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	Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . .	15
Spray Tip Selection Table . . . . . . . . . . . . . . . . . . . . . . .	. 3	Pinion and Drive Housing Assemblies . . . . . . . . . .	16
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 4	Parts
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 5	LineLazer III 3900/5900 . . . . . . . . . . . . . . . . . . . . . .	18
Repair		Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .	24
Bearing Housing & Connecting Rod . . . . . . . . . . . .	. 8	Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	29
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	. 9	Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	29
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	10	Graco Phone Number . . . . . . . . . . . . . . . . . . . . . . . . . .	29
Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . .	13	Graco Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .	30
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN	55440-1441
ECOPYRIGHT 2002, GRACO INC.

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

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.

Caution Symbol

CAUTION

This symbol alerts you to the possibility of damage to or destruction of equipment 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.

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 sprayer.

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.

2 309414

Spray Tip Selection Table

LineLazer Tip Selection Guide. Sprayer is supplied with tip LL5319. For additional applications, use the tip selection table as follows:

Note: the last three digits (LL5319) of the tip part number identifies the line width and tip orifice (opening).

For example: the line width for tip LL5319 is 4 in. as shown in the table below. The tip orifice for tip LL5319 is .019 in.

LineLazer Tip Selection Table
				Used For
Tip Size	Line Width
			Sport court -- light film build
221203*	2 inches
			Sport court -- heavy film build
LL5213*	2 inches
			Alkyd paints only -- light film build
LL5215*	4 inches
			Alkyd paints only -- medium film build
LL5217	4 inches
			Alkyd paints only -- heavy film build
LL5219	4 inches
			Most traffic paints -- light film build
LL5315	4 inches
			Most traffic paints -- medium film build
LL5317	4 inches
			Most traffic paints -- medium film build
LL5319	4 inches
			Most traffic paints -- heavy film build
LL5321	4 inches
			Most traffic paints -- heavy film build
LL5323	4 inches
			Most traffic paints -- heavy film build
LL5327†	4 inches
			All paints and high solids traffic paints -- light film build
LL5417#	4	-- 8 inches
			All paints and high solids	traffic paints -- medium film build
LL5419#	4	-- 8 inches
			All paints and high solids	traffic paints -- heavy film build
LL5421#	4	-- 8 inches
			All traffic paints -- light film build
LL5621	8	-- 12 inches
			All traffic paints -- medium film build
LL5623	8	-- 12 inches
			All traffic paints -- medium film build
LL5625	8	-- 12 inches
			All traffic paints -- heavy film build
LL5627	8	-- 12 inches

* 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

Maintenance

WARNING

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 are instructed to relieve the pressure, 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.

5.Lock gun trigger safety.

6.Open pressure drain valve. Leave valve open until ready to spray again.

If you suspect that the spray tip or hose is completely clogged, or that pressure has not been fully relieved after following the steps above, VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually, then loosen completely. Now clear tip or hose.

CAUTION

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

DAILY: Check engine oil level and fill as necessary.

DAILY: Check hose for wear and damage.

DAILY: Check gun safety for proper operation.

DAILY: Check pressure drain valve for proper operation.

DAILY: Check and fill the gas tank.

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.

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.

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).

4 309414

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 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 dis-	Error code displayed?	Reference pressure control repair. Page 13.
placement pump does not
operate
	Pump switch is OFF	Turn pump switch ON.
	Pressure setting is too low	Turn pressure adjusting knob clockwise to
		increase pressure.
	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	Repair pump. Manual 309277.
	dried paint
	Connecting rod is worn or damaged	Replace connecting rod. Page 8.
	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	Replace clutch. Manual 309890.
	positioned
	Pinion assembly is worn or damaged	Repair or replace pinion assembly. Manual
		309890.

309414 5

Troubleshooting

PROBLEM		CAUSE	SOLUTION
Pump output is low		Strainer (31) is clogged	Clean strainer. Sprayer 233716 strainer is for
			use in paint only.
		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
			leave 233716 sprayer under pressure for more
			than 5 minutes when spraying texture and not
			actively spraying.
		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	Clean filter. Manual 309413 or 309093.
		dirty
		Large pressure drop in hose with heavy	Use larger diameter hose and/or reduce overall
		materials	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 perfor-
			mance (50 ft minimum).
Excessive paint leakage into		Throat packing nut is loose	Remove throat packing nut spacer. Tighten
throat packing nut			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.
Fluid is spitting from gun		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.
Pump is difficult to prime		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. Reas-
			semble 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 surfaces are not matched to each other	Clutch surfaces need to wear into each other.
clutch engages		when new and may cause noise	Noise will dissipate after a day of run time.
High engine speed at no		Misadjusted throttle setting	Reset throttle to 3700 engine rpm at no load
load
		Worn engine governor	Replace or service engine governor
6	309414

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	Remove display and reconnect
	and display
	Display damaged	Replace display
Distance counter not operating properly	Trigger sensor not set correctly	See “Spray icon does not show on dis-
		play when fluid is sprayed”
	Bad wiring connections	Check connector, and reconnect
	Distance sensor not spaced correctly	Adjust space between sensor and gear
	from gear	to .050 --/+ .020”
	Distance and gear not aligned	Remove tire, and press in or pull out
		gear to align sensor and gear.
	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
		properly”
	Trigger sensor	See “Spray icon does not show on dis-
		play when fluid is sprayed”
	Gallon counter	See “Gallon counter not working”
	Bad or damaged control board	Replace control board
Fluid spray starts after spray icon is	Interrupter (213) is improperly positioned	Turn screw (215) counterclockwise until
shown on display		spray icon synchronizes with fluid spray
Fluid spray starts before spray icon is	Interrupter (213) is improperly positioned	Turn screw (215) clockwise until spray
shown on display		icon is synchronized with fluid spray
Spray icon does not show on display	Loose connector	Check that 5-pin connector and reed
when fluid is sprayed		switch are properly connected
	Interrupter (213) is improperly positioned	Turn screw (215) counterclockwise until
		spray icon synchronizes with fluid spray
	Reed switch assembly (207) is damaged	Replace reed switch assembly (207)
	Magnet on assembly (207) is missing	Replace reed switch assembly (207)
	A connector on wiring harness (58) or on	Disconnect reed switch and 5-pin con-
	reed switch (207) is damaged	nector 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 re-
		place reed switch assembly (207).
	Cut or sliced 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	Turn screw (215) clockwise until spray icon
		is synchronized with fluid spray
	Reed switch assembly (207) is damaged	Replace reed switch assembly (207)
		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 displacement pump outlet nipple (6).

5.Fig. 1. Use screwdriver to push up retaining spring (95) at top of pump. Push out pin (96).

96

Fig. 1	95
	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).

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).

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 note 3 value in Fig. 2.

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

B

92	2	E
	2	D
27		F	101
		83
3		C 1
25, 26
	94
	95	97
	96		12g

61

6

119 A

1 Oil	12

ti1965a

2Pack with bearing grease 114819

3LineLazer III 3900: Torque to 200 in-lb (22.6 N¡m) LineLazer III 5900: Torque to 25 ft-lb (34 N¡m)

Fig. 2	Model 233701 shown

8 309414

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).

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.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.

2 102

122 B

183

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.

		B
1	LineLazer III 3900 only	1 98 98
2	Torque to 125 in-lb -- LineLazer III 390099
	Torque to 200 in-lb -- LineLazer III 5900
3	Apply remaining grease to these areas

Fig. 3

3

101h

101g

101

250

145 2

100 98

TI0178A

309414 9