ti23074a
ThermoLazer 300TC
ThermoLazer ProMelt
ti23073a
ThermoLazer 200/200TC
ti22634a
Repair
ThermoLazer® 200/200TC/300TC and
ThermoLazer ProMelt™ Pavement Marking
Systems
3A1320F
- 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 44
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
SmartDie
FlexDie
™
™
II
3A1738
3A1738
EN
System Chart
System Chart
SmartDie II used on ThermoLazer 300TC/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)
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)
17A174 16 in. (40 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)
24J785 4-6-4 in. (10-15-10 cm)
17A175 6-4-6 in. (15-10-15 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 200/200
FlexDie
Part No.
16Y661 2 in. (5 cm)
16Y662 3 in. (8 cm)
16Y320 4 in. (10 cm)
16Y663 5 in. (12 cm)
16Y190 6 in. (15 cm)
16Y664 7 in. (18 cm)
16Y326 8 in. (20 cm)
16Y665 9 in. (22.5 cm)
16Y332 10 in. (25 cm)
16Y207 12 in. (30 cm)
16Y338 3-3-3 in. (8-8-8 cm)
16Y352 4-3-4 in. (10-8-10 cm)
16Y666 4-2-4 in. (10-5-10 cm)
16Y363 4-4-4 in. (10-10-10 cm)
FlexDie Description
TC only.
2 3A1320F
Contents
System Chart
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 Ignitor Electrode Gap . . . . . . 11
Kettle Over-Temperature Switch Replacement
(ProMelt only) . . . . . . . . . . . . . . . . . . . . . . . . . 11
Thermopile Replacement . . . . . . . . . . . . . . . . . . . 12
Removal and Installation of Electrode . . . . . . . . . 14
Pilot Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
(ThermoLazer 200TC/300TC/ProMelt) . . . . . . . 16
Cleaning Kettle Main Burner Gas Lines . . . . . . . 18
Cleaning Kettle Pilot Burner Gas Lines . . . . . . . . 18
Securing Bead Dispenser Wheel . . . . . . . . . . . . . 19
Bead Dispense Tension Adjustment . . . . . . . . . 19
Linkage Rod Adjustment . . . . . . . . . . . . . . . . . . 19
Screed Box/Bead Dispenser Box Actuator . . . . . 20
Screed Box Pivot Arm Loading . . . . . . . . . . . . . . 20
(ThermoLazer 300TC/ProMelt only) . . . . . . . . . 20
Carbide Runner Replacement on Screed Box . . 21
(1 on each side) . . . . . . . . . . . . . . . . . . . . . . . . . 21
Kettle Gas Regulator Replacement . . . . . . . . . . . 22
ThermoLazer 200/200TC . . . . . . . . . . . . . . . . . . 22
ThermoLazer 300TC . . . . . . . . . . . . . . . . . . . . . 23
ThermoLazer ProMelt . . . . . . . . . . . . . . . . . . . . 24
Torch and Screed Burners Gas Regulator
Replacement (ThermoLazer 300TC/ProMelt) 25
Rear Screed Burner Assembly . . . . . . . . . . . . . . . 26
Front Screed Burner Assembly . . . . . . . . . . . . . . 27
(ThermoLazer 300TC/ProMelt) . . . . . . . . . . . . . 27
Screed Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
(ThermoLazer 300TC/ProMelt) . . . . . . . . . . . . . 29
Screed Burner . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Main Gas Filter
(ThermoLazer 300TC/ProMelt) . . . . . . . . . . . . 31
Screed Burner Filter . . . . . . . . . . . . . . . . . . . . . . . . 31
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Piping Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
ThermoLazer 200 . . . . . . . . . . . . . . . . . . . . . . . 38
ThermoLazer 200TC . . . . . . . . . . . . . . . . . . . . . 39
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
ThermoLazer 200TC . . . . . . . . . . . . . . . . . . . . . 41
ThermoLazer 300TC . . . . . . . . . . . . . . . . . . . . . 42
ThermoLazer ProMelt . . . . . . . . . . . . . . . . . . . . 43
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 46
3A1320F 3
Warnings
WARNING
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.
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.
4 3A1320F
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.
3A1320F 5
Kettle Gas Safety Valve, Kettle Temperature Control, and Kettle Thermopile Diagnosis
TH
TP
TH
TP
1
2
3
ti14524c
Terminal Connections
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
If mV reading > 100 mV and the automatic valve (main
100 mV
80 mV
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.
