Graco 3A1696C User Manual

Repair

RoadLazer™ RoadPak™ 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. Save these instructions.

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Table of Contents

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

Component Identification . . . . . . . . . . . . . . . . . . . . 5

Component Function . . . . . . . . . . . . . . . . . . . . . . . 6

Pressure Relief Procedures . . . . . . . . . . . . . . . . . . 7

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . 8

Drain Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Refilling Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Compressor Belt and Hydraulic Pump Belt . . . . . 9

Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Belt Installation . . . . . . . . . . . . . . . . . . . . . . . . . 10

Hydraulic Pump Replacement . . . . . . . . . . . . . . . 12

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Compressor Replacement . . . . . . . . . . . . . . . . . . 14

Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Engine Replacement . . . . . . . . . . . . . . . . . . . . . . . 16

Engine Removal . . . . . . . . . . . . . . . . . . . . . . . . 16

Engine Installation . . . . . . . . . . . . . . . . . . . . . . . 17

Junction Box Circuit Board Replacement . . . . . . 18

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Schematics - 24F472, Controller . . . . . . . . . . . . 25

Schematics -16G161, Cable, Gun Arm . . . . . . . 26

Schematics - 16G049, Valve Air Solenoid . . . . . 27

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 28

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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, 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.

WARNING

WARNINGWARNINGWARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and can

ignite or explode if spilled on hot surface.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths

(potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are

present.

• Ground all equipment in the work area. See Grounding instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you

identify and correct the problem.

• Keep a working fire extinguisher in the work area.

SKIN INJECTION HAZARD

High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate SURGICAL TREATMENT.

• Keep clear of fluid outlet and leaks.

• Use guns, hoses and other components with pressure ratings equal to or higher than the pump rating.

• Follow the Pressure Relief Procedure before servicing or cleaning.

• Do not point dispensing device at anyone or at any part of the body.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow

the Pressure Relief Procedure and disconnect all power sources.

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Warnings

WARNING

WARNINGWARNINGWARNING

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.

• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all

equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and

follow the Pressure Relief Procedure when equipment is not in use.

• 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 distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or over bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

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 MSDSs to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. This equipment includes but is not limited to:

• Protective eyewear, and hearing protection.

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

CALIFORNIA PROPOSITION 65

The engine exhaust from this product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm.

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Component Identification

H AD

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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 Provides a means for hydraulic reservoir ventilation, oil check, and fill

Pressure Drain Valve Relieves Fluid Pressure when open

Fluid Inlet Displacement Pump entry for fluid from the paint drums (paint drums not shown)

Hydraulic Reservoir Holds 4 gallons (15.1 liters) of hydraulic oil for the hydraulic pump

Slide Beam Supports the spray gun boom arm

Bead Tank

Air Regulator Allows regulation of the bead tank air pressure

Programmable Skipline Controller Allows the user to program the operation of the RoadLazer

I/O Cable Carries electronic control signals from the Controller to the RoadLazer

18 HP Engine Powers the hydraulic pump and the air compressor

Hydraulic Pressure Control Knob Provides adjustment of hydraulic pressure (clockwise increases pressure)

Spray Gun Boom Arm Allows striping on either side of the vehicle at adjustable distances

Bead Spray Gun Sprays beads when commanded by the Controller

Paint Spray Gun Sprays fluid when controller by the Controller

Fuel Tank Holds 6 gallons (23 liters) of gasoline

Air Accumulator Tank Helps reduce air temperature from compressor and increases pop-off valve life

Battery Provides power to start the Engine and Control Box

2 in. Hitch Receiver (not provided) Needed to hook-up the gun arm to the back of a truck

Hitch Insert Allows the user to connect the gun arm to a single hitch vehicle

Mounting Bracket Allows the user to connect the gun arm mount to the optimum height

Gun Arm Mount Supports the main beam and the gun arm

Hydraulic Valve Valve to shut off/on the hydraulic fluid to the hydraulic motor

Compressor Provides an air supply for the solenoids and pressurizes the bead tanks

Slide in Mounting Frame Allows user to connect the gun arm to the RoadPak frame

RoadPak Pointer System Allows the user an alignment tool

Air Pressure Quick Release Allows the user to use pressurized air

Electrical Junction Box Allows the user access to electrical system

Holds up to 38 gallons of reflective materials or element for single or double drop beading

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Pressure Relief Procedures

INJECTION HAZARD

The system pressure must be manually relieved to prevent the system from starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:

• are instructed to relieve the pressure

• stop spraying

• check or service any of the system equipment

• install or clean the spray tip

Pressure Relief Procedures

5. Close paint gun ball valves.

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6. Open all drain valves, one at a time.

7. Close valves immediately to prevent paint from drying in system.

8. Shut off engine.

FIRE AND EXPLOSION HAZARD

When Flushing system, always connect grounding cord.

RPS 2900 Pump Fluid Pressure Relief

1. Set hydraulic valve to OFF position.

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2. Run engine at half throttle.

3. Place empty pail under paint guns to catch drainage.

NOTE: If you suspect that the spray gun or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, very slowly loosen the hose end coupling, and relieve pressure gradually. Then loosen it completely. Then clear the valve or hose.

Bead System Pressure Relief

1. Relieve air pressure in bead tank by turning bead system valve to OFF position.

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Air System Pressure Relief

1. Relieve air pressure in air tank by turning air valve to OPEN position.

4. Relieve hose pressure through guns. Use Programmable Skipline Controller to trigger each gun for at least 3 seconds each.

NOTE: Always relieve pressure with the guns--not with the filter drain valves.

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Changing Hydraulic Oil

Drain Oil

1. Use a funnel to drain oil into a drain pan. If a funnel is not available, remove the gas tank and place a drain pan under the oil tank.

2. Unscrew reservoir drain plug (126e) and drain oil from reservoir.

126e

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Refilling Oil

1. Replace drain plug (126e).

2. Fill tank with Graco hydraulic oil, ISO 46. NOTE: Tank holds approximately 4 gallons. Check dipstick to ensure oil level is at an acceptable level.

3. Replace gas tank if removed.

4. Run the unit and recheck hydraulic oil level. Add oil if necessary.

(cold)

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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.

145

5. Remove three screws (1) and two nuts (15) and bolts (22) from front belt guard.

108

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2. Loosen four mounting bolts on compressor to reduce compressor belt tension.

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3. Remove four screws (1) and two nuts (15) from top belt guard (108).

108

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6. Remove four nuts (15) and bolts (14) from top fan guard (104) and remove guard.

104

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