Graco 3A2091C User's Manual
Contents
1. Paint drums are heavy and could shift from side to side when the tow vehicle is cornering The paint drums could fall from the vehicle and cause serious injury Secure the drums when the vehicle is moving It is recommended that the paint drums be secured with a paint drum bracket Graco does not provide a paint drum bracket with the Tow Behind System Programmable Skipline Controller The Programmable Skipline Controller must be installed in the cab of the tow vehicle Select a position for ease of operation This controller connects to the RoadPak with an I O cable so there must be cable access from the tow vehicle cab to the RoadPak See manual 3A1215 3A2091C Hitch Receiver Kit 238944 Standard Hitch Receiver Kit 238944 Standard Installation Instructions for Hitch Kit 238944 straight cross tube Ref Part Description Qtv N Torque to 220 240 ft Ib 298 325 Nem 1 113665 SCREW cap hex head 6 grade 8 5 8 11 unc 2a DRAW TITE Class IV Ultra Frame tow 4 5 in 11 4 cm hitch is not included Cross tubes must be 2 113980 NUT lock hex grade 8 6 3 in x 8 in 7 6 cm x 7 6 cm square 5 8 11 unc 2b Ma NE ge ud 36 in NOTE For the nearest DRAW TITE installer call 1 800 428 7303 1 Have a DRAW TITE Class IV Ultra Frame tow NOTE Pre torque each of the screws to set the hitch or equivalent hitch with a 7500 Ib 3401 kg hitch receiver in place GTW rating and 3 in x 3 in 7 6 cm x 72. 10 Tow Vehicle Requirements 10 Hitch Requirements 10 HOCOIVOIS ae st iran dies 10 Paint Drum 10 Programmable Skipline Controller 10 Hitch Receiver Kit 238944 Standard 11 Installation Instructions for Hitch Kit 238944 straight GFOSS TUDE edd hoses a esto dee eet 11 Hitch Receiver Kit 239692 Optional 12 Installation Instructions for Hitch Kit 239692 angled COSS UDG 0 2 beside a DOR ade eect 12 SCUD g pee LII DE DUE EE LM EE 13 Charge Battery 13 Grounding Instructions 13 Level Draw Bar with Tow Behind System 13 Connect Tow Behind to Vehicle 13 liralef TIEOS 2 1 ba tug Ea in ea en ee eee es 14 Gun Arm Beam Bracket 15 Gun Arm Stow 15 Installing RoadLazer onto Trailer 16 Adjustable Gun Arm Beam Installation 246630 16 Adjustable Gun Arm Installation 245628 246629 17 Install Safety Switch and Gun Arm Stow Plate 17 Hose Routing to Pumps and Tanks 20 21 HOSO ROUINO 2 3 3 87 t ROI fa B 21 bua Ross gb adu dd s ara du ade aom aad ud dua di wa 23 LHP 24 Wiring Diagrams eee 25 Schematics 24F472 Controller 25 Schematics 16G161 Cable Gun Arm 26
3. MO V A S 16G049 Valve Air Solenoid F 1 4 QC ARM UP F 4 Qc SAFETY SWITCH RED 12vdc FROM BATTERY MAC VALVES 6 BLACK GROUND SWITCHED AT CONTROLLER SOLENOID F BEAD 3 5 BLACK GROUND SWITCHED AT CONTROLLER 4 BLACK GROUND SWITCHED AT CONTROLLER 3 BLACK GROUND SWITCHED AT CONTROLLER SOLENOID E BEAD 3 SOLENOID D BEAD 2 SOLENOID C BEAD 2 2 BLACK GROUND SWITCHED AT CONTROLLER CKIGROUND SWIT See SOLENOID B BEAD 1 00 N D kul N qe St v St v 00 E LM e St v Uu i L L oc H LLI 1 BLACK GROUND SWITCHED AT CONTROLLER CKIGROUND SWIK Sue SOLENOID A BEAD 1 i 1 RED 12vcd 2 BLACK GRD Td oJ EST 1 GREEN SIGNAL ti17511b 3A2091C 27 Setup Install Simple Guide System 5 Slide support bar 351 through brackets 355 and tighten fasteners to secure in place 1 Locate an area on the vehicle to mount the Simple Guide System that will allow the user to see the indi cator rod from the driving position or with the help of the RoadView Camera System ti17000a 6 Assemble extension clamp to support bar ti16408a 2 If needed drill two 9 16 in holes in the desired loca ti16925a tion 7 Insert indicator rod 362 into g
4. OSes RON e Q2 RO ee S x RS ZG S LEREKRKS SS IRS KRRNWNNANNMANA KRACK IKK eteta satata tetetete 50009 0005050 PION KID LEK K KI KIRIN ROKK NID OAAAMANMMMANO S CKO OO x USS KM 364969090909 49 9494949 9 9 5 NOSNOSTI SSSI SSS If tow vehicle is a pick up remove tailgate o QD tat QS RD RK RRR KIND RRR RRND RK SORKIN NOTE 21 3A2091C Setup Hose Connection 1 Modifv suction hoses bv loosening the hose clamps 5 and separating the flexible hose from the bent siphon tube Install barbed coupler and extension hose as shown ti18278a 2 Use supplied clamps to secure suction hose to each end of the barbed coupler and to bent siphon tube 6 3 Install modified suction tubes on the RPS 2900 pump and route to paint drum ti16444a 4 Extend return line by adding extra hose length and fitting included in the siphon and drain hose exten sion kit Install return line on the RPS 2900 filter assembly and route back to the paint drum ti16597a 22 ti16445a 7 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 ti16446a Install bead lines to the bead tank ti16598a Install air hose to quick connect fitting o
