Graco 231-132 Operation manual

308–082
Rev. W
Supersedes Rev. V
First choice when
quality counts. t
INSTRUCTIONS-PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
0001F
GM 3500
GASOLINE-POWERED AIRLESS LINESTRIPER
LineLazer
3000 psi (210 bar, 21.0 MPa)
Maximum Working Pressure
Model 231–132, Series A
With one gun, RAC IVRDripLesstTip guard,
Size 317 LineLazer Tip & Size 517 SwitchTipt,
and 50 foot (15 m) hose.
Model 231–140
Same as 231–132, except includes
Second Gun Kit, 224–097
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
Graco Inc. is registered to I.S. EN ISO 9001

2 308-082
Part Identification
Key
A Casterlever
B Dualgunselector
C Mainhose
D Suctionhose
E Fluidfilter
F Pressuredrain valve
G Arm
H Post
J Carriagebar
K Gunholder
L Rac IV tip guard
M Switch Tip
N Flexgun
O Displacementpump
P Caster
Q Dualgun selector cable
R Pressurecontrol
S Sparkplugcable
T AirCleaner
U Muffler
V FuelTank
W Hook eyelet (use to strap
pail or pail cover to cart)
X Pailcover
Y CasterCable
Z Groundingcableand
clamp
AA Collar
A
B
C
D
E
F
GH
JK
L
M
N
OP
Q
R
S
T
U
V
W
X
Y
Z
AA
0001F

3308-082
Table of Contents
Warnings 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fueling 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Second Gun and Hose Installation 11. . . . . . . . . . . . . . .
Flushing 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip and Tip Guard 15. . . . . . . . . . . . . . . . . . . . . . .
Gasket Selection 15. . . . . . . . . . . . . . . . . . . . . . .
Installation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operation 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearing a Clogged Tip 15. . . . . . . . . . . . . . . . . .
Maintenance 15. . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip Selection 16. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip Application Recommendations 16. .
Spray Techniques 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Line Width Adjustment 16. . . . . . . . . . . . . . . . . .
Positioning the Gun Arm Assembly 17. . . . . . . . . . . . . .
Vertical position of the first or second gun 17.
Horizontal position of the first gun 17. . . . . . . .
Horizontal position of the second gun 17. . . . .
Mount guns on the engine side of the cart 18.
Setup for spraying arcs 18. . . . . . . . . . . . . . . . .
Adjust Simultaneous Gun Triggering 18. . . . . . . . . . . . .
Gun Arm Positions 19. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Caster Lever & Cable Operation 20. . . . . . . . . . . . . . . . .
Operation 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 20. . . . . . . . . . . . . . . . . . . . . . . . . . .
Caster Tire Replacement 20. . . . . . . . . . . . . . . .
Caster Cable Tension Adjustment 20. . . . . . . .
Caster Alignment 20. . . . . . . . . . . . . . . . . . . . . . .
How to Mount the Gun 20. . . . . . . . . . . . . . . . . . . . . . . . .
Gun Cable & Dual Gun Selector Operation 21. . . . . . . .
How the Dual Gun Selector Works 21. . . . . . . .
How to Release the Selector Cable 21. . . . . . .
Adjust the Trigger Cable Tension 22. . . . . . . . .
Maintenance 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair or Replacement
Pressure Control 26. . . . . . . . . . . . . . . . . . . . . . .
Pressure Control Adjustment 27. . . . . . . . . . . .
Bearing Housing and Connecting Rod 28. . . . .
Drive Housing 29. . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Housing 30. . . . . . . . . . . . . . . . . . . . . . . . .
Clutch 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field & Wiring Harness 34. . . . . . . . . . . . . . . . . .
Clamp 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Housing Removal 35. . . . . . . . . . . . . . . .
Reassembly 36. . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts Pressure Control Parts 39. . . . . . . . . . . . . . . . . .
Cart Parts 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mechanical Parts 42. . . . . . . . . . . . . . . . . . . . . . .
Gun Mounting Parts 44. . . . . . . . . . . . . . . . . . . .
Pinion Parts 45. . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Warranty 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Change Summary
This manual has been updated to add items 194 – 196 and change item 2 to 240–484 from 238–361.

4 308-082
Symbols
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
equipment if you do not follow the instructions.
WARNING
INSTRUCTIONS
EQUIPMENT MISUSE HAZARD
Equipment misuse can cause the equipment to rupture or malfunction and result in serious injury.
DThis equipment is for professional use only.
DRead all instruction manuals, tags, and labels before operating the equipment.
DUse the equipment only for its intended purpose. If you are not sure, call your distributor.
DDo not alter or modify this equipment.
DCheck equipment daily. Repair or replace worn or damaged parts immediately.
DDo not exceed the maximum working pressure of the lowest rated system component. Refer to the
Technical Data on page 46 for the maximum working pressure of this equipment.
DUse fluids and solvents which are compatible with the equipment wetted parts. Refer to the Tech-
nical Data section of all equipment manuals. Read the fluid and solvent manufacturer’s warnings.
DDo not use hoses to pull equipment.
DRoute hoses away from traffic areas, sharp edges, moving parts, and hot surfaces. Do not expose
Graco hoses to temperatures above 82_C (180_F) or below –40_C (–40_F).
DDo not lift pressurized equipment.
DComply with all applicable local, state, and national fire, electrical, and safety regulations.
DWear hearing protection when operating this equipment.
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.

