Graco LineLazer IV 200HS Use and care manual

Repair - Parts List
LineLazer
™
IV 200 HS Auto-Layout
™
System
Airless Line Striper
For application of line striping materials. For professional use only.
Not for use in explosive atmospheres.
3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure
See page 2 for model information.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
312190 309055
309277 312345
311254 312307
ti10234a
312226P
EN

Models
2312226P
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tip Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
General Repair Information . . . . . . . . . . . . . . . . . . 6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Auto-Layout Can Actuator Adjustment . . . . . . . . 12
Auto-Layout System . . . . . . . . . . . . . . . . . . . . . . . 13
Control Board Diagnostics . . . . . . . . . . . . . . . . . . 15
Trigger Sensor Adjustment . . . . . . . . . . . . . . . . . 16
Distance Sensor Replacement . . . . . . . . . . . . . . . 16
Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Fan Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Hydraulic Motor Rebuild . . . . . . . . . . . . . . . . . . . . 21
Oil/Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Gallon Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . 24
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Auto-Layout System Wiring Diagram . . . . . . . . . 38
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 40
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 40
Models
253922 
253955 
255155 
255156 

Warnings
312226P 3
Warnings
The following warnings are for the setup, use, grounding, maintenance, and repair of this equipment. The exclama-
tion point symbol alerts you to a general warning and the hazard symbol refers to procedure-specific risk. Refer back
to these warnings. Additional, product-specific warnings may be found throughout the body of this manual where
applicable.
WARNING
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Do not fill fuel tank while engine is running or hot; shut off engine and let it cool. Fuel is flammable
and can ignite or explode if spilled on hot surface.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a working fire extinguisher in the work area.
CARBON MONOXIDE HAZARD
Exhaust contains poisonous carbon monoxide, which is colorless and odorless. Breathing carbon
monoxide can cause death. Do not operate in an enclosed area.
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
PRESSURIZED EQUIPMENT HAZARD
Fluid from the gun/dispense valve, leaks, or ruptured components can splash in the eyes or on skin and
cause serious injury.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.
• Tighten all fluid connections before operating the equipment.
• Check hoses, tubes, and couplings daily. Replace worn or damaged parts immediately.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.

Warnings
4312226P
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine manu-
facturer’s replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
• Always wear impervious gloves when spraying or cleaning equipment.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
• Gloves
• Hearing protection
RECOIL HAZARD
Gun may recoil when triggered. If you are not standing securely, you could fall and be seriously injured.
CALIFORNIA PROPOSITION 65
The engine exhaust from this product contains a chemical known to the State of California to cause can-
cer, birth defects or other reproductive harm.
This product contains a chemical known to the State of California to cause cancer, birth defects or other
reproductive harm. Wash hands after handling.
WARNING

Tip Selection
312226P 5
Tip Selection
* Use 100 mesh filter to reduce tip clogs.
LL5213* 2 (5) 
LL5215* 2 (5) 
LL5217 4 (10) 
LL5219 4 (10) 
LL5315 4 (10) 
LL5317 4 (10) 
LL5319 4 (10) 
LL5321 4 (10) 
LL5323 4 (10) 
LL5325 4 (10) 
LL5327 4 (10) 
LL5329 4 (10) 
LL5331 4 (10) 
LL5333 4 (10) 
LL5335 4 (10) 
LL5355 4 (10) 
LL5417 6 (15) 
LL5419 6 (15) 
LL5421 6 (15) 
LL5423 6 (15) 
LL5425 6 (15) 
LL5427 6 (15) 
LL5429 6 (15) 
LL5431 6 (15) 
LL5435 6 (15) 
LL5621 12 (30) 
LL5623 12 (30) 
LL5625 12 (30) 
LL5627 12 (30) 
LL5629 12 (30) 
LL5631 12 (30) 
LL5635 12 (30) 
LL5639 12 (30) 
in.
(cm)
in.
(cm)
in.
(cm)
in.
(cm)

