Graco LineLazer II 3900, LineLazer II 5900, 232651, 232652, 233011 Instruction manual

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INSTRUCTIONS--REPAIR

308874

KEEP FOR REFERENCE.

Read this and all related manuals for important warnings and instructions.

INSTRUCTIONS

LineLazer II 3900 and 5900

3300 psi (230 bar, 23 MPa ) Maximum Working Pressure

LineLazer II 3900

Model Series Description

232651 A Complete Sprayer 232652 A Complete Sprayer with 2nd Gun Kit 23301 1 A Complete Sprayer with Gauge and

Pail Kit

233012 A Complete Sprayer with 2nd Gun Kit,

Gauge and Pail Kit

LineLazer II 5900

Model Series Description

232661 A Complete Sprayer 232662 A Complete Sprayer with 2nd Gun Kit 233013 A Complete Sprayer with Gauge and

Pail Kit

233014 A Complete Sprayer with 2nd Gun Kit,

Gauge and Pail Kit

Rev. P

First choice when

quality counts.t

Model 232651

All models are not available in all countries

PATENTS PENDING

8824A

Related Manuals

Operation 308873..........................

Displacement Pump 308798.................

Spray Gun 308235.........................

Spray Tip *.................................

PC Board 308919..........................

Drain Valve Kit 308961......................

* for spray tip selection see page 4.

Table of Contents

Component Identification and Function 3............

Spray Tip Selection Guide 4.......................

Maintenance 5...................................

Troubleshooting 6................................

Repair

Bearing Housing & Connecting Rod 8.............

Drive Housing 9................................

Pinion Assembly/Rotor/Field/Shaft/Clutch 10.......

Clamp 1 1.....................................

Clutch Housing 12..............................

Engine 12.....................................

Pressure Control 14............................

Displacement Pump 16.........................

Parts

Model 232651, 232661 LineLazer II 17............

Pinion Assembly 25............................

Complete Sprayers 28..........................

Pressure Control 27............................

Dimensions 29...................................

Technical Data 29................................

Graco Warranty 29...............................

Graco Phone Number 29..........................

Warnings and Cautions

Warning Symbol

WARNING

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

WARNING

Fire and explosion can occur when spraying or flushing flammable

fluid in an area where air circulation is poor and flammable vapors can be ignited by an open flame or sparks.

To help prevent a fire and explosion:

DUse outdoors or in an extremely well ventilated area. DDo 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.

DRemove, extinguish or unplug all ignition sources;

tape wall switch. Do not smoke in spray area.

DNever fill fuel tank while the engine is running or hot. DGround Sprayer, object being sprayed, paint and solvent pails. DHold gun firmly to side of a grounded pail when triggering into pail. DUse only conductive airless paint hose. DNever run engine in inclosed area. DDo not flush with gasoline.

Caution Symbol

CAUTION

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

Fluid injection is a serious injury! If high pressure fluid pierces your skin, the injury might look like “just a cut”. But it is a serious

wound! Get immediate surgical treatment.

To help prevent injection, always:

DEngage trigger safety latch when not spraying. DPoint gun away from yourself or anyone else. DRelieve pressure before checking or repairing any leak. DRelieve pressure when you turn off the sprayer or stop spraying. DDo not use components rated less than system Maximum

Working Pressure

DWhen flushing, ground equipment to grounded object with orange

wire clamp.

DDo not flush equipment on asphalt or other non--conductive

surfaces.

Never allow children to use this unit. If you are injured using this equipment, get immediate medical treatment.

3088742

Component Identification and Function

Model 232651

ENGINE SPEED

TIP SIZE

ENGINE STOP

Fig. 1

A Pressure Control Switch ON/OFF, enables/disables clutch function B Pressure Adjusting Knob Controls fluid outlet pressure C Air Cleaner* Filters air entering the carburetor D Fuel Tank* Uses 86 octane gasoline E Muffler* Reduces noise of internal combustion F Spark Plug Cable* Routes electrical current to spark plug G Fuel Shutoff Lever* On/off lever to regulate fuel flow from gasoline tank to carburetor H Choke* Enriches air/gasoline mixture for cold starting J Throttle Lever* Adjusts engine speed for large or small orifice spray tips K Engine Switch* Enables/disables engine operation L Secondary Fluid Outlet Second hose and spray gun is connected here M Pressure Control Controls clutch cycling to maintain fluid pressure N Primary Fluid Outlet Hose and spray gun is connected here P Engine* 4--cycle gasoline engine

