Graco 249007, 248861, 24M609 User Manual

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Page 1

Repair

ti24865a

LineLazer™3400, FieldLazer S200

311019L

Airless Line Striper

- For the application of line striping materials. For professional use only. Not for use in explosive atmospheres.-

Important Safety Instructions

Read all warnings and instructions in this manual and in your gun manual. Save all instructions.

Models: 248861, 249007, 24M609

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

311016 309741

309250 309640

Page 2

Contents

WARNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

Drive Housing and Connecting Rod . . . . . . . . . . . 8

Pinion Assembly/Clutch Armature/Clamp . . . . . . . 9

Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . 14

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Pinion Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Gun Arm Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Pressure Control/Filter Assembly . . . . . . . . . . . . . 22

Pressure Control Wiring Diagram . . . . . . . . . . . . . 23

Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 26

2 311019L

Page 3

Warning

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

WARNING

FIRE AND EXPLOSION HAZARD

Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent fire and explosion:

• If using solvent based material, the LineLazer must only be used outside or in buildings very well ventilated with fresh air.

• The LineLazer must be separately grounded when being cleaned.

• The LineLazer uses special, conductive tires for static grounding. No substitutions are allowed. Use only Graco-supplied replacement wheels and tires.

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

• When flammable liquid is sprayed or used for flushing or cleaning, keep sprayer at least 20 feet (6 m) away from explosive vapors.

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

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

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

• Ground equipment and conductive objects in work area. See Grounding instructions.

• Use only grounded hoses.

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

• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until you identify and correct the problem.

SKIN INJECTION HAZARD

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

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

• Do not put your hand over the spray tip.

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

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

• Engage trigger lock when not spraying.

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, check- ing, or servicing equipment.

PRESSURIZED EQUIPMENT HAZARD

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

• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, check- ing, or servicing equipment.

• Tighten all fluid connections before operating the equipment.

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

MOVING PARTS HAZARD

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

• Keep clear of moving parts.

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

• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment, follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.

311019L 3

Page 4

Warning

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.

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

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

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

• Do not alter or modify equipment.

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

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

• Do not use hoses to pull equipment.

• Keep children and animals away from work area.

• Comply with all applicable safety regulations.

PRESSURIZED ALUMINUM PARTS HAZARD

Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death, serious injury, and property damage.

SUCTION HAZARD

Never place hands near the pump fluid inlet when pump is operating or pressurized. Powerful suction could cause serious injury.

CARBON MONOXIDE HAZARD

Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon monoxide can cause death. Do not operate in an enclosed area.

TOXIC FLUID OR FUMES HAZARD

Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or swallowed.

• Read MSDS’s to know the specific hazards of the fluids you are using.

• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.

BURN HAZARD

Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.

PERSONAL PROTECTIVE EQUIPMENT

You must wear appropriate protective equipment when operating, servicing, or when in the operating area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic fumes, burns, and hearing loss. This equipment includes but is not limited to:

• Protective eyewear

• Clothing and respirator as recommended by the fluid and solvent manufacturer

• Gloves

• Hearing protection

RECOIL HAZARD

Brace yourself; gun may recoil when triggered and cause you to fall, which could cause serious injury.

CALIFORNIA PROPOSITION 65

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

4 311019L

Page 5

Maintenance

ti6392a

Maintenance

Pressure Relief Procedure

Follow the Pressure Relief Procedure whenever

you see this symbol.

This equipment stays pressurized until pressure is manually relieved. To help prevent serious injury from pressurized fluid, such as skin injection, splashing fluid and moving parts, follow the Pressure Relief Procedure when you stop spraying and before cleaning, checking, or servicing the equipment.

1. Engage trigger lock.

2. Close the bleed-type master air valve.

3. Disengage the trigger lock.

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

5. Engage the trigger lock.

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

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

a. VERY SLOWLY loosen tip guard retaining nut or

hose end coupling to relieve pressure gradually.

b. Loosen nut or coupling completely.

DAILY: 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 and pump corrosion.AFTER THE FIRST 20 HOURS OF OPERATION:

Drain engine oil and refill with clean oil. Reference Honda Engines Owner's Manual for correct oil viscosity.

WEEKLY: Remove engine air filter cover and clean element. 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.

AFTER EACH 100 HOURS OF OPERATION:

Change engine oil. Reference Honda Engines Owner's Manual for correct oil viscosity.

