Graco RoadLazer RoadPak 24G677 Instruction Manual

Operation
RoadLazer™RoadPak™
Line Striping System
- 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.
3A1214D
ENG
ti15835b

Models
23A1214D
Models
Complete Assemblies
Ref. Model Number Description
1 24G624 1 Pump RoadPak
2 24G625 2 Pump RoadPak
3 24G626 Single Hitch Mounting Frame
4 24G627 RoadPak Slide in Mounting Frame
5 24G628 1 Pump RoadPak Gun Arm
6 24G629 2 Pump RoadPak Gun Arm
7 24G630 Gun Arm Beam
8 24G632 RoadLazer/RoadPak Control
9 24G633 Road View Camera System
10 24G634 RoadPak Pointer System
Part Number Description
24G677 RoadPak System Option 1 (1, 3, 5, 7, 8, 10)
24G679 RoadPak System Option 2 (1, 3, 5, 7, 8, 9, 10)
24G681 RoadPak System Option 3 (1, 4, 5, 7, 8, 10)
24G683 RoadPak System Option 4 (1, 4, 5, 7, 8, 9, 10)
24G685 RoadPak System Option 5 (2, 3, 6, 7, 8, 10)
24G687 RoadPak System Option 6 (2, 3, 6, 7, 8, 9, 10)
24G689 RoadPak System Option 7 (2, 4, 6, 7, 8, 10)
24G691 RoadPak System Option 8 (2, 4, 6, 7, 8, 9, 10)

Warnings
3A1214D 3
Warnings
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.
WARNINGWARNINGWARNING
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire
and explosion:
•Use equipment only in well ventilated area.
•Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and can
ignite or explode if spilled on hot surface.
•Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths
(potential static arc).
•Keep work area free of debris, including solvent, rags and gasoline.
•Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are
present.
•Ground all equipment in the work area. See Grounding instructions.
•Use only grounded hoses.
•Hold gun firmly to side of grounded pail when triggering into pail.
•If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you
identify and correct the problem.
•Keep a working fire extinguisher in the work area.
+
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin. This may look
like just a cut, but it is a serious injury that can result in amputation. Get immediate SURGICAL TREATMENT.
•Keep clear of fluid outlet and leaks.
•Use guns, hoses and other components with pressure ratings equal to or higher than the pump rating.
•Follow the Pressure Relief Procedure before servicing or cleaning.
•Do not point dispensing device at anyone or at any part of the body.
•Do not stop or deflect leaks with your hand, body, glove, or rag.
•Tighten all fluid connections before operating the equipment.
•Check hoses and couplings daily. Replace worn or damaged parts immediately.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
•Keep clear of moving parts.
•Do not operate equipment with protective guards or covers removed.
•Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow
the Pressure Relief Procedure and disconnect all power sources.

Warnings
43A1214D
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
•Do not operate the unit when fatigued or under the influence of drugs or alcohol.
•Do not exceed the maximum working pressure or temperature rating of the lowest rated system component.
See Technical Data in all equipment manuals.
•Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your
material, request MSDS from distributor or retailer.
•Do not leave the work area while equipment is energized or under pressure. Turn off all equipment and
follow the Pressure Relief Procedure when equipment is not in use.
•Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s
replacement parts only.
•Do not alter or modify equipment.
•Use equipment only for its intended purpose. Call your distributor for information.
•Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
•Do not kink or over bend hoses or use hoses to pull equipment.
•Keep children and animals away from work area.
•Comply with all applicable safety regulations.
CARBON MONOXIDE HAZARD
Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon monoxide
can cause death.
•Do not operate in an enclosed area.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.
•Read MSDSs to know the specific hazards of the fluids you are using.
•Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:
•Do not touch hot fluid or equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area of
the equipment to help protect you from serious injury, including eye injury, hearing loss, inhalation of toxic
fumes, and burns. This equipment includes but is not limited to:
•Protective eyewear, and hearing protection.
•Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.
WARNINGWARNINGWARNING
WARNING

Introduction and General Information
3A1214D 5
Introduction and General Information
Introduction
This manual and those listed below provide pre-setup
requirements, parts lists, setup, operation, and mainte-
nance instructions for the RoadLazer system. This man-
ual 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 RoadLazer is mounted to a vehicle and is used to
stripe up to two stripes in one or two colors with glass
beading.
The RoadLazer 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 cable. It is the main control for
the RoadLazer system and turns the spray guns and
accessories on and off.
Front Guidance System
The Front Mechanical Guidance System provides the
user with a pointer for alignment on either the left or right
side of the vehicle.
Video Guidance System™(optional)
The Video Guidance 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
displacement 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 Pro-
grammable Skipline Controller.

