Patcher II-Rev H May 2019 & up-57870.pdf

For 2016 & Newer Patcher II’s Parts Manual - 57870

Revision H

Fill in the appropriate fields that apply to this machine.

Machine S/N: ___________________________________ 1st Hose S/N: ___________________________________ 2nd Hose S/N: ___________________________________ 1st Pump S/N: __________________________________ 2nd Pump S/N: __________________________________ Engine S/N: ____________________________________ Compressor S/N: ________________________________ Gear Box S/N (Patcher): __________________________ Blower S/N (Magnum): ___________________________

Patcher II Part Manual

Revisions

Revision Description Date A Updated engine power specs 6/14/16

B Corrected Burner Baffle and Diffuser P/N’s on Table 9-11, Added section 9.16 H.C. Pump and Motor Assembly 8/23/16

C Updated warranty; added EAC and CE logos to page 2-3;

Copyright date; added overnight heater extension cord info Table 5-6; Added Section 5.14; Added Section 6.23; Fig 9.11 and Table 9-10 Updated; updated Fig. 5.3

2/19/18

D Removed Hot Tool Box PN 32310 and replaced with Hot Tool Box PN 57450N and Hot Tool Box Burner Assy 57485N .

Updated all related figures and tables to reflect the change.

Updated warranty start to invoice date

7/1/2018

E Table 9-3, Gear box p/n fixed, Table 9-21 Spare tire p/n fixed. 8/7/18

F Updated Prop. 65 information. Added a warning for overnight heater use. Added warnings and figure to section 5.14. Added parts 7 through 15 in Section 9.4.

1/4/19

G Added 44786 Extended Burner Flame Retainer for Main burner to help operation in moist climates in Section 9.9, Fixed P/N error 57475N in Table 9-3.

3/20/19

H Added Towing with Burner On Warning Section 2.5 5/15/19

Machine Views

Machine Views

Table of Contents

Contents

1.0 About This Manual ................................................................................................................ 1-1

How to use this Manual ................................................................................................... 1-1 1.1

2.0 Safety Precautions ............................................................................................................... 2-1

General Safety ................................................................................................................. 2-1 2.1 Personal Safety ............................................................................................................... 2-1 2.2 Equipment or Operational Safety ..................................................................................... 2-1 2.3 California Proposition 65 .................................................................................................. 2-2 2.4

All Crafco, Inc. Equipment ....................................................................................... 2-2 2.4.1 All Crafco, Inc. Equipment using a Diesel Engine .................................................... 2-2 2.4.2

Towing or Driving for Transporting with Burner On .......................................................... 2-2 2.5 Safety Symbols and Notices ............................................................................................ 2-3 2.6

3.0 Limited Warranty .................................................................................................................. 3-1

Warranty Claim Instructions ............................................................................................. 3-2 3.1

4.0 Machine Specifications ......................................................................................................... 4-1

5.0 Operating Instructions........................................................................................................... 5-1

Introduction ...................................................................................................................... 5-1 5.1 Preparing the Machine for Start Up .................................................................................. 5-1 5.2 Starting the Burner........................................................................................................... 5-5 5.3 Altitude Compensation System ........................................................................................ 5-7 5.4 Loading Material into Material Tank ................................................................................. 5-7 5.5 Dispensing the Material ................................................................................................... 5-9 5.6 Shutting Down and Cleaning Out the Machine ............................................................... 5-10 5.7 Storing the Machine ....................................................................................................... 5-10 5.8 Overnight Heaters ......................................................................................................... 5-11 5.9 Hot Applied Patching Material Placement .................................................................... 5-12 5.10 Application Steps ......................................................................................................... 5-13 5.11 Material Tank Depth to Capacity Chart ........................................................................ 5-15 5.12 Removing Optional Heated Chute ............................................................................... 5-16 5.13 Mounting a Skid Machine ............................................................................................. 5-18 5.14

6.0 Maintenance Instructions ...................................................................................................... 6-1

Engine ............................................................................................................................. 6-1 6.1 Hydraulic System ............................................................................................................. 6-1 6.2 Heat Transfer Oil ............................................................................................................. 6-1 6.3

