Graco LineLazer IV 3900 Manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2007, Graco Inc. is registered to I.S. EN ISO 9001
312195B
Repair - Parts List
LineLazer™IV 3900, 5900 Auto-Layout™System
Airless Line Stripers
For application of line striping materials.
3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure
See page 2 for model information.
Chinese Patent ZL03802251.6
U.S. Patent 6,913,417
U.S. Patent 7,303,155
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
ti10233a
312190
310643
309741
309055
312345
312307

Models
2312195B
Contents
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Tip Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Auto-Layout Can Actuator Adjustment. . . . . . . . . . . . . . 10
Bearing Housing and Connecting Rod . . . . . . . . . . . . . . 11
Drive Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Pinion Assembly/Clutch Armature/Clamp . . . . . . . . . . . 13
Clutch Housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Trigger Sensor Adjustment . . . . . . . . . . . . . . . . . . . . . . . 19
Distance Sensor Replacement . . . . . . . . . . . . . . . . . . . . 19
Control Board Diagnostics . . . . . . . . . . . . . . . . . . . . . . . 20
Displacement Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Parts - Drive and Pinion Housing Assemblies. . . . . . . . 23
Auto-Layout System Wiring Diagram . . . . . . . . . . . . . . . 34
Technical Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Models
3900 Line Stripers
5900 Line Stripers
253920 ✔✔
253953 ✔✔
255151 ✔✔
255152 ✔✔
253921 ✔✔
253954 ✔✔
255153 ✔✔
255154 ✔✔
Manual Language
312195 English
312196 French
312197 Spanish
312198 Dutch
312199 German
312200 Italian
312201 Tu r k i s h
312202 Greek
312203 Croatian
312204 Portuguese
312205 Danish
312206 Finnish
312207 Swedish
312208 Norwegian
312209 Russian
312210 Estonian
312211 Latvian
312212 Lithuanian
312213 Polish
312214 Hungarian
312215 Czech
312216 Slovakian
312217 Slovenian
312218 Romanian
312219 Bulgarian

Warnings
312195B 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
4312195B
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.
WARNING

Tip Selection
312195B 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)

Maintenance
6312195B
Maintenance
Pressure Relief Procedure
1. Engage trigger lock.
2. Turn engine ON/OFF switch to OFF.
3. Move pump switch 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 hose for wear and damage.
DAILY: Check gun safety for proper operation.
DAILY: Check pressure drain valve for proper operation.
DAILY: Check and fill the gas tank.
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: Check level of TSL in displacement pump
packing nut. Fill nut, if necessary. Keep TSL in nut to
help prevent fluid buildup on piston rod and premature
wear of packings.
AFTER EACH 100 HOURS OF OPERATION: Change
engine oil. Reference Honda Engines Owner's Manual
for correct oil viscosity.
SPARK PLUG: Use only BPR6ES (NGK) or W20EPR-U
(NIPPONDENSO) plug. Gap plug to 0.028 to 0.031 in.
(0.7 to 0.8 mm). Use spark plug wrench when installing
and removing plug.
Caster Wheel
(See letter call-outs in Parts, LineLazer IV Swivel
Wheel Assembly 240719 drawing on page 28.)
1. Once each year, tighten nut (127) under dust cap
(142) until spring washer bottoms out. then back off
the nut 1/2 to 3/4 turn.
2. Once each year, tighten nut (127) on screw (131)
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 screw (145), align wheel and tighten
screw.