6 3A1320F
Kettle Temperature Control
ti14557a
ti14124a
AA
BB
ti17067a
ti17066a
ThermoLazer 300TC (24H622, 24H625)
ThermoLazer ProMelt
41
124, 318
41
124
(24H624)
ti22652a
ThermoLazer 200TC
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.
Removal
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).
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.
6. Remove temperature control plastic 4-way insert
7. Use screwdriver to remove two screws on tempera-
from shaft. Insert behind knob (AA).
ture control slip-fit overlay ring (BB). Overlay ring
(BB) is attached to temperature control enclosure
(205).
3A1320F 7
15. .
Kettle Temperature Control
1
2
ti23234a
ti14124a
AA
BB
ti14124a
AA
BB
Installation (ThermoLazer 200TC)
1. Route tube through clips (1).
2. Route wire inside bracket (2) on inner wall of kettle.
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.
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.
(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 han-
dle 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.
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.
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).
Installation (ThermoLazer 300TC/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.
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
3. ThermoLazer: Route probe through stud (318).
Insert stud through screen (150) and tighten* stud
(318) to screen (150) with nut (124). Secure probe
8 3A1320F
and tighten four bolts (139).
12. Connect hoses (189) to bead hopper (43) and use
screw driver to tighten hose clamps (160)
Kettle Temperature Control
ti14523a
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).
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.
3A1320F 9
Kettle Thermometer
RESET
ti14525b
Adjusting Screw
Kettle Thermometer
Replacement
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).
Calibration
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.
7. If the kettle thermometer is higher than the remote
calibrated temperature probe, turn adjusting screw
clockwise.
10 3A1320F
Adjust Kettle Pilot Ignitor Electrode Gap
ti14519b
0.17 - 0.20 in.
7
ti17078b
Adjust Kettle Pilot Ignitor
Electrode Gap
(ThermoLazer 300TC/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).
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.
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.
3A1320F 11
Thermopile Replacement
ti14128a
29
ti14880a
ThermoLazer 300TC/ProMelt Shown
ti14852a
320
28
ti14853a
13
ti14855a
357
28
ThermoLazer 300TC/ProMelt
only
ti14854a
28
ti14856b
49
171
ThermoLazer 200TC/300TC/ProMelt
ti21952a
126
217
ti14857b
18
319
244
ThermoLazer 300TC/ProMelt
Shown
ti14858b
7
ThermoLazer
200TC/300TC/ProMelt
Thermopile Replacement
Removal
1. Shut off gas valve on LP-tank and disconnect hose.
2. Remove gas safety valve enclosure back cover
(29).
3. Remove cover (320) from gas safety valve enclosure (28).
4. Disconnect thermopile wires from gas safety valve
(13).
7. Disconnect gas pilot line (49) at gas pilot coupling
(171).
8. Thermolazer 300
TC/ProMelt only: Disconnect
electrode lead (217) from pulse fire igniter (126).
Pull electrode out of wire sleeving.
9. Remove gas pilot mounting housing (319) from gas
burner mounting plate (18). Disconnect ground lead
wire (244).
5. Remove wire strain relief fitting (357) from gas
safety valve enclosure (28).
10. Remove thermopile (7).
6. Pull thermopile wire out of gas safety valve enclosure (28).
12 3A1320F
11. Pull thermopile out of wire sleeving.
Installation
ti14862b
7
ti14863b
18
319
244
ThermoLazer 300TC/ProMelt
Shown
ti14861b
171
49
ThermoLazer 300TC/ProMelt
Shown
ti14864a
28
ti14865a
357
28
ThermoLazer 300TC/ProMelt
Shown
ti14866a
13
ti14867a
320
28
29
ti14881a
ThermoLazer 300TC/ProMelt
Shown
ti21951a
ti14127a
1. Replace thermopile (7).
2. Install gas pilot mounting plate (319) to gas burner
mounting plate (18). Connect ground lead wire
(244).
3. Connect gas pilot line (49) at gas pilot coupling
(171).
Thermopile Replacement
8. Replace cover (320) on gas safety valve enclosure
(28).
9. Replace gas safety enclosure back cover (29).
4. Pull thermopile through wire sleeving.
5. Guide thermopile wire into gas safety valve enclosure (28).
10. ThermoLazer 300
wire through wire sleeving.
11. ThermoLazer 300
trode lead to pulse fire igniter.
