Graco 311020L LineLazer IV 3900, 5900 Airless Line Stripers Repair - Parts List Owner's Manual

Repair – Parts List
LineLazer™IV
3900, 5900 Airless Line Stripers
Chinese Patent ZL03802251.6
U.S. Patent 6,913,417
311020L
– For application of line striping materials –
3300 psi (228 bar, 22.8 MPa) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this
manual. Save these instructions.
311017
310643
309741
309055
311049
ti6394b
248862
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Copyright 2005, Graco Inc. is registered to I.S. EN ISO 9001
Table of Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Spray Tip Selection Table . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Repair
Bearing Housing & Connecting Rod . . . . . . . . . . . . 10
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Pinion Assembly/Clutch Armature/Clamp . . . . . . . 12
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Trigger Sensor Adjustment . . . . . . . . . . . . . . . . . . . 18
Distance Sensor Adjustment . . . . . . . . . . . . . . . . . .
Control Board Diagnostics . . . . . . . . . . . . . . . . . . . .
Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . .
Parts
LineLazer IV 3900/5900 . . . . . . . . . . . . . . . . . . . . . .
Drive and Pinion Housing Assemblies . . . . . . . . . .
Pressure Control Wiring Diagram . . . . . . . . . . . . . . . .
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Models
3900
248862
n
n
248863
249008
n
n
n
n
249009
248864
n
n
n
n
248865
n
n
n
n
5900
248866
n
n
248867
249010
248869
2
311020
n
n
n
n
249011
248868
n
n
n
n
n
n
n
n
18
19
20
22
23
34
35
35
35
36
Warnings
The following Warnings are for safe setup, use, grounding, maintenance and repair of this equipment. The exclamation
point symbol alerts you to a general warning and the hazard symbols refer to procedure–specific risks. Refer back to
these Warnings.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire
and explosion:
D Use equipment only in well ventilated area.
D 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.
D Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
D Keep work area free of debris, including solvent, rags and gasoline.
D Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are
present.
D Ground equipment and conductive objects in work area. See Grounding instructions.
D Use only grounded hoses.
D Hold gun firmly to side of grounded pail when triggering into pail.
D If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until
you identify and correct the problem.
D Keep a fire extinguisher in work area.
CARBON MONOXIDE HAZARD
Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon monoxide
can cause death. Do not operate in an enclosed area.
SKIN INJECTION HAZARD
High–pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just a
cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
D Do not point gun at anyone or at any part of the body.
D Do not put your hand over the spray tip.
D Do not stop or deflect leaks with your hand, body, glove, or rag.
D Do not spray without tip guard and trigger guard installed.
D Engage trigger lock when not spraying.
D Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
D Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, checking, or servicing equipment.
D Tighten all fluid connections before operating the equipment.
D Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.
311020
3
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
D Do not exceed the maximum working pressure or temperature rating of the lowest rated system component. See Technical Data in all equipment manuals.
D 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.
D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not alter or modify equipment.
D Use equipment only for its intended purpose. Call your Graco distributor for information.
D Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
D Do not kink or overbend hoses or use hoses to pull equipment
D Keep children and animals away from work area.
D Comply with all applicable safety regulations.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns,
do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
D Keep clear of moving parts.
D Do not operate equipment with protective guards or covers removed.
D Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating area
of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes,
burns, and hearing loss. This equipment includes but is not limited to:
D Protective eyewear.
D Clothing and respirator as recommended by the fluid and solvent manufacturer.
D Gloves.
D Hearing protection.
RECOIL HAZARD
Brace yourself; gun may recoil when triggered and cause you to fall, which could cause serious injury.
4
311020
Tip Selection
in.
(cm)
LL5213*
2 (5)
LL5215*
2 (5)
in.
(cm)
in.
(cm)
in.
(cm)
n
n
n
LL5217
4 (10)
LL5219
4 (10)
LL5315*
4 (10)
n
LL5317
4 (10)
n
LL5319
4 (10)
n
LL5321
4 (10)
n
LL5323
4 (10)
n
LL5325
4 (10)
n
LL5327
4 (10)
n
LL5329
4 (10)
n
LL5331
4 (10)
n
LL5333
4 (10)
n
LL5335
4 (10)
n
LL5355
4 (10)
n
n
LL5417
6 (15)
n
LL5419
6 (15)
n
LL5421
6 (15)
n
LL5423
6 (15)
n
LL5425
6 (15)
n
LL5427
6 (15)
n
LL5429
6 (15)
n
LL5431
6 (15)
n
LL5435
6 (15)
n
LL5621
12 (30)
n
LL5623
12 (30)
n
LL5625
12 (30)
n
LL5627
LL5629
LL5631
LL5635
LL5639
12 (30)
12 (30)
12 (30)
12 (30)
12 (30)
n
n
n
n
n
* Use 100 mesh filter to reduce tip clogs
311020
5
Maintenance
DAILY:
Pressure Relief Procedure
1. Lock gun trigger safety.
2. Turn engine ON/OFF switch to OFF.
3. Move pump switch to OFF and turn pressure
control knob fully counterclockwise.
4. Unlock trigger safety. Hold metal part of gun firmly
to side of grounded metal pail, and trigger gun to
relieve pressure.
5. Lock gun trigger safety.
6. Open pressure drain valve. Leave valve open until
ready to spray again.
If you suspect that the spray tip or hose is completely
clogged, or that pressure has not been fully relieved
after following the steps above, VERY SLOWLY
loosen tip guard retaining nut or hose end coupling to
relieve pressure gradually, then loosen completely.
Now clear tip or hose.
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
CAUTION
D Minimum hose size allowable for proper sprayer
operation is 3/8 in. x 50 ft
D For detailed engine maintenance and specifications, refer to separate Honda Engines Owner’s
Manual, supplied.
DAILY:
Check engine oil level and fill as necessary.
DAILY:
Check hose for wear and damage.
DAILY:
Check gun safety for proper operation.
DAILY:
tion.
Check pressure drain valve for proper opera-
6
311020
(See letter call-outs in Parts drawing on page 28)
1. Once each year, tighten nut (127) under dust cap
(142) until spring washer bottoms out. Then back
off the nut 1/2 to 3/4 turn.
2. Once each year, tighten nut (127) on screw (131)
until it begins to compress spring washer. Then
tighten the nut an additional 1/4 turn.
