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Crafco EZ 500 Series II, Manual

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EZ 500 Series II Melter Part Manual

 

Chapter 9 Illustrated Parts List 

 

©2019 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-12 

9.6  Control Box Assembly – Electric Hose 

 

Fig. 9.6 Control Box Assembly: 46100SB

 

GRN

PRP

BLU

RE

D-

3

RE

D-

4

RE

D-

5

WH

T-

RE

D&

RE

D-

1

RE

D-

7

RED-5

BLK-6

BL

U

WH

T/

RE

D-

2

RE

D

WH

T/

GR

N-

3

BL

U

OR

N-

4

RE

D

BL

K-

7

BL

U

RE

D

GR

N-

1

Ac

c

B

RI

C

Br

Ra

BLK/RED

BLK-2

YL

W-

2

BRN-1

BL

U

-2

BL

K-

5

BL

K-

5

BL

K-

5

BL

K-

5

PR

P-

2

GR

Y-

2

PN

K-

3

BL

K-

5

BL

U

-2

GR

Y-

2

PN

K-

3

GRN

PRP

BLU

BL

K-

LI

GH

T

RE

D-

3

RE

D-

9

YL

W-

1

RE

D/

BL

K-

1

GR

Y-

3

OR

N-

2

PN

K-

4

WH

T/

RE

D-

1

WH

T-

1

PR

P-

3

PR

P-

1

RE

D-

TR

IG

BL

K-

1

BL

K 

GN

D

PN

K-

2

YE

LL

OW

RE

D/

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K

GR

Y-

1

WH

T/

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D-

4

RE

D 

LI

D 

D.

S.

WH

T/

GR

N-

4

WH

T/

GR

N-

5

OR

N-

1

BL

K-

4

BL

U

-1

&B

LU

-G

EN

PN

K-

1

WH

T 

CO

M

P

GR

N 

BR

NR

BL

U 

PM

P

GR

N 

TR

IG

BR

N-

4

BRN-3

BLK-11

WHT-3

BR

N-

4

BR

N-

2

RE

D-

8

RE

D/

BL

K-

3

RED/BLK-3

WHT-4

BLK-12

RE

D-

8

BR

N-

2

BR

N-

3

BR

N-

PU

M

P 

RE

V 

#1

BR

N-

M

IX

ER

 F

W

D 

#4

BL

U

-M

IX

ER

 #

4&

PM

P 

FW

D 

#2

RE

D 

LI

D 

P.

S.

RE

D/

BL

K-

2

BR

N-

M

IX

ER

 R

EV

 #

3

RE

D/

BL

K-

2

BL

K

W

HT

BL

K-

10

WH

T-

2

OR

N-

3

GR

N-

1

YL

W-

3

BL

K-

7&

BL

K-

8

W

HT

/R

ED

-3

WH

T/

GR

N-

3

BL

K-

16

BLK

-1

BL

K-

12

WH

T-

4

WH

T-

3

BL

K-

11

OR

N-

4

GR

N

BL

K/

YL

W

RE

D-

6

RE

D

BL

U

YL

W

/B

LK

BL

K/

BL

U

BR

N-

1

YL

W-

2

GR

Y-

5

BL

K-

2

BLU

-1

PNK

-1

PRP

-1

PNK

-1

GRY

-1

ORN

-1

PNK

-2

ORN

-1

PNK

-2

BLK

-4

ORN

-1

BLK

-4

W

HT

-2

BL

K-

10

W

HT

/B

LK

W

HT

/B

LK

8

5

4

1

14

13

12

9

W

HT

/R

ED

-2

WH

T/

RE

D

RE

D/

BL

K-

3

RE

D/

BL

K-

3

WH

T/

GR

N

W

HT

/R

ED

BL

K-

6

WH

T/

GR

N-

1

WH

T/

RE

D-

1(L

IG

HT

)

W

HT

/G

RN

-2

BL

K-

15

&B

LK

-1

6

PR

P-

2

W

HT

-1

(C

OM

P.

)