Component Identification
63A1214D
Component Identification
ti15836b
B
N
C
D
E
F
G
H
J
R
M
Z
L
AH
AG AF
AE
AC
AB
AA
P
S
T
W
X
AY
K
Q
AJ
AD

Component Function
3A1214D 7
Component Function
AAir Regulator Allows regulation of the bead tank air pressure
BBead Tank Holds up to 36 gallons of reflective materials or element for single or double drop
beading
CAir Accumulator Tank Helps reduce air temperature from compressor
DHydraulic Valve Valve to shut off/on the hydraulic fluid to the hydraulic motor
EFluid Filter Filters fluid between the fluid source and the spray gun
FPressure Drain Valve Relieves Fluid Pressure when open
GRPS 2900 Hydraulic Pump Provides fluid to be sprayed through the spray gun
HFluid Outlet Supplies fluid from the displacement pump to the spray gun
JFluid Inlet Displacement Pump entry for fluid from the paint drums (paint drums not shown)
KElectrical Junction Box Allows the user access to electrical system
L18 HP Engine Powers the hydraulic pump and the air compressor
M2 in. Hitch Receiver (not provided) Needed to hook-up the gun arm to the back of a truck
NFuel Tank Holds 6 gallons (23 liters) of gasoline
PHydraulic Pressure Control Knob Provides adjustment of hydraulic pressure (clockwise increases pressure)
QBattery Provides power to start the Engine and Control Box
RCompressor Provides an air supply for the solenoids and pressurizes the bead tanks
SHydraulic Reservoir Holds 4 gallons (15.1 liters) of hydraulic oil for the hydraulic pump
TI/O Cable Carries electronic control signals from the Controller to the RoadLazer
WProgrammable Skipline Controller Allows the user to program the operation of the RoadLazer
XBreather Cap Provides a means for hydraulic reservoir ventilation, oil check, and fill
YAir Pressure Quick Release Allows the user to use pressurized air
ZHitch Insert Allows the user to connect the gun arm to a single hitch vehicle
AA Mounting Bracket Allows the user to connect the gun arm mount to the optimum height
AB Stow Bracket Pin Secures the spray gun boom arm when the RoadLazer is in transport mode
AC Gun Arm Mount Supports the main beam and the gun arm
AD Slide Beam Supports the spray gun boom arm
AE Spray Gun Boom Arm Allows striping on either side of the vehicle at adjustable distances
AF Bead Spray Gun Sprays beads when commanded by the Controller
AG Paint Spray Gun Sprays fluid when controller by the Controller
AH Slide in Mounting Frame Allows user to connect the gun arm to the RoadPak frame
AJ RoadPak Pointer System Allows the user an alignment tool

Setup
83A1214D
Setup
Charge Battery
If the battery is newly purchased or has not been used
for a long time, charge it before you use it.
Installing RoadLazer Into Vehicle
RoadPak Installation
(24G624, 24G625)
Load RoadPak into vehicle using a forklift or a hoist that
is rated for the weight capacity of the RoadPak. For
RoadPak weight information see Technical Data, page
27.
The RoadPak can be mounted in the front or rear of the
vehicle bed as well as in any orientation desired. The
base of the RoadPak is 39.5 in. x 49.5 in. (1.0m x
1.25m).
After mounting the RoadPak on the vehicle, firmly
secure the RoadPak to the vehicle using the tie-down
brackets at all four corners, or by bolting the RoadPak
through the bed of the truck to the frame in all four loca-
tions.
RoadLazer needs to be properly secured to prevent it
from moving during transportation and operation.
Paint drums are heavy and could shift from side to side
when the vehicle is cornering. The paint drums could
fall from the vehicle and cause injury or death. Secure
the drums when the vehicle is in transport or spraying.
Paint could splash from the paint drum bung adapters
when the paint drums are full and the vehicle is mov-
ing. Do not overfill the paint drums.
ti16442a
ti16665a
ti16653a
ti16654a
ti16664a
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ti16443a

