Repair - Parts List
LineLazer™ IV 3900, 5900 Auto-Layout™ System
312195K
Airless Line Stripers
For application of line striping materials. For professional use only. Not for use in
explosive atmospheres.
3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
See page 2 for model information.
312190 309055
310643 312345
311254 312307
EN
ti10233a
Models
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Tip Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Auto-Layout Can Actuator Adjustment. . . . . . . . . . . . . . 10
Bearing Housing and Connecting Rod . . . . . . . . . . . . . . 11
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pinion Assembly/Clutch Armature/Clamp . . . . . . . . . . . 13
Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Trigger Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . 19
Distance Sensor Replacement . . . . . . . . . . . . . . . . . . . . 19
Control Board Diagnostics . . . . . . . . . . . . . . . . . . . . . . . 20
Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parts - Drive and Pinion Housing Assemblies. . . . . . . . 23
Auto-Layout System Wiring Diagram . . . . . . . . . . . . . . . 34
Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Models
3900 Line Stripers
253920
253953
255151
255152
5900 Line Stripers
253921
253954
255153
255154
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Manual Language
312195
312196
312197
312198
312199
312200
312201
312202
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312203
312204
312205
312206
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312219
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2 312195K
Warnings
Warnings
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 symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found 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:
• Use equipment only in well ventilated area.
• 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.
• 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 all equipment in the 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.
• Keep a working fire extinguisher in the 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.
• 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.
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.
312195K 3
Warnings
WARNING
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• 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. For complete information
about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manufacturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• 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.
• 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.
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.
• Always wear impervious gloves when spraying or cleaning equipment.
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
Gun may recoil when triggered. If you are not standing securely, you could fall and be seriously injured.
4 312195K
Tip Selection
Tip Selection
in.
(cm)
in.
(cm)
in.
(cm)
LL5213* 2 (5)
LL5215* 2 (5)
LL5217 4 (10)
LL5219 4 (10)
LL5315* 4 (10)
LL5317 4 (10)
LL5319 4 (10)
LL5321 4 (10)
LL5323 4 (10)
LL5325 4 (10)
LL5327 4 (10)
LL5329 4 (10)
LL5331 4 (10)
LL5333 4 (10)
LL5335 4 (10)
LL5355 4 (10)
LL5417 6 (15)
LL5419 6 (15)
LL5421 6 (15)
LL5423 6 (15)
LL5425 6 (15)
LL5427 6 (15)
LL5429 6 (15)
LL5431 6 (15)
LL5435 6 (15)
LL5621 12 (30)
LL5623 12 (30)
LL5625 12 (30)
LL5627 12 (30)
LL5629 12 (30)
LL5631 12 (30)
LL5635 12 (30)
LL5639 12 (30)
in.
(cm)
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✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
* Use 100 mesh filter to reduce tip clogs.
312195K 5
Maintenance
Maintenance
Pressure Relief Procedure
1. Engage trigger lock.
2. Turn engine ON/OFF switch to OFF.
3. Move pump switch to OFF and turn pressure control
knob fully counterclockwise.
4. Disengage the trigger lock.
5. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
6. Engage the trigger lock.
7. Open pressure drain valve. Leave valve open until
you are ready to spray again.
8. If you suspect the spray tip or hose is 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. Clear
hose or tip obstruction.
Trigger Lock
Always engage the trigger lock when you stop spraying
to prevent the gun from being triggered accidentally by
hand or if dropped or bumped.
Periodic Maintenance
DAILY: Check engine oil level and fill as necessary.
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.
Caster Wheel
(See letter call-outs in Parts, LineLazer IV Swivel
Wheel Assembly 240719 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).
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.
DAILY: Verify calibration.
6 312195K
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.
Troubleshooting
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 oil level is low. Try to start engine. Replenish oil, if necessary.
Honda Engines Owner's Manual.
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.
Clean or replace spark plug. Start engine. Keep
sprayer upright to avoid oil seepage.
Engine operates, but displacement pump does
not operate.
Error code displayed? Reference pressure control repair. Page 20.
Pump switch is OFF. Turn pump switch ON.
Pressure setting is too low. Turn pressure adjusting knob clockwise to
increase pressure.
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.
Drive housing is worn or damaged. Replace drive housing. Page 12.
Electrical power is not energizing clutch field. Check wiring connections. Page 16.
Repair pump. See pump manual.
Reference pressure control repair. Page 17.
Reference wiring diagram. 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.
Disconnect clutch wires from control board and
measure resistance across clutch coil. At 70° F,
the resistance must be between 1.2 +0.2 ohms
(LineLazer IV 3900); 1.7 +0.2 ohms (LineLazer IV
5900); if not, replace pinion housing.
Have pressure control checked by authorized
Graco dealer.
Clutch is worn, damaged, or incorrectly posi-
tioned.
Pinion assembly is worn or damaged. Repair or replace pinion assembly. Page 12.
312195K 7
Replace clutch. Page 13.
Troubleshooting
Problem Cause Solution
Pump output is low. 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 manual.
Large pressure drop in hose with heavy materi-
als.
Excessive paint leakage
into throat packing nut.
Fluid is spitting from gun. Air in pump or hose. Check and tighten all fluid connections. Reprime
Pump is difficult to prime. Air in pump or hose. Check and tighten all fluid connections.
Throat packing nut is loose. Remove throat packing nut spacer. Tighten throat
Throat packings are worn or damaged. Replace packings. See pump manual.
Displacement rod is worn or damaged. Replace rod. See pump manual.
Tip is partially clogged. Clear tip. See spray gun manual.
Fluid supply is low or empty. Refill fluid supply. Prime pump. See operation
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).
packing nut just enough to stop leakage.
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.
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. See pump manual.
Paint is too thick. Thin the paint according to the supplier's recom-
mendations.
Engine speed is too high. Decrease throttle setting before priming pump.
See operation manual.
8 312195K
Troubleshooting
Problem Cause Solution
Clutch squeaks each time
clutch engages.
High engine speed at no
load.
Gallon counter not working.
Sprayer operates, but display does not.
Distance counter not
operating properly.
