Graco LineLazer II 3900 User manual

308874
Rev. B
First choice when
quality counts. t
Model 232651
Related Manuals
Operation 308873. . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 308798. . . . . . . . . . . . . . . . .
Spray Gun 308235. . . . . . . . . . . . . . . . . . . . . . . . .
Spray Tip *. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PC Board 308919. . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Valve Kit 308961. . . . . . . . . . . . . . . . . . . . . .
* for spray tip selection see page 4.
All models are not available in all countries
PATENTS PENDING
8824A
INSTRUCTIONS-REPAIR
INSTRUCTIONS
KEEP FOR REFERENCE.
Read this and all related manuals for
important warnings and instructions.
LineLazer II 3900 and 5900
3300 psi (230 bar, 23 MPa ) Maximum Working Pressure

Model Series Description
232651 AComplete Sprayer
232652 AComplete Sprayer with 2nd Gun Kit

Model Series Description
232661 AComplete Sprayer
232662 AComplete Sprayer with 2nd Gun Kit
Table of Contents
Component Identification and Function 3. . . . . . . . . . . .
Spray Tip Selection Guide 4. . . . . . . . . . . . . . . . . . . . . . .
Maintenance 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Repair
Bearing Housing & Connecting Rod 8. . . . . . . . . . . . .
Drive Housing 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pinion Assembly/Rotor/Field/Shaft/Clutch 10. . . . . . .
Clamp 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clutch Housing 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Engine 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control 14. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Displacement Pump 16. . . . . . . . . . . . . . . . . . . . . . . . .
Parts
Model 232651, 232661 LineLazer II 17. . . . . . . . . . . .
Pinion Assembly 23. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Complete Sprayers 26. . . . . . . . . . . . . . . . . . . . . . . . . .
Pressure Control 25. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dimensions 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Data 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Phone Number 27. . . . . . . . . . . . . . . . . . . . . . . . . .
Graco Warranty 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GRACO INC. P.O. BOX 1441 MINNEAPOLIS, MN 55440–1441
ECOPYRIGHT 1999, GRACO INC.
Graco Inc. is registered to I.S. EN ISO 9001


Warnings and Cautions
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
or destruction of equipment if you do not follow the
instructions.
Fluid injection is a serious injury! If high pressure fluid pierces
your skin, the injury might look like “just a cut”. But it is a serious
wound! Get immediate medical attention.
To help prevent injection, always:
Engage trigger safety latch when not spraying.
Point gun away from yourself or anyone else.
Relieve pressure before checking or repairing any leak.
Relieve pressure when you turn off the sprayer or stop spraying.
Do not use components rated less than system
Maximum
Working Pressure
When flushing, ground equipment to grounded object with orange
wire clamp.
Do not flush equipment on asphalt or other non–conductive
surfaces.
Never allow children to use this unit. If you are injured using this
equipment, get immediate medical treatment.
Fire and explosion can occur when spraying or flushing flammable
fluid in an area where air circulation is poor and flammable vapors
can be ignited by an open flame or sparks.
To help prevent a fire and explosion:
Use outdoors or in an extremely well ventilated area.
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.
Remove, extinguish or unplug all ignition sources;
tape wall switch. Do not smoke in spray area.
Never fill fuel tank while the engine is running or hot.
Ground Sprayer, object being sprayed, paint and solvent pails.
Hold gun firmly to side of a grounded pail when triggering into pail.
Use only conductive airless paint hose.
Never run engine in inclosed area.
Do not flush with gasoline.
WARNING

 
Component Identification and Function
8825A
Fig. 1
U
W
AB
M
L
N
Model 232651
ENGINE SPEED ENGINE STOP
TIP SIZE
C
F
G
H
JK
P
R
S
T
V
APressure Control Switch ON/OFF, enables/disables clutch function
BPressure Adjusting Knob Controls fluid outlet pressure
CAir Cleaner* Filters air entering the carburetor
DFuel Tank* Uses 86 octane gasoline
EMuffler* Reduces noise of internal combustion
FSpark Plug Cable* Routes electrical current to spark plug
GFuel Shutoff Lever* On/off lever to regulate fuel flow from gasoline tank to carburetor
HChoke* Enriches air/gasoline mixture for cold starting
JThrottle Lever* Adjusts engine speed for large or small orifice spray tips
KEngine Switch* Enables/disables engine operation
LSecondary Fluid Outlet Second hose and spray gun is connected here
MPressure Control Controls clutch cycling to maintain fluid pressure
NPrimary Fluid Outlet Hose and spray gun is connected here
PEngine* 4–cycle gasoline engine
RClutch Housing Transfers power from engine to drive assembly
SDrive Housing Transfers power from clutch to displacement pump
TDisplacement Pump Provides fluid to be sprayed through spray gun
UFluid Filter Filters fluid between source and spray gun
VGrounding Clamp and Wire Grounds sprayer system
WPressure Drain Valve Relieves fluid pressure when open
*For more detailed explanations of these controls, refer to the Honda Engines Owner ’s Manual; supplied
1. Install the spray tip in the gun. Sprayer is supplied with tip LLT319. For additional applications, use the tip
selection table as follows:


