Graco 3A1320K, ThermoLazer 200/200TC/300TC and Thermolazer ProMelt Pavement Marking Systems, Repair Owner's Manual

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Graco 3A1320K, ThermoLazer 200/200TC/300TC and Thermolazer ProMelt Pavement Marking Systems, Repair Owner's Manual | Manualzz

Repair

ThermoLazer

ThermoLazer ProMelt

Pavement Marking

Systems

®

200/200

TC

/300

TC

and

3A1320K

EN

- 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) -

ThermoLazer 200/200 TC Fuel: LP Gas (Propane Vapor)

Burner capacities: See Technical Data

, page 47

Material capacity (max): 200-300 lb (91-136 kg)

IMPORTANT SAFETY INSTRUCTIONS

Read all warnings and instructions in this manual. Save these instructions.

Related Manuals:

Operation

Parts

Double Bead

SmartDie ™ II

FlexDie ™

3A1319

3A1321

3A0004

3A1738

3A1738

ThermoLazer ProMelt ti22634b

ThermoLazer 300 TC ti23073a ti23074a

2

System Chart

System Chart

SmartDie II used on ThermoLazer 300 TC /ProMelt only.

Smart Die II

Part No.

17A173

24H431

24H426

17J250

24H432

24H427

24H433

24H428

24H434

24H429

24H430

‡ 17A174

24H437

24H435

24H436

24J785

‡ 17A175

‡ 17R378

Smart Die Description

2 in. (5 cm)

3 in. (8 cm)

4 in. (10 cm)

4.75 in. (12 cm)

5 in. (13 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)

16 in. (40 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. (10-15-10 cm)

6-4-6 in. (15-10-15 cm)

5-5-5 in. (13-13-13 cm)

‡ Requires 16” (40 cm) Conversion Bead System Kit for 300TC/ProMelt Only.

- 17B190 Kit, accy, 16” (40 cm) Single Drop Bead System

- 17B189 Kit, accy, 16” (40 cm) Double Drop Bead Box (requires 17B190 to be installed)

FlexDie used on ThermoLazer 200/200TC only.

FlexDie

Part No.

16Y661

16Y662

16Y320

16Y663

16Y190

16Y664

16Y326

16Y665

16Y332

16Y207

16Y338

16Y352

16Y666

16Y363

FlexDie Description

2 in. (5 cm)

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)

4-2-4 in. (10-5-10 cm)

4-4-4 in. (10-10-10 cm)

3A1320K

System Chart

Contents

System Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Kettle Gas Safety Valve,

Kettle Temperature Control, and

Kettle Thermopile Diagnosis . . . . . . . . . . . . . . 6

Kettle Temperature Control . . . . . . . . . . . . . . . . . . 7

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Kettle Thermometer . . . . . . . . . . . . . . . . . . . . . . . . 10

Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Adjust Kettle Pilot Igniter Electrode Gap . . . . . . 11

Kettle Over-Temperature Switch Replacement

(ProMelt only) . . . . . . . . . . . . . . . . . . . . . . . . . 11

Thermopile Replacement . . . . . . . . . . . . . . . . . . . 12

Removal and Installation of Electrode . . . . . . . . . 16

Pilot Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

(ThermoLazer 200TC/300TC/ProMelt) . . . . . . . 18

Cleaning Kettle Main Burner Gas Lines . . . . . . . 20

Cleaning Kettle Pilot Burner Gas Lines . . . . . . . . 20

Securing Bead Dispenser Wheel . . . . . . . . . . . . . 21

Bead Dispense Tension Adjustment . . . . . . . . . 21

Linkage Rod Adjustment . . . . . . . . . . . . . . . . . . 21

Screed Box/Bead Dispenser Box Actuator . . . . . 22

Screed Box Pivot Arm Loading . . . . . . . . . . . . . . 22

(ThermoLazer 300TC/ProMelt only) . . . . . . . . . 22

Carbide Runner Replacement on Smart Die II

(300TC/ProMelt) . . . . . . . . . . . . . . . . . . . . . . . . 23

Carbide Runner Replacement on FlexDie

(200/200TC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Kettle Gas Regulator Replacement . . . . . . . . . . . 25

ThermoLazer 200/200TC . . . . . . . . . . . . . . . . . . 25

ThermoLazer 300TC . . . . . . . . . . . . . . . . . . . . . 26

ThermoLazer ProMelt . . . . . . . . . . . . . . . . . . . . 27

Torch and Screed Burners Gas Regulator

Replacement (ThermoLazer 300TC/ProMelt) 28

Rear Screed Burner Assembly . . . . . . . . . . . . . . . 29

Front Screed Burner Assembly . . . . . . . . . . . . . . 30

(ThermoLazer 300TC/ProMelt) . . . . . . . . . . . . . 30

Screed Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

(ThermoLazer 300TC/ProMelt) . . . . . . . . . . . . . 32

Screed Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Main Gas Filter

(ThermoLazer 300TC/ProMelt) . . . . . . . . . . . . 34

Screed Burner Filter . . . . . . . . . . . . . . . . . . . . . . . . 34

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

ThermoLazer 200 . . . . . . . . . . . . . . . . . . . . . . . 41

ThermoLazer 200TC . . . . . . . . . . . . . . . . . . . . . 42

ThermoLazer 300TC/ProMelt . . . . . . . . . . . . . . 43

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

ThermoLazer 200TC . . . . . . . . . . . . . . . . . . . . . 44

ThermoLazer 300TC . . . . . . . . . . . . . . . . . . . . . 45

ThermoLazer ProMelt . . . . . . . . . . . . . . . . . . . . 46

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 48

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 48

3A1320K 3

4

Warnings

Warnings

The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

WARNING

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.