Troubleshooting
312195B 7
Troubleshooting
Problem Cause Solution
E=XX is displayed. Fault condition exists. Determine fault correction from table, page 20.
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.
Error code displayed? Reference pressure control repair. Page 20.
Pump switch is OFF. Turn pump switch ON.
Pressure setting is too low. Turn pressure adjusting knob clockwise to
increase pressure.
Fluid filter (11) is dirty. Clean filter. Page 32.
Tip or tip filter is clogged. Clean tip or tip filter. See spray gun manual.
Displacement pump piston rod is stuck due to
dried paint.
Repair pump. See pump manual.
Connecting rod is worn or damaged. Replace connecting rod. Page 11.
Drive housing is worn or damaged. Replace drive housing. Page 12.
Electrical power is not energizing clutch field. Check wiring connections. Page 16.
Reference pressure control repair. Page 17.
Reference wiring diagram. Page 34.
With pump switch ON and pressure turned to
MAXIMUM, use a test light to check for power
between clutch test points on control board.
Disconnect clutch wires from control board and
measure resistance across clutch coil. At 70° F,
the resistance must be between 1.2 +0.2 ohms
(LineLazer IV 3900); 1.7 +0.2 ohms (LineLazer IV
5900); if not, replace pinion housing.
Have pressure control checked by authorized
Graco dealer.
Clutch is worn, damaged, or incorrectly posi-
tioned.
Replace clutch. Page 13.
Pinion assembly is worn or damaged. Repair or replace pinion assembly. Page 12.

Troubleshooting
8312195B
Pump output is low. Strainer (34f) is clogged. Clean strainer.
Piston ball is not seating. Service piston ball. See pump manual.
Piston packings are worn or damaged. Replace packings. See pump manual.
O-ring in pump is worn or damaged. Replace o-ring. See pump manual.
Intake valve ball is not seating properly. Clean intake valve. See pump manual.
Intake valve ball is packed with material. Clean intake valve. See pump manual.
Engine speed is too low. Increase throttle setting. See operation manual.
Clutch is worn or damaged. Replace clutch. Page 13.
Pressure setting is too low. Increase pressure. See operation manual.
Fluid filter (11), tip filter or tip is clogged or dirty. Clean filter. See operation or spray gun manual.
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).
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. See pump manual.
Displacement rod is worn or damaged. Replace rod. See pump manual.
Fluid is spitting from gun. Air in pump or hose. Check and tighten all fluid connections. Reprime
pump. See operation manual.
Tip is partially clogged. Clear tip. See spray gun manual.
Fluid supply is low or empty. Refill fluid supply. Prime pump. See operation
manual. Check fluid supply often to prevent run-
ning pump dry.
Pump is difficult to prime. Air in pump or hose. Check and tighten all fluid connections.
Reduce engine speed and cycle pump as slowly
as possible during priming.
Intake valve is leaking. Clean intake valve. Be sure ball seat is not nicked
or worn and that ball seats well. Reassemble
valve.
Pump packings are worn. Replace pump packings. See pump manual.
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.
See operation manual.
Problem Cause Solution

Troubleshooting
312195B 9
Clutch squeaks each time
clutch engages.
Clutch surfaces are not matched to each other
when new and may cause noise.
Clutch surfaces need to wear into each other.
Noise will dissipate after a day of run time.
High engine speed at no
load.
Misadjusted throttle setting. Reset throttle to 3600 engine rpm at no load.
Worn engine governor. Replace or service engine governor.
Gallon counter not work-
ing.
Broken or disconnected wire. Check wires and connections. Replace broken
wires.
Bad sensor. Replace sensor.
Missing magnet. Reposition or replace magnet.
Sprayer operates, but dis-
play does not.
Bad connection between control board and dis-
play.
Remove display and reconnect.
Display damaged. Replace display.
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.
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, page 31) Turn screw (126, page 31) counterclockwise until
spray icon synchronizes with fluid spray.
Spray icon does not show
on display when fluid is
sprayed.
Loose connector. Check connector and reconnect.
Interrupter (164, page 31) is improperly positioned. Turn screw (126, page 31) counterclockwise until
spray icon synchronizes with fluid spray.
Reed switch assembly (166, page 31) is damaged. Replace reed switch assembly (166, page 31).
Magnet on assembly (166, page 31) is missing. Replace reed switch assembly (166, page 31).
Cut or sliced wire. Replace distance sensor harness (66, page 25).
Control board is damaged. Replace control board.
Display is damaged. Replace display.
Spray icon is always
shown on display.
Interrupter (164, page 31) is improperly positioned. Turn screw (126, page 31) clockwise until spray
icon is synchronized with fluid spray.
Reed switch assembly (166, page31) is damaged. Replace reed switch assembly (166, page 31).
No dots or poor dots
with ghosting
No dots. 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 malfuntioning Replace solenoid module.
Problem Cause Solution

