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Ergon CRAFCO 100CFM Instruction Manual

Super shot 250 diesel compressor melter
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SUPER SHOT 250 DIESEL
COMPRESSOR MELTER 100CFM
Parts Manual – 26638N
Revision 0

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  • Page 1 SUPER SHOT 250 DIESEL COMPRESSOR MELTER 100CFM Parts Manual – 26638N Revision 0...
  • Page 2 Fill in appropriate fields that apply to this machine Machine S/N: ________________________________ Hose S/N: __________________________________ Wand S/N: __________________________________ Pump S/N: _________________________________ Engine S/N: ________________________________ Compressor S/N: ____________________________...
  • Page 3 Super Shot 250 Diesel Melter Part Manual Revisions Revision Date 0) Initial Release 1/2021...
  • Page 4 Super Shot 250 Diesel Melter with Compressor 100 CFM PN 47900N...

  • Page 5: Table Of Contents

    Super Shot 250 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 California Proposition 65 ......................
  • Page 6 Super Shot 250 Diesel Melter Part Manual Table of Contents 6.4 Heat Transfer Oil ......................... 6-1 6.5 Wheel Bearing ........................6-1 6.6 Material Sensor Tube ......................6-1 6.7 Cleaning Material Tank and Sensor Area ................6-2 6.8 Lug Nuts ..........................6-2 6.9 Brakes ..........................
  • Page 7 Super Shot 250 Diesel Melter Part Manual Table of Contents Excessive Smoke Coming Out of Exhaust Stack ............8-7 Burner Lights but Shuts Down After 15 Seconds ............8-7 Testing DC Controller ....................8-8 Burner Fuel Solenoid Testing ..................8-8 Burner Ignition Coil Testing ..................
  • Page 8 Super Shot 250 Diesel Melter Part Manual Table of Contents 9.10 Hydraulic Diagram: PN 26659N ..................9-26 9.11 Diesel Fuel Line Schematic ..................... 9-32 9.12 Electrical Schematic ......................9-36 9.13 Air Compressor Assembly: PN 47480N ................9-38 9.14 Hydraulic Compressor Valve Assembly: PN 45425 ............9-40 9.15 High Output Air Lance PN: 47483N (standard) ..............
  • Page 9 Super Shot 250 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 10 Super Shot 250 Diesel Melter Part Manual List of Figures Fig. 8-8 Junction Box Voltage Testing ..................8-22 Fig. 8-9 Hose Circuit Schematic ....................8-23 Fig. 8-10 Junction Box Wiring ..................... 8-24 Fig. 8-11 Pump Schematic ......................8-34 Fig. 8-12 Engine Control Display DTC ..................8-38 Fig.
  • Page 11 Super Shot 250 Diesel Melter 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 Burner ......................
  • Page 12 Super Shot 250 Diesel Melter Part Manual List of Tables Table 6-18 Material Pump Replacement (continued) ..............6-18 Table 6-19 Material Pump Replacement (continued) ..............6-19 Table 6-20 Material Pump Replacement (continued) ..............6-20 Table 6-21 Material Pump Replacement (continued) ..............6-21 Table 6-22 Burner Fuel Filter Replacement ................
  • Page 13 Super Shot 250 Diesel Melter Part Manual List of Tables Table 8-27 Pump Electrical Troubleshooting (continued) ............8-33 Table 8-28 Pump Hydraulic Troubleshooting ................8-35 Table 8-29 Engine DTC Table ..................... 8-38 Table 8-30 Engine DTC Table (continued) .................. 8-39 Table 8-31 Engine DTC Table (continued) ..................
  • Page 14 Super Shot 250 Diesel Melter Part Manual List of Tables Table 9-23 Wand Assembly PN 52200 ..................9-45 Table 9-24 Engine Cover Assembly PN: 48120N (optional) ............9-47 Table 9-25 Hot Air Lance (optional) .................... 9-49...

  • Page 15: About This Manual

    Super Shot 250 Diesel Melter Part Manual Chapter 1 Introduction 1.0 About This Manual This manual is supplied with each new Crafco Super Shot 250 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 17: Safety Precautions

    Super Shot 250 Diesel Melter Part Manual Chapter 2 Safety 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. 2.1 General Safety •...

  • Page 18: California Proposition 65

    Super Shot 250 Diesel Melter Part Manual Chapter 2 Safety 2.4 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

    Super Shot 250 Diesel Melter Part Manual Chapter 2 Safety 2.6 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 20: Table 2-2 Safety Symbols And Notices (Continued)

    Super Shot 250 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. Read and understand operator and safety manuals Read Manual before operating machine.

  • Page 21: Limited Warranty

    Super Shot 250 Diesel Melter 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

    Super Shot 250 Diesel Melter Part Manual Chapter 3 Warranty Information 3.1 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

    Super Shot 250 Diesel Melter Part Manual Chapter 4 Machine Specifications 4.0 Machine Specifications Table 4-1 Machine Specifications Specification PN 47900N Vat Capacity 250 gallons (946.3 liters) Melt Capacity 2000 lbs. (907.1 kg.) per hour Heat Transfer Oil 47 gallons (177.9 liters) at 70°F Required Tank Construction Double boiler type...

  • Page 25: Operating Instructions

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions 5.0 Operating Instructions The Crafco Super Shot 250 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 26: Fig. 5-1 Hydraulic Fluid Level And Temp. Gauge

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions Fig. 5-1 Hydraulic Fluid Level and Temp. Gauge Dipstick for Heat Transfer Oil Level at 150°F Level at 70°F Level at 0°F Bottom of Dipstick Fig. 5-2 Heat Transfer Oil Dip Stick ©2021 by Crafco, Inc.

  • Page 27: Machine Start Up

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions 5.2 Machine Start Up Table 5-2 Starting the Burner Step Action Fully open the exhaust stack cover. Turn the key to the “ON” position. Allow engine controller to boot up. To start engine, press “Auto”...

