Ergon CRAFCO 100CFM Manuel utilisateur

Parts Manual –26638N

Revision 0

SUPER SHOT 250 DIESEL

COMPRESSOR ME

ER 100CFM

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: ____________________________

Super Shot 250 Diesel Melter Part

Manual

Revisions

Revision

Date

0) Initial Release

1/2021

Super Shot 250 Diesel Melter with Compressor 100 CFM

PN 47900N

 
 
Super Shot 250 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 with 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.................................................................................................................5-3 
3 Air Compressor:...................................................................................................................5-5 
4 About the Heated Hose, Wand, Valve, and Tip Guard.........................................................5-6 
5 Operating the Electric Hose................................................................................................. 5-7 
6 Dispensing the Material.......................................................................................................5-8 
7 About the Active Screen Pump Protection...........................................................................5-8 
8 Loading Material into the Sealant Tank................................................................................5-9 
 Material Tank Depth Chart.........................................................................................5-10 
9 Shutting Down and Cleaning Out the Machine ..................................................................5-11 
10 Storing the Electric Hose for Transport............................................................................5-12 
11 Overnight Heater Use......................................................................................................5-13 
12 Mounting a Skid Machine ................................................................................................5-14 
13 Shot Timer Option ...........................................................................................................5-15 
14 Storing the Machine.........................................................................................................5-15 
0 Maintenance Instructions .....................................................................................................6-1 
1 Engine.................................................................................................................................6-1 
2 Air Compressor....................................................................................................................6-1 
3 Hydraulic System.................................................................................................................6-1 

 
 
Super Shot 250 Diesel Melter Part 
Manual
 
Table of Contents 
 
 
4 Heat Transfer Oil................................................................................................................. 6-1 
5 Wheel Bearing..................................................................................................................... 6-1 
6 Material Sensor Tube.......................................................................................................... 6-1 
7 Cleaning Material Tank and Sensor Area............................................................................ 6-2 
8 Lug Nuts.............................................................................................................................. 6-2 
9 Brakes................................................................................................................................. 6-2 
10 Tongue Jack...................................................................................................................... 6-2 
11 Temperature Control Calibration ....................................................................................... 6-3 
12 Cleaning the Melter........................................................................................................... 6-3 
13 Maintenance Chart............................................................................................................ 6-4 
14 Service Instructions........................................................................................................... 6-5 
15 General Maintenance Parts............................................................................................... 6-5 
16 Recommended Spare Parts .............................................................................................. 6-6 
17 Recommended Fluids and Lubricants ............................................................................... 6-7 
18 Applicable Brands of Heat Transfer Oil.............................................................................. 6-8 
19 Typical Heat Transfer Oil Specifications............................................................................ 6-8 
20 Changing the Heat Transfer Oil......................................................................................... 6-9 
21 Material Pump Replacement ........................................................................................... 6-10 
22 Wand Repair Instructions................................................................................................ 6-22 
Cable Replacement................................................................................................... 6-22 
Switch Replacement.................................................................................................. 6-22 
Terminal Block Replacement..................................................................................... 6-22 
Wand Handle Replacement....................................................................................... 6-23 
23 Burner Fuel Filter Replacement....................................................................................... 6-26 
0 How to Use a Multimeter...................................................................................................... 7-1 
1 Checking DC Voltage with a Multimeter .............................................................................. 7-1 
2 Checking AC Voltage with Multimeter.................................................................................. 7-1 
3 Checking Resistance (Ohms).............................................................................................. 7-1 
 How to Check Wire Continuity..................................................................................... 7-1 
 How to Check RTD Sensor.......................................................................................... 7-1 
4 Checking Amperage............................................................................................................ 7-2 
0 Troubleshooting................................................................................................................... 8-1 
1 Diesel Burner Troubleshooting............................................................................................ 8-1 
 Symptom: Burner will Not Ignite................................................................................... 8-1 
 Burner Electrical Troubleshooting................................................................................ 8-2 

 
 
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..........................................................................................8-9 
 Bleeding the Burner.....................................................................................................8-9 
 Sealant is Heating Slowly ..........................................................................................8-11 
8.2 Mixer Troubleshooting.......................................................................................................8-12 
 Symptom: Mixer Does Not Rotate..............................................................................8-12 
 Mixer Electrical Troubleshooting................................................................................8-13 
 Mixer Hydraulic Troubleshooting................................................................................8-17 
8.3 Hose Troubleshooting........................................................................................................8-20 
 Symptom: Hose Does Not Heat.................................................................................8-20 
 Hose Electrical Troubleshooting ................................................................................8-20 
 Symptom: Trigger is not Working...............................................................................8-25 
 RTD Sensor Ohms vs. Temperature..........................................................................8-26 
8.4 Pump Troubleshooting.......................................................................................................8-28 
 Symptom: Material Does Not Dispense When the Pump is Activated........................8-28 
 Pump Electrical Troubleshooting ...............................................................................8-29 
 Pump Hydraulic Troubleshooting...............................................................................8-35 
8.5 DPF and Regen Modes.....................................................................................................8-36 
8.6 Icons for the Regen Modes................................................................................................8-37 
8.7 Engine Diagnostic Trouble Codes (DTC)...........................................................................8-38 
 How to use the Diagnostic Trouble Code Table.........................................................8-38 
 Engine DTC Table.....................................................................................................8-38 
9.0 About the Illustrated Parts List..............................................................................................9-1 
9.1 Ordering Crafco Parts..........................................................................................................9-1 
9.2 Super Shot 250 Diesel Melter Comp. 100 CFM...................................................................9-2 
9.3 Tank Assembly....................................................................................................................9-8 
9.4 Control Box Assembly: PN: 47252N..................................................................................9-10 
9.5 Engine Assembly: PN 48000N...........................................................................................9-12 
9.6 Hydraulic Control Valve Assembly: PN 45420 ...................................................................9-18 
9.7 Material Flow Control Assembly: PN 46060.......................................................................9-20 
9.8 Pump/Mixer Motor Assembly: PN 44832 ...........................................................................9-22 
9.9 Diesel Burner Assembly: PN 46380...................................................................................9-24 

