LINEAR DYNAMICS INC.

OWNER‘S MANUAL

308–133

This manual contains important warnings and information.

READ AND RETAIN FOR REFERENCE

Rev. N

Supersedes F and PCN M

4.0 HP GASOLINE-POWERED AIRLESS LINESTRIPER

Model 160 Airless

3000 psi (210 bar, 21.0 MPa)

Maximum Working Pressure

Model 231–149, Series A

With one gun, RAC IV DripLess Tip guard,

Size 319 LineLazer Tip & Size 517 SwitchTip , and 50 foot (15 m) hose.

Model 231–151

Same as 231–149, except includes

Second Gun Kit, 224–097

NOTE: This is an example of the English language DANGER label on your sprayer.

This label is supplied with the sprayer in other languages. Before operating the sprayer, apply a DANGER label in the appropriate language for you operators, according to the separate instructions supplied with it.

0001C

FIRE AND

EXPLOSION HAZARD

SKIN INJECTION

HAZARD

Spray painting, flushing or cleaning equipment with flammable liquids in confined areas can result in fire or explosion.

Use outdoors or in extremely well ventilated areas. Ground equipment, hoses, containers and objects being sprayed.

Avoid all ignition sources such as static electricity from plastic drop cloths, open flames such as pilot lights, hot objects such as cigarettes, arcs from connecting or disconnecting power cords or turning light switches on and off.

Failure to follow this warning can result in death or serious injury.

Liquids can be injected into the body by high pressure airless spray or leaks – especially hose leaks.

Keep body clear of the nozzle. Never stop leaks with any part of the body. Drain all pressure before removing parts.Avoid accidental triggering of gun by always setting safety latch when not spraying.

Never spray without a tip guard.

In case of accidental skin injection, seek immediate

“Surgical Treatment”.

Failure to follow this warning can result in amputation or serious injury.

READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE

LINEAR DYNAMICS INC., 400 LANIDEX PLAZA, PARSIPPANY, NJ 07054

(201) 884–0300

COPYRIGHT 1990, GRACO INC.

Graco Inc. is registered to I.S. EN ISO 9001

B

Z

F

C

D

E

A

Part Identification

Y

X

Key

A Caster lever

B Dual gun selector

C Main hose

D Suction hose

E Fluid filter

F Pressure drain valve

G Arm

H Post

J Carriage bar

K Gun holder

L Rac IV tip guard

M Switch Tip

N Flex gun

O Displacement pump

P Caster

Q Dual gun selector cable

R Pressure control

S Spark plug cable

T Air Cleaner

U Muffler

V Fuel Tank

W Hook eyelet (use to strap pail or pail cover to cart)

X Pail cover

Y Caster Cable

Z Grounding cable and clamp

W

V

U

T

S

R

Q

G

H

J

K

O

N

M

L

0001C

P

Table of Contents

Warnings

Setup

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

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

Fueling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Second Gun and Hose Installation . . . . . . . . . . . . . . .

Flushing

Startup

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

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

10

11

12

13

4

7

Spray Tip and Tip Guard

Gasket Selection

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

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

Installation

Operation

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

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

15

15

15

15

Clearing a Clogged Tip

Maintenance

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

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

15

15

Spray Tip Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Spray Tip Application Recommendations . . 16

Spray Techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Line Width Adjustment . . . . . . . . . . . . . . . . . .

16

16

Positioning the Gun Arm Assembly . . . . . . . . . . . . . . 17

Vertical position of the first or second gun . 17

Horizontal position of the first gun . . . . . . . .

Horizontal position of the second gun . . . . .

17

17

Mount guns on the engine side of the cart . 18

Setup for spraying arcs . . . . . . . . . . . . . . . . . 18

Adjust Simultaneous Gun Triggering

Gun Arm Positions

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

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

Caster Lever & Cable Operation

Operation

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

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

18

19

20

20

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . .

Caster Tire Replacement . . . . . . . . . . . . . . . .

Caster Cable Tension Adjustment

Caster Alignment

. . . . . . . .

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

20

20

20

20

How to Mount the Gun . . . . . . . . . . . . . . . . . . . . . . . . .

Gun Cable & Dual Gun Selector Operation . . . . . . .

How the Dual Gun Selector Works

How to Release the Selector Cable

. . . . . . .

. . . . . . .

Adjust the Trigger Cable Tension

Maintenance

. . . . . . . . .

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

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Repair or Replacement

Displacement Pump

Pressure Control

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

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

Pressure Control Adjustment . . . . . . . . . . . .

Bearing Housing and Connecting Rod . . . .

Drive Housing

Pinion Housing

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

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

Clutch

Engine

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

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

Field & Wiring Harness

Clamp

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

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

Clutch Housing Removal

Reassembly

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

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

Parts

Displacement Pump Parts

Pressure Control Parts

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

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

Cart Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical Parts . . . . . . . . . . . . . . . . . . . . . .

Gun Mounting Parts . . . . . . . . . . . . . . . . . . . .

Pinion Parts

Technical Data

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

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

Accessories

Warranty

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

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

20

21

21

21

22

23

24

34

35

36

37

26

28

29

30

31

32

37

38

42

43

44

46

48

49

50

50

52

Manual Change Summary

This manual was updated to include the changes from PCN M except for 238–052 (CASTER, swivel).

This manual was changed to include the updated pressure relief system per ECO F4963.

Errors in the Parts Lists were corrected.

Symbols

Caution Symbol Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

CAUTION

This symbol alerts you to the possibility of damage to equipment if you do not follow the instructions.

INSTRUCTIONS

WARNING

EQUIPMENT MISUSE HAZARD

Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.

This equipment is for professional use only.

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

Use the equipment only for its intended purpose. If you are not sure, call your distributor.

Do not alter or modify this equipment.

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

Do not exceed the maximum working pressure of the lowest rated system component. Refer to the

Technical Data on page 50 for the maximum working pressure of this equipment.

Use fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-

nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.

Do not use hoses to pull equipment.

Route hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose

Graco hoses to temperatures above 82 C (180 F) or below –40 C (–40 F).

Do not lift pressurized equipment.

Comply with all applicable local, state, and national fire, electrical, and safety regulations.

Wear hearing protection when operating this equipment.

Do not use 1,1,1–trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use could result in a chemical reaction, with the possibility of explosion.

4 308-133

WARNING

INJECTION HAZARD

Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also cause serious injury.

Fluid injected into the skin may look like just a cut, but it is a serious injury. Get immediate medi- cal attention.

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

Do not put your hand or fingers over the spray tip.

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

Do not “blow back” fluid; this is not an air spray system.

Always have the tip guard and the trigger guard on the gun when spraying.

Check the gun diffuser operation weekly. Refer to the gun manual.

Be sure the gun trigger safety operates before spraying.

Lock the gun trigger safety when you stop spraying.

Follow the Pressure Relief Procedure on page 7 if the spray tip clogs and before cleaning, checking or servicing the equipment.

Tighten all fluid connections before operating the equipment.

Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not repair high pressure couplings; you must replace the entire hose.

Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by kinks or bends near the couplings.

TOXIC FLUID HAZARD

Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin, inhaled, or swallowed.

Know the specific hazards of the fluid you are using.

Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local, state and national guidelines.

Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and solvent manufacturer.

FUEL HAZARD

The fuel used in this unit is combustible and when spilled on a hot surface can ignite and cause a fire.

Do not fill the fuel tank while the engine is running or hot.

EXHAUST HAZARD

The exhaust contains poisonous carbon dioxide which is colorless and odorless.

Do not operate this equipment in a closed building.

308-133 5

WARNING

FIRE AND EXPLOSION HAZARD

Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and result in a fire or explosion and serious injury.

If there is any static sparking or you feel an electric shock while using this equipment, stop spray-

ing immediately. Do not use the equipment until you identify and correct the problem.

Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid being sprayed.

Keep the spray area free of debris, including solvent, rags, and gasoline.

Disconnect all electrical equipment in the spray area.

Extinguish all open flames or pilot lights in the spray area.

Do not smoke in the spray area.

Do not turn on or off any light switch in the spray area while operating or if fumes are present.

Do not operate a gasoline engine in the spray area.

Ground the sprayer to a true earth ground with the ground wire and clamp (supplied).

Use only electrically conductive hoses.

MOVING PARTS HAZARD

Moving parts can pinch or amputate your fingers.

Keep clear of all moving parts when starting or operating the sprayer.

Before servicing the equipment, follow the Pressure Relief Procedure on page 7 to prevent the equipment from starting unexpectedly.

6 308-133

NOTE: Always use Genuine Graco Parts and Accessories, available from your Graco distributor.

Grounding

WARNING

FIRE AND EXPLOSION HAZARD

Before operating the pump, ground the system as explained below. Also read the section FIRE OR EXPLOSION HAZ-

ARD on page 6.

Setup

Pressure Relief Procedure General Information

NOTE: Reference numbers and letters in parentheses in the text refer to the callouts in the figures and the parts drawing.

WARNING

INJECTION HAZARD

Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you: are instructed to relieve the pressure, stop spraying, check or service any of the system equipment, or install or clean the spray tips.

1.

Sprayer: make sure that the grounding chain (106) contacts the ground while the unit is moving. See page 46. For stationary spraying, connect a ground wire and clamp (159) to a true earth ground.

2.

Fluid hoses: use only grounded hoses with a maximum of 500 ft. (150 m) combined hose length to ensure grounding continuity.

3.

Spray gun: obtain grounding through connection to a properly grounded fluid hose and sprayer.

4.

Object being sprayed: according to local code.

5.

Fluid supply container: follow your local code.

1.

Engage the spray gun safety latch.

2.

Turn the ON/OFF switch to OFF.

3.

Flip the pressure control switch to OFF.

4.

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

5.

Engage the gun safety latch.

6.

Hold the pressure relief tube firmly to the side of a grounded metal pail, and open the pressure relief valve. Leave the valve open until you are ready to spray again.

7.

Disconnect the spark plug cable to prevent the system from starting unexpectedly.

If you suspect that the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, very slowly loosen the tip guard retaining nut or hose end coupling and relieve pressure gradually, then loosen completely. Now clear the tip or hose.

6.

Solvent pails used when flushing: follow your local code. Use only metal pails, which are conductive, placed on a grounded surface. Do not place the pail on a nonconductive surface, such as paper or cardboard, which interrupts the grounding continuity.

Valve shown in

CLOSED position.

Valve shown in OPEN position.

Pressure

Hose

7.

To maintain grounding continuity when flushing or relieving pressure, hold a metal part of the spray gun firmly to the side of a grounded metal pail, then trigger the gun.

159

Fig. 1

Fig. 2

Suction

Tube

Pressure

Relief Tube

308-133 7

Setup

7.

Provide adequate ventilation when spraying indoors.

1.

Read and follow the warnings on pages 4 and 6 before installing or operating this sprayer.

2.

Unpack the Linestriper Carefully raise the handle

(19) to a vertical position. Four screws (39) and locknuts (40) are packed in a bag. Install the two rear screws (39A) and finger tighten the nuts (40A). Install one screw (39B) and nut (40B) on each side of the handle. Firmly tighten all four nuts. See Fig. 3.

WARNING

If the Linestriper is used indoors, you must vent the exhaust to the outdoors or provide adequate ventilation as specified by you local code. This is to reduce the risk of carbon monoxide poisoning.

CAUTION

When raising the cart handle (19), be sure no cables are caught on the frame or become kinked.

3.

To install a second gun and hose, see page 11.

4.

Fill the packing nut/wet–cup (216) 1/3 full with

Graco Throat Seal Liquid (TSL), supplied, and keep it filled, to help extend the pump life. See

Fig. 4.

8.

Fill the gas tank. See Fueling on page 10.

9.

Flush the pump to remove the lightweight oil which was left in the pump to protect it from rust. Follow the

Flushing on page 12.

10. Prepare the paint according to the manufacturer’s recommendations. Remove any skin that may have formed. Stir the paint to mix pigments.

Strain the paint through a fine nylon mesh bag (available at most paint dealers) to remove particles that could clog the filter or spray tip. This is an important step toward trouble–free spraying.

5.

