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Graco LINE LAZER GM 5000 Series, Instructions And Parts List

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Graco LINE LAZER GM 5000 Series Instructions And Parts List Download Page 24

Troubleshooting

WARNING

To reduce the risk of serious bodily injury, always fol-

low the 

Pressure Relief Procedure W arning

 on

page 4 before repairing the sprayer.

Check everything in the chart before disassembling the sprayer.  

(Continued on page 25.)

PROBLEM

CAUSE

SOLUTION

Engine/sprayer won’t start

Engine switch not on

Turn on engine switch.

Out of gas

Refill gas tank.

Engine oil level low

Try starting engine. If light on rear of 

engine

glows, replenish oil.

Spark plug cable disconnected or

spark plug damaged

Connect cable on top of engine or replace spark

plug.

Water frozen in pressure control

Return pressure control to authorized Graco

dealer for repair.

Engine won’t “fire”

Oil seepage into combustion

chamber

Remove spark plug. Pull starter rope 3 or 4 times.

Clean and replace plug. Try to start. Keep spray-

er upright to avoid oil seepage.

Engine operates, but displacement

pump doesn’t

Pressure control switch turned OFF

Turn on pressure control switch.

Pressure setting too low

Increase pressure.

Displacement pump outlet filter dirty

Clean filter.

Tip or tip filter clogged

Clean tip or tip filter.

Displacement pump rod seized by

dry paint

Service pump. See page 28.

Connecting rod worn or damaged

Replace connecting rod. See page 30.

Drive housing worn or damaged

Replace drive housing. See page 31.

Electrical power not energizing field

Check wiring connections. See page 36.
With pressure control switch ON and pressure

turned to MAXIMUM, use a test light to check

continuity  across black and white wires from

pressure control.
Have pressure control checked by authorized

Graco dealer.

Clutch worn or damaged

Service clutch. See page 34.

Pinion assembly worn or damaged

Service pinion assembly. See page 32.

Engine starts but dies

Oil level drops below oil sensor

Add oil.

Displacement pump output low on

upstroke

Pump inlet screen clogged

Clean screen.

Piston ball check not seating

Service piston ball check. See page 26.

Piston packings worn or damaged

Replace packings. See page 26.

Sleeve gasket in displacement pump

worn or damaged

Replace sleeve gasket. See page 26.

Summary of Contents for LINE LAZER GM 5000 Series

Page 1: ...re airless spray or leaks especially hose leaks Keep body clear of the nozzle Never stop leaks with any part of the body Drain all pressure before removing parts Avoid accidental triggering of gun by always setting safety latch when not spraying Never spray without a tip guard In case of accidental skin injection seek immediate Surgical Treatment Failure to follow this warning can result in amputa...

Page 2: ...t J Carriage bar K Gun holder L Rac IV tip guard M Switch Tip N Flex gun O Displacement pump P Caster Q Dual gun selector cable R Pressure control S Spark plug cable T AIr Cleaner U Muffler V Fuel Tank W Hook eyelet use to strap pail or pail cover to cart X Pail cover Y Caster Cable A B C D E F G H J K L M N O P Q R S T U V W X Y 02154 ...

Page 3: ...e 35 Field Wiring Harness 36 Clamp 37 Clutch Housing Removal 37 Reassembly 38 Parts Displacement Pump Parts 40 Pressure Control Parts 41 Cart Parts 42 Mechanical Parts 44 Gun Mounting Parts 46 Pinion Parts 47 Accessories Back Page Warranty Back Page Technical Data Engine 5 0 Horsepower Honda Maximum Working Pressure 3000 psi 210 bar Noise Level Sound Power 105 dbA Sound Pressure 97 dbA 1 meter und...

Page 4: ...l pail holding the gun firmly to the pail Using the lowest possible pres sure trigger the gun If the fluid emitted is not diffused into an irregular stream replace the diffuser immediately Tip Guard ALWAYS have the tip guard in place on the spray gun while spraying The tip guard alerts you to the fluid injection hazard and helps reduce but does not prevent the risk of accidentally placing your fin...

Page 5: ... Check the electrical resistance of your fluid hoses at least once a week If your hose does not have a tag on it which specifies the maximum electrical resistance contact the hose supplier or manufacturer for the maximum re sistance limits Use a resistance meter in the appropriate range for your hose to check the resistance If the resistance exceeds the recommended limits replace it immediately An...

