Repair
ThermoLazer™ and ThermoLazer™ ProMelt™
Pavement Marking Systems
3A1320B
EN
US Patent No. D619,625.5 and other patents pending
- For professional application of thermoplastic traffic marking compound materials
(reflective beads applied simultaneously with screeding) - For outdoor use only (not to be operated in rain or damp conditions) Fuel: LP Gas (Propane Vapor)
Burner capacities: See Technical Data, page 31.
Material capacity (max): 300 lb (136 kg)
IMPORTANT SAFETY INSTRUCTIONS
Read all warnings and instructions in this
manual. Save these instructions.
Related Manuals:
Operation
3A1319
Parts
3A1321
ThermoLazer ProMelt 24H624, 24H626
ThermoLazer 24H622, 24H625
For use with the following
SmartDie II™ Screed Box:
Part
24H431
24H426
24H432
24H427
24H433
24H428
24H434
24H429
24H430
24H437
24H435
24H436
24J785
24C528
Description
3 in. (8 cm)
4 in. (10 cm)
5 in. (12 cm)
6 in. (15 cm)
7 in. (18 cm)
8 in. (20 cm)
9 in. (22.5 cm)
10 in. (25 cm)
12 in. (30 cm)
3-3-3 in. (8-8-8 cm)
4-3-4 in. (10-8-10 cm)
4-4-4 in. (10-10-10 cm)
4-6-4 in. (10-17-10 cm)
Kit, Double Bead Box
ti15947a
ti14144a
Table of Contents
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Kettle Gas Safety Valve,
Kettle Temperature Control, and
Kettle Thermopile Diagnosis . . . . . . . . . . . . . . 5
Kettle Temperature Control . . . . . . . . . . . . . . . . . . 6
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Kettle Thermometer . . . . . . . . . . . . . . . . . . . . . . . . . 8
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Adjust Kettle Pilot Ignitor Electrode Gap . . . . . . . 9
Kettle Over-Temperature Switch Replacement
(Models 24H624 and 24H626 only) . . . . . . . . . 9
Thermopile Replacement . . . . . . . . . . . . . . . . . . . 10
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjust Kettle Pilot
Burner Flame . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Adjust Kettle Main Burners Flame . . . . . . . . . . . . 12
Cleaning Kettle Main Burner Gas Lines . . . . . . . 13
Cleaning Kettle Pilot Burner Gas Lines . . . . . . . . 13
Securing Bead Dispenser Wheel . . . . . . . . . . . . . 14
Linkage Rod Adjustment . . . . . . . . . . . . . . . . . . . 14
Screed Box/Bead Dispenser Box Actuator . . . . . 15
2
Screed Box Pivot Arm Loading . . . . . . . . . . . . . . 15
Carbide Runner Replacement on Screed Box (1 on
each side) . . . . . . . . . . . . . . . . . . . . . . . . . 16
Kettle Gas Regulator Replacement . . . . . . . . . . 17
Torch and Screed Burners Gas Regulator
Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Rear Screed Burner Assembly . . . . . . . . . . . . . . . 19
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Front Screed Burner Assembly . . . . . . . . . . . . . . 20
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Screed Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
ThermoLazer ProMelt (24H624, 24H626) . . . . . 29
ThermoLazer (24H622, 24H625) . . . . . . . . . . . 30
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 32
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 32
3A1320B
Warnings
Warnings
The following are general warnings related to the safe setup, use, grounding, maintenance and repair of this equipment. In the text of this manual, the exclamation point symbol alerts you to a warning and the hazard symbol refers to
specific risks. Refer back to these General Warnings pages. Additional procedure-specific warnings will be included
where applicable.
Warnings
FIRE AND EXPLOSION HAZARD
Flammable fumes and liquids, such as propane gas, gasoline and combustible fuel, in work area can
ignite or explode. To help prevent fire and explosion:
• Do not use equipment unless fully trained and qualified.
• Do not allow open containers of flammables within 25 ft (7.6 m) of equipment. Do not operate equipment within 10 ft (3 m) of any structure, combustible material, or other gas cylinders.
• Shut off all burners when adding fuel to equipment.
• Close the tank shut-off valve immediately if you smell propane gas; extinguish all open flames. If gas
odor continues, keep away from equipment and immediately call the fire department.
• Follow lighting instructions for the burner and torch.
• Do not heat thermoplastic traffic marking compound material above its maximum temperature rating.
• Fire extinguisher equipment shall be present and working.
• Keep work area free of debris, including solvent, rags and gasoline.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not leave equipment unattended.
• Keep children and animals away from work area.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Do not fill material beyond maximum capacity.
• Route gas lines, hoses, wires and cables away from traffic areas, sharp edges, moving parts, and hot
surfaces.
• Do not kink or overbend gas lines.
• Do not override or defeat safety devices.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
BURN HAZARD
Equipment surfaces and fluid that is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
• Wait until equipment and material has cooled completely.
CARBON MONOXIDE HAZARD
Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon
monoxide can cause death. Do not operate in an enclosed area.
3A1320B
3
Warnings
Warnings
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
• Read MSDS to know the specific hazards of the materials you are using.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Clothing and respirator as recommended by the fluid, material, and solvent manufacturer.
• Gloves, shoes, overalls, face shield, hat, etc. rated for elevated temperatures of at least 500° F
(260° C).