BL

K-

15

RE

D-

1

BL

K

YL

W

/R

ED

WHT

/BL

K

WHT

/BL

K

WHT

/GR

N-5

WHT

/GR

N-4

RED

-LI

D

RED

-LI

D

WHT

/RE

D-4

BLU

-PM

P R

EV 

#1

BRN

-PM

P R

EV 

#1

BLU

-M

IXE

R R

EV 

#3

BRN

-M

IXE

R R

EV 

#3

BLU

-M

IXE

R F

WD 

#4

BRN

-M

IXE

R F

WD 

#4

RED

/BL

K-2

RED

/BL

K-2

WHT

BLK

RED

-TR

G

GRN

-TR

G

YEL

LOW

RED

/BL

K

WHT

-CO

MP

BLU

-GE

N

BLK

-GN

D

GRN

-BR

NR

RED

-7

WHT

-RE

D

RE

D-

8

PR

P-

3

PNK-3

PNK-4

RE

D-

2

ORN

-2

YLW-1

BLK/RED-1

W

HT

/R

ED

-3

ORN

-2

BLK

-5

GRY

-3

GRY

-2

W

HT

/G

RN

-1

WH

T/

GR

N-

2

RE

D-

2

RE

D-

4

GR

AY

-5

BL

U-

3

BLK

/W

HT

GRN

BLK

/YE

L

BLU

WHT

/GR

N

YEL

YEL

/RE

D

BLK

/BL

U

BLK

/GR

N

WHT

/RE

D

BLK

CUT BACK 1.5" & SOLDER
DIODE WITH SILVER MARK 
TOWARDS TERMINAL BLOCK
COVER WITH 1.5" OF 51532

BL

U-

M

IX

ER

 #

3&

PM

P 

RE

V 

#

1

HO

SE

51

69

1

M

AT

ER

IA

L

5

16

72

5

18

36

51

83

5

51

83

4

4

39

84

HO

T 

O

IL

43

3

91

M

AT

'L

HO

SE

RE

D 

- 

9

BLU

-PM

P F

WD 

#2

BRN

-PM

P F

WD 

#2

BR

N-

PU

M

P 

FW

D 

#2

BL

U

 P

M

P

MOUNT SWITCH 
NOTCH DOWN

BL

U

-3

BL

K-

LI

GH

T

E

2

4

5

6

7

8

9

10

12

13

14

15

16

17

18

19

20

21

22

24

24

25

9

26

27

28

Summary of Contents for EZ 500 Series II

Page 1: ...Parts Manual 26603 Revision K...

Page 2: ...________________ 2nd Hose S N _______________________________ 1st Pump S N _______________________________ 2nd Pump S N ______________________________ Engine S N ________________________________ Compr...

Page 3: ...achines no longer in production 46100EC63 and 46100SC63 Replaced diagrams for sections 9 2 and 9 3 with non compressor machines Updated Prop 65 warning warranty information Added warning to Section 5...

Page 4: ...EZ500 Series II Melter Electric Hose PN 46100EB EZ500 Series II Melter Standard Hose PN 46100SB...

Page 5: ...ions 5 1 5 1 Preparing the Machine for Start Up 5 1 5 2 Machine Start Up for Electric Hose 5 3 5 3 Altitude Compensation System 5 5 5 4 About the Heated Hose Wand Valve and Tip Guard 5 5 5 5 Electric...

Page 6: ...Sensor Area 6 10 6 20 Cleaning the Melter 6 10 7 0 How to Use a Multimeter 7 1 7 1 Checking DC Voltage with a Multimeter 7 1 7 2 Checking AC Voltage with Multimeter 7 1 7 3 Checking Resistance Ohms 7...

Page 7: ...Hose 9 16 9 8 Engine Assembly 9 20 9 9 Hydraulic Control Valve Assembly 9 22 9 10 Material Flow Control Assembly 9 23 9 11 Compressor Hydraulic Valve Assembly 9 24 9 12 Diesel Burner Assembly 9 25 9 1...

Page 8: ...t 8 17 Fig 8 6 Hydraulic Valve Pressure Setting 8 19 Fig 8 7 Din Plug Layout 8 20 Fig 8 8 Junction Box Voltage Testing 8 23 Fig 8 9 Hose Circuit Schematic 8 24 Fig 8 10 Junction Box Wiring 8 25 Fig 8...

Page 9: ...p 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 9 19 Diesel Fuel Line Schematic 9 36 Fig 9 20 Electrical...

Page 10: ...e 5 12 Table 5 11 Shutting Down with a Standard Hose 5 12 Table 5 12 Overnight Heaters 5 14 Table 5 13 Mounting a Skid Machine 5 15 Table 6 1 Maintenance Chart 6 4 Table 6 2 Service Instructions 6 5 T...

Page 11: ...r Hydraulic Troubleshooting 8 18 Table 8 19 Basic Visual Troubleshooting 8 21 Table 8 20 Electrical Troubleshooting 8 21 Table 8 21 Electrical Troubleshooting continued 8 22 Table 8 22 Electrical Trou...

Page 12: ......

Page 13: ...ucted in this manual Maintain your machine regularly as stated in this manual 1 1 How to use this manual This manual is formatted to start each new chapter on the right page There may be a blank page...

Page 14: ......

Page 15: ...ake sure an operator fully knows how to operate the machine before using the machine 2 2 Personal Safety The high operating temperatures of this machine and the sealant it contains requires that prote...

Page 16: ...Instructions are mounted on the control box on the machine Calibrate the temperature control operation after each 50 hours of machine operation Refer to section 6 10 Temperature Control Calibration R...

Page 17: ...tices The table below includes the most commonly used symbols and notices Symbol Item Remarks WARNING Warning Refers to possible bodily injury or death CAUTION Caution Refers to possible equipment dam...

Page 18: ...ved Safety 2 4 Symbol Item Remark Crush Hazard Keep feet and legs clear Pinch Hazard Keep hands and feet clear Exhaust Hazard Avoid breathing engine exhaust Read Manual Read and understand operator an...

Page 19: ...ed by accident alteration abuse improper lubrication maintenance normal wear or other cause beyond our control The warranty provided herein extends only to the repair and or replacement of those compo...

Page 20: ...te All engine warranties are covered through the engine manufacturer If you need information for a distributor in your area please contact us and we will direct you to the closest engine distributor A...

