Graco 311021U User's Manual
Contents
1. ti6511a Fig 5 18 311021U Engine Engine Removal Installation 1 Install rocker plate 87c dampers 59 and washers N 170 washers 114 on engine 185 with four a screws 189 washers 170 and nuts 118 torque to 20 ft lb 27 1 N m 1 Relieve pressure page 7 dia ES 2 Install engine and rocker plate 87c on sprayer 2 Remove throttle cable from engine 3 Connect blue brown and orange leads Do Fan Belt Removal page 18 i nene Mere 4 DoFan Belt Installation page 18 4 Loosen hand nut 241 Swing bracket 30 out A oM 5 Swing motor retainer bracket 30 in Tighten hand 5 Fig 6 Disconnect blue brown and orange leads nut 241 from engine 185 6 Remove engine and rocker plate 87c from NOTICE sprayer i i All service to the engine must be performed by an 7 Remove four screws 189 washers 114 washers authorized HONDA dealer 170 and nuts 118 and remove rocker plate dampers 59 and washers 114 from engine ti6520a Fig 6 311021U 19 Hydraulic Motor Yoke Hydraulic Motor Yoke Removal Installation ASA A 1 Relieve pressure page 7 FLYING PARTS HAZARD 2 Place drip pan or rags under sprayer to catch hydraulic oil that leaks out during repair 1 Slide piston rod assembly A into hydraulic motor cylinder 69 Remove pump page 16 2 Screw2. 31 Parts Drawing LineLazer IV 200HS Parts Drawing LineLazer IV 200HS 32 311021U Parts List LineLazer IV 200HS Parts List LineLazer IV 200Hs Ref Part Description Qty 21 27 068 PUMP displacement Manual 1 309277 25 288754 KIT trip rod piston cap 1 26 245226 HOSE coupled 3 8 in 1 32 287175 HOSE hydraulic supply 1 34 287206 HOSE suction drain 1 35 287176 HOSE hydraulic return 1 48 117328 FITTING nipple straight 1 60 196176 ADAPTER nipple 1 69 246176 SLEEVE hydraulic cylinder includes 1 213 92 193394 NUT retaining 1 107 117441 VALVE ball 1 108 101566 NUT lock 4 137 15F911 GUARD pump rod 1 138 106276 SCREW cap hex hd 1 149 119841 FITTING tee branch str thd 1 158 116838 PIN spring 2 159 155685 O RING 1 166 119720 SWITCH reed wi connector 2 173 100139 PLUG pipe 1 174 102040 NUT lock hex 2 179 108014 O RING 1 183 15A726 NUT jam 1 186 112342 BEARING rod 1 187 112561 PACKING block 1 194 116551 RING retaining 1 213 117283 O RING 2 217 117607 FITTING elbow std thd 2 218 117608 FITTING nipple straight 1 220 117739 WIPER rod 1 222 287186 MAGNET ring 1 230 15A728 MANIFOLD adapter 1 231 15B063 LABEL 1 233 107210 SCREW cap socket head 4 235 15B804 LABEL Graco logo 1 243 178179 WASHER sealing 1 244 178207 BEARING piston 1 245 178226 SEAL piston 1 249 197443 PIN pump 1 250 15F519 TUBE hydraulic supply 1 283 110982 SCREW cap h
3. um e O N O 11 12 13 16 74 MPa bar PSI a Allow hydraulic system to cool before beginning service Relieve pressure page 7 Place drip pan or rags under sprayer to catch hydraulic oil that leaks out during repair Remove drain plug 195 and oil filter 199 and allow hydraulic oil to drain Remove screw 224 loosen belt guard knob 241 and belt guard 24 Raise motor and remove belt 143 Remove two set screws 169 and fan pulley 86 Remove case drain tube 251 Remove elbow 182 Loosen screw 184 and remove pressure control guard 63 Loosen set screw 102 and remove remote pressure control cable 12 Remove eight screws 184 and washers 101 reservoir cover 237 filter assembly A and gasket 85 Remove four screws 215 and o rings 178 o ring 180 and hydraulic pump 252 from reservoir cover 237 Installation 1 Install hydraulic pump 252 on reservoir cover 237 with four screws 215 Install gasket 85 filter assembly A and reservoir cover 237 with eight washers 101 and screws 184 torque 90 in Ib 10 N m Install elbow 182 per instructions page 6 torque to 15 ft lb 20 3 N m Install pressure control guard 63 and tighten screw 184 Connect hydraulic hoses 32 and 35 Install case drain tube 251 torque to 15 ft lb 20 3 N m Install fan pulley 86 with two set screws 193 Raise mo
4. ws 49 1 iN Si P um 4 russe am ue 4 ue 40 us an ue 40 um 4 A A A iN Hin O O 01 O1 01 OO C1 O1 D d iN um 4 um 4 usss 4f LL5421 fuses 89 1 LL5427 1 1 1 iN oO O r D SIAS D NENNEN Hal eO 1 e user ed j v usas 6 ism eg v Je uses tO L5625 a ise 0 G0 v f J 5629 0g 0 v Jq use 0q 0 v J us 1 0g 0 S v J use J 1 0 v Use 100 mesh filter to reduce tip clogs Nr o e e SA O a i T n 311021U 5 General Repair Information General Repair Information AG 1 Keep all screws nuts washers gaskets and SAE O Ring Installation electrical fittings removed during repair procedures These parts are not normally provided 1 Unscrew lock nut to touch fitting with replacement assemblies 4 Test repair after problem is corrected 2 Lubricate o ring A A If sprayer do
5. Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclama tion 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 311021U FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Do not fill fuel tank while engine is running or hot shut off engine and let it cool Fuel is flammable and can ignite or explode if spilled on hot surface Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc 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 Ground equipment and conductive objects in work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering into pail Stop operation immediately if static sparking occurs or you feel a shock Do not use equipment until you