SPARK PLUG: Use only BPR6ES (NGK) or W20EPR-U (NIPPONDENSO) plug. Gap plug to 0.028 to 0.031 in. (0.7 to 0.8 mm). Use spark plug wrench when installing and removing plug.

Front Wheel Alignment:

Align front wheel as follows:

1. Fig. Loosen cap screw (90).

c. Clear hose or tip obstruction.

NOTICE

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

DAILY: Check engine oil level and fill as necessary.

DAILY: Check hose for wear and damage.

DAILY: Check gun safety for proper operation.

DAILY: Check pressure drain valve for proper operation.

DAILY: Check and fill the gas tank.

311019L 5

FIG. 1

2. Position front wheel left or right, as necessary, to straighten alignment.

3. Tighten cap screw (90). Push striper and let striper roll with hands off of striper. Note: If striper rolls straight or veers right or left. Repeat steps 1 and 2 until striper rolls straight.

Page 6

Troubleshooting

Problem Cause Solution

Engine will not start Engine switch is OFF Turn engine switch ON

Engine is out of gasoline Refill gas tank. Honda Engines

Owner's Manual.

Engine oil level is low Check oil level. Replenish oil, if neces-

sary. Honda Engines Owner's Manual.

Engine operates, but displacement pump does not operate

Spark plug is disconnected or damaged Cold engine Use choke Fuel shutoff lever is OFF Move lever to ON position Oil is seeping into combustion chamber

Pump switch is OFF Turn pump switch ON Pressure setting too low Turn pressure adjusting knob clock-

Fluid filter (104) is dirty Clean filter. Page 22. Tip or tip filter is clogged Displacement pump piston rod is stuck due to dried paint Connecting rod is worn or damaged Drive housing is worn or damaged Replace drive housing. Page 8. Electrical power is not energizing clutch field

Connect spark plug cable or replace spark plug

Remove spark plug. Pull starter 3 to 4 times. Clean or replace spark plug. Start engine. Keep sprayer upright to avoid oil seepage

wise to increase pressure.

Clean tip or tip filter. Manual 309741. Repair pump. Manual 309250.

Replace connecting rod. Page 8.

Check wiring connections. Page 11, 12.

Reference pressure control repair. Page 13.

Troubleshooting

Reference wiring diagram. Page 23.

With pump switch ON and pressure turned to MAXIMUM, use a test light to check for power between clutch test points on control board.

Remove clutch wires from control board and measure resistance across clutch coil. At 70° F, the resistance must be between 1.2 +0.2; 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. Page 9.

Adjust or replace clutch. Page 9.

6 311019L

Page 7

Problem Cause Solution

Pump output is low Strainer (56) is clogged Clean strainer.

Piston ball (206) is not seating Service piston ball. Manual 309250.

Piston packings are worn or damaged

O-ring (227) in pump is worn or damaged

Intake valve ball is not seating properly

Intake valve ball is packed with material

Engine speed is too low

Replace packings. Manual 309250.

Replace o-ring. Manual 309250.

Clean intake valve. Manual 309250.

Increase throttle setting. Manual 311016.

Clutch is worn or damaged Adjust or replace clutch. Page 9.

Pressure setting is too low Increase pressure. Manual 311016.

Fluid filter (104), tip filter or tip is

Clean filter. Manual 311016 or 309741.

clogged or dirty

Large pressure drop in hose with heavy materials

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

Excessive paint leakage into throat packing nut

Throat packing nut is loose Remove throat packing nut spacer.

Tighten throat packing nut just enough to stop leakage.

Throat packings are worn or damaged

Displacement rod is worn or damaged

Fluid is spitting from gun Air in pump or hose

Replace packings. Manual 309250.

Replace rod. Manual 309250.

Check and tighten all fluid connections. Reprime pump. Manual 311016.

Tip is partially clogged Clear tip. Manual 309639.

Fluid supply is low or empty Refill fluid supply. Prime pump. Manual

311016. Check fluid supply often to prevent running pump dry.

Pump is difficult to prime Air in pump or hose

Check and tighten all fluid connections.

Troubleshooting

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

Intake valve is leaking Clean intake valve. Be sure ball seat is

not nicked or worn and that ball seats well. Reassemble valve.