Page 6: ...du pistolet sert à diviser le jet et à réduire les risques d injection accidentelle quand l ajutage n est pas en place Véri fier le fonctionnement du diffuseur régulièrement Pour cette vé rification détendre la pression en observant la Marche à Sui vre Pour Détendre la Pression donnée plus loin enlever l ajutage du pulvérisateur Pointer le pistolet dans un seau en métal en le maintenant fermement ...

Page 7: ...e ou avec une mise à la terre incorrecte peut entraîner des risques pour votre système Lisez aussi les risques d incendie ou d explosion RISQUES D INCENDIE OU EXPLOSION De l électricité statique est produite par le passage du fluide à grande vitesse dans la pompe et dans les tuyaux Si toutes les pièces de l appareil de pulvérisation ne sont pas convenable ment reliées ou à la masse ou à la terre d...

Page 8: ...lo puede llevar al disparo imprevisto de la pistola Difusor El difusor de la pistola dispersa el chorro pulverizado y reduce el riesgo de inyección cuando no está instalada la boquilla Re visar con regularidad el funcionamiento del difusor Seguir el procedimiento de descarga de presión dado más abajo y después sacar la boquilla Apuntar la pistola a un balde metáli co sosteniéndola bien firme contr...

Page 9: ...las condiciones Leer también la infor mación sobre RIESGO DE INCENDIO O EXPLOSION más arriba PELIGRO DE INCENDIO O EXPLOSION El flujo a alta velocidad del fluido al pasar por la bomba y man guera crea electricidad estática Si todas las partes del equipo pulverizador no tienen buena tierra pueden ocurrir chispas convirtiéndo al sistema en algo peligroso T ambién pueden producirse chispas al enchufa...

Page 10: ...is increases the risk of hazardous static electric discharge which can result in serious bodily injury fire or explosion and property damage Whenever you flush connect the ground clamp 159 to a true earth ground Using as an outdoor striper Be sure the static chain attached to the bottom of the cart drags on the ground to help dissipate static electricity Ground the sprayer to a true earth ground i...

Page 11: ...losive un der certain conditions To reduce the risk of a fire or explosion 1 Always shut off the engine before refueling 2 Refuel in a well ventilated area 3 Do not smoke or allow flames or sparks in the area where the engine is refueled or where the gasoline is stored 4 Do not overfill the tank Make sure the filler cap is securely closed after refueling 5 Fuel vapor or spilled fuel can ignite If ...

Page 12: ...lamps B C 5 Slide the second gun bar 404 far enough into the carriage bar that the clamp 405B engages the bar Position the clamps 405A 405B over the notches A in the carriage bar 4 and tighten the clamps NOTE For stable gun operation the second gun bar 404 has a maximum recommended extension from the carriage bar of about 11 1 4 286 mm 6 Disconnect the trigger cable from the second gun at the scre...

Page 13: ... the pressure drain valve 13 4 Put the suction tube in a grounded pail of water or solvent 5 Remove the gun s from the holder Remove the spray tip s to prevent splashing WARNING To reduce the risk of static sparking and splashing when flushing always remove the spray tip from the gun and hold a metal part of the gun firmly to the side of and aimed into a grounded metal pail 6 Follow Startup on pag...

Page 14: ... weather In cold weather leave the choke closed for 10 to 30 seconds before opening it to keep the engine running 6 Release the trigger cable and engage the gun trigger safety latch See page 22 7 Remove the gun from the holder by unscrewing the gun holder knob and lifting out the gun 8 To start the pump NOTE Lower the throttle setting for easier priming a Open the pressure drain valve R b Turn ON ...

Page 15: ...r which makes start up very difficult E A B H C D AT REAR OF ENGINE KEY A Engine Oil Light B Engine On Off Switch C Throttle Lever D Gray Choke Lever E Black Fuel Shutoff Lever F Pail Cover G Starter Rope H Air Cleaner J Spark Plug Cable K Pressure Control On Off Switch L Pressure Adjusting Knob M SwitchTip N Rac IV Tip Guard P Gun Trigger Safety Latch Q Remote Trigger Cable R Pressure Drain Valve...

Page 16: ... the spray tip guard J See Fig 9 Place the seat E on a pencil curved side out as shown in Fig 10 Guide the seat into the retaining nut A and turn the seat until it straddles the cylinder of the spray tip F Drop in the appropriate gasket and press it down If using the red or yellow gasket C be sure the flat side faces out of the retainer A See Fig 9 Screw the spray tip guard snugly onto the gun hol...

Page 17: ...that many factors af fect the straight ness of a line including uneven surfaces potholes rocks and other debris and a clogged or worn spray tip See page 16 for how to clear or change a spray tip 7 To minimize the effect of bumps on the spray pattern keep the spray tip guard centered with the front wheel axis 8 The spray tip size and the rate at which you move the unit affect the coating thickness ...

