Crafco SUPER SHOT 125 User manual

Parts Manual - 26631
Revision D
SUPER SHOT 125 DIESEL ME LT ER
ALL MODELS

Fill in appropriate fields that apply to this machine
Machine S/N: ________________________________
1st Hose S/N: _______________________________
2nd Hose S/N: _______________________________
1st Pump S/N: _______________________________
2nd Pump S/N: ______________________________
Engine S/N: ________________________________
Compressor S/N: _____________________________
Gear Box S/N (Patcher): ______________________
Blower S/N (Magnum): ________________________

Super Shot 125 Diesel Melter Part Manual
Revisions
Revision Date
A) Converted to Microsoft Word from ICM Pdf file. Changed manual layout. 4/2016
B) Updated a typo error and changed some chapter text for consistency 8/2016
C) Removed SS125DCRC, added SS125DC100CFM 6/2017
D) Compressor altitude limits in Section 5.5; Air Comp Oil Changes Sec. 6.12;
Air Comp Oil Sec. 6.16; Temp Switch Table 10-39; Temp Switch Table 10-
40, Diagnostic Trouble Codes Sec. 9.5 8/9/17

Super Shot 125 Diesel Melter
PN 43600
Super Shot 125 Diesel Melter with Compressor 100 CFM
PN 47400

***Export Only***
Super Shot 125 Diesel Melter Compressor 70 CFM
PN 45500
***Export Only***
Super Shot 125 Diesel Melter Compressor 53.8 CFM
PN 43800

Super Shot 125 Diesel Melter Part Manual
Table of Contents
1.0 About This Manual..................................................................................................................1-1
1.1 How to use this manual:......................................................................................................1-1
2.0 Safety Precautions..................................................................................................................2-1
2.1 General Safety....................................................................................................................2-1
2.2 Personal Safety...................................................................................................................2-1
2.3 Equipment or Operational Safety......................................................................................... 2-1
2.4 Safety Symbols and Notices................................................................................................2-2
3.0 Limited Warranty.....................................................................................................................3-1
3.1 Warranty Claim Instructions................................................................................................. 3-2
4.0 Machine Specifications........................................................................................................... 4-1
5.0 Operating Instructions.............................................................................................................5-1
5.1 Preparing the Machine for Start Up .....................................................................................5-1
5.2 Machine Start Up for 43600, 43800 and 45500................................................................... 5-2
5.3 Machine Start Up for 47400................................................................................................. 5-5
5.4 Altitude Compensation System (43600) .............................................................................. 5-7
5.5 Air Compressor: PN 43800, 45500 and 47400.................................................................... 5-7
5.6 About the Heated Hose, Wand, Valve, and Tip Guard......................................................... 5-8
5.7 Operating the Electric Hose................................................................................................. 5-9
5.8 Dispensing the Material..................................................................................................... 5-10
5.9 About the Active Screen Pump Protection......................................................................... 5-10
5.10 Loading Material into the Sealant Tank ........................................................................... 5-11
Material Tank Depth Chart......................................................................................... 5-125.10.1
5.11 Shutting Down and Cleaning Out the Machine (43600, 43800 & 45500) ......................... 5-13
5.12 Shutting Down and Cleaning Out the Machine (47400)................................................... 5-14
5.13 Storing the Electric Hose for Transport............................................................................ 5-15
5.14 Overnight Heater Use...................................................................................................... 5-16
5.15 Mounting a Skid Machine................................................................................................ 5-17
5.16 Shot Timer Option........................................................................................................... 5-18
5.17 Storing the Machine ........................................................................................................ 5-20
6.0 Maintenance Instructions........................................................................................................6-1
6.1 Engine................................................................................................................................. 6-1
6.2 Hydraulic System ................................................................................................................6-1
6.3 Heat Transfer Oil.................................................................................................................6-1
6.4 Wheel Bearing.....................................................................................................................6-1

