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Super Shot 125 Diesel Melter Part Manual

Chapter 8 Troubleshooting (43600, 43800 and 45500)

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

Fig. 8-2 Diesel Burner Electrode Adjustment

Fig. 8-3 Diesel Burner Air Settings

Air Shutter = 7
Air Band = 0
Fuel Pressure = 140 PSI
Adjustment Plate = 3

Summary of Contents for SUPER SHOT 125

Page 1: ...Parts Manual 26631 Revision D SUPER SHOT 125 DIESEL MELTER ALL MODELS...

Page 2: ...________________ 2nd Hose S N _______________________________ 1st Pump S N _______________________________ 2nd Pump S N ______________________________ Engine S N ________________________________ Compr...

Page 3: ...ual layout 4 2016 B Updated a typo error and changed some chapter text for consistency 8 2016 C Removed SS125DCRC added SS125DC100CFM 6 2017 D Compressor altitude limits in Section 5 5 Air Comp Oil Ch...

Page 4: ...Super Shot 125 Diesel Melter PN 43600 Super Shot 125 Diesel Melter with Compressor 100 CFM PN 47400...

Page 5: ...Export Only Super Shot 125 Diesel Melter Compressor 70 CFM PN 45500 Export Only Super Shot 125 Diesel Melter Compressor 53 8 CFM PN 43800...

Page 6: ...tem 43600 5 7 5 5 Air Compressor PN 43800 45500 and 47400 5 7 5 6 About the Heated Hose Wand Valve and Tip Guard 5 8 5 7 Operating the Electric Hose 5 9 5 8 Dispensing the Material 5 10 5 9 About the...

Page 7: ...Repair Instructions 6 11 Cable Replacement 6 11 6 20 1 Switch Replacement 6 11 6 20 2 Terminal Block Replacement 6 11 6 20 3 Wand Handle Replacement 6 12 6 20 4 6 21 Burner Fuel Filter Replacement 6 1...

Page 8: ...he Pump is Activated 8 29 8 4 1 Pump Electrical Troubleshooting 8 30 8 4 2 Pump Hydraulic Troubleshooting 8 36 8 4 3 9 0 Troubleshooting 47400 9 1 9 1 Diesel Burner Troubleshooting 9 1 Symptom Burner...

Page 9: ...10 6 Tank Assembly All Models 10 18 10 7 Control Box Assembly 43600 43800 and 45500 10 20 10 8 Control Box Assembly 47400 10 24 10 9 Engine Assembly PN 43600 10 28 10 10 Engine Assembly PN 47400 10 3...

Page 10: ...ly PN 47480N 47400 10 68 10 27 Hydraulic Compressor Valve Assembly PN 45425 43800 47400 and 45500 10 70 10 28 High Output Air Lance Assembly 10 72 10 29 Wand Assembly 10 74 10 30 Optional Engine Cover...

Page 11: ...Fig 8 1 Diesel Burner Schematic 8 6 Fig 8 2 Diesel Burner Electrode Adjustment 8 10 Fig 8 3 Diesel Burner Air Settings 8 10 Fig 8 4 Checking Din Plug Voltage 8 16 Fig 8 5 Mixer Schematic 8 17 Fig 8 6...

Page 12: ...ssembly PN 45500 10 34 Fig 10 12 Hydraulic Control Valve Assembly PN 45420 All Models 10 36 Fig 10 13 Control Box Assembly 46400SB 46400SC63 10 36 Fig 10 14 Material Flow Control Assembly PN 46060 All...

Page 13: ...400SC63 10 69 Fig 10 30Hydraulic Compressor Valve Assembly PN 45425 43800 47400 and 45500 10 70 Fig 10 31 High Output Air Lance Assembly 10 72 Fig 10 32 Wand Assembly 10 74 Fig 10 33 Optional Engine C...

Page 14: ...Down and Cleaning Out the Machine 43600 43800 45500 5 13 Table 5 11 Shutting Down and Cleaning Out the Machine 47400 5 14 Table 5 12 Hose for Transport Instructions 5 15 Table 5 13 Overnight Heater U...

Page 15: ...r Electrical Troubleshooting continued 8 15 Table 8 18 Mixer Hydraulic Troubleshooting 8 18 Table 8 19 Basic Visual Hose Troubleshooting 8 21 Table 8 20 Hose Electrical Troubleshooting 8 21 Table 8 21...

Page 16: ...r Electrical Troubleshooting continued 9 16 Table 9 18 Mixer Hydraulic Troubleshooting 9 19 Table 9 19 Basic Visual Hose Troubleshooting 9 22 Table 9 20 Hose Electrical Troubleshooting 9 22 Table 9 21...

Page 17: ...mp 70 CFM PN 45500 continued 10 17 Table 10 13 Tank Assembly All Models 10 19 Table 10 14 Control Box Assembly 43600 43800 and 45500 10 21 Table 10 15 Control Box Assembly 43600 43800 and 45500 contin...

Page 18: ...Schematic PN 43600 10 61 Table 10 37 Electrical Schematic PN 47400 10 63 Table 10 38 Electrical Schematic Export Only PN 43800 and 45500 10 65 Table 10 39 Air Compressor Assembly Export Only PN 45345...

Page 19: ...us 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 whe...

Page 20: ......

Page 21: ...afety 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 s...

Page 22: ...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...

Page 23: ...erved 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...

Page 24: ......

Page 25: ...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...

Page 26: ...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 distrib...

Page 27: ...00 RPM 4 cylinder Model 4LE2T 48 0 BHP 2350 RPM 3 cylinder Model 3CE1 32 5 BHP 2800 RPM 3 cylinder Model 3CD1TK 35 9 BHP 2800 RPM Drive Mechanism All hydraulic with infinite speed forward and reverse...

Page 28: ......

Page 29: ...e of 70 F 21 1 C The oil should be at the full mark on the dipstick There are two other full marks representing 0 F 17 8 C and 150 F 65 6 C See Fig 5 2 Heat Transfer Oil Dip Stick DO NOT overfill or s...