4
3A1320B
Kettle Gas Safety Valve, Kettle Temperature Control, and Kettle Thermopile Diagnosis
Kettle Gas Safety Valve,
Kettle Temperature Control, and
Kettle Thermopile Diagnosis
Terminal Connections
3
TH
TH
TP
The gas safety valve, temperature control and thermopile can be checked by using a millivolt meter. Before
checking, make certain all electrical connections are
clean and tight.
1
TP
Connect millivolt meter to appropriate terminals (see
Terminal Connections).
Step
Status of
Temperature
Part(s) to Be
Terminal
Control
Checked
Connections
Contacts
1
Gas safety
valve
2 and 3
Closed
2
Temperature
control
1 and 2
Closed
ti14524b
Desired
Meter
Reading
2
Diagnosis
Greater than If mV reading > 100 mV and the automatic valve (main
100 mV
burners) does not come on, replace the gas safety valve.
If mV reading < 100mV, proceed with diagnostic steps 2
and 3.
Less than
80 mV
If reading > 80 mV:
•
Clean and tighten electrical connections at temperature control and gas safety valve.
•
Check valve to make sure wires are in good condition. Replace as required.
•
Rapidly change temperature setting on temperature
control to see if cycling cleans the contacts.
If the preceding fails to give mV reading < 80 mV, replace
temperature control.
3
Gas safety
valve magnet
and
thermopile
1 and 2
Open
Greater than If mV reading < 325 mV:
325 mV
•
Clean and tighten all electrical connections.
•
Adjust pilot burner to increase millivolt output (see
page 12).
If the preceding fails to give mV reading > 325 mV, replace
thermopile.
Check valve magnet after obtaining correct mV output for
thermopile:
•
Ignite pilot burner only and allow the mV reading to
stabilize.
•
Shut pilot burner (turn gas safety valve knob OFF).
Note the mV reading where magnet drops out.
If magnet unlocks at mV reading < 120 mV, the magnet is
OK. NOTE: When magnet unlocks a click can be heard
and mV reading may fluctuate slightly.
3A1320B
5
Kettle Temperature Control
Kettle Temperature Control
Replacement
8. Use screwdriver to remove four screws (221) and
remove temperature control enclosure (205) from
handle bar mounting plate (122).
When replacing temperature control, keep in mind that
the temperature probe is an integral part of the assembly. Do not make any sharp bends in the capillary tubing.
Bends should be 0.25 in. (0.64 cm) in radius or greater.
Be sure to seal capillary tubing with high temperature
mortar at kettle outlet.
9. Use screwdriver to disconnect wires (242 and 243
for ThermoLazer), (243 and 360 for ThermoLazer
ProMelt).
10. Use wrench and extension to remove nut (124) from
temperature probe (162).
11. Use needle-nosed pliers to remove clip (41) from
probe 162).
12. Pull probe (162) through nut and clamp openings.
13. Use flat screwdriver or a small chisel to chip away
mortar on inside and outside of kettle until probe
freely passes through.
14. Pull probe (162) completely out of kettle (14) and
remove from temperature control enclosure (205).
ti14557a
ThermoLazer (24H622, 24H625)
Removal
41
1. Empty kettle and clean all material out. Make sure
stud (318), nut (124), clip (41) and probe (162) are
completely free of material.
2. Use screwdriver to loosen hose clamps (160) and
disconnect hoses (189) from bead hopper (43).
3. Use wrench to remove four bolts (139) and remove
bead hopper (43).
ti17067a
4. Pull temperature capillary tube (162) and grommet
(350) free of heat shield (270).
124, 318
5. Remove temperature control knob (AA) by hand.
ProMelt ThermoLazer
(24H624, 24H626)
AA
BB
ti14124a
6. Remove temperature control plastic 4-way insert
from shaft. Insert behind knob (AA).
7. Use screwdriver to remove two screws on temperature control slip-fit overlay ring (BB). Overlay ring
(BB) is attached to temperature control enclosure
(205).
6
41
124
ti17066a
3A1320B
Kettle Temperature Control
Installation
1. Route new probe (162) through grommet (350).
2. Route probe:
a. Between tube, lock (71) and bracket, handle,
mount, and tube (19).
b.
c.
Through slotted hole in heat shield (270). Insert
grommet (350) in heat shield hole.
Through kettle (14) probe opening.
3. ThermoLazer: Route probe through stud (318).
Insert stud through screen (150) and tighten* stud
(318) to screen (150) with nut (124). Secure probe
(162) to screen (150) with three clips (41). Use needle-nose pliers to secure probe inside clips (41).
*Torque stud (318) to 7-15 in-lb./079-1.69 N•m.
ProMelt: Route probe (162) through Z-clips (2)
welded to kettle (14). Route probe through stud
welded to kettle. Tighten* nut (124) to stud securing
probe. Secure probe to angle clip welded to kettle
with clip (41). Use needle-nose pliers to secure
probe inside clip(41).
*Torque nut (124) to 7-15 in-lb./079-1.69 N•m.
NOTE: Make sure probe cannot come into contact
with material agitator once installed.
ing plate (122). NOTE: For best results, keep probe
capillary tubing in spiral coil.
8. Install temperature control enclosure (205) to ThermoLazer handle bar mounting plate (122) with four
screws (221).
9. Install plastic 4-way insert on temperature control
shaft.
10. Install temperature control knob (AA) on temperature control shaft.
11. Install bead hopper (43) and use wrench to install
and tighten four bolts (139).
12. Connect hoses (189) to bead hopper (43) and use
screw driver to tighten hose clamps (160).
