308105W GM 5000 GASOLINE-POWERED AIRLESS

INSTRUCTIONS-PARTS LIST
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
308–105
First choice when
quality counts.t
Rev. W
Supersedes Rev. V
INSTRUCTIONS
GM 5000
GASOLINE-POWERED AIRLESS LINESTRIPER
LineLazer
3000 psi (210 bar, 21.0 MPa)
Maximum Working Pressure
Model 231–133, Series B
With one gun, RAC IVR DripLesst Tip guard,
Size 317 LineLazer Tip & Size 517 SwitchTipt,
and 50 foot (15 m) hose.
Model 231–141
Same as 231–133, except includes
Second Gun Kit, 224–097
7360C
GRACO INC.
P.O. BOX 1441
MINNEAPOLIS, MN
ECOPYRIGHT 1990, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
55440–1441
Part Identification
Key
A
B
C
D
E
F
G
H
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
Caster lever
Dual gun selector
Main hose
Suction hose
Fluid filter
Pressure drain valve
Arm
Post
Carriage bar
Gun holder
Rac IV tip guard
Switch Tip
Flex gun
Displacement pump
Caster
Dual gun selector cable
Pressure control
Spark plug cable
Air Cleaner
Muffler
Fuel Tank
Hook eyelet (use to strap
pail or pail cover to cart)
X Pail cover
Y Caster Cable
Z Grounding wire and clamp
AA Collar
A
Y
Z
B
X
F
V
W
C
U
T
S
D
R
E
Q
G
P
O
H
AA
K
J
N
M
L
2
308-105
7360C
Table of Contents
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Second Gun and Hose Installation . . . . . . . . . . . . . . . 11
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Startup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Spray Tip and Tip Guard . . . . . . . . . . . . . . . . . . . . . . . 15
Gasket Selection . . . . . . . . . . . . . . . . . . . . . . . 15
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Clearing a Clogged Tip . . . . . . . . . . . . . . . . . . 15
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Spray Tip Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Spray Tip Application Recommendations . . 16
Spray Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Line Width Adjustment . . . . . . . . . . . . . . . . . . 16
Positioning the Gun Arm Assembly . . . . . . . . . . . . . . 17
Vertical position of the first or second gun . 17
Horizontal position of the first gun . . . . . . . . 17
Horizontal position of the second gun . . . . . 17
Mount guns on the engine side of the cart . 18
Setup for spraying arcs . . . . . . . . . . . . . . . . . 18
Adjust Simultaneous Gun Triggering . . . . . . . . . . . . . 18
Gun Arm Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Caster Lever & Cable Operation . . . . . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Caster Tire Replacement . . . . . . . . . . . . . . . . 20
Caster Cable Tension Adjustment . . . . . . . . 20
Caster Alignment . . . . . . . . . . . . . . . . . . . . . . .
How to Mount the Gun . . . . . . . . . . . . . . . . . . . . . . . . .
Gun Cable & Dual Gun Selector Operation . . . . . . . .
How the Dual Gun Selector Works . . . . . . . .
How to Release the Selector Cable . . . . . . .
Adjust the Trigger Cable Tension . . . . . . . . .
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair or Replacement
Pressure Control . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Adjustment . . . . . . . . . . . .
Bearing Housing and Connecting Rod . . . . .
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Housing . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field & Wiring Harness . . . . . . . . . . . . . . . . . .
Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Housing Removal . . . . . . . . . . . . . . . .
Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts
Pressure Control Parts . . . . . . . . . . . . . . . . . .
Cart Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Parts . . . . . . . . . . . . . . . . . . . . . . .
Gun Mounting Parts . . . . . . . . . . . . . . . . . . . .
Pinion Parts . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
20
21
21
21
22
23
24
26
27
28
29
30
32
34
35
36
36
37
39
40
42
44
45
46
46
48
Manual Change Summary
This manual has been updated by ECO F5553 to include the addition of Parts List items 194 – 196.
Symbols
Warning Symbol
Caution Symbol
WARNING
CAUTION
This symbol alerts you to the possibility of serious
injury or death if you do not follow the instructions.
This symbol alerts you to the possibility of damage to
equipment if you do not follow the instructions.
WARNING
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
INSTRUCTIONS
This equipment is for professional use only.
Read all instruction manuals, tags, and labels before operating the equipment.
Use the equipment only for its intended purpose. If you are not sure, call your distributor.
Do not alter or modify this equipment.
Check equipment daily. Repair or replace worn or damaged parts immediately.
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 46 for the maximum working pressure of this equipment.
Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Technical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82C (180F) or below –40C (–40F).
Do not lift pressurized equipment.
Comply with all applicable local, state, and national fire, electrical, and safety regulations.
Wear hearing protection when operating this equipment.
Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or
fluids containing such solvents in pressurized aluminum equipment. Such use could result in a
chemical reaction, with the possibility of explosion.
4
308-105
WARNING
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely
serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also
cause serious injury.
Fluid injected into the skin may look like just a cut, but it is a serious injury. Get immediate medical attention.
Do not point the gun at anyone or at any part of the body.
Do not put your hand or fingers over the spray tip.
Do not stop or deflect leaks with your hand, body, glove or rag.
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard and the trigger guard on the gun when spraying.
Check the gun diffuser operation weekly. Refer to the gun manual.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 7 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high pressure couplings; you must replace the entire hose.
Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
FUEL HAZARD
The fuel used in this unit is combustible and when spilled on a hot surface can ignite and cause a fire.
Do not fill the fuel tank while the engine is running or hot.
EXHAUST HAZARD
The exhaust contains poisonous carbon dioxide which is colorless and odorless.
Do not operate this equipment in a closed building.
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
If there is any static sparking or you feel an electric shock while using this equipment, stop spraying immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Disconnect all electrical equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not operate a gasoline engine in the spray area.
Ground the sprayer to a true earth ground with the ground wire and clamp (supplied).
Use only electrically conductive hoses.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
Keep clear of all moving parts when starting or operating the sprayer.
Before servicing the equipment, follow the Pressure Relief Procedure on page 7 to prevent the
equipment from starting unexpectedly.
FIRE AND
EXPLOSION HAZARD
Spray painting, flushing or cleaning equipment with flammable
liquids in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground
equipment, hoses, containers and objects being sprayed.
Avoid all ignition sources such as static electricity from plastic
drop cloths, open flames such as pilot lights, hot objects such as
cigarettes, arcs from connecting or disconnecting power cords
or turning light switches on and off.
Failure to follow this warning can result in death or serious injury.
SKIN INJECTION
HAZARD
Liquids can be injected into the body by high pressure airless
spray or leaks – especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts.Avoid accidental
triggering of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical Treatment”.
Failure to follow this warning can result in amputation or serious
injury.
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
6
308-105
Setup
General Information
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
NOTE: Always use Genuine Graco Parts and Accessories, available from your Graco distributor.
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE OR EXPLOSION HAZARD on page 6.
Pressure Relief Procedure
WARNING
INJECTION HAZARD
Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury
from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tips.
1. Engage the spray gun safety latch.
2. Turn the ON/OFF switch to OFF.
3. Flip the pressure control switch to OFF.
1. Sprayer: make sure the grounding chain (106)
contacts the ground while the unit is moving. See
Page 42. For stationary spraying, connect a
ground wire and clamp (159) to a true earth
ground.
2. Fluid hoses: use only grounded hoses with a
maximum of 500 ft. (150 m) combined hose
length to ensure grounding continuity.
3. Spray gun: obtain grounding through connection to
a properly grounded fluid hose and sprayer.
4. Object being sprayed: according to local code.
5. Fluid supply container: follow your local code.
6. Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place the
pail on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continuity.
4. Disengage the gun safety latch. Hold a metal part
of the gun firmly to the side of a grounded metal
pail, and trigger the gun to relieve pressure.
5. Engage the gun safety latch.
6. Hold the pressure relief tube firmly to the side of a
grounded metal pail, and open the pressure relief
valve. Leave the valve open until you are ready to
spray again.
7. Disconnect the spark plug cable to prevent the
system from starting unexpectedly.
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 the
tip guard retaining nut or hose end coupling and relieve
pressure gradually, then loosen completely. Now clear
the tip or hose.
Valve shown in
CLOSED position.
Valve shown
in OPEN position.
Pressure
Hose
7. To maintain grounding continuity when flushing or
relieving pressure, hold a metal part of the spray
gun firmly to the side of a grounded metal pail,
then trigger the gun.
159
Fig. 1
Suction
Tube
Fig. 2
Pressure
Relief Tube
06877
308-105
7
Setup
1. Read and follow the warnings on pages 4–6 before installing or operating this sprayer.
2. Unpack the LineLazer Carefully raise the handle (19)
to a vertical position. Four screws (39) and locknuts
(40) are packed in a bag. Install the two rear screws
(39A) and finger tighten the nuts (40A). Install one
screw (39B) and nut (40B) on each side of the handle. Firmly tighten all four nuts. See Fig. 3.
CAUTION
When raising the cart handle (19), be sure no cables
are caught on the frame or become kinked.
3. To install a second gun and hose, see page 11.
4. Fill the packing nut/wet–cup (216) 1/3 full with
Graco Throat Seal Liquid (TSL), supplied, and
keep it filled, to help extend the pump life. See
Fig. 4.
5. Check the engine oil level. Refer to the Honda
engine manual, supplied. This is a summary of the
information: Remove one of the oil fill plugs (A);
the oil should be almost overflowing. See Fig. 4.
Add oil as necessary. Also read the Maintenance
section on page 23.
7. Provide adequate ventilation when spraying indoors.
WARNING
If the LineLazer is used indoors, you must vent the
exhaust to the outdoors or provide adequate ventilation as specified by you local code. This is to
reduce the risk of carbon monoxide poisoning.
8. Fill the gas tank. See Fueling on page 10.
9. Flush the pump to remove the lightweight oil which
was left in the pump to protect it from rust. Follow the
Flushing on page 12.
10. Prepare the paint according to the manufacturer’s
recommendations. Remove any skin that may have
formed. Stir the paint to mix pigments.
Strain the paint through a fine nylon mesh bag (available at most paint dealers) to remove particles that
could clog the filter or spray tip. This is an important
step toward trouble–free spraying.
Recommended engine oil: Use a high–quality, detergent oil, SAE 10W–40, classified “FOR SERVICE
SE or SF”.
19
6. Ground the sprayer. Proper grounding is essential to
maintaining an electrically safe system. Also read
and follow FIRE OR EXPLOSION HAZARD on page
6.
WARNING
Ground the sprayer whenever it is used indoors,
either as a moving line striper or as a stationary
sprayer. Floors in most factories are coated, which
causes them to be poor electrical conductors. This
increases the risk of hazardous static electric
discharge, which can result in serious injury, fire, or
explosion and property damage.
39A
40A
40B
39B
02163C
Fig. 3
Whenever you flush: connect the ground clamp
(159) to a true earth ground.
