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2013 INSTRUCTION MANUAL BK SERIES ALL

1. HIGH PRESSURE RUBBER DIESEL FUEL BURNER TORSION AXLES 80 Bite 01992 29 Description 2013 BK 400 Over all Dimensions MAX 197 LENGTH WILL VARY DEPENDING ON HITCH 170 TOOL DIESEL FUEL STORAGE IN E HEATED T SIDE MOUNTED 248 69 SWIVEL JACK TEMPERATURE CONTROL PANEL HYDRAULIC FLUID TANK date ET DELL se d LOADING HEIGHT HIGH PRESSURE HUBBEH DIESEL FUEL BURNER TORSION AXLES V01993 30 SAFETY PRECAUTIONS Personal Safety Persons responsible for the operation and maintenance of BearCat BK Series All Diesel Krackers should read and understand the following safety precautions and the remainder of this manual before operating the equipment MINA llc cM n c E MEME WARNING THE MATERIALS USED IN THE Kracker ARE NORMALLY HEATED FROM 3004F TO 4504F DURING APPLICATION MATERIALS USED AT THESE TEMPERATURES CAN CAUSE SERIOUS OR FATAL BURNS AND CAN BECOME EXPLOSIVE UNDER CERTAIN CONDITIONS DIESEL FUEL USED IN THE BURNER WHICH HEATS THESE MATERIALS IS HIGHLY FLAMMABLE EXTREME CARE MUST BE EXERCISED AT ALL TIMES TO ASSURE THE SAFETY OF PERSONS WORKING IN PROXIMITY TO THESE POTENTIALLY HAZARDOUS
2. GUN ASSY ELC 24230 MODIFIED TERMINAL BLOCK 4 GANG 5 16 BOLT THRU HOUSING GROUNDING POST 50 57 ADJUST ELECTRODES WITH GAUGE MTR 100107 INSTALL IN BURNER Figure 6 7 Diesel Burner Assembly 96 8 gt Set fuel pressure to 150 psi NOTE FIGURE 6 7 DIESEL BURNER ASSEMBLY ___ 5 memes Gun Assembly Modified ELC 80683 1 ui Fuel Spray Nozzle FIT 80686 mezns Bh Ls 2 mem 55 co moana i 1 Parts 97 2013 FIGURE 6 8 CONTROL BOX ASSEMBLY 5 Control Assembly Conduit Connector 1 2 in NPT 1 2 in 12 ELC 24230 Screw 8 32 X 3 A in FAS 25814 Nut Hex 8 32 FAS 28552 Timer Capsule ELC 80427 Screw 6 32 X 1 2 in FAS 25760 Nut Hex 6 32 FAS 28551 25 Circuit Breaker 30 Amp ELC 24290 Screw 6 32 X 1 2 in FAS 25760 Nut Hex 6 32 FAS 28551 mme 0 serae 1 Ds serae Relay 70 Amp ELC 24270 Hex Bolt 1 4 in 20 X 3 A in FAS 28701 Washer Flat 1 4 in FAS 28632 Washer Lock 1 4 in FAS 28645 Nut Hex 1 4 in 20 FAS 28500 Temperature Control Probe MTR 80702A CENE 1 1 1 1
3. iJ m a Li DSL i 17775 a a z CLOSED CAUTION MAKE SURE ALL VALVES ARE IN THE CORRECT STARTUP POSTION BEFORE THE MACHINE COOLS DOWN APPLICATION RECIRCULATION VALVE 0 TANK VALVE CLOSED WAND VALVE OPEN V02024 70 FIELD MAINTENANCE The recommended field maintenance procedures and scheduled intervals for the care of the BK Series All Diesel Crack Sealing machines are listed in this section Overall productivity of the Kracker is increased and equipment downtime is minimized by carefully following the procedures given in this section In addition the individual component manufacturers literature included in the back of this manual should be followed Perform all diesel engine checks oil and filter changes and other maintenance procedures as recommended by the engine manufacturer Replace the hydraulic system filter element every 500 hours of machine operation as indicated by the hour meter on the temperature control panel 13 2 LJ uveri Hydraulic System Filter 2013 Scheduled Maintenance Table 5 1 lists Kracker maintenance and inspection items and the necessary intervals when they are to be performed Table 5 1 Scheduled Maintenance PERIOD MAINTENANCE AND INSPECTION ITEM Daily Check trailer lights and connectors Check for leaks at hose connections valves and t
4. 88 966 80353 RNG 29054 PMP 80355 PART NO MD Yeas 252 WSs 4 Sg E ET CU Era 1 f NNS gt 1 p 1 2 2 A 1 Ww AUS a LLI 0 lt lt lt o X 7 m a FIGURE 6 LIK lt 91501510 2 2lala 2 5 z z ziz 2 9 Il sl cle OF o 101 o I VI OOF OOF 5151 51 5 L I lt lt e Auger Motor 2013 LO r ise m V01997 We A we 65 DE 60 FIGURE 6 4 CIRCULATION PLUMBING DESCRIPTION QTY eT aes as uk coment Mae Gasket 1 1 2 in RNG 29047 Product Pump BC 110 see Figure 6 5 PMP 81108 60 65 Strainer Kracker HSG 80234 Screen Strainer FTR 80222 Gasket RNG 29046 o _ 91 N gt B 2013 4 AAG NS WS NON Figure 6 5 Product Pump 92 i Plat
5. nui Au L CAUTION DO NOT SET BLOCKS OF MATERIAL DIRECTLY ON GROUND ROCKS AND DIRT WILL STICK TO THE BLOCKS V02013 59 General Operation 2013 STARTING MACHINE AND BURNER POTENTIAL FIRE OR EXPLOSION HAZARDS EXIST WHEN OPERATING THE BURNER DO NOT OPERATE THE BURNER WHEN THE MACHINE IS TOWED OR IS UNATTENDED FAILURE TO FOLLOW THE BURNER OPERATION SAFETY PROCEDURES COULD RESULT IN SEVERE BURNS INJURY OR DEATH 1 Hold key in preheat position count 10 seconds Coil will glow start engine 2 Move throttle control to 3 4 speed to excite alternator then back off to 1 4 to 1 2 speed for most work Allow engine to warm up for approximately one minute 4 Set desired temperature 3 Partially CLOSE hot oil pump bypass valve until engine bogs slightly 5 Switch burner ON Burner has a one minute delay Wait at least 65 seconds PS y my ih D ox 6 When transfer reaches 250 F fully CLOSE hot oil pump bypass valve V02014 60 RECIRCULATING MATERIAL INTO TANK WARNING NEVER LOOK INTO THE SEALANT TANK FROM THE FRONT OF THE MACHINE SEALANT CIRCULATING FROM THE CIRCULATION PIPE OR THE APPLICATION WAND IS PUMPED FORWARD HOT SEALANT MAY SPLASH FORWARD RESULTING IN SEVERE BURNS OR INJURY 1 Wait for burner to cycle off for the first time 20 30 minutes heatin
6. Adjust the throttle until the engine reaches a smooth idle speed Do not let the cold engine hammer m Allow the engine to warm up for one minute After one minute increase the engine speed to the 1 2 position on the throttle and tighten the throttle lock 43 Preparation 2013 Hot Oil Circulation The hot oil pressure switch requires a minimum of 4 psi system pressure to close The burner will not ignite until the sealant heating system is pressurized by the hot oil pump a With the engine running gradually move the hot oil bypass valve to the RUN close position b Make sure the hot oil pump hydraulic motor starts to rotate Stop as soon as the engine RPM begins to drop due to the load placed on the hydraulic system by the hot oil pump usually 1 2 to 3 4 closed The hot oil bypass valve can be moved to the full RUN position once the hot oil reaches the minimum full circulation temperature approximately 250 F as indicated on the hot oil temperature gauge Burner Operation CAUTION BEFORE STARTING THE BURNER POSITION THE MACHINE BROADSIDE TO THE WIND TO ALLOW THE WIND TO CARRY EMITTED VAPORS AWAY FROM THE HOT EXHAUST STACK OF THE ENGINE FAILURE TO DO SO CREATES AN EXPLOSION HAZARD The diesel fuel burner is used to heat the hot oil which is circulated in the sealant heating system The burner requires the following five inputs before it can light e Ignition switch ON e Burner ON OFF switc
7. LAC S 5 Lay hose on the ground 4 Place product pump in REVERSE 67 General Operation 2013 CLEAN OUT PROCEDURE cont 6 Raise application wand assembly overhead 7 OPEN CLOSE application wand valve 10 12 times DO NOT SHORTCUT THIS STEP 8 Meanwhile have helper lift hose and slowly walk back to the machine to drain hose SA lt N A i 3 B Y TA A ato V02022 CLEAN OUT PROCEDURE cont WARNING ALWAYS REVERSE THE PRODUCT PUMP AND CLOSE THE APPLICATION WAND VALVE BEFORE REMOVING THE HOSE ASSEMBLY FROM THE HOSE THROUGH OR RETURNING THE HOSE ASSEMBLY TO THE HOSE TROUGH 9 CLOSE the application wand valve and return the hand wand to the hose trough Put the hose assembly in the hose trough and make sure the hose is under the trough cover 10 Move the application recirculation valve to 0 wait one minute before proceeding 12 Quickly move product pump control valve to NEUTRAL General Operation 13 OPEN hot oil pump bypass valve 14 Turn augers off NEUTRAL V02023 69 2013 CLEAN OUT PROCEDURE cont 15 Throttle at IDLE for one minute to allow engine to cool 16 Turn key OFF 17 Store hose and wand on machine in hose trough Leave wand valve in the OPEN position to lock wand a Lily d 4 LL al
8. 2 in thick mineral wool panel insulation equal to 3 1 2 in of fiberglass at 400 F moisture absorption rate less than 1 Wrapped with 16 gauge hot roll steel Circulating Augers Two hydraulically driven right hand spiral circulating augers one on each side of the sealant tank Packing Glands High temperature leak proof packing gland on each end of the auger shafts Product Pump Circulation Plumbing 3 way valve allows variable circulation of sealant material to tank or through the application wand Material Screen Application Wand and Hose Hose Trough Wand Return Tube 2 in positive displacement pump with hydraulic bi directional variable speed control Located below pump intake prevents any foreign objects from entering pump mechanism Accessible for daily clean out Description Insulated hose enclosure heated by heat trace portion of hot oil system Capable of heating and clearing a clogged hose Insulated hose enclosure heated by heat trace portion of hot oil system Capable of heating and clearing a clogged hose Located at rear of unit allows continuous circulation of sealant through application wand into tank when sealant is not being applied Wand Lockout Secures application wand in return tube or hose trough the hose Flushing Requirement Product pump inlet plumbing tank valve and hose trough are heat traced with hot oil The heat trace
9. SYSTEM COMPONENTS OPERATE AT THEIR RATED PRESSURES FAILURE TO CHECK THE CONDITION OF ALL HOSES AND CONNECTIONS WHEN PUMPING COULD RESULT IN SEVERE BURNS INJURY OR DEATH FROM PUMPING ERRORS MADE WITH FAULTY COMPONENTS f The sealant material in the Kracker sealant tank must be heated to a partial liquid state before the sealant material can start to circulate in the sealant tank 42 CAUTION THE SUCTION AND RETURN LINE GATE VALVES FOR THE HYDRAULIC RESERVOIR MUST BE OPEN AND WIRED IN THE OPEN POSITION DO NOT START THE ENGINE WITH EITHER VALVE CLOSED FAILURE TO DO SO WILL CAUSE THE HYDRAULIC FILTER TO BURST CAUTION DO NOT TO START THE ENGINE UNTIL THE INITIAL CHECKOUT OF MACHINE PROCEDURES IN THIS SECTION ARE PERFORMED Diesel Engine Startup g Loosen the throttle lock on the engine and let the throttle linkage float during engine start h Position the IGNITION switch on the engine control panel to PREHEAT Wait approximately 10 seconds for the glow plugs to heat i Rotate the IGNITION switch to the START position and release it when the engine starts j Increase the engine speed to the 3 4 throttle position for a few seconds and then reduce the engine RPM back to idle The initial RPM increase is required to excite the engine alternator charging circuit and initiate battery charging k Check the temperature charge and oil warning lights on the engine control panel Make sure the warning lights go out
10. cover and contains the following components e Burner ON OFF switch Beacon switch e Partlow temperature control Hour meter BURNER SWITCH HAS The burner ON OFF switch Missio on starts the burner ignition sequence The burner ignition system has a built in one minute delay which allows the electrically heated injection nozzle to preheat the diesel fuel prior to ignition The preheat sequence eliminates burner backfires 37 2013 switch controls the amber safety top of the machine The Partlow temperature control is used to set sealant material temperature The upper indicator on the control is set to the desired sealant material pour temperature set point by rotating the knob on the face of the control The pour temperature is usually determined by the sealant manufacturer s specification The lower indicator shows actual sealant material temperature within the sealant tank pot temperature The hour meter records actual engine run time in hours The hour meter enables accurate tracking of run time for scheduled maintenance such as engine oil changes Directional Control Valves The directional control valves provide bi directional variable speed control of the auger and product pump motors Each valve has a center detent or NEUTRAL position Moving the handle in either the indicated FORWARD or REVERSE direction provides proportional speed control of the hyd
