Crafco Super Shot 125 Parts Manual
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Crafco Super Shot 125 Parts Manual

43600;47400;43800; 45500
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SUPER SHOT 125 DIESEL MELTER
ALL MODELS
Parts Manual - 26631
Revision D

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Summary of Contents for Crafco Super Shot 125

  • Page 1 SUPER SHOT 125 DIESEL MELTER ALL MODELS Parts Manual - 26631 Revision D...
  • Page 2 Fill in appropriate fields that apply to this machine Machine S/N: _ _______________________________ Hose S/N: _______________________________ Hose S/N: _______________________________ Pump S/N: _______________________________ Pump S/N: ______________________________ Engine S/N: ________________________________ Compressor S/N: _____________________________ Gear Box S/N (Patcher): ______________________ Blower S/N (Magnum): ________________________...
  • Page 3 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;...
  • Page 4 Super Shot 125 Diesel Melter PN 43600 Super Shot 125 Diesel Melter with Compressor 100 CFM PN 47400...
  • Page 5 ***Export Only*** Super Shot 125 Diesel Melter Compressor 53.8 CFM PN 43800 ***Export Only*** Super Shot 125 Diesel Melter Compressor 70 CFM PN 45500...

  • Page 6: Table Of Contents

    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 ....................
  • Page 7 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 ......................
  • Page 8 Super Shot 125 Diesel Melter Part Manual Table of Contents 8.1.6 Burner Fuel Solenoid Testing ..................8-8 8.1.7 Burner Ignition Coil Testing ..................8-9 8.1.8 Bleeding the Burner ..................... 8-9 8.1.9 Sealant is Heating Slowly ..................8-11 8.2 Mixer Troubleshooting ....................... 8-12 8.2.1...
  • Page 9 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 ....................
  • Page 10 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 ......................
  • Page 11 Super Shot 125 Diesel Melter Part Manual List of Figures Fig. 5-1 Hydraulic Fluid Level and Temp. Gauge ................5-2 Fig. 5-2 Heat Transfer Oil Dip Stick ....................5-2 Fig. 6-1 Lug bolt Tightening Sequence ..................6-2 Fig. 6-2 Temperature Control Calibration ..................6-3 Fig.
  • Page 12 Fig. 10-2 Super Shot 125 Diesel Melter Comp. 100 CFM PN 47400 ........... 10-6 Fig. 10-3 ***Export Only*** Super Shot 125 Diesel Melter Comp. 53.8 CFM PN 43800 .... 10-10 Fig. 10-4 ***Export Only*** Super Shot 125 Diesel Melter Comp. 70 CFM PN 45500 ....10-14 Fig.
  • Page 13 Super Shot 125 Diesel Melter Part Manual List of Figures Fig. 10-28 Hydraulic Diagram w/Compressor 46400EC63, 46400SC63 ........10-69 Fig. 10-29 Hydraulic Diagram w/Compressor 46400EC63, 46400SC63 ........10-69 Fig. 10-30Hydraulic Compressor Valve Assembly: PN 45425 (43800, 47400 and 45500) ..10-70 Fig.10-31 High Output Air Lance Assembly ................
  • Page 14 Super Shot 125 Diesel Melter Part Manual List of Tables Table 2-1 Safety Symbols and Notices ..................2-2 Table 2-2 Safety Symbols and Notices (continued) ............... 2-3 Table 4-1 Machine Specifications ....................4-1 Table 5-1 Preparing the Machine for Start Up ................5-1 Table 5-2 Starting the Burner ......................
  • Page 15 Super Shot 125 Diesel Melter Part Manual List of Tables 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 ............
  • Page 16 Super Shot 125 Diesel Melter Part Manual List of Tables Table 9-4 Burner Electrical Troubleshooting (continued) ............... 9-4 Table 9-5 Burner Electrical Troubleshooting (continued) ............... 9-5 Table 9-6 Burner Electrical Troubleshooting (continued) ............... 9-6 Table 9-7 Smoke Coming Out of Exhaust Stack ................9-8 Table 9-8 Burner Lights but Shuts Down After 15 Seconds ............
  • Page 17 Table 10-6 Super Shot 125 Diesel Melter Comp. 100 CFM PN 47400 (continued) ..... 10-9 Table 10-7 ***Export Only*** Super Shot 125 Diesel Melter Comp. 53.8 CFM PN 43800 ..10-11 Table 10-8 ***Export Only*** SS125 Diesel Melter Comp. 53.8 CFM PN 43800 (continued) ..10-12 Table 10-9 ***Export Only*** SS125 Diesel Melter Comp.
  • Page 18 Super Shot 125 Diesel Melter Part Manual List of Tables Table 10-32 Hydraulic Diagram: PN 26663 (43800 & 45500 ***Export Engine Only***) .... 10-54 Table 10-33 Hydraulic Diagram: PN 26663 (43800 & 45500 ***Export Engine Only***) .... 10-55 Table 10-34 Diesel Fuel Line Schematic – Non-Compressor ............ 10-57 Table 10-35 Diesel Fuel Line Schematic - Compressors ............

  • Page 19: About This Manual

    Chapter 1 Introduction 1.0 About This Manual This manual is supplied with each new Crafco Super Shot 125 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.

  • Page 21: Safety Precautions

    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.

  • Page 22: Safety Symbols And Notices

    Super Shot 125 Diesel 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.

  • Page 23: Table 2-2 Safety Symbols And Notices (Continued)

    Super Shot 125 Diesel 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.

  • Page 25: Limited Warranty

    CAUTION Use of replacement parts other than genuine Crafco parts may impair the safety or reliability of your equipment and nullifies any warranty. ©2017 by Crafco, Inc. All Rights Reserved………………………………………………………….…Warranty Information 3-1...

  • Page 26: Warranty Claim Instructions

    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.

  • Page 27: Machine Specifications

    26 Gal (98L) 30 Gal (113L) Capacity 100CFM 53.8CFM 70CFM (2,831 l/m) @ (1,525 l/m) @ (1,982 l/m) @ Air Compressor 125 PSI 125 PSI 125 PSI (8.61 bar) (8.61 bar) (8.61 bar) ©2017 by Crafco, Inc. All Rights Reserved……………………………………………………………Machine Specifications 4-1...

  • Page 29: Operating Instructions

    Super Shot 125 Diesel Melter Part Manual Chapter 5 Operating Instructions 5.0 Operating Instructions The Crafco Super Shot 125 Diesel Melter 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.

  • Page 30: Machine Start Up For 43600, 43800 And 45500

    Bottom of Dipstick Fig. 5-2 Heat Transfer Oil Dip Stick 5.2 Machine Start Up for 43600, 43800 and 45500 Table 5-2 Starting the Burner Step Action Fully open the exhaust stack cover. ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-2...
  • Page 31 Adjust the temperature dial to the manufacturer’s recommended temperature. Note: The hose reaches operating temperature in approximately 30 minutes. After the hose reaches the temperature set point, the light in the control box marked “HEATED HOSE” turns off. ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-3...

  • Page 32: Table 5-3 Starting The Burner For Electric Hose (Continued)

    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. ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-4...

  • Page 33: Machine Start Up For 47400

    Jamming the mixer can cause the hydraulic oil to overheat and damage the machine. The hose automatically turns “ON” when the material temperature reaches 275°F (135°C). The red light marked ‘HEATED HOSE” will illuminate when the hose control is calling for heat. ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-5...

  • Page 34: Table 5-5 Starting The Burner For Electric Compressor (Continued)

    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. ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-6...

  • Page 35: Altitude Compensation System (43600)

    2,624 ft. (800 Meters) indicating that the system is active. 5.5 Air Compressor: PN 43800, 45500 and 47400 Three machine models in the Super Shot 125 series include an air compressor unit which is designed to assist in the cleaning of debris from cracks and joints.

  • Page 36: About The Heated Hose, Wand, Valve, And Tip Guard

    GEAR CLAMP ONTO THE DUCKBILL VALVE 50270 TRIGGER LOCK MAKE SURE TRIGGER LOCK IS TIP GUARD IS HELD IN PLACE ENGAGED AT ALL TIMES EXCEPT WITH 2 BOLTS WHEN APPLYING MATERIAL! 50278 ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-8...

