Summary of Contents for Ergon CRAFCO E-Z 500 II Series
Page 1
DIESEL MELTER PART MANUAL - 26603 REV. C...
Page 2
Revisions Rev. B 3/2012 Updated manual to reflect full recirculation and all changes associated. Rev. C 4/1/2014 Updated hydraulic schematics and some graphics. Revised: 4/2014...
Page 3
E - Z E - Z E - Z500 E - Z E - Z Series II Series II Series II Series II Series II D I E S E L D I E S E L D I E S E L M E L M E L M E LT E R...
TABLE OF CONTENTS EZ500 Series II Diesel Melter......................Safety Precautions..........................6-7 Limited Warranty..........................7 Warranty Claim Instructions....................... 8 Specifications............................9 Introduction............................10 Operating Instructions Machine Start Up - Electric Hose................11-15 Machine Startup - Standard Hose................16-18 Air Compressor (OPTION)..................19 Storing Machine......................
E - Z E - Z Series II Series II E - Z E - Z500 Series II E - Z Series II Series II DIESEL MELTER This manual is furnished with each new CRAFCO E - Z Series II DIESEL E - Z E - Z500 Series II E - Z...
SAFETY PRECAUTIONS • High operating temperatures of sealant and machine require protective clothing, hard-soled shoes and heat resistant gloves to be worn by operator. • Always wear eye protection. • Observe all CAUTION AND WARNING signs posted on machine. • Avoid the entrance of water into any part of the machine. Water will displace heat transfer oil or sealant, which could be hazardous to personnel surrounding the machine when it reaches operating temperatures.
SAFETY PRECAUTIONS • Replace any hoses which show signs of wear, fraying, or splitting. Be sure all fittings and joints are tight and leak-proof, each time machine is used. •Precaution is the best insurance against accidents. •The melter should not be left unattended with burner lit. •Tighten all bolts and screws after every 100 hours of operation.
WARRANTY CLAIM INSTRUCTIONS Crafco, Inc., warrants parts and machinery purchased through Crafco or one of it’s affiliated distributors for one year from purchased or inservice date **. If a parts fail to function within the first year of purchase, a return authorization number (RA) must be obtained. If the part was purchased through Crafo, Inc., please contact the Crafco returns department at Returns@Crafco.com for a RA number or if purchased through a Crafco distributor please contact your distributor.
SPECIFICATIONS Vat Capacity................133 Gallons(500 Liters) Melt Capacity................110 Gallons/Hour Heat Transfer Oil Required............. 21.5 Gallons at 70° F Tank Construction..............Double Boiler Type Tank Opening Size..............14” X 18” Maximum Heat Input............. 250,000 BTU’s Burner and Temperature Control..........Diesel-Forced Air Thermostatic Control Engine - Standard..............Isuzu Three Cylinder Model 3CB1 - Diesel...
MACHINE START UP for ELECTRIC HOSE TO START BURNER Fully open the damper vent. Start engine per Engine Manual. Turn “POWER” toggle switch at control box “ON”. Turn “Hose Selector” switch to “ELECTRIC Hose” . NOTE: Electric hose will only work if hose selector switch is in the electric hose position.
MACHINE START UP for ELECTRIC HOSE 9.Remove hose and wand from transport position and place wand tip in shoebox. When sealant reaches correct application temperature, open “TANK VALVE”, “RECIRCULATION VALVE”, and close “APPLICATOR VALVE”. Reverse pump for 3-5 minutes by turning the toggle switch on the main control panel to “PUMP REVERSE”. When pump turns freely, return toggle switch to “ON ELECTRIC”.
HOSE TRANSPORT INSTRUCTIONS 1. Leaving the hose in the boom, swing the boom towards the front of the machine and lock the boom into position with the latch provided. 2. Place the wand in the wand holder and lock the wand into position with the latch provided.
DISPENSING THE MATERIAL NOTE: PROTECTIVE CLOTHING, GLOVES, HARD-SOLED SHOES, AND FACE SHIELD OR SAFETY GLASSES SHOULD BE WORN WHEN OPERATING OR FILLING THIS EQUIPMENT. READ ENTIRE MANUAL BEFORE OPERATING. The wand is equipped with a disposable duckbill valve on the end, which shuts off the flow of mate- rial when the pump is turned off and prevents excessive dripping of material.
