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

www.graco.com/techsupport

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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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