Mils not calculating. Distance sensor. See “Distance counter not operating properly”.
Fluid spray starts after
spray icon is shown on
display.
Spray icon does not show
on display when fluid is
sprayed.
Spray icon is always
shown on display.
No dots or poor dots
with ghosting
Clutch surfaces are not matched to each other
when new and may cause noise.
Misadjusted throttle setting. Reset throttle to 3600 engine rpm at no load.
Worn engine governor. Replace or service engine governor.
Broken or disconnected wire. Check wires and connections. Replace broken
Bad sensor. Replace sensor.
Missing magnet. Reposition or replace magnet.
Bad connection between control board and dis-
play.
Display damaged. Replace display.
Trigger sensor not set correctly. See “Spray icon does not show on display when
Bad wiring connections. Check connector, and reconnect.
Gear teeth missing or damaged. Replace distance gear/wheel.
Wire cracked or broken. Replace sensor.
Trigger sensor. See “Spray icon does not show on display when
Gallon counter. See “Gallon counter not working”.
Bad or damaged control board. Replace control board.
Interrupter (164, page 31) Turn screw (126, page 31) counterclockwise until
Loose connector. Check connector and reconnect.
Interrupter (164, page 31) is improperly positioned.
Reed switch assembly (166, page 31) is damaged.
Magnet on assembly (166, page 31) is missing. Replace reed switch assembly (166, page 31).
Cut or sliced wire. Replace distance sensor harness (66, page 25).
Control board is damaged. Replace control board.
Display is damaged. Replace display.
Interrupter (164, page 31) is improperly positioned.
Reed switch assembly (166, page31) is damaged.
No dots. Solenoid cartridge bar is too far away from aero-
Poor dots or dots with ghosting. Solenoid cartridge bar is too close to aerosol
Engine speed to slow Engine speed must be greater than 2600 rpm.
Aerosol can malfunctioning Check that can sprays. Replace if not.
Solenoid module malfunctioning Replace solenoid module.
Clutch surfaces need to wear into each other.
Noise will dissipate after a day of run time.
wires.
Remove display and reconnect.
fluid is sprayed”.
fluid is sprayed”.
spray icon synchronizes with fluid spray.
Turn screw (126, page 31) counterclockwise until
spray icon synchronizes with fluid spray.
Replace reed switch assembly (166, page 31).
Turn screw (126, page 31) clockwise until spray
icon is synchronized with fluid spray.
Replace reed switch assembly (166, page 31).
sol marking can spray tip. Do Auto-Layout Can
Actuator Adjustment.
marking can spray tip. Do Auto-Layout Can
Actuator Adjustment.
312195K 9
Auto-Layout Can Actuator Adjustment
Auto-Layout Can Actuator Adjustment
Adjustments
The can actuator is set at the factory. If the dot size is
not as desired, do the coarse and/or fine adjustments.
Coarse Adjustment
1 Locate four screws on side of holder base.
ti10070a
2 Loosen screws to allow holder base to move freely.
4 Carefully tighten screws. Verify gap.
ti10073a
Fine Adjustment
If coarse adjustment did not achieve desired dot size,
proceed as follows:
1 Start striper and move to PARKING MODE display.
PARKING MODE
0 mph
STALL SIZE 9.00’
DOT SIZE
2Set
DOT SIZE
setting to smallest size (least amount of bars
on display). Press arrow keys to increase/decrease size.
SETUP
MODE
ti9919a
Do not aim aerosol can at your face.
3 Move holder base until solenoid cartridge bar is
approximately 0.10 in. (thickness of two dimes) from spray tip.
ti10071a
ti10072a
3Do Coarse Adjustment steps 1 and 2. Move holder base
until a dot size of approximately a dime is achieved.
Tighten screws on holder base.
Good Dot Poor Dot with Ghosting
ti10379a
ti10380a
Note: Dot size consistency can vary due to weather
changes and differences in aerosol marking can brands.
10 312195K
Bearing Housing and Connecting Rod
Bearing Housing and Connecting Rod
Removal
1. Relieve pressure, page 6.
2. F
IG. 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. F
IG. 1. Use screwdriver to push up retaining spring
(236) at top of pump. Push out pin (235).
235
2. Assemble connecting rod (26) and bearing housing (22).
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 (188) on bearing housing. Torque evenly to note 3 value in F
IG. 2.
6. Install pump. Refer to Displacement Pump, Instal-
lation, page 21.
B
2
83
236
E
2
D
7675b
236
FIG. 1
6. F
IG. 2. Loosen retaining nut (84). Unscrew and
remove displacement pump (21).
7. Remove four screws (183) and lockwashers (188)
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.
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.
60
26
C
1
100
187
3
183
235
21
3
188
A
Model 253920
1
Oil.
2
Pack with bearing grease 114819.
3
LineLazer IV 3900: Torque to 200 in-lb (22.6 N•m).
LineLazer IV 5900: Torque to 200 in-lb (22.6 N•m).
FIG. 2
24
22
34g
84
F
34
TI6395A
312195K 11
Drive Housing
Drive Housing
Removal
1. Relieve pressure, page 6.
2. F
IG. 3. Remove bearing housing. Do Bearing
Housing and Connecting Rod procedure on page
11.
3. Remove two screws (158) and reed switch (182).
4. Remove six screws (189) from pinion housing (25).
5. Lightly tap around drive housing (24) to loosen drive
housing. Pull drive housing straight off pinion housing. Be prepared to support gear cluster (23), which
may also come out.
Installation
1. Liberally apply bearing grease (supplied with
replacement gear cluster) to gear cluster (23) and to
areas called out by note 2.
2. Place bronze colored washer (24g) on shaft protruding from large shaft of drive housing (24). Place silver colored washer (24h) on pinion housing. Clean
mating surfaces of pinion and drive housings. Align
gears and push new drive housing straight onto pinion housing and locating pins (A).
3. Install six screws (189). Torque evenly to note 1
value in F
4. Install reed switch (182) with two screws (158).
5. Install bearing housing. Do steps 1 through 6 of
Bearing Housing and Connecting Rod procedure
on page 11.