6. identify and correct the problem Keep a fire extinguisher in work area CARBON MONOXIDE HAZRD Exhaust contains poisonous carbon monoxide which is colorless and odorless Breathing carbon monoxide can cause death e Do not operate in an enclosed area SKIN INJECTION HAZARD High pressure fluid from gun 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 Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop spraying 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 PRESSURIZED EQUIPMENT HAZARD Fluid from the gun dispense valve leaks or ruptured components can splash in the eyes or on skin and cause serious injury e Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning checking or servicing equipment e Tighten all fluid connections before operating the equipment e Check hoses tubes and couplings daily Replace worn or damaged parts immediately Warnings EQUIPMENT M
7. not show on display Loose connector Check that 5 pin connector and reed switch when fluid is sprayed are properly connected Interrupter 164 is improperly positioned Turn screw counterclockwise until spray icon synchronizes with fluid spray Reed switch assembly 18 is damaged Replace reed switch assembly 18 Magnet on assembly 18 is missing Replace reed switch assembly 18 A connector on wiring harness or on Disconnect reed switch and 5 pin connector reed switch 18 is damaged from back of control board Check continuity between pin 1 on 2 pin connector and pin 1 and 5 pin connector Check continuity between 2 on 2 pin connector and pin 4 on 5 pin connector If there is no continuity in either case replace wiring harness If there is continuity in both cases replace reed switch assembly 18 Control board is damaged Replace control board Display is damaged Replace display Spray icon is always shown on display Interrupter 164 is improperly positioned Turn screw clockwise until spray icon is synchronized with fluid spray Heed switch assembly 18 is damaged Heplace reed switch assembly 18 Pressure control knob does not rotate Knob is jammed Pull back cover where remote cable connects to hydraulic pump and turn counterclockwise until free Pressure control knob rotates freely with Remote cable broken or disconnected Replace or reconnect cable no pressure change Engine bounces when striping Spring is broken loose
8. oe Spm ak D 16 Fan Bell NR is aud e dE 18 REMOVAL 18 IristallatlOn us sede arabe ae Dp o de fag 18 eji 19 Sne HEET 19 Installation A Se ade ew ee NERA 19 Hydraulic Motor Yoke 20 Removal 20 Installatlol 2 are dto denti 20 2 Oil Filter Change 22 Removal 33 x case ee E EO Sete x ER 22 Installation 22 ECH e ee Te 0 tiores 22 Removal a antes eit ol acca a ce Sorte S ete aei iata oo OS 22 Installation 22 Displacement Pump 23 Removal fit dau Xa ok de ba ww c 23 InstallallODi ds e dac De Mop EE 23 NONBS EE 24 Parts LineLazer IV 200HS 25 Parts Drawing LineLazer IV 200HS 26 Parts List LineLazer IV 200HS 27 Parts Drawing LineLazer IV 200HS 28 Parts List LineLazer IV 200HS 29 Parts Drawing LineLazer IV 200HS 30 Parts List LineLazer IV 200HS 31 Parts Drawing LineLazer IV 200HS 32 Parts List LineLazer IV 200HS 33 Parts Drawing LineLazer IV 200HS 34 Parts List LineLazer IV 200HS 35 Parts Drawing LineLazer IV 200HS 36 Parts List LineLazer IV 200HS 37 Pressure Control Wiring Diagram 38 Technical Data ovk REA TERR ines 39 ACCESSOS 32 X dae dde AIRE Vet Ae AG 39 Graco Standard Warranty 40 311021U
9. or missing Replace or reconnect spring 311021U 17 Digital Tracking System Digital Tracking System ON OFF Switch Removal HOA Relieve pressure page 7 Fig 2 Remove screws 103 and front cover 31 Pull display connector wings A open on PC board and pull display connector out Disconnect ON OFF switch connector B from PC board Press in on two retaining tabs on each side of ON OFF switch 15g and remove switch Installation 1 Fig 2 Install new ON OFF switch 159 so tabs of switch snap into place on inside of pressure control housing Connect ON OFF switch connector B to PC board Push display connector into PC board and close display connector wings A on PC board Install cover 31 with two screws 103 PC Board Removal HOA Relieve pressure page 7 Fig 2 Remove two screws 103 and cover 31 Pull display connector wings A open on PC board and pull display connector out Note on paper lead connections to the control board Disconnect leads from control board 15d Remove four screws 15k from control board Installation 1 Fig 2 Install control board 15d and four screws 15k Torque to 105 115 in Ib Connect leads to control board Refer to note on lead connections Push display connector into PC board close display connector wings A on PC board Install cover 31 with two screws 10