Spay Tip Selection Guide
LineLazer Tip Selection Guide. Sprayer is supplied with tip LLT319. For additional applications, use the tip selec-
tion table as follows:
Note: the last three digits (LLT319) of the tip part number identifies the line width and tip orifice (opening) in millimeters.
For example: the line width for tip LLT319 is 4 in. as shown in the table below. The tip orifice for tip LLT319 is 19 mm.
LineLazer Tip Selection Table
Tip Size Line Width Used For
221211* 2 inches Sport court – light film build
LLT213* 2 inches Sport court – heavy film build
LLT215* 4 inches Alkyd paints only – light film build
LLT217 4 inches Alkyd paints only – medium film build
LLT219 4 inches Alkyd paints only – heavy film build
LLT315 4 inches Most traffic paints – light film build
LLT317 4 inches Most traffic paints – medium film build
LLT319 4 inches Most traffic paints – medium film build
LLT321 4 inches Most traffic paints – heavy film build
LLT323 4 inches Most traffic paints – heavy film build
LLT417# 4 – 8 inches All paints and high solids traffic paints – light film build
LLT419# 4 – 8 inches All paints and high solids traffic paints – medium film build
LLT421# 4 – 8 inches All paints and high solids traffic paints – heavy film build
LLT621 8 – 12 inches All traffic paints – light film build
LLT623 8 – 12 inches All traffic paints – medium film build
LLT625 8 – 12 inches All traffic paints – medium film build
LLT627 8 – 12 inches All traffic paints – heavy film build
* May require 100 mesh filter to minimize tip plugging.
# Best for cold weather applications.
How to Maximize Line Quality and Reduce T ip Wear. Observe the following suggestions to increase line quality
and minimize sprayer tip wear.
1. Select a larger tip orifice and run the sprayer at a reduced operating pressure.
2. Running larger tip sizes (example: use tip LLT321 @ 2000 psi instead of LLT317 @ 3300 psi) will significantly
increase tip life and reduce tip plugging. It will also produce a more uniform film build across the line.

 
Maintenance
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. To reduce the risk of
an injury from injection, splashing fluid, or moving
parts, follow the Pressure Relief Procedure
whenever you:
are instructed to relieve the pressure,
stop spraying,
check or service any of the system equipment,
or install or clean the spray tip.
Pressure Relief Procedure
1. Lock gun trigger safety.
2. Turn engine ON/OFF switch to OFF.
3. Move pressure control switch to OFF and turn
pressure control knob fully counterclockwise.
4. Unlock trigger safety. Hold metal part of gun firmly
to side of grounded metal pail, and trigger gun to
relieve pressure.
5. Lock gun trigger safety.
6. Open pressure drain valve. Leave valve open until
ready to spray again.
7. Disconnect 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, VERY SLOWLY
loosen tip guard retaining nut or hose end coupling to
relieve pressure gradually, then loosen completely.
Now clear tip or hose.
CAUTION
For detailed engine maintenance and specifications,
refer to separate Honda Engines Owner’s Manual,
supplied.
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 opera-
tion.
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 air filter cover and clean element.
Replace element, if necessary. If operating in an
unusually 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 oil.
MONTHLY: Oil connecting rod.
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.


