Graco 231-560 Operation manual

308–685
REV. B
Supercedes Rev. A
INSTRUCTIONS–PARTS LIST
INSTRUCTIONS
This manual contains important
warnings and information.
READ AND KEEP FOR REFERENCE.
GM3000
GASOLINE-POWERED AIRLESS LINESTRIPER
LineLazer 3000
3000 psi (207 bar, 21 MPa)
Maximum Working Pressure
Model 231–560, Series A
Patent Pending.
CAUTION
Always use a minimum hose length of 25 foot
(7.5 m) 1/4 inch ID. An undersized hose may result
in poor equipment performance and damage to the
clutch.
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
COPYRIGHT 1996, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001
0694
1


Table of Contents
Warnings 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Identification and Function 5. . . . . . . . . . . .
Setup 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fueling 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Startup 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Spray Techniques 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Positioning the Gun Arm Assembly 13. . . . . . . . . . . . . .
Gun Arm Positions 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
How to Mount the Gun 14. . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flushing 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Housing, Connecting Rod, Crankshaft 21. . . . . .
Pressure Control 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Module 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ON/OFF Switch 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Transducer 25. . . . . . . . . . . . . . . . . . . . . . . . . .
Suction Tube 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion, Clutch, Clamp, Field, & Engine 26. . . . . . . . . . .
Pinion Housing 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Field & Wiring Harness 31. . . . . . . . . . . . . . . . . . . . . . . . .
Clamp 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Housing 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reassembly 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump Repair 35. . . . . . . . . . . . . . . . . . . . .
Sprayer Parts Drawing 40. . . . . . . . . . . . . . . . . . . . . . . . .
Sprayer Parts List 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gun Mounting Parts list and Drawing 37. . . . . . . . . . . .
Pinion Assembly Parts list and Drawing 37. . . . . . . . . .
Pressure Control Parts List, Drawing, & Schematic 43
T
echnical Data 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 44 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 44. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco W arranty 44. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 .
D
This equipment is for professional use only .
D
Read all instruction manuals, tags, and labels before operating the equipment.
D Use the equipment only for its intended purpose. If you are not sure, call your Graco Distributor .
D
Do not alter or modify this equipment. Use only genuine Graco parts and accessories.
D Check equipment daily . Repair or replace worn or damaged parts immediately .
D
Do not exceed the maximum working pressure of the lowest rated system component. Refer to the
T echnical Data on page 43 for the maximum working pressure of this equipment.
D Use 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.
D Do not use hoses to pull equipment.
D Route 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).
D
Do not lift pressurized equipment.
D Comply with all applicable local, state, and national fire, electrical, and safety regulations.
DW ear hearing protection when operating this equipment.
D Do 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.

 
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 .
D
Fluid injected into the skin may look like just a cut, but it is a serious injury . Get immediate medi -
cal attention.
D
Do not point the gun at anyone or at any part of the body .
D Do not put your hand or fingers over the spray tip.
D Do not stop or deflect leaks with your hand, body , glove or rag.
D Do not “blow back” fluid; this is not an air spray system.
D Always have the tip guard and the trigger guard on the gun when spraying.
D Check the gun dif fuser operation weekly . Refer to the gun manual.
D Be sure the gun trigger safety operates before spraying.
D Lock the gun trigger safety when you stop spraying.
D Follow the Pressure Relief Procedure on page 17 if the spray tip clogs and before cleaning,
checking or servicing the equipment.
DT ighten all fluid connections before operating the equipment.
D Disconnect gun trigger cable before servicing spray gun.
D 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.
D 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.
D Know the specific hazards of the fluid you are using.
D Store hazardous fluid in an approved container . Dispose of hazardous fluid according to all local,
state and national guidelines.
D 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.
D 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.
D Do not operate this equipment in a closed building.