11. procedures are performed with the hot oil bypass valve in the STOP position 14 sealant heating system is closed controlled flow heating system which utilizes a high pressure diesel fuel burner to heat the heat transfer oil hot oil Diesel fuel for the burner is drawn from the Kracker fuel tank The hot oil is circulated through the heating system by the hot oil pump Heat transfer from the NEN Sealant Heating System hot oil is used to heat the sealant material to the temperature necessary for application The system designed hot oil circulation rate eliminates any localized hot spots within the hot oil system Description V01987 The elimination of hot spots within the heating system reduces hot oil breakdown and product coking on the heating coils The sealant heating system completely isolates the sealant tank from any direct contact with the hot gases produced by the burner The primary heating coil is surrounded by a heating chamber The heating chamber is enclosed by a hot oil filled outer jacket heat jacket heat related contact with the sealant material is accomplished through the Kracker sealant heating system The hot oil from the sealant heating system is also circulated through a heat trace system used to heat the hose trough the product pump and product related plumbing 15 2013 The diesel fuel burner is a sealed self contained unit The burner
12. 1 99 Parts Schematics 2013 OL pe SS HOLON oa NO ASSV 31ZZON H31V3H OL 9I 8 OL H3NHf8 OL WWL 8 HOLIMS 30 248 1VNIWH3 L GION31OS udldvis lH9 Il IVL 1231 anova 01 463 OL LH N 1391 01 4 01 48 OL ONY m e t s NOOV38 OL ISNA S H3XvH8 HOLIMS HUS 0 NOILINSI 2 gt 1290 s adh g 209 948 ROMS 34065344 110 OL 110A2L Control Box Schematic 100 HOLIMS 11 8 ct a 06 qaad qaad 3 vug ang T TOT MOTISA poy NHn1 1431 HOLIMS Xog 1 1 5 HH 5 1 Lights and Brakes Schemat 101 320 0 1uvis 1V3H 3Hd NOILISOd A35 1 16 JV3H 3H
13. 7 Move the application recirculation valve from 0 position to the 10 position 8 CLOSE the application wand shutoff valve and remove the application wand from the application wand return tube and retaining bracket assembly 9 Remove the application wand hose from the hose boom and lay the hose out straight on the ground WARNING ALWAYS KEEP THE APPLICATION WAND POINTED AWAY FROM ALL PERSONNEL FAILURE TO DO SO COULD RESULT IN SEVERE BURNS INJURY OR DEATH 10 Raise the application wand overhead With the nozzle pointing up cycle the shutoff valve OPEN and CLOSED 10 to 12 times An audible sucking sound should be heard from the nozzle when the hose starts to clear General Operation 11 With the shutoff valve OPEN and the wand raised have a helper raise the hose and slowly walk the hose toward the machine to let the hose drain sealant down into the ma chine 12 CLOSE the application wand shutoff valve and place the application wand in the application wand return tube and retaining bracket assembly 13 OPEN the left hand sealant loading door 14 Remove the application wand from the application wand re turn tube and place the application wand in the hose trough 15 CLOSE the left hand sealant loading door 16 Install the external cap on the application wand return tube 53 2013 17 18 19 20 Place the application wand hose into the hose trough Close the hose trough door and mak
14. CONDITIONS Safety WARNING FOLLOW THESE PRECAUTIONARY INSTRUCTIONS EXACTLY DO NOT TAKE SHORTCUTS DO NOT ASSUME THAT SOMEONE ELSE HAS ACTED ON YOUR BEHALF IF ANY RULE OR PRECAUTION IS NOT CLEAR TO YOU SEE YOUR SUPERVISOR BEFORE USING THE MACHINE Safety Rules Read each safety rule and make them a part of the daily work routine General Protection WARNING EXHAUST SPARKS FROM AN ENGINE CAN IGNITE VOLATILE GASES FROM THE SEALANT MATERIAL ALWAYS KEEP A DRY CHEMICAL FIRE EXTINGUISHER FULLY CHARGED AND ON HAND AT ALL TIMES Protect yourself e ALWAYS make sure the return and suction line gate valves at the front of the hydraulic reservoir are wired OPEN before starting the engine A closed valve will cause the hydraulic filter to burst e NEVER start the engine until you have read and understand the operating manual e ALWAYS wear suitable insulated gloves and 2013 clothing long sleeve shirt long pants and coveralls when touching any part of the equipment e ALWAYS wear suitable safety glasses and a face shield ALWAYS keep your body and clothing clear of rotating drive parts Potential Explosive Fire Hazard Conditions WARNING FAILURE TO COMPLY WITH THE FOLLOWING SAFETY RULES MAY RESULT IN A FIRE OR EXPLOSION THAT COULD CAUSE SEVERE BURNS INJURY OR DEATH e NEVER allow lighted cigarettes any burning material near open loading doors or vents e NEVER attempt to light the burner with any t
15. NOLLISOd IWNIWYSL ALIOVdVD 151405 3718911 NOILO3NNOO ae 9 8 1016 3108 z 4015 05 a ai 1304 4 4 2 uH D i 5 40 HOLIMS uO1VU3N35 10 H31HV1S ways uos HOLIMS 4 N3dO 1TVWHON es HOLIAS 1 18 INIT 791513 JONVISIS3H 7041405 He a 1 gt NO dWv1 Diesel Engine Schematic 102 50020 YOLOW IVNOILO3HIQ llO LOH HIOAH3S3H 1 SSVdAg8 83113 Q O3INV IW Ol Ia vHaAH ALldOldd 910713 3AT1VA OH1lNOO TWNOILOAYIG 33139 Hydraulic System Flow Diagram 103
16. air pressure to purge any remaining hot oil from the sealant heating system Remove the air hose from the quick coupling 7 A diagram of the hot oil replacement setup for Kracker This portion of the procedure will effectively drain the hot oil from the sealant heating system To refill the system with new oil perform the following steps a 76 Remove the pipe bushing and male quick coupling from the 90 degree elbow on the hot oil expansion tank Install the overflow line and straight fitting in the hot oil expansion tank 90 degree elbow Install the flex line fitting on the drain valve heat jacket fitting Remove the filler cap located on the top of the hot oil expansion tank Start the hot oil pump DO NOT START THE BURNER Add hot oil until the expansion tank is full Allow the hot oil pump to run for 15 minutes and check the expansion tank cold level sight glass CAUTION THE HOT OIL EXPANSION TANK SHOULD CONTAIN APPROXIMATELY A 4 INCH DEPTH OF HOT OIL COLD SYSTEM DO NOT OVERFILL g Add hot oil as necessary to maintain a visible level in the lower sight glass of the hot oil expansion tank h Shut down the hot oil pump and diesel engine Replace the hot oil expansion tank filler cap i Check the flex line to drain valve heat jacket fitting for leaks NOTE When the burner is operated for the first time after the hot oil replacement procedure some hot oil may
17. at the rear of the Kracker Emi The hot oil is pumped through the primary heating coil into the right hand circulating auger heating coil to heat the sealant material The circulating auger heating coil turns are spaced to allow melted sealant material to flow through them However large pieces of un melted sealant material cannot pass between the coils and jam the rotating auger blades Description Circulating Auger Heating Coil The hot oil is circulated through the circulating auger heating coil and back into the heat jacket The hot oil is circulated through the heat jacket for additional heat transfer to the hot oil The hot oil exits from the left side of the heat jacket and is circulated through the left hand circulating auger heating coil to provide sealant material heating in the left side of the sealant tank The BK 400D has an additional heat transfer coil in the forward portion of the sealant tank The added sealant material heating capability ensures fast and efficient heating operation with the larger capacity sealant tank The hot oil is circulated from the left hand auger heating coil and into the hot oil manifold assembly The hot oil pump draws the hot oil from the manifold assembly and begins the heat transfer and circulation cycle again The sealant heating system uses a hot oil expansion tank located on top of the sealant tank to contain the hot oil as it is heated The hot oil expansion tank has a capacity equ
18. contains an integral high pressure A diesel fuel pump a solid state igniter and a cage type blower The diesel fuel is pressurized to approximately 150 psi and injected into the burner head through an atomizing nozzle The atomized fuel is ignited and the hot gases are forced out of the burner by the blower The diesel fuel burner blows the hot gases through the inside of the hot oil filled primary heating coil The direct heat from the burner provides the initial heat transfer to the hot oil system The primary heating coil is surrounded by the heating chamber which contains the hot gases after they exit the heating coil When the hot gases exit the end of the heating coil they are deflected back over the outside of the heating coil by a refractory material bulkhead which closes the end of the heating chamber Circulating the hot gases over the outside of the heating coil provides additional heat transfer to the hot oil Heating Chamber and Coils surrounding Mixing Augers The heating chamber is constructed with hot oil filled outer heat jacket The hot oil is circulated through the heat jacket to provide additional heat transfer to the hot oil and indirect heating to the sealant material By containing the hot gases in this manner near maximum theoretical heat transfer from the burner to the hot oil is accomplished The hot gases circulate through the heating chamber and exit through two exhaust stacks
19. f Make sure the fuel feed valve for the burner is OPEN and the flush fuel valve is CLOSED NOTE No 2 grade diesel fuel will start to gel at temperatures below 50 F If the Kracker is operated at temperatures below 50 F use No 1 grade diesel fuel If No 1 diesel fuel is not available mix 80 JET A fuel with 20 No 2 diesel fuel JET A fuel is available at most airports 39 2013 0 Make sure fluid levels are adequate Add fluid if necessary e Engine oil the dipstick is located on the left side of the engine Radiator coolant check the coolant level in the radiator overflow tank Diesel fuel check the fuel level in the fuel tank CAUTION USE EITHER TYPE 32 OR TYPE 46 HYDRAULIC FLUID IN THE HYDRAULIC RESERVOIR DO NOT MIX FLUID TYPES Hydraulic fluid the sight glass is located on the forward end of the hydraulic reservoir e Heat transfer oil hot oil the hot and cold level sight glasses are located on the left side of the hot oil expansion tank CAUTION THE SUCTION AND RETURN LINE GATE VALVES FOR THE HYDRAULIC RESERVOIR MUST BE OPEN AND WIRED IN THE OPEN POSITION DO NOT START THE ENGINE WITH EITHER VALVE CLOSED FAILURE TO DO SO WILL CAUSE THE HYDRAULIC FILTER TO BURST h Make sure the gate valves on the hydraulic reservoir are fully OPEN and are wired in the OPEN position i Position the IGNITION switch on the engine control panel to OFF j Position the BURN
