The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama tion point symbol alerts you to a general warning and the hazard symbols refer to procedure-specific risks. When these symbols appear in the body of this manual or on warning labels, refer back to these Warnings. Product-specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable.

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in

work area

can ignite or explode. To help prevent fire and explosion:

• Use equipment only in well ventilated area.

• Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable and can ignite or explode if spilled on hot surface.

• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are present.

• Ground equipment and conductive objects in work area. See

Grounding

instructions.

• Use only grounded hoses.

• Hold gun firmly to side of grounded pail when triggering into pail.

•

Stop operation immediately

if there is static sparking or you feel a shock. Do not use equipment until you identify and correct the problem.

• Keep a fire extinguisher in work area.

CARBON MONOXIDE HAZRD

Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon monoxide can cause death.

• Do not operate in an enclosed area.

SKIN INJECTION HAZARD

High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a cut, but it is a serious injury that can result in amputation.

Get immediate surgical treatment.

• Do not spray without tip guard and trigger guard installed.

• Engage trigger lock when not spraying.

• Do not point gun at anyone or at any part of the body.

• Do not put your hand over the spray tip.

• Do not stop or deflect leaks with your hand, body, glove, or rag.

• Follow

Pressure Relief Procedure

when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses and couplings daily. Replace worn or damaged parts immediately.

PRESSURIZED EQUIPMENT HAZARD

Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and cause serious injury.

• Follow

Pressure Relief Procedure

in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

311020ZAA

Warnings

PRESSURIZED ALUMINUM PARTS HAZARD

Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture. Failure to follow this warning can result in death, serious injury, or property damage.

• Do not use 1,1,1--trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents

• Do not use chlorine bleach.

• Many other fluids may contain chemicals that can react with aluminum. Contact your material supplier for compatibility.

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

• Do not operate the unit when fatigued or under the influence of drugs or alcohol.

• Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See

Technical Data

in all equipment manuals.

• Use fluids and solvents that are compatible with equipment wetted parts. See

Technical Data

in all equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information about your material, request MSDS from distributor or retailer.

• Do not leave the work area while equipment is energized or under pressure.

• Turn off all equipment and follow the

Pressure Relief Procedure

when equipment is not in use.

• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.

• Do not alter or modify equipment. Alterations or modifications may void agency approvals and create safety hazards.

• Make sure all equipment is rated and approved for the environment in which you are using it.

• Use equipment only for its intended purpose. Call your distributor for information.

• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.

• Do not kink or ever bend hoses or use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns:

• Do not touch hot fluid or equipment.

MOVING PARTS HAZARD

Moving parts can pinch, cut or amputate fingers and other body parts.

• Keep clear of moving parts.

• Do not operate equipment with protective guards or covers removed.

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the

Pressure Relief Procedure

and disconnect all power sources.

PERSONAL PROTECTIVE EQUIPMENT

Wear appropriate protective equipment when in the work area to help prevent serious injury, including eye injury, hearing loss, inhalation of toxic fumes, and burns. Protective equipment includes but is not limited to:

• Protective eyewear, and hearing protection

• Respirators, protective clothing, and gloves as recommended by the fluid and solvent manufacturer.

RECOIL HAZARD

Gun may recoil when triggered. If you are not standing securely, you could fall and be seriously injured.

311020ZAA

CALIFORNIA PROPOSITION 65

The engine exhaust from this product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm.

This product contains a chemical known to the State of California to cause cancer, birth defects or other reproductive harm. Wash hands after handling.

Tip Selection

Tip Selection

LL5435

LL5621

LL5623

LL5625

LL5627

LL5629

LL5631

LL5635

LL5639

LL5417

LL5419

LL5421

LL5423

LL5425

LL5427

LL5429

LL5431

LL5213*

LL5215*

LL5217

LL5219

LL5315

LL5317

LL5319

LL5321

LL5323

LL5325

LL5327

LL5329

LL5331

LL5333

LL5335

LL5355

in.

(cm)

2 (5)

in.

(cm)

4 (10)

Use 100 mesh filter to reduce tip clogs.

in.

(cm)

6 (15)

in.

(cm)

12 (30)



311020ZAA

Maintenance

Maintenance

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure

Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

Engage trigger lock.

Close the bleed-type master air valve.

Disengage the trigger lock.

Hold a metal part of the gun firmly to a grounded metal pail. Trigger the gun to relieve pressure.

Engage the trigger lock.

Open all fluid drain valves in the system, having a waste container ready to catch drainage. Leave drain valve(s) open until you are ready to spray again.

If you suspect the spray tip or hose is clogged or that pressure has not been fully relieved: a.

VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradu ally.

Loosen nut or coupling completely.

Clear hose or tip obstruction.

NOTICE

Minimum hose size allowable for proper sprayer operation is 3/8 in. x 50 ft.

For detailed engine maintenance and specifications, refer to separate Honda Engine’s Owner’s Manual, supplied.

DAILY:

Check engine oil level and fill as necessary.

DAILY:

Check hose for wear and damage.

DAILY:

Check gun safety for proper operation.

DAILY:

Check pressure drain valve for proper operation.

311020ZAA

DAILY:

Check and fill the gas tank.

AFTER THE FIRST 20 HOURS OF OPERATION:

Drain engine oil and refill with clean oil. Reference

Honda Engines Owner’s Manual for correct oil viscosity.

WEEKLY:

Remove air filter cover and clean element.

Replace element, if necessary. If operating in an unusually dusty environment: check filter daily and replace, if necessary.

Replacement elements can be purchased from your local HONDA dealer.

WEEKLY:

Check level of TSL in displacement pump packing nut. Fill nut, if necessary. Keep TSL in nut to help prevent fluid buildup on piston rod and premature wear of packings.

AFTER EACH 100 HOURS OF OPERATION:

Change engine oil. Reference Honda Engines Owner’s

Manual for correct oil viscosity.