IG. 3.
FIG. 3
189
1
182
158
188
178
24g 24h
24
2
179
A
25
189
178
23
2
1
LineLazer IV 3900: Torque to 140 in-lb (15.8 N•m).
LineLazer IV 5900: Torque to 200 in-lb (22.6 N•m).
2
Apply remaining grease to these areas.
A
1
TI6396a
12 312195K
Pinion Assembly/Clutch Armature/Clamp
Pinion Assembly/Clutch Armature/Clamp
Pinion Assembly/Clutch
Armature Removal
175
Pinion Assembly
If pinion assembly (25) is not removed from clutch housing (85), do steps 1 through 3. Otherwise, start at 4.
172
E
E
1. Remove drive housing, page 12.
2. F
IG. 12. Remove junction box (226).
3. F
IG. 11. Disconnect pump stroke sensor and clutch
cables.
4. F
IG. 4. Remove four screws (189) and lockwashers
(188) and pinion assembly (25).
189
188
85
189
188
25
TI5480b
FIG. 4
IG. 5. Place pinion assembly (25) on bench with
5. F
rotor side up.
6. Remove four screws (175) and lockwashers (172).
Install two screws in threaded holes (E) in rotor.
Alternately tighten screws until rotor comes off.
TI5481b
TI5987c
FIG. 5
7. F
IG. 6. Remove retaining ring (25e).
8. Tap pinion shaft (25d) out with plastic mallet.
86
25e
25d
25c
TI5482b
IG. 6
F
Clutch Armature
9. FIG. 7. Use an impact wrench or wedge something
between armature (87) and clutch housing to hold
engine shaft during removal.
10. Remove four screws (175) and lockwashers (172).
11. Remove armature (87).
87
172
175
TI8704a
IG. 7
F
312195K 13
Pinion Assembly/Clutch Armature/Clamp
Installation
Clutch Armature
1. FIG. 8. Lay two stacks of two dimes on smooth
bench surface.
2. Lay armature (87) on two stacks of dimes.
3. Press center of clutch down on bench surface.
87
0.12 +.01 in. (3.0 +.25 mm)
dimes
TI8705a
F
IG. 8
4. Install armature (87) on engine drive shaft.
5. F
IG. 7. Install four screws (175) and lockwashers
(172) with torque of 125 in-lb.
Clamp
Removal
1. Do Engine Removal.
2. Drain gasoline from tank according to Honda manual.
3. Tip engine on side so gas tank is down and air
cleaner is up.
4. F
IG. 9. Loosen two screws (175) on clamp (82),
5. Push screwdriver into slot in clamp (82) and remove
clamp.
Installation
1. FIG. 9. Install engine shaft key (88).
2. Tap clamp (82) on engine shaft (A) with plastic mallet. Maintain dimension shown note 2. Chamfer
must face engine.
3. Check dimension: Place rigid, straight steel bar (B)
across face of clutch housing (5). Use accurate
measuring device to measure distance between bar
and face of clamp. Adjust clamp as necessary.
Torque two screws (175) to 125 +10 in-lb (14 +1.1
N•m).
Pinion Assembly
6. FIG. 6. Check o-ring (25c) and replace if missing or
damaged.
7. Tap pinion shaft (25d) in with plastic mallet.
8. Install retaining ring (25e) with beveled side facing
up.
9. F
IG. 5. Place pinion assembly on bench with rotor
side up.
10. Apply thread sealant to screws. Install four screws
(175) and lockwashers (172). Alternately torque
screws to 125 in-lb until rotor is secure. Use
threaded holes to hold rotor.
11. F
IG. 4. Install pinion assembly (25) with five screws
(189) and lockwashers (188).
12. F
IG. 11. Connect pump stroke sensor and clutch
cables.
13. F
IG. 12. Install junction box (226).
1
Face of clutch housing.
2
LineLazer IV 3900: 2.55 +/- .010 in. (64.77 +/- 0.25 mm).
LineLazer IV 5900: 2.61 +/- .010 in. (66.29 +/- 0.25 mm)
3
Torque to 125 +/- 10 in-lb (14 +/- 1.1 N•m).
4
Chamfer this side.
85
1
88
B
A
FIG. 9
175
2
82
4
3
TI5484b
14 312195K
Clutch Housing
Removal
1. FIG. 10. Remove four cap screws (186) and lock
washers (188) which hold clutch housing (85) to
engine.
2. Remove screw (177) from under mounting plate (96).
3. Pull off clutch housing (85).
Installation
1. FIG. 10. Push on clutch housing (85).
2. Install four cap screws (186) and lock washers (188)
and secure clutch housing (85) to engine. Torque to
180 in-lb (20.3 N•m).
Clutch Housing
3. Install capscrew (177) from beneath mounting plate
(96). Torque to 20 ft-lb (27.1 N•m).
85
186
188
TI6643
F
IG. 10
88
96
177
312195K 15
Engine
Engine
Removal
1. Remove
ture/Clamp
2. FIG. 12. Remove junction box (226).
3. F
IG. 11. Disconnect all necessary wiring.
4. F
IG. 12. Remove screw (177). Remove two screws
(117), locknuts (118), and ground conductor (223,
260) from base of engine (185).
5. Lift engine carefully and place on work bench.
All service to the engine must be performed by an
authorized HONDA dealer.
Pinion Assembly/Clutch Arma-
and
Clutch Housing
Solenoid Actuator Cable
Main Control Box Cable
Wheel Sensor Cable
To Engine
. See pages 13 - 15.
Engine
223
Ref. 118
185
117
96
ti6398b
118
F
IG. 11
DISTANCE
SENSOR
TO MAIN
CONTROL
BOX
Bottom View
PUMP STROKE
COUNTER
JUNCTION
BOX
CLUTCH
TO
ENGINE
SOLENOID
ACTUATOR
CABLE
ti6397b
226
ti6536a
FIG. 12
Installation
1. FIG. 12. Lift engine carefully and place on engine
mount plate (96).