General Repair Information
6312226P
General Repair Information
1. Keep all screws, nuts, washers, gaskets, and
electrical fittings removed during repair proce-
dures. These parts are not normally provided with
replacement assemblies.
2. Test repair after problem is corrected.
3. If sprayer does not operate properly, review
repair procedure to verify procedure was done cor-
rectly. If necessary, see Troubleshooting, page 8,
for other possible solutions.
4. Install belt guard before operation of sprayer and
replace if damaged. Belt guard reduces risk of
pinching and loss of fingers.
Grounding
Ground sprayer with grounding clamp to earth ground
when flushing sprayer. FIG. 1.
SAE O-Ring Installation
1. Unscrew lock nut to touch
fitting.
2. Lubricate o-ring (A).
3. Screw in fitting hand tight.
4. Unscrew fitting until
oriented properly.
5. Tighten lock nut to
FIG. 1
TI06250
water pipe, steel
sign post, or
metal light pole
grounding
clamp
A
A
ti5414a
TI5415a
TI5416a
TI5417a

Maintenance
312226P 7
Maintenance
Pressure Relief Procedure
1. Engage trigger lock.
2. Turn engine ON/OFF switch to OFF.
3. Move pump valve to OFF and turn pressure control
knob fully counterclockwise.
4. Disengage the trigger lock.
5. Hold a metal part of the gun firmly to a grounded
metal pail. Trigger the gun to relieve pressure.
6. Engage the trigger lock.
7. Open pressure drain valve. Leave valve open until
you are ready to spray again.
8. If you suspect the spray tip or hose is clogged or
that pressure has not been fully relieved after follow-
ing the steps above, VERY SLOWLY loosen tip
guard retaining nut or hose end coupling to relieve
pressure gradually, then loosen completely. Clear
hose or tip obstruction.
Trigger Lock
Always engage the trigger lock when you stop spraying
to prevent the gun from being triggered accidentally by
hand or if dropped or bumped.
Periodic Maintenance
DAILY: Check engine oil level and fill as necessary.
DAILY: Check hydraulic oil level and fill as necessary.
DAILY: Check hose for wear and damage.
DAILY: Check gun safety for proper operation.
DAILY: Check prime/spray drain valve for proper opera-
tion.
DAILY: Check and fill the gas tank.
DAILY: Check that displacement pump is tight.
DAILY: Top off TSL level in displacement pump packing
nut to help prevent material buildup on piston rod and
early wear of packings.
DAILY: Verify calibration.
AFTER THE FIRST 20 HOURS OF OPERATION: Drain
engine oil and refill with clean oil. Reference Honda
Engines Owner's Manual for correct oil viscosity.
WEEKLY: Remove air filter cover and clean element.
Replace element, if necessary. If operating in an unusu-
ally dusty environment: check filter daily and replace, if
necessary.
Replacement elements can be purchased from your
local HONDA dealer.
WEEKLY/DAILY: Remove any debris from hydraulic
rod.
AFTER EACH 100 HOURS OF OPERATION: Change
engine oil. Reference Honda Engines Owner's Manual
for correct oil viscosity.
SEMI-ANNUALLY: Check belt wear, page 18; replace if
necessary.
YEARLY OR 2000 HOURS: Replace hydraulic oil and
filter element with Graco hydraulic oil 169236 (5 gal-
lon/18.9 liter) or 207428 (1 gallon/3.8 liter) and filter ele-
ment 246173; page 23.
SPARK PLUG: Use only BPR6ES (NGK) or
W20EPR-U (NIPPONDENSO) plug. Gap plug to 0.028
to 0.031 in. (0.7 to 0.8 mm). Use spark plug wrench
when installing and removing plug.
CAUTION
• Minimum hose size allowable for proper
sprayer operation is 3/8 in. x 50 ft.
• For detailed engine maintenance and specifica-
tions, refer to separate Honda Engines Owner's
Manual, supplied.