Page 18: ...together to obtain the max imum distance of one gun from the unit which is helpful when spraying around obstacles Horizontal Position of the Second Gun Method 1 Disengage the trigger cable Loosen the clamps 405A 405B Slide the second gun bar 404 horizontally being sure both clamps engage the second gun bar Tighten the clamps Engage the trigger cable Method 2 Disengage the trigger cable Loosen the ...

Page 19: ... A 6 Fig 14 Adjust Simultaneous Gun Triggering WARNING To reduce the risk of a fluid injection injury always dis engage the trigger cable to the gun s and engage the guns trigger safety latch before moving or adjusting the guns or gun arms 1 Align the front of the guns by adjusting the gun arms See page 18 2 Position the dual gun selector to trigger both guns See page 21 3 Start the sprayer using ...

Page 20: ... Gun Arm Positions ONE GUN CURB SINGLE LINE DOUBLE LINE OR SINGLE LINE UP TO 24 WIDE TWO GUN CURB DOUBLE LINE OR SINGLE LINE UP TO 24 WIDE SINGLE OR DOUBLE LINE SPRAYING AROUND OBSTACLES 0017 ...

Page 21: ...k E Re move screw G and the tire 1 14a Install the new tire and the setscrews F Tighten the setscrews equally so the tire has no play in it but turns freely Caster Cable Tension Adjustment See Fig 16 1 Loosen the nut A located just outside the carriage clamp B 2 With the pin D fully engaged in the caster fork E pull back on the cable 2 to increase the cable ten sion or push it forward to reduce th...

Page 22: ...the cable grasp the cable 1or 402 just behind the block 48 Pull the cable back about 1 2 inch 13 mm and then up and out of the block The gun will trigger briefly See Fig 19 2 To engage the cable slide the cable 1 into the block 48 making sure the end of the cable jacket seats firmly in the seat of the block The gun will trigger briefly See Fig 19 CAUTION Keep the seat in the gun cable block 48 and...

Page 23: ...e ment In very dusty environments check the filter daily Replace the element as needed Replacement elements can be purchased from your local HONDA dealer Weekly Check the level of the TSL in the displace ment pump packing nut Fill the nut if necessary Keep TSL in the nut to help lubricate the pump packings See page 10 Weekly Use a grease gun to grease the zerks 32 on this unit The grease purges pi...

Page 24: ...n pressure control switch Pressure setting too low Increase pressure Displacement pump outlet filter dirty Clean filter Tip or tip filter clogged Clean tip or tip filter Displacement pump rod seized by dry paint Service pump See page 28 Connecting rod worn or damaged Replace connecting rod See page 30 Drive housing worn or damaged Replace drive housing See page 31 Electrical power not energizing f...

Page 25: ... suction tube as sembly separately to prevent further clogging Large pressure drop in hose Use larger diameter hose Paint leaks into wet cup Loose wet cup Tighten wet cup just enough to stop leakage Throat packings worn or damaged Replace packings See page 26 Displacement rod worn or damaged Replace displacement rod See page 26 Spitting from gun Air in fluid pump or hose Check for loose connection...

Page 26: ...nscrew the intake valve 223 and remove all parts See Fig 21 2 Remove the plug 205 Unscrew the packing nut 216 See Fig 22 213 209 216 205 208 222 211 219 224 207 Fig 22 3 Tap the piston rod 224 down and then pull it out the bottom of the cylinder 219 See Fig 22 4 Remove the glands 209 208 and v packings 207 213 from the throat See Fig 22 5 Clamp the flats of the piston rod 224 in a vise Loos en the...

Page 27: ... 5 Tighten the nut 211 onto the rod 224 to 19 ft lb 25 N m Use two wrenches to maintain the alignment as mentioned in Step 3 6 Stack the throat packings into the top of the cylinder 219 Install the packing nut 216 loosely C D 219 218 202 0030 Fig 26 7 Insert the piston rod assembly C into the top of the sleeve 218 Install the gasket 202 on the sleeve Slide the sleeve assembly into the bottom of th...

Page 28: ...ductor and wires out with it See Fig 29 5 Use a wrench to hold the hex of the adapters C while removing the swivel unions 108 See Fig 29 WARNING To reduce the risk of electric shock be sure all grounding features of the pressure control are prop erly assembled 1 Ground wire 308 connected in pressure control 2 Serrated flange capscrews to mount the pres sure control to the cart 3 Grounding chain 10...