Page 30: ...Reserved Operating Instructions 5 2 5 2 Machine Start Up for 43600 43800 and 45500 Step Action 1 Fully open the exhaust stack cover Fig 5 1 Hydraulic Fluid Level and Temp Gauge Fig 5 2 Heat Transfer O...

Page 31: ...ing temperature but the material in the center of the tank is still solid This is normal and when the heated hose is ready for operation most of the material in the tank will be melted and heated to t...

Page 32: ...remove the plug in the line 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...

Page 33: ...the RESET toggle switch in the DOWN position for 5 seconds then release The burner should ignite If the burner still does not ignite refer to 8 1 1 Symptoms Burner will Not Ignite to determine the mal...

Page 34: ...en the trigger is activated allow the material to heat longer If the hose still does not dispense shut the machine down locate and remove the plug in the line CAUTION DO NOT twist or kink the hose Avo...

Page 35: ...8 CFM 125 PSI compressor o For PN 45500 a 70 CFM 125 PSI compressor o For PN 47400 a 100 CFM 125 PSI compressor For both 43800 and 45500 The engine RPM is set by factory for maximum air compressor per...

Page 36: ...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 d...

Page 37: ...se stops heating Note This type of failure is not covered under the Crafco warranty 1 Set the hose temperature at 380 F or manufacturer recommended operating temperature 2 Allow the hose to be turned...

Page 38: ...r proper operating temperatures 2 Turn the pump speed control to the lowest setting by turning the speed control knob fully clockwise 3 With the wand tip inserted in the shoebox on top of the melter d...

Page 39: ...using 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 For approximate material volume...

Page 40: ...123 22 99 97 378 46 8 37 20 140 82 95 32 360 86 9 41 85 158 42 90 67 343 26 10 46 50 176 02 86 02 325 66 11 51 15 193 62 81 37 308 06 12 55 80 211 23 76 72 290 46 13 60 45 228 83 72 07 272 86 14 65 1...

Page 41: ...al becomes molten 1 Leaving the hose in the boom swing the boom clockwise towards the front of the machine and lock the boom into position with the latch provided CAUTION DO NOT kink or twist the hose...

Page 42: ...the machine and lock the boom into position with the latch provided CAUTION DO NOT kink or twist the hose or permanent damage may result 2 Place the wand in the wand holder and lock the wand into pos...

Page 43: ...n with the latch provided 3 Place the hose in the hose guide and secure with the Velcro strap CAUTION Hose damage occurs if The hose is bent or moved when cold The hose is twisted or bent at a sharp r...

Page 44: ...for 15 amps minimum WARNING Suitable extension cord size requirements for 110 Volt use 25 50 FT 16 20 Amps 12 Gauge Heavy Duty or 10 Gauge Extra Heavy Duty 100 FT 16 20 Amps 10 Gauge Extra Heavy Duty...

Page 45: ...l truck bed or any other non flammable surface Failure to use the correct mounting surface could result in damage and possible fire 1 Mount with four bolts minimum using the loading tubes 2 WARNING Le...

Page 46: ...g up on cold days Although 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 into the shoebox to facilitate material melting in the v...

Page 47: ...he size of the shot needed for the job WARNING 8 While in the MARKER mode the material pump turns for the duration of time set by the shot size dial Once the wand trigger is pulled the pump will not s...

Page 48: ...e heat transfer oil to 300 F 149 C for two to three hours to evaporate the moisture Failure to follow this procedure will cause the heat transfer oil to overflow the tank resulting in possible machine...

Page 49: ...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 59 1 ml required 6 6 Cleaning Material...

Page 50: ...in at 50 miles 80 km Check periodically thereafter Torque in stages as follows First stage 20 25 foot pound ft lb 89 111 N Second stage 50 60 foot pound ft lb 222 266 N Third stage 90 120 foot pound f...

Page 51: ...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 Fig 6 2 Temperature Control Calibration 6 11 Cleaning the Melter We...

Page 52: ...instructions for the engine Material Sensor Tube Check for HTO fluid X Add As needed Heat Transfer Oil Check X Change X Hydraulic Oil Check X Change X Hydraulic Oil Filter Change X Burner Check burner...

Page 53: ...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 cen...

Page 54: ...mate Diesel 2 Warm Climate 26 Gal 98 l PN 43600 32 Gal 121 l PN 43800 45500 30 Gal 113 l PN 47400 Engine Oil Refer to engine manual 3 Qt 2 8 l PN 43600 6 7 Qt 6 3 l PN 43800 45500 2 75 Gal 10 4 l PN 4...

Page 55: ...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 Usi...

Page 56: ...and 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 a...

Page 57: ...ds 40 8 kg 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 plat...

Page 58: ...t Manual Chapter 6 Maintenance Instructions 2017 by Crafco Inc All Rights Reserved Maintenance Instructions 6 10 PUMP ASSEMBLY BOLTS PUMP MOUNTING BOLTS PUMP ASSEMBLY PUMP MOUNTING PLATE TANK BOTTOM F...

Page 59: ...nstall Note white black wire is routed under switch see Fig 6 5 Wire Routing on open terminals of terminal block Make sure to install completely under the clamp before tightening screws Torque screws...

Page 60: ...or actuator lock pin and spring 3 Remove 2 4 40 x 1 2 pan head screws from switch then remove switch from handle 4 Remove 2 10 32 x 5 8 round head machine screw from terminal block then remove termina...

Page 61: ...r Shot 125 Diesel Melter Part Manual Chapter 6 Maintenance Instructions 2017 by Crafco Inc All Rights Reserved Maintenance Instructions 6 13 Fig 6 6 Terminal Block Wiring Fig 6 7 Actuator Spring Locat...