Troubleshooting
8312226P
Caster Wheel
(See letter call-outs in Parts drawing on page 25.)
1. Once each year, tighten nut (127, detail A) until
spring washer bottoms out. Then back off the nut
1/2 to 3/4 turn.
2. Once each year, tighten nut (127) until it begins to
compress spring washer. Then tighten the nut an
additional 1/4 turn.
3. Once each month, grease the wheel bearing (F).
4. Check pin (55) for wear. If pin is worn out, there will
be play in the caster wheel. Reverse or replace the
pin as needed.
5. Check caster wheel alignment as necessary. To
align: loosen bolt (145), align wheel and tighten bolt.
Troubleshooting
Problem Cause Solution
E=XX is displayed. Fault condition exists. Determine fault correction from table, page 19.
Gas engine pulls hard
(won't start).
Hydraulic pressure is too high. Turn hydraulic pressure knob counterclockwise to
lowest setting.
Engine won't start. Engine switch is OFF. Turn engine switch ON.
Engine is out of gas. Refill gas tank. Honda Engines Owner's Manual.
Engine oil level is low. Try to start engine. Replenish oil, if necessary.
Honda Engines Owner's Manual.
Spark plug cable is disconnected or damaged. Connect spark plug cable or replace spark plug.
Cold engine. Use choke.
Fuel shutoff lever is OFF. Move lever to ON position.
Oil is seeping into combustion chamber. Remove spark plug. Pull starter 3 to 4 times.
Clean or replace spark plug. Start engine. Keep
sprayer upright to avoid oil seepage.
Engine operates, but dis-
placement pump does
not operate.
Pump valve is OFF. Turn pump valve ON.
Pressure setting is too low. Turn pressure adjusting knob clockwise to
increase pressure. Manual 312190.
Fluid filter (11) is dirty. Clean filter.
Tip or tip filter is clogged. Clean tip or tip filter. Manual 311254.
Displacement pump piston rod is stuck due to
dried paint.
Repair pump. Manual 309277.
Belt worn, broken or off pulley. Replace.
Hydraulic fluid too low. Shut of sprayer. Add fluid*.
Hydraulic motor not shifting. Set pump valve OFF. Turn pressure down. Turn
engine OFF. Pry rod up or down until hydraulic
motor shifts.
* Check hydraulic fluid level often. Do not allow it to become too low. Use only Graco approved hydraulic fluid, page 7.

Troubleshooting
312226P 9
Displacement pump
operates, but output is
low on upstroke
Piston ball is not seating. Service piston ball. Manual 309277.
Piston packings are worn or damaged. Replace packings. Manual 309277.
Displacement pump
operates but output is low
on downstroke and/or on
both strokes.
Strainer (34e) is clogged. Clean strainer.
O-ring in pump is worn or damaged. Replace o-ring. Manual 309277.
Intake valve ball is packed with material or is not
seating properly.
Clean intake valve. Manual 309277.
Engine speed is too low. Increase throttle setting. Manual 312190.
Suction tube air leak. Tighten suction tube.
Pressure setting is too low. Increase pressure. Manual 312190.
Fluid filter (11), tip filter or tip is clogged or dirty. Clean filter. Manual 312190 or 311254.
Large pressure drop in hose with heavy materi-
als.
Use larger diameter hose and/or reduce overall
length of hose. Use of more than 100 ft of 1/4 in.
hose significantly reduces performance of
sprayer. Use 3/8 in. hose for optimum perfor-
mance (50 ft minimum).
Pump is difficult to prime. Air in pump or hose. Check and tighten all fluid connections.
Reduce engine speed and cycle pump as slowly
as possible during priming.
Intake valve is leaking. Clean intake valve. Be sure ball seat is not nicked
or worn and that ball seats well. Reassemble
valve.
Pump packings are worn. Replace pump packings. Manual 309277.
Paint is too thick. Thin the paint according to the supplier's recom-
mendations.
Engine speed is too high. Decrease throttle setting before priming pump.
Manual 312190.
High engine speed at no
load.
Misadjusted throttle setting. Reset throttle to 3700-3800 engine rpm at no
load.
Worn engine governor. Replace or service engine governor.
Low stall or run pressure
shown on display.
New pump or new packings. Pump break-in period takes up to 100 gallons of
material.
Faulty transducer. Replace transducer.
Excessive paint leakage
into throat packing nut.
Throat packing nut is loose. Remove throat packing nut spacer. Tighten throat
packing nut just enough to stop leakage.
Throat packings are worn or damaged. Replace packings. Manual 309277.
Displacement rod is worn or damaged. Replace rod. Manual 309277.
Fluid is spitting from gun. Air in pump or hose. Check and tighten all fluid connections. Reprime
pump. Manual 312190.
Tip is partially clogged. Clear tip. Manual 311254.
Fluid supply is low or empty. Refill fluid supply. Prime pump. Manual 312190.
Check fluid supply often to prevent running pump
dry.
Problem Cause Solution