5. A Compressor Provides an ai suppl forthe solenoids and pressures the beadiarks S Hydraulic Reservoir Holds 4 gallons 15 1 liters of hydraulic oil for the hydraulic pump W PegrammabeSHpineConroler Alows he user to program te operation ofthe Roadlazer Y Air Pressure Quick Connect Allows the user to use pressurized air Stow Bracket Pin Secures the spray gun boom arm when the RoadLazer is in transport mode AC Provides a means for hydraulic reservoir ventilation oil check and fill Supports the RoadPak Gun Arm RoadPak Gun Arm Allows striping on either side of the vehicle at adjustable distances AG Paint Spray Gin Sprays tud when controler by he Conboy AJ AK Gun Arm Siow Bracket Aow upright storage RoasPak Used to hold Tow Behind System upright when disconnected from tow vehicle Trailer Jack l and during storage AN Gun Arm Beam Bracket Supports the slide beam AP Wheel Assembly Supports RoadLazer RoadPak trailer AR RoadLazer RoadPak Trailer Allows user to tow RoadPak behind a vehicle 3A2091C 9 Pre Setup Requirements Pre Setup Requirements Tow Vehicle Requirements e Tow vehicle with minimum wheel base front to back of 130 in 830 cm Tow vehicle with minimum rated payload capacity of 3500 Ib 1588 kg NOTE Tongue weight TW of Tow Behind System is 1000 Ib 454 kg e Tow vehicle with minimum rated capacity of 7500 Ib 3402 kg gross trailer weight GTW e ow hitch wit
6. 6 cm square cross tube installed on your vehicle refer ence DRAW TITE part no series 419XXX 4 Repeating the process from step 2 attach the right hitch receiver 4 to the trailer hitch with the three remaining screws 1 and nuts 2 2 Both of the Graco clamp on receivers mustbe 18in 5 Verify that the centers of the hitch receivers are 36 from the center of the hitch frame A in 91 cm apart Make any necessary adjustments 3 Attach the left hitch receiver 3 to the trailer hitch 6 Torque all of the screws to 220 240 ft Ib 298 325 with three of the supplied screws 1 and nuts 2 Nem 3A2091C 11 Hitch Receiver Kit 239692 Optional Hitch Receiver Kit 239692 Optional Installation Instructions for Hitch Kit 239692 angled cross tube Ref Part Description Qtv N Torque to 220 240ft Ib 298 325 Nem 1 113665 SCREW cap hex head 6 grade 8 5 8 11 unc 2a DRAW TITE Class IV Ultra Frame tow 4 5 in 11 4 cm hitch is not included Cross tubes must be 2 113980 NUT lock hex grade 8 6 3 in x 3 in 7 6 cm x 7 6 cm square 5 8 11 unc 2b X A EF l Po N A m 36 in NOTE For the nearest DRAW TITE installer call 1 800 428 7303 1 Have a DRAW TITE Class IV Ultra Frame tow 4 Repeating the process from step 2 attach the right hitch or equivalent hitch with a 7500 Ib 3401 kg hitch receiver 4 to the trailer hitch with the three GTW rating and 3 in x 3 in 7 6 cm x 7 6 cm remaining sc
7. Schematics 16G049 Valve Air Solenoid 27 Install Simple Guide System 28 Operation i ii i ie ka d E accus 29 Pressure Relief Procedure 29 Emergency Shut Off 30 Load Reflecting Materials 30 Set Up Adjustable Gun Arm Beam and Gun Arm 30 Prepare System to Paint 31 Star ENGINE ee cecal atop di ec dU oU ear 33 Select Prime Pumps 33 Prime GUNS hee eee ees 34 Turn on Bead System 34 Begin to Spray x sex 34 Flushing the System 35 Securing Gun Arm for Transportation 37 Removing RoadLazer from Vehicle 38 wild et Rm 39 Traller DIG i epi A 39 Trailer Tire Replacement 39 General Trailer Service 39 T TIT 40 mew Sees 40 RT eae 41 Parts LIS a 3 felt aa i ht ae Solas teu 41 Technical Data ies ewe eee ae 42 NOIBS pi are tet i alee ee 43 Graco Standard Warranty 44 3A2091C Models Models et wee een O Complete Assemblies 9 2 Pump Tow Behind RoadPak Svstem 2 4 5 6 8 9 x2 10 11 12 Tow Behind Trailer Conversion Kit 9 x2 10 11 12 16N438 2 Pump Tow Behind System with Camera 2 4 5 6 7 8 9 x2 10 11 12 3A2091C 3 Warnings Warnings
8. all tires be sure new tires are from the same manufacturer as existing tires to ensure consistent size General Trailer Service its For any other trailer specific service needs contact IL Graco Technical Service or a certified manufacturer ser vice center ti18338a 3A2091C 39 Parts Parts List Ref OONOOUOkoNnNL 40 Part 24M140 125976 16M018 123982 100696 126023 16M239 125977 125978 108527 100454 101566 100454 16M022 Description KIT repair wheel pneumatic JACK BRACKET slide weldment SCREW cap hex head WASHER wrought NUT hex lock TRAILER Roadpak SCREW cap hex hd WASHER plain wide NUT lock hex SCREW cap hex hd NUT lock SCREW cap hex hd RECEIVER pin slide Qty 19 21 22 23 24 25 ti18339a Part 100023 101566 115473 246624 246625 113696 238301 113467 191099 113451 111040 113304 Description WASHER flat NUT lock PIN hitch MODULE Roadpak 1 pump model 24m143 MODULE Roadpak 2 pump model 24m144 PIN safety GUIDE bracket SCREW cap socket hd CLAMP wedge WASHER wave NUT lock insert nylock 5 16 CLAMP cam over Qty 3A2091C Parts Parts m 3 E ES ti18473a i Parts List Ref Part Description Qtv 1 16N405 FITTING 1 1 2 x 1 1 2 hose 1 barbed 2 101368 CLAMP hose 2 3 24M136 HOSE suction 8
