Repair – Parts List

LineLazer

t

IV 200

HS

Airless Paint Striper

U.S. Patent Number 6,913,417

311021G

– For the application of line striping materials –

3300 psi (228 bar, 22.8 MPa) Maximum Working Pressure

248870

248871

249012

249013

248872

248873 n n n n n n n n n n n n n n n

311018

309277

309741

309055

311049

Important Safety Instructions

Read all warnings and instructions in this manual. Save these instructions.

ti6502b

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

Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spray Tip Selection Table . . . . . . . . . . . . . . . . . . . . . . . .

General Repair Information . . . . . . . . . . . . . . . . . . . . . .

Maintenance

Troubleshooting

Repair

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Digital Tracking System

PC Board Diagnostics

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . .

12

14

7

8

3

5

6

Trigger Sensor Adjustment

Distance Sensor Adjustment

. . . . . . . . . . . . . . . . . . . 15

. . . . . . . . . . . . . . . . . . 15

Hydraulic Pump

Fan Belt

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

18

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic Motor Yoke . . . . . . . . . . . . . . . . . . . . . . . .

19

20

Oil/Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . .

22

23

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

39

40

2 311021

Warnings

The following Warnings are for the 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 grounded hoses only.

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 the 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 any part of the body.

D Do not put your hand over 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 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, check or servicing equipment.

D

Tighten all fluid connections before operating equipment.

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

311021 3

WARNING

EQUIPMENT MISUSE HAZARD

INSTRUCTIONS

Misuse can cause death or serious injury.

D Do not exceed the maximum working pressure of the lowest rated system component. See Technical Data in all equipment manuals.

D

Use fluids or solvents that are compatible with equipment’s wetted parts. See the Technical Data in all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

D

Check the equipment daily. Repair or replace worn or damaged parts immediately.

D

Do not alter or modify equipment

D Read all instruction manuals, tags, and labels before operating the equipment.

D

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

D Route the hoses away from the traffic areas, sharp edges, moving parts, and hot surfaces.

D

Do not kink or overbend hoses or use hoses to pull the 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 311021

Tip Selection in.

(cm) in.

(cm) in.

(cm)

LL5431

LL5435

LL5621

LL5623

LL5625

LL5627

LL5629

LL5631

LL5635

LL5639

LL5355

LL5417

LL5419

LL5421

LL5423

LL5425

LL5427

LL5429

LL5213*

LL5215*

LL5217

LL5219

LL5315

LL5317

LL5319

LL5321

LL5323

LL5325

LL5327

LL5329

LL5331

LL5333

LL5335

2 (5)

2 (5)

4 (10)

4 (10)

4 (10)

4 (10)

4 (10)

4 (10)

4 (10)

4 (10)

4 (10)

4 (10)

4 (10)

4 (10)

4 (10)

4 (10)

6 (15)

6 (15)

6 (15)

6 (15)

6 (15)

6 (15)

6 (15)

6 (15)

6 (15)

* Use 100 mesh filter to reduce tip clogs

in.

(cm)

12 (30)

12 (30)

12 (30)

12 (30)

12 (30)

12 (30)

12 (30)

12 (30) n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n n

311021 5

General Repair Information

SAE O-Ring Installation

1.

Unscrew lock nut to touch fitting.

1.

Keep all screws, nuts, washers, gaskets, and electrical fittings removed during repair procedures. These parts are not normally provided with replacement assemblies.

2.

Test repair after problem is corrected.

3.

If sprayer does not operate properly , review repair procedure to verify procedure was done correctly. If necessary, see Troubleshooting Guide, page 8, for other possible solutions.

2.

Lubricate o-ring (A).

3.

Screw in fitting hand tight.

A ti5415a

4.

Unscrew fitting until oriented properly.

4.

Install belt guard before operation of sprayer and replace if damaged. Belt guard reduces risk of pinching and loss of fingers; see preceding

WARNING .

Grounding

Ground sprayer with grounding clamp to earth ground when flushing sprayer. Fig. 1.

grounding clamp

5.

Tighten lock nut to indicated torque.

(Make sure washer is seated properly without pinching o-ring).

ti5416a water pipe, steel sign post, or metal light pole

06250

Fig. 1 ti5417a

6 311021

Maintenance

DAILY: Top off TSL level in displacement pump packing nut to help prevent material buildup on piston rod and early wear of packings.

Pressure Relief Procedure

1.

Engage gun trigger safety.

2.

Turn engine ON/OFF switch to OFF.

3.

Move pump valve to OFF (clockwise) and turn pressure control knob fully counterclockwise.

AFTER THE FIRST 20 HOURS OF OPERATION:

Drain engine oil and refill with clean oil. Reference

Honda Engines Owner’s Manual for correct oil viscosity.

WEEKLY: Remove engine air filter cover and clean element and replace, if necessary. If operating in an unusually dusty environment: check filter daily.

4.

Disengage trigger safety. Hold metal part of gun firmly to side of grounded metal pail, and trigger gun to relieve pressure.

5.

Engage gun trigger safety.

WEEKLY/DAILY: Remove any debris from hydraulic rod.

AFTER EACH 100 HOURS OF OPERATION:

Change engine oil. Reference Honda Engines Owner’s

Manual for correct oil viscosity.

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.

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.

SEMI-ANNUALLY:

Check belt wear, page 18; replace if necessary.

YEARLY OR 2000 HOURS:

Replace hydraulic oil and filter element with Graco hydraulic oil 169236 (5 gallon/18.9 liter) or 207428 (1 gallon/3.8 liter) and filter element 246173; page 22.

SPARK PLUG: Use only BPR6ES (NGK) or

W20EPR–U (NIPPONDENSO) plug. Gap plug to

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

DAILY: Check engine oil level and fill as necessary.

DAILY: Check hydraulic oil level and fill as necessary.

DAILY: Check hose for wear and damage.

DAILY: Check gun safety for proper operation.

DAILY: Check prime/spray drain valve for proper operation.

DAILY: Check and fill gas tank.

DAILY: Check that displacement pump is tight.

Caster Wheel

(See letter call-outs in Parts drawing on page 36)

1.

