Graco 308611B Hydraulic, Stainless Steel, Line Striper Road Lazer System Owner's Manual

INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
308–611
Rev. B
Supercedes Rev. A
INSTRUCTIONS
Hydraulic, Stainless Steel, Line Striper
Road Lazer System
2000 psi (138 bar) Maximum Working Pressure
Model 231–378, Series A
United States Patent No. 5, 368, 232
Other US Patents Pending
06241
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN
COPYRIGHT 1996, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
55440–1441
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Introduction and General Information . . . . . . . . . . . . . 5
Component Identification and Function . . . . . . . . . . . . 6
Pre-Installation Requirements . . . . . . . . . . . . . . . . . . . . 8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Application Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
25
27
41
48
48
48
Symbols
Warning Symbol
Caution Symbol
WARNING
CAUTION
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury.
D If there is any static sparking or you feel an electric shock while using this equipment, stop spraying immediately. Do not use the equipment until you identify and correct the problem.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed.
D Keep the spray area free of debris, including solvent, rags, and gasoline.
D If spraying indoors, electrically disconnect all equipment in the spray area.
D Extinguish all open flames or pilot lights in the 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 on page 13.
WARNING
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely
serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also
cause serious injury.
D Fluid injected into the skin is a serious injury. The injury may look like just a cut, but it is a serious
injury. Get immediate medical attention.
D Do not point the gun at anyone or at any part of the body.
D Do not put your hand or fingers over the spray tip.
D Do not stop or deflect leaks with your hand, body, glove or rag.
D Do not “blow back” fluid; this is not an 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. Refer to the gun manual.
D Be sure the gun ball valves and stencil gun trigger safety operate before spraying.
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 15 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
D Tighten all fluid connections before operating the equipment.
D Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high pressure couplings; you must replace the entire hose.
D Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
D Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
D This equipment is for professional use only.
D Read all instruction manuals, tags, and labels before operating the 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.
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. Refer to the
Technical Data on page 48 for the maximum working pressure of this equipment.
D Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
D Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
D Do not use hoses to pull equipment.
D Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 65_C (150_F) or below –40_C (–40_F).
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
D Do not raise the Road Lazer with a jack unless the Road Lazer is connected to a tow vehicle.
D Wear ear protection when operating this equipment.
4
308-611
Introduction and General Information
INTRODUCTION
This manual provides pre-installation requirements,
installation, operation and maintenance instructions
and a parts breakdown for the Road Lazer system
when used with the related manuals:
D 308–612: Bead Spray Gun
D 308–613: Paint Spray Gun
D 308–616: Programmable Skipline Control
Video Guidance Systemt (optional)
The Video Guidance System provides the operator
with a bore sight view for alignment. The system
consists of a 6 in. x 5.5 in. monitor, interfacing cables,
video camera and mounting bracket.
Viscount I Hydraulic Motors
D 308–674: Viscount I Hydraulic Motor
and Displacement Pump
The Viscount I Hydraulic Motors power the displacement pumps to supply paint to the spray gun. There
are three hydraulic motors. Two hydraulic motors
provide power for the yellow paint displacement pumps
and one powers the displacement pump for white
paint.
GENERAL INFORMATION
Displacement Pumps
D 308–618: Viscount I Hydraulic Motor
D 308–650: Displacement Pump
The Road Lazer is attached to a pickup truck as the
means of transport and is used to stripe up to two
stripes and in one or two colors with glass beading.
The Road Lazer consists of a Programmable Skipline
Control, a Front Mechanical Guidance System, three
Viscount I Hydraulic Motors, three Displacement
Pumps, two Paint Spray Guns and two Bead Spray
Guns.
Programmable Skipline Control
The Programmable Skipline Control consists of the
programmable skipline control and a 30 ft cable. It is
the main control for the RL system. It is used to turn
the spray guns and accessories on and off.
Front Mechanical Guidance System
The Mechanical Guidance System provides the operator with a bore sight view for alignment on either the
left or right side of the vehicle. Fig. 3.
The Displacement Pumps are powered by the
Viscount I Hydraulic Motors to supply paint to the
spray guns. There are three displacement pumps. Two
displacement pumps provide yellow paint to the two
yellow paint spray guns and one provides white paint
to the white paint spray gun.
Paint Spray Guns
The Paint Spray Guns are pneumatically triggered to
spray paint stripes when commanded by the Programmable Skipline Control.
Bead Spray Guns
The Bead Spray Guns are pneumatically triggered to
spray glass beads when commanded by the Programmable Skipline Control.
Receivers
The two clamp-on receivers are mounted on the
installed trailer hitch to provide receptacles for 2 in. ball
mounts. See Manual 308–670 for receiver mounting
instructions.
308-611
5
Component Identification and Function
O
P
A
R
S
T
B
U
C
D
E
V
F
G
H
W
I
X
J
Y
K
L
M
N
Z
AA
AB
06242
Fig. 1
Component Identification and Function
A
Viscount I Hydraulic Motor
Operates the displacement pump
B
Boom Arm Hitch Pin
Secures spray gun boom arm when the Road Lazer is in transport
C
Displacement Pump
Provides fluid to be sprayed through spray gun
D
Fluid Outlet
Supplies fluid from displacement pump to spray gun (not shown)
E
Fluid Filter
Filters fluid between source and spray gun
F
Breather Cap
Provides a means for hydraulic reservoir ventilation, oil check and fill
G
Pressure Drain Valve
Relieves fluid pressure when open
H
Fluid Inlet
Displacement pump entry for fluid from paint drums (not shown)
I
Hydraulic Reservoir
Holds 12 gallons of hydraulic oil for hydraulic pump
J
Hydraulic Select/BYPASS Valve
Selects displacement pumps for guns 1 & 2, or 3; or by-passes all guns
K
Swivel Hub
Allows trailer wheel to swivel
L
Hydraulic Pump
Creates hydraulic pressure for the hydraulic power supply system
M
Wheel Hub
Supports trailer wheel and allows free rotation of wheel
N
Main Beam
Supports spray gun boom arm
O
Bead Tank
Holds up to 300 lb of glass beads for continuous spraying
P
Air Regulator
Allows regulation of bead tank air pressure
R
Programmable Skipline Control
Allows the operator to program the operation of the Road Lazer.
S
I/O Cable
Carries electronic control signals from the Programmable Skipline
Control to Road Lazer.
T
Compressor
Provides pneumatic supply to switch paint spray gun and bead spray
guns on and off as directed by the programmable skipline control
U
Engine*
18.0 HP gasoline engine
V
Tail Light
Standard tail light that includes brake and directional lights
W
Hydraulic Pressure Knob
Provides adjustment of hydraulic pressure. Clock wise rotation increases pressure. Pressure setting is locked with inner lock knob.
X
Jack
Used to roll Road Lazer into place for connection to tow vehicle and
hold Road Lazer upright when disconnected from tow vehicle and
stored
Y
Spray Gun Boom Arm
Allows striping on either side of the tow vehicle at adjustable distances
Z
Bead Spray Gun
Sprays beads when commanded by the programmable skipline control
AA
Paint Spray Gun
Sprays fluid when commanded by the programmable skipline control
AB
Fuel Tank
Holds 6 gallons (23 liters) of 86 octane gasoline
Choke*
Enriches air/gasoline mixture for cold starting
Throttle*
Adjusts engine speed for large or small orifice spray tips
Engine Switch*
Enables/disables engine operation
*
For more detailed explanations of these controls, refer to the Kohler engine manual; supplied
308-611
7
Pre-Installation Requirements
Vehicle
Paint Drum Bracket
The tow vehicle must have 1/2 ton or greater carrying
capacity with the following additional equipment:
D Warning lights and/or sign board per federal, state
and local regulations. Reference Part IV of the
Manual on Uniform Traffic Control Devices
(MUTCD) by the U.S. Department of Transportation, Federal Highway Adminstration for federal
regulations.
WARNING
Paint drums are heavy and may shift from side to
side when the tow vehicle is cornering. The paint
drums could fall from the vehicle causing possible
injury or death. Secure the drums when the vehicle
is in transport or spraying.
D Secure paint supply containers that can be sealed
during transport.
It is recommended that the paint drums are secured
with a paint drum bracket. Graco does not provide the
paint drum bracket.
D Standard trailer light connector.
Front Mechanical Guidance System
D DRAW-TITER Class III Ultra Frame Hitch with two
Graco clamp-on receivers that are 32 inches on
center.
