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Graco 3A1696C manual

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Table of contents for the manual

  • Page 1

    Repair RoadLazer ™ RoadPak ™ Line Striping System - For the Application of Road Ma rking and Reflective Coatings - - For Professional Use Only - 2900 psi (20 MPa, 200 bar) Maximum Wor king Pressure Important Safety Instructions Read all warnings and in structions in this manual. Save these instructions. 3A1696C EN ti15835a[...]

  • Page 2

    Table of Contents 2 3A1696C Table of Contents Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Component I dentifica tion . . . . . . . . . . . . . . . . . . . . 5 Component Function . . . . . . . . . . . . . . . . . . . . . . . 6 Pressure Relief Procedures . . . . . . . . . . . . . . . . . . 7 Changing Hydraulic Oil . .[...]

  • Page 3

    Warnings 3A1696C 3 Warnings The following warnings are fo r the setup, use, grounding, mainte nance, and repair of this equip ment. The exclama- tion point symbol alerts you to a genera l warning and the ha zard symbols refer to procedure-specific risks. When these symbols appe ar in the body of this manual, refer ba ck to thes e Warnings. Product-[...]

  • Page 4

    Warnings 4 3A1696C 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[...]

  • Page 5

    Component Identi fication 3A1696C 5 Component Identification ti15836a K U V AC D F A C G AD Y Z P AE T S R AB B AA Q H N M E L AG AH W AF A J[...]

  • Page 6

    Component Function 6 3A1696C Component Function A RPS 2900 Hydraulic Pump Provides fluid to be sprayed through the spray gun B Stow Bracket Pin Secures the spray gun boom arm when the RoadLazer is in tra nsport mode C Fluid Outlet Supplies fluid from the displacement pump to the spray gun D Fluid Filter Filters fluid between the fluid source and th[...]

  • Page 7

    Pressure Relief Procedures 3A1696C 7 Pressure Relief Procedures RPS 2900 Pump Fluid Pressure Relief 1. Set hydraulic valve to OFF position. 2. Run engin e at half thro ttle. 3. Place empty pail under paint guns to catch drain- age. 4. Relieve hose pressure thro ugh guns. Use Program- mable Skipline Contro ller to trigger each gun for at least 3 sec[...]

  • Page 8

    Changing Hydraulic Oil 8 3A1696C Changing Hydraulic Oil Drain Oil 1. Use a funnel to drain oil into a drain pan. If a funnel is not available, remove the gas tank and place a drain pan under the oil tank. 2. Unscrew re servoir dra in plug (12 6e) and drain oil from reservoir. Refilling Oil 1. Replace drain plug (1 26e). 2. Fill tank with Graco hydr[...]

  • Page 9

    Compressor Belt and Hydraulic Pump Belt 3A1696C 9 Compressor Belt and Hydraulic Pump Belt Belt Removal NOTE: In or der to remov e the comp ressor belt, the hydraulic pum p belt must first be remov ed. 1. Remove air line (145) from compre ssor. 2. Loosen four mounting bolts on comp ressor to reduce compressor belt tension. 3. Remove four screws (1) [...]

  • Page 10

    Compressor Belt and Hydraulic Pump Belt 10 3A1696C 7. Remove eight screws from side guard (105) an d remove guard . 8. Remove t wo screws f rom engine m uffler brac ket. 9. Loosen four nuts (5) a nd bolts (3) which secure engine to relieve tension on hydraulic pump belt. 10. Tilt engine back and remove hydra ulic pump belt (103). Loop belt around t[...]

  • Page 11

    Compressor Belt and Hydraulic Pump Belt 3A1696C 11 4. Visually inspect and make sure belts will be properly lined up when engin e is tightened. 5. Tighten four nuts (5) an d bolts (3) to secure engi ne in place. Visually in spect and make sure hydraulic belt is properly aligned. Repeat until prop er align- ment is achieved. 6. Tighten four nuts (5)[...]

  • Page 12

    Hydraulic Pump Replacement 12 3A1696C Hydraulic Pump Replacement Removal 1. Perform Pressure Relief Procedures , page 7. 2. Drain and Change Hy draulic Oil , page 8. 3. Remove hydraulic pump belt, see Compressor Belt and Hydrauli c Pump Belt Removal , page 9. 4. Unscrew suction line connections to hydraulic pump. Place a container under hoses to ca[...]

  • Page 13

    Hydraulic Pump Replacement 3A1696C 13 Installation 1. Install fittings (115, 116, 127 ) from old pump onto new pump. Torque fittings (116, 127) to 600 +/1 10 in-lb (67.8 N•m) . Torque fitting (1 15) to 450 in-lb (50.8 N•m) NOTE: Fill pump casing with hydraulic oil before installing fitting (115). 2. Install new pump (95) to frame . 3. Install b[...]

  • Page 14

    Compressor Replacement 14 3A1696C Compressor Replacement Removal 1. Perform Pressure Relief Procedures , page 7. 2. Remove are line (145) from co mpressor. 3. Remove f our screws ( 1) and two nuts (15) s ecuring top belt guard (1 08). 4. Loosen four moun ting bolts on compressor to reduce comp ressor belt tension . 5. Remove top belt guar d (108). [...]

  • Page 15

    Compressor Replacement 3A1696C 15 Installation 1. Apply high t emperatur e thread sea lant to threa ds of relief valve and screw in re lief valve to new air com- pressor. 2. Hand-tighten four bolts (12) and nuts (5) to hold compressor (100) and belt gua rd (101) to frame. 3. Loop compressor belt (102) onto idler pulley, e ngine pulley, and comp res[...]