Pump packings are worn

Replace pump packings. Manual 309250.

Paint is too thick Thin the paint according to the sup-

plier's recommendations

Engine speed is too high Decrease throttle setting before prim-

ing pump. Manual 311016.

Clutch squeaks each time clutch engages

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

Clutch surfaces need to wear into each other. Noise will dissipate after a day of run time.

High engine speed at no load Misadjusted throttle setting Reset throttle to 3300 engine rpm at no

load

Worn engine governor Replace or service engine governor

311019L 7

Page 8

Drive Housing and Connecting Rod

ti24871a

140

136

141

118

107

Oil Pack with bearing grease 110293

Torque to 130 - 150 in-lb (14 - 16.9 N.m)

ti5990a

Steel

Copper

Drive Housing and Connecting Rod

Removal

1. Relieve pressure, page 5.

IG. 2. Remove screws (32) and front cover (52).

2. F

3. Remove pump. Refer to Displacement Pump, Removal, page 14.

4. Remove four screws (34) from drive housing (43).

NOTICE

Thrust washers may stick to grease inside of drive housing. Do not lose or misplace.

5. Pull connecting rod (29) and lightly tap lower rear of drive housing (43) with plastic mallet to loosen from pinion housing (44). Pull drive housing and connecting rod assembly off pinion housing.

6. Inspect crank (47) and connecting rod (29) for excessive wear and replace parts as needed.

7. Install screws (34) in drive housing. Torque evenly to note 3 value in Fig. 1.

8. Install pump. Refer to Displacement Pump, Installation, page 14

9. Install front cover (52) with two screws (32).

Installation

1. Evenly lubricate inside of bronze bearing (C) in drive housing (43) with high-quality motor oil. Liberally pack top roller bearing (E), lower bearing (D) inside connecting rod (29) with bearing grease.

2. Assemble connecting rod (29) to drive housing (43). Rotate connecting rod to lowest position.

3. Apply grease to washers 46, 49 and 48. Install in order

4. Lubricate gears with 0.26 pint of 110293 grease (supplied

5. Clean mating surfaces of pinion and drive housings.

6. Align connecting rod with crank (47) and carefully align

DO NOT use drive housing screws (34) to align or seat bearing housing with drive housing. Align these parts with locating pins, to avoid premature bearing wear.

shown in F

with drive housing). Pack grease evenly around gears.

IG. 3.

locating pins in drive housing (43) with holes in pinion housing (44). Push drive housing onto pinion housing or tap into place with plastic mallet.

NOTICE

FIG. 2

FIG. 3

8 311019L

Page 9

Pinion Assembly/Clutch Armature/Clamp

ti5530a

ti5531a

ti5987b

ti5532a

44d

44c

44e

ti5533a

Pinion Assembly/Clutch Armature Removal

Pinion Assembly

If pinion assembly (44) is not removed from clutch housing (45), do 1. through 3. Otherwise, start at 4.

1. Relieve pressure, page 5.

2. Remove drive housing; page 8.

IG. 11. Disconnect clutch (+) and clutch (–) connectors

3. F from wire harness located under sprayer cart.

FIG. 4

. Remove four screws (18) and pinion assembly (44).

Pinion Assembly/Clutch Armature/Clamp

FIG. 5

7. FIG. 6. Remove retaining ring (44d).

8. Turn pinion assembly over and tap pinion shaft (44c) out with plastic mallet.

FIG. 4

5. FIG. 5. Place pinion assembly (44) on bench with rotor side up.

6. Remove four screws (42) and lock washers (35). Install two screws in threaded holes (E) in rotor. Alternately tighten screws until rotor comes off.

FIG. 6

Clutch Armature

9. FIG. 7. Use an impact wrench or wedge something between clutch armature (39) and clutch housing to hold engine shaft during removal.

10. Remove four screws (36) and lock washers (35).

11. Remove armature (39).

FIG. 7

311019L 9

Page 10

Installation

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

dimes

ti5534a

ti6199a

333

444

ti5988a

Pinion Assembly/Clutch Armature/Clamp

Clutch Armature

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

2. Lay armature (39) on two stacks of dimes.

3. Press center of hub down to bench surface.

FIG. 8

Clamp Removal

1. Do Engine Removal.

2. Drain gasoline from tank according to Honda manual.

FIG. 9

. Tip engine on side so gas tank is down and air

cleaner is up.

