SUPER SHOT 125 DIESEL MELTER
Contents
1. SS 125 MELTER PARTS LISTS SS 125 MELTER SS 125 MELTER PARTS LIST PART NUMBER ICI IN ren Lem 4 DISK W RESTRICTOR me 3 8 ROUND SEALING TP TANK DETAIL TANK DETAIL PART ITEM NUMBER E DESCRIPTION SPROCKET DRIVEN KEY SPROCKET CHAIN DRIVE BEARING FLANGED SHAFT AGITATOR SHAFT DRIVE PUMP KEY DRIVE SHAFT PUMP MATERIAL PADDLE AGITATOR 1 X 10 LG PIPE NIPPLE 1 PIPE CAP 2 X 4 LG PIPE NIPPLE 2 PIPE CAP 1 X 4 LG PIPE NIPPLE 1 PIPE ELBOW 1 X 3 4 REDUCER BUSHING CONTROL BOX2. p DIESEL BURNER HYDRAULIC DIAGRAM AGITATOR DIRECTION COUNTERCLOCKWISE MATERIAL PUMP DIRECTION CLOCKWISE HYDRAULIC FLOW 7 5 GPM 2400 RPM RELIEF VALVE RVA 1300 PSI RELEIF VALVE RVM 1800 PSI 44809 REF 43595 REF MATL PUMP MOTOR HYD TANK 22027 REF MIXER MOTOR mu mu 44871 REF 2 HYD PUMP 44820 REF HYD VALVE ASSY HYDRAULIC DIAGRAM 2 HYDRAULIC PUMP TO HYDRAULIC VALVE P PORT 29812 5 8 TUBE X 7 8 14 O RING ADAPTER AX6 10FJ 8FJ9L 94 HYDRAULIC HOSE ASSEMBLY 3 8 X 94 LONG 29897 1 2 TUBE X 3 4 16 O RING ADAPTER 3 HYDRAULIC VALVE A PORT TO MAT L PUMP MOTOR 40311 3 8 TUBE X 9 16 18 O RING ADAPTER AX6 6FJ 6FJ9L 20 HYDRAULIC HOSE ASSEMBLY 3 8 X 20 LONG 22029 3 8 TUBE X 7 8 14 O RING ADAPTER 4 HYDRAULIC VALVE PMP B PORT TO MAT L PUMP MOTOR 29919 1 2 TUBE X 9 16 18 O RING ADAPTER AX6 8FJ 6FJ9 18 HYDRAULIC HOSE ASSEMBLY 3 8 X 18 LONG 22029 3 8 TUBE X 7 8 14 O RING ADAPTER 5 HYDRAULIC VALVE AGIT B PORT TO MIXER MOTOR 29919 1 2 TUBE X
3. o MATERIAL w H 22 Bh IT i m 2 o H Be P rn nt Log RR e e 9 o RE TRA MEA reel 1 r IP Dp El HH EUV x E vela im B im a Kg Dunn ee ee Se 5 gt go Pavo Nore Poma mee 186 mues 9 WIRING es Ti Po aufs d ti Tur em t trl T 5 E lila nl o 1 1 E E enl 1 E 27 d P d 6 er rx B EB T Er 5 M lo fh e
4. 4 02 49 SuHO80 3313N TOH C C D C C 2 E 2 beca o 3 Bg O 1 JNd Q e ana em 90 350 o 0121 zm y 11 Dg o TmE ma of LLYN SLC et Nd 008 MW LHM MW LIHA am o o LL e EE T Ne o JVIddlVN o RTD SENSOR OHMS vs TEMPERATURE The following chart shows what the ohm reading would be for a given temperature The follow ing are the instructions for use 1 Measure the resistance Ohms of the sensor in question with an Ohm meter 2 Find the reading in the chart 3 Follow the row to the left and get the temperature in 10 increment then follow the column up to get the 1 increment Example 1573 Ohms 2302 o 930 3 932 5 934 7 936 9 939 1 941 3 943 4 945 6 947 8 950 0 952 2 954 3 956 5 958 7 960 9 963 0 965 2 967 4 969 6 971 8 20 973 9 976 1 978 3 980 5 982 6 984 8 987 0 989 1 991 3 993 5 30 995 7 997 8 1000 0 1002 2 1004 3 1006 5 1008
5. TROUBLE SHOOTING GUIDE TRIGGER RED TRIGGER RED SENSOR BLACK SENSOR WHITE HEATER BLUE HEATER BLUE HEATER BLUE HEAT ELEM BLUE HEAT ELEM BLUE HEAT ELEM BLUE TRIGGER RED TRIGGER GREEN QC SENSUR BLACK SENSOR WHITE HEATER WHITE HEATER GREEN e o HEATER BLACK END WAND END KE HOSE DOES NOT HEAT Step 1 Is the MATERIAL temperature at 275 F YES Go to step 2 NO Turn POWER toggle switch ON Step 2 Is HEATED HOSE light illuminated YES Go to step 3 NO Check for tripped circuit breaker in front panel YES Reset circuit breaker NO Remove front panel and check for 12 volts at pink wire terminal 2 of the material Pak Stat YES Go to step 2a NO Check for 12 volts at pink wire terminal 9 of the hose Pak Stat Step 2a Check for 12 volts at 3 terminal pink wire on the hose Pak Stat YES Go to step 2b NO Check wire connections or go to step 1 Step 2b Check for 12 volts at 4 terminal blue wire when Pak Stat is on YES Go to step 3 NO Check the ohms between black and white wires at terminals 6 and 7 NOTE One of the sensor wires must be diconnected to check resistance See page 28 for the corresponding temperature reading Temperature reading should match LCD readout YES Replace Pak Stat NO Replace hose Step 3 Check for 12 volts at BATT terminal on generator YES Go to step
6. 1 Part number 2 Machine model 3 Serial number Write telephone or fax CRAFCO INCORPORATED 420 N Roosevelt Ave Chandler Az 85226 2601 Phone 602 276 0406 Fax 480 961 0513 Toll Free 1 800 528 8242 A ELECTRIC HOSE CARE AND CAUTIONS A Twisting and kinking of the electric hose used on LF BAX SS60 SS125 and SS250 Melter is the number one cause of hose failure When this happens the electric heating wires are shorted out to the metal hose cover and the hose stops heating This type of failure is not covered under the Crafco warranty To help prevent twisting and kinking and the resulting hose damage the operator should a Not move or use hose unless it has been turned on at least 30 minutes and set at a minimum temperature of 300 F b Make sure hose swivel between hose and wand moves freely C Avoid bending the hose over sharp edges such as the edge of the frame or tank d Avoid twisting e Do not exceed 400 F on the hose or material temperature f Follow all instructions of the melter as well as those in the instruction manual HOSE TRANSPORT INSTRUCTIONS 1 Leaving the hose in the boom swing the boom clockwise towards the front of the machine and lock the boom into position with the latch provided 2 Place the wand in the wand holder and lock the wand into position with the latch provided CAUTION A Hose damage will occur if a b Hose is bent or moved when cold Hose
