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Graco LineLazer 3400 Operation - Repair - Parts Download Page 22

Troubleshooting 

22

3A4587B Operation, Repair, Parts

Troubleshooting

Problem

Cause

Solution

Engine will not start

Engine switch is OFF

Turn engine switch ON

Engine is out of gasoline

Refill gas tank. Honda Engines 
Owner's Manual.

Engine oil level is low

Check oil level. Replenish oil, if neces-
sary. Honda Engines Owner's Manual.

Spark plug is disconnected or dam-
aged

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 displacement 
pump does not operate

Pump switch is OFF

Turn pump switch ON

Pressure setting too low

Turn pressure adjusting knob clock-
wise to increase pressure.

Fluid filter (104) is dirty

Clean filter. Page 18.

Tip is clogged

Clean tip. Page 17.

Displacement pump piston rod is 
stuck due to dried paint

Repair pump. Manual 309250.

Connecting rod is worn or damaged Replace connecting rod. Page 24.
Drive housing is worn or damaged

Replace drive housing. Page 24.

Electrical power is not energizing 
clutch field

Check wiring connections. Page 32, 42.

Reference pressure control repair. 
Page 32.

Reference wiring diagram. Page 42.

With pump switch ON and pressure 
turned to MAXIMUM, use a test light to 
check for power between clutch test 
points on control board.

Remove clutch wires from control board 
and measure resistance across clutch 
coil. At 70° F, the resistance must be 
between 1.2+0.2 ohms; if not, replace 
pinion housing.

Have pressure control checked by 
authorized Graco dealer.

Clutch is worn, damaged, or incor-
rectly positioned

 Adjust or replace clutch. Page 27.

Pinion assembly is worn or damaged

Repair or replace pinion assembly. Page 
27.

Summary of Contents for LineLazer 3400

Page 1: ...300 psi 22 8 MPa 228 bar Maximum Operating Pressure Important Safety Instructions Read all warnings and instructions in this manual related manuals and on the equipment Be familiar with the controls and the proper usage of the equipment Save these instructions Related Manuals 311254 Gun 309250 Pump Operation Repair Parts LineLazer 3400 Airless Line Striper 3A4587B EN ti30298a ...

Page 2: ...6 Pinion Assembly Clutch Armature Clamp 27 Pinion Assembly Clutch Armature Removal 27 Installation 28 Clamp Removal 29 Clamp Installation 29 Clutch Housing 30 Removal 30 Installation 30 Engine 30 Removal 30 Installation 30 Pressure Control Transducer 31 Removal 31 Installation 31 Pressure Control On Off Switch 32 Removal 32 Installation 32 Pressure Adjust Potentiometer 33 Removal 33 Installation 3...

Page 3: ... parts Check hoses and parts for signs of damage Replace any damaged hoses or parts This system is capable of producing 3300 psi Use Graco replacement parts or accessories that are rated a minimum of 3300 psi Always engage the trigger lock when not spraying Verify the trigger lock is functioning properly Verify that all connections are secure before operating the unit Know how to stop the unit and...

Page 4: ...way from work area Comply with all applicable safety regulations PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture Failure to follow this warning can result in death serious injury or property damage Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon s...

Page 5: ... not limited to Protective eyewear and hearing protection Respirators protective clothing and gloves as recommended by the fluid and solvent manufacturer CALIFORNIA PROPOSITION 65 The engine exhaust from this product contains a chemical known to the state of California to cause cancer birth defects or other reproductive harm This product contains a chemical known to the State of California to caus...

Page 6: ...323 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 ti27606a in cm ti27505a in cm ti27506a in cm ti27507a in cm ti27508a ti27509a ti27510a ti27605a...

