Graco RoadLazer RoadPak Guide

Installation & Operation
RoadLazer™RoadPak™& RoadPak
HD 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 and in related manuals.
Be familiar with the controls and the proper usage of the equipment.
Save these instructions.
Related Manuals:
3A5385 Repair
3A5386 Parts
3A5384B
EN
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Complete Assemblies
23A5384B
Complete Assemblies
Models
Part Number Description
25D268 RoadPak System Option 1 (1, 6, 7, 10, 12) 
25D269 RoadPak System Option 2 (1, 6, 7, 10, 11, 12) 
25D270 RoadPak System Option 3 (1, 6, 7, 10, 12, 13, 14, 15) 
25D271 RoadPak System Option 4 (1, 6, 7, 10, 11, 12, 13, 14, 15) 
25D272 RoadPak System Option 5 (2, 6, 8, 10, 12) 
25D273 RoadPak System Option 6 (2, 6, 8, 10, 11, 12) 
25D274 RoadPak System Option 7 (2, 6, 8, 10, 12, 13, 14, 15) 
25D275 RoadPak System Option 8 (2, 6, 8, 10, 11, 12, 13, 14, 15) 
25D276 RoadPak System Option 9 (3, 6, 8, 10, 12) 
25D277 RoadPak System Option 10 (3, 6, 8, 10, 11, 12) 
25D278 RoadPak System Option 11 (3, 6, 8, 10, 12, 13, 14, 15) 
25D279 RoadPak System Option 12 (3, 6, 8, 10, 11, 12, 13, 14, 15) 
25D280 RoadPak System Option HD1 (4, 6, 9, 10, 12, 14) 
25D281 RoadPak System Option HD2 (4, 6, 9, 10, 11, 12, 14) 
25D282 RoadPak System Option HD3 (4, 6, 9, 10, 12, 13, 134, 15) 
25D283 RoadPak System Option HD4 (4, 6, 9, 10, 11, 12, 13, 14, 15) 
Ref. Model Number Description
1 25M701 1 Pump RoadPak (450 lb. Bead Tank, 5 gpm)
25M702 1 Pump RoadPak (No Bead Tank, 5 gpm)
2 25M703 2 Pump RoadPak (450 lb. Bead Tank, 5 gpm)
3 25M704 2 Pump RoadPak (1350 lb. Bead Tank, 5 gpm)
25M705 2 Pump RoadPak (No Bead Tank, 5 gpm)
4 25M706 2 Pump RoadPak HD (1350 lb. Bead Tank, 10 gpm)
25M707 2 Pump RoadPak HD (No Bead Tank, 10 gpm)
24G626 Single Hitch Mounting Frame
6 24G627 RoadPak Slide in Mounting Frame
7 25M708 1 Pump RoadPak Gun Arm
8 25M709 2 Pump RoadPak Gun Arm
25D932 2 Pump RoadPak Gun Arm (No Bead Guns)
9 25M710 2 Pump RoadPak HD Gun Arm
10 25M711 RoadLazer/RoadPak Control
11 24G633 RoadView Camera System
12 24G634 RoadPak Pointer System
13 25M712 Steerable Carriage
14 25M713 Winch Kit
15 25M716 Seat Kit

Table of Contents
3A5384B 3
Table of Contents
Complete Assemblies . . . . . . . . . . . . . . . . . . . . . . .2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
Introduction and General Information . . . . . . . . . .7
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
General Information . . . . . . . . . . . . . . . . . . . . . . .7
Optional Accessory Kits . . . . . . . . . . . . . . . . . . . .7
Component Identification . . . . . . . . . . . . . . . . . . . .8
Component Function . . . . . . . . . . . . . . . . . . . . . . . .9
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Charge Battery . . . . . . . . . . . . . . . . . . . . . . . . . .10
Installation of RoadLazer into Vehicle . . . . . . . .10
RoadPak Installation . . . . . . . . . . . . . . . . . . . . .10
Gun Arm Bracket Mount . . . . . . . . . . . . . . . . . . .11
Hose Routing to Pumps and Tanks . . . . . . . . . .18
Install Front Pointer Instructions . . . . . . . . . . . . .21
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Pressure Relief Procedure . . . . . . . . . . . . . . . . 22
EMERGENCY SHUT OFF . . . . . . . . . . . . . . . . 23
Load Reflecting Materials . . . . . . . . . . . . . . . . . 23
Set Up Slide Beam and Gun Arm . . . . . . . . . . . 24
Prepare System to Paint . . . . . . . . . . . . . . . . . . 24
Start Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Begin to Spray . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Flush the System . . . . . . . . . . . . . . . . . . . . . . . . 29
Securing Gun Arm for Transportation . . . . . . . . 31
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 33
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 34