Troubleshooting
WARNING
INJECTION HAZARD
To reduce risk of serious injury, including fluid injection or splashing in eyes or on skin, or injury from
moving parts, always follow Pressure Relief Procedure Warning, page 5, before checking, adjust-
ing, cleaning or shutting down sprayer. Disconnect spark plug!
Check everything in chart before disassembling sprayer.
PROBLEM CAUSE SOLUTION
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 rope 3 or 4
times. Clean or replace spark plug. Try to start
engine. Keep sprayer upright to avoid oil seep-
age.
Engine operates, but dis-
p
lacement
p
um
p
does not
Pressure control switch is OFF. Turn pressure control switch ON.
p
l
acement pump
d
oes not
operate. Pressure setting is too low. Turn pressure adjusting knob clockwise to
increase pressure.
Fluid filter (318) is dirty. Clean filter. See page 25.
Tip or tip filter is clogged. Clean tip or tip filter. See gun instruction
manual.
Displacement pump piston rod is stuck due to
dried paint.
Repair pump. See manual 308798.
Connecting rod is worn or damaged. Replace connecting rod. See page 8.
Drive housing is worn or damaged. Replace drive housing. See page 9.
Electrical power is not energizing field. Check wiring connections. See page 12.
Reference control board diagnostics. Page 15.
 ! # !
! !    
# #!   

"! # 
! # 
 !  # 1.2  0.2Ω
(LL 3900); 1.7  0.2Ω (LL 5900); if not, replace
pinion housing.
Check control board fuse. If blown, replace
with equivalent automotive fuse.
Have pressure control checked by authorized
Graco dealer.
Clutch is worn, damaged, or incorrectly
positioned.
Replace clutch. See page 10.
Pinion assembly is worn or damaged. Repair or replace pinion assembly, see pg 10.

 
PROBLEM CAUSE SOLUTION
Pump output is low on
u
p
stroke
Hose inlet screen (27) is clogged. Clean inlet screen.
upstro
k
e.
Piston ball (25) is not seating. Service piston ball. See manual 308798.
Piston packings are worn or damaged. Replace packings. See manual 308798.
O-ring (17) in displacement pump is worn or
damaged.
Replace o-ring. See manual 308798.
Pump output is low on down-
stroke or on both strokes
Hose strainer (27) is clogged. Clean strainer screen.
stro
k
e or on
b
ot
h
stro
k
es.
Piston packings are worn or damaged. Replace packings. See manual 308798.
Intake valve ball is not seating properly. Clean intake valve. See manual 308798.
Engine speed is too low. Increase throttle setting. See manual 308873.
Clutch is worn or damaged. Replace clutch. See page 10.
Paint leaks into wetcup. Wetcup is loose. Tighten wetcup just enough to stop leakage.
Throat packings are worn or damaged. Replace packings. See manual 308798.
Displacement rod is worn or damaged. Replace rod. See manual 308798.
Fluid delivery is low. Inlet screen is clogged. Clean inlet screen.
Pressure setting is too low. Increase pressure. See manual 308873.
Engine speed is too low. Increase throttle setting. See manual 308873.
Fluid filter (318), tip filter or tip is clogged or
dirty.
Clean filter. See manual 308873. Or, see gun
instruction manual.
Large pressure drop in hose with heavy
materials.
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).
Fluid is spitting from gun. Air in pump or hose. Check and tighten all fluid connections.
Reprime pump. See manual 308873.
Tip is partially clogged. Clear tip. See gun instruction manual.
Fluid supply is low or empty. Refill fluid supply. Prime pump. See manual
308873. Check fluid supply often to prevent
running 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. Reas-
semble valve.
Pump packings are worn. Replace pump packings. See manual 308798.
Paint is too thick. Thin the paint according to the supplier’s
recommendations.
Engine speed is too high. Decrease throttle setting before priming pump.
See manual 308873.
Clutch squeaks each time
clutch engages.
Small irregularities of new clutch surfaces
grind together and cause noise
Clutch surfaces need to wear into each other.
Noise will dissipate after a day of run time.