Page 15
SHUTDOWN AND CLEAN-OUT PROCEDURE When shutting down the machine for the day, there are several schools of thought about how much material to leave in the machine. Crafco recommends leaving the melter about half full. This will give a fairly rapid heat up rate in the morning, but will allow enough mate- rial to start dispensing right away when the material becomes molten.
MACHINE START UP for STANDARD HOSE TO START BURNER 1. Fully open the damper vent. 2. Start engine per Engine Manual. 3. Turn “POWER” toggle switch at control box “ON”. 4. Turn “Hose Selector” switch to “STD. Hose” . 5. Set hot oil temperature at 450 F.
Page 17
12. Close “Recirculation Valve”. Important: Adjust the flow control valve to get close to the desired flow from the applicator wand then close “Recirculation Valve” to get to the desired flow. This method of operation will give maximum pump life. If the sealant does not flow from the applicator wand, close hand wand valve and placed hose and hand wand back in the oven to allow the sealant to become more liquid, then repeat procedure.
Page 18
SHUTDOWN AND CLEAN-OUT PROCEDURE When shutting down the machine for the day, there are several schools of thought about how much material to leave in the machine. Crafco recommends leaving the melter about half full. This will give a fairly rapid heat up rate in the morning, but will allow enough material to start dispensing right away when the material becomes molten.
AIR COMPRESSOR (OPTION) The air compressor unit installed on the E-Z Series II is designed to assist in the cleaning of debris from cracks & joints. Always use approved high pressure air hoses with properly installed fittings. Do not use frayed or worn hoses. A cold air lance, or approved hot air lance can be used with this compressor.
STORING MACHINE The melter should be stored in an area where moisture cannot enter the machine heating system such as hot oil, controls, etc. Extended down time can cause moisture build up in heating oil tank. If there is any suspicion that moisture may have collected in heat transfer oil, warm heat transfer fluid to 300°F.
MAINTENANCE INSTRUCTIONS ENGINE See Engine Owner Manual for operating and maintenance instructions. HYDRAULIC SYSTEM Check hydraulic fluid daily. Change hydraulic filter every 250 hours of operation. Change hydraulic fluid every 500 hours of operation. HEAT TRANSFER OIL Check oil level every 8 hours of operation. Change oil every 500 hours of operation. WHEEL BEARINGS Re-pack wheel bearings every 24,000 miles or every two years, using a good grade of bearing grease.
MAINTENANCE INSTRUCTIONS TEMPERATURE CONTROL CALIBRATION Check control knob calibration weekly. 1. Calibrate by aligning the line on the control knob with with the calibration line on the scale plate (See Fig. 1). Fig. 1 REPLACING HEAT TRANSFER OIL 1. Drain oil by removing oil drain cap located under machine. 2.
RECOMMENDED FLUIDS AND LUBRICANTS APPLICATION RECOMMENDED FULL POINT Engine oil Refer to Isuzu owners manual. 3 Qts. #1 Cold climate Diesel 30 Gals. #2 Warm climate ISO 68 (40° F (4.4° C) - 180° F (82.2° C)) Hydraulic oil 24 Gals. ISO 46 (30°...
TROUBLE SHOOTING GUIDE - ELECTRIC HOSE HOSE DOES NOT HEAT Step 1: Is the “MATERIAL” temperature at 275°F? YES: Go to step 2. NO: Turn “POWER” toggle switch “ON”. Step 2: Is “HEATED HOSE” light illuminated? YES: Go to step 3. NO: Check for tripped circuit breaker in front panel.
TROUBLE SHOOTING GUIDE - ELECTRIC HOSE Step 5: Check for 30 amps (cold) or 22-24 amps (hot) at the 3 blue wires in the junction box. (Always use a clamp-on AMP meter to perform this test) YES: Hose should be operating properly. NO: Go to step 6.