  • Page 28: Table 5-3 Starting The Burner (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions Table 5-3 Starting the Burner (continued) Step Action 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”...

  • Page 29: Air Compressor

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions 5.3 Air Compressor: This unit is equipped with an air compressor, which is designed to assist in the cleaning of debris from cracks and joints. • Always use approved high-pressure air hoses with properly installed fittings that are not frayed or worn.

  • Page 30: About The Heated Hose, Wand, Valve, And Tip Guard

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions 5.4 About the Heated Hose, Wand, Valve, and Tip Guard The Heated Hose The heated hose supplied with the machine is Teflon-lined with steel over braid. It has a heating element, that runs the length of the hose to heat the material within the hose.

  • Page 31: Operating The Electric Hose

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions 5.5 Operating the Electric Hose Table 5-4 Operating the Electric Hose Step Action CAUTION Twisting and kinking of the electric hose (used on SS60, SS125, and SS250 Melter) causes the hose to fail; the electric heating wires are shorted out to the metal hose cover and the hose stops heating.

  • Page 32: Dispensing The Material

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions 5.6 Dispensing the Material Table 5-5 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 33: Loading Material Into The Sealant Tank

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions 5.8 Loading Material into the Sealant Tank This unit is equipped with a safety interlock system on the loading door. This system disables the mixer hydraulic system when the lid is open. This is a safety feature for the operator and should never be disabled for any reason.

  • Page 34: Material Tank Depth Chart

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions Material Tank Depth Chart Table 5-7 Material Tank Depth Chart CAPACITY IN CAPACITY IN CAPACITY IN CAPACITY IN DEPTH OF GALLONS LITERS BOTTOM GALLONS TOP LITERS TOP MATERIAL TANK BOTTOM UP DOWN DOWN...

  • Page 35: Shutting Down And Cleaning Out The Machine

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions 5.9 Shutting Down and Cleaning Out the Machine Table 5-8 Shutting Down and Cleaning Out the Machine Step Action CAUTION When shutting down the machine for the day, Crafco recommends leaving the melter about half full with material.

  • Page 36: Storing The Electric Hose For Transport

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions 5.10 Storing the Electric Hose for Transport Table 5-9 Hose for Transport Instructions Step Action Leave the hose in the boom, swing the boom toward the front of the machine and lock the boom into position with the latch provided.

  • Page 37: Overnight Heater Use

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions 5.11 Overnight Heater Use An overnight heater rod is available as an option. PN 24190 for 110V, and PN 24194 for 220V. The overnight heater may be used to maintain an overnight heat transfer oil temperature of approximately 200-250°F (93.3°C) Table 5-10 Overnight Heater Use Step...

  • Page 38: Mounting A Skid Machine

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions 5.12 Mounting a Skid Machine Table 5-11 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.

  • Page 39: Shot Timer Option

    Super Shot 250 Diesel Melter Part Manual Chapter 5 Operating Instructions 5.13 Shot Timer Option For more information on Shot Timer use, installation, and troubleshooting, please see the supplement manual that came with your machine or with the Shot Timer Kit if it was purchased separately.

  • Page 41: Maintenance Instructions

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions 6.0 Maintenance Instructions This chapter contains all normal maintenance instructions to properly maintain your machine. 6.1 Engine Refer to the manufacturer’s operating and maintenance instructions for the engine. 6.2 Air Compressor Table 6-1 contains the recommended service intervals for the air compressor, as well as the part numbers for the maintenance kits.

  • Page 42: Fig. 6-1 Lug Bolt Tightening Sequence

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions 6.7 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 43: Fig. 6-2 Temperature Control Calibration

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions 6.11 Temperature Control Calibration Check the control knob calibration weekly. Calibrate by turning the knob counterclockwise. If the marks do not align, loosen screw in knob and align the line on the control knob with the calibration mark on the scale plate.

  • Page 44: Heat Transfer Oil

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions 6.13 Maintenance Chart Table 6-2 Maintenance Chart Hours Possible Cause Procedure Refer to the manufacturer’s instructions Engine Check Oil Level for the engine Change the primary filter when restriction indicator says to. Engine Air Filter(s) Fig.

  • Page 45: Service Instructions

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions 6.14 Service Instructions Table 6-3 Service Instructions Step Action Do a general inspection of the machine at least once a week. Replace all worn or damaged parts. Note: Keep regular replacement items in stock for emergency repairs to prevent costly downtime.

  • Page 46: Recommended Spare Parts

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Table 6-5 General Maintenance Parts (continued) 47900N Quantity Description Part No. Burner Fuel Filter 41867 Pre-Fuel Filter 48162N Fuel Filter 48143N Oil Filter 48144N Air Filter 48147N Nozzle, Burner 1.65 x 80B 41881 Hydraulic Oil Filter 45438...

  • Page 47: Recommended Fluids And Lubricants

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions 6.17 Recommended Fluids and Lubricants Table 6-7 Recommended Fluids and Lubricants 48300N Application Recommended Full Point Ultra-Low Sulfur Diesel #2 Warm Climate Fuel 30 Gal (113 l) Ultra-Low Sulfur Diesel #1 Cold Climate Engine Oil Refer to engine manual 4.9 Qt.
  • Page 48 Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions 6.18 Applicable Brands of Heat Transfer Oil Table 6-8 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 49: Changing The Heat Transfer Oil

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions 6.20 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).

  • Page 50: Material Pump Replacement

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions 6.21 Material Pump Replacement Table 6-10 Material Pump Replacement Step Action Bring the melter to temperature as preparation to drain the sealant tank. Remove the pipe cap located at the rear of the machine and drain the sealant tank. WARNING The material in the sealant tank is extremely hot.

  • Page 51: Fig. 6-5 Removal Of Motor Mount Assembly

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Table 6-11 Material Pump Replacement (continued) Step Action Disassemble the connecting link and remove the drive chain. Loosen the set screw in the lower coupling half located between the hydraulic motor and the material pump drive shaft.

