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Ergon Crafco Patcher 4 Operator's & Parts Manual

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For January 2023 & Newer Patcher 4's
Operator/Parts Manual – 56645N
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Summary of Contents for Ergon Crafco Patcher 4

  • Page 1 For January 2023 & Newer Patcher 4’s Operator/Parts Manual – 56645N Revision O...
  • Page 2 Fill in the appropriate fields that apply to this machine. Machine S/N: ___________________________________ Engine S/N: ____________________________________ Gear Box S/N: __________________________________...
  • Page 3 Patcher 4 Operator/Part Manual Revisions Revision Description Date...
  • Page 4 Patcher 4 Operator/Part Manual Machine Views...
  • Page 5 Patcher 4 Operator/Part Manual Machine Views...

  • Page 6: Table Of Contents

    Patcher 4 Operator/Part Manual Table of Contents Contents 1.0 About This Manual ........................ 1-1 How to use this Manual ....................1-1 2.0 Safety Precautions ....................... 2-1 General Safety ......................... 2-1 Personal Safety ....................... 2-1 Equipment or Operational Safety ..................2-1 California Proposition 65 ....................
  • Page 7 Patcher 4 Operator/Part Manual Table of Contents Heat Transfer Oil ......................6-1 Mixer Packing Gland Seals ....................6-1 Mixer Shaft Bearings ......................6-1 Material Sensor Tube ....................... 6-1 Lug Nuts .......................... 6-1 Wheel Bearing ......................... 6-2 Brakes ..........................6-2 Tongue Jack ........................6-2 Water Separator......................
  • Page 8 Patcher 4 Operator/Part Manual Table of Contents Testing the DC Controller ....................8-8 Fuel Solenoid Troubleshooting ..................8-8 Ignition Coil Troubleshooting ................... 8-9 Bleeding the Diesel Burners .................... 8-9 Smoke Coming Out of the Exhaust Stack ..............8-10 Burner Electrode Adjustment ..................8-11 Burner Air Settings .......................
  • Page 9 Patcher 4 Operator/Part Manual Table of Contents...
  • Page 10 Patcher 4 Operator/Part Manual List of Figures Figure 5-1 Hydraulic and Diesel Fill Caps ................... 5-2 Figure 5-2 Hydraulic Fluid Level and Temp Gauge ..............5-2 Figure 5-3 Heat Transfer Oil Dipstick ..................5-3 Figure 5-4 Discharge Gate ......................5-4 Figure 5-5 Mixer &...
  • Page 11 Patcher 4 Operator/Part Manual List of Figures Figure 9-15 Electrical schematic parts list (P/N 26582P4) ............9-26 Figure 9-16 Heated Toolbox Parts List (P/N 57450N) ............... 9-28 Figure 9-17 Optional Material Chute (P/N 56895N)..............9-30 Figure 9-18 Optional Heated Chute (P/N 56890N) ..............9-32 Figure 9-19 Optional Heated Chute Parts List (continued) ............
  • Page 12 Patcher 4 Operator/Part Manual List of Tables Table 2-1 Safety Symbols and Notices ..................2-3 Table 2-2 Safety Symbols and Notices (continued) ..............2-4 Table 4-1 Machine Specifications ....................4-1 Table 5-1 Preparing the Machine for Start Up................5-1 Table 5-2 Starting the Engine and Burner ................... 5-5 Table 5-3 Loading Material into the Material Tank ..............
  • Page 13 Patcher 4 Operator/Part Manual List of Tables Table 8-11 Mixer Basic Visual Troubleshooting ................ 8-12 Table 8-12 Mixer Basic Visual Troubleshooting (continued) ............8-13 Table 8-13 Mixer Electrical Troubleshooting ................8-13 Table 8-14 Mixer Electrical Troubleshooting (continued)............8-14 Table 8-15 Mixer Electrical Troubleshooting (continued)............8-15 Table 8-16 Mixer Hydraulic Troubleshooting ................

  • Page 15: 1.0 About This Manual

    Patcher 4 Operator/Part Manual Chapter 1 Introduction 1.0 About This Manual This manual is supplied with each new Crafco Patcher 4. The manual assists your machine operators in the proper use of the Patcher 4 and provides information about the machine’s mechanical functions.

  • Page 17: Safety Precautions

    Patcher 4 Operator/Part Manual Chapter 2 Safety Precautions 2.0 Safety Precautions For more in-depth safety information, please see Safety Manual (PN 26221) which comes with the machine. Or contact your nearest authorized Crafco Distributor at crafco.com/Distributors. General Safety • Crafco, Inc. assumes no liability for an accident or injury incurred through improper use of the machine.

  • Page 18: California Proposition 65

    Patcher 4 Operator/Part Manual Chapter 2 Safety Precautions California Proposition 65 The state of California currently maintains a list of chemicals that can cause cancer, birth defects or other reproductive harm. Your Crafco, Inc. equipment comes with the following warnings: All Crafco, Inc.

  • Page 19: Safety Symbols And Notices

    Patcher 4 Operator/Part Manual Chapter 2 Safety Precautions 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, severe injury, or death. Please read and comply with all symbols and notices.

  • Page 20: Table 2-2 Safety Symbols And Notices (Continued)

    Patcher 4 Operator/Part Manual Chapter 2 Safety Precautions 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. Moving Machinery Never reach into moving machinery. Exhaust Hazard Avoid breathing engine exhaust.

  • Page 21: 3.0 Limited Warranty

    Patcher 4 Operator/Part Manual Chapter 3 Warranty Information 3.0 Limited Warranty Crafco, Inc. (Manufacturer), or one of its affiliated distributors, will replace for the original purchaser free of charge any parts found upon examination by the Manufacturer, to be defective in material or workmanship.

