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Super Shot 60 Diesel Melter Part Manual

Chapter 6 Maintenance Instructions

………………..…………………………………..….…Maintenance Instructions 6-4

6.11 Service Instructions

Step

Action

Do a general inspection of the machine at least once a week.

Replace all worn or damaged parts.

Note:

Keep regular replacement items in stock for emergency repairs to prevent

costly downtime. See

Table 6-4 Recommended Spare Parts

Make necessary adjustments and tighten all loose nuts or screws.

Watch for leaks. Tighten fittings or repair as necessary.

Clean the external surfaces of the machine at regular intervals.

Note:

Refer to the

material manufacturer’s instructions for recommendations.

Follow the recommended maintenance per

Table 6-1 Maintenance Chart

For service, find a list of authorized Distributors and service centers at

Crafco.com/Distributors

6.12 General Maintenance Parts

Quantity

Description

Part No.

Engine Fuel Filter

41867

Engine Oil Filter

45389

Engine Air Filter

45391

Nozzle, Burner

46912

Hydraulic Oil Filter

45438

Table 6-5

Hydraulic Oil

Table 6-5

Heat Transfer Oil

Table 6-6

Table 6-2 Service Instructions

Table 6-3 General Maintenance Parts

Summary of Contents for SS60-Diesel

Page 1: ...Parts Manual 26618 Revision B ...

Page 2: ..._________________ 2nd Hose S N _______________________________ 1st Pump S N _______________________________ 2nd Pump S N ______________________________ Engine S N ________________________________ Compressor S N _____________________________ Gear Box S N Patcher ______________________ Blower S N Magnum ________________________ ...

Page 3: ...SUPER SHOT 60 Diesel Melter Part Manual Revisions Revision Date Updated to new format 6 9 2015 Added trailer mount information 8 2016 ...

Page 4: ...SUPER SHOT 60 DIESEL SKID MOUNT MELTER PN 46800 SUPER SHOT 60 DIESEL TRAILER MELTER PN 46950 ...

Page 5: ......

Page 6: ... 5 3 About the Heated Hose Wand Valve and Tip Guard 5 5 5 4 Electric Hose Care and Cautions 5 6 5 5 Storing the Electric Hose for Transport 5 6 5 6 Loading Material into the Sealant Tank 5 7 Material Tank Depth Chart 5 8 5 6 1 5 7 Dispensing the Material 5 9 5 8 Shutting Down and Cleaning Out the Machine 5 10 5 9 Storing the Machine 5 10 6 0 Maintenance Instructions 6 1 6 1 Engine 6 1 6 2 Hydrauli...

Page 7: ...12 8 2 1 Mixer Hydraulic Troubleshooting 8 18 8 2 2 8 3 Hose Troubleshooting 8 21 Symptom Hose Does Not Heat 8 21 8 3 1 Symptom Trigger is not Working 8 26 8 3 2 RTD Sensor Ohms vs Temperature 8 27 8 3 3 8 4 Pump Troubleshooting 8 29 Symptom Material Does Not Dispense When the Pump is Activated 8 29 8 4 1 Pump Hydraulic Troubleshooting 8 35 8 4 2 9 0 About the Illustrated Parts List 9 1 9 1 Orderi...

Page 8: ...Super Shot 60 Diesel Melter Part Manual Table of Contents 10 0 Tools and Accessories 10 1 ...

Page 9: ...igure 8 5 Mixer Circuit Schematic 8 17 Figure 8 6 Hydraulic Valve Pressure Setting 8 19 Figure 8 7 Din Plug Layout 8 20 Figure 8 8 Junction Box Voltage Test 8 23 Figure 8 9 Hose Circuit Schematic 8 24 Figure 8 10 Junction Box Wiring 8 25 Figure 8 11 Pump Circuit Schematic 8 36 Figure 9 1 Super Shot 60 Diesel Skid Mount Melter 9 2 Figure 9 2 Super Shot 60 Diesel Trailer Melter 9 6 Figure 9 3 Tank A...

Page 10: ...ble 6 4 Recommended Spare Parts 6 5 Table 6 5 Recommended Fluids and Lubricants 6 5 Table 6 6 Applicable Brand of Heat Transfer Oil 6 6 Table 6 7 Material Pump Replacement 6 7 Table 6 8 Material Pump Replacement continued 6 8 Table 8 1 Basic Visual Burner Troubleshooting 8 1 Table 8 2 Basic Visual Burner Troubleshooting continued 8 2 Table 8 3 Burner Electrical Troubleshooting 8 2 Table 8 4 Burner...

Page 11: ...rical Troubleshooting 8 30 Table 8 27 Pump Electrical Troubleshooting continued 8 31 Table 8 28 Pump Electrical Troubleshooting continued 8 32 Table 8 29 Pump Electrical Troubleshooting continued 8 33 Table 8 30 Pump Electrical Troubleshooting continued 8 34 Table 8 31 Pump Hydraulic Troubleshooting 8 35 Table 9 1 Super Shot 60 Diesel Skid Mount Melter PN 46800 9 3 Table 9 2 Super Shot 60 Diesel S...

Page 12: ...Super Shot 60 Diesel Melter Part Manual List of Tables Table 9 13 Hydraulic Diagram PN 46959 9 25 Table 9 14 Hydraulic Diagram PN 46959 continued 9 26 Table 9 15 Electrical Schematic 9 29 ...

Page 13: ...vious chapter ends on the right page If you are viewing this in a digital format PDF the following features are available 1 The Table of Contents List of Tables and List of Figures are all hyperlinks when left mouse clicked on section table or figure you will be sent to that page 2 The blue highlighted text throughout the manual is a hyperlink when left mouse clicked you will be sent to that page ...

Page 14: ......

Page 15: ...rom all moving parts 2 3 Equipment or Operational Safety Do not operate the machine in buildings or work areas that do not have sufficient airflow Shut down the burner and the engine before refilling the fuel tank Make sure mixer stops before adding solid material to the sealant tank Lift the lid place the material on the lid and close the lid The mixer should restart automatically Always keep a c...

Page 16: ... notices The table below includes the most commonly used symbols and notices Symbol Item Remarks WARNING Warning Refers to possible bodily injury or death CAUTION Caution Refers to possible equipment damage or operational malfunction Severe Burn Hazard Hot material can cause severe burns Protective Shoes Wear hard soled work shoes Protective Gloves Wear heat resistant gloves Protective Face or Eye...

