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Graco ThermoLazer 200, Repair Manual

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Graco ThermoLazer 200 Repair Manual Download Page 12

Thermopile Replacement 

12

3A1320L

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 enclo-

sure (28).

4. Disconnect thermopile wires from gas safety valve 

(13).

5. Remove wire strain relief fitting (357) from gas 

safety valve enclosure (28).

6. Pull thermopile wire out of gas safety valve enclo-

sure (28).

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

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

8.

Thermolazer 300

TC

/ProMelt only: 

Disconnect 

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

ti14128a

29

ti14880a

ThermoLazer 300TC/ProMelt Shown

ti14852a

320

28

ti14853a

13

ti14855a

357

28

ThermoLazer 300TC/ProMelt 
only

ti14854a

28

71

ti25692b

421

ti25740a

ThermoLazer 200TC/300TC/ProMelt 

Summary of Contents for ThermoLazer 200

Page 1: ...nd 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 Related Manuals IMPORTANT SAFETY INSTRUCTIONS Read all warnings and instructions in this manual Save these instructions Operation 3A1319 Parts 3A1321 D...

Page 2: ... 13 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 17R378 5 5 5 in 13 13 13 cm 26C273 6 3 6 in 15 8 15 cm FlexDie Part No FlexDie Description 16Y661 2 in 5 cm 16Y662 3 in 8 cm 1...

Page 3: ...d Dispenser Box Actuator 22 Screed Box Pivot Arm Loading 22 ThermoLazer 300TC ProMelt only 22 Carbide Runner Replacement on Smart Die II 300TC ProMelt 23 Carbide Runner Replacement on FlexDie 200 200TC 24 Kettle Gas Regulator Replacement 25 ThermoLazer 200 200TC 25 ThermoLazer 300TC 26 ThermoLazer ProMelt 27 Torch and Screed Burners Gas Regulator Replacement ThermoLazer 300TC ProMelt 28 Rear Scree...

Page 4: ...nguisher 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 man...

Page 5: ...irator 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 ca...

Page 6: ...e control 1 and 2 Closed Less than 80 mV If reading 80 mV Clean and tighten electrical connections at tempera ture control and gas safety valve Check valve to make sure wires are in good condi tion Replace as required Rapidly change temperature setting on temperature control to see if cycling cleans the contacts If the preceding fails to give mV reading 80 mV replace temperature control 3 Gas safe...

Page 7: ...ure control plastic 4 way insert from shaft Insert behind knob AA 7 Use screwdriver to remove two screws on tempera ture control slip fit overlay ring BB Overlay ring BB is attached to temperature control enclosure 205 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 The...

Page 8: ...ten 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 i...

Page 9: ...ature control probe 5 Compare temperature of remote calibrated tem perature probe to temperature setting on tempera ture control 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 7 If the temperature control setting is higher than the remote calibrat...

Page 10: ...hreads 2 Install new thermometer into kettle coupling and tighten NOTE Make sure the face of the thermom eter is position toward the front of the unit for opti mal 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 ...

Page 11: ... 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 fitt...

Page 12: ...e enclosure 28 6 Pull thermopile wire out of gas safety valve enclo sure 28 7 Disconnect gas pilot line 71 from flared adapter 421 Only rotate the nut on gas pilot line 71 while keeping flared adapter 421 stationary 8 Thermolazer 300TC ProMelt only Disconnect electrode lead 217 from pulse fire igniter 126 Pull electrode out of wire sleeving ti14128a 29 ti14880a ThermoLazer 300TC ProMelt Shown ti14...

Page 13: ...pilot mounting housing 319 from gas burner mounting plate 18 Disconnect ground lead wire 244 10 Remove thermopile 7 11 Pull thermopile out of wire sleeving 319 18 244 ti25739b ti25741b ThermoLazer 300TC ProMelt Shown ThermoLazer 200TC 300TC ProMelt ...

Page 14: ...eplace wire strain relief fitting 357 on gas safety valve enclosure 28 7 Connect thermopile wires to gas safety valve 13 See Wiring Diagram and Parts manual 3A1321 for additional details 8 Replace cover 320 on gas safety valve enclosure 28 9 Replace gas safety enclosure back cover 29 ti25742b 319 18 244 ti25743b 71 ti25690b 421 Shown ti14864a 28 ti14865a 357 28 ThermoLazer 300TC ProMelt Shown ti14...

Page 15: ...Melt Only Pull electrode wire through wire sleeving 11 ThermoLazer 300TC ProMelt Only Connect elec trode lead to pulse fire igniter 12 Reconnect hose and turn LP gas tank valve ON 13 Check for gas leaks at final assembly see Opera tion manual ti25745a ti14127a ...

