Graco LineLazer GM 3500 Operation manual

INSTRUCTIONS-PARTS LIST 308-082'
This manual contains important
Rev. S
warningsandInformation. GRACo Supersedes Rev. P
READ AND KEEP FOR REFERENCE.
INSTRUCTIONS
GM.3500
GASOLINE-POWEREDAIRLESS LINESTRIPER \
3000 psi (2 10 bar; 2 1.0 MPa) \I
Maximum Working Pressure
Model 231-132, Series A
With onegun, RAC IV" DripLess" Tip guard,
Size 319 LineLazerTip
8 Size 517 Switchlip".
and
50 foot (15 m) hose.
Model 231-140
Same as 231-132, except includes
SecondGunKit, 224497
NOTE: This isanexampleof the English languageDANGER labelon your sprayer.
This label
is supplied with the sprayerinother languages. Before operating the
sprayer, apply aDANGER label inthe appropriate language for you operators,
accordingto the separate instructions supplied withit.
WID
FIRE AND
EXPLOSION
HAZARD
Spray painting. flushing or claanlng equipment wlth flammable
liquids
In confined areas can resun in fireor explosion.
Use outdoore or In ememely WSII ventllatad amas. Ground
equipment, hoses,containanand
objects baingsprsysd.
Avold
ai1 IgnRion sourcaa such as statlc slectrlcity from plastic
drop cloths,
open flamed such as pilotlights, hot object8 such a
clgaretkas, aru from connectingor diseonnectlng powor cords
or turnlngllghtswitches
on end off.
Faliure to follow hls rmmlngcan result In death orwrlous Injury
READ AND UNDERSTAND ALL LABELS
I
I
SKIN INJECTION
HAZARD
Uqulds csn bs Injected into the body by hlghpre-ure alrless
apmyor leab -especially hose iesks.
Keep body clear of the nozzle. Never stop Isab Wm, any pen of the
body. Drain all pressureMoreremovingparts.Avold accidental
trlggerlng
of gun by slwsys setting safety latch when not spraying.
In case of sccldentai skin Injectton, seek lmmedlaw
Never spray
wrthout a Up guard.
"Surgical Treabnenr'.
Fsliure to follow his warning can result In amputation or serlous
idUN.
..
4D INSTRUCTION MANUALS BEFORE USE
1
GRACOINC. P.O. BOX 1441MINNEAPOLIS, MN 55440-1441
@COPYRIGHT 1990, GRACO INC.
Graco Inc. is registeredto 13. EN IS0 9001

Part Identification
Key
A Casterlever
B Dualgunselector
CMain hose
D
Suction hose
E Fluidfilter
F Pressuredrainvalve
G An
H Post
J Canlagebar
K Gunholder
L Rac IV fipguard
0 Displacementpump
N Flexgun
0 Dualgunselectorcable
PCaster
R Pressurecontrol
T Air Cleaner
S Spark plugcable
U Muffler
V FuelTank
W Hook evelet luseto StraD
M switchnp
pi11orbailcover
to carti
X Pailcover
Y CasterCable
Z Groundingcableand
clamp
V
2 308-082

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
GasketSelection ....................... 15
Operation 15
Installation 15
Clearinga CloggedTip
................. 15
SprayTipSelection16 Maintenance 15
Spray Tip Application Recommendations
.. 16
SprayTechniques
............................. 16
Positioningthe GunArmAssembly17
LineWidthAdjustment16
Vertical position
of the first or second gun . 17
Horizontalpositionof the first gun
........ 17
Horizontal position
of the second gun ..... 17
Mount guns onthe engine side
of the cart . 18
AdjustSimultaneousGunTriggering18Setupforsprayingarcs18
GunArmPositions
............................ 19
Caster Lever & Cable Operation ................. 20
Operation
............................. 20
Maintenance
.......................... 20
Caster Cable Tension Adjustment
........ 20
CasterAlignment
...................... 20
............................
.............................
..........................
............................
..................
..............
.................
.............
Caster Tire Replacement ................ 20
Howto Mountthe Gun
......................... 20
GunCable
& Dual Gun Selector Operation ....... 21
How
the DualGunSelector Works ....... 21
How to Releasethe Selector Cable
....... 21
Adjust theTrigger Cable Tension
......... 22
Maintenance
.................................. 23
Troubleshooting
............................... 24
Repair or Replacement
DisplacementPump
.................... 26
PressureControl
....................... 28
PressureControlAdjustment
............ 29
Bearing Housing and ConnectingRod
.... 30
DriveHousing
......................... 31
PinionHousing
........................ 32
clutch ................................ 34
Field&WiringHarness36 Engine
35
Clamp ................................ 37
ClutchHousingRemoval
................ 37
Reassembly
........................... 38
DisplacementPump Paris
............... 42
CartParts
44
PressureControlParts 43
MechanicalParts
...................... 46
GunMountingParts
.................... 48
TechnicalData
50
PinionParts 49
Accessories
.................................. 50
Warranty ..................................... 52
................................
.................
Parts .
..................
.............................
...........................
................................
Manual Change Summary
This manual was updated to include the changes from PCN N except for23&052 (CASTER. swivel) .
This manual was changed to include the updated pressure relief system per ECO F4963 .
0 Errors in the Parts Lists were corrected .
308-082 3