  • Page 22: Warranty Claim Instructions

    Patcher 4 Operator/Part Manual Chapter 3 Warranty Information Warranty Claim Instructions Crafco, Inc. warrants parts and machinery purchased through Crafco or one of its affiliated distributors for two years from the invoice date. Wear items are not covered under the Crafco, Inc. limited warranty.

  • Page 23: Machine Specifications

    Patcher 4 Operator/Part Manual Chapter 4 Machine Specifications 4.0 Machine Specifications Table 4-1 Machine Specifications Specification PN 56600N Vat capacity 395 gallons Heat transfer oil required 50 gallons at 70°F Tank construction Double boiler type 2 material openings 16” x 24” Tank opening size 1 bucket opening 15.5”...

  • Page 25: Operating Instructions

    Chapter 5 Operating Instructions 5.0 Operating Instructions Introduction The Crafco Patcher 4 was developed to melt Crafco TechCrete, Mastic One, Matrix 501 and PolyPatch products. Note: DO NOT attempt to operate the machine without using these and all other instructions.

  • Page 26: Figure 5-1 Hydraulic And Diesel Fill Caps

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Figure 5-1 Hydraulic and Diesel Fill Caps DIESEL FUEL FILL CAP HYDRAULIC FLUID FILL CAP Figure 5-2 Hydraulic Fluid Level and Temp Gauge ©2023 by Crafco, Inc. All Rights Reserved……………………………..……………………. Operating Instructions 5-2...
  • Page 27 Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Figure 5-3 Heat Transfer Oil Dipstick HEAT TRANSFER OIL DIPSTICK ©2023 by Crafco, Inc. All Rights Reserved……………………………..……………………. Operating Instructions 5-3...

  • Page 28: Figure 5-5 Mixer & Engine Speed Switch

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Figure 5-4 Discharge Gate DISCHARGE GATE SAFETY CHAIN Figure 5-5 Mixer & Engine Speed Switch Engine Speed Switch Mixer Control Switch ©2023 by Crafco, Inc. All Rights Reserved……………………………..……………………. Operating Instructions 5-4...

  • Page 29: Starting The Engine And Burner

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Figure 5-6 Mixer Bearings MIXER BEARING MIXER BEARING & GREASE FITTING GREASE FITTING GREASE FITTING USE CRAFCO P/N USE CRAFCO P/N 56860 HI TEMP 56860 HI TEMP BEARING GREASE BEARING GREASE Starting the Engine and Burner Table 5-2 Starting the Engine and Burner Step Action...

  • Page 30: Figure 5-7 Control Panel

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Figure 5-7 Control Panel ©2023 by Crafco, Inc. All Rights Reserved……………………………..……………………. Operating Instructions 5-6...

  • Page 31: Altitude Compensation System

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Altitude Compensation System This unit may be equipped with an Altitude Compensation System. If so, there will be a small, boxed housing mounted on the engine mount cross member. The system is automatic during most operating conditions.

  • Page 32: Figure 5-8 Loading Material Using The Lid

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Figure 5-8 Loading Material Using the Lid Figure 5-9 Lid Hold-Down/Lid Pins LID HOLD-DOWN LID PIN LID HOLD-DOWN LID PIN ©2023 by Crafco, Inc. All Rights Reserved……………………………..……………………. Operating Instructions 5-8...

  • Page 33: Dispensing The Material

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Figure 5-10 Flow Control Knob Dispensing the Material Table 5-4 Dispensing the Material Step Action WARNING Put on protective clothing, gloves, hard-soled shoes, and face shield or safety glasses when operating or filling this machine. Read the entire manual before operating the machine.

  • Page 34: Shutting Down And Cleaning Out The Machine

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Table 5-4 Dispensing the Material (continued) Step Action For the first pour after initial heat up, place a pour bucket under the chute hooking the handle on the end of the chute to hold it. Open the discharge gate and allow the poorly mixed material from the discharge tube to pour into the bucket until nicely mixed material starts to flow, then immediately close the discharge gate.

  • Page 35: Storing The Machine

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Storing the Machine Store the machine in an area where moisture cannot enter the heating system, i.e., the heat transfer oil tank, etc. Extended down time can cause moisture to build up in the heating tank. Evidence that moisture has collected in the heat transfer oil is a constant popping noise.

  • Page 36: Hot Applied Patching Material Placement

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Table 5-7 Overnight Heaters (continued) Step Action WARNING Suitable extension cord size requirements for 110 Volt use: 25-50 FT • 16-20 Amps • 12 Gauge (Heavy Duty) or 10 Gauge (Extra Heavy Duty) 100 FT •...

  • Page 37: Application Steps

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Application Steps Table 5-8 Application Steps Step Action Locate area to be repaired. Calculate the amount of material needed for the repairs. Place bags or cubes of material into the mixer and heat. Start the agitator as soon as possible to break up the bags.

  • Page 38: Table 5-9 Application Steps (Continued)

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Table 5-9 Application Steps (continued) Step Action Allow this material to cool similar to the first lift - you may not experience as many bubbles this time, but some may appear. When they do, flash them with the torch. If applicable, dry the aggregate dressing prior to placing the material, as wet or damp dressing will not adhere.

  • Page 39: Heated Toolbox Operation

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Heated Toolbox Operation The Patcher 4 is equipped with a Heated Toolbox that is designed to heat up the tools necessary when making a patch using mastic type materials. Follow the steps below in order to operate the heated toolbox safely.