2. Install two screws (117) and ground conductor (223,
260) in base of engine and secure with locknuts
(118). Torque to 20 ft-lb (27.1 N•m).
3. F
IG. 11. Connect all necessary wiring.
4. Install Pinion Assembly/Clutch Armature/Clamp
and Clutch Housing. See pages 13 - 15.
16 312195K
Pressure Control
Pressure Control
On/Off Switch
Note: A complete wiring diagram is on page 34.
Removal
1. Relieve pressure, page 6.
2. F
IG. 13. Remove two screws (125) and cover (31).
3. Remove three screws (125) from control plate (15a).
Slide control plate out to access ON/OFF switch
(15g).
15o
4. Press locking tab on ON/OFF switch connector (B)
and disconnect from control board.
5. Press in on two retaining tabs on each side of
ON/OFF switch and remove switch.
Installation
1. Install ON/OFF switch (15g) so tabs of switch snap
into place on inside of pressure control housing.
2. Connect ON/OFF switch connector (B) to J3 on control board.
3. Slide control plate (15a) back to original position
and secure with three screws (125).
4. Install cover (31) with two screws (125).
15a
15f
15g
15n
15i
TO ENGINE
15r
125
GROUND
Transduser
31
C
15d
125
15j
A
216
B
D
Main Control
Box Cable
217
TI6408b
FIG. 13
312195K 17
Pressure Control
Control Board
Removal
1. Relieve pressure, page 6.
2. F
IG. 13. Remove two screws (125) and control cover
(31). Pull display connector wings open on control
board and pull display connector out.
3. F
IG. 13 and FIG. 21. Note on a paper lead connec-
tions to the control board. Disconnect leads from
control board (15d).
4. F
IG. 13. Remove five screws (15j) from control
board (15d).
Installation
1. FIG. 13. Install control board (15d) with five screws
(15j).
2. F
IG. 13 and FIG. 21. Refer to note on lead connec-
tions to the control board. Connect leads to control
board (15d).
3. F
IG. 13. Push display connector into control board
close display connector wings on control board.
Install control cover (31) with two screws (125).
Installation
1. FIG. 13. Install o-ring (217) and pressure control
transducer (216) in filter manifold (40). Torque to
35-45 ft-lb.
2. Connect transducer lead (C) to control board (15d).
3. Install control cover (31) with two screws (125).
Pressure Adjust Potentiometer
Removal
1. Relieve pressure, page 6.
2. F
IG. 13. Remove two screws (125) and control cover
(31).
3. Disconnect lead (D) from control board (15d).
4. Loosen set screws on potentiometer knob (15o) and
remove knob, shaft nut, lockwasher and pressure
adjust potentiometer (15i).
5. Remove seal (15n) from potentiometer (15i).
Installation
1. Install seal (15n) on potentiometer (15i).
Pressure Control Transducer
Removal
1. Relieve pressure, page 6.
2. F
IG. 13. Remove two screws (125) and control cover
(31).
3. Disconnect transducer lead (C) from control board
(15d).
4. Remove pressure control transducer (216) and
o-ring (217) from filter manifold (40).
18 312195K
2. F
IG. 13. Install pressure adjust potentiometer (15i),
shaft nut, lockwasher and potentiometer knob (15o).
a. Turn potentiometer shaft (15i) clockwise to inter-
nal stop. Assemble potentiometer knob (15o) to
strike pin on plate (15r).
b. After adjustment of step a, tighten both set
screws in knob 1/4 to 3/8 turn after contact with
shaft.
3. Connect lead (D) to control board (15d).
4. Install control cover (31) with two screws (125).
Engine Stop Switch
Note: A complete wiring diagram is on page 34.
Trigger Sensor Adjustment
Removal
1. Relieve pressure, page 6.
2. F
IG. 13. Remove two screws (125) and cover (31).
3. Remove two spade connectors from ENGINE STOP
switch (15f).
Trigger Sensor Adjustment
Refer to Troubleshooting for trigger sensor adjustment,
and see operation manual.
Distance Sensor Replacement
1. Remove wheel (120) from LineLazer.
2. Remove screw (273), wire clamp (115) and distance
sensor (66).
4. Press in on two retaining tabs on each side of
ENGINE STOP switch and remove switch.
Installation
1. Install ENGINE STOP switch (15f) so tabs of switch
snap into place on inside of pressure control housing.
2. Install cover (31) with two screws (125).
3. Install new distance sensor (66) with wire clamp
(115) and screw (273).
4. Install wheel (120) on LineLazer.
273
115
66
130
120
130
127
142
TI10237a
FIG. 14
312195K 19
Control Board Diagnostics
Control Board Diagnostics
Digital Display Messages
Relieve pressure before repair; page 6. No display does not mean that sprayer is not pressurized.
Display Sprayer Operation Indication Action
No Display Sprayer may be pres-
surized.
Sprayer may be pres-
ti6314a
surized.
Loss of power or display not connected.
Pressure less than 200
psi (14 bar, 1.4 MPa).
Check power source. Relieve pressure before
repair or disassembly. Verify display is connected.
Increase pressure as needed.
Normal operation. Spray.
Exceeded pressure
limit.
Pressure transducer
faulty, bad connection
or broken wire.
High clutch current. 1. Check clutch connections. Clean contacts.
ti6315a
ti6316a
ti6317a
psi
bar
MPa
Sprayer is pressurized. Power is applied.
(Pressure varies with
tip size and pressure
control setting.)
Sprayer stops. Engine
is running.
Sprayer stops. Engine
is running.
Sprayer stops. Engine
is running.
ti6318a
After a fault, follow these steps to restart sprayer:
Remove any filter clogs or flow obstructions.
Check transducer connections and wire. Replace
transducer or control board, if necessary.
2. Measure 1.2 +0.2 Ohms (LineLazer IV 3900);
1.7 +0.2 Ohms (LineLazer IV 5900) across
clutch field at 70°F.
3. Replace clutch field assembly.
1. Correct fault condition.
2. Turn sprayer OFF.
3. Turn sprayer ON.
20 312195K
Displacement Pump
Displacement Pump
Removal
1. Flush pump.
2. Relieve pressure, page 6.
3.
