Crafco SS60-Diesel User Manual

Parts Manual - 26618

Revision B

Fill in appropriate fields that apply to this machine Machine S/N: _ _______________________________ 1st Hose S/N: _______________________________ 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): ________________________

SUPER SHOT 60 Diesel Melter Part

Manual

Revisions

Revision

Date

Updated to new format.

6/9/2015

Added trailer mount information

8/2016

SUPER SHOT 60 DIESEL SKID MOUNT MELTER

PN 46800

SUPER SHOT 60 DIESEL TRAILER MELTER

PN 46950

Super Shot 60 Diesel Melter Part

Manual

Table of Contents

1.0 About This Manual .................................................................................................................. 1-1

1.1 How to use this manual: ...................................................................................................... 1-1

2.0 Safety Precautions .................................................................................................................. 2-1

2.1 General Safety .................................................................................................................... 2-1

2.2 Personal Safety ................................................................................................................... 2-1

2.3 Equipment or Operational Safety ......................................................................................... 2-1

2.4 Safety Symbols and Notices ................................................................................................ 2-2

3.0 Limited Warranty ..................................................................................................................... 3-1

3.1 Warranty Claim Instructions................................................................................................. 3-2

4.0 Machine Specifications ........................................................................................................... 4-1

5.0 Operating Instructions ............................................................................................................. 5-1

5.1 Preparing the Machine for Start Up ..................................................................................... 5-1

5.2 Machine Start Up for Electric Hose ...................................................................................... 5-3

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 Hydraulic System ................................................................................................................ 6-1

6.3 Heat Transfer Oil ................................................................................................................. 6-1

6.4 Wheel Bearing ..................................................................................................................... 6-1

6.5 Material Sensor Tube .......................................................................................................... 6-1

6.6 Lug Nuts .............................................................................................................................. 6-1

6.7 Brakes ................................................................................................................................. 6-2

6.8 Tongue Jack ........................................................................................................................ 6-2

6.9 Temperature Control Calibration ......................................................................................... 6-2

6.10 Maintenance Chart ............................................................................................................ 6-3

6.11 Service Instructions ................................ ........................................................................... 6-4

6.12 General Maintenance Parts ............................................................................................... 6-4

Super Shot 60 Diesel Melter Part

Manual

Table of Contents

6.13 Recommended Spare Parts ............................................................................................... 6-5

6.14 Recommended Fluids and Lubricants ................................................................................ 6-5

6.15 Applicable Brands of Heat Transfer Oil .............................................................................. 6-6

6.16 Typical Heat Transfer Oil Specifications ............................................................................ 6-6

6.17 Material Pump Replacement .............................................................................................. 6-7

7.0 How to Use a Multimeter ......................................................................................................... 7-1

7.1 Checking DC Voltage with a Multimeter ............................................................................... 7-1

7.2 Checking AC Voltage with Multimeter .................................................................................. 7-1

7.3 Checking Resistance (Ohms) .............................................................................................. 7-1

7.4 Checking Amperage ............................................................................................................ 7-2

8.0 Burner Troubleshooting ........................................................................................................... 8-1

8.1 Sealant heating Slowly ...................................................................................................... 8-11

8.2 Mixer Troubleshooting ....................................................................................................... 8-12

Symptom: Mixer Does Not Rotate .......................................................................... 8-12 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 Ordering Crafco Parts .......................................................................................................... 9-1

9.2 Super Shot 60 Diesel Skid Mount Melter ............................................................................. 9-2

9.3 Super Shot 60 Diesel Trailer Melter ..................................................................................... 9-6

9.4 Tank Assembly .................................................................................................................. 9-10

9.5 Control Box Assembly ....................................................................................................... 9-12

9.6 Engine Assembly ............................................................................................................... 9-16

9.7 Hydraulic Control Valve Assembly ..................................................................................... 9-18

9.8 Pump/Mixer Motor Assembly: PN 44832 ........................................................................... 9-20

9.9 Diesel Burner Assembly: PN46380 .................................................................................... 9-22

9.10 Hydraulic Schematic ........................................................................................................ 9-24

9.11 Electrical Schematic ........................................................................................................ 9-28

Super Shot 60 Diesel Melter Part

Manual

Table of Contents

10.0 Tools and Accessories ........................................................................................................ 10-1

Super Shot 60 Diesel Melter Part

Manual

List of Figures

Figure 5.1 Hydraulic Fluid Level and Temp. Gauge ...................................................................... 5-2

Figure 5.2 Heat Transfer Oil Dipstick ................................ ............................................................ 5-2

Figure 6.1 Lug Bolt Tightening Sequence ..................................................................................... 6-1

Figure 6.2 Scale Plate ................................................................................................................... 6-2

Figure 6.3 Material Pump Replacement ........................................................................................ 6-9

Figure 7.1 Standard Multimeter ..................................................................................................... 7-2

Figure 7.2 Clamp – On Amp Meter/Multimeter .............................................................................. 7-3

Figure 8.1 Diesel Burner Schematic .............................................................................................. 8-6

Figure 8.2 Diesel Burner Electrode Adjustment ........................................................................... 8-10

Figure 8.3 Diesel Burner Air Settings .......................................................................................... 8-10

Figure 8.4 Checking Din Plug Voltage ......................................................................................... 8-16

Figure 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 Assembly .......................................................................................................... 9-10

Figure 9.4 Control Box Assembly ................................................................................................ 9-12

Figure 9.5 Engine Assembly ....................................................................................................... 9-16

Figure 9.6 Hydraulic Control Valve Assembly: PN 45420 ............................................................ 9-18

Figure 9.7 Pump/Mixer Motor Assembly: PN 44832 .................................................................... 9-20

Figure 9.8 Diesel Burner Assembly: PN 46380 ........................................................................... 9-22

Figure 9.9 Hydraulic Diagram: PN 46959 .................................................................................... 9-24

Figure 9.10 Electrical Schematic ................................................................................................. 9-28

Super Shot 60 Diesel Melter Part

Manual

List of Tables

Table 2-1 Safety Symbols and Notices ......................................................................................... 2-2

Table 2-2 Safety Symbols and Notices (continued) ....................................................................... 2-3

Table 4-1 Machine Specifications ................................................................................................. 4-1

Table 5-1 Preparing the Machine for Start Up ............................................................................... 5-1

Table 5-2 Starting the Burner ........................................................................................................ 5-3

Table 5-3 Electric Hose Care ........................................................................................................ 5-6

Table 5-4 Hose for Transport Instructions ..................................................................................... 5-6

Table 5-5 Loading Material into the Sealant Tank ......................................................................... 5-7

Table 5-6 Material Tank Depth Chart ............................................................................................ 5-8

Table 5-7 Dispensing the Material ................................................................................................ 5-9

Table 5-8 Shutting Down the Machine ........................................................................................ 5-10

Table 6-1 Maintenance Chart ........................................................................................................ 6-3

Table 6-2 Service Instructions ....................................................................................................... 6-4

Table 6-3 General Maintenance Parts .......................................................................................... 6-4

Table 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 Electrical Troubleshooting (continued) ............................................................... 8-3

Table 8-5 Burner Electrical Troubleshooting (continued) ............................................................... 8-4

Table 8-6 Burner Electrical Troubleshooting (continued) ............................................................... 8-5

Table 8-7 Smoke Coming Out of Exhaust Stack ........................................................................... 8-7

Table 8-8 Burner Lights But Shuts Down After 15 Seconds .......................................................... 8-7

Table 8-9 Testing the DC Controller .............................................................................................. 8-8

Table 8-10 Burner Fuel Solenoid Testing ...................................................................................... 8-8

Table 8-11 Burner Ignition Coil Testing ......................................................................................... 8-9

Table 8-12 Bleeding the Burner .................................................................................................... 8-9

Super Shot 60 Diesel Melter Part

Manual

List of Tables

Table 8-13 Sealant is Heating Slowly .......................................................................................... 8-11

Table 8-14 Basic Visual Mixer Troubleshooting........................................................................... 8-12

Table 8-15 Mixer Electrical Troubleshooting ............................................................................... 8-13

Table 8-16 Mixer Electrical Troubleshooting (continued) ............................................................. 8-14

Table 8-17 Mixer 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 Hose Electrical Troubleshooting (continued) ............................................................. 8-22

Table 8-22 Trigger is not Working ............................................................................................... 8-26

Table 8-23 RTD Sensor Ohms vs. Temperature ......................................................................... 8-27

Table 8-24 RTD Sensor Ohms vs. Temperature (continued) ....................................................... 8-28

Table 8-25 Basic Visual Pump Troubleshooting ................................ .......................................... 8-29

Table 8-26 Pump Electrical 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 Skid Mount Melter: PN 46800 (continued) ................................... 9-4

Table 9-3 Super Shot 60 Diesel Trailer Melter: PN 46950 ............................................................. 9-7

Table 9-4 Super Shot 60 Diesel Trailer Melter: PN 46950 (continued) .......................................... 9-8

Table 9-5 Super Shot 60 Diesel Trailer Melter: PN 46950 (continued) .......................................... 9-9

Table 9-6 Tank Assembly ........................................................................................................... 9-11

Table 9-7 Control Box Assembly ................................................................................................. 9-13

Table 9-8 Control Box Assembly (continued) .............................................................................. 9-14

Table 9-9 Engine Assembly ........................................................................................................ 9-17

Table 9-10 Hydraulic Control Valve Assembly: PN 45420 ........................................................... 9-19

Table 9-11 Pump/Mixer Motor Assembly: PN 44832 ................................................................... 9-21

Table 9-12 Diesel Burner Assembly: PN 46380 .......................................................................... 9-23

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

Super Shot 60 Diesel Melter Part

Manual

Chapter 1 Introduction

WARNING

California Proposition 65 Warning

Engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Always use care to avoid breathing engine exhaust. Failure to comply could result in death or serious injury.

1.0 About This Manual

This manual is supplied with each new Crafco Super Shot 60 Diesel Melter. The manual assists your machine operators in the proper use of the melter applicator and provides information about the machine’s mechanical functions.

Your Crafco Super Shot 60 Diesel Melter is specially made to give excellent service and save maintenance expense. However, as with all specially engineered equipment, you get best results at minimum cost if you:

Operate your machine as instructed in this manual. Maintain your machine regularly as stated in this manual.

1.1 How to use this manual:

This manual is formatted to start each new chapter on the right page. There may be a blank page on the left page if the previous 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, table, or figure.

3. The panel to the left in the PDF is a bookmarks panel, if you left mouse click on any section/heading in the bookmarks panel you will be sent to that page.

4. There is an attachments icon (paper clip) to the left of the bookmarks, this is where you will find full size prints of the control box, electrical, and hydraulic schematics.

Super Shot 60 Diesel Melter Part

Manual

Chapter 2 Safety

2.0 Safety Precautions

For more in-depth safety information, please see Safety Manual (PN 26221) which comes with the machine. Or contact your nearest authorized Crafco Distributor at crafco.com/Distributors.

2.1 General Safety

 Crafco, Inc. assumes no liability for an accident or injury incurred through improper use of

the machine.

 Read this manual thoroughly before operating the machine.  Obey all CAUTION and WARNING signs posted on the machine.  Make sure an operator fully knows how to operate the machine before using the machine.

2.2 Personal Safety

 The high operating temperatures of this machine and the sealant it contains requires that

protective clothing, gloves, hard-soled shoes, and safety glasses or a face shield be worn at all times by operators of the machine.

