Graco RoadLazer 231378 Instructions-Parts List Manual Download Page 25

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308611

Service

Engine Replacement

Disassembly

Relieve the pressure.

See page 16.

2. Set POWER ON/OFF on Programmable Skipline

Controller to OFF.

3. Loosen four nuts (24) and bolts (23) at base of air

compressor.

4. Slide compressor to right to remove tension on

belt.

5. Remove four nuts (15) and bolts (132) from rear

plate (110) on hitch side of frame. Remove plate.

6. Remove two bolts (30) and washers (31 and 32)

from left and right sides of hydraulic vane

pump (33).

7. Remove two bolts (13 and 115) from plate (108)

behind hydraulic vane pump (33). Remove plate.

8. Pull back hydraulic vane pump (33).

9. Disconnect I/O cable from Programmable Skipline

Controller.

10. Disconnect battery cable from starter.

11. Tag and disconnect ignition switch and power

wires located on inboard side of engine.

12. Disconnect fuel line at fuel pump.

13. Remove four screws of lower muffler mounting

bracket. Remove lower muffler mounting bracket.

14. Remove four locknuts (15), eight washers (21),

and four capscrew (14).

15. Remove vee belt (19) from engine pulley.

16. Remove engine from main base.

Assembly

1. Place engine on main base.

2. Be sure vee belt (19) is in place. Thread belt

around idler and bottom drive pulley (see Fig. 16

on page 22). Push engine in, and install to other

half of coupler (16) on hydraulic vane pump.

3. Install four locknuts (15), eight washers (21), and

four capscrews (14).

4. Install lower muffler mounting bracket with four

screws.

5. Connect fuel line at fuel pump.

6. Connect ignition switch and power wires located

on inboard side of engine.

7. Connect battery cable to starter.

8. Connect I/O cable from Programmable Skipline

Controller.

9. Push in hydraulic vane pump (33).

10. Install plate (108) behind hydraulic vane pump

(33). Install with two bolts (13 and 115).

11. Install two bolts (30) and washers (31 and 32) to

left and right sides of hydraulic vane pump (33).

12. Install rear plate (110) on hitch side of frame with

four nuts (15) and bolts (132).

13. Slide compressor to left to increase tension on

belt.

14. Tighten four nuts (24) and bolts (23) at base of air

compressor.

Summary of Contents for RoadLazer 231378

Page 1: ...instructions Hydraulic Stainless Steel RoadLazerR Line Striper System 2000 psi 13 8 MPa 138 bar Maximum Working Pressure Model 231378 Series A 3 pump 2 color system Model 231572 Series A 2 pump 1 color system Model 231571 Series A 1 pump 1 color system United States Patents 5 368 232 and 5 947 385 Chinese Patent ZL97111289 4 Brazilian Patent PI9701899 6 06242B ...

Page 2: ...abels before you operate this equipment D Use the equipment only for its intended purpose If you are not sure call your distributor D Do not alter or modify this equipment Use only genuine Graco parts and accessories D Check equipment daily Repair or replace worn or damaged parts immediately D Do not exceed the maximum working pressure of the lowest rated system component See Technical Data on pag...

Page 3: ...air spray system D Always have the tip guard and the trigger guard on the gun when spraying D Check the gun diffuser operation weekly See the gun manual D Be sure the gun ball valves and stencil gun trigger safety operate before you spray D Lock the stencil gun trigger safety when you stop spraying D Close the gun ball valves when you stop spraying D Follow the Pressure Relief Procedure on page 16...

Page 4: ...e spray or clean up area D Do not smoke in the spray area D Do not turn on or off any light switch in the spray area while operating or if fumes are present D Ground the equipment and the object being sprayed See Step 1 in Flushing the System on page 14 EXHAUST HAZARD The engine exhaust contains poisonous carbon monoxide which is colorless and odorless Do not operate this equipment in a closed bui...

Page 5: ... and off Front Mechanical Guidance System The Front Mechanical Guidance System provides the operator with a bore sight view for alignment on either the left or right side of the tow vehicle See manual 309008 Video Guidance Systemt optional The Video Guidance System provides the operator with video of a bore sight view for alignment on either the left or right side of the tow vehicle The system con...