Page 17: ...served Safety 2 3 Symbol Item Remark Crush Hazard Keep feet and legs clear Pinch Hazard Keep hands and feet clear Exhaust Hazard Avoid breathing engine exhaust Read Manual Read and understand operator and safety manuals before operating machine Table 2 2 Safety Symbols and Notices continued ...

Page 18: ......

Page 19: ...e been damaged by accident alteration abuse improper lubrication maintenance normal wear or other cause beyond our control The warranty provided herein extends only to the repair and or replacement of those components on the equipment covered above and does not cover labor costs The warranty does not extend to incidental or consequential damages incurred as a result of any defect covered by this w...

Page 20: ...s etc Note All engine warranties are covered through the engine manufacture If you need information for a distributor in your area please contact us and we will direct you to the closest engine distributor All parts returned are tested and evaluated If the part has been modified in any way without prior consent from a Crafco Inc representative warranty is void Please follow the instructions stated...

Page 21: ...aged by accident alteration abuse improper lubrication maintenance normal wear or other cause beyond our control The warranty provided herein extends only to the repair and or replacement of those components on the equipment covered above and does not cover labor costs The warranty does not extend to incidental or consequential damages incurred as a result of any defect covered by this warranty Al...

Page 22: ... All engine warranties are covered through the engine manufacturer If you need information for a distributor in your area please contact us and we will direct you to the closest engine distributor All parts returned are tested and evaluated If the part has been modified in any way without prior consent from a Crafco Inc representative warranty is void Please follow the instructions stated below wh...

Page 23: ...in 31 2 cm x 38 1 cm Maximum Heat Input 205 000 BTUs Burner and Temperature Control Diesel forced air thermostatic control Engine Isuzu Diesel Three cylinder Model 3CJ1 19 HP 3 000 RPM 14 2 kW 3 000 RPM Drive Mechanism All hydraulic with infinite speed forward and reverse on material pump Fixed speed agitator Mixer Full sweep mixer with 2 horizontal paddles vertical risers Dry Weight Approximately...

Page 24: ......

Page 25: ...n level surface check the heat transfer oil level while at a temperature of 70 F 21 1 C The oil should be at the full mark on the dipstick DO NOT overfill or spillage may occur when the oil is heated and expands See Figure 5 2 Heat Transfer Oil Dipstick 5 Make sure all toggle switches are turned OFF and all temperature control dials are set to their minimum settings WARNING The safe operation of t...

Page 26: ... Part Manual Chapter 5 Operating Instructions 2016 by Crafco Inc All Rights Reserved Operating Instructions 5 2 Figure 5 1 Hydraulic Fluid Level and Temp Gauge Figure 5 2 Heat Transfer Oil Dipstick Dipstick for Heat Transfer Oil ...

Page 27: ...rst around the walls and bottom of the tank The material temperature sensor is located by the wall therefore it is possible that at the beginning of the melting process the indicated temperature reaches operating value but the material between to the center tower and the outside wall of the tank is still solid This is normal and when the heated hose is ready for operation most of the material in t...

Page 28: ...s not dispense shut the machine down locate and remove the plug in the line 12 See Table 5 7 Dispensing the Material CAUTION DO NOT twist or kink the hose Avoid sharp bends and continuous twisting by maintaining a minimum 10 inch bend radius DO NOT use a setting on the hose controller if more than 400 F 204 4 C DO NOT move or bend the hose when cold it can cause damage to the hose DO NOT leave the...

Page 29: ...CKED position at all times except when intentionally pumping material The Valve The wand has a disposable duckbill valve on the end which shuts off the flow of material when the pump is turned off and prevents excessive dripping of material This valve also directs the material into a stream for easy application into the crack Other sealing tips are available See 10 0 Tools and Accessories for othe...

Page 30: ...k Crafco Inc recommends you do not work directly under the boom this may cause damage to the hose 4 Follow all machine instructions in this manual CAUTION Hose damage occurs if The hose is bent or moved when cold The hose is twisted or bent at a sharp radius The hose is moved before being heated a minimum of 30 minutes and set at 380 F 193 3 C The operator crosses over or under the hose causing th...

Page 31: ...vents hot material from getting on operators and causing severe burns Never throw blocks of material directly into tank Hot material splash hazard will result 1 To load material into the sealant tank first open the lid 2 Place the solid material on the lid then close the lid 3 Continue adding solid material at intervals to allow the mixer to rotate without jamming Note If blocks of solid material ...

Page 32: ... 2 9 18 34 75 49 54 187 53 101 6 12 24 46 33 46 48 175 95 127 15 30 57 92 43 42 164 36 152 4 18 36 69 50 40 36 152 78 177 8 21 42 81 08 37 3 141 20 207 8 24 48 92 67 34 24 129 61 233 2 27 54 104 25 31 18 118 03 258 6 30 60 115 83 28 12 106 45 284 33 66 127 42 25 06 94 86 309 4 36 72 139 00 22 83 28 334 8 39 78 150 58 18 94 71 70 360 2 42 84 162 17 15 88 60 11 385 6 45 90 173 75 12 82 48 53 411 48 ...

Page 33: ...ugh the wand is designed to heat the material all the way down to the tip on cold days you can place the tip of the wand under the lid to facilitate material melting in the valve Insert the wand tip for only a short time before proceeding 1 When the material and hose have reached manufacturer s application temperature you are ready to dispense material 2 Turn the pump speed control to the lowest s...

Page 34: ...e OFF position 6 Stop the engine by turning the key to the OFF position 5 9 Storing the Machine Store the machine in an area where moisture cannot enter the heating system such as the heat transfer oil tank etc Extended down time can cause moisture build up in the heating tank Evidence that moisture has collected in the heat transfer oil is a constant popping noise If this popping noise is heard w...

Page 35: ...ation or 1 year whichever comes first Failure to follow this oil change interval will result in machine damage 6 4 Wheel Bearing Pack the wheel bearing every 24 000 miles or every two years whichever comes first Use a good grade of bearing grease 6 5 Material Sensor Tube Check for heat transfer oil in tube every 50 hours of operation 2 ounces required 6 6 Lug Nuts Torque all nuts bolts before firs...