Page 28
TROUBLE SHOOTING GUIDE - ELECTRIC HOSE PNK-3 PNK-2 ORN-2 ORN-1 BLK-1 BLK-5 BLK GND BLK-4 PNK-4 PNK-1 BLU-2 BLU-1&BLU-GEN HOSE MAT'L HOT OIL 43391 MOUNT SWITCH BLU-2 NOTCH DOWN BLK-5 RED-3 WHT-2 BLK-10 WHT/BLK WHT/BLK HOSE MATERIAL RED-2 51691 51672 BLK-12 WHT-4 BLK-11...
TROUBLE SHOOTING GUIDE - ELECTRIC HOSE PUMP ROTATES BUT NO MATERIAL IS DISCHARGED Step 1: Has the sealant and heated hose had sufficient time to reach temperature? YES: Go to step 2. NO: Allow the sealant and hose to heat longer. Step 2: Check material outlet pipe and connection between hose and wand for obstruction.
RTD SENSOR - OHMS vs. TEMPERATURE The following chart shows what the Ohm reading would be for a given temperature. This is to be used when trouble shooting the burner and the hose. The following are the instructions for use. Measure the resistance (Ohms) of the sensor in question with an Ohm meter.
PUMP SECTION PACKING INSTRUCTIONS Operate the pump under normal conditions and, after a short run-in period, examine pack- ing for leakage. If leakage is excessive tighten locknuts evenly until there is only slight leakage from the packing rings. This slight leakage is a necessary and normal condition for packing and allows for expansion and proper seating.
TROUBLE SHOOTING HYDRAULICS PROBLEM CAUSE REMEDY Mixer will not rotate. Sealant temperature too low. Continue to heat material. Too many blocks placed at one Mixer will not rotate. Continue to heat material. time. Mixer will not rotate. Inadequate hydraulic flow/pressure. Check hydraulic fluid level. Reset pressure, check flow if Mixer will not rotate.
Page 39
EZ500 SERIES II MELTER P A R T N U M B E R Q T Y. D E S C R IP T IO N N U M B E R 4 4 3 4 2 2 /4 * T IR E A N D W H E E L A S S E M B L Y 4 6 1 1 5 1 /2 *...
Page 41
EZ500 SERIES II MELTER P A R T N U M B E R Q T Y. D E S C R IP T IO N N U M B E R 3 2 3 6 5 C L E A R E N C E M A R K E R - Y E L L O W 4 6 7 0 7 S U P P O R T A S S E M B L Y, W A N D 2 4 0 0 0...
Page 43
EZ500 SERIES II MELTER OPTIONS PAR T NU MB ER QTY. D ESCR IPTION N U MB ER 51230 C ONVEYOR ASSEMBLY 46280K ARROW BOARD 46279 KIT, GRAVITY FEED 46271 RACK, AIR HOSE 46260 TOOL BOX 46170K STROBE LIGHT KIT (NOT SHOWN) 46160K LIGHT BAR KIT (NOT SHOWN) 46148...
Page 45
TANK DETAIL PAR T IT E M D E S C R IP TION N U MB E R 46146 PA D D LE , A GITATOR 22310 MOTOR, HYD RA ULIC - A GITATOR 46050 S HA FT A S S E MB LY, MIX E R 46380 B URNE R, 14 V OLT D IE S E L 46058...
Page 47
PLUMBING P A R T N U M B E R Q T Y. D E S C R IP T IO N N U M B E R 4 6 0 2 0 P U M P A S S E M B L Y 2 2 0 2 7 H Y D R A U L IC M O T O R 2 2 0 3 0...
Page 57
ENGINE ASSEMBLY - 27.5 HP P A R T N U M B E R Q T Y. D E S C R IP T IO N N U M B E R 4 6 7 1 1 2 7 .5 H P E N G IN E W / G E N E R A T O R (E B O N L Y) 4 6 4 8 0 2 7 .5 H P E N G IN E (S B O N L Y) 4 3 8 9 9...
