Graco 3900, 5900 User Manual

INSTRUCTIONS-PARTS LIST

LineLazert III 3900 and 5900 Airless Paint Stripers

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

309414J

LineLazer III 3900

Model Series Description

233688 A Striper with one Gun

233689 A Striper with Second Gun Kit

233664 A International Striper with one Gun

233694 A International Striper with 2nd Gun Kit

LineLazer III 5900

Model Series Description

233690 A Striper with one Gun

233691 A Striper with Second Gun Kit

233627 A International Striper with one Gun

233695 A International Striper with 2nd Gun Kit

Important Safety Instructions

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

ENG

233688

ti1935a

Related Manuals

Operator 309413...........................

Displacement Pump 309277.................

Spray Gun 309093.........................

Spray Tip *.................................

PC Board 309459..........................

Drain Valve Kit 308961......................

Clutch Replacement Kit 309890..............

* for spray tip selection, see page 4

Table of Contents

Warnings and Cautions 2.........................

Spray Tip Selection Table 3........................

Maintenance 4...................................

Troubleshooting 5................................

Repair

Bearing Housing & Connecting Rod 8.............

Drive Housing 9................................

Engine 10.....................................

Pressure Control 13............................

GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440--1441

Graco Inc. is registered to I.S. EN ISO 9001

Displacement Pump 15.........................

Pinion and Drive Housing Assemblies 16..........

Parts

LineLazer III 3900/5900 18......................

Pressure Control 24............................

Dimensions 29...................................

Technical Data 29................................

Graco Phone Number 29..........................

Graco Warranty 30...............................

Warnings and Cautions

Warning Symbol

WARNING

This symbol alerts you to the possibility of serious injury or death if you do not follow the instructions.

WARNING

Fire and explosion hazard: Solvent and paint fumes can ignite

or explode.

To help prevent a fire and explosion:

DUse only in an extremely well ventilated area. DEliminate all ignition sources; such as pilot lights, cigarettes and

plastic drop cloths (static arc hazard). Do not plug or unplug power cords or turn lights on or off in spray area.

DGround Sprayer, object being sprayed, paint and solvent pails. DHold gun firmly to side of grounded pail when triggering into pail. DUse only conductive airless paint hose. DDo not use 1,1,1-trichloroethane, methylene chloride, other

halogenated hydrocarbon solvents or fluids containing such solvents in pressurized aluminum equipment. Such use could result in a chemical reaction, with the possibility of explosion.

DDo not fill fuel tank while engine is running or hot. DDo not flush with gasoline.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment if you do not follow the instructions.

Fluid injection and high pressure hazard: High pressure spray or leaks can inject fluid into the body.

To help prevent injection, always:

DEngage trigger safety latch when not spraying. DKeep clear of nozzle and leaks. DNever spray without a tip guard. DDo PRESSURE RELIEF if you stop spraying or begin servicing

spraye r.

DDo not use components rated less than sprayer Maximum

Working Pressure.

DNever allow children to use this unit.

If high pressure fluid pierces your skin, the injury might look like “just a cut”. But it is a serious wound! Get immediate surgical treatment.

3094142

Spray Tip Selection Table

LineLazer Tip Selection Guide. Sprayer is supplied with tip LL5319. For additional applications, use the tip selec-

tion table as follows:

Note: the last three digits (LL5319 For example: the line width for tip LL5319 is 4 in. as shown in the table below. The tip orifice for tip LL5319

LineLazer Tip Selection Table

Tip Size

221203* 2 inches Sport court -- light film build

LL5213* 2 inches Sport court -- heavy film build

LL5215* 4 inches Alkyd paints only -- light film build

LL5217 4 inches Alkyd paints only -- medium film build

LL5219 4 inches Alkyd paints only -- heavy film build

LL5315 4 inches Most traffic paints -- light film build

LL5317 4 inches Most traffic paints -- medium film build

LL5319 4 inches Most traffic paints -- medium film build

LL5321 4 inches Most traffic paints -- heavy film build

LL5323 4 inches Most traffic paints -- heavy film build

LL5327† 4 inches Most traffic paints -- heavy film build

LL5417# 4 -- 8 inches All paints and high solids traffic paints -- light film build

LL5419# 4 -- 8 inches All paints and high solids traffic paints -- medium film build

LL5421# 4 -- 8 inches All paints and high solids traffic paints -- heavy film build

LL5621 8 -- 12 inches All traffic paints -- light film build

LL5623 8 -- 12 inches All traffic paints -- medium film build

LL5625 8 -- 12 inches All traffic paints -- medium film build

LL5627 8 -- 12 inches All traffic paints -- heavy film build

Line Width Used For

) of the tip part number identifies the line width and tip orifice (opening).

is .019 in.

* May require 100 mesh filter to minimize tip plugging. † Best for use with LineDriver.

# Best for cold weather applications.

How to Maximize Line Quality and Reduce Tip Wear. Observe the following suggestions to increase line quality

and minimize sprayer tip wear.