Keep filled with TSL
Using as an outdoor striper: Be sure the static
chain attached to the bottom of the cart drags on the
ground to help dissipate static electricity. Ground the
sprayer to a true earth ground if specified by your
local electrical code.
Indoor spraying: Ground the sprayer whenever the
sprayer is used indoors. The ground wire supplied
with the sprayer is not long enough to allow much
operator movement. Therefore, the operator must
provide a longer ground wire or provide some other
method of effective electrical grounding as specified
by your local electrical code.
216
Fig. 4
0008
A
Setup
11. Observe the following cautions to avoid pressure
control damage.
CAUTION
To avoid damaging the pressure control, follow these
precautions.
Allow the main hose to act as a pulsation dampener: Always use nylon spray hose at least 50 ft.
(15 m) long for the main gun; Never use a wire
braid hose; it is too rigid.
12. To use the wheel brake, lift the brake handle (A–
bottom rear of cart) to engage the brake. Lower
the handle to disengage the break. See Fig. 5. For
positive break engagement, be sure there is
proper tire pressure and that tire wear is not
excessive.
13. For how to operate and adjust the various features
of the LineLazer see pages 11–22.
14. Start the sprayer. See page 13.
Never install a ball valve or shutoff device between the filter and the 50 ft. (15 m) hose.
Do not allow water or water-base material to
freeze in the pressure control.
A
CAUTION
Close the black fuel shutoff lever whenever you are
transporting the sprayer to prevent fuel from flooding
the engine.
Keep the sprayer upright and level when operating it
and transporting it. This prevents crankcase oil from
leaking into the combustion chamber, which makes
startup very difficult.
ÂÂ
ÂÂ
ÂÂ
ÂÂ
03586
Fig. 5
308-105
9
Fueling
WARNING
Gasoline is extremely flammable and explosive
under certain conditions. To reduce the risk or a fire
or explosion:
1. Always shut off the engine before refueling.
NOTE: The HONDA engine warranty does not cover
damage resulting from the use of gasolines containing alcohol. See the HONDA engine manual for more information.
3. General. Do not use oil and gasoline mixtures or contaminated gasoline. Avoid getting dirt, dust or water
in the fuel tank.
2. Refuel in a well-ventilated area.
4. Tank capacity: 0.95 gallons (3.6 liter). Leave 1/2 in.
(13 mm) at the top of the tank for gas expansion.
3. Do not smoke or allow flames or sparks in the
area where the engine is refueled or where
gasoline is stored.
5. Shut off the engine switch (A) before refueling.
6. After refueling, tighten the fuel tank cap (B) firmly.
4. Do not overfill the tank. Make sure the filler cap
is securely closed after refueling.
B
A
5. Fuel vapor or spilled fuel can ignite. If any fuel
is spilled during refueling, make sure the area
is dry before starting the engine.
1. Fuel specifications. Use automotive gasoline with
a pump octane number of 86 or higher. If the
engine knocks or pings, use a higher octane fuel.
Unleaded fuel minimizes combustion chamber
deposits.
2. Gasolines containing alcohol (gasohol). Do not use
gasohol which contains methanol, if the gasohol
does not contain cosolvents and corrosion inhibitors for methanol. Even if it does contain such
additives, do not use the gasohol if it contains
more than 5% methanol.
Fig. 6
0009
Second Gun and Hose Installation
NOTE: Fig. 7 represents the installation at Step 3.
6. Disconnect the trigger cable from the second gun at
the screw (34). See Fig. 7 DETAIL B.
NOTE: To switch the gun assemblies to the engine side
of the cart, refer to the instructions on page 17 before installing the second gun kit.
7. Unscrew the filter’s second outlet cap (14). Screw
the short hose (403) onto the filter nipple.
1. Disengage the trigger cable from the block (48) of
the unit’s existing gun. See page 21. Engage the
gun’s trigger safety latch.
8. Remove the guide clamp screw (27).
9. Snap the cable bushing (E) into the guide plate (D).
Route the trigger cable (402) parallel with the main
gun cable, separating the guide clamp (104) to feed
the cable through it. Install and tighten the clamp
screw (27). Route the cable through the cable guide
(7) and to the second gun.
2. Loosen the carriage clamps (B, C). Slide the
carriage bar (4) off the cart.
3. For mounting the second gun bar on the pump
side of the cart: Slide a clamp (405A) onto the
carriage bar (4). Slide the carriage bar through the
pump-side carriage clamp (B) and into the center
of the cart. Now slide another clamp (405B) onto
the carriage bar. See Fig. 7.
10. Slide the hooked end of the cable (402) through the
hole (F) in the lever plate (122). Rotate and slide the
hook back until it engages the plate. See DETAIL A.
11. Reconnect the trigger cable to the second gun at
screw (34). Torque the screw to 15 in–lb (1.7 N.m),
back it off 1/16 to 1/8 turn and then tighten the jam
nut (99) while holding the screw (34). Be sure the
plate (94) moves freely.
For mounting the second gun bar on the engine side
of the cart: Follow Step 3, except slide the carriage
bar through the engine-side carriage clamp (C) and
the into the center of the cart. The knobs of the
clamps (405A, 405B) must face back toward the
handle bars.
12. Install the clip (401) to hold the cable onto the frame.
4. Slide the carriage bar (4) through to the opposite carriage clamp. Tighten the carriage clamps (B,C).
13. Connect both trigger cables to the blocks (48). Then
adjust the cable tension. See pages 20–22.
5. Slide the second gun bar (404) far enough into the
carriage bar that the clamp (405B) engages the bar.
Position the clamps (405A, 405B) over the notches
(A) in the carriage bar (4) and tighten the clamps.
14. Do not install the spray tip until the system is primed.
15. Adjust simultaneous gun triggering. See page 18.
Torque to 15 in–lb
(1.7 N.m)
and then back up
1/16 to 1/8 turn
NOTE: For stable gun operation, the second
gun bar (404) has a maximum recommended
extension from the carriage bar of about
11-1/4” (286 mm).
DETAIL A
How to install cable
correctly installed cable
D
E
HOW TO INSTALL CABLE
122
27,104
402
401
14
402
C
F
7
403
405E
404
DETAIL B
402
99
34
4
405A
94
B
A
02157C
48
Fig. 7
Flushing
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
WARNING
To reduce the risk of static sparking and splashing
when flushing, always remove the spray tip from
the gun, and hold a metal part of the gun firmly to
the side of, and aimed into, a grounded metal pail.
Be sure the pump is properly grounded.
CAUTION
Never leave water in the sprayer if the is any chance
it could freeze. Push the water out with compatible
solvent. Water frozen in the pressure control tube
prevents the sprayer from being started, and causes
serious damage to the pressure control.
When to Flush
1. Flush a new sprayer to remove the protective oil.
Before using water–base paint, use compatible solvent, then soapy water, and then clean water.
Before using oil–base paint, use compatible solvent.
6. Follow Startup on page 13. Keep the gun triggered
until clean water or solvent comes from the nozzle.
See Fig. 9. Release the trigger and engage the gun
safety latch.
NOTE: If you have two guns, release the trigger safety
latch on the second gun and trigger that gun until clean
water or solvent comes from the nozzle. To ensure that
the hoses are well-flushed, flush the first gun and then the
second gun at least one more time.
7. Check all fluid connections for leaks. Relieve pressure before tightening any connections. Start the
sprayer. Recheck the connections for leaks.
8. Remove the suction tube from the solvent pail. Disengage the gun safety latch. Trigger the gun to force
water or solvent from the hose. Do not let the pump
run dry for more than 30 seconds to avoid damaging
the pump packings! Relieve pressure.
2. Changing colors. Use a compatible solvent.
3. Changing from water–base to oil–base paint. Use
warm, soapy water, and then a compatible solvent.
13
A
B
4. Changing from oil–base to water–base paint. Use a
compatible solvent, then warm, soapy water, and
then clean water.
5. Storage. After the compatible solvent flush, relieve
pressure, but do not drain the compatible solvent.
C
Fig. 8
6. Startup after storage.
Before using water–base paint, flush out the compatible solvent with soapy water, and then with clean
water.
When using oil–based paint, flush out the compatible
solvent with the paint to be sprayed.
0013
Maintain firm metalto-metal contact
when flushing to
reduce the chance
of static sparking
and splashing.
How to Flush
1. Relieve pressure.
Fig. 9
2. Remove the filter bowl (A) and screen (B); see manual 307–273. Install the bowl and support (C), without
the screen, to flush it. Clean the screen separately.
See Fig. 8.
3. Close the pressure drain valve (13).
0014
9. If you have been spraying paint, remove the strainer,
suction tube and suction hose and clean them separately to be sure all paint sediment is removed. Dried
paint in the suction tube assembly can build up and
cause performance problems later on.
4. Put the suction tube in a grounded pail of water or
solvent.
10. Install the clean filter screen. Install the filter bowl and
hand tighten.
5. Remove the gun(s) from the holder. Remove the
spray tip(s) to prevent splashing.
12
308-105
11. See Storage or Changing Colors, above. Relieve
pressure.
Startup
Before You Start the Linestriper
1. See Flushing, page 12, to determine if the Line Lazer
should be flushed.
2. Be sure the gas tank is full.
3. Check the engine oil level.
NOTE: The engine stops automatically, or will not start,
if it is low on oil. If you try to start it again without adding
more oil, a red light (A) near the engine on/off switch
glows as you pull the starter rope.
4. Be sure the spark plug cable (J) is firmly pushed onto
the spark plug.
Startup See Fig. 10
1. When starting a sprayer that IS NOT PRIMED, remove the spray tip.
2. Place the suction tube (S) into the paint, water or solvent container, depending on whether you are flushing or are ready to spray.
3. Open the black fuel shutoff lever (E) by pushing it in
the direction of the arrow.
CAUTION
Never start the engine unless fluid pressure is relieved and the pressure control switch is turned OFF.
Attempting to start the engine when it is pressurized
could damage the electrical system.
g. Open the choke as soon as the engine starts,
except in cold weather. In cold weather, leave
the choke closed for 10 to 30 seconds before
opening it to keep the engine running.
6. Release the trigger cable and engage the gun trigger
safety latch. See page 21.
7. Remove the gun from the holder by unscrewing the
gun holder knob and lifting out the gun.
8. To start the pump:
NOTE: Lower the throttle setting for easier priming.
a. Open the pressure drain valve (R).
b. Turn ON the pressure control switch (K).
c. Turn the pressure control knob (L) about 1/4
turn from minimum pressure. Run the pump
until fluid is flowing smoothly from the pressure
drain valve, indicating the pump is fully primed.
d. Close the pressure drain valve (R).
e. Disengage the gun safety latch. Hold a metal
part of the gun firmly against a grounded metal
pail, squeeze the trigger until fluid flows from
the gun.
f. Release the trigger. Engage the safety latch.
NOTE: If you are using two guns, follow Step e and f,
above, for the second gun.