Mixer Packing Gland Seals .............................................................................................. 6-1 6.4 Mixer Shaft Bearings ........................................................................................................ 6-1 6.5 Material Sensor Tube ....................................................................................................... 6-1 6.6 Lug Nuts .......................................................................................................................... 6-1 6.7 Wheel Bearing ................................................................................................................. 6-2 6.8 Brakes ............................................................................................................................. 6-2 6.9 Tongue Jack .................................................................................................................. 6-2 6.10 Water Separator............................................................................................................. 6-2 6.11 Temperature Control Calibration .................................................................................... 6-2 6.12 Maintenance Chart ......................................................................................................... 6-3 6.13 Service Instructions ........................................................................................................ 6-4 6.14 Recommended Fluids and Lubricants ............................................................................ 6-4 6.15 General Maintenance Parts ........................................................................................... 6-5 6.16 Recommended Spare Parts ........................................................................................... 6-5 6.17 Applicable Brands of Heat Transfer Oil .......................................................................... 6-6 6.18 Typical Heat Transfer Oil Specifications ......................................................................... 6-6 6.19 Adjusting the Discharge Gate ........................................................................................ 6-7 6.20 Adjusting and Replacing Mixer Shaft Packing ................................................................ 6-8 6.21 Cleaning Material Tank and Sensor Area ....................................................................... 6-9 6.22 Cleaning the Melter ........................................................................................................ 6-9 6.23

7.0 How to Use a Multimeter ....................................................................................................... 7-1

Checking DC Voltage with a Multimeter ........................................................................... 7-1 7.1 Checking AC Voltage with Multimeter .............................................................................. 7-1 7.2 Checking Resistance (Ohms) .......................................................................................... 7-1 7.3

How to Check Wire Continuity ................................................................................. 7-1 7.3.1 How to Check RTD Sensor ...................................................................................... 7-1 7.3.2

Checking Amperage ........................................................................................................ 7-2 7.4

8.0 Troubleshooting .................................................................................................................... 8-1

Burner Troubleshooting ................................................................................................... 8-1 8.1 Symptom: Burner will Not Ignite ............................................................................... 8-1 8.1.1

Electrical Schematic ......................................................................................................... 8-7 8.2 Testing the DC Controller ................................................................................................. 8-8 8.3 Burner Troubleshooting ................................................................................................... 8-8 8.4 Ignition Coil Troubleshooting ............................................................................................ 8-9 8.5

Bleeding the Diesel Burner .............................................................................................. 8-9 8.6 Smoke Coming Out of the Exhaust Stack ...................................................................... 8-10 8.7 Burner Electrode Adjustment ......................................................................................... 8-11 8.8 Burner Air Settings......................................................................................................... 8-11 8.9 Material is Heating Slowly ............................................................................................ 8-12 8.10 Mixer Troubleshooting ................................................................................................. 8-12 8.11

Symptom: Mixer Does Not Rotate .......................................................................... 8-12 8.11.1 Mixer Hydraulic Troubleshooting .................................................................................. 8-16 8.12 Hydraulic Schematic .................................................................................................... 8-18 8.13 RTD Sensor Ohms vs. Temperature ............................................................................ 8-19 8.14

9.0 About the Illustrated Parts List .............................................................................................. 9-1

Ordering Crafco Parts ...................................................................................................... 9-1 9.1 Patcher II Parts List ......................................................................................................... 9-2 9.2 Fuel and Hydraulic Tanks Parts List ................................................................................ 9-8 9.3 Engine Parts List ........................................................................................................... 9-10 9.4 Hydraulic Schematic and Parts List ............................................................................... 9-12 9.5 Hydraulic Valve Parts List .............................................................................................. 9-16 9.6 Safety Chain Parts List .................................................................................................. 9-17 9.7 Diesel Burner Fuel Line Schematic ................................................................................ 9-18 9.8 Main Diesel Burner Parts List (P/N 46380) .................................................................... 9-20 9.9 Tool Box Diesel Burner Parts List (P/N 57485N) .......................................................... 9-21 9.10 Control Box Parts List .................................................................................................. 9-22 9.11 Electrical Schematic Parts List ..................................................................................... 9-24 9.12 Optional Material Chute Parts List (P/N 56825) ........................................................... 9-26 9.13 Hydraulic Schematic for Optional Heated Chute .......................................................... 9-28 9.14 Optional Heated Chute Parts List (P/N 57783) ............................................................. 9-32 9.15 Heated Chute Pump and Motor Assembly (P/N 41696) ............................................... 9-36 9.16 Patcher II Options ........................................................................................................ 9-38 9.17

10.0 Tools and Accessories ...................................................................................................... 10-1