Auto-Layout Can Actuator Adjustment
10 312195B
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,
procede 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.
Note: Dot size consistency can vary due to weather
changes and differences in aerosol marking can brands.
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

Bearing Housing and Connecting Rod
312195B 11
Bearing Housing and Connecting Rod
Removal
1. Relieve pressure, page 6.
2. FIG. 2. Remove screws (187) and front cover (83).
3. Unscrew suction tube (34) from pump, hold wrench on
pump intake valve (A) to keep pump from loosening.
4. Disconnect pump outlet hose (100) from displace-
ment pump outlet nipple (60).
5. FIG. 1. Use screwdriver to push up retaining spring
(236) at top of pump. Push out pin (235).
6. FIG. 2. Loosen retaining nut (84). Unscrew and
remove displacement pump (21).
7. Remove four screws (183) and lockwashers (188)
from bearing housing (22).
8. Pull connecting rod (26) and lightly tap lower rear of
bearing housing (22) with plastic mallet to loosen
from drive housing (24). Pull bearing housing and
connecting rod assembly (26) off drive housing.
9. Inspect crank (B) for excessive wear and replace
parts as needed.
Installation
1. Evenly lubricate inside of bronze bearing (C) in bear-
ing housing (22) with high-quality motor oil. Liberally
pack top roller bearing (E), lower bearing (D) inside
connecting rod assembly (26) with bearing grease.
2. Assemble connecting rod (26) and bearing housing (22).
3. Clean mating surfaces of bearing and drive housings.
4. Align connecting rod with crank (B) and carefully
align locating pins (F) in drive housing (24) with holes
in bearing housing (22). Push bearing housing onto
drive housing or tap into place with plastic mallet.
5. Install screws (183) and lockwashers (188) on bear-
ing housing. Torque evenly to note 3 value in FIG. 2.
6. Install pump. Refer to Displacement Pump, Instal-
lation, page 21.
FIG. 1
235
236
7675b
CAUTION
Do not use bearing housing screws (183) to align or seat
bearing housing with drive housing. Align these parts
with locating pins (F), to avoid premature bearing wear.
FIG. 2
1
2
3
B
E
D
236
83
187
183
235
21
A
60 100
34
84
34g
22
24
F
C
26
188
3
2
Oil.
Pack with bearing grease 114819.
LineLazer IV 3900: Torque to 200 in-lb (22.6 N•m).
LineLazer IV 5900: Torque to 25 ft-lb (34 N•m).
1
2
3
TI6395A
Model 253920

Drive Housing
12 312195B
Drive Housing
Removal
1. Relieve pressure, page 6.
2. FIG. 3. Remove bearing housing. Do Bearing
Housing and Connecting Rod procedure on page
11.
3. Remove two screws (158) and reed switch (182).
4. Remove six screws (189) from pinion housing (25).
5. Lightly tap around drive housing (24) to loosen drive
housing. Pull drive housing straight off pinion hous-
ing. Be prepared to support gear cluster (23), which
may also come out.
Installation
1. Liberally apply bearing grease (supplied with
replacement gear cluster) to gear cluster (23) and to
areas called out by note 2.
2. Place bronze colored washer (24g) on shaft protrud-
ing from large shaft of drive housing (24). Place sil-
ver colored washer (24h) on pinion housing. Clean
mating surfaces of pinion and drive housings. Align
gears and push new drive housing straight onto pin-
ion housing and locating pins (A).
3. Install six screws (189). Torque evenly to note 1
value in FIG. 3.
4. Install reed switch (182) with two screws (158).
5. Install bearing housing. Do steps 1 through 6 of
Bearing Housing and Connecting Rod procedure
on page 11.
FIG. 3
1
LineLazer IV 3900: Torque to 200 in-lb (22.6 N•m).
LineLazer IV 5900: Torque to 25 ft-lb (34 N•m).
Apply remaining grease to these areas.
1
2
189
188
182
158
24
178 24g 24h
179
178
23
189
25
A
A
2
TI6396a
2
1