7. 4 NO Check 12 volts at terminal strip blue wire in control box Step 4 Check for 24 volts AC at the BLACK WHITE and GREEN wires on the generator Check between blk and wht blk and grn wht and grn YES Go to step 5 NO Replace generator 22 ae LINJA 50H LOH _SJMV SHLVS N UIHO SdWVSC UE jsvHd t LLYW ANYA 3SOH O 3n18 3n18 N3339 E 30714 3114 30748 3 ama 32914 ines 4404 99 STOH 5 2 H Ema H 1112 E pan WO 7 18 o JSHH 23 E 1 EN ii et TONE Nd Dog AE LAMA SIE IHA 3 L2 4 hu Lo fau 9 1014417 TROUBLE SHOOTING GUIDE Step 5 Check for 30 amps cold or 22 24 amps hot at the 3 blue wires in the junction box Always use a clamp on
8. 9 16 18 O RING ADAPTER AX6 8FJ 6FJ9 24 HYDRAULIC HOSE ASSEMBLY 3 8 X 22 LONG 22029 3 8 TUBE X 7 8 14 O RING ADAPTER 6 MIXER MOTOR TO HYDRAULIC VALVE AGIT A PORT T HYDRAULIC VALVE T PORT TO HYDRAULIC FILTER ELECTRICAL CABLES 9 SdaIA 3014 22914 N31V3H Ond ALIHM 19 H N3339 43193 E 3LIHN 208 8 T L 22914 aHSN S AI es o EE 5 gs 5 gt NH 01 ND e ae e fo SEAS 2 a 5 dlg3H a 2 A3311V8 9 S CT o IMA im ay MA A3XIW 5 35 D aaa a 33 3309I3L m F T WIVOS f Svo 3319338 1043108 SE NOLLON f 2096 UISNI s 55 JOSNIS S aIA N3339 See 210 10H ge gt Ja ea
9. Not Heat continued 24 Trouble Shooting Guide Material Does Not Dispense 24 Hose Circuit 25 Trouble Shooting Guide Material Does Not 26 Trouble Shooting Guide Pump Rotates but No Material Is Discharged 26 Trouble Shooting Guide Material Dispening Rate Too Slow 26 Hose Circuit Diagram sse enne 27 RTD Sensor Ohms vs 2 28 Diesel Burner Adjustments Diesel Burner 5 29 Burner Schematic iyd an A UN e aee ua EON 30 Burner Trouble Shootind lt 31 Hydraulic Schematic 5 2 AA La ti 32 Trouble Shooting Hydraulics sess 33 Parts 55125 Diesel Melter Diagrams and 34 39 Tank Detail Diagram and Parts sse nennen 40 41 Control Box Diagram and 42 43 Engine Assembly Diagram and 44 45 Hydraulic Control Valve Diagram and Parts 46 Pump Agitator Motor Assembly Diagram and 47 Diesel Burner Diagram
10. POINT 1 Cold climate Diesel 2 Warm climate rear Hydraulic oil Rondo HD 68 Texaco 24 Gals Heat transfer oil Regal R amp O 68 34 Gals The following is a list of suitable heat transfer oil to be used in Crafco equipment PRODUCER PRODUCT NUMBER TYPICAL SPECIFICATIONS ISO 68 Viscosity Index 95 100 Flash Point COC 445 F Pour Point 0 F Viscosity 100 F SUS 325 Carbon Residue 1 Viscosity 210 F SUS 50 A WARNING The heat transfer oil in this machine is a grade that has been tested and recommended by Crafco Inc The addition of any grade of oil not specifically recommended by Crafco Inc shall be cause for warranties to be voided All oils subjected to high temperatures deteriorate with time and lose many of their characteristics Tests conducted by Crafco Inc have determined that for best results and safety the heat transfer oil in this machine must be drained and replaced with Crafco Inc recommended oil after five hundred 500 hours of operation or one 1 year whichever occurs first SUPER SHOT PUMP REPLACEMENT Step 1 Bring melter up to temperature as preparation for draining the material tank Remove pipe cap located at rear of machine and drain tank CAUTION EXTREMELY HOT MATERIAL te Remove both guards from the motor mount to access the chain and sprockets Rotate agitator until connecting link is accessible Disassemble the connecting link and remove the drive
11. is twisted or bent at sharp radius Hose is moved prior to being turned on at least 35 minutes and set at 380 F Operator crosses over or under hose causing hose to twist or wires between hose and wand connection to twist or wrap up Swivel is cold and not free to move allowing hose to twist Hose to wand wiring is pulled stressed or used to support the wand MAINTENANCE INSTRUCTIONS ENGINE See Engine Owner Manual for operating and maintenance instructions HYDRAULIC SYSTEM Check hydraulic fluid daily Change hydraulic filter every 250 hours of operation Change hydraulic fluid every 500 hours of operation HEAT TRANSFER OIL Check oil level every 8 hours of operation Change oil every 500 hours of operation WHEEL BEARINGS Re pack wheel bearings every 24 000 miles or every two years using a good grade of bearing grease LUG NUTS Wheel nuts bolts should be torqued before first road use and after each wheel removal Check and retorque after the first 10 miles 25 miles and again at 50 miles Check periodi cally thereafter Torque in stagas 1st stage u 25 ft lbs ena stage 50 60 ft lbs 3rd stage 90 120 ft IDs 4 BOLT 5 BOLT 6 BOLT TIGHTENING SEQUENCE BRAKES Check brakes daily Refer to DEXTER AXLE Operation Maintenance Service Manual located in the manual box TONGUE JACK Lubricate tongue jack using a good grade of bearing grease MIXER BEARING Lubricate every 50 hours with good quality high tem