Check the engine oil level. Refer to the Honda engine manual, supplied. This is a summary of the information: Remove one of the oil fill plugs (A); the oil should be almost overflowing. See Fig. 4.

Add oil as necessary. Also read the Maintenance section on page 23.

Recommended engine oil: Use a high–quality, detergent oil, SAE 10W–40, classified “FOR SERVICE

SE or SF”.

6.

Ground the sprayer. Proper grounding is essential to maintaining an electrically safe system. Also read and follow FIRE OR EXPLOSION HAZARD on page

6.

19

39A

WARNING

Ground the sprayer whenever it is used indoors, either as a moving line striper or as a stationary sprayer. Floors in most factories are coated, which causes them to be poor electrical conductors. This increases the risk of hazardous static electric discharge, which can result in serious injury, fire, or explosion and property damage.

40A

40B

39B

Fig. 3

0007C

Whenever you flush: connect the ground clamp

(159) to a true earth ground.

Using as an outdoor striper: Be sure the static chain attached to the bottom of the cart drags on the ground to help dissipate static electricity. Ground the sprayer to a true earth ground if specified by your local electrical code.

Indoor spraying: Ground the sprayer whenever the sprayer is used indoors. The ground wire supplied with the sprayer is not long enough to allow much operator movement. Therefore, the operator must provide a longer ground wire or provide some other method of effective electrical grounding as specified by your local electrical code.

Fig. 4

Keep filled with TSL

216

A

Setup

11. Observe the following cautions to avoid pressure control damage.

CAUTION

To avoid damaging the pressure control, follow these precautions.

12. To use the wheel brake, lift the brake handle (A– bottom rear of cart) to engage the brake. Lower the handle to disengage the break. See Fig. 5. For positive break engagement, be sure there is proper tire pressure and that tire wear is not excessive.

Allow the main hose to act as a pulsation dampener: Always use nylon spray hose at least 50 ft.

(15 m) long for the main gun; Never use a wire braid hose; it is too rigid.

13. For how to operate and adjust the various features of the Linestriper see pages 11–22.

14. Start the sprayer. See page 13.

Never install a ball valve or shutoff device between the filter and the 50 ft. (15 m) hose.

Do not allow water or water-base material to freeze in the pressure control.

A

CAUTION

Close the black fuel shutoff lever whenever you are transporting the sprayer to prevent fuel from flooding the engine.

Keep the sprayer upright and level when operating it and transporting it. This prevents crankcase oil from leaking into the combustion chamber, which makes startup very difficult.

Fig. 5

ÂÂ

ÂÂÂ

ÂÂÂ

03586

308-133 9

WARNING

Gasoline is extremely flammable and explosive under certain conditions. To reduce the risk or a fire or explosion:

1.

Always shut off the engine before refueling.

2.

Refuel in a well-ventilated area.

3.

Do not smoke or allow flames or sparks in the area where the engine is refueled or where gasoline is stored.

4.

Do not overfill the tank. Make sure the filler cap is securely closed after refueling.

Fueling

NOTE: The HONDA engine warranty does not cover damage resulting from the use of gasolines containing alcohol. See the HONDA engine manual for more information.

3.

General. Do not use oil and gasoline mixtures or contaminated gasoline. Avoid getting dirt, dust or water in the fuel tank.

4.

Tank capacity: 0.66 gallons (2.5 liter). Leave 1/2 in.

(13 mm) at the top of the tank for gas expansion.

5.

Shut off the engine switch (A) before refueling.

6.

After refueling, tighten the fuel tank cap (B) firmly.

A

B

5.

Fuel vapor or spilled fuel can ignite. If any fuel is spilled during refueling, make sure the area is dry before starting the engine.

1.

Fuel specifications. Use automotive gasoline with a pump octane number of 86 or higher. If the engine knocks or pings, use a higher octane fuel.

Unleaded fuel minimizes combustion chamber deposits.

2.

Gasolines containing alcohol (gasohol). Do not use gasohol which contains methanol, if the gasohol does not contain cosolvents and corrosion inhibitors for methanol. Even if it does contain such additives, do not use the gasohol if it contains more than 5% methanol.

Fig. 6 0009

Second Gun and Hose Installation

NOTE: Fig. 7 represents the installation at Step 3.

NOTE: To switch the gun assemblies to the engine side of the cart, refer to the instructions on page 17 before installing the second gun kit.

1.

Disengage the trigger cable from the block (48) of the unit’s existing gun. See page 21. Engage the gun’s trigger safety latch.

6.

Disconnect the trigger cable from the second gun at the screw (34). See Fig. 7 DETAIL B.

7.

Unscrew the filter’s second outlet cap (14). Screw the short hose (403) onto the filter nipple.

8.

Remove the guide clamp screw (27).

2.

Loosen the carriage clamps (B, C). Slide the carriage bar (4) off the cart.

9.

Snap the cable bushing (E) into the guide plate (D).

Route the trigger cable (402) parallel with the main gun cable, separating the guide clamp (104) to feed the cable through it. Install and tighten the clamp screw (27). Route the cable through the cable guide

(7) and to the second gun.

3.

For mounting the second gun bar on the pump side of the cart: Slide a clamp (405A) onto the carriage bar (4). Slide the carriage bar through the pump-side carriage clamp (B) and into the center of the cart. Now slide another clamp (405B) onto the carriage bar. See Fig. 7.

10. Slide the hooked end of the cable (402) through the hole (F) in the lever plate (122). Rotate and slide the hook back until it engages the plate. See DETAIL A.

11. Reconnect the trigger cable to the second gun at screw (34). Torque the screw to 15 in–lb (1.7 N.m), back it off 1/16 to 1/8 turn and then tighten the jam nut (99) while holding the screw (34). Be sure the plate (94) moves freely.

For mounting the second gun bar on the engine side of the cart: Follow Step 3, except slide the carriage bar through the engine-side carriage clamp (C) and the into the center of the cart. The knobs of the clamps (405A, 405B) must face back toward the handle bars.

4.

Slide the carriage bar (4) through to the opposite carriage clamp. Tighten the carriage clamps (B,C).

5.

Slide the second gun bar (404) far enough into the carriage bar that the clamp (405B) engages the bar.

Position the clamps (405A, 405B) over the notches

(A) in the carriage bar (4) and tighten the clamps.

NOTE: For stable gun operation, the second gun bar (404) has a maximum recommended extension from the carriage bar of about

111 /

4

” (286 mm).

12. Install the clip (401) to hold the cable onto the frame.

13. Connect both trigger cables to the blocks (48). Then adjust the cable tension. See pages 20 and 22.

14. Do not install the spray tip until the system is primed.

15. Adjust simultaneous gun triggering. See page 18.

DETAIL A

HOW TO INSTALL CABLE

122

402

401

14

D

E

27,104

402

C

F

7

403

405B

404

CORRECTLY INSTALLED CABLE

DETAIL B

402

Fig. 7

Torque to 15 in–lb

(1.7 N.m) and then back up

1/16 to 1/8 turn

First gun

Second gun

34

99

94

4

405A

B

A

48

02490B

Flushing

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 7.

Be sure the pump is properly grounded.

CAUTION

Never leave water in the sprayer if the is any chance it could freeze. Push the water out with compatible solvent. Water frozen in the pressure control tube prevents the sprayer from being started, and causes serious damage to the pressure control.

When to Flush

1.

Flush a new sprayer to remove the protective oil.

Before using water–base paint, use compatible solvent, then soapy water, and then clean water.

Before using oil–base paint, use compatible solvent.

2.

Changing colors. Use a compatible solvent.

3.

Changing from water–base to oil–base paint. Use warm, soapy water, and then a compatible solvent.

4.

Changing from oil–base to water–base paint. Use a compatible solvent, then warm, soapy water, and then clean water.

5.

Storage. After the compatible solvent flush, relieve pressure, but do not drain the compatible solvent.

6.

Startup after storage.

Before using water–base paint , flush out the compatible solvent with soapy water, and then with clean water.

When using oil–based paint, flush out the compatible solvent with the paint to be sprayed.

How to Flush

1.

Relieve pressure.

2.

Remove the filter bowl (A) and screen (B); see manual 307–273. Install the bowl and support (C), without the screen, to flush it. Clean the screen separately.

See Fig. 8.

3.

Close the pressure drain valve (13).

4.

Put the suction tube in a grounded pail of water or solvent.

5.

Remove the gun(s) from the holder. Remove the spray tip(s) to prevent splashing.

WARNING

To reduce the risk of static sparking and splashing when flushing, always remove the spray tip from the gun, and hold a metal part of the gun firmly to the side of, and aimed into, a grounded metal pail.

6.

Follow Startup on page 13. Keep the gun triggered until clean water or solvent comes from the nozzle.

See Fig. 9. Release the trigger and engage the gun safety latch.

NOTE: If you have two guns, release the trigger safety latch on the second gun and trigger that gun until clean water or solvent comes from the nozzle. To ensure that the hoses are well-flushed, flush the first gun and then the second gun at least one more time.

7.

Check all fluid connections for leaks. Relieve pressure before tightening any connections. Start the sprayer. Recheck the connections for leaks.

8.

Remove the suction tube from the solvent pail. Disengage the gun safety latch. Trigger the gun to force water or solvent from the hose. Do not let the pump run dry for more than 30 seconds to avoid damaging the pump packings! Relieve pressure.

A

13

B

C

Fig. 8

Maintain firm metalto-metal contact when flushing to reduce the chance of static sparking and splashing.

0013

0014

Fig. 9

9.

If you have been spraying paint, remove the strainer, suction tube and suction hose and clean them separately to be sure all paint sediment is removed. Dried paint in the suction tube assembly can build up and cause performance problems later on.

10. Install the clean filter screen. Install the filter bowl and hand tighten.

11. See Storage or Changing Colors, above. Relieve pressure.

Startup

Before You Start the Linestriper

1.

See Flushing, page 12, to determine if the Linestriper should be flushed.

2.

Be sure the gas tank is full.

3.

Check the engine oil level.

NOTE: The engine stops automatically, or will not start, if it is low on oil. If you try to start it again without adding more oil, a red light (A) near the engine on/off switch glows as you pull the starter rope.

4.

Be sure the spark plug cable (J) is firmly pushed onto the spark plug.

Startup

See Fig. 10

1.

When starting a sprayer that IS NOT PRIMED, remove the spray tip.

2.

Place the suction tube (S) into the paint, water or solvent container, depending on whether you are flushing or are ready to spray.

3.

Open the black fuel shutoff lever (E) by pushing it in the direction of the arrow.

CAUTION

Never start the engine unless fluid pressure is relieved and the pressure control switch is turned OFF.

Attempting to start the engine when it is pressurized could damage the electrical system.

4.

Turn OFF the pressure control switch (K).

5.

To start the engine: a.

Turn the pressure adjusting knob (L) all the way counterclockwise to the lowest pressure setting.

b.

Slide the metal throttle lever (C) away from the fuel tank to the maximum position (fully left).

c.

If the engine is cold, close the choke by moving the gray lever (D).

d.

If the engine is warm, close the choke by moving the gray lever (D) only half way or not at all.

e.

Turn ON the engine switch (B).

WARNING

A rope that recoils too quickly may hit someone and cause serious bodily injury. The rope could also jam in the recoil assembly.

f.

Hold the frame of the sprayer with one hand and pull the starter rope (G) rapidly and firmly.

Continue holding the rope as you let it return.

Pull and return the rope until the engine starts.

g.

Open the choke as soon as the engine starts, except in cold weather. In cold weather, leave the choke closed for 10 to 30 seconds before opening it to keep the engine running.

6.

Release the trigger cable and engage the gun trigger safety latch. See page 21.

7.

Remove the gun from the holder by unscrewing the gun holder knob and lifting out the gun.

8.

To start the pump:

NOTE: Lower the throttle setting for easier priming.

a.

Open the pressure drain valve (R).

b.

Turn ON the pressure control switch (K).

c.

Turn the pressure control knob (L) about 1/4 turn from minimum pressure. Run the pump until fluid is flowing smoothly from the pressure drain valve, indicating the pump is fully primed.

d.