3. Once each month, grease the wheel bearing (F).
4. Check pin (55) for wear. If pin is worn out, there
will be play in the caster wheel. Reverse or replace the pin as needed.
5. Check caster wheel alignment as necessary.
To align: loosen screw (145), align wheel and
tighten screw.
Troubleshooting
PROBLEM
CAUSE
SOLUTION
E=XX is displayed
Fault condition exists
Determine fault correction from table, page 19.
Engine won’t start
Engine switch is OFF
Turn engine switch ON
Engine is out of gas
Refill gas tank. Honda Engines Owner’s Manual.
Engine oil level is low
Try to start engine. Replenish oil, if necessary.
Honda Engines Owner’s Manual.
Spark plug cable is disconnected or damaged
Connect spark plug cable or replace spark plug
Cold engine
Use choke
Fuel shutoff lever is OFF
Move lever to ON position
Oil is seeping into combustion chamber
Remove spark plug. Pull starter 3 to 4 times.
Clean or replace spark plug. Start engine.
Keep sprayer upright to avoid oil seepage.
Error code displayed?
Reference pressure control repair. Page 17.
Pump switch is OFF
Turn pump switch ON.
Pressure setting is too low
Turn pressure adjusting knob clockwise to
increase pressure.
Fluid filter (11) is dirty
Clean filter. Page 32.
Tip or tip filter is clogged
Clean tip or tip filter. See spray gun manual.
Displacement pump piston rod is stuck due to
dried paint
Repair pump. See pump manual.
Connecting rod is worn or damaged
Replace connecting rod. Page 10.
Drive housing is worn or damaged
Replace drive housing. Page 11.
Electrical power is not energizing clutch field
Check wiring connections. Page 15.
Reference pressure control repair. Page 17.
Reference wiring diagram. Page 34.
Engine operates, but displacement pump does not
operate
With pump switch ON and pressure turned to
MAXIMUM, use a test light to check for power
between clutch test points on control board.
Remove 7–pin connector from control board
and measure resistance across clutch coil. At
70_ F, the resistance must be between 1.2
±0.2Ω (LineLazer IV 3900); 1.7 ±0.2Ω (LineLazer IV 5900); if not, replace pinion housing.
Have pressure control checked by authorized
Graco dealer.
Clutch is worn, damaged, or incorrectly
positioned
Replace clutch. Page 12.
Pinion assembly is worn or damaged
Repair or replace pinion assembly. Page 12.
311020
7
Troubleshooting
PROBLEM
CAUSE
SOLUTION
Pump output is low
Strainer (34f) is clogged
Clean strainer.
Piston ball is not seating
Service piston ball. See pump manual.
Piston packings are worn or damaged
Replace packings. See pump manual.
O-ring in pump is worn or damaged
Replace o-ring. See pump manual.
Intake valve ball is not seating properly
Clean intake valve. See pump manual.
Intake valve ball is packed with material
Clean intake valve. See pump manual.
Engine speed is too low
Increase throttle setting. See operation manual.
Clutch is worn or damaged
Replace clutch. Page 12.
Pressure setting is too low
Increase pressure. See operation manual.
Fluid filter (11), tip filter or tip is clogged or dirty
Clean filter. See operation or spray gun manual.
Large pressure drop in hose with heavy
materials
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).
Throat packing nut is loose
Remove throat packing nut spacer. Tighten
throat packing nut just enough to stop leakage.
Throat packings are worn or damaged
Replace packings. See pump manual.
Displacement rod is worn or damaged
Replace rod. See pump manual.
Air in pump or hose
Check and tighten all fluid connections.
Reprime pump. See operation manual.
Tip is partially clogged
Clear tip. See spray gun manual.
Fluid supply is low or empty
Refill fluid supply. Prime pump. See operation
manual. Check fluid supply often to prevent
running pump dry.
Air in pump or hose
Check and tighten all fluid connections.
Excessive paint leakage into
throat packing nut
Fluid is spitting from gun
Pump is difficult to prime
Reduce engine speed and cycle pump as
slowly as possible during priming.
Intake valve is leaking
Clean intake valve. Be sure ball seat is not
nicked or worn and that ball seats well. Reassemble valve.
Pump packings are worn
Replace pump packings. See pump manual.
Paint is too thick
Thin the paint according to the supplier’s
recommendations
Engine speed is too high
Decrease throttle setting before priming pump.
See operation manual.
Clutch squeaks each time
clutch engages
Clutch surfaces are not matched to each other
when new and may cause noise
Clutch surfaces need to wear into each other.
Noise will dissipate after a day of run time.
High engine speed at no
load
Misadjusted throttle setting
Reset throttle to 3600 engine rpm at no load
Worn engine governor
Replace or service engine governor
8
311020
Troubleshooting
PROBLEM
CAUSE
SOLUTION
Gallon counter not working
Broken or disconnected wire
Check wires and connections. Replace
broken wires.
Bad sensor
Replace sensor
Missing magnet
Reposition or replace magnet.
Bad connection between control board
and display
Remove display and reconnect
Display damaged
Replace display
Trigger sensor not set correctly
See “Spray icon does not show on display when fluid is sprayed”
Bad wiring connections
Check connector, and reconnect
Distance sensor not spaced correctly
from gear
Adjust space between sensor and gear
to .050 –/+ .020 in. See page 18.
Distance sensor and gear not aligned
Remove tire, and press in or pull out
gear to align sensor and gear.
Gear teeth missing or damaged.
Replace distance gear/wheel
Wire cracked or broken
Replace sensor
Distance sensor
See “Distance counter not operating
properly”
Trigger sensor
See “Spray icon does not show on display when fluid is sprayed”
Gallon counter
See “Gallon counter not working”
Bad or damaged control board
Replace control board
Fluid spray starts after spray icon is
shown on display
Interrupter (164) is improperly positioned
Turn screw (126) counterclockwise until
spray icon synchronizes with fluid spray
Fluid spray starts before spray icon is
shown on display
Interrupter (164) is improperly positioned
Turn screw (126) clockwise until spray
icon is synchronized with fluid spray
Spray icon does not show on display
when fluid is sprayed
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
Replace distance sensor harness (66)
Control board is damaged
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)
Sprayer operates, but display does not
Distance counter not operating properly
Mils not calculating
Spray icon is always shown on display
311020
9
Bearing Housing and Connecting Rod
3. Clean mating surfaces of bearing and drive housings.
Removal
1. Relieve pressure, page 6.
2. Fig. 2. Remove screws (187) and front cover (83).
4. Align connecting rod with crank (B) and carefully
align locating pins (F) in drive housing (24) with
holes in bearing housing (22). Push bearing housing onto drive housing or tap into place with plastic
mallet.