10. 3 311021U Displacement Pump Installation NOTICE If the pump jam nut loosens during operation the threads of the hydraulic motor manifold will be damaged Tighten jam nut as specified 1 Fig 14 Screw jam nut to bottom of pump threads Screw pump completely into manifold Unscrew pump from manifold until pump outlet aligns with hose Hand tighten jam nut then tap 1 8 to 1 4 turn with hammer or torque to 200 ft lb 270 N m Fig 14 Ze U 2 Fig 15 Slowly pull engine starter rope until pump rod pin hole is aligned with hydraulic rod hole Fig 12 Push pin 249 into hole Push magnet ring 222 down Push retaining spring 194 into groove ti6518a Fig 15 3 Fill packing nut with Graco TSL RE DG E Fig 16 ti6519a 23 311021U Parts LineLazer IV 200HS Parts LineLazer IV 200Hs Parts Page 30 Parts Page 34 Parts Page 34 Parts Page 28 Pa lt due dei d N N N gt FLL LA ES SS Se Parts Page 26 SSS SS ss SSS A Zo a lt SSS se SSS SSS P 311021U 25 Parts Drawing LineLazer IV 200HS Parts Drawing LineLazer IV 200HS E e ti25601a To remove cover 257 press tabs to
11. 3 Pressure Control Transducer Removal HOA Relieve pressure page 7 Fig 2 Remove two screws 103 and cover 31 Disconnect transducer lead C from control board 15d 4 Remove pressure control transducer 259 and o ring 124 from filter housing Installation 1 Fig 2 Install o ring 124 and pressure control transducer 259 in filter housing Torque to 35 45 ft lb 2 Connect transducer lead C to motor control board 15d 3 Install cover 31 with two screws 103 311021U Digital Tracking System Digital Tracking System R Main Control X Box Cable F gt A 259 wit ti25599a Li _ CC EEX LEE Fig 2 311021U 13 PC Board Diagnostics PC Board Diagnostics Wes Relieve pressure before repair page 7 No display does not mean the sprayer is not pressurized Digital Display Messages DISPLAY SPRAYER OPERATION INDICATION ACTION No Display Sprayer may be pressurized Loss of power or display not Check power source Relieve connected pressure before repair or disassembly Verify display is connected Sprayer may be pressurized Pressure less than 200 psi Increase pressure as needed 14 bar 1 4 MPa Sprayer is pressurized Normal operation Power is applied Pressure varies with tip size and pressure control setting Engine and system continue Exceeded pressure limit Remove any
12. ANK reservoir TUBE hydraulic case drain includes 150 PUMP hydraulic includes 43 102 155 178 180 215 223 238 239 240 RETAINER ball press bypass Qty N sch A NI sch sch A A esch 1 A Replacement Danger and Warning labels tags and cards are available at no cost 35 Parts Drawing LineLazer IV 200HS Parts Drawing LineLazer IV 200HS ei a 131 Detail A AN Install washers 130 concave surface to inside 36 311021U Parts List LineLazer IV 200HS 153 154 Part 240942 240991 15G952 287623 181818 193528 193658 193661 193662 15F910 198606 100731 101566 15J603 108483 110754 110837 111040 112405 112776 112825 113471 113484 113485 113962 114548 114549 241445 114648 114681 114682 114802 114982 120476 Description SHAFT fork BRACKET caster front BRACKET hub FRAME linestriper painted KNOB pronged ARM detent SPACER seal JAW STOP wedge BRACKET cable DISK adjuster WASHER NUT lock WASHER plain SCREW shoulder soc hd SCREW cap soc hd SCREW flange hex 1 NUT lock NUT lock WASHER plain SPRING Belleville SCREW cap hex hd SEAL grease BEARING cup cone WASHER hardened BEARING bronze WHEEL pneumatic CABLE CAP dust SCREW cap hex hd SPRING compression STOP wire SCREW cap flng hd BOLT e lt lt N sch DA NM sch NM sch DA JM ON
13. CKET cable 49 188135 GUIDE cable 71 198895 PLATE lever pivot 72 198896 BLOCK mounting mach 83A 15F637 LABEL skin injection 89A 15A644 LABEL trigger 96 15F624 NUT cable gun 97 15F377 HARNESS wiring 104 119647 SCREW cap socket flthd 105 119648 SCREW mach tursshd cross recess 109 102478 STRAP wiring tie 112 111145 KNOB pronged 117 110837 SCREW flange hex 119 111017 BEARING flange 121 111040 NUT lock 126 112381 SCREW mach pan hd 136 287566 KIT clamp 141 241445 CABLE 144 114659 GRIP handle 160 116941 SCREW shoulder socket head 161 287696 CABLE includes 96 162 116969 NUT lock 163 116973 SCREW 10 taptite phil 164 117268 BRACKET interrupter 165 117269 SPRING 168 117317 SCREW plastite pan head 360 15F389 BRACKET gun arm e lt A sch S sch Ss Ss sch ch e mu sesch sch N ea sch ch NI sch sch NM sch sch sch WM WM NM sch 3 sch NGN sch ck sch NI sch sch ch ch A Replacement Danger and Warning labels tags and cards are available at no cost 311021U 29 Parts Drawing LineLazer IV 200HS Parts Drawing LineLazer IV 200HS AN Torque to 115 135 in Ib ti25603a A Torque to 130 150 in Ib 30 311021U Parts List LineLazer IV 200HS Parts List LineLazer IV 200Hs Ref Part Description Qty 2 245103 VAVLE drain 1 2a 193709 SEAT valve 1 2b 193710 SEAT valve 1 2c 116424 NUT cap 1 2d 114708 SPRING 1 11 244067 FILTER