20. of the door The loading shelf keeps the block of sealant material from falling into the sealant tank until the door is closed This design prevents hot sealant from splashing out of the tank during material loading The sealant loading doors are equipped with DOT approved safety latches for transportation of elevated temperature materials The safety latches may also be locked for added safety or security reasons The sealant tank contains two hydraulically driven circulating augers The circulating augers rotate inside the circulating auger heating coils The design assures splash free horizontal circulation of the 20 sealant material within the tank The heating coils prevent blocks of unmelted sealant material from jamming the circulating augers The circulating auger shaft is equipped with a leak proof high temperature packing gland The special packing gland reduces the need for periodic repacking and prevents sealant leakage during operation Sealant Plumbing The product pump is a positive displacement pump which is driven by the product pump hydraulic motor The product pump directional control valve is used to set pump rate or speed and direction forward reverse Hot oil from the sealant heating system is circulated through the product pump heating jacket The hot oil is also used to heat the product tank valve the tank and pump drain valve and related plumbing Any frozen sealant material within the
21. related blockages Continuous sealant material circulation also maintains sealant material consistency With the application recirculation valve in the 0 position all sealant material is circulated back into the sealant tank With the application recirculation valve moved to approximately the 10 position maximum sealant material flow is directed to the application wand Sealant Application Wand The sealant material is pumped through a 20 foot long high temperature hose to the application wand The hose has a high temperature outer cover to protect it from the heat trace lines located inside the hose trough The aluminum application wand is connected to the hose with a swivel joint to prevent binding and permit tangle free operation The application wand has two insulated 22 handles and insulated section between the handles The rear handle of the application wand is also the application wand shutoff valve The shutoff valve is a 1 4 turn ball type valve which allows precise control of the sealant material during application The Kracker is equipped with an application wand return tube The return tube allows continuous circulation of the sealant material HERI through the application wand and back into the sealant tank Circulating hot sealant material through the application wand and hose eliminates any frozen sealant material blockage problems during sealing operations Place the application wand in the
22. return tube and open the shutoff valve when the sealant wand is not in use The application wand retaining bracket located below the return tube secures the application wand during wand to sealant tank circulation As an aid to safe operation the application wand cannot be installed or removed from the retaining bracket unless the shutoff valve is in the CLOSE position Description Hose Trough Optional The application wand and hose are stored in the hose trough during transportation and initial sealant material heating The heated hose trough contains heat trace lines from the sealant heating system Hot oil from the sealant heating system is circulated through the hose trough heat trace lines to heat the application wand and hose The hose trough is insulated and is constructed with a flexible access cover to help retain the heat The heated hose trough is capable of melting the residual frozen sealant material within the application wand and hose in a minimum amount of time The hose trough is designed to allow sealant material circulation through the application wand and hose while the application wand is positioned in the hose trough Two cutouts in the side of the hose trough provide clearance for the application wand handles The cutout for the rear handle has a retaining bracket for the shutoff valve For safety purposes the application wand shutoff valve must be in the CLOSE position before the wand can be removed or p
23. work shift is minimized when the sealant tank is kept full Preparation Following Extended Shutdown If the Kracker is shutdown for two or more days the following preparation will allow normal startup for the next work shift On the day before the normal work shift start the hot oil pump and the burner in accordance with the procedures given in PREPARING EQUIPMENT FOR USE SECTION DO NOT run the circulating augers or the product pump After one hour shut off the burner and the hot oil pump and shut down the machine The heat will diffuse through the sealant material overnight and normal startup procedures may be used the next day 55 2013 Quick Reference Operating Guide The following illustrated operating guide is provided as an aid to Kracker operation The illustrated guide is meant to supplement the setup and operating instructions provided in this manual not replace them The operator must be trained and familiar with all safety and operating information given in this manual prior to performing any crack sealing operations A separate copy of this quick reference operating guide is provided for use on the machine Replacement copies of the operating guide are available from BearCat Wear Safety Glasses and Face Shield Wear Insulated Gloves Wear Protective Clothing long sleeve shirt pants boots and coveralls Avoid Fire or Flame Near Machine CHECKOUT MACHINE BEFORE ST
24. 2013 INSTRUCTION MANUAL BK SERIES ALL DIESEL KRACKER Hot Rubberized Crack Filling Machine BearCat Mfg Inc 3650 Sabin Brown Road Wickenburg AZ 85390 Phone 928 684 7851 Fax 928 684 3241 2013 September 10 2013 Unit Serial Number Date of Service Customer www bearcatmfg com This manual describes the BK Series All Diesel Kracker as it is normally delivered to the user Due to a continuing program of product improvement changes may be made in equipment delivered at a later date Every attempt is made to keep users fully informed of such changes d WARRANTY AND CLAIM PROCEDURES LIMITED WARRANTY Emm BearCat Mfg Inc hereinafter referred to as BearCat extends to the original purchaser user of the BK Series All Diesel Kracker the following warranty covering goods manufactured by BearCat and subject to the following qualifications The warranty applies only when the product Intro 1 1 properly used and maintained in accordance with BearCat instructions governing agencies or associations 2 1 being operated under proper fuel and or cargo specifications 3 15 not subjected to corrosive or abrasive atmosphere or materials 4 not been damaged through malice or ignorance 5 not been subjected to flood lightning accidents misuse neglect or unauthorized modification repair or service Parts replaced under this warranty are warranted only throug
25. 51 Diesel engines stalls or runs Malfunction or mis Refer to engine poorly adjustment in engine manufacturer s literature 82 Table 5 6 Troubleshooting cont Circulating augers do not rotate Product pump does not rotate Sealant material does not flow Hot oil pump does not rotate 1 Auger directional control set too low 2 Cold sealant 3 Lack of hydraulic pressure due to a Insufficient hydraulic fluid b Hydraulic valve closed c Malfunction in hydraulic pump motor or directional control valve 1 Cold sealant 2 Lack of hydraulic pressure due to a Insufficient hydraulic fluid b Hydraulic valve closed c Malfunction in hydraulic pump motor or directional control valve 3 Malfunction in product pump 1 Cold sealant 2 Application recirculation valve setting incorrect 3 application wand or hose 4 Damaged or worn valves 5 Worn product pump 1 Hot oil bypass valve open 2 Malfunction in pump hydraulic motor Increase to higher setting 1 2 Allow sealant to heat 3 a Check fluid level Add fluid as necessary b Open hydraulic valve Check components repair as necessary Consult factory technical support 1 Allow sealant to heat 2 a Check fluid level Add fluid as necessary b Open hydraulic valve Check components repair as necessary Consult factory technical support 3 Check produc
26. ARTING 1 Heat Transfer oil Hot oil sight glass Cold oil sight glass e roua2 se ecd 5 2 Diesel Fuel 3 Engine Coolant gt lt gt zw Y P 5 i 9 4 N EM s 4 Hydraulic Fluid 5 Make sure valves are wired OPEN 7 Fire Extingisher 6 Engine Oil 57 2013 BEFORE STARTING ENGINE CHECK VALVES 1 Aplication Recirculation Valve at 0 A 6 A yd m mal I Jed o Fx S E 9 4 2 Pump Control X Valve NEUTRAL 4 Tank Valve CLOSED 3 Drain Valve CLOSED Lf DAN SPN a q 3 2 5 Hot Oil Pump Bypass Valve OPEN 6 Auger Control Valve NEUTRAL 58 CHECK AND LOAD MATERIAL 1 For best results ALWAYS place application hose in hose trough whenever stored or transported 21 CAUTION CHECK HOSE DAILY FOR SIGNS OF WEAR OR DAMAGE WARNING DO NOT LOAD SEALANT MATERIAL INTO THE SEALANT TANK WITH BOTH LOADING DOORS OPEN HOT SEALANT MATERIAL WILL SPLASH OUT OF THE OPEN DOOR HOT SEALANT MATERIAL CAN CAUSE SERIOUS OR FATAL BURNS 2 Place blocks of material on lid then close lid allowing block to drop into tank 3 For maximum production keep tank full at all times OD
27. ER switch on the temperature control panel to OFF 40 Make sure the hot oil bypass valve is the STOP open position CAUTION THE VALVES LISTED IN STEP 9 CANNOT BE MOVED WHEN THE SEALANT MATERIAL IS FROZEN MAKE SURE THE VALVES ARE IN THIS POSITION WHEN THE MACHINE IS SHUT DOWN l Verify the following valves are positioned as indicated e Product tank valve CLOSED e Application recirculation valve 0 full tank circulate m Make sure the circulating auger and product pump directional control valves are in the center detent NEUTRAL position n Make sure the tank and pump drain valve is CLOSED and the external pipe plug is installed Preparation Loading Sealant Material WARNING DO NOT LOAD SEALANT MATERIAL INTO THE SEALANT TANK WITH BOTH LOADING DOORS OPEN HOT SEALANT MATERIAL WILL SPLASH OUT OF THE OPEN DOOR HOT SEALANT MATERIAL CAN CAUSE SERIOUS OR FATAL BURNS Load the sealant material into the Kracker sealant tank as follows a Open either sealant loading door until the door is fully open b Place a block of sealant material on the sealant loading door and position it so the block rests against the loading shelf WARNING DO NOT HOLD ONTO THE SEALANT LOADING DOOR HANDLE LET THE DOOR FALL CLOSED TO KEEP HOT SEALANT FROM SPLASHING OUT OF THE TANK c Push the sealant loading door up and allow it to close The block of sealant material drops into the sealant tank when the do
28. FECTIVE PARTS REPLACED OR REPAIRED UNLESS THE USER HAS REACHED A PRIOR AGREEMENT WITH BEARCAT EXCLUSIONS The provisions of the foregoing warranty are BearCat s sole obligation and exclude all other warranties expressed or implied BearCat shall not be responsible for any loss damage incidental or consequential damages of any kind whether based upon warranty contract or negligence arising concerning the sale use or repair of the product Components manufactured by any supplier other than BearCat shall bear only the warranty made by the manufacturer of that product 4 INTRODUCTION This manual describes the BK Series All Diesel Crack Sealing machines manufactured by BearCat The machines are identified by the EE proprietary term Kracker BearCat BK Series All Diesel Krackers are designed and manufactured to ensure personal safety when the equipment is operated properly and all safety precautions are strictly followed Persons responsible for the operation and field maintenance of the BK Series All Diesel Kracker should read this manual carefully before attempting to operate the equipment or performing any service or adjustment procedures on it Intro NOTE BearCat Manufacturing assumes no liability for accident or injury incurred through improper use of this equipment WARNING BEARCAT EQUIPMENT USES VOLATILE MATERIALS AT HIGH TEMPERATURES AND PRESSURES THIS EQUIPMENT EMPLOYS HIGHLY COMBUSTIBLE OR EXPLOSIVE FUELS PO