FIG. 15
4. FIG. 15. Remove suction tube (34) and hose (100).
F
IG. 15
. Cycle pump piston rod (A) to lowest position.
A
100
34
TI7672c
Installation
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.
CAUTION
If the pump locknut loosens during operation, the
threads of the bearing housing will be damaged.
Make sure locknut is properly tightened.
1. FIG. 18. Pull piston rod out 1.5 in. Screw in pump
until holes in bearing cross link and piston rod align.
1.5 in.
5. F
IG. 16. Use screwdriver: push retaining spring up
and push out pin (235).
235
TI7675b
IG. 16
F
IG. 17. Loosen locknut by hitting firmly with a 20 oz
6. F
(maximum) hammer. Unscrew pump.
TI7676b
F
IG. 18
2. F
IG. 16. Push pin (235) into hole. Push retaining
spring into groove around connecting rod.
3.
FIG. 19
. Screw jam nut onto pump until nut stops. Screw
pump into bearing housing until stopped by jam nut.
Back off pump and jam nut to align pump outlet to back.
Hand tighten jam nut; then tap 1/8 - 1/4 turn with a 20 oz
hammer to approximately 75 +/- 5 ft-lb (102 N•m).
TI7673b
F
IG. 19
4. FIG. 20. Fill packing nut with Graco TSL until fluid
flows onto the top of seal.
TI7673b
IG. 17
F
TI7677b
7. See manual 310643 for pump repair instructions.
312195K 21
F
IG. 20
Parts
Parts
LineLazer IV
Page 32
Page 26
Page 30
Page 24
Page 28
Page 31
ti10062a
22 312195K
Parts - Drive and Pinion Housing Assemblies
Parts - Drive and Pinion Housing Assemblies
Ref No. 24 and 25
Ref No. 24: Drive Housing Assembly 287467 for
LineLazer IV 3900; Drive Housing Assembly 287469 for
LineLazer IV 5900
Ref Part Description Qty
24 287467 HOUSING, drive (3900) 1
287469 HOUSING, drive (5900) 1
24g WASHER
107089 LineLazer IV 3900 1
194173 LineLazer IV 5900 1
24h WASHER
116191 LineLazer IV 3900 1
116192 LineLazer IV 5900 1
Ref No. 25: Pinion Housing Assembly 287463 for
LineLazer IV 3900; Pinion Housing Assembly 287465
for LineLazer IV 5900
Ref Part Description Qty
25 287463 HOUSING, pinion (3900) 1
287465 HOUSING, pinion (5900) 1
25a KIT, repair, coil
287474 LineLazer IV 3900 1
287476 LineLazer IV 5900 1
25b 105489 PIN 2
25c O-RING
165295 LineLazer IV 3900 1
114683 LineLazer IV 5900 1
25d* PINION SHAFT
241110 LineLazer IV 3900 1
241114 LineLazer IV 5900 1
25e* RETAINING RING, large
113094 LineLazer IV 3900 1
112770 LineLazer IV 5900 1
*Must be ordered separately.
Ref 212
24h
Ref 178
24
1
Pinion housing assembly (25) includes clutch field
and connector.
24g
Ref 179
25a
Ref 23
25b
25e
25d
Ref 170
Ref 172
Ref 86
25c
1
Ref 189
TI6407c
312195K 23
Parts - Drive and Pinion Housing Assemblies
LineLazer IV Auto-Layout System
268
57
144
267
264
141
33
27
14
77
60
77
13
277
107
177177
94
120
177
153
66
272
68
108
177
177
129
232
108
112
273
115
42
35
5
154
177
93
134
117
58
153
74
108108108
70
121121
73
115
117
130130
127
51
122
142
24 312195K
115
117
16
TI14597A
Parts - Drive and Pinion Housing Assemblies
LineLazer IV Auto-Layout System
Ref Part Description Qty Ref Part Description Qty
5 237686 WIRE, ground assembly w/ clamp 1 117 110837 SCREW, flange, hex 10
13 245225 HOSE, cpld, 3/8 in. x 50 1 120 255162 WHEEL, pneumatic 2
14 245798 HOSE, cpld, 1/4 in. x 7 1 121 111040 NUT, lock, insert, nylock, 5/16 6
16 287623 FRAME, linestriper (painted) 1 122 111194 SCREW, cap flang hd 2
27 287417 HANDLE 1 127 112405 NUT, lock 4
28 287622 SUPPORT, handle (painted) 1 129 112798 SCREW, thread forming, hex hd 1
33 287590 COVER, pail , includes 35 1 130 119563 WASHER, spring 4
35 119771 STRAP, cover 1 134 113961 SCREW, cap, hex hd 1
42 108471 KNOB 1 141 241445 CABLE, swivel wheel 1
51 193405 AXLE 1 142 114648 CAP, dust 3
57 194310 LEVER, actuator 1 144 114659 GRIP, handle 2
58 195134 SPACER, ball, guide 1 153 114982 SCREW, cap, flng hd 8
60 196176 ADAPTER, nipple 2 154 115077 PAIL, plastic 1
66 15K357 SENSOR, distance 1 158 114528 SCREW, mach, phillips, pnhd 2
68 15J088 SHIELD, distance sensor 1 177 112395 SCREW, cap, flng hd 5
70 198891 BRACKET, mounting 1 181 116618 MAGNET 1
73 198930 ROD, brake 1 182 119562 SWITCH, reed w/connector 1
74 198931 BEARING 1 220 15F638 LABEL, GMAX warning fire & skin 2
77 114271 STRAP, retaining 1 232 15K633 LABEL, LineLazer IV front 1
