[3] Tank Temperature Meter (Bimetallic only) ................................................................................ 18
[4] Tank Heating Indicator Light...................................................................................................... 18
[5] Overtemperature Indicator Light................................................................................................. 18
[6] Head Activate/Deactivate Test (HAT) Switch (user-added option only) ................................... 19
5.2 Startup ........................................................................................................................................... 20
5.3 Adjustments................................................................................................................................... 21
5.3.1 Temperature Adjustments - Bimetallic.................................................................................... 21
5.3.2 Flow Control Valve.................................................................................................................. 23
6 Maintenance ...................................................................................................................24
6.1 Preventive Maintenance ............................................................................................................... 24
6.2 General Maintenance.................................................................................................................... 24
6.2.1 Warning and Caution Notes..................................................................................................... 24
6.2.2 Heating of Parts........................................................................................................................ 25
6.2.3 Monthly Inspection Procedure................................................................................................. 25
7 Troubleshooting .............................................................................................................28
8 Repair and Replacement ................................................................................................40
8.1 Supply Hose Replacement............................................................................................................ 40
8.2 Hose Controller Replacement - Bimetallic ................................................................................. 41
8.3 Pump Motor Replacement ........................................................................................................... 41
8.4 V4 Pump (.450 and .675), Flow Control & Drive Shaft Replacement ..................................... 42
8.4.1 V4 Pump Replacement - .450 and .675 ................................................................................... 42
8.4.2 V4 and V3 Drive Shaft Assembly Replacement...................................................................... 43
9 Parts List .........................................................................................................................44
9.1 Pumps, V4 and Accessories.......................................................................................................... 44
9.2 Pumps, V2 and Accessories.......................................................................................................... 45
9.3 Pumps, V3 and Accessories.......................................................................................................... 46
9.4 Standard Melt Unit Switches ....................................................................................................... 47
9.5 HAT Switches................................................................................................................................ 48
9.6 Tank Heaters ................................................................................................................................. 49
9.7 Standard Fan-Cooled Motors ...................................................................................................... 50
9.8 Standard Fan-Cooled Motor Support......................................................................................... 51
9.9 Temperature Controllers ............................................................................................................. 52
9.10 Tank Level Sensors..................................................................................................................... 53
9.11 Weather-Resistant Housing ....................................................................................................... 53
9.12 Chassis Fans ................................................................................................................................ 53
9.13 Reverse Hose Mounting Kits...................................................................................................... 53
9.14 Adhesive Pressure Gauges ......................................................................................................... 54
ii KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009
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