Close the pressure drain valve (R).

e.

Disengage the gun safety latch. Hold a metal part of the gun firmly against a grounded metal pail, squeeze the trigger until fluid flows from the gun.

f.

Release the trigger. Engage the safety latch.

NOTE: If you are using two guns, follow Step e and f, above, for the second gun.

9.

If you have not primed the sprayer with paint yet, move the suction tube (S) to the paint container. Release the trigger safety latch. Trigger the gun into the water/solvent pail just until paint appears. Release the trigger and engage the trigger safety latch. Repeat for the second gun, if two guns are used.

10. Place the pail cover (F) on the pail.

WARNING

To reduce the risk or serious injury from fluid injection, never operate the spray gun with the tip guard removed.

11. Install the tip guard and spray tip (M). See page 15.

12. Mount the gun in the gun holder. See page 20.

13. Engage the trigger cable. See page 21.

CAUTION

Always use the lowest fluid pressure and the lowest throttle setting needed. Higher settings cause excessive clutch cycling, premature tip wear and premature pump wear.

14. Adjust the engine speed and pump pressure. Trigger the gun onto a test paper to check the spray pattern and atomization. Turn the pressure adjusting knob

(L) until you get a good pattern. Then slowly lower the throttle setting (C) as far as you can without changing the spray pattern.

Startup

15. Read Spray Techniques on page 16.

CAUTION

Close the black fuel shutoff lever (E) whenever you are transporting the sprayer to prevent fuel from flooding the engine.

Keep the sprayer upright and level when operating it and when transporting it. This prevents crankcase oil from leaking into the combustion chamber, which makes start up very difficult.

F

A

––AT REAR OF ENGINE––

B

H

E

D

C

R

Shown in choked position

Shown off

Shown in off position

S

G

H

J

L

K

N

P

Q

R

S

KEY

A

B

C

D

E

F

G

H

Engine Oil Light

Engine On/Off Switch

Throttle Lever

Gray Choke Lever

Black Fuel Shutoff Lever

Pail Cover

Starter Rope

Air Cleaner

J

K

Spark Plug Cable

Pressure Control On/Off Switch

L Pressure Adjusting Knob

M SwitchTip

Rac IV Tip Guard

Gun Trigger Safety Latch

Remote Trigger Cable

Pressure Drain Valve

Suction Tube

Fig. 10

14 308-133

Q P

M

N

0001C

Spray Tip and Tip Guard

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 7.

WARNING

Failure to install or use the RAC IV tip guard assembly correctly may result in an undirected spray of paint into the eyes or on the skin of the operator.

Be sure you:

Use the appropriate gasket for the solvent used.

Fully insert the tip into the guard.

Fully tighten the guard onto the gun nozzle using a wrench.

Turn the handle so it is parallel to the gun nozzle.

When replacing a worn spray tip, always install a new gasket and seat.

Gasket Selection

WARNING

To reduce the risk of fluid splashback into the eyes or on the skin, use the appropriate gasket as specified in the following text.

Operation

WARNING

Keep clear of the nozzle! High pressure fluid from leaks or spray can penetrate the skin and cause extremely serious injury, including the need for amputation. The spray tip guard provides extra protection against injection, but does not prevent it!

Never cut off the spray tip guard.

Be sure the spray tip handle is in the FULL SPRAY position before operating the gun. See Fig. 11.

Clearing a Clogged Spray Tip

Disengage the trigger cable(s). Engage the gun safety latch. Turn the arrow handle to the FULL CLEAN position. See Fig. 13. Release the safety latch and trigger the gun. Fluid pressure should force out the clog. Return the arrow handle to the full spray position. If it is still

clogged, follow the Pressure Relief Procedure on page 7 and remove the spray tip for cleaning.

Maintenance

Change the seat and gasket when the spray tip wears out; these parts wear at about the same rate.

C

RED or YELLOW

A

D

BLACK

J

E

F

Fig. 11 H

G

0091

Use the black rubber gasket (D) ONLY with latex and oil-based paints, stoddard solvents, mineral spirits, turpentine and water. When using this gasket, the spray tip can be removed and replaced without using tools.

Use the red or yellow plastic gasket (C) with the same fluids as above and with most other solvents, including lacquer thinner, trichloroethylene, MEK, acetone, brush cleaner, xylol. When using this gasket, loosen the RAC

IV retaining nut to remove the spray tip.

Installation

Relieve pressure. Install a tip (F) so the flange (G) on the cylinder fits into the slots (H) at the base of the spray tip guard (J). See Fig. 11.

Place the seat (E) on a pencil, curved side out, as shown in Fig. 12. Guide the seat into the retaining nut (A) and turn the seat until it straddles the cylinder of the spray tip

(F). Drop in the appropriate gasket and press it down. If using the red or yellow gasket (C), be sure the flat side faces out of the retainer (A). See Fig. 11.

Screw the spray tip guard snugly onto the gun, holding it in the desired position while tightening retaining nut (A).

NEVER use a wrench to turn the plastic tip guard (J), to avoid damaging the guard.

Fig. 12

A

E

GUN NOZZLE

RAC IV

DripLess

TIP GUARD

TIP

HANDLE

Fig. 13

FULL SPRAY POSITION

F

0092

FULL CLEAN POSITION

308-133

0093

15

Spray Tip Selection

Spray Tip Application Recommendations

Lineal Feet/Minute

(rate at which unit is moved)

Based on 4” wide line and 15 mils of paint

120 144 184 220 264 308 352 400 Application

Parking Lot Lines

4” wide

6” wide

Long Lines,

4–6” wide

Curbs

217 LLT–319*

317 319*

417* 419*

221*

321*

221*

223

323

223

224

325

225 227 228 231

* Tips can be used with two guns. Supplied with the Linestriper .

Fig. 14

Other Applications

Sport Court,

2” wide line

Crosswalk,

12” wide line, 1 gun

115, 117

621,

623, 625

Airport,

24” wide line, two guns 721

Stencils

General Stationary

417*, 419*

Painting 517

Spray Techniques

These spray techniques discuss how to use and adjust the features of the Linestriper. You must also consider operator technique, job site conditions and weather.

1.

Use water rather than paint to practice spraying technique and positioning the guns.

2.

Be sure the RAC IV Tip Guard is always parallel to the ground and the “wings” of the spray tip guard face the front and back of the unit, as shown in Fig. 15.

WARNING

To reduce the risk of a fluid injection injury, always disengage the remote trigger cable to the gun(s) and engage the gun trigger safety latch(es) before moving or adjusting the spray tip guards, guns, or gun arms. See Page 21.

3.

Use the lowest pressure necessary for good atomization. High pressure may cause excessive paint buildup and overspray.

4.

Start moving the Linestriper before triggering the gun to prevent a build up of paint at the beginning of the line. Release the trigger a second before stopping the Linestriper. Move at an even rate of speed.

5.

Always check your gun adjustments on cardboard or paper before starting each job. When painting curbs, paint first in an area that is less frequently seen.

6.

Keep in mind that many factors affect the straightness of a line, including uneven surfaces, potholes, rocks and other debris and a clogged or worn spray tip. See page 15 for how to clear or change a spray tip.

7.

To minimize the effect of bumps on the spray pattern, keep the spray tip guard centered with the front wheel axis.

16 308-133

8.

The spray tip size and the rate at which you move the unit affect the coating thickness. Generally, the faster you move the unit, the larger the spray tip orifice should be. The fan width of the spray tip indicates approximately how wide the line will be. See the chart in Fig. 14 for spray tip application recommendations.

9.

Position the guns to suit your requirements. See the section below and pages 17 to 19.

10. Traffic paints may be formulated for air spray, airless spray or have no formulation description.Generally, air spray formulas are pre–thinned, and will work well in the Linestriper, but there may be more overspray.

Non–air spray formulas tend to deliver more lineal feet of line per gallon with less overspray, since they are less easily absorbed into the pavement.

11. If you use fast–draying traffic paint on a hot day, float compatible solvent on top of the paint to prevent skin from forming on it.

Line Width Adjustment

Several factors affect line width: vertical distance of the spray tip to the spraying surface, spray tip fan pattern, using one or two guns, paint pressure, and a worn or clogged spray tip.

The typical conditions for a 4 in. wide line are: 319 size

LineLazer Tip (supplied), the gun positioned one inch from the lowest vertical position, and just enough pressure to atomize the paint. Depending on the fan pattern of the spray tip, use one gun to paint 2 to 12 in. wide lines, and two guns to paint 12 to 24 in. wide lines.

To decrease line width, lower the gun (if possible) or use a tip with a narrower fan pattern.

To increase line width, raise the gun, or use a tip with a wider fan pattern, or use two guns.

Positioning the Gun Arm Assembly

PUMP SIDE ENGINE SIDE

D

405B

402

1

First gun

Second gun

6

DETAIL B

06723

4

B

405A

93

404

“WINGS” OF TIP GUARD

0012D

E

B

A

DETAIL A

D

Fig. 15

NOTE: To prevent premature arm clamp (6) wear, make sure that the half of the clamp holding the gun support arm is supported by the notch in its side. See Fig. 15

DETAIL B.

The gun arms can be positioned for a variety of spraying needs. The drawings on page 19 primarily show the guns mounted on the pump side of the Linestriper. However, one or both guns may be mounted on the engine side.

Whenever You Move the Guns

CAUTION

Do not kink the cables, which could prevent them from properly triggering and untriggering the guns.

Disengage the trigger cables and engage the gun trigger safety latch first. See page 21. Do not kink the trigger cables. Pull out more of the 50 ft. hose, if necessary.

After moving the guns, reposition the spray tip guard so it is parallel to the ground and its “wings” face the front and back of the unit. Disengage the gun trigger safety latch and engage the trigger cable.

Vertical Position of the First or Second Gun

Loosen the arm clamp (6) and move the gun up or down.

Tighten the clamp. Engage the trigger cable.

Horizontal Position of the First Gun

Method 1: Disengage the trigger cable. Loosen the carriage clamps (B,D) and slide the carriage bar (4) left or right, so the gun will be outside the tire path. Tighten the clamps. Engage the trigger cable.

Method 2: Disengage the trigger cable. Loosen the arm clamp (6) and rotate the gun out to the side. Tighten the bolt. Engage the trigger cable.

NOTE: Use methods 1 and 2 together to obtain the maximum distance of one gun from the unit, which is helpful when spraying around obstacles.

Horizontal Position of the Second Gun

Method 1: Disengage the trigger cable. Loosen the clamps (405A, 405B). Slide the second gun bar (404) horizontally, being sure both clamps engage the second gun bar. Tighten the clamps. Engage the trigger cable.

Method 2: Disengage the trigger cable. Loosen the arm clamp (6) and rotate the gun out to the side. Tighten the bolt. Engage the trigger cable.

NOTE: Use methods 1 and 2 together to obtain the maximum distance of 33–

1

/

2

in. (851 mm) between the center of two guns.

308-133 17

Positioning the Gun Arm Assembly

Mount Guns on the Engine Side of the Cart

1.

For both guns, disengage the trigger cable and engage the trigger safety latch. See page 22.

2.

Loosen the gun holder knobs (93) and remove the gun. Lay the guns out of the way.

3.

Remove the knobs (E) on both carriage clamps

(B,D); the carriage bar (4) and extension clamps (A) will drop down. See Fig. 15 DETAIL A.

4.

Lift the front tire and rotate the carriage bar 180 under the cart and to the other side of it.

5.

Position the carriage bar below the carriage clamps

(B,D). Align the holes in the top of the extension clamps (A) with the holes in the carriage bar clamps and install the knobs (E). See Fig. 15 DETAIL A.

6.

Loosen the post/arm clamps (6) and rotate the guns forward. Retighten the clamps.

7.

Install the guns. Note which gun and position on the dual gun selector each of the cables (1 and 402) goes. Route the hoses and cables to prevent kinking.

Position the spray tip guards. Disengage the gun trigger safety latches. Engage the trigger cables.

Setup for Spraying Arcs

1.

Disengage the trigger cable (1) and engage the gun trigger safety latch. See page 21.

2.