12. o gt 2 5 er D pS Loosen set screw in the lower coupling half between the hydraulic motor and the drive shaft er D Remove the 4 hydraulic hoses and cap off all ports Note Mark hoses for ease of replacement er D Remove the 4 bolts holding motor mount on top of melter Lift off motor mounting and set aside D N emove 2 bolts holding agitator shaft bearing Note Do not remove bearing from agitator shaft er D 00 When unit has cooled sufficiently remove 6 bolts holding paddles on top of screen Remove paddles from tank Step 9 Remove pump drive shaft from center of agitator shaft then lift agitator shaft and screen assembly as high as possible and insert screw driver into shaft hole This will support the assembly while removing the pump from the tank Step 10 Remove the 6 bolts which fasten the pump to the tank Lift the pump from the material tank CAUTION THE PUMP WEIGHS APPROXIMATELY 90LBS Step 10 IMPORTANT Clean any sealant from top of pump mounting plate and clean out shaft holes WARNING PREMATURE PUMP WEAR WILL OCCUR IF THIS IS NOT DONE SUPER SHOT PUMP REPLACEMENT UMP ASSEMBLY BULIS UNTING BULTS PUMP ASSEMBLY UMP MUUNTING PLATE BOTTOM
13. opens automatically when fluid pressure is applied The wand is equipped with a trigger lock to prevent accidental pump actuation when not pumping material The trigger should be in the LOCKED position at all times except when intentionally pumping material DISPENSING THE MATERIAL NOTE PROTECTIVE CLOTHING GLOVES HARD SOLED SHOES AND FACE SHIELD OR SAFETY GLASSES SHOULD BE WORN WHEN OPERATING OR FILLING THIS EQUIPMENT READ ENTIRE MANUAL BEFORE OPERATING The wand is equipped with a disposable duckbill valve on the end which shuts off the flow of material when the pump is turned off and prevents excessive dripping of material This valve also directs the material into a stream for easy application into the crack Other sealing tips are available See your local distributor for options Some difficulty may be encountered when starting up on cold days Although the wand is designed to heat the material all the way down to the tip on cold days it may be necessary to place the tip of the wand under the lid to facilitate material melting in the valve Insert the wand tip for only a short time before proceeding When the material and the hose have reached proper application temperature you are ready to dispense material Turn the pump speed control to the lowest setting by turning the speed control knob fully counter clockwise With the wand tip inserted into the top of the melter depress trigger on the wand and slowly increase pump spe
14. will result and slow down the melting process SHUTDOWN AND CLEAN OUT PROCEDURE When shutting down the machine for the day there are several schools of thought about how much material to leave in the machine Crafco recommends leaving the melter about half full This will give a fairly rapid heat up rate in the morning but will allow enough material to start dispensing right away when the material becomes molten 1 Leaving the hose in the boom swing the boom clockwise towards the front of the machine and lock the boom into position with the latch provided 2 Place the wand in the wand holder and lock the wand into position with the latch provided 3 Reverse the pump for approximately 30 seconds 4 Turn the mixer toggle switch to OFF 5 Turn the POWER switch to OFF 6 Shut the engine down by turning the key to the OFF position STORING MACHINE The melter should be stored in an area where moisture cannot enter the machine heating system such as hot oil controls etc Extended down time can cause moisture build up in heating oil tank If there is any suspicion that moisture may have collected in heat transfer oil warm heat transfer fluid to 300 F for 2 to 3 hours to evaporate the moisture INSTRUCTIONS FOR ORDERING PARTS Parts may be ordered from your local CRAFCO Distributor or directly from CRAFCO Inc if a distributor is not available in your area When ordering parts give the following information
