SealMaster CrackPro 125 Service Manual
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SealMaster CrackPro 125 Service Manual

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C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0
125/ 200/ 260/ 400
C R AC K PRO H EATED H O SE
S e r v i c e M a n u a l A u g u s t 2 0 1 9

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  • Page 1 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 125/ 200/ 260/ 400 C R AC K PRO H EATED H O SE S e r v i c e M a n u a l A u g u s t 2 0 1 9...

  • Page 2: Contact Information

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Contact Information HEADQUARTERS: 2520 South Campbell Street Sandusky, Ohio 44870 Phone: 1-800-326-1994 Fax: 419-626-5477 E-mail: info@thorworks.com...

  • Page 3: Parts Ordering

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Parts Ordering INFORMATION Please provide as much of the following if available: CONTACT INFORMATION: • Customer Name 2520 South Campbell Street •...
  • Page 4 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Parts Warranty Wear Items • Wear items are not covered ThorWorks warrants parts under ThorWorks limited purchased through ThorWorks warranty.

  • Page 5: Return Authorization

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Return Authorization • If a part fails to function within the first year of purchase, a RETURN AUTHORIZATION number must be obtained.

  • Page 6: Return Parts

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Return Parts • The same procedure should be followed if a customer has purchased a part but it is no longer needed.

  • Page 7: Technical Assistance

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Technical Assistance Contact Information: 2520 South Campbell Street Sandusky, Ohio 44870 Phone: 1-800-326-1994 Fax: 419-626-5477 E-mail: info@thorworks.com...

  • Page 8: Warranty Information

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Warranty Information • Limited Warranty • Product Registration • Authorized SealMaster Representative Only!

  • Page 9: Where To Find Product Information

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Where to find product information: • Owner’s Manual • Website: https://sealmaster.net/...
  • Page 10 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Questions?
  • Page 11 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 • A manual is furnished with each new CrackPro Heated Hose Machine. • The manual will help your machine operators learn to run the melter applicator properly and understand...
  • Page 12 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Operating Instructions – Diesel Fuel Burner DC Controller Located in Appendix...
  • Page 13 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Burner Parts Identification Blower Motor Blower Wheel Fuel Pump Pump Coupling Coil 12-Volt Ignition Coil Electrode Assembly Cad Cell DC Controller Part Number: P662A009...
  • Page 14 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Burner Parts – Blower Motor • DC motor. These are highly reliable and this type of motor has been in use for more than 25 years.
  • Page 15 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Burner Parts – Blower Wheel • Provide air needed for proper combustion. • The blower wheel is attached to the blower motor shaft.
  • Page 16 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Burner Parts – Fuel Pump • Pressurizes the fuel for proper combustion. • Always bleed the fuel pump if the unit has run out of fuel.
  • Page 17 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Burner Parts – Pump Coupling • Fuel Pump Coupling comes with both 5/16” and ½” ends. The coupling connects the blower motor to the fuel pump and is located inside the blower wheel.
  • Page 18 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Burner Parts – Colt 12-Volt • The solenoid is made of wire coiled around a spring-loaded piston. Without power, the piston is in the normally closed position (will not allow fuel to pass).
  • Page 19 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Burner Parts – Ignition Coil Beckett Power Light 12V • Wiring for new a style • Yellow wires not used (must be capped separately).
  • Page 20 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Burner Parts – Ignition Coil Beckett Power Light 12V • Transforms the systems voltage (12 volts) into the very high voltage needed to create an electrical spark.
  • Page 21 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Burner Parts – Electrode Assembly Nozzle, Line & Electrode Assembly...
  • Page 22 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Burner Parts – Cad Cell • Cadmium Sulfide Cell is used to sense the presence of a flame. •...
  • Page 23 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Burner Parts – DC Controller • “Brain” for the burner assembly. Allows for safe operation. • Works with the Cad Cell Flame sensor to control the burner motor, ignitor, and fuel solenoid valve.

  • Page 24: Repair And Maintenance

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Repair & Maintenance To perform the work listed on the following slides… • Need basic hand tools •...
  • Page 25 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Bleeder Diesel Fuel Burner The Burner Does not Run/Light Check the voltage at the battery, it needs to be at least 12.5 volts.

  • Page 26: Air Shutter Setting

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Air Shutter Setting • Loosen screw • Adjust shutter to appropriate setting by machine model • Tighten screw...
  • Page 27 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Air Band Setting • Loosen the screw on band • Adjust band to the appropriate setting by machine model •...

  • Page 28: Electrode Removal

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Electrode Removal • Loosen electrode nut on the left side of the housing • Remove igniter housing mounting screws •...
  • Page 29 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Electrode Troubleshooting • Replace the electrode if the ceramic insulator of the electrode is cracked or chipped •...

  • Page 30: Electrode Assembly

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Electrode Assembly Electrode Tip Setting • Carries the spark out to the nozzle. • Assembly contains the nozzle adaptor which houses the nozzle tip.
  • Page 31 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Replacing Pump Coupling • Remove bolts on motor flange with 3/8” wrench • Remove coupling (located inside of fan wheel) •...
  • Page 32 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Bench Test DC Controller 1. Attach cad cell wires to DC controller and cover Cad Cell (no light) 2.
  • Page 33 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Cad Cell (Flame Eye) • Clean Cad Cell with a cloth • Check for any defects on the face of Cad Cell •...
  • Page 34 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Fuel Solenoid Troubleshooting • Remove cord set • Check the ohms between terminals • If the ohm reading is between 15-25 ohms coil is good •...
  • Page 35 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Ignition Coil Troubleshooting • Make sure the burner is off • Make sure the power to the burner is off •...

  • Page 36: Burner Troubleshooting

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Burner Troubleshooting • FUEL NOT IGNITING • Check air shutter adjustment. Too much air may prevent the spark from reaching the fuel spray •...
  • Page 37 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Burner Troubleshooting • FLUCTUATING OR NO PUMP PRESSURE • Check motor rotational speed. Low RPM will cause erratic or no pump pressure •...
  • Page 38 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Burner Troubleshooting • Burner lights but goes out after 15 • Excessive Smoke from seconds… Burner Exhaust •...

  • Page 39: Temperature Controller

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Temperature Controller Digital PID Controller FY400-101000 Located in Appendix...

  • Page 40: Wiring Diagrams

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Wiring Diagrams Electric Brakes & Running Lights...
  • Page 41 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Wiring Diagrams Key Switch Installed on models prior to 2017...
  • Page 42 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 See Appendix for larger size print...
  • Page 43 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Installed on models after 2017 Lofa EL 240...
  • Page 44 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Wiring Diagrams Control Panel-Heated Hose Wiring Control Panel-Heated Hose Wiring (drawings Located in Appendix)
  • Page 45 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Wiring Diagrams Control Panel-Heated Hose Wiring Temperature Controller Digital PID Controller FY400-101000 Located in Appendix...
  • Page 46 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Hydraulics Part Number: P601A042...
  • Page 47 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Hydraulics...
  • Page 48 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Hydraulics...
  • Page 49 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0...

  • Page 50: Temperature Controller Settings

    C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Temperature Controller Settings (J...
  • Page 51 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0 Heated Hose Wiring...
  • Page 52 C R A C K P R O 1 2 5 / 2 0 0 / 2 6 0 / 4 0 0...

This manual is also suitable for:

Crackpro 200Crackpro 260Crackpro 400Cp-125Cp-200Cp-260 ... Show all

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