SealMaster CRACK PRO 125 User manual

S:\Engineering\13-Operator Manuals\Current\CRACKPRO_HEATEDHOSE_V2.0_OCT2019.docx

CRACK PRO HEATED HOSE

Owner’s Manual

Version 2.0

Issue Date: Oct. 2019

Effective Date: May 2019

Version

Date

Changes

Approval

1.0

Original Issue

2.0

8/19

New Format and Updates

Table of Contents

CORRESPONDENCE .......................................................................................................................................................5

SealMaster® LIMITED WARRANTY ...............................................................................................................................6

INTRODUCTION .............................................................................................................................................................7

CRACK PRO® HEATED HOSE ......................................................................................................................................7

SAFETY PRECAUTIONS AND CAUTIONS........................................................................................................................8

PRECAUTIONS............................................................................................................................................................8

CAUTIONS..................................................................................................................................................................8

FIRST AID ...................................................................................................................................................................9

CHECK IT OUT ..........................................................................................................................................................10

KNOW YOUR MACHINE ...........................................................................................................................................10

FIRE PREVENTION....................................................................................................................................................10

DRESS FOR SAFETY ..................................................................................................................................................11

LEARN TO BE SAFE...................................................................................................................................................11

WALK AROUND INSPECTION ...................................................................................................................................12

TRAFFIC CONTROL ...................................................................................................................................................12

PRE-OPERATION INSTRUCTIONS ................................................................................................................................13

CHECK LIST...............................................................................................................................................................13

CAUTIONS................................................................................................................................................................14

CLOTHING................................................................................................................................................................14

THINGS TO KNOW ...................................................................................................................................................15

FLUID SPECIFICATIONS ............................................................................................................................................16

SERVICE TIP FOR ENGINE START PUSHBUTTON ......................................................................................................18

A. ENGINE START-UP...........................................................................................................................................18

B. ENGINE SHUT DOWN ......................................................................................................................................18

MACHINE MAINTENANCE...........................................................................................................................................19

TROUBLE SHOOTING GUIDE....................................................................................................................................19

MAINTENANCE SCHEDULE ......................................................................................................................................21

OPERATING INSTRUCTIONS - DIESEL FUEL BURNER ..................................................................................................30

CHECK LIST...............................................................................................................................................................30

STARTING THE ENGINE............................................................................................................................................31

THE TEMPERATURE CONTROL ................................................................................................................................32

ADDING MATERIAL..................................................................................................................................................33

MATERIAL TEMPERATURE.......................................................................................................................................33

AUTOMATIC SAFETY INTERLOCKS ...........................................................................................................................34

APPLICATION OF MATERIAL ....................................................................................................................................35

SETTING TEMPERATURE CONTROL .........................................................................................................................36

POURING MATERIAL................................................................................................................................................37

BURNER INFORMATION CHART ..............................................................................................................................38

WIRING DIAGRAMS ....................................................................................................................................................39

TEMPERATURE CONTROL BOX ................................................................................................................................39

HEATED HOSE MAIN CONNECTOR J1 AND HEATED HOSE J2 ..................................................................................40

ELECTRIC BRAKES AND RUNNING LIGHTS ...............................................................................................................41

MACHINE PICTURES AND PARTS LIST.........................................................................................................................42

PARTS LIST PICTURE-1 .............................................................................................................................................43

PARTS LIST PICTURE-2 .............................................................................................................................................45

PARTS LIST PICTURE-3 .............................................................................................................................................47

PARTS LIST PICTURE-4 .............................................................................................................................................50

PARTS LIST PICTURE-5 .............................................................................................................................................52

PARTS LIST PICTURE-6 .............................................................................................................................................54

PARTS LIST FOR TEMPERATURE CONTROL BOX.........................................................................................................55

PARTS LIST PICTURE-7 .............................................................................................................................................55

PARTS LIST PICTURE-8 .............................................................................................................................................56

WIRELESS WAND CONTROL BOX OPTIONAL..............................................................................................................57

PARTS LIST PICTURE-9 .............................................................................................................................................57

PARTS LIST FOR DIESEL BURNER .............................................................................................................................59

PARTS LIST FOR AIR COMPRESSOR..........................................................................................................................60

PARTS LIST FOR ROPER 2” PUMP ............................................................................................................................61

DIESEL ENGINE PARTS LIST .........................................................................................................................................63

PARTS LIST FOR 1505 DIESEL ENGINE .....................................................................................................................63

PARTS LIST FOR 902 DIESEL ENGINE .......................................................................................................................64