15. 11114441 YANYANA 145410 L L 9 1198 I 010437105 5 FT gt en OMA Yanan Ya cl B li va 43324 OG PT LINIJO AILIN YNOH yl eE d pI HI O 407 Oel Hs suyo B 80D Le ee DSN3S e wl YR 4 02 o aly bn suuo FI E it 380112 1 2 440 MDSN3S 7 H H qm 114 coma B j 2 j A cow Nd AdH o o D yp 1 H ran 44 Cg H vong 2090 MIddIVM e 1HN SV 1433 3 jSDdafld V33N39 Y 81 JAA 11 BURNER TROUBLE SHOOTING BURNER WILL NOT IGNITE Step 1 Check for 12 volts at POWER toggle switch No Engine key OFF Toggle switch OFF Blown fuse Broken wire YES 12 volts at terminal 4 on MATERIAL Pak Stat NO Bad Pak Stat Faulty sensor YES Check for 12 volts at terminal 47 on OIL Pak Stat NO Bad Pak Stat Faulty sensor YES Check for 12 volts at solenoid frame NO Bad solenoid Bad connection at battery Faulty circuit breaker Broken or loose wire YES Faulty DC Controll
16. 7 1010 9 1013 0 1015 2 80 1103 8 1106 0 1108 1 1110 3 1112 4 1114 6 1116 7 1118 9 1121 0 1123 2 90 1125 3 1127 5 1129 6 1131 8 1133 9 1136 1 1138 2 1140 4 1142 5 1144 7 140 1232 4 1234 5 1236 7 1238 9 1240 9 1243 0 1245 2 1247 3 1249 4 1251 6 150 1253 7 1255 8 1258 0 1260 1 1262 2 1264 3 1266 5 1268 6 T270 7 1272 8 270 1506 6 1508 7 1510 8 1512 8 1514 9 1517 0 1519 1 1521 2 1523 3 280 1527 4 1529 5 1531 6 1533 7 1535 7 1537 8 1539 9 1542 0 1544 1 330 1631 1 1633 2 1635 2 1637 3 1639 3 1641 4 1643 5 1645 5 1647 6 1651 7 1653 8 1655 8 1657 9 1660 0 1662 0 1664 1 1666 1 1668 2 390 1754 3 1756 3 1758 4 1760 4 1762 5 1764 5 1766 6 1768 6 1770 6 1772 7 400 1774 7 1776 8 1778 8 1780 8 1782 9 1784 9 1786 9 1789 0 1791 0 1793 1 DIESEL BURNER ADJUSTMENTS 5 32 rue 1 4 T 5 32 Lo NOZZLE DIESEL BURNER SETTINGS Air Shutter 7 Air Band 0 Fuel Pressure 140 PSI Adjustment Plate 3 Use fuel and hydraulic pressure gauge kit part number 29960 a Is 227 des 2 5 FUEL PRESSURE ADJUSTMENT SCREW 29 BURNER SCHEMATIC
17. AMP meter to perform this test YES Hose should be operating properly NO Goto step 6 Step 6 Check for continuity between three heating element wires blue in junction box NOTE Wires must be disconnected from terminal block YES Go to step 7 NO Check continuity between terminals A E and D at the wand YES Wand is Ok Go to step 7 NO Replace wand Step 7 Check for continuity between element wires blue and the fitting of the hose YES Replace hose NO Hose is OK MATERIAL DOES NOT DISPENSE WHEN PUMP IS ACTIVATED Step 1 Is the motor coupling turning clockwise YES Go to step 2 NO Has the sealant had sufficient time to completely melt YES Go to step 2 NO Has the hose had sufficient time to reach operating temperature YES Go to step 2 NO Allow hose to heat up to operating temperature Step 2 Is the MATERIAL temperature at 275 F YES Go to step 3 NO Allow material to heat longer or turn POWER toggle switch ON Step 3 Is the PUMP light illuminated YES Go to step 4 NO Hose temperature must be at 325 F before the pump will activate Step 4 Check for 12 volts at terminals 12 red blk wire and terminal 14 green wire of the relay NOTE Terminal 12 will have 12 volts when the key is ON Terminal 14 will have 12 volts when trigger is activated YES Go to step 4a NO Check continuity of red trigger wires in junction box Yes Go to step 5 No Check for continuity betw
18. PORATED 235 SOUTH HIBBERT DRIVE MESA AZ 85210 480 655 8333 Toll Free 1 800 528 8242 100 SPECIFICATIONS eei NR CR HE 133 Gallons MelECapaclly EK 90 Gallons Hour Heat Transfer Oil Required 34 Gallons at 70 F Tank Double Boiler Type Tank Opening SIZE Skies 14 X 18 Maximum Heat Input a 250 000 BTU s Burner and Temperature Control Diesel Forced Air Thermostatic Control Engine ISUZU Twin Cylinder Model 3CB1 Diesel 25 4 BHP 3600 RPM Hydraulic Drive All hydraulic with infinite speed on mixer and material pump MIXET m Full sweep mixer with two horizontal paddles vertical risers PC to AW a ud HN ements Single 5 200 Lb Torsional MeS 2 II ST225 75R15 Load Range D PN NN Approximately 2 800 Lbs Diesel Tank Ga pany 26 Gallons Hydraulic Tank CADA 26 Gallons ko SUPER SHOT 125 DIESEL MELTER OPERATING INSTRUCTIONS INTRODUCTION The CRAFCO SUPER SHOT 125 MELTER was developed to melt Crafco brand sealant However it will work well with most road asphalt and federal specification crack or joint sealant DO NOT operate machine without following these instructions 1 2 Fill f