 Prevent water from going into any part of the machine. If there is indication of water in the

heat transfer oil system, warm heating oil to 250-300°F (121.1-148.96°C) for 2 to 3 hours.

 Bodily contact with hot sealant or heat transfer oil can cause severe burns.  If the mixer is not stopped before adding solid material, hot material can get on an operator’s

body and cause severe burns.

 Keep hands, feet, and clothing away from 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 correctly maintained fire extinguisher near the machine and know how to use

it.

 DO NOT heat transfer oil to a temperature of more than 525°F (273.9°C).  DO NOT put too much heat transfer oil in the reservoir. The expansion of oil while it heats

up can cause overflow. With the machine on level ground, check the oil each day before starting the burner. Add oil to the top mark on the dipstick if required (at 70°F (21.1°C)). Use only recommended heat transfer oil. Change the oil after 500 hours of machine operation, or one year, whichever comes first.

 Follow the operating instructions for starting and shutting down the burner. Instructions are

mounted on the control box on the machine.

 Calibrate the temperature control operation after each 50 hours of machine operation. Refer

to section 6.9 Temperature Control Calibration.

 Replace any hoses which show signs of wear, fraying or splitting.  Make sure all fittings and joints are tight and do not leak each time the machine is used.  Do not leave the machine unattended while the burner is lit.  Tighten all bolts and screws every 100 hours of machine operation.

Super Shot 60 Diesel Melter Part

Manual

Chapter 2 Safety

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 Wear

Wear face shield or safety glasses.

Body Crush Hazard

Do not stand between trailer and hitch when hooking melter to truck.

Table 2-1 Safety Symbols and Notices

2.4 Safety Symbols and Notices

Important safety symbols and notices are marked on the machine and in this manual. Failure to comply could result in equipment damage, operational malfunction, serious injury, or death. Please read and comply with all symbols and notices. The table below includes the most commonly used symbols and notices.

Super Shot 60 Diesel Melter Part

Manual

Chapter 2 Safety

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)

Super Shot 60 Diesel Melter Part

Manual

Chapter 3 Warranty Information

CAUTION

Use of replacement parts other than genuine Crafco parts may impair the safety or reliability of your equipment and nullifies any warranty.

3.0 Limited Warranty

Crafco, Inc., through Crafco or one of its affiliated distributors, will replace for the original purchaser free of charge any parts found upon examination by the factory at Chandler, Arizona, to be defective in material or workmanship. This warranty is for a period one year from in-service date, but excludes engine or components, tires, and battery as these items are subject to warranties issued by their manufactures.

Crafco, Inc. shall not be liable for parts that have 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 warranty.

All transportation and labor costs incurred by the purchaser in submitting or repairing covered components must be borne by the purchaser. Crafco, Inc. specifically disavows any other representation, warranty, or liability related to the condition or use of the product.

Super Shot 60 Diesel Melter Part

Manual

Chapter 3 Warranty Information

3.1 Warranty Claim Instructions

Crafco, Inc. warrants parts and machinery purchased through Crafco or one of its affiliated distributors for one year from purchased or in-service date. If parts fail to function within the first year of purchase, a return authorization number (RA) must be obtained. If the part was purchased through Crafco, Inc., please contact Crafco returns department at Returns@Crafco.com for an RA number or if purchased through a Crafco distributor please contact your distributor. Note: if the part has a serial number associated with it, for example; a machine or electric hose or wand, this must be furnished when requesting the RA number. The customer will be emailed or faxed an RA form with all instructions to return the item to Crafco, Inc. See example. If the part is found to be within the one year warranty period and has not been abused or modified, a credit will be issued to the

customer’s account or credit card. The customer may request the part be replaced instead of a

credit, if desired. Wear items are not covered under Crafco, Inc. limited warranty. A wear item is defined as but not

limited to: material pumps, sealing tips, tires, 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 below when calling in a Warranty Claim. Failure to follow these

procedures may be cause to void the warranty. Call your local Crafco Distributor. If you do not know who your local distributor is, call a Crafco

Customer Service Representative, (Toll Free 1-800-528-8242) for name, location and telephone number.

On contacting the distributor, be prepared to identify the serial number, model number, engine number, engine manufacturer, and the date of purchase if available.

Should the cause of the malfunction be a defective part, the Distributor will advise you of the procedure to follow for a replacement.

The warranty is valid only for parts, which have been supplied or recommended by Crafco, Inc. If you have any additional questions regarding warrant repairs and parts, please do not hesitate to

call toll free 1-800-528-8242.

For Warranty: Crafco, Inc. 25527 South Arizona Avenue, Chandler, AZ

85248 Phone: (480) 655-8333 or (800) 528-8242 Fax: (480) 655-1712

.

For all other inquires: Crafco, Inc. 6165 W Detroit St, Chandler, AZ 85226 Phone: (602) 276-0406 or (800) 528-8242 Fax: (480) 961-0513

CustomerService@crafco.com

2018 Model Year Warranty Addendum

Chapter 3 Warranty Information

CAUTION

Use of replacement parts other than genuine Crafco parts may impair the safety or reliability of your equipment and nullifies any warranty.

3.0 Limited Warranty

Crafco, Inc. (Manufacturer), or one of its affiliated distributors, will replace for the original purchaser free of charge any parts found upon examination by the Manufacturer, to be defective in material or workmanship. This warranty is for a period two years from the invoice date, but excludes engine or components, tires, and battery as these items are subject to warranties issued by their manufacturers.

Crafco, Inc. shall not be liable for parts that have 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 warranty.

All transportation and labor costs incurred by the purchaser in submitting or repairing covered components must be borne by the purchaser. Crafco, Inc. specifically disavows any other representation, warranty, or liability related to the condition or use of the product.

2018 Model Year Warranty Addendum

Chapter 3 Warranty Information

3.1 Warranty Claim Instructions

Crafco, Inc. warrants parts and machinery purchased through Crafco or one of its affiliated distributors for two years from the invoice date. Wear items are not covered under the Crafco, Inc. limited warranty. A wear item is defined as but not limited to: material pumps, sealing tips, tires, etc.

If parts fail to function within two years of invoice date, a return authorization number (RA) must be obtained. If the part was purchased through Crafco, Inc., please contact Crafco returns department at Returns@Crafco.com for an RA number or if purchased through a Crafco distributor please contact your distributor.

Note: if the part has a serial number associated with it, for example; a machine or electric hose or wand, this must be furnished when requesting the RA number. The customer will be emailed or faxed an RA form with all instructions to return the item to Crafco, Inc. See example. If the part is found to be within the two year warranty period and has not been abused or modified, a credit will be issued to the customer’s account or credit card. The customer may request the part be replaced instead of a credit, if desired.

Note: 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 when calling in a Warranty Claim. Failure to follow these procedures may be cause to void the warranty.

Call your local Crafco Distributor. If you do not know who your local distributor is, call a Crafco Customer Service Representative, (Toll Free 1-800-528-8242) for name, location and telephone number.

On contacting the distributor, be prepared to identify the serial number, model number, engine number, engine manufacturer, and the date of purchase if available.

Should the cause of the malfunction be a defective part, the Distributor will advise you of the procedure to follow for a replacement.

The warranty is valid only for parts, which have been supplied or recommended by Crafco, Inc. If you have any additional questions regarding warranty repairs and parts, please do not

hesitate to call toll free 1-800-528-8242.

For Warranty: Crafco, Inc. 25527 South Arizona Avenue Chandler, AZ 85248 Phone: (480) 655-8333 or (800) 528-8242 Fax: (480) 655-1712

For all other inquires: Crafco, Inc. 6165 W Detroit Street Chandler, AZ 85226 Phone: (602) 276-0406 or (800) 528-8242 Fax: (480) 961-0513

CustomerService@crafco.com

Super Shot 60 Diesel Melter Part

Manual

Chapter 4 Machine Specifications

Specification

PN 46800 SKID

PN 46950 TRAILER

Vat Capacity

58 Gallons (220 Liters)

Melt Capacity

480 Pounds per hour (218 Kg, per hour)

Heat Transfer Oil Required

21 Gallons at 70°F (82 Liters at 21°C)

Tank Construction

Double boiler type

Tank Opening Size

12.25 in x 14.63 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

3,200 Lbs. (1,451 kg)

Diesel tank Capacity

26 Gallons (98.4 Liters)

Hydraulic Tank Capacity

26 Gallons (98.4 Liters)

Axle Capacity

N/A

Single Torsional 4,200 lbs. (1,905 kg)

Tires

N/A

ST225/75 R15 (Load Range D)

Table 4-1 Machine Specifications

4.0 Machine Specifications

Super Shot 60 Diesel Melter Part

Manual

Chapter 5 Operating Instructions

Step

Action

1

Fill the engine fuel tank with diesel fuel. Note: Use No. 1 Diesel fuel in cold weather and No. 2 Diesel fuel in warm weather

2

Check the oil level in the engine crankcase. (Refer to the manufacturer’s instruction for the engine.)

3

Check the hydraulic fluid level while at a temperature of 70°F (21.1°C). Add fluid if necessary. See Figure 5.1 Hydraulic Fluid Level and Temp. Gauge

4

With the machine on 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 this machine is the operator’s responsibility. Use extreme care when operating this machine; safety is the result of being careful

and paying attention to details. Remember the propane flame is approximately 2,200°F (1204.4°C). Some exposed parts of the machine reach 500°F (260°C), the sealant 400°F (204.4°C), and the hydraulic fluid 180°F (82.2°C).

Always put on protective clothing, gloves, hard-soled shoes, and safety glasses or a face shield. Be sure that all joints and fittings are tight and leak proof. Immediately replace any hose, which shows any signs of wear, fraying, or splitting. Tighten all bolts, nuts, and screws every 100 hours.

Table 5-1 Preparing the Machine for Start Up

5.0 Operating Instructions

The Crafco Super Shot 60 Diesel was developed to melt Crafco sealants. However, it works well with most road asphalt and federal specification crack or joint sealants.

Note: DO NOT attempt to operate the machine without using these and all other instructions.

5.1 Preparing the Machine for Start Up

Super Shot 60 Diesel Melter Part

Manual

Chapter 5 Operating Instructions

Figure 5.1 Hydraulic Fluid Level and Temp. Gauge

Figure 5.2 Heat Transfer Oil Dipstick

Dipstick for Heat Transfer Oil

Super Shot 60 Diesel Melter Part

Manual

Chapter 5 Operating Instructions

Step

Action

1

Fully open the exhaust stack cover.

2

Start the engine. (Refer to the manufacturer’s instructions for the engine).

3

Turn the “POWER” toggle switch in the control box to the “ON” position. The red light

marked “BURNER” will illuminate indicating that the material and hot oil temperatures are below set point. When the red light goes off this indicates the material or oil temperatures are up to the set point.

NOTE: Just because this light is illuminated does not indicate the burner is actually

working.

4

Set the heat transfer oil temperature at 500°F (260°C).

5

Set the material temperature to the manufacturer’s recommended temperature.

CAUTION

If the burner does not ignite the first time, turn the “POWER” toggle switch to the “OFF” position. Turn the toggle switch to “ON” again; the burner should ignite. If the burner still

does not ignite, refer to 8.0.1 Symptoms: Burner will Not Ignite to determine the malfunction.

Important: The solid material in the tank melts first 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 the tank will be melted and heated to the proper application temperature.

6

Allow the heat transfer oil to continue to heat.

7

When the material reaches 275°F (135°C), the mixer light will illuminate which indicates the mixer can be engaged by turning the toggle switch at the control panel to “FORWARD” position. If the mixer does not move, allow the material to heat longer.

