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SealMaster Crack Pro 250, Owner'S Manual

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SealMaster Crack Pro 250 Owner'S Manual Download Page 17

17 

 

 

CRACK PRO® MASTIC MACHINE

 

MACHINE MAINTENANCE 

 

 

TROUBLE SHOOTING GUIDE 

 

See oil burner trouble shooting guide for step by step instructions

 

 

 

 

 

PROBLEM 

 
 

DIESEL BURNER 

 HAS LOW OPERATING PSI 

 
 
 
 
 
 
 

BURNER 

DOES NOT LIGHT 

POSSIBLE CAUSES/SOLUTIONS 

PUMP WORN / CHECK AND REPLACE 

FUEL LINE PLUGGED / CLEAN OR REPLACE 

PUMP COUPLER BROKEN / REPLACE COUPLER 

BURNER MOTOR WORN / REPLACE MOTOR 

ELECTRODES WORN AT TIPS / REPLACE ELECTRODES 

ELECTRODES SPACING INCORRECT/ RESET SPACING 

CAD CELL DIRTY / CLEAN GLASS LENS 

WATER IN FUEL / REPLACE FUEL & FILTER 

BURNER IN LOCKOUT / REMOVE NEGATIVE CABLE & REATTACH 

FUEL NOZZLE PLUGGED / REFER TO OWNER’S MANUAL 

AIR SHUTTER MOVED / REFER TO OWNER’S MANUAL 

FUEL FILTER PLUGGED / CLEAN AS NEEDED 

AIR IN PUMP / OPEN BLEEDER 

TRANSFORMER WORN / REPLACE TRANSFORMER 

PRIMARY CONTROL FAILED / REPLACE PRIMARY CONTROL 

FUEL SOLENOID FAILED / REPLACE SOLENOID 

NO POWER FROM CONTROLLER / TRACE WIRES 

HI-TEMP LIGHT IS ON / PUSH RESET 

Summary of Contents for Crack Pro 250

Page 1: ......

Page 2: ...021 docx CRACK PRO MASTIC MACHINE Owner s Manual Version 2 2 Issue Date March 2021 Effective Date March 2021 Version Date Changes Approval 1 0 8 20 Original Issue DS 2 0 10 20 Control Box Tool Box JG 2 1 12 20 Oil Filter Head with Gauge JG 2 2 3 21 Beckett Info Tires JG ...

Page 3: ...TROL 11 PRE OPERATION INSTRUCTIONS 12 CHECKLIST 12 CAUTIONS 13 CLOTHING 13 THINGS TO KNOW 14 FLUID SPECIFICATIONS 15 MACHINE MAINTENANCE 17 TROUBLE SHOOTING GUIDE 17 MAINTENANCE SCHEDULE 19 OPERATING INSTRUCTIONS DIESEL FUEL BURNER 28 CHECK LIST 28 STARTING THE ENGINE 29 THE TEMPERATURE CONTROL 30 ADDING MATERIAL 31 MATERIAL TEMPERATURE 31 AUTOMATIC SAFETY INTERLOCKS 32 APPLICATION OF MATERIAL 33 ...

Page 4: ...PACITY CHART 42 MATERIAL DEPTH AND GALLON VOLUME 42 MACHINE PARTS LIST 43 PICTURE 1 45 PICTURE 2 46 PICTURE 3 47 PICTURE 4 48 PICTURE 5 49 PICTURE 6 50 PARTS LIST FOR TEMPERATURE CONTROL BOX 51 PICTURE 7 51 PARTS LIST FOR DIESEL BURNER 53 PARTS LIST FOR 602 DIESEL ENGINE 54 RECOMMENDED SPARE PARTS LIST 55 LIST FOR DIESEL ENGINE 55 GROSS WEIGHT LIST 55 ...

Page 5: ..._______________________________ Acceptance Date ________________ City _____________ State______ Zip _______ CORRESPONDENCE All Correspondence regarding this equipment as well as general correspondence should be addressed to ThorWorks Industries Inc PO Box 2277 Sandusky OH 44870 In referring to the equipment kindly state the Model Number Serial Number and any part number involved ...

Page 6: ...ed SealMaster representative Any claims for defective material or workmanship must be made prior to the expiration of thirty 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 repai...

