CIMLINE MA4 Owner'S/Operator'S Manual Download Page 36

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MA4 Spare Parts Kit Part #302-178-000

MA4 Melter Applicator Service Parts Kits (Optional)

PART # DESCRIPTION

QTY.

PART # DESCRIPTION

QTY.

153621 Pump Thermocouple Bent

1 7

403527 Tool Box Assembly

156287 Spray Tip, 1/2 NPT 95-50

5 8

172675 4FJ Cap 304-C-4

156286 Gasket, Applicator Valve

5 9

172XXX 4 MB Plug MORB-STR

111904 Sprocket, No. 35 11 Tooth

1 10 172674 4 MB Plug Hex Head 6408-4

156285 Poppet, Spray Valve

11 172673 O-Ring .875

101245 Roll Pin / Spring .06 x 1.00

172664 Cylinder Application Tip

M-Series Melter Spare Parts Kit Part #404695

PART # DESCRIPTION

QTY.

PART # DESCRIPTION

QTY.

152105 Electric Eye

1 5

130384 Material Controller

200352 Burner Primary Control

1 6

130097 Thermocouple

130113 12V/30A Relay (Hose & Burner)

1 7

130505 240V/18A Ceramic Fuse

152399 Burner Coupling

1 8

152883 12V/10A Blade Fuse (Qty 5)

Summary of Contents for MA4

Page 1: ...Linear Joint Seal Melter Applicator Machine Owner Operator Manual CIMLINE COM 2601 Niagara Lane Plymouth MN 55447 763 557 1982 877 841 0848 Fax 763 557 1971 Part 302 000 000 Rev C 1 20 20 MA4 ...

Page 2: ...onents Specifications 21 MA4 Heat Transfer Oil Specs 22 MAINTENANCE AND TROUBLESHOOTING MA4 Maintenance Schedule 24 MA4 Maintenance Changing the Heat Transfer Oil 25 MA4 Maintenance Sealant Material Pump 26 MA4 Maintenance Sealant Material Plumbing 27 MA4 Maintenance Hydraulic Oil Servicing 28 29 MA4 Maintenance Tank Burner 30 34 MA4 Maintenance Trouble Shooting Guide 35 MA4 Melter Applicator Serv...

Page 3: ...cal dealer is always your first point of contact when looking for parts maintenance technical support warranty information or answers to your questions No one should know you and your business better than your local dealer and they should always be the first call you make when looking for answers to your questions CIMLINE Local Dealer Name CIMLINE Local Dealer Phone Number ________________________...

Page 4: ... level Never leave machine unattended while it is running Do not touch exhaust stacks or mufflers Keep material door closed at all times except when adding material Personal Safety The melter operates at elevated temperature which can cause burns Operator and anyone working in close proximity to hot materials must always wear protective clothing WARNING Signal Words in Manual The signal words DANG...

Page 5: ...rial The weight of your trailer will vary weigh your machine to determining your Gross Vehicle Weight GVW Scales are sometimes available to use at state highway weigh stations refuse transfer stations and commercial truck stops TRAILER STABILIZATION PROCEDURE Going under the trailer puts a person at risk of severe injury or death Follow the procedure below to stabilize trailer before going under t...

Page 6: ...6 Replacement Labels Inspect your labels and replace any that are damaged Contact your dealer to order replacement labels PN 161808 PN 161441 ...

Page 7: ...s contained in this manual may differ from the actual product MA4 BASE WEIGHT 6954 POUNDS 3154 kg Sealant Material Tank Size is 410 Gallons NOTICE A sealant material depth gauge is included to assist in monitoring the sealant material level in the MA4 Maximum Safe Operational Sealant Material Tank Capacity is 307 Gallons MA4 Weight and Dimensions To maintain safe operation of trailer while in tran...

Page 8: ...8 MA4 Feature Overview 17 ...

Page 9: ...material to be pumped directly into the MA4 sealant material tank from an external source 10 Secondary Tank Valve Allows sealant material to enter the Draw Off Sample system out to the Draw Off Sample Valve 11 Draw Off Sample Valve Allows sealant material to gravity pour into a pour pot for manual application on areas unreachable by the application bar or can be used for drawing off sealant materi...