Setup
3A1214D 9
Filter Orientation
After mounting and securing the RoadPak to the vehi-
cle, position the filter assemblies as desired.
1. Use a hammer to loosen the large jam nut on the
pump assembly.
2. Rotate the filter assembly to the desired orientation
and use a hammer to tighten the jam nut and lock
the assembly into place.
Gun Arm Bracket Mount
Single Hitch Mounting Bracket (24G626)
Installation (Option 1)
1. Install hitch insert bracket (A) into receiver (C).
Ensure hitch pin (B) goes through tightening rod
hole (D).
2. Tighten nut until the hitch insert bracket is pulled
securely to the receiver and no play is seen
between the two parts.
3. Install the height adjustment bracket (303) to the
hitch insert bracket with bolts (312), washers (307),
and nuts (315). Ensure the height adjustment
bracket is installed level.
4. Install stow bracket (302) to height adjustment
bracket (303) with bolts (312), washers (307), and
nuts (315). Locate the bottom of the stow-bracket
21-in. to 25-in. (53cm - 63cm) from the ground.
Ensure the stow-bracket is installed level.
ti16782a
ti16784a
ti16783a
ti15839a
ti15955a
ti16648a
AC
D
B
ti16785a
ti15956a
315
307
307
312
303
ti15957a
21 in. - 25 in.
(53 cm - 63 cm)
302
315
302
307 312

Setup
10 3A1214D
RoadPak Mounting Bracket (24G627)
Installation (Option 2)
NOTE: Cutting the RoadPak mounting arms and bolting
them through the bed to the frame of the vehicle is an
option in addition to the following mounting techniques:
Narrow Orientation
1. Slide the RoadPak mounting arms (304) between
the two fork lift channels in the frame.
2. Depending on where the RoadPak is located on the
vehicle determines which holes to bolt through on
the RoadPak frame. There are 8 possible mounting
holes for each mounting arm. Fasten to at least two
holes on each side.
3. Hand-tighten bolts (312), nuts (315), and washers
(307) to mounts.
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ti16661a
ti16656a
ti16917a
304
ti16659a
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315
312
307

Setup
3A1214D 11
4. Install the height adjustment bracket (303) to the
RoadPak mounting arms (304) with bolts (312),
washers (307), and nuts (315).
5. Use wrench to tighten all bolts to lock into place
(torque to 28 ft-lb).
6. Install stow-bracket (302) to height adjustment
bracket (303). Locate the bottom of the
stow-bracket 21 in. to 25 in. (53cm - 63cm) from the
ground. Ensure the stow-bracket is installed level.
NOTE: It is recommended to bolt the mounting
bracket through the bed of the vehicle to the frame
of the vehicle.
ti16912a
315
307 312
303
ti16787a
21 in. - 25 in.
53 cm - 63 cm
302
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Setup
12 3A1214D
Wide Orientation
1. Bolt brackets (316) to the RoadPak in four locations
with bolts (312), washers (307), and nuts (315). It is
ideal to locate the brackets as far apart as possible
to provide optimal support. The mounting location of
the brackets will depend on where the RoadPak is
mounted on the vehicle.
2. Slide the RoadPak mounting brackets (304) through
the cut out holes in the frame and hand-tighten the
mounting arms to the brackets with bolts (312),
washers (307), and nuts (315).
3. Install the height adjustment bracket to the RoadPak
mounting arms (303).
4. Use wrench to tighten all bolts to lock into place
(torque to 28 ft-lb).
ti16657a
ti16786a
316
318
307
315
ti16913a
ti16911a
316
304
315
307
312
ti16921a
315
307
303
312
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Setup
3A1214D 13
5. Install stow-bracket (302) to height adjustment
bracket (303). Locate the bottom of the
stow-bracket 21 in. to 25 in. (53cm - 63cm) from the
ground. Ensure the stow-bracket is installed level.
NOTE: It is recommended to bolt the mounting
bracket through the bed of the vehicle to the frame
of the vehicle.
Slide Beam Installation (24G630)
The slide beam is 87.75 in. (2.2m) long. The Slide Beam
is shipped to accommodate wider vehicles. The beam
can be cut down to 75.75 in. (1.9m) long or 60 in. (1.5m)
long to accommodate different vehicle sizes.
1. To shorten the beam to 75.75 in. long, cut 12 in.
from the end the beam towards the next hole on the
beam. To shorten the beam to 60 in., cut 27.75 in.
from the end of the beam towards the third hole as
shown below.
2. After determining the desired length, slide the beam
into the bracket on the channel.
Gun Arm Installation (24G628, 24G629)
1. Position the gun arm assembly next to the vehicle.
2. Pull the slide 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 slide beam as
shown below.
ti16787a
21 in. - 25 in.
53 cm - 63 cm
ti16960a
302
ti16916a
ti16600a
12 in.
27.75 in.
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ti15959a

Setup
14 3A1214D
3. Attach the handle (702) to each end of the slide
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.
4. Route hoses for the gun arm before moving arm to
prevent hoses from being pinched.
5. Position gun arm at the end of the slide beam and
secure the hose bundle to the height adjustment
bracket with a rubber pad and hose clamp (320).
6. Lift gun arm to a vertical position and slide it over
the stow bracket.
7. Rest the gun arm on the stow bracket and position
the stop to sit properly on the stow bracket. Slide the
pin (321) through the gun arm bracket and stow
bracket to secure the gun arm. Tighten the two bolts
(579) down to lock the gun arm bracket into place.
ti16662a
708
707
705
706
704
ti16658a
ti16788a
302
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ti16918a
ti15837a
579