List of Figures

Figure 5-1 Hydraulic and Diesel Fill Caps ................................................................................... 5-2 Figure 5-2 Hydraulic Fluid Level and Temp Gauge ..................................................................... 5-2 Figure 5-3 Heat Transfer Oil Dipstick .......................................................................................... 5-3 Figure 5-4 Discharge Gate .......................................................................................................... 5-4 Figure 5-5 Mixer Control Switch .................................................................................................. 5-4 Figure 5-6 Mixer Bearings ........................................................................................................... 5-5 Figure 5-7 Engine Control Area .................................................................................................. 5-6 Figure 5-8 Control Panel ............................................................................................................. 5-6 Figure 5-9 Loading Material Using the Lid .................................................................................. 5-8 Figure 5-10 Flow Control Valve................................................................................................... 5-9 Figure 5-11 Material Tank Depth to Capacity Chart .................................................................. 5-15 Figure 6-1 Lug Bolt Tightening Sequence ................................................................................... 6-1 Figure 6-2 Temperature Control Calibration ................................................................................ 6-2 Figure 7-1 Standard Multimeter .................................................................................................. 7-2 Figure 7-2 Clamp-On Amp Meter/Multimeter .............................................................................. 7-3 Figure 8-1 Electrical Schematic (PN 26582) ............................................................................... 8-7 Figure 8-2 Diesel Burner Electrode Adjustment ........................................................................ 8-11 Figure 8-3 Diesel Burner Air Settings ........................................................................................ 8-11 Figure 8-4 Checking Din Plug Voltage ...................................................................................... 8-15 Figure 8-5 Hydraulic Pressure Adjustment Location ................................................................. 8-17 Figure 8-6 Din Plug Layout ....................................................................................................... 8-17 Figure 8-7 Hydraulic Schematic (P/N 26589) ............................................................................ 8-18 Figure 9-1 Right Iso View ............................................................................................................ 9-2 Figure 9-2 Left Iso View .............................................................................................................. 9-4 Figure 9-3 Top Section View ....................................................................................................... 9-6 Figure 9-4 Fuel and Hydraulic Tanks Section View ..................................................................... 9-8 Figure 9-5 Engine ..................................................................................................................... 9-10 Figure 9-6 Hydraulic Schematic (P/N 26589) ............................................................................ 9-12 Figure 9-7 Hydraulic Schematic (PN 26589) (continued) .......................................................... 9-14 Figure 9-8 Hydraulic Valve ........................................................................................................ 9-16 Figure 9-9 Safety Chains .......................................................................................................... 9-17 Figure 9-10 Burner Fuel Line Schematic (PN 26599) ................................................................ 9-18 Figure 9-11 Main Diesel Burner ................................................................................................ 9-20 Figure 9-12 Tool Box Diesel Burner .......................................................................................... 9-21 Figure 9-13 Control Box Parts List (P/N 57856) ........................................................................ 9-22 Figure 9-14 Electrical Schematic Parts List (PN 26582) ............................................................ 9-24 Figure 9-15 Optional Material Chute (P/N 56825) ..................................................................... 9-26 Figure 9-16 Hydraulic Schematic for Optional Heated Chute (P/N 26569) ................................ 9-28 Figure 9-17 Hydraulic Schematic for Optional Heated Chute (PN 26569) (continued) .............. 9-30

List of Figures

Figure 9-18 Optional Heated Chute (P/N 57783) ...................................................................... 9-32 Figure 9-19 Optional Heated Chute Parts List (continued) ........................................................ 9-34 Figure 9-20 Heated Chute Pump and Motor Assembly (P/N 41696) ......................................... 9-36 Figure 9-21 Patcher II Options .................................................................................................. 9-38 Figure 9-22 Patcher II Options .................................................................................................. 9-40

List of Tables

Table 2-1 Safety Symbols and Notices ....................................................................................... 2-3 Table 2-2 Safety Symbols and Notices (continued)..................................................................... 2-4 Table 4-1 Machine Specifications ............................................................................................... 4-1 Table 5-1 Preparing the Machine for Start Up ............................................................................. 5-1 Table 5-2 Starting the Burner ...................................................................................................... 5-5 Table 5-3 Loading Material into the Material Tank ...................................................................... 5-7 Table 5-4 Dispensing the Material .............................................................................................. 5-9 Table 5-5 Shutting Down and Cleaning Out the Machine .......................................................... 5-10 Table 5-6 Overnight Heaters ..................................................................................................... 5-11 Table 5-7 Application Steps ...................................................................................................... 5-13 Table 5-8 Application Steps Continued ..................................................................................... 5-14 Table 5-9 Temporary Removal of Optional Heated Chute ......................................................... 5-16 Table 5-10 Complete Removal of Optional Heated Chute ......................................................... 5-17 Table 5-11 Mounting a Skid Machine ........................................................................................ 5-18 Table 6-1 Maintenance Chart ..................................................................................................... 6-3 Table 6-2 Maintenance Chart (continued) ................................................................................... 6-4 Table 6-3 Service Instructions .................................................................................................... 6-4 Table 6-4 Recommended Fluids and Lubricants ......................................................................... 6-4 Table 6-5 General Maintenance Parts ........................................................................................ 6-5 Table 6-6 Recommended Spare Parts ........................................................................................ 6-5 Table 6-7 Applicable Brand of Heat Transfer Oil ......................................................................... 6-6 Table 6-8 Typical Heat Transfer Oil Specifications...................................................................... 6-6 Table 6-9 Adjusting the Discharge Gate ..................................................................................... 6-7 Table 6-10 Adjusting and Replacing Mixer Shaft Packing ........................................................... 6-8 Table 8-1 Burner Basic Visual Troubleshooting .......................................................................... 8-1 Table 8-2 Burner Electrical Troubleshooting ............................................................................... 8-2 Table 8-3 Testing the DC Controller ........................................................................................... 8-8 Table 8-4 Burner Troubleshooting .............................................................................................. 8-8 Table 8-5 Ignition Coil Troubleshooting ....................................................................................... 8-9 Table 8-6 Bleeding the Diesel Burner ......................................................................................... 8-9 Table 8-7 Smoke Coming Out of the Exhaust Stack ................................................................. 8-10 Table 8-8 Burner Air Settings .................................................................................................... 8-11 Table 8-9 Material is Heating Slowly ......................................................................................... 8-12 Table 8-10 Mixer Basic Visual Troubleshooting ........................................................................ 8-12 Table 8-11 Mixer Basic Visual Troubleshooting (continued) ...................................................... 8-13 Table 8-12 Mixer Electrical Troubleshooting ............................................................................. 8-13 Table 8-13 Mixer Electrical Troubleshooting (continued)........................................................... 8-14 Table 8-14 Mixer Electrical Troubleshooting (continued)........................................................... 8-15 Table 8-15 Mixer Hydraulic Troubleshooting ............................................................................. 8-16