308-6854
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
.
D 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.
D Provide fresh air ventilation to avoid the buildup of flammable fumes from solvents or the fluid
being sprayed.
D Keep the spray area free of debris, including solvent, rags, and gasoline.
D Disconnect all electrical equipment in the spray area.
D Extinguish all open flames or pilot lights in the spray area.
D Do not smoke in the spray area.
D Do not turn on or of f any light switch in the spray area while operating or if fumes are present.
D Do not operate a gasoline engine in the spray area.
D Ground the sprayer to a true earth ground with the ground wire and clamp (supplied).
D Use only electrically conductive hoses.
MOVING P ARTS HAZARD
Moving parts can pinch or amputate your fingers.
D Keep clear of all moving parts when starting or operating the sprayer .
D
Before servicing the equipment, follow the Pressure Relief Procedure on page 17 to prevent the
equipment from starting unexpectedly
.
Liquids can 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.A void accidental
triggering of gun by always setting safety latch when not spraying.
Never spray without a tip guard.
In case of accidental skin injection, seek immediate
“Surgical T reatment”.
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
Spray painting, 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, containers and objects being sprayed.
A void 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 .
NOTE: This is an example of the DANGER label on your sprayer . This label is available in other languages, free of
charge.
See page 37 to order .

 
Component Identification and Function
06941
C
Fig. 1
A
G
M
B
H
R
T
S
U
E
J
K
L
V


PD
F
N
W
A Pressure Control Switch ON/OFF , enables/disables clutch function
B Pressure Adjusting Knob Controls fluid outlet pressure
C Air Cleaner* Filters air entering the carburetor
DFuel Tank* Holds 0.66 gallons (2.5 liters) of [(R+M)/2]; 86 octane gasoline
EMuffler* Reduces noise of internal combustion
F Spark Plug Cable* Routes electrical current to spark plug
G Fuel V alve* On/of f valve to regulate fuel flow from gasoline tank to carburetor
HChoke* Enriches air/gasoline mixture for cold starting
JThrottle* Adjusts engine speed for large or small orifice spray tips
K Engine Switch* Enables/disables engine operation
L Fluid Outlet Hose and spray gun are connected here
M Pressure Control Controls clutch cycling to maintain fluid pressure.
NEngine* 4.0 HP gasoline engine
PClutch T ransfers power from engine to drive assembly
R Drive Assembly T ransfers power from clutch to displacement pump
S Displacement Pump Provides fluid to be sprayed through spray gun
T Fluid Filter Filters fluid between source and spray gun
U Grounding Clamp and Wire Grounds sprayer system
V Pressure Drain V alve Relieves fluid pressure when open
W Spray Gun Actuator Handle T urns spray gun on and of f.
* For more detailed explanations of these controls, refer to the Honda engine manual; supplied


Setup
CAUTION
To avoid damaging the pressure control, which may
result in poor equipment performance and component
damage, follow these precautions.
1. Always use nylon spray hose. Never use a wire
braid hose; it is too rigid to act as a pulsation
dampener.
2.
Always use a minimum hose length of 25 foot
(7.5 m) x 1/4 inch ID or 25 foot (7.5 m) x 3/8 inch
ID hose.
3. Never install any shutof f device between the filter
(120) and the main hose. See Fig. 2.
1. Connect hose and gun. (Refer to Fig. 2.)
a. Remove the plastic cap from the 1/4 npsm (m)
filter outlet nipple (A). Screw the main fluid
hose onto the nipple. Read the CAUTION,
above.
b.
Connect the hose between the main fluid hose
and the inlet adapter of the gun.
c. Do not use thread sealant, and do not install
the spray tip yet!
WARNING
If you replace your hoses and spray gun, be sure
the hoses are electrically conductive, that the gun
has a tip guard, and that each part is rated for at
least 3000 psi (207 bar , 21 MPa) Maximum Work -
ing Pressure . This is to reduce the risk of serious
injury caused by static sparking, fluid injection or
over-pressurization and rupture of the hose or gun.
2. Fill packing nut/wetcup. Fill the packing nut/wet -
cup (B) 1/3 full with Graco Throat Seal Liquid
(TSL), supplied. See Fig. 2.
3. 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 (M);
the oil should be almost overflowing. See Fig. 3.
Add oil as necessary .
Recommended lubrication oil: Use a high-quality ,
detergent oil, SAE 10W–30, classified “FOR
SER VICE SG or SF”, for regular use and for
breaking–in a new engine.
Fig. 2
B
120
120 Fluid Filter
A 1/4 npsm(m) fluid outlet
B W etcup
A
06918