Page 36: ... jack using a good grade of bearing grease 6 9 Temperature Control Calibration Check the control knob calibration weekly Calibrate by turning the knob counterclockwise If the marks do not align loosen screw in knob and align the line on the control knob with the calibration mark on the scale plate See Figure 6 2 Scale Plate Figure 6 2 Scale Plate 200 220 240 260 280 300 320 340 360 380 400 Calibra...

Page 37: ...dd As needed Heat Transfer Oil Check X Change X Hydraulic Oil Check X Change X Hydraulic Oil Filter Change X Burner Check burner box insulation X Clean CAD cell X Check Electrodes X Replace burner nozzle X Wheel Bearings Clean and re pack using a good grade of bearing grease Every 24 000 miles or two years Tongue Jack Grease using a good grade of bearing grease Once a year Material Tank Scrape out...

Page 38: ...for leaks Tighten fittings or repair as necessary 5 Clean the external surfaces of the machine at regular intervals Note Refer to the material manufacturer s instructions for recommendations 6 Follow the recommended maintenance per Table 6 1 Maintenance Chart For service find a list of authorized Distributors and service centers at Crafco com Distributors 6 12 General Maintenance Parts Quantity De...

Page 39: ...troller Electric Hose 51691 1 Temperature Controller Hot Oil 43391 1 DC Controller 42335 1 Coupling Fuel Pump 41970 1 Electric Hose 52400 1 Solenoid 39602 6 14 Recommended Fluids and Lubricants Application Recommended Full Point Engine Oil Refer to engine manual 3 Qts 2 8 L Hydraulic Oil Shell AW Hydraulic 46 26 Gals 98 4 L Heat Transfer Oil Shell Turbo T 68 Group II 21 Gals 82 L Table 6 4 Recomme...

Page 40: ...sfer Oil 3 Shell Turbo T 68 Group II Phillips 66 Magnus Oil 68 Shell Turbo T 68 Group II CAUTION The heat transfer oil in this machine is a grade that has been tested and recommended by Crafco Inc Using a grade of oil not specifically recommended by Crafco Inc is cause for warranties to be voided All oils subjected to high temperatures deteriorate with time and lose many of their characteristics T...

Page 41: ...nd remove the drive chain 6 Loosen the set screw in the lower coupling half located between the hydraulic motor and the material pump drive shaft 7 Remove the four 4 hydraulic hoses and put caps on all the ports Note Mark the hoses for ease of replacement 8 Remove the four 4 bolts holding the motor mount on top of the melter See Figure 6 3 Material Pump Replacement 9 Lift off the motor mount and s...

Page 42: ...ounds Take precautions not to drop the pump on any part of your body or pinch any part of your body between the pump and another object 16 Clean any sealant from the top of the pump mounting plate and clean the shaft holes See Figure 6 3 Material Pump Replacement CAUTION Premature pump wear results if the pump mounting plate and bolt holes are not properly cleaned Table 6 8 Material Pump Replaceme...

Page 43: ... Manual Chapter 6 Maintenance Instructions 2016 by Crafco Inc All Rights Reserved Maintenance Instructions 6 9 Figure 6 3 Material Pump Replacement PUMP ASSEMBLY BOLTS PUMP MOUNTING BOLTS PUMP ASSEMBLY PUMP MOUNTING PLATE TANK BOTTOM ...

Page 44: ......

Page 45: ...o ground If the item you are checking has a ground wire attached then use that ground or you can use a non painted surface on the frame 7 2 Checking AC Voltage with Multimeter Connect the probes to the meter See Figure 7 1 Standard Multimeter Set the range to a position that includes 24 volts or higher There are three steps to test the generator voltage All 3 values should be in the range of 24 30...

Page 46: ...ic hose always use a clamp on amp meter See Figure 7 2 Clamp On Amp Meter Multimeter The amperage in the hose can reach as high as 35 amps Clamp the meter around one wire at a time Remember most clamp on meters do not work on DC current Figure 7 1 Standard Multimeter AC Voltage Generator Output Audible Continuity Hose Wand and wire connection Ohms Ω Sensors Hyd Coils Burner Ignition Coil Use these...

Page 47: ... Crafco Inc All Rights Reserved How to Use a Multimeter 7 3 Figure 7 2 Clamp On Amp Meter Multimeter Ohms Ω Sensors Hyd Coils Burner Ignition Coil Audible Continuity Hose Wand and wire connection DC Voltage Everything except Generator AC Voltage Generator Output AC Amps Hose Current ...

Page 48: ......

Page 49: ...aterial temperature according to the type of material you are using and the Hot Oil 100 F 37 8 C above the Material set point 5 Does either readout display a 1 NOTE This occurs only when there is a short in the sensor circuit Yes this indicates a short in the circuit Check the RTD sensor for water under the cap causing a short Also look for worn wires possibly shorting to frame between sensor and ...

Page 50: ... to burner plug of the frame solenoid and the black wire in the burner plug Yes go to Step 4 No go to Step 1b 1b Is there 12Vdc between the other large terminal red wire going to the circuit breaker of the frame solenoid and the ground wire attached to the mounting bolt Yes replace frame solenoid No go to Step 2 2 Is there 12Vdc between the circuit breaker red wire going to frame solenoid located ...

Page 51: ... No go to Step 5 5 Is there 12Vdc between gray wire labeled GRY 2 and nearby ground source Yes replace terminal block No go to Step 5a 5a Is there 12Vdc between terminal 7 gray wire and terminal 5 black wire of the hot oil PAKSTAT Yes check for loose or broken wires between terminal block and terminal 7 of the hot oil PAKSTAT No go to Step 5b 5b Is there 12Vdc between terminal 6 gray wire and term...

Page 52: ...STAT and terminal block No go to Step 8a 8a Is there 12Vdc between orange wire labeled ORN 2 on upper terminal blocks and a nearby ground source black wire Yes replace terminal block No go to Step 9 9 Is there 12Vdc between terminal 3 orange wire and terminal 5 black wire on hot oil PAKSTAT Yes check for loose or broken wires between terminal 3 of the hot oil PAKSTAT and terminal block No go to St...

