Graco 311020W User Manual

Repair -- Parts List

LineLazerIV 3900, R300, 5900, and
FieldLazer R300 Airless Line Stripers

- For application of line striping materials -

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

Important Safety Instructions

Read all warnings and instructions in this
manual. Save these instructions.

311017
312540

310643

311020W

EN

311254

309055

311049

ti6394b

248862

Table of Contents

Models 3........................................

Warnings 4......................................

Spray T ip Selection Table 6........................

Maintenance 7...................................

Troubleshooting 8................................

Repair

Bearing Housing & Connecting Rod 1 1............

Drive Housing 12...............................

Pinion Assembly/Clutch Armature/Clamp 13.......

Engine 16.....................................

Pressure Control 17............................

Trigger Sensor Adjustment 19...................

Distance Sensor Adjustment 19..................

Control Board Diagnostics 20....................

Displacement Pump 21.........................

Parts

LineLazer IV 3900/R300/5900 22.................

Drive and Pinion Housing Assemblies 23..........

Pressure Control Wiring Diagram 34................

Technical Data 35................................

Dimensions 35...................................

Graco Phone Number 35..........................

Graco Warranty 36...............................

3110202

Models

3900

248862 n n

248863 n n

249008 n n

249009 n n

248864 n n n

248865 n n n

R300

24M605 n n n n

24M607 n n

5900

248866 n n

248867 n n

249010 n n

24901 1 n n

248868 n n n

248869 n n n

311020 3

Warnings

The following Warnings are for safe 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. Refer back to
these Warnings.

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:

D Use equipment only in well ventilated area.
D 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.

D Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop

cloths (potential static arc).

D Keep work area free of debris, including solvent, rags and gasoline.
D Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes are

present.

D Ground equipment and conductive objects in work area. See Grounding instructions.
D Use only grounded hoses.
D Hold gun firmly to side of grounded pail when triggering into pail.
D If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment until

you identify and correct the problem.

D Keep a fire extinguisher in work area.

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.

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.

D Do not point gun at anyone or at any part of the body.
D Do not put your hand over the spray tip.
D Do not stop or deflect leaks with your hand, body, glove, or rag.
D Do not spray without tip guard and trigger guard installed.
D Engage trigger lock when not spraying.
D 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 .

D Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning, check-

ing, or servicing equipment.

D Tighten all fluid connections before operating the equipment.
D Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.

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.

3110204

WARNING

EQUIPMENT MISUSE HAZARD

Misuse can cause death or serious injury.
D Do not exceed the maximum working pressure or temperature rating of the lowest rated system compo-

nent. See Technical Data in all equipment manuals.

D 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.

D Check equipment daily. Repair or replace worn or damaged parts immediately.
D Do not alter or modify equipment.
D Use equipment only for its intended purpose. Call your Graco distributor for information.
D Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
D Do not kink or over bend hoses or use hoses to pull equipment
D Keep children and animals away from work area.
D Comply with all applicable safety regulations.

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.

MOVING PARTS HAZARD

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

D Keep clear of moving parts.
D Do not operate equipment with protective guards or covers removed.
D 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.

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:

D Protective eyewear.
D Clothing and respirator as recommended by the fluid and solvent manufacturer.
D Gloves.
D Hearing protection.

RECOIL HAZARD

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

311020 5

Tip Selection

in.

(cm)

LL5213* 2(5) n

LL5215* 2(5) n

LL5217 4 (10) n

LL5219 4 (10) n

LL5315* 4 (10) n

LL5317 4 (10) n

LL5319 4 (10) n

LL5321 4 (10) n

LL5323 4 (10) n

LL5325 4 (10) n

LL5327 4 (10) n

LL5329 4 (10) n

LL5331 4 (10) n

LL5333 4 (10) n

LL5335 4 (10) n

LL5355 4 (10) n

LL5417 6 (15) n

LL5419 6 (15) n

LL5421 6 (15) n

LL5423 6 (15) n

LL5425 6 (15) n

LL5427 6 (15) n

LL5429 6 (15) n

LL5431 6 (15) n

LL5435 6 (15) n

LL5621 12 (30) n

LL5623 12 (30) n

LL5625 12 (30) n

LL5627 12 (30) n
LL5629 12 (30) n
LL5631 12 (30) n
LL5635 12 (30) n
LL5639 12 (30) n

in.

(cm)

in.

(cm)

in.

(cm)

* Use 100 mesh filter to reduce tip clogs

3110206

Maintenance

Pressure Relief Procedure

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.

