Graco ThermoLazer 200TC Repair Manual
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Graco ThermoLazer 200TC Repair Manual

Pavement marking systems
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Repair
ThermoLazer
ThermoLazer ProMelt™ Pavement Marking
Systems
- For professional application of thermoplastic traffic marking compound materials
(reflective beads applied simultaneously with screeding) -
- For outdoor use only (not to be operated in rain or damp conditions) -
Fuel: LP Gas (Propane Vapor)
Burner capacities: See Technical Data, page 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
3A1319
Parts
3A1321
Double Bead
3A0004
™
3A1738
SmartDie
II
3A1738
™
FlexDie
®
200/200
/300
TC
ThermoLazer ProMelt
ti23073a
and
TC
ThermoLazer 200/200
3A1320L
TC
ti22634b
ThermoLazer 300
TC
EN
ti23074a

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Summary of Contents for Graco ThermoLazer 200TC

  • Page 1 Repair ® ThermoLazer 200/200 /300 ThermoLazer ProMelt™ Pavement Marking Systems 3A1320L - 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 Fuel: LP Gas (Propane Vapor) Burner capacities: See Technical Data, page 47...

  • Page 2: System Chart

    System Chart System Chart SmartDie II used on ThermoLazer 300 /ProMelt only. Smart Die II Smart Die Description Part No. 17A173 2 in. (5 cm) 24H431 3 in. (8 cm) 24H426 4 in. (10 cm) 17J250 4.75 in. (12 cm) 24H432 5 in.

  • Page 3: Table Of Contents

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

  • Page 4: Warnings

    • 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.
  • Page 5 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.

  • Page 6: Kettle Gas Safety Valve, Kettle Temperature Control, And Kettle Thermopile Diagnosis

    Kettle Gas Safety Valve, Kettle Temperature Control, and Kettle Thermopile Diagnosis Kettle Gas Safety Valve, Terminal Connections Kettle Temperature Control, and Kettle Thermopile Diagnosis The gas safety valve, temperature control and thermo- pile can be checked by using a millivolt meter. Before checking, make certain all electrical connections are clean and tight.

  • Page 7: Kettle Temperature Control

    Kettle Temperature Control Kettle Temperature Control Replacement 8. Use screwdriver to remove four screws (221) and remove temperature control enclosure (205) from handle bar mounting plate (122). 9. Use screwdriver to disconnect wires (242 and 243 for ThermoLazer), (243 and 360 for ThermoLazer ProMelt).
  • Page 8 Kettle Temperature Control Installation (ThermoLazer 200 dle-nose pliers to secure probe inside clips (41). *Torque stud (318) to 7-15 in-lb./079-1.69 N•m. 1. Route tube through clips (1). ProMelt: Route probe (162) through Z-clips (2) welded to kettle (14). Route probe through stud 2.

  • Page 9: Calibration

    Kettle Temperature Control Calibration 6. If the temperature control setting is lower than the remote calibrated temperature setting on tempera- ture 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.

  • Page 10: Kettle Thermometer

    Kettle Thermometer Kettle Thermometer Calibration Replacement NOTE: The thermometer can only be replaced while the To Check Kettle Thermometer Calibration: material inside the kettle is warm. If material inside the kettle is cold, it will adhere to the probe and cause it to 1.

  • Page 11: Adjust Kettle Pilot Igniter Electrode Gap

    Adjust Kettle Pilot Igniter Electrode Gap Kettle Over-Temperature Adjust Kettle Pilot Igniter Switch Replacement Electrode Gap (ProMelt only) (ThermoLazer 300 /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. Removal 3.

  • Page 12: Thermopile Replacement

    (28). keeping flared adapter (421) stationary. ti14852a 4. Disconnect thermopile wires from gas safety valve (13). ti25692b ThermoLazer 200TC/300TC/ProMelt 8. Thermolazer 300 /ProMelt only: Disconnect electrode lead (217) from pulse fire igniter (126). Pull electrode out of wire sleeving. ti14853a...
  • Page 13 Thermopile Replacement 9. Remove gas pilot mounting housing (319) from gas 10. Remove thermopile (7). burner mounting plate (18). Disconnect ground lead wire (244). ThermoLazer ThermoLazer 300TC/ProMelt 200TC/300TC/ProMelt Shown ti25741b 11. Pull thermopile out of wire sleeving. ti25739b 3A1320L...
  • Page 14 Thermopile Replacement Installation 5. Guide thermopile wire into gas safety valve enclo- sure (28). 1. Replace thermopile (7). ti14864a 6. Replace wire strain relief fitting (357) on gas safety valve enclosure (28). ti25742b ThermoLazer 300TC/ProMelt 2. Install gas pilot mounting plate (319) to gas burner Shown mounting plate (18).
  • Page 15 Thermopile Replacement 10. ThermoLazer 300 /ProMelt Only: Pull electrode 12. Reconnect hose and turn LP-gas tank valve ON. wire through wire sleeving. 11. ThermoLazer 300 /ProMelt Only: Connect elec- trode lead to pulse fire igniter. ti14127a 13. Check for gas leaks at final assembly (see Opera- tion manual).

