Graco RoadLazer A Series Operation manual

308611Z
EN
First choice when
quality counts.t
INSTRUCTIONS--PARTS LIST
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
Hydraulic, Stainless Steel
RoadLazerRLine 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

2 308611
Table of Contents
Warnings 2......................................
Introduction and General Information 5..............
Component Identification and Function 6............
Pre-Setup Requirements 8........................
Setup 10........................................
Operation 12....................................
Application Data 17...............................
Maintenance 18..................................
Service 20......................................
Troubleshooting 27...............................
Maintenance Schedule 34.........................
Parts
RoadLazer Line Striper Components 35...........
Pump Systems 36.............................
Bead Tank Assembly 38........................
Engine System 40.............................
Main Base Assembly (1 of 2) 42.................
Main Base Assembly (2 of 2) 44.................
Boom Arm Assembly 46........................
Battery System 48.............................
Schematics
Solenoid Air Valves 49..........................
Main Harness 238680 50.......................
Power Cable 51................................
Accessories 52..................................
Technical Data 53................................
Graco Warranty and Limitation of Liability 54.........
Graco Phone Number 54..........................
Symbols
Warning Symbol
WARNING
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
Caution Symbol
CAUTION
This symbol alerts you to the possibility of damage to
or destruction of equipment if you do not follow the
instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before you operate this equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your distributor.
DDo not alter or modify this equipment. Use only genuine Graco parts and accessories.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest-rated system component. See
Technical Data on page 53 for the maximum working pressure of this equipment.
DUse fluids and solvents that are compatible with the equipment wetted parts. See the Technical
Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DDo 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.
DDo not use hoses to pull equipment.
DRoute 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).
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
DDo not raise the RoadLazer with a portable jack unless the RoadLazer is connected to a tow
vehicle.
DWear ear and eye protection when you operate this equipment.

3308611
WARNING
SKIN 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.
DFluid injected into the skin is a serious injury. The injury might look like just a cut, but it is a serious
injury. Get immediate surgical treatment.
DDo not point the gun at anyone or at any part of the body.
DDo not put your hand or fingers over the spray tip.
DDo not stop or deflect leaks with your hand, body, glove or rag.
DDo not “blow back” fluid; this is not an air spray system.
DAlways have the tip guard and the trigger guard on the gun when spraying.
DCheck the gun diffuser operation weekly. See the gun manual.
DBe sure the gun ball valves and stencil gun trigger safety operate before you spray.
DLock the stencil gun trigger safety when you stop spraying.
DClose the gun ball valves when you stop spraying.
DFollow the Pressure Relief Procedure on page 16 if the spray tip clogs and before you clean,
check, or service this equipment.
DTighten all fluid connections before you operate this equipment.
DCheck the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high-pressure couplings; you must replace the entire hose.
DFluid hoses must have spring guards on both ends to help protect them from rupture caused by
kinks or bends near the couplings.

4 308611
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.
DIf there is any static sparking, or if you feel an electric shock while using this equipment, stop
spraying immediately. Do not use the equipment until you identify and correct the problem.
DProvide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
DKeep the spray area free of debris, including solvent, rags, and gasoline.
DIf spraying indoors, electrically disconnect all equipment in the spray area.
DExtinguish all open flames or pilot lights in the spray or clean-up area.
DDo not smoke in the spray area.
DDo not turn on or off any light switch in the spray area while operating or if fumes are present.
DGround 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 building.
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.
DKnow the specific hazards of the fluid you are using. Read the fluid manufacturer’s warnings.
DStore hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state, and national guidelines.
DAlways wear protective eyewear, gloves, clothing, and respirator as recommended by the fluid and
solvent manufacturer.

