Graco 3A1320A - ThermoLazer and ThermoLazer ProMelt Pavement Marking System, Repair Owner's Manual

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Graco 3A1320A - ThermoLazer and ThermoLazer ProMelt Pavement Marking System, Repair Owner's Manual | Manualzz

Repair

ThermoLazer

and ThermoLazer

ProMelt

Pavement Marking Systems

US Patent No. D619,625.5 and other patents pending

3A1320A

- 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) -

ENG

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

For use with the following

SmartDie II

Screed Box:

Part Description

24H431 3 in. (8 cm)

24H426 4 in. (10 cm)

24H432 5 in. (12 cm)

24H427 6 in. (15 cm)

24H433 7 in. (18 cm)

24H428 8 in. (20 cm)

24H434 9 in. (22.5 cm)

24H429 10 in. (25 cm)

24H430 12 in. (30 cm)

24H437 3-3-3 in. (8-8-8 cm)

24H435 4-3-4 in. (10-8-10 cm)

24H436 4-4-4 in. (10-10-10 cm)

24C528 Kit, Double Bead Box ti15947a

ThermoLazer 24H622, 24H625 ti14144a

2

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

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

3A1320A

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.

3A1320A 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 3A1320A

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

TP

TH

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 ).

ti14524b 2

Step

1

2

Part(s) to Be

Checked

Terminal

Connections

Status of

Temperature

Control

Contacts

Gas safety valve

Temperature control

2 and 3

1 and 2

Closed

Closed

Desired

Meter

Reading Diagnosis

Greater than

100 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.

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.

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 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.

3A1320A 5

6

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.

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 (24H622, 24H625) 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.

124, 318 ti17067a

ProMelt ThermoLazer

(24H624, 24H626)

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).

41 ti17066a

124

3A1320A

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.

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 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.

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.

Kettle Temperature Control 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.

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).

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 mountti14523a

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.

3A1320A 7

8

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.

3A1320A

Adjust Kettle Pilot Ignitor Electrode Gap

Adjust Kettle Pilot Ignitor

Electrode Gap

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).

.17 - .20 in.

7

Kettle Over-Temperature

Switch Replacement

(Models 24H624 and 24H626 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.

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.

3A1320A 9

Thermopile Replacement

Thermopile Replacement

Removal

1.

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

6.

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

28 ti14854a ti14128a

2.

Remove gas safety valve enclosure back cover (29).

7.

Disconnect gas pilot line (49) at gas pilot coupling

(171).

171

49

29 ti14880a

3.

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

28

320 ti14857a

18 ti14852a

4.

Disconnect thermopile wires from gas safety valve

(13).

13

9.

Remove thermopile (7).

7

318 ti14856a

8.

Remove gas pilot mounting plate (318) from gas burner mounting plate (18).

ti14853a

5.

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

ti14858a

10. Pull thermopile out of wire sleeving.

28 ti14855a

357

10 3A1320A

Installation

1.

Replace thermopile (7).

7

Thermopile Replacement

7.

Connect thermopile wires to gas safety valve (13).

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

13 ti14862a

2.

Install gas pilot mounting plate (318) to gas burner mounting plate (18).

ti14866a

8.

Replace cover (320) on gas safety valve enclosure

(28).

18

318 ti14863a

3.

Connect gas pilot line (49) at gas pilot coupling

(171).

171

49 ti14861a

4.

Pull thermopile through wire sleeving.

5.

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

320

28 ti14867a

9.

Replace gas safety enclosure back cover (29).

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).

ti14127a

28 ti14865a

357

3A1320A 11

Adjust Kettle Pilot Burner Flame

Adjust Kettle Pilot

Burner Flame

Adjust Kettle Main

Burners Flame

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.

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

Flame Height in. (cm)

2-3 (5-8)

2-3 (5-8)

3-4 (8-10)

3-4 (8-10)

1.

Ignite kettle gas pilot burner.

2.

Turn kettle gas safety valve (CC) to ON.

3.

Turn kettle temperature control knob (AA) to 250° F

(121° C).

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).

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.

ti14525a see table ti14522a see table ti14413a

.17 - .20 in.

12 3A1320A

Cleaning Kettle Main Burner Gas Lines

Cleaning Kettle Main

Burner Gas Lines

1.

Disconnect gas tubing line (49) from gas tube fitting tee (165).

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).

3.

Reconnect gas tubing line (49) to gas tube fitting tee

(165).