Page 7: ...3 12 11 18 5 4 9 10 4 5 PRIME SPRAY ti30299a 8 1 Pump ON OFF Switch 2 Pressure Control 3 Spray Gun Trigger 4 Filter 5 Pressure Gauge 6 Prime Valve 7 Pump 8 Trigger Lock 9 Choke 10 Engine ON OFF Switch 11 Throttle 12 Drain Hose 13 Suction Tube 14 Parking Brake 15 Adjustable Handle 16 Front Wheel Unlock Lock 17 Adjustable Pail Holder 18 Serial ID ...

Page 8: ...ot place pail on a non conductive surface such as paper or cardboard which interrupts grounding continuity Always ground a metal pail connect a ground wire to the pail Clamp one end to the pail and the other end to a true earth ground such as a water pipe To maintain ground continuity when sprayer is flushed or pressure is relieved hold metal part of spray gun firmly to the side of a grounded meta...

Page 9: ...e spray tip or hose is clogged or that pressure has not been fully relieved a VERY SLOWLY loosen tip guard retaining nut or hose end coupling to relieve pressure gradually b Loosen nut or coupling completely c Clear hose or tip obstruction This equipment stays pressurized until pressure is manually relieved To help prevent serious injury from pressurized fluid such as skin injection splashed fluid...

Page 10: ... filter cover and clean ele ment 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 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...

Page 11: ...e oil level See Honda engine manual 4 Fill fuel tank See Honda engine manual Check that tires are inflated to recommended pressure The equipment must be grounded to reduce the risk of static sparking Static sparking can cause fumes to ignite or explode Grounding provides an escape wire for the electric current ti30065a ti30066a ti27610a ti27611a ...

Page 12: ...lly filled with flushing fluid Attach ground wire to pail and to true earth ground Use water to flush water base paint and mineral spirits to flush oil base paint and storage oil 3 Turn prime valve down 4 Turn pressure control counterclockwise to lowest pressure 5 Set pump switch to OFF 6 Start Engine a Move fuel valve to open b Move choke to closed ti27613a ti6254b ti6256b ti5696b ti27616b ti3049...

Page 13: ...crease pressure enough to start pump Allow fluid to circulate for 15 seconds 8 Turn pressure down close prime valve Disengage gun trigger lock 9 Hold gun against grounded metal flushing pail Trig ger gun and increase fluid pressure slowly until pump runs smoothly ti5250a ti27619a ti27620b ti27766b ti5250b NOTICE Do not run pump without fluid flow Damage to packings can occur ti30076a ti30077a ti30...

Page 14: ... fluid pail until paint appears Assemble Rac Tip and Rac Guard Rac Tip and Guard Assembly To prevent spray tip leaks make certain spray tip and tip guard are installed properly 1 Perform Pressure Relief Procedure page 8 2 Engage trigger lock Insert seat and Rac Tip Seal Insert Rac Tip 3 Screw assembly onto gun Hand tighten High pressure spray is able to inject toxins into the body and cause seriou...

Page 15: ...to gun holder with hose guard pressed against the holder assembly bracket Tighten gun into clamp Position Gun 2 Position gun up down and forward reverse 3 Position gun left right a Right side gun position Place gun and related hardware on right hand side ti30093a ti30300a ti30301a ti30302a ...

Page 16: ...and side 4 For Curb Position place gun at 45 angle 5 For Gun Arc Spray Position place gun at rear of striper Rear position improves arc quality NOTE Verify that the gun can still be triggered and that the trigger lock can still be engaged after installation Make adjustments if necessary ti30303a ti30098a ti30099a ...

Page 17: ...y test pattern Slowly adjust pressure to eliminate heavy edges Use smaller tip size if pressure adjustment can not eliminate heavy edges Clearing Tip Clogs 1 Release trigger Engage gun trigger lock Rotate Rac Tip Disengage gun trigger lock and trigger gun to clear the clog 2 Engage gun trigger lock return Rac Tip to original position disengage gun trigger lock and continue spraying ti30304a ti3030...