5308-082
WARNING
INJECTION HAZARD
Spray from the gun, leaks or ruptured components can inject fluid into your body and cause extremely
serious injury, including the need for amputation. Fluid splashed in the eyes or on the skin can also
cause serious injury.
Fluid injected into the skin may look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
Do not point the gun at anyone or at any part of the body.
Do not put your hand or fingers over the spray tip.
Do not stop or deflect leaks with your hand, body, glove or rag.
Do not “blow back” fluid; this is not an air spray system.
Always have the tip guard and the trigger guard on the gun when spraying.
Check the gun diffuser operation weekly. Refer to the gun manual.
Be sure the gun trigger safety operates before spraying.
Lock the gun trigger safety when you stop spraying.
Follow the Pressure Relief Procedure on page 7 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
Tighten all fluid connections before operating the equipment.
Check the hoses, tubes, and couplings daily. Replace worn or damaged parts immediately. Do not
repair high pressure couplings; you must replace the entire hose.
Fluid hoses must have spring guards on both ends, to help protect them from rupture caused by
kinks or bends near the couplings.
TOXIC FLUID HAZARD
Hazardous fluid or toxic fumes can cause serious injury or death if splashed in the eyes or on the skin,
inhaled, or swallowed.
Know the specific hazards of the fluid you are using.
Store hazardous fluid in an approved container. Dispose of hazardous fluid according to all local,
state and national guidelines.
Always wear protective eyewear, gloves, clothing and respirator as recommended by the fluid and
solvent manufacturer.
FUEL HAZARD
The fuel used in this unit is combustible and when spilled on a hot surface can ignite and cause a fire.
Do not fill the fuel tank while the engine is running or hot.
EXHAUST HAZARD
The exhaust contains poisonous carbon dioxide which is colorless and odorless.
Do not operate this equipment in a closed building.

6 308-082
WARNING
FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result in a fire or explosion and serious injury.
If there is any static sparking or you feel an electric shock while using this equipment, stop spray-
ing immediately. Do not use the equipment until you identify and correct the problem.
Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
Keep the spray area free of debris, including solvent, rags, and gasoline.
Disconnect all electrical equipment in the spray area.
Extinguish all open flames or pilot lights in the spray area.
Do not smoke in the spray area.
Do not turn on or off any light switch in the spray area while operating or if fumes are present.
Do not operate a gasoline engine in the spray area.
Ground the sprayer to a true earth ground with the ground wire and clamp (supplied).
Use only electrically conductive hoses.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
Keep clear of all moving parts when starting or operating the sprayer.
Before servicing the equipment, follow the Pressure Relief Procedure on page 7 to prevent the
equipment from starting unexpectedly.
Liquidscan be injected into the body by high pressure airless
spray or leaks – especially hose leaks.
Keep body clear of the nozzle. Never stop leaks with any part of the
body. Drain all pressure before removing parts.Avoidaccidental
triggering of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
Incase of accidental skin injection,seek immediate
“SurgicalTreatment”.
Failure to follow this warning can result in amputation or serious
injury.
FIRE AND
EXPLOSION HAZARD SKIN INJECTION HAZARD
READ AND UNDERSTAND ALL LABELS AND INSTRUCTION MANUALS BEFORE USE
Spraypainting,flushing or cleaning equipment with flammable
liquids in confined areas can result in fire or explosion.
Use outdoors or in extremely well ventilated areas. Ground
equipment,hoses,containersand objectsbeingsprayed.
Avoid all ignition sources such as static electricity from plastic
drop cloths, open flames such as pilot lights, hot objects such as
cigarettes, arcs from connecting or disconnecting power cords
or turning light switches on and off.
Failure to follow this warning can result in death or serious injury.

7308-082
Setup
General Information
NOTE: Reference numbers and letters in parentheses
in the text refer to the callouts in the figures and the
parts drawing.
NOTE: Always use Genuine Graco Parts and Acces-
sories, available from your Graco distributor.
Grounding
WARNING
FIRE AND EXPLOSION HAZARD
Before operating the pump, ground the
system as explained below. Also read
the section FIRE OR EXPLOSION HAZ-
ARD on page 6.
1. Sprayer: make sure the grounding chain (106)
contacts the ground while the unit is moving. See
page 42. For stationary spraying, connect a
ground wire and clamp (159) to a true earth
ground.
2. Fluid hoses: use only grounded hoses with a
maximum of 500 ft. (150 m) combined hose
length to ensure grounding continuity.
3. Spray gun: obtain grounding through connection to
a properly grounded fluid hose and sprayer.
4. Object being sprayed: according to local code.
5. Fluid supply container: follow your local code.
6. Solvent pails used when flushing: follow your local
code. Use only metal pails, which are conductive,
placed on a grounded surface. Do not place the
pail on a nonconductive surface, such as paper or
cardboard, which interrupts the grounding continu-
ity.
7. To maintain grounding continuity when flushing or
relieving pressure , hold a metal part of the spray
gun firmly to the side of a grounded metal pail,
then trigger the gun.
Fig. 1
159
Pressure Relief Procedure
WARNING
INJECTION HAZARD
Fluid under high pressure can be in-
jected through the skin and cause seri-
ous injury. To reduce the risk of an injury
from injection, splashing fluid, or moving parts, fol-
low the Pressure Relief Procedure whenever you:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tips.
1. Engage the spray gun safety latch.
2. Turn the ON/OFF switch to OFF.
3. Flip the pressure control switch to OFF.
4. Disengage the gun safety latch. Hold a metal part
of the gun firmly to the side of a grounded metal
pail, and trigger the gun to relieve pressure.
5. Engage the gun safety latch.
6. Hold the pressure relief tube firmly to the side of a
grounded metal pail, and open the pressure relief
valve. Leave the valve open until you are ready to
spray again.
7. Disconnect the spark plug cable to prevent the
system from starting unexpectedly.
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 the
tip guard retaining nut or hose end coupling and relieve
pressure gradually, then loosen completely. Now clear
the tip or hose.
06877
Fig. 2
Valve shown in
CLOSED position. Valve shown
in OPEN position.
Pressure
Hose
Suction
Tube
Pressure
Relief Tube

