Repair RoadLazer™ RoadPak™ Line Striping System 3A1696C EN - 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.
Table of Contents Table of Contents Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component Identification . . . . . . . . . . . . . . . . . . . . 5 Component Function . . . . . . . . . . . . . . . . . . . . . . . 6 Pressure Relief Procedures . . . . . . . . . . . . . . . . . . 7 Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . 8 Drain Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Refilling Oil . . . . . . . . . . . . . . . . . . . . .
Warnings 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.
Warnings 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. • 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.
Component Identification Component Identification L AG A M E K V N AC H AD D F Q A W C U G AH P Y AA B Z AE AB R J AF T S 3A1696C ti15836a 5
Component Function Component Function 6 A RPS 2900 Hydraulic Pump Provides fluid to be sprayed through the spray gun B Stow Bracket Pin Secures the spray gun boom arm when the RoadLazer is in transport mode C Fluid Outlet Supplies fluid from the displacement pump to the spray gun D Fluid Filter Filters fluid between the fluid source and the spray gun E Breather Cap Provides a means for hydraulic reservoir ventilation, oil check, and fill F Pressure Drain Valve Relieves Fluid Pressure whe
Pressure Relief Procedures Pressure Relief Procedures 5. Close paint gun ball valves. 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.
Changing Hydraulic Oil Changing Hydraulic Oil Drain Oil Refilling 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. 1. Replace drain plug (126e). 2. Unscrew reservoir drain plug (126e) and drain oil from reservoir. 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.
Compressor Belt and Hydraulic Pump Belt Compressor Belt and Hydraulic Pump Belt 4. Remove top belt guard (108). 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 ti16821a 5. Remove three screws (1) and two nuts (15) and bolts (22) from front belt guard. 22 ti17366a 15 2. Loosen four mounting bolts on compressor to reduce compressor belt tension. ti16820a 1 ti17364a 3.
Compressor Belt and Hydraulic Pump Belt 7. Remove eight screws from side guard (105) and remove guard. Belt Installation 1. Install new compressor belt (102) if necessary. 105 102 ti17368a 8. Remove two screws from engine muffler bracket. ti17362a 2. Install hydraulic pump belt (103). ti17361a 9. Loosen four nuts (5) and bolts (3) which secure engine to relieve tension on hydraulic pump belt. 3 103 ti17363a 3.
Compressor Belt and Hydraulic Pump Belt 4. Visually inspect and make sure belts will be properly lined up when engine is tightened. 9. Install side guard (105) by tightening eight screws. 5. Tighten four nuts (5) and bolts (3) to secure engine in place. Visually inspect and make sure hydraulic belt is properly aligned. Repeat until proper alignment is achieved. 105 3 ti17368a 10. Install top fan guard (104) by tightening four bolts (14) and nuts (15). 15 5 104 14 ti17365a 6.
Hydraulic Pump Replacement Hydraulic Pump Replacement 7. Remove nuts (13) and bolts (12) from pump frame. 13 Removal 1. Perform Pressure Relief Procedures, page 7. 2. Drain and Change Hydraulic Oil, page 8. 3. Remove hydraulic pump belt, see Compressor Belt and Hydraulic Pump Belt Removal, page 9. 4. Unscrew suction line connections to hydraulic pump. Place a container under hoses to catch any dripping oil. ti16826a 12 8. Remove hydraulic pump (95). 95 ti16825a ti16823a 5.
Hydraulic Pump Replacement Installation 1. Install fittings (115, 116, 127) from old pump onto 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) 4. Replace large pulley (96) on hydraulic pump shaft. 97 116 96 95 127 ti16831a 5. Align pulley (96) on shaft. 6. Replace set-screw (97). Tighten and torque to 60 +/- 2 in-lb (6.8 +/- 0.2 N•m). 115 ti16827a NOTE: Fill pump casing with hydraulic oil before installing fitting (115). 2.
Compressor Replacement Compressor Replacement 5. Remove top belt guard (108). 108 Removal 1. Perform Pressure Relief Procedures, page 7. 2. Remove are line (145) from compressor. 145 ti16821a 6. Remove belt from compressor pulley. If belts needs to be replaced, see Compressor Belt and Hydraulic Pump Belt Replacement, page 9. ti17366a 3. Remove four screws (1) and two nuts (15) securing top belt guard (108). 15 7. Unscrew relief valve assembly from the old compressor. ti17369a 1 108 ti16822a 4.
Compressor Replacement Installation 5. Tighten four nuts (5) and bolts (12) to secure compressor. 1. Apply high temperature thread sealant to threads of relief valve and screw in relief valve to new air compressor. 6. Install top belt guard (108) by tightening four screws (1) and two nuts (15). 12 108 ti16829a 7. Install air line (145) to compressor. ti17378a 2. Hand-tighten four bolts (12) and nuts (5) to hold compressor (100) and belt guard (101) to frame. ti17370a 145 ti17366a 3.
