SS60 Diesel Melter Manual Rev. A

Parts Manual - 26618
Revision A
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): ________________________
EZ 500 Series II Melter Part Manual
Revisions
Revision
Updated to new format.
Date
6/9/2015
SUPER SHOT 60 DIESEL MELTER
PN 46800
Super Shot 60 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
5.6.1
Material Tank Depth Chart ....................................................................................... 5-8
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 Material Sensor Tube .......................................................................................................... 6-1
6.5 Temperature control Calibration .......................................................................................... 6-1
6.6 Maintenance Chart .............................................................................................................. 6-2
6.7 Service Instructions ............................................................................................................. 6-3
6.8 General Maintenance Parts ................................................................................................. 6-3
6.9 Recommended Spare Parts................................................................................................. 6-4
6.10 Recommended Fluids and Lubricants................................................................................ 6-4
6.11 Applicable Brands of Heat Transfer Oil .............................................................................. 6-5
6.12 Typical Heat Transfer Oil Specifications ............................................................................ 6-5
Super Shot 60 Melter Part Manual
Table of Contents
6.13 Material Pump Replacement ............................................................................................. 6-6
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
8.2.1
Symptom: Mixer Does Not Rotate.......................................................................... 8-12
8.2.2
Mixer Hydraulic Troubleshooting ........................................................................... 8-18
8.3 Hose Troubleshooting ....................................................................................................... 8-21
8.3.1
Symptom: Hose Does Not Heat ............................................................................. 8-21
8.3.2
Symptom: Trigger is not Working ........................................................................... 8-26
8.3.3
RTD Sensor Ohms vs. Temperature...................................................................... 8-27
8.4 Pump Troubleshooting ...................................................................................................... 8-29
8.4.1
Symptom: Material Does Not Dispense When the Pump is Activated .................... 8-29
8.4.2
Pump Hydraulic Troubleshooting ........................................................................... 8-34
9.0 About the Illustrated Parts List ................................................................................................ 9-1
9.1 Ordering Crafco Parts ......................................................................................................... 9-1
9.2 Super Shot 60 Diesel Melter ............................................................................................... 9-2
9.3 Tank Detail .......................................................................................................................... 9-6
9.4 Control Box Assembly ........................................................................................................ 9-8
9.5 Engine Assembly.............................................................................................................. 9-12
9.6 Hydraulic Control Valve Assembly ..................................................................................... 9-13
9.7 Diesel Burner Assembly .................................................................................................... 9-14
9.8 Hydraulic Schematic ......................................................................................................... 9-16
9.9 Electrical Schematic .......................................................................................................... 9-20
9.10 Hot Air Lance ................................................................................................................. 9-22
10.0 Tools and Accessories ........................................................................................................ 10-1
Super Shot 60 Melter Part Manual
List of Figures
Fig. 5-1 Hydraulic Fluid Level and Temp. Gauge .......................................................................... 5-2
Fig. 5-2 Heat Transfer Oil Dipstick ................................................................................................ 5-2
Fig. 6-1 Temperature Control Calibration ...................................................................................... 6-1
Fig. 6-2 Material Pump Replacement ............................................................................................ 6-7
Fig. 7-1 Standard Multimeter ......................................................................................................... 7-2
Fig. 7-2 Clamp – On Amp Meter/Multimeter .................................................................................. 7-3
Fig. 8-1 Diesel Burner Schematic .................................................................................................. 8-6
Fig. 8-2 Diesel Burner Electrode Adjustment ............................................................................... 8-10
Fig. 8-3 Diesel Burner Air Settings .............................................................................................. 8-10
Fig. 8-4 Checking Din Plug Voltage............................................................................................ 8-16
Fig. 8-5 Mixer Circuit ................................................................................................................... 8-17
Fig. 8-6 Hydraulic Valve Pressure Setting ................................................................................... 8-19
Fig. 8-7 Din Plug Layout.............................................................................................................. 8-20
Fig. 8-8 Junction Box Voltage Testing ........................................................................................ 8-23
Fig. 8-9 Hose Circuit Schematic .................................................................................................. 8-24
Fig. 8-10 Junction Box Wiring ..................................................................................................... 8-25
Fig. 8-11 Pump Circuit Schematic ............................................................................................... 8-33
Fig. 9-1 Super Shot 60 Diesel Melter ............................................................................................ 9-2
Fig. 9-2 Super Shot 60 Diesel Melter ............................................................................................ 9-4
Fig. 9-3 Tank Detail ....................................................................................................................... 9-6
Fig. 9-4 Control Box Assembly ...................................................................................................... 9-8
Fig. 9-5 Control Box Assembly .................................................................................................... 9-10
Fig. 9-6 Engine Assembly ........................................................................................................... 9-12
Fig. 9-7 Hydraulic Control Valve .................................................................................................. 9-13
Fig. 9-8 Diesel Burner ................................................................................................................. 9-14
Fig. 9-10 Hydraulic Diagram........................................................................................................ 9-16
Fig. 9-11 Hydraulic Diagram........................................................................................................ 9-18
Fig. 9-12 Electrical Schematic .................................................................................................... 9-20
Fig. 9-13 Hot Air Lance (Option) ................................................................................................ 9-22
Super Shot 60 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 5-6 Loading Material into the Sealant Tank ......................................................................... 5-7
Table 5-7 Material Tank Depth Chart ............................................................................................ 5-8
Table 5-8 Dispensing the Material ................................................................................................ 5-9
Table 5-10 Shutting Down the Machine ..................................................................................... 5-10
Table 6-1 Maintenance Chart........................................................................................................ 6-2
Table 6-2 Service Instructions....................................................................................................... 6-3
Table 6-3 General Maintenance Parts .......................................................................................... 6-3
Table 6-4 Recommended Spare Parts .......................................................................................... 6-4
Table 6-5 Recommended Fluids and Lubricants ........................................................................... 6-4
Table 6-6 Applicable Brand of Heat Transfer Oil ........................................................................... 6-5
Table 6-7 Material Pump Replacement ......................................................................................... 6-6
Table 8-1 Basic Visual Burner Troubleshooting ............................................................................ 8-1
Table 8-2 Basic Visual 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
Table 8-13 Sealant is Heating Slowly.......................................................................................... 8-11
Super Shot 60 Melter Part Manual
List of Tables
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 Electrical Troubleshooting (continued) ...................................................................... 8-22
Table 8-22 Electrical Troubleshooting (continued) ...................................................................... 8-23
Table 8-23 Trigger is not Working ............................................................................................... 8-26
Table 8-24 RTD Sensor Ohms vs. Temperature ......................................................................... 8-27
Table 8-25 RTD Sensor Ohms vs. Temperature (continued)....................................................... 8-28
Table 8-26 Basic Visual Pump Troubleshooting .......................................................................... 8-29
Table 8-27 Pump Electrical Troubleshooting ............................................................................... 8-30
Table 8-28 Pump Electrical Troubleshooting (continued) ............................................................ 8-31
Table 8-29 Pump Electrical Troubleshooting (continued) ............................................................ 8-32
Table 8-30 Pump Hydraulic Troubleshooting .............................................................................. 8-34
Super Shot 60 Melter Part Manual
Chapter 1 Introduction
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
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.
©2015 by Crafco, Inc. All Rights Reserved
……..
Introduction 1-1
Super Shot 60 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 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.
• 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). 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.
©2015 by Crafco, Inc. All Rights Reserved………………………………………..…………………………………Safety 2-1
Super Shot 60 Melter Part Manual
Chapter 2 Safety
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.
Table 2-1 Safety Symbols and Notices
Symbol
Item
Remarks
WARNING
Warning
Refers to possible bodily injury or death.
CAUTION
Caution
Refers to possible equipment damage or operational
malfunction.
Severe Burn Hazard
Hot material can cause severe burns.
Protective Shoes
Wear hard-soled work shoes.
Protective Gloves
Wear heat resistant gloves.
Protective Face or Eye Wear
Wear face shield or safety glasses.
Body Crush Hazard
Do not stand between trailer and hitch when hooking
melter to truck.
©2015 by Crafco, Inc. All Rights Reserved………………………………………..…………………………………Safety 2-2
Super Shot 60 Melter Part Manual
Chapter 2 Safety
Table 2-2 Safety Symbols and Notices (continued)
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.
©2015 by Crafco, Inc. All Rights Reserved………………………………………..…………………………………Safety 2-3
Super Shot 60 Melter Part Manual
Chapter 3 Warranty Information
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
CAUTION
Use of replacement parts other than genuine Crafco parts may impair the safety or reliability of your
equipment and nullifies any warranty.
©2015 by Crafco, Inc. All Rights Reserved………………………………………………………….…Warranty Information 3-1
Super Shot 60 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 anyway 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.
420 North Roosevelt Avenue, Chandler, AZ
85226
Phone: (602) 276-0406 or (800) 528-8242
Fax: (480) 961-0513
CustomerService@crafco.com
.
©2015 by Crafco, Inc. All Rights Reserved………………………………………………………….…Warranty Information 3-2
Super Shot 60 Melter Part Manual
Chapter 4 Machine Specifications
4.0 Machine Specifications
Table 4-1 Machine Specifications
Specification
PN 46800
Vat capacity
220 Liters
Melt Capacity
800 Kg. per hour
Heat transfer oil required
82 Liters at 21°C
Tank construction
Double boiler type
Tank opening size
312mm x 381mm
Maximum heat input
2.17 x 108 Joules (250,000 BTUs)
Burner and temperature control
Diesel-forced air thermostatic control
Engine Isuzu diesel
Three cylinder Model 3TNV70 – 12.5KW @2600 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
1,380 Kg. (2,800 Lbs.)