3. Unscrew suction tube (34) from pump, hold
wrench on pump intake valve (A) to keep pump
from loosening.
4. Disconnect pump outlet hose (100) from 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
CAUTION
DO NOT use bearing housing screws (183) to align
or seat bearing housing with drive housing. Align
these parts with locating pins (F), to avoid premature bearing wear.
5. Install screws (183) and lockwashers (173) on
bearing housing. Torque evenly to note 3 value in
Fig. 2.
6. Install pump. Refer to Displacement Pump,
Installation, page 20.
B
2
2
D
Fig. 1
83
236
E
236
7675B
ti6395a
6. Fig. 2. Loosen retaining nut (84). Unscrew and
remove displacement pump (21).
3
173
7. Remove four screws (183) and lockwashers (173)
from bearing housing (22).
8. Pull connecting rod (26) and lightly tap lower rear
of bearing housing (22) with plastic mallet to
loosen from drive housing (24). Pull bearing housing and connecting rod assembly (26) off drive
housing.
26
C
F
24
22
1
34g
183
3
187
84
235
21
9. Inspect crank (B) for excessive wear and replace
parts as needed.
A
60
100
34
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).
10
311020
1
Oil
2
Pack with bearing grease 114819
LineLazer IV 3900: Torque to 200 in-lb (22.6 Nm)
LineLazer IV 5900: Torque to 25 ft-lb (34 Nm)
Model 248862 shown
Fig. 2
3
Drive Housing
Installation
Removal
1. Liberally apply bearing grease (supplied with
replacement gear cluster) to gear cluster (23) and
to areas called out by note 2.
1. Relieve pressure, page 6.
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).
2. Fig. 3. Remove bearing housing. Do Bearing
Housing and Connecting Rod procedure on
page 10.
3. Remove two screws (158) and reed switch (182).
3. Install six screws (189). Torque evenly to note 1
value in Fig. 3.
4. Remove six screws (189) from pinion housing (25).
4. Install reed switch (182) with two screws (158).
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.
5. Install bearing housing. Do steps 1. through 6. of
Bearing Housing and Connecting Rod procedure on page 10.
ti6396a
A
25
24h
24g
173
1
189
189
2
178
178
182
1
A
23
179
158
2
24
181
Fig. 3
1
2
LineLazer IV 3900: Torque to 200 in-lb (22.6 Nm)
LineLazer IV 5900: Torque to 25 ft-lb (34 Nm)
Apply remaining grease to these areas
311020
11
Pinion Assembly/Clutch Armature/Clamp
Pinion Assembly/Clutch Armature Removal
Pinion Assembly
If pinion assembly (25) is not removed from clutch
housing (85), do 1. through 3. Otherwise, start at 4.
E
175
172
E
ti5987c
ti5481b
1. Remove drive housing, page 11.
Fig. 5
2. Fig. 12. Remove clip (251) and junction box (226).
3. Fig. 11. Disconnect pump stroke sensor and clutch
cables.
7. Fig. 6. Remove retaining ring (25e).
8. Tap pinion shaft (25d) out with plastic mallet.
86
4. Fig. 4. Remove four screws (189) and lockwashers (188) and pinion assembly (25).
25e
25d
189
188
25c
25
ti5482b
8703A
Fig. 6
189
188
ti5480b
Fig. 4
Clutch Armature
9. Fig.7. Use an impact wrench or wedge something
between armature (87) and clutch housing to hold
engine shaft during removal.
10. Remove four screws (175) and lockwashers (172).
5. Fig. 5. Place pinion assembly (25) on bench with
rotor side up.
11. Remove armature (87).
87
6. Remove four screws (170) and lockwashers (172).
Install two screws in threaded holes (E) in rotor.
Alternately tighten screws until rotor comes off.
175
Fig. 7
12
311020
172
8704A
Installation
Clutch Armature
Pinion Assembly
1. Fig. 8. Lay two stacks of two dimes on smooth
bench surface.
6. Fig. 6. Check o–ring (25c) and replace if missing
or damaged.
2. Lay armature (87) on two stacks of dimes.
7. Tap pinion shaft (25d) in with plastic mallet.
3. Press center of clutch down on bench surface.
8. Install retaining ring (25e) with beveled side
facing up.
87
9. Fig. 5. Place pinion assembly on bench with rotor
side up.
0.12 ±.01 in. (3.0 ±.25 mm)
10. Apply locktite to screws. Install four screws (170)
and lockwashers (172). Alternately torque screws
to 125 in-lb until rotor is secure. Use threaded
holes to hold rotor.
dimes
Fig. 8
8705A
4. Install armature (87) on engine drive shaft.
5. Install four screws (175) and lockwashers (172)
with torque of 125 in-lb.
11. Fig. 4. Install pinion assembly (25) with five screws
(189) and lockwashers (188).
12. Fig. 11. Connect pump stroke sensor and clutch
cables.
13. Fig. 12. Install junction box (226) with clip (251).
Clamp
Removal
1. Do Engine Removal.
1
Face of clutch housing
2
2.55 ±.010 in. (39.37 ±.25 mm); LineLazer lV 3900
2.61 ±.010 in. (66.29 ±.25 mm); LineLazer lV 5900
3
Torque to 125 ±.10 in-lb (14 ±1.1 Nm)
4
Chamfer this side
2. Drain gasoline from tank according to Honda
manual.
1
85
3. Tip engine on side so gas tank is down and air
cleaner is up.
2
4. Fig. 9. Loosen two screws (175) on clamp (82),
82
5. Push screwdriver into slot in clamp (82) and remove clamp.
88
B
Installation
4
1. Fig. 9. Install engine shaft key (88).
2. Tap clamp (82) on engine shaft (A) with plastic
mallet. Maintain dimension shown note 2. Chamfer
must face engine.
3. Check dimension: Place rigid, straight steel bar (B)
across face of clutch housing (5). Use accurate
measuring device to measure distance between bar
and face of clamp. Adjust clamp as necessary.