Page 53: ... between ACC of ignition switch and bottom terminal of circuit breaker No go to Step 13a 13a Is there 12Vdc between B blue wire of ignition switch and nearby ground source black wire Yes replace ignition switch No go to Step 14 14 Is there 12Vdc between blue wire on starter solenoid and nearby ground source black wire or bare metal on engine case Yes check for loose or broken wire between starter ...

Page 54: ... Solenoid Circuit Breaker Engine Oil Pressure Switch RTD Sensors 1 08k Ohms 70 F BLK 5 GRY 2 GRY 3 ORN 2 BLK 1 GRY 1 WHT GRN WHT GRN ORN 1 BLK 3 BLK 1 ORN 1 BLK 4 WHT BLK WHT BLK 4 1 14 13 12 9 WHT GRN 1 WHT GRN 2 BLK 3 WHT BLK WHT BLK WHT GRN WHT GRN GRN BRNR MATERIAL 51672 BLK 4 GRN BRNR GRY 1 ORN 1 ORN 1 5 8 RED 4 WHT RED WHT RED 4 T1 T2 T3 T4 T7 T6 T9 T8 T1 T2 T3 T4 T7 T6 T9 T8 Acc BLK 5 GRY 2...

Page 55: ... sure the electrodes are in the correct position Loosen the clamp holding the electrodes in place so they can be adjusted Inspect the porcelain ceramic insulator for any cracks Also check the tip of each of the electrodes to make sure they still have a sharp point and are not rounded off 5 If it has been longer than 500 hours since the last time the burner nozzle was replaced Crafco recommends rep...

Page 56: ...le Fuel Solenoid wire should have 12Vdc after the delay 5 Twist the yellow wires together once voltage registers on the orange blue and purple wires Orange Blower Motor wire should maintain 12Vdc Blue Igniter wire should lose voltage after 15 seconds Purple Valve wire should maintain 12Vdc Purple Fuel Solenoid wire should maintain 12Vdc 6 If any of the above tests fail replace the DC Controller 8 ...

Page 57: ...e between the two springs to ground resistance readings is greater than 20 Or the spring to spring resistance does not read approximately twice the spring to ground 8 0 7 Bleeding the Burner Step Bleeding the Diesel Burner 1 Place an oil pan under the machine in front of the burner 2 Using a 3 8 wrench loosen the bleeder valve on the fuel pump refer to Figure 8 3 Diesel Burner Air Settings for ble...

Page 58: ...ustment Figure 8 3 Diesel Burner Air Settings ELECTRODE NOZZLE 5 32 R 1 4 5 32 FUEL PRESSURE GAUGE KIT BLEEDER NOZZLE LINE NUT COPPER FUEL LINE NUT AIR SHUTTER SCREW IGNITION COIL LOCKING TAB FUEL PRESSURE ADJUSTMENT SCREW FUEL PRESSURE GAUGE AIR BAND AIR SETTING AIR SHUTTER AIR BAND SCREW Air Shutter 4 Air Band 0 Fuel Pressure 140 PSI 9 65 bar Adjustment Plate 3 ...

Page 59: ... the material inside the tank When the tank is empty use an air chisel to remove this built up material Remove as much as possible all around the tank including the roof of the material tank Remove all the old sealant chunks from the bottom of the material tank This should be done every year or as conditions require 3 Check your level of the heat transfer oil the mark on the dipstick is for 70 F 2...

Page 60: ...tch to the Reverse position Is the agitator moving Yes allow mixer to reverse for 15 seconds and then move the Mixer toggle switch to the Forward position Go to Step 6 No go to Table 8 15 Mixer Electrical Troubleshooting 6 Open the Material loading door Are there several un melted blocks in the tank Yes this may cause the agitator to jam Use the mixer toggle switch to move the agitator forward and...

Page 61: ...y ground wire blue wire With the Mixer toggle switch in the Forward position See Figure 8 5 Mixer Circuit Schematic Yes replace din plug No go to Step 2a 2a Is there 12Vdc between the Mixer toggle switch center post red wire and nearby ground source blue wire Yes replace mixer toggle switch No go to Step 3 3 Is there 12Vdc between the lid switch red wires and a nearby ground source Check both red ...

Page 62: ...ck and material PAKSTAT Yes on ORN 2 and No on ORN 1 replace terminal block No on both go to Step 6 6 Is there 12Vdc between orange wire labeled ORN 2 terminal 3 and terminal 5 black ground of hot oil PAKSTAT Yes check for loose connections or broken wires between terminal 3 and terminal block No go to Step 7 7 Is there 12Vdc between top terminal of the power switch and a nearby ground black wire ...

Page 63: ...9a 9a Is there 12Vdc between B blue wire of ignition switch and nearby ground source black wire Yes replace ignition switch No go to Step 10 10 Is there 12Vdc between blue wire on starter solenoid and nearby ground source black wire or bare metal on engine case Yes check for loose or broken wire between starter solenoid and ignition switch No go to Step 10a 10a Check connections and condition of r...

Page 65: ...T BLK Lid Switch Mixer Toggle Switch Pump Rev Toggle Switch Pump Rev Coil with Light Mixer Fwd Coil with Light Mixer Rev Coil with Light BLK 5 PNK 3 ORN 2 BLK 1 PNK 2 ORN 1 BLK 3 BLK 1 ORN 1 BLK 4 WHT BLK WHT BLK 8 5 4 1 14 13 12 9 BLK 3 RED LID HOSE 51691 MATERIAL 51672 BLK 4 PNK 2 ORN 1 RED LID WHT BLK WHT BLK T1 T2 T3 T4 T7 T6 T9 T8 T1 T2 T3 T4 T7 T6 T9 T 8 Acc Br Ra BLK 5 PNK 3 RED 2 ORN 2 BLK...

Page 66: ...ove the Mixer toggle switch to the Forward position and read the pressure gauge If the pressure needs to be adjusted use the pressure relief valve labeled RVA loosen the jam nut and adjust the pressure with the allen screw at the end of the relief Turn clockwise to increase pressure and counter clockwise to decrease pressure then tighten the jam nut to lock the pressure Next turn OFF the diesel en...