  • Page 16: Removal And Installation Of Electrode

    Removal and Installation of Electrode Removal and Installation of Electrode (ThermoLazer 300TC/ProMelt only) Removal 4. Remove thermopile (7). 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. ti25741b 5.
  • Page 17 Removal and Installation of Electrode 2. Replace thermopile (7). 4. Connect gas pilot line (71) to flared adapter (421). ti25690b 5. Pull electrode wire through wire sleeving. ti25742b 6. Connect electrode lead to pulse fire igniter. 3. Install gas pilot mounting plate (319) to gas burner mounting plate (18).

  • Page 18: Pilot Burner

    Pilot Burner Pilot Burner (ThermoLazer 200TC/300TC/ProMelt) Removal 4. Remove thermopile (7). 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. ti25741b 5. ThermoLazer 300 /ProMelt only: Remove elec- trode.
  • Page 19 Pilot Burner Installation 5. Install gas pilot mounting plate (319) to gas burner mounting plate (18). 1. Install pilot burner. ThermoLazer 300 /ProMelt only: Connect ground lead wire (244). 25743b ti25749a 6. Connect gas pilot line (71) to flared adapter (421). 2.

  • Page 20: Cleaning Kettle Main Burner Gas Lines

    Cleaning Kettle Main Burner Gas Lines Cleaning Kettle Main Cleaning Kettle Pilot Burner Gas Lines Burner Gas Lines 1. Disconnect gas tubing line (76) from gas tube fitting 1. Disconnect gas pilot line (71) from flared adapter tee (165). (421). Only rotate the nut on gas pilot line (71), while keeping flared adapter (421) stationary.

  • Page 21: Securing Bead Dispenser Wheel

    Securing Bead Dispenser Wheel Securing Bead Dispenser Linkage Rod Adjustment Wheel (ThermoLazer 300 /ProMelt only) Adjustments can be made to linkage rods by removing clevis cotter hairpin (268), clevis pin from clevis (179), To properly dispense beads, drive wheel (27) must be in loosening nuts (128), and then turning clevis as required direct contact with tire (89).

  • Page 22: Screed Box/Bead Dispenser Box Actuator

    Screed Box/Bead Dispenser Box Actuator ti14883a ti14604a 3. Reconnect clevis to deployment bar and again rotate bead box wheel to see if adjustments cause ThermoLazer to move forward and backwards. Screed Box Pivot Arm 4. Continue to rotate clevis 1/2 turn counterclockwise Loading until rotating bead box wheel causes ThermoLazer to move forward and backwards.

  • Page 23: Carbide Runner Replacement On Smart Die Ii (300Tc/Promelt)

    1. Apply grease to groove where carbide runner sits. time. If both runners are removed, adjustment will be lost and screed box will need to be reassembled by a Graco approved technician. 1. Remove screed box. ti16845a 2. Replace plate, die runner (504) with new plate, die runner.

  • Page 24: Carbide Runner Replacement On Flexdie

    Carbide Runner Replacement on FlexDie (200/200TC) Carbide Runner Replacement on FlexDie (200/200TC) Removal Installation 1. Remove screed box. 1. Apply grease to inside surface of carbide runner. 2. Turn the die upside down, then use 5/8 wrench to 2. Replace die runner with new die runner. loosen nut 17D593 and 105327.

  • Page 25: Kettle Gas Regulator Replacement

    Kettle Gas Regulator Replacement Kettle Gas Regulator Replacement ThermoLazer 200/200 Removal Installation 1. Close propane tank valve. 1. Apply pipe sealant and connect gas supply hose (a) to manifold (e). 2. Connect gas supply hose (a) to propane tank (a). 3.

  • Page 26: Thermolazer 300Tc

    Kettle Gas Regulator Replacement ThermoLazer 300 2. Apply pipe sealant to pipe elbow (142) and screw into new gas regulator (10). Turn connection until gas tight. Removal NOTE: Make sure IN connection of regulator is con- nected to the pipe elbow (142). See F 1.

  • Page 27: Thermolazer Promelt

    Kettle Gas Regulator Replacement ThermoLazer ProMelt Removal 3. Add pipe sealant to fitting (408) and screw pipe sub- assembly (408, 409, 410) into elbow (401). Turn 1. Close manual gas shut-off valve on propane tank. connection until gas tight. NOTE: Make sure IN connection of regulator is con- nected to the pipe elbow (142).

  • Page 28: Torch And Screed Burners Gas Regulator Replacement (Thermolazer 300Tc/Promelt)

    Torch and Screed Burners Gas Regulator Replacement (ThermoLazer 300TC/ProMelt) Torch and Screed Burners Gas Regulator Replacement (ThermoLazer 300 /ProMelt) Removal 3. Screw swivel union (323) onto upstream pipe elbow (142); which is now connected to gas regulator 1. Close manual gas shut-off valve on propane tank. (152).

  • Page 29: Rear Screed Burner Assembly

    Rear Screed Burner Assembly Rear Screed Burner Assembly (ThermoLazer 300 /ProMelt) Removal Installation 1. Close manual gas shut-off valve on propane tank. 1. Install burner manifold in mounting bracket (104, 109). Secure with snap rings (75). See F . 4. 2.