9. o o Hz mw 2 86 lt cs e o O gt oO T ko S a Description lt 2 1 Paint Gun 1 Solenoid 1 2 Bead Gun 1 Solenoid 2 jii L 3 jPaint un 2 Solenoid 3 O 4 Bead Gun 2 Solenoid 4 5 Paint Gun 3 Solenoid 5 24F922 BOARD 6 Bead Gun 3 Solenoid 6 Interconnect 7 Wheel Sensor Signal Wheel Sensor Ground 89 Wheel Sensor Power 12 VDC 10 Solenoid Power 12 VDC dNV v l 1 06 Description TAI 1 Not Used mus f die d 2 JPump Counter Signal m 6 7 8 9 10 Pump Counter Ground Pumper Counter Power 12 VDC 3A2091C 25 Setup Schematics 16G161 Cable Gun Arm 16G161 Cable Gun Arm 16G161 Cable Gun Arm 10 BLUE 8 6 ORANGE 6 a 5 WHITE BLACK 5 a aa T 5 4 RED BLACK 4 35 e s C sz l aS 3 WHITE 3 SE 2 GREEN BLACK 2 A Li a aa a a 1 a 1 ORANGE BLACK 1 v EMI O LL LL 9 RED 8 BLACK 7 GREEN 26 3A2091C Setup Schematics 16G049 Valve Air Solenoid 16G049 Valve Air Solenoid Description Wheel Sensor Power 12VDC Wheel Sensor Ground 3 Wheel Sensor Signal 15E943 Senor Distance TG
10. other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Do not wear loose clothing jewelry or long hair while operating equipment Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources 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 MPa bar PSI 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 ho
11. 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 4 3A2091C Warnings SKIN INJECTION HAZARD High pressure fluid from dispensing device hose leaks or ruptured components will pierce skin This mav look like just a cut but it is a serious injurv 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 anvone or at anv part of the bodv 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
12. 5 ft 1 4 867280 CONNECTOR hose connector 1 1 4 18 NPS 5 24M253 HOSE coupled 1 4 in x 10 ft 1 3A2091C 41 Technical Data Technical Data RoadLazer RoadPak Maximum Working Pressure Paint 2900 psi 200 bar 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 7 dB A 1 Pump RoadPak Complete Tow Behind System 1544 Ib 700 kg 2 Pump RoadPak Complete Tow Behind System 746 kg 24G627 Trailer 254 kg 24G629 2 Pump Gun Arm 134 Ib 61 kg Miscellaneous aa a Hydraulic oil reservoir capacity 4 gallons 15 liters Compressor Oil 9502 SAE 30W 9502 SAE 30W non detergent oil non detergent oil Hydraulic Oil Graco approved 169236 Graco approved 169236 5 gallon 207428 1 gal ISO 46 19 liter 207428 3 8 liter ISO 46 Glass bead capacity 450 Ib 204 kg Kohler is a registered trademark of the Kohler Co Dyna Beads is a registered trademark of Innovative Balancing Add 450 Ib 204 kg for a full glass bead tank Do not install the second bead tank option 42 3A2091C Notes 3A2091C Notes 43 Graco Standard Warrantv 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 Grac
13. A2091C Setup Install Safety Switch and Gun Arm Stow Plate Nu s 0 Remove two nuts and washers from safety switch bracket and remove from gun arm las w til8147a 2 Disconnect two wires on safetv switch and pull wires out of rectangular tube til8147a 3 Reposition and install safety switch bracket as shown ti18150a Install gun arm stow plate as shown ti18147a 17 Setup 5 Hand tighten two mounting nuts but allow enough movement to make slight adjustments once in place til8154a 8 Measure gap between safetv switch and stowing ti18152a bracket NOTE If gap is less than O in or greater than 3 16 in 4 7 mm use a mallet to tap stowing NOTICE bracket to create a proper gap Move safety switch away from this area when adjusting gap Use cable ties to secure wires to gun arm System will not operate if wires become damaged 7 Swing gun arm up and align stow plate in channel of stow bracket Slide gun arm towards center of stow bracket until safety switch aligns with stow bracket as shown NOTE Be sure that the hose bundle does not become caught or pinched when moving gun arm ti18158a 9 Align hole in stow bracket with slot in stow plate install safety pin 18 3A2091C Setup 181598 sej Od By SUE 2 0 oal ti18157a 10 Align safety switch bracket so safet
14. HIS 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 for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties ac
15. N position to activate pumps ti16920a 16 17 18 19 20 When flushing fluid comes out of spray gun set hydraulic valve to OFF position Turn off guns with Programmable Skipline Controller Shut off engine and Programmable Skipline Control ler Leave paint pump dump valves and spray gun ball valves open Remove and secure ground clamp from earth ground 3A2091C Operation Securing Gun Arm for 4 Putstow bracket pin through gun arm stowing bracket and plate Secure with attached clip Transportation v 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 dis charge 1 Perform Pressure Relief Procedure page 29 2 Unlock gun arm red handled clamp on gun arm beam si 16923a d 6 Lockthree red handle clamps to secure the slide P beam and gun arm fl ti16425a 3 Lift gun arm up from ground and push in to center of Tow Behind System 169158 182808 181548 3A2091C 37 Removing RoadLazer from Vehicle Removing Road Lazer 2 Block trailer wheels 3 Disconnect Programmable Skipline Controller from Vehicle trailer lighting suction tubes return lines and any straps that connect RoadLazer or its hose assem blies to t