Torque two screws (175) to 125 ±10 in-lb (14 ±1.1
Nm).
175
Fig. 9
A
3
ti5484b
311020
13
Clutch Housing
Removal
1. Fig. 10. Remove four cap screws (186) and lock
washers (188) which hold clutch housing (85) to
engine.
85
88
2. Remove screw (177) from under mounting
plate (96).
3. Pull off clutch housing (85).
188
Installation
186
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 NSm).
ti6643a
96
177
Fig. 10
3. Install capscrew (177) from beneath mounting
plate (96). Torque to 26 ft-lb (35.2 NSm).
14
311020
Engine
Removal
1. Remove Pinion Assembly/Clutch Armature/
Clamp and Clutch Housing. See pages 10 – 14.
185
Engine
2. Fig. 12. Remove clip (251) and junction box (226).
3. Fig. 11. Disconnect all necessary wiring.
223
4. Fig. 12. Remove screw (177). Remove two
screws (117), locknuts (118), and ground conductor (230, 260) from base of engine (185).
117
5. Lift engine carefully and place on work bench.
Ref.118
NOTE: All service to the engine must be performed by
an authorized HONDA dealer.
ti6398a
Main Control Box Cable
118
ÍÍ
ÍÍ
Bottom View
Wheel Sensor Cable
To Engine
177
251
ti6536a
226
ÍÍÍÍÍ
ÍÍÍÍÍ
ÍÍÍÍÍ
Fig. 12
ti6397a
Installation
1. Lift engine carefully and place on cart.
Clutch
Distance
Sensor
ËËËË
ËËËË
To Main
Control
Box
Fig. 11
Pump Stroke
Counter
Junction
Box
To
Engine
2. Fig. 12. Install two screws (117) and ground conductor (223, 260) in base of engine and secure
with locknuts (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 10 – 14.
311020
15
Pressure Control
On/Off Switch
Installation
Removal
1. Install ON/OFF switch (15g) so tabs of switch snap
into place on inside of pressure control housing.
1. Relieve pressure, page 6.
2. Connect ON/OFF switch connector (B) to PC
board.
2. Fig. 13. Remove two screws (125) and cover (31).
3. Push display connector into PC board close display connector wings (A) on PC board.
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.
4. Install cover (31) with two screws (125).
5. Press in on two retaining tabs on each side of
ON/OFF switch (15g) and remove switch.
15g
15n
15i
15o
15r
B
A
C
GROUND
ti6408a
15d
15j
D
31
ENGINE
Main Control
Box Cable
125
Transducer
216
217
Fig. 13
16
311020
Pressure Control
Control Board
Installation
Removal
1. Fig. 13. Install control board (15d) with four
screws (15j).
1. Relieve pressure, page 6.
2. Fig. 13. Remove two screws (125) and
control cover (31). Pull display connector wings
open on PC board and pull display connector out.
3. Figs. 13 and 21. Note on a paper lead connections
to the control board. Disconnect leads from control
board (15d).
4. Fig. 13. Remove four screws (15j) from control
board (15d).
2. Figs. 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
4. Remove pressure control transducer (216) and
o-ring (217) from filter manifold (40).
1. Relieve pressure, page 6.
2. Fig. 13. Remove two screws (125) and
control cover (31).
3. Disconnect transducer lead (C) from control
board (15d).
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 6.
2. Fig. 13. Remove two screws (125) and
control cover (31).
3. Disconnect lead (D) from control board (15d).
Installation
1. Install seal (15n) on potentiometer (15i).
2. Fig. 13. Install pressure adjust potentiometer (15i),
shaft nut, lockwasher and potentiometer
knob (15o).
a. Turn potentiometer shaft (15i) clockwise to
internal stop. Assemble potentiometer knob
(15o) to strike pin on plate (15r).
b. After adjustment of step a., tighten both set
screws in knob 1/4 to 3/8 turn after contact
with shaft.
4. Loosen set screws on potentiometer knob (15o)
and remove knob, shaft nut, lockwasher and
pressure adjust potentiometer (15i).
3. Connect lead (D) to control board (15d).
5. Remove seal (15n) from potentiometer (15i).
4. Install control cover (31) with two screws (125).
311020
17
Trigger Sensor Adjustment
Refer to Troubleshooting for trigger sensor adjustment, and see operation manual.
Distance Sensor Adjustment
Gear Alignment
5. Install wheel (120) on LineLazer.
6. Install nut (127) until tight, then back off 1/4 turn.
Install dust cap (142) on wheel.
Sensor Height Adjustment
1. Relieve pressure, page 6.
1. Remove wheel (120) from LineLazer.
2. Fig. 14. Remove dust cap (142) from wheel.
Remove nut (127).
2. Remove distance sensor (66).
3. Remove wheel (120) from LineLazer.
a. Pull gear out from wheel with gear puller.
3. 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.
b. Push gear in toward wheel with mallet.
4. Reassemble distance sensor (66) and wheel (82).
4. Align gear (67) with sensor.
66
Frame
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
Distance
Sensor (66)
.638 in.
127
142
Inside of tire
120
Axle
Gear (67)
ti6400a
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
ÇÇ
Gear (67)
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Ç
Distance Sensor Detail
Fig. 14
18
311020
Tire
(120)
Control Board Diagnostics
Digital Display Messages
Relieve pressure before repair; page 6. No display does not mean that sprayer is not pressurized.
DISPLAY
No Display
psi
bar
MPa
SPRAYER
OPERATION
INDICATION
ACTION
Sprayer may be pressurized.
Loss of power or display
not connected
Check power source. Relieve
pressure before repair or disassembly. Verify display is connected.
Sprayer may be pressurized.
Pressure less than
200 psi (14 bar, 1.4
MPa)
Increase pressure as needed
Sprayer is pressurized. Power is applied. (Pressure varies with tip size
and pressure control setting.)
Normal operation
Spray
Sprayer stops. Engine is running.
Exceeded pressure limit
Remove any filter clogs or flow
obstructions. Make sure gun trigger is locked open if using AutoClean valve.
Sprayer stops. Engine is running.
Pressure transducer
faulty, bad connection or
broken wire.
Check transducer connections
and wire. Replace transducer or
control board, if necessary.