List of Tables

Table 8-16 RTD Sensor Ohms vs. Temperature ....................................................................... 8-19 Table 9-1 Right View Parts List................................................................................................... 9-3 Table 9-2 Left View Parts List ..................................................................................................... 9-5 Table 9-3 Top Section View Parts List ........................................................................................ 9-7 Table 9-4 Fuel and Hydraulic Tanks Parts List ........................................................................... 9-8 Table 9-5 Engine Parts List ...................................................................................................... 9-11 Table 9-6 Hydraulic Parts List ................................................................................................... 9-13 Table 9-7 Hydraulic Parts List (continued) ................................................................................ 9-15 Table 9-8 Hydraulic Valve Parts List ......................................................................................... 9-16 Table 9-9 Safety Chains Parts List ........................................................................................... 9-17 Table 9-10 Main Diesel Burner Parts List ................................................................................. 9-21 Table 9-11 Tool Box Diesel Burner ........................................................................................... 9-21 Table 9-12 Control Box Parts List ............................................................................................. 9-23 Table 9-13 Electrical Schematic Parts List ................................................................................ 9-25 Table 9-14 Optional Material Chute .......................................................................................... 9-27 Table 9-15 Hydraulic Schematic for Optional Heated Chute Parts List ..................................... 9-29 Table 9-16 Hydraulic Schematic for Optional Heated Chute Parts List (continued) ................... 9-31 Table 9-17 Optional Heated Chute Parts List............................................................................ 9-33 Table 9-18 Optional Heated Chute Parts List (continued) ......................................................... 9-35 Table 9-19 Heated Chute Pump and Motor Assembly Parts List .............................................. 9-37 Table 9-20 Options Parts List ................................................................................................... 9-39 Table 9-21 Options Parts List (continued) ................................................................................. 9-41

Chapter 1 Introduction

©2019 by Crafco, Inc. All Rights Reserved…………………………………………………………………Introduction 1-1

1.0 About This Manual

This manual is supplied with each new Crafco Patcher II. The manual assists your machine operators in the proper use of the Patcher II and provides information about the machine’s mechanical functions.

Your Crafco Patcher II is specially made to give excellent service and save maintenance expense.

However, as with all specially engineered equipment, you will get the best results at minimum cost if you:

• Operate your machine as instructed in this manual.

• Maintain your machine regularly as stated in this manual.

How to use this Manual 1.1

This manual is formatted to start each new chapter on the right page. There may be a blank page on the left page if the previous chapter ends on the right page.

If you are viewing this in a digital format (PDF) the following features are available:

1. The Table of Contents, List of Tables, and List of Figures are all hyperlinks, when left mouse clicked on section, table, or figure you will be sent to that page.

2. The blue highlighted text throughout the manual is a hyperlink, when left mouse clicked you will be sent to that page, table, or figure.

3. The panel to the left in the PDF is a bookmarks panel, if you left mouse click on any section/heading in the bookmarks panel you will be sent to that page.

4. There is an attachments icon (paper clip) to the left of the bookmarks, this is where you will find full size prints of the control box, electrical, and hydraulic schematics if available.

Chapter 2 Safety Precautions

©2019 by Crafco, Inc. All Rights Reserved………...……………………………………………….…Safety Precautions 2-1

2.0 Safety Precautions

For more in-depth safety information, please see Safety Manual (PN 26221) which comes with the machine. Or contact your nearest authorized Crafco Distributor at crafco.com/Distributors.

