Graco 311020W User's Manual
Contents
1. 36 Trigger Sensor Adjustment 19 2 311020 Models pee O O a per ug lcm _ pam eme i aepo pem ug aq e qu G 311020 3 Warnings The following Warnings are for safe 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 Refer back to these Warnings WARNING 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 when2. 4 Fig 15 Remove suction tube 34 and hose 100 34 7672C Fig 15 Repair See manual 310643 for pump repair instructions Installation WARNING If pin works loose parts could break off due to force of pumping action Parts could project through the air and result in serious injury or prop erty damage Make sure pin and retaining spring are properly installed CAUTION If the pump locknut loosens during operation the threads of the bearing housing will be damaged Make sure locknut is properly tightened 1 Fig 18 Pull piston rod out 1 5 in Screw in pump until holes in bearing cross link and piston rod align 7676B Fig 18 5 Fig 16 Use screwdriver push retaining spring up and push out pin 235 Fig 16 7675B 6 Fig 17 Loosen locknut by hitting firmly with a 20 oz maximum hammer Unscrew pump 7673B Fig 17 2 Fig 16 Push pin 235 into hole Push retaining spring into groove around connecting rod Fig 19 Screw jam nut down onto pump until nut stops Screw pump up into bearing housing until it is stopped by jam nut Back off pump and jam nut to align pump outlet to back Tighten jam nut by hand then tap 1 8 to 1 4 turn with a 20 oz maximum ham mer to approximately 75 5 ft Ib 102 N m 7673B Fig 19 Fig 20 Fill packing nut with Graco TSL until fluid flows onto the top of seal 7677B Fig 20 311020 21 Parts LineLa
3. Ref 100 Sheet 7 of 7 32 311020 Ref No 2a 2b 2c 2d 11 15a 15b 15d 15f 15g 15i 15m 15n 150 15q 15r 15s 15t 15v 15w Part No 245103 193709 193710 116424 114708 244067 15F272 287688 287689 114954 116752 256219 116719 198650 116167 15F543 15F544 287692 119736 15F777 15F776 Parts LineLazer IV Description VALVE drain SEAT valve SEAT valve NUT cap SPRING FILTER fluid PLATE control KIT display board BOARD control SWITCH rocker SWITCH rocker POTENTIOMETER KIT SCREW 8 32 hx hd SPACER shaft KNOB potentiometer LABEL control top LABEL control bottom KIT control throttle CLAMP cable GASKET control GASKET throttle Qty G Ref No 152 31 37 38 40 41 62 63 64 76 92 97 123 125 167 215 216 217 Part No 109466 15F589 15C766 15G563 15H561 287285 196178 196179 196181 156331 111348 15 910 15 814 116719 117285 111801 287172 111457 Description NUT lock hex COVER control TUBE diffusion HANDLE MANIFOLD filter 3 8 npt KIT repair filter cap includes 37 167 ADAPTER nipple FITTING elbow street FITTING nipple PLUG pipe BUSHING relief strain WIRE harness GASKET SCREW 8 32 hex washer hd PACKING o ring SCREW cap hex hd TRANSDUCER pressure control PACKING o ring Qty ai Ny
4. Figs 18 and 21 Refer to note on lead connections to the control board Connect leads to control board 15d Fig 13 Push display connector into PC board close display connector wings on PC board Install control cover 31 with two screws 125 Pressure Control Transducer Removal NAN Relieve pressure page 7 2 Fig 13 Remove two screws 125 and control cover 31 3 Disconnect transducer lead C from control board 154 4 Remove pressure control transducer 216 and o ring 217 from filter manifold 40 Installation 1 3 Fig 13 Install o ring 217 and pressure control transducer 216 in filter manifold 40 Torque to 35 45 ft Ib Connect transducer lead C to control board 154 Install control cover 31 with two screws 125 Pressure Adjust Potentiometer Removal Mar Relieve pressure page 7 2 Fig 13 Remove two screws 125 and control cover 31 3 Disconnect lead D from control board 15 4 Loosen set screws on potentiometer knob 150 and remove knob shaft nut lockwasher and pressure adjust potentiometer 15 5 Remove seal 15n from potentiometer 15i 18 311020 Installation 1 2 Install seal 15n on potentiometer 15i Fig 13 Install pressure adjust potentiometer 15i shaft nut lockwasher and potentiometer knob 150 a Turn potentiometer shaft 15i clockwise to internal stop Assemb
5. QY Y Ny 42434479 Replacement warning labels may be ordered free of charge Included in Filter Repair Kit 288100 311020 33 Pressure Control Wiring Diagram Red clip on yellow Yellow 4 CH f White Yellow A4 8 6 1 GROUND D D Lt GROUND White Red 2 Red ENGINE OFF SWITCH DISPLAY BOARD GUN TRIGGER is adr POTENTIOMETER 686668 C EAS TRANSDUCER 0 SENSOR me ti6401a PUMP ON OFF A PUMP U 1 SWITCH STROKE WE COUNTER J9 m J4 J3 O CONTROL BOARD 2 i J J16 TTE A8 SS J11 t NE y ipic J12 A6 TO ENGINE ieee GENERATOR PINON 1