Sprayer stops. Engine is running.
High clutch current
1. Check clutch 7–pin bulkhead
connector. Clean contacts.
2. Measure 1.2 ±0.2Ω
(LineLazer IV 3900);
1.7 ±0.2Ω (LineLazer IV
5900) across clutch field at
70_F
3. Replace clutch field assembly
After a fault, follow these steps to restart sprayer:
1. Correct fault condition
2. Turn sprayer OFF
3. Turn sprayer ON
311020
19
Displacement Pump
Removal
1. Flush pump.
5. Fig. 16. Use screwdriver: push retaining spring up
and push out pin (235).
235
2. Relieve pressure, page 6.
3. Fig. 15. Cycle pump piston rod (A) to lowest position.
4. Fig. 15. Remove suction tube (34) and hose (100).
Fig. 16
7675B
6. Fig. 17. Loosen locknut by hitting firmly with a
20 oz (maximum) hammer. Unscrew pump.
A
100
34
7672C
Fig. 15
Fig. 17
7673B
Repair
See manual 310643 for pump repair instructions.
Installation
2. Fig. 16. Push pin (235) into hole. Push retaining
spring into groove around connecting rod.
WARNING
If pin works loose, parts could break off due to
force of pumping action. Parts could project
through the air and result in serious injury or property damage. Make sure pin and retaining spring
are properly installed.
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 approximately 75" 5 ft–lb (102 Nm).
CAUTION
If the pump locknut loosens during operation, the
threads of the bearing housing will be damaged.
Make sure locknut is properly tightened.
1. Fig. 18. Pull piston rod out 1.5 in. Screw in pump
until holes in bearing cross link and piston rod
align.
Fig. 19
7673B
Fig. 20. Fill packing nut with Graco TSL until fluid flows
onto the top of seal.
1.5 in.
Fig. 18
20
311020
7676B
Fig. 20
7677B
Notes
311020
21
Parts – LineLazer IV
Parts Page 32
Parts Page 26
Parts Page 30
Parts Page 28
Parts Page 24
ti6391b
Parts Page 30
Sheet 1 of 7
22
311020
ti6491b
Parts – Drive and Pinion Housing Assemblies
Ref No. 24 and 25
Ref No. 24: Drive Housing Assembly 287467 for
LineLazer IV 3900; Drive Housing Assembly
287469 for LineLazer IV 5900
Ref
No.
24
Ref No. 25: Pinion Housing Assembly 287463 for
LineLazer IV 3900; Pinion Housing Assembly 287465
for LineLazer IV 5900
Ref
No.
Part No.
Description
287467
287469
HOUSING, drive (3900)
HOUSING, drive (5900)
WASHER
LineLazer IV 3900
LineLazer IV 5900
WASHER
LineLazer IV 3900
LineLazer IV 5900
24g
107089
194173
24h
116191
116192
Part No.
Description
Qty
Qty
1
1
1
1
1
1
25
287463
287465
HOUSING, pinion (3900)
HOUSING, pinion (5900)
25a
KIT, repair, coil
287474
LineLazer IV 3900
287476
LineLazer IV 5900
25b
105489
PIN
25d*
PINION SHAFT
241110
LineLazer IV 3900
241114
LineLazer IV 5900
25e*
RETAINING RING, large
113094
LineLazer IV 3900
112770
LineLazer IV 5900
158
114528
SCREW, machine
181
116618
MAGNET
182
119562
SWITCH, reed w/connector
*Must be ordered separately.
1
1
1
1
2
1
1
1
1
2
1
1
Ref. 170
25e
25a
25d
25b
Ref. 212
Ref. 172
24
24h
Ref. 86
24g
Ref 189
ti6407b
1
Ref. 179
Ref 190
Ref. 189
Ref. 23
Ref. 178
158
181
182
1
Pinion housing assembly (25) includes clutch field and connector
Sheet 2 of 7
311020
23
Parts – LineLazer IV
33
57
144
141
264
35
91
27
154
177
233
129
107
5
177
ti7495a
232
177
93
220
134
94
112
177
153
148
58
108
153
74
73
108
28
117
129
115
70
13
121
60
14
66
115
157
68
120
67
117
108
117
122
Sheet 3 of 7
24
311020
121
51
127
142
115
16
Parts – LineLazer IV
Ref.
No.
Part No.
Description
5
237686
WIRE, ground assembly
w/ clamp
HOSE, 3/8 X 50 ft
HOSE, 1/4 X 7 ft
FRAME, linestriper (painted)
HANDLE
SUPPORT, handle (painted)
KIT, pail cover, includes 35
KIT, Euro pail cover, no 35
STRAP, cover
AXLE
LEVER, actuator
SPACER, ball, guide
ADAPTER, nipple
KIT, sensor, distance,
includes 68,115, 129, 157
GEAR, distance, includes 120
SHIELD, sensor, distance
BRACKET, mounting
ROD, brake
BEARING
KIT, label, blank
BRACE, left (painted)
BRACE, right (painted)
CLIP
13
14
16
27
28
33
35
51
57
58
60
66
245225
245798
287623
287417
287622
287590
240926
119771
193405
194310
195134
196176
287698
67
68
70
73
74
91
93
94
107
245734
198612
198891
198930
198931
189919
15F577
15F576
178342
Qty.
1
1
2
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
2
1
1
2
Ref.
No.
Part No.
Description
108
112
115
117
120
121
122
127
129
134
141
142
144
148
153
154
157
158
177
181
182
220Y
232
233
264
101566
111145
108868
110837
255162
111040
111194
112405
112798
113961
241445
114648
114659
114808
114982
115077
116287
114528
112395
116618
119562
15F638
15F545
194312
120151
NUT, lock
KNOB, pronged
CLAMP, wire
SCREW, flange, hex
WHEEL, pneumatic
NUT, lock, insert, nylock, 5/16
SCREW, cap flang hd
NUT, lock
SCREW, thread forming, hex hd
SCREW, cap, hex hd
CABLE, caster
CAP, dust
GRIP, handle
CAP, vinyl
SCREW, cap, flng hd
PAIL, plastic
WASHER, sst, external
SCREW, mach, phillips, pnhd
SCREW, cap, flnghd
MAGNET
SWITCH, reed, with connector
LABEL, GMAX warning fire& skn
LABEL, brand, handle
PLATE, pail, Euro pail only
PLUG, tube
8
1
3
3
2
3
2
2
2
1
1
2
2
1
4
1
1
2
6
1
1
1
1
1
2
311020
25
Qty.