4. Turn OFF the pressure control switch (K).
9. If you have not primed the sprayer with paint yet,
move the suction tube (S) to the paint container. Release the trigger safety latch. Trigger the gun into the
water/solvent pail just until paint appears. Release
the trigger and engage the trigger safety latch. Repeat for the second gun, if two guns are used.
5. To start the engine:
10. Place the pail cover (F) on the pail.
a. Turn the pressure adjusting knob (L) all the
way counterclockwise to the lowest pressure
setting.
b. Slide the metal throttle lever (C) away from the
fuel tank to the maximum position (fully left).
c.
If the engine is cold, close the choke by moving the gray lever (D).
d. If the engine is warm, close the choke by
moving the gray lever (D) only half way or not
at all.
e. Turn ON the engine switch (B).
WARNING
A rope that recoils too quickly may hit someone
and cause serious bodily injury. The rope could
also jam in the recoil assembly.
f.
Hold the frame of the sprayer with one hand
and pull the starter rope (G) rapidly and firmly.
Continue holding the rope as you let it return.
Pull and return the rope until the engine starts.
WARNING
To reduce the risk or serious injury from fluid
injection, never operate the spray gun with the tip
guard removed.
11. Install the tip guard and spray tip (M). See page 15.
12. Mount the gun in the gun holder. See page 20.
13. Engage the trigger cable. See page 21.
CAUTION
Always use the lowest fluid pressure and the lowest
throttle setting needed. Higher settings cause excessive clutch cycling, premature tip wear and premature pump wear.
14. Adjust the engine speed and pump pressure. Trigger
the gun onto a test paper to check the spray pattern
and atomization. Turn the pressure adjusting knob
(L) until you get a good pattern. Then slowly lower the
throttle setting (C) as far as you can without changing
the spray pattern.
Startup
15. Read Spray Techniques on page 16.
CAUTION
Close the black fuel shutoff lever (E) whenever you
are transporting the sprayer to prevent fuel from
flooding the engine.
A
Keep the sprayer upright and level when operating it
and when transporting it. This prevents crankcase oil
from leaking into the combustion chamber, which
makes start up very difficult.
B
––AT REAR OF ENGINE––
H
C
D
R
E
F
S
Shown in
choked position
Shown off
Shown in
off position
G
H
J
K
L
KEY
A
B
C
D
E
F
G
H
J
K
L
M
N
P
Q
R
S
Engine Oil Light
Engine On/Off Switch
Throttle Lever
Gray Choke Lever
Black Fuel Shutoff Lever
Pail Cover
Starter Rope
Air Cleaner
Spark Plug Cable
Pressure Control On/Off Switch
Pressure Adjusting Knob
SwitchTip
Rac IV Tip Guard
Gun Trigger Safety Latch
Remote Trigger Cable
Pressure Drain Valve
Suction Tube
Fig. 10
14
308-105
Q
P
M
N
7360C
Spray Tip and Tip Guard
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
WARNING
Failure to install or use the RAC IV tip guard assembly correctly may result in an undirected spray
of paint into the eyes or on the skin of the operator.
Be sure you:
Use the appropriate gasket for the solvent used.
Fully insert the tip into the guard.
Fully tighten the guard onto the gun nozzle
using a wrench.
Turn the handle so it is parallel to the gun
nozzle.
When replacing a worn spray tip, always install
a new gasket and seat.
Operation
WARNING
Keep clear of the nozzle! High pressure fluid from
leaks or spray can penetrate the skin and cause
extremely serious injury, including the need for
amputation. The spray tip guard provides extra
protection against injection, but does not prevent it!
Never cut off the spray tip guard.
Be sure the spray tip handle is in the FULL SPRAY position before operating the gun. See Fig. 11.
Clearing a Clogged Spray Tip
Disengage the trigger cable(s). Engage the gun safety
latch. Turn the arrow handle to the FULL CLEAN position. See Fig. 13. Release the safety latch and trigger the
gun. Fluid pressure should force out the clog. Return the
arrow handle to the full spray position. If it is still
clogged , follow the Pressure Relief Procedure on
page 7 and remove the spray tip for cleaning.
Maintenance
Change the seat and gasket when the spray tip wears
out; these parts wear at about the same rate.
Gasket Selection
C
RED or YELLOW
WARNING
To reduce the risk of fluid splashback into the eyes
or on the skin, use the appropriate gasket as
specified in the following text.
Use the black rubber gasket (D) ONLY with latex and
oil-based paints, stoddard solvents, mineral spirits, turpentine and water. When using this gasket, the spray tip
can be removed and replaced without using tools.
A
D
BLACK
E
J
F
Fig. 11
H
G
0091
E
A
Use the red or yellow plastic gasket (C) with the same
fluids as above and with most other solvents, including
lacquer thinner, trichloroethylene, MEK, acetone, brush
cleaner, xylol. When using this gasket, loosen the RAC
IV retaining nut to remove the spray tip.
F
Fig. 12
0092
Installation
Relieve pressure. Install a tip (F) so the flange (G) on the
cylinder fits into the slots (H) at the base of the spray tip
guard (J). See Fig. 11.
Place the seat (E) on a pencil, curved side out, as shown
in Fig. 12. Guide the seat into the retaining nut (A) and
turn the seat until it straddles the cylinder of the spray tip
(F). Drop in the appropriate gasket and press it down. If
using the red or yellow gasket (C), be sure the flat side
faces out of the retainer (A). See Fig. 11.
GUN NOZZLE
RAC IV
DripLess
TIP GUARD
TIP
HANDLE
Screw the spray tip guard snugly onto the gun, holding
it in the desired position while tightening retaining nut (A).
NEVER use a wrench to turn the plastic tip guard (J), to
avoid damaging the guard.
FULL SPRAY POSITION
FULL CLEAN POSITION
0093
Fig. 13
Spray Tip Selection
Spray Tip Application Recommendations
Other Applications
Sport Court,
2” wide line
Crosswalk,
12” wide line, 1 gun
Lineal Feet/Minute
(rate at which unit is moved)
Based on 4” wide line and 15 mils of paint
Application
Parking Lot Lines
4” wide
6” wide
120
217*
317*
144
184
LLT–317*
317*
Long Lines,
4–6” wide
Curbs
417*
220
264
221*
321*
223
323
224
325
221*
223
225
308
227
352
228
400
231
Airport,
24” wide line, two guns
Stencils
General Stationary
Painting
LLT–213*
621,
623, 625
721
417*, 419*
517
419*
* Tips can be used with two guns.
Supplied with the Line Lazer.
Fig. 14
Spray Techniques
These spray techniques discuss how to use and adjust
the features of the Line Lazer. You must also consider operator technique, job site conditions and weather.
1. Use water rather than paint to practice spraying technique and positioning the guns.
2. Be sure the RAC IV Tip Guard is always parallel to
the ground and the “wings” of the spray tip guard face
the front and back of the unit, as shown in Fig. 15.
WARNING
To reduce the risk of a fluid injection injury, always
disengage the remote trigger cable to the gun(s)
and engage the gun trigger safety latch(es) before
moving or adjusting the spray tip guards, guns, or
gun arms. See Page 21.
3. Use the lowest pressure necessary for good atomization. High pressure may cause excessive paint
buildup and overspray.
4. Start moving the Line Lazer before triggering the gun
to prevent a build up of paint at the beginning of the
line. Release the trigger a second before stopping
the Line Lazer. Move at an even rate of speed.
5. Always check your gun adjustments on cardboard or
paper before starting each job. When painting curbs,
paint first in an area that is less frequently seen.
6. Keep in mind that many factors affect the straightness of a line, including uneven surfaces, potholes,
rocks and other debris and a clogged or worn spray
tip. See page 15 for how to clear or change a spray
tip.
7. To minimize the effect of bumps on the spray pattern,
keep the spray tip guard centered with the front
wheel axis.
16
308-105
8. The spray tip size and the rate at which you move the
unit affect the coating thickness. Generally, the faster you move the unit, the larger the spray tip orifice
should be. The fan width of the spray tip indicates approximately how wide the line will be. See the chart
in Fig. 14 for spray tip application recommendations.
9. Position the guns to suit your requirements. See the
section below and pages 17 to 19.
10. Traffic paints may be formulated for air spray, airless
spray or have no formulation description.Generally,
air spray formulas are pre–thinned, and will work well
in the Line Lazer, but there may be more overspray.
Non–air spray formulas tend to deliver more lineal
feet of line per gallon with less overspray, since they
are less easily absorbed into the pavement.
11. If you use fast–draying traffic paint on a hot day, float
compatible solvent on top of the paint to prevent skin
from forming on it.
Line Width Adjustment
Several factors affect line width: vertical distance of the
spray tip to the spraying surface, spray tip fan pattern, using one or two guns, paint pressure, and a worn or
clogged spray tip.
The typical conditions for a 4 in. (10 cm) wide line are: 317
size Line Lazer Tip (supplied), the gun positioned one
inch from the lowest vertical position, and just enough
pressure to atomize the paint. Depending on the fan pattern of the spray tip, use one gun to paint 2 to 12 in. ( 5
to 30 cm) wide lines, and two guns to paint 12 to 24 in.
(30 to 61 cm) wide lines.
To decrease line width, lower the gun (if possible) or use
a tip with a narrower fan pattern.
To increase line width, raise the gun, or use a tip with a
wider fan pattern, or use two guns.
Positioning the Gun Arm Assembly
PUMP SIDE
ENGINE SIDE
D
405B
1
402
B
02158D
4
DETAIL A
F
405A
D
93
404
E
B
“WINGS” OF TIP GUARD
A
Fig. 15
The gun arms can be positioned for a variety of spraying
needs. The drawings on page 19 primarily show the guns
mounted on the pump side of the Linestriper. However,
one or both guns may be mounted on the engine side.
Whenever You Move the Guns
CAUTION
Do not kink the cables, which could prevent them
from properly triggering and untriggering the guns.
Disengage the trigger cables and engage the gun trigger
safety latch first. See page 21. Do not kink the trigger
cables. Pull out more of the 50 ft. hose, if necessary.
Horizontal Position of the First Gun
Method 1: Disengage the trigger cable. Loosen the carriage clamps (B,D) and slide the carriage bar (4) left or
right, so the gun will be outside the tire path. Tighten the
clamps. Engage the trigger cable.
Method 2: Disengage the trigger cable. Loosen the arm
clamp (6) and rotate the gun out to the side. Tighten the
bolt. Engage the trigger cable.
NOTE: Use methods 1 and 2 together to obtain the maximum distance of one gun from the unit, which is helpful
when spraying around obstacles.
Horizontal Position of the Second Gun
After moving the guns, reposition the spray tip guard so
it is parallel to the ground and its “wings” face the front
and back of the unit. Disengage the gun trigger safety
latch and engage the trigger cable.
Method 1: Disengage the trigger cable. Loosen the
clamps (405A, 405B). Slide the second gun bar (404)
horizontally, being sure both clamps engage the second
gun bar. Tighten the clamps. Engage the trigger cable.
Vertical Position of the First or Second Gun
Loosen the arm clamp (6) and move the gun up or down.
Tighten the clamp. Engage the trigger cable.