SPARK PLUG:

Use only BPR6ES (NGK) or

W20EPR--U (NIPPONDENSO) plug. Gap plug to

0.028 to 0.031 in. (0.7 to 0.8 mm). Use spark plug wrench when installing and removing plug.

Caster Wheel

(See letter call-outs in Parts drawing on page 28)

Once each year, tighten nut (127) under dust cap

(142) until spring washer bottoms out. Then back off the nut 1/2 to 3/4 turn.

Once each year, tighten nut (127) on screw (131) until it begins to compress spring washer. Then tighten the nut an additional 1/4 turn.

Once each month, grease the wheel bearing (F).

Check pin (55) for wear. If pin is worn out, there will be play in the caster wheel. Reverse or replace the pin as needed.

Check caster wheel alignment as necessary. To align: loosen screw (145), align wheel and tighten screw.

Troubleshooting

Troubleshooting

Problem

E=XX is displayed

Engine won’t start

Engine operates, but displacement pump does not operate

Cause

Fault condition exists

Engine switch is OFF

Engine is out of gas

Engine oil level is low

Spark plug cable is disconnected or damaged

Cold engine

Fuel shutoff lever is OFF

Oil is seeping into combustion chamber

Error code displayed?

Pump switch is OFF

Pressure setting is too low

Solution

Determine fault correction from table, page

20.

Turn engine switch ON

Refill gas tank. Honda Engines Owner’s

Manual.

Try to start engine. Replenish oil, if necessary. Honda Engines Owner’s Manual.

Connect spark plug cable or replace spark plug

Use choke

Move lever to ON position

Remove spark plug. Pull starter 3 to 4 times.

Clean or replace spark plug. Start engine.

Keep sprayer upright to avoid oil seepage.

Reference pressure control repair. Page 18.

Turn pump switch ON.

Turn pressure adjusting knob clockwise to increase pressure.

Clean filter. Page 32.

Clean tip or tip filter. See spray gun manual.

Repair pump. See pump manual.

Fluid filter (11) is dirty

Tip or tip filter is clogged

Displacement pump piston rod is stuck due to dried paint

Connecting rod is worn or damaged

Drive housing is worn or damaged

Electrical power is not energizing clutch field

Clutch is worn, damaged, or incorrectly positioned

Replace connecting rod. Page 11.

Replace drive housing. Page 12.

Check wiring connections. Page 16.

Reference pressure control repair. Page 18.

Reference wiring diagram. Page 34.

With pump switch ON and pressure turned to

MAXIMUM, use a test light to check for power between clutch test points on control board.

Measure resistance across clutch coil. At 70

F, the resistance must be between

1.2 0.2

(LineLazer IV 3900/R300);

1.7 0.2

(LineLazer IV 5900); if not, replace pinion housing.

Have pressure control checked by authorized

Graco dealer.

Replace clutch. Page 13.

311020ZAA

Troubleshooting

Problem

Pump output is low

Excessive paint leakage into throat packing nut

Fluid is spitting from gun

Pump is difficult to prime

Clutch squeaks each time clutch engages

High engine speed at no load

311020ZAA

Cause

Pinion assembly is worn or damaged

Strainer (34f) is clogged

Piston ball is not seating

Piston packings are worn or damaged

O-ring in pump is worn or damaged

Intake valve ball is not seating properly

Intake valve ball is packed with material

Engine speed is too low

Clutch is worn or damaged

Pressure setting is too low

Fluid filter (11), tip filter or tip is clogged or dirty

Large pressure drop in hose with heavy materials

Throat packing nut is loose

Throat packings are worn or damaged

Displacement rod is worn or damaged

Air in pump or hose

Tip is partially clogged

Fluid supply is low or empty

Air in pump or hose

Intake valve is leaking

Pump packings are worn

Paint is too thick

Engine speed is too high

Clutch surfaces are not matched to each other when new and may cause noise

Misadjusted throttle setting

Worn engine governor

Solution

Repair or replace pinion assembly. Page 13.

Clean strainer.

Service piston ball. See pump manual.

Replace packings. See pump manual.

Replace o-ring. See pump manual.

Clean intake valve. See pump manual.

Increase throttle setting. See operation manual.

Replace clutch. Page 13.

Increase pressure. See operation manual.

Clean filter. See operation or spray gun manual.

Use larger diameter hose and/or reduce overall length of hose. Use of more than 100 ft of 1/4 in. hose significantly reduces performance of sprayer. Use 3/8 in. hose for optimum performance (50 ft minimum).

Remove throat packing nut spacer. Tighten throat packing nut just enough to stop leakage.

Replace packings. See pump manual.

Replace rod. See pump manual.

Check and tighten all fluid connections.

Reprime pump. See operation manual.

Clear tip. See spray gun manual.

Refill fluid supply. Prime pump. See operation manual. Check fluid supply often to prevent running pump dry.

Check and tighten all fluid connections.

Reduce engine speed and cycle pump as slowly as possible during priming.

Clean intake valve. Be sure ball seat is not nicked or worn and that ball seats well.

Reassemble

Replace pump packings. See pump manual.

Thin the paint according to the supplier’s recommendations

Decrease throttle setting before priming pump. See operation manual.

Clutch surfaces need to wear into each other.

Noise will dissipate after a day of run time.

Reset throttle to 3600 engine rpm at no load

Replace or service engine governor

Troubleshooting

Problem

Gallon counter not working

Sprayer operates, but display does not

Distance counter not operating properly

Miles not calculating

Fluid spray starts after spray icon is shown on display

Fluid spray starts before spray icon is shown on display

Spray icon does not show on display when fluid is sprayed

Cause Solution

Broken or disconnected wire

Bad sensor

Missing magnet

Bad connection between control board and display

Display damaged

Trigger sensor not set correctly

Check wires and connections. Replace broken wires.

Replace sensor

Reposition or replace magnet.