8 308-082
Setup
1. Read and follow the warnings on pages 4 and 6
before installing or operating this sprayer.
2. UnpacktheLineLazerCarefullyraisethehandle(19)
to a vertical position. Four screws (39) and locknuts
(40) are packed in a bag. Install the two rear screws
(39A) and finger tighten the nuts (40A). Install one
screw (39B) and nut (40B) on each side of the han-
dle. Firmly tighten all four nuts. See Fig. 3.
CAUTION
When raising the cart handle (19), be sure no cables
are caught on the frame or become kinked.
3. To install a second gun and hose, see page 11.
4. Fill the packing nut/wet–cup (216) 1/3 full with
Graco Throat Seal Liquid (TSL), supplied, and
keep it filled, to help extend the pump life. See
Fig. 4.
5. Check the engine oil level. Refer to the Honda
engine manual, supplied. This is a summary of the
information: Remove one of the oil fill plugs (A);
the oil should be almost overflowing. See Fig. 4.
Add oil as necessary. Also read the Maintenance
section on page 23.
Recommendedengineoil:Useahigh–quality,deter-
gent oil, SAE 10W–40, classified “FOR SERVICE
SE or SF”.
6. Ground the sprayer. Propergrounding is essentialto
maintaining an electrically safe system. Also read
andfollowFIRE OR EXPLOSIONHAZARDonpage
6.
WARNING
Ground the sprayer whenever it is used indoors,
either as a moving line striper or as a stationary
sprayer. Floors in most factories are coated, which
causes them to be poor electrical conductors. This
increases the risk of hazardous static electric
discharge, which can result in serious injury, fire, or
explosion and property damage.
Whenever you flush: connect the ground clamp
(159) to a true earth ground.
Using as an outdoor striper: Be sure the static
chain attached to the bottom of the cart drags on the
groundto help dissipate staticelectricity.Groundthe
sprayer to a true earth ground if specified by your
local electrical code.
Indoor spraying: Groundthesprayerwheneverthe
sprayer is used indoors. The ground wire supplied
with the sprayer is not long enough to allow much
operator movement. Therefore, the operator must
provide a longer ground wire or provide some other
method of effective electrical grounding asspecified
by your local electrical code.
7. Provideadequateventilationwhensprayingindoors.
WARNING
If the LineLazer is used indoors, you must vent the
exhaust to the outdoors or provide adequate ven-
tilation as specified by you local code. This is to
reduce the risk of carbon monoxide poisoning.
8. Fill the gas tank. See Fueling on page 10.
9. Flush the pump to remove the lightweight oil which
wasleft in the pumptoprotect it from rust.Followthe
Flushing on page 12.
10. Prepare the paint according to the manufacturer’s
recommendations. Remove any skin that may have
formed. Stir the paint to mix pigments.
Strainthepaintthroughafine nylonmeshbag(avail-
able at most paint dealers) to remove particles that
could clog the filter or spray tip. This is an important
step toward trouble–free spraying.
0007D
Fig. 3
19
39A
40A
40B
39B
216
Fig. 4


Keepfilled with TSL
A0008

9308-082
Setup
11. Observe the following cautions to avoid pressure
control damage.
CAUTION
To avoid damaging the pressure control, follow these
precautions.
Allow the main hose to act as a pulsation damp-
ener: Always use nylon spray hose at least 50 ft.
(15 m) long for the main gun; Never use a wire
braid hose; it is too rigid.
Never install a ball valve or shutoff device be-
tween the filter and the 50 ft. (15 m) hose.
Do not allow water or water-base material to
freeze in the pressure control.
CAUTION
Close the black fuel shutoff lever whenever you are
transporting the sprayer to prevent fuel from flooding
the engine.
Keep the sprayer upright and level when operating it
and transporting it. This prevents crankcase oil from
leaking into the combustion chamber, which makes
startup very difficult.
12. To use the wheel brake, lift the brake handle (A–
bottom rear of cart) to engage the brake. Lower
the handle to disengage the break. See Fig. 5. For
positive break engagement, be sure there is
proper tire pressure and that tire wear is not
excessive.
13. For how to operate and adjust the various features
of the LineLazer see pages 11 – 22.
14. Start the sprayer. See page 13.
Fig. 5
ÂÂ
ÂÂ
ÂÂ
ÂÂ
03586
A