Page 21: ...x 18 Maximum heat input 250 000 BTUs Burner and temperature control Diesel forced air thermostatic control Engine Isuzu diesel Three cylinder Model 3CH1 21 2 BHP 3000 RPM Drive Mechanism All hydraulic...

Page 22: ......

Page 23: ...eat transfer oil level while at a temperature of 70 F The oil should be at the full mark on the dipstick DO NOT overfill or spillage may occur when the oil is heated and expands See Fig 5 2 Heat Trans...

Page 24: ...Part Manual Chapter 5 Operating Instructions 2019 by Crafco Inc All Rights Reserved Operating Instructions 5 2 Fig 5 1 Hydraulic Fluid Level and Temp Gauge Fig 5 2 Heat Transfer Oil Dipstick Dipstick...

Page 25: ...mportant The solid material in the tank melts first around the walls bottom and around the center tower of the tank The material temperature sensor is located by the wall therefore it is possible that...

Page 26: ...ture open TANK RECIRCULATION 15 Reverse pump for 3 5 minutes by turning the pump toggle switch to PUMP REVERSE When pump turns freely return switch to ON ELECTRIC position 16 Depress wand trigger to r...

Page 27: ...e operator The pistol grip actuator is equipped with an electric switch which when depressed sends a signal to actuate the pump The wand is equipped with a trigger lock to prevent accidental pump actu...

Page 28: ...rafco Inc recommends you do not work directly under the boom this may cause damage to the hose 4 Follow all machine instructions in this manual CAUTION Hose damage occurs if The hose is bent or moved...

Page 29: ...all therefore it is possible that at the beginning of the melting process the indicated temperature reaches operating value but the material between the center tower and the outside wall of the tank i...

Page 30: ...ystem on the loading door This system disables the mixer hydraulic system when the lid is open to stop the mixer from turning This is a safety feature for the operator and should never be disabled for...

Page 31: ...29 104 857 396 93 6 30 88 116 89 99 45 376 46 7 36 06 136 50 94 27 356 85 8 41 24 156 11 89 08 337 20 9 46 42 175 72 83 89 317 56 10 51 60 195 33 78 71 297 95 11 56 78 214 94 73 52 278 30 12 61 96 23...

Page 32: ...o the lowest setting by turning the speed control knob fully clockwise 3 Insert the wand tip into the shoebox depress trigger on the wand and slowly increase pump speed until the pump motor starts to...

Page 33: ...Open recirculation valve to get the desired flow rate 5 This method of operation will give maximum pump life If the sealant does not flow from the applicator wand close hand wand valve and place hose...

Page 34: ...VE and TANK VALVE 5 Turn the mixer toggle switch to the OFF position 6 Turn the POWER switch to the OFF position 7 Stop the engine by turning the key to the OFF position Step Action 1 Close recirculat...

Page 35: ...is heard warm the heat transfer oil to 300 F for two to three hours to evaporate the moisture Failure to follow this procedure will cause the heat transfer oil to overflow the tank resulting in possib...

Page 36: ...uitable extension cord 2 Attach each extension cord to its own outlet rated for 15 amps CAUTION Attaching both heaters to the same outlet will most likely pop the circuit breaker inline from the power...

Page 37: ...sult in damage and possible fire WARNING Mount the machine a minimum of 3 76mm above the truck bed Depending on the machine and airflow you may have to mount it higher to prevent excessive temperature...

Page 38: ......

Page 39: ...eck for heat transfer oil in tube every 50 hours of operation 2 ounces required 6 6 Pump Packing Adjustment and Replacement Material pump packing should leak a small amount 5 10 drops per minute durin...

Page 40: ...ond stage 50 60 foot pound ft lb Third stage 90 120 foot pound ft lb Tighten bolts and nuts in the sequence shown in Fig 6 1 6 8 Brakes Check the brakes daily 6 9 Tongue Jack Lubricate the tongue jack...

Page 41: ...ball valve located rear driver s side of machine before refilling This allows the air to escape the center column 3 Start burner and heat the heat transfer oil until one drop of oil comes out of ball...

Page 42: ...raulic Oil Check X Change X Hydraulic Oil Filter Change X Burner Check burner box insulation X Clean CAD cell X Check Electrodes X Check Flame Retainer Head X Replace burner nozzle X Wheel Bearings Cl...

Page 43: ...Clean the external surfaces of the machine at regular intervals Note Refer to the material manufacturer s instructions for recommendations 6 Follow the recommended maintenance per Table 6 1 Maintenanc...

Page 44: ...0SB 43397 1 DC Controller All 42335 1 Coupling Fuel Pump All 41970 1 Electric Hose 15 46100EB 51731 1 Solenoid All 39602 6 16 Recommended Fluids and Lubricants Application Recommended Full Point Machi...

Page 45: ...ansfer Oil 3 Shell Turbo T 68 Group II Phillips 66 Magnus Oil 68 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 U...

Page 46: ...the material pump Make note of tee direction 8 Install lower suction tee and flanged nipple assembly into new pump 9 Install material pump in heat compartment Flange gasket P N 29060 will also need to...

Page 47: ...00 Series II Melter Part Manual Chapter 6 Maintenance Instructions 2019 by Crafco Inc All Rights Reserved Maintenance Instructions 6 9 Step 3 Step 4 Step 5 Step 6 Step 7 Fig 6 3 Material Pump Replacem...