  • Page 37: Operating The Electric Hose

    Do not twist or bend 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. Follow all machine instructions in this manual.

  • Page 38: Dispensing The Material

    360 degrees around the pump whenever the sealant agitator is engaged. The active screen protects the pump from foreign object damage and self-cleans as it rotates around the sealant pump and suction port. ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-10...

  • Page 39: Loading Material Into The Sealant Tank

    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. ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-11...

  • Page 40: Material Tank Depth Chart

    387.25 30.22 114.46 106.95 404.85 25.57 96.86 111.60 422.45 20.92 79.26 116.25 440.05 16.27 61.66 120.90 457.66 11.62 44.06 125.55 475.26 6.97 26.46 130.20 492.86 2.32 8.86 28.5 132.52 501.66 0.00 ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-12...

  • Page 41: Shutting Down And Cleaning Out The Machine (43600, 43800 & 45500)

    Action CAUTION 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.

  • Page 42: Shutting Down And Cleaning Out The Machine (47400)

    Action CAUTION 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.

  • Page 43: Storing The Electric Hose For Transport

    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. ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-15...

  • Page 44: Overnight Heater Use

    Disconnect the heater when using the machine’s burner system. CAUTION Do not use the heater without heat transfer oil in the tank. Doing so will overheat and damage the heater, and it will have to be replaced. ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-16...

  • Page 45: Mounting A Skid Machine

    Leave 15” clearance around the machine. Keep this area clear of any flammable material such as empty sealant boxes. Failure to keep this area clear could result in damage and possible fire! ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-17...

  • Page 46: Shot Timer Option

    Once the material is flowing properly release the wand trigger and change the toggle switch labeled “PUMP” to “Marker”. ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-18...

  • Page 47: Table 5-16 Shot Timer Option (Continued)

    Locate the shot size control box (It will be near the main control box). Inside this box is a knob that controls how long the pump stays running each time you pull the trigger (1/4 to 5 seconds). Crafco recommends setting the dial between ¼ and ½ for the shot size.

  • Page 48: Storing The Machine

    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. ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….Operating Instructions 5-20...

  • Page 49: Maintenance Instructions

    Once the walls and sensor guard areas are cleaned, remove all the loose chunks from the tank, and vacuum out any smaller pieces. ©2017 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-1...

  • Page 50: Lug Nuts

    Fig. 6-1 Lug bolt Tightening Sequence. 4-BOLT 5-BOLT 6-BOLT Fig. 6-1 Lug bolt Tightening Sequence 6.8 Brakes Check the brakes daily. 6.9 Tongue Jack Lubricate the tongue jack, using a good grade of bearing grease. ©2017 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-2...

  • Page 51: Temperature Control Calibration

    Calibration Mark Fig. 6-2 Temperature Control Calibration 6.11 Cleaning the Melter We recommend using Orange-Sol industrial cleaner for cleaning the exterior of the machine. Here is the website for the cleaner; https://www.orange-sol.com/industrial-formula/. ©2017 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-3...

  • Page 52: Maintenance Chart

    Once a year or as needed the material tank Scrape out built up material Material Sensor Guard around guard For a list of parts required for maintenance see Table 6-3 General Maintenance Parts. ©2017 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-4...

  • Page 53: Service Instructions

    Refer to the material manufacturer’s instructions for recommendations. Table 6-1 Maintenance Chart Follow the recommended maintenance per For service, find a list of authorized Distributors and service centers at Crafco.com/Distributors. 6.14 General Maintenance Parts Table 6-3 General Maintenance Parts Quantity...

  • Page 54: Recommended Spare Parts

    PN 43600: Super Shot 125 Diesel Melter PN 47400: Super Shot 125 Diesel Melter 100 CFM Compressor PN 43800: Super Shot 125 Diesel Melter 53.8 CFM Air Compressor PN 45500: Super Shot 125 Diesel Melter 70 CFM Air Compressor ©2017 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-6...

  • Page 55: Applicable Brands Of Heat Transfer Oil

    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.

  • Page 56: Material Pump Replacement

    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. ©2017 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-8...

  • Page 57: Table 6-8 Material Pump Replacement (Continued)

    Clean any sealant from the top of the pump mounting plate and clean the shaft holes. (See Fig. 6-3 Material Pump Replacement) CAUTION Premature pump wear results if the pump mounting plate and bolt holes are not properly cleaned. ©2017 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-9...

  • Page 58: Fig. 6-3 Material Pump Replacement

    Super Shot 125 Diesel Melter Part Manual Chapter 6 Maintenance Instructions PUMP ASSEMBLY BOLTS PUMP MOUNTING BOLTS PUMP ASSEMBLY PUMP MOUNTING PLATE TANK BOTTOM Fig. 6-3 Material Pump Replacement ©2017 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-10...

  • Page 59: Wand Repair Instructions

    3. Replace terminal block and install (2) #10-32 x 5/8” screws and tighten. 4. Follow steps 10-12 from 6.20.1 above. If actuator, pin, and spring need to be reinstalled see Fig.6-7 Actuator Spring Location Fig.6-8 Actuator / Trigger Assembly. ©2017 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-11...

  • Page 60: Wand Handle Replacement

    5. Flip wand over and remove the remaining (2) 1/4-20 x 1/2” screws from the handle. Remove handle from wand tube. 6. Install new handle by reversing previous steps. Fig.6-4 Switch Wire Location Fig.6-5 Wire Routing ©2017 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-12...

  • Page 61: Fig.6-6 Terminal Block Wiring

    Super Shot 125 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Fig.6-6 Terminal Block Wiring Fig.6-7 Actuator Spring Location ©2017 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-13...

  • Page 62: Fig.6-8 Actuator / Trigger Assembly

    Super Shot 125 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Pin location Switch lever location Spring location Fig.6-8 Actuator / Trigger Assembly ©2017 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-14...

  • Page 63: Burner Fuel Filter Replacement

    It may take a couple cycles to fill the new fuel filter and bleed the fuel system. Once the burner is running, check for any fuel leaks and tighten the filter if needed. Turn off the main power switch and power key. ©2017 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-15...

  • Page 65: How To Use A Multimeter

    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. ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…How to Use a Multimeter 7-1...

  • Page 66: Checking Amperage

    DC Voltage • Everything except Generator Use these ports. Do not AC Voltage ~ use the fuse port, it is for • Generator Output amps Fig. 7-1 Standard Multimeter ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…How to Use a Multimeter 7-2...

  • Page 67: Fig. 7-2 Clamp - On Amp Meter/Multimeter

    • Hyd. Coils AC Amps ~ • Burner Ignition Coil • Hose Current Audible Continuity • Hose, Wand, and wire connection Fig. 7-2 Clamp – On Amp Meter/Multimeter ©2017 by Crafco, Inc. All Rights Reserved………………..…………………………………..….…How to Use a Multimeter 7-3...

  • Page 69: Troubleshooting (43600, 43800 And 45500)

    • Yes, you need to bleed your burner, go to Did you run the diesel tank low on fuel or empty? Table 8-12 Bleeding the Diesel Burner. • No, go to Step 8. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-1...

  • Page 70: Burner Electrical Troubleshooting

    • Yes, replace or repair damaged wire and Check for loose or broken wires between circuit breaker and battery positive cable. repeat Step 3. • No, go to step 3. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-2...

  • Page 71: Table 8-4 Burner Electrical Troubleshooting (Continued)

    Is there 12Vdc between terminal #4 gray wire and terminal #8 black wire of the material between terminal block and terminal #4 of PAKSTAT? the material PAKSTAT. • No, go to Step 7a. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-3...

  • Page 72: Table 8-5 Burner Electrical Troubleshooting (Continued)

    (red wire) and nearby ground source bottom terminal (red wire) of power switch. (black wire)? • No, go to Step 12a. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-4...

  • Page 73: Table 8-6 Burner Electrical Troubleshooting (Continued)

    • No, go to step 14a. • Yes, there should be 12Vdc at all previous Check connections and condition of red steps. battery cable. • No, replace battery cable. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-5...

  • Page 74: Fig. 8-1 Diesel Burner Schematic

    Pressure Switch 12 GA. RED 14 GA. RED 14 GA. RED WHT/GRN WHT/GRN Circuit Breaker Burner Solenoid BLACK BLACK Burner Plug Battery 12vdc Fig. 8-1 Diesel Burner Schematic ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-6...