16. Operation 3 7 RoadLazer RoadPak Tow Behind Svstem U S Patent No 5 368 232 and 5 947 385 3A2091C Chinese Patent ZL97111289 4 Brazilian Patent No PI9701899 6 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 fel 5 a f L FU AUENA 528 Read all warnings and instructions in this manual Save these instructions e Important Safety Instructions Trailer Ratings e Gross Vehicle Weight Rating GVWR 2800 Ib 1270 kg Gross Axle Weight Rating GAWR 1200 Ib 544 kg per axle with 5 70 x 8 tire 8 x 3 75 5 45 rim at 100 psi 690 KPA cold single Tire Ratings Size 5 70 x 8 Load Range D Cold tire pressure 100 psi 690 KPA Lug Torque 90 120 ft Ib 122 163 Nem NOTE This manual replaces the Operation Manual 3A1214 for the standard RoadLazer RoadPak Line Striping System PROVEN QUALITY LEADING TECHNOLOGY Table of Contents Table of Contents leer d D e i ee ee wee 9 Complete Assemblies 3 Warnings Soci Gant DETENER ba sions 4 Introduction and General Information 7 IMTOGUCHON doo ue b eed edes 7 General Information 7 Component Identification 8 Component Function 9 Pre Setup Requirements
17. Rout NOTICE ing Q O p c D Q9 O te Q0 Qn O X gt G G c G O Q Ba O gt c 9 Q9 O O Q G o G o Q o D c 5 O o e O D 5 3203 um O e D 0 ie O O x 5 ee 9 D j Q b 5 B n c o B o SESS di 77 c fo P tim Z O O Oo D pu G L O G I lt x i 2 O o z o D o O S n O O G c G Q c o Underside View place Center the gun arm beam to the vehicle Lock ti18156a the gun arm beam and gun arm into place by 3 Putgun arm back to the stow position and pin it into engaging the clamps for each til8151a SE S 5009090 exo gt KA KA lt 009 e e Q2 C2 KO KO 52505 lt e e e e 2 gt AM Q2 9 Q S55 gt e o5 e Q2 Q2 Q2 Q2 AL CX 0X X X0 X0 CX OOOO E5525 252525250525 25 SSS SSS x Q2 Q2 Q gt gt 90 KO es 09 oS KO 9090 Q2 KO 5505052 Q2 e Q2 Q2 5 z Se KAN KA e S 255 SKS 9090909 Qoo 90906 909090900 9090905 0909 tel AX Q X 9 Q2 a e Q2 9 SS 9 9 Q2 SR 2 Q2 X e Q2 9 lt 9 c2 e 0908 ex 2906 tete RRS ARON x SESS OK 9 Q2 te SSSL RLC PRO tet tat KANA
18. 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 TOWING HAZARD The driver can lose control when pulling trailer if correct equipment is not used The driver and passengers could be seriously injured The vehicle or system may also be damaged Tow vehicle must meet all requirements and load ratings See Tow Vehicle Requirements Clamp on hitch receivers must be installed properly See Tow Hitch Requirements Do not use additional bead or paint tanks on Tow Behind System Clamp on hitch receivers are to be used for towing Graco double hitch equipment only Do not tow any other equipment with these receivers Do not use Tow Behind System trailer for other equipment 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 D 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
19. ack to lift tires and rotate wheels into their correct orientation then lower to ground 8 Move tow vehicle forward to clear ball mounts If all connections between vehicle and trailer have been removed the tow vehicle can be removed from the trailer 9 Crank jacks down equally to bring Tow Behind System to level position for storage lt O 9s VA y p g G 10 Alwavs use rear jack during storage to provide addi Q tional stability ti18281a ti18279a 38 3A2091C Repair Repair Trailer Tire 3 Crank en 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 e Connect Tow Behind System to tow vehicle 1i18336a before raising with jack e Follow Connect Tow Behind to Vehicle instructions page 13 1 Connect Tow Behind System to tow vehicle d cup L ti18140a B ti18337a NOTE Any service station can repair a Tow Behind System flat tire 5 Install new wheel and lug nuts Torque lug nuts to 2 Rotate rear jack to vertical position and install safety 90 120 ft lb 122 163 Nem pin to secure jack NOTE Replace lug nuts in same orientation as when they were removed NOTE If not replacing
