Operation RoadLazer™ RoadPak™ Tow-Behind System U.S. Patent No. 5,368,232 and 5,947,385 Chinese Patent ZL97111289.4 Brazilian Patent No. PI9701899-6 3A2091C EN - For the application of road marking and reflective coatings - For professional use only - List of Models (see page 2) 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 Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Complete Assemblies . . . . . . . . . . . . . . . . . . . . . 3 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Introduction and General Information . . . . . . . . . . 7 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 General Information . . . . . . . . . . . . . . . . . . . . . . 7 Component Identification . . . . . . . . . . . . . . . .
Models Models Ref. Model Number Description 1 24G624 1 Pump RoadPak 2 24G625 2 Pump RoadPak 3 24G628 1 Pump RoadPak Gun Arm 4 24G629 2 Pump RoadPak Gun Arm 5 24G630 Adjustable Gun Arm Beam 6 24G632 Programmable Skipline Controller 7 24G633 RoadView™ Camera System 8 24G634 Simple Guide System 9 24M255 Siphon and Drain Hose Extension Kit (Waterborne) 10 16M239 RoadPak Trailer (mounting parts not included) 11 239692 Hitch Receiver Kit (class 4, 2 in.
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 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.
Warnings WARNING WARNING 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.
Introduction and General Information Introduction and General Information Introduction Simple Guide System This manual and those supplied provide pre-setup requirements, parts lists, setup, operation, and maintenance instructions for the RoadLazer RoadPak Tow-Behind System. This manual includes instructions for a 2-pump system. For 1-pump systems, all parts remain the same with the exception of plugged ports for missing pumps and hoses.
Component Identification Component Identification B A AC Y W C AK T AL D S R AB E F P G H M N J K L AN AJ AR AM AP ti18135a AE AD AG 8 AF 3A2091C
Component Function Component Function A Air Regulator Allows regulation of the bead tank air pressure B Bead Tank Holds up to 36 gallons (136 liters) of reflective materials or element for single or double drop beading C Air Accumulator Tank Helps reduce air temperature from compressor D Hydraulic Valve Valve to shut off/on the hydraulic fluid to the hydraulic motor E Fluid Filter Filters fluid between the fluid source and the spray gun F Pressure Drain Valve Relieves fluid pressure when o
Pre-Setup Requirements Pre-Setup Requirements Tow Vehicle Requirements Receivers • Tow vehicle with minimum wheel base (front to back) of 130 in (330 cm). • Tow vehicle with minimum rated payload capacity of 3500 lb (1588 kg). NOTE: Tongue weight (TW) of Tow-Behind System is 1000 lb (454 kg). Two Graco clamp-on receivers must be mounted 36 in. (91 cm) on center on the installed DRAW-TITE Class IV Ultra Frame Hitch. See Hitch Receiver Kit for mounting instructions, pages 11 and 12.
Hitch Receiver Kit: 238944 (Standard) Hitch Receiver Kit: 238944 (Standard) Installation Instructions for Hitch Kit 238944 (straight cross tube) 1 Torque to 220-240 ft-lb (298-325 N•m) Ref. 1 2 DRAW-TITE® Class IV Ultra-Frame tow hitch is not included. Cross tubes must be 3 in. x 3 in. (7.6 cm x 7.6 cm) square. 2 Part Description 113665 SCREW, cap, hex head, grade 8; 5/8-11 unc-2a; 4.5 in. (11.4 cm) 113980 NUT, lock, hex, grade 8; 5/8-11 unc-2b Qty. 6 6 A 2 7246c 18 in. 36 in.
Hitch Receiver Kit: 239692 (Optional) Hitch Receiver Kit: 239692 (Optional) Installation Instructions for Hitch Kit 239692 (angled cross tube) 1 Torque to 220-240ft-lb (298-325 N•m) Ref. 1 2 DRAW-TITE® Class IV Ultra-Frame tow hitch is not included. Cross tubes must be 3 in. x 3 in. (7.6 cm x 7.6 cm) square 2 A Part Description 113665 SCREW, cap, hex head, grade 8; 5/8-11 unc-2a; 4.5 in. (11.4 cm) 113980 NUT, lock, hex, grade 8; 5/8-11 unc-2b Qty. 6 6 2 1 1 18 in. 2 36 in.
Setup Setup Connect Tow-Behind to Vehicle Charge Battery If the battery is newly purchased or has not been used for a long time, charge it before you use it. If the wheels are not rotated to the rear of the trailer, it can become unstable and tip over if the tow vehicle is removed, causing serious injury. Grounding Instructions Only remove the Tow-Behind system from its tow vehicle when the wheels are facing the rear of the trailer and are blocked on both sides. 1.
Setup 2. Connect trailer to ball mounts: a. Back tow vehicle into trailer and align ball mounts with trailer arms. g. Rotate jack to horizontal position. Insert safety pins into place to secure jacks. b. Crank trailer arm jacks to clear ball mounts. ti18141a 3. Shorten each safety chain: a. Unscrew nut fastening chain to RoadLazer. ti18139a c. Move tow vehicle backward and align ball mounts under trailer arms. d. Crank trailer arm jacks to lower RoadPak trailer arms onto ball mounts. b.