  • Page 75: Excessive Smoke Coming Out Of Exhaust Stack

    If the reading is between 15-25 ohms the coil is good. If the reading is outside the above range or the meter indicates an open circuit, replace the fuel solenoid. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-7...

  • Page 76: Testing Dc Controller

    If the reading is between 15-25 ohms the coil is good. If the reading is outside the above range or the meter indicates an open circuit, replace the fuel solenoid. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-8...

  • Page 77: Burner Ignition Coil Testing

    “Main Power” and “Burner” switch is “ON” and burner fuel pump will start circulating fuel through the fuel lines, which removes all air bubbles automatically, since it has a return line to the fuel tank. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-9...

  • Page 78: Fig. 8-2 Diesel Burner Electrode Adjustment

    FUEL PRESSURE ADJUSTMENT SCREW COPPER FUEL LINE NUT BLEEDER AIR BAND SCREW AIR SHUTTER AIR BAND FUEL PRESSURE GAUGE KIT FUEL PRESSURE GAUGE Fig. 8-3 Diesel Burner Air Settings ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-10...

  • Page 79: Sealant Is Heating Slowly

    500 hours, or one year, you need to change your oil. 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.

  • Page 80: Mixer Troubleshooting

    Troubleshooting the sight gauge? Check at ambient • No, fill oil to the center of the sight gauge. temperature. See Fig. 5-1 Hydraulic Fluid Level and Temp. Gauge ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-12...

  • Page 81: Mixer Electrical Troubleshooting

    Readjust the lid switch so that the lid completely depresses the switch, and then recheck for 12Vdc. If the same result happens, replace the lid switch. • No, go to Step 4. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-13...

  • Page 82: Table 8-16 Mixer Electrical Troubleshooting (Continued)

    Is there 12Vdc between orange wire labeled ORN-2 terminal #3 and terminal #5 black wires between terminal #3 and terminal ground of hot oil PAKSTAT? block. • No, go to Step 7. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-14...

  • Page 83: Table 8-17 Mixer Electrical Troubleshooting (Continued)

    • No, go to step 10a. • Yes, there should be 12Vdc at all previous Check connections and condition of red steps. battery cable? • No, replace battery cable. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-15...

  • Page 84: Fig. 8-4 Checking Din Plug Voltage

    Super Shot 125 Diesel Melter Part Manual Chapter 8 Troubleshooting (43600, 43800 and 45500) Fig. 8-4 Checking Din Plug Voltage ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-16...

  • Page 85: Fig. 8-5 Mixer Schematic

    Light Coil AMP Draw 12vdc @2.71 AMPS Mixer Fwd Coil with Light Mixer Pump Rev Toggle Switch Toggle Switch Pump Rev Coil with Light Fig. 8-5 Mixer Schematic ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-17...

  • Page 86: Mixer Hydraulic Troubleshooting

    • No, replace the hydraulic pump. test for you. (Refer to Fig. 8-6 Hydraulic Valve Pressure Setting for flow rate). ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-18...

  • Page 87: Fig. 8-6 Hydraulic Valve Pressure Setting

    Hydraulic Flow Compressor = Front section 16.61 GPM @ 2800 RPM Hydraulic Flow Compressor = Rear section 7.03 GPM @ 2800 RPM Compressor Relief = 2500 PSI Fig. 8-6 Hydraulic Valve Pressure Setting ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-19...

  • Page 88: Fig. 8-7 Din Plug Layout

    DIN PLUG #4 DIN PLUG #3 MIXER FORWARD MIXER REVERSE DIN PLUG #1 DIN PLUG #2 MATERIAL PUMP MATERIAL PUMP REVERSE FORWARD MOUNTING BRACKET Fig. 8-7 Din Plug Layout ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-20...

  • Page 89: Hose Troubleshooting

    • No, go to Step 3. 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). ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-21...

  • Page 90: Table 8-21 Hose Electrical Troubleshooting (Continued)

    Is there 12Vdc between pink wire labeled “PNK-3 and nearby ground source (black customer service technician you should have wire)? been able to find the problem. • No, replace terminal block. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-22...

  • Page 91: Fig. 8-8 Junction Box Voltage Testing

    Chapter 8 Troubleshooting (43600, 43800 and 45500) 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 ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-23...

  • Page 92: Fig. 8-9 Hose Circuit Schematic

    Hose 30-35 AMPS COLD 20-24 AMPS HOT 18 GA. BLUE TFE 12 GA. SO CORD (ALL SIX WIRES) (BLACK, WHITE AND GREEN) Generator Fig. 8-9 Hose Circuit Schematic ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-24...

  • Page 93: Fig. 8-10 Junction Box Wiring

    HEATER BLUE HEATER BLUE HEATER BLUE TRIGGER RED TRIGGER GREEN SENSOR BLACK SENSOR WHITE HEATER GREEN HEATER WHITE HEATER BLACK KETTLE END WAND END Fig. 8-10 Junction Box Wiring ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-25...

  • Page 94: Symptom: Trigger Is Not Working

    C and B wand side. back the hose for repair. • No, this wand needs to be repaired or replaced. Contact Crafco, Inc. to send back the hose for repair. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-26...

  • Page 95: Rtd Sensor Ohms Vs. Temperature

    1443.8 1445.9 1448.0 1450.1 1452.2 1454.3 1456.4 1458.5 1460.6 1462.7 1464.8 1466.9 1469.0 1471.1 1473.2 1475.3 1477.3 1479.4 1481.5 1483.6 1485.7 1487.8 1489.9 1492.0 1494.1 1496.1 1498.2 1500.3 1502.4 1504.5 ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-27...

  • Page 96: Table 8-24 Rtd Sensor Ohms Vs. Temperature (Continued)

    2040.8 2042.8 2044.7 2046.7 2048.7 2050.7 2052.7 2054.7 2056.7 2058.7 2060.7 2062.7 2064.6 2066.6 2068.6 2070.6 2072.6 2074.6 2076.6 2078.5 2080.5 2082.5 2084.5 2086.5 2088.5 2090.4 2092.4 2094.4 ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-28...

  • Page 97: Pump Troubleshooting

    • Yes, go to Table 8-26 Pump Electrical sight gauge? Troubleshooting • No, fill oil to the center of the sight Fig. 5-1 Hydraulic Fluid Level and Temp. gauge. Gauge ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-29...

  • Page 98: Pump Electrical Troubleshooting

    • No, check for a broken wire or poor wire checked in Step 4) and a nearby ground crimp on the red trigger going toward source? the hose. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-30...

  • Page 99: Table 8-27 Pump Electrical Troubleshooting (Continued)

    "B" socket.) • Still no or continuity to both red trigger wire, then call Crafco, Inc. and request an RA# so you can send your hose back for repair. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-31...

  • Page 100: Table 8-28 Pump Electrical Troubleshooting (Continued)

    Is the amber light "ON" when the wand trigger is pulled? (Looking down at the top of the hydraulic valve, Pump forward is the din plug lower right-hand corner, Refer to Fig. 8-7 Din Plug Layout.) ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-32...

  • Page 101: Table 8-29 Pump Electrical Troubleshooting (Continued)

    Is there 12 Vdc between the "Pump" toggle • Yes, replace the toggle switch. switch center post red wire and the blue (4) wires • No, go to Step 10d. ground din plug? ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-33...

  • Page 102: Table 8-30 Pump Electrical Troubleshooting (Continued)

    • No, recheck the amber light, if the light comes "ON" and you do not have 12 Vdc then replace the din plug. ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-34...

  • Page 103: Fig. 8-11 Pump Schematic

    Super Shot 125 Diesel Melter Part Manual Chapter 8 Troubleshooting (43600, 43800 and 45500) Fig. 8-11 Pump Schematic ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-35...

  • Page 104: Pump Hydraulic Troubleshooting

    • No, call a local hydraulic shop to see if they can run a hydraulic pump flow test, using Fig. 8-6 Hydraulic the information in Valve Pressure Setting ©2017 by Crafco, Inc. All Rights Reserved………………...……………Troubleshooting (43600, 43800, and 45500) 8-36...

  • Page 105: Troubleshooting (47400)

    • Yes, you need to bleed your burner, go to Did you run the diesel tank low on fuel or empty? Table 9-12 Bleeding the Diesel Burner. • No, go to Step 9. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-1...

