Crafco SUPER SHOT 125 User manual

SUPER SHOT 125 DIESEL MELTER
PART MANUAL - 26378
REV. E

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Revised: 05/22/02

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SUPER SHOT 125 DIESEL MELTER

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TABLE OF CONTENTS
SuperShot125DieselMelter...................................................................................................... 5
SafetyPrecautions....................................................................................................................... 6-7
LimitedWarranty.......................................................................................................................... 7
WarrantyClaimInstructions......................................................................................................... 8
Specifications............................................................................................................................... 9
Introduction...................................................................................................................................10
Operating Instructions
MachineStartUp...................................................................................................... 11-12
DispensingtheMaterial/ActivePump Protection..................................................... 13
Loading The Machine/Shutdown and Clean-out Procedures/Storing Machine.......14
Instructions For Ordering Parts/Electric Hose Care and Cautions.......................... 15
HoseTransportInstructions..................................................................................... 16
Maintenance
MaintenanceInstructions......................................................................................... 17
MaintenanceChart/ServiceInstructions.................................................................. 18
RecommendedFluidsansLubricants/TypicalSpecifications................................. 19
SuperShotPumpReplacement.............................................................................. 20
SuperShotPump Replacement Diagram............................................................... 21
Trouble Shooting
Trouble Shooting Guide - Hose Does Not Heat...................................................... 22
HoseCircuitDiagram............................................................................................... 23
Trouble Shooting Guide - Hose Does Not Heat (continued)................................... 24
Trouble Shooting Guide - Material Does Not Dispense ......................................... 24
HoseCircuitDiagram............................................................................................... 25
Trouble Shooting Guide - Material Does Not Dispense.......................................... 26
Trouble Shooting Guide - Pump Rotates but No Material Is Discharged................ 26
Trouble Shooting Guide - Material Dispening Rate Too Slow................................. 26
HoseCircuitDiagram............................................................................................... 27
RTDSensor - Ohms vs.Temperature...................................................................... 28
DieselBurnerAdjustments/Diesel Burner Settings.................................................. 29
BurnerSchematic..................................................................................................... 30
BurnerTrouble Shooting.......................................................................................... 31
HydraulicSchematic................................................................................................. 32
Trouble ShootingHydraulics.................................................................................... 33
Parts SS125Diesel MelterDiagramsandParts............................................................... 34-39
TankDetail Diagram and Parts................................................................................ 40-41
ControlBoxDiagramandParts............................................................................... 42-43
EngineAssemblyDiagram and Parts...................................................................... 44-45
HydraulicControlValve DiagramandParts............................................................ 46
Pump/AgitatorMotorAssemblyDiagramandParts................................................ 47
DieselBurnerDiagramandParts............................................................................ 48-49
HydraulicDiagramandParts................................................................................... 50-51
ElectricalCablesandParts...................................................................................... 52-53

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SUPER SHOT
125 DIESEL MELTER
This manual is furnished with each new CRAFCO SUPER SHOT 125 DIESEL MELTER.
This manual will help your machine operators learn to run the melter applicator properly
and understand its mechanical functions for trouble-free operation.
Your CRAFCO SUPER SHOT 125 DIESEL MELTER is designed to give excellent service
and save maintenance expense. However, as with all specially engineered equipment, you
can get best results at minimum costs if:
1. You operate your machine as instructed in this manual.
2. Maintain your machine regularly as stated in this manual.
WARNING: The engine exhaust from this product contains chemicals
known to the State of California to cause cancer, birth defects or other
reproductive harm. Operate in well ventilated area only. Engine exhaust
is deadly.

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SAFETY PRECAUTIONS
•High operating temperatures of sealant and machine require protective clothing,
hard-soled shoes and heat resistant gloves to be worn by operator.
•Always wear eye protection.
•Observe all CAUTION AND WARNING signs posted on machine.
•Avoid the entrance of water into any part of the machine. Water will displace heat transfer
oil or sealant, which could be hazardous to personnel surrounding the machine when it
reaches operating temperatures.
•Avoid bodily contact with hot sealant material or heat transfer oil, serious burns may
result.
•Read Operator Manual thoroughly before operating machine.
•Make sure operator is familiar with machine operation.
•Do not operate in closed building or confined areas.
•Shut-down burner and engine prior to refilling diesel tank.
•When adding solid material to sealant tank, stop mixer, lift lid, place material onto lid and
close lid before restarting mixer. Hot material could splash and cause serious burns if this
procedure is not followed.
•Keep hands, feet, and clothing away from all moving parts.
•Always keep a fire extinguisher near the unit. Maintain extinguisher properly and be
familiar with its use.
•DO NOT exceed 525°F for heat transfer oil temperature.
•DO NOT overfill heat transfer oil level. Expansion of oil during heat up could cause
overflow. With machine in level position, check oil each day before starting burner, add oil
to top mark on dipstick if required (at 70°F.). Use only recommended heat transfer oil
and change after 500 hours of operation or one year, whichever occurs first.
•Follow operating instructions for starting and shut-down of burner. See Operating
Instructions.
•Calibrate temperature control prior to initial operation and each 50 hours of operation.
See Temperature Control Calibration.