Remove display and reconnect

Bad wiring connections

Distance sensor not spaced correctly from gear

Distance sensor and gear not aligned

Replace display

See “Spray icon does not show on display when fluid is sprayed”

Check connector, and reconnect

Adjust space between sensor and gear to

.050 --/+ .020 in. See page 19.

Gear teeth missing or damaged.

Wire cracked or broken

Distance sensor

Remove tire, and press in or pull out gear to align sensor and gear.

Replace distance gear/wheel

Replace sensor

Trigger sensor

Gallon counter

Bad or damaged control board

See “Distance counter not operating properly”

See “Spray icon does not show on display when fluid is sprayed”

See “Gallon counter not working”

Replace control board

Interrupter (164) is improperly positioned Turn screw (126) counterclockwise until spray icon synchronizes with fluid spray

Interrupter (164) is improperly positioned Turn screw (126) clockwise until spray icon is synchronized with fluid spray

Loose connector Check connector and reconnect

Interrupter (164) is improperly positioned Turn screw (126) counterclockwise until spray icon synchronizes with fluid spray

Reed switch assembly (166) is damaged Replace reed switch assembly (166)

Magnet on assembly (166) is missing Replace reed switch assembly (166)

Cut or sliced wire

Control board is damaged

Replace distance sensor harness (66)

Replace control board

Display is damaged Replace display

Interrupter (164) is improperly positioned Turn screw (126) clockwise until spray icon is synchronized with fluid spray

Reed switch assembly (166) is damaged Replace reed switch assembly (166)

10 311020ZAA

Bearing Housing and Connecting Rod

Bearing Housing and Connecting Rod

Removal

3 Clean mating surfaces of bearing and drive housings.

4 Align connecting rod with crank (B) and carefully align locating pins (F) in driving housing (24) with holes in bearing housing (22). Push bearing housing onto drive housing or tap into place with plastic mallet.

1 Relieve pressure, page 7.

2 Fig. 2. Remove screws (187) and front cover (83).

3 Unscrew suction tub (34) from pump, hold wrench on pump intake valve (A) to keep pump from loosening.

4 Disconnect pump outlet hose (100) from displacement pump outlet nipple (60).

5 Fig. 1. Use screwdriver to push up retaining spring

(236) at top of pump. Push out pin (235).

235

NOTICE

To prevent damage to soft key buttons, do not press the buttons with sharp objects such as pens, plastic cards, or fingernails.

5 Install screws (183) and lock-washers (173) on bearing housing. Torque evenly, referencing note 3 value in Fig. 2.

6 Install pump. Refer to

Displacement Pump,

Installation,

page 21.

236

173

Fig. 1

7675B

6 Fig. 2. Loosen retaining nut (84). Unscrew and remove displacement pump(21).

7 Remove four screws (183) and lock-washers (173) from bearing housing (22).

8 Pull connecting rod (26) and lightly tap lower rear of bearing housing (22) with plastic mallet to loosen from drive housing (24). Pull bearing housing and connecting rod assembly (26) off drive housing.

9 Inspect crank (B) for excessive wear and replace parts as needed.

Installation

1 Evenly lubricate inside of bronze bearing (C) in bearing housing (22) with high-quality motor oil.

Liberally pack top roller bearing (E), lower bearing

(D) inside connecting rod assembly (26) with bearing grease.

2 Assemble connecting rod (26) and bearing housing

(22).

183

187

235

100

Oil

Pack with bearing grease 114819

LineLazer IV 3900/R300: Torque to

200 in-lb (22.6 N·m) LineLazer V

5900: Torque to 25 ft-lb

Model 248862 shown

Fig. 2

34g

34 ti25624a

311020ZAA 11

Drive Housing

Drive Housing

Removal

1 Relieve pressure, page 7.

2 Fig. 3. Remove bearing housing. Refer to

Bearing

Housing and Connecting Rod

procedure on page

11.

3 Remove two screws (158) and reed switch (182).

4 Remove six screws (189) and reed switch (25).

5 Lightly tap around drive housing (24) to loosen drive housing. Pull drive housing straight off pinion housing. Be prepared to support gear cluster (23), which may also come out.

Installation

1 Liberally apply bearing grease (supplied with replacement gear cluster) to gear cluster (23) and to areas called out by reference 2 in Fig. 3.

2 Place bronze colored washer (24g) on shaft protruding from large shaft of drive housing (24).

Place silver colored washer (24h) on pinion housing. Clean mating surfaces of pinion and drive housings. Align gears and push new drive housing straight onto pinion housing and locating pins (A).

3 Install six screws (189). Torque evenly, referencing note 1 value in Fig. 3.

4 Install reed switch (182) with two screws (158).

5 Install bearing housings. Do steps 1 through 6 of

Bearing Housing and Connecting Rod

procedures on page 11.

Fig. 3

189

173

178

24g

24h

179

182

178

158

2 ti6396a

181

189

LineLazer IV 3900/R300: Torque to 200 in-lb (22.6 N·m)

LineLazer IV 5900: Torque to 25 ft-lb (34 N·m)

Apply remaining grease to these areas

12 311020ZAA

Pinion Assembly/Clutch Armature/Clamp

Pinion Assembly/Clutch Armature/Clamp

Pinion Assembly Removal

If pinion assembly (25) is not removed from clutch hous ing (85), so 1 through (3). Otherwise, start at 4.

175

172

1 Remove drive housing, page. 12.

2 Fig. 12. Remove clip (251) and junction box (226).

3 Fig. 11. Disconnect pump stroke sensor and clutch cables.

4 Fig. 4. Remove four screws (189) and lock-washers

(188) and pinion assembly (25).