Diesel tank Capacity
98.4 Liters (26 Gallons)
Hydraulic Tank Capacity
98.4 Liters (26 Gallons)
©2015 by Crafco, Inc. All Rights Reserved……………………………………………………………Machine Specifications 4-1
Super Shot 60 Melter Part Manual
Chapter 5 Operating Instructions
5.0 Operating Instructions
The Crafco Super Shot 60 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
Table 5-1 Preparing the Machine for Start Up
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. Add fluid if necessary.
See Fig. 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. 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 Fig. 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. Some exposed parts of the machine reach 500°F, the sealant 400°F, and
the hydraulic fluid 180°F.
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.
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-1
Super Shot 60 Melter Part Manual
Chapter 5 Operating Instructions
Fig. 5-1 Hydraulic Fluid Level and Temp. Gauge
Dipstick for Heat Transfer Oil
Fig. 5-2 Heat Transfer Oil Dipstick
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-2
Super Shot 60 Melter Part Manual
Chapter 5 Operating Instructions
5.2 Machine Start Up for Electric Hose
Table 5-2 Starting the Burner
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.
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, 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.
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. 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.
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-3
Super Shot 60 Melter Part Manual
Chapter 5 Operating Instructions
Table 5-2.1 Starting the Burner for Electric Hose (continued)
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 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 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 5-8 Dispensing the Material – Electric Hose.
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.
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.
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-4
Super Shot 60 Melter Part Manual
Chapter 5 Operating Instructions
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 the duckbill and to protect the operator in the event of a duckbill failure. Ensure
this guard is installed properly before operating equipment. See below.
INSTALL 26084 MINI
GEAR CLAMP ONTO
THE DUCKBILL VALVE
50270
DETAIL A
26083 CLAMP NEEDS TO
BE ROTATED TO THE
SIDE AS SHOWN. THIS
KEEPS IT FROM CATCHING
ON SHOEBOX.
A
50278
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-5
Super Shot 60 Melter Part Manual
Chapter 5 Operating Instructions
5.4 Electric Hose Care and Cautions
Table 5-3 Electric Hose Care
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 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.
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.
5.5 Storing the Electric Hose for Transport
Table 5-4 Hose for Transport Instructions
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.
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-6
Super Shot 60 Melter Part Manual
Chapter 5 Operating Instructions
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.
CAUTION
Personal injury could occur if this safety system is disabled.
Table 5-5 Loading Material into the Sealant Tank
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.
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-7
Super Shot 60 Melter Part Manual
Chapter 5 Operating Instructions
5.6.1
Material Tank Depth Chart
Table 5-6 Material Tank Depth Chart
DEPTH OF
MATERIAL
TANK
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
19.19
CAPACITY IN
GALLONS
BOTTOM UP
3.06
6.12
9.18
12.24
15.30
18.36
21.42
24.48
27.54
30.60
33.66
36.72
39.78
42.84
45.90
48.96
52.02
55.08
58.14
58.72
CAPACITY IN
LITERS
BOTTOM UP
CAPACITY IN
GALLONS
TOP DOWN
CAPACITY IN
LITERS TOP
DOWN
11.58
55.66
210.70
23.17
52.6
199.11
34.75
49.54
187.53
46.33
46.48
175.95
57.92
43.42
164.36
69.50
40.36
152.78
81.08
37.3
141.20
92.67
34.24
129.61
104.25
31.18
118.03
115.83
28.12
106.45
127.42
25.06
94.86
139.00
22
83.28
150.58
18.94
71.70
162.17
15.88
60.11
173.75
12.82
48.53
185.33
9.76
36.95
196.92
6.7
25.36
208.50
3.64
13.78
220.08
0.58
2.20
222.28
0
0.00
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-8
Super Shot 60 Melter Part Manual
Chapter 5 Operating Instructions
5.7 Dispensing the Material
Table 5-7 Dispensing the Material
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.
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-9
Super Shot 60 Melter Part Manual
Chapter 5 Operating Instructions
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.
Table 5-8 Shutting Down the Machine
Step
1
Action
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.
5.9 Storing the Machine
Store the machine in an area where moisture cannot enter the heating system such as 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 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 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.
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-10
Super Shot 60 Melter Part Manual
Chapter 6 Maintenance Instructions
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 Material Sensor Tube
Check for heat transfer oil in tube every 50 hours of operation. 2 ounces required.
6.5 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 Fig. 6.2)
280
260
300
320
340
240
360
220
380
200
400
Knob
Calibration Mark
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-1
Super Shot 60 Melter Part Manual
Chapter 6 Maintenance Instructions
6.6 Maintenance Chart
Table 6-1 Maintenance Chart
Hours
Possible Cause
Procedure
Engine check oil level
Refer to the manufacturer’s
instructions for the engine
Other engine maintenance
Refer to the manufacture’s
operating and maintenance
instructions for the engine.
Material Sensor Tube
Heat Transfer Oil
Hydraulic Oil
Hydraulic Oil Filter
Burner
8
50
250
X
Check for HTO fluid
X
Add
As needed
Check
X
Change
Check
500
X
X
Change
X
Change
X
Check burner box insulation
X
Clean CAD cell.
X
Check Electrodes
X
Replace burner nozzle
X
Material Tank
Scrape out built up material in
the material tank
Material Sensor Guard
Scrape out built up material
around guard
Once a year or as needed
X
For a list of parts required for maintenance see Table 6-3 General Maintenance Parts.
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-2
Super Shot 60 Melter Part Manual
Chapter 6 Maintenance Instructions
6.7 Service Instructions
Table 6-2 Service 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
For service, find a list of authorized Distributors and service centers at Crafco.com/Distributors.
6.8 General Maintenance Parts
Table 6-3 General Maintenance Parts
Quantity
Description
Part No.
1
Fuel Filter
46963
1
Oil Filter
46964
1
Air Filter
46965
1
Nozzle, Burner
46912
1
Hydraulic Oil Filter
45438
Table 6-5
Hydraulic Oil
Table 6-5
Table 6-5
Heat Transfer Oil
Table 6-6
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-3
Super Shot 60 Melter Part Manual
Chapter 6 Maintenance Instructions
6.9 Recommended Spare Parts
Quantity
1
1
1
1
1
1
1
Table 6-4 Recommended Spare Parts
Description
Temperature Controller, Material
Temperature Controller, Electric Hose
Temperature Controller, Hot Oil
DC Controller
Coupling, Fuel Pump
Electric Hose, 15’
Solenoid
Part No.
51672
51691
43391
42335
41970
51731
39602
6.10 Recommended Fluids and Lubricants
Table 6-5 Recommended Fluids and Lubricants
Application
Recommended
Full Point
Engine Oil
Refer to engine manual
2.8 L
Hydraulic Oil
Shell AW Hydraulic 46
98.4 L.
Heat Transfer Oil
Shell Turbo T 68 (Group II)
82 L.
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-4
Super Shot 60 Melter Part Manual
Chapter 6 Maintenance Instructions
6.11 Applicable Brands of Heat Transfer Oil
Table 6-6 Applicable Brand of Heat Transfer Oil
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.
6.12 Typical Heat Transfer Oil Specifications
ISO
68
Flash Point, COC
445°F
Viscosity @ 100°F-SUS
325
Viscosity @ 210°F-SUS
50
Viscosity Index
95-100
Pour Point
0°F
Carbon residue
1%
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-5
Super Shot 60 Melter Part Manual
Chapter 6 Maintenance Instructions
6.13 Material Pump Replacement
Table 6-7 Material Pump Replacement
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
7
Remove the four (4) hydraulic hoses and put caps on all the ports.
Note: Mark the hoses for ease of replacement.
Remove the four (4) bolts holding the motor mount on top of the melter.
(See Fig. 6.3 Material Pump Replacement)
Lift off the motor mount and set aside.
8
9
10
11
12
13
14
15
Remove the two (2) bolts holding the agitator shaft bearing.
Note: Do not remove the bearing from the agitator shaft.
When the unit has cooled sufficiently, remove the six (6) bolts holding the paddles on
top of the screen.
Remove the paddles from the tank.
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.
Remove the six (6) bolts attaching the pump to the tank.
Lift the pump from the sealant tank.
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.
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-6
Super Shot 60 Melter Part Manual
Chapter 6 Maintenance Instructions
PUMP ASSEMBLY BOLTS
PUMP MOUNTING BOLTS
PUMP ASSEMBLY
PUMP MOUNTING PLATE
TANK BOTTOM
Fig. 6-2 Material Pump Replacement
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…Maintenance Instructions 6-7
Super Shot 60 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.
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 Fig. 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 Fig. 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.
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…How to Use a Multimeter 7-1
Super Shot 60 Melter Part Manual
Chapter 7 How to Use a Multimeter
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 Fig.
7.2 Clamp – On Amp Meter/Multimeter). The amperage in the hose can reach as high as 35 amps.
Clamp the meter around one wire at a time. Remember most clamp-on meters do not work on DC
current.
Audible Continuity
Ohms Ω
• Hose, Wand, and
wire connection
• Sensors
• Hyd. Coils
• Burner Ignition Coil
DC Voltage
• Everything
except Generator
Use these ports. Do not
use the fuse port, it is for
amps
AC Voltage ~
• Generator Output
Fig. 7-1 Standard Multimeter
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…How to Use a Multimeter 7-2
Super Shot 60 Melter Part Manual
Chapter 7 How to Use a Multimeter
DC Voltage
• Everything
except Generator
AC Voltage ~
• Generator Output
Ohms Ω
• Sensors
• Hyd. Coils
• Burner Ignition Coil
AC Amps ~
• Hose Current
Audible Continuity
• Hose, Wand, and
wire connection
Fig. 7-2 Clamp – On Amp Meter/Multimeter
©2015 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…How to Use a Multimeter 7-3
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
8.0 Burner Troubleshooting
8.0.1. Symptoms: Burner will Not Ignite
Table 8-1 Basic Visual Burner Troubleshooting
Step
1
Possible Cause
If . . .
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.
2
Is the “POWER” toggle switch in the “ON”
position?