Page 29: ... No 223 541 0 5000 psi 0 350 bar fluid filled pressure gauge Part No 102 814 New spray tip size 0 025 to 0 029 3 8 in ignition wrench or nut driver 5 gallon pail of water or mineral spirits Swivel 156 823 Nipple 162 453 Tee 104 984 Set Up 1 Follow the Pressure Relief Procedure Warning on page 4 2 Set up the system as shown in Fig 30 Set the Dead Band Pressure Differential 1 Remove the pressure con...

Page 30: ... necting rod link D with high quality motor oil Liber ally pack the roller bearing E in the connecting rod assembly 79 with bearing grease 77d supplied 6 Assemble the connecting rod 79 and bearing hous ing 76 7 Clean the mating surfaces of the bearing and drive housings 8 Align the connecting rod with the crank A and care fully align the locating pins F in the drive housing 77 with the holes in th...

Page 31: ... gear may stay engaged in either the drive housing or the pinion housing DO NOT lose the thrust balls 77c and 138k located at each end of the gear cluster The balls which are heavily covered with grease usually stay in the shaft recesses but they could be dislodged If they are caught between the gears and not removed the balls will seriously damage the drive housing If the balls are not in place t...

Page 32: ...information NOTE To disassemble the pinion continue with Repair ing the Pinion below To disassemble more of the sprayer go to page 34 To reassemble the sprayer from this point skip ahead to Reassembly page 39 Step 8 Repairing the Pinion NOTE A hydraulic press is required for disassembly and reassembly if you purchase the pinion parts individually If you do not have such a press use Repair Kit No 2...

Page 33: ... steel blocks and bar stock when pressing off large bearing Hub 138f Steel bar stock Two steel blocks Round steel bar to push on shaft 138b Large bearing 138d 1 3 4 2 1 2 3 4 5 5 6 7 6 Hydraulic press Press plataform 7 4 Using a hydraulic press place pieces of steel bar stock on the inner race of the large bearing 138d and press the shaft through the hub and bearing Then turn the shaft over and pr...

Page 34: ...ing three screws 67 4 Tap lightly on the back of the bearing housing 77 with a plastic mallet to loosen the assembly D from the clutch housing 61 Pull the assembly away the armature 55a will come with it 5 Remove the armature from the pinion shaft 6 Remove the four socket head capscrews 157 and lockwashers 156 Install two of the screws in the threaded holes in the rotor 55b Alternately tighten the...

Page 35: ...Disconnect the black and white wires 58 from the field Pull the wires carefully through the grommets 24 before removing the en gine See Fig 39 and 40 3 Lift the engine carefully and place it on a work bench 4 Remove the Field and Wiring Harness Clamp and Clutch Housing as instructed on pages 36 and 37 5 Skip ahead to Reassembly page 38 Step 1 NOTE All service to the engine must be performed by an ...

Page 36: ... housing 61 Unplug the wiring harness 58 from under the engine mounting plate Pull the field out to expose the black and white wires 58 2 Pull the caps A of f the wire screws 57 in both places on the field Loosen the screws and release the wires 58 3 Skip ahead to Reassembly page 38 Step 4 Fig 41 57 58 A 70 61 62 0046 ...

Page 37: ... working through the slot at the bottom of the clutch housing 61 2 Install two screws B of the tool A in two of the threaded holes in the clamp T ighten the screws C until the clamp comes off 3 Skip ahead to Reassembly page 38 Step 3 or continue below Clutch Housing NOTE Refer to Fig 43 1 Remove the four capscrews 8 and lock washers 48 which hold the clutch housing 2 to the engine 1 2 Remove the e...

Page 38: ... 14 N m 4 Connect the wires of the harness 58 to the screws 57 in both places on the field Pull the plastic caps C up and snap them over the screws Guide the wires of the harness 58 through the slot in the clutch housing Slide the field 70 into the clutch Align the setscrew chamfers in the field and the clutch housing 61 T ighten the setscrews 62 oppositely and evenly to 25 in lb 2 8 N m See Fig 4...

Page 39: ...ngine turns freely and there is no friction between the rotor 55b and the field 61 If there is friction loosen the setscrews 62 and reposition the field 61 as necessary Tighten the setscrews oppositely and evenly to 25 in lb 2 8 N m Also make sure there are no burrs on the out side edge of the rotor 7 Be sure the face of the armature 55a is clean As semble the armature to the shaft in the pinion h...