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.

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.

3A1320K

3A1320K

Warnings

WARNING

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This protective 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).

CALIFORNIA PROPOSITION 65

Exhaust from this product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm.

This product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm. Wash hands after handling.

5

6

Kettle Gas Safety Valve, Kettle Temperature Control, and Kettle Thermopile Diagnosis

Kettle Gas Safety Valve,

Kettle Temperature Control, and

Kettle Thermopile Diagnosis

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.

Terminal Connections

3 2

Connect millivolt meter to appropriate terminals (see

Terminal Connections

Step

1

2

).

ti14524c

1

Part(s) to Be

Checked

Gas safety valve

Terminal

Connections

2 and 3

Temperature control

1 and 2

Status of

Temperature

Control

Contacts

Closed

Closed

Desired

Meter

Reading Diagnosis

Greater than

100 mV

Less than

80 mV

If mV reading > 100 mV and the automatic valve (main burners) does not come on, replace the gas safety valve.

If mV reading < 100mV, proceed with diagnostic steps 2 and 3.

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.

3 Gas safety valve magnet and thermopile

1 and 2 Open Greater than

325 mV

If the preceding fails to give mV reading < 80 mV, replace temperature control.

If mV reading < 325 mV:

• Clean and tighten all electrical connections.

• Adjust pilot burner to increase millivolt output (see page 18).

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.

3A1320K

Kettle Temperature Control

Kettle Temperature Control

Replacement

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.

ti14557a

Removal

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).

4. Pull temperature capillary tube (162) and grommet

(350) free of heat shield (270).

5. Remove temperature control knob (AA) by hand.

8. Use screwdriver to remove four screws (221) and remove temperature control enclosure (205) from handle bar mounting plate (122).

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).

ThermoLazer 200 TC ti22652a

ThermoLazer 300 TC (24H622, 24H625) ti17067a

41

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).

15. .

41

3A1320K

124, 318

ThermoLazer ProMelt

(24H624) ti17066a

124

7

Kettle Temperature Control

Installation (ThermoLazer 200 TC )

1. Route tube through clips (1).

2. Route wire inside bracket (2) on inner wall of kettle.

1

2 ti23234b

3. Install temperature control (162) to temperature control enclosure (205) with two screws supplied with temperature control. Install overlay ring (BB) parallel with temperature probe.

AA

BB ti14124a

4. Route wires and probe capillary tubing so they will not be pinched when installing temperature control enclosure (205) to ThermoLazer handle bar mounting plate (122).

NOTE: For best results, keep probe capillary tubing in spiral coil.

5. Install in bracket, then attach bracket to kettle.

6. Install plastic 4-way insert on temperature control shaft.

7. Install temperature control knob (AA) on temperature control shaft.

Installation (ThermoLazer 300 TC /ProMelt)

1. Route new probe (162) through grommet (350).

2. Route probe: a. Between tube, lock (71) and bracket, handle, mount, and tube (19).

b. Through slotted hole in heat shield (270). Insert grommet (350) in heat shield hole.

c. 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 nee-

8 dle-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.

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).

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.

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 mounting 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)

3A1320K

Kettle Temperature Control

Calibration

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).

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. 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. ti14523a

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.

3A1320K 9

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.

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.

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).

To Check Kettle Thermometer Calibration:

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.

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.

10 3A1320K

Adjust Kettle Pilot Igniter

Electrode Gap

(ThermoLazer 300 TC /ProMelt only)

1. Loosen screw (231).

2. Rotate ignitor electrode (7) until gap of 0.17 to 0.20 in. (0.43 to 0.51 cm) is achieved.

3. Retighten screw (231).

0.17 - 0.20 in.

Adjust Kettle Pilot Igniter Electrode Gap

Kettle Over-Temperature

Switch Replacement

(ProMelt only)

Removal

1. Unscrew switch fitting from kettle. NOTE: To keep wire sleeve from twisting, counter-rotate sleeve when turning switch fitting.

2. Disconnect wire leads from switch terminals.

7 ti14519b ti17078b

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.

3A1320K 11

Thermopile Replacement

Thermopile Replacement

Removal

1. Shut off gas valve on LP-tank and disconnect hose.

5. Remove wire strain relief fitting (357) from gas safety valve enclosure (28).

ti14128a

2. Remove gas safety valve enclosure back cover

(29).

ThermoLazer 300TC/ProMelt Shown

ThermoLazer 300TC/ProMelt only

28 ti14855a

357

6. Pull thermopile wire out of gas safety valve enclosure (28).

29 ti14880a

3. Remove cover (320) from gas safety valve enclosure (28).

28

320

28 ti14854a

7. Disconnect gas pilot line (71) from flared adapter

(421). Only rotate the nut on gas pilot line (71), while keeping flared adapter (421) stationary.

421

71 ti14852a

4. Disconnect thermopile wires from gas safety valve

(13).

13 ti25692b

ThermoLazer 200TC/300TC/ProMelt

8.

Thermolazer 300 TC /ProMelt only: Disconnect electrode lead (217) from pulse fire igniter (126).