PARTS LIST FOR 602 DIESEL ENGINE .......................................................................................................................65

OPERATING INSTRUCTIONS –DOUBLE PUMPER .......................................................................................................66

TEMPERATURE CONTROL........................................................................................................................................66

WIRING DIAGRAM ...................................................................................................................................................68

HEATED HOSE MAIN CONNECTOR J1 AND HEATED HOSE (J2-TIMES 2) .................................................................69

MACHINE PICTURES AND PARTS LIST DOUBLE PUMPER ...........................................................................................70

PARTS LIST PICTURE-10 ...........................................................................................................................................70

PARTS LIST PICTURE-11 ...........................................................................................................................................72

PARTS LIST PICTURE-12 ...........................................................................................................................................73

RECOMMENDED SPARE PARTS LIST ...........................................................................................................................74

LIST FOR: DIESEL ENGINE ........................................................................................................................................74

LIST FOR: CRACK PRO HEATED HOSE.......................................................................................................................74

ThorWorks Industries, Inc.

Purchased by __________________________ Model NO. _______________________

Company Name _______________________ Serial NO. _______________________

Address ________________________________ 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

SealMaster® LIMITED WARRANTY

SealMaster warrants that its products are of quality material and workmanship. SealMaster

agrees to replace, within a period of one (1) year from date of delivery, or at its option, repair,

without charge, any part of their manufacture which proved defective. The repair or

replacement will be free of charge F.O.B. Sandusky, Ohio, proving the damaged part or parts

are returned, freight prepaid, to SealMaster and investigation show such repair or replacement

is made necessary by an inherent defect of material or workmanship.

It is hereby understood that engines, motors, pumps, or other components purchased by

SealMaster for use on its equipment are not warranted by SealMaster and are sold only with

the standard warranty of the manufacturer of that component.

SealMaster will make no allowances for repairs or alterations completed by outside sources

unless authorization is in writing and approved by an authorized 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 repair of the

defective part or parts. No allowances for damages, lost time, or any other claim will be

recognized.

This warranty is null and void if other than genuine SealMaster parts are used.

SealMaster is constantly striving to improve their products. Changes in design and

improvement will be made whenever the manufacturer believes the efficiency of the product

will be improved, without incurring any obligation to incorporate such improvements in any

machines which have been shipped or are in service.

In an effort to continue to improve product quality, SealMaster reserves the right to change

specifications without notice.

Any modification or alteration of this machine without prior approval of the manufacturer may

void this warranty.

CRACK PRO® HEATED HOSE MACHINE

APPLIES TO ALL DIESEL FUEL BURNER

INTRODUCTION

CRACK PRO® HEATED HOSE

This manual covers the oil jacketed CRACK PRO® model sizes 125, 200, 260 & 400

- gallon models.

Included also is the oil jacketed CRACK PRO® model size 260 double pumper.

Congratulations on the purchase of your new CRACK PRO® HEATED HOSE joint

sealing machine. This machine is manufactured with the commitment of quality

the CRACK PRO® is known for. It is manufactured for high speed melting of joint

sealing material and the shortest melting time for all hot pour materials.

This manual will assist you in the maintenance and operation of your joint sealing

machine for many years.

SAFETY PRECAUTIONS AND CAUTIONS

PRECAUTIONS

Always wear eye and ear protection, long sleeve shirt, face shield

and gloves.

Be aware of all CAUTION, WARNING, and DANGER signs on the

unit.

The high operating temperatures of your joint sealing machine

and materials require special training and 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 NOT exceed 10 mph while

towing, or damage to the burner or machine may occur.

SAFETY PRECAUTIONS AND CAUTIONS

FIRST AID

SAFETY PRECAUTIONS AND CAUTIONS

CHECK IT OUT

Know what protective devices your machine is equipped with and see that

each item is securely in place and in operating condition.

For example:

1. Warning Decals

2. Guards

3. Material hose connections and protective sleeve

4. Grounding wires

KNOW YOUR MACHINE

Have all of the repairs been made that you reported? The most minor

malfunction could be the result of more serious trouble.

FIRE PREVENTION

Avoid fire hazards such as:

1. Always stop the engine when refueling, do not refuel while smoking

or when near an open 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, replace as

needed.

WARNING: LETHAL FUMES!

Engine and burner exhaust gases contain carbon monoxide. Carbon

monoxide is odorless, colorless and can cause death if inhaled. Avoid

inhaling exhaust fumes, and never run the burner or engine in an enclosed

building or confined area. Symptoms of poisoning are:

1. Dizziness

2. Headache

3. Weakness, Sleepiness and Vomiting

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