308-685 7
Setup
4. Be sure your system is properly grounded
before flushing or fueling it. Connect the spray -
er to a true earth ground with the grounding wire
and clamp (76) ; for example, a cold water pipe, a
metal fence post or a metal rod driven into the
earth.
5. Fill the gas tank. See Fueling
, page 8.
6. Flush the pump to remove the lightweight oil
which was left in the pump to protect it from corro -
sion.
a.
Before using water–base paint, flush with
mineral spirits, followed by soapy water , and
then flush with clean water .
b.
Before using oil–base paint, flush with mineral
spirits, only .
c.
See Flushing on page 17 for the flushing
procedure.
7.
Prepare the paint according to the manufacturer ’s
recommendations.
a.
Remove any skin that may have formed.
b. Stir the paint to mix the pigments.
c. Strain the paint through a fine nylon mesh bag
(available at most paint dealers) to remove the
particles that could clog the filter or spray tip.
This is probably the most important step
toward trouble–free spraying.
CAUTION
Close the black fuel shutof f lever 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 startup very dif ficult.
8. Keep the sprayer upright and level during
operation and whenever it is being transported.
Set the fuel valve (G, Fig.1) to OFF
.
Fig. 3
K
L
76
M
0015
06919


Fueling
WARNING
FIRE AND EXPLOSION HAZARD
Gasoline is extremely flammable and
explosive under certain conditions.
Always turn the engine switch (K) to of f
before refueling. (Fig. 3)
Refuel in a well-ventilated area.
Do not smoke or allow flames or sparks in the area
where the engine is refueled or where the gasoline
is stored.
Do not overfill the tank. Make sure the gas fill cap
(L) is securely closed after refueling. (Fig. 3)
Be careful not to spill fuel when fueling. Fuel vapor
or spilled fuel can ignite. If any fuel is spilled, 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 , or a
research octane number of 91 or higher . Unleaded
fuel minimizes the combustion chamber deposits.
2. Gasolines containing alcohol (gasohol). Do not
use gasohol which contains methanol, if the gaso -
hol does not contain cosolvents and corrosion
inhibitors for methanol. Even if it does contain such
additives, do not use the gasohol if it contains
more than 5% methanol or 10 % ethanol.
NOTE: The Honda engine warranty does not cover
the damage resulting from the use of gasolines con -
taining a higher percentage of alcohol than mentioned
in step 2. See the Honda engine manual for more
information.
3. General.
Do not use any oil and gasoline mixtures
or contaminated gasoline. A
void getting any dirt,
dust or water in the fuel tank.
4. T ank Capacity . 0.66 gallons (2.5 liters). Always
leave at least 1/2 in. (13 mm) at the top of the tank
for expansion.
5. Shut off and cool the engine before refueling
(Fig 3).
6. After refueling, tighten the fuel tank cap firmly.

308-685 9
Startup
Before Y ou Start the LineLazer
1. See Flushing on page 17 to determine if you
should flush the LineLazer .
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. Refer to the oil fill procedure in
the Honda engine manual or to step 3, page 6.
4. Be sure the spark plug cable is firmly pushed
onto the plug.
Starting the LineLazer
NOTE: Refer to Fig. 1 as you start the sprayer .
1.
When starting a sprayer that IS NOT PRIMED,
remove the spray tip.
2. Place the suction tube into the paint, water or
solvent container,
depending on whether you are
flushing or are ready to spray .
3.
Detach pressure drain valve (V , Fig. 1) from
suction tube and place pressure valve drain tube
in another bucket.
4. Open the black fuel shutoff lever by pushing it in
the direction of the arrow .
CAUTION
Never try to start the engine unless fluid pressure is
relieved and the pressure control switch is OFF
.
T
rying to start the engine when it is pressurized
could damage the recoil system.
5. Move the pressure control switch to OFF.
6. To start the engine:
a. T
urn the pressure adjusting knob all the way
counterclockwise to the lowest pressure set -
ting.
b. Slide the metal throttle lever away from the
fuel tank to maximum position (fully left).
c. If the engine is cold, close the choke by mov -
ing the gray lever to full choke.
d. If the engine is warm, close the choke by
moving the gray lever only half way or not at
all.
e. T
urn the engine switch to ON.
WARNING
MOVING P ARTS HAZARD
A rope which recoils too quickly may hit
someone and cause serious injury . The
rope could also jam in recoil assembly .
f. Hold the frame of the sprayer with one hand
and pull the starter rope 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.
7. Unlock the gun trigger safety.
8.
Release the trigger cable and engage the gun
trigger safety latch.
9. Remove the gun from the holder by unscrewing
the gun holder knob and lifting out the gun.