  • Page 52: Fig. 6-6 Supporting The Agitator Away From The Material Pump

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Table 6-12 Material Pump Replacement (continued) Step Action When the unit has cooled sufficiently, remove the six (6) bolts holding the paddles on top of the screen. Remove the paddles from the tank. Lift the agitator shaft and screen assembly as high as possible and insert a screwdriver into the shaft hole.

  • Page 53: Fig. 6-7 Unbolting The Material Pump

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Table 6-13 Material Pump Replacement (continued) Step Action Remove the six (6) bolts attaching the pump to the tank. Note: A clean pump was used in the figure below for clarity. (See Error! Reference source not found.)

  • Page 54: Fig. 6-8 Cleaning Of The Pump Mounting Plate

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Table 6-14 Material Pump Replacement (continued) Step Action Clean any sealant from the top of the pump mounting plate and clean the shaft holes. (See Fig. 6-8 Cleaning of the Pump Mounting Plate) CAUTION Premature pump wear results if the pump mounting plate and bolt holes are not...

  • Page 55: Fig. 6-9 Pump Drive Shaft Dry Fit To Material Pump

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Table 6-15 Material Pump Replacement (continued) Step Action Make sure that the pump shaft coupling fits correctly onto the new material pump before mounting the material pump inside the tank. Also make sure the pump spins freely.

  • Page 56: Fig. 6-10 New Material Pump Mounting

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Table 6-16 Material Pump Replacement (continued) Step Action Make sure the 1” material port matches the 1” hole in the pump plate; there should be an alignment pin in the pump plate to insure the correct positioning. Use new hardware to secure the material pump to the pump plate (6) 3/8”-16 x 5”...

  • Page 57: Fig. 6-11 Agitator Shaft And Paddles Mounting

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Table 6-17 Material Pump Replacement (continued) Step Action Crafco, Inc. recommends that you use a new screen assembly to ensure the agitator and paddles have good threads to secure with, along with new hardware. Fig.

  • Page 58: Fig. 6-12 Pump Shaft Placement

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Table 6-18 Material Pump Replacement (continued) Step Action Secure the agitator bearing using new hardware (2) ½” grade 8 washers, (2) ½” lock washer and (2) ½-13 hex nut. Note: Make sure the agitator spins freely at this point.

  • Page 59: Fig. 6-13 Pump Shaft To Hydraulic Pump Motor Placement

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Table 6-19 Material Pump Replacement (continued) Step Action Place the motor mounting bracket back into place, using new hardware (4) 5/16”-18 x 1” bolt and (4) 5/16” lock washer. Slide the pump shaft onto the hydraulic motor shaft and tighten the set screws.

  • Page 60: Fig. 6-14 Agitator Connecting Link

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Table 6-20 Material Pump Replacement (continued) Step Action Loosen the four bolts holding the agitator hydraulic motor in place and slide it toward the material pump hydraulic motor. Using a new chain assembly, wrap the double chain around both sprockets, with the master link provided with the chain.

  • Page 61: Fig. 6-15 Agitator Chain Tightening Steps

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Table 6-21 Material Pump Replacement (continued) Step Action Slide the agitator hydraulic motor away from the material pump hydraulic motor to tighten the agitator chain and then tighten the (4) bolts that hold the agitator hydraulic motor in place.

  • Page 62: Wand Repair Instructions

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions 6.22 Wand Repair Instructions The following sections will address how to replace the wand handle, wand cable, switch, and terminal block of the 52200 wand assembly. Actuator, actuator lock, and spring can also be replaced.

  • Page 63: Wand Handle Replacement

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Wand Handle Replacement 1. Follow steps 1-6 from 6.22.1 above. 2. Remove actuator, actuator lock, pin, and spring. 3. Remove (2) #4-40 x 1/2” pan head screws from switch, then remove switch from handle. 4.

  • Page 64: Fig.6-18 Terminal Block Wiring

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Fig.6-18 Terminal Block Wiring Fig.6-19 Actuator Spring Location ©2021 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-24...

  • Page 65: Fig.6-20 Actuator / Trigger Assembly

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions Pin location Spring location Switch lever location Fig.6-20 Actuator / Trigger Assembly ©2021 by Crafco, Inc. All Rights Reserved………………..………………………………..….…Maintenance Instructions 6-25...

  • Page 66: Burner Fuel Filter Replacement

    Super Shot 250 Diesel Melter Part Manual Chapter 6 Maintenance Instructions 6.23 Burner Fuel Filter Replacement For machines that have a separate fuel filter for the burner, follow the steps below to replace the fuel filter. Table 6-22 Burner Fuel Filter Replacement Step Action The machine should be off and cooled to ambient temperature.

  • Page 67: How To Use A Multimeter

    Super Shot 250 Diesel Melter Part Manual Chapter 7 Troubleshooting (44100) 7.0 How to Use a Multimeter Melters use 12-volt direct current (DC) to power the burner, hydraulic valves, and trigger on electric wand. The DC power is from a 12-volt battery. The electric hose and wand uses 24-volt 3-phase alternating current (AC).

  • Page 68: Checking Amperage

    Super Shot 250 Diesel Melter Part Manual Chapter 7 Troubleshooting (44100) 7.4 Checking Amperage The Multimeter can be used to check amperages under 10 amps in AC or DC current. When checking the amperage of the electric hose always use a clamp-on amp meter. (See Fig.

  • Page 69: Troubleshooting

    Super Shot 250 Diesel Melter Part Manual Chapter 7 Troubleshooting (44100) DC Voltage • Everything except Generator AC Voltage ~ • Generator Output Ohms Ω • Sensors • Hyd. Coils AC Amps ~ • Burner Ignition Coil • Hose Current Audible Continuity •...