Pull electrode out of wire sleeving. ti14853a ti25740a

12 3A1320K

Thermopile Replacement

9. Remove gas pilot mounting housing (319) from gas burner mounting plate (18). Disconnect ground lead wire (244).

18

ThermoLazer 300TC/ProMelt

Shown

10. Remove thermopile (7).

ThermoLazer

200TC/300TC/ProMelt

319 ti25741b

11. Pull thermopile out of wire sleeving.

244 ti25739b

3A1320K 13

Thermopile Replacement

Installation

1. Replace thermopile (7).

5. Guide thermopile wire into gas safety valve enclosure (28).

28 ti14864a

6. Replace wire strain relief fitting (357) on gas safety valve enclosure (28).

ti25742b

2. Install gas pilot mounting plate (319) to gas burner mounting plate (18). Connect ground lead wire

(244).

18

ThermoLazer 300TC/ProMelt

Shown

319

28

ThermoLazer 300TC/ProMelt

Shown ti14865a

357

7. Connect thermopile wires to gas safety valve (13).

See Wiring Diagram and Parts manual 3A1321 for additional details.

13

244 ti25743b

3. Connect gas pilot line (71) to flared adapter (421).

ti14866a

8. Replace cover (320) on gas safety valve enclosure

(28).

421

320

71

ThermoLazer 300TC/ProMelt

Shown ti25690b

4. Pull thermopile through wire sleeving.

28 ti14867a

9. Replace gas safety enclosure back cover (29).

ThermoLazer 300TC/ProMelt

Shown

29 ti14881a

14 3A1320K

Thermopile Replacement

10.

ThermoLazer 300 TC /ProMelt Only: Pull electrode wire through wire sleeving.

11.

ThermoLazer 300 TC /ProMelt Only: Connect electrode lead to pulse fire igniter.

12. Reconnect hose and turn LP-gas tank valve ON.

ti14127a

13. Check for gas leaks at final assembly (see Operation manual).

ti25745a

3A1320K 15

Removal and Installation of Electrode

Removal and Installation of Electrode

(ThermoLazer 300TC/ProMelt only)

Removal

1. Disconnect gas pilot line (71) from flared adapter

(421). Only rotate the nut on gas pilot line (71), while keeping flared adapter (421) stationary.

4. Remove thermopile (7).

421

71

5. Remove electrode.

ti25741b ti25692b

2. Disconnect electrode lead (217) from pulse fire igniter (126). Pull electrode out of wire sleeving.

ti121953a

217

ThermoLazer 300 TC /ProMelt Only ti25747a

ThermoLazer 300 TC /ProMelt Only

126

ThermoLazer 300TC/ProMelt Only

3. Remove gas pilot mounting housing (319) from gas burner mounting plate (18). Disconnect ground lead wire (244).

Installation

1. Replace electrode. (See Operation Manual for correct spacing between electrode and pilot burner).

18

319 ti21954a

244 ti25739b

16 3A1320K

2. Replace thermopile (7).

Removal and Installation of Electrode

4. Connect gas pilot line (71) to flared adapter (421).

421

71 ti25742b

3. Install gas pilot mounting plate (319) to gas burner mounting plate (18). Connect ground lead wire

(244).

5. Pull electrode wire through wire sleeving.

ti25690b

6. Connect electrode lead to pulse fire igniter.

18

ThermoLazer 300TC/ProMelt

Shown

319

ThermoLazer 300TC/ProMelt Only

ThermoLazer 300 TC /ProMelt Only ti25746a

7. Reconnect hose and turn LP-gas tank valve ON.

244 ti25743b ti14127a

8. Check for gas leaks at final assembly (see Operation manual).

3A1320K 17

Pilot Burner

Pilot Burner

(ThermoLazer 200TC/300TC/ProMelt)

Removal

1. Disconnect gas pilot line (71) from flared adapter

(421). Only rotate the nut on gas pilot line (71), while keeping flared adapter (421) stationary.

4. Remove thermopile (7).

421

71 ti25692b

2.

ThermoLazer 300 TC /ProMelt only: Disconnect electrode lead (217) from pulse fire igniter (126).

Pull electrode out of wire sleeving.

ti25741b

5.

ThermoLazer 300 TC /ProMelt only: Remove electrode.

ti121953a

217

ThermoLazer 300 TC /ProMelt Only ti25747a

ThermoLazer 300TC/ProMelt Only

ThermoLazer 300 TC /ProMelt Only

126

3. Remove gas pilot mounting housing (319) from gas burner mounting plate (18).

ThermoLazer 300 TC /ProMelt only: Disconnect as ground lead wire (244).

6. Remove pilot burner.

18 7. Remove pilot burner fittings.

ti25748b

319

18

244

25739b ti25749a

3A1320K

Installation

1. Install pilot burner.

Pilot Burner

5. Install gas pilot mounting plate (319) to gas burner mounting plate (18).

ThermoLazer 300 TC /ProMelt only: Connect ground lead wire (244).

18

319

2. Install pilot burner. ti25749a

244

25743b

6. Connect gas pilot line (71) to flared adapter (421).

421

71 ti25750b

3.

ThermoLazer 300 TC /ProMelt only: Install electrode.

ti21954a ti25690b

7.

ThermoLazer 300 TC /ProMelt only: Pull electrode wire through wire sleeving.

8.

ThermoLazer 300 TC /ProMelt only: Connect electrode lead to pulse fire igniter.