4. FIG. 10. Loosen two screws (36) on clamp (38),

5. Push screwdriver into slot in clamp (38) and remove clamp.

4. Install armature (39) on engine drive shaft.

5. Install four screws (36) and lock washers (35) with torque of 125 in-lb.

Pinion Assembly

IG. 6. Install o-ring (44e).

6. F

7. Tap pinion shaft (44c) in with plastic mallet.

8. Install retaining ring (44d) with beveled side facing up.

9. FIG. 5. Place pinion assembly on bench with rotor side up.

10. Apply locktite to screws. Install four screws (42) and lock washers (35). Alternately torque screws to 125 in-lb until rotor is secure. Use threaded holes to hold rotor.

IG. 4. Install pinion assembly (44) with four screws (18).

11. F

12. Connect clutch (+) and clutch (–) connectors to wire harness.

Face of clutch housing

1.550 ±.010 in. (39.37±.25 mm)

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

Chamfer this side

FIG. 9

Clamp Installation

1. FIG. 10 Install engine shaft key (37)

2. Tap clamp (38) onto engine shaft (A). Maintain dimension shown note 2. Chamfer must face engine.

3. Check dimension: Place rigid, straight steel bar (B) across face of clutch housing (45). Use accurate measuring device to measure distance between bar and face of clamp. Adjust clamp as necessary. Torque two screws (36) to 125 ±10 in-lb (14 ±1.1 N·m)

10 311019L

FIG. 10

Page 11

Clutch Housing

ti6322a

145

ti6390a

pink

(from engine)

green/yellow

ground

clutch wires

ti6323a

110

111

Removal

1. Remove clamp. Do Clamp Removal, page 10.

2. FIG. 11. Remove four screws (51) and lock washers (50) which hold clutch housing (45) to engine.

3. Remove screw (145) from under mounting plate.

4. Pull off clutch housing (45).

Installation

1. FIG. 11. Push on clutch housing (45).

2. Install four capscrews (51) and lock washers (56) and secure clutch housing (45) to engine. Torque to 200 in-lb (22.6 N·m).

3. Install screw (145) from beneath mounting plate. Torque to 26 ft-lb (35.2 N·m).

Clutch Housing

FIG. 11

Engine

Removal

NOTE: All service to the engine must be performed by

an authorized HONDA dealer.

1. Remove Pinion Assembly/Clutch Armature/Clamp and Clutch Housing, as instructed on pages 9, 10 and 11.

IG. 12. Disconnect all necessary wiring.

2. F

3. FIG. 13. Remove two locknuts (111) and screws (110) from base of engine.

4. Lift engine carefully and place on work bench.

IG. 13

Installation

1. Lift engine carefully and place on cart.

2. FIG. 13. Install two screws (110) in base of engine and secure with locknuts (111). Torque to 20 ft-lb (27.12 N·m).

IG. 12. Connect all necessary wiring.

3. F

FIG. 12

311019L 11

4. Install Pinion Assembly/Clutch Armature/Clamp and Clutch Housing, as instructed on pages 9 and 10 and 11.

5. Set engine to 3300 rpm.

Page 12

Pressure Control

ti6389a

62d

62c

62b

62a

62e

62g

62f

155

62b

ground

green/yellow

pink

(from engine)

clutch (-)

clutch (+)

(black)

(red)

108

On/Off Switch

Pressure Control

Removal

1. Relieve pressure, page 5.

2. FIG. 14. Remove two screws (108) and open cover (62a).

3. Disconnect ON/OFF switch connector from PC board.

4. Press in on two retaining tabs on each side of ON/OFF switch (62d) and remove switch from cover.

Installation

1. Install new ON/OFF switch (62d) so tabs of switch snap into place on inside of cover.

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

3. Close cover (62a) and secure with two screws (108).

FIG. 14

12 311019L

Page 13

Control Board

Pressure Control

Removal

1. Relieve pressure, page 5.

2. FIG. 14. Remove two screws (108) and open cover (62a)

3. Disconnect engine and ground wires from wire harness (66).

4. Disconnect at control board (62e):

• Lead from potentiometer (62b)

• Lead from transducer (155)

• Lead from ON/OFF switch (62d)