Page 10: ...s to turn on the pump agitator and burner CLEAN OUT Shuts down the burner and reverses pump flow direction to clean out material from the spray bar and internal plumbing returning the sealant material to the material tank COOL DOWN Shuts down the burner and sealant material pump and turns the agitator only This allows the material to cool down more consistently extending the life of the material r...

Page 11: ...o mode the unit will control how much sealant material is applied by the speed wheel as it moves across the ground In the manual mode the sealant material application will be controlled by the pump speed that is set by the application rate APPLICATION RATE Pressing the top right button 4 will highlight the APPLICATION RATE function Purple and allow the dial knob to adjust the sealant material appl...

Page 12: ...12 MA4 Manual Sub Control Panel and Its Functions 1 2 3 4 5 6 7 8 9 10 11 ...

Page 13: ...rials See page 19 to override or change settings 6 MATERIAL READY LIGHT Green This LED light indicates that the sealant material has reached the preset temperature if the unit is running in the auto mode 7 HEAT TRANSFER OIL CONTROLLER The control system on you CIMLINE melter has been factory set to not exceed the OEM heat transfer oil limits for maximum temperature It is advised to only use heat t...

Page 14: ...aterial B on the open door against the holder C 2 Push door to the closed position TO PREVENT CONTACT WITH HOT SEALANT DO NOT DROP MATERIAL INTO THE MELTER WITH EITHER OR BOTH DOORS OPEN LOADING OPERATOR MUST WEAR ALL PROTECTIVE CLOTHING COVERED ON PAGE 4 LOAD MATERIAL FROM GROUND ONLY NEVER CLIMB ON THE TRAILER TO LOAD 2 VERIFY SWITCHES ON CONTROL PANEL A Verify main control switch inside control...

Page 15: ...into the top of the sealant material tank C Move both control handles B from CIRCULATE to SPRAY BAR CIRCULATE MA4 Start Up Procedure 5 ALLOW UNIT TO HEAT SEALANT MATERIAL TO CORRECT APPLICATION TEMPERATURE The green MATERIAL READY light will illuminate when the correct sealant material temperature is reached in the tank 6 LOWER APPLICATION BAR Lower the application bar close and secure the cabinet...

Page 16: ...f the remote B When the key fob remote transmitter powers on you should see the signal strength light illuminate green indicating that the unit is on and communicating with the com puterized control panel C Use the START green and STOP red buttons to begin and end application of sealant material through the application spray bar D The buttons numbered 1 through 5 control which spray nozzles are ac...

Page 17: ...FROM SPRAY BAR CIRCULATE TO CIRCULATE AND CYCLE BOTH VALVES TOGETHER EVERY 2 MINUTES 5 TIMES TO FULLY CLEAR SYSTEM A Move BOTH control handles A a minimum of 5 times every 2 minutes over a 10 minute period finishing With both control handles in the Circulate position 14 CLOSE MAIN TANK VALVE B AT PUMP TURN TO FULLY SHUT 15 SET ROTARY SWITCH OUTSIDE CONTROL BOX TO COOL DOWN The Cool Down function o...

Page 18: ... B C Count the number of slots showing from the top of the gauge down to the top of the material tank ceiling Count only the slots that are ABOVE the tank ceiling C D Multiply each slot shown above the material tank ceiling by 20 gallons and that is approximately what you have left in the tank Example The above drawing shows the gauge is exactly on the 9th slot from the top So 8 slots are above th...

Page 19: ...CONTROL SETTINGS The Sealant Temperature Control A on your CIMLINE melter applicator has been factory set to run the most common types of sealants These sealants have an application temperature of 325 F 163 C With some sealants it may require a change to the controller to achieve the appropriate application tempera ture To achieve this open the control box and alter the Sealant Temperature Control...

Page 20: ...m the other so communication is crucial between crew members when starting and stopping application A Use the START and STOP buttons to begin and end application of sealant material through the application spray bar B The buttons numbered 1 through 5 green red lights control which spray nozzles are active on the application spray bar while applying sealant material C Pressing a numbered button wil...