Page 67: ...s Reserved Troubleshooting 8 19 Figure 8 6 Hydraulic Valve Pressure Setting RVP PUMP PRESSURE RELIEF SET 1000 PSI RVA AGITATOR PRESSURE RELIEF SET 1000 PSI PRESSURE RELIEF JAM NUT ALLEN SCREW Agitation Direction Counterclockwise Material Pump Clockwise Hydraulic Flow 9 71 GPM 36 8 LPM 2 550 RPM ...

Page 68: ...apter 8 Troubleshooting 2016 by Crafco Inc All Rights Reserved Troubleshooting 8 20 Figure 8 7 Din Plug Layout DIN PLUG 3 MIXER REVERSE DIN PLUG 1 MATERIAL PUMP REVERSE DIN PLUG 2 MATERIAL PUMP FORWARD DIN PLUG 4 MIXER FORWARD MOUNTING BRACKET ...

Page 69: ...eshooting NOTE Use Figure 8 9 Hose Circuit Schematic while troubleshooting the hose electrical system Step Possible Cause If 1 Is there 12Vdc between BATT terminal of the generator and a nearby ground source lug on battery tray Yes go to Step 2 No go to Step 6 2 Is there 24Vac between the white green and black wires NOTE Do this test inside the junction box Check between black and white black and ...

Page 70: ...ontinuity in the wand between D E and A NOTE Check between D and E D and A and A and E Yes go to Step 5 No this wand needs to be repaired or replaced Contact Crafco Inc to send back the wand for repair 5 Is there 12Vdc between wire labeled BLU GEN on the upper terminal block and nearby ground source black wire Yes check for loose or broken connections between terminal block and the BATT terminal o...

Page 71: ...ual Chapter 8 Troubleshooting 2016 by Crafco Inc All Rights Reserved Troubleshooting 8 23 Figure 8 8 Junction Box Voltage Test Test 1 between black and white wires Test 3 between white and green wires Test 2 between black and green wires ...

Page 72: ...CORD BLACK WHITE AND GREEN 12vdc 5 7 amps RTD Sensor 1 08K ohms at 70 F Batt GREEN WHITE BLACK BLUE BLUE BLUE BLU BLUE BLUE BLUE BLK WHT Hose Generator Wand t BLK 5 PNK 3 BLU 2 BLK 1 PNK 1 PNK 2 BLK 3 BLK 1 PNK 2 BLK 4 WHT BLK 8 5 4 1 14 13 12 9 BLK 3 WHT BLK BLU HOSE 51691 MATERIAL 51672 BLK 4 BLU 1 BLU BLU 1 PNK 1 PNK 2 T1 T2 T3 T4 T7 T6 T9 T8 T1 T2 T3 T4 T7 T6 T9 T8 GRN PRP BLU BLU 2 BLK 5 BLK ...

Page 73: ...ting 8 25 Figure 8 10 Junction Box Wiring HEATER BLACK HEATER WHITE HEATER GREEN SENSOR WHITE SENSOR BLACK TRIGGER GREEN TRIGGER RED HEATER BLUE TRIGGER RED TRIGGER RED SENSOR BLACK SENSOR WHITE HEATER BLUE HEATER BLUE TRIGGER RED TRIGGER RED C B HEAT ELEM BLUE HEAT ELEM BLUE HEAT ELEM BLUE E D A KETTLE END WAND END ...

Page 74: ...n box NOTE These wires must be disconnected from the terminal block and the trigger depressed to perform this test Yes go to Table 8 25 Basic Visual Pump Troubleshooting No go to Step 2 2 Disconnect the electrical connector between the hose and wand check for continuity between C and B wand side Yes this hose needs to be repaired or replaced Contact Crafco Inc to send back the hose for repair No t...

Page 75: ...1106 0 1108 1 1110 3 1112 4 1114 6 1116 7 1118 9 1121 0 1123 2 90 1125 3 1127 5 1129 6 1131 8 1133 9 1136 1 1138 2 1140 4 1142 5 1144 7 100 1146 8 1149 0 1151 1 1153 2 1155 4 1157 5 1159 7 1161 8 1164 0 1166 1 110 1168 3 1170 4 1172 5 1174 7 1176 9 1179 0 1181 1 1183 3 1185 4 1187 5 120 1189 7 1191 8 1194 0 1196 1 1198 2 1200 4 1202 5 1204 6 1206 8 1208 9 130 1211 0 1213 2 1215 3 1217 5 1219 6 122...

Page 76: ... 5 1764 5 1766 6 1768 6 1770 6 1772 7 400 1774 7 1776 8 1778 8 1780 8 1782 9 1784 9 1786 9 1789 0 1791 0 1793 1 410 1795 1 1797 1 1799 2 1801 2 1803 2 1805 3 1807 3 1809 3 1811 4 1813 4 420 1815 4 1817 5 1819 5 1821 5 1823 6 1825 6 1827 6 1829 6 1831 7 1833 7 430 1835 7 1837 8 1839 8 1841 8 1843 8 1845 9 1847 9 1849 9 1851 9 1854 0 440 1856 0 1858 0 1860 0 1862 1 1864 1 1866 1 1868 1 1870 2 1872 2...

Page 77: ...rease the flow Still no go to Step 4 4 Inside the control box and under the front panel find the relay cube for the pump It is found near the middle left hand side of the box It is a clear yellow cube with a green button facing the top of the control box When you press this button material should dispense from the wand so be careful Does the material pump shaft coupler turn when you press the gree...

Page 78: ... 8 black ground wire Yes check for a broken wire or poor wire crimp on terminal 1 pink wire If you have 12 Vdc on terminal 9 pink then you must have 12 Vdc on terminal 1 pink wire they are the same wire No if this is the case you would have had a hose heating issue 3 Is there 12 Vdc between the terminal block purple wire and the terminal black ground wire Yes go to Step 4 No check for a broken wir...

Page 79: ...equest an RA so you can send your wand back for repair 5a Disconnect the two red trigger wires in the junction box going toward the hose Move the wand end of the hose next to the junction box Is there continuity on the hose connector C socket and only one red trigger in the junction box Check both red trigger wires in the junction box one at a time Yes go to Step 5b No recheck the hose connector C...

Page 80: ...ss to the left of the terminal block red black wire and the pump relay base 13 terminal black ground wire Yes check for a loose wire in the terminal block If you have power on one side you should have it on the other If still the case after checking then replace the terminal block No go to Step 7c 7c Is there 12 Vdc between the circuit breaker bottom post red wire and the pump relay base 13 termin...