20. alve to pressurize air svstem 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 Sy ti15657a Turn guns on with Programmable Skipline Control ler see Skipline Controller manual Place an empty pail under spray guns to catch drainage from spray guns Set hydraulic valve s to ON position to activate pumps ti16920a 6 When paint begins to flow out of guns turn off guns 34 with Programmable Skipline Controller Turn on Bead System Turn bead system valve to ON position ti16549a Set desired bead tank pressure by turning regulator knob ti16910a Hemove and secure ground clamp from earth ground System is now ready for painting Select guns 1 or 2 with the Programmable Skipline Controller Begin to Spray Select appropriate procedure from menu on RoadLazer control system See Skipline Controller manual 3A2091C Operation Flushing the System 5 Place paint return lines in empty pail 6 Open all paint pump dump valves NOTE Use only compatible solvents to flush system 1 Perform Pressure Relief Procedure see page 29 ti16552a 2 Attach Tow Behind System with grounding clampto 7 Turn on Programmable Skipline Controller earth ground NOTE The ground
21. e is removed causing serious injury 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 ZB z is ZNSE e NOS ea 11 TAS EXTA i C A a SA l L P 2 182798 1 Install two ball mounts in hitch receivers a Slide ball mount into hitch receiver ti18138a b Insert pin c Insert clip 13 Setup 2 Connect trailer to ball mounts g Rotate jack to horizontal position Insert safety pins into place to secure jacks a Back tow vehicle into trailer and align ball mounts with trailer arms b Crank trailer arm jacks to clear ball mounts 3 Shorten each safety chain a Unscrew nut fastening chain to RoadLazer Vy ti18139a b Refasten chain to RoadLazer so it connects to Move tow vehicle backward and align ball tow vehicle with minimum slack mounts under trailer arms 4 Connectwires for lights d Crank trailer arm jacks to lower RoadPak trailer 5 If trailer is still attached to shipping pallet remove arms onto ball mounts straps and tow trailer off of pallet Trailer Tires Trailer tires can cause noticeable vibration when out of balance For extended highway use Graco recommends adding 1 oz of Dyna Beads to each wheel Dyna Beads and installation instructions can be found at www innovativebalancing com l p a ti18140a e Sec
22. h minimum rated capacity of 750 Ib 340 kg TW 7500 Ib 3402 kg GTW e Warning lights and or sign board per federal state and local regulations Reference Part IV of the Manual on Uniform Traffic Control Devices MUTCD by the U S Department of Transportation Federal Highway Administration or equivalent regulations for your region e Securing device for paint supply containers e Standard trailer light connector e Ocable access from the tow vehicle cab to the RoadLazer Hitch Requirements Have a DRAW TITE Class IV Ultra Frame tow hitch or equivalent hitch with a 7500 Ib 3402 kg GTW rating and 3 in x 3 in 7 6 cm x 7 6 cm square cross tube installed on your vehicle reference DRAW TITE part no series 419XXX NOTE Tow hitch not supplied by Graco Choose a ball mount that allows the Tow Behind System to travel level to the ground with an average payload A recommended option is two DRAW TITE adjustable 2 in 5 cm ball mounts The ball mount must have a 2 in x 2 in 5 cm x 5 cm insert with at least a 1 in diameter ball mount hole The ball mount hole and shank diameter must match The ball mount must have a rating of at least 5000 Ib 2270 kg GTW 5000 Ib 2270 kg TW 10 Receivers 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 Paint Drum Bracket
23. he RoadPak to the trailer using the supplied bolts nuts and washers Torque bolts to 28 ft lb 38 Nem Replace rear jack ti18137a Adjustable Gun Arm Beam Installation 244690 The gun arm beam is shipped at 87 75 in 2 2 m long to accommodate wider vehicles The beam can be cut down to 75 75 in 1 9 m long or 60 in 1 5 m long to accommodate different vehicle sizes 1 To shorten the beam to 75 75 in 2 2 m cut 12 in 30 cm from the end of the beam towards the next hole on the beam To shorten the beam to 60 in 1 5 m cut 27 75 in 70 cm from the end of the beam towards the third hole as shown below 27 75 in ti6600a 2 After shortening to the desired length slide the beam into the channel in the gun arm beam bracket 3A2091C Adjustable Gun Arm Installation 24G628 244629 il 2 3 Position the gun arm next to the vehicle 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 thev are mounted on the track of the gun arm beam as shown below ti18143a Attach the handle 704 to each end of the gun arm beam Press the cotter pin 707 through the handle to hold it in place Fasten nut 706 and bolt 705 through the slide beam on both ends to act as stops on the channel 708 707 US 6662a 3