29. G NEVER LOOK INTO THE SEALANT TANK FROM THE FRONT OF THE MACHINE SEALANT CIRCULATING FROM THE CIRCULATION PIPE OR THE APPLICATION WAND IS PUMPED FORWARD HOT SEALANT MAY SPLASH FORWARD RESULTING IN SEVERE BURNS OR INJURY f Looking from the rear of the sealant tank verify there is adequate sealant flow from the circulation pipe into the sealant tank g Close the right hand sealant loading door NOTE It is not necessary for the entire sealant tank to be liquefied to begin work Crack sealing operations may begin as soon as there is adequate flow through the application wand The sealant material is normally ready for application in about one hour Preparation h With the application wand positioned in the hose trough OPEN the application wand shutoff valve i Gradually move the application recirculation valve from the 0 position to the 8 position product pump begins to squeal immediately move the product pump directional control valve to the REVERSE position and immediately back to the FORWARD position If necessary wait several minutes for the sealant to melt and attempt to circulate sealant through the application wand again k OPEN the left hand sealant loading door WARNING NEVER LOOK INTO THE SEALANT TANK FROM THE FRONT OF THE MACHINE SEALANT CIRCULATING FROM THE CIRCULATION PIPE OR THE APPLICATION WAND IS PUMPED FORWARD HOT SEALANT MAY SPLASH FORWARD RESULTING IN SEVERE BURNS OR INJU
30. LING CRACKS 67 CLEAN OUT PROCEDURE 68 CLEAN OUT PROCEDURE cont 69 CLEAN OUT PROCEDURE cont 70 CLEAN OUT PROCEDURE cont FIELD MAINTENANCE 8 72 Scheduled Maintenance 74 Heat Transfer Hot Oil Replacement 77 Product Pump Packing Gland Replacement 79 Hot Oil Pump Packing Gland Replacement 81 Recommended Fluids 81 Heat Transfer Oil Specification 82 Hydraulic Fluid 82 Troubleshooting 84 ILLUSTRATED PARTS LIST SCHEMATICS 100 Control Box Schematic 101 Lights and Brakes Schematic 102 Diesel Engine Schematic 103 Hydraulic System Flow Diagram 2013 DESCRIPTION Equipment Description BK Series All Diesel Krackers use a diesel engine as their power source and an enclosed high pressure diesel fuel burner for heating the asphalt sealing material No gasoline propane or other fuels are used in BearCat machines identified as All Diesel Two models are described in this manual e BK 250D BK 400D The BK 250D has a 250 gallon sealant tank and the BK 400D has a 400 gallon tank Both models are identical in performance and operation except where noted The following description of the equipment should be read to familiarize the operator with the features and capabilities of the BK Series All Diesel Kracker 4 BearCat ALL DIESEL 928 684 7851 BK 250D 10 4000 Hydraulic System The Kracker hydraulic system is powered by a 3 cyli
31. MACHINE ALWAYS keep the application wand pointed AWAY from all personnel e ALWAYS check the condition of the hoses before beginning sealing operations e ALWAYS make sure that all pipe and hose connections secure before opening a valve e ALWAYS start the product pump VERY SLOWLY and make sure that all hoses and valves work properly e NEVER pump against a closed valve e NEVER remove the application wand from the machine without the shutoff valve in the CLOSE position e NEVER look into sealant tank from the front of the machine Hot sealant material from the tank circulation pipe and application wand is pumped forward and may splash out NEVER load a block of sealant material into the sealant 33 2013 tank when both loading doors are open Towing Procedures Drive defensively and watch your speed The machine contains diesel fuel and a large amount of liquid sealant at high temperature An accident can lead to a major fire e NEVER tow the machine with the burner operating because you would be a Breaking the law b Risking damage to the burner c Violating the first rule of burner operation never leave the burner unattended when it is lit e ALWAYS make sure the wheel lug nuts and hitch bolts are tight Check them daily ALWAYS use safety chains Connect them a criss cross pattern e ALWAYS connect the safety breakaway chain 34 e ALWAYS make sure the machine is le
32. RY 47 2013 48 Looking from rear of the sealant tank verify there is adequate sealant flow from the application wand nozzle into the sealant tank If necessary wait until the sealant flow from the application wand increases Remove the external cap from the application wand return tube Position the product pump directional control valve to full REVERSE CLOSE the application wand shutoff valve and lift the application wand from the hose trough Keep the application wand from falling off the hose trough and remove the entire application wand hose from the hose trough Stretch out the application wand hose and attach the hose to the hose boom Place the application wand in the application wand return tube and retaining bracket assembly OPEN the application wand shutoff valve CLOSE the left hand sealant loading door Position the product pump directional control valve to full FORWARD Allow the sealant material to circulate through the application wand Crack sealing operations can begin Continue to add blocks of sealant material to the sealant tank Always keep the sealant tank full As work continues the remainder of the sealant material will liquefy CAUTION IF THE CIRCULATING AUGERS MAKE A SQUEALING SOUND WHEN THE DIRECTIONAL CONTROL VALVE HANDLE IS MOVED IMMEDIATELY STOP THE AU GERS ALLOW ADDITIONAL TIME FOR THE SEALANT TO HEAT AND ATTEMPT TO RESTART THE CIRCULAT ING AUGERS FAILURE TO DO
33. SO MAY DAMAGE THE HYDRAULIC SYSTEM w When the sealant material temperature reaches the pour temperature as indicated on the Partlow temperature control gradually move the circulating auger directional control valve to the FORWARD or REVERSE position X Operate the circulating augers for the remainder of the crack sealing operation 49 Preparation 2013 OPERATING INSTRUCTIONS WARNING WARNING WARNING WARNING WARNING BEARCAT EQUIPMENT USES VOLATILE MATERIALS AT HIGH TEMPERATURES AND PRESSURES THIS EQUIPMENT EMPLOYS HIGHLY COMBUSTIBLE OR EXPLOSIVE FUELS POTENTIALLY LIFE THREATENING HAZARDS MAY EXIST DURING EQUIPMENT OPERATION ONLY QUALIFIED PERSONS SHOULD ATTEMPT TO OPERATE SERVICE OR MAKE ADJUSTMENTS TO THE BEARCAT EQUIPMENT EXTREME CARE MUST BE USED DURING CIRCULATION AND SEALING OPERATIONS TO MAKE SURE THAT SYSTEM COMPONENTS OPERATE AT THEIR RATED PRESSURES FAILURE TO CHECK THE CONDITION OF ALL HOSES AND CONNECTIONS WHEN PUMPING COULD RESULT IN SEVERE BURNS INJURY OR DEATH FROM PUMPING ERRORS MADE WITH FAULTY COMPONENTS TO AVOID POTENTIAL SEVERE BURNS INJURY OR DEATH PERSONS MUST READ SECTION 2 SAFETY PRECAUTIONS BEFORE OPERATING BEARCAT EQUIPMENT ALWAYS WEAR SAFETY GEAR AND PROTECTIVE CLOTHING TO INCLUDE INSULATED GLOVES SAFETY GLASSES AND FACE SHIELD LONG SLEEVE SHIRT LONG PANTS BOOTS AND COVERALLS WHEN OPERATING THE Kracker FAILURE TO DO SO MAY RESULT IN SEVERE BURNS INJ
34. TED WARRANTY 4 Warranty Claims 4 EXCLUSIONS 5 INTRODUCTION 6 Abbreviation Definition Table DESCRIPTION 10 Equipment Description 11 Hydraulic System 12 Circulating Augers 14 Heat Transfer Pump 15 Sealant Heating System 17 Circulating Auger Heating Coil 18 Temperature Control 20 Sealant Tank and Circulating Augers 21 Sealant Plumbing 22 Sealant Application Wand 23 Hose Trough Optional 29 BK 250D Over all Dimensions 30 BK 400 Over all Dimensions SAFETY PRECAUTIONS 31 31 32 32 33 34 Personal Safety Safety Rules Potential Explosive Fire Hazard Conditions Burner Operations Sealing Operations Towing Procedures 2013 PREPARING EQUIPMENT FOR USE 37 Operating Controls Gages and Indicators 39 Initial Checkout of Machine 41 Loading Sealant Material 42 Heating Circulating Sealant 43 Diesel Engine Startup 44 Hot Oil Circulation 44 Burner Operation 46 Sealant Circulation OPERATING INSTRUCTIONS 51 Sealant Application 52 Shutdown 54 Preparation for Overnight Shutdown 55 Preparation Following Extended Shutdown QUICK REFERENCE OPERATING GUIDE 57 MACHINE BEFORE STARTING 58 BEFORE STARTING ENGINE CHECK VALVES 59 CHECK HOSE AND LOAD MATERIAL 60 STARTING MACHINE AND BURNER 61 RECIRCULATING MATERIAL INTO TANK 62 RECIRCULATING MATERIAL THRU HOSE AND WAND 63 REMOVING THE HOSE FROM THE TROUGH 64 SEALING CRACKS 65 SEALING CRACKS cont 66 AFTER SEA
35. TENTIALLY LIFE THREATENING HAZARDS MAY EXIST DURING EQUIPMENT OPERATION PERSONS MUST BE TRAINED AND FAMILIAR WITH SECTION 2 SAFETY PRECAUTIONS BEFORE OPERATING BEARCAT EQUIPMENT WARNING POTENTIALLY LIFE THREATENING HAZARDS MAY EXIST DURING EQUIPMENT OPERATION ONLY QUALIFIED PERSONS SHOULD ATTEMPT TO OPERATE SERVICE OR MAKE ADJUSTMENTS TO THE BEARCAT EQUIPMENT WARNING FOLLOW THESE PRECAUTIONARY INSTRUCTIONS EXACTLY DO NOT TAKE SHORTCUTS DO NOT ASSUME THAT SOMEONE ELSE HAS ACTED ON YOUR BEHALF FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN DEATH OR SERIOUS INJURY IF ANY RULE OR PRECAUTION IS NOT CLEAR TO YOU SEE YOUR SUPERVISOR BEFORE USING THE MACHINE 2013 WARNING THE MATERIALS USED IN THE BK SERIES Kracker ARE NORMALLY HEATED FROM 300 F 450 DURING APPLICATION MATERIALS USED AT THESE TEMPERATURES CAN CAUSE SERIOUS OR FATAL BURNS AND CAN BECOME EXPLOSIVE UNDER CERTAIN CONDITIONS DIESEL FUEL USED IN THE BURNER TO HEAT THESE MATERIALS IS HIGHLY FLAMMABLE EXTREME CARE MUST BE EXERCISED AT ALL TIMES TO ENSURE THE SAFETY OF PERSONS WORKING IN PROXIMITY TO THESE POTENTIALLY HAZARDOUS CONDITIONS Abbreviation Definition Table Te British Thermal Unit ec Counterclockwise e Cubic feet per minute Clockwise Pounds per square inch Revolutions per minute Table of Contents WARRANTY AND CLAIM PROCEDURES 3 LIMI
36. URY OR DEATH Ensure the necessary procedures in the PREPARATION section are accomplished before performing any of the operations described in this section 50 Crack sealing operations begin as soon as there is adequate through the application wand as described in PREPARING EQUIPMENT FOR USE SECTION Sealant Application WARNING ALWAYS KEEP THE APPLICATION WAND POINTED AWAY FROM ALL PERSONNEL FAILURE TO DO SO COULD RESULT IN SEVERE BURNS INJURY OR DEATH 25 CLOSE the application wand shutoff valve 26 Remove the application wand from the application wand return tube eneral Operation 27 Place the application wand tip in the selected crack and OPEN the application wand shutoff valve Move the appli cation wand along the crack 28 CLOSE the application wand shutoff valve at the end of the crack Keep the application wand shutoff valve in the CLOSE position when moving from one crack to the next 29 Use the application recirculation valve to adjust the flow rate of the sealant material through the application wand nor mally the 7 or 8 position 51 2013 30 Place the application wand the application wand return tube and OPEN the shutoff valve when the application wand is not in use 31 Keep the sealant material tank full during crack sealing operations Add sealant material in accordance with the procedures given in PREPARING EQUIPMENT FOR USE SECTION Loading Sealan