Once each year, tighten nut (127, Detail A) until spring washer bottoms out. Then back off the nut

1/2 to 3/4 turn.

2.

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

3.

Once each month, grease 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 pin as needed.

5.

Check caster wheel alignment as necessary.

To align: loosen bolt (145), align wheel and tighten bolt.

311021 7

Troubleshooting

PROBLEM

E=XX is displayed

Gas engine pulls hard (won’t start)

Engine won’t start

CAUSE

Fault condition exists

Hydraulic pressure is too high

Engine switch is OFF

SOLUTION

Determine fault correction from table, page 14.

Turn hydraulic pressure knob counterclockwise to lowest setting

Turn engine switch ON

Engine is out of gas

Engine oil level is low

Refill gas tank. Honda Engines Owner’s Manual.

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

Fuel shutoff lever is OFF

Oil is seeping into combustion chamber

Use choke

Move lever to ON position

Pump valve is OFF

Remove spark plug. Pull starter 3 to 4 times.

Clean or replace spark plug. Start engine.

Keep sprayer upright to avoid oil seepage.

Turn pump valve ON.

Engine operates, but displacement pump does not operate

Pressure setting is too low

Fluid filter (11) is dirty

Tip or tip filter is clogged

Displacement pump piston rod is stuck due to dried paint

Belt worn, broken or off pulley

Hydraulic fluid too low

Hydraulic motor not shifting

Turn pressure adjusting knob clockwise to increase pressure. Manual 311018.

Clean filter.

Clean tip or tip filter. Manual 309741.

Repair pump. Manual 309277.

Replace

Shut of sprayer. Add fluid*.

Set pump valve OFF. Turn pressure down.

Turn engine OFF. Pry rod up or down until hydraulic motor shifts.

*Check hydraulic fluid level often. Do not allow it to become too low. Use only Graco approved hydraulic fluid, page 7.

8 311021

Troubleshooting

PROBLEM

Displacement pump operates, but output is low on upstroke

CAUSE

Piston ball is not seating

Piston packings are worn or damaged

Displacement pump operates but output is low on downstroke and/or on both strokes

Strainer (34e) is clogged

Pump is difficult to prime

High engine speed at no load

Low stall or run pressure shown on display

SOLUTION

Service piston ball. Manual 309277.

Replace packings. Manual 309277.

Clean strainer.

O-ring in pump is worn or damaged

Intake valve ball is packed with material or is not seating properly

Engine speed is too low

Suction tube air leak

Pressure setting is too low

Replace o-ring. Manual 309277.

Clean intake valve. Manual 309277.

Fluid filter (11), tip filter or tip is clogged or dirty Clean filter. Manual 311018 or 309741.

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).

Air in pump or hose

Intake valve is leaking

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 valve.

Pump packings are worn

Paint is too thick

Replace pump packings. Manual 309277.

Thin the paint according to the supplier’s recommendations

Engine speed is too high

Increase throttle setting. Manual 311018.

Tighten suction tube.

Increase pressure. Manual 311018.

Misadjusted throttle setting

Worn engine governor

New pump or new packings

Faulty transducer

Decrease throttle setting before priming pump.

Manual 311018.

Reset throttle to 3700 – 3800 engine rpm at no load

Replace or service engine governor

Pump break-in period takes up to 100 gallons of material

Replace transducer

311021 9

––––––––––––––––––––––––––––––––––––––

––––––––––––––––––––––––––––––––––––––

––––––––––––––––––––

Troubleshooting

PROBLEM

Excessive paint leakage into throat packing nut

CAUSE

Throat packing nut is loose

Fluid is spitting from gun

Throat packings are worn or damaged

Displacement rod is worn or damaged

Air in pump or hose

Excessive leakage around hydraulic motor piston rod wiper

Fluid delivery is low

The sprayer overheats

Tip is partially clogged

Fluid supply is low or empty

Piston rod seal worn or damaged

Pressure setting too low

Displacement pump outlet filter (if used) is dirty or clogged

Intake line to pump inlet is not tight

Hydraulic motor is worn or damaged

Large pressure drop in fluid hose

Paint buildup on hydraulic components

Oil level is low

Low hydraulic fluid level

SOLUTION

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

Replace packings. Manual 309277.

Replace rod. Manual 309277.

Check and tighten all fluid connections.

Reprime pump. Manual 311018.

Clear tip. Manual 309741.

Refill fluid supply. Prime pump. Manual

311018. Check fluid supply often to prevent running pump dry.

Replace these parts.

Increase pressure. See manual 311018.

Clean filter

Excessive hydraulic pump noise

Gallon counter not working

Tighten

Bring sprayer to Graco distributor for repair

Use larger diameter or shorter hose

Clean

Fill with oil, page 7.

Shut off sprayer. Add fluid*, page 7.

Broken or disconnected wire

Bad sensor

Missing or damaged magnet

Sprayer operates, but display does not

Bad connection between control board and display

Display damaged

Loose cables

Control board LED not flashing

Check wires and connections. Replace broken wires.

Replace sensor

Replace magnet. Locate in correct spot.

Remove display and reconnect

Replace display

Connect cables to back of control board

Replace control board

10 311021

Troubleshooting

PROBLEM CAUSE

Distance counter not operating properly Trigger sensor not set correctly

Mils 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

Spray icon is always shown on display

Pressure control knob does not rotate

Pressure control knob rotates freely with no pressure change

Engine bounces when striping

Bad wiring connections

Distance sensor not spaced correctly from gear

Distance and gear not aligned

Gear teeth missing or damaged.

Wire cracked or broken

Distance sensor

Trigger sensor

Check connector, and reconnect

Adjust space between sensor and gear to .050 –/+ .020 in. (page 15.)

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

Replace distance gear/wheel

Replace sensor

See “Distance counter not operating properly”

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

Gallon counter

Bad or damaged control board

See “Gallon counter not working”

Replace control board

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

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

Loose connector Check that 5-pin connector and reed switch are properly connected

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

Reed switch assembly (18) is damaged Replace reed switch assembly (18)

Magnet on assembly (18) is missing

A connector on wiring harness or on reed switch (18) is damaged

Replace reed switch assembly (18)

Disconnect reed switch and 5-pin connector from back of control board.