TC/ProMelt Only: Pull electrode
TC/ProMelt Only: Connect elec-
6. Replace wire strain relief fitting (357) on gas safety
valve enclosure (28).
12. Reconnect hose and turn LP-gas tank valve ON.
7. Connect thermopile wires to gas safety valve (13).
See Wiring Diagram and Parts manual 3A1321 for
additional details.
3A1320F 13
13. Check for gas leaks at final assembly (see Operation manual).
Removal and Installation of Electrode
ti14861b
171
49
ti21952a
126
217
ThermoLazer 300TC/ProMelt Only
ti14857b
18
319
244
ti14858b
7
ti121953a
ThermoLazer 300TC/ProMelt Only
ti21954a
ti14862b
7
Removal and Installation of Electrode
(ThermoLazer 300TC/ProMelt only)
Removal
1. Disconnect gas pilot line (49) at gas pilot coupling
(171).
2. Disconnect electrode lead (217) from pulse fire
igniter (126). Pull electrode out of wire sleeving.
5. Remove electrode.
Installation
1. Replace electrode. (See Operation Manual for cor-
rect spacing between electrode and pilot burner).
3. Remove gas pilot mounting housing (319) from gas
burner mounting plate (18). Disconnect ground lead
wire (244).
4. Remove thermopile (7).
2. Replace thermopile (7).
14 3A1320F
Removal and Installation of Electrode
ti14863b
18
319
244
ThermoLazer 300TC/ProMelt
Shown
ti14861b
49
171
ti21951a
ThermoLazer 300TC/ProMelt Only
ti14127a
3. Install gas pilot mounting plate (319) to gas burner
mounting plate (18). Connect ground lead wire
(244).
4. Connect gas pilot line (49) at gas pilot coupling
(171).
5. Pull electrode wire through wire sleeving.
6. Connect electrode lead to pulse fire igniter.
7. Reconnect hose and turn LP-gas tank valve ON.
8. Check for gas leaks at final assembly (see Opera-
tion manual).
3A1320F 15
Pilot Burner
ti14861b
171
49
ti21952a
126
217
ThermoLazer 300TC/ProMelt Only
ti14857b
18
319
244
ti14858b
7
ti121953a
ThermoLazer 300
TC/ProMelt Only
ti22062a
ti122061a
Pilot Burner
(ThermoLazer 200TC/300TC/ProMelt)
Removal
1. Disconnect gas pilot line (49) at gas pilot coupling
(171).
2. ThermoLazer 300
electrode lead (217) from pulse fire igniter (126).
Pull electrode out of wire sleeving.
TC/ProMelt only: Disconnect
5. ThermoLazer 300
TC/ProMelt only: Remove elec-
trode.
6. Remove pilot burner.
3. Remove gas pilot mounting housing (319) from gas
burner mounting plate (18).
ThermoLazer 300
TC/ProMelt only: Disconnect
ground lead wire (244).
4. Remove thermopile (7).
7. Remove pilot burner tubing.
16 3A1320F
Pilot Burner
ti122061a
ti22059a
ti21954a
ThermoLazer 300
TC/ProMelt only
ti4862b
ti14863b
18
319
244
ti14856b
49
171
ti21951a
ThermoLazer 300TC/ProMelt only
ti14127a
Installation
1. Install pilot burner tubing.
2. Install 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).
6. Connect gas pilot line (49) at gas pilot coupling
(171).
7. ThermoLazer 300
TC/ProMelt only: Pull electrode
wire through wire sleeving.
3. ThermoLazer 300
trode.
4. Install thermopile.
TC/ProMelt only: Install elec-
8. ThermoLazer 300
TC/ProMelt only: Connect elec-
trode lead to pulse fire igniter.
9. Reconnect hose and turn LP-gas tank valve ON
10. Check for gas leaks at final assembly (see Operation manual).
3A1320F 17
Cleaning Kettle Main Burner Gas Lines
ThermoLazer 300TC/ProMelt shown
165
ti24817a
49
ti14559b
186
118
Cleaning Kettle Main
Burner Gas Lines
1. Disconnect gas tubing line (49) 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 (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. Insert rubber hose over gas tubing (118) and force
air into gas tubing line (118) at 30 psi (2.1 bar).
3. Reconnect gas tubing line (186) to gas tubing tee
(118).
18 3A1320F
Securing Bead Dispenser Wheel
81
27
211
ti14564a
ti23692a
13.13 in.
ti14565a
182
181
(33.34 cm)
81
27
ti14882a
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).