Loosen the arm clamp (6) and rotate the arm (A) back near the rear tire and then position the arm so the spray tip guard aligns with the back axle of the unit. Retighten the clamp.

3.

Extend the carriage bar (4) or second gun bar (404) so you can easily watch the line you are painting and also to avoid running over the paint line. See page

17.

4.

Adjust the vertical and horizontal position of the gun.

5.

Spray the arc from the outside.

A

6

1

4

0002C Fig. 16

Adjust Simultaneous Gun Triggering

WARNING

To reduce the risk of a fluid injection injury, always disengage the trigger cable to the gun (s) and engage the guns’ trigger safety latch before moving or adjusting the guns or gun arms.

1.

Align the front of the guns by adjusting the gun arms.

See page 17.

2.

Position the dual gun selector to trigger both guns.

See page 21.

3.

Start the sprayer, using water, or spray on cardboard. See page 13. Trigger the guns to see if the lines begin at the same time and place.

If one gun triggers before the other gun, reduce the cable tension of the gun that triggers first. See Ad-

just the trigger cable tension on page 22 .

If one line starts in front of the other, adjust the position of the guns. See page 17.

Trigger the guns to recheck the adjustments.

Gun Arm Positions

SINGLE LINE ONE GUN CURB

DOUBLE LINE OR SINGLE LINE UP TO 24” WIDE TWO GUN CURB

SINGLE OR DOUBLE LINE; SPRAYING AROUND OBSTACLES

0017

DOUBLE LINE OR SINGLE LINE UP TO 24”

WIDE

308-133 19

Caster Lever and Cable Operation

CAUTION

The AccuTrack caster is factory-adjusted to track in a straight line. It should not require adjustment unless it is replaced. If a line is tracking poorly, check for the following items before aligning the caster.

1.

Even back tire pressure.

2.

Even tension on the rear tire bearings (adjust nuts (10) as needed.) See page 44.

3.

Even tightness of the caster screws (F). See

Fig. 18.

4.

Uneven painting surface.

5.

Operator technique.

Maintenance

See Fig. 18

Paint builds up on the caster triggering mechanism. To keep it operating properly, use a grease gun at the grease zerks (32A, 32B) to flush out the buildup – two to four times a month, depending on use.

Caster Tire Replacement

See Fig. 18.

Remove the setscrews (F) from the caster fork (E). Remove screw (G) and the tire (114a). Install the new tire and the setscrews (F). Tighten the setscrews equally so the tire has no play in it, but turns freely.

Caster Cable Tension Adjustment

See Fig. 18.

1.

Loosen the nut (A) located just outside the carriage clamp (B).

2.

With the pin (D) fully engaged in the caster fork (E), pull back on the cable (2) to increase the cable tension, or push it forward to reduce the tension. Finger tighten the nut (H). Tighten the nut (A) firmly.

Operation

The normal operating mode of the AccuTrack caster is locked in the straight forward position.

1.

For a free moving caster: Squeeze and hold the caster lever (22).

Shown removed only for visual purposes

Tighten equally so tire has no play in it but turns freely

A

2

H

B

D

87

2.

To lock the caster in the free moving position, squeeze the trigger, push in and hold the the button

(A) and release the trigger. See Fig. 17.

114a

32A

3.

To return to the normal mode, squeeze and release the caster lever and move the Linestriper forward to lock the caster in the straight position.

Fig. 18

G F

E

32B

D

0019

Fig. 17

22

Caster Alignment

Do this adjustment only if the caster or tire is replaced, or if no other solutions to poor tracking are found.

A

0018

1.

Loosen the two capscrews (87). Grasp the tire and visually it. Tighten the capscrews evenly. Move the unit forward. If the caster appears straight, start the unit (use water) and spray along a true straight line.

Continue adjusting as necessary. See Fig. 18.

How To Mount the Gun

1.

Relieve pressure. See page 7.

2.

Disengage the trigger cable. See page 21. Engage the gun’s trigger safety latch (B).

3.

Loosen the gun holder knob (93).

4.

Position the gun so the gun trigger is resting on the remote trigger lever (A).

5.

Be sure that the gun is mounted straight and then tighten the knob (93) firmly.

6.

Disengage the gun safety latch. Engage the remote trigger cable. See page 21.

Fig. 19

95

93

B

A

0020B

Gun Cable & Dual Gun Selector Operation

B

118d

1 or 402

Fig. 20

C

A

Shown in three positions

0021

How the Dual Gun Selector Works

See Fig. 20.

The gun is remotely triggered with the dual gun selector on the right handlebar. The gun is mounted in the holder so its trigger rests on a trigger lever which is connected to the dual gun selector by a trigger cable.

How to Release the Dual Gun Selector

Cable

WARNING

The gun is remotely triggered with a dual gun selector on the handle bar.

To reduce the risk of an injection injury due to remotely triggering the gun by accident, always disengage the trigger cable from the block before handling the gun. See Fig 21 DETAIL A. The gun will trigger briefly when releasing the cable!

Before you remove the gun from the holder, engage the gun’s trigger safety latch.

The main gun cable is black. In a two–gun operation, the second gun cable (402) is black with a light red cover at each end. Use the color coding to determine how each trigger cable is routed to the dual gun selector.

1.

To disengage the cable, grasp the cable (1or 402) just behind the block (48). Pull the cable back about

1/2 inch (13 mm) and then up and out of the block.

The gun will trigger briefly! See Fig. 21.

2.

To engage the cable, slide the cable (1) into the block

(48), making sure the end of the cable jacket seats firmly in the seat of the block. The gun will trigger

briefly! See Fig. 21.

CAUTION

Always note to which gun and position on the dual gun selector (C) each of the cables goes so that the correct gun is triggered.

CAUTION

Keep the seat in the gun cable block (48) and the end of the cable jacket clean at all times to be sure the cable functions properly.

To trigger the main gun only, move the selector (C) left until the spool (118d) protrudes through the plate (B) and disengages from the other plate (A).

To trigger the optional second gun only, move the selector (C) right until the spool protrudes through the plate (A) and disengages from the other plate (B).

To trigger both guns, center the selector (C).

CAUTION

A loose cable prevents the gun from being fully triggered causing premature wear of the gun needle.

A tight cable prevents the gun from being fully untriggered resulting in dripping and premature tip wear.

Follow Trigger cable tension adjustment on page

22.

Gun Cable & Dual Gun Selector Operation

1 or 402

Trigger Cable Tension Adjustment

See Fig. 21

1.

Relieve pressure. See page 7.

2.

Be sure the gun is properly mounted in the holder as instructed on page 20.

3.

Pull the actuator lever (94) forward and hold it. Lift up on the gun trigger (A) until there is slight resistance.

Visually check to see if there is about 1/32 to 1/16 in.

gap between the trigger lever (B) and where the gun trigger touches the bar.

4.

To adjust the tension, loosen the screw (C) in the block (48). Slide the block forward to increase the gap and backward to decrease the gap. Tighten the screw.

5.

Recheck the gap and adjust as needed.

FORWARD

94

A

B

DETAIL A

1/32 – 1/16”

(1–2 mm)

0023

Be sure end jacket of cable seats here. keep jacket and seat clean

1 or 402

48

C

45

CAUTION

Do not allow the cable (402) to rub against the outside edges of the slot (H) in the block (48), to prevent premature wear of the cable. Rotate the block slightly to eliminate rubbing. See Fig. 21

DETAIL A.

48

Fig. 21

45

0024

Maintenance

WARNING

To reduce the risk of serious injury always follow the Pressure Relief Procedure on page 7, before checking, adjusting, cleaning, or shutting down the Linestriper.

CAUTION

For detailed engine maintenance and specifications, refer to the separate HONDA engine manual.

Daily: Check the engine oil level and fill as necessary.

After the first 20 hours of operation and each 100

hours thereafter: Change the oil.

Weekly: Remove the air filter cover and clean the element. In very dusty environments, check the filter daily.

Replace the element as needed. Replacement elements can be purchased from your local HONDA dealer.

Weekly: Check the level of the TSL in the displacement pump packing nut. Fill the nut, if necessary. Keep

TSL in the nut to help lubricate the pump packings. See page 8.

Weekly: Use a grease gun to grease the zerks (32) on this unit. The grease purges pivot areas of paint buildup.

See Fig. 22.

Spark plug: Use only a (NGK) BP6ES or BPR6ES plug. Gap the plug to 0.025 to 0.030 in. (0.7 to 0.8 mm).

Always use a spark plug wrench.

Daily: Check and fill the gas tank.

1

3

4

1

2

One zerk on dual gun selector

One zerk on each gun holder

One zerk on caster lever

One zerk on caster latch

5 One zerk on wheel

Fig. 22

2

3

5

4

0001C

Troubleshooting

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 7.

Check everything in the chart before disassembling the sprayer.

PROBLEM

Engine/sprayer won’t start

CAUSE

Engine switch not on

Out of gas

Engine oil level low

Engine won’t “fire”

Spark plug cable disconnected or spark plug damaged

Water frozen in pressure control

Oil seepage into combustion chamber

Engine operates, but displacement pump doesn’t

Pressure control switch turned OFF

Pressure setting too low

Displacement pump outlet filter dirty

Tip or tip filter clogged

Displacement pump rod seized by dry paint

Connecting rod worn or damaged

Drive housing worn or damaged

Electrical power not energizing field

Clutch worn or damaged

Engine starts but dies

Pinion assembly worn or damaged

Oil level drops below oil sensor

Displacement pump output low on upstroke

Pump inlet screen clogged

Piston ball check not seating

Piston packings worn or damaged

Sleeve gasket in displacement pump worn or damaged

SOLUTION

Turn on engine switch.

Refill gas tank.

Try starting engine. If light on rear of engine glows, replenish oil.

Connect cable on top of engine or replace spark plug.

Return pressure control to authorized Graco dealer for repair.

Remove spark plug. Pull starter rope 3 or 4 times.

Clean and replace plug. Try to start. Keep sprayer upright to avoid oil seepage.

Turn on pressure control switch.

Increase pressure.

Clean filter.

Clean tip or tip filter.

Service pump. See page 26.

Replace connecting rod. See page 30.

Replace drive housing. See page 31.

Check wiring connections. See page 36.

With pressure control switch ON and pressure turned to MAXIMUM, use a test light to check continuity across black and white wires from pressure control.

Have pressure control checked by authorized

Graco dealer.

Service clutch. See page 34.

Service pinion assembly. See page 32.

Add oil.

Clean screen.

Service piston ball check. See page 26.

Replace packings. See page 26.

Replace sleeve gasket. See page 26.

Troubleshooting

PROBLEM CAUSE

Displacement pump output low on downstroke or both strokes

Pump inlet screen clogged

Paint leaks into wet–cup

Spitting from gun

SOLUTION

Clean screen.

Pressure setting too low

Dirty outlet filter, tip filter or tip

Piston packings worn or damaged

Intake valve ball check not seating properly

Increase pressure. See Startup,

Step 14, page 13.

Clean filters and/or tips.

Replace packings. See page 26.

Clean and service intake valve. See page 26.

Engine RPM too low Increase throttle setting. See Startup,

Steps 5b and 14, page 13.

Clutch worn or damaged Replace clutch. See page 34.

Partially clogged suction tube assembly Remove and clean suction tube. During normal flushing remove and clean the suction tube assembly separately to prevent further clogging.

Large pressure drop in hose

Loose wet–cup

Use larger diameter hose.

Tighten wet–cup just enough to stop leakage.

Throat packings worn or damaged

Displacement rod worn or damaged

Air in fluid pump or hose

Replace packings. See page 26.

Replace displacement rod. See page 26.

Check for loose connections at pump intake and tighten. Them prime the pump.

See Startup, page 13.

Clear tip clog. See page 15.

Tip partially clogged

Fluid supply is low or empty Refill and prime the pump. See Startup, page 13.

Check fluid supply often to prevent running the pump dry.

Dried paint particles from a poorly cleaned suction tube assembly

Remove and clean suction tube. During normal flushing remove and clean the suction tube assembly separately to prevent further clogging.

Displacement Pump

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 7.

Removing the Pump

See Fig. 23.