R Clutch Housing Transfers power from engine to drive assembly S Drive Housing Transfers power from clutch to displacement pump T Displacement Pump Provides fluid to be sprayed through spray gun U Fluid Filter Filters fluid between source and spray gun V Grounding Clamp and Wire Grounds sprayer system

W Pressure Drain Valve Relieves fluid pressure when open

* For more detailed explanations of these controls, refer to the Honda Engines Owner’s Manual; supplied

8825A

Install the spray tip in the gun. Sprayer is supplied with tip LLT319. For additional applications, use the Tip Selection T able on page 4.

308874 3

Spray Tip Selection Table

LineLazer Tip Selection Guide. Sprayer is supplied with tip LL5319. For additional applications, use the tip

selection table as follows: Note: the last three digits (LL5319

For example: the line width for tip LL5319 is 4 in. as shown in the table below . The tip orifice for tip LL5319

LineLazer Tip Selection Table

Tip Size

28621 1* 2 inches Sport court -- light film build LL5213* 2 inches Sport court -- heavy film build LL5215* 4 inches Alkyd paints only -- light film build LL5217 4 inches Alkyd paints only -- medium film build LL5219 4 inches Alkyd paints only -- heavy film build LL5315 4 inches Most traffic paints -- light film build LL5317 4 inches Most traffic paints -- medium film build LL5319 4 inches Most traffic paints -- medium film build LL5321 4 inches Most traffic paints -- heavy film build LL5323 4 inches Most traffic paints -- heavy film build LL5417# 4 -- 8 inches All paints and high solids traffic paints -- light film build LL5419# 4 -- 8 inches All paints and high solids traffic paints -- medium film build LL5421# 4 -- 8 inches All paints and high solids traffic paints -- heavy film build LL5621 8 -- 12 inches All traffic paints -- light film build LL5623 8 -- 12 inches All traffic paints -- medium film build LL5625 8 -- 12 inches All traffic paints -- medium film build LL5627 8 -- 12 inches All traffic paints -- heavy film build

Line Width Used For

) of the tip part number identifies the line width and tip orifice (opening) in millimeters.

is 19 mm.

* May require 100 mesh filter to minimize tip plugging.

# Best for cold weather applications.

How to Maximize Line Quality and Reduce Tip Wear. Observe the following suggestions to increase line quality

and minimize sprayer tip wear.

1. Select a larger tip orifice and run the sprayer at a reduced operating pressure.

2. Running larger tip sizes (example: use tip LL5321 @ 2000 psi instead of LL5317 @ 3300 psi) will significantly increase tip life and reduce tip plugging. It will also produce a more uniform film build across the line.

3088744

Maintenance

WARNING

INJECTION HAZARD

The system pressure must be manually relieved to prevent the system from

starting or spraying accidentally. 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:

D are instructed to relieve the pressure, D stop spraying, D check or service any of the system equipment, D or install or clean the spray tip.

DAILY: Check and fill the gas tank. AFTER THE FIRST 20 HOURS OF OPERATION:

Drain the oil and refill with clean oil. WEEKLY: Remove air filter cover and clean element.

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

Replacement elements can be purchased from your local HONDA dealer.

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

Pressure Relief Procedure

1. Lock gun trigger safety.

2. Turn engine ON/OFF switch to OFF.

3. Move pressure control switch to OFF and turn pressure control knob fully counterclockwise.

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

5. Lock gun trigger safety.

6. Open pressure drain valve. Leave valve open until ready to spray again.

7. Disconnect spark plug cable.

If you suspect that the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, VERY SLOWLY

loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear tip or hose.

CAUTION

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

AFTER EACH 100 HOURS OF OPERA TION:

Change oil.

MONTHLY: Oil connecting rod. SPARK PLUG: Use only BPR6ES (NGK) or

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

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

Caster Wheel

(See letter call-outs in Parts drawing on page 21)

1. Once each year, tighten nut (A) until spring washer bottoms out. Then back off the nut 1/2 to 3/4 turn.

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

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

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

5. Check caster wheel alignment as necessary. To align: loosen bolt (D), align wheel and tighten bolt (D).

DAILY: Check engine oil level and fill as necessary. DAILY: Check hose for wear and damage. DAILY: Check gun safety for proper operation. DAILY: Check pressure drain valve for proper

operation.

