Graco LineLazer IV 200HS Repair And Parts Manual Download

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Repair - Parts List

LineLazer

™

IV 200

Auto-Layout

™

System

Airless Line Striper

For application of line striping materials. For professional use only.
Not for use in explosive atmospheres.

3300 psi (22.8 MPa, 228 bar) Maximum Working Pressure

See page 2 for model information.

Important Safety Instructions

Read all warnings and instructions in this manual.
Save these instructions.

312190

309055

309277

312345

311254

312307

ti10234a

312226P

Summary of Contents for LineLazer IV 200HS

Page 1: ...ials For professional use only Not for use in explosive atmospheres 3300 psi 22 8 MPa 228 bar Maximum Working Pressure See page 2 for model information Important Safety Instructions Read all warnings and instructions in this manual Save these instructions 312190 309055 309277 312345 311254 312307 ti10234a 312226P EN ...

Page 2: ... 13 Control Board Diagnostics 15 Trigger Sensor Adjustment 16 Distance Sensor Replacement 16 Hydraulic Pump 17 Fan Belt 19 Engine 20 Hydraulic Motor Rebuild 21 Oil Filter Change 23 Gallon Counter 23 Displacement Pump 24 Parts 25 Auto Layout System Wiring Diagram 38 Technical Data 39 Accessories 39 Graco Standard Warranty 40 Graco Information 40 Models 253922 253955 255155 255156 ...

Page 3: ...g 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...

Page 4: ...dy 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 in...

Page 5: ...319 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 ...

Page 6: ...f necessary see Troubleshooting page 8 for other possible solutions 4 Install belt guard before operation of sprayer and replace if damaged Belt guard reduces risk of pinching and loss of fingers Grounding Ground sprayer with grounding clamp to earth ground when flushing sprayer FIG 1 SAE O Ring Installation 1 Unscrew lock nut to touch fitting 2 Lubricate o ring A 3 Screw in fitting hand tight 4 U...

Page 7: ... gas tank DAILY Check that displacement pump is tight DAILY Top off TSL level in displacement pump packing nut to help prevent material buildup on piston rod and early wear of packings DAILY Verify calibration AFTER THE FIRST 20 HOURS OF OPERATION Drain engine oil and refill with clean oil Reference Honda Engines Owner s Manual for correct oil viscosity WEEKLY Remove air filter cover and clean ele...

Page 8: ...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 Ke...

Page 9: ...e pump as slowly as possible during priming Intake valve is leaking Clean intake valve Be sure ball seat is not nicked or worn and that ball seats well Reassemble valve Pump packings are worn Replace pump packings Manual 309277 Paint is too thick Thin the paint according to the supplier s recom mendations Engine speed is too high Decrease throttle setting before priming pump Manual 312190 High eng...

Page 10: ...se cables Connect cables to back of control board Control board LED not flashing Replace control board Distance counter not operating properly Trigger sensor not set correctly See Spray icon does not show on display when fluid is sprayed Bad wiring connections Check connector and reconnect Distance sensor not spaced correctly from gear Adjust space between sensor and gear to 050 020 in See page 16...

Page 11: ...isplay Interrupter 164 is improperly positioned Turn screw clockwise until spray icon is synchro nized with fluid spray Reed switch assembly 18 is damaged Replace reed switch assembly 18 Pressure control knob does not rotate Knob is jammed Pull back cover where remote cable connects to hydraulic pump and turn counter clockwise ccw until free Pressure control knob rotates freely with no pressure ch...

Page 12: ...0 10 in thickness of two dimes from spray tip 4 Carefully tighten screws Verify gap Fine Adjustment If coarse adjustment did not achieve desired dot size proceed as follows 1 Start striper and move to PARKING MODE display 2 Set DOT SIZE setting to smallest size least amount of bars on display Press arrow keys to increase decrease size 3 Do Coarse Adjustment steps 1 and 2 Move holder base until a d...