General Safety 2.1

• Crafco, Inc. assumes no liability for an accident or injury incurred through improper use of the machine.

• Read this manual thoroughly before operating the machine.

• Obey all CAUTION and WARNING signs posted on the machine.

• Make sure an operator fully knows how to operate the machine before using the machine.

Personal Safety 2.2

• The high operating temperatures of this machine and the material it contains requires that protective clothing, gloves, hard-soled shoes, and safety glasses or a face shield be worn at all times by operators of the machine.

• Prevent water from going into any part of the machine. If there is indication of water in the heat transfer oil system, warm heating oil to 250-300°F for 2 to 3 hours.

• Bodily contact with hot material or heat transfer oil can cause severe burns.

• If the mixer is not stopped before adding solid material, hot material can get on an operator’s body and cause severe burns.

• Keep hands, feet, and clothing away from all moving parts.

Equipment or Operational Safety 2.3

• Do not operate the machine in buildings or work areas that do not have sufficient airflow.

• Shut down the burner and the engine before refilling the fuel tank.

• Make sure the mixer stops before adding solid material to the material tank. Lift the lid, place the material on the lid and close the lid. The mixer should start automatically.

• Always keep a correctly maintained fire extinguisher near the machine and know how to use it.

• DO NOT heat transfer oil to a temperature of more than 525°F.

• DO NOT put too much heat transfer oil in the reservoir. The expansion of oil while it heats up can cause overflow. With the machine on level ground, check the oil each day before starting the burner. Add oil to the top mark on the dipstick if required (at 70°F). Use only recommended heat transfer oil. Change the oil after 500 hours of machine operation, or one year, whichever comes first.

• Follow the operating instructions for starting and shutting down the burner.

• Calibrate the temperature control knobs after each 50 hours of machine operation. Refer to

Figure 6.2 Temperature Control Calibration.

• Replace any hoses which show signs of wear, fraying or splitting.

• Make sure all fittings and joints are tight and do not leak each time the machine is used.

• Do not leave the machine unattended while the burner is lit.

• Tighten all bolts and screws every 100 hours of machine operation.

http://www.crafco.com/Distributors%20&%20Centers/Distributors%20and%20Centers.htm

©2019 by Crafco, Inc. All Rights Reserved………...……………………………………………….…Safety Precautions 2-2

California Proposition 65 2.4 The state of California currently maintains a list of chemicals that can cause cancer, birth defects or other reproductive harm. Your Crafco, Inc. equipment comes with the following warnings:

All Crafco, Inc. Equipment 2.4.1

All Crafco, Inc. Equipment using a Diesel Engine 2.4.2

Towing or Driving for Transporting with Burner On 2.5 The burner in your Crafco machine is designed for operation only while the unit is parked or towed at slow speeds while applying sealant at a jobsite. When driving or towing this machine for transport, the burner shall be turned off. Operating the burner when transporting the machine is a violation of The Code of Federal Regulations, CFR Title 49, Part 392, Subpart G, 392.67 and may cause damage to the burner and/or machine.

CAUTION

The burner in your Crafco machine is designed for operation only while the unit is parked or towed at slow speeds while applying sealant at a jobsite. When driving or towing this machine for transport, the burner shall be turned off.

©2019 by Crafco, Inc. All Rights Reserved………...……………………………………………….…Safety Precautions 2-3

Safety Symbols and Notices 2.6 Important safety symbols and notices are marked on the machine and in this manual. Failure to comply could result in equipment damage, operational malfunction, serious injury, or death. Please read and comply with all symbols and notices. The table below includes the most commonly used symbols and notices.

Table 2-1 Safety Symbols and Notices

Symbol Item Remarks

WARNING Warning Refers to possible bodily injury or death.

CAUTION Caution Refers to possible equipment damage or operational malfunction.

Severe Burn Hazard Hot material can cause severe burns.

Protective Shoes Wear hard-soled work shoes.

Protective Gloves Wear heat resistant gloves.

Protective Face or Eye Wear Wear face shield or safety glasses.

Body Crush Hazard Do not stand between trailer and hitch when hooking melter to truck.

©2019 by Crafco, Inc. All Rights Reserved………...……………………………………………….…Safety Precautions 2-4

Table 2-2 Safety Symbols and Notices (continued) Symbol Item Remark

Crush Hazard Keep feet and legs clear.

Pinch Hazard Keep hands and feet clear.

Moving Machinery Never reach into moving machinery.

Exhaust Hazard Avoid breathing engine exhaust.

Noise Hazard Ear protection is advisable.

Read Manual Read and understand operator and safety manuals before operating machine.