  • Page 106: Table 9-2 Basic Visual Troubleshooting (Continued)

    Is your burner working properly, but it Table 9-13 Sealant is Heating seems like it takes a lot longer to reach Slowly. operating temperature? • No, Call Crafco, Inc. and speak to a customer service technician. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-2...

  • Page 107: Burner Electrical Troubleshooting

    • No, go to step 2b. • Yes, replace or repair damaged wire and Check for loose or broken wires between circuit breaker and battery positive cable. repeat Step 3. • No, go to step 3. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-3...

  • Page 108: Table 9-4 Burner Electrical Troubleshooting (Continued)

    Is there 12Vdc between terminal #4 gray wire and terminal #8 black wire of the material between terminal block and terminal #4 of PAKSTAT? the material PAKSTAT. • No, go to Step 7a. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-4...

  • Page 109: Table 9-5 Burner Electrical Troubleshooting (Continued)

    • No, go to Step 13. source (black wire)? • Yes, replace contact block. Is there 12Vdc between the “Main Power • No, go to Step 14. Switch” (red-3 wire) and nearby ground source (black wire)? ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-5...

  • Page 110: Table 9-6 Burner Electrical Troubleshooting (Continued)

    (red wire) and nearby ground source (black wire)? • Yes, there should be 12Vdc at all previous Check connections and condition of red steps. battery cable. • No, replace battery cable. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-6...

  • Page 111: Fig. 9-1 Diesel Burner Schematic

    1.08k Ohms @ 70°F 12 GA. RED 12 GA. RED 14 GA. RED 14 GA. RED WHT/GRN WHT/GRN Circuit Breaker Burner Solenoid BLACK BLACK Burner Plug Battery 12vdc Fig. 9-1 Diesel Burner Schematic ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-7...

  • Page 112: Excessive Smoke Coming Out Of Exhaust Stack

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

  • Page 113: Testing Dc Controller

    Check the ohms between the terminals of fuel solenoid. If the reading is between 15-25 ohms the coil is good. If the reading is outside the above range or the meter indicates an open circuit, replace the fuel solenoid. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-9...

  • Page 114: Burner Ignition Coil Testing

    “Main Power” and “Burner” switch is “ON” and burner fuel pump will start circulating fuel through the fuel lines, which removes all air bubbles automatically, since it has a return line to the fuel tank. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-10...

  • Page 115: Fig. 9-2 Diesel Burner Electrode Adjustment

    AIR SETTING # FUEL PRESSURE ADJUSTMENT SCREW COPPER FUEL LINE NUT BLEEDER AIR BAND SCREW AIR SHUTTER AIR BAND FUEL PRESSURE GAUGE KIT FUEL PRESSURE GAUGE Fig. 9-3 Diesel Burner Air Settings ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-11...

  • Page 116: Sealant Is Heating Slowly

    500 hours, or one year, you need to change your oil. 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.

  • Page 117: Mixer Troubleshooting

    Is the hydraulic fluid level near the center of Troubleshooting. the sight gauge? Check at ambient • No, fill oil to the center of the sight gauge. temperature. See Fig. 5-1 Hydraulic Fluid Level and Temp. Gauge ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-13...

  • Page 118: Mixer Electrical Troubleshooting

    Readjust the lid switch so that the lid completely depresses the switch, and then recheck for 12Vdc. If the same result happens, replace the lid switch. • No, go to Step 4. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-14...

  • Page 119: Table 9-16 Mixer Electrical Troubleshooting (Continued)

    Is there 12Vdc between orange wire labeled ORN-2 terminal #3 and terminal #5 black wires between terminal #3 and terminal ground of hot oil PAKSTAT? block. • No, go to Step 7. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-15...

  • Page 120: Table 9-17 Mixer Electrical Troubleshooting (Continued)

    (red wire) and nearby ground source (black wire)? • Yes, there should be 12Vdc at all previous Check connections and condition of red steps. battery cable. • No, replace battery cable. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-16...

  • Page 121: Fig. 9-4 Checking Din Plug Voltage

    Super Shot 125 Diesel Melter Part Manual Chapter 9 Troubleshooting (47400) Fig. 9-4 Checking Din Plug Voltage ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-17...

  • Page 122: Fig. 9-5 Mixer Schematic

    Light BRN PUMP REV #1 BLU PUMP REV #1 RTD Sensor 1.08k Ohms @ 70°F Coil AMP Draw Pump Rev Coil 12vdc @2.71 AMPS with Light Fig. 9-5 Mixer Schematic ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-18...

  • Page 123: Mixer Hydraulic Troubleshooting

    Next turn "OFF" the Isuzu engine, remove the cap and pressure gauge, then re-attach the hose. • Yes, call Crafco, Inc. and speak to a Is the hydraulic flow 1.5 GPM from the hydraulic valve? If you do not have a flow...

  • Page 124: Fig. 9-6 Hydraulic Valve Pressure Setting

    Hydraulic Flow Compressor = Front section 22.79 GPM @ 2350 RPM Hydraulic Flow Compressor = Rear section 7.94 GPM @ 2350 RPM Compressor Relief = 2500 PSI Fig. 9-6 Hydraulic Valve Pressure Setting ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-20...

  • Page 125: Fig. 9-7 Din Plug Layout

    Chapter 9 Troubleshooting (47400) DIN PLUG #4 DIN PLUG #3 MIXER FORWARD MIXER REVERSE DIN PLUG #1 DIN PLUG #2 MATERIAL PUMP MATERIAL PUMP REVERSE FORWARD MOUNTING BRACKET Fig. 9-7 Din Plug Layout ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-21...

  • Page 126: Hose Troubleshooting

    • No, go to Step 3. 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). ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-22...

  • Page 127: Table 9-21 Hose Electrical Troubleshooting (Continued)

    #1. nearby ground source (black wire)? • No go to Step 7. • Yes, call Crafco, Inc. and speak to a Is there 12Vdc between pink wire labeled “PNK-3 and nearby ground source (black customer service technician you should wire)? have been able to find the problem.

  • Page 128: Fig. 9-8 Junction Box Voltage Testing

    Chapter 9 Troubleshooting (47400) Test #2 between black and green wires Test #1 between black and white wires Test #3 between white and green wires Fig. 9-8 Junction Box Voltage Testing ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-24...

  • Page 129: Fig. 9-9 Hose Circuit Schematic

    24VAC 3-PHASE Wand Hose 30-35 AMPS COLD 20-24 AMPS HOT 18 GA. BLUE TFE 12 GA. SO CORD (ALL SIX WIRES) (BLACK, WHITE AND GREEN) Generator Fig. 9-9 Hose Circuit Schematic ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-25...

  • Page 130: Fig. 9-10 Junction Box Wiring

    SENSOR WHITE HEATER BLUE HEATER BLUE HEATER BLUE TRIGGER RED TRIGGER GREEN SENSOR BLACK SENSOR WHITE HEATER GREEN HEATER WHITE HEATER BLACK KETTLE END WAND END Fig. 9-10 Junction Box Wiring ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-26...

  • Page 131: Symptom: Trigger Is Not Working

    C and B wand side. back the hose for repair. • No, this wand needs to be repaired or replaced. Contact Crafco, Inc. to send back the hose for repair. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-27...

  • Page 132: Rtd Sensor Ohms Vs. Temperature

    1422.9 1425.0 1427.1 1429.2 1431.3 1433.4 1435.5 1437.6 1439.6 1441.7 1443.8 1445.9 1448.0 1450.1 1452.2 1454.3 1456.4 1458.5 1460.6 1462.7 1464.8 1466.9 1469.0 1471.1 1473.2 1475.3 1477.3 1479.4 1481.5 1483.6 1485.7 1487.8 1489.9 1492.0 1494.1 1496.1 1498.2 1500.3 1502.4 1504.5 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-28...

  • Page 133: Table 9-24 Rtd Sensor Ohms Vs. Temperature (Continued)

    2034.8 2036.8 2038.8 2040.8 2042.8 2044.7 2046.7 2048.7 2050.7 2052.7 2054.7 2056.7 2058.7 2060.7 2062.7 2064.6 2066.6 2068.6 2070.6 2072.6 2074.6 2076.6 2078.5 2080.5 2082.5 2084.5 2086.5 2088.5 2090.4 2092.4 2094.4 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-29...