1.

Flush the pump. Relieve pressure.

2.

Hold the intake valve (223) with a wrench and unscrew the suction tube swivel union (53). Unscrew the hose (133).

3.

Push the retaining spring (75) up. Push the pin (71) out the rear.

4.

Loosen the locknut (137). Unscrew the pump.

3.

Tap the piston rod (224) down and then pull it out the bottom of the cylinder (219). See Fig. 24.

4.

Remove the glands (209*, 208*) and v–packings

(207*, 213*) from the throat. See Fig. 24.

5.

Clamp the flats of the piston rod (224) in a vise. Loosen the piston (222). Unscrew the nut (211) from the piston. Remove the glands (210*, 214*) and packings (212*, 206*, 203*) from the piston. See Fig. 24.

1

2

3

4

5

Leather

Poly

Lips must face down

Lips must face up

Torque to

67 ft–lb (90 N.m)

224

205

216

76

133

219

72

75

224

220

221*

57

71

137

204*

202*

223

53

Fig. 23 0025A

Disassembling the Pump

1.

Unscrew the intake valve (223) and remove all parts.

See Fig. 23.

2.

Remove the plug (205). Unscrew the packing nut

(216). See Fig. 24.

205

216

*209

219

*209

137

*207

1 3

*208

*202

*210

*206

1 4

*215

*214

213*

2 3

219

218

212*

2 4

203*

3

*213

207*

224

211

*202

5

*208

Fig. 24

222

0026 Fig. 25 0027

Displacement Pump

WARNING

6.

Stack the throat packings into the top of the cylinder

(219). Install the packing nut (216) loosely.

To reduce the risk or serious injury from pump rupture, use only tool 224–788 to remove the sleeve. If the sleeve is stuck, send the cylinder to your Graco distributor for removal.

C

219

202*

218

D

A

B

Fig. 28

0030

Fig. 26

219

0028

6.

Remove the sleeve when servicing the pump. Use special tool, Part No. 224–787 only. Screw the nut

(B) into the cylinder (219). Screw down the rod (A) to push the sleeve out. See Fig. 26.

Assembling the Pump

NOTE: Repair Kit 222–588 is available. For best results, use all the parts in this kit. The kit includes parts marked with an asterisk, for example (201*).

NOTE: Soak the packings in oil, and coat the rod and inside of the cylinder with oil.

NOTE: Alternate leather and plastic packings Be sure the lips of the v–packings face the direction shown.

Incorrect installation damages the packings and results in pump leakage.

1.

Check the piston rod (224) and the inside of the sleeve (218) for scoring or scratches. If these parts are damaged, new packings will not seal properly.

2.

Stack the piston packings onto the piston (222) as shown in Fig. 25.

3.

Tighten the piston nut (211) onto the piston to

10.5 in–lb (1.2 N.m.) to seat the packings, and then back off and finger tighten.

7.

Insert the piston rod assembly (C) into the top of the

sleeve (218). Install the gasket (202*) on the sleeve.

Slide the sleeve assembly into the bottom of the

cylinder (219). Note that the tapered end (D) of the sleeve is at the bottom. See Fig. 28.

8.

Assemble and install the intake valve. Use a new gasket (202*). Tighten the valve to 67 ft–lb

(90 N.m). See Fig. 23.

Installing the Pump

See Fig. 23 and 29.

1.

Screw the pump 3/4 of the way into the bearing housing (76). Hold the pin (71) up to the pin hole in the connecting rod (79) and continue screwing in the pump until the pin slides easily into the hole.

2.

Align the top threads of the pump cylinder flush with the face (E) of the bearing housing and so the outlet nipple (15) faces the rear of the unit.

3.

Push the retaining spring (75) completely into the connecting rod groove. Tighten the locknut (137) very tight - 70 ft–lb (95 N.m), to prevent it loosening and damaging the threads of the bearing housing.

Torque:

70 ft–lb

(95 N.m) 79

76

E

71

75

137

Apply one drop of sealant to these threads

224

225*

211

Fig. 29 0031

WARNING

222

Fig. 27 0029

NOTE; Note and maintain the alignment of the piston

(222) to the nut (211) through Steps 4, 5 and 6.

4.

Apply ONE drop of adhesive, supplied with the repair kit, to the piston threads. Place the ball (225*) on the piston. Hand tighten the piston into the rod (224) just until the nut (211) contacts the rod. Place the flats of the rod in a vise.

5.

Tighten the nut (211) onto the rod (224) to 19 ft–lb (25

N.m). Use two wrenches to maintain the alignment as mentioned in Step 3.

Be sure the retaining spring (75) is firmly in the groove all the way around, to prevent the pin (71) from working loose due to vibration.

If the pin works loose, it or other parts could break off due to the force of the pump action. These parts could be projected through the air and result in serious injury or property damage, including damage to the connecting rod and bearing housing.

4.

Tighten the packing nut (216) just enough to stop leakage. Fill the nut 1/3 full with Graco TSL, and assemble the remaining parts.

Pressure Control

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 7.

1.

Disconnect both hoses (133) at the pressure control swivel unions (108). Note the original location of each hose to be sure you reassemble them correctly at the end of this procedure. See Fig. 30.

2.

Working under the engine mounting plate of the cart, disconnect the pressure control wires at A. Remove the four nuts (40) and related hardware from the capscrews (91 & 87).

3.

Remove the pressure control covers (89). See Fig.

30.

4.

Disconnect the red, black and white wires from the rectifier (307) which are sheathed with the conductor

(309). Unscrew the connector (313) from the pressure control, pulling the conductor and wires out with it. See Fig. 31.

5.

Use a wrench to hold the hex of the adapters (C) while removing the swivel unions (108). See Fig. 31.

WARNING

To reduce the risk of electric shock, be sure all grounding features of the pressure control are properly assembled:

Ground wire (308) connected in pressure control.

Serrated flange capscrews to mount the pressure control to the cart.

Grounding chain (106) connected by the long pressure control mounting capscrew (87).

6.

Reassemble the pressure control in the reverse order. Use the long pressure control mounting screw

(87) in hole B. From below the mounting plate (25) assemble the grounding chain (106), washer (105) and nut (40) to the screw. See Fig. 30.

7.

Perform the Pressure Control Adjustment on page 29 before regular operation of the sprayer.

RED

WHITE

106

105

40

TO ENGINE

108

B

109

91,87

89

309

40

309

313

BLACK

307

A

C

RECTIFIER (307) CONNECTIONS

~

RED BLACK

-

0033

133

TO FILTER +

WHITE

Fig. 30

28 308-133

TO PUMP

0032 Fig. 31 0034

Pressure Control Adjustment

WARNING

Use extreme caution when performing this calibraplosion. It may also prevent the sprayer from obtaining

tion procedure to reduce the risk of a fluid injection inthe maximum working pressure, resulting in poor sprayer performance.

jury or other serious bodily injury, which can result from component rupture, electric shock, fire, explosion or moving parts.

This procedure sets the sprayer to 2600–3000 psi

(190–210 bar, 19.0–21.0 MPa) Maximum Working

Pressure.

NEVER attempt to increase the fluid outlet pressure by performing these calibrations in any other way. Never

Exceed 3000 Psi (210 Bar, 21.0 MPa) Maximum

Working Pressure. Normal operation of the sprayer at higher pressures could result in component rupture, fire or explosion.

Perform this procedure whenever the pressure control assembly is removed and reinstalled, or replaced, to be sure the sprayer is properly calibrated.

Improper calibration can cause the sprayer to over– pressurize and result in component rupture, fire or ex-

ALWAYS use a new 50 foot (15.2 m) spray hose, rated for at least 3000 psi (210 bar, 21.0 MPa) Maximum

Working Pressure, when performing this procedure. A used, under–rated hose could develop a high pressure leak or rupture.

Service Tools Needed:

New 50 foot (15.2 m), 3000 psi (210 bar, 21.0 MPa), flexible nylon airless spray hose, Part No. 223–541

0–5000 psi (0–345 bar, 34.5 MPa) fluid–filled pressure gauge,

Part No. 102–814

New spray tip, size 0.025 to 0.029

3/8 in. ignition wrench or nut driver

5 gallon pail of water or mineral spirits

Swivel, 156–823

Nipple, 162–453

Tee, 104–984

Set Up

1.

Follow the Pressure Relief Procedure Warning on page 7.

2.

Set up the system as shown in Fig. 32.

Set the Dead Band (Pressure Differential)

1.

Remove the pressure control cover.

NOTE: Do not alter this adjustment if the wheel is already set as shown in Fig. 33.

2.

Set the white differential wheel (A) on the microswitch. Turn the wheel so the letter F is concealed behind the switch and the letter E is the first letter seen.

Pressure Up

1.

Start the sprayer and prime it.

2.

Adjust the pressure to 2600 psi (180 bar, 18.0 MPa).

3.

Shut off the engine. If the pressure drops after the engine is shut off, replace the pump packings before proceeding. See page 26.

Adjust the Pressure

See Fig. 34.

1.

Remove the plug (320) in the bottom of the control.

2.

Turn and hold the pressure control knob (B) at the maximum pressure.

3.

Engage the nut (C): Insert the nut driver through the pressure control hole (D), or use an ignition wrench inserted from the front of the pressure control.

Fig. 32

Inside pressure control looking up at differential wheel

Fig. 33

A

102–814

156–823

104–984

162–453

223–541

0035

0036

D

B

320

C

Fig. 34

0037 a.

Loosen the nut just until you hear a click. Stop.

b.

Slowly tighten the nut just until another click is heard. Stop.

4.

Replace the plug (320) and the pressure control cover.

Bearing Housing and Connecting Rod

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 7.

9.

Install the screws (81) and lockwashers (46) on the bearing housing. Tighten the screws evenly to 175 in–lb (20 N.m).

10. Refer to Installing the pump on page 27.

Torque to 175 in–lb (20 N.m)

NOTE: Steps 1 to 10 refer to Fig. 35.

1.

Refer to Removing the Pump on page 26.

2.

Remove the four screws (81) and lockwashers (46) from the bearing housing (76).

3.

While pulling the connecting rod assembly (79) with one hand, lightly tap the lower rear of the bearing housing (76) with a plastic mallet to loosen it from the drive housing (77). Pull the bearing housing and the connecting rod assembly off the drive housing.

4.

Inspect the crank (A) for excessive wear and replace parts as needed.

5.

Evenly lubricate the inside of the bronze bearing (D) in the bearing housing (76), and the inside of the connecting rod link (C), with high–quality motor oil. Liberally pack the roller bearing (B) in the connecting rod assembly (79) with bearing grease (77d), supplied.

6.

Assemble the connecting rod (79) and bearing housing (76).

7.

Clean the mating surfaces of the bearing and drive housings.

8.

Align the connecting rod with the crank (A) and carefully align the locating pins (E) in the drive housing

(77) with the holes in the bearing housing (76). Push the bearing housing onto the drive housing or tap it into place with a plastic mallet.

81,46

59

C

B

79

80,59

72

73

74

15

71

A

77

76

75

54

D

137

E

CAUTION

Do not use the bearing housing screw (81) to align or seat the bearing housing with the drive housing.

These parts must be aligned using the locating pins

(E) to help avoid premature bearing wear.

Fig. 35

53

0038A

Drive Housing

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 7.

CAUTION

Do not drop the gear cluster (78) when removing the drive housing (77). The gear cluster is easily damaged. The gear may stay engaged in either the drive housing or the pinion housing.

NOTE: Refer to Fig. 36 for this procedure.

1.

2.

Remove the front cover (74).

Disconnect the pump outlet hose (133).

Do not lose the thrust balls (77c and 138k) located at each end of the gear cluster. The balls, which are heavily covered with grease, usually stay in the shaft recesses, but they could be dislodged. If they are caught between the gears and not removed, the balls will seriously damage the drive housing. If the balls are not in place, the bearings will wear prematurely.

3.

Remove the four screws (81) and lockwashers (46) from the bearing housing (76).

4.

Lightly tap the back of the bearing housing (76) with a plastic mallet. Pull the pump, bearing housing and connecting rod away from the drive housing as one assembly.