Page 6: ...06242B X E A U H Y AA J O T N C G I V AB K P Z W B F L M D R S AC 6 308611 Component Identification and Function ...

Page 7: ...able Skipline Controller Allows the operator to program the operation of the RoadLazer S I O Cable Carries electronic control signals from the Programmable Skipline Controller to the RoadLazer T Compressor Provides an air supply to switch paint spray gun and bead spray gun on and off as directed by the Programmable Skipline Controller U 18 HP Gasoline Engine Powers the hydraulic pumps and the air ...

Page 8: ...ity requirement for the RoadLazer tow vehicle RoadLazer with full tank of beads 1400 lb Striping paint 15 lb per gal gal x 15 lb Additional glass beads 50 lb per bag bags x 50 lb Tow vehicle minimum payload capacity 1400 lb lb lb lb Calculation assumes waterborne traffic paint and 50 lb bags of glass beads Actual numbers could vary depending on the paint or beads used Fig 1 Example One 55 gallon d...

Page 9: ... 06196B Paint Drum Bracket WARNING 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 injury or death Secure the drums when the vehicle is in transport or spraying It is recommended that the paint drums be secured with a paint drum bracket Graco does not provide the paint drum bracket with the RoadLazer Fr...

Page 10: ...iver b Insert pin c Insert clip 2 Connect RoadLazer to ball mounts a Roll RoadLazer to vehicle and align RoadLazer trailer arms with ball mounts b Crank trailer arm jacks to clear ball mounts c Roll RoadLazer forward and align RoadLazer trailer arms over ball mounts d Crank trailer arm jacks to lower RoadLazer trailer arms onto ball mounts e Rotate jack to horizontal position Snap retaining handle...

Page 11: ... from the paint drum bung adapters when the paint drums are full and the vehicle is moving Do not overfill the paint drums 1 Use fork lift to install full 55 gallon paint drums or use transfer pump to fill already installed drums 2 Secure paint drums Insert Fluid Lines There are three suction lines one white and two yellow Insert the lines into their respective paint drums Install and Align Front ...

Page 12: ...rom upright stowed position and slide to end of boom Slowly lower gun arm and lock into position with clamp 3 Open the paint gun ball valves on guns to be used NOTE Never open both ball valves on the two color gun at the same time Paint color contamination could result 4 Fill a 5 gallon pail with water or compatible solvent and place paint suction hose in pail 5 Place an empty pail under the drain...

Page 13: ...mps 6 When water or solvent comes out of drain valves set hydraulic bypass valve to BYPASS position 7 Place suction hoses in paint drums 8 Close hydraulic bypass valve to activate pumps 9 When paint comes out of drain valves set hydraulic bypass valve to BYPASS position 10 Close all drain valves Prime Guns 1 Open only spray gun ball valves corresponding to paint pumps or color used NOTE Never open...

Page 14: ...n e Set throttle to half speed WARNING FIRE AND EXPLOSION HAZARD To reduce 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 8 Place empty pail under spray guns to catch drainage from spray guns 9 Turn pump lever s to select paint pump s 10 Close hydraulic bypass valve to activate pump...

Page 15: ...clip E 6 Center main beam on RoadLazer 7 Lock three red handle clamps A on main beam B See Fig 9 WARNING FIRE AND EXPLOSION HAZARD Gasoline is extremely flammable and explosive under certain conditions Fuel could spray from the fuel line connector when it is disconnected from engine Fuel could come in contact with the hot muffler and cause fire or explosion To reduce the risk of fire or explosion ...

Page 16: ...nt paint from drying in system 9 Relieve beads system pressure by turning bead system valve to OFF position 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 completely Then clear the valve or hose Removing RoadLazer from ...

Page 17: ... PSI bar 2000 137 9 10 14 16 Bead Nozzle 0 234 PSI bar 50 3 4 These settings produce approximately a 15 mil wet line with 6 lb of glass beads per gallon paint Different materials can produce different results See Bead Gun manual for additional application rate information For GHDXXX paint tips use 222674 tip holder For 221XXX paint tips use 237859 tip holder Filter Information Filters of 30 mesh a...