Note: Mixer speed is preset at the factory and cannot be adjusted. The mixer cannot be

engaged until the material reaches 275°F (135°C).

CAUTION

Jamming the mixer can cause the hydraulic oil to overheat and damage the machine.

8

The hose automatically turns “ON” when the material temperature reaches 275°F (135°C). The red light marked ‘HEATED HOSE” will illuminate when the hose control is calling for heat.

9

Adjust the temperature dial to the manufacturer’s recommended temperature.

Note: The hose reaches operating temperature in approximately 30 minutes.

Table 5-2 Starting the Burner

5.2 Machine Start Up for Electric Hose

Super Shot 60 Diesel Melter Part

Manual

Chapter 5 Operating Instructions

Step

Action

10

After the hose reaches the temperature set point, the light in the control box marked “HEATED HOSE” turns off.

11

Once the hose reaches 325°F (162.8°C) the red light marked “PUMP” will illuminate indicating that the temperature interlock will allow operation of material pump.

Important: The hose must reach 325°F (162.8°C) before dispensing can take place. If

the hose does not dispense when 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.

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 hose cycling for longer than 30 minutes without dispensing material;

coking can occur and permanently damage the hose. DO NOT remove the hose from the boom during operation or kinking will occur.

Important: It is strongly recommended that the hose be stored in the boom (locked

position) when not in use or when in transit. This will prevent twisting or kinking.

Table 5-2.1 Starting the Burner for Electric Hose (continued)

Super Shot 60 Diesel Melter Part

Manual

Chapter 5 Operating Instructions

26083 CLAMP NEEDS TO BE ROTATED TO THE SIDE AS SHOWN. THIS KEEPS IT FROM CATCHING ON SHOEBOX.

INSTALL 26084 MINI GEAR CLAMP ONTO THE DUCKBILL VALVE

A

DETAIL A

50278

50270

5.3 About the Heated Hose, Wand, Valve, and Tip Guard The Heated Hose

The heated hose supplied with the machine is Teflon-lined with steel over braid. It has a heating element, which runs the length of the hose to heat the material within the hose. The hose is covered with high temperature, durable rubber.

The Wand

The wand has an aluminum tube to protect both the wand and the operator. The pistol grip actuator is equipped with an electric switch which, when depressed, sends a signal to actuate the pump. The wand is equipped with a trigger lock to prevent accidental pump actuation when it is not

pumping material. The trigger must be in the “LOCKED” 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 other sealing tips and options.

Tip Guard

The wand has a Tip Guard installed at the factory only when a duckbill is installed. This Tip Guard is not required when using sealing disk or dripless tip adapter. The purpose of this guard is to prolong the life of using a duckbill and to protect the operator in the event of a duckbill failure. Ensure this guard is installed properly before operating equipment. See below.

Super Shot 60 Diesel Melter Part

Manual

Chapter 5 Operating Instructions

Step

Action

CAUTION

Twisting and kinking of the electric hose (used on BAX, Super Shots, and EZ Series Melters) causes the hose to fail; the electric heating wires are shorted out to the metal hose cover and the hose stops heating.

This type of failure is not covered under the Crafco warranty.

1

Set the hose temperature at 193.3°C (380°F), or manufacturer recommended operating temperature.

2

Allow the hose to be turned “ON” and heating for a minimum of 30 minutes.

3

Make sure the hose swivel between the hose and wand moves freely.

Note: Do not twist or bend the hose over sharp edges such as the edge of the frame or

tank. 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 the wires between the hose and

wand connection to twist or wrap up. The swivel is cold and is not flexible which can cause the hose to twist. The wiring between the hose and the wand is pulled, stressed, or used to support the

wand.

Step

Action

1

Leave 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.

2

Place the wand in the wand holder and lock the wand into position with the latch provided.

Table 5-3 Electric Hose Care

Table 5-4 Hose for Transport Instructions

5.4 Electric Hose Care and Cautions

5.5 Storing the Electric Hose for Transport

Super Shot 60 Diesel Melter Part

Manual

Chapter 5 Operating Instructions

CAUTION

Personal injury could occur if this safety system is disabled.

Step

Action

WARNING

Following this procedure prevents 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 are added too quickly, jamming results and slows

down the melting process.

Note: When sealant placement volume is low, or the crew has stopped working for

lunch hot oil and material temperatures can equalize. To lower material temperature add a few blocks of cold sealant. This may not be an option if the tank is full.

Table 5-5 Loading Material into the Sealant Tank

5.6 Loading Material into the Sealant Tank

This unit is equipped with a safety interlock system on the loading door. This system disables the mixer hydraulic system when the lid is open to stop the mixer from turning. This is a safety feature for the operator and should never be disabled for any reason.

Super Shot 60 Diesel Melter Part

Manual

Chapter 5 Operating Instructions

DEPTH OF MATERIAL

TANK

CAPACITY IN

GALLONS

BOTTOM UP

CAPACITY IN

LITERS

BOTTOM UP

CAPACITY IN

GALLONS

TOP DOWN

CAPACITY IN

LITERS TOP

DOWN

25.4

3.06

11.58

55.66

210.70

50.8

6.12

23.17

52.6

199.11

76.2

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

48.96

185.33

9.76

36.95

436.4

52.02

196.92

6.7

25.36

461.8

55.08

208.50

3.64

13.78

487.2

58.14

220.08

0.58

2.20

487.43

58.72

222.28

0

0.00

Table 5-6 Material Tank Depth Chart

Material Tank Depth Chart 5.6.1

Super Shot 60 Diesel Melter Part

Manual

Chapter 5 Operating Instructions

Step

Action

WARNING

Put on protective clothing, gloves, hard-soled shoes, and face shield or safety glasses when operating or filling this machine. Read the entire manual before operating the machine.

Never point the wand at any part of the body or at any other person. Hot material can cause severe burns.

Important: Some difficulty may be encountered when starting 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 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 setting by turning the speed control knob fully clockwise.

3

Insert the wand tip under the lid, depress trigger on the wand and slowly increase pump speed until the pump motor starts to turn.

4

Adjust the pump speed for the desired flow rate for the application. The rate of flow may be varied while the pump is running.

Table 5-7 Dispensing the Material

5.7 Dispensing the Material

Super Shot 60 Diesel Melter Part

Manual

Chapter 5 Operating Instructions

Step

Action

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 or permanent damage may result.

2

Place the wand in the wand holder and lock the wand into position with the latch provided.

3

Reverse the pump for approximately 30 seconds.

4

Turn the mixer toggle switch to the “OFF” position.

5

Turn the “POWER” switch to the “OFF” position.

6

Stop the engine by turning the key to the “OFF” position.

Table 5-8 Shutting Down the Machine

5.8 Shutting Down and Cleaning Out the Machine

When shutting down the machine for the day, Crafco recommends leaving the melter about half full with material. This will give a fairly rapid heat up rate in the morning, but allows enough material to start dispensing right away when the material becomes molten.

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, warm the heat transfer oil to 300°F (148.9°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 damage and/or personal injury.

Best practice is to check in the material tank prior to starting the burner. If water is present, try and remove as much as possible, heat the material to 300°F (148.9°C) for two to three hours to evaporate the moisture. Failure to follow this procedure will cause the material to overflow the tank resulting in possible machine damage and/or personal injury.

Store the machine for longer periods with the material tank empty.

Super Shot 60 Diesel Melter Part

Manual

Chapter 6 Maintenance Instructions

Figure 6.1 Lug Bolt Tightening Sequence

4-BOLT 5-BOLT 6-BOLT

1

2

34

1

2

34

5

1

2

3

4 5

6

6.0 Maintenance Instructions

This chapter contains all normal maintenance instructions to properly maintain your machine.

6.1 Engine

Refer to the manufacturer’s operating and maintenance instructions for the engine.

6.2 Hydraulic System

Check hydraulic fluid daily. Change hydraulic filter every 250 hours of machine operation. Replace if necessary. Change hydraulic fluid every 500 hours of operation.

6.3 Heat Transfer Oil

Check the oil level at the start of every day. Change the oil every 500 hours of machine operation 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 first road use and after each wheel removal. Check and torque after the first 10 miles, 25 miles, and again at 50 miles. Check periodically thereafter.

Torque in stages as follows: First stage 20-25 foot-pound (ft-lb) Second stage 50-60 foot pound (ft-lb) Third stage 90-120 foot pound (ft-lb) Tighten bolts and nuts in the sequence shown in Figure 6.1 Lug Bolt Tightening Sequence.

Super Shot 60 Diesel Melter Part

Manual

Chapter 6 Maintenance Instructions

Figure 6.2 Scale Plate

200

220

240

260

280

300

320

340

360 380

400

Calibration Mark

Knob

6.7 Brakes

Check the brakes daily.

6.8 Tongue Jack

Lubricate the tongue 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)

Super Shot 60 Diesel Melter Part

Manual

Chapter 6 Maintenance Instructions

Hours

Possible Cause

Procedure

8

50

250

500

Engine Check Oil Level

Refer to the manufacturer’s

instructions for the engine

X

Other Engine Maintenance

Refer to the manufacture’s

operating and maintenance 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 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 built up material in the material tank

Once a year or as needed

Material Sensor Guard

Scrape out built up material around guard

X

Table 6-1 Maintenance Chart

6.10 Maintenance Chart

For a list of parts required for maintenance see Table 6-3 General Maintenance Parts.

Super Shot 60 Diesel Melter Part

Manual

Chapter 6 Maintenance Instructions

Step

Action

1

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

2

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

3

Make necessary adjustments and tighten all loose nuts or screws.

4

Watch 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

Quantity

Description

Part No.

1

Engine Fuel Filter

41867

1

Engine Oil Filter

45389

1

Engine Air Filter

45391

1

Nozzle, Burner

46912

1

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

6.11 Service Instructions

For service, find a list of authorized Distributors and service centers at Crafco.com/Distributors.

6.12 General Maintenance Parts

Super Shot 60 Diesel Melter Part

Manual

Chapter 6 Maintenance Instructions

Quantity

Description

Part No.

1

Temperature Controller, Material

51672

1

Temperature Controller, 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

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 Recommended Spare Parts

Table 6-5 Recommended Fluids and Lubricants

6.13 Recommended Spare Parts

6.14 Recommended Fluids and Lubricants

Super Shot 60 Diesel Melter Part

Manual

Chapter 6 Maintenance Instructions

Manufacturer

Product Name

Crafco Heat Transfer Fluid

Chevron

Heat Transfer Oil Grade 46

Shell Turbo T 68 (Group II)

Citgo

Hytherm Oil 46

Shell Turbo T 68 (Group II)

Conoco

Hydroclear Heat Transfer Oil

Shell Turbo T 68 (Group II)

Fina

Vulcan Heat Transfer Oil 46

Shell Turbo T 68 (Group II)

Lubrication Engineers

Heat Transfer Oil

Shell Turbo T 68 (Group II)

Exxon Mobile

Caloria HT 43

Shell Turbo T 68 (Group II)

Mobil

Mobiltherm 43

Shell Turbo T 68 (Group II)

Mobil

Mobiltherm 603

Shell Turbo T 68 (Group II)

Phillips 66

Heat Transfer 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. Tests conducted by Crafco, Inc. have determined that for best results and safety, the heat transfer oil in this machine must be drained and replaced with Crafco, Inc. recommended oil after five hundred (500) hours of machine operation or one (1) year, whichever occurs first.