3
Is the red "Burner" light "ON"?
• Yes, go to Step3.
• No, turn the toggle switch to the “ON”
ii
• 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 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 Step8
• No, start the engine.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-1
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
Table 8-2 Basic Visual Troubleshooting (continued)
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.
Note: Use Fig. 8.1 Diesel Burner Schematic while troubleshooting the burner electrical system.
Table 8-3 Burner Electrical Troubleshooting
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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-2
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
Table 8-4 Burner Electrical Troubleshooting (continued)
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 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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-3
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
Table 8-5 Burner Electrical Troubleshooting (continued)
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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-4
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
Table 8-6 Burner Electrical Troubleshooting (continued)
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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-5
Super Shot 60 Melter Part Manual
RED
BLU
RED
BLU
RED
BLU
RED-3
RED-3
GRN-1
WHT-R ED-3
BLK-7
YEL-3
WHT-GRN-3
WHT-R ED-2
Chapter 8 Troubleshooting
Ra
ORN-2
RED-2
YEL-2
Br
Acc
GRN
PRP
BLU
BRN-1
B
C
BLK-RED
BLK-2
GRY-4
RED-4
RED-2
Ri
BLU-3
HOT OIL
ORN-2
BLK-5
BLK-6
GRY-2
BLK-5
GRY-3
GRY-2
+
+
+
+
RED-5
WHT-GRN-2
WHT-GRN-1
HOUR METER
RTD SENSOR
(1.08k ohms
@ 70°)F)
GRY-3
GRY-4
BLK-5
ORN-2
WHT-GRN-2
WHT-GRN-2
BLK-3
BLK-GND
BLK-1
ORN-1
WHT-GRN
WHT-GRN
RED
GRY-2
+
GRN-BRNR
-
(12vdc)
BATTERY
GREEN
t°
ORN-1
2
1
7 6
YELLOW
8
BLK-4
RTD SENSOR
(1.08k ohms
@ 70°F)
9
ORN-1
MATERIAL
BLACK
CAD CELL YELLOW
CAD CELL YELLOW
GND (MTR) BLACK
3
WHT-BLK
CAD CELL
YELLOW
BURNER PLUG
4
WHT-BLK
t°
WHITE
POWER RED
GND (MAIN) BLACK
ENABLE WHITE
BLACK
RED
SOLENOID
39602
GRY-4
TO ENG. OIL
PRESS. SW.
WHT/RED
BLACK
RED
CIRCUIT
BREAKER
BLOWER
MOTOR
ORANGE
MOTOR ORANGE
GND (IGN) BLACK
BLACK
IGNITOR BLUE
GND (VLV) BLACK
VALVE PURPLE
ALARM
BLACK OR
ORANGE
FUEL
VALVE
IGNITOR
BLACK OR
WHITE
RED
Fig. 8-1 Diesel Burner Schematic
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-6
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
8.0.2. Excessive Smoke Coming Out of Exhaust Stack
Table 8-7 Smoke Coming Out of Exhaust Stack
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 Fig. 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 Fig. 8.3
Diesel Burner Air Settings
3
Refer to Fig. 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 Fig. 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
7b
Make sure the insulation inside the burner box is not soaked with diesel fuel.
If the insulation is soaked with diesel fuel, you will need to replace the insulation.
7c
Reassemble the burner box.
8.0.3. Burner Lights but Shuts Down After 15 Seconds
Table 8-8 Burner Lights But Shuts Down After 15 Seconds
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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-7
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
8.0.4. Testing the DC Controller
Table 8-9 Testing the DC Controller
Step
Bench Test DC Controller
1
Remove all wire nuts attaching 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.
8.0.5. Burner Fuel Solenoid Testing
Table 8-10 Burner Fuel Solenoid Testing
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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-8
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
8.0.6. Burner Ignition Coil Testing
Table 8-11 Burner Ignition Coil Testing
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 2000 ohms. (Take note of the readings, you will use them in
Step 5.)
Check resistance between both springs. (Take note of the reading, you will use it in Step 5.)
4
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.
8.0.7. Bleeding the Burner
Step
Table 8-12 Bleeding the Burner
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 Fig. 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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-9
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
5/32
ELECTRODE
R 1/4
NOZZLE
5/32
Fig. 8-2 Diesel Burner Electrode Adjustment
Air Shitter = 4
Air Band = 0
Fuel Pressure = 140 PSI
Adjustment Plate = 3
IGNITION COIL LOCKING TAB
AIR SHUTTER SCREW
NOZZLE LINE NUT
AIR SETTING #
FUEL PRESSURE
ADJUSTMENT SCREW
COPPER FUEL LINE NUT
BLEEDER
AIR SHUTTER
FUEL PRESSURE GAUGE KIT
AIR BAND SCREW
AIR BAND
FUEL PRESSURE GAUGE
Fig. 8-3 Diesel Burner Air Settings
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-10
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
8.1 Sealant heating Slowly
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.
Check your level of the heat transfer oil, the mark on the dipstick is for 70°F.
3
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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-11
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
8.2 Mixer Troubleshooting
8.2.1 Symptom: Mixer Does Not Rotate
Table 8-14 Basic Visual Mixer Troubleshooting
Step
1
2
Possible Cause
If . . .
Is the Material Temperature Display at or
above 275°F?
• Yes, go to Step 2.
Is the red "Mixer" light "ON"?
• Yes, go to Step 4.
• No, continue to allow the machine to heat.
(Make sure the Material dial and the Hot Oil
dial are set at operating temperatures.)
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
5
Is the "Mixer" toggle switch in the "Forward"
position?
• Yes, go to Step 5.
Move the "Mixer" toggle switch to the
“Reverse” position.
• Yes, allow mixer to reverse for 15 seconds
and then move the "Mixer" toggle switch to
the "Forward" position. Go to Step 6.
Is the agitator moving?
6
Open the Material loading door. Are there
several unmelted blocks in the tank?
• No, move the toggle switch to the forward
position.
No, go to Table 8-15 Mixer Electrical
Troubleshooting
• 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 Fig. 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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-12
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
Note: Use Fig. 8.5 Mixer Circuit while troubleshooting the mixer electrical system.
Table 8-15 Mixer Electrical 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 Fig. 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
Fig. 8.5 Mixer Circuit
• 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
Is there 12Vdc between the lid switch red
wires and a nearby ground source?
• Yes, on both red wires check for loose
connections or broken wires between lid
switch and mixer toggle switch.
3
(Check both red wires on the bottom of the lid
switch with the lid closed.)
• No, go to step 3.
• 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 3a.
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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-13
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
Table 8-16 Mixer Electrical Troubleshooting (continued)
Step
Possible Cause
If . . .
4a
Is there 12Vdc between the Material
PAKSTAT terminal #2 pink wire and terminal
#8 black ground wire?
• Yes, check for loose connections or broken
wires between PAKSTAT terminal #2 and
terminal block.
• No, go to Step 4b
(Refer to Fig. 8.5 Mixer Circuit.)
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.
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.
5
• No, go to step 5.
• 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
8
Is there 12Vdc between bottom terminal wire
labeled RED-3 and a nearby ground source
(black wire)?
• Yes, replace toggle switch.
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 8.
• 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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-14
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
Table 8-17 Mixer Electrical Troubleshooting (continued)
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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-15
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
Fig. 8-4 Checking Din Plug Voltage
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-16
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
275° MAT'L.
TEMP.
t°
BLU
BLU
9
8
BLU
MATERIAL
PAK-STAT
AGITATOR
FORWARD
(12 Vdc @
2.72 Amps)
WHT-BLK
WHT-BLK
AGITATOR
REVERSE
(12 Vdc @
2.72 Amps)
2
ORN-1
3
FWD/REV
SWITCH
4
REV SWITCH
RED
1
PNK-2
BRN
BRN
BRN
6 7
PUMP
REVERSE
(12 Vdc @
2.72 Amps)
+
HOUR METER
BLK-5
PNK-3
+
HOT OIL
PAK-STAT
+
+
PNK-2
RED-LID
ORN-1
BLK-1
BLK-GND
BLK-3
PNK-3
TERMINAL
BLOCKS
ORN-2
BLK-5
LID SWITCH
Acc
C
POWER TOGGLE SWITCH
IGNITION
SWITCH
RED-3
RED-3
Ra
Br
RED-2
ORN-2
B
Ri
RED-2
ORN-2
CIRCUIT BREAKER
Fig. 8-5 Mixer Circuit
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-17
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
8.2.2
Mixer Hydraulic Troubleshooting
Table 8-18 Mixer Hydraulic Troubleshooting
Step
Possible Cause
1
Remove the din plug, 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?
• 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.
(Refer to Fig. 8.6 Hydraulic Valve Pressure
Setting, for pressure settings.)
If . . .
3
Is the hydraulic flow 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 Fig. 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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-18
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
RVP PUMP
PRESSURE RELIEF
SET @ 1000 PSI
RVA AGITATOR
PRESSURE RELIEF
SET @ 1000 PSI
ALLEN SCREW
PRESSURE
RELIEF JAM NUT
Mixer Direction = Counterclockwise
Material Pump = Clockwise
Hydraulic Flow = 9.71GPM @ 2550 RPM
Fig. 8-6 Hydraulic Valve Pressure Setting
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-19
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
Mixer Reverse
Mixer Forward
Pump Forward
Pump Reverse
Mounting Plate
Fig. 8-7 Din Plug Layout
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-20
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
8.3 Hose Troubleshooting
8.3.1 Symptom: Hose Does Not Heat
Table 8-19 Basic Visual Hose Troubleshooting
Step
1
2
Possible Cause
If . . .
Is the Material Temperature Display at or
above 275°F?
• Yes, go to Step 2.
Is the red "HEATED HOSE" light "ON"?
• Yes, go to Table 8-20 Electrical
Troubleshooting
• No, continue to allow the machine to heat.