Page 21: ...t the viscosity based on the air temperature at the time of operation Reference your engine manual for other recommendations MA4 Fluid and Components Specifications HYDRAULIC OIL RESERVE TANK HEAT TRANSFER OIL EXPANSION TANK DIESEL FUEL TANK Hydraulic Reserve Capacity 33 Gallons 125L Hydraulic Oil Type Conoco MV32 or equivalent Diesel Fuel Capacity 33 Gallons 125L Diesel Fuel Type ASTM D975 No 2 H...

Page 22: ...stems Excellent conductivity provides rapid heating and cooling properties in various operations while maintain longer life ISO GRADE Is a viscosity index ability to flow thickness An ISO Grade 68 oil can be an engine oil hydraulic oil etc The manufacturer uses different additives to make the oil conform to different applications YOU MUST CLARIFY WITH THE SUPPLIER that the oil is to be used in a h...

Page 23: ...sfer Oil 25 MA4 Maintenance Sealant Material Pump 26 MA4 Maintenance Sealant Material Plumbing 27 MA4 Maintenance Hydraulic Oil Servicing 28 29 MA4 Maintenance Tank Burner 30 34 MA4 Maintenance Trouble Shooting Guide 35 MA4 Melter Applicator Service Parts Kits 36 37 MA4 Maintenance And Troubleshooting ...

Page 24: ... cleaner element gaskets X 51 Inspect sealant material flow plumbing X 27 Inspect tank burner nozzle electrode head position adjust if necessary X 32 47 Change engine oil and oil filter X 21 51 Grease agitator bearing block load adapter X 58 Replace engine fuel filter X 50 54 Inspect diesel tank burner electric eye clean if dirty X 46 47 Grease trailer wheel bearings X Inspect tank burner chamber ...

Page 25: ...can occur NOTICE COLD OIL LEVEL OIL MUST BE AT MARKING WHEN COLD A THESE LINES ARE NOT USED FOR THE MA4 HEAT TRANSFER OIL LONGEVITY The regular interval for changing heat transfer oil is once annually or every 500 hours If the time frame between heat transfer oil changes is not known a significant difference in temperature from the digital oil controller readout and the analog gauge may mean the o...

Page 26: ...MATERIAL PUMP PACKING REPLACEMENT 1 Remove the locknuts packing gland clips spring clip and square head bolts 2 Slide the packing gland back as far as possible on the shaft 3 Using a packing extractor tool C remove as much of the old packing as possible 4 Clean the shaft and adjacent parts 5 Examine the shaft if excessively worn or scored the pump may need to be replaced 6 Install new the 8 new pa...

Page 27: ...rs of run time then every 200 hours after that Accessing Plumbing A Open rear cabinet door A B Remove heat baffle plate B C Remove pump heat duct plate C Use a torque wrench with an extension and check the 6 nuts from each of the upper flanges D Set torque to 40 ft pounds Use a torque wrench with an extension and check the 8 nuts on the lower pump flanges E These need to be set to 40 ft pounds ...

Page 28: ...hydraulic reserve tank is 33 gallons 125L HYDRAULIC OIL CAPACITY The maximum capacity of the hydraulic tank is 33 gallons but the actual fill level of hydraulic oil is between 27 and 28 gallons Do not fill the tank higher than the top level of the site gauge G on the tank Normal operating capacity of the hydraulic oil should be around the top 3 4 on the site gauge MA4 Maintenance Hydraulic Oil Ser...

Page 29: ...ll the components of the suction strainer E and related hydraulic connections and leak test them before filling the tank completely with hydraulic oil 8 Reassemble the return filter assembly in reverse of the disassembly instructions being careful to not drop the filter cup o ring B into the tank while replacing the filter cup A into the return filter base 9 Place a new filter cartridge C Cimline ...

Page 30: ...fications from CIMLINE E Clean and inspect the electrodes for damage replacing any that are cracked or chipped F Check electrode tip settings Replace electrodes if tips are rounded G Inspect the igniter spring contacts Clean or replace if corroded H Clean the cad cell electric eye if applicable I Inspect all gaskets including the igniter base plate gasket Replace any that are damaged or missing J ...