Calibration
To Check Kettle Temperature Control Calibration:
1. Move unit to an area with no wind.
2. Turn temperature control to 400° F (204° C).
3. Agitate material for 4 to 5 minutes.
4. Apply high temperature mortar to inside and outside
of kettle opening contact points after the probe is
installed and locked into position by the nut and
clamps.
5. ThermoLazer: Route wires (242, 243) through handle bar mounting plate (122). Use screwdriver to
connect and tighten wires (242, 243) to temperature
control (162).
ProMelt: Route wires (243, 360) through handle bar
mounting plate (122). Use screwdriver to connect
and tighten wires (243, 360) to temperature control
(122).
4. After control has reached steady state temperature
and burners do not cycle more than once per minute, insert remote calibrated temperature probe in
material and directly adjacent kettle temperature
control probe.
5. Compare temperature of remote calibrated temperature probe to temperature setting on temperature
control.
6. If the temperature control setting is lower than the
remote calibrated temperature setting on temperature probe, turn adjusting screw clockwise. Every
1/4 in. turn will change temperature 35° F (19.4° C).
6. Install temperature control (162) to temperature
control enclosure (205) with two screws supplied
with temperature control. Install overlay ring (BB)
parallel with temperature probe.
ti14523a
AA
BB
ti14124a
7. Route wires and probe capillary tubing so they will
not be pinched when installing temperature control
enclosure (205) to ThermoLazer handle bar mount3A1320B
7. If the temperature control setting is higher than the
remote calibrated temperature probe, turn adjusting
screw counterclockwise--every 1/4 in. turn will
change temperature 35° F (19.4° C).
8. Recheck calibration by turning temperature control
to 410° F (210° C) and repeat steps 3-7.
7
Kettle Thermometer
Kettle Thermometer
Replacement
Calibration
NOTE: The thermometer can only be replaced while the
material inside the kettle is warm. If material inside the
kettle is cold, it will adhere to the probe and cause it to
separate from the thermometer once it is unscrewed.
To Check Kettle Thermometer Calibration:
1. Empty material from kettle until material level is just
below the thermometer probe (162) (approximately
1 inch of material).
2. Unscrew thermometer (38) from kettle coupling.
NOTE: Look inside the kettle to make sure the
probe is rotating at the same rate as the thermometer as you unscrew it. If the probe is sticking, use the
hand torch to heat the probe and material so that
the probe can rotate freely.
1. Move ThermoLazer™ to an area with no wind.
2. Turn temperature control to 400° F (204° C).
3. Agitate material for 4 to 5 minutes.
4. After control has reached steady state temperature
and burners do not cycle more than once per minute, insert remote calibrated temperature probe in
material and directly adjacent kettle temperature
control probe.
5. Compare temperature of remote calibrated temperature probe to thermometer.
Installation
1. Apply pipe sealant to thermometer (38) threads.
2. Install new thermometer into kettle coupling and
tighten. NOTE: Make sure the face of the thermometer is position toward the front of the unit for optimal
viewing (an approximately 15 degree angle).
6. If kettle thermometer is lower than the remote calibrated temperature probe, turn adjusting screw
counterclockwise.
Adjusting Screw
RESET
ti14525b
7. If the kettle thermometer is higher than the remote
calibrated temperature probe, turn adjusting screw
clockwise.
8
3A1320B
Adjust Kettle Pilot Ignitor Electrode Gap
Kettle Over-Temperature
Switch Replacement
Adjust Kettle Pilot Ignitor
Electrode Gap
(Models 24H624 and 24H626 only)
1. Loosen screw (231).
2. Rotate ignitor electrode (7) until gap of .17 to .20 in.
(.43 to .51 cm) is achieved.
3. Retighten screw (231).
Removal
.17 - .20 in.
1. Unscrew switch fitting from kettle. NOTE: To keep
wire sleeve from twisting, counter-rotate sleeve
when turning switch fitting.
7
2. Disconnect wire leads from switch terminals.
ti14519a
ti17078a
3. Unscrew switch and remove.
Installation
1. Apply anti-seize (LPS-04110 or equal) to switch
(339).
2. Install switch and torque to 120 - 140 in-lb (13.6 15.8 N•m).
3. Apply anti-seize (LPS-04110 or equal) to switch
fittings (343).
4. Connect wire leads (359 and 360) to switch.
5. Install switch fitting and torque to 180 - 200 in-lb
(20.3 - 22.6 N•m). NOTE: To keep wire sleeve from
twisting, counter-rotate sleeve when turning switch
fitting.
3A1320B
9
Thermopile Replacement
Thermopile Replacement
Removal
6. Pull thermopile wire out of gas safety valve enclosure (28).
1. Shut off gas valve on LP-tank and disconnect hose.
28
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ti14128a
2. Remove gas safety valve enclosure back cover (29).
7. Disconnect gas pilot line (49) at gas pilot coupling
(171).
171
49
29
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ti14880a
3. Remove cover (320) from gas safety valve enclosure (28).
8. Remove gas pilot mounting plate (318) from gas
burner mounting plate (18).
28
320
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18
318
ti14852a
4. Disconnect thermopile wires from gas safety valve
(13).
9. Remove thermopile (7).
13
7
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5. Remove wire strain relief fitting (357) from gas
safety valve enclosure (28).
ti14858a
10. Pull thermopile out of wire sleeving.
28
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357
10
3A1320B
Thermopile Replacement
Installation
7. Connect thermopile wires to gas safety valve (13).
See Wiring Diagram and Parts manual 3A1321 for
additional details.