Method 2: Disengage the trigger cable. Loosen the arm
clamp (6) and rotate the gun out to the side. Tighten the
bolt. Engage the trigger cable.
NOTE: See Fig. 15. Two collars (F) are located above
and below each gun. The collars can be adjusted to provide stops for preset spray width positions for each gun.
NOTE: Use methods 1 and 2 together to obtain the maximum distance of 33–1/2 in. (851 mm) between the center
of two guns.
308-105
17
Positioning the Gun Arm Assembly
1. See Fig. 15. For both guns, disengage the trigger
cable and engage the trigger safety latch. See page
22.
7. Install the guns. Note which gun and position on the
dual gun selector each of the cables (1 and 402)
goes. Route the hoses and cables to prevent kinking.
Position the spray tip guards. Disengage the gun trigger safety latches. Engage the trigger cables.
2. Loosen the gun holder knobs (93) and remove the
gun. Lay the guns out of the way.
Setup for Spraying Arcs
Mount Guns on the Engine Side of the Cart
3. Remove the knobs (E) on both carriage clamps
(B,D); the carriage bar (4) and extension clamps (A)
will drop down.
1. See Fig. 16. Disengage the trigger cable (1) and engage the gun trigger safety latch. See page 21.
4. Lift the front tire and rotate the carriage bar 180 under the cart and to the other side of it.
2. Loosen the arm clamp (6) and rotate the arm (A)
back near the rear tire and then position the arm so
the spray tip guard aligns with the back axle of the
unit. Retighten the clamp.
5. Position the carriage bar below the carriage clamps
(B,D). Align the holes in the top of the extension
clamps (A) with the holes in the carriage bar clamps
and install the knobs (E).
3. Extend the carriage bar (4) or second gun bar (404)
so you can easily watch the line you are painting and
also to avoid running over the paint line. See page
17.
6. Loosen the post/arm clamps (6) and rotate the guns
forward. Retighten the clamps.
4. Adjust the vertical and horizontal position of the gun.
5. Spray the arc from the outside.
A
6
1
4
7360C
Fig. 16
Adjust Simultaneous Gun Triggering
WARNING
To reduce the risk of a fluid injection injury, always
disengage the trigger cable to the gun (s) and
engage the guns’ trigger safety latch before moving
or adjusting the guns or gun arms.
1. Align the front of the guns by adjusting the gun arms.
See page 17.
2. Position the dual gun selector to trigger both guns.
See page 21.
3. Start the sprayer, using water, or spray on cardboard. See page 13. Trigger the guns to see if the
lines begin at the same time and place.
If one gun triggers before the other gun, reduce the
cable tension of the gun that triggers first. See Adjust the trigger cable tension on page 22.
If one line starts in front of the other, adjust the position of the guns. See page 17.
Trigger the guns to recheck the adjustments.
Gun Arm Positions
SINGLE LINE
DOUBLE LINE OR SINGLE LINE UP TO 24” WIDE
ONE GUN CURB
TWO GUN CURB
0017A
SINGLE OR DOUBLE LINE; SPRAYING AROUND OBSTACLES
DOUBLE LINE OR SINGLE LINE UP TO 24”
WIDE
308-105
19
Caster Lever and Cable Operation
Maintenance
CAUTION
The AccuTrack caster is factory-adjusted to track
in a straight line. It should not require adjustment
unless it is replaced. If a line is tracking poorly, check
for the following items before aligning the caster.
1. Even back tire pressure.
2. Even tension on the rear tire bearings (adjust
nuts (10) as needed.) See page 40.
3. Even tightness of the caster screws (F). See
Fig. 18.
See Fig. 18
Paint builds up on the caster triggering mechanism. To
keep it operating properly, use a grease gun at the grease
zerks (32A, 32B) to flush out the buildup – two to four
times a month, depending on use.
Caster Tire Replacement
See Fig. 18.
Remove the setscrews (F) from the caster fork (E). Remove screw (G) and the tire (114a). Install the new tire
and the setscrews (F). Tighten the setscrews equally so
the tire has no play in it, but turns freely.
Caster Cable Tension Adjustment See Fig. 18.
1. Loosen the nut (A) located just outside the carriage
clamp (B).
4. Uneven painting surface.
5. Operator technique.
2. With the pin (D) fully engaged in the caster fork (E),
pull back on the cable (2) to increase the cable tension, or push it forward to reduce the tension. Finger
tighten the nut (H). Tighten the nut (A) firmly.
Operation
The normal operating mode of the AccuTrack
locked in the straight forward position.
caster is
1. For a free moving caster: Squeeze and hold the caster lever (22).
Shown removed only
for visual purposes
Tighten equally so tire
has no play in it but
turns freely
A
2
H
B
D
87
32A
2. To lock the caster in the free moving position,
squeeze the trigger, push in and hold the the button
(A) and release the trigger. See Fig. 17.
114a
32B
D
3. To return to the normal mode, squeeze and release
the caster lever and move the Line Lazer forward to
lock the caster in the straight position.
E
G
Fig. 18
F
0019
Caster Alignment
Do this adjustment only if the caster or tire is replaced,
or if no other solutions to poor tracking are found.
22
A
0018
Fig. 17
1. Loosen the two capscrews (87). Grasp the tire and
visually align it. Tighten the capscrews evenly. Move
the unit forward. If the caster appears straight, start
the unit (use water) and spray along a true straight
line. Continue adjusting as necessary. See Fig. 18.
How To Mount the Gun
1. Relieve pressure. See page 7.
95
2. Disengage the trigger cable. See page 21. Engage
the gun’s trigger safety latch (B).
93
3. Loosen the gun holder knob (93).
B
4. Position the gun so the gun trigger is resting on the
remote trigger lever (A).
5. Be sure that the gun is mounted straight and then
tighten the knob (93) firmly.
6. Disengage the gun safety latch. Engage the remote
trigger cable. See page 21.
20
308-105
A
Fig. 19
0020B
Gun Cable & Dual Gun Selector Operation
Shown in
three positions
A
How to Release the Dual Gun Selector
Cable
WARNING
B
118d
1 or 402
Fig. 20
The gun is remotely triggered with a dual gun
selector on the handle bar.
C
0021
How the Dual Gun Selector Works See Fig. 20.
The gun is remotely triggered with the dual gun selector
on the right handlebar. The gun is mounted in the holder
so its trigger rests on a trigger lever which is connected
to the dual gun selector by a trigger cable.
The main gun cable is black. In a two–gun operation, the
second gun cable (402) is black with a light red cover at
each end. Use the color coding to determine how each
trigger cable is routed to the dual gun selector.
CAUTION
Always note to which gun and position on the dual
gun selector (C) each of the cables goes so that the
correct gun is triggered.
To trigger the main gun only, move the selector (C) left until the spool (118d) protrudes through the plate (B) and
disengages from the other plate (A).
To trigger the optional second gun only, move the selector (C) right until the spool protrudes through the plate (A)
and disengages from the other plate (B).
To trigger both guns, center the selector (C).
To reduce the risk of an injection injury due to
remotely triggering the gun by accident, always
disengage the trigger cable from the block before
handling the gun. See Fig, 21 DETAIL A. The gun
will trigger briefly when releasing the cable!
Before you remove the gun from the holder, engage the gun’s trigger safety latch.
1. To disengage the cable, grasp the cable (1or 402)
just behind the block (48). Pull the cable back about
1/2 inch (13 mm) and then up and out of the block.
The gun will trigger briefly! See Fig. 21.
2. To engage the cable, slide the cable (1) into the block
(48), making sure the end of the cable jacket seats
firmly in the seat of the block. The gun will trigger
briefly! See Fig. 21.
CAUTION
Keep the seat in the gun cable block (48) and the
end of the cable jacket clean at all times to be sure
the cable functions properly.
CAUTION
A loose cable prevents the gun from being fully
triggered causing premature wear of the gun needle.
A tight cable prevents the gun from being fully untriggered resulting in dripping and premature tip wear.
Follow Trigger cable tension adjustment on page
22.
308-105
21
Trigger Cable & Dual Gun
Selector Operation
Trigger Cable Tension Adjustment See Fig. 21
FORWARD
1. Relieve pressure. See page 7.
2. Be sure the gun is properly mounted in the holder as
instructed on page 20.
48
C
45
Do not allow the cable (402) to rub against the
outside edges of the slot (H) in the block (48), to
prevent premature wear of the cable. Rotate the
block slightly to eliminate rubbing. See Fig. 21
DETAIL A.
22
308-105
1/32 – 1/16”
(1–2 mm)
B
0023
DETAIL A
Be sure end jacket of cable
seats here. keep jacket and
seat clean
5. Recheck the gap and adjust as needed.
CAUTION
94
A
3. Pull the actuator lever (94) forward and hold it. Lift up
on the gun trigger (A) until there is slight resistance.
Visually check to see if there is about 1/32 to 1/16 in.
(1–2 mm) gap between the trigger lever (B) and
where the gun trigger touches the bar.
4. To adjust the tension, loosen the screw (C) in the
block (48). Slide the block forward to increase the
gap and backward to decrease the gap. Tighten the
screw.
1 or 402
1 or 402
45
48
Fig. 21
0024
Maintenance
After the first 20 hours of operation and each 100
hours thereafter: Change the oil.
WARNING
To reduce the risk of serious injury always follow
the Pressure Relief Procedure on page 7,
before checking, adjusting, cleaning, or shutting
down the LineLazer.
Weekly: Remove the air filter cover and clean the element. In very dusty environments, check the filter daily.
Replace the element as needed. Replacement elements
can be purchased from your local HONDA dealer.
Weekly: Check the level of the TSL in the displacement pump packing nut. Fill the nut, if necessary. Keep
TSL in the nut to help lubricate the pump packings. See
page 8.
CAUTION
For detailed engine maintenance and specifications,
refer to the separate HONDA engine manual.
Daily:
Check the engine oil level and fill as necessary.
Daily:
Check and fill the gas tank.
1
Weekly: Use a grease gun to grease the zerks (32) on
this unit. The grease purges pivot areas of paint buildup.
See Fig. 22.
Spark plug: Use only a (NGK) BP6ES or BPR6ES
plug. Gap the plug to 0.025 to 0.030 in. (0.7 to 0.8 mm).
Always use a spark plug wrench.
1
One zerk on dual gun selector
2
One zerk on each gun holder
3
One zerk on caster lever
4
One zerk on caster latch
5
One zerk on wheel
3
4
5
Fig. 22
2
7360C
308-105
23
Troubleshooting
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
Check everything in the chart before disassembling the sprayer.
PROBLEM
CAUSE
SOLUTION
Engine/sprayer won’t start
Engine switch not on
Turn on engine switch.
Out of gas
Refill gas tank.
Engine oil level low
Try starting engine. If light on rear of engine
glows, replenish oil.
Spark plug cable disconnected or
spark plug damaged
Connect cable on top of engine or replace spark
plug.
Water frozen in pressure control
Return pressure control to authorized Graco
dealer for repair.
