSTRUCTIONS - DIESEL FUEL BURNER POURING MATERIAL 6. Set pour pot or applicator under the material discharge valve #30 and raise the handle to open. CAUTION: ALWAYS WEAR LONG SLEEVE SHIRT, GLOVES, AND A FACE SHIELD WHEN PERFORMING THIS OPERATION! 7. -
Page 16: Operating Instructions - Lp Gas Burner
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL LP GAS BURNERS OPERATING INSTRUCTIONS - LP GAS BURNER STARTUP CHECKLIST • Check engine oil level. Follow manufacturers guidelines as to type and frequency of changes. • Check hydraulic oil level. Use grade AW68 hydraulic oil. •... -
Page 17: Starting The Engine
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL LP GAS BURNERS OPERATING INSTRUCTIONS - LP GAS BURNER STARTUP THROTTLE ENGINE PULL START HANDLE CHOKE ON/OFF FUEL SWITCH STARTING THE ENGINE • Set the fuel shutoff and choke levers to the position. -
Page 18: Operating Instructions - Lp Gas Burner
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL LP GAS BURNERS OPERATING INSTRUCTIONS - LP GAS BURNER MATERIAL OIL DIP STICK MATERIAL THERMOMETER THERMOMETER DISCHARGE VALVE ENGINE MATERIAL AGITATOR DISCHARGE VALVE CONTROL VALVE... -
Page 19: Lp Gas Burner Pictures
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL LP GAS BURNER LP GAS BURNER PICTURES HAND TORCH REGULATOR LP GAS HOSE 1/2” TEMPERATURE CONTROL LP GAS HOSE 1/4” GAS VALVE MAIN BURNER REGULATOR TEMPERATURE CONTROL BOX BURNER ACCESS DOOR GAS BURNERS PILOT LIGHT LP GAS HOSE 1/2”... -
Page 20: Startup
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL LP GAS BURNERS OPERATING INSTRUCTIONS - LP GAS BURNER STARTUP 1. Open the temperature control box #7, and turn the temperature control knob #8 all the way clockwise to its lowest setting. This will prevent the burners from lighting prematurely. - Page 21 CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL LP GAS BURNERS OPERATING INSTRUCTIONS - LP GAS BURNER TEMPERATURE PICTURES CONTROL AGITATOR CONTROL VALVE MATERIAL DISCHARGE VALVE ENGINE...
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Page 22: Pouring Material
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL LP GAS BURNERS OPERATING INSTRUCTIONS - LP GAS BURNER 8. As the material temperature gets close to the recommended pouring temperature, you need to turn the temperature control #8 down. When constantly adding blocks of material, the temperature control should be set about 50°... -
Page 23: Machine Maintenance
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNER & LP GAS BURNER MACHINE MAINTENANCE MAINTENANCE SCHEDULE Follow maintenance procedures listed on the engine burner manuals. MAINTAIN WEEK MONTH MONTHS YEAR YEARS CHECK ENGINE OIL LEVELS CHECK HYDRAULIC OIL LEVELS... -
Page 24: Troubleshooting Diesel Fuel Burner
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNER TROUBLESHOOTING DIESEL FUEL BURNER PROBLEM POSSIBLE CAUSES/SOLUTIONS SHUTOFF VALVE IS CLOSED / OPEN VALVE HYDRAULIC OIL LOW / FILL OIL LEVEL 4” FROM TOP OF TANK AGITATOR SPLINED COUPLER WORN / REPLACE COUPLER DOES NOT ROTATE... -
Page 25: Troubleshooting Lp Gas Burner
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL LP GAS BURNERS MACHINE MAINTENANCE TROUBLESHOOTING LP GAS BURNER POSSIBLE CAUSES/SOLUTIONS PROBLEM SHUTOFF VALVE IS CLOSED / OPEN VALVE HYDRAULIC OIL LOW / FILL OIL LEVEL 4” FROM TOP OF TANK AGITATOR SPLINED COUPLER WORN / REPLACE COUPLER DOES NOT ROTATE... -
Page 26: Hydraulic Oil Sheet
HYDRAULIC OIL SHEET HYDRAULIC OIL SHEET... -