  • Page 16

    Engine Replacement 16 3A1696C Engine Replacement Engine Removal 1. Perform Pressure Relief Procedure , page 7. 2. Disconnect ground terminal of batt ery, then dis- connect the positive terminal. 3. Disconnect white and yellow electrical wires located behind muffler. 4. Disconnect the positive red wire (90) attached to the engine. 5. Disconnect gas [...]

  • Page 17

    Engine Replacement 3A1696C 17 Pulley Installation 1. Position new pulley on engine. 2. Install bolt (19), washer (4), and lock washer (20) in center of pulley. Torque to 125 +/- 1 0 in-lb (14.1 +/- 1.1 N•m). 3. Tighten set screw (21). Torque to 60 +/- 2 in-lb (2 5.4 N•m). Engine Installation 1. Use a lift ring to tu rn the engine and insert it [...]

  • Page 18

    Junction Box Circuit Board Replacement 18 3A1696C Junction Box Circuit Board Replacement Removal 1. Disconnect ground ter minal of battery and then dis- connect positive terminal of battery. 2. Remove red and black wires from battery area. 3. Unplug control cable and gun arm cable from junc- tion box (179). 4. Disconnect pump counter wires. 5. Disc[...]

  • Page 19

    Troubleshooti ng 3A1696C 19 Troubleshooting Before you proceed with T roublesho oting, perform Pressure Relief Procedure , page 7. Check everything in the troublesho oting tables before you disassemble any equip ment. Paint Guns and Bead Guns PROBLEM CAUSE SOLUTION Paint guns not spraying C logged tips Clean tips Fuse (20A) is blown Check 20A fuse [...]

  • Page 20

    Troubleshooting 20 3A1696C Bead guns not spraying Paint guns and bead guns If paint guns and bead guns are not wo rking, check paint guns first. Bead tank air valve Turn bead tank valve ON Nozzles plugged 1. Turn off air pressure. 2. Remove nozzles and clean out any plug- ging. 3. If paper or other de br is is constantly plug- ging nozzles use a fi[...]

  • Page 21

    Troubleshooti ng 3A1696C 21 Paint guns not turning off immediately or at all Valve needed 1. Spray needle with light coat of lubricant. Use air hose or water hose to break up and remove solidi fied beads. 2. Replace needle, seat, and packings (see Repair Kit 238339). Gun arm wobbling or hopping exce s- sively Swivel nut Gun arm wobbles 1. Remove du[...]

  • Page 22

    Troubleshooting 22 3A1696C Programmable Skipline Controller PROBLEM CAUSE SOLUTION Controller not turning on Fuse, battery, or wiring 1. Check fuse located next to 12V RoadLazer battery. 2. Check battery voltage. Replace if necessary. 3. Inspect wiring at battery for corro- sion. Inspect control cable for dam- age. Controller shutting down or cutti[...]

  • Page 23

    Troubleshooti ng 3A1696C 23 Air and Bead System PROBLEM CAUSE SOLUTION Belts squealing during engine startup Compressor belt needs tigh tening or replacing See Air Compressor Belt Replace- ment , page 9. Paint guns not spraying when empty bead tank is empty All of air supplied by air compressor is rushing out of bead gun nozzles. In turn, system ai[...]

  • Page 24

    Troubleshooting 24 3A1696C Kohler Engine Paint Pumps Paint and Paint Manufacturers PROBLEM CAUSE SOLUTION Engine not starting Programmable Skipline Controller is shut off, or engine is out of fuel 1. Turn on Programmable Skipli ne Control- ler. Engine will not start with control off. 2. Check fuel supply. 3. See Kohler engine instruction manual . E[...]

  • Page 25

    Wiring Diagrams 3A1696C 25 Wiring Diagrams Schematics - 24F472, Controller Control Cable Diagram for RoadPak System 4 AMP 20 AMP 9 1 4 3 8 7 12 13 16 17 17 2 5 6 10 11 15 14 18 9 1 12 3 4 5 67 8 9 1 0 4 3 8 7 12 13 16 2 5 6 10 11 15 14 18 White Engine Shutdown Negative battery +12 VDC Postive Battery POWER ON OFF RESET HOLD BEADS ON BEAD TEST ABC D[...]

  • Page 26

    Wiring Diagrams 26 3A1696C Schematics -16G161, Cable, Gun Arm 19418-0022 & 19420-0002 FEMALE TERMINALS 19418-0024 & 19420-0002 FEMALE TERMINALS 10 BL UE 8 6 ORANGE 6 5 WHITE/BLACK 5 4 RED/BLACK 4 3 WHITE 3 2 GREEN/BLACK 2 1 ORANGE/BLACK 1 9 RED 8 BLACK 7 GREEN 16G161, Cable, Gun Arm 16G161, Cable, Gun Arm[...]

  • Page 27

    Wiring Diagrams 3A1696C 27 Schematics - 16G049, Valve Air Solenoid SOLENOID F BEAD 3 SOLENOID E BEAD 3 SOLENOID D BEAD 2 SOLENOID C BEAD 2 SOLENOID B BEAD 1 SOLENOID A BEAD 1 19435-0814 & 19417-0028 MALE TERMINALS 8 RED (12vdc FROM BA TTERY ) 6 BLACK (GROUND SWIT CHED A T C ONTROLLER) 5 BLACK (GROUND SWIT CHED A T C ONTROLLER) 4 BLACK (GROUND S[...]

  • Page 28

    All written and visual data contained in this document reflects the latest product info rmation available at the time of publica tion. Graco reserves the right to make changes at any time without notice. Original instructions. This manual contains English. MM 3A1696 Graco He adquarters: Minneapolis International Offices: Belgium, China, Japan, Kore[...]