1. Replace thermopile (7).
7
13
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ti14866a
2. Install gas pilot mounting plate (318) to gas burner
mounting plate (18).
8. Replace cover (320) on gas safety valve enclosure
(28).
18
320
318
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3. Connect gas pilot line (49) at gas pilot coupling
(171).
171
28
ti14867a
9. Replace gas safety enclosure back cover (29).
49
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4. Pull thermopile through wire sleeving.
5. Guide thermopile wire into gas safety valve enclosure (28).
29
ti14881a
10. Reconnect hose and turn LP-gas tank valve ON.
28
ti14864a
6. Replace wire strain relief fitting (357) on gas safety
valve enclosure (28).
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28
ti14865a
357
3A1320B
11
Adjust Kettle Pilot Burner Flame
Adjust Kettle Pilot
Burner Flame
Adjust Kettle Main
Burners Flame
1. Ignite kettle gas pilot burner.
1. Ignite kettle gas pilot burner.
2. Record pilot burner flame height and color. Flame
should be 2 to 3 in. (5 to 7 cm) high and blue-orange
in color.
2. Turn kettle gas safety valve (CC) to ON.
3. Turn kettle temperature control knob (AA) to 250° F
(121° C).
3. Remove flame adjusting screw cap.
4. Turn adjusting screw clockwise to decrease flame
height (counterclockwise to increase flame height).
5. Install flame adjusting screw cap.
Model
258699
24H622
24H624
24H626
4. Record pilot burner flame height and color. Flame
should be 2 - 3 in. (5 - 7.5 cm) high and blue-orange
in color.
5. Record burner venturi gap. Gap should be .17 to .20
in. (4 to 5 mm).
Flame Height
in. (cm)
2-3 (5-8)
2-3 (5-8)
3-4 (8-10)
3-4 (8-10)
6. Loosen air shutter jam nut and adjust air shutter to
obtain correct gap.
7. Lock air shutter jam nut. Use thread sealant for a
more secure locking.
see table
ti14525a
ti14522a
see table
.17 - .20 in.
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12
3A1320B
Cleaning Kettle Main Burner Gas Lines
Cleaning Kettle Main
Burner Gas Lines
Cleaning Kettle Pilot
Burner Gas Lines
1. Disconnect gas tubing line (49) from gas tube fitting
tee (165).
1. Disconnect gas tubing line (186) from gas tubing
line (118).
2. Force air into gas tubing line (49). Insert rubber
hose over gas tubing tee and force air into tubing at
30 psi (2.1 bar).
2. Force air into gas tubing line (118). Insert rubber
hose over gas tubing tee and force air at 30 psi
(2.1 bar).
3. Reconnect gas tubing line (49) to gas tube fitting tee
(165).
3. Reconnect gas tubing line (186) to gas tubing tee
(118).
165
ti14559a
ti14558a
186
49
3A1320B
118
13
Securing Bead Dispenser Wheel
Securing Bead Dispenser
Wheel
To properly dispense beads, drive wheel (27) must be in
direct contact with tire (89). If drive wheel (27) becomes
loose and/or starts to slip, use allen wrench to tighten
set screw (211).
Adjust the bead box linkage rod (181) so bead box drive
wheel (27) is touching ThermoLazer tire (81) when
screed box is in down (but not open) position. A slight
downward force on the bead box rod (181) should be
required when inserting the clevis pin through the clevis
(179) and deployment bar (78).
1. With screed box in down (but not open) position,
rotate the bead box wheel by hand.
NOTE: To ensure proper contact between drive wheel
(27) and tire (81), make sure air pressure is always at 60
psi (4.14 bar).
ti14882a
211
81
81
27
ti14564a
Linkage Rod Adjustment
Adjustments can be made to linkage rods by removing
clevis cotter hairpin (268), clevis pin from clevis (179),
loosening nuts (128), and then turning clevis as required
to lengthen or shorten rod connectors.
To ensure proper application of beads and thermoplastic, make sure screed box linkage rod (182) measures
13.13 in. (33.34 cm). Be sure to measure where nut
(128) meets clevis (179) when checking for proper linkage rod length.
13.13 in.
(33.34 cm)
27
2. If the wheel does not cause the ThermoLazer tire to
rotate both forward and backwards, loosen nuts
(128), remove clevis cotter hair pin (268), remove
clevis pin from clevis (179), and rotate the clevis
(179) one turn counterclockwise.
78
268
179
128
ti14883a
3. Reconnect clevis to deployment bar and again
rotate bead box wheel to see if adjustments cause
ThermoLazer to move forward and backwards.
4. Continue to rotate clevis 1/2 turn counterclockwise
until rotating bead box wheel causes ThermoLazer
to move forward and backwards.
5. Lock nut (128) to clevis when final adjustment has
been made.
181
NOTE: Linkage rod (182): If converting from SmartDie
to SmartDie II, use Die Link Kit 24J714.
182
ti14565a
14
3A1320B
Screed Box/Bead Dispenser Box Actuator
Screed Box/Bead
Dispenser Box Actuator
Screed Box Pivot Arm
Loading
If the screed box/bead dispenser box actuator does not
remain in the “down and locked” position, adjust the
3/4-16 lock nut by turning clockwise 1/4 to 1/2 turn or
until the actuator does not freely rotate.
Preload screed box pivot arm to ensure gate closes fully
before lifting screed box off the ground. If screed box
leaks when closing and lifting, increase loading.