The Front Mechanical Guidance System 238–801 is
mounted on a trailer hitch installed on the front of the
tow vehicle. The hitch is a single 2 in. x 2 in. receiver
as shown in Fig. 3. Graco does not provide receiver.
D A 2 in. x 2 in. front receiver (not provided by
Graco).
D I/O cable access from the tow vehicle cab to the
Road Lazer.
Hitch
The DRAW-TITER Class III Ultra Frame Hitch (not
provided by Graco) must be Installed by a certified
DRAW-TITER installer.
Choose a ball mount that allows the Road Lazer to
travel level to the ground with an average payload. A
recommended option is two DRAW-TITER adjustable
2 in. ball mounts. See Fig. 2.
32 in.
Fig. 2
Fig. 3
06196
Receivers
Two Graco clamp-on receivers must be mounted 32
inches on center on the installed DRAW-TITER Class
III Ultra Frame Hitch. Refer to Manual 308–670 for
mounting instructions. See Fig. 2.
Hitch
06243
Programmable Skipline Control
The Programmable Skipline Control 238–050 is
installed in the cab of the tow vehicle. Select a position
for ease of operation. The Road Lazer control system
connects to the Road Lazer with an I/O cable so there
must be a cable access from the tow vehicle cab to the
Road Lazer. See Manual 308–616.
Installation
NOTE: Reference numbers and letters in parentheses
in the text refer to Fig. and Parts Drawings callouts.
Size Ball Mount to Road Lazer
Use the following procedure to assure level operation
of the Road Lazer. Fig. 4.
1. Empty tow vehicle of any payload.
2. Measure 21 in. from top of ball mount to ground.
06245
Fig. 5
21 in.
Loading and Unloading Paint
06244
Fig. 4
Connect Road Lazer To Vehicle
Connect the Road Lazer to the vehicle as follows:
WARNING
Paint drums are heavy and may shift from side to
side when the tow vehicle is cornering. The paint
drums could fall from the vehicle causing possible
injury or death. Secure the drums when the vehicle
is in transport or spraying.
1. Install two ball mounts in hitch receivers:
a. Slide ball mount into hitch receiver.
b. Insert pin.
c.
Insert clip.
2. Connect Road Lazer to ball mounts:
a. Roll Road Lazer to vehicle and align Road
Lazer trailer arms with ball mounts.
b. Crank trailer arm jacks to clear ball mounts.
c.
Roll Road Lazer forward and align Road Lazer
trailer arms over ball mounts.
d. Crank trailer arm jacks to lower Road Lazer
trailer arms onto ball mounts.
e. Rotate jack to horizontal position. Snap retaining handles in place to secure jacks.
f.
Connect safety chains.
CAUTION
Paint may splash from paint drum bung adapters
when paint drums are full and vehicle is moving. Do
not over fill paint drums.
1. Use fork lift to install 55 gallon paint drums or
transfer pump for drums already installed.
2. Secure paint drums.
Insert the Fluid Lines
There are three suction lines; one white and two
yellow. Insert the lines into their respective paint
drums.
ACCESSORIES INSTALLATION
Video Guidance System
See Manual 308–617.
308-611
9
Installation
Align Front Mechanical Guidance System
WARNING
The gun arm has a safety sensor that does not
allow the spray guns to spray when the gun arm is
in the upright position. Do not remove or impair this
sensor. A skin injection injury or splashing in the
eyes may occur.
8. Make reference marks on front mechanical pointer
when alignment is attained to shorten future setup
times.
NOTE: The more distant the visual reference point, the
straighter the paint lines will be.
1. Unlock three red-handle clamps (A) on main beam
(B) and slide main beam completely out to side
selected for painting. See Fig. 6. Lock two redhandle clamps (D). See Fig. 7.
2. Pull gun arm hitch pin out of frame.
3. Pull gun arm (C) back and out to end of main
beam and set on ground. See Fig. 6.
4. Put gun arm hitch pin back in frame.
C
A
B
Fig. 6
06246
5. Lock red-handle clamp (A) in place on main beam.
6. Drive tow vehicle to align spray gun on gun arm
with stripe to be painted.
7. Move front mechanical pointer left or right to align
with stripe to be painted. Move front mechanical
pointer up and down as necessary for visual
alignment. See Fig. 7.
NOTE: The front mechanical pointer and the gun arm
may be used on on either side of tow vehicle.
Fig. 7
D
D
06247
Operation
EMERGENCY SHUT OFF
Start Engine
The entire Road Lazer system is shut down by simply
setting POWER ON/OFF on the Programmable Skipline Control to OFF.
Loading Glass Beads
06248
Fig. 8
1. Set POWER ON/OFF on Programmable Skipline
Control to OFF.
2. Set engine ignition key to OFF.
3. Relieve air pressure.
1. Set POWER ON/OFF on Programmable Skipline
Control to ON.
2. Set hydraulic pump lever in BYPASS position.
3. Connect gas tank fuel line to Road Lazer fuel
intake.
4. Open fuel tank vent.
4. Remove cover from bead tank.
5. Prime fuel line.
6. Pull choke out.
5. Screen glass beads to prevent debris from entering tank.
7. Set throttle.
8. Turn key.
6. Load bead tank with glass beads.
9. After engine starts, push choke in.
Operation
Prepare the System for Painting
a. Set hydraulic pump lever in BYPASS position.
1. Set hydraulic pump lever in BYPASS position.
b. Pull choke out.
2. Ground Road Lazer ground strap to earth ground.
Fig. 10.
c.
3. Turn on Road Lazer Control System in the vehicle.
e. After engine starts, push choke in.
Set throttle.
d. Turn key.
10. When water or solvent comes out of drain valve,
place hydraulic pump lever in BYPASS position
11. Place paint suction hose in paint drum.
12. Turn BYPASS lever to select the paint pump(s)
desired.
13. When paint comes out of the drain valves, place
hydraulic pump lever in BYPASS position and
close drain valves.
hydraulic pump lever
in BYPASS position
Fig. 9
14. Open only spray gun ball valves corresponding to
paint pumps or color used.
06249
4. Fill a five gallon pail with water or compatible
solvent. Place paint suction hose in pail of water or
solvent.
15. Place an empty pail under the spray guns to catch
drainage from the spay guns.
16. Turn hydraulic pump lever to select gun. When
paint comes out of spray gun, place hydraulic
pump lever in BYPASS position.
5. Place an empty pail under the drain valves to
catch drainage from the drain valves.
17. Set hydraulic pressure to maximum or slightly
lower.
6. Open all paint drain valves.
18. Select appropriate air pressure on pressure tank
regulator.
7. Turn hydraulic pump lever to select paint pump(s).
8. Set hydraulic pressure to approximately 500 psi.
9. Start engine.
Begin to Spray
Select appropriate procedure from menu on Road
Lazer control system. See Manual 308–616.
Operation
Flush the System
5. Open all paint pump drain valves.
Before flushing, always follow the Pressure Relief
Procedure on page 15. Flush the system with a
compatible solvent. Check the system under pressure
for leaks; if any are found, follow the Pressure Relief
Procedure on page 15 and repair the leaks. Pressurize the system again and make sure the leaking has
stopped.
6. Turn on Road Lazer Programmable Skipline Control in the vehicle.
1. Ground Road Lazer ground strap to earth ground.
Fig. 10.
7. Start engine.
a. Pull choke out.
b. Set throttle.
c.
Turn key.
d. After engine starts, push choke in.
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 when
flushing.
1
8. Place empty pail under spray guns to catch drainage from spray guns.
1
Water pipe, steel sign post or light pole.
Fig. 10
9. Open spray gun ball valves.
06250
2. Place hydraulic pump lever in BYPASS position.
Fig. 9.
10. Turn hydraulic pump lever to select paint pump(s).
11. When water or solvent comes out of spray guns
and drain valves, place hydraulic pump lever in
BYPASS position.
3. Fill five gallon pail with water or compatible solvent. Place paint suction hose in pail of water.
12. Shut off engine.
4. Place empty pail under drain valves to catch
drainage from drain valves.
13. Leave paint pump drain valves and spray gun ball
valves open.
Operation
Prepare the Road Lazer for Transport
CAUTION
Never transport the Road Lazer while the system
has the paint gun ball valves open, system under
pressure and engine running as this may cause
damage to components.
1. Unlock all three red-handle clamps (A) on main
beam.
2. Lift spray gun arm (C) up from ground and push in
to center of Road Lazer. See Fig. 11.
D
E
C
B
3. Pull gun arm hitch pin (D) out of frame.
4. Push spray gun arm in to frame.
5. Put gun arm hitch pin back in frame and secure
with clip (E).