Troubleshooting
10 312226P
Excessive leakage
around hydraulic motor
piston rod wiper.
Piston rod seal worn or damaged. Replace these parts.
Fluid delivery is low. Pressure setting too low. Increase pressure. Manual 312190.
Displacement pump outlet filter (if used) is dirty or
clogged.
Clean filter.
Intake line to pump inlet is not tight. Tighten.
Hydraulic motor is worn or damaged. Bring sprayer to Graco distributor for repair.
Large pressure drop in fluid hose. Use larger diameter or shorter hose.
The sprayer overheats. Paint buildup on hydraulic components. Clean.
Oil level is low. Fill with oil, page 7.
Excessive hydraulic
pump noise.
Low hydraulic fluid level. Shut off sprayer. Add fluid*, page 7.
Gallon counter not work-
ing.
Broken or disconnected wire. Check wires and connections. Replace broken
wires.
Bad sensor. Replace sensor.
Missing or damaged magnet. Reposition or replace magnet.
Sprayer operates, but
display does not.
Bad connection between control board and dis-
play.
Remove display and reconnect.
Display damaged. Replace display.
Loose cables. Connect cables to back of control board.
Control board LED not flashing. Replace control board.
Distance counter not
operating properly.
Trigger sensor not set correctly. See “Spray icon does not show on display when
fluid is sprayed”.
Bad wiring connections. Check connector, and reconnect.
Distance sensor not spaced correctly from gear. Adjust space between sensor and gear to .050 -/+
.020 in. See page 16.
Distance sensor and gear not aligned. Remove tire, and press in or pull out gear to align
sensor and gear.
Gear teeth missing or damaged. Replace distance gear/wheel.
Wire cracked or broken. Replace sensor.
Mils not calculating. Distance sensor. See “Distance counter not operating properly”.
Trigger sensor. See “Spray icon does not show on display when
fluid is sprayed”.
Gallon counter. See “Gallon counter not working”.
Bad or damaged control board. Replace control board.
Fluid spray starts after
spray icon is shown on
display.
Interrupter (164) is improperly positioned. Turn screw counterclockwise until spray icon syn-
chronizes with fluid spray.
Fluid spray starts before
spray icon is shown on
display.
Interrupter (164) is improperly positioned. Turn screw clockwise until spray icon is synchro-
nized with fluid spray.
Problem Cause Solution

Troubleshooting
312226P 11
Spray icon does not show
on display when fluid is
sprayed.
Loose connector. Check that 5-pin connector and reed switch are
properly connected.
Interrupter (164) is improperly positioned. Turn screw counterclockwise until spray icon syn-
chronizes with fluid spray.
Reed switch assembly (18) is damaged. Replace reed switch assembly (18).
Magnet on assembly (18) is missing. Replace reed switch assembly (18).
A connector on wiring harness or on reed switch
(18) is damaged.
Disconnect reed switch and 5-pin connector from
back of control board.
Check continuity between pin 1 on 2-pin connec-
tor and pin 1 on 5-pin connector. Check continuity
between pin 2 on 2-pin connector and pin 4 on
5-pin connector. If there is no continuity in either
case, replace wiring harness.
If there is continuity in both cases replace reed
switch assembly (18).
Cut or sliced wire. Replace wiring harness.
Control board is damaged. Replace control board.
Display is damaged. Replace display.
Spray icon is always
shown on display.
Interrupter (164) is improperly positioned. Turn screw clockwise until spray icon is synchro-
nized with fluid spray.
Reed switch assembly (18) is damaged. Replace reed switch assembly (18).
Pressure control knob
does not rotate.
Knob is jammed. Pull back cover where remote cable connects to
hydraulic pump and turn counter clockwise (ccw)
until free.
Pressure control knob
rotates freely with no
pressure change.
Remote cable broken or disconnected. Replace or reconnect cable.
Engine bounces when
striping.
Spring is broken, loose or missing. Replace or reconnect spring.
No dots or poor dots
with ghosting
No dots. Check that solenoid power cord is plugged in.
Check Remote button. Verify Remote button
operation by changing angle in ANGLE CALC
display.
Solenoid cartridge bar is too far away from aero-
sol marking can spray tip. Do Auto-Layout Can
Actuator Adjustment.
Poor dots or dots with ghosting. Solenoid cartridge bar is too close to aerosol
marking can spray tip. Do Auto-Layout Can
Actuator Adjustment.
Engine speed to slow Engine speed must be greater than 2600 rpm.
Aerosol can malfunctioning Check that can sprays. Replace if not.
Solenoid module malfunctioning Replace solenoid module.
Problem Cause Solution