1. Unhook bottom of box pivot arm spring (199).
ti14604a
ti14628b
2. Move bottom of box pivot arm spring to desired hole
and reconnect. Moving the spring in will decrease
loading, while moving the spring out will increase
loading.
ti14629b
If screed box leaks after placing spring at maximum
loading, replace box pivot arm spring.
3A1320B
15
Screed Box Pivot Arm Loading
Carbide Runner Replacement on
Screed Box (1 on each side)
Installation
1. Apply grease to groove where carbide runner sits.
NOTICE
Carbide runners need to be replaced one side at a
time. If both runners are removed, adjustment will be
lost and screed box will need to be reassembled by a
Graco approved technician.
ti16845a
1. Remove screed box.
2. Replace plate, die runner (504) with new plate, die
runner. See Parts manual 3A1321.
ti16839a
3. While applying pressure to shear bar (506) directly
over support bar (509), use allen wrench to replace
and tighten four screws (513). There should be no
gap between the shear bar and support bar when
applying pressure.
2. Use allen wrench to loosen and remove upper pivot
bolt (511) to free yoke (502).
ti17068a
4. Use allen wrench to replace and tighten pivot bolt
(511) on yoke (502).
ti16843a
3. Turn unit upside-down and use an allen wrench to
remove four screws (513) and plate, die runner
(504).
ti16843a
5. Install screed box.
ti16845a
ti16846a
16
3A1320B
Screed Box Pivot Arm Loading
Kettle Gas Regulator
Replacement
Removal
1. Close manual gas shut-off valve on propane tank.
nection of regulator is connected to the downstream
pipe coupling.
2. Apply pipe sealant to upstream pipe elbow (142)
and screw on gas pipe train with replacement regulator. Turn connection until gas tight. NOTE: Make
sure “in” connection of regulator is connected to the
upstream pipe elbow.
3. Connect gas line at downstream tube elbow (161).
Turn connection until gas tight.
4. Connect gas supply hose to propane tank.
ti14128a
2. Disconnect gas supply hose from propane tank.
ti14411a
3. Disconnect gas line at downstream tube elbow
(161).
4. Remove (temporarily) red plastic regulator cap.
5. Unscrew gas regulator pipe train from upstream
pipe elbow (142).
5. Open manual gas shut-off valve on propane tank.
6. Unscrew and remove gas regulator (10) from gas
pipe train.
Installation
1. Apply pipe sealant to downstream pipe coupling
(64) and screw on replacement regulator. Turn connection until gas tight. NOTE: Make sure “out” con-
ti14127a
6. Check gas lines for gas leaks (see operation manual).
142
323
(ProMelt Only)
10
IN
OUT
64
161
ti17069b
3A1320B
17
Torch and Screed Burners Gas Regulator Replacement
Torch and Screed Burners
Gas Regulator Replacement
2. Apply pipe sealant to upstream pipe elbow (142)
and screw on gas regulator (152). Turn connection
until gas tight. Make sure “in” connection of regulator is connected to the upstream pipe elbow (142).
Removal
3. Apply pipe sealant to downstream pipe tee (12).
Screw pipe tee (12) with elbow (161) to gas regulator (152). Turn connection until gas tight. Make sure
out connection of regulator is connected to tee (12).
1. Close manual gas shut-off valve on propane tank.
4. Connect gas line at downstream tube elbows (161).
Turn connection until gas tight.
5. Connect gas supply hose to propane tank.
ti14128a
2. Disconnect gas supply hose from propane tank.
3. Disconnect gas line at downstream tube elbows
(161).
ti14411a
4. Unscrew gas regulator pipe train from upstream
pipe elbow (142).
6. Open manual gas shut-off valve on propane tank.
5. Unscrew and remove gas regulator (152) from
downstream pipe tee (12).
Installation
1. Apply pipe sealant to downstream pipe tee and
screw on replacement regulator. Turn connection
until gas tight. Make sure “out” connection of regulator is connected to the downstream pipe coupling.
ti14127a
7. Check gas lines for gas leaks (see operation manual).
142
323
152
IN
OUT
161
12
161
18
ti17070b
3A1320B
Rear Screed Burner Assembly
Rear Screed Burner
Assembly
Installation
Removal
2. Install burner assembly with mounting bracket to
bead dispenser.
1. Install burner manifold in mounting bracket (104,
109). Secure with snap rings (75).
1. Close manual gas shut-off valve on propane tank.
3. Connect burner hose (98) to valve fitting (151).
4. Connect gas supply hose (99) to propane tank.
99
ti14128a
ti14411a
2. Disconnect gas supply hose (99) from propane
tank.
3. Disconnect gas hose (98) at valve fitting (151).
5. Open manual shut-off valve on propane tank.
4. Remove burner gas train mounting bracket fasteners (104, 109). Unscrew six screws (115).
5. Remove burner assembly.
6. Remove snap rings (75) from gas manifold.
ti14127a
151
ti17071a
98
104
75
109
3A1320B
115
19
Front Screed Burner Assembly
Front Screed Burner
Assembly
7. Unscrew gas manifold mounting bracket fasteners
(146) and remove burner assembly from front screed
housing (20).
Installation
Removal
1. Close manual gas shut-off valve on the propane
tank.
1. Install gas manifold in bracket support manifold (52)
and screw gas manifold mounting bracket to front
screed housing (20) with fasteners (146).