(Make sure the Material dial and the Hot
Oil dial are set at operating temperatures.)
• No, allow the machine to heat material to
275°F.
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 Electrical
Troubleshooting
NOTE: Use Fig. 8.9 Hose Circuit Schematic while troubleshooting the hose electrical system.
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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-21
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
Table 8-21 Electrical Troubleshooting (continued)
Step
Possible Cause
If . . .
3
Check for continuity in the hose from end to
• Yes, go to Step 3a.
end. Disconnect the three blue heating
• No, either there was no continuity from one
element wires (blue) from the terminal block
letter to the other end of the hose or there
inside the junction box and disconnect the five was more than one wire with continuity to a
pin plug between the hose and wand. Refer
letter. This hose needs to be repaired or
to Fig. 8.10 Junction Box Wiring.
replaced. Contact Crafco, Inc. to send back
NOTE: Check each letter “D”, “E”, and “A”
the hose for repair.
with the three blue wires on the other end of
the hose. There should only be continuity on
one wire to each letter.
3a
Check the RTD sensor in the hose against the • Yes, the readout matches the table, go to
readout in the control box. Disconnect the
Step 4.
black and white wires from the terminal block • No, this hose needs to be repaired or
in the junction box and test for ohms.
replaced. Contact Crafco, Inc. to send back
Refer to Table 8-24 RTD Sensor Ohms vs.
the hose for repair.
Temperature
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”.
5
Is there 12Vdc between wire labeled “BLU” on • Yes, check for loose or broken connections
the terminal block and nearby ground source
between terminal block and “BATT” terminal
(black wire)?
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
• Yes, check for loose or broken wire between
“PNK-2 on the Material PAKSTAT and a black terminal #2 Material PAKSTAT and terminal
wire terminal #8?
#1 Hose PAKSTAT.
• No go to Step 7.
Is there 12Vdc between Orange wire labeled • Yes, replace terminal block.
“Orn-1” and black wire terminal #8?
• No, go to Step 8.
7a
• Yes, go to Step 5.
• No, this wand needs to be repaired or
replaced. Contact Crafco, Inc. to send back
the wand for repair.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-22
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
Table 8-22 Electrical Troubleshooting (continued)
Step
8
Possible Cause
Is there 12Vdc between orange wire labeled
ORN-1, terminal #9 and terminal #8 ground
source (black wire)?
If . . .
• Yes, check for loose connections or
broken wires between terminals #8 and
#1.
• No, go to step 9.
9
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 10.
10
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 steps 7 -10a of Table 8-16 Mixer
Electrical Troubleshooting (continued).
Test #2 between black
and green wires
Test #1 between
black and white wires
Test #3 between
white and green wires
Fig. 8-8 Junction Box Voltage Testing
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-23
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
BLUE
BLUE
BLUE
MATERIAL
PAK-STAT
WAND
t°
WHT-BLK
WHT-BLK
3
HOSE
BLUE
BLUE
BLUE
4
t°
1
7 6
RTD SENSOR
1.08K OHMS @70°F
2
ORN-1
PNK-2
9
8
275° MAT'L. TEMP.
BLK-4
8
HOSE
PAK-STAT
BLK
BLACK
WHITE
GREEN
3
BLU-1
WHT
PNK-1
4
2
7 6
1
9
PNK-2
24Vac 3-Phase
30-35 Amps Cold
20-24 Amps Hot
GENERATOR
BLK-GND
12Vdc
5-7Amps
BLK-4
BLK-3
BLU
13
9
14
12
5
1
8
4
+
+
BLK-5
BLU-2
BLU-2
RED-2
ORN-2
BLK-5
PNK-3
BLU
BLU
BLK-3
BLU-1
PNK-2
PNK-1
BLK-1
ORN-1
BATT
TERMINAL
BLOCKS
BLU
Ri
Br
Acc
C
BRN-1
ORN-2
Ra
BLU
RED
BLU
RED
BLU
RED
WHT-RED-2
WHT-GRN-3
ORN-4
BLK-7
WHT-RED-3
GRN-1
RED-3
YEL-2
RED-2
BLU
PRP
GRN
RED-2
BLK-RED
B
BLK-2
BLU-3
HOT OIL
ORN-2
HOUR METER
+
+
PRP
GRN
IGNITION
SWITCH
Fig. 8-9 Hose Circuit Schematic
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-24
Super Shot 60 Melter Part Manual
HEATER BLUE
HEATER BLUE
HEATER BLUE
HEAT ELEM. (BLUE)
HEAT ELEM. (BLUE)
TRIGGER RED
TRIGGER RED
SENSOR BLACK
SENSOR WHITE
HEAT ELEM. (BLUE)
Chapter 8 Troubleshooting
E
D
KETTLE END
B
TRIGGER (RED)
HEATER GREEN
HEATER WHITE
HEATER BLACK
C
TRIGGER (RED)
TRIGGER RED
TRIGGER GREEN
SENSOR BLACK
SENSOR WHITE
A
WAND END
Fig. 8-10 Junction Box Wiring
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-25
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
8.3.2
Step
1
Symptom: Trigger is not Working
Table 8-23 Trigger is not Working
Possible Cause
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.
2
Disconnect the electrical connector between
the hose and wand, check for continuity
between C and B wand side.
If . . .
• Yes, go to Table 8-26 Basic Visual Pump
Troubleshooting
• No, go to Step 2.
• 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.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-26
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
8.3.3 RTD Sensor Ohms vs. Temperature
Table 8-23 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, 1391 Ohms = 215°F)
Table 8-24 RTD Sensor Ohms vs. Temperature
°F
0
1
2
3
4
5
6
7
8
9
0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
150
160
170
180
190
200
210
220
230
240
250
260
930.3
952.2
973.9
995.7
1017.4
1039.0
1060.7
1082.2
1103.8
1125.3
1146.8
1168.3
1189.7
1211.0
1232.4
1253.7
1275.0
1296.2
1317.4
1338.6
1359.7
1380.8
1401.8
1422.9
1443.8
1464.8
1485.7
932.5
954.3
976.1
997.8
1019.5
1041.2
1062.8
1084.4
1106.0
1127.5
1149.0
1170.4
1191.8
1213.2
1234.5
1255.8
1277.1
1298.3
1319.5
1340.7
1361.8
1382.9
1403.9
1425.0
1445.9
1466.9
1487.8
934.7
956.5
978.3
1000.0
1021.7
1043.4
1065.0
1086.6
1108.1
1129.6
1151.1
1172.5
1194.0
1215.3
1236.7
1258.0
1279.2
1300.4
1321.6
1342.8
1363.9
1385.0
1406.0
1427.1
1448.0
1469.0
1489.9
936.9
958.7
980.5
1002.2
1023.9
1045.5
1067.1
1088.7
1110.3
1131.8
1153.2
1174.7
1196.1
1217.5
1238.9
1260.1
1281.3
1302.6
1323.8
1344.9
1366.0
1387.1
1408.1
1429.2
1450.1
1471.1
1492.0
939.1
960.9
982.6
1004.3
1026.0
1047.7
1069.3
1090.9
1112.4
1133.9
1155.4
1176.9
1198.2
1219.6
1240.9
1262.2
1283.5
1304.7
1325.9
1347.0
1368.1
1389.2
1410.3
1431.3
1452.2
1473.2
1494.1
941.3
963.0
984.8
1006.5
1028.2
1049.8
1071.5
1093.0
1114.6
1136.1
1157.5
1179.0
1200.4
1221.7
1243.0
1264.3
1285.6
1306.8
1328.0
1349.1
1370.2
1391.3
1412.4
1433.4
1454.3
1475.3
1496.1
943.4
965.2
987.0
1008.7
1030.4
1052.0
1073.6
1095.2
1116.7
1138.2
1159.7
1181.1
1202.5
1223.9
1245.2
1266.5
1287.7
1308.9
1330.1
1351.2
1372.4
1393.4
1414.5
1435.5
1456.4
1477.3
1498.2
945.6
967.4
989.1
1010.9
1032.5
1054.2
1075.8
1097.3
1118.9
1140.4
1161.8
1183.3
1204.6
1226.0
1247.3
1268.6
1289.8
1311.0
1332.2
1353.4
1374.5
1395.5
1416.6
1437.6
1458.5
1479.4
1500.3
947.8
969.6
991.3
1013.0
1034.7
1056.3
1077.9
1099.5
1121.0
1142.5
1164.0
1185.4
1206.8
1228.1
1249.4
1270.7
1292.0
1313.2
1334.3
1355.5
1376.6
1397.6
1418.7
1439.6
1460.6
1481.5
1502.4
950.0
971.8
993.5
1015.2
1036.9
1058.5
1080.1
1101.6
1123.2
1144.7
1166.1
1187.5
1208.9
1230.3
1251.6
1272.8
1294.1
1315.3
1336.5
1357.6
1378.7
1399.7
1420.8
1441.7
1462.7
1483.6
1504.5
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-27
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
Table 8-25 RTD Sensor Ohms vs. Temperature (continued)
°F
0
1
2
3
4
5
6
7
8
9
270
280
290
300
310
320
330
340
350
360
370
380
390
400
410
420
430
440
450
460
470
480
490
500
510
520
530
540
550
1506.6
1527.4
1548.2
1569.0
1589.7
1610.4
1631.1
1651.7
1672.3
1692.9
1713.4
1733.9
1754.3
1774.7
1795.1
1815.4
1835.7
1856.0
1876.2
1896.4
1916.6
1936.7
1956.8
1976.8
1996.9
2016.8
2036.8
2056.7
2076.6
1508.7
1529.5
1550.3
1571.1
1591.8
1612.5
1633.2
1653.8
1674.4
1694.9
1715.4
1735.9
1756.3
1776.8
1797.1
1817.5
1837.8
1858.0
1878.2
1898.4
1918.6
1938.7
1958.8
1978.8
1998.9
2018.8
2038.8
2058.7
2078.5
1510.8
1531.6
1552.4
1573.1
1593.9
1614.6
1635.2
1655.8
1676.4
1697.0
1717.5
1737.9
1758.4
1778.8
1799.2
1819.5
1839.8
1860.0
1880.3
1900.5
1920.6
1940.7
1960.8
1980.8
2000.9
2020.8
2040.8
2060.7
2080.5
1512.8
1533.7
1554.5
1575.2
1595.9
1616.6
1637.3
1657.9
1678.5
1699.0
1719.5
1740.0
1760.4
1780.8
1801.2
1821.5
1841.8