  • Page 40: Figure 5-11 Heated Toolbox

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Table 5-11 Heated Toolbox Operation (continued) Step Action CAUTION The burner should not be left on for extended periods. It is meant to be turned on and off as needed through the job to prevent the overheating of tools and damage to the heated toolbox itself When you are finished using the heated toolbox, turn off the burner switch, and remove the tools and place them in the storage locations towards the front of the...

  • Page 41: Material Tank Depth To Capacity Chart

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Material Tank Depth to Capacity Chart Figure 5-12 Material Tank Depth to Capacity Chart MATERIAL TANK DEPTH TO CAPACITY CHART DEPTH OF CAPACITY IN CAPACITY IN MATERIAL GALLONS LITERS 36.500 1" 3.02 11.43 2"...

  • Page 42: Removing Optional Heated Chute

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Removing Optional Heated Chute If desired, your Patcher 4 will have a heated chute kit already installed from the factory. If you want to remove the heated chute from the machine, you must follow the steps below, or injury to operators and damage to your machine could result.

  • Page 43: Table 5-13 Complete Removal Of Optional Heated Chute

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Table 5-13 Complete Removal of Optional Heated Chute Step Action WARNING Following this procedure prevents hot oil from getting on operators and causing severe burns. Never operate the machine without the heat transfer oil lines connected correctly.

  • Page 44: Figure 5-13 Optional Heated Chute Components (P/N 56890N)

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Figure 5-13 Optional Heated Chute Components (P/N 56890N) CHUTE SUPPORT ASSY CHUTE ASSEMBY HEAT TRANSFER OIL BALL VALVES (X2) SWIVEL FITTING (X2) HITCH PIN STEEL BRAIDED LINES BULKHEAD FITTINGS (WITH FIRE SLEEVE) X3 HITCH MOUNTING HYD.

  • Page 45: Mounting A Skid Machine

    Patcher 4 Operator/Part Manual Chapter 5 Operating Instructions Mounting a Skid Machine Table 5-14 Mounting a Skid Machine Step Action WARNING The truck needs to be of proper size to hold the loaded weight and size of the machine and any extra material to be carried. The center of gravity of the loaded machine should be above or in front of the rear main axle.

  • Page 47: Maintenance Instructions

    Patcher 4 Part Manual Chapter 6 Maintenance Instructions 6.0 Maintenance Instructions This chapter contains all normal maintenance instructions to properly maintain your machine. Engine Check oil daily. Service engine per the Isuzu owner’s manual. See engine owner’s manual for additional operating and maintenance instructions. Hydraulic System Check hydraulic fluid daily.

  • Page 48: Wheel Bearing

    Patcher 4 Part Manual Chapter 6 Maintenance Instructions Wheel Bearing Pack the wheel bearing every 24,000 miles or every two years, whichever comes first. Use a good grade of bearing grease. Brakes Check the brakes daily. Tongue Jack Lubricate the tongue jack, using a good grade of bearing grease. Water Separator Check the water separator for excess water in the housing.

  • Page 49: Maintenance Chart

    Patcher 4 Part Manual Chapter 6 Maintenance Instructions Maintenance Chart Table 6-1 Maintenance Chart Hours Location Procedure Refer to the manufacturer’s Engine check oil level instructions for the engine Engine Radiator Check and clean fins with water Refer to the manufacture’s Other engine maintenance operating and maintenance instructions for the engine.

  • Page 50: Service Instructions

    Patcher 4 Part Manual Chapter 6 Maintenance Instructions Table 6-2 Maintenance Chart (continued) Hours Location Procedure Clean out material drippings. Heated Toolbox Replace chute assembly as needed. PN 57475N If red ring is halfway up the Water Separator body then drain. Adjusting Discharge Gate Check and adjust if leaking Table 6-5 General Maintenance Parts...

  • Page 51: General Maintenance Parts

    Patcher 4 Part Manual Chapter 6 Maintenance Instructions General Maintenance Parts Table 6-5 General Maintenance Parts Recommended Quantity Description Part No. 10.25” ea., 4 per location Packing, Mixer Shaft 32226 Main Burner Nozzle (2.50) 56646N Toolbox Burner Nozzle (0.5) 32403 Toolbox Burner Replacement Insulation 57474N Toolbox Burner Door Replacement...
  • Page 52 Patcher 4 Part Manual Chapter 6 Maintenance Instructions Applicable Brands of Heat Transfer Oil Table 6-7 Applicable Brand of Heat Transfer Oil Manufacturer Product Name Crafco Heat Transfer Fluid Chevron Heat Transfer Oil Grade 46 Shell Turbo T 68 (Group II) Citgo Hytherm Oil 46 Shell Turbo T 68 (Group II)

  • Page 53: Changing The Heat Transfer Oil

    Patcher 4 Part Manual Chapter 6 Maintenance Instructions Changing the Heat Transfer Oil Table 6-9 Changing the Heat Transfer Oil Step Action To facilitate easier draining of the heat transfer oil, heat the oil to approximately 100°F (38°C). WARNING Wear proper PPE (safety glasses, face shield, gloves, long sleeve shirt) to prevent bodily injury while servicing the heat transfer oil.

  • Page 54: Adjusting The Discharge Gate

    Patcher 4 Part Manual Chapter 6 Maintenance Instructions Adjusting the Discharge Gate Due to normal wear and tear, the discharge gate will need periodic adjustment to keep it sealed. It features a double nut tightening system. If the gate is leaking material excessively, you will need to adjust the nuts so it can re-form a seal when closed.