Page 81: ...e agitator is working properly go to Table 8 31 Pump Hydraulic Troubleshooting No recheck the amber light if the light comes ON and you do not have 12 Vdc then replace the din plug 10 Does the hydraulic pump shaft coupler turn counter clock wise when you hold the Pump toggle switch in the Reverse position Yes this feature is working properly No go to Step 10a 10a Is the amber light ON when you hol...

Page 82: ...ire between the Mixer toggle switch and the Pump toggle switch No if this is the case you would have had an agitator problem Call Crafco Inc and speak to a service technician 10e Unscrew the din plug center screw so you can pull the din plug up about 1 4 so you can check for voltage Is there 12 Vdc from side post to side post when the wand trigger is pulled Yes the electrical system for the agitat...

Page 83: ...ump hydraulic motor cap off the fitting on the motor and use a 3000 PSI gauge with the proper JIC fitting attach it to the hose Start the Isuzu engine turn ON the main power in the control box pull the wand trigger and read the pressure gauge If the pressure needs to be adjusted use the pressure relief valve marked RVP loosen the jam nut and adjust the pressure with the allen screw at the end of t...

Page 84: ...RIG Trigger RTD Sensor 1 08K ohms at 70 F Batt GREEN WHITE BLACK BLUE BLUE BLUE BLUE BLUE BLUE BLK WHT Hose Generator Wand t BLK 5 PRP 1 RED TRIG BLK 1 PNK 1 PNK 2 BLK 3 BLU PMP GRN TRIG BLK 1 PNK 2 BLK 4 WHT BLK 8 5 4 1 14 13 12 9 PRP 2 BLK 3 BLU PMP WHT BLK RED TRG GRN TRG HOSE 51691 MATERIAL 51672 RED 1 BLK 4 PRP 1 PNK 1 PNK 2 RED 2 RED 1 T1 T2 T3 T4 T7 T6 T9 T8 T1 T2 T3 T4 T7 T6 T9 T8 GRN PRP ...

Page 85: ...ions are designed to show general shape and size of a part and the relationship that part has to other parts Actual size and shape of parts or components may differ or vary from the actual part or component 9 1 Ordering Crafco Parts Crafco distributors and Crafco Pavement Preservation Supply Centers are strategically located throughout the United States Parts can be ordered from your local Crafco ...

Page 86: ...fco Inc All Rights Reserved Tools and Accessories 9 2 9 2 Super Shot 60 Diesel Skid Mount Melter Figure 9 1 Super Shot 60 Diesel Skid Mount Melter 23 24 25 24 1 3 5 4 6 10 8 9 11 13 16 15 17 18 19 20 22 21 44 45 46 47 28 27 26 29 31 32 33 30 34 35 a b 36 38 40 39 41 42 43 37 2 7 12 14 ...

Page 87: ...1 8 44818 TUBING SIGHT GAUGE 1 9 44817 FITTING SIGHT GAUGE 2 10 46908 DRIP PAN 1 11 45415 SIGHT GAUGE HYDRAULIC TANK 1 12 47106 ENGINE ASSEMBLY 1 13 29399 ISOMOUNT 4 14 45402 HYDRAULIC PUMP ASSEMBLY 1 15 39602 SOLENOID 1 16 31512 CIRCUIT BREAKER 1 17 43465 SENSOR RTD 2 18 51065 CORD GRIP 2 19 45525 CONTROL BOX ASSEMBLY ELECTRIC 1 20 44027 JUNCTION BOX ASSEMBLY 1 21 52400 HOSE ELECTRIC 15 1 22 4683...

Page 88: ...46878 CHAIN GUARD 2 32 43374 DIPSTICK 1 33 26025 AIR BREATHER 1 34 46855 FUEL TANK ASSEMBLY 1 35 45498 HYDRAULIC FILTER ASSEMBLY 1 35a 45438 HYDRAULIC FILTER ELEMENT 1 35b 45440 O RING HYDRAULIC FILTER 1 36 46850 HYDRAULIC TANK ASSEMBLY 1 37 43579 FILLER BREATHER 2 38 46945 ENGINE COVER 1 39 24000 BATTERY 1 40 24002 BATTERY BOX 1 41 46909 COVER BURNER 1 42 46380 BURNER 14 VOLT 1 43 39608 SWITCH LI...

Page 90: ...l Rights Reserved Tools and Accessories 9 6 9 3 Super Shot 60 Diesel Trailer Melter 1 3 2 5 6 7 8 9 10 11 12 13 14 16 17 18 19 20 21 4 22 23 24 25 26 27 28 29 30 29 31 32 33 34 35 36 37 38 39 40 a b 41 42 43 45 47 46 48 49 50 53 54 55 56 51 52 15 44 Figure 9 2 Super Shot 60 Diesel Trailer Melter ...

Page 91: ...RIC 1 8 43355 OVERFLOW TANK 1 9 44818 TUBING SIGHT GAUGE 1 10 44817 FITTING SIGHT GAUGE 2 11 46908 DRIP PAN 1 12 45415 SIGHT GAUGE HYDRAULIC TANK 1 13 47106 ENGINE ASSEMBLY 1 14 29399 ISOMOUNT 4 15 20013 3 PINTLE OPTIONAL 1 16 23082 5 000 LBS TONGUE JACK 1 17 45402 HYDRAULIC PUMP ASSEMBLY 1 18 39602 SOLENOID 1 19 31512 CIRCUIT BREAKER 1 20 43465 SENSOR RTD 2 21 51065 CORD GRIP 2 22 44779 PASSENGER...

Page 92: ...MP AGITATOR MOTOR ASSEMBLY 1 36 46878 CHAIN GUARD 2 37 43374 DIPSTICK 1 38 26025 AIR BREATHER 1 39 46855 FUEL TANK ASSEMBLY 1 40 45498 HYDRAULIC FILTER ASSEMBLY 1 40a 45438 HYDRAULIC FILTER ELEMENT 1 40b 45440 O RING HYDRAULIC FILTER 1 41 46850 HYDRAULIC TANK ASSEMBLY 1 42 43579 FILLER BREATHER 2 43 46945 ENGINE COVER 1 44 23117 BREAKAWAY SWITCH 1 45 32365 YELLOW CLEARANCE LIGHT 2 46 24000 BATTERY...

