Crafco SUPER SHOT 125 User Manual
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Crafco SUPER SHOT 125 User Manual

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

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Summary of Contents for Crafco SUPER SHOT 125

  • Page 1 SUPER SHOT 125 DIESEL MELTER PART MANUAL - 26378 REV. E...
  • Page 2 Revised: 05/22/02...
  • Page 3 SUPER SHOT 125 DIESEL MELTER...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Super Shot 125 Diesel Melter...................... 5 Safety Precautions........................6-7 Limited Warranty.......................... 7 Warranty Claim Instructions......................8 Specifications..........................9 Introduction........................... 10 Operating Instructions Machine Start Up...................... 11-12 Dispensing the Material/Active Pump Protection............. 13 Loading The Machine/Shutdown and Clean-out Procedures/Storing Machine..14 Instructions For Ordering Parts/Electric Hose Care and Cautions......

  • Page 5: Super Shot 125 Diesel Melter

    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.

  • Page 6: Safety Precautions

    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.

  • Page 7: Limited Warranty

    (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.

  • Page 8: 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. 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.

  • Page 9: Specifications

    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..........

  • Page 10: Introduction

    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: Fill fuel tank with diesel fuel (use #1 in cold weather, #2 in warm weather).

  • Page 11: Machine Start Up

    MACHINE START UP TO START BURNER Fully open the damper vent. Start engine per Engine Manual. Turn “POWER” toggle switch at control box “ON”. Set hot oil temperature at 500°F. and material temperature at manufacturers recommended temperature. CAUTION: If burner does not ignite the first time, turn toggle switch to “OFF.” Turn toggle switch to “ON”...
  • Page 12 MACHINE START UP IT IS STRONGLY RECOMMENDED THAT THE HOSE BE STORED IN THE HOSE HANGER WHEN NOT IN USE OR WHEN IN TRANSIT. THIS WILL HELP PREVENT TWISTING OR KINKING. The heated hose supplied with the machine is Teflon lined with steel over braid. It has a heating element, which runs down the hose to heat the material within the hose.

  • Page 13: Dispensing The Material/Active Pump Protection

    DISPENSING THE MATERIAL NOTE: PROTECTIVE CLOTHING, GLOVES, HARD SOLED SHOES, AND FACE SHIELD OR SAFETY GLASSES SHOULD BE WORN WHEN OPERATING OR FILLING THIS EQUIPMENT. READ ENTIRE MANUAL BEFORE OPERATING. The wand is equipped with 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.

  • Page 14: Loading The Machine/Shutdown And Clean-Out Procedures/Storing Machine

    When shutting down the machine for the day, there are several schools of thought about how much material to leave in the machine. Crafco recommends leaving the melter about half full. This will give a fairly rapid heat up rate in the morning, but will allow enough material to start dispensing right away when the material becomes molten.

  • Page 15: Instructions For Ordering Parts/Electric Hose Care And Cautions

    INSTRUCTIONS FOR ORDERING PARTS Parts may 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.

  • Page 16: Hose Transport Instructions

    HOSE TRANSPORT INSTRUCTIONS Remove hose from jib support and rotate jib support towards front of machine until it locks into position. Wrap hose on hose hanger two complete wraps (Approximately 20 inch diameter). Store wand in support hook. CAUTION: Hose damage will occur if: Hose is bent or moved when cold.

  • Page 17: Maintenance Instructions

    MAINTENANCE INSTRUCTIONS ENGINE See Engine Owner Manual for operating and maintenance instructions. HYDRAULIC SYSTEM Check hydraulic fluid daily. Change hydraulic filter every 250 hours of operation. Change hydraulic fluid every 500 hours of operation. HEAT TRANSFER OIL Check oil level every 8 hours of operation. Change oil every 500 hours of operation. WHEEL BEARINGS Re-pack wheel bearings every 24,000 miles or every two years, using a good grade of bearing grease.

  • Page 18: Maintenance Chart/Service Instructions

    MAINTENANCE CHART . y l c i l t l i f c i l . l i c i l . l i . l l & e l i SERVICE INSTRUCTIONS Conduct a general inspection of your machine at least once a week. Replace all worn or damaged parts, make any necessary adjustments and tighten all loose nuts or screws.

  • Page 19: Recommended Fluids Ans Lubricants/Typical Specifications

    . s l l i o & . s l The following is a list of suitable heat transfer oil to be used in Crafco equipment. & r o l e l i g t i y r t &...

  • Page 20: Super Shot Pump Replacement

    SUPER SHOT PUMP REPLACEMENT Step 1 Bring melter up to temperature as preparation for draining the material tank. Remove pipe cap located at rear of machine and drain tank (CAUTION!! EXTREMELY HOT MATERIAL). Step 2 Remove both guards from the motor mount to access the chain and sprockets. Step 3 Rotate agitator until connecting link is accessible.

  • Page 21: Super Shot Pump Replacement Diagram

    SUPER SHOT PUMP REPLACEMENT...

  • Page 22: Trouble Shooting

    TROUBLE SHOOTING GUIDE HOSE DOES NOT HEAT Step 1: Is the “MATERIAL” temperature at 275°F? YES: Go to step 2. NO: Turn “POWER” toggle switch “ON”. Step 2: Is “HEATED HOSE” light illuminated? YES: Go to step 3. NO: Check for tripped circuit breaker in front panel. YES: Reset circuit breaker.