93 15F577 BRACE, left (painted) 1 264 120151 PLUG, tube 1
94 15F576 BRACE, right (painted) 1 267 15K162 BLOCK 1
107 178342 CLIP, spring 4 268 15K283 SWITCH, push button 1
108 101566 NUT, lock 16 272 15K452 SPACER, round, .500 O.D. 1
109 102478 STRAP, wiring tie (not shown) 4 273 260212 SCREW, hex washer hd, thd form 1
115 108868 CLAMP, wire 3 277 15M133 CALIBRATION BAR 1
312195K 25
Parts - Drive and Pinion Housing Assemblies
LineLazer IV Auto-Layout System
Models 253920, 253921
83
182
158
21
187
258
233
188
183
117
100
60
Ref 24, page 23
189
190
236
84
Ref 25, page 23
26
235
259
22
23
181
178
175
179
172
212
81
247
175
86
186
172
189
188
87
172
85
170
82
189
88
185
249
248
234
ti6405d
117
96
108
114
34n
34c
34m
34d
34h
34b
34k
34j
34d
34 (Detail E)
34g
34a
34e
34f
Detail E (12)
177
226
Ref 16, page 24
260
223
118
59
261
174
TI6405c
26 312195K
LineLazer IV Auto-Layout System
Parts - Drive and Pinion Housing Assemblies
Ref Part Description Qty
21 277069 PUMP, displacement, (3900) 1
277070 PUMP, displacement, (5900) 1
22 287714 HOUSING, bearing (3900) 1
287715 HOUSING, bearing (5900) 1
23 287653 GEAR, combination, (3900) 1
287460 GEAR, combination, (5900) 1
26 287719
287720
34 245730 HOSE, drain, includes 34a thru 34n 1
34a 15F149 TUBE, suction 1
34b 185381 HOSE 1
34c 110194 SWIVEL, 180° 1
34d 101818 CLAMP, hose 2
34e 15F513 GASKET, pail 1
34f 181072 STRAINER 1
34g 245731 TUBE, drain (includes 34h) 1
34h DEFLECTOR, threaded 1
34j 245798 HOSE, coupled, 1/4 in. x 7 ft 1
34k 114958 STRAP. tie 2
34m 196180 BUSHING 1
34n
▲
195119
59 119695 DAMPENER, engine mount 4
60 196176 ADAPTER, nipple 1
81† HUB, armature 1
82 193680 COLLAR, shaft 1
83 287521 COVER, front, (3900) 1
287511 COVER, front, (5900) 1
84 192723 NUT, retaining, (3900) 1
84 193031 NUT, retaining, (5900) 1
85 15E535 HOUSING, clutch, machine, (3900) 1
85 15E277 HOUSING, clutch, mach (5900) 1
86† ROTOR, clutch, 4, (3900) 1
87† ARMATURE, clutch, 4 in., (3900) 1
88 183401 KEY, parallel 1
96 15F583 PLATE, engine mount 1
100 245797 HOSE, cpld, 3/8 in.X 3 1
108 101566 NUT, lock 16
114 108851 WASHER, plain 4
117 110837 SCREW, flange, hex 10
118 110838 NUT, lock 2
158 114528 SCREW, mach, phillips, pnhd 2
170† 101682 SCREW, cap, sch 4
172† 105510 WASHER, lock, spring (hi-collar) 10
174 113743 SCREW, cap, hex hd 4
175 108803 SCREW, hex, socket head 6
177 112395 SCREW, cap, flng hd 5
178 114672 WASHER, thrust 1
179 114699 WASHER, thrust 2
181 116618 MAGNET 1
182 119562 SWITCH, reed w/connector 1
183 113467 SCREW, cap, socket hd, (3900) 4
114666 SCREW, cap, socket hd, (5900) 4
185 108879 ENGINE, gasoline, 4.0 HP, (3900) 1
114530 ENGINE, gasoline, 5.5 HP, (5900) 1
ROD, connecting (3900), includes 236a
ROD, connecting (5900), includes 236b
LABEL, warning (not shown) 1
ROTOR, clutch, 5, (5900) 1
ARMATURE, clutch, 5 in., (5900) 1
Ref Part Description Qty
186 108842 SCREW, cap, hex hd 4
187 118444 SCREW, mach, slot hex wash hd 4
188 100214 WASHER,(3900) 10
106115 WASHER, (5900) 10
189 119426
15C753
190 15F947 SHIELD, magnetic 1
1
212 15F250 WASHER, thrust, (3900) 1
1
223 119579 CONDUCTOR, ground 1
226 15F369 BOX 1
233 15K636 LABEL, linelazer iv front, (3900) 1
234▲
235 15F855 PIN, pump, (3900) 1
236 119676 SPRING, retaining, (3900) 1
247 290228 LABEL, caution 1
248 114629 GROMMET, transducer 1
249 119569 BUSHING, strain relief 1
258 15C762 SHIELD, pump rod 1
259 110996 NUT, hex, flange head 2
260 240997 CONDUCTOR, ground (5900) 1
261 120761 COVER, jack 1
▲
† Included in Clutch Repair Kit 241109 (3900) and 241113 (5900)
114672 WASHER, thrust, (5900) 1
15K637 LABEL, linelazer iv front, (5900) 1
194126
15F856 PIN, pump, (5900) 1
119778 SPRING, retaining, (5900) 1
Replacement warning labels may be ordered free of charge
SCREW, mach, hex washer hd, (3900)
SCREW, mach, hex washer hd, (5900)
LABEL, warning 1
12
6
312195K 27
Parts - Drive and Pinion Housing Assemblies
LineLazer IV Swivel Wheel Assembly 240719
Models 253920 and 253921
Ref 141 (page 24)
Ref 16 (page 24)
208
Ref 6
146
121
108
106
56
Ref 141
(Detail D)
7
147
130
117
153
1
127
1
142
130
10
46
55
139
65
127
133
113
54
128
133
132
116
52
110
209
6
F
140
135
145
Detail D
131
28 312195K
1
Install washers (130) concave surface to inside.