ISO

68

Flash Point, COC

445°F (229.4°C)

Viscosity @ 100°F-SUS

325

Viscosity @ 210°F-SUS

50

Viscosity Index

95-100

Pour Point

0°F (-17.78°C)

Carbon Residue

1%

Table 6-6 Applicable Brand of Heat Transfer Oil

6.15 Applicable Brands of Heat Transfer Oil

6.16 Typical Heat Transfer Oil Specifications

Super Shot 60 Diesel Melter Part

Manual

Chapter 6 Maintenance Instructions

Step

Action

1

Bring the melter to temperature as preparation to drain the sealant tank.

2

Remove the pipe cap located at the rear of the machine and drain the sealant tank.

WARNING

The material in the sealant tank is extremely hot. Bodily contact with hot sealant can cause severe burns.

The high operating temperatures of this machine and the sealant it contains require that protective clothing, gloves, hard-soled shoes, and safety glasses or a face shield be worn at all times by operators of the machine.

3

Remove both guards from the motor mount to access the chain and the sprockets.

4

Rotate the agitator until the connecting link is accessible.

5

Disassemble the connecting link 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 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 set aside.

10

Remove the two (2) bolts holding the agitator shaft bearing.

Note: Do not remove the bearing from the agitator shaft.

11

When the unit has cooled sufficiently, remove the six (6) bolts holding the paddles on top of the screen.

12

Remove the paddles from the tank.

13

Remove the pump drive shaft from the center of the agitator shaft, next lift the agitator shaft and screen assembly as high as possible and insert a screw driver into the shaft hole.

Note: This will support the assembly while removing the pump from the tank.

14

Remove the six (6) bolts attaching the pump to the tank.

15

Lift the pump from the sealant tank.

Table 6-7 Material Pump Replacement

6.17 Material Pump Replacement

Super Shot 60 Diesel Melter Part

Manual

Chapter 6 Maintenance Instructions

Step

Action

WARNING

Crush Hazard. The pump weighs approximately 90 pounds. 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 Replacement (continued)

Super Shot 60 Diesel Melter Part

Manual

Chapter 6 Maintenance Instructions

Figure 6.3 Material Pump Replacement

PUMP ASSEMBLY BOLTS

PUMP MOUNTING BOLTS

PUMP ASSEMBLY

PUMP MOUNTING PLATE

TANK BOTTOM

Super Shot 60 Diesel Melter Part

Manual

Chapter 7 How to Use a Multimeter

7.0 How to Use a Multimeter

Melters use 12-volt direct current (DC) to power the burner, hydraulic valves, and trigger on electric wand. The DC power is from a 12-volt battery. The electric hose and wand uses 24-volt 3-phase alternating current (AC). The AC power is from the generator which hangs under the radiator. This system has no reference to ground so there is no possibility of electrical shock unless you are between 2 of the phases. NOTE: ONLY CHECK AMPERAGE ON A HOSE WITH A CLAMP-ON AMP METER. ( See Figure 7.2 Clamp – On Amp

Meter/Multimeter)

12-volt DC power has little danger of electrical shock. Care must still be taken when dealing with DC power systems because it is capable of producing large amounts of current.

7.1 Checking DC Voltage with a Multimeter

Connect the probes to the meter. Set the range to a position that includes 12-volts or higher. Touch the red probe to the positive side of accessory and black probe 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 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 volts AC.

• Touch red probe to the white wire of the generator and the black probe to the green wire of the generator.

• Next move black probe to black wire.

• Then move red probe to green wire.

7.3 Checking Resistance (Ohms)

Connect probes to the meter (See Figure 7.1 Standard Multimeter).

Note: When checking Ohms the circuit cannot be completed. This means one end of the wire will

need to be disconnected.

7.3.1 How to Check Wire Continuity

Set the meter to “Audible Continuity”. Now touch the probe to each end of the wire in question. The meter will read “0” on the screen and

make an audible beep if the wire has continuity from end to end.

7.3.2 How to Check RTD Sensor

Set dial to Ohms Ω. If your meter has different ranges set to 2K or 2000 ohm range. Touch one probe to each screw or wire of the sensor. The meter will read X.XX if in the 2K range

or XXX.X if in the 2000 range.

Super Shot 60 Diesel Melter Part

Manual

Chapter 7 How to Use a Multimeter

Figure 7.1 Standard Multimeter

AC Voltage ~

• Generator Output

Audible Continuity

wire connection

Ohms Ω

• Burner Ignition Coil

Use these ports. Do not amps

DC Voltage

except Generator

7.4 Checking Amperage

The Multimeter can be used to check amperages under 10 amps in AC or DC current. When checking the amperage of the electric 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.

• Hose, Wand, and

• Everything

• Sensors

• Hyd. Coils

use the fuse port, it is for

Super Shot 60 Diesel Melter Part

Manual

Chapter 7 How to Use a Multimeter

Figure 7.2 Clamp – On Amp Meter/Multimeter

Ohms Ω

• Burner Ignition Coil

Audible Continuity

wire connection

DC Voltage

except Generator

AC Voltage ~

• Generator Output

AC Amps ~

• Hose Current

• Everything

• Sensors

• Hyd. Coils

 Hose, Wand, and

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible Cause

If . . .

1

Is the engine running?

NOTE: You can troubleshoot the burner

without the engine running, but you must connect a battery charger to the battery

and the ignition must be in the “ON”

position.

 Yes, go to Step 2.  No, start the engine.

2

Is the “POWER” toggle switch in the “ON”

position?

 Yes, go to Step 3.  No, turn the toggle switch to the “ON”

position.

3

Is the red "Burner" light "ON"?

 Yes, go to Step 6.  No, go to Table 8-3 Burner Electrical

Troubleshooting Step 4.

4

Are both the Material and Hot Oil temperature dials set above the current temperatures?

 Yes, go to Step 4.  No, set the Material 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 control box.

 No, go to Step 4a.

5a

Does either readout display a 1?

NOTE: This occurs only when the sensor

circuit is not completed.

 Yes, this indicates a break in one or both of

the sensor wires between the RTD sensor and the PAKSTAT. Check for broken wires between senor and PAKSTAT.

 No, go to Step 6.

6

Is the circuit breaker tripped?

 Yes, reset by pushing in the button that

popped out.

 No go to Step 7.

7

Is the fuel level low or empty?

 Yes, fill with #2 diesel fuel. Then bleed the

burner, see Table 8-12 Bleeding the Burner.

 No, go to Step 8.

Table 8-1 Basic Visual Burner Troubleshooting

8.0 Burner Troubleshooting

8.0.1. Symptoms: Burner will Not Ignite

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible Cause

If . . .

8

Is there smoke coming out of the exhaust stack?

 Yes, go to Table 8-13 Sealant is Heating

Slowly.

 No, go to Step 9.

9

Is your burner working properly, but it seems to take a while to reach operating temperature?

 Yes, go to Table 8-13 Sealant is Heating

Slowly.

 No, Call Crafco, Inc. and speak to a

customer service technician.

Step

Possible Cause

If . . .

1

Is there 12Vdc between the 2 center terminals of the frame solenoid?

 Yes, go to 1a.  No, check for poor connection or broken

wire between frame solenoid and engine oil pressure switch white/red wire.

1a

Is there 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 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 under the battery and the ground lug on the battery tray?

 Yes, check for loose or broken wires

between circuit breaker and frame solenoid.

 No, go to Step 2a.

2a

Is there 12Vdc between the circuit breaker (red wire going to battery positive cable) and the ground lug on the battery tray?

 Yes, wait 15 seconds then repeat step 2.  If still no voltage then replace circuit

breaker.

 No, go to Step 2b.

2b

Check for loose or broken wires between circuit breaker and battery positive cable.

 Yes, replace or repair damaged wire and

repeat Step 3.

 No, go to Step 3.

Table 8-2 Basic Visual Burner Troubleshooting (continued)

Table 8-3 Burner Electrical Troubleshooting

Note: Use Figure 8.1 Diesel Burner Schematic while troubleshooting the burner electrical system.

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible Cause

If . . .

3

Is there 12Vdc between the positive and negative battery post? If this check is done while the engine is running the reading should be 13.8 volts.

 Yes, then there should be 12Vdc on the

battery side of the circuit breaker.

 No, replace battery.  NOTE: If the reading is less than 13.8 volts

while the engine is running the alternator needs to be rebuilt or replaced.

4

Find insulated quick connect between green wire and white wire that goes to burner plug. Is there 12Vdc between the green wire and a nearby ground source (black wire)?

 Yes, go to Table 8-9 Testing the DC

Controller.

 No, go to Step 4a.

4a

Is there 12Vdc between green wire labeled “GRN-BRNR” on upper terminal blocks and nearby ground source (black wire).

 Yes, check for loose or broken wires

between burner plug and terminal block.

 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 terminal #5 black wire of hot oil PAKSTAT?

 Yes, replace hot oil PAKSTAT.  No, go to Step 6.

6

Is there 12Vdc between gray wire labeled “GRY-3” on upper terminal blocks and a nearby ground source (black wire)?

 Yes, check for loose or broken wires

between terminal block and terminal #6 of the hot oil PAKSTAT.

 No, go to Step 6a.

6a

Is there 12Vdc between gray wire labeled “GRY-1” on upper terminal blocks and a nearby ground source (black wire)?

 Yes, replace terminal block.  No, go to Step 7.

7

Is there 12Vdc between terminal #4 gray wire and terminal #8 black wire of the material PAKSTAT?

 Yes, check for loose or broken wires

between terminal block and terminal #4 of the material PAKSTAT.

 No, go to Step 7a.

Table 8-4 Burner Electrical Troubleshooting (continued)

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible Cause

If . . .

7a

Is there 12Vdc between terminal #3 orange wire and terminal #8 black wire of the material PAKSTAT?

 Yes, replace PAKSTAT.  No, go to step 7b.

7b

Is there 12Vdc between terminal #1 orange wire and terminal #8 black wire of the material PAKSTAT?

 Yes, check for loose or broken wires

between terminal #1 and #3 of material PAKSTAT.

 No, go to Step 7c.

7c

Is there 12Vdc between terminal #9 orange wire and terminal #8 black wire of the material PAKSTAT?

 Yes, check for loose or broken wires

between terminal #9 and #1 of material PAKSTAT.

 No, go to Step 8.

8

Is there 12Vdc between orange wire labeled “ORN-1” on upper terminal blocks and a nearby ground source (black wire)?

 Yes, check for loose or broken wires

between terminal #9 of the material PAKSTAT 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 Step10.

10

Is there 12Vdc between top terminal (orange wire) of power switch and nearby ground source (black wire)?

 Yes, check for loose or broken wires

between top terminal power switch and terminal #3 of the hot oil PAKSTAT.

 No, go to Step 11.

11

Is there 12Vdc between bottom terminal (red wire) of power switch and nearby ground source (black wire)?

 Yes, replace switch.  No, go to Step 12.

12

Is there 12Vdc between top terminal of circuit breaker (red wire) and nearby ground source (black wire)?

 Yes, check for loose or broken wires

between top terminal of circuit breaker and bottom terminal (red wire) of power switch.

 No, go to Step 12a.

Table 8-5 Burner Electrical Troubleshooting (continued)

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible Cause

If . . .

12a

Is there 12Vdc between bottom terminal of circuit breaker (red wire) and nearby ground source (black wire)?

 Yes, replace circuit breaker.  No, go to Step 13.

13

Is there 12Vdc between “ACC” (red wire) of

ignition switch and nearby ground source (black wire)?