6. NUT lock insert nylock 5 16 SCREW cap flang hd NUT lock SCREW thread forming hex hd SCREW cap hex hd CABLE caster CAP dust GRIP handle CAP vinyl SCREW cap flng hd PAIL plastic WASHER sst external SCREW mach phillips pnhd SCREW cap flnghd MAGNET SWITCH reed with connector LABEL GMAX warning fire amp skn LABEL brand handle LABEL brand handle models 24M605 24M607 PLUG tube HOPPER 15 gal models 24M605 311020 Gty O N N N NNN ON N j 25 Parts LineLazer IV Models 248862 and 248866 86 172 170 34 Detail E Detail E 12 Sheet 4 of 7 26 311020 Ref No 21 22 23 26t 34 34a 34b 34c 34d 34e 34f 34g 34h 34j 34k 34m 34nA 60 811 82 83 84 85 861 871 88 96 100 108 114 117 118 277069 277070 287714 287715 287653 287460 287719 287720 245730 15 149 185381 110194 101818 15 513 181072 245731 241920 245798 114958 196180 195119 119695 196176 193680 287521 287511 192723 193031 15E535 15E277 183401 15F583 245797 101566 108851 110837 110838 Parts LineLazer IV Description Qty PUMP displacement 3900 R300 PUMP displacement 5900 HOUSING bearing 3900 R300 HOUSING bearing 5900 GEAR combination 3900 R300 GEAR combination 5900 ROD connecting 8900
7. clutch engages High engine speed at no load Troubleshooting CAUSE Strainer 34f is clogged Piston ball is not seating Piston packings are worn or damaged O ring in pump is worn or damaged Intake valve ball is not seating properly Intake valve ball is packed with material Engine speed is too low Clutch is worn or damaged Pressure setting is too low Fluid filter 11 tip filter or tip is clogged or dirty Large pressure drop in hose with heavy materials Throat packing nut is loose Throat packings are worn or damaged Displacement rod is worn or damaged Air in pump or hose Tip is partially clogged Fluid supply is low or empty Air in pump or hose Intake valve is leaking Pump packings are worn Paint is too thick Engine speed is too high Clutch surfaces are not matched to each other when new and may cause noise Misadjusted throttle setting Worn engine governor SOLUTION Clean strainer Service piston ball See pump manual Replace packings See pump manual Replace o ring See pump manual Clean intake valve See pump manual Clean intake valve See pump manual Increase throttle setting See operation manual Replace clutch Page 13 Increase pressure See operation manual Clean filter See operation or spray gun manu Use larger diameter hose and or reduce 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 o
8. straight onto pinion housing and locating pins A Install six screws 189 Torque evenly to note 1 value in Fig 3 Install reed switch 182 with two screws 158 Install bearing housing Do steps 1 through 6 of Bearing Housing and Connecting Rod proce dure on page 11 ti6396a 2 181 LineLazer IV 3900 R300 Torque to 200 in Ib 22 6 LineLazer IV 5900 Torque to 25 ft lb 34 2 Fig 3 Remove bearing housing Do Bearing Housing and Connecting Rod procedure on page 11 3 Remove two screws 158 and reed switch 182 4 Remove six screws 189 from pinion housing 25 5 Lightly tap around drive housing 24 to loosen drive housing Pull drive housing straight off pinion housing Be prepared to support gear cluster 23 which may also come out Fig 3 12 311020 A Apply remaining grease to these areas Pinion Assembly Clutch Armature Clamp Pinion Assembly Clutch Armature Removal Pinion Assembly If pinion assembly 25 is not removed from clutch housing 85 do 1 through 3 Otherwise start at 4 A N 1 Remove drive housing page 12 2 Fig 12 Remove clip 251 and junction box 226 3 Fig 11 Disconnect pump stroke sensor and clutch cables 4 Fig 4 Remove four screws 189 and lockwash ers 188 and pinion assembly 25 tib480b Fig 4 5 Fig 5 Place pinion assembly 25 on bench with rotor side up 6 Remove four screws 170 and lockwa
9. 224052 BRACKET support gun 1 4 248157 GUN flex basic includes guard amp tip 1 8 287570 HOLDER ASSEMBLY gun 1 items 8a thru 8f 8a 287569 HOLDER GUN 1 8b 102040 NUT lock 4 8c 15F214 LEVER actuator 1 8d 15F209 STUD pull trigger 1 8e 15F210 STUD pivot 1 8f 15F211 STUD cable 1 17 245733 KIT trigger handle repair 1 includes items 17 89 126 164 and 165 44 15F212 ARM holder gun 1 47 15F213 BRACKET cable 1 49 188135 GUIDE cable 1 71 198895 PLATE lever pivot 2 72 198896 BLOCK mounting mach 1 89 15A644 LABEL trigger 1 95 15F389 BRACKET gun arm 1 104 119647 SCREW cap socket flthd 2 Ref No 105 108 112 119 126 136 136a 153 160 161 162 163 164 165 166 168 219A 227 Part No 119648 101566 111145 111017 112381 287566 114028 114982 116941 287696 116969 116973 117268 117269 287699 117317 15F637 15F624 Description SCREW mach trusshd NUT lock KNOB pronged BEARING flange SCREW mach pan hd KIT clamp includes 136a NUT wing SCREW cap flng hd SCREW shoulder socket head CABLE gun includes 227 NUT lock SCREW 10 taptite phil BRACKET interrupter SPRING SENSOR trigger SCREW plastite pan head LABEL GMAX warning skn injct NUT cable gun knurled Included in Trigger Repair Kit 245733 311020 Qty Ap A 31 Parts LineLazer IV 15m Models 248862 and 248866 d 151 15b