24. he tow vehicle Do not disconnect safety chains 4 Remove safety pins and rotate two side jacks and rear jack to vertical position Replace safety pins to secure jacks 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 5 Crank rear jack until jack foot plate touches the never move Tow Behind System without it being ground Crank jack 5 more times to help stabilize properly secured to a tow vehicle trailer while in storage Make sure wheels do not leave the ground If wheels leave the ground lower If the wheels are not rotated to the back of the trailer jacks until all trailer wheels are in contact with the it can become unstable and tip over if the tow vehicle round is removed B Never remove the Tow Behind RoadLazer RoadPak 6 Unlatch ball couplers and crank side jacks to raise from its tow vehicle if the wheels are not facing the trailer arms from ball mounts rear of the trailer NOTE Crank jacks sequentially 3 4 turns per side to ensure the trailer arms are lifted evenly 1 Parkon level concrete surface where Tow Behind keeping the trailer stable System is intended to be parked NOTE Make sure trailer wheels are at the far rear 7 Disconnect safety chains of the trailer as shown If parking the trailer with wheels in this orientation is not possible use rear j
25. ing clamp is NOTE Unit will not start until Controller is turned required for safe RoadPak operation The grounding ON clamp is for stationary use only 115838a 4 Filla grounded 5 gallon 19 liter pail with flushing fluid Place paint suction hose in pail l 6547a b C 8 Start Engine 3 Set pump hvdraulic valves to OFF position 4 Set choke ON Set throttle to half speed Turn key After engine starts set choke to OFF Set throttle to desired speed To reduce the risk of static sparking and splashing always remove the spray tip from the gun and hold a metal part of the gun firmly to the side of a grounded metal pail during flushing 9 Sethydraulic valve to ON position to activate pumps Ll WA ti16920a 10 When flushing fluid comes out of spray gun set hydraulic valve to OFF position 3A2091C 35 Operation 11 12 13 14 15 36 Close dump valves ti16551a 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 Place empty pail under spray guns to catch drainage from spray guns Turn guns on with Programmable Skipline Controller Set hydraulic valves to O
26. knowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com TO PLACE AN ORDER contact your Graco distributor or call 1 800 690 2894 to identify the nearest distributor All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice For patent information see www graco com patents Original instructions This manual contains English MM 3A2091 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES 9 P O BOX 1441 e MINNEAPOLIS MN 55440 1441 USA Copyright 2011 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revised November 2013
27. n air tank L A N 2 S LZ Bi A 3A2091C Electrical Cable Connections 1 Connect gun arm cable to the junction box Fasten cable to cable clamp for strain relief S on the con nection Qu IS a ti16596a Pl 2 Connect control cable to the junction box Fasten cable to cable clamp for strain relief S on the con nection ti16595a S 3A2091C Setup 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 con nection 166018 29 Setup Notes 24 3A2091C Setup Wiring Diagrams Schematics 24F472 Controller Control Cable Diagram for RoadPak Svstem Contact Desorption Reon 1 peve Sup Vortage 72 Leave Open DoNot Connect 3 Leave Open Do Not Connect 6 Paint Gun 7 Solenoid T Output T amp Wax 8 PaimtGun S Solendid5 Output T amp Max 9 Bead Gun 1 Solenoid2 Output T amp Max 712 Engine Shutdown ground 15 4 Ground 15 round 17 Ground Ground TJ 18 Leave Open Do Not Connect Schematics 24F922 BOARD Interconnect O41u02 48 e9rJrc lt D o 2 9 4 m NO 8 6
28. n tube and drain tube in grounded metal 31 Operation 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 32 p b ti16553a 13 Turn pressure control counterclockwise to lowest pressure 169198 3A2091C Start Engine 1 Set POWER ON OFF on Programmable Skipline Controller to ON 2 Setengine to choke position ON 3 Set throttle to half speed and turn key Le E AN A l SOW WAN I gt E 4 After engine starts set choke to OFF Select Prime Pumps 1 Open hydraulic valves to activate pumps 169208 2 Slowly turn pressure control clockwise until pump begins to stroke ti16922a 3A2091C Operation 3 When flushing fluid comes out of return lines set hydraulic valve to OFF position ti15838a 4 Place suction hoses in paint drums a ti16645a 2 169208 6 When paint comes out of return lines set hvdraulic valve to OFF position 7 Close all prime valves ti16551a 8 Place return lines into paint drum 33 Operation Prime Guns 1 Close air v