Auto-Layout Can Actuator Adjustment
12 312226P
Auto-Layout Can Actuator Adjustment
Adjustments
The can actuator is set at the factory. If the dot size is
not as desired, do the coarse and/or fine adjustments.
Coarse Adjustment
1 Locate four screws on side of holder base.
2 Loosen screws to allow holder base to move freely.
Do not aim aerosol can at your face.
3 Move holder base until solenoid cartridge bar is
approximately 0.10 in. (thickness of two dimes) from spray tip.
4 Carefully tighten screws. Verify gap.
Fine Adjustment
If coarse adjustment did not achieve desired dot size,
proceed as follows:
1 Start striper and move to PARKING MODE display.
2Set DOT SIZE setting to smallest size (least amount of
bars on display). Press arrow keys to increase/decrease
size.
3DoCoarse Adjustment steps 1 and 2. Move holder base
until a dot size of approximately a dime is achieved.
Tighten screws on holder base.
ti10070a
ti10071a
ti10072a
ti10073a
MODE
SETUP
STALL SIZE 9.00’
0 mph
DOT SIZE
PARKING MODE
ti9919a
Good Dot Poor Dot with Ghosting
ti10379a ti10380a

Auto-Layout System
312226P 13
Auto-Layout System
Engine Stop Switch
Removal
1. Relieve pressure, page 7.
2. FIG. 2. Remove two screws (103) and cover (31).
3. Remove two spade connectors from ENGINE STOP
switch (15f).
4. Press in on two retaining tabs on each side of
ENGINE STOP switch and remove switch.
Installation
1. FIG. 2. Install ENGINE STOP switch (15f) so tabs of
switch snap into place on inside of pressure control
housing.
2. Connect two spade connectors to ENGINE STOP
switch (15f).
3. Install cover (31) with two screws (103).
Control Board
Removal
1. Relieve pressure, page 7.
2. FIG. 2. Remove two screws (103) and cover (31).
3. Pull display connector wings (A) open on control
board and pull display connector out.
4. Note on paper, lead connections to the control
board. Disconnect leads from control board (15d).
5. Remove six screws (15k) from control board.
Installation
1. FIG. 2. Install control board (15d) and six screws
(15k). Torque to 105-115 in-lb.
2. Connect leads to control board. (Refer to note on
lead connections.)
3. Push display connector into control board close dis-
play connector wings (A) on control board.
4. Install cover (31) with two screws (103).
Pressure Control Transducer
Removal
1. Relieve pressure, page 7.
2. FIG. 2. Remove two screws (103) and cover (31).
3. Disconnect transducer lead (C) from control board
(15d).
4. Remove pressure control transducer (259) and
o-ring (124) from filter housing.
Installation
1. FIG. 2. Install o-ring (124) and pressure control
transducer (259) in filter housing. Torque to 35-45
ft-lb.
2. Connect transducer lead (C) to motor control board
(15d).
3. Install cover (31) with two screws (103).

Auto-Layout System
14 312226P
FIG. 2
TO ENGINE
GROUND
Main Control
Box Cable
Transducer
103
31
15f
15k
B
D
259
124
123
15d
C
A
15f
ti10327a

Control Board Diagnostics
312226P 15
Control Board Diagnostics
Display Messages
Relieve pressure before repair; page 7. No display does not mean that sprayer is not pressurized.
After a fault, follow these steps to restart sprayer:
1. Correct fault condition.
2. Turn sprayer OFF.
3. Turn sprayer ON.
Display Sprayer Operation Indication Action
No Display Sprayer may be pres-
surized.
Loss of power or dis-
play not connected.
Check power source. Relieve pressure before
repair or disassembly. Verify display is con-
nected.
Sprayer may be pres-
surized.
Pressure less than 200
psi (14 bar, 1.4 MPa).
Increase pressure as needed.
Sprayer is pressurized.
Power is applied.
(Pressure varies with
tip size and pressure
control setting.)
Normal operation. Spray.
Engine and system
continue to run.
Exceeded pressure
limit.
Remove any filter clogs or flow obstructions.
Engine and system
continue to run.
Pressure transducer
faulty, bad connection
or broken wire.
Check transducer connections and wire. Replace
transducer or control board, if necessary.
ti6314a
psi
bar
MPa
ti6315a
ti6316a
ti6317a

Trigger Sensor Adjustment
16 312226P
Trigger Sensor Adjustment
Refer to Troubleshooting for trigger sensor adjust-
ment, and see Operation Manual 312190.
Distance Sensor Replacement
1. Remove wheel (120) from LineLazer.
2. Remove screw (273), wire clamp (115), spacer
(272) and distance sensor (66).
3. Install new distance sensor (66) and spacer (272)
with wire clamp (115) and screw (273).
4. Install wheel (120) on LineLazer.
FIG. 3
TI10237a
142
127
120
66
273
115
272
130