20
52
146
ti14128a
75
ti17074a
2. Disconnect gas supply hose from propane tank.
2. Install gas manifold snap ring (75).
3. Install front screed housing (20) to screed housing.
Secure with fasteners (146).
ti14411a
146
3. Remove screed box from screed housing (see Operation manual).
20
ti17073a
4. Disconnect gas tubing at 45° elbow (32).
4. Connect gas tubing to 45° elbow (32).
ti17072a
ti17072a
32
32
5. Unscrew front screed housing fasteners (146) and
remove front housing (20).
5. Connect gas supply hose (99) to propane tank.
99
146
ti14411a
20
ti17073a
6. Remove gas manifold snap ring (75).
75
6. Open manual gas shut-off valve on propane tank.
ti17074a
ti14127a
20
3A1320B
Screed Burner
Screed Burner
Removal
Installation
1. Remove screed burner flame indicator (67).
1. Apply high-temperature thread sealant to 3/8-16
threads of orifice (60) and screw into burner (2).
NOTE: The orifice end with the smallest hole should
be screwed into the screed burner.
67
ti17075a
60
ti17077a
2. Unscrew screed burner and orifice from gas manifold.
2
2. Apply pipe sealant to 1/8 in. NPT thread of orifice fitting and screw into gas manifold.
ti17076a
ti17076a
3. Unscrew orifice fitting (60) from screed burner (2).
3. Install screed burner flame indicator (67).
60
ti17077a
2
67
ti17075a
3A1320B
21
Troubleshooting
Troubleshooting
Problem
Kettle pilot burner does
not ignite or does not
remain ignited
Cause
Solution
Low or empty LP-gas tank
Replace with full tank.
Gas supply hose not connected to tank
Connect gas supply hose.
LP-gas tank shut-off valve closed
Open LP-gas tank shut-off valve.
Manual gas shut-off valve closed
Open manual gas shut-off valve.
Gas lines leaking or disconnected
Check for gas leaks. Connect and tighten fittings.
Kettle gas safety valve knob not in correct position
Turn knob to “PILOT” position and fully push
in (see Operation manual).
Not providing adequate time for thermopile to
heat up
See Operation manual.
Kettle pilot igniter has weak battery
Replace part (see Parts manual).
Kettle pilot electrode gap incorrect
Adjust gap (see page 9).
Incorrect flame length and/or gas pressure
Adjust flame and pressure (see Repair manual).
Strong wind blowing flame out
Move ThermoLazer™ out of strong winds.
Make sure burner view ports are closed.
Burner and/or gas lines plugged
Unplug holes and lines. Isolate all gas regulators if clearing line with forced air (see page
5).
Kettle gas safety valve not functioning correctly
Replace part if it fails diagnostic test (see
page 5).
Thermopile not functioning correctly
Replace part if it fails diagnostic test (see
page 10).
Kettle pilot electrode ground wire not correctly
connected
Clean connections and retighten. Replace
ground wire if damaged.
Kettle pilot electrode lead wire has a short
Replace part (see Parts manual).
Kettle pilot igniter not functioning correctly
Replace part (see Parts manual).
Kettle burner regulator not functioning correctly
Replace part (see Parts manual).
Kettle burners shut off
Material level is low.
before material is melted
Add material to kettle. Once material level is
up to thermometer, this condition will be corrected.
ProMelt Only:
Replace part (see Parts manual).
22
Over temperature safety switch not functioning
correctly
3A1320B
Troubleshooting
Problem
Cause
Kettle main burners do
Kettle gas safety valve knob not at correct posinot ignite or are not burn- tion
ing correctly
Kettle temperature control dial set at a lower temperature than material temperature
Kettle main burners do
not shut off
Kettle main burner does
not turn on
Solution
Turn knob to ON position (see Operation
manual).
Turn kettle temperature control dial to temperature 25° F (13.9° C) higher than material
temperature.
Kettle gas safety valve not functioning correctly
See Repair manual and replace part if it fails
diagnostic testing.
Burner and/or gas lines plugged
Unplug holes and lines. Isolate all gas regulators if clearing line with forced air (see page
13).
Kettle temperature control not functioning correctly
Replace part (see Parts manual).
Gas lines have been disconnected
Connect and tighten hose fittings. Check for
gas leaks.
Incorrect flame length and/or gas pressure
Adjust flame and pressure (see page 12).
Kettle gas safety valve knob not at correct position
Replace part (see Parts manual).
Kettle temperature control dial is not turned to a
setting lower than material temperature
Turn kettle temperature control dial to a setting 25° F (13.9° C) (minimum) lower than
material temperature.
Kettle temperature control not functioning correctly
Replace part (see Parts manual).
Kettle gas safety valve not functioning correctly
Replace part if it fails diagnostic testing (see
page 5).
Kettle temperature control dial is not turned to a
setting higher than material temperature
Turn kettle temperature control dial to a setting 25° F (13.9° C) (minimum) higher than
material temperature.
Kettle temperature control not functioning correctly
Replace part (see Parts manual).
Kettle gas safety valve not functioning correctly
Replace part if it fails diagnostic test (see
page 5).
Over temperature safety switch not functioning
correctly
Replace part (see Parts manual).
Thermometer not match- Material has not reached temperature control set Allow time for material to reach operating
ing material temperature point
temperature.
in kettle
Material not fully agitated
Agitate material.
3A1320B
Cool or windy ambient conditions
Move ThermoLazer™ out of cool windy conditions. Discharge material and check thermometer.
Thermometer calibrated incorrectly
Calibrate thermometer (see page 8).
Kettle temperature control calibrated incorrectly
See Repair manual and replace part if it can
not be calibrated (see Parts manual).