Oil seepage into combustion
chamber
Remove spark plug. Pull starter rope 3 or 4 times.
Clean and replace plug. Try to start. Keep sprayer upright to avoid oil seepage.
Engine won’t “fire”
Engine operates, but displacement Pressure control switch turned OFF
pump doesn’t
Engine starts but dies
Pressure setting too low
Increase pressure.
Displacement pump outlet filter dirty
Clean filter.
Tip or tip filter clogged
Clean tip or tip filter.
Displacement pump rod seized by
dry paint
Service pump. See 307–806.
Connecting rod worn or damaged
Replace connecting rod. See page 28.
Drive housing worn or damaged
Replace drive housing. See page 29.
Electrical power not energizing field
Check wiring connections. See page 35.
With pressure control switch ON and pressure
turned to MAXIMUM, use a test light to check
continuity across black and white wires from
pressure control.
Have pressure control checked by authorized
Graco dealer.
Clutch worn or damaged
Service clutch. See page 32.
Pinion assembly worn or damaged
Service pinion assembly. See page 30.
Oil level drops below oil sensor
Add oil.
Displacement pump output low on Pump inlet screen clogged
upstroke
24
308-105
Turn on pressure control switch.
Clean screen.
Piston ball check not seating
Service piston ball check. See 307–806.
Piston packings worn or damaged
Replace packings. See 307–806.
Sleeve gasket in displacement pump
worn or damaged
Replace sleeve gasket. See 307–806.
Troubleshooting
PROBLEM
CAUSE
Displacement pump output low on Pump inlet screen clogged
downstroke or both strokes
Paint leaks into wet–cup
Spitting from gun
SOLUTION
Clean screen.
Pressure setting too low
Increase pressure. See Startup,
Step 14, page 13.
Dirty outlet filter, tip filter or tip
Clean filters and/or tips.
Piston packings worn or damaged
Replace packings. See page .
Intake valve ball check not seating
properly
Clean and service intake valve. See 307–806.
Engine RPM too low
Increase throttle setting. See Startup,
Steps 5b and 14, page 13.
Clutch worn or damaged
Replace clutch. See page 32.
Partially clogged suction tube assembly
Remove and clean suction tube. During normal
flushing remove and clean the suction tube assembly separately to prevent further clogging.
Large pressure drop in hose
Use larger diameter hose.
Loose wet–cup
Tighten wet–cup just enough to stop leakage.
Throat packings worn or damaged
Replace packings. See 307–806.
Displacement rod worn or damaged
Replace displacement rod. See 307–806.
Air in fluid pump or hose
Check for loose connections at pump intake and
tighten. Them prime the pump.
See Startup, page 13.
Tip partially clogged
Clear tip clog. See page 15.
Fluid supply is low or empty
Refill and prime the pump. See Startup, page 13.
Check fluid supply often to prevent running the
pump dry.
Dried paint particles from a poorly cleaned
suction tube assembly
Remove and clean suction tube. During normal
flushing remove and clean the suction tube assembly separately to prevent further clogging.
308-105
25
Pressure Control
WARNING
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
To reduce the risk of electric shock, be sure all
grounding features of the pressure control are
properly assembled:
Ground wire (308) connected in pressure control.
1. Disconnect both hoses (133) at the pressure control
swivel unions (108). Note the original location of
each hose to be sure you reassemble them correctly
at the end of this procedure. See Fig. 23.
Serrated flange capscrews to mount the pressure control to the cart.
2. Working under the engine mounting plate of the cart,
disconnect the pressure control wires at A. Remove
the four nuts (40) and related hardware from the
capscrews (91 & 87).
Grounding chain (106) connected by the long
pressure control mounting capscrew (87).
3. Remove the pressure control covers (89). See Fig.
23.
6. Reassemble the pressure control in the reverse order. Use the long pressure control mounting screw
(87) in hole B. From below the mounting plate (25)
assemble the grounding chain (106), washer (105)
and nut (40) to the screw. See Fig. 23.
4. Disconnect the red, black and white wires from the
rectifier (307) which are sheathed with the conductor
(309). Unscrew the connector (313) from the pressure control, pulling the conductor and wires out with
it. See Fig. 24.
5. Use a wrench to hold the hex of the adapters (C)
while removing the swivel unions (108). See Fig. 24.
7. Perform the Pressure Control Adjustment on
page 27 before regular operation of the sprayer.
WHITE
RED
109
91,87
B
108
309
89
106
309
307
40
105
40
313
TO ENGINE
BLACK
C
0033
RECTIFIER (307) CONNECTIONS
RED
BLACK
~
A
-
133
+
TO FILTER
Fig. 23
26
308-105
TO PUMP
0032
Fig. 24
WHITE
~
GROUND
0034
Pressure Control Adjustment
WARNING
Use extreme caution when performing this calibration procedure to reduce the risk of a fluid injection injury or other serious bodily injury, which can result from
component rupture, electric shock, fire, explosion or
moving parts.
This procedure sets the sprayer to 2600–3000 psi
(180–207 bar, 18.0–20.7 MPa) Maximum Working
Pressure.
Perform this procedure whenever the pressure control
assembly is removed and reinstalled, or replaced, to be
sure the sprayer is properly calibrated.
Improper calibration can cause the sprayer to over–
pressurize and result in component rupture, fire or ex-
plosion. It may also prevent the sprayer from obtaining
the maximum working pressure, resulting in poor
sprayer performance.
NEVER attempt to increase the fluid outlet pressure by
performing these calibrations in any other way. Never
Exceed 3000 Psi (207 Bar, 20.7 MPa) Maximum
Working Pressure. Normal operation of the sprayer at
higher pressures could result in component rupture,
fire or explosion.
ALWAYS use a new 50 foot (15.2 m) spray hose, rated
for at least 3000 psi (207 bar, 20.7 MPa) Maximum
Working Pressure, when performing this procedure. A
used, under–rated hose could develop a high pressure
leak or rupture.
Service Tools Needed:
102–814
New 50 foot (15.2 m), 3000 psi (210 bar, 21.0 MPa),
flexible nylon airless spray hose, Part No. 223–541
0–5000 psi (0–345 bar, 34.5 MPa)
fluid–filled pressure gauge,
Part No. 102–814
New spray tip, size 0.025 to 0.029
3/8 in. ignition wrench or nut driver
5 gallon pail of water or mineral spirits
Swivel, 156–823
Nipple, 162–453
Tee, 104–984
Set Up
1. Follow the Pressure Relief Procedure Warning on
page 7.
2. Set up the system as shown in Fig. 25.
156–823
104–984
162–453
223–541
Fig. 25
0035
Inside pressure
control looking up
at differential wheel
Set the Dead Band (Pressure Differential)
1. Remove the pressure control cover.
A
NOTE: Do not alter this adjustment if the wheel is already
set as shown in Fig. 26.
2. Set the white differential wheel (A) on the microswitch. Turn the wheel so the letter F is concealed
behind the switch and the letter E is the first letter
seen.
Fig. 26
0036
Pressure Up
1. Start the sprayer and prime it.
2. Adjust the pressure to 2600 psi (180 bar, 18.0 MPa).
3. Shut off the engine. If the pressure drops after the engine is shut off, replace the pump packings before
proceeding. See 307–806.
Adjust the Pressure See Fig. 27.
1. Remove the plug (320) in the bottom of the control.
2. Turn and hold the pressure control knob (B) at the
maximum pressure.
3. Engage the nut (C): Insert the nut driver through the
pressure control hole (D), or use an ignition wrench
inserted from the front of the pressure control.
D
B
320
Fig. 27
C
0037
a. Loosen the nut just until you hear a click. Stop.
b. Slowly tighten the nut just until another click is
heard. Stop.
4. Replace the plug (320) and the pressure control
cover.
Bearing Housing and Connecting Rod
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
9. Install the screws (81) and lockwashers (46) on the
bearing housing. Tighten the screws evenly to 175
in–lb (20 N.m).
10. Install pump. See 307–806.
NOTE: Steps 1 to 10 refer to Fig. 28.
1. Remove pump. See 307–806.
Torque to 175 in–lb
(20 N.m)
B
3. While pulling the connecting rod assembly (79) with
one hand, lightly tap the lower rear of the bearing
housing (76) with a plastic mallet to loosen it from the
drive housing (77). Pull the bearing housing and the
connecting rod assembly off the drive housing.
81,46
59
4. Inspect the crank (A) for excessive wear and replace
parts as needed.
E
D
5. Evenly lubricate the inside of the bronze bearing (D)
in the bearing housing (76), and the inside of the connecting rod link (C), with high–quality motor oil. Liberally pack the roller bearing (B) in the connecting rod
assembly (79) with bearing grease (77d), supplied.
76
75
6. Assemble the connecting rod (79) and bearing housing (76).
72
7. Clean the mating surfaces of the bearing and drive
housings.
73
8. Align the connecting rod with the crank (A) and carefully align the locating pins (E) in the drive housing
(77) with the holes in the bearing housing (76). Push
the bearing housing onto the drive housing or tap it
into place with a plastic mallet.
308-105
74
15
71
137
54
53
CAUTION
28
77
C
79
80,59
2. Remove the four screws (81) and lockwashers (46)
from the bearing housing (76).
Do not use the bearing housing screw (81) to align or
seat the bearing housing with the drive housing.
These parts must be aligned using the locating pins
(E) to help avoid premature bearing wear.
A
Fig. 28
Drive Housing
WARNING
CAUTION
Do not drop the gear cluster (78) when removing the
drive housing (77). The gear cluster is easily damaged. The gear may stay engaged in either the drive
housing or the pinion housing.
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
Do not lose the thrust balls (77c and 138k) located at
each end of the gear cluster. The balls, which are
heavily covered with grease, usually stay in the shaft
recesses, but they could be dislodged. If they are
caught between the gears and not removed, the balls
will seriously damage the drive housing. If the balls
are not in place, the bearings will wear prematurely.
NOTE: Refer to Fig. 29 for this procedure.
1. Remove the front cover (74).
2. Disconnect the pump outlet hose (133).
3. Remove the four screws (81) and lockwashers (46)
from the bearing housing (76).
7. Liberally apply bearing grease (77d, supplied) to the
gear cluster (78). Be sure the thrust balls (77c and
138k) are in place.
4. Lightly tap the back of the bearing housing (76) with
a plastic mallet. Pull the pump, bearing housing and
connecting rod away from the drive housing as one
assembly.
8. Place the bronze colored washer (77a) and then the
silver–colored washer (77b) on the shaft protruding
from the big bearing of the drive housing (77). Align
the gears and push the new drive housing straight
onto the pinion housing and locating pins (B).
5. Remove the two bearing housing screws (80) and
lockwashers (59). Remove the four pinion housing
screws (67) and lockwashers (59).
9. Starting at Step 5, work backwards to reassemble
the sprayer. Or, move ahead to the next section in
this manual if further service is needed.