308874 5

Troubleshooting

WARNING

INJECTION HAZARD

To reduce risk of serious injury, including fluid injection or splashing in eyes or on skin, or injury from moving parts, always follow Pressure Relief Procedure Warning, page 5, before checking, adjusting, cleaning or shutting down sprayer. Disconnect spark plug!

Check everything in chart before disassembling sprayer.

PROBLEM

Engine won’t start

Engine operates, but displacement pump does not operate.

CAUSE SOLUTION

Engine switch is OFF Turn engine switch ON Engine is out of gas Refill gas tank. Honda Engines Owner’s Manual. Engine oil level is low Tryto start engine. Replenish oil, if necessary.

Spark plug c able is disconnected or damaged Connect spark plug cable or replace spark

Cold engine Use choke Fuel shutoff lever is OFF Move lever to ON position Oil is seeping into combustion chamber Remove spark plug. Pull starter rope 3 or 4

Pressure control switch is OFF. Turn pressure control switch ON. Pressure setting is too low. Turn pressure adjusting knob clockwise to

Fluid filter(318)is dirty. Clean filter. See page 27. Tip or tip filter is clogged. Cleantip or tip filter. See gun instruction

Displacementpump piston rod is stuck due to dried paint.

Honda Engines Owner’s Manual.

plug

times.Clean or replace spark plug. Try to start engine. Keep sprayer uprightto avoid oil seepage.

increase pressure.

manual. Repair pump. See manual 308798.

Connecting rod is worn or damaged. Replace connecting rod. See page 8. Drive housing is worn or damaged. Replace drive housing. See page 9. Electrical power is not energizing field. Check wiringconnections.See page 12.

Reference control board diagnostics. Page 15. With pressure control switch ON and pressure

turned to MAXIMUM, use a test lightto check for power between clutch terminals on control board.

Remove black clutch wires from control board and measure resistance across wires. At 70_ F, the resistance must be between 1.2 ¦ 0.2 (LL 3900); 1.7 ¦ 0.2 (LL 5900); if not, replace pinion housing.

Have pressure control checked by authorized Graco dealer.

Clutch is worn, damaged, or incorrectly positioned.

Pinion assembly is worn or damaged. Repair or replace pinion assembly, see pg 10.

Replace clutch. See page 10.

3088746

PROBLEM

CAUSE SOLUTION

Pump output is low on upstroke.

Pump output is low on downstroke or on both strokes.

Paint leaks into wetcup.

Fluid delivery is low.

Hose inlet screen (27) is clogged. Clean inlet screen. Piston ball (25) is not seating. Servicepiston ball. See manual 308798. Piston packings are worn or damaged. Replacepackings. See manual 308798. O-ring(17) in displacement pump is worn or

damaged. Hose strainer (27) is clogged. Clean strainerscreen. Piston packings are worn or damaged. Replacepackings. See manual 308798. Intake valve ball is not seating properly. Clean intake valve. See manual 308798. Engine speed is too low. Increase throttlesetting.See manual 308873. Clutch is worn or damaged. Replace clutch. See page 10. Wetcup is loose. Tightenwetcup just enough to stop leakage. Throat packings are worn or damaged. Replace packings. See manual 308798. Displacementrod is worn or damaged. Replace rod. See manual 308798. Inletscreen is clogged. Clean inletscreen. Pressure setting is too low. Increase pressure. See manual 308873. Engine speed is too low. Increase throttlesetting.See manual 308873. Fluid filter(318),tipfilter or tip is clogged or

dirty.

Replace o-ring. See manual 308798.

Clean filter. See manual 308873. Or,see gun instruction manual.

Fluid is spitting from gun.

Pump is difficult to prime.

Clutch squeaks each time clutch engages.

Large pressure drop in hose withheavy materials.

Air in pump or hose. Check and tighten all fluid connections.

Tip is partially clogged. Clear tip. See gun instructionmanual. Fluid supply is low or empty. Refill fluid supply.Prime pump. See manual

Air in pump or hose. Check and tighten all fluid connections.

Intake valve is leaking. Clean intake valve. Be sure ball seat is not

Pump packings are worn. Replace pump packings. See manual 308798. Paint is too thick. Thin the paint according to the supplier’s

Engine speed is too high. Decrease throttle setting before priming pump.