308-68510
Startup
10. Prime the pump:
a. Place the suction tube in the bucket of paint,
water , or solvent.
b. Detach pressure drain valve (V , Fig. 1) from
suction tube and place pressure valve drain
tube in another bucket.
c. Open the pressure drain valve.
d. Set engine speed to idle.
WARNING
INJECTION HAZARD
Operating sprayer with the pressure
drain tube plugged will cause a back
pressure that may rupture the tube.
Sprayed fluid from the ruptured drain
tube may cause serious injury from
splashing fluid into the eyes and/or skin
injection.
e. Check that the drain tube it is clear . Clean
and/or replace as necessary .
f.
Move the pressure control switch to ON. T urn
the pressure adjusting knob slowly until the
pump starts.
g. Run the pump until fluid is flowing smoothly
from the pressure drain valve tube, indicating
the pump is primed.
h. Move the pressure control switch to OFF .
i.
If the pump was primed with water or solvent,
remove the suction tube from the water or
solvent and place it in the paint. Repeat steps
c. through g. until paint flows from the pres -
sure drain valve tube.
j. Close the pressure drain valve.
11. When the pump is primed:
a. Remove the spray tip.
b. Set the engine speed to maximum.
c. Move the pressure control switch to ON. T urn
the pressure adjusting knob slowly until the
pump starts.
d. Unlock the gun trigger safety .
e. T
rigger the gun into the pail until fluid flows
from the gun. If pumping solvent or solvent–
based paint, hold a metal part of the gun firmly
against a grounded metal pail.
f. Release the gun trigger and lock the gun
trigger safety .
g.
Move the pressure control switch to OFF .
h.
Relieve pressure by opening the pressure
drain valve.
i. Close the pressure drain valve.
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury from
fluid injection, never operate the spray
gun with the tip guard removed.
12. Install the spray tip in the gun. See the separate
tip instruction manual, 308–235, supplied.
13. Place the gun in the gun holder. Secure the gun in
the holder by screwing down the gun holder knob.
14. Engage the gun trigger safety latch and set the
trigger cable.
15. Move the pressure control switch to ON.
16. Adjust the engine speed and pump pressure.
Unlock the gun trigger safety . T rigger the gun onto
a test paper to check spray pattern and atomiza -
tion. T urn pressure adjusting knob until you get a
good pattern. Slowly lower the throttle setting as
far as you can without changing the spray pattern.
CAUTION
Always use the lowest needed fluid pressure and the
lowest needed throttle setting, to increase the life of
the sprayer . Higher settings cause excessive clutch
cycling, premature tip wear and premature pump
wear.
Close
the black fuel shutof f lever 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 startup very dif ficult.

308-685 11
Startup
CAUTION
Operating the sprayer with the pump not primed can
lead to premature packing wear and/or damage to
the pump.
Loss of Prime to Pump
Introduction of air into the pump, either by changing
fluids or due to a suction leak, may result in the loss of
prime to the pump. If the pump loses prime, no fluid is
pumped.
T
o prime the pump, relieve the pressure on the system
by opening the drain valve and following the instruction
on Prime the pump , page 10.