A
6. Center main beam on Road Lazer.
7. Lock three red-handle clamps (A) on main beam
(B). See Fig. 11.
14
308-611
Fig. 11
06251
Operation
Pressure Relief Procedure
WARNING
INJECTION HAZARD
The system pressure must be manually
relieved to prevent 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:
D
D
D
D
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
install or clean the spray tip.
1. Set hydraulic pump lever in BYPASS position.
2. Place empty pail under the drain valves to catch
drainage from the drain valves.
3. Open all paint drain valves.
4. Place empty pail under guns to catch drainage
from the guns.
5. Actuate guns to relieve pressure.
Removing Road Lazer from Vehicle
WARNING
The Road Lazer is heavy. If the Road Lazer is
parked on asphalt or ground, the jacks may sink
into the asphalt or ground and cause the Road
Lazer to tip over, causing possible injury or death.
1. Rotate jacks clockwise to vertical position. Snap
retaining handles in place to secure jacks.
2. Crank trailer arm jacks to raise Road Lazer trailer
arms from ball mounts.
3. Disconnect safety chains.
4. Roll Road Lazer backward and clear of ball
mounts.
5. Park the Road Lazer on a concrete slab whenever
the Road Lazer is disconnected from the tow
vehicle.
6. Crank jacks down equally to bring Road Lazer to
level position for storage.
6. Shut off engine.
7. Leave drain valve(s) open until ready to spray
again.
8. Close all ball valves when paint is left in system to
prevent paint from drying in system.
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 completely. Now clear the valve or hose.
308-611
15
Application Data
Paint and Bead Guns
PAINT LINE WIDTH PER GUN
MPH (KPH)
4 in. (10 cm)
6 in. (15 cm)
8 in. (20 cm)
10 in. (25 cm) 12 in. (30 cm)
Paint Tip
433
439
645
651
657
PSI (bar)
2000 (137)
2000 (137)
2000 (137)
2000 (137)
2000 (137)
0.234
0.234
0.234
0.234
0.234
PSI (bar)
20 (1.4)
30 (2.1)
40 (2.8)
50 (3.4)
60 (4.1)
Paint Tip
439
445
651
657
663
PSI (bar)
2000 (137)
2000 (137)
2000 (137)
2000 (137)
2000 (137)
0.234
0.234
0.234
0.234
0.281
30 (2.1)
40 (2.8)
50 (3.4)
60 (4.1)
50 (3.4)
Paint Tip
445
451
657
663
PSI (bar
2000 (137)
2000 (137)
2000 (137)
2000 (137)
0.234
0.234
0.234
0.281
PSI (bar
40 (2.8)
50 (3.4)
60 (4.1)
50 (3.4)
Paint Tip
451
457
663
PSI (bar)
2000 (137)
2000 (137)
2000 (137)
0.234
0.234
0.281
50 (3.4)
60 (4.1)
50 (3.4)
3–4 (5–7)
Bead Nozzle
5–6 (8–10)
Bead Nozzle
PSI
7–8 (11–13)
Bead Nozzle
9–10 (14–16)
Bead Nozzle
PSI (bar)
These settings produce approximately a 15 mil
wet line with 6 lb of glass beads per gallon paint.
Different materials may produce different results.
Filter Information
Filters of 30 mesh are recommended for most applications. For smaller tips or if frequent tip plugging occurs,
use 60 mesh filters.
Requires two pumps to
operate in this range.
Maintenance
Cleaning
Fueling
Clean the Road Lazer daily, as follows:
CAUTION
Be sure that the solvent you use is compatible with
the fluid being dispensed, to avoid clogging the
system fluid passages.
An important part of the care and maintenance of the
Road Lazer system is proper flushing. Flush the valves
daily with a compatible solvent until all traces of fluid
are removed from the system passages. Follow the
Pressure Relief Procedure on page 15 before flushing.
CAUTION
WARNING
FIRE AND EXPLOSION HAZARD
Gasoline is extremely flammable and
explosive under certain conditions. To
reduce the risk of a fire or explosion,
always follow the refueling procedure.
1. Shut off engine before fueling.
2. Refuel in well-ventilated area.
3. Do not smoke or allow flames or sparks in refuel
area or gasoline storage area.
4. Do not overfill tank. Close filler cap securely after
refueling.
Never immerse the system components in solvent.
Immersing in solvent removes lubricants and tends
to damage packings.
5. Remove any spilled fuel before starting engine.
Clean the outside surfaces of the system by wiping
with a soft cloth dampened with a compatible solvent.
6. Secure fuel tank (AB) to prevent fuel tank from
tipping during operation and transport.
Fuel Filter
Replace fuel filter after each year of operation.
Engine
Check engine oil level daily.
Refer to Kohler engine manual for proper care and
maintenance of engine.
Air compressor
Check air compressor oil level daily.
Refer to air compressor manual for proper care and
maintenance of air compressor.
Battery
Check the battery fluid level every 3 months. Top off
with water.
Displacement Pumps
Keep packing nut/wet cup full of throat seal liquid
(TSL) at all times.
Hydraulic Supply System
CAUTION
Dust or dirt in the hydraulic system may damage the
hydraulic system components. Do not allow dust or
dirt to get into the hydraulic system when servicing
the system.
1. Check the hydraulic oil level weekly.
2. Change the return line filter (36) every 500 hours
or 6 months of operation.
3. Change the hydraulic oil every 2000 hours or 12
months of operation. See Service.
308-611
17
Maintenance
Trailer Swivel Hub
Boom Arm Swivel Hub
CAUTION
Improper torque on trailer swivel hub castle nut could
leave trailer swivel hub free of restriction and cause
the swivel wheel to wobble. A wobbling swivel wheel
may result in serious damage.
Fig. 12. It is normal for the swivel wheel to turn hard
(restricted). After every 3 months of operation:
Fig. 13. After every 3 months of operation torque boom
arm swivel hub (A) until tight; then loosen 1/8 turn.
Boom Arm Wheel Hub
Fig. 13. After every 3 months of operation torque boom
arm wheel hub (B) until tight; then loosen 1/8 turn.
1. Turn trailer swivel hub castle nut (A) until tight;
then loosen one complete turn.
2. Secure with cotter pin (B). No lubrication required.
A
Trailer Wheel Hub
CAUTION
Overtightening trailer wheel hub castle nut may
cause wheel bearings to overheat and cause extreme bearing wear and short bearing life.
Fig. 12. After every 3 months of operation:
1. Tighten trailer wheel castle nut until tight.
2. Loosen trailer wheel castle nut until wheel spins
freely.
3. Turn trailer wheel hub castle nut (C) hand tight;
then secure with cotter pin (D).
06253
Fig. 13
Main Beam and Boom Arm Clamps
A
B
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 beam or boom arm. Do not over tighten the
clamps.
C
D
Fig. 12
B
06252
Check daily that main beam and boom arm clamps are
capable of securing main beam and boom arm without
bending attaching brackets. Adjust as necessary.
Service
Hydraulic Supply System Oil Change
CAUTION
Dust or dirt in the hydraulic system may damage the
hydraulic system components. Do not allow dust or
dirt to get into the hydraulic system when servicing
the system.
The hydraulic oil is changed as follows:
1. Relieve pressure. Perform Pressure Relief Procedure on page 15.
2. Place 15 gallon waste pail under hydraulic reservoir drain plug.
3. Remove o-ring (38) and drain plug (39) and drain
reservoir.
WARNING
FALLING OBJECT HAZARD
A free standing Road Laser may become unstable if raised with a jack. The
Road Laser may fall on you and cause
serious bodily injury or death. Do not raise the
Road Laser with a jack unless the Road Laser is
connected to a tow vehicle.
1. Connect Road Laser to tow vehicle.
2. Raise rear of Road Laser with hydraulic jack.
3. Place blocks under Road Laser as precaution
against jack failure or slippage.
4. Loosen five lug nuts.
5. Remove cotter key (7) from axle castle nut (6).
4. Replace o-ring (38) and drain plug (39).
6. Remove axle castle nut (6), axle bolt (19) and
spacers (5).
5. Remove nuts (5) gasket (25) and reservoir cover
(26).
7. Remove lug nuts and wheel.
6. Remove return line filter (36). Install new return
line filter.
7. Inspect inlet filter. Replace if necessary.
8. Install nuts (5), gasket (25) and reservoir cover
(26).
6
5
9. Fill reservoir with 12 gallons of Graco Hydraulic
Oil. Install fill cap.