67
59
6. Lightly tap around the drive housing (77) with a plastic mallet to loosen it from the pinion housing (138p).
B
138p
Torque to 175 in–lb (20 N.m)
77b
77a
77
67
79
74
59
76
138k
73
78
77c
59
80
46
81
133
0039A
Fig. 29
Pinion, Clutch, Clamp, Field, & Engine
Disassembling these parts can start from the pinion
housing or from the clutch, if no pinion service is
needed.
If starting from the pinion housing, first follow Steps
1 to 6 of DRIVE HOUSING, on page 29, and then continue with the procedure below.
If starting from the clutch, see page 32.
Pinion Housing
Removing the Pinion Housing
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
NOTE: Refer to Fig. 30 for Steps 1 to 3.
1. Remove the two bottom screws (67) first, and then
remove the top three screws (67).
2. Push on the front of the shaft (138b) to force the
bearing and hub assembly out of the housing
(138p).
3. Install the new shaft assembly (138a), pushing it to
the shoulder of the pinion housing (138p).
4. Install the rings (138e and 138m).
5. Skip ahead to Reassembly, page 38, Step 7, or
continue on page 32.
2. Pull the pinion housing (138p) away from the clutch
housing (61). The armature (55a) will come with it.
3. Pull out the armature (55a).
See page 31
CAUTION
67
59
Do not lose the thrust ball (138k). Refer to the CAUTION on page 29 for more information.
61
NOTE: To disassemble the pinion, continue with Repairing the Pinion, below. To disassemble more of the
sprayer, go to page 32. To reassemble the sprayer from
this point, skip ahead to Reassembly, page 38, Step 8.
55a
Repairing the Pinion
NOTE: A hydraulic press is required for disassembly and
reassembly if you purchase the pinion parts individually.
If you do not have such a press, use Repair Kit No.
223–189, which includes the shaft and bearings pre–assembled and lubricated.
67
59
NOTE: Refer to Fig. 31 except where noted.
138p
If using Repair Kit 221–032, follow steps 1 to 5 below.
1. Remove the small ring (138e) from the hub (138f)
and the large ring (138m) from the bearing recess
of the pinion housing (138p).
138k
Fig. 30
0040
Pinion Housing
DETAIL A
0041
138p
1
1
Back of pinion housing
2
Press fit small bearing (138c) and roller clutch (138g) in here
3
Lubricate exterior
4
Lubricate inner and outer diameters
5
Lubricate teeth
138m
2
138a
138n
138e
CUTAWAY VIEW OF PINION
HOUSING (138p)
138f
4
138d
138b
3
138g
138c
138h
4
138j
138k
Fig. 31
5
3
If you purchased parts separately, use the following instructions. Disassemble only as far as needed for the
parts being replaced.
NOTE: The old bearings (138c and 138d) will be damaged when removed. Have extra ones on hand if you
need to remove them for any reason.
0042
4. Using a hydraulic press, place pieces of steel
bar stock on the inner race of the large bearing
(138d) and press the shaft through the hub and
bearing. See Fig. 31.
5. Apply lubricant to the parts as shown in Fig. 31.
1. Remove the small ring (138e) from the hub (138j).
CAUTION
2. Remove the snap ring (138m) from the bearing
recess of the pinion housing (138p).
3. Push on the front of the shaft (138b) to force the
bearing and hub assembly out of the housing
(138p)
The arrow on the roller clutch (138g) must point
toward the small bearing (138c) for the shaft (138b)
to rotate in the right direction.
6. Press fit the following parts:
6
1
Round steel bar to
push on shaft (138b)
2
Large bearing
3
Hub
4
Steel bar stock
Two steel blocks
6
Hydraulic press
7
Press platform
3
1
4
2
5
138f
138d
5
Large bearing (138d) to the shoulder of the shaft
(138b).
Small bearing (138c) to the shoulder of the shaft
(138b).
Hub (1138f) onto the shaft (138b) all the way to
the large bearing (138d).
7. Install the shaft assembly (138a), pushing it to the
shoulder of the housing (138p).
8. Install the rings (138e and 138m).
7
0043
Fig. 32
PLACEMENT OF STEEL BLOCKS AND BAR
STOCK WHEN PRESSING OFF LARGE BEARING
9. Skip ahead to Reassembly, page 38, Step 7, or
continue on the next page.
Clutch
NOTE: The clutch assembly (55) includes the armature
(55a) and rotor (55b). The armature and rotor must be replaced together so they wear evenly.
4. Tap lightly on the back of the drive housing (77) with
a plastic mallet to loosen the assembly (D) from the
clutch housing (61). Pull the assembly away; the armature (55a) will come with it.
NOTE: If the pinion assembly (138) is not yet separated
from the clutch housing, follow Steps 1 to 4. Otherwise,
start at Step 5.
5. Remove the armature from the pinion shaft.
1. Follow the Pressure Relief Procedure Warning on
page 7.
2. Disconnect the hose (133) from the displacement
pump.
6. Remove the four socket head capscrews (157) and
lockwashers (156). Install two of the screws in the
threaded holes in the rotor (55b). Alternately tighten
the screws until the rotor comes off. See Fig. 33.
3. Remove the bottom two screws (67) from the clutch
housing (61) and then remove the remaining three
screws (67).
7. Skip ahead to Reassembly, page 38, Step 6, or continue on the next page.
Torque to 7 ft–lb (9.5 N.m)
Pinion shaft
Threaded holes
67
59
61
55b
156
157
55a
D
138
133
A
B
C
77
Fig. 33
32
308-105
USE A STEERING WHEEL
PULLER TO REMOVE ROTOR
0044A
Clutch Rotor/Field Adjustment
Adjustment See Fig. 34.
WARNING
1. Remove any residue from the clutch housing (61).
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
2. Seat the field (70) squarely in the clutch housing.
Do not tighten the four field set screws (62).
3. Install the rotor (4b). Set the clearance between
the outside diameter of the rotor and the inside
diameter of the field with the four 0.010 in. (0.25
mm) gages (A), supplied. Place the gauges 90
apart.
Tool List
3/8 in. hex key wrench
4. Adjust the position of the field with the four field set
screws to maintain 0.010 in. (0.25 mm) minimum
clearance all the way around the rotor.
1/4 in. hex key wrench
5. Tighten the four field set screws, evenly, to 27 in-lb
(3.1 N.m). Remove the four gauges.
Cleaning solvent
62
61
70
A
55b
Fig. 34
05701
Engine
1. Working under the mounting plate (25) of the cart, remove the screw (51), lockwasher (132) and washer
(50) which hold the clutch housing (61) to the cart.
See Fig. 35.
2. Still working under the mounting plate, remove the
two locknuts (40), and then pull the screws (63) out
of the base of the engine. Disconnect the red wire
from the engine lead. Disconnect the black and white
wires (58) from the field. Pull the wires carefully
through the grommets before removing the engine.
See Fig. 35 and 36.
3. Lift the engine carefully and place it on a work bench.
4. Remove the Field and Wiring Harness, Clamp and
Clutch Housing, as instructed on pages 35 and 36.
5. Skip ahead to Reassembly, page 37, Step 1.
NOTE: All service to the engine must be performed by
an authorized HONDA dealer.
67
59
TO FIELD
61
63
RED
TO ENGINE
104
25
58
View from under engine mounting plate
0032
Fig. 36
50
132
40
51
Fig. 35
34
308-105
0045
Field & Wiring Harness
NOTE: Refer to Fig. 37.
2. Pull the caps (A) off the wire screws (57) in both
places on the field. Loosen the screws and release
the wires (58).
1. Loosen the four setscrews (62) holding the field (70)
to the clutch housing (61). Unplug the wiring harness
(58) from under the engine mounting plate. Pull the
field out to expose the black and white wires (58).
3. Skip ahead to Reassembly, page 37, Step 4.
62
61
70
57
58
A
0046
Fig. 37
Clamp
NOTE: A standard steering wheel puller is required to remove the clamp. Two 1/4–28 x 3 or 4
in. long screws are also needed.
NOTE: Refer to Fig. 38.
1. Loosen the two screws (60) on the clamp (68),
working through the slot at the bottom of the
clutch housing (61).
2. Install two screws (B) of the tool (A) in two of
the threaded holes in the clamp. Tighten the
screws (C) until the clamp comes off.
3. Skip ahead to Reassembly, page 37, Step 3,
or continue below.
61
B
C
A
60
68
Torque to 125 in–lb (14 N.m)
0047
Fig. 38
Clutch Housing
NOTE: Refer to Fig. 39.
64
1. Remove the four capscrews (156) and lockwashers (157) which hold the clutch housing
(61) to the engine (64).
61
2. Remove the engine key (66).
3. Pull off the clutch housing (61).
4. Skip ahead to Reassembly, page 37,
Step 1.
157
156
Fig. 39
36
308-105
66
0048
Reassembly
1. Install the clutch housing (61), capscrews (156)
and lockwashers (157) on the engine. See Fig. 40.
2. Install the engine shaft key (66). See Fig. 40.
3. Install the clamp (68) onto the engine shaft (A).
Maintain the 1.99 in. +/– 0.01 (50.55 mm) dimension
shown in Fig. 41.
To check the dimension, place a rigid, straight steel
bar (B) across the face of the clutch housing (61).
Use an accurate measuring device to measure the
distance between the inside of the bar and the face
of the clamp. Adjust the clamp as necessary. Torque
the two screws (60) to 125 in–lb (14 N.m).
4. Connect the wires of the harness (58) to the screws
(57) in both places on the field. Pull the plastic caps
(C) up and snap them over the screws. Guide the
wires of the harness (58) through the slot in the clutch
housing. Slide the field (70) into the clutch. Align the
setscrew chamfers in the field and the clutch housing
(61). Tighten the setscrews (62) oppositely and
evenly, to 25 in–lb (2.8 N.m). See Fig. 40.
Face of housing
1.99” (50.55 mm)
Torque to 125 in–lb (14 N.m)
61
B
Torque oppositely and evenly
to 25 in–lb (2.8 N.m)
A
Connect wiring harness (58) here before
sliding field (70) into housing (61)
Torque to 125 in–lb (14 N.m)
60
SIDE CUTAWAY VIEW OF CLUTCH HOUSING
66
A
Fig. 41
0050
62
61
157
156
68
70
D
60
Fig. 40
58
C
57
0049
308-105
37
Reassembly
5. Place the engine (64) assembly on the cart. Align
the mounting holes. Guide the engine wire (A)
through the clamp at the the rear of the mounting
plate (25). See Detail A. Guide the wiring harness
(58) from the field, through the grommet (24) in the
mounting plate (25). Install the serrated flange
screws (63) and nuts (40) and torque to 15 ft–lb (20.4
N.m). Install the capscrews (51), lockwashers (132)
and washer (50) from under the engine mounting
plate to secure the clutch housing (61). Connect the
engine wire (A) to the red wire, and connect the black
and white wires of the pressure control at B as
shown in the Detail A, Fig. 42.
