Graco 249007, 248861, 24M609 User Manual

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

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

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

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

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.

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

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

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

+ 18 hidden pages