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Graco RoadLazer RoadPak Manual

Line striping system
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Repair
RoadLazer
Line Striping System
- For the Application of Road Marking and Reflective Coatings -
2900 psi (20 MPa, 200 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
™
RoadPak
- For Professional Use Only -
™
3A1696D
EN
ti15835b

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Summary of Contents for Graco RoadLazer RoadPak

  • Page 1 Repair ™ ™ RoadLazer RoadPak 3A1696D 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.

  • Page 2: Table Of Contents

    Installation ......13 Graco Standard Warranty ....28...

  • Page 3: Warnings

    Warnings Warnings The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama- tion 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, 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.
  • Page 4 Warnings WARNING 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 component. See Technical Data in all equipment manuals.

  • Page 5: Component Identification

    Component Identification Component Identification ti15836b 3A1696D...

  • Page 6: Component Function

    Component Function Component Function RPS 2900 Hydraulic Pump Provides fluid to be sprayed through the spray gun Stow Bracket Pin Secures the spray gun boom arm when the RoadLazer is in transport mode Fluid Outlet Supplies fluid from the displacement pump to the spray gun Fluid Filter Filters fluid between the fluid source and the spray gun Breather Cap...

  • Page 7: Pressure Relief Procedures

    Pressure Relief Procedures Pressure Relief Procedures 5. Close paint gun ball valves. INJECTION HAZARD The system pressure must be manually relieved to pre- vent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury.

  • Page 8: Changing Hydraulic Oil

    1. Use a funnel to drain oil into a drain pan. If a funnel 1. Replace drain plug (126e). is not available, remove the gas tank and place a 2. Fill tank with Graco hydraulic oil, ISO 46. drain pan under the oil tank. NOTE: Tank holds approximately 4 gallons. Check 2.

  • Page 9: Compressor Belt And Hydraulic Pump Belt

    Compressor Belt and Hydraulic Pump Belt Compressor Belt and Hydraulic Pump Belt 4. Remove top belt guard (108). Belt Removal NOTE: In order to remove the compressor belt, the hydraulic pump belt must first be removed. 1. Remove air line (145) from compressor. ti16821a 5.

  • Page 10: Belt Installation

    Compressor Belt and Hydraulic Pump Belt Belt Installation 7. Remove eight screws from side guard (105) and remove guard. 1. Install new compressor belt (102) if necessary. ti17368a 8. Remove two screws from engine muffler bracket. ti17362a 2. Install hydraulic pump belt (103). ti17361a 9.
  • Page 11 Compressor Belt and Hydraulic Pump Belt 4. Visually inspect and make sure belts will be properly 9. Install side guard (105) by tightening eight screws. lined up when engine is tightened. 5. Tighten four nuts (5) and bolts (3) to secure engine in place.

  • Page 12: Hydraulic Pump Replacement

    Hydraulic Pump Replacement Hydraulic Pump Replacement 7. Remove nuts (13) and bolts (12) from pump frame. Removal 1. Perform Pressure Relief Procedures, page 7. 2. Drain and Change Hydraulic Oil, page 8. 3. Remove hydraulic pump belt, see Compressor ti16826a Belt and Hydraulic Pump Belt Removal, page 9.

  • Page 13: Installation

    Hydraulic Pump Replacement Installation 1. Install fittings (115, 116, 127) from old pump onto 4. Replace large pulley (96) on hydraulic pump shaft. new pump. Torque fittings (116, 127) to 600 +/1 10 in-lb (67.8 N•m). Torque fitting (115) to 450 in-lb (50.8 N•m) ti16831a 5.

  • Page 14: Compressor Replacement

    Compressor Replacement Compressor Replacement 5. Remove top belt guard (108). Removal 1. Perform Pressure Relief Procedures, page 7. 2. Remove are line (145) from compressor. ti16821a 6. Remove belt from compressor pulley. If belts needs to be replaced, see Compressor Belt and Hydrau- lic Pump Belt Replacement, page 9.