5.

Remove the two bearing housing screws (80) and lockwashers (59). Remove the four pinion housing screws (67) and lockwashers (59).

7.

Liberally apply bearing grease (77d, supplied) to the gear cluster (78). Be sure the thrust balls (77c and

138k) are in place.

8.

Place the bronze colored washer (77a) and then the silver–colored washer (77b) on the shaft protruding from the big bearing of the drive housing (77). Align the gears and push the new drive housing straight onto the pinion housing and locating pins (B).

6.

Lightly tap around the drive housing (77) with a plastic mallet to loosen it from the pinion housing (138p).

Torque to 175 in–lb (20 N.m)

9.

Starting at Step 5, work backwards to reassemble the sprayer. Or, move ahead to the next section in this manual if further service is needed.

59

67

B

77a

77b

138p

77

73

74

76

79

77c

78

138k

59

67

46

81

80

59

133

0039A

Fig. 36

Pinion, Clutch, Clamp, Field, & Engine

Disassembling these parts can start from the pinion housing or from the clutch, if no pinion service is needed.

If starting from the pinion housing, first follow Steps

1 to 6 of DRIVE HOUSING, on page 31, and then continue with the procedure below.

If starting from the clutch, see page 34.

Pinion Housing

Removing the Pinion Housing

WARNING

To reduce the risk of serious injury whenever you are instructed to relieve pressure, always follow the

Pressure Relief Procedure on page 7.

2.

Push on the front of the shaft (138b) to force the bearing and hub assembly out of the housing

(138p).

3.

Install the new shaft assembly (138a), pushing it to the shoulder of the pinion housing (138p).

4.

Install the rings (138e and 138m).

NOTE: Refer to Fig. 37 for Steps 1 to 3.

1.

Remove the two bottom screws (67) first, and then remove the top three screws (67).

2.

Pull the pinion housing (138p) away from the clutch housing (61). The armature (55a) will come with it.

3.

Pull out the armature (55a).

5.

Skip ahead to Reassembly, page 39, Step 7, or continue on page 34.

See page 33

CAUTION

Do not lose the thrust ball (138k). Refer to the CAU-

TION on page 31 for more information.

59

67

61

NOTE: To disassemble the pinion, continue with Repair-

ing the Pinion, below. To disassemble more of the sprayer, go to page 34. To reassemble the sprayer from this point, skip ahead to Reassembly, page 39, Step 7.

Repairing the Pinion

NOTE: A hydraulic press is required for disassembly and reassembly if you purchase the pinion parts individually.

If you do not have such a press, use Repair Kit No.

223–189, which includes the shaft and bearings pre–assembled and lubricated.

NOTE: Refer to Fig. 38 except where noted.

If using Repair Kit 221–032, follow steps 1 to 5 below.

1.

Remove the small ring (138e) from the hub (138f) and the large ring (138m) from the bearing recess of the pinion housing (138p).

Fig. 37

55a

138k

138p

59

67

0040

Pinion Housing

DETAIL A

0041

2

138p

CUTAWAY VIEW OF PINION

HOUSING (138p)

1

3 138h

Fig. 38

138k

138j

3

If you purchased parts separately, use the following instructions. Disassemble only as far as needed for the parts being replaced.

NOTE: The old bearing (138d) will be damaged when removed. Have an extra one on hand if you need to remove it for any reason.

1.

If replacing the small bearing (138c) or roller clutch

(138g), press the old ones out of the pinion housing (138p).

2.

Remove the small ring (138e) from the hub (138f).

Remove the snap ring (138m) from the bearing recess of the housing (138p).

3.

Push on the front of the shaft (138b) to force the bearing and hub assembly out of the housing

(138p).

6

1

2

3

4

5

6

7

Round steel bar to push on shaft (138b)

1

Large bearing

Hub

Steel bar stock

Two steel blocks

Hydraulic press

Press platform

2 138d

Fig. 39

138f

3

4

5

7

0043

PLACEMENT OF STEEL BLOCKS AND BAR

STOCK WHEN PRESSING OFF LARGE BEARING

1

2

3

4

5

Back of pinion housing

Press fit small bearing (138c) and roller clutch (138g) in here

Lubricate exterior

Lubricate inner and outer diameters

Lubricate teeth

138m

138a

138n

138b

5

138d

138e

138f

4

138g

138c

4

4.

Using a hydraulic press, place pieces of steel bar stock on the inner race of the large bearing

5.

CAUTION

The arrow on the roller clutch (138g) must point toward the small bearing (138c) for the shaft (138b) to rotate in the right direction.

6.

(138d) and press the shaft through the hub and bearing. See Fig. 38.

Apply lubricant to the parts as shown in Fig. 38.

Press fit the following parts:

0042

Small bearing (138c) and then the roller clutch

(138g), with its arrow pointing to the bearing, into the rear of the housing (138n). See Detail A in Fig. 38.

Large bearing (138d) to the shoulder of the shaft

(138b).

Hub (138f) onto the shaft (138b) all the way to the large bearing (138d).

7.

Install the shaft assembly (138a), pushing it to the shoulder of the housing (138p).

8.

Install the rings (138e and 138m).

9.

Skip ahead to Reassembly, page 39, Step 7, or continue on the next page.

Clutch

NOTE: The clutch assembly (55) includes the armature

(55a) and rotor (55b). The armature and rotor must be replaced together so they wear evenly.

NOTE: If the pinion assembly (138) is not yet separated from the clutch housing, follow Steps 1 to 4. Otherwise, start at Step 5.

1.

Follow the Pressure Relief Procedure Warning on page 7.

2.

Disconnect the hose (133) from the displacement pump.

3.

Remove the bottom two screws (67) from the clutch housing (61) and then remove the remaining three screws (67).

4.

Tap lightly on the back of the drive housing (77) with a plastic mallet to loosen the assembly (D) from the clutch housing (61). Pull the assembly away; the armature (55a) will come with it.

5.

Remove the armature from the pinion shaft.

6.

Remove the four socket head capscrews (157) and lockwashers (156). Install two of the screws in the threaded holes in the rotor (55b). Alternately tighten the screws until the rotor comes off. See Fig. 40.

7.

Skip ahead to Reassembly, page 39, Step 6, or continue on the next page.

Torque to 7 ft–lb (9.5 N.m)

Pinion shaft

Threaded holes

55a

157

156

55b

61

59

67

D

Fig. 40

133

77

138

A

B

C

USE A STEERING WHEEL

PULLER TO REMOVE ROTOR

0044A

34 308-133

61

59

67

104

25

50

132

51

Fig. 41

Engine

3.

Lift the engine carefully and place it on a work bench.

1.

Working under the mounting plate (25) of the cart, remove the screw (51), lockwasher (132) and washer

(50) which hold the clutch housing (61) to the cart.

See Fig. 41.

2.

Still working under the mounting plate, remove the two locknuts (40), and then pull the screws (63) out of the base of the engine. Disconnect the red wire from the engine lead. Disconnect the black and white wires (58) from the field. Pull the wires carefully through the grommets before removing the engine.

See Fig. 41 and 42.

4.

Remove the Field and Wiring Harness, Clamp and

Clutch Housing, as instructed on pages 36 and 37.

5.

Skip ahead to Reassembly, page 38, Step 1.

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

TO FIELD

63

TO ENGINE

58

RED

View from under engine mounting plate

0032

Fig. 42

40

0045

308-133 35

Field & Wiring Harness

NOTE: Refer to Fig. 43.

1.

Loosen the four setscrews (62) holding the field (70) to the clutch housing (61). Unplug the wiring harness

(58) from under the engine mounting plate. Pull the field out to expose the black and white wires (58).

2.

Pull the caps (A) off the wire screws (57) in both places on the field. Loosen the screws and release the wires (58).

3.

Skip ahead to Reassembly, page 38, Step 4.

70

61

62

Fig. 43

57 58

A

0046

36 308-133

Clamp

NOTE: A standard steering wheel puller is required to remove the clamp. Two 1/4–28 x 3 or 4 in. long screws are also needed.

NOTE: Refer to Fig. 44.

1.

Loosen the two screws (60) on the clamp (68), working through the slot at the bottom of the clutch housing (61).

2.

Install two screws (B) of the tool (A) in two of the threaded holes in the clamp. Tighten the screws (C) until the clamp comes off.

3.

Skip ahead to Reassembly, page 38, Step 3, or continue below.

61

A

C

B

68

Torque to 125 in–lb (14 N.m)

Fig. 44

Clutch Housing

NOTE: Refer to Fig. 45.

1.

Remove the four capscrews (156) and lockwashers (157) which hold the clutch housing

(61) to the engine (64).

2.

Remove the engine key (66).

3.

Pull off the clutch housing (61).

4.

Skip ahead to Reassembly, page 38,

Step 1.

156

157

61

66

64

60

0047

Fig. 45 0048

308-133 37

Reassembly

1.

Install the clutch housing (61), capscrews (156) and lockwashers (157) on the engine. See Fig. 46.

2.

Install the engine shaft key (66). See Fig. 46.

3.

Install the clamp (68) onto the engine shaft (A).

Maintain the 1.41 in. +/– 0.01 (35.8 mm) dimension shown in Fig. 47.

To check the dimension, place a rigid, straight steel bar (B) across the face of the clutch housing (61).

Use an accurate measuring device to measure the distance between the inside of the bar and the face of the clamp. Adjust the clamp as necessary. Torque the two screws (60) to 125 in–lb (14 N.m).

4.

Connect the wires of the harness (58) to the screws

(57) in both places on the field. Pull the plastic caps

(C) up and snap them over the screws. Guide the wires of the harness (58) through the slot in the clutch housing. Slide the field (70) into the clutch. Align the setscrew chamfers in the field and the clutch housing

(61). Tighten the setscrews (62) oppositely and evenly, to 25 in–lb (2.8 N.m). See Fig. 46.

Torque oppositely and evenly to 25 in–lb (2.8 N.m)

Connect wiring harness (58) here before sliding field (70) into housing (61)

Torque to 125 in–lb (14 N.m)

61

B

Face of housing

1.41” (35.8 mm)

Torque to 125 in–lb (14 N.m)

A

60

Fig. 47

SIDE CUTAWAY VIEW OF CLUTCH HOUSING

0050

70

68

156

157

61

62

A

66

57

C

58

0049 Fig. 46

60

5.

Place the engine (64) assembly on the cart. Align the mounting holes. Guide the engine wire (A) through the clamp at the the rear of the mounting plate (25). See Detail A. Guide the wiring harness

(58) from the field, through the grommet (24) in the mounting plate (25). Install the serrated flange screws (63) and nuts (40) and torque to 15 ft–lb (20.4

N.m). Install the capscrews (51), lockwashers (132) and washer (50) from under the engine mounting plate to secure the clutch housing (61). Connect the engine wire (A) to the red wire, and connect the black and white wires of the pressure control at B as shown in the Detail A, Fig. 48.

NOTE: With the autogap style armature, the gap between the rotor and the armature is critical for proper operation. The clutch kits with an autogap style armature include a cardboard spacer (p/n 186–857) to set the proper gap. This spacer is used only during operation.

6.

Clean the face of the armature (55a). With the flat side of the armature facing the rotor (55b), slide the armature onto the hub (138f) in the drive/pinion assembly just until the chamfered end of the hub (138) protrudes through the armature. See Detail B, Fig.

48. There will be significant resistance. Attach the cardboard spacer, supplied with the clutch kit, to the face of the armature. Engage the tabs on the spacer with the slots in the armature.

Reassembly

Brace the cart against a wall to keep it from rolling.

Push the drive/pinion assembly onto the clutch housing (61). There will be significant resistance.

When the mating surfaces of the drive/pinion assembly and the clutch housing are flush, remove the drive/pinion assembly. Remove the card-

board spacer.

7.

Be sure the face of the rotor (55b) and the field (61) is free of all oil and contaminants. Install the rotor, lockwashers (59) and capscrews (60). Torque the capscrews to 7 ft–lb (9.5 N.m). See Fig. 48

After installing the rotor (55b), pull the engine recoil rope to assure that there is no friction between the rotor (55b) and the field (70). If there is friction, loosen the setscrews (62) and reposition the field (70) as necessary. Tighten the setscrews oppositely and evenly to 25 in-lb (2.8 N.m). Also make sure there are no burrs on the outside edge of the rotor.