308-68512
Spray T echniques
These spray techniques discuss how to use and adjust
the
features of the LineLazer . Y ou must also consider op -
erator
technique, job site conditions and weather .
1. Use
water rather than paint to practice spraying tech -
nique and positioning the gun. Slight readjustment
may
be required when switching from water to paint.
2. Be sure the RAC IV T ip Guard is always parallel to
the
ground and the “wings” of the spray tip guard face
the front and back of the unit, as shown in Fig. 4.
WARNING
T o reduce the risk of a fluid injection injury , always
disengage the remote trigger cable to the gun and
engage the gun trigger safety latch before moving
or adjusting the spray tip guard, gun, or gun arm.
3. Use the lowest pressure necessary for good atom-
ization. High pressure may cause excessive paint
buildup
and overspray .
4. Start
moving the LineLazer before triggering the gun
to prevent a build up of paint at the beginning of the
line. Release the trigger a second before stopping
the
LineLazer. Move at an even rate of speed.
5. Always check your gun adjustments on cardboard or
paper before starting each job. When painting curbs,
paint first in an area that is less frequently seen.
6. Keep in mind that many factors af fect the straight-
ness of a line, including uneven surfaces, potholes,
rocks
and other debris and a clogged or worn spray
tip. See manual 308–235 for how to clear or change
a spray tip.
7. To minimize the ef fect of bumps on the spray pattern,
keep the spray tip guard centered with the front
wheel
axis.
8. The spray tip size and the rate at which you move the
unit af fect the coating thickness. Generally , the fast -
er you move the unit, the larger the spray tip orifice
should
be. The fan width of the spray tip indicates ap -
proximately
how wide the line will be.
9. Position the gun to suit your requirements. See the
section
below and pages 13 to 14.
10. Traffic paints may be formulated for air spray , airless
spray or have no formulation description.Generally,
air
spray formulas are pre–thinned, and will work well
in the LineLazer, 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 use fast–draying traf fic paint on a hot day , float
compatible solvent on top of the paint to prevent skin
from forming on it.
Line Width Adjustment
Several factors affect line width: vertical distance of the
spray tip to the spraying surface, spray tip fan pattern,
paint
pressure, and a worn or clogged spray tip.
The typical conditions for a 4 in. wide line are: 217 size
LineLazer 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
of the spray tip, the gun can paint 2 to 12 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.

308-685 13
Positioning the Gun Arm Assembly
06943
6
PUMP
SIDE
Fig. 4
ENGINE SIDE
93
461
61
The gun arm can be positioned for a variety of spraying
needs.
The drawings on page 14 show the gun mounted
on the pump side of the Linestriper . However, the gun
may
be mounted on the engine side.
Whenever Y ou Move the Gun
CAUTION
Do not kink the cable, which could prevent it from
properly triggering and untriggering the gun.
Disengage the trigger cable and engage the gun trigger
safety latch first. Do not kink the trigger cables. Pull out
more
of the 25 (7.5 m) ft. hose, if necessary .
After
moving the gun, 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 Gun
Loosen the arm clamp (6) and move the gun up or down.
Tighten the clamp. Engage the trigger cable.
Horizontal Position of the Gun
Loosen the knobs and slide the gun support bracket (4)
in
or out, so the gun will be outside the tire path. T ighten
the
knobs.
Mount Gun on the Engine Side of the Cart
1. Disengage the trigger cable and engage the gun trig -
ger
safety latch.
2. Loosen the gun holder knob (93) and remove the
gun.
Lay the gun out of the way .
3. Loosen the knobs (61) and slide the gun support
bracket (4) out.
4. Slide
the gun support bracket (4) in from the engine
side and tighten knobs (61, making sure not to kink
the
cable or hose.
5. Loosen the arm support clamp (6) and slide the gun
forward. Retighten the clamp.
6. Install the gun. Route the hose and cable to prevent
kinking. Position the spray tip guard. Disengage the
gun trigger safety latch. Engage the trigger cable.
Remount Gun on the Pump Side of the Cart
1. Disengage the trigger cable and engage the trigger
safety
latch.
2. Loosen the gun holder knob (93) and remove the
gun.
Lay the gun out of the way .
3. Loosen the knobs (61) and slide the gun support
bracket (4) out.
4. Slide the gun support bracket (4) in from the pump
side
and tighten knobs (61), making sure not to kink
the cable or hose.
5. Loosen the arm support clamp (6) and slide the gun
forward. Retighten the clamp.
6. Install the gun. Route the hose and cable to prevent
kinking. Position the spray tip guard. Disengage the
gun trigger safety latch. Engage the trigger cable.

