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Graco RoadLazer RoadPak Repair Manual

Line striping system for the application of road marking and reflective coatings for professional use only
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See also: Operation & Installation Manual
Repair
RoadLazer
Line Striping System
For the Application of Road Marking and Reflective Coatings. For Professional Use Only.
2900 psi (20 MPa, 200 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this manual and in related manuals.
Be familiar with the controls and the proper usage of the equipment.
Save these instructions.
Related Manuals:
Installation &
3A5384
Operation
3A5386
Parts
™
RoadPak
™
& RoadPak
™
HD
3A5385A
EN

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Summary of Contents for Graco RoadLazer RoadPak

  • Page 1 Repair RoadLazer ™ RoadPak ™ & RoadPak ™ 3A5385A Line Striping System For the Application of Road Marking and Reflective Coatings. For Professional Use Only. 2900 psi (20 MPa, 200 bar) Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual and in related manuals. Be familiar with the controls and the proper usage of the equipment.

  • Page 2: Table Of Contents

    Removal ......18 Graco Standard Warranty ....40 Installation .

  • Page 3: Warnings

    • This system is capable of producing 2900 psi (200 bar, 20 MPa). Use Graco parts or accessories that are rated a minimum of 2900 psi (200 bar, 20 MPa).
  • Page 4 Warnings WARNING WARNING WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury. • Do not operate the unit when fatigued or under the influence of drugs or alcohol. • Do not exceed the maximum working pressure or temperature rating of the lowest rated system com- ponent.
  • Page 5 Warnings WARNING WARNING 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. Protective equipment includes but is not limited to: •...

  • Page 6: Component Identification

    Component Identification Component Identification 3A5385A...

  • Page 7: Component Function

    Component Function Component Function Air Regulator Allows regulation of the bead tank air pressure 36 gallon or 120 gallon bead tank. Holds reflective materials or element for single Bead Tank or double drop beading Air Accumulator Tank Helps maintain consistent air power to accessories Hydraulic Valve Valve to shut off/on the hydraulic fluid to the hydraulic motor Fluid Filter...

  • Page 8: Grounding

    Component Function Grounding Pressure Relief Procedure Follow the Pressure Relief Procedure when- ever you see this symbol. The equipment must be grounded to reduce the risk of static sparking. Static sparking can cause fumes to ignite or explode. Grounding provides an escape wire for the electric current.
  • Page 9 Component Function Bead System Pressure Relief 5. Close paint gun ball valves. 1. Relieve air pressure in bead tank by turning bead system valve to OFF position. ti15953a 6. Open all drain valves, one at a time. ti16550a 7. Close valves immediately to prevent paint from dry- ing in system.

  • Page 10: Changing Hydraulic Oil

    Changing Hydraulic Oil Changing Hydraulic Oil Refilling Oil 1. Replace drain plug (126e). 2. Fill tank with Graco synthetic hydraulic oil, ISO 46. Drain Oil NOTE: Small tank holds approximately 4 gallons. Large tank holds approximately 8 gallons. Check 1. Use a funnel to drain oil into a drain pan. If a funnel dipstick to ensure oil level is at an acceptable level.

  • Page 11: Compressor Belt And Hydraulic Pump Belt

    Compressor Belt and Hydraulic Pump Belt Compressor Belt and Hydraulic Pump Belt 4. Remove six screws (1) and two nuts (15) from top belt guard (108). Belt Removal NOTE: In order to remove the compressor belt, the hydraulic pump belt must first be removed. 1.
  • Page 12 Compressor Belt and Hydraulic Pump Belt 6. Remove three screws (1) and two nuts (15) and 8. Remove eight screws from side guard (105) and bolts (22) from front belt guard. remove guard. 9. Remove two screws from engine muffler bracket. 7.