5 Fig. 5. Place pinion assembly (25) on bench with rotor side up.

Fig. 5 ti5481b ti5987c

7 Fig. 6. Remove retaining ring (25e).

8 Tap pinion shaft (25d) out with plastic mallet.

189

188

25e

25d

25c

Fig. 4

189

188 ti5480b

6 Remove four screws (170) and lock-washers (172).

Install two screws in threaded holes (E) in rotor.

Alternately tighten screws until rotor comes off.

Fig. 6 ti5482b

Clutch Armature Removal

9 Fig. 7. Use an impact wrench to wedge between armature (87) and clutch housing to hold engine shaft during removal.

10 Remove four screws (175) and lock-washers (172).

11 Remove armature (87).

172

175

Fig. 7

8704A

311020ZAA 13

Pinion Assembly/Clutch Armature/Clamp

Clutch Armature Installation

1 Fig. 8. Lay two stacks of two dimes on smooth bench surface.

2 Lay armature (87) on two stacks of dimes.

3 Press center of clutch down on bench surface.

0.12 +.01 in. (3.0 +.25 mm)

8705A

Pinion Assembly Installation

1 Fig. 6. Check o-ring (25c) and replace if missing or damaged.

2 Tap pinion shaft (25d) in with plastic mallet.

3 Install retaining ring (25e) with beveled side facing up.

4 Fig. 5. Place pinion assembly on bench with rotor side up.

5 Apply thread sealant to screws. Install four screws (170) and lock-washers (172). Alternately torque screws to 125 in-lb until rotor is secure. Use threaded holes to hold rotor.

6 Fig.4. Install pinion assembly (25) with five screws (189) and lock-washers (188).

7 Fig. 11. Connect pump stroke sensor and clutch cables.

8 Fig. 12. Install junction box (226) with clip (251).

Fig. 8

1 85

4 Install armature (87) on engine drive shaft.

5 Install four screws (175) and lock-washers (172) with torque of 125 in-lb.

Clamp Removal

Perform Engine Removal

175

2 Drain gasoline from tank according to Honda manual.

3 Tip engine on side to ensure gas tank is down and air cleaner is up.

4 Fig. 9. Loosen two screws (175) on clamp (82).

5 Push screwdriver into slot on clamp (82) and remove clamp.

Clamp Installation

1 Fig. 9. Install engine shaft key (88).

2 Tap clamp (82) on engine shaft (A) with plastic mallet. Maintain dimension shown on note 2 in Fig.

3 Check dimensions: Place rigid, straight steel bar (B) across face of clutch housing (5). Use accurate measuring device to measure distance between bar and face of clamp. Adjust clamp as necessary.

Torque two screws (175) to 125±10 in-lb (14 ± 1.1

N·m).

Fig. p

A ti5484b

Face of clutch housing

1.55 ± .010 in. (39.37 ± .25 mm); LineLazer IV 3900/R300

2.612 ± .010 in. (66.34 ± .25 mm); LineLazer IV 5900

Torque to 125 ± .10 in-lb (14 ± 1.1 N·m)

Chamfer this side

14 311020ZAA

Clutch Housing

Clutch Housing

Removal

1 Fig. 10. Remove four cap screws (186) and lock washers

(188) which hold clutch housing (85) to engine.

2 Remove screw (177) from under mounting plate (96).

3 Pull off clutch housing (85).

Installation

1 Fig. 10. Push on clutch housing (5).

2 Install four cap screws (186) and lock-washers (188) and secure clutch housing (85) to engine. Torque to 200 in-lb

(22.6 N·m). ti6643a

Fig. 10

177

188 186

311020ZAA 15

Engine

Engine

Removal

NOTICE

All service to the engine must be performed by an authorized HONDA dealer.

1 Remove

Pinion Assembly/Clutch

Armature/Clamp

and

Clutch Housing

. See pages

11-15.

2 Fig. 12. Remove clip (251) and junction box (226).

3 Fig. 11. Disconnect all necessary wiring.

4 Fig. 12. Remove screw (177). Remove two screws

(117), lock nuts (118), and ground conductor (230,

260) from base of engine (185).

5 Lift engine carefully and place on work bench.

Main Control Box Cable

Wheel Sensor Cable

To Engine

Bottom View

Engine ti6397a

DISTANCE

SENSOR

TO MAIN

CONTROL

BOX

Fig. 11

PUMP STROKE

COUNTER

JUNCTION

BOX

CLUTCH

ENGINE

Fig. 12 ti25625a

Installation

1 Lift engine carefully and place on cart.

2 Fig. 12. Install two screws (117) and ground conductor

(223, 260) in base of engines and secure with lock nuts

(118). Torque to 20 to 30 ft-lb.

3 Fig. 11. Connect all necessary wiring.

4 Install

Pinion Assembly/ Clutch Armature/Clamp

and

Clutch Housing

. See pages 11-15.

311020ZAA

Pressure Control

Pressure Control

On/Off Switch

Removal

1 Relieve pressure, page 7.

2 Fig. 13. Remove two screws (125) and cover (31).

3 Pull display connector wings (A) open on PC board and pull display connector out.

4 Disconnect ON/OFF switch connector (B) from PC board.

5 Press in on two retaining tabs on each side of

ON/OFF switch (15g) and remove switch.

Installation

1 Install ON/OFF switch (15g) so tabs of switch snap into place on inside of pressure control housing.

2 Connect ON/OFF switch connector (B) to PC board.

3 Push display connector into PC board close display connector wings (A) on PC board.

4 Install cover (31) with two screws (125).

15g

15n

15i

15o

15r

GROUND

15d

15j

TO ENGINE

Main Control

Box Cable

311020ZAA

Fig. 13

Transducer

216

217 ti6408a

Pressure Control

Pressure Control

Control Board

Removal

1 Relieve pressure, page 7.

2 Fig.13. Remove two screws (125) and control cover

(31). Pull display connector wings open on PC board and pull display connector out.