308-68514
Gun Arm Positions
CURB SPRAYINGLINE SPRAYING
06920
How T o Mount the Gun
1. Relieve pressure. See page 17.
2. Disengage the trigger cable. See page 14. 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) and the stop pin.
5. Be sure that the gun is mounted straight and then
tighten
the knob (93) firmly .
6. Disengage the gun safety latch. Engage the trigger
cable.
See page 15.
93
95
A
B
Fig. 5 06921
Stop Pin
How to Release the Gun Selector Cable
WARNING
The gun is remotely triggered with a gun selector
on the handle bar .
T
o reduce the risk of an injection injury due to
remotely triggering the gun by accident, always
disengage the trigger cable from the block before
handling the gun. See Fig. 6, DET AIL A, . The gun
will trigger briefly when releasing the cable!
Before you remove the gun from the holder , en -
gage the gun trigger safety latch.
1. To disengage the cable, grasp the cable (1) just be -
hind
the block (48). Pull the cable back about 1/2 inch
(13 mm) and then up and out of the block. The gun
will trigger briefly ! See Fig. 6.
2. To engage the cable, slide the cable (1) into the block
(48), making sure the end of the cable jacket seats
firmly in the seat of the block. The gun will trigger
briefly!
See Fig. 6.
CAUTION
Keep the seat in the gun cable block (48) and the
end of the cable jacket clean at all times to be sure
the cable functions properly .
CAUTION
A loose cable prevents the gun from being fully
triggered causing premature wear of the gun needle.
A tight cable prevents the gun from being fully untrig -
gered resulting in dripping and premature tip wear .
Follow T rigger cable tension adjustment, page 15.

308-685 15
How T o Mount the Gun
Trigger Cable Tension Adjustment See Fig. 6
1. Relieve pressure. See page 17.
2. Be sure the gun is properly mounted in the holder as
instructed on page 14.
3. Pull the actuator lever (94) forward and hold it. Lift up
on the gun trigger (A) until there is slight resistance.
Visually check to see if there is about 1/32 to 1/16 in.
gap between the trigger lever (B) and where the gun
trigger touches the bar .
4. To adjust the tension, loosen the screw (C) in the
block (48). Slide the block forward to increase the
gap and backward to decrease the gap. T ighten the
screw.
5. Recheck
the gap and adjust as needed.
CAUTION
Do not allow the cable (1) to rub against the outside
edges of the slot (H) in the block (48), to prevent
premature wear of the cable. Rotate the block slight -
ly to eliminate rubbing. See Fig. 6, DET AIL A.

1
48
1/32 – 1/16 in.
(1–2 mm)
94
A
B
FORWARD
Be sure end jacket of cable
seats here. keep jacket and
seat clean
1
48
45
45
C
DETAIL A
0024
Fig. 6
Shown Inverted
H

308-68516
Maintenance
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
Procedure on page 17.
CAUTION
For detailed engine maintenance and specifications,
refer to the separate engine manual, supplied.
DAILY: Check the engine oil level and fill as neces -
sary.
DAILY:
Check and fill the gas tank.
AFTER THE FIRST 20 HOURS OF OPERA TION
Drain the oil and refill with clean oil.
WEEKLY: Remove the cover of the air filter and
clean the element. Replace the element, if necessary .
If operating in an unusually dusty environment, check
the filter daily and replace it, if necessary
.
Replacement elements may be purchased from your
local Honda dealer .
WEEKLY:
Check the level of the TSL in the displace -
ment pump packing nut. Fill the nut, if necessary . Keep
TSL in the nut to help prevent fluid buildup on the
piston rod and premature wear of the packings.
Monthly: Remove the front cover (9) and fill the
cavity in the connecting rod with non-detergent motor
oil 1/4 in. below the surface. See Fig. 7.
AFTER EACH 100 HOURS OF OPERA TION:
Change the oil. Refer to the engine manual for addi -
tional maintenance instructions.
SP ARK PLUG : Use only an (NGK) BPR6ES or a
(NIPPONDENSO) W20EPR-U plug. Gap the plug to
0.028 to 0.031 inch (0.7 to 0.8 mm). Use a spark plug
wrench when installing and removing the plug.
Fig. 7
Fill to .25 in. below sur -
face with non-detergent
motor oil.
9
06922