  • Page 71: Diesel Burner Troubleshooting

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting 8.0 Troubleshooting 8.1 Diesel Burner Troubleshooting Symptom: Burner will Not Ignite Table 8-1 Basic Visual Troubleshooting Step Possible Cause If . . . • Yes, go to Step 2. Start Troubleshooting at the control box. Is •...

  • Page 72: Burner Electrical Troubleshooting

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-2 Basic Visual Troubleshooting (continued) Step Possible Cause If . . . • Yes, go to Is there smoke coming out of the exhaust Table 8-6 Smoke Coming Out of stack? Exhaust Stack.

  • Page 73: Table 8-4 Burner Electrical Troubleshooting (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-4 Burner Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, then there should be 12Vdc on the Is there 12Vdc between the positive and negative battery post? If this check is done battery side of the circuit breaker.

  • Page 74: Table 8-5 Burner Electrical Troubleshooting (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-5 Burner Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, check for loose or broken wires Is there 12Vdc between bottom terminal “ORN-1” wire of burner ON/OFF toggle between top terminal power switch and switch and nearby ground source (black terminal #3 of the hot oil PAKSTAT.
  • Page 75 Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Step Possible Cause If . . . • Yes, check for loose or broken wires Is there 12Vdc between top terminal of circuit breaker “RED-1” wire and nearby ground between top terminal of circuit breaker and source (black wire)? bottom terminal (red wire) of power switch.

  • Page 76: Fig. 8-1 Diesel Burner Schematic

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Detail View HOT OIL ORN-1 43391 HOSE MAT' L RED-3 YEL-CH1-E GRN-CH1-S CRANK COMPRESSOR BURNER LOCKOUT LOCKOUT ORN-1 HOSE MATERIAL 51672 51691 WHT/RED-1 WHT/RED-1 BRN-CH1-P RED-CH1-D RED-3 BLK-2 ORN-1 TAN-EH4 RED-2 WIRES NOT USED TO BE FOLDED AND COVERED RED-2...

  • Page 77: Excessive Smoke Coming Out Of Exhaust Stack

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Excessive Smoke Coming Out of Exhaust Stack Table 8-6 Smoke Coming Out of 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 counterclockwise to reduce air.

  • Page 78: Testing Dc Controller

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Testing DC Controller Table 8-8 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 79: Burner Ignition Coil Testing

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Burner Ignition Coil Testing Table 8-10 Burner Ignition Coil Test Step Ignition Coil Test Make sure the burner is off. Open the ignition transformer (located above the blower) to expose the springs. Check resistance between each of the springs and the ground (exposed metal on the burner).

  • Page 80: Fig. 8-2 Diesel Burner Electrode Adjustment

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting 5/32 ELECTRODE R 1/4 5/32 NOZZLE Fig. 8-2 Diesel Burner Electrode Adjustment Air Shutter = 8 Air Band = 0 Fuel Pressure = 140 PSI Adjustment Plate = 3 IGNITION COIL LOCKING TAB AIR SHUTTER SCREW NOZZLE LINE NUT AIR SETTING #...

  • Page 81: Sealant Is Heating Slowly

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Sealant is Heating Slowly Table 8-11 Sealant is Heating Slowly Step Sealant is Heating Slowly With the material level half or less, open the loading lid and inspect the inside edge of the material tank.

  • Page 82: Mixer Troubleshooting

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting 8.2 Mixer Troubleshooting Symptom: Mixer Does Not Rotate Table 8-12 Basic Visual Troubleshooting Step Possible Cause If . . . • Yes, go to Step 2. Is the Material Temperature Display at or above 275°F? •...

  • Page 83: Mixer Electrical Troubleshooting

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Mixer Electrical Troubleshooting Note: Fig. 8-5 Mixer Schematic while troubleshooting the mixer electrical system. Table 8-13 Mixer Electrical Troubleshooting Step Possible Cause If . . . • Yes, then the mixer should be working. If it Is the amber light "ON"...

  • Page 84: Table 8-14 Mixer Electrical Troubleshooting (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-14 Mixer Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, replace mixer toggle switch Is there 12Vdc between the "Mixer" toggle switch center post “RED/WHT-TH1-26” wire •...

  • Page 85: Fig. 8-4 Checking Din Plug Voltage

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Fig. 8-4 Checking Din Plug Voltage ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting 8-15...

  • Page 86: Fig. 8-5 Mixer Schematic

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Detail View HOT OIL 43391 HOSE MAT' L 32513 CRANK COMPRESSOR BURNER LOCKOUT LOCKOUT 51678 HOSE MATERIAL 51691 51672 RED-3 ORN-1 EH-1 CH-1 TH-1 ENGINE HARNESS CHASSIS HARNESS TANK HARNESS BRN-TH1-13 BLU-TH1-14 Mixer Rev Coil...

  • Page 87: Mixer Hydraulic Troubleshooting

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Mixer Hydraulic Troubleshooting Table 8-15 Mixer Hydraulic Troubleshooting Step Possible Cause If . . . • Yes, go to Step 2. Remove the din plug, then remove the coil by unscrewing the nut on top of the coil.

  • Page 88: Fig. 8-6 Hydraulic Valve Pressure Setting

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting RVP PUMP PRESSURE RELIEF SET @ 1000 PSI RVA AGITATOR PRESSURE RELIEF SET @ 1200 PSI ALLEN SCREW PRESSURE RELIEF JAM NUT Agitation Direction = Counterclockwise Hydraulic Flow Compressor = Front section 18.79 GPM @ 2800 RPM Hydraulic Flow Compressor = Rear section 7.52 GPM @ 2800 RPM Compressor Relief = 2500 PSI Fig.

  • Page 89: Fig. 8-7 Din Plug Layout

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting 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 ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting 8-19...

  • Page 90: Hose Troubleshooting

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting 8.3 Hose Troubleshooting Symptom: Hose Does Not Heat Table 8-16 Basic Visual Hose Troubleshooting Step Possible Cause If . . . • Yes, go to Step 2. Is the Material Temperature Display at or above 275°F? •...