3 Fig. 13 and 21. Note on a paper lead connections to the control board. Disconnect leads from control board (15d).

4 Fig. 13. Remove four screws (15j) from control board (15d).

Installation

1 Fig. 13. Install control board (15d) with four screws

(15j).

2 Fig. 13 and 21. Refer to note on lead connections to the control board. Connect leads to control board

(15d).

3 Fig. 13. Push display connector into PC board close display connector wings on PC board. Install control cover (31) with two screws (125).

Pressure Control Transducer

Removal

1 Relieve pressure, page 7.

2 Fig. 13. Remove two screws (125) and control cover

(31).

3 Disconnect transducer lead (C) from control board

(15d).

4 Remove pressure control transducer (216) and o-ring (217) from filter manifold (40).

Installation

1 Fig. 13. Install o-ring (217) and pressure control transducer (216) in filter manifold (40). Torque to

35-45 ft-lb.

2 Connect transducer lead (C) to control board (15d).

3 Install control cover (31) with two screws (125).

Pressure Adjust Potentiometer

Removal

1 Relieve pressure, page 7.

2 Fig. 13. Remove two screws (125) and control cover

(31).

3 Disconnect lead (D) from control board (15d).

4 Loosen set screws on potentiometer knob (15o) and remove knob, shaft nut, lock-washer and pressure adjust potentiometer (15i).

5 Remove seal (15n) from potentiometer (15i).

Installation

1 Install seal (15n) on potentiometer (15i).

2 Fig. 13. Install pressure adjust potentiometer (15i), shaft nut, lock-washer and potentiometer knob

(15o).

Turn potentiometer shaft (15i) clockwise to internal stop. Assemble potentiometer knob

(15o) to strike pin on plate (15r).

After adjustment of step a, tighten both set screws in knob 1/4 to 3/8 turn after contact with shaft.

3 Connect lead (D) to control board (15d).

4 Install control cover (31) with two screws (125).

18 311020ZAA

Trigger Sensor Adjustment

Trigger Sensor Adjustment

Refer to

Troubleshooting

for trigger sensor adjust ment, and see

Operation manual.

Distance Sensor Adjustment

Gear Alignment

Install wheel (120) on LineLazer.

Install nut (127) until tight, then back off 1/4 turn.

Install dust cap (142) on wheel.

Relieve pressure, page 7.

Fig. 14. Remove dust cap (142) from wheel.

Remove nut (127).

Remove wheel (120) from LineLazer.

Align gear (67) with sensor.

Pull gear out from wheel with gear puller.

Push gear in toward wheel with mallet.

Sensor Height Adjustment

Remove wheel (120) from LineLazer.

Remove distance sensor (66).

Adjust sensor assembly height with two 17 mm nuts of sensor so bottom surface of sensor is 0.638 +/-

0.020 from bottom surface of shield. Torque to 8 +/-

2 in-lb.

Reassemble distance sensor (66) and wheel (82).

Distance

Sensor

120

Tire

Frame

142 127

Inside of tire

120

Axle

.638 in.

Fig. 14

311020ZAA

ti6400a

Gear

Distance Sensor Detail

Control Board Diagnostics

Control Board Diagnostics

Digital Display Messages

Relieve pressure before repair; page 7. No display does not mean that sprayer is not pressurized.

DISPLAY

No Display

- - - -

SPRAYER OPERATION INDICATION

Sprayer may be pressurized Loss of power or display not connected

ACTION

Check power source. Relieve pressure before repair or disassembly. Verify display is connected.

Increase pressure as needed.

Sprayer may be pressurized Pressure less than 200 psi (14 bar, 1.4 MPa)

Normal operation Sprayer is pressurized.

Power is applied. (Pressure varies with tip size and pressure control setting).

Sprayer stops. Engine is running.

Exceeded pressure limit

Sprayer stops. Engine is running.

Sprayer stops. Engine is runnings.

Spray

Pressure transducer faulty, bad connection or broken wire.

High clutch current

Remove any filter clogs or flow obstructions. Make sure gun triggering is locked open if using

Auto-Clean valve.

Check transducer connections and wire. Replace transducer or control board, if necessary.

1. Check clutch 7-pin bulkhead connector. Clean contacts.

2. Measure 1.2 ± 0.2

(LineLazer IV 3900/R300); 1.7 ±

0.2

(LineLazer IV 5900) across clutch field at 70°F.

3. Replace clutch field assembly

After a fault, follow these steps to restart sprayer:

Correct fault condition

Turn sprayer OFF

Turn sprayer ON

20 311020ZAA

Displacement Pump

Displacement Pump

Removal

Flush pump.

Installation

NOTICE

If pin works loose, parts could break off due to force of pumping action. Parts could project through the air and result in serious injury or property damage. Make sure pin and retaining spring are properly installed.

Relieve pressure, page 7.

Fig. 15. Cycle pump piston rod (A) to lowest posi tion.

Fig. 15. Remove suction tube (34) and hose (100).

NOTICE

If the pump locknut loosens during operation, the threads of the bearing housing will be damaged. Make sure locknut is properly tightened.

Fig. 18. Pull piston rod out 1.5 in. Screw in pump until holes in bearing cross link and piston rod align.

100

Fig. 15

34 ti25646a

Fig. 16. Use screwdriver: push retaining spring up and push out pin (235).

1.5 in.

Fig. 18 ti25647a

Fig. 16. Push pin (235) into hole. Push retaining spring into groove around connecting rod.

Fig. 19. Screw jam nut down onto pump until nut stops.

Screw pump up into bearing housing until it is stopped by jam nut. Back off pump and jam nut to align pump outlet to back. Tighten jam nut by hand, then tap 1/8 to

1/4 turn with a 20 oz (maximum) hammer to approxi mately 75± 5 ft-lb (102 N•m).

Fig. 16

7675B

Fig. 17. Loosen locknut by hitting firmly with a 20 oz

(maximum) hammer. Unscrew pump.