TI6404b
LineLazer IV Swivel Wheel Assembly 240719
65133
Ref Part Description Qty
6 240942 SHAFT, fork 1
7 240991 BRACKET, caster, front 1
10* 15G952 BRACKET 1
46 181818 KNOB 1
52 193528 ARM, detent 1
54 193661 JAW 1
55 193662 STOP, wedge 1
56 15F910 BRACKET, cable 1
65 198606 DISK, adjuster 1
106 100731 WASHER 2
108 101566 NUT, lock 16
110 15J603 WASHER 1
113 108483 SCREW, shoulder, sch 1
116 110754 SCREW, cap 2
117 110837 SCREW, flange, hex 10
121 111040 NUT, lock, insert, nylock, 5/16 6
127 112405 NUT, lock 4
128 112776 WASHER 1
130 119563 SPRING, belleville 2
131 113471 SCREW, cap, hex hd 1
132* 113484 SEAL 1
133* 113485 BEARING 2
135 113962 WASHER 1
139 114548 BEARING, bronze 2
140 114549 WHEEL, pneumatic 1
141 241445 CABLE 1
142 114648 CAP, dust 3
145 114681 SCREW 1
146 114682 SPRING, compression 1
147 114802 STOP, wire 1
153 114982 SCREW, cap, flng hd 8
208 193658 SPACER, seal 2
209* 120476 BOLT 1
Parts - Drive and Pinion Housing Assemblies
* Included In Bracket Repair Kit 240940
312195K 29
Parts - Drive and Pinion Housing Assemblies
LineLazer IV Auto-Layout System
Models 253920 and 253921
49
136a
153
108
136
95
44
219
112
1
161
104
8f
8b
105
47
8c
8d
ti6494a
Ref 14
8
8e
8a
8b
4
Ref 144 (page 24)
119
162
126 89
17
71
72
165
119
163
160
71
227 Ref 161
166
164
TI6497a
30 312195K
LineLazer IV Auto-Layout System
Parts - Drive and Pinion Housing Assemblies
Ref Part Description Qty
1 224052 BRACKET, support gun 1
4 248157 GUN, flex, basic 1
8 287570 HOLDER ASSEMBLY, gun 1
8a 287569 HOLDER, gun 1
8b 102040 NUT, lock 4
8c 15F214 LEVER, actuator 1
8d 15F209 STUD, pull, trigger 1
8e 15F210 STUD, pivot 1
8f 15F211 STUD, cable 1
17* 245733 KIT, trigger handle repair (includes
1
17. 89, 126, 164, 165)
44 15F212 ARM, holder, gun 1
47 15F213 BRACKET, cable 1
49 188135 GUIDE, cable 1
71 198895 PLATE, lever, pivot 2
72 198896 BLOCK, mounting (mach) 1
89* 15A644 LABEL, trigger 1
95 15K198 BRACKET, gun arm 1
104 119647 SCREW, cap, socket, filhd 2
Paint Can Holder Assembly 255346
315
307
Ref Part Description Qty
105 119648 SCREW, mch, trs hd, cross recess 1
108 101566 NUT, lock 16
112 111145 KNOB, pronged 1
119 111017 BEARING, flange 2
126* 112381 SCREW, mach, pan head 1
136 287566 KIT, clamp, (includes 136a) 1
136a 114028 NUT, winged 1
153 114982 SCREW, cap, flng hd 8
160 116941 SCREW, shoulder, socket head 1
161 287696 CABLE, gun, includes 227 1
162 116969 NUT, lock 1
163 116973 SCREW, #10 taptite phil 1
164* 117268 BRACKET, interrupter 1
165 117269 SPRING 1
166 287699 SENSOR, trigger 1
219▲
15F637
LABEL, warning skin inject 1
227 15F624 NUT, cable, gun (knurled) 2
* Included in Trigger Repair Kit 245733
▲
Replacement warning labels may be ordered free of charge
317
310
309
320
313
302
318
ti10236a
Ref Part Description Qty
301 15K757 HOLDER, paint can, base (painted) 1
302 15K570 CLAMP, paint can 1
303 255347 CARTRIDGE, solenoid 1
304 120865 KNOB, T-handle 1
305 101501 SCREW, mach., slot hex wash hd 4
306 117155 SPRING, compression 1
307 15K567 CLAMP 1
308 15K568 ARM, pivot 1
309 100428 SCREW, cap hex hd 2
310 120856 WASHER, Belleville 2
311 101712 NUT, lock 2
306
301
316
311
310309
314
319
Ref Part Description Qty
312 110755 WASHER, plain 4
313 100004 SCREW, cap, hex hd 1
314 120879 BUSHING, strain relief 1
315 111145 KNOB, pronged 1
316 15K103 CORD, power, solenoid 1
317 113696 PIN, ball coupler 1
318 15M216 TAG, chalk can 1
319 15M220 LABEL, Auto Layout System 1
320 260188 NUT, jam 1
312
311
308
305304
303
312195K 31
Parts - Drive and Pinion Housing Assemblies
LineLazer IV Auto-Layout System
Models 253920 and 253921
15g
15o
15s
15w
15f
15r
191
190
15a
15k
15d
15x
15t
103
15u
15c
268
15b
269
15n
15m
31
2c
38
76
62
125
29
13
Ref 14
167
37
11
2d
41
62
2a
2
2b
40
64
123
125
262
271
97
259
124
Ref 100
ti17487b
32 312195K
LineLazer IV Auto-Layout System
Ref Part Description Qty
2* 245103 VALVE, drain 1
2a 193709 SEAT, valve 1
2b 193710 SEAT, valve 1
2c 116424 NUT, cap 1
2d 114708 SPRING 1
11* 244067 FILTER, fluid 1
13 245225 HOSE, 3/8 in. x 50 ft 1
15 289264 KIT, switch, panel, includes 15a,
15r, 15s, 15w
15a
15b 289265
15c 15M509 GASKET, board 1
15d 289135 CONTROL, board, includes 15k 1
15f 114954 SWITCH, rocker 1
15g 116752 SWITCH, rocker 1
15k 111839 SCREW, mach, pnh, sems 6
15m 120743 SCREW, mach, pan head, sems 4
15n 109466 NUT, lock, hex hd 2
15o 116167 KNOB,potentiometer 1
15r SWITCH, membrane 1
15s LABEL, control, bottom 1
15t 287692 CONTROL, throttle 1
15u 119736 CLAMP, cable 1
15w 15F777 GASKET, control 1
15x 15F776 GASKET, throttle 1
29 196179 FITTING, elbow, street 2
31 15F589 COVER, control 1
37* 15C766 TUBE, diffuser 1
38* 15G563 HANDLE `1
40* 15H561 MANIFOLD, filter, 3/8 npt 1
41* 287285
62 196178 ADAPTER, nipple 2
64 196181 FITTING, nipple 1
76 104813 PLUG, pipe 1
97 15K102 HARNESS, wiring 1
103 116719 SCREW, 8/32, hex washer hd 1
123 15F814 GASKET,handle 2
124* 111457 O-RING 1
125 117501 SCREW, set, sch 5
167* 117285 O-RING 1
190 115999 RING, retaining 1
191 176754 GLAND, packing, male 1
225 15A464 LABEL, control 1
259* 287172 TRANSDUCER, pressure control
262 111801 SCREW, cap, hex 2
268 198650 SPACER,shaft 1