Thermometer not functioning correctly
Replace part (see Parts manual).
Kettle temperature control not functioning correctly
Replace part (see Parts manual).
Kettle gas safety valve not functioning correctly
Replace part if it fails diagnostic test (see
page 5).
Incorrect flame length and/or gas pressure
Adjust flame and pressure (see page 12).
23
Troubleshooting
Problem
Screed box burner does
not ignite, does not
remain ignited, or can
not change heat output
Torch does not ignite
Agitator crank handle is
hard to move
Cause
Solution
Empty LP-gas tank
Replace with full tank.
LP-gas tank shut-off valve closed
Open LP-gas tank shut-off valve.
Gas supply hose not connected to tank
Connect gas supply hose.
Gas lines leaking or disconnected
Check for gas leaks. Connect and tighten fittings.
Burner regulator/flow flame adjusting valve not
functioning correctly
Replace part (see Parts manual).
Burner orifice plugged
Clean or replace part (see Parts manual).
Burner assembly not functioning correctly.
Replace part (see Parts manual).
Empty LP-gas tank
Replace with full tank.
LP-gas tank shut-off valve closed
Open LP-gas tank shut-off valve.
Torch manual gas shut-off valve closed
Open manual shut-off valve.
Gas supply hose not connected to tank
Connect gas supply hose.
Gas lines leaking or disconnected
Check for gas leaks. Connect and tighten fittings.
Torch assembly not functioning correctly
Replace part (see Parts manual).
Material is cold
Allow time for material to reach operating
temperature
Bushings are worn
Replace bushings (see Parts manual).
Linkage ball rod ends need lubrication
Add grease
Foreign material lodged between agitator and
kettle
Remove material in kettle and CAREFULLY
dislodge and remove foreign material.
ControlFlow™ gate valve Cold material temperature
difficult to open
or close
Gate sticking in guides
Heat material to operating temperature.
Make sure thermometer is free to move.
Check for excess material in guides. Apply
heat as required and remove excess material. Add grease to lubricate guides.
Bushings are worn
™
ControlFlow
leaking
Screed box leaking
Excessive material
buildup when starting
and stopping extruding
24
Replace bushings (see Parts manual).
gate valve Gate not completely closed
Foreign material lodged in gate opening
Close gate completely.
CAREFULLY dislodge and remove foreign
material.
Foreign material in screed box discharge opening
CAREFULLY dislodge and remove foreign
material.
Dirty screed box
CAREFULLY clean box. All moving parts
need to be free of debris.
Incorrect deployment rod linkage length
Adjust length (see page 14).
Incorrectly adjusted screed box/bead dispenser
box actuator
Adjust lever (see page 14).
Worn screed box shear bar
Replace gate (see Parts manual).
Worn screed box shear bar stop
Replace trough (see Parts manual).
Screed box not adjusted to ground
Screed box open when ThermoLazer
stationary
See Operation manual.
™
is
Synchronize ThermoLazer™ and screed box
motion.
Foreign material in screed box discharge opening
CAREFULLY dislodge and remove foreign
material.
Dirty screed box
CAREFULLY clean box. All moving parts
need to be free of debris.
3A1320B
Troubleshooting
Problem
Cause
Beads not discharging or Low bead level in bead hopper
discharging unevenly
Bead dispenser doors closed
Bead dispenser drive wheel not engaged
Solution
Fill bead hopper.
Open doors as required to obtain desired
flow pattern width.
Secure bead dispenser wheel (see page 14).
Bead dispenser drive wheel slipping
Tighten. Check air pressure (see page 14).
Debris in discharge opening of bead dispenser
Remove debris.
Debris on ThermoLazer™ tire or bead dispenser Remove debris.
wheel
Moisture in beads
Beads not discharging at Bead dispenser flow rate lever not correctly set
required flow rate
Bead dispenser drive wheel slipping
Hard pushing when
screed box is on ground
3A1320B
Remove wet beads. Dry hopper, bead hoses
and bead dispenser. Fill hopper with dry
beads.
Rotate flow rate lever to correct position.
Tighten wheel and check tire pressure (see
page 14).
Bead dispenser doors not fully open
Open door fully.
Moisture in beads
Remove wet beads. Dry hopper, bead hoses
and bead dispenser. Fill hopper with dry
beads.
Moisture on road surface
Allow road surface moisture to dry.
Rough road surface
Smooth road surface.
Bead Dispenser low on material
Add material to bead hopper.
Screed box not adjusted correctly
See Operation manual.
25
Troubleshooting
Applying Material
Problem
Cause
Ragged line edges when extruding
Solution
Dirty screed box
CAREFULLY clean box. Discharge
opening and screed box plate runners need to be free of debris.
Cold material temperatures
Heat material as required.
Marking speed too fast
Slow Thermolazer™ speed.
Rough material surface when extrud- Overheated material
ing
Moisture on road surface
Reduce heat.
Allow road surface moisture to dry.
Rough road surface
Smooth road surface.
Screed box low on material
Add material to screed box.