DAILY: Check and fill the gas tank.

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

Replacement elements can be purchased from your
local HONDA dealer.

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

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.

CAUTION

D Minimum hose size allowable for proper sprayer

operation is 3/8 in. x 50 ft

D For detailed engine maintenance and specifica-

tions, 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 opera-

tion.

Caster Wheel

(See letter call-outs in Parts drawing on page 28)

1. Once each year, tighten nut (127) under dust cap
(142) until spring washer bottoms out. Then back
off the nut 1/2 to 3/4 turn.

2. Once each year, tighten nut (127) on screw (131)
until it begins to compress spring washer. Then
tighten the nut an additional 1/4 turn.

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

4. Check pin (55) for wear. If pin is worn out, there
will be play in the caster wheel. Reverse or re­place the pin as needed.

5. Check caster wheel alignment as necessary.
To align: loosen screw (145), align wheel and
tighten screw.

311020 7

Troubleshooting

PROBLEM CAUSE SOLUTION

E=XX is displayed Fault condition exists Determine fault correction from table, page 20.

Engine won’t start Engine switch is OFF Turn engine switch ON

Engine is out of gas Refill gas tank. Honda Engines Owner’s Manual.

Engine operates, but dis­placement pump does not
operate

Engine oil level is low Try to start engine. Replenish oil, if necessary.

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

Cold engine Use choke

Fuel shutoff lever is OFF Move lever to ON position

Oil is seeping into combustion chamber Remove spark plug. Pull starter 3 to 4 times.

Error code displayed? Reference pressure control repair. Page 18.

Pump switch is OFF TurnpumpswitchON.

Pressure setting is too low Turn pressure adjusting knob clockwise to

Fluid filter (11) is dirty Clean filter. Page 32.

Tip or tip filter is clogged Clean tip or tip filter. See spray gun manual.

Displacement pump piston rod is stuck due to
dried paint

Connecting rod is worn or damaged Replace connecting rod. Page 11.

Honda Engines Owner’s Manual.

Clean or replace spark plug. Start engine.
Keep sprayer upright to avoid oil seepage.

increase pressure.

Repair pump. See pump manual.

Drive housing is worn or damaged Replace drive housing. Page 12.

Electrical power is not energizing clutch field Check wiring connections. Page 16.

Reference pressure control repair. Page 18.
Reference wiring d iagram. Page 34.

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

Measure resistance across c lutch coil. At 70_
F, the resistance must be between 1.2
(LineLazer IV 3900/R300); 1.7
er IV 5900); if not, replace pinion housing.

Have pressure control checked by authorized
Graco dealer.

Clutch is worn, damaged, or incorrectly
positioned

Pinion assembly is worn or damaged Repair or replace pinion assembly. Page 13.

Replace clutch. Page 13.

0.2 (LineLaz-

0.2

3110208

Troubleshooting

load

PROBLEM CAUSE SOLUTION

Pump output is low

Excessive paint leakage into
throat packing nut

Strainer (34f) is clogged Clean strainer.

Piston ball is not seating Service piston ball. See pump manual.

Piston packings are worn or damaged Replace packings. See pump manual.

O-ring in pump is worn or damaged Replace o-ring. See pump manual.

Intake valve ball is not seating properly Clean intake valve. See pump manual.

Intake valve ball is packed with material Clean intake valve. See pump manual.

Engine speed is too low Increase throttle setting. See operation manual.

Clutch is worn or damaged Replace clutch. Page 13.

Pressure setting is too low Increase pressure. See operation manual.

Fluid filter (11), tip filter or tip is clogged or dirty Clean filter. See operation or spray gun manu-

Large pressure drop in hose with heavy
materials

Throat packing nut is loose Remove throat packing nut spacer. Tighten

Throat packings are worn or damaged Replace packings. See pump manual.

al.

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).

throat packing nut just enough to stop leakage.

Fluid is spitting from gun

Pump is difficult to prime

Clutch squeaks each time
clutch engages

Displacement rod is worn or damaged Replace rod. See pump manual.

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

Tip is partially clogged Clear tip. See spray gun manual.

Fluid supply is low or empty Refill fluid supply. Prime pump. See operation

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

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

Pump packings are worn Replace pump packings. See pump manual.

Paint is too thick Thin the paint according to the supplier’s

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

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

Reprime pump. See operation manual.

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

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

nicked or worn and that ball seats well. Reas­semble valve.

recommendations

See operation manual.