Page 7: ...d maintenance of your equipment Read and follow these operating instructions to every detail Make sure the operator is familiar with the units operation CAUTIONS Keep hands feet and clothing away from moving parts Do not operate the machine without all guards in place Never fill the fuel tank with a lit burner WARNING When checking oil levels never check when HOT WARNING When the burner is on DO N...

Page 8: ...8 SAFETY PRECAUTIONS AND CAUTIONS FIRST AID ...

Page 9: ...en flame or sparks 2 Always wipe up any spills immediately 3 Batteries produce explosive gases keep open flame or sparks away 4 Remove all trash or debris from the machine make sure that oily rags or other flammable materials are not stored in or on the machine 5 Check for fuel engine oil and hydraulic leaks replace worn or damaged hoses 6 Inspect electrical wiring for worn or damaged insulation r...

Page 10: ...nt information furnished with the equipment Learn your machines operating and maintenance characteristics capacities and limitations 2 Learn the location and function of all controls indicators and warning devices 3 Be familiar with the safety devices on your machine 4 Learn to recognize the machines warning and safety signals they will alert you to conditions that may make it hazardous to continu...

Page 11: ...e machine and inspect for leaks loose or missing parts damaged parts or parts out of adjustment Perform all recommended daily maintenance TRAFFIC CONTROL Proper traffic control is your responsibility REMEMBER ONLY YOU CAN PREVENT INJURY TO YOURSELF AND OTHERS SAFETY IS YOUR RESPONSIBILITY ...

Page 12: ...ion of the machine and call the factory immediately 419 626 4375 The most important items to check are listed below Check nuts set screws and bolts to assure that no loosening occurred doing shipment Check to be sure the HTO vent pipe is clear and open for venting Located on the HTO expansion tank Check wheel lug nuts torque 100FT LBS after the first 100 miles of travel Never operate machines unat...

Page 13: ...e joint sealing material fumes Do not exceed 10 mph when towing with the burner on Do not operate the machine in the rain Do not pressure wash the burner area in front of the machine Do not work on the machine while it is in operation Do not work on the machine when heat transfer oil has been heated over 90 F Never expose the material tank to an open flame CLOTHING Proper clothing should be worn a...

Page 14: ...STRUCTIONS THINGS TO KNOW Everyone who uses or works on this machine should receive this information Never operate when conditions are wet Allow the machine to dry completely before using it The digital temperature control box houses 12 volts dc ...

Page 15: ...r below SAE 10 or 10w 30 with filter 100 hours Hydraulic oil The hydraulic system should be drained cleaned and refilled every two years If the oil becomes contaminated at any time flush the system immediately The oil filter should be changed yearly The system capacity is 30 gallons Change the hydraulic oil filter after the first 20 hours of operation The factory installed oil meets the following ...

Page 16: ...ometer from the top rear curbside corner Install a funnel here and check with the dipstick Heat Transfer Oil Gallons per Tank Tank Size Gallons 250 30 300 37 DO NOT OVERFILL FILL 4 FROM TOP OVER FILLING WILL CAUSE OIL TO COME OUT THE OVERFLOW VENT PIPE AND ONTO THE GROUND WHEN THE MACHINE IS BEING HEATED Oil coming out of the vent pipe means one of two reasons overfilling or moisture is present in...

Page 17: ...EPLACE MOTOR ELECTRODES WORN AT TIPS REPLACE ELECTRODES ELECTRODES SPACING INCORRECT RESET SPACING CAD CELL DIRTY CLEAN GLASS LENS WATER IN FUEL REPLACE FUEL FILTER BURNER IN LOCKOUT REMOVE NEGATIVE CABLE REATTACH FUEL NOZZLE PLUGGED REFER TO OWNER S MANUAL AIR SHUTTER MOVED REFER TO OWNER S MANUAL FUEL FILTER PLUGGED CLEAN AS NEEDED AIR IN PUMP OPEN BLEEDER TRANSFORMER WORN REPLACE TRANSFORMER PR...

Page 18: ...EAD BATTERY REPLACE BATTERY LOW ON FUEL FILL FUEL TANK PLUGGED FUEL LINE CLEAN FUEL SYSTEM PLUGGED FILTER CHANGE FILTER OVERHEATED HTO CHECK TEMPERATURE CONTROL MOISTURE IN HTO TANK DRAIN AND REPLACE HTO PAST OPERATING LIFE DRAIN AND REPLACE LOW OIL LEVEL CHECK LEVEL AND FILL HYDRAULIC PUMP WORN REPLACE PUMP FILTER PLUGGED REPLACE FILTER TANK VALVE CLOSED OPEN VALVE KINKED HOSE REPLACE HOSE NO POW...