Check continuity between pin 1 on 2-pin connector and pin 1 on 5-pin connector.

Check continuity between pin 2 on 2-pin connector and pin 4 on 5-pin connector.

If there is no continuity in either case, replace wiring harness.

If there is continuity in both cases replace reed switch assembly (18).

Cut or sliced wire

Control board is damaged

Replace wiring harness.

Replace control board

Display is damaged Replace display

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

Reed switch assembly (18) is damaged Replace reed switch assembly (18)

Knob is jammed

Remote cable broken or disconnected

Pull back cover where remote cable connects to hydraulic pump and turn counter clockwise (ccw) until free

Replace or reconnect cable

Spring is broken, loose or missing

SOLUTION

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

Replace or reconnect spring

311021 11

Digital Tracking System

Removal

1.

Relieve pressure ; page 7.

2.

Fig. 2. Remove two screws (103) 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.

ON/OFF Switch

Installation

1.

Fig. 2. Install new 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 and close display connector wings (A) on PC board.

4.

Install cover (31) with two screws (103).

Removal

1.

Relieve pressure ; page 7.

2.

Fig. 2. Remove two screws (103) and cover (31).

PC Board

4.

Note on paper, lead connections to the control board. Disconnect leads from control board (15d).

5.

Remove four screws (15k) from control board.

Installation

1.

Fig. 2. Install control board (15d) and four screws

(15k). Torque to 105–115 in–lb.

3.

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

2.

Connect leads to control board. (Refer to note on lead connections.)

3.

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

4.

Install cover (31) with two screws (103).

Removal

Pressure Control Transducer

1.

Relieve pressure ; page 7.

2.

Fig. 2. Remove two screws (103) and cover (31).

3.

Disconnect transducer lead (C) from control board

(15d).

4.

Remove pressure control transducer (259) and o-ring (124) from filter housing.

Installation

1.

Fig. 2. Install o-ring (124) and pressure control transducer (259) in filter housing. Torque to 35–45 ft-lb.

2.

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

3.

Install cover (31) with two screws (103).

12 311021

Fig. 2

123

TO ENGINE

Digital Tracking System

15g

15g

B

A

GROUND

15d

15k

31

C

Main Control

Box Cable

103

Transducer

124

259

311021 13

PC Board Diagnostics

D No display does not mean the sprayer is not pressurized.

Digital Display Messages

DISPLAY SPRAYER

OPERATION

No Display Sprayer may be pressurized.

INDICATION ACTION

Loss of power or display not connected psi bar

MPa

Sprayer may be pressurized.

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

Engine and system continue to run.

Pressure less than

200 psi (14 bar, 1.4 MPa)

Normal operation

Exceeded pressure limit

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

Increase pressure as needed

Spray

Remove any filter clogs or flow obstructions.

Engine and system continue to run.

Pressure transducer faulty, bad connection or broken wire.

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

After a fault, follow these steps to restart sprayer:

1.

Correct fault condition

2.

Turn sprayer OFF

3.

Turn sprayer ON

14 311021

Trigger Sensor Adjustment

Refer to Troubleshooting for trigger sensor adjustment, and Operation Manual 311018.

Gear Alignment

Distance Sensor Adjustment

1.

Relieve pressure ; page 7.

2.

Fig. 3. Remove dust cap (142) from wheel.

Remove nut (127).

3.

Remove wheel (120) from LineLazer.

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.

Remove wheel (120) from LineLazer.

2.

Remove distance sensor (66).

4.

Align gear (67) with sensor.

a.

Pull gear out from wheel with gear puller.

b.

Push gear in toward wheel with mallet.

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.

66

Fig. 3

Frame

142

127

I

nside of tire

120

Axle

Ç

Ç

Ç

Ç

Ç

Ç

Ç

Ç

Ç

Ç

Ç

Ç

Ç

.638 in.

67

(66)

Distance

ÇÇ

Sensor

ÇÇ

ÇÇ

ÇÇ

(120)

Tire

ÇÇ

Gear

ÇÇ

ÇÇ

ÇÇ

ÇÇ

ÇÇ

ÇÇ

ÇÇ

ÇÇ

ÇÇ

ÇÇ

ÇÇ ti3680a

ÇÇ

311021 15

Removal

Hydraulic Pump

Installation

1.

Install hydraulic pump (252) on reservoir cover

(237) with four screws (215) and o-rings (178), o-ring (180); torque 100 in-lb (11 N·m).

1.

Allow hydraulic system to cool before beginning service.

2.

Relieve pressure ; page 7.

3.

Place drip pan or rags under sprayer to catch hydraulic oil that leaks out during repair.

2.

Install gasket (85) filter assembly (A) and reservoir cover (237) with eight washers (101) and screws

(184); torque 90 in-lb (10 N·m).

3.

Install elbow (182) per instructions, page 6; torque to 15 ft-lb (20.3 N·m).

4.

Remove drain plug (195) and oil filter (199) and allow hydraulic oil to drain.

4.

Install pressure control guard (63) and tighten screw (184).

5.

Remove screw (224), loosen belt guard knob

(241) and belt guard (24).

5.

Connect hydraulic hoses (32) and (35).

6.

Raise motor and remove belt (143).

6.

Install case drain tube (251); torque to 15 ft-lb

(20.3 N·m).

7.

Remove two set screws (169) and fan pulley (86).

7.

Install fan pulley (86) with two set screws (193).

8.

Remove case drain tube (251).

8.

Raise motor and install belt (143).

9.

Remove elbow (182).

9.

Install belt guard (24) with screw (224) and belt guard knob (241).

10. Loosen screw (184) and remove pressure control guard (63).

10. Install remote pressure control cable (12).Tighten

set screw (102).

11. Loosen set screw (102) and remove remote pressure control cable (12).

12. Remove eight screws (184) and washers (101), reservoir cover (237), filter assembly (A) and gasket (85).

11. Install drain plug (195); torque to 110 in-lb

(12.4 N·m). Install oil filter (199); tighten 3/4 turn after gasket contacts base. Fill with Graco hydraulic oil, page 7.