  • Page 134: Pump Troubleshooting

    Is the hydraulic fluid level near the center of the Troubleshooting sight gauge? • No, fill oil to the center of the sight gauge. Fig. 5-1 Hydraulic Fluid Level and Temp. Gauge ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-30...

  • Page 135: Table 9-26 Pump Electrical Troubleshooting

    (just above where • No, check for a broken wire or poor wire you checked in Step 4) and a nearby ground crimp on the red trigger going toward source? the hose. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-31...

  • Page 136: Table 9-27 Pump Electrical Troubleshooting (Continued)

    RA# so you can send your hose back for repair. Is there continuity on the hose connector "B" • Yes, call Crafco, Inc. and speak to a socket and red trigger in the junction box? service technician, you should have found the problem.

  • Page 137: Table 9-28 Pump Electrical Troubleshooting (Continued)

    Is the amber light "ON" when the wand trigger is pulled? (Looking down at the top of the hydraulic valve, Pump forward is the din plug lower right-hand corner, Refer to Fig. 9-7 Din Plug Layout.) ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-33...

  • Page 138: Table 9-29 Pump Electrical Troubleshooting (Continued)

    "Reverse" position? (Refer to Fig. 9-5 Mixer Schematic.) Is there 12 Vdc between the "Pump" toggle • Yes, replace the toggle switch. switch center post red wire and a nearby ground? • No, go to Step 10d. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-34...

  • Page 139: Table 9-30 Pump Electrical Troubleshooting (Continued)

    Is there 12 Vdc from side post to side post, when the wand trigger is pulled? • No, recheck the amber light, if the light comes "ON" and you do not have 12 Vdc then replace the din plug. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-35...

  • Page 140: Fig. 9-11 Pump Schematic

    BLU PUMP FOR #2 BLUE BLUE BLACK BLUE BLUE WHITE Pump Fwd Coil BLUE BLUE GREEN Batt with Light Wand Hose Pump Rev Coil See Mixer Schematic Generator Fig. 9-11 Pump Schematic ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-36...

  • Page 141: Pump Hydraulic Troubleshooting

    Next turn “OFF” the Isuzu engine, remove the cap, pressure gauge and reattach the hose. Is the hydraulic flow correct from the • Yes, call Crafco, Inc. and speak to a service hydraulic pump? technician. You should have been able to Fig. 9-6 Hydraulic Valve (Refer to find the problem.

  • Page 142: Engine Diagnostic Trouble Codes (Dtc)

    9.5.1 How to use the Diagnostic Trouble Code Table The engine supplied on the Super Shot 125 Diesel 100CFM Compressor machine is capable of displaying Diagnostic Trouble Codes (DTC) on the engine control panel display. If your engine displays a DTC, most likely you will have to contact your local engine repair center for service. To locate your closest engine repair center, please go here: http://www.isuzuengines.com/#!/network...

  • Page 143: Table 9-33 Engine Dtc Table Pn 47400 (Continued)

    Intake air temp sensor malfunction (high voltage) 172-4 Intake air temp sensor malfunction (low voltage) 174-3 Fuel temp sensor malfunction (high voltage) 174-4 Fuel temp sensor malfunction (low voltage) 190-0 Over run ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-39...

  • Page 144: Table 9-34 Engine Dtc Table Pn 47400 (Continued)

    Crank sensor malfunction (no or abnormal signal) 91-2 Accelerator sensor 1-2 comparison malfunction 91-3 Accelerator sensor 1-2 malfunction (high voltage) 91-4 Accelerator sensor 1-2 malfunction (low voltage) 968-2 Idle up down switch malfunction ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting (47400) 9-40...

  • Page 145: About The Illustrated Parts List

    10.1 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.

  • Page 146: Super Shot 125 Diesel Melter Assembly 43600

    10.2 Super Shot 125 Diesel Melter Assembly 43600 2 3 4 12 13 14 40 41 43 44 45 46 54 53 52 51 50 Fig. 10-1 Super Shot 125 Diesel Melter: PN 43600 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-2...

  • Page 147: Table 10-1 Super Shot 125 Diesel Melter: Pn 43600

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List Table 10-1 Super Shot 125 Diesel Melter: PN 43600 FIG. ITEM PART NO. DESCRIPTION QTY. 44797 LED LICENSE PLATE LAMP Fig. 10-1 45989 LOCKING ARM, WAND SUPPORT 26104 ¼...

  • Page 148: Table 10-2 Super Shot 125 Diesel Melter: Pn 43600 (Continued)

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List Table 10-2 Super Shot 125 Diesel Melter: PN 43600 (continued) FIG. ITEM PART NO. DESCRIPTION QTY. 44882 COVER, HYDRAULIC VALVE Fig. 10-1 51678 TOGGLE SWITCH AGITATOR 32513 TOGGLE SWITCH PUMP REVERSE...

  • Page 149: Table 10-3 Super Shot 125 Diesel Melter: Pn 43600 (Continued)

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List Table 10-3 Super Shot 125 Diesel Melter: PN 43600 (continued) FIG. ITEM PART NO. DESCRIPTION QTY. 43821 HEAT GUARD Fig. 10-1 44027 JUNCTION BOX ASSEMBLY 52405 18’ ELECTRIC HEATED HOSE (NOT SHOWN) 27170 3/8”...

  • Page 150: Super Shot 125 Diesel Melter Comp. 100 Cfm Pn 47400

    10.3 Super Shot 125 Diesel Melter Comp. 100 CFM PN 47400 8 9 10 11 12 13 14 26 25 23 22 21 36 37 41 42 Fig. 10-2 Super Shot 125 Diesel Melter Comp. 100 CFM PN 47400 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-6...

  • Page 151: Table 10-4 Super Shot 125 Diesel Melter Comp. 100 Cfm Pn 47400

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List Table 10-4 Super Shot 125 Diesel Melter Comp. 100 CFM PN 47400 FIG. ITEM PART NO. DESCRIPTION QTY. 44797 LED LICENSE PLATE LAMP Fig. 10-2 47472N BRACKET, WAND MOUNTING...

  • Page 152: Table 10-5 Super Shot 125 Diesel Melter Comp. 100 Cfm Pn 47400 (Continued)

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List Table 10-5 Super Shot 125 Diesel Melter Comp. 100 CFM PN 47400 (continued) FIG. ITEM PART NO. DESCRIPTION QTY. 46172 PASSENGER SIDE FENDER Fig. 10-2 44832 PUMP / AGITATOR MOTOR ASSEMBLY...

  • Page 153: Table 10-6 Super Shot 125 Diesel Melter Comp. 100 Cfm Pn 47400 (Continued)

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List Table 10-6 Super Shot 125 Diesel Melter Comp. 100 CFM PN 47400 (continued) FIG. ITEM PART NO. DESCRIPTION QTY. 47220N CONTROL BOX ASSEMBLY Fig. 10-2 45562 HOSE GUIDE (NOT SHOWN)

  • Page 154: Export Only*** Super Shot 125 Diesel Melter Comp. 53.8 Cfm Pn 43800

    10.4 ***Export Only*** Super Shot 125 Diesel Melter Comp. 53.8 CFM PN 43800 3 4 5 12 13 48 49 57 56 55 54 Fig. 10-3 ***Export Only*** Super Shot 125 Diesel Melter Comp. 53.8 CFM PN 43800 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-10...

  • Page 155: Table 10-7 ***Export Only*** Super Shot 125 Diesel Melter Comp. 53.8 Cfm Pn 43800

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List Table 10-7 ***Export Only*** Super Shot 125 Diesel Melter Comp. 53.8 CFM PN 43800 FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 10-3 44797 LED LICENSE PLATE LAMP 45559...

  • Page 156: Table 10-8 ***Export Only*** Ss125 Diesel Melter Comp. 53.8 Cfm Pn 43800 (Continued)

    12V BATTERY 23117 BREAKAWAY SWITCH 20130 48” SAFETY CHAIN 32365 YELLOW LED CLEARANCE MARKER 47200 CONTROL BOX ASSEMBLY 24076 HOUR METER 41948 KEY AND TUMBLER 44341 TIRE AND WHEEL ASSEMBLY ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-12...