10. No display does not mean that sprayer is not pressurized DISPLAY SPRAYER INDICATION ACTION OPERATION No Display Sprayer be pressurized Loss of power or display Check power source Relieve not connected pressure before repair or disas sembly Verify display is con nected Sprayer may be pressurized Pressure less than Increase pressure as needed 200 psi 14 bar 1 4 MPa 2000 psi Sprayer is pressurized Power is ap Normal operation bar plied Pressure varies with tip size a MPa and pressure control setting Sprayer stops Engine is running Exceeded pressure limit Remove any filter clogs or flow obstructions Make sure gun trig ger is locked open if using Auto Clean valve Sprayer stops Engine is running Pressure transducer Check transducer connections faulty bad connection or and wire Replace transducer or broken wire control board if necessary Sprayer stops Engine is running High clutch current Check clutch 7 pin bulkhead connector Clean contacts Measure 1 2 0 2 LineLazer IV 3900 R300 1 7 0 2Q LineLazer IV 5900 across clutch field at 70 F 3 Replace clutch field assembly After a fault follow these steps to restart sprayer 1 Correct fault condition 2 Turn sprayer OFF 3 Turn sprayer ON 20 311020 Displacement Pump Removal 1 Flush pump MAN Relieve pressure page 7 3 Fig 15 Cycle pump piston rod A to lowest posi tion
11. R300 ROD connecting 6900 HOSE ASSEMBLY drain items 34a thru 34n TUBE suction HOSE SWIVEL 180 CLAMP hose GASKET pail STRAINER TUBE drain includes diffuser DIFFUSER HOSE coupled 1 4 in x 7 ft STRAP tie BUSHING LABEL warning DAMPENER engine mount ADAPTER nipple HUB armature COLLAR shaft COVER front 3900 R300 COVER front 5900 NUT retaining 3900 R300 NUT retaining 5900 HOUSING clutch 3900 R300 HOUSING clutch 5900 ROTOR clutch 4 3900 9300 ROTOR clutch 5 in 5900 ARMATURE clutch 4 3900 R300 ARMATURE clutch 5 in 5900 KEY parallel PLATE engine mount HOSE 3 8 in x 3 0 ft NUT lock WASHER plain SCREW flange hex NUT lock Ref No 169 1701 171 1721 173 174 1751 177 178 179 183 185 186 187 188 189 190 212 223 226 233 2344 235 2363 247 248 249 258 259 260 Part No 119426 102962 101682 104008 105510 100214 106115 113743 108803 112395 114672 114699 113467 114666 108879 114530 108842 118444 100214 119426 15 753 15 947 15 250 114672 119579 240997 287695 15F546 15F547 16N452 194126 15F855 15F856 119676 119778 290228 114629 119569 15C762 110996 240997 Description SCREW hex washr hd 3900 8300 SCREW cap sch 5900 SCREW cap sch WASHER lock spring 5900 WASHER lock spr hi co
12. engine 3 Check dimension Place rigid straight steel bar B across face of clutch housing 5 Use accurate measuring device to measure distance between bar and face of clamp Adjust clamp as necessary Torque two screws 175 to 125 10 in Ib 14 1 1 N m 14 311020 Pinion Assembly 6 Fig 6 Check o ring 25c and replace if missing or damaged 7 Tap pinion shaft 25d in with plastic mallet 8 Install retaining ring 25e with beveled side facing up 9 Fig 5 Place pinion assembly on bench with rotor side up 10 Apply thread sealant to screws Install four screws 170 and lockwashers 172 Alternately torque screws to 125 in lb until rotor is secure Use threaded holes to hold rotor 11 Fig 4 Install pinion assembly 25 with five screws 189 and lockwashers 188 12 Fig 11 Connect pump stroke sensor and clutch cables 13 Fig 12 Install junction box 226 with clip 251 AN Face of clutch housing 2 55 010 in 39 37 25 mm LineLazer IV 3900 R300 2 61 010 in 66 29 25 mm LineLazer IV 5900 Torque to 125 10 in Ib 14 1 1 Chamfer this side N 85 N tib484b Fig 9 A Clutch Housing Removal 1 3 Fig 10 Remove four cap screws 186 and lock washers 188 which hold clutch housing 85 to engine Remove screw 177 from under mounting plate 96 Pull off clutch housing 85 Installation 1 2 Fi
13. 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 sub stitution 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 defective to an authorized Graco distributor for verification of the claimed defect Ifthe 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 ofthe equipment does notdisclose 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 setforth above The buyer agrees that no other reme
14. triggering into pail If there is static sparking or you feel a shock stop operation immediately Do not use equipment until you identify and correct the problem Keep a fire extinguisher in work area CARBON MONOXIDE HAZARD Exhaust contains poisonous carbon monoxide which is colorless and odorless Breathing carbon monoxide can cause death 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 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 Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying Follow Pressure Relief Procedure in this manual when you stop spraying and before cleaning check ing or servicing equipment 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 check ing 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 PRESSURIZED A