Setup Gun Arm Beam Bracket Gun Arm Stow Bracket 1. Center Gun Arm Beam Bracket on trailer cross-member as shown and install supplied bolts and nuts as shown. Torque to 215-235 in-lb (24.3-26.5 N•m). NOTE: Install Gun Arm Stow Bracket before mounting RoadPak to trailer. 1. Align stow bracket with mounting holes. 2. Install and tighten four bolts and washers (use one washer on each side of each bolt). Torque bolts to 28 ft-lb (38 N•m).
Setup Installing RoadLazer onto Trailer After loading the RoadPak on the trailer, secure the RoadPak to the trailer using the supplied bolts, nuts, and washers. Torque bolts to 28 ft-lb (38 N•m). Replace rear jack. If RoadPak is not properly secured to trailer, it can fall off of trailer and cause serious injury. Use only Graco supplied fasteners and tighten them to the required torque. Use all of the fasteners provided.
Setup Adjustable Gun Arm Installation (24G628, 24G629) Install Safety Switch and Gun Arm Stow Plate 1. Position the gun arm next to the vehicle. 2. Pull the gun arm beam out to the side of the vehicle where the gun arm is located. Lift the gun arm and hold the traverse bracket in the position shown below. Slide the beam through the wheels so they are mounted on the track of the gun arm beam as shown below. 1. Remove two nuts and washers from safety switch bracket and remove from gun arm. ti18147a 2.
Setup 5. Hand-tighten two mounting nuts but allow enough movement to make slight adjustments once in place. ti18148a 6. Connect safety switch wires. ti18154a ti18152a NOTICE Use cable ties to secure wires to gun arm. System will not operate if wires become damaged. 8. Measure gap between safety switch and stowing bracket. NOTE: If gap is less than 0 in. or greater than 3/16 in. (4.7 mm) use a mallet to tap stowing bracket to create a proper gap.
Setup ti18159a ti18157a 10. Align safety switch bracket so safety switch is aligned with stowing bracket as shown and tighten nuts.
Setup Hose Routing to Pumps and Tanks ti18153a 20 3A2091C
Setup Filter Orientation 1. Use a hammer to loosen the large jam nut on the pump assembly. 1. Pull gun arm beam out to one side of the vehicle. Pull gun arm out and lower it to make sure the hose bundle has been secured at the proper location to ensure full movement for the gun arm to move from one side to the other. Make adjustments as needed. ti16782a ti18276a 2. Rotate the filter assembly to the desired orientation and use a hammer to tighten the jam nut and lock the assembly into place. 2.
Setup Hose Connection 1. Modify suction hoses by loosening the hose clamps and separating the flexible hose from the bent siphon tube. Install barbed coupler and extension hose as shown. 5. Install paint lines to RPS 2900 filter assemblies. For a two color system, route the hose from paint gun 1 to pump 1 and route one hose from paint gun 2 to pump 1. Route the second hose from paint gun 2 to pump 2. ti18278a ti16446a 2.
Setup Electrical Cable Connections 1. Connect gun arm cable to the junction box. Fasten cable to cable clamp for strain relief (S) on the connection. ti16596a S 3. Route the control cable to the cab of the vehicle without pinching the cable. Connect the cable to the Programmable Skipline Controller. Route cable through the cable clamp for strain relief on the connection. ti16601a 2. Connect control cable to the junction box. Fasten cable to cable clamp for strain relief (S) on the connection.
Setup Notes 24 3A2091C
Setup 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 Input Output
Setup 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 3A2091C
Setup 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.
Setup Install Simple Guide System 1. Locate an area on the vehicle to mount the Simple Guide System that will allow the user to see the indicator rod from the driving position or with the help of the RoadView Camera System. 5. Slide support bar (351) through brackets (355) and tighten fasteners to secure in place. 355 351 ti17000a 6. Assemble extension clamp to support bar. ti16408a 2. If needed, drill two 9/16 in. holes in the desired location. 3.
Operation Operation 5. Close paint gun ball valves. Pressure Relief Procedure 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.
Operation Emergency Shut Off To shut down the entire Tow-Behind system, set POWER ON/OFF on the Programmable Skipline Controller to the OFF position. Set Up Adjustable Gun Arm Beam and Gun Arm 1. Unlock gun arm clamp and gun arm beam clamps. Load Reflecting Materials 1. Set POWER ON/OFF on Programmable Skipline Controller to OFF. 2. Set RoadPak engine ignition key to OFF. 3. Relieve air system pressure by opening ball valve until gauge reads 0. 4.
Operation Prepare System to Paint 6. Check oil level in compressor. NOTE: If red dot is visible, add oil. Initial Settings 1. Attach Tow-Behind System ground clamp to earth ground. See Grounding Instructions, page 13. 2. Fill throat packing nut with TSL to prevent premature packing wear. Do this each time you spray and store. 7. Verify all hose/fitting connections are tight. 8. Turn hydraulic lines to closed position. Approximate Fill Level ti5240a 3. Check engine oil level.