 Yes, check for 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 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 solenoid and ignition switch.

 No, go to Step 14a.

14a

Check connections and condition of red battery cable

 Yes, there should be 12Vdc at all previous

steps.

 No, replace battery cable.

Table 8-6 Burner Electrical Troubleshooting (continued)

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Figure 8.1 Diesel Burner Schematic

14 GA. WHITE

WHT/GRN

WHT/BLK

WHT/RED

GRN/BRNR

REDBLACK

BLACK

12 GA. RED

12 GA. RED 14 GA. RED 14 GA. RED

BLACK

Burner Plug

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

4

1

14 13

12 9

WHT/GRN-1 WHT/GRN-2

BLK-3

WHT/BLK

WHT/GRN

GRN-BRNR

MATERIAL

51672

BLK-4

GRN BRNR

GRY-1

ORN-1

58

RED-4

WHT-RED

WHT/RED-4

T1T2T3T4

T7 T 6

T9

T8

T1T2T3T4

T7 T 6

T9

T8

Acc

BLK-5

GRY-2

RED-2

ORN-2

BLK-5

GRY-3

GRY-2

WHT/GRN-1

WHT/GRN-2

RED-2

HOT OIL

43391

MAT'LHOSE

RED-3

ORN-2

GRN

PRP

BLU

GRN

PRP

BLU

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Smoke Coming Out of the Exhaust Stack

1

White smoke indicates that there is too much air being forced though the burner. Loosen the Air Shutter screw and rotate the Air Shutter counter clockwise to reduce air. Refer to Figure

8.3 Diesel Burner Air Settings, for the proper air settings and diagram.

2

Black smoke indicates that there is not enough air being forced through the burner. First check the air settings, if more air is required rotate Air Shutter clockwise. Refer to Figure 8.3

Diesel Burner Air Settings.

3

Refer to Figure 8.3 Diesel Burner Air Settings to locate the following components. Using a 7/16" wrench, remove the copper fuel line nut attached to the nozzle line. Next remove the locking nut for the nozzle tube. Then loosen the locking tabs on the ignition coil and open the ignition coil. Remove the nozzle line assembly.

4

Using Figure 8.2 Diesel Burner Electrode Adjustment, make 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 replacing the burner nozzle at this time.

6

Reassemble the burner, using the reverse order in Step 3.

7

Remove the burner box assembly by removing the four (4) 1/2" bolts, flat washer, lock washer, and nuts holding the burner box onto the trailer.

7a

Make sure the insulation inside the burner box is not soaked with diesel fuel.

7b

If the insulation is soaked with diesel fuel, you will need to replace the insulation.

7c

Reassemble the burner box.

Step

Burner

Troubleshooting

1 Remove cord set from fuel solenoid.

2 Check the ohms between the terminals of fuel solenoid.

3 If the reading is between 15-25 ohms the coil is good.

4 If the reading is outside the above range or the meter indicates an open circuit, replace the

fuel solenoid.

Table 8-7 Smoke Coming Out of Exhaust Stack

Table 8-8 Burner Lights But Shuts Down After 15 Seconds

8.0.2. Excessive Smoke Coming Out of Exhaust Stack

8.0.3. Burner Lights but Shuts Down After 15 Seconds

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Bench Test DC

Controller

1 Remove all wire nuts at taching the DC Controller to the burner.

2

Attach the black ground wire to the negative battery post.

3

Attach the red wire to the positive battery post.

4 Attach the white (Enable) wire to the positive battery post to start the test. (Genesis II

Controllers will have a 15-second delay.)

 Orange (Blower Motor) wire 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 maintain 12Vdc.  Blue (Igniter) wire should lose voltage after 15 seconds.  Purple (Valve) wire should maintain 12Vdc.

6 If any of the above tests fail, replace the DC Controller.

Step

Fuel Solenoid

Test

1 Remove cord set from fuel solenoid.

2 Check the ohms between the terminals of fuel solenoid.

3 If the reading is between 15-25 ohms the coil is good.

4 If the reading is outside the above range or the meter indicates an open circuit, replace the

fuel solenoid.

Table 8-9 Testing the DC Controller

Table 8-10 Burner Fuel Solenoid Testing

8.0.4. Testing the DC Controller

8.0.5. Burner Fuel Solenoid Testing

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Ignition Coil

Test

1 Make sure the burner is off. Open the ignition transformer (located above the blower) to

expose the springs.

2 Check resistance between each of the springs and the ground (exposed metal on the burner).

3 The meter should read less than 2,000 ohms. (Take note of the readings, you will use them in

Step 5.)

4 Check resistance between both springs. (Take note of the reading, you will use it in Step 5.)

5 The igniter should be replaced if:

 The difference 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.

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 bleeder location.

3 Turn the ignition key to the "ON" position, then turn the power toggle switch to the “ON” position. Fuel should flow out of the bleeder valve. You want the fuel to be clear from any air bubbles, this may require you to turn the ignition key "OFF" and "ON" a couple of times.

4 Allow burner to cycle itself off 30 seconds.

5 Tighten the bleeder valve.

Table 8-11 Burner Ignition Coil Testing

Table 8-12 Bleeding the Burner

8.0.6. Burner Ignition Coil Testing

8.0.7. Bleeding the Burner

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Figure 8.2 Diesel Burner Electrode Adjustment

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

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Table 8-13 Sealant is Heating Slowly

Step

Sealant is Heating

Slowly

1 With the material level half or less, open the loading lid and inspect the inside edge of the material tank. Check if there is a buildup of old, dried out and hardened material along the top half of the material tank.

2 If this is the case you will need to drain 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 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 (21.1°C).

4 Check your records of the last service replacement of the heat transfer oil. If it has been longer than 500 hours, or one year, you need to change your oil.

5 Many of Crafco, Inc. service centers can perform these service steps for you if you cannot. Call your local service center to find out if they can.

8.1 Sealant heating Slowly

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible

Cause

If . . .

1 Is the Material Temperature Display at or above (1350C) 275°F?

 Yes, go to Step 2.  No, continue to allow the machine to heat.

(Make sure the Material dial and the Hot Oil dial are set at operating temperatures.)

2 Is the red "Mixer" light "ON"?

 Yes, go to Step 4. No, go to Table 8-15 Mixer Electrical

Troubleshooting.

3 Is the loading door closed?

 Yes, go to Step 4.  No, shut the loading door.

4 Is the "Mixer" toggle switch in the "Forward" position?

 Yes, go to Step 5.  No, move the toggle switch to the forward

position.

5 Move 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 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 backward until the material melts enough to allow forward movement without jamming. Crafco, Inc. recommends you add one to two blocks every three to four minutes during dispensing of product.

 No, go to Table 8-15 Mixer Electrical

Troubleshooting.

7 Is the hydraulic fluid level near the center of the sight gauge? Check at ambient temperature. See Figure 5.1 Hydraulic Fluid

Level and Temp. Gauge.

 Yes, go to Table 8-15 Mixer Electrical

Troubleshooting.

 No, fill oil to the center of the sight gauge.

Table 8-14 Basic Visual Mixer Troubleshooting

8.2 Mixer Troubleshooting Symptom: Mixer Does Not Rotate 8.2.1

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible

Cause

If . . .

1

Is the amber light "ON" on the Din Plug when the "Mixer" toggle switch is in the "Forward" position? (For forward din plug location, refer to Figure 8.7 Din Plug Layout).

 Yes, then the mixer should be working. If it

is not working see Table 8-18 Mixer

Hydraulic Troubleshooting.

 No, go to Step 1a.

1a

Unscrew the din plug center screw so you can pull the din plug up about 1/4" in order to check for voltage.

Is there 12Vdc from side post to side post?

 Yes, the electrical system for the agitator is

working properly, go to Table 8-18 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 brown wire and nearby 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 wires on the bottom of the lid switch with the lid closed.)

 Yes, on both red wires check for loose

connections or broken wires between lid switch and mixer toggle switch.

 Yes, on only one red wire when the lid is

closed. Readjust the lid switch so that the lid completely depresses the switch, and then recheck for 12Vdc. If the same result happens, replace the lid switch.

 No, go to Step 4.

4

Check for 12Vdc at red wire labeled Red Lid and pink wire labeled Pink-2 on terminal block and a nearby ground source (black wire).

 Yes on both, check for loose connections or

broken wires between lid switch and terminal block.

 No on Red Lid and Yes on Pink-2, ensure

yellow jumper bar is securely installed between the two terminal blocks.

 No, go to Step 4a.

Table 8-15 Mixer Electrical Troubleshooting

Note: Use Figure 8.5 Mixer Circuit Schematic while troubleshooting the mixer electrical system.

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible Cause

If . . .

4a

Is there 12Vdc between the Material PAKSTAT terminal #2 pink wire and terminal #8 black ground wire?

(Refer to Figure 8.5 Mixer Circuit Schematic).

 Yes, 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 ground wire?

 Yes, replace the Material PAKSTAT.  No, go to Step 4c.

4c

Is there 12Vdc between orange wire labeled ORN-1, terminal #9 and terminal #8 ground source (black wire)?

 Yes, check for loose connections or broken

wires between terminals #8 and #1.

 No, go to Step 5.

5

Is there 12Vdc at orange wire labeled ORN-1 and ORN-2 on the terminal block?

 Yes on both, check for loose connections or

broken wires between terminal block 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)?

 Yes, check for loose connections or broken

wires between toggle switch and hot oil PAKSTAT terminal #3.

 No, go to step 7a.

7a

Is there 12Vdc between bottom terminal wire labeled RED-3 and a nearby ground source (black wire)?

 Yes, replace toggle switch.  No, go to Step 8.

8

Is there 12Vdc between the top terminal of circuit breaker red wire labeled RED-3 and nearby ground source (black wire)?

 Yes, check for loose connections or broken

wires between circuit breaker 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 Step 9.

Table 8-16 Mixer Electrical Troubleshooting (continued)

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible

Cause

If . . .

9

Is there 12Vdc between ignition switch “ACC”

terminal and nearby ground source (black wire)?

 Yes, check for loose connections or broken

wires between “ACC” terminal and circuit

breaker.

 No, go to Step 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 red battery cable?

 Yes, there should be 12Vdc at all previous

steps.

 No, replace battery cable.

Table 8-17 Mixer Electrical Troubleshooting (continued)

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Figure 8.4 Checking Din Plug Voltage

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Figure 8.5 Mixer Circuit Schematic

Coil AMP Draw

12vdc @2.71 AMPS

RED/LID

BRN

RED

BRN

BLU

RTD Sensor

1.08k Ohms @ 70°F

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-1

ORN-1

BLK-4

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

T1T2T3T4

T7 T 6

T9

T8

T1T2T3T4

T7 T6

T9

T8

Acc

Br

Ra

BLK-5

PNK-3

RED-2

ORN-2

BLK-5

RED-2

HOT OIL

43391

MAT'L

HOSE

RED-3

ORN-2

GRN

PRP

BLU

GRN

PRP

BLU

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible

Cause

If . . .

1 Remove the din plug, and then remove the coil by unscrewing the nut on top of the coil. With the coil removed, re-attach the din plug and energize the coil by moving the mixer switch to Forward or Reverse, then insert a screw driver into the center of the coil. Does the coil magnetize when the din plug amber light is "ON"?

 Yes, go to Step 2.  No, replace the coil.

2

Is the relief pressure set correctly?

(Refer to Figure 8.6 Hydraulic Valve Pressure

Setting, for pressure settings.)