Small irregularitiesof new clutch surfaces grind together and cause noise

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

Reprime pump. See manual 308873.

308873. Check fluidsupply often to prevent running pump dry.

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

nicked or worn and that ballseats well. Reassemble valve.

recommendations.

See manual 308873. Clutch surfaces need to wear into each other.

Noise will dissipate after a day of run time.

High engine speed at no load.

Misadjustedthrottle setting. Reset throttle to 3600--3800 engine rpm at no

load.

Worn engine governor. Replace or service engine governor.

308874 7

Bearing Housing and Connecting Rod

NOTE: The item numbers referenced are for the

Hi-Boy models. The Lo-Boy models may have different item numbers. Use the Hi-Boy item number and part to find the corresponding Lo-Boy part and item number.

Removal

2. Fig. 3. Remove screws (29) and front cover (86).

3. Unscrew suction tube (27) from pump, hold wrench on pump intake valve (A) to keep pump from loosening.

4. Disconnect pump outlet hose (25) from displacement pump outlet nipple (107).

5. Fig. 2. Use screwdriver to push up retaining spring (83) at top of pump. Push out pin (82).

Fig. 2

6. Fig. 3. Loosen jam nut (81). Unscrew and remove displacement pump.

7. Remove four screws (31) and lockwashers (32) from bearing housing (84).

8. Pull connecting rod (85) and lightly tap lower rear of bearing housing (84) with plastic mallet to loosen from drive housing (87). Pull bearing housing and connecting rod assembly (85) off drive housing.

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

Installation

10. Evenly lubricate inside of bronze bearing (C) in bearing housing (84), and inside of connecting rod link (D), with high-quality motor oil (do not use grease). Liberally pack roller bearing (E) in connecting rod assembly (85) with bearing grease.

Relieve pressure; page 5.

7675B

1 1. Assemble connecting rod (85) and bearing housing

(84).

12. Clean mating surfaces of bearing and drive housings.

13. Align connecting rod with crank (B) and carefully align locating pins (F) in drive housing (87) with holes in bearing housing (84). Push bearing housing onto drive housing or tap into place with plastic mallet.

CAUTION

DO NOT use bearing housing screws (31) to align or seat bearing housing with drive housing. Align these parts with locating pins (F), to avoid premature bearing wear.

14. Install screws (31) and lockwashers (32) on bearing housing. Tighten evenly to 175 in-lb (19 N¡m).

15. Refer to Displacement Pump, Installation, page 16.

82 107

Oil

Pack with bearing grease 114819

LL 3900: T orque to 200 in-lb (22.6 N¡m) LL 5900: T orque to 25 ft-lb (34 N¡m)

Fig. 3

Model 232651 shown

31,32

8796A

3088748

Drive Housing

Removal

1. Relieve pressure; page 5.

2. Fig. 4. Remove bearing housing. Do 1. through 8.

of Bearing Housing and Connecting Rod procedure on page 8.

3. Remove two screws (51) and lockwashers (50).

4. Remove four screws (120) and lockwashers (119)

from pinion housing (88a).

5. Lightly tap around drive housing (87c) to loosen

drive housing. Pull drive housing straight off pinion housing. Be prepared to support gear cluster (78), which may also come out.

Installation

1. Liberally apply bearing grease (supplied with replacement gear cluster) to gear cluster (78). and to areas called out by note 3. Use full 0.62 pint (0.29 liter) of grease for LL 3900 and 0.68 pint (0.32 liter) of grease for LL 5900.

2. Place bronze colored washer (87g) on shaft protruding from large shaft of drive housing(87c). Note: If replacing a washer with pin holes with a washer without pin holes, remove guide pins from housing. Place silver colored washer (87h) on pins on pinion housing. Align gears and push new drive housing straight onto pinion housing and locating pins (B).

3. Install four screws (120) and lockwashers (119) into pinion housing (88a).

4. Install two screws (5) and lockwashers (50).

5. Fig. 3. Install bearing housing. Do 10. through 15. of Bearing Housing and Connecting Rod procedure on page 8.

LL 3900 only

Torque to 125 in-lb -- LL 3900 Torque to 200 in-lb -- LL 5900

Apply remaining grease to these areas

Fig. 4

120

119

88a

87h

87g

87c

50 (LL 3900) 51 (LL 5900)

51 (LL 3900)

52 (LL 5900)

TI0178A

308874 9

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