1862.1
1882.3
1902.5
1922.6
1942.7
1962.8
1982.9
2002.9
2022.8
2042.8
2062.7
2082.5
1514.9
1535.7
1556.5
1577.3
1598.0
1618.7
1639.3
1660.0
1680.5
1701.1
1721.6
1742.0
1762.5
1782.9
1803.2
1823.6
1843.8
1864.1
1884.3
1904.5
1924.6
1944.7
1964.8
1984.9
2004.9
2024.8
2044.7
2064.6
2084.5
1517.0
1537.8
1558.6
1579.4
1600.1
1620.8
1641.4
1662.0
1682.6
1703.1
1723.6
1744.1
1764.5
1784.9
1805.3
1825.6
1845.9
1866.1
1886.3
1906.5
1926.6
1946.8
1966.8
1986.9
2006.9
2026.8
2046.7
2066.6
2086.5
1519.1
1539.9
1560.7
1581.4
1602.2
1622.8
1643.5
1664.1
1684.6
1705.2
1725.7
1746.1
1766.6
1786.9
1807.3
1827.6
1847.9
1868.1
1888.3
1908.5
1928.7
1948.8
1968.8
1988.9
2008.8
2028.8
2048.7
2068.6
2088.5
1521.2
1542.0
1562.8
1583.5
1604.2
1624.9
1645.5
1666.1
1686.7
1707.2
1727.7
1748.2
1768.6
1789.0
1809.3
1829.6
1849.9
1870.2
1890.4
1910.5
1930.7
1950.8
1970.8
1990.9
2010.8
2030.8
2050.7
2070.6
2090.4
1523.3
1544.1
1564.8
1585.6
1606.3
1627.0
1647.6
1668.2
1688.7
1709.3
1729.8
1750.2
1770.6
1791.0
1811.4
1831.7
1851.9
1872.2
1892.4
1912.6
1932.7
1952.8
1972.8
1992.9
2012.8
2032.8
2052.7
2072.6
2092.4
1525.3
1546.1
1566.9
1587.7
1608.4
1629.0
1649.7
1670.2
1690.8
1711.3
1731.8
1752.3
1772.7
1793.1
1813.4
1833.7
1854.0
1874.2
1894.4
1914.6
1934.7
1954.8
1974.8
1994.9
2014.8
2034.8
2054.7
2074.6
2094.4
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-28
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
8.4 Pump Troubleshooting
8.4.1 Symptom: Material Does Not Dispense When the Pump is Activated
Table 8-26 Basic Visual Pump Troubleshooting
Step
Possible Cause
1
Is the Hose Temperature Display at or above
325°F?
• Yes, go to Step 2.
Is the red "Pump" light "ON"?
• Yes, go to Step 3.
2
If . . .
• No, continue to allow the hose to heat.
(Make sure the Hose dial is set at proper
operating temperature.)
• No, go to Table 8-27 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
5
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
the trigger is engaged does the green light
illuminate?
• Yes, this indicates that 12Vdc is reaching
the relay coil. Go to Table 8-28 Pump
Electrical Troubleshooting (continued) Step
5 to find the problem.
Is the hydraulic fluid level near the center of
the sight gauge when the machine is cold?
• Yes, go to Table 8-27 Pump Electrical
Troubleshooting.
See Fig. 5.1 Hydraulic Fluid Level and Temp.
Gauge
• No, fill oil to the center of the sight gauge.
• No, go to Table 8-27 Pump Electrical
Troubleshooting, Steps 2 to find the
problem.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-29
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
NOTE: Use Fig. 8.11 Pump Circuit Schematic while troubleshooting the pump electrical system.
Table 8-27 Pump Electrical Troubleshooting
Step
Possible Cause
If . . .
1
Is the amber light “ON” on the Din Plug when
the trigger is actuated? For pump forward
din plug location Refer to Fig. 8.7 Din Plug
Layout
• Yes, then the pump should be working. If it
is not working see Table 8-31 Pump
Hydraulic Troubleshooting
• No, go to Step 1a.
1a
Unscrew the center screw of the din plug so
you can pull the din plug up 1/4” in order to
check voltage.
Is there 12Vdc from side post to side post?
• Yes, the electrical system for the pump is
working properly. Refer to Table 8-31
Pump Hydraulic Troubleshooting
• No, go to Step 4.
2
Is there 12Vdc between red wire labeled
“RED- TRIG” in junction box and nearby
ground source?
• Yes, go to Step 2a.
• No, go to Table 8-29 Pump Electrical
Troubleshooting (continued) Step 10.
2a
Is there 12Vdc between green wire labeled
“GRN- TRIG” in junction box and nearby
ground source?
NOTE: Wand trigger must be actuated
during this test.
• Yes, go to Step 3.
• No, see Table 8-23 Trigger is not Working
3
Is there 12Vdc between green wire on
terminal #14 of pump relay and black wire
terminal #13 pump relay?
NOTE: Wand trigger must be actuated
during this test.
• Yes, go to Step 5.
• No, check for loose or broken wire between
relay and junction box.
4
Is there 12Vdc between the blue wire on
terminal #12 of pump relay and the black wire
on terminal #13 of pump relay?
NOTE: Trigger must be actuated or pump
switch in “ON STANDARD” position during
this test.
• Yes, check for loose or broken wire
between terminal #12 and the terminal
block.
• No, go to Step 4a for Electric Hose.
• No, go to Step 4b for Standard Hose.
4a
Is there 12Vdc on red wire terminal #8 of
pump relay and black wire terminal #13?
• Yes, replace relay.
• Go to Step 5
4b
Is there 12Vdc on red wire terminal #4 of
pump relay and black wire terminal #13?
NOTE: This only applies to “ON
STANDARD” position of pump switch.
• Yes, replace relay.
• No, go to Step 6.
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-30
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
Table 8-28 Pump Electrical Troubleshooting (continued)
Step
Possible Cause
If . . .
5
Is there 12Vdc between red wire labeled
RED-1 upper terminal block and a nearby
ground source (black wire)?
• Yes, check for loose or broken wire
between terminal block and terminal #8.
• No, go to Step 6a.
5a
Is there 12Vdc between red wire labeled
RED-4 upper terminal block and nearby
ground source (black wire)?
• Yes, replace terminal block.
• No, go to Table 8-17 Mixer Electrical
Troubleshooting (continued) steps 9-10a.
6
Is there 12Vdc between red wire labeled
RED-9 on top right hand terminal of pump
switch and a nearby ground source?
• Yes, check for loose or broken wire
between pump switch and pump relay.
• No, go to Step 6a.
6a
Is there 12Vdc between purple wire labeled
PRP-3 on center right hand terminal of pump
switch and a nearby ground source(black
wire)?
• Yes, replace pump switch.
• No, go to Step 7.
7
Is there 12Vdc between purple wire labeled
PRP-3 top left terminal of hose selector
switch and nearby ground (black wire)?
• Yes, check for loose or broken wire
between hose selector switch and pump
switch.
• No go to Step 7a.
7a
Is there 12Vdc between pink wire labeled
PNK-3 center left terminal of hose selector
switch and nearby ground (black wire)?
• Yes, replace hose selector switch.
• No, go to Step 8.
8
Is there 12Vdc between pink wire labeled
PNK-3 upper terminal block and nearby
ground (black wire)?
• Yes, check for loose or broken wire
between terminal block and hose selector
switch.
• No, go to Step 8a.
8a
Is there 12Vdc between pink wire labeled
PNK-2 upper terminal block and nearby
ground (black wire)?
• Yes, replace terminal block.
• No, go to Table 8-16 Mixer Electrical
Troubleshooting (continued) Steps 4a
through 10a.
9
Is there 12Vdc between red wire labeled
“RED-TRIG” upper terminal block and nearby
ground source (black wire)?
• Yes, check for loose or broken wire
between terminal block and junction box.
• No, go to Step 10.
10
Is there 12Vdc between purple wire labeled
“PRP-1” upper terminal block and nearby
ground source (black wire)?
• Yes, ensure the yellow jumper in the middle
of the terminal blocks connected to the
“PRP-1” and “RED-TRIG” wires is push in
all the way.
• No, Go to Step 11
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-31
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
Table 8-29 Pump Electrical Troubleshooting (continued)
Step
Possible Cause
If . . .
11
Is there 12Vdc between purple wire on
terminal #2 of hose PAKSTAT and terminal
#8 black ground wire?
• Yes, check for loose or broken wire
between PAKSTAT and terminal block.
NOTE This wire has a diode that could be
bad and cause an open circuit.
• No, go to Step 11a.
11a
Is there 12Vdc between pink wire on terminal
#1 of hose PAKSTAT and terminal #8 black
ground wire?
• Yes, replace the hose PAKSTAT.
• No, go to Step 12.
12
Is there 12Vdc between pink wire labeled
“PNK-1” upper terminal blocks and nearby
ground source (black wire)?
• Yes, check for loose or broken wire
between terminal blocks and hose
PAKSTAT.
• No, go to Step 12a
12a
Is there 12Vdc between pink wire labeled
“PNK-4” upper terminal blocks and nearby
ground source (black wire)?
• Yes, replace terminal block.
• No, go to Step 13.
13
Is there 12Vdc between pink wire labeled
“PNK-4” lower left terminal of hose selector
switch and nearby ground source (black
wire)?