19. TM AN ERGONE COMPANY SUPER SHOT 125 DIESEL MELTER PART MANUAL 26378 REV G Revised 03 06 SUPER SHOT 125 DIESEL MELTER TABLE OF CONTENTS Super Shot 125 Diesel 5 Safety Precautions usce a qae i ii 6 7 Eirmited Warrarnty uice tre 7 Warranty Claim 8 IR E E 9 INTOUC PDC 10 Operating Instructions Machine Start c a tbe f taa 11 12 Dispensing the Material Active Pump 2 13 Loading The Machine Shutdown and Clean out Procedures Storing Machine 14 Instructions For Ordering Parts Electric Hose Care and Cautions 15 Hose Transport 16 Maintenance Maintenance Instructions sse 17 Maintenance Chart Service 18 Recommended Fluids ans Lubricants Typical Specifications 19 Super Shot Pump 20 Super Shot Pump Replacement 21 Trouble Shooting Trouble Shooting Guide Hose Does Not 22 Hose Circuit Diagram aici e Reine blieben 23 Trouble Shooting Guide Hose Does
20. VA 1300 PSI Relief Valve RVM 1800 PSI TROUBLE SHOOTING HYDRAULICS PROBLEM CAUSE REMEDY Mixer will not rotate Sealant temperature too low Mixer will not rotate blocks placed at Continue to heat material Mixer will not rotate Inadequate hydraulic flow pressure Check hydraulic fluid level Mixer will not rotate Toggle switch turned off BESE pressus ERBEN owi necessary Material pump will not rotate Material mank operanng Continue heating material temperature Material pump will not rotate Inadequate hydraulic flow pressure uid Reset pressure check flow as necessary Material pump will not rotate Material pump damaged Remove and replace Material pump will not rotate Foreign object lodged in pump Remove pump clean amp replace Material pump will not rotate Jempetalite upis Set wand tip inside material tank inadequate Material pump will not rotate Hydraulic cartridge failure Remove and replace Material pump will not rotate Hydraulic coil failure Remove and replace Add more material or continue heating material until more liquid material is available Material pump will not rotate Bad switch at wand Remove and replace When applying sealant it stops Tank fluid level too low for material flowing from applicator wand to flow into pump Material cold inlet still solid Pump rotates but will not pump Hose not to temperat
21. and 48 49 Hydraulic Diagram and 50 51 Electrical Cables and 52 53 SUPER SHOT 125 DIESEL MELTER This manual is furnished with each new CRAFCO SUPER SHOT 125 DIESEL MELTER This manual will help your machine operators learn to run the melter applicator properly and understand its mechanical functions for trouble free operation Your CRAFCO SUPER SHOT 125 DIESEL MELTER is designed to give excellent service and save maintenance expense However as with all specially engineered equipment you can get best results at minimum costs if 1 You operate your machine as instructed in this manual 2 Maintain your machine regularly as stated in this manual known to the State of California to cause cancer birth defects or other reproductive harm Operate in well ventilated area only Engine exhaust WARNING The engine exhaust from this product contains chemicals is deadly SAFETY PRECAUTIONS High operating temperatures of sealant and machine require protective clothing hard soled shoes and heat resistant gloves to be worn by operator Always wear eye protection Observe all CAUTION AND WARNING signs posted on machine Avoid the entrance of water into any part of the machine Water will displace heat transfer oil or sealant which could be hazardous to personnel surround
22. ce any hoses which show signs of wear fraying or splitting Be sure all fittings and joints are tight and leak proof each time machine is used Precaution is the best insurance against accidents Fr The melter should not be left unattended with burner lit Tighten all bolts and screws after every 100 hours of operation Inc assumes no liability for an accident or injury incurred through improper use of the machine LIMITED WARRANTY Crafco Inc through its authorized distributor will replace for the original purchaser free of charge any parts found upon examination by the factory at Mesa Arizona to be defective in material or workmanship This warranty is for a period within 60 days of purchase date but excludes engine or components tires and battery as these items are subject to warranties issued by their manufacturers After 60 days Crafco Inc warrants structural parts excluding heating system hydraulic components material pump and hoses hot oil pump applicator valves and electrical components for a period of 1 one year from date of delivery Crafco Inc shall not be liable for parts that have been damaged by accident alteration abuse improper lubrica tion maintenance normal wear or other cause beyond our control The warranty provided herein extends only to the repair and or replacement of those components on the equipment covered above and does not cover labor costs The warranty doe