Page 61
ENGINE ASSEMBLY - 35.5 HP PART NUMBER QTY. DESCRIPTION NUMBER 46727 35.5 HP ENGINE 45449 HYDRAULIC OIL PUMP 29885 1 1/4" TUBE X 1 5/8-12" O-RING ADAPTER 29842 5/8" TUBE X 1 1/16-12" O-RING ELBOW 45381 OIL FILTER 41867 FUEL FILTER 45382 AIR FILTER ELEMENT THIS ENGINE IS FOR THE FOLLOWING MACHINE MODEL NUMBERS...
Page 71
COMPRESSOR ASSEMBLY P A R T IT E M Q T Y D E S C R IP T IO N N U M B E R 4 5 3 2 0 C O M P R E S S O R , R O TA R Y V A N E 4 5 3 4 7 S H A F T, C O M P R E S S O R D R IV E 4 5 3 4 6...
Page 75
HYDRAULIC DIAGRAM W/O COMPRESSOR FLOW CONTROL #2 PORT TO HYDRAULIC VALVE TANK PORT 29896 3/4-16 O-RING X 1/2" TUBE ELBOW 8M3K 8G-8FJX 8G-8FJX90S 30 26.5 HYDRAULIC HOSE ASSEMBLY 1/2 X 30" LONG 29932 3/4-16 O-RING RUN TEE HYDRAULIC VALVE TANK PORT TO HYDRAULIC OIL COOLER 29932 3/4-16 O-RING RUN TEE 8M3K 8G-8FJX 8G-10FJX 21 17.75...
Page 81
HYDRAULIC DIAGRAM W/ COMPRESSOR 13. COMP. VALVE TO HYDRAULIC OIL COOLER 29900 1 1/16-12 O-RING RUN TEE 16G4H 16G-12FJX 16G-16FJX90S 75 68.5 HYD. HOSE ASSY . 1" X 75" LG . 29951 1 5/16-12 O-RING X 1"JIC RUN TEE 14. HYDRAULIC OIL COOLER TO HYDRAULIC TANK 29824 1 5/16-12 O-RING X 1"...
Page 83
ELECTRICAL SCHEMATIC - ELECTRIC HOSE P A R T IT E M Q T Y D E S C R IP T IO N N U M B E R 4 6 6 2 0 C O N T R O L B O X A S S Y. C O M P L E T E 4 4 9 7 8 W IR IN G H A R N E S S , E N G IN E 5 1 8 3 6...
Page 85
ELECTRICAL SCHEMATIC - STANDARD HOSE PAR T ITE M D E S C R IP TION N U MB E R 46715 C ONTROL B OX A S S Y. C OMP LE TE 44978 W IRING HA RNE S S , E NGINE 51836 C A B LE A S S Y., TRIGGE R/S E NS OR 51835...
Page 87
HOT AIR LANCE (OPTION) P A R T IT E M Q T Y . D E S C R IP T IO N N U M B E R 4 5 6 5 1 M IX IN G B L O C K 5 1 4 0 1 N IP P L E , 1 /4 N P T H E X 2 9 1 9 5...
TOOLS AND ACCESSORIES Crafco Sealing Foot / Protruded Crafco Applicator Disk 27159 - 1/4” Protruding 27162 - 3” Disk Assembly 27160 - 3/8” Protuding 27163 - 4” Disk Assembly 27164 - 6” Disk Assembly Crafco Joint Sealing Tip 27146 - 1/4” Sealing Tip 27147 - 3/8”...
Page 89
TOOLS AND ACCESSORIES Crafco Pour Pot with Wheels - 40200 Crafco Heavy Duty Squeegee with Aluminum Handle - 27199 27195 - Replacement Blade Crafco Heavy Duty Squeegee with Aluminum Handle - 27245 27241 - Repalcement Blade Crafco Hand Held Pour Pot - 40201 Super Shot Drip Stopper Use with 50270 Duckbill 27114 - Tip Adapter...
Page 90
TOOLS AND ACCESSORIES Crafco Heat Lance with Regulator and Attachments - 32259 Crafco Hand Torch w/ 20ft. Hose - 25012...
Need help?
Do you have a question about the CRAFCO E-Z 500 II Series and is the answer not in the manual?
Questions and answers