1. Select a larger tip orifice and run the sprayer at a reduced operating pressure.

2. Running larger tip sizes (example: use tip LL5321 @ 2000 psi instead of LL5317 @ 3300 psi) will significantly increase tip life and reduce tip plugging. It will also produce a more uniform film build across the line.

309414 3

WARNING

Maintenance

DAILY: Check pressure drain valve for proper opera-

tion.

INJECTION HAZARD

The system pressure must be manually relieved to prevent the system from

starting or spraying accidentally. Fluid under high pressure can be injected through the skin and cause serious injury. To reduce the risk of an injury from injection, splashing fluid, or moving parts, follow the Pressure Relief Procedure whenever you:

D areinstructedtorelievethepressure, D stop spraying, D check or service any of the system equipment, D or install or clean the spray tip.

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.

DAILY: Check and fill the gas tank.

AFTER THE FIRST 20 HOURS OF OPERA TION:

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.

Repack connecting rod (22) top needle bearing after every pump change.

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.

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 SLOW LY

loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear tip or hose.

CAUTION

For detailed engine maintenance and specifications, refer to separate Honda Engines Owner’s Manual, supplied.

DAILY: Check engine oil level and fill as necessary.

DAILY: Check hose for wear and damage.

DAILY: Check gun safety for proper operation.

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 drawing on page 22)

1. Once each year, tighten nut (164m) until spring washer bottoms out. Then back off the nut 1/2 to 3/4 turn.

2. Once each year, tighten nut (62) 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 (164e) 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 bolt (164t), align wheel and tighten bolt (164t).

3094144

Troubleshooting

Relieve pressure; page 4.

PROBLEM CAUSE SOLUTION

E=XX is displayed Fault condition exists Determine fault correction from table, page 14.

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

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 13.

Pump switch is OFF TurnpumpswitchON.

Pressure setting is too low Turn pressure adjusting knob clockwise to

Fluid filter (318) is dirty Clean filter. Page 24.

Tip or tip filter is clogged Clean tip or tip filter. Manual 309091.

Displacement pump piston rod is stuck due to dried paint

Connecting rod is worn or damaged Replace connecting rod. Page 8.

Honda Engines Owner’s Manual.

plug

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

increase pressure.

Repair pump. Manual 309277.

Drive housing is worn or damaged Replace drive housing. Page 9.

Electrical power is not energizing clutch field Check wiring connections. Page 10.

Reference pressure control repair. Page 13. Reference wiring diagram. Page 28.

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

Remove 7--pin connector from control board and measure resistance across clutch coil. At 70_ F, the resistance must be between 1.2

±0.2Ω (LineLazer III 3900); 1.7 ±0.2Ω (Line-

Lazer III 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. Manual

Replace clutch. Manual 309890.

309890.

309414 5

Troubleshooting

load

PROBLEM CAUSE SOLUTION

Pump output is low

Strainer (31) is clogged Clean strainer. Sprayer 233716 strainer is for

Piston ball (206) is not seating Service piston ball. Manual 309277.

Piston packings are worn or damaged Replace packings. Manual 309277.

O-ring (227) in pump is worn or damaged Replace o-ring. Manual 309277.

Intake valve ball is not seating properly Clean intake valve. Manual 309277.

Intake valve ball is packed with material Clean intake valve. Manual 309277. Do not

Engine speed is too low Increase throttle setting. Manual 309413.

Clutch is worn or damaged Replace clutch. Manual 309890.

Pressure setting is too low Increase pressure. Manual 309413.

Fluid filter (318), tip filter or tip is clogged or dirty

Large pressure drop in hose with heavy materials

use in paint only.

leave 233716 sprayer under pressure for more than 5 minutes when spraying texture and not actively spraying.

Clean filter. Manual 309413 or 309093.

Use larger diameter hose and/or reduce overall length of hose. Use of more than 100 ft of 1/4 in. hose significantly reduces performance of sprayer. Use 3/8 in. hose for optimum performance (50 ft minimum).

Excessive paint leakage into throat packing nut

Fluid is spitting from gun

Pump is difficult to prime

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

throat packing nut just enough to stop leakage.

Throat packings are worn or damaged Replace packings. Manual 309277.

Displacement rod is worn or damaged Replace rod. Manual 309277.

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

Reprime pump. Manual 309413.

Tip is partially clogged Clear tip. Manual 309093.

Fluid supply is low or empty Refill fluid supply. Prime pump. Manual

309413. Check fluid supply often to prevent running pump dry.

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

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

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

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

Pump packings are worn Replace pump packings. Manual 309277.

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

recommendations

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

Manual 309413.

Clutch squeaks each time clutch engages

High engine speed at no

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

Misadjusted throttle setting Reset throttle to 3700 engine rpm at no load

Worn engine governor Replace or service engine governor

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

3094146

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 Replace magnet. Locate in correct spot.

