Ergon Crafco SUPER SHOT 125 Manuale utente

Parts Manual - 26633N

Revision 0

SUPER SHOT 125 DIESEL ME

Fill in appropriate fields that apply to this machine

Machine S/N: ________________________________

1st Hose S/N: _______________________________

2nd Hose S/N: _______________________________

1st Pump S/N: _______________________________

2nd Pump S/N: ______________________________

Engine S/N: ________________________________

Compressor S/N: _____________________________

Gear Box S/N (Patcher): ______________________

Blower S/N (Magnum): ________________________

Super Shot 125 Diesel Melter Part

Manual

Revisions

Revision

Date

0) Initial Release

7/24/2019

Super Shot 125 Diesel Melter

PN 43600

Super Shot 125 Skid Diesel Melter

PN 57200

Super Shot 125 Dual Axle Diesel Melter

PN 43600DX

 
 
Super Shot 125 Diesel Melter Part 
Manual
 
Table of Contents 
 
 
0 About This Manual.................................................................................................................. 1-1 
1 How to use this manual....................................................................................................... 1-1 
0 Safety Precautions.................................................................................................................. 2-1 
1 General Safety.................................................................................................................... 2-1 
2 Personal Safety................................................................................................................... 2-1 
3 Equipment or Operational Safety......................................................................................... 2-1 
4 California Proposition 65 ..................................................................................................... 2-2 
 All Crafco, Inc. Equipment........................................................................................... 2-2 
 All Crafco, Inc. Equipment using a diesel engine......................................................... 2-2 
5 Towing or Driving for Transporting with Burner On.............................................................. 2-2 
6 Safety Symbols and Notices................................................................................................ 2-3 
0 Limited Warranty..................................................................................................................... 3-1 
1 Warranty Claim Instructions................................................................................................. 3-2 
0 Machine Specifications ........................................................................................................... 4-1 
0 Operating Instructions............................................................................................................. 5-1 
1 Preparing the Machine for Start Up ..................................................................................... 5-1 
2 Machine Start Up for 43600, 57200, and 43600DX ............................................................. 5-3 
3 Altitude Compensation System (3CH1 Engine) ................................................................... 5-4 
4 About the Heated Hose, Wand, Valve, and Tip Guard......................................................... 5-5 
5 Operating the Electric Hose................................................................................................. 5-6 
6 Dispensing the Material....................................................................................................... 5-7 
7 About the Active Screen Pump Protection........................................................................... 5-7 
8 Loading Material into the Sealant Tank ............................................................................... 5-8 
 Material Tank Depth Chart........................................................................................... 5-9 
9 Shutting Down and Cleaning Out the Machine (43600, 57200, and 43600DX).................. 5-10 
10 Storing the Electric Hose for Transport............................................................................ 5-11 
11 Overnight Heater Use...................................................................................................... 5-12 
12 Mounting a Skid Machine................................................................................................ 5-13 
13 Shot Timer Option........................................................................................................... 5-14 
14 Storing the Machine ........................................................................................................ 5-14 
0 Maintenance Instructions........................................................................................................ 6-1 
1 Engine................................................................................................................................. 6-1 
2 Hydraulic System ................................................................................................................ 6-1 
3 Heat Transfer Oil................................................................................................................. 6-1 

 
 
