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Graco RoadLazer RoadPak, Repair Manual

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Graco RoadLazer RoadPak Repair Manual Download Page 2

Table of Contents 

2

3A5385A

Table of Contents

Warnings   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification  . . . . . . . . . . . . . . . . . . . . 6
Component Function   . . . . . . . . . . . . . . . . . . . . . . .  7

Grounding  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Pressure Relief Procedure  . . . . . . . . . . . . . . . . .  8

Changing Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . 10

Drain Oil   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10
Refilling Oil  . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10

Compressor Belt and Hydraulic Pump Belt   . . . .  11

Belt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . .  11
Belt Installation  . . . . . . . . . . . . . . . . . . . . . . . . .  13

Hydraulic Pump Replacement  . . . . . . . . . . . . . . .  18

Removal  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  18
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  20

Compressor Replacement   . . . . . . . . . . . . . . . . . . 23

Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Engine Replacement  . . . . . . . . . . . . . . . . . . . . . . . 27

Engine Removal   . . . . . . . . . . . . . . . . . . . . . . . . 27
Engine Installation  . . . . . . . . . . . . . . . . . . . . . . . 29

Junction Box Circuit Board Replacement  . . . . . . 30

Removal   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Wiring Diagrams   . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Schematics - 24S169, Controller . . . . . . . . . . . . 39

Graco Standard Warranty  . . . . . . . . . . . . . . . . . . . 40

Summary of Contents for RoadLazer RoadPak

Page 1: ...sional 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 3A5384 Installation Operation 3A5386 Parts 3A5385A EN ...

Page 2: ...or Belt and Hydraulic Pump Belt 11 Belt Removal 11 Belt Installation 13 Hydraulic Pump Replacement 18 Removal 18 Installation 20 Compressor Replacement 23 Removal 23 Installation 25 Engine Replacement 27 Engine Removal 27 Engine Installation 29 Junction Box Circuit Board Replacement 30 Removal 30 Installation 31 Troubleshooting 32 Wiring Diagrams 39 Schematics 24S169 Controller 39 Graco Standard W...

Page 3: ...g into pail Do not use liners unless they are anti static or conductive Stop operation immediately if static sparking occurs or you feel a shock 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 spray is able to inject toxins into the body and cause serious injury that can result in amputation In th...

Page 4: ...hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations 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 th...

Page 5: ...es and burns Protective 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 WARNING WARNING WARNING ...

Page 6: ...Component Identification 6 3A5385A Component Identification ...

Page 7: ...k holds 4 gallons 15 1 liters of hydraulic oil for the hydraulic pump RoadPak HD holds 8 gallons 30 28 liters of hydraulic oil for the hydraulic pump T I O Cable Carries electronic control signals from the Controller to the RoadLazer W Programmable Skipline Controller Allows the user to program the operation of the RoadLazer X Breather Cap Provides a means for hydraulic reservoir ventilation oil c...

Page 8: ...ch 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 TI3058A This equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as skin injection splash ing fluid and moving parts follow Pressure Relief Proce...

Page 9: ...SLOWLY loosen the tip guard retaining nut or the hose end coupling and relieve pres sure gradually b Loosen the nut or the coupling completely c Clear the obstruction in the hose or tip Bead System Pressure Relief 1 Relieve air pressure in bead tank by turning bead system valve to OFF position Air System Pressure Relief and Condensation Drain 1 Relieve air pressure and drain condensation in air ta...

Page 10: ...nscrew reservoir drain plug 126e and drain oil from reservoir Refilling Oil 1 Replace drain plug 126e 2 Fill tank with Graco synthetic hydraulic oil ISO 46 NOTE Small tank holds approximately 4 gallons Large tank holds approximately 8 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 necessar...

Page 11: ... remove the compressor belt the hydraulic pump belt must first be removed 1 Perform Pressure Relief Procedure page 8 2 Remove air line 145 from compressor 3 Loosen four mounting bolts on compressor to reduce compressor belt tension 4 Remove six screws 1 and two nuts 15 from top belt guard 108 5 Remove top belt guard 108 ...

Page 12: ...Remove three screws 1 and two nuts 15 and bolts 22 from front belt guard 7 Remove four nuts 15 and bolts 14 from top fan guard 104 and remove guard 8 Remove eight screws from side guard 105 and remove guard 9 Remove two screws from engine muffler bracket ...