10. Run Road Lazer and cycle pumps for a few seconds to fill hydraulic motors with hydraulic oil.
Recheck hydraulic oil level. Do not over fill.
7
5
Trailer Tire Removal
Any service station can repair a Road Laser flat tire.
Proceed as follows:
19
Fig. 14
06254
308-611
19
Service
Trailer Tire Replacement
WARNING
Static electricity may cause fire and/or explosion
and possible injury or death. Replacement of the
Road Lazer trailer tire with a non-conductive tire
may cause static electricity buildup. Replace the
Road Lazer tire only with a class C (conductive) tire
marked 5.70–8(C).
1. Install wheel and lugs nuts.
CAUTION
Serious damage will occur to trailer wheel and axle
assemblies if the spacers are not installed.
2. Install spacers (5), axle bolt (19) and axle castle
nut (6).
CAUTION
Overtightening trailer wheel hub castle nut may
cause wheel bearings to overheat and cause extreme bearing wear and short bearing life.
6. Pull hydraulic pump back and remove belt.
7. Push down new belt from top. Push hydraulic
pump in and install belt.Thread belt around idler
and bottom drive pulley, then install on compressor
pulley. Fig. 15.
8. Push hydraulic pump back into place, aligning
coupler with mating half on engine.
9. Install plate (108) behind pump with two bolts (13
and 115).
10. Install two bolts (30), washers (31) and (32) to left
and right sides of hydraulic pump.
11. Slide compressor to left to tension belt. Adjust belt
tension for 1/2 in. total play.
12. Tighten four nuts (24) and bolts (23) at base of air
compressor.
13. Install rear plate. Secure plate on hitch side of
frame with four nuts (15) and bolts (132).
3. Tighten axle castle nut (6). Loosen axel castle nut
until it spins freely. Turn axel castle nut hand tight;
then secure with cotter pin (7).
4. Tighten five lug nuts. Torque to 60 – 70 ft-lb.
5. Remove blocks under Road Laser.
6. Lower rear of Road Laser with hydraulic jack.
Air Compressor Belt Replacement
1. Loosen four nuts (24) 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 on hitch side of frame. Remove plate.
4. Remove two bolts (30), 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.
Fig. 15
06255
Service
Air Compressor Replacement
Disassembly
Assembly
1. Follow Pressure Relief Procedure on page 15.
1. Place air compressor over slots on cart for air
compressor. Loosely install four nuts (24) and bolts
(23) to base of air compressor.
2. Set POWER ON/OFF on Programmable Skipline
Control to OFF.
3. Remove 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 on hitch side of frame. Remove plate.
6. Remove two bolts (30), washers (31) and (32)
from left and right sides of hydraulic pump.
7. Remove two bolts (13 and 115) from plate (108)
behind pump. Remove plate.
8. Pull hydraulic pump back and remove belt.
9. Disconnect two air lines from air compressor.
e. Use flat side of 7/16 in. open-end wrench.
f.
Push up on base of air fitting and pull down on
air line.
10. Remove air compressor.
2. Push down new belt from top. Push hydraulic
pump in and install belt.Thread belt around idler
and bottom drive pulley, then install on compressor
pulley. Fig. 15.
3. Install plate (108) behind pump with two bolts (13
and 115).
4. Install two bolts (30), washers (31) and (32) to left
and right sides of hydraulic pump.
5. Slide compressor to left to tension belt. Adjust belt
tension for 1/2 in. total play.
6. Tighten four nuts (24) and bolts (23) at base of air
compressor.
7. Install rear plate. Secure plate on hitch side of
frame with four nuts (15) and bolts (132).
8. Connect two air lines to air compressor.
a. Use flat side of 7/16 in. open-end wrench.
b. Push up on base of air fitting and insert air
line.
Service
Hydraulic Vane Pump Replacement
Disassembly
Assembly
1. Follow Pressure Relief Procedure on page 15.
1. Install elbow (105), adapter (106), elbow (140) and
insert (141) on hydraulic vane pump (33).
2. Set POWER ON/OFF on Programmable Skipline
Control to OFF.
3. Remove two bolts (30), washers (31) and (32)
from left and right sides of hydraulic pump.
4. Remove two bolts (13 and 115) from plate (108)
behind pump. Remove plate.
2. Install nipple (82) and install reducer (BYPASS
valve) (84) on hydraulic vane pump (33).
3. Install hydraulic vane pump (33), reducer (BYPASS valve) (84) and half of coupler (16). If coupler half has been removed, install coupler half on
hydraulic vane pump shaft to dimension in Fig. 16.
.15± .01
CAUTION
Dust or dirt in the hydraulic system may damage the
hydraulic system components. Do not allow dust or
dirt to get into the hydraulic system when servicing
the system.
5. Disconnect three hydraulic fittings (90 and 91) on
top of reducer (BYPASS valve) (84).
6. Loosen clamp (94) and remove hydraulic by-pass
hose (95) at rear of reducer (BYPASS valve) (84).
7. Loosen clamp (67) and remove hydraulic inlet
hose (89) from hydraulic vane pump (33).
8. Loosen clamp (94) and remove hydraulic return
hose (98) from hydraulic vane pump (33).
16
Fig. 16
06256
4. Install hydraulic return hose (98) and clamp (94) to
hydraulic vane pump (33). Tighten clamp (94).
5. Install hydraulic inlet hose (89) and clamp 967) to
hydraulic vane pump (33). Tighten clamp (67).
6. Install hydraulic by-pass hose (95) at rear of
reducer (BYPASS valve) (84). Tighten clamp (94).
9. Remove hydraulic vane pump (33), reducer (BYPASS valve) (84) and half of coupler (16).
7. Connect three hydraulic fittings (90 and 91) on top
of reducer (BYPASS valve) (84).
10. Remove nipple (82) and remove reducer (BYPASS
valve) (84) from hydraulic vane pump (33).
8. Install plate (108) behind hydraulic vane pump (33)
with two bolts (13 and 115).
11. Remove elbow (105), adapter (106), elbow (140)
and insert (141) from hydraulic vane pump (33).
9. Install two bolts (30), washers (31) and (32) to left
and right sides of hydraulic vane pump.
Service
Engine Replacement
Disassembly
Assembly
1. Follow Pressure Relief Procedure on page 15.
1. Place engine on main base.
2. Set POWER ON/OFF on Programmable Skipline
Control to OFF.
2. Be sure vee belt (19) is in place. Thread belt
around idler and bottom drive pulley. Fig. 15. Push
engine in and install to other half of coupler (16) on
hydraulic vane pump.
3. Loosen four nuts (24) and bolts (23) at base of air
compressor.
4. Slide compressor to right to remove tension on
belt.
3. Install four locknuts (15), eight washers (21), and
four capscrews (14).
5. Remove four nuts (15) and bolts (132) from rear
plate (110) on hitch side of frame. Remove plate.
4. Install lower muffler mounting bracket with four
screws.
6. Remove two bolts (30), washers (31) and (32)
from left and right sides of hydraulic vane
pump (33).
5. Connect fuel line at fuel pump.
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
Control.
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
Control.
9. Push in hydraulic vane pump (33).
10. Disconnect battery cable to 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 capscrews (14).
15. Remove vee belt (19) from engine pulley.
16. Remove engine from main base.
10. Install plate (108) behind hydraulic vane pump
(33). Install with two bolts (13 and 115).
11. Install two bolts (30), 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.
Service
Paint Filter Replacement
Disassembly
Assembly
1. Do Flush the System procedure on page 13.
1. Install new o-ring (601).
2. Follow Pressure Relief Procedure on page 15.
3. Set POWER ON/OFF on Programmable Skipline
Control to OFF.
2. Install spring (605) into filter bowl (604).
3. Install filter support (603) and screen (602) into
filter bowl (604).
4. Set engine ignition key to OFF.
5. Remove paint outlet hose from ball valve (121).
6. Unscrew filter bowl (604) from filter housing (606).
7. Remove screen (602) from filter bowl (604).
NOTE: Order 167–025 if screen (602) is damaged.
Order 104–361 for new o-ring.
4. Screw filter bowl (604) into filter housing (606).
8. Remove filter support (603) from filter bowl (604).
9. Remove spring (605) from filter bowl (604).
Displacement Pump
10. Remove o-ring (601).
See Manual 308–650.
Viscount I Hydraulic Motor
606
See Manual 308–618.
601
Bead Spray Gun
See Manual 308–612.
602
Paint Spray Gun
603
See Manual 308–613.
605
Stencil Spray Gun
See Manual 308–235.