37. al to half the volume of the total filled system The tank contains a sight glass for both hot and cold oil level checks The tank uses an integral cold seal to minimize oxidation of the hot oil during 2013 system cooling cycles hot oil expansion tank is connected to upper portion of the manifold assembly and is the final component in the closed loop sealant heating system A fill connection for servicing the sealant heating system and a vent is located at the top of the tank Temperature Control The Kracker temperature control panel is located on the right side of the machine The temperature control panel contains the following controls and indicators e Burner ON OFF switch e Beacon switch Partlow sealant temperature control e Hour meter As part of the Kracker safety system the sealant heating system requires five separate inputs before the diesel fuel burner can operate If the burner is operating and any of the required inputs are removed the burner shuts down When the temperature control system cycles to the burner OFF condition the burner fuel pump is immediately shut off This ensures raw fuel is never pumped into the burner chamber The burner inputs are listed below e Ignition switch e Burner ON OFF switch e Hot oil pressure switch e High limit switch Partlow sealant temperature control 18 The five switches are wired in series routed through the control panel If
38. ank fittings Check tire pressure Make sure hitch bolts and lug nuts are secure Make sure safety chains are secure Make sure the safety break away chain is attached Check hydraulic fluid level Note 1 Check hot oil fluid level Note 2 Weekly Inspect product pump bearings for leaks Check brake fluid level in hitch master cylinder if applicable Check battery water level and connections 6 Months Pack product pump bearings Note 3 Pack wheel bearings Inspect brake linings Replace fuel filter or service sediment bowl 12 Months Sample hot oil and test or drain and replace Note 3 Replace hydraulic system filter Replace hydraulic system fluid 500 Hours Replace hydraulic system filter Replace fuel filter or service sediment bowl 1000 Hours Sample hot oil and test or drain and replace Note 3 Replace hydraulic system fluid 1 Check the hydraulic fluid level with the sight glass located on the front of the hydraulic reservoir Fluid should be visible when the system is cold 2 Check the hot oil level with the sight glass located on the left side of the hot oil expansion tank Oil should be visible on the lower sight glass when the system is cold 72 Table 5 2 Engine Maintenance Schedule DESCRIPTION OF DAILY 600 REMARK CHECK HRS COOLING SYSTEM Coolant level and coolant 10 mm upper position from the fouling check radiator core meme Radiator filler cap fitting To be secur
39. any of the switches are open the circuit is broken and the burner cannot ignite Only the ignition switch burner ON OFF switch and Partlow sealant temperature control are operable by the user When the ignition switch is ON the burner ON OFF switch is energized Positioning the burner ON OFF switch to ON allows the rest of the ERI system to energize provided the necessary input conditions are met With the burner ON OFF switch in the ON position a one minute burner startup delay is initiated The startup delay is for the igniter preheat system Cycling the burner switch OFF and ON restarts the one minute delay Wait a full minute before attempting to restart the burner The hot oil pressure switch requires a minimum pressure of 4 psi within the hot oil system to close With the ignition ON and the engine running the hot oil bypass valve must be closed enough for the heating system to build the minimum hot oil system pressure Loss of pressure valve open shuts Placas ee USE ONLY BEARCAT down the burner Description The high limit switch is a thermal switch with contacts that expand as the hot oil temperature increases When the hot oil temperature reaches the factory preset value normally 500 F the switch opens and the burner shuts down When the hot oil temperature drops approximately 5 F the high limit switch contacts close and allow the burner to ignite The temperature gauge for the hot oil system is lo
40. cated at the rear of the Kracker The Partlow sealant temperature control is manually set by the operator The correct temperature setting set point is determined by the sealant manufacturer s recommendation The Partlow sealant temperature control receives temperature input through a mercury filled capillary tube connected to a thermal sensing element located in the sealant tank When the sealant material within the sealant tank reaches the set 2013 point the Partlow sealant temperature control switch opens and the burner is shut down When the sealant material temperature drops approximately 5 F the Partlow sealant temperature control switch closes and allows the burner to ignite The sealant material retains heat much longer than the hot oil During normal operation hot oil temperature may drop as much as 100 F before the sealant material temperature drops enough to allow the burner to ignite These temperature differences cause the burner to cycle on and off at different intervals Sealant Tank and Circulating Augers WARNING DO NOT LOAD SEALANT MATERIAL INTO THE SEALANT TANK WITH BOTH LOADING DOORS OPEN HOT SEALANT WILL SPLASH OUT OF THE OPEN DOOR HOT SEALANT CAN CAUSE SERIOUS OR FATAL BURNS The Kracker has two sealant loading doors on the top of the sealant tank The sealant loading doors are accessible from the sides of the machine Each sealant loading door has a loading shelf attached to the inside
41. d flow into two circuits The first or priority circuit drives the hydraulic motor for the heat transfer oil hot oil pump The second hydraulic circuit operates the product pump hydraulic motor The priority valve is also equipped with a relief valve The relief valve allows excess hydraulic fluid to circulate back to the reservoir through a separate bypass line connected to the hydraulic manifold assembly without placing a load on the hydraulic system Hydraulic fluid from the priority valve primary circuit is sent to the hot oil bypass valve During normal sealing operations the hot oil bypass valve is set in the RUN closed position With the hot oil bypass valve closed full hydraulic fluid flow is sent to the hot oil pump hydraulic motor to maintain constant hot oil circulation This allows optimum heat transfer to the sealant material Hydraulic fluid from the hot oil pump hydraulic motor is returned to the hydraulic manifold assembly The hydraulic fluid from the hydraulic manifold passes through the 10 micron filter and gate valve and back into the hydraulic reservoir When the hot oil bypass valve is in the STOP open position hydraulic fluid is allowed to circulate through the hydraulic manifold assembly and the hot oil pump does not operate The hydraulic fluid passes through the hydraulic manifold assembly the 10 micron filter and gate valve and back into the hydraulic reservoir Kracker startup and shutdown
42. door Verify material flow from application wand Close sealant loading door After clear flow is reached through 4 Put product pump hose move application recirculation valve in FORWARD to desired application setting WARNING NEVER LOOK INTO THE SEALANT TANK FROM THE FRONT OF THE MACHINE SEALANT CIRCULATING FROM THE CIRCULATION PIPE OR THE APPLICATION WAND IS PUMPED FORWARD HOT SEALANT MAY SPLASH FORWARD RESULTING IN SEVERE BURNS OR INJURY V02016 62 REMOVING THE HOSE FROM THE TROUGH 3 Lift the application wand assembly out of the hose trough and let it rest on top of the hose trough 4 Have one person hold the application wand assembly while another pulls the hose completely out of the hose trough 5 Insert the application wand into the return tube and OPEN the wand valve General Operation 6 Secure the hose to the hose jib N Ia N 9 7 Put the product pump in FORWARD V02017 63 2013 SEALING CRACKS WARNING THE MATERIALS USED IN THE BK SERIES KRACKER ARE NORMALLY HEATED FROM 300 F TO 450 F DURING APPLICATION MATERIALS USED AT THESE TEMPERATURES CAN CAUSE SERIOUS OR FATAL BURNS AND CAN BECOME EXPLOSIVE UNDER CERTAIN CONDITIONS 1 CLOSE application wand valve before removing from machine 2 2 2 When the product temperature on Partlow gauge reaches 300 star
43. e Warning o s 5 10 15 20 25 30 35 40 45 50 55 65 70 75 85 93 2013 6661 0 00t 8 ISOH cae ISOH NI 3NI113318 052 TOHLNOO OL 94 FIGURE 6 6 SYSTEM ITEM DESCRIPTION PART NO Coiling BK 250D 5 71207 O Ring Viton BK 250D RNG 71032 s Line Cross Over BK 250D MSC 71214 Feed Line Cross Over BK 250D MSC 71215 Hot Oil Return and Suction Assembly BK 250D MSC 71202 O Ring Bolt to Flange RNG 71031 O Ring Viton RNG 71032 a 5 5 Hose 3 8 in X 18 in MSC 80371 5 5 Hose 3 8 in X 18 in MSC 80371 Product Temperature Gauge MTR 80311 S S Hose 3 8 in X 18 in MSC 80371 m Manifold Lower MSC 80391 5 5 Hose 3 8 in X 1 04 ft MSC 80370 m 5 5 Flex Hose 34 in MSC 82080 Hm Coiling Supply Line MSC 71206 E Hot Oil Temperature Gauge MTR 80311 im 90 Coiling BK 400D MSC 71208 O Ring Viton BK 400D RNG 71032 Line Cross Over BK 400D MSC 71216 Coiling Extension BK 400D MSC 71212 Hot Oil Expansion Tank TNK 71201 Hot Oil Return and Suction Assembly BK 400D MSC 71217 Pressure Line to Control Box 3 8 in Brake Line Hot Oil Motor Assembly MSC 71205 Hot Oil Pump Suction Line MSC 71203 m Adaptor Outlet MSC 71204 Coiling Heat MSC 71025 IM 95 Parts 2013
44. e sure the flexible hose trough cover is pulled over the top of the hose Position the BURNER switch on the temperature control panel to OFF Position the circulating auger directional control valve to the NEUTRAL center position Position the hot oil bypass valve to the STOP open posi tion CAUTION THE VALVES LISTED IN STEP 21 AND STEP 22 CAN 21 22 23 24 25 26 NOT BE MOVED WHEN THE SEALANT MATERIAL IS FROZEN MAKE SURE THE VALVES ARE IN THIS POSITION WHEN THE MACHINE IS SHUTDOWN Position the application recirculation valve to the 0 posi tion Position the product tank valve to the CLOSE position Position the product pump directional control valve to the NEUTRAL center position Loosen the throttle lock on the engine and reduce the en gine speed to a smooth idle Allow the engine to run at idle speed for a one minute cool down prior to shutdown Position the BEACON switch on the temperature control panel to OFF Position the IGNITION switch on the engine control panel to OFF Preparation for Overnight Shutdown Before the present work shift ends add sealant material to the sealant tank until the tank is full 4 to 5 inches above the heating coils Close and latch the sealant loading doors and make sure the external cap is installed on the application wand return tube A full load of sealant retains heat longer than a partial load Startup 54 time at the beginning of the next