Pinion Assembly/Clutch Armature/Clamp
312195B 13
Pinion Assembly/Clutch Armature/Clamp
Pinion Assembly/Clutch
Armature Removal
Pinion Assembly
If pinion assembly (25) is not removed from clutch hous-
ing (85), do steps 1 through 3. Otherwise, start at 4.
1. Remove drive housing, page 12.
2. FIG. 12. Remove junction box (226).
3. FIG. 11. Disconnect pump stroke sensor and clutch
cables.
4. FIG. 4. Remove four screws (189) and lockwashers
(188) and pinion assembly (25).
5. FIG. 5. Place pinion assembly (25) on bench with
rotor side up.
6. Remove four screws (175) and lockwashers (172).
Install two screws in threaded holes (E) in rotor.
Alternately tighten screws until rotor comes off.
7. FIG. 6. Remove retaining ring (25e).
8. Tap pinion shaft (25d) out with plastic mallet.
Clutch Armature
9. FIG. 7. Use an impact wrench or wedge something
between armature (87) and clutch housing to hold
engine shaft during removal.
10. Remove four screws (175) and lockwashers (172).
11. Remove armature (87).
FIG. 4
189
188
189 188
25
TI5480b
85
FIG. 5
FIG. 6
FIG. 7
E
TI5481b TI5987c
E172
175
25d
25e
25c
86
TI5482b
87
172
175
TI8704a

Pinion Assembly/Clutch Armature/Clamp
14 312195B
Installation
Clutch Armature
1. FIG. 8. Lay two stacks of two dimes on smooth
bench surface.
2. Lay armature (87) on two stacks of dimes.
3. Press center of clutch down on bench surface.
4. Install armature (87) on engine drive shaft.
5. FIG. 7. Install four screws (175) and lockwashers
(172) with torque of 125 in-lb.
Pinion Assembly
6. FIG. 6. Check o-ring (25c) and replace if missing or
damaged.
7. Tap pinion shaft (25d) in with plastic mallet.
8. Install retaining ring (25e) with beveled side facing
up.
9. FIG. 5. Place pinion assembly on bench with rotor
side up.
10. Apply Loctite to screws. Install four screws (175)
and lockwashers (172). Alternately torque screws
to 125 in-lb until rotor is secure. Use threaded holes
to hold rotor.
11. FIG. 4. Install pinion assembly (25) with five screws
(189) and lockwashers (188).
12. FIG. 11. Connect pump stroke sensor and clutch
cables.
13. FIG. 12. Install junction box (226).
Clamp
Removal
1. Do Engine Removal.
2. Drain gasoline from tank according to Honda man-
ual.
3. Tip engine on side so gas tank is down and air
cleaner is up.
4. FIG. 9. Loosen two screws (175) on clamp (82),
5. Push screwdriver into slot in clamp (82) and remove
clamp.
Installation
1. FIG. 9. Install engine shaft key (88).
2. Tap clamp (82) on engine shaft (A) with plastic mal-
let. Maintain dimension shown note 2. Chamfer
must face engine.
3. Check dimension: Place rigid, straight steel bar (B)
across face of clutch housing (5). Use accurate
measuring device to measure distance between bar
and face of clamp. Adjust clamp as necessary.
Torque two screws (175) to 125 +10 in-lb (14 +1.1
N•m).
FIG. 8
0.12 +.01 in. (3.0 +.25 mm)
dimes
87
TI8705a
FIG. 9
Face of clutch housing.
LineLazer IV 3900: 2.55 +/- .010 in. (64.77 +/- 0.25 mm).
LineLazer IV 5900: 2.61 +/- .010 in. (66.29 +/- 0.25 mm)
Torque to 125 +/- 10 in-lb (14 +/- 1.1 N•m).
Chamfer this side.
1
2
3
4
TI5484b
1
A
88
175
82
85
B
2
4
3