13. Remove four screws (215) and o-rings (178), o-ring (180) and hydraulic pump (252) from reservoir cover (237).

12. Start up and allow pump to operate at low pressure for approximately 5 minutes to purge all air.

13. Check and top off hydraulic oil level.

16 311021

224

24

162

169

86

143

63

184

12

102

182

237

252

178 180

35

218

32

199

196

215

A

184

101

85

251

241 ti6551a

195

Fig. 4

311021 17

Removal

1.

Relieve pressure ; page 7.

2.

Fig. 5. Loosen belt guard knob (241).

3.

Rotate belt guard (24) up.

4.

Lift engine (185) up to remove tension on belt

(143).

5.

Remove belt from fan pulley (86) and fan pulley

(87a).

Fan Belt

Installation

1.

Thread belt (143) around fan pulley (87a) and fan pulley (86).

2.

Lower engine (185) to put tension on belt.

3.

Rotate belt guard (24) down.

4.

Tighten belt guard knob (241).

24

143

87a

185

86

241 ti6511a

Fig. 5

18 311021

Removal

1.

Relieve pressure ; page 7.

2.

Remove throttle cable from engine.

3.

Do Fan Belt, Removal ; page 18.

4.

Loosen hand nut (241). Swing bracket (30) out.

5.

Fig. 6. Disconnect blue, brown and orange leads from engine (185).

6.

Remove engine and rocker plate (87c) from sprayer.

7.

Remove four screws (189), washers (114), washers (170) and nuts (118) and remove rocker plate, dampeners (59) and washers (114) from engine.

Engine

Installation

1.

Install rocker plate (87c), dampeners (59) and washers (170), washers (114) on engine (185) with four screws (189), washers (170) and nuts

(118); torque to 20 ft-lb (27.1 N·m).

2.

Install engine and rocker plate (87c) on sprayer.

3.

Connect blue, brown and orange leads.

4.

Do Fan Belt, Installation ; page 18.

5.

Swing motor retainer bracket (30) in. Tighten hand nut (241).

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

GREY

BROWN

ORANGE

BLUE

Fig. 6 ti6520a

241

30

114

59

118

170

GREEN

87c

114

189

311021 19

Removal

1.

Relieve pressure ; page 7.

Hydraulic Motor Yoke

Installation

1.

Assemble yoke (22b) to trip rod (22a)

2.

Place drip pan or rags under sprayer to catch hydraulic oil that leaks out during repair.

a.

Clean threads with primer or chlorinated solvent and let dry 3 to 4 minutes. Apply thread sealant to female threads of yoke. Clamp yoke in vise and, with wrench on flats of trip rod, screw trip rod into yoke. Torque to 55 in-lb (6.2

N·m). Install set screw (22c). Allow thread sealant to dry for 3 hours prior to contact with hydraulic fluid.

3.

Fig. 7. Slide retainer clip (194) and magnet ring

(222) down to remove. Remove pump pin (249).

4.

Remove hydraulic lines (35, 250) from fittings

(217) at top left and right side of hydraulic motor.

5.

Loosen jam nut (183).

6.

Unscrew and remove hydraulic motor cap (25).

7.

Slide piston rod/hydraulic motor cap assembly (A) from hydraulic motor cylinder.

8.

Remove yoke (22).

a.

Clamp hydraulic motor cap in vise with hydraulic motor piston rod facing up.

b.

Use shortened Allen wrench to remove two screws (175) from spring retainer (247). Remove yoke, spring retainer, piston and trip rod assembly from hydraulic motor cap.

Do not remove spring retainer (247) from yoke (22). If yoke is worn, replace yoke and spring retainer assembly with Yoke Repair Kit 246175.

c.

Put yoke in vise. Remove set screw (22c) and remove piston rod assembly from yoke.

b.

Fig. 7. Put hydraulic motor cap (25) in vise.

c.

Install yoke, spring retainer, piston and trip rod assembly in hydraulic motor cap. Use shortened Allen wrench to install two screws (175) in spring retainer to secure piston rod assembly to hydraulic motor cap.

2.

Slide piston rod assembly (A) into hydraulic motor cylinder.

3.

Screw down hydraulic motor cap (25) until cap bottoms out. Unscrew hydraulic motor cap until inlet and outlet align with hydraulic line fittings and test hole in hydraulic motor cap points toward belt guard (24).

4.

Torque jam nut (183) against hydraulic motor cap

(25) to 150 ft-lb (17 N·m).

5.

Install hydraulic lines (35, 250) to fittings (217) to top left and right side of hydraulic motor per procedure on page 6; torque to 40 ft-lb (54.2 N·m).

6.

Pull start rope slowly to align pin holes of hydraulic motor and displacement pump (21). Connect with pump pin (249); install magnet ring (222) and retainer clip (194), page 23.

7.

Start engine and operate pump for 30 seconds.

Turn engine OFF. Check hydraulic oil level and fill with Graco hydraulic oil, page 7.

20 311021

5. a.

test hole

217

35

217

5. b.

25

250

183

249

222

194

5. c.

A

22b

22c

22a

22

247

175 ti3476c

Fig. 7

311021 21

Oil/Filter Change

Removal

1.

Fig. 8. Place drip pan or rags under sprayer to catch hydraulic oil that drains out.

199

2.

Remove drain plug (195). Allow hydraulic oil to drain.

3.

Unscrew filter (199) slowly – oil runs into groove and drains out rear.

Installation

1.

Install drain plug (195). Apply a light coat of oil to oil filter gasket and install oil filter (199). Tighten oil filter 3/4 turn after gasket contacts base.

2.

Fill with1.25 gallons (4.73 liters) of Graco hydraulic oil 169236 (5 gallon/20 liter) or 207428 (1 gallon/3.8 liter)

3.

Check oil level.

Fig. 8

Gallon Counter

Removal

1.

Fig. 9. Disconnect gallon counter cable at back of pressure control and at engine.

2.

Remove guard (137) and reed switch from hydraulic motor.

137 ti6512a

Fig. 9

3.

Fig. 11 – 13. Remove pump.

4.

Fig. 10. Remove ring magnet (150).

ti2271a ti6513a

222

Fig. 10

Installation

1.

Fig. 10. Install new ring magnet (222) with dimple marks facing down.

2.

Fig. 14 – 16. Install pump.

