Graco 312195K User Manual

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

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

✔✔

Manual Language 312195 312196 312197 312198 312199 312200 312201 312202

✔✔

312203 312204 312205 312206 312207 312208 312209 312210 312211 312212 312213 312214 312215 312216 312217 312218 312219

English

French

Spanish

Dutch

German

Italian

Tu rk is h

Greek

Croatian

Portuguese

Danish

Finnish

Swedish

Norwegian

Russian

Estonian

Latvian

Lithuanian

Polish

Hungarian

Czech Slovakian Slovenian

Romanian

Bulgarian

2 312195K

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

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)

✔

* Use 100 mesh filter to reduce tip clogs.

312195K 5

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

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”.

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

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

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.

236

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.

100

187

183

235

188

Model 253920

Oil.

Pack with bearing grease 114819.

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

34g

TI6395A

312195K 11

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

182

158

188

178

24g 24h

179

189

178

LineLazer IV 3900: Torque to 140 in-lb (15.8 N•m). LineLazer IV 5900: Torque to 200 in-lb (22.6 N•m).

Apply remaining grease to these areas.

TI6396a

12 312195K

+ 26 hidden pages