Bead Dispense Tension
Linkage Rod Adjustment
(ThermoLazer 300TC/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.
Adjustment
(ThermoLazer 200TC 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.
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.
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.
3A1320F 19
Screed Box/Bead Dispenser Box Actuator
128
179
268
78
ti14883a
ti14604a
ti14628b
ti14629b
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.
Screed Box/Bead
Dispenser Box Actuator
(ThermoLazer 300TC/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.
Screed Box Pivot Arm Loading
(ThermoLazer 300TC/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).
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.
20 3A1320F
Carbide Runner Replacement on Screed Box
ti16839a
ThermoLazer 300TC/ProMelt shown
ti16843a
ti16845a
ti16845a
ti17068a
ti16843a
ti16846a
ThermoLazer 300TC/ProMelt shown
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.
1. Remove screed box.
2. Use allen wrench to loosen and remove upper pivot
bolt (511) to free yoke (502).
Installation
1. Apply grease to groove where carbide runner sits.
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.
3. Turn unit upside-down and use an allen wrench to
remove four screws (513) and plate, die runner
4. Use allen wrench to replace and tighten pivot bolt
(511) on yoke (502).
(504).
5. Install screed box.
3A1320F 21
Kettle Gas Regulator Replacement
ti14128a
ti14127a
a
10
410
415
c
d
b
e
IN
OUT
ti23236a
Kettle Gas Regulator Replacement
ThermoLazer 200/200TC
Removal
1. Close propane tank valve.
2. Disconnect gas supply hose (a) from propane tank.
3. Disconnect lines to front (b) and rear (c) screed
torches and main kettle burner (d).
4. Remove bolts (415) holding manifold to unit.
5. Unscrew fittings (410) and regulator (10).
Installation
1. Apply pipe sealant and install regulator (10) so flow
arrows point at the manifold.
2. Install fittings (415).
3. Install manifold (e) in unit and tighten bolts (415).
4. Connect lines to front (b) and rear (d) screed
torches and main kettle burner (c).
5. Connect gas supply hose to propane tank (a).
6. Open propane tank valve.
7. Check for leaks.
8. Verify gauge PSI. Gauge should read 3 PSI
higher than 4 PSI, slightly open torch valve and
recheck.
IG. 1
F
± 1. If
22 3A1320F
ThermoLazer 300TC
ti14128a
ti14411a
ti14127a
142
64
10
118
409
408
415
401
410
9
ti22015a
10
IN
OUT
142
64
ti22066a
Direction
Arrow
Indicates
Flow
of Gas
Kettle Gas Regulator Replacement
Removal
1. Close manual gas shut-off valve on propane tank.
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.
6. Open manual gas shut-off valve on propane tank.
7. Check gas lines for gas leaks (see Operation
manual).
F
IG. 2
3A1320F 23
Kettle Gas Regulator Replacement
ti14128a
ti14411a
ti14127a
ti24818a
ti24819a
ti24818a
412
402
406
410
118
142
10
323
64
401
408
409
ti24819a
142
10
64
412
IN
OUT
Arrow
Indicates
Direction
of Gas
Flow
ThermoLazer ProMelt
Removal
1. Close manual gas shut-off valve on propane tank.
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 fitting (323) from fitting (64) and from gas
regulator (10).
7. Unscrew gas regulator (10) from pipe elbow (64).
Installation
1. Apply pipe sealant to fitting (64) and screw into
adapter fitting (323). Turn connection until gas tight.
NOTE: Make sure OUT connection of regulator is
connected to adapter fitting (323). See F
2. Apply pipe sealant to pipe elbow (142) and screw
into new gas regulator (10). Turn connection until
gas tight.
IG. 3
3. Place label (412) onto fitting (64). Add pipe sealant
to adapter fitting (323) and screw into new gas regulator. 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 gauge (402). 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.
7. Open manual gas shut-off valve on propane tank.
8. Check gas lines for gas leaks (see Operation
manual).
F
IG. 3
24 3A1320F
Torch and Screed Burners Gas Regulator Replacement (ThermoLazer 300TC/ProMelt)
ti14128a
ti14411a
ti14127a
7.
ti24821a
ti24820a
323
142
12
152
161
161
OUT
IN
323
152
12
OUT
IN
Arrow
Indicates
Direction
of Gas
Flow
ti24820a
Torch and Screed Burners Gas Regulator Replacement
(ThermoLazer 300TC/ProMelt)
Removal
1. Close manual gas shut-off valve on propane tank.
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 gas regulator (152) from fitting (323).