Chapter 3 Warranty Information

©2019 by Crafco, Inc. All Rights Reserved………...……………………………………………….…Warranty Information 3-1

3.0 Limited Warranty

Crafco, Inc. (Manufacturer), or one of its affiliated distributors, will replace for the original purchaser free of charge any parts found upon examination by the Manufacturer, to be defective in material or workmanship. This warranty is for a period two years from the invoice date, but excludes engine or components, tires, and battery as these items are subject to warranties issued by their manufacturers.

Crafco, Inc. shall not be liable for parts that have been damaged 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 components on the equipment covered above and does not cover labor costs. The warranty does not extend to incidental or consequential damages incurred as a result of any defect covered by this warranty.

All transportation and labor costs incurred by the purchaser in submitting or repairing covered components must be borne by the purchaser. Crafco, Inc. specifically disavows any other representation, warranty, or liability related to the condition or use of the product.

Use of replacement parts other than genuine Crafco parts may impair the safety or reliability of your equipment and nullifies any warranty.

Chapter 3 Warranty Information

©2019 by Crafco, Inc. All Rights Reserved………...……………………………………………….…Warranty Information 3-2

Warranty Claim Instructions 3.1 Crafco, Inc. warrants parts and machinery purchased through Crafco or one of its affiliated distributors for two years from the invoice date. Wear items are not covered under the Crafco, Inc.

limited warranty. A wear item is defined as but not limited to: material pumps, sealing tips, tires, etc.

If parts fail to function within the two years of invoice date, a return authorization number (RA) must be obtained. If the part was purchased through Crafco, Inc., please contact Crafco returns department at Returns@Crafco.com for an RA number or if purchased through a Crafco distributor please contact your distributor.

Note: if the part has a serial number associated with it, for example; a machine or electric hose or wand, this must be furnished when requesting the RA number. The customer will be emailed or faxed an RA form with all instructions to return the item to Crafco, Inc. See example. If the part is found to be within the two year warranty period and has not been abused or modified, a credit will be issued to the customer’s account or credit card. The customer may request the part be replaced instead of a credit, if desired.

Note: 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.

All parts returned are tested and evaluated. If the part has been modified in any way without prior consent from a Crafco, Inc. representative, warranty is void.

Please follow the instructions stated below when calling in a Warranty Claim. Failure to follow these procedures may be cause to void the warranty.

Call your local Crafco Distributor. If you do not know who your local distributor is, call a Crafco Customer Service Representative, (Toll Free 1-800-528-8242) for name, location and telephone number.

On contacting the distributor, be prepared to identify the serial number, model number, engine number, engine manufacturer, and the date of purchase if available.

Should the cause of the malfunction be a defective part, the Distributor will advise you of the procedure to follow for a replacement.

The warranty is valid only for parts, which have been supplied or recommended by Crafco, Inc.

If you have any additional questions regarding warranty repairs and parts, please do not hesitate to call toll free 1-800-528-8242.

For Warranty:

Crafco, Inc.

25527 South Arizona Avenue, Chandler, AZ 85248 Phone: (480) 655-8333 or (800) 528-8242 Fax: (480) 655-1712

For all other inquires:

Crafco, Inc.

6165 West Detroit Street Chandler, AZ 85226 Phone: (602) 276-0406 or (800) 528-8242 Fax: (480) 961-0513 CustomerService@crafco.com mailto:Returns@Crafco.com mailto:CustomerService@crafco.com

Chapter 4 Machine Specifications

©2019 by Crafco, Inc. All Rights Reserved……………………………..…………………….Machine Specifications 4-1

4.0 Machine Specifications

Table 4-1 Machine Specifications

Specification PN 56700

Vat capacity 200 gallons

Heat transfer oil required 35 gallons at 70°F

Tank construction Double boiler type

Tank opening size 1 material opening 16” x 24”

Bucket Opening Size 1 bucket opening 15.5” x 18”

Maximum heat input 370,000 BTUs Burner and temperature control Diesel-forced air thermostatic control

Engine Isuzu Diesel Three cylinder Model 3CJ1 Tier 4

19 HP @ 3000 RPM

Drive Mechanism All hydraulic with infinite forward and reverse speed control

Mixer Horizontal shaft with 4 sweep paddles

Dry Weight Approximately 4,900 lbs.

Shipping Weight Approximately 5,300 lbs.

Diesel Tank Capacity 26 Gallons

Hydraulic Tank Capacity 12 Gallons

Axle Capacity Dual 5,200 lbs.

Tires ST225/75R15, Load Range D

Chapter 5 Operating Instructions

©2019 by Crafco, Inc. All Rights Reserved……………………………..…………………….Operating Instructions 5-1

5.0 Operating Instructions

Introduction 5.1 The Crafco Patcher II was developed to melt Crafco TechCrete, Mastic One, Matrix 501 and PolyPatch products.