Operation ti16553a ti16547a 13. Turn pressure control counterclockwise to lowest pressure. 11. Turn prime valve down. ti16552a 12. Install clean inlet strainer. NOTE: There must be a minimum of 0.5 in. (1.3 cm) between bottom of strainer and suction tube.
Operation Start Engine 3. When flushing fluid comes out of return lines, set hydraulic valve to OFF position. 1. Set POWER ON/OFF on Programmable Skipline Controller to ON. 2. Set engine to choke position ON. 3. Set throttle to half speed and turn key. ti15838a 4. Place suction hoses in paint drums. 4. After engine starts, set choke to OFF. Select/Prime Pumps ti16645a 1. Open hydraulic valves to activate pumps. 5. Open hydraulic valves to activate pumps. ti16920a ti16920a 2.
Operation Prime Guns Turn on Bead System 1. Close air valve to pressurize air system. 1. Turn bead system valve to ON position. ti16959a 2. Open only spray gun ball valves corresponding to paint pumps or color used. NOTE: Never open both ball valves on the two-color gun at the same time. Paint color contamination could result. ti16549a 2. Set desired bead tank pressure by turning regulator knob. ti15657a 3. Turn guns on with Programmable Skipline Controller (see Skipline Controller manual). + 4.
Operation Flushing the System 5. Place paint return lines in empty pail. 6. Open all paint pump dump valves. When flushing system, always connect grounding cord to reduce the risk of fire and explosion. ti16552a NOTE: Use only compatible solvents to flush system. 1. Perform Pressure Relief Procedure, see page 29. 2. Attach Tow-Behind System with grounding clamp to earth ground. NOTE: The grounding clamp is required for safe RoadPak operation. The grounding clamp is for stationary use only. 3.
Operation 16. When flushing fluid comes out of spray gun, set hydraulic valve to OFF position. 11. Close dump valves. 17. Turn off guns with Programmable Skipline Controller. 18. Shut off engine and Programmable Skipline Controller. ti16551a 19. Leave paint pump dump valves and spray gun ball valves open. 12. Open only spray gun ball valves corresponding to paint pumps or color used. NOTE: Never open both valves on the two-color gun at the same time. Paint color contamination could result. 20.
Operation Securing Gun Arm for Transportation 4. Put stow bracket pin through gun arm stowing bracket and plate. Secure with attached clip. . NOTICE Never transport the RoadLazer while the paint gun ball valves are open, the system is under pressure, and the engine is running, as this could cause accidental discharge. ti18157a 5. Unlock two red-handled clamps and center the gun arm beam on the trailer. 1. Perform Pressure Relief Procedure, page 29. 2. Unlock gun arm red-handled clamp on gun arm beam.
Removing RoadLazer from Vehicle Removing RoadLazer from Vehicle A free-standing RoadLazer RoadPak Tow-Behind System could become unstable when being moved without a tow vehicle, causing serious injury. To reduce the risk of injury and equipment damage, never move Tow-Behind System without it being properly secured to a tow vehicle. If the wheels are not rotated to the back of the trailer, it can become unstable and tip over if the tow vehicle is removed.
Repair Repair Trailer Tire 3. Crank jack to lift Tow-Behind System wheels off the ground. NOTE: Replace trailer tire when damaged. or tread on tire is 3/32 in. (2.4 mm) or less. Trailer Tire Replacement A free-standing Tow-Behind System could become unstable and fall when raised by the jack, causing serious injury. To reduce the risk of injury and equipment damage: • Connect Tow-Behind System to tow vehicle before raising with jack.
Parts Parts 4 5 6 18 10 17 3 16 15 9 14 13 8 7 19 20 1 12 2 22 11 21 23 24 ti18339a 25 Parts List Ref.
Parts Parts 3 ti18473a 1 2 5 4 Parts List Ref. 1 2 3 4 5 Part Description 16N405 FITTING, 1-1/2 x 1-1/2 hose, barbed 101368 CLAMP, hose 24M136 HOSE, suction, 8.5 ft 867280 CONNECTOR, hose connector, 1/4-18 NPS 24M253 HOSE, coupled, 1/4 in. x 10 ft 3A2091C Qty.
Technical Data Technical Data RoadLazer™ RoadPak™ U.S. Metric Paint 2900 psi 200 bar Hydraulics 1950 psi 134 bar 75 psi 5 bar 4.5 gpm @ 2000 psi 17 lpm @ 138 bar Minimum 80 psi 5.5 bar Maximum 200 psi 14 bar Maximum Working Pressure Glass bead system Maximum paint flow Operating pressure of air-actuated trigger Sound levels - measured at 6.2 ft (2 m) under maximum operating conditions per ISO-3744 Sound power level 111.7 dB(A) Sound pressure level 91.
Notes Notes 3A2091C 43
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.