Pressure Control Transducer

Removal

1. Relieve pressure, page 5.

2. FIG. 14. Remove two screws (108) and open cover (62a)

3. Disconnect transducer (155) lead from control board (62e).

4. Pull transducer connector through strain relief bushing (151).

5. Remove transducer and o-ring (99) from filter housing (67).

• Clutch wires

5. Remove four screws (62f) and control board (62e).

Installation

1. FIG. 14. Install control board (62e) with four screws (62f).

2. Connect at control board (62e):

• Clutch wires

• Lead from ON/OFF switch (62d)

• Lead from transducer (155)

• Lead from potentiometer (62b)

3. Connect engine and ground wires.

4. Close cover (62a) and secure with two screws (108).

Installation

1. FIG. 14. Install o-ring (99) and transducer (155) in filter housing (67). Torque to 35 - 45 ft-lb.

2. Install transducer connector and strain relief bushing in control housing.

3. Connect lead (E) to control board (62e).

4. Close cover (62a) and secure with two screws (108).

Pressure Adjust Potentiometer

Removal

1. Relieve pressure, page 5.

2. Fig. 13.Remove two screws (108) and open cover (62a).

3. Disconnect potentiometer (62b) lead from control board (62e).

4. Loosen set screws on potentiometer knob (62c) and remove knob, shaft nut, lock washer and potentiometer (62b).

5. Remove spacer (62g) from potentiometer.

Installation

1. Install spacer (62g) on potentiometer (62b).

IG. 14. Install potentiometer, shaft nut, lock washer and

2. F potentiometer knob (62c). a.Turn potentiometer shaft clockwise to internal stop.

Assemble potentiometer knob (62c) to strike pin on cover (62a).

b.After adjustment of step a., tighten both set screws in

knob 1/4 to 3/8 turn after contact with shaft.

3. Connect potentiometer (62b) lead to control board (62e).

4. Close cover (62a) and secure with two screws (108).

311019L 13

Page 14

Displacement Pump

ti6468a

107

ti6467a

118

201

ti5545a

Displacement Pump

Removal

1. Flush pump.

2. Relieve pressure, page 5.

IG. 16. Stop pump with piston rod (201) in its lowest

3. F position.

FIG. 15

. Loosen two screws (32) and remove pump rod

cover (107).

FIG. 15

6. FIG. 17. Loosen jam nut by hitting firmly with a hammer. Unscrew pump.

FIG. 17

Repair

See manual 309250 for pump repair instructions.

5. FIG. 16. Remove hose (118) and suction hose (57). Use screwdriver; push retaining spring up; push out pin (31).

FIG. 16

14 311019L

Page 15

Installation

ti5546a

ti5546b

ti5544a

ti6110a

ti6111a

ti5543a

Drive housing face

NOTICE

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

NOTICE

If the pump jam nut loosens during operation, the threads of the bearing housing and drive train will be damaged. Tighten jam nut as specified.

1. Fig. FIG. 18. Pull piston rod out distance shown. Screw in pump until holes in connecting rod and piston rod align.

Displacement Pump

FIG. 18

2. FIG. 12. Push pin (31) into hole. Push retaining ring spring into groove all the way around connecting rod.

FIG. 19

. Screw jam nut down onto pump until nut stops.

Screw pump up into drive housing until top threads of

FIG. 20

pump are flush with drive housing face ( pump and jam nut to align pump outlet to side. Tighten jam nut by hand, then tap 1/8 to 1/4 turn with a 20 oz (maximum) hammer to approximately 75 ±5 ft-lb (102 N·m). Connect hose (118) suction hose (57).