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

High engine speed at no

Misadjusted throttle setting Reset throttle to 3600 engine rpm at no load

Worn engine governor Replace or service engine governor

311020 9

Troubleshooting

PROBLEM CAUSE SOLUTION

Gallon counter not working Broken or disconnected wire Check wires and connections. Replace

broken wires.

Bad sensor Replace sensor

Missing magnet Reposition or replace magnet.

Sprayer operates, but display does not Bad connection between control board

and display

Display damaged Replace display

Distance counter not operating properly Trigger sensor not set correctly See “Spray icon does not show on dis-

Bad wiring connections Check connector, and reconnect

Distance sensor not spaced correctly
from gear

Distance sensor and gear not aligned Remove tire, and press in or pull out

Gear teeth missing or damaged. Replace distance gear/wheel

Wire cracked or broken Replace sensor

Mils not calculating Distance sensor See “Distance counter not operating

Trigger sensor See “Spray icon does not show on dis-

Gallon counter See “Gallon counter not working”

Bad or damaged control board Replace control board

Fluid spray starts after spray icon is
shown on display

Fluid spray starts before spray icon is
shown on display

Spray icon does not show on display
when fluid is sprayed

Interrupter (164) is improperly positioned Turn screw (126) counterclockwise until

Interrupter (164) is improperly positioned Turn screw (126) clockwise until spray

Loose connector Check connector and reconnect

Interrupter (164) is improperly positioned Turn screw (126) counterclockwise until

Reed switch assembly (166) is damaged Replace reed switch assembly (166)

Remove display and reconnect

play when fluid is sprayed”

Adjust space between sensor and gear
to .050 --/+ .020 in. See page 19.

gear to align sensor and gear.

properly”

play when fluid is sprayed”

spray icon synchronizes with fluid spray

icon is synchronized with fluid spray

spray icon synchronizes with fluid spray

Magnet on assembly (166) is missing Replace reed switch assembly (166)

Cut or sliced wire Replace distance sensor harness (66)

Control board is damaged Replace control board

Display is damaged Replace display

Spray icon is always shown on display Interrupter (164) is improperly positioned

Reed switch assembly (166) is damaged Replace reed switch assembly (166)

31102010

Turn screw (126) clockwise until spray icon
is synchronized with fluid spray

Bearing Housing and Connecting Rod

Removal

1. Relieve pressure, page 7.

2. Fig. 2. Remove screws (187) and front cover (83).

3. Unscrew suction tube (34) from pump, hold
wrench on pump intake valve (A) to keep pump
from loosening.

4. Disconnect pump outlet hose (100) from displace­ment pump outlet nipple (60).

5. Fig. 1. Use screwdriver to push up retaining spring
(236) at top of pump. Push out pin (235).

235

Fig. 1

236

7675B

6. Fig. 2. Loosen retaining nut (84). Unscrew and
remove displacement pump (21).

7. Remove four screws (183) and lockwashers (173)
from bearing housing (22).

8. Pull connecting rod (26) and lightly tap lower rear
of bearing housing (22) with plastic mallet to
loosen from drive housing (24). Pull bearing hous­ing and connecting rod assembly (26) off drive
housing.

3. Clean mating surfaces of bearing and drive hous­ings.

4. Align connecting rod with crank (B) and carefully
align locating pins (F) in drive housing (24) with
holes in bearing housing (22). Push bearing hous­ing onto drive housing or tap into place with plastic
mallet.

CAUTION

DO NOT use bearing housing screws (183) to align
or seat bearing housing with drive housing. Align
these parts with locating pins (F), to avoid prema­ture bearing wear.

5. Install screws (183) and lockwashers (173) on
bearing housing. Torque evenly to note 3 value in
Fig. 2.

6. Install pump. Refer to Displacement Pump,
Installation, page 21.

B

2

E

ti6395a

24

22

26

C

F

1

34g

84

83

187

2

D

236

3

173

183

3

235

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

Installation

1. Evenly lubricate inside of bronze bearing (C) in
bearing housing (22) with high-quality motor oil.
Liberally pack top roller bearing (E), lower bearing
(D) inside connecting rod assembly (26) with
bearing grease.

2. Assemble connecting rod (26) and bearing
housing (22).

21

A

1

Oil

2

Pack with bearing grease 114819

3

LineLazer IV 3900/R300: Torque to 200 in-lb
(22.6 N¡m)

Fig. 2

LineLazer V 5900: Torque to 25 ft-lb

Model 248862 shown

60

100

34

311020 11