  • Page 157: Table 10-9 ***Export Only*** Ss125 Diesel Melter Comp. 53.8 Cfm Pn 43800 (Continued)

    30 AMP CIRCUIT BREAKER (NOT SHOWN) 24190 OVERNIGHT HEATER ROD OPT. 43520 SPARE TIRE WITH MOUNT OPT. 51756 DUCKBILL TIP (NOT SHOWN) 27162R 3” DISK WITH RESTRICTOR OPT. 27163R 4” DISK WITH RESTRICTOR OPT. ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-13...

  • Page 158: Export Only*** Super Shot 125 Diesel Melter Comp. 70 Cfm Pn 45500

    10.5 ***Export Only*** Super Shot 125 Diesel Melter Comp. 70 CFM PN 45500 3 4 5 12 13 48 49 57 56 55 54 Fig. 10-4 ***Export Only*** Super Shot 125 Diesel Melter Comp. 70 CFM PN 45500 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-14...

  • Page 159: Table 10-10 ***Export Only*** Super Shot 125 Diesel Melter Comp. 70 Cfm Pn 45500

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List Table 10-10 ***Export Only*** Super Shot 125 Diesel Melter Comp. 70 CFM PN 45500 FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 10-4 44797 LED LICENSE PLATE LAMP 45559...

  • Page 160: Table 10-11 ***Export Only*** Ss125 Diesel Melter Comp. 70 Cfm Pn 45500 (Continued)

    12V BATTERY 23117 BREAKAWAY SWITCH 20130 48” SAFETY CHAIN 32365 YELLOW LED CLEARANCE MARKER 47200 CONTROL BOX ASSEMBLY 24076 HOUR METER 41948 KEY AND TUMBLER 44341 TIRE AND WHEEL ASSEMBLY ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-16...

  • Page 161: Table 10-12 ***Export Only*** Ss125 Diesel Melter Comp. 70 Cfm Pn 45500 (Continued)

    OPT. 50720 WEATHER TIGHT BOOT (NOT SHOWN) 31512 30 AMP CIRCUIT BREAKER (NOT SHOWN) 24190 OVERNIGHT HEATER ROD OPT. 43520 SPARE TIRE WITH MOUNT OPT. 51756 DUCKBILL TIP (NOT SHOWN) ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-17...

  • Page 162: Tank Assembly, All Models

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.6 Tank Assembly, All Models 2 3 4 Fig. 10-5 Tank Assembly: All Models ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-18...

  • Page 163: Table 10-13 Tank Assembly: All Models

    1” X 10” LONG PIPE NIPPLE 28039 1” X 4” LONG PIPE NIPPLE 28210 1” PIPE ELBOW 28351 1” X ¾” REDUCER BUSHING 28046 2” X 4” LONG PIPE NIPPLE 28273 2” PIPE CAP ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-19...

  • Page 164: Control Box Assembly, 43600, 43800, And 45500

    YELLOW PNK-1 PRP-1 WHT/RED RED-LID WHT/GRN PNK-2 PNK-1 WHT/GRN BLU-PMP WHT/BLK BLK-4 WHT/BLK GRY-1 ORN-1 PNK-2 ORN-1 ORN-1 BLK-4 19 18 Fig. 10-6 Control Box Assembly: 43600, 43800, and 45500 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-20...

  • Page 165: Table 10-14 Control Box Assembly: 43600, 43800, And 45500

    CABLE ASSEMBLY, SENSOR (NOT SHOWN) 44984 CABLE ASSEMBLY, POWER (NOT SHOWN) 44985 CABLE, TRIGGER/SENSOR (NOT SHOWN) 44993 MOUNTING RAIL 44978 WIRING HARNESS, ENGINE (NOT SHOWN) 45950 SOCKET CONNECTOR 45954 PANEL NUT 44994 TERMINAL BLOCK ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-21...

  • Page 166: Table 10-15 Control Box Assembly: 43600, 43800, And 45500 (Continued)

    DESCRIPTION QTY. Fig. 10-6 41994 IGNITION SWITCH WITH OUT TUMBLER 47203 ENCLOSURE, CONTROL BOX 50593 KNOB (NOT SHOWN) 51684 RIBBON CABLE, 36” (NOT SHOWN) 51698 RIBBON CABLE, 5” (NOT SHOWN) ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-22...
  • Page 167 Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List This page left blank intentionally ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-23...

  • Page 168: Control Box Assembly, 47400

    BRN-MIXER REV #3 ORN-1 BLU-MIXER REV #3 BRN-PMP REV #1 BLU-PMP REV #1 PNK-2 BRN-PMP FWD #2 BLU-PMP FWD #2 ORN-1 ORN-1 BLK-4 21 20 Fig. 10-7 Control Box Assembly: 47400 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-24...

  • Page 169: Table 10-16 Control Box Assembly: 47400

    50280 ½” CONDUIT NUT 24021 CORD GRIP CONNECTOR ½” 52361N CABLE ASSEMBLY, DIN PLUG 52365N CABLE ASSEMBLY, SENSOR 52363N CABLE, BURNER 52362N CABLE, TRIGGER/SENSOR 47211N HARNESS, CONTROLLER 45954 PANEL NUT ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-25...

  • Page 170: Table 10-17 Control Box Assembly : 47400 (Continued)

    Fig. 10-7 47209 ENGINE CONTROLLER 46239 SWITCH ON/OFF (NOT SHOWN) 47203 ENCLOSURE, CONTROL BOX 50593 KNOB (NOT SHOWN) 51684 RIBBON CABLE, 36” (NOT SHOWN) 51698 RIBBON CABLE, 5” (NOT SHOWN) ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-26...
  • Page 171 Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List This page left blank intentionally ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-27...

  • Page 172: Engine Assembly: Pn 43600

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.9 Engine Assembly: PN 43600 Fig. 10-8 Engine Assembly: 43600 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-28...

  • Page 173: Table 10-18 Engine Assembly: Pn 43600

    PART NO. DESCRIPTION QTY. 47102 ENGINE, 23 HP 3CH1 Fig. 10-8 43612 GENERATOR. 24VAC 45748 DRIVE BELT, GENERATOR 41867 FUEL FILTER 45389 OIL FILTER 45391 AIR FILTER ELEMENT 45402 HYDRAULIC PUMP ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-29...

  • Page 174: Engine Assembly: Pn 47400

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.10 Engine Assembly: PN 47400 Fig.10-9 Engine Assembly – 47400 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-30...

  • Page 175: Table 10-19 Engine Assembly: Pn 47400

    BELT, ENGINE FAN (Not Shown) 47178N CAP, RAIN (Not Shown) 47179N STARTER (Not Shown) 47180N ALTERNATOR, ENGINE (Not Shown) 47181N THERMOSTAT (Not Shown) 47182N PUMP, WATER (Not Shown) 47185N FUEL PUMP ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-31...

  • Page 176: Engine Assembly: Pn 43800

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.11 Engine Assembly: PN 43800 Fig. 10-10 Engine Assembly: PN 43800 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-32...

  • Page 177: Table 10-20 Engine Assembly: Pn 43800

    PART NO. DESCRIPTION QTY. Fig. 45380 ENGINE, 37 HP 3CE1 10-10 43612 GENERATOR. 24VAC 45748 DRIVE BELT, GENERATOR 41867 FUEL FILTER 45381 OIL FILTER 45401 HYDRAULIC PUMP 45382 AIR FILTER ELEMENT ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-33...

  • Page 178: Engine Assembly: Pn 45500

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.12 Engine Assembly: PN 45500 Fig. 10-11 Engine Assembly: PN 45500 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-34...

  • Page 179: Table 10-21 Engine Assembly: Pn 45500

    PART NO. DESCRIPTION QTY. Fig. 45348 AIR FILTER ELEMENT 10-11 45332 ENGINE, 41.6 HP 3CDTK1 43612 GENERATOR, 24VAC 45748 DRIVE BELT, GENERATOR 43851 OIL FILTER 41867 FUEL FILTER 45403 HYDRAULIC PUMP ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-35...

  • Page 180: Hydraulic Control Valve Assembly: Pn 45420 All Models

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.13 Hydraulic Control Valve Assembly: PN 45420 All Models Fig. 10-12 Hydraulic Control Valve Assembly: PN 45420 All Models ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-36...