Note: DO NOT attempt to operate the machine without using these and all other instructions.

Preparing the Machine for Start Up 5.2 Table 5-1 Preparing the Machine for Start Up

Step Action

Fill the engine fuel tank with diesel fuel.

Note: Refer to the manufacturer’s instruction manual for more specifications on fuel requirements.

2 Check the oil level in the engine crankcase. Refer to the manufacturer’s instruction manual for the engine.

3 Check the hydraulic fluid level while at a temperature of 70°F. Add fluid if necessary.

See Figure 5.2 Hydraulic Fluid Level and Temp Gauge.

With the machine on level surface, check the heat 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 Figure 5.3 Heat Transfer Oil Dipstick

5 Make sure discharge gate is in the closed position. See Figure 5.4 Discharge Gate

6 Place the mixer control switch in the neutral position. See Figure 5.5 Mixer Control Switch

7 Make sure all toggle switches are turned “OFF” and all temperature control dials are set to their minimum settings.

8 Grease both front and rear mixer bearings weekly. See Figure 5.6 Mixer Bearings

9 Make sure the fuel valve on the water separator is set to “ON”.

WARNING

The safe operation of this machine is the operator’s responsibility.

Use extreme care when operating this machine; safety is the result of being careful and paying attention to details. Remember the diesel flame is approximately 2,200°F. Some exposed parts of the machine reach 500°F, the material 400°F, and the hydraulic fluid 200°F.

Always put on protective clothing, gloves, hard-soled shoes, and safety glasses or a face shield. Be sure that all joints and fittings are tight and leak proof. Immediately replace any hose, which shows any signs of wear, fraying, or splitting. Tighten all bolts, nuts, and screws every 100 hours.

©2019 by Crafco, Inc. All Rights Reserved……………………………..…………………….Operating Instructions 5-2

Figure 5-1 Hydraulic and Diesel Fill Caps

Figure 5-2 Hydraulic Fluid Level and Temp Gauge

HYDRAULIC FLUID

FILL CAP

DIESEL FUEL

FILL CAP

©2019 by Crafco, Inc. All Rights Reserved……………………………..…………………….Operating Instructions 5-3

Figure 5-3 Heat Transfer Oil Dipstick

HEAT TRANSFER OIL

DIPSTICK

©2019 by Crafco, Inc. All Rights Reserved……………………………..…………………….Operating Instructions 5-4

Figure 5-4 Discharge Gate

Figure 5-5 Mixer Control Switch

DISCHARGE GATE

SAFETY CHAIN

Mixer Control Switch

©2019 by Crafco, Inc. All Rights Reserved……………………………..…………………….Operating Instructions 5-5

Figure 5-6 Mixer Bearings

Starting the Burner 5.3 Table 5-2 Starting the Burner

MIXER BEARING

GREASE FITTING

USE CRAFCO P/N

56860 HI-TEMP

BEARING GREASE

MIXER BEARING &

GREASE FITTING

Step Action 1 Fully open the exhaust stack cover.

2 Start the engine. Refer to the manufacturer’s instructions for the engine. Insert the key into the control panel near the engine. If the engine is cold, turn the key to the preheater position. Let it warm up for 30 seconds or so. The warning lights should turn “ON”. Turn the key to the second position, and the engine should start. Release the key once the engine is running. Leave at idle when heating up the heat transfer oil. When you are ready to agitate, then move the throttle knob to the desired speed. See Figure 5.7 Engine Control Area

3 Turn the “POWER” toggle switch in the control box to the “ON” position.

4 Set the heat transfer oil temperature at 525°F. See Figure 5.8 Control Panel

5 Set the material temperature to the manufacturer’s recommended temperature.

CAUTION

If the burner does not ignite the first time, turn the “POWER” toggle switch to the “OFF” position. Turn the toggle switch to “ON” again; the burner should ignite. If the burner still does not ignite, refer to Table 8-1 Burner Basic Visual Troubleshooting to determine the cause of the malfunction.

Important: The solid material in the tank melts first around the walls and bottom of the tank. The material temperature sensor is located by the wall, therefore, it is possible that at the beginning of the melting process the indicated temperature reaches operating value, but the material closer to the center of the tank is still solid. This is normal.

6 Allow the heat transfer oil to continue to heat.

©2019 by Crafco, Inc. All Rights Reserved……………………………..…………………….Operating Instructions 5-6

Figure 5-7 Engine Control Area

Figure 5-8 Control Panel

Throttle Lever

Engine Control Panel

Ignition Key

Temperature Dials

Burner Power Switch

©2019 by Crafco, Inc. All Rights Reserved……………………………..…………………….Operating Instructions 5-7

Altitude Compensation System 5.4 This unit may be equipped with an Altitude Compensation System. If so, there will be a small boxed housing mounted right below the engine start key panel on the engine mount cross member. The system is automatic during most operating conditions. However, if the machine is taken from above or below an altitude of 2,624 ft. (800 Meters) while the engine is running, the engine will need to be stopped and then restarted. There is a yellow indicator light that illuminates when the machine is above 2,624 ft. (800 Meters) indicating that the system is active.