Page 93: ...ccessories 9 9 Table 9 5 Super Shot 60 Diesel Trailer Melter PN 46950 continued FIG ITEM PART NO DESCRIPTION QTY Figure 9 2 55 46851 BASE BOOM 1 56 46862 LOCK BOOM 1 57 52400 HOSE ELECTRIC 15 NOT SHOWN 1 58 46958 SAFETY CHAIN NOT SHOWN 2 59 44797 LED LICENSE PLATE LAMP NOT SHOWN 1 60 26099 LICENSE PLATE BRACKET NOT SHOWN 1 ...

Page 94: ...t 60 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 2016 by Crafco Inc All Rights Reserved Tools and Accessories 9 10 9 4 Tank Assembly Figure 9 3 Tank Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 ...

Page 95: ...2 BEARING FLANGED 1 2 43321 CHAIN DRIVE 1 3 44163 KEY SPROCKET 1 4 44165 SPROCKET DRIVEN 1 5 43548 SHAFT DRIVE PUMP 1 6 46896 SHAFT AGITATOR 1 7 46803 SCREEN PUMP 1 8 44850 PUMP MATERIAL 1 9 28270 1 PIPE CAP 1 10 28101 1 X 8 LONG PIPE NIPPLE 1 11 28055 1 X 5 LONG PIPE NIPPLE 1 12 28210 1 PIPE ELBOW 1 13 28351 1 X REDUCER BUSHING 1 14 28060 2 X 5 LONG PIPE NIPPLE 1 15 28273 2 PIPE CAP 1 16 46900 PA...

Page 96: ...2 WHT 1 COMP BLK 3 RED BLK YLW RED WHT BLK WHT BLK WHT GRN WHT GRN RED LID BLU PMP WHT RED WHT BLK RED TRG GRN TRG YELLOW RED BLK WHT COMP BLU BLK GND GRN BRNR RED WHT RED BLK WHT GRN BLK YEL BLU WHT GRN YEL YEL RED BLK BLU BLK GRN WHT RED BLK HOSE 51691 MATERIAL 51672 RED 1 BLU 3 BLK LIGHT BLK 4 WHT RED 4 GRN BRNR BLU 1 BLU BLU 1 PNK 1 PRP 1 PNK 1 GRY 1 ORN 1 PNK 2 ORN 1 BLK YLW RED 6 RED BLU YLW...

Page 97: ... 51802 END BRACKET TENSION CLAMP 1 11 51803 MOUNTING RAIL TENSION CLAMP 1 12 51800 FEED THROUGH TERMINAL 26 13 51801 2 POLE JUMPER 1 14 51804 3 POLE JUMPER 1 15 44979 RELAY STARTER 2 16 44980 TIMER 1 17 51673 RELAY NORMALLY CLOSED 1 18 51672 TEMPERATURE CONTROLLER 400 F 275 F 1 19 51670 SPACER CONTROLLER 8 20 51691 TEMPERATURE CONTROLLER 400 F 325 F 1 21 50280 CONDUIT NUT 3 22 24021 CORD GRIP CONN...

Page 98: ...hts Reserved Tools and Accessories 9 14 Table 9 8 Control Box Assembly continued FIG ITEM PART NO DESCRIPTION QTY Figure 9 4 31 41994 IGNITION SWITCH WITH OUT TUMBLER 1 32 47203 ENCLOSURE CONTROL BOX 1 33 50593 KNOB NOT SHOWN 3 34 51684 RIBBON CABLE 36 NOT SHOWN 2 35 51698 RIBBON CABLE 5 NOT SHOWN 1 ...

Page 100: ...Super Shot 60 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 2016 by Crafco Inc All Rights Reserved Tools and Accessories 9 16 9 6 Engine Assembly 1 2 3 4 5 7 6 Figure 9 5 Engine Assembly ...

Page 101: ...Tools and Accessories 9 17 Table 9 9 Engine Assembly FIG ITEM PART NO DESCRIPTION QTY Figure 9 5 1 47105 ENGINE 19 HP 3CJ1 1 2 43612 GENERATOR 24VAC 1 3 45748 DRIVE BELT GENERATOR 1 4 41867 FUEL FILTER 1 5 45389 OIL FILTER 1 6 45391 AIR FILTER ELEMENT 1 7 45402 HYDRAULIC PUMP 1 8 47150 WATER SEPARATOR NOT SHOWN 1 ...

Page 102: ...elter Part Manual Chapter 9 Illustrated Parts List 2016 by Crafco Inc All Rights Reserved Tools and Accessories 9 18 9 7 Hydraulic Control Valve Assembly Figure 9 6 Hydraulic Control Valve Assembly PN 45420 1 2 3 7 5 6 9 8 4 ...

Page 103: ...Control Valve Assembly PN 45420 FIG ITEM PART NO DESCRIPTION QTY Figure 9 6 1 45418 VALVE DIRECTIONAL 2 2 45419 COIL DIRECTIONAL VALVE 4 3 45417 VALVE RELIEF 2 4 29897 FITTING 8 ORB X 8 MALE JIC STR 1 5 45413 DUST CAP 2 6 45414 FITTING TEST PORT 2 7 45416 FLOW CONTROL PRIORITY 1 8 40308 FITTING 6 ORB X 6 MALE JIC STR 2 9 29919 FITTING 6 ORB X 8 MALE JIC STR 2 ...

Page 104: ...Melter Part Manual Chapter 9 Illustrated Parts List 2016 by Crafco Inc All Rights Reserved Tools and Accessories 9 20 9 8 Pump Mixer Motor Assembly PN 44832 Figure 9 7 Pump Mixer Motor Assembly PN 44832 1 2 3 4 5 6 7 8 10 9 ...

Page 105: ...tor Assembly PN 44832 FIG ITEM PART NO DESCRIPTION QTY Figure 9 7 1 22029 3 8 TUBE X 5 8 O RING ADAPTOR 2 2 22027 HYDRAULIC MOTOR MIXER 1 3 44809 HYDRAULIC MOTOR PUMP 1 4 29913 1 2 TUBE X 5 8 O RING ADAPTOR 2 5 43345 MOUNTING BRACKET MOTORS 1 6 26002 SPROCKET CHAIN COUPLING 2 7 26016 CHAIN COUPLING 1 8 26030 CONNECTING LINK CHAIN 1 9 43323 SPROCKET MIXER DRIVE 1 ...