45. ely tightened condition Fan belt tension check X Deflection of 8 12 mm approx replace if necessary 10 kg force Coolant temperature check o 75 90 Coolant replacement Every 6 months Radiator external face X cleaning Cooling system circuit X cleaning Radiator filler cap function X According to engine check manufacturer s specifications AIR INTAKE SYSTEM erens Ammeter registration Immediately after engine start gauge goes to side _ x reheating condition cheek ENONE Engine starting conditions and X noise conditions Exhaust smoke condition Exhaust smoke color Valve clearance check According to engine manufacturer s specifications The service intervals after 1200 hours of operation should be made every 100 hours of operation in accordance with Table 5 1 2 When service on the asterisked items is necessary consult the engine manufacturer s requirements 73 Maintenance 2013 Heat Transfer Hot Oil Replacement Table 5 3 lists the tools and equipment necessary to replace the hot oil in the sealant heating system Table 5 3 Tools and Equipment TYPE DESCRIPTION 100 CFM capacity or larger Minimum 1 2 in 1 0 with Female Quick Coup
46. g and 525 on hot oil temperature gauge 4 Carefully open the right hand sealant loading door Verify material flow from circulation pipe Close sealant loading door 5 Make sure application recirculation valve is set at for full circulation SS NS 2 3 ANS i b E C if aN N 7E 3 Put pump FORWARD 6S if a squealing noise is heard 7 FAN Rc p B e T EL or the engine bogs down put the pump NEUTRAL and allow E E ey machine to heat longer L my EL 2 After 30 minutes try to OPEN the tank valve The valve should open easily if it does not allow machine to heat longer DO NOT FORCE 61 General Operation 2013 RECIRCULATING MATERIAL HOSE AND WAND WARNING ALWAYS REVERSE THE PRODUCT PUMP AND CLOSE THE APPLICATION WAND VALVE BEFORE REMOVING THE HOSE ASSEMBLY FROM THE HOSE TROUGH OR RETURNING THE HOSE ASSEMBLY TO THE HOSE TROUGH 1 Make sure application hose and wand assembly are in hose trough and application wand is in locked position OPEN wand valve 2 CLOSE sealant loading door Ga T S 3 Move application recirculation Ne valve from 0 to 8 MI LJ N dg gt M MN S EM Y 4274 1 5 Carefully open left hand sealant loading
47. h ON e Hot oil pressure switch CLOSED e High limit switch CLOSED e Partlow sealant temperature control CLOSED 44 With the ignition ON and the engine running bypass valve must be closed enough for the heating system to build the minimum hot oil system pressure Once the hot oil system reaches 4 psi the pressure switch closes a Make sure the burner fuel feed valve is OPEN b the temperature control panel set the Partlow temperature control to the desired pour temperature set point This temperature is normally specified by the sealant material manufacturer C Position the BURNER switch on the temperature control panel to ON The burner has a one minute preheat delay before it ignites Wait one FULL minute for burner ignition NOTE NOTE When the hot oil temperature reaches approximately 250 F move hot oil bypass valve to the full RUN position d The burner runs until the hot oil temperature high limit switch opens or the Partlow sealant temperature control switch opens e Position the BEACON switch on the temperature control panel to ON f During the initial heating cycle the burner runs continuously for approximately 20 minutes Once the hot oil reaches operating temperature the burner cycles on and off about every 1 1 2 to 2 1 2 minutes depending on the hot oil and sealant temperature differences Each time the burner ignition sequence is initiated the g one minu
48. h the remaining time of the original warranty BearCat warrants that at the time of delivery the product manufactured by BearCat and delivered new to the original purchaser user shall be free from defects in material and workmanship for a period of one 1 year after delivery This warranty is valid when the product is operated and maintained under normal use and service and in accordance with the written instructions provided by BearCat 2013 Warranty Claims BearCat agrees at its option to repair or replace F O B Wickenburg Arizona any part acknowledged by BearCat to be defective provided 1 The user shall notify BearCat of any defect within this warranty no later than fifteen 15 days after a defect is discovered 2 Written or verbal authorization has been obtained from the BearCat Service Department to return the product 3 Upon authorization the defective part is returned within thirty 30 days to the address provided below for inspection with transportation charges prepaid to BearCat BearCat Mfg Inc 3650 Sabin Brown Road Phone 928 684 7851 Wickenburg AZ 85390 Fax 928 684 3241 4 BearCat determines the defective part failed under the terms of the above warranty o Warranty coverage will not be applied unless the requirements listed above are met BEARCAT WILL NOT INSTALL AND WILL NOT PAY ANY IN SIALLATION COST TRANSPORTATION COST TRAVEL TIME MILEAGE LABOR COSTS OR OTHER EXPENSES OF ANY DE
49. ifferences are noted in the parts list or difference drawings are provided in the applicable figure 34 TN Ilo DAT Tae NE C 2 222 4 2224 45 PS ys zz ee silts 223 VN 2 5 Ld i L N d PM Sis j d 50 55 80 75 M eM p ens ve P 25 9 N gt B a D 125 130 135 140 V01994 Figure 6 1 BK 250D Kracker ITEM DESCRIPTION PART NO 2013 o i co uem mesas i a Heated ose rough Te a i i Frores nereo a osamme meme i peek 2 86 n NI y NN 097 Figure 6 2 Hydraulic System 87 2013 FIG 6 2 HYDRAULIC SYSTEM Lo i ce mesa
50. laced in the hose trough The hose trough connects to an opening in the side of the left hand sealant loading door When the application wand is placed in the hose trough the nozzle is positioned 23 2013 inside the sealant tank Once the sealant material is hot enough to circulate the application wand shutoff valve is opened to allow sealant circulation through the application wand Specifications 6 in channel iron side rails square tubular cross members all welded construction Dual 7 000 Ib rated load axle with rubber torsion suspension BRAKES Standard Electric includes cab servo TIRES AND WHEELS LT235 85R16 E highway tread tires 6 75 X 16 5 8 hole BC wheels TONGUE JACK 5 000 Ib side mounted top wind swivel jack with base plate HITCH TONGUE Pintle or ball height adjustable from 16 in to 32 in SAFETY CHAINS 3 8 in X 48 high test chain with a combined working load limit of 10 800 Ibs with chain shackles Tank BK 250D 250 gallon capacity 3 16 in steel plate all welded construction Tank BK 400D 400 gallon capacity 3 16 in steel plate all welded construction Sealant Loading Doors 21 in X 36 in insulated doors on each side of the tank positioned at a 30 angle for ease of opening Splash proof hinged lids with integral loading shelf Meets all DOT requirements for 49 CFR part 172 and 173 loading height 48 in Optional Hydraulic surge actuated 24 Insulation
51. ler Pipe Bushing 1 in X 1 4 in NPT Bushing Air Coupling 1 4 in Male Quick Coupler Fitting Bucket or Drain Pan 11 gallon or larger WARNING ALLOW THE HOT OIL TO COOL FOR A MINIMUM OF 24 HOURS AFTER BURNER OPERATION BEFORE DRAINING THE SEALANT HEATING SYSTEM FAILURE TO DO SO COULD RESULT IN SEVERE BURNS INJURY OR DEATH Perform the following procedures to replace the hot oil in the sealant heating system 1 Place the drain pan 11 gallon minimum below the drain valve and product pump 2 Loosen the bottom fitting of the flex line which connects the heat trace system to the drain valve heat jacket CAUTION THE HOT OIL DRAINS FROM THE FLEX LINE FITTING AND THE HEAT JACKET FITTING 3 Remove the flex line from heat jacket fitting and allow the hot oil to drain from the sealant heating system into the drain pan 4 Start the hot oil pump in accordance with the procedures given in PREPARING EQUIPMENT FOR USE SECTION DO NOT START THE BURNER 5 Let the hot oil pump run until the hot oil stops flowing from the flex line fitting 6 Shutdown the hot oil pump and diesel engine in accordance with the procedures given in OPERATING INSTRUCTIONS SECTION 7 Remove the overflow line and straight fitting from the hot oil expansion tank 90 degree elbow 8 Install the pipe bushing and male quick coupling inthe B 90 degree elbow Maintenance 2013 10 Attach an air hose to the quick coupling and allow
52. liquefies material in sealant lines hose and pump when hot oil is heated No solvent flushing is required with heat trace system Heat Exchanger Flame Contact Primary heating coil and heating chamber Entire heating system is located below 100 gallon level of sealant tank Flame contact heats primary heating coil and inner surface of oil jacketed heating chamber Total contact area 7 000 sq in 25 2013 Heat Transfer Area Heat transfer area consists of two circulating auger heating coils outer portion of oil jacketed heating chamber and heat trace plumbing Minimum heat transfer area 7 700 sq in The BK 400D contains an additional heating coil in the forward portion of the sealant tank Hot Oil Pump and Plumbing Positive displacement pump provides forced circulation of hot oil through heating system Forced circulation prevents premature hot oil breakdown which reduces heating efficiency Standard approved paraffin base heat transfer oil with a maximum operating temperature of 600 F in a closed forced circulation system System capacity BK 250D 14 gallons BK 400D 17 gallons Expansion Tank Equipped with fill connection vent and overflow line Cold seal system prevents oxidation of hot oil Capacity 1 2 of total system capacity 7 or 8 1 2 gallons TEMPERATURE CONTROL Burner ON OFF switch beacon ON OFF switch Partlow temperature control hour meter PANEL Burner Forced air diesel fired burne
53. nd back to the directional control valve Circulating Augers inside Heat Coiling 12 Hydraulic fluid from the circulating auger directional control valve is returned to the hydraulic manifold assembly The hydraulic fluid from the hydraulic manifold passes through the 10 micron filter and gate valve and back into the hydraulic reservoir Product Pump The product pump and hydraulic motor are located at the rear of the Kracker The priority valve secondary hydraulic circuit is used to operate the product pump Hydraulic fluid is sent from the priority valve secondary output to the product pump directional control valve The product pump directional control valve directs the flow of hydraulic fluid to the product pump hydraulic motor The directional control valve allows proportional speed control and either forward or reverse rotation of the product pump Hydraulic fluid from the product pump hydraulic motor is circulated back to the product pump directional control valve The hydraulic fluid is sent from the directional control valve to the hydraulic manifold assembly The hydraulic fluid from the hydraulic manifold passes through the 10 micron filter and gate valve and back into the hydraulic reservoir 13 Description 2013 Heat Transfer Pump The hydraulic line from the rear output port of the dual vane hydraulic pump is connected to the priority valve The priority valve separates the hydraulic flui