Page 13: ...tor out 4 Note on paper lead connections to the control board Disconnect leads from control board 15d 5 Remove six screws 15k from control board Installation 1 FIG 2 Install control board 15d and six screws 15k Torque to 105 115 in lb 2 Connect leads to control board Refer to note on lead connections 3 Push display connector into control board close dis play connector wings A on control board 4 In...

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

Page 15: ...source Relieve pressure before repair or disassembly Verify display is con nected Sprayer may be pres surized Pressure less than 200 psi 14 bar 1 4 MPa Increase pressure as needed Sprayer is pressurized Power is applied Pressure varies with tip size and pressure control setting Normal operation Spray Engine and system continue to run Exceeded pressure limit Remove any filter clogs or flow obstruct...

Page 16: ...nd see Operation Manual 312190 Distance Sensor Replacement 1 Remove wheel 120 from LineLazer 2 Remove screw 273 wire clamp 115 spacer 272 and distance sensor 66 3 Install new distance sensor 66 and spacer 272 with wire clamp 115 and screw 273 4 Install wheel 120 on LineLazer FIG 3 TI10237a 142 127 120 66 273 115 272 130 ...

Page 17: ...oir cover 237 Installation 1 Install hydraulic pump 252 on reservoir cover 237 with four screws 215 and o rings 178 o ring 180 torque 100 in lb 11 N m 2 Install gasket 85 filter assembly A and reservoir cover 237 with eight screws 184 torque 90 in lb 10 N m 3 Install elbow 182 per instructions page 6 torque to 15 ft lb 20 3 N m 4 Install pressure control guard 63 and tighten screw 260 5 Connect hy...

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

Page 19: ...d 24 up 4 Lift engine 185 up to remove tension on belt 143 5 Remove belt from fan pulley 86 and fan pulley 87a Installation 1 Thread belt 143 around fan pulley 87a and fan pulley 86 2 Lower engine 185 to put tension on belt 3 Rotate belt guard 24 down 4 Tighten belt guard knob 241 FIG 5 241 TI6511a 24 86 185 143 87a ...

Page 20: ...ocker plate dampeners 59 and washers 114 from engine Installation 1 Install rocker plate 87c dampeners 59 and washers 170 washers 114 on engine 185 with four screws 189 washers 170 and nuts 118 torque to 20 ft lb 27 1 N m 2 Install engine and rocker plate 87c on sprayer 3 Connect white red yellow and red leads 4 Do Fan Belt Installation page 19 5 Swing motor retainer bracket 30 in Tighten hand nut...

Page 21: ...et align with hydraulic line fittings and test hole in hydraulic motor cap points away from belt guard 24 3 Torque jam nut 183 against hydraulic motor cap 25 to 150 ft lb 17 N m 4 Install hydraulic lines 35 250 to fittings 217 to top left and right side of hydraulic motor per procedure on page 6 torque to 40 ft lb 54 2 N m 5 Install pump page 24 6 Start engine and operate pump for 30 seconds Turn ...

Page 22: ...Hydraulic Motor Rebuild 22 312226P FIG 7 TI8818a 217 217 35 250 25 183 Test Hole A 69 ti8817a ...

Page 23: ...169236 5 gallon 20 liter or 207428 1 gallon 3 8 liter 3 Check oil level Gallon Counter Removal 1 Remove two screws 103 and cover 31 2 FIG 9 Disconnect gallon counter cable from in line connector A to J12 on control board 3 Remove guard 137 and reed switch 166 from hydraulic motor 4 FIG 11 FIG 13 Remove pump 5 FIG 10 Remove ring magnet 222 Installation 1 FIG 10 Install new ring magnet 222 with dimp...