Page 62: ...Diesel Melter Part Manual Chapter 6 Maintenance Instructions 2017 by Crafco Inc All Rights Reserved Maintenance Instructions 6 14 Fig 6 8 Actuator Trigger Assembly Spring location Switch lever locatio...

Page 63: ...ly 3 Close the ball valve that is located inline before the burner fuel filter assembly 4 Unscrew the filter from the assembly using an oil filter or strap style wrench 5 Screw the new filter into pla...

Page 64: ......

Page 65: ...be to 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 t...

Page 66: ...ctric hose always use a clamp on amp meter See Fig 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...

Page 67: ...by Crafco Inc All Rights Reserved How to Use a Multimeter 7 3 Fig 7 2 Clamp On Amp Meter Multimeter Ohms Sensors Hyd Coils Burner Ignition Coil Audible Continuity Hose Wand and wire connection DC Volt...

Page 68: ......

Page 69: ...p 3 No turn the toggle switch to the ON position 3 Are both the Material and Hot Oil temperature dials set to proper operating temperatures Yes go to Step 4 No set the Material according to the type o...

Page 70: ...here 12Vdc between the large terminal red wire going 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 la...

Page 71: ...o Step 5 5 Is there 12Vdc between gray wire labeled GRY 2 on terminal block lower right hand corner and nearby ground source Yes replace terminal block No go to Step 5a 5a Is there 12Vdc between termi...

Page 72: ...9 of the material PAKSTAT and terminal block No go to Step 8a 8a Is there 12Vdc between orange wire labeled ORN 2 on the terminal block left side middle and a nearby ground source black wire Yes repl...

Page 73: ...loose or broken wires 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...

Page 74: ...Battery 12vdc Burner 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...

Page 75: ...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 o...

Page 76: ...ire should have 12Vdc all the time Blue Igniter wire should have 12Vdc 5 Twist the yellow wires together once voltage registers on the orange blue and purple wires Orange Blower Motor wire should main...

Page 77: ...ad approximately twice the spring to ground Bleeding the Burner 8 1 8 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 bleede...

Page 78: ...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...

Page 79: ...rain out use up the rest of 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...

Page 80: ...e the Mixer toggle switch 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 T...

Page 81: ...8 Mixer Hydraulic Troubleshooting Also replace din plug at earliest convenience to retain visual troubleshooting ability No go to Step 2 2 Is there 12Vdc between the Mixer toggle switch bottom post br...

Page 82: ...check for loose connections or broken wires between PAKSTAT terminal 2 and terminal block No go to Step 4b 4b Is there 12Vdc between the Material PAKSTAT terminal 1 orange wire and terminal 8 black gr...

Page 83: ...er and toggle switch No go to step 8a 8a Is there 12Vdc between the bottom terminal of circuit breaker red wire labeled RED 2 and nearby ground source black wire Yes replace circuit breaker No go to s...

Page 84: ...per Shot 125 Diesel Melter Part Manual Chapter 8 Troubleshooting 43600 43800 and 45500 2017 by Crafco Inc All Rights Reserved Troubleshooting 43600 43800 and 45500 8 16 Fig 8 4 Checking Din Plug Volta...

Page 85: ...s 70 F WHT BLK WHT 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...

Page 86: ...power in the control box move 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...

Page 87: ...PUMP PRESSURE RELIEF SET 1000 PSI RVA AGITATOR PRESSURE RELIEF SET 1000 PSI PRESSURE RELIEF JAM NUT ALLEN SCREW Fig 8 6 Hydraulic Valve Pressure Setting Agitation Direction Counterclockwise Hydraulic...

Page 88: ...ng 43600 43800 and 45500 2017 by Crafco Inc All Rights Reserved Troubleshooting 43600 43800 and 45500 8 20 Fig 8 7 Din Plug Layout DIN PLUG 3 MIXER REVERSE DIN PLUG 1 MATERIAL PUMP REVERSE DIN PLUG 2...

Page 89: ...l Troubleshooting 8 3 2 NOTE Use Fig 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 ne...

Page 90: ...repair 4 Check for continuity 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 bac...

Page 91: ...hooting 43600 43800 and 45500 2017 by Crafco Inc All Rights Reserved Troubleshooting 43600 43800 and 45500 8 23 Fig 8 8 Junction Box Voltage Testing Test 1 between black and white wires Test 3 between...

Page 92: ...4 AMPS HOT 12 GA SO 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...

Page 93: ...oting 43600 43800 and 45500 8 25 Fig 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 BLAC...

Page 94: ...hese 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 electrica...

Page 95: ...99 5 1101 6 80 1103 8 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 4 115...

Page 96: ...6 3 1758 4 1760 4 1762 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...

Page 97: ...Step 5 No adjust the material flow control to increase the flow 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 ha...

Page 98: ...inal 9 pink wire and terminal 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 p...

Page 99: ...and 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...

Page 100: ...l block red wire across 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...

Page 101: ...the electrical system for the 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...

Page 102: ...itch 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 th...

Page 103: ...Super Shot 125 Diesel Melter Part Manual Chapter 8 Troubleshooting 43600 43800 and 45500 2017 by Crafco Inc All Rights Reserved Troubleshooting 43600 43800 and 45500 8 35 Fig 8 11 Pump Schematic...

Page 104: ...c hoses going to the pump 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 t...

Page 105: ...itch in the ON position Yes go to Step 4 No turn the toggle switch to the ON position 4 Are both the Material and Hot Oil temperature dials set to proper operating temperatures Yes go to Step 5 No set...

Page 106: ...smoke coming out of the exhaust stack Yes go to Table 9 7 Smoke Coming Out of Exhaust Stack No go to Step 10 10 Is your burner working properly but it seems like it takes a lot longer to reach operati...

Page 107: ...e between those two points No recheck the above steps something was missed 1d Is there 12Vdc between the large terminal red wire going to burner plug of the frame solenoid and the black wire in the bu...