Fig. 19 ti25649a

Fig. 20. Fill packing nut with Graco TSL unit fluid flows onto the top of seal.

Fig. 17 ti25648a

Repair

See manual 310643 for pump repair instructions.

Fig. 20 ti25650a

311020ZAA 21

Parts - LineLazer IV

Parts - LineLazer IV

Parts Page

Sheet 1 of 7

ti25626a

Parts Page 30

311020ZAA

Parts - Drive and Pinion Housing Assemblies

Parts - Drive and Pinion Housing Assemblies

Ref No. 24 and 25

Ref No. 24: Drive Housing Assembly 287467 for

LineLazer IV 3900/R300; Drive Housing Assembly

287469 for LineLazer IV 5900

Ref.

Part

24g

24h

287467

Description

HOUSING, drive (3900/R300)

287469 HOUSING, drive (5900)

WASHER

107089 (3900/R300)

194173 (5900)

WASHER

116191 (3900/R300)

116192 (5900)

Qty.

Ref No. 25: Pinion Housing Assembly 287463 for

LineLazer IV 3900/R300; Pinion Housing Assembly

287465 for LineLazer IV 5900

Ref.

Part Description

25a

287463 HOUSING, pinion (3900/R300)

287465 HOUSING, pinion (5900)

KIT, repair, coil

287474 (3900/R300)

287476 (5900)

25b 105489 PIN

25d* PINION SHAFT

241110 (3900/R300)

241114 (5900)

25e RETAINING RING, large

113094 (3900/R300)

112770 (5900)

158 114528 SCREW, machine

181 116618 MAGNET

182 119562 SWITCH, reed w/ connector

Must be ordered separately

Qty.

1 ref. 170

25a

25b

25d

25e ref. 172 ref. 190 ref. 189

24 ref. 179

24g

24h

158 ti6407b

182 ref. 86

1 ref. 189

181 ref. 178 ref. 23 ref. 212

Pinion housing assembly (25) includes clutch field and connector

Sheet 2 of 7

311020ZAA 23

Parts Drawing - LineLazer IV

Parts Drawing - LineLazer IV

144

264

141

177

154

129

107

177

220

232

177

112

153

108

129

115

134

153

108

120

157

108

142

127

117

122

117

115

121

148

121

115

117 ti25627a

Sheet 3 of 7

24 311020ZAA

Parts List - LineLazer IV

Parts List - LineLazer IV

Ref.

Part Description

237686 WIRE, ground assembly w/ clamp

245225 HOSE, 3/8 in. x 50 ft

245798 HOSE, 1/4 in. x 7 ft

287623 FRAME, linestriper (painted)

287417 HANDLE

287622 SUPPORT, handle (painted)

24U241 COVER, pail (includes 35)

119771 STRAP, cover

108471 KNOB, pronged

193405 AXLE

194310 LEVER, actuator

195134 SPACER, ball, guide

196176 ADAPTER, nipple

287698 KIT, sensor, distance (includes 68,

198612

115, 129, 157)

GEAR, signal

SHIELD, sensor, distance

198891 BRACKET, mounting

198930 ROD, brake

198931

15F577

BEARING

BRACE, left (painted)

94 15F576 BRACE, right (painted)

107 178342 CLIP

108 101566 NUT, lock

115 108868 CLAMP, wire

117 110837 SCREW, flange, hex

120 111020 WHEEL, pneumatic (includes 67)

249082 WHEEL, turf (models 24M605,

24M607)

121 111040 NUT, lock, insert, nylock, 5/16

Qty.

122 111194 SCREW, cap flang hd

127 112405 NUT, lock

129 112798 SCREW, thread forming, hex hd

134 113961 SCREW, cap, hex hd

141 241445 CABLE, caster

142 114648 CAP, dust

144 114659 GRIP, handle

148 114808 CAP, vinyl

153 114982 SCREW, cap, flng hd

154 115077 PAIL, plastic

157 116287 WASHER, sst, external

158 114528 SCREW, mach, phillips, pnhd

177 112395 SCREW, cap, flnghd

181 116618 MAGNET

182 119562 SWITCH, reed, w/ connector

220



15F638 LABEL, GMAX warning fires & skin

232 15F545 LABEL, brand, handle

16N543 LABEL, brand, handle (models

264

265

120151

241104

24M605, 24M607)

PLUG, tube

HOPPER, 15 gal (models 24M605)

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

311020ZAA 25

Parts Drawing - Line Lazer IV

Parts Drawing - Line Lazer IV

Models 248862, 248866

247

170

233

83 158

182

190

189

Ref. 24

187

258

173

183

172

235

236

259

181

178

179

212

189

175

188

172

186

171

169

175

172

185

117

100

34a

34d

34g

34m

249

248

34j

34b

234

117

108

114

34e

34f

34k

177

260

223

118

226

174

34d

34c ti25628a

Sheet 4 of 7

26 311020ZAA

Parts List - LineLazer IV

Parts List - LineLazer IV

Models 248862, 248866

Ref.

Part Description

277069 PUMP, displacement (3900/R300)

277070 PUMP, displacement (5900)

287714 HOUSING, bearing (3900/R300)

287715 HOUSING, bearing (5900)

23 287653 GEAR, combination (3900/R300)

287460 GEAR, combination (5900)

26‡ 287719 ROD, connecting (3900/R300)

287720 ROD, connecting (5900)

34 24V567 HOSE ASSEMBLY, drain (items 34a thru 34n)

34a 15F149 TUBE, suction

34b 185381 HOSE

34c 110194 SWIVEL, 180°

34d 101818 CLAMP, hose

34e 278722 GASKET, pail

34f 181072 STRAINER

34g 16X071 TUBE, drain (includes diffuser)

34j 245798 HOSE, coupled, 1/4 in. x 7 ft

34k 114958 STRAP, tie

34m 196180 BUSHING

34n



195119 LABEL, warning

119695 DAMPENER, engine mount

196176 ADAPTER, nipple

81†

HUB, armature

193680 COLLAR, shaft

287521 COVER, front (3900/R300)

287511 COVER, front (5900)

192723 NUT, retaining (3900/R300)

193031 NUT, retaining (5900)

15E535 HOUSING, clutch (3900/R300)

86†

87†

15E277 HOUSING, clutch (5900)

ROTOR, clutch, 4 in. (3900/R300)

ROTOR, clutch, 5 in. (5900)

ARMATURE, clutch, 4 in.