  • Page 15: Installation

    Compressor Replacement Installation 5. Tighten four nuts (5) and bolts (12) to secure com- pressor. 1. Apply high temperature thread sealant to threads of 6. Install top belt guard (108) by tightening four screws relief valve and screw in relief valve to new air com- (1) and two nuts (15).

  • Page 16: Engine Replacement

    Engine Replacement Engine Replacement 6. Remove belts, see Compressor Belt and Hydrau- lic Pump Belt Replacement, page 9. 7. Remove four bolts (3) from the engine (which will also disconnect the ground wire). Engine Removal 1. Perform Pressure Relief Procedure, page 7. 2.

  • Page 17: Engine Installation

    Engine Replacement Pulley Installation 5. Connect positive red wire (90) to engine. 1. Position new pulley on 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 18: Junction Box Circuit Board Replacement

    Junction Box Circuit Board Replacement Junction Box Circuit Board Replacement 7. Remove circuit board (178) from junction box (179). Installation Removal 1. Insert circuit board (178) into junction box (179). 2. Replace four screws (38) and two screws (37) to 1.

  • Page 19: Troubleshooting

    Troubleshooting Troubleshooting Before you proceed with Troubleshooting, perform Pressure Relief Procedure, page 7. 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 20 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 Turn off air pressure. Remove nozzles and clean out any plug- ging.
  • Page 21 Troubleshooting PROBLEM CAUSE SOLUTION Paint guns not turning off immediately Valve needed Spray needle with light coat of lubricant. or at all Use air hose or water hose to break up and remove solidified beads. Replace needle, seat, and packings (see Repair Kit 238339).
  • Page 22 Troubleshooting Programmable Skipline Controller PROBLEM CAUSE SOLUTION Check fuse located next to 12V Controller not turning on Fuse, battery, or wiring RoadLazer battery. Check battery voltage. Replace if necessary. Inspect wiring at battery for corro- sion. Inspect control cable for dam- age.
  • Page 23 Troubleshooting Air and Bead System PROBLEM CAUSE SOLUTION See Air Compressor Belt Replace- Belts squealing during engine startup Compressor belt needs tightening or ment, page 9. replacing Fill bead tank with beads or turn off air Paint guns not spraying when empty All of air supplied by air compressor is supply to bead tank.
  • Page 24 Waterborne paints will not redissolve. Dried paint film in paint containers or paint suction lines must be removed. Graco offers a Suction Line Strainer Kit 24G774 that should be installed at least 2 ft from pump inlet to remove contamination.

  • Page 25: Wiring Diagrams

    Wiring Diagrams Wiring Diagrams Schematics - 24F472, Controller Control Cable Diagram for RoadPak System Contact Description Action 12 VDC Supply Voltage Leave Open- Do Not Connect Leave Open- Do Not Connect Sensor, pump (1) Input Sensor, pump (2) Input Paint Gun (1) Solenoid 1 Output (1 amp Max) S TE S TA...

  • Page 26: Schematics -16G161, Cable, Gun Arm

    Wiring Diagrams Schematics -16G161, Cable, Gun Arm 16G161, Cable, Gun Arm 16G161, Cable, Gun Arm BLUE ORANGE WHITE/BLACK RED/BLACK WHITE GREEN/BLACK ORANGE/BLACK BLACK GREEN 3A1696D...

  • Page 27: Schematics - 16G049, Valve Air Solenoid

    Wiring Diagrams Schematics - 16G049, Valve Air Solenoid 16G049, Valve, Air Solenoid PIN Description Wheel Sensor Power +12VDC Wheel Sensor Ground 2 3 4 (Gun On) Wheel Sensor Signal 15E943, Senor Distance (Gun Off) 16G049, Valve, Air Solenoid F-1/4” QC. ARM-UP SAFETY SWITCH F-1/4”...

  • Page 28: 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.

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