• Yes, check for loose or broken wire
between hose selector switch and terminal
block.
• No, go to Step 13a.
13a
Is there 12Vdc between pink wire labeled
“PNK-3” center left terminal of hose selector
switch and nearby ground source (black
wire)?
• Yes, replace hose selector switch.
• No, go to Step 14.
14
Is there 12Vdc between pink wire labeled
“PNK-3 on the upper terminal block and a
nearby ground source black wire?
• Yes, check for loose or broken wire
between terminal block and hose selector
switch.
• No go to Step 8a.
Is there 12Vdc between pink wire labeled
“PNK-2” on upper terminal block and nearby
ground source black wire?
• Yes, replace terminal block.
• No, go to Table 8-16 Mixer Electrical
Troubleshooting (continued) Steps 4a
through 9a.
14a
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-32
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
275° MAT'L. TEMP. t°
MATERIAL
PAKSTAT
8
6
6
WHT-BLK
BLK
WHT-BLK
WHT
6
7
4
1
2
PRP-1
PNK-3
3
PNK-1
2
ORN-1
6
7
1
PUMP FWD.
12Vdc
2.72 Amps
BRN
8
BLU
HOSE
PAKSTAT
3
4
12
9
13
GRN-TRIG
RED-1
14
1
4
8
5
BLK-4
BLK-3
BLU-PMP
PUMP
RELAY
325° HOSE TEMP.
RED-1
t°
BLK-1
BLK-3
BLK-GND
WAND
PRP-1
PNK-1
TERMINAL
BLOCKS
ORN-1
PNK-3
RED-TRIG
TRIGGER
+
+
BLK-5
HOUR METER
+
HOT OIL
PAKSTAT
+
PRP-2
PRP-3
PNK-4
ORN-2
BLK-5
HOSE
Acc
C
POWER
SWITCH
IGNITION
SWITCH
RED-3
RED-3
Ra
Br
RED-2
ORN-2
B
Ri
RED-2
BLU-3
ORN-2
CIRCUIT
BREAKER
Fig. 8-11 Pump Circuit Schematic
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-33
Super Shot 60 Melter Part Manual
Chapter 8 Troubleshooting
8.4.2
Pump Hydraulic Troubleshooting
Table 8-30 Pump Hydraulic Troubleshooting
Step
Possible Cause
If…
1
Does the coil magnetize when the din plug
• Yes, go to Step 2.
amber light is “ON”?
• No, remove the din plug, 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 Fig. 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,
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 Fig. 8.6 Hydraulic Valve
Pressure Setting
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Troubleshooting 8-34
Super Shot 60 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.
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
420 N. Roosevelt Ave.
Chandler, AZ 85226-2601
Phone: (602) 276-0406
Toll Free: (800) 528-8242
Fax: (480) 961-0513
Visit our website at www.crafco.com
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-1
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
9.2 Super Shot 60 Diesel Melter
26
6 8
7
24
19
20
1
2
15
5
12
11
17 27
29 14
4
23
10
9 18
22
4 4a 4b 4c
7
13
3
16
28
9
10
21 22
Fig. 9-1 Super Shot 60 Diesel Melter
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-2
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
FIG.
ITEM
PART NO.
DESCRIPTION
QTY.
Fig. 9.1
1
46840
ENGINE ASSEMBLY – 46100EB
1
2
29399
ISOMOUNT
4
3
46850
HYDRAULIC TANK ASSEMBLY
1
4
45498
HYDRAULIC FILTER ASSEMBLY
1
4a
45438
HYDRAULIC FILTER ELEMENT
1
4b
45440
O-RING, HYDRAULIC FILTER
1
4c
45497
GASKET, HYDRAULIC FILTER
1
5
45525
CONTROL BOX ASSEMBLY – ELECTRIC
1
6
43355
OVERFLOW TANK
1
7
43374
DIPSTICK
1
8
26025
AIR BREATHER
1
9
46863
PUMP AGITATOR MOTOR ASSEMBLY
1
10
46860
BOOM – HOSE
1
11
46851
BASE, BOOM
1
12
46862
LOCK, BOOM
1
13
45553
BEARING, BOOM
2
14
45420
HYDRAULIC CONTROL VALVE ASSEMBLY
1
15
44027
JUNCTION BOX ASSEMBLY
1
16
46060
REGULATOR, FLOW
1
17
43465
SENSOR, RTD
2
18
46878
CHAIN GUARD
2
19
46908
DRIP PAN
1
20
46905
SUPPORT ASSEMBLY, WAND
1
21
24000
BATTERY
1
22
24002
BATTERY BOX
1
23
45442
HYDRAULIC PUMP ASSEMBLY – EC63/SC63
1
24
51730
WAND ASSEMBLY – ELECTRIC
1
25
51731
HOSE, ELECTRIC – 15’(NOT SHOWN)
1
26
43768
WAND HANDLE
1
27
51065
CORD GRIP
3
28
39608
SWITCH, LID
1
29
46931
BRACKET, HYDRAULIC VALVE
1
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-3
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
46
41 40 34
47 44
38 37
38 36
42
5
45
31
30
46
43
Fig. 9-2 Super Shot 60 Diesel Melter
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-4
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
FIG.
ITEM
PART NO.
DESCRIPTION
QTY.
Fig. 9-2
30
46864
COVER, CONTROL VALVE
1
31
39602
SOLENOID
1
32
43579
FILLER/BREATHER
2
33
46855
FUEL TANK ASSEMBLY
1
34
45415
SIGHT GAUGE, HYDRAULIC TANK
1
35
46380
BURNER, 14 VOLT
1
35
46909
COVER, BURNER
1
36
32513
TOGGLE SWITCH – PUMP REVERSE
1
37
51678
TOGGLE SWITCH – AGITATOR
1
38
50720
BOOT, TOGGLE SWITCH
2
39
51065
CORD GRIP
2
40
44818
TUBING, SIGHT GAUGE
1
41
44817
FITTING, SIGHT GAUGE
2
42
46839
HEAT GUARD
1
43
39608
SWITCH, LID
1
44
46933
GUARD, VENT
2
45
31512
CIRCUIT BREAKER
1
46
46906
LOCKING ARM, WAND SUPPORT
1
47
26104
1/4” X 2” GRIP, QUICK RELEASE PIN
2
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-5
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
9.3 Tank Detail
9 8 7
1 2
4
6
5
10
15 14
19
18
17
16
13
14
12
11
20 21
Fig. 9-3 Tank Detail
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-6
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
FIG.
ITEM
PART NO.
DESCRIPTION
QTY.
Fig. 9-3
1
44165
SPROCKET, DRIVEN
1
2
44163
KEY, SPROCKET
1
3
43321
CHAIN, DRIVE
1
4
46872
BEARING, FLANGED
1
5
46896
SHAFT, AGITATOR
1
6
43548
SHAFT, DRIVE – PUMP
1
7
26002
SPROCKET
2
8
26016
CHAIN, SPROCKET
1
9
31368
KEY, SPROCKET
1
10
46900
PADDLE, AGITATOR
2
11
46803
SCREEN, PUMP
1
12
44850
PUMP, MATERIAL
1
13
28101
NIPPLE, 1” X 8” LG. PIPE
1
14
28270
CAP, 1” PIPE
1
15
28060
NIPPLE, 1” X 5” LG. PIPE
1
16
28273
CAP, 2” PIPE
1
17
28055
NIPPLE, 1” X 5” LG. PIPE
1
18
28210
ELBOW, 1” PIPE
1
19
28351
BUSHING, 1” X 3/4” REDUCER
1
20
51066
SWIVEL, 90°
1
21
46920
BURNER BOX
1
22
43179
INSULATION KIT, BURNER BOX
1
23
55357
HEAT GUARD
1
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-7
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
BLK-4
ORN-1
WHT-BLK
2
ORN-1
WHT-BLK
PNK-2
3
7 6
1
ORN-1
6
8
9.4 Control Box Assembly
4
GRY-1
8 24
WHT
BLK
7 24
HOSE
PAKSTAT
WHT-BLU
YEL-GRN
WHT-GRN
GRN
BLK-BLU
WHT-RED
GRN-1
YEL-GRN
YEL-BLK
BLK-GRN
WHT-BLU
WHT-RED-2
ORN-3
2 3
BLK-7
BLK-8
WHT-GRN-3
WHT-RED-3
ORG
BLK
YEL
WHT-BLK
WHT-RED
RED-WHT
26
BLK-4
BLK-3
BLU-PMP
YELLOW
RED-BLK
GRY-1
WHT-RED
PNK-2
PNK-1
RED-LID
WHT-GRN
WHT-GRN
ORN-1
BLK-1
BLK-GND
BLK-3 RED-TRIG
PRP-1BLU
BLU-1
RED-1
WHT-COMP
GRN-BRNR
WHT-RED
RED
WHT-RED
BLK-GRN
YEL-RED
22
YEL-BLK
BLU
RED
RED-6
BLK-YEL
GRY-4
BLK-2
GRN
BLK-1
BLK-BLU
BLK-LIGHT
BLU-3
9
12
YEL-2
13
GRN-TRIG 14
BLK-WHT
BLU
1
BLK-5
PRP-2
+
PNK-3
+
BLK-5
BLU-2
BLK-YEL
YEL
4 5 6
BLK-5
14
BRN-1
1
4
RED-1
5
8
PRP-2
BLU-2
RED-2
WHT-1
GRY-2
RED-4
RED-5
WHT-GRN-1
WHT-GRN-2
ORN-2
BLK-5
BLK-6
PUMP
RELAY
BLK
BLK-BLU
WHT-GRN
10
+
BLK-5
GRY-2
+
BLU
PRP
GRN
16
RED-5
WHT-RED-1
GRY-3
BLK-LIGHT
GRY-2
RED-3
WHT-GRN-2
WHT-GRN-1
WHT-1
HOT OIL
PAKSTAT
21
BLK
WHT
RED-TRIG
GRN-TRIG
YEL-1
RED-BLK-1
GRY-3
WHT-RED-1
PNK-3
12
13 11
YELLOW
RED-BLK
WHT-COMP
BLU
BLK-GND
GRN-BRNR
WHT-RED
RED
ORN-4
GRN
WHT-RED
YEL-RED
BLK
WHT-GRN
WHT-RED
25
9
20
WHT-BLK
WHT-BLK
BLU-PMP
WHT-GRN
WHT-GRN
RED-LID
WHT-RED
YEL
BLK-BLU
BLK-WHT
YEL-GRN
TERMINAL
BLOCKS
PNK-2
YEL-3 16.5"
BLK-8 18"
ORG-3 15.5"
RED-6 13.5"
YEL-3
30
87A
85
86
27
4
BLU-1
YEL
BLK
BLU
RED-BLK
9
PNK-1
BLK-4
7 6
1
PRP-1
2
28
PNK-1
3
8
MATERIAL
PAKSTAT
BLK-6
BLK-5
RED-3
ORN-2
POWER
SWITCH
17
Ri
C
BRN-1
18
B
Acc
Br
Ra
BLU
RED
BLU
RED
BLU
RED
IGNITION
SWITCH
CIRCUIT BREAKER
WHT-RED-2
WHT-GRN-3
ORN-4
BLK-7
WHT-RED-3
GRN-1
RED-2
YEL-2
RED-3
BLU
PRP
GRN
GRY-4
BLK-RED
BLK-2
19 15
RED-4
RED-2
BLU-3
ORN-2
Fig. 9-4 Control Box Assembly
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-8
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
FIG.