Cleaning Kettle Pilot

Burner Gas Lines

1.

Disconnect gas tubing line (186) from gas tubing line (118).

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 (186) to gas tubing tee

(118).

165 ti14558a ti14559a

49 118

186

3A1320A 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).

NOTE: To ensure proper contact between drive wheel

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

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. ti14882a

211

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.

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.

78

268

179

128

181

13.13 in.

(33.34 cm) 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.

182 ti14565a

14 3A1320A

Screed Box/Bead Dispenser Box Actuator

Screed Box/Bead

Dispenser Box Actuator

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.

Screed Box Pivot Arm

Loading

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.

3A1320A 15

Screed Box Pivot Arm Loading

Carbide Runner Replacement on

Screed Box (1 on each side)

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.

Installation

1.

Apply grease to groove where carbide runner sits. ti16845a

1.

Remove screed box.

ti16839a

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.

2.

Use allen wrench to loosen and remove upper pivot bolt (511) to free yoke (502). ti17068a ti16843a

3.

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

(504).

4.

Use allen wrench to replace and tighten pivot bolt

(511) on yoke (502).

5.

Install screed box. ti16843a ti16845a ti16846a

16 3A1320A

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.

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).

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” conti14411a

5.

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

6.

Check gas lines for gas leaks (see operation manual).

142

10

64

IN

OUT

161 ti17069a

3A1320A 17

Torch and Screed Burners Gas Regulator Replacement

Torch and Screed Burners

Gas Regulator Replacement

Removal

1.

Close manual gas shut-off valve on propane tank.

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).

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).

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).

4.

Unscrew gas regulator pipe train from upstream pipe elbow (142).

5.

Unscrew and remove gas regulator (152) from downstream pipe tee (12). ti14411a

6.

Open manual gas shut-off valve on propane tank.

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).

18

152

142

IN

161

OUT

12

161 ti17070a

3A1320A

Rear Screed Burner Assembly

Rear Screed Burner

Assembly

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).

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.

99 ti14128a

2.

Disconnect gas supply hose (99) from propane tank.

3.

Disconnect gas hose (98) at valve fitting (151).

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.

ti14411a

5.

Open manual shut-off valve on propane tank.

ti14127a

151 98

3A1320A

75

109 115 ti17071a

104

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).

Removal

1.

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

Installation

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

2.

ti14128a

Disconnect gas supply hose from propane tank.

75 ti17074a

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).

4.

Disconnect gas tubing at 45° elbow (32).

20 ti17073a

4.

Connect gas tubing to 45° elbow (32).

ti17072a

32 ti17072a

32

5.

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

146

5.

Connect gas supply hose (99) to propane tank.

99 ti14411a

20 ti17073a

6.

Remove gas manifold snap ring (75).

6.

Open manual gas shut-off valve on propane tank.

75 ti17074a ti14127a

20 3A1320A

Screed Burner

Screed Burner

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 ti17075a

2.

Unscrew screed burner and orifice from gas manifold.

60 ti17077a

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

2 ti17077a

67 ti17075a

3A1320A 21

Troubleshooting

Troubleshooting

Problem Cause Solution

Kettle pilot burner does not ignite or does not remain ignited

Kettle burners shut off before material is melted

ProMelt Only:

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

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 Operation manual).

See Operation manual.

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

Replace part (see Parts manual).

Adjust gap (see page 9).

Adjust flame and pressure (see Repair manual).

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

Kettle pilot electrode lead wire has a short

Clean connections and retighten. Replace ground wire if damaged.

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).

Material level is low.

Over temperature safety switch not functioning correctly

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

Replace part (see Parts manual).

22 3A1320A

Troubleshooting

Problem Cause Solution

Kettle main burners do not ignite or are not burning correctly

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

13).

Replace part (see Parts manual).

Kettle temperature control not functioning correctly

Gas lines have been disconnected Connect and tighten hose fittings. Check for gas leaks.

Incorrect flame length and/or gas pressure

Kettle gas safety valve knob not at correct position

Adjust flame and pressure (see page 12).

Replace part (see Parts manual).

Kettle main burners do not shut off

Kettle main burner does not turn on

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 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) 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 5).

Replace part (see Parts manual).

Thermometer not matching material temperature in kettle

Material has not reached temperature control set point

Material not fully agitated

Cool or windy ambient conditions

Thermometer calibrated incorrectly

Thermometer not functioning correctly

Kettle temperature control not functioning correctly

Allow time for material to reach operating temperature.