6. Be sure the face of the rotor (55b) and the field (61)
is free of all oil and contaminants. Install the rotor,
lockwashers (59) and capscrews (60). Torque the
capscrews to 7 ft–lb (9.5 N.m). See Fig. 42
After installing the rotor (55b), pull the engine recoil
rope to assure that the engine turns freely, and there
is no friction between the between the rotor (55b) and
the field (70). If there is friction, loosen the setscrews
(62) and reposition the field (70) as necessary. Tighten the setscrews oppositely and evenly to 25 in-lb
(2.8 N.m) Also make sure there are no burrs on the
outside edge of the rotor.
7. Be sure the face of the armature (55a) is clean.
Assemble the armature to the shaft in the pinion
housing (C). A retaining ring located within the
armature makes it difficult to assemble these
parts. For the best results, first engage a few
splines of both parts, then use a screwdriver to
gently push the retaining ring into the armature,
and then engage the remaining splines. Push the
armature onto the shaft until it contacts the ring.
8. Assemble the drive/pinion housing (C) to the
clutch housing, using the capscrews (67) and lockwashers (59). See Fig. 42.
DETAIL B
64
138f
67
1
59
61
62
4
70
55a
2
55b
59
60
63
138n,138k
0051
58
25
24
1
Chamfered end of hub
2
Torque to
7 ft–lb (9.5 N.m)
3
Face must be clean
4
Tighten oppositely and
evenly torque to
25 in–lb (2.8 N.m)
5
Torque to
15 ft–lb (20.4 N.m)
3
55a
C
0052A
50
132
51
DETAIL A
40
5
VIEW FROM UNDER ENGINE
MOUNTING PLATE
To field
A
B
To engine
To pump
Fig. 42
To filter
0060
Parts –Pressure Control
Part No. 222–369 – Replacement Pressure Control for All GM 5000 Sprayers
Part No. 222–369 includes all items marked with a . It does not include unmarked items. Order the Basic Control,
222–369, and/or items 309 or 313 as needed.
Ref.
No.
Part No.
Description
300
222–380
PRESSURE CONTROL
Includes items 302 to 304
LABEL, caution
ON/OFF SWITCH
BOOT, switch
GUARD, locking
LOCKWASHER, No. 8, internal
NUT, hex, 8–32
CONDUCTOR, red
CONDUCTOR, red, white, black
301
302
303
304
305
306
308
309
183–466
111–930
105–659
107–255
157–021
100–284
220–979
220–978
Qty.
1
1
1
1
1
2
1
2
1
Ref.
No.
Part No.
Description
310
100–035
311
313
316
317
318
319
320
108–783
108–852
222–352
107–070
100–072
103–181
101–754
SCREW, mach, slotted pan hd,
8–32 x .312”
SCREW, mach, flat hd; 8–32 x .812”
CONNECTOR, 45
TRIAC
SCREW, flat head, 6–32 x .625
NUT, hex, 6–32
LOCKWASHER, No. 6, external
PLUG, pipe, 3/8 npt
317 , 318 , 319
1
1
1
1
2
2
2
1
308
RED
316
ENGINE
Qty.
RED
302
MAIN
SWITCH
303
310
305
304
WHITE
RED
308
RED
311 ,
305 ,
306
RED
C
MT2
313
NO
MT1
G
307
R
BLACK
RECTIFIER
301
LABEL
309
300
320
0033
RED
CLUTCH
FIELD
CLUTCH
FIELD
BLACK
WIRING SCHEMATIC
WHITE
GROUND
RECTIFIER (307) CONNECTIONS
0034
Parts – Cart
21
20
22
Ref 13
159
195
83
3
168
169
84
171
23
170
118
1
52
86
1
172
2
28
94
99
32
33
139
24
162
35
33
90
40
39
34
82
167
4
REF 3
36
37
27
E
29
194
163
30
A
19
40
40
42
104
26
26
41
117
110
39
25
11
87
30
38
42
2
10
185
39
41
40
114
116
115
31
E
1
See page 41
2
Label
3
See page 44
4
See page 42
184
A
32
3
114a
112
105
40
114d
183
114c
189
10
114e
114b
02167D
40
308-105
Parts – Cart
Model 231–133, Series A With one gun
Includes items 1–195
Model 231–141 With two guns
Includes items 1–195, and 401–405 (see page 44)
Ref.
No.
Part No.
Description
1
2
3
10
11
19
20
21
22
23
24
25
26
27
111–154
240–484
111–153
112–405
111–020
224–021
108–063
186–787
111–197
235–697
109–099
186–672
111–040
110–963
28
29
30
31
32
33
34
35
36
37
38
39
111–236
104–766
108–471
186–668
100–846
111–016
111–230
100–015
186–814
103–262
186–731
111–194
40
41
42
52
82
83
84
85
86
87
101–566
186–821
224–136
101–818
170–957
178–342
238–959
103–473
185–381
111–193
90
94
99
104
105
107
110
112
181–072
186–747
101–345
108–868
100–731
186–620
224–019
224–066
CABLE,dual gun selector, 9.6 ft (2.9 m) 1
KIT, hose, linestriper
1
CABLE, 4.3 ft (1.3 m)
1
NUT
3
WHEEL, pneumatic, 16” dia.
2
HANDLE
1
GRIP, handle
2
BRACKET, release lever
1
LEVER, release
1
COVER, pail
1
BUSHING, snap
2
PLATE, mounting
1
LOCKNUT, 5/16–18 w/nylon insert
1
SCREW, serrated flange, hex hd,
5/16–18 x 3/4”
1
CAPSCREW, hex hd, 3/8–16 x 4–1/2” 4
MOUNT, motor
4
KNOB
2
BRACKET, rear caster
1
FITTING, lubrication
1
BEARING, flanged
2
SCREW, mach, flhd, 1/4–20 x 1”
1
NUT, hex, 1/4–20
1
PIN, pivot
1
CAPSCREW, sch, 5/16–18 x 3–1/2”
1
BRACKET, front caster
1
CAPSCREW, serrated flange hd,
3/8–16 x 2”
6
LOCKNUT, 3/8–16 w/nylon insert
12
LABEL, Warning (trigger cable)
2
CLAMP, extension
2
CLAMP, hose, 1–3/4”
1
TUBE, suction, 5 gal, 1” pipe
1
CLIP, spring
3
HOSE, cpld 3/16” x 60”
1
WIRE TIE STRAP
2
HOSE, suction, 1” ID x 41”(1041 mm) 1
CAPSCREW, serrated flange, hex hd,
3/8–16 x 7/8”
3
STRAINER, 16 mesh
1
LEVER, actuator
1
NUT, hex, jam, 1/4–20
1
CLAMP, wire
2
WASHER, 3/8”
2
LABEL, grounding, not shown
1
CART
1
CASTER LATCH ASSY
Includes 1 of item 32
1
Qty.
REMOTE TRIGGER DETAIL,
Ref No. 118, Includes 118a–118e
Ref.
No.
Part No.
Description
114
238–052
114a
114b
114c
114d
114e
115
116
117
112–820
112–822
112–823
112–824
112–825
801–020
101–044
111–195
118
224–144
118a
118b
118c
118d
118e
119
120
121
122
127
111–018
111–206
186–746
186–694
186–832
186–695
190–098
111–017
186–696
107–110
139
147
159
162
163
164
165
107–194
206–994
237–686
183–461
186–715
111–235
235–456
166
167
168
169
170
171
172
183
184
185
189
194
195
100–718
112–798
191–874
113–789
113–791
102–040
100–014
192–222
192–221
100–538
113–690
224–068
114–271
SWIVEL CASTER
Includes items 114a–114c
1
SCREW, cap, hex hd
1
BEARING, needle
1
RACE, needle
1
SEAL
1
SPRING, Belleville
NUT, 1/2–13 w/nylon insert
4
WASHER, flat, 1/2”
4
CAPSCREW, serrated flange, hex hd,
1/2–13 x 1–1/4”
4
REMOTE TRIGGER KIT
Includes items 118a to 118e
1
.SPRING, compression
1
.BEARING, ball, 3/32”
1
.TRIGGER
1
.SPOOL, cable selector
1
.KNOB
1
BLOCK, mounting
1
PIN, trigger pivot
1
BEARING, flanged
2
PLATE, lever
2
LOCKNUT, with nylon insert,
10–32 unf-2b
1
WASHER, flat 3/8”
1
THROAT SEAL LIQUID, 8 oz (0.27 l) 1
GROUNDING CLAMP ASSY
1
NIPPLE, adapter
1
SPACER
4
SCREW, mach, pnh, 10–24 x 1.25”
1
BRAKE KIT
See manual 308–227 for instructions 1
WASHER
1
SCREW, hex, hd, thd forming
1
BRACKET, pressure relief
1
SCREW, mach, truss hd 8–32 x 0.5” 1
CLAMP, pressure relief
1
NUT, lock
1
SCREW, cap hex hd
1
INDICATOR, line
1
HOLDER, indicator
1
CAPSCREW, hex hd, 5/16–18 x 1/2 in. 1
CAP, vinyl
1
HOSE, cpld, 1/4 in. x 78 in. (f x f)
1
STRAP, retaining
1
Qty.
Replacement Danger and Warning labels, tags and cards
are available at no cost.
BRAKE KIT, Ref No. 165
Includes solid colored parts
32
119
164
122
127
121
120
121
122
118a
118b
118c
166 118d
118e
0005
Â
Â
ÂÂ
01919
308-105
41
Parts – Mechanical
77 77a
59
67
138
59
79
46
81
77b
78
65
76
1
64
67
73 74
129
59
77c
1
66
62
80
59
128
69
75
68
67
63
157
156
70
59
60
59
133
55b
71
89
88
155
26
60
87
109
104
61
135
58
57
55a
88
REF 24
91
2
162
72
140
92
137
54
3
85
REF 25
107
1
REF 86
53
17
16
40
105
40
108
50
132
51
C
REF 133
D
106
Ref 2
REF 133
162
15
14
18
12
111
43
Ref 84
A
42
2
26
4
52
2
5
6
308-105
1
Label
2
See page 40
3
See 307–806
4
Located on bottom
5
Located on inside of cover
6
Located on outside of cover
02168B
Parts – Mechanical
Ref.
No.
Part No.
Description
12
162–453
NIPPLE, hex 1/4 npt x 1/4 npsm
1-3/16” long
VALVE, pressure relief
CAP, secondary fluid outlet
NIPPLE, hex, 1/4 npt x 1/4 npsm
1-3/16” long
FLUID FILTER,
13
14
15
238–960
240–571
162–453
16
218–029
17
18
26
40
43
100–040
162–485
111–040
101–566
110–997
46
50
51
106–115
108–851
100–469
see 307–273 for parts
52
53
101–818
110–194
54
220–872
55
236–568
PLUG, 3/8 npt
ADAPTER, 3/8 npsm x 3/8 npt
LOCKNUT, 5/16–18 w/nylon insert
LOCKNUT, 3/8–16 w/nylon insert
SCREW, serrated flange, hex hd,
1/4–20 x 5/8”
LOCKWASHER, 3/8”, high collar
WASHER, plain, 3/8”
CAPSCREW, hex hd; 3/8–16
x 3/4”
CLAMP, hose, 1–3/4”
UNION, 180, 1” ID hose x
3/4 npsm swivel
DISPLACEMENT PUMP KIT
see 307–806 for parts
108–860
58
59
60
61
62
63
220–980
105–510
108–803
183–397
108–801
110–837
64
65
66
67
68
69
70
71
72
108–802
181–867
183–401
100–644
183–517
108–800
183–400
183–210
155–494
73
74
108–850
183–168
Part No.