Page 108: ...ere 12Vdc between gray wire labeled GRY 2 on terminal block lower right hand corner and nearby ground source Yes replace terminal block No go to Step 5a 5a Is there 12Vdc between terminal 7 gray wire...

Page 109: ...s there 12Vdc between orange wire labeled ORN 2 on the terminal block left side middle and a nearby ground source black wire Yes replace terminal block No go to Step 9 9 Is there 12Vdc between termina...

Page 110: ...heck for loose or broken wires between top terminal of circuit breaker and bottom terminal red wire of power switch No go to Step 14a 14a Is there 12Vdc between bottom terminal of circuit breaker red...

Page 111: ...N PRP BLU ORN 2 BLK 1 PNK 1 PNK 2 WHT GRN 4 WHT GRN 5 ORN 1 BLK 4 GRN BRNR BLK 1 GRY 1 ORN 1 PNK 2 ORN 1 BL 4 ORN 1 BLK 4 WHT BLK WHT BLK 8 5 4 1 14 13 12 9 WHT GRN 1 WHT GRN 2 ORN 2 BLK 5 GRY 3 GRY 2...

Page 112: ...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...

Page 113: ...12Vdc all the time Blue Igniter wire should have 12Vdc 5 Twist the yellow wires together once voltage registers on the orange blue and purple wires Orange Blower Motor wire should maintain 12Vdc Blue...

Page 114: ...twice the spring to ground Bleeding the Burner 9 1 8 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 f...

Page 115: ...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 SHU...

Page 116: ...the rest of 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 tan...

Page 117: ...le switch 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 9 15 Mixer...

Page 118: ...raulic Troubleshooting Also replace din plug at earliest convenience to retain visual troubleshooting ability No go to Step 2 2 Is there 12Vdc between the Mixer toggle switch bottom post brown wire an...

Page 119: ...connections or broken wires between PAKSTAT terminal 2 and terminal block No go to Step 4b 4b Is there 12Vdc between the Material PAKSTAT terminal 1 orange wire and terminal 8 black ground wire Yes re...

Page 120: ...en top terminal power switch and terminal 3 of the hot oil PAKSTAT No go to Step 10 10 Is there 12Vdc between middle terminal red wire of burner ON OFF toggle switch and nearby ground source black wir...

Page 122: ...1 PNK 2 ORN 1 ORN 1 BLK 4 WHT BLK WHT BLK 8 5 4 1 14 13 12 9 PNK 3 ORN 2 BLK 5 HOSE 51691 MATERIAL 51672 HOT OIL 43391 MAT L HOSE BRN 2 PNK 3 BRN 3 BLK 16 BRN 4 BRN MIXER REV 3 BLU MIXER 3 PMP REV 1...

Page 123: ...ntrol box move 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...

Page 124: ...RVP PUMP PRESSURE RELIEF SET 1000 PSI RVA AGITATOR PRESSURE RELIEF SET 1000 PSI PRESSURE RELIEF JAM NUT ALLEN SCREW Fig 9 6 Hydraulic Valve Pressure Setting Agitation Direction Counterclockwise Hydra...

Page 125: ...9 Troubleshooting 47400 2017 by Crafco Inc All Rights Reserved Troubleshooting 47400 9 21 Fig 9 7 Din Plug Layout DIN PLUG 3 MIXER REVERSE DIN PLUG 1 MATERIAL PUMP REVERSE DIN PLUG 2 MATERIAL PUMP FO...

Page 126: ...g 9 3 2 NOTE Use Fig 9 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 sour...

Page 127: ...pair 4 Check for continuity 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...

Page 128: ...apter 9 Troubleshooting 47400 2017 by Crafco Inc All Rights Reserved Troubleshooting 47400 9 24 Fig 9 8 Junction Box Voltage Testing Test 1 between black and white wires Test 3 between white and green...

Page 129: ...20 24 AMPS HOT 12 GA SO CORD BLACK WHITE AND GREEN 12vdc 5 7 amps RTD Sensor 1 08K ohms at 70 F Batt GREEN WHITE BLACK BLUE BLUE BLUE BLUE BLUE BLUE BLK WHT Hose Generator Wand t BLU 2 BLK 5 BLK 5 BLU...

Page 130: ...oting 47400 9 26 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 TRIGGE...

Page 131: ...be disconnected from the terminal block and the trigger depressed to perform this test Yes go to Table 9 25 Basic Visual Pump Troubleshooting No go to Step 2 2 Disconnect the electrical connector betw...

Page 132: ...103 8 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...

Page 133: ...4 1762 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...

Page 134: ...t the material flow control to increase the flow 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 b...

Page 135: ...and terminal 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 ar...

Page 136: ...ir 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...

Page 137: ...across 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...

Page 138: ...s the electrical system for the agitator is working properly go to Table 9 31 Pump Hydraulic Troubleshooting No recheck the amber light if the light comes ON and you do not have 12 Vdc then replace th...

Page 139: ...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 s...

Page 140: ...Batt GREEN WHITE BLACK BLUE BLUE BLUE BLUE BLUE BLUE BLK WHT Hose Generator Wand t Coil AMP Draw 12vdc 2 71 AMPS RED 4 RED 1 BLK 5 PRP 2 BLK 5 BLU 2 PRP 1 RED TRIG BLK 1 PNK 1 PNK 2 BLK 4 BLU 1 BLU PM...

Page 141: ...the pump 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 p...

Page 142: ...engine repair center please go here http www isuzuengines com network or call 734 582 9470 and they can help you locate your closest repair center To use the table find the SPN and FMI from the contr...

Page 143: ...Baro pressure sensor malfunction high voltage 108 4 Baro pressure sensor malfunction low voltage 110 0 Over heat 110 3 Water temp sensor malfunction high voltage 110 4 Water temp sensor malfunction lo...

Page 144: ...onnection 652 5 Injection nozzle 2 driving system disconnection 653 5 Injection nozzle 3 driving system disconnection 654 5 Injection nozzle 4 driving system disconnection 676 5 Glow relay malfunction...