Page 48: ...ture sensor from reading as accurately because it becomes insulated from the fresh material The coked material needs to be scraped or chipped from the tank walls The area between the sensor and sensor...

Page 49: ...you are checking has a ground wire attached then use that ground or you can use a non painted surface on the frame 7 2 Checking AC Voltage with Multimeter Connect the probes to the meter See Fig 7 1 S...

Page 50: ...ic hose always use a clamp on amp meter See Fig 7 2 Clamp On Amp Meter Multimeter The amperage in the hose can reach as high as 35 amps Clamp the meter around one wire at a time Remember most clamp on...

Page 51: ...Crafco Inc All Rights Reserved How to Use a Multimeter 7 3 Fig 7 2 Clamp On Amp Meter Multimeter Ohms Sensors Hyd Coils Burner Ignition Coil Audible Continuity Hose Wand and wire connection DC Voltage...

Page 52: ......

Page 53: ...aterial temperature according to the type of material you are using and the Hot Oil 100 F above the Material set point 5 Does either readout display a 1 NOTE This occurs only when there is a short in...

Page 54: ...urner plug of the frame solenoid and the black wire in the burner plug Yes go to Step 4 No go to Step 1b 1b Is there 12Vdc between the other large terminal red wire going to the circuit breaker of the...

Page 55: ...go to Step 5 5 Is there 12Vdc between gray wire labeled GRY 2 and nearby ground source Yes replace terminal block No go to Step 5a 5a Is there 12Vdc between terminal 7 gray wire and terminal 5 black...

Page 56: ...T and terminal block No go to Step 8a 8a Is there 12Vdc between orange wire labeled ORN 2 on upper terminal blocks and a nearby ground source black wire Yes replace terminal block No go to Step 9 9 Is...

Page 57: ...tween ACC of ignition switch and bottom terminal of circuit breaker No go to Step 13a 13a Is there 12Vdc between B blue wire of ignition switch and nearby ground source black wire Yes replace ignition...

Page 58: ...BLK WHT GRN 1 WHT GRN 2 WHT BLK WHT BLK WHT GRN 5 WHT GRN 4 RED LID BLK GND GRN BRNR RED 2 ORN 2 ORN 2 BLK 5 GRY 3 GRY 2 WHT GRN 1 WHT GRN 2 HOSE 51691 MATERIAL 51672 51836 51835 51834 43984 44978 HOT...

Page 59: ...electrodes are in the correct position Loosen the clamp holding the electrodes in place so they can be adjusted Inspect the porcelain ceramic insulator for any cracks Also check the tip of each of th...

Page 60: ...l the time Blue Igniter wire should have 12Vdc 5 Twist the yellow wires together once voltage registers on the orange blue and purple wires Orange Blower Motor wire should maintain 12Vdc Blue Igniter...

Page 61: ...between the two springs to ground resistance readings is greater than 20 Or the spring to spring resistance does not read approximately twice the spring to ground 8 0 7 Bleeding the Burner Step Bleedi...

Page 62: ...FUEL PRESSURE GAUGE KIT BLEEDER NOZZLE LINE NUT COPPER FUEL LINE NUT AIR SHUTTER SCREW IGNITION COIL LOCKING TAB FUEL PRESSURE ADJUSTMENT SCREW FUEL PRESSURE GAUGE AIR BAND AIR SETTING AIR SHUTTER AIR...

Page 63: ...the material inside the tank When the tank is empty use an air chisel to remove this built up material Remove as much as possible all around the tank including the roof of the material tank Remove al...

Page 64: ...o the Reverse position Is the agitator moving Yes allow mixer to reverse for 15 seconds and then move the Mixer toggle switch to the Forward position Go to Step 6 No go to Table 8 15 Mixer Electrical...

Page 65: ...e switch bottom post brown wire and nearby ground wire black wire With the Mixer toggle switch in the Forward position See Fig 8 5 Mixer Circuit Yes replace din plug No go to Step 2a 2a Is there 12Vdc...

Page 66: ...wo terminal blocks No go to step 4a 4a Is there 12Vdc between the Material PAKSTAT terminal 2 pink wire and terminal 8 black ground wire Refer to Fig 8 5 Mixer Circuit Yes check for loose connections...

Page 67: ...step 8a 8a Is there 12Vdc between the bottom terminal of circuit breaker red wire labeled RED 2 and nearby ground source black wire Yes replace circuit breaker No go to step 9 9 Is there 12Vdc between...

Page 68: ...EZ 500 Series II Melter Part Manual Chapter 8 Troubleshooting 2019 by Crafco Inc All Rights Reserved Troubleshooting 8 16 Fig 8 4 Checking Din Plug Voltage...

Page 69: ...S BRN MIXER REV 3 WHT RED 3 BLK 16 BLK 1 PNK 2 ORN 1 ORN 1 BLK 4 WHT BLK WHT BLK WHT BLK WHT BLK RED LID RED LID BLU MIXER REV 3 BRN MIXER REV 3 BLU MIXER FWD 4 BRN MIXER FWD 4 BLK GND RED 8 RED 2 ORN...