Description
75
76
77
183–169
220–639
241–291
SPRING, retaining
BEARING HOUSING KIT
DRIVE HOUSING
1
1
Includes items 77a to 77c
77a
77b
77c
78
79
80
81
106–227
183–209
100–069
220–919
220–640
108–849
110–141
1
1
1
1
1
1
2
85
87
103–473
111–193
88
110–885
1
1
89
91
186–663
111–192
1
92
105
106
107
108
186–856
100–731
186–811
186–620
157–705
109
111
128
129
132
133
222–369
178–034
186–758
185–953
100–133
222–516
135
137
138
101–754
189–969
241–286
140
177–762
155
156
157
162
172
224–128
108–842
100–214
183–461
100–014
1
1
1
2
1
1
1
3
4
2
4
1
1
CLUTCH ASSEMBLY
Includes items 55a and 55b
55a
55b
57
Ref.
No.
Qty.
1
ARMATURE
1
ROTOR, clutch
1
SCREW, mach, slotted, bdgh
8–32 x 1/4”
2
CONDUCTOR, electrical
1
LOCKWASHER, 1/4”
17
CAPSCREW, hex sch; 1/4–28 x 1”
6
CLUTCH HOUSING KIT
1
SETSCREW, 1/4–20 x 5/16”
4
SCREW, serrated flange, hex hd,
5/16–18 x 1–1/2”
3
ENGINE, gasoline, 5 HP
1
LABEL, WARNING on engine
1
KEY, shaft
1
CAPSCREW, hex sch; 1/4–20 x 3/4” 9
CLAMP, mounting, rotor
1
PIN, dowel; 5/16 x 1”
1
FIELD KIT
1
PIN, 3/8 x 1–1/8” (special)
1
UNION, 90, 3/8 npt x
3/8 npsm swivel
1
SCREW, mach, filh; 8–32 x 1–1/4”
4
DRIVE HOUSING COVER KIT
1
Qty.
. WASHER, bronze
. WASHER, silver
. BALL
GEAR REDUCER KIT
CONNECTING ROD
CAPSCREW, hex sch; 1/4–20 x 3”
CAPSCREW, sch;
3/8–16 x 1–1/2” (special)
WIRE TIE STRAP
CAPSCREW, serrated flange hex hd,
3/8–16 x 1–1/4”
SCREW, pnh, thread forming,
10–24 x 3/8”
BRACKET, pressure control
CAPSCREW, serrated flange hex hd,
3/8–16 x 7/8”
LABEL
WASHER, 3/8”
GROUND CHAIN, heavy, 17–5/8” long
LABEL, grounding
UNION, straight, 1/4 npt(m) x
3/8 npt(f) swivel
PRESSURE CONTROL KIT
TAG, WARNING at filter
LABEL, identification, drive cover
LABEL, DANGER on drive housing
LOCKWASHER, 3/8”
HOSE, 3/8” ID x 29”,
cpld 3/8 npt(m) x 3/8 npsm(f),
spring guard both ends
PLUG, pipe, 3/8 npt
NUT, hex (special)
PINION HOUSING
See parts on page 45
LABEL, WARNING
inside pressure control cover
WIRING HARNESS
CAPSCREW, sch, 5/16–24 x 3/4”
LOCKWASHER, 5/16”
ADAPTER, 1/4 npt(m) x 3/8 npsm (m)
SCREW, cap hex hd
4
1
1
8
2
3
1
1
1
1
2
1
1
1
1
1
2
1
1
1
1
1
4
4
2
1
Replacement Danger and Warning labels, tags and cards
are available at no cost.
308-105
43
Parts – Gun Mounting
Ref.
No.
Part No.
Description
4
6
7
32
33
34
224–052
114–029
188–135
100–846
111–016
111–230
35
44
45
47
100–015
100–016
181–734
100–101
48
49
186–699
100–021
93
94
95
96
181–818
186–747
188–452
108–483
97
98
181–795
235–459
BRACKET, gun support 1
CLAMP, arm support
1
GUIDE, cable
1
FITTING, lubrication
1
BEARING, flanged
2
SCREW, mach, flhd,
1/4–20 x 1”
1
NUT, hex, 1/4–20
1
LOCKWASHER, 1/4”
2
ARM, support
1
CAPSCREW, hex hd,
3/8–16 x 1”
1 or 2
BLOCK, mounting cable 1
CAPSCREW, hex hd,
1/4–20 x 1”
2
KNOB
1
LEVER, actuator
1
HOLDER, gun
1
SCREW, shoulder, sch,
1/4 x 3/8 ”
1
JAW, clamp
1
FLEX GUN
See manual 308–235
for parts
1
NUT, hex, jam, 1/4–20 2
BEARING, sleeve
1
CAPSCREW, sch,
1/4–20 x 1–1/2”
1
SCREW, shoulder, sch,
5/16 x 1”
1
Line Lazer Tip, Sz 317 1
WASHER
1
LOCKWASHER, 3/8”
1
RAC IV DripLess
TIP GUARD
1
SwitchTip, Size 517
1
COLLAR, screw, set
2
NUT, hex; 5/16–18 unc 2
SCREW, thumb; 5/16
2
99
100
101
101–345
108–535
107–445
103
111–045
113
123
132
136
LLT–317
110–755
100–133
237–859
158
190
191
192
221–517
113–975
100–077
100–220
Qty.
OPTIONAL SECOND GUN AND HOSE KIT
Model 224–097
Included with Sprayer Model 231–141 only
This kit includes the parts shown in the
box to the right, which includes items
401–405 and the items listed above
except 4.
Ref.
No.
Part No.
Description
401
402
403
178–342
111–155
224–068
CLIP, spring
CABLE, remote trigger
HOSE, 1/4” ID,
cpld 1/4–18 npsm(f)
6.5 ft (1.2 m) grounded,
spring guards
BRACKET, support,
extension
CLAMP, extension
404
224–096
405
224–071
44
308-105
7
190
6
45
REF 1
191
192
132
34
99
32
94
47
48
4
33
35
44
49
97
93
95
96
98
136
123
0055A
SECOND GUN AND HOSE KIT
7
192
190
45
405
6
132
48
Ref 402
43
47
191
401
33
35
44
49
97
Qty.
93
95
1
1
96
403
1
2
33
99
100
101
113,158
404
1
103
402
98
113,158
136
99
94
32
103
33
99
100
101
123
0056A
Parts – Pinion Assembly
Ref.
No.
Ref No. 138
Pinion Housing
Part No.
Description
Qty.
Includes items 138a to 138f
Ref.
No.
Part No.
Description
138a
221–032
138b
138c
138d
138e
138f
183–395
108–797
108–798
108–796
183–396
PINION SHAFT ASSEMBLY
Includes items 138b to 138f
.SHAFT, pinion
.BEARING, needle
.BEARING, ball
.RING, retaining, external
.HUB, armature
Qty.
1
1
1
1
1
1
NOTE: Items 138h to 138p are not included in a kit. Order them separately as needed.
138h
138j
138k
138m
138n
138p
108–692
107–088
100–069
108–799
105–489
194–311
BEARING, ball, roller
BEARING, ball, needle
BALL, sst
RING, retaining, internal
PIN, dowel
HOUSING, pinion
1
1
1
1
2
1
Lubricate exterior
Lubricate inner and outer diameters
Lubricate teeth
138m
138a
138n
138p
138e
138f
138h
138d
138b
138c
138k
138j
0169
308-105
45
Technical Data
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5 Horsepower, Honda
Maximum Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3000 psi (207 bar, 20.7 MPa)
Noise Level
Sound Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 dbA
Sound Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 dbA @ 1 meter under maximum operating conditions
per ISO–3744
Cycles/Gallon (liter) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 (53)
Maximum Delivery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.25 gpm (4.7 liter/min)
Fuel Tank Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.95 gallons (3.6 liter)
Maximum Tip Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 gun with 0.035 tip;
2 guns with 0.025 tip
3 guns with 0.019 tip
Inlet Paint Strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 mesh (1190 micron)
Stainless Steel screen, reusable
Outlet Paint Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mesh (250 micron)
Stainless Steel screen, reusable
Pump Inlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt (m)
Fluid Outlet Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npsm from fluid filter
Wetted parts
Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zinc-Plated Carbon Steel, Stainless Steel,
Chrome-Plated Stainless Steel, Polyethylene,
Tungsten Carbide, Leather, Polyurethane
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zinc-Plated Carbon Steel, Stainless Steel
Weight (dry, without packaging) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 237 lb (107 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 in. (1016 mm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 in. (1422 mm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 in. (940 mm)
Accessories
USE ONLY GENUINE GRACO PARTS AND ACCESSORIES
DANGER LABELS
The English language DANGER label shown on
page 1 is also on your sprayer. If you have painters
who do not read English, order one of the following
labels to apply to your sprayer. The drawing below
shows the best placement of these labels for good
visibility. Order the labels directly from Graco, free
of charge.
Toll Free:
1–800–328–0211
Apply other
language here
French
Spanish
German
Greek
Korean
English
185–956
185–961
186–041
186–045
186–049
185–953
LINE GUIDE POINTER
Works only with Second Gun and Hose Kit 224–097.
Order One each of the following:
100–538
Screw
181–735
Indicator Holder
192–222
Line Indicator
THROAT SEAL LIQUID
Non–evaporating liquid for the wet–cup. Helps prevent
buildup of paint on the rod and throat packings, to reduce
premature wear.
0057
FLEX GUN REPAIR KIT
235–474
Includes needle, gasket, diffuser/seat.
206–994
206–995
206–996
8 oz.
1 quart
1 gallon
Notes
Graco Warranty
Graco warrants all equipment listed in this manual which is manufactured by Graco and bearing its name to be free from defects in
material and workmanship on the date of sale by an authorized Graco distributor to the original purchaser for use. 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 or 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. 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.
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, gas engines,
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.
LIMITATION OF LIABILITY
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.
Graco Phone Number
TO PLACE AN ORDER, contact your Graco distributor, or call this number to identify the distributor closest to you:
1–800–690–2894 Toll Free.
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.
Sales Offices: Atlanta, Chicago, Detroit, Los Angeles
Foreign Offices: Belgium, Canada, England, Korea, Switzerland, France, Germany, Hong Kong, Japan
GRACO INC.
P.O. BOX 1441
MINNEAPOLIS, MN
55440–1441
http://www.graco.com
PRINTED IN USA 308–105 October 1990, Revised November 1998
48
308-105
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