Loading Material into Material Tank 5.5 This unit is equipped with a safety interlock system on the loading door. This system disables the mixer hydraulic system when the lid is open. This is a safety feature for the operator and should never be disabled for any reason. Note: Units with the European Spec are not equipped with this system.

WARNING

Personal injury could occur if this safety system is disabled.

Table 5-3 Loading Material into the Material Tank Step Action

WARNING

Following this procedure prevents hot material from getting on operators and causing severe burns.

1 To load material into the material tank, first open the lid.

Note: The mixer stops when the lid is opened to load solid material into the material tank. European Spec units need to manually stop the mixer before opening the lid.

2 Place the solid material on the lid, then close the lid. Add the desired amount of material. Not more than 10 at a time, without mixing and heating the material.

See Figure 5.9 Loading Material Using the Lid

3 Engage the mixer by moving the Mixer Control Switch to clockwise or c’clockwise rotation.

Note: If blocks of solid material are added too quickly, jamming results and slows down the melting process. The mixer control switch can be moved for opposite rotation.

4 The speed of mixing is controlled by the Flow Control Valve. See Figure 5.10 Flow Control Valve. To adjust the speed, rotate the knob to the desired setting.

5 Allow the mixer to continually rotate as you add blocks, and while the machine is in use. It will help keep the aggregate suspended in the mixture.

Note: If you don’t run the mixer, the aggregate will settle to the bottom and produce low quality patches.

CAUTION

A block of material could cause the lid to open while it is mixing. If this happens, it will automatically stop the mixer. You will need to open the lid and use a scraping tool to push it back down in the tank. You may need to change the direction of the mixer using the control switch so it pulls the block back down into the tank after the lid is closed.

©2019 by Crafco, Inc. All Rights Reserved……………………………..…………………….Operating Instructions 5-8

Figure 5-9 Loading Material Using the Lid

©2019 by Crafco, Inc. All Rights Reserved……………………………..…………………….Operating Instructions 5-9

Figure 5-10 Flow Control Valve

Dispensing the Material 5.6 Table 5-4 Dispensing the Material

Step Action

WARNING

Put on protective clothing, gloves, hard-soled shoes, and face shield or safety glasses when operating or filling this machine. Read the entire manual before operating the machine.

Hot material can cause severe burns.

1 Allow the material to reach proper operating temperatures according to the manufacturer. Ensure the mixture is fully melted and mixed thoroughly. Draw off material by moving the handle up on the discharge gate.

Important: The material temperature sensor is located by the wall where the heat is coming from. Because of this factor, the material temperature readout on the control panel could be reading higher than what the majority of the material is actually at. The readout should only be used as a guide. A hand held non-contact infrared thermometer should be used on a sample of dispensed material to determine if appropriate application temperature has been achieved. If the application temperature has not been reached, continue heating until it does.

CONTROL PANEL

FLOW CONTROL VALVE

©2019 by Crafco, Inc. All Rights Reserved……………………………..…………………….Operating Instructions 5-10

Table 5-4 Dispensing the Material (continued)

Step Action 2 Drain material into the patch, pour bucket, shoebox or Hot Mastic Applicator.

3 Remove excess patching material from chute with scraping tool.

Shutting Down and Cleaning Out the Machine 5.7

When shutting down the machine for the day, Crafco recommends emptying all, if not most of the material before shutting down the machine. It will result in faster start up times in the morning, help keep the aggregate from settling at the bottom, and offer better material performance by using fresh material.

Table 5-5 Shutting Down and Cleaning Out the Machine

1 Turn burner toggle switch to “OFF”

2 Return mixer switch to “OFF” position.

3 Idle down the engine with the throttle knob, and turn off engine by turning off the key.

4 Drain un-used material out of discharge gate.

WARNING

DO NOT put the tank scraper tool into the discharge pipe with mixer running.

Serious damage and personal injury will result.

5 Periodically, you will want to use the tank scraper tool to clean out old material from the bottom of the tank.

Storing the Machine 5.8 Store the machine in an area where moisture cannot enter the heating system, i.e. the heat transfer oil tank, etc. Extended down time can cause moisture to build up in the heating tank.

Evidence that moisture has collected in the heat transfer oil is a constant popping noise. If this popping noise is heard, warm the heat transfer oil to 300°F for two to three hours to evaporate the moisture.