Page 19: ...LEVELS CHECK HTO LEVELS CHECK IGNITORS CHECK HITCH BOLTS CHECK BRAKES CHECK LUG NUTS CHANGE HTO OIL CHANGE HYDRAULIC OIL CHANGE HYDRAULIC OIL FILTER CHANGE DIESEL FILTER CHANGE PRIMARY CONTROL CHANGE SOLENOID CHANGE NOZZLE DRAIN WATER FROM DIESEL FILTER CHECK BREAKAWAY BOX BATTERY CHECK TIRE PRESSURE PACK WHEEL BEARINGS INSPECT ALL HOSES Use a good quality AW68 hydraulic oil with a rating of 352 S...

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Page 28: ... AW68 hydraulic oil 3 Check heat transfer oil level with oil dipstick Use a good quality grade 68 turbine oil or heat transfer oil The heat transfer oil level must always be checked when it is COLD Never attempt to check it when the oil is hot or severe injury could occur NEVER CHECK WHEN HOT 4 Fill burner fuel tank with diesel 5 Completely read and understand all owner s manuals before trying to ...

Page 29: ...draulic valves to the on position Turn the engine switch key to run 3 indicator lights will come on Battery Preheat Oil Pressure Wait until the preheat plug is ready indicator light will turn off then turn engine switch key to start up position FUEL HYDRAULIC VALVES BATTERY OIL PRESSURE PREHEAT RUN START ENGINE SWITCH COOLANT ...

Page 30: ... of the digital temperature controller The digital controllers monitor the heat transfer oil temperature and the material temperature 2 The controller will cycle the burner off and on as the temperature of the heat transfer oil increases and decreases The heat from the transfer oil will be absorbed by the material in the tank TRANSFER OIL TEMP SET POWER CONTROL SWITCH MATERIAL TEMP SET ...

Page 31: ...the specific product 4 Be sure to empty the machine to 1 3 or lower when shutting down for the night Leaving to much material in the machine will result in slower heat up time the next day MATERIAL TEMPERATURE 5 On the top rear Driver side is the thermometer for Heat Transfer oil and Material The thermometer will correspond with the digital readouts on the control box 6 If the material temperature...

Page 32: ...temperature on the respective digital controllers Once the material controller reaches the programmed temperature settings the white interlock light comes on then the agitator will automatically start turning when engaged Opening the lid turns off the agitator When adding material open the lid and place a single block on it and push it closed Do not add more than 4 boxes of material at a time See ...

Page 33: ...l temperature controller should be set for 500 F 9 The material temperature controller should be set for 300 F 400 F Depending on material See the temperature control page for instructions on how to set the controllers TOOL HEATER BOX 10 The Tool Heater Box is equipped with a 5min auto off timer so you don t forget to turn it off while working 11 It also has a full on timer for the jobs that requi...

Page 34: ... the oil to be heated to The burner shuts off when your setting is exceeded by 10 It comes back on when the oil drops to 10 under your setting The sequence for setting 475 temperature is 1 Press the left arrow 4 times then up or down for the 4 2 Press the left arrow again then up or down for the 7 3 Press the left arrow again then up or down for the 5 4 Press SET ARROW SETTINGS BOTTOM SCALE SET TO...

Page 35: ... into position CAUTION ALWAYS WEAR LONG SLEEVE SHIRT GLOVES AND A FACE SHIELD WHEN PERFORMING THIS OPERATION 13 Fill the cracks with appropriate tools 14 To stop for the day perform the following steps Leave the agitator switch on the forward position Turn the power control switch heat switch to the off position Shut off the engine HEAT SWITCH POWER CONTROL SWITCH AGITATOR SWITCH ...

Page 36: ... BURNER INFORMATION CHART MACHINE UNIT HEAD TYPE GPH NOZZLE SIZE NOZZLE HEAD AIR BAND POSITION SHUTTER POSITION MM250 300 TOOL BOX F0 5 80A P662A076 075 0 0 MM250 MAIN BURNER STANDARD 1 65 90B P662A073 024 5 7 MM300 MAIN BURNER STANDARD 2 00 90B P662A064 024 5 7 ...