Page 106: ...esel Melter Part Manual Chapter 9 Illustrated Parts List 2016 by Crafco Inc All Rights Reserved Tools and Accessories 9 22 9 9 Diesel Burner Assembly PN46380 Figure 9 8 Diesel Burner Assembly PN 46380 4 3 2 1 5 6 8 9 7 ...

Page 107: ...er Assembly PN 46380 FIG ITEM PART NO DESCRIPTION QTY Figure 9 8 1 41949 IGNITION TRANSFORMER 1 2 41870 CAD EYE NOT SHOWN 1 3 42335 DC CONTROLLER NOT SHOWN 1 4 41890 BLOWER MOTOR 1 5 41970 COUPLING FUEL PUMP 1 6 41892 PUMP FUEL 1 7 41888 SOLENOID FUEL 1 8 46912 NOZZLE 1 9 41993 ELECTRODE 1 10 24258 DIESEL GAUGE KIT SEE Figure 8 3 Diesel Burner Air Settings OPT ...

Page 108: ...d Parts List 2016 by Crafco Inc All Rights Reserved Tools and Accessories 9 24 9 10 Hydraulic Schematic Figure 9 9 Hydraulic Diagram PN 46959 7 5 3 4 6 MIXER MOTOR MATERIAL PUMP MOTOR HYDRAULIC VALVE HYDRAULIC TANK 2 HYDRAULIC PUMP 3 2 1 FLOW CONTROL VALVE 1 9 8 ...

Page 109: ...90L 24 HYDRAULIC HOSE 1 40311 FITTING 6 ORB X 6 JIC REF 3 HYDRAULIC VALVE AA PORT TO MIXER MOTOR 29919 FITTING 6 ORB X 8 JIC REF 6M3K 6G 8FJX 6G 6FJX90S 23 HYDRAULIC HOSE 1 22029 FITTING 10 ORB X 6 JIC REF 4 HYDRAULIC VALVE PB PORT TO MATERIAL PUMP MOTOR 29919 FITTING 6 ORB X 8 JIC REF 8M3K 8G 8FJX 8G 8FJX90S 16 HYDRAULIC HOSE 1 29913 FITTING 10 ORB X 8 JIC REF 5 FLOW CONTROL VALVE 2 TO HYDRAULIC ...

Page 110: ...AL PUMP MOTOR 29896 FITTING 8 ORB X 8 JIC ELBOW REF 8M3K 8G 8FJX 8G 8FJX90L 29 HYDRAULIC HOSE 1 29913 FITTING 10 ORB X 8 JIC REF 8 HYDRAULIC VALVE T PORT TO HYDRAULIC FILTER RETURN 29932 FITTING 8 ORB X 8 JIC RUN TEE REF 8M3K 8G 8FJX 8G 12FJX 58 HYDRAULIC HOSE 1 29929 FITTING 16 ORB X 12 JIC REF 9 HYDRAULIC PUMP PRESSURE PORT TO HYDRAULIC VALVE P PORT 29862 FITTING 10 ORB X 10 JIC REF 8M3K 8G 10FJ...

Page 112: ...BLACK 6 8 7 POWER TO ENGINE STARTER GROUND TO ENGINE 5 4 3 2 1 SOLENOID BURNER PLUG BATTERY CIRCUIT BREAKER MATERIAL PUMP REVERSE MATERIAL PUMP FORWARD MIXER FORWARD MIXER REVERSE PUMP REV TOGGLE SWITCH MIXER TOGGLE SWITCH BRN PUMP BRN BRN BRN LID SWITCH BLACK TO SOLN MTG BOLT GREEN RED MIXER FWD 4 MIXER REV 3 PUMP FWD 2 PUMP REV 1 BRN MATERIAL SENSOR HOT OIL SENSOR BLK WHT WHT GRN WHT GRN BLK WHT...

Page 113: ...Schematic FIG ITEM PART NO DESCRIPTION QTY Figure 9 10 1 43901 CABLE ASSEMBLY HOSE 1 2 44985 CABLE ASSEMBLY TRIGGER SENSOR 1 3 43921 CABLE ASSEMBLY HYDRAULIC VALVE 1 4 44983 CABLE ASSEMBLY SENSOR 1 5 44984 CABLE ASSEMBLY POWER 1 6 24015 BATTERY CABLE POSITIVE TO ENGINE 1 7 27174 BATTERY CABLE ENGINE TO GROUND LUG 1 8 24010 BATTERY CABLE NEGATIVE TO GROUND LUG 1 ...

Page 114: ......

Page 115: ... Assembly 27163 4 Disk Assembly 27164 6 Disk Assembly Crafco Swivel Disk Applicator 27120 3 Swivel Applicator 27130 4 Swivel Applicator Crafco Sealing Foot Flush 27154 1 4 Flush 27155 3 8 Flush Crafco Sealing Foot Protruded 27159 1 4 Protruding 27160 3 8 Protruding Crafco Joint Sealing Tip 27146 1 4 Sealing Tip 27147 3 8 Sealing Tip Crafco Round Sealing Tip 27170 3 8 Sealing Tip 27171 1 2 Sealing ...

Page 116: ...ed Tools and Accessories 10 2 Crafco Heavy Duty Squeegee with Aluminum Handle 27199 27195 Replacement Blade Super Shot Drip Stopper Use with 50270 Duckbill 27114 Tip Adapter 27115 Shroud Tip Adapter Crafco Duckbill 50270 Crafco Pour Pot with Wheels 40200 Crafco Hand Held Pour Pot 40201 Crafco Heat Lance 31370 ...

Page 117: ...Diesel Melter Part Manual Chapter 10 Tools and Accessories 2016 by Crafco Inc All Rights Reserved Tools and Accessories 10 3 Crafco Heat Lance with Regulator and Attachments 32259 Crafco Hand Torch w 20ft Hose 25012 ...

Page 118: ......

Page 119: ... 2016 Crafco Inc ...

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