14. D sch HAH NNN sch AH HAH AH NM sch AS SS ch sch sch CC Parts Included in Bracket Repair Kit 240940 purchase separately 311021U Parts List LineLazer IV 200HS 37 Pressure Control Wiring Diagram Pressure Control Wiring Diagram TO ENGINE a GROUND ENGINE OFF SWITCH DISPLAY BOARD GUN TRIGGER TRANSDUCER DISTANCE SENSOR PUMP ON OFF SWITCH Eo PUMP STROKE TO ENGINE COUNTER GENERATOR ti25604A Fig 17 38 311021U Technical Data Technical Data Engine Engine Generator Output US X Mee Maximum fluid working pressure Maximum free flow delivery Cycles Hydraulic reservoir capacity Hydraulic pressure Maximum Tip Size 1 gun 0 046 in 2 guns 0 033 in Noise level dBa Sound power 110 dBa per ISO 3744 Sound pressure 96 dBa measured at 3 1 feet 1m Vibration level Left Hand Right Hand Vibration measured per ISO 5349 bsed on 8 hr daily exposure Inlet Outlet Sizes Inlet paint strainer 16 mesh 1190 micron stainless steel screen reusable 2 90 m sec 2 83 m sec Outlet paint filter 60 mesh 250 micron stainless steel screen reusable Pump inlet size 1 in npsm m Fluid outlet size 3 8 npt f Dimensions Weight Height Length width Weight dy without packaging Wetted parts PTFE Nylon polyurethane V Max leather tungsten carbide stainless steel chrome plating nickel plated carbon steel ceramic Accessor
15. ISUSE HAZARD e Misuse can cause death or serious injury Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS 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 j BURN HAZARD iu Gi E Equipment surfaces and fluid that is heated can become
16. Repair Parts G 311021U LineLazer IV 200dHs Airless Paint Striper EN For application of line stripling materials 3300 psi 22 8 MPa 228 bar Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual and in LineLazer FieldLazer Operation manual Be familiar with the controls and the proper usage of the equipment Save these instructions aw o os we Jv A v 311018 309277 L 311254 P 309055 a S 311049 LE PROVEN QUALITY LEADING TECHNOLOGY Contents WaInilldS SB OSI drow banda ere deat Eb 3 Tip Selection 5 General Repair Information 6 GIOUNGING BREED 6 SAE O Ring Installation 6 Maintenance nS RN EE 7 Pressure Relief Procedure 7 Troubleshooting 8 Digital Tracking System 12 ON OFF SWIICHh er ehe oa CR Rb X ds 12 Ia e mx Lm 12 EEGENEN ew Hs 12 Installation 12 Pressure Control Transducer 12 Digital Tracking System 13 PC Board Diagnostics 14 Distance Sensor Adjustment 15 Gear Alignment 15 Sensor Height Adjustment 15 Hydraulic Pump 000 cece ee ees 16 Removal oa dp ackoletbu a atipdoe a ok cea ak Bae ee 16 Installation sse Sak dea deco E diede
17. ad forming hex hd 134 113961 SCREW cap hex hd 141 241445 CABLE caster 142 114648 CAP dust 144 114659 GRIP handle 148 114808 CAP vinyl 154 115077 PAIL plastic models 248870 248871 248872 and 248873 156 112395 SCREW cap flng hd 157 116287 WASHER st ext starwasher 221 119771 STRAP cover 256 119696 SPRING extension 257 287695 BOX electric includes 109 258 15F441 BRACKET frame 261 116780 SCREW hex hd 290 120151 PLUG tube esch sesch wech sesch wech wesch wesch hi bh A apap A Replacement Danger and Warning labels tags and cards are available at no cost 311021U 2r Parts Drawing LineLazer IV 200HS Parts Drawing LineLazer IV 200HS AN Torque to 90 110 in Ib A Torque to 10 20 in lb ti25602a 28 311021U Parts List LineLazer IV 200HS Parts List LineLazer IV 200Hs Ref Part Description 1 224052 BRACKET support gun 4 248157 GUN flex basic includes guard amp tip 8 287570 KIT holder gun 8a 287569 HOLDER gun 8b 15F214 LEVER actuator 8c 15F209 STUD pull trigger 8d 15F210 STUD pivot 8e 15F211 STUD cable 8f 102040 NUT lock 14 245798 HOSE 1 4 x 7 ft 17 245733 KIT trigger handle repair includes 89 126 164 165 18 287699 KIT repair trigger includes 18 166 168 27 287417 HANDLE 28 287622 SUPPORT handle painted not shown 35 287176 HOSE hydraulic return not shown 44 15F212 ARM support 47 15F213 BRA
18. ce transducer Throat packing nut is loose Remove throat packing nut spacer Tighten Excessive paint leakage into throat packing nut throat packing nut just enough to stop leakage Throat packings are worn or damaged Replace packings Manual 309277 Displacement rod is worn or damaged Replace rod Manual 309277 Fluid is spitting from gun Air in pump or hose Check and tighten all fluid connections Reprime pump Manual 311018 Tip is partially clogged Clear tip Manual 311254 Fluid supply is low or empty Refill fluid supply Prime pump Manual 311018 Check fluid supply often to prevent running pump dry Excessive leakage around hydraulic Piston rod seal worn or damaged Replace these parts motor piston rod wiper 311021U 9 Troubleshooting Prt ee rm Fluid delivery is low Pressure setting too low Increase pressure See manual 311018 Displacement pump outlet filter if used Clean filter is dirty or clogged Intake line to pump inlet is not tight Tighten Hydraulic motor is worn or damaged Bring sprayer to Graco distributor for repair Large pressure drop in fluid hose Use larger diameter for shorter hose The sprayer overheats Paint buildup on hydraulic components Oil level is low Fill with oil page 7 Excessive hydraulic pump noise Low hydraulic fluid level Shut off sprayer Add fluid page 7 Gallon counter not working Broken or disconnected wire Check wires and connections Replace broken wires Missing or