 Yes, go to Step 3.  No, first turn "OFF" the diesel engine, then

remove one of the two hydraulic hoses going to the agitator hydraulic motor, cap off the fitting on the motor and use a 3,000 PSI gauge with the proper JIC fitting, attach it to the hose. Start the diesel engine, turn "ON" the main 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 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 engine, remove the cap and pressure gauge, then re-attach the hose.

3 Is the hydraulic flow 5.68 Liters/min (1.5 GPM) from the hydraulic valve? If you do not have a flow meter, call a local hydraulic shop to run the test for you.

 Yes, call Crafco, Inc. and speak to a

customer service technician, you should have been able to find the problem.

 No, replace the flow divider in the hydraulic

valve.

4

Is the hydraulic flow correct from the hydraulic pump? If you do not have a flow meter, call a local hydraulic shop to run the test for you. (Refer to Figure 8.6 Hydraulic Valve Pressure

Setting for flow rate).

 Yes, call Crafco, Inc. and speak to a

customer service technician, you should have been able to find the problem.

 No, replace the hydraulic pump.

Table 8-18 Mixer Hydraulic Troubleshooting

Mixer Hydraulic Troubleshooting 8.2.2

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

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

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

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

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible Cause

If . . .

1

Is the Material Temperature Display at or above 135°C (275°F)?

 Yes, go to Step 2.  No, continue to allow the machine to heat.

(Make sure the Material dial and the Hot Oil dial are set at operating temperatures.)

2

Is the red "HEATED HOSE" light "ON"?

 Yes, go to Table 8-20 Hose Electrical

Troubleshooting.

 No, allow the machine to heat material to

275°F (135°C).

2a

Is the circuit breaker tripped?

 Yes, reset the circuit breaker by pushing in

the button which has popped out.

 No, go to Table 8-20 Hose Electrical

Troubleshooting.

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 green, and green and white.

 Yes, go to Step 3.  No, stop the engine, tighten the belt, restart

engine and recheck output voltage.

 Still no, replace the generator.

2a

Check the three heating element wires (blue) in the junction box for 30 Amps cold or 20-22 Amps hot.

NOTE: Always use a clamp-on amp meter to

perform this test. Each wire should have the same amp reading (+/- 1 amp).

 Yes, the hose should be working properly.  No, go to Step 3.

Table 8-19 Basic Visual Hose Troubleshooting

Table 8-20 Hose Electrical Troubleshooting

8.3 Hose Troubleshooting Symptom: Hose Does Not Heat 8.3.1

NOTE: Use Figure 8.9 Hose Circuit Schematic while troubleshooting the hose electrical system.

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible Cause

If . . .

3

Check for continuity in the hose from end to end. Disconnect the three blue heating element wires (blue) from the terminal block inside the junction box and disconnect the five pin plug between the hose and wand. Refer to Figure 8.10 Junction Box Wiring.

NOTE: Check each letter “D”, “E”, and “A”

with the three blue wires on the other end of the hose. There should only be continuity on one wire to each letter.

 Yes, go to Step 3a.  No, either there was no continuity from one

letter to the other end of the hose or there was more than one wire with continuity to a letter. This hose needs to be repaired or replaced. Contact Crafco, Inc. to send back the hose for repair.

3a

Check the RTD sensor in the hose against the readout in the control box. Disconnect the black and white wires from the terminal block in the junction box and test for ohms.

Refer to Table 8-20 Hose Electrical

Troubleshooting.

 Yes, the readout matches the table, go to

Step 4.

 No, this hose needs to be repaired or

replaced. Contact Crafco, Inc. to send back the hose for 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 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 of generator.

 No, go to Step 6.

6

Is there 12Vdc between Hose PAKSTAT blue wire terminal #4 and black wire terminal #8?

 Yes, check for loose or broken wire between

terminal #4 and the terminal block.

 No, go to Step 6a.

6a

Is there 12Vdc between Hose PAKSTAT terminal #3 Pink wire and terminal #8 black wire?

 Yes, replace hose PAKSTAT.  No, go to Step 6b.

6b

Is there 12Vdc between Hose PAKSTAT pink wire terminal #1 and black wire terminal #8?

 Yes, check for loose or broken wires

between terminal #1 and terminal #3.

 No, go to Step 7.

7

Is there 12Vdc between pink wire labeled “PNK-1 on the upper terminal block and a nearby ground source (black wire)?

 Yes, check for loose or broken wire between

terminal block and terminal #1.

 No go to Step 7a.

7a

Is there 12Vdc between pink wire labeled “PNK-3 and nearby ground source (black wire)?

 Yes, call Crafco, Inc. and speak to a

customer service technician you should have been able to find the problem.

 No, replace terminal block.

Table 8-21 Hose Electrical Troubleshooting (continued)

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Figure 8.8 Junction Box Voltage Test

black and white wires

white and green wires

Test #2 between black

and green wires

Test #1 between

Test #3 between

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Figure 8.9 Hose Circuit Schematic

18 GA. BLUE TFE (ALL SIX WIRES)

24VAC 3-PHASE 30-35 AMPS COLD 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

BLU

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

T1T2T3T4

T7 T 6

T9

T8

T1T2T3T4

T7 T6

T9

T8

GRN

PRP

BLU

BLU-2

BLK-5

PNK-3

GRN

PRP

BLU

HOT OIL

43391

MAT'L

HOSE

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

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

TRIGGER (RED)

C B

HEAT ELEM. (BLUE)

E

D

A

KETTLE END WAND END

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Table 8-22 Trigger is not Working

Step

Possible Cause

If . . .

1

Check continuity between two red wires coming from the hose in junction 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, this wand needs to be repaired or

replaced. Contact Crafco, Inc. to send back the hose for repair.

Symptom: Trigger is not Working 8.3.2

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

°F

0

1

2

3

4

5

6

7

8

9

0

930.3

932.5

934.7

936.9

939.1

941.3

943.4

945.6

947.8

950.0

10

952.2

954.3

956.5

958.7

960.9

963.0

965.2

967.4

969.6

971.8

20

973.9

976.1

978.3

980.5

982.6

984.8

987.0

989.1

991.3

993.5

30

995.7

997.8

1000.0

1002.2

1004.3

1006.5

1008.7

1010.9

1013.0

1015.2

40

1017.4

1019.5

1021.7

1023.9

1026.0

1028.2

1030.4

1032.5

1034.7

1036.9

50

1039.0

1041.2

1043.4

1045.5

1047.7

1049.8

1052.0

1054.2

1056.3

1058.5

60

1060.7

1062.8

1065.0

1067.1

1069.3

1071.5

1073.6

1075.8

1077.9

1080.1

70

1082.2

1084.4

1086.6

1088.7

1090.9

1093.0

1095.2

1097.3

1099.5

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

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

1221.7

1223.9

1226.0

1228.1

1230.3

140

1232.4

1234.5

1236.7

1238.9

1240.9

1243.0

1245.2

1247.3

1249.4

1251.6

150

1253.7

1255.8

1258.0

1260.1

1262.2

1264.3

1266.5

1268.6

1270.7

1272.8

160

1275.0

1277.1

1279.2

1281.3

1283.5

1285.6

1287.7

1289.8

1292.0

1294.1

170

1296.2

1298.3

1300.4

1302.6

1304.7

1306.8

1308.9

1311.0

1313.2

1315.3

180

1317.4

1319.5

1321.6

1323.8

1325.9

1328.0

1330.1

1332.2

1334.3

1336.5

190

1338.6

1340.7

1342.8

1344.9

1347.0

1349.1

1351.2

1353.4

1355.5

1357.6

200

1359.7

1361.8

1363.9

1366.0

1368.1

1370.2

1372.4

1374.5

1376.6

1378.7

210

1380.8

1382.9

1385.0

1387.1

1389.2

1391.3

1393.4

1395.5

1397.6

1399.7

220

1401.8

1403.9

1406.0

1408.1

1410.3

1412.4

1414.5

1416.6

1418.7

1420.8

230

1422.9

1425.0

1427.1

1429.2

1431.3

1433.4

1435.5

1437.6

1439.6

1441.7

240

1443.8

1445.9

1448.0

1450.1

1452.2

1454.3

1456.4

1458.5

1460.6

1462.7

250

1464.8

1466.9

1469.0

1471.1

1473.2

1475.3

1477.3

1479.4

1481.5

1483.6

260

1485.7

1487.8

1489.9

1492.0

1494.1

1496.1

1498.2

1500.3

1502.4

1504.5

Table 8-23 RTD Sensor Ohms vs. Temperature

RTD Sensor Ohms vs. Temperature 8.3.3

Table 8-23/8-24 below shows what the ohm reading would be for a given temperature. The following are the instructions for using the table.

Measure the resistance (ohms) of the sensor in question with an ohm meter (See 7.3 Checking

Resistance (Ohms)) in Section 7.0 How to Use a Multimeter.

Find the reading in the chart (columns 0 through 9). Follow the row to the left and get the temperature in 10°F increments, then follow the column up to

get the 1°F increment. (For example, 1,391 Ohms = 215°F (102°C))

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

°F

0

1

2

3

4

5

6

7

8

9

270

1506.6

1508.7

1510.8

1512.8

1514.9

1517.0

1519.1

1521.2

1523.3

1525.3

280

1527.4

1529.5

1531.6

1533.7

1535.7

1537.8

1539.9

1542.0

1544.1

1546.1

290

1548.2

1550.3

1552.4

1554.5

1556.5

1558.6

1560.7

1562.8

1564.8

1566.9

300

1569.0

1571.1

1573.1

1575.2

1577.3

1579.4

1581.4

1583.5

1585.6

1587.7

310

1589.7

1591.8

1593.9

1595.9

1598.0

1600.1

1602.2

1604.2

1606.3

1608.4

320

1610.4

1612.5

1614.6

1616.6

1618.7

1620.8

1622.8

1624.9

1627.0

1629.0

330

1631.1

1633.2

1635.2

1637.3

1639.3

1641.4

1643.5

1645.5

1647.6

1649.7

340

1651.7

1653.8

1655.8

1657.9

1660.0

1662.0

1664.1

1666.1

1668.2

1670.2

350

1672.3

1674.4

1676.4

1678.5

1680.5

1682.6

1684.6

1686.7

1688.7

1690.8

360

1692.9

1694.9

1697.0

1699.0

1701.1

1703.1

1705.2

1707.2

1709.3

1711.3

370

1713.4

1715.4

1717.5

1719.5

1721.6

1723.6

1725.7

1727.7

1729.8

1731.8

380

1733.9

1735.9

1737.9

1740.0

1742.0

1744.1

1746.1

1748.2

1750.2

1752.3

390

1754.3

1756.3

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

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

1874.2

450

1876.2

1878.2

1880.3

1882.3

1884.3

1886.3

1888.3

1890.4

1892.4

1894.4

460

1896.4

1898.4

1900.5

1902.5

1904.5

1906.5

1908.5

1910.5

1912.6

1914.6

470

1916.6

1918.6

1920.6

1922.6

1924.6

1926.6

1928.7

1930.7

1932.7

1934.7

480

1936.7

1938.7

1940.7

1942.7

1944.7

1946.8

1948.8

1950.8

1952.8

1954.8

490

1956.8

1958.8

1960.8

1962.8

1964.8

1966.8

1968.8

1970.8

1972.8

1974.8

500

1976.8

1978.8

1980.8

1982.9

1984.9

1986.9

1988.9

1990.9

1992.9

1994.9

510

1996.9

1998.9

2000.9

2002.9

2004.9

2006.9

2008.8

2010.8

2012.8

2014.8

520

2016.8

2018.8

2020.8

2022.8

2024.8

2026.8

2028.8

2030.8

2032.8

2034.8

530

2036.8

2038.8

2040.8

2042.8

2044.7

2046.7

2048.7

2050.7

2052.7

2054.7

540

2056.7

2058.7

2060.7

2062.7

2064.6

2066.6

2068.6

2070.6

2072.6

2074.6

550

2076.6

2078.5

2080.5

2082.5

2084.5

2086.5

2088.5

2090.4

2092.4

2094.4

Table 8-24 RTD Sensor Ohms vs. Temperature (continued)

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible Cause

If . . .