  • Page 181: Table 10-22 Hydraulic Control Valve Assembly: Pn 45420 All Models

    FITTING, #8 ORB X #8 MALE JIC STR 45413 DUST CAP 45414 FITTING, TEST PORT 45416 FLOW CONTROL, PRIORITY 40308 FITTING, #6 ORB X #6 MALE JIC STR 29919 FITTING, #6 ORB X #8 MALE JIC STR ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-37...

  • Page 182: Material Flow Control Assembly: Pn 46060 All Models

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.14 Material Flow Control Assembly: PN 46060 All Models Fig. 10-14 Material Flow Control Assembly: PN 46060 All Models ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-38...

  • Page 183: Table 10-23 Material Flow Control Assembly: Pn 46060 All Models

    ITEM PART NO. DESCRIPTION QTY. Fig. 10-14 29869 3/8” TUBE X 1/2” O-RING ELBOW 46077 KNOB ONLY 46060 HYDRAULIC FLOW CONTROL (NO FITTINGS) 29998 3/8” TUBE X 1/2” O-RING ADAPTOR ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-39...

  • Page 184: Pump/Mixer Motor Assembly: Pn 44832 All Models

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.15 Pump/Mixer Motor Assembly: PN 44832 All Models Fig. 10-15 Pump/Mixer Motor Assembly: PN 44832 All Models ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-40...

  • Page 185: Table 10-24 Pump/Mixer Motor Assembly: Pn 44832 All Models

    44809 HYDRAULIC MOTOR, PUMP 29913 1/2” TUBE X 5/8” O-RING ADAPTOR 43345 MOUNTING BRACKET MOTORS 26002 SPROCKET CHAIN COUPLING 26016 CHAIN COUPLING 26030 CONNECTING LINK CHAIN 43323 SPROCKET MIXER DRIVE ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-41...

  • Page 186: Diesel Burner Assembly: Pn 46380 All Models

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.16 Diesel Burner Assembly: PN 46380 All Models BACK VIEW SIDE VIEW Fig. 10-16 Diesel Burner Assembly: PN 46380 (All Models) ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-42...

  • Page 187: Table 10-25 Diesel Burner Assembly: Pn 46380 All Models

    ELECTRODE 41953N STD HEAD, F22, BURNER 41964N GASKET, AIR TUBE TO HOUSING 46381N AIR TUBE W/ HEAD & ELECTRODE MOUNT 41993 ELECTRODE ASSY (COMES WITH 2) 41966N AIR GUIDE, BURNER ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-43...

  • Page 188: Hydraulic Diagram: Pn 26554 (43600)

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.17 Hydraulic Diagram: PN 26554 (43600) Fig. 10-17 Hydraulic Diagram: PN 26554 (43600) ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-44...

  • Page 189: Table 10-26 Hydraulic Diagram: Pn 26554 (43600)

    FITTING, #8 ORB X #8 JIC RUN TEE 29932 FLOW CONTROL VALVE “1” TO HYDRAULIC VALVE “PA”PORT 29998 FITTING, #8 ORB X #8 JIC 8M3K 8G-8FJX 8G-6FJX 16 HYDRAULIC HOSE 40311 FITTING, #6 ORB X #6 JIC ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-45...

  • Page 190: Table 10-27 Hydraulic Diagram: Pn 26554 (43600 Continued)

    FITTING, #16 ORB X #12 JIC HYDRAULIC PUMP PRESSURE PORT TO HYDRAULIC VALVE “P” PORT 29862 FITTING, #10 ORB X #10 JIC 8M3K 8G-10FJX 8G-8FJX90L 110 HYDRAULIC HOSE 29897 FITTING, #8 ORB X #8 JIC ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-46...
  • Page 191 Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List This page left blank intentionally ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-47...

  • Page 192: Hydraulic Diagram: Pn 26662N (47400)

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.18 Hydraulic Diagram: PN 26662N (47400) Fig. 10-18 Hydraulic Diagram: PN 26662N (47400) ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-48...

  • Page 193: Table 10-28 Hydraulic Diagram: Pn 26662N (47400)

    FLOW CONTROL VALVE “2” TO HYDRAULIC VALVE “T”PORT 29896 FITTING, #8 ORB X #8 JIC ELBOW 8M3K 8G-8FJX 8G-8FJX90S 18 HYDRAULIC HOSE 29932 FITTING, #8 ORB X #8 JIC RUN TEE ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-49...

  • Page 194: Table 10-29 Hydraulic Diagram: Pn 26662N (47400 Continued)

    16M3K 16G-16FJX 16G-16FJX90S 27.5 HYDRAULIC HOSE 51408 #16 JIC BULKHEAD ELBOW 16M3K 16G-16FJX90S 16G-16FJX 38.5 HYDRAULIC HOSE 51415N #16 JIC BULKHEAD FITTING 16M3K 16G-16FJX 16G-16FJX 29 HYDRAULIC HOSE 29977 #16 O-RING BRANCH TEE ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-50...

  • Page 195: Table 10-30 Hydraulic Diagram: Pn 26662N (47400 Continued)

    #8 TUBE X #8 JIC FITTING COMPRESSOR HYDRAULIC MOTOR TO HYDRAULIC TANK 29848 FITTING, #6 ORB X #6 JIC ELBOW 6M3K 6G-6FJX 6G-6FJX90S 25.25 HYDRAULIC HOSE 29881 #6 JIC X #4 MALE PIPE ADAPTER ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-51...

  • Page 196: Hydraulic Diagram: Pn 26663 (43800 &45500 ***Export Engine Only***)

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.19 Hydraulic Diagram: PN 26663 (43800 &45500 ***Export Engine Only***) Fig. 10-19 Hydraulic Diagram: PN (43800 &45500 ***Export Engine Only***) ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-52...

  • Page 197: Table 10-31 Hydraulic Diagram: Pn 26663 (43800 & 45500 ***Export Engine Only***)

    FLOW CONTROL VALVE “2” TO HYDRAULIC VALVE “T”PORT 29896 FITTING, #8 ORB X #8 JIC ELBOW 8M3K 8G-8FJX 8G-6FJX90S 22 HYDRAULIC HOSE 29932 FITTING, #8 ORB X #8 JIC RUN TEE ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-53...

  • Page 198: Table 10-32 Hydraulic Diagram: Pn 26663 (43800 & 45500 ***Export Engine Only***)

    HYDRAULIC PUMP PRESSURE FRONT PORT TO COMPRESSOR VALVE “1” PORT 29916 FITTING, #12 ORB X #12 JIC ELBOW 10M3K 10G-12FJX 10G-10FJX90S 28 HYDRAULIC HOSE 29821 FITTING, #12 ORB X #10 JIC ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-54...

  • Page 199: Table 10-33 Hydraulic Diagram: Pn 26663 (43800 & 45500 ***Export Engine Only***)

    FITTING, #8 ORB X #8 JIC COMPRESSOR HYDRAULIC MOTOR TO HYDRAULIC TANK FITTING, #6 ORB X #6 JIC ELBOW 29848 6M3K 6G-6FJX 6G-6FJX90S 22.75 HYDRAULIC HOSE 29881 #6 JIC X #4 MALE PIPE ADAPTER ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-55...

  • Page 200: Diesel Fuel Line Schematic - Non-Compressor

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.20 Diesel Fuel Line Schematic – Non-Compressor Fig.10-20 Diesel Fuel Line Schematic – Non-Compressor ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-56...

  • Page 201: Table 10-34 Diesel Fuel Line Schematic - Non-Compressor

    3. ENGINE RETURN LINE TO DIESEL FUEL TANK 29591 HOSE, 5/16 FUEL LINE 26767 FITTING, #5 HOSE PUSH-ON 26782 FITTING, 1/4 MPT X 5/16 JIC ELBOW 26080 CLAMP, #4 GEAR ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-57...

  • Page 202: Diesel Fuel Line Schematic - Compressors

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.21 Diesel Fuel Line Schematic – Compressors Fig.10-21 Diesel Fuel Line Schematic - Compressors ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-58...