54. nder diesel engine The hydraulic system dual vane hydraulic pump is direct coupled to the diesel engine crankshaft The hydraulic system is used to drive the two circulating augers the heat transfer oil pump and the product pump Hydraulic Pump 2013 Hydraulic fluid for the system is stored in the hydraulic reservoir The hydraulic fluid is drawn from the reservoir through a suction strainer and gate valve to the dual vane hydraulic pump Circulating Augers The hydraulic line from the forward output port of the dual vane hydraulic pump is connected to the directional control valve for the dual circulating auger motors Hydraulic fluid is sent from the circulating auger directional control valve to the auger motors attached to the front of the product tank The directional control valve is equipped with an internal bypass circuit to allow hydraulic fluid circulation without placing a load on the hydraulic system when the auger motors are stopped The auger motors are connected in series and are designed to rotate at the same speed The circulating augers are also configured to rotate in opposite directions This enhances sealant material circulation and heating within the product tank and produces a swirl effect in the material The directional control valve allows proportional speed control and either forward or reverse rotation of the circulating augers Hydraulic fluid is circulated through the auger motors a
55. oil pump rotating carefully snug tighten the retainer bolts CAUTION ADJUST THE PUMP PACKING DAILY THE PACKING MUST LEAK ONE 1 DROP PER MINUTE FOR SHAFT LUBRICATION h Periodically snug tighten the retainer bolts as excess seepage appears at the hot oil pump shaft during operation 80 heat transfer oils hot oil listed in Table 5 4 are suitable for use in BK series crack sealing machines Oils other than those listed may be acceptable provided they meet the general specifications Recommended Fluids The heat transfer oil used in BK series crack sealing machines must be a solvent extracted thoroughly dewaxed clay filtered paraffin based oil recommended for operating temperatures up to 600 F 316 C in a closed forced circulation system Table 5 4 Suitable Heat Transfer Oils MANUFACTURER PRODUCT NAME PRODUCT NO Specification Table 5 5 lists the general specification for heat transfer oil suitable for use in BK series crack sealing machines Table 5 5 Heat Transfer Oil Specification CATEGORY SPEC CATEGORY SPEC Viscosity 100 F 38 C 110 Distillation Range 50 780 F Viscosity 210 F 99 C aoo Specific Gravity 500 F 260 C Viscosity Index Specific Heat 500 F 260 C NOTE Aromatic or high temperature flash point lubricating oils MUST NOT BE MIXED with paraffin base heat transfer oils 81 Maintenance 2013 Hydraulic Fl
56. on with which the operator must become familiar in order to prepare the BK Series All Diesel Kracker for crack sealing operations Four essential areas are covered 1 Operating Controls Gages and Indicators The operating functions of all Kracker controls are given The operator must be familiar with these controls before attempting to use the equipment 2 Initial Checkout of Machine Preliminary inspection and control settings are given for the machine 3 Loading Sealant Material Initial loading and safety procedures are provided for the machine 4 Heating Circulating Sealant Procedures are given and warning and cautionary notes are emphasized 36 for heating and circulating sealant material to the required temperature Familiarity with these areas of activity will prepare the operator for safe efficient operation of the equipment Operating Controls Gages and Indicators Engine Control Panel The engine control panel is mounted on a pedestal located in front of the engine on the right hand side of the machine It contains the ignition switch and indicators for engine glow plug preheat water temperature charging system and oil pressure The ignition switch must be in the ON position with the engine running to energize the burner circuitry Preparation Temperature Control Panel The temperature control panel is located on the right hand side of the sealant tank The temperature control panel has a lockable
57. or is almost closed 41 2013 d During initial sealant tank loading place as many blocks of sealant material as possible into the sealant tank e Once the sealant material melts add additional blocks of sealant to the sealant tank until the sealant level is 4 to 5 inches above the circulating auger heating coils Always keep the sealant tank full of sealant material The sealant tank is full when the sealant material is just below the edge of the loading shelf The melted sealant material should not wet the loading shelf A full sealant tank retains heat much longer than a partially loaded tank Due to heat retention by the sealant material a full sealant tank reheats to operating temperature the next day faster than an empty tank Heating Circulating Sealant WARNING POTENTIAL FIRE OR EXPLOSION HAZARDS EXIST WHEN OPERATING THE BURNER FAILURE TO FOLLOW THE BURNER OPERATION SAFETY PROCEDURES COULD RESULT IN SEVERE BURNS INJURY OR DEATH WARNING DO NOT HEAT MATERIAL BEYOND THE MAXIMUM TEMPERATURE RECOMMENDED BY THE SUPPLIER EXCESSIVELY HEATED MATERIAL COULD CREATE AN EXPLOSION HAZARD RESULTING IN SEVERE BURNS INJURY OR DEATH WARNING DO NOT LOAD SEALANT MATERIAL INTO THE SEALANT TANK WITH BOTH LOADING DOORS OPEN HOT SEALANT MATERIAL WILL SPLASH OUT OF THE OPEN DOOR HOT SEALANT MATERIAL CAN CAUSE SERIOUS OR FATAL BURNS WARNING EXTREME CARE MUST BE USED DURING CIRCULATION AND SEALING OPERATIONS TO MAKE SURE THAT
58. pump and plumbing is liquefied by the hot oil heat trace system The product pump is mounted in an inverted position which allows the pump to be drained of any residual material for maintenance purposes The product pump contains a pressure relief valve The pressure relief valve prevents any damage to the product pump in case of a plumbing system blockage The product tank valve is located at the rear of the product tank next to the product pump The product tank valve controls the sealant material flow from the product tank to the sealant plumbing The valve is operated by a handle connected to an extension shaft at the rear of the Kracker 21 Description 2013 Once the sealant material is melted enough to allow circulation the product pump directional control valve is positioned to start the product pump The product pump circulates the sealant material through the sealant plumbing The sealant material flow through the sealant plumbing is controlled by the application recirculation valve The application recirculation valve is a 3 way valve with a detent selector used to adjust sealant circulation through the plumbing The application recirculation valve can be set from the 0 position full tank circulation to the 10 position full flow to the application wand The application recirculation valve allows constant sealant material flow through the sealant plumbing system to eliminate any frozen sealant
59. r 500 000 BTU hr output Uses an electrically heated injection nozzle that preheats the fuel prior to ignition to prevent burner backfire Heat Shield Protects the coil and motor from burner chamber heat convection Burner Fuel Draws diesel fuel from Kracker fuel tank through a separate sediment filter and shutoff valve Burner Controls The burner ignition fuel pump and blower motor interlock with five switches e lgnition switch Burner switch Hot oil pressure switch High limit switch Material temperature control ENGINE CONTROL PANEL Ignition switch with preheat position glow plug indicator temperature warning light alternator charge warning light and oil pressure warning light 25 HP 1 1 liter 3 cylinder diesel engine Electric start hour meter rainproof muffler 12 V DC battery and 60 A alternator DIESEL FUEL TANK Capacity BK 250D 24 gallons BK 400D 35 gallons HYDRAULIC SYSTEM Hydraulic Pump Dual vane hydraulic pump with 1 39 cu in and 0 60 cu in displacement sections Circulating Auger Motor Two bi directional variable speed 9 6 cu in displacement hydraulic motors with built in relief valve Product Pump Motor Bi directional variable speed 9 6 cu in displacement hydraulic motor with built in relief valve Hot Oil Pump Motor 0 47 cu in displacement priority flow valve with built in relief to enable the operator to stop or run the pump at the desired speed Hydraulic Reservoir Config
60. raulic motor s Hot Oil Bypass Valve The hot oil bypass valve controls hydraulic fluid flow to the hot oil pump hydraulic motor Kracker startup and shutdown procedures are performed with the hot oil bypass valve in the STOP open position When the hot oil bypass valve is open hydraulic fluid is bypassed to the hydraulic manifold assembly and the hot oil pump does not operate As the valve is moved to the RUN close position hydraulic fluid is directed to the hot oil pump hydraulic motor The valve is not moved to the full RUN position until the hot oil operating temperature increases enough to decrease the hot oil viscosity approximately 250 Temperature Gages The Kracker has two temperature gages located at the rear of the machine The left hand gauge measures the hot oil temperature and the right hand gauge measures the sealant temperature in the system plumbing at the application recirculation valve Initial Checkout of Machine CAUTION THE INITIAL CHECKOUT PROCEDURES GIVEN BE LOW ARE MINIMUM REQUIREMENTS FAILURE TO PERFORM THESE STEPS CAN RESULT IN DAMAGE TO THE EQUIPMENT AND UNSAFE OPERATING CON DITIONS Preparation Each day before loading the machine with sealant material perform the following steps d Visually inspect the fire extinguisher tires lug nuts hitch bolts hoses fittings and engine belts e Make sure the battery is clean secure and has sufficient water in the cells
61. spill from the hot oil expansion tank overflow line j Place a bucket or drain pan under the hot oil expansion tank overflow line to catch any hot oil overflow the first time the burner is operated e Product Pump Packing Gland Replacement E Perform the following procedures to replace the product pump packing gland b Loosen the two bolts that hold the split retainer on the product pump shaft 2013 c Remove two bolts and the split retainer as far to the right as possible to allow access to the shaft packing CAUTION DO NOT SCRATCH THE PUMP SHAFT WHEN REMOV ING THE OLD SHAFT PACKING A DAMAGED SHAFT CAUSES EXCESSIVE PACKING WEAR AND LEAKAGE d Use an awl or scribe to remove the packing from the pump shaft Make sure all the old packing is removed from the packing recess e Repack the pump shaft with clean new packing material Use only BearCat Part No RNG 80054 f Position the split retainer over the new packing and install the two retainer bolts finger tight g Perform sealant heating and circulation operations in accordance with the procedures given in SECTION 3 PREPARING EQUIPMENT FOR USE CAUTION DO NOT OVER TIGHTEN THE SPLIT RETAINER BOLTS ONLY SNUG TIGHTEN THE BOLTS OVER TIGHTENED BOLTS WILL CAUSE THE PACKING TO SCORE THE PUMP SHAFT h With the machine at normal operating temperature and the product pump rotating carefully snug