Page 18: ... Assemble without filter Clean filter 4 Clean gun filter Rac Guard and Rac Tip in flushing fluid See Flushing Recommendations page 21 5 Remove siphon tube set from paint and place in flushing fluid Use water or pump conditioner for water base paint and mineral spirits for oil base paint 6 Turn engine ON and start engine Set pump switch ON ti30308a ti30309a ti30488a ti30112a ti27619a ...

Page 19: ...trol up until motor begins to drive pump Trigger gun until flushing fluid appears 10 Move gun to flushing pail hold gun against pail trig ger gun to thoroughly flush system Release trigger and engage trigger lock 11 Open prime valve and allow flushing fluid to circulate for 20 seconds to clean drain tube ti30114a ti30115a ti30116a ti30117a ti30118a ...

Page 20: ...ean Rac Tip Rac Guard and gasket with a soft bristle brush to prevent part failure due to dried materials Assemble parts and attach loosely onto gun 17 Wipe striper hose and gun with a rag soaked in water or mineral spirits NOTICE Do not run pump without fluid flow Damage to packings can occur NOTICE If flushing with water do not leave water in sprayer for extended periods Flush again with Pump Ar...

Page 21: ...ral spirits Spray water base paint Warm soapy water then clean water Water base paint Warm soapy water then clean water Mineral spirits Spray oil base paint Mineral spirits Oil base paint Mineral spirits Mineral spirits Change water base to oil base paint Warm soapy water then clean water Mineral spirits Mineral spirits Mineral spirits Change oil base to water base paint Mineralspirits soapywater ...

Page 22: ...ob clock wise to increase pressure Fluid filter 104 is dirty Clean filter Page 18 Tip is clogged Clean tip Page 17 Displacement pump piston rod is stuck due to dried paint Repair pump Manual 309250 Connecting rod is worn or damaged Replace connecting rod Page 24 Drive housing is worn or damaged Replace drive housing Page 24 Electrical power is not energizing clutch field Check wiring connections P...

Page 23: ...acking nut just enough to stop leakage Throat packings are worn or damaged Replace packings Manual 309250 Displacement rod is worn or damaged Replace rod Manual 309250 Fluid is spitting from gun Air in pump or hose Check and tighten all fluid connections Reprime pump Tip is partially clogged Clear tip Page 17 Fluid supply is low or empty Refill fluid supply Prime pump Check fluid supply often to p...

Page 24: ...ressure Relief Procedure page 9 3 Loosen two screws 108 and remove pump rod cover 107 4 Remove hose 118 and suction hose 57 Use screwdriver push retaining spring up push out pin 31 5 Loosen jam nut by hitting firmly with a hammer Unscrew pump Repair See manual 309250 for pump repair instructions 107 108 ti30159a 31 201 118 57 ti30160a ti30161a ...

Page 25: ...hten jam nut by hand then tap 1 8 to 1 4 turn with a 20 oz maximum hammer to approximately 75 5 ft lb 102 N m Connect hose 118 and suc tion hose 57 4 Fill packing nut with TSL until fluid flows onto the top of seal Install pump rod cover 107 If pin works loose parts could break off due to force of pumping action Parts could project through the air and result in serious injury or property damage Ma...

Page 26: ...od to lowest position 3 Apply grease to washers 46 49 and 48 Install in order 4 Lubricate gears with 0 26 pint of 110293 grease supplied with drive housing Pack grease evenly around gears 5 Clean mating surfaces of pinion and drive housings 6 Align connecting rod with crank 47 and carefully align locating pins in drive housing 43 with holes in pinion housing 44 Push drive housing onto pinion housi...

Page 27: ...ive housing page 26 3 Disconnect clutch and clutch connectors from wire harness located under sprayer cart 4 Remove four screws 34 and pinion assembly 44 5 Place pinion assembly 44 on bench with rotor side up 6 Remove four screws 42 and lock washers 35 Install two screws in threaded holes E in rotor Alternately tighten screws until rotor comes off 7 Remove retaining ring 44d 8 Turn pinion assembly...