Page 13: ... which secure engine to relieve tension on hydraulic pump belt 11 Tilt engine back and remove hydraulic pump belt 103 Loop belt around the cooling fan 12 If installing a new compressor belt remove old com pressor belt 102 Belt Installation 1 Install new compressor belt 102 if necessary ...

Page 14: ...lic Pump Belt 14 3A5385A 2 Install hydraulic pump belt 103 Ensure all belt ribs are aligned with corresponding pulley grooves 3 Make sure compressor belt 102 is looped around the engine pulley idler pulley and compressor pul ley ...

Page 15: ... is tightened 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 align ment is achieved 6 Tighten four nuts 5 and bolts 12 so compressor is level Before completely tightening bolts tension compressor belt 102 by shifting compressor to the right ...

Page 16: ...nd bolts 12 to secure com pressor in place ensuring pulley is aligned with idler and engine pulley 8 Install two screws securing muffler bracket to engine 9 Install side guard 105 by tightening eight screws 10 Install top fan guard 104 by tightening four bolts 14 and nuts 15 ...

Page 17: ... Pump Belt 3A5385A 17 11 Install front belt guard 107 by tightening three screws 1 and two nuts 15 and bolts 22 12 Install top belt guard 108 by tightening four screws 1 and two nuts 15 13 Install the air line 145 to the compressor ...

Page 18: ...ressor Belt and Hydraulic Pump Belt Removal page 11 4 Unscrew inlet and outlet line connections to hydrau lic pump Place a container under hoses to catch any dripping oil 5 Insert 3 8 diameter pin to prevent pulley from rotat ing Loosen keyless bushing on front of large pulley 96 6 Loosen four nuts 5 and bolts 3 which secure engine to relieve tension on hydraulic pump belt ...

Page 19: ...nt 3A5385A 19 7 Remove pulley 96 from hydraulic pump shaft Remove idler pulley 101 if necessary 8 Remove nuts and bolts from pump frame 9 Remove hydraulic pump 10 Remove fittings from pump and set aside to use on the new pump ...

Page 20: ... Not doing so may cause internal damage to the pump at start up NOTICE To prevent premature failure of the keyless bushing and or pump shaft Do not use impact of any kind to move it along the shaft Loosen move re torque Ensure bushing bore and pump shaft are com pletely free of paint grease oil and debris of any kind Thoroughly clean using non petroleum based solvent isopropyl alcohol Pump shaft m...

Page 21: ...5 Replace pulley bushing assembly 96 onto hydrau lic pump shaft Ensure inside gripping area of bush ing spans across the pump shaft key way and the shaft is inserted to or past the groove in bushing 6 Align pulley 96 on shaft Place pin through pulley and pump plates then torque keyless bushing to a maximum of 100 ft lb RoadPak and 125 ft lb RoadPak HD ...

Page 22: ... compressor belt 102 first then install hydraulic pump belt 103 see Compressor Belt and Hydraulic Pump Belt Installation page 11 8 Install hydraulic fluid lines to the hydraulic pump and tighten fittings 9 Refill Hydraulic Supply System see page 10 ...

Page 23: ...emoval 1 Perform Pressure Relief Procedures page 8 2 Remove air line 145 from compressor 3 Remove six screws 1 and two nuts 15 securing top belt guard 108 4 Loosen four mounting bolts on compressor to reduce compressor belt tension 5 Remove top belt guard 108 ...

Page 24: ... 24 3A5385A 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 ...

Page 25: ...bolts 12 and nuts 5 to hold new compressor 100 and belt guard 101 to frame 3 Loop compressor belt 102 onto idler pulley engine pulley and compressor pulley NOTE Make sure belt is in the proper groove and is not twisted 4 Tighten four nuts 5 and bolts 12 so that compressor is level Before completely tightening the bolts tension compressor belt 102 by shifting compressor to the right ...

Page 26: ...Compressor Replacement 26 3A5385A 5 Tighten four nuts 5 and bolts 12 to secure compres sor 6 Install top belt guard 108 by tightening four screws 1 and two nuts 15 7 Install air line 145 to compressor ...

Page 27: ... located behind muffler 4 Disconnect the positive red wire 90 attached to the engine 5 Disconnect gas line 130e and the evaporation line 130g from the engine 6 Remove belts see Compressor Belt and Hydraulic Pump Belt Replacement page 11 7 Remove four bolts 3 from the engine which will also disconnect the ground wire 89 8 Use a lift ring to lift and turn the engine 83 to remove it from the frame Se...

