Graco RoadLazer HPS 135 Severe Duty Guide

3A9247A
EN
Operation and Parts
RoadLazer HPS 135 and HPS 180
Hydraulic Pumping Systems
Pump System for use with traffic paints. For professional use only. Not approved for use in
explosive atmospheres or hazardous (classified) locations.
See page 2 for model information.
Maximum Fluid Working Pressure:
1000cc Pumps: 2500 psi (17 MPa, 172 bar)
1400cc Pumps: 2000 psi (14 MPa, 138 bar)
Important Safety Instructions
Read all warnings and instructions in this manual
before using the equipment. Be familiar with the
proper control and usage of the equipment.
Save these instructions.
ti42045a

2 3A9247A
Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Component Identification . . . . . . . . . . . . . . . . . . . . 5
Pump Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Pressure Relief Procedure. . . . . . . . . . . . . . . . . . . . 7
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Packing Nut / Wet-Cup . . . . . . . . . . . . . . . . . . . . 8
Flush the Pumping System . . . . . . . . . . . . . . . . . 8
Disconnect the Displacement Pump . . . . . . . . . . 8
Storage Maintenance. . . . . . . . . . . . . . . . . . . . . . 8
Lifetime Service Maintenance . . . . . . . . . . . . . . . 8
Recycling and Disposal . . . . . . . . . . . . . . . . . . . . . . 9
End of Product Life. . . . . . . . . . . . . . . . . . . . . . . . 9
End of Life Disposal . . . . . . . . . . . . . . . . . . . . . . . 9
Hydraulic Motor Parts . . . . . . . . . . . . . . . . . . . . . . 10
Hydraulic Motor Parts List . . . . . . . . . . . . . . . . . . . 11
Dimensions and Mounting Hole Layouts . . . . . . . 12
Technical Specifications . . . . . . . . . . . . . . . . . . . . 13
California Proposition 65 . . . . . . . . . . . . . . . . . . . . 13
Graco Standard Warranty. . . . . . . . . . . . . . . . . . . . 16
Related Manuals
Models
Manual in
English Description
3A9259 Dura-Flo® Lowers Repair, Parts
Part Number Model Hydraulic Motor Paint Displacement Pump Lower
25U989 HPS 135 Severe Duty
Heavy-Duty 900
Dura-Flo® XL 1000cc Severe Duty
26D809 HPS 180 Severe Duty Dura-Flo XL 1400cc Severe Duty
26D813 HPS 135 MaxLife Dura-Flo XL 1000cc MaxLife®
26D814 HPS 180 MaxLife Dura-Flo XL 1400cc MaxLife
Graco Date Code/
Serial Code
Month (First Character) Year (2nd and
3rd Characters)
Series (4th
Character)
Part Number
(5th-10th)
Series
(11th-16th)
Example Date Code:
A16A
A = January 16 = 2016 A = serial control
number
Example Serial Code:
L16A232749000102
L = December 16 = 2016 A = serial control
number
6 digit
alphanumeric
part number
6 digit
sequential
serial number

Warnings
3A9247A 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The
exclamation point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks.
When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings.
Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this
manual where applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. Paint or
solvent flowing through the equipment can cause static sparking. To help prevent fire and
explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic
drop cloths (potential static sparking).
• Ground all equipment in the work area. See Grounding instructions.
• Never spray or flush solvent at high pressure.
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable
fumes are present.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail. Do not use pail liners unless they
are anti-static or conductive.
•Stop operation immediately if static sparking occurs or you feel a shock. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
SKIN INJECTION HAZARD
High-pressure fluid from dispensing device, hose leaks, or ruptured components will pierce skin.
This may look like just a cut, but it is a serious injury that can result in amputation. Get immediate
surgical treatment.
• Engage trigger lock when not dispensing.
• Do not point dispensing device at anyone or at any part of the body.
• Do not put your hand over the fluid outlet.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Follow the Pressure Relief Procedure when you stop dispensing and before cleaning, checking,
or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses and couplings daily. Replace worn or damaged parts immediately.

Warnings
4 3A9247A
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Specifications in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical
Specifications in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For
complete information about your material, request Safety Data Sheets (SDSs) from distributor or
retailer.
• Do not leave the work area while equipment is energized or under pressure.
• Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine
manufacturer’s replacement parts only.
• Do not alter or modify equipment. Alterations or modifications may void agency approvals and
create safety hazards.
• Make sure all equipment is rated and approved for the environment in which you are using it.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch, cut or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Equipment can start without warning. Before checking, moving, or servicing equipment, follow
the Pressure Relief Procedure and disconnect all power sources.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read Safety Data Sheets (SDSs) to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable
guidelines.
PERSONAL PROTECTIVE EQUIPMENT
Wear appropriate protective equipment when in the work area to help prevent serious injury,
including eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment
includes but is not limited to:
• Protective eyewear, and hearing protection.
• Respirators, protective clothing, and gloves as recommended by the fluid and solvent
manufacturer.
WARNING