Page 70: ...move the Mixer toggle switch to the Forward position and read the pressure gauge If the pressure needs to be adjusted use the pressure relief valve labeled RVA loosen the jam nut and adjust the pressu...

Page 71: ...f Set 1000 PSI RVA Agitator Pressure Relief Set 1500 PSI RVHO Hot Oil Pump Pressure Relief Set 800 PSI Jam Nut Allen Screw Fig 8 6 Hydraulic Valve Pressure Setting Agitation Direction Counterclockwise...

Page 72: ...II Melter Part Manual Chapter 8 Troubleshooting 2019 by Crafco Inc All Rights Reserved Troubleshooting 8 20 Mixer Forward Mixer Reverse Pump Reverse Pump Forward Mounting Plate Mounting Tube Fig 8 7 D...

Page 73: ...g NOTE Use Fig 8 9 Hose Circuit Schematic while troubleshooting the hose electrical system Step Possible Cause If 1 Is there 12Vdc between BATT terminal of the generator and a nearby ground source lug...

Page 74: ...o send back the hose for repair 4 Check for continuity in the wand between D E and A NOTE Check between D and E D and A and A and E Yes go to Step 5 No this wand needs to be repaired or replaced Conta...

Page 75: ...d source Yes replace Hose Selector switch No go to Step 9 9 Is there 12Vdc between pink wire labeled PNK 3 on the upper terminal block and a nearby ground source black wire Yes check for loose or brok...

Page 76: ...K 10 WHT 2 BLK 1 BLK 12 WHT 4 WHT 3 BLK 11 BLU 1 PNK 1 PNK 2 ORN 1 PNK 2 BLK 4 WHT 2 BLK 10 WHT BLK WHT BLK 8 5 4 1 14 13 12 9 WHT BLK WHT BLK WHT BLK BLU GEN BLK GND PNK 3 PNK 4 RED 2 ORN 2 ORN 2 RED...

Page 77: ...ing 8 25 HEATER BLACK HEATER WHITE HEATER GREEN SENSOR WHITE SENSOR BLACK TRIGGER GREEN TRIGGER RED HEATER BLUE TRIGGER RED TRIGGER RED SENSOR BLACK SENSOR WHITE HEATER BLUE HEATER BLUE TRIGGER RED TR...

Page 78: ...nected from the terminal block and the trigger depressed to perform this test Yes go to Table 8 26 Basic Visual Pump Troubleshooting No go to Step 2 2 Disconnect the electrical connector between the h...

Page 79: ...08 1 1110 3 1112 4 1114 6 1116 7 1118 9 1121 0 1123 2 90 1125 3 1127 5 1129 6 1131 8 1133 9 1136 1 1138 2 1140 4 1142 5 1144 7 100 1146 8 1149 0 1151 1 1153 2 1155 4 1157 5 1159 7 1161 8 1164 0 1166 1...

Page 80: ...1764 5 1766 6 1768 6 1770 6 1772 7 400 1774 7 1776 8 1778 8 1780 8 1782 9 1784 9 1786 9 1789 0 1791 0 1793 1 410 1795 1 1797 1 1799 2 1801 2 1803 2 1805 3 1807 3 1809 3 1811 4 1813 4 420 1815 4 1817 5...

Page 81: ...pump shaft coupler Is it spinning clockwise Yes shut down machine and look for a plug in the plumbing No adjust the material flow control to increase the flow Still no go to Step 5 5 Inside the contr...

Page 82: ...source not found Step 10 for an Electric Hose No for a Standard Hose is normal because thi i it i t d 2a Is there 12Vdc between green wire labeled TRIGGER GRN in junction box and nearby ground source...

Page 83: ...n red wire labeled RED 4 upper terminal block and nearby ground source black wire Yes replace terminal block No go to Table 8 17 Mixer Electrical Troubleshooting continued steps 9 10a 7 Is there 12Vdc...

Page 84: ...check for loose or broken wire between PAKSTAT and terminal block NOTE This wire has a diode that could be bad and cause an open circuit No go to Step 12a 12a Is there 12Vdc between pink wire on term...

Page 85: ...1 BLU PMP GRN TRIG BRN 3 BLK 11 WHT 3 RED 8 WHT 4 BLK 12 BRN 3 BRN PUMP REV 1 BLU PMP FWD 2 BLK WHT BLK 10 WHT 2 BLK 16 BLK 1 BLK 12 WHT 4 WHT 3 BLK 11 PRP 1 PNK 1 PNK 2 ORN 1 PNK 2 BLK 4 ORN 1 BLK 4...

Page 86: ...hydraulic motor cap off the fitting on the motor and use a 3000 PSI gauge with the proper JIC fitting attach it to the hose Start the Isuzu engine turn ON the main power in the control box pull the w...

Page 87: ...lustrations are designed to show general shape and size of a part and the relationship that part has to other parts Actual size and shape of parts or components may differ or vary from the actual part...

Page 88: ...Manual Chapter 9 Illustrated Parts List 2019 by Crafco Inc All Rights Reserved Illustrated Parts List 9 2 9 2 EZ500 Series II Melter 1 3 5 6 15 19 2 4 8 17 18 20 7 7a 7b 7c 9 10 11 12 13 14 16 22 Fig...