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SAFETY PRECAUTIONS
•Replace any hoses which show signs of wear, fraying, or splitting. Be sure all fittings and
joints are tight and leak-proof, each time machine is used.
•Precaution is the best insurance against accidents.
•The melter should not be left unattended with burner lit.
•Tighten all bolts and screws after every 100 hours of operation.
•Crafco, Inc. assumes no liability for an accident or injury incurred through improper use of
the machine.
LIMITED WARRANTY
Crafco, Inc., through its authorized distributor, will replace for the original purchaser free of
charge any parts found upon examination by the factory at Mesa, Arizona, to be
defective in material or workmanship. This warranty is for a period within 60 days of
purchase date, but excludes engine or components, tires, and battery as these items are
subject to warranties issued by their manufacturers.
After 60 days, Crafco, Inc., warrants structural parts, excluding heating system, hydraulic
components, material pump and hoses, hot oil pump, applicator valves, and electrical
components for a period of (1) one year from date of delivery. Crafco, Inc., shall not be
liable for parts that have been damaged by accident, alteration, abuse, improper lubrica-
tion/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.
WARNING: Use of replacement parts other than genuine Crafco parts
may impair the safety or reliability of your equipment and nullifies any
warranty.

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WARRANTY CLAIM INSTRUCTIONS
Please follow the instructions stated below when calling in a warranty claim. Failure to
follow these procedures may be cause to void the warranty.
1. 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.
2. On contacting the distributor, be prepared to identify the machine type, model
number, and serial number, also, the date of purchase if available.
3. Should the cause of the malfunction be a defective part, the distributor will advise
you of the procedure to follow for a replacement.
4. The warranty is valid only for parts, which have been supplied or recommended by
Crafco, Inc.
If you have any additional questions regarding warranty repairs and parts, please do not
hesitate to call toll free 1-800-528-8242.
CRAFCO, INCORPORATED
235 SOUTH HIBBERT DRIVE
MESA, AZ 85210
480-655-8333
Toll Free 1-800-528-8242

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SPECIFICATIONS
Vat Capacity..................................................................125 Gallons
Melt Capacity................................................................90 Gallons/Hour
Heat Transfer Oil Required...........................................34 Gallons at 70°F.
Tank Construction.........................................................Double Boiler Type
Tank Opening Size....................................................... 14” X 18”
Maximum Heat Input.................................................... 250,000 BTU’s
Burner and Temperature Control..................................Diesel-Forced Air
Thermostatic Control
Engine - Isuzu...............................................................Twin Cylinder
Model 3LB1 - Diesel 25.4 BHP @ 3600 RPM
Hydraulic Drive Mechanism..........................................All hydraulic with infinite
speed on mixer and material
pump.
Mixer.............................................................................Full sweep mixer with two
horizontal paddles
vertical risers.
Axle....................................................................................Single-5,200Lb.Torsional
Tires (2)........................................................................ ST225/75R15 Load Range D
Dry Weight....................................................................Approximately 2,600 Lbs.
Diesel Tank Capacity.................................................... 24 Gallons
Hydraulic Tank Capacity............................................... 24 Gallons

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SUPER SHOT 125 DIESEL MELTER
OPERATING INSTRUCTIONS
INTRODUCTION
The CRAFCO SUPER SHOT 125 MELTER was developed to melt Crafco brand
sealant. However, it will work well with most road asphalt and federal specification crack or
joint sealant.
DO NOT operate machine without following these instructions:
1. Fill fuel tank with diesel fuel (use #1 in cold weather, #2 in warm weather).
2. Check engine crankcase oil level (refer to Engine Operator’s Manual).
3. Check hydraulic fluid level, at 70°F. Add fluid if necessary.
4. Check heat transfer oil level, at 70°F., the oil should be at the full mark on the
dipstick. DO NOT overfill or spillage may occur when oil is heated and
expands.
5. All toggle switches should be turned “OFF” and both temperature control dials at
minimum settings.
6. Remember that safe operation of this equipment is the operator’s responsibility.
CAUTION:
Extreme care must be used when operating this equipment. Safety is the result
of being careful and paying attention to details. Remember the diesel flame is
about 2,200°F. Certain exposed parts of this machine when operating reach
500°F.; the sealant as high as 400°F. and the hydraulic fluid may reach 200°F.
Always wear protective clothing, hard-soled shoes, and eye protection. 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 250 hours.