Page 28: ... surface 4 Install armature 39 on engine drive shaft 5 Install four screws 36 and lock washers 35 with torque of 125 in lb Pinion Assembly 6 Install o ring 44e 7 Tap pinion shaft 44c in with plastic mallet 8 Install retaining ring 44d with beveled side facing up 9 Place pinion assembly on bench with rotor side up 10 Apply locktite to screws Install four screws 42 and lock washers 35 Alternately to...

Page 29: ...mp Clamp Installation 1 Install engine shaft key 37 2 Tap clamp 38 onto engine shaft A Maintain dimension shown note 2 Chamfer must face engine 3 Check dimension Place rigid straight steel bar B across face of clutch housing 45 Use accurate mea suring device to measure distance between bar and face of clamp Adjust clamp as necessary Torque two screws 36 to 125 10 in lb 14 1 1 N m Face of clutch ho...

Page 30: ...oval NOTE All service to the engine must be performed by an authorized HONDA dealer 1 Remove Pinion Assembly Clutch Arma ture Clamp and Clutch Housing as instructed on pages 27 29 and 30 2 Disconnect all necessary wiring 3 Remove two locknuts 111 and screws 110 from base of engine 4 Lift engine carefully and place on work bench Installation 1 Lift engine carefully and place on cart 2 Install two s...

Page 31: ...oard 62e 3 Pull transducer connector through strain relief bushing 151 4 Remove transducer and o ring 99 from filter housing 67 Installation 1 Install o ring 99 and transducer 155 in filter hous ing 67 Torque to 35 45 ft lb 2 Install transducer connector and strain relief bush ing in control housing 3 Connect lead 155 to control board 62e 4 Close cover 62a and secure with two screws 108 ...

Page 32: ...ector from PC board 4 Press in on two retaining tabs on each side of ON OFF switch 62d and remove switch from cover Installation 1 Install new ON OFF switch 62d so tabs of switch snap into place on inside of cover 2 Connect ON OFF switch connector B to PC board 3 Close cover 62a and secure with two screws 108 ti6389a 62d 62c 62b 62a 62e 62g 62f 155 62b ground green yellow pink from engine clutch c...

Page 33: ...cover 62a b After adjustment of step a tighten both set screws in knob 1 4 to 3 8 turn after contact with shaft 3 Connect potentiometer 62b lead to control board 62e 4 Close cover 62a and secure with two screws 108 Control Board Removal 1 Remove two screws 108 and open cover 62a 2 Disconnect engine and ground wires from wire harness 66 3 Disconnect at control board 62e Lead from potentiometer 62b ...

Page 34: ...4 1 5 10 7 6 64 93 2 65 91 64 93 112 114 8 9 26 14 115 153 92 13 137 87 192 86 194 114 81 82 83 84 60 64 93 3 16 131 15 110 111 54 19 89 89 85 72 11 94 97 132 9 90 149 74 74 25 151 143 66 62 129 108 147 183 148 184 170 55 53 59 53 130 68 68 201 144 150 172 ti30311a 96 18 ...

Page 35: ...1 BEARING 1 84 113961 SCREW cap hex hd 1 85 867517 SCREW hex head 3 8 16 x 3 5 4 86 111802 SCREW 4 87 111801 SCREW cap hex hd 4 89 17N536 HOLDER bucket 2 90 15F047 CONTROL box 1 91 113665 SCREW cap hex hd 1 92 114802 WIRE stop 1 93 119554 NUT lock nylon thin pattern 4 94 24Z284 BAR handle LL 1 96 114271 STRAP hose wrap 1 97 116935 SCREW cap flng hd 2 108 128978 SCREW 8 32 hex washer head 6 110 112...