Warnings
43A5384B
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 or on warning labels, 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.
WARNING
WARNINGWARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or solvent
flowing through the equipment can cause static sparking. 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 sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• 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.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering 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 the event that injection occurs, get immediate surgical treatment.
• Do not aim the gun at, or spray any person or animal.
• Keep hands and other body parts away from the discharge. For example, do not try to stop leaks with
any part of the body.
• Always use the nozzle tip guard. Do not spray without nozzle tip guard in place.
• Use Graco nozzle tips.
• Use caution when cleaning and changing nozzle tips. In the case where the nozzle tip clogs while
spraying, follow the Pressure Relief Procedure for turning off the unit and relieving the pressure
before removing the nozzle tip to clean.
• Equipment maintains pressure after power is shut off. Do not leave the equipment energized or under
pressure while unattended. Follow the Pressure Relief Procedure when the equipment is
unattended or not in use, and before servicing, cleaning, or removing parts.
• This system is capable of producing 2900 psi (200 bar, 20 MPa). Use Graco parts or accessories that
are rated a minimum of 2900 psi (200 bar, 20 MPa).
• Always engage the trigger lock when not spraying. Verify the trigger lock is functioning properly.
• Verify that all connections are secure before operating the unit.
• Know how to stop the unit and bleed pressure quickly. Be thoroughly familiar with the controls.

Warnings
3A5384B 5
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 com-
ponent. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Specifica-
tions in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete infor-
mation about your material, request Safety Data Sheets (SDSs) 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 manu-
facturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create
safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• 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.
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.
ENTAGLEMENT HAZARD
Rotating parts can cause serious injury.
• 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.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow the
Pressure Relief Procedure and disconnect all power sources.
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 Safety Data Sheets (SDSs) 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 is heated can become very hot during operation. To avoid severe
burns:
• Do not touch hot fluid or equipment.
WARNING
WARNINGWARNING

Warnings
63A5384B
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. 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
WARNINGWARNING

Introduction and General Information
3A5384B 7
Introduction and General Information
Introduction
This manual and those listed below provide pre-setup require-
ments, parts lists, setup, operation, and maintenance instruc-
tions for the RoadLazer, RoadPak and RoadPak HD systems.
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 RoadLazer is mounted to a vehicle and is used to stripe
up to five stripes in one or two colors with glass beading.
The RoadLazer RoadPak consists of a Programmable Skipline
Controller, Displacement Pumps, two Paint Spray Guns, and
two Bead Spray Guns. The RoadPak HD is provided with
three paint spray guns, and three 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.
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 Programmable Skipline
Controller.
Bead Spray Guns
The Bead Spray Guns are pneumatically triggered to spray
reflective materials when commanded by the Programmable
Skipline Controller.
Optional Accessory Kits
Winch Kit
The RoadPak Winch Kit is used to lift the gun arm during spray
operation.
Seat Kit
The Seat Kit allows for an operator position to be added to the
bed of the vehicle. This allows for better control of the guns
and steerable carriage.
Additional Gun Kit
The Additional Gun Kit consists of one bead gun and one
spray gun, and the needed fittings, hoses, air tubing and
mounting hardware to add the guns to the gun arm carriage.
Laser Kit
The Laser Kit provides the user with a bright green line to fol-
low for vehicle and spray gun alignment.
Steerable Carriage Kit
The Steerable Carriage is fitted to the existing gun arm car-
riage, which gives the operator the ability to drive the carriage
left or right at a chosen speed. The control can be mounted to
the Seat Kit control arm, or used as a hand-held control.
Pressure Balancing Kit
The Pressure Balancing Kit allows the operator to connect the
two paint pumps at their outlets to balance the pressure
between the two pumps. This ensures that each spray pattern
is equal at each gun.
Double Drop Kit
The Double Drop Kit consists of one bead gun, one bead
hose, and the fittings to connect the parts. It is used for ele-
ment double drop applications.
Video Guidance System™
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 vehicle. The system consists of a 9 in. monitor, interfacing
cables, video camera and mounting bracket.
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.

Component Identification
83A5384B
Component Identification

Component Function
3A5384B 9
Component Function
AAir Regulator Allows regulation of the bead tank air pressure
BBead Tank 36 gallon or 120 gallon bead tank. Holds reflective materials or element for sin-
gle or double drop beading
CAir Accumulator Tank Helps maintain consistent air power to accessories
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
FPrime/Spray Valve Used to switch between priming and spraying
GRPS 2900 Paint 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
RoadPak 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
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 Connection 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
AK Gun Arm Support Wheel Supports gun arm when needed for wide/multi-gun patterns
AL 26.5 HP Engine Powers the hydraulic pump and air compressor on RoadPak HDs
AM Air Cooler/Dryer Cools and dries air to bead tank and accessories
AN Grounding Clamp Dissipates static electricity during flushing

Setup
10 3A5384B
Setup
Charge Battery
If the battery is newly purchased or has not been used
for a long time, use a standard 12vdc automotive battery
charger to charge it before use.
Installation of RoadLazer into
Vehicle
RoadPak Installation
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
32.
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.
CRUSH HAZARD
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.
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