15. 10 118 116 117 121 127 Part No 240942 240991 15G952 181818 193528 193661 193662 15F910 198606 100731 101566 15J603 108483 110754 110837 111040 112405 Parts LineLazer IV Description SHAFT fork BRACKET caster front BRACKET KNOB pronged ARM detent JAW STOP wedge BRACKET cable DISK adjuster WASHER NUT lock WASHER plain SCREW shoulder sch SCREW cap sch SCREW flange hex NUT lock insert nylock 5 16 NUT lock Qty Ny aaa a Ref No 128 130 131 132 133 135 139 140 142 145 146 147 153 208 209 Part No 112776 112825 113471 113484 113485 113962 114548 114549 114648 114681 114682 114802 114982 193658 120476 Description WASHER plain SPRING belleville SCREW cap hex hd SEAL grease BEARING cup cone WASHER hardened SAE BEARING bronze WHEEL pneumatic CAP dust SCREW cap hex hd SPRING compression STOP wire SCREW cap flng hd SPACER seal BOLT Qty a hyp AND H Ww Included in 240940 Bracket Repair Kit purchase separately 311020 29 Parts LineLazer IV Models 248862 and 248866 5 lt 49 Ref 161 Ref 16 page 24 ti6403a 22 A 04 136 136a e M 44 LZ 161 160 Ref 144 page 24 Ref 161 166 Sheet 6 of 7 30 311020 Parts LineLazer IV Ref No Part No Description Qty 1
16. HOUSIN A5 WHITE ons A TO CLUTCH NCTION j iiid CLUTCH TEST POINTS J12 97 RS a E TT WHITE YELLOW A4 rj YELLOW A3 YELLOW E Fig 21 4 311020 Technical Data Honda GX120 Engine Power Rating 2 3600 rpm AINSI Ene br UU rre 4 0 Horsepower DIN 6270B DIN 6271 e xS 2 1 Kw 2 8 Ps NE al nyata amat ues 2 6 Kw 3 6 Ps Honda GX160 Engine Power Rating 2 3600 rpm ANSI i ver e Rr 5 5 Horsepower DIN 6270B DIN 6271 Qr 2 9 Kw 4 0 Ps 3 6 Kw 4 9 Ps Maximum working pressure 3300 psi 228 bar 22 8 MPa Noise Level Sound power 105 dBa per ISO 3744 Sound pressure 96 dBa measured at 3 1 feet 1 m Vibration Level LineLazer IV 3900 R300 Left hand 1 81 m sec Righthand 1 45 m sec2 LineLazer IV 5900 Left hand 2 05 m sec Righthand 1 70 m sec2 Vibration measured per ISO 5349 based on 8 hour daily exposure Maximum delivery LineLazer IV 3900 R300 1 15 gpm 4 4 liter min LineLazer IV 5900 1 5 gpm 5 7 liter min Maximum tip size LineLazer IV 3900 R300 1 gun with O 034 in tip 2 guns with 0 024 in tip LineLazer IV 5900 1 gun with 0 044 in tip 2 guns with 0 028 in tip Inlet paint s
17. LUMINUM PARTS HAZARD Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment Such use can cause serious chemical reac tion and equipment rupture and result in death serious injury and property damage 4 311020 7 7 WARNING EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury e Do not exceed the maximum working pressure or temperature rating of the lowest rated system compo nent 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 Check equipment daily Repair or replace worn or damaged parts immediately Do not alter or modify equipment Use equipment only for its intended purpose Call your Graco 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 BURN HAZARD Equipment surfaces and fluid that s heated can become very hot during operation To avoid severe burns do not touch hot fluid or equipment Wait until equipment fluid has cooled completely MOVING PARTS HAZARD Moving parts can pinch or amputate finger
18. Repair Parts List GRACO LineLazer IV 3900 R300 5900 and FieldLazer Airless Line Stripers 311020 For application of line striping materials 3300 psi 228 bar 22 8 MPa Maximum Working Pressure Important Safety Instructions Read all warnings and instructions in this manual Save these instructions 311017 312540 310643 311254 309055 311049 PROVEN QUALITY LEADING TECHNOLOGY C Table of Contents MOdGIS 2g tect ne shee rre bet Galen Seed eee 3 Distance Sensor Adjustment 19 WAININGS lt 2 serine m Lt eats Geet wear 4 Control Board Diagnostics 20 Spray Tip Selection 6 Displacement Pump 21 Maintenance 7 Parts Troubleshooting 8 LineLazer IV 3900 R300 5900 22 Repair Drive and Pinion Housing Assemblies 23 Bearing Housing amp Connecting Rod 11 Pressure Control Wiring Diagram 34 Drive Housing 12 Technical Data 35 Pinion Assembly Clutch Armature Clamp 13 DIMENSIONS RC RR RAD RA 35 E 16 Graco Phone Number 35 Pressure Control 17 Graco Warranty
19. dy 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 ofthe 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 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 reconnais sent avoir convenu que la r daction du pr sente document sera en Anglais ainsi qu
20. e 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 procedures concern es ADDITIONAL WARRANTY COVERAGE Graco does provide extended warranty and wear warranty for products described in the Graco Contractor Equipment Warranty Program Graco Information 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 For patent information see www graco com patents Original instructions This manual contains English MM 311020 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2010 Graco Inc All Graco manufacturing locations are registered to ISO 9001 www graco com Revised February 2014 36 311020