Page 18: ...ng nut wet cup full of throat seal liquid TSL at all times Battery Check the battery fluid level every 3 months Top off with water If the battery is newly purchased or has not been used for a long time charge it before you use it The battery self discharges during storage and gradually loses its capacity Periods of time over which the battery can be stored without requiring charging are shown belo...

Page 19: ... swivel hub A until tight then loosen 1 8 turn After every 3 months of operation torque boom arm wheel hub B until tight then loosen 1 4 turn Fig 11 B A 06253 Main Beam and Boom Arm Clamps CAUTION The main beam and boom arm clamps are capable of exerting great pressures due to their design If the clamps are over tightened the pressures exerted can bend the brackets attaching the clamps to the main...

Page 20: ...voir with 12 gallons 45 4 liters of Graco Hydraulic Oil Install fill cap 10 Run RoadLazer and cycle pumps for a few seconds to fill hydraulic motors with hydraulic oil Recheck hydraulic oil level Do not overfill Trailer Tire Removal Fig 14 WARNING FALLING OBJECT HAZARD A free standing RoadLazer could become unstable when raised by a portable jack To reduce the risk of injury and equipment damage D...

Page 21: ... overheat and cause ex treme bearing wear and short bearing life 4 Tighten axle castle nut 527 Loosen axle castle nut until it spins freely Turn axle castle nut hand tight and secure with cotter pin 528 5 Remove blocks under RoadLazer 6 Lower rear of RoadLazer with hydraulic jack Trailer Wheel Swivel Hub The trailer wheel swivel hub might require service over the life of the RoadLazer Service incl...

Page 22: ... and bolts 23 at base of air compressor 2 Slide compressor to right to remove tension on belt 3 Remove four nuts 15 and bolts 132 from rear plate A on hitch side of frame Remove plate 4 Remove two bolts 30 and washers 31 and 32 from left and right sides of hydraulic pump 5 Remove two bolts 13 and 115 from plate 108 behind pump Remove plate 6 Pull hydraulic pump back and remove belt 7 Push down new...

Page 23: ...f air fitting and pull down on air line 10 Remove air compressor Assembly 1 Place air compressor 22 over slots on cart for compressor Loosely install four nuts 24 and bolts 23 to base of compressor 2 Push down new belt from top Push hydraulic pump in and install belt Thread belt around idler and bottom drive pulley and install on compressor pulley Fig 16 3 Install plate 108 behind pump with two bo...

Page 24: ...nd half of coupler 16 10 Remove nipple 82 and remove reducer valve manifold 84 from hydraulic vane pump 33 11 Remove elbow 105 adapter 106 elbow 140 and insert 141 from hydraulic vane pump 33 Assembly 1 Install elbow 105 adapter 106 elbow 140 and insert 141 on hydraulic vane pump 33 2 Install nipple 82 and install reducer valve manifold 84 on hydraulic vane pump 33 3 Install hydraulic vane pump 33...

Page 25: ...4 Remove four locknuts 15 eight washers 21 and four capscrew 14 15 Remove vee belt 19 from engine pulley 16 Remove engine from main base Assembly 1 Place engine on main base 2 Be sure vee belt 19 is in place Thread belt around idler and bottom drive pulley see Fig 16 on page 22 Push engine in and install to other half of coupler 16 on hydraulic vane pump 3 Install four locknuts 15 eight washers 21...

Page 26: ...04 606 603 605 602 601 06257 104361 167024 171941 193331 186075 185632 Assembly 1 Install new O ring 601 2 Install spring 605 into filter bowl 604 3 Install filter support 603 and screen 602 into filter bowl 604 NOTE Order 167025 if screen 602 is damaged Order 104361 for new O ring 4 Screw filter bowl 604 into filter housing 606 Displacement Pump Service See manual 308650 Viscount I Hydraulic Moto...

Page 27: ...n silver toggle switch at top of unloader 41 to horizontal NOTE Unloader bypasses air when system pressure reaches approximately 100 psi 7 bar 2 Turn off bead tank air valve 47 to isolate system 3 If no leaks check paint gun actuation airline Paint gun actuation airline 1 Remove paint gun actuation airline 338 from paint gun 2 Trigger skipline controller 3 If air flows from airline repair paint gu...