Component Identification
3A9247A 5
Component Identification
Ref. Description
C Hydraulic Inlet
D Hydraulic Outlet
F Motor, HPS
G Displacement Pump, Dura-Flo
H Coupling Adapter
J Coupling Nut
K Coupling Collars
L Tie Rod with Extension
N Hex Nuts
P Packing Nut/Wet Cup
Q Packing Nut Wrench
S Plug
T Cup Cover
Ref. Description

Pump Assembly
6 3A9247A
Pump Assembly
1. Assemble Coupling Adapter (H) to the Motor (F).
2. Assemble Tie Rod with Extension (L) to the Motor
(F).
3. Assemble Displacement Pump (G) to Tie Rod with
Extension (L) and hand-tighten the Hex Nuts (N).
4. Assemble Coupling Collars (K) and Coupling Nut (J)
to Coupling Adapter (H).
5. Assemble Hex Nuts (N) to Tie Rod with Extension
(L).
NOTICE
Use the 3 lift rings (eyebolts), attached to the
mounting plate, for lifting and moving the motor into
place for installation. Moving the motor by any other
means could damage the pump assembly.

Pressure Relief Procedure
3A9247A 7
Pressure Relief Procedure
1. Shut off pump by turning off hydraulic line supply
shutoff valve.
2. Open recirculation valve and trigger auto gun(s) to
relieve pressure.
3. Trigger each auto gun for at least 3 seconds.
This equipment stays pressurized until pressure is
manually relieved. To help prevent serious injury from
pressurized fluid, such as skin injection, splashing
fluid and moving parts, follow the Pressure Relief
Procedure when you stop spraying and before
cleaning, checking, or servicing the equipment.

Maintenance
8 3A9247A
Maintenance
Packing Nut / Wet-Cup
1. Fill the Packing Nut/Wet Cup (P) 1/3 full with Graco
Throat Seal Liquid (TSL).
2. Use the supplied Packing Nut Wrench (Q) to adjust
the packing nut weekly so that it is just snug. Do
NOT over-tighten.
Flush the Pumping System
The pump is tested with lightweight oil, which is left in
to protect the pump parts. If the fluid you are using may
be contaminated by the oil, flush it out with a
compatible flush material before using the pump.
• Flush at the lowest pressure possible. Check
connections for leaks and tighten as necessary.
• Flush with a fluid that is compatible with the fluid
being dispensed and the equipment wetted parts.
1. Perform the Pressure Relief Procedure, page 7.
2. Set pump to lowest possible fluid pressure, and
then start the pump.
3. Dispense fluid into a grounded metal pail.
Disconnect the Displacement
Pump
1. Flush the pump, see Flush the Pumping System,
page 8.
2. Stop the pump at the bottom of its stroke.
3. Perform the Pressure Relief Procedure, page 7.
4. Disconnect the hydraulic hose. Plug all hydraulic
hoses immediately to prevent the contamination of
the hydraulic system. Hold the fluid outlet fitting
with a wrench to keep it from being loosened while
you disconnect the fluid hose.
5. Disconnect the Displacement Pump (G) from the
Motor (F) as follows. Make sure to note the relative
position of the pump fluid outlet to the hydraulic
inlet of the motor due to orientation restrictions on
the system. If the motor does not require servicing,
leave it attached to its mounting.
6. Using adjustable wrenches to unscrew the
Coupling Nut (J) from the Coupling Adapter (H).
Remove the Coupling Collars (K). Take care not to
lose or drop the collars. See page 5.
7. Hold the Tie Rod (L) flats with a wrench to keep the
rods from turning. Unscrew the Hex Nuts (N) from
the Tie Rods extensions (L). Carefully remove the
Displacement Pump (G) from the Motor (F). See
page 5.
Storage Maintenance
Replace leather packings every five years.
Lifetime Service Maintenance
Replace leather packings every five years or less based
on use.
Use at least two people when lifting, moving, or
disconnecting the pump. If disconnecting the
displacement pump from a motor which is still
mounted (for example, on a wall bracket), be sure to
support the displacement pump while it is being
disconnected. Failure to do so may result in the pump
falling and causing injury or damage to property.

Recycling and Disposal
3A9247A 9
Recycling and Disposal
End of Product Life
At the end of the product’s useful life, dismantle and
recycle it in a responsible manner.
• Perform the Pressure Relief Procedure, page 7.
• Drain and dispose of fluids according to applicable
regulations. Refer to the material manufacturer’s
Safety Data Sheet.
• Deliver remaining product to a recycling facility.
End of Life Disposal
If the pumping system is in a condition that it can no
longer operate, the pump should be taken out of
service and dismantled. Individual parts should be
sorted by material and disposed of properly. Key
construction materials can be found in the Materials of
Construction Section.

Hydraulic Motor Parts
10 3A9247A
Hydraulic Motor Parts
† Included in Repair Kit 288061
★ Included in Repair Kit 25V515
‡ Included in Repair Kit 287870