ThermoLazer 300 TC /ProMelt only

4. Install thermopile.

ThermoLazer 300 TC /ProMelt only ti25746a

ThermoLazer 300TC/ProMelt Only

9. Reconnect hose and turn LP-gas tank valve ON

3A1320K ti25742b ti14127a

10. Check for gas leaks at final assembly (see Operation manual).

19

Cleaning Kettle Main Burner Gas Lines

Cleaning Kettle Main

Burner Gas Lines

1. Disconnect gas tubing line (76) from gas tube fitting tee (165).

2. Insert rubber hose over gas tubing tee (165) and force air into tubing at 30 psi (2.1 bar).

3. Reconnect gas tubing line (76) to gas tube fitting tee

(165).

Cleaning Kettle Pilot

Burner Gas Lines

1. Disconnect gas pilot line (71) from flared adapter

(421). Only rotate the nut on gas pilot line (71), while keeping flared adapter (421) stationary.

2. Insert rubber hose over flared adapter (421) and force air into tubing at 30 psi (2.1 bar).

3. Reconnect gas line (71) to flared adapter (421).

421

76

ThermoLazer 300 TC /ProMelt shown ti24817b

71 ti25690b

20 3A1320K

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).

NOTE: To ensure proper contact between drive wheel

(27) and tire (81), make sure air pressure is always at 60 psi (4.14 bar).

Linkage Rod Adjustment

(ThermoLazer 300 TC /ProMelt only)

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.

211

13.13 in.

(33.34 cm)

181

81

27 ti14564a

Bead Dispense Tension

Adjustment

(ThermoLazer 200 TC only)

When screed box is down, turn bolt/knob clockwise to increase spring force.

Make sure bead dispense wheel engaged unit wheel.

Put screed box in STO position. Make sure bead wheel does not contact unit wheel. If it does, turn knob to decrease spring force.

182 ti14565a

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 required when inserting the clevis pin through the clevis

(179) and deployment bar (78). ti25751a

1. With screed box in down (but not open) position, rotate the bead box wheel by hand.

3A1320K ti23692a ti14882a

81 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.

21

Screed Box/Bead Dispenser Box Actuator

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.

NOTE: Linkage rod (182): If converting from SmartDie to SmartDie II, use Die Link Kit 24J714.

ti14604a

Screed Box Pivot Arm

Loading

(ThermoLazer 300 TC /ProMelt only)

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).

Screed Box/Bead

Dispenser Box Actuator

(ThermoLazer 300 TC /ProMelt only)

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.

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.

22 ti14629b

3A1320K

Carbide Runner Replacement on Smart Die II (300TC/ProMelt)

Carbide Runner Replacement on Smart Die II

(300TC/ProMelt)

(1 on each side)

Installation

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.

1. Apply grease to groove where carbide runner sits.

1. Remove screed box.

ti16845a ti16839a

ThermoLazer 300TC/ProMelt shown

2. Use allen wrench to loosen and remove upper pivot bolt (511) to free yoke (502).

2. Replace plate, die runner (504) with new plate, die runner. See Parts manual 3A1321.

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.

ti16843a

3. Turn unit upside-down and use an allen wrench to remove four screws (513) and plate, die runner

(504). ti17068a

4. Use allen wrench to replace and tighten pivot bolt

(511) on yoke (502).

5. Install screed box. ti16843a ti16845a

3A1320K ti16846a

ThermoLazer 300TC/ProMelt shown

23

Carbide Runner Replacement on FlexDie (200/200TC)

Carbide Runner Replacement on FlexDie (200/200TC)

Removal

1. Remove screed box.

2. Turn the die upside down, then use 5/8 wrench to loosen nut 17D593 and 105327.

3. Remove die runner 17D502 and 17D504.

Installation

1. Apply grease to inside surface of carbide runner.

2. Replace die runner with new die runner.

3. Use two 5/8 wrenches to tighten the nuts. a. Tighten the nut 105327 to make the die runner just touch the pivot table.

b. Hold the wrench which is on 105327, use another 5/8 wrench to tighten nut 17D593.

NOTE: Make sure die runner can rotate freely after the nuts are tight.

4. Install screed box.

ti26046a ti26047a

24 3A1320K

Kettle Gas Regulator Replacement

Kettle Gas Regulator Replacement

ThermoLazer 200/200

TC

Removal

1. Close propane tank valve.

Installation

1. Apply pipe sealant and connect gas supply hose (a) to manifold (e).

2. Connect gas supply hose (a) to propane tank (a).

3. Open propane tank valve.

ti14128a

2. Disconnect gas supply hose (a) from propane tank.

3. Disconnect gas supply hose (a) from manifold (e).

ti14127a

4. Check for leaks.

5. Verify gauge PSI. Gauge should read 3 PSI

±

1. If higher than 4 PSI, slightly open torch valve and recheck.

51

169 a e ti25683a

F IG . 1

3A1320K 25

Kettle Gas Regulator Replacement

ThermoLazer 300

TC

Removal

1. Close manual gas shut-off valve on propane tank. ti14128a

2. Disconnect gas supply hose from propane tank.

3. Disconnect gas tube (118) from fitting (410).

4. Unscrew pipe subassembly (408, 409, 410, 415) from elbow (401).

5. Unscrew gas regulator (10) from pipe elbow (142).

6. Unscrew gas regulator (10) from fitting (64).

Installation

1. Apply pipe sealant to fitting (64) and screw into new gas regulator (10). Turn connection until gas tight.

NOTE: Make sure OUT connection of regulator is connected to the fitting (64).