). Back off

FIG. 19

4. FIG. 20. Fill packing nut with Graco TSL until fluid flows onto the top of seal. Install pump rod cover (107).

FIG. 20

311019L 15

Page 16

Parts Drawing

ti6242c

112

115

150

131

184

108

94 149

143

151

132

148

147

129

148 ref

144

110

153

158

137

111

115

114

ti24872a

130

Parts Drawing

16 311019L

Page 17

Parts List

Ref. No. Part No. Description

1 287630 FRAME, LL 1 2 119542 WHEEL, small 1 3 119543 WHEEL, large 2 4 15F127 FORK, painted 1 5 119532 BEARING, flanged 2 6 15E780 PIN, fork 1 7 15E773 DISK, adjuster 1 8 15E792 PIN, lever 1 9 101566 NUT, lock 7 10 114682 SPRING, compression 1 11 108471 KNOB, pronged 1 14 287682 LEVER, caster, includes 26 1 15 108879 ENGINE, gasoline, 4.0 hp 1 16 206994 FLUID, TSL, 8 oz 18 249080 19 24U241 KIT, pail cover 53 194310 LEVER, actuator 2 54 115077 PAIL, plastic 1 55 116139 GRIP, handle 2 59 15E992 CABLE, gun 1 60 15E993 ROD, brake 1 64 119563 WASHER, belleville 4 65 15E996 SPACER, wheel 2 66 15E995 HARNESS, wiring, control 1 74 241445 CABLE, caster 1 81 195134 SPACER, ball, guide 1 82 198891 BRACKET, mounting 1 83 198931 BEARING 1 84 113961 SCREW, cap, hex hd 1 85 114808 CAP, vinyl 1 86 119569 BUSHING, strain relief 1

HOSE, coupled, 1/4 in. x 50 ft, nickel

Qty

Ref. No. Part No. Description

89 15E955 HOLDER, bucket 2 90 100057 SCREW, cap, hex hd 1 91 113665 SCREW, cap, hex hd 1 93 119554 NUT, lock, nylon, thin pattern 4 94 248912 BAR, handle, LL 1 97 116935 SCREW, cap, flnghd 2 108 116719 SCREW, 8-32 hex washer head 2 110 110837 SCREW, flange, hex 2 111 110838 NUT, lock 2 112 118866 WASHER, flat, extra thick 1 114 110963 SCREW, cap, flng hd 2 115 111040 NUT, lock, insert, nylock, 5/16 in. 3 129 101550 SCREW, cap, sch 2 130 278723 GASKET, pail 1 131 15C871 CAP, leg 2

132 100731 WASHER 2 137 119579 CONDUCTOR, ground 1 143 15F549 LABEL, identification 1

16N451 LABEL, BRAND, HANDLE

(Model 24M609)

144 194126 LABEL, warning 1 147 112798 SCREW, thread forming, hex hd 1 148 237686 WIRE, ground assembly w/ clamp 1 149 15F638 LABEL, GMAX warning fire & skin 1 150 15F637 LABEL, GMAX warning skin inject 1 151 15F928 BUSHING, strain relief 1 153 111025 GASKET, polypropylene (Wagner) 1 158 114802 STOP, wire 1 184 119771 STRAP, cover (Model 249007) 1

 Replacement Danger and Warning labels, tags, and

cards are available at no cost.

Qty

311019L 17

Page 18

Parts Drawing

ti24873a

130

145

107

140

139

130

146

141

118

142

136

Parts Drawing

18 311019L

Page 19

Parts List

Parts Drawing

Ref No. Part No. Description Qty

27 246428 PUMP, displacement, st 1 28 196750 SPRING, retaining 1 29 287053 ROD, connecting 1 30 195150 NUT, jam, pump 1 31 196762 PIN, straight 1 32 117501 SCREW, mach, hex washer head 4 33† 115099 WASHER 1 34 119426 SCREW, mach, hex washer hd 8 35* 105510 WASHER, lock, spring (hi-collar) 10 36* 108803 SCREW, hex, socket head 6 37 183401 KEY, parallel 1 38 193680 COLLAR, shaft 1 39* ARMATURE, clutch, 4 in. 1 40* HUB, armature 1 41* ROTOR, clutch, 4 in. 1 42* 101682 SCREW, cap, sch 4 43 287483 HOUSING, drive, includes 32, 34 1 44 287376 HOUSING, pinion 1 45 15E535 HOUSING, clutch, machine 1 46 116074 WASHER, thrust 1 47 287484 CRANK, GMAX 3000, includes 46,

48, 49 48 180131 BEARING, thrust 1 49 107434 BEARING, thrust 1

Ref No. Part No. Description Qty

50 100214 WASHER, lock 4 51 108842 SCREW, cap, hex hd 4 52 287487 COVER, front, painted, includes 32 1 56 246385 STRAINER, 7/8-14 unf 1 57

