Graco 311019K User Manual

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Page 1

Repair

LineLazer™3400, FieldLazer S200

311019K

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

ti6243a

ti16243a

Page 2

ontents

Manual Conventions

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

Manual Conventions

WARNING

Hazard Symbol

WARNING: a potentially hazardous situation which, if

not avoided, could result in death or serious injury. Warnings in the instructions usually include a symbol

indicating the hazard. Read the general Warnings section for additional safety information.

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

CAUTION

CAUTION: a potentially hazardous situation which, if

not avoided, may result in property damage or destruction of equipment.

Note

Additional helpful information.

2 311019K

Page 3

Warning

The following warnings include general safety information for this equipment. Further product specific warnings may be included in the text 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, checking, 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, checking, 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.

311019K 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

equipment 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.

4 311019K

Page 5

Maintenance

Pressure Relief Procedure

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

1. Lock gun trigger safety.

2. Turn engine ON/OFF switch to OFF.

3. Move pump 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.

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 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).

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.

ti6392a

DAILY: Check level of TSL in displacement pump packing nut. Fill nut, if necessary. Keep TSL in nut to help

FIG. 1

prevent fluid buildup on piston rod and premature wear of packings and pump corrosion.

311019K 5

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 +0.2Ω; 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 311019K

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. 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 signifi-

cantly reduces performance of sprayer.

Use 3/8 in. hose for optimum perfor-

mance (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

311019K 7

Page 8

Drive Housing and Connecting Rod

Removal

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

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).

CAUTION

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

Drive Housing and Connecting Rod

CAUTION

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.

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).

ti6469a

107

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.

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 shown in F

4. Lubricate gears with 0.26 pint of 110293 grease (supplied with drive housing). Pack grease evenly around gears.

5. Clean mating surfaces of pinion and drive housings.

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

IG. 3.

FIG. 2

118

141

Oil

Pack with bearing grease 110293

2 3

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

140

136

Steel

ti5990a

Copper

FIG. 3

8 311019K

Page 9

Pinion Assembly/Clutch Armature/Clamp

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.

WARNING

42 35

Pinion Assembly/Clutch Armature/Clamp

Read Injection Hazard, page 3; Burn Hazard, page 4

1. Relieve pressure, page 5.

2. Remove drive housing; page 8.

3. F

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

from wire harness located under sprayer cart.

FIG. 4

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

ti5530a

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.

ti5531a

ti5987b

FIG. 5

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

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

44d

44c

44e

FIG. 6

ti5532a

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).

ti5533a

FIG. 7

311019K 9

Page 10

Installation

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.

ti5534a

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

dimes

FIG. 8

Clamp Removal

1. Do Engine Removal.

WARNING

Gasoline can spill and cause a fire or explosion if engine is tipped on side.

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)

333

Chamfer this side

444

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.

ti6199a

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)

FIG. 10

ti5988a

10 311019K

Page 11

Clutch Housing

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).

FIG. 11

Clutch Housing

145

ti6322a

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.

clutch wires

pink

(from engine)

ground

green/yellow

IG. 13

Installation

110

ti6323a

111

1. Lift engine carefully and place on cart.

2. FIG. 13. Install two screws (110) in base of engine and

ti6390a

FIG. 12

311019K 11

secure with locknuts (111). Torque to 20 ft-lb (27.12 N·m).

IG. 12. Connect all necessary wiring.

3. F

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

On/Off Switch

Pressure Control

Removal

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

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.

pink

(from engine)

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).

62d

62c

62b

62a

62e

FIG. 14

ground

green/yellow

clutch (-)

(black)

clutch (+)

(red)

108

ti6389a

155

62f

62g

62b

12 311019K

Page 13

Control Board

Pressure Control

Removal

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

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)

Pressure Control Transducer

Removal

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

• Lead from ON/OFF switch (62d)

• 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).

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).

Pressure Adjust Potentiometer

Removal

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

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).

311019K 13

Page 14

Displacement Pump

Removal

1. Flush pump.

WARNING

Read Injection Hazard, page 3; Burn Hazard, page 4

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).

ti6468a

107

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

ti5545a

FIG. 17

Repair

See manual 309250 for pump repair instructions.

FIG. 15

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

ti6467a

201

118

FIG. 16

14 311019K

Page 15

Installation

WARNING

If pin works loose, parts could break off and project through the air and result in serious injury or property damage. Make sure pin is properly installed.

Displacement Pump

ti6111a

CAUTION

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.

ti5546a

ti6110a

ti5544a

FIG. 19

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

ti5543a

FIG. 18

ti5546b

2. FIG. 12. Push pin (31) into hole. Push retaining ring spring

Drive housing face

FIG. 20

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 pump

FIG. 20

are flush with drive housing face (

). Back off 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).

311019K 15

Page 16

Parts Drawing -

Parts

130

94 149

147

108

148 ref

148

129

143

151

184

132

115

114

111

150

144

137

110

112

153

158

131

ti6242c

115

16 311019K

Page 17

Parts List -

Parts

Ref. No. Part No. Description Qty.

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 287590 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

Ref. No. Part No. Description Qty.

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 15F514 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.

311019K 17

Page 18

Parts Drawing -

140

139

135

146

130 Ref

Parts

ti6240a

145

142

107

141

118

136

18 311019K

Page 19

Parts List -

Parts

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. 1 135 241920 DEFLECTOR, threaded 1 136† 117559 O-RING 2 139 196180 BUSHING 1 140 198601 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

311019K 19

Page 20

Parts Drawing and List - Pinion Housing

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

44a44b44e44c44d

ti5539a

20 311019K

Page 21

Gun Arm Parts

Parts

ti6241a

18 Ref

156

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

20e

20b

20a

20d

20c

20f

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

311019K 21

Page 22

Pressure Control/Filter Assembly

62d

(from engine)

pink

ground

(green/yellow)

clutch (-)

(black)

clutch (+)

(red)

62h

155

62f

62c

62b

62a

62g 62b

62e

18 Ref

106

101

152

102

103

141

105

104

67 106

118 Ref

155 Ref

ti6239b

100

75 Ref

183

ti6389a

22 311019K

182

181

106 Ref

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

311019K 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 311019K

Page 25

Notes

311019K 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. 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 April 2013