Agitate material.

Move ThermoLazer

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

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).

Replace part (see Parts manual).

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).

3A1320A 23

Troubleshooting

Problem

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

Cause

Empty LP-gas tank

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

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

Bushings are worn

Linkage ball rod ends need lubrication

Foreign material lodged between agitator and kettle

Cold material temperature

ControlFlow

gate valve difficult to open or close Gate sticking in guides

ControlFlow

gate valve leaking

Screed box leaking

Excessive material buildup when starting and stopping extruding

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 14).

Adjust lever (see page 14).

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.

24 3A1320A

Troubleshooting

Problem Cause Solution

Beads not discharging or discharging unevenly

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 14).

Tighten. Check air pressure (see page 14).

Debris in discharge opening of bead dispenser Remove debris.

Debris on ThermoLazer

tire or bead dispenser wheel

Remove debris.

Moisture in beads

Bead dispenser doors not fully open

Moisture in beads

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

Beads not discharging at required flow rate

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 14).

Open door fully.

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

Hard pushing when screed box is on ground

Moisture on road surface

Rough road surface

Bead Dispenser low on material

Screed box not adjusted correctly

Allow road surface moisture to dry.

Smooth road surface.

Add material to bead hopper.

See Operation manual.

3A1320A 25

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

26 3A1320A

Problem

Swollen rounded line •

Cause

Material temperature is too high •

Solution

Troubleshooting

Lower material temperature

Material shadows on sides ti14512a ti14513a

• 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

Line is wavy ti14514a

• Strong road surface camber • Apply so camber does not influence application

• Incorrect Thermolazer

operation

• Use correct application methods

(for example, try locking swivel wheel)

Cracks in line • Cracks in road surface

• Temperature stress from overheating

• Material applied too cold

Repair cracks

Lower temperature in material

• Increase material temperature ti14515a

Rough edges and lines in surface

• Material applied too thin

• Material temperature is too low

• Slow Thermolazer

speed to apply thicker material

• Raise material temperature

• 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

• 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 ti14517a

• Worn screed box trough shear bar stop

• Replace screed box trough

• Surface temperature too cold • Allow surface temperature to increase

3A1320A 27

Piping Diagram

Piping Diagram

13 psi (0.89 bar) ThermoLazer

5 psi (0.34 bar) ThermoLazer ProMelt

18 psi (1.24 bar) ThermoLazer and ThermoLazer ProMelt

(24H622, 24H625, 24H624, 24H626) ti17083a

24H626 ONLY

24H624 ONLY

28 3A1320A

Wiring Diagram

ThermoLazer ProMelt (24H624, 24H626)

Wiring Diagram

3A1320A ti17084a

29

Wiring Diagram

ThermoLazer (24H622, 24H625)

30 3A1320A

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 2 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 ProMelt with Rear

Heat without Rear

Heat with Rear

Heat without Rear

Heat

24H622 24H625 24H624 24H626

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

0.5

(0.034)

18

(1.24)

18

(1.24)

18

(1.24)

30,000

(8.8)

100,000

(29.3)

27,000

(7.9)

36,000 (10.6)

193,000

(56.6)

250 (17.24)

0.5

(0.034)

5

(0.34)

18

(1.24)

18

(1.24)

N/A

18

(1.24)

18

(1.24)

30,000

(8.8)

100,000

(29.3)

18

(1.24)

100,000

(29.3)

100,000

(29.3)

27,000

(7.9)

N/A

157,000

(46.0)

27,000

(7.9)

36,000 (10.6)

263,000

(77.1)

5

(0.34)

18

(1.24)

18

(1.24)

N/A

100,000

(29.3)

100,000

(29.3)

27,000

(7.9)

N/A

227,000

(66.5)

450

(232)

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)

480

(249)

45

(3.10)

60

(4.14)

300

(136)

295

(134)

72 (1.83)

51 (1.3)

48 (1.22)

AA (1.5 V)

350

(159)

345

(157)

3A1320A 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.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

Graco Information

TO PLACE AN ORDER, contact your Graco distributor or call to identify the nearest distributor.

Toll Free: 1-800-690-2894.

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. P.O. BOX 1441 MINNEAPOLIS, MN 55440-1441

Copyright 2008, Graco Inc. is registered to I.S. EN ISO 9001 www.graco.com

Revision A - 03/2011

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