  • Page 55: Adjusting And Replacing Mixer Shaft Packing

    Patcher 4 Part Manual Chapter 6 Maintenance Instructions Adjusting and Replacing Mixer Shaft Packing Table 6-11 Adjusting and Replacing Mixer Shaft Packing Step Action Bring the Patcher 4 to temperature as preparation to drain the material tank below the mixer shaft level. Drain material until the level is below the mixer shaft so material will not leak out during replacement.

  • Page 56: Cleaning Material Tank And Sensor Area

    Patcher 4 Part Manual Chapter 6 Maintenance Instructions Cleaning Material Tank and Sensor Area The material tank needs to be cleaned every year or as needed for proper operation. As the machine is used, material builds up around the tank walls and sensor guard. The built up material prevents heat from getting to the fresh material and causes longer heat up times.

  • Page 57: How To Use A Multimeter

    Patcher 4 Part Manual Chapter 7 How to Use a Multimeter 7.0 How to Use a Multimeter Crafco machines use 12-volt direct current (DC) to power the burners, and hydraulic valves. The DC power is from a 12-volt battery. 12-volt DC power has little danger of electrical shock. Care must still be taken when dealing with DC power systems because it is capable of producing large amounts of current.

  • Page 58: Checking Amperage

    Patcher 4 Part Manual Chapter 7 How to Use a Multimeter Checking Amperage The Multimeter can be used to check amperages under 10 amps in AC or DC current. Figure 7-1 Standard Multimeter Audible Continuity Ohms Ω • Wire connections •...

  • Page 59: Figure 7-2 Clamp-On Amp Meter/Multimeter

    Patcher 4 Part Manual Chapter 7 How to Use a Multimeter Figure 7-2 Clamp-On Amp Meter/Multimeter DC Voltage • Everything Ohms Ω • Sensors • Hydraulic Coils • Burner Ignition Coil Audible Continuity • Wire connection ©2023 by Crafco, Inc. All Rights Reserved……………………………..……………………. How to Use a Multimeter 7-3...

  • Page 61: Troubleshooting

    Patcher 4 Part Manual Chapter 8 Troubleshooting 8.0 Troubleshooting Burner Troubleshooting Symptom: Burner will Not Ignite Table 8-1 Burner Basic Visual Troubleshooting Step Possible Cause If . . . • Start Troubleshooting at the control box. Is Yes, go to Step 2. the engine running? •...
  • Page 62 Patcher 4 Part Manual Chapter 8 Troubleshooting Table 8-2 Burner Electrical Troubleshooting Part 1 Step Possible Cause If . . . • Is the "BURNER" toggle switch in the "ON" Yes, go to Step 1a. position? • No, turn the main power switch to the "ON"...

  • Page 63: Table 8-2 Burner Electrical Troubleshooting Part 1

    Patcher 4 Part Manual Chapter 8 Troubleshooting Table 8-2 Burner Electrical Troubleshooting Part 1 (continued) Step Possible Cause If . . . • Are both the Material and Hot Oil readouts Yes, go to Step 3. displaying a three-digit number? •...
  • Page 64 Patcher 4 Part Manual Chapter 8 Troubleshooting Table 8-2 Burner Electrical Troubleshooting Part 2 Step Possible Cause If . . . • Yes, go to Step 4. Is there 12Vdc between the yellow and black wires at the burner plug? •...
  • Page 65 Patcher 4 Part Manual Chapter 8 Troubleshooting Table 8-2 Burner Electrical Troubleshooting Part 2 (continued) Step Possible Cause If . . . • Yes, replace PAKSTAT. Is there 12Vdc between terminal #6 grey wire and terminal #5 black wire of the material •...

  • Page 66: Burner Lights But Shuts Down After 15 Seconds

    Patcher 4 Part Manual Chapter 8 Troubleshooting Table 8-2 Burner Electrical Troubleshooting Part 2 (continued) Step Possible Cause If . . . • Yes, check for loose or broken wires Is there 12Vdc between the red wire on top-left terminal of ignition switch and nearby ground between of ignition switch and bottom source (black wire)? terminal of circuit breaker.

  • Page 67: Electrical Schematic

    Patcher 4 Part Manual Chapter 8 Troubleshooting Electrical Schematic Figure 8-1 Electrical Schematic (PN 26582P4) LICENSE CENTER PLATE MARKER LAMP LAMP TOOLBOX BURNER GRN/WHT SWITCH SAFETY LID SWITCH RED/BLK WORK LIGHT AND SAFETY LIGHT WIRES TUCKED INTO HARNESS WHT/BLU (WORK) RED/BLK SAFETY WHT/RED (SAFETY)

  • Page 68: Testing The Dc Controller

    Patcher 4 Part Manual Chapter 8 Troubleshooting Testing the DC Controller Table 8-4 Testing the DC Controller Step Bench Test DC Controller Remove all wire nuts attaching the DC Controller to the burner. Attach the black ground wire to the negative battery post. Attach the red wire to the positive battery post.

  • Page 69: Ignition Coil Troubleshooting

    Patcher 4 Part Manual Chapter 8 Troubleshooting Ignition Coil Troubleshooting Table 8-6 Ignition Coil Troubleshooting Step Ignition Coil Test Make sure the burner is off. Check resistance between each of the springs and the ground (exposed metal on the burner). The meter should read less than 2000 ohms.

  • Page 70: Smoke Coming Out Of The Exhaust Stack

    Patcher 4 Part Manual Chapter 8 Troubleshooting Smoke Coming Out of the Exhaust Stack Table 8-8 Smoke Coming Out of the Exhaust Stack Step Smoke Coming Out of the Exhaust Stack White smoke indicates that there is too much air being forced though the burner. Loosen the Air Shutter screw and rotate the Air Shutter clockwise to increase air and counterclockwise to reduce air.