3.

Install new reed switch and guard (137) on hydraulic motor.

4.

Fig. 9. Connect gallon counter cable at back of pressure control and at engine.

22 311021

Displacement Pump

Installation

See manual 309277 for pump repair instructions.

Removal

1.

Flush pump.

CAUTION

If the pump jam nut loosens during operation, the threads of the hydraulic motor manifold will be damaged. Tighten jam nut as specified.

2.

Relieve pressure ; page 7.

3.

Fig. 11. Remove suction tube (34) and hose (26).

1.

Fig. 14. Screw jam nut to bottom of pump threads.

Screw pump completely into manifold. Unscrew pump from manifold until pump outlet aligns with hose. Hand tighten jam nut, then tap 1/8 to 1/4 turn with hammer or torque to 200 ft-lb (270 N·m).

26

34

Fig. 14 ti6517a ti6514a

Fig. 11

CAUTION

Gallon counter may error if magnet ring and/or sensor assembly are damaged during disassembly and assembly.

4.

Fig. 12. Push magnet ring (222) up. Push retaining spring (194) up. Push out pin (249).

222

194

249

2.

Fig. 15. Slowly pull engine starter rope until pump rod pin hole is aligned with hydraulic rod hole.

Fig. 12. Push pin (249) into hole. Push magnet ring

(222) down. Push retaining spring (194) into groove.

222 ti6515a

Fig. 12

5.

Fig. 13. Loosen jam nut. Unscrew pump.

ti6518a

Fig. 15

Fig. 16. Fill packing nut with Graco TSL.

Fig. 13 ti6516a

Fig. 16 ti6519a

311021 23

24 311021

Notes

Parts Page 30

Parts – LineLazer IV 200

HS

Parts Page 34

Parts Page 28

Parts Page 26

Parts Page 34 ti6521b

Parts Page 28

Parts Page 36

311021 25

Parts – LineLazer IV 200

HS

144

57

141

290

27

36

354

90

60

108

5

129

355

84

13

156

94

66a

157

68

118

148

156

93

112

261

28

129

115

2

121

134

261

73

74

58

121

117

70

67

120 1

51

122

117

99

117

121

142

127

121

257

258

16 ti6498c

256

33

221

154 ti6532b

To remove cover (257), press tabs together and pull cover away from plate (99).

26 311021

Ref.

No.

5

13

16

27

28

33

36

51

57

58

60

66

66a

67 245734

68

70

73

198612

198891

198930

74 198931

81 240997

84

Y

15F638

90 15D849

93

94

15F577

15F576

99

108

109

15F425

101566

102478

112 111145

Part No.

237686

245225

287623

287417

287622

287590

240926

115642

193405

194310

195134

196176

287698

Parts – LineLazer IV 200

HS

Ref.

No.

Description Qty.

Part No.

Description

CLAMP, grounding assy

HOSE, 3/8 in. X 50 ft

FRAME, linestriper

HANDLE

SUPPORT, handle, painted

COVER, pail

(models 248870, 248871, 248872,

and 248873), includes 221

(models 249012, 249013) no 221

BUSHING, strain relief

AXLE

LEVER, actuator

SPACER, ball guide

ADAPTER, nipple

KIT, sensor, distance includes 66a, 68, 115, 129, 157

SENSOR, distance

KIT, repair, wheel, LineLazer includes 120

SHIELD, sensor, distance

BRACKET, mounting

ROD, brake

BEARING

CONDUCTOR, ground (not shown)

1

LABEL, warning, fire and skin 1

TAG, Endurance Advantage Program 1

BRACE, left, painted

BRACE. right, painted

1

1

BRACKET, reservoir

NUT, lock

STRAP, wiring tie (not shown)

1

2

6

KNOB, pronged 2

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

156

157

221

256

257

258

261

290

354

115

117

118

120

121

122

127

129

134

141

142

144

148

154

355

108868

110837

110838

111020

111040

111194

112405

112798

113961

241445

114648

114659

114808

115077

112395

116287

119771

119696

287695

15F441

116780

120151

194312

240717

Qty.

CLAMP, wire

SCREW, flange, hex

NUT, lock

WHEEL, pneumatic

NUT, lock, insert, nylock, 5/16

SCREW, cap flange hd

NUT, lock

SCREW, thread forming, hex hd

SCREW, cap, hex hd

CABLE, caster

CAP, dust

GRIP, handle

CAP, vinyl

PAIL, plastic (models 248870, 248871,

248872 and 248873)

3

10

10

2

4

2

4

2

1

2

1

1

3

1

SCREW, cap, flng hd

WASHER, sst, ext, starwasher

STRAP, cover

SPRING, extension

BOX, electric, includes 109

BRACKET, frame

SCREW, hex hd

PLUG, tube

BRACKET, pail

(models 249012, 249013 )

KIT, conversion, (Euro pail),

(models 249012, 249013 ) includes 33, 354 but not 221

1

1

4

2

1

2

1

2

1

1

Y Replacement warning labels may be ordered free of charge

Notes

1 Maintain tire pressure at 28–32 psi

2 Torque to 17–23 ft–lb

311021 27

Parts – LineLazer IV 200

HS

49

136

28 311021

89

2

162

119

126

17

71

117

360

161

105

1

14

4

144

72

18

71

121 ti6494a

44

83

46

104 1

8e

8d

8

47

8f

8a

Detail 8

8c

8f

8b

8f

8f

119

160

27

161

165

163

41

Ref

161

164

96 ti6497a

287417

287622

287176

15F212

111145

15F213

188135

198895

198896

Part No.

224052

248157

287570

287569

15F214

15F209

15F210

15F211

102040

245798

245733

287699

Ref.

No.

1

4

8

8a

8b

8c

8d

8e

8f

14

17

18

27

28

35

44

46

47

49

71

72

Parts – LineLazer IV 200

HS

Description Qty.