Page 28: ...Check for broken wiring or damaged plug See Schematics on pages 49 to 51 3 Check for 12V DC between red wire and ground Note If all solenoids fail there is a broken wire replace wire If some solenoid operate and some fail replace failed solenoids Programmable Skipline Controller 1 Inspect wiring and plugs for damage 2 Replace any damaged wiring or plugs Manual 308616 Actual line length not matchin...

Page 29: ... coat of WD 40R Use air hose or water hose to break up and remove solidi fied beads from tank 2 Replace needle seat and packings Repair kit 238339 Gun arm wobbling or hopping excessively Swivel nut Gun arm wobbles 1 Remove dust cap 348 2 Tighten boom arm swivel nut 304 until swivel has slight restriction Gun arm hops 1 Lower air pressure in gun arm wheel 2 Replace damaged gas shock 307 Excessive o...

Page 30: ...ess you are ready to stripe 2 System Delay must be turned back on after engine is turned off or gun arm is returned to stowed position Controller not displaying MPH KM H or readout is erratic Gun arm sensor or sensor wiring 1 Check sensor 324 located on gun arm wheel assembly Set sensor approximately 1 8 in 3 mm from target plate 2 Check sensor head for damage Replace if damaged 3 Check sensor wir...

Page 31: ...ir leaks at gun nozzle or air fittings cause continuous moisture to be pumped into tank 3 For areas of extreme humidity a Bendix air dryer or equivalent may be installed in air line to bead tank Typically when beads are used continuously they do not spend enough time in tank to collect enough mois ture to be a problem Usually it is continuous stencil painting for long periods of time with little b...

Page 32: ...nstallation 1 See instruction manual 308670 2 Graco hitch kit must be installed on a 3 in x 3 in cross tube only Replace hitch with a DRAW TITE Ultra Frame Hitch Graco hitch kit receivers not spreading to 32 in 81 cm Too narrow vehicle frame 1 Some late model vehicles have a narrow frame Install Graco Hitch Kit and spread apart as far as possible 2 If still too narrow have a custom drawbar fabrica...

Page 33: ...ines must be removed Graco offers a Suction Line Strainer Kit 240499 that should be installed at least 2 ft from pump inlet to remove contamination Strainers must be cleaned regularly to avoid pump starving or cavitation D Waterborne paints cannot freeze or tolerate temperatures above 120_F 49_C Consult paint manufacturer D Use only Graco 300 grade stainless steel wetted replacement parts Other me...

Page 34: ...aulics Check for Leaks Change oil and filter ISO VG No 40 hydrau lic oil Paint Pumps TSL Fill Packings Check for wear and adjust Replace Hoses Check for damage Paint Guns Needle Oil Tips Clean after use Replace as needed Bead Guns Nozzle Check for clogs Replace as needed Needle Replace as needed Stencil Gun Replace as needed Trailer Wheel Swivel Hub Adjust hub castle nut Wheel Hub Pack with bearin...

Page 35: ...age 36 See page 38 See page 40 See page 48 238346 Main Base Assembly 238357 Boom Arm Assembly Pump Systems Bead Tank Assembly Engine System Battery System See manual 308616 See pages 42 and 44 See page 46 RoadLazer Line Striper Components 35 308611 Parts ...

Page 36: ...19 120 124 15 241 130 133 134 124 Ref A B C A B C 191 185 1 Pump System 2 Pump System 3 Pump System 1 Pump System 2 Pump System 3 Pump System 245 244 235 227 90 186 90 187 275 TI0649A 68 36 308611 Parts RoadLazer Line Striper Pump Systems 1 Pump System Model 231571 2 Pump System Model 231572 3 Pump System Model 231378 ...

Page 37: ...5 STRAINER inlet 3 74 176684 ADAPTER bung 3 75 100220 SCREW thumb grade 5 3 76 191641 CAP splash 3 90 191645 HOSE coupled 29 5 in 3 101 191647 HOSE coupled 27 0 in 3 104 235208 UNION adapter swivel 3 8 in npt m x 3 8 in npsm f 3 109 191688 GUARD belt compressor 1 116 166469 NIPPLE 3 8 in x 3 8 in sst 3 117 238782 FILTER fluid sst 3 118 501684 CHECK VALVE 3 8 in x 3 8 in sst 3 119 166866 ELBOW 90_ ...