  • Page 91: Table 8-18 Hose Electrical Troubleshooting (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-18 Hose Electrical Troubleshooting (continued) Step Possible Cause If . . . • Check for continuity in the hose from end • Yes, go to Step 3a. to end. Disconnect the three blue heating •...

  • Page 92: Fig. 8-8 Junction Box Voltage Testing

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting 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 ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Troubleshooting 8-22...

  • Page 93: Fig. 8-9 Hose Circuit Schematic

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Detail View HOT OIL 43391 HOSE MAT' L BLU-CH1-B CRANK COMPRESSOR BURNER LOCKOUT LOCKOUT MATERIAL HOSE 51691 51672 EH-1 CH-1 TH-1 ENGINE HARNESS TANK HARNESS CHASSIS HARNESS RTD Sensor (1.08K ohms at 70°F) W HT-CH1-V BLK-CH1-U t°...

  • Page 94: Fig. 8-10 Junction Box Wiring

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting TRIGGER RED TRIGGER RED SENSOR BLACK SENSOR WHITE HEATER BLUE HEATER BLUE HEATER BLUE TRIGGER "RED-CH1-L" TRIGGER "GRN/WHT-CH1-M" SENSOR "BLK-CH1-U" SENSOR "WHT-CH1-V" HEATER GREEN HEATER WHITE HEATER BLACK KETTLE END WAND END Fig.

  • Page 95: Symptom: Trigger Is Not Working

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Symptom: Trigger is not Working Table 8-19 Trigger is Not Working Step Possible Cause If . . . • Yes, go to Check continuity between two red wires Table 8-22 Basic Visual Pump coming from the hose in junction box.

  • Page 96: Rtd Sensor Ohms Vs. Temperature

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting RTD Sensor Ohms vs. Temperature Table 8-23 and Table 8-24 below shows what the ohm reading would be for a given temperature. The following are the instructions for using the table. Measure the resistance (ohms) of the sensor in question with an ohm meter (See 7.3 Checking Resistance...

  • Page 97: Table 8-21 Rtd Sensor Ohms Vs. Temperature (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-21 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...

  • Page 98: Pump Troubleshooting

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting 8.4 Pump Troubleshooting Symptom: Material Does Not Dispense When the Pump is Activated Table 8-22 Basic Visual Pump Troubleshooting Step Possible Cause If . . . • Yes, go to Step 2. Start Troubleshooting at the control box.

  • Page 99: Pump Electrical Troubleshooting

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Pump Electrical Troubleshooting NOTE: Fig. 8-11 Pump Schematic while troubleshooting the pump electrical system. Table 8-23 Pump Electrical Troubleshooting Step Possible Cause If . . . • Yes, go to Step 2. Is the Hose Temperature at or above 325°F? •...

  • Page 100: Table 8-24 Pump Electrical Troubleshooting (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-24 Pump Electrical Troubleshooting (continued) Step Possible Cause If . . . Is there 12 Vdc between the trigger “RED” • Yes, go to Step 3c. wire (the second red trigger wire) going •...

  • Page 101: Table 8-25 Pump Electrical Troubleshooting (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-25 Pump Electrical Troubleshooting (continued) Step Possible Cause If . . . 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 102: Table 8-26 Pump Electrical Troubleshooting (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-26 Pump Electrical Troubleshooting (continued) Step Possible Cause If . . . • Yes, go to Step 9. Move to the rear of the machine. Remove the cover over the hydraulic manifold. •...

  • Page 103: Table 8-27 Pump Electrical Troubleshooting (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-27 Pump Electrical Troubleshooting (continued) Step Possible Cause If . • Yes, replace the toggle switch. Is there 12 Vdc between the "Pump" toggle switch center post “RED-TH1-26” wire and ground •...

  • Page 104: Fig. 8-11 Pump Schematic

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Detail View HOT OIL 43391 HOSE MAT' L 32513 BRN-TH1-9 CRANK COMPRESSOR BURNER LOCKOUT LOCKOUT PUMP FORWARD 51678 MATERIAL HOSE 51691 51672 BLK-2 RED-3 GRN/WHT-CH1-M RED-3 ORN-1 EH-1 CH-1 TH-1 RTD Sensor (1.08K ohms at 70°F) 18 GA.

  • Page 105: Pump Hydraulic Troubleshooting

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Pump Hydraulic Troubleshooting Table 8-28 Pump Hydraulic Troubleshooting If… Step Possible Cause • Yes, go to Step 2. Does the coil magnetize when the din plug amber light is “ON”? •...

  • Page 106: Dpf And Regen Modes

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting 8.5 DPF and Regen Modes This engine is equipped with an emissions control system that includes a “Diesel Particulate Filter” (DPF). This filter traps large soot particles during normal operation of the engine. Over time, the filter accumulates enough soot that it must be cleaned by running a “Regeneration”...

  • Page 107: Icons For The Regen Modes

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting 8.6 Icons for the Regen Modes The following ICONS appear during the various REGEN modes: Diesel Particulate Filter (DPF) Lamp A Solid Lamp provides warning that DPF soot levels are increasing. A Flashing Lamp indicates that DPF soot levels have reached a critical DPF LAMP stage where a DPF Regen is required.

  • Page 108: Engine Diagnostic Trouble Codes (Dtc)

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting 8.7 Engine Diagnostic Trouble Codes (DTC) How to use the Diagnostic Trouble Code Table The engine supplied on the Super Shot 250 Diesel 100CFM Compressor machine is capable of displaying Diagnostic Trouble Codes (DTC) on the engine control panel display.

  • Page 109: Table 8-30 Engine Dtc Table (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-30 Engine DTC Table (continued) Area Status SPN-FMI Crank angle error 7F8A1-7 Camshaft speed sensor Error (high voltage) 5B-3 Accelerator sensor 1 Error (low voltage) 5B-4 Accelerator sensor 1 Error (high voltage) 33-3 Intake throttle position sensor...