Parts – LineLazer IV
Models 248862 and 248866
86
247
172
170
25
23
Ref 24
(page 23)
234
189
189
83
190
185
182
158
233
88
212
26
187
173
183
178
181
85
186
175
235
259
236
179
175
22
169
171
188
ti6405C
172
117
81
172
84
258
21
82
117
87
249
100
248 96
60
108
114
34 (Detail E)
59
260
34g
223
34m
177
34n
34a
118
226
174
34d
34h
34b
34k
34e
Ref. 16
(page 24)
34f
34j
34d
34c
Detail E (12)
26
311020
Sheet 4 of 7
Parts – LineLazer IV
Ref.
No.
21
22
23
26‡
34
34a
34b
34c
34d
34e
34f
34g
34h
34j
34k
34m
34nY
59
60
81†
82
83
84
85
Part No.
Description
277069
277070
287714
287715
287653
287460
287719
287720
245730
PUMP, displacement (3900)
PUMP, displacement (5900)
HOUSING, bearing (3900)
HOUSING, bearing (5900)
GEAR, combination (3900)
GEAR, combination (5900)
ROD, connecting (3900)
ROD, connecting (5900)
HOSE ASSEMBLY, drain
(items 34a thru 34n)
TUBE, suction
HOSE
SWIVEL, 180_
CLAMP, hose
GASKET, pail
STRAINER
TUBE, drain (includes diffuser)
DIFFUSER
HOSE, coupled, 1/4 in. x 7 ft
STRAP, tie
BUSHING
LABEL, warning
DAMPENER, engine mount
ADAPTER, nipple
HUB, armature
COLLAR, shaft
COVER, front (3900)
COVER, front (5900)
NUT, retaining (3900)
NUT, retaining (5900)
HOUSING, clutch (3900)
HOUSING, clutch (5900)
ROTOR, clutch, 4 in. (3900)
ROTOR, clutch, 5 in. (5900)
ARMATURE, clutch, 4 in. (3900)
ARMATURE, clutch, 5 in. (5900)
KEY, parallel
PLATE, engine mount
HOSE, 3/8 in. x 3.0 ft
NUT, lock
WASHER, plain
SCREW, flange, hex
NUT, lock
170957
185381
110194
101818
15F513
181072
245731
245798
114958
196180
195119
119695
196176
193680
287521
287511
192723
193031
15E535
15E277
86†
87†
88
96
100
108
114
117
118
183401
15F583
245797
101566
108851
110837
110838
Qty.
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
4
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
8
2
2
Ref.
No.
169
Part No.
Description
Qty.
119426
102962
101682
104008
105510
SCREW, hex washr hd (3900)
4
SCREW, cap sch (5900)
4
170†
SCREW, cap, sch
4
171
WASHER, lock, spring (5900)
4
172†
WASHER, lock, spr (hi–collar)
10
173
WASHER, lock, spr (hi–collar)
100214
(3900)
4
106115
(5900)
4
174
113743
SCREW, cap, hex hd
4
175† 108803
SCREW, hex, socket head
6
177
112395
SCREW, cap, flnghd
1
178
114672
WASHER, thrust
1
179
114699
WASHER, thrust
1
183
113467
SCREW, cap, soc hd (3900)
4
114666
SCREW, cap, soc hd (5900)
4
185
108879
ENGINE, gas, 4.0 hp (3900)
1
114530
ENGINE, gas, 5.5 hp (5900)
1
186
108842
SCREW, cap, hex hd
4
187
118444
SCREW, machine hex washer hd
4
188
100214
WASHER, lock
4
189
119426
SCREW, mach, hex washr hd (3900) 8
15C753
SCREW, mach, hex washr hd (5900) 6
190
15F947
SHIELD, magnetic
1
212
15F250
WASHER, thrust (3900)
1
114672
WASHER, thrust (5900)
1
223
119579
CONDUCTOR, ground (3900)
1
240997
CONDUCTOR, ground (5900)
1
226
287695
BOX
1
233
15F546
LABEL, brand (3900)
1
15F547
LABEL, brand (5900)
1
234Y 194126
LABEL, warning
1
235
PIN, pump
15F855
(3900)
1
15F856
(5900)
1
236‡ 119676
SPRING, retaining (3900)
1
119778
SPRING, retaining (5900)
1
247
290228
LABEL, caution
1
248
114629
GROMMET
1
249
119569
BUSHING
1
258
15C762
SHIELD, pump rod
1
259
110996
NUT, hex
2
260
240997
CONDUCTOR, ground (5900)
1
Y Replacement warning labels may be ordered free of charge
† Included in Clutch Repair Kits 241109 (3900) and 241113
(5900)
‡ Included in Connecting Rod Kits
311020
27
Parts – LineLazer IV
Models 248862 and 248866
Ref. 141
(page 24)
117
56
142
127
1 130
133
7
146
121
113
153
10
54
128
Ref. 16
(page 24)
Ref. 141
108
133
106
127
132
147
46
116
55
52
139
208
130 1
110
Ref. 6
209
65
(Detail D)
6
F
135
140
145
Detail D
ti6404b
131
1
Install washers (130) concave surface to inside.
Sheet 5 of 7
28
311020
Parts – LineLazer IV
Ref.
No.
Part No.
Description
6
7
10*
46
52
54
55
56
65
106
108
110
113
116
117
121
127
240942
240991
15G952
181818
193528
193661
193662
15F910
198606
100731
101566
15J603
108483
110754
110837
111040
112405
SHAFT, fork
BRACKET, caster, front
BRACKET
KNOB, pronged
ARM, detent
JAW,
STOP, wedge
BRACKET, cable
DISK, adjuster
WASHER,
NUT, lock
WASHER, plain
SCREW, shoulder, sch
SCREW, cap, sch
SCREW, flange, hex
NUT, lock, insert, nylock, 5/16
NUT, lock
Qty.
1
1
1
1
1
1
1
1
1
2
2
1
1
2
2
2
2
Ref.
No.
Part No.