 
Pressure Relief Procedure
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 . T o 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 install or clean the spray tip.
1. Engage the gun safety latch.
2. T urn the engine switch to OFF .
3. Move the pressure control ON/OFF switch to OFF .
4.
Disengage the gun safety latch. Hold a metal part
of the gun firmly to a grounded metal pail. T rigger
the gun to relieve pressure.
5. Engage the gun safety latch.
6. Open the pressure drain valve. Leave the pressure
drain valve open until you are ready to spray
again.
7. Disconnect the spark plug cable.
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, VER Y SLOWL Y
loosen the tip guard retaining nut or hose end coupling
to Relieve the pressure gradually, then loosen com -
pletely
. Now clear the tip or hose.
Flushing
When to Flush
1. New Sprayer . This sprayer was factory tested in
lightweight oil,which was left in to protect the pump
parts.
Before using water–base paint, flush with mineral
spirits, followed by a soapy water flush, and then a
clean water flush.
Before using oil–base paint, flush with mineral
spirits.
2. Changing Colors. Flush with a compatible solvent
such as mineral spirits or water .
3.
Changing from water–base to oil–base paint. Flush
with warm, soapy water , then mineral spirits.
4. Changing from oil–base to water–base paint. Flush
with mineral spirits, followed by warm, soapy
water , and then a clean water flush.
CAUTION
T o prevent pump corrosion or damage to pump
components, never leave water or any type of paint
in the sprayer when it is not in use. Pump the water
or the paint out with mineral spirits.
5. Storage.
W ater base paint: flush with water , then mineral
spirits and leave the pump, hose and gun filled
with mineral spirits. Set the ENGINE SW (K) to
OFF , remove the spark plug cable, and open the
pressure drain valve to Relieve the pressure.
Leave the drain valve open.
Oil base paint: flush with mineral spirits and leave
the pump, hose and gun filled with mineral spirits.
Shut of f the sprayer , remove the spark plug cable,
and open the pressure drain valve to Relieve the
pressure. Leave the drain valve open.
6. Startup after storage
Follow the Startup procedures on page 9.
Before using water–base paint , flush out the
mineral spirits with soapy water
, and then with
clean water .
When using oil–based paint, flush out the mineral
spirits with the paint to be sprayed.

308-68518
Flushing
How to Flush
CAUTION
When changing fluids, do not drain all of the first fluid
from the suction tube before inserting the suction tube
into another fluid. Not doing so may introduce exces -
sive air into the pump and cause the pump to lose
prime.
After moving the suction tube to a new fluid, pump the
first fluid and any trapped air , out through the drain
valve and into another pail before beginning to pump
the new fluid to the gun.
NOTE: The word solvent refers to water or oil-based
solvent.
1.
Follow the Pressure Relief Procedure , page 17.
2. Remove the filter bowl and screen; see instruction
manual 307–273, supplied. Install the bowl and
support, without the screen, to flush. Clean the
screen separately .
3.
Close the pressure drain valve.
4. Put the suction tube in a grounded pail of solvent.
5. Remove the spray tip from the gun.
WARNING
FIRE AND EXPLOSION HAZARD
T o reduce static sparking and splashing,
always remove the spray tip from the
gun, and hold a metal part of the gun
firmly to the side of a grounded metal pail when
flushing.
6. Follow Startup on page 9. Keep the gun trig -
gered until clean solvent comes from the nozzle.
Release the trigger and lock the gun trigger safety .
CAUTION
Operation with the pump not primed can lead to
premature packing wear and damage to the pump.
7. Check all fluid connections for leaks. Relieve the
pressure before tightening any connections. Start
the sprayer . Recheck the connections for leaks.
8. Remove the suction tube from the solvent pail.
Unlock the gun trigger safety
. T rigger the gun to
force solvent from the hose. Do not let the pump
run dry for more than 30 seconds, to avoid damag -
ing the pump packings. Relieve the pressure.
9. Unscrew the filter bowl and reinstall the clean
screen. Reinstall the bowl, hand tight only .
10.
Follow Storage or Changing Colors, on page 17
Relieve the pressure.