Page 40: ... 179 NUT hex retaining 1 212 183 182 V PACKING polyethylene 3 213 183 183 V PACKING polyethylene 3 214 186 653 WASHER backup 1 215 183 185 GLAND female 1 216 183 186 NUT packing 1 217 183 172 O RING 1 218 183 361 SLEEVE cylinder 1 219 183 181 CYLINDER 1 220 183 180 GUIDE ball 1 221 183 173 PIN ball stop 1 222 220 631 VALVE piston 1 223 220 629 VALVE intake 1 224 220 630 ROD piston 1 225 101 947 BA...

Page 41: ... 157 021 LOCKWASHER No 8 internal 2 306 100 284 NUT hex 8 32 1 308 220 979 CONDUCTOR red 2 309 220 978 CONDUCTOR red white black 1 310 100 035 SCREW mach slotted pan hd 8 32 x 312 1 311 108 783 SCREW mach flat hd 8 32 x 812 1 313 108 852 CONNECTOR 45 1 316 222 352 TRIAC 1 317 107 070 SCREW flat head 6 32 x 625 2 318 100 072 NUT hex 6 32 2 319 103 181 LOCKWASHER No 6 external 2 320 101 754 PLUG pip...

Page 42: ...1 84 90 34 35 94 36 38 39 114 3 83 1 110 104 26 24 28 33 32 33 139 37 40 42 117 87 116 115 112 41 25 105 40 32 30 30 26 52 99 150 160 107 40 2 147 40 41 159 REF 3 B E E 86 85 118 114a 163 See page 43 See page 46 Label 1 3 4 2 See page 44 3 1 1 2 Parts Cart ...

Page 43: ... drain 78 1981 mm 1 85 103 473 WIRE TIE STRAP 2 86 185 381 HOSE suction 1 ID x 41 1041 mm 1 87 111 193 CAPSCREW serrated flange hex hd 3 8 16 x 7 8 2 90 187 147 STRAINER 16 mesh 1 94 186 747 LEVER actuator 1 99 101 345 NUT hex jam 1 4 20 1 104 108 868 CLAMP wire 2 105 100 731 WASHER 3 8 2 107 186 620 LABEL grounding 1 110 224 019 CART 1 112 224 066 CASTER LATCH Includes 1 of item 32 and 112a 1 114...

Page 44: ...6 66 59 67 74 73 109 135 REF 25 40 108 REF 133 106 105 40 26 REF 133 18 111 13 12 43 14 15 Ref 2 Ref 84 55a 56b 70 77a 77b 77c B A A 50 132 51 85 REF 86 16 17 61 104 26 59 60 155 88 C C D D 107 129 1 1 2 3 2 4 1 2 6 See page 42 See page 40 Label Located on bottom Located on inside of cover Located on outside of cover 1 3 4 2 5 6 02168 59 58 REF 24 2 6 ...

Page 45: ...1 8 special 1 72 155 494 UNION 90 3 8 npt x 3 8 npsm swivel 1 73 108 850 SCREW mach filh 8 32 x 1 1 4 4 74 183 168 COVER drive housing 1 75 183 169 SPRING retaining 1 76 220 639 BEARING HOUSING 1 77 220 879 DRIVE HOUSING Includes items 77a to 77d 1 77a 106 227 WASHER bronze 1 77b 183 209 WASHER silver 1 77c 100 069 BALL 1 77d 110 293 GREASE not shown 1 78 220 919 GEAR REDUCER 1 79 220 640 CONNECTI...

Page 46: ...47 LEVER actuator 1 95 188 452 HOLDER gun 1 96 108 483 SCREW shoulder sch 1 4 x 3 8 1 97 181 795 JAW clamp 1 98 235 459 FLEX GUN See manual 308 235 for parts 1 99 101 345 NUT hex jam 1 4 20 2 100 108 535 BEARING sleeve 1 101 107 445 CAPSCREW sch 1 4 20 x 1 1 2 1 103 111 045 SCREW shoulder sch 5 16 x 1 1 113 LLT 319 Line Lazer Tip Sz 319 1 123 110 755 WASHER 1 132 100 133 LOCKWASHER 3 8 1 136 220 4...

Page 47: ...ing internal 1 138n 105 489 PIN dowel 2 138p 183 394 HOUSING pinion 1 138h 138m 138a 138n 138e 138f 138d 138b 138c 138j 138k 138p 0042 1 3 2 Lubricate exterior Lubricate inner and outer diameters Lubricate teeth 1 1 2 2 3 Manual Change Summary This sprayer now complies with the European Commu nity Directives that are required in order to use the CE mark which is shown on the cover of this manual T...

Page 48: ...ment of structures accessories equipment or materials not supplied by Graco or the improper design manufacture instal lation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized Graco distributor for verification of the claim If the claimed defec...

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