Page 37: ...37 WIRING DIAGRAMS TEMPERATURE CONTROL BOX ...

Page 38: ...38 WIRING DIAGRAMS TEMPERATURE CONTROL BOX ...

Page 39: ...39 MASTIC MACHINE CONNECTOR J1 ...

Page 40: ...40 WIRING DIAGRAMS ELECTRIC BRAKES AND RUNNING LIGHTS WHITE BLUE BLUE BLUE BLUE BLUE BLACK GREEN BROWN BROWN YELLOW BROWN BROWN GREEN BROWN BROWN YELLOW BROWN BROWN WHITE WHITE ...

Page 41: ...41 WIRING DIAGRAMS ALL THE WIRING COMES OUT OF THE CONTROL BOX TO THE LIGHTS ...

Page 42: ...LLONS 300 GALLONS INCHES GALLONS GALLONS 1 242 290 2 233 279 3 224 269 4 215 258 5 206 248 6 197 237 7 189 226 8 180 216 9 171 205 10 162 195 11 153 184 12 144 173 13 136 163 14 127 152 15 118 142 16 109 131 17 100 120 18 92 110 19 83 100 20 74 89 21 66 79 22 58 70 23 50 60 24 42 51 25 35 42 26 28 34 27 22 26 28 16 19 29 10 12 30 6 7 31 2 2 32 0 0 ...

Page 43: ...Y 250 13 P511A044 2 WHEEL AXLE 14 P74000C226 1 LID WELDMENT 15 P74000B017 1 HTO TANK 16 P518A004 1 BREAK AWAY KIT 17 P519A007 1 7 POLE PLUG 18 P646A003 1 3 PINTLE EYE 19 P517A002 2 CLEVIS HOOK 20 P531A004 2 CHAIN W CLEVIS HOOK 21 P516A033 1 ARROW BOARD 22 P932A001 1 NIPPLE INLET 23 P933A001 1 NUT NIPPLE 24 P735A015 1 REGULATOR HAND TORCH 25 P935A001 2 COUPLER LP 26 P669A005 1 GAS HOSE ASSEMBLY 10 ...

Page 44: ...601A042 1 PUMP HYDRAULIC 49 P519B007 1 WIRE HARNESS 50 P74000B019 1 DIP STICK 51 P679A017 1 THERMOCOUPLE 23 LONG 52 P474A066 1 WHEEL DRIVE NO BRAKE 53 P474A090 1 DRIVE MOTOR 54 P1018A017 12 NORD LOCK WASHER 55 P513A056 5 STUD DOUBLE END M14 X 1 5 56 P1015A018 12 SOCKET HD CAP SCREW M14 X 1 5 57 P474B019 5 FLANGE NUT M14 X 1 5 58 P467A020 2 4 ROUND LIGHT RED 59 P467A010 1 LAMP LICENSE PLATE 60 P709...

Page 45: ...REAK AWAY KIT 17 7 POLE PLUG 15 HTO TANK 41 OIL FILTER 42 FILTER HEAD WITH GAUGE 6 JACK SCREW 12 TIRE WHEEL ASSEMBLY 13 WHEEL AXLE 4 LUG NUT 45 BECKETT BURNER FOR TOOL BOX 60 CLEAR HOSE 37 DIESEL TANK 50 DIP STICK 38 DIESEL CAP 40 HYD CAP 39 HYDRAULIC OIL TANK 68 MASTIC TOOLS ...

Page 46: ...S AND PARTS LIST PICTURE 2 63 LED LIGHTS 8 4 BOLT FLANGE BEARING 46 STROBE LIGHT 21 ARROW BOARD 59 LAMP LICENSE PLATE 44 CHAIN HOOK 61 CHAIN 62 QUICK LINK 5 TEMP CONTROL BOX 58 4 RED LIGHT 1 NIGHT HEATER 64 CHUTE ASSEMBLY 65 DRAIN VALVE ASSEMBLY ...

Page 47: ...ACHINE MACHINE PICTURES AND PARTS LIST PICTURE 3 27 LP GAS HOSE 6 FT 48 HYD PUMP 14 LID WELDMENT 47 LED MARKER LIGHT 18 3 PINTLE EYE 19 CLEVIS HOOK 20 CHAIN W CLEVIS HOOK 31 HAND TORCH ASSEMBLY 32 VALVE NEEDLE 3 DOOR SWITCH ...