Page 36: ...36 3A4587B Operation Repair Parts Parts Drawing 45 20 145 40 51 50 39 38 44 41 42 36 35 35 35 35 36 34 46 49 48 47 34 34 146 52 107 108 142 108 43 141 118 30 27 31 29 28 33 130 57 136 56 140 139 75 68 57 ti30312a 37 ...

Page 37: ...E535 HOUSING clutch machine 1 46 116074 WASHER thrust 1 47 287484 CRANK GMAX 3400 includes 46 48 49 1 48 180131 BEARING thrust 1 49 107434 BEARING thrust 1 50 100214 WASHER lock 4 51 108842 SCREW cap hex hd 4 52 287487 COVER front painted 1 56 246385 STRAINER 7 8 14 unf 1 57 17M875 HOSE suction includes 33 136 1 68 404989 STRAP tie 6 75 249232 HOSE cpld 1 4 in X 3 0 ft 1 107 15B589 COVER pump rod ...

Page 38: ...d List Pinion Housing Ref No 44 Pinion Housing May be ordered separately Ref Part Description Qty 44 287376 PINION HOUSING 1 44a 287482 KIT repair coil 1 44b 105489 PIN 2 44c 287485 PINION SHAFT 1 44d 113094 RETAINING RING large 1 44e 165295 O RING packing 1 44 44a 44e 44b 44c 44d ti30133a ...

Page 39: ...02040 NUT lock 3 20g 17J576 SPACER special 1 21 243161 GUARD Rac V 1 23 24Y645 KIT clamp 1 24 17J145 ARM holder gun 1 25 15F213 BRACKET cable 1 70 119648 SCREW mach trusshd cross recess 1 72 17J407 BRACKET support gun 1 73 119647 SCREW cap socket flthd 2 77 188135 GUIDE cable 1 156 LL5319 TIP spray striping includes 157 1 17H720 STRAP tie 5 in 3 202 17J424 BAR height adjustment assy includes 203 2...

Page 40: ...ure Control Filter Assembly CLUTCH RED CLUTCH BLACK 62d 62b 62g 62e 62c 62b 62j 62h 62 62a B 90 62f 155 151 108 66 PINK FROM ENGINE GROUND GREEN YELLOW ti30129a ti30134a 67 13 87 99 155 ref 18 ref 75 ref 118 ref 106 141 101 102 152 152 195 182 196 106 98 100 105 103 104 63 ...

Page 41: ...40 LABEL controls 1 62j 15C973 GASKET 1 63 287285 CAP manifold includes 103 105 1 67 17K166 MANIFOLD filter 1 87 111801 SCREW cap hex hd 4 98 15C780 HANDLE 1 99 111457 O RING 1 100 15C972 PIN grooved 1 101 224807 BASE valve 1 102 239914 VALVE drain 1 103 117285 O RING 1 104 243984 FILTER fluid 1 105 15C766 TUBE diffusion 1 106 196177 ADAPTER nipple 2 141 196181 FITTING nipple 1 152 15G331 PIPE plu...

Page 42: ...Parts Pressure Control Wiring Diagram GROUND GREEN YELOW ON OFF SWITCH POTENTIOMETER CONTROL BOARD TRANSDUCER FROM CLUTCH HOUSING BLACK FROM ENGINE PINK PINK CLUTCH RED CLUTCH BLACK 66 REF 155 PINK FROM CLUTCH HOUSING RED BLACK RED GREEN YELLOW 137 REF ti30126a ...

Page 43: ...ise Level Sound power per ISO 3741 95 4 dBA Sound pressure per ISO 3741 91 0 dBA Vibration per ISO 5349 Left hand 260 in s2 6 60 m s2 Right hand 225 in s2 5 72 m s2 Wetted parts stainless steel PTFE leather nylon zinc plated and nickel plated carbon steel tungsten carbide chrome plating UHMWPE acetal polyethylene Dimensions 25M224 Weight dry without packaging 160 0 lb 72 5 kg Height Handles Down 3...

Page 44: ...o distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of...

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