Page 145: ...ort Only Super Shot 125 Diesel Melter with Compressor 70 CFM PN 45500 Illustrations are designed to show general shape and size of a part and the relationship that part has to other parts Actual size...

Page 146: ...hts Reserved Illustrated Parts List 10 2 10 2 Super Shot 125 Diesel Melter Assembly 43600 1 2 3 4 8 9 11 6 15 16 17 19 20 21 22 23 25 28 29 30 5 10 33 40 41 39 43 44 45 46 47 48 54 53 55 56 57 58 32 4...

Page 147: ...G FUEL SIGHT GAUGE 1 11 43594 DIESEL FUEL TANK ASSEMBLY 1 12 43114 COVER BURNER 1 13 41891 14 VOLT BURNER 1 14 39602 SOLENOID 1 15 23082 TONGUE JACK 1 16 23095 SWIVEL BUSHING 1 17 20014 3 PINTLE HITCH...

Page 148: ...R OIL 1 37 46306 KNOB THREADED BOOM LOCK 1 38 45575 BOOM LATCHING ASSEMBLY 1 39 39608 LID SWITCH 1 40 43465 RTD SENSOR 2 41 51065 CORD GRIP RTD SENSOR 2 42 45541 HYDRAULIC COOLER SMALL 1 43 47102 23 H...

Page 149: ...8 ROUND SEALING TIP OPT 61 27171 ROUND SEALING TIP OPT 62 27173 SEALING SHOE OPT 63 27146 ELONGATED SEALING TIP OPT 64 43672 MOUNT STROBE LIGHT OPT 65 24095 STROBE LIGHT OPT 66 50720 WEATHER TIGHT BO...

Page 150: ...ved Illustrated Parts List 10 6 10 3 Super Shot 125 Diesel Melter Comp 100 CFM PN 47400 3 2 4 5 6 7 8 9 10 11 12 15 16 17 18 19 20 23 22 21 24 27 28 29 30 31 33 34 36 37 35 39 38 40 41 42 44 43 47 50...

Page 151: ...E FENDER 1 9 44818 TUBING FUEL SIGHT GAUGE 1 10 44817 FITTING SIGHT GAUGE ELBOW 2 11 47060N 30 GALLON DIESEL TANK ASSEMBLY 1 12 46255 30 GALLON HYDRAULIC ASSEMBLY 1 13 23117 BREAKAWAY SWITCH 1 14 2001...

Page 152: ...355 OVERFLOW TANK 1 36 47475N DIP STICK HEAT TRANSFER OIL 1 37 26025 AIR BREATHER HEAT TRANSFER OIL 1 38 46306 KNOB THREADED BOOM LOCK 1 39 45582 BOOM LOCK ASSEMBLY 1 40 39608 LID SWITCH 1 41 47111N 4...

Page 153: ...N WAND UPPER EDGE TRIM NOT SHOWN 1 60 47531N WAND LOWER EDGE TRIM NOT SHOWN 1 61 52405 18 ELECTRIC HEATED HOSE NOT SHOWN 1 62 27170 3 8 ROUND SEALING TIP OPT 63 27171 ROUND SEALING TIP OPT 64 27173 SE...

Page 154: ...ts List 10 10 10 4 Export Only Super Shot 125 Diesel Melter Comp 53 8 CFM PN 43800 Fig 10 3 Export Only Super Shot 125 Diesel Melter Comp 53 8 CFM PN 43800 1 3 4 5 12 13 11 17 18 19 20 22 23 24 25 28...

Page 155: ...SE GUARD 1 9 43842 DRIP PAN ASSEMBLY 1 10 42648 COLD AIR LANCE 1 11 43592 DIESEL FUEL TANK ASSEMBLY 1 12 44818 TUBING FUEL SIGHT GAUGE 1 13 44817 FITTING SIGHT GAUGE ELBOW 2 14 43114 COVER BURNER 1 15...

Page 156: ...4 46060 FLOW CONTROL VALVE 1 35 45549 BOOM BASE 1 36 45550 HOSE BOOM 1 37 43355 OVERFLOW TANK 1 38 47475N DIP STICK HEAT TRANSFER OIL 1 39 26025 AIR BREATHER HEAT TRANSFER OIL 1 40 46306 KNOB THREADED...

Page 157: ...L LIGHT 2 60 43821 HEAT GUARD 1 61 44027 JUNCTION BOX ASSEMBLY 1 62 52405 18 ELECTRIC HEATED HOSE NOT SHOWN 1 63 27170 3 8 ROUND SEALING TIP OPT 64 27171 ROUND SEALING TIP OPT 65 27173 SEALING SHOE OP...

Page 158: ...arts List 10 14 10 5 Export Only Super Shot 125 Diesel Melter Comp 70 CFM PN 45500 Fig 10 4 Export Only Super Shot 125 Diesel Melter Comp 70 CFM PN 45500 1 3 4 5 12 13 11 17 18 19 20 22 23 24 25 28 31...

Page 159: ...E GUARD 1 9 43842 DRIP PAN ASSEMBLY 1 10 42648 COLD AIR LANCE 1 11 43592 DIESEL FUEL TANK ASSEMBLY 1 12 44818 TUBING FUEL SIGHT GAUGE 1 13 44817 FITTING SIGHT GAUGE ELBOW 2 14 43114 COVER BURNER 1 15...

Page 160: ...4 46060 FLOW CONTROL VALVE 1 35 45549 BOOM BASE 1 36 45550 HOSE BOOM 1 37 43355 OVERFLOW TANK 1 38 47475N DIP STICK HEAT TRANSFER OIL 1 39 26025 AIR BREATHER HEAT TRANSFER OIL 1 40 46306 KNOB THREADED...