21. g 10 Push on clutch housing 5 Install four cap screws 186 and lock washers 188 and secure clutch housing 85 to engine Torque to 200 in Ib 22 6 Nem Install cap screw 177 from beneath mounting plate 96 Torque to 26 ft lb 35 2 SS ti6643a Fig 10 311020 15 Engine Removal 1 Remove Pinion Assembly Clutch Armature Clamp and Clutch Housing See pages 11 15 2 Fig 12 Remove clip 251 and junction box 226 3 Fig 11 Disconnect all necessary wiring 4 Fig 12 Remove screw 177 Remove two screws 117 locknuts 118 and ground conduc tor 230 260 from base of engine 185 5 Lift engine carefully and place on work bench NOTE All service to the engine must be performed by an authorized HONDA dealer gs Main Control Box Cable Wheel Sensor Cable Engine P Bottom View 18 0 S ti6397a Clutch Distance Sensor To Main Control Box To Engine Junction Pump Stroke Fig 11 Counter 16 311020 Fig 12 Installation 1 Lift engine carefully and place on cart 2 Fig 12 Install two screws 117 and ground con ductor 223 260 in base of engine and secure with locknuts 118 Torque to 20 to 30 ft lb 3 Fig 11 Connect all necessary wi
22. le potentiometer knob 150 to strike pin on plate 15r b After adjustment of step a tighten both set screws in knob 1 4 to 3 8 turn after contact with shaft Connect lead D to control board 15d Install control cover 31 with two screws 125 Trigger Sensor Adjustment Refer to Troubleshooting for trigger sensor adjust ment and see operation manual Distance Sensor Adjustment Gear Alignment 5 Install wheel 120 on LineLazer 6 Install nut 127 until tight then back off 1 4 turn C Install dust cap 142 on wheel gt Sensor Height Adjustment Ht 1 Remove wheel 120 from LineLazer 2 Fig 14 Remove dust cap 142 from wheel Remove nut 127 2 Remove distance sensor 66 3 Remove wheel 120 from LineLazer 3 Adjust sensor assembly height with two 17 mm nuts of sensor so bottom surface of sensor is 4 Align gear 67 with sensor 0 638 0 020 from bottom surface of shield a Pull gear out from wheel with gear puller Torque to 8 2 in Ib b Push gear in toward wheel with mallet 4 Reassemble distance sensor 66 and wheel 82 Distance Sensor 66 Tire E 120 Axle Gear 67 g Gear 67 ti6400a Distance Sensor Detail Fig 14 311020 19 Control Board Diagnostics Digital Display Messages A N Relieve pressure before repair page 7
23. llar WASHER lock spr hi collar 3900 R300 5900 SCREW cap hex hd SCREW hex socket head SCREW cap flnghd WASHER thrust WASHER thrust SCREW cap soc hd 3900 R300 SCREW cap soc hd 5900 ENGINE gas 4 0 hp 3900 R300 ENGINE gas 5 5 hp 5900 SCREW cap hex hd SCREW machine hex washer hd WASHER lock SCREW mach hex washr hd 3900 R300 SCREW mach hex washr hd 5900 SHIELD magnetic WASHER thrust 3900 R300 WASHER thrust 5900 CONDUCTOR ground 3900 R300 CONDUCTOR ground 5900 BOX LABEL brand 3900 R300 LABEL brand 5900 LABEL brand R300 models 24M605 24M607 LABEL warning PIN pump 3900 5900 SPRING retaining 3900 R300 SPRING retaining 5900 LABEL caution GROMMET BUSHING SHIELD pump rod NUT hex CONDUCTOR ground 5900 Qty 4 4 4 O gt P 4 4 1 0 lt ci Ny 32 a ann un A Replacement warning labels may be ordered free of charge T Included in Clutch Repair Kits 241109 3900 R300 and 241113 5900 t Included in Connecting Rod Kits 311020 27 Parts LineLazer IV Models 248862 and 248866 Ref 141 Ref 6 Detail D L 195 140 2 145 Detail D ti6404b 131 Install washers 130 concave surface to inside Sheet 5 of 7 28 311020 Ref No 10 46 52 54 55 56 65 106 108 1
24. n does not show on dis play when fluid is sprayed Bad wiring connections Check connector and reconnect Adjust space between sensor and gear to 050 020 in See page 19 Distance sensor not spaced correctly Remove tire and press in or pull out gear to align sensor and gear Distance sensor and gear not aligned Gear teeth missing or damaged Replace distance gear wheel Wire cracked or broken Replace sensor Mils not calculating Distance sensor See Distance counter not operating properly Trigger sensor See Spray icon does not show on dis play when fluid is sprayed Gallon counter See Gallon counter not working Bad or damaged control board Fluid spray starts after spray icon is Interrupter 164 is improperly positioned Turn screw 126 counterclockwise until shown on display spray icon synchronizes with fluid spray Fluid spray starts before spray icon is Interrupter 164 is improperly positioned Turn screw 126 clockwise until spray shown on display icon is synchronized with fluid spray Spray icon does not show on display Loose connector Check connector and reconnect when fluid is sprayed Replace control board and display Interrupter 164 is improperly positioned Turn screw 126 counterclockwise until spray icon synchronizes with fluid spray Reed switch assembly 166 is damaged Replace reed switch assembly 166 Magnet on assembly 166 is missing Replace reed switch assembly 166 Cut or sliced