Symbols
Warning Symbol Caution Symbol
This symbol alertsyouto thepossibilityof serious This symbol alertsyouto the possibility of damage to
injury
or death if you do notfollow the instructions. equipment ifyou do not follow the instructions.
EQUIPMENT MISUSE HAZARD
Equipment misusecancausethe equipment to rupture or malfunctionand result inserious injury.
This equipmentis for professional use only.
Readall instruction manuals, tags, and labelsbeforeoperating the equipment.
Use the equipment only for its intended purpose. If you are not sure,call your distributor.
Do notalter or modifythis equipment.
Check equipment daily. Repairor replace womor damaged parts immediately.
Do notexceed the maximum working pressureof the lowest rated system component. Refer to the
Technical
Data on page 50 for the maximum working pressureof this equipment.
Use fluids andsolvents which are compatible with the equipment'wetted parts. Referto the Tech-
nical
Data sectionof all equipment manuals. Read the fluid and solvent manufacturer's warnings.
D Do not use hoses to pull equipment.
Route hoses away from traffic areas, sharp edges, moving parts, andhotsurfaces. Do not expose
Graco hoses to temperatures above82°C (180°F) or below-40°C (40°F).
Do not li pressurized equipment.
B Comply withall applicable local, state, and nationalfire, electrical, andsafety regulations.
B Wear hearing protection when operating thisequipment.
b Do not use 1,l ,I-trichloroethane, methylene chloride, other halogenated hydrocarbon solventsor
fluidscontainingsuchsolvents
in pressurized aluminum equipment.Suchusecouldresultina
chemical reaction, with the possibility
of explosion.
4 308-082

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 splashedinthe eyes or on the skin can also
cause serious injury.
e Fluidinjected into the skin may look like just a cut, but it is a serious injury. Get immediate medi-
cal attention.
e Do not point the gun at anyone or at any partof the body.
e Do not put your hand or fingers over the spray tip.
e Do not stop or deflect leaks with your hand,body, glove or rag.
e Do not "blowbacVfluid; this isnot an air spray system.
e Always have thetip guard and the trigger guard on the gun when spraying.
e Check the gundiffuseroperation weekly. Refer to the gun manual.
'. e Be sure the gun trigger safety operates before spraying,
e Lock the gun trigger safetywhen you stop spraying.
e Follow the Pressure Relief Procedure on page 7 if the spraytip clogs and before cleaning,
checking or servicing the equipment.
e Tighten all fluid connections before operating the equipment.
e 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.
e Fluid hoses must have spring guards on both ends, to help protect themfromrupturecam4by
kinks or bends near the couplings.
TOXIC FLUID HAZARD
Hazardousfluid or toxic fumes can cause serious injury or death if splashed in the eyes or on theskin,
inhaled, or swallowed.
Know the specific hazardsof the fluid you are using.
0 Sfore hazardousfluid in an approved container. Disposeof hazardous fluid according to alllocal,
state and national guidelines.
0 Always wear pratective eyewear, gloves, clothing and respirator as recommendedbythe fluidand
solvent manufacturer.
FUEL HAZARD
The fuelused in this unit is combustible and when spilled on a hot surfacecanignite and cause a fire.
e Do not fill the fuel tank while the engineisrunning or hot.
EXHAUST HAZARD
The exhaust contains poisonous carbon dioxide whichiscolorless and odorless.
e Do not operate this equipmentina closed building.
308-082 5