19. damaged magnet Replace magnet Locate in correct spot Sprayer operates but display does not Bad connection between control board Remove display and reconnect and display Display damaged Replace display Connect cables to back of control board Control board LED not flashing Replace control board Distance counter not operating properly Trigger sensor not set correctly See Spray icon does not show on display when fluid is sprayed Bad wiring connections Check connector and reconnect Distance sensor not spaced correctly Adjust space between sensor and gear to from gear 0 50 020 in page 15 Distance and gear not aligned Remove tire and press in or pull out gear to align sensor and gear Gear teeth missing or damaged Replace distance gear wheel Mils not calculating Distance sensor See Distance counter not operating properly Trigger sensor See Spray icon does not show on display when fluid is sprayed Gallon counter See Gallon counter not working Bad or damaged control board Replace control board Fluid spray starts after spray icon is Interrupter 164 is improperly positioned Turn screw counterclockwise until spray icon shown on display synchronizes with fluid spray Fluid spray starts before spray icon is Interrupter 164 is properly positioned Turn screw clockwise until spray icon is shown on display synchronized with fluid spray 10 311021U Troubleshooting em mm Som Spray icon does
20. down hydraulic motor cap 25 until cap 4 Fig 7 Remove hydraulic lines 35 250 from fittings bottoms out Unscrew hydraulic motor cap until inlet 217 at top left and right side of hydraulic motor and outlet align with hydraulic line fittings and test Loosen jam nut 183 dom motor cap points opposite of belt Unscrew and remove hydraulic motor cap 25 3 Torque jam nut 183 against hydraulic motor cap Slide piston rod hydraulic motor cap assembly A 25 to 150 ft Ib 17 N m from hydraulic motor cylinder 4 Install hydraulic lines 35 250 to fittings 217 to top left and right side of hydraulic motor per procedure on page 6 torque to 40 ft lb 54 2 N m Install pump page 24 Start engine and operate pump for 30 seconds Turn engine OFF Check hydraulic oil level and fill FLYING PARTS HAZARD with Graco hydraulic oil page 7 Detent spring has high energy potential If detent spring is released without due care detent spring and balls could fly into the eyes of the disassembler Wear safety glasses when removing or installing detent spring and balls Failure to wear safety glasses when removing detent spring could result in eye injury or blindness 20 311021U Hydraulic Motor Yoke Oil Filter Change Oil Filter Change Removal 1 Fig 8 Place drip pan or rags under sprayer to catch hydraulic oil that drains out 2 Remove drain plug 195 Allow hydraulic oil to drain 3 Unscrew filter 199 slowly oi
21. es not operate properly review repair procedure to verify procedure was done A cd correctly If necessary see Troubleshooting Guide em page 8 for other possible solutions NM 3 Screw in fitting hand tight 4 Install belt guard before operation of sprayer and replace if damaged Belt guard reduces risk of pinching and loss of fingers see preceding WARNING Grounding 4 Unscrew fitting until oriented prope Ground sprayer with grounding clamp to earth ground when flushing sprayer Fig 1 Grounding clamp 5 Tighten lock nut to indicate torque seated properly without pinching o ring water pipe steel sign post or metal REN light pole Fig 1 D S 311021U 6 Maintenance Pressure Relief Procedure Follow the Pressure Relief Procedure whenever va 2 you see this symbol 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 Engage trigger lock Close the bleed type master air valve Disengage the trigger lock Hold a metal part of the gun firmly to a grounded metal pail Trigger the gun to relieve pressure Engage the trigger lock 6 Open all fluid drain valves
22. ex head 1 284 100139 PLUG pipe headless 1 Parts included in Trip Rod Piston Cap Repair Kit 288754 purchase separately Parts included in Seal Repair Kit 246174 purchase separately Parts included in Hydraulic Motor Repair Kit 248021 311021U 33 Parts Drawing LineLazer IV 200HS Parts Drawing LineLazer IV 200HS ti24884a 34 311021U Parts List LineLazer IV 200HS Ref 12 23 24 30 32 34 34a 34b 34c 34d 34e 34f 34h 34j 34k 34m 34n 43 59 63 75 81 82 85 86 87a 87b 87c 88 101 102 114 117 118 125 143 150 151 162 169 170 172 174 178 180 181 182 184 185 188 Part No 287687 289227 288734 15E476 287175 24V064 15F149 194306 198119 101818 181072 16X071 248008 114958 196180 195119 2 8 22 15C400 15E888 15C958 15E587 240997 15M106 246172 16U205 15E758 15E759 15F485 117632 100016 112303 108851 110837 110838 101962 119433 154594 114956 116969 100002 100023 100084 102040 107188 156401 108842 110792 112166 116080 112717 311021U Description SHAFT flexible includes 125 190 191 268 269 RAIL belt includes 162 174 224 241 GUARD belt includes 162 193 214 224 228 BRACKET retainer motor HOSE hydraulic supply HOSE suction drain TUBE suction HOSE fluid ELBOW barbed CLAMP hose STRAINER inlet TUBE drain HOSE coupled 1 4 in x 4ft STRAP tie BUSHING LABEL war