8.

Assemble the drive/pinion housing (C) to the clutch housing, using the capscrews (67) and lockwashers (59). See Fig. 48.

308-133 39

138f

DETAIL B

1

0051

55a

1

2

3

4

5

Chamfered end of hub

Torque to

7 ft–lb (9.5 N.m)

Face must be clean

Tighten oppositely and evenly torque to

25 in–lb (2.8 N.m)

Torque to

15 ft–lb (20.4 N.m)

Reassembly

138n,138k

2 60

59

55b

70

61

59

67

64

58

24

3

50

132

51

DETAIL A

VIEW FROM UNDER ENGINE

MOUNTING PLATE

0052A

55a

C

63

25

40 5

62 4

To field

A

To engine

To pump

B

To filter

0060

Fig. 48

40 308-133

Notes

308-133 41

Parts – Displacement Pump

Model 222–580, Series A

Sleeved Displacement Pump

Includes items 202 to 225

Ref.

No.

Part No.

Description

202* 108–526 PACKING, o–ring

203* 107–093 SEAL, u–cup, poly

Qty.

2

1

204* 105–445 BALL

205 179–810

1

PLUG 1

206* 178–939 V–PACKING, leather

207* 178–940 V–PACKING, leather

2

2

208* 178–942 GLAND, male

209* 178–943 GLAND, female

210* 178–944 GLAND, male

1

1

1

211 178–945 NUT, hex, retaining

212* 178–964 V–PACKING, poly

213* 178–965 V–PACKING, poly

214* 181–338 WASHER, backup

215* 178–969 GLAND, female

216 179–809 NUT, packing

3

1

1

3

1

1

218

219

188–335 SLEEVE, cylinder

188–334 CYLINDER

220 185–214 GUIDE, ball

221* 178–938 PIN, ball stop

222

223

224

235–554

222–437

235–572

VALVE, piston

VALVE, intake

ROD, piston

225* 105–444 BALL

1

1

1

1

1

1

1

1

*207

205

216

209*

213*

208*

*212

* These parts are also included in Repair Kit

222–588, which may be purchased separately .

219

202*

218

206*

221*

204*

202*

223

0053

215*

203*

214*

222

220

224

225*

211

210*

Parts –Pressure Control

Part No. 222–369 – Replacement Pressure Control for All GM 3500 Sprayers

Part No. 222–369 includes all items marked with a . It does not include unmarked items. Order the Basic Control,

222–369, and/or items 309 or 313 as needed.

Ref.

No.

300

301

302

303

304

305

306

308

309

Part No.

Description

222–380 PRESSURE CONTROL

Includes items 302 to 304

183–466 LABEL, caution

111–930 ON/OFF SWITCH

105–659 BOOT, switch

107–255 GUARD, locking

157–021 LOCKWASHER, No. 8, internal

100–284 NUT, hex, 8–32

220–979 CONDUCTOR, red

220–978 CONDUCTOR, red, white, black

Qty.

1

2

1

2

1

1

1

1

1

Ref.

No.

310

311

313

316

317

318

319

320

Part No.

Description Qty.

100–035 SCREW, mach, slotted pan hd,

8–32 x .312” 1

108–783 SCREW, mach, flat hd; 8–32 x .812” 1

108–852 CONNECTOR, 45

222–352 TRIAC

107–070 SCREW, flat head, 6–32 x .625

100–072 NUT, hex, 6–32

103–181 LOCKWASHER, No. 6, external

101–754 PLUG, pipe, 3/8 npt

2

2

1

1

2

1

317 , 318 , 319

316

ENGINE

308

RED

MAIN

SWITCH

RED

RED

C

NO

R

RECTIFIER

G

MT2

MT1

RED

310

305

WHITE

308

RED

313

302

303

304

311 ,

305 ,

306

307

BLACK

301

LABEL

309

320

BLACK

300

0033

RED

CLUTCH

FIELD

CLUTCH

FIELD

WIRING SCHEMATIC

WHITE GROUND

RECTIFIER (307) CONNECTIONS

0034

118 1

150

1

2

19

39

11

20

10

1

2

3

4

See page NO TAGNO TAG

Label

See page 48

See page 46

21

22

Parts – Cart

Ref 13

83

3

168

84

169

171

159

170

86

4

40

172

52

82

24

28

90

33

32

33

139

27

29

23

REF 3

34

35

94

99

37

E

36

104

26

30

40

42

26

41 2

117 110

40

39

25

30

42

2

41

40

31

87

38

E

39

114

116

115

112

105

40

3

114a

114d

32

114c

114b

10

114e

0003C

44 308-133

Parts – Cart

28

34

35

36

37

38

39

29

30

31

32

33

40

41

42

52

82

83

84

85

86

87

1

21

22

23

24

25

26

27

2

3

10

11

19

20

Model 231–132, Series A With one gun

Includes items 1–173

Ref.

No.

Part No.

Description

90

94

99

104

Qty.

111–154

111–153

112–405

111–020

111–197

CABLE, dual gun selector,

9.6 ft (2.9 m)

238–361 HOSE, hp 50’ x 1/4”

CABLE

NUT

WHEEL, pneumatic, 16” dia.

224–021 HANDLE

108–063 GRIP, handle

186–787 BRACKET, release lever

LEVER, release

224–246 COVER, pail

109–099 BUSHING, snap

186–672 PLATE, mounting

111–040 LOCKNUT, 5/16–18 w/nylon insert

110–963 SCREW, serrated flange, hex hd,

5/16–18 x 3/4”

106–212 CAPSCREW, hex hd, 3/8–16 x 2–

1

3

/

4

” 4

104–766 MOUNT, motor 4

108–471 KNOB

186–668 BRACKET, rear caster

2

1

100–846 FITTING, lubrication

111–016 BEARING, flanged

111–230 SCREW, mach, flhd,1/4–20 x 1”

100–015 NUT, hex, 1/4–20

186–814 PIN, pivot

103–262 CAPSCREW, sch, 5/16–18 x 3– 1 /

2

”

186–731 BRACKET, front caster

1

1

1

1

2

1

1

2

1

2

1

1

1

2

1

4

1

1

1

3

111–194 CAPSCREW, serrated flange hd,

3/8–16 x 2”

101–566 LOCKNUT, 3/8–16 w/nylon insert

186–821 LABEL, Warning (trigger cable)

224–136 CLAMP, extension

103–927 CLAMP, hose, 1–1/4”

6

16

2

2

1

183–769 TUBE, suction, 5 gal, 3/4” pipe

178–342 CLIP, spring

238–959 HOSE, cpld, 3/16” x 60”

1

5

1

103–473 WIRE TIE STRAP

176–920 HOSE, suction

111–193 CAPSCREW, serrated flange, hex hd,

3/8–16 x 7/8”

183–770 STRAINER, 16 mesh

186–747 LEVER, actuator

101–345 NUT, hex, jam, 1/4–20

108–868 CLAMP, wire

3

1

1

1

1

2

1

Model 231–140 With two guns

Includes items 1–172, and 401–405 (see page 48)

Ref.

No.

Part No.

Description Qty.

166

168

169

170

171

172

105

107

110

112

100–731 WASHER, 3/8”

186–620 LABEL, grounding

224–019 CART

224–066 CASTER LATCH ASSY

114

114a

114b

114c

Includes 1 of item 32

237–832 SWIVEL CASTER

112–820

112–822

112–823

Includes items 1 14a–114c

SCREW, cap, hex hd

BEARING, needle

RACE, needle

1

114d 112–824 SEAL

114e 112–825 SPRING, Belleville

115 801–020 NUT, 1/2–13 w/nylon insert

116

117

101–044 WASHER, flat, 1/2”

118

111–195 CAPSCREW, serrated flange, hex hd,

1/2–13 x 1– 1 /

4

”

224–144 REMOTE TRIGGER KIT

Includes items 118a to 118e

118a 111–018

118b 111–206

.SPRING, compression

.BEARING, ball, 3/32”

4

118c 186–746 .TRIGGER

118d 186–694 .SPOOL, cable selector

118e 186–832 .KNOB

119

120

121

122

127

139

147

150

159

161

165

186–695

190–098

BLOCK, mounting

PIN, trigger pivot

111–017 BEARING, flanged

186–696 PLATE, lever

107–110 LOCKNUT, with nylon insert,

107–194

10–32 unf-2b

WASHER, flat 3/8”

206–994 THROAT SEAL LIQUID, 8 oz (0.27 l) 1

112–798 SCREW, thd frmg,

237–686 GROUNDING CLAMP ASSY

1

1

111–235 SCREW, mach, pnhd

235–456 BRAKE KIT, See manual 308–227

1

1

1

1

1

1

1

1

1

1

2

2

1

1

4

4

1

1

1

1

1

2

1

1

100–718 WASHER 1

191–874 BRACKET, pressure relief 1

113–789 SCREW, mach, truss hd. 8–32 x 0.5” 1

113–790 CLAMP, pressure relief

102–040 NUT, lock

100–014 SCREW, cap hex hd

1

1

1

Replacement Danger and W arning labels, tags and cards are available at no cost.

BRAKE KIT, Ref No. 165

Includes solid colored parts

REMOTE TRIGGER DETAIL,

Ref No. 118, Includes 118a–118e

32

119

127

122

121

166

164

121

120

122

118d

118c

118a

118b

118e 0005

ÂÂ

Â

Â

01919

308-133 45

Parts – Mechanical

73

74

81

46

76

80

79

59

77

77a

77b

78

59

67

129 1

128

75

59

77c

67

70

69

68

157

59

156

67

62

138

60

59

66

61

57

58

59

60

133

56

55

REF 24

155

26

104

65 1

64

63

89

88

87

109

135

88

91

72

137

140

92 6

5

15

71

REF 25

2

85

REF 86

2 Ref 2

14

15

54 3

52

53

16

111

43

Ref 84

17

12

107

1 4

105

40

50

132

51

REF 133

18

40

108

106

26

REF 133

1

2

3

4

5

6

Label

See page 44

See page 42

Located on bottom

Located on inside of cover

Located on outside of cover

0004B

46 308-133

54

55

55a

56b

57

64

65

66

67

68

69

70

71

72

58

59

60

61

62

63

16

17

18

26

40

43

46

50

51

52

53

12

13

14

15

73

74

Ref.

No.

Part No.

Description

162–453 NIPPLE. 1/4–18 npsm x 1/4–18 npt

238–960 VALVE, pressure relief

220–285 CAP, secondary fluid outlet

162–453 NIPPLE, hex, 1/4 npsm x 1/4 npt

1-3/16” long

218–029 FLUID FILTER, see 307–273 for parts

100–040 PLUG, 3/8 npt

164–672 ADAPTER, 1/4 npsm x 3/8 npt

111–040 LOCKNUT, 5/16–18 w/nylon insert

101–566 LOCKNUT, 3/8–16 w/nylon insert

110–997 SCREW, serrated flange, hex hd,

1/4–20 x 5/8”

106–115 LOCKWASHER, 3/8”, high collar

108–851 WASHER, plain, 3/8”

100–469 CAPSCREW, hex hd; 3/8–16 x 3/4”

103–927 CLAMP, hose, 1– 1 /

4

”

110–229 UNION, 90 , 3/4” ID hose x

3/4 npsm swivel

222–580 DISPLACEMENT PUMP KIT see page 42 for parts

221–044 CLUTCH ASSEMBLY

3

1

1

. ARMATURE

. ROTOR, clutch

109–033 SCREW, mach, slotted, bdgh

221–183

6–32 x 3/16”

CONDUCTOR, electrical

1

1

105–510 LOCKWASHER, 1/4”

108–803 CAPSCREW, hex sch; 1/4–28 x 1”

183–512 HOUSING, clutch

108–801 SETSCREW, 1/4–20 x 5/16”

110–837 SCREW, serrrated flange, hex hd,

5/16–18 x 1– 1 /

2

”

108–879 ENGINE, gasoline, 3.5 HP

181–867 LABEL, WARNING on engine

183–401 KEY, shaft

100–644 CAPSCREW, hex sch; 1/4–20 x 3/4” 9

183–517 CLAMP, mounting, rotor 1

1

1

108–800 PIN, dowel; 5/16 x 1”

185–529 FIELD KIT

1

1

176–818 PIN, 5/16 x 1.023” (special)

3

1

1

17

6

1

4

155–541 UNION, 90 , 1/4 npt x

2

1

1/4 npsm swivel

107–209 SCREW, mach, filh; 8–32 x 1”

179–899–154COVER, drive housing

1

4

1

1

1

1

1

1

2

4

1

1

1

1

3

4

Parts – Mechanical

Ref.