23. ed by turning the speed control knob clockwise until the pump motor starts to turn Material should start to flow from the tip of the duckbill valve Adjust the pump speed for the desired rate of flow for the application and dispense material as required The rate of flow may be varied while the pump is running by rotating the control knob AT ANY OTHER PERSON HOT MATERIALS CAN CAUSE SEVERE BURNS WEAR PROTECTIVE EQUIPMENT WHEN FILLING OR OPERATING THE EQUIPMENT READ MANUAL NEVER POINT THE WAND AT ANY PART OF THE BODY OR BEFORE OPERATING EQUIPMENT ACTIVE PUMP PROTECTION The pump is completely encircled by a protective screen The screen shall not allow any thing larger than 1 2 1 27 cm in size to pass from the sealant tank into the pump suction port The screen shall continuously rotate 360 around the pump whenever the sealant agitator is engaged The active screen will protect the pump from foreign object damage and will self clean as it rotates around the sealant pump and suction port LOADING THE MACHINE When loading solid material into the sealant tank the mixer will stop when the lid is lifted To load lift the lid place the material on the lid and close lid Following this procedure will prevent the hot material from splashing and causing serious burns to personnel The solid material must be added at intervals which will allow the mixer to rotate without jamming If blocks of material are fed in too quickly jamming
24. een terminals C and B on wand when the trigger is activated YES Go to step 5 NO Replace trigger or check for poor connections Step 4a Check relay by pressing the white test button on top of relay CAUTION Pump will dispense material YES Go to step 5 NO Replace relay ANYA 111134 SOH LOH _SJNV SHLVS N GILIO SANVST 0E JSVHd E jS UH 30186 41118 Jn 18 3078 ana G SdMV 3n Java que m 404 49 anal LLYW SLC et suuogo YNOH E ANd F X1B LHA o SIE ima L3 4 1 ANd 3SHH fr NR som B E TH pas Fm 5 Sm aa o M TE LHM L3 4 EN E TNA o VIN TROUBLE SHOOTING GUIDE S
25. er poor ground loose wire Faulty or dirty flame Faulty igniter transformer cracked electrode ceramic Incorrect igniter gap Faulty fuel solenoid Bleed fuel pump check fuel pump coupling Fuse under DC Controller Blower motor relay Faulty blower motor Alternator charging 14 volts Faulty 12 volt battery BURNER LIGHTS BUT SHUTS DOWN AFTER 15 SEC Faulty flame eye Broken loose flame eye sensor wires receptacle Faulty DC Controller Bleed fuel system if white or blue smoke appears through exhaust stack BURNER LIGHTS BUT WILL NOT RELIGHT Bad connection at battery Broken or loose wires Faulty DC Controller Alternator charging at 14 volts Faulty 12 volt battery EXCESSIVE SMOKE FROM BURNER EXHAUST Air vent incorrectly set set at 7 Blower motor not turning at correct speed Alternator charging at 14 volts Faulty 12 volt battery 31 HYDRAULIC SCHEMATIC AGITATOR PUMP COMPRESSOR a 2221 9251 PEE exe s T Bu tal T AUX JE i Flow 7 5 GPM 2400 RPM Relief Valve R
26. ing the machine when it reaches operating temperatures Avoid bodily contact with hot sealant material or heat transfer oil serious burns may result Read Operator Manual thoroughly before operating machine Make sure operator is familiar with machine operation Do not operate in closed building or confined areas Shut down burner and engine prior to refilling diesel tank When adding solid material to sealant tank stop mixer lift lid place material onto lid and close lid before restarting mixer Hot material could splash and cause serious burns if this procedure is not followed Keep hands feet and clothing away from all moving parts Always keep a fire extinguisher near the unit Maintain extinguisher properly and be familiar with its use 4 DO NOT exceed 525 F for heat transfer oil temperature DO NOT overfill heat transfer oil level Expansion of oil during heat up could cause overflow With machine in level position check oil each day before starting burner add oil to top mark on dipstick if required at 70 F Use only recommended heat transfer oil and change after 500 hours of operation or one year whichever occurs first Follow operating instructions for starting and shut down of burner See Operating Instructions Calibrate temperature control prior to initial operation and each 50 hours of operation See Temperature Control Calibration lo SAFETY PRECAUTIONS Repla
27. m Lu Li 16 S aIA 32914 D BEA en Lu 1YAN TE IA 3018 gt 4 A 1708 31914 91 5 19 QNTHa E 1148 HILIAS 84915 eier T 1 MLAS qu ALS NADIE Er NOLLINMF Zc0FF INYA 05 15 3SUH Q31V3H 81 94218 01 1009 02208 31974 330 ND 4096 HILIAS OSNISSJA33 Y UML 61626 ELECTRICAL CABLES 7 HOSE CABLE ASSEMBLY CABLE ASSEMBLY VALVE BATTERY CABLE 38 POSITIVE BATTERY CABLE 12 GROUND BATTERY CABLE 22 ENGINE GROUND Pioneering Leadership and Innovation in Quality Pavement Maintenance Products TM INC AM ERGONE 235 South Hibbert Mesa Arizona 85210 480 655 8333 Watts 1 800 528 8242 Fax 480 655 1712 OCopyright 2002 by Crafco Inc