EXAMPLES:
Correct line application will produce a full straight line with sharp edges; correct color,
thickness and width; a firm bond to the surface; and have uniform reflectivity.
ti14507a
Insufficient adhesion (material bulges •
at beginning of line)
•
Material temperature too low
•
Raise material temperature
Thermolazer™ speed too fast
•
Decrease speed of
Thermolazer™
•
Clear debris from road
•
Wait for temperature of surface to
raise
•
Debris on road
•
Surface temperature too cold
ti14508a
Rough and bumpy line
•
Debris on surface
•
Clear debris from surface
•
Crust from overheated material
•
Lower material temperature
•
Debris caught in screed box
•
Clean debris from screed box
•
Material not covering road high
spot
•
Adjust screed box line thickness
•
Moisture or solvent on surface
•
Remove solvent from surface
•
Material is overheated
•
Lower temperature of material
ti14509a
Gas bubbles in line
ti14510a
Ragged edges and gaps in line
• Material temperature is too low
• Raise material temperature
• Thermolazer™ speed is too fast
• Wait for change in ambient conditions to remove moisture
• Reduce Thermolazer™ speed
ti14511a
26
3A1320B
Troubleshooting
Problem
Cause
Swollen rounded line
Solution
• Material temperature is too high
• Lower material temperature
• Uneven road surface
• Apply to even road surfaces
ti14512a
Material shadows on sides
• Screed box is not evenly riding on • Remove debris from screed box
substrate
lever rod
• Inspect/replace damaged screed
box lever rod/lever arm
ti14513a
Line is wavy
• Strong road surface camber
• Apply so camber does not influence application
• Incorrect Thermolazer™ operation • Use correct application methods
(for example, try locking swivel
wheel)
ti14514a
Cracks in line
ti14515a
Rough edges and lines in surface
• Cracks in road surface
• Repair cracks
• Temperature stress from
overheating
• Lower temperature in material
• Material applied too cold
• Increase material temperature
• Material applied too thin
• Slow Thermolazer™ speed to
apply thicker material
• Material temperature is too low
• Raise material temperature
• Material is overheated or scorched • Lower material temperature
• Moisture in road surface
• Wait until road surface is dry
• Screed box does not fully close
• Clean screed box
• Debris caught in screed box
• Clear debris from screed box
• Worn screed box shear bar
• Replace screed box gate
ti14516a
Jagged line ends; material drips
between lines
ti14517a
• Worn screed box trough shear bar • Replace screed box trough
stop
• Surface temperature too cold
3A1320B
• Allow surface temperature to
increase
27
Piping Diagram
Piping Diagram
13 psi (0.89 bar) ThermoLazer
5 psi (0.34 bar) ThermoLazer ProMelt
24H626 ONLY
24H624 ONLY
18 psi (1.24 bar) ThermoLazer and ThermoLazer ProMelt
(24H622, 24H625, 24H624, 24H626)
ti17083a
28
3A1320B
Wiring Diagram
Wiring Diagram
ThermoLazer ProMelt (24H624, 24H626)
ti17084a
3A1320B
29
Wiring Diagram
ThermoLazer (24H622, 24H625)
30
3A1320B
Technical Data
Technical Data
ThermoLazer
Fuel
with Rear
Heat
without Rear
Heat
with Rear
Heat
without Rear
Heat
24H622
24H625
24H624
24H626
Liquefied Petroleum Gas (LP-gas) (propane vapor)
Maximum Heating
Capacity
Btu/hr (kW)
Operating
Pressure
(psi - bar)
Gas supply maximum pressure - psi (bar)
250 (17.24)
Kettle burners
0.5
(0.034)
0.5
(0.034)
5
(0.34)
5
(0.34)
Torch
20
(1.38)
20
(1.38)
20
(1.38)
20
(1.38)
Screed box front burners
20
(1.38)
20
(1.38)
20
(1.38)
20
(1.38)
Screed box rear burners
20
(1.38)
N/A
20
(1.38)
N/A
Kettle burners (sum of 2 burners)
30,000
(8.8)
30,000
(8.8)
100,000
(29.3)
100,000
(29.3)
Torch
100,000
(29.3)
100,000
(29.3)
100,000
(29.3)
100,000
(29.3)
Screed box front burner (sum of 3 burners)
27,000
(7.9)
27,000
(7.9)
27,000
(7.9)
27,000
(7.9)
Screed box rear burner (sum of 4 burners)
36,000 (10.6)
N/A
36,000 (10.6)
N/A
193,000
(56.6)
157,000
(46.0)
263,000
(77.1)
227,000
(66.5)
Total
Material
Capacity
lb (kg)
Gas
20
(9.1)
Main kettle
Maximum operating temperature - °F (°C)
90 (40) - Type II glass bead
450
(232)
450
(232)
Front tire pressure - psi (bar)
45
(3.10)
Rear tire pressure - psi (bar)
60
(4.14)
Weight - lb (kg)
Physical
20,30
(9.1, 13.6)
300 (136) - Thermoplastic traffic marking
compound materials
Bead hopper
3A1320B
ProMelt
300
(136)
295
(134)
Length - in. (m)
72 (1.83)
Height - in. (m)
51 (1.3)
Width - in. (m)
48 (1.22)
Igniter battery
AA (1.5 V)
480
(249)
480
(249)
350
(159)
345
(157)
31
Graco Standard Warranty
Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty
published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by
Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by faulty
installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non-Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of Graco equipment with
structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture, installation, operation or
maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of
the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned
to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will
be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy
(including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or
consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.
GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT
MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to
the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these
warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or
the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the
negligence of Graco, or otherwise.
Graco Information
For the latest information about Graco products, visit www.graco.com.
TO PLACE AN ORDER, contact your Graco distributor or call 1-800-690-2894 to identify the nearest distributor.
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
This manual contains English. MM 3A1320
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA
Copyright 2008, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
www.graco.com
Revised April 2012