(3900/R300)

ARMATURE, clutch, 5 in. (5900)

183401

15F583

KEY, parallel

PLATE, engine mount

100 245797 HOSE, 3/8 in. x 3.0 ft

108 101566 NUT, lock

114 108851 WASHER, plain

117 110837 SCREW, flange, hex

118 110838 NUT, lock

169 119426 SCREW, hex washr hd (3900/R300)

102962 SCREW, cap sch (5900)

170† 101682 SCREW, cap sch

171 104008 WASHER, lock, spring (5900)

172† 105510 WASHER, lock, spr (hi-collar)

Qty.

Ref.

Part Description

173 WASHER, lock spr (hi-collar)

100214 (3900/R300)

106115 (5900)

174 113743 SCREW, cap, hex hd

175† 108803 SCREW, hex, socket head

177 112395 SCREW, cap, flnghd

178 114672 WASHER, thrust

179 114699 WASHER, thrust

183 113467 SCREW, cap, soc hd (3900/R300)

114666 SCREW, cap, sock hd (5900)

185 108879 ENGINE, gas, 4.0 hp (3900/R300)

114530 ENGINE, gas 5.5 hp (5900)

186 108842 SCREW, cap, hex hd

187 118444 SCREW, machine hex washer hd

188 100214 WASHER, lock

189 119426

SCREW, mach, hex washr hd

(3900/R300)

15C753 Screw, mach, hex washr hr (5900)

190 15F947 SHIELD, magnetic

212 15F250 WASHER, thrust (3900/R300)

114672 WASHER, thrust (5900)

223 119579 CONDUCTOR, ground (3900/R300)

240997 CONDUCTOR, ground (5900)

226 287695 BOX

233 15F546 LABEL, brand (3900/R300)

15F547 LABEL, brand (5900)

16N452 LABEL, brand (R300) (models

24M605, 34M607)

234



194126 LABEL, warning

235 PIN, pump

15F855 (3900)

15F856 (5900)

236‡ 119676 SPRING, retaining (3900/R300)

119778 SPRING, retaining (5900)

247 290228 LABEL, caution

248 114629 GROMMET

249 119569 BUSHING

258 15C762 SHIELD, pump rod

259 110996 NUT, hex

260 240997 CONDUCTOR, ground (5900)

Qty.

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

†

Parts included in Clutch Repair Kits 241109

(3900/R300) and 241113 (5900) (purchase separately).

‡

Parts included in Connecting Rod Kits (purchase separately).

311020ZAA 27

Parts Drawing - LineLazer IV

Parts Drawing - LineLazer IV

Models 248862, 248866

208

Ref. 6

Ref. 141

(page 24)

146

121

108

106

(Detail D)

117

153

Ref. 141

147

127

130

142

130

127

133

113

139

133

132

128

116

110

209

140

Sheet 5 of 7

131

Install washers (130) concave surface to inside.

Detail D

135

145 ti6404b

28 311020ZAA

Parts List - LineLazer IV

Models 248862, 248866

Ref.

Part Description

240942 SHAFT, fork

240991 BRACKET, caster, front

10* 15G952 BRACKET

46 181818 KNOB, pronged

193528 ARM, detent

193661 JAW

193662

15F910

STOP, wedge

BRACKET, cable

65 198606 DISK, adjuster

106 100731 WASHER

108 101566 NUT, lock

110 15J603 WASHER, plain

113 108483 SCREW, shoulder, sch

116 110754 SCREW, cap, sch

117 110837 SCREW, flange, hex

121 111040 NUT, lock, insert, nylock, 5/16

127 112405 NUT, lock

128 112776 WASHER, plain

130 112825 SPRING, belleville

131 113471 SCREW, cap, hex hd

132* 113484 SEAL, grease

133* 113485 BEARING, cup/cone

135 113962 WASHER, hardened, SAE

139 114548 BEARING, bronze

140 114549 WHEEL, pneumatic

142 114648 CAP, dust

145 114681 SCREW, cap, hex hd

146 114682 SPRING, compression

147 114802 STOP, wire

153 114982 SCREW, cap, flng hd

208 193658 SPACER, seal

209* 120476 BOLT

* Parts included in Bracket Repair Kit 240940 (pur chase separately).

Qty.

Parts List - LineLazer IV

311020ZAA 29

Parts Drawing - LineLazer IV

Parts Drawing - LineLazer IV

Models 248862, 248866

49 ref. 161

153

153, 108

136a

136

1 ti27326a

Ref 14 ref. 14

161

105

4 ref. 144

108 ref. 16

219

112

104

119

160

168

227

126

119

162

165

163

227

164 ref. 161 ti6403a

Sheet 6 of 7

30 311020ZAA

Parts List - LineLazer IV

Models 248862, 248866

Ref.

Part Description Qty.