  • Page 203: Table 10-35 Diesel Fuel Line Schematic - Compressors

    HOSE ASSEMBLY, 5/16 X 65.5” 26767 FITTING, #5 HOSE PUSH-ON 29891 FITTING, 1/4” FPT X 5/16 JIC ELBOW 43758N FILLER CAP, RPLCMNT, FUEL-HYD TANKS 43723N GASKET, NARROW STYLE, FOR FILLER CAP ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-59...

  • Page 204: Electrical Schematic: Pn 43600

    TRIGGER RED TRIGGER GRN SENSOR BLACK SENSOR WHITE #4 MATERIAL #1 MATERIAL HEATER GREEN PUMP FORWARD PUMP REVERSE HEATER WHITE HEATER BLACK JUNCTION BOX WIRING Fig. 10-22 Electrical Schematic: PN 43600 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-60...

  • Page 205: Table 10-36 Electrical Schematic: Pn 43600

    CABLE ASSEMBLY, HYDRAULIC VALVE 44983 CABLE ASSEMBLY, SENSOR 44984 CABLE ASSEMBLY, POWER 24015 BATTERY CABLE, POSITIVE TO ENGINE 27174 BATTERY CABLE, ENGINE TO GROUND LUG 24010 BATTERY CABLE, NEGATIVE TO GROUND LUG ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-61...

  • Page 206: Electrical Schematic: Pn 47400

    TRIGGER RED TRIGGER GRN SENSOR BLACK SENSOR WHITE #2 MATERIAL #1 MATERIAL HEATER GREEN PUMP FORWARD PUMP REVERSE HEATER WHITE HEATER BLACK JUNCTION BOX WIRING Fig. 10-23 Electrical Schematic: PN 47400 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-62...

  • Page 207: Table 10-37 Electrical Schematic: Pn 47400

    BATTERY CABLE, ENGINE TO GROUND LUG 52354N BATTERY CABLE, NEGATIVE TO GROUND LUG 52347N WIRE ASSY, CIRCUIT BREAKER TO BATTERY 52380N WIRE ASSY, BURNER POWER 52352N BATTERY CABLE, POSITIVE TO ENGINE ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-63...

  • Page 208: Electrical Schematic: ***Export Only*** Pn 43800 And 45500

    SENSOR BLACK SENSOR WHITE #4 MATERIAL #1 MATERIAL HEATER GREEN PUMP FORWARD PUMP REVERSE HEATER WHITE HEATER BLACK JUNCTION BOX WIRING Fig. 10-25 Electrical Schematic: ***Export Only*** PN 43800 and 45500 ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-64...

  • Page 209: Table 10-38 Electrical Schematic: ***Export Only*** Pn 43800 And 45500

    CABLE ASSEMBLY, SENSOR 44984 CABLE ASSEMBLY, POWER 43886 CABLE ASSEMBLY, COMPRESSOR 24015 BATTERY CABLE, POSITIVE TO ENGINE 27174 BATTERY CABLE, ENGINE TO GROUND LUG 32602 BATTERY CABLE, NEGATIVE TO GROUND LUG ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-65...

  • Page 210: Air Compressor Assembly: ***Export Only*** Pn 45345 (43800, And 45500)

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.25 Air Compressor Assembly: ***Export Only*** PN 45345 (43800, and 45500) Fig. 10-26 Air Compressor Assembly: ***Export Only*** PN 45345 (43800, and 45500) ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-66...

  • Page 211: Table 10-39 Air Compressor Assembly: ***Export Only*** Pn 45345 (43800, And 45500)

    TEE, 1/2” NPT PIPE 45564 NIPPLE, RESTRICTOR 50267 MUFFLER, AIR 45476 RETURN LINE, COMPRESSOR 45475 SUPPLY LINE, COMPRESSOR 29881 6MJ X 4MP FITTING (NOT SHOWN) 45349 SWITCH, TEMP 110C, COMPRESSOR ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-67...

  • Page 212: Air Compressor Assembly: Pn 47480N (47400)

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.26 Air Compressor Assembly: PN 47480N (47400) SIGHT GAUGE Fig. 10-27 Air Compressor Assembly: PN 47480N (47400) ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-68...

  • Page 213: Table 10-40 Air Compressor Assembly: Pn 47480N (47400)

    FITTING, 1/2” NPT AIR HOSE 29881 6MJ X 4MP FITTING 28254 TEE, 3/4” NPT PIPE 45564 NIPPLE, RESTRICTOR 50267 MUFFLER, AIR 45476 RETURN LINE, COMPRESSOR 45475 SUPPLY LINE, COMPRESSOR 47484N SWITCH, TEMP 130C, COMPRESSOR ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-69...

  • Page 214: Hydraulic Compressor Valve Assembly: Pn 45425 (43800, 47400 And 45500)

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.27 Hydraulic Compressor Valve Assembly: PN 45425 (43800, 47400 and 45500) Fig. 10-30Hydraulic Compressor Valve Assembly: PN 45425 (43800, 47400 and 45500) ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-70...

  • Page 215: Table 10-41 Hydraulic Compressor Valve Assembly: Pn 45425 (43800, 47400 And 45500)

    COIL, SOLENOID VALVE 45424 VALVE, SOLENOID FITTING, #12 ORB X #10 JIC STRAIGHT 45436 FLOW CONTROL, PRESSURE COMP. 45414 FITTING, TEST POINT 45413 CAP, DUST TEE, #12 ORB X #12 JIC RUN ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-71...

  • Page 216: High Output Air Lance Assembly

    Fig.10-31 47483N LANCE, AIR, HIGH OUTPUT WITH SWVL & CPLR 70250 3/4” SWIVEL 47488N FITTING, 3/4” AIR HOSE 47491N OPTIONAL WATER SEPARATOR KIT 47482N 3/4” X 50 FT AIR HOSE ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-72...
  • Page 217 Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List This page left blank intentionally ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-73...

  • Page 218: Wand Assembly

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.29 Wand Assembly Fig.10-32 Wand Assembly ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-74...

  • Page 219: Table 10-43 Wand Assembly

    52201 HANDLE, WAND – RIGHT (W/INSERTS) 52201L HANDLE, WAND – LEFT (NOT SHOWN) 52208 SWITCH, WAND 52202 ACTUATOR 52207 SPRING, ACTUATOR 52209 PIN, ACTUATOR 52203 LOCK, TRIGGER 51656 TERMINAL STRIP ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-75...

  • Page 220: Optional Engine Cover For Compressor Models

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.30 Optional Engine Cover for Compressor Models Fig.10-33 Optional Engine Cover for Compressor Models ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-76...

  • Page 221: Table 10-44 Optional Engine Cover For Compressor Models

    PASS SIDE DOOR 47507N AIR CLEANER DOOR 47509N RADIATOR SEAL KIT 47519N WEATHERSTRIP, BULB STYLE (FOR HOOD) 9 FT 47511N WEATHERSTRIP, FLAT (FOR DOORS) 6 FT 47525N OPTIONAL ENGINE COVER INSULATION KIT ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-77...

  • Page 222: Hot Air Lance

    Super Shot 125 Diesel Melter Part Manual Chapter 10 Illustrated Parts List 10.31 Hot Air Lance Fig. 10-36 Hot Air Lance (Option) ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-78...

  • Page 223: Table 10-45 Hot Air Lance (Option)

    BUSHING, 3/8” NPT X 1/4” NPT REDUCER 45659 VALVE, NEEDLE 45675 HOSE ASSEMBLY, PROPANE 45679 COUPLING, 1/4” FPT X M 45681 COUPLING, 1/4” NPT X FM 45664 FITTING, 1/4” NPT X 3/8 JIC FERRULE LOCK ©2017 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 10-79...

  • Page 225: Tools And Accessories

    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 Crafco Cold Air Lance - 42648 ©2017 by Crafco, Inc. All Rights Reserved………………...………………………………..………………..Tools and Accessories 11-1...
  • Page 226 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 ©2017 by Crafco, Inc. All Rights Reserved………………...………………………………..………………..Tools and Accessories 11-2...
  • Page 227 Super Shot 125 Diesel Melter Part Manual Chapter 11 Tools and Accessories Crafco Heat Lance with Regulator and Attachments - 32259 Crafco Hand Torch w/ 20ft. Hose - 25012 ©2017 by Crafco, Inc. All Rights Reserved………………...………………………………..………………..Tools and Accessories 11-3...
  • Page 230 ©2017 Crafco, Inc.

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