Super Shot 125 Diesel Melter Part 
Manual
 
Table of Contents 
 
 
6.4 Wheel Bearing.....................................................................................................................6-1 
6.5 Material Sensor Tube ..........................................................................................................6-1 
6.6 Cleaning Material Tank and Sensor Area............................................................................6-2 
6.7 Lug Nuts..............................................................................................................................6-2 
6.8 Brakes................................................................................................................................. 6-2 
6.9 Tongue Jack........................................................................................................................6-2 
6.10 Temperature Control Calibration........................................................................................6-3 
6.11 Cleaning the Melter ...........................................................................................................6-3 
6.12 Maintenance Chart ............................................................................................................6-4 
6.13 Service Instructions...........................................................................................................6-5 
6.14 General Maintenance Parts...............................................................................................6-5 
6.15 Recommended Spare Parts...............................................................................................6-6 
6.16 Recommended Fluids and Lubricants................................................................................6-7 
6.17 Applicable Brands of Heat Transfer Oil..............................................................................6-8 
6.18 Typical Heat Transfer Oil Specifications ............................................................................6-8 
6.19 Material Pump Replacement..............................................................................................6-9 
6.20 Wand Repair Instructions ................................................................................................6-21 
Cable Replacement...................................................................................................6-21 
Switch Replacement..................................................................................................6-21 
Terminal Block Replacement.....................................................................................6-21 
Wand Handle Replacement.......................................................................................6-22 
6.21 Burner Fuel Filter Replacement.......................................................................................6-25 
7.0 How to Use a Multimeter.........................................................................................................7-1 
7.1 Checking DC Voltage with a Multimeter...............................................................................7-1 
7.2 Checking AC Voltage with Multimeter..................................................................................7-1 
7.3 Checking Resistance (Ohms)..............................................................................................7-1 
 How to Check Wire Continuity .....................................................................................7-1 
 How to Check RTD Sensor..........................................................................................7-1 
7.4 Checking Amperage............................................................................................................7-2 
8.0 Troubleshooting (43600, 57200, and 43600DX)......................................................................8-1 
8.1 Diesel Burner Troubleshooting ............................................................................................8-1 
 Symptoms: Burner will Not Ignite.................................................................................8-1 
 Burner Electrical Troubleshooting................................................................................8-2 
 Excessive Smoke Coming Out of Exhaust Stack.........................................................8-6 
 Burner Lights but Shuts Down After 15 Seconds.........................................................8-6 

 
 
Super Shot 125 Diesel Melter Part 
Manual
 
Table of Contents 
 
 
 Testing DC Controller.................................................................................................. 8-7 
 Burner Fuel Solenoid Testing...................................................................................... 8-7 
 Burner Ignition Coil Testing ......................................................................................... 8-8 
 Bleeding the Burner..................................................................................................... 8-8 
 Sealant is Heating Slowly.......................................................................................... 8-10 
8.2 Mixer Troubleshooting....................................................................................................... 8-11 
 Symptom: Mixer Does Not Rotate ............................................................................. 8-11 
 Mixer Electrical Troubleshooting................................................................................ 8-12 
 Mixer Hydraulic Troubleshooting ............................................................................... 8-16 
8.3 Hose Troubleshooting ....................................................................................................... 8-19 
 Symptom: Hose Does Not Heat................................................................................. 8-19 
 Hose Electrical Troubleshooting................................................................................ 8-19 
 Symptom: Trigger is not Working............................................................................... 8-24 
 RTD Sensor Ohms vs. Temperature ......................................................................... 8-25 
8.4 Pump Troubleshooting ...................................................................................................... 8-27 
 Symptom: Material Does Not Dispense When the Pump is Activated........................ 8-27 
 Pump Electrical Troubleshooting............................................................................... 8-28 
 Pump Hydraulic Troubleshooting............................................................................... 8-34 
9.0 About the Illustrated Parts List ................................................................................................ 9-1 
9.1 Ordering Crafco Parts ......................................................................................................... 9-1 
9.2 Super Shot 125 Diesel Melter Assembly 43600................................................................... 9-2 
9.3 Super Shot 125 Diesel Melter Skid Mount Assembly 57200................................................ 9-8 
9.4 Super Shot 125 Diesel Melter Dual Axle PN 43600DX...................................................... 9-12 
9.5 Tank Assembly, All Models ............................................................................................... 9-18 
9.6 Control Box Assembly, 43600, 57200, and 43600DX........................................................ 9-20 
9.7 Engine Assembly: PN 43600, 57200, and 43600DX.......................................................... 9-22 
9.8 Hydraulic Control Valve Assembly: PN 45420 All Models.................................................. 9-24 
9.9 Material Flow Control Assembly: PN 46060 All Models ..................................................... 9-26 
9.10 Pump/Mixer Motor Assembly: PN 44832 All Models........................................................ 9-28 
9.11 Diesel Burner Assembly: PN 46380 All Models ............................................................... 9-30 
9.12 Hydraulic Diagram: PN 26554 (43600, and 57200) ......................................................... 9-32 
9.13 Hydraulic Diagram: PN 26554DX (43600DX) .................................................................. 9-36 
9.14 Diesel Fuel Line Schematic –43600, and 57200 Engines............................................... 9-40 
9.15 Diesel Fuel Line Schematic –43600DX Engine............................................................... 9-42 
9.16 Electrical Schematic: PN 43600, 57200, and 43600DX................................................... 9-46 