  • Page 71: Burner Electrode Adjustment

    Patcher 4 Part Manual Chapter 8 Troubleshooting Burner Electrode Adjustment Figure 8-2 Diesel Burner Electrode Adjustment Burner Air Settings Table 8-9 Burner Air Settings Main Burner Settings Toolbox Burner Settings Air Shutter Air Band Fuel Pressure 140 PSI 140 PSI Figure 8-3 Diesel Burner Air Settings Ignition coil locking tab...

  • Page 72: Material Is Heating Slowly

    Patcher 4 Part Manual Chapter 8 Troubleshooting Material is Heating Slowly Table 8-10 Material is Heating Slowly Step Material is Heating Slowly With the material level half or less, open the loading lid and inspect the inside edge of the material tank.

  • Page 73: Table 8-12 Mixer Basic Visual Troubleshooting (Continued)

    Patcher 4 Part Manual Chapter 8 Troubleshooting Table 8-12 Mixer Basic Visual Troubleshooting (continued) Step Possible Cause If . . . • Yes, this can cause the agitator to jam. Use Open the Material loading door. Are there more than six (20) un-melted blocks in the the mixer toggle switch to move the agitator tank? forward and backward until the material...

  • Page 74: Table 8-14 Mixer Electrical Troubleshooting (Continued)

    Patcher 4 Part Manual Chapter 8 Troubleshooting Table 8-14 Mixer Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, go to Step 5. Is there 12Vdc between the "Mixer" toggle switch center post green wire and the main •...

  • Page 75: Figure 8-4 Checking Din Plug Voltage

    Patcher 4 Part Manual Chapter 8 Troubleshooting Table 8-15 Mixer Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, go to Step 11. Is the din plug light "ON" when the "Mixer" is in the "C ’Clockwise" position? •...

  • Page 76: Mixer Hydraulic Troubleshooting

    Patcher 4 Part Manual Chapter 8 Troubleshooting Mixer Hydraulic Troubleshooting Table 8-16 Mixer Hydraulic Troubleshooting Step Possible Cause If . . . • Yes, go to Step 2. Does the coil magnetize when the din plug green light is "ON"? •...

  • Page 77: Figure 8-5 Hydraulic Pressure Adjustment Location

    Patcher 4 Part Manual Chapter 8 Troubleshooting Figure 8-5 Hydraulic Pressure Adjustment Location Set pressure is 2000 PSI. Pressure Adjustment Port Figure 8-6 Din Plug Layout Counterclockwise Plug Clockwise Plug (Side with pressure adj. port) ©2023 by Crafco, Inc. All Rights Reserved………………………...…………………………..…………..Troubleshooting 8-17...

  • Page 78: Hydraulic Schematic

    Patcher 4 Part Manual Chapter 8 Troubleshooting Hydraulic Schematic Figure 8-7 Hydraulic Schematic (P/N 56690N) HYD PUMP - PT# 56807 0.62 in. / rev. - 7.51 gpm @ 2800 rpm 29821 29824 29991 29819 (REF.) (REF. ) HYD RESERVIOR - PT# 44030 16.75 GAL.

  • Page 79: Rtd Sensor Ohms Vs. Temperature

    Patcher 4 Part Manual Chapter 8 Troubleshooting RTD Sensor Ohms vs. Temperature Table 8.15 below shows what the ohm reading should be for a given temperature. The following are the instructions for using the table. 1. Measure the resistance (ohms) of the sensor in question with an ohm meter. 2.
  • Page 80 Patcher 4 Part Manual Chapter 8 Troubleshooting Table 8-15.1 RTD Sensor Ohms vs. Temperature (continued) °F 1506.6 1508.7 1510.8 1512.8 1514.9 1517.0 1519.1 1521.2 1523.3 1525.3 1527.4 1529.5 1531.6 1533.7 1535.7 1537.8 1539.9 1542.0 1544.1 1546.1 1548.2 1550.3 1552.4 1554.5 1556.5 1558.6 1560.7...

  • Page 81: 9.0 About The Illustrated Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List 9.0 About the Illustrated Parts List The Illustrated Parts List (IPL) is designed to help technical service or maintenance personnel correctly identify orderable replacement parts. The figure and table titles reference the part number (PN) to which they apply. The PN’s for each of the Patcher 4 models are as follows: Patcher II PN 56700 Illustrations and pictures are designed to show general shape and size of a part and the relationship...

  • Page 82: Patcher 4 Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Patcher 4 Parts List Figure 9-1 Right ISO View ©2023 by Crafco, Inc. All Rights Reserved………………………...………………………..………..Illustrated Parts List 9-2...

  • Page 83: Table 9-1 Right Iso View Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-1 Right Iso View Parts List FIG. ITEM PART NO. DESCRIPTION Fig. 9.1 32246 CHUTE SCRAPER ASSEMBLY 32258 TANK SCRAPER ASSEMBLY 32243 TECHCRETE IRONING WAND ASSEMBLY 56679N VENT COVER 57440N FUEL TANK ASSEMBLY, 32 GALLON DOT 47129N ENGINE ASSY, 3CJ1, D.E.C, NO GEN...

  • Page 84: Figure 9-2 Left Iso View

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Figure 9-2 Left ISO View 3 2 1 ©2023 by Crafco, Inc. All Rights Reserved………………………...………………………..………..Illustrated Parts List 9-4...