1

Is the Hose Temperature Display at or above 325°F (163°C)?

 Yes, go to Step 2.  No, continue to allow the hose to heat.

(Make sure the Hose dial is set at proper operating temperature.)

2

Is the red "Pump" light "ON"?

 Yes, go to Step 3.  No, go to Table 8-26 Pump Electrical

Troubleshooting.

3

With the wand under the lid, pull the wand trigger and look at the material pump shaft coupler.

Is it spinning clockwise?

 Yes, shut down machine and look for a plug

in the plumbing.

 No, adjust the material flow control to

increase 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.

 Yes, this tells you that everything from the

cube relay to the hydraulic manifold is working properly; your issue is inside the hose and wand. Go to Table 8-20 Hose

Electrical Troubleshooting, Steps 1

through 5 to find the problem.

 No, go to Step 5.

5

Is the hydraulic fluid level near the center of the sight gauge when the machine is cold?

See Figure 5.1 Hydraulic Fluid Level and

Temp. Gauge.

 Yes, go to Table 8-26 Pump Electrical

Troubleshooting.

 No, fill oil to the center of the sight gauge.

Table 8-25 Basic Visual Pump Troubleshooting

8.4 Pump Troubleshooting Symptom: Material Does Not Dispense When the Pump is Activated 8.4.1

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible

Cause

If . . .

1 Is the Material Temperature at or above 275°F?

 Yes go to Step 2.  No, continue to allow the machine to

heat.

2 Is there 12 Vdc between the Hose PAKSTAT terminal #2 purple wire and terminal #8 black ground wire?

(Refer to the pump circuit schematic Figure

8.11 Pump Circuit Schematic).

 Yes, go to Step 3.  No, go to Step 2a.

2a

Is there 12 Vdc between the Hose PAKSTAT terminal #1 pink wire and terminal #8 black ground wire?

 Yes, check for a broken wire or poor

wire crimp on the terminal #2 purple wire and recheck for 12 Vdc. (If still no voltage replace the Material PAKSTAT.)

 No, go to Step 2b.

2b

Is there 12 Vdc between the Hose PAKSTAT terminal #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 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 wire or poor

wire crimp between the Hose PAKSTAT terminal

#2

purple wire and

the terminal block purple wire.

4 Move to the junction box at the rear of the machine and open the cover.

Is there 12 Vdc between the trigger red wire coming from the control box and a nearby ground source?

 Yes, go to Step 4a.  No, check for a broken wire or poor

wire crimp between the junction box and the control box red wire labeled red-trig.

4a

Is there 12 Vdc between the trigger red wire going toward the hose (just above where you checked in Step 4) and a nearby ground source?

 Yes go to Step 4b.  No, check for a broken wire or poor

wire crimp on the red trigger going toward the hose.

Table 8-26 Pump Electrical Troubleshooting

NOTE: Use Figure 8.11 Pump Circuit Schematic while troubleshooting the pump electrical system.

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Table 8-27 Pump Electrical Troubleshooting (continued)

Step

Possible

Cause

If . . .

4b

Is there 12 Vdc between the trigger red wire going toward the hose and a nearby ground source?

(Make sure the wand trigger is pulled during this Step.)

 Yes, go to Step 4c.  No, go to Step 5.

4c Is there 12 Vdc between the trigger green wire coming from the control box and a nearby ground source?

(Make sure the wand trigger is pulled during this Step.)

 Yes, go to Step 6.  No, check for a broken wire or poor

wire crimp on the green trigger wire going to the control box.

5 Disconnect the five pin connector between the hose and wand. Refer to Figure 8.10 Junction

Box Wiring.

Is there continuity on the wand connector between red trigger "C" post and red trigger "B" post while the wand trigger is pulled?

 Yes, go to Step 5a.  No, call Crafco, Inc. and request 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"

socket to the other red trigger wire in the junction box. (You want to see continuity between only one red trigger wire and the "C" socket.)

 Still no continuity to both red trigger

wire, then call Crafco, Inc. and request an RA# so you can send your hose back for repair.

5b

Is there continuity on the hose connector "B" socket and red trigger in the junction box?

 Yes, call Crafco, Inc. and speak to a

service technician, you should have found the problem.

 No, recheck the hose connector "B"

socket to the other red trigger wire in the junction box. (You want to see continuity between only one red trigger wire and the "B" socket.)

 Still no continuity to both red trigger

wire, then call Crafco, Inc. and request an RA# so you can send your hose back for repair.

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible

Cause

If . . .

6 Move back to the control box. Is there 12 Vdc between the pump relay base

#14 terminal green trigger wire and the #13 terminal black ground wire, when the trigger is pulled?

 Yes, go to Step 7.  No, check for a broken wire or loose wire

at the relay base on both the green trigger wire and the two black ground wires. Also check for any damage to the green trigger wire from the junction box to the control box.

7 Is there 12 Vdc between the pump relay base #12 terminal red wire and the #13 terminal black ground wire?

 Yes, go to Step 8.  No, go to Step 7a.

7a

Is there 12 Vdc between the terminal block red black wire and the pump relay base #13 terminal black ground wire?

 Yes, check for a broken wire or loose

wire at the pump relay base #12 terminal.

 No, go to Step 7b.

7b

Is there 12 Vdc between the terminal 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 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 terminal black ground wire?

 Yes, check for a broken wire or loose

wire at the circuit breaker and at the terminal block red wire.

 No, if this is the case you would have

had problems with the burner working. Call Crafco, Inc. and speak to a service technician.

8

Is there 12 Vdc between the pump relay base #8 terminal blue pump wire and the #13 terminal black ground wire?

 Yes, go to Step 9.  No, replace the pump relay cube.

9 Move to the rear of the machine. Remove the

cover over the hydraulic manifold. Is the amber light "ON" when the wand trigger is

pulled? (Looking down at the top of the hydraulic valve,

Pump forward is the din plug lower right-hand corner, refer to Figure 8.7 Din Plug Layout).

 Yes, go to Step 9c.  No, go to Step 9a.

Table 8-28 Pump Electrical Troubleshooting (continued)

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible

Cause

If . . .

9a

Follow the brown wire "Forward Pump" din plug to where the insulated spade connection is to the blue pump wire coming from the control box.

Are these two wires still connected?

 Yes, go to Step 9b.  No, connect these two wires.

9b

Disconnect these two wires. Is there 12 Vdc between the blue pump wire and the blue (4) wire ground connection for the din plugs?

 Yes, check for a broken wire or poor wire

crimp along the brown "Forward Pump" din plug.

 No, check for a broken wire or poor wire

crimp along the blue pump wire.

9c

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 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 hold the "Pump" toggle switch in the "Reverse" position?

(Looking down at the top of the hydraulic valve, Pump reverse is the din plug lower left-hand corner, Refer to Figure 8.7 Din Plug Layout.)

 Yes, go to Step 10e.  No, go to Step 10b.

10b

Is there 12 Vdc between the "Pump" toggle switch bottom post brown wire and the blue (4) wires ground din plug, when the toggle switch is in the "Reverse" position? (Refer to Figure 8.5

Mixer Circuit Schematic.)

 Yes, go to Step 10e.  No, go to Step 10c.

10c

Is there 12 Vdc between the "Pump" toggle switch center post red wire and the blue (4) wires ground din plug?

 Yes, replace the toggle switch.  No, go to Step 10d.

Table 8-29 Pump Electrical Troubleshooting (continued)

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Table 8-30 Pump Electrical Troubleshooting (continued)

Step

Possible

Cause

If . . .

10d

Is there 12 Vdc between the "Mixer"

toggle

switch

center post red wire and the blue (4) wires

ground din plug?

 Yes, check for a broken wire or poor wire

crimp on the red wire 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 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.

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Step

Possible Cause

If…

1

Does the coil magnetize when the din plug amber light is “ON”?

 Yes, go to Step 2.  No, remove the din plug, and then remove

the coil by unscrewing the nut on the end of

the coil. With the coil removed, reattach the

din plug and place a metal screw driver in

the center of the coil to see if the coil is

magnetic. If it is not, recheck the din plug is

plugged into the coil and the amber light is

“ON”. If still not magnetic replace the coil.

2

Is the relief pressure set correctly? (Refer to Figure 8.6 Hydraulic Valve

Pressure Setting).

 Yes, go to Step 3.  No, first turn “OFF” the Isuzu engine, then

remove one of the two hydraulic 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 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 the relief.

Turn clockwise to increase pressure and

counter clockwise to decrease pressure,

and then tighten the jam nut to lock

pressure. Next turn “OFF” the Isuzu

engine, remove the cap, pressure gauge

and reattach the hose.

3

Is the hydraulic flow correct from the hydraulic pump? (Refer to Table 8-31 Pump Hydraulic

Troubleshooting).

 Yes, call Crafco, Inc. and speak to a service

technician. You should have been able to

find the problem.  No, call a local hydraulic shop to see if they

can run a hydraulic pump flow test, using

the information in Figure 8.6 Hydraulic

Valve Pressure Setting.

Table 8-31 Pump Hydraulic Troubleshooting

Pump Hydraulic Troubleshooting 8.4.2

Super Shot 60 Diesel Melter Part

Manual

Chapter 8 Troubleshooting

Figure 8.11 Pump Circuit Schematic

Pump Rev Coil

See Mixer Schematic

BLU PMP

BRN

Pump Fwd Coil

with Light

BLU

18 GA. RED TFE (ALL FOUR WIRES)

RED RED

RED TRIG

GREEN TRIG

Trigger

RTD Sensor (1.08K ohms at 70°F)

Batt

GREEN

WHITE

BLACK

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

T1T2T3T4

T7 T6

T9

T8

T1T2T3T4

T7 T 6

T9

T8

GRN

PRP

BLU

BLK-5

PRP-2

GRN

PRP

BLU

HOT OIL

43391

MAT'LHOSE

RED-2

Acc

Coil AMP Draw

12vdc @2.71 AMPS

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

9.0 About the Illustrated Parts List

The Illustrated Parts List (IPL) is designed to help technical service or maintenance personnel correctly identify orderable replacement parts.

The figure and table titles reference the part number (PN) to which they apply. The PNs for each of the Super Shot 60 Diesel Melter machine models are as follows:

• Super Shot 60 Diesel Skid Mount Melter PN 46800

• Super Shot 60 Diesel Trailer Melter PN 46950

Illustrations 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 distributor or directly from Crafco, Inc. if a distributor is not available in your area. When ordering parts, give the following information:

 Part Number  Machine Model  Serial Number

Write, call, or Fax Crafco, Inc. at the following: Crafco, Inc. Headquarters 6165 W Detroit St. Chandler, AZ 85226 Phone: (602) 276-0406 Toll Free: (800) 528-8242 Fax: (480) 961-0513

Visit our website at www.crafco.com

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

Figure 9.1 Super Shot 60 Diesel Skid Mount Melter

2324

2524

1 3 54 6 108 9 11

13

16 151718

19

20

22

21

44

45

46

47

28

2726

29 31 32 3330

34 35 a b

36 38

40 39414243

37

2 7

12

14

9.2 Super Shot 60 Diesel Skid Mount Melter

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

Table 9-1 Super Shot 60 Diesel Skid Mount Melter: PN 46800

FIG.