Page 161: ...59 32363 4 RED LED STOP TURN AND TAIL LIGHT 2 60 43821 HEAT GUARD 1 61 44027 JUNCTION BOX ASSEMBLY 1 62 52405 18 ELECTRIC HEATED HOSE NOT SHOWN 1 63 27170 3 8 ROUND SEALING TIP OPT 64 27171 ROUND SEA...

Page 162: ...elter Part Manual Chapter 10 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 18 10 6 Tank Assembly All Models 1 5 6 8 11 13 2 3 4 7 9 10 12 14 16 15 Fig 10 5 Ta...

Page 163: ...1 43760 BEARING FLANGED 1 2 43321 CHAIN DRIVE 1 3 44163 KEY SPROCKET 1 4 44165 SPROCKET DRIVEN 1 5 43641 SHAFT DRIVE PUMP 1 6 43753 SHAFT AGITATOR 1 7 43649 PADDLE AGITATOR 2 8 43655 SCREEN PUMP 1 9 4...

Page 164: ...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 GR...

Page 165: ...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 T...

Page 166: ...Illustrated Parts List 10 22 Table 10 15 Control Box Assembly 43600 43800 and 45500 continued FIG ITEM PART NO DESCRIPTION QTY Fig 10 6 31 41994 IGNITION SWITCH WITH OUT TUMBLER 1 32 47203 ENCLOSURE...

Page 168: ...2 BLK 5 GRY 3 GRY 2 WHT GRN 1 WHT GRN 2 HOSE 51691 MATERIAL 51672 HOT OIL 43391 MAT L HOSE BLU PMP BRN 2 PNK 3 BRN 3 BLK 16 BRN 4 BRN MIXER REV 3 BLU MIXER 3 PMP REV 1 BLU MIXER 4 PMP FWD 2 BRN PUMP R...

Page 169: ...NTROLLER 150 F 550 F 1 10 51651 LIGHT 12VDC 4 11 51662 SOCKET RELAY 1 12 51661 RELAY 1 13 51663 HOLD DOWN SPRING 1 14 51802 END BRACKET TENSION CLAMP 1 15 51800 FEED THROUGH TERMINAL 26 16 51805 BRACK...

Page 170: ...llustrated Parts List 10 26 Table 10 17 Control Box Assembly 47400 continued FIG ITEM PART NO DESCRIPTION QTY Fig 10 7 31 47209 ENGINE CONTROLLER 1 32 46239 SWITCH ON OFF NOT SHOWN 1 33 47203 ENCLOSUR...

Page 172: ...per Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 28 10 9 Engine Assembly PN 43600 Fig 10 8 Engine Assembly 4360...

Page 173: ...ts Reserved Illustrated Parts List 10 29 Table 10 18 Engine Assembly PN 43600 FIG ITEM PART NO DESCRIPTION QTY Fig 10 8 1 47102 ENGINE 23 HP 3CH1 1 2 43612 GENERATOR 24VAC 1 3 45748 DRIVE BELT GENERAT...

Page 174: ...125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 30 10 10 Engine Assembly PN 47400 Fig 10 9 Engine Assembly 47400 5 6 1...

Page 175: ...a 47170N TENSIONER BELT NOT SHOWN 1 4 47167N FUEL FILTER 1 5 47168N OIL FILTER 1 6 45491N HYDRAULIC PUMP 1 7 47169N AIR FILTER ELEMENT 1 8 47173N WORKSHOP MANUAL OPT 9 47171N MANUAL PARTS OPT 10 47172...

Page 176: ...r Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 32 10 11 Engine Assembly PN 43800 Fig 10 10 Engine Assembly PN 4...

Page 177: ...ts Reserved Illustrated Parts List 10 33 Table 10 20 Engine Assembly PN 43800 FIG ITEM PART NO DESCRIPTION QTY Fig 10 10 1 45380 ENGINE 37 HP 3CE1 1 2 43612 GENERATOR 24VAC 1 3 45748 DRIVE BELT GENERA...

Page 178: ...r Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 34 10 12 Engine Assembly PN 45500 Fig 10 11 Engine Assembly PN 4...

Page 179: ...Reserved Illustrated Parts List 10 35 Table 10 21 Engine Assembly PN 45500 FIG ITEM PART NO DESCRIPTION QTY Fig 10 11 1 45348 AIR FILTER ELEMENT 1 2 45332 ENGINE 41 6 HP 3CDTK1 1 3 43612 GENERATOR 24...

Page 180: ...Chapter 10 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 36 10 13 Hydraulic Control Valve Assembly PN 45420 All Models Fig 10 12 Hydraulic Control Valve Assem...

Page 181: ...trol Valve Assembly PN 45420 All Models FIG ITEM PART NO DESCRIPTION QTY Fig 10 12 1 45418 VALVE DIRECTIONAL 2 2 45419 COIL DIRECTIONAL VALVE 4 3 45417 VALVE RELIEF 2 4 29897 FITTING 8 ORB X 8 MALE JI...

Page 182: ...Manual Chapter 10 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 38 10 14 Material Flow Control Assembly PN 46060 All Models 1 3 4 2 Fig 10 14 Material Flow Co...

Page 183: ...l Rights Reserved Illustrated Parts List 10 39 Table 10 23 Material Flow Control Assembly PN 46060 All Models FIG ITEM PART NO DESCRIPTION QTY Fig 10 14 1 29869 3 8 TUBE X 1 2 O RING ELBOW 2 2 46077 K...

Page 184: ...Manual Chapter 10 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 40 10 15 Pump Mixer Motor Assembly PN 44832 All Models 1 2 3 4 5 6 7 8 9 Fig 10 15 Pump Mixer...

Page 185: ...Assembly PN 44832 All Models FIG ITEM PART NO DESCRIPTION QTY Fig 10 15 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...

Page 186: ...10 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 42 10 16 Diesel Burner Assembly PN 46380 All Models 8 1 4 6 7 3 5 1 10 11 12 14 13 6 BACK VIEW SIDE VIEW Fig...