Setup
3A1214D 15
Hose Routing to Pumps and Tanks

Setup
16 3A1214D
Hose Routing
1. Pull slide beam out to one side of the vehicle. Pull
gun arm out and lower it to make sure the hose bun-
dle 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 to the hose
clamp that secures the bundle as needed.
2. Lift gun arm back to the stow position. Pull slide
beam out to other side of vehicle and pull the gun
arm to that side to ensure the hose length is ade-
quate for full movement.
3. Put gun arm back to the stow position and pin it into
place. Center the slide beam to the vehicle. Lock
the slide beam and gun arm into place by engaging
the clamps for each.
Hose Connection
1. Install suction tubes to the RPS 2900 pump and
route to paint drum.
2. Install return line from the RPS 2900 filter assembly
and route back to the paint drum.
3. 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.
4. Install bead lines to the bead tank.
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Setup
3A1214D 17
5. Install air hose to quick connect fitting on air tank.
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.
2. Connect control cable to the junction box. Fasten
cable to cable clamp for strain relief (S) on the con-
nection.
3. Route the control cable to the cab of the vehicle
without pinching the cable. Connect the cable to the
control box. Route cable through the cable clamp for
strain relief on the connection.
ti16914a
ti16596a S
ti16595a S
ti16601a

Setup
18 3A1214D
Install Front Pointer Instructions
1. Locate an area on the vehicle to mount the Road-
Pak pointer system that will allow the user to see the
indicator rod from the driving position or with the
help of the Road View Camera System.
2. If needed, drill two 9/16 in. holes in the desired loca-
tion.
3. Assemble mounting bracket (355) to desired loca-
tion with bolt (359), washer (360), and nut (361).
4. Hand tighten lock bar (6) to mounting bracket (355)
with bolts (357) and nuts (358).
5. Slide support bar (351) through brackets (355) and
tighten fasteners to secure in place.
6. Assemble extension clamp to support bar.
7. Insert indicator rod (362) into guide extension arm
(352) and secure in place with knob(354).
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 Front Mechanical
Guidance System (Optional)
See Guidance System manual.
Install and Align Video Guidance System
(Optional)
See RoadView Camera System manual.
Install Winch Kit (Optional)
See Winch Kit manual.
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ti16927a
361
360
355
359
ti16926a
357
6
358
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355
351
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Operation
3A1214D 19
Operation
Pressure Relief Procedure
RPS 2900 Pump Fluid Pressure Relief
1. Set hydraulic valve to OFF position.
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: Always relieve pressure with the guns--not
with the filter drain valves.
5. Close paint gun ball valves.
6. Open all 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 com-
pletely clogged, or that pressure has not been fully
relieved after following the steps above, very slowly
loosen the hose end coupling, and relieve pressure
gradually. Then loosen it completely. Then clear the
valve or hose.
Bead System Pressure Relief
1. Relieve air pressure in bead tank by turning bead
system valve to OFF position.
INJECTION HAZARD
The system pressure must be manually 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
FIRE AND EXPLOSION HAZARD
When Flushing system, always connect grounding
cord.
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Operation
20 3A1214D
Air System Pressure Relief
1. Relieve air pressure in air tank by turning air valve
to OPEN position.
EMERGENCY SHUT OFF
To shut down the entire RoadLazer system, set
POWER ON/OFF on the Programmable Skipline Con-
troller to the OFF position.
Load Reflecting Materials
1. Set POWER ON/OFF on Programmable Skipline
Controller to OFF.
2. Set RoadLazer engine ignition key to OFF.
3. Relieve air system pressure by opening ball valve
until gauge reads 0.
4. Relieve air pressure in bead tank by turning bead
system valve to OFF position.
5. Remove cover from bead tank.
6. Screen reflective materials to prevent debris from
entering tank.
7. Load bead tank with reflective materials.
Set Up Slide Beam and Gun Arm
1. Unlock gun arm clamp and slide beam clamps.
2. Pull slide 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 boom. Slowly lower gun arm, and
lock into position with clamp.
Prepare System to Paint
Initial Settings
1. Ground RoadLazer ground strap to earth ground.
2. Fill throat packing nut with TSL to prevent prema-
ture packing wear. Do this each time you spray and
store.
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TI3058A
Approximate
Fill Level
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