6. Unscrew and remove gas regulator (152) from
upstream pipe elbow (142).
Installation
3. Apply pipe sealant to upstream pipe elbow (142)
and screw gas regulator (152); which is now connected to fitting (323). Turn connection until gas
tight.
NOTE: Make sure IN connection of regulator is connected to the upstream pipe elbow (142). See 7.
4. Connect gas line at downstream tube elbows (161).
Turn connection until gas tight.
5. Connect gas supply hose to propane tank.
6. Open manual gas shut-off valve on propane tank.
1. Apply pipe sealant to downstream pipe tee (12).
Screw pipe tee (12) with elbow (161) to fitting (323).
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 OUT connection of regulator is
connected to fitting (323). See 7.
3A1320F 25
7. Check gas lines for gas leaks (see Operation man-
ual).
Rear Screed Burner Assembly
ti14128a
ti14411a
99
ti14127a
75
115
104
373
151
ti22658a
Rear Screed Burner Assembly
(ThermoLazer 300TC/ProMelt)
Removal
1. Close manual gas shut-off valve on propane tank.
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
4.
5. Remove burner assembly.
6. Remove snap rings (75) from gas manifold. See
F
IG. 4.
IG.
Installation
1. Install burner manifold in mounting bracket (104,
109). Secure with snap rings (75). See F
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.
5. Open manual shut-off valve on propane tank.
IG. 4.
F
IG. 4
26 3A1320F
Front Screed Burner Assembly
ti14128a
ti14411b
99
ti17072a
32
ti17073a
146
20
ti22060a
ti17074b
75
ti17074b
146
20
75
52
ti22060a
(ThermoLazer 300TC/ProMelt)
Front Screed Burner Assembly
Removal
1. Close manual gas shut-off valve on the propane
tank.
2. Disconnect gas supply hose from propane tank.
3. Remove screed box from screed housing (see
Operation manual).
4. Disconnect gas tubing at 45° elbow (32).
6. Remove screed burners.
7. Remove gas manifold snap ring (75).
8. Unscrew gas manifold (less burners) mounting
bracket fasteners (146) and remove burner assembly (less burners) from front screed housing (20).
5. Unscrew front screed housing fasteners (146) and
remove front housing (20).
3A1320F 27
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).
2. Install screed burner.
Front Screed Burner Assembly
ti17073a
146
20
ti17072a
32
ti14411b
99
ti14127a
3. Install gas manifold snap ring (75).
4. Install front screed housing (20) to screed housing.
Secure with fasteners (146).
5. Connect gas tubing to 45° elbow (32).
6. Connect gas supply hose (99) to propane tank.
7. Open manual gas shut-off valve on propane tank.
28 3A1320F
Screed Burner
ti21955a
67
ti21956a
ti21957a
60
363
119
ti21958a
60
2
60
2
ti21958a
ti21957a
60
363
363
ti21956a
ti21955a
67
(ThermoLazer 300TC/ProMelt)
Vertical front screed burner (1)
Screed Burner
Removal
1. Remove screed burner flame indicator (67).
2. Unscrew screed burner and orifice from gas manifold.
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.
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).
3. Unscrew adapter fitting (363) from orifice fitting (60).
Remove washer from orifice (119).
3. Apply pipe sealant to 1/8 in. NPT thread of adapter
fitting (363) and screw into gas manifold.
4. Unscrew orifice fitting (60) from screed burner (2).
4. Install screed burner flame indicator (67).
3A1320F 29
Screed Burner
ti17075b
67
ti17076b
ti21950a
363
60
ti17077b
60
2
ti17077b
60
2
ti21950a
60
363
ti17076b
363
ti17075b
67
Screed Burner
Horizontal screed burner(s)
Removal
1. Remove screed burner flame indicator (67).
2. Unscrew screed burner and orifice from gas manifold.
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.
2. Apply pipe sealant to 1/8 in. NPT thread of orifice fitting (60) and screw on adapter fitting (363).
3. Unscrew adapter fitting (363) from orifice fitting (60).
4. Unscrew orifice fitting (60) from screed burner (2).
3. Apply pipe sealant to 1/8 in. NPT thread of adapter
fitting (363) and screw into gas manifold.