FIRE AND EXPLOSION HAZARD
Improper grounding, poor ventilation, open flames or sparks can cause a hazardous condition and
result
in a fireorexplosion and serious injury.
0 If there isany 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.
0 Providefreshair ventilation to avoid the buildupof flammable fumes from solvents or the fluid
being sprayed.
0 Keep the spray area free of debris, including solvent, rags, and gasoline.
0 Disconnect all electrical equipment in the spray area.
0 Extinguishall open flames or pilot lights inthe spray area.
Do not smokeinthe spray area.
0 Do notturn onor off any light switch in the spray area while operating or if fumes are present.
0 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).
0 Use only electrically conductive hoses.
MOVING PARTS HAZARD
Moving parts can pinch or amputate your fingers.
Keep clearof all moving parts when starting or operating the sprayer.
0 Before servicing the equipment, follow the Pressure Relief Procedure on page 7 to prevent the
equipmentfromstarting unexpectedly.
6 308-082

Setup
GeneralInformationPressureReliefProcedure
NOTE: Reference numbers and lettersin parentheses
inthe text referto the callouts in the figures and the
parts drawing.
NOTE: Always use Genuine Graco Parts and Acces-
sories, available from your Graco distributor.
Grounding
FIRE AND EXPLOSION HAZARD
system as explained below. Also read
Beforeoperating,thepump, ground the
the section
FIRE OR EXPLOSION HAZ-
ARD on page 6.
1
2.
3.
4.
5.
6.
7.
Sprayer: make sure the grounding chain (106)
contacts the ground while the unit is moving. See
page
46. For stationary spraying, connect a
ground wire and clamp
(159) to a true earth
ground.
maximum of
500 ft. (150 m) combined hose
fluid hoses: use only grounded hoses with a
length to ensure grounding continuity.
Spray
gun: obtain grounding through connection to
a properly grounded fluid hose andsprayer.
Objectbeingsprayed: according to local code.
Fluidsupply container:follow your local code.
code. Use only metal pails, which are conductive,
Solventpails usedwhen flushing: follow your local
pailona nonconductive surface, such as paper or
placed on
a grounded surface. Do not place the
cardboard, which interrupts the grounding continu-
ity.
To maintaingrounding wntinuify when flushing or
gun firmlyto the sideof a groundedmetalpail,
relieving pressure, hold
a metal partof the spray
then triggerthe gun.
INJECTION HAZARD
Fluidunder 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-
I low the Pressure Relief Procedure whenever you:
are instructed to relieve the pressure,
stopspraying,
check or service any ofthe system equipment,
or install or clean the spray tips.
1. Engage the spray gun safety latch.
2. Turn the ON/OFF switchto OFF.
3. Fiip the pressure control switch to OFF.
4. Disengage the gunsafetylatch. Hold a metal part
of the gun firmlyto the sideof a grounded metal
pail, and triggerthe gun to relieve pressure.
5. Engagethegunsafetylatch.
6. Hold the pressure relief tube firmly to the sideof a
valve. Leave the valve openuntilyou are readyto
grounded metal pail, and open the pressure relief
spray again.
system from starting unexpectedly.
7. Disconnect the sparkplugcable to prevent the
clogged, orthatpressure has not been
fully relieved
If yoususpect that thespraytip or hose is complete/y
tip guard retaining nut or hose end coupling and relieve
afterfollowing thestepsabove,
very s/ow/y loosen the
pressure gradually, then loosen completely. Now clear
the tip or hose.
Valve shownIn Valve shown
CLOSED
position.
in OPEN position.
- Fig. 2
308-082 7