Page 187: ...IPTION QTY Fig 10 16 1 41949 IGNITION TRANSFORMER 1 2 41870 CAD EYE NOT SHOWN 1 3 42335 DC CONTROLLER 1 4 41890 BLOWER MOTOR 1 5 41970 COUPLING FUEL PUMP 1 6 41892 PUMP FUEL 1 7 41932 SOLENOID FUEL 1...

Page 188: ...Crafco Inc All Rights Reserved Illustrated Parts List 10 44 10 17 Hydraulic Diagram PN 26554 43600 Fig 10 17 Hydraulic Diagram PN 26554 43600 7 5 3 4 6 MIXER MOTOR MATERIAL PUMP MOTOR HYDRAULIC VALVE...

Page 189: ...RB 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 34 HYDRAULIC HOSE 1 22029 FITTING 10 ORB X 6 JIC REF 4 HYDRAULIC VALVE PB PORT TO MATERI...

Page 190: ...ULIC VALVE T PORT TO HYDRAULIC COOLER 29932 FITTING 8 ORB X 8 JIC RUN TEE REF 8M3K 8G 8FJX 8G 12FJX 60 HYDRAULIC HOSE 1 29916 FITTING 12 ORB X 12 JIC ELBOW REF 9 HYDRAULIC COOLER TO HYDRAULIC FILTER R...

Page 192: ...Illustrated Parts List 10 48 10 18 Hydraulic Diagram PN 26662N 47400 10 9 8 6 4 5 14 1 13 11 12 2 7 MIXER MOTOR MATERIAL PUMP MOTOR HYDRAULIC VALVE HYDRAULIC COOLER COMPRESSOR HYDRAULIC MOTOR COMPRES...

Page 193: ...29818 FITTING 20 ORB X 16 JIC REF 3 MIXER MOTOR TO HYDRAULIC VALVE AB PORT 22029 FITTING 10 ORB X 6 JIC REF 6M3K 6G 6FJX 6G 6FJX90L 36 HYDRAULIC HOSE 1 40311 FITTING 6 ORB X 6 JIC REF 4 HYDRAULIC VALV...

Page 194: ...DE LOWER 29896 FITTING 8 ORB X 8 JIC REF 8M3K 8G 8FJX 8G 10FJX 59 25 HYDRAULIC HOSE 1 29806 10 JIC X 10 JIC BKHEAD ELBOW REF 8M3K 8G 10FJX 8G 10FJX 64 25 HYDRAULIC HOSE 1 29806 10 JIC X 10 JIC BKHEAD...

Page 195: ...RESSOR MOTOR TO COMPRESSOR VALVE 2 PORT 29819 FITTING 12 ORB X 12 JIC REF 45476 COMPRESSOR RETURN LINE REF 29900 12 ORB X 12 JIC RUN TEE REF 14 HYDRAULIC PRESSURE PORT REAR PORT TO HYDRAULIC VALVE P P...

Page 196: ...st 10 52 10 19 Hydraulic Diagram PN 26663 43800 45500 Export Engine Only Fig 10 19 Hydraulic Diagram PN 43800 45500 Export Engine Only 10 9 8 6 4 5 14 1 13 11 12 2 7 MIXER MOTOR MATERIAL PUMP MOTOR HY...

Page 197: ...X 16 JIC REF 3 MIXER MOTOR TO HYDRAULIC VALVE AB PORT 22029 FITTING 10 ORB X 6 JIC REF 6M3K 6G 6FJX 6G 6FJX90L 36 HYDRAULIC HOSE 1 40311 FITTING 6 ORB X 6 JIC REF 4 HYDRAULIC VALVE AA PORT TO MIXER MO...

Page 198: ...6 FITTING 8 ORB X 8 JIC REF 8M3K 8G 8FJX 8G 12FJX 63 HYDRAULIC HOSE 1 27692 16 FEMALE TUBE X 12 JIC REF 29977 16 O RING BRANCH TEE REF 10 COMPRESSOR VALVE 2 PORT TO HYDRAULIC COOLER ROADSIDE 29900 12...

Page 199: ...X 12G 12FJX 23 HYDRAULIC HOSE 1 29900 12 ORB X 12 JIC RUN TEE REF 14 HYDRAULIC PRESSURE PORT REAR PORT TO HYDRAULIC VALVE P PORT 29842 FITTING 12 ORB X 10 JIC REF 8M3K 8G 8FJX90L 8G 10FJX 144 HYDRAULI...

Page 200: ...lter Part Manual Chapter 10 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 56 10 20 Diesel Fuel Line Schematic Non Compressor 3 1 2 Fig 10 20 Diesel Fuel Line...

Page 201: ...PUSH ON 1 1 29591 HOSE 5 16 FUEL LINE 1 2 26080 CLAMP 4 GEAR 2 1 BANJO FITTING REF 2 ENGINE FUEL FILTER UPPER FITTING TO BURNER 1 BANJO FITTING REF 1 29591 HOSE 5 16 FUEL LINE 1 1 26767 FITTING 5 HOSE...

Page 202: ...ter Part Manual Chapter 10 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 58 10 21 Diesel Fuel Line Schematic Compressors 1 3 2 4 5 6 7 Fig 10 21 Diesel Fuel L...

Page 203: ...R FUEL FILTER 26782 FITTING 1 4 MPT X 5 16 JIC ELBOW 1 26767 FITTING 5 HOSE PUSH ON 1 29650N HOSE 5 16 x 51 5 FUEL LINE 1 29984 HOSE BARB 1 4MPT X 5 16 HOSE 1 29195 BALL VALVE 1 4 NPT 1 29984 HOSE BAR...

Page 204: ...8 7 POWER TO ENGINE STARTER GROUND TO ENGINE 5 4 3 2 1 SOLENOID BURNER PLUG BATTERY CIRCUIT BREAKER 1 MATERIAL PUMP REVERSE 4 MATERIAL PUMP FORWARD 2 MIXER FORWARD 3 MIXER REVERSE PUMP REV TOGGLE SWI...