Page 24: ...ighten jam nut then tap 1 8 to 1 4 turn with hammer or torque to 200 ft lb 270 N m 2 FIG 15 Slowly pull engine starter rope until pump rod pin hole is aligned with hydraulic rod hole FIG 12 Push pin 249 into hole Push magnet ring 222 down Push retaining spring 194 into groove 3 FIG 16 Fill packing nut with Graco TSL FIG 11 CAUTION Gallon counter may error if magnet ring and or sensor assembly are ...

Page 25: ...Parts 312226P 25 Parts LineLazer IV 200HS Sheet 1 of 7 Parts Page 30 Parts Page 29 Parts Page 26 Parts Page 36 Parts Page 28 Parts Page 34 Parts Page 32 ti10325a ...

Page 26: ... 121 120 51 122 121 108 68 272 66 115 273 94 177 277 13 107 77 60 108 84 5 129 177 108 177 261 93 112 261 28 73 117 70 134 74 58 33 35 154 27 141 264 267 144 268 57 Sheet 2 of 7 TI14596A To remove cover 257 press tabs together and pull cover away from plate 99 42 ...

Page 27: ...ll guide 1 142 114648 CAP dust 3 60 196176 ADAPTER nipple 1 144 114659 GRIP handle 2 66 15K357 SENSOR distance 1 154 115077 PAIL plastic 1 68 15J088 SHIELD sensor distance 1 177 112395 SCREW cap flng hd 2 70 198891 BRACKET mounting 1 256 119696 SPRING extension 1 73 198930 ROD brake 1 257 287695 BOX electric includes 109 1 74 198931 BEARING 1 258 15F441 BRACKET frame 1 77 114271 STRAP retaining 1 ...

Page 28: ...8a 8g 8c 8b 8f 8e 8 8f 112 136 136a 1 44 104 47 Ref 14 4 161 105 153 95 49 219 108 TI6497a Sheet 3 of 7 165 Ref 161 164 163 96 161 71 72 Ref 144 119 18 162 89 126 71 17 119 Ref 27 160 2 Torque to 90 110 in lb Torque to 10 20 in lb 1 2 TI6497a TI6497a ...

Page 29: ...114028 NUT wing 1 153 114982 SCREW cap flange hd 2 160 116941 SCREW shoulder socket head 1 161 287696 CABLE includes 96 1 162 116969 NUT lock 2 163 116973 SCREW 10 taptite phil 1 164 117268 BRACKET interrupter 1 165 117269 SPRING 1 219 15F637 LABEL warning 1 Replacement Warning Labels available at no cost Ref Part Description Qty ti10236a 315 307 311 311 310 309 313 303 316 308 305 304 302 306 309...

Page 30: ...41 31 37 262 40 259 124 2 2d 11 167 29 62 76 13 2c Ref 100 15r 15x 15f 15a 15d 15s 15k 15n 15b 15t 15o 191 190 268 62 64 Ref 14 125 125 271 15u 103 97 15m 38 2b 2a 15g 123 15w 269 15c SOFTWARE REVISION LABEL ti17487b ti17487a Sheet 4 of 7 ...

Page 31: ... 38 15G563 HANDLE 1 40 15H561 MANIFOLD filter 3 8 npt 1 41 287285 KIT repair filter cap includes 37 167 1 62 196178 ADAPTER nipple 2 64 196181 FITTING nipple 1 76 104813 PLUG pipe 1 91 LABEL kit blank 2 97 15K102 HARNESS wiring 1 103 117501 SCREW mach slot hex wash hd 5 123 118359 KNOB pressure control 1 124 111457 O RING 1 125 101962 SCREW set sch 1 4 20 1 167 117285 O RING 1 190 115999 RING reta...

Page 32: ...4 108 34 26 60 21 284 213 187 186 220 230 166 283 233 92 137 174 32 107 48 173 149 2 Torque to 130 150 in lb Torque to 150 ft lb Torque to 40 ft lb Torque to 25 ft lb 2 3 6 7 3 6 7 179 245 25 217 35 183 69 138 217 250 235 213 159 243 231 222 194 218 35 2 3 158 ...