 
Troubleshooting
WARNING
INJECTION HAZARD
T o reduce the risk of serious injury ,
whenever you are instructed to relieve
pressure, follow the
Pressure Relief
Procedure on page 17.
Check everything in the chart before disassembling the sprayer. See pages 40 through 43 for description of
referenced parts
PROBLEM CAUSE SOLUTION
The engine or sprayer won’t
start
The engine switch is not on. T urn on the switch.
start.
The engine is out of gas. Refill the gas tank. See page 8.
The engine oil level is low .Try to start the engine. Replenish the oil, if nec -
essary
. See Step 3, page 6.
The spark plug cable is disconnected or it is
damaged
Reconnect the spark plug cable or replace the
spark plug.
There is frozen water in the sprayer . Allow the sprayer to thaw completely before
starting it.
The engine won’t “pull over”. Oil is seeping into the combustion chamber . Remove the spark plug. Pull the starter rope 3
or 4 times. Clean or replace the plug. T ry to
start the engine. Keep the sprayer upright to
avoid oil seepage.
The engine operates, but the
displacement pump does not
The pressure control switch is turned of f. T urn on the switch.
displacement pump does not
operate.
The pressure setting is too low . T urn the pressure adjusting knob clockwise to
increase pressure.
The fluid filter (21) is dirty . Clean the filter . See page 18.
The tip or the tip filter is clogged. Clean the tip or the tip filter . See the gun
instruction manual.
The displacement–pump rod is stuck due to
dried paint.
Repair the pump. See page 35.
The connecting rod is worn or damaged. Replace the connecting rod. See page 21.
The drive housing is worn or damaged. Replace the drive housing. See page 21.
The electrical power is not energizing the field. Check the wiring connections. See page 30.
With the pressure control switch turned on and
the pressure turned to maximum, use a test
light to check the power at the black and white
wires from the pressure control.
Have the pressure control checked by an au -
thorized Graco dealer .
The clutch is worn, damaged, or incorrectly
positioned.
Replace the clutch. See page 28.
The pinion assembly is worn or damaged. Repair or replace the pinion assembly . See
page 26.


PROBLEM CAUSE SOLUTION
The pump output is low on
the upstroke
The inlet screen (102) is clogged. Clean the screen.
the upstroke.
A piston ball (121) is not seating. Service the piston ball–check. See page 35.
The piston packings are worn or damaged. Replace the packings. See page 35.
A o-ring (1 19) in the displacement pump is
worn or damaged.
Replace the o-ring. See page 35.
The output of the pump is
low on the downstroke or on
The inlet screen (39) is clogged. Clean the screen.
low on the downstroke or on
both of the strokes.
The piston packings are worn or damaged. Replace the packings. See page 35.
An intake valve ball is not seating
properly.
Clean the intake valve. See page 35.
The engine speed is too low . Increase the throttle setting. See Step 16, page
10.
The clutch is worn or damaged. Replace the clutch. See page 28.
The paint leaks into the wet -
cup.
The wetcup is loose. T ighten the wetcup just enough to stop leak -
age.
The throat packings is worn or damaged. Replace the packings. See page 35.
A displacement rod is worn or damaged. Replace the rod. See page 35.
The fluid delivery is low .
The inlet screen (39) is clogged. Clean the screen.
The pressure setting is too low . Increase the pressure. See Step 16, page 10.
The engine speed is too low . Increase the throttle setting. See Step 16, page
10.
The fluid filter (21), the tip filter or the tip is
clogged or dirty .
Clean the filter . See page 18. Or , see the gun
instruction manual.
There is a large pressure drop in the hose. Use a larger diameter hose.
Fluid is spitting from the gun.
There is air in the pump or the hose. Check and tighten all the fluid connections.
Reprime the pump. See page 10.
The tip is partially clogged. Clear the tip. See the gun instruction manual.
The fluid supply is low or empty . Refill the fluid supply . Prime the pump. See
page 9. Check the fluid supply often to pre -
vent running the pump dry .
The pump is dif ficult to prime.
There is air in the pump or the hose. Check and tighten all the fluid connections.
Reduce the engine speed and cycle the pump
as slowly as possible during priming.
The intake valve is leaking. Clean the intake valve. Be sure ball seat is not
nicked or worn and that the ball seats well.
Reassemble the valve.
The pump packings are worn. Replace the pump packings. See page 35.
The paint is too thick. Thin the paint according to the supplier ’s
recommendations.
The engine speed is too high. Decrease the throttle setting before priming the
pump. See Step 16, page 10.