29. neral Information Introduction This manual and those supplied provide pre setup requirements parts lists setup operation and mainte nance instructions for the RoadLazer RoadPak Tow Behind Svstem 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 General Information The Tow Behind System is attached to a vehicle and is used to apply up to two stripes in one or two colors with glass beading The Tow Behind System consists of a Programmable Skipline Controller Displacement Pumps two Paint Spray Guns and two Bead Spray Guns Programmable Skipline Controller The Programmable Skipline Controller consists of the control box and a 30 ft 9 1 m cable It is the main con trol for the Tow Behind System and turns the spray guns and accessories on and off 3A2091C Simple Guide System The Simple Guide System provides the user with a pointer for alignment on either the left or right side of the vehicle RoadView Camera System optional The RoadView Camera System provides the user with video of a bore sight view for alignment on either the left or right side of the tow vehicle The system consists of a 9 in monitor interfacing cables video camera and mounting bracket RPS 2900 Hydraulic Pumps The RPS 2900 Hydraulic Pump supplies paint to the spray guns There are two displacement pumps Two displacemen
30. o 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 This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not 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 T
31. re with the guns not with the filter drain valves 3A2091C Operation 5 Close paint gun ball valves ti15953a 6 Openall drain valves one at a time 7 Close valves immediately to prevent paint from dry ing in system 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 com pletely 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 ti16550a Air System Pressure Relief 1 Relieve air pressure in air tank by turning air valve to OPEN position 1 D G eel es JP ii ti16961a 29 Operation Emergency Shut Off To shut down the entire Tow Behind system set POWER ON OFF on the Programmable Skipline Con troller to the OFF position Load Reflecting Materials 1 30 Set POWER ON OFF on Programmable Skipline Controller to OFF Set RoadPak engine ignition key to OFF Relieve air system pressure by opening ball valve until gauge reads 0 Relieve air pressure in bead tank by turning bead system valve to OFF position Remove cover from bead tank Screen reflective materials to prevent debris from entering tank Load bead tank with reflec
32. rews 1 and nuts 2 Square cross tube installed on your vehicle refer 5 Verify that the centers of the hitch receivers are 36 ence DRAW TITE part no series 419XXX d in apart Make any necessary adjustments 2 Both ofthe Graco clamp on receivers must be 18 in 6 Torque all of the screws to 220 240 ft Ib 298 325 from the center of the hitch frame A Nem 3 Attach the left hitch receiver 3 to the trailer hitch with three of the supplied screws 1 and nuts 2 NOTE Pre torque each of the screws to set the hitch receiver in place 12 3A2091C Setup Charge Batterv If the battery is newly purchased or has not been used for a long time charge it before you use it Grounding Instructions 1 Attach Tow Behind System ground clamp to earth ground TI3058A Level Draw Bar with Tow Behind System Use the following procedure to ensure level operation of the Tow Behind System 1 Empty tow vehicle of any payload 2 Install draw bar to measure approximately 22 in 56 cm from top of ball mount to ground 6244a 22 in 56 cm NOTE For initial setup leave trailer on supplied pallet until final step of Connect Tow Behind System to Vehicle procedure 3A2091C Setup Connect Tow Behind to Vehicle iA If the wheels are not rotated to the rear of the trailer it can become unstable and tip over if the tow vehicl
33. ses or use hoses to pull equipment Keep children and animals away from work area Comply with all applicable safety regulations 3A2091C 5 Warnings CARBON MONOXIDE HAZARD Exhaust contains poisonous carbon monoxide which is colorless and odorless Breathing carbon monoxide can cause death e Donotoperate 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 e 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 e Do not touch hot fluid or equipment PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent 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 e 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 6 3A2091C Introduction and General Information Introduction and Ge
34. t pumps allows the user to have a two color system Paint Spray Guns The Paint Spray Guns are pneumatically triggered to spray paint stripes when commanded by the Program mable Skipline Controller Bead Spray Guns The Bead Spray Guns are pneumatically triggered to spray reflective materials when commanded by the Programmable Skipline Controller Component Identification Component Identification AJ 1813958 3A2091C Component Function Component Function PA Air Regulator Allows regulation of the bead tank air pressure Holds up to 36 gallons 136 liters of reflective materials or element for single or Bead Tank double drop beading Air Accumulator Tank Helps reduce air temperature from compressor Hvdraulic Valve Valve to shut off on the hvdraulic fluid to the hvdraulic motor Pb fo oa E FudHle Fers fud beeen the tud source andhe sprayom F Pressure Dran vane relevas tud presse wenoo OOOO G RPS 2000 yarauie Pump Provides uia to be sprayed trough te spay T fuone Suppies tuia om he displacement pump o he spray gun access to lect M feae proves poverio sarthe engine andconvelBox N FuelTank Holds 6 gallons 23 liters of gasoline P HriauisPressue ConiiKroh Prov esansimentofydmuicpressure Gockwseoenses pressure