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)................................................................ 9-42

9.16 High Output Air Lance with Water Separator PN: 47491N (optional)............................... 9-43

9.17 Wand Assembly PN 52200.............................................................................................. 9-44

9.18 Engine Cover Assembly PN: 48120N (optional) .............................................................. 9-46

9.19 Hot Air Lance (optional)................................................................................................... 9-48

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

 
 
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. 6-3 Heat Transfer Oil Drain and Fill Ports...............................................................................6-9 
Fig. 6-4 Agitator and Pump Shaft Alignment ...............................................................................6-10 
Fig. 6-5 Removal of Motor Mount Assembly................................................................................6-11 
Fig. 6-6 Supporting the Agitator Away from the Material Pump...................................................6-12 
Fig. 6-7 Unbolting the Material Pump..........................................................................................6-13 
Fig. 6-8 Cleaning of the Pump Mounting Plate............................................................................6-14 
Fig. 6-9 Pump Drive Shaft Dry Fit to Material Pump....................................................................6-15 
Fig. 6-10 New Material Pump Mounting ......................................................................................6-16 
Fig. 6-11 Agitator Shaft and Paddles Mounting...........................................................................6-17 
Fig. 6-12 Pump Shaft Placement ................................................................................................6-18 
Fig. 6-13 Pump Shaft to Hydraulic Pump Motor Placement.........................................................6-19 
Fig. 6-14 Agitator Connecting Link..............................................................................................6-20 
Fig. 6-15 Agitator Chain Tightening Steps...................................................................................6-21 
Fig.6-16 Switch Wire Location.....................................................................................................6-23 
Fig.6-17 Wire Routing.................................................................................................................6-23 
Fig.6-18 Terminal Block Wiring ...................................................................................................6-24 
Fig.6-19 Actuator Spring Location...............................................................................................6-24 
Fig.6-20 Actuator / Trigger Assembly..........................................................................................6-25 
Fig. 7-1 Standard Multimeter.........................................................................................................7-2 
Fig. 7-2 Clamp –On Amp Meter/Multimeter..................................................................................7-3 
Fig. 8-1 Diesel Burner Schematic..................................................................................................8-6 
Fig. 8-2 Diesel Burner Electrode Adjustment...............................................................................8-10 
Fig. 8-3 Diesel Burner Air Settings..............................................................................................8-10 
Fig. 8-4 Checking Din Plug Voltage.............................................................................................8-15 
Fig. 8-5 Mixer Schematic ............................................................................................................8-16 
Fig. 8-6 Hydraulic Valve Pressure Setting...................................................................................8-18 
Fig. 8-7 Din Plug Layout..............................................................................................................8-19 

 
 
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. 9-1 Super Shot 250 Diesel Melter Comp. 100 CFM ............................................................... 9-2 
Fig. 9-2 Super Shot 250 Diesel Melter Comp. 100 CFM (continued)............................................. 9-4 
Fig. 9-3 Super Shot 250 Diesel Melter Comp. 100 CFM (continued)............................................. 9-6 
Fig. 9-4 Tank Assembly................................................................................................................ 9-8 
Fig. 9-5 Control Box Assembly: PN: 47252N .............................................................................. 9-10 
Fig. 9-6 Engine Assembly: 48000N............................................................................................. 9-12 
Fig. 9-7 Engine Assembly: PN 48000N (continued).................................................................... 9-14 
Fig. 9-8 Engine Assembly: PN 48000N (continued).................................................................... 9-16 
Fig. 9-9 Hydraulic Control Valve Assembly: PN 45420................................................................ 9-18 
Fig. 9-10 Material Flow Control Assembly: PN 46060................................................................. 9-20 
Fig. 9-11 Pump/Mixer Motor Assembly: PN 44832...................................................................... 9-22 
Fig. 9-12 Diesel Burner Assembly: PN 46380............................................................................. 9-24 
Fig. 9-13 Hydraulic Diagram: PN 26659N................................................................................... 9-26 
Fig. 9-14 Hydraulic Diagram: PN 26659N (continued)................................................................. 9-28 
Fig. 9-15 Hydraulic Diagram: PN 26659N (continued)................................................................. 9-30 
Fig. 9-16 Diesel Fuel Line Schematic.......................................................................................... 9-32 
Fig. 9-17 Diesel Fuel Line Schematic (continued)....................................................................... 9-34 
Fig. 9-18 Electrical Schematic..................................................................................................... 9-36 
Fig. 9-19 Air Compressor Assembly: PN 47480N ....................................................................... 9-38 
Fig. 9-20 Hydraulic Compressor Valve Assembly: PN 45425...................................................... 9-40 
Fig. 9-21 High Output Air Lance PN: 47483N (standard) ............................................................ 9-42 
Fig. 9-22 High Output Air Lance with Water Separator PN: 47491N (optional)............................ 9-43 
Fig. 9-23 Wand Assembly PN 52200.......................................................................................... 9-44 
Fig. 9-24 Engine Cover Assembly PN: 48120N (optional)........................................................... 9-46 
Fig. 9-25 Hot Air Lance (optional) ............................................................................................... 9-48 