Super Shot 125 Diesel Melter Part

Manual

Table of Contents

9.17 Wand Assembly (All Models)...........................................................................................9-48

9.18 Optional Engine Cover for 3CH1 Engine..........................................................................9-50

10.0 Tools and Accessories........................................................................................................10-1

 
 
Super Shot 125 Diesel Melter Part 
Manual
 
List of Figures 
 
 
Fig. 5-1 Hydraulic Fluid Level and Temp. Gauge.......................................................................... 5-2 
Fig. 5-2 Heat Transfer Oil Dip Stick............................................................................................... 5-2 
Fig. 6-1 Lug bolt Tightening Sequence ......................................................................................... 6-2 
Fig. 6-2 Temperature Control Calibration...................................................................................... 6-3 
Fig. 6-3 Agitator and Pump Shaft Alignment................................................................................. 6-9 
Fig. 6-4 Removal of Motor Mount Assembly ............................................................................... 6-10 
Fig. 6-5 Supporting the Agitator Away from the Material Pump................................................... 6-11 
Fig. 6-6 Unbolting the Material Pump.......................................................................................... 6-12 
Fig. 6-7 Cleaning of the Pump Mounting Plate............................................................................ 6-13 
Fig. 6-8 Pump Drive Shaft Dry Fit to Material Pump.................................................................... 6-14 
Fig. 6-9 New Material Pump Mounting........................................................................................ 6-15 
Fig. 6-10 Agitator Shaft and Paddles Mounting........................................................................... 6-16 
Fig. 6-11 Pump Shaft Placement................................................................................................ 6-17 
Fig. 6-12 Pump Shaft to Hydraulic Pump Motor Placement ........................................................ 6-18 
Fig. 6-13 Agitator Connecting Link.............................................................................................. 6-19 
Fig. 6-14 Agitator Chain Tightening Steps................................................................................... 6-20 
Fig. 6-15 Switch Wire Location ................................................................................................... 6-22 
Fig.6-16 Wire Routing................................................................................................................. 6-22 
Fig.6-17 Terminal Block Wiring................................................................................................... 6-23 
Fig.6-18 Actuator Spring Location............................................................................................... 6-23 
Fig.6-19 Actuator / Trigger Assembly.......................................................................................... 6-24 
Fig. 7-1 Standard Multimeter......................................................................................................... 7-2 
Fig. 7-2 Clamp –On Amp Meter/Multimeter.................................................................................. 7-3 
Fig. 8-1 Diesel Burner Schematic ................................................................................................. 8-5 
Fig. 8-2 Diesel Burner Electrode Adjustment ................................................................................ 8-9 
Fig. 8-3 Diesel Burner Air Settings................................................................................................ 8-9 
Fig. 8-4 Checking Din Plug Voltage ............................................................................................ 8-14 
Fig. 8-5 Mixer Schematic............................................................................................................ 8-15 
Fig. 8-6 Hydraulic Valve Pressure Setting................................................................................... 8-17 
Fig. 8-7 Din Plug Layout ............................................................................................................. 8-18 
Fig. 8-8 Junction Box Voltage Testing......................................................................................... 8-21 