Page 38: ...49 06260B 63 129 164 54 58 59 53 58 55 61 60 240 62 168 51 52 44 62 60 48 50 168 40 47 56 46 57 59 58 237 ref 168 168 239 38 308611 Parts RoadLazer Line Striper Bead Tank Assembly ...

Page 39: ...HING 1 52 104655 GAGE 1 53 238299 TANK bead 23 gallon 1 54 191222 FITTING bead tank 1 56 113291 REGULATOR air 1 57 100017 CAPSCREW hex hd grade 5 1 2 13 unc 2a 1 1 2 in 38 mm long 2 58 109570 WASHER plain 8 59 801020 NUT lock hex 1 2 13 unc 2b grade 5 4 60 113319 FITTING air 3 8 OD x 1 4 18 npt 1 61 191267 HOSE air 3 8 in x 164 in 417 cm 1 62 191643 HOSE air 3 8 in x 44 in 112 cm 2 63 104663 PLUG ...

Page 40: ... 29 32 115 115 32 108 140 105 106 92 100 34 35 30 32 31 82 84 95 92 33 85 107 167 37 114 15 1 141 67 89 3 192 181 218 86 90 Ref 27 206 91 06261A 139 247 242 87 83 205 206 2 1 Ref 136 257 136a 40 308611 Parts RoadLazer Line Striper Engine System ...

Page 41: ... 85 104813 PLUG pipe 3 8 18 npt 1 86 110311 NIPPLE straight 3 8 18 npt f x 3 4 16 unf 3 87 113703 REGULATOR hydraulic flow 3 89 191648 HOSE 1 in ID 1 90 191645 HOSE coupled 29 5 in 75 cm REF 91 210658 VALVE ball REF 92 107050 INSERT hose beaded 4 94 102473 CLAMP hose 2 95 191649 HOSE 0 63 in ID 15 in 38 cm 1 100 191651 HOSE 0 63 in ID 19 in 48 cm 1 105 107032 ELBOW 90_ 3 8 18 npt 1 106 156022 ADAP...

Page 42: ...19 423 423 412 413 418 417 451 94 457 451 94 458 419 423 416 414 415 420 421 445 444 406 408 189 15 418 422 401 409 146 145 15 37 213 184 182 13 461 461 462 454 456 403 447 419 410 460 249 169 169 198 215 417a 42 308611 Parts RoadLazer Line Striper Main Base Assembly 1 of 2 ...

Page 43: ... 2 409 100531 CAPSCREW hex hd grade 5 3 8 16 unc 2a 2 5 in 64 mm long 2 410 100731 WASHER 6 412 100469 CAPSCREW hex hd grade 5 3 8 16 unc 2a 3 4 in 19 mm long 5 413 191248 BASE pump mount 1 414 238806 FENDER tire painted 1 415 113820 BOLT hex hd 5 8 11 grade 8 6 416 113980 NUT lock 5 8 11 grade 8 6 417 113597 COOLER oil 1 417a 240798 KIT motor and fan replacement 1 418 100424 SCREW 4 419 801020 NU...

Page 44: ... 67 450 449 438 439 457 459 451 435 434 433 427 427 426 425 403 436 511 512 514 509 510 530 528 506 530 526 524 528 529 405 523 521 517 516 515 527 532 507 508 06263B 502 519 520 522 525 527 513 06945 7315A 423 410 421 421 464 410 460 518 44 308611 Parts RoadLazer Line Striper Main Base Assembly 2 of 2 ...

Page 45: ...3 103475 TEE pipe 1 2 14 npt f 1 455 106114 STRAINER inlet 1 457 191650 HOSE 0 63 in ID 14 in 36 cm REF 459 102473 CLAMP hose REF 464 114032 STRAP ground 1 500 238327 SWIVEL CASTER ASSEMBLY includes items 501 to 532 501 238324 FORK caster not shown 1 502 191182 SPINDLE fork 1 503 113961 SCREW cap hex hd grade 8 1 2 13 unc 2a 1 0 in 26 mm long not shown 6 504 113962 WASHER hardened sae not shown 6 ...