  • Page 85: Table 9-2 Left View Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-2 Left View Parts List FIG. ITEM DESCRIPTION PART NO. Fig. 9.2 24000 BATTERY, 12-VOLT 24002 BATTERY BOX BATTERY STRAP W/BUCKLE 4’ 24037 42574 MIXER HYDRAULIC MOTOR 57786 6:1 GEAR BOX ASSY 57750 DRIVE COVER 56681N...

  • Page 86: Figure 9-3 Top Section View

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Figure 9-3 Top Section View ©2023 by Crafco, Inc. All Rights Reserved………………………...………………………..………..Illustrated Parts List 9-6...

  • Page 87: Table 9-3 Top Section View Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-3 Top Section View Parts List FIG. ITEM PART NO. DESCRIPTION Fig.9.3 38020N JUNCTION BOX, TRAILER LIGHT BATTERY CABLE, BLACK, 4 GA X 15” L 24010 BATTERY CABLE, BLACK, 6 GA X 24” L 37038 56807 HYDRAULIC PUMP...

  • Page 88: Fuel And Hydraulic Tanks Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Fuel and Hydraulic Tanks Parts List Figure 9-4 Fuel and Hydraulic Tanks Section View Table 9-4 Fuel and Hydraulic Tanks Parts List FIG. ITEM PART NO. DESCRIPTION Fig. 9.4 43732N CAP, NON-VENTED, DIESEL FUEL TANK SECTION B-B 43734N VENT FUEL TANK SAFETY...
  • Page 89 Patcher 4 Part Manual Chapter 9 Illustrated Parts List This page is left blank on purpose. ©2023 by Crafco, Inc. All Rights Reserved………………………...………………………..………..Illustrated Parts List 9-9...

  • Page 90: Engine Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Engine Parts List Figure 9-5 Engine ©2023 by Crafco, Inc. All Rights Reserved………………………...………………………..………..Illustrated Parts List 9-10...

  • Page 91: Figure 9-5 Engine

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-5 Engine Parts List FIG. ITEM PART NO. DESCRIPTION Fig. 9.5 47129N ISUZU 20 HP 3CJ1 ENGINE, D.E.C. NO GEN. 47158N RADIATOR KIT 47149N CHECK VALVE 41867 FUEL FILTER, ENGINE 29399 ENGINE ISOMOUNT 47150...

  • Page 92: Hydraulic Schematic And Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Hydraulic Schematic and Parts List Figure 9-6 Hydraulic Schematic (P/N 56690N) 29824 29821 HYD. PUMP PT# 56807 29819 29991 HYD. RESERVIOR PT# 44030 29807 29807 C-CHANNEL C-CHANNEL MIXER MOTOR 22029 PT# 42574 29805 29805 29807...

  • Page 93: Table 9-6 Hydraulic Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-6 Hydraulic Parts List ITEM PART NO. DESCRIPTION Fig.9.6 HYDRAULIC RESERVOIR TO HYDRAULIC PUMP (SUCTION) 29819 3/4" TUBE X 3/4" STD THRD O-RING STR 12G4H 12G-12FJX90S 12G-16FJX 31 26.25 31” SUCTION HOSE 1"...

  • Page 94: Figure 9-7 Hydraulic Schematic (Pn 56690N) (Continued)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Figure 9-7 Hydraulic Schematic (PN 56690N) (continued) 29824 29821 HYD. PUMP PT# 56807 29819 29991 HYD. RESERVIOR PT# 44030 29807 29807 C-CHANNEL C-CHANNEL MIXER MOTOR 22029 PT# 42574 29805 29805 29807 29807 C-CHANNEL C-CHANNEL...

  • Page 95: Table 9-7 Hydraulic Parts List (Continued)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-7 Hydraulic Parts List (continued) ITEM PART NO. DESCRIPTION Fig. 9.7 “T” RETURN LINE HYDRAULIC VALVE "OUT" PORT 5/8" TUBE X 5/8" STD. THRD. O-RING STR 29812 8M3K 8G-10FJX 8G-10FJX90S 28.75 25 HYD HOSE X 28 3/4"...

  • Page 96: Hydraulic Valve Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Hydraulic Valve Parts List Figure 9-8 Hydraulic Valve Table 9-8 Hydraulic Valve Parts List FIG. ITEM PART NO. DESCRIPTION Fig. 9.8 56340 HYDRAULIC VALVE ASSEMBLY 56481 COIL, DIRECTIONAL VALVE 44812 PRESSURE RELIEF VALVE 56483 DIRECTIONAL VALVE BLOCK ©2023 by Crafco, Inc.

  • Page 97: Hitch Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Hitch Parts List Figure 9-9 Hitch Table 9-9 Hitch Parts List FIG. ITEM PART NO. DESCRIPTION Fig. 9.9 31512 CIRCUIT BREAKER 52310 WIRE ASSY, CIR. BRKR. TO BATT 48” X 3/8” CHAIN 20130 20132 SHACKLE CONNECTING LINK...

  • Page 98: Diesel Fuel Line Schematic

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Diesel Fuel Line Schematic Figure 9-10 Diesel Fuel Line Schematic (P/N 26599) ENGINE FUEL DIESEL ENGINE FILTER HOUSING FUEL RAIL CHECK VALVE ENGINE SUPPLY LINE ENGINE OUTLET INLET WATER SEPARATOR LIFT PUMP ENGINE RETURN LINE DRAIN PORT...

  • Page 99: Table 9-10 Diesel Fuel Line Schematic Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-10 Diesel Fuel Line Schematic Parts List FIG. ITEM PART NO. DESCRIPTION Fig. 9.10 41867 FUEL FILTER ELEMENT 47150 WATER SEPARATOR 47149N VALVE, CHECK, INLINE 5/16 BARB BRONZE BALL VALVE, 1/4” 29195 ©2023 by Crafco, Inc.