10 308-082
Fueling
WARNING
Gasoline is extremely flammable and explosive
under certain conditions. To reduce the risk or a fire
or explosion:
1. Always shut off the engine before refueling.
2. Refuel in a well-ventilated area.
3. Do not smoke or allow flames or sparks in the
area where the engine is refueled or where
gasoline is stored.
4. Do not overfill the tank. Make sure the filler cap
is securely closed after refueling.
5. Fuel vapor or spilled fuel can ignite. If any fuel
is spilled during refueling, make sure the area
is dry before starting the engine.
1. Fuel specifications. Use automotive gasoline with
a pump octane number of 86 or higher. If the
engine knocks or pings, use a higher octane fuel.
Unleaded fuel minimizes combustion chamber
deposits.
2. Gasolines containing alcohol (gasohol). Do not use
gasohol which contains methanol, if the gasohol
does not contain cosolvents and corrosion inhibi-
tors for methanol. Even if it does contain such
additives, do not use the gasohol if it contains
more than 5% methanol.
NOTE: The HONDA engine warranty does not cover
damageresultingfromtheuseofgasolinescontainingal-
cohol. See the HONDAengine manual for moreinforma-
tion.
3. General.Donotuseoilandgasolinemixturesorcon-
taminated gasoline. Avoid getting dirt, dust or water
in the fuel tank.
4. Tank capacity: 0.66 gallons (2.5 liter). Leave 1/2 in.
(13 mm) at the top of the tank for gas expansion.
5. Shut off the engine switch (A) before refueling.
6. After refueling, tighten the fuel tank cap (B) firmly.
A
B
0009
Fig. 6

02490C
48
C
4
27,104
7
404
405B
14
402
403
D
E
AB
401
HOW TO INSTALL CABLE
CORRECTLY INSTALLED CABLE
122
F
99
94
402
34
DETAIL B
402
DETAIL A
Fig. 7
Torqueto 15 in–lb
(1.7N.m)
and then back up
1/16 to 1/8 turn

405A


Firstgun
Secondgun


11308-082
Second Gun and Hose Installation
NOTE: Fig. 7 represents the installation at Step 3.
NOTE: To switch the gun assemblies to the engine side
of the cart, refer to the instructions on page 17 before in-
stalling the second gun kit.
1. Disengage the trigger cable from the block (48) of
the unit’s existing gun. See page 21. Engage the
gun’s trigger safety latch.
2. Loosen the carriage clamps (B, C). Slide the
carriage bar (4) off the cart.
3. For mounting the second gun bar on the pump
side of the cart: Slide a clamp (405A) onto the
carriage bar (4). Slide the carriage bar through the
pump-side carriage clamp (B) and into the center
of the cart. Now slide another clamp (405B) onto
the carriage bar. See Fig. 7.
For mounting the second gun bar on the engine side
of the cart: Follow Step 3, except slide the carriage
bar through the engine-side carriage clamp (C) and
the into the center of the cart. The knobs of the
clamps (405A, 405B) must face back toward the
handle bars.
4. Slidethecarriagebar(4)throughtotheoppositecar-
riage clamp. Tighten the carriage clamps (B,C).
5. Slide the second gun bar (404) far enough into the
carriage bar that the clamp (405B) engages the bar.
Position the clamps (405A, 405B) over the notches
(A) in the carriage bar (4) and tighten the clamps.
NOTE: For stable gun operation, the second
gun bar (404) has a maximum recommended
extension from the carriage bar of about
11-1/4” (286 mm).
6. Disconnect the trigger cable from the second gun at
the screw (34). See Fig. 7 DETAIL B.
7. Unscrew the filter’s second outlet cap (14). Screw
the short hose (403) onto the filter nipple.
8. Remove the guide clamp screw (27).
9. Snap the cable bushing (E) into the guide plate (D).
Route the trigger cable (402) parallel with the main
gun cable, separating the guide clamp (104) to feed
the cable through it. Install and tighten the clamp
screw (27). Route the cable through the cable guide
(7) and to the second gun.
10. Slide the hooked end of the cable (402) through the
hole (F) in the lever plate (122). Rotate and slide the
hook back until it engages the plate. See DETAIL A.
11. Reconnect the trigger cable to the second gun at
screw (34). Torque the screw to 15 in–lb (1.7 N.m),
back it off 1/16 to 1/8 turn and then tighten the jam
nut (99) while holding the screw (34). Be sure the
plate (94) moves freely.
12. Install the clip (401) to hold the cable onto the frame.
13. Connect both trigger cables to the blocks (48). Then
adjust the cable tension. See pages 20 and 22.
14. Do not install the spray tip untilthe systemis primed.
15. Adjust simultaneous gun triggering. See page 18.