Page 16: ...17 from pulse fire igniter 126 Pull electrode out of wire sleeving 3 Remove gas pilot mounting housing 319 from gas burner mounting plate 18 Disconnect ground lead wire 244 4 Remove thermopile 7 5 Remove electrode Installation 1 Replace electrode See Operation Manual for cor rect spacing between electrode and pilot burner 71 ti25692b 421 ThermoLazer 300TC ProMelt Only ti25747a 217 126 ThermoLazer ...

Page 17: ...lot line 71 to flared adapter 421 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 ti25742b 319 18 244 ti25743b Shown 71 ti25690b 421 ThermoLazer 300TC ProMelt Only ti25746a ThermoLazer 300TC ProMelt Only ti14127a ThermoLazer 300TC ProMelt ...

Page 18: ...e igniter 126 Pull electrode out of wire sleeving 3 Remove gas pilot mounting housing 319 from gas burner mounting plate 18 ThermoLazer 300TC ProMelt only Disconnect as ground lead wire 244 4 Remove thermopile 7 5 ThermoLazer 300TC ProMelt only Remove elec trode 6 Remove pilot burner 7 Remove pilot burner fittings 71 ti25692b 421 ThermoLazer 300TC ProMelt Only ti25747a 217 126 ThermoLazer 300TC Pr...

Page 19: ...Connect gas pilot line 71 to flared adapter 421 7 ThermoLazer 300TC ProMelt only Pull electrode wire through wire sleeving 8 ThermoLazer 300TC 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 ti25749a ti25750b ti21954a ThermoLazer 300TC ProMelt only ti25742b 319 18 244 25743b 71 t...

Page 20: ...bar 3 Reconnect gas tubing line 76 to gas tube fitting tee 165 Cleaning Kettle Pilot Burner Gas Lines 1 Disconnect gas pilot line 71 from flared adapter 421 Only rotate the nut on gas pilot line 71 while keeping flared adapter 421 stationary 2 Insert rubber hose over flared adapter 421 and force air into tubing at 30 psi 2 1 bar 3 Reconnect gas line 71 to flared adapter 421 ThermoLazer 300TC ProMe...

Page 21: ...n 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 thermoplas tic 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 link age rod length Adjust the bead box linkage rod 181 so bead box drive wheel 27 is touchin...

Page 22: ... 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 scre...

Page 23: ...e 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 4 Use allen wrench to replace and tighten pivot bolt 511 on yoke 502 5 Install screed box NOTICE Carbide runners need to be replaced one side at a time If...

Page 24: ...er 17D502 and 17D504 Installation 1 Apply grease to inside surface of carbide runner 2 Replace die runner with new die runner 3 Use two 5 8 wrenches to tighten the nuts a Tighten the nut 105327 to make the die runner just touch the pivot table b Hold the wrench which is on 105327 use another 5 8 wrench to tighten nut 17D593 NOTE Make sure die runner can rotate freely after the nuts are tight 4 Ins...

Page 25: ...opane tank 3 Disconnect gas supply hose a from manifold e Installation 1 Apply pipe sealant and connect gas supply hose a to manifold e 2 Connect gas supply hose a to propane tank a 3 Open propane tank valve 4 Check for leaks 5 Verify gauge PSI Gauge should read 3 PSI 1 If higher than 4 PSI slightly open torch valve and recheck FIG 1 ti14128a ti14127a 169 51 e a ti25683a ...

Page 26: ...sure OUT connection of regulator is connected to the fitting 64 See FIG 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 con nected to the pipe elbow 142 See FIG 2 3 Apply pipe sealant to fitting 408 and screw into elbow 401 4 Connect gas tube 118 to fitting 410 Turn con nection until gas tight...

Page 27: ...4 See FIG 3 2 Screw union swivel fitting 323 onto pipe elbow 142 Turn connection until gas tight 3 Add pipe sealant to fitting 408 and screw pipe sub assembly 408 409 410 into elbow 401 Turn connection until gas tight NOTE Make sure IN connection of regulator is con nected to the pipe elbow 142 See FIG 3 4 Apply pipe sealant to bushing 406 Screw gauge 402 into tee 409 Turn connection until gas tig...

Page 28: ...2 Turn connection until gas tight 2 Apply pipe sealant to fitting 323 and screw into gas regulator 152 Turn connection until gas tight NOTE Make sure IN connection of regulator is con nected to fitting 323 See FIG 7 3 Screw swivel union 323 onto upstream pipe elbow 142 which is now connected to gas regulator 152 Turn connection until gas tight NOTE Make sure IN connection of regulator is con necte...