  • Page 100: Main Diesel Burner Parts List (P/N 46380)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Main Diesel Burner Parts List (P/N 46380) Figure 9-11 Main Diesel Burner (P/N 46380) BACK VIEW SIDE VIEW ©2023 by Crafco, Inc. All Rights Reserved………………………...………………………..………..Illustrated Parts List 9-20...

  • Page 101: Toolbox Diesel Burner Parts List (P/N 57485N)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-11 Main Diesel Burner Parts List (P/N 46380) FIG. ITEM PART NO. DESCRIPTION Fig. 9.11 41949 IGNITION TRANSFORMER 41870 CAD EYE (NOT SHOWN) 42335 DC CONTROLLER 41890 BLOWER MOTOR 41970 COUPLING, FUEL PUMP 41892 PUMP, FUEL...

  • Page 102: Control Box Parts List (P/N 47265N)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Control Box Parts List (P/N 47265N) Figure 9-13 Control Box Parts List (P/N 47265N) MATERIAL PAKSTAT HTO PAKSTAT TO REAR PANEL WORK SAFETY LIGHTS LIGHTS TH1-13 BLK-1 NC NC ORN-1 WHT/RED-1 BRN-CH1-P W1RD04-01 RED-3...

  • Page 103: Table 9-13 Control Box Parts List (P/N 47265N)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-13 Control Box Parts List (P/N 47265N) FIG. ITEM PART NO. DESCRIPTION Fig. 9.13 50251 READOUT, LCD 43391 TEMP CONTROLLER (P64A0918-903) PLUG 1/2” 24269 51651 LIGHT, PILOT 12VDC 38090N ENGINE CONTROLLER 46239 SWITCH, ON/OFF W/ KEY 51852...

  • Page 104: Electrical Wiring Harness Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Electrical Wiring Harness Parts List Figure 9-14 Electrical Wiring Harness Parts List Table 9-14 Electrical Wiring Harness Parts List FIG. ITEM PART NO. DESCRIPTION Fig. 9.14 38235N HARNESS, MACHINE, PTCHR 4 (SHOWN IN GREEN) 38504N TRAILER LIGHT HARNESS...
  • Page 105 Patcher 4 Part Manual Chapter 9 Illustrated Parts List This page is left blank on purpose. ©2023 by Crafco, Inc. All Rights Reserved………………………...………………………..………..Illustrated Parts List 9-25...

  • Page 106: Electrical Schematic Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Electrical Schematic Parts List Figure 9-15 Electrical schematic parts list (P/N 26582P4) LICENSE CENTER PLATE MARKER LAMP LAMP TOOLBOX BURNER GRN/WHT SWITCH SAFETY LID SWITCH RED/BLK WORK LIGHT AND SAFETY LIGHT WIRES TUCKED INTO HARNESS WHT/BLU (WORK) SAFETY...

  • Page 107: Table 9-15 Electrical Schematic Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-15 Electrical Schematic Parts List FIG. ITEM PART NO. DESCRIPTION Fig. 9.15 32371 LED CENTER MARKER LAMP 44797 LICENSE PLATE LIGHT 39566 SINGLE POLE SWITCH 39608 AUTOSTOP LID SWITCH 43465 RTD SENSOR 45376 DIN PLUG, W/ CABLE...

  • Page 108: Heated Toolbox Parts List (P/N 57450N)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Heated Toolbox Parts List (P/N 57450N) Figure 9-16 Heated Toolbox Parts List (P/N 57450N) DOORS NOT SHOWN FOR CLARITY ©2023 by Crafco, Inc. All Rights Reserved………………………...………………………..………..Illustrated Parts List 9-28...

  • Page 109: Table 9-16 Heated Toolbox Parts List (P/N 57450N)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-16 Heated Toolbox Parts List (P/N 57450N) FIG. ITEM PART NO. DESCRIPTION Fig. 9.16 57475N FUNNEL AND CHUTE ASSY, INSULATED 57463N INNER SIDE PANEL, SS, (1 IS ATTACHED TO DOOR) 57476N INNER BOTTOM/FRONT PANEL, SS 57474N...

  • Page 110: Optional Material Chute Parts List (P/N 56895N)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Optional Material Chute Parts List (P/N 56895N) Figure 9-17 Optional Material Chute (P/N 56895N) 12 6 ©2023 by Crafco, Inc. All Rights Reserved………………………...………………………..………..Illustrated Parts List 9-30...

  • Page 111: Table 9-17 Optional Material Chute (56895N)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-17 Optional Material Chute (56895N) FIG. ITEM PART NO. DESCRIPTION Fig. 9.17 20144 SHACKLE, 3/8 CHAIN WITH SCREW PIN 3/8”-16 HEX NUT 28502 1/2”-13 HEX NUT 28504 1/2”-13 UPSET LOCK NUT 28540 28636 1/2' FLAT WASHER...

  • Page 112: Optional Heated Chute Parts List (P/N 56890N)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Optional Heated Chute Parts List (P/N 56890N) Figure 9-18 Optional Heated Chute (P/N 56890N) ©2023 by Crafco, Inc. All Rights Reserved………………………...………………………..………..Illustrated Parts List 9-32...

  • Page 113: Table 9-18 Optional Heated Chute Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-18 Optional Heated Chute Parts List FIG. ITEM PART NO. DESCRIPTION Fig. 9.18 SHACKLE, 3/8” CHAIN WITH SCREW PIN 20144 1/2” STREET ELBOW, GALVANIZED 28238 28344 1/2" X 1/4" REDUCER BUSHING 3/8”-16 HEX NUT 28502 28504...