23. fective to an authorized Graco distributor for verification of the claimed defect 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 THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought within two 2 years of the date of sale GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject to the warranty if any of their manufacturer Graco
24. filter clogs or flow to run obstructions Engine and system continue Pressure transducer faulty Check transducer connections to run bad connection or broken and wire Replace transducer wire or control board if necessary After a fault follow these steps to restart sprayer 1 Correct fault condition 2 Turn sprayer OFF 3 Turn sprayer ON 14 311021U Distance Sensor Adjustment Distance Sensor Adjustment Gear Alignment Sensor Height Adjustment 1 Remove wheel 120 from LineLazer N 2 Remove distance sensor 66 Adjust sensor assembly height with two 17 mm nuts 1 Relieve pressure page 7 of sensor so bottom surface of sensor is 0 638 0 020 from bottom surface of shield Torque to 8 2 in lb 2 Fig 3 Remove dust cap 142 from wheel Remove nut 127 Remove wheel 120 from LineLazer 4 Align gear 67 with sensor a Pull gear out from wheel with gear puller b Push gear in toward wheel with mallet Install wheel 120 on LineLazer Install nut 127 until tight then back off 1 4 turn Install dust cap 142 on wheel 120 Tire 142 127 120 Axle 67 ti6400a Gear Fig 3 311021U 15 Hydraulic Pump Hydraulic Pump Removal
25. fluid 1 13 245225 HOSE 3 8 in x 50 ft 1 15 287601 CONTROL plate 1 15a 15F272 PLATE control 1 15b 287688 BOARD display includes 15c 15m 1 15c DISPLAY board LCD included with 1 15b 15d 287689 CONTROL board includes 15k 1 15f 114954 SWITCH rocker 1 15g 116752 SWITCH rocker 1 15k 111839 SCREW mach pnh sems 4 15m 117317 SCREW plastite pan head 3 15n 109466 NUT lock hex hd 4 150 116719 SCREW 3 82 hex washer head 3 15r 15F543 LABEL control top 1 15s 15F544 LABEL control bottom 1 15t 287692 CONTROL throttle 1 15u 119736 CLAMP cable not shown 1 15w 15F777 GASKET control 1 15x 15F776 GASKET throttle 1 26 245797 HOSE coupled 3 8 in 1 27 287417 HANDLE 1 29 196179 FITTING elbow street 2 31 15F589 COVER control 1 37 15C766 TUBE diffuser 1 38 15G563 HANDLE 1 40 15H561 MANIFOLD filter 3 8 npt 1 41 287285 KIT repair filter cap includes 37 1 167 62 196178 ADAPTER nipple 2 64 196181 FITTING nipple 1 76 104813 PLUG pipe 1 103 116719 SCREW 8 32 hex washer hd 5 123 118359 KNOB pressure control 1 124 111457 O RING 1 125 101962 SCREW set sch 1 167 117285 O RING 1 190 115999 RING retaining 1 191 176754 GLAND packing male 1 225 15A464 LABEL control 1 259 287172 TRANSDUCER pressure control 1 includes 124 262 111801 SCREW cap hex 2 268 15F710 BUSHING mount panel 1 269 119775 NUT panel 1 270 288100 KIT repair filter includes 2 3 11 311021U 37 38 39 40 41 124 167 259
26. gether and pull cover away from plate 99 lt AN Maintain tire pressure at 28 32 psi A Torque to 17 23 ft lb 311021U 26 Parts List LineLazer IV 200HS Parts List LineLazer IV 200Hs Ref Part Description Qty 5 237686 CLAMP grounding assy 1 13 245225 HOSE 3 8 in x 50 ft 1 16 28 623 FRAME linestriper 1 27 287417 HANDLE 1 28 287622 SUPPORT handle painted 1 33 COVER pail 24U241 models 248870 248871 248872 1 and 248873 includes 221 36 111348 BUSHING strain relief 42 108471 KNOB 51 193405 AXLE 57 194310 LEVER actuator 58 195134 SPACER ball guide 60 196176 ADAPTER nipple 66 287698 KIT sensor distance includes 66a 68 115 129 157 66a SENSOR distance 67 GEAR signal 68 198612 SHIELD sensor distance 70 198891 BRACKET mounting 73 198930 ROD brake 74 198931 BEARING 81 240997 CONDUCTOR ground not shown 84A 15F638 LABEL warning fire and skin 90 15D849 TAG Endurance Advantage Program 93 15F577 BRACE left painted 94 15F576 BRACE right painted 99 15F425 BRACKET reservoir 108 101566 NUT lock 109 102478 STRAP wiring tie not shown 115 108868 CLAMP wire 117 110837 SCREW flange hex 118 110838 NUT lock 120 255162 WHEEL pneumatic includes 67 121 111040 NUT lock insert nylock 5 16 122 111194 SCREW cap flange hd 127 112405 NUT lock 129 112798 SCREW thre
27. ies Must be purchased separately GRACO APPROVED HYDRAULIC OIL 196236 5 Gallons 19 liters 207428 1 Gallon 3 8 liters 311021U 39 Graco Standard Warranty Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be 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 general wear and tear or 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 of Graco equipment with 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 de