Page 46: ...327 309 313 309 15 330 315 308 326 327 305 304 301 310 353 355 354 307 333 339 341 334 336 337 335 342 332 316 317 319 318 324 345 346 340 343 344 317 318 331 338 Ref 321 338 362 323 322 317 311 324 363 364 365 366 367 368 Hitch Pin Detail 372 370 369 374 370 Ref 330 Ref 309 320 373 46 308611 Parts RoadLazer Line Striper Boom Arm Assembly ...

Page 47: ...1834 NIPPLE pipe hex 2 332 191164 ARM mounting gun 90_ 4 333 207123 UNION swivel 90_ 3 8 in npsm f x 3 8 in npt m 3 334 238329 GUN spray bead See manual 308612 for parts 2 335 191163 ARM pivot gun 2 336 100101 CAPSCREW hex hd grade 5 8 3 8 16 unc 2a 1 0 in 25 mm long 337 100133 WASHER lock 3 8 in 8 338 191191 HOSE air 1 4 in OD 12 in 305 mm long 4 339 238694 VALVE ball 3 340 113321 FITTING elbow t...

Page 48: ...7 801958 PROTECTOR terminal red 1 8 801959 PROTECTOR terminal black 1 9 803525 BOLT battery 2 10 107069 CLAMP battery 1 11 100527 WASHER wrought 4 12 100016 WASHER lock 5 13 102040 NUT lock hex grade 5 1 4 20 unc 3b REF 14 102638 CAPSCREW hex hd grade 5 3 8 16 unc 2a 2 in 51 mm long REF 15 101566 LOCKNUT nylon 3 8 16 REF 21 100132 WASHER flat REF 37 100022 CAPSCREW hex hd grade 5 3 8 16 unc 2a 2 i...

Page 49: ...ines 1 1 Electronic control from Programmable Skipline Controller 2 2 Solenoid air valve 3 3 A E D B C A B C D E Paint gun 1 Paint gun 2 Bead gun 1 Bead gun 2 12V DC 06266 49 308611 Schematics Solenoid Air Valves ...

Page 50: ...1 From compressor To valve pack From pump 3 To pump 3 To pump 2 To pump1 To valve pack To extra valves To proximity sensor To battery post To battery post To cooling fan To engine switch 06267 1 5 3 2 4 Ref No Part No Description Qty 1 113486 CABLE power 1 2 113315 HOSE bead 3 4 in 2 3 191267 HOSE air 1 4 238952 KIT hose replacement 3 5 191857 TUBE protection 1 50 308611 Schematics Main Harness 23...

Page 51: ...e black R B Red black R W Red white G B Green black O B Orange black A B C D A B C A B C A B C A B C A B C D A E C B A P11 P12 P13 20 20 14 15 16 3 2 2 Fuse 20A 32V type AGC protects the following D Fan P13 D Solenoid air valves P6 D Proximity sensors for the pump skip timer and gun arm stowed safety P1 P4 Fuse 4A 32V type AGC protects the Programmable Skipline Controller P12 G 5 2 6 10 11 15 14 1...

Page 52: ...d Accessory 238957 Includes deflector tube ball valve 3 8 in nylon hose and tank fitting Manual 308679 Second Stencil Gun Kit 238958 Includes Flex Airless Spray Gun 50 ft hose and clamp assembly Manual 308681 Remote Digital Speed Indicator 238963 Includes LCD display and output cable Manual 308680 Spare Tire Kit 239029 Includes tire wheel and hub assembly Pump Kit 239041 Includes everything needed...

Page 53: ...s trailer weight 1090 1415 lb 494 641 kg Gross tongue weight each 380 470 lb 172 213 kg Gross axle weight 430 480 lb 195 218 kg Towing height boom arm raised 7 5 ft 2 3 m Engine KohlerR 18 HP Fluid connections paint two 3 8 npt f ports Air connections 1 4 npt f air inlets Hydraulic oil reservoir capacity 12 gallons 45 liters Glass bead capacity 300 lb 136 kg Wetted parts tungsten carbide 303 316 4...

Page 54: ...ost 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...

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