No.

Qty.

Part No.

Description Qty.

75

76

77

109

111

128

129

132

133

77a

77b

77c

78

79

80

81

85

87

88

89

91

92

105

106

107

108

135

137

138

140

155

156

157

176–817 SPRING, retaining

218–035 BEARING HOUSING

223–101 DRIVE HOUSING KIT

Includes items 77a to 77c

178–967 . WASHER, bronze

107–089 . WASHER, silver

100–069 . BALL

221–042 GEAR REDUCER 1

218–034 CONNECTING ROD KIT

107–218 CAPSCREW, hex sch; 1/4–20 x 2– 3 /

4

” 2

107–210 CAPSCREW, sch;

3/8–16 x 1– 1 /

2

” (special)

103–473 WIRE TIE STRAP

1

4

1

111–193 CAPSCREW, serrated flange hex hd,

3/8–16 x 1– 1 /

4

”

110–885 SCREW, pnh, thread forming,

10–24 x 3/8”

1

186–663

111–192

BRACKET, pressure control

CAPSCREW, serrated flange hex hd,

8

2

3/8–16 x 7/8” 3

186–856 LABEL 1

100–731

186–812 GROUND CHAIN, heavy, 15–

186–620

WASHER, 3/8”

LABEL, grounding

1

5 /

8

” long 1

1

156–823 UNION, straight, 1/4 npt(m) x

1/4 npt(f) swivel 2

222–369

178–034

186–757

PRESSURE CONTROL KIT

TAG, WARNING at filter

LABEL, identification, drive cover

185–953 LABEL, DANGER on drive housing

100–133 LOCKWASHER, 3/8”

235–695 HOSE, 1/4” ID x 2.4’, cpld 1/4 npt(m) x 1/4 npsm(f), spring guard full length

101–754 PLUG, pipe, 3/8 npt

178–941 NUT, hex, 1– 5 /

8

–18 (special)

223–188 PINION HOUSING

See parts on page 49

1

1

1

1

1

1

2

1

1

177–762 LABEL, WARNING inside pressure control cover

224–128 WIRING HARNESS

109–031 CAPSCREW, sch, 5/16–24 x 1”

104–008 LOCKWASHER, 5/16”

1

1

4

4

2

1

1

1

1

1

Replacement Danger and W arning labels, tags and cards are available at no cost.

308-133 47

Parts – Gun Mounting

Ref.

No.

4

6

7

32

33

34

35

44

45

47

48

49

93

94

95

96

97

98

99

100

101

103

113

123

132

136

Part No.

Description Qty.

224–025 BRACKET, gun support 1

111–817

188–135

100–846

111–016

111–230

CLAMP, arm support

GUIDE, cable

FITTING, lubrication

BEARING, flanged

SCREW, mach, flhd,

1/4–20 x 1”

100–015 NUT, hex, 1/4–20

1

2

1

1

1

1

100–016 LOCKWASHER, 1/4” 2

181–734 ARM, support 1

100–101 CAPSCREW, hex hd,

3/8–16 x 1” 1 or 2

186–699 BLOCK, mounting cable 1

100–021 CAPSCREW, hex hd,

1/4–20 x 1” 2

181–818 KNOB

186–747 LEVER, actuator

188–452 HOLDER, gun

108–483 SCREW, shoulder, sch,

1/4 x 3/8 ”

181–795 JAW, clamp

235–459 FLEX GUN

See manual 308–235

for parts 1

101–345 NUT, hex, jam, 1/4–20 2

1 108–535 BEARING, sleeve

107–445 CAPSCREW, sch,

111–045

1/4–20 x 1– 1 /

2

”

SCREW, shoulder, sch,

1

1

1

1

1

1

5/16 x 1” 1

LLT–319 LineLazer Tip, Sz 319 1

110–755 WASHER 1

100–133 LOCKWASHER, 3/8” 1

237–859 RAC IV DripLess

TIP GUARD 1

221–517 SwitchTip, Size 517 1 158 7

OPTIONAL SECOND GUN AND HOSE KIT

Model 224–097

Included with Sprayer Model 231–140 only

This kit includes the parts shown in the box to the right, which includes items

401–405 and the items listed above except 4.

Ref.

No.

Part No.

Description Qty.

6

404

401

401

402

403

404

405

178–342 CLIP, spring 1

111–155 CABLE, remote trigger 1

224–068 HOSE, 1/4” ID, cpld 1/4–18 npsm(f)

6.5 ft (1.2 m) grounded,

1 spring guards

224–096 BRACKET, support, extension 1

224–071 CLAMP, extension 2

403

402

4

7

6

45

98

136

SECOND GUN AND HOSE KIT

45

REF 1

49

48

44

132 47

96

97

35

33

93

95

103

33

99

101

100

123

0055A

113,158

34

99

32

94

49

44

97

48

132

47

405

Ref 402

43

99

94

32

33

35

95

96

98

113,158

136

93

123

103

33

99

101

100

0056A

48 308-133

Parts – Pinion Assembly

Ref No. 138

Pinion Housing

Includes items 138a to 138g

Ref.

No.

Part No.

Description

138a 223–189 PINION SHAFT ASSEMBLY

Includes items 138b to 138g

138b 185–916 .SHAFT, pinion

138c 109–001 .BEARING, needle

138d 109–002 .BEARING, ball

138e 108–880 .RING, retaining, external

138f 183–515 .HUB, armature

138g 110–607 .CLUTCH, roller

Qty.

1

1

1

1

1

1

1

Ref.

No.

Part No.

Description Qty.

NOTE: Items 138h to 138p are not included in a kit. Order them separately as needed.

138h 105–684 BEARING, ball, roller

138j 107–088 BEARING, ball, needle

138k 100–069 BALL, sst

138m 109–000 RING, retaining, internal

138n 105–489 PIN, dowel

138p 185–491 HOUSING, pinion

1

1

1

1

2

1

Lubricate exterior

Lubricate inner and outer diameters

Lubricate teeth

138m

138a

138n

138p

138f

138e

138d

138h

138b

138c

138g

138k 138j

Technical Data

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

Maximum Working Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4.0 Horsepower, Honda

3000 psi (210 bar, 21.0 MPa)

Noise Level

Sound Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sound Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

103 dbA

95 dbA @ 1 meter under maximum operating conditions

Cycles/Gallon (liter) per ISO–3744

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200 (53)

Maximum Delivery

Fuel Tank Capacity

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.0 gpm (3.79 liter/min)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0.66 gallons (2.5 liter)

Maximum Tip Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 gun with 0.031 tip;

2 guns with 0.021 tip

Inlet Paint Strainer

3 guns with 0.019 tip

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 mesh (1190 micron)

Outlet Paint Filter

Stainless Steel screen, reusable

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mesh (250 micron)

Stainless Steel screen, reusable

Pump Inlet Size

Fluid Outlet Size

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 npt (m)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npsm from fluid filter

Wetted parts

Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Zinc-Plated Carbon Steel, Stainless Steel,

Chrome-Plated Stainless Steel, Polyethylene,

Tungsten Carbide, Leather, Polyurethane

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight (dry, without packaging)

Zinc-Plated Carbon Steel, Stainless Steel

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212 lb (96.2 kg)

Height

Length

Width

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

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

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

40 in. (1016 mm)

56 in. (1422 mm)

37 in. (940 mm)

Accessories

USE ONLY GENUINE GRACO P ARTS AND ACCESSORIES

DANGER LABELS

The English language DANGER label shown on page 1 is also on your sprayer. If you have painters who do not read English, order one of the following labels to apply to your sprayer. The drawing below shows the best placement of these labels for good visibility. Order the labels directly from Graco, free of charge.

Toll Free: 1–800–328–0211

Apply other language here

French 185–956

Spanish 185–961

German 186–041

Greek 186–045

Korean 186–049

English 185–953

0057

DISPLACEMENT PUMP REPAIR Kit 222–588

See contents on page 42. Repair instructions are included with the kit.

50 308-133

FLEX GUN REPAIR KIT 235–474

Includes needle, gasket, diffuser/seat.

LINE GUIDE POINTER

Works only with Second Gun and Hose Kit 224–097.

Order One each of the following:

100–538 Screw

181–735

181–730

Indicator Holder

Line Indicator

SLEEVE REMOVAL TOOL 224–787

Required for removing the sleeve of the displacement pump during service.

THROAT SEAL LIQUID

Non–evaporating liquid for the wet–cup. Helps prevent buildup of paint on the rod and throat packings, to reduce premature wear.

206–994

206–995

206–996

8 oz.

1 quart

1 gallon

Notes

308-133 51

The LDI Warranty and Disclaimers

WARRANTY

Linear Dynamics Inc. (LDI) warrants all equipment manufactured by it and bearing its name to be free from defects in material and workmanship on the date of sale by an authorized LDI distributor to the original purchaser for use. As purchaser’s sole remedy for breach of this warranty, LDI will, for a period of twelve months from the date of sale, repair or replace any part of the equipment proven defective, with the exception of defects in parts on the drive train/gear box, which will be repaired or replaced for twenty–four months from the date of sale and the electric motor (excluding brush replacement, which is routine maintenance) or pressure control assembly which will be repaired or replaced for twenty-four months from the date of sale. This warranty applies only when the equipment is installed, operated and maintained in accordance with LDI’s written recommendations.

This warranty does not cover, and LDI shall not be liable for, any malfunction, damage or wear caused by faulty installation, misapplication, abrasion, corrosion, inadequate or improper maintenance, negligence, accident, tampering, or substitution of non–LDI component parts. Nor shall LDI be liable for malfunction, damage or wear caused by the incompatibility with LDI equipment of structures, accessories, equipment or materials not supplied by LDI, or the improper design, manufacture, installation, operation or maintenance of structures, accessories, equipment or materials not supplied by LDI.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized

LDI distributor for verification of the claim. If the claimed defect is verified, LDI 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.

DISCLAIMERS AND LIMITATIONS

The terms of this warranty constitute purchaser’s sole and exclusive remedy and are in lieu of any other warranties (express or implied), including warranty of merchantability or warranty of fitness for a particular purpose, and of any non-contractual liabilities, including product liabilities, based on negligence or strict liability.

Every form of liability for direct, special or consequential damages or loss is expressly excluded and denied. In no case shall LDI’s liability exceed the amount of the purchase price. Any action for breach of warranty must be brought within two (2) years of the date of sale.

EQUIPMENT NOT COVERED BY LDI WARRANTY

LDI makes no warranty, and disclaims all implied warranties of merchantability and fitness for a particular purpose, with respect to accessories, equipment, materials, or components sold but not manufactured by LDI.

These items sold, but not manufactured by LDI (such as electric motor, switches, hose, etc.) are subject to the warranty, if any, of their manufacturer. LDI will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

LDI Phone Number

TO PLACE AN ORDER OR FOR TECHNICAL ASSISTANCE, contact your LDI distributor, or call this number to identify the distributor closest to you: 1–201–884–0300.

FOR SPARE P ARTS: 1–800–233–8461 Toll Free

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

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

Manufacturing Facilities: Georgia, Pennsylvania, Texas

Company Distribution Centers: East Point, Georgia; Orlando, Florida; Omaha, Nebraska

LINEAR DYNAMICS INC., 400 LANIDEX PLAZA, PARSIPPANY, NJ 07054

PRINTED IN U.S.A. 308–133 March 1991, Revised November 1996