Page 31: ...or sufficient fuel pressure Pressure is 140 psig with valve energized Check the pump pressure Check for air in fuel lines Check burner for broken motor coupling If the coupling is broken check pump rotation prior to replacing the coupling Check for contaminated fuel and or partially plugged fuel filter Motor Not Operating If the blower motor is not operating check the following possibilities Check...

Page 32: ...sconnect the diesel fuel connector tube from the nozzle line C Loosen the two screws securing the igniter retaining clips a and rotate both clips to release the igniter baseplate Then tilt the igniter back on its hinge D Remove the splined nut b E Remove the nozzle line assembly from the burner being careful not to damage the electrodes or insulators while handling To ease removal of short assembl...

Page 33: ...r Supply Set up The tank burner is set up properly from the factory Air Band Position A should be set to 8 5 Shutter Position B should be set to 10 Motor Blower Wheel and Coupling Replacement See page 47 for the tank burner parts exploded view A Before servicing turn off and or disconnect all power to the burner B Disconnect the burner motor wires C Remove the bolts securing the motor to the burne...

Page 34: ...B for excessive cracking If cracks exceed guidelines contact your CIMLINE dealer to purchase a replacement PN 403400 Burner Chamber Lining Kit A 1 2 3 4 5 6 7 8 B MA4 Maintenance Tank Burner Assemble chamber insulation in the order shown 1 8 Do not run machine if cracks are wide enough to allow flame to contact the metal combustion chamber walls or if any piece has broken loose Do not attempt to r...

Page 35: ...Heat plumbing and valve to melt material Low hydraulic level Check hydraulic oil level Foreign object lodged in line Locate remove foreign object Pump worn or damaged Confirm pump switch on control panel is in SEAL forward position Material pump rotates but does not pump material Pump rotating in wrong direction Reverse pump switch Pump inlet line plugged Check sealant tank grid and lines for obst...

Page 36: ... 11 Tooth 1 10 172674 4 MB Plug Hex Head 6408 4 1 5 156285 Poppet Spray Valve 1 11 172673 O Ring 875 8 6 101245 Roll Pin Spring 06 x 1 00 5 12 172664 Cylinder Application Tip 1 M Series Melter Spare Parts Kit Part 404695 1 2 7 8 3 4 6 PART DESCRIPTION QTY PART DESCRIPTION QTY 1 152105 Electric Eye 1 5 130384 Material Controller 1 2 200352 Burner Primary Control 1 6 130097 Thermocouple 2 3 130113 1...

Page 37: ... MA4 Burner Chamber Lining Kit Part 403400 Part Description 1 403400 Burner Chamber Lining Kit MA4 Pump Packing Set Kit Part 120541 Part Description 1 120541 Pump Packing Set 1 2 3 4 1 1 MA4 Engine Hydraulic Fluids Service Kit Part 406597 Part Description 1 111111 Engine Air Filter Element 2 170407 Hydraulic Return Filter Element 3 111457 Engine Fuel Filter Element 4 170169 3 Fuel Tank Filter 1 11...

Page 38: ...4 MA4 Combustion Chamber Parts 45 MA4 Tank Burner Internal Wiring Diagram 46 MA4 Tank Burner Parts 47 MA4 Hydraulic Manifold Parts 48 MA4 Hydraulic Schematic 49 MA4 Diesel Engine Components 50 51 MA4 Sealant Material Plumbing Parts 52 53 MA4 Hydraulic Reservoir and Diesel Tank Parts 54 MA4 Rear Cabinet Parts 55 MA4 Miscellaneous Components and Parts 56 57 MA4 Agitation System Parts 58 ...

Page 39: ...30998 C C F A H J B E D D D B E K L TRAILER ELECTRICAL COMPONENTS PN Material Description Location 130360 LICENSE PLATE BRKT A 130374 CLEARANCE LIGHT RED B 130375 CLEARANCE LIGHT AMBER C 130402 CLEARANCE LIGHT RED D 130403 TAIL LIGHT LED OVAL E 130405 GROMMET FOR TAILLIGHT E 130988 GROUND SPEED ENCODER F 130989 RECIEVER KEY FOB G 130987 PROX SENSOR SPRAY BAR H 130984 PUMP ENCODER J 130985 ECU BODY...