  • Page 114: Figure 9-19 Optional Heated Chute Parts List (Continued)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Figure 9-19 Optional Heated Chute Parts List (continued) ©2023 by Crafco, Inc. All Rights Reserved………………………...………………………..………..Illustrated Parts List 9-34...

  • Page 115: Table 9-19 Optional Heated Chute Parts List (Continued)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-19 Optional Heated Chute Parts List (continued) FIG. ITEM PART NO. DESCRIPTION Fig. 9.19 56694N HYDRAULIC TUBE, HEATED CHUTE PRESSURE P4 56812 EXTENDED MOUNTING BASE PLATE ASSEMBLY 56822 BUMPER MOUNTING, MATERIAL TROUGH ASSY 56832 600°...

  • Page 116: Hydraulic Schematic For Optional Heated Chute

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Hydraulic Schematic for Optional Heated Chute Figure 9-20 Hydraulic Schematic for Optional Heated Chute 29807 HOT OIL MOTOR - P/N 22302 29806 29809 29810 OUTSIDE 29824 29821 INSIDE 56693N HYD. PUMP STEEL TUBE PT# 56807 56694N...

  • Page 117: Table 9-20 Hydraulic Schematic For Optional Heated Chute Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-20 Hydraulic Schematic for Optional Heated Chute Parts List ITEM PART NO. DESCRIPTION Fig.9.20 HYDRAULIC RESERVOIR TO HYDRAULIC PUMP (SUCTION) 29819 3/4" TUBE X 3/4" STD THRD O-RING STR 31” SUCTION HOSE 12G4H 12G-12FJX90S 12G-16FJX 31 26.25 1"...

  • Page 118: Figure 9-21 Hydraulic Schematic For Optional Heated Chute (Continued)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Figure 9-21 Hydraulic Schematic for Optional Heated Chute (continued) 29807 HOT OIL MOTOR - P/N 22302 29806 29809 29810 OUTSIDE 29824 29821 INSIDE 56693N HYD. PUMP STEEL TUBE PT# 56807 56694N STEEL TUBE 29819 29991...

  • Page 119: Figure 9-8 Hydraulic Valve

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-21 Hydraulic Schematic for Optional Heated Chute Parts List (continued) ITEM PART NO. DESCRIPTION Fig. 9.21 “T” RETURN LINE HYDRAULIC VALVE "OUT" PORT 5/8" TUBE X 5/8" STD. THRD. O-RING STR 29812 8M3K 8G-10FJX 8G-10FJX90S 28.75 25 HYD HOSE X 28 3/4"...

  • Page 120: Heated Chute Pump And Motor Assembly (P/N 41696)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Heated Chute Pump and Motor Assembly (P/N 41696) Figure 9-22 Heated Chute Pump and Motor Assembly (P/N 41696) ©2023 by Crafco, Inc. All Rights Reserved………………………...………………………..………..Illustrated Parts List 9-40...

  • Page 121: Table 9-22 Heated Chute Pump And Motor Assembly Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-22 Heated Chute Pump and Motor Assembly Parts List FIG. ITEM PART NO. DESCRIPTION Fig. 9.22 22303 HYD. MOTOR MNTG BRACKET 40311 STRAIGHT THREAD ADAPTER 22302 HYDRAULIC MOTOR 1/4-28 X 5/8” HEX SCREW 28850 1/4”...

  • Page 122: Patcher Ii Options

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Patcher II Options Figure 9-23 Patcher 4 Options ©2023 by Crafco, Inc. All Rights Reserved………………………...………………………..………..Illustrated Parts List 9-42...

  • Page 123: Table 9-23 Options Parts List

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-23 Options Parts List FIG. ITEM PART NO. DESCRIPTION Fig. 9.23 24095K MAST MOUNTED STROBE LIGHT, CLASS II 24095KCL1 MAST MOUNTED STROBE LIGHT, CLASSI/CA TITLE 13 VARIOUS SAFETY & WORK LIGHTS, SEE SALES BROCHURE 45535 ENGINE COVER 45599...

  • Page 124: Figure 9-24 Patcher 4 Options

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Figure 9-24 Patcher 4 Options ©2023 by Crafco, Inc. All Rights Reserved………………………...………………………..………..Illustrated Parts List 9-44...

  • Page 125: Table 9-24 Options Parts List (Continued)

    Patcher 4 Part Manual Chapter 9 Illustrated Parts List Table 9-24 Options Parts List (continued) FIG. ITEM PART NUMBER DESCRIPTION 3/8” HOOK W/SAFETY LATCH Fig. 9.24 26119 56620N WHEEL AND TIRE ASSEMBLY, PATCHER 4 57781 PROPANE TORCH KIT (INCLUDES 30# LP BOTTLE) 26058 10# FIRE EXTINGUISHER 26059...

  • Page 127: Tools And Accessories

    Patcher 4 Part Manual Chapter 10 Tools and Accessories 10.0 Tools and Accessories ©2023 by Crafco, Inc. All Rights Reserved………………………..……………………………..………..Tools and Accessories 10-1...
  • Page 128 Patcher 4 Part Manual Chapter 10 Tools and Accessories Crafco Hot Mastic Applicator PN# 57650 For handling and distributing of patching materials from the Patcher II to the repair area. Propane heated with material side discharge gate. ©2023 by Crafco, Inc. All Rights Reserved………………………..……………………………..………..Tools and Accessories 10-2...
  • Page 130 ©2023 Crafco, Inc.

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