ITEM
PART NO.
DESCRIPTION
QTY.
Fig. 9-4
1
45595
ENCLOSURE (NOT SHOWN)
1
2
24021
CORD CONNECTOR
3
3
50280
1/2” CONDUIT NUT
4
4
51662
SOCKET, RELAY
1
5
51661
RELAY
1
6
51663
HOLD DOWN SPRING
1
7
51691
TEMPERATURE CONTROLLER, 400°/325°
1
8
51672
TEMPERATURE CONTROLLER, 400°/275°
1
9
51803
MOUNTING RAIL
1
10
51802
END BRACKET
2
11
51800
FEED THROUGH TERMINAL
26
12
51801
JUMPER, 2-POLE
1
13
51804
JUMPER, 3-POLE
1
14
50251
READOUT, DIGITAL
3
15
43391
TEMPERATURE CONTROLLER 150°-550°
1
16
51651
LIGHT, 12VDC
4
17
50719
SWITCH, TOGGLE
1
18
51665
CIRCUIT BREAKER, 15 AMP
1
19
50593
KNOB
3
20
44983
CABLE ASSEMBLY, SENSOR
1
21
44984
CABLE ASSEMBLY, POWER
1
22
44985
CABLE ASSEMBLY, TRIGGER/SENSOR
1
23
51684
RIBBON CABLE, 36” (NOT SHOWN)
2
24
51670
SPACER, TEMPERATURE CONTRLLER
8
25
51805
END BRACKET
4
26
44979
RELAY, STARTER
2
27
44980
TIMER
1
28
-
RELAY
1
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-9
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
2
ORN-1
ORN-1
6
1
PNK-2
3
8
BLK-4
WHT-BLK
WHT-BLK
7 6
ORN-1
4
GRY-1
8
9
1
PRP-1
BLK-4
PNK-2
BLK
3
BLU-1
WHT
PNK-1
4
7 6
PNK-1
2
MATERIAL
PAKSTAT
YEL-3 16.5"
BLK-8 18"
ORG-3 15.5"
RED-6 13.5"
YEL
BLK
BLU
RED-BLK
HOSE
PAKSTAT
ORN-3
GRN-1
WHT-RED-2
YEL-3
BLK-7
BLK-8
WHT-GRN-3
WHT-RED-3
WHT-BLU
YEL-GRN
WHT-GRN
GRN
BLK-BLU
WHT-RED
BLK
WHT
RED-TRIG
GRN-TRIG
WHT-RED
BLK-GRN
BLK
BLK-BLU
BLK-4
BLK-3
BLU-PMP
YELLOW
RED-BLK
WHT-COMP
BLU
BLK-GND
GRN-BRNR
WHT-RED
RED
YEL-RED
BLK-YEL
BLK-WHT
BLU
GRN
BLK-1
RED
RED-6
BLU
BLK-BLU
YEL-BLK
BLK-YEL
YEL
31
32
BLK-2
GRY-4
9
12
BRN-1
YEL-2
13
GRN-TRIG 14
BLK-LIGHT
BLU-3
5
1
8
4
RED-1
WHT-GRN
PRP-2
BLU-2
RED-2
WHT-1
GRY-2
RED-4
RED-5
WHT-GRN-1
WHT-GRN-2
ORN-2
BLK-5
BLK-6
YEL-1
RED-BLK-1
GRY-3
WHT-RED-1
PNK-3
TERMINAL
BLOCKS
YELLOW
RED-BLK
GRY-1
WHT-RED
PNK-2
PNK-1
RED-LID
WHT-GRN
WHT-GRN
ORN-1
BLK-1
BLK-GND
BLK-3 RED-TRIG
PRP-1BLU
BLU-1
RED-1
WHT-COMP
GRN-BRNR
WHT-RED
RED
ORN-4
GRN
WHT-RED
YEL-RED
BLK
WHT-GRN
WHT-RED
YEL
BLK-BLU
BLK-WHT
YEL-GRN
44983
WHT-BLK
WHT-BLK
BLU-PMP
WHT-GRN
WHT-GRN
RED-LID
WHT-RED
44984
YEL-GRN
YEL-BLK
BLK-GRN
WHT-BLU
44985
30
87A
85
86
ORG
BLK
YEL
WHT-BLK
WHT-RED
RED-WHT
PRP-2
+
BLK-5
PNK-3
BLU-2
BLK-5
+
BLK-5
PUMP
RELAY
+
29
RED-5
GRY-3
BLK-LIGHT
WHT-1
GRY-2
WHT-RED-1
WHT-GRN-2
WHT-GRN-1
RED-3
HOT OIL
PAKSTAT
BLK-5
GRY-2
+
BLU
PRP
GRN
37
BLK-6
BLK-5
RED-3
ORN-2
POWER
SWITCH
Ri
C
BRN-1
B
Acc
Ra
IGNITION
SWITCH
WHT-RED-2
WHT-GRN-3
ORN-4
BLK-7
WHT-RED-3
GRN-1
39
30
Br
BLU
RED
BLU
RED
BLU
RED
RED-2
YEL-2
RED-3
BLU
PRP
GRN
GRY-4
BLK-RED
BLK-2
33
RED-4
RED-2
BLU-3
ORN-2
39
CIRCUIT BREAKER
Fig. 9-5 Control Box Assembly
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-10
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
FIG.
ITEM
PART NO.
DESCRIPTION
QTY.
Fig. 9-5
29
24076
HOUR METER
1
30
41994
IGNITION SWITCH
1
31
24024
CORD GRIP, YELLO2W
1
32
44978
CABLE ASSEMBLY, ENGINE
1
33
51698
RIBBON CABLE, 5”
1
34
44975
GAUGE, WATER TEMPERATURE (Not Shown)
OPT.
35
44976
GAUGE, OIL PRESSURE (Not Shown)
OPT.
36
44977
GAUGE, VOLT METER (Not Shown)
OPT.
37
44987
RESISTANCE CONTROL
1
38
44989
LIGHT, AMBER (Not Shown)
1
39
44988
LIGHT, RED
2
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-11
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
9.5 Engine Assembly
1
7
6
5
4
3
2
Fig. 9-6 Engine Assembly
FIG.
ITEM
PART NO.
DESCRIPTION
QTY.
Fig. 9-6
1
46840
ENGINE , 12.5kW
1
2
43612
GENERATOR, 24VAC
1
3
46966
BELT, DRIVE – GEN.
1
4
46963
FUEL FILTER
1
5
46964
OIL FILTER
1
6
46959
HYDRAULIC PUMP
1
7
46965
AIR FILTER ELEMENT
1
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-12
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
9.6 Hydraulic Control Valve Assembly
1
2
9
8
7
6
5
4
3
Fig. 9-7 Hydraulic Control Valve
FIG.
ITEM
PART NO.
DESCRIPTION
QTY.
Fig. 9-7
1
45418CH
VALVE ASSEMBLY
2
2
45419CH
COIL, VALVE ASSEMBLY
4
3
45417CH
VALVE, RELIEF
2
4
-
TEE, MALE #8 ORB X #8 JIC RUN
1
5
45413CH
CAP, DUST
2
6
45414CH
FITTING, TEST POINT
2
7
45416CH
FLOW CONTROL, PRIORITY
1
8
-
FITTING, #6 ORB X #6 JIC LONG STRAIGHT
2
9
-
FITTING, #6 ORB X #8 JIC STRAIGHT
2
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-13
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
9.7 Diesel Burner Assembly
5 4
3
1 2
6
7
8
10
9
Fig. 9-8 Diesel Burner
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-14
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
FIG.
ITEM
PART NO.
DESCRIPTION
QTY.
Fig. 9-8
1
41949
IGNITION TRANSFORMER
1
2
41890
BLOWER MOTOR
1
3
41970
COUPLING, FUEL PUMP
1
4
41892
PUMP, FUEL
1
5
41888
SOLENOID, FUEL
1
6
41993
ELECTRODE
1
7
46912
NOZZLE
1
8
41870
CAD EYE (NOT SHOWN)
1
9
42335
DC CONTROLLER (NOT SHOWN)
1
10
46951
HEAD, BURNER (Not Shown)
1
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-15
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
9.8 Hydraulic Schematic
HYD. VALVE
6
CONTROL VALVE
3
2
1
7
PUMP MOTOR
5
4
8
MIXER MOTOR
9
3
1
4
2
DIN PLUG LOCATION
HYD. TANK
3
2
1
HYD. PUMP
Fig. 9-9 Hydraulic Diagram
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-16
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
FIG.
