Graco 257500, 258699 User Manual

Repair

ThermoLazer™ Pavement Marking System

313879B

- 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) -

Model No. 258699 North America - Includes 257500 and 4 in. (10 cm) SmartDie™ Screed Box Model No. 257500 International (SmartDie

Fuel: LP Gas (Propane Vapor) Burner capacities (max total): 138,000 BTU/hr. (40.44 kW) [38,000 BTU/hr. (7.03 kW) without torch] Material capacity (max): 300 lb (136 kg)

IMPORTANT SAFETY INSTRUCTIONS

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

Related Manuals Operation 313787

Parts 313880

™

For use with the following SmartDie Part Description

256736 4 in. (10 cm) Screed Box 257469 5 in. (12 cm) Screed Box 256737 6 in. (15 cm) Screed Box 257470 7 in. (18 cm) Screed Box 256738 8 in. (20 cm) Screed Box 257471 9 in. (22.5 cm) Screed Box 257472 10 in. (26 cm) Screed Box 256739 12 in. (30 cm) Screed Box 256799 Double Line 4-4-4 in. (10-10-10 cm) Screed Box 24B729 Double Line 4-3-4 in. (10-8-10 cm) Screed Box

Screed Box:

™

Screed Box not included)

257500

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Table of Contents

Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Kettle Gas Safety Valve,

Kettle Temperature Control, and

Kettle Thermopile Diagnosis . . . . . . . . . . . . . . 5

Kettle Temperature Control Calibration . . . . . . . . . 6

Temperature Control Replacement . . . . . . . . . . . . 6

Thermometer Replacement . . . . . . . . . . . . . . . . . . 6

Kettle Thermometer Calibration . . . . . . . . . . . . . . . 7

Adjust Kettle Pilot Ignitor Electrode Gap . . . . . . . 7

Thermopile Replacement . . . . . . . . . . . . . . . . . . . . 8

Adjust Gas Pressure to Kettle Burners . . . . . . . . 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

Replacing Screed Box Spring . . . . . . . . . . . . . . . . 14

Securing Bead Dispenser Wheel . . . . . . . . . . . . . 15

Linkage Rod Adjustment . . . . . . . . . . . . . . . . . . . . 15

Screed Box/Bead Dispenser Box Actuator . . . . . 15

Adjusting Screed Box Pivot Arm . . . . . . . . . . . . . 16

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 24

Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 24

2 313879B

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 450° F (232° C)

• 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.

313879B 3

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 313879B

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.

Connect millivolt meter to appropriate terminals (see

Terminal Connections).

Status of

Part(s) to Be

Step

1 Gas safety

2 Temperature

Checked

valve

control

Temperature

Terminal

Connections

2 and 3 Closed Greater than

1 and 2 Closed Less than

Control

Contacts

Desired

Meter

Reading Diagnosis

100 mV

80 mV

Terminal Connections

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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 11).

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.

313879B 5

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 Thermolazer

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.

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to an area with no wind.

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.

Temperature Control Replacement

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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.

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Be sure to seal capillary tubing with high temperature mortar at kettle outlet.

Thermometer Replacement

Thermometer can not be removed from ThermoLazer™ without damaging thermometer probe. If probe end is frozen in material, heat material and remove until material level is lower than thermometer probe.

6 313879B

Kettle Thermometer Calibration

6. If kettle thermometer is lower than the remote calibrated temperature probe, turn adjusting screw counterclockwise.

To Check Kettle Thermometer Calibration:

Kettle Thermometer Calibration

Adjusting Screw

1. Move ThermoLazer

2. Turn temperature control to 400° F (204° C).

3. Agitate material for 4 to 5 minutes.

5. Compare temperature of remote calibrated temperature probe to thermometer.

™

to an area with no wind.

7. If the kettle thermometer is higher than the remote calibrated temperature probe, turn adjusting screw clockwise.

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).

RESET

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.17 to .20 in.

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313879B 7

Thermopile Replacement

Removal

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

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2. Remove gas safety valve enclosure back cover.

3. Remove cover (252) from gas safety valve enclosure (28).

252

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

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7. Cut wire tie.

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8. Disconnect gas pilot line (76) at gas pilot coupling (171).

171

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4. Disconnect thermopile wires from gas safety valve (13).

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5. Remove wire grommet (209) from gas safety valve enclosure (28).

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209

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9. Remove gas pilot mounting plate (18).

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10. Remove thermopile (7).

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8 313879B

+ 16 hidden pages