  • Page 110: Table 8-31 Engine Dtc Table (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-31 Engine DTC Table (continued) Area Status SPN-FMI H-bridge output: Short-circuit with B86-3 Intake throttle actuator power supply H-bridge output: Short-circuit with GRD B86-4 Intake throttle actuator H-bridge output: Short-circuit with B87-3 Intake throttle actuator power supply...
  • Page 111 Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-32 Engine DTC Table (continued) Area Status SPN-FMI Error (low voltage) AE7-1 EGR valve Stick error AE7-7 EGR valve Initialize error AE7-7 EGR valve Stick error AE7-7 EGR valve Initialize error AE7-7 EGR valve...

  • Page 112: Table 8-32 Engine Dtc Table (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-33 Engine DTC Table (continued) Area Status SPN-FMI Regeneration defect (stationary 7F951-11 regeneration not operated) Maintenance (maintenance is not CB3-16 conducted during the regular time) Ash cleaning request 1 E88-16 DPF operation interface Ash cleaning request 2...

  • Page 113: Table 8-34 Engine Dtc Table (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 8 Troubleshooting Table 8-35 Engine DTC Table (continued) Description SPN-FMI 40181-4 Low oil pressure 40181-5 Low fuel level 40181-6 Under speed 40181-7 Over speed 40181-8 Low battery voltage 40181-9 High battery voltage 40181-10 Low coolant level 40181-11...

  • Page 115: About The Illustrated Parts List

    Super Shot 250 Diesel Melter 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 PNs for each of the Super Shot 250 Diesel Compressor Melter machine models are as follows: •...

  • Page 116: Super Shot 250 Diesel Melter Comp. 100 Cfm

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.2 Super Shot 250 Diesel Melter Comp. 100 CFM Fig. 9-1 Super Shot 250 Diesel Melter Comp. 100 CFM ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-2...

  • Page 117: Table 9-1 Super Shot 250 Diesel Melter Comp. 100 Cfm

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-1 Super Shot 250 Diesel Melter Comp. 100 CFM FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-1 23095 SWIVEL BUSHING 23117 BREAKAWAY SWITCH 3” PINTLE HITCH 20014 OPT.

  • Page 118: Fig. 9-2 Super Shot 250 Diesel Melter Comp. 100 Cfm (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Fig. 9-2 Super Shot 250 Diesel Melter Comp. 100 CFM (continued) ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-4...

  • Page 119: Table 9-2 Super Shot 250 Diesel Melter Comp. 100 Cfm (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-2 Super Shot 250 Diesel Melter Comp. 100 CFM (continued) FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-2 24002 BATTERY BOX 24000 12V BATTERY 23082 TONGUE JACK 48”...

  • Page 120: Fig. 9-3 Super Shot 250 Diesel Melter Comp. 100 Cfm (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 55 56 Fig. 9-3 Super Shot 250 Diesel Melter Comp. 100 CFM (continued) ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-6...

  • Page 121: Table 9-3 Super Shot 250 Diesel Melter Comp. 100 Cfm (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-3 Super Shot 250 Diesel Melter Comp. 100 CFM (continued) FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-3 45550 HOSE BOOM 43355 OVERFLOW TANK 47917N DIP STICK, SS250 26025 AIR BREATHER, HEAT TRANSFER OIL HOSE, 3/4”...

  • Page 122: Tank Assembly

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.3 Tank Assembly Fig. 9-4 Tank Assembly ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-8...

  • Page 123: Table 9-4 Tank Assembly

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-4 Tank Assembly FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-4 44165 SPROCKET DRIVEN 43321 CHAIN DRIVE 44163 KEY, SPROCKET 43760 BEARING, FLANGED 47918N SHAFT, DRIVE PUMP 47920N SHAFT AGITATOR 43655...

  • Page 124: Control Box Assembly: Pn: 47252N

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.4 Control Box Assembly: PN: 47252N RED-1 RED-1 BLK-1 RED-EH3 RED-EH1 BLK-FUSE RED-1 RED-1 BRN-TH1-13 BRN-TH1-7 51678 32513 BLK-1 WHT/GRN RED/WHT-TH1-26 TH1-17 BRN-TH1-15 WHT/GRN WHT/RED-TH1-1 TH1-6 BLK-FUSE GRY-1 WHT/BLU-TH1-2 RED-3 GRN-CH1-S...

  • Page 125: Table 9-5 Control Box Assembly: Pn: 47252N

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-5 Control Box Assembly: PN: 47252N FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-5 51852 CONTACT BLOCK, N.O. 51665 CIRCUIT BREAKER, 15 AMP 50719 TOGGLE SWITCH, SPST ON-OFF 52338 TOGGLE SWITCH, SPDT ON-(ON) 46494...

  • Page 126: Engine Assembly: Pn 48000N

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.5 Engine Assembly: PN 48000N Fig. 9-6 Engine Assembly: 48000N ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-12...

  • Page 127: Table 9-6 Engine Assembly: Pn 48000N

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-6 Engine Assembly: PN 48000N FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-6 48147N AIR FILTER ELEMENT 48113N FILTER STATUS INDICATOR VALVE – CHECK INLINE 5/16 BARB 47149N 48143N FILTER, FUEL...

  • Page 128: Fig. 9-7 Engine Assembly: Pn 48000N (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Fig. 9-7 Engine Assembly: PN 48000N (continued) ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-14...

  • Page 129: Table 9-7 Engine Assembly: Pn 48000N (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-7 Engine Assembly: PN 48000N (continued) FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-7 48135N ISOMOUNT RADIATOR LOWER 48134N ISOMOUNT RADIATOR UPPER (NOT SHOWN) 45748 DRIVE BELT, HANG DOWN ALT/GENERATOR 43612 ALT/GENERATOR 12V 3-PHASE 48141N...

  • Page 130: Fig. 9-8 Engine Assembly: Pn 48000N (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Fig. 9-8 Engine Assembly: PN 48000N (continued) ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-16...