Page 48: ...48 CRACK PRO MASTIC MACHINE MACHINE PICTURES AND PARTS LIST PICTURE 4 7 HYD OIL COOLER 49 WIRE HARNESS 29 DIESEL ENGINE 34 ENGINE CONTROL PANEL 35 IGNITION KEY 36 IGNITION SWITCH 67 HOLDER 66 GREASE GUN ...

Page 49: ...MACHINE PICTURES AND PARTS LIST PICTURE 5 22 NIPPLE INLET 23 NUT NIPPLE 24 REGULATOR 25 COUPLER 26 LP GAS HOSE 43 FUEL WATER FILTER 30 BECKETT BURNER MAIN 9 GAUGE 2 HYDRAULIC ASSEMBLY 10 THERMOMETER 51 THERMOCOUPLE 69 THERMOCOUPLE ...

Page 50: ...E PICTURES AND PARTS LIST PICTURE 6 11 2 3 16 PILLOW BLOCK BEARING 52 PLANETARY DRIVE 28 HUB AGITATOR 33 PACKING GLAND 53 DRIVE MOTOR 54 NORD LOCK WASHER 56 SHCS M14 X 1 5 55 STUD DOUBLE END M14 X 1 5 57 FLANGE NUT M14 X 1 5 LOCK WASHER ...

Page 51: ...11 5 TOGGLE SWITCH LIGHTS 5 P735B021 2 SWITCH ASSEMBLY 6 P735B013 1 SWITCH ASSEMBLY 7 P735B012 1 LIGHT GREEN 8 P735B073 1 LIGHT AMBER 9 P735B072 1 SWITCH RED P735B023 1 CONTACT BLOCK CLOSED RED 10 P735B025 1 LIGHT WHITE 11 P735B082 1 TIMER 1 TEMPERATURE CONTROL PANEL 2 DIGITAL TEMPERATURE DISPLAYS 5 SWITCH ASSEMBLY HEATER AND AGITATOR 6 SWITCH POWER ON OFF 10 LIGHT FOR INTERLOCK 9 SWITCH RESET 7 L...

Page 52: ...52 CRACK PRO MASTIC MACHINE APPLIES TO ALL DIESEL FUEL BURNERS PARTS LIST PICTURE DIESEL BURNER 28 29 25 ...

Page 53: ...A043 1 12 VOLT COIL 12 P662A019 1 8 COPPER TUBING 15 P662A018 1 ELECTRODE KIT AIR TUBE COMBINATION 16 P662A014 1 CAD CELL DETECTOR 17 P662A056 1 IGNITER GASKET KIT 19 P662A010 1 BURNER PRIMARY CONTROL 20 P662A015 1 IGNITOR TRANSFORMER ASSEMBLY 22 P662A021 1 FLANGE MOUNTING GASKET FOR AIR TUBE 23 P662A037 1 FLANGE MOUNTING GASKET 24 P662A044 1 MOTOR KIT W BLOWER WHEEL COUPLING 25 P662A076 1 BURNER ...

Page 54: ...NT 36682 P458B203 FUEL FILTER IN LINE 12581 43012 P458B254 FUEL WATER FILTER ASSEMBLY 36691BP P458B232 MUFFLER 15262 12110 P902A022 MUFFLER ME 507 M P458B288 ALTERNATOR 16678 64013 P458B351 FUEL PUMP 1G961 5203 0 P458B230 SWITCH TEMPERATURE 51601 37670 P458B224 STARTER SOLENOID 15852 63020 P458B356 AIR FILTER COMPLETE 1G657 11010 P458B041 SENSOR TEMPERATURE TD2A230RQCGG52 P660A041 BELT GENERATOR A...

Page 55: ...GINE PART QTY DESCRIPTION P458B147 1 FILTER OIL HH150 32430 P458B148 1 FILTER AIR 1G659 11222 P458B264 1 FILTER REPLACEMENT 36682 P458B203 1 FUEL FILTER IN LINE 12581 43012 P458B254 1 FUEL WATER FILTER ASSEMBLY 36691BP GROSS WEIGHT LIST UNIT GROSS WEIGHT LBS 250 5660 300 6160 ...

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