Page 89: ...LIC FILTER ASSEMBLY 1 7a 45438 HYDRAULIC FILTER ELEMENT 1 7b 45440 O RING HYDRAULIC FILTER 1 7c 45497 GASKET HYDRAULIC FILTER 1 8 47202 CONTROL BOX ASSEMBLY ELECTRIC 1 8 47201 CONTROL BOX ASSEMBLY STA...

Page 90: ...elter Part Manual Chapter 9 Illustrated Parts List 2019 by Crafco Inc All Rights Reserved Illustrated Parts List 9 4 27 28 29 38 34 47 48 35 45a 23 24 25 26 27 41 32 33 42 43 44 46 40 31 Fig 9 2 EZ500...

Page 91: ...T 31 46340 SUPPORT ELECTRIC HOSE 1 32 45439 HYDRAULIC PUMP ASSEMBLY EB SB 1 33 20130 SAFETY CHAIN 2 34 46174 FENDER ASSEMBLY 2 35 52200 WAND ASSEMBLY ELECTRIC OPT 36 41629 WAND STANDARD HOSE NOT SHOWN...

Page 92: ...ter Part Manual Chapter 9 Illustrated Parts List 2019 by Crafco Inc All Rights Reserved Illustrated Parts List 9 6 9 3 Series II Melter Options Fig 9 3 EZ500 Series II Melter Options 3 2 10 6 15 1 14...

Page 93: ...100 PROPANE TANK 1 12 27009 20 SEALANT HOSE 1 13 26119 3 8 SAFETY HOOK NOT SHOWN 2 14 26059 BRACKET FIRE EXTINGUISHER 1 15 26058 FIRE EXTINGUISHER W COVER 1 16 24190K HEATER FIREROD 110V 1 16 24194K...

Page 94: ...EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 2019 by Crafco Inc All Rights Reserved Illustrated Parts List 9 8 This page left blank intentionally...

Page 95: ...4 Tank Detail 1 2 7 6 4 5 3 FIG ITEM PART NO DESCRIPTION QTY Fig 9 4 1 46146 PADDLE AGITATOR 2 2 22310 MOTOR HYDRAULIC AGITATOR 1 3 46050 SHAFT ASSEMBLY AGITATOR 1 4 46380 BURNER 14 VOLT DIESEL 1 5 46...

Page 96: ...Manual Chapter 9 Illustrated Parts List 2019 by Crafco Inc All Rights Reserved Illustrated Parts List 9 10 9 5 Plumbing 1 2 3 4 5 6 28 7 8 3 12 11 9 25 26 27 24 23 4 4 4 30 17 16 15 14 18 19 16 20 21...

Page 97: ...NPT X 4 LG 1 11 28060 NIPPLE 2 NPT X 5 LG 1 12 28213 ELBOW 2 PIPE 1 13 29060 GASKET 3 CIRCULAR FLANGED TANK VALVE 2 14 28258 TEE 2 PIPE 1 15 28242 ELBOW 2 45 PIPE 1 16 28358 BUSHING 2 X 1 HEX HEAD RED...

Page 98: ...K 12 WHT 4 WHT 3 BLK 11 ORN 4 GRN BLK YLW RED 6 RED BLU YLW BLK BLK BLU BRN 1 YLW 2 GRY 5 BLK 2 BLU 1 PNK 1 PRP 1 PNK 1 GRY 1 ORN 1 PNK 2 ORN 1 PNK 2 BLK 4 ORN 1 BLK 4 WHT 2 BLK 10 WHT BLK WHT BLK 8 5...

Page 99: ...1 9 51803 MOUNTING RAIL 2 10 51802 END BRACKET 2 11 51800 FEED THROUGH TERMINAL 40 12 51801 JUMPER 2 POLE 3 13 51804 JUMPER 3 POLE 1 14 50251 READOUT DIGITAL 3 15 43391 TEMPERATURE CONTROLLER 150 550...

Page 100: ...RN 4 GRN BLK YLW RED 6 RED BLU YLW BLK BLK BLU BRN 1 YLW 2 GRY 5 BLK 2 BLU 1 PNK 1 PRP 1 PNK 1 GRY 1 ORN 1 PNK 2 ORN 1 PNK 2 BLK 4 ORN 1 BLK 4 WHT 2 BLK 10 WHT BLK WHT BLK 8 5 4 1 14 13 12 9 WHT RED 2...

Page 101: ...OUR METER 1 31 41994 IGNITION SWITCH 1 32 45950 SOCKET CONNECTOR 1 33 45970 WIRING HARNESS EXTENSION 1 34 51698 RIBBON CABLE 5 1 35 51811 SWITCH HOSE SELECTOR 1 36 32522 SWITCH PUMP 1 37 44975 GAUGE W...

Page 102: ...2 BLK 7 BLK 8 WHT RED 3 WHT GRN 3 BLK 16 BLK 1 ORN 4 GRN WHT RED BLK WHT GRN WHT RED BLK YLW RED 6 RED BLU YLW BLK BLK BLU BRN 1 YLW 2 GRY 5 BLK 2 GRY 1 ORN 1 PNK 2 ORN 1 ORN 1 BLK 4 WHT BLK WHT BLK R...