See F IG . 2

2. Apply pipe sealant to pipe elbow (142) and screw into new gas regulator (10). Turn connection until gas tight.

NOTE: Make sure IN connection of regulator is connected to the pipe elbow (142).

See F IG . 2

3. Apply pipe sealant to fitting (408) and screw into elbow (401).

4. Connect gas tube (118) to fitting (410). Turn connection until gas tight.

5. Connect gas supply hose to propane tank.

ti14411a

6. Open manual gas shut-off valve on propane tank. ti14127a

7. Check gas lines for gas leaks (see Operation manual).

142

10

64

401

9

408

415

118

409

410

10

142

64

IN

OUT

Arrow

Indicates

Direction of Gas

Flow

ti22066a ti25752a

F IG . 2

26 3A1320K

Kettle Gas Regulator Replacement

ThermoLazer ProMelt

Removal

1. Close manual gas shut-off valve on propane tank. ti14128a

2. Disconnect gas supply hose from propane tank.

3. Unscrew gauge (402) from tee (409).

4. Disconnect gas tube (118) at fitting (410).

5. Unscrew pipe subassembly (408, 409, 410) from elbow (401).

6. Unscrew union swivel (323) from pipe elbow (142).

7. Unscrew gas regulator (10) from fitting (64).

Installation

1. Apply pipe sealant to fitting (64) and screw into gas regulator (10). Turn connection until gas tight.

NOTE: Make sure OUT connection of regulator is connected to fitting (64).

See F IG . 3

2. Screw union swivel fitting (323) onto pipe elbow

(142). Turn connection until gas tight.

3. Add pipe sealant to fitting (408) and screw pipe subassembly (408, 409, 410) into elbow (401). Turn connection until gas tight.

NOTE: Make sure IN connection of regulator is connected to the pipe elbow (142).

See F IG . 3

4. Apply pipe sealant to bushing (406). Screw gauge

(402) into tee (409). Turn connection until gas tight.

5. Connect gas tube (118) to fitting (151). Turn connection until gas tight.

6. Connect gas supply hose to propane tank.

ti14411a

7. Open manual gas shut-off valve on propane tank. ti14127a

8. Check gas lines for gas leaks (see Operation manual).

142

323

412

64

401

408

409

10

402

406

410

118

IN

10

Arrow

Indicates

Direction of

Gas Flow.

64

OUT

142

323

412

F IG . 3

3A1320K ti25757a

27

Torch and Screed Burners Gas Regulator Replacement (ThermoLazer 300TC/ProMelt)

Torch and Screed Burners Gas Regulator Replacement

(ThermoLazer 300 TC /ProMelt)

Removal

1. Close manual gas shut-off valve on propane tank. ti14128a

2. Disconnect gas supply hose from propane tank.

3. Disconnect gas line at downstream tube elbows

(161).

4. Unscrew swivel union (323) from upstream pipe elbow (142).

5. Unscrew gas regulator (152) from fitting (323).

6. Unscrew and remove gas regulator (152) from upstream pipe elbow (142).

Installation

1. Apply pipe sealant to downstream pipe tee (12).

Screw pipe tee (12) with elbow (161) to gas regulator (152). Turn connection until gas tight.

2. Apply pipe sealant to fitting (323) and screw into gas regulator (152). Turn connection until gas tight.

NOTE: Make sure IN connection of regulator is connected to fitting (323). See FIG. 7

3. Screw swivel union (323) onto upstream pipe elbow

(142); which is now connected to gas regulator

(152). Turn connection until gas tight.

NOTE: Make sure IN connection of regulator is connected to the upstream pipe elbow (142). See FIG.

7

4. Connect gas line at downstream tube elbows (161).

Turn connection until gas tight.

5. Connect gas supply hose to propane tank.

ti14411a

6. Open manual gas shut-off valve on propane tank.

ti14127a

7. Check gas lines for gas leaks (see Operation manual). ti25753a

28

FIG. 7

142

323

152

IN

OUT

161

161

12

152

323

IN

OUT

Arrow

Indicates

Direction of Gas

Flow

12 ti24821a

3A1320K

Rear Screed Burner Assembly

Rear Screed Burner Assembly

(ThermoLazer 300 TC /ProMelt)

Removal

1. Close manual gas shut-off valve on propane tank.

Installation

1. Install burner manifold in mounting bracket (104,

109). Secure with snap rings (75).

See F IG . 4.

2. Install burner assembly with mounting bracket to bead dispenser.

3. Connect burner hose (98) to valve fitting (151).

4. Connect gas supply hose (99) to propane tank.

ti14128a

2. Disconnect gas supply hose (99) from propane tank.

3. Disconnect gas tube (373) at valve fitting (151).

See

F IG . 4.

4. Remove burner gas train mounting bracket fasteners (104, 109). Unscrew six screws (115).

See F IG .

4.

5. Remove burner assembly.

6. Remove snap rings (75) from gas manifold. See

F IG . 4.

ti14411a

99

5. Open manual shut-off valve on propane tank.

ti14127a

373

151

104

115

75 ti22658a

F IG . 4

3A1320K 29

Front Screed Burner Assembly

Front Screed Burner Assembly

(ThermoLazer 300 TC /ProMelt)

Removal

1. Close manual gas shut-off valve on the propane tank.

6. Remove screed burners.

ti14128a

2. Disconnect gas supply hose from propane tank.

99 ti22060a

7. Remove gas manifold snap ring (75).

ti14411b

3. Remove screed box from screed housing (see

Operation manual).