604
Air Compressor
121
If the air compressor needs service, replace it.
Hydraulic Power Supply
Fig. 17
06257
If the hydraulic power supply needs service, replace it.
Troubleshooting
WARNING
To reduce the risk of serious bodily injury, always follow the Pressure Relief Procedure on page 15
before repairing the sprayer.
Check everything in the chart before disassembling the sprayer.
PROBLEM
CAUSE
SOLUTION
Engine/sprayer won’t start
Programmable Skipline Control POWER
ON/OFF switch is OFF
Turn POWER ON/OFF switch to ON.
Fuse (3A) is blown
Check fuse between battery and Programmable
Skipline Control connector.
Engine switch not on
Turn on engine switch.
Out of gas
Refill gas tank.
Gas tank vent closed
Open gas tank vent.
Spark plug cable disconnected or
spark plug damaged
Connect cable on top of engine or replace spark
plug.
Engine operates, but displacement Pressure control switch turned OFF
pump doesn’t
Turn on pressure control switch.
Pressure setting too low
Increase pressure.
Displacement pump outlet filter dirty
Clean filter.
Tip or tip filter clogged
Clean tip or tip filter.
Displacement pump rod seized by
dry paint
Service pump. See Manual 308–650.
Displacement pump output low on Pump inlet screen clogged
upstroke
Clean screen.
Piston ball check not seating
Service piston ball check. See Manual 308–650.
Piston packings worn or damaged
Replace packings. See Manual 308–650.
Sleeve gasket in displacement pump
worn or damaged
Replace sleeve gasket. See Manual 308–650.
Troubleshooting
PROBLEM
CAUSE
Displacement pump output low on Pump inlet screen clogged
downstroke or both strokes
Paint leaks into wet–cup
Spitting from gun
Guns do not spray
Hydraulic oil fan not operating
SOLUTION
Clean screen.
Pressure setting too low
Increase pressure. See Startup,
Step 14, page 14.
Dirty outlet filter, tip filter or tip
Clean filters and/or tips.
Piston packings worn or damaged
Replace packings. See Manual 308–650.
Intake valve ball check not seating
properly
Clean and service intake valve. See Manual
308–650.
Engine RPM too low
Increase throttle setting. See Startup,
Steps 5b and 14, page 14.
Partially clogged suction tube assembly
Remove and clean suction tube. During normal
flushing remove and clean the suction tube assembly separately to prevent further clogging.
Large pressure drop in hose
Use larger diameter hose.
Loose wet–cup
Tighten wet–cup just enough to stop leakage.
Throat packings worn or damaged
Replace packings. See Manual 308–650.
Displacement rod worn or damaged
Replace displacement rod. See
308–650.
Air in fluid pump or hose
Check for loose connections at pump intake and
tighten. Them prime the pump.
See Startup, page 14.
Tip partially clogged
Clear tip clog. See page 16.
Fluid supply is low or empty
Refill and prime the pump. See Startup, page 14.
Check fluid supply often to prevent running the
pump dry.
Dried paint particles from a poorly cleaned
suction tube assembly
Remove and clean suction tube. During normal
flushing remove and clean the suction tube assembly separately to prevent further clogging.
Closed ball valves
Open ball valves.
Low pressure setting
Set pressure setting higher.
Wet beads
Remove wet beads. Dry tank. Add dry beads.
Clogged tips
Clean tips.
Fuse (10A) is blown
Check fuse between engine and solenoid air
valve connector.
Fuse (10A) is blown
Check fuse between engine and solenoid air
valve connector. This fuse also protects the hydraulic oil fan.
Manual
Parts
Page 28
Page 30
Page 32
Page 40
Manual 308–616
Page 34; Page 36
Page 38
06258
Parts
Model 231–378
101
64
30
90
68(Ref)
66
179 116
67
A
69
104
185
117
118
122
B
66
67
C
124(Ref)
119
71
15
121
70
191
76
120
124
66
72
67
A
75
B
74
C
68
72(Ref)
45
73
109
41
44
40
42
61
130
43
19
22
24
23
06259
Parts
Ref.
No.
Part No.
Description
15
19
22
23
101–566
113–300
112–796
107–129
24
30
111–040
100–004
40
159–239
41
42
43
44
112–795
100–206
113–477
158–683
45
61
64
113–286
191–642
238–349
64a
64b
66
67
68
69
238–348
238–356
113–607
101–818
191–627
108–761
70
71
113–606
113–561
LOCKNUT, nylon, 3/8–16
23
1
BELT, vee
COMPRESSOR, air
1
4
BOLT, rnd hd, 5/16–18 unc–2a,
1 in. (25 mm) long
NUT, lock, nylock, 5/16–18
4
12
CAPSCREW, hex hd,
3/8–16 unc–2a, 1–1/4 in. (32 mm) long
NIPPLE, reducing, 1/2 in. npt x
2
3/8 in. npt, 1–5/8 in. (41 mm) long
REGULATOR, unloader
1
BUSHING, pipe
1
TEE, air 3/8–18 npt
1
3
ELBOW, 90_, 1/2–14 npt(f) x
1/2–14 npt(m)
VALVE, safety
1
1
HOSE, air, 3/8 in. x 22 in.
3
PUMP, paint
Includes 64a and 64b
PUMP, displacement, sst
3
3
MOTOR, hydraulic, Viscount I
FITTING, barb 1 in., 1/2 npt
6
8
CLAMP, hose
HOSE, suction
3
SWIVEL, 1 in. nps(f) x
1
1 in., 1/2 npt(m)
TEE, 1 in., 1/2 npt
2
PLUG, pipe, 1 in., 1/2 npt
1
Qty.
Ref.
No.
Part No.
Description
72
73
74
75
76
91
101
104
191–624
191–635
176–684
100–220
191–641
191–646
191–647
235–208
109
116
191–688
166–469
117
118
238–782
164–856
119
166–866
120
166–846
121
122
124
130
179
185
191
238–694
207–123
220–285
113–687
102–814
054–163
191–731
TUBE, suction
STRAINER, inlet
ADAPTER, bung
SCREW, thumb
CAP, splash
HOSE, coupled, 16.0 in.
HOSE, coupled, 27.0 in
UNION, adapter, swivel,
3/8 in. npt(m) x 3/8 in. npsm(f)
GUARD, belt, compressor
NIPPLE, 3/8 in. npt x 3/8 in. in. npsm,
1–1/2 in. (38 mm) long, sst
FILTER, fluid, sst
NIPPLE, reducing, 3/8 in. npt x
1/4 in. npt, 1–11/16 in. (43) mm) long
ELBOW, 90_, sst, 1/4 npt x 1/4 npt,
1–11/32 in. (34 mm) long
NIPPLE, 1/4 in. npt x 1/4 in. npsm,
1–3/16 in. (31 mm) long, sst
VALVE, ball
UNION, swivel, 90_
CAP
FILTER, intake
GAUGE, pressure, fluid
TUBE, polyolefin, shrinkable
PIPE, pump, extension,
3/8–18 npt x 5in.
Qty.
2
2
2
2
2
1
3
3
1
3
3
3
2
2
3
3
2
1
1
1
1
Parts
Model 231–378
129
46
50
168
56
40
47
53
48
60
57
62
58
44
59
52
51
139
58
61 60 49
62
168
55
58
59
54
63
164
06260
Parts
Ref.
No.
Part No.
Description
40
159–239
44
158–683
46
157–191
47
48
113–292
166–999
49
50
51
52
53
54
164–259
108–124
100–030
104–655
238–299
191–222
NIPPLE, reducing, 1/2 in. npt x
3/8 in. npt, 1–5/8 in. (41 mm) long
ELBOW, 90_, 1/2–14 npt(f) x
1/2–14 npt(m)
NIPPLE, reducing, 3/4 in. npt x
1/2 in. npt, 1–7/8 in. (46 mm) long
VALVE, ball, 3-way
ELBOW, street reducing, 90_,
1/4 in. npt(f) x 1/2 in. npt(m)
ELBOW, street
VALVE, safety
BUSHING
GAGE
TANK, bead, 23 gallon
FITTING, bead tank
Qty.
2
3
1
1
1
1
1
1
1
1
1
Ref.
No.
Part No.