28. marked heated hose will turn off and the temperature may be reduced to approximately 360 F Itis advisable to run the hose at the recommended temperature setting NOTE The hose must be up to 325 F before dispensing can take place If hose does not dispense when trigger is activated then allow material to heat longer If hose still does not dispense material then shut machine down and locate plug in the line and remove IMPORTANT DO NOT twist or kink hose Avoid sharp bends and continuous twisting DO NOT exceed 400 F setting on hose controller DO NOT move or bend hose when cold Damage may result Once you reach operating temperatures DO NOT leave hose cycling for longer than 30 minutes without dispensing material Coking will occur and permanently damage your hose MACHINE START UP IT IS STRONGLY RECOMMENDED THAT THE HOSE BE STORED IN THE CORRECT LOCKED POSITION WHEN NOT IN USE OR WHEN IN TRANSIT The heated hose supplied with the machine is Teflon lined with steel over braid It has a heating element which runs down the hose to heat the material within the hose The hose is covered with high temperature durable rubber hose The wand has an aluminum tube to protect both the wand and the operator The pistol grip actuator is equipped with an electric switch which when depressed sends a signal to actuate the pump At the end of the wand a high temperature elastomeric output valve is attached The valve is pressure actuated and
29. ot ignite the first time turn toggle switch to OFF Turn toggle switch to ON again Burner should ignite If burner still does not ignite determine cause of malfunction see Trouble Shooting Guide Pg 22 26 NOTE The solid material in the tank melts first around the walls and bottom of the material tank Material temperature sensor is located by the wall therefore it is possible that at the beginning of the melting process the indicated temperature reaches operating value but the material closer to the center of the tank is still solid This is normal and when the heated hose is ready for operation most of the material in the tank will be melted and heated to application temperature Allow the heating oil to continue to heat When sealant material reaches 275 F mixer may be engaged by turning the toggle switch at hydraulic control panel ON If the mixer does not move allow the material to heat longer Jamming of mixer causes hydraulic oil to overheat and machine damage could occur NOTE Mixer speed is preset at the factory and cannot be adjusted Mixer cannot be engaged until material reaches 275 F Hose will automatically turn ON when material temperature reaches approximately 275 F See Operating Instructions Adjust the temperature dial to 380 F or manu facturers recommended temperature The hose will come up to temperature in approximately 30 minutes After the hose is hot the light in the control box
30. perature grease TEMPERATURE CONTROL CALIBRATION SM di loy Check control knob calibration weekly 1 Calibrate by aligning the line on the control knob with the calibration line on the scale plate See Fig 1 En Calibration Mark Fig 1 MAINTENANCE CHART Engine check level check oil level See See Engine Instruction Manual Instruction Manual 5 71 Maintenance Instructions Battery Check water level Check water level weekly uu Ba os ERE EE awen ome waew wm __ ce bem ww Wheel bearings lea amp re 2 using a good 2 of bearing grease earing grease Wheel 598 Every 24 000 miles or every two years SERVICE INSTRUCTIONS le Conduct a general inspection of your machine at least once aweek Replace all worn or damaged parts make any necessary adjustments and tighten all loose nuts or screws 2 Keep regular replacement items in stock for emergency repairs and to avoid costly down time 3 Watch for leaks Tighten fitting or repair as necessary 4 Clean machine externally periodically Check with sealant manufacturer for recommendation 5 Follow recommended maintenance procedures on maintenance chart 18 RECOMMENDED FLUIDS AND LUBRICANTS APPLICATION RECOMMENDED FULL