BRACKET, support gun 1

GUN, flex, basic, includes guard & tip 1

KIT, holder, gun

HOLDER, gun

1

1

LEVER, actuator

STUD, pull, trigger

STUD, pivot

1

1

1

STUD, cable

NUT, lock

HOSE, 1/4 x 7 ft

KIT, trigger handle repair, includes

89, 126, 164, 165

KIT, repair, trigger

11

1

1

4

1 includes 18, 166, 168

HANDLE 1

SUPPORT, handle, painted

(not shown) 1

HOSE, hydraulic, return (not shown) 1

ARM, support

KNOB, pronged

1

1

BRACKET, cable

GUIDE, cable

PLATE, lever, pivot

BLOCK, mounting (mach)

2

1

1

1

Ref.

No.

Part No.

Description

144

160

161

162

163

164

165

168

360

117

119

121

126

136

141

83

Y

15F637

89 Y 15A644

96 15F624

97

104

15F377

119647

105

109

119648

102478

110837

111017

111040

112381

287566

241445

114659

116941

287696

116969

116973

117268

117269

117317

15F389

Qty.

LABEL, skin injection

LABEL, trigger

NUT, cable, gun

HARNESS, wiring

SCREW, cap, socket, flthd 2

SCREW, mach tursshd, cross recess 1

STRAP, wiring tie 6

2

1

1

1

SCREW, flange, hex

BEARING, flange

NUT, lock

SCREW, mach, pan hd

KIT, clamp

CABLE

2

1

2

2

1

1

GRIP, handle

SCREW, shoulder, socket head

CABLE, includes 96

NUT, lock

SCREW, #10 taptite phil

BRACKET, interrupter

SPRING

SCREW, plastite, pan head

BRACKET, gun arm

1

1

1

1

2

2

1

2

1

Y Replacement warning labels may be ordered free of charge

Notes

1

2

Torque to 90–110 in–lb

Torque to 10–20 in–lb

311021 29

Parts – LineLazer IV 200

HS

225

15g

1 15q

125

15s

123

191

190

269

15e

15b

1 15n 15c

15m 1

103

15w

268

15f

15r

15a

15d

15k

15x

15t

15p 1

15h

15n

41

37

31 ti6496b

103

27

103

270

11

76

29

62

167

13 ti6495a ti6495b

38

39 62

26

262

40

2

3

2

259

124

64 2

34 Ref

30 311021

Ref.

No.

2

3

11

13

15

15a

15b

15c

Part No.

239914

224807

244067

245225

287601

15F272

287688

15d

15e

15f

15g

287689

287596

114954

116752

15h

15k

119541

111839

15m 117317

15n 109466

15p 116719

15q 195428

15r Y 15F543

15s

Y

15F544

15t 287692

15u

15v

119736

119737

15w 15F777

15x 15F776

26 248007

27 287417

Parts – LineLazer IV 200

HS

Description Qty.

VALVE, drain

BASE, valve

FILTER, fluid

HOSE, 3/8 in. x 50 ft

CONTROL, plate

PLATE, control

BOARD, display, includes 15c, 15m 1

1

1

1

1

1

1

DISPLAY, board, LCD (included with 15b)

CONTROL, board, includes 15k

BOARD, light, includes 15n

SWITCH, rocker

SWITCH, rocker

1

1

1

1

1

SWITCH, toggle

SCREW, mach, pnh, sems

SCREW, plastite, pan head

NUT, lock, hex hd

SCREW, 3/82 hex washer head

BOOT, toggle

LABEL, control, top

LABEL, control, bottom

CONTROL, throttle

CLAMP, cable (not shown)

PLUG (not shown)

GASKET, control

GASKET, throttle

HOSE, coupled, 3/8 in.

HANDLE

1

1

1

1

1

1

1

3

1

1

3

4

1

4

1

Ref.

No.

Part No.

Description Qty.

62

64

76

103

123

124

29

31

37

38

39

40

41

196179

15F589

15C766

15C780

15C972

15H561

287285

196178

196181

104813

116719

FITTING, elbow, street

COVER, control

TUBE, diffuser

HANDLE

PIN, grooved

MANIFOLD, filter, 3/8 npt

SCREW, set, sch

O-RING

RING, retaining

GLAND, packing, male

LABEL, control

TRANSDUCER, pressure control includes 124

1

1

1

1

1

1

5

2

1

1

1

2

1

1

‘1

1

1

KIT, repair, filter cap, includes 37, 167 1

ADAPTER, nipple

FITTING, nipple

PLUG, pipe

SCREW, 8/32, hex washer hd

118359 KNOB, pressure control

111457 O–RING

125

167

112303

117285

190 115999

191 176754

225 Y 15A464

259 287172

262

268

269

111801

15F710

119775

SCREW, cap, hex

BUSHING, mount panel

NUT, panel

1

2

1

1

270 288100 KIT, repair, filter, includes 2, 3, 11, 37

38, 39, 40, 41, 124, 167, 259

Y Replacement warning labels may be ordered free of charge

Notes

1

2

Torque to 115–135 in–lb

Torque to 130–150 in–lb

311021 31

108

Parts – LineLazer IV 200

HS

231

2

217

138

159

243

25

35

173 2

176

5

244

248

179

245

213

232

219

232

192

183

3

69

171

246

247

216

249

175 4

22

233

26

60

21

34

217

250

235

7

213

187

186

220

42

230

166

283

92

222

194

13

149

173

48

107

6

32

174

137

35

218 ti6499c

32 311021

Ref.

No.

21

22

22a

22b

22c

25

26

32

34

35

42

48

60

69

Part No.

277068

246610

15A690

246175

118123

246180

248007

287175

287206

287176

15A693

117328

196176

246176

92

107

108

137

138

149

159

166

171

173

174

175

176

179

193394

117441

101566

15F911

106276

119841

155685

119720

100069

100139

102040

104092

105765

108014

4

5

6

7

Notes

1

2

3

Torque to 75 ft–lb

Torque to 85–95 in–lb

Torque to 150 ft–lb

Torque to 54–56 in–lb

Torque to 40–44 ft–lb

Torque to 40 ft–lb

Torque to 25 ft–lb

Parts – LineLazer IV 200

HS

Description

PUMP, displacement

Manual 309277

YOKE, assembly

(includes 22a, 22b)

ROD, trip, (page 21)

YOKE, valve (page 21) includes 22c, 171, 175, 219, 247

SCREW, set (page 21)

CAP, hydraulic head, assy, includes

138, 173, 231, 235 and 243

HOSE, coupled, 3/8 in.