5308611
Introduction and General Information
INTRODUCTION
This manual and those listed below provide pre-setup
requirements, parts lists, setup, operation, and
maintenance instructions for the RoadLazer system.
This manual includes parts lists and instructions for a
3-pump system. For 1- and 2-pump systems, all parts
remain the same with the exception of plugged parts
for missing pumps.
D308612: Bead Spray Gun
D308613: Paint Spray Gun
D3A1215: Programmable Skipline Controller
D309008: RoadLazer Guidance System
D312484: Viscount I Hydraulic Motor
D308650: Displacement Pump
D308674: Viscount I Hydraulic Motor
and Displacement Pump
D308670: Hitch Receiver Kit
D308671: Unpacking Instructions
GENERAL INFORMATION
The RoadLazer is attached to a tow vehicle and is
used to stripe up to two stripes in one or two colors
with glass beading.
The RoadLazer consists of a Programmable Skipline
Controller, a Front Mechanical Guidance System, three
Viscount I Hydraulic Motors, three Displacement
Pumps, two Paint Spray Guns, and two Bead Spray
Guns.
Programmable Skipline Controller
The Programmable Skipline Controller consists of the
control box and a 30 ft cable. It is the main control for
the RoadLazer system and turns the spray guns and
accessories on and off.
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
consists of a 6 in. x 5.5 in. monitor, interfacing cables,
video camera and mounting bracket.
Viscount I Hydraulic Motors
The Viscount I Hydraulic Motors power the
displacement pumps to supply paint to the spray guns.
There are three hydraulic motors. Two hydraulic
motors power the yellow-paint displacement pumps,
and one powers the white-paint displacement.
Displacement Pumps
The Displacement Pumps supply paint to the spray
guns. There are three displacement pumps. Two
displacement pumps provide paint to the two
yellow-paint spray guns, and one provides 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 Controller.
Bead Spray Guns
The Bead Spray Guns are pneumatically triggered to
spray glass beads when commanded by the
Programmable Skipline Controller.
Receivers
The two clamp-on receivers are mounted on the
installed trailer hitch to provide receptacles for 2 in. ball
mounts. See manual 308670 for receiver mounting
instructions.

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

7308611
Component Identification and Function
AViscount I Hydraulic Motor Powers the displacement pump
BBoom Arm Hitch Pin Secures the spray gun boom arm when the RoadLazer is in transport
CDisplacement Pump Provides fluid to be sprayed through the spray gun
DFluid Outlet Supplies fluid from the displacement pump to the stencil spray gun
(stencil spray gun is not shown)
EFluid Filter Filters fluid between the fluid source and the spray gun
FBreather Cap Provides a means for hydraulic reservoir ventilation, oil check, and fill
GPressure Drain Valve Relieves the fluid pressure when it is open
HFluid Inlet Displacement pump entry for fluid from the paint drums (paint drums
are not shown)
IHydraulic Reservoir Holds 12 gallons (45 liters) of hydraulic oil for the hydraulic pump
JHydraulic Select/Hydraulic
Bypass Valve
Selects displacement pumps for guns 1 & 2, or 3; or by-passes all guns
KSwivel Hub Allows the trailer wheel to swivel
LHydraulic Pump Creates hydraulic pressure for the hydraulic power supply system
MWheel Hub Supports and allows free rotation of the trailer wheel
NMain Beam Supports the spray gun boom arm
OBead Tank Holds up to 300 lb (136 kg) of glass beads for continuous spraying
PAir Regulator Allows regulation of the bead tank air pressure
RProgrammable Skipline Controller Allows the operator to program the operation of the RoadLazer
SI/O Cable Carries electronic control signals from the Programmable Skipline
Controller to the RoadLazer
TCompressor Provides an air supply to switch paint spray gun and bead spray gun
on and off as directed by the Programmable Skipline Controller
U18 HP Gasoline Engine* Powers the hydraulic pumps and the air compressor
VTail Light Standard tail light set that includes brake lights and turn signals
WHydraulic Pressure Control Knob Provides adjustment of hydraulic pressure (clockwise increases
pressure), setting can be locked with inner lock knob
XJack Used to roll the RoadLazer into place for connection to the tow vehicle
and to hold RoadLazer upright when disconnected from tow vehicle
and stored
YSpray Gun Boom Arm Allows striping on either side of the tow vehicle at adjustable distances
ZBead Spray Gun Sprays beads when commanded by the Programmable Skipline
Controller
AA Paint Spray Gun Sprays fluid when commanded by the Programmable Skipline
Controller
AB Fuel Tank Holds 6 gallons (23 liters) of 86 octane gasoline
AC Safety Pins Safety devices used with the ball coupler and jackstand for safe
operation.
Engine Choke* Enriches air/gasoline mixture for cold starting
Engine Throttle* Adjusts the engine speed for large- or small-orifice spray tips
Engine Switch* Enables/disables engine operation
*For more detailed explanations of these controls, see the KohlerRengine manual; supplied