Description
55
56
57
191–268
113–291
100–017
58
59
60
61
62
63
129
139
164
109–570
801–020
113–319
191–642
191–643
104–663
191–700
113–372
111–834
168
100–840
1
BRACKET, fuel coupler
REGULATOR, air
1
2
CAPSCREW, hex hd,
1/2–13 unc–2a, 1–1/2 in. (38 mm) long
WASHER, plain
6
4
NUT, lock, hex, 1/2–13 unc–2b
2
FITTING, air, 3/8 OD x 1/4–18 npt
1
HOSE, air, 3/8 in. x 22 in.
2
HOSE, air, 3/8 in. x 44 in.
PLUG, pipe, 3/4 in. npt(m)
1
COVER, bead tank
1
COUPLING, fuel line
1
NIPPLE, pipe, hex, 3/4–14 npt,
2
3/4–11.5 nhr
ELBOW, street, 1/4–18 npt
2
Qty.
Parts
Model 231–378
2(ref)
1
181
192
167
91
85
87
107
37
86
114
115
2
32
218
40
86
83
217
108
115
32
113
44
92
94
90
83
17
95
18
20
84
28
83
105 106 92
94
82
29
16
112
15
3
21
14
27
33
98
34
30
32
35
31
140
141
67
89
06261
Parts
Ref.
No.
Part No.
Description
1
2
3
14
113–287
113–288
113–289
102–638
15
16
17
18
20
21
27
28
29
101–566
106–063
113–295
801–376
605–358
100–132
191–620
100–052
107–143
30
100–004
31
32
33
34
35
37
100–023
100–133
191–253
100–187
219–099
100–022
44
158–683
67
82
101–818
158–491
83
113–613
ENGINE, Kohler, 18 HP
1
MUFFLER, side mounting kit
1
GUARD, muffler
1
4
CAPSCREW, hex hd 2 in.,
3/8–16 unc–2a
LOCKNUT, nylon, 3/8–16
23
COUPLING, flexible
1
1
SHEAVE, 1 groove, ’B’
BUSHING, H–1.125
1
KEY, sprocket
1
WASHER, flat
11
1
SUPPORT, pump
WASHER, lock
4
4
CAPSCREW, soc hd,
7/16–14 unc–3a; 1.25 in. (31 mm) long
CAPSCREW, hex hd;
14
3/8–16 unc–2a; 1.25 in. (31 mm) long
WASHER, flat
2
4
WASHER, lock, 3/8 in.
1
PUMP, vane
1
NUT, 5/16–24
KNOB, pump
1
1
CAPSCREW, hex hd,
1/4–20 unc–2a, 3/4 in. (19 mm) long
ELBOW, 90_, 1/2–14 npt(f) x
3
1/2–14 npt(m)
CLAMP, hose
8
NIPPLE, 1/2 in. npt x 1/2 npt,
1
1–5/8 in. (41 mm) long
ADAPTER, female pipe,
2
1/2–14 npt(f) x 1 1/16–12 unf–2a
Qty.
Ref.
No.
Part No.
Description
84
85
113–489
113–616
86
113–620
87
89
90
91
92
94
95
98
105
106
113–584
191–648
191–645
191–646
107–050
102–473
191–649
191–651
107–032
156–022
107
108
112
113
114
115
191–686
191–687
191–695
191–696
113–609
100–575
140
141
167
181
192
217
218
100–549
107–049
100–015
112–179
191–863
100–081
155–699
VALVE, directional
REDUCER, 3/4–16 unf–2b
to 1 1/16–12 unf–2a
ELBOW, 90_, 3/4–16 unf–2a flared x
1 1/16–12 unf–2a
TEE, branch, 3/4–16 unf–2a
HOSE, 1 in. ID
HOSE, coupled, 29.5 in.
HOSE, coupled, 16.0 in.
INSERT, hose, beaded
CLAMP, hose
HOSE, 0.63 in. ID, 15.0 in.
HOSE, 0.63 in. ID, 19.0 in.
ELBOW, 90_, 3/8–18 npt
ADAPTER, 3/8 in. npt x 1/2 in. npt,
1–1/2 in. (38 mm) long
GUARD, top, left
GUARD, top, right
GUARD, motor, front
GUARD, belt, lower
BUMPER, nylon
CAPSCREW, hex hd,
3/8–16 unc–2a, 5/8 in. (16 mm) long
ELBOW, street, pipe, 90_
INSERT, hose, beaded
NUT, hex, 1/4–20 unc–2b
SCREW, mch, M5 x 12
GUARD, hose
BUSHING, pipe, 1/2 npt to 3/8 npt
ELBOW, street,
3/8–18 npt(m) x 3/8–18 npt(f)
Qty.
1
1
1
1
1
2
1
4
6
1
1
1
1
1
1
1
1
4
2
1
1
2
2
1
1
1
Parts
Model 231–378
210
211 212
216
204
209
202
15
119
401
13
132
419
128
13
110
404
213
448
424
418
189
207
412
208
37
413
111
15 15 423
423
442
441
440
26
159
25
421
445
444
411
407
410
417
419
422
408
446
419
423
92
94
92
94
145
420
146
418
98
406
423
98
415
184
212
182
1
402
13
414
1
416
409
1
34
308-611
See page 36
06262
Parts
Ref.
No.
Part No.
Description
15
25
26
101–566
113–619
111–803
92
94
98
110
111
128
132
107–050
102–473
191–651
191–690
191–697
113–608
100–531
145
146
159
113–317
113–686
107–257
189
202
203
204
207
208
209
210
211
191–855
068–097
108–061
108–837
188–452
181–795
108–483
181–818
103–547
212
213
216
401
402
404
110–755
237–686
191–869
238–337
238–327
113–609
LOCKNUT, nylon, 3/8–16
23
IDLER, vee, pulley
1
1
CAPSCREW, hex hd,
3/8–16 unc–2a, 2 in. (51 mm) long
INSERT, hose, beaded
4
6
CLAMP, hose
HOSE, 0.63 in. ID, 19.0 in.
1
GUARD, belt, front
1
GUARD, belt, side
1
PIN, hitch
1
4
CAPSCREW, hex hd,
3/8–16 unc–2a, 2.5 in. (63.5 mm) long
SENSOR, proximity
1
2
KIT. tail light.
SCREW, thd forming, hex, washer hd 2
1/4–20 unc–3a, 0.50 in. (13 mm) long
PLATE, logo
1
CHAIN, sst, sj, 12in.
1
1
RING (not shown)
SPRING, retaining
1
HOLDER, gun
1
1
JAW, clamp
1
SCREW, shldr, sch, 10–24 unc 3a
KNOB, pronged
1
2
CAPSCREW, hex hd,
1/4–20 unc–2a, 2.75 in. (70 mm) long
WASHER, plain
4
GROUNDING CLAMP, assy
1
BAR, lock
1
BASE, main
1
CASTER, swivel
1
BUMPER, nylon
2
Qty.
Ref.
No.
Part No.
Description
406
407
408
409
113–301
113–302
113–591
100–531
410
411
109–570
100–679
412
100–469
413
414
415
416
417
418
419
420
421
422
191–248
238–806
113–702
101–712
113–597
100–424
801–020
238–301
100–639
100–454
423
424
440
441
442
101–566
113–304
113–451
191–099
113–467
444
445
191–676
100–680
446
448
109–099
111–040
JACK, trailer
2
COUPLER, trailer
2
CHAIN, safety
2
2
CAPSCREW, hex hd,
3/8–16 unc–2a, 2.5 in. (64 mm) long
WASHER, plain
4
4
CAPSCREW, hex hd,
1/2–13 unc–2a, 3.5 in. (89 mm) long
CAPSCREW, hex hd,
5
3/8–16 unc–2a, 3/4 in. (19 mm) long
GASE, pump, mount
5
FENDER, tire, painted
1
3
BOLT, rnd hd, sq neck, 5/8–11
NUT, lock
3
COOLER, oil
1
SCREW
4
8
NUT, lock, hex, 1/2–13 unc–2b
1
BRACKET, guide
4
WASHER, lock, external tooth
4
CAPSCREW, hex hd,
3/8–16 unc–2a, 7/8 in. (22 mm) long
LOCKNUT
17
2
CLAMP, push pull
WASHER, wave
4
WEDGE, clamp
2
2
CAPSCREW, soc hd,
5/16–18 unc–2a, 1.5 in. (38 mm) long
BRACKET, tail light
2
4
CAPSCREW, hex hd,
3/8–16 unc–2a, 3/4 in. (19 mm) long
BUSHING, snap
2
2
NUT, lock, nylock, 5/16–18
Qty.