25. n valve Leave valve open until ready to spray again If you suspect that the spray tip or hose is completely clogged or that pressure has not been fully relieved after following the steps above VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually then loosen completely Now clear tip or hose CAUTION e Minimum hose size allowable for proper sprayer operation is 3 8 in x 50 ft e For detailed engine maintenance and specifica tions refer to separate Honda Engines Owner s Manual supplied DAILY Check engine oil level and fill as necessary DAILY Check hose for wear and damage DAILY Check gun safety for proper operation DAILY Check pressure drain valve for proper opera tion DAILY Check and fill the gas tank AFTER THE FIRST 20 HOURS OF OPERATION Drain engine oil and refill with clean oil Reference Honda Engines Owner s Manual for correct oil viscos ity WEEKLY Remove air filter cover and clean element Replace element if necessary If operating in an unusually dusty environment check filter daily and replace if necessary Replacement elements can be purchased from your local HONDA dealer WEEKLY Check level of TSL in displacement pump packing nut Fill nut if necessary Keep TSL in nut to help prevent fluid buildup on piston rod and premature wear of packings AFTER EACH 100 HOURS OF OPERATION Change engine oil Reference Honda Engines Owner s Manual f
26. ng D inside connecting rod assembly 26 with bearing grease 2 Assemble connecting rod 26 and bearing housing 22 3 Clean mating surfaces of bearing and drive hous ings 4 Align connecting rod with crank B and carefully align locating pins F in drive housing 24 with holes in bearing housing 22 Push bearing hous ing onto drive housing or tap into place with plastic mallet CAUTION DO NOT use bearing housing screws 183 to align or seat bearing housing with drive housing Align these parts with locating pins F to avoid prema ture bearing wear 5 Install screws 183 and lockwashers 173 on bearing housing Torque evenly to note 3 value in Fig 2 6 Install pump Refer to Displacement Pump Installation page 21 AN A Pack with bearing grease 114819 A LineLazer IV 3900 R300 Torque to 200 in Ib 22 6 LineLazer V 5900 Torque to 25 ft Ib Fig 2 Model 248862 shown 311020 11 Drive Housing Installation Removal N 1 N Relieve pressure page 7 1 5 Liberally apply bearing grease supplied with replacement gear cluster to gear cluster 23 and to areas called out by note 2 Place bronze colored washer 24g on shaft pro truding from large shaft of drive housing 24 Place silver colored washer 24h on pinion hous ing Clean mating surfaces of pinion and drive housings Align gears and push new drive housing
27. or correct oil viscosity SPARK PLUG Use only BPR6ES 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 28 1 Once each year tighten nut 127 under dust cap 142 until spring washer bottoms out Then back off the nut 1 2 to 3 4 turn 2 Once each year tighten nut 127 on screw 131 until it begins to compress spring washer Then tighten the nut an additional 1 4 turn 3 Once each month grease the wheel bearing F 4 Check pin 55 for wear If pin is worn out there will be play in the caster wheel Reverse or re place the pin as needed 5 Check caster wheel alignment as necessary To align loosen screw 145 align wheel and tighten screw 311020 7 Troubleshooting Y PROBLEM CAUSE SOLUTION is displayed Determine fault correction from table page 20 Engine won t start Engine switch is OFF Turn engine switch ON Engine is out of gas Refill gas tank Honda Engines Owner s Manual Try to start engine Replenish oil if necessary Honda Engines Owner s Manual Connect spark plug cable or replace spark plug 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 di
28. ptimum perfor mance 50 ft minimum Remove throat packing nut spacer Tighten throat packing nut just enough to stop leakage Replace packings See pump manual Replace rod See pump manual Check and tighten all fluid connections Reprime pump See operation manual Clear tip See spray gun manual Refill fluid supply Prime pump See operation manual Check fluid supply often to prevent running pump dry Check and tighten all fluid connections Reduce engine speed and cycle pump as slowly as possible during priming Clean intake valve Be sure ball seat is not nicked or worn and that ball seats well Reas semble valve Replace pump packings See pump manual Thin the paint according to the supplier s recommendations Decrease throttle setting before priming pump See operation manual Clutch surfaces need to wear into each other Noise will dissipate after a day of run time Reset throttle to 3600 engine rpm at no load Replace or service engine governor 311020 9 Troubleshooting CAUSE Gallon counter not working Broken or disconnected wire SOLUTION Check wires and connections Replace broken wires Bad sensor Replace sensor Missing magnet Reposition or replace magnet Sprayer operates but display does not Bad connection between control board Remove display and reconnect Display damaged Replace display Distance counter not operating properly Trigger sensor not set correctly See Spray ico