28. in the system having a waste container ready to catch drainage Leave drain valve s open until you are ready to spray again 7 f you suspect the spray tip or hose is clogged or that pressure has not been fully relieved a VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradu ally b Loosen nut or coupling completely PPa eo c Clear hose or tip obstruction NOTICE Minimum hose size allowable for proper sprayer operation is 3 8 in x 50 ft For detailed engine maintenance and specifications refer to separate Honda Engine s Owner s Manual supplied DAILY Check engine oil level and fill as necessary DAILY Check hydraulic oil level and fill as necessary DAILY Check hose for wear and damage DAILY Check gun safety for proper operation DAILY Check prime spray drain valve for proper operation DAILY Check and fill gas tank 311021U Maintenance DAILY Check that displacement pump is tight DAILY Top off TSL level in displacement pump packing nut to help prevent material buildup on piston rod and early wear of packing AFTER THE FIRST 20 HOURS OF OPERATION Drain engine oil and refill with clean oil Reference Honda Engines Owner s Manual for correct oil viscosity WEEKLY Remove engine air filter cover and clean element and replace if necessary If operating in an unusually dusty environment check filter daily WEEKLY DAILY Remove any debri
29. ine switch is OFF Turn engine switch ON Engine is out of gas Refill gas tank Honda Engines Owner s Manual Engine oil level is low Try to start engine Replenish oil if necessary Honda Engines Owner s Manual Spark plug cable is disconnected or Connect spark plug cable or replace spark damaged plug Fuel shutoff lever is OFF Move lever to ON position Oil is seeping into combustion chamber Remove spark plug Pull starter 3 to 4 times Clean or replace spark plug Start engine Keep sprayer upright to avoid oil seepage Engine operates but displacement Pump valve is OFF Turn pump valve ON ump does not operate pump Pressure setting is too low Turn pressure adjusting knob clockwise to increase pressure Manual 311018 Fluid filter 11 is dirty Clean filter Tip or tip filter is clogged Clean tip or tip filter Manual 311254 Displacement pump piston rod is stuck Repair pump Manual 309277 due to dried paint Hydraulic fluid too low Shut of sprayer Add fluid Hydraulic motor not shifting Set pump valve OFF Turn pressure down Turn engine OFF Pry rod up or down until hydraulic motor shifts Displacement pump operates but output Piston ball is not seating Service piston ball Manual 309277 is low on upstroke Piston packings are worn or damaged Replace packings Manual 309277 Check hydraulic fluid level often Do not allow it to become too low Use only Graco approved hydraulic f
30. l runs into groove and drains out rear Installation 1 Install drain plug 195 Apply a light coat of oil to oil filter gasket and install oil filter 199 Tighten oil filter 3 4 turn after gasket contacts base 2 Fill with 1 25 gallons 4 73 liters of Graco hydraulic oil 169236 5 gallons 20 liters or 207428 1 gallon 3 8 liters 3 Check oil level Gallon Counter Removal 1 Fig 9 Disconnect gallon counter cable at back of pressure control and at engine 2 Remove guard 137 and reed switch from hydraulic motor 3 Fig 11 13 Remove pump 4 Fig 10 Remove ring magnet 150 22 Fig 8 Fig 10 e e Installation 1 Fig 10 Install new ring magnet 222 with dimple marks facing down Fig 14 16 Install pump Install new reed switch and guard 137 on hydraulic motor 4 Fig 9 Connect gallon counter cable at back of pressure control and at engine 311021U Displacement Pump See manual 309277 for pump repair instructions Removal 1 Flush pump Wes 2 Relieve pressure page 7 3 Fo 11 Remove suction tube 34 and hose 26 26 Fig 11 NOTICE Gallon counter may error if magnet ring and or sensor assembly are damaged during disassembly and assembly 4 Fig 12 Push magnet ring 222 up Push retaining spring 194 up Push out pin 249 222 249 194 Fig 12 ti6515a 5 Fig 13 Loosen jam nut Unscrew pump Fig 1
31. luid page 7 8 311021U Troubleshooting LN I Jm o a Displacement pump operates but output Strainer 34a is clogged s low on downstroke and or on both Ger O ring in pump is worn or damaged Replace o ring Manual 309277 or is not seating properly Fluid filter 11 tip filter or tip is clogged Clean filter Manual 311018 or 311254 or dirty Large pressure drop in hose with heavy Use larger diameter hose and or reduce materials overall length of hose Use of more than 100 ft of 1 4 in hose significantly reduces performance of sprayer Use 3 8 in hose for optimum performance 50 ft minimum Pump is difficult to prime Air in pump or hose Check and tighten all fluid connections Reduce engine speed and cycle pump as slowly as possible during priming Intake valve is leaking Clean intake valve Be sure ball seat is not nicked or worn and that ball seats well Reassemble valve Pump packings are worn Replace pump packings Manual 309277 Paint is too thick Thin the paint according to the supplier s recommendations Engine speed is too high Decrease throttle setting before priming pump Manual 311018 High engine speed at no load Mis adjusted throttle setting Reset throttle to 3700 3800 engine rpm at no load Worn engine governor Replace or service engine governor Low stall or run pressure shown on New pump or new packings Pump break in period takes up to 100 gallons display of material Faulty transducer Repla