4. Disconnect gas tubing at 45° elbow (32).

32 ti17072a

5. Unscrew front screed housing fasteners (146) and remove front housing (20).

146

20 ti17073a

75 ti17074b

8. Unscrew gas manifold (less burners) mounting bracket fasteners (146) and remove burner assembly (less burners) from front screed housing (20).

Installation

1. Install gas manifold (less screed burners) in bracket support manifold (52) and screw gas manifold mounting bracket to front screed housing (20) with fasteners (146).

20

52

146

75

2. Install screed burner.

ti17074b

30 ti22060a

3A1320K

Front Screed Burner Assembly

3. Install gas manifold snap ring (75).

4. Install front screed housing (20) to screed housing.

Secure with fasteners (146).

6. Connect gas supply hose (99) to propane tank.

99

146 ti14411b

20 ti17073a

7. Open manual gas shut-off valve on propane tank.

5. Connect gas tubing to 45° elbow (32).

ti14127a

32 ti17072a

3A1320K 31

Screed Burner

Screed Burner

(ThermoLazer 300 TC /ProMelt)

Vertical front screed burner (1)

Removal

1. Remove screed burner flame indicator (67).

67

Installation

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. ti21955a

2. Unscrew screed burner and orifice from gas manifold.

2

60 ti21958a

2. Apply pipe sealant to 1/8 in. NPT thread of orifice fitting (60) and screw on adapter fitting (363). Install washer on orifice (60).

60 ti21956a

3. Unscrew adapter fitting (363) from orifice fitting (60).

Remove washer from orifice (119).

363 ti21957a

3. Apply pipe sealant to 1/8 in. NPT thread of adapter fitting (363) and screw into gas manifold.

60

119

363 ti21957a

4. Unscrew orifice fitting (60) from screed burner (2).

363 ti21956a

4. Install screed burner flame indicator (67).

2

60 ti21958a

67 ti21955a

32 3A1320K

Screed Burner

Screed Burner

Horizontal screed burner(s)

Removal

1. Remove screed burner flame indicator (67).

Installation

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 ti17075b

2. Unscrew screed burner and orifice from gas manifold.

60

2 ti17077b

2. Apply pipe sealant to 1/8 in. NPT thread of orifice fitting (60) and screw on adapter fitting (363).

ti17076b

60 ti21950a

3. Unscrew adapter fitting (363) from orifice fitting (60).

363

3. Apply pipe sealant to 1/8 in. NPT thread of adapter fitting (363) and screw into gas manifold.

60 ti21950a

363

4. Unscrew orifice fitting (60) from screed burner (2).

363 ti17076b

4. Install screed burner flame indicator (67).

60

2 ti17077b

67 ti17075b

3A1320K 33

Main Gas Filter (ThermoLazer 300TC/ProMelt)

Main Gas Filter

(ThermoLazer 300 TC /ProMelt)

Removal

1. Unscrew filter fitting (403) from tee (12).

2. Unscrew fitting (407) from hose (99).

Install

1. Apply pipe sealant to 1/4 in. NPT of hose (99) and screw on filter fitting (407).

2. Apply pipe sealant to 1/4 in. NPT of filter fitting (403) and screw into tee (12).

3. Check gas lines for leaks. (See Operation Manual).

403

Screed Burner Filter

Removal

1. See Screed Burner Removal, page 32.

Install

1. See Screed Burner Install, page 32.

99

12

407 ti21960a

34 3A1320K

Troubleshooting

Troubleshooting

Problem

Kettle pilot burner does not ignite or does not remain ignited

Kettle burners shut off before material is melted

ProMelt Only

Cause Solution

Low or empty LP-gas tank

Gas supply hose not connected to tank

LP-gas tank shut-off valve closed

Manual gas shut-off valve closed

Gas lines leaking or disconnected

Kettle gas safety valve knob not in correct position

Not providing adequate time for thermopile to heat up

Kettle pilot igniter has weak battery

Kettle pilot electrode gap incorrect

Incorrect flame length and/or gas pressure

Strong wind blowing flame out

Burner and/or gas lines plugged

Replace with full tank.

Connect gas supply hose.

Open LP-gas tank shut-off valve.

Open manual gas shut-off valve.

Check for gas leaks. Connect and tighten fittings.

Turn knob to “PILOT” position and fully push in (see

See

Operation

Operation

manual).

manual.

Replace part (see Parts manual).

Adjust gap (see page 11).

Adjust flame and pressure (see Repair manual).

Move ThermoLazer out of strong winds.

Make sure burner view ports are closed.

Unplug holes and lines. Isolate all gas regulators if clearing line with forced air (see

page 6).

Kettle gas safety valve not functioning correctly Replace part if it fails diagnostic test (see

page 6).

Thermopile not functioning correctly

Kettle pilot electrode ground wire not correctly connected

Replace part if it fails diagnostic test (see

page 12).

Clean connections and retighten. Replace ground wire if damaged.

Kettle pilot electrode lead wire has a short

Kettle pilot igniter not functioning correctly

Replace part (see Parts manual).

Replace part (see Parts manual).

Kettle burner regulator not functioning correctly Replace part (see Parts manual).

Material level is low Add material to kettle. Once material level is up to thermometer, this condition will be corrected.

Over temperature safety switch not functioning correctly

Replace part (see Parts manual).