Page 205: ...hematic PN 43600 FIG ITEM PART NO DESCRIPTION QTY Fig 10 22 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...

Page 206: ...LACK HEATER BLUE HEATER BLUE SENSOR WHITE SENSOR BLACK 10 7 6 POWER TO ENGINE STARTER GROUND TO ENGINE 5 4 3 2 1 SOLENOID BURNER PLUG BATTERY CIRCUIT BREAKER 1 MATERIAL PUMP REVERSE 2 MATERIAL PUMP FO...

Page 207: ...QTY Fig 10 23 1 47498N CABLE ASSEMBLY HOSE 1 2 52362N CABLE ASSEMBLY TRIGGER SENSOR 1 3 52361N CABLE ASSEMBLY HYDRAULIC VALVE 1 4 52365N CABLE ASSEMBLY SENSOR 1 5 52363N CABLE ASSEMBLY POWER 1 6 52348...

Page 208: ...8 7 POWER TO ENGINE STARTER GROUND TO ENGINE 5 4 3 2 1 SOLENOID BURNER PLUG BATTERY CIRCUIT BREAKER 1 MATERIAL PUMP REVERSE 4 MATERIAL PUMP FORWARD 2 MIXER FORWARD 3 MIXER REVERSE PUMP REV TOGGLE SWI...

Page 209: ...and 45500 FIG ITEM PART NO DESCRIPTION QTY Fig 10 25 1 43908 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 44...

Page 210: ...Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 66 10 25 Air Compressor Assembly Export Only PN 45345 43800 and 45500 Fig 10 26 Air Compressor Assembly Export Only PN 4534...

Page 211: ...LIC 1 7 29819 FITTING 12 ORB X 12 JIC STRAIGHT 2 8 45326 FITTING 12 BSPP X 12 JIC STRAIGHT 1 9 29773 ADAPTER 12 JIC X 3 4 FPT 90 1 10 28348 BUSHING 3 4 NPT X 1 2 NPT 1 11 51405 NIPPLE 1 2 NPT HEX 1 12...

Page 212: ...10 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 68 10 26 Air Compressor Assembly PN 47480N 47400 1 4 5 6 7 9 15 16 17 18 8 SIGHT GAUGE 10 14 12 11 2 3 13 Fi...

Page 213: ...AULIC 1 6 43874 MOTOR HYDRAULIC 1 7 29819 FITTING 12 ORB X 12 JIC STRAIGHT 2 8 45326 FITTING 12 BSPP X 12 JIC STRAIGHT 1 9 29773 ADAPTER 12 JIC X 3 4 FPT 90 1 10 28348 BUSHING 3 4 NPT X 1 2 NPT 1 11 2...

Page 214: ...ustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 70 10 27 Hydraulic Compressor Valve Assembly PN 45425 43800 47400 and 45500 Fig 10 30Hydraulic Compressor Valve Ass...

Page 215: ...ESCRIPTION QTY Fig 10 28 1 45417 VALVE RELIEF 1 2 45429 VALVE LOGIC RELIEF 1 3 45426 COIL SOLENOID VALVE 1 4 45424 VALVE SOLENOID 1 5 FITTING 12 ORB X 10 JIC STRAIGHT 2 6 45436 FLOW CONTROL PRESSURE C...

Page 216: ...28 High Output Air Lance Assembly FIG ITEM PART NO DESCRIPTION QTY Fig 10 31 1 47483N LANCE AIR HIGH OUTPUT WITH SWVL CPLR 1 2 70250 3 4 SWIVEL 1 3 47488N FITTING 3 4 AIR HOSE 1 4 47491N OPTIONAL WAT...

Page 218: ...r Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 74 10 29 Wand Assembly 1 2 3 4 6 7 8 9 10 11 Fig 10 32 Wand Asse...

Page 219: ...ART NO DESCRIPTION QTY Fig 10 32 1 52204 COVER WAND 1 2 50278 TIP GUARD LONG CLAMP ON 1 3 52206 CORD ASSEMBLY 1 4 52201 HANDLE WAND RIGHT W INSERTS 1 5 52201L HANDLE WAND LEFT NOT SHOWN 1 6 52208 SWIT...

Page 220: ...Part Manual Chapter 10 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 76 10 30 Optional Engine Cover for Compressor Models 2 1 4 5 6 3 Fig 10 33 Optional Engin...

Page 221: ...INE COVER 4LE2 ENGINE 1 2 47510N LATCH COMPRESSION W KEY 4 3 43746 NEOPRENE HANDLE TRIM 2 4 45600 RUBBER REPLACEMENT LATCH 2 5 47506N PASS SIDE DOOR 1 6 47507N AIR CLEANER DOOR 1 N A 47509N RADIATOR S...

Page 222: ...0 Illustrated Parts List 2017 by Crafco Inc All Rights Reserved Illustrated Parts List 10 78 10 31 Hot Air Lance Fig 10 36 Hot Air Lance Option 16 1 7 1 3 2 1 1 6 1 11 1 8 1 17 1 4 1 9 1 5 1 19 1 18 1...

Page 223: ...1 7 28340 BUSHING 1 4 NPT X 1 8 NPT 1 8 45654 PRIMARY BURNER TUBE 1 9 45657 AIR LANCE TUBE 1 10 45668 AIR ORIFICE A 125 1 11 45653 MAIN BURNER TUBE 1 12 45670 SCREW 10 32 X 1 2 ALLEN SCREW 4 13 45672...

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Page 225: ...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 P...

Page 226: ...ed Tools and Accessories 11 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 C...

Page 227: ...Diesel Melter Part Manual Chapter 11 Tools and Accessories 2017 by Crafco Inc All Rights Reserved Tools and Accessories 11 3 Crafco Heat Lance with Regulator and Attachments 32259 Crafco Hand Torch w...

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Page 230: ...2017 Crafco Inc...

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