32. ning not shown GASKET pail ADAPTER pressure control DAPENER motor mount GUARD pressure control TUBE suction CONDUCTOR ground LABEL brand 200HS GASKET reservoir PULLEY fan PULLEY 5 50 diameter SPACER shaft engine BRACKET engine mount KEY square 3 16 x 1 25 WASHER SCREW ste socket w patch WASHER plain SCREW flange hex NUT lock SCREW set 1 4 20 x 0 38 BELT vee gripnotch O RING TERMINAL wire tap insulated NUT lock SCREW set sch WASHER flat BALL metallic NUT lock O RING O RING SCREW cap hex head ELBOW male 90 degree SCREW cap sch ENGINE gas 6 5 hp Honda WASHER Qty 1 1 sch sch sch KS ll lI ll ll lll esch DEER E EE CEREREM PERENNE Ref 189 193 195 196 197 198 199 200 212 214 215 218 224 22 A 220A 237 241 242 251 252 253 Part No 113664 115477 101754 116793 120726 116919 246173 120981 116967 117284 117471 117608 119434 194126 198492 15M057 15D862 289227 246167 287179 198841 Parts List LineLazer IV 200HS Description SCREW flange hex SCREW mach torx pan hd PLUG hex head hydraulic FITTING elbow hydraulic CAP breather filler FILTER hydraulic suction FILTER oil spin on SCREW hex washhd SPRING compression GRILL fan guard SCREW 1 4 20 flat hd mach FITTING nipple straight SCREW shoulder socket head LABEL warning LABEL warning COVER reservoir GH200 LL NUT hand T
33. ntains English MM 311020 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 e USA Copyright 2012 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revision U January 2015
34. s from hydraulic rod AFTER EACH 100 HOURS OF OPERATION Change engine oil Reference Honda Engines Owner s Manual for correct oil viscosity SEMI ANNUALLY Check belt wear page 18 replace if necessary YEARLY OR 2000 HOURS Replace hydraulic oil and filter element with Graco hydraulic oil 169236 5 gallon 18 9 liter or 207428 1 gallon 3 8 liter and filter element 246173 page 22 SPARK PLUG Use only BPR6ES NGK or W20EPR U NIPPONDENSO plug Gap plug to 0 028 to 0 031 in 0 7 to 0 8 mm Use spark plug wrench when installing and removing plug Caster Wheel See letter call outs in Parts drawing on page 36 1 Once each year tighten nut 127 Detail A until spring washer bottoms out Then back off the nut 1 2 to 3 4 turn 2 Once each year tighten nut 127 until it beings to compress spring washer Then tighten the nut an additional 1 4 turn Once each month grease the wheel bearing F Check pin 55 for wear If pin is worn out there will be play in the caster wheel Reverse or replace the pin as needed 5 Check caster wheel alignment as necessary To align loosen screw 145 align wheel and tighten bolt Troubleshooting Troubleshooting AN em pe Pe E XX is displayed Fault condition exists Determine fault correction from table page 14 Gas engine pulls hard won t start Hydraulic pressure is too high Turn hydraulic pressure knob counterclockwise to lowest setting Engine won t start Eng
35. tor and install belt 143 Install remote pressure control cable 12 Tighten set screw 102 Install remote pressure control cable 12 Tighten set screw 102 Install drain plug 195 torque to 110 in Ib 12 4 N m Install oil filter 199 tighten 3 4 turn after gasket contacts base Fill with Graco hydraulic oil page 7 Start up and allow pump to operate at low pressure for approximately 5 minutes to purge all air Check and top off hydraulic oil level 311021U Hydraulic Pump 17 T I By deg AS M A B __ A ie 3 AO NS am VAL Mem NO NN NL A 3 d l E WV 1 7 8 GG DCH fA ie N ee E Y N Fig 4 311021U Fan Belt Fan Belt Removal Installation 1 Thread belt 143 around fan pulley 87a and fan pulley 86 2 Lower engine 185 to put tension on belt Relieve pressure page 7 3 Rotate belt guard 24 down Fig 5 Loosen belt guard knob 241 4 Tighten belt guard knob 241 Rotate belt guard 24 up Lift engine 185 up to remove tension on belt 143 Oo A c N Remove belt from fan pulley 86 and fan pulley 87a
36. very hot during operation To avoid severe burns e Do not touch hot fluid or equipment MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts e Keep clear of moving parts e Do not operate equipment with protective guards or covers removed e Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources 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 e Protective eyewear and hearing protection e Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer RECOIL HAZARD Gun may recoil when triggered If you are not standing securely you could fall and be seriously injured CALIFORNIA PROPOSITION 65 The engine exhaust from this product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm This product contains a chemical known to the State of California to cause cancer birth defects or other reproductive harm Wash hands after handling 4 311021U Tip Selection Tip Selection 4 ums 28 umw z8 um 34 o um 4 7
37. will provide purchaser with reasonable assistance in making any claim for breach of these warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com For patent information see www graco com patents TO PLACE AN ORDER contact your Graco distributor or call 1 800 690 2894 to identify the nearest distributor All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without notice Original instructions This manual co
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