62. t Material Shutdown At the end of crack sealing operations make sure the sealant tank is full If necessary add sealant material in accordance with the procedures given in SECTION 3 PREPARING EQUIPMENT FOR USE Loading Sealant Material prior to shutdown The BK Series All Diesel Kracker is designed with a Flush Free system to eliminate solvent flushing at the end of the work shift CAUTION DO NOT SHORT CUT THE FOLLOWING PROCEDURES FAILURE TO FOLLOW THESE PROCEDURES EXACTLY WILL RESULT IN BLOCKED PLUMBING AND EXTEND ED HEATING TIMES The shutdown procedures given below assume the machine is at normal operating temperature the product pump is in FORWARD and sealant material is circulating through the application wand and hose 1 Place the application wand in the application wand return tube and retaining bracket assembly and OPEN the appli cation wand shutoff valve 2 Loosen the throttle lock on the engine and increase the en gine speed to FULL throttle Tighten the throttle lock 3 Move the application recirculation valve to the 9 position A slight squealing may be heard from the product pump hydraulic motor 52 4 Allow machine to circulate sealant through the applica tion wand and hose for approximately three minutes 5 Position the product pump directional control valve to full REVERSE 6 Move the application recirculation valve from the 9 position to the 0 position for 30 seconds
63. t pump and repair or replace Refer to manufacturer s literature 1 Allow sealant to heat 2 Refer to PREPARING EQUIPMENT FOR USE Heating Circulating Sealant 3 Allow wand and hose assembly to heat in hose trough until wand circulates 4 Repair or replace as necessary Consult factory technical support 5 Replace product pump 1 Close hot oil bypass valve 2 Repair or replace as necessary Consult factory technical support 83 Maintenance 2013 ILLUSTRATED PARTS LIST The following recommended spare parts list Table 6 1 is provided as a guide to the user for convenience in the maintenance of BK series crack sealing machines All of the parts listed are available from BearCat Manufacturing Inc Table 6 1 Recommended Spare Parts DESCRIPTION PART NO Engine Oil Filter FTR 80932 Engine Air Filter FTR 80934 Diesel Fuel Filter Engine FTR 80930 Element Hydraulic Filter Element FTR 22502 Product Pump Packing RNG 80054 Hot Oil Pump Packing RNG 80297 Application Hose with Fittings MSC 80418 Y Hose Trough Application Hose with Fittings PIP 80415 Hose Box Wand Handle with Ball Valve VLV 27084 Coupling Chain only FIT 80017 Burner Nozzle 2 25 60 FIT 80686 Bus Bar Support BRK 81182 Fuel Pump Coupling 208731 The BK 250D Kracker and the BK 400D Kracker are similar in design and operation The BK 250D Kracker is used for most of the figures in the Illustrated Parts List D
64. t the augers If a squealing noise is heard put the valve in NEUTRAL and allow the machine to heat longer V02018 64 SEALING cont WARNING ALWAYS KEEP THE APPLICATION WAND POINTED AWAY FROM ALL PERSONNEL FAILURE TO DO SO COULD RESULT IN SEVERE BURNS INJURY OR DEATH OPEN application wand valve to apply sealant material into cracks c 5 CLOSE application wand valve at the end of each crack V02019 65 General Operation 2013 AFTER SEALING CRACKS CAUTION HOSE AND WAND ASSEMBLY MUST CIRCULATE TO TANK WHEN NOT FILLING CRACKS FAILURE TO CIRCULATE APPLICATION WAND ASSEMBLY WILL CAUSE CLOGS IN HOSE AND WAND 1 Place application wand assembly in the return tube and secure in assembly bracket 2 OPEN the application wand valve Sw Ez AGA 2 and allow wand assembly E to circulate FORWARD NOTE For maximum heat recovery keep the tank FULL V02020 66 CLEAN OUT PROCEDURE WARNING ALWAYS REVERSE THE PRODUCT PUMP AND CLOSE THE APPLICATION WAND VALVE BEFORE REMOVING THE HOSE ASSEMBLY FROM THE HOSE RETURN TUBE AND BRACKET OR RETURNING THE HOSE ASSEMBLY TO THE HOSE RETURN TUBE AND BRACKET 2 Move engine throttle to FULL 1 Switch burner OFF 3 Move application recirculation valve MC p to 10 Allow material to circulate p at full flow for one minute MSN V
65. te burner preheat delay is started before the burner can ignite 45 Preparation 2013 Sealant Circulation a Allow the heating system to operate for approximately 30 minutes and attempt to OPEN the product tank valve The product tank valve should move with reasonable hand pressure necessary wait several minutes for the sealant to melt and try to open the valve again CAUTION DO NOT FORCE THE PRODUCT TANK VALVE OPEN b C WAIT UNTIL THE SEALANT MATERIAL IN THE VALVE MELTS FORCING THE VALVE OPEN MAY DAMAGE THE EQUIPMENT AND CREATE AN UNSAFE CONDI TION Position the product tank valve to the OPEN position Gradually move the product pump directional control valve handle to the FORWARD position If the product pump squeals stop immediately If necessary let the sealant continue to heat for several minutes and try to move the product pump directional control valve handle to the FORWARD position again Allow the machine to heat and circulate the sealant material NOTE The circulation temperature gauge indicates approximately 46 300 F due to the heating system heat trace in the plumbing Actual product circulation does not begin until the gauge indicates an increase in temperature above When sealant material reaches pour temperature determined by the sealant manufacturer as indicated on the circulation temperature gauge OPEN the right hand sealant loading door WARNIN
66. tighten the split retainer bolts CAUTION ADJUST THE PUMP PACKING DAILY THE PACKING MUST LEAK ONE 1 DROP PER MINUTE FOR SHAFT LUBRICATION i Periodically snug tighten the split retainer bolts as excess seepage appears at the product pump shaft during operation 78 Ay Perform the following procedures to replace the hot oil pump packing gland Hot Oil Pump Packing Gland Replacement a Loosen the two bolts that hold the retainer on the hot oil pump shaft b Remove the two bolts and lift the retainer up to allow access to the hot oil pump shaft packing A Maintenance CAUTION DO NOT SCRATCH THE PUMP SHAFT WHEN ING THE OLD SHAFT PACKING A DAMAGED SHAFT CAUSES EXCESSIVE PACKING WEAR AND LEAKAGE c Use an awl or scribe to remove the packing from the pump shaft Make sure all the old packing is removed from the packing recess d Repack the pump shaft with clean new packing material Use only BearCat Part No RNG 80297 79 2013 e Position the retainer over new packing and install the two retainer bolts finger tight f Perform hot oil heating and circulation operations in accordance with the procedures given in SECTION 3 PREPARING EQUIPMENT FOR USE CAUTION DO NOT OVER TIGHTEN THE RETAINER BOLTS ONLY SNUG TIGHTEN THE BOLTS OVER TIGHTENED BOLTS WILL CAUSE THE PACKING TO SCORE THE PUMP SHAFT g With the hot oil at normal operating temperature and the hot
67. uid Premium quality hydraulic oil such as Union Unax AW or equivalent is recommended For minimum ambient temperature below 32 F 0 use SAE 10W 150 215 SUS grade Above 32 F 0 C use SAE 20 20W 315 SUS grade Troubleshooting Table 5 6 is provided as a guide to assist the user in the maintenance and troubleshooting of the BK Series All Diesel Kracker Table 5 6 Troubleshooting SYMPTOM POSSIBLE CAUSE SOLUTION Heat transfer oil hot oil is 1 Insufficient hot oil in 1 Check hot oil level Add slow to heat system oil as necessary 2 Hot oil is contaminated 2 Remove sample for or aged testing or drain system and install new oil Refer to procedures and specifications in this section 3 Temperature gauge out of calibration 3 Replace or recalibrate temperature gauge Burner does not light Insufficient pressure in sealant 1 Check hot oil pump heating system due to repair or replace 1 Hot oil pump inoperative 2 Check hot oil level Add oil as necessary Low hot oil level y 3 Close valve See procedure in SECTION 3 2 3 bypass valve open 4 Hydraulic valve closed 4 Open hydraulic valve Burner does not shut off Component malfunction or Shut off burner manually misadjustment with burner switch on control panel Consult factory for corrective action When sealant temperature When hot oil temperature Call Bearcat Service Dept exceeds 525 928 684 78
68. ured with a divider fill vent drain connection suction strainer return line filter and shutoff valve Capacity BK 250D 24 gallons BK 400D 35 gallons 27 Description 2013 TRALERLIGHTSANDWRNG Lights Equipped with federal motor carrier safety regulation compliant stoplight tail light and turn signals Warning Beacon Located on top of the unit ON OFF switch located on control panel Electrical Wiring All wiring is protected by conduit wire loom or other covering Berg 6 pin connector or equivalent wit Hitch Height 16 in to 32 in adjustable MISCELLANEOUS Tool Box Storage for safety equipment small tools spare nozzle tips and parts Fire Extinguisher 10 Ib ABC mounted on front of unit Thermometers Hot oil gauge 150 F to 750 F Sealant tank gauge 100 F to 450 Partlow temperature control Sealant plumbing gauge 150 F to 750 28 BK 250D Dimensions MAX 197 LENGTH WILL VARY DEPENDING ON HITCH DIESEL FUEL TOOL HOSE TANK BOX STORAGE IN HEATED TROUGH SET 1 ng mmm j 1 poe a HIT CH SIDE MOUNTED 65 SWIVEL JACK TEMPERATURE HYDRAULIC CONTROL PANEL FLUID TANK 82 1 2 H rar mE RU
69. vel If not adjust the hitch height Towing an out of level machine can result in an accident or spilled sealant e ALWAYS make sure the tires are properly inflated e ALWAYS make sure the electrical connector for the running lights break lights turn signals and electric brakes if applicable is connected ALWAYS make sure the turn signal and break light functions match the tow vehicle inputs BearCat Manufacturing assumes no liability for accident or injury incurred through improper use of this equipment Safety 35 2013 PREPARING EQUIPMENT FOR USE WARNING BEARCAT EQUIPMENT USES VOLATILE MATERIALS AT HIGH TEMPERATURES AND PRESSURES THIS EQUIPMENT EMPLOYS HIGHLY COMBUSTIBLE OR EXPLOSIVE FUELS POTENTIALLY LIFE THREATENING HAZARDS MAY EXIST DURING EQUIPMENT OPERATION ONLY QUALIFIED PERSONS SHOULD ATTEMPT TO OPERATE SERVICE OR MAKE ADJUSTMENTS TO THE BEARCAT EQUIPMENT WARNING TO AVOID POTENTIAL SEVERE BURNS INJURY OR DEATH PERSONS MUST READ SECTION 2 SAFETY PRECAUTIONS BEFORE OPERATING BEARCAT EQUIPMENT WARNING OPERATORS MUST READ AND UNDERSTAND THIS MATERIAL BEFORE ATTEMPTING TO USE THE MACHINE WARNING ALWAYS WEAR SAFETY GEAR AND PROTECTIVE CLOTHING TO INCLUDE INSULATED GLOVES SAFETY GLASSES AND FACE SHIELD WARNING LONG SLEEVE SHIRT LONG PANTS BOOTS AND COVERALLS WHEN OPERATING THE Kracker FAILURE TO DO SO MAY RESULT IN SEVERE BURNS INJURY OR DEATH This section contains informati
70. ype of open flame or igniter other than the burner automatic ignition system e NEVER use gasoline in the burner The burner operates on diesel fuel only e NEVER heat the sealant material beyond the maximum temperature recommended by the manufacturer NEVER heat the sealant material in sealant tank that leaks e NEVER use an open flame to heat valves or hoses Burner Operations WARNING POTENTIAL FIRE OR EXPLOSION HAZARDS EXIST WHEN OPERATING THE BURNER FAILURE TO FOLLOW THE BURNER OPERATION SAFETY PROCEDURES COULD RESULT IN SEVERE BURNS INJURY OR DEATH e NEVER operate the burner under the following conditions a While the machine is unattended b While the machine is in motion c When the machine is parked in a confined area 32 the sealant tank contains water e ALWAYS make sure the fire extinguisher is on the machine fully charged indicator in the green and the safety seal is unbroken ALWAYS make sure the heat jacket and heating coils are covered with sealant material before and during heating ALWAYS allow sufficient space the tank for the material to expand when heating e ALWAYS park the machine broadside to the wind so sealant vapors or fumes are carried away from the crew and the engine exhaust Sealing Operations Safety WARNING WORN OR FAULTY HOSES CAN BURST AND CAUSE SEVERE BURNS OR DEATH CHECK THE CONDITION OF ALL HOSES BEFORE OPERATING THE

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