12 308-082
Flushing
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
Be sure the pump is properly grounded.
CAUTION
Never leave water in the sprayer if the is any chance
it could freeze. Push the water out with compatible
solvent. Water frozen in the pressure control tube
prevents the sprayer from being started, and causes
serious damage to the pressure control.
When to Flush
1. Flush a new sprayer to remove the protective oil.
Before using water–base paint, use compatible sol-
vent, then soapy water, and then clean water.
Before using oil–basepaint, use compatible solvent.
2. Changing colors. Use a compatible solvent.
3. Changing from water–base to oil–base paint. Use
warm, soapy water, and then a compatible solvent.
4. Changing from oil–base to water–base paint. Use a
compatible solvent, then warm, soapy water, and
then clean water.
5. Storage. After the compatible solvent flush, relieve
pressure, but do not drain the compatible solvent.
6. Startup after storage.
Beforeusingwater–basepaint , flushoutthecompat-
ible solvent with soapy water, and then with clean
water.
Whenusingoil–basedpaint, flushoutthecompatible
solvent with the paint to be sprayed.
How to Flush
1. Relieve pressure.
2. Removethefilterbowl(A)andscreen(B);seemanu-
al 307–273. Install the bowl and support (C), without
the screen, to flush it. Clean the screen separately.
See Fig. 8.
3. Close the pressure drain valve (13).
4. Put the suction tube in a grounded pail of water or
solvent.
5. Remove the gun(s) from the holder. Remove the
spray tip(s) to prevent splashing.
WARNING
To reduce the risk of static sparking and splashing
when flushing, always remove the spray tip from
the gun, and hold a metal part of the gun firmly to
the side of, and aimed into, a grounded metal pail.
6. Follow Startup on page 13. Keep the gun triggered
until clean water or solvent comes from the nozzle.
See Fig. 9. Release the trigger and engage the gun
safety latch.
NOTE: If you have two guns, release the trigger safety
latch on the second gun and trigger that gun until clean
water or solvent comes from the nozzle. To ensure that
thehosesarewell-flushed,flushthefirstgunandthenthe
second gun at least one more time.
7. Check all fluid connections for leaks. Relieve pres-
sure before tightening any connections. Start the
sprayer. Recheck the connections for leaks.
8. Remove the suction tube from the solvent pail. Dis-
engage the gun safety latch. Trigger the gun to force
water or solvent from the hose. Do not let the pump
run dry for more than 30 seconds to avoid damaging
the pump packings! Relieve pressure.
Fig. 8
B
C
0013
A13
Fig. 9

0014
Maintainfirm metal-
to-metalcontact
whenflushing to
reducethechance
of static sparking
andsplashing.

9. If you havebeen spraying paint,remove thestrainer,
suction tube and suction hose and clean them sepa-
rately to be sureall paint sedimentis removed. Dried
paint in the suction tube assembly can build up and
cause performance problems later on.
10. Installthecleanfilterscreen.Installthefilterbowland
hand tighten.
11. See Storage or Changing Colors, above. Relieve
pressure.

13308-082
Startup
Before You Start the Linestriper
1. SeeFlushing,page 12,todetermineiftheLineLazer
should be flushed.
2. Be sure the gas tank is full.
3. Check the engine oil level.
NOTE: The engine stops automatically, or will not start,
if it is low on oil. If you try to start it again without adding
more oil, a red light (A) near the engine on/off switch
glows as you pull the starter rope.
4. Besurethesparkplugcable(J)isfirmlypushedonto
the spark plug.
Startup See Fig. 10
1. When starting a sprayer that IS NOT PRIMED, re-
move the spray tip.
2. Placethesuctiontube (S)intothepaint,wateror sol-
vent container, depending on whether you are flush-
ing or are ready to spray.
3. Open the black fuel shutoff lever (E) by pushing it in
the direction of the arrow.
CAUTION
Never start the engine unless fluid pressure is re-
lieved and the pressure control switch is turned OFF.
Attempting to start the engine when it is pressurized
could damage the electrical system.
4. Turn OFF the pressure control switch (K).
5. To start the engine:
a. Turn the pressure adjusting knob (L) all the
way counterclockwise to the lowest pressure
setting.
b. Slide the metal throttle lever (C) away from the
fuel tank to the maximum position (fully left).
c. If the engine is cold, close the choke by mov-
ing the gray lever (D).
d. If the engine is warm, close the choke by
moving the gray lever (D) only half way or not
at all.
e. Turn ON the engine switch (B).
WARNING
A rope that recoils too quickly may hit someone
and cause serious bodily injury. The rope could
also jam in the recoil assembly.
f. Hold the frame of the sprayer with one hand
and pull the starter rope (G) rapidly and firmly.
Continue holding the rope as you let it return.
Pull and return the rope until the engine starts.
g. Open the choke as soon as the engine starts,
except in cold weather. In cold weather, leave
the choke closed for 10 to 30 seconds before
opening it to keep the engine running.
6. Releasethetriggercableandengagetheguntrigger
safety latch. See page 21.
7. Remove the gun from the holder by unscrewing the
gun holder knob and lifting out the gun.
8. To start the pump:
NOTE: Lower the throttle setting for easier priming.
a. Open the pressure drain valve (R).
b. Turn ON the pressure control switch (K).
c. Turn the pressure control knob (L) about 1/4
turn from minimum pressure. Run the pump
until fluid is flowing smoothly from the pressure
drain valve, indicating the pump is fully primed.
d. Close the pressure drain valve (R).
e. Disengage the gun safety latch. Hold a metal
part of the gun firmly against a grounded metal
pail, squeeze the trigger until fluid flows from
the gun.
f. Release the trigger. Engage the safety latch.
NOTE: If you are using two guns, follow Step e and f,
above, for the second gun.
9. If you have not primed the sprayer with paint yet,
move the suction tube (S) to the paint container. Re-
leasethetriggersafetylatch. Trigger the gun into the
water/solvent pail just until paint appears. Release
the trigger and engage the trigger safety latch. Re-
peat for the second gun, if two guns are used.
10. Place the pail cover (F) on the pail.
WARNING
To reduce the risk or serious injury from fluid
injection, never operate the spray gun with the tip
guard removed.
11. Install the tip guard and spray tip (M). See page 15.
12. Mount the gun in the gun holder. See page 20.
13. Engage the trigger cable. See page 21.
CAUTION
Always use the lowest fluid pressure and the lowest
throttle setting needed. Higher settings cause exces-
sive clutch cycling, premature tip wear and prema-
ture pump wear.
14. Adjusttheenginespeedandpumppressure.Trigger
the gun onto a test paper to check the spray pattern
and atomization. Turn the pressure adjusting knob
(L)untilyougetagoodpattern.Thenslowlylowerthe
throttlesetting(C)asfarasyoucanwithoutchanging
the spray pattern.