Clutch Housing
312195B 15
Clutch Housing
Removal
1. FIG. 10. Remove four cap screws (186) and lock
washers (188) which hold clutch housing (85) to
engine.
2. Remove screw (177) from under mounting plate (96).
3. Pull off clutch housing (85).
Installation
1. FIG. 10. Push on clutch housing (85).
2. Install four cap screws (186) and lock washers (188)
and secure clutch housing (85) to engine. Torque to
200 in-lb (22.6 N•m).
3. Install capscrew (177) from beneath mounting plate
(96). Torque to 26 ft-lb (35.2 N•m).
FIG. 10
177
96
188
186
85
88
TI6643

Engine
16 312195B
Engine
Removal
1. Remove Pinion Assembly/Clutch Arma-
ture/Clamp
and Clutch Housing . See pages 13 - 15.
2. FIG. 12. Remove junction box (226).
3. FIG. 11. Disconnect all necessary wiring.
4. FIG. 12. Remove screw (177). Remove two screws
(117), locknuts (118), and ground conductor (223,
260) from base of engine (185).
5. Lift engine carefully and place on work bench.
Installation
1. FIG. 12. Lift engine carefully and place on engine
mount plate (96).
2. Install two screws (117) and ground conductor (223,
260) in base of engine and secure with locknuts
(118). Torque to 20 to 30 ft-lb.
3. FIG. 11. Connect all necessary wiring.
4. Install Pinion Assembly/Clutch Armature/Clamp
and Clutch Housing. See pages 13 - 15.
All service to the engine must be performed by an
authorized HONDA dealer.
FIG. 11
Solenoid Actuator Cable
Main Control Box Cable
Wheel Sensor Cable
To Engine
SOLENOID
ACTUATOR
CABLE
CLUTCH
TO
ENGINE
JUNCTION
BOX
PUMP STROKE
COUNTER
TO MAIN
CONTROL
BOX
DISTANCE
SENSOR
Bottom View
ti6397b
FIG. 12
Engine
ti6398b
117
118
226
223
Ref. 118
ti6536a
185
96

Pressure Control
312195B 17
Pressure Control
On/Off Switch
Note: A complete wiring diagram is on page 34.
Removal
1. Relieve pressure, page 6.
2. FIG. 13. Remove two screws (125) and cover (31).
3. Remove three screws (125) from control plate (15a).
Slide control plate out to access ON/OFF switch
(15g).
4. Press locking tab on ON/OFF switch connector (B)
and disconnect from control board.
5. Press in on two retaining tabs on each side of
ON/OFF switch and remove switch.
Installation
1. Install ON/OFF switch (15g) so tabs of switch snap
into place on inside of pressure control housing.
2. Connect ON/OFF switch connector (B) to J3 on con-
trol board.
3. Slide control plate (15a) back to original position
and secure with theree screws (125).
4. Install cover (31) with two screws (125).
FIG. 13
TO ENGINE
GROUND
Main Control
Box Cable
Transduser
15o
15r
15g
15n
15i
B
D
15j
31
216
217
125
15d
C
A
TI6408b
125
15a 15f