Page 40: ...2 Black Hose A C Voltage 3 Red Black Stripe Burner Power 4 Red Battery 5 White Burner Enable 6 Red Micro Panel Acc Input 7 Green Yellow Stripe Battery 8 Green Generator Excite 36 Brown Burner Reader MAIN CONTROL PANEL Tank Burner Generator Battery LOFA Engine Switch MA4 Main Wiring Harness Diagram NOT USED ...

Page 41: ...ox 10 Amp Fuse Display ECU Controller Pump Speed Encoder Application Bar Sensor Pump Speed Valve Spray Bar Sensor Receiver Power Receiver CAN Pump Speed Indicator Start Stop Indicator Ground Speed Encoder MA4 Spray Control Wiring Diagram ...

Page 42: ...42 SEALANT MANIFOLD ECU POWER MAIN HARNESS 130578 MA4 Control Panel Wiring Diagram MATERIAL THERMOCOUPLING H T Oil THERMOCOUPLING TANK THERMOCOUPLING ...

Page 43: ...YMBOLS ON DRAWING 18 Pink Material Controller to Burner Relay 19 White Sensor Wire Controller to Terminal Strip 20 Red Sensor Wire Controller to Terminal Strip 21 White Sensor Wire Terminal Strip Thermocouple 22 Red Sensor Wire Terminal Strip to Thermocouple 23 Blue White Stripe Clean Out 24 Green White Stripe Material Temp Ready 28 Red Manifold Switch to Rotary 29 Gray Oil Controller to Agitator ...

Page 44: ...Switch E 130222 12V 75A Relay F 130113 12V 30A Relay G Fuse Block H Lug I Yellow LED K Green LED M Terminal Strip N 153870 Relay Base R 130883 Selector Switch 13 200597 Material Controller 14 200596 Oil Controller 16 111204 Toggle Switch MA4 Control Panel Parts ...

Page 45: ...ber Lining Kit 1 2 402898 Burner Mount 1 3 402893 Heat Chamber Skin 1 4 417041 Inspection Cover 1 5 152487 Insulation Heat Chamber 1 6 100125 Washer Flat 31 16 7 100093 Washer Split Lock 38 2 8 100092 Washer Split Lock 31 8 9 100068 Nut Hex 31 8 10 100015 Bolt Hex 3 8 16 X 3 4 2 11 100006 HHCS 31 X 1 0 8 ...

Page 46: ...6 Orange Motor To Controller 17 Orange Motor Input Lead 7 Black Motor Ground To Controller 18 Black Motor Ground Lead 8 Yellow Cad Cell To Controller x2 19 Yellow Not Used Capped Individually X2 9 White Control Circuit Enable To Controller 20 Red 12V Power Wiring Harness 10 Red 12V Input To Controller 21 White Burner Enable Wiring Harness 11 Black Ground To Controller 22 Brown LOFA Alarm Wiring Ha...

Page 47: ...5 Cad Cell Electric Eye Assembly 5 152128 Gasket Burner Flange 15 152305 Nozzle Tip M1 C1 1 75gph x 90B 6 152173 Ignition Transformer Assembly 15 152204 Nozzle Tip M2 2 00gph x 90B 7 152668 Nozzle Electrode Set Gauge 15 152445 Nozzle Tip M4 MA4 2 25gph x 90B 8 200352 Primary Control Assembly 16 152106 Electrode Rod Assembly 9 120443 Air Tube 130166 Fuel Pressure Gauge 10 153446 Burner Head Tube No...

Page 48: ...Pump 172225 Coil for Material Pump 2 Required 5 172589 Spool and Coil Kit for Spray Actuators 172557 Spool for Spray Actuators 172585 Coil for Spray Actuators 6 172583 Spool and Coil Kit for Agitator 172584 Spool for Agitator 172585 Coil for Agitator 2 Required 7 172665 Control Valve 172668 Coil for Proportional Valve 8 172666 Compensator Valve MA4 Hydraulic Manifold Parts ...

Page 49: ...49 MA4 Hydraulic Schematic ...