Page 28: ...n the center of pulley 4 Remove pulley 85 from engine Pulley Installation 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 3 Tighten set screw 21 Torque to 60 2 in lb 25 4 N m 4 Install fan 88 to pulley 85 Note proper fan orienta tion Torque screws 11 to 125 in lb ...

Page 29: ... hand tighten four bolts 3 into engine 3 Replace belts see Compressor Belt and Hydraulic Pump Belt Replacement page 11 4 Connect evaporation line 130e and connect gas line 130g 5 Connect positive red wire 90 to engine 6 Connect yellow and white electrical wires behind muf fler 7 Connect positive terminal of battery then connect ground terminal ...

Page 30: ...nect positive terminal of battery 2 Remove red and black wires from battery area 3 Unplug control cable and gun arm cable from junction box 179 4 Disconnect pump counter wires 5 Disconnect white and yellow wires behind engine muf fler 6 Remove four screws 38 two screws and bushing 37 from junction box 179 7 Remove circuit board 178 from junction box 179 ...

Page 31: ... 38 two screws 37 and bush ing to secure circuit board to junction box 179 3 Reconnect pump counter wires and engine wires Plug in control cable and gun arm cable 4 When all maintenance is finished reattach battery con nections NOTICE Make sure control cable and gun arm cable have proper strain relief to prevent damage to connections ...

Page 32: ...rizontal NOTE Unloader bypasses air when system pressure reaches approxi mately 115 120 psi 8 bar 2 Turn off bead tank air valve 184 to isolate system 3 If no leaks check paint gun actuation air lines Paint gun actuation airline 1 Remove actuation air lines from paint gun 2 Trigger skipline controller 3 If air flows from airline repair paint gun manual 308613 If air does not flow check solenoid va...

Page 33: ... Skipline Controller manual 3A5387 2 Remove solenoid valve cover 19 3 Check for broken wiring or a damaged plug see Wiring Diagram page 39 4 Check for 12V DC between red wire and ground Programmable Skipline Controller 1 Go to diagnostic screen and make sure all switches are properly working manual 3A5387 2 Inspect wiring and plugs for damage 3 Replace any damaged wiring or plugs man ual 3A5387 Ac...

Page 34: ...lubricant Use air hose or water hose to break up and remove solidified paint 2 Replace needle seat and packings Repair Kit 238339 Gun arm wobbling or hopping excessively Swivel nut Gun arm wobbles 1 Remove dust cap 47 2 Tighten boom arm swivel nut until swivel has slight restriction Gun arm hops 1 Lower air pressure in gun arm wheel 2 Replace damaged gas shock 7 Excessive overspray on gun arm whee...

Page 35: ...y will not turn on unless you are ready to stripe 2 Go to Quick Setup and set System Delay to ON manual 3A5387 page 28 Controller not displaying MPH KM H or readout is erratic Gun arm sensor or sensor wiring 1 Check sensor 24 located on gun arm wheel assembly Set sensor approxi mately 1 8 in 3 mm from target plate 2 Check sensor head for damage Replace if damaged 3 Check sensor wiring by removing ...

Page 36: ...h on top of unloader valve 148 is turned hori zontally 2 Move silver switch on top of unloader valve 148 up and down This might loosen a sticky valve 3 Replace unloader valve 148 Beads not dispensing properly Excessive water or moisture in bead tank 1 Only pressurize reflective materials when dispensing Small air leaks at gun nozzle or air fittings cause mois ture to be pumped continuously into ta...

Page 37: ...ified 1 Never store RoadLazer with reflec tive materials in tank for long periods of time 2 If bead level is low enough open bead tank access port on side and use a rod to break apart beads 3 Remove aluminum fitting from bottom of tank Flush out solidified beads 4 Use air hose or water hose to break up and remove solidified beads from tank Completely dry tank before refilling PROBLEM CAUSE SOLUTIO...

Page 38: ...SO 46 synthetic hydraulic oil with a viscosity index VI of 154 or greater PROBLEM SOLUTION Do not know what type of paint to use When ordering paint from manufacturer Inform paint suppliers of type of equipment to be used RoadLazer filter screen sizes 30 mesh and tip sizes 33 to 45 thousands Require that paint must pass through a 30 mesh filter with minimal filter plugging Things to know about wat...

Page 39: ...Wiring Diagrams 3A5385A 39 Wiring Diagrams Schematics 24S169 Controller ...

Page 40: ...t disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy...

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