  • Page 131: Table 9-8 Engine Assembly: Pn 48000N (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-8 Engine Assembly: PN 48000N (continued) FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-8 48000N ENGINE YANMAR 3TNV86CT COMPLETE 57310 PUMP, HYDRAULIC 48136N COOLANT OVERFLOW BOTTLE 48148N RADIATOR 48160N ALTERNATOR, ENGINE...

  • Page 132: Hydraulic Control Valve Assembly: Pn 45420

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.6 Hydraulic Control Valve Assembly: PN 45420 Fig. 9-9 Hydraulic Control Valve Assembly: PN 45420 ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-18...

  • Page 133: Table 9-9 Hydraulic Control Valve Assembly: Pn 45420

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-9 Hydraulic Control Valve Assembly: PN 45420 FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-9 45418 VALVE, DIRECTIONAL REXROTH 45436 COIL, DIRECTIONAL VALVE REXROTH 45417 VALVE RELIEF 29897 FITTING, #8 ORB X #8 MALE JIC STR 45413...

  • Page 134: Material Flow Control Assembly: Pn 46060

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.7 Material Flow Control Assembly: PN 46060 Fig. 9-10 Material Flow Control Assembly: PN 46060 ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-20...

  • Page 135: Table 9-10 Material Flow Control Assembly: Pn 46060

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-10 Material Flow Control Assembly: PN 46060 FIG. ITEM PART NO. DESCRIPTION QTY. 3/8” TUBE X 1/2” O-RING ELBOW Fig. 9-10 29869 46077 KNOB ONLY 45431 CARTRIDGE, FLOW CONTROL (WITH KNOB) 46060 HYDRAULIC FLOW CONTROL (NO FITTINGS) 3/8”...

  • Page 136: Pump/Mixer Motor Assembly: Pn 44832

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.8 Pump/Mixer Motor Assembly: PN 44832 Fig. 9-11 Pump/Mixer Motor Assembly: PN 44832 ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-22...

  • Page 137: Table 9-11 Pump/Mixer Motor Assembly: Pn 44832

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-11 Pump/Mixer Motor Assembly: PN 44832 FIG. ITEM PART NO. DESCRIPTION QTY. 3/8” TUBE X 5/8” O-RING ADAPTOR Fig. 9-11 22029 22027 HYDRAULIC MOTOR, MIXER 44809 HYDRAULIC MOTOR, PUMP 1/2”...

  • Page 138: Diesel Burner Assembly: Pn 46380

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.9 Diesel Burner Assembly: PN 46380 BACK VIEW SIDE VIEW Fig. 9-12 Diesel Burner Assembly: PN 46380 ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-24...

  • Page 139: Table 9-12 Diesel Burner Assembly: Pn 46380

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-12 Diesel Burner Assembly: PN 46380 FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-12 41949 IGNITION TRANSFORMER 41870 CAD EYE (NOT SHOWN) 42335 DC CONTROLLER 41890 BLOWER MOTOR 41970 COUPLING, FUEL PUMP 41892...

  • Page 140: Hydraulic Diagram: Pn 26659N

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.10 Hydraulic Diagram: PN 26659N Fig. 9-13 Hydraulic Diagram: PN 26659N ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-26...

  • Page 141: Table 9-13 Hydraulic Diagram: Pn 26659N

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-13 Hydraulic Diagram: PN 26659N FIG. ITEM PART NO. DESCRIPTION Fig. 9-13 HYDRAULIC RESERVOIR TO HYDRAULIC PUMP SUCTION PORT 29885 FITTING, #20 ORB X #20 JIC 20GMVPLUS 20G-20FJX90M 20G-20FJX 24 HYDRAULIC HOSE 29888 FITTING, #20 ORB X #20 JIC 45°...

  • Page 142: Fig. 9-14 Hydraulic Diagram: Pn 26659N (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Fig. 9-14 Hydraulic Diagram: PN 26659N (continued) ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-28...

  • Page 143: Table 9-14 Hydraulic Diagram: Pn 26659N (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-14 Hydraulic Diagram: PN 26659N (continued) FIG. ITEM PART NO. DESCRIPTION Fig. 9-14 FLOW CONTROL VALVE “1” TO HYDRAULIC VALVE “PA” PORT 29897 FITTING, #8 ORB X #8 JIC 8M3K 8G-6FJX 8G-8FJX 24 HYDRAULIC HOSE 40311...

  • Page 144: Fig. 9-15 Hydraulic Diagram: Pn 26659N (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Fig. 9-15 Hydraulic Diagram: PN 26659N (continued) ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-30...

  • Page 145: Table 9-15 Hydraulic Diagram: Pn 26659N (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-15 Hydraulic Diagram: PN 26659N (continued) FIG. ITEM PART NO. DESCRIPTION Fig. 9-15 COMPRESSOR VALVE “1” PORT TO COMPRESSOR MOTOR 29821 FITTING, #12 ORB X #10 JIC 45475 COMPRESSOR SUPPLY LINE 29819...

  • Page 146: Diesel Fuel Line Schematic

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.11 Diesel Fuel Line Schematic Fig. 9-16 Diesel Fuel Line Schematic ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-32...

  • Page 147: Table 9-16 Diesel Fuel Line Schematic

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-16 Diesel Fuel Line Schematic FIG. ITEM PART NO. DESCRIPTION QTY. 1. ENGINE RETURN LINE TO DIESEL FUEL TANK Fig. 9-16 ENG INJECTOR. HOUSING, #6 HOSE PUSH-ON REF.

  • Page 148: Fig. 9-17 Diesel Fuel Line Schematic (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Fig. 9-17 Diesel Fuel Line Schematic (continued) ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-34...

  • Page 149: Table 9-17 Diesel Fuel Line Schematic (Continued)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-17 Diesel Fuel Line Schematic (continued) FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-17 BALL VALVE TO BURNER FUEL FILTER 29984 HOSE BARB, 1/4MPT X 5/16 HOSE HOSE ASSEMBLY, 5/16 X 10”...