Description
128
130
131
132*
133*
135
139
140
142
145
146
147
153
208
209*
112776
112825
113471
113484
113485
113962
114548
114549
114648
114681
114682
114802
114982
193658
120476
WASHER, plain
SPRING, belleville
SCREW, cap, hex hd
SEAL, grease
BEARING, cup/cone
WASHER, hardened, SAE
BEARING, bronze
WHEEL, pneumatic
CAP, dust
SCREW, cap, hex hd
SPRING, compression
STOP, wire
SCREW, cap, flng hd
SPACER, seal
BOLT
Qty.
1
3
1
1
2
1
2
1
1
1
1
1
2
2
1
* Included in 240940 Bracket Repair Kit; purchase separately
311020
29
Parts – LineLazer IV
Models 248862 and 248866
153,108
Ref. 16
(page 24)
Ref. 161
49
136
219
136a
ti6403a
95
44
8b
104
112
1
8f
161
105
ti6403a
8c
8d
8e
47
Ref. 14
8a
8b
4
160
119
71
Ref. 144
(page 24)
72
168
227
Ref. 161
119
162
89
166
163
126
71
165
164
17
Sheet 6 of 7
30
311020
Parts – LineLazer IV
Ref.
No.
Part No.
Description
1
4
8
224052
248157
287570
8a
8b
8c
8d
8e
8f
17*
287569
102040
15F214
15F209
15F210
15F211
245733
44
47
49
71
72
89*
95
104
15F212
15F213
188135
198895
198896
15A644
15F389
119647
BRACKET, support gun
GUN, flex, basic, includes guard & tip
HOLDER ASSEMBLY, gun
(items 8a thru 8f)
HOLDER, GUN
NUT, lock
LEVER, actuator
STUD, pull, trigger
STUD, pivot
STUD, cable
KIT, trigger handle repair
(includes items 17, 89, 126, 164 and
165)
ARM, holder, gun
BRACKET, cable
GUIDE, cable
PLATE, lever, pivot
BLOCK, mounting (mach)
LABEL, trigger
BRACKET, gun arm
SCREW, cap, socket, flthd
Qty.
1
1
1
1
4
1
1
1
1
1
1
1
1
2
1
1
1
2
Ref.
No.
Part No.
Description
105
108
112
119
126*
136
136a
153
160
161
162
163
164*
165*
166
168
219Y
227
119648
101566
111145
111017
112381
287566
114028
114982
116941
287696
116969
116973
117268
117269
287699
117317
15F637
15F624
SCREW, mach, trusshd
NUT, lock
KNOB, pronged
BEARING, flange
SCREW, mach, pan hd
KIT, clamp, includes 136a
NUT, wing
SCREW, cap, flng hd
SCREW, shoulder, socket head
CABLE, gun, includes 227
NUT, lock
SCREW, #10 taptite phil
BRACKET, interrupter
SPRING
SENSOR, trigger
SCREW, plastite, pan head
LABEL, GMAX warning skn injct
NUT, cable, gun (knurled)
Qty.
1
2
1
2
1
1
1
2
1
1
1
1
1
1
1
2
1
2
* Included in Trigger Repair Kit 245733
311020
31
Parts – LineLazer IV
Models 248862 and 248866
15g
15o
15m
part of 15i
15b
15t
15p
15r
15e
15n
15i
ti6399a
15h
15a
15q
15f
15u
15w
15v
15z
15d
125
15s
123
41
ti6399b
167
37
215
11
63
Ref.27
62
Ref. 13
92
76
216
97
217
40
2
3
62
39
64
38
Ref. 14
32
311020
Ref. 100
Sheet 7 of 7
31
125
Parts – LineLazer IV
Ref.
No.
Part No.
Description
2*
3*
11
15a
15b
15d
15e
15f
15g
15h
15i
15m
15n
15o
15p
15q
15r
15s
15t
15u
15v
15w
239914
224807
244067
15F272
287688
287689
287690
114954
116752
119541
241443
116719
198650
116167
195428
15F543
15F544
287692
119736
119737
15F777
15F776
VALVE, drain
BASE, valve
FILTER, fluid
PLATE, control
KIT, display board
BOARD, control
BOARD, light
SWITCH, rocker
SWITCH, rocker
SWITCH, toggle
POTENTIOMETER KIT
SCREW, 8–32, hx hd
SPACER, shaft
KNOB, potentiometer
BOOT, toggle
LABEL, control, top
LABEL, control, bottom
KIT, control, throttle
CLAMP, cable
PLUG
GASKET, control
GASKET, throttle
Qty.
1
1
1
1
1
1
1
1
1
1
1
3
1
1
1
1
1
1
1
1
1
1
Ref.
No.
Part No.
Description
15z
31
37*
38*
39*
40*
41*
62*
63*
64
76
92
97
123
125
167*
215
216*
217*
109466
15F589
15C766
15C780
15C972
15H561
287285
196178
196179
196181
104813
115642
15E910
15F814
116719
117285
111801
287172
111457
NUT, lock, hex
COVER, control
TUBE, diffusion
HANDLE,
PIN, grooved
MANIFOLD, filter, 3/8 npt
KIT, repair, filter cap, includes 37, 167
ADAPTER, nipple
FITTING, elbow, street
FITTING, nipple
PLUG, pipe
BUSHING, relief, strain
WIRE, harness
GASKET
SCREW, 8–32, hex washer hd
PACKING, o–ring
SCREW, cap, hex hd
TRANSDUCER, pressure control
PACKING, o–ring
Qty.