  • Page 30: Front Screed Burner Assembly

    Front Screed Burner Assembly Front Screed Burner Assembly (ThermoLazer 300 /ProMelt) Removal 6. Remove screed burners. 1. Close manual gas shut-off valve on the propane tank. ti14128a ti22060a 2. Disconnect gas supply hose from propane tank. 7. Remove gas manifold snap ring (75). ti14411b ti17074b 3.
  • Page 31 Front Screed Burner Assembly 3. Install gas manifold snap ring (75). 6. Connect gas supply hose (99) to propane tank. 4. Install front screed housing (20) to screed housing. Secure with fasteners (146). ti14411b ti17073a 7. Open manual gas shut-off valve on propane tank. 5.

  • Page 32: Screed Burner

    Screed Burner Screed Burner (ThermoLazer 300 /ProMelt) Vertical front screed burner (1) Removal Installation 1. Remove screed burner flame indicator (67). 1. Apply high-temperature thread sealant to 3/8-16 threads of orifice (60) and screw into burner (2). NOTE: The orifice end with the smallest hole should be screwed into the screed burner.

  • Page 33: Screed Burner

    Screed Burner Screed Burner Horizontal screed burner(s) Removal Installation 1. Apply high-temperature thread sealant to 3/8-16 1. Remove screed burner flame indicator (67). threads of orifice (60) and screw into burner (2). NOTE: The orifice end with the smallest hole should be screwed into the screed burner.

  • Page 34: Main Gas Filter (Thermolazer 300Tc/Promelt)

    Main Gas Filter (ThermoLazer 300TC/ProMelt) Main Gas Filter Screed Burner Filter (ThermoLazer 300 /ProMelt) Removal 1. See Screed Burner Removal, page 32. Removal 1. Unscrew filter fitting (403) from tee (12). Install 2. Unscrew fitting (407) from hose (99). 1. See Screed Burner Install, page 32. Install 1.

  • Page 35: Troubleshooting

    Troubleshooting Troubleshooting Problem Cause Solution Kettle pilot burner does Low or empty LP-gas tank Replace with full tank. not ignite or does not Gas supply hose not connected to tank Connect gas supply hose. remain ignited LP-gas tank shut-off valve closed Open LP-gas tank shut-off valve.
  • Page 36 Troubleshooting Problem Cause Solution Kettle main burners do Kettle gas safety valve knob not at correct posi- Turn knob to ON position (see Operation not ignite or are not burn- tion manual). ing correctly Kettle temperature control dial set at a lower Turn kettle temperature control dial to tem- temperature than material temperature perature 25°...
  • Page 37 Troubleshooting Problem Cause Solution Screed box burner does Empty LP-gas tank Replace with full tank. not ignite, does not LP-gas tank shut-off valve closed Open LP-gas tank shut-off valve. remain ignited, or can Gas supply hose not connected to tank Connect gas supply hose.
  • Page 38 Troubleshooting Problem Cause Solution Beads not discharging or Low bead level in bead hopper Fill bead hopper. discharging unevenly Bead dispenser doors closed Open doors as required to obtain desired flow pattern width. Bead dispenser drive wheel not engaged Secure bead dispenser wheel (see page 21). Bead dispenser drive wheel slipping Tighten.
  • Page 39 Troubleshooting Applying Material Problem Cause Solution Ragged line edges when extruding Dirty screed box CAREFULLY clean box. Discharge opening and screed box plate run- ners need to be free of debris. Cold material temperatures Heat material as required. Marking speed too fast Slow ThermoLazer speed.
  • Page 40 Troubleshooting Problem Cause Solution Swollen rounded line • 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 •...

  • Page 41: Piping Diagram

    Piping Diagram Piping Diagram ThermoLazer 200 ti25754a 3A1320L...

  • Page 42: Thermolazer 200Tc

    Piping Diagram ThermoLazer 200 3A1320L...

  • Page 43: Thermolazer 300Tc/Promelt

    Piping Diagram ThermoLazer 300 /ProMelt 3A1320L...

  • Page 44: Wiring Diagram

    Wiring Diagram Wiring Diagram ThermoLazer 200 3A1320L...

  • Page 45: Thermolazer 300Tc

    Wiring Diagram ThermoLazer 300 3A1320L...

  • Page 46: Thermolazer Promelt

    Wiring Diagram ThermoLazer ProMelt 3A1320L...

  • Page 47: Technical Data

    Technical Data Technical Data ThermoLazer ThermoLazer 200/200 ThermoLazer 300 ProMelt (24U280) with Rear without Rear (24H624) Heat Heat (24U281) (24H622) (24H625) Fuel Liquefied Petroleum Gas (LP-gas) (propane vapor) Gas supply maximum pressure - psi (bar) 250 (17.24) Kettle burners (0.21) (0.034) (0.034) (0.21)

  • Page 48: Graco Standard Warranty

    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 manual is also suitable for:

Thermolazer 300tcThermolazer promeltThermolazer 200

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