Pressure Control
18 312195B
Control Board
Removal
1. Relieve pressure, page 6.
2. FIG. 13. Remove two screws (125) and control cover
(31). Pull display connector wings open on control
board and pull display connector out.
3. FIG. 13 and FIG. 21. Note on a paper lead connec-
tions to the control board. Disconnect leads from
control board (15d).
4. FIG. 13. Remove five screws (15j) from control
board (15d).
Installation
1. FIG. 13. Install control board (15d) with five screws
(15j).
2. FIG. 13 and FIG. 21. Refer to note on lead connec-
tions to the control board. Connect leads to control
board (15d).
3. FIG. 13. Push display connector into control board
close display connector wings on control board.
Install control cover (31) with two screws (125).
Pressure Control Transducer
Removal
1. Relieve pressure, page 6.
2. FIG. 13. Remove two screws (125) and control cover
(31).
3. Disconnect transducer lead (C) from control board
(15d).
4. Remove pressure control transducer (216) and
o-ring (217) from filter manifold (40).
Installation
1. FIG. 13. Install o-ring (217) and pressure control
transducer (216) in filter manifold (40). Torque to
35-45 ft-lb.
2. Connect transducer lead (C) to control board (15d).
3. Install control cover (31) with two screws (125).
Pressure Adjust Potentiometer
Removal
1. Relieve pressure, page 6.
2. FIG. 13. Remove two screws (125) and control cover
(31).
3. Disconnect lead (D) from control board (15d).
4. Loosen set screws on potentiometer knob (15o) and
remove knob, shaft nut, lockwasher and pressure
adjust potentiometer (15i).
5. Remove seal (15n) from potentiometer (15i).
Installation
1. Install seal (15n) on potentiometer (15i).
2. FIG. 13. Install pressure adjust potentiometer (15i),
shaft nut, lockwasher and potentiometer knob (15o).
a. Turn potentiometer shaft (15i) clockwise to inter-
nal stop. Assemble potentiometer knob (15o) to
strike pin on plate (15r).
b. After adjustment of step a, tighten both set
screws in knob 1/4 to 3/8 turn after contact with
shaft.
3. Connect lead (D) to control board (15d).
4. Install control cover (31) with two screws (125).

Trigger Sensor Adjustment
312195B 19
Engine Stop Switch
Note: A complete wiring diagram is on page 34.
Removal
1. Relieve pressure, page 6.
2. FIG. 13. Remove two screws (125) 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. Install ENGINE STOP switch (15f) so tabs of switch
snap into place on inside of pressure control hous-
ing.
2. Install cover (31) with two screws (125).
Trigger Sensor Adjustment
Refer to Troubleshooting for trigger sensor adjustment,
and see operation manual.
Distance Sensor Replacement
1. Remove wheel (120) from LineLazer.
2. Remove screw (273), wire clamp (115) and distance
sensor (66).
3. Install new distance sensor (66) with wire clamp
(115) and screw (273).
4. Install wheel (120) on LineLazer.
FIG. 14
TI10237a
142
127
120
66
273
115
130
130

Control Board Diagnostics
20 312195B
Control Board Diagnostics
Digital Display Messages
Relieve pressure before repair; page 6. 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 pressur-
ized. Power is applied.
(Pressure varies with
tip size and pressure
control setting.)
Normal operation. Spray.
Sprayer stops. Engine
is running.
Exceeded pressure
limit.
Remove any filter clogs or flow obstructions.
Sprayer stops. Engine
is running.
Pressure transducer
faulty, bad connection
or broken wire.
Check transducer connections and wire. Replace
transducer or control board, if necessary.
Sprayer stops. Engine
is running.
High clutch current. 1. Check clutch connections. Clean contacts.
2. Measure 1.2 +0.2 Ohms (LineLazer IV 3900);
1.7 +0.2 Ohms (LineLazer IV 5900) across
clutch field at 70°F.
3. Replace clutch field assembly.
ti6314a
psi
bar
MPa
ti6315a
ti6316a
ti6317a
ti6318a