2
1
1
1
1
1
1
2
1
1
1
1
1
2
5
1
2
1
1
Y Replacement warning labels may be ordered free of charge
* Included in Filter Repair Kit 288100
311020
33
Pressure Control Wiring Diagram
Red clip on yellow
Yellow
TO ENGINE
White/Yellow
A4
5900
A3
GROUND
3900
GROUND
ENGINE OFF
SWITCH
GUN TRIGGER
PICK–UP
A2
White/Red
Red
DISPLAY BOARD
A1
POTENTIOMETER
TRANSDUCER
LIGHT
BOARD
LIGHT
SWITCH
DISTANCE
SENSOR
PUMP
ON/OFF
SWITCH
ti6401a
PUMP
STROKE
COUNTER
J15
J9
J4 J3
J5
CONTROL BOARD
J16
J11
A8
DRIVE
HOUSING
J12
A7
PINON
HOUSING
TO ENGINE
GENERATOR
A6
WHITE
A5
JUNCTION
BOX
TO CLUTCH
J1 J2
KIT
LIGHT
LED
CLUTCH TEST POINTS
A8
J12
97
A7
A4
A3
A1
A2
A6
Fig. 21
34
311020
A5
Technical Data
Honda GX120 Engine
Power Rating @ 3600 rpm
ANSI . . . . . . . . . . . . . . . . . . . . . . . 4.0 Horsepower
DIN 6270B/DIN 6271
NA . . . . . . . . . . . . . . . . . . . . . . 2.1 Kw – 2.8 Ps
NB . . . . . . . . . . . . . . . . . . . . . . 2.6 Kw – 3.6 Ps
Honda GX160 Engine
Power Rating @ 3600 rpm
ANSI . . . . . . . . . . . . . . . . . . . . . . . 5.5 Horsepower
DIN 6270B/DIN 6271
NA . . . . . . . . . . . . . . . . . . . . . . 2.9 Kw – 4.0 Ps
NB . . . . . . . . . . . . . . . . . . . . . . 3.6 Kw – 4.9 Ps
Maximum working pressure . . . . . . . . . . . . . . . 3300 psi
(228 bar, 22.8 MPa)
Noise Level
Sound power . . . . . . . . . . . . . . . . . . . . . . . . . 105 dBa
per ISO 3744
Sound pressure . . . . . . . . . . . . . . . . . . . . . . . . 96 dBa
measured at 3.1 feet (1 m)
*Vibration Level
LineLazer lV 3900
Left hand . . . . . . . . . . . . . . . . . . . . . . . . 1.81 m/sec2
Right hand . . . . . . . . . . . . . . . . . . . . . . . . 1.45 m/sec2
LineLazer lV 5900
Left hand . . . . . . . . . . . . . . . . . . . . . . . . 2.05 m/sec2
Right hand . . . . . . . . . . . . . . . . . . . . . . . . 1.70 m/sec2
* Vibration measured per ISO 5349 based on 8 hour daily
exposure
Maximum delivery
LineLazer IV 3900 . . . . . . . 1.15 gpm (4.4 liter/min)
LineLazer IV 5900 . . . . . . . . . 1.5 gpm (5.7 liter/min)
Maximum tip size
LineLazer IV 3900 . . . . . . . 1 gun with 0. 034 in. tip
2 guns with 0.024 in. tip
LineLazer IV 5900 . . . . . . . 1 gun with 0. 041 in. tip
2 guns with 0.028 in. 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 in. npt (m)
Fluid outlet size . . . . . . . . . . . . 1/4 npsm from fluid filter
Wetted parts . . . . . . . . . . . . . nickel-plated carbon steel,
PTFE, Nylon, polyurethane, UHMW polyethylene,
fluoroelastomer, acetal, leather, tungsten carbide,
stainless steel, chrome plating
Dimensions
LineLazer IV 3900
Model 248862, 249008 Striper
Model 248864 Striper with Bead
Weight (dry, without packaging) . . . . . . . 212 lb (96 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 40 in. (101.6 cm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. (165.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 in. (81.3 cm)
Model 248863, 249009 Striper with 2nd Gun Kit
Weight (dry, without packaging) . . . . . . . 212 lb (96 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 40 in. (101.6 cm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. (165.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 in. (81.3 cm)
Model 248865 Striper 2nd Gun Kit with Bead
Weight (dry, without packaging) . . . . . . 222 lb (101 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 40 in. (101.6 cm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. (165.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 in. (81.3 cm)
Weight (dry, without packaging) . . . . . . 222 lb (101 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 40 in. (101.6 cm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. (165.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 in. (81.3 cm)
LineLazer IV 5900
Model 248866, 249010 Striper
Model 248868 Striper with Bead
Weight (dry, without packaging) . . . . . . 232 lb (105 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 40 in. (101.6 cm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. (165.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 in. (81.3 cm)
Model 248867, 249011 Striper with 2nd Gun Kit
Weight (dry, without packaging) . . . . . . 232 lb (105 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 40 in. (101.6 cm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. (165.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 in. (81.3 cm)
Model 248869 Striper 2nd Gun Kit with Bead
Weight (dry, without packaging) . . . . . . 242 lb (110 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 40 in. (101.6 cm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. (165.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 in. (81.3 cm)
Weight (dry, without packaging) . . . . . . 242 lb (110 kg)
Height . . . . . . . . . . . . . . . . . . . . . . . . . . 40 in. (101.6 cm)
Length . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. (165.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 in. (81.3 cm)
311020
35
Graco Standard Warranty
Graco warrants all equipment manufactured by Graco and bearing its name to be free from defects in material and workmanship on the
date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco,
Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be
defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written
recommendations.
This warranty does not cover, and Graco shall not be liable for general wear and tear, or any malfunction, damage or wear caused by
faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–Graco component parts. Nor shall Graco be liable for malfunction, damage or wear caused by the incompatibility of
Graco equipment with structures, accessories, equipment or materials not supplied by Graco, or the improper design, manufacture,
installation, operation or maintenance of structures, accessories, equipment or materials not supplied by Graco.
This warranty is conditioned upon the prepaid return of the equipment claimed to be 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.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT
NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other
remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any
other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the
date of sale.
Graco makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose in connection
with accessories, equipment, materials or components sold but not manufactured by Graco. These items sold, but not manufactured
by Graco (such as electric motors, switches, hose, etc.), are subject to the warranty, if any, of their manufacturer. Graco will provide
purchaser with reasonable assistance in making any claim for breach of these warranties.
In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment
hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract,
breach of warranty, the negligence of Graco, or otherwise.
FOR GRACO CANADA CUSTOMERS
The parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings
entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procedures concernées.
ADDITIONAL WARRANTY COVERAGE
Graco does provide extended warranty and wear warranty for products described in the “Graco Contractor Equipment Warranty
Program”.
Graco Information
TO PLACE AN ORDER, contact your Graco distrubutor, or call 1–800–690–2894 to identify the nearest distributor.
All written and visual data contained in this document reflects the latest product information available at the time of publication.
Graco reserves the right to make changes at any time without notice.
This manual contains English. GN 311020 MM 311020
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
www.graco.com
3/2005, Rev 10/2007
36
311020

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