Bearing Housing and Connecting Rod
NOTE: The item numbers referenced are for the
Hi-Boy models. The Lo-Boy models may have different
item numbers. Use the Hi-Boy item number and part to
find the corresponding Lo-Boy part and item number.
Removal
1. Relieve pressure; page 5.
2. Fig. 3. Remove screws (29) and front cover (86).
3. Unscrew suction tube (27) from pump, hold
wrench on pump intake valve (A) to keep pump
from loosening.
4. Disconnect pump outlet hose (25) from displace-
ment pump outlet nipple (107).
5. Fig. 2. Use screwdriver to push up retaining spring
(83) at top of pump. Push out pin (82).
Fig. 2 
82
83
6. Fig. 3. Loosen jam nut (81). Unscrew and remove
displacement pump.
7. Remove four screws (31) and lockwashers (32)
from bearing housing (84).
8. Pull connecting rod (85) and lightly tap lower rear
of bearing housing (84) with plastic mallet to
loosen from drive housing (87). Pull bearing hous-
ing and connecting rod assembly (85) off drive
housing.
9. Inspect crank (B) for excessive wear and replace
parts as needed.
Installation
10. Evenly lubricate inside of bronze bearing (C) in
bearing housing (84), and inside of connecting rod
link (D), with high-quality motor oil ( do not use
grease ). Liberally pack roller bearing (E) in con-
necting rod assembly (85) with bearing grease.
11. Assemble connecting rod (85) and bearing housing
(84).
12. Clean mating surfaces of bearing and drive hous-
ings.
13. Align connecting rod with crank (B) and carefully
align locating pins (F) in drive housing (87) with
holes in bearing housing (84). Push bearing hous-
ing onto drive housing or tap into place with plastic
mallet.
CAUTION
DO NOT use bearing housing screws (31) to align
or seat bearing housing with drive housing. Align
these parts with locating pins (F), to avoid prema-
ture bearing wear.
14. Install screws (31) and lockwashers (32) on bear-
ing housing. Tighten evenly to 175 in-lb (19 Nm).
15. Refer to Displacement Pump, Installation, page 16.
84
31,32
29
83
82
B
25
81
85
CE
107
Pack with bearing grease 114819
Oil
A
F
27
3
2
1
1
2
3
Fig. 3 Model 232651 shown
86
87
D
8796A
LL 3900: Torque to 200 in-lb (22.6 Nm)
LL 5900: Torque to 25 ft-lb (34 Nm)
80

 
Drive Housing
Removal
1. Relieve pressure; page 5.
2. Fig. 4. Remove bearing housing. Do 1. through 8.
of Bearing Housing and Connecting Rod proce-
dure on page 8.
3. Remove two screws (51) and lockwashers (50).
4. Remove four screws (89) and lockwashers (50)
from pinion housing (88a).
5. Lightly tap around drive housing (87c) to loosen
drive housing. Pull drive housing straight off pinion
housing. Be prepared to support gear cluster (78),
which may also come out.
Installation
1. Liberally apply bearing grease (supplied with
replacement gear cluster) to gear cluster (78). and
to areas called out by note 3. Use full 0.62 pint
(0.29 liter) of grease for LL 3900 and 0.68 pint
(0.32 liter) of grease for LL 5900.
2. Place bronze colored washer (87g) on shaft pro-
truding from large shaft of drive housing(87c).
Place silver colored washer (87h) on pins on pinion
housing. Align gears and push new drive housing
straight onto pinion housing and locating pins (B).
3. Install four screws (89) and lockwashers (50) from
pinion housing (88a).
4. Install two screws (5) and lockwashers (50).
5. Fig. 3. Install bearing housing. Do 10. through 15.
of Bearing Housing and Connecting Rod proce-
dure on page 8.
8698A
Fig. 4
89 50
87h
87g
51 (LL 5900)
87c
88a
B
78
B
77 79
79
79
1
LL 3900 only
1
Torque to 125 in-lb – LL 3900
2
2
Torque to 200 in-lb – LL 5900
2
3
3
Apply remaining grease to these areas
50 (LL 3900)
52 (LL 5900)
51 (LL 3900)


Pinion Assembly/Rotor/Field/Shaft/Clutch
Removal
Fig. 6. If pinion assembly (88a) is attached to clutch
housing (92), do 1. through 4. Otherwise, start at 5.
1. Relieve pressure; page 5.
2. Fig. 5. Disconnect field cable (X) from pressure
control.
Fig. 5
X

3. Fig. 6. Remove five screws (89/96) and lockwash-
ers (50/51) and pinion assembly (88a).
50 (LL 3900)
Fig. 6 
88a
51 (LL 5900)
89 (LL 3900)
96 (LL 5900)
4. Fig. 7. Place pinion assembly (88a) on bench with
rotor side up.
Fig. 7
E
52
50

5. Remove four screws (52) and lockwashers (50).
Install two screws in threaded holes (E) in rotor.
Alternately tighten screws until rotor comes off.
6. Fig. 8. Remove retaining ring (Z).
7. Tap pinion shaft (A) out with plastic mallet.
Fig. 8
Z
A

8. Fig.9. Use an impact wrench or wedge something
between clutch and clutch housing to hold clutch
during removal.
9. Remove four screws (50) and lockwashers (53).
10. Remove clutch (91).
Fig. 9
53
50
91