Engine Replacement Engine Replacement 6. Remove belts, see Compressor Belt and Hydraulic 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. Disconnect ground terminal of battery, then disconnect the positive terminal. 3. Disconnect white and yellow electrical wires located behind muffler. 83 3 ti17384a 8.
Engine Replacement 5. Connect positive red wire (90) to engine. Pulley Installation 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). 3. Tighten set screw (21). Torque to 60 +/- 2 in-lb (25.4 N•m). ti17380a 90 Engine Installation 1. Use a lift ring to turn the engine and insert it into the frame. 6. Connect yellow and white electrical wires behind muffler. 2.
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). 1. Disconnect ground terminal of battery and then disconnect positive terminal of battery. 2. Replace four screws (38) and two screws (37) to secure circuit board to junction box (179). 2. Remove red and black wires from battery area. 179 3.
Troubleshooting Troubleshooting Before you proceed with Troubleshooting, perform Pressure Relief Procedure, page 7. Check everything in the troubleshooting tables before you disassemble any equipment.
Troubleshooting PROBLEM Bead guns not spraying CAUSE Paint guns and bead guns Bead tank air valve Nozzles plugged Solenoid valves Programmable Skipline Controller Actual line length not matching programmed line length Out of calibration SOLUTION If paint guns and bead guns are not working, check paint guns first. Turn bead tank valve ON 1. Turn off air pressure. 2. Remove nozzles and clean out any plugging. 3.
Troubleshooting PROBLEM Paint guns not turning off immediately or at all CAUSE Valve needed SOLUTION 1. Spray needle with light coat of lubricant. Use air hose or water hose to break up and remove solidified beads. 2. Gun arm wobbling or hopping excessively Swivel nut Replace needle, seat, and packings (see Repair Kit 238339). Gun arm wobbles 1. Remove dust cap (547). 2. Tighten boom arm swivel nut (504) until swivel has slight restriction.
Troubleshooting Programmable Skipline Controller PROBLEM Controller not turning on Controller shutting down or cutting out during striping System Delay not turning on Controller not displaying MPH (KM/H), or readout is erratic System Delay actual distance not precisely matching programmed distance 22 CAUSE Fuse, battery, or wiring Battery or wiring System not configured for striping or is shut off Gun arm sensor or sensor wiring SOLUTION 1. Check fuse located next to 12V RoadLazer battery. 2.
Troubleshooting Air and Bead System PROBLEM CAUSE SOLUTION See Air Compressor Belt Replacement, page 9. Belts squealing during engine startup Compressor belt needs tightening or replacing Paint guns not spraying when empty bead tank is empty Fill bead tank with beads or turn off air All of air supplied by air compressor is rushing out of bead gun nozzles. In turn, supply to bead tank. system air pressure cannot build enough to trigger guns. This is normal.
Troubleshooting Kohler Engine PROBLEM CAUSE Engine not starting SOLUTION Programmable Skipline Controller is shut off, or engine is out of fuel 1. Turn on Programmable Skipline Controller. Engine will not start with control off. 2. Check fuel supply. 3. See Kohler engine instruction manual. Engine fuel tank is empty or not breath- 1. ing, or engine oil is low. 2. Engine stalling Check fuel supply. Open breather on fuel tank. Check engine oil level. See Kohler engine instruction manual.
Wiring Diagrams Wiring Diagrams Schematics - 24F472, Controller Control Cable Diagram for RoadPak System Contact Description Action 12 VDC Leave Open- Do Not Connect Leave Open- Do Not Connect Sensor, pump (1) Sensor, pump (2) Paint Gun (1) Solenoid 1 Paint Gun (2) Solenoid 3 Paint Gun (3) Solenoid 5 Bead Gun (1) Solenoid 2 Bead Gun (2) Solenoid 4 Bead Gun (3) Solenoid 6 Engine Shutdown (ground) Ground ** Ground ** Ground ** Sensor Distance Ground ** Leave Open- Do Not Connect Supply Voltage Input Inp
Wiring Diagrams Schematics -16G161, Cable, Gun Arm 16G161, Cable, Gun Arm 26 10 BLUE 8 6 ORANGE 6 5 WHITE/BLACK 5 4 RED/BLACK 4 3 WHITE 3 2 GREEN/BLACK 2 1 ORANGE/BLACK 1 9 RED 8 BLACK 7 GREEN 19418-0022 & 19420-0002 FEMALE TERMINALS 19418-0024 & 19420-0002 FEMALE TERMINALS 16G161, Cable, Gun Arm 3A1696C
Wiring Diagrams Schematics - 16G049, Valve Air Solenoid 16G049, Valve, Air Solenoid 1 (Gun On) 2 3 4 5 6 PIN 1 2 3 Description Wheel Sensor Power +12VDC Wheel Sensor Ground Wheel Sensor Signal A 15E943, Senor Distance B (Gun Off) 3 16G049, Valve, Air Solenoid F-1/4” QC. 19435-0814 & 19417-0028 MALE TERMINALS F-1/4” QC.
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.