8 308611
Pre-Setup Requirements
Tow Vehicle Recommendations and Requirements
DGraco recommends a tow vehicle wheelbase of at least 130 in. (305 cm) for normal highway use.
DThe tow vehicle must have 1/2 ton or greater carrying capacity.
DThe tow vehicle must have a minimum payload capacity of 1400 lb (635 kg).
NOTE: This minimum payload capacity is for a RoadLazer trailer with a full bead tank only. The payload
capacity must be increased by the weight of striping paint, additional glass beads, cargo in the truck, and
passengers other than the driver. See Fig. 1.
DThe tow hitch must have a minimum rated capacity of 750 lb (340 kg) TW, 7500 lb (3402 kg) GTW.
NOTE: This is the minimum rated capacity as defined by SAE Standard J684 Class 4 hitch requirements for a
Gross Trailer Weight (GTW) of 7500 lb (3402 kg). Recommended hitch manufacturers available upon request.
Calculating Tow Vehicle Payload Capacity
Use the sample calculation below to determine the minimum payload capacity 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 drum of waterborne striping paint and 2 extra bags of beads:
Tow vehicle minimum payload capacity: 1400 lb + (15 x 55) + (50 x 2) = 2325 lb
+
The tow vehicle must have the following additional equipment:
DWarning 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 Administration, for
federal regulations.
DSecuring device for paint supply containers that can
be sealed during transport.
DStandard trailer light connector.
DDRAW-TITERClass IV Ultra Frame Hitch with two
Graco clamp-on receivers that are 32 in. (81 cm) on
center.
D2 in. x 2 in. front receiver (not provided by Graco).
DI/O cable access from the tow vehicle cab to the
RoadLazer.

9308611
Pre-Setup Requirements
Hitch
Have a DRAW-TITE Class IV Ultra Frame receiver
installed on your vehicle (DRAW-TITE Series
419XXX). See manual 308670 for additional
instructions.
Choose a ball mount that allows the RoadLazer to
travel level to the ground with an average payload.
A recommended option is two DRAW-TITE adjustable
2-in. ball mounts. See Fig. 5. The ball mount must
have a 2-in. by 2-in. insert with at least a 1-in. diameter
ball mount hole. The ball mount hole and shank
diameter must match. the ball mount must have a
rating of at least 5000 lb (227 kg) GTW, 500 lb
(227 kg) TW.
Receivers
Two Graco clamp-on receivers must be mounted 32 in.
(81 cm) on center on the installed DRAW-TITE Class
IV Ultra Frame Hitch. See manual 308670 for
mounting instructions. See Fig. 2.
Fig. 2
32 in.
(81 cm)
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.
Front Mechanical Guidance System
The Front Mechanical Guidance System (see manual
309008) is mounted on a trailer hitch installed on the
front of the tow vehicle. The receiver is a single 2-in. x
2-in. as shown in Fig. 3. Graco does not provide the
receiver.
Hitch receiver
Fi
g
.3 06243B
Programmable Skipline Controller
The Programmable Skipline Controller is installed in
the cab of the tow vehicle. Select a position for ease of
operation. This control system connects to the
RoadLazer with an I/O cable, so there must be a cable
access from the tow vehicle cab to the RoadLazer.
See manual 308616.

10 308611
Setup
NOTE: Reference numbers and letters in parentheses
in the text refer to Fig. and Parts Drawings callouts.
Charge Battery
If the battery is newly purchased or has not been used
for a long time, charge it before you use it. See
Battery on page 18.
Level Draw Bar with RoadLazer
Use the following procedure to assure level operation
of the RoadLazer. Fig. 4.
1. Empty tow vehicle of any payload.
2. Install draw bar to measure approximately 21 in.
(53 cm) from top of ball mount to ground.
Fig. 4
Approx. 21 in.
(53 cm)
06244
1.0 in. dia. shaft
2.0 in. dia. ball
Connect RoadLazer To Vehicle
1. Install two ball mounts in hitch receivers:
a. Slide ball mount into hitch receiver.
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 handles in place to secure jacks.
f. Secure safety pins (A) for both trailer arm
couplers and trailer arm jacks.
g. Connect safety chains.
3. Shorten each safety chain:
a. Unscrew nut fastening chain to RoadLazer.
b. Refasten chain to RoadLazer so it hooks up to
tow vehicle with minimum slack.
4. Connect control cable to RoadLazer
Programmable Skipline Controller.
NOTE: When you unhook the RoadLazer from the
tow vehicle, replace the safety pins (A) as shown in
Fig. 5.
Fig. 5
06245A
A