287683 HOSE, suction, includes 33, 56,

130, 136 68 114958 STRAP, tie 5 75 249232 HOSE, cpld, 1/4 in. X 3 ft 1 107 15B589 COVER, pump rod 1 118 249149 HOSE, coupled, 1/4 X 22.25 in. 1 136† 117559 O-RING 2 139 196180 BUSHING 1 140 16X071 TUBE, drain 1 141 196181 FITTING, nipple 2 142 15F538 LABEL, identification 1

16N450 LABEL, PUMP (Model 24M609) 1 145 112395 SCREW, cap, flnghd 1 146 290228 LABEL, caution 1

 Replacement Danger and Warning labels, tags, and

cards are available at no cost * Included in Clutch Replacement Kit 241109 † Included in Suction Hose Kit 249356

311019L 19

Page 20

Parts Drawing and List - Pinion Housing

ti5539a

44a44b44e44c44d

Ref No. 44: Pinion Housing

No. Part No. Description Qty

44 287376 PINION HOUSING 1 44a 287482 KIT, repair, coil 1 44b 105489 PIN 2 44c* 287485 PINION SHAFT 1 44d* 113094 RETAINING RING, large 1

* May be ordered separately

Parts Drawing

20 311019L

Page 21

Gun Arm Parts

ti6241a

20e

20b

20c

20d

20a

20f

156

18 Ref

Parts Drawing

Ref Part Description Qty

17 248157 GUN, Flex, basic 1 20 287570 HOLDER, gun 1 20a 287569 HOLDER, gun 1 20b 15F214 LEVER, actuator 1 20c 15F209 STUD, pull trigger 1 20d 15F210 STUD, pivot 1 20e 15F211 STUD, cable 1 20f 102040 NUT, lock 4 21 243161 GUARD, RAC 5 1

Ref Part Description Qty

23 287566 KIT, clamp 1 24 15F212 ARM, holder, gun 1 25 15F213 BRACKET, cable 1 59 15E992 CABLE, gun 1 70 119648

SCREW, mach, trusshd, cross recess 72 224052 BRACKET, support gun 1 73 119647 SCREW, cap, socket, flthd 2 77 188135 GUIDE, cable 1 156 LL5319 TIP, spray, striping 1

311019L 21

Page 22

Pressure Control/Filter Assembly

ti6389a

ti6239b

18 Ref

105

104

103

155 Ref

106

118 Ref

75 Ref

141

100

101

102

106

152

62d

62c

62b

62a

62e

62g

62f

155

62b

(green/yellow)

(from engine)

(black)

(red)

pink

clutch (-)

clutch (+)

ground

62h

106 Ref

182

181

183

Pressure Control/Filter Assembly

22 311019L

Page 23

Pressure Control/Filter Assembly

Ref Part Description Qty

13 15E748 BRACKET, manifold 1 62 CONTROL, assy 62a 15E991 COVER, control box 1 62b 256219 POTENTIOMETER 1 62c 116167 KNOB, potentiometer 1 62d 116752 SWITCH, rocker 1 62e 287486 BOARD, control, 1 62f 113045 62g 198650 SPACER, shaft 1 62h 15F540 LABEL, instructions 1 63* 287285 CAP, manifold, includes 103, 105 1 67* 15H561 MANIFOLD, filter 1 87 111801 SCREW, cap, hex hd 4 98* 15C780 HANDLE 1 99* 111457 O-RING 1

SCREW, sems, mach, phillips, truss

Pressure Control/Filter Assembly

Ref Part Description Qty

100* 15C972 PIN, grooved 1 101* 224807 BASE, valve 1 102* 239914 VALVE, drain 1 103* 117285 O-RING 1 104* 244067 FILTER, fluid 1 105* 15C766 TUBE, diffusion 1 106 196177 ADAPTER, nipple 2 141 196181 FITTING, nipple 1 152* 101748 PIPE, plug, sst 1 155* 15F782 HARNESS, transducer, line striper 1

181 196178 NIPPLE, 3/8 x 3/8 in. 1 182 102814 GAUGE, pressure fluid 1 183 241339

KIT, gauge, 3/8 in., includes 181, 182

* Included in Filter Repair Kit 287685

Pressure Control Wiring Diagram

TO ENGINE

CLUTCH B

TO GROUND

CONTROL BOARD

CLUTCH A

PINON HOUSING

ti5542b

DRIVE HOUSING

ON/OFF SWITCH

POTENTIOMETER

311019L 23

TRANSDUCER

Page 24

Technical Data

Honda GX120 Engine

ANSI Power Rating @ 3600 rpm 4.0 Horsepower

(2.9 kW)