Page 50: ...Exhaust 7 156057 Hydraulic Pump s 15 430104 Plate Radiator Bracket 17 111372 Fan Belt 18 111457 Fuel Filter 19 155976 Exhaust Tube Weld 20 100512 Muffler Clamp 21 30A Alternator MA4 Diesel Engine Components See the included engine manual for additional engine component diagrams and information ...

Page 51: ...37 Exhaust Weld 8 200543 Battery Box 9 152047 Rubber Isolator 10 111108 LOFA Control Switch 11 150212 Battery 26 26R 50 Wet 12 111111 Air Filter 13 111337 Oil Filter 14 111872 Radiator Hose 16 155266 Ignition Key MA4 Diesel Engine Components See the included engine manual for additional engine component diagrams and information ...

Page 52: ...52 MA4 Sealant Material Plumbing Parts ...

Page 53: ...nge 21 110500 Bearing 22 302 074 004 Plate Bearing Support 23 120932 Ball Valve 24 156278 90 Deg Swivel 25 302 101 004 Application Bar Weld 26 156304 Pivot Busing 27 302 156 004 Bushing Plate Weld With Act Mount 28 302 116 004 Bushing Plate Weld 29 156289 Ball End 30 302 090 004 Pivot Plate Weld 31 302 073 601 Valve Adapter Rod 32 120396 Pipe Nipple 33 156314 Flex Tube Elbow Weld 34 302 115 000 Re...

Page 54: ...rn Filter Assembly Non Compressor 4 170407 Element Return Filter Non Compressor 5 152044 Filler Cap Assembly 6 171631 Sight Gauge 7 172186 Suction Strainer 8 155396 Fuel Gauge Cap 9 120743 Fuel Shut off Valve 10 170169 Fuel filter 10 MA4 Hydraulic Reservoir and Diesel Tank Parts ...

Page 55: ...uard 9 302 184 004 Baffle Plate 10 302 123 004 Back Plate Weld 11 200628 Hinge 12 302 124 004 Front Plate Weld 13 200627 Hinge 14 302 157 003 Plate Depth Gauge 15 302 125 004 Top Plate Weld 16 302 144 004 Draw Off Cover 17 302 153 004 Plate Chain Shield 18 302 181 004 Plate Switch Mount Top 19 302 185 004 Sensor Plate Weld 20 302 182 004 Plate Switch Mount 21 302 172 004 Plate Pump Guard 22 302 19...

Page 56: ...56 MA4 Miscellaneous Components and Parts ...

Page 57: ...OFA Control 15 152664 Anchor Shackle 16 429336 Side Plate 17 429335 Plate Cap 18 130130 24 Thermometer 19 404341 Dipstick 20 130050 Breakaway Switch 21 150215 Amber Reflector 22 130989 Transmitter Receiver 23 156288 Lock Pin 24 302 085 601 Outrigger Rod 25 302 084 601 Outrigger Pin 26 130988 Ground Speed Encoder 27 121140 Camlock Hose Coupling 28 121139 Camlock Cover 29 302 099 004 Plate Wheel Sup...

Page 58: ...HCS 31 X 1 0 2 5 420169 Plate Agitator 1 15 100069 Nut Hex 38 1 6 420171 Adjustment Angle 1 16 100015 Bolt Hex 3 8 16 X 3 4 8 7 171173 Load Adapter 1 17 100092 Washer Split lock 31 2 8 100095 Washer Split lock 1 2 2 18 110488 Chain No 50 X 68 Links 1 9 100039 HHCS 1 2 X 3 1 2 2 19 110190 Link Master No 50 1 10 100295 HHCS 3 8 X 3 FL THD 1 PART DESCRIPTION 153772 Seal Kit for Hydraulic Motor MAINTE...

Page 59: ...59 Melter Applicator Optional Accessories Available Cimline Sales Toll Free 877 841 0848 Telephone 763 694 2665 Corporate Headquarters 2601 Niagara Lane N Plymouth Minnesota 55447 www cimline com ...

Page 60: ...tion of the replacement material pumps heated hoses and heated hoses with heated wands which use the above scale for pro rated coverage For replacement parts that are purchased the 60 day period will commence from the date of distributor to end user invoice A copy of the invoice will be required as proof of in service date If invoice is not provided policy will revert back to the original factory ...

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