Hydraulic Pump
312226P 17
Hydraulic Pump
Removal
1. Allow hydraulic system to cool before beginning ser-
vice.
2. Relieve pressure, page 7.
3. Place drip pan or rags under sprayer to catch
hydraulic oil that leaks out during repair.
4. Fig. 4. Remove drain plug (195) and oil filter (199)
and allow hydraulic oil to drain.
5. Remove screw (224), loosen belt guard knob (241)
and belt guard (24).
6. Raise motor and remove belt (143).
7. Remove two set screws (169) and fan pulley (86).
8. Remove case drain tube (251).
9. Remove elbow (182).
10. Loosen screw (260) and remove pressure control
guard (63).
11. Loosen set screw (102) and remove remote pres-
sure control cable (12).
12. Remove eight screws (184), reservoir cover (237),
filter assembly (A) and gasket (85).
13. Remove four screws (215) and o-rings (178), o-ring
(180) and hydraulic pump (252) from reservoir cover
(237).
Installation
1. Install hydraulic pump (252) on reservoir cover
(237) with four screws (215) and o-rings (178),
o-ring (180); torque 100 in-lb (11 N·m).
2. Install gasket (85) filter assembly (A) and reservoir
cover (237) with eight screws (184); torque 90 in-lb
(10 N•m).
3. Install elbow (182) per instructions, page 6; torque
to 15 ft-lb (20.3 N•m).
4. Install pressure control guard (63) and tighten screw
(260).
5. Connect hydraulic hoses (32) and (35).
6. Install case drain tube (251); torque to 15 ft-lb (20.3
N•m).
7. Install fan pulley (86) with two set screws (169).
8. Raise motor and install belt (143).
9. Install belt guard (24) with screw (224) and belt
guard knob (241).
10. Install remote pressure control cable (12).Tighten
set screw (102).
11. Install drain plug (195); torque to 110 in-lb (12.4
N•m). Install oil filter (199); tighten 3/4 turn after gas-
ket contacts base. Fill with Graco hydraulic oil, page
7.
12. Start up and allow pump to operate at low pressure
for approximately 5 minutes to purge all air.
13. Check and top off hydraulic oil level.

Hydraulic Pump
18 312226P
FIG. 4
TI6551a
224
24
162
169
86
143
241
195
85
A
260
215
237
35
178
252
180 218
184
199
32
251
196
182
102
12
63

Fan Belt
312226P 19
Fan Belt
Removal
1. Relieve pressure, page 7.
2. FIG. 5. Loosen belt guard knob (241).
3. Rotate belt guard (24) up.
4. Lift engine (185) up to remove tension on belt (143).
5. Remove belt from fan pulley (86) and fan pulley
(87a).
Installation
1. Thread belt (143) around fan pulley (87a) and fan
pulley (86).
2. Lower engine (185) to put tension on belt.
3. Rotate belt guard (24) down.
4. Tighten belt guard knob (241).
FIG. 5
241
TI6511a
24
86
185
143
87a

Engine
20 312226P
Engine
Removal
1. Relieve pressure, page 7.
2. Remove throttle cable from engine.
3. Do Fan Belt, Removal; page 19.
4. Loosen hand nut (241). Swing bracket (30) out.
5. FIG. 6. Disconnect red, yellow and white/red leads
from engine.
6. Remove engine and rocker plate (87c) from
sprayer.
7. Remove four screws (189), washers (114), washers
(170) and nuts (118) and remove rocker plate,
dampeners (59) and washers (114) from engine.
Installation
1. Install rocker plate (87c), dampeners (59) and
washers (170), washers (114) on engine (185) with
four screws (189), washers (170) and nuts (118);
torque to 20 ft-lb (27.1 N•m).
2. Install engine and rocker plate (87c) on sprayer.
3. Connect white/red, yellow and red leads.
4. Do Fan Belt, Installation; page 19.
5. Swing motor retainer bracket (30) in. Tighten hand
nut (241).
All service to the engine must be performed by an
authorized HONDA dealer.
FIG. 6
TI6520b
RED
WHITE/RED
GREY
YELLOW
118
114
30
241 170
59
87c
114
189
151