Setup
1. Read and follow the warningsonpages 4 and 6 7. Provideadequateventilationwhensprayingindoors.
before installing or operating thissprayer.
2. Unpack the LineLazer Carefully raise the handle (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 (4OA). Install one exhaust
to the outdoors or provide adequate veri-
screw (398) and nut (408) oneach side of the han-
dle. Firmly tightenallfour nuts. See Fig.
3.
If the LineLazeris used indoors, you must vent the
tilation as specified by youlocalcode. Thisisto
reduce the risk
of carbon monoxide poisoning.
8. Fillthe gas tank. See Fuelingon page 10.
9. Flush the pump to remove the lightweight oil which
was leftin
me pump to protectitfrom rust. Follow the
Flushing
on page 12.
10. Preparethepaintaccording tothemanufacturer's
recommendations. Remove any skin that may have
formed. Stir the paintto mix pigments.
Strain
the paint through a fine nylon mesh bag (avajl-
able at most paint dealers) to remove particles that
could clogthefilter or spray tip.This is an important
step towardtroublefreespraying.
3. To install a second gun and hose, see page 11.
4. Fill the packingnut/wet-cup (216) 1/3 full with
Graco ThroatSealLiquid(TSL), supplied, and
keepitfilled, to help extend the pump life. See
Fig.
4.
5. Check the engineoil level. Refer to the Honda
engine manual, supplied.This is
a summary of the
information: Remove oneof the oil
fill plugs (A);
Add oilas necessary. Also read theMaintenance
the oil should be almost overflowing. See Fig.
4.
section on page 23.
gentoil, SA€ iOW-40, classified "FORSERVICE
Recommended engine oil: Use a high-quality, deter-
SE or SF".
6. Ground the sprayer. Proper grounding is essential to
maintaining an electrically safe system.
Also read
6.
andfollow FIRE OR EXPLOSION HAZARD on page
Groundthesprayer wheneveritis used indoors,
either
as a movingline striper or as a stationary
sprayer. Floors
in most factories are coated, which
causesthemto
be poor electrical conductors. This
increases the risk of hazardous static electric
discharge, which can resultinserious injury, fire, or
explosion andpropeltydamage.
Whenever
you flush: connectthegroundclamp
(159) to a true earth ground.
chain attached to the bottomof the cart drags on the
Using
as an outdoor striper: Besurethestatic
ground
to help dissipate static electricity. Ground the
sprayer to a true earth ground
if specified by your
local electrical code.
Indoor spraying: Ground the sprayer whenever the
sprayer is used indoors. The ground wire supplied
with the sprayer is not long enough to allow much
operatormovement.Therefore,theoperatormust
provide a longergroundwire orprovide some other
methodof effectiveelectricalgroundingasspecified
Fig.
by your local electrical code.
8 308-082

11. Observe the following cautions to avoid pressure
control damage.
I
A CAUTION
To avoid damaging the pressure control, follow these
precautions.
0 Allow themainhoseto act asa pulsation damp-
ener: Always use nylon spray hose at least
50 ft.
(1 5 m) longfor the maingun; Never use a wire
braid hose;
it is too rigid.
0 Neverinstalla ballvalve or shutoff device be-
Weenthe filterandthe
50 R. (15 m) hose.
0 Do not allow wateror water-base material to
freeze inthe pressure control.
~
A CAUTION
Close the black fuel shutoff lever whenever you are
transporting the sprayerto prevent fuel from flooding
the engine.
Keep the sprayer upright andlevelwhen operating it
and transporting it. This prevents crankcase oil from
leaking into the combustionchamber, which makes
startuDvew difficult.
12. To use the wheel brake,liftthe brake handle(A-
the handleto disengagethebreak. See Fig.
5. For
bottom rear
of cart) to engage the brake. Lower
proper tire pressure and that tire wear is not
positive break engagement, be sure there
is
excessive.
13. Forhow to operate and adjust the various features
of the LineLazer
see pages 11 - 22.
14. Start thesprayer. See page 13.
308-082 9

Fueling
Gasolineis extremely flammableandexplosive
under certain conditions.To reduce the riskora fire
or explosion:
1. Always shut off the enginebeforerefueling.
2. Refuelinawell-ventilatedarea.
3. Do not smokeor allowflames or sparks inthe
' area wherethe engine is refueledor where
gasolineis stored.
4. Do not overfillthe tank. Make sure the filler cap
issecurely closed after refueling.
5. Fuel vaporor spilled fuel can ignite.Ifany fuel
is spilled during refueling, make sure the area
is dry before starting the engine.
1. Fuel specifications. Use automotivegasolinewith
a pump octane numberof
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 notcontaincosolvents and corrosion inhibi-
torsfor methanol. Even
if it does contain such
additives, do not usethe gasohol if it contains
more than
5% methanol.
NOTE: TheHONDAenginewarrantydoesnotcover
damage resulting from the
use of gasolines containing al-
cohol. See the HONDA engine manual for more informa-
tion.
3. General.Do not use oil and gasoline mixtures or con-
taminated gasoline. Avoid getting dirt,dustor water
inthe fueltank.
4. Tank capacity: 0.66 gallons (2.5 liter). Leave 1/2 in.
(13 mm) atthe topof the tankfor gas expansion.
5. Shut off the engine switch(A) beforerefueling.
6. After refueling, tighten the fuel tankcap (B) firmly.
Flg. 6 wo9
10 308-082