4. Install screed burner flame indicator (67).
30 3A1320F
Main Gas Filter (ThermoLazer 300TC/ProMelt)
403
12
407
99
ti21960a
Main Gas Filter
(ThermoLazer 300TC/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).
Screed Burner Filter
Removal
1. See Screed Burner Removal, page 29.
Install
1. See Screed Burner Install, page 29.
3A1320F 31
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 Over temperature safety switch not functioning
Low or empty LP-gas tank Replace with full tank.
Gas supply hose not connected to tank Connect gas supply hose.
LP-gas tank shut-off valve closed Open LP-gas tank shut-off valve.
Manual gas shut-off valve closed Open manual gas shut-off valve.
Gas lines leaking or disconnected Check for gas leaks. Connect and tighten fit-
Kettle gas safety valve knob not in correct position
Not providing adequate time for thermopile to
heat up
Kettle pilot igniter has weak battery Replace part (see Parts manual).
Kettle pilot electrode gap incorrect Adjust gap (see page 11).
Incorrect flame length and/or gas pressure Adjust flame and pressure (see Repair man-
Strong wind blowing flame out Move ThermoLazer out of strong winds.
Burner and/or gas lines plugged Unplug holes and lines. Isolate all gas regu-
Kettle gas safety valve not functioning correctly Replace part if it fails diagnostic test (see
Thermopile not functioning correctly Replace part if it fails diagnostic test (see
Kettle pilot electrode ground wire not correctly
connected
Kettle pilot electrode lead wire has a short Replace part (see Parts manual).
Kettle pilot igniter not functioning correctly Replace part (see Parts manual).
Kettle burner regulator not functioning correctly Replace part (see Parts manual).
Material level is low Add material to kettle. Once material level is
correctly
tings.
Turn knob to “PILOT” position and fully push
in (see Operation manual).
See Operation manual.
ual).
Make sure burner view ports are closed.
lators if clearing line with forced air (see
page 6).
page 6).
page 12).
Clean connections and retighten. Replace
ground wire if damaged.
up to thermometer, this condition will be corrected.
Replace part (see Parts manual).
32 3A1320F
Problem Cause Solution
Kettle main burners do
not ignite or are not burning correctly
Troubleshooting
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 regu-
lators if clearing line with forced air (see
page 18).
Kettle temperature control not functioning cor-
Replace part (see Parts manual).
rectly
Gas lines have been disconnected Connect and tighten hose fittings. Check for
gas leaks.
Incorrect flame length and/or gas pressure Adjust flame and pressure (see page 18).
Kettle gas safety valve knob not at correct posi-
Replace part (see Parts manual).
tion
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
Turn kettle temperature control dial to a setting 25° F (13.9° C) (minimum) lower than
material temperature.
Kettle temperature control not functioning cor-
Replace part (see Parts manual).
rectly
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) higher than
material temperature.
Kettle temperature control not functioning cor-
Replace part (see Parts manual).
rectly
Kettle gas safety valve not functioning correctly Replace part if it fails diagnostic test (see
page 6).
Over temperature safety switch not functioning
Replace part (see Parts manual).
correctly
Material has not reached temperature control set
point
Allow time for material to reach operating
temperature.
Material not fully agitated Agitate material.
Cool or windy ambient conditions Move ThermoLazer out of cool windy condi-
tions. 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 cor-
Replace part (see Parts manual).
rectly
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).
3A1320F 33
Troubleshooting
Problem Cause Solution
Screed box burner does
not ignite, does not
remain ignited, or can
not change heat output
Empty LP-gas tank Replace with full tank.
LP-gas tank shut-off valve closed Open LP-gas tank shut-off valve.
Gas supply hose not connected to tank Connect gas supply hose.
Gas lines leaking or disconnected Check for gas leaks. Connect and tighten fit-
tings.
Burner regulator/flow flame adjusting valve not
Replace part (see Parts manual).
functioning correctly
Burner orifice plugged Clean or replace part (see Parts manual).
Burner assembly not functioning correctly. Replace part (see Parts manual).
Torch does not ignite Empty LP-gas tank Replace with full tank.
LP-gas tank shut-off valve closed Open LP-gas tank shut-off valve.
Torch manual gas shut-off valve closed Open manual shut-off valve.
Gas supply hose not connected to tank Connect gas supply hose.
Gas lines leaking or disconnected Check for gas leaks. Connect and tighten fit-
tings.
Torch assembly not functioning correctly Replace part (see Parts manual).