308-611
35
Parts
Model 231–378
525
88
101
88
502
102
97
507
508
503
161
96
522
524
160
435
517
434
433
161
427
59
513
503
518
506
511
58
427
432
405
431
426
430
523
507
512
504
429
95
425
506
527
451
516
521
505
428
94
514
510
95
509
94
451
403
453
505
501
526
520
519
452
89
67
450
455
449
438
439
06263
Parts
Ref.
No.
Part No.
Description
58
59
67
88
109–570
801–020
101–818
157–785
89
94
95
96
97
101
102
160
161
403
405
425
426
427
428
429
191–648
102–473
191–649
160–032
111–337
191–647
113–671
191–656
113–672
238–787
102–040
191–634
238–818
107–074
178–794
500–054
430
431
432
433
100–485
100–474
107–067
178–750
434
435
105–429
160–327
438
439
449
104–444
104–126
100–549
WASHER, plain
NUT, lock, hex, 1/2–13 unc–2b
CLAMP, hose
UNION, swivel; 3/4 npt(m) x
3/4 npsm(f); carbon steel
HOSE, 1 in. ID
CLAMP, hose
HOSE, 0.63 in. ID, 15.0 in.
NIPPLE, 3/4–14 npt(m)
TEE, street, 3/4–14 npt(f)
HOSE, coupled, 27.0 in
ELBOW, 3/4–14 npt(f)
BRACKET, manifold
U-BOLT, 2 x 1/4–20 unc–2a
RESERVOIR. hydraulic
NUT, lock, hex, 1/4–20 unc–3b
GASKET, reservoir
COVER, reservoir
BREATHER
FILTER, fluid
BUSHING, hex hd, 1–11.5 npt(f) x
1–1/4–11.5 npt(m)
NIPPLE, pipe
COUPLING, pipe
PACKING, o-ring
FITTING, return, 1–11.5 npt(m) x
3/4–14 npt(f)
NUT, seal
UNION, angle adapter,
3/4–14 npsm x 3/4–14 npt(f)
PACKING, o-ring
PLUG, boss
ELBOW, street, pipe, 90_
Qty.
6
4
8
3
1
6
1
1
2
3
1
1
1
1
12
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Ref.
No.
Part No.
Description
450
451
452
107–049
107–050
101–353
453
455
501
502
503
504
505
506
507
508
509
510
511
512
513
103–475
106–114
113–611
191–186
191–176
191–178
191–177
113–701
113–461
113–457
101–926
101–044
113–458
191–221
113–590
514
516
517
518
519
520
521
522
523
524
525
526
527
801–020
113–460
101–712
191–220
191–180
238–325
238–326
238–323
238–324
113–588
113–603
113–586
158–884
INSERT, hose, beaded
INSERT, hose, beaded
NIPPLE, 1/2–4 npt,
4 in. (102 mm) long
TEE, pipe, 1/2–14 npt(f)
STRAINER, inlet
WHEEL, pneumatic caster
SPACER, bearing, cone
BEARING, cone, Delrinr
SPACER, fork
SPACER, wheel
PIN, cotter
NUT, slotted, hex, 1–14 uns
WASHER, belville
NUT, lock
WASHER, plain
SPRING, compression
BOLT, swing
CAPSCREW, hex hd,
1/2–13 unc–2a, 8.5 in. (216 mm) long
NUT, lock, hex, 1/2–13 unc–2b
BEARING, bronze
NUT, lock, 5/8–11 unc–2b
SPACER, spring
BOLT, axle
ARM, pivot, left hand
ARM, pivot, right hand
HUB, caster
FORK, caster
BEARING, roller
CAP, hub
WASHER, thrust
WASHER, plain
Qty.
308-611
1
2
1
1
1
1
1
2
1
2
2
2
2
2
2
2
2
1
1
2
2
2
1
1
1
1
1
2
1
2
1
37
Parts
Model 231–378
347
318
319
346
304
317
328 327 310
309
314
348
344
345
317
338(Ref)
308 307
352
316
323
317
322
343
343
315
312
318
310
309
311
313
337
321
342
332
331
310
327
330
315
308
306
302
305
304
303
301
310
329
348
350
334
324
359
77
81
341
356
78
304
352
125
79
80
131
357
325
362
361
333
358
15
340
339
351
355
338
326
349
354
353
336
362
309
301
335
06264
Parts
Ref.
No.
Part No.
Description
15
77
78
79
80
81
101–566
160–641
108–450
108–063
191–089
100–469
125
131
301
302
303
304
305
306
307
308
309
310
311
312
313
238–295
113–682
113–304
101–566
100–731
112–405
113–454
238–309
113–600
238–321
100–023
111–040
178–861
238–320
801–941
314
315
191–264
113–664
316
317
318
319
321
322
323
113–469
110–755
102–040
191–119
113–695
113–491
103–547
324
325
326
113–303
238–306
101–147
327
328
329
330
331
109–570
801–020
238–319
191–628
111–834
LOCKNUT, nylon, 3/8–16
23
WASHER, packing
2
PIN, cotter
2
2
GRIP, handle
HANDLE, beam
2
2
CAPSCREW, hex hd,
3/8–16 unc–2a, 3/4 in. (19 mm) long
BEAM, main
1
PLUG, tubing
2
1
CLAMP, push-pull
LOCKNUT
4
WASHER
4
4
NUT, lock, nylon, 3/4–16 unf–2b
BEARING, oilite
4
BRACKET, traverse
1
SHOCK, gas
1
ARM, wishbone
2
8
WASHER, flat, 3/8 in.
1
NUT, lock, nylock 516–18
2
PAD, foam
BEAM, boom
1
1
BOLT, hex hd, 5/16–18 unc–2a
1 in. (25 mm) long
SPACER, gas, spring
2
3
CAPSCREW, hex hd,
5/16–18 unc–2a, 2.75 in. (70 mm) long
PIN, clevis
2
10
WASHER, plain
5
NUT, lock, hex, 1/4–20 unc–3b
COVER, access
1
2
CLAMP, hose, 5 in.
1
CLAMP, wire
1
CAPSCREW, hex hd,
1/4–20 unc–2a, 2.75 in. (70 mm) long
SENSOR, proximity, 12 mm
1
1
SPROCKET, timing
2
CAPSCREW, hex hd,
1/2–13 unc–2a, 3.0 in. (76 mm) long
WASHER, plain
4
2
NUT, lock, hex, 1/2–13 unc–2b
WHEEL, bearing, linear
4
1
BRACKET, gun arm
NIPPLE, pipe, hex
2
Qty.
Ref.
No.
Part No.
Description
332
333
191–164
207–123
334
238–329
335
336
191–163
100–101
337
338
100–133
191–191
339
340
238–694
113–321
341
238–332
342
343
344
191–218
112–794
102–313
345
113–320
346
113–318
347
348
349
350
351
352
353
354
113–453
113–485
191–102
113–484
107–211
112–825
113–451
113–467
355
356
357
358
191–114
113–479
191–111
100–057
359
361
238–808
113–471
362
113–319
ARM, mounting, gun, 90_
4
UNION, swivel, 90_, 3/8 in. npsm(f) x 3
3/8 in. npt(m)
GUN, spray, bead
2
See Manual 308–612 for parts
ARM, pivot, gun
2
8
CAPSCREW, hex hd,
3/8–16 unc–2a, 1.0 in. (25 mm) long
WASHER, lock, 3/8 in.
8
4
HOSE, air, 1/4 in. OD,
12.0 in. (305 mm) long
VALVE, ball
3
FITTING, elbow, tube,
4
1/4–18 npt(f) x 1/4 in. npt(m) pipe
GUN, spray, auto
2
See Manual 308–613 for parts
CLAMP, support, arm
4
1
VALVE, air, solenoid
2
CAPSCREW, hex hd,
1/4–20 unc–2a, 1.75 in. (44 mm) long
FITTING, air, 1/8–27 npt(f) x
4
1/8 npt(m) pipe
FITTING, elbow, plug-in, 1/4 OD
4
female tube x 1/4 male stud elbow
CAP, dust
1
BEARING, cup/cone
2
COLLAR, stop
1
SEAL, grease
1
PIN, dowel
1
4
WASHER, belville
WASHER, wave
2
1
CAPSCREW, soc hd,
5/16–18 unc–2a, 1.5 in. (38 mm) long
CLAMP, retaining
1
WHEEL, pneumatic
1
SPACER, wheel
2
1
CAPSCREW, hex hd,
5/16–18 unc–2a, 0.75 in. (19 mm) long
FORK, caster
1
1
CAPSCREW, hex hd,
3/4–16 unc–2a, 5.5 in. (140 mm) long
FITTING, air, 1/4–18 npt(f) x
1
1/4 npt(m) pipe
Qty.