Maximum working pressure 3300 psi

(227 bar, 22.7 MPa)

Noise Level

Sound power 100 dBa

per ISO 3744

Sound pressure 86 dBa

measured at 3.1 feet (1 m)

Vibration Level

* Left hand

* Right hand

*Vibration measured per ISO 5349

Based on 8 hr daily exposure Maximum delivery rating 0.75 gpm (2.84 liter/min) Maximum tip size 1 gun with 0. 027 in. tip Inlet paint strainer 12 mesh (893 micron)

stainless steel screen, reusable

Outlet paint filter 60 mesh (250 micron)

stainless steel screen, reusable Pump inlet size 1¼-12 unf-2b Fluid outlet size ¼ npsm from fluid filter Wetted parts PTFE, Nylon, polyurethane, UHMW polyethylene, FKM,

acetal, leather, tungsten carbide, nickel-plated carbon

steel, stainless steel, chrome plating

3.89 m/sec

4.94 m/sec

Dimensions

Sprayer Weight lb (kg) Height in. (cm) Width in. (cm) Length in. (cm)

248861 150 (68) 40.5 (103) 32 (81) 61.5 (156) 249007 150 (68) 40.5 (103) 32 (81) 61.5 (156)

24M609 150 (68) 40.5 (103) 32 (81) 61.5 (156)

24 311019L

Page 25

Notes

311019L 25

Page 26

Graco Standard Warranty

Graco warrants all equipment referenced in this document which is manufactured by Graco and bearing its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use. With the exception of any special, extended, or limited warranty published by Graco, Graco will, for a period of twelve months from the date of sale, repair or replace any part of the equipment determined by Graco to be defective. This warranty applies only when the equipment is installed, operated and maintained in accordance with Graco’s written recommendations.

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

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claimed defect. If the claimed defect is verified, Graco will repair or replace free of charge any defective parts. The equipment will be returned to the original purchaser transportation prepaid. If inspection of the equipment does not disclose any defect in material or workmanship, repairs will be made at a reasonable charge, which charges may include the costs of parts, labor, and transportation.

Graco’s sole obligation and buyer’s sole remedy for any breach of warranty shall be as set forth above. The buyer agrees that no other remedy (including, but not limited to, incidental or consequential damages for lost profits, lost sales, injury to person or property, or any other incidental or consequential loss) shall be available. Any action for breach of warranty must be brought within two (2) years of the date of sale.

GRACO MAKES NO WARRANTY, AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, IN CONNECTION WITH ACCESSORIES, EQUIPMENT, MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO. These items sold, but not manufactured by Graco (such as electric motors, switches, hose, etc.), are subject to

the warranty, if any, of their manufacturer. Graco will provide purchaser with reasonable assistance in making any claim for breach of these warranties.

In no event will Graco be liable for indirect, incidental, special or consequential damages resulting from Graco supplying equipment hereunder, or the furnishing, performance, or use of any products or other goods sold hereto, whether due to a breach of contract, breach of warranty, the negligence of Graco, or otherwise.

FOR GRACO CANADA CUSTOMERS

The Parties acknowledge that they have required that the present document, as well as all documents, notices and legal proceedings entered into, given or instituted pursuant hereto or relating directly or indirectly hereto, be drawn up in English. Les parties reconnaissent avoir convenu que la rédaction du présente document sera en Anglais, ainsi que tous documents, avis et procédures judiciaires exécutés, donnés ou intentés, à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées.

ADDITIONAL WARRANTY COVERAGE

Graco does provide extended warranty and wear warranty for products described in the Graco Contractor Equipment Warranty Program.

Graco Information

For the latest information about Graco products, visit www.graco.com.

For patent information, see www.graco.com/patents.

TO PLACE AN ORDER, contact your Graco distributor or call 1-800-690-2894 to identify the nearest distributor.

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

GRACO INC. AND SUBSIDIARIES • P.O. BOX 1441 • MINNEAPOLIS MN 55440-1441 • USA

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

For patent information, see www.graco.com/patents

Original instructions. This manual contains English. MM 311019

Graco Headquarters: Minneapolis

International Offices: Belgium, China, Japan, Korea

www.graco.com

Revised L, November 2014