0001F
Shownin
chokedposition
E
AB
H
C
D
––AT REAR OF ENGINE––
KEY
A EngineOil Light
B EngineOn/Off Switch
C ThrottleLever
D Gray Choke Lever
E Black FuelShutoff Lever
F PailCover
G StarterRope
H AirCleaner
J SparkPlugCable
K Pressure ControlOn/Off Switch
L PressureAdjustingKnob
M SwitchTip
N Rac IV TipGuard
P Gun TriggerSafetyLatch
Q RemoteTriggerCable
R Pressure Drain Valve
S SuctionTube
F
G
H
J
L
M
N
P
Q
R
S
Shownin
offposition
Shownoff
Fig. 10






K
0001F
14 308-082
Startup
15. Read Spray Techniques on page 16.
CAUTION
Close the black fuel shutoff lever (E) whenever you
are transporting the sprayer to prevent fuel from
flooding the engine.
Keep the sprayer upright and level when operating it
and when transporting it. This prevents crankcase oil
from leaking into the combustion chamber, which
makes start up very difficult.

15308-082
Spray Tip and Tip Guard
WARNING
To reduce the risk of serious injury whenever you
are instructed to relieve pressure, always follow the
Pressure Relief Procedure on page 7.
WARNING
Failure to install or use the RAC IV tip guard as-
sembly correctly may result in an undirected spray
of paint into the eyes or on the skin of the operator.
Be sure you:
Use the appropriate gasket for the solvent used.
Fully insert the tip into the guard.
Fully tighten the guard onto the gun nozzle
using a wrench.
Turn the handle so it is parallel to the gun
nozzle.
When replacing a worn spray tip, always install
a new gasket and seat.
Gasket Selection
WARNING
To reduce the risk of fluid splashback into the eyes
or on the skin, use the appropriate gasket as
specified in the following text.
Use the black rubber gasket (D) ONLY with latex and
oil-based paints, stoddard solvents, mineral spirits, tur-
pentine and water. When using this gasket, the spray tip
can be removed and replaced without using tools.
Use the red or yellow plasticgasket (C)withthesame
fluids as above and with most other solvents, including
lacquer thinner, trichloroethylene, MEK, acetone, brush
cleaner, xylol. When using this gasket, loosen the RAC
IV retaining nut to remove the spray tip.
Installation
Relieve pressure. Install a tip (F) so the flange(G) on the
cylinder fits into the slots (H) at the base of the spray tip
guard (J). See Fig. 11.
Place the seat (E) on a pencil, curved side out, asshown
in Fig. 12. Guide the seat into the retaining nut (A) and
turn the seat until it straddles the cylinder of the spray tip
(F). Drop in the appropriate gasket and press it down. If
using the red or yellow gasket (C), be sure the flat side
faces out of the retainer (A). See Fig. 11.
Screw the spray tip guard snugly onto the gun, holding
itinthedesiredpositionwhiletighteningretainingnut(A).
NEVER use a wrench to turn the plastic tip guard (J), to
avoid damaging the guard.
Operation WARNING
Keep clear of the nozzle! High pressure fluid from
leaks or spray can penetrate the skin and cause
extremely serious injury, including the need for
amputation. The spray tip guard provides extra
protection against injection, but does not prevent it!
Never cut off the spray tip guard.
Be sure the spray tip handle is in the FULL SPRAY posi-
tion before operating the gun. See Fig. 11.
Clearing a Clogged Spray Tip
Disengage the trigger cable(s). Engage the gun safety
latch. Turn the arrow handle to the FULL CLEAN posi-
tion.SeeFig.13.Releasethesafetylatchandtriggerthe
gun. Fluidpressureshould force out the clog. Return the
arrow handle to the full spray position. If it is still
clogged , follow the Pressure Relief Procedure on
page 7 and remove the spray tip for cleaning.
Maintenance
Change the seat and gasket when the spray tip wears
out; these parts wear at about the same rate.
A
C
D
E
F
G
H
J
BLACK
RED or YELLOW
0091
Fig. 11
E
A
F0092
Fig. 12
FULLCLEAN POSITIONFULL SPRAY POSITION
GUN NOZZLE
TIP
HANDLE
RAC IV
DripLess
TIP GUARD
0093
Fig. 13