HOSE, hydraulic, supply

HOSE, suction/drain

HOSE, hydraulic, return

ROD, hydraulic motor

FITTING, nipple, straight

ADAPTER, nipple

SLEEVE, hydraulic cylinder, includes 213

NUT, retaining

VALVE, ball

NUT, lock

GUARD, pump rod

SCREW, cap, hex hd

FITTING, tee, branch, str thd

O–RING

SWITCH, reed w/connector

BALL

PLUG, pipe

NUT, lock, hex

SCREW, cap, sch

O–RING

O–RING

Qty.

1

1

1

1

1

1

1

1

1

1

1

1

1

1

1

2

1

1

1

4

1

1

2

2

2

1

1

‘

Ref.

No.

246

247

248

249

250

283

231

232

233

235

243

244

245

217

218

219

220

222

230

183

186

187

192

194

213

216

Kits

Part No.

Description

15B063

15B463

107210

15B804

178179

178207

178226

189072

192654

192656

197443

15F519

110982

15A726

112342

112561

114231

116551

117283

117494

117607

117608

117645

117739

287186

15A728

NUT, jam

BEARING, rod

PACKING, block

NUT, lock, hex

RING, retaining

O–RING

SPRING, compression

FITTING, elbow, std thd

FITTING, nipple, straight

SPRING, compression

WIPER, rod

MAGNET, ring

MANIFOLD, adapter

LABEL,

RETAINER, spring

SCREW, cap, socket head

LABEL, Graco Logo

WASHER, sealing

BEARING, piston

SEAL, piston

SLEEVE, valve

STOP, valve (spring retainer)

PISTON,

PIN, pump

TUBE, hydraulic, supply

SCREW, cap, hex head

246174, KIT, repair, seal, hydraulic, includes

176, 186, 213, 220, 244, 245

246255 KIT, repair, trip rod/piston, includes

42, 171, 175, 176, 192, 216, 219,

232, 247, 248

Qty.

1

1

1

1

1

1

1

1

1

4

1

1

2

1

1

2

1

1

1

1

1

1

1

1

1

1

311021 33

Parts – LineLazer IV 200

HS

184

193

214

224

23

24 ti6493a

63

169

86

169

143

12

102

252

43 182

178

150

180

32

251

196

169

88

181 188

199

87b

87a

162

82

228

184

101

172

212

253

215

180

75

197

237

114

189

174

198

34d

34h

34k

34f

34g

34b

34n

34a

34j 34e

34d

34c

Detail 34

241

117

170

85 241

30

242

195

200

227

185

118

170

114

59

87c

81

34 311021

Ref.

No.

12

23

24

Part No.

287687

248976

248973

30

32

34

34a

34b

34c

34d

102

114

117

118

143

150

151

162

169

15E476

287175

287206

170957

194306

198119

101818

34e

34f

34g

34h

181072

198601

241920

248008

34j

34k

114958

196180

34m 195119

86

87a

87b

87c

88

101

34n

43

59

63

15F513

15C400

15E888

15C958

75 15E587

81 240997

82 Y 15F548

85 246172

15E410

15E758

15E759

15F485

117632

100016

118123

108851

110837

110838

119433

154594

114956

116969

100002

Parts – LineLazer IV 200

HS

Ref.

No.

Description Qty.

Part No.

Description

SHAFT, flexible, includes 125, 190,

191, 268, 269

RAIL, belt, includes 162, 174, 224 and 241

GUARD, belt, includes: 162, 193, 214,

224, and 228

BRACKET, retainer, motor

HOSE, hydraulic supply

HOSE, suction/drain

TUBE, suction

HOSE, fluid

ELBOW, barbed

CLAMP, hose

STRAINER, inlet

TUBE, drain

DEFLECTOR, threaded

HOSE, coupled 1/4 in. x 4 ft

STRAP, tie

BUSHING

LABEL, warning (not shown)

GASKET, pail

ADAPTER, pressure control

DAMPENER, motor mount

GUARD, pressure control

TUBE, suction

CONDUCTOR, ground

LABEL, brand 200HS

GASKET, reservoir

PULLEY, fan

PULLEY, 5.50 diameter

SPACER, shaft, engine

BRACKET, engine mount

KEY, square, 3/16 X 1.25

WASHER

SCREW, ste, socket w/patch

WASHER, plain

SCREW, flange, hex

NUT, lock

BELT, vee, gripnotch

O–RING

TERMINAL, wire tap, insulated

NUT, lock

SCREW, set, sch

1

1

10

4

1

2

1

2

3

1

1

8

1

1

1

1

2

8

4

1

1

1

1

1

7

1

1

1

1

1

1

1

1

1

1

1

1

1

1

170

172

174

178

180

181

182

184

185

100023

100084

102040

107188

156401

108842

110792

112166

248943

185

188

189

193

195

196

197

198

114530

112717

113664

115477

116754

116793

116915

116919

199

200

206

208

211

212

214

246173

118280

70408

70274

73004

116967

117284

215

218

117471

117608

224 119434

227 Y 194126

228 Y 198492

237 15C676

241 15D862

242

251

15E342

246167

252

253

287179

198841

Qty.

WASHER, flat

BALL, metallic

NUT, lock

O–RING

O–RING

SCREW, cap, hex head

ELBOW, male, 90 degree

SCREW, cap, sch

KIT, engine, gas, 5.5 hp, Honda, includes: 59, 81, 87, 88, 98, 114, 118,

169, 170, 181, 185a, 188, 189, 227

15 and 234

ENGINE, gas, 5.5 hp, Honda

1

1

1

1

1

1

1

6

1

WASHER,

SCREW, flange, hex

SCREW, mach, torx pan hd

PLUG, hex head, hydraulic

FITTING, elbow, hydraulic

CAP, breather filler

FILTER, hydraulic, suction

FILTER, oil, spin on

SCREW, hex washhd

SEALANT, pipe, sst

TAPE, PTFE, sealant

FLUID, hydraulic

SPRING, compression

GRILL, fan guard

SCREW, 1/4–20 flat hd mach

FITTING, nipple, straight

SCREW, shoulder, socket head

LABEL, warning

LABEL, warning

COVER, reservoir, GH200 LL

NUT, hand

TANK, reservoir

TUBE, hydraulic, case drain, includes:

1

150

PUMP, hydraulic, includes: 43, 102,

1

155, 178, 180, 215, 223, 238, 239, 240 1

RETAINER, ball, press bypass 1

1

1

2

1

1

4

1

1

1

1

2

1

1

1

4

1

1

4

Y Replacement warning labels may be ordered free of charge

311021 35

ti6492b

53

F

121

16

108

106

Parts – LineLazer IV 200

HS

56

141 146

7

46

140

117

153

147

Detail A

127

130 1

46

139

142

127

130 1

133

10

113

128

54

133

132

16

55

52

139

110

154

65

6

135

145

Detail A

131

36 311021

Ref.