  • Page 13: Belt Installation

    Compressor Belt and Hydraulic Pump Belt Belt Installation 10. Loosen four nuts (5) and bolts (3) which secure engine to relieve tension on hydraulic pump belt. 1. Install new compressor belt (102) if necessary. 11. Tilt engine back and remove hydraulic pump belt (103).
  • Page 14 Compressor Belt and Hydraulic Pump Belt 2. Install hydraulic pump belt (103). Ensure all belt ribs 3. Make sure compressor belt (102) is looped around are aligned with corresponding pulley grooves. the engine pulley, idler pulley and compressor pul- ley. 3A5385A...
  • Page 15 Compressor Belt and Hydraulic Pump Belt 4. Visually inspect to make sure belts and pulleys will 5. Tighten four nuts (5) and bolts (3) to secure engine be properly aligned when engine is tightened. in place. Visually inspect and make sure hydraulic belt is properly aligned.
  • Page 16 Compressor Belt and Hydraulic Pump Belt 7. Tighten four nuts (5) and bolts (12) to secure com- 9. Install side guard (105) by tightening eight screws. pressor in place, ensuring pulley is aligned with idler and engine pulley. 10. Install top fan guard (104) by tightening four bolts 8.
  • Page 17 Compressor Belt and Hydraulic Pump Belt 11. Install front belt guard (107) by tightening three 12. Install top belt guard (108) by tightening four screws screws (1) and two nuts (15) and bolts (22). (1) and two nuts (15). 13. Install the air line (145) to the compressor. 3A5385A...

  • Page 18: Hydraulic Pump Replacement

    Hydraulic Pump Replacement Hydraulic Pump Replacement 5. Insert 3/8” diameter pin to prevent pulley from rotat- ing. Loosen keyless bushing on front of large pulley (96). Removal 1. Perform Pressure Relief Procedures, page 8. 2. Drain Oil, page 10. 3. Remove hydraulic pump belt, see Compressor Belt and Hydraulic Pump Belt Removal, page 11.
  • Page 19 Hydraulic Pump Replacement 7. Remove pulley (96) from hydraulic pump shaft. 9. Remove hydraulic pump. Remove idler pulley (101) if necessary. 8. Remove nuts and bolts from pump frame. 10. Remove fittings from pump and set aside to use on the new pump.

  • Page 20: Installation

    Hydraulic Pump Replacement Installation 1. Install fittings from old pump onto new pump. 3. Install bolts and nuts. Torque to 225 +/- 10 in-lb Tighten all fittings to ensure no leaking occurs (25.42 N•m). during operation. NOTICE Fill pump casing with hydraulic oil before installing top case drain fitting.
  • Page 21 Hydraulic Pump Replacement 4. Slide keyless bushing into pulley, ensure bushing is 6. Align pulley (96) on shaft. Place pin through pulley centered in the hub, then hand tighten to hold its and pump plates, then torque keyless bushing to a position.
  • Page 22 Hydraulic Pump Replacement 7. Install compressor belt (102) first, then install 8. Install hydraulic fluid lines to the hydraulic pump and hydraulic pump belt (103) (see Compressor Belt tighten fittings. and Hydraulic Pump Belt Installation, page 11). 9. Refill Hydraulic Supply System, see page 10. 3A5385A...

  • Page 23: Compressor Replacement

    Compressor Replacement Compressor Replacement 4. Loosen four mounting bolts on compressor to reduce compressor belt tension. Removal 1. Perform Pressure Relief Procedures, page 8. 2. Remove air line (145) from compressor. 5. Remove top belt guard (108). 3. Remove six screws (1) and two nuts (15) securing top belt guard (108).
  • Page 24 Compressor Replacement 6. Remove belt from compressor pulley. If belt(s) needs to be replaced, see Compressor Belt and Hydraulic Pump Belt Replacement, page 11. 7. Unscrew relief valve assembly from the old compres- sor. 8. Remove old compressor. 3A5385A...

  • Page 25: Installation

    Compressor Replacement Installation 3. Loop compressor belt (102) onto idler pulley, engine pulley, and compressor pulley. 1. Apply high temperature thread sealant to threads of NOTE: Make sure belt is in the proper groove and is not relief valve and screw in relief valve to new air com- twisted.
  • Page 26 Compressor Replacement 5. Tighten four nuts (5) and bolts (12) to secure compres- 7. Install air line (145) to compressor. sor. 6. Install top belt guard (108) by tightening four screws (1) and two nuts (15). 3A5385A...