31. s not extend to incidental or consequential damages incurred as a result of any defect covered by this warranty All transportation and labor costs incurred by the purchaser in submitting or repairing covered components must be borne by the purchaser Crafco Inc specifically disavows any other representation warranty or liability related to the condition or use of the product WARNING Use of replacement parts other than genuine Crafco parts may impair the safety or reliability of your equipment and nullifies any warranty IN WARRANTY CLAIM INSTRUCTIONS Please follow the instructions stated below when calling in a warranty claim Failure to follow these procedures may be cause to void the warranty 1 Call your local Crafco Distributor If you do not know who your local distributor is call a Crafco Customer Service Representative Toll Free 1 800 528 8242 for name location and telephone number 2 On contacting the distributor be prepared to identify the machine type model number and serial number also the date of purchase if available 3 Should the cause of the malfunction be a defective part the distributor will advise you of the procedure to follow for a replacement 4 The warranty is valid only for parts which have been supplied or recommended by Crafco Inc If you have any additional questions regarding warranty repairs and parts please do not hesitate to call toll free 1 800 528 8242 CRAFCO INCOR
32. tep 5 Is the top right light on hydraulic valve illuminated looking at the rear of the hydraulic valve when trigger is activated YES Replace hydraulic cartridge NO Goto step 4 PUMP ROTATES BUT NO MATERIAL IS DISCHARGED Step 1 Has the sealant and heated hose had sufficient time to reach temperature YES Go to step 2 NO Allow the sealant and hose to heat longer Step 2 Check material outlet pipe and connection between hose and wand for obstruction YES Remove obstruction and reassemble hose connection NO Goto step 3 Step 3 Is there an obstruction at the pump suction YES Reverse material pump for 30 seconds NO Refer to page 20 for pump removal if required MATERIAL DISPENSING RATE IS TOO SLOW Step 1 Check speed control knob for desired flow adjustment YES Go to step 2 NO Adjust to desired flow Step 2 Is there enough material in the tank YES Go to step 3 NO Add enough material to bring tank level above the screen Step 3 Check material outlet pipe and connection between hose and wand for obstruction YES Remove obstruction and reassemble hose connection NO Pump is worn out See page 20 for pump removal and installation 111341 490 LOH _SJNV LYASNS9 SaNVSE DE JSVHd E ONVA 3SHH 3078 3074 and JHA ana 4 ama IV TE mie
33. uel tank with diesel fuel use 1 in cold weather 2 in warm weather Check engine crankcase oil level refer to Engine Operator s Manual Check hydraulic fluid level at 70 F Add fluid if necessary Check heat transfer oil level at 70 F the oil should be at the full mark on the dipstick DO NOT overfill or spillage may occur when oil is heated and expands The POWER switche should be turned OFF and all three temperature control dials at minimum settings Remember that safe operation of this equipment is the operator s responsibility caution Extreme care must be used when operating this equipment Safety is the result of being careful and paying attention to details Remember the diesel flame is about 2 200 F Certain exposed parts of this machine when operating reach 500 F the sealant as high as 400 F and the hydraulic fluid may reach 200 F Always wear protective clothing hard soled shoes and eye protection Be sure that all joints and fittings are tight and leak proof Immediately replace any hose which shows any signs of wear fraying or splitting Tighten all bolts nuts and screws every 250 hours MACHINE START UP TO START BURNER 1 2 3 4 Fully open the damper vent Start engine per Engine Manual Turn POWER toggle switch at control box ON Set hot oil temperature at 500 F and material temperature at manufacturers recommended temperature CAUTION If burner does n
34. ure material Temperature at wand tip is inadequate Continue to heat material Allow to heat longer Set wand tip inside material tank Bad wire connection Find bad repair Bad switch at wand handle Remove and replace Hydraulic cartridge failure Remove and replace Hydraulic coil failure Remove and replace Pump does not rotate Built up of coked material on Allow machine to cool inside of material tank Remove deposits and flush with Slow heat up of sealant solvent Low heating oil level Make sure fluid level is correct Low heating oil temperature Set at recommended temperature SS 125 MELTER SS 125 MELTER PARTS LIST ICON CTE EU 1271 SS 125 MELTER Svr Sc
35. y Pino A ET Z pas ad n E 5 Be O i Lam an 0 Te i T 9898 38 Tod o o zB CONTROL BOX IN ee RN NN EIC 000000 ee e 11 ENGINE ASSEMBLY PRESET ENGINE SPEED 2400 RPM HOSE GENERATOR OUTPUT 30 35 AMPS COLD 24 VAC 3 PHASE ENGINE ASSEMBLY gt er m Bo a N CEN T al El a gt OOD PUMP AGITATOR MOTOR ASSEMBLY DESCRIPTION MOUNTING BRACKET MOTORS HYDRAULIC MOTOR PUMP HYDRAULIC MOTOR AGITATOR SPROCKET AGITATOR DRIVE 47 DIESEL BURNER
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