Page 29: ...et fasten ers 104 109 Unscrew six screws 115 See FIG 4 5 Remove burner assembly 6 Remove snap rings 75 from gas manifold See FIG 4 Installation 1 Install burner manifold in mounting bracket 104 109 Secure with snap rings 75 See FIG 4 2 Install burner assembly with mounting bracket to bead dispenser 3 Connect burner hose 98 to valve fitting 151 4 Connect gas supply hose 99 to propane tank 5 Open ma...

Page 30: ... fasteners 146 and remove front housing 20 6 Remove screed burners 7 Remove gas manifold snap ring 75 8 Unscrew gas manifold less burners mounting bracket fasteners 146 and remove burner assem bly less burners from front screed housing 20 Installation 1 Install gas manifold less screed burners in bracket support manifold 52 and screw gas manifold mounting bracket to front screed housing 20 with fa...

Page 31: ...ap 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 ti17073a 146 20 ti17072a 32 ti14411b 99 ti14127a ...

Page 32: ... 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 fit ting 60 and screw on adapter fitting 363 Install washer on orifice 60 3 Apply pipe sealant to 1 8 in NPT thread of adapter fitting 363 and screw into gas manifold ...

Page 33: ...mperature 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 fit ting 60 and screw on adapter fitting 363 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 ...

Page 34: ... 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 32 Install 1 See Screed Burner Install page 32 403 12 407 99 ti21960a ...

Page 35: ... man ual Strong wind blowing flame out 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 regu lators if clearing line with forced air see page 6 Kettle gas safety valve not functioning correctly Replace part if it fails diagnostic test see page 6 Thermopile not functioning correctly Replace part if it ...

Page 36: ...ty valve not functioning correctly Replace part if it fails diagnostic testing see page 6 Kettle main burner does not turn on Kettle temperature control dial is not turned to a setting higher than material temperature Turn kettle temperature control dial to a set ting 25 F 13 9 C minimum higher than material temperature Kettle temperature control not functioning cor rectly Replace part see Parts m...

Page 37: ...ettle Remove material in kettle and CAREFULLY dislodge and remove foreign material ControlFlow gate valve difficult to open or close Cold material temperature Heat material to operating temperature Make sure thermometer is free to move Gate sticking in guides Check for excess material in guides Apply heat as required and remove excess mate rial Add grease to lubricate guides Bushings are worn Repl...

Page 38: ... 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 21 Bead dispenser doors not fully open Open door fully Moisture in beads Remove wet beads Dry hopper bead hoses ...

Page 39: ...y Insufficient adhesion material bulges at beginning of line Material temperature too low ThermoLazer speed too fast Debris on road Surface temperature too cold Raise material temperature Decrease speed of ThermoLazer Clear debris from road Wait for temperature of surface to raise Rough and bumpy line Debris on surface Crust from overheated material Debris caught in screed box Material not coverin...

Page 40: ...rial applied too cold Material applied too thin Repair cracks Lower temperature in material Increase material temperature Slow ThermoLazer speed to apply thicker material Rough edges and lines in surface Material temperature is too low Material is overheated or scorched Moisture in road surface Raise material temperature Lower material temperature Wait until road surface is dry Jagged line ends ma...

Page 41: ...Piping Diagram 3A1320L 41 Piping Diagram ThermoLazer 200 ti25754a ...

Page 42: ...Piping Diagram 42 3A1320L ThermoLazer 200TC ti25755a ...

Page 43: ...1320L 43 ThermoLazer 300TC ProMelt ti25756b 0 5 psi 034 bar ThermoLazer 300TC 3 psi 0 21 bar ThermoLazer ProMelt 24H622 24H625 ONLY 24H624 ONLY Plug 24H625 ONLY 20 psi 1 38 bar ThermoLazer 300TC and ThermoLazer ProMelt ...

Page 44: ...Wiring Diagram 44 3A1320L Wiring Diagram ThermoLazer 200TC ti24841a Gas Safety Valve Thermopile White Wire Thermopile Red Wire Wire Harness Wire Harness Thermostat Thermopile ...

Page 45: ...Wiring Diagram 3A1320L 45 ThermoLazer 300TC ti17214a Thermostat Thermopile Wire Harness Wire Harness Gas Safety Valve Pulse Igniter Igniter Electrode Thermopile White Wire Thermopile Red Wire ...

Page 46: ... 3A1320L 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 ...

Page 47: ...3 100 000 29 3 Screed box front burner sum of 3 burners 27 000 7 9 27 000 7 9 27 000 7 9 27 000 7 9 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 30 2 193 000 56 6 157 000 46 0 263 000 77 1 Gas 20 9 1 20 9 1 20 30 9 1 13 6 Main kettle 200 91 300 136 Thermoplastic traffic marking compound materials Bead hopper 40 18 90 40 Type II glass bead Maximum op...

Page 48: ...e 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 m...

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