224052 BRACKET, support gun 1

248157 GUN, flex, basic, includes guard & tip 1

287570 HOLDER ASSEMBLY, gun (items 8a 1

287569

102040 thru 8f)

HOLDER, gun

NUT, lock

15F214 LEVER, actuator

15F209 STUD, pull, trigger

24Y991 KIT, pivot

15F211 STUD, cable

8g 24Y991 KIT, pivot

17* 245733 KIT, trigger handle repair (includes

15F212

15F213

188135

198895

17, 89, 126, 164, 165)

ARM, holder, gun

BRACKET, cable

GUIDE, cable

PLATE, lever, pivot

72 198896 BLOCK, mounting (mach)

89* 15A644 LABEL, trigger

95 15F389 BRACKET, gun arm

104 119647 SCREW, cap, socket, flthd

105 119648 SCREW, mach, trusshd

108 101566 NUT, lock

112 111145 KNOB, pronged

119 111017 BEARING, flange

126* 112381 SCREW, mach, pan hd

136 287566 KIT, clamp (includes 136a)

136a 114028 NUT, wing

153 114982 SCREW, cap, flng hd

160 116941 SCREW, shoulder, socket head

161 287696 CABLE, gun (includes 227)

162 116969 NUT, lock

163 116973 SCREW, #10 taptite phil

164* 117268 BRACKET, interrupter

165* 117269 SPRING

166 287699 SENSOR, trigger

168 117317 SCREW, plastite, pan head

219



15F637 LABEL, GMAX warning skin inject

227 15F624 NUT, cable, gun (knurled)

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

* Parts included in Trigger Kit 245733 (purchase separately).

311020ZAA

Parts List - LineLazer IV

Parts Drawing - LineLazer IV

Parts Drawing - LineLazer IV

Models 248862, 248866

part of 151

15m

15t

15g

150

15r ti6399a

15v

15f

15q

15a

15d

15w

15s

125

123

15z

15n

15i

15b

62 ref. 13

167

64 ref. 34j

217

216 ref.100

ref. 27 ti6399b

215

125

Sheet 7 of 7

32 311020ZAA

Parts List - LineLazer IV

Models 248862, 248866

Ref.

Part Description

2* 245103 VALVE, drain (includes 2a, 2b, 2c,

193709

193710

2d, 38)

SEAT, valve

SEAL, valve

116424 NUT, cap

114708 SPRING

11* 244067 FILTER, fluid

15a 15F272 PLATE, control

15b 287688 KIT, display board

15d 287689 BOARD, control

15f 114954 SWITCH, rocker

15g 116752 SWITCH, rocker

15i 256219 POTENTIOMETER KIT

15m 116719 SCREW, 8-32, hx hd

15n 198650 SPACER, shaft

15o 116167 KNOB, potentiometer

15q 15F543 LABEL, control, top

15r 15F544 LABEL, control, bottom

15s 287692 KIT, control, throttle

15t 119736 CLAMP, cable

15v 15F777 GASKET, control

15V 15F776 GASKET, throttle

15z 109466 NUT, lock, hex

31 15F589 COVER, control

15C766 TUBE, diffusion

15G563 HANDLE

15H561 MANIFOLD, filter, 3/8 npt

287285 KIT, repair, filter cap (includes 37,

167)

196178 ADPATER, nipple

196179 FITTING, elbow, street

196181 FITTING, nipple

15G331 PLUG, pipe

111348

15E910

BUSHING, relief, strain

WIRE, harness

123 15F814 GASKET

125 116719 SCREW, 8-32, hex hd

167

117285 PACKING, o-ring

215 111801 SCREW, cap, hex hd

216

287172 TRANSDUCER, pressure control

217

111457 PACKING, o-ring

Qty.

* Parts included in Kit 288100 (purchase separately).

311020ZAA

Parts List - LineLazer IV

Pressure Control Wiring Diagram

Pressure Control Wiring Diagram

GUN TRIGGER

PICK-UP

Red clip on yellow

Yellow

White/Yellow

ENGINE OFF

SWITCH

POTENTIOMETER

GROUND

DISPLAY BOARD

TO ENGINE

5900

3900/R300

White/Red

Red

TRANSDUCER

DISTANCE

SENSOR

PUMP

ON/OFF

SWITCH

DRIVE

HOUSING

PINON

HOUSING

TO CLUTCH

PUMP

STROKE

COUNTER

JUNCTION

BOX

WHITE

J15

CONTROL BOARD

J16

J11

J12

J4 J3

J1 J2

CLUTCH TEST POINTS

J12

TO ENGINE

GENERATOR

Fig. 21

A2 ti6401a

34 311020ZAA

Technical Data

Technical Data

LineLazer IV 3900, R300, 5900, and FieldLazer R300 Airless Line Stripers

Honda GX120 Engine

Power Rating @3600 rpm

ANSI

DIN 6270B/DIN 6271

Maximum working pressure

Noise Level

4.0 Horsepower

NA...............2.1 Kw - 2.8 Ps

3300 psi

NB.................2.6 Kw - 3.6 Ps

(228 bar, 22.8 MPa)

Sound power

105 dBa per ISO 3744

Sound pressure

96 dBa measured at 3.1 feet (1 m)

Vibration Level*

LineLazer IV 3900/R300

Left hand...........1.81 m/sec

LineLazer IV 5900

Left hand...........2.05 m/sec

* Vibration measured per ISO 5349 based on 8 hour daily exposure

Right hand...........1.45 m/sec

Right hand...........1.70 m/sec

Metric

Maximum Delivery

LineLazer IV 3900/R300

LineLazer IV 5900

Maximum tip size

LineLazer IV 3900/R300

LineLazer IV 5900

Inlet paint strainer

1.15 gpm

1.5 gpm

1 gun with 0.034 in. tip

1 gun with 0.041 in. tip

4.4 liter/min

5.7 liter/min

2 guns with 0.024 in. tip

2 guns with 0.028 in. tip

16 mesh (1190 micron) stainless steel screen reusable

Outlet paint filter

60 mesh (250 micron) stainless steel screen, reusable

Pump inlet size

3/4 in. npt (m)

Fluid outlet size

1/4 npsm from fluid filter

Wetted parts...............nickel-plated carbon steel, PTFE,

Nylon, polyurethane, UHMW polyethylene, fluoroelastomer, acetal, leather, tungsten carbide, stainless steel, chrome plating

311020ZAA 35

Technical Data