269 256219 POTENTIOMETER 1
271 111348 BUSHING, relief, strain 1
PLATE, control
BOARD, display, includes 15c
KIT, repair, filter cap, includes 37, 167
includes 124 1
1
1
1
1
Parts - Drive and Pinion Housing Assemblies
▲
Replacement warning labels may be ordered free of charge
* Included in Filter Repair Kit 288100
312195K 33
Auto-Layout System Wiring Diagram
Auto-Layout System Wiring Diagram
240997
119579
(ref. 268)
WHITE/BLACK
VIOLET
VIOLET/WHITE
1. BLUE
2. BLACK
3. WHITE/BLUE
4. BLACK/WHITE
GREEN
WHITE/GREEN
GREY
GREY
ti10235a
FIG. 21
34 312195K
Technical Data
Technical Data
Honda GX120 Engine (3900)
Power Rating @ 3600 rpm
ANSI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIN 6270B/DIN 6271
NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Honda GX160 Engine (5900)
Power Rating @ 3600 rpm
ANSI. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DIN 6270B/DIN 6271
NA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum working pressure . . . . . . . . . . . . . . . . . . . . . . . 3300 psi (228 bar, 22.8 MPa)
Noise Level
Sound power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sound pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
*Vibration Level
LineLazer IV 3900
Left hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LineLazer IV 5900
Left hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Right hand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
* Vibration measured per ISO 5349 based on 8 hour daily
exposure
Maximum delivery
LineLazer IV 3900 . . . . . . . . . . . . . . . . . . . . . . . . . . .
LineLazer IV 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum tip size
LineLazer IV 3900 . . . . . . . . . . . . . . . . . . . . . . . . . . .
LineLazer IV 5900 . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inlet paint strainer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 mesh (1190 micron) stainless steel screen, reusable
Outlet paint strainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 mesh (250 micron) stainless steel screen, reusable
Pump inlet size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/4 in. npt (m)
Fluid outlet size. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1/4 npsm from fluid filter
Wetted parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . nickel-plated carbon steel, PTFE, Nylon, polyurethane,
4.0 Horsepower
2.1 Kw - 2.8 Ps
2.6 Kw - 3.6 Ps
5.5 Horsepower
2.9 Kw - 4.0 Ps
3.6 Kw - 4.9 Ps
105 dBa, per ISO 3744
96 dBa, measured at 3.1 feet (1 m)
1.81 m/sec
1.45 m/sec
2.05 m/sec
1.70 m/sec
1.15 gpm (4.4 liter/min)
1.5 gpm (5.7 liter/min)
1 gun with 0. 034 in. tip
2 guns with 0.024 in. tip
1 gun with 0. 041 in. tip
2 guns with 0.028 in. tip
UHMW polyethylene, fluoroelastomer, acetal, leather,
tungsten carbide, stainless steel, chrome plating
2
2
2
2
312195K 35
Dimensions
Dimensions
LineLazer IV 3900 Auto-Layout System
Model 253920, 255151 Striper
Weight (dry, without packaging) . . . . . .212 lb (96 kg)
Height. . . . . . . . . . . . . . . . . . . . . . . 40 in. (101.6 cm)
Length . . . . . . . . . . . . . . . . . . . . . . 65 in. (165.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . 32 in. (81.3 cm)
Model 253953, 255152 Striper with 2nd Gun Kit
Weight (dry, without packaging) . . . . . 222 lb (101 kg)
Height. . . . . . . . . . . . . . . . . . . . . . . 40 in. (101.6 cm)
Length . . . . . . . . . . . . . . . . . . . . . . 65 in. (165.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . 32 in. (81.3 cm)
LineLazer IV 5900 Auto-Layout System
Model 253921, 255153 Striper
Weight (dry, without packaging) . . . . . 232 lb (105 kg)
Height. . . . . . . . . . . . . . . . . . . . . . . 40 in. (101.6 cm)
Length . . . . . . . . . . . . . . . . . . . . . . 65 in. (165.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . 32 in. (81.3 cm)
Model 253954, 255154 Striper with 2nd Gun Kit
Weight (dry, without packaging) . . . . . 242 lb (110 kg)
Height. . . . . . . . . . . . . . . . . . . . . . . 40 in. (101.6 cm)
Length . . . . . . . . . . . . . . . . . . . . . . 65 in. (165.1 cm)
Width . . . . . . . . . . . . . . . . . . . . . . . . 32 in. (81.3 cm)
36 312195K
Dimensions
312195K 37
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.
THIS WARRANTY IS EXCLUSIVE, AND IS IN LIEU OF ANY OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING BUT NOT LIMITED
TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE.
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.
POUR LES CLIENTS DE GRACO PARLANT FRANCAIS
Les parties reconnaissent avoir convenu que la rédaction du présent document ainsi que de tous les documents, avis et procédures judiciaires
exécutés, donnés ou intentés à la suite de ou en rapport, directement ou indirectement, avec les procédures concernées, sera en anglais.
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
Copyright 2007, Graco Inc. All Graco manufacturing locations are registered to ISO 9001.
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 312195
Graco Headquarters: Minneapolis
International Offices: Belgium, China, Japan, Korea
www.graco.com
Revised April 2013
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