Super Shot 125 Diesel Melter Part Manual
Table of Contents
6.5 Material Sensor Tube ..........................................................................................................6-1
6.6 Cleaning Material Tank and Sensor Area ............................................................................6-1
6.7 Lug Nuts..............................................................................................................................6-2
6.8 Brakes.................................................................................................................................6-2
6.9 Tongue Jack........................................................................................................................6-2
6.10 Temperature Control Calibration........................................................................................6-3
6.11 Cleaning the Melter ...........................................................................................................6-3
6.12 Maintenance Chart ............................................................................................................6-4
6.13 Service Instructions ...........................................................................................................6-5
6.14 General Maintenance Parts...............................................................................................6-5
6.15 Recommended Spare Parts...............................................................................................6-6
6.16 Recommended Fluids and Lubricants................................................................................6-6
6.17 Applicable Brands of Heat Transfer Oil..............................................................................6-7
6.18 Typical Heat Transfer Oil Specifications ............................................................................6-7
6.19 Material Pump Replacement..............................................................................................6-8
6.20 Wand Repair Instructions ................................................................................................6-11
Cable Replacement...................................................................................................6-116.20.1
Switch Replacement..................................................................................................6-116.20.2
Terminal Block Replacement.....................................................................................6-116.20.3
Wand Handle Replacement.......................................................................................6-126.20.4
6.21 Burner Fuel Filter Replacement.......................................................................................6-15
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
How to Check Wire Continuity .....................................................................................7-17.3.1
How to Check RTD Sensor..........................................................................................7-17.3.2
7.4 Checking Amperage............................................................................................................7-2
8.0 Troubleshooting (43600, 43800 and 45500)............................................................................8-1
8.1 Diesel Burner Troubleshooting ............................................................................................8-1
Symptoms: Burner will Not Ignite.................................................................................8-18.1.1
Burner Electrical Troubleshooting................................................................................8-28.1.2
Excessive Smoke Coming Out of Exhaust Stack.........................................................8-78.1.3
Burner Lights but Shuts Down After 15 Seconds .........................................................8-78.1.4
Testing DC Controller..................................................................................................8-88.1.5

Super Shot 125 Diesel Melter Part Manual
Table of Contents
Burner Fuel Solenoid Testing...................................................................................... 8-88.1.6
Burner Ignition Coil Testing .........................................................................................8-98.1.7
Bleeding the Burner.....................................................................................................8-98.1.8
Sealant is Heating Slowly.......................................................................................... 8-118.1.9
8.2 Mixer Troubleshooting....................................................................................................... 8-12
Symptom: Mixer Does Not Rotate ............................................................................. 8-128.2.1
Mixer Electrical Troubleshooting................................................................................ 8-138.2.2
Mixer Hydraulic Troubleshooting ............................................................................... 8-188.2.3
8.3 Hose Troubleshooting ....................................................................................................... 8-21
Symptom: Hose Does Not Heat................................................................................. 8-218.3.1
Hose Electrical Troubleshooting................................................................................ 8-218.3.2
Symptom: Trigger is not Working............................................................................... 8-268.3.3
RTD Sensor Ohms vs. Temperature ......................................................................... 8-278.3.4
8.4 Pump Troubleshooting ...................................................................................................... 8-29
Symptom: Material Does Not Dispense When the Pump is Activated........................ 8-298.4.1
Pump Electrical Troubleshooting............................................................................... 8-308.4.2
Pump Hydraulic Troubleshooting............................................................................... 8-368.4.3
9.0 Troubleshooting (47400)......................................................................................................... 9-1
9.1 Diesel Burner Troubleshooting............................................................................................ 9-1
Symptom: Burner will Not Ignite................................................................................... 9-19.1.1
Burner Electrical Troubleshooting................................................................................9-39.1.2
Excessive Smoke Coming Out of Exhaust Stack......................................................... 9-89.1.3
Burner Lights but Shuts Down After 15 Seconds......................................................... 9-89.1.4
Testing DC Controller.................................................................................................. 9-99.1.5
Burner Fuel Solenoid Testing...................................................................................... 9-99.1.6
Burner Ignition Coil Testing ....................................................................................... 9-109.1.7
Bleeding the Burner................................................................................................... 9-109.1.8
Sealant is Heating Slowly.......................................................................................... 9-129.1.9
9.2 Mixer Troubleshooting....................................................................................................... 9-13
Symptom: Mixer Does Not Rotate ............................................................................. 9-139.2.1
Mixer Electrical Troubleshooting................................................................................ 9-149.2.2
Mixer Hydraulic Troubleshooting ............................................................................... 9-199.2.3
9.3 Hose Troubleshooting ....................................................................................................... 9-22
Symptom: Hose Does Not Heat................................................................................. 9-229.3.1
Hose Electrical Troubleshooting................................................................................ 9-229.3.2