  • Page 27: Engine Replacement

    Engine Replacement Engine Replacement 5. Disconnect gas line (130e) and the evaporation line (130g) from the engine. Engine Removal 1. Perform Pressure Relief Procedure, page 8. 2. Disconnect ground terminal of battery, then dis- connect the positive terminal. 3. Disconnect white and yellow electrical wires located behind muffler.
  • Page 28 Engine Replacement Pulley Removal Pulley Installation 1. Remove fan (88) from pulley (85). 1. Position pulley (85) on new engine. 2. Install bolt (19), washer (4), and lock washer (20) in center of pulley. Torque to 125 +/- 10 in-lb (14.1 +/- 1.1 N•m).

  • Page 29: Engine Installation

    Engine Replacement Engine Installation 5. Connect positive red wire (90) to engine. 1. Use a lift ring to turn the engine and insert it into the frame. 2. Connect ground wire (89) and hand-tighten four bolts (3) into engine. 6. Connect yellow and white electrical wires behind muf- fler.

  • Page 30: Junction Box Circuit Board Replacement

    Junction Box Circuit Board Replacement Junction Box Circuit Board Replacement 5. Disconnect white and yellow wires behind engine muf- fler. Removal 1. Disconnect ground terminal of battery and then discon- nect positive terminal of battery. 2. Remove red and black wires from battery area. 3.

  • Page 31: Installation

    Junction Box Circuit Board Replacement Installation 3. Reconnect pump counter wires and engine wires. Plug in control cable and gun arm cable. 1. Insert circuit board (178) into junction box (179). NOTICE Make sure control cable and gun arm cable have proper strain relief to prevent damage to connections.

  • Page 32: Troubleshooting

    Troubleshooting Troubleshooting Before you proceed with Troubleshooting, perform Pres- sure Relief Procedure, page 8. Check everything in the troubleshooting tables before you disassemble any equipment. Paint Guns and Bead Guns PROBLEM CAUSE SOLUTION Paint guns not spraying Clogged tips Clean tips Fuse (20A) is blown Check 20A fuse between engine and solenoid air valve connector.
  • Page 33 Troubleshooting PROBLEM CAUSE SOLUTION Bead guns not spraying Paint guns and bead guns If paint guns and bead guns are not working, check paint guns first. Bead tank air valve Turn bead tank valve ON Nozzles plugged 1. Turn off air pressure, see Bead System Pressure Relief, page 9.
  • Page 34 Troubleshooting PROBLEM CAUSE SOLUTION Bead guns not synchronizing Out of calibration 1. Follow calibration in Programmable Skipline with paint guns Controller manual 3A5387. 2. If beads start before paint, add delay time to Bead ON Delay. If paint starts before beads, add equal delay time to both Paint ON and Paint OFF Delays (this does not affect paint skip line length).
  • Page 35 Troubleshooting Programmable Skipline Controller PROBLEM CAUSE SOLUTION Controller not turning on Fuse, battery, or wiring 1. Check fuse located next to 12V RoadLazer battery. 2. Check battery voltage. Charge or replace if necessary. 3. Inspect wiring at battery for corrosion. Inspect control cable for damage.
  • Page 36 Troubleshooting Air and Bead System PROBLEM CAUSE SOLUTION Belts squealing during engine Compressor belt needs tightening or See Compressor Belt and Hydraulic startup replacing Pump Belt, page 11. Paint guns not spraying when bead All of air supplied by air compressor Fill bead tank with beads or turn off air tank is empty is rushing out of bead gun nozzles.
  • Page 37 Troubleshooting PROBLEM CAUSE SOLUTION Low system pressure Excessive air leaks 1. Fix all air leaks before they become a problem. Air leaks can eventually starve system air supply. 2. Most air leaks occur at bead tank out- let fitting. If fitting leaks air, com- pletely remove it and use thread tape and liquid thread sealant before rein- stalling it.
  • Page 38 Keep piston throat full of TSL. • If possible, shorten lines to reduce pump back pressure. • Use Graco strainer at pump inlet to filter out dried paint and debris. • Inspect internal suction hoses for paint build-up, which can cause pump starving. •...

  • Page 39: Wiring Diagrams

    Wiring Diagrams Wiring Diagrams Schematics - 24S169, Controller 3A5385A...

  • Page 40: 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:

Roadpak hd

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