29. ring 4 Install Pinion Assembly Clutch Armature Clamp and Clutch Housing See pages 11 15 Pressure Control On Off Switch Installation Removal WN PN 1 Install ON OFF switch 15g so tabs of switch snap into place on inside of pressure control housing 1 Relieve pressure page 7 2 Connect ON OFF switch connector B to PC board 2 Fig 13 Remove two screws 125 and cover 31 3 Push display connector into PC board close dis 3 Pull display connector wings A open on PC board play connector wings A on PC board and pull display connector out 4 Disconnect ON OFF switch connector B from PC 4 Install cover 31 with two screws 125 board 5 Press on two retaining tabs on each side of ON OFF switch 15g and remove switch 2 gt D yd Main Control Box Cable 216 217 Fig 13 311020 17 Pressure Control Control Board Removal MAN Relieve pressure page 7 2 Fig 13 Remove two screws 125 and control cover 31 Pull display connector wings open on PC board and pull display connector out 3 Figs 13 and 21 Note on a paper lead connections to the control board Disconnect leads from control board 15d 4 Fig 13 Remove four screws 15j from control board 15d Installation 1 2 Fig 13 Install control board 15d with four screws 15j
30. s Error code displayed Reference pressure control repair Page 18 placement pump does not operate Pump switch is OFF Turn pump switch ON Pressure setting is too low Turn pressure adjusting knob clockwise to increase pressure Fluid filter 11 is dirty Clean filter Page 32 Tip or tip filter is clogged Clean tip or tip filter See spray gun manual Displacement pump piston rod is stuck due to Repair pump See pump manual dried paint Connecting rod is worn or damaged Replace connecting rod Page 11 Drive housing is worn or damaged Replace drive housing Page 12 Electrical power is not energizing clutch field Check wiring connections Page 16 Reference pressure control repair Page 18 Reference wiring diagram Page 34 With pump switch ON and pressure turned to MAXIMUM use a test light to check for power between clutch test points on control board Measure resistance across clutch coil At 70 F the resistance must be between 1 2 0 2 LineLazer IV 3900 R300 1 7 0 29 LineLaz er IV 5900 if not replace pinion housing Have pressure control checked by authorized Graco dealer Clutch is worn damaged or incorrectly Replace clutch Page 13 positioned Pinion assembly is worn or damaged Repair or replace pinion assembly Page 13 8 311020 PROBLEM Pump output is low Excessive paint leakage into throat packing nut Fluid is spitting from gun Pump is difficult to prime Clutch squeaks each time
31. s 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 in this manual Disconnect power or air supply PERSONAL PROTECTIVE EQUIPMENT You must wear appropriate protective equipment when operating servicing or when in the operating area of the equipment to help protect you from serious injury including eye injury inhalation of toxic fumes burns and hearing loss This equipment includes but is not limited to e Protective eyewear e Clothing and respirator as recommended by the fluid and solvent manufacturer e Gloves e Hearing protection RECOIL HAZARD Brace yourself gun may recoil when triggered and cause you to fall which could cause serious injury 311020 5 Tip Selection DH CNN NEN N WwW N WwW Use 100 mesh filter to reduce tip clogs 311020 6 Maintenance Pressure Relief Procedure 1 Lock gun trigger safety 2 Turn engine ON OFF switch to OFF 3 Move pump switch to OFF and turn pressure control knob fully counterclockwise 4 Unlock trigger safety Hold metal part of gun firmly to side of grounded metal pail and trigger gun to relieve pressure 5 Lock gun trigger safety 6 Open pressure drai
32. sembly 287463 for LineLazer IV 3900 R300 Pinion Housing Assembly Qty N A 23 Parts LineLazer IV Sheet 3 of 7 24 311020 Ref No 18 14 16 27 28 33 35 42 51 57 58 60 66 67 68 70 73 74 93 94 107 108 115 Part No 237686 245225 245798 287623 287417 287622 287590 119771 108471 193405 194310 195134 196176 287698 198612 198891 198930 198931 15F577 15F576 178342 101566 108868 Parts LineLazer IV Description WIRE ground assembly w clamp HOSE 3 8 X 50 ft HOSE 1 4 X 7 ft FRAME linestriper painted HANDLE SUPPORT handle painted COVER pail includes 35 STRAP cover KNOB pronged AXLE LEVER actuator SPACER ball guide ADAPTER nipple KIT sensor distance includes 68 115 129 157 GEAR signal SHIELD sensor distance BRACKET mounting ROD brake BEARING BRACE left painted BRACE right painted CLIP NUT lock CLAMP wire Gty a apa G N Ref No 117 120 121 122 127 129 134 141 142 144 148 153 154 157 158 177 181 182 220 232 264 265 Part No 110837 255162 249082 111040 111194 112405 112798 113961 241445 114648 114659 114808 114982 115077 116287 114528 112395 116618 119562 15F638 15F545 16N453 120151 241104 Description SCREW flange hex WHEEL pneumatic includes 67 WHEEL turf models 24M605 24M607