Page 103: ...IL 2 10 51802 END PLATE 2 11 51800 FEED THROUGH TERMINAL 33 12 51801 JUMPER 2 POLE 1 13 51804 JUMPER 3 POLE 2 14 50251 READOUT DIGITAL 3 15 43391 TEMPERATURE CONTROLLER 150 550 1 16 51651 LIGHT 12VDC...

Page 104: ...HT RED 2 BLK 7 BLK 8 WHT RED 3 WHT GRN 3 BLK 16 BLK 1 ORN 4 GRN WHT RED BLK WHT GRN WHT RED BLK YLW RED 6 RED BLU YLW BLK BLK BLU BRN 1 YLW 2 GRY 5 BLK 2 GRY 1 ORN 1 PNK 2 ORN 1 ORN 1 BLK 4 WHT BLK WH...

Page 105: ...9 31 44990 KEY AND TUMBLER 1 31a 41994 IGNITION SWITCH W O TUMBLER 1 32 45950 SOCKET CONNECTOR 1 33 45970 WIRING HARNESS EXTENSION 1 34 51698 RIBBON CABLE 5 2 35 44976 GAUGE OIL PRESSURE OPT 36 44977...

Page 106: ...es II Melter Part Manual Chapter 9 Illustrated Parts List 2019 by Crafco Inc All Rights Reserved Illustrated Parts List 9 20 9 8 Engine Assembly Fig 9 10 Engine Assembly 46100EB SB 1 2 3 4 5 6 7 8 9 1...

Page 107: ...45444U UPPER RADIATOR HOSE 1 3 47138N UPPER RADIATOR ISOMOUNT 1 4 45443N RADIATOR KIT RADIATOR SHROUD FINGER GUARD CAP 1 5 45444L LOWER RADIATOR HOSE 1 6 41872 LOWER RADIATOR ISOMOUNT 2 7 43612 GENERA...

Page 108: ...ssembly FIG ITEM PART NO DESCRIPTION QTY Fig 9 11 1 45418 VALVE ASSEMBLY 2 2 45419 COIL VALVE ASSEMBLY 4 3 45417 VALVE RELIEF 2 4 TEE MALE 8 ORB X 8 JIC RUN 1 5 45413 CAP DUST 2 6 45414 FITTING TEST P...

Page 109: ...Inc All Rights Reserved Illustrated Parts List 9 23 9 10 Material Flow Control Assembly 1 1 1 3 2 Fig 9 12 Material Flow Control Assembly FIG ITEM PART NO DESCRIPTION QTY Fig 9 12 1 29896 3 8 TUBE X...

Page 110: ...lve Assembly FIG ITEM PART NO DESCRIPTION QTY Fig 9 13 1 45417 VALVE RELIEF 1 2 45429 VALVE LOGIC RELIEF 1 3 45426 COIL SOLENOID VALVE 1 4 45424 VALVE SOLENOID 1 5 FITTING 12 ORB X 10 JIC STRAIGHT 2 6...

Page 111: ...EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 2019 by Crafco Inc All Rights Reserved Illustrated Parts List 9 25 This page left blank intentionally...

Page 112: ...er Part Manual Chapter 9 Illustrated Parts List 2019 by Crafco Inc All Rights Reserved Illustrated Parts List 9 26 9 12 Diesel Burner Assembly 9 1 4 6 8 3 5 1 10 11 12 14 13 6 BACK VIEW SIDE VIEW 7 Fi...

Page 113: ...RMER 1 2 41870 CAD EYE NOT SHOWN 1 3 42335 DC CONTROLLER 1 4 41890 BLOWER MOTOR 1 5 41970 COUPLING FUEL PUMP 1 6 41892 PUMP FUEL 1 7 41932 VALVE STEM FUEL SOLENOID 1 8 41933 COIL FUEL SOLENOID 1 9 418...

Page 114: ...EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 2019 by Crafco Inc All Rights Reserved Illustrated Parts List 9 28 This page left blank intentionally...

Page 115: ...27 MOTOR HYDRAULIC 1 2 42071 PUMP ASSEMBLY NON JACKETED 1 2a 29990S PACKING RING SET OF 7 1 3 43129 MOUNTING PLATE ASSEMBLY 1 4 22029 FITTING 10 ORB X 6 JIC STRAIGHT 2 5 42073N PUMP REBUILD KIT SEE NO...

Page 116: ...EZ 500 Series II Melter Part Manual Chapter 9 Illustrated Parts List 2019 by Crafco Inc All Rights Reserved Illustrated Parts List 9 30 9 14 Wand Assembly 1 2 3 4 6 7 8 9 10 Fig 9 16 Wand Assembly...

Page 117: ...DESCRIPTION QTY Fig 9 16 1 52204 COVER WAND 1 2 50278 TIP GUARD LONG CLAMP ON 1 3 52206 CORD ASSEMBLY 1 4 52201RN HANDLE WAND RIGHT W INSERTS GEN2 1 5 52201LN HANDLE WAND LEFT NOT SHOWN GEN2 1 6 52208...

Page 118: ...anual Chapter 9 Illustrated Parts List 2019 by Crafco Inc All Rights Reserved Illustrated Parts List 9 32 9 15 Hydraulic Diagram 2 1 3 4 3 5 2 1 BOTTOM PORT TOP PORT FRONT PORT REAR PORT Fig 9 17 Hydr...