308-611
39
Parts
Model 231–378
13
6
12
11
15
10(Ref)
21
9(Ref)
14
10
9
8
5
4
93
7
175
23
177
12
176
Ref.
No.
Part No.
Description
4
5
6
7
8
9
10
11
12
13
801–954
107–072
107–073
801–958
801–959
803–525
107–069
100–527
100–016
102–040
BATTERY, 12V
CABLE, electric, negative
CABLE, electric, positive
PROTECTOR, terminal, red
PROTECTOR, terminal, black
BOLT, battery
CLAMP, battery
WASHER, wrought
WASHER, lock
NUT, lock, hex, 1/4–20 unc–3b
40
308-611
Qty.
1
1
1
1
1
2
1
4
4
4
167
06265
Ref.
No.
Part No.
Description
14
102–638
15
21
23
93
167
175
176
177
101–566
100–132
107–129
801–972
100–015
100–214
100–188
107–139
CAPSCREW, hex hd,
3/8–16 unc–2a, 2 in. (51 mm) long
LOCKNUT, nylon, 3/8–16
WASHER, flat
SPRING, compression
PAD, battery
NUT, hex, mscr, 1/4–20 unc–2b
WASHER, lock
NUT, heavy, hex
BOLT, carriage
Qty.
4
23
11
5
1
2
1
1
1
Schematics
Solenoid Air Valves
B
A
C
E
D
3
P2
B1
2
1
1
Pneumatic lines
2
Solenoid air valve
3
Electronic control from Programmable Skipline Control
A
Paint gun (1)
B
Paint gun (2)
C
Bead gun (1)
D
Bead gun (2)
E
+ 12 Vdc
06266
308-611
41
1
To gun arm safety switch
To pump 3
To pump 2
To pump1
Ref.
No. Part No.
Description
1
2
3
4
5
CABLE, power
HOSE, bead, 3/4 in.
HOSE, air
KIT, hose, replacement
TUBE, protection
113–486
113–315
191–267
238–952
191–857
To + battery post
To – battery post
To engine kill switch
To cooling fan
1
1
1
1
1
2
To right bead gun
To left bead gun
To left paint gun
To inner right paint gun
To outer right paint gun
To valve pack
To extra valves
To valve pack
To proximity sensor
From bead tank
From bead tank
From pump 1
From pump 2
From pump 3
From compressor
To engine switch
Schematics
Main Harness 236–680
3
4
Qty.
5
06267
Schematics
Power Cable
2
P11
P5
P4
P3
P2
4
1
3
8
P1
9
5
2
6
10
7
11
12
13
15
14
17
16
18
Face View
P12
P6
3
P7
P8
P9
P13
P10
Connector
C
B
A
B
C
A
B
C
A
B
C
A
B
C
A
C
B
D EA
B A
D
C
B
A
P8
P9
P10
P11
A B C A B CA B C A B C A B C A B C D E A B C D
A
A
A
A
Wire Color
R B W R B WR B WR B W R B W G O W B W R B W B
Code 1
R
B
G
R
Connects
To
1
20
12
19
P1
1
P2
P3
P4
P5
P6
P7
19 20 3 19 2016 19 20 5 19 20 4 19 20 2 6 9 7 10 19 19 19 11
R = Red
B = Black
W = White
G = Green
O = Orange
B
L = Blue
W
B = White/black
B
B = Blue/black
R
B = Red/black
R
2
W = Red/white
G
B = Green/black
O
B = Orange/black
8
Fuse: 20A, 32V, type AGC
protects the following:
D Fan
D Solenoid air valves
2
P12
P13
13 14 15 16 A
B
B B B B BL B
20
19 20
Fuse: 4A, 32V, type AGC
protects the following:
D Programmable
Skipline Control
D Proximity sensors
for the pump, skip
timer and gun arm
stowed safety.
06339
308-611
43
Accessories
Third Gun Kit
238–956
Includes: paint spray gun, bead spray gun, paint hose,
bead hose and two solenoid air valves.
Manual 308–678.
Hand Gun Bead Accessory
238–957
Includes: deflector, tube, ball valve, 3/8 in. nylon hose,
and tank fitting. Manual 308–679.
Remote Digital Speed Indicator
238–963
Includes: LCD display and output cable.
Manual 308–680.
Video Guidance System
238–683
Includes: video camera, monitor and mounting hardware. Manual 308–617.
Second Stencil Gun Kit
238–958
Includes: flex gun, 50 ft hose and clamp assembly.
Manual 308–681.
Gallon Meter Kit
Includes: three sensors and brackets.
Manual 308–682.
44
308-611
238–954
Flex Gun Repair Kit
235–474
Includes: needle, gaskets, diffuser/seat, and insertion
tool.
Sleeve Removal Tool
238–943
Includes: Sleeve removal tool. Manual 308–665.
Throat Seal Liquid
Non–evaporating liquid for wet-cup. Helps prevent
paint buildup on the rod and throat packings to reduce
premature wear. Available in these quantities:
8 oz
206–994
32 oz
206–995
128 oz
206–996
Hitch Receiver Kit
238–944
Includes: left and right hitch receivers and hardware.
Manual 308–670.
Displacement Pump Repair Kit
238–793
Includes: see parts content in Manual 308–650.
Bead Spray Gun Repair Kit
238–340
Includes: see parts content in Manual 308–612.
Paint Spray Gun Repair Kit
238–339
Includes: see parts content in Manual 308–613.
Notes
308-611
45
Notes
46
308-611
Notes
Technical Data
Maximum working pressure:
Paint . . . . . . . . . . . . . . . . . . . . . . . . 2000 psi (138 bar)
Hydraulics . . . . . . . . . . . . . . . . . . . 1500 psi (103 bar)
Glass bead system . . . . . . . . . . . . . . . . 75 psi (5 bar)
Maximum flow: . . 2.5 gpm/pump @ 2000 psi (138 bar)
Operating pressure of air actuated trigger
Minimum . . . . . . . . . . . . . . . . . . . . . . . . . 50 psi (3 bar)
Maximum . . . . . . . . . . . . . . . . . . . . . 200 psi (12 bar)
Noise level
Sound power . . . . . . . . . . . . . . . . . . . . . . . 99.4 dB(A)
Sound pressure . . . . . . . . . . . . . . . . . . . . . . 81.5 dB(A
Measured at 3.1 feet (1 m) under maximum operating
conditions per ISO–3744
Weight . . . . . . . . . . . . . . . . . . . . . . . . . . 1015 lb (2233 kg)
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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
Glass bead capacity . . . . . . . . . . . . . . . . . . . . . . . . 300 lb
Towing height (boom arm raised) . . . . . . . . . . . . . . 7.5 ft
Wetted parts . . . . . . . . . . . . . . . . . . . . Tungsten Carbide,
303, 316 & 416 Series Stainless Steel,
PTFE R, Acetal Homopolymer, Leather
PTFE R
Graco Phone
Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor
closest to you: 1–800–367–4023 Toll Free
The Graco Warranty and Disclaimers
WARRANTY
Graco warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on
the date of sale by an authorized Graco distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this
warranty, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven
defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s
written recommendations.
This warranty does not cover, and Graco shall not be liable for, any malfunction, damage or wear caused by faulty installation,
misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of
non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility with Graco
equipment of structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor
for verification of the claim. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The
equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any
defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts,
labor and transportation.
DISCLAIMERS AND LIMITATIONS
The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or
implied), including warranty of merchantability or warranty of fitness for a particular purpose, and of any non–contractual
liabilities, including product liabilities, based on negligence or strict liability. Every form of liability for direct, special or consequential damages or loss is expressly excluded and denied. In no case shall Graco’s liability exceed the amount of the purchase price.
Any action for breach of warranty must be brought within two (2) years of the date of sale.
EQUIPMENT NOT COVERED BY GRACO WARRANTY
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with
respect to accessories, equipment, materials, or components sold but not manufactured by Graco. These items sold, but not
manufactured by Graco (such as electric motor, switches, hose, etc.) are subject to the warranty, if any, of their manufacturer.
Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.
Sales Offices: Atlanta, Chicago, Detroit, Los Angeles
Foreign Offices: Belgium, Canada, England, Korea, Switzerland, France, Germany, Hong Kong, Japan
GRACO INC.
P.O. BOX 1441 MINNEAPOLIS, MN
PRINTED IN U.S.A. 308–611 May 1996, Revised July 1996
48
308-611
55440–1441

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