ITEM
Fig. 9-10
1
PART NO.
12G4H 12G-16FJX 12G-12FJX 390
29802
FITTING, #20 ORB X #16 JIC 45°
1
HYDRAULIC HOSE
1
FITTING, #12 ORB X #12 JIC 45°.
1
HYDRAULIC PUMP TO HYDRAULIC VALVE “P” PORT
29862
8M3K 8G-10FJX 8G-10FJX90L 2800
29897
3
FITTING, #10 ORB X #10 JIC 90°.
1
HYDRAULIC HOSE
1
FITTING, #12 ORB X #8 JIC STR.
1
HYDRAULIC VALVE “T” PORT TO HYDRAULIC FILTER
29916
FITTING, #12 ORB X #12 JIC 90°.
12M3K 12G-12FJX 12G-12FJX90S 1550 HYDRAULIC HOSE
29929
4
8M3K 8G-8FJX 8G-8FJX90L 750
29913
8M3K 8G-8FJX 8G-8FJX 570
40311
8M3K 8G-8FJX 8G-8FJX90S 800
29932
FITTING, #8 ORB X #8 JIC 90°.
1
HYDRAULIC HOSE
1
FITTING, #10 ORB X #8 JIC STR.
1
FITTING, #8 ORB X #8 JIC
1
HYDRAULIC HOSE
1
FITTING, #6 ORB X #6 JIC STR.
1
FITTING, #8 ORB X #8 JIC 90°
1
HYDRAULIC HOSE
1
FITTING, #8 ORING RUN TEE
1
HYDRAULIC VALVE “PB” PORT TO MATERIAL PUMP MOTOR
29919
8M3K 8G-8FJX 8G-8FJX90S 410
29913
8
1
FLOW CONTROL VALVE #2 PORT TO HYDRAULIC VALVE “T” PORT
29896
7
1
HYDRAULIC VALVE “PA” TO FLOW CONTROL #1 PORT
29998
6
FITTING, #16 ORB X #12 JIC STR.
1
FLOW CONTROL #3 PORT TO PUMP MOTOR (TOP PORT)
29916
5
QTY
HYDRAULIC RESERVOIR TO HYDRAULIC PUMP SUCTION PORT
29898
2
DESCRIPTION
FITTING, #6 ORB X #8 JIC STR.
1
HYDRAULIC HOSE
1
FITTING, #10 ORB X #8 JIC STR.
1
HYDRAULIC VALVE “AA” PORT TO MIXER MOTOR
29919
6M3K 6G-8FJX 6G-6FJX90S 570
22029
FITTING, #6 ORB X #8 JIC STR.
1
HYDRAULIC HOSE
1
FITTING, #10 ORB X #6 JIC STR.
1
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-17
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
HYD. VALVE
6
CONTROL VALVE
3
2
1
7
PUMP MOTOR
5
4
8
MIXER MOTOR
9
3
1
4
2
DIN PLUG LOCATION
HYD. TANK
3
2
1
HYD. PUMP
Fig. 9-10 Hydraulic Diagram
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-18
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
FIG.
ITEM
Fig. 9-11
9
PART NO.
DESCRIPTION
QTY.
MIXER MOTOR TO HYDRAULIC VALVE “AB” PORT
22029
6M3K 6G-6FJX 6G-6FJX90L 590
40311
FITTING, #10 ORB X #6 JIC STR.
1
HYDRAULIC HOSE
1
FITTING, #6 ORB X #6 JIC STR.
1
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-19
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
9.9 Electrical Schematic
7
7
BLK/WHT
BLK/WHT
2
RED
DIN PLUG LOCATION
RED
RED
5
45425
COMPRESSOR
VALVE
4
11
17
RED TO OIL PRESS. SWITCH
WHT-RED TO OIL PRESS. SWITCH
BLACK TO SOLN. MTG. BOLT
WHITE WIRE TO TEMPERATURE SWITCH
GREEN
RED
PNK
BLK
RED
BLK
TRIGGER RED
TRIGGER RED
SENSOR BLACK
SENSOR WHITE
9
WHITE
BURNER PLUG
RED
15
8
24000 BATTERY
10
+BATT
RED/BLK
PUMPING
TEMP
18
RED
12
BLACK
3
GREEN
BLUE WIRE TO GENERATOR
2
16
TO ENG. OIL
PRESS SWITCH
1
RED
"PUMP REV #1"
BLU
BLU
BLU
BLU
"PUMP FWD #2"
"MIXER FWD #4"
"MIXER REV #3"
LID SWITCH
P.S.
LID SWITCH
D.S.
RED/BLK
4
3
1
6
BRN
BRN
BRN
BRN
WHT/GRN
WHT/GRN
HOT OIL
MATERIAL
SENSOR
14
45762 HYD. OIL
COOLER
13
HEATER BLUE
HEATER BLUE
HEATER BLUE
TRIGGER RED
TRIGGER GRN
SENSOR BLACK
SENSOR WHITE
HEATER GREEN
HEATER WHITE
HEATER BLACK
JUNCTION BOX WIRING
Fig. 9-11 Electrical Schematic
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-20
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
FIG.
ITEM
PART NO.
DESCRIPTION
QTY.
Fig. 9-12
1
45525
CONTROL BOX ASSEMBLY
1
2
44984
WIRING HARNESS, ENGINE
1
3
44985
CABLE ASSEMBLY, TRIGGER
1
4
44983
CABLE ASSEMBLY, SENSOR
1
5
39608
LID SWITCH
1
6
43465
SENSOR, RTD
2
7
44027
JUNCTION BOX, HOSE
1
8
31512
CIRCUIT BREAKER
1
9
43612
GENERATOR
1
10
43921
CABLE ASSEMBLY, VALVE
1
11
43901
CABLE ASSEMBLY, HOSE
1
12
39602
SOLENOID, FRAME
1
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-21
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
21
1
18
1
22
1
20
1
17
1
16
1
23
1
19
1
7
1
14
1
1
1
2
2
3
2
5
1
4
1
15
1
6
1
9
1
10
1
8
1
12
4
13
1
11
1
9.10 Hot Air Lance
Fig. 9-12 Hot Air Lance (Option)
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-22
Super Shot 60 Melter Part Manual
Chapter 9 Illustrated Parts List
FIG.
ITEM
PART NO.
DESCRIPTION
QTY.
Fig. 9-13
1
45651
MIXING BLOCK
1
2
51401
NIPPLE, 1/4 NPT HEX
2
3
29195
VALVE, 1/4” BALL
2
4
45656
AIR MIXER TUBE
1
5
45658
PROPANE TUBE W/ ORFICE
1
6
45652
BURNER BASE
1
7
28340
BUSHING, 1/4” NPT X 1/8” NPT
1
8
45654
PRIMARY BURNER TUBE
1
9
45657
AIR LANCE TUBE
1
10
45668
AIR ORFICE “A” - .125”
1
11
45653
MAIN BURNER TUBE
1
12
45670
SCREW, #10-32 X 1/2” ALLEN SCREW
4
13
45672
SCREW, #10-32 X 1/2” ALLEN SET
1
14
45671
SCREW, 1/4-20 X 3/8” ALLEN SET
1
15
45669
NUT, 1/8-27 JAM
1
16
27990
PLUG, 1/4” COUNTERSUNK
1
17
45655
HANDLE ASSEMBLY
1
18
45663
BUSHING, 3/8” NPT X 1/4” NPT REDUCER
1
19
45659
VALVE, NEEDLE
1
20
45675
HOSE ASSEMBLY, PROPANE
1
21
45679
COUPLING, 1/4” FPT X M
1
22
45681
COUPLING, 1/4” NPT X FM
1
23
45664
FITTING, 1/4” NPT X 3/8 JIC FERRULE LOCK
1
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………...Illustrated Parts List 9-23
Super Shot 60 Melter Part Manual
Chapter 10 Tools and Accessories
10.0 Tools and Accessories
Crafco Applicator Disk
27162 – 3” Disk Assembly
27163 – 4” Disk Assembly
27164 – 6” Disk Assembly
Crafco Sealing Foot/Protruded
27159 – 1/4” Protruding
27160 – 3/8” Protruding
Crafco Joint Sealing Tip
27146 – 1/4” Sealing Tip
27147 – 3/8” Sealing Tip
Crafco Swivel Disk Applicator
27120 – 3” Swivel Applicator
27130 – 4” Swivel Applicator
Crafco Round Sealing Tip
27170 – 3/8” Sealing Tip
27171 – 1/2” Sealing Tip
Crafco Sealing Foot/Flush
27154 – 1/4” Flush
27155 – 3/8” Flush
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………….....Tools and Accessories 10-1
Super Shot 60 Melter Part Manual
Chapter 10 Tools and Accessories
Crafco Heavy Duty Squeegee with
Aluminum Handle - 27199
27195 – Replacement Blade
Crafco Pour Pot with Wheels - 40200
Super Shot Drip Stopper
Use with 50270 Duckbill
27114 – Tip Adapter
27115 – Shroud, Tip Adapter
Crafco Hand Held Pour Pot - 40201
Crafco Duckbill - 50270
Crafco Heat Lance - 31370
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………….....Tools and Accessories 10-2
Super Shot 60 Melter Part Manual
Chapter 10 Tools and Accessories
Crafco Heat Lance with Regulator
and Attachments - 32259
Crafco Hand Torch w/ 20ft. Hose - 25012
©2015 by Crafco, Inc. All Rights Reserved………………...………………………………..……………….....Tools and Accessories 10-3
©2015 Crafco, Inc.
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