  • Page 150: Electrical Schematic

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.12 Electrical Schematic TRIGGER RED TRIGGER RED #4 MIXER #3 MIXER SENSOR BLACK FORWARD REVERSE SENSOR WHITE HEATER BLUE HEATER BLUE HEATER BLUE TRIGGER "RED-CH1-L" TRIGGER GRN/WHT-CH1-M" SENSOR "BLK-CH1-U" SENSOR "WHT-CH1-V"...

  • Page 151: Table 9-18 Electrical Schematic

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-18 Electrical Schematic FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-18 52364N CABLE ASSEMBLY, HOSE 38205N HARNESS - CHASSIS 38305N HARNESS - TANK 43886 CABLE ASSEMBLY, COMPRESSOR VALVE 52348N BATTERY CABLE, ENGINE TO GROUND LUG 52354N...

  • Page 152: Air Compressor Assembly: Pn 47480N

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.13 Air Compressor Assembly: PN 47480N 21 22 Fig. 9-19 Air Compressor Assembly: PN 47480N ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-38...

  • Page 153: Table 9-19 Air Compressor Assembly: Pn 47480N

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-19 Air Compressor Assembly: PN 47480N FIG. ITEM PART NO. DESCRIPTION QTY. NIPPLE, 3/4” NPT HEX Fig. 9-19 28004 TEE, 3/4” NPT PIPE 28254 BUSHING, 3/4” NPT X 1/2” NPT 28348 45564 NIPPLE, RESTRICTOR...

  • Page 154: Hydraulic Compressor Valve Assembly: Pn 45425

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.14 Hydraulic Compressor Valve Assembly: PN 45425 Fig. 9-20 Hydraulic Compressor Valve Assembly: PN 45425 ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-40...

  • Page 155: Table 9-20 Hydraulic Compressor Valve Assembly: Pn 45425

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-20 Hydraulic Compressor Valve Assembly: PN 45425 FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-20 45417 VALVE, RELIEF 45429 VALVE, LOGIC RELIEF 45426 COIL, SOLENOID VALVE 45424 VALVE, SOLENOID FITTING, #12 ORB X #10 JIC STRAIGHT 45436...

  • Page 156: High Output Air Lance Pn: 47483N (Standard)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.15 High Output Air Lance PN: 47483N (standard) Fig. 9-21 High Output Air Lance PN: 47483N (standard) Table 9-21 High Output Air Lance PN: 47483N (standard) FIG. ITEM PART NO.

  • Page 157: High Output Air Lance With Water Separator Pn: 47491N (Optional)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.16 High Output Air Lance with Water Separator PN: 47491N (optional) Fig. 9-22 High Output Air Lance with Water Separator PN: 47491N (optional) Table 9-22 High Output Air Lance with Water Separator PN: 47491N (optional) FIG.

  • Page 158: Wand Assembly Pn 52200

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.17 Wand Assembly PN 52200 Fig. 9-23 Wand Assembly PN 52200 ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-44...

  • Page 159: Fig. 9-23 Wand Assembly Pn 52200

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-23 Wand Assembly PN 52200 FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-23 52204 COVER, WAND 50278 TIP GUARD, LONG CLAMP ON 52206 CORD ASSEMBLY HANDLE, WAND – RIGHT (W/INSERTS) 52201RN HANDLE, WAND –...

  • Page 160: Engine Cover Assembly Pn: 48120N (Optional)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.18 Engine Cover Assembly PN: 48120N (optional) 5 6 7 Fig. 9-24 Engine Cover Assembly PN: 48120N (optional) ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-46...
  • Page 161 Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-24 Engine Cover Assembly PN: 48120N (optional) FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-24 48120N OPTIONAL ENGINE COVER COMPLETE 45597 RUBBER T-HANDLE DRAW LATCH 48127N HINGE DOOR YANMAR 48128N RADIATOR FILL DOOR 28671...

  • Page 162: Hot Air Lance (Optional)

    Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List 9.19 Hot Air Lance (optional) Fig. 9-25 Hot Air Lance (optional) ©2021 by Crafco, Inc. All Rights Reserved………………...…………………………………Illustrated Parts List 9-48...
  • Page 163 Super Shot 250 Diesel Melter Part Manual Chapter 9 Illustrated Parts List Table 9-25 Hot Air Lance (optional) FIG. ITEM PART NO. DESCRIPTION QTY. Fig. 9-25 45651 MIXING BLOCK 51401 NIPPLE, 1/4 NPT HEX VALVE, 1/4” BALL 29195 45656 AIR MIXER TUBE 45658 PROPANE TUBE W/ ORIFICE 45652...

  • Page 165: Tools And Accessories

    Super Shot 250 Diesel Melter Part Manual Chapter 10 Tools and Accessories 10.0 Tools and Accessories Crafco Sealing Foot/Protruded 27159 – 1/4” Protruding 27160 – 3/8” Protruding Crafco Applicator Disk 27162 – 3” Disk Assembly 27163 – 4” Disk Assembly 27164 –...
  • Page 166 Super Shot 250 Diesel Melter Part Manual Chapter 10 Tools and Accessories Crafco Pour Pot with Wheels - 40200 Crafco Heavy Duty Squeegee with Aluminum Handle - 27199 27195 – Replacement Blade Super Shot Drip Stopper Use with 50270 Duckbill 27114 –...
  • Page 167 Super Shot 250 Diesel Melter Part Manual Chapter 10 Tools and Accessories Crafco Love Velocity Heat Lance - 32259 Crafco Hand Torch W/ 20ft. Hose – 25012 W/ 12ft. Hose – 25016 W/ 50ft. Hose – 25021 ©2021 by Crafco, Inc. All Rights Reserved………………...………………………………..………………..Tools and Accessories 10-3...
  • Page 170 ©2021 Crafco, Inc.

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