ITEM

PART NO.

DESCRIPTION

QTY.

Figure 9.1

1

46905

SUPPORT ASSEMBLY, WAND

1

2

26104

1/4” X 2” GRIP, QUICK RELEASE PIN

2 3 46906

LOCKING ARM, WAND SUPPORT

1

4

46933

GUARD, VENT

2

5

43768

WAND HANDLE

1

6

43355

OVERFLOW TANK

1

7

52200

WAND ASSEMBLY – ELECTRIC

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

46839

HEAT GUARD

1

23

51678

TOGGLE SWITCH – AGITATOR

1

24

50720

BOOT, TOGGLE SWITCH

2

25

32513

TOGGLE SWITCH – PUMP REVERSE

1

26

46931

BRACKET, HYDRAULIC VALVE

1

27

46864

COVER, CONTROL VALVE

1

28

45420

HYDRAULIC CONTROL VALVE ASSEMBLY

1

29

46860

BOOM – HOSE

1

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

Table 9-2 Super Shot 60 Diesel Skid Mount Melter: PN 46800 (continued)

FIG.

ITEM

PART NO.

DESCRIPTION

QTY.

Figure 9.1

30

46863

PUMP AGITATOR MOTOR ASSEMBLY

1

31

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, LID

1

44

46060

REGULATOR, FLOW

1

45

45553

BEARING, BOOM

2

46

46851

BASE, BOOM

1

47

46862

LOCK, BOOM

1

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

This page left blank intentionally

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

1 32 5 6 7 8 9 10 11

12

13 14

16

1718192021

4

22232425

26

27

2829

3029

31 32 33 34 35 36 37 38

39 40 a b

41 42 43

4547 46484950

53

54

55

56

5152

15

44

Figure 9.2 Super Shot 60 Diesel Trailer Melter

9.3 Super Shot 60 Diesel Trailer Melter

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

Table 9-3 Super Shot 60 Diesel Trailer Melter: PN 46950

FIG.

ITEM

PART NO.

DESCRIPTION

QTY.

Figure 9.2

1

46905

SUPPORT ASSEMBLY, WAND

1

2

46906

LOCKING ARM, WAND SUPPORT

1

3

26104

1/4” X 2” GRIP, QUICK RELEASE PIN

2

4

44778

DRIVER SIDE FENDER ASSEMBLY

1 5 46933

GUARD, VENT

2 6 43768

WAND HANDLE

1 7 52200

WAND ASSEMBLY – ELECTRIC

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 SIDE FENDER ASSEMBLY

1

23

44772

2 ½” RED SIDE MARKER

2

24

32363

4” ROUND STOP, TURN AND TAIL LAMP

2

25

45525

CONTROL BOX ASSEMBLY – ELECTRIC

1

26

46839

HEAT GUARD

1

27

44027

JUNCTION BOX ASSEMBLY

1

28

51678

TOGGLE SWITCH – AGITATOR

1

29

50720

BOOT, TOGGLE SWITCH

2

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

Table 9-4 Super Shot 60 Diesel Trailer Melter: PN 46950 (continued)

FIG.

ITEM

PART NO.

DESCRIPTION

QTY.

Figure 9.2

30

32513

TOGGLE SWITCH – PUMP REVERSE

1

31

46931

BRACKET, HYDRAULIC VALVE

1

32

46864

COVER, CONTROL VALVE

1

33

45420

HYDRAULIC CONTROL VALVE ASSEMBLY

1

34

46860

BOOM – HOSE

1

35

46863

PUMP 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

1

47

24002

BATTERY BOX

1

48

46909

COVER, BURNER

1

49

46380

BURNER, 14 VOLT

1

50

39608

SWITCH, LID

1

51

46960

TORSIONAL AXLE ASSEMBLY

1

52

44342

TIRE AND RIM ASSEMBLY ST225/75 R15

2

53

46060

REGULATOR, FLOW

1

54

45553

BEARING, BOOM

2

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

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

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

Figure 9.3 Tank Assembly

1 2 3 4

5

6

78910

11

12

13

1415

16

9.4 Tank Assembly

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

Table 9-6 Tank Assembly

FIG.

ITEM

PART NO.

DESCRIPTION

QTY.

Figure 9.3

1

46872

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 ¾” REDUCER BUSHING

1

14

28060

2” X 5” LONG PIPE NIPPLE

1

15

28273

2” PIPE CAP

1

16

46900

PADDLE AGITATOR

2

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

Figure 9.4 Control Box Assembly

RED-4

RED-5

BLK-5

RED-2

GRY-2

PNK-3

YLW-1

RED/BLK-1

GRY-3

ORN-2

BLU-2

PRP-1 RED-TRIG

BLK-1

BLK GND

PNK-1 & PNK-2

YELLOW

RED/BLK

GRY-1

WHT/RED-4

RED LID

WHT/GRN

ORN-1

BLK-3

RED-1

WHT COMP

BLU PMP

GRN TRIG

ORN-3

GRN-1

YLW-3

BLK-7&BLK-8

WHT/RED-3

WHT/GRN-3

BLK-1

ORN-4

GRN

BRN-1

YLW-2

GRY-4

BLK-2

PNK-2

BLK-4

ORN-1

BLK-4

WHT

BLK

WHT/BLK

8

5

4

1

14

13

12 9

WHT/RED-2WHT/RED

WHT/GRN

WHT/RED

BLK-6

WHT/GRN-1

WHT/RED-1(LIGHT)

WHT/GRN-2

PRP-2

WHT-1(COMP.)

BLK-3

RED

BLK

YLW/RED

WHT/BLK WHT/BLK

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/BLK

BLK/BLU

GRN

PRP

BLU

RED-5

BLK-6

BLU

WHT/RED-2

REDWHT/GRN-3

BLUORN-4

REDBLK-7

BLU

REDGRN-1

Acc

B

RI

C

Br

Ra

BLK/RED

BLK-2

YLW-2

BRN-1

BLU-2

BLK-5

PRP-2

GRY-2

PNK-3

GRN

PRP

BLU

BLK-LIGHT

RED-3

RED-2

WHT/RED-3

ORN-2

BLK-5

GRY-3

GRY-2

WHT/GRN-1

WHT/GRN-2

RED-2

RED-4

GRAY-4

BLU-3

HOT OIL

43391

MAT'L

HOSE

WHT-1

WHT-RED-1

RED-3

ORN-2

1 2 3 4

5

7 8 9

6

10

11

12 13 14 15 15 16

17

19 182019

21

23

24

25

27

28

29

30

31

22

26

9.5 Control Box Assembly

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

Table 9-7 Control Box Assembly

FIG.

ITEM

PART NO.

DESCRIPTION

QTY.

Figure 9.4

1

41994

IGNITION SWITCH WITH OUT TUMBLER

1

2

51665

CIRCUIT BREAKER, 15 AMP

1

3

50719

TOGGLE SWITCH

1

4

43391

TEMPERATURE CONTROLLER, 150°F – 550°F

1 5 50251

DIGITAL READOUT

3

6

51651

LIGHT, 12VDC

4

7

51662

SOCKET RELAY

1

8

51661

RELAY

1

9

51663

HOLD DOWN SPRING

1

10

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

½” CONDUIT NUT

3

22

24021

CORD GRIP CONNECTOR ½”

3

23

44983

CABLE ASSEMBLY, SENSOR (NOT SHOWN)

1

24

44984

CABLE ASSEMBLY, POWER (NOT SHOWN)

1

25

44985

CABLE, TRIGGER/SENSOR (NOT SHOWN)

1

26

44993

MOUNTING RAIL

1

27

44978

WIRING HARNESS, ENGINE (NOT SHOWN)

1

28

45950

SOCKET CONNECTOR

1

29

45954

PANEL NUT

1

30

44994

TERMINAL BLOCK

1

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

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

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

This page left blank intentionally

Super Shot 60 Diesel Melter Part

Manual

Chapter 9 Illustrated Parts List

1

2

3

4

5

7

6

Figure 9.5 Engine Assembly

Crafco SS60-Diesel User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1.0 About This Manual

1.1 How to use this manual:

2.0 Safety Precautions

2.1 General Safety

2.2 Personal Safety

2.3 Equipment or Operational Safety

2.4 Safety Symbols and Notices

3.0 Limited Warranty

3.1 Warranty Claim Instructions

3.0 Limited Warranty

3.1 Warranty Claim Instructions

4.0 Machine Specifications

5.0 Operating Instructions

5.1 Preparing the Machine for Start Up

5.2 Machine Start Up for Electric Hose

5.3 About the Heated Hose, Wand, Valve, and Tip Guard The Heated Hose

5.4 Electric Hose Care and Cautions

5.5 Storing the Electric Hose for Transport

5.6 Loading Material into the Sealant Tank

Material Tank Depth Chart 5.6.1

5.7 Dispensing the Material

5.8 Shutting Down and Cleaning Out the Machine

5.9 Storing the Machine

6.0 Maintenance Instructions

6.1 Engine

6.2 Hydraulic System

6.3 Heat Transfer Oil

6.4 Wheel Bearing

6.5 Material Sensor Tube

6.6 Lug Nuts

6.7 Brakes

6.8 Tongue Jack

6.9 Temperature Control Calibration

6.10 Maintenance Chart

6.11 Service Instructions

6.12 General Maintenance Parts

6.13 Recommended Spare Parts

6.14 Recommended Fluids and Lubricants

6.15 Applicable Brands of Heat Transfer Oil

6.16 Typical Heat Transfer Oil Specifications

6.17 Material Pump Replacement

7.0 How to Use a Multimeter

7.1 Checking DC Voltage with a Multimeter

7.2 Checking AC Voltage with Multimeter

7.3 Checking Resistance (Ohms)

7.3.1 How to Check Wire Continuity

7.4 Checking Amperage

8.0 Burner Troubleshooting

8.0.1. Symptoms: Burner will Not Ignite

8.0.2. Excessive Smoke Coming Out of Exhaust Stack

8.0.3. Burner Lights but Shuts Down After 15 Seconds

8.0.4. Testing the DC Controller

8.0.5. Burner Fuel Solenoid Testing

8.0.6. Burner Ignition Coil Testing

8.0.7. Bleeding the Burner

8.1 Sealant heating Slowly

8.2 Mixer Troubleshooting Symptom: Mixer Does Not Rotate 8.2.1

Mixer Hydraulic Troubleshooting 8.2.2

8.3 Hose Troubleshooting Symptom: Hose Does Not Heat 8.3.1

Symptom: Trigger is not Working 8.3.2

RTD Sensor Ohms vs. Temperature 8.3.3

8.4 Pump Troubleshooting Symptom: Material Does Not Dispense When the Pump is Activated 8.4.1

Pump Hydraulic Troubleshooting 8.4.2

9.0 About the Illustrated Parts List

9.1 Ordering Crafco Parts

9.2 Super Shot 60 Diesel Skid Mount Melter

9.3 Super Shot 60 Diesel Trailer Melter

9.4 Tank Assembly

9.5 Control Box Assembly

9.6 Engine Assembly