16 308-082
Spray Tip Selection
Other Applications
Sport Court,
2” wide line LLT–213
Crosswalk,
12” wide line, 1 gun 621,
623, 625
Airport,
24” wide line, two guns 721
Stencils 417*, 419*
General Stationary
Painting 517{
Fig. 14
Lineal Feet/Minute
(rate at which unit is moved)
Based on 4” wide line and 15 mils of paint
Application 120 144 184 220 264 308 352 400
Parking Lot Lines
4” wide 217 LLT–317*{221* 223 224
6” wide 317 317* 321* 323 325
Long Lines,
4–6” wide 221* 223 225 227 228 231
Curbs 417* 419*
* Tips can be used with two guns. { Supplied with the Line Lazer.
Spray Tip Application Recommendations
Spray Techniques
These spray techniques discuss how to use and adjust
thefeaturesoftheLineLazer.Youmustalsoconsiderop-
erator technique, job site conditions and weather.
1. Usewaterratherthanpainttopracticesprayingtech-
nique and positioning the guns.
2. Be sure the RAC IV Tip Guard is always parallel to
thegroundandthe“wings”ofthespraytipguardface
the front and back of the unit, as shown in Fig. 15.
WARNING
To reduce the risk of a fluid injection injury, always
disengage the remote trigger cable to the gun(s)
and engage the gun trigger safety latch(es) before
moving or adjusting the spray tip guards, guns, or
gun arms. See Page 21.
3. Use the lowest pressure necessary for good atom-
ization. High pressure may cause excessive paint
buildup and overspray.
4. StartmovingtheLineLazerbeforetriggeringthegun
to prevent a build up of paint at the beginning of the
line. Release the trigger a second before stopping
the Line Lazer. Move at an even rate of speed.
5. Alwayscheckyourgunadjustmentson cardboard or
paperbeforestartingeachjob.When painting curbs,
paint first in an area that is less frequently seen.
6. Keep in mind that many factors affect the straight-
ness of a line, including uneven surfaces, potholes,
rocks and other debris and a clogged or worn spray
tip. See page 15 for how to clear or change a spray
tip.
7. Tominimizetheeffectofbumpsonthespraypattern,
keep the spray tip guard centered with the front
wheel axis.
8. Thespraytip sizeandtherateatwhichyoumovethe
unit affect the coating thickness. Generally, the fast-
er you move the unit, the larger the spray tip orifice
shouldbe.Thefanwidthofthespraytipindicatesap-
proximately how wide the line will be. See the chart
in Fig. 14forspraytipapplicationrecommendations.
9. Position the guns to suit your requirements. See the
section below and pages 17 to 19.
10. Traffic paints may be formulated for air spray,airless
spray or have no formulation description.Generally,
airsprayformulasarepre–thinned,andwillworkwell
in the Line Lazer, but there may be more overspray.
Non–air spray formulas tend to deliver more lineal
feet of line per gallon with less overspray, since they
are less easily absorbed into the pavement.
11. If you usefast–drayingtrafficpaintonahot day,float
compatiblesolventontopofthepainttoprevent skin
from forming on it.
Line Width Adjustment
Several factors affect line width: vertical distance of the
spraytiptothesprayingsurface,spraytipfanpattern,us-
ing one or two guns, paint pressure, and a worn or
clogged spray tip.
The typical conditions for a 4 in. wide line are: 317 size
Line Lazer Tip (supplied), the gun positioned one inch
from the lowest vertical position, and just enough pres-
sure to atomize the paint. Depending on the fan pattern
ofthespraytip, useoneguntopaint2to12in.widelines,
and two guns to paint 12 to 24 in. wide lines.
To decrease line width, lower the gun (if possible) or use
a tip with a narrower fan pattern.
To increase line width, raise the gun, or use a tip with a
wider fan pattern, or use two guns.

17308-082
Positioning the Gun Arm Assembly
0012E
D
93
405B
405A
404
4
ENGINE SIDE
PUMP SIDE
B
“WINGS” OF TIP GUARD B
E
A
D
DETAIL A
1
402
Fig. 15




Firstgun
Secondgun
F
The gun arms can be positioned for a variety of spraying
needs.Thedrawingsonpage19primarilyshowtheguns
mounted on the pump side of the Linestriper. However,
one or both guns may be mounted on the engine side.
Whenever You Move the Guns
CAUTION
Do not kink the cables, which could prevent them
from properly triggering the guns.
Disengagethe trigger cables and engage the gun trigger
safety latch first. See page 21. Do not kink the trigger
cables. Pull out more of the 50 ft. hose, if necessary.
After moving the guns, reposition the spray tip guard so
it is parallel to the ground and its “wings” face the front
and back of the unit. Disengage the gun trigger safety
latch and engage the trigger cable.
Vertical Position of the First or Second Gun
Loosen the arm clamp (6) and move the gun up or down.
Tighten the clamp. Engage the trigger cable.
NOTE: See Fig. 15. Two collars (F) are located above
and below each gun. The collars can be adjusted to pro-
vide stops for preset spray width positions for each gun.
Horizontal Position of the First Gun
Method 1: Disengage the trigger cable. Loosen the car-
riage clamps (B,D) and slide the carriage bar (4) left or
right, so the gun will be outside the tire path. Tighten the
clamps. Engage the trigger cable.
Method 2: Disengage the trigger cable. Loosen the arm
clamp (6) and rotate the gun out to the side. Tighten the
bolt. Engage the trigger cable.
NOTE: Usemethods1and2togethertoobtainthemax-
imum distance of one gun from the unit, which is helpful
when spraying around obstacles.
Horizontal Position of the Second Gun
Method 1: Disengage the trigger cable. Loosen the
clamps (405A, 405B). Slide the second gun bar (404)
horizontally, being sure both clamps engage the second
gun bar. Tighten the clamps. Engage the trigger cable.
Method 2: Disengage the trigger cable. Loosen the arm
clamp (6) and rotate the gun out to the side. Tighten the
bolt. Engage the trigger cable.
NOTE: Usemethods1and2togethertoobtainthemax-
imumdistanceof33–1/2in.(851mm)betweenthecenter
of two guns.