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 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 (213) is improperly positioned Turn screw (215) counterclockwise until

Interrupter (213) is improperly positioned Turn screw (215) clockwise until spray

Loose connector Check that 5-pin connector and reed

Interrupter (213) is improperly positioned Turn screw (215) counterclockwise until

Reed switch assembly (207) is damaged Replace reed switch assembly (207)

Remove display and reconnect

play when fluid is sprayed”

Adjust space between sensor and gear to .050 -- /+ .020”

gear to align sensor and gear.

properly”

play when fluid is sprayed”

spray icon synchronizes with fluid spray

icon is synchronized with fluid spray

switch are properly connected

spray icon synchronizes with fluid spray

Magnet on assembly (207) is missing Replace reed switch assembly (207)

A connector on wiring harness (58) or on reed switch (207) is damaged

Cut or s liced wire Replace wiring harness (58)

Control board is damaged Replace control board

Display is damaged Replace display

Spray icon is always shown on display Interrupter (213) is improperly positioned

Reed switch assembly (207) is damaged Replace reed switch assembly (207)

Disconnect reed switch and 5-pin connector from back of control board. Check continuity between pin 1 on 2-pin connector and pin 1 on 5-pin connector. Check continuity between pin 2 on 2-pin connector and pin 4 on 5-pin connector. If there is no continuity in either case, replace wiring harness (58). If there is continuity in both cases replace reed switch assembly (207).

Turn screw (215) clockwise until spray icon is synchronized with fluid spray

309414 7

Bearing Housing and Connecting Rod

Removal

1. Relieve pressure; page 4.

2. Fig. 2. Remove screws (27) and front cover (92).

3. Unscrew suction tube (12) from pump, hold

wrench on pump intake valve (A) to keep pump from loosening.

4. Disconnect pump outlet hose (61) from displace-

ment pump outlet nipple (6).

5. Fig. 1. Use screwdriver to push up retaining spring

(95) at top of pump. Push out pin (96).

Fig. 1

7675B

6. Fig. 2. Loosen retaining nut (97). Unscrew and

remove displacement pump (119).

7. Remove four screws (26) and lockwashers (25)

from bearing housing (94).

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 (101) with holes in bearing housing (94). Push bearing housing onto drive housing or tap into place with plastic mallet.

CAUTION

DO NOT use bearing housing screws (26) to align or seat bearing housing with drive housing. Align these parts with locating pins (F), to avoid premature bearing wear.

5. Install screws (26) and lockwashers (25) on bearing housing. Torque evenly to not e 3 value in Fig. 2.

6. Refer to Displacement Pump, Installation, page 15.

25, 26

101

8. Pull connecting rod (83) and lightly tap lower rear of bearing housing (94) with plastic mallet to loosen from drive housing (101). Pull bearing housing and connecting rod assembly (83) 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 (94) with high-quality motor oil. Liberally pack top roller bearing (E), lower bearing (D) inside connecting rod assembly (83) with bearing grease.

2. Assemble connecting rod (83) and bearing housing (94).

3094148

12g

119

Oil

Pack with bearing grease 1 14819

LineLazer III 3900: Torque to 200 in-lb (22.6 N¡m)

ti1965a

LineLazer III 5900: Torque to 25 ft-lb (34 N¡m)

Fig. 2

Model 233701 shown

Drive Housing

Removal

1. Relieve pressure; page 4.

2. Fig. 3. Remove bearing housing. Do 1. through 8.

of Bearing Housing and Connecting Rod procedure on page 8.

3. Fig. 3. Disconnect gallon counter sensor at (A).

Cut tie wrap holding gallon counting sensor wire to clutch wire.

4. Fig. 3. Remove two screws (145) and lockwashers

(122).

5. Remove four screws (102) and lockwashers (122)

from pinion housing (183).

6. Lightly tap around drive housing (101) to loosen

drive housing. Pull drive housing straight off pinion housing. Be prepared to support gear cluster (99), which may also come out.

Installation

1. Liberally apply bearing grease (supplied with replacement gear cluster) to gear cluster (99) and to areas called out by note 3. Use full 0.62 pint (0.29 liter) of grease for LineLazer III 3900 and

0.68 pint (0.32 liter) of grease for LineLazer III

5900.

2. Place bronze colored washer (101g) on shaft protruding from large shaft of drive housing (101). Place silver colored washer (101h) on pinion housing. Align gears and push new drive housing straight onto pinion housing and locating pins (B).

3. Install four screws (102) and lockwashers (122) from pinion housing (183).

4. Install two screws (145) and lockwashers (122).

5. Fig. 2. Connect gallon counter sensor at (A).

Secure gallon counting sensor wire to clutch wire with a tie wrap.

6. Fig. 3. Install bearing housing. Do 1. through 6. of Bearing Housing and Connecting Rod procedure on page 8.

LineLazer III 3900 only

Torque to 125 in-lb -- LineLazer III 3900 Torque to 200 in-lb -- LineLazer III 5900

Apply remaining grease to these areas

Fig. 3

102

122

183

101h

101g

101

250

145

100

TI0178A

309414 9

+ 21 hidden pages