3A1320K 35

Troubleshooting

Problem

Kettle main burners do not ignite or are not burning correctly

Cause Solution

Kettle gas safety valve knob not at correct position

Kettle temperature control dial set at a lower temperature than material temperature

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 20).

Replace part (see Parts manual).

Kettle temperature control not functioning correctly

Gas lines have been disconnected

Incorrect flame length and/or gas pressure

Connect and tighten hose fittings. Check for gas leaks.

Adjust flame and pressure (see page 18).

Kettle gas safety valve knob not at correct position

Replace part (see Parts manual).

Kettle main burners do not shut off

Kettle main burner does not turn on

Thermometer not matching material temperature in kettle

Kettle temperature control dial is not turned to a setting 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 6).

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) lower 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

Over temperature safety switch not functioning correctly

Replace part (see Parts manual).

Kettle gas safety valve not functioning correctly Replace part if it fails diagnostic test (see

page 6).

Replace part (see Parts manual).

Material has not reached temperature control set point

Material not fully agitated

Cool or windy ambient conditions

Allow time for material to reach operating temperature.

Agitate material.

Move ThermoLazer out of cool windy conditions. Discharge material and check thermometer.

Thermometer calibrated incorrectly

Calibrate thermometer (see page 10).

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 6).

Incorrect flame length and/or gas pressure Adjust flame and pressure (see page 18).

36 3A1320K

Troubleshooting

Problem

Screed box burner does not ignite, does not remain ignited, or can not change heat output

Empty LP-gas tank

Cause

LP-gas tank shut-off valve closed

Gas supply hose not connected to tank

Gas lines leaking or disconnected

Solution

Replace with full tank.

Open LP-gas tank shut-off valve.

Connect gas supply hose.

Check for gas leaks. Connect and tighten fittings.

Replace part (see Parts manual).

Torch does not ignite

Agitator crank handle is hard to move

ControlFlow gate valve leaking

Screed box leaking

Excessive material buildup when starting and stopping extruding

Burner regulator/flow flame adjusting valve not functioning correctly

Burner orifice plugged

Burner assembly not functioning correctly.

Empty LP-gas tank

LP-gas tank shut-off valve closed

Torch manual gas shut-off valve closed

Gas supply hose not connected to tank

Gas lines leaking or disconnected

Torch assembly not functioning correctly

Material is cold

ControlFlow

gate valve difficult to open or close

Bushings are worn

Linkage ball rod ends need lubrication

Foreign material lodged between agitator and kettle

Cold material temperature

Gate sticking in guides

Bushings are worn

Gate not completely closed

Foreign material lodged in gate opening

Foreign material in screed box discharge opening

Dirty screed box

Clean or replace part (see Parts manual).

Replace part (see Parts manual).

Replace with full tank.

Open LP-gas tank shut-off valve.

Open manual shut-off valve.

Connect gas supply hose.

Check for gas leaks. Connect and tighten fittings.

Replace part (see Parts manual).

Allow time for material to reach operating temperature.

Replace bushings (see Parts manual).

Add grease.

Remove material in kettle and CAREFULLY dislodge and remove foreign material.

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.

Replace bushings (see Parts manual).

Close gate completely.

CAREFULLY dislodge and remove foreign material.

CAREFULLY dislodge and remove foreign material.

CAREFULLY clean box. All moving parts need to be free of debris.

Adjust length (see page 21).

Adjust lever (see page 21).

Incorrect deployment rod linkage length

Incorrectly adjusted screed box/bead dispenser box actuator

Worn screed box shear bar

Worn screed box shear bar stop

Screed box not adjusted to ground

Screed box open when ThermoLazer is stationary

Foreign material in screed box discharge opening

Dirty screed box

Replace gate (see Parts manual).

Replace trough (see Parts manual).

See Operation manual.

Synchronize ThermoLazer and screed box motion.

CAREFULLY dislodge and remove foreign material.

CAREFULLY clean box. All moving parts need to be free of debris.

3A1320K 37

Troubleshooting

Problem

Beads not discharging or discharging unevenly

Beads not discharging at required flow rate

Hard pushing when screed box is on ground

Cause Solution

Low bead level in bead hopper

Bead dispenser doors closed

Fill bead hopper.

Open doors as required to obtain desired flow pattern width.

Bead dispenser drive wheel not engaged

Bead dispenser drive wheel slipping

Secure bead dispenser wheel (see page 21).

Tighten. Check air pressure (see page 21).

Debris in discharge opening of bead dispenser Remove debris.

Debris on ThermoLazer tire or bead dispenser wheel

Remove debris.

Moisture in beads Remove wet beads. Dry hopper, bead hoses and bead dispenser. Fill hopper with dry beads.

Bead dispenser flow rate lever not correctly set Rotate flow rate lever to correct position.

Bead dispenser drive wheel slipping Tighten wheel and check tire pressure (see

page 21).

Bead dispenser doors not fully open

Moisture in beads

Open door fully.

Remove wet beads. Dry hopper, bead hoses and bead dispenser. Fill hopper with dry beads.

Allow road surface moisture to dry.

Moisture on road surface

Rough road surface

Bead Dispenser low on material

Screed box not adjusted correctly

Smooth road surface.

Add material to bead hopper.

See Operation manual.

38 3A1320K

Troubleshooting

Applying Material

Problem Cause Solution

Ragged line edges when extruding Dirty screed box CAREFULLY clean box. Discharge opening and screed box plate runners need to be free of debris.

Heat material as required.