Page 28: Safety Data Sheet
SAFETY DATA SHEET HYDRAULIC OIL SHEET... -
Page 34: Wiring Diagrams
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNER WIRING DIAGRAMS TEMPERATURE CONTROL BOX TERMINALS: U – YELLOW 14 GA. TO BURNER G – BLACK 12 GA. TO BURNER P1 – RED 10 GA. TO MOTOR B –... -
Page 35: Wiring Diagrams
WIRING DIAGRAMS ELECTRIC BRAKES AND RUNNING LIGHTS BLUE WHITE BLUE / BLACK WHITE BLUE BLUE BLUE GREEN / BROWN BROWN GREEN / BROWN YELLOW / BROWN BROWN WHITE BROWN YELLOW / BROWN BROWN... -
Page 36: Machine Pictures And Parts List
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNER & LP GAS BURNER MACHINE PICTURES AND PARTS LIST BLADE SUPPORT SHAFT PIVOT PIN & LOWER AGITATOR BUSHING AGITATOR SHAFT BLADES SPLINE COUPLER & SHAFT COLLAR AGITATOR CONTROL VALVE PICTURE-1... -
Page 37: Parts List Picture-1
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNER & LP GAS BURNER PARTS LIST PARTS LIST PICTURE-1 ITEM # PART# QTY. DESCRIPTION P472A010 AGITATOR CONTROL VALVE P439A004 LOWER AGITATOR BUSHING P74000B015 SHAFT PIVOT PIN P514A015 TIRE AND WHEEL ASSEMBLY CP-60 / SM-125... - Page 38 CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNER & LP GAS BURNER PICTURE-2 OVERFLOW PIPE PROPANE TANK OIL DIP STICK NOT INCLUDED PROPANE TANK HOLDER LP GAS BURNER ONLY RATCHET TIE DOWN OR TANK LATCH LP GAS BURNER ONLY TRAILER JACK...
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Page 39: Parts List Picture-2
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNER & LP GAS BURNER PARTS LIST PARTS LIST PICTURE-2 * DENOTES YOUR CHOICE ITEM # PART# QTY. DESCRIPTION P75000B006 OIL OVERFLOW PIPE P75000B028 OIL DIPSTICK P75000B020 PROPANE BURNER ACCESS DOOR FOR CP-60... - Page 40 CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNER & LP GAS BURNER AGITATOR THERMOCOUPLE EXPANSION TANK DRIVE MOTOR PICTURE-3 MATERIAL TANK LID MATERIAL THERMOMETER TAILLIGHTS THERMOMETER FENDER MATERIAL DISCHARGE VALVE HYD. PUMP HYD. TANK ENGINE JAW COUPLERS &...
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Page 41: Parts List Picture-3
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNER & LP GAS BURNER PARTS LIST PICTURE-3 ITEM # PART# QTY. DESCRIPTION P659A004 OIL THERMOMETER CP-60 / CP-125 P659A017 OIL THERMOMETER CP-260 P659A009 MATERIAL THERMOMETER CP-60 / CP-125 P659A008 MATERIAL THERMOMETER CP-260... - Page 42 CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNERS PARTS LIST PICTURE - 4...
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Page 43: Parts List Picture-4
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL DIESEL FUEL BURNERS PARTS LIST PARTS LIST PICTURE-4 ITEM # PART# QTY. DESCRIPTION P662A009 COMPLETE BURNER SEE ITEM 24 P662A046 BLOWER WHEEL P662A016 COUPLING P662A022 AIR GUIDE P662A047 AIR BAND P662A049 AIR SHUTTER –... - Page 44 CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL LP GAS BURNER PICTURE - 5 HAND TORCH REGULATOR LP GAS HOSE 1/2” TEMPERATURE CONTROL LP GAS HOSE 1/4” GAS VALVE MAIN BURNER REGULATOR TEMPERATURE CONTROL BOX BURNER ACCESS DOOR GAS BURNERS LP GAS HOSE 1/2”...
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Page 45: Parts List Picture-5
CRACK PRO® GRAVITY FLOW AND DIRECT FIRE MELTER APPLIES TO ALL LP GAS BURNER PARTS LIST - LP GAS BURNER PILOT LIGHT ASSEMBLY GAS BURNERS THERMOPILE SENSOR PARTS LIST PICTURE-5 ITEM # PART# QTY. DESCRIPTION P75000B036 GAS CONTROL BOX ASSEMBLY P933A001 TANK CONNECTOR P669B007...
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