Page 33: ...720 SWITCH reed w connector 2 173 100139 PLUG pipe 1 174 102040 NUT lock hex 2 179 108014 O RING 183 15A726 NUT jam 1 186 112342 BEARING rod 1 187 112561 PACKING block 1 194 116551 RING retaining 1 213 117283 O RING 2 217 117607 FITTING elbow std thd 2 218 117608 FITTING nipple straight 1 220 117739 WIPER rod 1 222 287186 MAGNET ring 1 230 15A728 MANIFOLD adapter 1 231 15B063 LABEL 1 233 107210 SC...

Page 34: ...h 34b 34k 34d 34j 34c 34f 34e Detail 34 125 86 24 193 63 241 43 102 214 224 23 12 143 184 178 82 228 260 198 215 174 75 252 180 189 197 237 114 114 59 87c 81 170 227 185 118 87a 199 181 188 87b 212 169 Ref 32 251 196 150 182 172 253 200 195 242 30 85 117 170 241 88 255 254 162 ...

Page 35: ...143 119433 BELT vee gripnotch 1 150 154594 O RING 2 151 114956 TERMINAL wire tap insulated 1 162 116969 NUT lock 2 169 100002 SCREW set sch 1 170 100023 WASHER flat 6 172 100084 BALL metallic 1 174 102040 NUT lock 1 178 107188 O RING 1 180 156401 O RING 1 181 108842 SCREW cap hex head 1 182 110792 ELBOW male 90 degree 1 184 119426 SCREW cap sch 8 185 116080 ENGINE gas 6 5 hp Honda 1 188 112717 WAS...

Page 36: ... TI6404b Sheet 7 of 7 53 131 106 108 121 7 147 130 127 F 140 153 46 117 56 146 Ref 141 142 127 130 133 10 133 132 116 55 52 139 110 46 145 135 6 65 209 128 54 113 Detail A 139 1 Install washers 130 concave surface to inside 1 Detail A 1 ...

Page 37: ... 108483 SCREW shoulder soc hd 1 116 110754 SCREW cap soc hd 2 117 110837 SCREW flange hex 10 121 111040 NUT lock 2 127 112405 NUT lock 4 128 112776 WASHER plain 1 130 119563 SPRING Belleville 3 131 113471 SCREW cap hex hd 1 132 113484 SEAL grease 1 133 113485 BEARING cup cone 2 135 113962 WASHER hardened 1 139 114548 BEARING bronze 2 140 114549 WHEEL pneumatic 1 142 114648 CAP dust 3 145 114681 SC...

Page 38: ...Y BOARD TRANSDUCER PUMP ON OFF SWITCH GUN TRIGGER JUNCTION BOX TO ENGINE GENERATOR CONTROL BOARD SOFTWARE REVISION LABEL J10 J1 J2 J11 J12 A2 A1 A3 A4 A8 YELLOW WHITE YELLOW 5900 WHITE RED RED J5 SOLENOID CONNECTOR J9 J8 A5 A6 J4 J3 REMOTE BUTTON J17 J16 J15 WHITE WHITE BLACK A7 PUMP STROKE COUNTER A6 J12 A5 A1 A3 A8 A2 A4 PUMP STOKE COUNTER A7 WHITE WHITE BLACK ...

Page 39: ...in Maximum tip size 1 gun 2 guns with 0 046 in tip with 0 033 in tip Inlet paint strainer 16 mesh 1190 micron stainless steel screen reusable Outlet paint strainer 60 mesh 250 micron stainless steel screen reusable Pump inlet size 1 in npsm m Fluid outlet size 3 8 npt f Hydraulic reservoir capacity 1 25 gallon 4 73 liters Hydraulic pressure 1825 psi 124 bar Weight dry without packaging 242 lb 110 ...

Page 40: ...THER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or proper...

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