Rough material surface when extruding

Cold material temperatures

Marking speed too fast

Overheated material

Moisture on road surface

Rough road surface

Slow ThermoLazer speed.

Reduce heat.

Allow road surface moisture to dry.

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

• ThermoLazer speed too fast

• Debris on road

• Surface temperature too cold

Rough and bumpy line

Gas bubbles in line ti14508a

• Debris on surface

• Crust from overheated material

• Debris caught in screed box ti14509a

• Material not covering road high spot

• Moisture or solvent on surface

• Material is overheated

• Raise material temperature.

• Decrease speed of

ThermoLazer.

Clear debris from road.

• Wait for temperature of surface to raise.

• Clear debris from surface.

• Lower material temperature.

• Clean debris from screed box.

Adjust screed box line thickness.

• Remove solvent from surface.

• Lower temperature of material.

ti14510a

Ragged edges and gaps in line • Material temperature is too low

• ThermoLazer speed is too fast

• Raise material temperature.

• Wait for change in ambient conditions to remove moisture.

• Reduce ThermoLazer speed.

ti14511a

3A1320K 39

Troubleshooting

Problem

Swollen rounded line

Cause Solution

• Material temperature is too high • Lower material temperature.

ti14512a

Material shadows on sides • Uneven road surface • Apply to even road surfaces.

• Screed box is not evenly riding on substrate

• Remove debris from screed box lever rod.

• Inspect/replace damaged screed box lever rod/lever arm.

ti14513a

Line is wavy • Strong road surface camber

• Incorrect ThermoLazer operation

• Apply so camber does not influence application.

• Use correct application methods

(for example, try locking swivel wheel).

ti14514a

Cracks in line • Cracks in road surface

• Temperature stress from overheating

• Material applied too cold

• Repair cracks.

• Lower temperature in material.

ti14515a

Rough edges and lines in surface

• Material applied too thin

• Increase material temperature.

• Slow ThermoLazer speed to apply thicker material.

• Raise material temperature.

• Material temperature is too low

• Material is overheated or scorched • Lower material temperature.

• Moisture in road surface • Wait until road surface is dry.

ti14516a

Jagged line ends; material drips between lines ti14517a

• Screed box does not fully close

• Debris caught in screed box

• Worn screed box shear bar

• Clean screed box.

• Clear debris from screed box.

• Replace screed box gate.

• Worn screed box trough shear bar stop

• Replace screed box trough.

• Surface temperature too cold

• Allow surface temperature to increase.

40 3A1320K

Piping Diagram

ThermoLazer 200

Piping Diagram

3A1320K ti25754a

41

Piping Diagram

ThermoLazer 200

TC

42 3A1320K

ThermoLazer 300

TC

/ProMelt

Piping Diagram

3A1320K 43

Wiring Diagram

Wiring Diagram

ThermoLazer 200

TC

44 3A1320K

ThermoLazer 300

TC

Wiring Diagram

3A1320K 45

Wiring Diagram

ThermoLazer ProMelt

46 3A1320K

Technical Data

Technical Data

Fuel

Gas supply maximum pressure - psi (bar)

Kettle burners

Torch

Screed box front burners

Screed box rear burners

Kettle burners (sum of burners)

Torch

Screed box front burner (sum of 3 burners)

Screed box rear burner (sum of 4 burners)

Total

Gas

Main kettle

Bead hopper

Maximum operating temperature - °F (°C)

Front tire pressure - psi (bar)

Rear tire pressure - psi (bar)

Weight - lb (kg)

Length - in. (m)

Height - in. (m)

Width - in. (m)

Igniter battery

ThermoLazer

200/200

TC

ThermoLazer 300

TC

ThermoLazer

ProMelt

(24U280)

(24U281)

3

(0.21)

3

(0.21)

(1) 30,000

(8.8)

10,000

(2.93)

27,000

(7.9) with Rear

Heat

(24H622)

20

(1.38)

20

(1.38)

(2) 30,000

(8.8)

100,000

(29.3)

27,000

(7.9)

36,000 (10.6) 36,000 (10.6)

103,000

(30.2)

193,000

(56.6) without Rear

Heat

(24H625)

Liquefied Petroleum Gas (LP-gas) (propane vapor)

250 (17.24)

3

(0.21)

3

(0.21)

0.5

(0.034)

20

(1.38)

0.5

(0.034)

20

(1.38)

3

(0.21)

20

(1.38)

20

(1.38)

N/A

(2) 30,000

(8.8)

100,000

(29.3)

27,000

(7.9)

N/A

157,000

(46.0)

(24H624)

20

(1.38)

20

(1.38)

(2) 100,000

(29.3)

100,000 (29.3)

27,000

(7.9)

36,000 (10.6)

263,000 (77.1)

20

(9.1)

200

(91)

40 (18)

450 (232)

N/A

N/A

260

(118)

44 (1.12)

39 (1.00)

33 (0.84)

N/A

20

(9.1)

20,30

(9.1, 13.6)

300 (136) - Thermoplastic traffic marking compound materials

90 (40) - Type

II glass bead

450

(232)

480

(249)

450

(232)

45

(3.10)

60

(4.14)

300

(136)

350

(159)

295

(134)

72 (1.83)

51 (1.3)

48 (1.22)

AA (1.5 V)

3A1320K 47

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

.

For patent information, see www.graco.com/patents .

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.

For patent information see, www.graco.com/patents.

Original instructions. 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 2011, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.

www.graco.com

Revision K, August 2017

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