Agitator crank handle is
hard to move
Material is cold Allow time for material to reach operating
temperature.
Bushings are worn Replace bushings (see Parts manual).
Linkage ball rod ends need lubrication Add grease.
ControlFlow
™
gate valve
difficult to open
or close
Foreign material lodged between agitator and
kettle
Cold material temperature Heat material to operating temperature.
Gate sticking in guides Check for excess material in guides. Apply
Remove material in kettle and CAREFULLY
dislodge and remove foreign material.
Make sure thermometer is free to move.
heat as required and remove excess material. Add grease to lubricate guides.
Bushings are worn Replace bushings (see Parts manual).
ControlFlow gate valve
leaking
Gate not completely closed Close gate completely.
Foreign material lodged in gate opening CAREFULLY dislodge and remove foreign
material.
Screed box leaking Foreign material in screed box discharge open-
ing
CAREFULLY dislodge and remove foreign
material.
Dirty screed box CAREFULLY clean box. All moving parts
need to be free of debris.
Incorrect deployment rod linkage length Adjust length (see page 19).
Incorrectly adjusted screed box/bead dispenser
Adjust lever (see page 19).
box actuator
Worn screed box shear bar Replace gate (see Parts manual).
Worn screed box shear bar stop Replace trough (see Parts manual).
Excessive material
buildup when starting
and stopping extruding
Screed box not adjusted to ground See Operation manual.
Screed box open when ThermoLazer is
stationary
Foreign material in screed box discharge opening
Synchronize ThermoLazer and screed box
motion.
CAREFULLY dislodge and remove foreign
material.
Dirty screed box CAREFULLY clean box. All moving parts
need to be free of debris.
34 3A1320F
Problem Cause Solution
Beads not discharging or
discharging unevenly
Beads not discharging at
required flow rate
Hard pushing when
screed box is on ground
Troubleshooting
Low bead level in bead hopper Fill bead hopper.
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 19).
Bead dispenser drive wheel slipping Tighten. Check air pressure (see page 19).
Debris in discharge opening of bead dispenser Remove debris.
Debris on ThermoLazer tire or bead dispenser
Remove debris.
wheel
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 19).
Bead dispenser doors not fully open Open door fully.
Moisture in beads Remove wet beads. Dry hopper, bead hoses
and bead dispenser. Fill hopper with dry
beads.
Moisture on road surface Allow road surface moisture to dry.
Rough road surface Smooth road surface.
Bead Dispenser low on material Add material to bead hopper.
Screed box not adjusted correctly See Operation manual.
3A1320F 35
Troubleshooting
ti14507a
ti14508a
ti14509a
ti14510a
ti14511a
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.
Cold material temperatures Heat material as required.
Marking speed too fast Slow ThermoLazer speed.
Rough material surface when extruding
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.
Overheated material Reduce heat.
Moisture on road surface Allow road surface moisture to dry.
Rough road surface Smooth road surface.
Screed box low on material Add material to screed box.
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 • Debris on surface
• Crust from overheated material
• Debris caught in screed box
• Material not covering road high
spot
Gas bubbles in line • Moisture or solvent on surface
• Material is overheated
Ragged edges and gaps in line • Material temperature is too low
• ThermoLazer speed is too fast
• 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.
• Raise material temperature.
• Wait for change in ambient condi-
tions to remove moisture.
• Reduce ThermoLazer speed.
36 3A1320F
Troubleshooting
ti14512a
ti14513a
ti14514a
ti14515a
ti14516a
ti14517a
Problem Cause Solution
Swollen rounded line • Material temperature is too high • Lower material temperature.
Material shadows on sides • Uneven road surface
• Screed box is not evenly riding on
substrate
Line is wavy • Strong road surface camber
• Incorrect ThermoLazer operation
Cracks in line • Cracks in road surface
• Temperature stress from
overheating
• Material applied too cold
• Material applied too thin
Rough edges and lines in surface • Material temperature is too low
• Apply to even road surfaces.
• Remove debris from screed box
lever rod.
• Inspect/replace damaged screed
box lever rod/lever arm.
• Apply so camber does not influence application.
• Use correct application methods
(for example, try locking swivel
wheel).
• Repair cracks.
• Lower temperature in material.
• Increase material temperature.
• Slow ThermoLazer speed to apply
thicker material.
• Raise material temperature.