18 308-082
Positioning the Gun Arm Assembly
Mount Guns on the Engine Side of the Cart
1. See Fig. 15. For both guns, disengage the trigger
cable and engage the trigger safety latch. See page
22.
2. Loosen the gun holder knobs (93) and remove the
gun. Lay the guns out of the way.
3. Remove the knobs (E) on both carriage clamps
(B,D); the carriage bar (4) and extension clamps (A)
will drop down.
4. Lift the front tire and rotate the carriage bar 180un-
der the cart and to the other side of it.
5. Position the carriage bar below the carriage clamps
(B,D). Align the holes in the top of the extension
clamps (A) with the holes in the carriage bar clamps
and install the knobs (E).
6. Loosen the post/arm clamps (6) and rotate the guns
forward. Retighten the clamps.
7. Install the guns. Note which gun and position on the
dual gun selector each of the cables (1 and 402)
goes.Routethehosesandcablestopreventkinking.
Positionthespraytipguards.Disengagetheguntrig-
ger safety latches. Engage the trigger cables.
Setup for Spraying Arcs
1. See Fig. 16. Disengage the trigger cable (1) anden-
gage the gun trigger safety latch. See page 21.
2. Loosen the arm clamp (6) and rotate the arm (A)
back near the rear tire and then position the arm so
the spray tip guard aligns with the back axle of the
unit. Retighten the clamp.
3. Extend the carriage bar (4) or second gun bar (404)
soyou can easily watch theline youarepaintingand
also to avoid running over the paint line. See
page 17.
4. Adjust the vertical and horizontal position of the gun.
5. Spray the arc from the outside.
0002D
1
4
A
6
Fig. 16
Adjust Simultaneous Gun Triggering
WARNING
To reduce the risk of a fluid injection injury, always
disengage the trigger cable to the gun (s) and
engage the guns’ trigger safety latch before moving
or adjusting the guns or gun arms.
1. Alignthefrontof the guns byadjustingthegun arms.
See page 17.
2. Position the dual gun selector to trigger both guns.
See page 21.
3. Start the sprayer, using water, or spray on card-
board. See page 13. Trigger the guns to see if the
lines begin at the same time and place.
If one gun triggers before the other gun, reduce the
cable tension of the gun that triggers first. See Ad-
just the trigger cable tension on page 22 .
If one line starts in front of the other, adjust the posi-
tion of the guns. See page 17.
Trigger the guns to recheck the adjustments.

19308-082
Gun Arm Positions
ONE GUN CURBSINGLE LINE
DOUBLE LINE OR SINGLE LINE UP TO 24” WIDE TWO GUN CURB
DOUBLE LINE OR SINGLE LINE UP TO 24”
WIDE
SINGLE OR DOUBLE LINE; SPRAYING AROUND OBSTACLES 0017A

20 308-082
Caster Lever and Cable Operation
CAUTION
The AccuTrackcaster is factory-adjusted to track
in a straight line. It should not require adjustment
unless it is replaced. If a line is tracking poorly, check
for the following items before aligning the caster.
1. Even back tire pressure.
2. Even tension on the rear tire bearings (adjust
nuts (10) as needed.) See page 40.
3. Even tightness of the caster screws (F). See
Fig. 18.
4. Uneven painting surface.
5. Operator technique.
Operation
The normal operating mode of the AccuTrackcaster is
locked in the straight forward position.
1. Forafreemovingcaster:Squeezeandholdthecast-
er lever (22).
2. To lock the caster in the free moving position,
squeeze the trigger, push in and hold the the button
(A) and release the trigger. See Fig. 17.
3. To return to the normal mode, squeeze and release
the caster lever and move the Line Lazer forward to
lock the caster in the straight position.
22 A
0018
Fig. 17
Maintenance See Fig. 18
Paint builds up on the caster triggering mechanism. To
keepitoperatingproperly,useagreasegunatthegrease
zerks (32A, 32B) to flush out the buildup – two to four
times a month, depending on use.
Caster Tire Replacement See Fig. 18.
Remove the setscrews (F) from the caster fork (E). Re-
move screw (G) and the tire (114a). Install the new tire
and the setscrews (F). Tighten the setscrews equally so
the tire has no play in it, but turns freely.
Caster Cable Tension Adjustment SeeFig.18.
1. Loosen the nut (A) located just outside the carriage
clamp (B).
2. With the pin (D) fully engaged in the caster fork (E),
pull back on the cable (2) to increase the cable ten-
sion, or push it forward to reduce the tension. Finger
tighten the nut (H). Tighten the nut (A) firmly.
Shownremoved only
forvisual purposes A
2
B
87
32A
32B
D
D
114a
E
F
Tighten equally so tire
has no play in it but
turnsfreely
G
H
0019
Fig. 18




Caster Alignment
Do this adjustment only if the caster or tire is replaced,
or if no other solutions to poor tracking are found.
1. Loosen the two capscrews (87), grasp the tire and
visually alignit. Tighten the capscrews evenly. Move
the unit forward. If the caster appears straight, start
the unit (use water) and spray along a true straight
line. Continue adjusting as necessary. See Fig. 18.
How To Mount the Gun
1. Relieve pressure. See page 7.
2. Disengage the trigger cable. See page 21. Engage
the gun’s trigger safety latch (B).
3. Loosen the gun holder knob (93).
4. Position the gun so the gun trigger is resting on the
remote trigger lever (A).
5. Be sure that the gun is mounted straight and then
tighten the knob (93) firmly.
6. Disengage the gun safety latch. Engage the remote
trigger cable. See page 21.
93
95
A
B
Fig. 19 0020B