Page 119: ...6128 TUBE HYDRAULIC PRESSURE 1 8M3K 8G 8FJX90S 8G 10FJX 27 HYDRAULIC HOSE 1 29897 FITTING 12 ORB X 8 JIC STR 1 3 HYDRAULIC VALVE AA PORT TO AGITATOR MOTOR REAR PORT 29919 FITTING 6 ORB X 8 JIC STR 1 6...

Page 120: ...lter Part Manual Chapter 9 Illustrated Parts List 2019 by Crafco Inc All Rights Reserved Illustrated Parts List 9 34 2 1 3 6 8 7 9 BOTTOM PORT TOP PORT FRONT PORT REAR PORT 10 Fig 9 18 Hydraulic Diagr...

Page 121: ...OW CONTROL 2 PORT TO HYDRAULIC VALVE TANK PORT 29896 FITTING 8 ORB X 8 JIC STR 1 8M3K 8G 8FJX 8G 8FJX90S 30 HYDRAULIC HOSE 1 29932 FITTING 8 ORB RUN TEE 1 9 HYDRAULIC VALVE TANK PORT TO HYDRAULIC OIL...

Page 122: ...0 Series II Melter Part Manual Chapter 9 Illustrated Parts List 2019 by Crafco Inc All Rights Reserved Illustrated Parts List 9 36 9 16 Diesel Fuel Line Schematic 1 2 3 Fig 9 19 Diesel Fuel Line Schem...

Page 123: ...1 26767 FITTING 5 HOSE PUSH ON 1 1 29591 HOSE 5 16 FUEL LINE 1 2 26080 CLAMP 4 GEAR 2 1 BANJO FITTING REF 2 ENGINE FUEL FILTER UPPER FITTING TO BURNER 1 BANJO FITTING REF 1 29591 HOSE 5 16 FUEL LINE 1...

Page 124: ...RIGGER RED RED TO ENG OIL PRESS SWITCH 18 17 1 16 15 14 12 13 6 11 10 9 8 7 7 5 3 2 4 BURNER PLUG WHITE RED RED BLACK GREEN 45762 HYD OIL COOLER 24000 BATTERY RED BLK RED BLK PUMPING TEMP BATT BLUE WI...

Page 125: ...R 1 4 51835 CABLE ASSEMBLY ENGINE 1 5 51834 CABLE ASSEMBLY SENSOR 1 6 39608 LID SWITCH 2 7 43465 SENSOR RTD 2 8 46791 JUNCTION BOX HOSE 1 9 31512 CIRCUIT BREAKER 1 10 43612 GENERATOR 1 11 43984 CABLE...

Page 126: ...BRN BRN MATERIAL SENSOR HOT OIL SENSOR BLK WHT WHT GRN WHT GRN BLK WHT WHITE WIRE TO TEMPERATURE SWITCH PUMPING TEMP SENSOR WHT BLK SENSOR WHITE SENSOR BLK BLK RED BLK RED BLU BLU BLU BLU WHT RED TO...

Page 127: ...XTENSION 1 3 51836 CABLE ASSEMBLY TRIGGER 1 4 51835 CABLE ASSEMBLY ENGINE 1 5 51834 CABLE ASSEMBLY SENSOR 1 6 39608 LID SWITCH 2 7 43465 SENSOR RTD 2 8 31512 CIRCUIT BREAKER 1 9 43984 CABLE ASSEMBLY V...

Page 128: ...Illustrated Parts List 2019 by Crafco Inc All Rights Reserved Illustrated Parts List 9 42 9 19 Hot Air Lance 16 1 7 1 3 2 1 1 6 1 11 1 8 1 17 1 4 1 9 1 5 1 19 1 18 1 23 1 10 1 15 1 12 4 14 1 13 1 20...

Page 129: ...4 NPT X 1 8 NPT 1 8 45654 PRIMARY BURNER TUBE 1 9 45657 AIR LANCE TUBE 1 10 45668 AIR ORIFICE A 125 1 11 45653 MAIN BURNER TUBE 1 12 45670 SCREW 10 32 X 1 2 ALLEN SCREW 4 13 45672 SCREW 10 32 X 1 2 A...

Page 130: ......

Page 131: ...Disk Assembly 27164 6 Disk Assembly Crafco Swivel Disk Applicator 27120 3 Swivel Applicator 27130 4 Swivel Applicator Crafco Sealing Foot Flush 27154 1 4 Flush 27155 3 8 Flush Crafco Sealing Foot Pro...

Page 132: ...nd Accessories 10 2 Crafco Heavy Duty Squeegee with Aluminum Handle 27199 27195 Replacement Blade Super Shot Drip Stopper Use with 50270 Duckbill 27114 Tip Adapter 27115 Shroud Tip Adapter Crafco Duck...

Page 133: ...r Part Manual Chapter 10 Tools and Accessories 2019 by Crafco Inc All Rights Reserved Tools and Accessories 10 3 Crafco Low Velocity Heat Lance 32259 Crafco Hand Torch W 20ft Hose 25012 W 12ft Hose 25...

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Page 135: ......

Page 136: ...2019 Crafco Inc...

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