• Material is overheated or scorched
• Moisture in road surface
Jagged line ends; material drips
between lines
• Screed box does not fully close
• Debris caught in screed box
• Worn screed box shear bar
• Worn screed box trough shear bar
stop
• Surface temperature too cold
3A1320F 37
• Lower material temperature.
• Wait until road surface is dry.
• Clean screed box.
• Clear debris from screed box.
• Replace screed box gate.
• Replace screed box trough.
• Allow surface temperature to
increase.
Piping Diagram
ti23240
Piping Diagram
ThermoLazer 200
38 3A1320F
ThermoLazer 200TC
t123241
Piping Diagram
3A1320F 39
Piping Diagram
ti24822a
20 psi (1.38 bar) ThermoLazer 300TC and ThermoLazer ProMelt
0.5 psi (.034 bar); ThermoLazer 300TC
3 psi (0.21 bar) ThermoLazer ProMelt
(24H622, 24H625 ONLY)
(24H624 ONLY)
Plug
(24H625 ONLY)
ThermoLazer 300TC/ProMelt
40 3A1320F
Wiring Diagram
ti24841a
Gas Safety Valve
Thermopile
White Wire
Thermopile
Red Wire
Wire Harness
Wire Harness
Thermostat
Thermopile
ThermoLazer 200TC
Wiring Diagram
3A1320F 41
Wiring Diagram
ti17214a
Thermostat
Thermopile
Wire Harness
Wire Harness
Gas Safety Valve
Pulse Igniter
Igniter Electrode
Thermopile
White Wire
Thermopile
Red Wire
ThermoLazer 300TC
42 3A1320F
ThermoLazer ProMelt
ti17084a
Igniter Ground
Gas Safety Valve
Pulse Igniter
Thermopile
White Wire
Thermopile
Red Wire
Wire Harness
Wire Harness
Hi Temp Sensor
Wire Harness
Thermostat
Thermopile
Igniter Electrode
Wiring Diagram
3A1320F 43
Technical Data
Operating
(psi - bar)
Pressure
Maximum Heating
Btu/hr (kW)
Capacity
Capacity
lb (kg)
Material
Physical
Technical Data
ThermoLazer
200/200
(24U280)
(24U281)
Fuel Liquefied Petroleum Gas (LP-gas) (propane vapor)
Gas supply maximum pressure - psi (bar) 250 (17.24)
Kettle burners 3
Torch 3
Screed box front burners 3
Screed box rear burners 3
Kettle burners (sum of burners) (1) 30,000
Torch 10,000
Screed box front burner (sum of 3 burners) 27,000
Screed box rear burner (sum of 4 burners) 36,000 (10.6) 36,000 (10.6) N/A 36,000 (10.6)
Total 103,000
TC ThermoLazer 300TC
with Rear
Heat
(24H622)
0.5
(0.21)
(0.21)
(0.21)
(0.21)
(8.8)
(2.93)
(7.9)
(30.2)
(0.034)
20
(1.38)
20
(1.38)
20
(1.38)
(2) 30,000
(8.8)
100,000
(29.3)
27,000
(7.9)
193,000
(56.6)
without Rear
Heat
(24H625)
0.5
(0.034)
20
(1.38)
20
(1.38)
N/A 20
(2) 30,000
(8.8)
100,000
(29.3)
27,000
(7.9)
157,000
(46.0)
ThermoLazer
ProMelt
(24H624)
3
(0.21)
20
(1.38)
20
(1.38)
(1.38)
(2) 100,000
(29.3)
100,000 (29.3)
27,000
(7.9)
263,000 (77.1)
Gas 20
(9.1)
Main kettle 200
(91)
Bead hopper 40 (18) 90 (40) - Type
Maximum operating temperature - °F (°C) 450 (232) 450
Front tire pressure - psi (bar) N/A 45
Rear tire pressure - psi (bar) N/A 60
Weight - lb (kg) 260
(118)
Length - in. (m) 44 (1.12) 72 (1.83)
Height - in. (m) 39 (1.00) 51 (1.3)
Width - in. (m) 33 (0.84) 48 (1.22)
Igniter battery N/A AA (1.5 V)
300 (136) - Thermoplastic traffic marking
II glass bead
(232)
300
(136)
20
(9.1)
compound materials
450
(232)
(3.10)
(4.14)
295
(134)
20,30
(9.1, 13.6)
480
(249)
350
(159)
44 3A1320F
Notes
Notes
3A1320F 45
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 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.
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
www.graco.com
Revised F, October 2014
Loading...