35. tive materials Set Up Adjustable Gun Arm Beam and Gun Arm 1 Unlock gun arm clamp and gun arm beam clamps NMA Wa ti16425a Pull gun arm beam to left or right side of vehicle Lock slide beam clamps 3 Remove gun arm from upright stowed position and slide to end of gun arm beam Slowly lower gun arm and lock into position with clamp ti16423a 3A2091C Prepare Svstem to Paint Initial Settings 1 Attach Tow Behind Svstem ground clamp to earth ground See Grounding Instructions page 13 Fill throat packing nut with TSL to prevent prema ture packing wear Do this each time vou sprav and store Approximate Fill Level tib240a NS 3 Check engine oil level Add SAE 10W 30 summer or 5W 20 winter if necessary A cold ti16447a Fill fuel tank Check hydraulic oil level Add only Graco Hydraulic Oil ISO 46 169236 5 gallon 18 9 liter or 207428 1 gallon 3 8 liter Hydraulic tank capacity is approxi mately 4 0 gallons 15 14 liters U Safe Range cold 3A2091C Operation Check oil level in compressor NOTE If red dot is visible add oil 7 Verify all hose fitting connections are tight 8 Turn hydraulic lines to closed position ti15953a pail partially filled with flushing fluid Attach ground wire to pail and to earth ground 10 Place suctio
36. uide extension arm 3 Assemble mounting bracket 355 to desired loca 352 and secure in place with knob 354 tion with bolt 359 washer 360 and nut 361 8 Adjust the indicator rod by loosening extension clamps and sliding the guide extension arm 352 to desired position Secure by tightening knob 354 Install and Align RoadView Camera System Optional See RoadView Camera System manual 169278 4 Hand tighten lock bar 6 to mounting bracket 355 with bolts 357 and nuts 358 28 3A2091C ti16926a Operation Pressure Relief Procedure The svstem pressure must be manuallv 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 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 RPS 2900 Pump Fluid Pressure Relief 1 Set hydraulic valve to OFF position ti15838a 2 Run engine at half throttle 3 Place empty pail under paint guns to catch drain age 4 Relieve hose pressure through guns Use Program mable Skipline Controller to trigger each gun for at least 3 seconds each NOTE Alwavs relieve pres su
37. ure safety pins A for both trailer arm cou plers and connect safety chains f Connect safety chains ti18142a 14 3A2091C Gun Arm Beam 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 Ib 24 3 26 5 Nem til8145a 3A2091C Setup Gun Arm Stow Bracket 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 Nem ti18136a 15 Setup Installing RoadLazer onto Trailer If RoadPak is not properly secured to trailer it can fall off of trailer and cause serious injurv Use only Graco supplied fasteners and tighten them to the required torque Use all of the fasteners provided NOTE Only install RoadLazer onto trailer if trailer is properly attached to tow vehicle NOTE Remove rear jack from trailer before mounting RoadPak NOTE If tow vehicle is a pick up remove tailgate before installation Load RoadPak onto trailer using a forklift or a hoist that is rated for the weight of the RoadPak For RoadPak weight information see Technical Data page 42 ti16665a 16 After loading the RoadPak on the trailer secure t
38. y switch is aligned with stowing bracket as shown and tighten nuts 3A2091C 19 Setup Hose Routing to Pumps and Tanks 181558 A a 9 e INA L a Ie N S Y TG pU ARIS x A A i Ke N RS LZ NIKIN p 2 NE A Z re Nd Sy eee OI BEZA VKOVA Y Yo Y 4 Sd e 7 SV G 7 Q9 amp V ead _ F K d EXC 9 du P Br 33 Epp x 3A2091C 20 Setup Pull gun arm beam out to one side of the vehicle 1 ientation ilter Or F 1 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 Use a hammer to loosen the large jam nut on the pump assembiv ti18276a MSS aM TAID La dl RAGI Dy TAK ONE 9 ti16782a and use a hammer to tighten the jam nut and lock 2 Rotate the filter assembly to the desired orientation the assembly into place 2 Lift gun arm back to the stow position Pull gun arm arm to that side to ensure the hose location is ade beam out to other side of vehicle and pull the gun quate for full movement h Off Q f ti16783a ti16784a Hose
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