No.

56

65

106

108

110

113

116

117

121

127

6

7

10*

16

46

52

53

54

55

Part No.

240942

240991

15G952

287623

181818

193528

193658

193661

193662

15F910

198606

100731

101566

15J603

108483

110754

110837

111040

112405

Parts – LineLazer IV 200

HS

Description

SHAFT, fork

BRACKET, caster, front

BRACKET, hub

FRAME, linestriper, painted

KNOB, pronged

ARM, detent

SPACER, seal

JAW

STOP, wedge

BRACKET, cable

DISK, adjuster

WASHER

NUT, lock

WASHER, plain

SCREW, shoulder, soc hd

SCREW, cap, soc hd

SCREW, flange, hex

NUT, lock

NUT, lock

Qty.

Note

1 Install washers (130) concave surface to inside.

2

2

1

1

1

1

2

10

2

4

2

1

1

1

1

1

1

1

1

Ref.

No.

Part No.

Description

128

130

112776

112825

131 113471

132* 113484

133* 113485

135 113962

139

140

141

114548

114549

241445

142

145

146

147

114648

114681

114682

114802

153 114982

154* 120476

WASHER, plain

SPRING, Belleville

SCREW, cap, hex hd

SEAL, grease

BEARING, cup/cone

WASHER, hardened

BEARING, bronze

WHEEL, pneumatic

CABLE

CAP, dust

SCREW, cap, hex hd

SPRING, compression

STOP, wire

SCREW, cap, flng hd

BOLT

* Included in 240940 Bracket Repair Kit; purchase separately

Qty.

2

1

1

2

1

1

1

1

3

1

1

3

1

2

1

311021 37

Pressure Control Wiring Diagram

Red clip on yellow

Orange

A3

White

A4

GROUND

TO ENGINE

A2

ENGINE OFF

SWITCH

DISPLAY BOARD

GUN TRIGGER

PICK–UP

A1

DISTANCE

SENSOR

PUMP

STROKE

COUNTER

JUNCTION

BOX

A6

TRANSDUCER

LIGHT

SWITCH ti6533a

J9

J15

J4 J3

CONTROL BOARD

J16

J11

J1 J2

J12

PUMP

ON/OFF

SWITCH

TO ENGINE

GENERATOR

J12

DISTANCE

SENSOR

LITE

LED

PUMP STROKE

COUNTER

A6

A1

A3

38

Fig. 17

311021

A2

A4

LIGHT

BOARD

*

Technical Data

Honda GX160 Engine

Power Rating @ 3600 rpm

ANSI . . . . . . . . . . . . . . . . . . . . . . .

DIN 6270B/DIN 6271

5.5 Horsepower

NA

NB

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . .

Maximum working pressure

2.9 Kw – 4.0 Ps

3.6 Kw – 4.9 Ps

. . . . . . . . . . . . . . . 3300 psi

(227 bar, 22.7 MPa )

Noise Level

Sound power . . . . . . . . . . . . . . . . . . . . . . . . . 110 dBa per ISO 3744

Sound pressure . . . . . . . . . . . . . . . . . . . . . . . . 96 dBa measured at 3.1 feet (1 m)

Vibration Level*

Left Hand . . . . . . . . . . . . . . . . . . . . . . . . .

Right Hand . . . . . . . . . . . . . . . . . . . . . . .

2.90 m/sec

2

2.83 m/sec

2

*Vibration measured per ISO 5349 based on 8 hr daily exposure.

Maximum delivery

Maximum tip size

. . . . . . . . . . . . . . . 2.0 gpm (7.6 lpm)

1 gun

2 guns

. . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . .

Inlet paint strainer . . . . . . . . . . .

with 0.046 in. tip

with 0.033 in. tip

16 mesh (1190 micron) stainless steel screen, reusable

Outlet paint filter

Pump inlet size

. . . . . . . . . . . . . 60 mesh (250 micron) stainless steel screen, reusable

. . . . . . . . . . . . . . . . . . . . . . 1 in. npsm(m)

Fluid outlet size . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic reservoir capacity . . .

3/8 npt(f)

1.25 gallon (4.73 liters)

Hydraulic pressure . . . . . . . . . . . . . . 1825 psi (124 bar)

Weight (dry, without packaging)

Height

. . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . .

242 lb (110 kg)

40 in. (101.6 cm)

Length . . . . . . . . . . . . . . . . . . . . . . . . . . 65 in. (165.1 cm)

Width . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wetted parts . . .

32 in. (81.3 cm)

PTFE, Nylon, polyurethane, V-Max t

UHMWPE polyethylene, fluoroelastomer, acetal, leather, tungsten carbide, stainless steel, chrome plating, nickel-plated carbon steel, ceramic,

Cycles/gallon (liter) . . . . . . . . . . . . . . . . . . . . . 104 (27.5)

Must be purchased separately.

GRACO–APPROVED HYDRAULIC OIL

169236

207428

5 Gallons (19 liters)

1 Gallon (3.8 liters)

Accessories

311021 39

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 distributor, or call this number to identify the distributor closest to you:

1–800–690–2894 Toll Free

All written and visual data contained in this document reflects the latest product information available at the time of publication.

Graco reserves the right to make changes at any time without notice.

This manual contains English. GN 311021 MM 311021

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

GRACO INC.

P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441 www.graco.com

Written in USA 4/2005, Rev 10/2006

40 311021