Super Shot 125 Diesel Melter Part Manual
Table of Contents
Symptom: Trigger is not Working...............................................................................9-279.3.3
RTD Sensor Ohms vs. Temperature..........................................................................9-289.3.4
9.4 Pump Troubleshooting.......................................................................................................9-30
Symptom: Material Does Not Dispense When the Pump is Activated........................9-309.4.1
Pump Electrical Troubleshooting ...............................................................................9-319.4.2
Pump Hydraulic Troubleshooting...............................................................................9-379.4.3
9.5 Engine Diagnostic Trouble Codes (DTC)...........................................................................9-38
How to use the Diagnostic Trouble Code Table.........................................................9-389.5.1
Engine DTC Table (47400)........................................................................................9-389.5.2
10.0 About the Illustrated Parts List.............................................................................................10-1
10.1 Ordering Crafco Parts......................................................................................................10-1
10.2 Super Shot 125 Diesel Melter Assembly 43600...............................................................10-2
10.3 Super Shot 125 Diesel Melter Comp. 100 CFM PN 47400 ..............................................10-6
10.4 ***Export Only*** Super Shot 125 Diesel Melter Comp. 53.8 CFM PN 43800...............10-10
10.5 ***Export Only*** Super Shot 125 Diesel Melter Comp. 70 CFM PN 45500...................10-14
10.6 Tank Assembly, All Models............................................................................................10-18
10.7 Control Box Assembly, 43600, 43800, and 45500.........................................................10-20
10.8 Control Box Assembly, 47400........................................................................................10-24
10.9 Engine Assembly: PN 43600.........................................................................................10-28
10.10 Engine Assembly: PN 47400.......................................................................................10-30
10.11 Engine Assembly: PN 43800.......................................................................................10-32
10.12 Engine Assembly: PN 45500.......................................................................................10-34
10.13 Hydraulic Control Valve Assembly: PN 45420 All Models............................................10-36
10.14 Material Flow Control Assembly: PN 46060 All Models................................................10-38
10.15 Pump/Mixer Motor Assembly: PN 44832 All Models....................................................10-40
10.16 Diesel Burner Assembly: PN 46380 All Models............................................................10-42
10.17 Hydraulic Diagram: PN 26554 (43600) .......................................................................10-44
10.18 Hydraulic Diagram: PN 26662N (47400)......................................................................10-48
10.19 Hydraulic Diagram: PN 26663 (43800 &45500 ***Export Engine Only***)...................10-52
10.20 Diesel Fuel Line Schematic – Non-Compressor...........................................................10-56
10.21 Diesel Fuel Line Schematic – Compressors ................................................................10-58
10.22 Electrical Schematic: PN 43600...................................................................................10-60
10.23 Electrical Schematic: PN 47400...................................................................................10-62
10.24 Electrical Schematic: ***Export Only*** PN 43800 and 45500 .....................................10-64
10.25 Air Compressor Assembly: ***Export Only*** PN 45345 (43800, and 45500) ..............10-66

Super Shot 125 Diesel Melter Part Manual
Table of Contents
10.26 Air Compressor Assembly: PN 47480N (47400).......................................................... 10-68
10.27 Hydraulic Compressor Valve Assembly: PN 45425 (43800, 47400 and 45500)........... 10-70
10.28 High Output Air Lance Assembly................................................................................. 10-72
10.29 Wand Assembly .......................................................................................................... 10-74
10.30 Optional Engine Cover for Compressor Models........................................................... 10-76
10.31 Hot Air Lance.............................................................................................................. 10-78
11.0 Tools and Accessories........................................................................................................11-1