  • Page 24: Trouble Shooting Guide - Hose Does Not Heat (Continued)

    TROUBLE SHOOTING GUIDE Step 5: Check for 30 amps (cold) or 22-24 amps (hot) at the 3 blue wires in the junction box. (Always use a clamp-on AMP meter to perform this test.) YES: Hose should be operating properly. NO: Go to step 6. Step 6: Check for continuity between three heating element wires (blue) in junction box.

  • Page 26: Trouble Shooting Guide - Material Does Not Dispense

    TROUBLE SHOOTING GUIDE Step 5: Is the top right light on hydraulic valve illuminated (looking at the rear of the hydraulic valve) when trigger is activated? YES: Replace hydraulic cartridge. Go to step 4. PUMP ROTATES BUT NO MATERIAL IS DISCHARGED Step 1: Has the sealant and heated hose had sufficient time to reach temperature? YES: Go to step 2.

  • Page 28: Rtd Sensor - Ohms Vs. Temperature

    RTD SENSOR - OHMS vs. TEMPERATURE The following chart shows what the ohm reading would be for a given temperature.The follow- ing are the instructions for use. Measure the resistance (Ohms) of the sensor in question with an Ohm meter. Find the reading in the chart.

  • Page 29: Diesel Burner Adjustments/Diesel Burner Settings

    DIESEL BURNER ADJUSTMENTS DIESEL BURNER SETTINGS Air Shutter = 7 Air Band = 0 Fuel Pressure = 140 PSI Adjustment Plate = 3 Use fuel and hydraulic pressure gauge kit part number 29960.

  • Page 30: Burner Schematic

    BURNER SCHEMATIC...

  • Page 31: Burner Trouble Shooting

    BURNER TROUBLE SHOOTING BURNER WILL NOT IGNITE Step 1:Check for 12 volts at “POWER” toggle switch. No: Engine key “OFF” Toggle switch “OFF” Blown fuse Broken wire YES: 12 volts at terminal #4 on “MATERIAL” Pak-Stat NO: Bad Pak-Stat Faulty sensor YES: Check for 12 volts at terminal #7 on “OIL”...

  • Page 32: Hydraulic Schematic

    HYDRAULIC SCHEMATIC Flow = 7.5 GPM @ 2850 RPM Relief Valve (RVA) = 1300 PSI Relief Valve (RVM) = 1800 PSI...

  • Page 33: Trouble Shooting Hydraulics

    TROUBLE SHOOTING HYDRAULICS PROBLEM CAUSE REMEDY Mixer will not rotate. Sealant temperature too low. Continue to heat material. T oo many blocks placed at one Mixer will not rotate. Continue to heat material. time. Mixer will not rotate. Inadequate hydraulic flow/pressure. Check hydraulic fluid level. Reset pressure, check flow if Mixer will not rotate.

  • Page 34: Ss125 Diesel Melter Diagrams And Parts

    SS 125 MELTER...
  • Page 35 SS 125 MELTER PARTS LIST...
  • Page 36 SS 125 MELTER...
  • Page 37 SS 125 MELTER PARTS LISTS " "...
  • Page 38 SS 125 MELTER...
  • Page 39 SS 125 MELTER PARTS LIST " 3 " 4 " 2 " 4 " 4...

  • Page 40: Tank Detail Diagram And Parts

    TANK DETAIL...
  • Page 41 TANK DETAIL " 1 " 0 " 1 " 2 " 4 " 2 " 1 " 4 " 1 " 1 " 4...

  • Page 42: Control Box Diagram And Parts

    CONTROL BOX...
  • Page 43 CONTROL BOX " " " ° ° ° ° - ° ° "...

  • Page 44: Engine Assembly Diagram And Parts

    ENGINE ASSEMBLY PRESET ENGINE SPEED = 2850 RPM HOSE GENERATOR OUTPUT = 30 AMPS COLD 24 VAC 3-PHASE...
  • Page 45 ENGINE ASSEMBLY...

  • Page 46: Hydraulic Control Valve Diagram And Parts

    HYDRAULIC CONTROL VALVE...

  • Page 47: Pump/Agitator Motor Assembly Diagram And Parts

    PUMP / AGITATOR MOTOR ASSEMBLY...

  • Page 48: Diesel Burner Diagram And Parts

    DIESEL BURNER...
  • Page 49 DIESEL BURNER...

  • Page 50: Hydraulic Diagram And Parts

    HYDRAULIC DIAGRAM AGITATOR DIRECTION = COUNTERCLOCKWISE MATERIAL PUMP DIRECTION = CLOCKWISE HYDRAULIC FLOW = 7.5 GPM @ 2850 RPM RELIEF VALVE (RVA) = 1300 PSI RELEIF VALVE (RVM) = 1800 PSI...
  • Page 51 HYDRAULIC DIAGRAM " 1 " 4 " " " 0 " " " 0 " " " 8 " " " 2 " " " 4 " " " 0 " 6...

  • Page 52: Electrical Cables And Parts

    ELECTRICAL CABLES...
  • Page 53 ELECTRICAL CABLES - " - " - "...
  • Page 54 Pioneering Leadership and Innovation in Quality Pavement Maintenance Products. 235 South Hibbert Mesa, Arizona 85210 · 480-655-8333 Watts 1-800-528-8242 · Fax 480-655-1712 ÓCopyright 2002 by Crafco, Inc.

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