33. shers 172 Install two screws in threaded holes E in rotor Alternately tighten screws until rotor comes off tib987c tib481b Fig 5 7 Fig 6 Remove retaining ring 25e 8 Tap pinion shaft 25d out with plastic mallet IZEN 86 O tib482b 8703A Fig 6 Clutch Armature 9 Fig 7 Use an impact wrench or wedge something between armature 87 and clutch housing to hold engine shaft during removal 10 Remove four screws 175 and lockwashers 172 11 Remove armature 87 Fig 7 8704A 311020 13 Installation Clutch Armature 1 Fig 8 Lay two stacks of two dimes on smooth bench surface 2 Lay armature 87 on two stacks of dimes 3 Press center of clutch down on bench surface N 0 12 01 in 3 0 25 mm A Te dimes Fig 8 8705A 4 Install armature 87 on engine drive shaft 5 Install four screws 175 and lockwashers 172 with torque of 125 in lb Clamp Removal 1 Do Engine Removal NW 2 Drain gasoline from tank according to Honda manual 3 Tip engine on side so gas tank is down and air cleaner is up 4 Fig 9 Loosen two screws 175 on clamp 82 5 Push screwdriver into slot in clamp 82 and re move clamp Installation 1 Fig 9 Install engine shaft key 88 2 Tap clamp 82 on engine shaft A with plastic mallet Maintain dimension shown note 2 Chamfer must face
34. t dry without packaging 232 Ib 105 kg Weight dry without packaging 232 Ib 105 kg kieiglit i esr pesi 40 in 101 6 cm Height soci LEBER ERE 40 in 101 6 cm Length tain whe ERSTES 65 in 165 1 cm ss ale e EUR 65 in 165 1 cm Width Iesse Lewes 32 in 81 3 cm Width a 32 81 3 Model 248867 249011 Striper with 2nd Gun Kit Model 248869 Striper 2nd Gun Kit with Bead Weight dry without packaging 242 Ib 110 kg Weight dry without packaging 242 Ib 110 kg Bik peaks 40 in 101 6 cm Height 2 s rh ae ee be utpa 40 in 101 6 cm Length eS 65 in 165 1 cm Length opes 65 in 165 1 cm Width AR 32 in 81 3 cm WIG 242 nasa 32 in 81 3 cm 311020 35 Graco Standard Warranty Graco warrants all equipment 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
35. trainer 16 mesh 1190 micron stainless steel screen reusable Outlet paint filler 60 mesh 250 micron stainless steel screen reusable Pump inlet 5126 3 4 in npt m Fluid outlet size 1 4 npsm from fluid filter Wetted parts nickel plated carbon steel PTFE Nylon polyurethane UHMW polyethylene fluoroelastomer acetal leather tungsten carbide stainless steel chrome plating Dimensions LineLazer IV 3900 R300 Model 248862 249008 24M605 24M607 Striper Model 248864 Striper with Bead Weight dry without packaging 212 Ib 96 kg Weight dry without packaging 212 Ib 96 kg Height eere eun 40 in 101 6 cm Height 40 101 6 65 165 1 Length 65 165 1 Width Re nd 32 in 81 3 cm Width 3 crece ce 32 in 81 3 cm Model 248863 249009 Striper with 2nd Gun Kit Model 248865 Striper 2nd Gun Kit with Bead Weight dry without packaging 222 10 101 kg Weight dry without packaging 222 Ib 101 kg Height Snead 40 in 101 6 cm Height resres aa VE 40 in 101 6 cm Length tred ERE 65 in 165 1 cm Leng era terreni EET IT 65 in 165 1 cm 32 81 3 Midth Sasa Oa 32 in 81 3 cm LineLazer IV 5900 Model 248866 249010 Striper Model 248868 Striper with Bead Weigh
36. wire Replace distance sensor harness 66 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 126 clockwise until spray icon is synchronized with fluid spray Reed switch assembly 166 is damaged Replace reed switch assembly 166 10 311020 Bearing Housing and Connecting Rod Removal 1 Relieve pressure page 7 2 Fig 2 Remove screws 187 and front cover 83 3 Unscrew suction tube 34 from pump hold wrench on pump intake valve A to keep pump from loosening 4 Disconnect pump outlet hose 100 from displace ment pump outlet nipple 60 5 Fig 1 Use screwdriver to push up retaining spring 236 at top of pump Push out pin 235 236 Fig 1 6 Fig 2 Loosen retaining nut 84 Unscrew and remove displacement pump 21 7 Remove four screws 183 and lockwashers 173 from bearing housing 22 8 Pull connecting rod 26 and lightly tap lower rear of bearing housing 22 with plastic mallet to loosen from drive housing 24 Pull bearing hous ing and connecting rod assembly 26 off drive housing 9 Inspect crank B for excessive wear and replace parts as needed Installation 1 Evenly lubricate inside of bronze bearing C in bearing housing 22 with high quality motor oil Liberally pack top roller bearing E lower beari
37. zer IV Parts Page 32 Parts Page 26 ex Parts Page 30 Parts Page 30 Parts Page 28 Sheet 1 of 7 Parts Page 24 311020 22 Parts Drive and Pinion Housing Assemblies Ref No 24 and 25 Ref No 24 Drive Housing Assembly 287467 for LineLazer IV 3900 R300 Drive Housing Assembly 287469 for LineLazer IV 5900 Ref No 24 24g 24h Part No 287467 287469 107089 194173 116191 116192 AN Pinion housing assembly 25 includes clutch field and connector Description HOUSING drive 3900 R300 HOUSING drive 5900 WASHER LineLazer IV 3900 R300 LineLazer IV 5900 WASHER LineLazer IV 3900 R300 LineLazer IV 5900 Ref 212 287465 for LineLazer IV 5900 Ref No Qty 1 25 25a 25b 1 25d 25e 158 181 182 Part No 287463 287465 287474 287476 105489 241110 241114 113094 112770 114528 116618 119562 Description HOUSING pinion 3900 R300 HOUSING pinion 5900 KIT repair coil LineLazer IV 3900 R300 LineLazer IV 5900 PIN PINION SHAFT LineLazer IV 3900 R300 LineLazer IV 5900 RETAINING RING large LineLazer IV 3900 R300 LineLazer IV 5900 SCREW machine MAGNET SWITCH reed w connector Must be ordered separately Sheet 2 of 7 Ref 189 Ref 170 Ref 172 Ref 86 311020 Ref No 25 Pinion Housing As
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